WS 6449 - Engl Gesamt

WS 6449 1
SRM 500
MAINTENANCE INSTRUCTION
2 WS 6449
FOREWORD
This operating manual is required for the professional and safe handling of the machine. It
is important that this manual is read thoroughly and understood before the machine is put
into operation.
A copy of the present operating manual must be kept on the machine at all times.
REFERENCE TO STANDARDS
This operating manual is based on the following standards:
- EN ISO 12100:2013
- EN 14033-1:2011
- EN 14033-2:2012
- EN 14033-3:2012
Copyright © 2015 by Plasser & Theurer

All rights reserved, particularly the right of duplication, distribution and translation. Unless
written consent is given, this document may not be passed to third Parties.
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TABLE OF CONTENTS
1 MANUFACTURER’S NAMEPLATE ......................................................................................................5

2 GUIDELINES FOR SERVICING THE MACHINE .................................................................................7
3 INTRODUCTION ...................................................................................................................................9
4 PURPOSE ...........................................................................................................................................11
5 SAFETY ...............................................................................................................................................13
6 FIRE PROTECTION ............................................................................................................................17
7 FIRST AID ...........................................................................................................................................19
8 HAZARD ANALYSIS ...........................................................................................................................21
8.1 GENERAL ...........................................................................................................................................21
8.2 HAZARD INFORMATION....................................................................................................................22
8.3 EXTRACTS FROM THE SAFETY DATA SHEETS ............................................................................23
9 INSTRUCTIONS FOR USE OF STARTER BATTERIES ...................................................................25
10 MAINTENANCE ..................................................................................................................................29
11 MAINTENANCE WORKS ....................................................................................................................31
11.1 CLEANING ..........................................................................................................................................31
11.2 VISUAL CHECK ..................................................................................................................................32
11.3 TOPPING UP WORKING STOCK ......................................................................................................35
11.4 LUBRICATION ....................................................................................................................................36
11.5 CHANGING WORKING STOCK .........................................................................................................37
11.6 FILTER CARTRIDGE PACKAGE .......................................................................................................39
12 PICTOGRAPHS ..................................................................................................................................41
13 INTERVALS.........................................................................................................................................43
13.1 DISCLAIMER.......................................................................................................................................43
14 MAINTENANCE SCHEDULE SURVEY ..............................................................................................45
15 GENERAL SURVEY............................................................................................................................51
16 ORIGINAL FILLING OF WORKING STOCK.......................................................................................53
17 IN BETWEEN – PERIODICALLY ........................................................................................................55
17.1 SAFETY CONTRIVANCES .................................................................................................................55
17.2 BRAKE ................................................................................................................................................56
17.3 COOLER .............................................................................................................................................56
18 AFTER 10 HOURS OF OPERATION OR DAILY ...............................................................................57
18.1 PLAIN VISUAL CHECK .......................................................................................................................59
18.2 CHECKING WORKING STOCK .........................................................................................................59
19 AFTER 50 HOURS OF OPERATION OR WEEKLY ...........................................................................67
20 AFTER 100 HOURS OF OPERATON OR MONTHLY .......................................................................73
21 AFTER 250 HOURS OF OPERATION OR SEMI-ANNUALLY ...........................................................79
22 AFTER 500 HOURS OF OPERATION OR SEMI-ANNUALLY ...........................................................85
23 AFTER 1000 HOURS OF OPERATION OR ANNUALLY ...................................................................93
24 ANNEX ................................................................................................................................................99
4 WS 6449
TABLE OF VERSIONS
No. Reason Date Page Name

st
1.0 1 Version PHolzer
WS 6449 5
1 MANUFACTURER’S NAMEPLATE
2016 6449 / 6450
SRM 500
Sandräummaschine
6 WS 6449
WS 6449 7
2 GUIDELINES FOR SERVICING THE MACHINE
 The present guidelines on maintenance apply only to the “current maintenance“ and
are within the sole competence of the machine operating organization!!
 These current maintenance works carried out within the own competence of the
machine operator refer to working units, engines, gearboxes, etc.
 The adequate maintenance as well as the compliance with the stipulated time intervals
are decisive for the service life and permanent availability of the vehicle.
 The tightening torques according to VDI 2230 in the annex refer to all those screws that
are not explicitly stated in the Maintenance Instructions or Service Information Sheets.
 We urgently recommend to make notes in the logbook also of maintenance works

carried out in your own competence. These notes should document any kind of service
works (who, when, what, where and why).
 For oil filling quantities, oil sorts, service intervals etc. observe the Service Instruction!
 The operational labelling (machine weights, brake weights, line categories, etc.) in the
images section of this document may not necessarily match exactly with the actual
machine values. The actual values can be taken from the respective machine
documentation (labelling plan, acceptance certificates, approvals, certificate folders,
etc.).
 Service is divided into cleaning, checks, refilling or topping up of consumables, and

replacing of spare parts.
 An essential criterion of service works is safety of man, environment and machine.
 The supplied operating manuals (e.g. engine etc.) must be read in any case and the
operating, maintenance and service intervals specified must be adhered to, provided
that Plasser&Theurer service instructions do not state otherwise!
In the event of non-compliance the manufacturer cannot be held responsible for any
damage!
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3 INTRODUCTION
Maintenance of this machine over its entire service life has to be performed according to
the Maintenance Instructions (EN 14033-1 / chapter 18).
The owner respectively the operating organization is responsible for maintenance of this
machine!
At regular intervals of at least 2 years all machines will be inspected by the railway
infrastructure organization, on whose tracks the machine is deployed.
The railway infrastructure organization must be notified of any derailment, collision, rupture
of running gear as well as any anormal heating of the wheelset bearings, which will lead to
special inspection by qualified personnel of the railway infrastructure organization.
Machine parts and components influencing driving safety must not be modified without
prior consent of the authorized approval body.
Any modification entails the necessity of obtaining a new transport approval.
Any works at the machine frame, the bogie frames, brake system, wheelsets, wheels,
wheelset bearings, speedometers, equipment for repeating and recording of signal
indications and indications at the driver’s desks may only be carried out by workshops
holding the respective admission of the authorized approval body.
Current maintenance works will be carried out by the machine operating organization at its
own responsibility.
The general operating and safety instructions BS-02.05 (refer to auxiliary documentation)
are to keep.
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4 PURPOSE
The machine operating organization bears the responsibility for maintenance.
According to the present maintenance instruction this machine over its entire service life is
subject to regular maintenance.
Professional maintenance will be decisive for the term of service life of the machine and its
permanent readiness for service.
Essential maintenance criteria are:

- qualification of the maintenance staff
- quality of maintenance work
- observance of the time intervals prescribed
- use of the working stock prescribed
- use of original spare parts
Maintenance has to be carried out in stages, i. e., any time interval automatically includes
all preceding intervals.
EXAMPLE: At dates set for monthly maintenance there have to be carried out also all
works listed for weekly and daily maintenance.
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5 SAFETY
Maintenance works in principle have to be carried out when the vehicle is stationary and
secured against breaking away.
It is strictly prohibited to climb on the vehicle roof under catenary. Before beginning repair
and maintenance works it must be ensured that the catenary is switched off and earthed.
These safety measures have to be carried out and supervised by the responsible safety
officers!
Always pay attention to trains passing on adjacent tracks.
Use skid-pans when parking the vehicle on gradients.
If a check of certain structural elements might entail danger, these elements may be
checked only when the machine is stationary or after work.
Before starting maintenance works the parking brake has to be applied (with few
exceptions), the engine has to be turned off and the main switch must be switched off.
Never change the settings of safety valves.
Before disassembling hydraulic system elements make sure that the equipment is
unpressurized. Hydraulic oil coming out under pressure may penetrate skin and cause
serious injuries.
When draining engine oil or hydraulic oil at working temperature you might scald yourself.
Always ensure that on or in the vehicle nobody works with naked flames.
Do not smoke when refuelling the vehicle or checking the acid level of the batteries.
Never check the acid level of the battery or the fuel level in the tank with a naked flame.
Before beginning welding works (electric arc welding) particularly make sure that:
- the machine has been secured against breaking away (parking brake, skid-pans etc.);
- the engine has been switched off;
- the main switched has been switched "OFF“;
- the program control switch has been switched "OFF, if existing;
- the battery sets have been entirely disconnected.
- the earth electrode fastened at the vehicle has been connected as close to the weld as
possible.
continued on next page

14 WS 6449
continued: safety
The earth electrode must never be mounted on the rail.

Never connect the earth electrode to cylinder piston rods, hydraulic accumulators,
hydraulic pumps, batteries, earth cable, loose connections, such as bearings or similar, or
to hydraulic oil or fuel tanks.
Do not direct any high-pressure cleaning and lubricating devices to man or animal.
Do not use any easily flammable fluids or caustic cleansing agents to clean the machine.
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SI-0400-04
SAFETY GUIDELINES FOR PREPARING REPAIR WORK

TO BE CARRIED OUT ON THE MACHINE IN THE WORKSHOP
In working mode, the danger zone of the machine is a prohibited area!
Repair work on the machine must only be carried out by authorized and trained
personnel.
Before any repair work is carried out on the machine, the following safety instructions must
be observed:
 Deactivate hydraulic pressure (visual check of the pressure gauge reading).
 Deactivate the air system (visual check of the pressure gauge reading).
 Protect the machine from rolling away (parking brake, skid-pans etc.!)
 Turn off the engine!
 Turn off the working-mode main switch and protect it from unauthorized operation!
 Turn off the battery main switch and protect it from unauthorized operation!
 If repair work is carried out in closed workshops, the battery sets have to be
disconnected (machine without current) and the battery terminals have to be secured
accordingly.
 Furthermore, the machine crew and all persons that have access to the machine must
be informed of the intended repair work!
 A professionally competent person has to be nominated who will bear the main
responsibility for the repair work to be carried out and will supervise this work
according to all aspects of safety!
 Before the machine operating mode is restored, the entire crew must be notified of the
repair work carried out; only a professionally competent person is allowed to restore
the machine operating mode!
 In working mode, the working area is again prohibited!

16 WS 6449

TO BE CARRIED OUT ON THE MACHINE OUTSIDE THE WORKSHOP
personnel!
PLEASE OBSERVE THE LOCAL RAILWAY REGULATIONS!
Before any repair work is carried out on the machine, the following safety instructions must
be observed:
 Deactivate hydraulic pressure (visual check of the pressure gauge reading).
 Deactivate the air system (visual check of the pressure gauge reading).
 Protect the machine from rolling away (parking brake, skid-pans etc.!)
 Turn off the engine!
 Turn off the working-mode main switch and protect it from unauthorized operation!
 Furthermore, the machine crew and all persons that have access to the machine must
be informed of the intended repair work!
 A professionally competent person has to be nominated who will bear the main
 The decision whether to switch off the battery main switch and to protect it from
unauthorised operation for the repair work to be carried out is at the discretion of the
person chiefly responsible!
On the other hand, should an electrical failure have occurred, the battery main switch
MUST be switched off and protected from unauthorised operation before remedy work
is started!
 When repair work needs to be carried out with the battery main switch turned off, the
operating organisation must provide sufficient signal lights according to the respective
national regulations, as well as sufficient lighting of the working areas!
 Before the machine operating mode is restored, the entire crew must be notified of the
repair work carried out; only a professionally competent person is allowed to restore
the machine operating mode!
 In working mode the working area is again prohibited!

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6 FIRE PROTECTION
NOTE!
The use of open flames and easily flammable agents on the

vehicle and in immediate vicinity is strictly prohibited!
The diesel fuel tanks may only be filled with the engine
switched off and cooled off.
First aid procedures

 Rescuing people
 Alarming the fire brigade
 Attempting to extinguish fire
Everybody is obligated as far as possible and acceptable to refrain from everything that
may result in a fire or favour the spreading of a fire. In addition to this, all measures to
prevent the development or spreading of fires must be taken in individual cases.
Oily or greasy rags saturated in solvent must be kept in a fire-protected place since they
could cause fires through self-ignition.
In order to avoid the development of fires, the following parts, especially equipment subject
to the development of heat, must be kept free of deposits.
 Drives
 Heaters
 Belts
 Gears
 Control cabinets
 Power distribution boards
 etc.
For this reason, timely familiarise yourself with the operational fire protection regulations
and the proper use of the existing extinguishing agents.
For this purpose consult the fire protection representative of your department!
The fire extinguishers must always be ready for operation, freely accessible, periodically
tested and equipped with test plaques.
The date of expiry must be checked by the responsible fire protection representative!
Following the use of a fire extinguisher this must be immediately brought to the attention of
the fire protection representative who is responsible for the operation.
The representative will immediately arrange for the filling of all used fire extinguishers and
he is obligated to provide replacement fire extinguishers in the meantime!
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7 FIRST AID
Always ensure that the first aid kit is in a proper, complete

and neat condition.
For the purpose of first aid measures and suitable

equipment consult the first aid service or doctor of your
responsible department.
Immediately replenish used up material!
Medicines, tranquillisers or other medications can result in drowsiness or

impair for instance the reactivity.
Procedure for first aid measures

1. HELPING (refer to first aid measures in the extracts of the safety data sheets)
2. REPORTING
3. SECURING
4. WARNING
In the case of burning

Extinguish the burning person with water, fire extinguisher, blankets or through rolling.
In the case of eye contact with hazardous materials

Rinse out several times with spray bottle or beverage and subsequently consult a doctor.
In the case of skin contact with hazardous materials

Thoroughly wash with soap under running water and subsequently consult a doctor.
When inhaling hazardous materials

When inhaling higher concentration, take person into the fresh air and subsequently
consult a doctor.
After ingesting
Do not induce vomiting and immediately consult a doctor.
After intensive contact with clothing

Immediately change saturated clothing, shower and subsequently consult a doctor.
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8 HAZARD ANALYSIS
Carefully performed preventive maintenance to maximise the service life and increase the
operational safety, which will be reflected in a clear reduction of working accidents and
resultant damage to persons.
8.1 GENERAL
The instructions of the operations manager or machine operator must be followed under
any circumstances.
 Entering the machine is only permitted by way of the steps provided for this
purpose, which should be kept free of grease, oil, fuel, dirt, snow and ice.
 Climbing onto machine parts during loading, unloading and repair operations
located in the hazard area of the overhead line is always prohibited unless the
overhead line has been switched off, in which case the safety regulations issued by
the respective rail operators will have to be followed.
 Crossing underneath the machine during operation or working is prohibited.

Danger!
 When present in the vicinity of the machine the use of ear protection is absolutely
essential.
 If problems are encountered while work in progress, activate the emergency or

engine stop. Based on the type of the fault it must be decided how it should be
rectified most effectively.
Instinctive reactions for rectifying the fault during working operation may result in
serious injury to body and even death.
 The removal of covers and safety instructions is strictly prohibited.
 Touching the exhaust system may result in burns.
In addition to this the safety regulations of the responsible railway administration or more
stringent regulations of other competent authorities as amended will apply.
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8.2 HAZARD INFORMATION
Hazards
Mainly impact, drawing-in, pinching, squeezing and squashing hazards and the danger of
skin burns exist at the mentioned hazard locations as a result of which only instructed
personnel may be assigned to work with and on the machine.
When climbing onto the machine there is the additional danger of electric shock.
Information with regard to endangering third parties falls under the area of responsibility of
the local construction management (co-ordination).
Instruction sheets and sketches are submitted to the respective principal who will be
responsible for further distribution.
8.2.1 Responsibilities for implementation
Distributor…………………………...Announces the hazards

Operator…………………………. ….Technical issues
Local construction supervision…Specific construction site issues and the co-
ordination of all issues with the individual persons
The handling of hazardous service products without any danger must be clearly
established for the following working materials by means of regulations that must be
imparted to the employees in training courses. (References in the extracts of the safety
data sheets)
 Flammable and/or explosive materials (diesel, etc.)

 Working materials hazardous to health (oils, greases, etc.)
 Other hazardous materials (adhesives, cleaners, etc.)
8.2.2 Protective equipment
In order to keep hazards and their consequences to health as low as possible it is

imperative to ensure suitable protective equipment.
Head protection………. Hard hat

Ear protection…………. Ear muffs, earplugs
Hand protection………. Gloves
Foot protection……….. Steel cap shoes
Warning clothing……… Clothing in signal colours with reflecting stripes
Breathing protection…. Dust mask
It is imperative to observe the signs, covers, safety guards, earthing

cables, etc., attached to the machine for the protection of the health of
persons and the equipment as well as the environment!
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8.3 EXTRACTS FROM THE SAFETY DATA SHEETS
Gearbox oil SHELL SPIRAX S2 G 80W-90
Engine oil SHELL RIMULA R6 LM 10W40
Hydraulic oil SHELL TELLUS S2 V 68
SHELL OMALA HD150
Lubricating grease SHELL GADUS S2 V 100 2
The safety data sheets contain additional information on the following.

 Material, preparation and company designation
 Composition / details concerning ingredients
 Possible hazards
 Fire-fighting measures
 Measures if inadvertently liberated
 Handling and storage
 Physical and chemical properties
 Stability and reactivity
 Toxicological details
 Ecological details
 Disposal instructions
 Transport details
 Regulations
 Other information
For the material safety data sheets of the above lubricants please refer to
the Annex to these Maintenance Instruction.
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9 INSTRUCTIONS FOR USE OF STARTER BATTERIES
Storage and transport
Starter batteries require no maintenance prior to being filled. Store in a dry and cool place
(no frost).
Recharge filled starter batteries not later than at an acid density below 1.21 kg/l (1.18 kg/l
with filling acid 1.23 kg/l).
Transport and store filled batteries in the upright position to prevent acid spillage.
When transporting, secure the battery to prevent toppling over.
Commissioning
Empty charged starter batteries are ready for operating after having been filled with battery
acid without separate charging.The temperature of the battery and the acid should be at
least 10C when filling. Remove battery caps.Fill the individual cells of the battery with
sulphuric acid according to VDE 0510 of density 1.28 kg/l (for tropical countries 1.23 kg/l)
up to the maximum acid level mark or 15 mm above the upper edge of the plates.
Leave battery to stand for 15 minutes, slightly tilt several times and replenish acid if
required.Firmly screw in or press in the filler caps. Wipe off any spilled acid.
Batteries supplied in the filled state are ready for operation.
If a battery produces insufficient starting capacity due to low temperature or

unfavourable storage, recharge the battery.
Installation in the vehicle
Before removing and installing the battery, switch off the engine and all power consumers.
Avoid short-circuits through tools.
When removing the battery, first disconnect the negative terminal ( - ), then the positive
terminal ( + ). Prior to installing the battery, clean the standing area in the vehicle.
Firmly secure the battery.
Clean battery terminals and terminal clamps and lightly grease with acid-free grease.
On installation, first connect positive terminal ( + ), then negative terminal ( - ). Ensure

terminal clamps are tightened securely.
26 WS 6449
Charging outside the vehicle
Before charging, check the electrolyte level and, if required, add desalinated or distilled
water up to the maximum acid level mark or 15 mm above the upper edge of the plates.
Remove the battery for recharging to avoid damage to the vehicle.
Observe the vehicle manufacturer’s instructions when disconnecting the

battery.
Batteries may only be charged with direct current. Connect positive terminal
( + ) of the battery with the ( + ) of the charger and the negative terminal ( - )
with the negative terminal ( - ) of the charger.
Switch on the charger only once the battery has been connected. At the end
of the charge, switch off the charger first.
A tenth of the capacity is recommended as charge current.

(For instance: 44 Ah : 10 = 4.4 A charge current)
The acid temperature may not exceed 55 C during charging.

Interrupt the charging process if the temperature is exceeded.
The charging process is completed when the current is almost 0 or no longer

reduces or the automatic charger has switched off.
Ensure sound ventilation during the charging process.
Highly explosive oxyhydrogen is generated during charging! Fire,

sparks, naked light and smoking prohibited!
Maintenance
In order to achieve a long service life for the battery, the following instructions should be
observed. Keep the surface of the battery clean and dry.
Regularly check the acid level and, if necessary, replenish with desalinated or distilled
water. Never add acid. If there is a major loss of water, have the regulator voltage checked
by a specialist. Do not use any so-called conditioning agents. The charge condition can be
determined by measuring the acid density.
If the acid density is below 1.21 kg/l (or 1.18 kg/l with filling acid 1.23 kg/l), recharge the
battery. At that acid density the battery is protected against freezing up to - 15 C (at 1.28
kg/l up to -70 C ).
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Jump-starting
Because of the sensitive electronics in the vehicle, always use a starting booster for jump-
starting.
Jump-starting the car may lead to voltage peaks when disconnecting and damage or even
destroy the electronics of the vehicle.
For this reason follow the following instructions when using jumpstarting leads!
When jump-starting with jump-starting leads it is advisable to use standardised jump-
starting leads (for instance according to DIN 72 553).
Follow the instructions for use of the jump-starting leads.
Connect only batteries of the same rated voltage.
Connecting: Both vehicle engines off!

