Service Manual: 6060 FS Hydraulic Shovel No. DH360203
Uploaded by
Robinson CuadradoService Manual: 6060 FS Hydraulic Shovel No. DH360203
Uploaded by
Robinson Cuadrado
Service Manual
6060 FS
Hydraulic Shovel No. DH360203
Published by: Caterpillar Global Mining HMS GmbH
Dept. Rapid Response / Product Health
Management
D-44149 Dortmund, Caterpillarstr. 1
https://mining.cat.com
© Copyright Caterpillar Global Mining HMS GmbH 2019. The reproduction, distribution and utilization of this
manual / file as well as the communication of its content to others without express authorization is prohibited.
Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a
patent, utility model or design.
Printed in Germany
CONTENTS
Volume 1
1. General
2. Technical data
3. Tools, Assembly
4. Undercarriage
5. Superstructure
6. Drive unit
7. Gearboxes
8. Hydraulic system
9. Electric system
10. Attachment
11. Central lubrication system
12. Options
13. free
14. free
Volume 2
3720200en (01) Page 1
CONTENTS
Volume 2
15. Service Manual for fundamental principles of electricity
16. Service Manual for handling circuit diagrams
17. Service Manual for general information, conversion cal-
culations and tightening torques
18. Service Manual for sealing, protective, testing and clean-
ing agents
19. Service Manual for fittings, tube assemblies and hose
assemblies
20. Repair welding manual
21. Service Manual for oil samples and oil analysis
Page 2 3720200en (01)
03.2019
1. General
CONTENTS
1. GENERAL
1.1 Introduction ...................................................................................... 1.1 - 1
1.1.1 Service Manual ................................................................. 1.1 - 1
1.1.2 How to use the Service Manual ......................................... 1.1 - 1
1.1.3 Servicing and repair ........................................................... 1.1 - 2
1.1.4 Important hints ................................................................... 1.1 - 2
1.2 Safety instructions ........................................................................... 1.2 - 1
1.2.1 Risks of disregarding safety instructions............................ 1.2 - 1
1.2.2 Safety regulations .............................................................. 1.2 - 1
1.2.3 Modification of the machine ............................................... 1.2 - 4
1.2.4 Re-commissioning ............................................................. 1.2 - 4
1.3 General .............................................................................................. 1.3 - 1
3720201en Page 1 - 1
CONTENTS
Page 1 - 2 3720201en
1 GENERAL
1.1 Introduction Most tables referring to the drawings contain the
following information:
This Caterpillar hydraulic excavator is a part of
the extensive range of Caterpillar mining 1. Item number
equipment.
2. Quantity
Decades of experience in the manufacture of
3. Designation
earthmoving machines, modern design and pro-
duction techniques, stringent testing procedures 4. Weight
and the highest demands on quality guarantee the
reliability and functionality of your
Caterpillar hydraulic excavator. The information on the bolts contains:
Thread size M 20
1.1.1 Service Manual Steel grade 10.9
Size of wrench SW 30
This Service Manual is written with the servicing Tightening torque MA = 630 Nm
mechanic in mind and contains important informa- Liquid adhesive, if required Loctite
tion required to carry out repair and servicing pro-
cedures. Some drawings contain symbols and reference
numbers under them.
Read the Service Manual, but also the Operation
and Maintenance Manual for the Caterpillar hy- The symbols mean:
draulic excavator before commencing any servi-
cing or repair work. The Service Manual, as well Bolt joint with a certain
as the Operation and Maintenance Manual and tightening torque
Spare Parts Catalog should be used as a source
of reference and assistance - even when the user
is well acquainted with the range of Caterpillar ex- Component with a certain
cavators. play setting
Using the Service Manual allows the experienced
mechanic to carry out repair work correctly.
Bolt joint secured with ad-
hesive (P/No. 8432623)
Splines coated with mineral
1.1.2 How to Use the Service Manual
lubricating paste
(P/No.0244905)
The Service Manual contains information on the
main and subordinate construction elements of the
originally delivered excavator. It does not describe
The part "Sealing, Protective, Testing and Cleaning
any elements or special features introduced later.
Agents" contains comprehensive information on
adhesives and lubricating pastes.
The main table of contents allows you to find the
required information quickly.
To make it easier to understand the content, some
illustrations are simplified and therefore can slightly 1.1.3 Servicing and repair
differ from the actual appearance of the machine.
If you need some servicing and repair work, carry it
The item references in sectional and 3-D drawings out as soon as possible. It minimizes overall servic-
are mostly the same as those in the corresponding ing and repair costs and increases the functionality
drawings of the Spare Parts Catalog. It makes of the Caterpillar excavator.
cross referencing easier.
3849221en - (00) Page 1.1 - 1
1 GENERAL
During all servicing and repair work always follow When components are removed, close up
the instructions contained in the Service Manual all open hoses, pipes, ports and housings
and Operation and Maintenance Manual. to keep dirt out.
Caterpillar Service always performs major work Always use suitable tools, e.g. snub-nosed
that is not described in the Service Manual. screwdriver, when removing seals and
worn parts. Seal surfaces must not be
Caterpillar has a widespread net of customer damaged.
service and spare parts depots with fully
equipped workshops and qualified personnel. Always change all seals and O-rings to
prevent leaks at a later stage.
Use only original Caterpillar spare parts.
Caterpillar Global Mining HMS GmbH cannot be Fix any leakages as soon as possible.
held liable for any damage or injury caused by im-
proper operation of the Caterpillar hydraulic exca- Tighten up leaking fittings only after de-
vator or by non-observance of instructions written pressurization. Do not repair damaged
in this Service Manual. pipes. Change them. Change hoses im-
mediately if you see damages or "sweat-
This Service Manual does not supplement, in ing".
any way whatever, the general terms of sale
and delivery of the Caterpillar Global Mining Ensure that all changed consumables and
HMS GmbH. worn components, such as oil filters, hy-
draulic hoses and drained fluids are dis-
Please contact the Caterpillar Service for assis- posed of safely and with minimal environ-
tance and advice. mental impact.
When making any inquiries, please always use the Ensure that all national and local regula-
machine model and serial number. tions regarding environment protection are
carefully followed.
Check all mechanical connections and
1.1.4 Important hints locks, e.g. screws, nuts, bolts, lock wash-
ers, before inserting them again. Change
them if necessary.
Before carrying out any work on
the electrical system or before All seating surfaces must be even and free
welding set the red battery isola- of paint, grease, acid, dirt and rust.
tor switch on the power module to
OFF and lock it. Prepare suitable containers to catch all es-
After finishing the work set the caping fluids, e.g. cleaning fluid, hydraulic
oil, brake fluid, fuel, water, battery electro-
battery isolator switch to ON and
lyte. Dispose of the fluids in accordance
unlock it (see Operation and
with the requirements on environmental
Maintenance Manual).
protection.
Always provide the servicing and repair Dispose of used filter cartridges, old batter-
personnel with a suitable working place. ies and irreparable parts, such as hydraulic
hoses, in accordance with environmental
Before disassembling a component for protection requirements as well.
servicing or repair clean it thoroughly.
Connect the weld earth clamp as near to
To keep the working place clean is espe- the weld area as possible. Do not allow the
cially important. Never use cotton waste or welding current to run through swing bear-
other fibrous material for cleaning pur- ings, hydraulic cylinders, pins or bearing
poses. Use only fibreless cloths. points.
Page 1.1 - 2 3849221en - (00)
1. GENERAL
1.2 Safety instructions
1.2.1 Risks of disregarding safety 1.2.2 Safety regulations
instructions
Personnel
This Caterpillar hydraulic excava- The machine must not be started
tor has been built in accordance by unauthorized people.
with state-of-the-art standards and
the recognized safety rules. Therefore secure and lock it.
However, operating the machine if Follow the accident prevention
a fault is suspected or has oc- regulations.
curred, or carrying out repair work Only specially trained and qualified
inexpertly personnel with the appropriate
technical knowledge can operate,
endangers the lives of people in service or repair the hydraulic ex-
contact with it cavator.
damages the machine and other If you lack such knowledge, ex-
property. perienced personnel, e.g. from
Caterpillar, are to give you detailed
Stop the hydraulic excavator im-
instructions.
mediately if you suspect or notice
any damage to ensure the safety of The personnel must have read and
the operator, other people or mate- understood the Operation and
rial property at the application area Maintenance Manual and in par-
of the excavator. ticular the chapter
All components of Caterpillar ma- ‘Fundamental Safety Instructions.’
chines are perfectly tuned to each
Only such people can start up the
other. Trouble-free operation and a
machine after assembly work to
long service life can only be
adjust the attachment.
achieved with original Caterpillar
spare parts. Incorrect operation of the machine
or the equipment can result in life-
threatening situations.
During all works, always observe
the start and shut down proce-
dures described in the Operation
and Maintenance Manual.
2440539en – (01) Page 1.2 - 1
1. GENERAL
Personnel Tools and devices
Personal protective equipment and Tools, hoists, slings, trestles and
safety working clothing: other devices must be in a reliable,
safe state.
Wear a safety helmet, safety foot-
wear and safety gloves. Metal splinters may cause injury
when you take in or out attachment
Wear closely fitting working cloth-
bolts. Therefore during this proce-
ing when working on the machine.
dure use a brass or copper man-
Loose, wide garments can catch on
drel and wear safety glasses.
machine parts and result in injury.
When climbing onto or off the ma-
Personnel carrying out work at
chine use only ladders, steps, plat-
greater heights must wear safety
forms and handrails provided for
harnesses. Always put on a tested
this purpose.
harness which is equipped with fall
arrestors and safety lines. Always keep ladders, steps and
platforms in a non-slip state. Re-
If you need assistance to carry out
move any oil, grease, earth, clay,
the work, e.g. marshallers, clearly
snow, ice and other foreign matter
define the responsibilities of each
immediately.
assistant beforehand. The individ-
ual responsibilities are to be care-
fully observed to ensure safety.
Securing the working equip-
ment
Secure the machine and the work-
ing equipment against inadvertent
and unauthorized start. Position
working equipment on the ground
in such a way that it cannot move
when mechanical or hydraulic
connections become detached.
Use hoists or other appropriate
support devices when you install,
remove or displace any equipment
or component. Thus you prevent
them from inadvertent movements,
slip or fall.
Page 1.2 - 2 2440539en – (01)
1. GENERAL
Before opening systems and units Before carrying out works, espe-
(e.g. pipes, coolers, hydraulic res- cially on the electrical system, dur-
ervoirs and accumulators) depres- ing which tools, spare parts, etc.
surize them properly. can contact electric cables, always
disconnect the battery: first the
Open or remove protective devices
negative pole and then the positive
on moving machine parts only
pole. When reconnecting the bat-
when the drive unit is shut down
tery, connect first the positive and
and secured against inadvertent
then the negative pole.
start.
Always replace defective, me-
Before re-commissioning install all
chanically prestressed compo-
protective devices.
nents. Never open them! The Ser-
Before carrying out assembly work, vice Manual contains no informa-
the machine and the equipment tion on such work.
must be secured against inadver-
The operating temperature of the
tent movement, e.g. by placing the
machine is high and the consum-
working equipment on the ground.
ables have at least the same tem-
perature. Therefore take care to
avoid burns or scalds.
Hydraulic and lubricating sys-
tem: Be careful when handling acids,
e.g. battery acid. Acid splashes
Always observe the safety regula- may injure the eyes and the skin.
tions applicable to the product
when handling oils, greases and If the acid is splashed onto your
other chemical substances. skin, rinse it with plenty of clean
running water and seek medical
Close open unused bores, pipe and care immediately.
hose connections so that they are
impermeable to pressure. If the acid is splashed in your eyes,
rinse thoroughly with running wa-
Refill the hydraulic system with ter and seek medical care immedi-
collected drain hydraulic oil only ately.
through the return flow filters. Dis-
pose of waste oil without polluting Never smoke when handling flam-
the environment. mable liquids.
Observe the correct working se- Be careful with open flames and
quence when fitting or replacing unprotected light. Not only fuel but
components or equipment. also other consumables often have
a low flash point and catch fire
easily.
2440539en – (01) Page 1.2 - 3
1. GENERAL
1.2.3 Modifications of the machine 1.2.4 Re-commissioning
Unauthorized conversions or modi- Before re-commissioning:
fications of the hydraulic excavator
are forbidden for reasons of safety. Grease all lubricating points.
Never modify the nominal pressure Check all oil levels and correct
value of pressure relief valves them if necessary.
without explicit approval from Cat-
erpillar. Do not remove the lead Carry out function checks of all
seals from pressure relief valves repaired components.
and hydraulic accumulators.
Check all functions of the exca-
vator including brakes during a
test run. Release the hydraulic
excavator for re-commissioning
only if all its functions operate
properly.
Page 1.2 - 4 2440539en – (01)
1. GENERAL
1.3 General
This Service Manual contains information in addi- The Service Manual covers the information you
tion to the Operation and Maintenance Manual need when handling your excavator. However,
and the Spare Parts Catalog, to familiarise the Caterpillar Global Mining HMS GmbH will be
personnel with the designated use, maintenance pleased to answer any questions you have on its
and repair of the CAT hydraulic excavator. products. Please contact your local CAT dealer or
your Caterpillar subsidiary.
The information in the Service Manual corre-
sponds to the standard technical specification of
the machine when it was delivered.
All sketches and drawings show general principles.
They do not represent the actual design of the
machine and are not to be used for manufacturing.
Special equipment is normally not considered.
Technical modifications, which are introduced after
delivery of the machine, may also be incorporated
in machines which are already in operation.
In this case, you can find the updated version of
the Service Manual on the Caterpillar website.
2440540en – (02) Page 1.3 - 1
1. GENERAL
Page 1.3 - 2 2440540en – (02)
03.2019
2. Technical Data
CONTENTS
2. TECHNICAL DATA
2.1 Introduction ......................................................................................... 2 - 1
2.1.1 Foreword .............................................................................. 2 - 1
2.1.2 Safety ................................................................................... 2 - 1
2.1.3 General ................................................................................. 2 - 1
2.2 Engine / Motor ..................................................................................... 2 - 3
2.3 Hydraulic system ................................................................................. 2 - 4
2.3.1 Main pump ............................................................................ 2 - 4
2.3.2 Swing system ....................................................................... 2 - 5
2.3.3 Auxiliary pressure pump / Gear oil pump .............................. 2 - 6
2.3.4 Servo- and swing charge pump ............................................ 2 - 6
2.3.5 Cooling system hydraulic oil / water ..................................... 2 - 7
2.3.6 Travel motor ......................................................................... 2 - 9
2.3.7 Control block......................................................................... 2 - 9
2.3.8 Filter elements for hydraulic system ..................................... 2 - 9
2.4 Pressure setting ................................................................................ 2 - 10
2.5 Governing current for proportional valves ..................................... 2 - 11
2.6 Hydraulic cylinder ............................................................................. 2 - 12
2.6.1 Face shovel ........................................................................ 2 - 12
2.6.2 Backhoe.............................................................................. 2 - 12
2.7 Transmission ratio ........................................................................... 2 13
3720202en (00) Page 2 - 1
CONTENTS
2.8 Weights of modules and components.............................................2 - 14
2.8.1 Modules .............................................................................. 2 - 14
2.8.2 Components ....................................................................... 2 - 15
2.9 Tightening procedures for bolts ...................................................... 2 - 16
2.9.1 Tightening procedures for module bolts.............................. 2 - 16
2.9.2 Tightening procedures for component bolts........................ 2 - 18
Page 2 - 2 3720202en (00)
2.1 TECHNICAL DATA
2.1 Introduction
2.1.1 Foreword 2.1.2 Safety Instructions
The Service Manual contains important informa- Any person entrusted with com-
tion for personnel servicing the machine. Machine missioning, operation, inspection
specifications listed in other machine documents and servicing of the Caterpillar
are not always repeated in this section. hydraulic excavator are to have
read and understood the Operation
The documentation of a Caterpillar mining machine and Maintenance Manual and, in
includes: particular, the chapter FUNDA-
MENTAL SAFETY INSTRUCTIONS
Operation and Maintenance Manual before starting any work.
Spare Parts Catalog
Service Manual.
2.1.3 General
The present brochure does not contain the specifi- Technical modifications, which are introduced after
cations of auxiliary units for the operation of addi- delivery of the machine, may also be incorporated
tional or optional equipment or the specifications of in machines which are already in operation.
individual machines. In this case, you can find the updated version of
the Service Manual on the Caterpillar website
The refilling quantities specified for consumables
are approximate quantities which are intended as a
help for planning consumable requirements.
Each unit is equipped with suitable checking de-
vices, e.g. dipstick or checking plugs, permitting
the operator to check proper filling of the units.
2440542en - (01) Page 2 - 3
2.1 TECHNICAL DATA
Page 2 - 4 2440542en - (01)
2. TECHNICAL DATA
2.2 Engine
Caterpillar 3512 C
Designation
Unit Quantity
Manufacturer and type Caterpillar 2
3512 C
Displacement Liter 58.6
Rated output SAE J 1995 kW 1 120 each
Idling speed rpm 800
Rated speed (on full load) rpm 1 800
Maximum speed rpm 1 900
Weight kg 6 240
Max. altitude without output reduction m 3 048
Alternator V/A 24 / 150
Battery V / Ah 12 / 244 6
Fuel filter 2x2
Oil filter 2x3
Air intake filter (main filter element) 2x2
Air intake filter (safety filter element) 2x2
3849417en (00) Page 2 - 3
2. TECHNICAL DATA
2.3 Hydraulic system
2.3.1 Main pump
Designation Unit
Quantity 4 double pumps
Type Swash plate axial-piston pump with
variable displacement
Model LA 20 VO 520
Adjusted displacement cm3 / rev. 2 x 467
Operating speed rpm 1 450
Governing pressure bar 7.5 42.5
Max. oil flow l / min 2 x 650 ( = 0.96)
Working pressure bar 320 / 360
Page 2 - 4 3849417en - (00)
2. TECHNICAL DATA
2.3.2 Swing system
2.3.2.1 Swing pump
Designation Unit
Quantity 2x2=4
Type Swash plate axial-piston pump with
variable displacement
Model A4V G 250
Displacement cm3 / rev. Reduced to 180
Operating speed rpm 1 950
Max. oil flow l / min 337 ( = 0.96)
Working pressure bar 350
Setting of relief valve bar 400
Thermo switch in pump housing 1 x per pump
setting (high) °C 92
setting (low) °C 87
2.3.2.2 Swing motor
Designation Unit
Quantity 4
Type Fixed-displacement, axial-piston motor
Model A2F 180
Displacement cm3 / rev. 180
Operating speed rpm 1 797 ( = 0.96)
Working pressure bar 350
3849417en (00) Page 2 - 5
2. TECHNICAL DATA
2.3.3 Pilot pump and gear oil pump
2.3.3.1 Pilot pump
Designation Unit
Quantity 4
Type Gear pump
Operating speed rpm 1 950
Model Bosch
Displacement cm3 / rev. 22.5
Max. oil flow l / min 42 ( = 0.96)
Working pressure bar 80
2.3.3.2 Gear oil pump
Designation Unit
Quantity 1
Type gear pump
Operating speed rpm 1 556
Model Kracht
Displacement cm3 / rev. 12.58
Max. oil flow l / min 29
Working pressure bar max. 6
Page 2 - 6 3849417en - (00)
2. TECHNICAL DATA
2.3.4 Swing charge pump
Designation Unit
Quantity 2
Type Swash plate axial-piston - pump
variable-displacement
Operating speed rpm 1 950
Model A 10 VO 100
Displacement cm3 / rev. 100
Max. oil flow l / min 187 ( = 0.96)
Working pressure bar 50
3849417en (00) Page 2 - 7
2. TECHNICAL DATA
2.3.5 Cooling system for hydraulic oil / engine coolant
2.3.5.1 Hydraulic oil cooling fan drive pump
Designation Unit
Quantity 4
Type Gear pump
Model KP 5/250 E
Displacement cm3 / rev. 250
Operating speed rpm 1 950
Max. oil flow l / min 468 ( = 0.96)
Working pressure bar 50 (max. 65)
2.3.5.2 Engine coolant cooling fan drive pump
Designation Unit
Quantity 2
Type Swash plate axial-piston - pump
Model A 10 VED 100
Displacement cm3 / rev. 100
Operating speed rpm 1 950
Max. oil flow l / min 187 ( = 0.96)
Working pressure bar max. 280
2.3.5.3 Hydraulic oil cooling fan drive (motor)
Designation Unit
Quantity 4
Type Gear motor
Model KM 5/300 E
Displacement cm3 / rev. 300
max. operating speed rpm 1 497 ( = 0.96)
Working pressure bar 50 (max. 65)
Page 2 - 8 3849417en - (00)
2. TECHNICAL DATA
2.3.5.4 Engine coolant cooling fan drive motor
Designation Unit
Quantity 2
Type Gear motor
Model KM 3 / 100
Displacement cm3 / rev. 100
max. operating speed rpm 1 795 ( = 0.96)
Working pressure bar max. 280
3849417en (00) Page 2 - 9
2. TECHNICAL DATA
2.3.6 Travel motor
Designation Unit
Quantity 4
Type Variable-displacement, axial-piston
Model A6VM - 250
Max. displacement cm3 / rev. 250
Operating speed at max. displacement rpm 2 400 (e = 0.96)
Min. displacement cm3 / rev. 170
Operating speed at min. displacement rpm 3 168 (e = 0.96)
Working pressure bar max. 360
2.3.7 Control block
Designation Unit
(piston stroke measured from neutral position)
Boom, stick, bucket mm 17
Clam mm 17
Travel mm 17
Float valve mm 17
Page 2 - 10 3849417en - (00)
2. TECHNICAL DATA
2.3.8 Filter elements for hydraulic system
Designation rating [m
High pressure filter element for working pumps 100 8
Return flow filter element for hydraulic tank 10 14
Filter element swing charge circuit 40 2x2
Filter element - servo circuit 6 2x2
Filter element swing circuit 200 2
Filter element gear oil circuit 40 2
Air breather filter hydraulic tank 2
Bypass valve-screen hydraulic tank screen size 1.5 mm 6
Filter for main pump bearing flushing circuit 6 2x1
3849417en (00) Page 2 - 11
2. TECHNICAL DATA
2.4 Pressure setting
Note: You can find more details in chapter 8.6 Pressure checking and setting of this Service Manual.
Designation Unit
Pressure cut-off - main pumps Attachment bar 320 ± 5
Travel bar 360 ± 5
Primary relief for main pumps Attachment bar 330 + 10
Travel bar 330 + 10 / 370 + 10
Secondary relief for Boom cylinders bar 360 ± 5
Stick cylinders bar 360 ± 5
Bucket cylinders bar 360 ± 5
Clam (single valve) bar 350 ± 5
Clam close (piston side) bar 225 ± 5
according to M0079380
Clam (back wall) bar 330 + 10
Travel cross over relief bar 370 ± 5
Main pump flow control (PST) bar 4 42
Main pump support pressure (P) bar 50 ± 3
Pilot pressure bar Chapter 8.6
Swing circuit - max. working pressure (approx.) bar 350 ± 5
Swing circuit - charge pressure (approx.) bar 50 ± 3
Cooling pressure Hydraulic oil cooling bar 65 - 5
Page 2 - 12 3849417en - (00)
2. TECHNICAL DATA
2.5 Governing current for proportional valves
This chapter is available only on request.
2.6 Hydraulic cylinder
2.6.1 Face shovel attachment/ implement
Designation Unit
Rod - [mm] Piston - [mm]
Boom cylinder mm 230 350
Stick cylinder mm 200 300
Bucket cylinder mm 200 300
Clam cylinder mm 125 250
2.6.2 Backhoe attachment/ implement
Designation Unit
Rod - [mm] Piston - [mm]
Boom cylinder mm 280 420
Stick cylinder mm 220 330
Stick cylinder (only machine DHN60202) mm 230 335
Backhoe cylinder mm 200 280
3849417en (00) Page 2 - 13
2. TECHNICAL DATA
2.7 Transmission ratio
Designation
Pump gearbox - main pumps i = 1.235
Pump gearbox - swing pumps, swing charge i = 1.085
pumps, engine fan drive pumps, hydraulic oil
cooling pumps, pilot pumps (gearbox rear side)
Swing gearbox i = 49.28
Travel gearbox (final drive) i = 458.5
Page 2 - 14 3849417en - (00)
2. TECHNICAL DATA
2.8 Weights of modules and components
2.8.1 Modules
Designation Unit
RH crawler module without track kg 49 000
LH crawler module without track kg 49 000
1 Track 1 400 mm (42 links) kg 30 500
1 Track 1 600 mm (42 links) kg 32 400
1 Track 1 800 mm (42 links) kg 35 300
Carbody module with swing ring kg 52 000
Superstructure module kg 67 500
Engine module with hydraulic oil kg 54 300
Counterweight, bottom section kg 36 500
Counterweight, top section kg 19 900
Oil cooler module kg 9 700
Cab module kg 7 100
Cab kg 3 500
FS boom (without cylinders) kg 26 624
FS stick kg 16 300
FS backwall (without clam cylinders) kg 24 001
FS front part kg 27 090
BH boom (without cylinders) kg 37 500
BH stick (without cylinders) kg 15 974
BH bucket kg 36 800
3849417en (00) Page 2 - 15
2. TECHNICAL DATA
2.8.2 Components
Designation Unit
Diesel engine 3512 C kg 6 240
Travel gearbox (without hydraulic travel motors) kg 7 500
Swing gearbox (without hydraulic swing motors) kg 990
Pump gearbox (without pumps) kg 1 750
Travel valve block (with rotor) kg 898.8
Attachment valve block kg 388
Main pump kg 670
Swing pump kg 158
Swing motor kg 46
Travel motor kg 105
Swing bearing kg 7 058
Bottom roller kg 1 204
Support roller kg 295.1
Idler kg 4 200
Sprocket kg 2 780
Boom cylinder (face shovel) kg 3 935
Stick cylinder (face shovel) kg 2 844
Bucket cylinder (face shovel) kg 2 844
Clam cylinder (face shovel) kg 601
Boom cylinder (backhoe) kg 6 358
Stick cylinder (backhoe) kg 3 780
Stick cylinder (backhoe) for #202 machine kg 3 825
Bucket cylinder (backhoe) kg 2 283
Page 2 - 16 3849417en - (00)
2. TECHNICAL DATA
2.9 Tightening procedures for bolts
2.9.1 Tightening procedures for module bolts
Designation Chapter
Crawler frame - carbody Bolt size / wrench size M 36 x 4 x 200 / 46
(vertical bolts - top connection area) Bolt type double hex.
Quantity 116
Grade 11.9 / 12.9
Bolt treatment oiled
Initial torque Md = 2 400 ± 240 Nm
Pre-torque Md = 400 ± 40 Nm
Angle 60° ± 5°
Crawler frame - carbody Bolt size / wrench size MJ 36 x 4 x 400 / 36
(horizontal bolts bottom connection area) Bolt type double hex.
Quantity 52
Grade 11.9
Bolt treatment oiled
Initial torque Md = 2 400 ± 240 Nm
Pre-torque Md = 900 ± 90 Nm
Angle 120° ± 5°
Swing bearing carbody Bolt size / wrench size MJ 42 x 4.5 x 500 / 65
Bolt type hex.
Quantity 96
Grade 10.9
Bolt treatment oiled
Initial torque Md = 2 000 ± 200 Nm
Pre-torque Md = 1 200 ± 40 Nm
Angle 120 ° ± 3°
Swing bearing superstructure frame Bolt size / wrench size MJ 42 x 4.5 x 450 / 65
Bolt type hex.
Quantity 96
Grade 10.9
Bolt treatment oiled
Initial torque Md = 2 000 ± 200 Nm
Pre-torque Md = 1 000 ± 30 Nm
Angle 120° ± 3°
3849417en (00) Page 2 - 17
2. TECHNICAL DATA
Designation Chapter
Engine module Bolt size / wrench size M 36 x 4 x 240 / 55
Quantity 16
Grade 11.9
Bolt treatment oiled
Tightening torque Md = 2 800 ± 350 Nm
Cab module Bolt size / wrench size M 24 x 160 / 36
Quantity 21
Grade 10.9
Bolt treatment oiled
Tightening torque Md = 850 Nm
Oil cooler module Bolt size / wrench size M 24 x 180 / 36
Quantity 21
Grade 10.9
Bolt treatment oiled
Tightening torque Md = 850 Nm
Counterweight bottom section Bolt size / wrench size M 64 x 4 x 640 / 95
Quantity 8
Grade 12.9
Bolt treatment molycoted
Pre-torque Md = 4 500 Nm
Angle 180 °
Counterweight top section Bolt size / wrench size M 24 x 150 / 36
Quantity 33
Grade 10.9
Bolt treatment oiled
Tightening torque Md = 850 Nm
Page 2 - 18 3849417en - (00)
2. TECHNICAL DATA
2.9.2 Tightening procedures for component bolts
Designation Chapter
Bottom roller 4.5 Bolt size / wrench size MJ 30 x 3.5 x 190 / 46
Quantity 8
Grade 12.9
Bolt treatment oiled
Tightening torque Md = 2 250 Nm
Top roller 4.6 Bolt size / wrench size M 30 x 3.5 x 220 / 46
Quantity 4
Grade 12.9
Bolt treatment oiled
Tightening torque Md = 2 250 Nm
Sprocket see chapter 4.7
Travel gearbox see chapter 7.2
Engine mounting see chapter 5.3
Swing gearbox see chapter 7.3
Pump-gearbox - engine see chapter 7.4
3849417en (00) Page 2 - 19
2. TECHNICAL DATA
Page 2 - 20 3849417en - (00)
03.2019
3. Tools, Assembly
CONTENTS
3. TOOLS, ASSEMBLY
3.1 Introduction ...................................................................................... 3.1 - 1
3.1.1 Foreword ........................................................................... 3.1 - 1
3.1.2 Safety ................................................................................ 3.1 - 2
3.1.3 General .............................................................................. 3.1 - 8
3.1.4 Corrosion protection for pins and bearings ........................ 3.1 - 9
3.2 Tools ................................................................................................. 3.2 3
3.3 Assembling the excavator ............................................................... 3.3 - 1
3720203en - (00) Page 3 - 1
CONTENTS
Page 3 - 2 3720203en (00)
3.1 TOOLS, ASSEMBLY
3.1 Introduction
3.1.1 Foreword 3.1.2 Safety
Danger in case of non-observance of safety
The Service Manual contains important instructions
information for personnel servicing the machine.
Machine technical data listed in other machine This Caterpillar hydraulic
documents are not always repeated in this book. excavator has been built in
accordance with state-of-the-art
The documentation of a Caterpillar mining machine standards and the recognized
includes: safety rules.
Operation and Maintenance Manual However, operating the machine if
a fault is suspected or has
Spare Parts Catalog occurred, or carrying out repair
work inexpertly
Service Manual
endangers the lives of people in
contact with it
The service manual does not contain technical
data on auxiliary units for the operation of specific damages the machine and other
or optional equipment or data of individual devices. property.
Stop the hydraulic excavator
The refilling quantities specified for consumables
immediately if you suspect or
are approximate quantities which are intended as a
help for planning consumable requirements. notice any damage to ensure the
safety of the operator, other people
Each component is equipped with suitable or material property at the
checking devices, e.g. a dipstick or checking plugs, application area of the excavator.
permitting the operator to check exactly the filling of All components of Caterpillar
the components. machines are perfectly tuned to
each other. Trouble-free operation
and a long service life can only be
achieved with original Caterpillar
spare parts.
3849044en - (00) Page 3.1 - 1
3.1 TOOLS, ASSEMBLY
Rules for safety at work
Personnel Personnel
The machine must not be started Personal protective equipment and
by unauthorized people. safety working clothing:
Therefore secure and lock it. Wear a safety helmet, safety
footwear and safety gloves.
Follow the accident prevention
regulations. Wear closely fitting working cloth-
ing when working on the machine.
Only specially trained and qualified Loose, wide garments can catch on
personnel with the appropriate machine parts and result in injury.
technical knowledge can operate,
service or repair the hydraulic Personnel carrying out work at
excavator. greater heights must wear safety
harnesses. Always put on a tested
If you lack such knowledge, harness which is equipped with fall
experienced personnel, e.g. from arrestors and safety lines.
Caterpillar, are to give you detailed
instructions. If you need assistance to carry out
the work, e.g. marshallers, clearly
The personnel must have read and define the responsibilities of each
understood the Operation and assistant beforehand. The
Maintenance Manual and in individual responsibilities are to be
particular the chapter carefully observed to ensure
‘Fundamental Safety Instructions.’ safety.
Only such people can start up the
machine after assembly work to
adjust the attachment.
Incorrect operation of the machine
or the equipment can result in life-
threatening situations.
During all works, always observe
the start and shut down
procedures described in the
Operation and Maintenance
Manual.
Page 3.1 - 2 3849044en - (00)
3.1 TOOLS, ASSEMBLY
Tools and devices Before carrying out works,
especially on the electric system,
Tools, hoists, slings, trestles and during which tools, spare parts,
other devices must be in a reliable, etc. can contact electric cables,
safe state. always disconnect the battery: first
Metal splinters may cause injury the negative pole and then the
when you take in or out attachment positive pole. When reconnecting
bolts. Therefore during this the battery, connect first the
procedure use a brass or copper positive and then the negative
mandrel and wear safety glasses. pole.
When climbing onto or off the Always replace defective,
machine use only ladders, steps, mechanically prestressed
platforms and handrails provided components. Never open them!
for this purpose. The Service Manual contains no
information on such work.
Always keep ladders, steps and
platforms in a non-slip state. The operating temperature of the
Remove any oil, grease, earth, clay, machine is high and the
snow, ice and other foreign matter consumables have at least the
immediately. same temperature. Therefore take
care to avoid burns or scalds.
Be careful when handling acids,
Securing the working e.g. battery acid. Acid splashes
equipment may injure the eyes and the skin.
Secure the machine and the If the acid is splashed onto your
working equipment against skin, rinse it with plenty of clean
inadvertent and unauthorized start. running water and seek medical
Position working equipment on the care immediately.
ground in such a way that it cannot If the acid is splashed in your eyes,
move when mechanical or rinse thoroughly with running
hydraulic connections become water and seek medical care
detached. immediately.
Use hoists or other appropriate Never smoke when handling
support devices when you install, flammable liquids.
remove or displace any equipment
or component. Thus you prevent Be careful with open flames and
them from inadvertent movements, unprotected light. Not only fuel but
slip or fall. also other consumables often have
a low flash point and catch fire
easily.
3849044en - (00) Page 3.1 - 3
3.1 TOOLS, ASSEMBLY
Before opening systems and units Hydraulic equipment
(e.g. pipes, coolers, hydraulic
reservoirs and accumulators) Check all lines, hoses and screwed
depressurize them properly. connections regularly for leaks and
obvious damage. Repair damage
Open or remove protective devices immediately. Splashed oil may
on moving machine parts only cause injury and fire.
when the drive unit is shut down
and secured against inadvertent Before carrying out any repair work
start. depressurize all system sections
and pressure pipes. Remove them
Before re-commissioning install all in accordance with the specific
protective devices. instructions.
Before carrying out assembly work, Install hydraulic lines properly.
the machine and the equipment Ensure that no connections are
must be secured against interchanged. The fittings, length
inadvertent movement, e.g. by and quality of the hoses must
placing the working equipment on comply with the technical
the ground. requirements.
Hydraulic and lubricating
system:
Always observe the safety
regulations applicable to the
product when handling oils,
greases and other chemical
substances.
Close open unused bores, pipe and
hose connections so that they are
impermeable to pressure.
Refill the hydraulic system with
collected drain hydraulic oil only
through the return flow filters.
Dispose of waste oil without
polluting the environment.
Observe the correct working
sequence when fitting or replacing
components or equipment.
Page 3.1 - 4 3849044en - (00)
3.1 TOOLS, ASSEMBLY
Modifications of the machine
Warning of special dangers
Unauthorized conversions or
modifications of the hydraulic Electric energy
excavator are forbidden for
Use only original fuses with the
reasons of safety.
specified current rating. Switch off
Never modify the nominal pressure the machine immediately, if trouble
value of pressure relief valves occurs in the electrical system.
without explicit approval from
When working with the machine,
Caterpillar. Do not remove the lead
maintain a safe distance from
seals from pressure relief valves
overhead electric lines.
and hydraulic accumulators.
If the work is to be carried out
close to overhead lines, keep the
working equipment far away from
Transport and re-commissioning them.
Caution: danger!
Before re-commissioning: Check out the prescribed safety
distances.
Grease all lubricating points.
If your machine comes into contact
Check all oil levels and correct with a live wire, do not leave the
them if necessary. machine, but drive the machine out
of the hazard zone;
Carry out function checks of all warn others against approaching
repaired components. and touching the machine;
Check all functions of the de-energize the live wire;
excavator including brakes
do not leave the machine until the
during a test run. Release the
damaged or contacted line has
hydraulic excavator for re-
been safely de-energised.
commissioning only if all its
functions operate properly. Check the electrical equipment of
the machine at regular intervals.
Rectify immediately such defects
as loose connections or scorched
cables.
Transport and re-
commissioning
Load and transport the machine
only in accordance with the
Operation and Maintenance
Manual.
Use only appropriate means of
transport and lifting gear of
adequate capacity.
Carry out the re-commissioning
procedure only in accordance with
the Operation and Maintenance
Manual.
3849044en - (00) Page 3.1 - 5
3.1 TOOLS, ASSEMBLY
Gas, dust, steam and smoke 3.1.3 General
Operate engines and fuel operated
heating systems only on This Service Manual contains information in
adequately ventilated premises addition to the Operation and Maintenance
(risk of explosion). Manual and the Spare Parts Catalog, to
familiarise the personnel with the designated use,
Before starting the machine on
maintenance and repair of the Caterpillar
enclosed premises, ensure that
excavator.
there is sufficient ventilation.
Observe the legal regulations at The information in the Service Manual
the respective site. corresponds to the standard technical specification
of the machine when it was delivered.
Before carrying out welding, flame
cutting and grinding operations, All sketches and drawings show general principles.
clean the machine and its They do not represent the actual design of the
surroundings from dust and other machine and are not to be used for manufacturing.
inflammable substances and make
sure that the premises are Special equipment is normally not considered.
adequately ventilated.
Technical modifications, which are introduced after
Carry out welding, flame cutting
delivery of the machine, may also be incorporated
and grinding work on the machine
in machines which are already in operation.
only if it is authorised. Otherwise
In this case, you can find the updated version of
you face a risk of explosion and
the Service Manual on the Caterpillar website.
fire.
The Service Manual covers the information you
need when handling your excavator. However,
Caterpillar Global Mining HMS GmbH will be
pleased to answer any questions you have on its
Noise products. Please contact your local Caterpillar
dealer or your Caterpillar subsidiary.
During the operation close all
sounds baffles.
Always wear the prescribed ear
protectors.
Oil, grease and other
chemical substances
When handling oil, grease or other
chemical substances, observe the
product related safety regulations.
Be careful when handling hot
consumables (risk of burning or
scalding).
Page 3.1 - 6 3849044en - (00)
3.1 TOOLS, ASSEMBLY
3.1.4 Corrosion protection for pins
and bearings
Application of anticorrosive agent
Use only "GLEITMO 815"
anticorrosive agent. 1) Clean off grease, oil, dirt and corrosion
protection agents from pins and bearings
Other agents are not approved by
using white spirit or diesel fuel. Remove
Caterpillar Global Mining HMS
thoroughly any rust patches. All parts
GmbH. should have a dry shiny metal surface.
2) Apply a thin layer of the anticorrosive agent
Before fitting treat all pins and bearings (bushings on pins and all bearings using a brush or a
and hubs) of the working equipment or in spray can. Pin shafts and bearings should
equipment components with "GLEITMO 815" be completely covered by the protective
anticorrosive agent. layer. If the protective layer of a pin treated
with the anticorrosive agent is damaged,
Anticorrosive agent rework these areas before fitting the part.
Fitting and securing of pins
ensures easy fitting and dismantling
1) If the pin is too heavy to be fitted manually,
protects against rust, oxidation and wear apply the anticorrosive agent at first only at
a quarter of the pin length.
prevents non-moving parts of bearings from
seizing and fretting corrosion. 2) Position the pin for fitting with a lifting gear.
It is achieved because aluminium and copper 3) Apply the anticorrosive agent on the
particles form a protective layer on the metal. This remaining length of the pin shaft, fit the pin
layer removes surface irregularities and does not and fix it.
“sweat”, seize or harden.
Part no. for "GLEITMO 815" is 2764305. It is
available at CGM HMS GmbH Spare-Parts
Service.
3849044en - (00) Page 3.1 - 7
3.1 TOOLS, ASSEMBLY
Page 3.1 - 8 3849044en - (00)
CONTENTS
3.2 TOOLS
3.2.0 Tools reference list........................................................................3.2.0 - 1
3.2.1 Torque tools ................................................................................... 3.2.1 - 1
3.2.2 Cutting and tapping tools ............................................................. 3.2.2 - 1
3.2.3 Electric tools .................................................................................. 3.2.3 - 1
3.2.4 Hand tools ...................................................................................... 3.2.4 - 1
3.2.5 Miscellaneous ................................................................................ 3.2.5 - 1
3.2.6 Measuring tools ............................................................................. 3.2.6 - 1
3.2.7 Support ........................................................................................... 3.2.7 - 1
3.2.8 Consumables ................................................................................. 3.2.8 - 1
3.2.9 Service adaptors............................................................................3.2.9 - 1
3720620en - (02) Page 3.2 - 1
CONTENTS
Page 3.2 - 2 3720620en - (02)
3.2.0 TOOLS REFERENCE LIST
3.2 Tools
This section lists recommended tools essential for
carrying out servicing and assembly procedures.
These are not included in the machine’s own tool
set.
Items in the tools list that have part numbers can
be ordered from the
Caterpillar Global Mining HMS Spare Parts Divi-
sion
They are to be ordered in the same manner as
other spare parts.
3720691en – (07) Page 3.2.0 - 1
3.2.0 TOOLS REFERENCE LIST
3.2.1 Torque Tools
6015/FS
6018/FS
6030/FS
6040/FS
6050/FS
6060/FS
6090/FS
RH 120
RH 170
RH 200
RH 340
RH 400
RH 40
RH 90
RECOMMENDED TOOLS AND AC-
Pos CESSORIES FOR MAINTENANCE, Part No.
INSPECTION AND ASSEMBLY
Hydraulic drive unit/Power Pack 240V
1 3.2.1.01 1* 1* 1* 1* 1* 1* 1* 6002267
(torque only)
Hydraulic drive unit/Power Pack 240V
2 3.2.1.02 1* 1* 1* 1 1 1 1 1478386
(torque and angle)
3 3.2.1.03 HP Hose Set (6x5m) 1* 1* 1* 1 1 1 1 2470564
Hydraulic Torque Wrench 1 MXT
4 3.2.1.04 1* 1* 1* 1* 1* 1 2482923
(max. 1850 Nm)
Hydraulic Torque Wrench 3 MXT
5 3.2.1.04 1* 1* 1* 1* 1 2470558
(max. 4.450 Nm)
Hydraulic Torque Wrench 5 MXT
6 3.2.1.04 1* 1* 1* 1* 1 6003121
(max. 7.700 Nm)
Hydraulic Torque Wrench 20 MXT
7 3.2.1.04 1 1 1 6003104
(max. 27.000 Nm)
8 3.2.1.05 Impact Socket ¾” drive 30mm 1 1* 1* 1* 1* 1* 1 2482959
9 3.2.1.05 Impact Socket ¾” drive 32mm 1* 1* 1* 1* 1* 1 6004549
10 3.2.1.05 Impact Socket ¾” drive 36mm 1* 1* 1* 1* 1* 1 6003598
11 3.2.1.05 Impact Socket ¾” drive 41mm 1* 6003599
12 3.2.1.05 Impact Socket ¾” drive 46mm 1* 1* 1* 1* 1* 1 6003601
13 3.2.1.06 Impact Socket 1” drive 32mm 1 1 1 1 1 1 1 6004537
14 3.2.1.06 Impact Socket 1” drive 36mm 1* 1 1 1 1 1 1 1434705
15 3.2.1.06 Impact Socket 1” drive 41mm 1 1 1434706
Impact Socket 1” drive 46mm (Ø 69
16 3.2.1.06 1 1 1 1 1 1 1434707
mm)
Impact Socket 1” drive 46mm (Ø 65
17 3.2.1.06 1 6100296
mm)
18 3.2.1.06 Impact Socket 1” drive 55mm 1 1* 1434709
19 3.2.1.06 Impact Socket 1” drive 60mm 1* 1434710
20 3.2.1.06 Impact Socket 1” drive 95mm 1 1 1 6003610
21 3.2.1.07 Impact Socket 1½” drive 36mm 1 1 1461521
22 3.2.1.07 Impact Socket 1½” drive 46mm 1 1 1 1 1461523
23 3.2.1.07 Impact Socket 1½” drive 50mm 1461524
24 3.2.1.07 Impact Socket 1½” drive 55mm 1 1461525
25 3.2.1.07 Impact Socket 1½” drive 60mm 1 6003602
26 3.2.1.07 Impact Socket 1½” drive 65mm 1 6003603
27 3.2.1.07 Impact Socket 1½” drive 70mm 1 6003604
28 3.2.1.07 Impact Socket 1½” drive 75mm 1 1 1 1 1461528
29 3.2.1.08 Impact Socket 2½” drive 95mm 1 1 1 2482837
Hydraulic Torque Wrench “Stealth 2”
30 3.2.1.09 1* 1* 6003868
41mm (170 – 2.400 Nm)
Hydraulic Torque Wrench “Stealth 4”
31 3.2.1.09 1* 6003869
55mm (400 – 5.500 Nm)
Page 3.2.0 - 2 3720691en – (07)
3.2.0 TOOLS REFERENCE LIST
6015/FS
6018/FS
6030/FS
6040/FS
6050/FS
6060/FS
6090/FS
RH 120
RH 170
RH 200
RH 340
RH 400
RH 40
RH 90
RECOMMENDED TOOLS AND AC-
Pos CESSORIES FOR MAINTENANCE, Part No.
