R & R PC-5500

Remove & Replace Procedures R & R Procedures

PC5500-6

HYDRAULIC MINING SHOVEL

This material is proprietary to Komatsu Mining Germany GmbH and is not to be reproduced, used, or disclosed except in accordance with written authorization from Komatsu Mining Germany GmbH. It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or add improvements at any time without incurring any obligation to install such changes on products sold previously. Due to this continous program of research and development, periodic revisions may be made to this publication. It is recommended that customer contact their distributor for information on the latest revision.

Version 2009/2

Copyright 2008

Overview

Overview 1 INTRODUCTION 2 SAFETY AND STANDARDS 3 SUPERSTRUCTURE 4 UNDERCARRIAGE 5 ATTACHMENT 6 SERVICE INFORMATION 7 TOOLS CATALOGUE 8 PARTS & SERVICE NEWS 9 SUPPLIER’S DOCUMENTATION

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Overview - 2

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Table of contents

Table of contents 1 INTRODUCTION........................................................................................ 1-1 1.1

CONTENTS OF THE BINDER ........................................................................................................... 1-2

1.2

FOREWORD ...................................................................................................................................... 1-3 1.2.1 SERVICE ............................................................................................................................... 1-4

2 SAFETY AND STANDARDS ..................................................................... 2-1 2.1

SAFETY INSTRUCTIONS.................................................................................................................. 2-2 2.1.1 METHOD OF USING THIS MANUAL .................................................................................... 2-2 2.1.2 GENERAL PRECAUTIONS ................................................................................................... 2-4 2.1.3 PREPARATIONS FOR WORK .............................................................................................. 2-5 2.1.4 PRECAUTIONS DURING WORK.......................................................................................... 2-6 2.1.5 WARNING OF SPECIAL DANGERS..................................................................................... 2-8 2.1.5.1 ELECTRICAL ENERGY ......................................................................................... 2-8 2.1.5.2 GAS, DUST, STEAM AND SMOKE ....................................................................... 2-9 2.1.5.3 HYDRAULIC, AIR CONDITIONING AND PNEUMATIC EQUIPMENT................ 2-10 2.1.5.4 NOISE .................................................................................................................. 2-10 2.1.5.5 HEAT.................................................................................................................... 2-11 2.1.5.6 OIL, GREASE AND OTHER CHEMICAL SUBSTANCES ................................... 2-11 2.1.5.7 HEIGHT................................................................................................................ 2-11 2.1.6 SPECIAL SAFETY EQUIPMENT ........................................................................................ 2-13 2.1.6.1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) .................................................................................. 2-13 2.1.6.2 INSTRUCTIONS FOR USE ................................................................................. 2-15 2.1.6.3 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD-BACK HOOKS OF THE SAFETY HARNESS........................................... 2-17 2.1.6.4 INSTARUCTIONS FOR USING THE FALL ABSORBER .................................... 2-19 2.1.7 SAFETY HINTS FOR HYDRAULIC HOSE INSTALLATION ............................................... 2-20 2.1.8 SAFETY HINTS FOR LIFTING HEAVY PARTS.................................................................. 2-23 2.1.9 SAFETY HINTS FOR WIRE ROPES................................................................................... 2-23 2.1.10 SAFETY HINTS FOR SLING ACCESSORY ....................................................................... 2-25 2.1.11 WEIGHT TABLES ................................................................................................................ 2-26 2.1.11.1 SUPERSTRUCTURE........................................................................................... 2-26 2.1.11.2 UNDERCARRIAGE.............................................................................................. 2-29 2.1.11.3 BACKHOE ATTACHMENT (BHA) ....................................................................... 2-31 2.1.11.4 FACE SHOVEL ATTACHMENT (FSA) ................................................................ 2-32

2.2

TORQUE CHARTS ACCORDING TO DIN ...................................................................................... 2.2.1 METRIC STANDARD THREAD........................................................................................... 2.2.2 METRIC FINE THREAD ...................................................................................................... 2.2.3 CUMMINS MOTOR TORQUES - METRIC.......................................................................... 2.2.4 CUMMINS MOTOR TORQUES - U.S. CUSTOMARY......................................................... 2.2.5 SAE FLANGE CONNECTIONS ...........................................................................................

2-33 2-33 2-34 2-35 2-35 2-36

2.3

BLIND PLUGS ................................................................................................................................. 2.3.1 DUMMY PLATES FOR SAE-FLANGES .............................................................................. 2.3.2 CLASSIFICATION OF THREADS TO THE NOMINAL WIDTH ........................................... 2.3.3 PLUGS AND FITTINGS ACCORDING TO DIN 2353..........................................................

2-37 2-37 2-39 2-40

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2.4

CONVERSION TABLE..................................................................................................................... 2.4.1 METHOD OF USING THE CONVERSION TABLE ............................................................. 2.4.2 MILLIMETER - INCH & KILOGRAM - POUND .................................................................... 2.4.3 LITER - U.S. GALLON & LITER - U.K. GALLON................................................................. 2.4.4 NM - FT.LB........................................................................................................................... 2.4.5 BAR - PSI / PSI - BAR ......................................................................................................... 2.4.6 BASIC VALUES IN OHM ACCORDING TO DIN 43 76 ....................................................... 2.4.7 TEMPERATURE ..................................................................................................................

2-41 2-41 2-42 2-43 2-44 2-45 2-46 2-47

2.5

TOOLS.............................................................................................................................................. 2-48 2.5.1 STANDARD TOOL CASE.................................................................................................... 2-48

2.6

EXPLANATION OF ABBREVIATIONS ........................................................................................... 2-50

3 SUPERSTRUCTURE................................................................................. 3-1 3.1

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DIESEL ENGINE ................................................................................................................................ 3-2 3.1.1 REMOVAL OF THE DIESEL ENGINES ................................................................................ 3-2 3.1.1.1 PREPARATORY WORK FOR DIESEL ENGINES REMOVAL .............................. 3-2 3.1.1.2 REMOVAL OF THE FRONT DIESEL ENGINE (ENGINE 2) ................................. 3-7 3.1.1.3 REPLACEMENT OF THE FRONT DIESEL ENGINE (ENGINE 2) ...................... 3-11 3.1.1.4 REMOVAL OF THE REAR DIESEL ENGINE (ENGINE 1).................................. 3-14 3.1.1.5 REPLACEMENT OF THE REAR DIESEL ENGINE (ENGINE 1) ........................ 3-14 3.1.2 ENGINE TORQUE SUPPORT AND ENGINE/PTO MOUNTS ............................................ 3-16 3.1.2.1 FLEXIBLE MOUNTS ............................................................................................ 3-17 3.1.2.2 TORQUE SUPPORT............................................................................................ 3-19 3.1.3 ALTERNATOR ..................................................................................................................... 3-20 3.1.3.1 REMOVAL OF THE ALTERNATOR .................................................................... 3-20 3.1.3.2 REPLACEMENT OF THE ALTERNATOR ........................................................... 3-21 3.1.4 BATTERIES ......................................................................................................................... 3-22 3.1.4.1 REMOVAL OF THE BATTERIES......................................................................... 3-22 3.1.4.2 REPLACEMENT OF THE BATTERIES ............................................................... 3-24 3.1.5 RADIATOR FAN .................................................................................................................. 3-26 3.1.5.1 REMOVAL OF THE RADIATOR FAN ASSEMBLY ............................................. 3-27 3.1.5.2 REPLACEMENT OF THE RADIATOR FAN ASSEMBLY .................................... 3-31 3.1.5.3 REMOVAL OF THE RADIATOR FAN.................................................................. 3-33 3.1.5.4 REPLACEMENT OF THE RADIATOR FAN ........................................................ 3-33 3.1.5.5 REMOVAL OF THE RADIATOR FAN DRIVE PUMP .......................................... 3-34 3.1.5.6 REPLACEMENT OF THE RADIATOR FAN DRIVE PUMP ................................. 3-36 3.1.6 RADIATORS ........................................................................................................................ 3-38 3.1.6.1 REMOVAL OF THE RADIATOR ASSEMBLY...................................................... 3-38 3.1.6.2 REPLACEMENT OF THE RADIATOR ASSEMBLY ............................................ 3-41 3.1.7 STARTER SYSTEM............................................................................................................. 3-42 3.1.7.1 REMOVAL OF THE STARTER MOTOR ............................................................. 3-42 3.1.7.2 REPLACEMENT OF THE STARTER MOTOR .................................................... 3-43 3.1.8 TORSION TYPE COUPLING (GEISLINGER) ..................................................................... 3-44 3.1.8.1 REMOVAL OF THE GEISLINGER COUPLING................................................... 3-45 3.1.8.2 REPLACEMENT OF THE GEISLINGER COUPLING ......................................... 3-49

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3.2

PTO .................................................................................................................................................. 3.2.1 MAIN PUMPS ...................................................................................................................... 3.2.1.1 PREPARATORY WORKS FOR MAIN PUMP REMOVAL ................................... 3.2.1.2 REMOVAL OF MAIN PUMPS.............................................................................. 3.2.1.3 REPLACEMENT OF MAIN PUMPS .................................................................... 3.2.2 PTO OIL PUMP (AUXILIARY PUMP) .................................................................................. 3.2.2.1 REMOVAL OF PTO OIL PUMP (AUXILIARY PUMP) ......................................... 3.2.2.2 REPLACEMENT OF THE PTO OIL PUMP (AUXILIARY PUMP) ........................ 3.2.3 OIL CIRCULATION PUMP (AUXILIARY PUMP) ................................................................. 3.2.3.1 REMOVAL OF OIL CIRCULATION PUMP (AUXILIARY PUMP) ........................ 3.2.3.2 REPLACEMENT OF THE OIL CIRCULATION PUMP (AUXILIARY PUMP) ....... 3.2.4 PUMP DISTRIBUTOR GEARBOX (PTO)............................................................................ 3.2.4.1 REMOVAL OF THE PUMP DISTRIBUTOR GEARBOX (PTO) ........................... 3.2.4.2 REPLACEMENT OF THE PUMP DISTRIBUTOR GEARBOX (PTO)..................

3.3

HYDRAULICS .................................................................................................................................. 3-71 3.3.1 HYDRAULIC COOLER FAN DRIVE PUMP ........................................................................ 3-71 3.3.1.1 REMOVAL OF THE HYDRAULIC COOLER FAN DRIVE PUMP ........................ 3-72 3.3.1.2 REPLACEMENT OF THE HYDRAULIC COOLER FAN DRIVE PUMP .............. 3-75 3.3.2 HYDRAULIC COOLER FAN ASSEMBLY ........................................................................... 3-76 3.3.2.1 REMOVAL OF HYDRAULIC COOLER FAN ASSEMBLY ................................... 3-77 3.3.2.2 REPLACEMENT OF HYDRAULIC COOLER FAN ASSEMBLY.......................... 3-80 3.3.2.3 REMOVAL OF HYDRAULIC COOLER FAN AND MOTOR ................................ 3-82 3.3.2.4 REPLACEMENT OF HYDRAULIC COOLER FAN AND MOTOR ....................... 3-84 3.3.3 HYDRAULIC OIL COOLERS ............................................................................................... 3-86 3.3.3.1 REMOVAL OF THE HYDRAULIC OIL COOLERS .............................................. 3-88 3.3.3.2 REPLACEMENT OF THE HYDRAULIC OIL COOLERS ..................................... 3-92 3.3.3.3 REMOVAL OF THE HYDRAULIC OIL COOLER FRAME ................................... 3-94 3.3.3.4 REPLACEMENT OF THE HYDRAULIC OIL COOLER FRAME.......................... 3-98 3.3.4 MAIN RELIEF VALVES (MRV) ............................................................................................ 3-99 3.3.4.1 REMOVAL OF THE MRV .................................................................................... 3-99 3.3.4.2 REPLACEMENT OF THE MRV ........................................................................ 3-100 3.3.5 PILOT OIL PUMP (GEAR PUMP) ..................................................................................... 3-101 3.3.5.1 REMOVAL OF THE PILOT OIL PUMP .............................................................. 3-101 3.3.5.2 REPLACEMENT OF THE PILOT OIL PUMP .................................................... 3-103 3.3.6 MAIN GATE VALVE........................................................................................................... 3-104 3.3.6.1 REMOVAL OF THE MAIN GATE VALVE .......................................................... 3-104 3.3.6.2 REPLACEMENT OF THE MAIN GATE VALVE................................................. 3-105 3.3.7 HYDRAULIC OIL RESERVOIR ......................................................................................... 3-106 3.3.7.1 REMOVAL OF THE HYDRAULIC OIL RESERVOIR......................................... 3-108 3.3.7.2 REPLACEMENT OF THE HYDRAULIC OIL RESERVOIR ............................... 3-114 3.3.8 MAIN CONTROL VALVE BLOCKS ................................................................................... 3-117 3.3.8.1 REMOVAL OF THE MAIN CONTROL VALVE BLOCKS................................... 3-126 3.3.8.2 REPLACEMENT OF THE MAIN CONTROL VALVE BLOCKS ......................... 3-132 3.3.9 SERVICE LINE RELIEF VALVES (SRV) ........................................................................... 3-133 3.3.9.1 REMOVAL OF SRV ON MAIN CONTROL VALVE BLOCK .............................. 3-133 3.3.9.2 REPLACEMENT OF SRV ON MAIN CONTROL VALVE BLOCKS................... 3-136

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3-50 3-50 3-51 3-54 3-56 3-58 3-58 3-60 3-61 3-61 3-63 3-64 3-66 3-70

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3.3.10 ANTI-CAVITATION VALVES (ACV) ................................................................................. 3.3.10.1 REMOVAL OF ACV ON MANIFOLD ................................................................. 3.3.10.2 REPLACEMENT OF THE ACV ON MANIFOLD................................................ 3.3.10.3 REMOVAL OF ACV ON MAIN CONTROL VALVE BLOCKS ............................ 3.3.10.4 REPLACEMENT OF ACV ON MAIN CONTROL VALVE BLOCKS................... 3.3.11 THROTTLE CHECK VALVES ........................................................................................... 3.3.11.1 REMOVAL OF THROTTLE CHECK VALVES ................................................... 3.3.11.2 REPLACEMENT OF THROTTLE CHECK VALVES.......................................... 3.3.12 MANIFOLD......................................................................................................................... 3.3.12.1 REMOVAL OF THE MANIFOLD ........................................................................ 3.3.12.2 REPLACEMENT OF THE MANIFOLD...............................................................

3-138 3-139 3-144 3-145 3-148 3-150 3-152 3-155 3-156 3-156 3-158

3.4

SLEW DRIVE.................................................................................................................................. 3.4.1 SLEW GEAR...................................................................................................................... 3.4.1.1 REMOVAL OF THE SLEW GEAR ..................................................................... 3.4.1.2 REPLACEMENT OF THE SLEW GEAR............................................................ 3.4.2 SWING MOTOR................................................................................................................. 3.4.2.1 REMOVAL OF THE SWING MOTOR ................................................................ 3.4.2.2 REPLACEMENT OF THE SWING MOTOR....................................................... 3.4.3 SLEW PARKING BRAKE................................................................................................... 3.4.3.1 REMOVAL/DISASSEMBLY OF THE SLEW PARKING BRAKE (L&S) ............. 3.4.3.2 REPLACEMENT/ASSEMBLY OF THE SLEW PARKING BRAKE (L&S) .......... 3.4.3.3 REMOVAL OF THE SLEW PARKING BRAKE (SIEBENHAAR) ....................... 3.4.3.4 REPLACEMENT OF THE SLEW PARKING BRAKE (SIEBENHAAR) .............. 3.4.4 DYNAMIC SLEW BRAKE .................................................................................................. 3.4.4.1 REMOVAL OF THE SLEW BRAKE VALVE....................................................... 3.4.4.2 REPLACEMENT OF THE SLEW BRAKE VALVE ............................................. 3.4.5 SWING CIRCLE LUBRICATION PINION (DUMMY WHEEL) ........................................... 3.4.5.1 REMOVAL OF THE LUBRICATION PINION ASSEMBLY................................. 3.4.5.2 REPLACEMENT OF THE LUBRICATION PINION ASSEMBLY ....................... 3.4.6 SWING CIRCLE................................................................................................................. 3.4.6.1 REMOVAL OF THE SWING CIRCLE ................................................................ 3.4.6.2 REPLACEMENT OF THE SWING CIRCLE.......................................................

3-159 3-160 3-161 3-165 3-168 3-169 3-172 3-174 3-177 3-180 3-183 3-186 3-190 3-193 3-195 3-196 3-198 3-200 3-202 3-203 3-206

3.5

LUBRICATION PUMPS ................................................................................................................. 3-212 3.5.1 REMOVAL OF THE LUBRICATION PUMP....................................................................... 3-214 3.5.2 REPLACEMENT OF THE LUBRICATION PUMP ............................................................. 3-216

3.6

PUMP CONTROLLER MC7 ........................................................................................................... 3-217 3.6.1 REMOVAL OF THE PUMP CONTROLLER MC7.............................................................. 3-217 3.6.2 REPLACEMENT OF THE PUMP CONTROLLER MC7 .................................................... 3-217

3.7

OPERATOR’S CAB ....................................................................................................................... 3.7.1 REMOVAL OF THE OPERATOR’S CAB........................................................................... 3.7.2 REPLACEMENT OF THE OPERATOR’S CAB ................................................................. 3.7.3 CAB-MOUNTS ................................................................................................................... 3.7.3.1 REMOVAL OF THE CAB-MOUNTS .................................................................. 3.7.3.2 REPLACEMENT OF THE CAB-MOUNTS ......................................................... 3.7.4 FRONT WINDOW (WINDSCREEN) .................................................................................. 3.7.4.1 REMOVAL OF THE FRONT WINDOW ............................................................. 3.7.4.2 REPLACEMENT OF THE FRONT WINDOW ....................................................

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3.7.5

3.7.6

3.7.7

3.7.8 3.7.9

OPERATOR’S SEAT ......................................................................................................... 3.7.5.1 REMOVAL OF THE OPERATOR’S SEAT......................................................... 3.7.5.2 REPLACEMENT OF THE OPERATOR’S SEAT ............................................... ECS.................................................................................................................................... 3.7.6.1 REMOVAL OF THE ECS TEXT DISPLAY......................................................... 3.7.6.2 REPLACEMENT OF THE ECS TEXT DISPLAY ............................................... ACCESS LADDER............................................................................................................. 3.7.7.1 REMOVAL OF THE ACCESS LADDER ............................................................ 3.7.7.2 REPLACEMENT OF THE ACCESS LADDER................................................... 3.7.7.3 REMOVAL OF THE ACCESS LADDER CYLINDER ......................................... 3.7.7.4 REPLACEMENT OF THE ACCESS LADDER CYLINDER ............................... REMOVAL OF THE CAB BASE ........................................................................................ REPLACEMENT OF THE CAB BASE ...............................................................................

3-234 3-234 3-235 3-236 3-236 3-236 3-238 3-241 3-243 3-245 3-247 3-248 3-250

3.8

COUNTERWEIGHT........................................................................................................................ 3-252 3.8.1 REMOVAL OF THE COUNTERWEIGHT .......................................................................... 3-253 3.8.2 REPLACEMENT OF THE COUNTERWEIGHT................................................................. 3-255

3.9

SUPERSTRUCTURE LIFTING ...................................................................................................... 3-257 3.9.1 REMOVE THE SUPERSTRUCTURE FROM THE UNDERCARRIAGE ........................... 3-257 3.9.2 INSTALL THE SUPERSTRUCTURE ONTO THE UNDERCARRIAGE............................. 3-261

3.10 FUEL TANK ................................................................................................................................... 3-264 3.10.1 REMOVAL OF THE FUEL TANK ...................................................................................... 3-265 3.10.2 REPLACEMENT OF THE FUEL TANK ............................................................................. 3-269

4 UNDERCARRIAGE.................................................................................... 4-1 4.1

TRAVEL SYSTEM.............................................................................................................................. 4-2 4.1.1 TRACK GROUP..................................................................................................................... 4-2 4.1.1.1 CHANGING OF THE TRACK GROUP .................................................................. 4-2 4.1.2 SPROCKET ........................................................................................................................... 4-7 4.1.2.1 REMOVAL OF THE SPROCKET........................................................................... 4-7 4.1.2.2 REPLACEMENT OF THE SPROCKET ............................................................... 4-12 4.1.2.3 REMOVAL OF THE SEGMENTED SPROCKET (ONLY FOR TYPE WITH PINNED UNDERCARRIAGE UP TO SN 025)............ 4-14 4.1.2.4 REPLACEMENT OF THE SEGMENTED SPROCKET (ONLY FOR TYPE WITH PINNED UNDERCARRIAGE UP TO SN 025)............ 4-18 4.1.3 GUIDE WHEELS ................................................................................................................. 4-20 4.1.3.1 REMOVAL OF THE GUIDE WHEEL ASSEMBLY ............................................... 4-20 4.1.3.2 REPLACEMENT OF THE GUIDE WHEEL ASSEMBLY ..................................... 4-22 4.1.4 TRACK TENSIONING ACCUMULATORS .......................................................................... 4-23 4.1.4.1 REMOVAL OF THE LOW PRESSURE ACCUMULATORS ................................ 4-23 4.1.4.2 REPLACEMENT OF THE LOW PRESSURE ACCUMULATORS ....................... 4-25 4.1.4.3 REMOVAL OF THE HIGH PRESSURE ACCUMULATORS ............................... 4-26 4.1.4.4 REPLACEMENT OF THE HIGH PRESSURE ACCUMULATORS ...................... 4-27 4.1.5 TRACK TENSION VALVE BLOCK ...................................................................................... 4-28 4.1.5.1 REMOVAL OF THE TRACK TENSIONING VALVE BLOCK ............................... 4-28 4.1.5.2 REPLACEMENT OF THE TRACK TENSIONING VALVE BLOCK...................... 4-29 4.1.6 HYDRAULIC HOSES OF THE TRACK TENSIONING SYSTEM ........................................ 4-31 4.1.6.1 SUBSTITUTE THE HYDRAULIC HOSES ........................................................... 4-31 4.1.7 TRAVEL BRAKE VALVE BLOCK (OVERSPEED VALVE).................................................. 4-34 4.1.7.1 REMOVAL OF THE TRAVEL BRAKE VALVE BLOCK ....................................... 4-35 4.1.7.2 REPLACEMENT OF THE TRAVEL BRAKE VALVE BLOCK .............................. 4-37

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4.1.8

TRACK TENSIONING CYLINDERS .................................................................................... 4.1.8.1 REMOVAL OF THE TRACK TENSIONING CYLINDERS ................................... 4.1.8.2 REPLACEMENT OF THE TRACK TENSIONING CYLINDERS .......................... TRAVEL MOTOR................................................................................................................. 4.1.9.1 REMOVAL OF THE TRAVEL MOTORS.............................................................. 4.1.9.2 REPLACEMENT OF THE TRAVEL MOTORS .................................................... TRAVEL PARKING BRAKE................................................................................................. 4.1.10.1 REMOVAL OF THE TRAVEL PARKING BRAKE ................................................ 4.1.10.2 REPLACEMENT OF THE TRAVEL PARKING BRAKE....................................... TRAVEL GEARBOX ............................................................................................................ 4.1.11.1 REMOVAL OF THE TRAVEL GEARBOX............................................................ 4.1.11.2 REPLACEMENT OF THE TRAVEL GEARBOX .................................................. 4.1.11.3 REMOVAL OF THE TRAVEL GEARBOX (ONLY FOR TYPE WITH PINNED UNDERCARRIAGE UP TO SN 025) ............ 4.1.11.4 REPLACEMENT OF THE TRAVEL GEARBOX (ONLY FOR TYPE WITH PINNED UNDERCARRIAGE UP TO SN 025) ............ CARRIER ROLLER.............................................................................................................. 4.1.12.1 REMOVAL OF THE CARRIER ROLLER ASSEMBLY......................................... 4.1.12.2 REPLACEMENT OF THE CARRIER ROLLER ASSEMBLY ............................... TRACK ROLLER.................................................................................................................. 4.1.13.1 REMOVAL OF THE TRACK ROLLER ASSEMBLY............................................. 4.1.13.2 REPLACEMENT OF THE TRACK ROLLER ASSEMBLY ...................................

4-38 4-38 4-39 4-40 4-40 4-42 4-44 4-46 4-48 4-50 4-51 4-53

CAR BODY....................................................................................................................................... 4.2.1 REMOVAL OF THE CAR BODY AND THE CRAWLER CARRIERS (TYPE WITH PINNED UNDERCARRIAGE) ........................................................................ 4.2.2 REPLACEMENT OF THE CAR BODY AND THE CRAWLER CARRIERS (TYPE WITH PINNED UNDERCARRIAGE) ........................................................................ 4.2.3 REMOVAL OF THE CAR BODY AND THE CRAWLER CARRIERS (TYPE WITH BOLTED UNDERCARRIAGE) ....................................................................... 4.2.4 REPLACEMENT OF THE CAR BODY AND THE CRAWLER CARRIERS (TYPE WITH BOLTED UNDERCARRIAGE) ....................................................................... 4.2.4.1 TIGHTENING TORQUE FOR THE CRAWLER CARRIER MOUNTING BOLTS 4.2.5 ROTARY JOINT................................................................................................................... 4.2.5.1 REMOVAL OF THE ROTARY JOINT .................................................................. 4.2.5.2 REPLACEMENT OF THE ROTARY JOINT .........................................................

4-72

4.1.9

4.1.10

4.1.11

4.1.12

4.1.13

4.2

4-55 4-61 4-66 4-66 4-68 4-69 4-69 4-71

4-72 4-76 4-80 4-85 4-88 4-92 4-94 4-96

5 ATTACHMENT........................................................................................... 5-1 5.1

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BACKHOE.......................................................................................................................................... 5-2 5.1.1 BOOM .................................................................................................................................... 5-4 5.1.1.1 REMOVAL OF THE BOOM.................................................................................... 5-4 5.1.1.2 REPLACEMENT OF THE BOOM .......................................................................... 5-8 5.1.1.3 REMOVAL OF BOOM CYLINDERS .................................................................... 5-10 5.1.1.4 REPLACEMENT OF BOOM CYLINDERS........................................................... 5-16 5.1.2 STICK................................................................................................................................... 5-20 5.1.2.1 REMOVAL OF THE STICK .................................................................................. 5-20 5.1.2.2 REPLACEMENT OF THE STICK......................................................................... 5-24 5.1.2.3 REMOVAL OF STICK CYLINDERS..................................................................... 5-26 5.1.2.4 REPLACEMENT OF STICK CYLINDERS ........................................................... 5-32

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5.1.3

5.1.4

5.1.5 5.1.6

BUCKET .............................................................................................................................. 5.1.3.1 REMOVAL OF THE BUCKET.............................................................................. 5.1.3.2 REPLACEMENT OF THE BUCKET .................................................................... 5.1.3.3 REMOVAL OF BUCKET CYLINDERS ................................................................ 5.1.3.4 REPLACEMENT OF BUCKET CYLINDERS ....................................................... BUCKET LINK ROD AND STEERING RODS ..................................................................... 5.1.4.1 REMOVAL OF THE BUCKET LINK ROD ............................................................ 5.1.4.2 REPLACEMENT OF THE BUCKET LINK ROD .................................................. 5.1.4.3 REMOVAL OF THE STEERING RODS............................................................... 5.1.4.4 REPLACEMENT OF THE STEERING RODS ..................................................... GROUND ENGAGING TOOLS (GET)................................................................................. 5.1.5.1 REMOVAL AND REPLACEMENT OF THE GET ................................................ HYDRAULIC HOSES AT THE BACKHOE ATTACHMENT................................................. 5.1.6.1 SUBSTITUTE THE BOOM ARC HOSES ............................................................ 5.1.6.2 SUBSTITUTE THE BOOM CYLINDER HOSES .................................................. 5.1.6.3 SUBSTITUTE THE STICK CYLINDER HOSES .................................................. 5.1.6.4 SUBSTITUTE THE BUCKET CYLINDER HOSES ..............................................

5-36 5-36 5-39 5-40 5-46 5-49 5-49 5-51 5-52 5-55 5-56 5-57 5-58 5-58 5-62 5-66 5-70

5.2

FACE SHOVEL ................................................................................................................................ 5-74 5.2.1 USING THE INSTALLATION TOOLS FOR HYDRAULIC CYLINDERS.............................. 5-75 5.2.2 BOOM .................................................................................................................................. 5-76 5.2.2.1 REMOVAL OF THE BOOM ................................................................................. 5-76 5.2.2.2 REPLACEMENT OF THE BOOM ........................................................................ 5-81 5.2.2.3 REMOVAL OF THE BOOM CYLINDERS ............................................................ 5-86 5.2.2.4 REPLACEMENT OF THE BOOM CYLINDERS .................................................. 5-91 5.2.3 STICK .................................................................................................................................. 5-94 5.2.3.1 REMOVAL OF THE STICK.................................................................................. 5-94 5.2.3.2 REPLACEMENT OF THE STICK ........................................................................ 5-98 5.2.3.3 REMOVAL OF THE STICK CYLINDERS .......................................................... 5-100 5.2.3.4 REPLACEMENT OF THE STICK CYLINDERS ................................................. 5-105 5.2.4 BULL CLAM BUCKET ....................................................................................................... 5-108 5.2.4.1 REMOVAL OF THE BULL CLAM BUCKET ....................................................... 5-110 5.2.4.2 REPLACEMENT OF THE BULL CLAM BUCKET ............................................. 5-114 5.2.4.3 REMOVAL OF THE BUCKET CYLINDERS ...................................................... 5-116 5.2.4.4 REPLACEMENT OF THE BUCKET CYLINDERS ............................................. 5-121 5.2.4.5 REMOVAL OF THE CLAM CYLINDERS ........................................................... 5-124 5.2.4.6 REPLACEMENT OF THE CLAM CYLINDERS ................................................. 5-129 5.2.5 GROUND ENGAGING TOOLS (GET)............................................................................... 5-132 5.2.5.1 REMOVAL AND REPLACEMENT OF THE GET .............................................. 5-133 5.2.6 HYDRAULIC HOSES AT THE FACE SHOVEL ATTACHMENT ....................................... 5-134 5.2.6.1 SUBSTITUTE THE BOOM ARC HOSES .......................................................... 5-134 5.2.6.2 SUBSTITUTE THE BOOM CYLINDER HOSES ................................................ 5-138 5.2.6.3 SUBSTITUTE THE STICK ARC HOSES ........................................................... 5-142 5.2.6.4 SUBSTITUTE THE STICK CYLINDER HOSES ................................................ 5-146 5.2.6.5 SUBSTITUTE THE BUCKET CYLINDER HOSES ............................................ 5-150 5.2.6.6 SUBSTITUTE THE CLAM CYLINDER HOSES ................................................. 5-154

5.3

METERING VALVES (GREASE INJECTORS) AT THE ATTACHMENT ..................................... 5-162 5.3.1 REMOVAL OF THE METERING VALVES (GREASE INJECTORS)................................. 5-162 5.3.2 REPLACEMENT OF THE METERING VALVES (GREASE INJECTORS) ....................... 5-163

5.4

CYLINDER BYPASS TEST ........................................................................................................... 5-164

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Table of contents

6 SERVICE INFORMATION ......................................................................... 6-1 6.1

FLUIDS AND LUBRICANTS.............................................................................................................. 6-2 6.1.1 LUBRICANTS FOR OPERATION IN MODERATE AND HOT CLIMATES ........................... 6-2 6.1.2 LUBRICANTS FOR OPERATION IN COLD AND ARCTIC CLIMATES ................................ 6-4

6.2

FILLING CAPACITIES ....................................................................................................................... 6-5

6.3

WORK INSTRUCTIONS..................................................................................................................... 6-7 6.3.1 SURFACE COATING WITH INTERZINC 697 ....................................................................... 6-7 6.3.2 REMOVE / INSTALL THE CRAWLER CARRIER.................................................................. 6-9

6.4

USED SPECIAL TOOLS (OVERVIEW) ........................................................................................... 6-10

7 TOOLS CATALOGUE ................................................................................ 7-1 8 PARTS & SERVICE NEWS ....................................................................... 8-1 AH00511 Installation procedure for the swing circle / Slew Ring (SR) AH00514 Track group - Hints for sprocket exchange AH00515 Final drive: Wear and tear measurements Mounting procedures AH00519 Adhesive lubricants for the Slew Ring Gear AH01513 Bleeding of hydraulic pumps AH01521 Diesel engine suspension AH01531 Hydraulic accumulators - testing and refilling AH02513 Testing wear and tear of swing circle bearing AH02521 Track group – wear measurement AH03506 Hydraulic oil cooler and water cooler fan bearings AH03509 Slew gear GFB 174 E 9017 (Part No. 917 915 40) AH03510 ESCO bucket tooth system AH03511 Pilot Pressure Pump Part No. 907 209 40 AH03512 Gear Pumps (Part Nos. 907 209 40; 906 442 40; 896 730 40 and 654 930 40 AH04518 Welding procedure for welded counterweight AH05501 Abnormal vibration on hydraulic pipes AH05510 Bearing flushing of the A4VS variable displacement axial piston pump AH05511 Dual cone seal ring mounting

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AH05520 Installation hints for a new type of pilot pump AH05525 Suction elbows of the Main Pumps AH05535 Hints for replacing by the slewing gear of an other manufacturer AH05546 Automatic lubrication system - Vent valve (PN 769 879 73) AH06524 Hydraulic cylinder AH06529 Track group - Hints for sprocket exchange AH06530 Relieving of the track chain tension AH06542 Swash plate pump H-A4VSO500 AH06543 Gear pumps PN 907 622 40 and PN 940 048 40 (supplied from the company “Kracht”) (Pilot pressure pump; gear oil pump; circulation pump) AH06545 Hydraulic cylinder bushings AH07509 Swing brake manufactured by "Siebenhaar" (Swing gear PN 902 550 40 and PN 925 864 40) AH07526 Bolted undercarriage: Protective coating on the flange plates AH08503 Track drive AH08504 Windscreen AH08507 Steel structure AH08508 Bushings of the attachment and at the undercarriage

9 SUPPLIER’S DOCUMENTATION ............................................................. 9-1 AVANTI HYTORQUE

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Table of contents

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Introduction

1 INTRODUCTION

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Contents of the binder

1.1

Introduction

CONTENTS OF THE BINDER

Assembled in this file are the R&R Procedures with explanations of removing, installing, and adjustments of the major components and circuits for your KOMATSU Hydraulic Mining Shovel.

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Introduction

1.2

Foreword

FOREWORD

Observe the instructions in this manual for: z

Your Personal SAFETY

z

Operating SAFETY, and

z

READY and EFFICIENT PERFORMANCE of your KOMATSU Hydraulic Mining Shovel.

With this R&R Procedures Manual, KOMATSU provides you with the description of proper removal and replacement procedures of main components.

How do you find "your" desired information? In the TABLE OF CONTENTS all R&R PROCEDURES are shown in their sequence of description.

CAUTION Periodic preventive inspections and maintenance are the surest means of keeping the machine in proper working order. Prompt detection and correction of minor irregularities and immediate replacement of worn out or broken parts will prevent failures and avoid expenses.

Replace damaged graphics and symbols. Observe safety precautions to prevent injury and damage. If, after reading this R&R Procedures Manual, you can give us suggestions and comments for improvements - please do not hesitate to contact us.

Komatsu Mining Germany GmbH Service Training and Manuals Department 8151.30 P.O. Box 18 03 61 D - 40570 Düsseldorf GERMANY

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Introduction

WARNING Personnel entrusted with work on the machine must have read the section 2 SAFETY AND STANDARDS before beginning work. Reading the instructions after work has begun is too late.

Damages and defects caused by incorrect operation and maintenance are not covered by the manufacturer’s guarantee. In order to keep your shovel in first-class operating condition only use genuine spare and wear parts. The use of any part other than the genuine part releases the KOMATSU MINING GERMANY GmbH from any guarantee.

1.2.1

SERVICE

In all your written or phoned inquiries, please indicate the model and serial number of your shovel.

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Safety and Standards

2 SAFETY AND STANDARDS

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2.1

SAFETY INSTRUCTIONS

2.1.1

METHOD OF USING THIS MANUAL

z

When removing or installing a unit assembly, the order of work and techniques used are given for the removal procedure. The order of work for the installation is only given if the installation procedure differs from installation in reverse order of removal, for example any special technique needs to be applied.

z

Tightening torques according to DIN are not explicitly given in the installation procedures. For tightening torques according to DIN, refer to section 2.2 on page 2-33.

z

Figure references that appear in the operation procedures use the format (Fig. 4-12, Pos. 4), which means position number 4 in figure 12 of section 4.

z

Special requirements such as listing of special tools or size or numbers of blind plugs etc. are listed in a table at the beginning of each operation procedure.

z

Special tools that appear in the lists are given with part name, part number, and quantity (2 x thread protector, PN 409 329 40). For the special tools list, refer to section 6.4 on page 6-10.

z

The following symbols are used in the manual to designate additional information: Kind and amount of drained fluids (e.g. drain oil, 1500 liters). Lifting weight of an assembly (e.g. 140 kg). Kind and amount of fluids to fill (e.g. fill oil, 1500 liters). Special tightening torques for bolts etc., if not according to DIN, refer to section 2.2 on page 2-33 (e.g. 129 Nm). General information concerning a section, e.g. tightening torques according to DIN, refer to section 2.2 on page 2-33. Special authorized personnel is required.

All PARTS & SERVICE NEWS which are mentioned in the procedures are listed in chapter 8. The numbers of the PARTS & SERVICE NEWS do not label the latest edition. Ensure that the latest edition is always filed to the binder of this manual. 2 -2

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z

Safety Instructions

The following symbols and designations are used in the manual to designate instructions of particular importance: DANGER

Refers to orders and prohibitions designed to prevent serious injury or death.

WARNING Refers to orders and prohibitions designed to prevent injury or extensive damage.

CAUTION Refers to special information and/or orders and prohibitions directed towards preventing damage.

NOTE: Refers to special information on removing or installing assemblies, for example if any special technique needs to be applied.

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2.1.2


GENERAL PRECAUTIONS CAUTION

Proper service and repair is important for safe machine operation. The service and repair techniques recommended by Komatsu Mining Germany and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu Mining Germany for the specific purpose.

NOTE: Always attend to local regulations regarding the Personal Protective Equipment. WARNING z

Mistakes in operation and service are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine.

z

Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine.

z

When carrying out any operation, always wear safety shoes and a helmet. Do not wear loose work clothes or clothes with buttons missing.

z

Always wear safety glasses when hitting parts with a hammer. Always wear safety glasses when grinding parts with a grinder, etc.

z

Assure fire prevention according to the Operation & Maintenance Manual.

z

If welding repairs are needed, refer to the welding precautions given in the Operation & Maintenance Manual.

z

When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator's cab.

z

Keep all tools in good condition and learn the correct way to use them.

z

Decide on a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.

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Safety Instructions

DANGER Danger of explosion! Serious injury, permanent disfigurement, and scarring may result! Special care must be taken before welding, flame-cutting, and grinding operations are carried out on the counterweight. The filling of the counterweight chambers can create explosive gases which will accumulate in the chambers of the counterweight. These gases must be expelled before welding, flame-cutting, and grinding operations are carried out on the counterweight. Follow the instructions given in PARTS & SERVICE NEWS No. "AH04518" for expelling the gases from the counterweight chambers.

2.1.3

PREPARATIONS FOR WORK WARNING

z

Before adding oil or making repairs, park the machine on hard, level ground large enough to accommodate the machine, boom, and additional working equipment (crane mobile working platforms, forklift etc.).

z

If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane mobile working platforms, forklift etc.), make sure that the machine is moved to a place with appropriate ground conditions. Block the tracks to prevent the machine from moving.

z

Before starting work, lower bucket, hammer, or any other work equipment to the ground. If this procedure is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. Additionally, be sure to lock all the control levers and hang warning signs on them.

z

When disassembling or assembling, support the machine with blocks, jacks, or stands before starting work.

z

Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders, or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders, or steps, use a stand to provide safe footing.

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2.1.4


PRECAUTIONS DURING WORK WARNING

z

When removing the oil filler cap, drain plug, or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burnt. Wait for the oil and water to cool before carrying out work on the oil or water circuits.

z

Before starting work, isolate the machine according to local regulations. Remove the leads from the battery. ALWAYS remove the lead from the negative (-) terminal first.

z

When raising heavy components (25 kg or more), use a hoist or crane.

z

Check that the wire rope, chains, and hooks are free from damage.

z

Always use lifting equipment which has ample capacity.

z

Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane.

z

When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove.

z

When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires.

z

When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires.

z

As a general rule, do not use gasoline to wash parts.

z

Be sure to assemble all parts in their original places again. Replace any damaged parts with new parts.

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WARNING z

When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is being operated.

z

When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. Also check that connecting parts are correctly installed.

z

When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly.

z

When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole.

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2.1.5


WARNING OF SPECIAL DANGERS

2.1.5.1 ELECTRICAL ENERGY WARNING z

Use only original fuses and circuit breakers with the specified current rating. Switch off the machine immediately if trouble occurs in the electrical system.

z

When working with the machine, maintain a safe distance from overhead electric lines. If work is to be carried out close to overhead lines, the working equipment must be kept well away from them. Caution, danger! Check out the prescribed safety distances.

z

If your machine comes into contact with a live wire: z

do not leave the machine

z

drive the machine out of the hazard zone

z

warn others against approaching and touching the machine

z

have the live wire de-energized

z

do not leave the machine until the damaged line has been safely de-energized.

z

Work on the electrical system or equipment may only be carried out by a skilled electrician himself or by specially instructed personnel under the control and supervision of such electrician and in accordance with the applicable electrical engineering rules.

z

If provided for in the regulations, the power supply to parts of the machine, on which inspection, maintenance, and repair work is to be carried out must be cut off. Before starting any work, check the de-energized parts for the presence of power and ground or short-circuit them in addition to insulating adjacent live parts and elements.

z

The electrical equipment of the machine is to be inspected and checked at regular intervals. Defects such as loose connections or scorched cables must be rectified immediately.

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Safety Instructions

WARNING z

Necessary work on live parts and elements must be carried out only in the presence of a second person who can cut off the power supply in case of danger by actuating the emergency shut-off or main power switch. Secure the working area with a red-and-white safety chain and a warning sign. Use insulated tools only.

z

Before starting work on high-voltage assemblies and after cutting off the power supply, the feeder cable must be grounded and components such as capacitors shortcircuited with a grounding rod.

2.1.5.2 GAS, DUST, STEAM AND SMOKE WARNING z

Operate internal combustion engines and fuel operated heating systems only on adequately ventilated premises. Before starting the machine on enclosed premises, make sure that there is sufficient ventilation. Observe the regulations in force at the respective site.

z

Carry out welding, flame-cutting and grinding work on the machine only if this has been expressly approved, as there may be a risk of explosion and fire.

z

Special care must be taken before welding, flame-cutting and grinding operations are carried out on the counterweight. The filling of the counterweight chambers can create explosive gases which will accumulate in the chambers of the counterweight. These gases must be expelled before welding, flame-cutting and grinding operations are carried out on the counterweight. Danger of explosion. Follow the instructions given in PARTS & SERVICE NEWS No. "AH04518" for expelling the gases from the counterweight chambers.

z

Before carrying out welding, flame-cutting and grinding operations, clean the machine and its surroundings from dust and other inflammable substances and make sure that the premises are adequately ventilated (risk of explosion).

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2.1.5.3 HYDRAULIC, AIR CONDITIONING AND PNEUMATIC EQUIPMENT WARNING z

Work on hydraulic equipment and the air conditioning system may only be carried out by persons having special knowledge and experience in this systems.

z

Check all lines, hoses and screwed connections regularly for leaks and obvious damage. Repair any damage immediately. Splashed oil may cause injury and fire.

z

Depressurize all system sections and pressure pipes (hydraulic system, compressed-air system) to be removed in accordance with the specific instructions for the unit concerned before carrying out any repair work.

z

Refrigerant in the air conditioning system must be sucked off by authorized service specialists only before opening the refrigerant loop (e.g. removing pipes).

z

Hydraulic, air conditioning and compressed-air lines must be laid and fitted properly. Ensure that no connections are interchanged. The fittings, lengths, and quality of the hoses must comply with the technical requirements.

2.1.5.4 NOISE WARNING z

During operation, all sound baffles must be closed.

z

Always wear the prescribed ear protectors.

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Safety Instructions

2.1.5.5 HEAT WARNING z

Do not start working on hot machine parts until the temperature is below 50 °C.

z

Be careful when handling hot materials (risk of burning or scalding) such as:

z

z

Fuel

z

Engine coolant

z

Hydraulic oil

z

Engine oil

z

Grease

Use gloves when handling hot machine parts.

2.1.5.6 OIL, GREASE AND OTHER CHEMICAL SUBSTANCES WARNING z

When handling oil, grease, and other chemical substances, observe the product-related safety regulations given in the material safety data sheet (MSDS).

z

Be careful when handling hot materials (risk of burning or scalding).

2.1.5.7 HEIGHT WARNING When working in heights above 1.00 m, a special safety harness is required, refer to section 2.1.6 on page 2-13.

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Fig. 2-1 2 - 12


Safety harness in conformity with EN 361 PC5500-6

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2.1.6

Safety Instructions

SPECIAL SAFETY EQUIPMENT

2.1.6.1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) The safety harness (Fig. 2-1) should only be used together with connectors according to EN 354, and fall arrest according to EN 355, or fall protection devices according to EN 360. Legend for Fig. 2-1: (1)

Safety harness according to EN 361

(2)

Strap-type fall absorber according to DIN EN 355

(3)

Ladder to cab roof and railings (attachment points)

(4)

Protection hoods for roof mounted air conditioning, if so equipped

(A)

Shoulder strap

(B)

Back plate

(C)

Catching hook

(D)

Shoulder-strap fixing

(E)

Belly strap

(F)

Holding hook

(G)

Hold-back hook

(H)

Pelvis strap

(J)

Leg strap

WARNING Always use the safety harness (Fig. 2-1, Pos. 1) in conjunction with strap-type fall absorber (Fig. 2-1, Pos. 2), before mounting onto the loader attachment or other unsecured places of the shovel.

NOTE: The illustration (Fig. 2-1) shows a typical use of the safety harness. Shovels with the new type operator’s cab are not equipped with ladder (Fig. 2-1, Pos. 3), because the air conditioner unit of the new type cab is located on the back wall of the cab.

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Safety Instructions

Fig. 2-2 2 - 14



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Safety Instructions

2.1.6.2 INSTRUCTIONS FOR USE Open the lock and lift the harness by the catch hook (Fig. 2-2, Pos. C). The blue straps (leg straps Fig. 2-2, Pos. J) must be at the bottom. The harness is being put on just like a jacket. Pull the belly strap (Fig. 2-2, Pos. E) through the lock, as shown in the illustration, and secure it. By closing the breast strap, you avoid the shoulder straps to sideslip. Bring the leg straps (Fig. 2-2, Pos. J) around the legs to the front, pull them in, as shown in the illustration, and tighten them. Adapt the harness to body form, seeing to perfect fit, in particular that the catching hook (Fig. 2-2, Pos. C) is aligned in the center of the back. The safety harness should belong to its wearer personally. The safety harness should only be used together with connectors according to EN 354, and fall arrest according to EN 355, or fall protection devices according to EN 360. The attachment point for the safety harness should be above the wearer, and the carrying capacity of the attachment point should be sufficient to correspond with the minimum carrying capacity according to EN 795. z

Before using the harness: z

Carry out a visual check of the system or components. The correct functioning and perfect working order have to be assured.

z

Make sure that the recommendations for use with other components of the system are observed in conformity with the instructions for use. WARNING

The system or component must no longer be used, if there are any doubts in respect of its safe condition. The equipment has to be inspected by the manufacturer or by a qualified person. It is essential for safety reasons that a fall protection system or system component which has already been subjected to fall is removed from the service and sent back to the manufacturer or to an authorized qualified repair shop for maintenance and renewed testing.

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Safety Instructions

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Safety Instructions

Fall protection systems have to be treated with care and to be kept clean and ready for use. It has to be warned against bringing the systems into contact with acids or other caustic liquids and gases, oils, detergents, or sharp-edged objects. If the harness has become wet during use or cleaning, do not dry near a fire or other sources of heat, but rather in a natural way in not too warm rooms. Keep the harness freely suspended or loosely rolled up. When using the fall protection systems, the pertaining safety regulations in force and the "Rules for Use of Personal Fall Arrest Systems" have to be observed for protection against danger. WARNING At least every 12 months, the safety harness and its components have to be inspected by a competent person authorized by the manufacturer and they have to be maintained, if the manufacturer considers it to be necessary.

2.1.6.3 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD-BACK HOOKS OF THE SAFETY HARNESS During the holding function, the connectors may only be placed around a mast or any other construction between the two holding hooks, so that the free fall is limited to max. 0.5 m. It should be strictly seen to it that the connector is not slung around constructions with too small diameters or sharp edges. With the lateral holding hooks, work may only be carried out on horizontal or almost horizontal surfaces (roofs). The connectors have to be adjusted in such a way that the area, where danger of falling down prevails, cannot be reached.

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Safety Instructions

Fig. 2-4 2 - 18



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Safety Instructions

2.1.6.4 INSTARUCTIONS FOR USING THE FALL ABSORBER Strap-type fall absorber according to DIN EN 355 (type E.K.N.BFD) Use Within a fall-arrest system, the strap-type fall absorber (Fig. 2-4, Pos. 2) has to be used in conjunction with a safety harness (Fig. 2-4, Pos. 1) according to DIN EN 361. The maximum length including the safety rope must not exceed 2.0 m. For longer ropes, a rope-shortening device has to be applied in addition. Fix the rope to the attachment point and attach the strap-type fall absorber to the catching hook in the back of the safety harness. The attachment point should be above the wearer and its minimum carrying capacity should be 10 kN, according to DIN EN 795. The strap-type fall absorber and the safety rope must not be damaged, e.g. never pull them over sharp edges nor get them burnt by welding sparks. Storing and maintenance The strap-type fall absorber has to be kept dry in an airy and shady room. It must not be exposed to acids, caustic chemicals, nor to an aggressive atmosphere, and contact with any oil has to be avoided. If the strap-type fall absorber is dirty, it may be cleaned with a little water and a light-duty detergent. Dry it in a shady place (nowhere near fire or other sources of heat). Protect it from sharp-edged objects. Inspection Prior to use, all parts have to be inspected for safe condition and damages. At least once a year, the strap-type fall absorber has to be tested by a competent person. A damaged or used strap-type fall absorber has to be removed from the service immediately. The strap-type fall absorber must not be changed in any way. Repair work has to be done by the manufacturer or by an authorized qualified repair shop.

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Safety Instructions

2.1.7


SAFETY HINTS FOR HYDRAULIC HOSE INSTALLATION WARNING

The hydraulic hoses undergo natural aging. Hence, as they are safety critical parts, their usable lifetime is limited to a maximum of 6 years (including storage time). For further information refer to the Operation and Maintenance Manual, chapter 4, section "REPLACEMENT OF HYDRAULIC HOSE LINES AND FUEL HOSE".

To avoid damage to the hydraulic hose lines, follow the installation procedures listed below: CAUTION Pay attention to the Natural curvature of the hose!

Fig. 2-5

CAUTION Do not twist the hoses during installation!

Fig. 2-6

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Safety Instructions

CAUTION Mount angled flanges at first!

Fig. 2-7

CAUTION Pay attention to the changing in hose length, depending on the pressure inside the hose!

Fig. 2-8

CAUTION Pay attention to the bending radius!

Fig. 2-9

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Safety Instructions


CAUTION Pay attention to the bending radius!

Fig. 2-10

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2.1.8

Safety Instructions

SAFETY HINTS FOR LIFTING HEAVY PARTS

NOTE: In order to avoid damage to the lifting devices or parts that have to be lifted, use edge protection at all sharp edges. CAUTION Heavy parts (25 kg or more) must be lifted with a hoist etc.

CAUTION If any part cannot be removed from the machine smoothly by hoisting, the following checks should be made: Check for the removal of all bolts fastening the component to other parts. Check for existence of another part causing interference with the component to be removed.

2.1.9 z

SAFETY HINTS FOR WIRE ROPES

Use adequate ropes depending on the weight of the parts to be hoisted, referring to the below table: Wire ropes (Standard "Z" or "S" twist ropes without galvanizing) Rope diameter [mm]

10.0

11.2

12.5

14.0

16.0

18.0

20.0

22.4

30.0

40.0

50.0

60.0

Allowable load [Metric tons]

1.0

1.4

1.6

2.2

2.8

3.6

4.4

5.6

10.0

18.0

28.0

40.0

CAUTION The allowable load value is estimated to be 1/6 or 1/7 of the breaking strength of the rope used.

WARNING The table above may differ from local standards. Always attend to local standards when using wire ropes.

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Safety Instructions


z

Sling wire ropes around the middle portion of the hook. Slinging near the tip of the hook may cause the rope to slip off the hook during hoisting, which may cause a serious accident. Hooks have the maximum strength at the middle portion, see Fig. 2-11.

z

Do not sling a heavy load with one rope alone, but sling it with two or more ropes wound symmetrically around the load.

Fig. 2-11

WARNING Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which may cause a serious accident.

z

Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles. Figure 2-12 shows the variation of allowable load (kg) where hoisting is made with two ropes, each of which is allowed to sling up to 1000 kg vertically, at various hanging angles. When two ropes sling a load vertically, up to 2000 kg of total weight can be lifted. This weight becomes 1000 kg when two ropes make a 120° hanging angle. On the other hand, two ropes are subject to an excessive force as large as 4000 kg if they sling a 2000 kg load at a lifting angle of 150°.

2 - 24

PC5500-6

Fig. 2-12

Version 2009/2


Safety Instructions

2.1.10 SAFETY HINTS FOR SLING ACCESSORY WARNING Always attend to local standards when using sling accessory.

z

Do not use rigid eye bolts from steel C 15 for lifting (e.g. DIN 580). These eye bolts may only be loaded vertically or with a maximum permissible angle of 45° to the ring.

z

Always use suitable swivel hoist rings according to local standards or Vario-Starpoint hoist rings recommended by Komatsu, see following table: Thread

Komatsu Part Number

Tightening Torque

M8

941 650 40

10 Nm

M10

941 651 40

10 Nm

M12

906 519 40

25 Nm

M16

906 780 40

60 Nm

M20

906 782 40

115 Nm

M24

906 783 40

190 Nm

M30

906 421 40

330 Nm

M36

906 233 40

590 Nm

DANGER Vario-Starpoint hoist rings are not suited for turning under load. After installing Starpoint hoist ring disengage the star key. Adjust ring plane in direction of pull before attaching sling accessory.

DANGER Eye bolts or sling accessory which is not suitable can result in serious accidents.

z

Check that the wire rope, chains, and hooks are free from damage.

z

Always use lifting equipment which has ample capacity.

z

Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane.

Version 2009/2

PC5500-6

2 - 25

Safety Instructions


2.1.11 WEIGHT TABLES 2.1.11.1 SUPERSTRUCTURE Part or assembly

Weight

Diesel engine

7000 kg

Roof plate engine housing

397 kg max.

Beam (Bridge)

285 kg

Alternator

depending on type

38.25 kg

Battery

62 kg

Radiator fan

35 kg

Hydraulic fan motor

18 kg

Bearing block

each

77.5 kg

Radiator fan drive pump

40 kg

Radiator assembly

650 kg

Roof plate over radiator

116 kg

Fan cowl

67 kg

Starter motor

35.5 kg

Starter motor with prelubrication pump

43.6 kg

Geislinger coupling assembly

160 kg

Roof plate engine housing

260 kg

Main pump assembly with flanged gear pump

362.4 kg

Oil circulation pump (auxiliary pump)

each

25 kg

PTO (pump distributor gearbox)

1900 kg

Control frame assembly

260 kg

Hydraulic cooler fan drive pump

40 kg

Hydraulic cooler fan assembly

each

117.4 kg

Hydraulic cooler fan

19 kg

Hydraulic cooler fan mounting assembly

72 kg

Hydraulic motor assembly

26.4 kg

Hydraulic oil cooler

275 kg

Hydraulic oil cooler frame incl. Hydraulic oil coolers

3950 kg

Pilot oil pump

27.4 kg

Main gate valve

12.3 kg

Hydraulic oil reservoir incl. Back pressure valve

3465 kg

Main control valve block 1, incl. ACVs & SRVs

717 kg

2 - 26

Remark

PC5500-6

each element

Version 2009/2


Safety Instructions

Part or assembly

Weight


726 kg

High pressure filter (main control block 2)

44.6 kg


713 kg

Main control valve block 4

143 kg

High pressure filter (main control block 4)

15 kg

Anti cavitation valve on main control block (ACV)

3 kg

Throttle check valve on main control block (SRV)

4 kg

Single anti cavitation valve on manifold

15 kg

Double anti cavitation valve on manifold

44.6 kg

Manifold without valves

408 kg

Pressure relief valve assembly on manifold

18.2 kg

Throttle check valve on manifold (long version)

31 kg

Throttle check valve on manifold (short version)

28 kg

Manifold incl. ACVs & SRVs (BHA)

921.2 kg

Manifold incl. ACVs & SRVs (FSA)

893.2 kg

Slew gear (Siebenhaar)

1700 kg

Slew gear (L&S)

1880 kg

Swing motor

170 kg

Bearing ring of the slew parking brake (L&S)

32 kg

Slew brake valve

97

Pinion cover

11.6 kg

Lubrication pinion assembly

18.2 kg

Lubrication pump

28 kg

Operator's cab

2700 kg

Viscous mount

4 kg

Absorber plate incl. 2 viscous mount

11.9 kg

Absorber plate incl. 3 viscous mounts

17.4 kg

Front window

112 kg

Operator's seat

62 kg

Access ladder

167 kg

Access ladder cylinder

23 kg

Cab base

3785 kg

Support frame

987 kg

Counterweight

46,000 k

Version 2009/2

Remark

PC5500-6

2 - 27

Safety Instructions


Part or assembly

Weight

Superstructure incl. Diesel engine without counterweight, attachment and fluids

137,215 kg

Fuel tank (empty)

4486 kg

2 - 28

PC5500-6

Remark

Version 2009/2


Safety Instructions

2.1.11.2 UNDERCARRIAGE Part or assembly

Weight

Track group 1350 mm

Remark

32.192 kg

Pin between track shoes (Track group 1350 mm)

19 kg

Track group 1800 mm

39.066 kg

Pin between track shoes (Track group 1800 mm)

20.2 kg

Sprocket

4382 kg

Hollow shaft

612 kg

Drive shaft

1007 kg

Three segmented sprocket assembly

2250 kg

Sprocket segment 1 (5 teeth)

794.25 kg


794.25 kg


661.5 kg

Three segmented sprocket assembly (oversize)

2745 kg

Sprocket segment 1 (5 teeth, oversize)

968.99 kg


968.99 kg


807.02 kg

Guide wheel assembly

3323 kg

Low pressure accumulator

12 kg

High pressure accumulator

23 kg

Track tensioning valve block

40 kg

Hydraulic hoses of the track tensioning system

10 kg max

Travel brake valve block

75 kg

Track tensioning cylinder

400 kg

Travel motor

110 kg

Travel parking brake

75 kg

Travel gearbox

4020 kg

Carrier roller assembly (bolted connection)

205 kg

Carrier roller assembly (with mounting pins)

175 kg

Track roller assembly

654 kg

depending on type

each

each

Car body without crawler carrier (with mounting pins)

42,000 kg

Crawler carrier assembly (track width 1350 mm, with mounting pins)

70,000 kg

each


80,000 kg

each

Car body without crawler carrier (bolted connection)

46,000 kg

Crawler carrier assembly (track width 1350 mm, bolted connection)

76,722 kg

Version 2009/2

PC5500-6

each 2 - 29

Safety Instructions


Part or assembly

Weight


83,646 kg

Rotary joint

261 kg

Swing circle

10,000 kg

2 - 30

PC5500-6

Remark each

Version 2009/2


Safety Instructions

2.1.11.3 BACKHOE ATTACHMENT (BHA) Part or assembly

Weight

Boom

Remark

45,100 kg

Pin boom/superstructure

365 kg

Pin boom cylinder/boom

177 kg

Pin boom cylinder/superstructure

224 kg

Boom cylinder

6500 kg

Stick

each

19,160 kg

Pin stick/boom

1440 kg

Stick cylinder

4600 kg

Pin stick cylinder/stick

127 kg

Pin stick cylinder/boom

179 kg

Bucket

each

30,600 kg

Pin bucket/stick

574 kg

Pin bucket/bucket link rod

822 kg

Bucket cylinder

3210 kg

Pin bucket cylinder/stick

86 kg

Pin bucket cylinder/steering rod

865 kg

Rod protection cover

360 kg

Nut-Cap

35 kg

Bucket link rod

2280 kg

Steering rod

1300 kg

Pin steering rod/stick

479 kg

Point (ESCO)

55 kg

Shroud (ESCO)

337 kg

Tooth adapter (ESCO)

182 kg

Boom arc hose

39 kg

each

Boom cylinder hoses

29.5 kg 39 kg

depending on length

Stick cylinder hoses

23 kg 27,5 kg

depending on length

Bucket cylinder hoses

33 kg

Metering valve

<25 kg

Version 2009/2

PC5500-6

2 - 31

Safety Instructions


2.1.11.4 FACE SHOVEL ATTACHMENT (FSA) Part or assembly Boom with attached stick and boom cylinders

Weight

Remark

52,900 kg

boom without cylinders: 34,800 kg

Pin boom/superstructure

365 kg

Pin boom cylinder/boom

234 kg

Pin boom cylinder/superstructure

224 kg

Boom cylinder

5680 kg

Stick

21,000

Pin stick/boom

168 kg

Stick cylinder

3340 kg

Pin stick cylinder/stick

90 kg

Pin stick cylinder/boom

90 kg

Bucket

35,060 kg

Pin bucket cylinder/bucket

190 kg

Pin bucket/stick

318 kg

Bucket cylinder

4005 kg

Pin bucket cylinder/boom

168 kg

Clam cylinder

885 kg

Upper pin at clam cylinder

48 kg

Lower pin at clam cylinder

66 kg

Point (tooth) (ESCO)

55 kg

Shroud (ESCO)

270 kg

Tooth adapter (ESCO)

182 kg

Boom arc hose

39 kg

Boom cylinder hose

30.5 kg

Stick arc hose

29.5 kg

Stick cylinder hose

25 kg 27.4 kg

depending on length

Bucket cylinder hose

28 kg

depending on length

Clam cylinder hose at stick

28 kg

Clam cylinder hose at clam cylinder

8.8 kg 9.8 kg 10 kg 11.2 kg

Metering valve

<25 kg

2 - 32

PC5500-6

depending on length and type

Version 2009/2


Torque charts according to DIN

2.2

TORQUE CHARTS ACCORDING TO DIN

2.2.1

METRIC STANDARD THREAD

Bolt diameter

Wrench size [mm]

Tightening torque [Nm] Bolt quality grades

Metric regular 8.8

10.9

12.9

M 8

13

6

21

31

36

M 10

17

8

43

63

73

M 12

19

10

74

108

127

M 14

22

12

118

173

202

M 16

24

14

179

265

310

M 18

27

14

255

360

425

M 20

30

17

360

510

600

M 22

32

17

485

690

810

M 24

36

19

620

880

1030

M 27

41

19

920

1310

1530

M 30

46

22

1250

1770

2080

M 33

50

24

1690

2400

2800

M 36

55

27

2170

3100

3600

M 39

60

2800

4000

4700

M 42

65

3500

4950

5800

M 45

70

4350

6200

7200

M 48

75

5200

7500

8700

M 52

80

6700

9600

11200

M 56

85

8400

12000

14000

M 60

90

10400

14800

17400

M 64

95

12600

17900

20900

M 68

100

15200

21600

25500

32

35

41

46

NOTE: Threads and bolts must be greased carefully with grease KP2K. Contact surfaces which should be screwed together must be free of grease.

Version 2009/2

PC5500-6

2 - 33


2.2.2


METRIC FINE THREAD

Bolt diameter

Wrench size [mm]

Tightening torque [Nm] Bolt quality grades

Metric fine

8.8

10.9

12.9

M 8 x 1.0

13

6

23

33

39

M 10 x 1.0

17

8

48

70

82

M 12 x 1.25

19

10

81

119

139

M 14x1.5

22

12

127

187

219

M 16 x 1.5

24

14

191

280

330

M 18 x 2.0

27

14

270

385

450

M 20 x 2.0

30

17

380

540

630

M 22 x 2.0

32

17

510

720

850

M 24 x 2.0

36

19

680

960

1130

M 27 x 2.0

41

19

990

1410

1650

M 30 x 2.0

46

22

1380

1960

2300

M 33 x 2.0

50

24

1850

2650

3100

M 36 x 3.0

55

27

2300

3250

3850

M 39 x 3.0

60

3000

4200

4950

M 42 x 3.0

65

3750

5300

6200

M 45 x 3.0

70

4600

6600

7700

M 48 x 3.0

75

5700

8100

9500

M 52 x 3.0

80

7300

10400

12100

M 56 x 4.0

85

8900

12600

14800

M 60 x 4.0

90

11000

15600

18300

M 64 x 4.0

95

13300

19000

22200

M 68 x 4.0

100

16100

22900

27000

32

35

41

46

NOTE: Threads and bolts must be greased carefully with grease KP2K. Contact surfaces which should be screwed together must be free of grease. CAUTION Bolts at the slew rings have different torques, refer to Service NEWS No. "AH00511" last edition!

2 - 34

PC5500-6

Version 2009/2


2.2.3


CUMMINS MOTOR TORQUES - METRIC

Grade

8.8

10.9

12.9

Body size

Torque

Torque

Torque

Diameter

Cast iron

Aluminium

Cast iron

Aluminium

Cast iron

Aluminium

[mm]

[Nm]

[ft-lb]

[Nm]

[ft-lb]

[Nm]

[ft-lb]

[Nm]

[ft-lb]

[Nm]

[ft-lb]

[Nm]

[ft-lb]

6

9

5

7

4

13

10

7

4

14

9

7

4

7

14

9

11

7

18

14

11

7

23

18

11

7

8

23

17

18

14

33

25

18

14

40

29

18

14

10

45

33

30

25

65

50

30

25

70

50

30

25

12

80

60

55

40

115

85

55

40

125

95

55

40

14

125

90

90

65

180

133

90

65

195

145

90

65

16

195

140

140

100

280

200

140

100

290

210

140

100

18

280

200

180

135

390

285

180

135

400

290

180

135

20

400

290

-

-

550

400

-

-

-

-

-

-

2.2.4

CUMMINS MOTOR TORQUES - U.S. CUSTOMARY Grade

5 (three radial lines on cap)

8 (six radial lines on cap)

Body size

Torque

Torque

Diameter - threads

Cast iron

Aluminium

Cast iron

Aluminium

[Nm]

[ft-lb]

[Nm]

[ft-lb]

[Nm]

[ft-lb]

[Nm]

[ft-lb]

1/4 - 20

9

7

8

6

15

11

8

6

1/4 - 28

12

9

9

7

18

13

9

7

5/16 - 18

20

15

16

12

30

22

16

12

5/16 - 24

23

17

19

14

33

24

19

14

3/8 - 16

40

30

25

20

55

40

25

20

3/8 - 24

40

30

35

25

60

45

35

25

7/16 - 14

60

45

45

35

90

65

45

35

7/16 - 20

65

50

55

40

95

70

55

40

1/2 - 13

95

70

75

55

130

95

75

55

1/2 - 20

100

75

80

60

150

110

80

60

9/16 - 12

135

100

110

80

190

140

110

80

Version 2009/2

PC5500-6

2 - 35


2.2.5


SAE FLANGE CONNECTIONS

Fig. 2-13 Torques for SAE-flange connections

2 - 36

PC5500-6

Version 2009/2


Blind plugs

2.3

BLIND PLUGS

2.3.1

DUMMY PLATES FOR SAE-FLANGES

Fig. 2-14 Forms / types of dummy plates for SAE-flanges Up to 3000 PSI SAE size

Form / type according to Fig. 2-142-14

PN

DN (hose / pipe)

1/2"

A

506 521 98

12

3/4"

A

506 583 98

20

1 1/4"

A

506 584 98

32

1 1/2"

A

506 522 98

40

2"

A

506 523 98

50

2 1/2"

A

506 585 98

65

3"

A

512 570 98

80

3/4"

B

516 826 98

20

1 1/4

B

517 479 98

32

1 1/2"

B

506 528 98

40

2"

B

506 529 98

50

2 1/2"

B

506 530 98

65

3"

B

512 571 98

80

Version 2009/2

PC5500-6

2 - 37

Blind plugs


Up to 6000 PSI

2 - 38

SAE size

Form / type according to Fig. 2-142-14

PN

DN (hose / pipe)

3/4"

A

506 580 98

20

1"

A

506 519 98

25

1 1/4"

A

506 520 98

32

1 1/2"

A

506 581 98

40

2"

A

506 582 98

50

1"

B

506 524 98

25

1 1/4"

B

506 525 98

32

1 1/2"

B

506 526 98

40

2"

B

506 527 98

50

1 1/4"

C

516 499 98

32

1 1/2"

C

509 375 98

40

2"

C

509 376 98

50

PC5500-6

Version 2009/2


2.3.2

Blind plugs

CLASSIFICATION OF THREADS TO THE NOMINAL WIDTH Heavy class (up to 6000 PSI)

Light class (up to 3000 PSI)

Size

Ra

DN

Ra

DN

M 12 x 1.5

-

-

6

5

M 14 x 1.5

-

-

8

6

M 16 x 1.5

8

5

10

8

M 18 x 1.5

10

6

12

10

M 20 x 1.5

12

8

-

-

M 22 x 1.5

14

10

15

12

M 24 x 1.5

16

12

-

-

M 26 x 1.5

-

-

18

16

M 30 x 1.5

-

-

-

-

M 30 x 2

20

16

22

20

M 36 x 2

25

20

28

25

M 38 x 1.5

-

-

-

-

M 42 x 2

30

25

-

-

M 45 x 1.5

-

-

-

-

M 45 x 2

-

-

35

32

M 52 x 1.5

-

-

-

-

M 52 x 2

38

32

42

40

M 65 x 2

-

-

-

-

Method of using the above table to find an appropriate plugs and fittings according to Table 2.3.3 on page 40: EXAMPLE: To cover up a hose / tube with a diameter of 25 mm, for a pressure up to 3000 PSI perform the following steps: z

Locate the 25 in the column "DN" in the category "up to 3000 PSI".

z

Check the digit in the column "Ra" next to DN 25 in the same row and category. For this example the proper plug and fitting is BUZ 28-L and ROV 28-L, refer to Table 2.3.3 on page 40.

NOTE: The column "Size" indicates the thread-size for the ROV-fittings.

Version 2009/2

PC5500-6

2 - 39

Blind plugs

2.3.3


PLUGS AND FITTINGS ACCORDING TO DIN 2353 Up to 3000 PSI BUZ (plugs)

PN

ROV (fittings)

PN

8-L

501 692 98

8-L

518 113 98

10-L

371 852 99

10-PL

513 789 98

12-L

371 854 99

12-PL

513 547 98

15-L

371 855 99

15-PL

507 051 98

18-L

371 856 99

18-PL

513 787 98

22-L

371 857 99

22-PL

513 788 98

28-L

371 858 99

28-PL

509 377 98

35-L

371 859 99

35-PL

516 770 98

42-L

371 860 99

42-PL

513 790 98

Up to 6000 PSI

2 - 40

BUZ (plugs)

PN

ROV (fittings)

PN

-

-

8-PS

515 921 98

-

-

10-PS

507 023 98

-

-

12-PS

507 022 98

16-S

371 866 99

-

-

20-S

371 853 99

20-PS

512 005 98

25-S

371 867 99

25-PS

508 033 98

30-S

371 868 99

30-PS

507 021 98

38-S

371 869 99

38-PS

507 020 98

PC5500-6

Version 2009/2


Conversion table

2.4

CONVERSION TABLE

2.4.1

METHOD OF USING THE CONVERSION TABLE

The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below. EXAMPLE: Method of using the Conversion Table to convert from millimeters to inches. Convert 55 mm into inches: z

Locate the number 50 in the vertical column at the left side, take this as (A), then draw a horizontal line from (A).

z

Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down from (B).

z

Take the point where the two lines cross as (C). This point (C) gives the value when converting from millimeters to inches. Therefore, 55 millimeters = 2.165 inches.

Convert 550 mm into inches: z

The number 550 does not appear in the table, so divide by 10 (move the decimal one place to the left) to convert it to 55 mm.

z

Carry out the same procedure as above to convert 55 mm to 2.165 inches.

z

The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.

Version 2009/2

PC5500-6

2 - 41

Conversion table

2.4.2

2 - 42


MILLIMETER - INCH & KILOGRAM - POUND

PC5500-6

Version 2009/2


2.4.3

Conversion table

LITER - U.S. GALLON & LITER - U.K. GALLON

Version 2009/2

PC5500-6

2 - 43

Conversion table

2.4.4 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200


NM - FT.LB 0 0 7.37 14.74 22.11 29.48 36.85 44.22 51.59 58.96 66.33 73.70 81.07 88.44 95.81 103.18 110.55 117.92 125.29 132.66 140.03 147.40

1 0.74 8.11 15.48 22.85 30.22 37.59 44.96 52.33 59.07 67.07 74.44 81.81 89.18 96.55 103.92 111.29 118.66 126.03 133.40 140.77 148.14

2 1.47 8.84 16.21 23.58 30.95 38.32 45.69 53.06 60.43 67.80 75.17 82.54 89.91 97.28 104.65 112.02 119.39 126.76 134.13 141.50 148.87

3 2.21 9.58 16.95 24.32 31.69 39.06 46.43 53.08 61.17 68.54 75.91 83.28 90.65 98.02 105.39 112.76 120.13 127.50 134.87 142.24 149.61

4 2.95 10.32 17.69 25.06 32.43 39.80 47.17 54.54 61.91 69.28 76.65 84.02 91.39 98.76 106.13 113.50 120.87 128.24 135.61 142.98 150.35

5 3.69 11.06 18.43 25.80 33.17 40.54 47.91 55.28 62.65 70.02 77.39 84.76 92.13 99.50 106.87 114.24 121.61 128.98 136.35 143.72 151.09

6 4.42 11.79 19.16 26.53 33.90 41.27 48.64 56.01 63.38 70.75 78.12 85.49 92.86 100.23 107.60 114.97 122.34 129.71 137.08 144.45 151.82

7 5.16 12.53 19.90 27.27 34.64 42.01 49.38 56.75 64.12 71.49 78.86 86.23 93.60 100.97 108.34 115.71 123.08 130.45 137.82 145.19 152.56

8 5.90 13.27 20.64 28.01 35.38 42.75 50.12 57.49 64.86 72.23 79.60 86.97 94.34 101.71 109.08 116.45 123.82 131.19 138.56 145.93 153.30

9 6.63 14.00 21.37 28.74 36.11 43.48 50.85 58.22 65.59 72.96 80.33 87.70 95.07 102.44 109.81 117.18 124.55 131.92 139.29 146.66 154.03

1 Nm = 0,737 FT.LB

2 - 44

PC5500-6

Version 2009/2


2.4.5

Conversion table

BAR - PSI / PSI - BAR Conversion Table bar / PSI bar - PSI

bar 1 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200

PSI 14,5033 73 145 218 290 363 435 508 580 653 725 798 870 943 1015 1088 1160 1233 1305 1378 1450 1523 1595 1668 1740 1813 1885 1958 2030 2103 2175 2248 2321 2393 2466 2538 2611 2683 2756 2828 2901

PSI - bar bar 205 210 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320 325 330 335 340 345 350 355 360 365 370 375 380 385 390 395 400

PSI 2973 3046 3118 3191 3263 3336 3408 3481 3553 3626 3698 3771 3843 3916 3988 4061 4133 4206 4278 4351 4424 4496 4569 4641 4714 4786 4859 4931 5004 5076 5149 5221 5294 5366 5439 5511 5584 5656 5729 5801

PSI 1 75 150 225 300 375 450 525 600 675 750 825 900 975 1050 1125 1200 1275 1350 1425 1500 1575 1650 1725 1800 1875 1950 2025 2100 2175 2250 2325 2400 2475 2550 2625 2700 2775 2850 2925 3000

bar 0,06895 5,17 10 16 21 26 31 36 41 47 52 57 62 67 72 78 83 88 93 98 103 109 114 119 124 129 134 140 145 150 155 160 165 171 176 181 186 191 197 202 207

PSI 3075 3150 3225 3300 3375 3450 3525 3600 3675 3750 3825 3900 3975 4050 4125 4200 4275 4350 4425 4500 4575 4650 4725 4800 4875 4950 5025 5100 5175 5250 5325 5400 5475 5550 5625 5700 5775 5850 5925 6000

bar 212 217 222 228 233 238 243 248 253 259 264 269 274 279 284 290 295 300 305 310 315 321 326 331 336 341 346 352 357 362 367 372 378 383 388 393 398 403 409 414

PSI bar

x

14,5033 = PSI

=

bar

14,5033

Version 2009/2

PC5500-6

2 - 45

Conversion table

2.4.6


BASIC VALUES IN OHM ACCORDING TO DIN 43 76

Conversion Table - Ohm to Centigrade of PT100 sensors °C

-0

-1

-2

-3

-4

-5

-6

-7

-8

-9

-50

80.31

79.91

79.51

79.11

78.72

78.32

77.92

77.52

77.13

76.73

-40

84.27

83.88

83.48

83.08

82.69

82.29

81.89

81.50

81.10

80.70

-30

88.22

87.83

87.43

87.04

86.64

86.25

85.85

85.46

85.06

84.67

-20

92.16

91.77

91.37

90.98

90.59

90.19

89.80

89.40

89.01

88.62

-10

96.09

95.69

95.30

94.91

94.52

94.12

93.73

93.34

92.95

92.55

0

100.00

99.61

99.22

98.83

98.44

98.04

97.65

97.26

96.87

96.48

°C

0

1

2

3

4

5

6

7

8

9

0

100.00

100.39

100.78

101.17

101.56

101.95

102.34

102.73

103.12

103.51

10

103.90

104.29

104.68

105.07

105.46

105.85

106.24

106.63

107.02

107.40

20

107.79

108.18

108.57

108.96

109.35

109.73

110.12

110.51

110.90

111.28

30

111.67

112.06

112.45

112.83

113.22

113.61

113.99

114.38

114.77

115.15

40

115.54

115.93

116.31

116.70

117.08

117.47

117.85

118.24

118.62

119.01

50

119.40

119.78

120.16

120.55

120.93

121.32

121.70

122.09

122.47

122.86

60

123.24

123.62

124.01.

124.39

124.77

125.16

125.54

125.92

126.31

126.69

70

127.07

127.45

127.84

128.22

128.60

128.98

129.37

129.75

130.13

130.51

80

130.89

131.27

131.66

132.04

132.42

132.80

133.18

133.56

133.94

134.32

90

134.70

135.08

135.46

135.84

136.22

136.60

136.98

137.36

137.47

138.12

100

138.50

138.88

139.26

139.64

140.02

140.39

140.77

141.15

141.53

141.91

110

142.29

142.66

143.04

143.42

143.80

144.17

144.55

144.93

145.31

145.68

120

146.06

146.44

146.81

147.19

147.57

147.94

148.32

148.70

149.07

149.45

130

149.82

150.20

150.57

150.95

151.33

151.70

152.08

152.45

152.83

153.20

140

153.58

153.95

154.32

154.70

155.07

155.45

155.82

156.19

156.57

156.94

150

157.31

157.69

158.06

158.43

158.81

159.18

159.55

159.93

160.30

16067

2 - 46

PC5500-6

Version 2009/2


2.4.7

Conversion table

TEMPERATURE

The figures in the table below refer to the temperature in either degree Fahrenheit or degree Celsius. If it is desired to convert from degree Fahrenheit to degree Celsius, consider the center column as a table of Fahrenheit temperatures and read the corresponding Celsius temperature in the column at the left. If it is desired to convert from degree Celsius to degree Fahrenheit, consider the center column as a table of Celsius values, and read the corresponding Fahrenheit temperature on the right.

Version 2009/2

PC5500-6

2 - 47

Tools


2.5

TOOLS

2.5.1

STANDARD TOOL CASE

Komatsu provides a standard tool case, PN 232 709 40. Q‘ty 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 3 2 1 1 1 1 1 2 2 1 1 1

Part name Measuring tape 3 m long Hammer 500 g Sliding caliper, 200 mm long Reamer (countersink, stem diameter 10 mm; reamer diameter 20 mm Socket wrench ½“ - set (WS 10 - 32) Internal hexagon socket, 1/2“ - set, (WS 5 - 17) Double ended open wrench - set (WS 6 - 32) Combination wrenches - set (WS 10 - 32) Twist drill - set (1 - 13 mm) Needle files - set Tool bag Toolbox L= 460; B= 170; L= 310 Socket wrench ¼“ - set (WS 3 - 13) Drift punch 3 - 8 mm Socket wrench with ball head - set (1.5 - 10 mm) Side cutter insulated up to 1000 Volt, 190 mm Combination pliers insulated up to 1000 Volt, 185 mm Bent nose pliers, Knipex Water pump pliers 250 mm long Cable stripping knife 4 - 16 mm Screwdriver for slotted screws 11 x 300 mm Screwdriver for slotted screws 13 x 390 mm Crosstip screwdriver size 0 Crosstip screwdriver size 1 Crosstip screwdriver size 2 Infrared thermometer IR 1 LCD-Digital Multimeter VC 444 VDE Screwdriver, WERA Hydraulic mini testing kit Pressure gauge 400 bar Measuring hose 2.5 m Pressure gauge fitting G¼ Set – Screwdriver Side cutting pliers, Knipex Stripping- and cutting tool Stripax for PVC-isolation up to 6 mm², 20 mm Crimp pliers, rimp capacity 0.5 - 4 mm² Crimp pliers HTN 21 Testing wire 4mm Type 410 (red) Testing wire 4mm Type 410 (black) Testing tip "Hirschmann Prüf 2" (red) Testing tip "Hirschmann Prüf 2" (black) Clip terminal "Hirschmann Ak 2 S" (red)

2 - 48

PC5500-6

Part number 470 615 40 232 130 40 232 107 40 232 690 40 232 691 40 232 570 40 232 692 40 232 693 40 232 207 40 232 199 40 232 694 40 232 695 40 232 696 40 232 697 40 232 698 40 232 401 40 232 400 40 232 403 40 232 139 40 232 699 40 232 120 40 232 121 40 232 111 40 232 112 40 232 113 40 232 665 40 232 688 40 232 689 40 232 591 40 793 363 73 896 483 40 232 501 40 907 696 40 232 700 40 232 663 40 232 661 40 232 701 40 232 702 40 232 703 40 232 704 40 232 705 40 232 706 40

Version 2009/2


Q‘ty 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Tools

Part name Clip terminal "Hirschmann Ak 2 S" (black) Fluke 179 Digital-Multimeter Rollbox K 412 (740 x 365 x 375) Tachometer Moviport Magnet-stick Electric set with pliers Software (Bodem 24) Bodem connection cable Crimp-pliers for revolved contacts Cable set Prostat Cable VL 3 (X27 -PC) Prosyd Cable VL 12 (PLC-PC) TazETM Cable VL 10 (ETM-PC) Cable VL 9a Cable VL 9b PC4000-6 VHMS download-cable (new for 08156 and up) Converter, cable, and software as set Converter USB extension wire UMG diagnostic software (CD)

Version 2009/2

PC5500-6

Part number 232 707 40 232 708 40 232 711 40 232 551 40 232 712 40 793 265 73 796 726 73 896 791 40 793 729 73 796 443 73 659 820 40 926 503 40 891 175 40 891 176 40 891 177 40 894 580 40 796 442 73 796 439 73 796 440 73 796 441 73

2 - 49

Explanation of abbreviations

2.6


EXPLANATION OF ABBREVIATIONS

Abbrev.

Definition

A

Ampere

AC

Alternating Current

ACV

Anti-Cavitation Valve

API

American Petroleum Institute

BHA

Backhoe Attachment

°C

Degree Celsius

CLS

Central Lubrication System

CO

Cut Off function (main pump)

DC

Direct Current

DFT

Dry paint Film Thickness [1/1000 inch]

FSA

Front Shovel Attachment

GET

Ground Engaging Tools

HP

High Pressure

HT

High Tension

LED

Light Emitting Diode

MRV

Main Relief Valve

PIV

Pressure Increasing Valve

PTO

Power Take-Off (Pump Distributor Gear)

Qmax

Maximum pump delivery = maximum swash plate angle

Qmin

Minimum pump delivery = minimum swash plate angle

1/2 Qmax

1/2 pump delivery

SLS

Swing circle pinion Lubrication System

SRV

Secondary Relief Valve

V

Volt

WFT

Wet paint Film Thickness [1/1000 inch]

1/min

Revolutions Per Minute (RPM)

2 - 50

PC5500-6

Version 2009/2

Superstructure

3 SUPERSTRUCTURE

Version 2009/2

PC5500-6

3 -1

Diesel engine

3.1

Superstructure

DIESEL ENGINE

The excavator is powered by two Komatsu Diesel engines: Model:

SSA 12V 159

Type:

4-cycle, water-cooled, direct injection

Aspiration:

Turbocharged with intercooler

Number of cylinders:

12

Rated power:

940 kW (1260 HP) @ 1800 rpm

3.1.1

REMOVAL OF THE DIESEL ENGINES

3.1.1.1 PREPARATORY WORK FOR DIESEL ENGINES REMOVAL Special tools:

n/a

Additional equipment:

Crane 4 x swivel hoist rings: M16 Empty coolant storage tank Oil drain pans Roof plate: 397 kg max. Beam (transfer carrier): 285 kg

Dogman/rigger For further information about the needed blind plugs, refer to section 2.3 on page 2-37. z

Prepare an area of flat ground large enough to accommodate the machine, boom, and crane.

z

Park the machine on the prepared flat ground area.

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. z

Isolate the machine according to local regulations.

3 -2

PC5500-6

Version 2009/2

Superstructure

Diesel engine

WARNING Do not carry out the following work on a hot engine. Wait until the temperature of the engine is below 50 °C. Disobedience may result in personal injury from heated coolant or steam.

Drain the engine coolant of the engine to be removed, approx. 360 liters. Refer to the Operation & Maintenance Manual, chapter 3, section "CENTRAL REFILLING SYSTEM", and the Engine Operation & Maintenance Manual.

Drain the engine oil from the engine oil pan of the engine to be removed, approx. 190 liters. Refer to the Operation & Maintenance Manual, chapter 3, section "CENTRAL REFILLING SYSTEM", and the Engine Operation & Maintenance Manual.

Drain the engine oil reserve tank of the engine to be removed, approx. 580 liters. Refer to the Operation & Maintenance Manual, chapter 3, section "CENTRAL REFILLING SYSTEM", and the Engine Operation & Maintenance Manual.

z

Disconnect the hoses (Fig. 3-1, Pos. 1and 2) to the injector valves of all cold start systems. DANGER

Risk of fire! Serious injury, permanent disfigurement and scarring, or death may result. DO NOT smoke or use an open flame when working around inflammable fuels.

Fig. 3-1

Version 2009/2

PC5500-6

3 -3

Diesel engine

Superstructure

Fig. 3-2 z

Remove all engine air cleaners (Fig. 3-2, Pos. 1), and all exhaust mufflers (Fig. 3-2, Pos. 2) from the roof. WARNING

Pay attention to the Fire Detection and Suppression System. Refer to the separate manuals "Fire Detection and Actuating System" and "Fire Suppression System" The wires of the Fire Detection and Suppression System must not be bent excessively or be damaged to remain functional.

3 -4

PC5500-6

Version 2009/2

Superstructure

Fig. 3-3

Diesel engine

Roof plate removal

(1 to 3)

Roof plate

(4)

Sealing

(5, 6)

Bolt with lock washer

(7)

Bolt

(8)

Resilient sleeve

z

Clear all wire harnesses from the roof plates (Fig. 3-3, Pos. 1 to 3).

z

Dismount all attached parts from the roof plates (Fig. 3-3, Pos. 1 to 3).

z

Remove all bolts (Fig. 3-3, Pos. 5, Pos. 7) and resilient sleeves (Fig. 3-3, Pos. 8) of the roof plates (Fig. 3-3, Pos. 1 to 3).

z

Remove the roof plates (Fig. 3-3, Pos. 1 to 3) with a crane using swivel hoist rings. DANGER

Risk of falling weights! Death or serious injury may result. When lifting the roof plats, make sure that nobody steps below the weight.

Version 2009/2

PC5500-6

3 -5

Diesel engine

Superstructure

WARNING Pay attention to the Fire Detection and Suppression System. Refer to the separate manuals "Fire Detection and Actuating System" and "Fire Suppression System" The wires of the Fire Detection and Suppression System must not be bent excessively or be damaged to remain functional.

NOTE: Remove the sealings (Fig. 3-3, Pos. 4).

z

Clear all wire harnesses from the beam (transfer carrier) (Fig. 3-4, Pos. 1) and dismount all attached parts from the beam.

z

Remove the mounting bolts (Fig. 3-4, Pos. 3) and resilient sleeves (Fig. 3-4, Pos. 2).

z

Remove the beam (transfer carrier) (Fig. 3-4, Pos. 1) with a crane. DANGER

Risk of falling weights! Death or serious injury may result. When lifting the beam, make sure that nobody steps below the weight.

z

Dismount all attached parts from the fire protection wall (Fig. 3-5, Pos. 1) of the engine to be removed.

z

Remove the fire protection wall (Fig. 3-5, Pos. 1) of the engine to be removed.

Fig. 3-4

DANGER Risk of falling weights! Death or serious injury may result. When lifting the fire protection wall, make sure that nobody steps below the weight. Fig. 3-5

3 -6

PC5500-6

Version 2009/2

Superstructure

Diesel engine

3.1.1.2 REMOVAL OF THE FRONT DIESEL ENGINE (ENGINE 2) Special tools:

n/a


Crane Oil drain pan Diesel engine: 7000 kg

Dogman/rigger For further information about the needed blind plugs, refer to section 2.3 on page 2-37.

z

Carry out preparatory work for diesel engines removal, refer to section 3.1.1.1 on page 3-2.

z

Disconnect the fuel feeding hose (Fig. 3-6, Pos. 2) from the fuel filters.

z

Disconnect the fuel return hose (Fig. 3-6, Pos. 1).

NOTE: When a fuel hose is disconnected, the fuel inside the hose will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. DANGER Risk of fire! Serious injury, permanent disfigurement and scarring, or death may result.

Fig. 3-6

DO NOT smoke or use an open flame when working around inflammable fuels.

z

Disconnect the coolant hoses (Fig. 3-7, Pos. 1) leading to the heating of the operator’s cab.

Fig. 3-7

Version 2009/2

PC5500-6

3 -7

Diesel engine

Superstructure

z

Disconnect the (upper) main coolant lines (Fig. 3-8, Pos. 1).

z

Disconnect the (lower) main coolant return lines.

NOTE: For further information about the coolant lines, refer to section 3.1.6.1 on page 3-38.

Fig. 3-8 z

Disconnect all wire harnesses leading to the engine (Fig. 3-9).

Fig. 3-9 z

Disconnect all oil hoses of the oil management system (Fig. 3-10, Pos. 1).

z

Disconnect the oil filling hose leading from the engine oil pan to the service arm.

Fig. 3-10

3 -8

PC5500-6

Version 2009/2

Superstructure

z

Diesel engine

Remove the compressor (Fig. 3-11, Pos. 1) of the air conditioning system with attached refrigerant hoses and put it aside.

NOTE: Do not disconnect the refrigerant hoses of the air conditioning from the compressor, because the air conditioning must be serviced by authorized refrigeration specialists only.

Fig. 3-11 z

Remove the Geislinger coupling, refer to section 3.1.8.1 on page 3-45.

z

Remove the bolts attaching the PTO to the engine.

z

Attach the engine to a crane using the four lifting shackles (Fig. 3-12, arrow) at the engine.

Fig. 3-12 z

Remove eight rear engine mounting bolts (Fig. 3-13, Pos. 1) on both sides of the engine.

Fig. 3-13

Version 2009/2

PC5500-6

3 -9

Diesel engine

z

Superstructure

Remove the cover (Fig. 3-14, Pos. 1).

Fig. 3-14 z

Remove the engine mounting bolts (Fig. 3-15, Pos. 1) from the engine torque support (Fig. 3-15, Pos. 2).

z

Move the engine with the crane away from the PTO at first and then lift it out of the engine house. DANGER

Risk of falling weights! Death or serious injury may result. When removing the engine, make sure that nobody steps below the weight.

z

Remove the bolts (Fig. 3-15, Pos. 3 and 4) and the engine torque support (Fig. 3-15, Pos. 2) from the engine mounts (Fig. 3-15, Pos. 5).