First connect the two positive terminals 1 and 2, then the negative terminal of the donor
vehicle 3 with a metallically bright point on the vehicle requiring assistance 4 away from
the battery (pay attention to the vehicle manufacturer’s instructions).
1 2
+ +
Batteries of
the donor - - Battery of the
vehicle vehicle to be
2 x 12V jump-started
+ + 2 x 12V
- -
3 4
Start the incapacitated vehicle for a maximum of 15 seconds, do not start the donor
vehicle during this time.
Disconnection: Disconnect cables in reverse order.
Taking the battery out of service
Charge the battery and store in a cool place.

If the battery remains in the vehicle, disconnect the negative terminal.
Regularly check the charge condition.
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10 MAINTENANCE
Machine maintenance is divided into activities (maintenance works) – chapter 11 and

intervals – chapter 13
Only if both criteria are observed, the correct activity will be carried out at the correct
moment – as shown in the maintenance schedule survey – chapter 14
Maintenance works are divided as follows:
- cleaning - chapter 11.1

- visual check - chapter 11.2
- topping up of working stock - chapter 11.3
- lubrication - chapter 11.4
- changing working stock - chapter 11.5
If during maintenance works carried out at machine components that influence driving
safety there are discovered defects, the status automatically changes from maintenance to
inspection and, if necessary, on to repair.
EXAMPLE:
- During an extended visual check there are discovered wheel fissures.
- As this irregularity has been discovered at a machine component which influences driving
safety, status changes from maintenance to inspection.
- An inspection may be carried out only by those workshops that are admitted for such kind
of works by the authorized approval body!
- If during inspection it is found out that the number and dimensions of fissures exceed the
admissible values, the respective part has to be replaced.
- Status automatically changes to repair!
- A workshop of the above mentioned type will carry out repair works.
Maintenance works have to be recorded in the operator’s logbook.

These records should document any type of maintenance carried out (who, when, what,
where and why).
In case it is intended to park the machine for a period longer than 6 months, preservation
measures as usual in practise have to be provided.
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11 MAINTENANCE WORKS
11.1 CLEANING
- If the machine is soiled to such an extent that maintenance works would be impeded
and of no use, it is necessary to clean the machine before starting working.
- Additionally, periodical cleaning is prescribed for certain structural elements.
- Cleaning is the best opportunity to check an element visually.
- It is of particular importance to clean the coolers in time!
- Do not direct any high-pressure cleaning devices against thin covers.
- When using a high-pressure steam cleaner or high-pressure washer system observe

the following:
- maximum pressure of 80 bar
- maximum temperature of 60°C
- Minimum distance between cleaning nozzle and surface to be cleaned must be 30
cm. The cleaning jet shall not drift by more than 30° from the right angle to the
surface to be cleaned.
- Do not use any easily flammable or caustic cleansing agents.
- Clean underside periodically, however, at least once a year.

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11.2 VISUAL CHECK
plain visual check chapter 11.2.1

extended visual check chapter 11.2.2
immediate visual check chapter 11.2.3
 Fundamental requirements for a visual check

Visual checks are usually underestimated as maintenance factors.
The purpose of a visual check is to find out as soon as possible dangerous
changes, as well as wear and obvious irregularities in order to initiate suitable
measures.
To carry out visual checks successfully, a certain degree of experience and
responsibilty is required.
Machines, working units etc. that move, drive, work, are subject to wear and tear.
If wear is not taken into account, sooner or later it will lead to serious damage to the
machine that may entail unnecessary (avoidable) high costs and long down times.
 Dangerous changes are, e. g.:

(the list is not intended to be complete)
- massive and/or unevenly distributed wear

- deformations by force
- chafe marks with material shrinkage
- porosity
- leaks
- fissures
- notches in critical places
- rupture of structural elements
- corrosion
- loose fit of screwed connections
- loose securing elements
- lost parts
- discolouration as a consequence of high temperatures
- bad general condition
(dirty coolers, fluid levels below minimum etc)
It is assumed to be obvious and compelling that as a result of visual

checks it may be necessary to take measures!
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11.2.1 PLAIN VISUAL CHECK
A plain visual check usually will be carried out before putting the machine into operation
and after its deployment.
However, only the areas visible from outside are inspected.
Before starting the first operation of the day or after longer breaks it is recommended to
check the machine visually for its general condition and any obvious irregularities when
approaching towards the machine from a greater distance.
EXAMPLE: broken windows, bent machine parts etc. indicate to the use of force and
make a more detailed investigation necessary.
Depending on their nature structural elements have to be investigated visually for

dangerous changes, such as fissures, deformation, ruptures, corrosion, discolouration by
temperature, leaks, as well as for the general condition and the fit of securing elements.
Minor sealing tasks which may be reasonably carried out (such as re-tightening
connections, fittings and screws) are to be performed in the course of daily maintenance
work.
These maintenance operations, particularly in the area of hydraulics, can be executed with
very little maintenance expenditure and guarantee a high degree of availability of the
machine.
Check the general condition of the hydraulic system:

The exterior condition of the entire hydraulic system must be checked before start-up and
after every period of operation.
Facts that indicate possible leaks:

 Oil shortage in the tank.
 Traces of oil on equipment surfaces, in the place of storage or the place of work.
 Oil seepage from the system (tank, connecting pipes, pumps, motors, cylinders,
valves, filters, controls, etc.).
Removing the ventilating filter and putting the system into operation
without such filter constitutes improper use and leads to inevitable
massive damage to the hydraulic system!
34 WS 6449
11.2.2 EXTENDED VISUAL CHECK
An extended visual check is carried out in monthly intervals from an assembly pit.
An extended visual check will be necessary before start-up, if:
- the operating condition is not known,

- the machine had been parked over a longer period,
- a new or untrained crew will put the machine into operation.
For an extended visual check, the condition of the entire hydraulic system also needs to be
checked:
Oil shortage ⇒ top up
Leaking connections ⇒ retighten
Loose connections ⇒ retighten
Defective seals ⇒ replace
Defective pipes / hoses ⇒ replace
Defective functional components ⇒ repair or replace
Leaking tank ⇒ seal provisionally, repair
11.2.3 IMMEDIATE VISUAL CHECK
Irregularities during operation (abnormal noises, smoke, fire, suddenly running out
operating stock, discolouration by heat, smell of elements running hot etc.) require an
immediate visual check.
Lost structural elements are a serious indication of a dangerous change and require a
careful and immediate investigation of the reasons.
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11.3 TOPPING UP WORKING STOCK
Checks of working stock levels have to be carried out when the vehicle stands on a level
surface (without super-elevation or inclination).
Before dismantling hydraulic elements make sure that the system is unpressurized.
Hydraulic oil coming out under pressure may penetrate skin and cause serious injuries.
When draining engine oil or hydraulic oil at working temperature you might scald yourself.
Always ensure that on or in the vehicle nobody works with naked flames.
Do not smoke when refuelling the vehicle or checking the acid level of the batteries.
Never check the acid level of the battery or the fuel level in the tank with a naked flame.
When changing working stock (hydraulic oil, engine oil etc.) collect them and duly dispose
them.
Do not let working stock get into the soil.

36 WS 6449
11.4 LUBRICATION
For greasing and oiling remove any dirt and gummy grease and oil and lubricate the
respective part anew.
All measuring and tensioning trolleys have to be lubricated / greased at intervals according
to the maintenance schedule.
Furthermore, all hydraulic and pneumatic cylinder bearings (even if not listed in the
maintenance instruction) have to be checked visually every 50 hours of operation and, if
necessary, must be lubricated.
All movable parts not mentioned in the maintenance instruction, such as piston rods,
cylinder fastenings, guide bushes, spindles, slide faces etc., have to be lubricated every 50
hours of operation with oil / grease (Shell Gadus S2 V 100 2).
For lubrication never use a grease gun generating pressure of more than 15 bar!!
Grease and grease gun must be free of dirt and foreign bodies.
Clean the lubricating nipples of the bearings before and after lubricating them.
Continue to lubricate until evenly distributed fresh (clean) grease will come out the
bearings.
Then remove excess quantities of grease.

WS 6449 37
11.5 CHANGING WORKING STOCK
filter:
engine: oil filter after 250 working hours

(whenever changing oil)
fuel pre-filter after 500 working hours.
air cleaner Clean filter cartridge every 250

hours, renew at least annually. After 5
maintenance operations, no later than
after 2 years replace the safety cartridge.
gear box: oil filter the filter cartridge has to be replaced

every 500 engine hours
hy- oil tank: suction filter replace depending on the

contamination indication of the vacuum-
meter; however, at least every 250 or 500
engine hours
return filter the filter cartridge has to be replaced every

500 engine hours
compressed air: air dryer the filter cartridge has to be replaced

every 2 years.
filter: First change of all fuel filters after max. 100 hours of operation,
afterwards in accordance with maintenance instruction.
For order numbers of filters and filter spare parts, please see spare parts book only.
38 WS 6449
oils: First change of all engine and gearbox oils after max. 100 hours of operation,
afterwards in accordance with maintenance instruction.
brake blocks:
Please pay attention to the decreased braking

effect after replacing the brake blocks, if these
are unworked or not run in.
Therefore do not change all brake blocks at
once (e.g. in two stages).
Carry out a brake test whenever change brake

blocks.
Hydraulic/diesel hose lines
In accordance with DIN EN 20066 a hose line can be used for a maximum of 6 years. This
period of use can include storage of the hose line of up to 2 years maximum. The
maximum age of the hose when it is used for making a hose line must be no more than 4
years.
Do not store hose for more than 4 years.

Do not store hose lines for more than 2 years.
Do not use hose lines for more than 6 years. DIN EN 20 066
Max. 4 years Max. 6 years

storage of hose use of hose line
Max. 2 years
storage of hose line
WS 6449 39
11.6 FILTER CARTRIDGE PACKAGE
Order no. „Filter cartridge package“ (for 1000 hours of operation) -

according to Plasser & Theurer Maintenance Manuel:
EP-6449-1000H
40 WS 6449
WS 6449 41
12 PICTOGRAPHS
visual check
topping up of fluids (cooling agents etc.)
unscrewing / tightening of screws
topping up of machine oil
refuel
refilling AdBlue
greasing / lubricating
cleaning
lubricating (oil)
greasing / lubricating
42 WS 6449
WS 6449 43
13 INTERVALS
The following intervals are applied for maintenance:
- in between, periodically chapter 17
- after 10 hours of operation or daily chapter 18
- after 50 hours of operation or weekly chapter 19
- after 100 hours of operation or monthly chapter 20
- after 250 hours of operation or semi-annually chapter 21
- after 500 hours of operation or semi-annually chapter 22
- after 1000 hours of operation or annually chapter 23
Maintenance has to be carried out in stages, i. e., any time interval automatically includes
all previous intervals.
EXAMPLE: When performing monthly maintenance works all works listed for weekly and
daily maintenance have to be done as well.
13.1 DISCLAIMER
THE SUPPLIED OPERATING MANUALS (e.g. engine etc.) MUST BE READ IN

ANY CASE AND THE OPERATING, MAINTENANCE AND SERVICE
INTERVALS SPECIFIED MUST BE ADHERED TO, PROVIDED THAT
PLASSER & THEURER SERVICE INSTRUCTIONS DO NOT STATE
OTHERWISE!
IN THE EVENT OF NON-COMPLIANCE THE MANUFACTURER CANNOT BE

HELD RESPONSIBLE FOR ANY DAMAGE!
44 WS 6449
WS 6449 45
14 MAINTENANCE SCHEDULE SURVEY
17. IN BETWEEN – PERIODICALLY

SAFETY CONTRIVANCES …………………..…………………………………………………………………….55
BRAKE …………………………………………………………………………..…………………………………….56
COOLER ………………………………………………………………………………………………………………56
18. AFTER 10 HOURS OF OPERATION OR DAILY

PLAIN VISUAL CHECK:
CHECKING WORKING STOCK:

DEUTZ ENGINE – OIL LEVEL CHECK ...........................................................................................................59
ENGINE COOLING AGENT – LEVEL CHECK ................................................................................................60
FUEL RESERVES FOR THE DIESEL ENGINE ..............................................................................................61
DIESEL FUEL FILTER .....................................................................................................................................61
HYDRAULIC OIL LEVEL CHECK ....................................................................................................................62
HYDAC FILTER UNIT - CHECK ......................................................................................................................63
DRAIN ALL AIR RECEIVER.............................................................................................................................63
ALL CONVEYOR BELTS .................................................................................................................................64
ELEVATOR SURVEY.......................................................................................................................................65
support rollers – lubrication ..............................................................................................................................65
plough adjusting bearing – lubrication ..............................................................................................................66
scraper attachment – lubrication ......................................................................................................................66
46 WS 6449
19. AFTER 50 HOURS OF OPERATION OR WEEKLY

AXLE GEARBOX – OIL LEVEL CHECK ......................................................................................................... 69
AXLE GEARBOX – LUBRICATE ALL DIRT REPELLING AGENTS .............................................................. 69
PUMP DISTRIBUTOR GEARBOX – OIL LEVEL CHECK .............................................................................. 70
ELEVATOR CHAIN GEARBOX – OIL LEVEL CHECK ................................................................................... 70
ENGINE AIR CLEANER – CHECK ................................................................................................................. 71
DRAIN ALL DRIP CUPS.................................................................................................................................. 71
PNEUMATIC LUBRICATOR – OIL LEVEL CHECK........................................................................................ 72
STEEP CONVEYOR BELT ............................................................................................................................. 72
guide pulleys .................................................................................................................................................... 72
TURNING DEVICE .......................................................................................................................................... 72
cylinder ............................................................................................................................................................ 72
WS 6449 47
20. AFTER 100 HOURS OF OPERATION OR MONTHLY

EXTENDED VISUAL CHECK ..........................................................................................................................75
CONVERTER TORQUE BEARING .................................................................................................................75
CARDAN SHAFT – LUBRICATION .................................................................................................................76
CHECK OF BRAKE LININGS AND BRAKE BLOCK PLAY .............................................................................77
21. AFTER 250 HOURS OF OPERATION OR SEMI-ANNUALLY

DEUTZ ENGINE – OIL CHANGE ....................................................................................................................81
CHECK BRAKE LEVER BEARING AND BRAKE RODS ................................................................................82
HYDRAULIC FILTER CHANGE .......................................................................................................................83
GEARSHIFTING LINKAGE AND CLUTCHING GEAR OF HYDROSTATIC DRIVES ....................................83
CONDITION OF THE BATTERY AND THE CABLE CONNECTIONS ............................................................84
22. AFTER 500 HOURS OF OPERATION OR SEMI-ANNUALLY

AXLE GEARBOX – OIL CHANGE ...................................................................................................................87
ELEVATOR CHAIN GEARBOX – OIL CHANGE .............................................................................................87
PUMP DISTRIBUTOR GEARBOX – OIL CHANGE ........................................................................................88
SUPERFINE FILTER – CHANGE ....................................................................................................................89
DIESEL FUEL FILTER REPLACEMENT .........................................................................................................90
HYDRAULIC FILTER REPLACEMENT ...........................................................................................................91
48 WS 6449
23. AFTER 1000 HOURS OF OPERATION OR ANNUALLY

CHECK HYDRAULIC OIL VISCOSITY ........................................................................................................... 95
CENTRAL BUFFING GEAR ............................................................................................................................ 95
AIR DRIER – CHANGE FILTER AND GRANULATE CARTRIDGE................................................................ 95
PUMP DISTRIBUTOR GEARBOX – AERATION FILTER CHANGE.............................................................. 96
AXLE GEARBOX – AERATION FILTER CHANGE ........................................................................................ 96
FUEL TANK – AERATION FILTER CHANGE................................................................................................. 96
CHECK ALL V-BELT TENSIONS .................................................................................................................... 97
ALL CABLES AND INSULATIONS.................................................................................................................. 98
AXLE BEARING............................................................................................................................................... 98
RETIGHTENING OF THE SCREWS............................................................................................................... 98
FIRE EXTINGUISHER ..................................................................................................................................... 98
FIRST AID KIT ................................................................................................................................................. 98
24. ANNEX
TIGHTENING TORQUES FOR TORQUE WRENCHES
SERVICE INFORMATION – S-110506-D
SERVICE INFORMATION – S-230713-B
SERVICE INFORMATION – S-090209
SERVICE INFORMATION – S-280912
SERVICE INFORMATION – S-43h
SERVICE INFORMATION – SI-0300-01
SERVICE INFORMATION – SI-0400-04
SAFETY DATA SHEETS
WS 6449 49
In between - periodically:
Depending on working or environmental conditions, so to speak, on operational criteria.
Daily:
After 10 hours of operation at the latest, or daily before starting operation, depending on
which of these events occurs first.
Weekly:
After 50 hours of operation at the latest, or weekly before starting operation, depending on
which of these events occurs first.
Monthly:
After 100 hours of operation at the latest, or monthly before starting operation, depending
on which of these events occurs first.
Semi-annually:
After 250 respectively 500 hours of operation, or semi-annually before starting operation
(for exact instructions refer to the respective maintenance chapter „semi-annually“),
depending on which of these events occurs first.
Annually:
After 1000 hours of operation at the latest or yearly before starting operation, depending
on which of these events occurs first.
50 WS 6449
WS 6449 51
15 GENERAL SURVEY
1. elevator
2. steep conveyor belt
3. fuel tank
4. turning device
5. swivel conveyor belt
6. hydraulic tank
7. DEUTZ engine
52 WS 6449
WS 6449 53
16 ORIGINAL FILLING OF WORKING STOCK
engine oil Rimula R6LM 10W-40 (Shell) 34 litres
axle gearbox – axle 1 Spirax S2 G 80W-90 (Shell) ~8.8 litres
axle gearbox – axle 2 Spirax S2 G 80W-90 (Shell) ~10.9 litres

pump distributor gearbox Spirax S2 G 80W-90 (Shell) 3.5 litres
elevator chain gearbox (2x) Omala HD150 (Shell) 1.8 litres
hydraulic oil Tellus S2 V 68 (Shell) 1050 litres
pneumatic lubricators Tellus S2 V 68 (Shell) 0.25 litres
engine cooling agent Maintain Fricofin (Fuchs-35°C) / Water 65 litres
grease Gadus S2 V 100 2 (Shell)
The above working stock filling quantities are original fillings by the manufacturer. In any
case, the oil-level gauge, the inspection glass, the oil-level glass or the level plug mark will
be decisive.
The oil brands are valid only at the moment of delivery of the machine.
Manufacturers of lubricants use to change the designations of their products in
rapid succession! Besides, identical products have different names in different
countries.
If the above listed lubricants are not (or no longer) available, ensure
compatibility when changing the oil brand; obtain the respective confirmation by
the supplier. We point out particularly that blending lubricants may lead to
incompatibility and, consequently, to damage. Especially the change from
undoped to doped oil may cause leakage.
If these oil brands are not available in the operating organization’s country or if
the client wishes to use other oil brands, the above mentioned notes apply, too.
Service departments of the lubricant suppliers provide professional information!
During warranty period lubricants as specified in this chapter (original fillings) have to be
used! Otherwise no warranty may be claimed!
54 WS 6449
FUEL QUALITY
Please see engine operators guide!