INSPECTION AND ASSEMBLY
Hydraulic Torque Wrench “Stealth 8”
32 3.2.1.09 1 6003870
65mm (800 – 11.000 Nm)
Drive Cylinder for Hydraulic Torque
33 3.2.1.10 1 1 1 1477300
Wrench XLCT
Ratchet Insert 55mm for Hydraulic
34 3.2.1.10 1 1 1 1477299
Torque Wrench XLCT
Torque Multiplier XVR40
35 3.2.1.11 1 1 1 1 1 1 1437544
(max. 4.000 Nm) 1½” drive
Torque Multiplier XVR65
36 3.2.1.11 1 1 1 1 1 1448441
(max. 6.000 Nm) 1½” drive
37 3.2.1.12 ½” Torque Wrench (60-300 Nm) 1 1 1 1 1 1 1 1446762
38 3.2.1.13 Torque Wrench DSG 6 (500-1.300 Nm) 1 1 1 1 1 1 1331433
39 3.2.1.14 Torque Wrench DSG 7 (800-2.000 Nm) 1 1 1 1 1 1 0900890
Spanner Insert for DSG 6 + DSG 7
40 3.2.1.15 1 1 1 1 1 1 1 1590922
(36mm)
Spanner Insert for DSG 6 + DSG 7
41 3.2.1.15 1 1 0900891
(41mm)
Spanner Insert for DSG 6 + DSG 7
42 3.2.1.15 1 1 1 1 1 1740801
(46mm)
Spanner Insert for DSG 6 + DSG 7
43 3.2.1.15 1 1 1 1 1740115
(55mm)
Ratchet Insert for DSG 6 + DSG 7
44 3.2.1.16 1 1 1 1 1 1 1472005
(1”drive)
45 3.2.1.16 Repair Kit for Ratchet Insert 1 1 1 1 1 1 1472006
46 3.2.1.17 Air Impact Gun ½” drive 1 1 1 1 1 1 1 2482463
47 3.2.1.18 Ratchet and Socket Set ½” drive 1 1 1 1 1 1 1 0559027
48 3.2.1.19 Allen Key Socket Set ½” drive (4-19mm) 1 1 1 1 1 1 1 2482522
49 3.2.1.20 Air Impact Gun ¾” drive 1 1 1 1 1 1 1 2482462
50 3.2.1.21 Ratchet and Socket Set ¾” drive 1 1 1 1 1 1 1 2482464
51 3.2.1.22 Air Impact Gun 1” drive 1 1 1 1 2482461
52 3.2.1.23 Ratchet and Socket Set 1” drive 1 1 1 1 1 1 1 2482523
Adaptor for Socket Wrenches
53 3.2.1.24 1 1 1 1 1 1 1 2482471
(1” to ¾”)
Adaptor for Socket Wrenches
54 3.2.1.24 1 1 1 1 1 1 1 1431749
(1½” to 1”)
55 3.2.1.25 Impact Extension 1” drive, 6” length 1 1 1 1 1 1 1 2482956
56 3.2.1.25 Impact Extension 1” drive, 12” length 1 1 1 1 1 1 1 2482957
57 3.2.1.26 Universal Joint ½” drive 1 1 1 1 1 1 1 2482955
*Recommended/Optional
To ease assembly
3720691en – (07) Page 3.2.0 - 3
3.2.0 TOOLS REFERENCE LIST
3.2.2 Cutting and Tapping Tools
6015/FR
6018/FS
6030/FS
6040/FS
6050/FS
6060/FS
6090/FS
RH 120
RH 170
RH 200
RH 340
RH 400
RH 90
RECOMMENDED TOOLS AND AC-
H 40
Pos CESSORIES FOR MAINTENANCE, Part No.
INSPECTION AND ASSEMBLY
1 3.2.2.01 Hacksaw 1 1 1 1 1 1 1 0059324
2 3.2.2.01 Spare hacksaw blades 6 6 6 6 6 6 6 0060784
3 3.2.2.02 M6 x 1 tap 1 1 1 1 1 1 1 0059912
4 3.2.2.02 M8 x 1,25 tap 1 1 1 1 1 1 1 0059915
5 3.2.2.02 M10 x 1,5 tap 1 1 1 1 1 1 1 0059918
6 3.2.2.02 M12 x 1,75 tap 1 1 1 1 1 1 1 0059925
7 3.2.2.02 M14 x 2 tap 1 1 1 1 1 1 1 6003618
8 3.2.2.02 M16 x 2 tap 1 1 1 1 1 1 1 0059929
9 3.2.2.02 M20 x 2,5 tap 1 1 1 1 1 1 1 0157223
10 3.2.2.02 M24 x 3 tap 1 1 1 1 1 1 1 0157226
11 3.2.2.02 M27 x 3 tap 1 1 6003619
12 3.2.2.02 M30 x 3,5 tap 1 1 1 1 1 1 6003620
13 3.2.2.02 M36 x 4 tap 1 1 1 1 6003621
14 3.2.2.02 M39 x 4 tap 1 6003622
15 3.2.2.02 M42 x 3 tap 1 2739509
16 3.2.2.02 M48 x 5 tap 1 1 1 1 1 6003623
17 3.2.2.02 M64 x 4 tap 1 1 1 6004426
3.2.3 Electric Tools
6015/FS
6018/FS
6030/FS
6040/FS
6050/FS
6060/FS
6090/FS
RH 120
RH 170
RH 200
RH 340
RH 400
RH 40
RH 90
RECOMMENDED TOOLS AND AC-
Pos CESSORIES FOR MAINTENANCE, Part No.
INSPECTION AND ASSEMBLY
1 3.2.3.01 Electric Connector Assortment 1 1 1 1 1 1 1 2482882
2 3.2.3.02 Bootlace ferrule Assortment 1 1 1 1 1 1 1 2482529
3 3.2.3.03 Tool Set 1 1 1 1 1 1 1 1190887
4 3.2.3.04 Digital Multimeter 1 1 1 1 1 1 1 1088932
5 3.2.3.04 Pincers red 1 1 1 1 1 1 1 0764860
6 3.2.3.04 Pincers black 1 1 1 1 1 1 1 0764861
Installation Bar for grounding Cable
7 3.2.3.05 1* 1* 1* 1* 1* 1* 1* 1791163
Harness
8 3.2.3.06 Grounding Cable Harness 1* 1* 1* 1* 1* 1* 1* 0925649
9 3.2.3.07 Cable-hook 1* 1* 1* 1* 1* 1* 1* 2270413
10 3.2.3.08 Fuse Tool 1* 1* 1* 1* 1* 1* 1* 1725313
11 3.2.3.09 High Voltage Tester 1* 1* 1* 1* 1* 1* 1* 0255962
*for electric power train only
Page 3.2.0 - 4 3720691en – (07)
3.2.0 TOOLS REFERENCE LIST
3.2.4 Hand Tools
6015/FS
6018/FS
6030/FS
6040/FS
6050/FS
6060/FS
6090/FS
RH 120
RH 170
RH 200
RH 340
RH 400
RH 40
RH 90
RECOMMENDED TOOLS AND AC-
Pos CESSORIES FOR MAINTENANCE, Part No.
INSPECTION AND ASSEMBLY
1 3.2.4.01 ROE Spanner Set metric 6-32mm 1 1 1 1 1 1 1 2482524
2 3.2.4.01 ROE Spanner Set imperial ¼” - 1¼” 1 1 1 1 1 1 1 2482944
3 3.2.4.02 ROE Spanner 15mm 1 1 1 1 1 1 1 0717906
4 3.2.4.02 ROE Spanner 17mm 1 1 1 1 1 1 1 6003612
5 3.2.4.02 ROE Spanner 19mm 1 1 1 1 1 1 1 0717908
6 3.2.4.02 ROE Spanner 22mm 1 1 1 1 1 1 1 0717911
7 3.2.4.02 ROE Spanner 24mm 1 1 1 1 1 1 1 0717913
8 3.2.4.02 ROE Spanner 36mm 1 1 1 1 1 1 1 0215313
9 3.2.4.02 ROE Spanner 41mm 1 1 1 1 1 1 1 0717921
10 3.2.4.02 ROE Spanner 46mm 1 1 1 1 1 1 1 6003613
11 3.2.4.02 ROE Spanner 55mm 1 1 1 1 1 1 1 6003614
12 3.2.4.03 Open End Spanner 17mm 1 1 1 1 1 1 1 6003615
13 3.2.4.03 Open End Spanner 19mm 1 1 1 1 1 1 1 0014079
14 3.2.4.03 Open End Spanner 22mm 1 1 1 1 1 1 1 0014080
15 3.2.4.03 Open End Spanner 24mm 1 1 1 1 1 1 1 0014082
16 3.2.4.03 Open End Spanner 27mm 1 1 1 1 1 1 1 0014083
17 3.2.4.03 Open End Spanner 30mm 1 1 1 1 1 1 1 0014084
18 3.2.4.03 Open End Spanner 32mm 1 1 1 1 1 1 1 0014085
19 3.2.4.03 Open End Spanner 36mm 1 1 1 1 1 1 1 0014086
20 3.2.4.03 Open End Spanner 41mm 1 1 1 1 1 1 1 0014087
21 3.2.4.03 Open End Spanner 46mm 1 1 1 1 1 1 1 6003616
22 3.2.4.03 Open End Spanner 55mm 1 1 1 1 1 1 1 0014088
23 3.2.4.04 Shifter 10” 1 1 1 1 1 1 1 2482947
24 3.2.4.04 Shifter 12” 1 1 1 1 1 1 1 2482948
25 3.2.4.05 14” Pipe Wrench 1 1 1 1 1 1 1 2482951
26 3.2.4.06 Multigrip 1 1 1 1 1 1 1 0059336
27 3.2.4.07 Vice Grip 1 1 1 1 1 1 1 2482949
28 3.2.4.08 Allen Key 12mm 1 1 1 1 1 1 1 0014128
29 3.2.4.08 Allen Key 14mm 1 1 1 1 1 1 1 0014129
30 3.2.4.08 Allen Key 17mm 1 1 1 1 1 1 1 0014130
31 3.2.4.09 INHEX Socket ½” drive, 10mm 1 1 1 1 1 1 1 0059530
32 3.2.4.09 INHEX Socket ½” drive, 12mm 1 1 1 1 1 1 1 6003617
33 3.2.4.09 INHEX Socket ½” drive, 14mm 1 1 1 1 1 1 1 0717951
34 3.2.4.09 INHEX Socket ½” drive, 17mm 1 1 1 1 1 1 1 0511683
35 3.2.4.10 Pointed Pry Bar 1 1 1 1 1 1 1 2482521
36 3.2.4.11 Flat File 10” 1 1 1 1 1 1 1 0307679
37 3.2.4.12 Half round File 10” 1 1 1 1 1 1 1 0307697
3720691en – (07) Page 3.2.0 - 5
3.2.0 TOOLS REFERENCE LIST
6015/FS
6018/FS
6030/FS
6040/FS
6050/FS
6060/FS
6090/FS
RH 120
RH 170
RH 200
RH 340
RH 400
RH 40
RH 90
RECOMMENDED TOOLS AND AC-
Pos CESSORIES FOR MAINTENANCE, Part No.
INSPECTION AND ASSEMBLY
38 3.2.4.13 Paint Scraper 2” 3 3 3 3 3 3 3 0153425
39 3.2.4.14 Drift Punch Set (6Pcs.) 1 1 1 1 1 1 1 2482941
40 3.2.4.15 Chisel 1 1 1 1 1 1 1 2482952
41 3.2.4.16 Centre Punch 1 1 1 1 1 1 1 0309200
42 3.2.4.17 Wire Brush 3 3 3 3 3 3 3 0059644
43 3.2.4.18 Measuring Tape 5m 1 1 1 1 1 1 1 0661813
44 3.2.4.19 Ball Peen Hammer 1kg 1 1 1 1 1 1 1 0059687
Page 3.2.0 - 6 3720691en – (07)
3.2.0 TOOLS REFERENCE LIST
3.2.5 Miscellaneous
6015/FS
6018/FS
6030/FS
6040/FS
6050/FS
6060/FS
6090/FS
RH 120
RH 170
RH 200
RH 340
RH 400
RH 40
RH 90
RECOMMENDED TOOLS AND AC-
Pos CESSORIES FOR MAINTENANCE, Part No.
INSPECTION AND ASSEMBLY
1 3.2.5.01 Sledge Hammer 7kg 1 1 1 1 1 1 1 0059690
2 3.2.5.02 Crow Bar 1500mm 1 1 1 1 1 1 1 1477241
3 3.2.5.02 Crow Bar 1250mm 1 1 1 1 1 1 1 2482520
4 3.2.5.03 2” Paint Brush 3 3 3 3 3 3 3 0014234
5 3.2.5.04 Air Gun 1 1 1 1 1 1 1 Local
6 3.2.5.05 1/4” Air Die Grinder 1 1 1 1 1 1 1 Local
7 3.2.5.05 Cleaning pads for Grinder 10 10 10 10 10 10 10 Local
8 3.2.5.05 Grinding Bit 2 2 2 2 2 2 2 Local
9 3.2.5.06 Air Hose 13x4m 1 1 1 1 1 1 1 0530240
10 3.2.5.07 Electric Angle Grinder 1 1 1 1 1 1 1 Local
11 3.2.5.07 Various disks for angle grinder 10 10 10 10 10 10 10 Local
12 3.2.5.08 Extension Lead (10m) 1 1 1 1 1 1 1 Local
13 3.2.5.09 Control Body – Dye Penetrant Testing 1 1 1 1 1 1 1 6004972
Comparison Body – Magnetic Powder
14 3.2.5.10 1 1 1 1 1 1 1 6004973
Testing
UVA/LUX-Meter – Dye Penetrant &
15 3.2.5.11 1 1 1 1 1 1 1 6004974
Magnetic Powder Testing
16 3.2.5.12 Cleaner – Dye Penetrant Testing 1 1 1 1 1 1 1 6004975
17 3.2.5.13 Developer – Dye Penetrant Testing 1 1 1 1 1 1 1 6004976
18 3.2.5.14 Cleaner – Dye Penetrant Testing 1 1 1 1 1 1 1 6004977
19 3.2.5.15 Dye Penetrant – Dye Penetrant Testing 1 1 1 1 1 1 1 6004978
20 3.2.5.16 Cleaner – Magnetic Powder Testing 1 1 1 1 1 1 1 6004979
Underground – Magnetic Powder Test-
21 3.2.5.17 1 1 1 1 1 1 1 6004980
ing
Magnetic Powder Fluid – Magnetic
22 3.2.5.18 1 1 1 1 1 1 1 6004981
Powder Testing
Hook wrench (1.3 ltr. diaphragm accu-
23 3.2.5.19 1 1 6100264
mulator)
Hook wrench (2,8 ltr. diaphragm accu-
24 3.2.5.20 1 1 1 1 1 6004214
mulator)
3720691en – (07) Page 3.2.0 - 7
3.2.0 TOOLS REFERENCE LIST
3.2.6 Measuring Tools
6015/FS
6018/FS
6030/FS
6040/FS
6050/FS
6060/FS
6090/FS
RH 120
RH 170
RH 200
RH 340
RH 400
RH 40
RH 90
RECOMMENDED TOOLS AND AC-
Pos CESSORIES FOR MAINTENANCE, Part No.
INSPECTION AND ASSEMBLY
1 3.2.6.01 PMS Diagnostic: PC-CAN Dongle USB 1 1 1 1 1 1 1 2482239
2 3.2.6.02 PMS Diagnostic: PC-CAN Cable 1 1 1 1 1 1 1 3685323
3 3.2.6.03 PMS Diagnostic: PC-Software 1 1 1 1 1 1 1 2768865
4 3.2.6.04 PMS Diagnostic: PC Notebook WinXP 1 1 1 1 1 1 1 Local
5 3.2.6.05 3-way heavy Duty Coolant Test Kit 1 1 1 1 1 1 1 1469685
Charging and Testing Unit for Nitrogen
6 3.2.6.06 1 1 1 1 1 1 1 6003705
Accumulators (incl. adaptor 6003918)
Adaptor for Nitrogen Bottles G2: GB /
7 3.2.6.06 1441286
Austr.
8 3.2.6.06 Adaptor for Nitrogen Bottles G3: France 1441287
Adaptor for Nitrogen Bottles G4:
9 3.2.6.06 1441288
USA/Mex
Adaptor M28x1,5 – 7/8-14UNF for
10 3.2.6.06 6003918
charging and testing unit
11 3.2.6.07 Pressure Gauge Box 1 1 1 1 1 1 1 1476323
12 3.2.6.08 Oil Analysis Set (Box of 1) 6003611
13 3.2.6.08 Oil Analysis Set (Box of 6) 1 1 1 1 1 1465077
14 3.2.6.08 Oil Analysis Set (Box of 12) 1 1 6003624
15 3.2.6.08 Hand Pump 1465079
16 3.2.6.08 Hose for Hand Pump 1465080
17 3.2.6.09 Dial Gauge 1 1 1 1 1 1 1 2482692
18 3.2.6.09 100mm Extension for Dial Gauge 1 1 1 1 1 1 1 2482693
19 3.2.6.09 60 mm Extension for Dial Gauge 1 1 1 1 1 1 1 2482694
20 3.2.6.09 Magnetic Base for Dial Gauge 1 1 1 1 1 1 1 2482695
21 3.2.6.10 Digital Pressure Check Equipment 1 1 1 1 1 1 1 6003400
22 3.2.6.11 Pressure sensor 60 bar 1 1 1 1 1 1 1 6003401
23 3.2.6.11 Pressure sensor 600bar 6003399
24 3.2.6.11 Straight Fitting 6003798
25 3.2.6.11 90° Fitting 6003799
26 3.2.6.12 Extension Cable 2,5m 6003363
27 3.2.6.12 Extension Cable 5m 6003364
28 3.2.6.12 Extension Cable 10m 6003365
29 3.2.6.12 Extension Cable 20m 6003366
30 3.2.6.13 Power Supply 6003410
31 3.2.6.14 Stroke Gauge for Main Control Valves 1 1 1 1 3715535
32 3.2.6.14 Stroke Gauge for Main Control Valves 1 1 1 1 3715545
33 3.2.6.15 CAMP Test Equipment 1 1 1 1 1 1 1 6003905
34 3.2.6.16 Hydraulic Test Equipment 1 1 1 1 1 1 1 6003979
- spare parts and additional pieces (extensions, adaptors etc.) optional or where necessary
Page 3.2.0 - 8 3720691en – (07)
3.2.0 TOOLS REFERENCE LIST
3.2.7 Support
6015/FS
6018/FS
6030/FS
6040/FS
6050/FS
6060/FS
6090/FS
RH 120
RH 170
RH 200
RH 340
RH 400
RH 40
RH 90
RECOMMENDED TOOLS AND AC-
Pos CESSORIES FOR MAINTENANCE, Part No.
INSPECTION AND ASSEMBLY
1 3.2.7.01 Leaver Chain Hoist 1,5 t 2 2 2 2 2 2 2 2482933
2 3.2.7.01 Leaver Chain Hoist 3 t 2 4 4 4 4 4 0219531
3 3.2.7.01 Leaver Chain Hoist 6 t 1 1 1 1 1 1 6004529
4 3.2.7.02 Shackle 3ton 4 4 4 4 4 4 4 2482519
5 3.2.7.02 Shackle 4,75ton 4 4 4 4 4 4 4 2482928
6 3.2.7.02 Shackle 9,5ton 4 4 4 4 6004532
7 3.2.7.02 Shackle 17ton 4 4 4 4 6004531
8 3.2.7.02 Shackle 25ton 4 4 4 6004530
9 3.2.7.03 Lifting Eye Bolt M10 4 4 4 4 4 4 4 2482683
10 3.2.7.03 Lifting Eye Bolt M12 4 4 4 4 4 4 4 2482702
11 3.2.7.03 Lifting Eye Bolt M14 4 4 4 4 4 4 4 2482681
12 3.2.7.03 Lifting Eye Bolt M16 4 4 4 4 4 4 4 2482701
13 3.2.7.03 Lifting Eye Bolt M20 4 4 4 4 4 4 4 2482968
14 3.2.7.03 Lifting Eye Bolt M24 4 4 4 4 4 4 4 2482700
15 3.2.7.03 Lifting Eye Bolt M30 2 2 2 2 2482698
16 3.2.7.03 Lifting Eye Bolt M36 2 2 2482699
17 3.2.7.03 Lifting Eye Bolt M48 2 2 2 2 2 2 2482697
18 3.2.7.03 Lifting Eye Bolt M64 2 2 2 2 2 2 2482696
19 3.2.7.04 4 Leg Chain 5t/10mm 1 1 1 2 2 2 2 6004533
20 3.2.7.05 2 Leg Chain 25t/22mm 1 2 2 4 4 4 4 6004536
21 3.2.7.06 Roll of 3/8” Nylon Rope 1 1 1 1 1 1 1 Local
22 3.2.7.06 Roll of 1/2” Nylon Rope 1 1 1 1 1 1 1 Local
23 3.2.7.06 Roll of 5/8” Nylon Rope 1 1 1 1 1 1 1 Local
24 3.2.7.07 Lifting Gear/Slings 1ton, 2m 2168811
25 3.2.7.07 Lifting Gear/Slings 1ton, 3m 2 2 2 2 2 2 2 2168812
26 3.2.7.07 Lifting Gear/Slings 1ton, 4m 2168813
27 3.2.7.07 Lifting Gear/Slings 2ton, 2m 2168814
28 3.2.7.07 Lifting Gear/Slings 2ton, 3m 2168815
29 3.2.7.07 Lifting Gear/Slings 2ton, 4m 2 2 2 2 2 2 2 2168816
30 3.2.7.07 Lifting Gear/Slings 2ton, 6m 2168817
31 3.2.7.07 Lifting Gear/Slings 3ton, 4m 2 2 2 2 2 2 2 2168818
32 3.2.7.07 Lifting Gear/Slings 3ton, 6m 2168819
33 3.2.7.07 Lifting Gear/Slings 4ton, 4m 2168820
34 3.2.7.07 Lifting Gear/Slings 4ton, 6m 2168821
35 3.2.7.07 Lifting Gear/Slings 5ton, 3m 6004527
36 3.2.7.07 Lifting Gear/Slings 5ton, 5m 6004528
- additional lifting gear optional
3720691en – (07) Page 3.2.0 - 9
3.2.0 TOOLS REFERENCE LIST
6015/FS
6018/FS
6030/FS
6040/FS
6050/FS
6060/FS
6090/FS
RH 120
RH 170
RH 200
RH 340
RH 400
RH 40
RH 90
RECOMMENDED TOOLS AND AC-
Pos CESSORIES FOR MAINTENANCE, Part No.
INSPECTION AND ASSEMBLY
37 3.2.7.08 30-ton Hydraulic Jack 1 1 1 1 1 1 1 Local
38 3.2.7.09 Hydraulic Hand Pump 800bar 1 1 1 1 1 1 1 6001915
39 3.2.7.10 Hydraulic Cylinder (250kN) 1 1 1 1 1 1 1 6001918
40 3.2.7.10 Hydraulic Cylinder (130kN) 1 1 1 1 1 1 1 6003597
41 3.2.7.11 HP Hose for Hand Pump 1 1 1 1 1 1 1 6001916
42 3.2.7.12 Spirit Level 1m 1 1 1 1 1 1 1 2358109
Wooden Blocks
43 3.2.7.13 10 10 30 30 30 30 30 Local
1 500 mm x 250 mm x 150 mm
Wooden Blocks
44 3.2.7.13 10 10 20 20 20 20 20 Local
750 mm x 250 mm x 150 mm
45 3.2.7.14 Wooden Pallets 2 2 4 4 6 6 6 Local
46 3.2.7.15 Ladder 3m long 1 1 1 1 1 1 1 Local
47 3.2.7.16 Safety Harnesses 2 2 4 4 4 4 4 2482969
48 3.2.7.17 Box of Hand Gloves 1 1 1 1 1 1 1 Local
49 3.2.7.18 Loctite O-ring Set for gluing 1 1 1 1 1 1 1 0925395
50 3.2.7.19 O-Ring Set metric 1 1 1 1 1 1 1 1423537
51 3.2.7.20 O-Ring Set imperial 1 1 1 1 1 1 1 1424013
52 3.2.7.21 Loctite o-ring set Viton 1 1 1 1 1 1 1 2482525
53 3.2.7.22 Seal kit (green) 3/4 to 2" 1 1 1 1 1 1 1 6002000
54 3.2.7.23 Plastic Tarp 5m x 6m 1 1 1 1 1 1 1 2482970
55 3.2.7.24 Torches 2 2 2 2 2 2 2 Local
56 3.2.7.25 Empty 44 Gallon Drums for Waste 2 2 4 4 6 6 6 Local
57 3.2.7.26 Heavy duty plastic Buckets 5 5 10 10 10 10 10 Local
58 3.2.7.27 Hand Grease Pump 1 0 0 0 0 0 0 6004583
Page 3.2.0 - 10 3720691en – (07)
3.2.0 TOOLS REFERENCE LIST
3.2.8 Consumables
6015/FS
6018/FS
6030/FS
6040/FS
6050/FS
6060/FS
6090/FS
RH 120
RH 170
RH 200
RH 340
RH 400
RH 40
RH 90
RECOMMENDED TOOLS AND AC-
Pos CESSORIES FOR MAINTENANCE, Part No.
INSPECTION AND ASSEMBLY
1 3.2.8.01 Tubes of Omnifit 5 5 5 5 5 5 5 1991467
2 3.2.8.02 Assembly Spray for Pins 4 4 8 8 8 8 8 2764305
4 3.2.8.03 Loctite Master Gasket 1 1 6 6 6 6 6 Local
5 3.2.8.04 Loctite Thread Lock 1 1 2 2 2 2 2 Local
6 3.2.8.05 Paint stripper 5L 10L 10L 10L 10L 10L 10L Local
7 3.2.8.06 Solvent to remove rust inhibitor 20L 20L 40L 40L 60L 60L 60L Local
8 3.2.8.07 Sandpaper (fine) 2 2 2 2 2 2 2 Local
9 3.2.8.08 Sandpaper (coarse) 2 2 2 2 2 2 2 Local
10 3.2.8.09 Bag of Rags 2 4 4 6 6 6 6 Local
3.2.9 Service Adapters
6015/FS
6018/FS
6030/FS
6040/FS
6050/FS
6060/FS
6090/FS
RH 120
RH 170
RH 200
RH 340
RH 400
RH 40
RH 90
RECOMMENDED TOOLS AND AC-
Pos CESSORIES FOR MAINTENANCE, Part No.
INSPECTION AND ASSEMBLY
1 3.2.9.01 Gear Oil refilling Adapter 1960234
2 3.2.9.02 Engine Oil refilling Adapter 1960235
3 3.2.9.03 Hydraulic Oil refilling Adapter 1960236
4 3.2.9.04 Coolant Water refilling Adapter 2764855
5 3.2.9.05 Grease refilling Adapter 1960731
6 3.2.9.06 Diesel refilling Adapter 1438372
- used for service lift connection to refill fuel, grease etc.
necessary should service vehicle not have been equipped already
3720691en – (07) Page 3.2.0 - 11
3.2.0 TOOLS REFERENCE LIST
Page 3.2.0 - 12 3720691en – (07)
3.2.1 TORQUE TOOLS
Pos. 3.2.1.01
Hydraulic Drive Unit (240V)
Part No.:
6002267
Only torque adjustable
Fig.641567
Pos. 3.2.1.02
Hydraulic Drive Unit (240V)
Part No.:
1478386
Torque and angle adjustable
Fig.641505
Pos. 3.2.1.03
HP Hose Set (6x5m)
Part No.:
2470564
Coupling type 716
Fig.641699
3720692en – (02) Page 3.2.1 - 1
3.2.1 TORQUE TOOLS
Pos. 3.2.1.04
Hydraulic Torque Wrench MXT
Part No.:
1 MXT:
200 – 1.850 NM 2482923
¾” drive
3 MXT:
450 – 4.450 Nm 2470558
1” drive
5 MXT
800 – 7.700Nm 6003121
1½” drive
20 MXT
2.800 – 27.000Nm 6003104
2½” drive
Fig.641510
Pos. 3.2.1.05
Impact Socket ¾” drive (double hex)
Part No.:
30mm 2482959
32mm 6004549
36mm 6003598
41mm 6003599
46mm 6003601
Fig.641512
Pos. 3.2.1.06
Impact Socket 1” drive (double hex)
Part No.:
32mm 6004537
36mm 1434705
41mm 1434706
46mm (Ø 69 mm) 1434707
46mm (Ø 65 mm) 6100296
55mm 1434709
60mm 1434710
95mm 6003610
Fig.641512
Page 3.2.1 - 2 3720692en – (02)
3.2.1 TORQUE TOOLS
Pos. 3.2.1.07
Impact Socket 1 ½” drive (double hex)
Part No.:
36mm 1461521
46mm 1461523
50mm 1461524
55mm 1461525
60mm 6003602
65mm 6003603
70mm 6003604
75mm 1461528
Fig.641512
Pos. 3.2.1.08
Impact Socket 2 ½” drive (double hex)
Part No.:
95mm 2482837
Fig.641512
Pos. 3.2.1.09
Hydraulic Torque Wrench “Stealth”
Part No.:
Stealth 2, 41mm
6003868
(170 – 2.400Nm)
Stealth 4, 55mm
(400 – 5.500Nm) 6003869
Only for RH120
Stealth 8, 65mm
6003870
(800 – 11.000Nm)
Fig.641511
3720692en – (02) Page 3.2.1 - 3
3.2.1 TORQUE TOOLS
Pos. 3.2.1.10
Hydraulic Torque Wrench XLCT
Part No.:
Drive 1477300
Ratchet Insert
1477299
(55mm)
550 – 5450 Nm
Extra flat ratchet insert for tightening
swing bearing on RH170, RH200 and
RH340.
Fig.641830
Pos. 3.2.1.11
Torque multiplier 1½” drive
Part No.:
XVR 40
1437544
Max. torque 4000 Nm
XVR 65
1448441
Max. torque 6200 Nm
Input drive: ¾”
Output drive: 1½”
Fig.641694
Pos. 3.2.1.12
½” Torque Wrench
Part No.:
Torque range:
1446762
60 – 300 Nm
Includes ½” on ¾” adapter for use
with XVR 40 and XVR 65 (Part No.
1437544 + 1448441)
Fig.641574
Page 3.2.1 - 4 3720692en – (02)
3.2.1 TORQUE TOOLS
Set-up when working with XVR 40 and XVR 65
Fig. 640099
Pos 3.2.1.13
Torque wrench DSG 6
Part No.:
Torque range:
1331433
500 – 1300 Nm
Fig.641529
Pos 3.2.1.14
Torque wrench DSG 7
Part No.:
Torque range:
0900890
800 – 2000 Nm
Fig.641529
3720692en – (02) Page 3.2.1 - 5
3.2.1 TORQUE TOOLS
Pos 3.2.1.15
Flat ring spanner insert for DSG 6 + DSG 7
Part No.:
36mm 1590922
41mm 0900891
46mm 1740801
55mm 1740115
Fig.641531
Pos. 3.2.1.16
Ratchet Insert for DSG 6 + DSG 7
1” drive Part No.:
Ratchet Insert 1472005
Repair Kit 1472006
Fig.641530
Pos. 3.2.1.17
Air Impact Gun ½” drive
Part No.:
max 490Nm 2482463
Fig.641509
Page 3.2.1 - 6 3720692en – (02)
3.2.1 TORQUE TOOLS
Pos. 3.2.1.18
Metric Ratchet and Socket Set ½” drive
Part No.:
10 - 32mm double hex 0559027
Fig.641696
Pos. 3.2.1.19
½” drive metric Socket Set
Part No.:
4-19mm 2482522
Fig.641698
Pos. 3.2.1.20
Air Impact Gun ¾” drive
Part No.:
~900Nm 2482462
Fig.641568
3720692en – (02) Page 3.2.1 - 7
3.2.1 TORQUE TOOLS
Pos. 3.2.1.21
Metric Ratchet and Socket Set ¾” drive
Part No.:
22 – 50mm double hex 2482464
Fig.641697
Pos. 3.2.1.22
Air Impact Gun 1” drive
Part No.:
Max 2750Nm 2482461
Fig.640098
Pos. 3.2.1.23
Metric Ratchet and Socket Set 1” drive
Part No.:
36 – 80mm double hex 2482523
Fig.641695
Page 3.2.1 - 8 3720692en – (02)
3.2.1 TORQUE TOOLS
Pos. 3.2.1.24
Adaptor for socket wrenches
Part No.:
1” to ¾” 2482471
1 ½” to 1” 1431749
Fig.641542
Pos. 3.2.1.25
Impact Extension 1”drive
Part No.:
6” extension 2482956
12” extension 2482957
Fig.641503
Pos. 3.2.1.26
Universal Joint
Part No.:
For ½” drive 2482955
Fig.641534
3720692en – (02) Page 3.2.1 - 9
3.2.1 TORQUE TOOLS
Page 3.2.1 - 10 3720692en – (02)
3.2.2 CUTTING AND TAPPING TOOLS
Pos. 3.2.2.01
Hacksaw
Part No.:
Hacksaw 0059324
Spare hacksaw
0060784
blades
Fig. 641513
Pos. 3.2.2.02
Taps
Part No.:
M6 x 1 0059912
M8 x 1,25 0059915
M10 x 1,5 0059918
M12 x 1,75 0059925
M14 x 2 6003618
M16 x 2 0059929
M20 x 2,5 0157223
M24 x 3 0157226
M27 x 3 6003619
M30 x 3,5 6003620
M36 x 4 6003621
M39 x 4 6003622
M42 x 3 2739509
M48 x 5 6003623
M64 x 4 6004426
No sets, only one plug type tap to retap
thread holes prior to assembly.
Fig.641518
3720694en - (01) Page 3.2.2 - 1
3.2.2 CUTTING AND TAPPING TOOLS
Page 3.2.2 - 2 3720694en - (01)
3.2.3 ELECTRIC TOOLS
Pos. 3.2.3.01
Electric Connector Assortment
Part No.:
2482882
Fig. 641526
Pos. 3.2.3.02
Bootlace ferrule Assortment
Part No.:
2482529
Fig. 641527
Pos. 3.2.3.03
Tool Set
Part No.:
1190887
Fig. 641582
3720698en - (00) Page 3.2.3 - 1
3.2.3 ELECTRIC TOOLS
Pos. 3.2.3.04
Digital Multimeter
Part No.:
1088932
Includes test leads
Optional croc clips:
Pincers red 0764860
Pincers black 0764861
Fig. 641520
Pos. 3.2.3.05
Installation Bar for Grounding Cable Harness
Part No.:
1791163
for electric power train only
Fig. 640095
Pos. 3.2.3.06
Grounding Cable Harness
Part No.:
0925649
for electric power train only
Fig. 640094
Page 3.2.3 - 2 3720698en - (00)
3.2.3 ELECTRIC TOOLS
Pos. 3.2.3.07
Cable Hook
Part No.:
2270413
for electric power train only
Fig. 640092
Pos. 3.2.3.08
Fuse Tool
Part No.:
1725313
Fig. 640093
Pos. 3.2.3.09
High Voltage Tester
Part No.:
0255962
Fig. 640097
3720698en - (00) Page 3.2.3 - 3
3.2.3 ELECTRIC TOOLS
Page 3.2.3 - 4 3720698en - (00)
3.2.4 HAND TOOLS
Pos. 3.2.4.01
Ring Open End Spanner Set DIN 3113
Part No.:
Metric:
2482524
6mm – 32mm
Imperial:
2482944
¼”-1¼”
Fig. 641506
Pos. 3.2.4.02
Ring Open End Spanner DIN 3113
Part No.:
15mm 0717906
17mm 6003612
19mm 0717908
22mm 0717911
24mm 0717913
36mm 0215313
41mm 0717921
46mm 6003613
55mm 6003614
Fig. 641502
Pos. 3.2.4.03
Open End Spanner DIN 894
Part No.:
17mm 6003615
19mm 0014079
22mm 0014080
24mm 0014082
27mm 0014083
30mm 0014084
32mm 0014085
36mm 0014086
41mm 0014087
46mm 6003616
55mm 0014088
Fig. 641533
3720693en - (00) Page 3.2.4 - 1
3.2.4 HAND TOOLS
Pos. 3.2.4.04
Shifter
Part No.:
10“ 2482947
12“ 2482948
Fig. 641508
Pos. 3.2.4.05
Pipe Wrench 14”
Part No.:
2482951
Fig. 641507
Pos. 3.2.4.06
Multigrip
Part No.:
0059336
Fig. 641519
Page 3.2.4 - 2 3720693en - (00)
3.2.4 HAND TOOLS
Pos. 3.2.4.07
Vice Grip
Part No.:
2482949
Fig. 641566
Pos. 3.2.4.09
Allen Key Large
Part No.:
12mm 0014128
14mm 0014129
17mm 0014130
Fig. 641501
Pos. 3.2.4.10
INHEX Socket ½” drive
Part No.:
10mm 0059530
12mm 6003617
14mm 0717951
17mm 0511683
Fig. 641543
3720693en - (00) Page 3.2.4 - 3
3.2.4 HAND TOOLS
Pos. 3.2.4.11
Pointed pry bar
Part No.:
2482521
Fig. 641823
Pos. 3.2.4.12
Flat File
Part No.:
10” 0307679
Fig. 641517
Pos. 3.2.4.13
Half round File
Part No.:
10” 0307697
Fig. 641517
Page 3.2.4 - 4 3720693en - (00)
3.2.4 HAND TOOLS
Pos. 3.2.4.14
Paint Scraper
Part No.:
2” 0153425
Fig. 641571
Pos. 3.2.4.15
Drift Punch Set
Part No.:
6 Pcs. 2482941
Fig. 641565
Pos. 3.2.4.16
Chisel
Part No.:
300x23x13 2482952
Fig. 641546
Pos. 3.2.4.17
Centre Punch
Part No.:
0309200
3720693en - (00) Page 3.2.4 - 5
3.2.4 HAND TOOLS
Fig. 641514
Pos. 3.2.4.18
Wire Brush
Part No.:
0059644
Fig. 641515
Pos. 3.2.4.19
Measuring Tape
Part No.:
5m 0661813
Fig. 641547
Pos. 3.2.4.20
Ball peen hammer
Part No.:
1kg 0059687
Fig. 641572
Page 3.2.4 - 6 3720693en - (00)
3.2.5 MISCELLANEOUS
Pos. 3.2.5.01
Sledge Hammer
Part No.:
Weight 7kg 0059690
Fig.641563
Pos. 3.2.5.02
Crow Bar
Part No.:
1500mm 1477241
1250mm 2482520
Fig.641824
Pos. 3.2.5.03
Paint brush 2“
Part No.:
0014234
Fig.641536
3720695en – (02) Page 3.2.5 - 1
3.2.5 MISCELLANEOUS
Pos. 3.2.5.04
Air gun
Part No.:
Local
Fig.641561
Pos. 3.2.5.05
Air Grinder
Part No.:
Grinder
Cleaning Pads Local
Grinding bit
Fig.641578
Pos. 3.2.5.06
Air Hose 13x4m
Part No.:
For pneumatic tools 0530240
Fig.641535
Page 3.2.5 - 2 3720695en – (02)
3.2.5 MISCELLANEOUS
Pos. 3.2.5.07
Electric Angle Grinder
Part No.:
Diameter 5“ / 125 mm
Various disks for local
angle grinder
Fig.641552
Pos. 3.2.5.08
Extension Lead 10m
Part No.:
local
Fig.641573
3720695en – (02) Page 3.2.5 - 3
3.2.5 MISCELLANEOUS
Pos. 3.2.5.09
Control Body – Dye Penetrant Testing
Part No.:
See SM 2013-001 6004972
Fig.645720
Pos. 3.2.5.10
Comparison Body – Magnetic Powder Testing
Part No.:
See SM 2013-001 6004973
Fig.645721
Page 3.2.5 - 4 3720695en – (02)
3.2.5 MISCELLANEOUS
Pos. 3.2.5.11
UVA/LUX-Meter – Dye Penetrant & Magnetic Powder Testing
Part No.:
See SM 2013-001 6004974
Fig.645722
Pos. 3.2.5.12
Cleaner – Dye Penetrant Testing
500 ml
“Cold/Artic” Regions Part No.:
-30C up to +10C
See SM 2013-001 6004975
Fig.645718
3720695en – (02) Page 3.2.5 - 5
3.2.5 MISCELLANEOUS
Pos. 3.2.5.13
Developer – Dye Penetrant Testing
500 ml
“Cold/Artic” Regions
(-30C up to +10C) & Part No.:
& “Hot” Regions
(+10C up to +50C)
See SM 2013-001 6004976
Fig.645718
Pos. 3.2.5.14
Cleaner – Dye Penetrant Testing
500 ml
“Cold/Artic” Regions
(-30C up to +10C) & Part No.:
& “Hot” Regions
(+10C up to +50C)
See SM 2013-001 6004977
Fig.645718
Page 3.2.5 - 6 3720695en – (02)
3.2.5 MISCELLANEOUS
Pos. 3.2.5.15
Dye Penetrant – Dye Penetrant Testing
500 ml
“Hot” Regions Part No.:
(+10C up to +50C)
See SM 2013-001 6004978
Fig.645718
Pos. 3.2.5.16
Cleaner – Magnetic Powder Testing
500 ml
“Hot” Regions Part No.:
(+10C up to +50C)
See SM 2013-001 6004979
Fig.645719
3720695en – (02) Page 3.2.5 - 7
3.2.5 MISCELLANEOUS
Pos. 3.2.5.17
Underground – Magnetic Powder Testing
500 ml
“Hot” Regions Part No.:
(+10C up to +50C)
See SM 2013-001 6004980
Fig.645719
Pos. 3.2.5.18
Magnetic Powder Fluid – Magnetic Powder Testing
500 ml
“Hot” Regions Part No.:
(+10C up to +50C)
See SM 2013-001 6004981
Fig.645719
Page 3.2.5 - 8 3720695en – (02)
3.2.5 MISCELLANEOUS
Pos. 3.2.5.19
Hook wrench (1.3 ltr. diaphragm accumulator)
Part No.:
6100264
Fig. 646270
Pos. 3.2.5.20
Hook wrench (2.8 ltr. diaphragm accumulator)
Part No.:
6004214
Fig. 646270
3720695en – (02) Page 3.2.5 - 9
3.2.5 MISCELLANEOUS
Page 3.2.5 - 10 3720695en – (02)
3.2.6 MEASURING TOOLS
Pos. 3.2.6.01
PC-CAN USB Dongle
Part No.:
2482239
Fig. 642389
Pos. 3.2.6.02
PC-CAN Cable
Part No.:
3685323
Fig. 642390
Pos. 3.2.6.03
PC-Software
Part No.:
2768865
Fig. 642392
3720699en – (03) Page 3.2.6 - 1
3.2.6 MEASURING TOOLS
Pos. 3.2.6.04
PC-Notebook with Software Win XP
Part No.:
Local
Fig. 641693
Pos. 3.2.6.05
3-Way heavy duty coolant test kit
Part No.:
1469685
Cummins engines only
Fig.641832
Page 3.2.6 - 2 3720699en – (03)
3.2.6 MEASURING TOOLS
Pos. 3.2.6.06
Filling and testing Device for Accumulators
Part No.:
6003705
Adapter M28x1,5 – 7/8-14UNF
6003918
Filling and testing device 6003705
includes adapter 6003918
Adaptor for nitrogen bottles
GB / Australia 1441286
France 1441287
USA / Mexico 1441288
Fig. 646271
Pos. 3.2.6.07
Pressure Gauge Box
Part No.:
1476323
Contents:
2 x 600bar
1 x 250bar
1 x 60bar
Fig.630641
3720699en – (03) Page 3.2.6 - 3
3.2.6 MEASURING TOOLS
Pos. 3.2.6.08
Oil-Analysis Set No. 1
Part No.:
Box of 1 6003611
Box of 6 1465077
Box of 12 6003624
Analysis of gear oil, hydraulic oil and
engine oil.