Fig. 3-15

NOTE: For further information about the engine torque support, refer to section 3.1.2 on page 3-16.

3 - 10

PC5500-6

Version 2009/2

Superstructure

Diesel engine

3.1.1.3 REPLACEMENT OF THE FRONT DIESEL ENGINE (ENGINE 2) Special tools:

n/a


Crane 4 x swivel hoist rings: M16 Compound "KP2K", PN 324 969 40 Diesel engine: 7000 kg Roof plate: 397 kg max. Beam (transfer carrier): 285 kg Dogman/rigger If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.2 on page 2-33.

z

Replace all flexible bearings and rubber-bounded metal bars of the flexible mounts (Fig. 3-16, Pos. 5). Refer to PARTS & SERVICE NEWS No. "AH01521".

z

Mount the engine torque support (Fig. 3-16, Pos. 2) onto the flexible mounts.

z

Install the bolts (Fig. 3-16, Pos. 3 and 4) and tighten the bolts hand-tight.

z

Attach the new engine to the crane and move it into mounting position and install the engine mounting bolts (Fig. 3-16, Pos. 1). DANGER

Risk of falling weights! Death or serious injury may result.

Fig. 3-16

When installing the engine, make sure that nobody steps below the weight.

z

Install a new Geislinger coupling, refer to section 3.1.8.2 on page 3-49.

z

Reinstall the mounting bolts attaching the PTO to the engine.

Version 2009/2

PC5500-6

3 - 11

Diesel engine

z

Superstructure

Install eight rear engine mounting bolts (Fig. 3-17, Pos. 1) on both sides and tighten them to the specified torque. Tightening torque for rear engine mounting bolts: 400 Nm

Fig. 3-17 z

Tighten all bolts at the engine torque support, refer to section 3.1.2 on page 3-16 or to the PARTS & SERVICE NEWS No. "AH01521".

z

Carry out further installation in reverse order to removal.

z

Use new mounting bolts (Fig. 3-18, Pos. 1 and Pos. 2) of grade 10.9. Apply compound "KP2K", PN 324 969 40 on heads and threads of the mounting bolts and tighten them to the specified tightening torque. Tightening torque for beam (transverse carrier) mounting bolts: 880 Nm

Tightening torque for roof plats mounting bolts: 108 Nm Fig. 3-18

Refill the engine coolant, approx. 360 liters. Refer to the Operation & Maintenance Manual, chapter 3, section "CENTRAL REFILLING SYSTEM".

Refill the engine oil pan with engine oil, approx. 190 liters. Refer to the Operation & Maintenance Manual, chapter 3, section "CENTRAL REFILLING SYSTEM".

Refill the engine oil reserve tank with engine oil, approx. 580 liters. Refer to the Operation & Maintenance Manual, chapter 3, section "CENTRAL REFILLING SYSTEM".

3 - 12

PC5500-6

Version 2009/2

Superstructure

z

Diesel engine

Bleed the fuel lines to the engine: DANGER

Risk of fire! Serious injury, permanent disfigurement and scarring, or death may result. DO NOT smoke or use an open flame when working around inflammable fuels.

z

Assure that the emergency shut off valves (Fig. 3-19, Pos. 1) and the shut-off-cock (Fig. 3-19, Pos. 2) are opened.

z

Disconnect the feeding line at the engine fuel filter.

z

Wait until the fuel flows out.

Fig. 3-19

NOTE: Catch the leaking fuel in an oil pan. z

Reconnect the feeding line to the engine fuel filter.

z

Disconnect the feeding line at the engine fuel pump.

z



Reconnect the feeding line to the engine fuel pump. DANGER

Risk of fire! Loose or missing ground cables can cause fire, serious injury or death. After repairs on the Diesel engines or starter motors, make sure that the ground cables are correctly connected before starting the engines.

DANGER Risk of fire! Serious injury, permanent disfigurement and scarring, or death may result. NEVER attempt to start the engines by shorting across starter terminals. Start the engines from the operator’s seat only.

Version 2009/2

PC5500-6

3 - 13

Diesel engine

Superstructure

WARNING Before each starting make sure that all controls are in neutral position. Be sure to sound the signal horn before starting to make your intention clear.

NOTE: Before starting the engines pay attention to the hydraulic oil temperature. Refer to the Operation & Maintenance Manual, chapter 3, section "STARTING PROCEDURE".

3.1.1.4 REMOVAL OF THE REAR DIESEL ENGINE (ENGINE 1) The removal of the rear diesel engine (engine 1, Fig. 3-20, Pos. 1) is analogously the same as the removal of the front diesel engine (engine 2, Fig. 3-20, Pos.2), refer to section 3.1.1.2 on page 3-7. NOTE: The rear diesel engine (engine 1) has no compressor for the air conditioning system. The coolant hoses leading to the heating of the operator’s cab only connected at the front engine (engine 2).

Fig. 3-20

3.1.1.5 REPLACEMENT OF THE REAR DIESEL ENGINE (ENGINE 1) The replacement of the rear diesel engine (engine 1, Fig. 3-20, Pos. 1) is analogously the same as the replacement of the front diesel engine (engine 2, Fig. 3-20, Pos.2), refer to section 3.1.1.3 on page 3-11. NOTE: The rear diesel engine (engine 1) has no compressor for the air conditioning system. The coolant hoses leading to the heating of the operator’s cab only connected at the front engine (engine 2).

3 - 14

PC5500-6

Version 2009/2

Superstructure

Diesel engine

This page was left blank intentionally.

Version 2009/2

PC5500-6

3 - 15

Diesel engine

3.1.2

Superstructure

ENGINE TORQUE SUPPORT AND ENGINE/PTO MOUNTS

Fig. 3-21 Engine and PTO mounts with torque support

3 - 16

PC5500-6

Version 2009/2

Superstructure

Diesel engine

Legend for Fig. 3-21: Quantity both power units

Size

Grade

WS*

Torque

(1)

Flexible bearing

24

(2)

Tie bolt

12

M24

10.9

36

snug

(3)

Self-locking nut

12

M24

8.0

36

snug

(4)

Rubber-bounded metal bar

12

(5)

Stop bolt

4

M36

10.9

55

to distance "A"

(6)

Cup springs

28 (7 per bolt)

(7)

Lock nut

4

M36

10.0

55

(8)

Engine mounting bolt, rear

32

3/410 UNC

(9)

Bolt

12

M24

10.9

36

880

(10)

Engine mounting bolt, front

4

M18

10.9

27

360

(11)

PTO mounting bolt

8

M30

10.9

46

1770

400

* Wrench Size

3.1.2.1 FLEXIBLE MOUNTS The flexible mounts are installed to absorb the vibrations and the torsional forces. They carry the total weight of the engine and the pump distributor gear with all hydraulic pumps. For this reason, all connections must be checked frequently according to the maintenance manual (high-strength bolt connections) or when engine or PTO were replaced. In the case of fatigue or damage of a metal rubber guide (Fig. 3-21, Pos. 1), all metal rubber guides and their fastening bolts with nuts must be replaced. Also inspect the metal-rubber-bar (Fig. 3-21, Pos. 4) for fatigue or damage and replace if necessary. The bolt (Fig. 3-21, Pos. 2) must not have any axial play. If necessary, re-tighten the nut (Fig. 3-21, Pos. 3) until rubber is squeezed slightly out of rubber bar (Fig. 3-21, Pos. 4). NOTE: For further information, refer to PART & SERVICE NEWS No. "AH01521".

Version 2009/2

PC5500-6

3 - 17

Diesel engine

Superstructure

Fig. 3-22 Engine and PTO mounts with torque support

3 - 18

PC5500-6

Version 2009/2

Superstructure

Diesel engine

3.1.2.2 TORQUE SUPPORT To absorb the torque force, the front engine support is additionally supported with a cup spring package. Check the cup springs (Fig. 3-22, Pos. 6) of both supports for fatigue or damage regularly and replace them if necessary. Turn the bolt (Fig. 3-22, Pos. 5) down until it slightly pre-stresses the cup spring and secure with the lock nut. (Distance between engine torque support and bolt head "A" = 29 mm) NOTE: The lock nuts (Fig. 3-22, Pos. 7) can be re-used 3 to 4 times. Assumed the bolt (Fig. 3-22, Pos. 2) thread is cleaned thoroughly before turning the nut on or off, otherwise the locking part of the nut will be damaged and the lock is not ensured.

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3.1.3

Superstructure

ALTERNATOR

3.1.3.1 REMOVAL OF THE ALTERNATOR Special tools:

n/a


n/a Alternator: 38.25 kg

z

Prepare an area of flat ground large enough to accommodate the machine and boom.

z


z


z

Remove the keys from the battery main switches WARNING

Do not carry out the following work on a hot engine. Wait until the temperature of the engine is below 50 °C. Disobedience may result in personal injury from heated engine parts.

z


Fig. 3-23 z

Remove all electrical connections from the alternator (Fig. 3-24, Pos. 1) and remove the alternator.

NOTE: A second person is required to remove the alternator. For further information refer to the Engine Operation & Maintenance Manual.

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3.1.3.2 REPLACEMENT OF THE ALTERNATOR Special tools:

n/a


Belt tension gauge Alignment chart (steel ruler) Alternator: 38.25 kg If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.2 on page 2-33.

z

Carry out installation in reverse order to removal.

NOTE: A second person is required to remove the alternator. z

Check the alignment of the pulleys using an alignment chart.

NOTE: For the correct belt tension and use of the belt tension gauge, refer to the Engine Operation & Maintenance Manual and the User Instructions delivered together with the belt tension gauge. z

Check charging current of the new alternator.

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3.1.4

Superstructure

BATTERIES

3.1.4.1 REMOVAL OF THE BATTERIES Special tools:

n/a


Crane or forklift Battery: 62 kg each

Dogman/rigger

z

Prepare an area of flat ground large enough to accommodate the machine, boom, and crane or forklift.

z



Isolate the machine according to local regulations. DANGER

Danger of explosion due to hydrogen gas! Blindness, serious injury, permanent disfigurement, and scaring may result. Never allow sparks or open flame near the batteries! DO NOT short circuit or ground any terminals of the batteries!

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z

Diesel engine

Remove the keys from the battery main switches (Fig. 3-25, Pos. 1).

NOTE: The batteries are located below the hinged floor plats (Fig. 3-25, Pos. 2) in separate boxes. z

Remove floor plate fastening bolts and open the hinged floor plates (Fig. 3-25, Pos. 2).

NOTE: Wash the dirt of the floor plates (Fig. 3-25, Pos. 2) as they can be very heavy. z

Secure the open floor plates against falling down using the safety chains provided.

Fig. 3-25 z

Disconnect the cables from the batteries (Fig. 3-26, Pos. 1). DANGER

Risk of electrical and fire hazard! Death, serious injury, shock, or burns may result. Disconnect the ground cables (-) of both batteries first.

z

Remove the angles (Fig. 3-26, Pos. 2) from the batteries.

z

Take the batteries out of the battery boxes.

Fig. 3-26

WARNING Use the provided loops to carry the batteries. Do not drop the battery.

CAUTION Never run the engine with disconnected batteries. This may cause alternator damage.

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Superstructure

3.1.4.2 REPLACEMENT OF THE BATTERIES Special tools:

n/a


n/a Battery: 62 kg each

Dogman/rigger If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.2 on page 2-33. z

Carry out installation in reverse order to removal. DANGER

Risk of electrical and fire hazard! Death, serious injury, shock, or burns may result. Connect the positive cables (+) of the batteries first.

WARNING Avoid spilling any electrolyte on hands or clothing. Repair or replace all broken wires immediately. All terminals must be clean and securely fastened. Never paint connections.

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3.1.5

Superstructure

RADIATOR FAN

Fig. 3-27 Radiator fan assembly

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Legend for Fig. 3-27: (1)

Fan cage

(2)

Fan cowl

(3)

Bolt

(4)

Locking plate

(5)

Radiator fan

(6)

Hydraulic fan motor

(7)

Bolt

(8)

Fan bearing block

(9)

Bolt

(10)

Cover

The engine cooling system is a dual-circuit cooling circulation system. One cooling circuit cools the engine crankcase and the cylinder heads, the other circuit lowers the temperature of the aftercooling system.

3.1.5.1 REMOVAL OF THE RADIATOR FAN ASSEMBLY Special tools:

n/a


Crane Chain hoist Oil drain pan Radiator fan: 35 kg Hydraulic fan motor: 18 kg Bearing block: 77.5 kg Dogman/rigger For further information about the needed blind plugs, refer to section 2.3 on page 2-37.

z


z



Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".

z


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NOTE: Carry out the following three steps only if the hydraulic fan motor must be removed. z

Remove the radiator fan, refer to section 3.1.5.3 on page 3-33.

z

Close the hand wheel (Fig. 3-29, Pos. 1) of the main gate valve between suction oil reservoir and main oil reservoir.

z

Transfuse the oil from the suction oil reservoir into the main oil reservoir, refer to the Operation & Maintenance Manual, chapter 3, section "FUNCTION OF THE TRANSFER PUMP".

z


z

Disconnect the hydraulic hoses from the hydraulic fan motor (Fig. 3-28, Pos. 6).

Fig. 3-29

NOTE: When the hydraulic hoses are disconnected, the oil inside the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination.

z

Remove the bolts (Fig. 3-28, Pos. 7) and pull the hydraulic fan motor (Fig. 3-28, Pos. 6) out of the fan bearing block (Fig. 3-28, Pos. 9).

NOTE: The hydraulic lines may still be connected at the hydraulic fan motor if only the bearing block (Fig. 3-28, Pos. 9) is being removed. NOTE: Check if a lifting eye (Fig. 3-30, Pos. 1) is installed at the roof plate over the hydraulic motor. Use the lifting eye to hook a chain hoist. If no lifting eye is installed, it has to be welded to the roof plate. WARNING For welding follow the welding precautions given in the Operation & Maintenance Manual, chapter 4, section "WELD REPAIRS" and refer to PARTS & SERVICE NEWS No. "AH08507". Fig. 3-30

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z

Sling the bearing block (Fig. 3-31, Pos. 8).

z

Remove the bolts (Fig. 3-31, Pos. 9) and remove the bearing block using the chain hoist.

DANGER Risk of falling weights! May result in death or serious injury When removing the parts through the PVG sound silencer gate, make sure that nobody steps below the weight.

3.1.5.2 REPLACEMENT OF THE RADIATOR FAN ASSEMBLY Special tools:

Rotational speed infrared probe DS03, PN 793 788 73 (if hydraulic fan motor was replaced)


Chain hoist Radiator fan: 35 kg Hydraulic fan motor: 18 kg Bearing block: 77.5 kg Dogman/rigger If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.2 on page 2-33.

z


NOTE: If the hydraulic fan motor (Fig. 3-31, Pos. 6) was replaced, the fan speed needs to be adjusted, refer to the Service Manual for further information. z

Bleed air from the hydraulic system, refer to the Operation & Maintenance Manual, chapter 4, section "HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER" and PARTS & SERVICE NEWS No. "AH01513".

z

Add hydraulic oil up to the specified level.

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Fig. 3-32 Removal and replacement of the radiator fan

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3.1.5.3 REMOVAL OF THE RADIATOR FAN Special tools:

n/a


n/a Radiator fan: 35 kg

z


z

Removes the upper fan cage (Fig. 3-32, Pos. 1) from the fan cowl (Fig. 3-32, Pos. 2).

z

Remove the six attaching bolts (Fig. 3-32, Pos. 3) with the three locking plates (Fig. 3-32, Pos. 4).

NOTE: Discard the locking plates. z

Remove the radiator fan (Fig. 3-32, Pos. 5) from the fan cowl (Fig. 3-32, Pos. 2). WARNING

Fan blades could have sharp edges. Use gloves!

CAUTION Remove the assembly carefully in order not to damage the radiator or the fan blades.

NOTE: A second person is required to remove the radiator fan.

3.1.5.4 REPLACEMENT OF THE RADIATOR FAN Special tools:

n/a


n/a Radiator fan: 35 kg If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.2 on page 2-33.

NOTE: Use new locking plates (Fig. 3-32, Pos. 4). z


NOTE: A second person is required to install the radiator fan.

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Superstructure

3.1.5.5 REMOVAL OF THE RADIATOR FAN DRIVE PUMP Special tools:

n/a


Crane Chain hoist Oil drain pan Radiator fan drive pump: 40 kg


NOTE: The removal of the radiator fan drive pump (rear engine, Fig. 3-33, Pos. 1) is analogously the same as the removal of the radiator fan drive pump (front engine, Fig. 3-33, Pos. 2).

Fig. 3-33 z


z




z


z

Open the PVG sound silencer gate on the right side of the engine housing.

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z

Close the hand wheel (Fig. 3-34, Pos. 1) of the main gate valve between suction oil reservoir and main oil reservoir.

z

Transfuse the oil from the suction oil reservoir into the main oil reservoir, refer to the Operation & Maintenance Manual, chapter 3, section "FUNCTION OF THE TRANSFER PUMP".

Fig. 3-34 NOTE: Check if a lifting eye (Fig. 3-35, Pos. 1) is installed at the roof plate over the pump. Use the lifting eye to hook a chain hoist. If no lifting eye is installed, it has to be welded to the roof plate. WARNING For welding follow the welding precautions given in the Operation & Maintenance Manual, chapter 4, section "WELD REPAIRS" and refer to PARTS & SERVICE NEWS No. "AH08507". Fig. 3-35 WARNING Hot hydraulic oil! Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is below 50 °C. Disobedience may result in personal injury from heated oil.

z

Disconnect the pressure hose (Fig. 3-36, Pos. 1) and the suction hose (Fig. 3-36, Pos. 2) from the radiator fan drive pump.

NOTE: When the pump hoses are disconnected, the oil inside the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Sling the pump, remove the mounting bolts and remove the radiator fan drive pump by pulling it out of the PTO using a chain hoist.

NOTE: To simplify the removal, move the pump assembly lightly up and down. When the pump assembly is removed, oil will flow out of the spline shaft housing. Catch it in an oil pan.

Fig. 3-36 Version 2009/2

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Superstructure

z

Check the O-ring at the pump flange and replace it if required.

z

Remove the radiator fan drive pump through the PVG sound silencer gate using a crane. DANGER

Risk of falling weights! May result in death or serious injury When removing the radiator fan drive pump through the PVG sound silencer gate, make sure that nobody steps below the weight.

3.1.5.6 REPLACEMENT OF THE RADIATOR FAN DRIVE PUMP Special tools:

Rotational speed infrared probe DS03, PN 793 788 73


Paste "Optimol White" PN 999 039 Radiator fan drive pump: 40 kg



NOTE: Use "Optimol White" on the spline shafts of the pumps. Always use new O-rings at the SAE-flange connections. Use new bolts (Fig. 3-36, Pos. 4) with grade 8.8 at the mounting flanges. Tighten the bolts to the specified tightening torque. Tightening torque for mounting bolts: 74 Nm

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Refill the oil collector reservoir (Fig. 3-37, Pos. 1) for the spline shaft housing with lubricant, refer to the Operation & Maintenance Manual, chapter 4, section "PTO‘s (PUMP DISTRIBUTOR GEARS) AND OIL RESERVOIR - CHECK OIL LEVEL". For the proper lubricant, refer to section 6.1 on page 6-2.

Fig. 3-37 z


z


z

Check for leaks and proper operation.

z

Check the hydraulic oil level again and add oil if required.

z

Check and adjust the speed of the radiator fan, refer to the Operation & Maintenance Manual, section 2.5.

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3.1.6

Superstructure

RADIATORS

The engine cooling system is a dual-circuit cooling circulation system. One cooling circuit cools the engine crankcase and the cylinder heads, the other circuit lowers the temperature of the aftercooling system. Both circuits have separate radiators built in one single assembly.

3.1.6.1 REMOVAL OF THE RADIATOR ASSEMBLY Special tools:

n/a


Crane Empty coolant storage tank Roof plate: 116 kg Radiator assembly: 650 kg Fan cowl: 67 kg Dogman/rigger For further information about the needed blind plugs, refer to section 2.3 on page 2-37.

z


z



Isolate the machine according to local regulations. WARNING

Do not carry out the following work on a hot engine. Wait until the temperature of the engine is below 50 °C. Disobedience may result in personal injury from hot coolant or steam.

Drain the engine coolant, approx. 360 liters. Refer to the Operation & Maintenance Manual, chapter 3, section "CENTRAL REFILLING SYSTEM", and the Engine Operation & Maintenance Manual.

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z

Diesel engine

Disconnect all lines on both side of the roof plate (Fig. 3-38, Pos. 1).

NOTE: When the oil hoses are disconnected, the oil inside the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Dismount all attached parts from the roof plate (Fig. 3-38, Pos. 1).

z

Remove all bolts (Fig. 3-38, Pos. 2) and resilient sleeves (Fig. 3-38, Pos. 3) of the roof plate (Fig. 3-38, Pos. 1).

z

Sling the roof plate (Fig. 3-38, Pos. 1) and remove it using a crane.

Fig. 3-38

DANGER Risk of falling weights! Death or serious injury may result. When removing the roof plate, make sure that nobody steps below the weight.

z

Remove the upper and lower fan cage (Fig. 3-39, Pos. 1).

z

Remove the radiator fan, refer to section 3.1.5.3 on page 3-33.

Fig. 3-39 z

Open the hose clips (Fig. 3-40, Pos. 1) and disconnect the upper coolant hoses (Fig. 3-40, Pos.3) from the radiator assembly.

z

Disconnect the bypass hoses (Fig. 3-40, Pos. 4) and remove the union (Fig. 3-40, Pos. 2).

Fig. 3-40

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z

Superstructure

Open the hose clips (Fig. 3-41, Pos. 1) and disconnect the coolant hoses (Fig. 3-41, Pos. 2) from the radiator assembly (Fig. 3-41, Pos. 3).

Fig. 3-41

z

Sling the radiator at the eyes (Fig. 3-42, arrow) and attach it to a crane.

Fig. 3-42 z

Disconnect all lines attached at the cowl (Fig. 3-43, Pos. 5).

z

Remove all mounting bolts (Fig. 3-43, Pos. 7) with locking plates (Fig. 3-43, Pos. 8), and connector plates (Fig. 3-43, Pos. 8). Discard the locking plates.

z

Take off the cowl (Fig. 3-43, Pos. 5) from the radiator (Fig. 3-43, Pos. 5).

z

Remove all mounting bolts (Fig. 3-43, Pos. 1) and locking plates (Fig. 3-43, Pos. 2) attaching the radiator assembly (Fig. 3-43, Pos. 3) to the mount (Fig. 3-43, Pos. 4). Discard the locking plates.

z

Remove the radiator assembly from the machine house.

Fig. 3-43

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3.1.6.2 REPLACEMENT OF THE RADIATOR ASSEMBLY Special tools:

n/a


Crane Compound "KP2K", PN 324 969 40 Roof plate: 116 kg Radiator assembly: 650 kg Fan cowl: 67 kg Dogman/rigger If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.2 on page 2-33.

z


NOTE: Use new locking plates and use new roof plate mounting bolts of grade 10.9. Apply compound "KP2K", PN 324 969 40 on heads and threads of the mounting bolts and tighten them to the specified tightening torque.

Tightening torque for roof plate mounting bolts: 108 Nm

Fill up the engine coolant, approx. 360 liters. Refer to the Operation & Maintenance Manual, chapter 3, section "CENTRAL REFILLING SYSTEM", and the Engine Operation & Maintenance Manual. z

Run engine to circulate the coolant through the system.

z

Check the coolant level again. Refer to the Operation & Maintenance Manual, section 3.9. Add coolant if required.

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3.1.7

Superstructure

STARTER SYSTEM

Each diesel engine is equipped with two single starter motors. One of the starter motors is equipped with an attached prelubrication pump. This prelubrication system is activated by the starter switch. Turning and holding the starter switch in the start position sends current to the prelubrication starter solenoid. The starter motor starts spinning and propels the prelubrication pump. The prelubrication procedure runs until a pressure of 17 kPa (2.5 psi) has been attained in the cam oil rifle. After a 3 second delay, the current is directed to the starter solenoid switch for cranking the engine. NOTE: At low ambient temperatures and cold diesel engine, the prelubrication procedure will take more time.

3.1.7.1 REMOVAL OF THE STARTER MOTOR Special tools:

n/a


n/a Starter motor: 35.5 kg Starter motor with prelubrication pump: 43.6 kg

z


z

Remove the keys from the battery main switches. WARNING

Do not carry out the following work on a hot engine. Wait until the temperature of the engine is below 50 °C. Disobedience may result in personal injury from heated parts or oil.

z

Disconnect the positive cable (Fig. 3-44, Pos. 2) from the starter motor.

z

Disconnect the positive cable (Fig. 3-44, Pos. 6) and the control cables from the starter solenoid switch.

NOTE: Carry out the following step only if the starter motor with the prelubrication pump (Fig. 3-44, Pos. 1) needs to be removed. z

Disconnect the suction hose (Fig. 3-44, Pos. 3) and the pressure hose (Fig. 3-44, Pos. 4) of the prelubrication system.

NOTE: When the oil hoses are disconnected, the motor oil inside the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Fig. 3-44

Remove the multi-point mounting bolts and remove the starter motor (second person is required).

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3.1.7.2 REPLACEMENT OF THE STARTER MOTOR Special tools:

n/a


n/a Starter motor: 35.5 kg Starter motor with prelubrication pump: 43.6 kg If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.2 on page 2-33.

z

Carry out installation in reverse order to removal. Tightening torque for starter motor mounting bolts (multi-point): 215 Nm

z

Refill engine oil to the specified level. Refer to the Engine Operation and Maintenance Manual volume 2. DANGER

Risk of fire! Loose or missing ground cables can cause fire, serious injury or death. After repairs on the Diesel engines or starter motors, make sure that the ground cables are correctly connected before starting the engines.

DANGER Risk of fire! Serious injury, permanent disfigurement and scarring, or death may result. NEVER attempt to start the engines by shorting across starter terminals. Start the engines from the operator’s seat only.

WARNING Before each starting make sure that all controls are in neutral position. Be sure to sound the signal horn before starting to make your intention clear.

NOTE: Before starting the engines pay attention to the hydraulic oil temperature. Refer to the Operation & Maintenance Manual, chapter 3, section "STARTING PROCEDURE".

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3.1.8

Superstructure

TORSION TYPE COUPLING (GEISLINGER)

Fig. 3-45 Geislinger coupling (1)

Coupling assembly

(2)

Input drive flange

(3)

Leaf spring assembly

(4)

Output drive flange

(5)

Dip stick

(6)

Bleeder plug

(7)

O-rings

(8)

Spacer

(E)

Engine input flange

(G)

Gear box output flange

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The combination of the high elasticity of its leaf springs with complimentary viscous damping by oil displacement, ensures that the torsion type coupling removes major critical speeds outside the engine speed range and dampens minor torsional vibrations effectively. The widest engine speed range free of vibration periods and dangerous resonance is thus obtained. Furthermore, employment of these couplings with their highly dampening characteristics generally results in lower stress in all engine driving shafts and gears as well as in the crankshaft permitting further power development on standard components. In any similar application, a simple vibration damper and/or a pure flexible coupling would not confer the same advantages. The springs (Fig. 3-45, Pos. 3) together with the inner driving and outer driven member, form the chambers A and B (Fig. 3-45, Pos. A and B), which are filled with oil. If the outer member is displaced in relation to the inner member, the deflection of the leaf springs displaces oil from one chamber to the next, by this action the relative movements of the two members of the coupling are braked and the vibrations are dampened. The spacer (Fig. 3-45, Pos. 8) limits the movement of the leaf springs.

3.1.8.1 REMOVAL OF THE GEISLINGER COUPLING Special tools:

n/a


Swivel hoist ring: M16 Chain hoist Crane Coupling assembly: 160 kg

Dogman/rigger

z


z




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Fig. 3-46 Geislinger coupling - drain oil WARNING Do not carry out the following work on a hot engine. Wait until the temperature of the engine is below 50°C. Disobedience may result in personal injury from heated engine or PTO parts.

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z

Remove the guard (Fig. 3-46, Pos. 1).

z

Turn flexible coupling using barring device (Fig. 3-46, Pos. 2) to bring the bleeder plug (Fig. 3-46, Pos. 4) in its lowermost (6 o‘clock) position.

NOTE: To use the barring device, remove the clip and push the device shaft toward the flywheel. The barring device must be rotated counter clockwise to turn the flywheel (flexible coupling) in the direction of normal rotation. Drain the coupling oil, approx 1.45 liters, by removing the bleeder plug (Fig. 3-46, Pos. 4).

NOTE: When the plug is removed, the oil inside the coupling will flow out. Catch it in an oil pan. z

Remove the dip stick (Fig. 3-46, Pos. 3), to speed-up the draining procedure.

NOTE: Check if a lifting eye (Fig. 3-47, Pos. 1) is installed at the roof plate over the coupling. Use the lifting eye to hook a chain hoist. If no lifting eye is installed, it has to be welded to the roof plate. WARNING For welding follow the welding precautions given in the Operation & Maintenance Manual, chapter 4, section "WELD REPAIRS" and refer to PARTS & SERVICE NEWS No. "AH08507". Fig. 3-47

z

Install a swivel hoist ring at the thread (Fig. 3-48, Pos. 1) in the engine flange of the coupling.

Fig. 3-48

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Fig. 3-49 Removal of the coupling z

Remove the bolts (Fig. 3-49, Pos. 1) attaching the coupling assembly (Fig. 3-49, Pos. 4) to the PTO input flange and to the spacer (Fig. 3-49, Pos. 3).

z

Sling coupling. Dismantle the coupling assembly (Fig. 3-49, Pos. 4) from the drive using a chain hoist.

NOTE: The coupling (Fig. 3-49, Pos. 4) must be compressed to dismantle it from the PTO input flange. z

Remove the bolts (Fig. 3-49, Pos. 5) and demount the spacer (Fig. 3-49, Pos. 3).

z

Open the PVG sound silencer gate on the right side of the engine housing and remove the coupling through the gate using a crane.

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3.1.8.2 REPLACEMENT OF THE GEISLINGER COUPLING Special tools:

n/a


Swivel hoist ring: M16 Chain hoist Crane Coupling assembly: 160 kg


Insert the new coupling into the engine housing through the PVG sound silencer gate using a crane.

z

Carry out installation in reverse order to removal. Before installing the guard (Fig. 3-50, Pos. 1) refill the Geislinger coupling with lubricant approx. 1.45 liters, refer to the Operation & Maintenance Manual, chapter 4, section "FLEXIBLE DRIVE COUPLINGS- CHECK OIL LEVEL". For the proper lubricant, refer to section 6.1 on page 6-2.

Fig. 3-50

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PTO

Superstructure

3.2

PTO

3.2.1

MAIN PUMPS

Fig. 3-51 Main pumps assembly

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PTO


Main pump 1

(2)

Main pump 2

(3)

Main pump 3

(4)

Main pump 4

(5)

Main pump 5

(6)

Main pump 6

(7)

Pump distributor gear box (engine 2)

(8)

Pump distributor gear box (engine 1)

(9)

O-ring

The rotative energy from each main motor or engine propels the gears in the pump distributor gear boxes (Fig. 3-51, Pos. 7, Pos. 8) and the gears propel the main and auxiliary pumps. The pumps create a hydraulic oil flow to the cylinders or hydraulic motors. The main high pressure hydraulic circuits are supplied from six swash plate type variable displacement pumps (Fig. 3-51, Pos. 1 to 6). All Main pumps are additionally equipped with gear pumps.

3.2.1.1 PREPARATORY WORKS FOR MAIN PUMP REMOVAL Special tools:

n/a


4 x swivel hoist rings: M16 Crane Roof plate: 260 kg

Dogman/rigger

z


z




z


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PTO

Superstructure

z

Close the hand wheel (Fig. 3-52, Pos. 1) of the main gate valve between the suction oil reservoir and the main oil reservoir.

z

To accelerate the draining of oil from the pumps, loosen the vent plugs on the main pumps, refer to Operation & Maintenance Manual, chapter 4, section "HYDRAULIC SYSTEM CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER".

z

Transfuse the oil from the suction oil reservoir into the main oil reservoir, refer to the Operation & Maintenance Manual, chapter 3, section "FUNCTION OF THE TRANSFER PUMP". Fig. 3-52

NOTE: The following steps indicate the standard procedure for main pump removal. It is also possible to access the main pump assemblies with a crane by opening the PVG sound silencer gate on the right side of the engine house. Carry out the following steps only if you refer to the standard procedure. z

Remove all cables which lead through the roof plates over the pumps. WARNING


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PTO

Fig. 3-53 Right roof plate removal (1)

Roof plate

(2)

Bolt

(3)

Resilient sleeve

z

Remove all bolts (Fig. 3-53, Pos. 2) and resilient sleeves (Fig. 3-53, Pos. 3) of the roof plate.

z

Remove the roof plate (Fig. 3-53, Pos. 1 and 2) with a crane using swivel hoist rings.

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PTO

Superstructure

3.2.1.2 REMOVAL OF MAIN PUMPS Special tools:

n/a


Crane Oil drain pans Main pump assembly with flanged gear pump: 362.4 kg each


NOTE: The removal of all main pumps (Fig. 3-54, Pos. 1 - 6) is analogously always the same.

Fig. 3-54 z

Carry out the preparatory work, refer to section 3.2.1.1 on page 3-51.

z

If equipped with, remove fasteners for hoses of the main pump assembly to be removed.

z

Mark all pipes and hoses at that main pump assembly of the main pump to be removed. DANGER

Danger of hydraulic pressure! Blindness, serious injury, permanent disfigurement, or scaring may result. The hydraulic system may be pressurized. Make sure that the pressure is relieved before any hydraulic line will be removed.

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PTO

Drain the drive shaft housing oil, approx. 1.5 liters by removing the drain plug (Fig. 3-55, Pos. 3) of the main pump to be removed. Remove the level plug opening (Fig. 3-55, Pos. 2) to speed up the draining procedure.

NOTE: When the plugs are removed, the oil inside the drive shaft housing will flow out. Catch it in an oil pan.

Fig. 3-55 z

Disconnect the SAE-flanges of the pressure hose and the suction hose from the gear pump (Fig. 3-56, Pos. 4) of the main pump to be removed.


Disconnect the leak oil hose and all control hoses from the control block (Fig. 3-56, Pos. 1).

z

Disconnect the bearing flushing/lubrication hose from the right side of the pump mounting flange.

z

Disconnect the high pressure hose (Fig. 3-56, Pos. 2) from the main pump assembly.

z

Disconnect the suction hose (Fig. 3-56, Pos. 3) at the bottom side of the pump.

Fig. 3-56

NOTE: When the pump hoses are disconnected, the oil inside the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination.

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PTO

Superstructure

z

Sling pump assembly as shown in Fig. 3-57.

z

Remove mounting bolts. Then remove pump assembly by pulling it out of the pump distributor gear box. DANGER

Risk of falling weights! Death or serious injury may result. When removing the main pump assembly, make sure that nobody steps below the weight.

NOTE: To simplify the removal, move the pump assembly lightly up and down.

Fig. 3-57

When the pump assembly is removed, oil will flow out of the spline shaft housing. Catch it in an oil pan. z

Check the O-ring (Fig. 3-57, Pos. 1) at the pump assembly flange and replace it if required.

3.2.1.3 REPLACEMENT OF MAIN PUMPS Special tools:

n/a


Crane Paste Optimol White, PN 999 039 Main pump assembly with flanged gear pump: 362.4 kg each

Dogman/rigger If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.2 on page 2-33. NOTE: When mounting a new pump, activate the external flushing of bearing. Refer to PARTS & SERVICE NEWS No. "AH05510". z


NOTE: Use "Optimol White" on the spline shaft of the pump. Use new bolts with grade 8.8 at the mounting flanges of the main pump. Tighten the bolts to the specified tightening torque. Tightening torque for the mounting bolts: 360 Nm

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PTO

NOTE: Connecting the suction hose, refer to PARTS & SERVICE NEWS No. "AH05525". NOTE: Always use new O-rings at the SAE-flange connections and hose fittings. Refill lubricant in the drive shaft housing approx. 1.5 liters, refer to Operation & Maintenance Manual, chapter 4, section "PTO’s (PUMP DISTRIBUTOR GEARS) AND OIL RESERVOIR - CHECK OIL LEVEL". Fill up to lower edge of level plug opening (Fig. 3-58, Pos. 2). For the proper lubricant, refer to section 6.1 on page 6-2.

Fig. 3-58 z

Bleed air from the hydraulic system, refer to Operation & Maintenance Manual, chapter 4, section "HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER" and PARTS & SERVICE NEWS No. "AH01513".

z


z

Adjust main pump, refer to the Service Manual for further information and refer to PARTS & SERVICE NEWS No. "AH06542".

z

Check for leaks and proper operation.

z

Check the hydraulic oil level again and correct the oil level if required.

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PTO

3.2.2

Superstructure

PTO OIL PUMP (AUXILIARY PUMP)

The gear oil pumps (Fig. 3-59, Pos. 1) for the PTO gear lubrication aspirate gear oil from the PTO gear boxes sump and pumps it through filters and coolers back to the PTOs. The gear oil pumps are attached at the main pump 1 assembly or, respectively, at main pump 4 assembly.

Fig. 3-59

3.2.2.1 REMOVAL OF PTO OIL PUMP (AUXILIARY PUMP) Special tools:

n/a


Oil drain pan PTO oil pump: 25 kg



z




z


z

Disconnect the SAE-flanges of pressure hose and suction hose from the PTO oil pump (Fig. 3-59, Pos. 1) to be removed.

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PTO


Remove the two bolts (Fig. 3-60, Pos. 1) and pull the PTO oil pump (Fig. 3-60, Pos. 7) out of the adapter (Fig. 3-60, Pos. 2).

z

Remove the four bolts (Fig. 3-60, Pos. 6) and disconnect the adapter (Fig. 3-60, Pos. 2) from the main pump assembly (Fig. 3-60, Pos. 5).

z

Discard the O-ring (Fig. 3-60, Pos. 4).

NOTE: Check the joint element (Fig. 3-60, Pos. 3) for wear and replace it if required.

Fig. 3-60

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PTO

Superstructure

3.2.2.2 REPLACEMENT OF THE PTO OIL PUMP (AUXILIARY PUMP) Special tools:

Hydraulic testing kit, PN 232 591 40


Paste "Optimol White" PN 999 039 PTO oil pump: 25 kg


Check PTO oil pump before installing, refer to PARTS & SERVICE NEWS No. "AH03511" and "AH03512".

z

Remove the two bolts (Fig. 3-60, Pos. 1) at the new PTO oil pump and disconnect the new adapter (Fig. 3-60, Pos. 1) carefully.

z

To avoiding of corrosion coat the adapter surfaces and the pump surface with Optimol White, refer to PARTS & SERVICE NEWS No. "AH06543".

z


NOTE: Use "Optimol White" on the spline shaft of the pump and use a new O-ring (Fig. 3-60, Pos. 4). NOTE: Use new mounting bolts with grade 8.8 at the mounting flanges of the pump and adapter. Tighten the bolts to the specified tightening torque. Tightening torque for the mounting bolts: 74 Nm z


z


z

Run machine to warm, test pressure of the PTO oil pump and adjust if required. Refer to Service Manual.

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3.2.3

PTO

OIL CIRCULATION PUMP (AUXILIARY PUMP)

The oil circulation pumps (Fig. 3-61, Pos. 1) together with back pressure valves prevent cavitation in the swing motors during the swing down phases. For further information refer to section 3.4.4 on page 3-190 and the Service Manual. The oil circulation pumps are attached at the main pump 2 assembly or, respectively, at the main pump 5 assembly 5.

Fig. 3-61

3.2.3.1 REMOVAL OF OIL CIRCULATION PUMP (AUXILIARY PUMP) Special tools:

n/a


Oil drain pan Oil circulation pump: 25 kg



z




z


z

Disconnect the SAE-flanges of pressure hose and suction hose from the circulation pump (Fig. 3-61, Pos. 1) to be removed.

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PTO

Superstructure


Remove the two bolts (Fig. 3-62, Pos. 1) and pull the oil circulation pump (Fig. 3-62, Pos. 7) out of the adapter (Fig. 3-62, Pos. 2).

z

Remove the four bolts (Fig. 3-62, Pos. 6) and disconnect the adapter (Fig. 3-62, Pos. 2) from the main pump assembly (Fig. 3-62, Pos. 5).

z


z

Check the joint element (Fig. 3-62, Pos. 3) for wear and replace it if required.

Fig. 3-62

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PTO

3.2.3.2 REPLACEMENT OF THE OIL CIRCULATION PUMP (AUXILIARY PUMP) Special tools:

Hydraulic testing kit, PN 232 59140


Paste "Optimol White" PN 999 039 Oil circulation pump: 25 kg


Check the oil circulation pump before installing, refer to PARTS & SERVICE NEWS No. "AH03511" and "AH03512".

z

Remove the two bolts (Fig. 3-62, Pos. 1) at the new oil circulation pump and disconnect the new adapter (Fig. 3-60, Pos. 1) carefully.

z


z


NOTE: Use "Optimol White" on the spline shaft of the pump and use a new O-ring (Fig. 3-62, Pos. 4). NOTE: Use new mounting bolts with grade 8.8 at the mounting flanges of the pump and adapter. Tighten the bolts to the specified tightening torque. Tightening torque for the mounting bolts: 74 Nm z


z


z

Run machine to warm, test pressure of the oil circulation pump and adjust if required. Refer to Service Manual.

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PTO

3.2.4

Superstructure

PUMP DISTRIBUTOR GEARBOX (PTO)

Fig. 3-63 Pump distributor gearbox

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PTO


Oil level gauge

(2)

Oil filler plug

(3)

Breather filter

(4)

Oil collector reservoir for auxiliary pump drive shaft housing

(5)

Breather filter with oil level gauge (drive shaft housing)

(6)

Main pump drive shaft housings

(7)

Oil level plug of main pump drive shaft housing

(8)

Oil filler plug with breather pipe of main pump drive shaft housing

(9)

Oil drain plug of main pump drive shaft housing

(10)

Oil drain plug of PTO gear

(11)

Flange for heater studs

(12)

Gear oil temperature sensor mounting bore

(14)

Suction port to PTO lubrication pump

(16)

Return line connection from gear oil cooler

(D)

Drive flange

(M)

Power take off for main pumps

(R)

Power take off for engine radiator fan drive pump

(C)

Power take off for hydraulic oil cooler fan drive pump

The pump distribution gear (PTO gear) is from a spur gear design and driven by a Diesel engine. It is equipped with an external lubrication/cooling system. The PTO gear runs in anti friction bearings and has been provided with a splash lubrication system. The oil supply of the bearings and tooth contacts takes place by an injection. The gearwheels are of case-hardened steel. The hydraulic pumps are directly attached to the gearbox. The O-rings included in the delivery seal the unit statically and reliably. The gear box housing is a one-piece design and made of grey cast iron. Gear box design allows a direct attachment to the diesel engine via a connection flange. The gear box has been provided with connections for a separate cooling system or for a preheating system. Always check gear box oil level with unlocked dip stick and stopped engine.

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PTO

Superstructure

3.2.4.1 REMOVAL OF THE PUMP DISTRIBUTOR GEARBOX (PTO) Special tools:

n/a


Crane Oil drain pans PTO: 1900 kg each Control- and filter plate assembly: 260 kg each


Carry out the preparatory work, refer to section 3.2.1.1 on page 3-51.

NOTE: The removal of the pump distributor gearbox 1 (Fig. 3-64, Pos. 7) and pump distributor gearbox 2 (Fig. 3-64, Pos. 8) is analogously the same. Drain the gear oil of the PTO to be removed, approx. 95 liters. Refer to Operation & Maintenance Manual, chapter 4, section "PTO (PUMP DISTRIBUTOR GEAR) - CHANGE OIL". z

Remove main pump assemblies 1-3 (Fig. 3-64, Pos. 1-3) respectively main pump assemblies 4-6 (Fig. 3-64, Pos. 4-6), refer to section 3.2.1 on page 3-50. Fig. 3-64

z

Remove the radiator fan drive pump of the PTO to be removed, refer to section 3.1.5.5 on page 3-34.

z

Remove the hydraulic cooler fan drive pump of the PTO to be removed, refer to section 3.3.1.1 on page 3-72.

z

Relieve pilot pressure at the pressure check point M40 for accumulator, refer to Service Manual.

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Fig. 3-65 PTO 1+2 with control- and filter plates

z

(1)

Pump distributor gearbox (PTO), engine 1

(2)

Pump distributor gearbox (PTO), engine 2

(3)

Control- and filter plate (engine 1)

(4)

Control- and filter plate (engine 2)

Mark and disconnect all hydraulic lines and electrical wires leading to the control- and filter plate assembly of the PTO to be removed (Fig. 3-65, Pos. 3 respectively Fig. 3-65, Pos. 4).


Sling the control- and filter plate assembly of the PTO to be removed (Fig. 3-65, Pos. 3 respectively Fig. 3-65, Pos. 4) to a crane.

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z

Remove mounting bolts (Fig. 3-66, Pos. 1) with resilient sleeves (Fig. 3-66, Pos. 2).

z

Remove the control- and filter plate assembly (Fig. 3-66, Pos. 3) using a crane. DANGER

Risk of falling weights! Death or serious injury may result. When removing the control frame assembly make sure that nobody steps below the weight. Fig. 3-66 z

Disconnect all hydraulic hoses from the PTO.

NOTE: When the hoses are disconnected, the oil inside the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Disconnect all retainers for hydraulic hoses and electrical wires at the PTO.

Fig. 3-67 z

Disconnect the temperature sensor (Fig. 3-68, Pos. 1).

z

Disconnect the heating and the thermo switch if equipped.

z

Remove the coupling (Fig. 3-68, Pos. 2, refer to section 3.1.8.1 on page 3-45.

Fig. 3-68

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z

PTO

Attach the PTO to a crane, using the lifting eyes (Fig. 3-69, arrows).

Fig. 3-69 z

Remove the bolts (Fig. 3-70, Pos. 1) with resilient sleeves (Fig. 3-70, Pos. 2) attaching the PTO to the support (Fig. 3-70, Pos. 3).

Fig. 3-70 z

Remove the bolts attaching the PTO to the engine.

z

Remove the PTO using the crane. DANGER

Risk of falling weights! Death or serious injury may result. When removing the PTO, make sure that nobody steps below the weight.

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PTO

Superstructure

3.2.4.2 REPLACEMENT OF THE PUMP DISTRIBUTOR GEARBOX (PTO) Special tools:



Paste "Optimol White" PN 999 039 Crane PTO: 1900 kg each Control- and filter plate assembly: 260 kg each


If required, install the temperature sensor, the heating, and the thermo switch to the replacement PTO.

z

Check the flexible bearings (Fig. 3-71, Pos. 4) for damage and signs of fatigue, refer to the Operation & Maintenance Manual, chapter 4, section "HIGH STRENGTH BOLT CONNECTIONS - CHECK TORQUE LOAD". Replace the bearings if necessary.

z


NOTE: Always use new O-rings at all SAE-flange connections. NOTE: Use the specified tightening torque for PTO mounting bolts (Fig. 3-71, Pos. 1) at the support (Fig. 3-71, Pos. 3). Tightening torque for the PTO mounting bolts: 1770 Nm

Fig. 3-71 Refill gear oil of the PTO, approx. 95 liters. Refer to the Operation & Maintenance Manual, chapter 4, section "PTO (PUMP DISTRIBUTOR GEAR) - CHANGE OIL". z

Run machine to warm, test pressure of the circulation pump and adjust if required. Refer to Service Manual for further information.

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Hydraulics

3.3

HYDRAULICS

3.3.1

HYDRAULIC COOLER FAN DRIVE PUMP

The hydraulic cooler fan drive pump is a fixed displacement pump with variable setting. The pump of the type A7F0 is a variable displacement pump, designed to operate in open circuits. It has an internal case drain return. The rotary group is a robust self aspirating unit. External forces may be applied to the drive shaft. The right hydraulic pump on PTO 1 (Fig. 3-72, Pos. 1) supplies the lower and the right hydraulic pump on PTO 2 (Fig. 3-72, Pos. 2) supplies the upper hydraulic fan motor. The fans are mounted directly to the hydraulic motors drive shaft.

Fig. 3-72 Changing the swivel angle of the rotary group is achieved by sliding the control lens along a cylindrical formed track by means of an adjusting screw. z

With an increase in the swivel angel, the pump output increases together with the necessary drive torque.

z

With an decrease in the swivel angel, the pump output decreases together with the necessary drive torque.

NOTE: When increasing to maximum swivel angle, there is a danger of cavitation and over-speeding the hydraulic motor.

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3.3.1.1 REMOVAL OF THE HYDRAULIC COOLER FAN DRIVE PUMP Special tools:

n/a


Chain hoist Crane Oil drain pan Hydraulic cooler fan drive pump: 40 kg



z




z


z


z

Transfuse the oil from the suction oil reservoir into the main oil reservoir, refer to the Operation & Maintenance Manual, chapter 3, section "FUNCTIONS OF THE TRANSFER PUMP".

Fig. 3-73

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NOTE: Check if a lifting eye (Fig. 3-74, Pos. 1) is installed at the roof plate over the pump. Use the lifting eye to hook a chain hoist. If no lifting eye is installed, it has to be welded to the roof plate. WARNING For welding follow the welding precautions given in the Operation & Maintenance Manual, chapter 4, section "WELD REPAIRS" and refer to PARTS & SERVICE NEWS No. "AH08507". Fig. 3-74 WARNING Hot hydraulic oil! Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is below 50 °C. Disobedience may result in personal injury from heated oil.

z

Dismantle the hose mounting plate (Fig. 3-75, Pos. 1).


Disconnect the pressure hose (Fig. 3-75, Pos. 2) and the suction hose (Fig. 3-75, Pos. 3) from the hydraulic cooler fan drive pump (Fig. 3-75, Pos. 5).

z

Sling the pump, remove the bolts (Fig. 3-75, Pos. 4), and remove the hydraulic cooler fan drive pump (Fig. 3-75, Pos. 5) by pulling it out of the PTO using a chain hoist.

Fig. 3-75

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NOTE: To simplify the removal, move the pump assembly lightly up and down. When the pump assembly is removed, oil will flow out of the spline shaft housing. Catch it in an oil pan. z

Check the O-ring at the pump flange and replace it if required.

z

Remove the hydraulic cooler fan drive pump through the PVG sound silencer gate using a crane. DANGER

Risk of falling weights! Death or serious injury may result. When removing the hydraulic cooler fan drive pump through the PVG sound silencer gate, make sure that nobody steps below the weight.

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Hydraulics

3.3.1.2 REPLACEMENT OF THE HYDRAULIC COOLER FAN DRIVE PUMP Special tools:



Crane Chain Hoist Paste "Optimol White" PN 999 039 Compound "KP2K", PN 324 969 40 Hydraulic cooler fan drive pump: 40 kg



NOTE: Use "Optimol White" on the spline shaft of the pump. Always use new O-rings at the SAE-flange connections. Use new bolts (Fig. 3-75, Pos. 4) with grade 10.9 at the mounting flanges. Apply compound "KP2K", PN 324 969 40 on heads and threads of the bolts and tighten them to the specified tightening torque. Tightening torque for the mounting bolts: 74 Nm

Refill the oil collector reservoir (Fig. 3-76, Pos. 1) for the spline shaft housing. For the proper lubricant, refer to section 6.1 on page 6-2.

z

Bleed air from the hydraulic system, refer to Operation & Maintenance Manual, chapter 4, section "HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER" and PARTS & SERVICE NEWS No. "AH01513". Fig. 3-76

z


z

Check and adjust the speed of the hydraulic cooler fan, refer to the Operation and Maintenance Manual, chapter 3, section "ELECTRONIC MONITORING AND CONTROL SYSTEM ECS".

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3.3.2

Superstructure

HYDRAULIC COOLER FAN ASSEMBLY

There are four (temperature range up to 40 °C) hydraulic oil coolers in front of the hydraulic oil reservoir on the right-hand side of the platform. Two cooler elements are mounted in one frame at a time, one above the other. So two frames are installed with two cooler elements installed in each frame. The air stream needed for the cooling is produced by hydraulically driven fans. The air flows from inside to outside through the coolers. For better cleaning, the cooler frames are mounted via hinges to the cooler support so the cooler frames can be opened. ("swing out cooler"). The two cooler fans are driven by hydraulic motors. Each motor is supplied by one hydraulic pump. The right hydraulic pump on PTO 1 (Fig. 3-77, Pos. 1) supplies the lower and the right hydraulic pump on PTO 2 (Fig. 3-77, Pos. 2) supplies the upper hydraulic fan motor. The fans are mounted directly to the hydraulic motors drive shaft.

Fig. 3-77

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Hydraulics

3.3.2.1 REMOVAL OF HYDRAULIC COOLER FAN ASSEMBLY Special tools:

n/a


Oil drain pan Crane Hydraulic cooler fan assembly: 117.4 kg



z




z


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Superstructure

Fig. 3-78 Position of the hydraulic cooler fan assembly z

Open the hydraulic fan guard (Fig. 3-78, Pos. 1) WARNING

Hot hydraulic oil! Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is below 50 °C. Disobedience may result in personal injury from heated oil.

DANGER Danger of hydraulic pressure! Blindness, serious injury, permanent disfigurement, or scaring may result. The hydraulic system may be pressurized. Make sure that the pressure is relieved before any hydraulic line will be removed.

z

Disconnect the hydraulic pressure hoses (Fig. 3-78, Pos. 3) and the leak oil hose (Fig. 3-78, Pos. 2) from the hydraulic motor.

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NOTE: When the hoses are removed, the oil inside the hoses will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Remove the hydraulic cooler fan assembly (Fig. 3-79, Pos. 1) from the main cooler frame support, supported using a crane. WARNING


CAUTION Remove the assembly carefully in order not to damage the oil cooler or the fan blades.

Fig. 3-79

DANGER Risk of falling weights! Death or serious injury may result. When removing the hydraulic cooler fan drive pump through the PVG sound silencer gate, make sure that nobody steps below the weight.

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Superstructure

3.3.2.2 REPLACEMENT OF HYDRAULIC COOLER FAN ASSEMBLY Special tools:



Crane Hydraulic cooler fan assembly: 117.4 kg


Carry out installation in reverse order to removal. Refer to PARTS & SERVICE NEWS No. "AH03506". WARNING


CAUTION Install the assembly carefully in order not to damage the oil cooler or the fan blades.

z

Bleed air from the hydraulic system, refer to Operation & Maintenance Manual, chapter 4, section "HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER" and PARTS & SERVICE NEWS "AH01513".

z


z

Check and adjust the speed of the hydraulic cooler fan, refer to the Operation and Maintenance Manual, chapter 3, section "ELECTRONIC MONITORING AND CONTROL SYSTEM ECS".

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Hydraulics


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Superstructure

3.3.2.3 REMOVAL OF HYDRAULIC COOLER FAN AND MOTOR Special tools:

n/a


Oil drain pan Fan: 19 kg Hydraulic cooler fan mounting assembly: 72 kg Hydraulic motor assembly: 26.4 kg Dogman/rigger

z

Remove the hydraulic cooler fan assembly, refer to section 3.3.2.1 on page 3-77.

Fig. 3-80 Hydraulic cooler fan assembly

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Hydraulics


Bolt

(2)

Locking plate

(3)

Cooler fan

(4)

Drive shaft

(5)

Shaft protecting sleeve

(6)

Drive shaft seal

(7)

Bearing

(8)

Distance sleeve

(9)

Bearing group carrier

(10)

Bearing

(11)

Circlip

(12)

O-ring

(13)

Hydraulic motor

(14)

Bolt

WARNING Fan blades could have sharp edges. Use gloves!

NOTE: Carry out the two following two steps only if cooler fan needs to be removed.

z

z

Remove the attaching bolts (Fig. 3-80, Pos. 1) with the locking plates (Fig. 3-80, Pos. 2). Discard the locking plates.

z

Remove the cooler fan (Fig. 3-80, Pos. 3) from the drive shaft (Fig. 3-80, Pos. 4).

Remove the four bolts (Fig. 3-80, Pos. 14) and remove the hydraulic motor (Fig. 3-80, Pos. 13) from the bearing group carrier (Fig. 3-80, Pos. 9). Discard the O-ring (Fig. 3-80, Pos. 12).

NOTE: When the hydraulic motor is disconnected from the bearing group carrier, the oil inside the bearing group carrier will flow out. Catch it in an oil pan. z

If required remove the circlip (Fig. 3-80, Pos. 11), extract the drive shaft (Fig. 3-80, Pos. 4) out of the bearing group carrier (Fig. 3-80, Pos. 9), and remove the drive shaft seal (Fig. 3-80, Pos. 6), the bearings (Fig. 3-80, Pos. 7 and 10), and the sleeves (Fig. 3-80, Pos. 5 and 8).

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Superstructure

3.3.2.4 REPLACEMENT OF HYDRAULIC COOLER FAN AND MOTOR Special tools:

n/a


n/a Fan: 19 kg Hydraulic cooler fan mounting assembly: 72 kg Hydraulic motor assembly: 26.4 kg Dogman/rigger If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.2 on page 2-33.

Fig. 3-81 Hydraulic cooler fan assembly z

Carry out installation in reverse order to removal. Refer to PARTS & SERVICE NEWS No. "AH03506".

NOTE: If the drive shaft (Fig. 3-81, Pos. 4) is removed, check the drive shaft. Check drive shaft seal (Fig. 3-81, Pos. 6) for wear and damage. Replace if required. NOTE: Use a new O-ring (Fig. 3-81, Pos. 12) and new locking plates (Fig. 3-81, Pos. 2).

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Hydraulics

WARNING Fan blades could have sharp edges. Use gloves!

z

Install the hydraulic cooler fan assembly, refer to section 3.3.2.2 on page 3-80.

NOTE: Check the oil level in the bearing group carrier (Fig. 3-81, Pos. 9) and add oil if required, refer to the Operation & Maintenance Manual, chapter 4, section "HYDRAULIC OIL COOLER FAN BEARINGS - CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER". z


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3.3.3

Superstructure

HYDRAULIC OIL COOLERS

Fig. 3-82 Hydraulic oil cooler circuit 3 - 86

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Version 2009/2

Superstructure

Hydraulics


Back pressure valve

(2)

Solenoid valve (4/2-directional control valve)

(3)

Return lines from control blocks

(4)

Return oil collector tube

(5)

Restrictor (shock absorbers for the hydraulic oil cooler)

(6)

Lines to cooler (hot oil)

(7)

Hydraulic oil cooler

(8)

Lines to hydraulic oil reservoir

(9)

Hydraulic oil reservoir

The returning oil from the system flows via the ines (Fig. 3-82, Pos. 3) into the collector tube (Fig. 3-82, Pos. 4). On the top side of it the back pressure valve (Fig. 3-82, Pos. 1) is installed. The back pressure valve causes a back pressure which forces most of the relative hot oil via the lines (Fig. 3-82, Pos. 6) to the cooler (Fig. 3-82, Pos. 7). On the flow to the cooler the hydraulic oil passes the restrictor, gets cooled in the cooler and then flows through the lines (Fig. 3-82, Pos. 8) into the filter chamber of the hydraulic oil reservoir (Fig. 3-82, Pos. 9). The restrictors acts as shock absorbers to prevent cooler cracks created from pressure peaks. Besides the back pressure valve acts as an oil flow control valve as far as the oil temperature has not reached its steady temperature. During the warm up period (1/2 Qmax) the back pressure valve (Fig. 3-82, Pos. 1) is wide open, because the solenoid valve (Fig. 3-82, Pos. 2) is energized, which results in less oil flow through the cooler which causes the oil getting its optimum operating temperature quicker. With increasing oil temperature the oil gets thinner, so that the main pumps can be shifted to Qmax position and simultaneously the solenoid valve (Fig. 3-82, Pos. 2) will be de-energized, so that the valve piston will be closed further by the force of the spring resulting in more oil passing the cooler. NOTE: Each oil cooler contains the hydraulic oil cooler and PTO gear oil cooler. The machine is equipped with four oil coolers.

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3.3.3.1 REMOVAL OF THE HYDRAULIC OIL COOLERS Special tools:

n/a


Safety harness in conformity with DIN EN 361 Crane Mobile elevator working platform Oil drain pans Hydraulic oil cooler: 275 kg each



z



Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM"

z


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z


z

Transfuse the oil from the return manifold into the main oil reservoir, refer to the Operation & Maintenance Manual, chapter 3, section "FUNCTIONS OF THE TRANSFER PUMP".

z

Open the hydraulic oil cooler door. Refer to Operation & Maintenance Manual, chapter 4, section "HYDRAULIC OIL COOLERS - INSPECT AND CLEAN IF NECESSARY". WARNING

Fig. 3-83

z


z

Always wear a safety harness when working at the hydraulic oil coolers.

z

Disconnect the hoses (Fig. 3-84, Pos. 1 and 2) from the PTO gear oil cooler.

NOTE: When the hoses are removed, oil will flow out of the oil coolers. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination.

Fig. 3-84

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z

Superstructure

Disconnect all inlet hoses (Fig. 3-85, Pos. 2) and outlet hoses (Fig. 3-85, Pos. 1) from the hydraulic oil cooler.

NOTE: When the hoses are removed, oil will flow out of the oil coolers. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination.

Fig. 3-85 z

Sling the oil cooler (Fig. 3-86).

Fig. 3-86

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Fig. 3-87 Removal of the oil cooler z

Remove the bolts (Fig. 3-87, Pos. 2), the washers (Fig. 3-87, Pos. 3) and locking plates (Fig. 3-87, Pos. 4), and clear the oil cooler (Fig. 3-87, Pos. 1) from the angle (Fig. 3-87, Pos. 8).

z

Lift the oil cooler (Fig. 3-87, Pos. 1) out of the radiator mounting (Fig. 3-87, Pos. 9) using a crane. DANGER

Risk of falling weights! Death or serious injury may result. When removing the hydraulic oil cooler, make sure that nobody steps below the weight.

NOTE: Discard locking plates (Fig. 3-87, Pos. 4). Check condition of buffer elements (Fig. 3-87, Pos. 10), and replace them if required.

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3.3.3.2 REPLACEMENT OF THE HYDRAULIC OIL COOLERS Special tools:

n/a


Safety harness in conformity with DIN EN 361 Crane Mobile elevator working platform Glue PN 256 952 40 Hydraulic oil cooler: 275 kg each

Dogman/rigger If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.2 on page 2-33.

Fig. 3-88 Installation of the oil cooler

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WARNING Always wear a safety harness when working at the hydraulic oil coolers.

z

Exchange the restrictor (Fig. 3-82, Pos. 5) from the old oil cooler to the new oil cooler.

z

Apply glue PN 256 952 40 to the profiled joints (Fig. 3-88, Pos. 5 to 7) and attach them in the same manner as they were fixed to the old oil cooler.

z


NOTE: Use new locking plates (Fig. 3-88, Pos. 4). z

Bleed air from the hydraulic system, refer to the Operation & Maintenance Manual, chapter 4, section "HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER" and PARTS & SERVICE NEWS No."AH01513".

z


z

Add PTO gear oil to the specified level.

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3.3.3.3 REMOVAL OF THE HYDRAULIC OIL COOLER FRAME Special tools:

n/a


Safety harness in conformity with DIN EN 361 Crane 2 x swivel hoist rings: M36 Mobile elevator working platform Oil drain pans Hydraulic oil cooler frame: 3950 kg



z




z


z


z


z

Open the hydraulic oil cooler door. Refer to Operation & Maintenance Manual, chapter 4, section "HYDRAULIC OIL COOLERS - INSPECT AND CLEAN IF NECESSARY". Fig. 3-89

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WARNING z


z

Always wear a safety harness when working at the hydraulic oil cooler frame.

z

Disconnect all wiring harness connectors from the hydraulic oil cooler frame.

z

If required, remove the following parts from the hydraulic oil cooler frame (Fig. 3-90, Pos. 4):

1. Plate (Fig. 3-90, Pos. 1) 2. Rail (Fig. 3-90, Pos. 2) 3. Rail (Fig. 3-90, Pos. 3)

Fig. 3-90 z

Disconnect hydraulic inlet hoses (Fig. 3-91, Pos. 1) from the hydraulic cooler fan motor (Fig. 3-91, Pos. 2).

NOTE: When the hoses are disconnected, oil will flow out of the hoses. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination.

Fig. 3-91

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z

Superstructure

Disconnect the return hose (Fig. 3-92, Pos. 1) and the leak oil hose (Fig. 3-92, Pos. 2) from the hydraulic cooler fan motor.


Fig. 3-92 z

Disconnect hydraulic hoses (Fig. 3-93, Pos. 1 and 2) at the shown joints.


Fig. 3-93 z

Disconnect PTO oil hoses (Fig. 3-94, Pos. 1 and 2).


Fig. 3-94

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z

Insert the swivel hoist rings (M36) into the threads (Fig. 3-95, Pos. 1) of the hydraulic oil cooler frame (Fig 3-95, Pos. 2).

z

Sling hydraulic oil cooler frame (Fig. 3-95, Pos. 2) at the hoist rings.

Fig. 3-95 z

Remove mounting bolts (Fig. 3-96, Pos. 2 and 3) and remove the hydraulic oil cooler frame (Fig. 3-96, Pos. 1) from the superstructure using a crane. DANGER

Risk of falling weights! Death or serious injury may result. When removing the hydraulic oil cooler, make sure that nobody steps below the weight.

z

Rest the hydraulic oil cooler frame on the ground on an appropriate stand and carry out the following steps if required.

Fig. 3-96 z

If required, remove the hydraulic oil cooler from the hydraulic oil cooler frame, refer to section 3.3.3.1 on page 3-88.

z

If required, remove the cooler fan assembly from the hydraulic oil cooler frame, refer to section 3.3.2.1 on page 3-77.

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3.3.3.4 REPLACEMENT OF THE HYDRAULIC OIL COOLER FRAME Special tools:

n/a


Safety harness in conformity with DIN EN 361 2 x swivel hoist rings: M36 Crane Mobile elevator working platform Compound "KP2K", PN 324 969 40 Hydraulic oil cooler frame: 3950 kg


WARNING Always wear a safety harness when working at the hydraulic oil cooler frame.

z


NOTE: Use new mounting bolts (Fig. 3-97, Pos. 2 and 3) of grade 10.9. Apply compound "KP2K", PN 324 969 40 on heads and threads of the mounting bolts and tighten them to the specified tightening torque. Tightening torque for mounting bolts (Fig. 3-97, Pos. 2 and 3): 1770 Nm.

Fig. 3-97 z

Bleed air from the hydraulic system, refer to the Operation & Maintenance Manual, chapter 4, section "HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER" and PARTS & SRVICE NEWS No. "AH01513".

z


z

Add PTO gear oil to the specified level.

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MAIN RELIEF VALVES (MRV)

MRV (main relief valves) are pilot operated relief valves. The MRV limit the maximum pump supply line pressure. The valves are designed with an opening characteristic. That means, if the valve is activated after the response procedure, no further pressure increase is possible and damage is avoided. The valves are installed in the main control valve blocks.

3.3.4.1 REMOVAL OF THE MRV Special tools:

36 mm Socket wrench, PN 232 374 40


n/a

NOTE: For additional information about the MRV on the main control valve blocks, refer to section 3.3.8 on page 3-117. z


z


z


z


Fig. 3-98

WARNING Hot hydraulic oil! Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is below 50 °C. Disobedience may result in personal injury from heated oil.

z

Remove the MRV (Fig. 3-99, Pos. 1, 2 or 3) from the main control valve block.

NOTE: When the MRV is removed, oil will flow out of the main control valve block. Catch it in an oil pan.

Version 2009/2

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Fig. 3-99

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3.3.4.2 REPLACEMENT OF THE MRV Special tools:

36 mm Socket wrench, PN 232 374 40 Hydraulic testing kit, PN 232 591 40


n/a

NOTE: Fit new O-rings to the MRV. z


NOTE: Tighten the MRV to the specified torque. Tightening torque for MRV: 300 Nm z


z


z

Check and adjust the MRV. Refer to Service Manual. WARNING

Wear hearing protection when checking relief pressure.

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3.3.5

Hydraulics

PILOT OIL PUMP (GEAR PUMP)

3.3.5.1 REMOVAL OF THE PILOT OIL PUMP Special tools:

n/a


n/a Pilot oil pump: 27.4 kg For further information about the needed blind plugs, refer to section 2.3 on page 2-37.

z


z




z


z

The pilot oil pump (Fig. 3-100, Pos. 1) generates the pilot pressure that is used for all hydraulic control operations.

z

The pilot oil pump is attached at the main pump assembly 2.

z

Disconnect the SAE-flanges of pressure hose and suction hose from the pilot oil pump (Fig. 3-100, Pos. 1).

NOTE: When the pump hoses are disconnected, the oil inside the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. Fig. 3-100

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z

Remove the two bolts (Fig.3-101, Pos. 1) and pull the pilot oil pump (Fig. 3-101, Pos. 7) out of the adapter (Fig. 3-101, Pos. 2).

z

Remove the four bolts (Fig. 3-101, Pos. 6) and disconnect the adapter from the main pump assembly (Fig. 3-101, Pos. 5).

z


NOTE: Check the joint element (Fig. 3-101, Pos. 3) for wear and replace it if required.

Fig. 3-101

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3.3.5.2 REPLACEMENT OF THE PILOT OIL PUMP Special tools:



Paste "Optimol White" PN 999 039 Pilot oil pump: 27.4 kg


Check the pilot oil pump before installing, refer to PARTS & SERVICE NEWS No. "AH03511" and "AH03512".

z

Remove the two bolts (Fig. 3-102, Pos. 1) at the new pilot oil pump and disconnect the adapter (Fig. 3-102, Pos. 2) carefully.

z


z

Carry out installation in reverse order to removal, refer to PARTS & SERVICE NEWS No. "AH05520".

Fig. 3-102 NOTE: Use "Optimol White" on the spline shaft of the pump. NOTE: Use a new O-ring (Fig. 3-102, Pos. 4) and new mounting bolts (Fig. 3-102, Pos. 1 and Pos. 6) with grade 8.8 at the mounting flanges of the pump and the adapter. Tighten the mounting bolts to the specified tightening torque. Tightening torque for the mounting bolts: 74 Nm z


z


NOTE: Check and adjust the pilot pressure if required. Refer to Service Manual. Version 2009/2

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3.3.6

Superstructure

MAIN GATE VALVE

The connection between the suction reservoir and the hydraulic oil reservoir can be closed with the main gate valve to prevent oil flow during repairs. This unit is monitored by the switch S31. It makes sure that an engine start is not possible with a closed main gate valve. Fault message „Start blocked because of main shut-off (gate) valve“ is displayed on the operator’s dashboard.

3.3.6.1 REMOVAL OF THE MAIN GATE VALVE Special tools:

n/a


Oil tank (4450 liters) Main gate valve: 12.3 kg

z


z




z


z

Transfuse the oil from the suction oil reservoir into the main oil reservoir, refer to the Operation & Maintenance Manual, chapter 3, section "FUNCTIONS OF THE TRANSFER PUMP".

Fig. 3-103 Drain hydraulic oil from the hydraulic oil reservoir, approx. 4450 liters. Refer to the Operation & Maintenance Manual, chapter 4, section "HYDRAULIC SYSTEM CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER".

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z

Disconnect the harness connector S31 from the proximity switch at the main gate valve. Refer to Fig. 3-112 on page 3-111.

z

Remove the bolts (Fig. 3-104, Pos. 1), dismantle the compensator (Fig. 3-104, Pos. 2), and the main gate valve (Fig. 3-104, Pos. 3).

NOTE: When the main gate valve (Fig. 3-104, Pos. 3) and the compensator (Fig. 3-104, Pos. 2) are removed some oil inside the piping will flow out. Catch it in an oil pan. Check condition of the compensator (Fig. 3-104, Pos. 2) and replace as necessary.

Fig. 3-104

3.3.6.2 REPLACEMENT OF THE MAIN GATE VALVE Special tools:

n/a


Oil tank (4450 liters) Main gate valve: 12.3 kg If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.2 on page 2-33.

z

Carry out installation in reverse order to removal. Fill hydraulic oil into the hydraulic oil reservoir, approx. 4450 liters. Refer to the Operation & Maintenance Manual, chapter 4, section "HYDRAULIC SYSTEM CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER".

z


z


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3.3.7

Superstructure

HYDRAULIC OIL RESERVOIR

Fig. 3-105 Hydraulic oil reservoir

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Legend for Fig. 3-105: (A)

View from machine center

(B)

View from pump compartment

(C)

Top view

(1)

Main hydraulic oil reservoir

(2)

Oil level sight gauge

(3)

Auxiliary return oil connections

(4)

Breather filter

(5)

Leakage oil line connections

(6)

Back-pressure valve, temperature controlled

(7)

Return oil collector tube with strainer

(8)

Oil reservoir outlet (suction pipe)

(9)

Main gate valve

(10)

Drain coupling an collector pipe

(11)

Mounting brackets

(12)

Compensator

(13)

Drain coupling, main oil reservoir

(14)

Access cover

(15)

Return oil filters (four)

(16)

Refill plug

(17)

Leakage oil filter (one)

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3.3.7.1 REMOVAL OF THE HYDRAULIC OIL RESERVOIR Special tools:

Socket wrench 46 mm, PN 232 377 40


Safety harness in conformity with DIN EN 361 Crane Mobile elevator working platform 4 x swivel hoist rings: M 36 Hydraulic oil reservoir incl. back pressure valve: 3465 kg



z




Always wear a safety harness when working at the hydraulic oil reservoir.

Drain hydraulic oil from the hydraulic oil reservoir, approx. 4450 liters. Refer to the Operation & Maintenance Manual, chapter 4, section "HYDRAULIC SYSTEM CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER".

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z

Remove the main gate valve, refer to section 3.3.6.1 on page 3-104.

z

Remove the plates (Fig. 3-106, Pos. 1) beside the threads (Fig. 3-106, Pos. 2).

z

Insert swivel hoist rings (M 36) into the threads (Fig. 3-106, Pos. 2).

Fig. 3-106 z

Remove the rails (Fig. 3-107, Pos. 1) from the hydraulic oil reservoir (Fig. 3-107, Pos. 2).

Fig. 3-107 z

Disconnect the hydraulic outlet hoses (Fig. 3-108, Pos. 1), leading from the hydraulic coolers, from the hydraulic oil reservoir.

z

Disconnect the hydraulic inlet hoses (Fig. 3-108, Pos. 2), leading to the hydraulic coolers, from the hydraulic oil reservoir.

NOTE: When the hydraulic hoses are disconnected, the oil inside the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. Fig. 3-108

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z

Loosen all clamps (Fig. 3-109, Pos. 2) mounted at the hydraulic oil reservoir to clear all hydraulic lines from the hydraulic oil reservoir (Fig. 3-109, Pos. 3).

z

Mark and disconnect all hydraulic lines (Fig. 3-109, Pos. 1) from the hydraulic oil reservoir.

NOTE: When the hydraulic hoses/pipes are disconnected, the oil inside the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination.

Fig. 3-109

z

Disconnect the electrical wiring (Fig. 3-110, Pos. 1) from the transfer pump (Fig. 3-110, Pos. 7) and the hydraulic oil reservoir.

z

Shut the cock valves at the hydraulic hoses (Fig. 3-110, Pos. 3) and disconnect the hydraulic hoses from the union (Fig. 3-110, Pos. 4).

z

Clear all hydraulic hoses from the hydraulic oil reservoir.

z

Disconnect all hydraulic lines from the standpipe (Fig. 3-110, Pos. 5).

NOTE: When the hydraulic hoses/pipes are disconnected, the oil inside the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Remove the grating (Fig. 3-110, Pos. 6).

z

Disconnect all hydraulic lines (Fig. 3-111, Pos. 1) from the standpipe below the hydraulic oil reservoir.

Fig. 3-110

NOTE: When the hydraulic hoses are disconnected, the oil inside the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Loosen all clamps (Fig. 3-111, Pos. 2) below the hydraulic oil reservoir to clear all hydraulic lines from the hydraulic oil reservoir.

Fig. 3-111

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z

Disconnect all wiring harness connectors (Fig. 3-112, Pos. Bxx, Y101) and the head light assembly (Fig. 3-112, Pos. H49b).

z

Remove the wiring harnesses from the hydraulic oil reservoir.

Fig. 3-112 z

Attach the hydraulic oil reservoir to a crane.

z

Remove two mounting bolts (Fig. 3-113, Pos. 1) from each mounting flange (Fig. 3-113, Pos. 3) of the hydraulic oil reservoir (Fig. 3-113, Pos. 2).

z

Lift the hydraulic oil reservoir (Fig. 3-113, Pos. 2) off the superstructure using the crane and place it on the ground. DANGER

Risk of falling weights! Death or serious injury may result. When removing the hydraulic oil reservoir, make sure that nobody steps below the weight.

Fig. 3-113

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Fig. 3-114 Filter assembly/provided parts

z

(R)

Return oil filter location

(L)

Leakage oil filter location

(1)

Mounting bolt

(2)

Filter cover retainer

(3)

Filter cover assembly

(4)

Return and leakage filter unit

(5)

Oil filler plug

(6)

Gasket

(7)

Cover

(8)

Breather filter

Remove filters and all provided parts (Fig. 3-114, Pos. 1 - 8) from the top of the old hydraulic oil reservoir if required.

NOTE: Check O-rings and replace if required. Discard the gasket (Fig. 3-114, Pos. 6).

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z

Hydraulics

Carry out the following steps only if required: z

Remove the back pressure valve (Fig. 3-115, Pos. 2) and discard the gaskets (Fig. 3-115, Pos. 1 and 3).

z

Remove the whole standpipe (Fig. 3-115, Pos. 4).

z

Remove all covers (Fig. 3-115, Pos. 5).

z

Remove all plugs (Fig. 3-115, Pos. 6).

z

Remove the oil level plate (Fig. 3-115, Pos. 8) and hydraulic oil level sight gauge (Fig. 3-115, Pos. 7).

z

Remove all other equipment (clamps, bolts, etc.) if required.

Fig. 3-115

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3.3.7.2 REPLACEMENT OF THE HYDRAULIC OIL RESERVOIR Special tools:

Socket wrench 46 mm, PN 232 377 40 Hydraulic testing kit, PN 232 591 40


Safety harness in conformity with DIN EN 361 Crane Mobile elevator working platform Compound "KP2K", PN 324 969 40 Hydraulic oil reservoir incl. back pressure valve: 3465 kg


WARNING Always wear a safety harness when working at the hydraulic oil reservoir.

z

If required, install all provided parts (Fig. 3-114, Pos. 1 - 8) at the new hydraulic oil reservoir.

NOTE: Use new gasket (Fig. 3-114, Pos. 6) at the cover (Fig. 3-114, Pos. 7). Use new filter units (Fig. 3-114, Pos. 4). Check O-rings and replace if required.

z

Replace the return oil strainer (Fig. 3-116, Pos. 1).

NOTE: Use new gaskets (Fig. 3-116, Pos. 2).

Fig. 3-116 z

If required, install all provided parts (Fig. 3-115, Pos. 1 - 8) at the new hydraulic oil reservoir.

NOTE: Use new gaskets (Fig. 3-115, Pos. 1 and 3) at the back pressure valve (Fig. 3-115, Pos. 2). Check O-rings and replace if required. z


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NOTE: Use new bolts (Fig. 3-117, Pos. 1) of grade 10.9 at the mounting flanges (Fig. 3-117, Pos. 3) of the hydraulic oil reservoir (Fig. 3-117, Pos. 2). Apply compound "KP2K", PN 324 969 40 on heads and threads of the bolts (Fig. 3-117, Pos. 1) and tighten them to the specified tightening torque. Tightening torque for the mounting bolts: 1770 Nm

Fill hydraulic oil into the hydraulic oil reservoir, approx. 4450 liters. Refer to the Operation & Maintenance Manual, chapter 4, section "HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTIONSTRAINERS AND PULSATION DAMPER" z


z


z

Check and adjust the back pressure if required, refer to Service Manual. Fig. 3-117

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3.3.8

Hydraulics

MAIN CONTROL VALVE BLOCKS

Fig. 3-118 Main control valve blocks overview (1)

Main control valve block I

(2)

Main control valve block II

(3)

Main control valve block III

(4)

Swing control valve block IV

(5)

High pressure filter 1

(6)


(7)


(8)


There are three main control valve blocks (I - III) and one swing control valve block (IV) on each control and filter panel. Individual valve plugs are mounted on each main control valve block. These valves are anti-cavitation valves (ACV), service line relief valves (SRV), or main relief valves (MRV).

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Superstructure

Fig. 3-119 Main control valve blocks 1 and 2 (BHA)

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Legend for Fig. 3-119: Main control valve block I (BHA) (L.H. Travel, Stick, Bucket, Boom) (46.1)

High pressure filter, Pump 2 and 5

(31.1)

SRV Travel motors left backward

(32.1)

ACV Travel motors left backward

(31.2)

SRV Travel motors left forward

(32.2)

ACV Travel motors left forward

(33.1)

SRV Stick cylinder piston side

(32.3)

ACV Stick cylinder piston side

(32.4)

AVC Stick cylinder rod side

(32.5)

ACV Bucket cylinder rod side

(32.6)

ACV Bucket cylinder piston side

(32.7)

ACV Boom cylinder rod side

(32.8)

ACV Boom cylinder piston side

Main control valve block II (BHA) (Bucket, Boom, Reserved, Stick) (44.2)

High pressure filter, Pump 4

(32.9)


(32.10)

ACV Bucket piston side

(33.6)

SRV Boom cylinder rod side

(32.11)


(32.12)


(33.5)

SRV Stick cylinder piston side

(32.15)


(32.16)

ACV Stick cylinder rod side

NOTE: The numbers in brackets are component numbers for the hydraulic diagram. NOTE: There is one MRV in each control block.

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Superstructure

Fig. 3-120 Main control valve blocks 3 and 4 (BHA)

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Legend for Fig. 3-120: Main control valve block III (BHA) (R.H. Travel, Boom, Bucket, Stick) (46.2)


(31.3)

SRV Travel motors right backward

(32.17)

ACV Travel motors right backward

(31.4)

SRV Travel motors right forward

(32.18)

ACV Travel motors right forward

(32.19)


(32.20)


(32.21)


(32.22)


(32.23)


(32.24)


Main control valve block IV (BHA) (Single spool for swing) (44.1)



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Superstructure

Fig. 3-121 Main control valve blocks 1 and 2 (FSA)

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Legend for Fig. 3-121: Main control valve block I (FSA) (L.H. Travel, Stick, Bucket, Boom) (46.1)

High pressure filter, Pump 2 an 5

(31.1)

SRV Travel motors left backward

(32.1)

ACV Travel motors left backward

(31.2)

SRV Travel motors left forward

(32.2)

ACV Travel motors left forward

(33.1)

SRV Stick cylinder rod side

(32.3)


(32.4)


(32.5)


(33.2)

SRV Bucket cylinder rod side

(32.6)


(32.7)


(32.8)


Main control valve block II (FSA) (Bucket, Boom, Reserved, Stick) (44.2)


(32.9)

ACV bull clam cylinder rod side

(32.10)

ACV bull clam cylinder piston side

(30)

SRV bull clam cylinder piston side

(33.6)

SRV Bucket cylinder rod side

(32.11)


(32.12)


(32.13)


(33.4)

SRV Boom cylinder rod side

(32.14)


(32.15)


(191)

SRV (pressure increasing valve) Stick cylinder rod side

(32.16)



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Fig. 3-122 Main control valve blocks 3 and 4 (FSA)

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Legend for Fig. 3-122: Main control valve block III (FSA) (R.H. Travel, Boom, Bucket, Stick) (46.2)


(31.3)

SRV Travel motors right forward

(32.17)

ACV Travel motors right forward

(31.4)

SRV Travel motors right backward

(32.18)

ACV Travel motors right backward

(32.19)


(32.20)


(32.21)


(32.22)


(32.23)


(32.24)


Main control valve block IV (FSA) (Single spool for swing) (44.1)



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3.3.8.1 REMOVAL OF THE MAIN CONTROL VALVE BLOCKS Special tools:

n/a


Crane Oil drain pan Main control valve block I: 717 kg Main control valve block II: 726 kg High pressure filter (main control block II): 44.6 kg Main control valve block III: 713kg Main control valve block IV: 143 kg High pressure filter (main control block IV): 15 kg Dogman/rigger For further information about the needed blind plugs, refer to section 2.3 on page 2-37.

z


z




z


z


z


Fig. 3-123

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z

Remove all SRVs from the main control valve block, refer to section 3.3.9.1 on page 3-133.

z

Remove all ACVs from the main control valve block, refer to section 3.3.10.3 on page 3-145.

z

If required remove the load holding valves from the main control valve block.

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Fig. 3-124 z

Disconnect all hydraulic lines (Fig. 3-124, Pos. 3) at the respective main control valve block.

z

Disconnect all pilot lines from the spool valves (Fig. 3-124, Pos. 1) at the respective main control valve block.

NOTE: When the hydraulic lines are removed, the oil inside the lines will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Discard the O-rings (Fig. 3-124, Pos. 2) of the SAE-flanges.

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z

Hydraulics

Disconnect the return line (Fig. 3-125, Pos. 1) at the respective main control valve block (I - IV) and discard the O-ring (Fig. 3-230, Pos. 2) of the SAE-flange.

NOTE: When the return line is removed, the oil inside the line will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination.

Fig. 3-125 Removal of the Main Valve Control Blocks I and III z

Disconnect the pressure line (Fig. 3-126, Pos. 1) at the respective main control valve block (I or III) and discard the O-ring (Fig. 3-126, Pos. 2) of the SAE-flange.

NOTE: When the pressure line is removed, the oil inside the line will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Disconnect the harness connectors and clear the wiring harness from the main control valve block.

Fig. 3-126 z

Wind a lifting belt around the spool valves (Fig. 3-124, Pos. 1) and sling the main control valve block at the lifting belt as shown in Fig. 3-127.

z

Remove the mounting bolts and dismantle the main control valve block from the control valve carrier using a crane.

Fig. 3-127 WARNING Risk of falling weights! May result in death or serious injury When removing the main control valve blocks, make sure that nobody steps below the weight.

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Removal of the Main Valve Control Block II z

Remove the pressure filter (Fig. 3-128, Pos. 3) from the main control valve block II (Fig. 3-128, Pos. 1).

z

If required, disconnect the pressure lines (Fig. 3-128, Pos. 6) from the pressure filter (Fig. 3-128, Pos. 3) and discard the Oring (Fig. 3-126, Pos. 2) at the pressure filter side (Fig. 3-128, Pos. 3) and the quad ring (Fig. 3-128, Pos. 4) at the block side (Fig. 3-128, Pos. 5).

NOTE: When the pressure lines are removed, the oil inside the lines will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z


z

Wind a lifting belt around the spool valves and sling the main control valve block at the lifting belt as shown in Fig. 3-129.

z


Fig. 3-128

Fig. 3-129 WARNING Risk of falling weights! May result in death or serious injury When removing the main control valve blocks, make sure that nobody steps below the weight.

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Removal of the Main Valve Control Block IV z

Disconnect the pressure line (Fig. 3-130, Pos. 3) at the main control valve block (Fig.3-130, Pos.1) and discard the O-ring (Fig. 3-130, Pos. 2) of the SAE-flange.

z

Remove the pressure filter (Fig. 3-130, Pos. 4) from the main control valve block (Fig. 3-130, Pos. 1) and discard the O-ring (Fig. 3-130, Pos. 2) at the pressure filter.

z

If required, disconnect the pressure line (Fig. 3-130, Pos. 5) from the pressure filter (Fig. 3-130, Pos. 4) and discard the O-ring (Fig. 3-130, Pos. 2) of the SAE-flange.

NOTE: When the pressure lines are removed, the oil inside the lines will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z


z

Sling main control valve block using suitable sling accessory.

z


Fig. 3-130

WARNING Risk of falling weights! May result in death or serious injury When removing the main control valve blocks, make sure that nobody steps below the weight.

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3.3.8.2 REPLACEMENT OF THE MAIN CONTROL VALVE BLOCKS Special tools:



Crane Compound "KP2K", PN 324 969 40 Main control valve block I: 717 kg Main control valve block II: 726 kg High pressure filter (main control block II): 44.6 kg Main control valve block III: 713kg Main control valve block IV: 143 kg High pressure filter (main control block IV): 15 kg Dogman/rigger If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.2 on page 2-33.

NOTE: Ensure that the mating surfaces are clean and free of paint before assembly. Fit new O-rings. z


NOTE: Use new mounting bolts (Fig. 3-131, Pos. 1 and 2) of grade 10.9 and new screw nuts (Fig. 3-131, Pos. 4) for the respective main control valve block (I - III). Apply compound "KP2K", PN 324 969 40 on heads and threads of the mounting bolts and tighten them to the specified tightening torque. Tightening torques for the mounting bolts (Fig. 3-131, Pos. 1 and 2) at the main control valve blocks: 510 Nm NOTE: Use new mounting bolts (Fig. 3-131, Pos. 3) of grade 10.9 for main control valve block IV. Apply compound "KP2K", PN 324 969 40 on heads and threads of the mounting bolts and tighten them to the specified tightening torque.

Fig. 3-131

Tightening torques for the mounting bolts (Fig. 3-131, Pos. 3) at the main control valve block IV: 265 Nm z

Mount the pressure filter at main control block II (Fig.3-128, Pos. 3). If required, install the pressure lines using new bolts, a new O-ring (Fig.3-128, Pos.2) and a new quad ring (Fig 3-128, Pos. 4).

z

Mount the pressure filter at main control block IV (Fig.3-130, Pos. 4). If required, install the pressure lines using new bolts and a new O-rings (Fig.3-130, Pos. 2).

NOTE: Refer to PARTS & SERVICE NEWS No. "AH05501".

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z


z


z

Check pressure of all circuits of the control valve block (use 400 bar gauge).

3.3.9

SERVICE LINE RELIEF VALVES (SRV)

The service relief valves are pilot operated relief valves. The SRV limit the maximum possible pressure in the service lines created by external force. The valves are designed with an opening characteristic. That means, if the valve is activated after the response procedure, no further pressure increase is possible and damage is avoided. Service relief valves are located on the main control valve blocks on the manifold build and in the throttle check valves, refer to section 3.3.11.1 on page 3-152. NOTE: SRVs are also installed in the travel system, refer to section 4.1.7.1 on page 4-35.

3.3.9.1 REMOVAL OF SRV ON MAIN CONTROL VALVE BLOCK Special tools:

n/a


Oil drain pan

NOTE: For additional information about the SRV on the main control valve blocks, refer to section 3.3.8 on page 3-117. z

Relieve the pressure in the hydraulic system. Refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".

z


z


z

Transfuse the oil from the return manifold into the main oil reservoir. Refer to the Operation & Maintenance Manual, chapter 3, section "FUNCTIONS OF THE TRANSFER PUMP".

Fig. 3-132

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Fig. 3-133 SRV on the main control valve blocks (BHA)

Fig. 3-134 SRV on the main control valve blocks (FSA)

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z

Disconnect the hose from the SRV.

z

Remove the four bolts (Fig. 3-133 or Fig. 3-134, Pos. 1) attaching the SRV to the main control valve block.

z

Remove the SRV (Fig. 3-133 or Fig. 3-134, Pos. 2) and cap the openings with blind plugs to avoid contamination.

z

Remove the O-rings (Fig. 3-135, Pos. 1) and discard them.

NOTE: Carry out the following steps only if required: z

Remove the support rings (Fig. 3-135, Pos. 2) from the valve body (Fig. 3-135, Pos. 4).

z

Remove the pressure relief valve (Fig. 3-135, Pos. 3) from the valve body (Fig. 3-135, Pos. 4). CAUTION

Different SRVs with different pressures are installed. If removing more than one SRV at the same time, mark the SRV and the position where it is installed.

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3.3.9.2 REPLACEMENT OF SRV ON MAIN CONTROL VALVE BLOCKS Special tools:



n/a If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.2 on page 2-33.

NOTE: Ensure that the mating surfaces are clean and free of paint before assembly. z

Fit new O-rings (Fig. 3-135, Pos. 1) to the SRV.

z


NOTE: If the pressure relief valve (Fig. 3-135, Pos. 3) was removed from the valve body (Fig. 3-135, Pos. 4) tighten it to the specified torque: Tightening torque for the built-in SRV: 300 Nm z


z


z

Check and adjust the SRV. Refer to Service Manual.