WS 6449 55
17 IN BETWEEN – PERIODICALLY
Depends on external conditions or operational criteria.
17.1 SAFETY CONTRIVANCES
Safety contrivances must be checked at regular intervals for operativeness. If their

operativeness is not ensured, the machine is no longer “ready for service”!!
Immediate repair is required.
The inspection and its result must be recorded in the operator’s logbook.
Safety contrivances are, e. g.:

- direct-acting brake
- indirect-acting brake
- emergency brake
- emergency switch
- emergency stop buttons
- dead man’s handle
- audible warning systems (high and low frequency signals)
- optical warning systems
56 WS 6449
17.2 BRAKE
Break block play:
If the brake cylinder piston throw is on its limit, the brake force decreases
(as the brake-block play increases continuously) so that finally the brake
cannot apply.
Usually the break block play (distance between the brake block bottom and the wheel
tread) is approximately 5-7mm.
If the value exceeds the tolerances, check the brake piston stroke and adjust it, if
necessary.
The brake block play has to be re-adjusted, when:
- the break block play is not between 5-7 mm.
- the brake blocks are replaced
- the brake blocks are worn out on one side
- the wheel profile had been re-worked
How to adjust the brake block play:
- Secure the machine against breaking away (skid-pans)
- “RELEASE” the parking brake
- Release the brake cylinders (ZERO brake pressure)
- Engine is turned off
- When assembling new brake blocks, first shift the turnbuckles so that there is enough
room for new ones.
- Adjust the brake play by using the turnbuckles.
- Secure the turnbuckles with counternuts.
NOTE: there is no need to disassemble the truss bar head and the brake levers!!
brake blocks:
Please pay attention to the decreased braking

effect after replacing the brake blocks, if these
are unworked or not run in.
Therefore do not change all brake blocks at
once (e.g. in two stages).
Carry out a brake test whenever change brake

blocks.
17.3 COOLER
Timely cleaning
10h or daily WS 6449 57
18 AFTER 10 HOURS OF OPERATION OR DAILY
17.1 PLAIN VISUAL CHECK
17.2 CHECKING WORKING STOCK
DEUTZ ENGINE – OIL LEVEL CHECK ...........................................................................................................59

ENGINE COOLING AGENT – LEVEL CHECK ................................................................................................60
FUEL RESERVES FOR THE DIESEL ENGINE ..............................................................................................61
DIESEL FUEL FILTER .....................................................................................................................................61
HYDRAULIC OIL LEVEL CHECK ....................................................................................................................62
HYDAC FILTER UNIT - CHECK ......................................................................................................................63
DRAIN ALL AIR RECEIVER.............................................................................................................................63
ELEVATOR SURVEY.......................................................................................................................................65
plough adjusting bearing – lubrication ..............................................................................................................66
scraper attachment – lubrication ......................................................................................................................66
58 WS 6449 10h or daily
18.1 PLAIN VISUAL CHECK
Refer to chapter 11.2 “visual check”
Before starting the first operation of the day or after longer breaks it is recommended to
check the machine visually for its general condition and any obvious irregularities when
approaching towards the machine from a greater distance.
Check all areas that can be seen from outside.
A plain visual check is usually carried out before start-up and after work.
18.2 CHECKING WORKING STOCK
DEUTZ ENGINE – OIL LEVEL CHECK
oil level may in principle be checked only

when the vehicle stands on a level track
(without super elevation and gradient)
cold engine:
pull out the oil-level indicator, wipe it clean
with a clean cloth, put it in again up to the limit
stop, pull it out and check the oil level. If
necessary, top up to maximum level.
hot engine:
turn the engine off, wait for 5 minutes and then
check oil level as described above.
If the oil level is only just above the minimum

marker, top up.
Oil level must never be below the minimum
marker.
PLEASE SEE ENGINE OPERATORS GUIDE!

ENGINE COOLING AGENT – LEVEL CHECK
Check the cooling water level at regular

intervals, top up if necessary.
- unscrew the radiator cap to drop pressure
(ATTENTION: combustion hazard!!)
- ensure sufficient quantity of antifreeze.
Original filling by the manufacturer:

approx. 65 litres, Water / Maintain Fricofin
(Fuchs-35°C)
cooling agent indication: at the driver’s desk
Pos. 1: engine oil drain plug

Pos. 2: cooling water drain plug

FUEL RESERVES FOR THE DIESEL

ENGINE
As far as possible ensure that the diesel fuel

tank is filled to avoid water condensation.
filling level indication: at the driver’s desk.
Tank capacity: approx. 750 litres
DIESEL FUEL FILTER
If the dirt indicator (vacuum-meter) points to

the „caution“ zone, immediately replace the
cartridge, however, every 500 engine hours
(Pos.35)
HYDRAULIC OIL LEVEL CHECK
hydraulic oil tank: original filling:

approx. 1050l of Shell Tellus S2 V 68
The upper marker at the inspection glass
shows the maximum level!
Before replacing hydraulic system elements

make sure that the system is unpressurized.
Suction filter

cartridge, however, every 250/500 engine
hours
(Pos.4)
To distinguish the suction filters, please check

numbers on type plate of filters.
Return filter
The filter cartridge has to be replaced every

500 engine hours
(Pos.3)
Whenever changing suction or return filters,

also change aeration filters of the hydraulic
tank.
(Pos.27)
Please see
“SERVICE INFORMATION
S – 230713-B”
HYDAC FILTER UNIT - CHECK
If the gauge indication is within the red range,

the filter element has to be changed
(Pos.9)
filter element
2. pump
3. switching lever:
- lever in left hand position: tank bleeding
- lever in latched central position: filtration
- lever in right hand position: filling of the
tank with filtered fluid
DRAIN ALL AIR RECEIVER
Before start-up of the machine pull the strap to

drain condensation water that possibly may
have assembled.
ALL CONVEYOR BELTS
- check the scrapers, re-adjust, if necessary

- visual check of the conveyor belt suspensions
- check the belt for damage
- check the tight seat of all screws
ELEVATOR SURVEY
support rollers – lubrication
(on the left and right side)
- visual check
- lubricate – Shell Gadus S2 V 100 2
ELEVATOR SURVEY
support rollers – lubrication

plough adjusting bearing – lubrication
- visual check
scraper attachment – lubrication
- visual check
50h or weekly WS 6449 67
19 AFTER 50 HOURS OF OPERATION OR WEEKLY
AXLE GEARBOX – OIL LEVEL CHECK ..........................................................................................................69

AXLE GEARBOX – LUBRICATE ALL DIRT REPELLING AGENTS ...............................................................69
PUMP DISTRIBUTOR GEARBOX – OIL LEVEL CHECK ...............................................................................70
ELEVATOR CHAIN GEARBOX – OIL LEVEL CHECK ...................................................................................70
ENGINE AIR CLEANER – CHECK ..................................................................................................................71
DRAIN ALL DRIP CUPS ..................................................................................................................................71
PNEUMATIC LUBRICATOR – OIL LEVEL CHECK ........................................................................................72
STEEP CONVEYOR BELT ..............................................................................................................................72
guide pulleys .....................................................................................................................................................72
TURNING DEVICE ...........................................................................................................................................72
cylinder .............................................................................................................................................................72
68 WS 6449 50h or weekly
AXLE GEARBOX – OIL LEVEL CHECK
Power Bogie (axle 1 – 2):
- oil level checks may in principle be carried

out only at the vehicle standing on level track
(no super-elevation, no gradient).
- the optimum oil level is in the middle of the

oil inspection eye.
- in case oil level is below the minimum mark,

top up immediately.
Shell Spirax S2 G 80W-90
AXLE GEARBOX – LUBRICATE ALL DIRT

REPELLING AGENTS
- visual check
PUMP DISTRIBUTOR GEARBOX – OIL

LEVEL CHECK
Optimum oil level is in the middle of the oil

inspection eye.
Top up if necessary,
ELEVATOR CHAIN GEARBOX – OIL LEVEL

CHECK
Optimum oil level is in the middle of the oil

inspection eye.
Shell Omala HD150
ENGINE AIR CLEANER – CHECK
Type: STG 14
Open and clean dust reservoir (2) every 50

hrs.
Clean filter cartridge (3) every 250 hours and

replace it at the latest after one year of
operation. After 5 filter services, however, at
the latest, after 2 years the spare cartridge (4)
has to be replaced.
Note!
Do not clean filter cartridge with benzine or
any hot fluids!
For order numbers of filters and filter spare parts, please see spear parts book only.
DRAIN ALL DRIP CUPS
These must be drained at regular intervals to

protect the air drier from contamination.
PNEUMATIC LUBRICATOR – OIL LEVEL

CHECK
Drain water separator.
Shell Tellus S2 V 68
STEEP CONVEYOR BELT
guide pulleys
4 units
- visual check
TURNING DEVICE
cylinder
- visual check
- lubricate – Shell Rimula R6 LM 10W-40
100h or monthly WS 6449 73
20 AFTER 100 HOURS OF OPERATON OR MONTHLY
EXTENDED VISUAL CHECK ..........................................................................................................................75

CONVERTER TORQUE BEARING .................................................................................................................75
CARDAN SHAFT – LUBRICATION .................................................................................................................76
CHECK OF BRAKE LININGS AND BRAKE BLOCK PLAY .............................................................................77
74 WS 6449 100h or monthly
EXTENDED VISUAL CHECK
Refer to chapter „11.2 visual check”
Extended visual checks are performed monthly from the inspection pit.
Extended visual checks have to be carried out before start-up, if:

- the operating condition is unknown
- the machine had been parked over a longer period of time
- a new or untrained crew will put the machine into operation
CONVERTER TORQUE BEARING
Visual check:
- general condition of the rubber elements
- sharp-edged notches
- obvious deformation
- fit of screwed connections
- lubrication –
Shell Gadus S2 V 100 2
CARDAN SHAFT – LUBRICATION
Cardan shafts are lubricated monthly using

Shell Gadus S2 V 100 2 and a lubricating
pressure of max. 15 bar – lubricate until fresh
grease leaks from all four seals.
Clean the grease nipple before and after
lubricating.
Cardan shafts that have been stored for more

than 6 months must be lubricated before being
put into operation.
Venting valves must not be removed or

replaced with standard grease nipples.
Check cardan shafts for changing

running noise and vibration. If
necessary, examine them for
changes in the joint play and the
length compensator.
The balance status of a cardan shaft
must not be altered under any
circumstances.
Do not perform any modifications or
independent repairs to the cardan
shaft without prior written permission
by the manufacturer.
Please see
“SERVICE INFORMATION – S –
280912
CHECK OF BRAKE LININGS AND BRAKE BLOCK PLAY
Brake block:
Brake linings have to be changed at the latest

- the grooves still be fully visible
- the block is worn out on edge
- the block is worn out on one side
- the block is broken
Symbolpicture
Brake block play:

If the brake cylinder piston throw is on its limit, the brake force decreases
(as the brake-block play increases continuously) so that finally the brake
cannot apply.
Usually the brake block play (distance between the brake block bottom and the wheel
tread) is approximately 5-7mm.
If the value exceeds the tolerances, check the brake piston stroke and adjust it, if
necessary.
The brake block play has to be re-adjusted, when:
- the brake block play is not between 5-7 mm.
- the brake blocks are replaced
- the brake blocks are worn out on one side
- the wheel profile had been re-worked
How to adjust the brake block play:
- Secure the machine against breaking away (skid-pans)
- “RELEASE” the parking brake
- Release the brake cylinders (ZERO brake pressure)
- Engine is turned off
- When assembling new brake blocks, first shift the turnbuckles so that there is enough
room for new ones.
- Adjust the brake play by using the turnbuckles.
- Secure the turnbuckles with counternuts.
NOTE: there is no need to disassemble the truss bar head and the brake levers!!
Both brake rods must be screwed into the turnbuckles with the same
length which has to be the thread diameter at least.
250h or semi-annually WS 6449 79
21 AFTER 250 HOURS OF OPERATION OR SEMI-ANNUALLY
DEUTZ ENGINE – OIL CHANGE ....................................................................................................................81

CHECK BRAKE LEVER BEARING AND BRAKE RODS ................................................................................82
HYDRAULIC FILTER CHANGE .......................................................................................................................83
GEARSHIFTING LINKAGE AND CLUTCHING GEAR OF HYDROSTATIC DRIVES ....................................83
CONDITION OF THE BATTERY AND THE CABLE CONNECTIONS ............................................................84
80 WS 6449 250h or semi-annually
DEUTZ ENGINE – OIL CHANGE
Approx. 34l of Shell Rimula R6 LM 10W-40
First oil change after 100 hours of operation.

Any further oil change after 250 hours of
operation, however, at least once a year:
Procedure:
- Heat up the engine

- Ensure horizontal vehicle position
Lubrication oil temperature : approx. 80 °C
- turn off the engine
- clean the surrounding area of the oil drain
plug
- open the oil drain plug and collect the oil
running out in a cup
- beware the danger of scalding yourself by
the used oil
- insert the oil drain plug with a new sealing
ring, tighten it.
- top up oil up to the mark, when filling the oil,
clean and filtered oil only.
- duly deposit the drained oil
- wait for 5 minutes, then check the oil level
again; if it is correct, close the oil drain plug,
make sure that the washer is correctly Pos. 1: engine oil drain plug
seated Pos. 2: cooling water drain plug
Replace the filter cartridge whenever changing oil:
- loosen and unscrew the lubrication oil filter with the help of usual
tools.
- collect possibly running out oil
- clean the sealing surface of the filter support from dirt
- slightly lubricate the rubber seal of the new lubrication oil filter
cartridge
- screw down the cartridge manually until the seal will fit
- perform another half-revolution to screw down the filter cartridge
- check the oil level
- check the oil pressure
- check the seals of the lubrication oil filter cartridge for tightness

CHECK BRAKE LEVER BEARING AND

BRAKE RODS
Clean and check brake lever bearing and

brake rods every 250 hours, lubricate if
necessary.
(Shell Gadus S2 V 100 2)
Visual check:
- general condition
- fastenings
- damaged bellows
- contamination
- tightness of pneumatic connections
- thickness and condition of the brake block
HYDRAULIC FILTER CHANGE

Suction filter

hours
(Pos.4)

Please see
230713-B”
GEARSHIFTING LINKAGE AND CLUTCHING

GEAR OF HYDROSTATIC DRIVES
- Visual check
- Bolts check
- Clean, if necessary
- Lubricate – Shell Gadus S2 V 100 2
CONDITION OF THE BATTERY AND THE

CABLE CONNECTIONS
- keep the battery clean and dry

- loosen contaminated connecting terminals
- clean battery poles (+ / -) and terminals and
lubricate with acid-free and acid-resistant
grease
- when assembling, ensure tight contact of the
terminal connections and finger-tight
fastening of the terminal screws
- check acid level, the fluid level should be at
least 2-3 mm and maximum 10 mm above
the top of the battery plate; if necessary, add
distilled water.
- measure the acid number of the individual
cells with a battery tester.
22 AFTER 500 HOURS OF OPERATION OR SEMI-ANNUALLY
AXLE GEARBOX – OIL CHANGE ...................................................................................................................87

ELEVATOR CHAIN GEARBOX – OIL CHANGE .............................................................................................87
PUMP DISTRIBUTOR GEARBOX – OIL CHANGE ........................................................................................88
SUPERFINE FILTER – CHANGE ....................................................................................................................89
DIESEL FUEL FILTER REPLACEMENT .........................................................................................................90
HYDRAULIC FILTER REPLACEMENT ...........................................................................................................91
AXLE GEARBOX – OIL CHANGE
axle 1: ~8.8l Shell Spirax S2 G 80W-90

axle 2: ~10.9l Shell Spirax S2 G 80W-90
If possible drain the gear oil at working

temperature.
- clean the surroundings of the oil drain plug

- open the oil drain plug and collect the oil
running out in a cup
- beware the danger of scalding yourself by
the used oil
- investigate the drained oil for rubbed off
metal particles
(finger test) – rubbed of metal indicates
damage to the bearings or the gearbox
- insert the oil drain plug with a new sealing
ring, tighten it
- top up oil up to the mark, when filling the oil,
clean and filtered oil only.
- duly deposit the drained oil
- wait for 5 minutes, then check the oil level
again; if it is correct, close the oil drain plug,
make sure that the washer is correctly
seated
ELEVATOR CHAIN GEARBOX – OIL

CHANGE
1.8l of Shell Omala HD150
procedure:
refer to „axle gearbox – oil change“
PUMP DISTRIBUTOR GEARBOX – OIL

CHANGE
3.5l of Shell Spirax S2 G 80W-90
procedure:
refer to „axle gearbox – oil change“
ALL CONVEYOR BELTS
- lubricate the tension bearings of the

deflection pulley
Shell Gadus S2 V 100 2
- if necessary, re-tension the conveyor belt

(check whether the returning chain in clean
condition enters the deflection pulleys when
material is being conveyed)
SUPERFINE FILTER – CHANGE
(Pos.2)

500 engine hours.
DIESEL FUEL FILTER REPLACEMENT

500 engine hours.
(Pos.35)
Check the liquid level in the water separator

drip cups and empty them, if necessary.
(Attention: hazardous waste)
HYDRAULIC FILTER REPLACEMENT

Suction filter

hours
(Pos.4)

Return filter

500 engine hours
(Pos.3)
Change aeration filter every 500h or semi-

annually.
(Pos.27)
Please see
230713-B”
1000h or annually WS 6449 93
23 AFTER 1000 HOURS OF OPERATION OR ANNUALLY
CHECK HYDRAULIC OIL VISCOSITY ............................................................................................................95

CENTRAL BUFFING GEAR .............................................................................................................................95
AIR DRIER – CHANGE FILTER AND GRANULATE CARTRIDGE ................................................................95
PUMP DISTRIBUTOR GEARBOX – AERATION FILTER CHANGE ..............................................................96
AXLE GEARBOX – AERATION FILTER CHANGE .........................................................................................96
FUEL TANK – AERATION FILTER CHANGE .................................................................................................96
CHECK ALL V-BELT TENSIONS ....................................................................................................................97
ALL CABLES AND INSULATIONS ..................................................................................................................98
AXLE BEARING ...............................................................................................................................................98
RETIGHTENING OF THE SCREWS ...............................................................................................................98
FIRE EXTINGUISHER .....................................................................................................................................98
FIRST AID KIT ..................................................................................................................................................98
94 WS 6449 1000h or annually
CHECK HYDRAULIC OIL VISCOSITY
Send 1 litres of hydraulic oil to an authorized testing institute; in case of deviations from
the acid number or increased stage of contamination change the oil.
As the recipes of the individual hydraulic oil manufacturers may differ greatly and as this
might lead to possible undesired chemical reactions, it is strongly recommended not to mix
different brands.
This could lead to increased occurrence of mud and – consequently – to filter problems.
CENTRAL BUFFING GEAR
- visual check
- check all screws for tight fit
AIR DRIER – CHANGE FILTER AND

GRANULATE CARTRIDGE
To avoid damage to the pneumatic equipment

the air drier has to be checked periodically.
The filter cartridges have to be replaced every

2 years of operation.
(Pos.55)
Refer to “Service Instruction ER-67b”!
PUMP DISTRIBUTOR GEARBOX –

AERATION FILTER CHANGE
Change aeration filters every 1000h or

annually.
(Pos. 60)
AXLE GEARBOX – AERATION FILTER

CHANGE
Change aeration filters every 1000h or

annually.
(Pos.28)
FUEL TANK – AERATION FILTER CHANGE
Change aeration filter every 1000h or

annually.
(Pos.25)
CHECK ALL V-BELT TENSIONS
Visual check for damage of the V-belt over its

entire dimension.
Replace defective V-belts.
Check new V-belts after a working time of 15

minutes.
Check V-belt tension by finger test, maximum
depth of impression 15mm, or
use a V-belt tension measuring device.