Accessories:
Part No.:
Hand Pump 1465079
Hose for Pump 1465080
Bild 641833
Pos. 3.2.6.09
Dial Gauge
Part No.:
2482692
100 mm Extension 2482693
60 mm Extension 2482694
Magnetic Base 2482695
Fig.641581
Pos. 3.2.6.10
Digital Pressure Check Equipment
Page 3.2.6 - 4 3720699en – (03)
3.2.6 MEASURING TOOLS
Part No.:
6003400
Includes:
Measuring Instrument
Power Supply with adaptors
2 Pressure Sensors (600bar) with
2,5m cables
2 Fittings (minimess M16x2)
Fig.641825
Pos. 3.2.6.11
Pressure Sensor
Part No.:
60bar 6003401
600bar 6003399
Straight Fitting 6003798
90° Fitting 6003799
For use with Digital Pressure Check
Equipment
Fig.641826
3720699en – (03) Page 3.2.6 - 5
3.2.6 MEASURING TOOLS
Pos. 3.2.6.12
Extension Cable
Part No.:
2,5m 6003363
5m 6003364
10m 6003365
25m 6003366
For use with Digital Pressure Check
Equipment
Fig.641827
Pos. 3.2.6.13
Power Supply
Part No.:
6003410
For use with Digital Pressure Check
Equipment
Fig.641828
Pos. 3.2.6.14
Stroke Gauge for Main Control Valves
Part No.:
RH40E / 6015,
RH90C / 6018,
3715535
RH120E / 6030,
RH340B / 6060B
RH170B / 6040,
RH200 / 6050,
3715545
RH340A / 6060A,
RH400 / 6090
Fig. 642780
Page 3.2.6 - 6 3720699en – (03)
3.2.6 MEASURING TOOLS
Pos. 3.2.6.15
CAMP Test Equipment
Part No.:
RH120E / 6030,
RH340B / 6060B 6003905
RH400 / 6090
Fig. 645723
Pos. 3.2.6.16
Hydraulic Test Equipment
Part No.:
RH40E / 6015
RH90C / 6018
6020B
RH120E / 6030
6003979
RH170B / 6040
RH200 / 6050
RH340B / 6060B
RH400 / 6090
Fig. 645724
3720699en – (03) Page 3.2.6 - 7
3.2.6 MEASURING TOOLS
Page 3.2.6 - 8 3720699en – (03)
3.2.7 SUPPORT
Pos. 3.2.7.01
Leaver Chain Hoist
Part No.:
Load bearing capacity
2482933
Max. 1,5t
Load bearing capacity
0219531
Max. 3t
Load bearing capacity
6004529
Max. 5t
Fig.641528
Pos. 3.2.7.02
Shackle
Part No.:
3 ton 2482519
4,75 ton 2482928
9,5ton 6004532
17ton 6004531
25ton 6004530
Fig.641579
Pos. 3.2.7.03
Lifting Eye Bolts
Thread size Part No.:
M10 2482683
M12 2482702
M14 2482681
M16 2482701
M20 2482968
M24 2482700
M30 2482698
M36 2482699
M48 2482697
M64 2482696
Fig.641831
3720696en - (04) Page 3.2.7 - 1
3.2.7 SUPPORT
Pos. 3.2.7.04
4 Leg Chain
Part No.
5t/10mm 6004533
Fig. 642663
Pos. 3.2.7.05
2 Leg Chain
Part No.
25t/22mm 6004536
Fig. 642662
Pos. 3.2.7.06
Nylon Rope
Part No.:
3/8”
½” local
5/8”
Fig.641548
Page 3.2.7 - 2 3720696en - (04)
3.2.7 SUPPORT
Pos. 3.2.7.07
Lifting Gear/Slings
Part No.:
1 ton, 2m 2168811
1 ton, 3m 2168812
1 ton, 4m 2168813
2 ton, 2m 2168814
2 ton, 3m 2168815
2 ton, 4m 2168816
2 ton, 6m 2168817
3 ton, 4m 2168818
3 ton, 6m 2168819
4 ton, 4m 2168820
4 ton, 6m 2168821
5 ton, 3m 6004527
5 ton, 5m 6004528
Fig.641580
Pos. 3.2.7.08
30t Porta Power Ram
Part No.:
Local
Fig.641577
Pos. 3.2.7.09
Hydraulic Hand Pump
Part No.:
800bar
6001915
¼” thread
For use with hydraulic cylinders (part
no. 6001918 and 6003597)
Fig.641834
3720696en - (04) Page 3.2.7 - 3
3.2.7 SUPPORT
Pos. 3.2.7.10
Hydraulic Cylinder
Part No.:
250kN
6001918
Diameter: 85mm
130kN
6003597
Diameter: 65mm
Fig.641821
Pos. 3.2.7.11
HP Hose for Hand Pump
Part No.:
800bar
¼” fitting 6001916
Length: 2m
Fig.641822
Pos. 3.2.7.12
Spirit Level 1m
Part No.:
2358109
Fig.641559
Page 3.2.7 - 4 3720696en - (04)
3.2.7 SUPPORT
Pos. 3.2.7.13
Hard Wood Blocks
Dimensions L x B x H Part No.:
1500x250x150
local
750x250x150
Fig.641540
Pos. 3.2.7.14
Wooden Pallets
Part No.:
local
Fig.641541
Pos. 3.2.7.15
Ladder 3m
Part No.:
local
Fig.641562
3720696en - (04) Page 3.2.7 - 5
3.2.7 SUPPORT
Pos. 3.2.7.16
Safety Harness
Part No.:
2482969
Fig.641538
Pos. 3.2.7.17
Gloves
Part No.:
local
Fig.641537
Pos. 3.2.7.18
Loctite O-Ring Set for gluing
Part No.:
0925395
Fig. 641835
Page 3.2.7 - 6 3720696en - (04)
3.2.7 SUPPORT
Pos. 3.2.7.19
O-Ring Set metric, Perbunan
Part No.:
Diameter 3 – 42 mm 1423537
Fig.641545
Pos. 3.2.7.20
O-Ring Set imperial, Perbunan
Part No.:
Diameter 2,9 –
1424013
43,82mm
Fig.641545
Pos. 3.2.7.21
Loctite O-Ring Set, Viton
Part No.:
Diameter 18 – 50mm 2482525
Fig.641545
3720696en - (04) Page 3.2.7 - 7
3.2.7 SUPPORT
Pos. 3.2.7.22
Seal Set for Hoses and Pipes
Part No.:
Diameter 3/4“ to 2“ 6002000
Fig.641560
Pos. 3.2.7.23
Plastic Tarp 5x6 m
Part No.:
2482970
Fig.641539
Pos. 3.2.7.24
Torch
Part No.:
local
Fig.641549
Page 3.2.7 - 8 3720696en - (04)
3.2.7 SUPPORT
Pos. 3.2.7.25
Empty Barrels 44Gal / 167L
Part No.:
local
Fig.641553
Pos. 3.2.7.26
Buckets
Part No.:
local
Fig.641575
Pos. 3.2.7.27
Hand Grease Pump
Part No.:
pump 6004583
Required only for RH40 / 6015 machines to fill
grease container
Fig.642779
3720696en - (04) Page 3.2.7 - 9
3.2.7 SUPPORT
Page 3.2.7 - 10 3720696en - (04)
3.2.8 CONSUMABLES
Pos. 3.2.8.01
Tubes of Omnifit
Part No.:
1991467
Fig.641554
Pos. 3.2.8.02
Assembly Spray for Pins
Part No.:
2764305
Fig.641555
Pos. 3.2.8.03
Loctite Master Gasket
Part No.:
Local
Fig. 641692
3720697en - (00) Page 3.2.8 - 1
3.2.8 CONSUMABLES
Pos. 3.2.8.04
Loctite Thread Lock
Part No.:
Local
Fig. 641691
Pos. 3.2.8.05
Paint Stripper
Part No.:
Local
Fig. 640096
Pos. 3.2.8.06
Solvent to remove Rust Inhibitor
Part No.:
Local
Fig.641557
Page 3.2.8 - 2 3720697en - (00)
3.2.8 CONSUMABLES
Pos. 3.2.8.07
Sandpaper fine
Part No.:
Local
Fig.641570
Pos. 3.2.8.08
Sandpaper coarse
Part No.:
Local
Fig.641570
Pos. 3.2.8.09
Bag of rags
Part No.:
Local
Fig.641576
3720697en - (00) Page 3.2.8 - 3
3.2.8 CONSUMABLES
Page 3.2.8 - 4 3720697en - (00)
3.2.9 SERVICE ADAPTORS
Pos. 3.2.9.01
Gear Oil refilling Adaptor
Part No.:
1960234
Fig. 640070
Pos. 3.2.9.02
Engine Oil refilling Adaptor
Part No.:
1960235
Fig. 640071
Pos. 3.2.9.03
Hydraulic Oil refilling Adaptor
Part No.:
1960236
Fig. 640072
3721419en - (00) Page 3.2.9 - 1
3.2.9 SERVICE ADAPTORS
Pos. 3.2.9.04
Coolant Water refilling Adaptor
Part No.:
2764855
Fig. 640074
Pos. 3.2.9.05
Grease refilling Adaptor
Part No.:
1960731
Fig. 640075
Pos. 3.2.9.06
Diesel / Fuel refilling Adaptor
Part No.:
1438372
Fig. 640076
Page 3.2.9 - 2 3721419en - (00)
3.3 ASSEMBLY MANUAL
Table of Contents
3.3.1 Overview....................................................................................................................... 3
3.3.2 Safety instructions ........................................................................................................ 3
3.3.3 Personnel...................................................................................................................... 4
3.3.4 Assembly equipment ..................................................................................................... 5
3.3.5 Modules on arrival ......................................................................................................... 6
3.3.6 Assembly site................................................................................................................ 6
3.3.7 Preparation of modules for assembly.............................................................................. 8
3.3.8 General assembly procedures........................................................................................ 9
3.3.9 Workflow chart of assembly procedure ......................................................................... 12
3.3.10 Preparation of undercarriage and superstructure modules............................................. 13
3.3.11 Undercarriage assembly .............................................................................................. 18
3.3.12 Preparations for superstructure installation .................................................................. 23
3.3.13 Installation of superstructure frame .............................................................................. 26
3.3.14 Installation of swing gearboxes .................................................................................... 30
3.3.15 Connection of hydraulic lines between undercarriage and superstructure ...................... 31
3.3.16 Boom installation ........................................................................................................ 33
3.3.17 Installation of modules and components to superstructure frame................................... 40
3.3.18 Stick installation.......................................................................................................... 60
3.3.19 Connection of hydraulic lines on superstructure, boom and stick................................... 64
3.3.20 Top up operating fluids................................................................................................ 69
3.3.21 Connection of electric system and Operator Assi st system ............................................ 69
3.3.22 Preparations for machine start-up ................................................................................ 77
3.3.23 Machine start-up.......................................................................................................... 79
3.3.24 Bucket installation....................................................................................................... 79
3.3.25 Residual stroke ........................................................................................................... 82
3.3.26 Final preparations for machine start-up ........................................................................ 83
3746343en (03) Page 3.3 1
3.3 ASSEMBLY MANUAL
Page 3.3 2 3746343en (03)
3.3 ASSEMBLY MANUAL
3.3.1 Overview 3.3.2 Safety instructions
About this Assembly M anual Warnings and symbols
This Assembly Manual applies to machine type The following signs and symbols used in this As-
Cat 6060 FS. sembly Manual indicate steps in the assembly
process which involve particular risk or danger to
This Assembly Manual is intended for personnel persons or to the machine.
responsible for the assembly of a machine model
6060 FS.
This symbol indicates a hazardous
It contains a description of individual assembly situation that could result in injury,
steps for the machine and the work required be- serious injury or death.
fore and during the assembly of a component or
module.
You can find issues that go beyond those de- This symbol indicates a source of
scribed here in chapters of our Service Manual as potential damage to the machine or
well as the spare parts catalogs, and electric and other property.
hydraulic schematics.
Illustrations
Safety requirements
Illustrations in this Assembly Manual show the
Everybody involved in the assembly of the ma-
technical details required only for the respective
chine must have read and understood the safety
assembly step. The illustrations are not a substi- instructions and the code of conduct in chapter
tute for the Assembly Manual as we reserve the
3.1 of the Service Manual.
right to make technical changes. For technical
details please refer to the corresponding sections Everybody involved in the assembly process must
of the current Service Manual, Spare Parts Manu- be familiar with the local safety regulations and
al, electric and hydraulic schematics. special safety regulations at the assembly site.
Compliance with these regulations is mandatory
To make it easier to understand their content,
for everybody at all times.
some illustrations are simplified and therefore
differ slightly from the current assembly condition. You can find further safety instructions in chapter
1.2 of the Service Manual. They are mandatory for
Directional information everybody as well.
Directional information (right-hand, left-hand) al- For all safety issues, please contact the responsi-
ways refers to the forward travel direction of the ble personnel on site.
machine.
Provide safety regulations in the
Assembly duration local language and in English to
Schedule approx. twenty working days with ten ensure that everybody involved in
working hours per day for the assembly of the the machine assembly is able to
machine. understand them.
In addition schedule approximately five working
days for commissioning and functional testing.
3746343en (03) Page 3.3 3
3.3 ASSEMBLY MANUAL
Personal protective equipment and work Commissioning during assembly
clothing
Starting the machine before it is
Always wear closely fitting work clothing when completely assembled can cause
working on the machine. Baggy or loose fitting serious injuries and/or damage to
garments may be caught in machine parts and property.
cause serious injury.
If a start-up for testing and assem-
Wear the following personal protective equipment bly purposes is necessary, comply
when working on the machine: with all requirements of the ma-
helmet chine and the assembly site.
safety footwear
protective gloves If it is necessary to start the machine during as-
sembly, the start-up must be conducted by the
safety goggles supervisor and the machine must be operated by
ear protection a person who has been clearly authorized to do
so.
site specific personal protective equipment
3.3.3 Personnel
Handling of environmentally hazardous
substances Personnel required
During assembly of the machine, you will handle Experienced product experts (e.g. supplied by the
substances and materials classified as environ- factory or dealer):
mentally hazardous according to national and
regional environmental legislation. These include 1 service engineer
oil, fuel, and grease.
1 technician (mechanic)
Always follow the applicable national and regional Additional personnel (e.g. supplied by the cus-
regulations when handling such substances. tomer):
5 mechanics
Provide the regulations in the local
language and in English to ensure 1 electrician
that everybody involved in the ma- 2 assistants
chine assembly can understand
them. 1 welder on request
Qualification and training of personnel
Handling of substances hazardous to
health
It is mandatory that personnel have
During assembly of the machine, you will handle read, understood, and retained the
substances classified as hazardous to health. following measures and codes of
These include hydraulic oil, fuel, and grease. conduct.
Avoid direct skin contact with these substances.
Always follow applicable national and regional Mandatory personnel requirements:
legislation and regulations as well as manufactur-
er specifications. Assign only fully qualified, trained, and experi-
enced personnel to work on or with the ma-
Provide the regulations in the local chine.
language and in English to ensure Always obey legal age restrictions.
that everybody involved in the ma-
chine assembly is able to under- Define clearly and particularly the individual
stand them. responsibility of each person for operation,
setup, maintenance, and repair work.
Page 3.3 4 3746343en (03)
3.3 ASSEMBLY MANUAL
Authorize the respective personnel to ignore 1 forklift rough terrain, min. 20
any instructions given by a third party if these 7500 kg carrying capacity
contradict the applicable safety regulations.
1 Power supply for equip- throughout
Do not let persons who received only basic ment
instructions work on or with the machine. Oth-
erwise ensure that such persons are perma- Table 1
nently supervised by experienced personnel.
Assign only an experienced electrician or The cranes must be equipped with rigging equip-
trained personnel under the permanent super- ment, such as:
vision of an experienced electrician to work on chains
the electric system. Ensure that work on the
electric system is carried out in compliance ropes (steel and nylon)
with the applicable electrical standards and belts
regulations.
guide ropes
Assign only personnel specially trained and
experienced in hydraulics to work on the hy- in sufficient quantities and length.
draulic system. The rigging equipment must have the appropriate
Ensure that everybody involved in the assem- loading capacity and lengths and be available in
bly process has the necessary physical and in- sufficient quantities. The length required depends
tellectual abilities, such as unrestricted vision on the angle position of welded transport lugs on
and hearing, and quick reaction capability. individual modules, e.g. on the boom. The rigging
equipment must match the lugs.
Assign only experienced personnel who know
the valid accident prevention regulations with An adequate quantity of supporting materials such
rigging loads and instructing the crane operator as hardwood planks, blocks, and boards, pallets,
during assembly. plastic mats, etc. must also be available.
For further required assembly items, please refer
3.3.4 Assembly equipment to the data sheet "Assembly Requirements Hy-
draulic Shovel CAT6060", which can be down-
loaded from Caterpillar Service Information Sys-
The following equipment is supplied by the cus-
tem (SIS, http://sis.cat.com).
tomer (s. Assembly Requirements in SIS, media
Id. BI644856). Tools
Quan Equipment Required Assembly of the machine requires the usual
tity on days standard set of tools and a number of special
tools. Section 3.2. of the Service Manual contains
a list of these tools.
1 Crane with min. 180 000 1- 8
kg carrying capacity To ensure that several people can work continu-
ously provide four sets of standard tool equip-
1 Crane with min. 120 000 1 - 21 ment.
kg carrying capacity
You can download the Tools Reference List from
1 Mobile universal work plat- 23 the Excavator Support Portal or obtain it from your
form, working height 2 to local dealer.
7.5 m and 1 000 kg carry-
We recommend that the tools listed are kept on
ing capacity
site, not only for assembly, but also for future ser-
1 mobile equipment with 6 m vice work, overhauls or repairs.
reach for installing pins,
e.g. wheel loader, excava-
Equipment for personnel
tor, or telehandler, re- Assembly personnel should be provided with ac-
quired on "as and when" comodation, break room, and wash rooms as well
basis during assembly as place to store the tools.
1 Air compressor 20 Medical facilities must be accessible to provide
first aid in case of an accident at work.
1 Welding equipment 20
3746343en (03) Page 3.3 5
3.3 ASSEMBLY MANUAL
3.3.5 Modules on arrival Never work under a suspended
load. Do not lift modules by crane to
After assembly and testing at Caterpillar plants, access the bottom side. Instead
the machine is disassembled for transport. Sever- place the module on stable jack
al modules are shipped separately. For weights stands or similar suitable supports
and dimensions of the modules please refer to of sufficient carrying capacity. Use
chapter 2.8 o- stands or supports with anti-slip
of the Service Manual. surface or place anti-slip material
Local conditions, such as the maximum load ca- between the module and the stands
pacity of bridges, may require the separation of or supports.
the modules into smaller units.
Compare the data stated in Section 2.8 of the SM Place the superstructure frame (4, Fig. 1) on
with the packing list. If they differ, consider the stands or hardwood blocks of sufficient carrying
data in the packing list. capacity so that you can carry out work on the
underside. Comply with safety regulations at the
If necessary request the packing list via Dealer assembly site and legal regulations for working at
Support Network (DSN) or your Regional HMS heights.
Support.
Place one of the crawlers (2 or 3, Fig. 1) on suffi-
Assembly steps can vary from the steps described ciently stable supports 100 mm above the ground.
on the following pages depending on the disas- It must remain in this position until undercarriage
sembly level of the machine and the special con- assembly is completed.
ditions at the assembly site. In this case, please
contact your local dealer for additional infor- Pre-assemble smaller and lighter parts at the
mation. edge of the assembly site where you can easily
approach them without interfering with the main
assembly process.
3.3.6 Assembly site The items in Table 2 refer to Fig. 1.
Size and condition Item Description
An area of at least 50 x 50 m (164 x 164 ft) will be 1 Carbody
required for assembly of the machine, of which
2 Left craw ler
15 x 15 m (49 x 49 ft) must be level ground with a
maximum deviation of 1%. 3 Right craw ler
The soil must have a bearing capacity of at least 4 8 track chain segments
22 N/cm2 (32 lbf/sq.in.) and good drainage (for 5 Superstructure frame
example compacted gravel or rocks).
6 Engine module
The entire assembly site must be clean, dry, flat,
and firm. An even and horizontal surface is essen- 7 Counterw eight, low er section
tial for the correct inter-alignment of the compo- 8 Counterw eight, upper section
nents during assembly.
9 Boom
10 Oil cooler module
Modules arrangement on assembly site
11 Operator cab module
To avoid unnecessary relocation of the modules 12 Operator cab
and cranes, unload and arrange the modules ac-
cording to Fig. 1. 13 Stick
Leave sufficient space between the modules to 14 Bucket, rear w all
easily handle the parts and ensure easy access 15 Bucket, front shell
for a forklift or telehandler.
16 Boom cylinders
17 Stick cylinders
18 Bucket cylinders
19 Ladder
Page 3.3 6 3746343en (03)
3.3 ASSEMBLY MANUAL
Item Description Item Description
20 Cradle 24 Lubricant container
22 Bridge 25 Crates
23 Crane Table 2
Fig. 1 Modules arrangement on assembly site 642502b
Leave min. 1 max. 1.5 m space
between the modules.
3746343en (03) Page 3.3 7
ASSEMBLY MANUAL
3.3.7 Preparation of modules for as- Do not clean threaded bores with
sembly lubricants such as WD40 as this
may alter torque requirements.
Preparatory work Rework all threads completely not to
Before assembly of each module prepare the con- interrupt assembly procedure in
tact surfaces of the main frame and the relevant case of a stiff thread.
module according to the following instructions.
In general it is possible to combine this work and
prepare the contact surfaces, e.g., of the super- To achieve the correct tension of the fixing
structure frame, in one work process inde- bolts with the defined torque value, ensure that
pendently from the time when a module is assem- all threaded bores are in perfect condition.
bled. To avoid contamination during assembly, en-
In these cases you should apply a corrosion pro- sure that the surfaces around and over the mat-
tection to the contact surfaces immediately after ing surfaces are clean.
preparation and cover the threaded bores with a Immediately before assembly, carefully clean all
plastic cap. paint, dirt, grease, rust, and oil from the module
mating surfaces using a suitable solvent. On
Prepare the modules and other components as these surfaces, the metal must be clean and
follows: bright after treatment.
Check all parts and transport containers for Note: Oil based solvents such as Diesel will
damage caused in transit. Document any dam- leave an oily residue and are not suitable for
age found as evidence for the transport insur- surface treatment.
ance in case of a claim. Provide this documen-
tation with photographs of the damaged parts. To gain access to mating surfaces on the un-
derside of a module, place the module on suffi-
Remove all packaging and corrosion inhibitors ciently stable supports.
immediately before assembly of the compo-
nents in the corresponding module. If you do
not install the components immediately, do not Do not work below a suspended
remove the packaging. Longer periods of time load.
without protection will damage or contaminate
contact surfaces. Do not lift modules with a crane to
access the bottom side. Instead
Store any items that are required only for place the module on stable jack
transport, such as covers, blanking plates, stands or similar suitable supports
transport nuts etc. in a secure place, so that of sufficient carrying capacity.
you can use them again if required.
Proceed with the utmost care when removing Use stands or supports with anti-
the protective film from the cylinder pin assem- slip surface or place anti-slip mate-
blies. Even the slightest damage to their sur- rial between the module and the
face can cause destruction of pin assemblies stands or supports.
and bearing bushes in the future.
Prepare all fixing parts, e.g. nuts, bolts, wash- If assembly cannot take place immediately after
ers, spacer sleeves, etc. and check whether cleaning the mating surfaces, protect them from
they are available in sufficient quantities. Where corrosion. Remove this protection directly be-
necessary, grease bolts (see Section Bolt lu- fore assembly so that the mating surfaces are
of the Assembly Manual and Section clean, dry, and bright. If there is corrosion, re-
2.9 of the Service Manual). moved it cautiously and completely.
Carefully clean the threaded bores with com- If you have to remove components (covers, bolt
pressed air. Check all threaded bores with cor- plates etc.) during assembly, insert the re-
responding bolts and rework threads if neces- moved bolts in their places again. Thus, you do
sary. After rework, clean them again. not lose the bolts and keep dirt from entering
the threaded bores.
Page 3.3 8 3746343en (03)
3.3 ASSEMBLY MANUAL
Before assembly, clean any oil from the bear- 3.3.8 General assembly procedures
ings and pins and spray with an assembly
spray. Bolt tightening
Grease all bearing bushes and pin assemblies Always fix the bolts, washers, etc. using the tight-
before seating. Secure all pin assemblies as ening method described in this book or in the Ser-
soon as they have been seated. vice Manual.
You can find the specified tightening method as
Important notes well as the necessary torque value for all bolts in
chapter 2.9 and chapter 17 of the Service Manual.
Copy the relevant pages and keep them accessi-
If you face problems during assem- ble at the assembly site.
bly or disassembly, always contact
your local dealer. Devise a system of marking the bolts to distinguish
between pre-tightened and fully tightenend ones.
Do not try to solve problems intui-
tively or based on experience from
other assembly sites.
Bolt lubrication
1) Refer to chapter 2.9 of the Service Manual to
Always ensure that the modules are suspended see which bolts need to be coated with oil.
horizontally when they are assembled. The mod-
ules must rest evenly and vertically on their con- 2) If required, apply a few drops of oil to the
soles. thread (1, Fig. 2), between bolt head and
During assembly of the machine, always follow the washer (2), and below the washer (3). Do not
sequence of work steps described in this assembly dip the whole bolt in oil.
manual. The sequence of work steps has been
developed and tested by experienced specialists. If
you do not keep the sequence, you may have to
disassemble parts which you have already assem-
bled. This causes time losses and increases the
risk of damage to the parts.
This machine contains parts, e.g. hydraulic hoses
or handrail parts, which can easily be confused
with each other. To enable you to identify them
precisely, the number of the relevant subassembly Fig. 2 Bolt lubrication 647239
is indicated in this manual where necessary.
Please refer to the respective number in the Spare
Parts Manual to find an exact image of the respec- Screwing in connecting bolts
tive part and its part number if applicable.
When installing large modules, screw in the con-
All components in Caterpillar equipment are care- necting bolts while a module is still suspended.
fully selected to operate perfectly together. Fault-
free operation and a long service life can only be
guaranteed if genuine Caterpillar parts are used. Do not raise the module after you
The warranty does not cover any damages result- started screwing in connecting
ing from the use of parts which are not genuine bolts.
Caterpillar parts.
1) Lower the suspended module to 10 - 20 mm
(0.04 to 0.08 in) above its assembly position.
2) Screw all connecting bolts into the respective
bores manually as far as possible.
3) Make the last check to ensure that the assem-
bly position is correct.
4) Lower the suspended module another 5 10
mm (0.02 to 0.04 in) and again tighten the bolts
as far as possible.
3746343en (03) Page 3.3 9
ASSEMBLY MANUAL
5) Repeat step 4 until the suspended module is 8) Remove corrosion inhibitors from the access i-
fully lowered into its assembly position and all ble parts of the bushing (5, Fig. 3) and the pin.
connecting bolts are hand-tight.
9) Pull the pin (1, Fig. 3) out until it res t s only in
6) Tighten all bolts in accordance with chapters one bushing (4).
2.9 and 17 of the Service Manual. Use a hy-
draulic torque wrench to set the exact torque Clean pins and bushings carefully.
required. Do not damage their surfaces.
Ensure that the torque vs. pressure 10) Apply grease to the bushing (5, Fig. 3). Use
charts are available and personnel only delivered genuine grease in accordance
know how to use them to set the with Caterpillar Machine Fluids Recommenda-
correct torques. tions SEBU 6250 in SIS.
11) Push the pin back until it rests only in the
Note: Mark bolts to distinguish pre-tightened from bushing (5, Fig. 3) that you have just cleaned
fully tightened ones. and lubricated. Secure the pin to the crane.
12) Clean the second bushing (4, Fig. 3) and the
Preparation of pins and bushings part of the pin that was not accessible before.
Treat all pin assemblies as follows directly before 13) Apply grease to the second bushing (4, Fig. 3).
installation: Use only delivered genuine grease in accord-
ance with Caterpillar Machine Fluids Recom-
1) Remove the bolts from the pin cover except for mendations SEBU 6250 in SIS.
the uppermost bolt. The pin and bushings are now ready for compo-
nent installation.
2) Loosen the uppermost bolt and tilt the pin cov- Cover the bushing if you do not install the c ompo-
er upwards so that the bearing bushes and pin nent immediately.
are accessible.
Always cover bearing bushings after
3) Tighten the uppermost bolt to secure the pin
preparation. Otherwise dirt may pen-
cover in this position. etrate the bearings during the as-
4) Screw any removed bolts back in to prevent sembly period.
losing them and to prevent the pin cover from
swinging back into its normal position.
5) Define from which side a pin is to be pushed Proceed with the utmost care when
(depending on equipment access, space etc.). removing the protective film from
pins and bushings. Even the slight-
6) Attach an eyebolt (2, Fig. 3) to the opposite est damage to their surfaces can
end of the pin. lead to their future destruction.
Do not use a chain to pull the pin.
The dead weight of the chain can
pull out the pin unexpectedly.
7) Pull out about one third of the pin (1, Fig. 3).
After pulling out about one third of
a pin, fasten a strap around the pi n
and secure it to the crane.
This minimizes the risk that the pi n
slips out of the bushing and causes
personal injury or serious damage.
Note: Pulling can be supported by raising the pin Fig. 3 Pin procedure 644101a
(1, Fig. 3) slightly with the strap (3) and the crane.
Page 3.3 10 3746343en (03)
3.3 ASSEMBLY MANUAL
Fitting pin covers To prevent contamination of hydrau-
Wherever necessary, fit pin covers with a thin layer lic hoses, remove the blanking caps
of silicone or gasket maker as seen in Fig. 4. This from the hydraulic hoses directly
prevents lubricant from being squeezed out of the before fitting them.
sides of the covers when they are closed. Do not clean hoses that are deliv-
ered with intact blanking caps.
As soon as a pin has been fitted tighten all bolts of
the respective pin covers.
Store the blanking caps for future maintenance
and repair work.
If a blanking cap is damaged or missing, you have
to clean the respective hose before you install it.
For this purpose, use the Hose Cleaning Group
(Caterpillar part-ID-No. 233-7192).
Fig. 4 Pin cover with silicone 647223
Use of sealant
Always use the sealant currently
approved by Caterpillar Global Min-
ing HMS GmbH. For changes and
updates visit our webpage and read
General Service Information with
media-no. EM028719.
LOCTITE ® 518TM is a one part heat curable epoxy.
It is designed as non-reworkable CSP/BGA under-
fill for protection of solder joint against mechanical
stress when used for hand held electronics devic-
es.
LOCTITE ® 518TM has can be obtained from the
Caterpillar Global Mining HMS Parts Service.
This Assembly Manual refers to the use of LOC-
TITE® 518TM as sealant wherever it is required.
Before applying LOCTITE ® 518TM, clean the con-
tact surfaces of paint, oil, and grease, and of any
type of contamination.
Cleaning hydraulic hoses
Our hydraulic hoses are cleaned and closed with
blanking caps before delivery.
Hoses that are delivered with intact blanking caps
do not require cleaning.
3746343en (03) Page 3.3 11
ASSEMBLY MANUAL
3.3.9 Workflow chart of assembly
procedure
Start
Prepare Unload Prepare carbody, Assemble LH Install LH crawler
assembly site machine crawler track frames & crawler track track frame to
components chain links & frame with chain carbody
from trucks & segments links & segments
arrange them
in assembly Prepare RH chain
layout Install handrails &
links & segments
walkways on following
for RH crawler
modules: cab, power
track frame
(engine), cooler
module &
counterweight
Connect rotary lock & Install superstructure Prepare Install RH crawler
undercarriage frame to carbody superstructure frame, track frame to
hydraulic lines (tighten to torque) & gearbox cover & carbody, close RH
then install swing swing bearing chain
gearboxes (tighten to
Connect swing torque) to
bearing lubrication superstructure frame Prepare swing
lines gearboxes, boom &
power (engine)
module
Prepare cab, cooler
module, top & bottom
parts of counterweight
& boom
Install Install stick, connect
Install boom with Tri Install boom walkways
lubrication & stick cylinders from
Power link, boom & boom to stick &
stick cylinders; power AC platform
bucket cylinders to Tri
(engine) module, Connect electric & Power link
cooler module, cab hydraulic system to
module, operator cab counterweight, cooler
& counterweight with module, cab module, Connect hydraulic &
coolers (tighten to swing gearboxes & lubrication lines for
torque) to boom attachment (boom,
superstructure frame stick)
Top up hydraulic oil
tank & fuel tanks.
Check engine, pump
gearbox& swing
gearboxes fluids
Start machine & fill
attachment cylinders
Commission Install bucket with oil, then top up
machine, carry Install, with bucket & hydraulic oil tank
out final checks, commission & clam cylinders;
fire suppression calibrate connect
Clean up (customer Add- Operator hydraulic &
Assist system Assemble bucket
assembly site Ons) lubrication lines
648269
Fig. 5 Workflow chart of assembly procedure - 648269
Page 3.3 12 3746343en (03)
3.3 ASSEMBLY MANUAL
3.3.10 Preparation of undercarriage 2) Mount the lights (3) onto the front of the cab
and superstructure modules module.
3) Mount the handrails to the walkways (Fig. 8).
Prepare the carbody, crawler track frames, chain
links and segments as described in chapter 3.3.7 4) Lift the stairways onto the cab module and
of this Assembly Manual. Ensure that all contact screw it tight.
surfaces are free from any rests of preservative 5) Mount the horn (1, Fig. 7) to the catwalk.
spray.
At the same time, you can install handrails and
walkways on the following modules: cab module,
operator cab, power (engine) module, hydraulic oil
cooler module and counterweight. Use Spare
parts manual.
Cab module
1) Assemble the walkways (1, Fig. 6) and hand-
rails (2) on the cab module. Tighten the bolts
according to the specified tightening proce-
dure.
Fig. 7 Horn 644593
Fig. 6 Walkways, handrails, lights on cab module
643420
3746343en (03) Page 3.3 13
ASSEMBLY MANUAL
Fig. 8 Installation of handrails & stairways on cab module 648299
Emergency ladder
1) Clean contact surfaces on the cab module (2,
Fig. 9), on the walkway frame (1) and the cor-
responding contact points on the emergency
ladder.
2) Prepare all necessary bolts.
3) Raise the entire emergency assembly, con-
sisting of a ladder (1, Fig. 10) and a safety
cage (2), into the assembly position. Ensure
that the sliding part of the ladder cannot move.
4) Screw in all bolts according to section Screw-
ing in connecting bolts and chapter 2.9 of the
Service Manual.
Fig. 9 Contact surfaces on cab module 645476
Page 3.3 14 3746343en (03)
3.3 ASSEMBLY MANUAL
handrail (3, Fig. 12 & 1, Fig. 13) around the
access and connect it with a clip (4, Fig. 12).
4) Mount the ladder (5, Fig. 12 & 2, Fig. 13) in-
side the counterweight upper section.
5) Mount and connect all main lights (3, Fig. 13).
Fig. 10 Emergency ladder with safety cage 645479a
5) Mount the safety barriers (2, Fig. 11) in front of
the emergency exit ladder.
Fig. 12 Counterweight 648556
Fig. 11 Emergency exit ladder 643451
Fig. 13 Counterweight 644616
Counterweight
1) Mount two handrails (1, Fig. 12) on the coun-
terweight top section and connect them using
a clip (2).
2) If the access is not covered by a door in the
counterweight upper section, assemble the
3746343en (03) Page 3.3 15
ASSEMBLY MANUAL
Hydraulic oil cooler module
1) Install handrails (Fig. 14) before lifting the
hydraulic oil cooler module into its position on
the superstructure frame.
Fig. 16 Handrails assembly on power (engine) module)
648302a
2) Remove the transport covers from the hydrau-
lic oil tank.
Fig. 14 Handrails installation on hydraulic oil cooler mod- 3) Assemble the mounting plate (1, Fig. 17) for
ule 648301a the breather filters of the hydraulic oil tank.
Make sure no dirt enters the openings.
2) Install two main lights (3, Fig. 15) at the front
of the oil cooler module.
Fig. 17 Breather filters 645804
Fig. 15 Oil cooler module with main light and horn
646866
4) Assemble the breathers (2) to the socket (5).
5) Insert the plastic rings (4) to the filters and
3) Mount an angle plate (1, Fig. 15) for a signal attach the retainers (3).
horn.
6) Install engine air filter boxes (arrows, Fig. 18).
4) Mount a signal horn (2). Ensure that the horn
is positioned correctly; refer to the Service Let-
ter for details.
Power (engine) module components
1) Assemble handrails (Fig. 16) on the power
(engine) module:
Page 3.3 16 3746343en (03)
3.3 ASSEMBLY MANUAL
9) Attach the isolator main switch box (1, Fig.
21).
10) Connect the cables (2, Fig. 21 and 1, Fig. 22)
to the terminal bars (2, 3 and 4, Fig. 22) of t he
control cabinet (5) below deck.
Fig. 18 Engine air filter boxes 648309a
7) Complete the air intake system assembly
(arrows, Fig. 19).
Fig. 21 Isolator main switch box 645474a
Fig. 19 Installation of air intake elbows 648310
8) Install expansion tanks for the coolant (arrows,
Fig. 20).
Fig. 22 Switch box connections 646867
Fig. 20 Installation of coolant expansion tanks
648311a
3746343en (03) Page 3.3 17
ASSEMBLY MANUAL
3.3.11 Undercarriage assembly
Assembly of track segments
Each of the two tracks is supplied in three seg-
ments.
1) Connect four track segments to build one
track.
2) Lay two tracks on the ground side by side with
sufficient space between them to assemble
the machine in.
Note: The track plates must lie with the flat edge
(1, Fig. 23) against the travel forward direction (2)
of the machine. Fig. 24 Transport lugs 644577
5) Loosen four retaining bolts on the cover (ar-
rows, Fig. 25) and remove the cover.
Fig. 25 Cover bolts 648566
6) Remove eight mounting bolts on the track
Fig. 23 Aligning the track plates correctly 644575a guide (arrows, Fig. 26).
3) When both track parts are assembled and laid
out correctly, you can assemble the undercar-
riage.
Assembly of LH crawler track frame to
carbody
Positioning the crawler frame
1) Attach the rigging hardware of both cranes to
Fig. 26 Track guide bolts 648571
four transport lugs (1, Fig. 24) of one crawler
frame. 7) Insert the fork lift beams into the correspond-
2) Lift the crawler frame above the track. ing pockets (arrows, Fig. 27) and remove the
track guide with a forklift (Fig. 28).
3) Lower the crawler frame onto the track.
Note: Position the crawler frame so that the track
adjuster is three plates (1.5 m) away from the end
of the track. This way, the end of the track can
later be lifted slightly for assembly. Do not connect
the track yet.
Fig. 27 Position of fork lift beams 648567
4) Remove the transport lugs (1, Fig. 24).
Page 3.3 18 3746343en (03)
3.3 ASSEMBLY MANUAL
Fig. 28 Removal of track guide 648573
Fig. 30 Sealant application on vertical surface 648574
Preparation of mating surfaces
1) Clean the vertical and horizontal mating surfac-
es of the crawler frame (2 and 3, Fig. 29) and the
carbody as described in section "Preparatory
work".
Fig. 31 Sealant application on horizontal surface
642505a
Installation of LH crawler to carbody
1) Remove the wooden protective cover from the
swing bearing.
2) Attach lifting tackles to four inside lifting lugs
in the middle of the carbody (1, Fig. 32).
Use the four lugs to lift only the car-
Fig. 29 Mating surfaces 644581a body. Do not use them to lift the
complete undercarriage.
2) Rework the threaded bores and clean them
using compressed air.
Always wear safety goggles when
using compressed air.
3) Prepare the necessary bolts and sleeves.
4) Apply a thin layer of the sealant to the hori-
zontal and vertical mating surfaces of the
crawler frame (2 & 3, Fig. 29; Fig. 30 - Fig.
31). Follow the instruction on sealant of this
Assembly Manual.
Fig. 32 Lifting lug inside the carbody 643464
3746343en (03) Page 3.3 19
ASSEMBLY MANUAL
3) Raise the carbody into the assembly position
(Fig. 33).
Fig. 33 Carbody positioning 648583
4) Follow the safety instructions if you have to
adjust it manually. When the carbody is in the
correct position above the crawler frame,
Fig. 34 Supporting the carbody 644582a
screw in the bolts manually.
5) Fasten the horizontal and vertical bolts hand 3) Release the crane.
tight. Follow the safety instructions. 4) Install the track guide (1, Fig. 35) and the cov-
6) Tighten the bolts in the following sequence: er (2).
a) Start with the vertical bolts and tighten them
using a ratchet.
b) Tighten the horizontal bolts using a ratchet.
c) Loosen all horizontal bolts so that they re-
main hand tight.
d) Tighten the horizontal bolts to the specified
torque (see chapter 2.9 of the Service Manu-
al).
e) Loosen the vertical bolts so that they remain
hand tight.
f) Tighten the vertical bolts to the specified
torque.
Fig. 35 Cover 644578b
g) Tighten the horizontal and vertical bolts to
the specified angle of rotation.
Note: Use a hydraulic torque wrench to apply the Closing the track
specified torque. This will allow tightening to the Note: Before closing the track remove the plug
excact torque value and save time and effort. from the hose end and open the shut-off valve (1,
Mark the bolts to distinguish between pre- Fig. 36) to release the track tension system pres-
tightened and fully tightened ones. sure. This ensures the free movement of the idler
during the track installation procedure.
Supporting the carbody
1) Raise the carbody so that it is at a slight angle
(Fig. 34).
2) Support the carbody with a stand or wooden
blocks (1 and 2, Fig. 34). This side should be
around 10 cm higher than the other side.
Check distance to the track on the ground (3)
to make sure the crawler will fit in.
Page 3.3 20 3746343en (03)
3.3 ASSEMBLY MANUAL
Assembly of RH crawler to the carbody
Positioning RH crawler
1) Attach the rigging hardware of both cranes to
the four transport lugs (1, Fig. 39) of the RH
crawler.
Fig. 36 Shut-off valve, open 648303
After all bolts have been tightened, close the track
(Fig. 37). Full assembly of the LH crawler is now
complete.
Fig. 39 Transport lugs 644577
2) Lift the crawler frame above the track.
3) Lower the crawler frame onto the track.
Note: Position the crawler frame so that the track
adjuster is three plates (1.5 m) away from the end
of the track. Thus, the end of the track can be
lifted slightly for assembly.
4) Remove the transport lugs (1).
Fig. 37 Closing the track 644583b Note: Leave the cover mounted on the crawler. It
serves as support when the track is closed (2, Fig.
Note: If the machine has been assembled before 35).
and is now being re-assembled, check whether
the shut-off valve (1, Fig. 38) of the track tension Closing the track
system is closed (lever perpendicular to the hose).
Note: Before closing the track remove the plug
from the hose end and open the shut-off valve
(Fig. 40) to release the track tension system pres-
sure. This ensures the free movement of the idler
during the track installation procedure.
Fig. 38 Shut-off valve, closed 643466
Fig. 40 Shut-off valve, open 648303
3746343en (03) Page 3.3 21
ASSEMBLY MANUAL
1) Close the track (1, Fig. 41). Now it lies on the
cover.
Fig. 43 Lifting the crawler 644585
2) Prepare the mating surfaces on the crawler
and carbody as described in section
tion of mating surfaces .
3) Position the crawler as precisely as possible
below the supported side of the carbody. Bolt
Fig. 41 Closing the track 644583a the RH crawler to the carbody, as described in
section "Installation of LH crawler".
2) Now carefully lift the closed track (Fig. 42) to
enable disassembly of the cover. 4) Now lift the complete unit.
3) Support the raised track using wooden blocks 5) Remove the supports.