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3.3.10 ANTI-CAVITATION VALVES (ACV)

Fig. 3-136 Anti cavitation valve (ACV) (1)

ACV housing

(2)

Valve cone

(3)

Spring

(4)

O-ring

(5)

Control leak oil bore

(6)

Cap screw (torque 900 Nm)

(S)

Supply line

(A/B)

Line connections

The anti-cavitation valves (ACV) are installed to avoid cavitation damages on users (hydraulic cylinders) by compensating a lack of oil when the SRV at the opposite side of the cylinder opens. See hydraulic circuit diagram. The circuit pressure in the line (Fig. 3-136, Pos. A/B) hold the valve cone (Fig. 3-136, Pos. 2) closed. The pressure of the supply line (Fig. 3-136, Pos. S) forces onto the valve cone. The valve cone opens, whenever the pressure at the A and B side is lower than the back pressure at return oil port S, to allow necessary oil supply into circuit.

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The ACVs are installed at the attachment manifold and at the main control valve blocks.

3.3.10.1 REMOVAL OF ACV ON MANIFOLD Special tools:

n/a


Crane Oil drain pan Single-anti cavitation valve: 15 kg Double-anti cavitation valve: 44.6 kg



z




z


z


z


Fig. 3-137

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Fig. 3-138 Positions of the ACV at the BHA manifold NOTE: The numbers (Fig.3-138, Pos.140.1 - 140.9) are component numbers for the hydraulic diagram. NOTE: For further information about the ACV at the BHA manifold, refer to the hydraulic diagram and the Service Manual.

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Fig. 3-139 Positions of the ACV at the FSA manifold NOTE: The numbers (Fig.3-139, Pos.140.1 - 140.10) are component numbers for the hydraulic diagram. NOTE: For further information about the ACV at the FSA manifold, refer to the hydraulic diagram and the Service Manual.

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NOTE: In the following steps one ACV of the of the FSA manifold is removed exemplarily. The procedure is identical for all the ACV, except for the valves with other valves attached, so carry out the following four steps only if required: WARNING Hot hydraulic oil! Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is below 50 °C. Disobedience may result in personal injury from heated oil.

z

If required, remove the throttle check valve to gain access to the anti-cavitation valve, refer to section 3.3.11.1 on page 3-152.

If required, remove the non return valve (analogously to throttle check valve removal) to gain access to the anti-cavitation valve, refer to section 3.3.11.1 on page 3-152. z

Remove the four bolts attaching the oil pipe (Fig. 3-140, Pos. 3) to the main control valve block and the four bolts (Fig. 3-140, Pos. 2) at the ACV (Fig. 3-140, Pos. 1) end.

z

Remove the oil pipe and the two flange seals (Fig. 3-140, Pos. 4). Discard the seals.

NOTE: When the pipe is disconnected, the oil inside the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination.

Fig. 3-140

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z

Hydraulics

Disconnect the flex hoses (Fig. 3-141, Pos. 2) and remove the joint (Fig. 3-141, Pos. 3) from the anti-cavitation valve (Fig. 3-141, Pos. 1).

NOTE: When the flex hose is disconnected, the oil inside the hose and the valve will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination

Fig. 3-141 z

Remove the four bolts (Fig. 3-142, Pos. 1) attaching the ACV to the manifold.

z

Remove the ACV (Fig. 3-142, Pos. 2) and the O-ring (Fig. 3-142, Pos. 3). Discard the O-ring.

z

If required, repeat the procedure to remove the other ACV from the manifold.

Fig. 3-142

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3.3.10.2 REPLACEMENT OF THE ACV ON MANIFOLD Special tools:

n/a


Crane Compound "KP2K", PN 324 969 40 Single-anti cavitation valve: 15 kg Double-anti cavitation valve: 44.6 kg



Fit a new O-ring (Fig. 3-143, Pos. 3) to the new ACV (Fig. 3-143, Pos. 2).

z

Apply compound "KP2K", PN 324 969 40 on threads of the mounting bolts (Fig. 3-143, Pos. 1).

z

Align the new ACV to the manifold and insert the mounting bolts.

Fig. 3-143 z


NOTE: Carry out the following four steps only if required: z

If required, install the throttle check valve onto the ACV, refer to section 3.3.11.2 on page 3-155.

z

If required, install the non return valve (analogously to the throttle check valve installation), refer to section 3.3.11.2 on page 3-155.

z

Bleed air from the hydraulic system, refer to the Operation & Maintenance Manual chapter 4, section "HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER" and PARTS & SERVICE NEWS No. "AH01513".

z


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3.3.10.3 REMOVAL OF ACV ON MAIN CONTROL VALVE BLOCKS Special tools:

n/a


Oil drain pan

NOTE: For additional information about the ACV on the main control valve blocks, refer to section 3.3.8 on page 3-117. z


z


z


z


Fig. 3-144

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Fig. 3-145 ACV on the main control valve blocks (BHA)

Fig. 3-146 ACV on the main control valve blocks (FSA) 3 - 146

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NOTE: The numbers (Fig. 3-145 or Fig. 3-146, Pos. 32.1 - 32.24) are component numbers for the hydraulic diagram. NOTE: For further information about the ACV at the main control valve blocks, refer to the hydraulic diagram and the Service Manual. WARNING Hot hydraulic oil! Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is below 50 °C. Disobedience may result in personal injury from heated oil.

z

Remove the four bolts (Fig. 3-145 or Fig. 3-146, Pos. 1) attaching the ACV to the main control valve block.

z

Remove the ACV (Fig. 3-145 or Fig. 3-146, Pos. 2).

NOTE: When the ACV is removed, the oil inside the valves will flow out. Catch it in an oil pan. Cap the openings to avoid contamination. z

Remove the O-rings (Fig. 3-147, Pos. 1) and discard them.

z

Remove the support rings (Fig. 3-147, Pos. 2) from the valve body (Fig. 3-147, Pos. 3) only if required.

Fig. 3-147

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3.3.10.4 REPLACEMENT OF ACV ON MAIN CONTROL VALVE BLOCKS Special tools:

n/a



NOTE: Ensure that the mating surfaces are clean and free of paint before assembly. Fit new O-rings to the ACV (Fig. 3-147, Pos. 1). z


z


z


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3.3.11 THROTTLE CHECK VALVES

Fig. 3-148 Throttle check valve with built-in SRV

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Legend for Fig. 3-148: NOTE: The illustration shows the valve block up side down (1)

Throttle adjustment pin

(2)

Back-up ring

(3)

O-ring

(4)

Retainer

(5)

Back-up ring

(6)

O-ring

(7)

Spring

(8)

Spring cup

(9)

Throttle valve sleeve

(9.1)

Adjustable throttle holes

(9.2)

Permanent throttle holes (safety channel)

(10)

O-ring

(11)

Housing

(12)

Return line port, T

(13)

SRV

(14)

Bolt

(15)

Clip ring

(16)

Lock nut

(A)

Line ports from the control valve

(B)

Line port to the cylinder

(M)

Pressure check point

(Y)

Control oil drain port

The maximum permissible cylinder speed is set by the pin (Fig. 3-148, Pos.1). Depending on the pin setting, the radial holes (Fig. 3-148, Pos. 9.1) in the valve sleeve (Fig. 3-148, Pos. 9) will be opened partially to achieve the required throttling of the oil flow. The safety holes (Fig. 3-148, Pos. 9.2) prevent the valve from becoming completely closed. For the lifting operation the valve sleeve which is guided by the spindle (Fig. 3-148, Pos. 1) is pressed against the spring (Fig. 3-148, Pos. 7) so that the valve will be completely open. The build-in SRV (Fig. 3-148, Pos. 13) limits the maximum system pressure from the cylinder and relieves oil to the tank line when the pressure reaches the valve setting.

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3.3.11.1 REMOVAL OF THROTTLE CHECK VALVES Special tools:

n/a


Crane Oil drain pan Throttle check valve (long version): 31 kg Throttle check valve (short version): 28 kg


Fig. 3-149 Positions of the throttle check valves BHA NOTE: The numbers (Fig. 3-149, Pos. 138.1 - 145.5) are component numbers for the hydraulic diagram. NOTE: For further information about the SRV at the BHA manifold, refer to the hydraulic diagram and the Service Manual.

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Fig. 3-150 Positions of the throttle check valves FSA NOTE: The numbers (Fig. 3-150, Pos. 141.1 - 158) are component numbers for the hydraulic diagram. NOTE: For further information about the SRV at the FSA manifold, refer to the hydraulic diagram and the Service Manual. z


z




z


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z


z

Transfuse the oil from the return manifold into the main oil reservoir, refer to the Operation & Maintenance Manual, chapter 3, section "FUNCTIONS OF THE TRANSFER PUMP". WARNING


z

Disconnect the flex hose (Fig. 3-152, Pos. 5) from the throttle check valve (Fig. 3-152, Pos. 1).

z

Remove the four bolts (Fig. 3-152, Pos. 2) and remove the pipe (Fig. 3-152, Pos. 3) from the throttle check valve (Fig. 3-152, Pos. 1).

Fig. 3-151

NOTE: When the hydraulic lines are removed, the oil inside the piping and the valve will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination.

Fig. 3-152 z

Remove the four bolts (Fig. 3-153, Pos. 5) attaching the throttle check valve (Fig. 3-153, Pos. 1) to the manifold (Fig. 3-153, Pos. 2).

z

Remove the throttle check valve (Fig. 3-153, Pos. 1) and the O-ring (Fig. 3-153, Pos. 3). Discard the O-ring.

NOTE: When the throttle check valve is removed, the oil inside the valve and the manifold will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

If required, remove the adaptor (Fig. 3-153, Pos. 4) from the throttle check valve. Fig. 3-153

z

If required, repeat the procedure to remove the other throttle check valves from the manifold.

z

If required, remove the built-in SRV (Fig. 3-148, Pos. 13) from the throttle check valve’s housing (Fig. 3-148, Pos. 11).

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3.3.11.2 REPLACEMENT OF THROTTLE CHECK VALVES Special tools:

n/a


Crane Compound "KP2K", PN 324 969 40 Throttle check valve (long version): 31 kg Throttle check valve (short version): 28 kg

Dogman/rigger If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.2 on page 2-33. NOTE: Ensure that the mating surfaces are clean and free of paint before assembly. Fit a new O-ring (Fig. 3-153, Pos. 3) to the throttle check valve (Fig. 3-153, Pos. 1). z


NOTE: If the built-in SRV (Fig. 3-148, Pos. 13) has been removed from the housing (Fig. 3-148, Pos. 11), tighten it to the specified tightening torque: Tightening torque for the built-in SRV: 300 Nm NOTE: Apply compound "KP2K", PN 324 969 40 on heads and threads of the throttle check valve mounting bolts (Fig. 3-153, Pos. 5). z

Bleed air from the hydraulic system, refer to the Operation & Maintenance Manual, section 4.13.

z


z

Check and adjust the throttle check valve. Refer to the Service Manual, section 8.1.11.

z

Check and adjust the built-in SRV in the throttle check valves if required. Refer to the Service Manual, section 8.1.10.

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3.3.12 MANIFOLD 3.3.12.1 REMOVAL OF THE MANIFOLD Special tools:

n/a


Safety harness in conformity with DIN EN 361 Crane Oil drain pan Manifold BHA incl. ACVs and SRVs: 921.2 kg Manifold FSA incl. ACVs and SRVs: 893.2 kg



z




z


z


z


Fig. 3-154

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z

Disconnect all hydraulic hoses (Fig. 3-155, Pos. 1) leading to the attachment, refer to section 5.1.6.1 on page 5-58 (BHA) or refer to section 5.2.6.1 on page 5-134 (FSA). WARNING

Always wear a safety harness when working at the front side of the manifold.

z

Disconnect the hydraulic piping (Fig. 3-155, Pos. 2) at the front of the manifold.

NOTE: When the hydraulic lines are removed, the oil inside the hydraulic lines will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Sling the manifold.

z

Remove four mounting bolts (Fig. 3-155, Pos. 3).

z

Remove the manifold using a crane.

z

Remove the anti cavitation valves (ACV) from the manifold, refer to section 3.3.10.1 on page 3-139.

z

Remove the throttle check valves from the manifold, refer to section 3.3.11.1 on page 3-152.

Fig. 3-155

DANGER Risk of falling weights! May result in death or serious injury When removing the manifold, make sure that nobody steps below the weight.

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3.3.12.2 REPLACEMENT OF THE MANIFOLD Special tools:

n/a


Safety harness in conformity with DIN EN 361 Crane Compound "KP2K", PN 324 969 40 Manifold BHA incl. ACVs and SRVs: 921.2 kg Manifold FSA incl. ACVs and SRVs: 893.2 kg

Dogman/rigger If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.2 on page 2-33. NOTE: Ensure that the mating surfaces are clean and free of paint before assembly. Fit new O-rings to the SAE-flanges. Apply compound "KP2K", PN 324 969 40 on heads and threads of the manifold mounting bolts (Fig. 3-155, Pos. 3) and tighten them to the specified tightening torque. WARNING Always wear a safety harness when working at the front side of the manifold.

z


z


z


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3.4

Slew drive

SLEW DRIVE

Fig. 3-156 The PC5500-6 is equipped with two slew gear arrangements. For further information, refer to the Service Manual. Multi disc brakes (Fig. 3-156, Pos. 3) are installed between the swing motors (Fig. 3-156, Pos. 2) and the gear boxes (Fig. 3-156, Pos. 4). These brakes are safety brakes, applied by spring force and released by oil pressure. To operate the rotary motion, slew brake valves (Fig. 3-156, Pos. 1) are directly flanged to the swing motor heads. For further information, refer to the Service Manual.

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3.4.1

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SLEW GEAR

Fig. 3-157 Slew gear unit (Siebenhaar) NOTE: The machine can be equipped either with a slew gear of manufacturer "L&S" or of manufacturer "Siebenhaar". The Removal and the Replacement of the slew gear by different manufacturer are analogously the same. Refer to the data plate on each slew gear housing to find out the manufacturer of the slew gear. 3 - 160

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Superstructure

Slew drive

3.4.1.1 REMOVAL OF THE SLEW GEAR Special tools:

n/a


Crane 4 x swivel hoist rings: M16 Swing motor with attached slew service brake valve: 292.5 Slew gear (Siebenhaar): 1700 kg Slew gear (L&S): 1880 kg Dogman/rigger For further information about the needed blind plugs, refer to section 2.3 on page 2-37.

z


z




z


z


z

Transfuse the oil from the return manifold into the main oil reservoir, refer to the Operation & Maintenance Manual, chapter 3, section "FUNCTION OF THE TRANSFER PUMP".

Fig. 3-158 z

Remove the swing motor (Fig. 3-157, Pos. 2) from the slew gearbox (Fig. 3-157, Pos. 3), refer to section 3.4.2.1 on page 3-169. Leave the hydraulic hoses and the slew service brake valve (Fig. 3-157, Pos. 1) attached to the swing motor if possible. If not disconnect the hydraulic lines.

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z

Disconnect the oil pressure line from the slew parking brake.

NOTE: When the hydraulic lines are disconnected, the oil inside the lines will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Removing the rear slew gear, the hydraulic line (Fig. 3-159, Pos. 2) and the mounting (Fig. 3-159, Pos. 1) for hydraulic hoses have to be removed.

NOTE: When the hydraulic line is disconnected, the oil inside the line will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination.

Fig. 3-159

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Fig. 3-160 Slew gear (Siebenhaar) z

Remove the protection caps (Fig. 3-160, Pos. 1) from the bolt heads and remove the slew gear mounting bolts (Fig. 3-160, Pos. 2) and washers (Fig. 3-160, Pos. 3). Discard the bolts.

z

Disconnect the lubrication lines below the slew gear.

z

Install four swivel hoist rings (M16) displaced by 90° into the threaded bores for the swing motor mounting bolts and attach a crane.

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z

Superstructure

Remove the slew gear (Fig. 3-160, Pos. 4) using a crane. DANGER

Risk of falling weights! May result in death or serious injury When removing the slew gear, make sure that nobody steps below the weight.

z

Remove the bleeder valves (Fig. 3-161, Pos. 1) Drain the gear oil from the slew gear (Fig. 3-161, Pos. 3 respectively Pos. 5) at the drain coupling (Fig. 3-161, Pos. 2), • approx 60 liters (Siebenhaar), • approx. 42 liters (L&S), refer to the Operation & Maintenance Manual, chapter 4, section "SWING GEARS AND MOTOR ADAPTER HOUSING - CHANGE OIL"

z

Remove the oil drain coupling (Fig. 3-161, Pos. 2) and if equipped with remove the union (Fig. 3-161, Pos. 4) from the slew gear (Fig. 3-161, Pos. 3 respectively Pos. 5).

Fig. 3-161

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3.4.1.2 REPLACEMENT OF THE SLEW GEAR Special tools:

Feeler gauge (customary)


Crane 4 x swivel hoist rings: M16 Compound "KP2K", PN 324 969 40 Swing motor with attached slew service brake valve: 292.5 Slew gear (Siebenhaar): 1700 kg Slew gear (L&S): 1880 kg Dogman/rigger If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.2 on page 2-33.

WARNING New slew gears are delivered without gear oil.

NOTE: The machine can be equipped either with a slew gear of manufacturer "Siebenhaar" or of manufacturer "L&S". Refer to the data plate on each slew gear housing to find out the manufacturer of the slew gear. Both slew gears are replaceable using of a special modification kit. Refer to PARTS & SERVICE NEWS No. "AH05535". NOTE: Ensure that the mating surfaces are clean and free of paint before assembly. z

Install the oil drain coupling (Fig. 3-162, Pos. 2) with the union (Fig. 3-162, Pos. 4) if equipped, at the new slew gear (Fig. 3-162, Pos. 3 respectively Pos. 5).

z

Clean the bleeder valves (Fig. 3-162, Pos. 1) with compressed air from inside to outside and reinstall at the new slew gear (Fig. 3-162, Pos. 3 respectively Pos. 5).

Fig. 3-162

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Fig. 3-163 Slew gear unit (Siebenhaar)

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z


z

Insert the new slew gear (Fig. 3-163, Pos. 3) and mount it to the superstructure with the mounting bolts (Fig. 3-163, Pos. 1) and the washers (Fig. 3-163, Pos. 2).

NOTE: Use new slew gear mounting bolts (Fig. 3-163, Pos. 1) of grade 12.9. Apply compound "KP2K", PN 324 969 40 on heads and threads of the mounting bolts and tighten them to the specified tightening torque.. Tightening torque for the slew gear mounting bolts: 1030 Nm z

Connect the lubrication lines.

z

Carry out further installation in reverse order to removal. WARNING

Make sure to use the specified bolts and tightening torque for the swing motor mounting bolts, refer to section 3.4.2.2 on page 3-172.

Fill gear oil into the slew gear, • approx. 60 liters (Siebenhaar), • approx. 42 liters (L&S). Fill oil into the motor adapter housing, • approx. 0.6 liters (L&S), • up to level gauge marking (Siebenhaar). Fill oil into the brake housing (Siebenhaar only), approx. 0.2 liters. Refer to the Operation & Maintenance Manual, chapter 4, section "SWING GEARS AND MOTOR ADAPTER HOUSING - CHANGE OIL". For the proper lubricant, refer to section 6.1 on page 6-2. z

Check the tooth backlash between slew ring and slew pinion with a feeler gauge. Refer to PARTS & SERVICE NEWS No. "AH00511".

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3.4.2

Superstructure

SWING MOTOR

Fig. 3-164 Swing motor assembly (1)

Bolt

(12)

Bolt (only Siebenhaar)

(2)

Slew brake valve

(13)

Washer (only Siebenhaar)

(3)

O-ring

(14)

Expansion tank of the slew gear (only Siebenhaar)

(4)

Bolt

(15)

Sleeve (only Siebenhaar)

(5)

Intermediate plate

(6)

O-ring

(7)

Bolt

(8)

Washer

(9)

Swing motor

(10)

O-ring

(11)

Slew gear

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3.4.2.1 REMOVAL OF THE SWING MOTOR Special tools:

n/a


Crane Oil drain pan Swing motor: 170 kg



z




z


z


z


Fig. 3-165 WARNING Hot hydraulic oil! Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is below 50 °C. Disobedience may result in personal injury from heated oil.

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Drain gear oil from the motor adapter housing. Refer to the Operation & Maintenance Manual, chapter 4, section "SWING GEARS AND MOTOR ADAPTER HOUSING - CHANGE OIL" z

Disconnect all hydraulic hoses (Fig. 3-166, Pos. 1), attached to the swing motor (Fig. 3-166, Pos. 2).

NOTE: When the hydraulic hoses are disconnected, hydraulic oil from inside the hoses and the swing motor will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination.

Fig. 3-166

Fig. 3-167 Removal of the swing motor

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z

Slew drive

Remove the four mounting bolts (Fig. 3-167, Pos. 1) and take the slew brake valve (Fig. 3-167, Pos. 2) off. Discard the O-ring (Fig. 3-167, Pos. 3). For further information, refer to section 3.4.4.1 on page 3-193.

NOTE: The hydraulic hoses remain at the slew brake valve. When the slew brake valve is removed, the oil inside the valve will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Remove the mounting bolts (Fig. 3-167, Pos. 4) and take off the intermediate plate (Fig. 3-167, Pos. 5). Discard the O-ring (Fig. 3-167, Pos. 6).

z

Only slew gear (Siebenhaar): Remove the bolts (Fig. 3-167, Pos. 12), with washers (Fig. 3-167, Pos. 13), and the sleeves (Fig. 3-167,Pos. 15). Put the expansion tank (Fig. 3-167, Pos. 14) of the slew gear aside. Discard the bolts.

z

Remove the bolts (Fig. 3-167, Pos. 7) and the washers (Fig. 3-167, Pos. 8). Discard the bolts.

z

Sling the swing motor (Fig. 3-167, Pos. 9).

z

Pull the swing motor out of the slew gear (Fig. 3-167, Pos. 11) using a crane. Place the swing motor on the ground.

z

Discard the O-ring (Fig. 3-167, Pos. 10). DANGER

Risk of falling weights! May result in death or serious injury When removing the swing motor, make sure that nobody steps below the weight.

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3.4.2.2 REPLACEMENT OF THE SWING MOTOR Special tools:



Crane Paste "Optimol White" PN 999 039 Compound "KP2K", PN 324 969 40 Swing motor: 170 kg


Fig. 3-168 Installation of the swing motor

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NOTE: Ensure that the mating surfaces are clean and free of paint before assembly. Fit new O-rings (Fig. 3-168, Pos. 3, Pos. 6 and Pos. 10). z

Apply "Optimol White" to the spline shaft of the motor.

z


NOTE: Use new swing motor mounting bolts (Fig. 3-168, Pos. 7 and 12) of grade 10.9. Apply compound "KP2K", PN 324 969 40 on heads and threads of the bolts and tighten them to the specified torque. Tightening torque for the swing motor mounting bolts: 265 Nm z


z

Add hydraulic oil up to the specified level. Fill oil into the motor adapter housing, • approx. 0.6 liters (L&S), • up to level gauge marking (Siebenhaar). Refer to the Operation & Maintenance Manual, chapter 4, section "SWING GEARS AND MOTOR ADAPTER HOUSING - CHANGE OIL". For the proper lubricant, refer to section 6.1 on page 6-2.

z

Check the adjustments of the swing motors. Refer to the Service Manual for further information.

z

Check the slew brake valve and adjust it if required. Refer to the Service Manual for further information.

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3.4.3

Superstructure

SLEW PARKING BRAKE

NOTE: The machine can be equipped either with a slew parking brake of manufacturer "Siebenhaar" or of manufacturer "L&S". For the removal and the replacement, the "L&S" slew parking brake has to be disassembled/assembled. The "Siebenhaar" slew parking brake assembly can be exchanged completely.

Slew parking brake (L&S) (1)

Disc housing

(10)

Thrust washer

(2)

Thrust washer

(11)

Circlip

(3)

Inner discs

(12)

Drive shaft

(4)

Outer discs

(13)

Oil pressure port

(5)

Sinus spacer ring

(14)

Bolt

(6)

Piston

(15)

Bearing ring

(7)

Quad ring with back up ring

(16)

Rotary shaft seal

(8)

Quad ring with back up ring

(17)

Cylinder assembly

(9)

Springs

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General: Brake applied: The outer disks engaged to the housing by serration and the inner disks in serrated connection with the drive shaft are pressed together by the springs. This results in a fixed connection between housing and drive shaft due to the friction between the spring pressurized discs. Brake released: Oil pressure via the pilot port reaches the bottom of the piston and forces the piston upwards against the thrust washer and the spring force. This eliminates the spring force towards the disks so that the friction between the discs is released and the inner shaft can rotate. Only the brake of the L&S gear box uses an additional spacer ring (sinus ring) to keep the discs apart. It should reduce the friction in released condition. The minimum release pressure is 19 - 20 bar. In normal working conditions, the releasing pressure is about 60 bar. NOTE: The slew parking brake must only be applied with the superstructure at a complete standstill. Applying the parking brake with superstructure still slewing may result in severe damage to the brake. WARNING z

Only use the slew parking brake in emergency situations to stop the rotating superstructure.

z

If the parking brake has been used for an emergency stop, it is necessary to shut down the excavator and to have the parking brake of each swing gear inspected and repaired if necessary. Contact your Komatsu dealer for repairing the brakes.

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3.4.3.1 REMOVAL/DISASSEMBLY OF THE SLEW PARKING BRAKE (L&S) Special tools:

n/a


Crane 4 x swivel hoist rings: M16 Swing motor with attached slew service brake valve: 267 kg Bearing ring: 32 kg

Dogman/rigger

NOTE: The slew parking brake is attached to the slew gear with eight hexagon socket bolts. It is removed by disassembling it. z

Remove the swing motor from the slew gear, refer to section 3.4.2.1 on page 3-169. Leave the hydraulic hoses and the slew service brake valve attached to the swing motor.

NOTE: For further information relating the parking brake, refer to PARTS & SERVICE NEWS No. "AH03509". z


z

Remove the mounting bolts (Fig. 3-169, Pos. 1) at the swing motor flange.

z

Remove the inner snap ring (Fig. 3-169, Pos. 2).

z

Dismantle the bearing ring (Fig. 3-169, Pos. 3) from the slew gearbox using a crane.

Fig. 3-169

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Fig. 3-170 Slew parking brake (L&S) z

Check rotary shaft seal (Fig. 3-170, Pos. 16) for wear and damage. Replace it if required.

z

Disconnect the pressure hose from the oil pressure port (Fig. 3-170, Pos. 13).

NOTE: When the pressure hose is removed, the oil inside the hose and the cylinder (Fig. 3-170, Pos. 17) will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. WARNING The piston (Fig. 3-170, Pos. 6) of the break assembly is spring loaded.

z

Remove the two socket head cap bolts (Fig. 3-170, Pos. 14) and relieve the spring load of the springs (Fig. 3-170, Pos. 9) on the piston (Fig. 3-170, Pos. 6).

z

Take off the cylinder assembly (Fig. 3-170, Pos. 17).

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z

Dismount 10 inner discs (Fig. 3-170, Pos. 3), 11 outer discs (Fig. 3-170, Pos. 4), and 10 sinus spacer rings (Fig. 3-170, Pos. 5) from the disc housing (Fig. 3-170, Pos. 1).

z

Remove the drive shaft (Fig. 3-170, Pos. 12).

z

Remove the thrust washer (Fig. 3-170, Pos. 2) from the disc housing (Fig. 3-170, Pos. 1).

z

Check the inner discs (Fig. 3-170, Pos. 3), the outer discs (Fig. 3-170, Pos. 4), the sinus spacer rings (Fig. 3-170, Pos. 5), and the thrust washer (Fig. 3-170, Pos. 2) for wear and damage. Replace if required.

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3.4.3.2 REPLACEMENT/ASSEMBLY OF THE SLEW PARKING BRAKE (L&S) Special tools:

n/a


Crane Paste "Optimol White" PN 999 039 Hydraulic power unit (60 bar) with fitting (M18 x 1.5) Swing motor with attached slew service brake valve: 267 kg Bearing ring: 32 kg


Fig. 3-171 Slew parking brake (L&S)

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NOTE: Replace all O-rings. For further information relating the parking brake, refer to PARTS & SERVICE NEWS No. "AH03509". z

Install the thrust washer (Fig. 3-171, Pos. 2).

z

Install the drive shaft (Fig. 3-171, Pos. 12).

NOTE: Apply "Optimol White" to the spline shaft. z

Install new discs according to the following order: At first an outer disc (Fig. 3-171, Pos. 4), then an inner disc (Fig. 3-171, Pos. 3), and then a sinus spacer ring (Fig. 3-171, Pos. 5). Apply oil to the discs.

NOTE: Before reinstallation, apply pressure (max. 60 bar) to the cylinder assembly (Fig. 3-171, Pos. 17), otherwise the two socket head cap bolts (Fig. 3-171, Pos. 14) are prestressed (spring loaded). z

Install the cylinder assembly (Fig. 3-171, Pos. 17).

z


Make sure to use the specified bolts and torque for the swing motor mounting bolts, refer to section 3.4.2.2 on page 3-172.

Fill oil into the motor adapter housing, approx. 0.6 liters. Refer to the Operation & Maintenance Manual, chapter 4, section "SWING GEARS AND MOTOR ADAPTER HOUSING - CHANGE OIL". For the proper lubricant, refer to section 6.1 on page 6-2. z


z

Check slew parking brake for proper function. Refer to the Service Manual.

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3.4.3.3 REMOVAL OF THE SLEW PARKING BRAKE (SIEBENHAAR) Special tools:

n/a


Crane 2 x swivel hoist rings: M16 Swing motor with attached slew service brake valve: 267 kg Slew parking brake assembly: 115 kg

Dogman/rigger For further information about the needed blind plugs, refer to section 2.3 on page 2-37. NOTE: There can be two different types of "Siebenhaar" slew parking brake assemblies installed at the machines (depending on gear type): Old type: PN 925 864 40 New type: PN 936 540 40 If an old type is installed, it is recommended by KOMATSU to rebuild the brake assembly according to the PARTS & SERVICE NEWS No. "AH07509". Only the removal of the "new type" slew parking brake is described below. z

Remove the swing motor from the slew parking brake, refer to section 3.4.2.1 on page 3-169. Leave the hydraulic hoses and the slew service brake valve (Fig. 3-157, Pos. 1) attached to the swing motor. Drain oil of the brake housing, approx. 0.2 liters. Refer to the Operation & Maintenance Manual, chapter 4, section "SWING GEARS AND MOTOR ADAPTER HOUSING - CHANGE OIL".

NOTE: After draining the oil of the brake housing, cap the openings with blind plugs to avoid contamination. DANGER Danger of hydraulic pressure! Blindness, serious injury, permanent disfigurement, or scaring may result. The hydraulic system may be pressurized. Make sure that the pressure is relieved before any hydraulic line will be removed.

z

Disconnect the pilot oil pressure line from the slew parking brake.

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NOTE: When the pilot oil pressure line is disconnected, the oil inside the line will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Remove all hydraulic pipes (Fig. 3-172, Pos. 3) from the slew parking brake (Fig. 3-172, Pos.23) and cap the openings with blind plugs to avoid contamination. DANGER

Danger of parts blasting off! Serious injury, permanent disfigurement and scarring, or death may result! The piston of the slew parking break assembly is spring loaded. It is necessary to release the brake manually (see following procedure) before removing the mounting bolts (Fig. 3-172, Pos. 1) attaching the complete slew parking brake (Fig. 3-172, Pos. 2) to the slew gear box (Fig. 3-172, Pos. 4). Never open the brake by removing the flange mounting bolts (Fig. 3-173, Pos. 3) before the slew parking brake is manually released!

Fig. 3-172

Fig. 3-173 Slew parking brake (Siebenhaar), drawn released

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Releasing the slew parking brake manually: z

Insert two crews (Fig. 3-174, Pos. 1) of suitable length with nuts (Fig. 3-174, Pos. 3) in the threaded borings (Fig. 3-173, Pos. 2) of the piston (Fig. 3-174, Pos. 2) opposed to each other.

z

Tighten each nut (Fig. 3-174, Pos. 3) alternately with a half turn, to withdraw the piston Fig. 3-174, Pos. 2) to the flange (Fig. 3-174, Pos. 4).

NOTE: Avoid tilting the piston! z

Only remove the mounting bolts (Fig. 3-172 and 3-173, Pos. 1) attaching the complete slew parking brake (Fig. 3-174, Pos. 2) to the slew gearbox.

Fig. 3-174

DANGER Danger of parts blasting off! Serious injury, permanent disfigurement and scarring, or death may result! The piston of the slew parking break assembly is spring loaded. Never open the brake by removing the flange mounting bolts (Fig. 3-173, Pos. 3) before the slew parking brake is manually released!

z

Insert swivel hoist rings (M16) displaced by 180° into the threads of the swing motor mounting bolts and attach a crane.

z

Remove the slew parking brake (Fig. 3-172, Pos. 2) from the slew gearbox (Fig. 3-172, Pos. 4), using a crane. DANGER


z


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3.4.3.4 REPLACEMENT OF THE SLEW PARKING BRAKE (SIEBENHAAR) Special tools:

n/a


Crane 2 x swivel hoist rings: M16 Swing motor with attached slew service brake valve: 267 kg Slew parking brake assembly: 115 kg

Dogman/rigger If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.2 on page 2-33. NOTE: There can be two different types of "Siebenhaar" slew parking brake assemblies installed at the machines (depending on gear type): Old type: PN 925 864 40 New type: PN 936 540 40 If an old type is installed, it is recommended by KOMATSU to rebuild the brake assembly according to the PARTS & SERVICE NEWS No. "AH07509". Only the replacement of the "new type" slew parking brake is described below.

Fig. 3-175 Slew parking brake (Siebenhaar) , drawn released 3 - 186

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DANGER Danger of parts blasting off! Serious injury, permanent disfigurement and scarring, or death may result! The piston of the slew parking break assembly is spring loaded. Never open the brake by removing the flange mounting bolts (Fig. 3-175, Pos. 3) before the slew parking brake is manually released!


Apply paste "Optimol White" on the spline shaft at the adapter cover (Fig. 3-176, Pos. 4) of the gearbox.

z

Install swivel hoist rings (M16) on the new pre-assembled slew parking brake, displaced by 180° into the threads of the swing motor mounting bolts and attach the brake assembly to a crane.

z

Insert a new O-Ring (Fig. 3-176, Pos. 3).

z

Centre the new pre-assembled slew parking brake (Fig. 3-176, Pos. 2) onto the adapter cover (Fig. 3-176, Pos. 4) of the gearbox. DANGER

Fig. 3-176


Releasing the slew parking brake manually: z

Insert two bolts (Fig. 3-177, Pos. 1) of suitable length with nuts (Fig. 3-177, Pos. 3) in the threaded borings (Fig. 3-175, Pos. 2) of the piston (Fig. 3-177, Pos. 2) opposed to each other.

z

Tighten each nut (Fig. 3-177, Pos. 3) alternately with a half turn, to withdraw the piston Fig. 3-177, Pos. 2) to the flange (Fig. 3-177, Pos. 4).

NOTE: Avoid tilting the piston! z

Turn the slew parking brake (Fig. 3-176, Pos. 2) until the bores in slew parking brake are aligned to threads in the adapter cover (Fig. 3-176, Pos. 3).

z

Insert new mounting bolts (Fig. 3-176, Pos. 1) and tighten them crosswise.

z

Remove the release bolts (Fig. 3-177, Pos. 1) with nuts alternately stepwise to prevent the piston from tilting.

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Fig. 3-177

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z

Superstructure


Make sure to use the specified bolts and torques for the swing motor mounting bolts, refer to section 3.4.2.2 on page 3-172.

Fill oil into the motor adapter housing, up to level gauge marking. Fill oil in the brake housing approx. 0.2 liters. Refer to the Operation & Maintenance Manual, chapter 4, section "SWING GEARS AND MOTOR ADAPTER HOUSING - CHANGE OIL". For the proper lubricant, refer to section 6.1 on page 6-2. z


z

Check slew parking brake for proper function. Refer to the Service Manual.

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3.4.4

Superstructure

DYNAMIC SLEW BRAKE

Fig. 3-178 Slew brake valve

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Pressure increasing valve

(2)

Check valve circuit A

(3)

Check valve circuit B

(4)

Anti-cavitation valve circuit B (check valve)

(5)

Anti cavitation valve circuit A (check valve)

(6)

Jet bore of main relief valve spool

(7)

Spring of main relief valve spool

(8)

Jet bore pilot relief valve

(9)

Valve cone of pilot relief valve

(10)

Spring of pilot relief valve

(11)

Intermediate pin

(12)

Control piston for pressure increase

(13)

Main relief valve spool

(X)

Pilot control port for pressure increase

(Y)

Leak oil, pilot valve drain

(T)

Return oil to tank / reservoir

(A)

Service line from main control valve block

(A’)

Service line to the motor

(B)

Service line from main control valve block

(B’)

Service line to the motor

(MA)

Check point circuit A

(MB)

Check point circuit B

When ever a swing motion is carried out or the foot brake is used, pilot pressure is present at port X of the pressure increase valve (Fig. 3-178, Pos. 1). The pilot pressure preloads the relief valve. The oil for the hydraulic motor from the main control valve block feeds the service line port A or B depending of the slew direction left or right. The ports A and B are internally connected to the ports A’ and B’ and these ports in turn with the hydraulic motor. The operating pressure at either port A or B closes the anti-cavitation valves (Fig. 3-178, Pos. 4 and 5) and opens the check valves (Fig. 3-178, Pos. 2 and 3). That means the service lines are connected to the pressure increase valve by the check valves (Fig. 3-178, Pos. 2 and 3). When ever the pressure is higher than the setting of the pressure increase valve, the valve opens and dumps oil into the return line T to the reservoir. If the superstructure is slewing by dynamical momentum, the motor is driven by the slew gear and acts as a pump. The pressure in the service lines to the motor changes.

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The low pressure return line becomes pressurized and the pressurized service line changes to suction line. The service line is closed at the main control valve block so the oil can only circulate through the brake valve block’s pressure increase valve.

Fig. 3-179 Pressure increase valve Whenever a swinging motion is carried out or the foot brake is used, pilot pressure is present at port X of the pressure increasing valve. The pilot pressure preloads the relief valve. By applying pilot pressure via the external port X to piston (Fig. 3-179, Pos. 12), the pretension of the spring (Fig. 3-179, Pos. 10) is increased by the amount of the piston stroke S which results in a higher pressure setting for the pilot valve. The system pressure is present at the main piston (Fig. 3-179, Pos. 13) and via the jet bore (Fig. 3-179, Pos. 6) in the chamber of the spring (Fig. 3-179, Pos. 7) as well. System pressure also is present at the pressure relief valve cone (Fig. 3-179, Pos. 9) via the jet bore (Fig. 3-179, Pos. 8). Due to the force balance, the piston (Fig. 3-179, Pos. 13) is kept in its position, supported by the spring (Fig. 3-179, Pos. 7). If the system pressure is higher than the setting of the valve (Fig. 3-179, Pos. 9) the valve opens a channel to the drain port Y. Due to the drop of pressure, the piston (Fig. 3-179, Pos. 13) is moved by the spring (Fig. 3-179, Pos. 7). The pressure line is connected to the return line T. Dampened opening and closing is obtained by the throttled volumetric change that is caused by the jet bores.

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3.4.4.1 REMOVAL OF THE SLEW BRAKE VALVE Special tools:

n/a


Crane Slew brake valve: 97 kg



z




z


z


z


Fig. 3-180

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Superstructure


z

Disconnect the service hoses (Fig. 3-181, Pos. 2), the return hose (Fig. 3-181, Pos. 3), the leak oil hose (Fig. 3-181, Pos. 4), and the pilot hose (Fig. 3-181, Pos. 5) from the slew brake valve (Fig. 3-181, Pos. 6).

NOTE: When the hydraulic hoses are removed, hydraulic oil from inside the valve and the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Sling the slew brake valve (Fig. 3-181, Pos. 6).

z

Remove the four mounting bolts (Fig. 3-181, Pos. 1) and demount the slew brake valve (Fig. 3-181, Pos. 6) from the swing motor (Fig. 3-181, Pos. 7), using a crane.

Fig. 3-181

DANGER Risk of falling weights! May result in death or serious injury When removing the slew brake valve, make sure that nobody steps below the weight.

z

Discard the O-ring from below the slew brake valve (Fig. 3-181, Pos. 6).

NOTE: When the slew brake valve is removed, hydraulic oil from inside the valve will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination.

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3.4.4.2 REPLACEMENT OF THE SLEW BRAKE VALVE Special tools:



n/a Slew brake valve: 97 kg

Dogman/rigger If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.2 on page 2-33. NOTE: Ensure that the mating surfaces are clean and free of paint before assembly. Fit new O-rings below the slew brake valve and the SAEflanges. z


z


z


z

Check and adjust the slew brake valve. Refer to the Service Manual.

z

Check dynamic slew brake for proper function. Refer to the Service Manual.

Version 2009/2

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3 - 195

Slew drive

3.4.5

Superstructure

SWING CIRCLE LUBRICATION PINION (DUMMY WHEEL)

Fig. 3-182 Slew ring lubrication

3 - 196

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Superstructure

Slew drive


Lubrication pump station (SLS)

(2)

Lubricant supply line from pump to injector

(3)

Injectors

(4)

End line pressure switch

(5)

Lubricant feed line from injector to lubrication pinion

(6)

Lubrication pinion

(7)

Slew ring

(8)

Lubrication pinion

(9)

Lubricant outlet

(10)

Lubrication pinion center shaft with distributing drillings

The Swing circle lubrication system (SLS) lubricates the open gear of the outer slew ring with special open gear lubricant. The lubricant pump station (Fig. 3-182, Pos. 1) is identical with the central lubrication system (CLS), refer to section 3.5 on page 3-212. To apply the lubricant equably to the outer slew ring teeth (Fig. 3-182, Pos. 7), a special lubrication pinion (Fig. 3-182, Pos. 8) is mounted near the drive pinion of the front slew gear. The lubrication pinion (Fig. 3-182, Pos. 8) distributes the lubricant from the injectors (Fig. 3-182, Pos. 3) evenly to the teeth. Normally two or more small SL1 injectors (Fig. 3-182, Pos. 3) are parallel connected to supply the required amount of lubricant to the lubrication pinion. NOTE: The pinion center shaft (Fig. 3-182, Pos. 10) acts as a rotary joint and distributes lubricant through radial drillings only to the teeth, witch are in contact with the outer slew ring gear teeth. Outlet bores (Fig. 3-182, Pos. 9 on different position of the pinion gear distribute the lubricant equably to the outer slew ring teeth (Fig. 3-182, Pos. 7).

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3.4.5.1 REMOVAL OF THE LUBRICATION PINION ASSEMBLY Special tools:

n/a


Safety harness in conformity with DIN EN 361 Mobile elevator working platform Pinion cover: 11.6 kg Lubrication pinion assembly: 18.2 kg

z

Prepare an area of flat ground large enough to accommodate the machine, boom, and mobile working platform.

z

Park the machine on the prepared flat ground area with the lubrication pinion placed between the crawler carriers, so that the lubrication pinion can be accessed by a mobile working platform.



Before maintenance, stop the engine and remove ignition key in order to prevent operation of the lubrication system. Assure that the system pressure of the lubrication system is relieved before maintenance.

z

Relieve system pressure of the lubrication system by actuating the vent valve (Fig. 3-195, Pos. 2) by hand, refer to PARTS & SERVICE NEWS No. "AH05546". WARNING

Always wear a safety harness when working at the lubrication pinion.

NOTE: A second person is required for the work at the lubrication pinion.

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Slew drive

Fig. 3-183 Lubrication pinion assembly, removal and replacement z

Remove the mounting bolts (Fig. 3-183, Pos. 6) with sleeves (Fig. 3-183, Pos. 7) and remove the pinion cover (Fig. 3-183, Pos. 1).

NOTE: A second person is required for this work. z

Disconnect the lubrication lines (Fig. 3-183, Pos. 4).

z

Remove the nuts (Fig. 3-183, Pos. 5) and take the lubrication pinion assembly (Fig. 3-183, Pos. 3) with connector plate (Fig. 3-183, Pos. 2) off the superstructure.

NOTE: A second person is required for this work.

Version 2009/2

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Slew drive

Superstructure

3.4.5.2 REPLACEMENT OF THE LUBRICATION PINION ASSEMBLY Special tools:

n/a


Safety harness in conformity with DIN EN 361 Mobile elevator working platform Pinion cover: 11.6 kg Lubrication pinion assembly: 18.2 kg If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.2 on page 2-33.

WARNING Always wear a safety harness when working at the lubrication pinion.

z


NOTE: A second person is required for this work. z

After installation is complete, the swing circle lubrication system has to be activated manually, refer to the Operation & Maintenance Manual, chapter 3, section "SWING CIRCLE PINION LUBRICATION SYSTEM SLS”. Activate the switch S26 at the dash board until the correct pressure is reached.

z

Reset the lubrication cycle counter of the slew ring lubrication system. Refer to the Operation & Maintenance Manual, chapter 3, section "SWING CIRCLE PINION LUBRICATION SYSTEM SLS”.

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Version 2009/2

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3 - 201

Slew drive

3.4.6

Superstructure

SWING CIRCLE

Fig. 3-184 Slew ring assembly

3 - 202

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Version 2009/2

Superstructure

Slew drive


Superstructure

(2)

Swing circle

(3)

Bolt

(4)

Washer

(5)

Swing circle protection covers

(6)

Washer

(7)

Bolt

(8)

Car body

(9)

Bolt

(10)

Resilient sleeve

The swing circle is the movable connection between the superstructure and the car body. The swing circle bearing is connected to the central lubrication system. The outer ring gear is lubricated by an own lubrication system SLS which uses a special open gear lubricant. NOTE: For wear limits, refer to PARTS & SERVICE NEWS No. "AH02513". For additional information, refer to PARTS & SERVICE NEWS No. "AH00511" last edition.

3.4.6.1 REMOVAL OF THE SWING CIRCLE

Special tools:

Mounting cross, PN 477 577 40 Hydraulic torque wrench, PN 232 615 40 Electro-hydraulic pump set, PN 232 613 40 55 mm hexagon impact socket wrench, PN 232 267 40


2 x Crane (2nd. crane for superstructure lifting) Swing circle: 10,000 kg

Dogman/rigger

z

Prepare an area of flat ground large enough to accommodate the machine, boom, and two cranes.

z


NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. Version 2009/2

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3 - 203

Slew drive

Superstructure

z


z

Remove the superstructure from the car body (counterweight, fluids and attachment removed), refer to section 3.9.1 on page 3-257.

z

Place the superstructure on appropriate supports, high enough to handle the mounting cross underneath the swing circle. CAUTION

Supports need to be substantial enough to carry total weight of the superstructure (without counterweight, fluids and attachment), total weight 137,215 kg.

z

Before removing swing circle, mark location of both slew rings to superstructure and the car body as well for further investigations.

z

Disconnect all slew ring bearing lubrication hoses (Fig. 3-185, Pos. 1) from the inner slew ring (Fig. 3-185, Pos. 3), removing the unions (Fig. 3-185, Pos. 2).

Fig. 3-185 z

Position the mounting cross, PN 477 577 40 underneath the swing circle.

z

Connect the lifting device to a crane.

NOTE: In order to avoid damage to the sling accessory, use edge protection at all sharp edges. The lifting device is accessible from the centre of the machine (Fig. 3-186, arrow). CAUTION Move the sling accessory carefully between the pipe work/ hoses at the manifold to prevent the pipe work from being damaged or ripped off. Fig. 3-186

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Slew drive

z

Lift the mounting cross (Fig. 3-187, Pos. 1) to place it under the swing circle (Fig. 3-187, Pos. 2).

z

Remove the mounting bolts of the inner slew ring to dismount the swing circle (Fig. 3-187, Pos. 2) from the superstructure (Fig. 3-187, Pos. 3).

NOTE: In order to avoid damage to the lifting devices, use edge protection at all sharp edges.

Fig. 3-187

z

Lower the mounting cross with the swing circle (Fig. 3-188, Pos. 3) resting on it to the ground.

NOTE: The guides (Fig. 3-188, Pos. 2) ensure that the swing circle is aligned accurately with the superstructure (Fig. 3-188, Pos. 1) while it is removed and installed respectively. Do not remove the guides.

Fig. 3-188 z

Install four swivel hoist rings evenly distributed at the inner slew ring and remove the swing circle from the mounting cross using a crane. DANGER

Risk of falling weights! Death or serious injury result. When removing the swing circle, make sure that nobody steps below the weight.

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Superstructure

3.4.6.2 REPLACEMENT OF THE SWING CIRCLE

Special tools:

Mounting cross, PN 477 577 40 Measuring jaw, PN 376 792 40 8 x Measuring bolt, PN 409 437 40 and 8 x Measuring bolt (cold weather) respectively, PN 409 484 40 Test block, PN 379 077 40 Hydraulic torque wrench, PN 232 615 40 Electro-hydraulic pump set, PN 232 613 40 55 mm hexagon impact socket wrench, PN 232 267 40


2 x Crane (2nd. crane for superstructure lifting) Laser device for checking the level of bearing area Compound "KP2K", PN 324 969 40 Swing circle: 10,000 kg


Check the level of bearing area with a laser device before installing a new slew ring. Refer to PARTS & SERVICE NEWS No. "AH00511".

z

Check the outer diameter of the new slew ring top surface and compare with the outer diameter of the factory machined surface of the superstructure. Refer to PARTS & SERVICE NEWS No. "AH00511" last edition. Remove the shoulder by machining if necessary. WARNING

z

Shocks to the swing circle (especially radial shocks) must be avoided.

z

Transport and store the new swing circle exclusively with transport star fitted.

z

It is strictly forbidden to hook up the new swing circle at the transport star.

z

Hang up and/or transport and store the swing circle only horizontally. If a special attachment is available, the transportation and storage in inclined position may be carried out.

z

Only hang swing circle at four swivel hoist rings evenly distributed in screw circle of the inner slew ring.

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Superstructure

Slew drive

NOTE: When replacing the swing circle, all fastening bolts must also be replaced. z

Install four swivel hoist rings evenly distributed at the inner slew ring and lift it using a crane. DANGER

Risk of falling weights! Death or serious injury may result. When removing the swing circle, make sure that nobody steps below the weight.

z

Place the swing circle (Fig. 3-189, Pos. 2) onto the mounting cross (Fig. 3-189, Pos. 1).

z

Centre the swing circle (Fig. 3-189, Pos. 2) on the mounting cross (Fig. 3-189, Pos. 1) using the transport star.

z

Position the mounting cross with the swing circle resting on it under the superstructure (Fig. 3-189, Pos. 3) and connect the mounting cross to a crane.

Fig. 3-189 NOTE: In order to avoid damage to the sling accessory, use edge protection at all sharp edges. The lifting device is accessible from the centre of the machine (Fig. 3-186, arrow). CAUTION Move the sling accessory carefully between the pipe work/ hoses at the manifold to prevent the pipe work from being damaged or ripped off. Fig. 3-190

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3 - 207

Slew drive

Superstructure

Fig. 3-191 Swing circle installation z

Mating surfaces must be absolutely fat-free. Even the solvent must be rinsed away before assembling.

z

Check flatness of the mating surfaces.

z

Prepare new bolts (Fig. 3-191, Pos. 3) and washers (Fig. 3-191, Pos. 4). Lubricate the threads and the head surface of the bolts with compound "KP2K", PN 324 969 40.

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Superstructure

z

Slew drive

Align the "S-spots".

NOTE: The unhardened spot of race surfaces (changeover area between beginning and end of hardening process) is punch-marked with an "S" at the inner resp. outer side of each slew ring (Fig. 3-191, Pos. 1 and 2). These spots "S" must not be placed within the main load area of the swing circle. Hence, the unhardened spot "S" has to be turned in an angle of 90° to the main load area refer to Fig. 3-191. z

Remove the transport cross.

z

Align the teeth of the outer slew ring with the lubrication pinions and the pinions of the slew gears.

z

Lift the swing circle (Fig. 3-192, Pos. 3) to approx. 10 mm below the superstructure platform (Fig. 3-192, Pos. 1) by means of the mounting cross.

z

Align the holes in the inner slew ring with the treads in the superstructure platform. The guides (Fig. 3-192, Pos. 2) centre the swing circle horizontally (observe the unhardened "S-spots").

NOTE: The guides ensure that the swing circle is aligned accurately into its mounting position. Do not remove the guides (Fig. 3-192, Pos. 2) after installation. z

Install bolts (Fig. 3-191, Pos. 3) and washers (Fig. 3-191, Pos. 4) to the inner slew ring.

z

Join the swing circle (Fig. 3-191, Pos. 5) on to the supporting surface at the superstructure platform (Fig. 3-191, Pos. 6) by tightening the bolts crosswise manually.

z

Remove the mounting cross.

z

Connect all lubrication lines (Fig. 3-193, Pos. 1) to the unions (Fig. 3-193, Pos. 2) at the inner slew ring (Fig. 3-193, Pos. 3).

Fig. 3-192

Fig. 3-193

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Slew drive

z

Superstructure

Check the tooth backlash between slew ring and slew pinion with a feeler gauge. Refer to PARTS & SERVICE NEWS No. "AH00511". Tighten all bolts (Fig. 3-191, Pos. 3) of the inner slew ring crosswise to the required torque, refer to PARTS & SERVICE NEWS No. "AH00511" last edition.

NOTE: The procedure of tightening has to be performed twice or three times, to ensure a setting of the bolts. Refer to PARTS & SERVICE NEWS No. "AH00511" last edition. z

After tightening all bolts (Fig. 3-191, Pos. 3) the tooth back lash has to be checked once more at 4 points. Refer to PARTS & SERVICE NEWS No. "AH00511" last edition. If necessary adjust again.

z

Lift the superstructure (Fig. 3-191, Pos. 6) and install the superstructure onto the undercarriage, refer to section 3.9.2 on page 3-261. DANGER

Risk of falling weights! Death or serious injury may result. When lifting the superstructure, make sure that nobody steps below the weight.

z


z

Bleed air from the hydraulic system, refer to Operation & Maintenance Manual, chapter 4, section "HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER".


3 - 210

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Version 2009/2

Superstructure

Slew drive


Version 2009/2

PC5500-6

3 - 211

Lubrication pumps

3.5

Superstructure

LUBRICATION PUMPS

Fig. 3-194 Lubrication pumps

3 - 212

PC5500-6

Version 2009/2

Superstructure

Lubrication pumps


Coupling on service arm for filling up the grease container (3) of the Swing circle gear Lubrication

(2)

Grease filter for Swing circle gear Lubrication System "SLS"

(3)

Grease container of the Swing circle gear Lubrication "SLS"

(4)

Hydraulic motor with pump unit

(5)

Grease pressure gauge for "SLS"

(6)

Receiver panel on service arm

(7)

Coupling on service arm for filling the grease container (9) of the Central Lubrication System

(8)

Grease filter for Central Lubrication System "CLS"

(9)

Grease container of the Central Lubrication System

(10)

Hydraulic motor with pump unit

(11)

Grease pressure gauge for "CLS"

(12)

Mounting bolts of the grease container housing

The lubrication pump is a hydraulically driven seal-free differential piston pump. The pump pumps lubricant during the up and down stroke but sucks lubricant only during the up stroke. The scoop piston at the pump bottom supports the main pump with high viscosity lubricants. There is only one dynamic seal at the piston rod on top of the pump pipe. The lubrication pump is divided in two main components, the pump drive’s hydraulic cylinder and the pump. The pump drive and only the pump outlet are outside on top of the lubricant container, the pump itself is inside and reaches into the lubricant.

Version 2009/2

PC5500-6

3 - 213

Lubrication pumps

3.5.1

Superstructure

REMOVAL OF THE LUBRICATION PUMP

Special tools:

n/a


Crane Lubrication pump: 28 kg

Dogman/rigger

z


z




Before maintenance, stop the engine and remove ignition key in order to prevent operation of the lubrication system. Assure that the system pressure of the lubrication system is relieved before maintenance.

z

Relieve system pressure of the lubrication system by actuating the vent valve (Fig. 3-195, Pos. 1) by hand, refer to PARTS & SERVICE NEWS No. "AH05546".

z

Disconnect the hydraulic lines (Fig. 3-195, Pos. 2) from the lubrication pump.

z

Disconnect the quick coupling from the grease feeding line (Fig. 3-195, Pos. 3).

Fig. 3-195

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Version 2009/2

Superstructure

z

Lubrication pumps

Disconnect the grease feeding line (Fig. 3-196, Pos. 1) from the lubrication pump.

Fig. 3-196 z

Remove the bolt (Fig. 3-197, Pos. 1).

Fig. 3-197

z

Sling the lubrication pump (Fig. 3-197, Pos. 1) at the installed lifting eye (Fig. 3-197, Pos. 1) and pull the lubrication pump out of the grease container.

Fig. 3-198

Version 2009/2

PC5500-6

3 - 215

Lubrication pumps

3.5.2

Superstructure

REPLACEMENT OF THE LUBRICATION PUMP

Special tools:

n/a


Crane Lubrication pump: 28 kg



z

After replacement, bleed the pump at the breather port (Fig. 3-199, Pos. 1).

Fig. 3-199 z

Adjust the lubrication pump speed and pressure. Refer to the Service Manual.

3 - 216

PC5500-6

Version 2009/2

Superstructure

Pump controller MC7

3.6

PUMP CONTROLLER MC7

3.6.1

REMOVAL OF THE PUMP CONTROLLER MC7

Special tools:

n/a


n/a

z


z

Remove the keys from the battery main switches.

z

Remove the wiring harness connector X14 (Fig. 3-200, Pos. 2) from the electronic pump controller MC7 (Fig. 3-200, Pos. 3).

z

Remove four bolts and remove the pump controller MC7 from the wall of the cab base (Fig. 3-200, Pos. 1).

Fig. 3-200

3.6.2

REPLACEMENT OF THE PUMP CONTROLLER MC7

Special tools:

n/a



z


z

Check and adjust the parameters of the pump controller. Refer to the Service Manual for further information.

Version 2009/2

PC5500-6

3 - 217

Operator’s cab

3.7

Superstructure

OPERATOR’S CAB

Fig. 3-201 Operator’s cab overview 3 - 218

PC5500-6

Version 2009/2

Superstructure

Operator’s cab

Legend for Fig. 3-201: A

Rear View of Operator’s Cab

(1)

Door handle

(2)

Door latch (with door fully opened)

(3)

Door locking pin, engages into latch when the cab door is fully opened

(4)

Light switch for access area lighting

(5)

Light switch for interior cab lighting

(6)

Air conditioner door

(7)

Outside mirrors with integrated heaters, both mirrors are adjusted electrically via a control switch on the instrument panel

(8)

Main working lights

(9)

Adapter for warning beacon

B

Front View of Operator’s Cab

(10)

Release lever for door lock (2 - 3)

(11)

Door opener push button

(12)

Lock lever

(13)

Control levers for working attachment

(14)

Operator’s seat

(15)

Upper windshield wiper

(16)

Lower windshield wiper

WARNING The operator’s cab is equipped with an integrated Falling Object Protective Structure (FOPS) that meets the requirements of ISO 3449. Any modifications on the steel structure of the cab are inadmissible. Repairs on the FOPS must only be carried out by specialists having the authorization for repair work on Falling Object Protective Structures and in accordance with the manufacturer’s repair instructions.

Version 2009/2

PC5500-6

3 - 219

Operator’s cab

Superstructure


3 - 220

PC5500-6

Version 2009/2

Superstructure

3.7.1

Operator’s cab

REMOVAL OF THE OPERATOR’S CAB

Special tools:

n/a


Safety harness in conformity with DIN EN 361 Crane Mobile elevator working platform Tank for coolant storage Oil drain pan Operator’s cab: 3785 kg

Dogman/rigger Air condition service specialist For further information about the needed blind plugs, refer to section 2.3 on page 2-37. z


z




z

Remove the keys from the battery main switches. WARNING

Always wear a safety harness when working at the operator’s cab. Do not carry out the following work on a hot machine. Wait until the temperature of the coolant is below 50 °C. Disobedience may result in personal injury from heated coolant or steam.

Drain the engine coolant of engine 2, approx. 360 liters. Refer to the Operation & Maintenance Manual, chapter 3, section "CENTRAL REFILLING SYSTEM", and the Engine Operation & Maintenance Manual.

Version 2009/2

PC5500-6

3 - 221

Operator’s cab

z

Superstructure

Dismount the grommet plate (Fig. 3-202, Pos. 1) inside the cab base.

If machine is equipped with harness connectors: z

Disconnect all harness connectors at the back side of the grommet plate.

z

Disconnect all other harnesses leading to the operator’s cab from the X2-board and pull it out of the grommet plate.

If machine is not equipped with harness connectors: z

z

Disconnect all harnesses leading to the operator’s cab Fig. 3-202 from the X2C-board and remove the cable transfer elements.

Dismount the grommet plate (Fig. 3-203, Pos. 1) inside the cab base.

If machine is equipped with harness connectors: z

Disconnect all harness connectors of the manipulators at the back side of the grommet plate.


Disconnect all harnesses leading to the operator’s cab from the X2-board and remove the cable transfer elements. Fig. 3-203

z

Remove the ground cable (Fig. 3-204, Pos. 1) in the cab base (Fig. 3-204, Pos. 2) from the left lower fixing bolt at the X2-board and pull it out of the grommet plate.

Fig. 3-204

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Superstructure

Operator’s cab

z

Remove the cover (Fig. 3-205, Pos. 1) inside the cab base.

z

Disconnect the hose (Fig. 3-205, Pos. 2) between cab support and operator’s cab from the other side of the cover.

Fig. 3-205 DANGER Danger of high pressure. Blindness, serious injury, permanent disfigurement, or scaring may result. The air conditioning system is pressurized. Make sure that the refrigerant is sucked from the system before any lines will be removed.

z

Aspirate the refrigerant from the air condition system. WARNING

The air conditioning must be serviced by authorized service specialists only.

z

Open the plate (Fig. 3-206, Pos. 3) at the fuel tank and disconnect the refrigerant couplings (Fig. 3-206, Pos. 1) at the refrigerant hoses below the cab support (Fig. 3-206, Pos. 2).

z

Cap the openings with blind plugs to avoid contamination of the air conditioning system.

z

Disconnect the condensate lines from the air conditioning unit.

z

Clear all hoses from the operator’s cab.

Version 2009/2

Fig. 3-206

PC5500-6

3 - 223

Operator’s cab

z

Superstructure

Sling the operator’s cab (Fig. 3-207, Pos. 2) at the lifting eye bolts (Fig. 3-207, Pos. 1) delivered with the cab.

Fig. 3-207

Fig. 3-208 Removal of the operator’s cab, overview

3 - 224

PC5500-6

Version 2009/2

Superstructure

z

Operator’s cab

Remove the hoses (Fig. 3-208, Pos. 7) of the operator’s cab heating from inside the cab base.

NOTE: When the hoses of the operator’s cab heating are removed, fluid from inside the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Open the hose clips (Fig. 3-208, Pos. 5) and remove the water hoses (Fig. 3-208, Pos. 6).

z

Remove the gratings (Fig. 3-208, Pos. 8) from the cab support (Fig. 3-208, Pos. 9).

z

Remove the bolts (Fig. 3-208, Pos. 2) and resilient sleeves (Fig. 3-208, Pos. 3) from the viscous mounts (Fig. 3-208, Pos. 4).

z

Remove operator’s cab (Fig. 3-208, Pos. 1) using a crane.

NOTE: Lift the operater´s cab slowly while using a second person inside the cab base to guide the harnesses through the grommet plates. DANGER Risk of falling weights! Death or serious injury may result. When removing the operator’s cab make sure that nobody steps below the weight.

Version 2009/2

PC5500-6

3 - 225

Operator’s cab

3.7.2

Superstructure

REPLACEMENT OF THE OPERATOR’S CAB

Special tools:

n/a


Safety harness in conformity with DIN EN 361 Crane Mobile elevator working platform Compound "KP2K", PN 324 969 40 Operator’s cab: 3785 kg

Dogman/rigger Air condition service specialist If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.2 on page 2-33.

Fig. 3-209 Replacement of the operator’s cab, overview 3 - 226

PC5500-6

Version 2009/2

Superstructure

Operator’s cab

WARNING Always wear a safety harness when working at the operator’s cab.

WARNING Ensure no one stands between the cabin and the cab base during lowering.

z


NOTE: Use new bolts (Fig. 3-209, Pos. 2) of the grade 10.9 at the viscous mounts (Fig. 3-209, Pos. 4). Apply compound "KP2K", PN 324 969 40 on heads and threads of the bolts and tighten them to the specified torque. NOTE: When lowering the operator’s cab have a second person inside the cab base to guide the harnesses through the grommet plates. Tightening torque for the mounting bolts: 880 Nm z

Evacuate the air conditioning system and add refrigerant. WARNING

The air conditioning must be filled with refrigerant "R134a" by authorized service specialists only.

Refill the engine coolant, approx. 360 liters. Refer to the Operation & Maintenance Manual, chapter 3, section "CENTRAL REFILLING SYSTEM", and the Engine Operation & Maintenance Manual.

Version 2009/2

PC5500-6

3 - 227

Operator’s cab

3.7.3

Superstructure

CAB-MOUNTS

3.7.3.1 REMOVAL OF THE CAB-MOUNTS Special tools:

n/a


Safety harness in conformity with DIN EN 361 Crane Mobile elevator working platform Operator’s cab: 3785 kg Viscous mount: 4 kg Absorber plate incl. 2 viscous mounts: 11.9 kg Absorber plate incl. 3 viscous mounts: 17.4 kg Dogman/rigger

z


z




Always wear a safety harness when working at the operator’s cab.

z

Sling the operator’s cab (Fig. 3-207, Pos. 2) at the lifting eye bolts (Fig. 3-207, Pos. 1) delivered with the cab.

Fig. 3-210

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Superstructure

Operator’s cab

Fig. 3-211 Removal of the cab-mounts, overview z

Remove the gratings (Fig. 3-211, Pos. 8) from the cab support (Fig. 3-211, Pos. 9).

z

Remove the bolts (Fig. 3-211, Pos. 2) and resilient sleeves (Fig. 3-211, Pos. 3) from the viscous mounts (Fig. 3-208, Pos. 4).

z

Raise the operator’s cab (Fig. 3-208, Pos. 1) only a few millimeters, just enough to clear the viscous mounts (Fig. 3-208, Pos. 4).

z

Remove the bolts (Fig. 3-211, Pos. 5) from the absorber plate (Fig. 3-211, Pos. 6) and remove the absorber plate with the viscous mounts.

z

Remove the bolts (Fig. 3-211, Pos. 7) and dismount the viscous mounts (Fig. 3-208, Pos. 4) from the absorber plate (Fig. 3-211, Pos. 6).

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3 - 229

Operator’s cab

Superstructure

3.7.3.2 REPLACEMENT OF THE CAB-MOUNTS Special tools:

n/a


Safety harness in conformity with DIN EN 361 Crane Mobile elevator working platform Compound "KP2K", PN 324 969 40 Operator’s cab: 3785 kg Viscous mount: 4 kg Absorber plate incl. 2 viscous mounts: 11.9 kg Absorber plate incl. 3 viscous mounts: 17.4 kg Dogman/rigger If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.2 on page 2-33.

Fig. 3-212 Replacement of the cab-mounts, overview 3 - 230

PC5500-6

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Superstructure

Operator’s cab


z


NOTE: Always use new mounting bolts of the grade 10.9. Apply compound "KP2K", PN 324 969 40 on heads and threads of the bolts and tighten them to the specified torque. Tightening torque for the mounting bolts (Fig. 3-212, Pos. 7) at the cab mounts (Fig. 3-212, Pos. 4): 180 Nm Tightening torque for the mounting bolts (Fig. 3-212, Pos. 5) at the absorber plates (Fig. 3-212, Pos. 6): 880 Nm Tightening torque for the operator’s cab mounting bolts (Fig. 3-212, Pos. 2): 880 Nm

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3 - 231

Operator’s cab

3.7.4

Superstructure

FRONT WINDOW (WINDSCREEN)

3.7.4.1 REMOVAL OF THE FRONT WINDOW Special tools:

n/a


Suction lifters with hoist rings Safety harness in conformity with DIN EN 361 Crane Mobile elevator working platform Front window: 112 kg

Dogman/rigger

z


z




Always wear a safety harness when working at the operator’s cab.

z

Remove the wiper arms (Fig. 3-213, Pos. 1).

z

Use suction lifters with hoist rings at the front window (Fig. 3-213, Pos. 4) to sling the front window.

z

Remove the bolts (Fig. 3-213, Pos. 2). Hold nut (Fig. 3-213, Pos. 3) from inside the cab.

z

Remove the front window (Fig. 3-213, Pos. 4) using a crane.

Fig. 3-213

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Superstructure

Operator’s cab

3.7.4.2 REPLACEMENT OF THE FRONT WINDOW Special tools:

n/a


Suction lifters with hoist rings Safety harness in conformity with DIN EN 361 Crane Mobile elevator working platform Front window: 112 kg



z


NOTE: A different holes pattern is used since January 2007 for the frame of the front window. KOMATSU recommends to use front windows with new holes pattern in the frame, also for shovels, delivered before 2007. For further information refer to the PARTS & SERVICE NEWS No. "AH08504". z

Check the correct end position of the wiper arm(s) after installation of the front window.

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3 - 233

Operator’s cab

3.7.5

Superstructure

OPERATOR’S SEAT

3.7.5.1 REMOVAL OF THE OPERATOR’S SEAT Special tools:

n/a


Crane Operator’s seat: 62 kg

Dogman/rigger

z


z




z

Disconnect the wire harness connector (Fig. 3-214, Pos. 1) of the air suspension.

z

Remove both control lever carriers (Fig. 3-214, Pos. 2 and 3).

z

Remove all mounting bolts (Fig. 3-214, Pos. 4) from the cover plate (Fig. 3-214, Pos. 5).

z

Remove the cover plate (Fig. 3-214, Pos. 5) by removing all seat mounting bolts (Fig. 3-214, Pos. 6) and nuts (Fig. 3-214, Pos. 7) from the operator’s seat (Fig. 3-214, Pos. 8).

NOTE: A second person is required to carry the operator’s seat out of the operator’s cab. z

Sling the operator’s seat and lift it off the machine using a crane.

3 - 234

PC5500-6

Fig. 3-214

Version 2009/2

Superstructure

Operator’s cab

3.7.5.2 REPLACEMENT OF THE OPERATOR’S SEAT Special tools:

n/a


Crane Operator’s seat: 62 kg


Remove both control lever carriers from the new seat.

z


NOTE: A second person is required to carry the operator’s seat into the operator’s cab.

Version 2009/2

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3 - 235

Operator’s cab

3.7.6

Superstructure

ECS

3.7.6.1 REMOVAL OF THE ECS TEXT DISPLAY Special tools:

n/a


n/a

z


z


z

Open the operator’s console.

z

Disconnect the data cables (Fig. 3-215, Pos. 1 and 2) from the ECS text display (Fig. 3-215, Pos. 4).

z

Remove the wing nuts (Fig. 3-215, Pos. 3) and take the ECS text display (Fig. 3-215, Pos. 4) out of the operator’s console.

Fig. 3-215

3.7.6.2 REPLACEMENT OF THE ECS TEXT DISPLAY Special tools:

n/a


n/a

z


z

Set time, date and operating hours, refer to the Operation & Maintenance Manual, chapter 3, section "ELECTRONIC MONITORING AND CONTROL SYSTEM ECS".

3 - 236

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Superstructure

Operator’s cab


Version 2009/2

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3 - 237

Operator’s cab

3.7.7

Superstructure

ACCESS LADDER

Fig. 3-216 Access ladder assembly

3 - 238

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Superstructure

Operator’s cab


Access ladder

(2)

Pin

(3)

Pin

(4)

Access ladder cylinder

(5)

Cotter pin

(6)

Washer

(7)

Socket

(8)

Hydraulic hose

(9)

Hydraulic hose

(10)

Self-locking nut

(11)

Distance sleeve

(12)

Bearing

(13)

Shaft seal

(14)

Dowel Screw

(15)

Ladder bearing assembly

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3 - 239

Operator’s cab

Superstructure

Fig. 3-217 Access ladder removal

3 - 240

PC5500-6

Version 2009/2

Superstructure

Operator’s cab

3.7.7.1 REMOVAL OF THE ACCESS LADDER Special tools:

n/a


Safety harness in conformity with DIN EN 361 Oil drain pan Crane Mobile elevator working platform Access ladder: 167 kg

Dogman/rigger

z


z



Lower the access ladder (Fig. 3-217, Pos. 1) to the ground.

z


z

Isolate the machine according to local regulation.

NOTE: Relieve the remaining pilot pressure at the Minimess test point M40 on the control and filter plate at engine 2. WARNING z

Provide an adequate working platform for safe access to the access ladder bearing.

z

Always wear a safety harness when working at the access ladder assembly.

z

Secure the access ladder cylinder (Fig. 3-217, Pos. 4) in its position.

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3 - 241

Operator’s cab

Superstructure

Fig. 3-218 Access ladder replacement

3 - 242

PC5500-6

Version 2009/2

Superstructure

Operator’s cab

CAUTION Assure that the pressure in the hydraulic system is completely relieved before removing the pivot pin (Fig. 3-218, Pos. 2).

z

Clear the access ladder (Fig. 3-218, Pos. 1) by removing the pin (Fig. 3-218, Pos. 2) from the access ladder cylinder moving rod.

z

Sling the access ladder and remove the self locking nuts (Fig. 3-218, Pos. 10) from the ladder bearing assemblies (Fig. 3-218, Pos. 15).

z

Remove the ladder bearing assemblies and the ladder. Rest it on the ground.

3.7.7.2 REPLACEMENT OF THE ACCESS LADDER Special tools:

n/a


Safety harness in conformity with DIN EN 361 Crane Mobile elevator working platform Access ladder: 167 kg


WARNING z


z


NOTE: Apply grease to the pin (Fig. 3-218, Pos. 2) at the access ladder cylinder moving rod. z


NOTE: Always use new self-locking nuts (Fig. 3-218, Pos. 10). Tightening procedure for the self-locking nuts (Fig. 3-218, Pos. 10): 1000 Nm

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Operator’s cab

Superstructure

Fig. 3-219 Access ladder cylinder removal

3 - 244

PC5500-6

Version 2009/2

Superstructure

Operator’s cab

3.7.7.3 REMOVAL OF THE ACCESS LADDER CYLINDER Special tools:

n/a


Safety harness in conformity with DIN EN 361 Oil drain pan Crane Mobile elevator working platform Access ladder cylinder: 23 kg For further information about the needed blind plugs, refer to section 2.3 on page 2-37.

z

Prepare an area of flat ground large enough to accommodate the machine, boom, and elevator working platform.

z



Lower the access ladder (Fig. 3-219, Pos. 1) to the ground.

z


z


NOTE: Relieve the remaining pilot pressure at the Minimess test point M40 on the control and filter plate at engine 2. WARNING z


z


z

Assure that the pressure in the hydraulic system is completely relieved before removing the pivot pin (Fig. 3-219, Pos. 10) or disconnecting any hydraulic hoses.

z

Remove hydraulic hoses (Fig. 3-219, Pos. 8 and 9) with the socket (Fig. 3-219, Pos. 8) from the access ladder cylinder (Fig. 3-219, Pos. 4).

NOTE: When the hydraulic hoses are removed, hydraulic oil from inside the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination.

Version 2009/2

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3 - 245

Operator’s cab

Superstructure

Fig. 3-220 Access ladder cylinder installation

3 - 246

PC5500-6

Version 2009/2

Superstructure

Operator’s cab

z

Support the access ladder cylinder (Fig. 3-220, Pos. 4) from the bottom side.

z

Remove the pins (Fig. 3-220, Pos. 2 and 3) and remove the access ladder cylinder (Fig. 3-220, Pos. 4).

3.7.7.4 REPLACEMENT OF THE ACCESS LADDER CYLINDER Special tools:

n/a


Safety harness in conformity with DIN EN 361 Oil drain pan Crane Mobile elevator working platform Access ladder cylinder: 23 kg If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.2 on page 2-33.

WARNING z


z


z


NOTE: Apply grease to the pins (Fig. 3-220, Pos. 2 and 3). z


z


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3 - 247

Operator’s cab

3.7.8

Superstructure

REMOVAL OF THE CAB BASE

Special tools:

Hydraulic torque wrench, PN 232 615 40 Electro-hydraulic pump set, PN 232 613 40 55 mm hexagon impact socket wrench (1"), PN 232 267 40


Safety harness in conformity with DIN EN 361 Mobile elevator working platform Tank for coolant storage Crane Support frame: 987 kg Cab base: 3785 kg


Prepare an area of flat ground large enough to accommodate the machine, boom, elevator working platform and crane.

z




z


z

Remove the operator’s cab, refer to section 3.7.1 on page 3-221. WARNING

Always wear a safety harness when working at the cab base.

z

Disconnect all harnesses inside the cab base and pull the harnesses out of the cable transfer elements at the bottom of the cab base.

z

Clear all harnesses leading to the cab base from the cable channels at the cab base and at the tank.

z

Remove the hoses of the operator’s cab heating from the cab base.

NOTE: When the hoses of the operator’s cab heating are removed, fluid from inside the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination.

3 - 248

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Version 2009/2

Superstructure

Operator’s cab

z

Sling the support frame (Fig. 3-221, Pos. 2).

z

Remove the bolts (Fig. 3-221, Pos. 1) from within the cab base (Fig. 3-221, Pos. 3) and remove the support frame (Fig. 3-221, Pos. 2) using a crane.

Fig. 3-221 z

Sling cab base (Fig. 3-222, Pos. 1), refer to Fig. 3-223.

z

Remove bolts (Fig. 3-222, Pos. 2) attaching the cab base to the superstructure (Fig. 3-222, Pos. 2).

Fig. 3-222 z

Remove the cab base using a crane. DANGER

Risk of falling weights! May result in death or serious injury When moving cab base, make sure that nobody steps below the lifted cab base.

Fig. 3-223

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3 - 249

Operator’s cab

3.7.9

Superstructure

REPLACEMENT OF THE CAB BASE

Special tools:

Hydraulic torque wrench, PN 232 615 40 Electro-hydraulic pump set, PN 232 613 40 55 mm hexagon impact socket wrench (1"), PN 232 267 40


Safety harness in conformity with DIN EN 361 Mobile elevator working platform Crane Compound "Epple 28", PN 592 199 40 Compound "Loctite 222", PN 414 299 40 Compound "KP2K", PN 324 969 40 Support frame: 987 kg Cab base: 3785 kg


WARNING Always wear a safety harness when working at the cab base.

z

Sling the new cab base and align it with the superstructure using a crane (Fig. 3-224). DANGER

Risk of falling weights! May result in death or serious injury When moving cab base, make sure that nobody steps below the lifted cab base.

Fig. 3-224

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PC5500-6

Version 2009/2

Superstructure

z

Operator’s cab

Install bolts (Fig. 3-225, Pos. 2) attaching the cab base (Fig. 3-225, Pos. 1) to the superstructure (Fig. 3-225, Pos. 2).

NOTE: Use new mounting bolts (Fig. 3-225, Pos. 2) of grade 10.9. Apply compound "KP2K", PN 324 969 40 on heads and threads of the mounting bolts and tighten them to the specified tightening torque.

Fig. 3-225

Tightening torque for cab base mounting bolts (Fig. 3-225, Pos. 2): 3100 Nm

z

Apply sealing compound "Epple 28" onto the whole contact surfaces (Fig. 3-226, arrows) of the cab base.

z

Install the support frame (Fig. 3-226, Pos. 2) using a crane.

z

Apply compound "Loctite 222" on the threats of all bolts (Fig. 3-226, Pos. 1).

z

Install bolts (Fig. 3-226, Pos. 1) attaching the support frame (Fig. 3-226, Pos. 2) to the cab base (Fig. 3-226, Pos. 3).

NOTE: Use new mounting bolts (Fig. 3-226, Pos. 1) of grade 10.9 and tighten the mounting bolts to the specified tightening torque. Fig. 3-226

Tightening torque for support frame mounting bolts (Fig. 3-226, Pos. 1): 265 Nm z


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3 - 251

Counterweight

3.8

Superstructure

COUNTERWEIGHT

Fig. 3-227 Counterweight (1)

Counterweight

(2)

Lifting situation for horizontal transport

(3)

Lifting situation for vertical transport

(4)

Lifting situation for raising up the counterweight

(5)

Bolt

(6)

Washer

WARNING Make sure that the maximum rope angle depending on the lifting situation (Fig. 3-227, Pos. 2 to 4) is not exceeded.

3 - 252

PC5500-6

Version 2009/2

Superstructure

Counterweight

DANGER Risk of explosion! Blindness, serious injury, permanent disfigurement and scarring, or death may result. Do not weld, flame-cut, grind, or drill at the counterweight! Follow the instructions given in PARTS & SERVICE NEWS No. "AH04518" for expelling the gases from the counterweight chambers!

NOTE: The chambers of the counterweight are filled with a mixture of concrete, granulated ore and steel pellets. This mixture can create explosive gases which will accumulate in the chambers of the counterweight. Before any welding, flame-cutting, grinding, or drilling procedures are carried out on the counterweight, it is vital to expel these gases from the counterweight chambers. Failure to properly expel the gases from the counterweight chambers can result in an explosion with serious personal injury or death. Follow the instructions given in PARTS & SERVICE NEWS No. "AH04518" for expelling the gases from the counterweight chambers.

3.8.1

REMOVAL OF THE COUNTERWEIGHT

Special tools:

Hydraulic torque wrench, PN 232 615 40 Electro-hydraulic pump set, PN 232 613 40 75 mm hexagon impact socket wrench (2 1/2"), PN 232 269 40


Safety harness in conformity with DIN EN 361 Mobile elevator working platform Crane Counterweight: 42,000 kg

Dogman/rigger

z


z

Park the machine on the prepared flat area and position the bucket on the ground.



Version 2009/2

PC5500-6

3 - 253

Counterweight

Superstructure

WARNING Always wear a safety harness when working at the counter weight.

z

Secure the counterweight (Fig. 3-227, Pos. 1) at the lifting eyes using a crane. WARNING

Make sure that the maximum rope angle of 40° is not exceeded. Refer to Fig. 3-227, Pos. 3.

z

Remove the rails (Fig. 3-228, Pos. 1) from the counterweight.

z

Remove all additional equipment from the counterweight, if required.

z

Remove the tanks (Fig. 3-228, Pos. 2) and wires of the Fire Detection and Suppression System, if equipped. WARNING


z

Remove all mounting bolts (Fig. 3-227, Pos. 5).

z

Remove counterweight using the crane.

Fig. 3-228

DANGER Risk of falling weights! Death or serious injury may result. When moving counterweight, make sure that nobody steps below the lifted counterweight.

3 - 254

PC5500-6

Version 2009/2

Superstructure

3.8.2

Counterweight

REPLACEMENT OF THE COUNTERWEIGHT

Special tools:

Hydraulic torque wrench, PN 232 615 40 Electro-hydraulic pump set, PN 232 613 40 65 mm hexagon impact socket wrench (1 1/2"), PN 232 521 40


Safety harness in conformity with DIN EN 361 Mobile elevator working platform Crane Compound "KP2K", PN 324 969 40 Counterweight: 42,000 kg


WARNING Always wear a safety harness when working at the counter weight.

NOTE: Assure that the mounting surfaces are absolutely free of dirt, oil, fat, and paint before installation. z

Carry out installation in reverse order to removal. WARNING

Make sure that the maximum rope angle of 40° is not exceeded. Refer to Fig. 3-227, Pos. 3.

NOTE: Apply compound "KP2K", PN 324 969 40 on heads and threads of the bolts. Tighten the mounting bolts to the specified tightening torque. Tightening torque for the mounting bolts: 4950 Nm

Version 2009/2

PC5500-6

3 - 255

Counterweight

Superstructure


3 - 256

PC5500-6

Version 2009/2

Superstructure

Superstructure lifting

3.9

SUPERSTRUCTURE LIFTING

3.9.1

REMOVE THE SUPERSTRUCTURE FROM THE UNDERCARRIAGE

Special tools:

Hydraulic torque wrench, PN 232 615 40 Electro-hydraulic pump aggregate, PN 232 613 40 55 mm hexagon impact socket wrench (1"), PN 232 267 40


Safety harness in conformity with DIN EN 361 Mobile elevator working platform 2 x crane Superstructure without counterweight, attachment and fluids: 137,215 kg Dogman/rigger Crane operators trained in dual crane lift For further information about the needed blind plugs, refer to section 2.3 on page 2-37.

z


z




z


z

Relieve the pressure in the track tensioning system. Refer to the Operation & Maintenance Manual, chapter 4, section "CRAWLER TRACK - INSPECTION".

z


z

Transfuse the oil from the suction oil reservoir into the main oil reservoir, refer to the Operation & Maintenance Manual, chapter 3, section "FUNCTIONS OF THE TRANSFER PUMP". WARNING

Fig. 3-229

Always wear a safety harness when working in height.

Version 2009/2

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3 - 257


Superstructure

Fig. 3-230 Superstructure lifting z

Remove the counterweight from the superstructure, refer to section 3.8.1 on page 3-253.

z

Install shackels (Fig. 3-230, Pos. 6) delivered with the machine to the flanges of the counterweight using the mounting bolts of the counterweight. Tighten the mounting bolts to the specified tightening torque. Tightening torque for the mounting bolts: 4950 Nm

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PC5500-6

Version 2009/2

Superstructure


z

Remove the complete attachment, refer to section 5.1 on page 5-2.

z

Disconnect all hydraulic hoses leading to the superstructure from the rotary joint, refer to section 4.2.5.1 on page 4-94. If the machine is equipped with slew ring protection covers (Fig. 3-230, Pos. 9): z

Remove all bolts (Fig. 3-230, Pos. 7) and resilient sleeves (Fig. 3-230, Pos. 8) attaching the protection covers to the superstructure (Fig. 3-230, Pos. 4).

z

If equipped, remove the rotation direction sensors B98 and B99 from the slew ring protection cover. WARNING

Before lifting the superstructure, make sure that the crane operators are trained in dual crane lift.

z

Attach the superstructure to two cranes.

z

Remove all bolts (Fig. 3-230, Pos. 1) and washers (Fig. 3-230, Pos. 2) attaching the slew ring to the undercarriage (Fig. 3-230, Pos. 5).

z

Lift off the superstructure using the two cranes and rest it on appropriate supports on the ground. DANGER

Risk of falling weights! May result in death or serious injury When moving superstructure, make sure that all personnel are clear.

Version 2009/2

PC5500-6

3 - 259


Superstructure


3 - 260

PC5500-6

Version 2009/2

Superstructure

3.9.2


INSTALL THE SUPERSTRUCTURE ONTO THE UNDERCARRIAGE

Special tools:

Hydraulic torque wrench, PN 232 615 40 Electro-hydraulic pump set, PN 232 718 40 55 mm hexagon impact socket wrench (1"), PN 232 267 40 Gauge device for testing bolts M36, PN 376 762 40


Safety harness in conformity with DIN EN 361 Mobile elevator working platform 2 x Crane Compound "KP2K", PN 324 969 40 2 thread pins (M 36 x 250) Superstructure without counterweight, attachment and fluids: 137,215 kg Dogman/rigger Crane operators trained in dual crane lift If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.2 on page 2-33.

NOTE: Assure that the mounting surfaces are absolutely free of dirt, oil, fat, and paint before installation. WARNING Always wear a safety harness when working in height.

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3 - 261


Superstructure

Fig. 3-231 Superstructure lifting z

Clean the contact surfaces of the slew ring and the undercarriage very carefully and thoroughly. WARNING

Before lifting the superstructure, make sure that the crane operators are trained in dual crane lift.

z

Attach the superstructure to two cranes and lift it up. Refer to Fig. 3-231.

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PC5500-6

Version 2009/2

Superstructure


DANGER Risk of falling weights! May result in death or serious injury When moving superstructure, make sure that all personnel are clear.

NOTE: The unhardened spot of race surfaces (changeover area between beginning and ending of hardening process) is punch-marked with an "S" at the inner resp. outer side of each slew ring (Fig. 3-232, Pos. 1 and 2). Refer to PARTS & SERVICE NEWS No. "AH00511". z

Align the spots (Fig. 3-232, Pos. S) to each other.

z

Prepare new bolts, washers and sleeves. Lubricate the threads and the head surface of the bolts with compound "KP2K", PN 324 969 40.

Fig. 3-232 z

Remove the torque support lever of the rotary joint before installing the superstructure, refer to section 4.2.5.1 on page 4-94.

z

Align the superstructure to the undercarriage and lower the superstructure.

z

To simplify the alignment of the slew ring to the undercarriage, install two thread pins (M 36 x 250) displaced by 180° at the outer slew ring.

z

Insert 4 bolts (Fig. 3-231, Pos. 1) with washers (Fig. 3-231, Pos. 2) displaced by 90° and lower the superstructure.

z

Remove the two thread pins from the outer slew ring.

z

Install all remaining bolts and tight them manually. Tighten all bolts crosswise to the required torque, refer to PARTS & SERVICE NEWS No. "AH00511".

NOTE: If approx. 10 bolts (front and rear) are tightened the superstructure can be unhooked from the crane. z

Reinstall the torque support lever of the rotary joint. WARNING

Make sure to use the specified bolts and torque for the torque support lever mounting bolts, refer to section 4.2.5.2 on page 4-96.

z


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3 - 263

Fuel tank

Superstructure

3.10 FUEL TANK

Fig. 3-233 Fuel tank, overview (1)

Fuel tank

(2)

Breather valve

(3)

Main fuel shut-off cock

(4)

Drain coupling (to drain fuel, water, and sediments)

(5)

Shut-off cock for pressure transducer

(6)

Pressure transducer for fuel level indication

3 - 264

PC5500-6

Version 2009/2

Superstructure

Fuel tank

3.10.1 REMOVAL OF THE FUEL TANK Special tools:



Safety harness in conformity with DIN EN 361 Mobile elevator working platform Empty fuel storage tank Crane Fuel tank (empty): 4486 kg



z




Always wear a safety harness when working at the fuel tank.

z

Remove the operator’s cab (Fig. 3-234, Pos. 3), refer to section 3.7.1 on page 3-221.

z

Remove the handrails (Fig. 3-234, Pos. 1), the handlebar (Fig. 3-234, Pos. 2), and the gratings from the fuel tank.

NOTE: For safety, the handrail (Fig. 3-234, Pos. 3) at the steps will not be removed.

Fig. 3-234 z

Open the hinged cover below the fuel tank.

Version 2009/2

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3 - 265

Fuel tank

z

Superstructure

Attach a drain hose and open drain coupling (Fig. 3-233, Pos. 4). Drain fuel, approx. 10800 liters (max.).

z

Disconnect the tank breather hose (Fig. 3-235, Pos. 1) from the tank breather valve (Fig. 3-235, Pos. 2). WARNING

Risk of fire! Serious injury, permanent disfigurement and scarring, or death may result. DO NOT smoke or use an open flame when working around inflammable fuels

Fig. 3-235 . If machine is equipped with harness connectors: z

Disconnect the harness connectors (Fig. 3-236, Pos. 1) from the cab base.

z

Pull the harnesses out of the cable channels of the cab base (Fig. 3-236, Pos. 2) and of the tank (Fig. 3-237, Pos. 1).

Z 26172


Disconnect all harnesses leading to the operator’s cab.

z

Pull the harnesses out of the cable channels of the cab base (Fig. 3-236, Pos. 2) and of the tank (Fig. 3-237, Pos. 1). Fig. 3-236

3 - 266

PC5500-6

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Superstructure

Fuel tank

z

Remove the brackets and clear all hoses (Fig. 3-237, Pos. 2 and 3) from the tank.

z

Disconnect all fuel lines from the tank. DANGER

Z 26173

Danger of fuel pressure! May result serious injury, permanent disfigurement and scarring, or death! Fuel lines are pressurized by hydrostatic pressure due to the unknown amount of fuel in the tank. Be sure that the fuel is completely drained before opening any fuel lines.

Fig. 3-237

NOTE: When the fuel hoses are disconnected, the fuel inside the hoses will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Open the clamps and clear the hoses of the air conditioning from the tank.

z

Disconnect the wire harness connectors B63 and Y99 (Fig. 3-238).

z

Attach the fuel tank to a crane.