ALL CABLES AND INSULATIONS
Once every year all cables, pinch connections and insulations have to be
checked and changed if necessary.
AXLE BEARING
Refer to “Service Instructions - Axle Bearing”!
RETIGHTENING OF THE SCREWS
Retighten all screws and bolts once a year.
- all screws of the cardan shafts with a tightening moment as listed below, which
are not secured by retaining pins or washers
See Annex to the service instructions:

Tightening torques for torque wrenches (according to VDI 2230)
- tighten all the following screws if they are not secured by retaining pins or
washers:
- working mode drive

- power divider
- suspensions
- gearboxes
FIRE EXTINGUISHER
- Date of expiry
FIRST AID KIT
- Date of expiry
99
24 ANNEX
100
Tightening torque
Tightening torques for torque wrenches

Set of rules according to VDI 2230 part 1 and EN 25201-2:2010-03
Tightening torques M A when v= 0.9 for set screws with metric standard threads as per DIN
ISO 262; head dimensions of hexagon screws as per DIN EN ISO 4014 to 4018, screws with
hexalobular head as per DIN 34800 and/or cylinder screws as per DIN EN ISO 4762 and
"medium" bore as per DIN EN 20273
Tightening Tightening
Strength b Strength b
Thread torque when Thread torque when
a a
class friction value is class friction value is
0.12c in Nm 0.12c in Nm
8.8 2.7 8.8 265.5
M4 10.9 4.14 M18 10.9 378.9
12.9 4.59 12.9 442.8
8.8 5.31 8.8 373.5
M5 10.9 7.74 M20 10.9 532.8
12.9 9 12.9 622.8
8.8 9.09 8.8 510.3
M6 10.9 13.41 M22 10.9 726.3
12.9 15.66 12.9 850.5
8.8 15.12 8.8 642.6
M7 10.9 22.23 M24 10.9 915.3
12.9 26.01 12.9 1071
8.8 22.14 8.8
M8 10.9 32.49 M27 10.9 1346.4
12.9 37.98 12.9 1575
8.8 43.2 8.8 1285.2
M10 10.9 63.9 M30 10.9 1829.7
12.9 74.7 12.9 2142
8.8 75.6 8.8 1735.2
M12 10.9 110.7 M33 10.9 2472.3
12.9 129.6 12.9 2892.6
8.8 119.7 8.8 2233.8
M14 10.9 175.5 M36 10.9 3181.5
12.9 206.1 12.9 3722.4
8.8 185.4 8.8 2887.2
M16 10.9 271.8 M39 10.9 4112.1
12.9 318.6 12.9 4811.4
a
Strength classes as per DIN EN ISO 898-1 and DIN EN ISO 3506-1.
b
The tightening torques stated were calculated using the factor 0.9.
c
The friction value 0.12 applies to slightly oiled screws (as packaged).
Tightening torque
Tightening torques M A when v= 0.9 for set screws with metric fine threads as
per DIN ISO 262; head dimensions of hexagon screws as per DIN EN ISO 4014
to 4018, screws with hexalobular head as per DIN 34800 and/or cylinder
screws as per DIN EN ISO 4762 and "medium" bore as per DIN EN 20273
Tightening Tightening
Strength b Strength b
Thread torque when Thread torque when
a a
class friction value is class friction value is
0.12c in Nm 0.12c in Nm
8.8 23.49 8.8 408.6
M8x1 10.9 34.47 M20x1.5 10.9 581.4
12.9 40.41 12.9 680.4
8.8 34.29 8.8 551.7
M9x1 10.9 50.31 M22x1.5 10.9 785.7
12.9 58.86 12.9 919.8
8.8 47.7 8.8 716.4
M10x1 10.9 70.2 M24x1.5 10.9 1019.7
12.9 81.9 12.9 1193.4
8.8 45.9 8.8 692.1
M10x1.25 10.9 67.5 M24x2 10.9 985.5
12.9 78.3 12.9 1153.8
8.8 81 8.8 1037.7
M12x1.25 10.9 119.7 M27x1.5 10.9 1478.7
12.9 139.5 12.9 1729.8
8.8 78.3 8.8 1007.1
M12x1.5 10.9 115.2 M27x2 10.9 1434.6
12.9 135 12.9 1679.4
8.8 127.8 8.8 1400.4
M14x1.5 10.9 188.1 M30x2 10.9 1994.4
12.9 219.6 12.9 2334.6
8.8 196.2 8.8 1873.8
M16x1.5 10.9 288 M33x2 10.9 2668.5
12.9 336.6 12.9 3123
8.8 294.3 8.8 2452.5
M18x1.5 10.9 418.5 M36x2 10.9 3493.8
12.9 489.6 12.9 4087.8
8.8 279.9 8.8 3143.7
M18x2 10.9 398.7 M39x2 10.9 4476.6
12.9 467.1 12.9 5238.9
a
Strength classes as per DIN EN ISO 898-1 and DIN EN ISO 3506-1.
b
The tightening torques stated were calculated using the factor 0.9.
c
The friction value 0.12 applies to slightly oiled screws (as packaged).
Service Information S-110506-D 1
SERVICE INFORMATION S-110506-D
Intermediate Clutch
englisch
Version Date In charge Modification Pages
1.0 05-2006 - First version

All rights reserved, particularly the right of duplication, distribution and translation. Unless
written consent is given, this document may not be passed to third Parties.
englisch
Operating and Servicing Instructions
Moreover, please observe the current version of the general operational and
safety regulations for Plasser & Theurer track maintenance machines as well as
the safety guidelines for preparing repair work.
Intermediate Clutch
BR 152 0300
Part. No. Part. No. Part. No
WN 220.01 A WN 220.02 WN 220.03 A

WN 220.04 A(/3X) WN 220.05 WN 220.06
WN 220.07 WN 220.08 WN 220.09
WN 220.10 WN 220.11 WN 220.12 A
WN 220.13 WN 220.14 WN 220.15 A
WN 220.17 WN 220.18 WN 220.19 A
WN 220.20 WN 220.21 A WN 220.22
WN 220.23 A WN 220.25 WN 220.26
WN 220.27 WN 220.28 WN 220.29
WN 220.30 WN 220.31 WN 220.32
WN 220.34 A WN 220.35 WN 220.36
WN 220.37 WN 220.38 WN 220.39
WN 220.40 WN 220.41 WN 220.43
WN 220.44 WN 220.45 WN 220.46
WN 220.47 WN 220.48 WN 220.49
WN 220.50 WN 220.51 WN 220.53
WN 220.54 WN 220.55 WN 220.56
WN 220.57 WN 220.58 WN 220.59
WN 220.60 WN 220.61 WN 220.62
WN 220.63 WN 220.65
englisch
INSTALLATION AND SERVICING REGULATION

Intermediate Clutch BR 152 0300
Dismantling and stripping the intermediate clutch
For checking or for exchanging the clutch element (Pos. 3) the cardan
shaft screwed to the intermediate clutch is released and removed.
After this, the flywheel connecting bolts are released and the clutch can
be lifted out completely.
After releasing the out bolts (Pos. 7) and the inner bolts (Pos.), the
clutch can be dismantled into its separate parts.
Attention:
Only use original spare parts!!
englisch
Cleaning and checking the clutch parts
Before assembly all parts should be cleaned. Special care has

to be taken with the contact surface of the cardan shaft and the
fly wheel connection (see drawing).
Use a cloth with a bit of cleaning material; never clean the
whole clutch with the cleaning material.
No gasoline, petroleum or oil should be used on rubber parts.
englisch
In case of slight soiling, i.e. dry, powdery dust, the clutch parts
should be cleaned only with a hand brush.
Take care not to change the smoothly worn running faces of the
close-fitting steel parts for friction disc (Pos. 3). It is not possible to
re-work these surfaces due to the precision of the surfaces.
In the case of heavy soiling, i.e. sticky, smeared rubber residue as

occurring when the clutch turns through, the steel parts of the clutch
can be washed in a cold cleaning fluid.
If the element (Pos. 3) broke in operation, the clutch had turned

through. In that case the friction disc (Pos. 4) and the friction ring
(Pos. 5) generally should be exchanged.
During checks not in connection with damage, the friction disc and
friction ring should be checked for wear. The threshold values for
wear can be taken from the general checking and servicing guide-
lines.
englisch
INSTALLATION AND SERVICING REGULATION

Intermediate Clutch BR 152 0300
Assembly and installation instruction
When assembling the clutch the bolt tightening moments must be

observed.
Note the different clutches and their tightening moments (please see
list 1 – annex).
Assembly begins with the insertion of the friction ring (Pos. 5) and
the friction disc (Pos. 4) into the flange mantel (Pos. 1). If re-using
the friction disc (Pos. 4) the faces should be lightly coated with min-
eral oil. The friction ring (Pos. 5) should be inserted in dry condition.
After this, the hub (Pos. 2) is pushed in and the rubber element
(Pos. 3) inserted. The clutch is bolted together firmly using the inner
and the outer fastening bolts (Pos. 6 and 7).
The cardan shaft can now be mounted and bolted.
Balancing
All intermediate clutches are balanced with a balancing quality of

G = 6,3 as per. DIN ISO 1940!
The wearing parts to be renewed in the case of repair are rotation

symmetrical and in our experience do not lead to any impermissible
or disruptive imbalance.
If any irregularity in running should occur, it is necessary to make a

balancing check. The permissible imbalance data can then be taken
from the assembly drawing.
englisch
Checking and Service – general
Dismantling of the clutch is performed according to the appropriate dismantling guidelines.

When the clutch has been dismantled, the friction disc and friction ring can be measured.
See table for permissible wear.
The clutch element can be investigated for possible loose parts and cracks by pulling it
apart axially under a press.
The pulling distance should not exceed a maximum of 1/3 of the overall height of the
clutch element. Loose parts and cracks become visible in extended state, in which case
the element must be exchanged.
Cleaning and assembly should be carried out according to the appropriate cleaning and
assembly guidelines.
THE PARTS SHOULD BE EXCHANGED AT THE FOLLOWING INDICATIONS:
Clutch element - if damage has occurred

Friction disc and friction ring - if wear threshold values in the table are
exceeded
NOTE:
If the rubber element is exchanged, the friction ring and friction disc must also
be renewed at all events to ensure that the properties of the clutch comply
with those of a new one!
For orders, please use the ordering number for the clutch from the spare parts catalogue.
To avoid wrong deliveries, it is advisable also to state the production no. stamped on the
main body of the clutch!
Threshold values of wear for friction disc and friction ring above which it is recom-
mended to exchange these components
Type 005 010 020 030 035 040 045 050 055 060 065 070 075 080 085 090
Thickness 3 3 3 4 4 4 4 5 5 6 6 6 7 7 8 8
Permissible 0,3 0,3 0,3 0,4 0,4 0,4 0,4 0,5 0,5 0,6 0,6 0,6 0,7 0,7 0,8 0,8
wear
CAUTION:
All intermediate clutches are balanced with a balance quality of G = 6,3 as
per. DIN ISO 1940!
If running is not smooth after a repair, re-balancing is needed according to
the threshold values given in the assembly drawing.
englisch
ANNEX: List 1
Bild 2 Bild 3
Bild 1
Bild 4
Part. No. Type Pos. 6 [Nm] Pos. 7 [Nm] Pos. 8 [Nm] Pos. 9 [Nm]
WN 220.01A 045 190 49 120 -
WN 220.02 045 190 49 190 -
WN 220.03A 045 190 49 190 -
WN 220.04A 050 295 86 - 190
WN 220.04A 3X 050 295 86 - 190
WN 220.05 030 120 25 - -
WN 220.06 040 190 49 - 190
WN 220.07 055 405 135 - -
WN 220.08 050 120 86 210 210
WN 220.09 050 - 86 - -
WN 220.10 040 69 - - -
WN 220.11 030 120 35 - 120
WN 220.12A 040 190 49 120 -
WN 220.13 040 190 49 120 -
WN 220.14 040 120 49 - 190
WN 220.15A 045 190 49 120 -
WN 220.17 040 190 49 115 -
WN 220.18 030 69 25 - -
WN 220.19A 045 190 49 190 -
WN 220.20 045 180 49 - 180
WN 220.21A 040 190 49 120 -
- means "no screw at this pos."
englisch
Pos. 6 Pos. 7 Pos. 8 Pos. 9 Pos. 10

Part. No. Type
[Nm] [Nm] [Nm] [Nm] [Nm]
WN 220.22 050 295 86 - - -
WN 220.23A 045 190 49 190 - -
WN 220.25 030 120 25 - - -
WN 220.26 030 120 120 69 - -
WN 220.27 030 69 25 - - -
WN 220.28 050 295 86 - - -
WN 220.29 045 190 49 - 120 -
WN 220.30 045 190 49 - 180 -
WN 220.31 055 405 135 280 - -
WN 220.32 030 120 49 - - -
WN 220.34A 030 120 25 120 - -
WN 220.35 030 120 25 120 - -
WN 220.36 030 120 49 - - -
WN 220.37 060 580 135 295 - -
WN 220.38 040 190 49 190 - -
WN 220.39 040 190 49 120 - -
WN 220.40 055 405 135 295 - -
WN 220.41 030 120 49 - - -
WN 220.43 030 120 49 - - -
WN 220.44 040 190 49 - 190 -
WN 220.45 050 295 86 190 - -
WN 220.46 050 295 86 180 - -
WN 220.47 050 295 120 280 - -
WN 220.48 030 69 - - - -
WN 220.49 040 190 49 190 - -
WN 220.50 030 120 25 120 - -
WN 220.51 045 190 49 190 180 -
WN 220.53 055 405 135 - - -
WN 220.54 040 190 69 - 180 -
WN 220.55 040 190 69 - 180 -
WN 220.56 045 190 49 190 - -
WN 220.57 035 69 25 - - -
WN 220.58 040 190 49 120 - -
WN 220.59 055 405 135 280 - -
WN 220.60 035 120 35 180 - -
WN 220.61 045 115 69 190 120 -
WN 220.62 040 190 49 190 115 -
WN 220.63 050 - 86 - - -
WN 220.65 060 550 33 180 - -
WN 220.66 - 77 - - -
WN 220.67 055 390 125 - - -
WN 220.68 02 66 33 - 33 115
- means "no screw at this pos."
englisch
S – 230713_B 1
HYDRAULIC SUCTION FILTER

REPLACEMENT
englisch
2 S – 230713_B
A 23.7.13 SN Change interval HY-suction filter 11

B 11.10.13 MP Filter cartridge numbers added 11

All rights reserved, particularly the right to produce copies, to distribute these copies, as
well to translate the work.
englisch
S – 230713_B 3
HYDRAULIC SUCTION FILTER REPLACEMENT

 Before starting to replace the suction
filter, some principal requirements have
to be met:
 Under no circumstances handle open

fire on the machine.
 HAZARD OF FIRE!!!!
 The machine must be secured from

BREAKING AWAY (activated parking
brake, activated safety brake, skid-pans
etc.).
 Furthermore, the machine engine has to be

turned off and protected against
unauthorized starting.
 The hydraulic system must be

depressurized and secured against
unauthorized operation.
englisch
4 S – 230713_B
 It is necessary to cool down the hydraulic oil

to ambient temperature (the machine has to
be out of operation for several hours).
OTHERWISE HAZARD OF BURNS!
 replace the suction filter in accordance with

the service intervals and/or the degree of
contamination (see symbolic photograph).
 clean the suction filter case by using a

suitable cleansing agent. DO NOT USE
inflammable cleansing agents.
englisch
S – 230713_B 5
 When having cleaned the outer case of the

suction filter unit thoroughly from dust,
grease and other dirt, you may start to
replace the suction filter itself.
 For replacing the filter an open-end wrench

(opening 36) or a ring wrench (opening 36)
and a suitable receptacle for the old filter
are required.
englisch
6 S – 230713_B
 Press the above mentioned open-end

wrench, or, optionally, the ring wrench
tightly onto the hexagon on the suction filter
cover. The wrench must fit tightly.
 Put the receptacle for the old suction filter

and the oil running out underneath the
suction filter case.
 Turn off the cover for 25 mm, a slight

pressure exerted by the return valve has to
be felt. As the return valve is proportional to
the thread of the filter case cover, after 25
mm the return valve has to be closed.
englisch
S – 230713_B 7
 It is advisable to screw off the joint of the

mini-measuring line (see arrow). This
procedure makes it possible to test the
function of the return valve.
 Provided that it is operated and used as

directed the return valve incorporated in the
suction filter case ensures that no hydraulic
oil escapes from the hydraulic oil tank.
 If due functioning of the return valve is

ensured, completely screw out the cover
and remove it carefully, duly collect the oil
remaining in the filter case. After about ¾ of
a litre to 1 litre no more oil must come out.
englisch
8 S – 230713_B
 Remove the suction filter from its case and

put it into the receptacle.
 The hydraulic filter together with the

hydraulic oil coming out have, of course, to
be deposited duly.
englisch
S – 230713_B 9
 Caution: avoid damage to the O-ring on

the suction filter case.
 Seal the screwed connection of the mini-

measuring line again, screw it into the filter
case unit the connection will fit tightly, but
make sure not to screw it in too far, as
otherwise the return valve would not
function !!!!!!
 The new suction filter (item number – see

spare parts catalogue, hydraulic system
scheme) has to be put into the case in
accordance with the required mounting
position!
To ensure the operational safety of the

hydraulic system, only original spare parts
must be used.
englisch
10 S – 230713_B
 Check the tight fit and the due condition of

the O-ring.
 When the O-ring is safe for operation,

lubricate it slightly with hydraulic oil so that it
will more easily adapt to the surface.
 Screw in the case cover using the wrench

36 and tighten it. The O-ring must neither
come out nor get damaged !
 Now the hydraulic system again is ready for

operation.
 Check the tightness of the suction filter

case.
englisch
S – 230713_B 11
 It is recommendable to check the viscosity

of the hydraulic oil by an authorized institute
when replacing the suction filter. In case of
relevant deviations of the acid number or an
increased degree of contamination change
the hydraulic oil (as required according to
the service instruction). Observe the
respective safety instructions for handling
hydraulic oil.
CHANGE INTERVAL OF HYDRAULIC SUCTION FILTERS

To different the suction filters, please check numbers on type plate of filters.
Filter no.: Filter cartridge no.: Change intervals (operating hours)
HY-S501.360.150 HY-S501.360.150ES 500h

HY-S501.460.150 HY-S501.460.150ES 500h
HY-S501.560.150 HY-S501.560.150ES 500h
HY-S501.160.P10 HY-S501.160.P10ES 250h

HY-S501.300.P10 HY-S501.300.P10ES 250h
englisch
S – 090209 1
SERVICE INFORMATION S-090209
Measures to be taken in the event of

damaged brake blocks
englisch
2 S – 090209
1.0 02-2009 - Original issue -
All rights reserved, particularly the right to produce copies, to distribute these copies, as
well to translate the work.
englisch
S – 090209 3
Service Information
on measures to be taken in the event of damaged brake blocks
Please observe the instructions SI-0400-03 and BS-02.05!
englisch
4 S – 090209
1. Crack going through to the carrier sheet
Type of damage:
The friction material shows a radial crack
from the friction surface onto the carrier
sheet.
Required measure:
Immediate replacement of the
brake block!
2. Spalling friction material
Type of damage:
Frictional material spalling over more than
¼ of the length of the block.
(spalling > 63 mm over a block length of
250mm;
spalling > 80mm over a block length of
320 mm;
Required measure:
Immediate replacement of the
brake block!
NOTE:
Consider that after replacement of the brake shoes the braking effect is
reduced, if the shoes are not treated or run in.
englisch
S – 090209 5
3. Material detaching from the carrier sheet
Type of damage:
Material detaching from the carrier sheet.
Required measure:
If the length of the detaching
material exceeds 25 mm, the
brake block must be replaced
immediately!
4. Superficial fissures in a circumferential direction
Type of damage:
Superficial fissures in a circumferential
direction.
Required measure:
If the length of the superficial
fissure exceeds 25 mm, the brake
block must be replaced
immediately!
NOTE:
Consider that after replacement of the brake shoes the braking effect is
reduced, if the shoes are not treated or run in.
englisch
6 S – 090209
5. Through crack in the predetermined breaking point
Type of damage:
Through crack in the predetermined
breaking point.
Required measure:
No measures required.
6. Superficial radial fissures
Type of damage:
Superficial radial fissures in the block
material.
Required measure:
No measures required.
PLASSER & THEURER

SERVICE CENTER
LINZ - AUSTRIA
englisch
S – 280912 engl.
SERVICE INFORMATION S-280912
Checking and maintenance of

cardan shafts
S – 280912
Copyright © Plasser & Theurer

All rights reserved, particularly the right of duplication, distribution and translation. Without
written permission by Plasser & Theurer no part of this work may be reproduced in any
form (photocopy, microfilm or other methods) or stored, processed, duplicated or
distributed by means of electronic systems.
S – 280912 1
Service Information
Checking and maintenance of cardan shafts
Please observe SI-0400-04 and BS-02.05!
Work to the machine may only be carried out by qualified

and authorised personnel that has been instructed about
dangers.
2 S – 280912
Checking and maintenance interval of cardan shafts:

No later than 250 operating hours or monthly before putting into operation,
whichever event occurs first.
1. Safety information
• When working on cardan shafts the drive must be shut down - shut down the engine
and make sure that the drive cannot be put back in operation by unauthorised third
parties.
• Fitting, assembly and maintenance work on cardan shafts must only be carried out by
qualified and authorised personnel that has been instructed about the dangers.
• Do not reach into the joints when fitting, removing or transporting cardan shafts in order
to avoid crushing injuries from tipping flanges or joint components. Take appropriate
measures to prevent cardan shaft halves slideing apart inadvertently and cause
injuries or damage.
• Do not put any weights on cardan shafts when they are stationary; do not place, hook in
or otherwise fasten any tools or other objects on the shafts.
You must observe the following basic information to avoid damage and danger:
• Check the cardan shaft regularly for changing running noise and vibration. If
necessary, check the stationary cardan shaft for changes in the joint play and length
compensator.
• The balance status of a cardan shaft must not be altered under any circumstances.
• Do not perform modifications or independent repairs to the cardan shaft without prior
written permission by the manufacturer as this may result in danger to persons and
material and will make any warranty claims void.
• Cardan shafts must not be cleaned with a water or steam jet so as to avoid damage to
the seals and prevent the ingression of water and dirt.
• Do not use aggressive cleaning agents for cleaning.