(1, Fig. 42). 6) Lower the unit onto the ground.
7) Ensure that the undercarriage is horizontal by
placing a level gauge on top of the swing
bearing. Adjust if necessary by placing wood-
en blocks between tracks and rollers.
Correct horizontal position of the
undercarriage is important for the
correct assembly of the other mod-
ules.
8) Remove the steel ropes from the track.
Note: If the machine has been assembled before
and is now being re-assembled, check whether
Fig. 42 Supporting the track 644584 the shut-off valve (1, Fig. 44) of the track tension
system is closed (lever perpendicular to the hose).
4) Now disassemble the cover.
The RH crawler is now fully assembled and can
be connected to the carbody.
Connecting the crawler to the carbody
1) Lift the second crawler using both cranes (Fig.
43). This is the only way to align the crawler
precisely.
Use steel ropes to rig the tracks.
Do not use hooks.
Page 3.3 22 3746343en (03)
3.3 ASSEMBLY MANUAL
Fig. 44 Shut-off valve, closed 643466
Reassembly of RH cover
Before lifting the slider into the as-
sembly position ensure that the mat-
ing surfaces are clean.
Fig. 45 Protective caps on the swing bearing 643425
1) Assemble the cover and the track guide as for
LH crawler frame. Positioning the "soft spots"
2) Tighten the bolts using the tightening proce- 1) Check the location of the "soft spots" on the
dure in chapters 2.9 and 17 of this Service outer race (1, Fig. 46) and the inner race (2) of
Manual. the swing bearing.
3.3.12 Preparations for superstruc-
ture installation
The assembly steps on the undercarriage and
superstructure frame described below can be
carried out simultaneously. Clean all mating sur-
faces from rests of preservative spray. Prepare
boom and power (engine) module the same way.
Preparation of the swing bearing
1) Remove all transport and corrosion protection
from the swing bearing and the bolts contact
surfaces.
2) Remove the protective caps (1, Fig. 45) from
the bolts and loosen the nuts. Be careful when
the bolts fall.
3) Store the protective caps and nuts in a suita-
ble place.
Fig. 46 Inner and outer race of the swing bearing
643391
Depending on the manufacturer a "soft spot" is
S F(1, Fig. 47).
3746343en (03) Page 3.3 23
ASSEMBLY MANUAL
Fig. 47 Soft spot 643390
Chapter 5.2 of the SM contains detailed infor-
mation on soft spots as well as a drawing showing
their correct position.
2) If necessary, turn the swing bearing until the
soft spots are at the specified angle of 90° to
one another. Fig. 48 Lubricant injectors, teeth, seal ring 643385
4) Inspect the machined surface for damage.
Cleaning and lubrication of the swing bearing
5) Lubricate the entire inner race (2) of the swing
This work should be performed directly before
bearing.
assembly of the superstructure frame to prevent
contamination of the mating surfaces.
Cover
1) Carefully clean and dry the machined surface
1) Pre-assemble the cover (Fig. 51 - Fig. 50) on
of the outer race (1, Fig. 46) and inner race (2)
the ground.
of the swing bearing as described in section
"Preparatory work".
2) Use compressed air to clean the bolt heads
and threaded bores.
Always wear safety goggles when
using compressed air.
3) Remove the plastic caps from the bores for
the lubricant injectors (1, Fig. 48).
Fig. 49 Cover delivery state 648284
Page 3.3 24 3746343en (03)
3.3 ASSEMBLY MANUAL
Fig. 50 Cover assembly 648285
2) Fill the space between the swing bearing teeth
with as much grease as possible (Fig. 51 -
Fig. 52). Use only CAT geniuine product in
Fig. 52 Swing bearing teeth lubricated 648287
accordance with Caterpillar Machine Fluids
Recommendations SEBU 6250 in SIS. 3) Check grease (lubricant) filling from the bot-
tom of the swing bearing. Ensure that the lub-
ricant runs in at least 20 mm over the whole
circumference of the swing bearing (Fig. 53).
Maintenance Manual.
Fig. 51 Swing bearing teeth lubrication 648286
Fig. 53 Swing bearing lubrication check 102152
4) Lift the cover (1, Fig. 54) into assembly posi-
tion by crane and set it onto the swing bearing
(2). Ensure that the openings (3) for the swing
gearbox pinions are in the correct position at
the rear of the machine.
5) Fill the gap between the lubricant cover (1)
and the swing bearing (2) and the openings
for the swing gearboxes (3) with lubricant.
3746343en (03) Page 3.3 25
ASSEMBLY MANUAL
Use stable jack stands or similar
suitable supports of sufficient carry-
ing capacity.
Use stands or supports with anti-
slip surface or place anti-slip mate-
rial between the module and the
stands or supports.
2) Clean on the bottom of the superstructure
frame:
the threaded bores
Fig. 54 Lubricant cover 643469 the contact surfaces of the swing bearing
side
6) To center the superstructure frame correctly,
position a dowel pin (1, Fig. 55) on the outer the swing bearing housing
race of the swing bearing when the super- as described in section "Preparatory work".
structure frame positioned above the swing
bearing. 3) Fit the lubricating pinions (1, Fig. 56; 1 & 2,
Fig. 58).
Fig. 56 Lubricating pinion 643394
3.3.13 Installation of superstructure
frame
Fig. 55 Dowel pin 643392
Note: To optimize machine assembly process we
Preparation of superstructure frame recommend you to semaltaneously prepare cab
and cooler modules, boom as well as top and
1) Raise the superstructure frame on safety bottom parts of counterweight (ballast) for further
compliant blocks or stands approx. 1.2 m (4.9 installation steps as described in chapter 3.3.7 of
ft) above ground. this Assembly Manual.
1) Position the crane along the same axis as the
undercarriage to facilitate positioning of the
superstructure frame.
2) Prepare the retaining bolts for the swing bear-
ing using chapter 2.9 of the Service Manual.
Page 3.3 26 3746343en (03)
3.3 ASSEMBLY MANUAL
Do not apply oil to the top surface of
the outer race of the swing bearing.
3) Apply sealant to the outer race top surface
(Fig. 57) and spread in a thin, even layer using
a putty knife. Follow the instructions on seal-
ant of this Assembly Manual.
Fig. 59 Dowel and bore 643426
5) Position the superstructure frame over the
undercarriage.
Note: During the next assembly steps, check
continuously that the superstructure is horizontal
and adjust if necessary.
6) Slowly lower the superstructure frame. Stop
Fig. 57 Applying sealant 643393 when lubricating pinions (1 & 2, Fig. 58) are
about 10 cm (4 in) above the swing bearing
4) Lift the superstructure frame using the cranes
(Fig. 58).
(Fig. 58).
Ensure that the teeth of the lubrica-
tion pinion (1, Fig. 56) fit between
those of the swing bearing (2, Fig.
48).
7) Continue to lower the superstructure frame
until the dowel pin (2, Fig. 59) is seated in the
respective bore (1) on the superstructure
frame.
Continuously check the position of
the bore for the dowel pin. If the
dowel pin accidently enters one of
the threaded bores, it can damage
Fig. 58 Lowering the superstructure frame 644619
the thread.
To ensure the precise alignment and positioning
of the superstructure frame on the carbody, a 8) Lower the superstructure frame as far as 10 to
dowel (2, Fig. 59) is provided on the swing bear-
20 mm (0.4 to 0.8 in) above the swing bearing.
ing. This dowel must line up with the correspond-
ing bore (1) on the superstructure frame. 9) Screw in all bolts of the swing bearing: lift
bolts with a suitable tool (Fig. 60) and tighten
3746343en (03) Page 3.3 27
ASSEMBLY MANUAL
them manually as far as possible (read section 14) If applicable, fit scrapers (arrows, Fig. 61 -
Screwing in connecting bolts). Fig. 62) to the swing bearing.
Fig. 61 Scrapers location 648292
Fig. 60 Swing bearing bolt screwing in 647221
To prevent injury in case of a sudden
load drop always use a tool to lift the
bolts.
Do not insert your hands or fingers
into the gap under the bolts.
10) Make the last check to ensure that the dowel
and the associated bore are positioned pre-
cisely opposite each other (Fig. 59). Fig. 62 Scraper installation 648293
11) Bolt the swing bearing lubricant cover (1, Fig. To assemble them take the following steps:
51) to the superstructure frame when the
frame is suspended 10 mm above the swing 1) Install a bracket (3, Fig. 63) with a bolt (5) and
bearing. a washer (4) and tighten the bolt hand-tight.
12) Lower the superstructure bit by bit and con- 2) Insert scrapers (1 & 2) from both sides. Install
tinue to tighten the bolts of the swing bearing bolts and washers (6 & 7) using clearance of
manually until the superstructure frame is fully the bracket bolt (5) bore.
lowered onto the swing bearing. Ensure that
3) Tighten the bracket bolt first, then the scraper
all bolts are screwed in before the superstruc-
bolts (6) with a torque wrench. For torque in-
ture frame is fully lowered. formation refer to Chapter 17 of the Service
13) Mark all bolts which have already been tight- Manual.
ened.
The items in Table 4 refer to Fig. 63.
Note: In some cases, access to the bolts at the
left- and right-hand side of the swing bearing is Item Description
easier after turning the superstructure frame 90°. 1 Scraper, LH
2 Scraper, RH
Ensure that all bolts at the front and
rear of the swing bearing are tight- 3 Bracket
ened to assembly torque before turn-
4 Washer
ing the superstructure frame.
5 Hex. head bolt M20 x 2.5
6 4 bolts M12 x 1.75
Assembly torque and tightening procedure are
7 4 w ashers
specified in chapter 5.2 of the Service Manual.
Table 3
Page 3.3 28 3746343en (03)
3.3 ASSEMBLY MANUAL
2) Attach the lubrication lines (1, Fig. 65) and
cover plates (2) to the front of the superstruc-
ture frame.
Fig. 65 Lubricating lines on the superstructure frame
643472
3) Ensure that the lubrication lines are laid in
such a way that they cannot be damaged
when the other modules are assembled.
Fig. 63 Scraper assembly 648294
Preparation of swing gearboxes
Installation of swing bearing lubrication To install the swing gearbox correctly, turn the
lines pinion in the correct position while lowering. For
this purpose, release the swing park brake. There
Note: It is important to install the swing bearing
are two ways of doing it: with the manual pump
lubrication lines before installing any other mod-
and without it. We recommend you always use the
ules.
manual pump for swing park brake release.
The lubrication lines are pre-installed with the
Swing park brake release with manual pump
injectors. Lubricant injectors supply lubricant to
the swing bearing. Bores for the lubricant injectors 1) Connect a manual hydraulic pump with a
are positioned at irregular intervals on the super- pressure display to the line for the swing
structure frame above the swing bearing. brake (1, Fig. 66). To locate the swing brake
(Fig. 67) use the Spare Parts Manual.
1) Insert the injectors in the holes of the swing
bearing lubrication system (see chapter 11.3
in the SM and 1, Fig. 64).
Fig. 66 Connecting the hand pump 644609
Fig. 64 Lubricant injector 643471
3746343en (03) Page 3.3 29
ASSEMBLY MANUAL
2) Apply pressure to the line. The minimum 3.3.14 Installation of swing gearboxes
pressure is 35 bar or 40 bar. The brake is now
released. Note: Semaltaneously to the installation of the
swing gearboxes you can prepare the cab mod-
Never exceed a maximum pressure ule, hydraulic oil cooler module, top and bottom
of 40 bar to release the swing brake. parts of the counterweight and the boom for fur-
Higher pressure will damage the ther installation on the superstructure frame.
brake.
Install the swing gearboxes in turns. Each of the
four swing gearboxes is marked to ensure its in-
Swing park brake release without manual stallation in the correct position.
pump First install the front gearboxes and then the rear
If a manual pump with pressure indicator is not ones to avoid any unnecessary difficulties with the
available, remove the swing motors and turn the limited assembly space.
pinions by hand: 1) Remove the packaging from the swing gear-
1) Disassemble the swing motor above the box.
swing gearbox (Fig. 67). To do this, loosen 2) Clean the assembly surfaces and pinions.
the four retaining bolts (1, Fig. 68).
3) Attach the first swing gearbox to the crane and
lift it slightly and carefully. Ensure that it hangs
levelled.
4) Place the enclosed O-ring (O, Fig. 69) onto
the respective gearbox.
Fig. 67 Swing gearbox & swing motor 648289a
Fig. 69 Installation of swing gearboxes 648288
5) Secure the O-ring on the assembly surface
using a little lubricant.
6) Lower the swing gearbox to approx. 5 mm (0.2
in) above the assembly surface (Fig. 69).
7) Position the swing gearbox correctly (1 to 4,
Fig. 70).
Item Description
1 LH swing gearbox, rear
2 RH swing gearbox, rear
Fig. 68 Disassembling the swing motor 644586 3 LH swing gearbox, front
2) Mark the position of the swing motor and lift it 4 RH swing gearbox, front
out. Table 4
3) Pull out the intermediate gear (2, Fig. 68). It is
now possible to turn the pinion of the swing
gearbox.
Page 3.3 30 3746343en (03)
3.3 ASSEMBLY MANUAL
3.3.15 Connection of hydraulic lines
between undercarriage and
superstructure
Note: Depending on the delivery state of the indi-
vidual machine some components can already
be installed. In this case skip the unnecessary
installation steps und proceed with the re-
quired ones.
To prevent contamination and dam-
age of the machine hydraulic sys-
tem, blow all unsealed hydraulic
hoses with compressed air directly
Fig. 70 Aligning the swing gearbox 644622 before assembly. Remove transport
sealings from hoses and hydraulic
8) Fasten all bolts hand tight and check, if the components directly before assem-
gearbox is in the correct position. bly.
9) Lower the gearbox until it rests on the assem-
bly surface. Make sure that the O-ring stays in
place. Always wear safety goggles when
10) Tighten all bolts hand tight. Torque the first using compressed air.
bolts crosswise in the following sequence: 1,
13, 7, 19, 4, 16, 22, 10 (Fig. 71), then the rest Installation of travel system hydraulic
bolts. Use torque wrench and the information
on torque value in chapter 7.3. Mark all bolts
lines to the rotor
which have already been tightened.
1) If there is an optional cover (body plate) (1,
Fig. 72) connected to the carbody, loosen the
bolts of the lid (2) and slide it aside.
Fig. 72 Body plate installation 648442
Fig. 71 Torque pattern of swing gearbox 648298
11) Remove the manual hydraulic pump from the 2) Install a rotary lock (1, Fig. 73 - Fig. 73) to the
swing gearbox and assemble the swing motor. rotor (91).
12) If the swing motor has been disassembled,
reassemble it. Ensure that it is positioned as
before.
3746343en (03) Page 3.3 31
ASSEMBLY MANUAL
4) Route all hydraulic hoses from the carbody to
the rotor. For information about the function
and operation of the rotor, see chapters 8.4.9,
8.5.5, 8.5.7, and 5.9 of the Service Manual.
5) Connect high pressure hoses between rotor
(91) and secondary pressure relief manifold
(125) to the crawlers as shown in Fig. 76.
Fig. 73 Rotary lock installtion 648290
3) Ensure the correct position of the rotor on the
bottom of the travel control block. If the rotor
is turned to 180°, the forward and backward
travel motion will be interchanged. Port 9 of
the rotor (Fig. 74) must be on the right-hand
side. Fig. 76 Connection of high pressure hoses 646879f
6) Ensure connection between undercarriage
and travel motors (121, Fig. 77). Connect pilot
pressure hoses between rotor and travel mo-
tors.
Fig. 74 Rotor ports 648575
The narrow end of the rotary lock must latch into
the cut-out (arrow, Fig. 75). Fig. 77 Connection of pilot pressure hoses 646879c
7) Route all hydraulic hoses from the carbody to
both crawler frames (e.g., 1 and 2, Fig. 78).
8) If you have removed the lid (2, Fig. 72) of the
optional cover (body plate), reinstall it.
Fig. 75 Rotor installation 648291
Page 3.3 32 3746343en (03)
3.3 ASSEMBLY MANUAL
3.3.16 Boom installation
Preparations on the superstructure
Open the pin covers (items 1 to 5, Fig. 80) as
follows:
1) Remove the outer pin cover (1) on one side of
the superstructure frame.
2) Remove pin covers (2 to 5) on both sides of
the superstructure frame, inside and outside.
Note: The inside pin covers are opened to provide
a better view during alignment of the Tri-Power
rods and hydraulic cylinders.
Fig. 78 Hydraulic lines carbody/track crawler frames Open the pin covers one by one following steps
643388 3 6:
9) Connect all hydraulic hoses for the swing 3) Remove the bolts from the cover except for
circuit. Use chapter 8.5 Description of hydrau- the uppermost bolt.
lic circuits of the Service Manual.
4) Loosen the uppermost bolt and tilt the pin
10) Connect lubrication lines to the swing gear- cover upwards so that bearing bush and pin
boxes. are freely accessible (see Fig. 80).
5) Tighten the uppermost bolt to secure the pin
cover in this position.
6) Screw in any removed bolts again to prevent
losing them and to stop the pin cover from
swinging back into its closed position.
Fig. 79 Lubrication connection of the swing gearbox
644978
11) Tighten the bolts according to the tightening
procedure described in chapter 2.9 of the
Service Manual.
Fig. 80 Pin covers 643404
12) Connect all grease couplings.
13) Refill nitrogen accumulators for track tension
system on both sides.
3746343en (03) Page 3.3 33
ASSEMBLY MANUAL
Pin installation
1) Prepare pins and bushing as described in
Prepa
2) Attach an eyebolt (2, Fig. 81) to the end of the
pin.
Fasten a strap around the center of
the pin and secure it to the crane.
This minimises the risk that the pin
suddenly slips out of the bushing
and causes personal injury or seri-
ous damage.
Fig. 82 Pin puller assembly 648576
Do not use a chain to pull the pin.
The dead weight of the chain can For detailed information on its use refer to tool
pull out the pin unexpectedly. operating manual with media no. M0074390-00 in
SIS web.
6) Remove corrosion inhibitors from the bushing
3) Pull out about one third of the pin (1).
(5) that is now accessible and from the acces-
sible part of the pin (1).
Pulling the pin can be supported by 7) Grease the bushing (5) you have just cleaned.
raising the pin slightly with the Coat the cavity (Fig. 83) with lubricant com-
crane and the strap at the center of pletely.
the pin.
Fig. 83 Cavity filled with lubricant 647474
8) Push the pin back until it rests only in the
Fig. 81 Pulling the pin 644627a bushing (5) that you have just cleaned and
greased. Again, secure the pin with a strap
4) Attach two straps (3) to the part of the pin fastened around its center.
which has been pulled out and raise it slightly.
9) Clean the second bushing (4) and the part of
5) Pull out the pin until it rests only in one bear- the pin that was not accessible before.
ing bush (4).
10) Grease the second bushing (4).
Note: You can also use a special tool pin puller
(Fig. 82): 11) Prepare all pin assemblies on the superstruc-
ture the same way by repeating steps 2 to 10.
12) Spray all pins and bearing bushes with as-
sembly spray.
Page 3.3 34 3746343en (03)
3.3 ASSEMBLY MANUAL
Preparations on the boom Stick cylinders
1) Before assembly, clean all pin assemblies and Boom cylinders
aration
Cradle
1) Spray all bearing bushes and pin assemblies
Always cover the bearing bushes on the cradle (Fig. 85) and boom with assem-
after preparation. Otherwise dirt bly spray.
may enter the bearings during the 2) Rig a four-legged chain to the cradle.
assembly period.
3) Lift the cradle into the installation position.
2) Spray all bearing bushings and pins with as-
4) Insert the pins and bolt the lids to them.
sembly spray and cover them to prevent con-
tamination. 5) Install hydraulic hoses from the cradle to the
uppercarriage.
Always cover bearing bushings after
preparation. Otherwise dirt may en-
ter the bearings during the assem-
bly period.
Components for the boom installation are listed in
Table 5 and shown in Fig. 84.
Item Description
1 Cradle (not yet installed)
2 Steering rod
3 Stick cylinder (not yet installed)
4 Boom cylinder (not yet installed)
5 Rocker (TriPower) Fig. 85 Cradle components 648305
Table 5 Installation of stick cylinders on the boom
The two stick cylinders (3, Fig. 84) are supplied
separately and must be installed to the boom first.
1) Lift the boom using a crane.
2) Set the boom on stands or wooden blocks of
sufficient carrying capacity approx. 1 m above
the ground.
Use stable jack stands or similar
suitable supports of sufficient carry-
ing capacity.
Use stands or supports with anti-
slip surface or place anti-slip mate-
rial between the module and the
Fig. 84 Boom components 644587 stands or supports.
The following parts are mounted onto the boom
assembly on delivery: 3) Remove the packaging material from the stick
cylinders.
Rocker (5, Fig. 84).
4) Identify left-hand and right-hand side cylinders
TriPower steering rod (2). using machine data sheet and serial numbers.
Assemble the boom with all components laid out 5) Place the stick cylinders near the side of the
on the ground. The assembly sequence is: boom they will be installed on. Place them se-
Cradle
3746343en (03) Page 3.3 35
ASSEMBLY MANUAL
curely on wooden pallets which you can lift Installation of boom cylinders on the boom
with a fork lift.
1) Remove the packaging material from the cyl-
6) Prepare bushings and pins of the cylinders as inders.
described in the corresponding section of
2) Identify left-hand and right-hand side cylinders
chapter 3.3.8.
using machine data sheet and serial numbers.
7) Secure the fork with a steel rope (3, Fig. 86),
3) Prepare pins and bushings of the boom cylin-
so the rod cannot slide out.
der.
Continue with one of the cylinders:
4) Raise one boom cylinder (2, Fig. 88) slightly
and remove the transport lock (6).
5) Carefully lower the boom cylinder (2, Fig. 88)
onto the ground.
6) Repeat steps 1) through 5) to lower the sec-
ond boom cylinder.
7) Raise one TriPowerTM steering rod (3, Fig. 88)
slightly and remove the transport lock (4).
Lower the Tri-Power rod far enough to install it
easily.
8) Secure the TriPowerTM rod again in this posi-
Fig. 86 Stick cylinder preparation 643407b tion using a chain hoist.
From here continue with one stick cylinder: 9) Repeat steps 7) and 8) to lower the second
TriPowerTM rod for easier installation.
8) Raise the stick cylinder (2, Fig. 86) using a
fork lift to line up its bearings with the bearing 10) Secure cylinder piston rods of the boom cylin-
of the boom (1). ders using a chain hoist or steel the same way
as with the stick cylinders (Fig. 87) to prevent
9) Insert the pin and close the bearing with the them from sliding out.
pin covers.
10) Secure the stick cylinder to the lifting eye (3,
Fig. 87) using a chain hoist or a rope sling (1).
11) Repeat steps 8) through 10) to fit the second
stick cylinder.
Fig. 88 Preparation of boom 643411a
11) Make sure that the piston rods and the yoke
assemblies are correctly aligned.
12) Grease pin assemblies and bearing bushes.
Fig. 87 Securing the stick cylinder 643408a 13) Lift one boom cylinder into position using a
crane and insert the pin.
14) Assemble the pin lid and tighten all bolts as
specified in the Service Manual.
Page 3.3 36 3746343en (03)
3.3 ASSEMBLY MANUAL
15) Secure the boom cylinder to the boom using a 3) Seal the cavity at the boom head to prevent
chain hoist or rope sling. contamination. Remove the seal only directly
before installation procedure.
16) Repeat steps 13) through 15) to install the
second boom cylinder. 4) Also fill the cavities at the base shaft bearings
on the superstructure frame with as much
Installation of the boom on the super- grease as possible.
structure frame 5) Spray all bearing bushes and pins with as-
Final preparations sembly spray and then cover to prevent con-
tamination.
1) Fill the cavities at the boom base bearing
points (1, Fig. 89) and boom head (2) with as Always cover the bearing bushes
much grease as possible so that the time-
after preparation. Otherwise dirt
consuming operation of filling the grease cavi-
may enter the bearings during the
ty following assembly will not be necessary. assembly period.
Boom installation
1) Raise the boom with both cranes, one at the
foot (rear crane) (1, Fig. 91) and one at the
head (front crane) (2) of the boom.
Fig. 89 Assembling the bearing points and hydraulic lines
643409
2) Pile up grease near the bushing as indicated
(1, Fig. 90).
Use a service truck with a pipe of 2 Fig. 91 Raising the boom assembly 644590
m length to fill in the grease.
To avoid contamination, do not use 2) Loosen the safety fastenings for the boom
shovels. cylinder so that they do not interfere with fur-
ther assembly.
3) Lift the boom off the ground above the super-
structure and then slowly lower the boom until
it is suspended in the required position (Fig.
92) and the foot bearings line up with the
bushings of the superstructure frame.
Lower the boom into the bearing
bushes from above.
If you move it in from the front it
may tilt and get stuck.
4) When lowering the boom, make sure that the
TriPower rods (1) slide into the intended posi-
Fig. 90 Grease level in cavity 647226a tion of the superstructure frame.
3746343en (03) Page 3.3 37
ASSEMBLY MANUAL
5) Now insert the pin (3) on the boom foot. Installation of TriPowerTM steering rods on the
superstructure frame
1) Use suitable rigging equipment (1, Fig. 94) to
attach the first TriPowerTM rod to the rear
crane.
2) Use the rigging equipment and the rear crane
to ensure that the TriPowerTM rod (2) slides in-
to its required position on the superstructure
frame.
3) Use the front crane to lower and raise the
boom head to assist with the alignment.
Fig. 92 Boom installation 644600
6) Fit pin covers (see corresponding passage of
chapter 3.3.8). Ensure that the bearing cover
is positioned correctly: the hole for the lubrica-
tion tube (1, Fig. 93) must be at the top.
Fig. 94 Installation of steering rod 643414
4) Insert the pin (3, Fig. 94).
5) Remove the lifting gear (1) from the rod.
6) Fit the pin covers as described in the corre-
sponding section of chapter 3.3.8 and tighten
all bolts in accordance with the specified
tightening method.
Fig. 93 Closing the bearing cover 643437 7) Proceed in the same way with the second
TriPower rod.
7) Release the rear crane that is holding the
boom foot (4, Fig. 92). Keep the front crane Removal of the rocker lock
attached to the boom head (5). The following steps need to be carried out before
8) Mount the lubrication lines for the boom base fixing the boom cylinders to the superstructure
pin assembly on both sides of the superstruc- frame:
ture frame. 1) Secure the rocker lock (1, Fig. 95) with a belt
9) Remove any excessive grease. and the rear crane to prevent it from falling.
2) Manipulate the boom head with the front crane
to take the weight off the rocker lock.
3) Pull out the rocker lock.
Page 3.3 38 3746343en (03)
3.3 ASSEMBLY MANUAL
4) Leave the front crane attached to support the Selection of shims
boom head.
The shipment includes several different shims. To
determine the thickness of the shims needed,
measure the cylinder yoke (A, Fig. 97) and the
relevant cylinder fork (B).
Calculate as follows:
Thickness of cylinder yoke including bearing
bushing (A)
Internal gap of the cylinder fork (B)
Formula: (B - A) / 2 = size of the shim
Note: You need two shims of this size, one on
each side of the cylinder yoke.
Fig. 95 Rocker lock 643416
Installation of boom cylinders on the su-
perstructure frame
Shims
Fabrication tolerances may cause too much axial
play at the bearing points of the boom cylinders.
The play between cylinder yoke (1, Fig. 96) and
cylinder fork (2) must be at least 1 mm on both
sides and must not exceed 2 mm.
To adjust the play and to center the cylinder yoke
(1, Fig. 96) in the cylinder fork (2), it may be nec-
essary to fit shims (3) on both sides of the yoke.
Item Description
1 Cylinder yoke
2 Cylinder fork Fig. 97 Bearing position 644663
3 Shims
4 Pin Boom cylinder installation
Install the two boom cylinders one after the other:
Table 6
1) Lift the first boom cylinder (1, Fig. 98) into
position using the rear crane.
2) Install the shims on the bearing bushings of
the boom cylinder and insert the pin (2, Fig.
98).
3) Install the pin covers and tighten all bolts in
accordance with the tightening method speci-
fied in chapter 2.9 of the Service Manual.
4) Remove safety ropes between the cylinder rod
and cylinder liner and open cylinder ports.
5) Repeat steps 1) through 4) to fit the second
boom cylinder.
Fig. 96 Cylinder fork with shims 644803a
3746343en (03) Page 3.3 39
ASSEMBLY MANUAL
6) If you connect the hoses later, close the cylin- 3.3.17 Installation of modules and
der ports. components to superstructure
The boom is now held by the boom cylinders
and the TriPowerTM rods. frame
7) Release the front crane. Ensure that all modules and components of su-
perstructure listed in Table 7 and shown in Fig.
100 are either installed or ready for installation.
Item Description
1 Lubrication (pumps) module
2 Engine air filters (installed)
3 Coolant expansion tanks (installed)
4 Exhaust tube covers
5 Exhaust pipes
6 Hydraulic oil tank breathers (installed)
7 Isolator main switch box (installed)
8 Vise
9 On-board crane
10 Horn (installed)
11 On-board crane set (optional)
Fig. 98 Installation of boom cylinder 643415
12 Working lights
8) Install two steps (1 & 2, Fig. 99) on the main 13 Mirror
frame.
14 Lubrication & AC platform
Table 7
Preparation of power (engine) module
Complete power module preparation as described
in this Assembly Manual before fitting the power
module to the superstructure frame. However,
varying site conditions and crane schedules may
call for a different approach in some cases. It is
possible to carry out the following work alongside
the assembly of the undercarriage and the super-
structure frame.
To ensure working safety on the
superstructure fit handrails, walk-
ways, steps and gratings before lift-
Fig. 99 Installation of steps 648419 ing the power module into place.
Page 3.3 40 3746343en (03)
3.3 ASSEMBLY MANUAL
Fig. 100 Uppercarriage components 648568
3746343en (03) Page 3.3 41
ASSEMBLY MANUAL
Installation of hydraulic access ladder Note: Connect lubricating and hydraulic lines for
the ladder after the cab module has been in-
Assemble platforms and handrails stalled.
before lifting the ladder into place to
ensure working safety at heights. Installation of power (engine) module on su-
perstructure frame
1) Secure the hydraulic access ladder (Fig. 101) 1) Remove all packaging material from the ser-
in the delivery state. vice arm (1, Fig. 103) but do not lower it yet.
Fig. 101 Hydraulic access ladder in delivery state Fig. 103 Service arm 643399
648297
2) Secure all loose cables and hoses on the
2) Remove the packaging material from the lad- module so that they do not interfere with the
der and platform. assembly work.
3) Clean all mating surfaces on the platform and 3) Make sure that all machined mating surfaces
on the power module and prepare all bolts and bolt holes in both the power module and
and sleeves. the superstructure frame have been cleaned
according to the instructions (see Section
4) Use a crane to carefully lift the ladder into the
3.3.1 in the Service Manual). If necessary,
installation position (Fig. 102).
rework the threads.
4) Prepare all bolts and sleeves according to the
specifications (see Section 2.9 in the Service
Manual).
Note: steps 5) and 6) are valid for machines from
serial number #196 and up. If your machine has
another serial number, continue with step 7).
5) Install two friction shims (1, Fig. 104) without
any sealant on the front mating surfaces of
the superstructure frame using bolts (2) and
sleeves (3).
6) Apply a thin layer of sealant on the rear mat-
ing surfaces of the superstructure frame
(those without friction shims). Follow the in-
structions on the sealant of this Assembly
Fig. 102 Installation of hydraulic access ladder 644612 Manual. Continue with step 8).
5) Insert the bolts at all fixing points (1) and
tighten them according to the specified tight-
ening method (see Service Manual for de-
tails).
Page 3.3 42 3746343en (03)
3.3 ASSEMBLY MANUAL
11) Fully lower the power module.
12) Tighten the bolts as far as possible by hand.
13) Remove the rigging material.
14) Tighten the bolts in accordance with Section
2.9 of the Service Manual.
15) Slowly lower the service arm (1,Fig. 106).
Fig. 104 Friction shims 648684a
7) Apply a thin layer of sealant to the eight mat-
ing surfaces on the superstructure frame
(dashed circles, Fig. 105).
Fig. 106 Lowering the service arm 645467
Follow the instructions on sealant of this As-
sembly Manual. Installation of hydraulic oil cooler module
1) Clean the mating surfaces (dashed circles,
Fig. 107) of the hydraulic oil cooler module
and the superstructure frame, as described in
section "Preparatory work".
Fig. 105 Mating surfaces on the superstructure frame
643475a
8) Raise the engine (power) module using two
cranes and align it horizontally.
Ensure that no hoses or cables are
crushed or damaged when setting
the power module onto the super-
structure frame.
Fig. 107 Mating surfaces on hydraulic oil cooler module
9) Carefully position the power module in its end
643443
position.
10) Insert the bolts, start tightening them manually 2) Prepare all bolts and sleeves required for
while the power module is still suspended. installation of the module.
3746343en (03) Page 3.3 43
ASSEMBLY MANUAL
3) Apply sealant to the prepared surfaces on the
superstructure frame. Follow the instructions
on sealant of this Assembly Manual.
4) Attach the hydraulic oil cooler module to a
crane and raise it. Ensure it is suspended hor-
izontally.
5) Lift the module into its assembly position.
6) Insert the bolts. Start them according to chap-
ter 3.3.8 of this Assembly Manual. When the
module is fully lowered, tighten bolts accord-
ing to the specified tightening procedure (see
Section 2.9 of the Service Manual).
Installation of cab module
Fig. 109 Mating surfaces on superstructure frame
1) Clean the mating surfaces and threaded bores 643423
on the operator cab module (circles with
dashed lines, Fig. 108), as described in sec- 3) Apply sealant to all mating surfaces on the
tion "Preparatory work". superstructure frame. Follow the instructions
on sealant of this Assembly Manual.
4) Prepare all bolts and sleeves for assembly.
5) Lift the cab module into its final position. En-
sure that the module is suspenden horizontal-
ly. Use chain blocks or chains with shorteners
if necessary.
Note: While the module is lifted into its end posi-
tion, the cables and hoses of the engine module
must be fed through the opening in the lower right
corner and into the operator cab module (1, Fig.
110).
Fig. 108 Mating surfaces on cab module 643422a
2) Clean the mating surfaces on the superstruc-
ture frame (circles with dashed lines, Fig.
109), as described in section "Preparatory
work".
Fig. 110 Cable and hoses btw power (engine) & cab
modules 643401
Lower the module from above.
Do not swing it into positon from
a side.
6) Insert the bolts and fasten hand-tight.
7) Tighten all bolts as specified in the Service
Manual.
Page 3.3 44 3746343en (03)
3.3 ASSEMBLY MANUAL
8) Assemble the stairways between the cab 5) Raise the platform using a crane. Make sure it
module and the engine module (1, Fig. 111). is suspended horizontally.
6) Install the platform between the cab module,
the oil cooler module and the power module.
The support brackets (1, Fig. 112) are located
on the hydraulic oil cooler module and the cab
module.
7) Insert the mounting pins, secure the lock nut
with the splints as well as the front spacers
with washers and secure bolts (Fig. 112).
Note: In case you have to install air conditioning
system (AC) do not install handrail (4, Fig. 112) to
the platform.
Installation of hydraulic and electric lines be-
Fig. 111 Stairways btw cab & engine
tween power (engine) module and superstruc-
modules 644614 ture frame
Start the installation of the hydraulic lines from the
Installation of lubrication and air conditioning lower level and continue to the upper level:
platform
1) Remove the packaging material from the plat- pilot hoses between rotor and the engine
form (Fig. 112). module (Fig. 120);
2) Clean all mating surfaces as described in the high pressure hoses between swing gearbox-
corresponding section of the Assembly Manu- es (Fig. 113);
al.
3) Install plates (3, Fig. 112).
Fig. 113 High pressure hoses btw swing gearboxes
648577
high pressure hoses between main pumps
and swing blocking valves (Fig. 114);
Fig. 112 Lubrication & AC platform 648313
4) Loosen the support brackets (2, Fig. 112) on
the power (engine) module and turn 180°.
3746343en (03) Page 3.3 45
ASSEMBLY MANUAL
high pressure hoses (2 & 4, Fig. 117) from
main single pumps (s. Table 8) through high
pressure filter and control block (32, Fig. 118)
in the power module to the travel valves (92 &
93) and return line hoses (1 & 3) on the su-
perstructure frame. Connect them from below.
Fig. 114 High pressure hoses btw main pumps & swing
blocking valves 646815c
walkway grids on top of the superstructure
frame (Fig. 115);
Fig. 117 Hydraulic lines btw travel motors & power module
648304
Fig. 115 Walkway grids 648584
hydraulic hoses between high pressure filters Fig. 118 High pressure hoses from travel motors to high
and distributor plates (Fig. 116); pressure filters 647078a
Connect hydraulic hoses between distributor
blocks and the cradle on the boom;
Fig. 119 High pressure hoses btw distributors & boom
Fig. 116 High pressure hoses btw filters & distributors cradle 648580
648578
Page 3.3 46 3746343en (03)
3.3 ASSEMBLY MANUAL
Connect electric lines between the attachment
and the rear of the cab module.
The items in Table 8 refer to Fig. 117 - Fig. 120.
Item Description
1 Return oil line from LH travel valve 93
2 High pressure line from pumps P2 & P6
3 Return oil line from RH travel valve 92
4 High pressure line from pumps P1 & P7
5&6 Pilot pressure lines from RH travel
valve 92 to travel control manifold 25/1
6&7 Pilot pressure lines from LH travel valve
93 to travel control manifold 25/1
9 & 10 Return oil lines from rotor 91
25/1 Travel control manifold
32 High pressure filter & control block
91 Rotor
92 RH travel valve
93 LH travel valve
Table 8
Fig. 120 Pilot pressure hoses from travel motors to travel control manifold 647413a
3746343en (03) Page 3.3 47
ASSEMBLY MANUAL
Installation of operator cab
1) Remove the transport and packaging material
from the operator cab.
2) Lift the transport cover (1, Fig. 121) from the
upper section of the cab module.
Fig. 123 Cab installation on cab module 648569
Fig. 121 Lifting transport cover 643410
5) Check the correct seat of the plates.
3) Clean the four mounting surfaces on top of
the cab module (dashed circles, Fig. 122) and 6) Lift the operator cab using a crane (Fig. 124).
on the operator cab. Make sure it is suspended horizontally and
that the angle between the rigging and the
roof is no less than 45°.
Fig. 122 Mounting surfaces for the rubber dampers
643431
4) Place plates (arrow, Fig. 123) and top section
of the cab mount assembly onto the mounting
surfaces (dashed circles in Fig. 122).
Fig. 124 Lower the operator cab 643436
7) Lower the operator cab onto the mounting
surfaces (2, Fig. 123).
8) Start bolts while the cab is still suspended a
few mm above the mounts.
Page 3.3 48 3746343en (03)
3.3 ASSEMBLY MANUAL
9) Fully lower the cab when bolts and mounts
align.
10) Tighten the four bolts according to the speci-
fied tightening method.
11) Affix the large rear mirror (3, Fig. 125) to the
center bar (2) of the railings.
Do not remove the protective film
from the mirror before the machine
is put into operation to prevent its
damage during further assembly
steps.
Fig. 126 Electric lines btw cab & cab module 646868a
Counterweight installation
The counterweight is delivered in two parts: a top
and a bottom section. First assemble the bottom
section (Fig. 127), then the top section (Fig. 128).
Fig. 125 Operator cab, final work 646809
12) Install electric lines between the operator cab
and the cab module. Guide 3 connectors (1,
Fig. 126), antenna cable (2), 3 bus cables (5),
and camera cable (3) (optional) downwards
and wiping line through the opening (4) and
into the cab module. Fig. 127 Counterweight bottom section 644594
3746343en (03) Page 3.3 49
ASSEMBLY MANUAL
Fig. 128 Counterweight top section 644595 Fig. 130 Lift bottom section into position 644596
6) Start bolts while the bottom section is still
Installation of counterweight bottom section suspended a few mm above the installation
position.
1) Clean the mating surfaces on the superstruc-
ture frame and the bottom section of the coun- 7) Fully lower the bottom section when bolts and
terweight as described in chapter 3.3.7 of this threaded bores align.
Assembly Manual.
8) Tighten eight bolts (Fig. 131, 1 in Fig. 132)
2) Prepare all bolts and sleeves required for which retain the bottom section of the coun-
assembly. terweight in its position on the superstructure
frame to their final torque (chapter 2.9 of the
3) Apply a thin layer of sealant to the mating
surfaces on the superstructure frame. Follow Service Manual).
the instructions on sealant of this Assembly
Manual.
If assembly does not take place immediately:
4) Seal off six tube openings on the radiator (1,
Fig. 129) using appropriate materials which
can be removed again quickly during assem-
bly of the counterweight to the superstructure
frame.
Fig. 131 Bottom bolts 648317
Fig. 129 Radiator pipe openings 643434
5) Raise the bottom section of the counterweight
(1, Fig. 130) above its installation position on
the superstructure frame (2). Make sure it is
suspended horizontally.
Page 3.3 50 3746343en (03)
3.3 ASSEMBLY MANUAL
Fig. 133 Lowering the top section 644599
8) Tighten all bolts (2, Fig. 132) joining sections
of the counterweight according to the speci-
fied tightening procedure (chapter 2.9 of the
Service Manual).
Fig. 132 Counterweight sections fixing bolts 648318 Installation of engine coolers
1) Remove the packaging material.
Installation of counterweight top section on its 2) Insert the sealing band around the counter-
bottom section weight as arrows show in Fig. 134.
1) Clean the mating surfaces on the superstruc-
ture frame and the top section of the counter-
weight as described in chapter 3.3.7 of this
Assembly Manual.
2) Prepare the bolts and sleeves for assembly.
3) Apply a thin layer of sealant to the mating
surfaces on the superstructure frame. Follow
the instructions on sealant of this Assembly
Manual.
4) Suspend the top section of the counterweight
horizontally with a crane and lift it into installa-
tion position.
5) Slowly lower the top section to around 10 mm
above the lower section (Fig. 133). Fig. 134 Sealing band for engine cooler modules
648321a
6) Hand-tighten all bolts.
7) Fully lower the top section until it is lying com- 3) Suspend the first engine cooler (radiator) with
pletely on the bottom section. a crane and move it into the installation posi-
tion (Fig. 135).
3746343en (03) Page 3.3 51
ASSEMBLY MANUAL
4) Proceed the same way with the second radia-
tor.
5) Connect all coolant hoses to the radiators
(Fig. 138).
Fig. 135 Radiator installation 644601
3) Install the mounts (Fig. 136 - Fig. 137)
Fig. 138 Coolant hoses 643440
6) Connect hydraulic lines (Fig. 139) to the en-
gine cooling fan motors (use also chapter
8.5.9 of the Service Manual).
Note: Make sure that the hydraulic lines are con-
nected correctly, otherwise the rotation direction
of the fans will be reversed.
Fig. 136 Mount installation on top 648322
Fig. 139 Hydraulic lines of engine cooling fan motors
648323
Exhaust system
1) Install the exhaust system for both engines.
Fig. 137 Mount installation on bottom 648570 Install a cover (1, Fig. 140) on the power
module platform and an exhaust pipe (2).
Page 3.3 52 3746343en (03)
3.3 ASSEMBLY MANUAL
Then install a silencer (3) on the counter-
weight.
2) Install covers (4 & 5) for the exhaust pipe and
an exhaust silencer.
Fig. 140 Exhaust systeminstallation 648324
Fig. 141 Connections of lubricant container 646791a
Lubrication system container (module) 5) Connect the lubrication pipes (1 & 2) on the
1) Attach the container (Fig. 141, Fig. 146) to a lubricant platform to the hoses (3 & 4, Fig.
crane. Ensure that it is suspended horizontally 142).
and lift it onto the platform. 6) Route the hoses from the superstructure to
2) Insert all bolts and tighten them as specified in the flange plates and pipes on the platform (1
the Service Manual. & 2, Fig. 142) and connect them.
3) Connect hydraulic lines (2 & 3, Fig. 141) and
filler hose (1) to the connection point of the
power module.
4) Install hydraulic lines to the lubrication pump
using information of chapter 8 of the Service
Manual.
The items in Table 8 refer to Fig. 141.
Item Function
1 Connection to the fast fill station
2 Return oil hose
3 Auxiliary pressure hose
Table 8
Fig. 142 Lubrication lines on l ubricant container 648585
7) Connect the lubrication lines (5 & 6, Fig. 142)
to the connection ports on the platform.
8) Connect boom lubrication lines (arrows, Fig.
143) to the corresponding ports in the super-
structure frame (arrows, Fig. 144).