Fig. 3-238

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3 - 267

Fuel tank

z

Superstructure

Remove the mounting bolts (Fig. 3-239, Pos. 1) and lift the fuel tank (Fig. 3-239, Pos. 6) from the machine. Discard the mounting bolts (Fig. 3-239, Pos. 1). DANGER

Risk of falling weights! May result in death or serious injury When moving fuel tank, make sure that nobody steps below the lifted fuel tank.

z

Dismantle the handrail at the steps.

z

If required remove the fuel tank breather valve (Fig. 3-239, Pos. 3) and the plate (Fig. 3-239, Pos. 4). Discard the gaskets (Fig. 3-239, Pos. 5).

z

If required, remove all plugs (Fig. 3-239, Pos. 2).

Fig. 3-239

3 - 268

PC5500-6

Version 2009/2

Superstructure

Fuel tank

3.10.2 REPLACEMENT OF THE FUEL TANK Special tools:



Safety harness in conformity with DIN EN 361 Mobile elevator working platform Crane Compound "KP2K", PN 324 969 40 Fuel tank (empty): 4486 kg


WARNING Always wear a safety harness when working at the fuel tank.

z

If required, install the fuel tank breather valve (Fig. 3-240, Pos. 3), the plate (Fig. 3-240, Pos. 4) and all plugs (Fig. 3-240, Pos. 2) to the new tank.

NOTE: Use new gaskets (Fig. 3-240, Pos. 5). Assure that the mounting surfaces are absolutely free of dirt, oil, fat, and paint before installation. z

Install the handrail at the steps at first.

z


Fig. 3-240

Version 2009/2

PC5500-6

3 - 269

Fuel tank

Superstructure

NOTE: Use new mounting bolts (Fig. 3-240, Pos. 1) of grade 10.9. Apply compound "KP2K", PN 324 969 40 on heads and threads of the mounting bolts and tighten them to the specified tightening torque. Tightening torque for the fuel tank mounting bolts (Fig. 3-239, Pos. 1): 1770 Nm. Refill the fuel tank, approx. 10800 liters.

z

Bleed air from the fuel lines to the engine: z

Assure that the emergency shut off valve is opened.

z

Disconnect the feeding line at the engine fuel filter.

z



Reconnect the feeding line to the engine fuel filter.

z

Disconnect the feeding line at the engine fuel pump.

z



3 - 270

Reconnect the feeding line to the engine fuel pump.

PC5500-6

Version 2009/2

Undercarriage

4 UNDERCARRIAGE

Version 2009/2

PC5500-6

4 -1

Travel system

Undercarriage

4.1

TRAVEL SYSTEM

4.1.1

TRACK GROUP

4.1.1.1 CHANGING OF THE TRACK GROUP Special tools:

n/a


Personal Protective Equipment (PPE) Dozer Chain hoist Slide hammer Welding equipment Brass drift Track group 1350 mm: 32,192 kg Pin track group 1350 mm: 19 kg Track group 1800mm: 39,066 kg Pin track group 1800 mm: 20.2 kg Dogman/rigger If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.2 on page 2-33.

NOTE: Make sure that the wear of the track group was measured according to the PARTS & SERVICE NEWS No. "AH02521". z

Prepare an area of flat ground twice as large to accommodate the machine, the boom, and the dozer.

z




z

Relieve pressure in the track tensioning system, refer to the PARTS & SERVICE NEWS No. "AH06530".

NOTE: Make sure that the slack in the track group is at the lower part of the guide wheel.

4 -2

PC5500-6

Version 2009/2

Undercarriage

z

Travel system

Flame-cut the nuts (Fig. 4-1, Pos. 3) from the locking bolts (Fig. 4-1, Pos. 1). Remove the locking bolts (Fig. 4-1, Pos. 1), washers (Fig. 4-1, Pos. 2), and nuts (Fig. 4-1, Pos. 3) from one track shoe (Fig. 4-1, Pos. 5). WARNING

Ensure nothing flammable is in the working area when flamecutting the nuts.

z

Pull out two pins (Fig. 4-1, Pos. 4) to open the track group using a sliding hammer.

Fig. 4-1

NOTE: Open the track group at the guide wheel. z

Sling the upper end of the track group using a chain and link it to a dozer in front of the excavator.

z

De-isolate the machine according to local regulations. DANGER

Danger of getting overrun or squished. Serious injury or death may result. Make sure nobody stays in driving direction of the excavator or the dozer. Make sure nobody stays next to the crawler carrier. Fig. 4-2 z

Drive the excavator and the dozer backwards slowly and unroll the track group from the excavator (Fig. 4-2).

NOTE: Assure that excavator and dozer have the same speed. z

When the upper end of the track group runs off the sprocket, stop the excavator while driving the dozer backwards slowly to prevent the track from knocking over.

Version 2009/2

PC5500-6

4 -3

Travel system

z

Undercarriage

Align the new track group on the ground behind the old track group.

NOTE: Observe the running direction of the new track group. Make sure that the new track group has the correct running direction as shown in Fig. 4-3. z

Align the new track group on the ground behind the old track group.

z

Remove the chain from the old track group.

z

Continue to drive the excavator backwards slowly on the new track group until the end of the of the track group is nearly reached.

z

Sling the end of the new track group at the sprocket using a chain and link it to a dozer in front of the excavator. DANGER

Danger of getting overrun or squished. Serious injury or death may result. Make sure nobody stays in driving direction of the excavator or the dozer. Make sure nobody stays next to the crawler carrier. Fig. 4-3

z

Drive the excavator and the dozer forward slowly and pick up the track group with the sprocket.

z

Continue to drive the excavator and the dozer forward slowly to pull up the track group (Fig. 4-4).

NOTE: Assure that excavator and dozer have the same speed.

Fig. 4-4 z

Stop the excavator and the dozer, when the guide wheel reaches the end of the track group (approximately 3 track shoes away from the end of the track group).

z

Place the track group over the guide wheel as shown in Fig. 4-5.

z

Unchain the dozer.

Fig. 4-5 4 -4

PC5500-6

Version 2009/2

Undercarriage

Travel system

z

Align the holes (Fig. 4-6, Pos. 3) in the two open track shoes (Fig. 4-6, Pos. 2) in front of the guide wheel (Fig. 4-6, Pos. 1) using a hoist.

z

Insert the pins (Fig. 4-7, Pos. 4) into the holes (Fig. 4-6, Pos. 3).

Fig. 4-6 z

Instal the locking bolts (Fig. 4-7, Pos. 1), washers (Fig. 4-7, Pos. 2), and nuts (Fig. 4-7, Pos. 3) to the track shoes (Fig. 4-7, Pos. 5).

z

Weld the nuts (Fig. 4-7, Pos. 3) to the bolts (Fig. 4-7, Pos. 1). WARNING

z

Ensure nothing flammable is in the working area during welding work.

z

For welding follow the welding precautions given in the Operation & Maintenance Manual, chapter 4, section "WELD REPAIRS". Fig. 4-7

CAUTION The bolts (Fig. 4-8, Pos. 1) lock the pins (Fig. 4-8, Pos. 2). Therefore one side of the bolt’s head is hardened in order to prevent wear. This hardened side must face the pin. The hardened side (Fig. 4-8, arrow) of the bolt heads are marked.

Fig. 4-8

Version 2009/2

PC5500-6

4 -5

Travel system

z

Undercarriage

Perform the procedure given in the PARTS & SERVICE NEWS "AH06530" in reverse order.

4 -6

PC5500-6

Version 2009/2

Undercarriage

4.1.2

Travel system

SPROCKET

4.1.2.1 REMOVAL OF THE SPROCKET Special tools:

n/a


Personal Protective Equipment (PPE) Hydraulic torque wrench PN 232 614 40 Electro-hydraulic pump aggregate PN 232 613 40 2 x Crane Dozer Pulling bolts M30 Sprocket assembly: 4382 kg Hollow shaft: 612 kg Drive shaft: 1007 kg Dogman/rigger

NOTE: Only for removal of the sprocket it is not necessary to remove the travel gear. If changing the sprocket (Fig. 4-9, Pos. 2) it is recommended to change the flange bearings (Fig. 4-9, Pos. 1 + Pos. 3) too. Therefore the travel gear (Fig. 4-9, Pos. 4) has to be removed, refer to section 4.1.11.1 on page 4-51.

Fig. 4-9 WARNING Ensure appropriate (PPE) Personal Protective Equipment is used during the task. There maybe sharp edges on the worn sprocket that is being removed.

Version 2009/2

PC5500-6

4 -7

Travel system

Undercarriage

z

Prepare an area of flat ground twice as large to accommodate the machine, the boom, and two cranes.

z

Park the machine on the prepared flat ground area with the attachment placed at the final drive end of the machine, counterweight above guide wheels.



z

Relieve pressure in the track tensioning system, refer to PARTS & SERVICE NEWS No. "AH06530".

Drain oil of the final drive housing, approx. 165 liters. Refer to the Operation & Maintenance Manual, chapter 4, section "TRAVEL GEARS, MOTOR ADAPTER HOUSINGS AND FINAL DRIVES". z

Check the wear of the sprocket hub, refer to PARTS & SERVICE NEWS No. "AH00515".

NOTE: Make sure that the sprocket runs free after opening the track group and it has no contact to the ground or the track group. For example drive the excavator with the track rollers at the respective crawler frame side onto a knoll. NOTE: Before beginning the work, block the track group to prevent the track shoes against falling down (refer to Fig. 4-10). z

Open the track group at the sprocket end (Fig. 4-10, Pos. 1), refer to section 4.1.1.1 on page 4-2.

Fig. 4-10

4 -8

PC5500-6

Version 2009/2

Undercarriage

Travel system

z

Sling the upper end of the track group using a chain and link it to a dozer behind the excavator.

z



Drive the excavator and the dozer forwards slowly and unroll the track group from the excavator (refer to Fig. 4-11).


When the upper end of the track group is over the carrier roll next to the sprocket, stop the excavator and the dozer.

z


z

Fasten the track group to the carrier roll to hold it in position.

NOTE: In order to avoid damage to the lifting devices, use edge protection at all sharp edges. z

Sling sprocket (refer to Fig. 4-12).

NOTE: The travel parking brake may need to be released to allow sprocket to turn slightly to find centre of gravity.

Fig. 4-12

Version 2009/2

PC5500-6

4 -9

Travel system

Undercarriage

Fig. 4-13 Removal of the sprocket z

Remove the bolts (Fig. 4-13, Pos. 1) and the cover (Fig. 4-13, Pos. 10).

NOTE: When the cover is removed, oil may flow out. Catch it in an oil pan. z


z

Pull the drive shaft (Fig. 4-13, Pos. 6) out of the hollow shaft (Fig. 4-13, Pos. 5). WARNING

Sling the drive shaft as soon as possible and support it using a crane to prevent the shaft from falling.

DANGER Risk of falling weights! Death or serious injury may result. When lifting the drive shaft, make sure that nobody steps below the weight.

4 - 10

PC5500-6

Version 2009/2

Undercarriage

Travel system

CAUTION Make sure that the hollow shaft (Fig. 4-13, Pos. 5) is not weight loaded before removing the flange bearing (Fig. 4-13, Pos. 8).

z

Remove mounting bolts (Fig. 4-13, Pos. 1) and extract the flange bearing (Fig. 4-13, Pos. 8) including the bush (Fig. 4-13, Pos. 7) from the crawler carrier using pulling bolts.

z

Extract the hollow shaft (Fig. 4-13, Pos. 5) from the sprocket (Fig. 4-13, Pos. 3) and remove it using a crane. WARNING

Sling the drive shaft as soon as possible and support it using a crane to prevent the shaft from falling.

DANGER Risk of falling weights! Death or serious injury may result. When lifting the hollow shaft, make sure that nobody steps below the weight.

z

Lift the sprocket out of the crawler carrier. DANGER

Risk of falling weights! Death or serious injury may result. When lifting the sprocket, make sure that nobody steps below the weight.

z

Discard the dual-cone seals (Fig. 4-13, Pos. 2 and Pos. 4).

NOTE: Dual-cone seals are mounted in the sprocket hub as well as in the inner and outer flange bearing. For further information refer to PARTS & SERVICE NEWS No. "AH05511". z

If required, remove the sprocket from the hub, refer to PARTS & SERVICE NEWS No. "AH00514".

Version 2009/2

PC5500-6

4 - 11

Travel system

Undercarriage

4.1.2.2 REPLACEMENT OF THE SPROCKET Special tools:

Assembly tool for dual-cone seals (locally made)


Personal Protective Equipment (PPE) Hydraulic torque wrench PN 232 614 40 Electro-hydraulic pump aggregate PN 232 613 40 2 x Crane Dozer Compound "KP2K", PN 324 969 40 Paste "Optimol White", PN 999 039 Sprocket assembly: 4382 kg Hollow shaft: 612 kg Drive shaft: 1007 kg Dogman/rigger If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.2 on page 2-33.

Fig. 4-14 Replacement of the sprocket

4 - 12

PC5500-6

Version 2009/2

Undercarriage

Travel system

NOTE: Before reassembly of the sprocket, the axial play has to be determined, refer to PARTS & SERVICE NEWS No. "AH06529". If necessary adjust the axial play, refer to PARTS & SERVICE NEWS No. "AH06529". For mounting the dual-cone seals (Fig. 4-14, Pos. 2 and Pos. 4), an assembly tool has to be manufactured, refer to PARTS & SERVICE NEWS No. "AH05511". z

Mount new dual-cone seals (Fig. 4-14, Pos. 2 and Pos. 4) into the flange bearing, on the gear side and into the flange bearing (Fig. 4-14, Pos. 8) on the opposite side. Refer to PARTS & SERVICE NEWS No. "AH05511".

z

Mount new dual-cone seals (Fig. 4-14, Pos. 2 and Pos. 4) into the sprocket hub, refer to PARTS & SERVICE NEWS No. "AH05511".

NOTE: Observe the mounting position of the drive shaft when installing it. The splines at the drive shaft have different lengths. The longer splines must point to the gearbox. z

Apply "Optimol White" on the splines of the drive shaft (Fig. 4-14, Pos. 6), the hollow shaft (Fig. 4-14, Pos. 5), and the splines of the planet carrier inside the travel gearbox.

z


NOTE: Apply compound "KP2K", PN 324 969 40 on the sleeve of the flange bearing (Fig. 4-14, Pos. 8), and on heads and threads of new mounting bolts (Fig. 4-14, Pos. 1) of grade 10.9. Use the new mounting bolts with washers to attach the flange bearing with bush (Fig. 4-14, Pos. 7) to the track frame. Tighten the bolts to the specified tightening torque. Tightening torque for flange bearing mounting bolts (Fig. 4-14, Pos. 1): 1770 Nm

Refill oil in the final drive housing, approx. 165 liters. Refer to the Operation & Maintenance Manual, chapter 4, section "TRAVEL GEARS, MOTOR ADAPTER HOUSINGS AND FINAL DRIVES".

Version 2009/2

PC5500-6

4 - 13

Travel system

Undercarriage

4.1.2.3 REMOVAL OF THE SEGMENTED SPROCKET (ONLY FOR TYPE WITH PINNED UNDERCARRIAGE UP TO SN 025) Special tools:

n/a


Personal Protective Equipment (PPE) Crane Dozer 4 forcing screws M20 Hydraulic torque wrench PN 232 614 40 Electro-hydraulic pump aggregate PN 232 613 40 Regular sprocket assembly: Sprocket segment 1 (5 teeth): 794.25 kg Sprocket segment 2 (5 teeth): 794.25 kg Sprocket segment 3 (4 teeth): 661.5 kg Oversize sprocket assembly: Sprocket segment 1 (5 teeth): 968.99 kg Sprocket segment 2 (5 teeth): 968.99 kg Sprocket segment 3 (4 teeth): 807.02 kg Dogman/rigger

NOTE: Make sure that the wear of the track group and the sprocket was measured according to the PARTS & SERVICE NEWS No. "AH02521". NOTE: Only for removal of the segmented sprocket (Fig. 4-15, Pos. 1, 2 and 3) it is not necessary to remove the travel gear (Fig. 4-15, Pos. 4). WARNING Ensure appropriate (PPE) Personal Protective Equipment is used during the task. There maybe sharp edges on the worn sprocket that is being removed.

z

Prepare an area of flat ground twice as large to accommodate the machine, the boom, the dozer and the crane.

z

Park the machine on the prepared flat ground area with the attachment placed at the final drive end of he machine, counterweight above the guide wheels.

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.) make sure that the machine is moved to any location with appropriate ground condition. z

Fig. 4-15


4 - 14

PC5500-6

Version 2009/2

Undercarriage

z

Travel system

Relieve the pressure in the track tensioning system by opening the ball cock (Fig. 4-16, Pos. 1) at the track tensioning valve block (Fig. 4-16, Pos. 2) inside the car body.

NOTE: Make sure that the sprocket runs free after opening the track group and it has no contact to the ground or the track group. For example drive the excavator with the track rollers at the respective crawler frame side onto a knoll.

Fig. 4-16 NOTE: Before beginning the work, block the track group to prevent the track shoes against falling down (refer to Fig. 4-17). z

Open the track group at the sprocket end (Fig. 4-17, Pos. 1), refer to section 4.1.1.1 on page 4-2.

Fig. 4-17 z


z



Drive the excavator and the dozer forwards slowly and unroll the track group from the excavator (refer to Fig. 4-18).



z

Fasten the track group to the carrier roll to hold it in position.

Version 2009/2

PC5500-6

4 - 15

Travel system

Undercarriage

Fig. 4-19 Removal of the sprocket segments z

Turn the sprocket so that the first segment that has to be removed is in the upper position.

z


z

Loosen all bolts (Fig. 4-19, Pos. 1) from the drive sprocket ring (Fig. 4-19, Pos. 3). Don’t remove them. WARNING

Risk of falling weights! Do not remove all bolts from the drive sprocket ring. Death or serious injury may result.

NOTE: Lightly press off drive sprocket ring by means of 4 forcing screws M20 x 80 mm at the drive sprocket ring (Fig. 4-20, Pos. 1). To prevent blocking around the ring, all 4 screws must be tightened evenly. Fig. 4-20 NOTE: In order to avoid damage to the lifting devices, use edge protection at all sharp edges. z

Sling the upper sprocket segment using a crane.

4 - 16

PC5500-6

Version 2009/2

Undercarriage

z

Travel system

Remove the bolts (Fig. 4-19, Pos. 1) from the drive sprocket ring (Fig. 4-19, Pos. 3) at the upper sprocket segment. WARNING

Risk of falling weights! Remove only the bolts from the respective sprocket segment. Death or serious injury may result.

z

Lift the sprocket segment out of the crawler carrier using a crane.

z

De-isolate the machine according to local regulations.

z

Rotate the sprocket slowly by actuating the travel drive so that the next sprocket segment that has to be removed is in upper position.

z


z

To remove the other sprocket segments use the same procedure according to the first segment.

Version 2009/2

PC5500-6

4 - 17

Travel system

Undercarriage

4.1.2.4 REPLACEMENT OF THE SEGMENTED SPROCKET (ONLY FOR TYPE WITH PINNED UNDERCARRIAGE UP TO SN 025) Special tools:

n/a


Personal Protective Equipment (PPE) Crane Dozer Hydraulic torque wrench PN 232 614 40 Electro-hydraulic pump aggregate PN 232 613 40 Coating compound "INTERZINC 697", PN 674 997 40 Compound "KP2K", PN 324 969 40 Regular sprocket assembly: Sprocket segment 1 (5 teeth): 794.25 kg Sprocket segment 2 (5 teeth): 794.25 kg Sprocket segment 3 (4 teeth): 661.5 kg Oversize sprocket assembly: Sprocket segment 1 (5 teeth): 968.99 kg Sprocket segment 2 (5 teeth): 968.99 kg Sprocket segment 3 (4 teeth): 807.02 kg Dogman/rigger

z

Carefully clean all required contact surfaces of the sprocket segments, the sprocket drive ring and the travel gear.

z

The segments of the sprocket have to be erected in the shown arrangement (Fig. 4-21, Pos. 1, 2 and 3). Pos. 1: 5 teeth Pos. 2: 5 teeth Pos. 3: 4 teeth

NOTE: It is not allowed to replace single sprocket segments. Always replace all three segments.

Fig. 4-21 NOTE: If it is necessary to install the oversized sprocket segments, refer to PARTS & SERVICE NEWS No. "AH06529". z

Apply surface coating with coating compound "INTERZINC 697" at the contact surface (Fig. 4-22, Pos. 1) on both sides of the sprocket segments, refer to section 6.3.1 on page 6-7. WARNING

Only reassemble the sprocket segments after the coating compound has fully hardened. Fig. 4-22

4 - 18

PC5500-6

Version 2009/2

Undercarriage

Travel system

Fig. 4-23 Replacement of the sprocket segments z


NOTE: Use new bolts (Fig. 4-23, Pos. 1), nuts (Fig. 4-23, Pos. 2) and washers to attach the new sprocket segments to the travel gear (Fig. 4-23, Pos. 7). Apply compound "KP2K", PN 324 969 40 on heads and threads of the mounting bolts and tighten them to the specified tightening torque.

Tightening torque for sprocket segment mounting bolts (Fig. 4-23, Pos. 1): 3000 Nm

Version 2009/2

PC5500-6

4 - 19

Travel system

4.1.3

Undercarriage

GUIDE WHEELS

4.1.3.1 REMOVAL OF THE GUIDE WHEEL ASSEMBLY Special tools:

n/a


Crane Guide wheel assembly: 3323 kg

Dogman/rigger

z


z




z


Fig. 4-24

4 - 20

PC5500-6

Version 2009/2

Undercarriage

Travel system

z

Remove the track group from the guide wheel, refer to section 4.1.1.1 on page 4-2.

z

Remove bolts (Fig. 4-25, Pos. 1) and remove the stop plates (Fig. 4-25, Pos. 2) from both sides of the guide wheel assembly (Fig. 4-25, Pos. 3).

z


z


z

Sling guide wheel assembly (Fig. 4-25, Pos. 3) and pull the guide wheel assembly out of the crawler carrier.

Fig. 4-25 NOTE: In order to avoid damage to the lifting devices, use edge protection at all sharp edges. z

Sling guide wheel assembly (Fig. 4-26) and pull the guide wheel assembly out of the crawler carrier. WARNING

Ensure to keep hands away for the component sliding surfaces during removal.

Fig. 4-26 z

Check condtion of the sliding surfaces on the crawler carrier and the sliding blocks.

Version 2009/2

PC5500-6

4 - 21

Travel system

Undercarriage

4.1.3.2 REPLACEMENT OF THE GUIDE WHEEL ASSEMBLY Special tools:

n/a


Crane Guide wheel assembly: 3323 kg



NOTE: Observe the mounting position of the sliding blocks (Fig. 4-27, Pos. 3). Assure that the oil plug (Fig. 4-27, Pos. 2) at the guide wheel (Fig. 4-27, Pos. 1) is facing the inner side of the excavator.

Fig. 4-27

4 - 22

PC5500-6

Version 2009/2

Undercarriage

4.1.4

Travel system

TRACK TENSIONING ACCUMULATORS

The hydraulic track tensioning system automatically maintains the correct track tension. The pilot oil pressure of the travel brake release circuit is used to pressurize the four adjusting cylinders. The resulting force moves the guide wheels toward the front, until the correct track tension is obtained. External forces acting upon the guide wheels are absorbed through the pressure accumulators (Fig. 4-28, Pos. 1 and 2). Two different types of pressure accumulators are installed: A high pressure (150 bar) bladder accumulator (Fig. 4-28, Pos. 1) and a low pressure (31 bar) diaphragm type accumulator (Fig. 4-28, Pos. 2). Fig. 4-28

4.1.4.1 REMOVAL OF THE LOW PRESSURE ACCUMULATORS Special tools:

n/a


Oil drain pan Low pressure accumulator: 12 kg For further information about the needed blind plugs, refer to section 2.3 on page 2-37.

z


z


Fig. 4-29

Version 2009/2

PC5500-6

4 - 23

Travel system

z

Undercarriage

Remove the cover (Fig. 4-30, Pos. 1). WARNING

Hot hydraulic oil! Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is below 50°C. Disobedience may result in personal injury from heated oil.


z

Fig. 4-30

Disconnect the pressure hose (Fig. 4-31, Pos. 1).

NOTE: When the pressure hose is removed, hydraulic oil from inside the piping and the pressure accumulator will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Remove four bolts (Fig. 4-31, Pos. 4) and remove the pressure accumulator (Fig. 4-31, Pos. 3).

z

Remove union (Fig. 4-31, Pos. 2).

Fig. 4-31

4 - 24

PC5500-6

Version 2009/2

Undercarriage

Travel system

4.1.4.2 REPLACEMENT OF THE LOW PRESSURE ACCUMULATORS Special tools:

Testing and refilling device, PN 761 520 73


n/a Low pressure accumulator: 12 kg If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.2 on page 2-33.

z


z

Fill the pressure accumulator with nitrogen gas (N2). Refer to PARTS & SERVICE NEWS No. "AH01531". DANGER

Danger of explosion! Blindness, serious injury, permanent disfigurement, scaring, or death may result. Only fill pressure accumulators with nitrogen gas (N2). Do not use any other gases due to explosion hazard!

z

Bleed the track tensioning system. Refer to the Operation & Maintenance Manual, chapter 4, section "CRAWLER TRACK - INSPECTION".

z


z

Check the track tension system and adjust if required. Refer to the Service Manual for further information.

Version 2009/2

PC5500-6

4 - 25

Travel system

Undercarriage

4.1.4.3 REMOVAL OF THE HIGH PRESSURE ACCUMULATORS Special tools:

n/a


n/a High pressure accumulator: 23 kg For further information about the needed blind plugs, refer to section 2.3 on page 2-37.

z


z

Relieve the pressure in the track tensioning system by opening the ball cock (Fig. 4-32, Pos. 1) at the track tensioning valve block (Fig. 4-32, Pos. 2) inside the car body. WARNING


Fig. 4-32


z

Disconnect the pressure hose assembly (Fig. 4-33, Pos. 1).

NOTE: When the pressure hose is removed, hydraulic oil from inside the piping and the pressure accumulator will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Open two clamp clips (Fig. 4-33, Pos. 2) and remove the pressure accumulator (Fig. 4-33, Pos. 3).

z

Remove the socket (Fig. 4-33, Pos. 4) from the pressure accumulator (Fig. 4-33, Pos. 3).

4 - 26

PC5500-6

Fig. 4-33

Version 2009/2

Undercarriage

Travel system

4.1.4.4 REPLACEMENT OF THE HIGH PRESSURE ACCUMULATORS Special tools:

Testing and refilling device, PN 761 520 73


n/a High pressure accumulator: 23 kg If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.2 on page 2-33.

z


z

Fill the pressure accumulator with nitrogen gas (N2). Refer to PARTS & SERVICE NEWS No. "AH01531". DANGER

Danger of explosion! Blindness, serious injury, permanent disfigurement, scaring, or death may result. Only fill pressure accumulators with nitrogen gas (N2). Do not use any other gases due to explosion hazard!

z


z


z


Version 2009/2

PC5500-6

4 - 27

Travel system

4.1.5

Undercarriage

TRACK TENSION VALVE BLOCK

4.1.5.1 REMOVAL OF THE TRACK TENSIONING VALVE BLOCK Special tools:

n/a


Chain host Oil drain pan Track tensioning valve block: 40 kg For further information about the needed blind plugs, refer to section 2.3 on page 2-37.

z


z



Fig. 4-34


z

Disconnect all piping (Fig. 4-35, Pos. 2) from the track tensioning valve block (Fig. 4-35, Pos. 1).

NOTE: When the piping is removed, hydraulic oil from inside the piping and the track tensioning valve block will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Find an appropriate suspension point for the chain hoist and sling the track tensioning valve block (Fig. 4-35, Pos. 1).

z

Remove four mounting bolts and let down the track tensioning valve block (Fig. 4-35, Pos. 1) using the chain hoist.

4 - 28

PC5500-6

Fig. 4-35

Version 2009/2

Undercarriage

Travel system

z

Remove the pressure increase valve (Fig. 4-36, Pos. 1) from the track tensioning valve block.

z

Remove the check valves (Fig. 4-36, Pos. 2) from the track tensioning valve block.

z

Remove the unions (Fig. 4-36, Pos. 3) from the track tensioning valve block.

Fig. 4-36

4.1.5.2 REPLACEMENT OF THE TRACK TENSIONING VALVE BLOCK Special tools:

n/a


Chain host Track tensioning valve block: 40 kg If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.2 on page 2-33.

z


z


z


z


Version 2009/2

PC5500-6

4 - 29

Travel system

Undercarriage


4 - 30

PC5500-6

Version 2009/2

Undercarriage

4.1.6

Travel system

HYDRAULIC HOSES OF THE TRACK TENSIONING SYSTEM

4.1.6.1 SUBSTITUTE THE HYDRAULIC HOSES Special tools:

n/a


Oil drain pan Hydraulic hose: 10 kg max. If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.2 on page 2-33. For further information about the needed blind plugs, refer to section 2.3 on page 2-37

z

Prepare an area of flat ground large enough to accommodate the machine.

z


z


z



Fig. 4-37 DANGER Danger of hydraulic pressure! Blindness, serious injury, permanent disfigurement, or scaring may result. The hydraulic system may be pressurized. Make sure that the pressure is relieved before any hydraulic line will be removed.

NOTE: In the following descriptions, the hydraulic hoses are replaced one at a time.

Version 2009/2

PC5500-6

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Travel system

Undercarriage

Fig. 4-38 Hydraulic hoses of the track tensioning system

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Travel system

Substitute the hydraulic hoses (Fig. 4-38, Pos. 1): z


z

If equipped with protection sleeve (Fig. 4-38, Pos. 9), clear the hydraulic hose to be removed by opening the protection sleeve.

z

Disconnect both ends of the hydraulic hose to be removed.

NOTE: When the hose is disconnected, hydraulic oil from inside the piping and/or the track tensioning valve block will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Pull out the hydraulic hose completely.

z

Insert a new hydraulic hose.

z

Reinstall the cover (Fig. 4-39, Pos. 1).

Fig. 4-39

Substitute the hydraulic hoses (Fig. 4-38, Pos. 3, 4, and 5): z


z

Remove the cover (Fig. 4-40, Pos. 2) and open the clamp (Fig. 4-38, Type B) only if the hoses (Fig. 4-38, Pos. 4 and 5) for the track tensioning cylinders will be replaced.

z

Disconnect both ends of the hydraulic hose to be removed and replace the hose by a new one.

NOTE: When the hose is disconnected, hydraulic oil from inside the piping and/or the track tensioning valve block will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Fig. 4-40

Reinstall the cover(s) (Fig. 4-40, Pos. 1, 2).

Substitute the hydraulic hoses (Fig. 4-38, Pos. 2, 6, 7, and 8): z

Clear the hydraulic hose (Fig. 4-38, Pos. 6, 7, and 8) to be removed by opening the clamps (Fig. 4-38, Type A or B).

z

Disconnect both ends of the hydraulic hose to be removed and replace the hose by a new one.

NOTE: When the hose is disconnected, hydraulic oil from inside the piping and/or the track tensioning valve block will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination.

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Travel system

Undercarriage

Subsequent work z


z


z


4.1.7

TRAVEL BRAKE VALVE BLOCK (OVERSPEED VALVE)

Fig. 4-41 Travel brake valve blocks (1)

Travel brake valve block

(2)

Travel motor

The travel brake valve blocks (Fig. 4-41, Pos. 1) protect the travel motors (Fig. 4-41, Pos. 2) from overspeed during downhill travel. Two travel brake valve blocks are installed, one valve block for the two travel motors of each crawler track.

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Version 2009/2

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Travel system

4.1.7.1 REMOVAL OF THE TRAVEL BRAKE VALVE BLOCK Special tools:

n/a


Chain hoist Oil drain pan Travel brake valve block: 75 kg each For further information about the needed blind plugs, refer to section 2.3 on page 2-37.

z


z




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Travel system

Undercarriage

z

Disconnect the pressure hoses (Fig. 4-42, Pos. 2) to the rotary joint from the travel brake valve block (Fig. 4-42, Pos. 4).

z

Disconnect the hydraulic lines (Fig. 4-42, Pos. 1) to the travel motors from the travel brake valve block (Fig. 4-42, Pos. 4).

z

Disconnect the leakage oil line from the travel brake valve block (Fig. 4-42, Pos. 4).

NOTE: When the hydraulic lines are disconnected, hydraulic oil from inside the piping and the travel brake valve block will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Discard the O-rings (Fig. 4-42, Pos. 5).

z

Sling the travel brake valve block (Fig. 4-42, Pos. 4) at the installed hoist rings.

z

Remove the mounting bolts (Fig. 4-42, Pos. 3) and lift off the travel brake valve block (Fig. 4-42, Pos. 4) using a chain hoist.

z

Remove the relief valve (Fig. 4-43, Pos. 1) from the travel brake valve block (Fig. 4-43, Pos. 2).

Fig. 4-42

Fig. 4-43

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PC5500-6

Version 2009/2

Undercarriage

Travel system

4.1.7.2 REPLACEMENT OF THE TRAVEL BRAKE VALVE BLOCK Special tools:

n/a


Chain hoist Travel brake valve block: 75 kg If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.2 on page 2-33.

z


NOTE: Tighten the relief valve (Fig. 4-43, Pos. 1) to the specified torque. Tightening torque for relief valve (Fig. 4-43, Pos. 1): 300 Nm z


z


z

Check the travel system and adjust if required. Refer to the Service Manual for further information.

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4.1.8

Undercarriage

TRACK TENSIONING CYLINDERS

4.1.8.1 REMOVAL OF THE TRACK TENSIONING CYLINDERS Special tools:

n/a


Crane Oil drain pan Track tension cylinder: 400 kg each



z




z

Remove the guide wheel assembly, refer to section 4.1.3.1 on page 4-20.

z

Remove the cover (Fig. 4-44, Pos. 1). WARNING


Fig. 4-44

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Version 2009/2

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Travel system


z

Disconnect the pressure hoses from the track tension cylinder, refer to section 4.1.6 on page 4-31.

NOTE: When the pressure hoses are removed, hydraulic oil from inside the piping and the track tension cylinder will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Sling the track tension cylinder and pull the cylinder out of its guidance.

4.1.8.2 REPLACEMENT OF THE TRACK TENSIONING CYLINDERS Special tools:

n/a


Crane Track tension cylinder: 400 kg each



z

Bleed the track tensioning system. Refer to Operation & Maintenance Manual, chapter 4, section "CRAWLER TRACK - INSPECTION".

z


z

Check the track tensioning system and adjust if required. Refer to the Service Manual for further information.

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Travel system

4.1.9

Undercarriage

TRAVEL MOTOR

The travel motor is an axial piston unit with fixed displacement. The drive speed is proportional to the consumption capacity. The output torque increases with the pressure drop between high and low pressure side.

4.1.9.1 REMOVAL OF THE TRAVEL MOTORS Special tools:

n/a


Crane Oil drain pan Travel motor: 110 kg each



z




z


z

If equipped, remove the motor protection, refer to the PARTS & SERVICE NEWS No. "AH08503". Drain oil of the motor adapter housing, approx. 2 liters (L&S) each, 0.5 liters (Zollern) each. Refer to Operation & Maintenance Manual, chapter 4, section "TRAVEL GEARS, MOTOR ADAPTER HOUSINGS AND FINAL DRIVES CHANGE OIL".

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Version 2009/2

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Travel system

WARNING Hot hydraulic oil! Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is below 50°C. Disobedience may result in personal injury from heated oil.


z

Remove the pressure hoses (Fig. 4-45, Pos. 2) and the leak oil hoses (Fig. 4-45, Pos. 1 / Fig. 4-46, Pos. 4) from the travel motor (Fig. 4-45, Pos. 3).

NOTE: When the hoses are removed, hydraulic oil from inside the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Discard the O-rings.

NOTE: In order to avoid damage to the lifting devices, use edge protection at all sharp edges. z

Sling travel motor (Fig. 4-45, Pos. 3) and remove the mounting bolts (Fig. 4-45, Pos. 4). Discard the bolts.

z

Remove the travel motor (Fig. 4-45, Pos. 3) by pulling it out of the motor adapter housing (Fig. 4-45, Pos. 5) of the travel parking brake using a crane.

Fig. 4-45

DANGER Risk of falling weights! Death or serious injury may result. When lifting the travel motor, make sure that nobody steps below the weight. Fig. 4-46

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Travel system

Undercarriage

4.1.9.2 REPLACEMENT OF THE TRAVEL MOTORS Special tools:

n/a


Crane Paste "Optimol White" PN 999 039 Compound "KP2K", PN 324 969 40 Travel motor: 110 kg

Dogman/rigger If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.2 on page 2-33. NOTE: Ensure that the mating surfaces are clean and free of paint before assembly. z

Apply "Optimol White" at the spline shaft of the travel motor (Fig. 4-47, Pos. 1) before attaching the travel motor to the motor adapter housing (Fig. 4-47, Pos. 3).

Fig. 4-47 z


NOTE: Use new mounting bolts (Fig. 4-47, Pos. 2) of grade 10.9. Apply compound "KP2K", PN 324 969 40 on heads and threads of the mounting bolts and tighten them to the specified tightening torque. Tightening torque for travel motor mounting bolts: 265 Nm z

Add hydraulic oil up to the specified level. Refill oil of the motor adapter housing, approx. 2 liters (L&S) each, 0.5 liters (Zollern) each. Refer to Operation & Maintenance Manual, chapter 4, section "TRAVEL GEARS, MOTOR ADAPTER HOUSINGS AND FINAL DRIVES CHANGE OIL".

z

If equipped, install the motor protection, refer to the PARTS & SERVICE NEWS No. "AH08503".

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Version 2009/2

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Travel system


Version 2009/2

PC5500-6

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Travel system

Undercarriage

4.1.10 TRAVEL PARKING BRAKE

Fig. 4-48 Travel parking brake assembly (dry-type) NOTE: Up to SN 025, the travel gearboxes have been equipped with wet-type brakes. For information about the fluid, refer to section 6.1 on page 6-2.

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Version 2009/2

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Travel system


Disc carrier

(2)

Snap ring

(3)

Retainer

(4)

O-ring

(5)

Seal ring

(6)

Plug screw

(7)

Control pressure port to release the brake

(8)

Spring

(9)

Spring

(10)

O-ring

(11)

Snap ring

(12)

Retainer

(13)

Disk housing

(14)

O-ring

(15)

Radial seal rings

(16)

Piston

(17)

Quad-ring

(18)

Back-up rings

(19)

Back-up rings

(20)

Quad-ring

(21)

Outer discs

(22)

Inner discs

Brake applied: The outer discs (Fig. 4-48, Pos. 21) engaged to the housing by serration and the inner discs (Fig. 4-48, Pos. 1) in serration connection with the disc carrier are pressed together by the springs (Fig. 4-48, Pos. 8 and 9). This results in a fixed connection between housing and disc carrier (Fig. 4-48, Pos. 23). Brake released: Oil pressure via the control pressure port (Fig. 4-48, Pos. 7) forces the piston (Fig. 4-48, Pos. 16) against the springs (Fig. 4-48, Pos. 8 and 9) toward the retainer (Fig. 4-48, Pos. 12). This function eliminates the spring force onto the discs, thus the brake is released. The minimum release pressure is 18 bar, the maximum permissible pressure is 60 bar.

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PC5500-6

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Travel system

Undercarriage

4.1.10.1 REMOVAL OF THE TRAVEL PARKING BRAKE Special tools:

n/a


Crane Oil drain pan Travel parking brake: 75 kg

Dogman/rigger If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.2 on page 2-33. For further information about the needed blind plugs, refer to section 2.3 on page 2-37 z

Prepare an area of flat ground large enough to accommodate the machine and boom.

z


NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to a location with appropriate ground condition. z

Place wedges at front and rear side of both crawlers and lower the bucket onto the ground.

z

Relieve the pressure in the hydraulic system. Refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".

z



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Version 2009/2

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Travel system


z

Remove the relevant travel motor (Fig. 4-49, Pos. 6 and 7 respectively), refer to section 4.1.9.1 on page 4-40.

z

Remove the pressure hose (Fig. 4-49, Pos. 3) and the breather hose (Fig. 4-49, Pos. 4) from the travel parking brake (Fig. 4-49, Pos. 1 and 5 respectively).

NOTE: When the pressure hose is removed, hydraulic oil from inside the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. NOTE: In order to avoid damage to the lifting devices, use edge protection at all sharp edges. z

Fig. 4-49

If equipped with wet-type travel parking brakes (up to SN 025): Drain oil of the travel parking brake housing, approx. 0.1 liters.

z

Sling the travel parking brake (Fig. 4-49, Pos. 1 and 5 respectively).

z

Remove the mounting bolts (Fig. 4-49, Pos. 2) of the travel parking brake (Fig. 4-49, Pos. 1 and 5 respectively).

z

Remove the travel parking brake (Fig. 4-49, Pos. 1 and 5 respectively) by pulling it out of the travel gearbox using a crane. DANGER

Risk of falling weights! Death or serious injury may result. When lifting the parking brake, make sure that nobody steps below the weight.

Version 2009/2

PC5500-6

4 - 47

Travel system

Undercarriage

4.1.10.2 REPLACEMENT OF THE TRAVEL PARKING BRAKE Special tools:

n/a


Crane Paste "Optimol White" PN 999 039 Portable pressure source (hydraulic or air) Travel parking brake: 75 kg

Dogman/rigger If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.2 on page 2-33. NOTE: Ensure that the mating surfaces are clean and free of paint before assembly. z

Apply "Optimol White" at the input spline shaft (Fig. 4-50, Pos. 4) of the travel gearbox. DANGER

Risk of retainer (Fig. 4-50, Pos. 3) blasting off! Death or serious injury may result. Do not exceed the maximum pressure of 60 bar at the pressure port.

NOTE: Travel brake may need to be released to allow the splines to line up or the mounting bolts (Fig. 4-50, Pos. 1) to be installed. Therefore first install a portable pressure source to the pressure port (Fig. 4-50, Pos. 2) (M18 x 1.5) at the travel parking brake and apply 20 bar.

Fig. 4-50 z


z

If equipped with wet-type travel parking brakes (machines up to SN 025): Refill oil of the travel parking brake housing, approx. 0.1 liters.

CAUTION Since SN 026, the travel parking brakes are dry multiple disk brakes. DO NOT fill the housings with oil.

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Version 2009/2

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Travel system

z


z

Perform a function check of the travel parking brake. Refer to the Service Manual for further information.

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PC5500-6

4 - 49

Travel system

Undercarriage

4.1.11 TRAVEL GEARBOX

Fig. 4-51 Travel gearbox removal (1)

Drive shaft

(2)

O-ring

(3)

Travel gearbox

(4)

Travel motor

(5, 6)

Mounting bolts and washers for travel motor

(7, 8)

Mounting bolts and washers for travel gear to crawler carrier

(9)

Crawler carrier

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Version 2009/2

Undercarriage

Travel system

4.1.11.1 REMOVAL OF THE TRAVEL GEARBOX Special tools:

n/a


Hydraulic torque wrench PN 232 614 40 Electro-hydraulic pump aggregate PN 232 613 40 Crane Oil drain pan Travel gearbox: 4020 kg



z



Place wedges at front and rear side of both crawlers and lower the bucket onto the ground.

z


z


z

If equipped, remove the travel gearbox protection, refer to the PARTS & SERVICE NEWS No. "AH08503". WARNING


Version 2009/2

PC5500-6

4 - 51

Travel system

Undercarriage

Drain oil of the final drive housing, approx. 165 liters. Drain oil of the travel gear housing, approx. 155 liters (L&S), 180 liters (Zollern). Refer to the Operation & Maintenance Manual, chapter 4, section "TRAVEL GEARS, MOTOR ADAPTER HOUSINGS AND FINAL DRIVES".

WARNING Danger of hydraulic pressure! Blindness, serious injury, permanent disfigurement, or scaring may result. The hydraulic system may be pressurized. Make sure that the pressure is relieved before any hydraulic line will be removed..

z

Remove the two travel parking brakes, (Fig. 4-52, Pos. 1), refer to section 4.1.10.1 on page 4-46.

z

Remove breather hose (Fig. 4-52, Pos. 2) from the travel gearbox.

NOTE: Cap the openings with blind plugs to avoid contamination. z

Remove the driving performance meter (Fig. 4-53, Pos. 4) and cap the opening to avoid contamination.

Fig. 4-52 NOTE: In order to avoid damage to the lifting devices, use edge protection at all sharp edges. z

Sling the travel gearbox (Fig. 4-53, Pos. 3) at the installed hoist ring (Fig. 4-53, Pos. 2).

z

Remove the mounting bolts (Fig. 4-53, Pos. 5) with washers (Fig. 4-53, Pos. 6). Discard the bolts and washers.

z

Extract the travel gearbox (Fig. 4-53, Pos. 3) from the crawler carrier (Fig. 4-53, Pos. 7) using a crane.

z

Remove the O-ring (Fig. 4-53, Pos. 1) and discard it.

Fig. 4-53

DANGER Risk of falling weights! Death or serious injury may result. When lifting the travel gearbox, make sure that nobody steps below the weight.

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Version 2009/2

Undercarriage

Travel system

4.1.11.2 REPLACEMENT OF THE TRAVEL GEARBOX Special tools:

n/a


Hydraulic torque wrench PN 232 614 40 Electro-hydraulic pump aggregate PN 232 613 40 Crane Paste "Optimol White" PN 999 039 Compound "KP2K", PN 324 969 40 Travel gearbox: 4020 kg


NOTE: Ensure that the mating surfaces on the crawler carrier and travel gearbox (Fig. 4-54, Pos. 2) are clean and free of paint before assembly. z

Replace the driving performance meter (Fig. 4-54, Pos. 4).

z

Insert a new O-ring (Fig. 4-54, Pos. 2).

z

Apply "Optimol White" at the drive shaft (Fig. 4-54, Pos. 1) and the splines of the planet carrier inside the travel gearbox.

z

Sling the travel gearbox at the installed hoist ring (Fig. 4-54, Pos. 3). Fig. 4-54 DANGER

Risk of falling weights! Death or serious injury may result. When lifting the travel gearbox, make sure that nobody steps below the weight.

z

Align the travel gearbox to the drive shaft (Fig. 4-54, Pos. 1) and flange it to the crawler carrier.

z

Use new mounting bolts (Fig. 4-54, Pos. 5) of grade 10.9 and apply compound "KP2K", PN 324 969 40 on heads and threads of the bolts. Insert the new mounting bolts and washers (Fig. 4-54, Pos. 6) and tighten the bolts to the specified tigtening torque. Tightening torque for travel gearbox mounting bolts (Fig. 4-54, Pos. 6): 3100 Nm

Version 2009/2

PC5500-6

4 - 53

Travel system

z

Undercarriage

Carry out further installation in reverse order to removal. Refill oil of the final drive housing, approx. 165 liters. Refill oil of the travel gear housing, approx. 155 liters (L&S), 180 liters (Zollern). Refer to the Operation & Maintenance Manual, chapter 4, section "TRAVEL GEARS, MOTOR ADAPTER HOUSINGS AND FINAL DRIVES".

NOTE: Be sure to fill in the correct oil as specified, refer to section 6.1 on page 6-2. Refill oil of the motor adapter housing, approx. 2 liters (L&S) each, 0.5 liters (Zollern) each. Refer to the Operation & Maintenance Manual, chapter 4, section "TRAVEL GEARS, MOTOR ADAPTER HOUSINGS AND FINAL DRIVES". z

If equipped with wet-type travel parking brakes (machines up to SN 025): Refill oil of the travel parking brake housing, approx. 0.1 liters.

CAUTION Since SN 026, the travel parking brakes are dry multiple disk brakes. DO NOT fill the housings with oil.

z


z

Perform a function check of the travel parking brake. Refer to the Service Manual for further information.

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Version 2009/2

Undercarriage

Travel system

4.1.11.3 REMOVAL OF THE TRAVEL GEARBOX (ONLY FOR TYPE WITH PINNED UNDERCARRIAGE UP TO SN 025) Special tools:

n/a


Personal Protective Equipment (PPE) Crane Oil drain pan Hydraulic torque wrench PN 232 614 40 Travel motor: 110 kg each Spur gear housing with mounted brake housing: 580 kg Support bearing cover: 400 kg Spindle with installed support bearing: 278 kg Planetary gear housing with mounted sprocket: 7250 kg (7750 kg with oversize sprocket assembly) Drive sprocket ring: 244 kg Dogman/rigger For further information about the needed blind plugs, refer to section 2.3 on page 2-37.

z

Prepare an area of flat ground twice as large to accommodate the machine, the boom, the dozer and the crane.

z

Park the machine on the prepared flat ground area with the attachment placed at the final drive end of the machine, counterweight above the guide wheels.

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.) make sure that the machine is moved to any location with appropriate ground condition. NOTE: Before beginning the work, block the track group to prevent the track shoes against falling down (refer to Fig. 4-55). z

Relieve the pressure in the track tensioning system according to the PARTS & SERVICE NEWS "AH06530".

NOTE: The procedure in the PARTS & SERVICE NEWS "AH06530" prevent the track tensioning cylinders to get pressurized when moving the excavator. z

Open the track group at the sprocket end (Fig. 4-55, Pos. 1), refer to section 4.1.1.1 on page 4-2. Fig. 4-55

Version 2009/2

PC5500-6

4 - 55

Travel system

Undercarriage

z


z



Drive the excavator and the dozer forwards slowly and unroll the track group from the sprocket (refer to Fig. 4-56).



NOTE: Fasten the track group to the carrier roll to hold it in position.

Fig. 4-57 Removal / Replacement of the travel gearbox

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Version 2009/2

Undercarriage

Travel system

WARNING Danger of hydraulic pressure! Blindness, serious injury, permanent disfigurement, or scaring may result. The hydraulic system my be pressurized. Make sure that the pressure is relieved before any hydraulic line will be removed.

z


NOTE: For removal of the travel gearbox (Fig. 4-57, Pos. 1) from the crawler frame it is not necessary to remove the sprocket (Fig. 4-57, Pos. 3). z

Remove the travel motors from the travel gearbox, refer to section 4.1.9.1 on page 4-40. WARNING


Drain oil of the spur gear housing, approx. 10 liters. Drain oil of the planetary gear housing, approx. 105 liters. Drain oil of the support bearing, approx. 3.5 liters. Refer to the Operation & Maintenance Manual, chapter 4, section "TRAVEL GEARS, MOTOR ADAPTER HOUSINGS AND FINAL DRIVES".

z

Exchange one mounting bolt (Fig. 4-58, Pos. 1) between the travel motor flanges (Fig. 4-58, Pos. 2) with an adequate swivel hoist ring.

Fig. 4-58

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Travel system

Undercarriage

z

If equipped, remove the driving performance meter (Fig. 4-59, Pos. 1) and cap the opening to avoid contamination.

z

Sling the spur gear housing (Fig. 4-59, Pos. 2) together with the brake housing (Fig. 4-59, Pos. 3) at the installed swivel hoist ring and at both brake housings in a way the components are kept in upright position.

z

Remove the remaining mounting bolts (Fig. 4-59, Pos. 4) and install 3 threaded pins (M16×130, thread length: 30 mm) evenly distributed at the circumference as guidance elements.

z

Remove the spur gear housing by pulling it off the spindle (Fig. 4-59, Pos. 5) of the planetary gear housing. DANGER

Risk of falling weights! Death or serious injury may result. When lifting the travel gearbox, make sure that nobody steps below the weight.

Fig. 4-59

NOTE: To loosen a seized connection, jack bolts (M16) can be installed at two threaded bores (Fig. 4-58, Pos. 3).

z

Exchange the upmost mounting bolt (M30) with an adequate swivel hoist ring (Fig. 4-60, Pos. 1).

z

Sling the planetary gear housing at the swivel hoist ring (Fig. 4-60, Pos. 1) and at the sprocket (Fig. 4-60, Pos. 3).

z

Tense the sling gear to ease the load of the travel gear mounting bolts.

Fig. 4-60

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Travel system

z

Remove 3 mounting bolts (Fig. 4-61, Pos. 1) evenly distributed at the support bearing cover and install 3 threaded pins (M30×300, thread length: 80 mm) instead.

z

Remove the remaining mounting bolts (Fig. 4-61, Pos. 1).

z

Pull out the support bearing cover (Fig. 4-61, Pos. 2) out of the bore in the crawler frame using 3 jack bolts inserted in the threaded bores (Fig. 4-61, Pos. 3). WARNING

Sling the bearing cover as soon as possible and support it using an adequate lifting device to prevent the bearing cover from falling.

z

Remove the support bearing cover and the threaded pins.

z

Remove 3 mounting bolts (Fig. 4-62, Pos. 1) evenly distributed at the circumference of the spindle and install 3 threaded pins (M27×300, thread length: 40 mm) instead.

z

Remove the remaining mounting bolts (Fig. 4-62, Pos. 1) and pull the spindle (Fig. 4-62, Pos. 2) from the planetary gear cover (Fig. 4-62, Pos. 3).

Fig. 4-61

WARNING Sling the spindle (Fig. 4-62, Pos. 2) as soon as possible and support it using an adequate lifting device to prevent the spindle from falling.

z

Discard the dual cone seal halves attached to the bearing cover and the spindle (Fig. 4-62, Pos. 4).

NOTE: For further information about the dual cone seals, refer to PARTS & SERVICE NEWS No. "AH05511".

Version 2009/2

PC5500-6

Fig. 4-62

4 - 59

Travel system

Undercarriage

z

Remove the mounting bolts (Fig. 4-63, Pos. 1) attaching the spindle (Fig. 4-63, Pos. 2) to the crawler frame (travel motor side) (Fig. 4-63, Pos. 3).

z

Pull the planetary gear housing out of the bore in the crawler frame and lift it out of the crawler frame using a crane. DANGER

Risk of falling weights! Death or serious injury may result. When lifting the planetary gear housing, make sure that nobody steps below the weight.

Fig. 4-63 z

Lower the planetary gear housing (Fig. 4-64, Pos. 1) to the ground and rest it on appropriate supports (Fig. 4-64, Pos. 2).

NOTE: For the removal of the segmented sprocket (Fig. 4-64, Pos. 3) and the mounting ring (Fig. 4-64, Pos. 4), refer to section 4.1.2.3 on page 4-14.

Fig. 4-64

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Travel system

4.1.11.4 REPLACEMENT OF THE TRAVEL GEARBOX (ONLY FOR TYPE WITH PINNED UNDERCARRIAGE UP TO SN 025) Special tools:

n/a


Personal Protective Equipment (PPE) Crane Hydraulic torque wrench PN 232 614 40 Electro-hydraulic pump aggregate PN 232 613 40 3 x Threaded pin M16x130 (thread length: 30 mm) 3 x Threaded pin M27x300 (thread length: 40 mm) 3 x Threaded pin M30x300 (thread length: 80 mm) Paste "Optimol White", PN 999 039 Fluid "Loctite 245", PN 170 470 40 Sealant "Loctite 574", PN 255 239 40 Compound "KP2K", PN 324 969 40 Support bearing cover: 400 kg Spindle with installed support bearing: 278 kg Spur gear housing with mounted brake housing: 580 kg Planetary gear housing with mounted sprocket: 7250 kg (7750 kg with oversize sprocket assembly) Drive sprocket ring: 244 kg Dogman/rigger For further information about the needed blind plugs, refer to section 2.3 on page 2-37.

NOTE: It is assumed that all parts to be installed are checked and approved, and parts are replaced if required. For the following description it is also assumed that the components to be installed are in the same state of assembly as after removal. NOTE: Ensure that the mating surfaces are cleaned thoroughly, and that sealants are removed completely.

Version 2009/2

PC5500-6

4 - 61

Travel system

z

Undercarriage

Instal the segmented sprocket (Fig. 4-65, Pos. 3) to the planetary gear housing (Fig. 4-65, Pos. 1), refer to section 4.1.2.4 on page 4-18.

NOTE: Align the sprocket segments to the mounting bores in the travel gearbox by means of two pipes (dia. 38 mm×1000 mm). Instal three swivel hoist rings to the drive sprocket ring (Fig. 4-65, Pos. 4), and put the drive sprocket ring on the sprocket segments using a crane. Remove the swivel hoist rings. Use new bolts, nuts, and washers to attach the sprocket segments and the sprocket ring to the travel gear (Fig. 4-65, Pos. 1). Apply compound "KP2K", PN 324 969 40 on heads and threads of the mounting bolts and tighten them to the specified tightening torque.

Fig. 4-65

Tightening torque for drive sprocket ring mounting bolts (Fig. 4-23, Pos. 1): 3000 Nm z

Install a swivel hoist ring (Fig. 4-66, Pos. 1) to the planetary gear housing (Fig. 4-66, Pos. 9) in exchange for a mounting bolt at the rear cover of the planetary gear housing.

NOTE: Pay attention to the position of the oil plugs. z

Hook up the planetary gear housing at the installed swivel hoist ring (Fig. 4-66, Pos. 1) and the sprocket (Fig. 4-66, Pos. 3).

NOTE: Use a chain hoist (Fig. 4-66, Pos. 2) to align the planetary gear housing vertically. z

Apply "Optimol White" to the bore (Fig. 4-66, Pos. 8) in the crawler frame (travel motor side) (Fig. 4-66, Pos. 7).

z

Lift the planetary gear housing to the inside of the crawler carrier.

z

Align the spindle (Fig. 4-66, Pos. 4) of the planetary gear housing to the bores in the crawler frame and move it into the bore.

z

Apply compound "KP2K", PN 324 969 40 on heads and threads of the mounting bolts (Fig. 4-66, Pos. 6) and insert the mounting bolts with washers (Fig. 4-66, Pos. 5).

z

Tighten all mounting bolts to the specified tightening torque using the hydraulic torque wrench PN 232 614 40.

Fig. 4-66

Tightening torque for travel gearbox mounting bolts (Fig. 4-66, Pos. 6): 3000 Nm

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Travel system

NOTE: Leave the planetary gear housing hooked up to the crane. z

Install one half of the dual cone seal (Fig. 4-67, Pos. 1) to the support bearing spindle (Fig. 4-66, Pos. 2).

NOTE: Before installation, moist rubber seal ring with a mixture of water and spirit. For further information about mounting dual cone seals and the assembly tool that has to be used, refer to PARTS & SERVICE NEWS No. "AH05511". z

If required, install a new bearing (Fig. 4-66, Pos. 3) to the spindle.

Fig. 4-67 z

Install 3 threaded pins (M27×300 mm, thread length: 40 mm) equally distributed at the planetary gear housing (Fig. 4-68, Pos. 3) into the bores for the spindle mounting bolts (Fig. 4-68, Pos. 1).

z

Lift the spindle (Fig. 4-68, Pos. 2) by means of an adequate lifting device and move it onto the threaded pins. DANGER

Risk of falling weights! Death or serious injury may result. When lifting the support bearing spindle, make sure that nobody steps below the weight.

z

Apply compound "Loctite 245" on the threads of new mounting bolts (Fig. 4-68, Pos. 1) of grade 10.9, insert the mounting bolts with new HV-washers, and tighten the mounting bolts to the specified tightening torque.

Fig. 4-68

Tightening torque for spindle mounting bolts: 1520 Nm z

Remove the threaded pins.

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Travel system

Undercarriage

z

Apply oil onto the support bearing (Fig. 4-69, Pos. 4).

z

Apply paste "Optimol White" onto the bore in the crawler frame (Fig. 4-69, Pos. 6).

z

Install the other half of the dual cone seal (Fig. 4-69, Pos. 5) to the bearing cover (Fig. 4-69, Pos. 7).

NOTE: Before installation, moist rubber seal ring with a mixture of water and spirit. For further information about mounting dual cone seals and the assembly tool that has to be used, refer to PARTS & SERVICE NEWS No. "AH05511". z

Align the support bearing (Fig. 4-69, Pos. 4) to the bore in the crawler frame concentrically.

NOTE: Max. allowable eccentricity: 0.05 mm. If required, lift gear housing by means of hydraulic jacks and keep it in position using appropriate supports. z

Install 3 threaded pins (M30×300 mm, thread length: 80 mm) equally distributed to the bores in the crawler frame (Fig. 4-69, Pos. 6).

z

Sling the support bearing cover (Fig. 4-69, Pos. 7) and slip it onto the threaded pins.

Fig. 4-69

DANGER Risk of falling weights! Death or serious injury may result. When lifting the bearing cover, make sure that nobody steps below the weight.

NOTE: Pay attention to the position of the oil plugs in the bearing cover. z

Shift bearing cover over the support bearing into the bore in the crawler frame by means of 5 bolts (M30×160 mm) and washers, both delivered with the travel gear.

z

Remove the bolts.

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Undercarriage

z

Travel system

Install new mounting bolts (Fig. 4-69, Pos. 1) of grade 10.9 with washers (Fig. 4-69, Pos. 2).

NOTE: Apply compound "KP2K", PN 324 969 40 and tighten the bolts to the specified tightening torque. Tightening torque for bearing cover mounting bolts: 710 Nm z

Remove the lifting gear and the supporting tools from the gear housing.

z

Sling the spur gear housing (Fig. 4-70, Pos. 3) with the installed brake housing.

z

Install new O-ring (Fig. 4-70, Pos. 5) to the spur gear housing.

NOTE: Apply paste "Loctite 574" onto the sealing / mating surfaces (Fig. 4-70, Pos. 2). z

Install 3 threaded pins (M16×130, thread length: 30 mm) into 3 bores for the spur gear mounting bolts (Fig. 4-70, Pos. 6) evenly distributed at the spindle (Fig. 4-70, Pos. 1) of the planetary gear housing.

z

Lift spur gear housing (Fig. 4-70, Pos. 3) and slip it onto the threaded pins. DANGER

Risk of falling weights! Death or serious injury may result. When lifting the spur gear housing, make sure that nobody steps below the weight.

z

Fig. 4-70

Insert new mounting bolts (Fig. 4-70, Pos. 4) of grade 10.9.

NOTE: Apply compound "KP2K", PN 324 969 40 and tighten the bolts to the specified tightening torque. Tightening torque for spur gear housing mounting bolts: 255 Nm z

Remove the sling gear.

z

Replace the swivel hoist ring with a mounting bolt.

z


Version 2009/2

PC5500-6

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Travel system

Undercarriage

4.1.12 CARRIER ROLLER 4.1.12.1 REMOVAL OF THE CARRIER ROLLER ASSEMBLY Special tools:

n/a


Hydraulic jack 40 tonnes Forklift (as the most economical device) Chain hoist Carrier roller assembly (pinned undercarriage): 175 kg Carrier roller assembly (bolted undercarriage): 205 kg

z

Prepare an area of flat ground large enough to accommodate the machine, boom, and forklift.

z




z


Fig. 4-71 z

Push up track shoe assembly (Fig. 4-72, Pos. 3) at the carrier roller assembly (Fig. 4-72, Pos. 2) to be removed using hydraulic jack (Fig. 4-72, Pos. 1). In addition to the hydraulic jack, secure the track shoe assembly using appropriate blocks.

NOTE: Fig. 4-72 shows the crawler carrier of the bolted undercarriage, this step is accordingly identical for the crawler carrier of the pinned undercarriage.

Fig. 4-72

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Undercarriage

z

Travel system

Carry out the following steps at the crawler carrier of the bolted undercarriage only: z

Shove the forks (Fig. 4-73, Pos. 1) together that far, that the carrier roller (Fig. 4-73, Pos. 2) can rest on the forks. WARNING

z

If the forks can not be locked in that position, use a chain hoist at the forks to prevent them from sliding apart.

z

Make sure that nobody is in the danger zone while lifting the carrier roller assembly from the pedestal. Fig. 4-73

z

Carry out the following step at the crawler carrier of the pinned undercarriage only: z

Sling the carrier roller assembly (Fig. 4-74, Pos. 1) at both sides and connect the slings to the forks (Fig. 4-74, Pos. 2) of a forklift.

NOTE: In order to avoid damage to the lifting devices, use edge protection at all sharp edges.

Fig. 4-74 z

Remove the carrier roller assembly mounting bolts and lift off the carrier roller assembly using a forklift. DANGER

Risk of falling weights! May result in death or serious injury When lifting the carrier roller, make sure that nobody steps below the weight.

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Travel system

Undercarriage

4.1.12.2 REPLACEMENT OF THE CARRIER ROLLER ASSEMBLY Special tools:

n/a


Hydraulic jack 40 tonnes Forklift (as the most economical device) Chain hoist Carrier roller assembly (pinned undercarriage): 175 kg Carrier roller assembly (bolted undercarriage): 205 kg If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.2 on page 2-33.

z


NOTE: Observe the mounting position of the carrier rollers. The oil plug must face the outside of the excavator. Check the oil level in the carrier roller. The following positions of the oil level and filler plug have been defined for checking the oil level in the carrier rollers: z

9.00 o'clock or 3.00 o'clock position, equal to 90° angle from TOP position of the plug to left or to the right = MINIMUM oil level.

z

9.30 o'clock or 2.30 o'clock position, equal to 75° angle from TOP position of the plug to left or to the right = MAXIMUM oil level (factory filling).

z

For information about the proper lubricant, refer to section 6.1 on page 6-2. DANGER

Danger of crush or pinch injuries to hands and fingers! Exercise extreme care when aligning the carrier roller assembly to the crawler carrier.

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Version 2009/2

Undercarriage

Travel system

4.1.13 TRACK ROLLER 4.1.13.1 REMOVAL OF THE TRACK ROLLER ASSEMBLY Special tools:

Safety unit for changing track rollers, PN 921 149 40 Tool for changing track rollers (P&S-news in development)


Crane Track roller assembly: 654 kg

Dogman/rigger

z


z




Fig. 4-75 z

Jack up the machine with the work equipment.

z

Support two track rollers with the safety unit for changing track rollers, PN 921 149 40 (Fig. 4-76, Pos. 1).

z

Lower the machine and place the work equipment on the ground.

z


z

Support the track roller assembly (Fig. 4-76, Pos. 2) from the bottom side with the changing tool for track rollers (Fig. 4-78).

z

Remove the track roller mounting bolts (Fig. 4-76, Pos. 3) and lower the tool. Fig. 4-76

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Travel system

Undercarriage

NOTE: The track roller mounting bolts (Fig. 4-77, Pos. 1) are secured with lever-nuts (Fig. 4-77, Pos. 2) inside the crawler frame. When the bolts are removed, the nuts may slip away from their mounting position.

Fig. 4-77 NOTE: Make sure that both sides of the tool are balanced (e.g. with the new track roller assembly). z

Remove the track roller assembly. DANGER

Risk of falling weights! Death or serious injury may result. When lifting the track roller, make sure that nobody steps below the weight.

NOTE: A PARTS & SERVICE NEWS for this tool is under development.

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PC5500-6

Fig. 4-78

Version 2009/2

Undercarriage

Travel system

4.1.13.2 REPLACEMENT OF THE TRACK ROLLER ASSEMBLY Special tools:

Safety unit for changing track rollers, PN 921 149 40 Tool for changing track rollers (P&S-news in development)


Crane Track roller assembly: 654 kg

Dogman/rigger If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.2 on page 2-33. NOTE: Observe the mounting position of the track rollers. The oil plug must face the outside of the excavator. Check the oil level in the track roller. The following positions of the oil level and filler plug have been defined for checking the oil level in the track rollers:

z

z

9.00 o'clock or 3.00 o'clock position, equal to 90° angle from TOP position of the plug to left or to the right = MINIMUM oil level.

z

9.30 o'clock or 2.30 o'clock position, equal to 75° angle from TOP position of the plug to left or to the right = MAXIMUM oil level (factory filling).

z

For information about the proper lubricant, refer to section 6.1 on page 6-2.

Carry out installation in reverse order to removal. z

When inserting the track roller mounting bolts (Fig. 4-79, Pos. 1), hold the lever-nuts (Fig. 4-79, Pos. 2) inside the crawler frame by hand for the first convolutions.

NOTE: Use new track roller mounting bolts of the grade 10.9. Apply compound "KP2K", PN 324 969 40 to the bolts.

Fig. 4-79

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Car body

Undercarriage

4.2

CAR BODY

4.2.1

REMOVAL OF THE CAR BODY AND THE CRAWLER CARRIERS (TYPE WITH PINNED UNDERCARRIAGE)

Special tools:

n/a


2 x Crane Dozer Oil drain pan Car body: 42,000 kg Crawler carrier assembly: 40,000 kg each (without track group) Dogman/rigger Crane operators trained in dual crane lift For further information about the needed blind plugs, refer to section 2.3 on page 2-37.

NOTE: At first the wear of the bushes in the car body should be checked, refer to the PARTS & SERVICE NEWS No. "AH08508". z

Remove the track groups from both crawler cariers, refer to section 4.1.1.1 on page 4-2.

NOTE: Remove both track groups simultaneously. This can be done using the same dozer. WARNING Hot hydraulic oil! Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is below 50 °C. Disobedience may result in personal injury from heated oil.

z

Remove the travel gearboxes from both crawler carriers, refer to section 4.1.11.1 on page 4-51.

z

Lift the superstructure, refer to section 3.9.1 on page 3-257.

z

Attach a dozer to the car body by means of a chain.

z

Move the car body below the lifted superstructure using the dozer.

NOTE: Move the car body over the unrolled track group.

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Version 2009/2

Undercarriage

z

Car body

Remove the pressure hoses (Fig. 4-80, Pos. 1) of the track tensioning system leading to the shut-off cocks (Fig. 4-80, Pos. 2) and pull them out of the crawler carriers, refer to section 4.1.6.1 on page 4-31.

NOTE: When the pressure hoses are removed, the oil inside the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination.

Fig. 4-80 z

Attach one crawler to two cranes and lift it up (Fig. 4-81).

NOTE: In order to avoid damage to the lifting devices, use edge protection at all sharp edges. WARNING Before lifting, make sure that the crane operators are trained in dual crane lift.

Fig. 4-81 z

Rest the car body on appropriate supports (see Fig. 4-82). CAUTION

Supports need to be substantial enough to carry the total weight of both crawler carrier (40,000 kg) and car body (42,000 kg).

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Car body

Undercarriage

Fig. 4-82 Crawler carrier mounting z

Remove all bolts (Fig. 4-82, Pos. 6) and the retainer plates (Fig. 4-82, Pos. 7).

z

Remove the nuts (Fig. 4-82, Pos. 2), the cover plates (Fig. 4-82, Pos. 3), and the thread pins (Fig. 4-82, Pos. 4) only if required (changing to a replacement car body).

z

Pull out the four mounting pins (Fig. 4-82, Pos. 5) just enough to clear the crawler carrier assembly (Fig. 4-82, Pos. 1) from the car body as shown in (Fig. 4-82).

z

Remove the crawler carrier (Fig. 4-82, Pos. 1) using two cranes. WARNING

Before lifting, make sure that the crane operators are trained in dual crane lift.

DANGER Risk of falling weights! Death or serious injury may result. When lifting the crawler carrier, make sure that nobody steps below the weight.

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Undercarriage

Car body

z

Attach the car body to two cranes (Fig. 4-83).

z

Clear the other crawler carrier from the car body using the same procedure as before.

z

Remove the car body using two cranes.


Fig. 4-83

DANGER Risk of falling weights! Death or serious injury may result. When lifting the crawler carrier, make sure that nobody steps below the weight.

z


Remove the rotary joint from the car body, refer to section 4.2.5.1 on page 4-94.

z

Remove the high pressure accumulators from the car body, refer to section 4.1.4.3 on page 4-26.

z

Remove the track tensioning valve from the car body, refer to section 4.1.5.1 on page 4-28.

z

Remove the travel brake valve blocks from the car body, refer to section 4.1.7.1 on page 4-35.

z

Remove all hydraulic hoses from the car body, refer to section 4.1.6.1 on page 4-31.

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4 - 75

Car body

4.2.2

Undercarriage

REPLACEMENT OF THE CAR BODY AND THE CRAWLER CARRIERS (TYPE WITH PINNED UNDERCARRIAGE)

Special tools:

Water level gauge


AL-Compound, PN 509 623 98 2 x Crane Dozer Car body: 42,000 kg Crawler carrier assembly: 40,000 kg each (without track group) Dogman/rigger Crane operators trained in dual crane lift If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.2 on page 2-33.



Instal all hydraulic hoses into the new car body, refer to section 4.1.6.1 on page 4-31.

z

Instal the rotary joint in the new car body, refer to section 4.2.5.2 on page 4-96.

z

Instal the high pressure accumulators in the new car body, refer to section 4.1.4.4 on page 4-27.

z

Instal the track tensioning valve in the new car body, refer to section 4.1.5.2 on page 4-29.

z

Instal the travel brake valve blocks in the new car body, refer to section 4.1.7.2 on page 4-37.

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Version 2009/2

Undercarriage

Car body

z

If required, install new inner bushings (Fig. 4-84, Pos. 5) and new outer bushings (Fig. 4-84, Pos. 7) in the new car body.

z

Instal the thread pins (Fig. 4-84, Pos. 4) and the cover plates (Fig. 4-84, Pos. 3) with nuts (Fig. 4-84, Pos. 2) and washers at the four borings for the pins on the car body.

z

Attach the car body (Fig. 4-84, Pos. 1) to two cranes and lift it up. WARNING


DANGER

Fig. 4-84

Risk of falling weights! Death or serious injury may result. When lifting the car body, make sure that nobody steps below the weight.

NOTE: The oil supply lines to the travel motors must be aligned in the direction of the travel motors. z

Align the car body (Fig. 4-84, Pos. 1) to the crawler carrier (Fig. 4-84, Pos. 10) and let it down.

NOTE: The oil supply lines to the travel motors must be aligned in the direction of the travel motors. Insert the hydraulic lines for track tensioning into the crawler carrier before installing it. If applicable, re-assemble the protection sleeve on the hydraulic hose at the joint between the crawler carrier and the car body. z

Align the upper borings first and insert the mounting pins (Fig. 4-84, Pos. 6).

NOTE: Lubricate pins (Fig. 4-84, Pos. 6) with AL-Compound, PN 509 623 98. z

Align the lower borings and insert the mounting pins.

z

Instal the retainer plates (Fig. 4-84, Pos. 9) at the mounting pins and secure the retainer plates with the mounting bolts (Fig. 4-84, Pos. 8) and washers.

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Car body

z

Undercarriage

For easier mounting of the second crawler carrier, support left side of the car body with appropriate stands of appr. 1500 mm hight and lower the car body on the stands (see Fig. 4-85). CAUTION

Supports need to be substantial enough to carry the total weight of both crawler carrier (40,000 kg) and car body (42,000 kg).

NOTE: Assure that the track groups ar parallel and the distance "A" between track groups is: 4840 mm for track width 1350 4390 mm for track width 1800 Fig. 4-85

Fig. 4-86 Assembly of the car body z

Instal the thread pins (Fig. 4-86, Pos. 4) and the inner retainer plates (Fig. 4-86, Pos. 3) with nuts (Fig. 4-86, Pos. 2) and washers at the four borings for the pins on the car body.

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Undercarriage

z

Car body

Attach the second crawler carrier (Fig. 4-86, Pos. 1) to two cranes, lift it up and align it to the car body.


DANGER Risk of falling weights! Death or serious injury may result. When lifting the car body, make sure that nobody steps below the weight.

z

Align the upper borings first and insert the mounting pins (Fig. 4-86, Pos. 5).

NOTE: Lubricate pins (Fig. 4-86, Pos. 5) with AL-Compound, PN 509 623 98. z

Align the lower borings and insert the mounting pins.

z

Instal the retainer plates (Fig. 4-86, Pos. 7) at the mounting pins and secure the retainer plates with the mounting bolts (Fig. 4-86, Pos. 6) and washers.

z

Lift the undercarriage as far as it is necessary to remove the stands.

z

Rest the undercarriage to the ground.

z


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4 - 79

Car body

4.2.3

Undercarriage

REMOVAL OF THE CAR BODY AND THE CRAWLER CARRIERS (TYPE WITH BOLTED UNDERCARRIAGE)

Special tools:

Hydraulic torque wrench, PN 793 374 73 + PN 793 376 73 Electro-hydraulic pump set, PN 795 922 73


2 x Crane Dozer Car body: 46,000 kg Crawler carrier assembly: 44,000 kg each (without track group) Dogman/rigger Crane operators trained in dual crane lift For further information about the needed blind plugs, refer to section 2.3 on page 2-37.

z

Remove the track groups from both crawler carriers, refer to section 4.1.1.1 on page 4-2.

NOTE: Remove both track groups simultaneously. This can be done using the same dozer. z

Remove the travel gearboxes from both crawler carriers, refer to section 4.1.11.1 on page 4-51.

z

Lift the superstructure, refer to section 3.9.1 on page 3-257.

z

Attach a dozer to the car body by means of a chain.

z

Move the car body below the lifted superstructure using the dozer.

NOTE: Move the car body over the unrolled track group.

z

Disconnect the pressure hoses (Fig. 4-87, Pos. 1) for the track tensioning from the shut-off cocks (Fig. 4-87, Pos. 2).

NOTE: When the pressure hoses are removed, the oil inside the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Remove the hoses from both crawler carriers.

Fig. 4-87

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Version 2009/2

Undercarriage

z

Car body

Attach one crawler carrier (Fig. 4-88, Pos. 1) to two cranes at the installed lifting eyes (Fig. 4-88, Pos. 2) and lift it up. WARNING


z

Support the car body with appropriate stands so that all of the track rollers are clear of the track roller path. CAUTION

Supports need to be substantial enough to carry total weight of one crawler carrier assembly (44,000 kg) and the car body (46,000 kg).

Fig. 4-88

NOTE: Place supports between the cross-ties (Fig. 4-89, Pos. 1) in a manner that the mounting bolts can be removed.

Fig. 4-89

Version 2009/2

PC5500-6

4 - 81

Car body

Undercarriage

Fig. 4-90 Crawler carrier mounting bolts 4 - 82

PC5500-6

Version 2009/2

Undercarriage

z

Car body

Remove all mounting bolts (Fig. 4-90, Pos. M48) and the two measuring bolts (Fig. 4-90, Pos. 7) attaching the crawler carrier assembly to the car body using the hydraulic torque wrench PN 793 374 73 + PN 793 376 73. Discard the bolts.

NOTE: For hints using the hydraulic torque wrench refer to section 6.3.2 on page 6-9, and also refer to chapter 9 "Supplier’s documentation", "AVANTI HYTORQUE". z

Remove the crawler carrier using two cranes. WARNING


DANGER Risk of falling weights! Death or serious injury may result. When lifting the crawler carriage, make sure that nobody steps below the weight.

z

Carry out the same procedure described above to remove the second crawler carrier.

Version 2009/2

PC5500-6

4 - 83

Car body

Undercarriage


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PC5500-6

Version 2009/2

Undercarriage

4.2.4

Car body

REPLACEMENT OF THE CAR BODY AND THE CRAWLER CARRIERS (TYPE WITH BOLTED UNDERCARRIAGE)

Special tools:



2 x Crane Dozer Compound "KP2K", PN 324 969 40 Coating compound "INTERZINC 697", PN 674 997 40 Car body: 46,000 kg Crawler carrier assembly: 40,000 kg each (without track group) Dogman/rigger Crane operators trained in dual crane lift If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.2 on page 2-33.


Check the coated flange plates of the new car body for intactness, refer to PARTS & SERVICE NEWS "AH07526".

NOTE: If the coating of flange plates with "INTERZINC 697" has to be renewed, carry out the surface coating according to section 6.3.1 on page 6-7. To ensure an accurate coating, work has to be carried out in an industrial environment. z

Carry out further installation in reverse order to removal and according to section 4.2.2 on page 4-76. When mounting the crawler carrier to the car body, tighten the mounting bolts according to the following procedures.

Version 2009/2

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Car body

Undercarriage


PC5500-6

Version 2009/2

Undercarriage

z

Car body

Insert new bolts (Fig. 4-91, Pos. M48) and two measuring bolts (Fig. 4-91, Pos. 7) with resilient sleeves.

NOTE: Lubricate all bolts (Fig. 4-91, Pos. M48) with compound "KP2K", PN 324 969 40. Clean bottom and top surface of the resilient sleeves and contact areas completely free of paint. Insert the two measuring bolts (Fig. 4-91, Pos. 7) into the upper corners. The measuring bolts are part of the measuring device, PN 928 476 40. z

Pretighten the mounting bolts using the hydraulic torque wrench PN 793 374 73 + PN 793 376 73, refer to section 6.3.2 on page 6-9. Pretightening torque for crawler carrier mounting bolts: 2100 Nm

z

Determine the torque and tighten the crawler carrier mounting bolts to the determined torque, refer to section 4.2.4.1 on page 4-88.

NOTE: Check the torque of the crawler carrier mounting bolts after 1000 operating hours, refer to section 4.2.4.1 on page 4-88.

Version 2009/2

PC5500-6

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Car body

Undercarriage

4.2.4.1 TIGHTENING TORQUE FOR THE CRAWLER CARRIER MOUNTING BOLTS Special tools:

Hydraulic torque wrench, PN 793 374 73 + PN 793 376 73 Electro-hydraulic pump set, PN 795 922 73 Measuring device, PN 928 476 40


PC5500-6

Version 2009/2

Undercarriage

Car body

The required tightening torque for all fastening bolts has to be determined with the 4 measuring bolts (Fig. 4-92, Pos. 7), whose dimension resembles the fastening bolts (Fig. 4-92, Pos. M48). The required axial tension force of the bolts depends on the elongation of the fastening bolts. NOTE: The tightening torque must be determined at the first assembly of the excavator at the operation site, for the first inspection, and after 1000 operation hours, or after replacing either crawler carrier or car body. The required measuring device, PN 928 476 40 is delivered with the excavator. To determine the tightening torque, 4 specially prepared measuring bolts are supplied besides the normal fastening bolts. The measuring bolts can be recognized by the machined area at the end of the bolt. The measuring device (Fig. 4-92, Pos. 1 - 6) is composed of the following items and will be delivered with each new machine. Refer to Fig. 4-92: Pos.

Part name

Part number

Qty.

(1)

Angle bar

928 475 40

1

(2)

Dial gauge

092 706 40

1

(3)

Screw M5x16

502 515 98

1

(4)

Feeler

477 172 40

1

(5)

Bolt M10x25

307 777 99

2

(6)

Washer

517 122 98

2

(7)

Measuring bolt (installed)

933 613 40

4

WARNING Pre-condition: Crawler carrier is assembled and bolts tightened to 2100 Nm

z

Loosen all 4 measuring bolts (Fig. 4-92, Pos. 7). Do not lubricate the measuring bolts again.

z

Tighten the 4 measuring bolts (Fig. 4-92, Pos. 7) to 150 Nm.

z

Instal the measuring device (Fig. 4-92, Pos. 1 - 6).

z

Set the dial gauge (Fig. 4-92, Pos. 2) to zero.

z

Instal the special hydraulic torque wrench, PN 793 374 73 + PN 793 376 73, refer to section 6.3.2 on page 6-9.

Version 2009/2

PC5500-6

4 - 89

Car body

Undercarriage

Fig. 4-93 Crawler carrier mounting bolts

4 - 90

PC5500-6

Version 2009/2

Undercarriage

Car body

z

Adjust the pressure at the hydraulic torque wrench to 2100 Nm and tighten the measuring bolt (Fig. 4-93, Pos. 7).

z

List the pressure and the changed bolt length in a table.

z

Increase the pressure in steps of 10 bar until the measuring bolts have the required elongation of 0.93 mm.

z

List the corresponding hydraulic pressure in a table.

z

Repeat this procedure for all 4 measuring bolts.

z

Add all 4 determined hydraulic pressures and then divide by 4 to obtain an average value.

z

Loosen one mounting bolt (Fig. 4-93, Pos. M48) and tighten the bolt with the calculated average pressure. CAUTION

Do not lubricate the bolts again. Do not loosen more than one bolt at a time.

z

Repeat this procedure step by step for all the other bolts.

Version 2009/2

PC5500-6

4 - 91

Car body

4.2.5

Undercarriage

ROTARY JOINT

Fig. 4-94 Rotary joint

4 - 92

PC5500-6

Version 2009/2

Undercarriage

Car body

Legend for illustration Fig. 4-94: (1)

Stator, housing of rotary joint

(2)

Rotor, center part of rotary joint

(3)

Cover plate

(4)

Trust washer

(5)

O-ring seal between cover plate and stator

(6)

Guide ring

(7)

Shaft seal ring between rotor and stator

(7a)

Back-up ring, O-ring

(8)

Dust seal ring

(9)

Plug

(10)

Longitudinal bores

(11)

Stator connecting ports, cross holes

(12)

Torque support lever

(13)

Rotor connecting ports

(14)

Ring grooves

The rotary distributor (rotary joint) permits a hydraulic connection between the superstructure and the undercarriage. That means there is an unrestricted hydraulic connection installed between the rotating and stationary part which allows free rotation in both slew directions. During operation the superstructure and the undercarriage rotate towards each other. The travel motors must be supplied with hydraulic oil in each position in which the superstructure is slewed against the undercarriage. When slewing, the superstructure moves the stator (Fig. 4-94, Pos. 1) via the torque support lever (Fig. 4-94, Pos. 12) and the cover plate (Fig. 4-94, Pos. 3). Hydraulic hoses from the main control valve blocks and auxiliary systems from the superstructure are connected to the stator ports (Fig. 4-94, Pos. 11). The main pressure service lines to the travel motor are connected to the service line ports (Fig. 4-94, Pos. A, B, C, D) at the stator (Fig. 4-94, Pos. 1). The rotor (Fig. 4-94, Pos. 2) is fix bolted to the undercarriage and turns in the stator (Fig. 4-94, Pos. 1) while swinging. Oil flows from the stator connecting ports (Fig. 4-94, Pos. A, B, C, D) via cross holes (Fig. 4-94, Pos. 11) through ring grooves (Fig. 4-94, Pos. 14) and longitudinal bores (Fig. 4-94, Pos. 10) of the rotor to the outlet port (Fig. 4-94, Pos. A, B, C, D) of the rotor (Fig. 4-94, Pos. 2). The ring grooves from the rotor are sealed with special seal rings (Fig. 4-94, Pos. 7). Each seal ring is supported by an O-ring (Fig. 4-94, Pos. 7a). To prevent dust contamination between the rotor (Fig. 4-94, Pos. 2) and stator (Fig. 4-94, Pos. 1), a dust seal (Fig. 4-94, Pos. 8) is mounted.

Version 2009/2

PC5500-6

4 - 93

Car body

Undercarriage

The stator is locked to the rotor axially with the trust washer (Fig. 4-94, Pos. 4) which consists of two half segments for disassembling purposes. The stator is guided radially by the guide rings (Fig. 4-94, Pos. 6).

4.2.5.1 REMOVAL OF THE ROTARY JOINT Special tools:

n/a


Crane Rotary joint: 261 kg


Prepare an area of flat ground large enough to accommodate the machine, boom, and a crane.

z




z


z

Relieve pressure in the track tensioning system, refer to the PARTS & SERVICE NEWS No. "AH06530".

z

Close the hand wheel (Fig. 4-95, Pos. 1) of main gate valve between suction oil reservoir and main oil reservoir.

z

Transfuse oil from the suction oil reservoir into the main oil reservoir, refer to the Operation & Maintenance Manual, chapter 3, section "FUNCTIONS OF THE TRANSFER PUMP".

Fig. 4-95

4 - 94

PC5500-6

Version 2009/2

Undercarriage

Car body


z

Mark and disconnect all hydraulic hoses and pipes from the rotary joint. Discard the O-rings of the SAE-flange connections.

NOTE: When the hydraulic lines are removed, hydraulic oil from inside the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Sling rotary joint.

NOTE: The rotary joint is accessible from above, from between the pipe work at the manifold at the center of the machine (Fig. 4-96, arrow). CAUTION Move the sling carefully between the pipe work/hoses at the manifold to prevent the pipe work from being damaged or ripped off.

Fig. 4-96 z

Remove the mounting bolts (Fig. 4-97, Pos. 1) and remove the torque support lever (Fig. 4-97, Pos. 2) from the rotary joint (Fig. 4-97, Pos. 3).

z

Remove eight mounting bolts (Fig. 4-97, Pos. 4) and lift the rotary joint (Fig. 4-97, Pos. 3) off the center frame (Fig. 4-97, Pos. 5).

z

Lift the rotary joint up out of the superstructure and lay it down on the ground. DANGER

Risk of falling weights! Death or serious injury may result. When lifting the rotary joint, make sure that nobody steps below the weight. Fig. 4-97

Version 2009/2

PC5500-6

4 - 95

Car body

Undercarriage

4.2.5.2 REPLACEMENT OF THE ROTARY JOINT Special tools:

n/a


Crane Compound "KP2K", PN 324 969 40 Rotary joint: 261 kg


z

Instal the torque support lever to the new rotary joint (Fig. 4-98, Pos. 3). Use new mounting bolts (Fig. 4-98, Pos. 1) of grade 8.8. Tightening torque for torque support lever mounting bolts (Fig. 4-98, Pos. 1): 265 Nm

z

Place the new rotary joint (Fig. 4-98, Pos. 3) at the center frame (Fig. 4-98, Pos. 5) using a crane. DANGER

Risk of falling weights! Death or serious injury may result. When lifting the rotary joint, make sure that nobody steps below the weight. Fig. 4-98 z

Apply compound "KP2K", PN 324 969 40 to new mounting bolts (Fig. 4-98, Pos. 4) of grade 10.9, insert the mounting bolts and tighten them to the specified tightening torque. Tightening torque for rotary joint mounting bolts (Fig. 4-98, Pos. 4): 265 Nm

z


z


z


4 - 96

PC5500-6

Version 2009/2

Attachment

5 ATTACHMENT

Version 2009/2

PC5500-6

5 -1

Backhoe

Attachment

5.1

BACKHOE

Fig. 5-1

Backhoe attachment overview

(1)

Undercarriage with car body and side frames

(2)

Superstructure

(3)

Boom

(4)

Stick

(5)

Bucket (backhoe)

(6)

Boom cylinder

(7)

Stick cylinder

(8)

Bucket cylinder

(9)

Bucket link rod

(10)

Steering rod

5 -2

PC5500-6

Version 2009/2

Attachment

Backhoe


Version 2009/2

PC5500-6

5 -3

Backhoe

5.1.1

Attachment

BOOM

5.1.1.1 REMOVAL OF THE BOOM

Fig. 5-2

5 -4

Boom, removal and installation

PC5500-6

Version 2009/2

Attachment

Backhoe


Stick cylinder

(2)

Boom cylinder

(3)

Boom

(4)

Bolt

(5)

Shackle

(6)

Pin

(7)

Bush

(8)

Seal

(9)

Bush

(10)

Seal

(11)

Bush

Special tools:

n/a


Safety harness in conformity with DIN EN 361 Crane Mobile elevator working platform Boom: 45,100 kg Pin boom/superstructure: 365 kg



z

Park the machine on the prepared flat ground area and position the bucket with its flat side (underside) on the ground.


Use blocks and support the bucket from behind to secure the bucket.

z


Version 2009/2

PC5500-6

5 -5

Backhoe

Attachment

WARNING z

Always wear a safety harness when working at the attachment.

z

Most of the following operations require the use of men safety cages on elevator working platforms.

z

Remove the stick, refer to section 5.1.2 on page 5-20.

z

Support the boom with appropriate stands (Fig. 5-3, Pos. 1) of approx. 1 m height.

z

Remove the boom cylinders, refer to section 5.1.1.3 on page 5-10.

z

Disconnect the hydraulic hoses from the boom which are leading to the manifold, refer to section 5.1.6 on page 5-58.

NOTE: When the hoses are disconnected, the oil inside the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Disconnect all electric wires from the boom.

z

Disconnect the grease feed lines leading to the boom.

z

Sling the boom (Fig. 5-4).

Fig. 5-3

Fig. 5-4 z

Remove the two bolts (Fig. 5-5, Pos. 1), and the shackle (Fig. 5-5, Pos. 2) securing the pin (Fig. 5-5, Pos. 3).

z

Remove the pin (Fig. 5-5, Pos. 3) connecting the boom to the superstructure. WARNING

Sling the pin as soon as possible and support it using a crane to prevent the pin from falling.

Fig. 5-5 5 -6

PC5500-6

Version 2009/2

Attachment

Backhoe

DANGER Risk of falling weights! Death or serious injury may result. When pulling the pin out of the superstructure, make sure that the boom is fixed in its position and secured with a crane.

z

Remove the boom using a crane and place it on the ground and in an appropriate position. DANGER

Risk of falling weights! Death or serious injury may result. When moving the boom, make sure that nobody steps below the lifted boom.

z

If required, remove all provided parts and the hydraulic piping from the boom.