S – 280912 3

2. Lubrication
Cardan shafts are normally equipped with

two/three DIN 71412 conical grease
nipples. (see different designs)
Permitted lubricant:
Temperature range from -30 °C to max.
+100°C:
Only use lithium-saponified greases,
consistency class 2 with 265/295 penetration
and dripping point at approx. 180 °C.
The lubricants must not contain any MoS2
additives.
Shell Gadus S2 V100 2, the grease specified

by Plasser&Theurer, meets these criteria.
• Clean grease nipple before lubricating!

• Venting valves must not be removed or
replaced by standard grease nipples.
• The lubricant must not be pumped in with too
much force/pressure.
Max. permissible lubricating pressure: 15
bar.
• Make sure to pump in the grease until it is
leaking from all four bearing seals. This will
ensure that all four bearings will have
received fresh grease.
• Cardan shafts that have been stored for
more than six months must be lubricated
before being put into operation.
4 S – 280912

3. Information for checking
• Check that screw connections and

connection flanges are tightly seated.
• Check cardan shafts for unusual running
noise and vibration when in operation. If
necessary, establish the causes and arrange
repairs.
• Before lubricating check the cardan shaft
play in the joint bearings and in the length
compensator.
Checks when fitting the cardan shaft:

• Clean the cardan shaft flange faces and the
counter flange before fitting the cardan shaft.
Do not grease or lubricate!
Remove any anti-corrosion agents and
paint residues thoroughly.
Remove any potential slight damage
(impact and scratch marks).
• Check counter flange for radial and axial
run-out accuracy.
PLASSER & THEURER

Service Center
Linz/ Austria
S – 43h
GENERALINSPEKTION VON GENERAL INSPECTION OF DRIVE

ANTRIEBSKOMPONENTEN COMPONENTS
an Bahnbaumaschinen of Railway Machinery
und Oberbaufahrzeugen 6 YEARS AFTER THE FIRST START-UP,
NACH 6 JAHREN AB INBETRIEBNAHME, however, not later than after 8000 hours
aber spätestens nach 8000 of operation
Betriebsstunden.
Neben den vorgeschriebenen regulären In addition to compulsory standard
Wartungs- und Revisionsintervallen sind nach 6 maintenance and revision intervals, the
Jahren ab der ersten Inbetriebnahme, following examinations and preventive
spätestens aber nach 8000 Betriebsstunden, measures must be carried out 6 years after the
folgende Untersuchungen und first start-up, or at the latest, after 8000 hours
Präventivmaßnahmen durchzuführen: of operation:
Zustand u. Structural Condition Replace-

Baugruppe Bauteil Erneuerung Structural Component
Reparatur Unit and Repair ment
Allgemein X General X
Kraftstoffanlage X Fuel system X
Leitungen X Lines X
Filter X Filters X
Keilriemen X V-Belts X
Keilriemenscheiben X V-Belt pulleys X
Kühlsystem X Cooling system X
Luftpresser X Air compressors X
Alternatoren X Alternators X
Starter X Starter X
ENGINE
MOTOR
Abgasanlage X Exhaust system X

Aufstellung X Installation X
Dämpfungselemente X Damping elements X
Befestigungsschrauben X Fastening screws X
Rahmen und Stützen X Frame and supports X
Kupplung X Clutch X
Nebenantriebe X Auxiliary drives X
Radreifenprofil X Wheel tyre contour X

Verschleiß prüfen und ggf. reprofilieren. Check for wear and re-profile, if necessary
ACHTUNG ! ATTENTION !
1. Alle Radsätze müssen gleichen Laufkreis- 1. All wheelsets must have the same running circle
Durchmesser haben. diameter.
2. Die Verschleißgrenze (Marke) darf nicht 2. The wear limit (marked) must not be exceeded.
überschritten werden. 3. When re-profiled wheelsets are used, the
3. Bei nachgedrehten Radsätzen ist unter following must be adhered to taking into account
Berücksichtigung der Einfederung folgendes the spring deflection:
unbedingt zu beachten: a) Clearance between components.
a) Berührungsfreiheit zu anderen Bauteilen. b) Observance of the vehicle gauge.
RADSÄTZE
WHEEL SETS
b) Einhaltung des Fahrzeugprofiles. c) Unhindered brake application.

c) Unbehinderte Wirkung der Bremsen. d) Unimpeded effective stroke of shock
d) Freier Wirkungshub der Stoßdämpfer. absorbers
e) Bei Triebachsen:- e) For powered axles:
• Lage des Achsgetriebes, • position of the axle gearbox
• Lage der Drehmomentstütze, • position of the torque bracket
• Beugungswinkel und Längenausgleich • Deflection angle and length
der Gelenkwellen. compensation of cardan shafts
deutsch / englisch
S – 43h

Achslagergehäuse X Axle bearing housings X
Zerlegen und Lagersitze prüfen. Bei Verschleiß-spuren sind Disassemble and check the bearing seats. Fit new bearing
die Lagergehäuse zu erneuern. housings, if traces of wear have been found.
Alle Achslager * X All axle bearings X
Fettfüllung X Lubricant X
Alle Gummifedern X All rubber springs X
Spiralfedern X Spiral springs X
AUFHÄNGUNG
Federn auf Ermüdung überprüfen, ggf. sind die Federn aller Check springs for fatigue, if necessary, replace the springs
SUSPENSION
WHEEL SET
RADSATZ-
Radsätze zu erneuern. of all wheelsets.

Federhalterungen X Spring fastening X
Federführungen und Stützplatten überprüfen, bei Check spring guides and support plates, replace all guides
Verschleißerscheinungen sind alle Führungen und and support plates of a wheelset, if traces of wear have
Stützplatten eines Radsatzes zu erneuern. been found.
Alle Stoßdämpfer X All shock absorbers X
Drehzapfen X Bogie pin X

Drehzapfenlager X Bogie pin bearing X
DREHGESTELLE
Drehpfanne X Bogie pivot X

Fettfüllung X Lubricant X
BOGIES
Lateral spring system
Seitenfederung (Gummi) X X
(rubber)
Seitenfedern (Spiralfed.) X Lateral springs (spiral) X
Gleitplatten X Slide plates X
Stoßdämpfer X Shock absorbers X
Drehgestellrahmen X Bogie frame X
Achslagerführungen X Axle bearing guides X
Achsgetriebe X Axle gearboxes X

Zahnräder X Toothed wheels X
Lager X Bearings X
Antriebswellen X Drive shafts X
Kupplungsteile X Clutch components X
ACHSANTRIEBE
Dichtungen Seals X
AXLE DRIVES
X
Schmierpumpe X Lubrication pump X
Gelenkwellenflansch X Cardan shaft flange X
ACHTUNG !
ATTENTION !
1. Bei Kegelradgetrieben sind Tellerrad und Triebling
1. Crown wheel and pinion are paired in bevel gears. If
gepaart. Bei fehlerhaften Teilen ist das Achsgetriebe, bzw.
defective parts have been found, the axle gearbox or the
der Radsatz zu erneuern.
wheelset need to be replaced.
2. Bei formschlüssigen Antrieb mehrerer Achsen müssen
2. If positive engagement drives of several axles are used,
alle Radsätze unbedingt den gleichen
all wheelsets must have wheels of the same running circle
Laufkreisdurchmesser haben. Dazu entweder alle
diameter. In that case, all wheelset need to be replaced or
Radsätze zu erneuern oder auf den gleichen Durchmesser
reworked to provide the same diameter.
zu drehen.
Alle Gelenkwellen X All cardan shafts X

ACHTUNG !
CARDAN SHAFTS
GELENKWELLEN
Es dürfen nur vorgeschriebenen Schrauben, ATTENTION !

Sicherungsscheiben und Muttern verwendet werden. Die Only bolts, retaining washers and nuts as prescribed are
erforderlichen Anzugsmomente müssen eingehalten allowed to be used. The required tightening torques must
werden. Nach spätestens 25 Betriebsstunden die be observed. Check the cardan shafts and their screw
Gelenkwellen und deren Verschraubungen überprüfen; in connections not later than after 25 hours of operation;
der weiteren Folge monatlich. Weiters sind dabei die subsequently perform checks on a monthly base. Also carry
Gelenkwellen einer Sichtkontrolle zu unterziehen, auf out visual inspections of the cardan shafts, check them for
Laufgeräusch und Vibration und das Gelenkwellenspiel zu bearing noises and correct play.
prüfen.
*Ein Austausch der Achslager durch Plasser & Theurer original Ersatzteile ist empfehlenswert. Eine Aufarbeitung der Achslager
durch eine geeignete Werkstatt ist möglich, Plasser & Theurer haftet jedoch nicht für Schäden die durch deren Verwendung
entstanden sind.
* We recommend replacing of the axle bearings with original Plasser & Theurer spare parts. Axle bearings can be reworked in
workshops that are accordingly equipped; nevertheless, Plasser & Theurer does not accept liability for any damage caused by the
use of such reworked bearings.
deutsch / englisch
S – 43h

Alle Kraftübertragungen X All power transmissions X

ANTRIEBS-
FLANSCHE
FLANGES
Befestigungen, Lager, Dichtungen, Keilprofile und Fastenings, bearings, seals, spline profiles and flange
DRIVE
Flanschbohrungen auf Verschleiß überprüfen und bores need to be checked for wear, defective parts
schadhafte Teile erneuern. need to be replaced.
Alle Getriebe All gear boxes

X X
GETRIEBE
BOXES
GEAR
Generalinspektion und Erneuerung aller verschlis- General inspection and renewal of all worn or
senen, bzw. defekten Bauteile. defective components.
HINWEIS: NOTE:
Alle Inspektions- und Reparaturmaßnahmen dürfen nur von Only authorized and specialized workshops are allowed to carry out
autorisierten Fachdiensten durchgeführt werden. inspection and repair work..
Es sollen nur Original-Ersatzteile verwendet werden. Only original spare parts are recommended for use.
PLASSER & THEURER

SERVICE CENTER
LINZ - AUSTRIA
Alle Rechte, insbesondere auf Vervielfältigung, Verbreitung sowie Übersetzung, vorbehalten.
All rights reserved, particularly the right to produce copies, to distribute these copies, as well to translate the
work.
deutsch / englisch
SI – 0300-01
GENERAL DESCRIPTION FOR THE OPERATION, MAINTENANCE, PERIODICAL CHECKING AND

TRACK WORTHINESS OF PLASSER & THEURER TRACK MAINTENANCE MACHINERY.
On track Heavy Plant Machinery, Measuring Cars and Inspection Vehicles are subject to certain operation
and periodical maintenance procedures to maintain the correct standard and ensure they meet the safety
requirements.
The end user is responsible to follow the instructions of the manufacturer to keep the vehicles in correct
operational and working condition. For this purpose we the manufacturer hereby supply the following
instructions that should be strictly adhered to:
1) SAFETY REQUIREMENT:
Our Direction; “General Operation and Safety Requirements for Plasser & Theurer Track
Maintenance Machines, BS-02.05-*” This instruction is a part of the documentation originally delivered
with the machine. The instruction should be carefully read and followed, it contains instructions for
operating, how to reduce danger and risks, and other useful information.
2) TRACK WORTHINESS:
The End User is responsible for ensuring that all necessary requirements related to vehicle safety on
track have been fulfilled.
3) INTENDED USE, OPERATION AND LIABILITY:
a) The delivered vehicle should only be used for the purpose that it is designed for, and should only be
operated and maintained by qualified personnel.
b) In case the machine is not operated and maintained by qualified persons, or repairs are carried out
without following the service instruction, or the use of non original spare parts, the manufacturer can
not be held responsible for any damage.
4) OPERATING CONDITION AND MAINTENANCE:
Before putting the vehicle into operation the end user must ensure that the delivered product is fully
operational:
a) All necessary instructions and maintenance intervals as stipulated in the Service Instructions must
be followed by the machine personnel.
b) Only those materials described in the relevant instructions should be used for cleaning and
maintenance.
5) INSPECTION AND REPAIR:
In addition to the recommended periodical inspection of Track Maintenance Equipment, and with
reference to requirements for Heavy Plant Machinery, it is necessary to carry out frequent checks on;
Undercarriage, Drive Control, Brake System Components, Frame, General Working Functions,
Measuring Systems and Safety Controls. Any problem identified should be immediately reported and
dealt with.
a) The machine must always be repaired in a suitable workshop by qualified personnel using only
approved components.
b) In general a service network for technical assistance has been set up by Plasser & Theurer.
c) The End User (customer) in case of failure can contact the appropriate Plasser & Theurer Service
Branch.
d) The Service Branch is available for providing Technical Assistance for the checking and
commissioning of the machine, in both a practical and technical capacity.
e) To ensure an accurate and reliable performance of the equipment it is strongly recommended that
only original spare parts should be used. During the warranty period it is a condition of the warranty
that original spare parts from Plasser & Theurer have to be used.
f) Modifications, additional installations and using the equipment for purposes other than which it was
designed for, can seriously affect the safety requirements of the equipment, and therefore can only
be carried out with the prior approval of the manufacturer.
Plasser & Theurer

Export von Bahnbaumaschinen
Gesellschaft m.b.H.
SERVICE INFORMATION SI-0400-04

TO BE CARRIED OUT ON THE MACHINE IN THE WORKSHOP
personnel.
Before any repair work is carried out on the machine, the following safety instructions
must be observed:
• Deactivate hydraulic pressure (visual check of the pressure gauge reading).
• Deactivate the air system (visual check of the pressure gauge reading).
• Protect the machine from rolling away (parking brake, skid-pans etc.!)
• Turn off the engine!
• Turn off the working-mode main switch and protect it from unauthorized operation!
• Turn off the battery main switch and protect it from unauthorized operation!
• If repair work is carried out in closed workshops, the battery sets have to be
disconnected (machine without current) and the battery terminals have to be
secured accordingly.
• Furthermore, the machine crew and all persons that have access to the machine
must be informed of the intended repair work!
• A professionally competent person has to be nominated who will bear the main
• Before the machine operating mode is restored, the entire crew must be notified of
the repair work carried out; only a professionally competent person is allowed to
restore the machine operating mode!
• In working mode, the working area is again prohibited!

SI-0400-04 SERVICE INFORMATION

TO BE CARRIED OUT ON THE MACHINE OUTSIDE THE WORKSHOP
personnel!
PLEASE OBSERVE THE LOCAL RAILWAY REGULATIONS!
Before any repair work is carried out on the machine, the following safety instructions
must be observed:
• Deactivate hydraulic pressure (visual check of the pressure gauge reading).
• Deactivate the air system (visual check of the pressure gauge reading).
• Protect the machine from rolling away (parking brake, skid-pans etc.!)
• Turn off the engine!
• Turn off the working-mode main switch and protect it from unauthorized operation!
• Furthermore, the machine crew and all persons that have access to the machine
must be informed of the intended repair work!
• A professionally competent person has to be nominated who will bear the main
• The decision whether to switch off the battery main switch and to protect it from
unauthorised operation for the repair work to be carried out is at the discretion of the
person chiefly responsible!
On the other hand, should an electrical failure have occurred, the battery main
switch MUST be switched off and protected from unauthorised operation before
remedy work is started!
• When repair work needs to be carried out with the battery main switch turned off,
the operating organisation must provide sufficient signal lights according to the
respective national regulations, as well as sufficient lighting of the working areas!
• Before the machine operating mode is restored, the entire crew must be notified of
the repair work carried out; only a professionally competent person is allowed to
restore the machine operating mode!
• In working mode the working area is again prohibited!

Version 2.1
Effective Date 12.12.2012
Regulation 1907/2006/EC
Safety Data Sheet
SECTION 1. IDENTIFICATION OF THE SUBSTANCE/MIXTURE AND OF THE

COMPANY/UNDERTAKING
1.1 Product Identifier
Material Name : Shell Spirax S2 G 80W-90

Product Code : 001D8261
1.2 Relevant identified uses of the substance or mixture and uses advised against
Product Use : Transmission oil.
Uses Advised Against : This product must not be used in applications other than those
recommended in Section 1, without first seeking the advice of
the supplier.
1.3 Details of the Supplier of the safety data sheet
Manufacturer/Supplier : Shell UK Oil Products Limited

Shell Centre
London
SE1 7NA
United Kingdom
Telephone : (+44) 08708500939

Email Contact for : If you have any enquiries about the content of this SDS please
Safety Data Sheet email lubricantSDS@shell.com
1.4 Emergency Telephone Number
: +44-(0) 151-350-4595
SECTION 2. HAZARDS IDENTIFICATION
2.1 Classification of the substance or mixture
1999/45/EC
Hazard Characteristics R-phrase(s)
Not classified as dangerous under EC criteria.;
2.2 Label Elements
1/17
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MSDS_GB
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Safety Data Sheet
Labeling according to Directive 1999/45/EC
EC Symbols : No Hazard Symbol required
EC Classification : Not classified as dangerous under EC criteria.

EC Risk Phrases : Not classified.
EC Safety Phrases : Not classified.
2.3 Other Hazards
Health Hazards : Not expected to be a health hazard when used under normal
conditions. Prolonged or repeated skin contact without proper
cleaning can clog the pores of the skin resulting in disorders
such as oil acne/folliculitis. Used oil may contain harmful
impurities.
Safety Hazards : Not classified as flammable but will burn.
Environmental Hazards : Not classified as dangerous for the environment.
SECTION 3. COMPOSITION/INFORMATION ON INGREDIENTS
3.1 Substance
Material Name : Not applicable.
3.2 Mixtures
Mixture Description : Highly refined mineral oils and additives.
Hazardous Components
Classification of components according to Regulation (EC) No 1272/2008
Chemical Name CAS No. EC Number REACH Registration Conc.