3746343en (03) Page 3.3 53
ASSEMBLY MANUAL
Installation of lubrication lines for upper car-
riage
Connect the main lubrication hoses (3 & 4, Fig.
142) to the lubrication pipes (A & B, Fig. 145) on
the lubricant container.
Note: If the second lubrication pump is available,
it has a backup function and is not applicable for
the undercarriage lubrication. Therefore, do not
connect it to lubrication lines.
Fig. 143 Lubrication lines on boom bottom 648356
Fig. 144 Lubrication lines from from boom to superstructure
frame 648355a Fig. 145 Lubricant container 646791b
Page 3.3 54 3746343en (03)
3.3 ASSEMBLY MANUAL
Fig. 146 Lubrication system module 644617a
3746343en (03) Page 3.3 55
ASSEMBLY MANUAL
Air conditioning (AC) system
Depending on optional equipment chosen, the
machine can be equipped with one or two air con-
ditioning systems. In the case of two air condition-
ing systems, there are two evaporator units in the
cab and there are two condenser units (1, Fig.
147) next to the lubricant container.
1) Attach the condenser unit to a crane using the
four transport lugs. Ensure that it is suspend-
ed horizontally.
2) Install the condenser unit (1, Fig. 147) on the
platform next to the lubricant container (3).
Fig. 148 lines 1 646798
4) Connect heating hoses (2, Fig. 148) of the air
conditioning system to the connection points
(1 and 2, Fig. 149) on the operator cab.
Fig. 147 Air conditioning system 645480
3) Connect heating hoses (1 & 2, Fig. 148) com-
ing from the power module to the connection
points (1 & 2, Fig. 149) on operator cab as
well as AC hoses coming from the condenser
unit.
Fig. 149 Air conditioning system connections on the operator
cab 646870
5) Connect cooling hoses between the conden-
ser unit lines (2 and 4, Fig. 147) to the corre-
sponding connections on the operator cab.
Page 3.3 56 3746343en (03)
3.3 ASSEMBLY MANUAL
On-board crane (optional) 2) Insert the bolts and tighten them using the
specified tightening procedure.
1) Loosen the bolts and remove the dummy cov-
er (1, Fig. 150).
Fig. 152 Crane power unit installation 648327
3) Connect all hydraulic lines from the power unit
Fig. 150 Dummy cover 643445 to the on-board crane (Fig. 153).
2) Install mounting assembly (1, Fig. 151) to the
plates at the dummy cover.
3) Install shackles with the corresponding mount-
ing (2) to the mountings (1).
4) Install lock bracket assembly (3) to the plat-
form.
5) Raise the on-board crane (4, Fig. 151) using
an assembly crane and move it into the instal-
lation position.
Fig. 153 Hydraulic lines btw on-board crane & its power
unit 648328
4) Read sections
concerning on-board crane
and its power unit in Operation and Mainte-
nance Manual. If necessary read supplier
documentation as well.
5) Start the on-board crane.
6) Lower the boom (5, Fig. 151) of the crane into
Fig. 151 On-board crane installation 648310 the lock bracket (3) to secure it.
6) Align the on-board crane.
Fire extinguisher
7) Insert the bolts and tighten according to the
Install the fire extinguisher on the left next to the
specified tightening procedure.
operator cab doors (1, Fig. 154).
Crane power unit
1) Lower the crane power unit (Fig. 152) into the
required position on the counterweight.
3746343en (03) Page 3.3 57
ASSEMBLY MANUAL
Fig. 154 Fire extinguisher 643430
Grease collectors
Fig. 156 Hydraulic lines for access ladder cylinder
Install two collectors (1, Fig. 155) to catch the 643476a
used grease coming from boom pin inside the
superstructure frame. 2) Mount the lubricant distributor block (arrow,
Fig. 157) onto the rear of the access ladder.
Fig. 157 Lubrication lines of hydraulic access ladder
648308
Fig. 155 Grease collector 644613
3) Install lubrication lines to the corresponding
connection points and tighten the nuts accord-
Installation of lubrication and hydraulic oil ing to the specification.
lines for hydraulic access ladder
4) Mount the operation valve (arrow, Fig. 158)
1) Connect hydraulic lines to the hydraulic ac- for the hydraulic access ladder onto the left
cess ladder cylinder (Fig. 156). handrail of the engine module.
Page 3.3 58 3746343en (03)
3.3 ASSEMBLY MANUAL
Fig. 161). Connect electric lines of the ladder
using information of chapter 9.4 of the Service
Manual.
Fig. 158 Operation valve for hydraulic access ladder
648306a
5) Connect hydraulic control lines (Fig. 159) to
the valve. Fig. 160 Proximity switch for hydraulic access ladder
647705a
Fig. 161 Service arm switch 647704a
Fig. 159 Hydraulic lines of access ladder valve 648307
6) Install proximity switch (-2B2, Fig. 160) for
access ladder and service arm switch (-2S32,
3746343en (03) Page 3.3 59
ASSEMBLY MANUAL
3.3.18 Stick installation
When taking out the pin ensure that
its surface is not damaged.
1) Ensure that the stick is level.
2) Remove the pin cover (1, Fig. 162) from the
stick. 7) Install cylinder protection plates (2, Fig. 162)
on the brackets provided.
8) Fill the stick head cavity (3, Fig. 162) with
lubricant as described in section Preparing
bushings and pins for boom installation. Seal
the cavity.
9) Grease the pin and all bearings.
10) Attach rigging material to the lifting lugs (4,
Fig. 162).
Note: It is important, that the stick is suspended
horizontally when lifted. This may be difficult to
achieve as the stick will be unbalanced due to the
pin protruding on one side. To compensate for this
use chain shorteners or shackles of different siz-
Fig. 162 Components of the stick 644624a
es.
11) Lift the stick with a crane (Fig. 164).
3) Determine from which side the pin (1, Fig.
163) will be pushed. On this side of the pin, fit
an eyebolt (2) to the pin face.
Fig. 163 Securing the pin 643458a
4) On the same side of the stick, fit an eyebolt (3,
Fig. 163) to one of the threaded bores for the
pin cover. Fig. 164 Lifting the stick 644605
5) Prepare pin and bearing bushings as de-
scribed in section 12) Maneuver the stick into its installation position
of this Assembly Manual. from above or from the front.
6) Pull out the pin to the side with the two eye- Ensure that the stick does not
bolts (2 & 3, Fig. 163) until it rests only in one swing and hit the bearing bushings.
bushing. Secure the pin with a steel rope (4)
between the eyebolts (2 & 3) so that it cannot
slide out further. 13) Line up the bearing bushings of stick and
boom and push in the pin (1, Fig. 163).
Page 3.3 60 3746343en (03)
3.3 ASSEMBLY MANUAL
14) Lower the stick until it is suspended perpen-
dicularly by its own weight.
15) Release the crane.
16) Remove the eyebolts (2 & 3, Fig. 163).
17) Install the pin covers (arrow, Fig. 165) and the
tubes.
Fig. 165 Pin cover installation 648581
18) Tighten the bolts in accordance with the speci-
fied tightening method (chapters 2.9 and 17 of
the Service Manual). Fig. 166 Installation of stick cylinders to stick 648346
5) Ensure that the orientation of the fork is cor-
Installation of stick cylinders on stick rect. The fork lubrication holes (1, Fig. 167)
Note: Ensure that the stick is suspended vertically must point to the ground, not to the stick. Turn
on the boom. the fork if necessary.
1) Remove pin covers from the fork of one of the
stick cylinders.
2) Loosen the blanking plates from the cylinder
ports. Extend the cylinder by securing a chain
hoist with one end on the fork (1, Fig. 166),
the other on the boom chord lifting lugs (2).
3) Just before lining up fork and stick bushings
prepare the fork pin and bushings as de-
scribed in section
of the Assembly Manual.
4) Align the cylinder fork bushes (3, Fig. 166)
with the stick bearing bushes (4).
Fig. 167 Fork orientation 647225
6) Push in the pin and install the pin covers.
7) Tighten the bolts in accordance with the speci-
fied tightening method (see Service Manual).
8) Remove the chain hoist.
9) Repeat these steps to install the second stick
cylinder.
3746343en (03) Page 3.3 61
ASSEMBLY MANUAL
Installation of bucket cylinders on boom Tri
Power Do not lift the cylinder unless the pin
is pushed in and the pin covers are
Note: According to machine design there are left- firmly bolted. Otherwise the pin can
hand and right-hand cylinders. Ensure that you slide out during the lift and cause
differentiate them correctly. personal injury or damage to proper-
Install two bucket cylinders in turns: ty.
1) Remove the packaging material from the cyl-
inders. 5) Lift the bucket cylinder (2) into position using a
crane.
2) Identify LH and RH cylinders. The flanges (1,
Fig. 168) on the cylinder forks should face 6) Just before aligning cylinder fork and rocker
each other. bearing, remove the pin covers again and
slide the pin to one side.
7) Insert the pin (1).
Fig. 169 Assembling the bucket crowd cylinder 644625
Fig. 168 Cylinder identification 648344 8) Install the pin covers and tighten all bolts in
accordance with the specified tightening
Note: hydraulic hoses are shown in Fig. 168 only method (chapters 2.9 and 17 of the Service
to make identification clearer. They are not in- Manual).
stalled yet.
9) Install the lubrication tubes on the rod end of
3) Ensure that the fork orientation is correct. The the cylinder.
lubrication holes (5, Fig. 169) must be at the
10) Remove the safety ropes (4) between the
back (in the direction of travel).
cylinder rod and cylinder liner.
4) Remove the pin cover. Clean and grease the
11) Support the cylinder on a block approx.1 m
pin (1) and the bearing bush (s. p. 10 for de-
above the ground level. Slowly lower the
tails). Temporarily remove pin and pin covers
crane. During this, the cylinder rod will extend.
for lifting the cylinder into position.
12) Release the crane.
13) Repeat these steps to install the second
bucket cylinder.
Page 3.3 62 3746343en (03)
3.3 ASSEMBLY MANUAL
14) Install hydraulic lines for the bucket cylinders
and the lubricant distributor (1 3, Fig. 170)
on the inner side of the stick.
Make sure that the hoses are sealed off to prevent
contamination.
Fig. 170 Hydraulic & lubrication lines on stick inside Fig. 171 Hydraulic hoses btw stick & bucket cylinders
648347 648348
15) Install hose bracket (1, Fig. 171) and connect
hydraulic hoses (2 & 3) on the stick to the
boom and hydraulic hoses (4 & 5) between
the hose bracket (1) and the bucket cylinder.
3746343en (03) Page 3.3 63
ASSEMBLY MANUAL
3.3.19 Connection of hydraulic lines
on superstructure, boom and
stick
Assemble all hydraulic and lubricating connec-
tions on the boom and the boom cylinders. Use
the relevant sections in chapter 8 of the Service
Manual.
Note: Some hydraulic components and lines may
have already been installed. In this case proceed
with the next assembly steps depending on the
delivery state of your machine.
To prevent contamination and dam-
age of the machine hydraulic sys-
tem, blow all unsealed hydraulic
hoses with compressed air directly
before assembly.
Remove transport sealings from
hoses and hydraulic components
directly before assembly.
Always wear safety goggles when
using compressed air.
Hydraulic and lubrication lines on the
boom
1) Connect hydraulic hoses on the boom top
between boom cradle and high-pressure filters
of the superstructure (arrows in Fig. 172). If
necessary, remove the grid (arrows in Fig.
173) from its support bracket. Then re-install
the grid.
Fig. 172 Hydraulic hose connection btw boom cradle &
superstructure 648349
Page 3.3 64 3746343en (03)
3.3 ASSEMBLY MANUAL
Fig. 175 Installation of hydraulic hoses to stick cylinders
648353a
4) Install walkways (2, Fig. 176) with handrails
(1) to the boom.
Fig. 173 Grid 648351
2) Install hydraulic hoses between the boom and
the boom cylinders (arrows in Fig. 174).
Fig. 176 Boom walkways 643418
5) Install hydraulic hoses of the clam valve block
on the boom (Fig. 177).
Fig. 174 Installation of hydraulic hoses to boom cylinders
648352
3) Install hydraulic hoses between the boom and
the stick cylinders (arrows in Fig. 175).
Fig. 177 Hydraulic hoses of clam valve block 648354
3746343en (03) Page 3.3 65
ASSEMBLY MANUAL
Installation of hydraulic oil cooling lines 3) Connect hydraulic hoses (3, 4, 7 & 8, Fig.
178) to fan control manifolds in the hydraulic
For information about function and operation of oil cooling module.
the hydraulic oil cooling system read chapter 8.5
of the Service Manual. 4) Connect hydraulic hoses (9 & 10, Fig. 178)
from the hydraulic oil tank to the fan control
To install all hydraulic lines for the hydraulic oil manifolds.
cooling system, take the following steps:
5) Connect leak oil line (11, Fig. 178) from the
1) Install two pipes (5 & 6, Fig. 178) under lubri- hydraulic oil tank to the hydraulic oil cooling
cation and AC platform. module.
2) Connect hydraulic hoses (1 & 2, Fig. 178)
from LH hydraulic oil cooling pumps to the
pipes.
Fig. 178 Hydraulic oil cooling system connections 646977b
Page 3.3 66 3746343en (03)
3.3 ASSEMBLY MANUAL
module to the junction point (7, Fig. 179) in
Installation of gear oil cooling lines the power module.
1) Connect gear oil hoses (1 & 2, Fig. 179) be- 3) Connect RH gear oil hoses (8 & 9, Fig. 179) of
tween the power module and the lubricantion gear oil coolers in the hydraulic oil cooling
and AC platform to pipes (3 & 4, Fig. 179) un- module to junction point (7, Fig. 179) in the
der the lubrication and AC platform. power module.
2) Connect LH gear oil hoses (5 & 6, Fig. 179) of
gear oil coolers in the hydraulic oil cooling
Fig. 179 Gear oil cooling system connections 648366
3746343en (03) Page 3.3 67
ASSEMBLY MANUAL
Installation of engine fan motor cooling 6) Connect LH and RH pipes for pressure (P,
lines Fig. 181), tank (T) and leak (L) oil lines to the
corresponding hoses of the fan motors (ar-
1) Connect the hydraulic oil hose (1, Fig. 180) of rows, Fig. 181) in the counterweight.
LH engine cooling fan pump to high pressure
oil pipe (P). 7) Connect coolant hoses (Fig. 181) from the
coolant expansion reservoirs on the top of the
2) Connect hydraulic oil hose (2, Fig. 180) on superstructure to the corresponding engine
hydraulic oil tank to tank line pipe (T). coolers in the counterweight.
3) Connect the hydraulic oil hose (3, Fig. 180) of
RH engine cooling fan pump to high pressure
oil pipe (P).
4) Connect hydraulic oil hose (4, Fig. 180) on
hydraulic oil tank to tank line pipe (T).
5) Connect hydraulic oil hose (5, Fig. 180) on
hydraulic oil tank to leak oil line (L).
Fig. 180 Engine cooling system connections 648358
Page 3.3 68 3746343en (03)
3.3 ASSEMBLY MANUAL
Fig. 181 Engine cooling system lines from pumps to fan motors 648359
3.3.20 Top up operating fluids 3.3.21 Connection of electric system
Top up all and check the level of all machine op- and Operator Assist system
erating fluids using
of Operation and Maintenance Manual. Install, calibrate and commission Operator Assist
Always use only the fluids approved and recom- system in accordance with Special Instruction
mended by Caterpillar Global Mining HMS GmbH M0070460 and technical documentation with me-
(e.g., SEBU 6250). For this purpose, refer to cur- dia ID. M0071502 available in SIS Web.
rent publications in SIS Web. Connectors and sockets that are to be connected
Top up and check the level of the hydraulic accu- to each other are marked with the same number.
ell as cur-
rent technical publications in SIS Web. information about the electric system.
Main lights and maintenance lights
Main (work) lights are located outside the machine
and maintenance (service) lights are located
mostly inside its modules.
1) Connect main lights (Fig. 182 - Fig. 183) to
the pre-installed cables outside the super-
structure.
Note: Four additional main lights (optional) can be
fitted on the boom (Fig. 184).
2) Install and connect the maintenance lights
(Fig. 185) inside the modules.
3746343en (03) Page 3.3 69
ASSEMBLY MANUAL
The items in Table 9 refer to Fig. 182 - Fig. 185.
Item Designation
-1H3, Main light lamps on operator cab
-1H4
-1H5, Main light lamps on oil cooling module
-1H6
-1H7, Main light lamps on machine rear side
-1H8
-1H9, Main light lamps on machine platform
-1H10
-1H11 Main light lamps on boom
to -
1H14 Fig. 182 Main light lamps on machine front side 647807
-5H7, Maintenance light lamps in operator cab
-5H8
-5H9 Access ladder light lamp
-5H10 Maintenance light lamp for cab module
-5H11, Maintenance light lamps for LH pump
-5H26 module
-5H12, Maintenance light lamps for LH engine
-5H13 module
-5H14, Maintenance light lamps for RH engine
-5H15 module
-5H16 Maintenance light lamp for engine control
cabinet -X10 on hydraulic oil tank
-5H17, Maintenance light lamps for hydraulic oil
-5H18 cooler module
-5H19 Maintenance light lamp for superstructure
top surface
-5H27, Maintenance light lamps for RH pump
-5H28 module Fig. 183 Main light lamps on machine rear side 647806
Table 9
Page 3.3 70 3746343en (03)
3.3 ASSEMBLY MANUAL
Fig. 184 Main light lamps on boom (optional) 647805
Fig. 185 Maintenance light lamps on superstructure 647809
3746343en (03) Page 3.3 71
ASSEMBLY MANUAL
Between operator cab and cab module CAN bus
Plug connectors (1 and 3, Fig. 186) into the corre- CAN bus connectors are color coded. Fig. 187
sponding sockets on the bottom of the operator shows how to connect them. Use electric sche-
cab. Plug in the connector (2) if available. matics and chapter 9 of this Service Manual for
more information.
Table 10 refers to Fig. 186.
1) Use the cable with green markings to connect
Item Description Connection CAN bus II from pedals and joysticks to the
main electric cabinet -X1.
1 X180 Air conditioning sys-
2) Connect three CAN bus cables from the oper-
tem
ator cab as follows:
2 X181 2nd air conditioning
CAN bus I cable (yellow) to the main elec-
system (optional)
tric cabinet -X1 (9, Fig. 195).
3 X102 Operator cab plat-
two on-board diagnostics cables (blue and
form
red) to drive controller cabinets -X30 (red)
4 Forward travel and -X40 (blue) in the power module.
direction
3) Connect one CAN bus I cable (yellow) to the
Table 10 main electric cabinet X1 and to the socket on
the bottom of drive controller cabinet -X30.
4) Connect one CAN bus I cable (yellow) be-
tween drive controller cabinet X30 and drive
controller cabinet X40.
Table 11 refers to Fig. 187.
Item Description
1 Pedals and joysticks
2 Board Control System (BCS) monitor
3 Resistors on -X61 terminal
4 Main electric cabinet X1
Fig. 186 Electric connections btw cab module and operator 5 Cab module
cab 646859
6 RH drive controller
7 RH engine
8 LH drive controller
9 LH Engine
BL RH engine bus, blue
GN CAN bus II, green
RD LH engine bus, red
YE CAN bus I, yellow
Table 11
Page 3.3 72 3746343en (03)
3.3 ASSEMBLY MANUAL
Fig. 187 CAN BUS connection 647242
Horn and mirror Lubrication system terminal box
1) Attach the wiring harness X111 for the horn 1) Connect connector X109.1 (1, Fig. 189 resp.
(3, Fig. 188) and the mirror heating (4) to the 5, Fig. 190) to the terminal box (2, Fig. 189)
M8 threaded studs (2) and plug the connector for the lubrication system.
into the socket (1) under the walkway.
In countries with a warm climate the mirror 2) Connect connector X108 (3, Fig. 190) of the
heating can be blanked off. wiring harness for the proximity switch of the
stick lubrication system and other equipment
2) Connect the two ends of the wiring harness to to the respective socket on the right-hand side
the signal horn (3, Fig. 188) and to the mirror of the superstructure frame.
(4).
3) Connect connector X121 (4, Fig. 190) to the
3) Also connect the horn at the right-hand side of power supply for the proportional valves of the
the oil cooler module. attachment.
4) Connect connectors (6 and 7, Fig. 190) to the
corresponding positions (2 and 8, Fig. 195) on
the main electric cabinet -X1 in the cab mod-
ule.
Fig. 188 Horn and mirror connection 646810
Fig. 189 Lubrication terminal box 646811
3746343en (03) Page 3.3 73
3.3 ASSEMBLY MANUAL
Fig. 190 Lubrication system cables 646798 Fig. 192 Condenser connections 646860
Air conditioning system (optional) Hydraulic oil cooler module
1) Guide a cable (1, Fig. 186) from the cab mod- The wiring harness for the hydraulic oil cooler
ule up into the operator cab. Connect it (1, Fig. module is installed on the superstructure and
191) to the terminal box (3). The cable is used coiled up for shipment.
to supply power to the air conditioning.
1) Plug connector X107 (1, Fig. 193) into the
If a dual air conditioning (optional) is installed, socket (2). Attach the harness to the module
there is an additional cable (2, Fig. 186). In with the P-clamps provided (as seen on Fig.
this case connect it as well. 193).
Fig. 193 Hydraulic oil cooler module connection 646869
Fig. 191 Air conditioning system terminal box 646812a
2) Plug connector X185 (1, Fig. 192) of the 2) Guide the other end of the wiring harness into
cable (2, Fig. 191) into the socket (2, Fig. 192) the cab module and plug the connector into
on the condenser. socket X105 (7, Fig. 195).
Page 3.3 74 3746343en (03)
3.3 ASSEMBLY MANUAL
Hydraulic access ladder Item Designa- Connection
1) Install a wiring harness (1, Fig. 194) behind tion
the walkway (2). 1 -X101 Operator cab platform
2 -X122 Plugs between cab module &
boom and for attachment
valves
3 -X160 BCS in operator cab
4 -X161 BCS in operator cab
5 -
6 -X130 LH pump gearbox
7 -X140 RH pump gearbox
8 -X105 Swing motors / gearboxes
9 -X73 Hydraulic oil cooler
10 -X109 Lubrication terminal box
11 BUS Operator cab
12 -X110 Engine switch box
13 Cable gland for X1 wiring
harness
Fig. 194 Hydraulic stairway electrical connection 646991
14 -X100 LH & RH drive controllers
Table 12
2) Guide the wiring harness to the rear of walk-
way and stairway to the attachment point (3,
Fig. 194).
3) Install the switch box (4, Fig. 194) and sensor
in the proper position when the engine is run-
ning and the ladder can be hydraulically con-
trolled and stopped in the top position.
4) Plug the connector (5) into the socket on the
outer left wall of the cab module.
Main electric cabinet -X1
1) Remove protective film from the wiring har-
ness connectors and plug them into the corre-
sponding sockets at the left-hand side of the
main electric cabinet X1.
2) Guide the X1 wiring harness through the
cable gland (12, Fig. 195) at the side of the
main electric cabinet X1. Connect the indi-
vidual lines to the corresponding terminals ac-
cording to the terminal diagram and electric
Fig. 195 Main electric cabinet connections 646858
schematics.
3) Connect the connectors as seen in Table 12
and Fig. 195. Swing gearbox sensors
Table 12 refers to Fig. 195. 1) Connect all level swing gearbox sensors (1)
using Table 13 and Fig. 196. LH rear swing
motor has a temperature sensor (3) attached
3746343en (03) Page 3.3 75
3.3 ASSEMBLY MANUAL
to it. RH rear swing motor has two pressure Coolant expansion tanks
sensors (2).
Connect connectors (1, Fig. 197) to LH and RH
2) Connect all contamination switches (4, Fig. coolant level sensors (2) on two expansion tanks.
196).
The items in Table 13 refer to Fig. 196.
Item Description Function
1 -2B15, -2B16, - Level sensors
2B28, -2B29
2 -2B17, -2B18 Pressure sensors
3 -2B19 Temperature sen-
sor
4 -5B9 to -5B12 Contamination
switches
Table 13
Fig. 197 Coolant level sensor connection 646871
Connecting to ground
All modules in the machine must be connected to
each other by ground cables. Install the ground
cables as follows:
1) Between the superstructure frame, power
module and counterweight:
(2, Fig. 198) on the superstructure frame
(1) on the counterweight
Fig. 198 Ground connection 1 646861
2) Between the superstructure frame, power
module, and oil cooler module:
(2, Fig. 199) on the superstructure frame
Fig. 196 Swing gearbox sensors 647718a (1, Fig. 199) to (2, Fig. 200) on the cab
module
Proceed in the same way to connect the hy-
draulic oil cooler module to the ground.
Page 3.3 76 3746343en (03)
3.3 ASSEMBLY MANUAL
3.3.22 Preparations for machine start-
up
1) Check the whole electric system. Ensure that
it is installed in accordance with the electric
schematic and terminal diagrams.
Ensure that the battery isolator
switch is switched off. Use lock-
out-tagout procedure.
Fig. 199 Ground connection 2 646862
Fig. 202 Isolator main switch box 645474
2) In the power module remove the cover of the
Fig. 200 Hydr. access ladder, power module - cab
module interface 2 646979
batteries. They are located under the electric
cabinet behind the hydraulic tank.
3) Between the cab module and operator cab 3) Use the supplied leads (3, Fig. 203) to con-
threaded bolts (1 and 2, Fig. 201) at the upper nect the batteries (1 and 2) in series.
left-hand side in the cab module.
Fig. 201 Ground connection 3 646863
Fig. 203 Connecting the batteries 646865
3746343en (03) Page 3.3 77
3.3 ASSEMBLY MANUAL
4) Connect the rest of the six batteries in sets Note: You may need to top up hydraulic oil
similarly, i.e. three and four, five and six in se- several times while bleeding the hydraulic sys-
ries. tem and cylinders.
5) Connect the three sets of batteries in parallel. By starting the machine, the hydraulic cylinder is
filled with oil and the air forced out of the system.
6) Ensure that all hydraulic hoses have been
connected in accordance with hydraulic Ensure that all hydraulic and
schematic and the relevant sections of this electric lines are installed cor-
assembly manual.
rectly. Otherwise you´ll damage
7) Carry out the procedures according to Opera- people and machine.
tion and Maintenance Manual, Part 3 Inspec-
tion and servicing, Plan V. Check the oil level
and the condition of other operating equip- 1) Remove the cover plate (2, Fig. 204) under
ment or resources. the crawler center support to gain access to
the track tensioning housing.
Open the gate valves in the suction
lines of the hydraulic pumps before
starting the machine for the first
time. Otherwise you will damage the
hydraulic system.
8) Ensure that all pumps have been bled (chap-
ter 8.2 of the Service Manual).
9) Turn the battery isolator and starter isolator
switches on.
10) Switch the reset switch (a green button) on
the -X1 main cabinet in the cab module on.
11) Switch on ignition and allow the BCS to boot.
Use the BCS to detect any faults in the wiring Fig. 204 Cover 644578b
installation and take corrective action.
2) Open the shut-off valve (1, Fig. 205) of the
Note: Most wiring problems during assembly track tensioning system (lever parallel to the
are caused by bent pins or wrong connected line).
harnesses.
3) Secure the shut-off valve in this position using
Ensure that the BCS shows no active fault a cable tie or similar.
messages before starting the engines for the
first time.
12) Run each engine for 3 5 minutes during the
first start-up, then shut down and check all flu-
id levels. Top up where necessary.
13) The bucket cylinders are still on wooden
blocks. Use the retraction function of the
bucket cylinders to bleed them.
14) Use the extension function of the bucket cyl-
inders to bleed them.
Do not extend the cylinders too far,
as the foot pin is not yet secured
and hoses can be damaged.
Fig. 205 Shut off valve 643389
15) Bleed air from the hydraulic system and all
cylinders as described in chapter 8.2 of the 4) Close the housing by replacing the cover plate
Service Manual. This ensures the soft opera- (2, Fig. 205).
tion of the cylinders.
Page 3.3 78 3746343en (03)
3.3 ASSEMBLY MANUAL
5) Repeat the same procedure for the other 3.3.24 Bucket installation
track.
Always lubricate the bearing points Bucket assembly
before the first commissioning. Before bucket assembly
Otherwise pin assemblies and bear-
ing bushes can run dry and may be Ensure that the working a rea i s
seriously damaged. clean and level;
Ensure that cylinder assemblies Ensure that the clam is resting
can extend and retract safely when in a horizontally level posi ti on.
you start up the shovel. Support it with beams of hard-
wood to keep it from rocking.
1) Clean the bushings (4 to 6, Fig. 206), of
3.3.23 Machine start-up backwall (2) and clam (1). Clean and prepare
the corresponding pins.
Before starting the machine for the
first time, ensure that the gate
valves in suction line of the hydrau-
lic pumps are opened.
1) Start the machine with only one engine run-
ning and allow the engine to idle.
2) Slowly move the cylinders in and out as de-
scribed in section
of the Operation and Maintenance Manual.
This will fill the cylinders with hydraulic oil, the
system will be ventilated and control will be-
come softer.
3) Where necessary, switch the machine off and
refill the tank. Then proceed as described be-
low.
Note: A great quantity of oil is consumed when
filling the cylinders. Therefore, always check the Fig. 206 Backwall installation 646699
oil level in the hydraulic oil tank.
4) Ensure that the machine stands on the level 2) Lubricate the bushings (4 to 6, Fig. 206).
ground, lower the boom completely and 3) Attach a suitable 4-legged chain to the lifting
switch off the engine. lugs (1 to 4, Fig. 207) on the backwall and
raise it slowly.
Fig. 207 Bucket 646696
3746343en (03) Page 3.3 79
3.3 ASSEMBLY MANUAL
4) Position the backwall (2, Fig. 206) above the
stationary clam (1).
To join backwall and clam:
5) Lower the backwall onto the clam until the
hinge bores (4 and 6, Fig. 206) line up.
6) Insert the pins on both sides.
7) Slowly lower the backwall until it rests on the
clam.
Stay clear of the bucket assembly
as it may rock when the center of
gravity shifts.
Fig. 209 Bucket preparation 643462
8) Remove the lifting gear.
13) Clean the bearings and pin according to
9) Place the bucket in front of the machine using 10
a crane. Ensure that it is as level as the ma- and spray them with assembly spray.
chine.
14) The stick, boom, and travel functions of the
Note: If the machine is not level, the bucket machine can now be used to move the stick
must have the same slope as the machine. into position.
Machine and bucket must be parallel.
15) Remove the sealing material from the stick
10) Remove packaging material and corrosion head cavity.
inhibitors as described in 3.3.7 Preparation of
modules for assembly. 16) Align the bearing bushings of the bucket and
stick.
11) Remove rubber flaps (3, Fig. 208).
17) Push the pin into the bearing points.
18) Install the pin covers and tighten the bolts in
accordance with the specified tightening
method (see chapter 2.9 of the Service Manu-
al).
Installation of the bucket cylinders on the
bucket
1) Remove one pin cover from each bottom fork
of the bucket cylinders.
2) Pull the pins out so that they are held by only
one bearing bushing and clean them (see
p 10).
Fig. 208 Residual stroke 1 - 644620 3) Spray the bearing points and pins with as-
sembly spray.
12) Remove the pin cover (1, Fig. 209) and pull
out the pin (2) so that it is only held by one 4) Extend the bucket cylinders (1, Fig. 210) and
bearing bushing (see p. 10 for details). To move the stick (2) to align the forks at the
bearing points (3) of the bucket rear panel.
prevent the pin from falling out secure it with
additional support slings (4). If necessary, use the travel forward function
and the stick float function simultaneously to
move the stick in and to have the bucket cyl-
inders suspended right above the bucket bear-
ing points (3, Fig. 210).
Page 3.3 80 3746343en (03)
3.3 ASSEMBLY MANUAL
Fig. 210 Bucket assembly 643474 Fig. 212 Clam cylinder 646701
5) Insert the pins and screw on the pin covers in 10) Activate clam cylinder extension slowly until
accordance with the specified tightening the fork (3, Fig. 212) and clam bearing points
method (see chapter 2.9 of the Service Manu- line up. One of the clam cylinders will extend
al). before the other. Start with this cylinder.
6) Connect hydraulic hoses and install missing In case the second clam cylinder begins to ex-
lubrication tubes between stick and bucket. tend, ensure that it cannot damage ports or
7) Connect LH & RH clam cylinders. components: secure the fork of the second
clam cylinder to the cylinder with a steel cable.
8) Connect the clam supply hoses (3, Fig. 211)
between stick bottom chord and attachment 11) Insert the pin (5, Fig. 212) and install the pin
control manifold (see hydraulic schematics). retainer plate (4).
12) Attach lifting gear (1, Fig. 212) to the second
cylinder (2) and raise it with the crane. Re-
move the hardwood beam previously support-
ing the cylinder.
13) Remove the steel cable from the second cyl-
inder. Repeat the procedure described in step
14 to align clam cylinder fork (3, Fig. 212) and
clam bearing point.
14) Insert the pin (5, Fig. 212) and install the pin
retainer plate (4).
15) Connect lubrication lines to the clam cylinder
forks (6, Fig. 212).
Fig. 211 Connection between back wall and bucket cylinder
16) Connect main lubrication lines (6, Fig. 213)
646700 from the stick bottom chord to the bucket back
wall.
9) Attach a sling (1, Fig. 212) to one clam cylin-
der (2) and raise it slowly with a crane. Re-
move the hardwood beam previously used to
support the cylinder.
3746343en (03) Page 3.3 81
3.3 ASSEMBLY MANUAL
support bars, these strips need to be welded
into place to complete the buckets hardfacing.
Refer to the welding instructions supplied in
chapter 20 of the Service Manual.
Fig. 213 Clamshell cylinder 646701
17) Install the cover plates (7 and 8, Fig. 215)
18) Install the rubber flaps (5 and 6, Fig. 215). Fig. 216 Clam support 646697
22) Check contact surfaces of the clam and back
wall. This procedure is described in our Ser-
vice Information SI 2014- r-
mine residual stroke on clamshell cylin
Ensure that the bucket parts close
completely, otherwise you will dam-
age the clam cylinders.
3.3.25 Residual stroke
It is important that the clam cylinders (1, Fig. 217)
Fig. 214 Bucket 646696
are not fully extended when the bucket is com-
19) Install the cover plates (7 & 8, Fig. 215) pletely closed. Otherwise the piston head can hit
the piston ring with major force inside the cylinder
and cause damage.
The difference between the maximum possible
stroke and the actual stroke is called residual
stroke.
Always check the residual stroke
before operating the bucket for the
first time.
Repeat such checks regularly dur-
ing the machine life and take correc-
tive action if necessary.
Fig. 215 Bucket 646696 To measure the clam cylinder residual stroke
1) Close the bucket as seen in Fig. 217.
20) Install the rubber flaps (5 & 6, Fig. 215).
2) Ensure that the clam (2, Fig. 217) touches the
21) Remove the welded support beams (1 & 2,
back wall (3) along the full width of the bucket.
Fig. 216) from the clam using a cutting torch
and grind smooth. If hardfacing strips were
removed in the factory to accommodate the
Page 3.3 82 3746343en (03)
3.3 ASSEMBLY MANUAL
3.3.26 Final preparations for machine
start-up
Carry out the following steps after bucket installa-
tion, when the machine is completely assembled:
1) Check oil, lubricant, and coolant levels.
If the bearing points are not suffi-
ciently lubricated before the first
commissioning, the pin assemblies
and bearing bushings can run dry
and be seriously damaged.
Fig. 217 Residual stroke 647243 2) Check the lubricant fill level of the swing bear-
ing: turn the superstructure 360° and check
3) Remove the rubber flaps (3, Fig. 218). whether the lubricant has spread across the
4) Measure the distance (4, Fig. 217) using a entire height of the swing bearing. If neces-
tape measure. sary, top up the lubricant through the opening
in the swing bearing cover (see the "Inspec-
5) Compare the measured distance (4, Fig. 217) tion and Maintenance" chapter in the Opera-
(residual stroke) with the specifications in our tion and Maintenance Manual).
Service Information EM027833 available in
SIS Web. 3) The machine is now ready for start-up, com-
missioning, and functional testing.
4) Carry out final checks according to commis-
sioning report media no. BI644866 and per-
formance checks according to media no.
EM028478 available in SIS.
5) Clean up assembly site.
Fig. 218 Residual stroke 1 - 644620
If the residual stroke exceeds the distance speci-
fied in EM027833, apply material to the edge of
the bucket (2, Fig. 218). In this case, please con-
tact the service department of Caterpillar Global
Mining HMS for additional information or see DSN
and/or our Service Manual, chapter
3746343en (03) Page 3.3 83
3.3 ASSEMBLY MANUAL
Page 3.3 84 3746343en (03)
03.2019
4. Undercarriage
CONTENTS
4. UNDERCARRIAGE
4.1 Introduction ...................................................................................... 4.1 - 1
4.1.1 Foreword ........................................................................... 4.1 - 1
4.1.2 Safety ................................................................................ 4.1 - 1
4.1.3 General .............................................................................. 4.1 - 5
4.2 Travel system ................................................................................... 4.2 - 1
4.2.1 General .............................................................................. 4.2 - 1
4.2.2 Components of travel system ............................................ 4.2 - 1
4.2.3 Wear limits ......................................................................... 4.2 - 4
4.3 Track chain ....................................................................................... 4.3 - 1
4.3.1 General .............................................................................. 4.3 - 1
4.3.2 Components of Track chain ............................................... 4.3 - 1
4.3.3 Assembly ........................................................................... 4.3 - 2
4.3.3.1 Opening the track chain .................................... 4.3 - 2
4.3.3.2 Closing the track chain ..................................... 4.3 - 3
4.4 Idler .................................................................................................... 4.4 - 1
4.4.1 General .............................................................................. 4.4 - 1
4.4.2 Components of the idler..................................................... 4.4 - 1
4.4.3 Assembly of the idler ......................................................... 4.4 - 3
4.5 Bottom roller ..................................................................................... 4.5 - 1
4.5.1 General .............................................................................. 4.5 - 1
4.5.2 Components of the bottom roller ....................................... 4.5 - 1
4.5.3 Bottom roller installation .................................................... 4.5 - 4
3720204en (00) Page 4 - 1
CONTENTS
4.6 Top roller ........................................................................................... 4.6 - 1
4.6.1 General .............................................................................. 4.6 - 1
4.6.2 Components of the top roller ............................................. 4.6 - 1
4.6.3 Top roller installation ......................................................... 4.6 - 4
4.7 Sprocket ............................................................................................ 4.7 - 1
4.8 Travel gearbox removal and installation ..................... see chapter 7.2
4.9 Track pads ....................................................................................... 4.9 1
4.10 Hydraulic track tensioning system .............................................. 4.10 1
4.10.1 General ........................................................................... 4.10 1
4.10.2 Components ................................................................... 4.10 1
4.10.3 Releasing the track tension ............................................ 4.10 4
4.10.4 Checking the accumulators ............................................. 4.10 - 4
4.11 Duo cone seals ............................................................................... 4.11 - 1
Page 4 - 2 3720204en (00)
4.1 UNDERCARRIAGE
4.1 Introduction 4.1.2 Safety Instructions
4.1.1 Foreword Danger in case of non-observance of safety
instructions
The Service Manual contains important informa-
tion for personnel servicing the machine. Machine This Caterpillar hydraulic excava-
technical data listed in other machine documents tor has been built in accordance
are not always repeated in this book. with state-of-the-art standards and
the recognized safety rules.
The documentation of a Caterpillar mining machine
includes: However, operating the machine if
a fault is suspected or has oc-
Operation and Maintenance Manual curred, or carrying out repair work
inexpertly
Spare Parts Catalog
endangers the lives of people in
Service Manual contact with it
damages the machine and other
The service manual does not contain technical property.
data on auxiliary units for the operation of specific
or optional equipment or data of individual devices. Stop the hydraulic excavator im-
mediately if you suspect or notice
The refilling quantities specified for consumables any damage to ensure the safety of
are approximate quantities which are intended as a the operator, other people or mate-
help for planning consumable requirements. rial property at the application area
of the excavator.
Each component is equipped with suitable check- All components of Caterpillar ma-
ing devices, e.g. a dipstick or checking plugs, per- chines are perfectly tuned to each
mitting the operator to check exactly the filling of other. Trouble-free operation and a
the components.
long service life can only be
achieved with original Caterpillar
spare parts.
3849049en - (00) Page 4.1 - 1
4.1 UNDERCARRIAGE
Rules for safety at work
Personnel
Personnel
The machine must not be started
by unauthorized people. Personal protective equipment and
safety working clothing:
Therefore secure and lock it.
Wear a safety helmet, safety foot-
Follow the accident prevention wear and safety gloves.
regulations.
Wear closely fitting working cloth-
Only specially trained and qualified ing when working on the machine.
personnel with the appropriate Loose, wide garments can catch on
technical knowledge can operate, machine parts and result in injury.
service or repair the hydraulic ex-
cavator. Personnel carrying out work at
greater heights must wear safety
If you lack such knowledge, ex- harnesses. Always put on a tested
perienced personnel, e.g. from harness which is equipped with fall
Caterpillar, are to give you detailed arrestors and safety lines.
instructions.
If you need assistance to carry out
The personnel must have read and the work, e.g. marshallers, clearly
understood the Operation and define the responsibilities of each
Maintenance Manual and in par- assistant beforehand. The individ-
ticular the chapter ual responsibilities are to be care-
‘Fundamental Safety Instructions.’ fully observed to ensure safety.
Only such people can start up the
machine after assembly work to
adjust the attachment.
Incorrect operation of the machine
or the equipment can result in life-
threatening situations.
During all works, always observe
the start and shut down proce-
dures described in the Operation
and Maintenance Manual.
Page 4.1 - 2 3849049en - (00)
4.1 UNDERCARRIAGE
Tools and devices Before opening systems and units
(e.g. pipes, coolers, hydraulic res-
Tools, hoists, slings, trestles and ervoirs and accumulators) depres-
other devices must be in a reliable, surize them properly.
safe state.
Open or remove protective devices
Metal splinters may cause injury on moving machine parts only
when you take in or out attachment when the drive unit is shut down
bolts. Therefore during this proce- and secured against inadvertent
dure use a brass or copper man- start.
drel and wear safety glasses.
Before re-commissioning install all
When climbing onto or off the ma- protective devices.
chine use only ladders, steps, plat-
forms and handrails provided for Before carrying out assembly work,
this purpose. the machine and the equipment
must be secured against inadver-
Always keep ladders, steps and tent movement, e.g. by placing the
platforms in a non-slip state. Re- working equipment on the ground.
move any oil, grease, earth, clay,
snow, ice and other foreign matter
immediately.
Hydraulic and lubricating
system:
Securing the working equip- Always observe the safety regula-
ment tions applicable to the product
when handling oils, greases and
Secure the machine and the work- other chemical substances.
ing equipment against inadvertent
and unauthorized start. Position Close open unused bores, pipe and
working equipment on the ground hose connections so that they are
in such a way that it cannot move impermeable to pressure.
when mechanical or hydraulic Refill the hydraulic system with
connections become detached. collected drain hydraulic oil only
Use hoists or other appropriate through the return flow filters. Dis-
support devices when you install, pose of waste oil without polluting
remove or displace any equipment the environment.
or component. Thus you prevent Observe the correct working se-
them from inadvertent movements, quence when fitting or replacing
slip or fall. components or equipment.
3849049en - (00) Page 4.1 - 3
4.1 UNDERCARRIAGE
Modifications of the machine
Before carrying out works, espe-
cially on the electrical system, dur- Unauthorized conversions or modi-
ing which tools, spare parts, etc. fications of the hydraulic excavator
can contact electric cables, always are forbidden for reasons of safety.
disconnect the battery: first the
Never modify the nominal pressure
negative pole and then the positive
value of pressure relief valves
pole. When reconnecting the bat-
without explicit approval from Cat-
tery, connect first the positive and
erpillar. Do not remove the lead
then the negative pole.
seals from pressure relief valves
Always replace defective, me- and hydraulic accumulators.
chanically prestressed compo-
nents. Never open them! The Ser-
vice Manual contains no informa-
tion on such work. Re-commissioning
The operating temperature of the
machine is high and the consum-
ables have at least the same tem- Before re-commissioning:
perature. Therefore take care to
avoid burns or scalds.
Grease all lubricating points.
Be careful when handling acids, Check all oil levels and correct
e.g. battery acid. Acid splashes them if necessary.
may injure the eyes and the skin.
Carry out function checks of all
If the acid is splashed onto your repaired components.
skin, rinse it with plenty of clean
running water and seek medical Check all functions of the exca-
care immediately. vator including brakes during a
If the acid is splashed in your eyes, test run. Release the hydraulic
rinse thoroughly with running wa- excavator for re-commissioning
ter and seek medical care immedi- only if all its functions operate
ately. properly.