Version 2009/2

PC5500-6

5 -7

Backhoe

Attachment

5.1.1.2 REPLACEMENT OF THE BOOM Special tools:

n/a


Safety harness in conformity with DIN EN 361 Crane Mobile elevator working platform Boom: 45,100 kg Pin boom/superstructure: 365 kg


WARNING z


z


NOTE: When performing the installation procedures, comply to the following: Always discard used seals (Fig. 5-6, Pos. 2) and install new seals! Insert new bushes (Fig. 5-6, Pos. 1) if required! Apply the appropriate grease on every bush and pin on assembly! z

Carry out installation in reverse order to removal. Fig. 5-6

DANGER Never put hands into the holes when aligning the boom to the superstructure.

z


z

Bleed air from the hydraulic system, refer to the Operation & Maintenance Manual, chapter 4, section "HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER".

z


z

Check for leaks and the cylinders operation.

z


5 -8

PC5500-6

Version 2009/2

Attachment

Backhoe


Version 2009/2

PC5500-6

5 -9

Backhoe

Attachment

5.1.1.3 REMOVAL OF BOOM CYLINDERS

Fig. 5-7

5 - 10

Boom cylinder, removal and installation

PC5500-6

Version 2009/2

Attachment

Backhoe


O-ring

(2)

Pipe

(3)

Boom cylinder

(4)

Superstructure

(5)

Pin

(6)

Shackle

(7)

Bolt

(8)

Pin

(9)

Catch

(10)

Shackle

(11)

Bolt

(12)

Bush

(13)

Bush

(14)

Seal

(15)

Bush

Special tools:

n/a


Safety harness in conformity with DIN EN 361 Crane Mobile elevator working platform Oil drain pans Boom cylinder: 6500 kg each Pin boom cylinder/boom: 177 kg Pin boom cylinder/superstructure: 224 kg Dogman/rigger For further information about the needed blind plugs, refer to section 2.3 on page 2-37.

NOTE: At first the wear of the bushes in the hydraulic cylinder should be checked, refer to the PARTS & SERVICE NEWS No. "AH08508". WARNING z


z


Version 2009/2

PC5500-6

5 - 11

Backhoe

Attachment

z


z

Park the machine on the prepared flat area and position the bucket on the ground with the bucket cylinders in fully extended position (Fig. 5-8).

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition.

Fig. 5-8 z

Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE THE PRESSURE IN THE HYDRAULIC SYSTEM".

z


z

Remove grease feed lines and fittings from the boom cylinder(s) to be removed.

z

Sling boom cylinder (piston rod side) (Fig. 5-9).

z

Remove the bolts (Fig. 5-9, Pos. 3) and the shackle (Fig. 5-9, Pos. 4) securing the pin (Fig. 5-9, Pos. 2).

z

Remove the pin (Fig. 5-9, Pos. 2) connecting the boom cylinder to the superstructure. WARNING

Sling the pin as soon as it is possible and support it using a crane to prevent the pin from falling.

DANGER Risk of falling weights! Death or serious injury may result. When pulling the pin out of the superstructure, make sure that the cylinder is fixed in its position and secured with a crane.

Fig. 5-9

NOTE: Check bushes (Fig. 5-9, Pos. 1) for wear and damage. Replace if required. z


5 - 12

PC5500-6

Version 2009/2

Attachment

z

Backhoe

Switch S155 to Qmin and retract the boom cylinder to be removed fully.

NOTE: Use only engine no. 2 at Qmin. z

Retract the piston rod of the boom cylinder fully.

z

Tie the piston rod to the cylinder body with a wire rope.

z


z


Fig. 5-10



z

Disconnect the main hydraulic hoses from the cylinder, refer to section 5.1.6.2 on page 5-62.


Lift the boom cylinder into a horizontal position (Fig. 5-10).

Version 2009/2

PC5500-6

5 - 13

Backhoe

Attachment

z

Sling the other side of the cylinder additionally.

z

Ease the load of the pin (Fig. 5-11, Pos. 4) in the boom (Fig. 5-11, Pos. 5) by lifting the cylinder lightly.

z


NOTE: The catches (Fig. 5-11, Pos. 3) are welded to the boom. z

Remove the pin (Fig. 5-11, Pos. 4) connecting the boom cylinder to the boom. WARNING


Fig. 5-11

DANGER Risk of falling weights! Death or serious injury may result. When pulling the pin out of the boom, make sure that the cylinder is fixed in its position and secured with a crane.

NOTE: Pull the pin (Fig. 5-11, Pos. 4) using two puller bolts at the threaded holes (Fig. 5-12, Pos. 1). (Fig. 5-12 is an example)

Fig. 5-12 z

Lower the boom cylinder to the ground and place it in an appropriate position using a crane. DANGER

Risk of falling weights! Death or serious injury may result. When moving the cylinder, make sure that nobody steps below the lifted cylinder.

z

Check bushes for wear and damage. Replace if required.

5 - 14

PC5500-6

Version 2009/2

Attachment

Backhoe

z

If required, disconnect the other boom cylinder from the boom and remove it using the same procedure as above.

z

If required, remove the pipe work from the removed cylinder(s). Discard the O-rings and fit caps to the cylinder(s) openings to avoid environmental contamination.

Version 2009/2

PC5500-6

5 - 15

Backhoe

Attachment

5.1.1.4 REPLACEMENT OF BOOM CYLINDERS Special tools:

n/a


Safety harness in conformity with DIN EN 361 Crane Mobile elevator working platform Boom cylinder: 6500 kg each Pin boom cylinder/boom: 177 kg Pin boom cylinder/superstructure: 224 kg Dogman/rigger If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.2 on page 2-33.

WARNING z


z


NOTE: When performing the installation procedures, comply to the following: Prior to assembly all bushes (Fig. 5-13, Pos. 1) must be inspected and replaced as required, refer to the PARTS & SERVICE NEWS No. "AH06545". Always discard used seals (Fig. 5-13, Pos. 2) and install new seals! Apply the appropriate grease on every bush and pin on assembly!

Fig. 5-13 z

Flush out and clean all the pipes.

z

Install the hydraulic pipe at the boom cylinder, if required.

5 - 16

PC5500-6

Version 2009/2

Attachment

z

Backhoe

Position the replacement cylinder using a crane (Fig. 5-14). DANGER


z

Install the pin (Fig. 5-14, Pos. 4) connecting the boom cylinder to the boom. DANGER

Never put hands into the holes when aligning the cylinder to the boom.

NOTE: Align the pin’s head to the catches (Fig. 5-14, Pos. 3). z

Install the shackle (Fig. 5-14, Pos. 2) and the bolts (Fig. 5-14, Pos. 1) to secure the pin (Fig. 5-14, Pos. 4).

z

Connect the main hydraulic hoses to the boom cylinder, refer to section 5.1.6.2 on page 5-62.

Fig. 5-14

NOTE: Always use new O-rings at the SAE-flange connections.

z

Remove the wire rope from the cylinder at the side installed to the boom.

z

Lower the cylinder until the piston rod points in the direction of the mounting location at the superstructure (Fig. 5-15).

Fig. 5-15 z


Version 2009/2

PC5500-6

5 - 17

Backhoe

z

Attachment

Switch S155 to Qmin and retract the boom cylinder fully.


Remove the wire rope securing the piston rod to the boom cylinder body.

z

Extend and retract the boom cylinder slowly at Qmin 2…3 times as far as possible to partly bleed the cylinder.

z

Extend the piston rod to the required position to insert the pin (Fig. 5-16, Pos. 2) connecting the boom cylinder to the superstructure. DANGER

Never put hands into the holes when aligning the cylinder to the superstructure.

z

Fig. 5-16

Install the pin (Fig. 5-16, Pos. 2).

NOTE: Put the suitable grease into the bushes (Fig. 5-14, Pos. 1). z


z

Install the bolts (Fig. 5-14, Pos. 3) and the shackle (Fig. 5-14, Pos. 4) to secure the pin (Fig. 5-14, Pos. 2).

z


z


z

Perform the bleeding procedure for the stick cylinders. Refer to PARTS & SERVICE NEWS No. "AH06524".

z


z


z


z


5 - 18

PC5500-6

Version 2009/2

Attachment

Backhoe


Version 2009/2

PC5500-6

5 - 19

Backhoe

5.1.2

Attachment

STICK

5.1.2.1 REMOVAL OF THE STICK

Fig. 5-17 Stick assembly

5 - 20

PC5500-6

Version 2009/2

Attachment

Backhoe


Bucket

(2)

Bucket link rod

(3)

Bucket cylinder

(4)

Stick cylinder

(5)

Steering rod

(6)

Bushes

(7)

Bushes

(8)

Washers

(9)

Bushes

(10)

Stick

Special tools:

Thread protector PN 409 329 40


Safety harness in conformity with DIN EN 361 Swivel hoist ring Crane Mobile elevator working platform Stick: 19,160 kg Pin stick/boom: 1440 kg Nut-Cap: 48 kg Dogman/rigger For further information about the needed blind plugs, refer to section 2.3 on page 2-37.

WARNING z


z


z


z


NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition.

Version 2009/2

PC5500-6

5 - 21

Backhoe

Attachment

z

Use blocks and support the bucket from behind to secure it.

z

Remove the bucket, refer to section 5.1.3.1 on page 5-36.

NOTE: Fully retract the bucket cylinders. z

Disconnect all electric wires attached to the stick.

z

Disconnect the grease feeding lines leading to the stick.

z

Remove the pins connecting the stick cylinders to the stick, refer to section 5.1.2.3 on page 5-26.

NOTE: Support the stick cylinders (Fig. 5-18, Pos. 1) with blocks (Fig. 5-18, Pos. 2) between stick cylinders and boom (Fig. 5-18, Pos. 3) .

Fig. 5-18 z

Remove the pins connecting the stick cylinders to the stick, refer to section 5.1.2.3 on page 5-26.

z

Sling the stick (Fig. 5-19).

Fig. 5-19 z

Undo the lock of the nut-cap (Fig. 5-20, Pos. 1) at the pin connecting the stick with the boom by removing the cotter pin (Fig. 5-20, Pos. 2) from the bore (Fig. 5-20, Pos. 3) and removing the bolt (Fig. 5-20, Pos. 2) at next.

z

Insert a swivel hoist ring unto the nut-cap (Fig. 5-20, Pos. 1) and attach it to a crane.

Fig. 5-20

5 - 22

PC5500-6

Version 2009/2

Attachment

Backhoe

z

Remove the nut-cap (Fig. 5-21, Pos. 2) from the pin (Fig. 5-21, Pos. 1), then fit the "Thread Protector" PN 409 329 40.

z

Pull the pin (Fig. 5-20, Pos. 4) out completely to clear boom (Fig. 5-21, Pos. 3) and stick. WARNING

Sling the pin as soon as it is possible and support it using a crane to prevent the pin from falling.

Fig. 5-21 NOTE: Pull the pin (Fig. 5-20, Pos. 4) using two puller bolts at the threaded holes (Fig. 5-22, Pos.1). (Fig. 5-22 is an example) DANGER Risk of falling weights! Death or serious injury may result. When pulling the pin out of the boom, make sure that the stick is fixed in its position and secured with a crane.

Fig. 5-22 z

Remove the stick using a crane. DANGER

Risk of falling weights! Death or serious injury may result. When moving the stick, make sure that nobody steps below the lifted stick.

z

Lower the stick to the ground and rest it in an appropriate position.

z

Remove the bucket link rod and the steering rod(s), refer to section 5.1.4 on page 5-49 accordingly.

z

Remove the bucket cylinders from the stick, refer to section 5.1.3.3 on page 5-40 accordingly.

Version 2009/2

PC5500-6

5 - 23

Backhoe

Attachment

5.1.2.2 REPLACEMENT OF THE STICK Special tools:



Safety harness in conformity with DIN EN 361 Swivel hoist ring Crane Mobile elevator working platform Stick: 19,160 kg Pin stick/boom: 1440 kg Nut-Cap: 48 kg Dogman/rigger If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.2 on page 2-33.

WARNING z


z


NOTE: When performing the installation procedures, comply to the following: Always discard used seals (Fig. 5-23, Pos. 2) and install new seals! Insert new bushes (Fig. 5-23, Pos. 1) if required! Apply the appropriate grease on every bush and pin on assembly! z

Carry out installation in reverse order to removal. Fig. 5-23

DANGER Never put hands into the holes when aligning the stick to the boom.

z


z


z


z


z


5 - 24

PC5500-6

Version 2009/2

Attachment

Backhoe


Version 2009/2

PC5500-6

5 - 25

Backhoe

Attachment

5.1.2.3 REMOVAL OF STICK CYLINDERS

Fig. 5-24 Stick cylinder, removal and installation

5 - 26

PC5500-6

Version 2009/2

Attachment

Backhoe


Stick cylinder

(2)

Stick

(3)

Boom

(4)

Bolt

(5)

Shackle

(6)

Pin

(7)

Seal

(8)

Bolt

(9)

Shackle

(10)

Catch

(11)

Pin

(12)

Pipe

(13)

O-ring

(14)

Distributor block

(15)

Bush

Special tools:

n/a


Safety harness in conformity with DIN EN 361 Crane Mobile elevator working platform Oil drain pan Stick cylinder: 4600 kg each Pin stick cylinder/stick: 127 kg Pin stick cylinder/boom: 179 kg Dogman/rigger For further information about the needed blind plugs, refer to section 2.3 on page 2-37.

WARNING z


z


z

At first the wear of the bushes in the hydraulic cylinders should be checked, refer to the PARTS & SERVICE NEWS No. "AH08508".

Version 2009/2

PC5500-6

5 - 27

Backhoe

Attachment

z


z

Park the machine on the prepared flat area and position the bucket on the ground with the cylinders in partially extended position (Fig. 5-25).



z


z

Remove grease feed lines and fittings from the stick cylinder(s) to be removed.

z

Sling the cylinder (Fig. 5-26, Pos. 1) to be removed.

Fig. 5-25

Fig. 5-26

z

Remove the bolts (Fig. 5-27, Pos. 1), washers, and the shackle (Fig. 5-27, Pos. 2) securing the pin (Fig. 5-27, Pos. 3).

z

Remove the pin (Fig. 5-27, Pos. 3) connecting the stick cylinder to the stick. Remove the two seals (Fig. 5-27, Pos. 4). WARNING


Fig. 5-27 DANGER Risk of falling weights! Death or serious injury may result. When pulling the pin out of the cylinder, make sure that the cylinder is fixed in its position and secured with a crane.

5 - 28

PC5500-6

Version 2009/2

Attachment

Backhoe

z


z

Switch S155 to Qmin and retract the cylinder(s) to be removed fully.


Tie the piston rod to the cylinder body with a wire rope (refer to Fig. 5-46).

z


z


NOTE: If the stick is to be removed, put the stick cylinders (Fig. 5-28, Pos. 1) down on blocks (Fig. 5-28, Pos. 2) between the stick cylinders and the boom (Fig. 5-28, Pos. 3).

Fig. 5-28

Version 2009/2

PC5500-6

5 - 29

Backhoe

z

Attachment

If the stick cylinder (Fig. 5-29, Pos. 6) is to be removed, slightly lift up the cylinder to ease to load on the pin (Fig. 5-29, Pos. 4). WARNING



z

Disconnect the main hydraulic hoses from the stick cylinder, refer to section 5.1.6.3 on page 5-66.

Fig. 5-29


Remove the bolts (Fig. 5-29, Pos. 1), the washers, and the shackle (Fig. 5-29, Pos. 2) securing the pin (Fig. 5-29, Pos. 4).

NOTE: The catches (Fig. 5-29, Pos. 3) are welded to the boom. z

Remove the pin (Fig. 5-29, Pos. 4) connecting the stick cylinder to the boom (Fig. 5-29, Pos. 5).

5 - 30

PC5500-6

Version 2009/2

Attachment

Backhoe

NOTE: Pull the pin (Fig. 5-29, Pos. 4) using two puller bolts at the threaded holes (Fig. 5-30, Pos. 1). (Fig. 5-30 is an example) WARNING Sling the pin as soon as possible and support it using a crane to prevent the pin from falling.

DANGER Risk of falling weights! Death or serious injury may result. When pulling the pin out of the cylinder, make sure that the cylinder is fixed in its position and secured with a crane.

z

Remove the stick cylinder using a crane.

z

Lower the stick cylinder to the ground and place it in an appropriate position.

Fig. 5-30

DANGER Risk of falling weights! Death or serious injury may result. When moving the cylinder, make sure that nobody steps below the lifted cylinder.

z

If required, remove the other stick cylinder from the boom using the same procedure as above.

z

If required, remove the hydraulic pipe from the removed cylinder(s). Discard the O-rings and fit caps to the cylinder(s) openings to avoid environmental contamination.

Version 2009/2

PC5500-6

5 - 31

Backhoe

Attachment

5.1.2.4 REPLACEMENT OF STICK CYLINDERS Special tools:

n/a


Safety harness in conformity with DIN EN 361 Crane Mobile elevator working platform Stick cylinder: 4600 kg each Pin stick cylinder/stick: 127 kg Pin stick cylinder/boom: 179 kg Dogman/rigger If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.2 on page 2-33.

WARNING z


z


NOTE: When performing the installation procedures, comply to the following: Prior to assembly all bushes (Fig. 5-31, Pos. 1) must be inspected and replaced as required, refer to the PARTS & SERVICE NEWS No. "AH06545"! Always discard used seals and install new seals! Apply the appropriate grease on every bush and pin on assembly! z

Insert two seals (Fig. 5-31, Pos. 2) into the bushes (Fig. 5-31, Pos. 1) of the stick cylinder.

z

Flush out and clean all pipes.

z

Clean the mating surfaces at the cylinder mounting hole on the boom.

z

If required, install the hydraulic pipe at the cylinder(s).

5 - 32

PC5500-6

Fig. 5-31

Version 2009/2

Attachment

z

Backhoe

Using a crane, align the replacement cylinder (Fig. 5-32, Pos. 6). DANGER


z

Install the pin (Fig. 5-32, Pos. 4). CAUTION

Never put hands into the holes when aligning the cylinder to the boom.

NOTE: Align the pin’s head to the catches (Fig. 5-32, Pos. 3). z

Install the shackle (Fig. 5-32, Pos. 2) and the bolts (Fig. 5-32, Pos. 1) with washers to secure the pin (Fig. 5-32, Pos. 4). Fig. 5-32

z

Install the hydraulic pipe(s) to the stick cylinders, if required.

z

Connect the main hydraulic hoses to the cylinder, refer to section 5.1.6.3 on page 5-66.

NOTE: Always use new O-rings at the SAE-flange connections. z

Remove the wire rope from the piston rod.

z


z

Switch S155 to Qmin.


To partly bleed the new cylinders, perform the following procedure: z

Extend the cylinders as far as possible.

z

Fully retract the cylinders. WARNING

The air in the cylinder will result in slightly jerky movements of the cylinder.

Version 2009/2

PC5500-6

5 - 33

Backhoe

z

Attachment

Lower the cylinder and extend the piston rod to the required position to install the pin into the stick. WARNING

Never put hands into the holes when aligning the cylinder to the stick.

z


z

Install the two seals (Fig. 5-33, Pos. 4).

z

Install the pin (Fig. 5-33, Pos. 3) connecting the stick cylinder to the stick.

z

Install the two bolts (Fig. 5-33, Pos. 1), washers, and the shackle (Fig. 5-33, Pos. 2) to secure the pin (Fig. 5-33, Pos. 3).

Fig. 5-33 z


z


z


z


z


5 - 34

PC5500-6

Version 2009/2

Attachment

Backhoe


Version 2009/2

PC5500-6

5 - 35

Backhoe

5.1.3

Attachment

BUCKET

5.1.3.1 REMOVAL OF THE BUCKET

Fig. 5-34 Bucket assembly (1)

Bucket

(2)

Bucket link rod

(3)

Seal fixing ring

(4)

Seal

(5)

Seal fixing ring

(6)

Seal

5 - 36

PC5500-6

Version 2009/2

Attachment

Backhoe

Special tools:



Crane Pin bucket/stick: 574 kg Pin bucket/bucket link rod: 822 kg Bucket (if lifted): 30,600 kg Nut-cap: 35 kg Dogman/rigger For further information about the needed blind plugs, refer to section 2.3 on page 2-37.

z


z



Use blocks and support the bucket from behind to secure it.

z


z


z

Remove grease feeding line from the bucket mounting pin and from the link rod.

z

Undo the locks of both the nut-caps at the bucket by removing the cotter pin (Fig. 5-35, Pos. 2) from the bore (Fig. 5-35, Pos. 3) and removing the bolt (Fig. 5-35, Pos. 4) at next.

z

Insert swivel hoist rings into the nut-caps (Fig. 5-35, Pos. 1) and attach them to a crane.

Fig. 5-35

Version 2009/2

PC5500-6

5 - 37

Backhoe

Attachment

z

Remove the seal fixing rings (Fig. 5-36, Pos. 1) located on both sides of the stick and the bucket link rod.

z

Remove the nut-caps (Fig. 5-36, Pos. 7) from the pins (Fig. 5-36, Pos. 3 and 4), then fit the "Thread Protector" PN 409 329 40.

z

Remove the rings (Fig. 5-36, Pos. 6). CAUTION

Tie the link rod to the stick with a wire rope to prevent it from swinging when the pin is pulled out. Fig. 5-36 z

Pull the pin (Fig. 5-36, Pos. 3) out completely to clear the bucket (Fig. 5-36, Pos. 8) from the bucket link rod. Also remove the seals (Fig. 5-36, Pos. 2) when pulling out the pin. WARNING


z

Pull the pin (Fig. 5-36, Pos. 4) out completely to clear the bucket (Fig. 5-36, Pos. 8) from the stick. Also remove the seals (Fig. 5-36, Pos. 2) when pulling out the pin. WARNING


z

Check bushes (Fig. 5-36, Pos. 5) for wear and damage. Replace if required.

NOTE: Pull the pins using two puller bolts at the threaded holes (Fig. 5-37, Pos. 1), (Fig. 5-37 is an example). z


z

Switch S155 to Qmin and lift the boom to clear the bucket.



Fig. 5-37

5 - 38

PC5500-6

Version 2009/2

Attachment

Backhoe

5.1.3.2 REPLACEMENT OF THE BUCKET Special tools:



Crane Pin bucket/stick: 574 kg Pin bucket/bucket link rod: 822 kg Bucket (if lifted): 30,600 kg Nut-cap: 35 kg Dogman/rigger If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.2 on page 2-33.

NOTE: When performing the installation procedures, comply to the following: Always discard used seals and install new seals (Fig. 5-38, Pos. 2 and 6)! Apply the appropriate grease on every bush and pin on assembly! z

Stick the seals (Fig. 5-38, Pos. 2) which are held by the seal fixing rings (Fig. 5-38, Pos. 1) to both sides of the stick and the bucket link rod using appropriate grease.

NOTE: During installation, there is not enough space to insert these seals. z

Fig. 5-38


Version 2009/2

PC5500-6

5 - 39

Backhoe

Attachment

5.1.3.3 REMOVAL OF BUCKET CYLINDERS

Fig. 5-39 Bucket cylinder, removal and installation

5 - 40

PC5500-6

Version 2009/2

Attachment

Backhoe


Bucket cylinder

(2)

Cylinder piston rod

(3)

Bucket link rod

(4)

Steering rod

(5)

Bolt

(6)

Shackle

(7)

Pin cylinder/stick

(8)

Nut-cap

(9)

Pin cylinder/steering rods

(10)

Seal fixing ring

(11)

Seal

(12)

Seal

(13)

Bush

(14)

Rod protection cover

(15)

Pipe

Special tools:



Safety harness in conformity with DIN EN 361 2 x Crane Mobile elevator working platform Oil drain pan Bucket cylinder: 3210 kg each Pin bucket cylinder/stick: 86 kg Pin bucket cylinder/steering rods: 865 kg Nut-Cap: 35 kg Rod protection cover: 360 kg Dogman/rigger For further information about the needed blind plugs, refer to section 2.3 on page 2-37.

WARNING z


z


Version 2009/2

PC5500-6

5 - 41

Backhoe

Attachment

NOTE: At first the wear of the bushes in the hydraulic cylinder should be checked, refer to the PARTS & SERVICE NEWS No."AH08508". z


z

Park the machine on the prepared flat ground area and position the bucket on the ground as shown in Fig. 5-40, with the bucket cylinders not fully retracted.


Base the stick on an appropriate stand (Fig. 5-40, Pos. 1).

z

Base the bucket cylinders with appropriate blocks (Fig. 5-40, Pos. 2).

z


z


z

Remove grease feed lines and fittings from the cylinder(s) to be removed.

z

Carry out the following two steps only if the bucket cylinder is equipped with a rod protection cover. z

Connect the rod protection cover (Fig. 5-41, Pos. 1) to a crane using the shackle (Fig. 5-41, arrow).

z

Remove the protection cover (Fig. 5-41, Pos. 1) from the bucket cylinder (Fig. 5-41, Pos. 2).

Fig. 5-40

Fig. 5-41 z

Undo the lock of the nut-cap at the piston rod side of the bucket cylinder by removing the cotter pin (Fig. 5-42, Pos. 2) from the bore (Fig. 5-42, Pos. 3) and removing the bolt (Fig. 5-42, Pos. 4) at next.

z

Insert a swivel hoist ring into the nut-cap (Fig. 5-42, Pos. 1) and attach it to a crane.

Fig. 5-42 5 - 42

PC5500-6

Version 2009/2

Attachment

Backhoe

z

Remove the seal fixing rings (Fig. 5-43, Pos. 1) located on both sides of the cylinder piston rods (Fig. 5-43, Pos. 2).

z


Fig. 5-43 z

Sling the steering rods (Fig. 5-44, Pos. 2).

z

Using a crane, support the bucket link rod (Fig. 5-44, Pos. 1) if both or the left cylinder needs to be removed.

z

Pull the pin (Fig. 5-44, Pos. 4) at the bucket cylinders, refer to section 5.1.3.1 on page 5-36. WARNING

Sling the pin as soon as it is possible and support it using a crane to prevent the pin from falling. Fig. 5-44 NOTE: If removing the right-hand cylinder only, pull the pin (Fig. 5-44, Pos. 4) out just enough to clear the cylinder piston rod. NOTE: Pull the pin (Fig. 5-43, Pos. 4) out using two puller bolts at the threaded holes (Fig. 5-45, Pos. 1).

Fig. 5-45 z


z

Switch S155 to Qmin and retract the bucket cylinder(s) to be removed.

NOTE: Use only engine no. 2 at Qmin.

Version 2009/2

PC5500-6

5 - 43

Backhoe

z

Attachment

Tie the piston rod to the cylinder body with a wire rope (Fig. 5-46).

Fig. 5-46 z

Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE THE PRESSURE IN THE HYDRAULIC SYSTEM". WARNING



z


z

Disconnect the main hydraulic hoses from the cylinder(s), refer to section 5.1.6.4 on page 5-70.

NOTE: When the hydraulic hoses are disconnected, the oil inside the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination.

5 - 44

PC5500-6

Version 2009/2

Attachment

z

Backhoe

Using a crane, sling the cylinder (Fig. 5-47, Pos. 1) to be removed. Ease the load of the pin (Fig. 5-47, Pos. 2) by lifting the cylinder lightly.

Fig. 5-47 z

Remove the two bolts (Fig. 5-48, Pos. 2), washers, and the shackle (Fig. 5-48, Pos. 3) securing the pin (Fig. 5-48, Pos. 4).

z

Remove the pin (Fig. 5-48, Pos. 4) connecting the cylinder (Fig. 5-48, Pos. 1) to the stick. Remove the two seals (Fig. 5-48, Pos. 5). WARNING

Sling the pin as soon as possible and support it using a crane to prevent the pin from falling. Fig. 5-48 z

Remove the cylinder using a crane. Lower the cylinder to the ground and place it in an appropriate position. DANGER


NOTE: If required, disconnect the other bucket cylinder from the stick and remove it using the same procedure as above. z

If required, remove the pipe work, the connecting blocks, and the seals from the removed cylinder(s). Discard the seals and fit caps to the cylinder(s) openings to avoid environmental contamination.

Version 2009/2

PC5500-6

5 - 45

Backhoe

Attachment

5.1.3.4 REPLACEMENT OF BUCKET CYLINDERS Special tools:



Safety harness in conformity with DIN EN 361 2 x Crane Mobile elevator working platform Bucket cylinder: 3210 kg each Pin bucket cylinder/stick: 86 kg Pin bucket cylinder/steering rods: 865 kg Nut-Cap: 35 kg Rod protection cover: 360 kg Dogman/rigger If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.2 on page 2-33.

WARNING z


z


NOTE: When performing the installation procedures, comply to the following: Always discard used seals and install new seals! Prior to assembly all bushes must be inspected and replaced as required, refer to the PARTS & SERVICE NEWS No. "AH06545"! Apply the appropriate grease on every bush and pin on assembly! z

Flush out and clean all the pipes and connecting blocks.

5 - 46

PC5500-6

Version 2009/2

Attachment

Backhoe

z

On the stick at the bucket cylinder mounting hole, clean the mating surfaces and put appropriate grease on both sides of two new seals (Fig. 5-49, Pos. 5) and position them on both sides of the bush.

z

Using a crane, support and position the replacement bucket cylinder (Fig. 5-49, Pos. 1). DANGER


z

Fig. 5-49

Install the pin (Fig. 5-49, Pos. 4). CAUTION

Never put hands into the holes when aligning the cylinder to the stick.

z

Install the shackle (Fig. 5-49, Pos. 3), the two washers, and the bolts (Fig. 5-49, Pos. 2) to secure the pin (Fig. 5-49, Pos. 4).

z

Connect the main hydraulic hoses to the bucket cylinder(s), refer to section 5.1.6.4 on page 5-70.



z

Remove the wire rope from the piston rod.

z



To partly bleed the new cylinder, perform the following procedure 2…3 times: z

Extend the cylinder as far as possible.

z

Fully retract the cylinder. WARNING


z


Version 2009/2

PC5500-6

5 - 47

Backhoe

Attachment

z


z


z


z


z


5 - 48

PC5500-6

Version 2009/2

Attachment

5.1.4

Backhoe

BUCKET LINK ROD AND STEERING RODS

5.1.4.1 REMOVAL OF THE BUCKET LINK ROD Special tools:



Safety harness in conformity with DIN EN 361 2 x Crane Mobile elevator working platform Bucket link rod: 2280 kg Steering rod: 1300 kg Pin bucket cylinder/steering rod: 865 kg Pin bucket/bucket link rod: 822 kg Nut-cap: 35 kg Dogman/rigger For further information about the needed blind plugs, refer to section 2.3 on page 2-37.

WARNING z


z


z


z




z

Base the bucket cylinders with appropriate blocks (Fig. 5-50, Pos. 2).

z

Relieve the pressure in the bucket cylinders only. Refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE THE PRESSURE IN THE HYDRAULIC SYSTEM".

z


z

Disconnect the grease feed lines from the bucket link rod.

Version 2009/2

PC5500-6

Fig. 5-50

5 - 49

Backhoe

Attachment

z

Sling the bucket link rod (Fig. 5-51, Pos. 1) and both steering rods (Fig. 5-51, Pos. 2).

z

Remove the pin (Fig. 5-51, Pos. 3) at the bucket cylinders, refer to section 5.1.3.3 on page 5-40. WARNING


z


z

At Qmin fully retract the bucket cylinder to clear the link rod.

z

Remove the pin (Fig. 5-51, Pos. 4) at the bucket, refer to section 5.1.3.1 on page 5-36.

Fig. 5-51

WARNING Sling the pin as soon as possible and support it using a crane to prevent the pin from falling.

z

Remove the bucket link rod (Fig. 5-51, Pos. 1) using a crane. DANGER

Risk of falling weights! Death or serious injury may result. When moving the bucket link rod, make sure that nobody steps below the lifted weight.

5 - 50

PC5500-6

Version 2009/2

Attachment

Backhoe

5.1.4.2 REPLACEMENT OF THE BUCKET LINK ROD Special tools:



Safety harness in conformity with DIN EN 361 2 x Crane Mobile elevator working platform Bucket link rod: 2280 kg Steering rod: 1300 kg Pin bucket cylinder/steering rod: 865 kg Pin bucket/bucket link rod: 822 kg Nut-cap: 35 kg Dogman/rigger If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.2 on page 2-33.

WARNING z


z


NOTE: Always discard used seals and install new seals! Prior to assembly all bushes must be inspected and replaced as required! Apply the appropriate grease on every bush and pin on assembly! z


Version 2009/2

PC5500-6

5 - 51

Backhoe

Attachment

5.1.4.3 REMOVAL OF THE STEERING RODS Special tools:



Safety harness in conformity with DIN EN 361 2 x Crane Mobile elevator working platform Bucket link rod: 2280 kg Steering rod: 1300 kg Pin bucket cylinder/steering rod: 865 kg Pin steering rod/stick: 479 kg Nut-cap: 35 kg Dogman/rigger For further information about the needed blind plugs, refer to section 2.3 on page 2-37.

WARNING z


z


z


z




z

Base the bucket cylinder with appropriate blocks (Fig. 5-52, Pos. 2).

z

Relieve the pressure in the bucket cylinders only. Refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE THE PRESSURE IN THE HYDRAULIC SYSTEM".

z


z

Disconnect the grease feed line from the left side steering rod.

5 - 52

PC5500-6

Fig. 5-52

Version 2009/2

Attachment

z

Backhoe

Sling the bucket link rod (Fig. 5-53, Pos. 1) and the steering rod (Fig. 5-53, Pos. 2) to be removed.

NOTE: If removing the left-hand steering rod only, sling both steering rods. z

Remove the pin (Fig. 5-53, Pos. 3) at the bucket cylinders, refer to section 5.1.3.3 on page 5-40. WARNING

Sling the pin as soon as possible and support it using a crane to prevent the pin from falling. Fig. 5-53 NOTE: If removing the right-hand steering rod only, pull the pin out just enough to clear the steering rod. If removing the left-hand steering rod or both steering rods, pull out the pin completely to clear both steering rods. z

Undo the lock of the nut-cap at the pin (Fig. 5-53, Pos. 4) by removing the cotter pin (Fig. 5-54, Pos. 2) from the bore (Fig. 5-54, Pos. 3) and removing the bolt (Fig. 5-54, Pos. 4) at next.

z

Insert a swivel hoist ring into the nut-cap (Fig. 5-54, Pos. 1) and attach it to a crane.

Fig. 5-54 z

Remove the seal fixing rings (Fig. 5-55, Pos. 1) located on both sides between the steering rod (Fig. 5-55, Pos. 3) and the stick (Fig. 5-55, Pos. 5).

z


z

Pull the pin (Fig. 5-55, Pos. 4) out completely to clear both steering rods. WARNING


Version 2009/2

PC5500-6

Fig. 5-55

5 - 53

Backhoe

Attachment

NOTE: Pull the pin (Fig. 5-55, Pos. 5) out using two puller bolts at the threaded holes (Fig. 5-56, Pos. 1). If removing the right-hand steering rod only, pull the pin out just enough to clear the steering rod (Fig. 5-55, Pos. 3). If removing the left-hand steering rod or both steering rods, pull out the pin completely to clear both steering rods

Fig. 5-56 z

Remove the steering rod(s) using a crane. DANGER

Risk of falling weights! Death or serious injury may result. When moving the steering rod, make sure that nobody steps below the lifted weight.

5 - 54

PC5500-6

Version 2009/2

Attachment

Backhoe

5.1.4.4 REPLACEMENT OF THE STEERING RODS Special tools:



Safety harness in conformity with DIN EN 361 2 x Crane Mobile elevator working platform Bucket link rod: 2280 kg Steering rod: 1300 kg Pin bucket cylinder/steering rod: 865 kg Pin steering rod/stick: 479 kg Nut-cap: 35 kg Dogman/rigger If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.2 on page 2-33.

WARNING z


z


NOTE: Always discard used seals and install new seals! Prior to assembly all bushes must be inspected and replaced as required! Apply the appropriate grease on every bush and pin on assembly! z


Version 2009/2

PC5500-6

5 - 55

Backhoe

5.1.5

Attachment

GROUND ENGAGING TOOLS (GET)

As ground engaging tools, the ESCO POSILOK Tooth System is used.

Fig. 5-57 POSILOK System (1)

Shroud

(2)

Toplok boss

(3)

Wedge

(4)

Point (tooth)

(5)

Lock

(6)

Tooth adapter (center/corner)

(7)

Pin

(8)

Wear cap

5 - 56

PC5500-6

Version 2009/2

Attachment

Backhoe

5.1.5.1 REMOVAL AND REPLACEMENT OF THE GET Special tools:

POSILOK Pin removal tool PN 795 502 73 Hensley Pin removal tool (ask local dealer)


ESCO POSILOK Tooth System S130 Hensley Tooth System (ask local dealer) Forklift Point (tooth): 55 kg (ESCO) Shroud: 337 kg (ESCO) Tooth adapter: 182 kg (ESCO) Dogman/rigger If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.2 on page 2-33.

CAUTION Hazard of injuries from splinters! When working on the locking pins, always wear hard hat, safety glasses, steel-toed shoes, and gloves. To avoid injury to others, keep people not directly involved well out of the way.

z

Prepare an area of flat ground large enough to accommodate the machine, bucket, and a forklift.

z

Park the machine on the prepared flat ground area and position the bucket in an appropriate height for work.



z

For removing and installing the ESCO Tooth System, refer to PARTS & SERVICE NEWS No. "AH03510".

z

Remove and install the Hensley Tooth System accordingly to PARTS & SERVICE NEWS No. "AH03510", Hensley uses basically the similar system.

NOTE: Use a forklift to remove and install the GET.

Version 2009/2

PC5500-6

5 - 57

Backhoe

5.1.6

Attachment

HYDRAULIC HOSES AT THE BACKHOE ATTACHMENT

5.1.6.1 SUBSTITUTE THE BOOM ARC HOSES

Fig. 5-58 Arc hoses, removal and installation

5 - 58

PC5500-6

Version 2009/2

Attachment

Backhoe


Hose clamp

(2)

Clamp line

(3)

Nut

(4)

Manifold

(5)

Hydraulic pipe

(6)

Hydraulic hose

(7)

Bolt

(8)

O-ring

Special tools:

n/a


Safety harness in conformity with DIN EN 361 Crane Oil drain pan Boom arc hose: 39 kg

Dogman/rigger If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.2 on page 2-33. For further information about the needed blind plugs, refer to section 2.3 on page 2-37.

WARNING Always wear a safety harness when working at the attachment.

z


z

Park the machine on the prepared flat area and position the bucket on the ground with the bucket cylinders in fully extended and the stick cylinders in fully retracted position (Fig. 5-59).

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. Fig. 5-59

Version 2009/2

PC5500-6

5 - 59

Backhoe

Attachment

Fig. 5-60 Arc hoses, removal and installation z


z


5 - 60

PC5500-6

Version 2009/2

Attachment

z

Backhoe

Open the hose clamps (Fig. 5-60, Pos. 1) and clear the hydraulic hose (Fig. 5-60, Pos. 6) to be removed from the clamp lines (Fig. 5-60, Pos. 2). WARNING



z

Sling the hydraulic hose (Fig. 5-60, Pos. 6) to be removed.

z

Remove the bolts (Fig. 5-60, Pos. 7) as well as the nuts (Fig. 5-60, Pos. 3) and disconnect the SAE-flanges from the manifold (Fig. 5-60, Pos. 4) and from the hydraulic pipe (Fig. 5-60, Pos. 5) at the boom.


Remove the hydraulic hose using a crane.

z

Replace the boom arc hoses by new ones and carry out installation in reverse order to removal.

NOTE: Always replace the O-rings (Fig. 5-60, Pos. 8) at the SAE-flange connections. z

Substitute the other boom arc hoses if required, using the same procedure.

z

Perform the bleeding procedure for all cylinders. Refer to PARTS & SERVICE NEWS No. "AH06524".

z


z


z

Check hydraulic oil level again and add oil if required.

Version 2009/2

PC5500-6

5 - 61

Backhoe

Attachment

5.1.6.2 SUBSTITUTE THE BOOM CYLINDER HOSES

Fig. 5-61 Hoses of the boom cylinders, removal and installation (1, 2)

Hydraulic hose

(3)

Hydraulic piping at the boom cylinder

(4)

Hydraulic pipe

(5)

Guard plate

(6)

Bolt

(7)

Boom cylinder

(8)

O-ring

5 - 62

PC5500-6

Version 2009/2

Attachment

Backhoe

Special tools:

n/a


Safety harness in conformity with DIN EN 361 Crane Oil drain pan Boom cylinder hose (depending on length): 29.5 kg 39 kg Dogman/rigger If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.2 on page 2-33. For further information about the needed blind plugs, refer to section 2.3 on page 2-37.

WARNING z


z


z


z


NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. Fig. 5-62 z


z


Version 2009/2

PC5500-6

5 - 63

Backhoe

Attachment

Fig. 5-63 Hoses of the boom cylinders, removal and installation z

Sling the hydraulic hose (Fig. 5-63, Pos. 1 or 2) to be removed.

z

Remove the guard plate (Fig. 5-63, Pos. 5).

5 - 64

PC5500-6

Version 2009/2

Attachment

Backhoe



z

Remove the bolts (Fig. 5-63, Pos. 6) and disconnect the SAE-flanges from the boom cylinder (Fig. 5-63, Pos. 7) respective the hydraulic piping (Fig. 5-63, Pos. 3) at the boom cylinder and from the pipe (Fig. 5-63, Pos. 4) at the boom.



z

Replace the boom cylinder hoses by new ones and carry out installation in reverse order to removal.


Substitute all other boom cylinder hoses if required, using the same procedure.

z

Perform the bleeding procedure for the boom cylinder(s). Refer to PARTS & SERVICE NEWS No. "AH06524".

z


z


z


Version 2009/2

PC5500-6

5 - 65

Backhoe

Attachment

5.1.6.3 SUBSTITUTE THE STICK CYLINDER HOSES

Fig. 5-64 Hoses of the stick cylinders, removal and installation (1)

Hydraulic hose

(2)

Hydraulic hose

(3)

Hydraulic pipe

(4)

O-Ring

(5)

Bolt

5 - 66

PC5500-6

Version 2009/2

Attachment

Backhoe

Special tools:

n/a


Safety harness in conformity with DIN EN 361 Crane Oil drain pan Stick cylinder hose (depending on length): 23 kg 27.5 kg Dogman/rigger If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.2 on page 2-33. For further information about the needed blind plugs, refer to section 2.3 on page 2-37.

WARNING z


z


z


z




z


Version 2009/2

PC5500-6

5 - 67

Backhoe

Attachment

Fig. 5-66 Hoses of the stick cylinders, removal and installation z

Sling the hydraulic hose (Fig. 5-66, Pos. 1 or 2) to be removed. WARNING



5 - 68

PC5500-6

Version 2009/2

Attachment

z

Backhoe

Remove the bolts (Fig. 5-66, Pos. 5) and disconnect the SAE-flanges at the stick cylinder and the hydraulic pipe (Fig. 5-66, Pos. 3) at the boom.



z

Replace the stick cylinder hoses by new ones and carry out installation in reverse order to removal.


Substitute all other stick cylinder hoses if required, using the same procedure.

z

Perform the bleeding procedure for the stick cylinder(s). Refer to PARTS & SERVICE NEWS No. "AH06524".

z


z


z


Version 2009/2

PC5500-6

5 - 69

Backhoe

Attachment

5.1.6.4 SUBSTITUTE THE BUCKET CYLINDER HOSES

Fig. 5-67 Hoses of the bucket cylinders, removal and installation (1)

Hydraulic hose

(2)

Hydraulic hose

(3)

Hydraulic pipe

(4)

O-ring

(5)

Bolt

5 - 70

PC5500-6

Version 2009/2

Attachment

Backhoe

Special tools:

n/a


Safety harness in conformity with DIN EN 361 Crane Oil drain pan Bucket cylinder hose: 33 kg


WARNING z


z


z


z




z


Version 2009/2

PC5500-6

5 - 71

Backhoe

Attachment

Fig. 5-69 Hoses of the bucket cylinders, removal and installation z




5 - 72

PC5500-6

Version 2009/2

Attachment

z

Backhoe

Remove the bolts (Fig. 5-69, Pos. 5) and disconnect the SAE-flanges from the bucket cylinder and the hydraulic pipe (Fig. 5-69, Pos. 3) at the boom.



z

Replace the bucket cylinder hoses by new ones and carry out installation in reverse order to removal.


Substitute all other bucket cylinder hoses if required, using the same procedure.

z

Perform the bleeding procedure for the bucket cylinder(s). Refer to PARTS & SERVICE NEWS No. "AH06524".

z


z


z


Version 2009/2

PC5500-6

5 - 73

Face shovel

5.2

Attachment

FACE SHOVEL

Fig. 5-70 Face shovel attachment overview (1)

Bull clam bucket (clam)

(2)

Bull clam bucket (wall)

(3)

Stick

(4)

Boom

(5)

Bucket cylinder

(6)

Boom cylinder

(7)

Stick cylinder

5 - 74

PC5500-6

Version 2009/2

Attachment

5.2.1

Face shovel

USING THE INSTALLATION TOOLS FOR HYDRAULIC CYLINDERS

Designated use: Each hydraulic cylinder has a groove (Fig. 5-71, arrow) at each end of the cylinder body (Fig. 5-71, Pos. 1) . Clamp the installation tool (Fig. 5-71, Pos. 2) on the hydraulic cylinder using the groove.

Fig. 5-71

The tools are designed to handle the attachment’s hydraulic cylinders vertically in combination with a forklift. Thereby, the forks of the forklift are inserted between the cylinder body and the scorpers (Fig. 5-72, Pos. 2). The tools’ extensions (Fig. 5-72, Pos. 1) rest on the forks of the forklift. This is the tools’ main direction of stress, indicated by "F". DANGER Use the installation tools in the proper way shown only! Cylinders may only be handled vertically when using these tools. Misuse may result in death, serious injury, or damage to the tools.

Version 2009/2

PC5500-6

Fig. 5-72

5 - 75

Face shovel

5.2.2

Attachment

BOOM

5.2.2.1 REMOVAL OF THE BOOM

Fig. 5-73 Boom removal (1)

Boom

(2)

Pin

(3)

Shackle

(4)

Bolt

(5)

Shackle

(6)

Bolt

(7)

Pin

(8)

Chain hoist

5 - 76

PC5500-6

Version 2009/2

Attachment

Face shovel

Special tools:

n/a


Safety harness in conformity with DIN EN 361 Mobile elevator working platform 2 x Crane 4 x Chain hoist Oil drain pan Boom with attached stick and boom cylinders: 52,900 kg Pin boom/superstructure: 365 kg Pin boom cylinder/superstructure: 224 kg Dogman/rigger Crane operators trained in dual crane lift For further information about the needed blind plugs, refer to section 2.3 on page 2-37.

WARNING z


z


z


z

Park the machine on the prepared flat area and position the bucket on the ground with the stick and the bucket cylinders in vertical position (Fig. 5-74).



z


z

Remove the stick, refer to section 5.2.3 on page 5-94.

NOTE: Leave the stick cylinders retracted and fixed to the boom. Secure them under the boom using chain hoists.

Version 2009/2

PC5500-6

5 - 77

Face shovel

Attachment

Fig. 5-75 Boom removal z

Tie the piston rods to the stick cylinder bodies with a wire rope (refer to Fig. 5-46).

z

Disconnect the grease feeding lines leading to the boom.

z

Disconnect all electric wires from the boom.

z

Fix the boom cylinders at the boom using chain hoists (Fig. 5-75, Pos. 8).

z

Attach the front part of the boom to a crane.

z

Remove the bolts (Fig. 5-75, Pos. 6) and the shackles (Fig. 5-75, Pos. 5) securing the pins (Fig. 5-75, Pos. 7).

5 - 78

PC5500-6

Version 2009/2

Attachment

z

Face shovel

Remove the pins (Fig. 5-75, Pos. 7) attaching the boom cylinders to the superstructure. Note the seals. WARNING


z


z

Switch S155 to Qmin and retract the boom cylinders.


Tie the piston rods to the boom cylinder body with a wire rope (refer to Fig. 5-46).

z


z

Isolate the machine according to local regulations. DANGER

Danger of hydraulic pressure! Blindness, serious injury, permanent disfigurement, or scaring may result. The hydraulic system may be pressurized. Make sure that the pressure is relieved before any hydraulic line will be removed.

z

Disconnect all hydraulic hoses from the boom which are leading to the manifold, refer to section 5.2.6.1 on page 5-134.


Attach the rear part of the boom to another crane.

z

Remove the bolts (Fig. 5-75, Pos. 4) and the shackles (Fig. 5-75, Pos. 3) securing the pins (Fig. 5-75, Pos. 2).

z

Remove the pins (Fig. 5-75, Pos. 2) attaching the boom to the superstructure. WARNING


Version 2009/2

PC5500-6

5 - 79

Face shovel

z

Attachment

Remove the boom with attached stick cylinders and boom cylinders using two cranes. Place it on appropriate blocks. WARNING

Make sure that the crane operators are trained in dual crane lift.

DANGER Risk of falling weights! Death or serious injury may result. When moving the boom, make sure that nobody steps below the lifted boom.

z

Carry out the next steps with the boom placed on the ground: z

Remove the pins of the boom cylinders, refer to section 5.2.2.3 on page 5-86 and remove the boom cylinders from the boom.

z

Remove the pins of the stick cylinders, refer to section 5.2.3.3 on page 5-100 and remove the stick cylinders from the boom.

z

Remove all provided parts and the hydraulic piping from the boom.

5 - 80

PC5500-6

Version 2009/2

Attachment

Face shovel

5.2.2.2 REPLACEMENT OF THE BOOM Special tools:

n/a


Safety harness in conformity with DIN EN 361 2 x Crane 4 x Chain hoist Mobile elevator working platform Boom with attached stick and boom cylinders: 52,900 kg Pin boom/superstructure: 365 kg Pin boom cylinder/superstructure: 224 kg Dogman/rigger Crane operators trained in dual crane lift If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.2 on page 2-33.

WARNING z


z


NOTE: When performing the installation procedures, comply to the following: Always discard used seals (Fig. 5-76, Pos. 3) and install new seals! Insert new bushes (Fig. 5-76, Pos. 2) into the boom (Fig. 5-76, Pos. 1) if required! Put the appropriate grease in every bush (Fig. 5-76, Pos. 2) on assembly!

Fig. 5-76 z

Install all provided parts and the hydraulic piping to the boom.

NOTE: Tie the piston rods to the cylinder bodies with wire ropes (refer to Fig. 5-46). z

Install the boom cylinders to the boom in reverse order to removal, refer to section 5.1.1.4 on page 5-16.

z

Install the stick cylinders to the boom in reverse order to removal, refer to section 5.1.2.4 on page 5-32.

NOTE: Make sure the hydraulic hoses are already connected to the cylinders at this state.

Version 2009/2

PC5500-6

5 - 81

Face shovel

Attachment

Fig. 5-77 FSA boom installation z

Fix the cylinders at the boom using chain hoists (Fig. 5-77, Pos. 8).

z

Attach the boom to two cranes. WARNING

Before lifting the boom, make sure that the crane operators are trained in dual crane lift.

z

Lift the boom (Fig. 5-77, Pos. 1) with the boom and stick cylinders attached using two cranes.

NOTE: Lift the front part of the boom higher than the back part.

5 - 82

PC5500-6

Version 2009/2

Attachment

Face shovel

DANGER Risk of falling weights! Death or serious injury may result. When moving the boom, make sure that nobody steps below the lifted boom.

z

Align the boom (Fig. 5-77, Pos. 1) with the superstructure. DANGER

Never put hands into the holes when aligning the boom to the superstructure.

z

Insert the two pins (Fig. 5-77, Pos. 2).

z

Detach the rear part ob the boom from the crane.

z

Install the shackles (Fig. 5-77, Pos. 3), and bolts (Fig. 5-77, Pos. 4) to secure the pins (Fig. 5-77, Pos. 2).

z

Connect the hydraulic lines leading from the manifold to the boom, refer to section 5.2.6.1 on page 5-134. WARNING

Do not open the plugged hydraulic ports for the cylinders when the wire ropes are removed, because the cylinder rods may start sliding by their own mass. First connect the hydraulic line, then remove the wire ropes.

z

Remove the wire ropes from the boom cylinders.

z


z

Align the boom cylinder to the superstructure by lifting or lowering the boom using the crane.

NOTE: Use the chain hoist (Fig. 5-77, Pos. 8) to lift or lower the boom cylinders until they point to the mounting location at the superstructure. z


z

Extend and retract the boom cylinder slowly at Qmin 2...3 times as far as possible to partly bleed the cylinder.

NOTE: Use only engine no. 2 at Qmin. WARNING The air in the cylinder will result in slightly jerky movements of the cylinder.

Version 2009/2

PC5500-6

5 - 83

Face shovel

z

Attachment

Extend the boom cylinder as needed to align cylinder and superstructure. DANGER

Never put hands into the holes when aligning the boom to the superstructure.

z

Insert the pin (Fig. 5-77, Pos. 7).

z


z

Install the shackle (Fig. 5-77, Pos. 5) and the bolt (Fig. 5-77, Pos. 6) to secure the pin (Fig. 5-77, Pos. 7).

z

Fix the other boom cylinder using the same procedure as above.

z


z


z


z


z


z


z


z


5 - 84

PC5500-6

Version 2009/2

Attachment

Face shovel


Version 2009/2

PC5500-6

5 - 85

Face shovel

Attachment

5.2.2.3 REMOVAL OF THE BOOM CYLINDERS

Fig. 5-78 Boom cylinder, removal and installation

5 - 86

PC5500-6

Version 2009/2

Attachment

Face shovel


Boom cylinder

(2)

Boom

(3)

Catch

(4)

Pin

(5)

Cover

(6)

Bolt

(7)

Seal

(8)

Bush

(9)

Seal

(10)

Bush

(11)

O-ring

(12)

Hydraulic hose

(13)

Bolt

(14)

Bush

(15)

Bush

(16)

Pin

(17)

Superstructure

(18)

Shackle

(19)

Bolt

Special tools:

Installation tool, PN 934 611 40


Safety harness in conformity with DIN EN 361 Forklift Chain hoist Mobile elevator working platform (telescopic or articulated boom lift) Oil drain pan Boom cylinder: 5680kg Pin boom cylinder/superstructure: 224 kg Pin boom cylinder/boom: 234 kg Dogman/rigger For further information about the needed blind plugs, refer to section 2.3 on page 2-37.

Version 2009/2

PC5500-6

5 - 87

Face shovel

Attachment

WARNING z


z


z


z

Park the machine on the prepared flat area with the superstructure turned by 90° and position the bucket on the ground as shown (Fig. 5-79).


Relieve the pressure in the hydraulic system, refer to the Fig. 5-79 Operation & Maintenance Manual, chapter 3, section "RELIEVE THE PRESSURE IN THE HYDRAULIC SYSTEM".

z


z

Disconnect the grease feeding lines from the boom cylinder(s) to be removed.

z

Sling the lower end of the boom cylinder (Fig. 5-80, Pos. 1) and fix it to the boom (Fig. 5-80, Pos. 2) using a chain hoist.

z

Remove the bolt (Fig. 5-80, Pos. 3) and the shackle (Fig. 5-80, Pos. 4) securing the pin (Fig. 5-80, Pos. 5).

z

Remove the pin (Fig. 5-80, Pos. 5) attaching the boom cylinder to the superstructure. Note the seals. WARNING

Sling the pin as soon as possible and support it using a crane to prevent the pin from falling. Fig. 5-80 z


z



Tie the piston rods to the boom cylinder body with a wire rope.

z


5 - 88

PC5500-6

Version 2009/2

Attachment

z

Face shovel




z

Disconnect the hydraulic hoses from the boom cylinder, refer to section 5.2.6.2 on page 5-138.

NOTE: When the hydraulic hoses are disconnected, the oil inside the piping and the hoses will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Lower the boom cylinder with the chain hoist until the cylinder is in vertical position.

z

Install the installation tool PN 934 611 40 at the boom cylinder’s upper side.

z

Support the boom cylinder by means of the installation tool using the forks of the forklift.

z

Remove the bolts (Fig. 5-81, Pos. 1), the cover (Fig. 5-81, Pos. 2), and the ring (Fig. 5-81, Pos. 3).

z

Remove the pin (Fig. 5-81, Pos. 4) with the catches (Fig. 5-81, Pos. 5) as well as the seals (Fig. 5-82, Pos. 2) at the boom cylinder. WARNING


Fig. 5-81

Version 2009/2

PC5500-6

5 - 89

Face shovel

z

Attachment

Remove the boom cylinder using the forklift. DANGER

Risk of falling weights! Death or serious injury may result. When moving the boom cylinder, make sure that nobody steps below the lifted cylinder.

z


5 - 90

PC5500-6

Version 2009/2

Attachment

Face shovel

5.2.2.4 REPLACEMENT OF THE BOOM CYLINDERS Special tools:



Safety harness in conformity with DIN EN 361 Chain hoist Forklift Mobile elevator working platform (telescopic or articulated boom lift) Boom cylinder: 5680kg Pin boom cylinder/superstructure: 224 kg Pin boom cylinder/boom: 234 kg Dogman/rigger If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.2 on page 2-33.

WARNING z


z


NOTE: When performing the installation procedures, comply to the following: Always discard used seals (Fig. 5-82, Pos. 2) and install new seals! Insert a new bush (Fig. 5-82, Pos. 3) into the boom cylinder (Fig. 5-82, Pos. 1) if required, refer to the PARTS & SERVICE NEWS No. "AH06545". Apply the appropriate grease on every bush and pin on assembly! Fig. 5-82 z

If required, install the pipe work, the connecting blocks, and the seals at the cylinder(s).

z

Install the installation tool PN 934 611 40 at the upper end of the new boom cylinder.

z

Tie the moving rod to the cylinder body with a wire rope .

Version 2009/2

PC5500-6

5 - 91

Face shovel

z

Attachment

Sling the boom cylinder and place it on the forklift in a vertical position so that the upper end of the cylinder is at the top and that the cylinder is supported by means of the installation tool. DANGER

Risk of falling weights! Death or serious injury may result. When moving the boom, make sure that nobody steps below the lifted boom.

z

Align the upper end of the boom cylinder with the boom using the forklift. DANGER

Never put hands into the holes when aligning the boom cylinder to the boom.

z

Insert the pin (Fig. 5-83, Pos. 4) with the catches (Fig. 5-83, Pos. 5) and mount the seals (Fig. 5-82, Pos. 2) at the boom cylinder.

z

Install the ring (Fig. 5-83, Pos. 3), the cover (Fig. 5-83, Pos. 2), and the bolts (Fig. 5-83, Pos. 1).

Fig. 5-83 z

Sling the boom cylinder body at the piston rod side using a chain hoist. Fix the chain hoist to the boom.

z

Hoist the boom cylinder and align the cylinder with the superstructure using the chain hoist.

z

Connect the hydraulic lines to the boom cylinder, refer to section 5.2.6.2 on page 5-138. WARNING

Do not open the plugged hydraulic ports at the cylinder when the wire ropes are removed, because the cylinder rod starts sliding by its own mass. First connect the hydraulic line, then remove the wire ropes.

Fig. 5-84



5 - 92

PC5500-6

Version 2009/2

Attachment

z

Face shovel



Remove the wire rope securing the piston rod of the boom cylinder.

z

Extend and retract the boom cylinder slowly at Qmin 2...3 times as far as possible to partly bleed the cylinder. WARNING


z

Extend the boom cylinder as needed to align the cylinder with the superstructure. DANGER

Never put hands into the holes when aligning the boom cylinder to the superstructure.

z

Insert the pin (Fig. 5-84, Pos. 5).

z


z

Install the shackle (Fig. 5-84, Pos. 4), and the bolt (Fig. 5-84, Pos. 3) to secure the pin (Fig. 5-84, Pos. 5).

z

Detach the chain hoist from the boom cylinder body.

z


z


z


z


z


z


z


Version 2009/2

PC5500-6

5 - 93

Face shovel

5.2.3

Attachment

STICK

5.2.3.1 REMOVAL OF THE STICK

Fig. 5-85 Stick, removal and installation

5 - 94

PC5500-6

Version 2009/2

Attachment

Face shovel


Boom

(2)

Stick

(3)

Bush

(4)

Seal ring

(5)

Catch

(6)

Pin

(7)

Ring

(8)

Cover

(9)

Bolt

(10)

Seal

(11)

Seal

(12)

Flange bush

(13)

Bush

(14)

Pin

(15)

Shackle

(16)

Bolt

Special tools:

n/a


Safety harness in conformity with DIN EN 361 Crane 2 x Chain hoist Mobile elevator working platform (telescopic or articulated boom lift) Stick: 21,000 kg Pin stick/boom: 168 kg Pin stick cylinder/stick: 90 kg Dogman/rigger For further information about the needed blind plugs, refer to section 2.3 on page 2-37.

WARNING z


z


Version 2009/2

PC5500-6

5 - 95

Face shovel

Attachment

z


z




z


z

Remove all grease feeding lines and electric wires from the stick.

z

Remove the bull clam bucket, refer to section 5.2.4.1 on page 5-110.

z

Hook up both stick cylinders (Fig. 5-87, Pos. 1) using chain hoists (Fig. 5-87, Pos. 2).

z

Carry out the following steps for each stick cylinder: z


z

Remove the pin (Fig. 5-87, Pos. 3). WARNING


NOTE: Note the seals (Fig. 5-87, Pos. 5) when removing the pin. Fig. 5-87 z

Check the bushes (Fig. 5-87, Pos. 6) and replace if required.

z


z

Switch S155 to Qmin and retract the stick cylinders (Fig. 5-87, Pos. 1) fully.



z


5 - 96

PC5500-6

Version 2009/2

Attachment

Face shovel


z

Disconnect all hydraulic hoses from the stick leading to the boom, refer to section 5.2.6.3 on page 5-142.

z

Sling the stick (Fig. 5-88, Pos. 1) and lift it using a crane.

z

Remove the bolts (Fig. 5-88, Pos. 2), the covers (Fig. 5-88, Pos. 3), and the rings (Fig. 5-88, Pos. 4).

z

Remove the pins (Fig. 5-88, Pos. 6) with the catches (Fig. 5-88, Pos. 5). WARNING

Sling the pins as soon as possible and support them using a crane to prevent the pins from falling.

z

Remove the stick and rest it on the ground using a crane. DANGER

Risk of falling weights! Death or serious injury may result. When moving the stick, make sure that nobody steps below the lifted stick. Fig. 5-88 z

Remove all provided parts and the hydraulic piping from the stick (Fig. 5-88, Pos. 1).

Version 2009/2

PC5500-6

5 - 97

Face shovel

Attachment

5.2.3.2 REPLACEMENT OF THE STICK Special tools:

n/a


Safety harness in conformity with DIN EN 361 Crane 2 x Chain hoist Mobile elevator working platform (telescopic or articulated boom lift) Stick: 21,000 kg Pin stick/boom: 168 kg Pin stick cylinder/stick: 90 kg Dogman/rigger If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.2 on page 2-33.

WARNING z


z


NOTE: When performing the installation procedures, comply to the following: Always discard used seals (Fig. 5-89, Pos. 3) and install new seals! Insert new bushes (Fig. 5-89, Pos. 2) into the stick (Fig. 5-89, Pos. 1) if required! Put the appropriate grease in every bush (Fig. 5-89, Pos. 2) on assembly!

Fig. 5-89

5 - 98

PC5500-6

Version 2009/2

Attachment

Face shovel

z

Install all provided parts and hydraulic piping to the stick (Fig. 5-90, Pos. 1).

z

Sling the stick (Fig. 5-90, Pos. 1) and align it to the boom using a crane. DANGER

Risk of falling weights! Death or serious injury may result. When moving the stick, make sure that nobody steps below the lifted stick.

DANGER Never put hands into the holes when aligning the stick to the boom.

z

Install the pins (Fig. 5-90, Pos. 6) attaching the stick (Fig. 5-90, Pos. 1) to the boom.

z

Install the catches (Fig. 5-90, Pos. 5), the rings (Fig. 5-90, Pos. 4), the covers (Fig. 5-90, Pos. 3), and the bolts (Fig. 5-90, Pos. 2) to secure the pins (Fig. 5-90, Pos. 6).

z

Bring the stick to the position shown in Fig. 5-91 using the crane.

z


z

Switch S155 to Qmin and extend the stick cylinders (Fig. 5-91, Pos. 1) to align the stick cylinders with the stick horizontally. Use the chain hoists (Fig. 5-91, Pos. 2) to align the stick cylinders with the stick vertically.

Fig. 5-90

NOTE: Use only engine no. 2 at Qmin. DANGER Never put hands into the holes when aligning the stick cylinders to the stick. Fig. 5-91 z

Put the appropriate grease in the bushes (Fig. 5-91, Pos. 6) and install the pins (Fig. 5-91, Pos. 3) with new seals (Fig. 5-91, Pos. 5).

z

Install the shackle (Fig. 5-91, Pos. 4) and the bolts (Fig. 5-91, Pos. 7) to secure the pins (Fig. 5-91, Pos. 3).

Version 2009/2

PC5500-6

5 - 99

Face shovel

Attachment

z


z


z


z


z


z


5.2.3.3 REMOVAL OF THE STICK CYLINDERS

Fig. 5-92 Stick cylinder, removal and installation

5 - 100

PC5500-6

Version 2009/2

Attachment

Face shovel


Stick cylinder

(2)

Boom

(3)

Stick

(4)

Seal

(5)

O-ring

(6)

Connecting block

(7)

Pipe

(8)

Pin

(9)

Seal

(10)

Bush

(11)

Bolt

(12)

Catch

(13)

Pin

(14)

Catch

(15)

Bolt

Special tools:

n/a


Safety harness in conformity with DIN EN 361 2 x Chain hoist Forklift Mobile elevator working platform (telescopic or articulated boom lift) Oil drain pan Stick cylinder: 3340 kg each Pin stick cylinder/boom: 90kg Pin stick cylinder/stick: 90 kg Dogman/rigger For further information about the needed blind plugs, refer to section 2.3 on page 2-37.

WARNING z


z


Version 2009/2

PC5500-6

5 - 101

Face shovel

Attachment

z


z




z


z

Remove the grease feeding lines from the stick cylinder(s) to be removed.

z

Secure the stick cylinder (Fig. 5-94, Pos. 1) to be removed under the boom using one chain hoist at each side of the cylinder.

z

Pull out the pin connecting the stick cylinder piston rod to the stick, refer to section 5.2.3.1 on page 5-94. WARNING

Sling the pin as soon as possible and support it using a crane to prevent the pin from falling when it is pulled out completely. Fig. 5-94 z


z

Switch S155 to Qmin and retract the stick cylinder (Fig. 5-94, Pos. 1) fully.

NOTE: Use ony engine no. 2 at Qmin. z

Tie the piston rod to the cylinder body with a wire rope (refer to Fig. 5-46).

z


z


5 - 102

PC5500-6

Version 2009/2

Attachment

Face shovel



z

Disconnect the hydraulic hoses from the stick cylinder, refer to section 5.2.6.4 on page 5-146.

NOTE: When the hydraulic hoses are disconnected, the oil inside the piping and the hoses will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Remove the bolts (Fig. 5-95, Pos. 1) and the catch (Fig. 5-95, Pos. 2), securing the pin (Fig. 5-95, Pos. 3). WARNING

Sling the pin as soon as possible and support it using a crane to prevent the pin from falling when it is pulled out completely.

NOTE: Note the seals (Fig. 5-95, Pos. 4) when removing the pin. z

Check bush (Fig. 5-95, Pos. 5) and replace if required.

Fig. 5-95

Version 2009/2

PC5500-6

5 - 103

Face shovel

z

Attachment

Lower the stick cylinder into a horizontal position using the chain hoists simultaneously. Use the Forklift to take over the stick cylinder. DANGER

Risk of falling weights! Death or serious injury may result. When moving the stick cylinder, make sure that nobody steps below the lifted cylinder.

z

If both stick cylinders are to be removed, repeat the dismounting procedure for the second stick cylinder.

z


5 - 104

PC5500-6

Version 2009/2

Attachment

Face shovel

5.2.3.4 REPLACEMENT OF THE STICK CYLINDERS Special tools:



Safety harness in conformity with DIN EN 361 Forklift 2 x Chain hoist Mobile elevator working platform (telescopic or articulated boom lift) Stick cylinder: 3340 kg each Pin stick cylinder/boom: 90kg Pin stick cylinder/stick: 90 kg Dogman/rigger If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.2 on page 2-33.

WARNING z


z


NOTE: When performing the installation procedures, comply to the following: Always discard used seals and install new seals! Insert new bushes into the stick cylinder if required, refer to the PARTS & SERVICE NEWS No. "AH06545". Apply the appropriate grease on every bush and pin on assembly! z

If required, install the pipe work, the connecting blocks, and the seals at the cylinder(s).

z

Attach two chain hoists to the underside of the boom.

z

Tie the pistion rod of the stick cylinder to be installed to the cylinder body with a wire rope (refer to Fig. 5-46).

z

Place the stick cylinder on a forklift horizontally and position the stick cylinder right underneath the chain hoists.

z

Connect a chain hoist to each side ot the stick cylinder.

Version 2009/2

PC5500-6

5 - 105

Face shovel

Attachment

DANGER Risk of falling weights! Death or serious injury may result. When moving the stick cylinder, make sure that nobody steps below the lifted cylinder.

z

Pull up the stick cylinder using the chain hoists and align the stick cylinder to the boom. DANGER

Never put hands into the holes when aligning the stick cylinders to the boom.

z

Insert the pin (Fig. 5-96, Pos. 3) and the seals (Fig. 5-96, Pos. 4).

z

Install the catch (Fig. 5-96, Pos. 2) and the bolts (Fig. 5-96, Pos. 1) to secure the pin (Fig. 5-96, Pos. 3).

Fig. 5-96 z

Connect the hydraulic hoses to the stick cylinder (Fig. 5-97, Pos. 1) , refer to section 5.2.6.4 on page 5-146.

z


z

Switch S155 to Qmin and retract the stick cylinder (Fig. 5-97, Pos. 1) fully.

NOTE: Use only engine no. at Qmin. z

Remove the wire rope from the stick cylinder (Fig. 5-97, Pos. 1).

z

Extend and retract the stick cylinder (Fig. 5-97, Pos. 1) slowly at Qmin 2…3 times as far as possible to partly bleed the cylin- Fig. 5-97 der.

5 - 106

PC5500-6

Version 2009/2

Attachment

Face shovel

WARNING The air in the cylinder will result in slightly jerky movements of the cylinder.

z

Extend the stick cylinder slowly at Qmin and use the chain hoist to align the stick cylinder to the stick. DANGER

Never put hands into the holes when aligning the stick cylinder to the stick.

z

Install the pin connecting the stick cylinder with the stick, refer to section 5.1.2.2 on page 5-24.

z


z


z


z


z


z


z


z


Version 2009/2

PC5500-6

5 - 107

Face shovel

5.2.4

Attachment

BULL CLAM BUCKET

Fig. 5-98 Bull clam bucket, removal and installation

5 - 108

PC5500-6

Version 2009/2

Attachment

Face shovel


Bull clam bucket

(2)

Bush

(3)

Seal

(4)

Pin

(5)

Axle stirrup

(6)

Catch

(7)

Shackle

(8)

Bolt

(9)

Bush

(10)

Pin

(11)

Axle stirrup

(12)

Catch

(13)

Shackle

(14)

Bolt

(15)

Bucket cylinder

(16)

Seal

(17

Stick

(18)

Seal fixing ring

Version 2009/2

PC5500-6

5 - 109

Face shovel

Attachment

5.2.4.1 REMOVAL OF THE BULL CLAM BUCKET Special tools:

n/a


Crane Oil drain pan Bucket: 35,060 kg Pin bucket cylinder/bucket: 190 kg Pin bucket/stick: 318 kg Dogman/rigger For further information about the needed blind plugs, refer to section 2.3 on page 2-37.

z


z




z


z

Disconnect the grease feeding lines leading to the bucket.

z

Remove the plate (Fig. 5-100, Pos. 2) from inside the bucket (Fig. 5-100, Pos. 1) to gain access to the assembly opening.

Fig. 5-100

5 - 110

PC5500-6

Version 2009/2

Attachment

Face shovel



z

Disconnect the hydraulic hoses from the clam cylinder distributor blocks, refer to section 5.2.6.6 on page 5-154.


Remove the seal fixing rings (Fig. 5-101, Pos. 1) from the pin (Fig. 5-101, Pos. 4) located on both sides of the cylinder respectively the stick (Fig. 5-101, Pos. 3).

NOTE: Always use new seals (Fig. 5-101, Pos. 2).

Fig. 5-101

Version 2009/2

PC5500-6

5 - 111

Face shovel

Attachment

Fig. 5-102 Bull clam bucket removal z

Sling the bucket cylinders (Fig. 5-102, Pos. 15) to prevent them from swinging when the pins (Fig. 5-102, Pos. 10) are removed.

z

Remove the bolts (Fig. 5-102, Pos. 14) with washers and the shackle (Fig. 5-102, Pos. 13).

z

Push the pin (Fig. 5-102, Pos. 10) to the inside just enough to remove the axle stirrups (Fig. 5-102, Pos. 11) from the catches (Fig. 5-102, Pos. 12).

NOTE: The catches (Fig. 5-102, Pos. 12) are welded to the bucket (Fig. 5-102, Pos. 1).

5 - 112

PC5500-6

Version 2009/2

Attachment

z

Face shovel

Remove the pin (Fig. 5-102, Pos. 10) to clear the bucket cylinder (Fig. 5-102, Pos. 15). Remove the seals (Fig. 5-101, Pos. 2) when removing the pin. WARNING


z

Remove the bolts (Fig. 5-102, Pos. 8) with washers and the shackle (Fig. 5-102, Pos. 7).

z

Push the pins (Fig. 5-102, Pos. 4) to the inside just enough to remove the axle stirrups (Fig. 5-102, Pos. 5) from the catches (Fig. 5-102, Pos. 6).

NOTE: The catches (Fig. 5-102, Pos. 6) are welded to the bucket. Use the assembly opening (refer to Fig. 5-100) to push the pins. z

Push the pins (Fig. 5-103, Pos. 1) out of the inner pin bearing (Fig. 5-103, Pos. 2) to the outside until the stick is cleared from the bucket. Remove the seals (Fig. 5-101, Pos. 2) and the rings (Fig. 5-102, Pos. 3) when removing the pin

NOTE: When the stick is cleared, the pins can maintain in the outer pin bearings (Fig. 5-103, Pos. 3).

Fig. 5-103 z

Check bushes (Fig. 5-102, Pos. 2 and 9) for wear or damage and replace if required.

z


z

Lift the boom and move the excavator away.

z


Version 2009/2

PC5500-6

5 - 113

Face shovel

Attachment

5.2.4.2 REPLACEMENT OF THE BULL CLAM BUCKET Special tools:

n/a


n/a Bucket: 35,060 kg Pin bucket cylinder/bucket: 190 kg Pin bucket/stick: 318 kg Dogman/rigger If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.2 on page 2-33.

Fig. 5-104 Bull clam bucket replacement

5 - 114

PC5500-6

Version 2009/2

Attachment

Face shovel

NOTE: When performing the installation procedures, comply to the following: Always discard used seals and install new seals! Insert new bushes into the stick (Fig. 5-104, Pos. 17) if required! Apply the appropriate grease on every bush and pin on assembly! z

Stick the seals (Fig. 5-104, Pos. 16) which are held by the seal fixing rings (Fig. 5-104, Pos. 18) to both sides of the stick (Fig. 5-104, Pos. 17) using appropriate grease.

z

Also stick the seals located on both sides of the bucket cylinders to the cylinders, refer to section 5.2.4.4 on page 5-121.

NOTE: During installation, there is not enough space to insert these seals. z


NOTE: Perform the bleeding procedure for the clam cylinder. Refer to PARTS & SERVICE NEWS No. "AH06524". z


z


z


z


z


Version 2009/2

PC5500-6

5 - 115

Face shovel

Attachment

5.2.4.3 REMOVAL OF THE BUCKET CYLINDERS

Fig. 5-105 Bucket cylinders, removal and installation

5 - 116

PC5500-6

Version 2009/2

Attachment

Face shovel


Bucket cylinder

(2)

Stick

(3)

Boom

(4)

Axle stirrup

(5)

Pin

(6)

Ring

(7)

Cover

(8)

Bolt

(9)

Bull clam bucket

(10)

Bush

(11)

Seal fixing ring

(12)

Seal

(13)

Catch

(14)

Shackle

(15)

O-ring

(16)

SAE-flange

(17)

Flange

(18)

Connecting plate

Version 2009/2

PC5500-6

5 - 117

Face shovel

Attachment

Special tools:



Safety harness in conformity with DIN EN 361 Crane Forklift Mobile elevator working platform (telescopic or articulated boom lift) Oil drain pan Bucket cylinder: 4005 kg Pin bucket cylinder/boom: 168 kg Pin bucket cylinder/bucket: 190 kg Dogman/rigger For further information about the needed blind plugs, refer to section 2.3 on page 2-37.

WARNING z


z


z


z

Park the machine on the prepared flat area with the superstructure turned by 90° and position the bucket on the ground as shown (Fig. 5-106), bucket cylinders in vertical position.



z


z

Disconnect the grease feeding lines from the bucket cylinder(s) to be removed.

z

Install the installation tool, PN 909 374 40 at the piston rod side of the bucket cylinder, refer to section 5.2.1 on page 5-75.

z

Support the bucket cylinder by means of the installation tool using the forks of a forklift.

5 - 118

PC5500-6

Version 2009/2

Attachment

Face shovel

z

Remove the bolts (Fig. 5-107, Pos. 1), the cover (Fig. 5-107, Pos. 2), and the ring (Fig. 5-107, Pos. 3).

z

Remove the pin (Fig. 5-107, Pos. 4) with the catches (Fig. 5-107, Pos. 5) as well as the seals at the bucket cylinder. WARNING


Fig. 5-107 z


z

Switch S155 to Qmin and retract the bucket cylinder fully.


Tie the piston rods to the bucket cylinder body with a wire rope.

z

Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE THE PRESSURE IN THE HYDRAULIC SYSTEM". WARNING



z


z

Disconnect the hydraulic hoses from the bucket cylinder, refer to section 5.2.6.5 on page 5-150.

NOTE: When the hydraulic hoses are disconnected, the oil inside the piping and the hoses will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. Version 2009/2

PC5500-6

5 - 119

Face shovel

z

Attachment

Remove the seal fixing rings (Fig. 5-108, Pos. 1) from the pin (Fig. 5-108, Pos. 4) located on both sides of the bucket cylinder (Fig. 5-108, Pos. 3).

NOTE: Always use new seals (Fig. 5-108, Pos. 2). z

Remove the pin connecting the bucket cylinder to the bucket, refer to section 5.2.4 on page 5-108.

Fig. 5-108 z

Remove the bucket cylinder using the forklift.

NOTE: Use a crane to lift the bucket cylinder from the forklift and to lay it down on the ground. WARNING Do not sling the bucket cylinder at the installation tool, refer to section 5.2.1 on page 5-75.

DANGER Risk of falling weights! Death or serious injury may result. When moving the bucket cylinder, make sure that nobody steps below the lifted cylinder.

5 - 120

PC5500-6

Version 2009/2

Attachment

Face shovel

5.2.4.4 REPLACEMENT OF THE BUCKET CYLINDERS Special tools:



Safety harness in conformity with DIN EN 361 Crane Forklift Mobile elevator working platform (telescopic or articulated boom lift) Bucket cylinder: 4005 kg Pin bucket cylinder/boom: 168 kg Pin bucket cylinder/bucket: 190 kg Dogman/rigger If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.2 on page 2-33.

WARNING z


z


NOTE: When performing the installation procedures, comply to the following: Always discard used seals and install new seals! Apply the appropriate grease on every bush and pin on assembly! z

Insert new bushes (Fig. 5-109, Pos. 1) into the bucket cylinder if required, refer to the PARTS & SERVICE NEWS No. "AH06545".

z

Install new seals (Fig. 5-109, Pos. 2) into the bushes in the piston rod.

z

Stick new seals (Fig. 5-109, Pos. 3) to bucket cylinder using appropriate grease.

NOTE: During installation of the cylinder, there is not enough space to insert the seals (Fig. 5-109, Pos. 3). z

z

Install the installation tool, PN 909 374 40 at the piston rod side of the new bucket cylinder.

Fig. 5-109

Sling the bucket cylinder to a crane at the piston rod side, using the installation tool as a stop for the wire rope. WARNING

Do not sling the wire rope to the installation tool.

Version 2009/2

PC5500-6

5 - 121

Face shovel

Attachment

z

Lift the bucket cylinder until it is in upright position.

z

Take over the bucket cylinder with a forklift, supporting the cylinder at the installation tool with the forks of the forklift. DANGER

Risk of falling weights! Death or serious injury may result. When moving the bucket cylinder, make sure that nobody steps below the lifted cylinder.

z

Align the bucket cylinder with the bucket. DANGER

Never put hands into the holes when aligning the bucket cylinder to the bucket.

z

Insert the pin (Fig. 5-110, Pos. 1) and the seals (Fig. 5-111, Pos. 2). Secure the pin with the axle stirrups (Fig. 5-110, Pos. 2) in the catches (Fig. 5-110, Pos. 3).

z

Install the shackle (Fig. 5-110, Pos. 4) and insert the bolts (Fig. 5-110, Pos. 5) with washers.

Fig. 5-110 z

Install the seal fixing rings (Fig. 5-111, Pos. 1) at the pin (Fig. 5-111, Pos. 4) located on both sides of the bucket cylinder (Fig. 5-111, Pos. 3) to fix the seals (Fig. 5-111, Pos. 2).

z

Connect the hydraulic lines to the bucket cylinder, refer to section 5.2.6.5 on page 5-150.

NOTE: Always use new O-rings at the SAE-flange connections.

Fig. 5-111 z


5 - 122

PC5500-6

Version 2009/2

Attachment

z

Face shovel



Extend and retract the bucket cylinder slowly at Qmin 2…3 times as far as possible to partly bleed the cylinder. WARNING


z

Extend the bucket cylinder slowly at Qmin and align the piston rod with the boom vertically. Use the forklift to align the stick cylinder to the boom horizontally. DANGER

Never put hands into the holes when aligning the bucket cylinder to the boom.

z

Insert the pin (Fig. 5-112, Pos. 4) with the catches (Fig. 5-112, Pos. 5) and mount the seals (Fig. 5-109, Pos. 2) at the bucket cylinder.

z

Install the ring (Fig. 5-112, Pos. 3), the cover (Fig. 5-112, Pos. 2), and the bolts (Fig. 5-112, Pos. 1).

z


z

Isolate the machine according to local regulations. Fig. 5-112

z


z


z


z


z


z


z


Version 2009/2

PC5500-6

5 - 123

Face shovel

Attachment

5.2.4.5 REMOVAL OF THE CLAM CYLINDERS

Fig. 5-113 Clam cylinders, removal and installation

5 - 124

PC5500-6

Version 2009/2

Attachment

Face shovel


Clam cylinder

(2)

Clam

(3)

Seal

(4)

Pin

(5)

Cover

(6)

Bolt

(7)

Bush

(8)

Seal

(9)

Bush

(10)

Hydraulic hose

(11)

O-ring

(12)

Pin

(13)

Bolt

(14)

Plate

(15)

Catch

Special tools:

n/a


Crane Oil drain pan Clam cylinder: 885 kg Clam cylinder’s upper pin: 48 kg Clam cylinder’s lower pin: 66 kg Dogman/rigger For further information about the needed blind plugs, refer to section 2.3 on page 2-37.

Version 2009/2

PC5500-6

5 - 125

Face shovel

Attachment

z

Prepare an area of flat ground large enough to accommodate the machine boom and crane.

z

Park the machine on the prepared flat area and position the bucket horizontally on the ground (Fig. 5-114).


Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE THE PRESSURE IN THE HYDRAULIC SYSTEM". Fig. 5-114

z


z

Support the clam cylinder with appropriate blocks (Fig. 5-115, arrows) to fix it in its position.

z

Disconnect the grease feeding lines from the clam cylinder.

Fig. 5-115 z

Remove the bolts (Fig. 5-116, Pos. 1) and the cover (Fig. 5-116, Pos. 2) to access the pin connecting the clam cylinder to the clam.

Fig. 5-116

5 - 126

PC5500-6

Version 2009/2

Attachment

Face shovel

z

Remove the bolts (Fig. 5-117, Pos. 6), the cover (Fig. 5-117, Pos. 5), and the catches (Fig. 5-117, Pos. 7).

z

Pull out the pin (Fig. 5-117, Pos. 4) to clear the clam cylinder (Fig. 5-117, Pos. 2) from the clam (Fig. 5-117, Pos. 1). Remove the seals (Fig. 5-117, Pos. 3).

Fig. 5-117 z


z

Switch S155 to Qmin and retract the clam cylinder to be removed fully.

NOTE: Use only engine no. 2 at Qmin. WARNING Both clam cylinders are connected to the same hydraulic line, so when the cleared cylinder is fully retracted, the clam will open. Do not open the clam.

z


z




Version 2009/2

PC5500-6

5 - 127

Face shovel

z

Attachment

Disconnect the hydraulic hoses from the clam cylinder, refer to section 5.2.6.6 on page 5-154.

NOTE: When the hydraulic hoses are disconnected, the oil inside the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. Discard the O-rings. z

Sling the clam cylinder at both ends.

z

Remove the bolt (Fig. 5-118, Pos. 1) and the plate (Fig. 5-118, Pos. 2).

z

Pull out the pin (Fig. 5-118, Pos. 3) using pulling bolts.

z

Remove the clam cylinder from the bucket using a crane. DANGER

Risk of falling weights! Death or serious injury may result. When moving the clam cylinder, make sure that nobody steps below the lifted cylinder. Fig. 5-118

5 - 128

PC5500-6

Version 2009/2

Attachment

Face shovel

5.2.4.6 REPLACEMENT OF THE CLAM CYLINDERS Special tools:

n/a


Crane Clam cylinder: 885 kg Clam cylinder’s upper pin: 48 kg Clam cylinder’s lower pin: 66 kg Dogman/rigger If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.2 on page 2-33.

NOTE: When performing the installation procedures, comply to the following: Always discard used seals (Fig. 5-119, Pos. 2) and install new seals! Insert new bushes (Fig. 5-119, Pos. 1) into the clam cylinder if required, refer to the PARTS & SERVICE NEWS No. "AH06545". Apply the appropriate grease on every bush and pin on assembly!

Fig. 5-119 z

Insert the clam cylinder into the bucket using a crane and align the cylinder with the bucket to insert the lower pin. DANGER

Never put hands into the holes when aligning the clam cylinder to the bucket.

NOTE: For easier alignment it is recommended to support the clam cylinder at the front side and from below with appropriate blocks (Fig. 5-120, arrows) to fix it in its position. Fig. 5-120

Version 2009/2

PC5500-6

5 - 129

Face shovel

Attachment

z

Insert the pin (Fig. 5-121, Pos. 3) and install the seals. Fix the pin with the plate (Fig. 5-121, Pos. 2).

z

Secure the plate with the bolt (Fig. 5-121, Pos. 1).

Fig. 5-121 z

Connect the hydraulic hoses to the clam cylinder, refer to section 5.2.6.6 on page 5-154.

NOTE: Use new O-rings at the SAE-flange connections. z

Detach the clam cylinder from the crane.

z


z



Extend and retract the clam cylinder slowly at Qmin 2…3 times as far as possible to partly bleed the cylinder. WARNING

Both clam cylinders are connected to the same hydraulic line, so when the cleared cylinder is fully retracted, the clam will open. Do not open the clam.

WARNING The air in the cylinder will result in slightly jerky movements of the cylinder.

z

Extend the clam cylinder slowly at Qmin to align the cylinder piston rod with the clam. WARNING

Never put hands into the holes when aligning the clam cylinder to the clam.

5 - 130

PC5500-6

Version 2009/2

Attachment

Face shovel

z

Insert the pin (Fig. 5-122, Pos. 4) connecting clam cylinder (Fig. 5-122, Pos. 2) to the clam (Fig. 5-122, Pos. 1) and install the seals (Fig. 5-122, Pos. 3).

z


z

Install the cover (Fig. 5-122, Pos. 5) and the bolts (Fig. 5-122, Pos. 6).

Fig. 5-122 z


z


z

Perform the bleeding procedure for the clam cylinders. Refer to PARTS & SERVICE NEWS No. "AH06524".

z


z


z


z


Version 2009/2

PC5500-6

5 - 131

Face shovel

5.2.5

Attachment

GROUND ENGAGING TOOLS (GET)

As ground engaging tools, the ESCO POSILOK Tooth System is used.

Fig. 5-123 GET (1)

Shroud

(2)

Toplok boss

(3)

Wedge

(4)

Point (tooth)

(5)

Lock

(6)

Tooth adapter (center/corner)

(7)

Pin

(8)

Wear cap

5 - 132

PC5500-6

Version 2009/2

Attachment

Face shovel

5.2.5.1 REMOVAL AND REPLACEMENT OF THE GET Special tools:

POSILOK Pin removal tool PN 795 502 73


ESCO POSILOK Tooth System S130 Forklift Point (tooth): 55 kg (ESCO) Shroud: 270 kg (ESCO) Tooth adapter: 182 kg (ESCO) Dogman/rigger If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.2 on page 2-33.

CAUTION Hazard of injuries from splinters! When working on the locking pins, always wear hard hat, safety glasses steel-toed shoes, and gloves. To avoid injury to others, keep people not directly involved well out of the way.

z

Prepare an area of flat ground large enough to accommodate the machine, bucket and a forklift.

z

Park the machine on the prepared flat ground area and position the bucket in an appropriate height for work.



z

For removing and installing the ESCO Tooth System, refer to PARTS & SERVICE NEWS No. "AH03510".

NOTE: Use a forklift to remove and install the GET.

Version 2009/2

PC5500-6

5 - 133

Face shovel

5.2.6

Attachment

HYDRAULIC HOSES AT THE FACE SHOVEL ATTACHMENT

5.2.6.1 SUBSTITUTE THE BOOM ARC HOSES

Fig. 5-124 Boom arc hoses, removal and installation 5 - 134

PC5500-6

Version 2009/2

Attachment

Face shovel


Hose clamp

(2)

Clamp line

(3)

Nut

(4)

Manifold

(5)

Hydraulic pipe

(6)

Hydraulic hose

(7)

Bolt

(8)

O-ring

Special tools:

n/a


Safety harness in conformity with DIN EN 361 Crane Oil drain pan Boom arc hose: 39 kg


WARNING Always wear a safety harness when working at the attachment.

z


z

Park the machine on the prepared flat area with the stick cylinder fully retracted and position the bucket horizontally on the ground (Fig. 5-125).


Version 2009/2

PC5500-6

5 - 135

Face shovel

Attachment

Fig. 5-126 Boom arc hoses, removal and installation z


5 - 136

PC5500-6

Version 2009/2

Attachment

Face shovel

z


z

Open the hose clamps (Fig. 5-126, Pos. 1) and clear the hydraulic hose (Fig. 5-126, Pos. 6) to be removed from the clamp lines (Fig. 5-126, Pos. 2). WARNING



z


z

Remove the bolts (Fig. 5-126, Pos. 7) and disconnect the SAE-flanges from the manifold (Fig. 5-126, Pos. 4) and from the hydraulic tube (Fig. 5-126, Pos. 5) at the boom.



z

Replace the boom arc hoses by new ones and carry out installation in reverse order to removal.


Substitute the other boom arc hoses if required, using the same procedure.

z

Perform the bleeding procedure for all cylinders. Refer to PARTS & SERVICE NEWS No. "AH06524".

z


z


z


Version 2009/2

PC5500-6

5 - 137

Face shovel

Attachment

5.2.6.2 SUBSTITUTE THE BOOM CYLINDER HOSES

Fig. 5-127 Boom cylinder hoses, removal and installation

5 - 138

PC5500-6

Version 2009/2

Attachment

Face shovel


Hydraulic hose

(2)

Hydraulic hose

(3)

Bolt

(4)

O-ring

(5)

Ring

(6)

Boom cylinder

Special tools:

n/a


Safety harness in conformity with DIN EN 361 Crane Mobile elevator working platform (telescopic or articulated boom lift) Oil drain pan Boom cylinder hose: 30.5 kg


WARNING z


z


z


z



Version 2009/2

PC5500-6

5 - 139

Face shovel

Attachment

Fig. 5-129 Boom cylinder hoses, removal and installation

5 - 140

PC5500-6

Version 2009/2

Attachment

Face shovel

z


z




z

Sling the hydraulic hose (Fig. 5-129, Pos. 1 or 2) to be removed.

z

Remove the bolts (Fig. 5-129, Pos. 3) and disconnect the SAE-flanges from the boom cylinder (Fig. 5-129, Pos. 6) and from the hydraulic tube at the boom.



z

Replace the boom cylinder hoses by new ones and carry out installation in reverse order to removal.