No.
Interchangeable low * * * 0.00 - 90.00%
viscosity base oil
(<20,5 cSt @40°C) *
Chemical Name Hazard Class & Category Hazard Statement

Interchangeable low Asp. Tox., 1; H304;
2/17
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MSDS_GB
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Safety Data Sheet
viscosity base oil

(<20,5 cSt @40°C) *
Additional Information : The highly refined mineral oil contains <3% (w/w) DMSO-
extract, according to IP346.
Refer to Ch 16 for full text of H phrases.
* contains one or more of the following CAS-numbers (REACH

registration numbers): 64742-53-6 (01-2119480375-34), 64742-
54-7 (01-2119484627-25), 64742-55-8 (01-2119487077-29),
64742-56-9 (01-2119480132-48), 64742-65-0 (01-2119471299-
27), 68037-01-4 (01-2119486452-34), 72623-86-0 (01-
2119474878-16), 72623-87-1 (01-2119474889-13), 8042-47-5
(01-2119487078-27), 848301-69-9 (01-0000020164-80).
This mixture does not contain any REACH registered

substances that are assessed to be a PBT or a vPvB.
SECTION 4. FIRST AID MEASURES
4.1 Description of First Aid Measures
General Information : Not expected to be a health hazard when used under normal
conditions.
Inhalation : No treatment necessary under normal conditions of use. If
symptoms persist, obtain medical advice.
Skin Contact : Remove contaminated clothing. Flush exposed area with water
and follow by washing with soap if available. If persistent
irritation occurs, obtain medical attention.
Eye Contact : Flush eye with copious quantities of water. If persistent
Ingestion : In general no treatment is necessary unless large quantities
are swallowed, however, get medical advice.
Self-protection of the first : When administering first aid, ensure that you are wearing the
aider appropriate personal protective equipment according to the
incident, injury and surroundings.
4.2 Most important : Oil acne/folliculitis signs and symptoms may include formation
symptoms and effects, of black pustules and spots on the skin of exposed areas.
both acute and delayed Ingestion may result in nausea, vomiting and/or diarrhoea.
4.3 Indication of any : Notes to doctor/physician:
immediate medical Treat symptomatically.
attention and special
treatment needed
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Safety Data Sheet
SECTION 5. FIRE FIGHTING MEASURES
Clear fire area of all non-emergency personnel.
5.1 Extinguishing Media : Foam, water spray or fog. Dry chemical powder, carbon
dioxide, sand or earth may be used for small fires only.
Unsuitable Extinguishing : Do not use water in a jet.
Media
5.2 Special hazards : Hazardous combustion products may include: A complex
arising from the mixture of airborne solid and liquid particulates and gases
substance or mixture (smoke). Carbon monoxide. Unidentified organic and inorganic
compounds.
5.3 Advice for firefighters : Proper protective equipment including chemical resistant
gloves are to be worn; chemical resistant suit is indicated if
large contact with spilled product is expected. Self-Contained
Breathing Apparatus must be worn when approaching a fire in
a confined space. Select fire fighter's clothing approved to
relevant Standards (e.g. Europe: EN469).
SECTION 6. ACCIDENTAL RELEASE MEASURES
Avoid contact with spilled or released material. For guidance on selection of personal protective
equipment see Chapter 8 of this Material Safety Data Sheet. Observe the relevant local and
international regulations.
6.1 Personal Precautions, : 6.1.1 For non emergency personnel: Avoid contact with skin
Protective Equipment and and eyes.
Emergency Procedures
6.1.2 For emergency responders: Avoid contact with skin and
eyes.
6.2 Environmental : Use appropriate containment to avoid environmental
Precautions contamination. Prevent from spreading or entering drains,
ditches or rivers by using sand, earth, or other appropriate
barriers.
6.3 Methods and Material : Slippery when spilt. Avoid accidents, clean up immediately.
for Containment and Prevent from spreading by making a barrier with sand, earth or
Cleaning Up other containment material. Reclaim liquid directly or in an
absorbent. Soak up residue with an absorbent such as clay,
sand or other suitable material and dispose of properly.
Additional Advice : Local authorities should be advised if significant spillages
cannot be contained.
6.4 Reference to other : For guidance on selection of personal protective equipment
sections see Chapter 8 of this Material Safety Data Sheet. For guidance
4/17
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Safety Data Sheet
on disposal of spilled material see Chapter 13 of this Material

Safety Data Sheet.
SECTION 7. HANDLING AND STORAGE
General Precautions : Use local exhaust ventilation if there is risk of inhalation of

vapours, mists or aerosols. Use the information in this data
sheet as input to a risk assessment of local circumstances to
help determine appropriate controls for safe handling, storage
and disposal of this material.
7.1 Precautions for Safe : Avoid prolonged or repeated contact with skin. Avoid inhaling
Handling vapour and/or mists. When handling product in drums, safety
footwear should be worn and proper handling equipment
should be used. Properly dispose of any contaminated rags or
cleaning materials in order to prevent fires. Keep container
tightly closed and in a cool, well-ventilated place. Use properly
labelled and closeable containers.
Product Transfer : This material has the potential to be a static accumulator.
Proper grounding and bonding procedures should be used
during all bulk transfer operations.
7.2 Conditions for safe : Store at ambient temperature.
storage, including any
incompatibilities
Refer to section 15 for any additional specific legislation
covering the packaging and storage of this product.
The storage of this product may be subject to the Control of
Pollution (Oil Storage) (England) Regulations. Further
guidance may be obtained from the local environmental
agency office.
Recommended Materials : For containers or container linings, use mild steel or high
density polyethylene.
Unsuitable Materials : PVC.
7.3 Specific end use(s) : Not applicable
Additional Information : Polyethylene containers should not be exposed to high
temperatures because of possible risk of distortion.
Exposure to this product should be reduced as low as
reasonably practicable. Reference should be made to the
Health and Safety Executive's publication "COSHH Essentials".
SECTION 8. EXPOSURE CONTROLS/PERSONAL PROTECTION
If the American Conference of Governmental Industrial Hygienists (ACGIH) value is provided on this
document, it is provided for information only.
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Safety Data Sheet
8.1 Control Parameters
Occupational Exposure Limits
Material Source Type ppm mg/m3 Notation

Oil mist, mineral ACGIH TWA(Inhala 5 mg/m3
ble fraction.)
Biological Exposure Index (BEI)

No biological limit allocated.
PNEC related information : Data not available
Monitoring Methods : Monitoring of the concentration of substances in the breathing

zone of workers or in the general workplace may be required to
confirm compliance with an OEL and adequacy of exposure
controls. For some substances biological monitoring may also
be appropriate. Validated exposure measurement methods
should be applied by a competent person and samples
analysed by an accredited laboratory. Examples of sources of
recommended exposure measurement methods are given
below or contact the supplier. Further national methods may be
available.
National Institute of Occupational Safety and Health (NIOSH),

USA: Manual of Analytical Methods http://www.cdc.gov/niosh/
Occupational Safety and Health Administration (OSHA), USA:

Sampling and Analytical Methods http://www.osha.gov/
Health and Safety Executive (HSE), UK: Methods for the

Determination of Hazardous Substances
http://www.hse.gov.uk/
Institut für Arbeitsschutz Deutschen Gesetzlichen

Unfallversicherung (IFA), Germany.
http://www.dguv.de/inhalt/index.jsp
L'Institut National de Recherche et de Securité, (INRS), France

http://www.inrs.fr/accueil
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Safety Data Sheet
8.2 Exposure Controls

General Information : The level of protection and types of controls necessary will vary
depending upon potential exposure conditions. Select controls
based on a risk assessment of local circumstances.
Appropriate measures include: Adequate ventilation to control
airborne concentrations. Where material is heated, sprayed or
mist formed, there is greater potential for airborne
concentrations to be generated.
Define procedures for safe handling and maintenance of

controls. Educate and train workers in the hazards and control
measures relevant to normal activities associated with this
product. Ensure appropriate selection, testing and
maintenance of equipment used to control exposure, e.g.
personal protective equipment, local exhaust ventilation. Drain
down system prior to equipment break-in or maintenance.
Retain drain downs in sealed storage pending disposal or for
subsequent recycle. Always observe good personal hygiene
measures, such as washing hands after handling the material
and before eating, drinking, and/or smoking. Routinely wash
work clothing and protective equipment to remove
contaminants. Discard contaminated clothing and footwear that
cannot be cleaned. Practice good housekeeping.
Occupational Exposure Controls

Personal Protective : The provided information is made in consideration of the PPE
Equipment directive (Council Directive 89/686/EEC) and the CEN
European Committee for Standardisation (CEN) standards.
Personal protective equipment (PPE) should meet
recommended national standards. Check with PPE suppliers.
Eye Protection : Wear safety glasses or full face shield if splashes are likely to
occur. Approved to EU Standard EN166.
Hand Protection : Where hand contact with the product may occur the use of
gloves approved to relevant standards (e.g. Europe: EN374,
US: F739) made from the following materials may provide
suitable chemical protection: PVC, neoprene or nitrile rubber
gloves. Suitability and durability of a glove is dependent on
usage, e.g. frequency and duration of contact, chemical
resistance of glove material, dexterity. Always seek advice
from glove suppliers. Contaminated gloves should be replaced.
Personal hygiene is a key element of effective hand care.
7/17
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Safety Data Sheet
Gloves must only be worn on clean hands. After using gloves,

hands should be washed and dried thoroughly. Application of a
non-perfumed moisturizer is recommended.
For continuous contact we recommend gloves with
breakthrough time of more than 240 minutes with preference
for > 480 minutes where suitable gloves can be identified. For
short-term/splash protection we recommend the same, but
recognise that suitable gloves offering this level of protection
may not be available and in this case a lower breakthrough
time may be acceptable so long as appropriate maintenance
and replacement regimes are followed. Glove thickness is not
a good predictor of glove resistance to a chemical as it is
dependent on the exact composition of the glove material.
Body protection : Skin protection not ordinarily required beyond standard issue
work clothes.
Respiratory Protection : No respiratory protection is ordinarily required under normal
conditions of use. In accordance with good industrial hygiene
practices, precautions should be taken to avoid breathing of
material. If engineering controls do not maintain airborne
concentrations to a level which is adequate to protect worker
health, select respiratory protection equipment suitable for the
specific conditions of use and meeting relevant legislation.
Check with respiratory protective equipment suppliers. Where
air-filtering respirators are suitable, select an appropriate
combination of mask and filter. Select a filter suitable for
combined particulate/organic gases and vapours [boiling point
>65 °C (149 °F)] meeting EN14387.
Thermal Hazards : Not applicable.
Environmental Exposure Controls

Environmental exposure : Minimise release to the environment. An environmental
control measures assessment must be made to ensure compliance with local
environmental legislation. Information on accidental release
measures are to be found in section 6.
SECTION 9. PHYSICAL AND CHEMICAL PROPERTIES
9.1 Information on basic physical and chemical properties

Appearance : Amber. Liquid at room temperature.
Odour : Slight hydrocarbon.
Odour threshold : Data not available
pH : Not applicable.
Initial Boiling Point and : > 280 °C / 536 °F estimated value(s)
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Boiling Range
Pour point : Typical -27 °C / -17 °F
Flash point : Typical 175 °C / 347 °F (COC)
Upper / lower Flammability : Typical 1 - 10 %(V) (based on mineral oil)
or Explosion limits
Auto-ignition temperature : > 320 °C / 608 °F
Vapour pressure : < 0.5 Pa at 20 °C / 68 °F (estimated value(s))
Relative Density : Typical 0.900 at 15 °C / 59 °F
Density : Typical 900 kg/m3 at 15 °C / 59 °F
Water solubility : Negligible.
Solubility in other solvents : Data not available
n-octanol/water partition : > 6 (based on information on similar products)

coefficient (log Pow)
Dynamic viscosity : Data not available
Kinematic viscosity : Typical 146 mm2/s at 40 °C / 104 °F
Vapour density (air=1) : > 1 (estimated value(s))
Evaporation rate (nBuAc=1) : Data not available
Decomposition : Data not available
Temperature
Flammability : Data not available
Oxidizing Properties : Data not available
Explosive Properties : Not classified
9.2 Other Information

Electrical conductivity : This material is not expected to be a static accumulator.
Other Information : not a VOC

Volatile organic compound : 0%
SECTION 10. STABILITY AND REACTIVITY
10.1 Reactivity : The product does not pose any further reactivity hazards in
addition to those listed in the following sub-paragraph.
10.2 Chemical stability : No hazardous reaction is expected when handled and stored
according to provisions.
10.3 Possibility of :
Hazardous Reactions Reacts with strong oxidising agents.
10.4 Conditions to Avoid : Extremes of temperature and direct sunlight.
10.5 Incompatible : Strong oxidising agents.
Materials
10.6 Hazardous : Hazardous decomposition products are not expected to form
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Decomposition Products during normal storage.
SECTION 11. TOXICOLOGICAL INFORMATION
11.1 Information on Toxicological effects

Basis for Assessment : Information given is based on data on the components and the
toxicology of similar products.
Unless indicated otherwise, the data presented is
representative of the product as a whole, rather than for
individual component(s).
Likely Routes of : Skin and eye contact are the primary routes of exposure
Exposure although exposure may occur following accidental ingestion.
Acute Oral Toxicity : Expected to be of low toxicity: LD50 > 5000 mg/kg , Rat
Acute Dermal Toxicity : Expected to be of low toxicity: LD50 > 5000 mg/kg , Rabbit
Acute Inhalation Toxicity : Not considered to be an inhalation hazard under normal
conditions of use.
Skin corrosion/irritation : Expected to be slightly irritating. Prolonged or repeated skin
contact without proper cleaning can clog the pores of the skin
resulting in disorders such as oil acne/folliculitis.
Serious eye : Expected to be slightly irritating.
damage/irritation
Respiratory Irritation : Inhalation of vapours or mists may cause irritation.
Respiratory or skin : For respiratory and skin sensitisation: Not expected to be a
sensitisation sensitiser.
Aspiration Hazard : Not considered an aspiration hazard.
Germ cell mutagenicity : Not considered a mutagenic hazard.

Carcinogenicity : Not expected to be carcinogenic. Product contains mineral oils
of types shown to be non-carcinogenic in animal skin-painting
studies. Highly refined mineral oils are not classified as
carcinogenic by the International Agency for Research on
Cancer (IARC).
Material : Carcinogenicity Classification

Highly refined mineral oil : ACGIH Group A4: Not classifiable as a human carcinogen.
(IP346 <3%)
Highly refined mineral oil : IARC 3: Not classifiable as to carcinogenicity to humans.
(IP346 <3%)
Highly refined mineral oil : GHS / CLP: No carcinogenicity classification
(IP346 <3%)
Reproductive and : Not expected to be a hazard.
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Developmental Toxicity
Summary on evaluation of the CMR properties

Carcinogenicity : This product does not meet the criteria for classification in
categories 1A/1B.,
Mutagenicity : This product does not meet the criteria for classification in
categories 1A/1B.
Reproductive Toxicity : This product does not meet the criteria for classification in
(fertility) categories 1A/1B.
Specific target organ : Not expected to be a hazard.

toxicity - single exposure
toxicity - repeated
exposure
Additional Information : Used oils may contain harmful impurities that have
accumulated during use. The concentration of such impurities
will depend on use and they may present risks to health and
the environment on disposal. ALL used oil should be handled
with caution and skin contact avoided as far as possible.
Classifications by other authorities under varying regulatory
frameworks may exist.
SECTION 12. ECOLOGICAL INFORMATION
Basis for Assessment : Ecotoxicological data have not been determined specifically for
this product. Information given is based on a knowledge of the
components and the ecotoxicology of similar products. Unless
indicated otherwise, the data presented is representative of the
product as a whole, rather than for individual component(s).
12.1 Toxicity
Acute Toxicity : Poorly soluble mixture. May cause physical fouling of aquatic
organisms. Expected to be practically non toxic: LL/EL/IL50 >
100 mg/l (to aquatic organisms) LL/EL50 expressed as the
nominal amount of product required to prepare aqueous test
extract. Mineral oil is not expected to cause any chronic effects
to aquatic organisms at concentrations less than 1 mg/l.
12.2 Persistence and : Expected to be not readily biodegradable. Major constituents

degradability are expected to be inherently biodegradable, but the product
contains components that may persist in the environment.
12.3 Bioaccumulative : Contains components with the potential to bioaccumulate.
Potential
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12.4 Mobility in Soil : Liquid under most environmental conditions. If it enters soil, it
will adsorb to soil particles and will not be mobile. Floats on
water.
12.5 Result of PBT and : This mixture does not contain any REACH registered
vPvB assesment substances that are assessed to be a PBT or a vPvB.
12.6 Other Adverse : Product is a mixture of non-volatile components, which are not
Effects expected to be released to air in any significant quantities. Not
expected to have ozone depletion potential, photochemical
ozone creation potential or global warming potential.
SECTION 13. DISPOSAL CONSIDERATIONS
13.1 Waste Treatment Methods
Material Disposal : Recover or recycle if possible. It is the responsibility of the

waste generator to determine the toxicity and physical
properties of the material generated to determine the proper
waste classification and disposal methods in compliance with
applicable regulations. Do not dispose into the environment, in
drains or in water courses.
Container Disposal : Dispose in accordance with prevailing regulations, preferably to
a recognised collector or contractor. The competence of the
collector or contractor should be established beforehand.
Local Legislation : Disposal should be in accordance with applicable regional,
national, and local laws and regulations.
EU Waste Disposal Code (EWC): 13 02 05 mineral-based non-
chlorinated engine, gear and lubricating oils. Classification of
waste is always the responsibility of the end user.
SECTION 14. TRANSPORT INFORMATION
Land transport (ADR/RID):

ADR
This product is not classified as dangerous for this mode of transport. Therefore 14.1 UN
Number, 14.2 UN Proper Shipping name, 14.3 Transport hazard class(es), 14.4 Packing group,
14.5 Environmental hazards, 14.6 Special precautions for user do not apply.
RID
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Inland waterways transport (ADN):

Sea transport (IMDG Code):

Air transport (IATA):

14.7 Transport in bulk according to Annex II of MARPOL 73/78 and the IBC Code
Pollution Category : Not applicable.
Ship Type : Not applicable.
Product Name : Not applicable.
Special Precaution : Not applicable.
Additional Information : MARPOL Annex 1 rules apply for bulk shipments by sea.
SECTION 15. REGULATORY INFORMATION
The regulatory information is not intended to be comprehensive. Other regulations may apply to this
material.
15.1 Safety, health and environmental regulations/legislation specific for the substance or
mixture
Other regulatory Information
Authorisations and/or : Product is not subject to Authorisation under REACh.
restrictions on use
Recommended : This product must not be used in applications other than those
Restrictions on Use recommended in Section 1, without first seeking the advice of
(Advice Against) the supplier.
Chemical Inventory Status
EINECS : All components

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listed or polymer
exempt.
TSCA : All components
listed.
Other Information : Environmental Protection Act 1990 (as amended).

Health and Safety at Work etc. Act 1974.
Consumers Protection Act 1987.
Pollution Prevention and Control Act 1999.
Environment Act 1995.
Factories Act 1961.
The Carriage of Dangerous Goods and Use of Transportable
Pressure Equipment (Amendment) Regulations 2011.
Chemicals (Hazard Information and Packaging for Supply)
Regulations 2009.
Control of Substances Hazardous to Health Regulations 2002
(as amended).
Merchant Shipping (Dangerous Goods and Marine Pollutants)
Regulations 1997.
Reporting of Injuries, Diseases and Dangerous Occurrences
Regulations 1995 (as amended).
Personal Protective Equipment Regulations 2002.
Personal Protective Equipment at Work Regulations 1992.
Hazardous Waste (England and Wales) Regulations 2005(as
amended).
Control of Major Accident Hazards Regulations 1999 (as
amended).
Renewable Transport Fuel Obligations Order 2007 (as
amended).
Energy Act 2011.
Environmental Permitting (England and Wales) Regulations
2010 (as amended).
Waste (England and Wales) Regulations 2011 (as amended).
Planning (Hazardous Substances) Act 1990 and associated
regulations.
The Environmental Protection (Controls on Ozone-Depleting
Substances) Regulations 2011.
15.2 Chemical Safety : No Chemical Safety Assessment has been carried out for this
Assessment substance/mixture by the supplier.
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SECTION 16. OTHER INFORMATION
Not classified.
CLP Hazard Statements

H304 May be fatal if swallowed and enters airways.
Additional Information : No Exposure Scenario annex is attached to this safety data

sheet. It is a non-classified mixture containing hazardous
substances as detailed in Section 3; relevant information from
Exposure Scenarios for the hazardous substances contained
have been integrated into the core sections 1-16 of this SDS.
Other Information
Abbreviations and : Acute Tox. = Acute toxicity

Acronyms Asp. Tox. = Aspiration hazard
Aquatic Acute = Acute hazards to the aquatic environment
Aquatic Chronic = Hazardous to the aquatic environment -
Long-term Hazard
Eye Dam. = Serious eye damage/eye irritation
Flam. Liq. = Flammable liquids
Skin Corr. = Skin corrosion/irritation
Skin Sens. = Skin sensitizer
STOT SE = Specific target organ toxicity - single exposure
STOT RE = Specific target organ toxicity - repeated exposure
The standard abbreviations and acronyms used in this

document can be looked up in reference literature (e.g.
scientific dictionaries) and/or websites.
ACGIH = American Conference of Governmental Industrial

Hygienists
ADR = European Agreement concerning the International
Carriage of Dangerous Goods by Road
AICS = Australian Inventory of Chemical Substances
ASTM = American Society for Testing and Materials
BEL = Biological exposure limits
BTEX = Benzene, Toluene, Ethylbenzene, Xylenes
CAS = Chemical Abstracts Service
CEFIC = European Chemical Industry Council
CLP = Classification Packaging and Labelling
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COC = Cleveland Open-Cup

DIN = Deutsches Institut fur Normung
DMEL = Derived Minimal Effect Level
DNEL = Derived No Effect Level
DSL = Canada Domestic Substance List
EC = European Commission
EC50 = Effective Concentration fifty
ECETOC = European Center on Ecotoxicology and Toxicology
Of Chemicals
ECHA = European Chemicals Agency
EINECS = The European Inventory of Existing Commercial
Chemical Substances
EL50 = Effective Loading fifty
ENCS = Japanese Existing and New Chemical Substances
Inventory
EWC = European Waste Code
GHS = Globally Harmonised System of Classification and
Labelling of Chemicals
IARC = International Agency for Research on Cancer
IATA = International Air Transport Association
IC50 = Inhibitory Concentration fifty
IL50 = Inhibitory Level fifty
IMDG = International Maritime Dangerous Goods
INV = Chinese Chemicals Inventory
IP346 = Institute of Petroleum test method N° 346 for the
determination of polycyclic aromatics DMSO-extractables
KECI = Korea Existing Chemicals Inventory
LC50 = Lethal Concentration fifty
LD50 = Lethal Dose fifty per cent.
LL/EL/IL = Lethal Loading/Effective Loading/Inhibitory loading
LL50 = Lethal Loading fifty
MARPOL = International Convention for the Prevention of
Pollution From Ships
NOEC/NOEL = No Observed Effect Concentration / No
Observed Effect Level
OE_HPV = Occupational Exposure - High Production Volume
PBT = Persistent, Bioaccumulative and Toxic
PICCS = Philippine Inventory of Chemicals and Chemical
Substances
PNEC = Predicted No Effect Concentration
REACH = Registration Evaluation And Authorisation Of
Chemicals
RID = Regulations Relating to International Carriage of
Dangerous Goods by Rail
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SKIN_DES = Skin Designation

STEL = Short term exposure limit
TRA = Targeted Risk Assessment
TSCA = US Toxic Substances Control Act
TWA = Time-Weighted Average
vPvB = very Persistent and very Bioaccumulative
SDS Distribution : The information in this document should be made available to

all who may handle the product.
SDS Version Number : 2.1
SDS Effective Date : 12.12.2012
SDS Revisions : A vertical bar (|) in the left margin indicates an amendment
from the previous version.
SDS Regulation : Regulation 1907/2006/EC as amended by Regulation (EU)
453/2010
Disclaimer : This information is based on our current knowledge and is
intended to describe the product for the purposes of health,
safety and environmental requirements only. It should not
therefore be construed as guaranteeing any specific property
of the product.
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Shell Rimula R6 LM 10W-40
Version 3.0
Safety Data Sheet

COMPANY/UNDERTAKING
Material Name : Shell Rimula R6 LM 10W-40

Product Code : 001C4596
Product Use : Engine oil.
the supplier.