Never smoke when handling flam-
mable liquids.
Be careful with open flames and
unprotected light. Not only fuel but
also other consumables often have
a low flash point and catch fire
easily.
Page 4.1 - 4 3849049en - (00)
4.1 UNDERCARRIAGE
4.1.3 General
This Service Manual contains information in addi-
tion to the Operation and Maintenance Manual The Service Manual covers the information you
and the Spare Parts Catalog, to familiarise the need when handling your excavator. However,
personnel with the designated use, maintenance Caterpillar Global Mining HMS GmbH will be
and repair of the Caterpillar excavator. pleased to answer any questions you have on its
products. Please contact your local Caterpillar
The information in the Service Manual corre- dealer or your Caterpillar subsidiary.
sponds to the standard technical specification of
the machine when it was delivered.
All sketches and drawings show general principles.
They do not represent the actual design of the ma-
chine and are not to be used for manufacturing.
Special equipment is normally not considered.
Technical modifications, which are introduced after
delivery of the machine, may also be incorporated
in machines which are already in operation.
In this case, you can find the updated version of
the Service Manual on the Caterpillar website.
3849049en - (00) Page 4.1 - 5
4.1 UNDERCARRIAGE
Page 4.1 - 6 3849049en - (00)
4.2 TRAVEL SYSTEM
4.2 Travel system
4.2.1 General
The hydraulic excavator is equipped with a low- Track pad and chain link are forming one unit.
maintenance undercarriage.
4.2.2 Components of travel system
Table for Fig. 1
Weight
Ref. no. Quantity Designation Further remarks
[kg]
1 1 Carbody
2 2 Track frame
3 2 Travel gearbox
4 2 Track tensioning system
5 14 Bottom roller
6 4 Top roller
7 84 Track link (2 x 42)
8 2 Idler
9 2 Sprocket
Table 1
Fig. 1 Travel system
3849038en - (00) Page 4.2 - 1
4.2 TRAVEL SYSTEM
Table for Fig. 2
Weight
Ref. no. Quantity Designation Further remarks
[kg]
1 ----
2 1 Track frame
3 1 Travel gearbox
4 ----
5 7 Bottom roller 1 002 each
6 2 Top roller 445 each
7 1 Track chain 1 400 mm 42 links 675 each
8 1 Idler
9 1 Sprocket
10 56 Hex bolt M 30 x 190 – 12.9 for bottom rollers
11 56 Washer for bottom rollers
12 8 Hex bolt M 30 x 220 – 12.9 for top rollers
13 8 Washer for top rollers
Table 2
Page 4.2 - 2 3849038en - (00)
4.2 TRAVEL SYSTEM
10, 12
Fig. 2 Travel system
3849038en - (00) Page 4.2 - 3
4.2 TRAVEL SYSTEM
4.2.3 Wear limits Track components must be replaced when they
have worn down to between 75 and 100%.
Wear on the track components is due to move- Sudden failure is otherwise pre-programmed.
ment, loading and ground contact, as well as to the
hardness (abrasiveness) of the ground. Careful and regular measurements are necessary
to determine the extent of wear and to be ready for
Wear can also be increased by the following fac- component exchange when it is necessary.
tors:
Before measuring components, clean them thor-
1. unstable position of excavator because of un- oughly. Measure at several points. It is not the
even ground. average, but the maximum wear value that is to be
taken as wear limit.
2. one-sided stressing of the tracks when turning
on the spot. Because the wear life between 75 and 100% is
low, we recommend that components be changed
3. Driving over obstacles. as a preventive measure as soon as the 75% limit
has been reached. Exchange can take place while
4. high amount of travelling of more than 7% of other servicing is being carried out.
the operating hours.
Page 4.2 - 4 3849038en - (00)
4.2 TRAVEL SYSTEM
Wear limits for travel system
Component Wear limits [mm]
N W W W W meas-
New 25 % 50 % 75 % 100 % ured
Track pad
475 478 481 484 487
Track chain (4 links)
1 900 1 912 1 924 1 936 1 948
Track pad
A 145 141 138 134 131
B 317 303 289 275 261
C 70 59 48 37 26
Pad bush
Ø 110,8 112,3 113,8 115,3 116,8
Pad pin
Ø 110 108,5 107 105,5 104
Pad cam
246 241 236 231 226
160 155 150 145 140
3849038en - (00) Page 4.2 - 5
4.2 TRAVEL SYSTEM
Component Wear limits [mm]
N W W W W meas-
New 25 % 50 % 75 % 100 % ured
Bottom roller
Ø 410 402 394 386 378
52,5 57 61,5 66 70,5
Top roller
Ø 360 354 345 335 323
51,5 54,5 59 64 70
Idler rim
Ø 1 486 1479 1472 1465 1458
63 66,5 70 73,5 77
Sprocket rim
Ø 1620 1615 1610 1605 1600
67 69,5 72 74,5 77
Sprocket tooth
244 239 234 229 224
202 197 192 187 182
Page 4.2 - 6 3849038en - (00)
4.3 TRACK CHAIN
4.3 Track chain Proportionate weight transmitted through the
sprocket does not strain the pins and bushings
4.3.1 General connecting the pad-links.
The “combined pad-link” type track chain combines The track pins are full-floating.
a chain link and a track pad into one unit.
The drive forces are directly transferred from the
sprocket into the massive pad-link unit.
4.3.2 Components
The quantities are valid for 1 track chain.
Weight
Ref. No. Quantity Designation Further remarks
[kg]
1 42 Pad-link 675 each
2 336 Bushing 3,5 each
3 84 Pin 23,6 each
4 84 Cover plate 2,1 each
5 84 Circlip
Table 1
A A
1
2
3
4
5
2452540A.SKD
Fig. 1 Track chain
3663871en - (00) – 03.04 Page 4.3 - 1
4.3 TRACK CHAIN
4.3.3 Assembly 2. First open the connection above the track link
which is to be removed. (Arrow A in Fig. 2).
4.3.3.1 Opening the track chain
The track chain can be opened as follows:
Avoid uncontrolled movement of
1. Position the excavator in such a way that the the track by fixing it with help of
chain link which is to be removed is positioned appropriate means, e.g. chain
at the lower section of the sprocket (Arrow A in hoists or forklift before it is
Fig.2). opened.
3. Remove both circlips (5, Fig. 1).
Before opening the track chain has
to be slackened in accordance with 4. Remove both cover plates (4, Fig. 1).
the operating instructions.
5. Remove both track pins (3, Fig. 1).
The ball valve in the line to the
track tensioning cylinder must be 6. Afterwards remove the other two track pins
closed to avoid the piston being accordingly.
completely pushed out of the bar-
rel when an engine is started.(see
chapter 4.10).
Secure against falling down!
When the chain is not engaged
with the sprocket the whole upper
section of the chain may roll off
from the idler and create injury and
damage!
Therefor uncontrolled rolling of the
chain has to be avoided by secur-
ing the chain by appropriate
means!
Page 4.3 - 2 3663871en - (00) – 03.04
4.3 TRACK CHAIN
Fig. 2 Opening the track chain
4.3.3.2 Closing the track chain
1. Align the track chain so that the links which
are to be connected are positioned in front of
the sprocket (Fig. 2).
2. Clean bushings in the track link and the track
pins with degreaser.
3. Cover the track pins with a thin layer of as-
sembly paste part-no. 271 554.
4. Install both track pins, cover plates and cir-
clips.
5. Tension the track according to the ‘Operating
Instructions’.
3663871en - (00) – 03.04 Page 4.3 - 3
4.3 TRACK CHAIN
Page 4.3 - 4 3663871en - (00) – 03.04
4.4 IDLER
4.4. Idler With the idler the track is hydraulically tensioned
via spacer piece and track tensioning cylinder.
4.4.1 General
The idler is mounted in the two slider pieces, which
are guided in the track frame.
4.4.2 Components of the idler
The reference numbers are related to Fig. 1 and Fig. 2
Weight
Ref. no. Quantity Designation Further remarks
[kg]
1 1 Idler 4 235
2 2 Slider piece 351 each
3 1 Shaft 494
4 2 Disk
5 2 Labyrinth ring
6 2 Bushing
7 2 Duo-cone seal
8 2 O-ring
9 4 Locking pin
10 4 Disc
11 12 Dowel pin
12 ----
14 2 Pin
30 0,6 kg Grease KPF2K - 30
31 Anti-seize paste Part-no. 271 554
32 Port for grease filling
Table 1
3663872en - (00) – 03.04 Page 4.4 - 1
4.4 IDLER
Fig. 1 Idler 2796251a
Z 13
10 11 4 7 B 5
15
Z 3
9 8
Y 12
9 14
Fig. 2 Idler 2707843A
Page 4.4 - 2 3663872en - (00) – 03.04
4.4 IDLER
4.4.3 Assembly of the idler 3. Pick up idler shaft with lifting device (6, Fig. 3)
and install into the idler.
When assembling the idler the working sequence
has to be as follows:
1. Place idler onto suitable support (1, Fig. 1) and
completely press, respectively drive in bushing
(2, Fig. 1).
Fig. 3 Installation of idler shaft 630425
4. Insert labyrinth ring into the groove in the idler
(5, Fig. 2).
The seal must not be pressed into the grove but
Fig. 1 Installation of bushings 630423
move freely.
Grease the surface on both sides of the seal
2. Fit two halves of duo-cone seals (5, Fig. 2) into with high pressure grease (30, Fig. 2).
idler (see chapter 4.11 ‘Duo-cone seals’).
Grease must not penetrate into the
grease channels of the idler.
5. Grease seal ring (7, Fig. 4) and place into
slider piece (8, Fig. 4).
Fig. 2 Installation of duo-cone seal 630424
Fig. 4 Installation of seal 630426
3663872en - (00) – 03.04 Page 4.4 - 3
4.4 IDLER
6. Place disk (3, Fig. 5) with grease into slider 8. Clean indicated area of the idler shaft (arrow,
piece (8, Fig. 5) and secure by knocking in Fig. 2) with degreaser and cover with a thin
dowel pins (4, Fig. 5). layer of anti-seize paste part-no. 271 554.
Assemble the first slider piece (8, Fig. 7) and
the shaft (6, Fig. 7) with help of a lifting device.
Ensure that the slider piece is brought exactly
into position and the borings for the locking pins
(9 & 10, Fig. 8) in the slider piece and the shaft
are aligned.
Before assembling the duo-cone seal clean the
contact surface carefully and cover the contact
surface slightly with oil.
Do not oil the other areas of the duo-cone
seals..
Fig. 5 Installation of disc 630427
7. Fit half of duo-cone seal (5, Fig. 6) into slider
piece (8, Fig. 6).
Fig. 7 Installation of slider piece 630429
Fig. 6 Installation of duo-cone seal 630428
Page 4.4 - 4 3663872en - (00) – 03.04
4.4 IDLER
9. Install the locking pins (9 & 10, Fig. 8). The
grove in the locking pin has to show into the di-
rection of the shaft.
Fig. 8 Installation of locking pins 630430
10. Turn idler and fill idler housing with grease
according to Service Manual.
Fig. 9 Filling with grease 630431
For grease quantity and -quality refer to the
‘Operating Manual’.
11. Install second slider piece according to section
8.
3663872en - (00) – 03.04 Page 4.4 - 5
4.4 IDLER
Page 4.4 - 6 3663872en - (00) – 03.04
4.5 BOTTOM ROLLER
4.5 Bottom roller The majority of roller leaks is due to dirt that enters
through the labyrinth (see arrow B, fig. 2) and pen-
4.5.1 General etrates into the duo-cone seals. The roller can be
made fully operational by removing and cleaning it,
Bottom rollers have lifetime lubrication. They do and then filling it with fresh lubricant.
not require any maintenance until the wear limits
have been reached. Loose fastening bolts will immediately result in
leaks and further damage to the bottom rollers.
In order to assure the bottom rollers longevity,
sufficient axial clearance of the rollers between the
bearing caps must be ensured.
4.5.2 Components of the bottom roller
The parts listed in table 1 refer to fig.1 - 10.
Components of the bottom roller
Weight
Ref. no. Quantity Designation Further remarks
[kg]
1 1 Roller body 715
2 2 Bearing cap 115 each
3 2 Bushing 13 each
4 2 Thrust disc
6 2 Duo-cone seal
7 2 Plug used during operation
8 2 Sealing ring
9 2 Hex. bolt M 16 x 65 – 8.8 – A3B used for transport and storing
10 2 Sealing ring
11 2 Washer
12 2 O-ring
13 8 Hex. bolt M 30 x 190 – 12.9 Tightening torque = 2 250 Nm
14 8 Washer
15 2 Plug used for transport and storing
16 1 Auxiliary bolt
Table 1
3663873en - (01) – 12.11 Page 4.5 - 1
4.5 BOTTOM ROLLER
13
Fig. 1 Components of bottom roller – 2796261-01
13 A
Fig. 2 Bottom roller - 2765689-01
Page 4.5 - 2 3663873en - (01) – 12.11
4.5 BOTTOM ROLLER
4.5.3 Bottom roller installation Installation
Transport and storing The rollers are sealed with duo-cone seals (6).
Function and assembly of duo-cone seals see
For storing and transportation roller and bearings chapter 4.11.
are screwed together with two bolts (9, fig. 3). The
boring for lubrication is closed with a plug (15, fig. Before assembling the bearing caps fill up sealing
4). gap above duo-cone seal with grease (G, fig. 5).
Fig. 5 G: fill up with grease 642790
B: If the roller is filled with oil no grease is
Fig. 3 Detail Z from fig. 2 3742528-03 permitted to flow into the bore B.
Storing and transport condition
Clean contact surfaces (A, fig. 2) on frame
and bottom roller with cleaning agent down to
the shiny metal (no rust, paint or grease).
Remove plug (15, fig. 4).
Install O-rings (12, fig. 2) for grease channel.
Position roller under the track frame. Threat in
lightly oiled mounting bolts (13) with washers
(14). Tighten bolts hand tight.
Remove items 8, 9, 10, 11 (fig. 3) on both
bearings.
Press bearing with auxiliary bolt (fig. 6)
against connecting surfaces of the track
Fig. 4 Storing and transport condition – 3700541-02
frame.
** ATTENTION ** The bearings must lay at
the whole connecting surface of the track
frame without any axial tolerances.
3663873en - (01) – 12.11 Page 4.5 - 3
4.5 BOTTOM ROLLER
Tighten bolts (13) with the required torque. Find an appropriate place to fix the dial
gauge.
Tightening torque, pos. 13, lightly oiled:
Remove plug from bearing cap. Make sure,
Md = 2 250 Nm that transportation bore in roller (T, fig. 8)
does not line up with with the bore of end cap.
This avoids damage of roller bore.
Screw auxiliary bolt (16) into bearing end cap.
This pushes the roller into its end position (fig.
8). Take into consideration, that rubber rings
in the slide ring packing will keep the roller
from sliding into its end position.
Once the roller has reached its end position,
set the dial gauge to zero (fig. 8).
Remove the auxiliary bolt and close bore with
sealing ring (8) and plug (7).
Insert the auxiliary bolt into the other bearing
end cap and turn it in, till the roller reaches the
other end position (fig. 9).
Fig. 6 Auxiliary bolt - 2765702
Record the measurement of axial clearance
and where necessary make corrections.
Measuring axial clearance of roller
In most cases the proper axial clearance can
Axial clearance of the roller between the bearing be attained by first loosening and then retight-
caps: ening the end cap bolts (13).
1,0 – 1,8 mm
If specified clearance on the rollers is not able
to be confirmed, remove roller and check
track frame to ensure, that there is no paint,
burrs or damage on the inside of the track
frame, where the roller end cap vertical sur-
face contacts the track frame.
If specified clearance on the roller is still not
able to be measured, contact your Caterpillar
Hex dealer.
Remove auxiliary bolt.
Check grease according to the service- and
operating instructions.
Plug bearing with items 7 and 8.
For rollers with central greasing system:
Fig. 7 A: Axial clearance 642791
B: Auxiliary bolt (pos. 16) fits here Check function of the central greasing system!
Page 4.5 - 4 3663873en - (01) – 12.11
4.5 BOTTOM ROLLER
Fig. 8 Roller gets pushed to thrust washer by tightening auxiliary bolt. Here from left to right. 642792-01
16: Auxiliary bolt
A: Axial clearance
T: Transportation bore
U: Undercarriage sideframe
Fig. 9 Roller gets pushed to thrust washer by tightening auxiliary bolt. Here from right to left. 642793-02
3663873en - (01) – 12.11 Page 4.5 - 5
4.5 BOTTOM ROLLER
13
Fig. 10 Bottom roller - Installation – 2760068-02
Page 4.5 - 6 3663873en - (01) – 12.11
4.6 TOP ROLLER
4.6 Top roller The roller can be made fully operational by
removing and cleaning it, and then filling it with
4.6.1 General fresh grease.
Top rollers have long term lubrication. Loose fastening bolts will immediately result in
leaks and further damage to the rollers.
The rollers are sealed with duo-cone seals (6).
Function and assembly of duo-cone seals -
see chapter 4.11.
The majority of roller leaks is due to dirt that
enters through the labyrinth (see arrow, Fig. 2)
and penetrates into the duo-cone seals.
4.6.2 Components of the top roller
The parts listed in table 1 refer to Fig.1, 2 and 3.
Components of the top roller
Weight
Ref. no. Quantity Designation Further remarks
[kg]
1 1 Roller body 360 mm 321
2 2 Support 52 each
3 2 Bushing 6,5 each
4 2 Disk 1,4 each
5 2 O-Ring
6 2 Duo-cone seal
7 1 Plug
8 2 Sealing ring
9 ----
10 2 O-Ring
11 2 Plug
12 ----
13 4 Hex. bolt M 30 x 220 – 12.9 Tightening torque Md = 2 250 Nm
14 4 Washer
20 1 Securing device for transport
30 0,2 kg Grease
Table 1
3663874en - (00) – 03.04 Page 4.6 - 1
4.6 TOP ROLLER
Fig. 1 Top roller 3659737a
13 A
Fig. 2 Top roller 3648212a
Page 4.6 - 2 3663874en - (00) – 03.04
4.6 TOP ROLLER
13
Fig.3 Top roller - Installation 3678060-03
3663874en - (00) – 03.04 Page 4.6 - 3
4.6 TOP ROLLER
4.6.3 Top roller installation Press bearings against connecting surface of the
track frame.
Sequence of assembly for roller installation
Tighten mounting bolts with torque according
Position roller on the track frame and threat in to chapter 2.9 - ‘Tightening procedures’.
mounting bolts (13) with washers (14).
Fill in grease according to the service- and
Remove securing device (20, Fig. 4). operating instructions and plug bearing with
items 7 and 8.
Because of the securing device for
transport the roller body and the
supports have been pre-loaded.
Therefore it is important to press the
supports against the contact surface
of the frame before the mounting
bolts (13) are tightened. So the axial
clearance of 1,0 to 2,0 mm is
achieved.
The supports have to contact the
whole connecting surface of the
track frame without any axial toler-
ances.
Fig. 4 securing device for transport 630821
Page 4.6 - 4 3663874en - (00) – 03.04
4.7 SPROCKET
4.7 Sprocket sprocket (1, Fig. 1) so that you can see the mark
from a safe distance.
1) Let the operator park the machine in such a
4.7.1 General way, that the threaded bore (2, Fig. 1) is
located at the top of the sprocket.
The sprocket (1, Fig 1 – 4) is bolted to the travel
gearbox (13, Fig. 3 and 4).
Before opening the crawler track
chain fix it with chain hoists or a
The installation of the travel gearbox is described
forklift truck to prevent its
in chapter 7.2 “Travel gearbox”.
uncontrolled movement.
You can remove or install the sprocket without
2) Open the crawler track chain link (A, Fig. 1)
removal of the travel gearbox from the crawler
above the sprocket (1, Fig. 1) as described in
frame.
chapter 4.3.3.1 “Opening the track chain”.
3) Attach lifting gear to the bore (3, Fig. 1) of the
4.7.2 Sprocket removal fender (4) and attach it to a crane. Slightly
raise the fender.
The sprocket (1, Fig. 1) needs to be lifted with a
4) Remove bolts (5) and sleeves (6).
crane. For this purpose it is provided with a
threaded bore (2, Fig. 1) to install an eyebolt. The 5) Remove the fender (4).
threaded bore is located between two teeth of the
sprocket and sealed with a plug. 6) Fit an eyebolt to the sprocket (1).
To find the threaded bore, you have to approach 7) Attach lifting gear to the eyebolt on the
the machine. sprocket (1). Slightly raise the sprocket using a
crane.
Approach the machine only after it 8) Unscrew all assembly bolts (7, Fig. 2).
has come to a complete standstill.
Keep at a safe distance while the 9) Remove the plugs (8). Replace the plugs by 4
machine is moving. bolts (18, Table 2).
10) Screw in all 4 bolts equally to separate the
sprocket from the gearbox.
Let the operator turn the machine superstructure
so that it forms a right angle of 90° with the 11) Remove the sprocket (1).
undercarriage to allow visual contact with the 12) Clean the gasket (11, Fig. 3) and check it for
operator. damages. If it is in good condition, store it and
Let the operator stop the machine. Walk up close use it again for sprocket installation.
to the sprocket you want to remove. Examine the
visible surfaces between the teeth. Clean them if
necessary.
Do not touch the sprocket or any
other part of the machine while the
machine is moving.
If you cannot see the threaded bore in one of the
visible surfaces, walk away from the machine.
When you are at a safe distance, have the
operator move the machine so that the sprocket is
turned 90 °. Have the operator stop the machine.
Walk up to the sprocket again to examine the
surfaces now visible. Repeat this procedure until
you have found the threaded bore.
If you can see the threaded bore, mark the
respective position on the outer surface of the
3663875en - (01) Page 4.7 - 1
4.7 SPROCKET
4.7.3 Sprocket installation Fully tighten all assembly bolts
within max. 8 hours after joining
1) Slightly oil the threads and the heads of the
the metal surfaces.
assembly bolts (7, Fig. 3).
2) Use a solvent (19, Table 2) to clean all contact 10) Pick up the sprocket (1, Fig. 4) with a crane.
surfaces (9, Fig. 3 and 4) between the
11) Align the sprocket and the travel gearbox (13,
sprocket (1) and the travel gearbox (13) from
Fig. 4). Insert all assembly bolts (7). Ensure
rust, paint and grease till they are metallically
that they do not contact the adhesive.
shiny.
12) Tighten the bolts (7) hand-tight.
3) Check the contact surfaces of the sprocket (1)
and the travel gearbox (13) for mechanical 13) Use a hydraulic torque wrench to tighten the
damages. bolts crosswise (Fig. 5) to the specified torque
of 2000 Nm.
4) Clean all the threads from paint, rust, and
grease and blow them out with compressed 14) Detach the crane from the sprocket.
air. Check them for damages and tap the
15) Slightly oil the assembly bolts (5, Fig. 1).
threads again if required.
16) Use the crane to pick up the fender (4).
5) Clean the surface (10, Fig. 4) thoroughly.
Check the silicone fillings in this surface. 17) Align the fender with the crawler frame.
Replace missing or loose fillings with silicone
18) Insert the bolts (5) and sleeves (6) and tighten
(21, Table 2).
the bolts hand-tight.
6) Position the gasket (11, Fig. 3) in the
19) Use a hydraulic torque wrench to tighten the
respective groove.
bolts to the specified torque of 2250 Nm.
7) Use a paintbrush or lintless cloth to apply a
20) Detach the crane from the fender.
thin layer of anti-seize lubricant (20, Table 2) to
the contact surfaces (9, Fig. 4) of the sprocket 21) Close the crawler track chain as described in
(1) and the travel gearbox (13). chapter 4.3.3.2 “Closing the track chain”.
8) Use a scraper or putty knife to apply a thin Note: To ensure that the track chain is tensed,
layer of adhesive (22, Table 2) to the contact close the pressure relief valve at the track tension
surface (12, Fig. 4). relief block and open the ball valve in the crawler
frame as described in chapter 4.10.3.
Penetration of adhesive into a
threaded bore increases friction
and invalidates torque values.
To prevent this, leave approx.
10 mm around the threaded bores
free of adhesive.
At temperatures below -10°C, spray the other
contact surface (the one without adhesive) with
an activator (23, Table 2).
9) Start the sprocket installation immediately after
the application of adhesive. The adhesive
starts hardening when the metal surfaces join
without air between them.
Page 4.7 - 2 3663875en - (01)
4.7 SPROCKET
The items in Table 1 refer to Fig. 1 to 5.
Weight each
Item Quantity Designation Further remarks
[kg]
A 1 Crawler track chain link to be opened
1 1 Sprocket, 12 teeth 2,730
2 1 Threaded bore M 30 for eyebolt
3 1 Bore
4 1 Fender 481.4
5 4 Hex. bolt M 30 x 140 Tightening requirements:
Bolt treatment: slightly oiled
Tightening torque: 2250 Nm
6 4 Sleeve 1.1
7 52 Double hex. bolt M 30 x 240 Tightening requirements: 1.6
Bolt treatment: slightly oiled
Tightening torque: 2000 Nm
8 4 Plug 0.004
9 Surface
10 Surface
11 Gasket Part no. 1460750
12 Surface
13 1 Travel gearbox 14,500
14 48 Hex. bolt M 36 x 360 3.1
15 48 Washer 0.09
16 2 Travel motor 104
17 1 Travel motor cover 481.4
Table 1
The items in Table 2 are not shown in the illustrations.
Weight each
Item Quantity Designation Further remarks
[kg]
18 4 Hex. bolt M 30 x 300, fully threaded Part no. 4022889 1.6
19 1l Solvent Part no. 1519429
20 Anti-seize lubricant Part no. 1519702
21 Silicone Part no. 1519008
22 Adhesive omniFIT® Part no. 1519432
23 Activator for omniFIT® Part no. 1469952
Table 2
3663875en - (01) Page 4.7 - 3
4.7 SPROCKET
5
Fig. 1 Sprocket drive, side view – 647368
7
Fig. 2 Sprocket – 647371
Page 4.7 - 4 3663875en - (01)
4.7 SPROCKET
5, 7, 14 7 9
Fig. 3 Sprocket drive, top view – 647368
5, 7, 14 12 9
Fig. 4 Travel gearbox and sprocket, exploded view – 647370
3663875en - (01) Page 4.7 - 5
4.7 SPROCKET
5
Fig. 5 Bolt tightening pattern – 647371a
Page 4.7 - 6 3663875en - (01)
4.8 TRAVEL GEARBOX - REMOVAL & INSTALLATION
4.8 Travel gearbox -
removal and installation
The removal and installation of the travel gearbox
is described in
chapter 7.2
2461035en - (00) Page 4.8 - 1
4.8 TRAVEL GEARBOX - REMOVAL & INSTALLATION
Page 4.8 - 2 2461035en - (00)
4.9 TRACK PAD
4.9 Track pad
The “combined pad-link” type track chain combines
a chain link and a track pad into one unit.
For further details see chapter 4.3 ‘Track chain‘.
3663876en - (00) – 03.04 Page 4.9 - 1
4.9 TRACK PAD
Page 4.9 - 2 3663876en - (00) – 03.04
4.10 HYDRAULIC TRACK TENSIONING SYSTEM
4.10 Hydraulic track tensioning system
4.10.1 General
Technical data:
Track tensioning pressure 60 bar
Setting of pressure relief valve: 330 bar
Nitrogen pre-charge of accumulator: 48 bar
Suspension travel: 100 mm
Maximum retensioning distance: 120 mm
4.10.2 Components of the track tensioning system
The reference numbers are related to Fig. 1 and Fig. 2
Ref. no. Quantity Designation Further remarks Weight
[kg]
1 1 Idler-unit 5 350
2 1 Spacer piece 505
3 1 Tensioning cylinder 550
6 1 Accumulator 22
7 1 Hose
10 1 Ball valve
14 4 Hex. bolt M 24 x 110 Md = 670 Nm
15 8 Hex. bolt M 24 x 160 Md = 670 Nm
18 4 Hex. bolt M 8 x 20 Md = 21 Nm
22 4 Spring washer
30 1 Filling and testing port
Table 1
3663877en - (00) – 03.04 Page 4.10 - 1
4.10 HYDRAULIC TRACK TENSIONING SYSTEM
Fig. 1 Idler with track tensioning cylinder 630468
Page 4.10 - 2 3663877en - (00) – 03.04
4.10 HYDRAULIC TRACK TENSIONING SYSTEM
2415503a.S K
22
30
18
13
6
7
10
14
3
2
15
1
14, 15, 18
Fig. 2 Idler with track tensioning system 2415503a
3663877en - (00) – 03.04 Page 4.10 - 3
4.10 HYDRAULIC TRACK TENSIONING SYSTEM
4.10.3 Releasing the track tension 4.10.4 Checking the accumulators
Before carrying out repair work the tracks have The procedure how to check the accumulators is
to be slackened. described in chapter 8.6.4.8 ‘Track tensioning sys-
tem’.
Procedure:
Shut down the engines
Open both pressure relief valves (3, Fig. 3);
the track is slackening (each track is related to
a pressure relief valve).
Before opening the track the ball valve (10.
Fig. 2) in the line to the track tensioning cylin-
der must be closed to avoid the piston being
completely pushed out of the barrel when an
engine is started.
After completion of the repair close the pres-
sure relief valves (turn in completely).
Fig. 3 Track tensioning system 630372
Each pressure relief valve (3, Fig. 3) is adjusted to
330 bar and sealed in this position.
The seal must not be removed and the pressure
setting of 330 bar must not be changed.
Attention!
Tensioning of the tracks:
See operator’s manual.
Pressure setting:
See chapter 8.6
‘Checking and setting pressures’
Page 4.10 - 4 3663877en - (00) – 03.04
4.11 Duo-cone seals
Fig. 2 Duo-cone seals 630218
In case of leakages, the duo-cone
seals are to be changed immediately
and before installing the new duo-
cone seals mating surfaces of both
the rigid and the rotating compo-
nent(s) need to be inspected and
refurbished if necessary.
Please contact Caterpillar Global
Mining Service Department for in-
structions/guidelines.
Fig. 3 Duo-cone seals 630219
Attention:
Fig. 1 Duo-cone seals 630217
NEVER fit a new half of a duo-cone seal to a
used half. When re-assembling used duo-cone
seals, make sure that pairs that were previously
installed together are kept together.
03.2019
5. Superstructure
CONTENTS
5. SUPERSTRUCTURE
5.1 Introduction ...................................................................................... 5.1 - 1
5.1.1 Foreword ........................................................................... 5.1 - 1
5.1.2 Safety ................................................................................ 5.1 - 1
5.1.3 General .............................................................................. 5.1 - 5
5.2 Swing ring ......................................................................................... 5.2 - 1
5.2.1 General .............................................................................. 5.2 - 1
5.2.2 Components of the swing ring ........................................... 5.2 - 2
5.2.3 Hardness gap, Soft spot .................................................... 5.2 - 3
5.2.4 Assembly swing ring undercarriage ................................ 5.2 - 5
5.2.5 Assembly swing ring superstructure ............................... 5.2 - 8
5.3 Engine / Motor installation ............................................................... 5.3 - 1
5.3.1 Engine mounting ................................................................ 5.3 - 1
5.3.2 Radiator installation ........................................................... 5.3 - 4
5.4 Engine / Motor coupling ................................................................... 5.4 - 1
5.5 Swing gearbox installation .............................................. see chapter 7.3
5.6 Pump gearbox installation ............................................... see chapter 7.4
5.7 Pump installation.............................................................. see chapter 8.7
5.8 Oil cooler installation ....................................................................... 5.8 - 1
5.9 Rotor installation ..............................................................................5.9 - 1
3720205en (00) Page 5 - 1
CONTENTS
Page 5 - 2 3720205en (00)
5.1 SUPERSTRUCTURE – INTRODUCTION
5.1 Introduction 5.1.2 Safety Instructions
5.1.1 Foreword Danger in case of non-observance of safety
instructions
The Service Manual contains important informa-
tion for personnel servicing the machine. Machine This Caterpillar hydraulic excava-
technical data listed in other machine documents tor has been built in accordance
are not always repeated in this book. with state-of-the-art standards and
the recognized safety rules.
The documentation of a Caterpillar mining machine
includes: However, operating the machine if
a fault is suspected or has oc-
Operation and Maintenance Manual curred, or carrying out repair work
inexpertly
Spare Parts Catalog
endangers the lives of people in
Service Manual contact with it
damages the machine and other
The service manual does not contain technical property.
data on auxiliary units for the operation of specific
or optional equipment or data of individual devices. Stop the hydraulic excavator im-
mediately if you suspect or notice
The refilling quantities specified for consumables any damage to ensure the safety of
are approximate quantities which are intended as a the operator, other people or mate-
help for planning consumable requirements. rial property at the application area
of the excavator.
Each component is equipped with suitable check- All components of Caterpillar ma-
ing devices, e.g. a dipstick or checking plugs, per- chines are perfectly tuned to each
mitting the operator to check exactly the filling of other. Trouble-free operation and a
the components.
long service life can only be
achieved with original Caterpillar
spare parts.
3849050en - (00) Page 5.1 - 1
5.1 SUPERSTRUCTURE – INTRODUCTION
Rules for safety at work
Personnel
Personnel
The machine must not be started
by unauthorized people. Personal protective equipment and
safety working clothing:
Therefore secure and lock it.
Wear a safety helmet, safety foot-
Follow the accident prevention wear and safety gloves.
regulations.
Wear closely fitting working cloth-
Only specially trained and qualified ing when working on the machine.
personnel with the appropriate Loose, wide garments can catch on
technical knowledge can operate, machine parts and result in injury.
service or repair the hydraulic ex-
cavator. Personnel carrying out work at
greater heights must wear safety
If you lack such knowledge, ex- harnesses. Always put on a tested
perienced personnel, e.g. from harness which is equipped with fall
Caterpillar, are to give you detailed arrestors and safety lines.
instructions.
If you need assistance to carry out
The personnel must have read and the work, e.g. marshallers, clearly
understood the Operation and define the responsibilities of each
Maintenance Manual and in par- assistant beforehand. The individ-
ticular the chapter ual responsibilities are to be care-
‘Fundamental Safety Instructions.’ fully observed to ensure safety.
Only such people can start up the
machine after assembly work to
adjust the attachment.
Incorrect operation of the machine
or the equipment can result in life-
threatening situations.
During all works, always observe
the start and shut down proce-
dures described in the Operation
and Maintenance Manual.
Page 5.1 - 2 3849050en - (00)
5.1 SUPERSTRUCTURE – INTRODUCTION
Tools and devices Before opening systems and units
(e.g. pipes, coolers, hydraulic res-
Tools, hoists, slings, trestles and ervoirs and accumulators) depres-
other devices must be in a reliable, surize them properly.
safe state.
Open or remove protective devices
Metal splinters may cause injury on moving machine parts only
when you take in or out attachment when the drive unit is shut down
bolts. Therefore during this proce- and secured against inadvertent
dure use a brass or copper man- start.
drel and wear safety glasses.
Before re-commissioning install all
When climbing onto or off the ma- protective devices.
chine use only ladders, steps, plat-
forms and handrails provided for Before carrying out assembly work,
this purpose. the machine and the equipment
must be secured against inadver-
Always keep ladders, steps and tent movement, e.g. by placing the
platforms in a non-slip state. Re- working equipment on the ground.
move any oil, grease, earth, clay,
snow, ice and other foreign matter
immediately.
Hydraulic and lubricating
system:
Securing the working equip- Always observe the safety regula-
ment tions applicable to the product
when handling oils, greases and
Secure the machine and the work- other chemical substances.
ing equipment against inadvertent
and unauthorized start. Position Close open unused bores, pipe and
working equipment on the ground hose connections so that they are
in such a way that it cannot move impermeable to pressure.
when mechanical or hydraulic Refill the hydraulic system with
connections become detached. collected drain hydraulic oil only
Use hoists or other appropriate through the return flow filters. Dis-
support devices when you install, pose of waste oil without polluting
remove or displace any equipment the environment.
or component. Thus you prevent Observe the correct working se-
them from inadvertent movements, quence when fitting or replacing
slip or fall. components or equipment.
3849050en - (00) Page 5.1 - 3
5.1 SUPERSTRUCTURE – INTRODUCTION
Modifications of the machine
Before carrying out works, espe-
cially on the electrical system, dur- Unauthorized conversions or modi-
ing which tools, spare parts, etc. fications of the hydraulic excavator
can contact electric cables, always are forbidden for reasons of safety.
disconnect the battery: first the
Never modify the nominal pressure
negative pole and then the positive
value of pressure relief valves
pole. When reconnecting the bat-
without explicit approval from Cat-
tery, connect first the positive and
erpillar. Do not remove the lead
then the negative pole.
seals from pressure relief valves
Always replace defective, me- and hydraulic accumulators.
chanically prestressed compo-
nents. Never open them! The Ser-
vice Manual contains no informa-
tion on such work. Re-commissioning
The operating temperature of the
machine is high and the consum-
ables have at least the same tem- Before re-commissioning:
perature. Therefore take care to
avoid burns or scalds.
Grease all lubricating points.
Be careful when handling acids, Check all oil levels and correct
e.g. battery acid. Acid splashes them if necessary.
may injure the eyes and the skin.
Carry out function checks of all
If the acid is splashed onto your repaired components.
skin, rinse it with plenty of clean
running water and seek medical Check all functions of the exca-
care immediately. vator including brakes during a
If the acid is splashed in your eyes, test run. Release the hydraulic
rinse thoroughly with running wa- excavator for re-commissioning
ter and seek medical care immedi- only if all its functions operate
ately. properly.
Never smoke when handling flam-
mable liquids.
Be careful with open flames and
unprotected light. Not only fuel but
also other consumables often have
a low flash point and catch fire
easily.
Page 5.1 - 4 3849050en - (00)
5.1 SUPERSTRUCTURE – INTRODUCTION
5.1.3 General
This Service Manual contains information in addi-
tion to the Operation and Maintenance Manual The Service Manual covers the information you
and the Spare Parts Catalog, to familiarise the need when handling your excavator. However,
personnel with the designated use, maintenance Caterpillar Global Mining HMS GmbH will be
and repair of the Caterpillar excavator. pleased to answer any questions you have on its
products. Please contact your local Caterpillar
The information in the Service Manual corre- dealer or your Caterpillar subsidiary.
sponds to the standard technical specification of
the machine when it was delivered.
All sketches and drawings show general principles.
They do not represent the actual design of the ma-
chine and are not to be used for manufacturing.
Special equipment is normally not considered.
Technical modifications, which are introduced after
delivery of the machine, may also be incorporated
in machines which are already in operation.
In this case, you can find the updated version of
the Service Manual on the Caterpillar website.
3849050en - (00) Page 5.1 - 5
5.1 SUPERSTRUCTURE – INTRODUCTION
Page 5.1 - 6 3849050en - (00)
5.2 SWING BEARING
5.2 Swing bearing Technical data
5.2.1 General Total weight (without bolts): 10 500 kg
Outer diameter: 3 671 mm
This chapter applies to machines
Inner diameter: 2 926 mm
DH3 / DHN 60 from serial no. #
196. Height: 482 mm
Table 1 lists bolt types and tightening procedure
Before starting this procedure con-
for swing bearing installation.
sider General Service Information
The swing bearing is designed as a triple-race
combined axial/radial roller bearing.
Swing bearing carbody (undercar- Swing bearing superstructure
riage) frame (uppercarriage)
Bolt size MJ 42 x 4.5 x 500 MJ 42 x 4.5 x 450
Bolt weight 5.2 kg 5.6 kg
Quality 10.9 10.9
Wrench / Socket size 65 mm 65 mm
Bolt surface Bolt head / washer area and thread are Bolt head / washer area and thread are
slightly oiled with CLP220 gearbox oil slightly oiled with CLP220 gearbox oil
Quantity 96 96
Initial torque [Nm] 2 000 Nm ± 200 Nm 2 000 Nm ± 200 Nm
Pre-torque [Nm] 1 200 Nm ± 40 Nm 1 000 Nm ± 30 Nm
+ turning angle of [°] 120° ± 3° 120° ± 3°
Maximum torque [Nm] 5 800 Nm 5 800 Nm
Inspection torque 3 500 Nm 3 500 Nm
[Nm]
Table 1
The inspection torque provides only the indication Thereafter, it is essential to re-
if the bolted joint is loose.
check adjacent bolts with the in-
A bolt that can be turned when the inspection spection torque.
torque is applied, is not correctly tightened. In this
case it must be exchanged and refitted with the
pre-torque and the turning angle.
It is NOT permitted to fit the swing
bearing or individual bolts of the
bearing without the inspection
torque and put the machine into
operation in such condition.
3849418en - (00) Page 5.2 - 1
5.2 SWING BEARING
5.2.2 Components of swing bearing 5.2.3 Hardness gap, S -
The swing bearing is completely pre-assembled by The rings of the swing bearing have induction-
the manufacturer. This means that the supporting hardened races. Between the beginning and the
ring and the retaining ring are bolted together. end of the hardened race there is always an un-
hardened area designed as "hardness gap area"
The individual components of the swing bearing (soft spot) and identified by letter "S" stamped into
are listed in Table 2 and shown in Fig. 1. the metal. The swing bearing is to be installed in
such a way that the soft spots "S" of the individual
Item Designation rings are positioned outside the main area of load.
1 nose ring (with inside gear ring) Outer ring: supporting and retaining rings
2 retaining ring (bottom)
Two soft spot areas "S" on the supporting ring (3,
3 supporting ring (top) Fig. 1) and retaining ring (2, Fig. 1) are identified
4 row of axial rollers (top) by the manufacturer (, Fig. 2) stamped into the
metal). Both rings have been bolted together in
5 row of axial rollers (bottom) such a way that the soft spots are in alignment.
6 row of radial rollers (side) These two rings build the outer ring that is mount-
ed to the superstructure frame.
7 seal (bottom)
8 seal (top) markings on retaining ring and
supporting ring must be mounted at
A contact surface carbody / swing bearing
90° to the RIGHT regarding the longi-
contact surface superstructure frame / tudinal axis of the superstructure
B frame viewed in front direction (arrow,
swing bearing
Fig. 2).
dowel pin - superstructure frame / swing
C
bearing
Table 2
Fig. 2 -areas on outer ring
648589a
Fig. 1 Swing bearing components. Cross section drawing
648588
Page 5.2 - 2 3849418en - (00)
5.2 SWING BEARING
Inner ring (nose ring)
The nose ring, or inner ring (3, Fig. 1 & 1, Fig. 3) is
be mounted according to Fig. 3 with
toothed inside of the swing bearing. The pinions of regard to the longitudinal axis of the
the swing gearboxes mesh with the teeth to gener-
undercarriage.
ate the swing movement of the superstructure
(uppercarriage).
Soft spot area (, Fig. 3) on the nose ring is Note: If a machine is delivered from the factory,
stamped into the metal by the manufacturer. The the swing bearing is already mounted on the car-
nose ring is mounted on the carbody of the under- body.
carriage. The soft spot area "S on the nose ring
(toothed ring) must be aligned as shown in Fig. 3.
The arrow shows the front travel direction.
Fig. 3 Mounting position -area on inner ring 648590a
3849418en - (00) Page 5.2 - 3
5.2 SWING BEARING
5.2.4 Fitting the swing bearing onto 5) Insert all bolts and washers required for fas-
the undercarriage tening the swing bearing to the undercarriage
into the swing bearing. The washer side with
On a new machine, the swing bearing is already the countersink must point to the bolt head.
fitted to the carbody, when the machine leaves the
factory. During usual site assembly of the machine 6) Insert all bolts and washers required for fas-
only the uppercarriage must be installed. tening the superstructure frame onto the swing
bearing and secure them in the raised position
Note: If you must install the swing bearing on the with appropriate nuts. Do not forget to remove
undercarriage, strictly observe the following proce- the nuts during final assembly.
dures.
Note: The insertion of these bolts after mounting of
Preparation the swing bearing on the carbody (undercarriage)
is time-consuming and possible only if each bolt is
1) Carry out installation and removal of the swing passed one after the other through the assembly
bearing only after lifting the uppercarriage off opening in the left-hand rear area of the central
the machine. part of the carbody (undercarriage).
2) Unpack the swing bearing and perform a visual 7) Ensure that all exposed threads of the bolts
inspection for any damage. are protected properly from damage with a
short term corrosion protection.