NOTE: Always replace the O-rings (Fig. 5-129, Pos. 4) and the rings (Fig. 5-129, Pos. 5) at the SAE-flange connections. z

Substitute the other boom cylinder hoses if required, using the same procedure.

z

Perform the bleeding procedure for the boom cylinder(s). Refer to PARTS & SERVICE NEWS No. "AH06524".

z


z


z


Version 2009/2

PC5500-6

5 - 141

Face shovel

Attachment

5.2.6.3 SUBSTITUTE THE STICK ARC HOSES

Fig. 5-130 Stick arc hoses, removal and installation (1)

Hydraulic hose

(2)

Hose clamp line

(3)

Bolt

(4)

O-ring

(5)

Ring

(6)

Hydraulic tube

5 - 142

PC5500-6

Version 2009/2

Attachment

Face shovel

Special tools:

n/a


Safety harness in conformity with DIN EN 361 Crane Mobile elevator working platform (telescopic or articulated boom lift) Oil drain pan Stick arc hose: 29.5 kg


WARNING z


z


z


z



Version 2009/2

PC5500-6

5 - 143

Face shovel

Attachment

Fig. 5-132 Stick arc hoses, removal and installation z


z


5 - 144

PC5500-6

Version 2009/2

Attachment

Face shovel

z

Remove the hose clamp lines (Fig. 5-132, Pos. 2).

z

Sling the hydraulic hose (Fig. 5-132, Pos. 1) to be removed. WARNING



z

Remove the bolts (Fig. 5-132, Pos. 3) and disconnect the SAE-flanges from the hydraulic tubes (Fig. 5-132, Pos. 6).



z

Replace the stick arc hoses by new ones and carry out installation in reverse order to removal.


Substitute the other stick arc hoses if required, using the same procedure.

z

Perform the bleeding procedure for the bucket and clam cylinders. Refer to PARTS & SERVICE NEWS No. "AH06524".

z


z


z


Version 2009/2

PC5500-6

5 - 145

Face shovel

Attachment

5.2.6.4 SUBSTITUTE THE STICK CYLINDER HOSES

Fig. 5-133 Stick cylinder hoses, removal and installation (1)

Hydraulic hose

(2)

Hydraulic hose

(3)

Bolt

(4)

O-ring

(5)

Ring

5 - 146

PC5500-6

Version 2009/2

Attachment

Face shovel

Special tools:

n/a


Safety harness in conformity with DIN EN 361 Forklift Mobile elevator working platform (telescopic or articulated boom lift) Oil drain pan Stick cylinder hose (depending on length): 25 kg 27.4 kg Dogman/rigger If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.2 on page 2-33. For further information about the needed blind plugs, refer to section 2.3 on page 2-37.

WARNING z


z


z


z




z


Version 2009/2

PC5500-6

5 - 147

Face shovel

Attachment

Fig. 5-135 Stick cylinder hoses, removal and installation

5 - 148

PC5500-6

Version 2009/2

Attachment

z

Face shovel

Sling the hydraulic hose (Fig. 5-135, Pos. 1 or 2) to be removed using a forklift. WARNING



z

Remove the bolts (Fig. 5-135, Pos. 3) and disconnect the SAE-flanges.

NOTE: When the hydraulic hose is disconnected, the oil inside the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Remove the hydraulic hose using a forklift.

z

Replace the stick cylinder hoses by new ones and carry out installation in reverse order to removal.


Substitute the other stick cylinder hoses if required, using the same procedure.

z

Perform the bleeding procedure for the stick cylinder(s). Refer to PARTS & SERVICE NEWS No. "AH06524".

z


z


z


Version 2009/2

PC5500-6

5 - 149

Face shovel

Attachment

5.2.6.5 SUBSTITUTE THE BUCKET CYLINDER HOSES

Fig. 5-136 Bucket cylinder hoses, removal and installation (1)

Hydraulic hose

(2)

Hydraulic hose

(3)

Bolt

(4)

O-ring

(5)

Ring

(6)

Intermediate flange

(7)

Bucket cylinder

(8)

Stick

5 - 150

PC5500-6

Version 2009/2

Attachment

Face shovel

Special tools:

n/a


Safety harness in conformity with DIN EN 361 Crane Mobile elevator working platform (telescopic or articulated boom lift) Oil drain pan Bucket cylinder hose (depending on length): 28 kg


WARNING z


z


z


z




z


Version 2009/2

PC5500-6

5 - 151

Face shovel

Attachment

Fig. 5-138 Bucket cylinder hoses, removal and installation z



5 - 152

PC5500-6

Version 2009/2

Attachment

Face shovel


z

Remove the bolts (Fig. 5-138, Pos. 3) and disconnect the SAE-flanges. z

Remove the intermediate flange (Fig. 5-138, Pos. 6) from the cylinder when removing the bucket cylinder hose (Fig. 5-138, Pos. 1) on the piston rod side of the bucket cylinder (Fig. 5-138, Pos. 7).



z

Replace the bucket cylinder hoses by new ones and carry out installation in reverse order to removal.


Substitute the other bucket cylinder hoses if required, using the same procedure.

z

Perform the bleeding procedure for the bucket cylinder(s). Refer to PARTS & SERVICE NEWS No. "AH06524".

z


z


z


Version 2009/2

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5 - 153

Face shovel

Attachment

5.2.6.6 SUBSTITUTE THE CLAM CYLINDER HOSES The clam cylinder hose set contains two hydraulic hoses at the stick and four (two for each cylinder) hydraulic hoses at the clam cylinders. Substitute the clam cylinder hoses at the stick

Fig. 5-139 Clam cylinder hoses at stick, removal and installation (1)

Hydraulic hose

(2)

Bolt

(3)

O-Ring

(4)

Ring

5 - 154

PC5500-6

Version 2009/2

Attachment

Face shovel

Special tools:

n/a


Forklift Oil drain pan Clam cylinder hose: 28 kg


z


z




z


z


Version 2009/2

PC5500-6

5 - 155

Face shovel

Attachment

Fig. 5-141 Clam cylinder hoses at stick, removal and installation WARNING Hot hydraulic oil! Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is below 50 °C. Disobedience may result in personal injury from heated oil.


5 - 156

PC5500-6

Version 2009/2

Attachment

z

Face shovel

Remove the bolts (Fig. 5-141, Pos. 2) and disconnect the SAE-flanges.


Remove the hydraulic hose using a forklift.

z

Replace the clam cylinder hose by a new one and carry out installation in reverse order to removal.


Substitute the other clam cylinder hose if required, using the same procedure.

z

If required, substitute the clam cylinder hoses at the clam cylinders as described in the next section on page 158.

z

Perform the bleeding procedure for the clam cylinders. Refer to PARTS & SERVICE NEWS No. "AH06524".

z


z


z


Version 2009/2

PC5500-6

5 - 157

Face shovel

Attachment

Substitute the clam cylinder hoses at the cylinders

Fig. 5-142 Clam cylinder hoses, removal and installation 5 - 158

PC5500-6

Version 2009/2

Attachment

Face shovel


Hydraulic hose

(2)

Hydraulic hose

(3)

Hydraulic hose

(4)

Hydraulic hose

(5)

Bolt

(6)

O-ring

(7)

Distributor block

(8)

Clam cylinder

(9)

Flange half

Special tools:

n/a


Oil drain pan Clam cylinder hose (depending on length): 9.8 kg 8.8 kg 10 kg 11.2 kg Dogman/rigger If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.2 on page 2-33. For further information about the needed blind plugs, refer to section 2.3 on page 2-37.

z

Prepare an area of flat ground large enough to accommodate the machine.

z




z


Version 2009/2

PC5500-6

5 - 159

Face shovel

Attachment

Fig. 5-144 Clam cylinder hoses, removal and installation

5 - 160

PC5500-6

Version 2009/2

Attachment

Face shovel



z

Remove the bolts (Fig. 5-144, Pos. 5) from the flange halves (Fig. 5-144, Pos. 9) to disconnect the SAE-flanges from the distributor block (Fig. 5-144, Pos. 7) and from the clam cylinder (Fig. 5-144, Pos. 8).


Replace the hydraulic hoses (Fig. 5-144, Pos. 1 to 4).

z

Replace the clam cylinder hoses by a new ones and carry out installation in reverse order to removal.


Perform the bleeding procedure for the clam cylinder(s). Refer to PARTS & SERVICE NEWS No. "AH06524".

z


z


z


Version 2009/2

PC5500-6

5 - 161

Metering valves (grease injectors) at the attachment

Attachment

5.3

METERING VALVES (GREASE INJECTORS) AT THE ATTACHMENT

5.3.1

REMOVAL OF THE METERING VALVES (GREASE INJECTORS)

Special tools:

n/a


Safety harness in conformity with DIN EN 361 Mobile elevator working platform

WARNING z


z

The work requires the use of men safety cages on elevator working platforms.

z

Prepare an area of flat ground large enough to accommodate the machine, boom, and mobile elevator working platform.

z




Fig. 5-145

NOTE: It is described how to remove metering valves at the BHA boom exemplarily, all other metering valves at the attachment (also FSA) are removed analogously. z

Disconnect all grease feeding lines (Fig. 5-146, Pos. 2) from the metering valve assemblies (Fig. 5-146, Pos. 6).

z

Remove the union (Fig. 5-146, Pos. 3) from the metering valve assembly (Fig. 5-146, Pos. 6).

z

Remove the bolts (Fig. 5-146, Pos. 5) and remove the metering valve assemblies (Fig. 5-146, Pos. 6) from the boom (Fig. 5-146, Pos. 1).

NOTE: Separate the metering valve assemblies (Fig. 5-146, Pos. 6) at the union (Fig. 5-146, Pos. 4).

Fig. 5-146 5 - 162

PC5500-6

Version 2009/2

Attachment

z

Metering valves (grease injectors) at the attachment

Remove the adapter bolt (Fig. 5-147, Pos. 2) and remove the valve housing (Fig. 5-147, Pos. 1) from the metering valve assembly (Fig. 5-147, Pos. 4).

Fig. 5-147

5.3.2

REPLACEMENT OF THE METERING VALVES (GREASE INJECTORS)

Special tools:

n/a


Safety harness in conformity with DIN EN 361 Mobile elevator working platform If there is nothing mentioned explicitly, tighten all bolts according to DIN, refer to section 2.2 on page 2-33.

WARNING z


z

The work requires the use of men safety cages on elevator working platforms.

z


z

Use new seals (Fig. 5-147, Pos. 3) at the valve housing (Fig. 5-147, Pos. 1).

z

Check metering valves at the attachment for proper operation, refer to the Operation & Maintenance chapter 4, section "WALK AROUND INSPECTION".

Version 2009/2

PC5500-6

5 - 163

Cylinder bypass test

5.4

Attachment

CYLINDER BYPASS TEST

Special tools:

n/a Safety harness in conformity with DIN EN 361 Mobile elevator working platform Infrared thermometer Oil drain pan


Hydraulic hose with 1 1/2" or 2" 6000 PSI SAE-flange The SAE-flange size depends on the cylinder flange size, the hose should be long enough to lead from the respective cylinder to an oil pan. For further information about the needed blind plugs, refer to section 2.3 on page 2-37.

The cylinder bypass test can be performed to check if a hydraulic cylinder has an internal leakage. NOTE: A cylinder with an internal leakage also has a higher temperature (at working temperature of the machine) than a hydraulic cylinder which has no internal leakage. WARNING Always wear a Safety harness when working at the attachment.

NOTE: First check hydraulic cylinder temperature using an infrared thermometer if an internal leakage is assumed. If the temperature is not higher than the temperature of the other cylinders, another reason e.g. leakage of a valve may be the reason for loosing pressure. If the temperature is higher than the temperature of the other cylinders, perform the following steps: z

Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, section 3.15.1.

z



5 - 164

PC5500-6

Version 2009/2

Attachment


DANGER Danger of hydraulic pressure. May result in blindness, serious injury, permanent disfigurement, or scaring. The hydraulic system may be pressurized. Make sure that the pressure is relieved before any hydraulic lines will be removed.

z

Disconnect the hydraulic hose from the piston rod side of the respective cylinder.

NOTE: When the hydraulic hose is disconnected, the oil inside the piping will flow out. Catch it in an oil pan. Cap the hydraulic hose with a blind plug to avoid contamination. z

Connect a hydraulic hose to the piston rod side of the cylinder. Put the open end of the hose into an oil pan.

z

De-isolate the machine according to local regulations. WARNING

Make sure that nobody is at close range of the hydraulic hose’s open end when extending the cylinder.

z

Swtich S155 to Qmin and slowly extend the hydraulic cylinder.

NOTE: Use only engine no. 2 at Qmin. NOTE: The oil inside the cylinder will flow out of the hydraulic hose connected to the piston rod side of the cylinder. Catch it in the oil pan. z

When the piston of the cylinder reaches its mechanical stop, continue to extend the cylinder.

If the cylinder has an internal leakage, some oil will continously flow out of the hydraulic hose connected to the piston rod side of the cylinder. If the cylinder has no internal leakage, oil will stop flowing out of the hydraulic hose.

Version 2009/2

PC5500-6

5 - 165


Attachment


5 - 166

PC5500-6

Version 2009/2

Service Information

6 SERVICE INFORMATION

Version 2009/2

PC5500-6

6 -1

Fluids and lubricants

Service Information

6.1

FLUIDS AND LUBRICANTS

6.1.1

LUBRICANTS FOR OPERATION IN MODERATE AND HOT CLIMATES

Lubrication Point

Lubricant

Engine Oil Coolant Fuel

Hydraulic System

Travel gears, Final drives and Swing gears Break housings and Motor adapter housings of Travel gears *3) and Swing gears *4)

Ambient Temperature [°C]

Viscosity Grades

Quality Grades DIN/API

Refer to Engine Operation and Maintenance Manual for specifications. Hydraulic oil HLP or HLPD with ZINC anti-wear additives *1) Gear oil CLP *2)

-20 to +11

22

-14 to +21

32

-6 to +31

46

0 to +40

68

+5 to +48

100

-15 to +50

CLP 220

Engine oil or Hydraulic oil

DIN-51524 T.2 and T.3-HLP

DIN 51517 3 - CLP

SAE 10 all

HLP 32


PTO (Pump distributor gear)

Gear oil CLP *2)

-15 to +50

CLP 150

DIN 51517 3 - CLP

Pump drive shaft housings

Hydraulic oil

all

HLP 32


Fan bearing housings of Radiator and Hydraulic oil cooler

Gear oil CLP

all

CLP 150

DIN 51517 3 - CLP

NOTE: *1) DO NOT mix zinc-free hydraulic oils with hydraulic oils containing Zinc. DO NOT mix mineral hydraulic oils with synthetic hydraulic oils. Mixing the above oils will reduce anti wear properties and oxidation stability of the oil. The oil filters in the hydraulic system will clog quickly. *2) Refer to the chart -gear oils- in the binder containing volume 2 for the released gear oil qualities and viscosity grades. *3) Only for wet running brakes of travel gears GFT 1300 K 1003 manufactured by L&S with a serial no. up to and including 15025. *4) Brake housings of swing gears manufactured by L&S have no separate oil compartment, as brake discs are lubricated by splash oil from the gear box.

6 -2

PC5500-6

Version 2009/2

Service Information

Point of lubrication Grease fittings (manual lubrication) Central lubrication system Swing circle teeth (manual lubrication) Swing circle pinion lubrication system


Ambient temperature °C

Lubricant

Viscosity grades

Quality grades DIN/API

Multi-purpose grease "MPG"

Refer to the lubricant chart in the binder containing volume 2 for the recommended multi-purpose greases. The part numbers of recommended multi-purpose greases are listed in the parts catalogue.

Adhesive lubricant

Refer to PARTS & SERVICE NEWS No. "AH00519" for the recommended adhesive lubricants. The part numbers of the recommended adhesive lubricants are listed in the parts catalogue.

Track rollers, carrier rollers and guide wheels

Gear oil "CLP"

all

CLP 220

DIN 51517 3 CLP

Geislinger couplings

Engine oil "API"

all

SAE 15W-40

API CG-4SH

Air conditioning system Refrigerant compressor

R 134a

Refrigerant Special oil. See warning below.

The air conditioning is prepared for refrigerant "R134a" only. See warning below.

WARNING The air conditioning may only be filled with refrigerant "R134a" by authorized service specialists only. DO NOT use refrigerant "R12", otherwise serious damage to system components could occur. The lubrication oil for the refrigerant compressor must be compatible with "R134a" refrigerant.

WARNING The lubricating instructions in this book refer to the recommended grade specifications. Damages caused by using lubricants other than specified are not covered by the manufacturer’s warranty.

Version 2009/2

PC5500-6

6 -3


6.1.2

Service Information

LUBRICANTS FOR OPERATION IN COLD AND ARCTIC CLIMATES Lubrication Point

Lubricant

Ambient Temperature °C

Hydraulic System (pre-heated)

Shell Tellus Arctic 32 ESSOTRANS EXTRA

- 50 to + 35 - 50 to + 28

Travel Gears

Shell Omala HD 220

All seasons

Final Drives

Shell Omala HD 220

All seasons

Swing Gear

Shell Omala HD 220

All seasons

Track Rollers and Idler Wheels

Shell Omala HD 220

All seasons

Pump Distributor Gears (pre-heated)

Shell Transaxle Oil 75W-90 Tranself Synthese FE 75W-90

All seasons - 45 to + 35

Pump drive shaft housing on the Pump Distributor Gears

Shell Tellus Arctic 32

All seasons

Brake housings *1) and Motor adapter housing of Gears

Shell Omala HD 220

All seasons

Fan Bearing Housings of Radiators and Hydraulic Oil Coolers

Shell Omala HD 220

All seasons

Central Lubrication System

Fuchs Stabyl L-TS MO Shell Darina XL 102 Moly Fuchs Urethyn HGO

- 10 to + 35 - 10 to + 35 - 50 to - 10

Swing Circle Lubrication System

Shell Malleus GL 400 Shell Malleus GL 25 Fuchs Urethyn HGO

- 10 to + 35 - 30 to 0 - 50 to - 10

Refrigerant Lubricant

Shell Clavus Oil R 68

- 50 to + 35

Refrigerant

Shell R 134 a

- 50 to + 35

Engine Oil

SAE 15W-40 API Category CG-4SH

All seasons

Flexible Couplings

SAE 15W-40 API Category CG-4SH

All seasons

Engine Coolant and Fuel

Refer to Engine Operation and Maintenance Manual for specifications

NOTE: *1) For wet running brakes of travel gears GFT 1300 K 1003 manufactured by L&S with a serial no. up to and including 15025 only use engine oil SAE 10 or hydraulic oil HLP 32.

6 -4

PC5500-6

Version 2009/2

Service Information

6.2

Filling capacities

FILLING CAPACITIES Units or system

Liters (approximate)

Engine cooling system Front engine (engine 2)

360

Rear engine (engine 1)

360

Engine oil Front engine (engine 2) oil pan

190

Rear engine (engine 1) oil pan

190

Front engine reserve tank

580 (425 refill)

Rear engine reserve tank

580 (425 refill)

Fuel tank

10.800

Main hydraulic oil reservoir

3600*1

Complete hydraulic system

6600

Pump distributor gear (PTO), each

95

Oil collector reservoir, auxiliary hydraulic pumps

1

Main hydraulic pumps, drive shaft housing

1.5

Geislinger coupling

1.45

Slew gear (L&S), each

42

Motor adapter housing

0.6

Slew gear (Siebenhaar), each

60


*2

Brake housing

0.2

Travel gear (L&S, type GFT 1300 K 1003), each Motor adapter housing

2.5 *2

Brake housing

0.1 *2

Spur gear housing

10 *2

Planetary gear housing

105 *2

Support bearing

3.5 *2

NOTE: *1) Oil change quantity, including suction oil tank and return oil collector pipes, is approx. 4450 liters (when attachment is in oil level checking position), see oil level gauge on the main hydraulic oil reservoir. *2) Fill up to level gauge marking.

Version 2009/2

PC5500-6

6 -5

Filling capacities

Service Information

Units or system

Liters (approximate)

Travel gear (L&S, type GFA 305 K 1017), each

155


2

Travel gear (Zollern), each

180


0.5

Final drive housing

165

Guide wheel

3.2

Carrier rollers

*3

Track rollers

*3

Water tank in operator’s cabin

50

Water reservoir for windshield washer

7

NOTE: *3) Fill up to the specified level, refer to section 4.1.12 on page 4-66. NOTE: Capacities listed above are approximate values. For proper checking use level plugs, dipsticks, and inspection openings, provided for this purpose.

6 -6

PC5500-6

Version 2009/2

Service Information

Work instructions

6.3

WORK INSTRUCTIONS

6.3.1

SURFACE COATING WITH INTERZINC 697 Coating compound "INTERZINC 697", PN 674 997 40 Thinner, PN 907 886 40 Dust bonding cloths, PN 932 911 40


WARNING z

All working procedures in coherency with the coating compound "INTERZINC 697" must be carried out according to local regulations and standards concerning occupational health and safety.

z

All working procedures in coherency with the coating compound "INTERZINC 697" must be carried out by authorized specialists only.

CAUTION Welding or cutting on parts which have been coated with the coating compound "INTERZINC 697" results in harmful dusting and gassing. Carry out welding or cutting work with personal protective equipment only. Dust and gases must be lead away from the workplace.

z

Clean the surface to be coated according to ISO 8504, purity level 3 with thinner, PN 907 886 40. The surface to be coated must be completely free of dirt, grease, or oil.

NOTE: Do not use compressed air because it contains oil. z

Plug all threads.

z

Set up the surface to be coated with sand paper (grain 60) or a grinder, according to ISO 8504-1:1998.

z

Cover the area around the surface to be coated (e. g. with plastic film).

z

Use dust bonding cloths, PN 932 911 40 to clean the surface to be coated from grinding swarf.

NOTE: Do not use compressed air because it contains oil. If a rust film has formed at the surface to be coated before INTERZINC can be applied, repeat the cleaning procedure.

Version 2009/2

PC5500-6

6 -7

Work instructions

Service Information

NOTE: INTERZINC contains of two parts, a liquid binder and powder. z

Pour the powder into the liquid binder while agitating. Mixing ratio: 1 part liquid binder: 0.7 parts powder (volume) 1 part liquid binder: 4 parts powder (weight) WARNING

z

Don not add liquid to the powder.

z

Do not water down the powder or the final coating compound.

z

Apply the INTERZINC compound with a clean spraygun equipped with a 2.5 mm flat spray nozzle. WARNING

Only use a compressed air supply without air line lubricator.

NOTE: Apply interzinc in one pass only to obtain the permissible film thickness. z

The specified dry paint film thickness (DFT) must be 75 µm (3.0 Mil) or 125 µm (5.0 Mil) wet paint film thickness (WFT). WARNING

Do not use brushes or paint rollers.

WARNING z

The temperature of the surface to be coated must be at least 10 °C (50 °F). The humidity should be 50% to 60%, otherwise the hardening time will increase considerably.

z

The coated parts must be ventilated well while drying. The air speed must be at least 0.1 m/s (4 in/sec). Otherwise the coating will be cracked. If the coating is cracked, the coating must be removed, and the coating procedure has to be repeated.

z

Pay attention to the hardening time. The hardening time depends on ambient temperature, humidity and dry paint film thickness (DFT). At an ambient temperature of 20 °C (68 °F), the hardening takes about five days.

6 -8

PC5500-6

Version 2009/2

Service Information

6.3.2

Work instructions

REMOVE / INSTALL THE CRAWLER CARRIER

Special tools:


NOTE: Fig. 6-1 shows the following: (Fig. 6-1, Pos. 1) Hydraulic wrench PN 793 374 73. (Fig. 6-1, Pos. 2) Special wrench socket PN 793 376 73. (Fig. 6-1, Pos. 3) Electro-hydraulic pump set PN 795 922 73 (picture as example). For information about the Electro-hydraulic pump set, refer to chapter 9 "Supplier’s documentation", "AVANTI HYTORQUE".

Fig. 6-1

Version 2009/2

PC5500-6

Hydraulic torque wrench

6 -9

Used special tools (overview)

6.4

Service Information

USED SPECIAL TOOLS (OVERVIEW)

Component

Swing circle mounting

Track rollers

Pressure accumulators of the track tensioning system

Part number

Part name

Q‘ty

PN 376 792 40

Measuring jaw

1

PN 409 437 40

Measuring bolt

8

PN 409 484 40

Measuring bolt (cold weather)

8

PN 376 762 40

Test block

1

PN 921 159 40

Safety unit for changing track rollers

1

Removal and installation of the track rollers and guide wheel assembly

PN ??? (P&S-news under development)

Tool for changing track rollers

1

Removal and installation of the track rollers

PN 761 520 73

Testing- and refilling device

1

Refilling pressure accumulators

6 - 10

Installation of the swing circle. Assembly of superstructure onto undercarriage

PN 409 329 40

Thread protector

1

Removal and installation of the bucket BHA Removal and installation of the bucket cylinders BHA Removal and installation of the steering rods BHA Removal and installation of the stick BHA

PN 909 374 40

Installation tool

1

Removal and installation of the bucket cylinders FSA

PN 923 828 40

Installation tool

1

Removal and installation of the stick cylinders FSA

PN 934 611 40

Installation tool

1

Removal and installation of the boom cylinders FSA

PN 793 502 73

POSILOK pin removal tool

1

Removal and installation of the GET

Attachment

GET

Nature of work, remarks

PC5500-6

Version 2009/2

Service Information

Component


Part number

Part name

Q‘ty

PN 793 376 73

Hydraulic torque wrench

1

PN 793 374 73

Wrench socket with supporting bar

PN 793 375 73

Electro-hydraulic pump set

PN 928 476 40

Measuring device

Sprocket

locally made (refer to PARTS & SERVICE NEWS No. "AH05511")

Assembly tool for dual-cone seals

1

Installation of new dual-cone seals

Hydraulic system (general)

PN 232 315 40

Hydraulic testing kit

1

Measurements of hydraulic pressures

PN 793 788 730

Rotational speed infrared probe DS03s

1

Measurements of rotation fan speed

PN 232 521 40

65 mm hexagon impact socket wrench (1 1/2")

1

PN 232 615 40

Hydraulic torque wrench (7800 Nm)

1

PN 795 922 73


1

PN 232 264 40

55 mm hexagon impact socket wrench (1")

1

PN 232 615 40


1

PN 795 922 73


1

PN 232 265 40

46 mm hexagon impact socket wrench (1")

1

PN 232 615 40


1

PN 795 922 73


1

Car body/crawler carrier

Nature of work, remarks

Removal and installation of the car body/crawler carrier

Installation of the crawler carriers

Radiator fan assembly Radiator fan drive pump Hydraulic cooler fan drive pump Hydraulic cooler fan assembly

Counterweight

Superstructure

Fuel tank

Version 2009/2

PC5500-6

Removal and installation of the counterweight

Removal and installation of the superstructure

Removal and installation of the fuel tank

6 - 11


Service Information


6 - 12

PC5500-6

Version 2009/2

Tools catalogue

7 TOOLS CATALOGUE

Version 2009/2

PC5500-6

7 -1

Tools catalogue

7 -2

PC5500-6

Version 2009/2

Tools and Accessories Werkzeuge und Zubehör

th

Release: November 11 , 2009 Ausgabe: 11. November 2009

Content / Inhalt

Page No. Seite Section 1

Assembly Tools for Screws and Nuts

3

Gruppe 1

Schraubwerkzeuge

3

Section 2

Pliers

16

Gruppe 2

Zangen

16

Section 3

Metal Working Tools

19

Gruppe 3

Werkzeuge für die Metallbearbeitung

19

Section 4

Measuring Tools

22

Gruppe 4

Messwerkzeuge

22

Section 5

Data Transfer and IT Tools

30

Gruppe 5

Datenübertragung und IT-Zubehör

30

Section 6

Others

33

Gruppe 6

Sonstiges

33

Section 7

Paint and Accessories

38

Gruppe 7

Lackiermaterialien

38

Section 8

Auxiliaries, Cleaner, Adhesive & Sealant

40

Gruppe 8

Hilfsstoffe, Reiniger, Kleber

40

Part-No.

Description

ET-Nr.

Gegenstand

Release: Ausgabe:

th

November 11 , 2009 11. November 2009

Combination wrenches, single Gabelringschlüssel, einzeln 232 001 40 232 002 40 232 002 40 232 003 40 232 004 40 232 005 40 232 006 40 232 007 40 232 008 40 232 009 40 232 010 40 232 011 40 232 012 40 323 013 40 232 014 40 232 015 40 232 016 40 232 017 40 232 018 40 232 019 40 232 557 40

SW 6 SW 7 SW 7 SW 8 SW 9 SW 10 SW 11 SW 12 SW 13 SW 14 SW 15 SW 17 SW 19 SW 22 SW 24 SW 27 SW 30 SW 32 SW 36 SW 41 SW 46 Combination wrenches, single Gabelringschlüssel, einzeln

232 432 40 232 433 40 232 434 40 232 435 40 232 436 40 232 437 40 232 438 40 232 439 40 232 440 40 232 441 40 232 442 40 232 443 40 232 444 40 232 445 40 232 446 40 232 447 40

SW 1/4” SW 5/16” SW 3/8” SW 7/16” SW 1/2” SW 9/16” SW 5/8” SW 11/16” SW 3/4” SW 13/16” SW 7/8” SW 15/16” SW 1” SW 11/16” SW 11/8” SW 11/4”

991-1010 Tools


Werkzeug

Schraubwerkzeuge

Section / Gruppe 1 Page / Seite Continued / Fortsetzung

3 4

Part-No.

Description

ET-Nr.

Gegenstand

Release: Ausgabe:

th


Special ring wrench – open Spezial-Ringschlüssel – offen 232 305 40 232 306 40 232 307 40 232 308 40

SW 41 SW 46 SW 50 SW 60

Double ended open wrenches, single Doppelgabelschlüssel, einzeln 232 020 40 232 021 40 232 022 40 232 023 40 232 024 40 232 025 40 232 026 40 232 027 40 232 028 40 232 029 40 232 030 40 232 031 40 232 032 40 232 033 40

SW 6 x 7 SW 8 x 9 SW 10 x 11 SW 12 x 13 SW 14 x 15 SW 16 x 17 SW 18 x 19 SW 20 x 22 SW 21 x 23 SW 24 x 27 SW 25 x 28 SW 30 x 32 SW 36 x 41 SW 50 x 55 Single ended open wrenches, single Einfachgabelschlüssel, einzeln

232 361 40 232 211 40 232 212 40 232 213 40 232 214 40 232 215 40 232 362 40 232 216 40 232 363 40 232 217 40

SW 41 SW 46 SW 50 SW 55 SW 60 SW 65 SW 70 SW 75 SW 80 SW 85

991-1010 Tools


Werkzeug

Schraubwerkzeuge


4 5

Part-No.

Description

ET-Nr.

Gegenstand

Release: Ausgabe:

th


Hook wrenches, single Hakenschlüssel, einzeln 232 275 40 232 276 40 232 277 40 232 278 40 232 279 40 232 280 40

120 – 130 mm Ø 155 – 165 mm Ø 180 – 195 mm Ø 205 – 220 mm Ø 260 – 270 mm Ø 280 – 300 mm Ø Push-pull ratchet Knarre

232 337 40 232 047 40 232 562 40 232 563 40

1/4” 1/2” 3/4” 1” Reversible ratchet Umschaltknarre 1” x 660 mm (26”)

232 380 40 232 218 40

3/4” x 620 mm 1” x 660 mm (26”) Torque wrench Drehmomentschlüssel

232 262 40 232 285 40 232 477 40 232 478 40 232 379 40 232 304 40 232 220 40 232 221 40

7 – 32 mkp 30 – 75 mkp 50 – 130 mkp 80 – 200 mkp 3/4” x 200 mm 3/4” x 430 mm 1” x 250 mm (8”) 1” x 405 mm (16”)

70 – 320 Nm 300 – 750 Nm 500 – 1300 Nm 800 – 2000 Nm

991-1010 Tools


Werkzeug

Schraubwerkzeuge


5 6

Part-No.

Description

ET-Nr.

Gegenstand

Release: Ausgabe: 232 285 40

th


Torque wrench with scale DSG-5S, measuring range: 300 - 750Nm Drehmomentschlüssel mit Skala DSG-5S, Messbereich: 300 - 750 Nm

232 477 40

Torque wrench with scale DSG-6S, measuring range: 500 - 1300 Nm Drehmomentschlüssel mit Skala DSG-6S, Messbereich: 500 - 1300 Nm

232 478 40

Torque wrench with scale DSG-7S measuring range: 800 - 2000 Nm Drehmomentschlüssel mit Skala DSG-7S, Messbereich: 800 - 2000 Nm

232 681 40

Elbow socket, 28/5 - 3/4 x 70 Einsteck-Winkelstück, 28/5 - 3/4 x 70

232 682 40

Elbow socket, 28/6 - 7; 1” x 70 Einsteck-Winkelstück, 28/6 - 7; 1” x 70

232 574 40

Reducer socket, 1 1/2 - 1 Reduzierstück, 1 1/2 - 1

232 577 40

Extension socket, 1 1/2 - 1 Vergrößerungsstück, 1 1/2 - 1 Sliding & tommy bar Griff mit Gleitstück

232 339 40 232 050 40 232 303 40 232 219 40

1/4” 1/2” x 290 mm (12”) 3/4” x 500 mm (20”) 1” x 640 mm (25”)

991-1010 Tools


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6 7

Part-No.

Description

ET-Nr.

Gegenstand

Release: Ausgabe:

th


Universal joint Kardangelenk 232 051 40

1/2” Socket wrench 1/4", single Stecknuss, 1/4”, einzeln

232 326 40 232 327 40 232 328 40 232 329 40 232 330 40 232 331 40 232 332 40 232 333 40 232 334 40 232 335 40 232 336 40

SW 4 SW 4,5 SW 5 SW 5,5 SW 6 SW 7 SW 8 SW 9 SW 10 SW 11 SW 13 Socket wrench, 1/2”, single Steckschlüsseleinsatz, 1/2”, einzeln

232 034 40 232 035 40 232 036 40 232 037 40 232 038 40 232 039 40 232 040 40 232 041 40 232 042 40 232 340 40 232 043 40 232 044 40 232 045 40 232 046 40

SW 9 SW 10 SW 11 SW 12 SW 13 SW 14 SW 15 SW 17 SW 19 SW 21 SW 24 SW 27 SW 30 SW 32

991-1010 Tools


Werkzeug

Schraubwerkzeuge


7 8

Part-No.

Description

ET-Nr.

Gegenstand

Release: Ausgabe:

th


Socket wrench, 1/2”, single Steckschlüsseleinsatz, 1/2”, einzeln 232 448 40 232 449 40 232 450 40 232 451 40 232 452 40 232 453 40 232 454 40 232 455 40 232 456 40 232 457 40 232 458 40 232 459 40 232 460 40 232 461 40 232 462 40 232 463 40 232 464 40 232 465 40

SW 3/8” SW 13/32” SW 7/16” SW 1/2” SW 9/16” SW 19/32” SW 5/8” SW 11/16” SW 3/4” SW 25/32” SW 13/16” SW 7/8” SW 15/16” SW 1” SW 1 1/16” SW 1 1/8” SW 1 3/16” SW 1 1/4” Socket wrench, 3/4”, single Steckschlüsseleinsatz, 3/4”, einzeln

232 369 40 232 370 40 232 371 40 232 372 40 232 373 40 232 374 40 232 375 40 232 376 40 232 377 40 232 378 40


991-1010 Tools


Werkzeug

Schraubwerkzeuge


8 9

Part-No.

Description

ET-Nr.

Gegenstand

Release: Ausgabe:

th


Socket wrench, 1”, single Steckschlüsseleinsatz, 1”, einzeln 232 223 40 232 224 40 232 225 40 232 226 40 232 227 40 232 228 40 232 229 40 232 230 40 232 231 40 232 232 40


232 569 40

Extra deep socket wrench for grease nipple of grease cylinder 1/2”, long, SW 27 Steckschlüsseleinsatz für Schmiernippel am Schmierzylinder 1/2”, lang, SW 27

Internal hexagon socket, 1/2“ , single Innensechskant Steckschlüsseleinsatz, 1/2”, einzeln 232 052 40 232 053 40 232 054 40 232 055 40 232 056 40 232 057 40 232 058 40 232 059 40 232 060 40

SW 5 SW 6 SW 7 SW 8 SW 9 SW 10 SW 12 SW 14 SW 17 Internal hexagon socket, 1/2", single Innensechskant Steckschlüsseleinsatz, 1/2”, einzeln

232 423 40 232 424 40 232 425 40 232 426 40 232 427 40 232 428 40 232 429 40 232 430 40 232 431 40

SW 3/16” SW 7/32” SW 1/4” SW 9/32” SW 5/16” SW 3/8” SW 1/2” SW 9/16” SW 5/8”

991-1010 Tools


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9 10

Part-No.

Description

ET-Nr.

Gegenstand

Release: Ausgabe:

th


Internal hexagon socket, 1/2“, single Innensechskant-Steckschlüsseleinsatz, 1/2”, einzeln 232 341 40 232 342 40 232 343 40 232 344 40 232 345 40 232 346 40

SW 5 x 180 mm SW 6 x 90 mm SW 8 x 120 mm SW 10 x 140 mm SW 12 x 140 mm SW 14 x 140 mm Internal hexagon socket, 3/4” Innensechskant Steckschlüsseleinsatz, 3/4”

232 347 40 232 348 40 232 349 40 232 350 40

SW 14 SW 17 SW 19 SW 22 Internal hexagon socket,1” Innensechskant Steckschlüsseleinsatz, 1”

232 351 40 232 352 40 232 353 40

SW 19 SW 22 SW 24 Internal Torx socket Innen-Torx Steckschlüsseleinsatz

232 597 40 232 598 40 232 599 40 232 600 40 232 601 40 232 602 40 232 603 40

SW 4 – 5 SW 4,5 – 5 SW 4,5 – 5 – 6 SW 6 – 7 SW 7 – 8 SW 8 – 10 SW 10

991-1010 Tools


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10 11

Part-No.

Description

ET-Nr.

Gegenstand

Release: Ausgabe:

th


External Torx socket Außen-Torx Steckschlüsseleinsatz 232 604 40 232 605 40 232 606 40 232 607 40 232 608 40 232 609 40 232 610 40

SW 4 SW 5 SW 6 SW 6 – 7 SW 8 SW 10 SW 12 Reducing socket Reduzierstück

232 573 40 232 096 40 232 574 40

1 – 3/4 3/4 – 1/2 1 1/2 – 1 Expansion socket Vergrößerungsstück

232 575 40 232 576 40 232 577 40

1/2 – 3/4 3/4 – 1 1 – 1 1/2

232 146 40

Strap wrench (fuel-water filter) Bandschlüssel (Kraftstoff-Wasserfilter)

232 511 40

Torque multiplier max. 2700 Nm (2000 lbf-ft) Drive 3/4” Reduction 1 : 5 Drehmomentvervielfältiger max. 2700 Nm Antrieb 3/4” Untersetzung 1 : 5 Electric torque wrench Elektroschrauber

232 611 40 232 612 40

600 – 2.800 1600 – 7.000

991-1010 Tools


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Schraubwerkzeuge


11 12

Part-No.

Description

ET-Nr.

Gegenstand

Release: Ausgabe:

th


Hydraulic torque wrench Hydraulikschrauber 232 614 40 232 615 40

0 – 4500 0 – 7800

Electro-hydraulic pump aggregate, 220 Volt/800 bar Elektro-hydraulisches Pumpenaggregat, 220 Volt/800 bar 232 613 40

5 bar

232 269 40 232 366 40 232 367 40 232 097 40

SW 75 SW 80 SW 85 3 – 15 mkp

232 718 40

Electro-hydraulic pump set, assy

30 – 150 Nm

Hydraulikaggregat, Satz 793 375 73

Electro-hydraulic pump Hydraulikaggregat

232 719 40

Transportation box Transportbox

793 374 73

Servo screw driver for side member assembly Kraftschrauber für Seitenträgermontage

793 376 73

Servo screw driver assembly Kraftschrauber-Aggregat

795 923 73

High pressure hose DN6 x 10000 Hochdruckschlauch DN6 x 10000 Additional equipment / Zusatzteile

232 749 40

Reaction arm Reaktionsarm

232 750 40

Fixing screw for the reaction arm Fixierschraube für den Reaktionsarm

991-1010 Tools


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Schraubwerkzeuge


12 13

Part-No.

Description

ET-Nr.

Gegenstand


th


Electro-hydraulic aggregate, 230 Volt, for servicing undercarriage and slew ring. Max. pressure output 700 bar (10000 psi), double acting, with wired remote control for the motor Elektro-hydraulisches Aggregat, 230 Volt, für die Fahrwerks- und Zahnkranzwartung. Max. Betriebsdruck 700 bar, doppelt wirkend, mit Kabelfernsteuerung für den Motor

Impact socket wrench, 1“, single Kraftschrauberstecknuss 1”, einzeln 232 264 40 232 515 40 232 516 40 232 265 40 232 266 40 232 267 40 232 494 40 232 268 40

SW 36 SW 38 SW 41 SW 46 SW 50 SW 55 SW 60 SW 65 Impact socket wrench, 1 ½" Kraftschrauberstecknuss 1 1/2”

232 517 40 232 518 40 232 519 40 232 520 40 232 521 40

SW 46 SW 50 SW 55 SW 60 SW 65 Impact internal hexagon socket, 1", single Kraftschrauberstecknuss Innensechskant, 1 ", einzeln

232 765 40 232 766 40 232 767 40 232 768 40 232 769 40 232 770 40

SW 19 SW 22 SW 24 SW 27 SW 32 SW 36 Screwdriver for slotted screws Schraubendreher für Schlitzschrauben

232 120 40 232 121 40

11 x 300 mm 13 x 390 mm

991-1010 Tools


Werkzeug

Schraubwerkzeuge


13 14

Part-No.

Description

ET-Nr.

Gegenstand

Release: Ausgabe:

th


Screwdriver, insulated up to 1000 Volt Schraubendreher, isoliert bis 1000 Volt 232 391 40 232 392 40 232 393 40 232 394 40 232 395 40

2,5 X 75 mm 3,5 x 100 mm 4 x 100 mm 5,5 x 125 mm 6,5 x 150 mm Crosstip screwdriver, insulated up to 1000 Volt Kreuzschlitzschraubendreher, isoliert bis 1000 Volt

232 397 40 232 398 40 232 399 40

Größe / size 0 Größe / size 1 Größe / size 2

232 208 40

Screw extractor kit with spiral drills to remove damaged or broken screws Schraubenausdrehersatz mit Spiralbohrern zum Entfernen beschädigter oder abgebrochener Schrauben

Allen head wrench “L” type, single Innensechskantschlüssel, einzeln 232 066 40 232 067 40 232 068 40 232 069 40 232 070 40 232 071 40 232 072 40 232 073 40 232 074 40 232 075 40 232 076 40 232 077 40 232 078 40 232 079 40 232 080 40 232 081 40 232 082 40 232 354 40 232 355 40 232 356 40

SW 2 SW 2,5 SW 3 SW 4 SW 5 SW 6 SW 7 SW 8 SW 9 SW 10 SW 12 SW 14 SW 17 SW 19 SW 22 SW 24 SW 27 SW 30 SW 32 SW 36

991-1010 Tools


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14 15

Part-No.

Description

ET-Nr.

Gegenstand

Release: Ausgabe:

th


Allen head wrench “L” type Innensechskantschlüssel 232 414 40 232 415 40 232 416 40 232 417 40 232 418 40 232 419 40 232 420 40 232 421 40 232 422 40

SW 3/16” SW 7/32” SW 1/4” SW 5/16” SW 3/8” SW 1/2” SW 9/16” SW 5/8” SW 3/4” Allen head wrench “L” type, with spherical head Innensechskantschlüssel, mit Kugelkopf

232 582 40 232 583 40 232 584 40 232 585 40 232 586 40 232 587 40 232 588 40 232 589 40

SW 2 SW 3 SW 4 SW 5 SW 6 SW 8 SW 10 SW 12

232 666 40

Pneumatic impact wrench (Bosch) Druckluft-Schlagschrauber (Bosch)

232 667 40

Pneumatic impact wrench (Bosch) Druckluft-Schlagschrauber (Bosch)

991-1010 Tools


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Schraubwerkzeuge


15 16

Part-No.

Description

ET-Nr.

Gegenstand


th


Water pump pliers 250 mm long Wasserpumpenzange 250 mm lang

232 140 40

Grip pliers 250 mm long Gripzange 250 mm lang

232 141 40

Stork beak pliers, straight, 200 mm long Storchschnabelzange, gerade, 200 mm lang

232 142 40

Telephone pliers, 200 mm long, bent jaws Storchschnabelzange, abgewinkelt, 200 mm lang

232 143 40

Wire strippers 160 mm long Abisolierzange 160 mm lang

232 663 40

Stripping- and cutting tool Stripax for PVC-isolation up to 6 mm², 20mm Abisolier- und Schneidewerkzeug Stripax für PVC-Isolation bis 6 mm², 20 mm

232 401 40

Side cutter insulated up to 1000 Volt, 190 mm Seitenschneider isoliert bis 1000 Volt, 190 mm

232 400 40

Combination pliers insulated up to 1000 Volt, 185 mm Kombizange isoliert bis 1000 Volt, 185 mm

232 147 40

Pipe wrenches, angeled jaws, with adjusting nut, 350 mm long Eckrohrzange abgewinkelt, mit Stellmutter, 350 mm lang

232 404 40

Flat nose pliers, insulated up to 1000 Volt, 185 mm Flachzange, isoliert bis 1000 Volt, 185 mm

232 405 40

Round nose pliers, insulated up to 1000 Volt, 185 mm Rundzange, isoliert bis 1000 Volt, 185 mm

991-1010 Tools

Pliers

Werkzeug

Zangen


16 17

Part-No.

Description

ET-Nr.

Gegenstand

Release: Ausgabe:

th


Circlip pliers, straight, for external circlips Sicherungsringzange, gerade, für Außenringe 232 150 40 232 151 40 232 152 40

19 – 60 Ø 40 – 100 Ø 85 – 140 Ø Circlip pliers, 90°, for external circlips Sicherungsringzange, gewinkelt, für Außenringe

232 156 40 232 157 40 232 158 40

19 – 60 Ø 40 – 100 Ø 85 – 140 Ø Circlip pliers, straight, for internal circlips Sicherungsringzange, gerade, für Innenringe

232 159 40 232 160 40 232 161 40

19 – 60 Ø 30 – 100 Ø 85 – 130 Ø Circlip pliers, angled, for internal circlips Sicherungsringzange, gewinkelt, für Innenringe

232 153 40 232 154 40 232 155 40

19 – 60 Ø 31 – 100 Ø 85 – 140 Ø

232 281 40

Circlip pliers, straight, for external circlips 122 – 300 mm Ø Seegerringzange, gerade, für Außenringe 122 – 300 mm Ø

232 282 40

Circlip pliers, angled, for external circlips 122 – 300 mm Ø Seegerringzange, gewinkelt, für Außenringe 122 – 300 mm Ø

232 283 40

Circlip pliers, straight, for internal circlips 122 – 300 mm Ø Seegerringzange, gerade, für Innenringe 122 – 300 mm Ø

232 284 40

Circlip pliers, angled, for internal circlips 122 – 300 mm Ø Seegerringzange, gewinkelt, für Innenringe 122 – 300 mm Ø

991-1010 Tools

Pliers

Werkzeug

Zangen


17 18

Part-No.

Description

ET-Nr.

Gegenstand


th


Crimp set Crimp pliers, crimp capacity 0,5 - 4,0 mm² Crimp-Set Crimpzange, Crimpbereich 0,5 - 4,0 mm²

232 661 40

Crimp pliers Crimp capacity 0,5-4 mm² Crimpzange Crimpbereich 0,5-4 mm²

793 729 73

Crimp-pliers for revolved contacts Crimpzange für gedrehte Kontakte

232 209 40

Crimp pliers with cable lugs, set in a metal box Crimpzange im Kasten mit Kabelschuhsortiment

991-1010 Tools

Pliers

Werkzeug

Zangen


18 19

Part-No.

Description

ET-Nr.

Gegenstand

Release: Ausgabe:

th


Hammer Handhammer 232 129 40 232 130 40 232 131 40

300 g 500 g 1000 g

232 310 40

Sledge hammer, 5 kg Vorschlaghammer, 5 kg

232 579 40

Plastic hammer, 450 g Plastikhammer, 450 g

Flat chisel Flachmeißel 232 135 40 232 136 40

16 x 165 mm 19 x 180 mm

232 137 40

Cape chisel, 6 x 165 mm Kreuzmeißel, 6 x 165 mm

232 138 40

Center punch, 4 x 130 mm Körner, 4 x 130 mm Drift punch Durchtreiber

232 132 40 232 133 40 232 134 40

5 x 150 mm 6 x 160 mm 8 x 180 mm Cotter pin drive Splintentreiber

232 099 40 232 100 40 232 101 40 232 102 40 232 103 40 232 104 40

3 mm Ø 4 mm Ø 5 mm Ø 6 mm Ø 8 mm Ø 10 mm Ø

232 122 40

Hack saw with blade Metallbügelsäge mit Sägeblatt

991-1010 Tools

Metal Working Tools

Werkzeug



19 20

Part-No.

Description

ET-Nr.

Gegenstand


th


Three square scraper (hollow), 250 mm long Dreikanthohlschaber, 250 mm lang

232 124 40

Flat scraper, 250 mm long Flachschaber, 250 mm lang Adjustable tap wrench for taps Verstellbares Wendeisen für Gewindebohrer

232 164 40 232 165 40 232 235 40

Gr. 1 M 1 – 10 Gr. 4 M 10 – 27 Gr. 6 M 20 – 42 Tap Gewindebohrer

232 166 40 232 167 40 232 168 40 232 169 40 232 170 40 232 171 40 232 172 40 232 173 40 232 174 40 232 357 40 232 175 40 232 240 40 232 241 40 232 242 40 232 243 40

M3 M4 M5 M6 M8 M 10 M 12 M 14 M 16 M 18 M 20 M 24 M 30 M 36 M 42 Tap Gewindebohrer

232 244 40 232 245 40 232 246 40 232 247 40 232 248 40 232 236 40 232 237 40R 232 238 40 232 239 40

M8x1 M 10 x 1 M 14 x 1,5 M 20 x 1,5 M 24 x 1,5 R 1/8” R 3/8” R 1/4” R 1/2”

991-1010 Tools

Metal Working Tools

Werkzeug



20 21

Part-No.

Description

ET-Nr.

Gegenstand

Release: Ausgabe:

th


Thread restorer Gewindefeile 232 162 40 232 163 40

Whitworth Metric Holder for threading dies Schneideisenhalter für Schneideisen

232 176 40 232 177 40 232 178 40 232 179 40 232 180 40 232 359 40 232 249 40 232 250 40 232 364 40 232 365 40 232 358 40

M3/M4 M5/M6 M 8 / M 8 x 1,0 M 10 / M 10 x 1 M 12 / M 14 M 16 / M 18 / M 20 M 24 M 30 / M 36 M 14 x 1,5 / R 1/8” / R 1/4” M 24 x M 1,5 R 3/8” / R 1/2”

20 x 5 mm 20 x 7 mm 25 x 9 mm 30 x 11 mm 38 x 14 mm 45 x 18 mm 55 x 22 mm 65 x 25 mm 38 x 10 mm 55 x 16 mm 45 x 14 mm

Threading die Schneideisen 232 181 40 232 182 40 232 183 40 232 184 40 232 185 40 232 186 40 232 187 40 232 188 40 232 189 40 232 360 40 232 190 40 232 261 40 232 260 40 232 259 40 232 255 40 232 256 40 232 257 40 232 258 40 232 251 40 232 252 40 232 253 40 232 254 40

M3 M4 M5 M6 M8 M 10 M 12 M 14 M 16 M 18 M 20 M 24 M 30 M 36 M8x1 M 10 x 1 M 14 x 1,5 M 24 x 1,5 R 1/8” R 1/4” R 3/8” R 1/2”

947 173 40

Auxiliary tool 1 for threaded pins M12 Hilfswerkzeug 1 für Gewindestift M12

947 178 40

Auxiliary tool 2 for threaded pins M16 Hilfswerkzeug 2 für Gewindestift M16

991-1010 Tools

Metal Working Tools

Werkzeug



21 22

Part-No.

Description

ET-Nr.

Gegenstand


th


Inside caliper, 200 mm long Lochtaster, 200 mm lang

232 195 40

Outside caliper, 200 mm long Dickentaster 200 mm lang

232 107 40

Sliding caliper, 200 mm long Schieblehre, 200 mm lang

232 108 40

Measuring tape, 2000 mm long Rollbandmaß, 2000 mm lang

232 590 40

Metal rule, 1000 mm long Stahlmaß, 1000 mm lang

232 109 40

Feeler gauge set Fühlerlehrenset

232 110 40

Thread gauge, metric & whithworth Gewindeschablone, metrisch & Whitworth

232 668 40

Micrometer gauge Measuring range: 0 - 150 mm Bügelmessschraube Messbereich: 0 - 150 mm

232 669 40

Micrometer gauge Measuring range: 150 - 300 mm Bügelmessschraube Messbereich: 150 - 300 mm

991-1010 Tools

Measuring tools

Werkzeug

Messwerkzeuge


22 23

Part-No.

Description

ET-Nr.

Gegenstand


th


Hydraulic mini testing kit, consisting of: 1 pressure gauge 0 – 25 bar 1 pressure gauge 0 – 60 bar 2 pressure gauges 0 – 400 bar 2 instrument hoses 3 m each 1 hose 5 m and diverse adapters Hydraulik Mini-Messbox, bestehend aus: 1 Manometer 0 – 25 bar 1 Manometer 0 – 60 bar 2 Manometer 0 – 400 bar 2 Messschläuche je 3 m 1 Messschlauch 5 m und diverse Anschlüsse

79453773

Digital dial gauge, 0 - 12,5 mm Digitalmessuhr, 0 - 12,5 mm

232 673 40

Magnetic articulated stand, 390 mm, 60 x 50 x 55 mm Magnet-Gelenkstativ, 390 mm, 60 x 50 x 55 mm

232 720 40

Digital pressure manometer SPG-DIGI Digitales Druckmanometer SPG-DIGI

232 664 40

Fluke multimeter Fluke Multimeter

232 753 40

Fuse 440 m Sicherung 440 mA

232 754 40

Fuse 11 A Sicherung 11

991-1010 Tools

Measuring tools

Werkzeug

Messwerkzeuge


23 24

Part-No.

Description

ET-Nr.

Gegenstand


th


Autorange digital multimeter incl. fuse set and temperature sensor Specification: V = : 100 µV – 1 KV accuracy ± 0,3% + 2 Dig. V ~ : 100 µV – 1 KV accuracy ± 0,5% + 3 Dig. A = : 100 nA – 20 A accuracy ± 1% + 5 Dig. A ~ : 100 nA – 20 A accuracy ± 1% + 5 Dig. Resistance: 100 mOhm– 40 MOhm Genauigkeit ± 0,5% + 3 Dig. Frequenz (Hz): 1 Hz – 200 kHz accuracy ± 0,2% + 2 Dig. Diode test: Test voltage (open) below 3 V Acust. continuity tester: sounds below 100 Ohm Voltage supply: 1 x 9 V block battery Autorange Digital-Multimeter inkl. Sicherungssatz und Temperatursensor Technische Daten: V = : 100 µV – 1 KV Genauigkeit ± 0,3% + 2 Dig. V ~ : 100 µV – 1 KV Genauigkeit ± 0,5% + 3 Dig. A = : 100 nA – 20 A Genauigkeit ± 1% + 5 Dig. A ~ : 100 nA – 20 A Genauigkeit ± 1% + 5 Dig. Widerstand: 100 mOhm– 40 MOhm Genauigkeit ± 0,5% + 3 Dig. Frequenz (Hz): 1 Hz – 200 kHz Genauigkeit ± 0,2% + 2 Dig. Diodentest: Prüfspannung (offen) unter 3 V akust. Durchgangsprüfer: ertönt unter 100 Ohm Spannungsversorgung: 1 x 9 V Block-Batterie

232 670 40

SUBITO Internal gauge, 280 - 510 mm, in a case without dial SUBITO Innenmessgerät, 280 - 510 mm, im Etui ohne Uhr

232 671 40

SUBITO Measuring depth extension Pipe Ø 18mm, 2000 mm long SUBITO Messtiefenverlängerung Rohr Ø 18mm, 2000 mm lang

232 384 40

Flow meter gauge incl. Accessories Volumenstrom-Messgerät inkl. Zubehör

793 787 73

Measuring turbine RE4 Measuring range: 16,0 up to 600 l/min Messturbine RE4 Messbereich: 16,0 bis 600 l/min

991-1010 Tools

Measuring tools

Werkzeug

Messwerkzeuge


24 25

Part-No.

Description

ET-Nr.

Gegenstand


th


Shock pulse measuring instrument Stossimpuls-Messgerät

232 665 40

Infrared thermometer Infrarot-Thermometer

694 944

Electric thermometer with temp. probe tip Temperaturmessgerät mit Temperaturfühler

793 788 73

Infrared revolution counter DS03, -1 Measuring range : 1 to 9999 min Infrarot-Drehzahlmesser DS03 -1 Messbereich: 1 bis 999 min

793 789 73

Magnetic holder for DS03 Magnethalter für DS03

232 551 40

Manual non-contact revolution counter (digital) Berührungsloser Drehzahlmesser (digital)

232 756 40

Clamp-on ammeter AC/DC, Fluke 336 incl. carrying case, test lead, 2 batteries (AAA), user manual Technical data: Measurement range A/AC & A/DC: 0 - 600 A Measurement range V/AC & V/DC: 0 - 600 V Frequency range: 10 - 400 Hz Measurement range resistance: 0 – 6000 Ω Strommesszange AC/DC, Fluke 336 inkl. Tragetasche, Messleitung, 2 Batterien (AAA), Bedienungsanleitung Technische Daten: Messbereich A/AC & A/DC: 0 - 600 A Messbereich V/AC & V/DC: 0 - 600 V Frequenzbereich: 10 - 400 Hz Messbereich Widerstand: 0 – 6000 Ω

991-1010 Tools

Measuring tools

Werkzeug

Messwerkzeuge


25 26

Part-No.

Description

ET-Nr.

Gegenstand


th


Cable set for part no. 232 323 40 Kabelset für ET-Nr. 232 323 40 (s.o.)

Test manometer, incl. accessories Prüfmanometer, inkl. Zubehör 770 466 73 769 150 73 770 464 73 770 465 75

0 - 60 bar 0 - 400 bar 0 -16 bar 0 - 25 bar Pressure gauge Druckmanometer

793 361 73 793 362 73 793 363 73

0-25 bar (1 Stück / pc.) 0-60 bar (1 Stück / pc.) 0-400 bar (2 Stück / pcs.)

232 501 40

Pressure gauge fitting (4 pcs.) Anschluss für Druckmanometer (4 Stück)

Measuring hose Messschlauch 792 283 73 792 284 73

3200 mm lg (2 Stück / pcs.) 5000 mm lg (1 Stück / pc.)

761 520 73

Filling and testing device for piston, diaphragm and bladder accumulators 0 – 100 bar (with pressure reducer) Füll- und Prüfvorrichtung für Kolben-, Membran- und Blasenspeicher 0 – 100 bar (mit Druckminderer)

232 752 40

Tool case (without tools) Koffer (ohne Inhalt)

991-1010 Tools

Measuring tools

Werkzeug

Messwerkzeuge


26 27

Part-No.

Description

ET-Nr.

Gegenstand


th


Filling and testing device for piston and diaphragm and accumulators 0 – 25 bar Füll- und Prüfvorrichtung für Kolben- und Membranspeicher 0 – 25 bar

Thread reducing fitting (manometer) Gewindereduzierung (Manometer) 232 506 40 232 507 40 232 508 40

R 1/4” R 3/8” R 1/2”

232 385 40

Voltage tester 25 kV Spannungsprüfer 25 kV

232 386 40

Universal grounding short-circuiting device 2 Ø 95/35, mm Universale Erdungs- und Kurzschließvorrichtung 2 Ø 95/35, mm

232 387 40

Insulation tester . . . 500 V Isolationsmesser . . . 500 V

232 713 40

ALIGNEO laser set, for the alignment of horizontal mounted machines ALIGNEO Laser-Set, für die Ausrichtung horizontal verbauter Maschinen

232 714 40

ALIGNEO Bracket set ALIGNEO Halterungssatz

991-1010 Tools

Measuring tools

Werkzeug

Messwerkzeuge


27 28

Part-No.

Description

ET-Nr.

Gegenstand


th


Phase-sequence indicator 100 . . . 600 V Drehfeldrichtungsanzeiger 100 . . . 600 V

Electronical unipolar voltage meter Elektronischer einpoliger Spannungsprüfer 232 389 40 232 390 40

5 – 10 kV 3 – 6 kV

232 594 40

Shock pulse transducer Stoßimpulsaufnehmer

232 595 40

Shock pulse transducer Stoßimpulsaufnehmer

232 596 40

Head receiver for shock pulse measuring instrument Kopfhörer für Stoßimpulsmessgerät

232 762 40

Test box for electrical components with Deutsch connectors Test-Box für elektrische Bauteile mit Deutsch-Steckern

991-1010 Tools

Measuring tools

Werkzeug

Messwerkzeuge


28 29

Part-No.

Description

ET-Nr.

Gegenstand


th


System diagnostic for lubrication system Systemdiagnose für Schmieranlage

966 225

Crack detection testing kit, consisting of: Test-Set Rissprüfung, bestehend aus:

966 229

Permanent magnet Permanentmagnet

966 226

Magnetic powder Magnetpulver

996 228

Cleaner, spray can, 500 ml Reiniger, Sprühdose, 500 ml

966 227

Contrasting agent Kontrastmittel

232 723 40

Universal box Universalkoffer

991-1010 Tools

Measuring tools

Werkzeug

Messwerkzeuge


29 30

Part-No.

Description

ET-Nr.

Gegenstand


th


Hand-held measuring unit MH 3020, 3 channels, USB interface, ISDS Memory: max. 1 million readings incl. power supply unit, USB cable and software Handmessgerät MH 3020, 3 Kanäle, USB-Schnittstelle, ISDS Speicher: max. 1 Million Messwerte inkl. Netzgerät, USB-Kabel und Software

793 781 73

Pressure sensor (2 pcs), 0 - 400 bar, ISDS Druckaufnehmer (2 Stck.), 0 - 400 bar, ISDS

793 783 73

Direct connector for pressure sensor no. 1620 (2 pcs) Direktanschluss für Drucksensor Nr. 1620 (2 Stck.)

793 784 73

Screw-in temperature sensor no. 1620 (2 pcs) -50°C up to 200°C, ISDS Temperatur-Einschraubfühler Nr. 1620 (2 Stck.) -50°C bis 200°C, ISDS

793 785 73

Rev counter sensor DS 03, incl. 25 reflection foils Drehzahlsonde DS 03, inkl. 25 Reflexionsfolien

793 787 73

Measuring cable (2 pcs), 5.0 m Messkabel (2 Stck.), 5,0 m

793 786 73

Measuring extension cable, 5.0 m Messkabel-Verlängerung, 5,0 m

793 782 73

Carrier box Transportkoffer

991-1010 Tools


Werkzeug



30 31

Part-No.

Description

ET-Nr.

Gegenstand


th


USB extension wire USB-Kabel

793 796 73

Data communication cable USB Datenübertragungskabel USB

796 441 73

UMG diagnostic software (CD) UMG-Diagnosesoftware (CD)

796 439 73

Converter Konverter

796 443 73

Cable set Kabel-Set

873 570 40

Content:

Inhalt:

Cable VL3 Cable VL12 Cable VL10 Cable VL9a Cable VL9b

Kabel VL3 Kabel VL12 Kabel VL10 Kabel VL9a Kabel VL9b

Data transfer, grease, memory ETM, ECS, 1 set Datenübertragung, Fett, Speicher ETM, ECS, 1 Satz

796 726 73

Bodem PC software Bodem PC-Software

896 791 40

Bodem connection cable Bodem Verbindungskabel

991-1010 Tools


Werkzeug



31 32

Part-No.

Description

ET-Nr.

Gegenstand


th


Vibrotip-Set „Trend“ Engine analyzer and data collector Vibrotip-Paket ”Trend” Maschinen-Analysator und Datensammler

232 686 40

Drill for Vibrotip Bohrer für Vibrotip

232 685 40

Sensor with quick coupling Aufnehmer mit Schnellkupplung

232 747 40

LAN card, USB 2.0, 10/100 Mbit/s This USB-RJ45-adapter is a high-performance network converter for the USB 2.0 port LAN-Karte, USB 2.0, 10/100 Mbit/s Dieser USB-RJ45-Adapter ist ein leistungsstarker Netzwerkkonverter für die USB 2.0-Schnittstelle

232 748 40

CAT-5 Crossover adapter For fast direct PC connection via LAN (RJ45) CAT-5 Crossover-Adapter Für die schnelle PC-Direktverbindung über LAN (RJ45)

232 755 40

Crossover cabel, for CAT-5 Crossover adapter, double shielded, 1 meter Crossover-Patchkabel, für CAT-5 Crossover-Adapter, doppelt geschirmt, 1 Meter

991-1010 Tools


Werkzeug



32 33

Part-No.

Description

ET-Nr.

Gegenstand


th


Cordless headphone intercom Sprechfunkanlage

232 623 40

Vacuum pump + adaptor Vakuumpumpe + Adapter

Puller, grip width/depth Abzieher, Spannweite/Spanntiefe 232 300 40 232 301 40 232 302 40

120 mm/100 mm 200 mm/150 mm 350 mm/200 mm

232 287 40

Grease gun, hand-lever type, with couplings, 400 bar Handhebelfettpresse, mit Anschlüssen, 400 bar

232 288 40

Fitters tub Montagewanne

232 000 40

Tool box, 5 trays 420 x 200 x 210 mm Werkzeugkasten, 5-teilig 420 x 200 x 210 mm

232 299 40

Pinch bar with pointed and claw ends, 1000 mm long Brechstange mit Klaue und Spitze, 1000 mm lang

793 639 73

Removal tool for double-level terminals Lösewerkzeug für Doppelstockklemmen

991-1010 Tools

Others

Werkzeug

Sonstiges


33 34

Part-No.

Description

ET-Nr.

Gegenstand


th


Oil analysis Öl-Analyse

232 622 40

Suction pump, extracting oil for testing Pumpe zur Entnahme einer Ölprobe

Flat-link chain hoist Hubzug mit Gelenkkette 232 368 40 232 289 40 ???

Lifting capacity 0,75 t Lifting capacity 1,5 t Lifting capacity 3,0 t

324460 40

Cable suspension, 5 t

Tragkraft 0,75 t Tragkraft 1,5 t Tragkraft 3,0 t

Drahtseilgehänge, 5 t

792 005 73

Edge protector Kantenschoner

792 006 73

Edge protector Kantenschoner

991-1010 Tools

Others

Werkzeug

Sonstiges


34 35

Part-No.

Description

ET-Nr.

Gegenstand


th


4-hook chain WMH S6 A = 1500 mm 4-Strang-Kette WM 1401 A = 1500 mm

232 617 40

Nylon lifting belt, AL 4 Width 75 mm, length 3500 mm 1500 kg Nylon Hebegurt, AL 4 Breite 75 mm, Länge 3500 mm 1500 kg

232 618 40

Nylon lifting belt Width 25 mm, length 1500 mm 1000 kg Nylon Hebegurt, AL 5 Breite 25 mm, Länge 1500 mm 1000 kg Lifting bolt Ringschraube

313 500 99 313 501 99 313 502 99 313 503 99 313 504 99 313 505 99 313 510 99 313 506 99 313 507 99 313 508 99 313 514 99 313 527 99

M8 M 10 M 12 M 16 M 20 M 24 M 27 M 30 M 36 M 42 M 48 M 56 Pin-driving press, complete set for crawler chassis Bolzenpresse, komplett für Traktorenlaufwerk

232 313 40

100 t, for all excavators up to H 121 100 t, für alle Bagger bis H 121

232 381 40

150 t, for all excavators up to H 185 150 t für alle Bagger bis H 185

991-1010 Tools

Others

Werkzeug

Sonstiges


35 36

Part-No.

Description

ET-Nr.

Gegenstand


th


Mounting bushing set for cylinder repair. When ordering tools, please always state the identification number of the cylinder. Montage-Buchsensatz für Zylinder-Reparatur. Bei Bestellung der Werkzeuge unbedingt die Ident-Nr. des Zylinders angeben.

999 860 73

5 finger gloves, with textile extension, with lining 5-Finger-Handschuhe mit Strickbund, gefüttert

999 861 73

Rubber gloves, size F3 and F4 Gummi-Handschuhe, Größe F3 und F4

999 925 73

Working gloves, pork leather, with lining Arbeits-Handschuhe, Schweinsleder mit Futter

950 642

Canister 10 l (plastics) Kanister 10 l (Kunststoff)

991-1010 Tools

Others

Werkzeug

Sonstiges


36 37

Part-No.

Description

ET-Nr.

Gegenstand

Release: Ausgabe: 950 643

th


Canister 25 l (plastics) Kanister 25 l (Kunststoff)

232 683 40

Combination angle set Satz Kombinationswinkel

232 717 40

Stud welding unit for threaded pins, with welding gun Bolzenschweiß-Kompaktanlage, mit Schweißpistole

232 712 40

Magnet-Stick Magnetfeldprüfer

232 715 40

Hydro-pump, type IPV 3-8 101 Hydropumpe, Typ IPV 3-8 101

232 716 40

Coupling Kupplung

991-1010 Tools

Others

Werkzeug

Sonstiges


37 38

Part-No.

Description

ET-Nr.

Gegenstand

Release: Ausgabe: 766 307 73 766 308 73 766 309 73 766 310 73 766 311 73 766 312 73 766 313 73 766 314 73 766 315 73 766 316 73 766 317 73 766 318 73 766 319 73 766 320 73 766 321 73 766 322 73 766 323 73 768 881 73 797 549 73

th


Mounting tools for dual cone seal rings at the undercarriage Montagewerkzeuge für Gleitdichtringe am Unterwagen

For detailed information refer to PARTS & SERVICE NEWS AH05511 Ausführliche Informationen siehe PARTS & SERVICE NEWS AH05511

991-1010 Tools

Others

Werkzeug

Sonstiges


38 39

Part-No.

Description

ET-Nr.

Gegenstand


th


Thinner, 10 kg Verdünner, 10 kg

767 567 73

Primer, lemon yellow, 1 kg Grundierung, zitronengelb, 1 kg

083 026

Paint yellow, RAL 1007 Spray can, 400 ml Farbe gelb, RAL 1007 Spraydose, 400 ml

501 415 98

Paint sky-blue, RAL 5015 Can, 2,5 kg Farbe himmelblau, RAL 5015 Dose, 2,5 kg

767 568 73

Paint black, RAL 9005 Can, 1 kg Farbe Schwarz, RAL 9005 Dose, 1 kg

991-1010 Tools

Paint and accessories

Werkzeug

Lackiermaterialien


39 40

Part-No.

Description

ET-Nr.

Gegenstand


th


Paint yellow = DEMAG KOMATSU colour Can, 1 kg Farbe gelb = DEMAG KOMATSU-gelb Dose, 1 kg

767 570 73

Paint grey = KOMATSU colour Can, 1 kg Farbe grau = KOMATSU-grau Dose, 1 kg

999 019

Nickel spray can, Metaflux 70-81 Nickelspray, Metaflux 70-81

991-1010 Tools

Paint and accessories

Werkzeug

Lackiermaterialien


40 41

Part-No.

Description

ET-Nr.

Gegenstand


th


Liquid sealing compound (Epple blue, No. 28), 250 ml Flüssigdichtung (Epple blau, Nr. 28), 250 ml

461 798 40

Adhesive Sicomet 85, in tubes, for sealing the rotary joint (with rollers or balls) Klebstoff Sicomet 85, in Tuben, für die Abdichtung der Rollendrehverbindung, Kugeldrehverbindung

390 905

Teflon tape Teflonband

464 814

Insulating tape, 33-19 Tesa PVCd Isolierband, 33-19 Tesa PVCd

691 959

Filler bottle Startpilot Füllflasche Startpilot

989 967

Oil binding agent (paper sacks, 8 kg each) Ölbindemittel (Papiersäcke à 8 kg)

993 528 73

Cleaning agent Bio Pent E, for steam blasting cleaners Reinigungsmittel Bio Pent E, für Dampfstrahler

993 529 73

Cleaning agent Bio Versal, for steam blasting cleaners Reinigungsmittel Bio Versal für Dampfstrahler

999 926 73

Cleaning rags (fleece rags) 35 x 35 cm, bale of 30 kg Paket Putzlappen (Vliestücher) 35 x 35 cm, in 30 kg-Ballen

991-1010 Tools

Auxiliaries, cleaners, adhesive & sealant

Werkzeug

Hilfsstoffe, Reiniger, Kleber & Dichtungsmittel


41 42

Part-No.

Description

ET-Nr.

Gegenstand

Release: Ausgabe:

th


Loctite products Loctite-Produkte 414 299 40

Loctite No. 222 E, bolt lock fluid, 50 ml low stability, up to M36 Loctite Nr. 222 E, Schraubensicherung, 50 ml niedrigfest, bis M 36

973 125

Loctite No. 241, bolt lock fluid, 50 ml medium stability, up to M12 Loctite Nr. 241, Schraubensicherung, 50 ml mittelfest, bis M 12

973 130


255 242 40


170 470 40

Loctite No. 245, bolt lock fluid, 250 ml medium stability, up to M80 Loctite Nr. 245, Schraubensicherung, 250 ml mittelfest, bis M80

158 856 40

Loctite No. 27041, bolt lock fluid, 250 ml high stability, up to M20 Loctite Nr. 27041, Schraubensicherung, 50 ml hochfest, bis M20

167 644 40

Loctite No. 307, 50 ml metal adhesive (only in conjunction with 7471) Loctite Nr. 307, 50 ml Metallkleber (nur in Verbindung mit 7471)

288 906 40

Loctite No. 330, bonding set bonds nearly all materials (except Gi) Loctite Nr. 330, Klebeset verbindet nahezu alle Materialien (außer Gi)

461 798 40

Loctite No. 401, 20 g, Cyanacrylat bonds Kn, rubber, paperboard, leather, wood, and many more Loctite Nr. 401, 20 g, Cyanacrylat zum Verkleben von Kn, Gummi, Pappe, Leder, Holz, u.v.m.

991-1010 Tools


Werkzeug



42 43

Part-No.

Description

ET-Nr.

Gegenstand


th


Loctite No. 511, fluid sealing, 50 ml low stability, sealing threaded connections up to R2” Loctite Nr. 511, Flüssigdichtung, 50 ml niedrigfest, zum Abdichten von Verschraubungen bis R2”

232 554 40

Loctite No. 511, fluid sealing, 250 ml low stability Loctite Nr. 511, Flüssigdichtung, 250 ml niedrigfest

083 399 40

Loctite Nr. 586, fluid sealing, 50 ml high stability, up to R 2” Loctite Nr. 586, Flüssigdichtung, 50 ml hochfest, bis R 2”

255 239 40

Loctite 574, sealant for surfaces, 50ml gap size up to 0,5 mm Loctite Nr. 574, Flächendichtung, 50 ml Spaltgröße bis 0,5 mm

255 237 40

Loctite No. 603, for join connections, 50 ml high stability Loctite Nr. 603, Fügeverbindung, 50 ml hochfest

288 907 40

Loctite No. 706, fast cleaner, 400 ml Loctite Nr. 706, Schnellreiniger, 400 ml

321 32240

Loctite, removal of adhesives and sealants spray can, 300 ml Loctite, Klebstoff- u. Dichtungsentferner 300 ml-Sprühdose

083 376 40

Loctite Nr. 7471, activator, 500 ml (for hardening of 307 and for the acceleration of the hardening process) Loctite Nr. 7471, Aktivator, 500 ml (zur Aushärtung von 307 und zur Beschleunigung des Aushärtevorgangs)

991-1010 Tools


Werkzeug



43 -

Parts & Service News

8 PARTS & SERVICE NEWS

Version 2009/2

PC5500-6

8 -1


Contents of this chapter: SB-No.

Subject

AH00511

Installation procedure for the swing circle / Slew Ring (SR)

AH00514

Track group - Hints for sprocket exchange

AH00515

Final drive: Wear and tear measurements Mounting procedures

AH00519

Adhesive lubricants for the Slew Ring Gear

AH01513

Bleeding of hydraulic pumps

AH01521

Diesel engine suspension

AH01531

Hydraulic accumulators - testing and refilling

AH02513

Testing wear and tear of swing circle bearing

AH02521

Track group – wear measurement

AH03506

Hydraulic oil cooler and water cooler fan bearings

AH03509

Slew gear GFB 174 E 9017 (Part No. 917 915 40)

AH03510

ESCO bucket tooth system

AH03511

Pilot Pressure Pump Part No. 907 209 40

AH03512

Gear Pumps (Part Nos. 907 209 40; 906 442 40; 896 730 40 and 654 930 40

AH04518

Welding procedure for welded counterweight

AH05501

Abnormal vibration on hydraulic pipes

AH05510

Bearing flushing of the A4VS variable displacement axial piston pump

AH05511

Dual cone seal ring mounting

AH05520

Installation hints for a new type of pilot pump

AH05525

Suction elbows of the Main Pumps

AH05535

Hints for replacing by the slewing gear of an other manufacturer

AH05546

Automatic lubrication system - Vent valve (PN 769 879 73)

AH06524

Hydraulic cylinder

AH06529

Track group - Hints for sprocket exchange

AH06530

Relieving of the track chain tension

AH06542

Swash plate pump H-A4VSO500

AH06543

Gear pumps PN 907 622 40 and PN 940 048 40 (supplied from the company “Kracht”) (Pilot pressure pump; gear oil pump; circulation pump)

AH06545

Hydraulic cylinder bushings

AH07509

Swing brake manufactured by "Siebenhaar" (Swing gear PN 902 550 40 and PN 925 864 40)

AH07526

Bolted undercarriage: Protective coating on the flange plates

AH08503

Track drive

AH08504

Windscreen

AH08507

Steel structure

8 -2

PC5500-6

Version 2009/2


SB-No.

Subject

AH08508

Bushings of the attachment and at the undercarriage

The numbers of the PARTS & SERVICE NEWS do not label the latest edition. Ensure that the latest edition is always filed to the binder of this manual.

Version 2009/2

PC5500-6

8 -3


8 -4

PC5500-6

Version 2009/2

PARTS & SERVICE NEWS

COMPONENT CODE:

2500

REF NO.

AH00511h

DATE

July 7, 2010 Page 1 of 22

This PARTS & SERVICE NEWS supersedes the previous issue No. AH00511g which should be discarded. SUBJECT:

Installation procedure for the Swing Circle (SC)

PURPOSE:

Revision

APPLICATION:

PC3000/6; PC4000/6; PC5500/6; PC8000/6

FAILURE CODE:

2500Z9

DESCRIPTION:

W

 Before carrying out any repairs, read all the safety instructions of the Operation and Maintenance manual of your shovel.  The local safety rules must also be observed.

Content

Page

1. 2. 3. 4.

Safety instructions General Measurements of bearing areas Determining of tightening torques

02 03 04 06

4.1.

Test bolt types 4.1.1. Type 1 4.1.2 Type 2 Two types of measuring devices 4.2.1. Measuring jaw 4.2.2. New measuring device

06

5.

Mounting of a swing circle

11

5.1. 5.2. 5.3. 5.4.

General Unhardened spot “s” Tooth back lash Hints for rotating the swing circle

12 14 15 17

6. 7.

Checking of the bolts Lubrication and Maintenance

19 19

7.1 7.2

Roller bearings Outer toothing

19 21

4.2.

07

AH00511h

Page 2 of 22

1. Safety Instructions 

Assign trained or well-instructed personnel only and clearly define the respective spheres of responsibility for the repair work.



Inform the operating personnel prior to the commencing special and regular maintenance work.



Secure the maintenance area amply enough, as far as required.



Carry out repair and maintenance work only with the machine standing on firm and level ground and secured against rolling away and sinking in.



During exchange action, fix and secure individual parts and assemblies carefully to the lifting devices so that they cannot become dangerous in any way. Use exclusively suitable lifting devices consistent with sound engineering and load-lifting elements with sufficient load-bearing capacity! Never stay or work beneath suspended loads!



Entrust experienced personnel only with fastening and securing of loads and guiding crane operators! The guide has to be within the operator's visual range or have voice contact with him.



In case of assembly work exceeding body height, use suitable and otherwise secure means of access and working platforms. Never step on machine parts as an access! For maintenance work at higher levels, use the appropriate safety devices! Keep all handles, steps, handrails, landings, working platforms, ladders, etc. free from dirt, snow and ice!



Retighten immediately all bolted connections loosened during repair and maintenance work!



If disassembly of safety devices is required for rigging, maintenance, and repair, reassembly and checking of such safety devices has to be carried out immediately after having finished the respective work.



Strictly observe all safety instructions and warnings in the country of destination.

AH00511h

Page 3 of 22

2. General 

Before removing swing circle mark location of both - swing circle to superstructure and - swing circle to the car body as well for further investigations.



Shocks to the swing circle, especially radial ones, must be avoided.



Transport and store exclusively with transport star fitted. It is strictly forbidden to hook up the SC (Swing Circle) at the transport star.



Hang up and/or transport and store swing circle only horizontally. If a special attachment is available, the transportation and storage in oblique position may be carried out.



Only hang SC at four/three eyebolts evenly distributed in screw circle of the upper ring.



Prior to mounting the SC clean all supporting surfaces and the toothing, if necessary clean those areas with fat solvents, methylene chloride, cold cleaners. The cleaning agents must not enter the races. Hence, the swing circle has to be thoroughly lubricated before and after cleaning.



With each replacement swing circle and each new machine, fastening bolts, measuring bolts, a measuring device and the special grease for the Bolts will be delivered. If this parts delivery is not complete, please get immediately in contact with our Service Department 8151, because a proper mounting may not be possible in case of missing items.

AH00511h

Page 4 of 22

3. Measurements of the bearing area  

Check the level of bearing area (only center section undercarriage) with a laser device before installing a new swing circle. To prevent incorrect measuring results caused by partial sun radiation onto the pedestal /carbody it is recommended that the whole area be protected from the direct sunlight.

Illustration1 Legend ID = Inner diameter swing circle (mm) OD = Outer diameter swing circle (mm)  = 3.14 P = Maximum Deviation (deflection) (mm)

P = (OD – ID) ÷ 1000

Example: OD = 4000 mm ID = 3600 mm

W

P= P= P=

(4000mm – 3600mm) ÷ 1000

400mm ÷ 1000 0.4 mm

 If the measured value exceeds the calculated value P, the surface has to be remachined.

AH00511h

Page 5 of 22  

Check the outer diameter of the new swing circle top surface and compare with the outer diameter of the factory machined surface of the superstructure. Remove the shoulder by machining if necessary.

New swing circle Outer diameter

Illustration 2



 Such a shoulder exists only at some older shovels.

AH00511h

Page 6 of 22

4. Determining of tightening torque for the fastening bolts The required tightening torque for all fastening bolts (inner and outer) has to be determined with the 8 measuring bolts, which dimension is analogous to the outer fastening bolts mounted to carbody / swing circle.  The required axial tension force of the bolts is determined by means of the elongation of the fastening bolts.  The tightening torque must be determined each time the SC (Swing Circle) is replaced as well as at the first assembling of the shovel at the operation site and for the first and final inspection after 1000 operation hours.  The required measuring device is delivered with the shovel or with the SC (Swing Circle).  To determine the tightening torque, eight specially prepared test bolts are supplied besides the normal fastening bolts. The test bolts can be recognized at the end of the threads.  There exists two types of measuring devices and for each type, special test bolts.  Both measuring methods are useful.

4.1 Test bolts types 4.1.1 Test bolts (type 1) for using with measuring jaw Shovel

Bolts

PC3000/6 M30 x 190 PC4000/6 M36 x 220 PC5500/6 M36 x 230 PC8000/6 M36 x 295

PN Test Bolts 930 631 40 928 844 40* 389 816 40 389 815 40* 409 437 40 409 484 40* 909 004 40 898 287 40*

Illustration 3

*low temperature version

4.1.2 Test bolts (type 2) for using with the new measuring device Shovel

Bolts

PC3000/6 M30 x 190 PC4000/6 M36 x 220 PC5500/6 M36 x 230 PC8000/6 M36 x 295

PN Test Bolts 954 030 40 954 034 40* 954 029 40 954 033 40* 954 028 40 954 032 40* 954 027 40 954 031 40*

Illustration 4

*low temperature version

AH00511h

Page 7 of 22 4.2 Two Types of measuring devices 4.2.1 Measuring jaw This measuring device is composed of the following items: (1) Measuring jaw

1pce.

(2) Test block

1pce.

(3) Measuring bolt (type 1)

8pcs.

(4) Washer *

1pce.

* Only used for PC3000/6 bolts

Illustration 5

Procedure for the determining of the needed tightening torque: 1. Secure the test block (2) against twisting (e.g. on a work bench); 2. Grease the threads and the bolt head bearing areas with International Compound No. 2 (PN 324 969 40);



 Pay special attention for clean threads when determining the tightening torque of the test bolts.

3. Screw test bolt (3) into test block (2) hand-tight *; 4. Fit jaw (1) and micrometer gauge into the centerings "Z" of the bolt and set gauge to zero; 5. Increase tightening torque of test bolts by steps of app. 200 Nm until the required elongation of the bolt according to the table below is reached and list this torque value; 6. Determine the needed tightening torque as result of average over the eight listed torque values. *only for PC3000/6 with washer (4)

AH00511h

Page 8 of 22

Measuring bolts (type 1) Type

Analogous to the dimension of the outer fastening bolts (8)

Quality grade

Wrench size

Required gauge indication [mm]

H 185S

M 30 x 230

10.9

46 mm

0.550 0.015

H 255S / PC3000/1

M 30 x 230

10.9

46 mm

0.550 0.015

PC3000/6

M 30 x 230

10.9

46 mm

0.550±0.015

PC3000/6

M 30 x 190

10.9

46 mm

0.442±0.013

H 285S

M 36 x 220

10.9

55 mm

0.610 0.020

PC4000

M 36 x 220

10.9

55 mm

0.610 0.020

H 455S / PC5500

M 36 x 230

10.9

55 mm

0.580 0.020

H 485S (to 12010) H 485S (12011 up)

M 36 x 230 M 36 x 270

10.9 10.9

55 mm 55 mm

0.580 0.020 0.650 0.020

M 36 x 270

10.9

55 mm

0.650 0.020

M 36 x 295

10.9

55 mm

0.710 0.020

H 685SP

M 36 x 270

10.9

55 mm

0.650 0.020

H 685SX (12030)

M 36 x 295

10.9

55 mm

0.710 0.020

H 655S PC8000 (to 12036) PC8000 (12037 up)

AH00511h

Page 9 of 22 4.2.2 New measuring device Torque support

No.

PN Measuring device

For shovel type

1

954 025 40

PC3000/6

2

954 023 40

PC4000/6

3

954 021 40

PC5500/6

4

954 016 40

PC8000/6

Illustration 6

Illustration 7

AH00511h

Page 10 of 22

Measuring bolts (type 2) Type

Analogous to the dimension of the outer fastening bolts

Quality grade

Wrench size

Required gauge indication [mm]

Preload torque *

PC3000/6

M 30 x 190

10.9

46 mm

0.565±0.015

100 Nm

PC4000/6

M 36 x 220

10.9

55 mm

0.710 0.020

200 Nm

PC5500/6

M 36 x 230

10.9

55 mm

0.770 0.020

200 Nm

M 36 x 295 10.9 55 mm 0.970 0.020 PC8000 (12037 up) * Set the micrometer gauge by these preload torques to 0.000 mm

200 Nm

Procedure for determining the needed tightening torque (refer to illustration 6): 1. Fasten the new measuring device with the two bolts (6) and two nuts (8) onto a suitable base (e.g. workbench), 2. Grease the threads and the bolt head bearing areas with International Compound No. 2 (P/N. 324 969 40);



 Pay special attention for clean threads when determining the tightening torque of the test bolts.

3. Screw test bolt (12) into test block and preload the bolt according to the table above *; 4. Fit micrometer gauge. Make sure that micrometer gauge contacts the test bolt at the contact area as shown; 5. Set gauge to zero; 6. Increase tightening torque of test bolt until the required gauge indication according to the table above is reached and list this torque value; 7. Repeat the procedure according to the section 2 to 6 with each test bolt; 8. Determine the needed tightening torque as result of average over the eight listed torque values. *only for PC3000/6 with washer (11)

AH00511h

Page 11 of 22

5. Mounting of a Swing circle

Illustration 8



 PC3000/6 - Install extension sleeve (11);  PC4000/6; PC5500/6; PC8000/6 - Install washers (10)

AH00511h

Page 12 of 22 5.1.

General



 When replacing the swing circle, all fastening bolts must also be replaced.

If scratches are found at supporting surfaces of washers or bushes, they must be reworked or replaced. The eight measuring bolts have to be mounted equally distributed on the outer ring of the swing circle.  

Clean the supporting surfaces (A) of car body and platform absolute fat-free (Illustration 8). Even the solvent must be rinsed away before assembling. Check surface evenness (A) (refer to section 4).



 Alignment the swing circle can be mounted easier with two center pins.

No.

Type

1 PC3000-6 2 PC4000-6 3 PC5500-6 4 PC8000-6 Loosening lever: 955 797 40

Center Pin 955 798 40 956 902 40 956 902 40 956 904 40

If the Swing circle was aligned to the platform with the two center pins, mount some fastening bolts and then remove the center pins.

AH00511h

Page 13 of 22



The swing circles (5/6) must have good contact to the carbody and superstructure platform. Check mating surfaces with feeler gauge.



Check lube lines for correct condition and grease passage.



Check accordance of tapped and through holes in (Swing Circle) with those in carbody and platform. Discordances may easily cause distortions of SC.  For disassembly and assembly always use a Mounting cross (M). Fabricate mounting cross (M) according to the drawing or order it. The construction drawing of the mounting cross has to be ordered from the Parts Department if necessary. Swing circle weight [t]

Mounting cross PN /Drawing No.

H 185S

3.5

379 383 40

H 255S / PC3000

3.5

379 383 40

H 285S

6.0

379 128 40

PC4000

6.7

379 128 40

9.0 / 10.0

477 577 40

H 485S

14.0

379 129 40

H 655S; PC8000 ( - 12036)

14.0

379 129 40

PC8000 (12037 - )

16.3

379 129 40

H685SX (12030)

16.3

379 129 40

H 685SP

14.0

379 129 40

Type

H 455S / PC5500

AH00511h

Page 14 of 22   

Deposit and center SC with transport star (T) on mounting cross (M). Check length of threads in platform and SC, if necessary retap. Place SC at its fastening position under the jacked-up platform.

5.2. Unhardened spot „S“ For the adjustment of the Unhardened spot "S", refer to illustration below. The Unhardened spot of race surfaces (changeover area between beginning and ending of hardening process) is punch marked with "S" at the inner resp. outer side of each race ring. These spots "S" should not be placed within the main load area of the swing circle. Hence, the unhardened spot "S" has to be turned in an angle of 90° to the main load area as illustrated.

AH00511h

Page 15 of 22      

Lift SC until approx. 10 mm below the platform (observe unhardened spot "S"). Slightly treat bolt heads, threads and washers with Compound PN 324 969 40. Screw fastening bolts (7) with washers (10) through swing circle into the platform. Lift SC to the supporting surface by screwing in the bolts crosswise. Lower mounting cross. Remove transport cross.

5.3

Tooth backlash

The tooth backlash is the gap measured by a feeler gauge in point D if tooth A presses on the reference circle (B) against tooth C. On swing circle where you find a green color marking on 3 teeth, rotate the lower ring (6) until the 3 green marked teeth are mating with the teeth of a swing pinion.

Type

Tooth back lash [mm]

H 185S H 255S/PC3000 H 285S PC4000 H 455S/PC5500 H 485S H 655S/PC8000 ( -12036) PC8000 (12037 - ) H685SX (12030) H 685SP

0.4 – 0.8 0.4 – 0.8 0.6 – 1.0 0.6 – 1.0 0.6 – 1.0 0.5 – 0.9 0.5 – 0.9 0.5 – 2.5 0.5 – 2.5 0.5 – 0.9

Note: The green teeth indicate the point of the SC having the greatest circularity deviation of the reference circle (positive deviation). At this narrowest spot, a tooth backlash clearance according to the chart should be measured. On machines without green color marking at the teeth, adjust backlash at 4 points evenly distributed according to the following dimensions.