Shell Centre
London
SE1 7NA
United Kingdom
Telephone : (+44) 08708500939

: +44-(0) 151-350-4595
1999/45/EC
2.2 Label Elements
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2.3 Other Hazards
impurities.
3.1 Substance
3.2 Mixtures
Mixture Description : A blend of severely hydrotreated slack wax and additives.

Highly refined mineral oil.

No.
Alkyl phenol 125643-61-0 406-040-9 Not available / Not 1.00 - 3.00%
applicable.
viscosity base oil
(<20,5 cSt @40°C) *
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Alkyl phenol Aquatic Chronic, 4; H413;
viscosity base oil
(<20,5 cSt @40°C) *
Classification of components according to 67/548/EEC
Chemical Name CAS No. EC

REACH Symbol(s) R-phrase(s) Conc.
Number
Registration
No.
Alkyl phenol 125643-61-0 406-040-9 Not available R53 1.00 -
/ Not 3.00%
applicable.
extract, according to IP346. The highly refined mineral oil is
only present as additive diluent.
Refer to Ch 16 for full text of R- and H- phrases.

54-7 (01-2119484627-25), 64742-55-8 (01-2119487077-29),
64742-56-9 (01-2119480132-48), 64742-65-0 (01-2119471299-
27), 68037-01-4 (01-2119486452-34), 72623-86-0 (01-
2119474878-16), 72623-87-1 (01-2119474889-13), 8042-47-5
(01-2119487078-27), 848301-69-9 (01-0000020164-80).

conditions.
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both acute and delayed Ingestion may result in nausea, vomiting and/or diarrhoea.
attention and special
treatment needed
Media
compounds.
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eyes.
barriers.
Safety Data Sheet.

incompatibilities
agency office.
5/17
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ble fraction.)


available.
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work clothes.
>65 °C (149 °F)] meeting EN14387.
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Boiling Range
Upper / lower Flammability : Typical 1 - 10 %(V)
or Explosion limits

Temperature

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Materials

conditions of use.
damage/irritation
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Carcinogenicity : Not expected to be carcinogenic.

(IP346 <3%)
(IP346 <3%)
(IP346 <3%)


categories 1A/1B.,
categories 1A/1B.

toxicity - repeated
exposure
Continuous contact with used engine oils has caused skin
cancer in animal tests.
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12.1 Toxicity
extract.

Potential
water.

EU Waste Disposal Code (EWC): 13 02 06 synthetic engine,
gear and lubricating oils. Classification of waste is always the
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responsibility of the end user.

ADR
RID



material.
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mixture
restrictions on use

listed or polymer
exempt.
listed.

Factories Act 1961.
Regulations 2009.
(as amended).
Regulations 1997.
amended).
amended).
amended).
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Energy Act 2011.

2010 (as amended).
regulations.
R-phrase(s)
Not classified.
R53 May cause long-term adverse effects in the aquatic environment.

H413 May cause long lasting harmful effects to aquatic life.

Other Information

Long-term Hazard

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Hygienists
Of Chemicals
Chemical Substances
Inventory
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Substances
Chemicals

453/2010
of the product.
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COMPANY/UNDERTAKING
Material Name : Shell Tellus S2 V 68

Product Code : 001D7751
Product Use : Hydraulic oil.
the supplier.

Shell Centre
London
SE1 7NA
United Kingdom
Telephone : (+44) 08708500939

: +44-(0) 151-350-4595
1999/45/EC
2.2 Label Elements
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2.3 Other Hazards
such as oil acne/folliculitis. High-pressure injection under the
skin may cause serious damage including local necrosis. Used
oil may contain harmful impurities.
3.1 Substance
3.2 Mixtures
Mixture Description : Highly refined mineral oils and additives.

No.
viscosity base oil
(<20,5 cSt @40°C) *
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viscosity base oil
(<20,5 cSt @40°C) *
Refer to Ch 16 for full text of H phrases.

54-7 (01-2119484627-25), 64742-55-8 (01-2119487077-29),
64742-56-9 (01-2119480132-48), 64742-65-0 (01-2119471299-
27), 68037-01-4 (01-2119486452-34), 72623-86-0 (01-
2119474878-16), 72623-87-1 (01-2119474889-13), 8042-47-5
(01-2119487078-27), 848301-69-9 (01-0000020164-80).

conditions.
irritation occurs, obtain medical attention. When using high
pressure equipment, injection of product under the skin can
occur. If high pressure injuries occur, the casualty should be
sent immediately to a hospital. Do not wait for symptoms to
develop. Obtain medical attention even in the absence of
apparent wounds.
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both acute and delayed Local necrosis is evidenced by delayed onset of pain and
tissue damage a few hours following injection. Ingestion may
result in nausea, vomiting and/or diarrhoea.
attention and special High pressure injection injuries require prompt surgical
treatment needed intervention and possibly steroid therapy, to minimise tissue
damage and loss of function.
Because entry wounds are small and do not reflect the
seriousness of the underlying damage, surgical exploration to
determine the extent of involvement may be necessary. Local
anaesthetics or hot soaks should be avoided because they can
contribute to swelling, vasospasm and ischaemia. Prompt
surgical decompression, debridement and evacuation of
foreign material should be performed under general
anaesthetics, and wide exploration is essential.
Media
compounds.
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eyes.
barriers.
Safety Data Sheet.

incompatibilities
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agency office.

ble fraction.)


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available.







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work clothes.
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>65 °C (149 °F)] meeting EN14387.


Boiling Range
Upper / lower Flammability : Typical 1 - 10 %(V) (based on mineral oil)
or Explosion limits

Temperature

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Materials

conditions of use.
damage/irritation
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Carcinogenicity : Not expected to be carcinogenic. Product contains mineral oils
of types shown to be non-carcinogenic in animal skin-painting
studies. Highly refined mineral oils are not classified as
carcinogenic by the International Agency for Research on
Cancer (IARC).

(IP346 <3%)
(IP346 <3%)
(IP346 <3%)


categories 1A/1B.,
categories 1A/1B.

toxicity - repeated
exposure
with caution and skin contact avoided as far as possible. High
pressure injection of product into the skin may lead to local
necrosis if the product is not surgically removed.
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12.1 Toxicity
extract. Mineral oil is not expected to cause any chronic effects
to aquatic organisms at concentrations less than 1 mg/l.

Potential
water.

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EU Waste Disposal Code (EWC): 13 01 10 mineral based non-
chlorinated hydraulic oils. Classification of waste is always the
responsibility of the end user.

ADR
RID



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material.
mixture
restrictions on use

listed or polymer
exempt.
listed.

Factories Act 1961.
Regulations 2009.
(as amended).
Regulations 1997.
14/17
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amended).
amended).
amended).
Energy Act 2011.
2010 (as amended).
regulations.
Not classified.


Other Information

Long-term Hazard
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Hygienists
Of Chemicals
Chemical Substances
Inventory
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Substances
Chemicals

453/2010
of the product.
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Shell Omala Oil 150
Version 1.1
Material Safety Data Sheet according to EC directive 2001/58/EC
1. IDENTIFICATION OF THE SUBSTANCE/PREPARATION AND COMPANY/UNDERTAKING
Material Name : Shell Omala Oil 150

Uses : Gear lubricant.
Product Code : 001A0775

PO Box 3
Ellesmere Port
CH65 4HB
United Kingdom
Telephone : +44-(0) 151-350-4000

Fax : +44-(0) 151-350-4843
Emergency Telephone : +44-(0) 151-350-4595

Number
2. COMPOSITION/INFORMATION ON INGREDIENTS
Preparation description : Highly refined mineral oils and additives.
3. HAZARDS IDENTIFICATION
impurities.
Signs and Symptoms : Oil acne/folliculitis signs and symptoms may include formation
of black pustules and spots on the skin of exposed areas.
Ingestion may result in nausea, vomiting and/or diarrhoea.
4. FIRST AID MEASURES
conditions.
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Shell Omala Oil 150
Version 1.1

Advice to Physician : Treat symptomatically.
5. FIRE FIGHTING MEASURES
Specific Hazards : Hazardous combustion products may include: A complex

mixture of airborne solid and liquid particulates and gases
(smoke). Carbon monoxide. Unidentified organic and inorganic
compounds.
Extinguishing Media : Foam, water spray or fog. Dry chemical powder, carbon
Media
Protective Equipment for : Proper protective equipment including breathing apparatus
Firefighters must be worn when approaching a fire in a confined space.
6. ACCIDENTAL RELEASE MEASURES
equipment see Chapter 8 of this Material Safety Data Sheet. See Chapter 13 for information on
disposal. Observe all relevant local and international regulations.
Protective measures : Avoid contact with skin and eyes. Use appropriate containment
to avoid environmental contamination. Prevent from spreading
or entering drains, ditches or rivers by using sand, earth, or
other appropriate barriers.
Clean Up Methods : Slippery when spilt. Avoid accidents, clean up immediately.
Prevent from spreading by making a barrier with sand, earth or
other containment material. Reclaim liquid directly or in an
7. HANDLING AND STORAGE

vapours, mists or aerosols. Properly dispose of any
contaminated rags or cleaning materials in order to prevent
fires. Use the information in this data sheet as input to a risk
assessment of local circumstances to help determine
appropriate controls for safe handling, storage and disposal of
this material.
Handling : Avoid prolonged or repeated contact with skin. Avoid inhaling
vapour and/or mists. When handling product in drums, safety
should be used.
Storage : Keep container tightly closed and in a cool, well-ventilated
place. Use properly labelled and closeable containers. Storage
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Shell Omala Oil 150
Version 1.1
Temperature: 0 - 50°C / 32 - 122°F

guidance maybe obtained from the local environmental agency
office.
8. EXPOSURE CONTROLS/PERSONAL PROTECTION
Exposure Controls : The level of protection and types of controls necessary will vary
Personal Protective : Personal protective equipment (PPE) should meet
Equipment recommended national standards. Check with PPE suppliers.
<65 °C (149 °F)] meeting EN371.
resistance of glove material, glove thickness, dexterity. Always
seek advice from glove suppliers. Contaminated gloves should
be replaced. Personal hygiene is a key element of effective
hand care. Gloves must only be worn on clean hands. After
using gloves, hands should be washed and dried thoroughly.
Application of a non-perfumed moisturizer is recommended.
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Version 1.1
Protective Clothing : Skin protection not ordinarily required beyond standard issue
work clothes.
be appropriate.
Environmental Exposure : Minimise release to the environment. An environmental
Controls assessment must be made to ensure compliance with local
environmental legislation.
9. PHYSICAL AND CHEMICAL PROPERTIES
Appearance : Brown. Liquid.

Boiling point : > 280 °C / 536 °F estimated value(s)
Explosion / Flammability : Typical 1 - 10 %(V) (based on mineral oil)
limits in air
10. STABILITY AND REACTIVITY
Stability : Stable.
Conditions to Avoid : Extremes of temperature and direct sunlight.
Materials to Avoid : Strong oxidising agents.
Hazardous : Hazardous decomposition products are not expected to form
11. TOXICOLOGICAL INFORMATION
Acute Oral Toxicity : Expected to be of low toxicity: LD50 >2000 mg/kg , Rat
Acute Dermal Toxicity : Expected to be of low toxicity: LD50 >2000 mg/kg , Rabbit
Acute Inhalation Toxicity : This product is not expected to pose an inhalation hazard
under conditions of foreseeable use.
Skin Irritation : Expected to be slightly irritating. Prolonged or repeated skin
Eye Irritation : Expected to be slightly irritating.
Sensitisation : Not expected to be a skin sensitiser.
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Shell Omala Oil 150
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Repeated Dose Toxicity : Not expected to be a hazard.

Mutagenicity : Not considered a mutagenic hazard.
Carcinogenicity : Product contains mineral oils of types shown to be non-
carcinogenic in animal skin-painting studies. Highly refined
mineral oils are not classified as carcinogenic by the
International Agency for Research on Cancer (IARC). Other
components are not known to be associated with carcinogenic
effects.
12. ECOLOGICAL INFORMATION
Ecotoxicological data have not been determined specifically for this product. Information given is
based on a knowledge of the components and the ecotoxicology of similar products.
100 mg/l (to aquatic organisms) (LL/EL50 expressed as the
extract). Mineral oil is not expected to cause any chronic
effects to aquatic organisms at concentrations less than 1 mg/l.
Mobility : Liquid under most environmental conditions. Floats on water. If
it enters soil, it will adsorb to soil particles and will not be
mobile.
Persistence/degradability : Expected to be not readily biodegradable. Major constituents
are expected to be inherently biodegradable, but the product
Bioaccumulation : Contains components with the potential to bioaccumulate.
Other Adverse Effects : Product is a mixture of non-volatile components, which are not
expected to be released to air in any significant quantities. Not
13. DISPOSAL CONSIDERATIONS

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Shell Omala Oil 150
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EU Waste Disposal Code (EWC): 13 02 05 mineral-based non-

chlorinated engine, gear and lubricating oils. Classification of
waste is always the responsibility of the end user.
14. TRANSPORT INFORMATION
ADR
This material is not classified as dangerous under ADR regulations.
RID
This material is not classified as dangerous under RID regulations.
ADNR
This material is not classified as dangerous under ADNR regulations.
IMDG
This material is not classified as dangerous under IMDG regulations.
IATA (Country variations may apply)

This material is not classified as dangerous under IATA regulations.
15. REGULATORY INFORMATION
material.

listed or polymer
exempt.
listed.
Other Information : Environmental Protection Act 1990 (as amended). Health and
Safety at Work Act 1974. Consumers Protection Act 1987.
Control of Pollution Act 1974. Environmental Act 1995.
Factories Act 1961. Carriage of Dangerous Goods by Road
and Rail (Classification, Packaging and Labelling) Regulations.
Regulations 2002. Control of Substances Hazardous to Health
Regulations 1994 (as amended). Road Traffic (Carriage of
Dangerous Substances in Packages) Regulations. Merchant
Shipping (Dangerous Goods and Marine Pollutants)
Regulations. Road Traffic (Carriage of Dangerous Substances
in Road Tankers in Tank Containers) Regulations. Road Traffic
(Training of Drivers of Vehicles Carrying Dangerous Goods)
Regulations. Reporting of Injuries, Diseases and Dangerous
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Version 1.1
Occurrences Regulations. Health and Safety (First Aid)

Regulations 1981. Personal Protective Equipment (EC
Directive) Regulations 1992. Personal Protective Equipment at
Work Regulations 1992.
16. OTHER INFORMATION
R-phrase(s)
Not classified.
MSDS Version Number : 1.1
MSDS Effective Date : 05.03.2007
MSDS Revisions : A vertical bar (|) in the left margin indicates an amendment
MSDS Regulation : The content and format of this safety data sheet is in
accordance with Commission Directive 2001/58/EC of 27 July
2001, amending for the second time Commission Directive
91/155/EEC.
MSDS Distribution : The information in this document should be made available to
of the product.
7/7
SAFETY DATA SHEET
Shell Gadus S2 V100 2
Version 2.1 Revision Date 03.02.2015 Print Date 05.02.2015
SECTION 1: Identification of the substance/mixture and of the company/undertaking
1.1 Product identifier

Trade name : Shell Gadus S2 V100 2
Product code : 001D8463
Use of the : Automotive and industrial grease.
Substance/Mixture
Uses advised against :
This product must not be used in applications other than those
listed in Section 1 without first seeking the advice of the
supplier.
1.3 Details of the supplier of the safety data sheet

Manufacturer/Supplier : Shell Austria Gesellschaft m.b.H.
Lobgrundstrasse 3
1220 Wien
Austria
Telephone : (+43) 1797970
Telefax : (+43) 1797971199
Email Contact for Safety Data : If you have any enquiries about the content of this SDS
Sheet please email lubricantSDS@shell.com
1.4 Emergency telephone number

: (+43) 1797972444
Vergiftungsinformationszentrale : +43 1 406 43 43
SECTION 2: Hazards identification

Classification (REGULATION (EC) No 1272/2008)
Chronic aquatic toxicity , Category 3 H412: Harmful to aquatic life with long lasting
effects.
Classification (67/548/EEC, 1999/45/EC)
Dangerous for the environment R52/53: Harmful to aquatic organisms, may cause
long-term adverse effects in the aquatic
environment.
2.2 Label elements
Labelling (REGULATION (EC) No 1272/2008)
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Hazard pictograms : No Hazard Symbol required
Signal word : No signal word
Hazard statements : PHYSICAL HAZARDS:

Not classified as a physical hazard
according to CLP criteria.
HEALTH HAZARDS:
Not classified as a health hazard under CLP
criteria.
ENVIRONMENTAL HAZARDS:
H412 Harmful to aquatic life with long lasting
effects.
Precautionary statements : Prevention:

P273 Avoid release to the environment.
Response:
No precautionary phrases.
Storage:
No precautionary phrases.
Disposal:
P501 Dispose of contents/ container to an
approved waste disposal plant.
2.3 Other hazards

This mixture does not contain any REACH registered substances that are assessed to be a PBT or a
vPvB.
Prolonged or repeated skin contact without proper cleaning can clog the pores of the skin resulting in
disorders such as oil acne/folliculitis.
Used grease may contain harmful impurities.
High-pressure injection under the skin may cause serious damage including local necrosis.
Not classified as flammable but will burn.
SECTION 3: Composition/information on ingredients

3.2 Mixtures
Chemical nature : A lubricating grease containing highly-refined mineral oils and
additives.
The highly refined mineral oil contains <3% (w/w) DMSO-
Hazardous components
Chemical Name CAS-No. Classification Classification Concentration
EC-No. (67/548/EEC) (REGULATION [%]
Registration (EC) No
number 1272/2008)
Zinc naphthenate 12001-85-3 Xi-N; R36/38- Skin Irrit.2; H315 0,25 - 2,4
234-409-2 R50/53 Eye Irrit.2; H319
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Aquatic Acute1;
H400
Aquatic Chronic1;
H410
For explanation of abbreviations see section 16.
SECTION 4: First aid measures
4.1 Description of first aid measures

General advice : Not expected to be a health hazard when used under normal
conditions.
Protection of first-aiders : When administering first aid, ensure that you are wearing the
appropriate personal protective equipment according to the
If inhaled : No treatment necessary under normal conditions of use.

If symptoms persist, obtain medical advice.
In case of skin contact : Remove contaminated clothing. Flush exposed area with
water and follow by washing with soap if available.
If persistent irritation occurs, obtain medical attention.
When using high pressure equipment, injection of product

under the skin can occur. If high pressure injuries occur, the
casualty should be sent immediately to a hospital. Do not wait
for symptoms to develop.
Obtain medical attention even in the absence of apparent
wounds.
In case of eye contact : Flush eye with copious quantities of water.