3) Ensure that the contact surfaces of the swing
bearing are free of paint, grease and corrosion. 8) Install the dowel pin into the swing bearing
Remove all existing corrosion protection from outer ring.
the swing bearing mating surfaces and the bolt
mating surfaces with diluting agent Loctite® 9) Apply corrosion protection to the superstruc-
Teroson VR20. Ensure that the contact surfac- ture frame mating surface (1, Fig. 5) and the
es are metallically clean (no rust), dry and top of the swing bearing outer ring (2).
grease-free.
4) Attach the swing bearing to a suitable lifting
device. For this purpose, insert three eye bolts
M 42 x 4.5 spaced by 120° respectively into
the threaded bores provided (A, B, C, Fig. 4).
Fig. 5 Swing bearing cross section drawing 648601
Fig. 4 Position of lifting bolts 648615
Page 5.2 - 4 3849418en - (00)
5.2 SWING BEARING
Always refer to media No. EM028426
equirements for swing bearing mounted according to Fig. 3 regard-
Installation on certain Cat 60xx Hy- ing the longitudinal axis of the un-
draulic Mi dercarriage.
Assembly
1) Lubricate the washers, bolt head mating sur- The swing bearing must be fitted
faces and bolt threads with CLP 220 gear oil immediately after application of the
and insert them in the swing bearing inner ring sealant.
bores. Always consider hardening time
under different conditions as spec-
2) Ensure that the carbody has passed quality
ified in manufacturer documenta-
inspection including dimensional audit. If the
tion.
printed documentation is available from the in-
spection tool, save it for your future documen-
tation. 8) Insert the inner bolts one by one and tighten all
bolts manually to ensure they enter the
3) Ensure that the mating surface of the carbody threaded bores properly. If the resistance is
is free of paint, corrosion and not damaged. unexpectedly high or you even cannot install
the bolts, stop the assembly procedure and in-
4) Ensure that all threaded bores in the carbody spect the bolts and threads. Use threaded
are free of machining fluid, metal chips, debris gauges to ensure that both parts are manufac-
or corrosion protection. tured correctly.
5) Inspect 5 random threaded bores. Measure the Never tighten bolts with damaged
thread depth and inner diameter. Record this threads. Otherwise you´ll damage
data in your installation documentation. both parts of assembly. Improper
assembly causes wrong torque val-
6) Apply a thin and even layer of sealant Loctite® ues and compromises bolted joint
518 to the carbody mating surface with a integrity.
paint roller, hard brush or a flexible metal
scraper.
9) Number all bolts of the inner ring, starting at
Note: Leave approximately 10 12 mm around the the rear center of the carbody and proceeding
threaded bores. The sealant should not penetrate clockwise: 1, 2, 3, 4 , ...
the threaded bores of the undercarriage when the
swing bearing is placed on it. The penetration of a 10) To seat the swing bearing, apply initial torque
sealant into a threaded bore increases friction and of 2000 Nm (± 200 Nm) to all 96 bolts in a
thus causes incorrect tightening torque values. crosswise pattern, e.g. 1, 49, 25, 73, 2, 50, 26,
Make sure every
The use of a sealant increases the transfer of radi- torqued bolt is marked with a permanent
al forces and seals the contact surfaces from mois- marker, e.g., with a dot on the head. This
ture. This protects the machine mounting surfaces measure ensures that the swing bearing is fully
against corrosion. Since the sealant can transfer in contact with the opposite surface and any
only small tension forces, the separation of the adhesive applied too thickly is squeezed away.
glued swing bearing from the superstructure frame
and the carbody (undercarriage) is not difficult. 11) Torque all odd numbered bolts in the follow-
Fig. 6). The arrow
7) Align the swing bearing inner ring to the car- indicates the front travel direction.
body considering Fig. 3 and the following in-
formation: 12) Loosen one single (odd) bolt completely, then
apply pre-torque of 1200 Nm (± 40 Nm) to the
bolt. Additionally, tighten the bolt with a turning
angle of 120° (± 3°).
3849418en - (00) Page 5.2 - 5
5.2 SWING BEARING
13) Make sure the bolt is not over torqued, note Note: If torque procedure is not completed, or is
the maximum torque of 5.800 Nm. completed but out of the specified tolerance range,
14) Mark the torqued bolt in an appropriate way do not reuse the bolt (see EM028426).
(e.g., write o.k. on its head with a permanent
marker).
Fig. 6 Torque sequence for odd numbered bolts of inner ring 648591a
Page 5.2 - 6 3849418en - (00)
5.2 SWING BEARING
15) Torque all even numbered bolts in the follow- 18) Mark the torqued bolt in an appropriate way
ing ). (e.g., write o.k. on its head with a permanent
marker).
16) Loosen one single (even) bolt completely, then
apply pre-torque of 1200 Nm (± 40 Nm) to the Note: If torque procedure is not completed, or is
bolt. Additionally, tighten the bolt with a turning completed but out of the specified tolerance range,
angle of 120° (± 3°). do not reuse the bolt (see EM028426).
17) Make sure the bolt is not over torqued, note
the maximum torque of 5.800 Nm.
Fig. 7 Torque sequence for even numbered bolts of inner ring 648592a
3849418en - (00) Page 5.2 - 7
5.2 SWING BEARING
Seal replacement Replacement of inner bolts
If the seal (1, Fig. 8) is damaged, replace it as If it is necessary to replace individual inner bolts
follows: with the superstructure frame installed, the super-
structure base-plate is equipped with two fitting
1) Remove the old seal and check the area be- openings (3, Fig. 8). These openings are closed
tween retaining ring of the grease cover seal with covers (4) to prevent dirt from penetrating into
and undercarriage for tightness. the toothed area of the swing bearing.
2) If necessary, reseal the area with sealing com- To replace a bolt, it is necessary to position the
pound Loctite® 5203. superstructure frame in such a way, that one of the
fitting openings is exactly above the bolt head.
3) Put the new seal with a blunt chisel into the The bolts can be removed and installed only
retaining ring and glue the ends with adhesive through this fitting opening.
Cat Part No. 533-8478.
The items in Table 3 refer to Fig. 8.
Item Designation
1 Seal
2 Carbody
3 Fitting openings
4 Covers
5 Grease cover
6 Swing bearing
Table 3
Page 5.2 - 8 3849418en - (00)
5.2 SWING BEARING
Fig. 8 Swing bearing installation 648593a
3849418en - (00) Page 5.2 - 9
5.2 SWING BEARING
5.2.5 Fitting the uppercarriage onto Sealant
the swing bearing
When the superstructure frame is ready for mount-
ing apply a thin and even layer of sealant Loctite®
Before starting the procedure en- 518 on the whole contact surface (B, Fig. 1) of
sure that grease pinions are in- the swing bearing using a paint roller, hard brush
stalled. or a flexible metal scraper.
Note: If you must install the superstructure frame Apply the sealant in such a way that approx. 10
onto the swing bearing, strictly observe the follow- 12 mm around the threaded holes remain free from
ing procedures. it to prevent the sealant from being squeezed into
the threaded bores when the superstructure is
Condition of bolts placed on the swing bearing. The penetration of
the sealant into a threaded bore increases friction
The threads of the fastening bolts and the c ont act and thus leads to incorrect tightening torque val-
surfaces of the bolt heads must be slightly oiled. ues.
Note: For the installation of a new swing bearing, The use of a sealant increases the transfer of radi-
always use new bolts. al forces and seals the contact surfaces from mois-
ture. This protects the machine mounting surfaces
Contact surfaces from corrosion. Since the sealant can transfer only
small tension forces, the separation of the glued
Check the contact surfaces (B, Fig. 1) of the su- swing bearing from the superstructure frame and
perstructure frame and the swing bearing for dam- the carbody (undercarriage) is not difficult.
age and thoroughly clean them to remove paint
and grease with diluting agent Loctite® Teroson Fitting
VR20.
Ensure that the contact surfaces are metallically The "S" marks on retaining ring
clean (no rust), dry and grease-free. and supporting ring (outer ring)
must be mounted at 90° to the
Always refer to media No. EM028426 right-hand side regarding the lon-
equirements for swing bearing gitudinal axis of the superstructure
Installation on certain Cat 60xx Hy- viewed in front direction (Fig. 2).
This is also determined with the
dowel pin that is inserted into the
Threaded bores rear side of the superstructure
frame.
Clean thoroughly all threaded bores in the super-
structure frame and carefully checked them for dirt,
paint residues, rust and other visible defects. If
necessary, the rethread the threads. Install superstructure frame imme-
diately after application of sealant.
Back-lash of gear ring (gearbox pinion) Always consider hardening time
under different conditions as spec-
Since the position of the swing bearing regarding ified in manufacturer documenta-
the superstructure frame is fixed by a dowel pin (C, tion.
Fig. 5), an adjustment of the back-lash between
the swing bearing teeth and the swing gearbox
pinion is not required. 1) Align the swing bearing with the soft spot area
"S" in the correct position (Fig. 2).
To prevent damage of the swing bearing teeth and
the gearbox pinion during installation of the super- 2) Insert the bolts one by one and hand tighten all
structure frame, loosen the swing gearboxes and the bolts to ensure they enter the threaded
lift and support them to such an extent that the bores properly.
gearbox pinions do not protrude over the super-
structure base plate.
Page 5.2 - 10 3849418en - (00)
5.2 SWING BEARING
Be careful: the weight of each bolt is Initial torque
approximately 6 kg.
apply initial torque of 2000 Nm (± 200 Nm) to all 96
bolts. The torque is to be applied in packages of 6
3) Number all bolts of the outer ring, starting at
bolts, crosswise, in a pattern as shown in Fig. 8.
the rear center of the superstructure frame and
Mark each torqued bolt with a permanent marker,
proceeding clockwise. 1, 2, 3, 4, ... as shown
e.g., with a dot on the head.
in Fig. 9. The arrow indicates forward travel di-
rection. This measure ensures that the swing bearing is
fully in contact with the opposite surface and that
any sealant applied too thickly is being squeezed
away.
Fig. 9 Initial torque pattern 648594
3849418en - (00) Page 5.2 - 11
5.2 SWING BEARING
Torque odd numbered bolts 4) Mark the torqued bolt in an appropriate way
(e.g., write o.k. on its head with a permanent
1) Torque all odd numbered bolts in the following marker).
Fig. 10).
Note: If torque procedure is not completed, or is
2) Loosen one single (odd) bolt completely, then completed but out of the specified tolerance range,
apply pre-torque of 1000 Nm (± 30 Nm) to the do not reuse the bolt (see EM028426).
bolt. Additionally, tighten the bolt with a turning
angle of 120° (± 3°). Never loosen more than one bolt at a
time.
3) Make sure the bolt is not over torqued, note
the maximum torque of 5.800 Nm.
Fig. 10 Torque sequence for odd numbered bolts of outer ring 648595a
Page 5.2 - 12 3849418en - (00)
5.2 SWING BEARING
Torque even numbered bolts 4) Mark the bolt in an appropriate way (e.g. use a
permanent marker, writing o.k. on the head).
1) Torque all even numbered bolts in the follow-
ing ). Note: If torque procedure is not completed, or is
completed but out of the specified tolerance range,
2) Loosen one single (even) bolt completely, then do not reuse the bolt (see EM028426).
apply pre-torque of 1000 Nm (± 30 Nm) to the
bolt. Additionally, tighten the bolt with a turning Never loosen more than one bolt at a
angle of 120° (± 3°). time.
3) Make sure the bolt is not over torqued, notice
the maximum torque of 5.800 Nm.
Fig. 11 Torque sequence for even numbered bolts of outer ring 648596a
3849418en - (00) Page 5.2 - 13
5.2 SWING BEARING
Replacement of outer bolts Connection of central lubrication system
If it is necessary to replace individual outer bolts, Finally, connect the central lubrication system
the superstructure frame must be positioned in lines using chapters 3.3 Assembly manual and
such a way that the bolt in question is at the rear
between the swing gearboxes. A groove in the Manual. Check the central lubrication system
carbody base-plate permits the removal and the for proper operation to ensure adequate lubrica-
installation of the bolt. This grove is also available tion of the swing bearing.
in the front of the carbody.
Installation of lubrication pinions (optional)
The fitting opening in the carbody (undercarriage)
base-plate offers another possibility for bolt re- The machine can be equipped with optional lu-
placement. In this case, the superstructure must be brication pinions. These 2 pinions need to be
positioned in such a way that the fitting opening is mounted below the superstructure frame. The
at the rear on the left-hand side of the carbody pinions are driven by machine swing movement
base-plate exactly below the bolt head. and their purpose is to spread grease on the
teeth of the gear ring. The pinions are connect-
Installation of swing gearboxes ed to the central lubrication system. You can al-
The installation of the swing gearboxes is de- cation sy
scribed in chapter 7.3 Swing gearbox.
Note: If the lubrication pinion is mounted to the
When inserting the swing gearbox pinion into the machine, the regular grease supply connection
teeth of the swing bearing, you may have to turn through the superstructure base plates has to
the pinion to perfectly match the bore patterns of be plugged with an appropriate plug (G, Fig.12).
the gearbox fastening bolts in the superstructure
frame and the swing gearbox after engagement of
the pinion in the swing bearing teeth.
For this purpose, it is necessary to release the
spring-loaded multiple-disk brake of the swing
gearbox with a hand pump, to dismantle the swing
motor and to turn the gearbox input shaft accord-
ingly.
Always monitor swing brake re-
lease pressure with a pressure
gauge. The brake releases at 35
bar. Release pressure must not
exceed 50 bar, otherwise brake
seals will be damaged.
Installation of grease cover
Fasten the grease cover (5, Fig. 8) with the retain-
ing plates and the hex bolts to the superstructure
frame base-plate and fill it with grease in accord-
ance with the servicing and inspection instruc-
tions. Fig. 12 Grease supply connection through superstructure
base plate 648597
Page 5.2 - 14 3849418en - (00)
5.3 ENGINE INSTALLATION
5.3 Engine installation
This section is valid for engine
Caterpillar 3512 C.
5.3.1 Engine mounting
The components are listed in table 1. The numbers
refer to fig. 2 and 3. Quantities are valid for 1 en-
gine.
The diesel engines are elastically mounted. The
elastic elements (5) are preloaded with the bolts
(8) and nuts (11). The preload is defined by the
length of the spacer (7).
The tightening torque of pos. 8 is
Md = 1 700 Nm
Until coupling and pump gearbox are installed,
support the diesel engine on coupling side, e.g. Fig. 1 Fitted pairs of lock washers – 630918-01
with timber or bracket.
Install the pairs of lock washers as shown in fig. 1.
Check the required tightening torque regularly.
Check the components of the elastic mounting
regularly for damage. For check and maintenance
intervals see motor operation manual, section
‘maintenance schedule’.
3720601en - (02) Page 5.3 - 1
5.3 ENGINE INSTALLATION
Components of the elastic mounting
Weight
Ref. no. Quantity Designation Further remarks
[kg]
1 1 Bracket 249
2 2 Bracket 35
3 1 Bracket 1 292
4 16 Disc
5 16 Megiflex-disc
7 8 Sleeve
8 8 Hex. bolt M 30 x 240 – 10.9 Tightening torque Md = 1 700 Nm
9 6 Hex. Bolt 1-14NFX152 – 8.8 Tightening torque Md = 895 Nm
10 16 Pair of lock washer
11 8 Hex. nut M 30
14 6 Sleeve
15 8 Sleeve
16 4 Washer
18 8 Hex. bolt M 24 x 140 – 8.8 Tightening torque Md = 600 Nm
20 4 Hex. bolt M 20 x 130 – 10.9 Tightening torque Md = 490 Nm
21 4 Sleeve
22 4 Stud bolt M 20 x 70 – 10.9 Tightening torque Md = 350 Nm
23 4 Hex. nut M 20
Table 1
Page 5.3 - 2 3720601en - (02)
5.3 ENGINE INSTALLATION
8, 9, 18,
20, 22
Fig. 2 Engine mounting – 3720577-01
3720601en - (02) Page 5.3 - 3
5.3 ENGINE INSTALLATION
8, 9, 18,
20, 22
Fig. 3 Engine mounting – 3692998-02
Page 5.3 - 4 3720601en - (02)
5.3 ENGINE INSTALLATION
5.3.2 Radiator installation Tightening torques
The components are listed in table 2. Quantities Pos. 5 & 10: Md = 350 Nm
are valid for 1 radiator. The numbers refer to fig. 4 Pos. 8 & 11: Md = 41 Nm
– 9.
Check the required tightening torques regularly.
The radiators for the diesel engines are elastically Check the components of the elastic mounting
mounted. The elastic elements (6) are preloaded regularly for damage. For check and maintenance
with the bolts (10). intervals see motor operation manual, section
‘maintenance schedule’.
Install the radiator vertically without distortion. Dis-
tortion will reduce the service life. Adjust the radia-
tor at the upper elastic element (13) with bolt (14)
and nuts (18).
Components for radiator installation (fig. 4 – 9)
Weight
Ref. no. Quantity Designation Further remarks
[kg]
1 1 Radiator 400
2 9,4 m Sponge rubber 20 x 15 glued on
3 1 Plate 32
4 4 Sleeve
5 4 Hex. bolt M 20 x 130 – 8.8 – A3B Tightening torque Md = 350 Nm
6 2 Elastic element
7 8 Disc
8 8 Hex. bolt M10 x 20 – 8.8 – A3B Tightening torque Md = 41 Nm
9 2 Disk
10 2 Hex. bolt M20 x 140 – 8.8 – A3B Tightening torque Md = 350 Nm
11 2 Hex. bolt M10 x 110 – 8.8 – A3B Tightening torque Md = 41 Nm
12 2 Disk
13 2 Elastic element
14 2 Stud bolt M20 x 110 – 8.8 – A3B
15 2 Disk
16 2 Conical washer D23,2
17 2 Rounded washer
18 4 Hex. nut M20
19 2 Disc
Table 2 Quantities are valid for 1 radiator.
3720601en - (02) Page 5.3 - 5
5.3 ENGINE INSTALLATION
5, 8, 10, 11 2
Fig. 4 Radiator – installation – 3726393a-01
Page 5.3 - 6 3720601en - (02)
5.3 ENGINE INSTALLATION
Fig. 5 Installation of filling lines and vent lines to the expansion tank continously rising - 3726393a-02
3720601en - (02) Page 5.3 - 7
5.3 ENGINE INSTALLATION
Fig. 6 Radiator – installation – 3726393b-01
Page 5.3 - 8 3720601en - (02)
5.3 ENGINE INSTALLATION
Fig. 7 Radiator – installation – 3726393c-01
3720601en - (02) Page 5.3 - 9
5.3 ENGINE INSTALLATION
5, 8, 10, 11 2
Fig. 8 Radiator – installation – 3695543a-02
Page 5.3 - 10 3720601en - (02)
5.3 ENGINE INSTALLATION
5, 8, 10, 11 2
Fig. 9 Radiator – installation – 3720381a-03
3720601en - (02) Page 5.3 - 11
5.3 ENGINE INSTALLATION
5.3.3 Radiator fan installation Tightening torques
The fan wheel for the radiator is hydraulically driv- Pos. 85 & 99: Md = 79 Nm
en and mounted in the counterweight. Pos. 91: Md = 41 Nm
Pos. 102: Md = 390 Nm
The components are listed in table 3. Quantities Pos. 103: Md = 195 Nm
are valid for 1 radiator. The numbers refer to fig. 10
– 12. Check the required tightening torque regularly. For
check and maintenance intervals see motor opera-
tion manual, section ‘maintenance schedule’.
Components for radiator fan installation (fig. 10 - 12)
Weight
Ref. no. Quantity Designation Further remarks
[kg]
85 6 Hex. bolt M12 x 80 – 8.8 – A3B Tightening torque Md = 79 Nm
86 6 Sleeve
87 1 Fan wheel 140
88 1 Hub
89 1 Lid
90 1 Circlip
91 6 Hex. bolt M10 x 30 – 8.8 – A3B Tightening torque Md = 41 Nm
92 6 Disk
93 1 Lid
94 1 Hub
95 1 Sleeve
96 2 Bearing
97 1 Locking plate
98 1 Ring nut
99 4 Cyl. head screw M12 x 70 – 8.8 Tightening torque Md = 79 Nm
100 1 Bracket 86
101 1 Fan motor 78
102 4 Cyl. head screw M20 x 130 – 8.8 Tightening torque Md = 390 Nm
103 8 Hex. bolt M16 x 140 – 8.8 Tightening torque Md = 195 Nm
104 16 Sleeve
105 8 Hex. nut M16
106 1 Plate Glued on
107 1 Plate
Table 3 Quantities are valid for 1 fan.
Page 5.3 - 12 3720601en - (02)
5.3 ENGINE INSTALLATION
16, 20, 21,
106
22
Fig. 10 Fan wheel installation – 3726393d-01
3720601en - (02) Page 5.3 - 13
5.3 ENGINE INSTALLATION
103 106
Fig. 11 Fan drive installation – 3695543-01
Page 5.3 - 14 3720601en - (02)
5.3 ENGINE INSTALLATION
85, 99, 102
Fig. 12 Fan drive installation – 3694139-01
3720601en - (02) Page 5.3 - 15
5.3 ENGINE INSTALLATION
Page 5.3 - 16 3720601en - (02)
5.4 ENGINE COUPLING
5.4 Engine coupling
This section is valid for
coupling part no. 3 796 964
with engine Caterpillar 3512.
5.4.1 General
Between engine and pump gearbox an elastic
coupling is installed (Fig. 1 to 4).
5.4.2 Components
The components are listed in table 1. The numbers
refer to fig. 1 to fig. 4.
Components of coupling mounting
Ref. no. Quantity Designation Tightening torque Weight
[Nm] [kg]
1 1 Engine
2 1 Pump gearbox shaft
3 1 Outer part of coupling 19
4 1 Inner part of coupling 35
5 8 Rubber rollers
6 1 Washer
7 1 Assembly strap
8 12 Hex. bolt 5/8-11 UNC X2 1/4 Md = 195
9 2 Hex. bolt M16 x 40 – 8.8 – A3B Md = 210
Table 1
3721593en - (00) - 08.11 Page 5.4 - 1
5.4 ENGINE COUPLING
5.4.3 Dismantling
Insert the rubber rollers (5) into each of the sockets
Remove pump gearbox with inner coupling part of the inner part (4). Their largest diameter should
as described in chapter 7.4. lay at the deepest point of the pockets.
At pulling pump gearbox apart, secure the rubber Secure the rubber rollers with the assembly strap
rollers against falling down. (7). If the assembly strap is not available use a
string or tape secured with a slip knot. Ensure that
For dismantling the inner part of the coupling the loose end is placed to the gearbox side.
loosen the bolts (9). Remove washer and inner
part of the coupling off the shaft. Put the loose end of the assembly strap upwards.
For dismantling the outer part of the coupling
loosen the screws (fig. 1, pos. 8).
5.4.4 Assembly
Measure the axial play in each direction of the
engine crankshaft to ensure the engine thrust
bearings are not loaded. Record the result.
Disassemble coupling for mounting. Push the inner
part (4) with the rubber rollers (5) off the outer part
(3).
Clean contact surfaces. Contact surfaces must be
metallically clean (no rust), dry and grease-free.
Mount outer part (3) with slightly oiled bolts (8) to
the flywheel of the engine. Tighten the bolts in Fig. 2 Secure the rubber rollers - 642702-02
several stages crosswise until the required tighten-
ing torque is reached.
Grease the gearbox shaft.
The tightening torque of pos. 8 is:
Md = 195 Nm Push inner part (4) onto the pump gearbox shaft
(2) until the required depth d = 8 mm between
pump gearbox shaft and inner part of coupling is
reached (see fig. 4).
Tighten the inner part with washer and slightly
oiled bolts (9).
The tightening torque of pos. (9) is:
Md = 210
Fig. 1 Mounting the outer part – 3846433-02
Page 5.4 - 2 3721593en - (00) - 08.11
5.4 ENGINE COUPLING
Connecting inner and outer part Check correct mounting
For easy assembly moisten the pockets of the Rotate the complete assembly a few times to en-
outer part with soap solution (10% liquid soap with sure that there is no interference. If there is, the
90% water) or silicon spray. source must be identified and eliminated.
Push the pump gearbox with the inner part of the Motor damage can occur as a result of high axial
coupling into the outer part. Ensure that the arrows bearings of the crank shaft. Prior to comissioning
cast into both coupling parts are aligned (fig. 3). the system, ensure that the crank shaft has axial
Incorrect positioning of outer and inner part can play.
occur material damage.
Measure the axial play of the engine crankshaft
again. Measure in each direction to ensure the
engine thrust bearings are not loaded. Compare
with the result of first measuring before coupling
was fitted. The result should be the same.
On completion of assembly work,
all installation inspections pre-
scribed by the engine manufac-
turer (e.g. measurement of axial
play of the engine crankshaft) must
be carried out.
Fig. 3 Positioning of inner and outer part - 642703-02
Pass the loosen end of the assembly strap through
the upper hole of the gearbox bell housing.
When the rubber rollers are held in place by outer
and inner part of the coupling remove the assem-
bly strap (7).
Push inner and outer part further together.
Connect engine and pump gearbox as described
in chapter 7.4.
3721593en - (00) - 08.11 Page 5.4 - 3
5.4 ENGINE COUPLING
8, 9 d
Fig. 4 Engine coupling – 379694-01
Page 5.4 - 4 3721593en - (00) - 08.11
5.5 SWING GEARBOX - REMOVAL & INSTALLATION
5.5 Swing gearbox -
removal and installation
The removal and installation of the swing gearbox
is described in
chapter 7.3
2471306en - (00) Page 5.5 - 1
5.5 SWING GEARBOX - REMOVAL & INSTALLATION
Page 5.5 - 2 2471306en - (00)
5.6 PUMP GEARBOX - REMOVAL & INSTALLATION
5.6 Pump gearbox -
removal and installation
The removal and installation of the pump gearbox
is described in
chapter 7.4
2471307en - (00) Page 5.6 - 1
5.6 PUMP GEARBOX - REMOVAL & INSTALLATION
Page 5.6 - 2 2471307en - (00)
5.7 HYDRAULIC PUMPS - INSTALLATION
5.7 Hydraulic pumps - instal-
lation
The installation of the hydraulic pumps is de-
scribed in
chapter 8.7
2461189en - (00) Page 5.7 - 1
5.7 HYDRAULIC PUMPS - INSTALLATION
Page 5.7 - 2 2461189en - (00)
5.8 OIL COOLER - INSTALLATION
5.8 Oil cooler – installation Always ensure, that the oil cooler
sets are free of oil leaks and dirt, to
There are 4 oil cooler sets installed in the oil cooler
avoid overheating of the machine
module.
because of plugged coolers.
To each drive unit 2 oil coolers are allocated.
Do not damage the aluminium core
The items in table 1are referring to fig. 1, 2, 3. of the coolers when using pressure
cleaners.
The quantities in table 1 are related to one drive
unit.
Components for installation of the oil cooler
Ref. no. Quantity Designation Further remarks Weight [kg]
1 1 Oil cooler (2 segments) 400
2 2 Bracket 41 each
3 2 Fan motor Gear motor 53 each
4 2 Fan wheel 50 each
5 2 Rubber mounting
6 2 Rubber mounting
7 4 Hex. bolt M 16 x 120 – 8.8 Torque Md = 160 Nm
8 2 Washer
9 2 Stud bolt M 20 x 120 – 8.8 Torque Md = 220 Nm
10 6 Hex. nut M 20
11 4 Washer
12 20 Hex. bolt M 12 x 80 – 8.8 Torque Md = 71 Nm
13 8 Hex. bolt M 10 x 40 – 8.8 Torque Md = 41 Nm
14 8 Washer
15 8 Hex. nut M 10
16 16 Hex. bolt M 16 x 140 – 8.8 Torque Md = 160 Nm
17 32 Sleeve
18 16 Hex. nut M 16
19 8 Hex. nut M 12
20 8 Washer
21 2 Shaft nut
22 2 Locking plate
23 4 Roller bearing
24 2 Sleeve
25 2 Felt strip
26 2 Plate
27 2 Hub
28 6 Sleeve
3664872en - (00) – 11.05 Page 5.8 - 1
5.8 OIL COOLER - INSTALLATION
Ref. no. Quantity Designation Further remarks Weight [kg]
29 12 Hex. bolt M 8 x 20 – 8.8 Torque Md = 20,5 Nm
30 12 Washer
Table 1
Fig. 1 Hydraulic oil cooler – installation 3685900a
Page 5.8 - 2 3664872en - (00) – 11.05
5.8 OIL COOLER - INSTALLATION
29
Fig. 2 Fan mounting 3685963a
3664872en - (00) – 11.05 Page 5.8 - 3
5.8 OIL COOLER - INSTALLATION
7, 9, 10
Fig. 3 Hydraulic oil cooler – installation 3685900b
Page 5.8 - 4 3664872en - (00) – 11.05
5.8 OIL COOLER - INSTALLATION
7, 9, 10,
12, 13, 16,
29
Fig. 4 Hydraulic oil cooler – installation 3666566c
3664872en - (00) – 11.05 Page 5.8 - 5
5.8 OIL COOLER - INSTALLATION
Page 5.8 - 6 3664872en - (00) – 11.05
5.9 ROTOR - INSTALLATION
5.9 Rotor - installation The hydraulic systems of superstructure and un-
dercarriage are connected by means of the rotor.
This section is valid for rotor The rotor is mounted on the superstructure.
part no. 2101521
See also chapter 8.4.
Weight
Ref. no. Quantity Designation Further remarks
[kg]
1 1 Rotor 473
2 1 Control valve block, right 143
3 1 Control valve block, left 143
4 1 Brake valve block, right 26
5 1 Brake valve block, left 26
6 4 Valve
7 6 Hex. bolt M 20 x 120 - 8.8 - A3B Tightening torque = 350 Nm
8 6 Sleeve
9 1 Retainer 54
10 8 Retaining washer
11 4 Hex. bolt M 20 x 140 – 10.9 - A3B Tightening torque = 490 Nm
12 4 Hex. nut M 20 - 10 - A3B
Table 1
7, 11
Fig. 1 F: Front Rotor with travel valve blocks – 3663237-04
3663883en - (01) – 03.12 Page 5.9 - 1
5.9 ROTOR - INSTALLATION
7, 11
Fig. 2 Rotor installation - 3686066-02
Page 5.9 - 2 3663883en - (01) – 03.12
03.2019
6. Drive Unit
DRIVE UNIT
6. DRIVE UNIT
If required, engine or motor workshop manuals can
be ordered from Caterpillar Global Mining HMS
GmbH.
3720206en (00) Page 6 - 1
DRIVE UNIT
Page 6 - 2 3720206en (00)
03.2019
7. Gearboxes
CONTENTS
7. GEARBOXES
7.1 Introduction ...................................................................................... 7.1 - 1
7.1.1 Foreword ........................................................................... 7.1 - 1
7.1.2 Safety instructions ............................................................. 7.1 - 1
7.1.3 General .............................................................................. 7.1 - 5
7.1.4 Checking procedures ......................................................... 7.1 - 5
7.1.5 Hubs and bearings ............................................................ 7.1 - 6
7.1.6 Fitting of toroidal sealing rings ........................................... 7.1 - 8
7.2 Travel gearbox .................................................................................. 7.2 - 1
7.2.1 General .............................................................................. 7.2 - 1
7.2.2 Dismantling and installing the travel gearbox .................... 7.2 - 3
7.2.3 Disassembly- and Assembly Instructions .......................... 7.2 - 6
7.3 Swing gearbox .................................................................................. 7.3 - 1
7.3.1 General .............................................................................. 7.3 - 1
7.3.2 Dismantling and installing the swing gearbox .................... 7.3 - 2
7.3.3 Disassembly- and Assembly Instructions .......................... 7.3 - 4
7.4 Pump gearbox................................................................................... 7.4 - 1
7.4.1 General .............................................................................. 7.4 - 1
7.4.2 Dismantling and installing the pump gearbox .................... 7.4 - 2
7.4.3 Disassembly- and Assembly Instructions .......................... 7.4 - 4
3720207en (00) Page 7 - 1
CONTENTS
Page 7 - 2 3720207en (00)
7 GEARBOXES
7.1 Introduction 7.1.2 Safety instructions
7.1.1 Foreword Danger in case of non-observance of safety
instructions
This chapter contains important information on
gearboxes installed in Caterpillar excavators. This Caterpillar hydraulic
excavator has been built in
The assembly of a gearbox requires care and
accordance with state-of-the-art
cleanliness. Incorrectly installed components may
standards and the recognized
cause severe gearbox damage even in short
safety rules.
operation time.
However, operating the machine if
Wash gearbox housings clean with a detergent or a fault is suspected or has
diesel fuel if no detergent is available. Eliminate the occurred, or carrying out repair
damage to machined surfaces caused during work inexpertly
dismantling (e.g. scratches). Clean each part
before refitting and check for damage or wear and endangers the lives of people in
replace, if required. Before pressing in shafts, contact with it;
bearings, etc., oil the both parts.
damages the machine and other
Never use open flame for warming property.
up bearings or seats.
Stop the hydraulic excavator
Use hot plates, heating stoves or
immediately if you suspect or
similar equipment instead.
notice any damage to ensure the
safety of the operator, other people
To ensure the proper assembly always re-fit parts
or material property at the
assembled in a warm condition after their cooling
application area of the excavator.
down.
All components of Caterpillar
machines are perfectly tuned to
each other. Trouble-free operation
and a long service life can only be
achieved with original Caterpillar
spare parts.
2440570en - (02) Page 7.1 - 1
7 GEARBOXES
Rules for safety at work
Personnel Personnel
The machine must not be started Personal protective equipment and
by unauthorized people. safety working clothing:
Therefore secure and lock it. Wear a safety helmet, safety
Follow the accident prevention footwear and safety gloves.
regulations. Wear closely fitting working cloth-
Only specially trained and qualified ing when working on the machine.
personnel with the appropriate Loose, wide garments can catch on
technical knowledge can operate, machine parts and result in injury.
service or repair the hydraulic Personnel carrying out work at
excavator. greater heights must wear safety
If you lack such knowledge, harnesses. Always put on a tested
experienced personnel, e.g. from harness which is equipped with fall
Caterpillar, are to give you detailed arrestors and safety lines.
instructions. If you need assistance to carry out
The personnel must have read and the work, e.g. marshallers, clearly
understood the Operation and define the responsibilities of each
Maintenance Manual and in assistant beforehand. The
particular the chapter individual responsibilities are to be
carefully observed to ensure
‘Fundamental Safety Instructions.’ safety.
Only such people can start up the
machine after assembly work to
adjust the attachment.
Incorrect operation of the machine
or the equipment can result in life-
threatening situations.
During all works, always observe
the start and shut down
procedures described in the
Operation and Maintenance
Manual.
Page 7.1 - 2 2440570en - (02)
7 GEARBOXES
Tools and devices Before opening systems and units
(e.g. pipes, coolers, hydraulic
Tools, hoists, slings, trestles and reservoirs and accumulators)
other devices must be in a reliable, depressurize them properly.
safe state.
Open or remove protective devices
Metal splinters may cause injury on moving machine parts only
when you take in or out attachment when the drive unit is shut down
bolts. Therefore during this and secured against inadvertent
procedure use a brass or copper start.
mandrel and wear safety glasses.
Before re-commissioning install all
When climbing onto or off the protective devices.
machine use only ladders, steps,
platforms and handrails provided Before carrying out assembly work,
for this purpose. the machine and the equipment
must be secured against
Always keep ladders, steps and inadvertent movement, e.g. by
platforms in a non-slip state. placing the working equipment on
Remove any oil, grease, earth, clay, the ground.
snow, ice and other foreign matter
immediately.
Hydraulic and lubricating
Securing the working system:
equipment Always observe the safety
regulations applicable to the
Secure the machine and the product when handling oils,
working equipment against greases and other chemical
inadvertent and unauthorized start. substances.
Position working equipment on the
ground in such a way that it cannot Close open unused bores, pipe and
move when mechanical or hose connections so that they are
hydraulic connections become impermeable to pressure.
detached. Refill the hydraulic system with
Use hoists or other appropriate collected drain hydraulic oil only
support devices when you install, through the return flow filters.
remove or displace any equipment Dispose of waste oil without
or component. Thus you prevent polluting the environment.
them from inadvertent movements, Observe the correct working
slip or fall. sequence when fitting or replacing
components or equipment.
2440570en - (02) Page 7.1 - 3
7 GEARBOXES
Before carrying out works, Modifications of the machine
especially on the electrical system,
during which tools, spare parts, Unauthorized conversions or
etc. can contact electric cables, modifications of the hydraulic
always disconnect the battery: first excavator are forbidden for
the negative pole and then the reasons of safety.
positive pole. When reconnecting
the battery, connect first the Never modify the nominal pressure
positive and then the negative value of pressure relief valves
pole. without explicit approval from
Caterpillar. Do not remove the lead
Always replace defect, seals from pressure relief valves
mechanically pre-stressed and hydraulic accumulators.
components. Never open them!
The Service Manual contains no
information on such work.
Re-commissioning
The operating temperature of the
machine is high and the
consumables have at least the Before re-commissioning:
same temperature. Therefore take
care to avoid burns or scalds. Grease all lubricating points.
Be careful when handling acids, Check all oil levels and correct
e.g. battery acid. Acid splashes them if necessary.
may injure the eyes and the skin.
If the acid is splashed onto your Carry out function checks of all
skin, rinse it with plenty of clean repaired components.
running water and seek medical
care immediately.
Check all functions of the
excavator including brakes
If the acid is splashed in your eyes, during a test run. Release the
rinse thoroughly with running hydraulic excavator for re-
water and seek medical care commissioning only if all its
immediately. functions operate properly.
Never smoke when handling
flammable liquids.
Be careful with open flames and
unprotected light. Not only fuel but
also other consumables often have
a low flash point and catch fire
easily.
Page 7.1 - 4 2440570en - (02)
7 GEARBOXES
7.1.3 General 7.1.4 Check procedures
In addition to the Operation and Maintenance Noise
Manual and the Spare Parts Catalog, this
Service Manual contains information enabling the Mechanical gearboxes produce noise during
user of the Caterpillar hydraulic excavator to operation. The amount of noise depends on
safely operate, maintain and repair the machine in gearbox loading and condition. Normal gearbox
accordance with the specifications. noise consists of a spectrum of many different
frequencies. The greater part of it is produced by
The information in the Service Manual roller bearings and toothed wheels. If the bearings
corresponds to the standard technical specification or toothed wheels are damaged, you can hear
of the machine when it was delivered. rumbling and knocking or bumps and impacts. To
check the noise and identify its cause you can use
All sketches and drawings show general principles. a simple stethoscope.
They do not represent the actual design of the
machine and are not to be used for manufacturing.
Leaks
No reference is made to special versions.
Oil losses caused by leaks are dangerous for two
Special equipment is normally not considered. reasons: on the one hand, a lack of oil causes a
gearbox breakdown; on the other hand, it pollutes
Technical modifications, which are introduced after the environment.
delivery of the machine, may also be incorporated
in the machines which are already in operation. Therefore eliminate them immediately!
In this case, you can find the updated version of
the Service Manual on the Caterpillar website. Leaks can occur at sealing surfaces, joints and, in
most cases, at shaft outlets.
The Service Manual covers the information you
need when handling your excavator. However, You can quickly detect leaks with the help of leak-
detecting sprays. For this purpose, pressurize the
Caterpillar Global Mining HMS GmbH will be
gearbox slightly with compressed air and apply a
pleased to answer any questions you have on its
leak-detecting spray to the surface to check. If air
products. Please contact your local Caterpillar
bubbles appear, the component under check has
dealer or your Caterpillar subsidiary.
leaks.
Otherwise you can use oil absorbing contrasting
colours (e.g. Spanish white) which can detect even
the least amount of leaks. Larger amount of leaks
with the formation of droplets require immediate
corrective actions up to replacement of the seals.
2440570en - (02) Page 7.1 - 5
7 GEARBOXES
7.1.5 Removal and fitting procedures Removal of hubs
Removal of bearings Always apply the force "F" required for removal of a
hub (2, Fig. 2) from a housing (1) to the outer ring
Before removal of a bearing, clean the surfaces of the bearing with a properly fitting mandrel (4).
around it. Remove any bearing locking devices During the removal support the housing (1) with
(lock rings, screw locks, etc.). spacer blocks or a spacer bushing (3) as closely as
possible to the bearing. The spacers are to enable
To determine the tools and the dismantling the application of the reaction force "F 1" required
procedure and to find out how the bearing was for the movement of the hub to the housing (1).
installed, use the corresponding cross-sectional
drawing.
To easily remove outer bearing rings pressed in a
housing, heat the housing evenly.
To extract a bearing (5, Fig. 1) from a shaft (6), use
a special tool, e.g. a double- or triple-arm extractor
(7). Apply the force "F" required for extraction as
closely as possible to the bearing seat, i.e. to the
inner ring of the bearing. In this case, the reaction
force "F1" acts on the shaft (6) via the spindle of
the extractor (7).
Fig. 2 Removal of a hub – 630235
Fig. 1 Removal of a bearing – 630236
Page 7.1 - 6 2440570en - (02)
7 GEARBOXES
Fitting bearings Fitting hubs
Fit roller bearings so that after the assembly you When inserting a hub (2, Fig. 4) into a housing (1),
can see the component side with the inscription. ensure that the required fitting force "F" acts on the
outer ring of the bearing via a fitting mandrel (4).
The instructions for the removal of bearings on the Support the housing (1) as closely as possible to
previous page refer to the fitting of bearings as the bearing mounting point so that it absorbs the
well. reaction force "F 1".
When a bearing (11, Fig. 3) is mounted on a shaft
(12), the fitting force "F" acts on the inner ring of
the bearing via a fitting bushing (4). Support the
shaft end opposite to the mounting direction of the
bearing so that it absorbs the reaction force "F 1".
Fig. 4 Fitting a hub – 630237
Fig. 3 Fitting a bearing – 630239
2440570en - (02) Page 7.1 - 7
7 GEARBOXES
Fitting o-ring seals 7.1.6 Fitting toroidal sealing rings in
gearboxes
When fitting o-ring seals, e.g., rotary shaft seals (9,
Fig. 5), into a housing (8) use a suitable mandrel or Toroidal sealing rings (seals) are supplied by
fitting bushing (10) to prevent any damage to the Caterpillar by the meter.
sealing element.
To install these seals proceed as follows:
1. Place a seal into a groove and cut it off with a
slight tolerance.
2. Cut one end of the seal straight (not
diagonally) using a sharp and clean knife free
of grease.
3. Make a straight cut at the second end to cut
the seal to length. Cut it off 1 to 2 mm shorter
to give the toroidal sealing ring a slight pre-
stress in the groove (after gluing) and to
prevent it from leaving the groove during the
assembly. Too much pre-stress causes
twisting of the ring during the assembly and
increases leaks.
4. Glue the toroidal sealing ring together with
butt ends using adhesive Caterpillar part no. 0
861 732.
Fig. 5 Fitting an o-ring seal – 630238
5. Press the glued ends together by hand and
hold them for at least 30 seconds.
Always prevent any contact of the
adhesive with the skin. Otherwise
you risk skin detachment.
6. Insert the toroidal sealing ring into the groove.
If you have to install bushings or similar parts
over the seal, grease it before the installation.
Page 7.1 - 8 2440570en - (02)
7.2 TRAVEL GEARBOX
7.2 Travel gearbox Technical data
This section is valid for the travel gearbox Gearbox type: GFT 1300 N
Ratio: i = 458,5
part no. 3 683 483 Oil capacity: approx. 105 l
Pre-chamber: approx. 9 l
7.2.1 General Table 1
The travel gearbox forms one structural unit to-
gether with the travel motors and the parking
brakes. It is designed as a 3-stage planetary gear
system.
Components of chain wheel drive
Numbers refer to fig. 1 – 3.
Weight
Ref. no. Quantity Designation Further remarks
[kg]
1 1 Travel gearbox 7 100
2 1 Sprocket 3 350
3 2 Travel motor 90 each
6 52 12 point screw M 30 x 240 – 12.9 See chapter 4.7 Sprocket
Assembly torque 400 Nm
7 48 Hex. bolt M 36 x 360 – 12.9 Turning angle 120°
Testing torque 2800 Nm
8 48 Washer
9 2 Valve
10 2 Sealing ring
11 2 Bleeder
16 4 Plug
17 8 12 point screw M 20 x 50 – 10.9 – A3B Tightening torque = 490 Nm
18 8 Washer
25 3,9 m Sealing
Table 2 Quantities are valid for one chain wheel drive.
3664882en - (01) Page 7.2 - 1
7.2 TRAVEL GEARBOX
6, 7, 17
Fig. 1 Travel gearbox with sprocket – 3720403-02
7.2.2 Dismantling and installing the 8. Remove bolts (17) and remove travel motor.
travel gearbox
9. Repeat step 7 and 8 for the second motor.
Dismantling
10. Pick up gearbox with crane.
1. Remove gearbox cover.
11. Remove bolts (7) and lift gearbox out of the
2. Open the track chain as described in section frame.
4.3 ‘Track Chain’.