AH00511h

Page 16 of 22 Before lowering the platform with SC on center section of the undercarriage: 1. Mark 4 teeth(1; 2; 3; 4 - refer to illustration) displaced by 90 °. The swing gears are marked gear 1, gear 2 and gear 3 (if so present). 2. Rotate the swing circle so far that tooth 1 is engaged at pinion of swing gear 1. 3. Measure play between A and D. Note value in the table below. C means tooth 1 and must have contact at point B. 4. Rotate superstructure further until tooth 1 is engaged at pinion of swing gear 2. Measure play as described under step 3. 5. Rotate superstructure further until tooth 1 is engaged at pinion of swing gear 3. Measure play as described under step 3. 6. Rotate superstructure further that tooth two is engaged at pinion of swing gear 1. Measure play and note value in table. 7. Carry out same measuring procedure as described for the other teeth. At the end for every swing gear, four dimensions are noted in the table. 8. If necessary, adjust the backlash by displacement of the SC. For the correct backlash, refer to chart above. 9. Hints for the three swing gear version Adjust an equal play at pinion of swing gear 1 and 3 by shifting the swing circle. For this use the installed adjusting bolts. Afterwards adjust play at swing gear 2 to the same value before adjusted at gear 1 and gear 3.

Tooth backlash Swing gear Play – nominal value gear 1 gear 2 gear 3

Tooth 1 Tooth 2 Tooth 3 Tooth 4

refer to table at page 10

AH00511h

Page 17 of 22 5.4

Hints for rotating the swing circle

1. Remove the swing motor. 2. Remove the hoses at the other swing motor(s) if the shovel is equipped with more than one swing motor. 3. Loosen the swing brake(s) by applying external pressure (25 - 60 bar). 4. Use the below shown tool in place of the removed swing motor for rotating the swing circle (drive: 36 mm).

36 mm



 The shown tool can be used for Series: PC3000; PC4000; PC5500; PC8000.

Toothed shaft: DIN 5480 W 60x2x30x28x9g

Part no.: 864 501 40

AH00511h

Page 18 of 22

Tighten all SC fastening bolts with the torque determined. Use the same torque multiplier you have used for the determination.



 Before mounting the bearing surface of bolt head, threads and washers have to be applied with compound PN 324 969 40.



Fasten crosswise fastening bolts (7) with the previously determined tightening torque. This has to be performed twice or three times, to ensure a setting of the bolts. During tightening check permanently toothed outer ring (6) for easy running. For this purpose unscrew hydraulic lines of swing motor and loosen all swing brakes by applying external pressure (25 - 60 bar).



Check for easy motion in all ranges by turning the outer ring (6).



After tightening of all bolts (7) from SC to the superstructure, the tooth backlash has to be checked once more at 4 points, if necessary adjust again.



Lower platform with SC on center section of the undercarriage. Watch position of not hardened spot "S" of the ring (6. If necessary turn ring (6).



Screw in 8 measuring bolts with washers resp. bushings (11) evenly distributed and the other fastening bolts (8) with washers (10), and bushings (11).



Tighten crosswise all fastening bolts (7/8) with the previously determined tightening torque. This has to be performed twice or three times, to ensure a setting of the bolts.

AH00511h

Page 19 of 22

6.

Checking of bolts

To compensate settling between SC and parts connected to it the bolts must be checked after 1000 operation hours. If necessary, retighten bolts with the determined torque.   

Unscrew the eight test bolts (4) of the connection SC / carbody. Determine the required torque again with these eight test bolts (4) Retighten all bolts (4/7/8) with the same torque multiplier you have used for the determination.

7.

Lubrication and maintenance (RDV)

7.1. Roller bearings Races of roller bearings must be lubricated regularly using high quality brands of lubricants. This is particularly important before and after longer interruptions of operation (e.g. winter intermission). The grease content in the race system is intended to avoid friction, to seal and to prevent corrosion. Greasing must be done abundantly until a continuous collar of grease pours out of the entire circumference of the upper seal "L" and the lower bearing gap "G". When greasing check visually the upper bearing seal "L" and, if necessary, replace immediately in order to prevent dirt and/or water to penetrate into the race system.



 Avoid cleaning agents to enter the race system when cleaning the shovel with high-pressure water or with vapor blast apparatuses. Before and after each cleaning grease thoroughly. The even distribution of grease requires swing circle of the superstructure during greasing.

AH00511h

Page 20 of 22

Lubricating by central lube systems use With central lube systems, the lubricating intervals are controlled by the time control unit and the grease quantity is controlled by the adjustable metering valves / distributor valves in order to meet the local requirements. Manual greasing The lubrication intervals can be found in the Lubrication and Maintenance Manual. Before greasing clean grease nipples. Shorter intervals must be selected in tropical climate, in high humidity, under important effects of dust and dirt, considerable changes of temperature and continuous swing circle motions e.g. during material transfer. Lubricants For greasing only use high quality grease which meets the requirements of the KOMATSU MINING GERMANY Lubricant Specification WN 011 597 99 (Published in July 2001). When choosing the grease, consider the ambient temperature range (Refer also to PSN AH02539 latest version). Exchange of the lip type seal "L" (refer to page 11) If a damage of the seal is determined while greasing operation, it has to be exchanged immediately, to avoid damages, caused by contamination. The exchange has to be performed as follows:    

Remove the complete lip type seal. Clean groove fat-free, remove lip remainder completely Insert new lip type seal (PN, refer Parts Catalogue). The seal must not be stretched during pushing in. Finally, the seal has to be cut to the needed length and the ends has to be glued together. The gluten is available under PN 989 965.

AH00511h

Page 21 of 22

7.2.

Outer toothing

Adhesive lubricants may be applied by means of an automatic swing circle gear lubrication system or manually by a spatula, a brush or a spray tin. Lubrication with automatic lubrication system 

Spray lube system



Drop lube system



Swing circle gear lubrication system

The most important requirement of a swing circle gear lubricant, besides the extreme pressure resistance, is its optimum adhesion to the tooth flanks, which can only be obtained by using the recommended lubricants in the prescribed temperature ranges. The Parts & Service News AH00519 (latest version) includes several adhesive lubricants providing excellent results on several machines under different working conditions. The use of other lubricants is not recommended before consultation of the Service Dept. 8151.

Lubrication: Manual The manually lubrication has to be carried out with the following adhesive lubricants. Those lubricants are suitable for all temperature ranges.

AH00511h

Page 22 of 22

General The adhesive lubricants protect the tooth profile against dust, dirt, and damage resulting from driving or braking actions. However, this protection is effective only when the adhesive greases have been applied to clean surfaces where it can form a continuous coating. When bright spots show up at the tooth profile the toothing must be sprayed or laid on immediately with the special adhesive grease. When visiting customers, the service staff or dealers should also check the machine equipment and stock of lubricant and advise the exchange, if necessary, to prevent premature wear of the toothing. 

The adhesive lubricants provide totally different features compared to the Bearing greases / MPG (e.g. used in the central lubrication system). Hence, those lubricants must not be replaced against each other or mixed. Example: This may happen when grease pressed out of the upper sealing system of the races forms too big collar at the swing circle and penetrates into the toothing. This eventuality must be avoided by removing the excess grease.

 If tooth profiles of the swing circle connection have been damaged due to one of the above-mentioned reasons they do not fall under our warranty.

AH00511h


COMPONENT CODE:

30

REF NO.

AH00515c

DATE


This PARTS & SERVICE NEWS supersedes the previous issue No. AH00515b which should be discarded. SUBJECT:

Final drive:

Wear and tear measurements Mounting procedures

PURPOSE:

Revision

APPLICATION:

H 185S; H 285; H 285S; PC4000; PC5500 (#15026 and up); H 485; H485S; H 685S/SX; H 655S; PC8000

FAILURE CODE:

3000CA

DESCRIPTION: 1. Wear and tear measurements 1.1 Radial wear determination a) Preparation b) Measuring procedure Method A c) Measuring procedure Method B d) Determination of wear depending on the Bushing version Old or New 1.2. Axial play determination of the hollow shaft a) Measuring procedure b) Reducing the axial play by remachining 2. Mounting procedures 2.1 Mounting of drive shaft a) Gap between drive shaft and cover plate b) Measuring procedure c) How to establish the recommended gap 2.2 Exchange bushings a) Freeze shrinking bush b) Flange Assy. with freezed in bush 3. Final works

1. Wear and tear measurements The wear- and tear-measurements on the bearing bushings in mounted condition inform quickly and exactly about the axial and parallel abrasion, without quickly a time and cost-intensive disassembly of the final drive. It is recommended to perform the measurements every 5000 working hours to avoid consequential damages as a result of a too high abrasion amount. The wear- and tear-measurements are described and illustrated on the following pages.

AH00515c

Page 2 of 10

1. Wear and tear measurements 1.1. Radial wear determination a) Preparation For the measurements proceed according to the following sequence: • • • • •

Place suitable oil pan for outflowing oil and remove cover (H). Operate travel gear that the bores (B) in the hollow shaft are placed in vertical position (see illustration). Turn the superstructure to the illustrated position. Hoist the sprocket side by using the attachment, until a wooden plank can be placed under the track (middle of sprocket). Lift attachment until the bucket no longer touches the ground.

AH00515c

Page 3 of 10 b) Measuring procedure Method A • • • •

Place dial gauge bracket with magnet (1), dial gauge (2) and bolt (3) as shown in illustration below. Set dial gauge (2) to “0” when attachment is lifted. Wooden plank must lie under the sprocket. Hoist the sprocket side by using the attachment until the wooden plank is free. Take reading of dial gauge.

c) Measuring procedure Method B •

Check by using a feeler gauge between hollow shaft and bearing bush.

AH00515c

Page 4 of 10 d) Determination of wear depending on the Bushing version Old or New Because of technical development the bushings (P/N 429 649 40 for H 485; H485S; H 685S/SX; H 655S; PC8000) and (P/N 429 652 40 for PC4000) are made of a new material and have spiral grooves instead of radial grooves of the former version.

Type H 485; H485S; H 685S/SX; H 655S; PC8000 H 285; H 285S; PC4000 PC5500 (#15026 and up)

Bearing assy.* (outside) old new

Bearing assy.* (inside) old new

Bushings * old

new

31335540

91159540

31335640

92298040

42964940

92298440

36103640 ----

92253840 93360240

36103740 ---

92253940 93360440

42965240 ---

92253740 93360040

* Refer to the respective Parts Catalogue of the machines.

Old bushing version

)

• The radial play after new machine assembly amounts to 0.35 mm to 0.45 mm *. • If the maximum permissible parallel play comes up to 2 mm, the bushings have to be changed *. * – H 485; H485S; H 685S/SX; H 655S; PC8000 only up to S/N 12041. – PC4000 only up to S/N 08155.

New bushing version

)

• For machines with the new bushings (P/N 922 984 40) the radial play after installation amounts to 0.74 mm to 0.85 mm. If the maximum permissible parallel play comes up to 2.0 mm, the bushings have to be changed. • For machines with the new bushings (P/N 922 537 40) the radial play after installation amounts to 0.56 mm to 0.66 mm. If the maximum permissible parallel play comes up to 2.0 mm, the bushings have to be changed. • For machines with the new bushings (P/N 933 600 40) the radial play after installation amounts to 0.67 mm to 0.77 mm. If the maximum permissible parallel play comes up to 2.0 mm, the bushings have to be changed.

AH00515c

Page 5 of 10

1.2. Axial play determination of the hollow shaft a) Measuring procedure • • • • • • • • •

Make bracket (1) as shown in the illustration. The bores dia. have drilled respectively to the thread diameter (see table). Screw threaded rods (4) into the hollow shaft. Mount nuts (3), bracket (1) and bolts (2) as shown in the illustration. Hoist the sprocket side by using the attachment until the sprocket no longer touches the ground. Slide hollow shaft in by using nuts (3) until it comes against the final stop. Place dial gauge with bracket, set dial gauge to “0”. Slide hollow shaft out by nuts (3) until it comes against the final stop. Take reading of dial gauge. When the maximum values (see table) are reached, the play can be reduced to the new machine value by remachining according to page 5.

Type

H 185 / S H 285 / S PC4000 PC5500 H 485 / S H 685S / SX H 655S/PC8000

Mounting bolt (2)

Threaded shaft (mm)

M 12 M 16 M 16 M 12 M 16 M 16 M 16

M 16 M 20 M 20 M 20 M 20 M 20 M 20

Gauge (S) (mm)

316 360 360 435 460 460 460

Axial play new (mm)

0.2 – 0.9 0.2 – 0.9 0.2 – 0.9 0.2 – 0.9 0.2 – 0.9 0.2 – 0.9 0.2 – 0.9

Max. permissible axial play (mm) 2.75 2.75 2.75 2.75 2.75 2.75 2.75

AH00515c

Page 6 of 10 b) Reducing the axial play by remachining When the axial play comes up to the maximum value according to the table on page 4, flange (2) can be remachined in area (E) , to bring the axial play to the new machine condition. • • • •

Underpin sprocket, suspend to a crane. Remove bolts (S) (see page 06), remove flange (2) by means of puller bolts. Remachine flange (2) in area (E), until the axial play (new value) is reached. For the mounting , proceed in inverse sequence of the removal.

AH00515c

Page 7 of 10

2. Mounting procedures 2.1 Mounting of drive shaft a) Gap between drive shaft and cover plate • Install drive shaft (12)

)

• The drive shaft has a multi-spline shaft at both ends. • The correct mounting position is when the longer toothing faces the gear.

b) Measuring procedure • Check if the drive shaft rests completely against the stop in the gear by means of a hit with a mounting bar and a metallic click is audible. • Measure dimension “A” at the cover plate (7). • Measure dimension “B” according to the illustration by mean of measuring device (1). • Calculate the existing play with formula: “B” minus “A” = 2 mm.

c) How to establish the recommended gap Play too much, machine cover plate at surface “C”. Play too low, machine cover plate at surface “D”. C

Cover (Drawing enlarged)

7

D „B“

1

12

5

„A“ AH00515c

Page 8 of 10

2.2 Exchange bushings

)

• The removal of the travel gear is described in Service News AH00514 (latest version), the mounting of the dual-cone seals (4) is described in Service Bulletin AH05511 (latest version).

Exchange bushings are available in the following types: a) Freeze shrinking bush Exchange bush (3) has to be fixed by freeze- shrinking according to Service Bulletin 21 – 62a. Afterwards, it has to be remachined to the final dimension according to table below. Parts (3; 4; 5 and 6) have to be ordered for the conversion. For the part no. refer to the respective Part Catalogue of the machines. Type

Dnew (mm)

H 185 / S

355.35+0.07

H 285 / S

400.56+0.06

PC4000 PC5500

400.56+0.06 480.67+0.06

H 485 / S

520.74+0.07

H 685S / SX

520.74+0.07

H655S/PC8000 520.74+0.07

AH00515c

Page 9 of 10 b) Flange Assy. with freezed in bush If the remachining of the flange under consideration of the tolerances and diameters is not possible, it is recommended to order the flanges with freezed–in and machined bushings , to shorten the standstill of the machine. For conversion, the parts shown below (3; 4; 5; 6 and 7) have to be ordered according to the respective Parts Catalogue of the machines.

AH00515c

Page 10 of 10 3. Final works (For detailed informations refer to the respective Maintenance Manual of the machines.) 1. Fill in new oil up to the ”MAX” marking on oil level gauge (3). 2. After short operating period check oil level and gear for leaks.

AH00515c


COMPONENT CODE:

25

REF NO.

AH00519e

DATE

January 15, 2007 Page 1 of 4

This PARTS & SERVICE NEWS supercedes the previous issue AH00519d which should be discarded. SUBJECT:

Adhesive lubricants for the Slew Ring Gear

PURPOSE:

Revision

APPLICATION:

All types

FAILURE CODE:

2500Z9

DESCRIPTION: The transmission of a torque from the slew pinion to the toothing of the slew ring causes the slewing of the superstructure. The existing extreme force in this section requires the separating of the engaged gears by means of grease film, to ensure a proper damping of shocks and to prevent metallic abrasion. Adhesive lubricants may be applied by means of an automatic slew ring gear lubrication system or manually by a spatula, a brush or a spray tin. Automatically tooth lubrication systems provides the upper most protection because of the continuously uninterrupted lubrication, permanent checks are not required.

AH00519e

Page 2 of 4

)

• Independent of the lubricant and lubrication system, the toothing should be visually checked approx. every 500 working hours. If the check is not possible because of applied lubricant, the toothing has to be cleaned at several points equally distributed on the circumference of the slew ring. In case of wear or damages, Dept. 8151 has to be informed to discuss suitable remedies.

ã

• These adhesive lubricants provide totally different features compared to the Bearing greases / MPG (e.g. used in the central lubrication system). Hence, those lubricants must not replace against each other or mixed. Example: This may happen when grease (1) pressed out of the upper sealing system of the races forms too big collar at the slew ring and penetrates into the toothing (2). This eventuality must be avoided by removing the excess grease.

AH00519e

Page 3 of 4 The following table includes several adhesive lubricants providing excellent results on several machines under different working conditions. The use of other lubricants is not recommended before consultation of Dept. 8151. Note: Use these Greases for Swing Circle open Gear Lubrication only Ambient Temperature °C ⇒ °F ⇒ Supplier

-50 -58

-40 -40

-30 -22

-20 -4

-10 14

0 32

10 50

20 68

30 86

40 104

50 122

60 140

Castrol Molub-Alloy 936 SF Heavy NG Castrol Industrie GmbH

Castrol Molub-Alloy 936 SF Heavy Castrol Molub-Alloy 958 SF Castrol Molub-Alloy 936 SF Arctic BERULIT GA 2500 / BERUGEAR W4000

BECHEM

BERULIT GA 800 BERUGEAR W 3000 Beru Gear FG 34 (Biodegradable) Molub unee lubricant 7059 Molub Gear Tac 6895

BEL RAY Molub Gear Tac 6894 / 6899 ESSO

Dynagear Extra Ceplattyn KG 10 HMF

FUCHS LUBRITECH

Ceplattyn KG 10 HMF LT URETHYN HG O *1)

MOLYBOND

TSG Heavy Malleus GL 500

SHELL

Malleus GL 400 Malleus GL 25

TEXACO LUBRITENE *1)

*2)

Crater 2X Fluid *2) Lubrene Multi ServOGL

The URETHYN HG O Grease should only be used in Arctic climates where the ambient temperatures fall to –50° C. In regions where the ambient temperatures do not fall below –40° C, a grease of the temperature range to –40° C should be used. Use the Crater 2X Fluid for Spray systems only.

AH00519e

Page 4 of 4 The manually lubrication has to be carried out with the following adhesive lubricants. Those lubricants are suitable for all temperature ranges.

Company

Product

T1 -5°C ⇒ +60°C +23°F ⇒ +140°F

T2 -20°C ⇒ +10°C -4°F ⇒ +10°F

T3 -40°C ⇒ -10°C -40°F ⇒ +14°F

Voler Compound

KOMATSU

2000 E Spray (0,625kg)

P/N 500 893 98

Voler Compound

Special grease

)

2000 E Adhesive lub (indicate quantity in kg)

P/N 006 057 98

• What has to be done in case of grease exchange according to the chart on page 03 ? • The new adhesive grease may directly be changed without a complete cleaning of the toothing. An increased grease supply after the exchange is recommended until the toothing is completely applied.

AH00519e

COMPONENT CODE:

K1; J1

REF NO.

AH01513

DATE

06252001


Page 1 of 4 This PARTS & SERVICE NEWS supercedes the previous issues No.: 21–491 which should be discarded. SUBJECT:

Bleeding of hydraulic pumps

PURPOSE:

Avoiding of cavitation

APPLICATION:

All types

FAILURE CODE:

J100PH; K100PH

DESCRIPTION:

The bleeding of the hydraulic pumps (Axial piston and Gear pumps) and the complete filling of the suction oil reservoir and the suction lines has strictly be done, to prevent damages caused by air in the suction system (cavitation). If the oil level decreases in the suction oil reservoir or the pump flows empty in case of commissioning or repairs the bleeding of the system is momentous and has to carried out as follows.

.

The bleeding procedure has to be carried out on all pumps !

Hydraulic pump

PTO

Suction line Hydraulic oil reservoir Cock closed

Suction oil reservoir

AH01513

Page 2 of 4

Hydraulic pumps at the Pump Distributer gear (Example PC4000)

3; 4

Gear pumps

1; 2

Axial piston pump (bent axis design)

I; II; III; IV

Axial piston pump (swashing plate design)

AH01513

Page 3 of 4

1. Gear pump

5 4

1

Cock closed

Precondition Þ • Hydraulic oil reservoir (1) filled • Cock (2) closed • Suction oil reservoir (3) totally empty or decreased level • Suction line (4) empty • Hydraulic pump (5) empty

3 2

5 outflowing oil

4

1

Measure Þ • Place oil pan for out coming oil. • Loosen suction line (4) • Open cock (2), when oil runs out, reconnect suction line (4)

Cock opened

3 2 The a.m. precondition has also be observed for the axial piston pumps.

2.a Axial piston pump (bent axis design)

Precondition (see above) Measure Þ • Remove plug (6) • Open cock (2) • When oil flows out of the bore, insert plug (6) tighten.

6

Cock opened

.

• The bleeding plug (6) may be placed different, it depends on

the design and mounting position.

AH01513

Page 4 of 4

2.a Axial piston pump (swashing plate design) The pump housings has to be filled up with hydraulic oil before installation and after repairs via the special bore (A) or via the leak oil connection (B).

A

B

C

.

• The suction lines of the Axial piston pumps (swashing plate

design) have to be bled via plug “C”. For that open the plug and wait until oil is coming out.

After the bleeding procedure, the hydraulic oil reservoir has to be refilled to the permissible level.

AH01513

COMPONENT CODE:

A2

REF NO.

AH01521a


DATE

20 Sept. 2002 Page 1 of 9

This PARTS & SERVICE NEWS supersedes the previous issue No.: AH01521 dated November 2001 which should be discarded. SUBJECT:

Diesel engine suspension

PURPOSE:

Hints for checking

APPLICATION:

H 185; H 255; H 285; H 455; H 485; H 655; H 685; PC3000; PC4000; PC5500; PC8000

FAILURE CODE:

A2T0EH

DESCRIPTION:

Diesel engines are mounted on elastic elements. With increase of life the flexible mountings will show setting effects. 1.

Inspection intervals

• Damages to the engine might arise if the bolts of the flexible mountings are not tightened correctly.

1.1 Therefore check bolts after the following intervals: • Prior to putting the machine into operation or after replacement of the flexible mountings • after the first 250 operating hours • every 1000 operating hours or every 6 month latest

1.2 The elastic engine suspension must be checked (visual check): • Every 6 month or every 1000 operation hours (check the flexible mountings for damage). 1.3

Check the fatigue of the rubber elements according to the appendix (pages 5 to 9) once a year and give the records to our service department. Take a calliper.

AH01521a

Page 2 of 9

2.

Kinds of mounts

There are two types of mounts at each location: Type A: Flexible engine mountings Type B: Flexible engine mountings with self locking nut item (3) for limiting of the flexible distance.

3.

Control measures (see also in your Operation and Maintenance Manual) (Caterpillar-Engine fig.1; Cummins/Komastu - Engine fig.2) • All tests during motor stop!

The bolts of the flexible engine mountings have to be checked as follows: 1. Tighten the bolt (2) to 880 Nm (649 lbf ft). 2. Position the nut (3) so it just touches the steel plate of the rubber mount item (6). Tighten the nut an additional ¼ turn (90°).

F

Over tightening of this nut will result in removing the required elasticity of the rubber mounts and may cause engine failure.

3. Only by Cummins Engines Check distance „C“ between torque support and stop bolt(4). With setting of the flexible engine mountings the distance „C“ increases and must be readjusted. To do this, loosen lock nut (7) and tighten stop bolt (4) until the correct distance „C“ is obtained. Tighten lock nut (7) and recheck distance (C). 4. Check all rubber metal bars (1) and all strips (6) for damage.

F

• All rubber metal bars(1), all strips(6) and all cup springs(5) should be replaced during engine overhaul.

AH01521a

Page 3 of 9 Fig. 1: For example PC8000 with Caterpillar - engine

1

2 A

A B 6

3

2

B A 3 2

M24x150

M24x150 M24x350

A

A

B

Legend: (A); (B) Two types of engine mounts (1) Rubber metal bar (2) Bolt of engine mount type (A (3) Self locking retainer nut of the engine mount type (B)) (6) Strip

3

AH01521a

Page 4 of 9 Fig. 2: For example PC4000 with Cummins/Komatsu - engine

LEGEND: (A); (B) Two types of engine mounts (C) Distance between torque support and stop bolt(4) (1) Rubber metal bar (2) Bolt of the engine mount type (A) (3) Self locking retainer nut of the engine mount type (B) (4) Stop bolt (5) Cup spring package (6) Stip (7) Lock nut

6

4

5 C

7 2 6 B

1 A

A

Lock nut tighten snugly

B 3 AH01521a

Page 5 of 9

Record of measurement - fatigue of the engine bearings Excavator model:

PC3000

Inspector:

Serial number:

Date:

Engine manufacturer:

Signature:

Measuring point

Value (X) (mm)

1 2 3 4 5 6 7 8 AH01521a

Page 6 of 9


PC4000

Inspector:

Serial number:

Date:


Signature:

Measuring point

Value (X) (mm)

1 2 3 4 5 6 7 8

AH01521a

Page 7 of 9


PC5500

Inspector:

Serial number:

Date:


Signature:

5

Measuring points PC5500

1

Pump distributer gear

Measuring point

Value (X) (mm)

1 6

2 Engine

7

2 3

3

4 5 6 7

8

4

8 AH01521a

Page 8 of 9


PC8000

Inspector:

Serial number:

Date:


Signature:

5

1

Measuring points PC 8000

6

2 Engine 7

3

Measuring point

Value (X) (mm)

1 2 3 4 5


6 7 8

4

8 AH01521a

Page 9 of 9


PC8000

Inspector:

Serial number:

Date:


Signature:

5

Measuring points PC 8000 (CAT)

1

Measuring point

Engine 6

2

7

3

Value (X) (mm)

1 2 3 4 5


6 7

8

4

8 AH01521a

COMPONENT CODE:

30; 63

REF NO.

AH01531A


DATE

06122002 Page 1 of 9

This PARTS & SERVICE NEWS supersedes the previous issues No. 21-426; 21-549 and AH01531 which should be discarded. SUBJECT:

Hydraulic accumulators – testing and refilling

PURPOSE:

Regular check

APPLICATION:

All types

FAILURE CODE:

307EPB; 6347PB

DESCRIPTION: The testing and refilling of the hydraulic accumulators have to be performed by testing- and refilling device Part no. 761 520 73. When ordering this particular device, please always indicate country of destination.

1. Testing of existing gas pressure at piston and diaphragm accumulators For testing of existing gas pressure at bladder accumulators, refer to page 7 – 9. •

Stop engine.

•

Allow pressure relief of the system to be checked.

•

Remove protective cap from accumulator.

•

Unscrew a union of the feeding line in order to allow the hydraulic oil to pour out.

AH01531A

Page 2 of 9

The testing- and refilling device includes following pressure gauges:

0 to 25 bar 0 to 100 bar 0 to 250 bar •

Screw the pressure gauge with the correct pressure range into the testing and refilling device.

•

Screw home screw (14) at the filling device.

•

Loosen the socket-head screw of the gas valve by ½ turn with a hex key 6 mm.

•

Screw filling device without hose carefully by hand onto accumulator.

•

Observe correct position of the o-ring.

. •

• Check valve in hose connection is operative only if hose is not connected.

Turn T-handle (12) several times in both directions until it is engaged in socket head of gas filler screw (11).

•

By means of the T-handle unscrew gas filler screw (11) by 4 to 5 turns until pressure gauge indicates the existing gas pressure.

AH01531A

Page 3 of 9

For the specified gas pressure of the piston-diaphragm and bladder type accumulator, refer to the circuitry diagrams in the Operation Manual.

Compare the pressure reading on the gauge with the specified gas pressure.

If the pressure reading is too low, the accumulator has to be refilled. • To fill the accumulator, a pressure – reducing valve must be used. • Only nitrogen must be used to fill the accumulator.

2. Filling of the accumulator •

Close shut-off valve (5) at the bottle pressure – reducing valve. Turn in completely outlet screw (14) of filling device and install the hose.

AH01531A

Page 4 of 9

•

Open valve (8) of nitrogen bottle and check bottle pressure. The bottle pressure must always be higher than the pressure specified for the accumulator.

•

adjust specified accumulator pressure with pressure-reducing valve (6).

•

Turn out the filling screw (11) by means of the T-handle of the filling device.

•

Open slowly shut-off valve at bottle pressure reducing valve and let nitrogen flow into accumulator, until pressure gauge on filling device indicates the specified pressure. Then close shut – off valve.

AH01531A

Page 5 of 9

•

Wait for temperature to be equalized (approx. 5 min.) and open outlet screw (14) to let the pressure drop to the specified value.

•

Close outlet screw (14).

•

Screw in tightly screw (11) by means of T – handle (12).

•

Open outlet screw to let nitrogen escape from filling device.

•

Disconnect hose connection and unscrew filling device.

•

Fasten O - ring (13) to the testing device.

•

Tighten the screw (11) by means of a hex key 6 mm.

AH01531A

Page 6 of 9

•

Reinstall protective card and retighten union in feeding line.

•

Close bottle valve (8).

•

Turn out completely the T – handle at the pressure reducing valve (6).

AH01531A

Page 7 of 9

3. Testing of existing gas pressure bladder accumulators The testing- and refilling device includes pressure gauges: 0 to 25 bar 0 to 100 bar 0 to 250 bar. •

• • • •

Screw the pressure gauge with the correct pressure range in the testing- and refilling device. Shut down the engine. Allow pressure relief of the system to be checked. Unscrew the feeding line in order to allow the hydraulic oil to pour out. Remove cap (1) and nut (2). Do not remove O - ring (3).

. • • • • • • •

• Check valve in hose connection is operative only when hose is not connected.

Turn the socket head screw (4) installed in the adapter (2) a little bit. Mount testing- and refilling device to adapter (2). Install adapter (2) to testing connection (3). Turn in completely outlet screw of the filling device. Turn T – handle (12) several times in both directions until it is engaged in the screw (4) of the adapter (2). By means of the T – handle (12) turn in the screw so far that the existing gas pressure is indicated by the pressure gauge. Do not turn in the screw any further; the gas valve may be destroyed.

AH01531A

Page 8 of 9

If the pressure reading does not correspond with the nominal filling pressure, the accumulator has to be refilled.

4. Filling of the bladder accumulator • To fill the accumulator, a pressure – reducing valve must be used. • Only nitrogen must be used to fill the accumulator. •

Close the shut off valve (5) on the pressure-reducing valve.

•

Turn in completely the outlet screw (14), see illustration on page 5.

•

By means of the T-handle (12), turn out the screw (4) of the adapter (2) until the gas valve in the testing connection (3) of the accumulator is closed. After that, install connecting hose.

•

Open the valve (8) at the nitrogen bottle and check the gas pressure of the bottle. The gas pressure of the nitrogen bottle must always be higher than the specified filling pressure of the accumulator.

•

Adjust the specified filling pressure by means of setting screw (6) of the pressure reducing valve. Open the gas valve in the testing connection (3) of the accumulator ba turning in screw (4).

•

Slowly open the shut off valve (5) at the pressure reducing valve and fill the accumulator until the pressure gauge (7) of the testing and refilling device indicates the specified filling pressure. Then close the shut-off valve (5).

AH01531A

Page 9 of 9

•

Wait for temperature to be equalized (approx. 5 min) and, if necessary, reduce pressure with outlet screw (14) or let the pressure reach the specified value according to page o4.

•

Close outlet screw (14).

By means of T-handle (12) turn out screw (4) from the adapter (2) till the gas valve in the testing connection (3) is closed. • •

•

Open outlet screw (14) that the nitrogen can escape from the filling and testing device. Close the nitrogen bottle and remove the filling- and testing device, filling hose and pressure –reducing valve. Turn out completely screw (6) of the pressure-reducing valve. By doing so, the spring-reducing valve is discharged.

•

Re-install protection cap in the testing connection.

•

Re-tighten the hydraulic line.

AH01531A

COMPONENT CODE:

25

REF NO.

AH02513b


DATE


This PARTS & SERVICE NEWS supersedes the previous issue No. AH02513a which should be discarded. SUBJECT:

Testing wear and tear of swing circle bearing

PURPOSE:

In time ordering of a new swing circle in order to prevent unexpected downtime

APPLICATION:

All types

FAILURE CODE:

2500CA

DESCRIPTION: For assessing the condition of the swing circle bearing, we recommend that its normal wear rate is determined. The first measurement must be performed when the excavator is put into operation in order to obtain a base value for subsequent repeat measurements. The following measurements have to be effected: 1. Period of the first 10.000 h: 2. Period more than 10.000 h:

every 5.000 working hours; every 2.500 working hours.

After finishing the measurements, record the values obtained in a tabular form. The diagram shows the principle of bearing wear progression. If the “increased wear” situation is reached, prepare the changing of the swing circle.

)

• We recommend to turn the swing circle (180°) after 20 000 working hours.

normal wear

increased extrem wear wear

Axial movement/wear

mm

Base value

Working hours

h AH02513b

Page 2 of 4 Measurement procedure

1. Park the machine on level ground. 2. Slew the attachment to the normal working position (idler wheel in front). 3. Remove cover as shown in the photos (Illust. 7 and 8). 4. Clean the center slew gear tooth and the contact point on the superstructure. 5. Install the dial gauge* as shown in the photos. 6. Turn the swing brake switch in the on position. 7. Straighten the attachment fully (lmax) and raise the shovel approx. A=3 m over the ground (Illust. 1, 3 or 5). 8. Set measuring instrument (dial gauge*) to zero.

ã

• Make sure the area below and around the excavator is clear of all persons before you start operating.

9. Move the attachment in the shown position (Illust. 2, 4 or 6). Lower the attachment until the track lift off the ground up to the sprocket (B).

)

• Use for all measurements the same distances “A” and “B”.

10. Move the attachment in the normal parking position. 11. Read measurement “M 1” (out of the memory) and record in the table (page 4). 12. Repeat the measuring procedure at the same point for a 2nd value (M 2). 13. Remove the dial gauge, swing the superstructure 180 degrease and repeat the measuring procedure two times. * We recommend to use a digital dial gauge with min. / max. measuring value memory (Part No. 794 537 73).

Photo only as example

AH02513b

Page 3 of 4

AH02513b

Page 4 of 4

Excavator Typ:

Planned h 0

Actual h

Date

Serial number:

Front M1

Front M2

Mfront = (M1 + M2)/2

Rear M1

Rear M2

Mrear = (M1 + M2)/2

5 000 10 000 12 500 15 000 17.500 20 000 22.500 25 000 27.500 30 000 32.500 35 000 37.500 40.000

AH02513b

COMPONENT CODE:

75

REF NO.

AH02521b


DATE

April 3, 2007 Page 1 of 10

This PARTS & SERVICE NEWS supersedes the previous issue Number AH02521a which should be discarded. SUBJECT:

Track group – wear measurement

PURPOSE:

Revision

APPLICATION:

H 185 to PC8000

FAILURE CODE:

752DCA

DESCRIPTION: 1. 2. 3. 4. 5. 6. 7.

Preconditions for the measurements Adjusting range for guide wheels Chain elongation / measured over three track pads (4 pins) Circular pitch (Sprocket / Track pad) Wear of track pads (Roller contact surface) The X-dimension becomes zero Table

The professional and regular inspection increases the service life of the track group and can avoid early and very expensive repairs, including unforeseen standstill of the machine. It is recommended to perform the inspections every 3 month or 1500 working hours according to the description and to fill in the measured values to the table on page 10. The measurements are described in detail and illustrated on pages 4 to 6. To prevent unnecessary problems and standstills and to assure fast help when wear limits are reached, it is recommended to send the filled-in tables in the mentioned intervals to Komatsu Mining Germany, Service Department 8151.

Illustration 1

AH02521b

Page 2 of 10 1.

Preconditions for the measurements:

1.1.

Cleaning of the track group, according to the Maintenance Manual

Illustration 2 1.2

Track sag (A): On Machines without the hydraulic track - tensioning system up to max. 230 mm • H 185S • H 285 - H 285S up to max. 300 mm • H 485 - H 485S up to max. 420 mm

1.3

Track sag (A): On Machines with hydraulic track - tensioning system • No specification, since self-regulating

Illustration 3

AH02521b

Page 3 of 10 2.

Adjusting range for guide wheels

Illustration 4

Legend (1)Guide wheel (2)Slide block (3)Stop plate “X” Adjusting range for track tension The adjusting range for track tension is the distance “X” between guide wheel slide block (2) and stop plate (3). Depending on the stretching of the track the slide block (2) may come in contact with stop plate (3). In such a case, it must be ensured that the track does not become too loose. Depending on track condition; the removal of one track pad will restore the adjusting range “X”. If necessary contact our Service Department for more information.

AH02521b

Page 4 of 10

3. Chain elongation / measured over three track pads (4 pins) This wear check has to be carried out in 4 equally distributed areas of the track chain (L1 to L4 - l.h. and R1 to R4 - r.h.). • Turn superstructure 90° to the travel direction. • Retract attachment and lower bucket on the ground until the chain has no longer contact with the ground. • Block the machine against inadvertent lowering with suitable devices.

ã

• Turn sprocket until the first measuring area (L1) is located at the deepest point of sag (“T“).

)

• To measure the areas L2-L4 turn the chain always forward until point “T“ is reached.

• To obtain a comparable measuring result, stop the main drive motor/engine of short duration, so that the track tensioning system is released to pilot pressure. • Place the points of the dividers into the centre bores of pins 1 and 4 of the measuring area L1 / R1, determine the distance and record in the table on page 10. • Repeat measuring procedure at measuring areas L2 / R2 to L4 / R4.

Illustration 5

AH02521b

Page 5 of 10 4.

Circular pitch (Sprocket / Track pad)

For this inspection, the excavator has to be placed on an even surface and only one chain has to be moved, like turning. Diesel engine: Electric motor:

Operate at low idle. Operate joy-stick slightly.

• Move l.h. track group forward (Sprocket rotation F = forward), until the contact area of the uppermost sprocket tooth (0) and the track-pad lug (0) is in the illustrated position, (Refer to illustration 6 “A”, page 6). • Measure gaps (X1). A. Measure inside and outside of the sprocket between the sprocket teeth (7) and track-pad lug (7) at 3 points, equally distributed on the chain. • Record the values into table -circular pitch A- on page 10. • Repeat the measurements on the r.h. track group. • Move l.h. track group back (Sprocket rotation R = backwards), until the contact area of the lowest sprocket tooth (0) and the track-pad lug (0) is in the illustrated position, (Refer to illustration 6 “B”, page 6). • Measure gaps (X2). Measure inside and outside of the sprocket between the sprocket teeth (7) and track-pad lug (7) at 3 points, equally distributed on the chain. • Record the values to the table -circular pitch B- on page 10. • Repeat the measurements at the r.h. track group. 5.

Wear of track pads (Roller contact surface)

• Stop the engine/motor and secure the machine against unintentional movement. • Mark 3 track pads of each track group (l.h. track group and r.h. track group) to make repeated measurements in the future comparable. • Take a ruler to measure the wear of the roller contact surface. The ruler needs an even contact surface, if not exist, prepare the track pad as necessary. (Refer to illustration 6 “C”, page 6). • Record the measuring results in the form sheet on page 10.

)

• For wear limits of individual parts please refer to P&S News “AH06507 Undercarriage – wear limit values”.

AH02521b

Page 6 of 10

Illustration 6 AH02521b

Page 7 of 10

6.

One X-dimension becomes zero

What to do if one X-dimension becomes zero 1.

If the connection point of Roller path depth and Elongation is in the oversize sprocket area*, change to oversize sprocket. 2.1 If the connection point of Roller path depth and Elongation is in the standard sprocket area* run further with this configuration as long as you reach the oversize sprocket area. 2.2 If there becomes a significant interference of sprocket and track pad match; in such case it could become necessary to change to standard sprocket size. * refer to illustrations 7 to 10 For the exchange of the oversize sprockets, refer to Service Bulletin AH00514.

AH02521b

Page 8 of 10

Illustration 7


Page 9 of 10

Illustration 9


Page 10 of 10

7.

Table for measurements

Machine-Type : Customer : Oversize sprocket ? : (left hand side)

Oversize sprocket ? : (right hand side)

NO

Serial-No. : Location : Date of installation: ................... at operating hours: ..................... Date of installation: ................... at operating hours: .....................

YES

Ö

NO

YES

Ö

Chain elongation (Illustration 5): Measuring area W-dimension [mm] via 4 pins

Left hand crawler track “L“ L1

Chain elongation (Illustration 5): Measuring area W-dimension [mm] via 4 pins

Operating hours : Date of measurement : Part-No. of track pad :

L2

L3

L4

Right hand crawler track “R“ L1

L2

L3

L4

Circular pitch: Illustration 6 “A“ Sprocket side X1-dimension [mm] L.H X1-dimension [mm] R.H

3

inside

3 points (equally distributed on the chain) 1 2 outside inside outside inside

3

inside

3 points (equally distributed on the chain) 1 2 outside inside outside inside

Illustration 6 “B“ Sprocket side X2-dimension [mm] L.H X2-dimension [mm] R.H

outside

outside

Wear of Track pads (Illustration 6 “C“): Track pad

Side

No.1 No.2 No.3 No.4 No.5 No.6

L.H. L.H. L.H. R.H. R.H. R.H.

Dimension “B“ [mm]

Number of cracked track pads left hand crawler track

right hand crawler track

AH02521b

COMPONENT CODE:

03

REF NO.

AH03506b


DATE

October 25, 2003 Page 1 of 5

This PARTS & SERVICE NEWS supersedes the previous issue AH03506a which should be discarded. SUBJECT:

Hydraulic oil cooler and water cooler fan bearings

PURPOSE:

Replacement of the bearings

APPLICATION:

PC4000; PC5500; PC8000

FAILURE CODE:

0373CA

DESCRIPTION: Two types of bearing units are used for the cooler fans at the above mentioned excavator models: 1. Grease lubricated bearings

)

2. Gear oil lubricated bearings

• We recommend to replace these bearings to avoid consequential damages according to the following table: Bearing unit Replacing time after: Grease lubricated bearings 8 000 working hours Gear oil lubricated bearings 10 000 working hours * * or if damage or a leak has occurred.

)

• The hydraulic motors for the fans should be replaced preventively every 10.000 working hours.

AH03506b

Page 2 of 5

Hints for replacement: 1. Grease lubricated bearings

1 Bearing retainer 2 Shaft 3 Hydraulic motor 4 Fan 5 Bearing 6 Grease nippel 7 Circlip 8 Bolt 9 Bolt 10 Locking plate

1. Remove the hydraulic and the grease lines; the fan; and then the motor. 2. Remove the bearings and the fan shaft. 3. Clean all parts carefully. 4. Install the first bearing (5) and fill the chamber between the bearings to 50% with grease. 5. Install the shaft with the first bearing (5) and the grease into the bearing retainer. 6. Install the second bearing and fix it with the circlip (7). (Install also the sleeve between the bearings if applicable.) 7. Grease the hydraulic motor drive shaft with “Optimol paste white T” and fill the chamber in the fan shaft to 50% with normal grease according to the drawing above. 8. Reinstall the bearing hub, the fan and the motor. 9. Reconnect all lines. • Grease the bearings every 500 working hours with maximal 2 strokes with the hand greasing pump.

AH03506b

Page 3 of 5

2. Gear oil lubricated bearings 2. Gear oil lubricated bearings 1 Bearing retainer 2 Shaft 3 Circlip 4 Bearing 5 Shaft grommet 6 Shaft seal 7 Plug Fill the chamber at the lip type seal with grease.

1. Remove the hydraulic lines; the fan, then the complete unit. 2. Drain off the gear oil and remove the motor, the bearings, the fan shaft, the shaft grommet and the shaft seal. 3. Clean all parts carefully. 4. Check the dia. “d” according to drawing and table at the next page. 5. Install a new shaft grommet with the flanged end at first (press it into depth “a” see next page). 6. Do not remove the seam of the shaft grommet. 7. Install the 1st bearing and the shaft seal into the bearing retainer. 8. Grease the shaft and install it. 9. Mount the 2nd bearing(4) and the circlip. 10. Check the spline and grease the hydraulic motor drive shaft with “Optimol paste white T”. 11. Reinstall the motor by using a new O – ring and mount then the fan. 12. Fill in the bearing retainer gear oil according to the Maintenance Manual. 13. Reconnect the hydraulic lines.

AH03506b

Page 4 of 5

PC4000

PC5500

PC8000

Oil cooler

Water cooler

Oil cooler

Water cooler

Oil cooler

Water cooler*

Part no.

Part no.

Part no.

Part no.

Part no. Part no.**

Part no.

Fan mounting 89590740 90202640 91091140 90479140 90389040 93394140 90968540b (assy.) Repair kit *** Press depht "a" (mm) Shaft dia. "d" (mm)

79296573 79296673 79296573 79296673 79296773 79484873 79296873

4 -0,5

3,7 +0,2

4 -0,5

3,7 +0,2

∅80 ±0,05

∅110 ±0,05

∅80 ±0,05

∅110 ±0,05

4 -0,5

6,4 ±0,8

∅100±0,05 ∅130−0,025

4,3 ±0,8 ∅ 85 ±0,05

* Serial No. 12040 up – see drawing next page ** Serial No. 12048/12049 only *** The Repair kit includes: 2 bearings; 1 shaft seal; 1 shaft grommet; 1 O-ring

Fill the chamber at the lip type seal with grease.

AH03506b

Page 5 of 5

PC8000-6 Water cooler fan bearings

Intermediate ring

AH03506b

COMPONENT CODE:

26

REF NO.

AH03509a


DATE

22nd July 2003 Page 1 of 25

This PARTS & SERVICE NEWS supersedes the previous issue AH03509 which should be discarded. SUBJECT:

Slew gear GFB 174 E 9017 (Part No. 917 915 40)

PURPOSE:

Modification to slew gear GFB 174 E 9020 (Part No. 92432540) including exchanging the sun gear shaft

APPLICATION:

PC8000 (12037 – 39); PC5500 (15012 – 15017); PC4000 (08151); PC3000 (06194)

FAILURE CODE:

2600Z9

DESCRIPTION:

General In order to increase the lifetime of the parking brake discs the swing gear oil filling capacity should be reduced by approximately 20 liters. The new filling capacity is approx. 42 liters. The present oil level gauge on the gear can no longer be used for checking the oil level. There are two possibilities to modify the oil level checking system. For increasing the lifetime of the slew gear the sun gear shaft should be changed during the slew gear modification. Page 1. Modification Kits 2 2.

Variant (A) – Modification by replacing of the swing gear cover with the complete parking brake unit,

6

3.

Variant (B) – Modification by machining the swing gear cover. 3.1 Modification of the swing gear cover a) Dismounting b) Machining of the swing gear cover c) Reassembly

8 11 11 12 13

4.

Completion of the swing gear cover

24

5.

Oil level checking procedure

25

AH03509a

Page 2 of 25 1. 1.0

Modification Kits One new gear shaft is required for one slew gear (Part No. 757 360 73 – differences to the old sun gear shaft: refer to illustration 6) 1.1 Kits for modification of the slew gear(s) according to Variant (A) 1.1.1 PC3000-1 Part No.: 794 016 73 Pos.

Part-No.

1 15 16 17 14 18 1 20 1 2

79227073 37441299 90635240 37126599 92582540 31318499 90756840 92582940 972111 50774898

Qty. Description 1 4 4 4 4 4 1 1 1 1

Cover/brake assy. Socket Cutting ring Union nut Oil level gauge tube Plug Oil level gauge Oil level gauge bracket O-ring O-ring

Illustration 3 6 6 6 6 6 6 6 2 2

1.1.2 PC4000-6 Part No.: 794 017 73 Pos.

Part-No.

1 15 16 17 14 18 19 20 1 2

79227073 37441299 90635240 37126599 92582540 31318499 90756840 92582940 972111 50774898

Qty. Description 2 12 12 12 12 12 2 2 2 2


Illustration 3 6 6 6 6 6 6 6 2 2

(Cover plates must be adapted.)

AH03509a

Page 3 of 25 1.1.3 PC5500 Part No.: 794 018 73 Pos.

Part-No.

1 15 16 17 14 18 19 20 1 2

79227073 37441299 90635240 37126599 92582440 31318499 90756940 92582840 972111 50774898

Qty. Description 2 10 10 10 10 10 1 1 2 2


Illustration 3 6 6 6 6 6 6 6 2 2

1.1.4 PC8000 Part No.: 794 019 73 Pos.

Part-No.

1 15 16 17 14 18 19 20 1 2 1 1

79227073 37441299 90635240 37126599 92582440 31318499 90756940 92582840 972111 50774898 92583240 92583140

Qty. Description 3 14 14 14 14 14 2 2 3 3 1 1

Cover/brake assy. Socket Cutting ring Union nut Oil level gauge tube Plug Oil level gauge Oil level gauge bracket O-ring O-ring Cover plate Cover plate

Illustration 3 6 6 6 6 6 6 6 2 2 -

AH03509a

Page 4 of 25 1.2 Kits for modification of the slew gear(s) according to Variant (B) 1.2.1 PC3000-1 Part No.: 794 020 73 Pos.

Part-No.

15 16 17 14 18 19 20 99 504 1; 3; 4 2

37441299 90635240 37126599 92582540 31318499 90756840 92582940 33132299 79224973 972111 50774898

Qty. Description 4 4 4 4 4 1 1 1 1 3 1

Socket Cutting ring Union nut Oil level gauge tube Plug Oil level gauge Oil level gauge bracket Plug Disc (thickness: 8.5-0.1mm) O-ring O-ring

Illustration 6 6 6 6 6 6 6 4 4 2 2

1.2.2 PC4000 Part No.: 794 021 73 Pos.

Part-No.

15 16 17 14 18 19 20 99 504 1; 3; 4 2

37441299 90635240 37126599 92582540 31318499 90756840 92582940 33132299 79224973 972111 50774898

Qty. Description 12 12 12 12 12 2 2 2 2 6 2


Illustration 6 6 6 6 6 6 6 4 4 2 2

(Cover plates must be adapted.)

AH03509a

Page 5 of 25 1.2.3 PC5500 Part No.: 794 022 73 Pos.

Part-No.

15 16 17 14 18 19 20 99 504 1; 3; 4 2

37441299 90635240 37126599 92582440 31318499 90756940 92582840 33132299 79224973 972111 50774898

Qty. Description 10 10 10 10 10 1 1 2 2 6 2


Illustration 6 6 6 6 6 6 6 4 4 2 2

1.2.4 PC8000 Part No.: 794 023 73 Pos.

Part-No.

15 16 17 14 18 19 20 99 504 1; 3; 4 2 1 1

37441299 90635240 37126599 92582440 31318499 90756940 92582840 33132299 79224973 972111 50774898 92583240 92583140

Qty. Description 14 14 14 14 14 2 2 3 3 9 3 1 1

Socket Cutting ring Union nut Oil level gauge tube Plug Oil level gauge Oil level gauge bracket Plug Disc (thickness: 8.5-0.1mm) O-ring O-ring Cover plate Cover plate

Illustration 6 6 6 6 6 6 6 4 4 2 2 -

AH03509a

Page 6 of 25 2. Variant (A) – Modification by replacing of the swing gear cover with the complete parking brake unit 1. 2. 3. 4.

Prepare the swing gear cover as described on page 23. Drain the motor adapter housing (about 0.6l oil). Remove the 8 bolts (7) M16 mm at the hydraulic motor (refer to illustration 1). Remove the motor with connected hoses and place it beside or if this is not possible, disconnect the hydraulic lines and close the ports. 5. Remove the 34 gearbox fastening bolts (8) M24 and the 8 mounting screws (8) M16 from the gear box. 6. Install 2 eye bolts M16 and lift the gearbox cover with the brake unit. 7. Replace the sun gear shaft (5) (refer to illustration 2). 8. Install the new Cover-Brake-Unit by using a new O-ring. 9. Modify the Swing gear type on the type plate old: GFB 174 E9017 to new: GFB 174 E9020 with punch marks. 10. Reinstall the hydraulic motor with the brake valve block by using a new O-ring. 11. Fill the motor adapter housing with oil according to the Maintenance Manual. 12. Weld on the oil level gauge brackets (20) on the hydraulic oil reservoir carrier and if so planed a second one onto the machinery house wall. 13. Insert the attached oil level gauges (19)into the brackets. 14. Check the oil level in the swing gear as described on page 25.

AH03509a

Page 7 of 25

Illustration 1 Illustration 1 – before modification 1

Oil level gauge swing machinery

2

Oil filler plug swing machinery

3

Breather filter swing machinery

4

Oil level gauge motor adapter housing

5

Breather filter motor adapter housing

6

Oil drain plug

7

Motor fastening bolts

8

- Gearbox fastening bolts (quantity: 34) - Mounting screws (quantity: 8)

AH03509a

Page 8 of 25 3. Variant (B) – Modification by machining the swing gear cover 1. Drain the motor adapter housing (about 0.6l oil). 2. Remove the 8 bolts (7) M16 at the hydraulic motor (refer to illustration 1). 3. Remove the motor with connected hoses and place it beside or if this is not possible, disconnect the hydraulic lines and close the ports. 4. Remove the 34 gearbox fastening bolts (8) M24 and the 8 mounting screws (8) M16 from the gear box (refer to illustration 1). 5. Install 2 eye bolts M16 and lift the gearbox cover with the brake unit. 6. Replace the sun gear shaft (5) (refer to illustration 2). 7. Remove the old O-ring and clean the groove. 8. Modify the swing gear cover as described on pages 11 - 22. 8. Install the modified Cover-Brake-Unit by using a new O-ring. 9. Modify the Swing gear type on the type plate old: GFB 174 E9017 Part No. 917 915 40 to new: GFB 174 E9020 Part No. 924 325 40 with punch marks. 10. Reinstall the hydraulic motor with the brake valve block by using a new O-ring. 11. Fill the motor adapter housing with oil according to the Maintenance Manual. 12. Weld on an oil level gauge bracket (20) on the hydraulic oil reservoir carrier and if so planed a second one onto the machinery house wall. 13. Insert the attached oil level gauges (19)into the brackets. 14. Check the oil level in the swing gear as described on page 24.

AH03509a

Page 9 of 25 Illustration 2 – Overview before modification 1

3

4 5

2

AH03509a

Page 10 of 25 Illustration 3 – Cover with brake (partly)

1

Pressure connection (M18x1.5) – max 60 bar

AH03509a

Page 11 of 25 3.1 Modification of the swing gear cover a) Dismounting 1. Remove the old oil level gauge assy. (390) and close the opening with a plug (99). 2. Remove the both snap rings (508; 549). 3. Loosen the 8 socket head cap screws (519). 4. Remove the bearing ring (503) by using of 2 eyebolts (M 16). 5. Before reinstallation apply the piston (116) with pressure (max. 60 bar) (see also illustration 4), otherwise the 2 screws (316)are prestressed (springloaded). 6. Remove the 2 socket head cap screws (316). Remove the piston (116). 6. Dismount the 10 Inner discs (505); the 11 outer discs (506) and the 10 sinus rings (551). 7. Remove the drive shaft (130). 501 8. Remove the disc (504). 99 501 390 316 551 505 503 506 504

130 549

508

116

519 Illustration 4

AH03509a

Page 12 of 25 b) Machining of the swing gear cover (501 – disc housing) 1. Mill at the swing gear cover six areas as shown. 2. Drill 6 holes in the milled areas and tap 1 ¼ inch. Illustration 5

45°

45°

R31.5 30

30°

+0.5

30°

Ø524 Ø660 R 1.6 30

G 5/4 AH03509a

Page 13 of 25

AH03509a

Page 14 of 25 c) Reassembly 3. Install the new disc (504) as shown.

4. Reinstall the drive shaft (130) with the ball bearing (51353298).

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Page 15 of 25

5. Install the new discs. At first an outer disc (grease it with oil), then an inner disc and then a sinus ring ... and so on.

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Page 16 of 25

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Page 17 of 25

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Page 18 of 25 Before installation supply the piston (116) with pressure (max. 60 bar). Do not forget to exchange the O-ring.

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Page 19 of 25

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Page 23 of 25

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Page 24 of 25 4. Completion of the swing gear cover 1. Remove plugs* (A3) from the swing gear cover. * numbers depends on type of the excavator 2. Install the oil level gauge tubes (14; 15; 16; 17) as shown in the illustration 6. 3. Close the tubes with plugs M24 (18).

20

19

Illustration 6

A3 – Plug 14 – Oil level gauge tube 15 – Socket 16 – Cutting ring 17 – Union nut 18 – Plug 19 – Oil level gauge 20 – Oil level gauge bracket AH03509a

Page 25 of 25 5. Oil level checking procedure (engine at standstill) The design of the swing gear requires four or five locations for oil level checking. The correct oil level is below the upper planetary stage. To reach this level between the planetary gears it is necessary to find out at which of the four, five or six tubes the oil level gauge can be insert to the stop.

Proceed as follow: 1. Take out oil level gauge (19) from bracket (20). 2. Remove plug (18) from one tube (14) and insert gauge (19). If the gauge can not be moved in to the stop use the next tube (14). Repeat this procedure until the gauge can be inserted to the stop. 3. The oil level should be between the MIN and MAX marking on the gauge. Add oil if necessary. 4. Remove oil level gauge from the tube and insert into bracket (20). 5. Close the tubes with the plugs (18).

• Do not leave the gauge (19) in the tube (14). If the gauge is left in the tube the swing gear and the gauge will be damaged when the swing gear operates.

AH03509a

COMPONENT CODE:

71

REF NO.

AH03510


DATE

2nd June 2003 Page 1 of 18

SUBJECT:

ESCO bucket tooth system

PURPOSE:

Hints for handling

APPLICATION:

PC4000; PC5500 (15012 - ); PC8000

FAILURE CODE:

7168Z9

DESCRIPTION: At our excavators PC4000; PC5500 (15012-) and PC8000 the new bucket tooth system “POSILOK” is used. In the following is showed how to handle the parts of this system. Page 2

1.

Overview

1.1 1.2

Komatsu standard version Optional version

2.

The Points

3

2.1 2.2

Removing the points Installing the points

4 5

2 2

3.

The Adapters

3.1 3.2 3.2.1 3.2.2 3.2.3 3.3 3.4

Adapter removal Nose rebuild Nose end and sides rebuild Nose flats rebuild Rear corner rebuild Adapter installation Retighten Sidewinder Pin

6 8 8 9 9 10 11

6

4.

Wear Caps

11

4.1 4.1.1 4.1.2 4.2

11 11 12 13

4.2.1 4.2.2

Lock style wear caps (PC4000) Removal Installation Non lock style wear caps (Option PC4000; PC5500; PC8000) Removal Installation

5.

The Shrouds

14

5.1 5.2 5.2.1 5.2.2 5.2.3 5.3 5.4

Removal the shrouds Installing the shrouds Prepare the surface Position the bosses Welding the bosses Inspecting Worn Shrouds Installing (Shrouds and Pins)

14 15 15 16 17 17 18

13 13

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Page 2 of 18 1. 1.1

Overview Komatsu standard version

Additional wearcap for plate lips version (PC4000) Wearcap

1.2

Optional version

!

• For changing to optional version new points, new adapters and the wearcaps are required.

AH03510

Page 3 of 18 Classification of the Tooth Systems to the Excavator Types Type of Excavator PC4000 PC5500 PC8000 - ( 12030) - ( 12034)

Shovel Version S 110 S 130 S 145 S 130 S 130

Backhoe Version S 95 S 130 S 145 -

Component Preparation Prior to installing the new tooth system components: • Thoroughly clean all bearing surfaces on the tooth base, adapter and pin. • Visually inspect top and bottom of tooth base for wear, refer to following sections. • Replace all damaged components.

2.

The points

4 2

3

6

5 1 1

Point

2

Posilok Locking Pin

3

Integral rubber lock

4

Adapter

5

Mating rails between point and adapter

6

Stabilizing flats

AH03510

Page 4 of 18 2.1

Removing the points

!

• All persons performing maintenance work should wear a approved hard hat, safety glasses, steel-toed shoes and gloves. • To avoid injury to others, keep people not directly involved well out of the way.

1. Removal tool between the (PART NO. 79350273) Posilok Pin and the lock

2. Drive the Posilok Pin out using a removal tool

(Part No. 793 502 73)

Use this end to start the Posilok Pin out.

• • •

Use this end to drive it through.

Remove the vertical drive-through pin using a hammer and a pin removal tool (Part No. 79350273). Make sure to insert the tip of the removal tool between the Posilok Pin and the rubber lock. In order to loosen the point for removal from the adapter, it may be necessary to tap the sides of the point to loosen fines.

AH03510

Page 5 of 18 2.2

Installing the points

Preparation Prior to point replacement, make sure adapters are clean and free of damage. Carefully inspect adapters for excessive wear. If the nose is worn or if insufficient wear metal remains to see adapters through their work cycle, they should be replaced with new ones. Vertical locking pins: Locking pins may be reused provided they do not show signs of significant wear, damage or distortion. Points: If you are going to install new points, make sure the rubber lock is installed so the arrows embossed on the surface of the lock are pointing forward (toward the tip of the point).

Position the locking pin and drive it in.

Vertical locking pin

Point • •

Install the points onto the adapters. After positioning a point onto its adapter, drive in the vertical locking pin using an 4 kg (8lb) hammer. The rubber lock keeps the Posilok Pin securely in place.

Posilok Pin engages the lock.

Topside and forward •

Drive in the Posilok Pin until it engages the lock. When the Posilok Pin is correctly in place, the rubber lock fits into the slot of the Posilok Pin to secure it.

AH03510

Page 6 of 18 3.

The adapters

3.1

Adapter removal Prior to using an adapter tool be sure that the following safety precautions are followed at all times: • Always wear proper safety equipment including hardhat, gloves, safety glasses and steel-toed shoes. • Never exceed the lifting capacity of the tool. Lifting tool 122K (Part No. 793 503 73) rated capacity 270kg (600lb) - for the S145 tooth system. Lifting tool 112K (Part No. 793 504 73) rated capacity 230kg (500lb) - for the S130 tooth system. • Tool is intended for vertical lift only. • Always stand clear of the raised adapter. • Never allow anyone to work under the adapter until it is secured to the lip by the appropriate locking mechanism. • Always use the safety features (lock and safety pin) as indicated. Never use hand tools or other fastener to secure the sleeve. Never use anything other than the sleeve provided to support the adapter. • Replace the tool when it becomes visibly damaged or distorted. Do not attempt to repair a damaged tool.

• •

Position the bucket with the nose tilted slightly upward. Clean debris from adapter Sidewinder Pin head slot and remove cap from Sidewinder Pin head. (The fastening Sidewinder Pin may become frozen in the nose hole by cemented fines. In this event, use either a hammer and drift or a porta-power, applied directly against the end of the Sidewinder Pin sleeve, to force the Sidewinder Pin out. Use a striking plate, as needed, to avoid hammering the end of the Sidewinder Pin base. With body completely retracted, insert drift that fits inside hex recess and hammer Sidewinder Pin through nose hole. Alternately, drift can be placed against outer sleeve. Avoid hammering over hex recess and thereby peening over the edges of this recess.)

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Page 7 of 18

•

Insert Allen hex bit (14; 17 or 19 mm) into the head of Sidewinder Pin and turn counterclockwise (only for S 95 clockwise) until the Sidewinder Pin body is fully retracted. Do not continue to turn after “stop” is felt. The Sidewinder Pin is designed for operation with a ratchet wrench and should not normally require use of an air-impact wrench.

! •

• For removing the adapter the Sidewinder Pin need not to remove out off the adapter base if it is in good condition. • If the Sidewinder Pin have to be removed the end opposite the hex socket must be removed at first.

Lifting tools (refer to drawing next page): 122K (793 503 73): (for S145)

- Remove the safety pin of the adapter tool and slide the sleeve off the arm. - Guide the arm through the square hole in the nose of the adapter. - Arm must be pointed towards rear of the adapter. - Slide the sleeve onto the arm, align the holes in the arm and sleeve and install safety pin.

112K (793 504 73): (for S130)

- Guide the lug on the end of the arm through the D-shaped hole in the nose of the adapter. - Rotate the arm towards the rear of the adapter until the tool is aligned with the adapter 90° and slide the lock down through the D-shaped hole and insert the safety pin.

AH03510

Page 8 of 18

Part No. 793 503 73 (for S145) Part No. 793 504 73 (for S130) Rotate the arm 90° for fixing

Safety pin of the adapter tool Sleeve •

Using a boom rated at 270 kg (600 lb) or greater (PC5500 and PC8000) or a boom rated at 230 kg (500 lb) or greater (PC4000), hook into the shackle at the top of the arm and remove the adapter.

3.2 Nose rebuild Nose fit: This tooth system is designed to operate with movement of the adapter on the nose. However, movement may become excessive over long term service because of nose wear. In this event, the nose can be rebuilt in the indicated areas with welding and grinding.

3.2.1 Nose end and sides rebuild

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Page 9 of 18

•

Place the nose side template on the centerline of nose. Nose side template Size S 95 S 110 S 130 S 145

• •

Nose Side Template 79350573 79350773 79350973 79400373

Nose Flats Template 79350673 79350873 79351073 79400473

Weld–rebuild nose end surface and grind flat until gage ends align with front edge of pin hole. Weld stringer beads should run parallel to the nose width. Rebuild nose end radii as necessary.

3.2.2 Nose flats rebuild • •

Place the nose flats template over the nose as shown. Weld buildup nose flats and radii and grind flat until template contacts nose end. Nose flat template

3.2.3 Rear corner rebuild • • • •

Weld rebuild rear corners of nose. Chalk or paint weld buildup areas, place adapter as far as possible on nose and then remove. High spots will be indicated by missing chalk or paint. Grind weld buildup areas until a new adapter has a little or no movement up and down. Grind blend smoothly into rear shoulders.

AH03510

Page 10 of 18 3.3

Adapter installation Prior to using an adapter tool be sure that the following safety precautions are followed at all times: • Always wear proper safety equipment including hardhat, gloves, safety glasses and steel-toed shoes. • Never exceed the lifting capacity of the tool. Lifting tool 122K (Part No. 793 503 73) rated capacity 270kg (600lb) - for the S145 tooth system. Lifting tool 112K (Part No. 793 504 73) rated capacity 230kg (500lb) - for the S130 tooth system. • Tool is intended for vertical lift only. • Always stand clear of the raised adapter. • Never allow anyone to work under the adapter until it is secured to the lip by the appropriate locking mechanism. • Always use the safety features (lock and safety pin) as indicated. Never use hand tools or other fastener to secure the sleeve. Never use anything other than the sleeve provided to support the adapter. • Replace the tool when it becomes visibly damaged or distorted. Do not attempt to repair a damaged tool.

•

The Sidewinder Pin must be fully retracted in the adapter base. Sidewinder Pin can be inserted from either side of base. Recommend corner positions be installed from inside.

•

Position the bucket with the nose tilted slightly upward.

•

Use a lifting tool and a lifting boom for the movement of the adapter as described in section 3.1. Test lift the adapter to check for satisfactory adapter tilt angle.

!

• The adapter should tilt downwards at the rear for easy installation onto the nose.

•

Lower the adapter and reposition the shackle as needed to achieve appropriate tilt angle.

•

Lift the adapter and slide it onto the nose. With the lifting boom still holding the adapter, install the adapter locking pin:

!

• For applications where soil fines pack and harden, it is recommended that the outer sleeve of the pin be covered in grease.

AH03510

Page 11 of 18

•

Using hex bit and socket drive, turn hex socket end of Sidewinder Pin clockwise to extend the pin into the pin hole in the opposite side of the adapter. Tighten to the specified torque value shown below. Size S 95 S 110 S 130 S 145

•

3.4

Allen type wrench size 14 mm 17 mm 19 mm 19 mm

Recommended pin torque 160-200 Nm (120-150ft-lb) 200-260 Nm (150-190ft-lb) 260-390 Nm (190-290 ft-lb) 260-390 Nm (190-290 ft-lb)

Insert the Sidewinder Pin cap to prevent the pin hex socket from filling with soil fines. Cap should snap into place. Retighten Sidewinder Pin

Retighten the Sidewinder Pin every 600 to 1200 hours of operating service depending on the severity of application.

!

• Some loosening of pin ½ - ¾ turns is normal. It is not necessary to keep it tightened to the recommended torque.

4. Wear Caps 4.1 Lock style wear caps (PC4000) 4.1.1 Removal • •

•

Clean debris from the gaps around the wearcap lock. Do not strike corners or edges with hammer! Rotate Lock : Use a drift and a 2-4 kg/4-8 lb hammer to rotate the lock to the unlocked position.

It may be necessary to partially rotate the lock in both directions to break loose soil fines, before fully rotating it.

!

• Lock must be rotated completely (180 degrees) to release the wearcap. • Lock can rotate either way.

AH03510

Page 12 of 18

Remove Wearcap: Slide wearcap out of adapter slots. Use appropriate lifting devices to support and remove wearcap. It may be necessary to place a pry bar between the adapter and the rear inside face of the wearcap to lift and free it from soil fines.

4.1.2 Installation

!

• Wearcap tabs, adapter tab slots, and lock recesses must be thoroughly cleaned. Inspect all components for damage. Replace any damaged parts.

•

Position Wearcap Lock First place the lock flat side down against the inside of the wearcap, adjacent to the lock opening. Slide it toward the wearcap lug. One of the lock shafts will enter the hole in the lug. Push the lock up tight against the lug. Then, using a drift placed in one of the lock pockets, tap the drift with a hammer to cause the lock to rotate halfway around, until the flat side of the lock is facing you and is lined up with the inside face of the wearcap.

•

Wearcap Installation Place the wearcap on the adapter. The tabs on the inside of the wearcap fit into the tab slots in the adapter.

•

Lock Wearcap Use an suitable tool and hammer to rotate the lock to the locked position. If lock resists rotation, this indicates more cleaning of the adapter slots is required. When flat is facing out, the lock is in a locked position.

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Page 13 of 18

4.2

Non lock style wear caps (Option PC4000; PC5500; PC8000)

!

• For using of these kind of wear caps special points and special adapters are required.

4.2.1 Removal • •

Drive out the point pin and remove the point. Slide the worn wearcap off the adapter.

!

• If soil packs tightly between the wearcap and the adapter, it may be necessary to strike the flat sides of the wearcap several times with a hammer, to loosen it for removal. • Do not strike corners or edges with hammer!

4.2.2 Installation • • •

Inspect all components for damage. Replace any damaged parts. Slide wearcaps onto the adapter top and bottom surfaces, so that the wearcap rear central and two forward side tabs insert fully into the respective slots of the adapter. Install and pin the point.

AH03510

Page 14 of 18 5. 5.1

The Shrouds Removal the shrouds

The Toplok shroud system is engineered to make change-out easy. Before following these simple steps shown to the Figures, it’s important to clean fines from pin area by tapping the shroud to loosen them, then scraping them using a chisel or needle gun (if fines are heavily packed). • •

Use a small bar with flat end (19 mm wide maximum) to retract the latch and lift the pin out. Pins can be reused if not worn below the locator flange and the insert latch rubber is fully bonded to the steel tip and fully seated in the pin body.

Place a pry bar or pinch bar behind the latch as shown, as a lever to compress it.

!

Lift out and remove the lock. Slide the shroud off the lip base.

• In severe applications assist removal by inserting a pry bar under the lock from the rear of the shroud and lifting up the latch end of the pin while prying as shown.

AH03510

Page 15 of 18

5.2 Installing the shroud 5.2.1 Prepare the surface In order to provide sufficient support for the boss as well as its pin, the mounting surface must: • Be relatively smooth and free of debris, weld spatter, and other irregularities. • Have a profile that produces a gap no greater than 3 mm or 1/16" at the boss weld. Any gap greater than 3 mm or 1/16" must be shimmed. Checking the Fit Pad Areas • • • •

The fit pad surface (1) & (2) should be perpendicular to each other. Make sure 70% of the fit pad surfaces (1) & (2) are in contact with the gauge. After achieving this, the fit pad surface (3) should be checked. Use a straight edge to help check the surface consistency.

Plate lips (PC4000)

Cast lips (PC5500 and PC8000)

Templates Part numbers for checking and preparation the lips Type of Excavator PC4000 PC5500 PC8000

Shovel Version Lip Shroud Template 654 547 40 654 548 40 794 005 73 655 867 40 or 907 281 40 907 006 40

794 007 73

Backhoe Lip Shroud 654 627 40 654 628 40 654 629 40 655 867 40

Version Template

794 008 73

907 448 40 On request

794 006 73 794 007 73

AH03510

Page 16 of 18

5.2.2 Position the bosses Checking the Boss Position To insure the boss is located correctly, the gap between the gauge and the boss rails should not exceed 1mm/.04in. If the gap exceeds 1mm/.04in.,the boss has to be removed and a new boss installed (see below). The back of the boss should line up with the back of the gauge rail. If the boss does not line up with the back of the gauge rail, then two repair options are possible: • (A) If the gap does not exceed 1.5mm/.06in., build up the back of the boss; or • (B) Weld build the leading edge fit pad (2). This may result in the ramp fit pad (3) also requiring weld build up.

Weld Rebuilding Fit Pads When weld rebuilding fit pads ensure the weld surface is clean and free of any contamination that might prevent a good weld. Follow the preheat, interpass and post heat guidelines below. Summary of Welding Specifications • Electrodes: E7016 or E7018 low hydrogen (keep dry!) • Wires: E70T-5, E71T-1, or E70T-1 with CO 2 gas. • Preheat: 200°F/95°C (350-400°F/175-205°C if air temperature is 40°F/5°C or lower.) • Interpass: Maintain interpass temperature less than 500°F/260°C. • Postheat: If air temperature is 40°F or lower, postheat 350-400°F, then let air cool. • Remove slag after each pass and peen each bead. New Boss installation • Set the boss onto the gauge rails and locate the back of the boss with the back of the gauge rails. If no gauge is available, use a new shroud to locate the boss. • Move the gauge onto the lip, making sure the gauge is centered between the nose bases and the gauge is in contact with fit pad surfaces (1) & (2). • Practice has shown, that the boss will suck down 1/16" during welding. To equalize this use a 1/16" shim under the boss, even if there is no gap between the fit pad (1) and the boss. This will ensure the boss height is correct after welding. • If there is a gap between the fit pad surface (1) and the boss, use a thicker shim accordingly.

AH03510

Page 17 of 18 5.2.3 Welding the bosses The weld surface must be clean and free of any contamination that might prevent a good weld. Follow the preheat interweld and post heat guidelines below. Summary of Welding Specifications • Electrodes: E7016 or E7018 low hydrogen (keep dry!) • Wires: E70T-5, E71T-1, or E70T-1 with CO 2 gas. • Preheat: 200°F/95°C (350-400°F/175-205°C if air temperature is 40°F/5°C or lower.) • Interpass: Maintain interpass temperature less than 500°F/260°C. • Postheat: If air temperature is 40°F or lower, postheat 350-400°F, then let air cool. • Remove slag after each pass and peen each bead. Weld the boss to the lip. Make sure that the boss is shimmed, so that the height of the boss will be correct after welding. Weld area (A) completely before welding areas (B) & (C). Welding Guide Weld Location Boss TAB TBB TCB

(A) Depth of weld plug holes mm/in Plug Weld 10/.38 Plug Weld 13/.50 Plug Weld 16/.62

(B) Size of fillet weld-on ends mm/in Fillet 10/.38 Fillet 13/.50 Fillet 13/.50

(C) Size of fillet weld-on ends mm/in Fillet 3/.19 Fillet 6/.25 Fillet 6/.25

5.3 Inspecting Worn Shrouds Toplok shrouds protect the bucket lip and wings from abrasive wear. Use of ESCO 12S abrasion resistant alloy assures long life before change out. • Periodic inspection should be made to determine when to replace a shroud. • Monitor high wear surfaces of the Toplok shroud for wear. • Special “wear indicators” are special panels that will open up to alert the user of the need for changing shrouds.

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Page 18 of 18

5.4

Installing

Installing the shroud •

Slide the shroud over the lip and boss to install the pin. If installing a new shroud, the pin must have contact with the back of the boss and with the back of the shroud without losing contact at the leading edge.

Installing the pin •

Position the pin in the shroud cavity as shown.

•

A light blow with a hammer will engage the pin.

•

The shroud is now securely attached.

AH03510


COMPONENT CODE:

J1

REF NO.

AH03511

DATE

14th April 2003 Page 1 of 2

SUBJECT:

Pilot Pressure Pump Part No. 907 209 40

PURPOSE:

Good flange connection between main pump and gear pump

APPLICATION:

PC5500

FAILURE CODE:

J100Z9

DESCRIPTION: 1. Control all new pumps before installing. 2. If necessary remachine chamfer that the face of the gear pump fit very well to the main pump. 3. Install this new pump with surface sealing agent “Loctite 510” (Part No. 461 543 40).

AH03511

Page 2 of 2 1.

Remachine this chamfer 2.

AH03511

COMPONENT CODE:

J1

REF NO.

AH03512


DATE

14th April 2003 Page 1 of 1

SUBJECT:

Gear pumps (Part Nos. 907 209 40; 906 442 40; 896 730 40 and 654 930 40)

PURPOSE:

Seal the flange connection

APPLICATION:

H 255; H 455; PC3000; PC4000; PC5500; PC8000

FAILURE CODE:

J100Z9

DESCRIPTION: At replacement of the above mentioned gear pumps the flange of the new pump has to seal additional with surface sealing agent “Loctite 510”. The Part No. of “Loctite 510” is 461 543 40.

AH03512


COMPONENT CODE:

46

REF NO.

AH04518a

DATE

June 29, 2005 Page 1 of 2

This PARTS & SERVICE NEWS supersedes the previous issue AH04518 which should be discarded. SUBJECT: Welding procedure for welded counterweight PURPOSE:

Emphasize the importance of expelling the accumulate gases from the counterweight chambers before welding

APPLICATION:

H 255; PC3000; PC5500(SN15011 and up); PC4000; PC8000(SN12037 and up)

FAILURE CODE:

4621Z9

DESCRIPTION:

ã

• Avoid injury or death! • Do not perform welding operation before expelling the accumulated gases from the counterweight chambers! • The gases may explode!

The welded counterweights are filled with a mixture of iron ore and breech blocks. They are not fully filled. It is possible that in the separate chambers explosive gases have collected. There is a risk of explosion during welding, grinding, cutting and drilling without coolant.

The following outlines the proper gas expelling procedure from counterweight (Illustrations 1 and 2) 1. Counterweights with a thread connection point(1): Connect a hose to this point and blow compressed air toward the inside. At these counterweights all chambers are connected to each other. 2. Counterweights without thread connection point: Make the holes (2) larger by means of a 10 mm drill. Blow out carefully all chambers separately through the holes (2).

AH04518a

Page 2 of 2

(1)

(2)

Illustration 2 AH04518a

COMPONENT CODE:

6A

REF NO.

AH05501a


DATE

September 15, 2006 Page 1 of 1


Abnormal vibration on hydraulic pipes

PURPOSE:

Reduction of stress on the pipes

APPLICATION:

All types

FAILURE CODE:

6A00GB

DESCRIPTION: To reduce the stress on hydraulic pipes and the flange bolts install a pair* of metal half clamps (weight approx. 5 kg). Start in the middle of the line and check the effect by laying on a hand. Try to optimize the effect by shifting the clamps. Mark the optimal position. *if required two pairs of half clamps can be used Description

Pipe 50x6 (PN)

Pipe 65x8 (PN)

Modification kit (assy.)

938 578 40

938 581 40

AH05501a


COMPONENT CODE:

K1

REF NO.

AH05510

DATE

February 16, 2005 Page 1 of 1

SUBJECT:

Bearing flushing of the A4VS variable displacement axial piston pump

PURPOSE:

Activate the external flushing of bearing by mounting a new pump

APPLICATION:

PC4000 (SN08151 up); PC5500 (SN15011 up); H 455S (SN15007; 15009); PC8000 (SN12037 up); H685SP (SN12020; 12030)

FAILURE CODE:

K100FA

DESCRIPTION: The installed main pumps are provided with an external cooling and lubrication system for flushing of drive shaft bearing and shaft seal. Oil supply is provided from the X4-pressure circuit. To direct the external cooling oil to the bearing and shaft seal it is necessary to turn in the throttle screw all the way. Observe also the information plate fixed at the pump.

Drawing and photos as example

AH05510

COMPONENT CODE:

30

REF NO.

AH05511


DATE

March 23, 2005 Page 1 of 4

This PARTS & SERVICE NEWS supersedes the previous issue No. 21-558 which should be discarded. SUBJECT:

Dual cone seal ring mounting

PURPOSE:

Mounting hints

APPLICATION:

all types

FAILURE CODE:

3047AA

DESCRIPTION: Leaky dual cone seal rings must be replaced, in order to prevent damages through "dry running". Dual cone seals have also to be replaced in case of component repairs. Dual cone seals are precision parts made from chilled cast iron. Therefore, sharp knocks and blows should be avoided. The correct way to install dual cone seals is as follows: • Only remove the seal (1) from its original wrapping just before installing. This protects the super - finished seal faces (2) from damage and contamination. • Seal housing (3) must be free of dirt and machining residues; all edges in the housing bore must be rounded. • The illustration shows the preloaded seal (1). • Install the face seal by means of the assembly tool (4). Pressure is applied directly via the O-ring (5). • For easier assembly, moisten the housing bore and O-rings with spirit (no oil or grease!). • Order number for assembly tool (4), refer to the table on page 2. For the machining dimensions of the assembly tool, refer to the illustration and Fig. on page 3. • The illustration shows the dual cone seal (1) before mounting it with tool (4) into housing (3).

AH05511

Page 2 of 4 • Press the seal ring (1) with the special tool like a push button into the housing (3). Take care that afterwards the housing surface (6) lies parallel to the seal face (2). The O-ring (1) must not sit wave-like in the housing bore or bulge partially looped out of the bore. C = correct W = wrong

• Before the seal rings (1) are clamped to the installation dimensions, apply a thin grease or oil film to the seal faces (2), preferably with a soaked chamois leather cloth. Fig. 1 2 3 4 5 6

Description Seal ring Seal face Seal housing Tool O – ring Housing surface

Table for selection of the assembly tool (other tools on inquiry) Part No. Dual Cone Seal 145 800 40 180 472 40 180 624 40 202 986 40 226 424 40 226 425 40 255 058 40 269 454 40 270 460 40

Order-No. Assembly tool 766 311 73 766 308 73 766 312 73 766 315 73 766 322 73 766 317 73 766 314 73 766 312 73 766 316 73

Part No. Dual Cone Seal 323 823 40 324 067 40 461 627 40 461 628 40 696 523 73 696 525 73 804 595 73 963 754

Order-No. Assembly tool 766 323 73 766 309 73 766 318 73 766 307 73 766 310 73 766 311 73 766 313 73 766 321 73

AH05511

Page 3 of 4 Assembly tool (locally made) The assembly tool consists of two half-shells that are closed around the seal ring. The two halves are joined by a hinge. Step (d) grips between the O-ring (5) and the land of the seal ring. The pressure required to insert the seal is then applied directly via the O-ring (5). Measure dimension "b" at the dual cone seal. Determine the machining dimensions "a", "b", "c" and "d" according to this measured dimension in the chart. The dimension "X" can be chosen freely.

∅b mm 95 99 104 110 111 112 121 127 126 139 142 141,5 143 146 157 162 175 159 174,5 177 169 172,5 169 171 170 176 182 194

∅a mm 100 107 118 115 118 120 128 131 134 148 150 149 150 153 163 169 182 166 181,5 185 176 180 175 177 176 183 190 201

∅c mm 89,5 92,5 98 104 105 107 115 121 120 133 135 133 137 137,7 150,5 155 169 153,5 162 168 161 166,5 165 168 165 167,5 177 182,5

d mm 1,8 3,5 3 2,5 4 3 4 3,5 3 3 4 3 4 4 4 3 4,5 3 4 4 2,8 3,5 2 2,5 4 3,5 3 4

∅b mm 191 200 202 213 217 231 229,5 242 254 270,5 282,8 295,5 326 343,5 348 377,5 397 418 458 503 536,5 563 593 611 703 626 753 890

∅a mm 198 208 209 220 225 238 236,5 249 261 279 292 302,5 334 350,5 357 384,5 407 426 468 518 545 578 608 620 710 642 768 898

∅c mm 185 192 196 201 210 220 220,5 232 242,5 258,5 269 282 321 335 342 369 385 410 446 495 528,4 555 585 603 694 618 745 878

d mm 4 4 4 4 4 4 4 4 4 4 4 4 4 4 7 4 4 5 4 7 5 7 7 5 5 7 7 10

AH05511

Page 4 of 4

Assembly tools for mounting of dual cone seal

AH05511

COMPONENT CODE:

J1

REF NO.

AH05520a


DATE

March 17, 2006 Page 1 of 3

This PARTS & SERVICE NEWS supersedes the previous issue No. AH05520 which should be discarded. SUBJECT:

Installation hints for a new type of gear pump (Pilot pump)

PURPOSE:

Product improvement: Old designs: PN 634 121 40; PN 634 122 40; PN 907 209 40; PN 907 608 40 New design: PN 907 622 40

APPLICATION:

H 455S (#15003 to 15009); PC5500 (# 15011 to 15024)

FAILURE CODE:

J100FA

DESCRIPTION: Modification Kit PN 793 749 73 (refer to Illustrations 1 and 2) Valid for old pumps PN 634 121 40 and PN 634 122 40 Pos.

Part No.

Qty.

Description

01

886 218 40

1

Reduction flange

02

385 243 40

1

Flange seal

03

319 272 99

4

Bolt M12 x 30

04

515 812 98

1

Coupling

05

356 209 40

1

Flange seal

06*

319 272 99

4

Bolt M12 x 30

07*

515 658 40

2

Half flange

08*

356 210 40

1

Quad ring

* Positions 06; 07 and 08 will be used for replacing the old pumps PN 907 209 40 and PN 907 608 40 • Close the main gate valve between hydraulic oil tank and suction tank. • Drain the suction tank. (Use the transfusing pump if so equipped). • Remove all lines from the old gear pump. • Replace this pump (illustration 1)**. • Reinstall the suction line as showed on next page (illustration 2). • Reinstall the pressure line (illustration 3). • Open the main gate valve. • Install the coupling (04). • Bleed the hydraulic pump (refer to Service Bulletin AH01513). • Start the engine and let it run for 15 minutes in low idle for bleeding the lines. • Check the hydraulic oil level at the tank. ** For installation of the new pump refer to the next page. AH05520a

Page 2 of 3 Installation the new pump (PN 907 622 40)

Illustration 1 • • •

Remove the two hexagon bolts (2) and the flange (1) from the new pump. Install the flange (1) by using of the four cylinder head bolts (3) (M12 - 70Nm) at the big main pump. Install the new gear pump by using of the two bolts (2) (M12 – 70 Nm) at the flange (1).

AH05520a

Page 3 of 3

Illustration 2

Illustration 3

AH05520a

COMPONENT CODE:

K1

REF NO.

AH05525


DATE


SUBJECT:

Suction elbows of the Main Pumps

PURPOSE:

Hints for sealing

APPLICATION:

PC3000-1; PC4000-6 (to # 08156) PC5500 (to # 15019); PC8000 (to # 12042)

FAILURE CODE:

K1T3AA

DESCRIPTION:

1. 2.

PC3000-1 PC4000; PC5500; PC8000

AH05525

Page 2 of 3 1. PC3000-1 1 2 3 4

Seal Intake Remachining surface Bolt

Illustration 1 as example

• •

In case of leakiness disassemble the suction elbow (2) and remachine the sealing surface (3). Then reassemble the suction elbow (2) by using a new seal (1).

)

• • • •

Install the 4 bolts (4) crosswise and evenly. Final torque: maximum 179 Nm! Replace the intake (2) by a new one if necessary. Check the surface (3) for evenness also of the new intake (2) before installing. Even it out if necessary.

AH05525

Page 3 of 3 2. PC4000; PC5500; PC8000 •

Type PC4000-6 PC5500-6

PC8000-6

In case of leakiness replace the old suction elbow (2) by a new one with an other sealing system (1)(O-ring). Intake (old)

Intake (new)

O - ring

891 451 40

928 335 40

517 582 98

624 085 40

928 706 40

517 582 98

624 085 40

928 706 40

517 582 98

894 317 40

928 287 40

517 582 98

894 321 40

928 285 40

517 582 98

894 322 40

928 288 40

517 582 98

894 323 40

928 289 40

517 582 98

624 085 40

928 706 40

517 582 98

• Screw in the 4 bolts (4) crosswise and evenly. • Final torque: maximum 179 Nm!

Illustration 2 as example AH05525


COMPONENT CODE:

26

REF NO.

AH05535c

DATE

May 21, 2007 Page 1 of 22

This PARTS & SERVICE NEWS supersedes the previous issue AH05535b which should be discarded. SUBJECT:

Hints for replacing by the slewing gear of an other manufacturer

PURPOSE:

Revision

APPLICATION:

PC3000 (#06193 and up); PC4000 (#08152 and up); PC5500 (#15018 and up); PC8000 (#12041 and up)

FAILURE CODE:

2600CA

DESCRIPTION: • New swing gears will be delivered without gear oil. • After replacing the swing gear, fill in oil according to the Maintenance Manual. REMARK The machines can be equipped either with a swing machinery of manufacturer "L&S" Part No. 926 795 40 or of manufacturer "Siebenhaar" Part No. 925 864 40 or 936 560 40. Refer to the data plate on each swing machinery housing to find out the manufacturer of the swing machinery. Both swing gears are replaceable by using of a special modification kit. Lubricants

Filling Capacities (liters)

AH05535b

Page 2 of 22

1.

Description (general)

2.

Overview 2.1 Swing Machinery manufactured by "L&S" 2.2 Swing machinery manufactured by “Siebenhaaar”

3.

Modification kits 3.1 Modification kit PC3000-6 3.1.1

Replacing “L+S” gear to “Siebenhaar” gear

3.1.2

Replacing “Siebenhaar” gear to “L+S” gear

3.2 Modification kit PC4000-6 3.2.1


3.2.2




3.3.2




3.4.2


AH05535b

Page 3 of 22 1.

Description (general)

1. Remove the bolts at the hydraulic motor. 2. Remove the motor with connected hoses and place it beside or if this it not possible, disconnect the hydraulic lines and block the ports. 3. Disconnect the lubrication lines below the gearbox. 4. Remove all fastening bolts from the gearbox. 5. Install 2 eye bolts to lift the gearbox assy. 6. Remove the gearbox from the superstructure frame. 7. Clean the flange area at the superstructure free of grease, oil, dust and paint. 8. Insert the new gearbox and mount it with the new bolts and the washers to the superstructure 9. Cover the bolt heads with plugs. 10. Swap the drain valves and the breather filters from the old to the new gearbox. 11. Remove the cover below the gearbox and connect the lubrication lines. 12. Reinstall the cover with bolts. 13. Reinstall the motor with bolts. 14. Reconnect all hydraulic lines. 15. Fill in oil to the max. oil level markings*. 16. Install the cover plates (PC3000; PC4000).

* "L&S" gear (Part No. 926 795 40) 2 oil chambers: (gear housing; motor adapter housing); "Siebenhaar" (Part No. 925 864 40 or 936 560 40) Three oil chambers: (gear housing; motor adapter housing, brake housing)

AH05535b

Page 4 of 22 2.

Overview

2.1

Swing Machinery manufactured by "L&S"

Legend for illustration 1 Swing gears (1) Oil level gauge (2) Oil filler plug (3) Breather filter (10) Drain couplings or evacuation nozzles for Wiggins system Motor Adapter Housing (4) Oil level gauge and filler opening. (5) Breather filter (6) Oil drain plug

Illustration 1

AH05535b

Page 5 of 22 2.2

Swing machinery manufactured by “Siebenhaaar”

Legend for illustration 2 (1) Swing machinery (2) Brake housing (3) Compensator oil tank for swing machinery (4) Oil level gauge for swing machinery (5) Oil drain plug for motor adapter housing (6) Oil level gauge for motor adapter housing (7) Breather filter for brake housing (8) Oil level gauge for brake housing (9) Oil drain plug for brake housing (10) Breather filter (11) Drain coupling or evacuation nozzle for Wiggins system

For avoiding overheating of the disks inside the brake a correct adjustment of the brake oil level (8) is necessary.