If persistent irritation occurs, obtain medical attention.
If swallowed : In general no treatment is necessary unless large quantities

4.2 Most important symptoms and effects, both acute and delayed
Symptoms : Oil acne/folliculitis signs and symptoms may include formation
of black pustules and spots on the skin of exposed areas.
Ingestion may result in nausea, vomiting and/or diarrhoea.
Local necrosis is evidenced by delayed onset of pain and

tissue damage a few hours following injection.
4.3 Indication of any immediate medical attention and special treatment needed
Treatment : Notes to doctor/physician:
Treat symptomatically.
High pressure injection injuries require prompt surgical
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intervention an d possibly steroid therapy, to minimise tissue

damage and loss of function.
Because entry wounds are small and do not reflect the
seriousness of the underlying damage, surgical exploration to
determine the extent of involvement may be necessary. Local
anaesthetics or hot soaks should be avoided because they
can contribute to swelling, vasospasm and ischaemia. Prompt
surgical decompression, debridement and evacuation of
foreign material should be performed under general
anaesthetics, and wide exploration is essential.
SECTION 5: Firefighting measures
5.1 Extinguishing media

Suitable extinguishing media : Foam, water spray or fog. Dry chemical powder, carbon
Unsuitable extinguishing : Do not use water in a jet.
media
5.2 Special hazards arising from the substance or mixture
Specific hazards during : Hazardous combustion products may include: A complex
firefighting mixture of airborne solid and liquid particulates and gases
(smoke). Carbon monoxide may be evolved if incomplete
combustion occurs. Unidentified organic and inorganic
compounds.
5.3 Advice for firefighters
Special protective equipment : Proper protective equipment including chemical resistant
for firefighters gloves are to be worn; chemical resistant suit is indicated if
Specific extinguishing : Use extinguishing measures that are appropriate to local
methods circumstances and the surrounding environment.
SECTION 6: Accidental release measures
6.1 Personal precautions, protective equipment and emergency procedures

Personal precautions : 6.1.1 For non emergency personnel:
Avoid contact with skin and eyes.
6.1.2 For emergency responders:
Avoid contact with skin and eyes.
6.2 Environmental precautions
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Environmental precautions : Use appropriate containment to avoid environmental

contamination. Prevent from spreading or entering drains,
barriers.
6.3 Methods and materials for containment and cleaning up

Methods for cleaning up : Shovel into a suitable clearly marked container for disposal or
reclamation in accordance with local regulations.
6.4 Reference to other sections

For guidance on selection of personal protective equipment see Chapter 8 of this Safety Data Sheet.,
For guidance on disposal of spilled material see Chapter 13 of this Safety Data Sheet.
SECTION 7: Handling and storage

vapours, mists or aerosols.
Use the information in this data sheet as input to a risk
assessment of local circumstances to help determine
appropriate controls for safe handling, storage and disposal of
this material.
7.1 Precautions for safe handling

Advice on safe handling : Avoid prolonged or repeated contact with skin.
Avoid inhaling vapour and/or mists.
When handling product in drums, safety footwear should be
worn and proper handling equipment should be used.
Properly dispose of any contaminated rags or cleaning
materials in order to prevent fires.
Fire-fighting class : Fires involving liquids or liquid containing substances. Also

includes substances which become liquid at elevated
temperatures.
7.2 Conditions for safe storage, including any incompatibilities

Storage class (TRGS 510) : 10, Combustible liquids
Other data : Keep container tightly closed and in a cool, well-ventilated

place. Use properly labeled and closable containers.
Store at ambient temperature.

Packaging material : Suitable material: For containers or container linings, use mild
steel or high density polyethylene.
Unsuitable material: PVC.
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Container Advice : Polyethylene containers should not be exposed to high

7.3 Specific end use(s)

Specific use(s) : Not applicable.
SECTION 8: Exposure controls/personal protection
8.1 Control parameters
Value type (Form

Components CAS-No. Control parameters Basis
of exposure)
Oil mist, mineral TWA 5 mg/m3 US. ACGIH
Threshold
Limit Values
Monitoring Methods
Monitoring of the concentration of substances in the breathing zone of workers or in the general
workplace may be required to confirm compliance with an OEL and adequacy of exposure controls.
For some substances biological monitoring may also be appropriate.
Validated exposure measurement methods should be applied by a competent person and samples
analysed by an accredited laboratory.
Examples of sources of recommended exposure measurement methods are given below or contact
the supplier. Further national methods may be available.
National Institute of Occupational Safety and Health (NIOSH), USA: Manual of Analytical Methods
http://www.cdc.gov/niosh/
Occupational Safety and Health Administration (OSHA), USA: Sampling and Analytical Methods
http://www.osha.gov/
Health and Safety Executive (HSE), UK: Methods for the Determination of Hazardous Substances
Institut für Arbeitsschutz Deutschen Gesetzlichen Unfallversicherung (IFA) , Germany

L'Institut National de Recherche et de Securité, (INRS), France http://www.inrs.fr/accueil
8.2 Exposure controls

Engineering measures The level of protection and types of controls necessary will vary depending
upon potential exposure conditions. Select controls based on a risk assessment of local
circumstances. Appropriate measures include:
Adequate ventilation to control airborne concentrations.
Where material is heated, sprayed or mist formed, there is greater potential for airborne
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General Information:
Define procedures for safe handling and maintenance of controls.
Educate and train workers in the hazards and control measures relevant to normal activities
associated with this product.
Ensure appropriate selection, testing and maintenance of equipment used to control exposure, e.g.
personal protective equipment, local exhaust ventilation.
Drain down system prior to equipment break-in or maintenance.
Retain drain downs in sealed storage pending disposal or subsequent recycle.
Always observe good personal hygiene measures, such as washing hands after handling the material
and before eating, drinking, and/or smoking. Routinely wash work clothing and protective equipment
to remove contaminants. Discard contaminated clothing and footwear that cannot be cleaned.
Practice good housekeeping.
Due to the product's semi-solid consistency, generation of mists and dusts is unlikely to occur.
Personal protective equipment
The provided information is made in consideration of the PPE directive (Council Directive
89/686/EEC) and the CEN European Committee for Standardisation (CEN) standards.
Personal protective equipment (PPE) should meet recommended national standards. Check with
PPE suppliers.
Eye protection : If material is handled such that it could be splashed into eyes,
protective eyewear is recommended.
Approved to EU Standard EN166.
Hand protection
Remarks : Where hand contact with the product may occur the use of
suitable chemical protection. PVC, neoprene or nitrile rubber
gloves Suitability and durability of a glove is dependent on
from glove suppliers. Contaminated gloves should be
replaced. Personal hygiene is a key element of effective hand
care. Gloves must only be worn on clean hands. After using
gloves, hands should be washed and dried thoroughly.
Application of a non-perfumed moisturizer is recommended.

recognize that suitable gloves offering this level of protection
time maybe acceptable so long as appropriate maintenance
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Glove thickness should be typically greater than 0.35 mm
depending on the glove make and model.
Skin and body protection : Skin protection is not ordinarily required beyond standard
work clothes.
It is good practice to wear chemical resistant gloves.
Respiratory protection : No respiratory protection is ordinarily required under normal

conditions of use.
In accordance with good industrial hygiene practices,
precautions should be taken to avoid breathing of material.
If engineering controls do not maintain airborne
Check with respiratory protective equipment suppliers.
Where air-filtering respirators are suitable, select an
appropriate combination of mask and filter.
Select a filter suitable for combined particulate/organic gases
and vapors [Type A/Type P boiling point > 65°C (149°F)]
meeting EN14387 and EN143.
Thermal hazards : Not applicable
Environmental exposure controls

General advice : Take appropriate measures to fulfill the requirements of
relevant environmental protection legislation. Avoid
contamination of the environment by following advice given in
Chapter 6. If necessary, prevent undissolved material from
being discharged to waste water. Waste water should be
treated in a municipal or industrial waste water treatment plant
before discharge to surface water.
Local guidelines on emission limits for volatile substances
must be observed for the discharge of exhaust air containing
vapour.
SECTION 9: Physical and chemical properties

Appearance : Semi-solid at room temperature.
Colour : light brown

Odour : Slight hydrocarbon
Odour Threshold : Data not available
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pH : Not applicable
Drop point : 180 °CMethod: IP 396
Initial boiling point and boiling : Data not available

range
Flash point : >= 200 °C
Method: ASTM D92
Evaporation rate : Data not available

Flammability (solid, gas) : Data not available
Upper explosion limit : Typical 10 %(V)
Lower explosion limit : Typical 1 %(V)
Vapour pressure : < 0,5 Pa (20 °C)

estimated value(s)
Relative vapour density : > 1estimated value(s)
Relative density : 0,900 (15 °C)
Density : 900 kg/m3 (15,0 °C)

Method: Unspecified
Solubility(ies)
Water solubility : negligible
Partition coefficient: n- : Pow: > 6(based on information on similar products)

octanol/water
Auto-ignition temperature : >
320 °C
Viscosity
Viscosity, dynamic : Data not available
Viscosity, kinematic : 100 mm2/s (40,0 °C)
Method: ASTM D445
11 mm2/s (100 °C)

Method: ASTM D445
Explosive properties : Not classified
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Oxidizing properties : Data not available
9.2 Other information
Conductivity : This material is not expected to be a static accumulator.

Decomposition temperature : Data not available
SECTION 10: Stability and reactivity
10.1 Reactivity
The product does not pose any further reactivity hazards in addition to those listed in the following
sub-paragraph.
10.2 Chemical stability
Stable.
No hazardous reaction is expected when handled and stored according to provisions.
10.3 Possibility of hazardous reactions
Hazardous reactions : Reacts with strong oxidising agents.
10.4 Conditions to avoid

Conditions to avoid : Extremes of temperature and direct sunlight.
10.5 Incompatible materials

Materials to avoid : Strong oxidising agents.
10.6 Hazardous decomposition products

Hazardous decomposition : Hazardous decomposition products are not expected to form
products during normal storage.
SECTION 11: Toxicological information

11.1 Information on toxicological effects
Basis for assessment : Information given is based on data on the components and
the toxicology of similar products.Unless indicated otherwise,
the data presented is representative of the product as a
whole, rather than for individual component(s).
Information on likely routes of : Skin and eye contact are the primary routes of exposure
exposure although exposure may occur following accidental ingestion.
Acute toxicity
Product:
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Acute oral toxicity : LD50 rat: > 5.000 mg/kg

Remarks: Expected to be of low toxicity:
Acute inhalation toxicity : Remarks: Not considered to be an inhalation hazard under

normal conditions of use.
Acute dermal toxicity : LD50 Rabbit: > 5.000 mg/kg

Remarks: Expected to be of low toxicity:
Skin corrosion/irritation
Product:
Remarks: Expected to be slightly irritating., Prolonged or repeated skin contact without proper
cleaning can clog the pores of the skin resulting in disorders such as oil acne/folliculitis.
Serious eye damage/eye irritation

Product:
Remarks: Expected to be slightly irritating.
Respiratory or skin sensitisation

Product:
Remarks: For respiratory and skin sensitisation:, Not expected to be a sensitiser.
Germ cell mutagenicity

Product:
: Remarks: Not considered a mutagenic hazard.
Carcinogenicity
Product:
Remarks: Not expected to be carcinogenic.
Remarks: Product contains mineral oils of types shown to be non-carcinogenic in animal skin-
painting studies., Highly refined mineral oils are not classified as carcinogenic by the
International Agency for Research on Cancer (IARC).
Material GHS/CLP Carcinogenicity Classification

Highly refined mineral oil No carcinogenicity classification.
Reproductive toxicity
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Product:
:
Remarks: Not expected to impair fertility., Not expected to be
a developmental toxicant.
STOT - single exposure

Product:
Remarks: Not expected to be a hazard.
STOT - repeated exposure

Product:
Remarks: Not expected to be a hazard.
Aspiration toxicity
Product:
Not considered an aspiration hazard.
Further information
Product:
Remarks: Used grease may contain harmful impurities that have accumulated during use. The
concentration of such harmful impurities will depend on use and they may present risks to health
and the environment on disposal., ALL used grease should be handled with caution and skin
contact avoided as far as possible.
Remarks: High pressure injection of product into the skin may lead to local necrosis if the
product is not surgically removed.
Remarks: Slightly irritating to respiratory system.
Remarks: Classifications by other authorities under varying regulatory frameworks may exist.

Germ cell mutagenicity- : This product does not meet the criteria for classification in
Assessment categories 1A/1B.
Carcinogenicity - : This product does not meet the criteria for classification in
Reproductive toxicity - : This product does not meet the criteria for classification in
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SECTION 12: Ecological information
12.1 Toxicity
Basis for assessment : Ecotoxicological data have not been determined specifically
for this product.
Information given is based on a knowledge of the components
and the ecotoxicology of similar products.
individual component(s).(LL/EL/IL50 expressed as the
extract.)
Product:
Toxicity to fish (Acute : Remarks: Expected to be harmful:
toxicity) LL/EL/IL50 10-100 mg/l
Toxicity to crustacean (Acute : Remarks: Expected to be harmful:

toxicity) LL/EL/IL50 10-100 mg/l
Toxicity to algae/aquatic : Remarks: Expected to be harmful:

plants (Acute toxicity) LL/EL/IL50 10-100 mg/l
Toxicity to fish (Chronic : Remarks: Data not available

toxicity)
Toxicity to crustacean : Remarks: Data not available
(Chronic toxicity)
Toxicity to microorganisms :
(Acute toxicity) Remarks: Data not available
Components:
Zinc naphthenate :
M-Factor (Acute aquatic : 1
toxicity)
12.2 Persistence and degradability
Product:
Biodegradability : Remarks: Expected to be not readily biodegradable., Major
constituents are expected to be inherently biodegradable, but
12.3 Bioaccumulative potential

Product:
Bioaccumulation : Remarks: Contains components with the potential to
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bioaccumulate.
Partition coefficient: n- : Pow: > 6Remarks: (based on information on similar products)

octanol/water
12.4 Mobility in soil
Product:
Mobility : Remarks: Semi-solid under most environmental conditions., If
it enters soil, it will adsorb to soil particles and will not be
mobile.
Remarks: Floats on water.
12.5 Results of PBT and vPvB assessment
Product:
Assessment : This mixture does not contain any REACH registered
12.6 Other adverse effects
Product:
Additional ecological : Product is a mixture of non-volatile components, which are not
information expected to be released to air in any significant quantities.,
Not expected to have ozone depletion potential,
photochemical ozone creation potential or global warming
potential.
Poorly soluble mixture., May cause physical fouling of aquatic
organisms.
Mineral oil is not expected to cause any chronic effects to
aquatic organisms at concentrations less than 1 mg/l.
SECTION 13: Disposal considerations
13.1 Waste treatment methods

Product : Recover or recycle if possible.
It is the responsibility of the waste generator to determine the
toxicity and physical properties of the material generated to
determine the proper waste classification and disposal
methods in compliance with applicable regulations.
Do not dispose into the environment, in drains or in water
courses
Contaminated packaging : Dispose in accordance with prevailing regulations, preferably

to a recognized collector or contractor. The competence of
the collector or contractor should be established beforehand.
Disposal should be in accordance with applicable regional,
Local legislation
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Waste catalogue :
EU Waste Disposal Code (EWC):
Waste Code :
12 01 12*
Remarks : Disposal should be in accordance with applicable regional,

Classification of waste is always the responsibility of the end

user.
SECTION 14: Transport information
14.1 UN number
ADN : Not regulated as a dangerous good
ADR : Not regulated as a dangerous good
RID : Not regulated as a dangerous good
IMDG : Not regulated as a dangerous good
IATA : Not regulated as a dangerous good
14.2 Proper shipping name
14.3 Transport hazard class
14.4 Packing group
14.5 Environmental hazards
14.6 Special precautions for user
Remarks : Special Precautions: Refer to Chapter 7, Handling & Storage,
for special precautions which a user needs to be aware of or
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needs to comply with in connection with transport.
Pollution category : Not applicable
Ship type : Not applicable
Product name : Not applicable
Special precautions : Not applicable
ADN - Classified ID9006 only when carried in tank vessels.
SECTION 15: Regulatory information
15.1 Safety, health and environmental regulations/legislation specific for the substance or mixture
REACH - List of substances subject to authorisation : Product is not subject to
(Annex XIV) Authorisation under REACH.
Water contaminating class : WGK 2 water endangering

(Germany) Remarks: Classification according VwVwS, Annex 2.
Volatile organic compounds : 0%
Other regulations : Technische Anleitung Luft: Product not listed by name.

Observe section 5.2.5 in connection with section 5.4.9
Product is subject to Vorgaben der Betriebs-Sicherheits-

Verordnung (BetrSichV).
Compliance with paragraph 22 of Youth Employment Law.
Compliance with Maternity Protection Act paragraphs 4 and 5
The components of this product are reported in the following inventories:

EINECS : All components listed or polymer exempt.
TSCA : All components listed.
15.2 Chemical Safety Assessment

No Chemical Safety Assessment has been carried out for this substance/mixture by the supplier.
SECTION 16: Other information

REGULATION (EC) No 1272/2008 Classification procedure:
Chronic aquatic toxicity, Category 3, Expert judgement and weight of evidence
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H412 determination.
Full text of R-Phrases

R36/38 Irritating to eyes and skin.
R50/53 Very toxic to aquatic organisms, may cause long-term adverse effects in
the aquatic environment.
Full text of H-Statements

H315 Causes skin irritation.
H319 Causes serious eye irritation.
H400 Very toxic to aquatic life.
H410 Very toxic to aquatic life with long lasting effects.
Full text of other abbreviations

Aquatic Acute Acute aquatic toxicity
Aquatic Chronic Chronic aquatic toxicity
Eye Irrit. Eye irritation
Skin Irrit. Skin irritation
Abbreviations and Acronyms : The standard abbreviations and acronyms used in this

Hygienists
ECETOC = European Center on Ecotoxicology and
Toxicology Of Chemicals
Chemical Substances
Inventory
17 / 18 800001006645
AT
SAFETY DATA SHEET

Substances
Chemicals
Further information
Other information : A vertical bar (|) in the left margin indicates an amendment
This information is based on our current knowledge and is intended to describe the product for the
purposes of health, safety and environmental requirements only. It should not therefore be
construed as guaranteeing any specific property of the product.
18 / 18 800001006645
AT

WS 6449 - Engl Gesamt

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WS 6449 - Engl Gesamt

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WS 6449 1

Copyright © 2015 by Plasser & Theurer

1 MANUFACTURER’S NAMEPLATE ......................................................................................................5

No. Reason Date Page Name

2016 6449 / 6450

2 GUIDELINES FOR SERVICING THE MACHINE

 We urgently recommend to make notes in the logbook also of maintenance works

 Service is divided into cleaning, checks, refilling or topping up of consumables, and

 An essential criterion of service works is safety of man, environment and machine.

The machine operating organization bears the responsibility for maintenance.

Essential maintenance criteria are:

Always pay attention to trains passing on adjacent tracks.

Use skid-pans when parking the vehicle on gradients.

Never change the settings of safety valves.

continued on next page

The earth electrode must never be mounted on the rail.

SAFETY GUIDELINES FOR PREPARING REPAIR WORK

In working mode, the danger zone of the machine is a prohibited area!

 Deactivate hydraulic pressure (visual check of the pressure gauge reading).

 Turn off the engine!

 In working mode, the working area is again prohibited!

SAFETY GUIDELINES FOR PREPARING REPAIR WORK

In working mode, the danger zone of the machine is a prohibited area!

PLEASE OBSERVE THE LOCAL RAILWAY REGULATIONS!

 Deactivate hydraulic pressure (visual check of the pressure gauge reading).

 Turn off the engine!

 In working mode the working area is again prohibited!

The use of open flames and easily flammable agents on the

First aid procedures

Always ensure that the first aid kit is in a proper, complete

For the purpose of first aid measures and suitable

Immediately replenish used up material!

Medicines, tranquillisers or other medications can result in drowsiness or

Procedure for first aid measures

In the case of burning

In the case of eye contact with hazardous materials

In the case of skin contact with hazardous materials

When inhaling hazardous materials

After intensive contact with clothing

 Crossing underneath the machine during operation or working is prohibited.

 If problems are encountered while work in progress, activate the emergency or

 The removal of covers and safety instructions is strictly prohibited.

 Touching the exhaust system may result in burns.

8.2 HAZARD INFORMATION

8.2.1 Responsibilities for implementation

Distributor…………………………...Announces the hazards

 Flammable and/or explosive materials (diesel, etc.)

8.2.2 Protective equipment

In order to keep hazards and their consequences to health as low as possible it is

Head protection………. Hard hat

It is imperative to observe the signs, covers, safety guards, earthing

8.3 EXTRACTS FROM THE SAFETY DATA SHEETS

Gearbox oil SHELL SPIRAX S2 G 80W-90

Engine oil SHELL RIMULA R6 LM 10W40

Hydraulic oil SHELL TELLUS S2 V 68

SHELL OMALA HD150

Lubricating grease SHELL GADUS S2 V 100 2

The safety data sheets contain additional information on the following.

9 INSTRUCTIONS FOR USE OF STARTER BATTERIES

Storage and transport

If a battery produces insufficient starting capacity due to low temperature or

Installation in the vehicle

On installation, first connect positive terminal ( + ), then negative terminal ( - ). Ensure