)

• Too high oil level reduces the life time of the brake.

AH05535b

Page 6 of 22 Swing machinery manufactured by “Siebenhaaar”

Illustration 2

AH05535b

Page 7 of 22 3.

Modification kits

3.1

Modification kit PC3000-6

3.1.1 Replacing “L+S” gear to “Siebenhaar” gear (PC3000-6; illustration 3) Modification Kit: PN 794 853 73 Pos.

Part No.

Qty.

Description

10

323 460 40

1

Bleeder valve

11

517 676 98

34

Bolt

12

516 920 98

34

Washer

15

507 037 98

2

Nut

16

340 465 99

2

Washer

22

907 142 40

34

Plug

30

307 824 99

2

Bolt

31

374 428 99

1

Union

32

517 905 98

1

Hose assy.

33

500 141 98

2

Union

34

372 174 99

1

Union

35

334 601 99

2

Nut

36

340 469 99

2

Washer

37

0443452511

1

Clip

38

340 467 99

2

Washer

AH05535b

Page 8 of 22


Page 9 of 22 3.1.2 Replacing “Siebenhaar” gear to “L+S” gear (PC3000-6; illustration 4) Modification Kit: PN 794 867 73 Pos.

Part No.

Qty.

Description

10

323 460 40

2

Bleeder valve

11

517 013 98

34

Bolt

20

872 200 40

1

Union

30

925 833 40

1

Pipe

31

517 489 98

1

Socket

32

906 868 40

1

Olive

33

371 264 99

1

Union nut

34

517 490 98

1

Union

35

907 568 40

1

Dipstick

36

921 815 40

1

Cover

37

319 159 99

7

Bolt

38

504 149 98

7

Washer

39

517 073 98

2

Union

40

371 273 99

2

Union nut

41

906 346 40

4

Olive

42

215 627 99

1

Pipe 400 mm

43

517 074 98

1

Union

44

371 258 99

2

Union nut

45

907 228 40

1

Union

AH05535b

Page 10 of 22


Page 11 of 22 3.2



Part No.

Qty.

Description

11

515 791 98

34

Bolt

12

516 920 98

34

Washer

15

374 428 99

1

Union

16

507 037 98

10

Nut

17

512 545 98

10

Washer

18

507 488 98

10

Pin bolt

19

506 129 98

10

Washer

20

904 613 40

1

Cover plate rear r.h.

21

904 618 40

1

Cover plate front r.h.

22

904 614 40

1

Cover plate rear l.h.

23

904 617 40

1

Cover plate front r.h.

24

307 827 99

2

Bolt

26

907 142 40

34

Plug

27

914 777 40

1

Pinion cover l.h.

28

914 775 40

1

Pinion cover r.h.

29

510 213 98

2

Thread pin

30

340 112 99

2

Washer

31

512 545 98

2

Washer

32

334 600 99

2

Nut

AH05535b

Page 12 of 22


Page 13 of 22 3.2.2 Replacing “Siebenhaar” gear to “L+S” gear (PC4000-6; illustration 6) Modification Kit: PN 794 869 73 Pos.

Part No.

Qty.

Description

15

872 200 40

1

Union

20

922 584 40

1

Cover plate

21

922 583 40

1

Cover plate

22

922 586 40

1

Cover plate

23

922 587 40

1

Cover plate

25

516 919 98

34

Bolt

28

921 815 40

1

Cover

29

319 159 99

7

Bolt

30

517 073 98

2

Union

31

371 273 99

2

Union nut

32

906 346 40

2

Olive

33

215 627 99

1

Pipe 400 mm

34

517 074 98

1

Union

35

371 258 99

2

Union nut

36

906 346 40

2

Olive

37

907 228 40

1

Union

38

371 257 99

1

Union nut

39

907 080 40

1

Olive

40

922 580 40

1

Cover

41

922 587 40

1

Cover

42

517 489 98

1

Socket

43

517 490 98

1

Union

44

906 868 40

1

Olive

45

371 264 99

1

Union nut

46

215 787 99

1

Pipe 400 mm

47

907 569 40

1

Dipstick

49

399 907 99

1

Seal ring

AH05535b

Page 14 of 22

Illustration 6

AH05535b

Page 15 of 22 3.3



Part No.

Qty.

Description

10

323 460 40

2

Bleeder valve

12

307 827 99

2

Screw

15

339 907 99

2

Seal ring

24

516 920 98

34

Washer

25

517 612 98

34

Bolt

26

907 142 40

34

Plug

AH05535b

Page 16 of 22


Page 17 of 22 3.3.2 Replacing “Siebenhaar” gear to “L+S” gear (PC5500-6; Illustration 8) Modification Kit: PN 794 871 73 Pos.

Part No.

Qty.

Description

17

921 815 40

1

Cover

18

907 131 40

1

Union

19

214 140 99

1

Pipe 85 mm

20

374 460 99

1

Socket

21

872 200 40

1

Union

22

371 279 99

2

Union nut

23

906 979 40

2

Olive

24

516 929 98

34

Washer

25

517 889 98

34

Bolt

26

907 142 40

34

Plug

27

907 228 40

1

Union

28

517 074 98

1

Union

29

371 258 99

2

Union nut

30

907 227 40

4

Olive

31

517 073 98

2

Union

32

371 273 99

2

Union nut

34

215 627 99

1

Pipe 200mm

35

319 159 99

7

Bolt

36

504 149 98

7

Washer

50

517 489 98

1

Socket

51

517 490 98

1

Union

52

906 868 40

1

Olive

53

371 264 99

1

Union nut

54

215 787 99

1

Pipe 400 mm

55

907 569 40

1

Dipstick

AH05535b

Page 18 of 22


Page 19 of 22 3.4 Modification kit PC8000-6 3.4.1 Replacing “L+S” gear to “Siebenhaar” gear (PC8000-6; illustration 9) Modification Kit: PN 794 872 73 Pos.

Part No.

Qty.

Description

2

904 613 40

1

Cover plate r.h.

3

904 618 40

1

Cover plate l.h.

7

517 612 98

34

Bolt

8

516 920 98

34

Washer

9

907 142 40

34

Plug

10

323 460 40

3

Bleeder valve

12

307 827 99

2

Bolt

13

374 428 99

1

Union

AH05535b

Page 20 of 22


Page 21 of 22 3.4.2 Replacing “Siebenhaar” gear to “L+S” gear Modification Kit: PN 794 873 73 Pos.

Part No.

Qty.

Description

2

898 288 40

1

Cover plate

3

914 737 40

1

Cover plate

7

374 460 99

1

Screwed socket

8

371 279 99

2

Union nut

9

906 979 40

2

Olive

10

914 736 40

1

Pipe 85 mm

11

907 131 40

1

Union

12

921 815 40

1

Cover

13

319 159 99

7

Bolt

14

907 569 40

1

Dipstick

15

906 868 40

1

Olive

16

371 264 99

1

Union nut

17

925 830 40

1

Pipe 350 mm

19

517 489 98

1

Socket

20

517 490 98

1

Union

22

872 200 40

1

Union

23

516 919 98

34

Bolt

26

517 073 98

2

Union

27

371 273 99

2

Union nut

28

906 346 40

4

Olive

29

215 627 99

1

Pipe 200 mm

30

907 228 40

1

Union

31

517 074 98

1

Union

32

371 258 99

2

Union nut

AH05535b

Page 22 of 22


COMPONENT CODE:

8D

REF NO.

AH05546


DATE

December 6, 2005 Page 1 of 2

SUBJECT:

Automatic lubrication system - Vent valve (PN 769 879 73)

PURPOSE:

Hints for trouble shooting

APPLICATION:

All types with “Lincoln” Lubrication System

FAILURE CODE:

8D00ME

DESCRIPTION:

Manual actuation (Vent valve: PN 769 879 73)

FUNCTION: The solenoid gets energized when the lubrication starts. The connection from A to B gets closed, thus a pressure build-up is possible. The solenoid gets de-energized, as soon as the lubrication cycle is finished. This causes opening of the connection A to B, thus the supply line to the lubricant barrel is open. The lubricant flows from A to B. TASK (Refer to illustration next page): By the function of the vent valve (7) the lubricant supply line gets pressure released, after the lubrication cycle is finished. The injector pistons can move into their initial position.

AH05546

Page 2 of 2

Troubleshooting: The solenoid valve (7) sometimes is blocked by dirt and causing that the pumping pressure will be not built correctly due to bypassed pressure back to grease barrel. On the monitor in the operators cab any failure in lubrication system will be indicated.

Manual actuation

To make easy troubleshooting the 2/2 – Directional valve (7) is equipped with the possibility of manual actuation. The valve had a push button on the top to verify whether the electric problem or the vent valve itself causing the lubrication pressure bypassed. For manual actuating of the valve (7) push down the pin on top of the valve e.g. with a screwdriver.

AH05546

COMPONENT CODE:


REF NO. DATE

AH06524 September 6, 2006 Page 1 of 2

This PARTS & SERVICE NEWS supersedes the previous issue 21 – 199b which should be discarded. SUBJET:

Hydraulic cylinder

PURPOSE:

Hints for bleeding

APPLICATION:

All types

FAILURE CODE:

H100BJ

DESCRIPTION: To avoid damages to the hydraulic system caused by air in the cylinders, a bleeding procedure has to be carried out after each opening or cylinder exchange. • Read the safety instruction in the Operation and Maintenance Manual carefully, before starting any work on the excavator.

1. Standard procedure for bleeding of hydraulic cylinder 1. Run the engine at low idle. PC5500 and PC8000: Start for the bleeding procedure only one engine. Electric driven excavators: Set the service switch S155 (X2 – main board) to position “2” for “QMIN” control of the main pumps. 2. Extend and retract each cylinder 4 or 5 times without going to the end of its stroke (stop approx. 100 mm before the end of the stroke). At first there can be a large amount of air inside the cylinders, so the cylinder may not move for the first ten seconds. In such cases, do not operate the joy stick to the end of its travel. Be carefully! 3. Keep the engine running at low idle/or QMIN* and operate each cylinder from a point 100 mm from the end of its stroke slowly (take at least 10 seconds) to the end of its stroke (fully extended) and hold the work equipment joy stick at the full stroke position for 3 minutes.

AH06524

Page 2 of 2 4. Next run the engine at high idle/or QMAX* and operate each cylinder from a point 100 mm from the end of its stroke slowly (take at least 10 seconds) to the end of its stroke (fully extended) and hold the work equipment joy stick at the full stroke position for 1 minutes. 5. Repeat steps 2 – 4 if necessary. 6. Make sure that the switch S155 is set to the “0” position as soon as the bleeding procedure of the hydraulic cylinders is finished.* * Electric driven excavator

• After bleeding the cylinders check oil level in the hydraulic tank according to the Maintenance Manual and add oil if necessary.

AH06524

COMPONENT CODE:

30

REF NO.

AH06529


DATE


SUBJET:

Track group – Hints for sprocket exchange

PURPOSE:

Sprocket exchange in case of normal wear

APPLICATION:

PC5500-6 (#15026 and up)

FAILURE CODE:

3000CA

DESCRIPTION: 1.

Sprocket types 1.1

Standard sprocket

1.2

Oversize sprocket

2.

Removal sprocket

3.

Determination of the Axial Play

4.

Remachining

5.

Radial wear determination

6.

Assembly

7.

Torque Data for Standard Application

AH06529

Page 2 of 7 1.

Sprocket types

1.1 Standard sprocket The standard sprocket has to be used in case of assembling new machine or regenerating the track group in connection with new track pads. 1.2 Oversize sprocket The oversize sprocket has to be used to compensate chain elongation, wear on sprocket diameter and wear in the roller path on track pads, caused by the wear of the chain, if the X-dimension / circular pitch come up to 0.5 mm (refer to Service Bulletin AH02521 latest edition). This retrofitting assures assembly condition of the X – dimension of a new machine, furthermore the service life of the track group will be increased. The oversize sprocket is available without a sprocket hub, if the old one is reuseable. For the part no. of sprockets and the mounting procedure, refer to the following pages, the table below and the part catalogue of your machine. The conversion of the sprockets is time- and cost-intensive, so it is recommended to exchange the final-drive bearings at the same time if the dimensions have reached the wear tolerances, to avoid a standstill of the machine for the final-drive bearing exchange only. Before placing the order, pay attention to Service News AH00515 (latest version) and Parts Catalogue for correct choice of the bush type. Basically, all seals (13, 23, 27, 28 refer to illustration 1) have to be replaced.

)

• The difference between the standard version (NT) and the very low temperature version (TT) are only the bolts. The sprocket and the hub are the same. PC5500

Part number

Standard sprocket with hub

929 320 40

Oversize sprocket with hub

938 778 40

Drive sprocket standard

933 626 40

Drive sprocket oversize

938 777 40

AH06529

Page 3 of 7 2. Removal sprocket • • • • • • • • • •

Remove the drain plug and the filler plug and drain the lubricating oil of the final drive housing (refer to the Maintenance Manual). Suspend travel gear (02) to a crane; remove mounting bolts (31). Remove travel gear by using pulling bolts; put aside. Remove cover (14). Suspend sprocket (01) to a crane and underpin it from below. Pull out drive shaft (06). Remove mounting bolts (12) in flange bearing (08); loosen by using pulling bolts; extract. Extract hollow shaft (32) to cover side (14) and remove it by using the crane or a fork-lift. Lift sprocket (01) out. Remove mounting bolts (12) in flange bearing (25); loosen by using pulling bolts; extract.

Illustration 1 AH06529

Page 4 of 7

Illustration 2

AH06529

Page 5 of 7 3.

Determination of the Axial Play

After removal, all seals have to be renewed. • • • • • • • • • • •

Slide O-ring (26) over flange bearing (6). Mount flange bearing (6) without dual-cone seal (17). Pay attention to the lubrication-grooves position; they have to be displaced by 22.5° to the vertical line. Mount all bolts (61) and tighten according to tightening torques (M30 / 1770Nm). Suspend the sprocket to a crane; insert without dual-cone seals (17). Mount hollow shaft (32) and slide against collar “B”. By this, the sprocket (1) is moved against the collar “A” of the bushing. Mount flange bearing (5) with 3 bolts (61) without dual-cone seal (17). Measure dimension “X”. Slide sprocket (1) to direction “C” until the hollow shaft (32) rests against the collar “D” of the flange bushing. Measure dimension “Y”. The axial play result in X minus Y . Type PC5500-6

4.

Original axial play 0.2 – 0.9 mm

Wear limit 2,75 mm

Remachining

If the amount of axial play exceeds 0.9 mm, area E has to be remachined until the original dimension, is reached. If the amount of axial play is less than 0.2 mm, area F has to be remachined until the original dimension, is reached. •

5.

Suspend sprocket (1) to crane, pull out hollow shaft (32), lift sprocket (1) out.

Radial wear determination

The radial play after installation amounts maximally to 0.77 mm. If the maximum permissible parallel play comes up to 2.0 mm, the bushings have to be changed. For determination of the bushings check the inner diameter (D) several times. If the maximal value reaches 482.7 mm the bushings must be changed.

AH06529

Page 6 of 7

Illustration 3

AH06529

Page 7 of 7 6. • • • • • • • • • • • • • •

Assembly Mount dual-cone seal (17) according to Service Bulletin AH05511 into flange bearing (6). Mount dual-cone seals (17) according to Service Bulletin AH05511 into sprocket. Place sprocket into the side frame by using a crane, align and underpin sprocket in mounting position. Mount hollow shaft (11). Mount dual-cone seal (17) according to Service Bulletin AH05511 into flange bearing (5). Mount flange bearing (5). The lubrication grooves of the bushing (5.2) have to be displaced by 22.5° to the vertical line. Tighten bolts (61) according to the tightening torques (M30 / 1770Nm). Insert O-ring (25) into the cover (7). Mount cover (7) with bolts (21). Tighten bolts (21), according to the tightening torques (M12 / 74Nm). Insert O-ring (27). Suspend travel gear (14) to a crane and mount to side frame. Tighten bolts (59) according to the tightening torques (M36 / 3100Nm). Refill oil and check levels.

) 7.

• When selecting tightening torques, observe size and quality grade of the bolts.

Torque Data for Standard Application

Bolt dia. [mm] M 10 M 12 M 14 M 16 M 18 M 20 M 22 M 24 M 27 M 30 M 33 M 36

Wrench size [mm] 17 19 22 24 27 30 32 36 41 46 50 55

8.8 43/32 74/54.6 118/87 179/132 255/188 360/265 485/358 620/457 920/679 1250/922 1690/1246 2170/1600

Tightening torque Nm/lbs.ft. Quality grades 10.9 63/47 108/80 173/128 265/196 360/265 510/376 690/509 880/649 1310/966 1770/1305 2400/1770 3100/2286

12.9 73/54 127/94 202/149 310/229 425/313 600/443 810/597 1030/760 1530/1128 2080/1534 2800/2065 3600/2655

Insert all bolts lubricated with MPG, KP2K type lubricant.

AH06529

COMPONENT CODE:

32

REF NO.

AH06530


DATE


SUBJET:

Relieving of the track chain tension

PURPOSE:

Hints for working at the crawler unit

APPLICATION:

PC3000; PC4000; PC5500; PC8000

FAILURE CODE:

3200FA

DESCRIPTION:

)

• Read the safety instruction in the Operation and Maintenance Manual carefully, before starting repair works.

For avoiding damages at the travel brakes (4) the following procedure should be used: • Turn the superstructure (90°) and lift the machine. • Shut off the engine. • Open cock (2) for releasing the pressure. • Close cocks (1) and cock (3) if installed. • Close cock (2) (important!). • Now the engine can be started and the sprocket can be turned to the working position. The travel brake is released by pilot pressure.

Illustration as example

AH06530

Page 2 of 2

AH06530

COMPONENT CODE:

K1

REF NO.

AH06542


DATE

October 5, 2006 Page 1 of 2

SUBJECT:

Swash plate pump H-A4VSO500

PURPOSE:

Efficient Performance at an altitude of more than 1000 m above sea level

APPLICATION:

PC5500-6

FAILURE CODE:

K100PB

DESCRIPTION: The H-A4VSO500 is a variable displacement axle piston pump in swash plate design intended for drives in open circuit operation. For efficient performance at an altitude of more than 1000 m above sea level the maximum displacement at one revolution of the pump has to be reduced according to the following table. Vg max (revolutions per min)

Altitude* (m)

Turn in setting screw (3) (revolutions)

Q max (l/min)

Diesel

Electric

Diesel

Electric

Diesel

Electric

0

500

500

735

700

0

0

about 1400

460

483

676

676

1¾

¾

about 2900

418

440

615

615

3½

2½

about 3200

405

426

596

596

4¼

3¼

about 4700

355

373

522

522

6¼

5½

•

For adjustments of other altitudes please contact our Service Department.

)

• All spare part pumps will be delivered with standard adjustment. • When installing these pumps at an altitude of more than 1000 m an alteration according to the table above has to be carried out. • If the excavator is displaced to a mine site above an altitude over 3000 m the engine needs also a corresponding adjustment.

Adjustment 1. Unscrew box nut (1). 2. Loosen the lock nut (2). 3. Turn in the stop bolt (3) with an allen key according to the table above. (The distance “X” has to be reduced.) 4. Tighten the lock (2) nut and screw on box nut (1). AH06542

Page 2 of 2 Illustration 1

AH06542


COMPONENT CODE:

J1

REF NO.

AH06543a

DATE



Gear pumps PN 907 622 40 and PN 940 048 40 (supplied from the company “Kracht”) (Pilot pressure pump; gear oil pump; circulation pump)

PURPOSE:

Increasing of the life time Releasing of a new type of shaft seal rings (Product improvement!)

APPLICATION:

PC5500-6 (PN 15018; 15019, 15022; 15023; 15025;15027; 15032; 15035; 15038, 15040 to 15046; 15048 to 15053, 15055; 15056; 15060; 15062)

FAILURE CODE:

J100AA

DESCRIPTION:

W

• Before carrying out any repairs, read all the safety instructions of the Operation and Maintenance manual of your shovel. • The local safety rules must also be observed.

Please check the strainer (35); it must be clean (illustration 1). Dirt and paint have to be removed. For increasing of the lifetime, a new type of shaft seal (Positions 17 and 32 - PN 793 357 73) was released for the above mentioned pumps. With order of an old shaft seal the new type will be supplied automatically.

AH06543a

Page 2 of 3

35 Illustration 1

Illustration 2

Illustration 3

AH06543a

Page 3 of 3 Installation hints for the shaft seals • Grease the shaft seals inside and outside before installation (illustration 3). • Use mounting sleeves according to illustration 4. • To avoiding of corrosion coat the adapter surface and the pump surface (illustration 2 and 3) with one of the following types of grease before mounting the pump to the adapter: - CASTROL OPTIMOL PASTE WHITE T - STABYL L 120 Do not close the strainer (35) with grease.

Illustation 4 AH06543a

COMPONENT CODE:

H2

REF NO.

AH06545


DATE

November 22, 2006 Page 1 of 3

SUBJECT:

Hydraulic cylinder bushings

PURPOSE:

Installation hints

APPLICATION:

All types

FAILURE CODE:

H2Z6CA

DESCRIPTION:

)

• Pay attention to the position of the lubricating holes and the lubrication grooves when installing new bushes to ensure good lubrication and maximum lifetime. • Install the bushes as shown at the next pages.

AH06545

Page 2 of 3

AH06545

Page 3 of 3

AH06545

COMPONENT CODE:

26

REF NO.

AH07509


DATE

May 29, 2007 Page 1 of 7

SUBJECT:

Swing gear brake manufactured by “Siebenhaar” (Swing gear PN 902 550 40 and PN 925 864 40)

PURPOSE:

Hints for replacement of the brake assy.

APPLICATION:

PC3000; PC4000; PC5500

FAILURE CODE:

2600FA

DESCRIPTION:

Note In case of a brake failure we recommend to rebuild the brake assembly according to the procedure given below. This method allows later a quick and efficient exchange of the complete brake assembly. 1. Modification kits 1.1 Modification kit for swing gear PN 902 550 40 (PC4000-6 #08152; 08153; 08154) 1.2 Modification kit for swing gear PN 925 864 40 2. Modification instructions 2.1 Disassembly 2.2 Assembly 3. Appendix 3.1 Spare Parts Catalogue page 991 – 0737 3.2 Spare parts Catalogue page 991 – 0715

W

• Before carrying out any repairs, read all the safety instructions of the Operation and Maintenance manual of your shovel. • The local safety rules must also observed.

AH07509

Page 2 of 7

AH07509

Page 3 of 7 1. Modification kits 1.1 Modification kit for swing gear PN 902 550 40 (PC4000-6 #08152; 08153; 08154) Pos.

Part No.

Qty.

Description

1

796 050 73

1

Adapter

2

795 836 73

1

Disc brake

3

972 122

1

O - Ring

4

516 354 98

1

O - Ring

5

501 532 98

1

Hexagon head socket pipe plug

6

339 796 99

1

Seal ring

After conversion the following page of Spare Parts catalogue apply: 991 – 0737.

1.2 Modification kit for swing gear PN 925 864 40 Pos.

Part No.

Qty.

Description

1

795 840 73

1

Adapter

2

795 836 73

1

Disc brake

3

972 122

1

O - Ring

4

516 354 98

1

O - Ring

5

501 532 98

1

Hexagon head socket pipe plug

6

339 796 99

1

Seal ring

After conversion the following page of Spare Parts catalogue apply: 991 – 0715.

AH07509

Page 4 of 7

AH07509

Page 5 of 7 2. Modification instructions 2.1 Disassembly 1. 2. 3.

The oil must be drained completely before the modification of the gearbox, in accordance to the Maintenance Manual of the shovel. Take off all oil fittings of the gear to attach them later to the new adapter. Take off all hydraulic pipes from the brake.

W 4. 5. 6. 7. 8. 9.

• Unscrewing or removing of hydraulic pipes under pressure resp. of connections is hazardous. Take care that - in case of works at the brake (mounting, dismounting) -the brake and the belonging hydraulic pipes are depressurized.

Remove all fixing screws of the motor and take off the motor from the gear. Remove the 24 fixing bolts (1) (M24 x 550) of the gear (1). Remove the 4 fixing bolts (2) (M16x360) of the adapter (3). By means of 2 pulling screws loosen adapter (3). Install 2 eye bolts M16 to the adapter (3). Lift off the adapter (3) with attached brake by adequate lifting device. First lift up approx. 150 mm.

W ã

• If the sun gear is lifted together with the assy. secure it against falling down before lifting up completely. • Do not open the brake cause of DANGER OF ACCIDENT. Under no circumstances you have to unscrew the red marked screws.

AH07509

Page 6 of 7

AH07509

Page 7 of 7

2.2

Assembly 1. Centre the new adapter (1) with put on O-ring (4) into the gear and fasten it with 4 bolts (M16x360). 2. Fasten the gear with 24 bolts (M24 x 550) back to the machine. 3. Centre the new pre-assembled brake (2) with put on O-ring into the adapter and fasten it with 8 bolts (M16 x 210). 4. Insert the new O-ring (3) in the groove provided for this purpose at the motor pivot. The motor pivot has to be pushed into the disc carrier. Centre the motor into the motor flange and fasten it.

)

• To prevent premature wear at the involute spline joint (motor/gear driving shaft), the room between motor and gear gets an oil filling according Maintenance Manual..

5. Fasten the oil fittings back to the gear and the hydraulic pipes back to the brake. 6. Fill the gear and the brake housing with oil according to the instructions in the Maintenance Manual.

)

• Too high oil level in the brake housing reduces the life time of the brake.

Screw in the gauge, see detail ”A”. Remove the gauge. The oil level should be 1. At the lower mark of the gauge in case the oil is cold. 2. At the upper mark of the gauge in case the oil is warm.

7. Connect the brake to the hydraulic system.

AH07509


COMPONENT CODE:

30

REF NO.

AH07526

DATE


SUBJECT:

Bolted undercarriage: Protective coating on the flange plates

PURPOSE:

References to renew the protective coating

APPLICATION:

PC5500-6

FAILURE CODE:

3010Z9

DESCRIPTION:

W


Check the coated surfaces for spots that may be damaged before assembling or reassembling. Spots less than 20 cm² are acceptable. In case of bigger damages the whole surface coating has to be renewed. 1. Spots less than 20 cm² - Remove carefully all loosen parts of the coated surface. - Assemble the undercarriage as described in the Assembling Manual. 2. Spots more largely than 20 cm² - Remove the whole surface coating carefully. - Close the tap holes with plugs (PN 932 313 40). - Clean the surface oil-free and grease-free. - Machine the surface with a vibration grinder (emery paper grain 60). If abrasive blast cleaning is available, this could be done alternatively according to the attached data sheet. - Clean the surface with special dust clothes (PN 932 911 40). - Prepare and use the protective coat according to the attached data sheet.

)

• For laying on the surface coating a conventional air spray has to be used (no brush or roller). • The prescribed dry layer thickness amounts to 75 µm, according to 125 µm wet layer thickness. • Cure is a function of temperature, humidity and airflow. The film will exhibit full cure in 5 days at 20°C and 7 days at 10°C (relative humidity between 50 and 60%) • Two pack size (PN 674 997 40) are needed for renew the whole coating of an undercarriage.

AH07526

= >?@ABC ®

R e d o x

S C

S i l i c a t e ( F o r m e r l y :

5 1 1 5 )

Product Description

A two component, low VOC, water borne alkali metallic zinc silicate primer.

Intended Uses

As a high performance corrosion resistant primer for use on correctly prepared steel substrates in new construction situations. Suitable for use where a high friction grip is required in accordance with TL 918 300, Page 85.

Practical Information for Interzinc 697

Interzinc 697

Protective Coatings

Interzinc 697 S i l i c a t e ( F o r m e r l y :

®

Application

Mixing

Colour

Grey

Gloss Level

Matt

Volume Solids

60%

Typical Thickness

75 microns (3 mils) dry equivalent to 125 microns (5 mils) wet

Mix Ratio

Theoretical Coverage

8 m2/litre at 75 microns d.f.t and stated volume solids 321 sq.ft/US gallon at 3 mils d.f.t and stated volume solids

Practical Coverage

Allow appropriate loss factors

Working Pot Life Airless Spray Air spray (Conventional) Brush

Temperature

Touch Dry†

Hard Dry†

Overcoating Interval with recommended topcoats Minimum Maximum

5°C (41°F) 15°C (59°F) 25°C (77°F) 40°C (104°F)

45 minutes 30 minutes 25 minutes 15 minutes

4 hours 1½ hours 45 minutes 30 minutes

N/A N/A N/A N/A

Flash Point

Base (Part A) >100°C (212°F)

Powder (Part B) N/A

Product Weight

3,62 kg/l (30,2 lb/gal)

VOC

0 g/l (0 lb/gal)

Interzinc 697 is supplied in 2 parts, a liquid Binder base component (Part A) and a Powder component (Part B). Powder (Part B) should be slowly added to the Liquid Binder (Part A) whilst stirring with a mechanical agitator. DO NOT ADD LIQUID TO POWDER. Material should be filtered prior to application and should be constantly agitated in the pot during spraying. Once the unit has been mixed it should be used within the working pot life specified 1 part (Part A) : 0.7 parts (Part B) by volume 1 part (Part A) : 4 parts (Part B) by weight 20°C (68°F) 8 hours Not Suitable Recommended Use suitable proprietary equipment.

Suitable - small areas Typically 50-75 microns (2-3 mils) can be only achieved Roller Suitable - small areas Typically 50-75 microns (2-3 mils) can be only achieved Thinner DO NOT THIN Cleaner Clean potable water, International GTA991 Work Stoppages Do not allow material to remain in hoses, gun or spray equipment. Thoroughly flush all equipment with clean water followed by International GTA991. Once units of paint have been mixed they should not be resealed and it is advised that after prolonged stoppages work recommences with freshly mixed units. Clean Up Clean all equipment immediately after use with clean water followed by International GTA991. It is good working practice to periodically flush out spray equipment during the course of the working day. Frequency should depend upon amount sprayed, temperature and elapsed time, including any delays. All surplus materials and empty containers should be disposed of in accordance with appropriate regional regulations/legislation.

N/A N/A N/A N/A

† Drying times are dependent upon ambient conditions. The figures quoted above have been determined at the quoted temperature and 60% relative humidity.

Page No. 1 of 4

5 1 1 5 )

All surfaces to be coated should be clean, dry and free from contamination. Prior to paint application all surfaces should be assessed and treated in accordance with ISO 8504:1992. Oil or grease should be removed in accordance with SSPC-SP1 solvent cleaning. Strict adherence to all cleanliness standards is essential for application of water based coatings. Abrasive Blast Cleaning Abrasive blast clean to Sa2½ (ISO 8501-1:1988) or SSPC-SP6. If oxidation has occurred between blasting and application of Interzinc 697, the surface should be reblasted to the specified visual standard. Surface defects revealed by the blast cleaning process, should be ground, filled, or treated in the appropriate manner.

Drying Time

E N G 0 5 0 4

S C

Surface Preparation

Method of Application Airspray, Brush, Roller

Regulatory Data

R e d o x

Mixed >100°C (212°F)

(Calculated)

E N G 0 5 0 4

Page 2 of 4

= >?@ABC ®

R e d o x

S C


5 1 1 5 )

Product Description

A two component, low VOC, water borne alkali metallic zinc silicate primer.

Intended Uses

As a high performance corrosion resistant primer for use on correctly prepared steel substrates in new construction situations. Suitable for use where a high friction grip is required in accordance with TL 918 300, Page 85.

Practical Information for Interzinc 697

Interzinc 697

Protective Coatings


®

Application

Mixing

Colour

Grey

Gloss Level

Matt

Volume Solids

60%

Typical Thickness

75 microns (3 mils) dry equivalent to 125 microns (5 mils) wet

Mix Ratio

Theoretical Coverage

8 m2/litre at 75 microns d.f.t and stated volume solids 321 sq.ft/US gallon at 3 mils d.f.t and stated volume solids

Practical Coverage

Allow appropriate loss factors

Working Pot Life Airless Spray Air spray (Conventional) Brush

Temperature

Touch Dry†

Hard Dry†

Overcoating Interval with recommended topcoats Minimum Maximum

5°C (41°F) 15°C (59°F) 25°C (77°F) 40°C (104°F)

45 minutes 30 minutes 25 minutes 15 minutes

4 hours 1½ hours 45 minutes 30 minutes

N/A N/A N/A N/A

Flash Point

Base (Part A) >100°C (212°F)

Powder (Part B) N/A

Product Weight

3,62 kg/l (30,2 lb/gal)

VOC

0 g/l (0 lb/gal)

Interzinc 697 is supplied in 2 parts, a liquid Binder base component (Part A) and a Powder component (Part B). Powder (Part B) should be slowly added to the Liquid Binder (Part A) whilst stirring with a mechanical agitator. DO NOT ADD LIQUID TO POWDER. Material should be filtered prior to application and should be constantly agitated in the pot during spraying. Once the unit has been mixed it should be used within the working pot life specified 1 part (Part A) : 0.7 parts (Part B) by volume 1 part (Part A) : 4 parts (Part B) by weight 20°C (68°F) 8 hours Not Suitable Recommended Use suitable proprietary equipment.

Suitable - small areas Typically 50-75 microns (2-3 mils) can be only achieved Roller Suitable - small areas Typically 50-75 microns (2-3 mils) can be only achieved Thinner DO NOT THIN Cleaner Clean potable water, International GTA991 Work Stoppages Do not allow material to remain in hoses, gun or spray equipment. Thoroughly flush all equipment with clean water followed by International GTA991. Once units of paint have been mixed they should not be resealed and it is advised that after prolonged stoppages work recommences with freshly mixed units. Clean Up Clean all equipment immediately after use with clean water followed by International GTA991. It is good working practice to periodically flush out spray equipment during the course of the working day. Frequency should depend upon amount sprayed, temperature and elapsed time, including any delays. All surplus materials and empty containers should be disposed of in accordance with appropriate regional regulations/legislation.

N/A N/A N/A N/A

† Drying times are dependent upon ambient conditions. The figures quoted above have been determined at the quoted temperature and 60% relative humidity.

Page No. 1 of 4

5 1 1 5 )

All surfaces to be coated should be clean, dry and free from contamination. Prior to paint application all surfaces should be assessed and treated in accordance with ISO 8504:1992. Oil or grease should be removed in accordance with SSPC-SP1 solvent cleaning. Strict adherence to all cleanliness standards is essential for application of water based coatings. Abrasive Blast Cleaning Abrasive blast clean to Sa2½ (ISO 8501-1:1988) or SSPC-SP6. If oxidation has occurred between blasting and application of Interzinc 697, the surface should be reblasted to the specified visual standard. Surface defects revealed by the blast cleaning process, should be ground, filled, or treated in the appropriate manner.

Drying Time

E N G 0 5 0 4

S C

Surface Preparation

Method of Application Airspray, Brush, Roller

Regulatory Data

R e d o x

Mixed >100°C (212°F)

(Calculated)

E N G 0 5 0 4

Page 2 of 4


R e d o x

Product Characteristics

Interzinc 697 S C


5 1 1 5 )

Apply by airspray. Thoroughly flush equipment with International 991 thinner, or alcohol, followed by water prior to use. To obtain maximum edge protection and film build, airspray application is recommended. Application by other methods, e.g. brush or roller, may require more than one coat.

R e d o x

S C

5 1 1 5 )

Further information regarding industry standards, terms and abbreviations used in this data sheet can be found in the following sections of the International Protective Coatings data manual:

Additional Information

With all water based coatings careful control of application conditions is required to ensure good long term performance. International Protective Coatings have available a set of working procedures relating to the application of water borne paints which are available on request. The following basic parameters must be adhered to:

•

Definitions & Abbreviations

•

Surface Preparation

•

Paint Application

•

Theoretical & Practical Coverage

Individual copies of these information sections are available upon request.

Interzinc 697 must be protected from freezing at all times during storage. Safety Precautions

The minimum steel temperature for application must be above 10°C (50°F), and be at least 3°C (5°F) above dew point. Ideally, the relative humidity during application and cure should be kept between 50 and 60%, otherwise drying and overcoating times will be severely extended.

This product is intended for use only by professional applicators in industrial situations in accordance with the advice given on this sheet, the Material Safety Data Sheet and the container(s), and should not be used without reference to the Material Safety Data Sheet (MSDS) which International Protective Coatings has provided to its customers. All work involving the application and use of this product should be performed in compliance with all relevant national Health, Safety & Environmental standards and regulations.

Good airflow is essential around the object being painted [minimum air speed 0.1m/sec (4 inches/sec)]. Minor areas which are difficult to ventilate should be brush applied to prevent overapplication.

In the event welding or flame cutting is performed on metal coated with this product, dust and fumes will be emitted which will require the use of appropriate personal protective equipment and adequate local exhaust ventilation.

Application below the minimum film forming temperature (M.F.F.T.) of the coating and/or poor ventilation will result in poor film coalescence and will result in a powdery cracked film which will require removal and re-application.

If in doubt regarding the suitability of use of this product, consult International Protective Coatings for further advice.

Maximum continuous dry temperature resistance for Interzinc 697 is 400°C (752°F). Cure is a function of temperature, humidity and airflow. Normally films at 75 microns (3 mils) dry film thickness will exhibit full cure in 5 days at 20°C (68°F) and 7 days at 10°C (50°F).

1.4 litre unit

Pack Size

Interzinc 697 Base Interzinc 697 Powder

1 kg in a 1 litre container 4 kg in a 4 litre container

For availability of other pack sizes contact International Protective Coatings Shipping Weight

Storage

U.N. Shipping No. Non-hazardous 1.4 litre unit

1.05 kg (2.31 lb) Base (Part A) 4.36 kg (9.61 lb) Powder (Part B)

Shelf Life

12 months minimum at 25°C (77°F). Subject to re-inspection thereafter. Store in dry, shaded conditions away from sources of heat and ignition.

Disclaimer Systems Compatibility

The information given in this sheet is not intended to be exhaustive and any person using the product for any purpose other than that specifically recommended in this sheet without first obtaining written confirmation from us as to the suitability of the product for the intended purpose does so at his own risk. Any warranty, if given, or specific Terms & Conditions of Sale are contained in International’s Terms & Conditions of Sale, a copy of which can be obtained on request. Whilst we endeavour to ensure that all advice we give about the product (whether in this sheet or otherwise) is correct we have no control over either the quality or condition of the substrate or the many factors affecting the use and application of the product. Therefore, unless we specifically agree in writing to do so, we do not accept any liability whatsoever or howsoever arising for the performance of the product or for any loss or damage (other than death or personal injury resulting from our negligence) arising out of the use of the product. The information contained in this sheet is liable to modification from time to time in the light of experience and our policy of continuous product development.

Interzinc 697 is only recommended for application to correctly prepared steel substrate. Interzinc 697 is not normally overcoated.

It is the user’s responsibility to check that this sheet is current prior to using the product. Issue date: 28/05/2004 Copyright © International Paint Ltd.

and International are trademarks.

International Protective Coatings World Centre P.O Box 20980 Oriel House 16 Connaught Place London, W2 2ZB England

Asia Region 3 Neythal Road Jurong Town Singapore 628570

Tel: (44) 20 7479 6000 Tel: (65) 663 3066 Fax: (44) 20 7479 6500 Fax: (65) 266 5287

Page No. 3 of 4

E N G 0 5 0 4

Page No. 4

Australasia Region 115 Hyde Road Yeronga Brisbane Queensland Australia

Europe Region P.O Box 20980 Oriel House 16 Connaught Place London, W2 2ZB England

Middle East Region PO Box 37 Dammam 31411 Saudi Arabia

North America Region 6001 Antoine Drive Houston Texas 77091

Tel: (61) 7 3892 8888 Fax: (61) 7 3892 4287 H&S (61) 1800 807 001

Tel: (44) 20 7479 6000 Tel: (966) 3 812 1044 Tel: (1) 713 682 1711 Fax: (44) 20 7479 6500 Fax: (966) 3 812 1169 Fax: (1) 713 684 1514

South America Region Av Paiva 999, Neves, Sao Gonçalo, Rio de Janeiro Brazil

Tel: (55) 21 624 7100 Fax: (55) 21 624 7123

E N G 0 5 0 4


R e d o x

Product Characteristics

Interzinc 697 S C

5 1 1 5 )

Apply by airspray. Thoroughly flush equipment with International 991 thinner, or alcohol, followed by water prior to use. To obtain maximum edge protection and film build, airspray application is recommended. Application by other methods, e.g. brush or roller, may require more than one coat.


R e d o x

Additional Information

S C

5 1 1 5 )

Further information regarding industry standards, terms and abbreviations used in this data sheet can be found in the following sections of the International Protective Coatings data manual:

With all water based coatings careful control of application conditions is required to ensure good long term performance. International Protective Coatings have available a set of working procedures relating to the application of water borne paints which are available on request. The following basic parameters must be adhered to:

•

Definitions & Abbreviations

•

Surface Preparation

•

Paint Application

•

Theoretical & Practical Coverage

Individual copies of these information sections are available upon request.

Interzinc 697 must be protected from freezing at all times during storage. Safety Precautions

The minimum steel temperature for application must be above 10°C (50°F), and be at least 3°C (5°F) above dew point. Ideally, the relative humidity during application and cure should be kept between 50 and 60%, otherwise drying and overcoating times will be severely extended.

This product is intended for use only by professional applicators in industrial situations in accordance with the advice given on this sheet, the Material Safety Data Sheet and the container(s), and should not be used without reference to the Material Safety Data Sheet (MSDS) which International Protective Coatings has provided to its customers. All work involving the application and use of this product should be performed in compliance with all relevant national Health, Safety & Environmental standards and regulations.

Good airflow is essential around the object being painted [minimum air speed 0.1m/sec (4 inches/sec)]. Minor areas which are difficult to ventilate should be brush applied to prevent overapplication.

In the event welding or flame cutting is performed on metal coated with this product, dust and fumes will be emitted which will require the use of appropriate personal protective equipment and adequate local exhaust ventilation.

Application below the minimum film forming temperature (M.F.F.T.) of the coating and/or poor ventilation will result in poor film coalescence and will result in a powdery cracked film which will require removal and re-application.

If in doubt regarding the suitability of use of this product, consult International Protective Coatings for further advice.

Maximum continuous dry temperature resistance for Interzinc 697 is 400°C (752°F). Cure is a function of temperature, humidity and airflow. Normally films at 75 microns (3 mils) dry film thickness will exhibit full cure in 5 days at 20°C (68°F) and 7 days at 10°C (50°F).

Pack Size

1.4 litre unit

Interzinc 697 Base Interzinc 697 Powder

1 kg in a 1 litre container 4 kg in a 4 litre container

For availability of other pack sizes contact International Protective Coatings Shipping Weight

Storage

U.N. Shipping No. Non-hazardous 1.4 litre unit

1.05 kg (2.31 lb) Base (Part A) 4.36 kg (9.61 lb) Powder (Part B)

Shelf Life

12 months minimum at 25°C (77°F). Subject to re-inspection thereafter. Store in dry, shaded conditions away from sources of heat and ignition.

Disclaimer Systems Compatibility

Interzinc 697 is only recommended for application to correctly prepared steel substrate. Interzinc 697 is not normally overcoated.

The information given in this sheet is not intended to be exhaustive and any person using the product for any purpose other than that specifically recommended in this sheet without first obtaining written confirmation from us as to the suitability of the product for the intended purpose does so at his own risk. Any warranty, if given, or specific Terms & Conditions of Sale are contained in International’s Terms & Conditions of Sale, a copy of which can be obtained on request. Whilst we endeavour to ensure that all advice we give about the product (whether in this sheet or otherwise) is correct we have no control over either the quality or condition of the substrate or the many factors affecting the use and application of the product. Therefore, unless we specifically agree in writing to do so, we do not accept any liability whatsoever or howsoever arising for the performance of the product or for any loss or damage (other than death or personal injury resulting from our negligence) arising out of the use of the product. The information contained in this sheet is liable to modification from time to time in the light of experience and our policy of continuous product development. It is the user’s responsibility to check that this sheet is current prior to using the product. Issue date: 28/05/2004 Copyright © International Paint Ltd.

and International are trademarks.

Deutschland: H & S Beschichtungssysteme Vertriebs GmbH | Niekamp 24 | 59399 Olfen | Telefon +49 (25 95) 34 35 / 30 16 | Telefax +49 (25 95) 91 20 | [email protected]

Page No. 3 of 4

Page No. 4

COMPONENT CODE:

L5

REF NO.

AH08503


DATE SUBJECT:

Track drive

PURPOSE:

Complete track drive protection

APPLICATION:

PC5500-6 (SN 15026 and up)

FAILURE CODE:

L510FA


DESCRIPTION:

W


For heavy duty use we recommend to install the complete drive protection according to the drawings below.

1.

Gear box protection (PN 946 692 40)

2.

Motor protection (PN 936 640 40) (only for diesel drive shovels with L&S travel gears)

AH08503

Page 2 of 6

Illustration 1

AH08503

Page 3 of 6 1.

Gear box protection (PN 946 692 40)

Illustration 2 • •

Install the 4 intermediate plates (02) by using the new bolts (03) and washers (04) (remove the respective bolts from the gear box). Mount the protecting cage (01) by using the bolts (05) as shown.

)

• Pay attention to the hydraulic hoses.

AH08503

Page 4 of 6 1.

Gear box protection (PN 946 692 40) Pos.

Part No.

Qty.

Description

01

946 685 40

2

Protecting cage

02

946 684 40

4

Intermediate plate

03

518 354 98

20

Bolt

04

255 056 40

20

Washer

05

517 876 98

24

Bolt

06

621 707 40

24

Resilient sleeve

07

501 133 98

24

Nut

08

255 057 40

24

Washer

AH08503

Page 5 of 6 2.

Motor protection (PN 936 640 40)

Illustration 3 • • •

Mount the intermediate plates (01) by using bolts (07) (existing bolts have to be replaced); Install the bolt protection (04) with bolts (07) (not necessary by mounting the gear box protection); Now install the motor protection assy. by using the bolts (08); the washers (9) and the nuts (10).

)

• Pay attention to the hydraulic hoses.

AH08503

Page 6 of 6 2.

Motor protection (PN 936 640 40) (only for gears delivered by L&S - SN 15026 and up)

Pos.

Part No.

Qty.

Description

01

936 639 40

2

Intermediate plate

02

936 631 40

1

Motor protection left

03

936 632 40

1

Motor protection right

04

936 647 40

2

Bolt protection travel gear

05

936 641 40

2

Cover

06

936 642 40

6

Cover

07

517 967 98

40

Bolt

08

304 331 99

20

Bolt

09

316 213 99

40

Washer

10

332 359 99

20

Nut

11

307 800 99

20

Nut

12

324 741 40

2

Plug

AH08503

COMPONENT CODE:

55

REF NO.

AH08504


DATE

August 7, 2008 Page 1 of 2

SUBJECT:

Windscreen

PURPOSE:

Mounting hints

APPLICATION:

PC4000; PC5500; PC8000

FAILURE CODE:

5532PB

DESCRIPTION:

W


A different holes pattern is used since January 2007 for the frame of the windscreen. We offer two types of windscreens for replacement of a damaged one: 1. Windscreen with mounting holes in the frame and 2. Windscreen without mounting holes. We recommend using windscreen with new holes pattern in the frame, also for shovels, delivered before 2007. Advantages: • Only one fitting of new bore holes in the cab. • In case of a next windscreen exchange the same holes can be used.

AH08504

Page 2 of 2

Pos. 01

Pos.

Part No.

769 528 73 12 mm; green; drilled 12 mm; green; 797 251 73 undrilled

Part No. 793 739 73 797 253 73

01

Description

796 564 73

797 254 73

Description 12 mm; green; drilled 12 mm; green; undrilled 19 mm, with splinter shield foil coating; drilled 19 mm, with splinter shield foil coating; undrilled

AH08504

COMPONENT CODE:

71

REF NO.

AH08507


DATE

April 9, 2008 Page 1 of 9

SUBJECT:

Steel structure

PURPOSE:

Repair welding procedure

APPLICATION:

PC3000-6; PC4000-6; PC5500-6; PC8000-6

FAILURE CODE:

7100FE

DESCRIPTION:

W Content 1. 2. 3. 4. 4.1 4.2 5. 6. 7. 8.


Introduction General Protective Measures Steps of the weld repair procedure Selection of appropriate electrodes and welding rods Selection of appropriate electrodes Selection of appropriate welding rods Preparation of the defective Part Carrying out the Weld Repair Post heating Inspection of Repair

AH08507

Page 2 of 9

1. Introduction Weld repairs can cause severe damage to an entire structure if performed incorrectly. Therefore we recommend consulting your Komatsu Service Organization in order to avoid improper welding procedures. If cracks are found in the steel construction of your excavator, please inform our service department as soon as possible. Attach suitable information material (photos, catalogue drawings etc.) showing the location and nature of the crack. 2. General Protective Measures Welding operations can cause damage to electronic components (Computers, Control Units, Sensors etc.) in case the welding current goes through these units. Therefore protective measures are necessary before any weld repair is started. 1. Observe the prevailing safety and fire prevention regulations. Get advice from authorized Electricians for all medium and high voltage systems related questions. 2. Before any weld repair is started, a survey should be made of the area and all safety considerations satisfied such as fuel tanks, hydraulic oil reservoirs, oil lines, electrical cables and synthetic materials. 3. Remove the battery main switch keys and switch off all circuit breakers, refer to the Operation Manual of the Excavator for more information. 4. Attach the welding ground directly to the part that is being repaired. Do not allow welding current to go through bearings. Welding current could arc the bearings, resulting in severe damage to the bearing. 3. Steps of the weld repair procedure 1. Clean the damaged part or area to be repaired. 2. Inspect the worn or fractured area by visual inspection and/or non-destructive testing. 3. Determine the type of material to be repaired. 4. Determine the welding electrode or the welding wire and process to be used. 5. Preheat before welding. 6. Weld by using appropriate welding techniques. 7. Post heat. 8. Make a survey of the repair welding.

AH08507

Page 3 of 9

4. Selection of appropriate welding electrodes and welding wires Table 1: The components shown in illustrations 3 and 4 are made of six different materials (a, b, c, d, e or f) as shown in the table below. Material designation

former

present

international

a

St52-3N

S355J2G3

1.0570 (17G1S)

b

GS24Mn6V

GS24Mn6V

1.1118

c

StE690

S690Q

1.8931

d

GS18NiMoCr36

GS18NiMoCr36

1.6759

e

TStE355

P355NL1

1.0566

f

Hardox 400

4.1 Selection of appropriate welding electrodes Table 2: The following welding electrodes are required for the weld repairs: Key number

Welding Electrode (AWS)

4 5* 7* 9*

E 7016 E 7018-G E 8018-G E 100 18-G

* Hydrogen content less than 5mg per 100ml

Table 3: Types of welding electrodes to be used for the different materials (a to f) Material a b c d e f

a 4 4 4 4 4 7

b 4 4 7 5 7

c 4 7 9 9 7

d 4 5 9 9 7

f 7 7 7 7 7 7

AH08507

Page 4 of 9

Example: Selection of the correct welding electrode for weld repair a crack in the welded joint between material (a) and (c). The table 4 shows the correct electrode with key number 4 in the red shaded field. Table 4 Material a b c d e f

a 4 4 4 4 4 7

b 4 4 7 5 7

c 4 7 9 9 7

d 4 5 9 9 7

f 7 7 7 7 7 7

4.2. Selection of appropriate welding wires Table 5: The following welding wires are required for the weld repairs Key number

Welding wire (AWS)

21 25/25a 30 32

ER70 S6 ER100 S1 E70 T5 E90 T5-G

Table 6: Types of welding wires to be used for the different materials (a to f) Welding wires a b c d e f

a 21; 30 21; 30 21; 30 21; 30 21; 30 25; 32

b 21; 30 21; 30 21; 30 21; 30 21; 30 ---

c 21; 30 21; 30 25; 25a; 32 32 21; 30 25; 25a; 32

d 21; 30 21; 30 25; 25a; 32 32 21; 30 ---

f 25; 25a; 32 --25; 25a; 32 --25; 25a; 32 25; 25a; 32

AH08507

Page 5 of 9

5. Preparation of the defective Part • Clean the fractured area or worn part of all oil, grease, paint, moisture, dirt, rust, spalled material or any other materials, which may be detrimental to a weld. • Inspect the fractured areas carefully by non-destructive testing such as magnetic particle or dye penetrant inspection. • When removing cracks, a V groove should be made with a 30° to 45° angle. Remove defective material up to the bottom of the crack.

Illustration 1 Use electrodes out of a freshly opened can or from an electrode holding oven. Dry the electrodes according to the instructions of the electrode manufacturer. Preheating of the part before preparing it for weld repair is essential to reduce the thermal shock. The preheat temperature depends on the composition of the material, see table 7 for the required temperature. Measure the temperature beside the joint at a distance equal to the sheet metal thickness using suitable temperature indicating devices. Table 7 Material S355J2G3 P355NL1

S690Q

GS24Mn6V GS18NiMoCr3 Hardox 400

Groove depth (mm) <10

Preheat temperature (°C) 20

Interpass temperature (°C) 220

10 - 20 20 - 50 10 10 - 20 >20 <10 10 - 20 >20

50 100 50 100 150 50 100 150

220 220 150 180 220 150 180 180

>10

150

200

Post heat temperature (drop per hour)

50 degree. max.

AH08507

Page 6 of 9

6. Carrying out the Weld Repair

) • •

•

• •

• All weld repairs should be carried out by qualified and experienced welders. • Provide the necessary equipment such as the correct clothing, head gear, exhausts systems or respirators and if required platforms for safe access to the repair area. It is important to maintain the preheat temperature according to table 7 throughout the repair. The interpass temperature should never exceed the maximum permissible value shown in table 3. Measure the temperature beside the joint at a distance equal to the sheet metal thickness using suitable temperature indicating devices. All cracks through the parent material will require a welding from both sides, see illustration 1. The Service Bulletin No. 21-594 contains instructions for making a “Man Hole” which is necessary for weld repairs from inside the boom or stick. When welding in a vertical position always weld using the vertical up technique. Properly applied multiple pass welding is the required procedure, illustration 2. Use a blunt-nosed chisel (C) to calk the weld beads (A and B) with the groove wall before welding the space between the beads (A and B). Repeat the calking of beads (A and B) at each weld layer.

Illustration 2 • •

Once a repair has been started by preheating and welding, the part should be worked on until completed. A recommended technique for repair is to butter the groove with weld metal. Buttering is the addition of one or more layers of weld metal to the face of the joint or surfaces to be welded.

AH08507

Page 7 of 9 •

•

After the welding has been completed, check the repair for any undercuts, overlaps or any other notch type discontinuity while the preheat is still up to temperature. Make any repair necessary at this time. After the repair cools, grind all butt-welded repairs smooth using 36 or finer grit grinding material. All grinding marks should be parallel to the direction of primary stress if possible. Make sure there is a smooth transition between the weld metal and the parent plate.

7. Post heating •

Maintain the preheat temperature according to table 7 for at least 15 minutes after the weld repair is finished and then cool the repair area slowly, refer to table 3 for maximum allowable temperature drop per hour.

8. Inspection of Repair •

• •

)

Inspect the completed weld after it has cooled to the ambient temperature by non-destructive procedures as dye penetrant, or magnetic particle inspection and ultrasonic inspection, if possible. A final inspection of the weld repair should be made after 24 hours in order to detect hydrogen induced cracks. If surface defects are found, remove all defects by grinding to a maximum depth of 1.5 mm. Larger defects have to be removed according to the repair procedures described on the preceding pages. Grind welds so they blend in with the parent material. All spot welding also require preheating and post heating. • It is not recommended to weld on reinforcement plates as the main stress will remain ~float~ through the steel structure regardless how many additional plates would be applied to the structure.

AH08507

Page 8 of 9


Page 9 of 9


COMPONENT CODE:

71

REF NO.

AH08508


DATE

June 13, 2008 Page 1 of 3

SUBJECT:

Bushings of the attachment and at the undercarriage

PURPOSE:

Wear checking procedure

APPLICATION:

PC3000-1; PC3000-6; PC4000-6; PC5500-1; PC5500-6; PC8000-1; PC8000-6

FAILURE CODE:

7100CA

DESCRIPTION:

W


)

• For installation of bushes please refer also to Parts & Service news AH06545.

1. Bushings of the attachment 2. Bushings between bolted track frame and undercarriage (depends on the execution)

AH08508

Page 2 of 3 1. Bushings of the attachment

Illustration 1 Example for determining the clearance of the boom cylinder bushes (The procedure for the other attachment bushes is analogues.) 1. Place the attachment on the ground as shown on illustration 1. 2. Raise the attachment a little bit from the ground. 3. Make a line with a felt pen from boom bearing to the boom cylinder barrel (a = 30 cm). 4. Make a 2nd line with a felt pen from boom bearing to the boom cylinder piston rod (b = 30 cm). 5. Press the attachment on the ground so far that the chains at “c” just remove from the ground. 6. Measure the distances at “a” and “b”.

)

• We recommend to renew the bushes if the clearance reaches a value of about 3 mm.

AH08508

Page 3 of 3 2. Bushings between bolted track frame and undercarriage 1. Position the machine in a position so that the track frame can be lifted of the ground.

2. Install a dial gauge so that the dial gauge magnetic portion is on the side frame. 3. Set the pointer on to the car body and set to zero.

4. Raise the track frame slowly off the ground until the dial gouge stops moving. Record the measurement.

)

• We recommend to renew the bushes if the clearance reaches a value of about 3 mm.

AH08508

Supplier’s documentation

9 SUPPLIER’S DOCUMENTATION

Version 2009/2

PC5500-6

9 -1

Supplier’s documentation

Contents of this chapter: AVANTI HYTORQUE

9 -2

PC5500-6

Version 2009/2

XXI/Avanti/Stealth SERIES Operational Manual

July 2004

Table of Contents XXI/Avanti/Stealth SERIES Operational Manual

SECTION I IMPORTANT SAFETY INSTRUCTIONS SECTION II BEFORE USE

2-1 Working Pressure 2-2 Hydraulic Connections 2-3 Electrical Connections 2-4 Air Connections

SECTION III OPERATION

3-1 General 3-2 Connecting the System 3-3 Drive Direction Change 3-4 Reaction Arm XXI/Avanti 3-5 Setting Torque 3-6 Setting Pump Pressure 3-7 Tightening Procedures 3-8 Operating the XXI, Avanti & Stealth Systems 3-9 Loosening Procedures

SECTTION IV 4-1 Tool set up and operation USE WITH LoaDISC 4-2 LoaDISC Tensioning WASHER & CLAMP-NUT 4-3 LoaDISC De-tensioning 4-4 LoaDISC Lubrication 4-5 CLAMP-NUT Tensioning 4-6 Clamp-nut De-tensioning 4-7 Clamp Lubrication SECTTION V 5-1 General Information OPERATION 5-2 Hydraulic Connections HYTORC POWER PACKS 5-3 Prior to Use 5-4 Operation –Electric Pump-5-5 Operation –Air Pump-5-6 Automatic Pump 5-7 Starting with Automatic System SECTION VI HELPFUL INFORMATION

Tool Dimensions & Parts List Field-proven Torquing Procedure Pressure/Torque & Pressure/Load Conversion Chart Recommended Torque For ASTM A193 Grade B7 Studs

INTRODUCING THE NEW GENERATION HYTORC

Thank you for buying the NEW HYTORC FREEDOM-LINE! This manual is designed to provide you with the basic knowledge required to operate and maintain your HYTORC bolting equipment. Please read this manual carefully and follow the instructions provided. If you have any questions regarding HYTORC bolting equipment, please call us at 201-512-9500 or contact us at [email protected]. Your purchase of HYTORC bolting equipment entitles you to the following services at no extra cost to you. Free on-site training in the application and operation of your HYTORC bolting equipment * Free semi-annual training * Free annual tool inspection. * Free loner tools in case of failure under warranty * Free engineering assistance by calling 1-800-FOR-HYTORC or our international office. Your local HYTORC bolting specialist is available around the clock for your convenience. Should you require any assistance, please contact us to obtain our local specialist’s information. World-wide Warranty HYTORC bolting equipment is engineered to the latest technological standards and is accompanied by our exclusive 12 word, 12-month warranty: “YOU BREAK IT UNDER NORMAL USE, WE FIX IT FREE OF CHARGE!” If your HYTORC equipment cannot be repaired on site, FREE loaner equipment will be made available to you upon request, while under warranty.

INTRODUCTION

HYTORC tools are uniquely multi-purpose. They can be used as accurate bolting equipment on conventional nuts in open or confined spaces. They also can be used as reaction arm free tensioning equipments, when used with HYTORC LoaDISC washer or HYTORC-Clamp, Hydraulically Actuated Mechanical Tensioner. SECTION I IMPORTANT SAFETY INSTRUCTIONS HYTORC tools are designed for the safety of operators. However, they are powerful tools and certain safety precautions should be observed to avoid accidents or personal injury. The following tips will assist you. READ ALL INSTRUCTIONS KEEP WORK AREA CLEAN AND WELL LIT CONSIDER WORK AREA ENVIRONMENT

Electric pumps should never be used in any atmosphere which can be considered potentially volatile. If there is any doubt, use an air pump.

Also note: Metal to metal contact can cause sparks. Precautions must be taken. AVOID PREMATURE TOOL STARTING

The pump remote control should be operated by a designated operator and ensure “ALL CLEAR” prior to starting and to avoid premature tool starting.

STAY CLEAR DURING OPERATION

In most cases, the tool will allow “hands free” operation. If the tool must be reset on bolt during operation, make sure the remote control operator is aware of turning the pump off.

IMPORTANT NOTE: NEVER HOLD THE TOOL DURING OPERATION! GUARD AGAINST ELECTRIC SHOCK

Ensure the pump is properly grounded and the proper voltage is used.

STORE EQUIPMENT PROPERLY

When not in use, tools and accessories should be properly stored to avoid deterioration.

USE THE RIGHT TOOL Do use tools or attachments suitable for the applications. *refer to our recommended torque/load chart PROPER SAFETY ATTIRE

When handling/operating hydraulic equipment, wear work gloves, hard hats, safety shoes, safety glasses and other applicable clothing.

MOVING EQUIPMENT

Do not use hydraulic hoses, uniswivels, pump power or remote cords as means of moving the equipment.

SECTION I IMPORTANT SAFETY INSTRUCTIONS -continued from the previous pageHOSES

Do not kink hoses. Inspect and replace if damaged.

SHROUDS AND COVER PLATES

All tools are equipped with shrouds and/or cover plates to prevent contact with the moving internal parts. Do not use tools without these safety covers. If the covers are missing or damaged, replace immediately.

MAINTAIN TOOLS

For the best results, inspect tools, power packs, hoses, connectors, electric lines and accessories for visual damage before each usage. Always follow instructions for proper tool and pump maintenance.

SAFETY ALERT

Do not use power equipment under the influence of any mood altering substance.

PRIOR TO OPERATION

Ensure that all hydraulic connectors are securely connected. Verify that the hydraulic hoses are not kinked. Insure the square drive and its retainer are fully and securely engaged.

PRIOR TO USE (if use with reaction arm)

Before placing your tool on the application, cycle it to ensure proper function. If using the torque mode, locate a solid and secure reacting point. Be sure the reaction arm is retained firmly and positioned to face the same direction as the square drive. Be sure the hydraulic hoses are free of the reacting point. Pressurize the system momentarily; if the tool tends to “ride up” or to “creep”, stop and adjust the reaction arm to a solid and secure position.

NOTE: Remain clear of the reaction arm during operation and never put body parts between reaction arm and reaction surface. ALWAYS USE QUALITY ACCESSORIES

Use genuine HYTORC accessories. Use correct size accessories and engage them fully. Stay clear of all moving accessories during operation.

DO NOT USE FORCE

Do not apply any impact by using hard objects on bolting equipment or accessories. This may cause malfunction or breakage.

ALWAYS CONSULT

Please contact HYTORC for any questions related to our equipment or your bolting needs. Safety is always the number one priority.

SECTION II INSTRUCTIONS BEFORE USING YOUR NEW HYTORC READ CAREFULLY: Most malfunctions, in new equipment, are the result of improper operation and/or set-up. PREPARATION: Remove HYTORC equipment from shipping container. INSPECTION: Visually inspect all components for any damage during transportation. If damages are found, notify HYTORC immediately. 2-1 Working Pressure The tool’s maximum working pressure is 10,000 PSI (700kg/cm2, 690 Bar) Make sure that all hydraulic equipment used is rated for 10,000 PSI operating pressure. To set pump pressure for XXI models to 10,000 PSI for both advance & retract, locate selector valve underneath the couplers. Turn the pump off and loosen the lock nut. Turn the center screw counter-clockwise until it stops. Tighten the lock-nut. For Avanti & Stealth models, turn the center screw clockwise until it stops. Tighten the lock-nut to set the pump pressure to 1,500 PSI for retract. 2-2 Hydraulic Connections With older style pumps, (SST-10, SST-20), the retract side of the system may remain pressurized after the pump has been switched “off”. This trapped pressure makes it impossible to loosen the retract-side fittings by hand. To release the pressure, find the 5/16 manual override holes in the end of the black solenoids on the pump. With a welding rod, Allen-key or similar device, push in on the ends of both solenoids, each in turn, and the residual pressure will be released. All fittings will, then, be hand tightened again. Hoses and couplers must be free and unobstructed before and during the operation of the tool. External impact on the couplers may break off the fittings. Current pump models are equipped with an auto-pressure relief. Never disconnect or connect any hydraulic hoses or fittings without first unloading wrench and the pump. Double check the gauge reading to assure pressure has been released. When making connections with quick disconnect couplings, make sure the couplings are fully engaged. Threaded connections such as fittings and gauges must be clean and securely tightened and leak free. CAUTION: Loose or improper threaded fittings can be potentially dangerous if pressurized. Severe over tightening can cause premature thread failure. Never grab, touch or in any way come in contact with a hydraulic pressure leak. Escaping oil can penetrate the skin and cause injury.

SECTION II INSTRUCTIONS BEFORE USING YOUR NEW HYTORC -continued from the previous page2-3 ELECTRICAL CONNECTIONS Ensure proper power availability to prevent motor failure or dangerous electrical overloading. Compare the motor nameplate for required amperage. Do not use electric pump, if three prong electrical plug is not whole. Minimize the length of extension cords and be sure they are of adequate wire size, with ground connectors. Extension cord up to 50 feet should be #10 AWG gauge. CAUTION: Electric motors may spark. Do not operate in an explosive atmosphere or in the presence of conductive liquids. Use an air pump instead. 2-4 AIR CONNECTIONS Ensure that you have sufficient air flow of 80 psi ( 50 cfm) to operate your pneumatic pump. If in doubt, compare the pump manufacturer’s recommended air flow rating prior to pressurizing pump. Improper air flow may damage the pump motor. For best results, use air hose larger than 3/4 “ diameter. Use of a filter regulator lubricator (FRL) is highly recommended. (diagram below) AIR ADJUSTMENT KNOB AIR FLOW ON/OFF LEVER

OIL LUBRICATOR ADJUSTMENT KNOB FILTER CAP

AIR PRESSURE GAUGE CONDENSATION BOWL

DRIER 1. 2.

Adjust flow to 1-2 drops per minute. Fill half way with grade 46 hydraulic oil supplied.

AUTO WATER DRAIN PORT

SECTION III OPERATION – Torquing Conventional Nuts 3-1 General All HYTORC tools are supplied completely assembled and are ready to use. A HYTORC Hydraulic Power Pack, for use with your HYTORC tools, is recommended to provide the speed, pressure and portability that makes your HYTORC SYSTEM more efficient and accurate. The SYSTEM accuracy of your HYTORC tool is +-3% based upon manufacturer’s specifications. This accuracy maybe certified through calibration by HYTORC or any other qualified calibration facility whose program is traceable to the National Institute of Standards and Technology (N.I.S.T.) Using a calibrated gauge enhances the accuracy of your HYTORC SYSTEM. 3-2 Connecting the SYSTEM The wrench head and power pack are connected by a 10,000 PSI operating pressure (40,000 PSI burst) twin line hose assembly. Each end of the hose have one male and one female connector to assure proper interconnection between pump and wrench head. IMPORTANT:

To avoid tool malfunction, do not reverse connectors.

Connect the twin line hose to the uniswivel as shown below. Make sure male couplers are connected to female couplers. During the operation, check the connection to ensure the couplers are not loose. Insure the connectors are fully engaged and screwed snugly and completely together.

Connect to tool

Connect to pump

*Connect male end of hose to female end of both tool and pump & female end of hose to male end on both tool and pump

From hose

From hose

SECTION III OPERATION – Torquing Conventional Nuts -continued from the previous page3-3 Drive Direction Change Avanti tools To remove the square drive, disengage the drive retainer assembly by depressing the retaining round button and gently pulling on the square end of the square drive. The square drive will slide out. To insert the drive in the tool, place the drive in the desired direction, engage drive spline and ratchet spline, then twist bushing until engage to the housing spline. Push drive through ratchet. Depress drive retainer button, engage retainer with drive and release button to lock.

Button Drive Retainer

Square Drive

The diagram on the right illustrates the direction that the square drive should face for tightening and loosening of a standard right hand fastener.

Loosening

Tightening

Stealth tools The Stealth tools use interchangeable ratcheting links. For tightening, simply engage the nut with the right side of the link facing down. For loosening, the left side of the link faces down. Ratcheting link can be detached from the Stealth power head by pulling the power head out while pressing the button shown below.

STEALTH MADE IN U.S.A.

STEALTH

MADEIN USA

Loosening

Link release button

3-4 Reaction Arm

Please read operating instructions prior to use, and use common sense.

Tightening

KEEP HANDS OFF DURING OPERATION!

The Avanti can be used with a 360 degree adjustable universal reaction arm.

Make sure the reaction arm spline is fully engaged on the square drive spline. Secure the position by tightening the set screw on the reaction arm. *ALWAYS USE A SAFETY HANDLE

SECTION III OPERATION – Torquing Conventional Nuts -continued from the previous page3-5 Setting Torque Once the SYSTEM is fully connected and the proper power supply is available, it is time to adjust the pump pressure to the level needed on your job. When tightening, use the manufacturer’s specifications to determine the torque value ultimately required. Appendix I – which is presented as a guideline for comparison only – gives typical torque values specified for the most commonly encountered fasteners. Torque sequence varies from plant to plant and even within the same plant may vary depending on the gasket material and other factors. Always abide by on-site-procedures. Always refer to the pressure-torque conversion table that came with the tool. 3-6 Setting the Pressure on the Pump

T Handle

To set the pressure on the pump, follow this procedure. 1. Loosen the knurled locking ring below the “T” handle on the pump’s external pressure regulator. Then turn the “T” handle counterclockwise until it turns freely and easily. 2. Turn the pump “ON”. Using the pump’s remote control pendant, push down the advance switch (or button on air pump) and hold it.

Locking Ring

3. While holding the pump in the advance mode, slowly turn the “T” handle clockwise and observe the pump pressure gauge rise. NOTE: Always adjust the regulator pressure up – never down. 4. Once the desired pressure is reached. Turn off the pump and “LOCK IN” the pressure by tightening the knurled lock nut. Turn on the pump once more and pressurize to verify the pressure is maintained. 3-7 Applying the Avanti – the Tightening Process 1. Once your target pressure is set, cycle the tool three or four times to full pressure. Cycling the tool ensures that the system is operating properly and removes trapped air, if any. 2. Place the proper size driving unit on the square drive and secure properly. 3. Place the tool on the bolt, making sure that everything is fully engaged. Further ensure that the drive retainer is engaged. 4. Make sure the reaction arm is firmly abutted against a stationary object. 5. When positioning the wrench, make sure that the hose connections are well clear of any obstructions. 6. After all the above are confirmed, apply momentary pressure to the SYSTEM to ensure proper tool placement.

SECTION III OPERATION – Torquing Conventional Nuts -continued from the previous page3-7 Applying the Stealth – the Tightening Process 1. Once the target pressure is set (refer to 3-6) Cycle the tool several times to full pressure to assure proper operation. 2. Place the right side of the ratchet link directly over the nut. Ensuring the hex is fully engaged and the reaction pad portion of the link abuts solidly against an adjacent nut or other stationary object. (see 3-3 for proper tool placement) 3. Ensure hose connections are clear of any obstacles. 4. After all the above are confirmed, apply momentary pressure to the SYSTEM to assure the reaction point is stable. 3-8 Operating the Avanti and Stealth SYSTEMS 1. By pushing down on the remote control button in the advance position, the rear of the tool will be pushed back until the reaction surface will contact its reaction point. 2. Continue to hold down the advance button as the socket turns until you hear a “CLICK” which will signify the hydraulic cylinder inside the tool is fully extended and will not turn the socket further. 3. Continuing to hold down the remote control button will result in a rapid buildup of pressure to the point of where the gauge reads what was preset prior to applying the wrench. IMPORTANT: The reading of full preset pressure after the cylinder is extended DOES NOT INDICATE that this pressure (torque) is applied to the bolt. It only indicates that the cylinder is fully extended and cannot turn the nut further until the tool automatically resets itself. Releasing the remote control button will retract the cylinder. The tool will automatically reset itself and the operator will hear a “CLICK” indicating he can again push the remote control button and the socket will turn. Each time the cylinder is extended and retracted, it is called a cycle. Successive cycles are made until the tool “STALLS” at the preset Torque/PSI with an accuracy of +-3%. Repeatability is +-1%. IMPORTANT: ALWAYS ATTEMPT ONE FINAL CYCLE TO INSURE THE “STALL” POINT HAS BEEN REACHED. NEVER HOLD THE TOOL DURING OPERATION. Use safety handle to set and remove tools.

SECTION III OPERATION – Torquing Conventional Nuts -continued from the previous page3-8 Operating the Avanti and Stealth SYSTEMS Releasing “LOCKED-ON” tools. Should the tool “LOCK-ON” after the final cycle, slide the slider (or the lever on Avanti) with the pump off or in retract position. Turn the pump back on and while maintaining the pressure, cycle Avanti in the pump’s manual mode. Should Stealth “LOCK-ON”, advance pump pressure and while advancing, press down on the release button located on the sides of the ratchet link. Once you are able to press down the button without resistance, continue holding the button down and release the advance pressure on the pump. Shut off the pump, and remove the tool from the nut.

Avanti Release Procedure

Disengage lever

1)

Push lever to position A

2)

Cycle tool in manual mode, release advance button

3)

Shut pump off

4)

Remove tool and reset lever to position B

Stealth Release Procedure STEALTH

1)

Push remote to full pressure for final stroke

2)

Disengage the reaction pawl by holding the button in the direction of arrow

3)

Release the rocker switch

4)

Shut pump off

5)

Remove tool

MADE IN U. S.A.

Disengage button

SECTION III OPERATION – Torquing Conventional Nuts -continued from the previous page3-9 Loosening Procedures Avanti and Stealth SYSTEM First, set the pump to 10,000PSI. Set the tools for the loosening mode (Refer to 3-3), assuring the reaction surface abuts squarely off a solid reaction point. Press and hold the remote control button down. Pressure will decrease as the socket begins to turn. As the cylinder extends fully, you will hear a “CLICK”. Release the remote control button and the cylinder automatically retracts, at which time you again hear a “CLICK”. Repeat this process until the fastener can be removed by hand. NOTE: If the bolt does not loosen with the above procedure, it is an indication that you may require the next larger size tool to loosen the bolt. Corroded nuts and thread galling on bolts can cause difficulty in loosening. Please consult your HYTORC bolt specialist.

SECTION IV OPERATION – HYTORC LoaDISC and Clamp 4-1 Tool Set up and Operation When used in conjunction with the HYTORC LoaDISC Washer or Clamp, the operation is essentially the same as with the conventional nuts, but with one notable exception: THERE ARE NO REACTION FORCES TO CONSIDER OR PROVIDE FOR! The reaction forces are absorbed through the fastener assembly itself. Each individual customer order for LoaDISC or Clamps will be provided with specific installation instructions for each application. However, the following general guidelines outline correct installation procedures. 4-2 HYTORC LoaDISC Tensioning 1. Do not use grease or lubricants on LoaDISC , nut, bolt or joint face. LoaDISC is “DRY LUBE” protected. 2. Place the LoaDISC over the bolt with the flat surface firmly against joint face. 3. Install the nuts on the bolt and hand tighten snugly on both sides of assembly. 4. Set required pump pressure. 5. Place tooling to engage a nut and the LoaDISC with “TIGHTENING” side facing the operator.

-continued to the next page-

DRIVE SOCKET

HOLDING SOCKET

Soft Joint LoaDISC

Reusable LoaDISC

Hard Joint LoaDISC

Limited Clearance

HEX NUT

DISC WASHER THREADED SEGMENT

LoaDISC

SECTION IV OPERATION – HYTORC LoaDISC and Clamp -continued from the previous page4-2 HYTORC LoaDISC Tensioning 6. Verify proper socket engagement by momentarily pressurizing tool. If tool remains stationary, operate normally until tool “STALLS OUT” 7. Should tool rotate during initial pressurizing: A. Insure both socket and sleeve are fully engaged. B. Insure that joint faces are free from grease and oil. *Also refer to the trouble shooting section (4-4) LoaDISC Driver Installation for Tensioning LOCK-RING 'NEUTRAL' POSITION

PLACE DRIVER NUT/LoaDisc

ROTATE 'CW' BY HAND, TO SNUG LoaDisc TO FLANGE

LoaDisc LOCK-GROOVE

NOTE:

ROTATE DRIVER ASSEMBLY 'CCW' DIRECTION FOR TIGHTEN MODE

TIGHTEN 'CCW' DIRECTION

LOOSEN 'CW' DIRECTION

1

2

3

* DO NOT GRAB A SWIVEL DURING OPERATION! * DO NOT PLACE TOOL HOUSING * TO ABUT AGAINST STATIONARY OBJECTS * DO NOT STAND UNDERNEATH OR CLOSE TO TOOL * DO NOT RE-USE SINGLE-TIME USE LoaDISC

VERIFY ROTATE LOCK-RING

LOCK-RING ENGAGE LoaDisc LOCK-GROOVE

4

5

SECTION IV OPERATION – HYTORC LoaDISC and Clamp -continued from the previous page4-3 HYTORC LoaDISC De-tensioning 1. Set pump to maximum pressure. 2. Place tooling to disengage the nut and the LoaDISC with “LOOSENING” side facing the operator. 3. Verify proper socket engagement by momentarily pressurizing tool. If tool remains stationary, operate normally until the nut is loose. 4. Should tool rotate during initial pressurizing: A. Insure both socket and sleeve are fully engaged. B. Insure that joint faces are free from grease and oil. *Also refer to the trouble shooting section (4-4)

ROTATE DRIVER ASSEMBLY 'CW' DIRECTION FOR LOOSEN MODE

LoaDISC Driver Installation for De-tensioning

VERIFY ROTATE LOCK-RING

3

4

5

Releasing “LOCKED-ON” tools. (Refer to 3-8 for Avanti and Stealth) Should the tool “LOCK-ON” after the final cycle, slide the slider with the pump off or in retract position. Turn the pump back on and while maintaining the pressure, cycle XXI in the pump’s manual mode. the pump. Shut off the pump, and remove the tool from the nut. XXI Release Procedure HYT RC

1)

Push slide cover up to position A

2)

Cycle tool in manual mode, release advance button

3)

Shut pump off

4)

Remove tool and reset slide cover to position B

SECTION IV OPERATION – HYTORC LoaDISC and Clamp -continued from the previous page4-4 HYTORC LoaDISC Lubrication Instruction & Trouble Shooting STEP 1:

Make sure all threads and surfaces are free of dirt or grit.

STEP 2:

Apply spray lube TS801 moly spray to nut per procedure indicated below. Allow spray lube to dry (spray lube is shipped with LoaDISC order). Refer to the Dry-lube container label for a drying time. Do Not Apply Lube to LoaDISC

STEP 3:

Clean and dry protruding stud threads and nut seat surfaces.

STEP 4:

Install LoaDISC with flat side against joint, turn till snug.

STEP 5:

Install lubricated hex nut on top of LoaDISC , snug against top surface of LoaDISC .

LoaDISC Application of Spray TS801

NOTE: *Allow sufficient time for spray to dry before use. Hex nut can be reused, if re-lubricated per illustration. NO NOT REUSE ONE TIME USE LoaDISC

HYTORC LoaDISC Trouble Shooting SYMPTOM Driver does not lock

CAUSE Lock ring misaligned with LoaDISC

SOLUTION Check for excessive stud protrusion Check that holding socket is flush to flange surface

LoaDISC groove damaged

Replace LoaDISC

Missing or damage lock-ring

Replace lock-ring

LoaDISC not snug against

flange surface

Tighten LoaDISC to flange surface with driver assembly (CW direction)

Driver un-locks during verification

Worn lock-ring

Replace lock-ring

Driver un-locks during use

Lock-ring rotated in wrong direction

Rotate Holding socket and lock-ring •CCW toward ‘T’ for Tighten •CW toward ‘L’ for Loosen

Driver does not un-lock after torque procedure

Stud driven up into bottom of drive socket

Check for excessive stud extension.

SECTION IV OPERATION – HYTORC LoaDISC and Clamp -continued from the previous page4-5 HYTORC Clamp Installation - Tensioning The HYTORC Clamp is provided with lubrication and is shipped ready for use. For re-lubrication, please refer to lubrication Instructions. (4-6) 1. Thread the Clamp down on the stud, turn the Puller Sleeve to contact the flange, contacting the flange or the spot face firmly. The Clamp should fit easily onto the spot face. 2. The Puller Sleeve, when properly installed, should protrude no more than 1/16 (15mm) past the top of the Nut (outside sleeve). If the Puller Sleeve is raised beyond 1/16”, hold the Puller Sleeve or the Bridge by hand and turn the Nut counter-clockwise (loosen direction) until the Puller Sleeve protrudes no more than 1/16” past the top of the Nut. After adjusting the Nut, turn the entire Clamp assembly down to contact the flange or the spot face firmly. 3. Before using XXI tool on the Clamp, make sure the tool and the drive member are set properly. The castellated drive and the splined reaction member should stick out on the right side for tensioning. Cycle the tool and the drive a few times to ensure that the tool is properly operating. Repeat this step only when you change the tool or the drive. 4. Refer to the load chart supplied with the Clamp and set the pump pressure to achieve the desired load. Do not engage drive on the Clamp while setting the pump pressure. Turn the pressure regulator counter-clockwise to set it below the target pressure. While holding the advanced button on the remote control, slowly turn the pressure regulator clock wise to increase the pressure to the desired value. Ensure the pressure value is set properly by holding the advanced button. 5 Before applying the tool and the drive, engage the splined reaction member to the Puller Sleeve first. Then engage the castellated drive to the castellated section of the Nut. Turn the drive manually until both castellation are fully engaged. IMPORTANT: If the castellated teeth do not fully engage, the Puller Sleeve is sticking up too far or stud protrusion is more than maximum value. Refer back to Step 3. Then reposition the Puller Sleeve and check stud protrusion. 6 Apply the pump pressure to tension the Clamp, until the target pressure is reached. To ensure that the proper tension has been applied to the stud, allow the tool to fully retract then advance to the target pressure a final time. 7 Repeat 5 & 6 until all bolts are fully tensioned.

SECTION IV OPERATION – HYTORC LoaDISC and Clamp -continued from the previous page4-6 HYTORC Clamp Installation - Detensioning 1. Before using XXI or Avanti tool on the Clamp, make sure the tool and the drive member are set properly. The castellated drive and the splined reaction member should stick out on the left side for detensioning. Cycle the tool and the drive a few times to ensure that the tool is properly operating. Repeat this step only when you change the tool or the drive. 2. Detensioning, in general, requires higher pump pressure. Refer to the load chart and set the pump pressure slightly higher than the value used for tensioning. Turn the pressure regulator counter clockwise to set it below the target pressure. While holding the advanced button on the remote control, slowly turn the pressure regulator clockwise to increase the pressure to the desired value. Ensure the pressure value is set properly by holding the advanced button. 3. Remove drive from tool, engage the splined reaction member to the Puller Sleeve first. Then engage the castellated drive to the castellated section of the Nut. Turn the drive manually until both castellation are fully engaged. Place tool on drive with “LOOSEN” side facing the operator. Install drive retainer. 4. Apply the pump pressure to detension the Clamp, until it can be turned by hand. 5. Repeat 3 & 4 until all bolts are fully tensioned. On applications that require two or three passes to tension, it is advised to detension the last few bolts in two passes. If corrosion makes it impossible for the Clamp to be turned by hand even after detensioning, use the hex/spine adaptor. To use the hex/spline adaptor, insert the male spline of the adaptor into the female spline of the Puller Sleeve. Place a wrench over the hex of the adaptor and rotate the Sleeve off the bolt.

NOTE: Before reusing the Clamps, it is imperative that the Clamps are properly cleaned and re lubricated to prolong their life. Refer to the lubrication instruction on the next page.

SECTION IV OPERATION – HYTORC LoaDISC and Clamp -continued from the previous page4-7 HYTORC Clamp Lubrication Instruction The Clamp Lubrication Instructions: (Use a clean stiff bristle brush) STEP 1:

Make sure all threads and splines are free of dirt or grit. Generously grease internal threads on the Jack-up Sleeve with a brush to get full coverage to the thread root.

STEP 2:

Generously grease external threads on the Puller Sleeve with a brush to get full coverage to the thread root.

STEP 3:

Grip the bottom splined section and internal threads of the Jack-up Sleeve into the Jack-up Sleeve as the arrow indicates. Leave the bottom splined section sticking out the bottom.

STEP 4:

Turn the assembled parts upside-down. Spread excess grease around to coat bottom surface of the Jack-up Sleeve and splines. Apply grease on the splines if coating is thin.

STEP 5:

Apply grease to internal splines on the Washer to get full coverage to the spline root. Coat top surface of the Washer.

STEP 6:

Slide the Washer to the assembled Sleeves as the arrow indicates. When the Puller Sleeve and the Washer are in contact, the Puller Sleeve and the Washer bottoms should be flush with each other. Rotate the Jack-up Sleeve while holding the Washer to achieve this desired condition.

SECTION V OPERATION – HYTORC Power Packs 5-1 HYOTRC Power Packs General Information All HYTORC Power Packs operate at a pressure range from 500 to 10,000 PSI and are fully adjustable. They have been engineered and designed for portability and high flow for increased speed. Before using your HYTORC Power Pack, check the following points: • • • • •

Is the reservoir filled with oil? Where is the closest electrical outlet at the job site? (Electric pump only) Is there enough air pressure (100 PSI) and flow (50 CFM) at the job site? (Air units only) Is the gauge mounted and rated for 10,000 PSI Is the oil filler plug securely in place?

The Power Packs maximum working pressure is 10,000 PSI (700 kg/cm2, 690 Bar) Make sure all hydraulic equipment and accessories are rated for 10,000 PSI operating pressure. 5-2 Hydraulic Connections When making a connection with quick connect couplings, make sure the couplings are fully engaged. Threaded connectors such as fittings, gauges etc. must be clean and securely tightened and leak free. CAUTION: Loose or improperly threaded couplers can be potentially dangerous if pressurized. Severe over tightening can cause premature thread failure. Knurled sleeve on couplers need to be only hand tight. Never grab, touch or in any way come in contact with a hydraulic pressure leak. Escaping oil can penetrate the skin and cause injury. Do not subject the hose to potential hazard such as sharp surfaces, extreme heat or heavy impact. Do not allow the hose to kink and twist. Inspect the hose for wear before each usage. 5-3 Prior to Use Do not use a power or extension cord that is damaged or has exposed wiring. All single phase motors come equipped with a three prong grounding type plug to fit the proper grounded type electrical outlet. Do not use a two prong ungrounded extension cord as the pump’s grounded type electrical outlet. Compare motor nameplate against power availability to prevent motor burnout or dangerous electrical overloading. *For electric cord extension, refer to below chart 0-25 Foot Extension 26-50 Foot Extension 51-75 Foot Extension 76-100 Foot Extension

Use size 12 gauge cord Use size 10 gauge cord Use size 8 gauge cord Use size 6 gauge cord

Check hydraulic oil level to prevent possible pump burnout. Look at oil fill level on the oil sight gauge. The oil level should be approximately 2” from the top of the reservoir plate-with motor off. Add HYTORC oil as necessary. Air Pump Oil Sight Gauge

*Do not mix different grades of oil.

Electric Pump Oil Sight Gauge

SECTION V OPERATION – HYTORC Power Packs -continued from the previous page5-3 Prior to Use -ContinuedMake sure all desired gauge, valve, hose and quick coupler connections are tight and secure. The gauge permits the operator to monitor the load on the wrench. *Calibrated gauges are available for most application. Before starting your HYTORC pump, connect your hydraulic hoses to both the pump and torque wrench. (Refer to 3-2) 5-4 Operation Electric Pump Push the rocker switch on the hand control pendant in the OFF position. Then, depress and release the safety button. NOTE: The safety button is an added feature designed to prevent premature starting and should only be depressed by the tool operator. Safety Button

Push the rocker switch to advance position and release it. This will start your pump and place it in the retract position. Your HYTORC electric pump has been designed with an auto shut off system. The pump will shut off after approximately 20 seconds of non-cycling. This will prevent overheating or unnecessary wear and results in longer life of your pump. To restart the pump, depress the safety button again.

OFF Retract/Neutral Advance

Rocker Switch

5-5 Operation Air Pump Before connecting air supply line to the Air Filter Lubricator, make sure the Air Flow Lever is in the OFF position. Then connect air supply line. Open the Air Flow Lever. Check the PSI reading on the Air Pressure Gauge. It should be at 100 psi. Depress the Air Adjustment Knob to increase psi reading. Air Adjustment Knob Air Flow Lever Adjust lubricator to approximately one drop per Lubricator Adjust Minute. *Before operating your HYTORC air pump, check for air leaks on the air hoses/tubing. Air Pressure gauge

SECTION V OPERATION – HYTORC Power Packs -continued from the previous page5-5 Operation Air Pump To start the pump, depress the advance button and release it. This will put the tool in the retract mode. To advance the tool, depress the advance button and hold it down. When you are done, depress the stop button and the motor will stop. NOTE: The pump is still pressurized. To release the air pressure from the pump, put the Air Flow Lever in the OFF position, then depress the advance button on the air remote control. This will purge the air in the motor. Now it is safe to disconnect your air supply line.

Advance Button Stop Button

5-6 Operation of automatic pump Before operating automatic pump, the cable line attached to each hose must be connected securely with the appropriate receptacle on the pump manifold and the receptacle on the tool.

Securely connect

NOTE: Connect only the number of tools used on the application to the pump.

Set pump pressure to achieve desired torque value. (refer to 3-5 and 3-6)

SECTION V OPERATION – HYTORC Power Packs -continued from the previous page5-7 Starting with automatic operation MANUAL MODE For manual operation, depress the Mode [M] 3-position rocker switch to the ‘MANUAL’ position. Hold down the Control [C] rocker switch in the ‘RUN’ position to advance the tool(s). The switch will toggle to the ‘NEUTRAL’ position when released, retracting the tool(s). Depress the Control [C] switch to the ‘OFF’ position to turn off the system. AUTOMATIC MODE

CONTROL SWITCH

PERSS FOR RUN (TOOL ADVANCE) RELEASE (TOOL RETRACT) (NEUTRAL)

PRESS FOR PUMP OFF

Initialize Computer: To operate the automatic system, the computer has to recognize how many tools are attached to the system. To accomplish this, attach the required number of tools to both hydraulic and electric lines. Then cycle system in manual mode for at least one full cycle.

PRESS FOR TIGHTENING NEUTRAL LOOSENING PRESS FOR MANUAL

MODE SWITCH AUTOMATIC TIGHTENING MODE Initialize the computer (see above). Without shutting pump off, push Mode switch [M] into ‘TIGHTENING’ position. Press and hold control switch [C] in ‘RUN’ position. As long as the run switch is held depressed, the pump will function in automatic tightening mode. The tool(s) will continue to cycle until the preset torque Is achieved. Allow sufficient time to be sure that the tool(s) have stopped rotating before releasing the run switch. The pump motor will automatically shut off after 20 seconds, allowing the tool(s) to return to the retract position. The ‘OFF’ position on the Control switch turns off the system. AUTOMATIC LOOSENING MODE Initialize the computer (see above). Without shutting pump off, push Mode switch [M] into ‘LOOSENING’ position. Press and hold control switch [C] in ‘RUN’ position. As long as the run switch is held depressed, the pump will function in automatic loosening mode. The tool(s) will continue to cycle until the Control switch is released. Cycle tool(s) until nuts are free and can be removed by hand. Release the Control switch and depress the Control switch to the ‘OFF’ position to complete the loosening cycle.

R & R PC-5500

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