3. Start up one engine and move the machine
carefully until the sprocket is exposed. Secure
the track from slipping.
4. Remove the sprocket as described in section
4.7 ‘Sprocket’.
5. Drain gearbox oil out of gearbox and pre-
chambers acc. to ‘servicing instructions’.
6. Dismantle hydraulic lines of travel motors and
plug open connections. Collect escaping oil in
a suitable container.
7. Pick up first travel motor with crane.
Page 7.2 - 2 3664882en - (01)
7.2 TRAVEL GEARBOX
Installing 3. Installation of gearbox
1. Cleaning After installing the travel gearbox oil bolts (7) lightly
and tighten with a torquing tool (e.g. Plarad HPA
Clean contact surfaces between gearbox and un- 500). Tighten the bolts crosswise.
dercarriage frame with solvent (arrows B, fig. 3). All
traces of rust, paint and grease must be removed. Tightening torque = 1 500 Nm
2. Adhesive Tighten as many bolts as possible within 1-2 hours
to prevent the gearbox from moving. The gearbox
When the travel gearbox is ready for installation, is then in full contact and any adhesive applied to
apply adhesive to the entire contact surface of the thickly is squeezed away.
track frame (arrows B, fig. 3). Use a paint roller,
hard brush or plastic spatula to apply a thin, uni- The following procedure must then be observed in
form coating of the adhesive. clockwise direction (1st cycle):
Apply the adhesive with ca. 10 mm clearance from Unscrew the first bolt completely.
the threaded holes. Ensure that no adhesive can
be forced into the threaded holes when the gear- Pre-install this bolt with a
box is set down. Penetration of adhesive into a pre torque of 400 Nm.
threaded hole leads to increased friction and thus
to invalidation of the starting power data. Tighten the bolt completely with an
additional turning angle of 120°.
The use of an adhesive permits the transfer of
radial forces three times as high as the normal Mark the tightened bolt in a suitable way
force. Since the adhesive is capable of transferring (e.g. with paint).
only small tension forces, the separation of the
glued gearbox from the undercarriage frame is no In the same way every second bolt (no. 3, 5, 7,
problem. etc.) has to be loosened and then tightened with
the indicated pre torque plus turning angle.
Start gearbox installation as soon
as the adhesive has been applied. It is not permissible to loosen more
The adhesive starts hardening than one bolt at the same time.
when the metal surfaces have been All bolts must be tightened within a
joined without any air being admit- period of 8 hours maximum.
ted and is completed after approx.
12 hours at an ambient tempera-
ture of approx. 20°C.
After completion of the first step all bolts with even
The hardening process is initially numbers (no. 2, 4, 6, etc.) have to be tightened in
strongly delayed, so that the instal- the same way.
lation time can be extended to a
maximum of 8 hours. Seal the joint between gearbox and undercarriage
At temperatures below -15°C, acti- frame with silicon sealant (D, fig. 3).
vator must be sprayed onto the
second joining surface - the sur- Fill up borings (A, fig. 3) with silicon.
face with no adhesive.
3664882en - (01) Page 7.2 - 3
7.2 TRAVEL GEARBOX
4. Installation of sprocket 6. Filling with oil
See chapter 4.7 – Sprocket. Fill up travel gearbox and pre-chambers with oil as
specified in the operating instructions.
5. Installation of travel motor
7. Closing the track
1. Coat the shaft with mounting paste to pre-
vent fret corrosion and reduce friction. Bring track to a suitable position by moving the
excavator and close track (see chapter 4.3 ‘Track
2. Mount the travel motors. chain’).
3. Insert lightly oiled bolts (17) with washers.
Tighten with the required torque:
Tightening torque = 490 Nm
4. Connect hydraulic lines.
17
Fig. 2 Travel gearbox with hydraulic motors – 3730801-02
Page 7.2 - 4 3664882en - (01)
7.2 TRAVEL GEARBOX
B, C (adhesive)
6, 7 B, C
A, D (silicon)
Fig. 3 Drive unit – travel – 3730801-03
3664882en - (01) Page 7.2 - 5
7.2 TRAVEL GEARBOX
7.2.3 Disassembly & assembly in-
structions for the gearbox
Please refer to the attached manual:
GFT1300 SN 3683483
Page 7.2 - 6 3664882en - (01)
Demontage- Montageanleitung
Disassembly- Assembly Instructions RDE 77958-02-R/02.13
20.02.13
Fahrgetriebe / Propel Drive
Sach-Nr. / Part-No. 3683483
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 2/84
Inhaltsverzeichnis • Table of Contents
Kapitel Chapter
1. Einleitung 1. Preliminary Notes
1.1 Einführung 1.1 Introduction
1.2 Anziehdrehmomente 1.2 Tightening Torques
1.3 Werkzeuge und Zubehör 1.3 Tools and Accecories
1.4 Passungen 1.4 Fit´s
1.5 Verzahnungen (Zahnweite) 1.5 Gearing (base tangent length)
1.6 Toleranzen Lagerlaufbahn 1.6 Tolerances bearing race
Pos.9,10,12 Item 9,10,12
2. Teileliste 2. Parts List
Teileliste Getriebe Parts List Gearbox
3. Zeichnungen 3. Drawings
4. Demontage 4. Disassembly
4.1 Demontage Allgemein 4.1 Disassembly General
4.2 Demontage Bremse 4.2 Disassembly Brake
4.3 Demontage Stirnradstufe 4.3 Disassembly Spur Gear Stage
4.4 Demontage 4.4 Disassembly
Planetenstufen und Dichtungen Planetary Stages and Seals
5. Montage 5. Assembly
5.1 Montage Allgemein 5.1 Assembly General
5.2 Montage Stirnradstufe 5.2 Assembly Spur Gear Stage
(Teilmontage I) (Partial Assembly I)
5.3 Montage 5.3 Assembly
Planetenstufen und Dichtungen Planetary Stages and Seals
5.4 Montage Stirnradstufe 5.4 Assembly Spur Gear Stage
(Teilmontage II) (Partial Assembly II)
5.5 MontageVorstufe 5.4 Assembly Input Stage
5.6 Montage Bremse 5.6 Assembly Brake
6. Probelauf 6. Test Run
6.1 Prüfstandsaufbau 6.1 Test set-up
6.2 Ölversorgung 6.2 Lubrication
6.3 Drehzahl, Laufzeit und Prüflast 6.3 Speed, Running Time, Test Load
6.4 Thermische Werte 6.4 Thermal Parameters
6.5 Laufgeräusch 6.5 Running Noise
6.6 Dichtigkeitsprüfung 6.6 Tightness Testing
6.7 Funktionsprüfung der Bremsen 6.7 Hydraulic Brakes
6.8 Fremdkörper 6.8 Oil Contamination Test
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 3/84
1. Einleitung • 1. Preliminary Notes
1.1 Einführung 1.1 Introduction
Beachten Sie unbedingt die Sicherheitsbe- The safety instructions and the appropriate
stimmungen und die einschlägigen Unfallver- accident prevention instructions have abso-
hütungsvorschriften! lutely to be observed !.
Bauen Sie nur Originalersatzteile ein. Exclusively install original spares.
Lassen Sie das Öl ab. Drain the oil from the gearbox.
Verwenden Sie dabei geeignete Auffanggefäße. For this purpose use suitable containers.
Markieren Sie vor dem Trennen verschraubte und Mark all screwed and toothed parts before disas-
verzahnte Teile auf deren Lage und Position. sembling to ensure that all parts are in the same
running direction and position at reassembling.
Achten Sie darauf, daß kein Schmutz oder Fremd- Make sure that no dirt or foreign bodies are allowed
körper in das Getriebe gelangt. to enter the gearbox.
Ersetzen Sie beschädigte Teile sowie Dichtringe Replace damaged parts and all seals with new
durch neue Teile von Bosch Rexroth. BOSCH REXROTH parts.
Erwärmen Sie Lager vor der Montage nur auf Prior to assembly heat up bearings. Make sure to
Heizplatten bzw. im Wärmeofen. use a warming plate or in a heating furnace exclu-
Niemals mit direkter Flamme erwärmen. sively. Never heat up with a direct flame.
Vor dem Einbau sind alle beweglichen Teile sowie Oil all moving parts and seals prior to assembly.
Dichtringe einzuölen.
Unter Umständen ist der Farbanstrich des Getrie- In the event the paint coat of the gearbox has been
bes durch das Zerlegen und Zusammenbauen be- damaged as a result of disassembly / assembly
schädigt. Erneuern Sie deshalb den Farbanstrich, work, touch up or renew the paint coat as neces-
um das Getriebe gegen Korrosion zu schützen. sary to protect the gear against corrosion.
Führen Sie einen Probelauf des Getriebes durch. Carry out a test run of the gearbox.
(Beachten Sie hierzu Kapitel 6.) (See chapter 6.)
Alle Rechte bei Bosch Rexroth AG, auch für den Fall This document, as well as the data, specifications
von Schutzrechtsanmeldungen. Jede Verfügungsbefug- and other information set forth in it, are the exclusive
nis, wie Kopier- und Weitergaberecht, bei uns. property of Bosch Rexroth AG. It may not be repro-
duced or given to third parties without ist consent.
Die angegebenen Daten dienen allein der Produktbe- The data specified above only serve to describe the
schreibung. Eine Aussage über eine bestimmte Beschaf- product. No statements concerning a certain condition
fenheit oder eine Eignung für einen bestimmten Einsatz- or suitability for a certain application can be derived
zweck kann aus unseren Angaben nicht abgeleitet wer- from our information. The information given does not
den. Die Angaben entbinden den Verwender nicht von release the user from the obligation of own judgment
eigenen Beurteilungen und Prüfungen. Es ist zu beach- and verification. It must be remembered that our prod-
ten, dass unsere Produkte einem natürlichen Verschleiß- ucts are subject to a natural process of wear and ag-
und Alterungsprozess unterliegen. ing.
Hinweis! Note!
Die verwendeten Bilder müssen nicht der beschriebe- The photos may show other drive types than the de-
nen Getriebetype entsprechen. scribed one.
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 4/84
1. Einleitung • 1. Preliminary Notes
1.2 Anziehdrehmomente 1.2 Tightening Torques
Die Angabe der Anziehdrehmomente The specification of the tightening
erfolgt an den jeweiligen Positionen torques are at the relevant positions of
der Ersatzteilzeichnung. the parts drawing
(Pos. 48) Zylinderschraube (Item 48) Cylinder head bolt
M 20x80 M 20x80
Qualität 10.9 Quality 10.9
Anzugsmoment: 520 Nm Tightening Torque: 520Nm
Drehmomentschlüssel Torque Wrench
1.3 Werkzeuge und Zubehör 1.3 Tool and Accessories
- Anzugsvorrichtung für Wellenmutter - Mounting device for shaft nut
CAT Sach-Nr. 6003533 CAT Part-no. 6003533
- Maschinenbohrersatz - Machine drill bits
- Drehmomentschlüssel - Torque Wrench
- Kupferbolzen - Copper shaft
- Maulschlüssel - Open-enden spanner
- Abziehvorrichtung für Wälzlager - Bearing Puller
- Montagehilfe für Gleitringdichtung - Mounting device for face seal
- Meißel - Chisel
- Dorn - Punch
- Sicherungsringzangen - Tools for Snap Rings
- Plastik Hammer - Plastic Hammer
- Augenschrauben M12; M16; M20 - Eye Bolts M12; M16; M20
- Wälzlagerfett K3N 30 DIN 51502 - Roller bearing grease K3N 30 DIN 51502
z.B. „Klüberplex BE31-222“ e.g. „Klüberplex BE31-222“
- LOCTITE 270 - LOCTITE 270
- LOCTITE 480 - LOCTITE 480
- LOCTITE 128068 - LOCTITE 128068
- LOCTITE 406 - LOCTITE 406
- Schnellreiniger - Quick cleaner
z.B. LOCTITE 7061 oder „Liqui moly Artikel Nr: 3333“ e.g. LOCTITE 7061 or „Liqui moly Article Nr: 3333“
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 5/84
1. Einleitung • 1. Preliminary Notes
1.3 Werkzeuge und Zubehör 1.3 Tool and Accessories
Bild / fig. 1.3-01 Montagewerkzeug Pos. 44
Mounting Tool Item 44
Ø120
Bild / fig. 1.3-02 Montagewerkzeug Pos. 45
Mounting Tool Item 45
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 6/84
1. Einleitung • 1. Preliminary Notes
1.3 Werkzeuge und Zubehör 1.3 Tool and Accessories
Bild / fig. 1.3-03 Montagewekzeug Pos. 502
Mounting Tool Item 502
Hilfswerkzeug Montage Gleitringdichtung Pos.43
Auxiliary mounting tool face seal item 43
Bild / fig. 1.3-04
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 7/84
1. Einleitung • 1. Preliminary Notes
1.3 Werkzeuge und Zubehör 1.3 Tool and Accessories
Bild / fig. 1.3-05 Montagewerkzeug Pos. 20; 35
Mounting Tool Item 20; 35
Bild / fig. 1.3-06 Montagewerkzeug Pos. 19
Mounting Tool Item 19
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 8/84
1. Einleitung • 1. Preliminary Notes
1.4 Passungen 1.4 Fit´s
(siehe Bild 1.4-01) (note fig. 1.4-01)
Position Bohrung / Bore Welle / Shaft
A Ø 150 J6 Ø 85 k6
B Ø 140 J6 Ø 80 k6
C Ø 820,075 N7 Ø 536,625 n6
D Ø 820,075 N7 Ø 536,625 k6
E Ø 197,82 +0,075 Ø 140 j6
+0,049
F Ø 183,81 +0,075 Ø 130 j6
+0,049
G Ø 240 J6 Ø 160 m6
H Ø 240 J6 Ø 160 m6
I Ø 340 K6 Ø 220 m6
J Ø 177 +0,067 Ø 110 j6
+0,045
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 9/84
1. Einleitung • 1. Preliminary Notes
1.4 Passungen 1.4 Fit´s
(siehe Bild 1.4-01) (note fig. 1.4-01)
A B C D E F
G H J I
Bild / fig. 1.4-01
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 10/84
1. Einleitung • 1. Preliminary Notes
1.5 Verzahnungen 1.5 Gearing
(siehe Bild 1.5-02) (note fig. 1.5-02)
Pos. Zahnweite (w)/ base Messzähne / no. of Zähnezahl / no.
tangent length (w) teeth spanned of teeth
w min w max
A 43,638 43,684 3 17
B 160,882 161,003 10 81
C 99,271 99,389 4 27
D 113,889 113,979 8 42
E 127,238 127,314 5 28
F 154,283 154,386 6 42
G 154,52 154,601 6 38
H 99,709 99,804 4 22
Messbeispiel / Example for measurement Bild / fig. 1.5-01
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 11/84
1. Einleitung • 1. Preliminary Notes
1.5 Verzahnungen 1.5 Gearing
(siehe Bild 1.5-02) (note fig. 1.5-02)
A C E G
B D F H
Bild / fig. 1.5-02
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 12/84
1. Einleitung • 1. Preliminary Notes
1.6 Toleranzen Lagerlaufbahn 1.6 Tolerances bearing race
Planetenrad Pos. 9,10,12 Planet gear Item 9,10,12
(siehe Bild 1.6-01) (note fig. 1.6-01)
Bild / fig. 1.6-01
Planetenrad / Pos. Ø Lagerlaufbahn Toleranz
Planet gear / item Ø bearing race Tolerances
+0,075
9 197,82 +0,049
+0,075
10 183,81 +0,049
+0,067
12 177 +0,045
Zustand „neu“ / condition „new“
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 13/84
2. Teilelisten • 2. Parts List
2 Teilelisten 2 Parts Lists
Inhaltsverzeichnis Table of Contents
Teileliste Parts List 1
- Sach-Nr. / Part-No. 3683483 - Sach-Nr. / Part-No. 3683483
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 14/84
2. Teilelisten • 2. Parts List
Teileliste / Parts List
Matnr./Material No :
Produkt/Product : 3683483
Zeichnungs-Nr./Drawing No :
Menge Pos. Benennung Bestell-Nr.
Quantity Item Designation Part-No
1,000 001 Tragachse
Spindle
1,000 002 Stützring
Supporting ring
1,000 003 Hohlrad
Ring gear
1,000 004 Hohlrad
Ring gear
1,000 005 Deckel
Cover
1,000 006 Planetensteg
Planet carrier
1,000 007 Planetensteg
Planet carrier
1,000 008 Planetensteg
Planet carrier
7,000 009 Planetenrad
Planet gear
4,000 010 Planetenrad
Planet gear
3,000 012 Planetenrad
Planet gear
1,000 013 Sonnenrad
Sun gear
1,000 014 Sonnenradwelle
Sun gear shaft
1,000 015 Sonnenradwelle
Sun gear shaft
2,000 016 Antriebswelle
Input shaft
1,000 017 Stirnrad
Spur wheel
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 15/84
2. Teilelisten • 2. Parts List
Teileliste / Parts List
Matnr./Material No :
Produkt/Product : 3683483
Zeichnungs-Nr./Drawing No :
Menge Pos. Benennung Bestell-Nr.
Quantity Item Designation Part-No
1,000 018 Wellenmutter
Shaft nut
1,000 019 Mitnehmer
Coupler
2,000 020 Dichtungsring
Seal ring
1,000 022 Gehäusescheibe
Housing washer
1,000 023 Scheibe
Disk
1,000 024 Anlaufscheibe
Locating ring
2,000 025 Mitnehmer
Coupler
1,000 027 Gehäuse
Housing
1,000 028 Flansch
Flange
1,000 029 Zwischenring
Spacer ring
2,000 030 Kegelrollenlager
Tapered roller bearing
7,000 031 Zylinderrollenlager
Cylindrical roller bearing
4,000 032 Zylinderrollenlager
Cylindrical roller bearing
3,000 033 Zylinderrollenlager
Cylindrical roller bearing
2,000 034 Rillenkugellager
Ball bearing
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 16/84
2. Teilelisten • 2. Parts List
Teileliste / Parts List
Matnr./Material No :
Produkt/Product : 3683483
Zeichnungs-Nr./Drawing No :
Menge Pos. Benennung Bestell-Nr.
Quantity Item Designation Part-No
2,000 035 Zylinderrollenlager
Cylindrical roller bearing
2,000 036 Zylinderrollenlager
Cylindrical roller bearing
1,000 037 Rillenkugellager
Ball bearing
6,000 040 Anlaufscheibe
Locating ring
2,000 041 Zylinderstift
Cylindrical dowel pin
4,000 042 Zylinderschraube
Socket head cap screw
1,000 043 Gleitringdichtung
Face seal
2,000 044 Radialdichtring
Radial shaft seal ring
4,000 045 Radialdichtring
Radial shaft seal ring
13,000 048 Zylinderschraube
Socket head cap screw
36,000 049 6kt-Schraube
Hex head bolt
11,000 050 6kt-Schraube
Hex head bolt
18,000 051 Zylinderschraube
Socket head cap screw
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 17/84
2. Teilelisten • 2. Parts List
Teileliste / Parts List
Matnr./Material No :
Produkt/Product : 3683483
Zeichnungs-Nr./Drawing No :
Menge Pos. Benennung Bestell-Nr.
Quantity Item Designation Part-No
13,000 052 HV-Scheibe
HV-washer
2,000 060 Sicherungsring
Snap ring
3,000 061 Sicherungsring
Snap ring
1,000 062 Sicherungsring
Snap ring
1,000 063 Sicherungsring
Snap ring
6,000 064 Sicherungsring
Snap ring
1,000 068 Sicherungsring
Snap ring
4,000 070 Sicherungsring
Snap ring
4,000 071 Sicherungsring
Snap ring
1,000 072 Sicherungsring
Snap ring
3,000 073 Sicherungsring
Snap ring
7,000 074 Sicherungsring
Snap ring
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 18/84
2. Teilelisten • 2. Parts List
Teileliste / Parts List
Matnr./Material No :
Produkt/Product : 3683483
Zeichnungs-Nr./Drawing No :
Menge Pos. Benennung Bestell-Nr.
Quantity Item Designation Part-No
3,000 075 O-Ring
O-ring
6,500 076 Rundschnur
Chord
6,000 078 Rundschnur
Chord
5,000 081 Verschlußschraube
Screw plug
5,000 082 Dichtring
Seal ring
1,000 083 Entlüfter
Vent
1,000 084 Dichtring
Seal ring
1,000 085 Verschlußschraube
Screw plug
1,000 086 Dichtring
Seal ring
2,000 087 Zylinderstift
Cylindrical dowel pin
1,000 088 Scheibe GFT
Disk
2,000 089 O-Ring
O-ring
2,000 090 6kt-Schraube
Hex head bolt
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 19/84
2. Teilelisten • 2. Parts List
Teileliste / Parts List
Matnr./Material No :
Produkt/Product : 3683483
Zeichnungs-Nr./Drawing No :
Menge Pos. Benennung Bestell-Nr.
Quantity Item Designation Part-No
1,000 094 Dichtung
Gasket
1,000 095 Ölstandsauge
Oil level sight gauge
2,000 105 Verschlußstopfen
Cap plug
2,000 501 Lamellenträger
Disk housing
2,000 502 Kolben
Piston
2,000 503 Scheibe
Disk
2,000 504 Scheibe
Disk
16,000 505 Innenlamelle
Inner disk
18,000 506 Außenlamelle
Outer disk
44,000 507 Druckfeder
Pressure spring
2,000 508 Sicherungsring
Snap ring
44,000 509 Druckfeder
Pressure spring
2,000 512 Quadring
Piston seal
4,000 513 Stützring6461662
Supporting ring
2,000 514 Quadring
Piston seal
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 20/84
2. Teilelisten • 2. Parts List
Teileliste / Parts List
Matnr./Material No :
Produkt/Product : 3683483
Zeichnungs-Nr./Drawing No :
Menge Pos. Benennung Bestell-Nr.
Quantity Item Designation Part-No
4,000 515 Stützring
Supporting ring
2,000 517 Stopfen
Plug
14,000 519 Zylinderschraube
Socket head cap screw
2,000 520 Sicherungsring
Snap ring
4,000 526 Verschlußschraube
Screw plug
2,000 527 Entlüfter
Vent
2,000 528 Dichtring
Seal ring
2,000 511 O-Ring
O-ring
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 21/84
3. Zeichnungen • 3. Drawings
3 Zeichnungen 3 Drawings
Inhaltsverzeichnis Table of Contents
Einbauzeichnung 3683483 Installation drawing 3683483
Ersatzteilzeichnung 3683483 Spare parts drawing 3683483
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 22/84
4. Demontage • 4. Disassembly
4.1 Demontage Allgemein 4.1 Disassembly General
Getriebe nur im ausgebautem Zustand Make sure to remove the gearbox from the
demontieren. machine frame before disassembling it.
Für die Demontage des Fahrgetriebes sind folgende Prior to disassembly prepare the propel drive as follows:
Vorarbeiten erforderlich:
Beachten Sie hierzu auch Kapitel 8 der Also observe chapter 8 of Operating In-
Betriebsanleitung. structions.
Getriebeöl ablassen. Lösen Sie dafür Ver-
schlußschrauben (Pos. 81, 82, 526). Verwen- Remove screw plugs (item 81, 82, 526) and
drain oil.
den Sie dabei geeignete Auffanggefäße. Use suitable oil drain pan.
Ölinhalt: Lube oil volume:
- Planetengetriebe: ca. 105 l - planetary gear: approx. 27,74 US gall.
- Stirnradvorstufe: ca. 9 l - spur gear stage: approx. 3,8 US gall.
- Bremskammer: ca. 0,3 l - brake housing: approx. 0,08 US gall.
Beim Ölwechsel des Bremsraumes muß Make sure that the brake is released for oil
die Bremse gelüftet sein. change of inner brake housing area.
Hydraulikmotoren vom Getriebe abbauen
und Anschlüsse mit Hilfsdeckel verschlie- Dismount hydraulic motors from gearbox
and seal ports with provisional cover.
ßen.
Achten Sie beim Transport auf eine ausrei- When handling the equipment make sure the
chende Tragkraft des Kranes. carrying capacity of the crane is adequate.
Getriebegewicht ohne Motoren: Weight without motors:
ca. 7100 kg. appr. 15620 lbs
Stellen Sie sicher, daß das abgesetzte
Getriebe seine Lage nicht ändern kann. Make sure the set down gearbox rests
immovably.
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 23/84
4. Demontage • 4. Disassembly
4.2 Demontage Bremse 4.2 Disassembly Brake
Lassen Sie das Öl ab. Verwenden Sie dabei geeignete
Auffanggefäße.
Drain the oil from the gearbox. For this purpose use
suitable containers.
Bild / fig. 4.2-01
Motorbefestigungsschrauben lösen.
Hydromotor und O-Ring (Pos. 511) entfernen.
Remove motor mounting bolts.
Remove hydraulic motor and o-ring (item 511).
Bild / fig. 4.2-02
Mit geeigneter Vorrichtung Scheibe (Pos. 503) gegen
die Federn (Pos. 507+509) pressen.
Press disk (item 503) with suitable fixture against
springs (item 507+509).
Bild / fig. 4.2-03
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 24/84
4. Demontage • 4. Disassembly
4.2 Demontage Bremse 4.2 Disassembly Brake
Sicherungsring (Pos. 520) entfernen.
Remove snap ring (item 520)
Bild / fig. 4.2-04
Über die Vorrichtung die Federn (Pos. 507+509) ent-
spannen.
Release springs (item 507+509) with fixture.
Bild / fig. 4.2-05
Scheibe (Pos. 503) entfernen.
Remove disk (item 503).
Bild / fig. 4.2-06
Federn (Pos. 507+509) herausnehmen.
Remove pressure springs (item 507+509).
Bild / fig. 4.2-07
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 25/84
4. Demontage • 4. Disassembly
4.2 Demontage Bremse 4.2 Disassembly Brake
Kollben (Pos. 502) entfernen.
Kolben über Bremslüftanschluß M16x1,5 mit Lüftdruck
beaufschlagen (p= ca. 18bar).
Remove piston (item 502).
Release piston with a release pressure of p= appr.
18bar (brake release port M16x1,5).
Bild / fig. 4.2-08
Zylinderschrauben (Pos. 519) lösen und entfernen.
Loosen and remove socket head cap screws (item 519).
Bild / fig. 4.2-09
Lamellenträger (Pos. 501) entfernen.
Remove disk housing (item 501).
Bild / fig. 4.2-10
O-Ring (Pos. 89) entfernen.
Remove o-ring (item 89).
Bild / fig. 4.2-11
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 26/84
4. Demontage • 4. Disassembly
4.2 Demontage Bremse 4.2 Disassembly Brake
Lamellenpaket (Pos. 505+506) herausnehmen.
Remove brake disks (item 505+506).
Bild / fig. 4.2-12
Quad- und Stützringe (Pos. 512 + 513, 514 + 515) ent-
fernen.
Remove piston seals and supporting rings (items 512 +
513, 514 + 515).
Bild / fig. 4.2-13
Sicherungsring (Pos. 508) entfernen.
Remove snap ring (item 508).
Bild / fig. 4.2-14
Scheibe (Pos. 504) entfernen.
Remove disk (item 504).
Bild / fig. 4.2-15
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 27/84
4. Demontage • 4. Disassembly
4.2 Demontage Bremse 4.2 Disassembly Brake
Sicherungsring (Pos. 70) entfernen.
Remove snap ring (item 70).
Bild / fig. 4.2-16
Mitnehmer (Pos. 25) entfernen.
Remove coupler (item 25).
Bild / fig. 4.2-17
Sicherungsring (Pos. 70) entfernen.
Remove snap ring (item 70).
Bild / fig. 4.2-18
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 28/84
4. Demontage • 4. Disassembly
4.3 Demontage Stirnrad / 4.3 Disassembly Spur Gear Stage
Verschlußschrauben (Pos. 81, 82) lösen und Öl ablas-
sen.
Ölauffangbehälter verwenden!
Remove screw plugs (item 81, 82) and drain oil.
Oil drain pan to be used!
Bild / fig. 4.3-01
6kt-Schrauben (Pos. 50, 90) lösen und entfernen.
Loosen and remove hex head bolts (item 50, 90).
Bild / fig. 4.3-02
Komplett montiertes Gehäuse (Pos. 27, 28) abbauen.
Dismantle complete mounted housing (item 27, 28).
Bild / fig. 4.3-03
1x O-Ring (Pos. 76) entfernen.
Remove 1x o-ring (item 76).
Bild / fig. 4.3-04
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 29/84
4. Demontage • 4. Disassembly
4.3 Demontage Stirnrad / 4.3 Disassembly Spur Gear Stage
Zylinderstifte (Pos. 41) austreiben.
Expel cylindrical dowel pins (item 41).
Bild / fig. 4.3-05
Zylinderschrauben (Pos. 42) lösen und entfernen.
Loosen and remove socket head cap screws (item 42).
Bild / fig. 4.3-06
Flansch (Pos. 28) aus Einpaß von Gehäuse (Pos. 27)
entfernen.
Remove flange (item 28) out of fit from housing (item
27).
Bild / fig. 4.3-07
2ten O-Ring (Pos. 76) entfernen.
nd
Remove 2 o-ring (item 76).
Bild / fig. 4.3-08
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 30/84
4. Demontage • 4. Disassembly
4.3 Demontage Stirnrad / 4.3 Disassembly Spur Gear Stage
Antriebswelle (Pos. 16) ausbauen. Lagerinnenringe von
Zylinderrollenlager (Pos. 35+36) verbleiben auf der
Antriebswelle.
Dismantle inuit shaft (item 16). The bearing inner rings
of cylindrical roller bearings (item 35+36) remains on the
input shaft.
Bild / fig. 4.3-09
Stirnrad (Pos. 17) entfernen.
Remove spur wheel (item 17).
Bild / fig. 4.3-10
1x Rillenkugellager (Pos. 34) von Stirnrad (Pos. 17)
abziehen.
Pull off 1x ball bearing (item 34) from spur wheel (item
17).
Bild / fig. 4.3-11
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 31/84
4. Demontage • 4. Disassembly
4.3 Demontage Stirnrad / 4.3 Disassembly Spur Gear Stage
Ggf. 2tes Rillenkugellager (Pos. 34) von Stirnrad (Pos.
17) abziehen.
nd
If necessary pull of 2 ball bearing (item 34) from spur
wheel (item 17).
Bild / fig. 4.3-12
Falls erforderlich Aussenringe mit Wälzkörpern der
Zylinderrollenlager (Pos. 35+36) aus den Aufnahmeboh-
rungen entfernen.
If necessary remove outer rings of bearings with rolling
elements from cylindrical roller bearings (item 35+36).
Bild / fig. 4.3-13
Sicherungsring (Pos. 60) entfernen.
Remove snap ring (item 60).
Bild / fig. 4.3-14
Dichtungsring (Pos. 20) mit Wellendichtringen (Pos. 45)
ausbauen.
Dismantle the seal ring (item 20) with mounted radial
shaft sealing rings (item 45).
Bild / fig. 4.3-15
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 32/84
4. Demontage • 4. Disassembly
4.3 Demontage Stirnrad / 4.3 Disassembly Spur Gear Stage
Wellendichtringe (Pos. 45) aus Aufnahmebohrung von
Dichtungsring (Pos. 20) entfernen.
Remove the shaft sealing rings (item 45) out of the loca-
tion hole of seal ring (item 20).
Bild / fig. 4.3-16
O-Ring (Pos. 75) entfernen.
Remove o-ring (item 75).
Bild / fig. 4.3-17
Sonnenrad (Pos. 14) entnehmen.
Remove sun gear shaft (item 14).
Bild / fig. 4.3-18
Zylinderschrauben (Pos. 51) lösen und entfernen.
Loosen and remove socket head cap screws (item 51).
Bild / fig. 4.3-19
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 33/84
4. Demontage • 4. Disassembly
4.3 Demontage Stirnrad / 4.3 Disassembly Spur Gear Stage
Hohlrad (Pos. 4) ausbauen.
Dismantle ring gear (item 4).
Bild / fig. 4.3-20
Sicherungsring (Pos. 73) lösen.
Loosen snap ring (item 73).
Bild / fig. 4.3-21
Plantenräder bestehend aus (Pos. 12, 33, 40, 64) von
Planetenbolzen abziehen.
Falls erforderlich Abziehvorrichtung verwenden.
Pull off plantet gears consisting of (items 12, 33, 40, 64)
from planet bolts.
If necessary use a bearing puller.
Bild / fig. 4.3-22
Sicherungsring (Pos. 61) entfernen.
Remove snap ring (item 61).
Bild / fig. 4.3-23
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 34/84
4. Demontage • 4. Disassembly
4.3 Demontage Stirnrad / 4.3 Disassembly Spur Gear Stage
Planetensteg (Pos. 8) ausbauen.
Dismantle planetary carrier (item 8).
Bild / fig. 4.3-24
Sicherungsring (Pos. 62) entfernen.
Remove snap ring (item 62).
Bild / fig. 4.3-25
Hilfswerkzeug (Bild 1.3-06) auf Mitnehmer (Pos. 19)
montieren und mit Sicherungsring (Pos. 61) befestigen.
Mount a suitable fixture (fig 1.3-06) onto coupler (item
19) and secure with snap ring (item 61).
Bild / fig. 4.3-26
Montiertes Hilfswerkzeug in Kran einhängen und Mit-
nehmer (Pos. 19) unter Kettenspannung aus dem Ge-
triebe entfernen.
Hilfswerkzeug entfernen.
Hang suitable fixture onto a crane and create slight
string tension. Remove coupler (item 19) out of gearbox.
Remove suitable fixture.
Bild / fig. 4.3-27
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 35/84
4. Demontage • 4. Disassembly
4.3 Demontage Stirnrad / 4.3 Disassembly Spur Gear Stage
Sicherungsring (Pos. 61) entfernen.
Remove snap ring (item 61).
Bild / fig. 4.3-28
Rillenkugellager (Pos. 37) ggf. mit Abziehvorrichtung
von Mitnehmer (Pos. 19) abziehen.
Pull off ball bearing (item 37) if necessary with a pulling-
off device from coupler (item 19).
Bild / fig. 4.3-29
Sicherungsring (Pos. 61) entfernen.
Remove snap ring (item 61).
Bild / fig. 4.3-30
Anlaufscheibe (Pos. 24) entfernen.
Achtung!
Anlaufscheibe ist mit LOCTITE 270 gesichert.
Remove locating ring (item 24).
Attention!
Locating ring is secured with LOCTITE 270.
Bild / fig. 4.3-31
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 36/84
4. Demontage • 4. Disassembly
4.3 Demontage Stirnrad / Disassembly Spur Gear Stage
O-Ring (Pos. 75) entfernen.
Remove o-ring (item 75).
Bild / fig. 4.3-32
Wellendichtringe (Pos. 44) aus Aufnahmebohrung von
Tragachse (Pos. 1) ausbauen.
Dismantle the radial shaft sealings (item 44) out of the
location hole of spindle (item 1).
Bild / fig. 4.3-33
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 37/84
4. Demontage • 4. Disassembly
4.4 Demontage Plantenstufen und Dichtungen /
4.4 Disassembly Planetary Stages and Seals
Verschlußschrauben (Pos. 81, 82) lösen und Öl ablas-
sen.
Ölauffangbehälter verwenden!
Remove screw plugs (item 81, 82) and drain oil.
Oil drain pan to be used!
Bild / fig. 4.4-01
Deckelbefestigungsschrauben (Pos. 49) lösen.
ACHTUNG!
Schrauben sind mit LOCTITE 270 gesichert, vor dem
Lösen mit Flamme erwärmen.
Loosen and cover fixing bolts (item 49).
CAUTION!
Bolts are fastened with LOCTITE 270. Heat with flame
prior to loosing.
Bild / fig. 4.4-02
Abdrückgewinde für Deckel (Pos. 5) benutzen.
Use threaded holes for cover (item 5):
Bild / fig. 4.4-03
2x Augenschrauben M16 in Deckel (Pos. 5) einschrau-
ben, in Kran einhängen und Deckel mit O-Ring (Pos. 76)
entfernen.
Insert 2x eyebolts M 16 into cover (item 5), hang onto
crane and remove cover with o-ring (item 76).
Bild / fig. 4.4-04
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 38/84
4. Demontage • 4. Disassembly
4.4 Demontage Plantenstufen und Dichtungen /
4.4 Disassembly Planetary Stages and Seals
Sonnenradwelle (Pos. 15) entnehmen.
Take out sun gear shaft (item 15).
Bild / fig. 4.4-05
Kompletten Planetenträger der Vorstufe entnehmen.
Remove complete pre-stage.
Bild / fig. 4.4-06
Sicherungsring (Pos. 74) lösen.
Loosen snap ring (item 74).
Bild / fig. 4.4-07
Plantenräder bestehend aus (Pos. 9, 31) von Planeten-
bolzen abziehen.
Falls erforderlich Abziehvorrichtung verwenden.
Pull-off plantet gears consisting of (items 9, 31) from
planet bolts.
If necessary use a bearing puller.
Bild / fig. 4.4-08
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 39/84
4. Demontage • 4. Disassembly
4.4 Demontage Plantenstufen und Dichtungen /
4.4 Disassembly Planetary Stages and Seals
Stützringbefestigungsschrauben (Pos. 48) lösen.
Loosen supporting ring fixing bolts (item 48).
Bild / fig. 4.4-09
Hohlrad (Pos. 3) mit O-Ring (Pos. 78) aus Einpaß von
Stützring (Pos. 2) entfernen.
Remove ring gear (item 3) with o-ring (item 78) from fit
of supporting ring (item 2).
Bild / fig. 4.4-10
Sicherungsring (Pos. 68) lösen.
Remove snap ring (item 68).
Bild / fig. 4.4-11
Scheibe (Pos. 23) entnehmen.
Remove disk (item 23).
Bild / fig. 4.4-12
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 40/84
4. Demontage • 4. Disassembly
4.4 Demontage Plantenstufen und Dichtungen /
4.4 Disassembly Planetary Stages and Seals
Planetensteg (Pos. 6) entfernen.
Remove planet carrier (item 6).
Bild / fig. 4.4-13
Bohren Sie im Bereich der Zylinderstifte (Pos. 87) ent-
sprechend der nebenstehenden Skizze ein Loch in die
Wellenmutter (Pos. 18).
Start drilling one side of the shaft nut (item 18) close to
one of the dowel pins (item 18) according to the at-
tached sketch.
50
Bild / fig. 4.4-14
Setzen Sie neben diese Bohrung eine weitere und wie-
derholen Sie den Vorgang zum AußenØ der Wellenmut-
ter (Pos. 18) hin, bis diese Seite ausgebohrt ist.
Wiederholen Sie die Arbeitsschritte um 180° versetzt an
der Wellenmutter.
Drill another hole next to the one you just completed and
keep working your way towards the shaft nut (item 18)
outside diameter until that side is drilled out.
Go 180° degrees around the shaft nut and start the
processe over again.
Bild / fig. 4.4-15
Wellenmutter (Pos. 18) mit Hilfe eines Meißels im Be-
reich der Ausbohrungen sprengen und von der Trag-
achse (Pos. 1) entfernen.
Use a chisel to open up the shaft nut (item 18) where
you completed your drilling and remove it from the spin-
dle (item 1).
Bild / fig. 4.4-16
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 41/84
4. Demontage • 4. Disassembly
4.4 Demontage Plantenstufen und Dichtungen /
4.4 Disassembly Planetary Stages and Seals
Reinigen Sie das Gewinde auf der Tragachse (Pos. 1)
mit einer Drahtbürste von allen Materialien.
Clean area from all materials and wire brush the threads
clean on the spindle (item 1).
Bild / fig. 4.4-17
Oberes Kegelrollenlager (Pos. 30) mit Flamme erwär-
men und entfernen.
Heat upper tapered roller bearing (item 30) with flame
and remove.
Bild / fig. 4.4-18
Stützring (Pos. 2) von Tragachse (Pos. 1) abheben.
Lift-off supporting ring (item 2) from the spindle (item 1).
Bild / fig. 4.4-19
Rollenkäfig des unteren Kegelrollenlagers (Pos. 30)
gleichmäßig am Umfang mit Flamme erwärmen.
Heat roller cage of lower tapered roller bearing (item 30)
on it´s circumference evenly.
Bild / fig. 4.4-20
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 42/84
4. Demontage • 4. Disassembly
4.4 Demontage Plantenstufen und Dichtungen /
4.4 Disassembly Planetary Stages and Seals
Unteres Kegelrollenlager (Pos. 30) entfernen.
Remove lower tapered roller bearing (item 30).
Bild / fig. 4.4-21
Dichtung (Pos. 94) von Tragachse (Pos. 1) entfernen.
Remove gasket (item 94) from the spindle (item 1).
Bild / fig. 4.4-22
Scheibe (Pos. 88) von Tragachse (Pos. 1) entfernen.
Remove disk (item 88) from spindle (item 1).
Bild / fig. 4.4-23
Gleitringdichtungshälfte (Pos. 43) aus Tragachse (Pos.
1) entfernen.
Remove the face seal half (item 43) from the spindle
(item 1).
Bild / fig. 4.4-24
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 43/84
4. Demontage • 4. Disassembly
4.4 Demontage Plantenstufen und Dichtungen /
4.4 Disassembly Planetary Stages and Seals
Gleitringdichtungshälfte (Pos. 43) aus Stützring (Pos. 2)
entfernen.
Remove the face seal half (item 43) from the supporting
ring (item 2).
Bild / fig. 4.4-25
Stützring (Pos. 2) abheben.
Lift-off the supporting ring (item 2).
Bild / fig. 4.4-26
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 44/84
5. Montage • 5. Assembly
5.1 Montage Allgemein 5.1 Assembly General
Vor der Montage sind folgende Ver- Prior to assembly the following in-
schleißprüfungen erforderlich: spections of wear and tear are re-
quired:
Prüfen Sie auf Verschleiß:
- axiale Anlaufflächen
Check for wear:
- axial contact faces
- Paßsitze (siehe Kapitel 1.5) - machined seats (note chapter 1.5)
- Gewindebohrungen - threaded holes
- Verzahnungen (siehe Kapitel 1.6) - gear parts (note chapter 1.6)
- Lagerlaufbahn (siehe Kapitel 1.7) - bearing race (note chapter 1.7)
Prüfen Sie alle Dichtflächen auf:
- Beschädigung
Check all sealing faces for:
- damage
Prüfen Sie die Lager auf:
Check the bearings for:
usability (excessive clearance)
- Verwendbarkeit (Spiel übermäßig) -
- visuelle Prüfung - visual appearance
Prüfen Sie die Verzahnung auf:
- Zahnausbrüche
Check the gear teeth for:
- tooth breakage
- Pittings - pitting
- Rißbildung - cracks
- Gratbildung - burrs
- Verschleiß - wear
MET-L-CHEK / Rißprüfung:
1. Entfetten und reinigen der Prüfteile
(z.B. Spezialreiniger NPU).
1. Degrease and clean the parts to be
checked (e.g. special cleaner NPU).
2. Aufbringen des Eindringmittel
(z.B. DYE VP 30).
2. Apply penetrant fluid (e.g. DYE VP 30).
Reaction time approx. 5-30 minutes
Einwirkzeit ca. 5-30 Min. je nach Tem- depending on temperature and mate-
peratur und Werkstoff. rial.
3. Werkstück von Eindringmittel reini-
gen.
3. Clean off penetrant fluid from work
piece (e.g. with special cleaner NPU or
(z.B. mit Spezialreiniger NPU oder water). Allow surface to dry.
Wasser)
Oberfläche trocknen lassen.
4. Den Entwickler „weiß“, hauchdünn
auftragen. Nach einer kurzen Trocken-
4. Apply a very thin layer of developer
„white“. After a short drying time, the
zeit tritt aus den Fehlstellen das Ein- penetrant fluid (e.g. DYE VP 30)
dringmittel (z.B. DYE VP 30) aus und emerges from the defective spots and
bildet mit dem weißen Entwickler ei- creates a red contrast to the white
nen roten Kontrast. developer.
5. Inspektion – rote Linien im weißen
Entwicklerfeld zeigen Risse oder Über-
5. Inspection – red lines on the white
developer field indicate cracks or
lappungen an, während punktförmige overlappings, while point shaped col-
Farbaustritte als Poren zu werten sind. our patterns can be rated as blow-
holes and pores.
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 45/84
5. Montage • 5. Assembly
5.1 Montage Allgemein 5.1 Assembly General
Vor der Montage des Getriebes sind alle Teile zu säu-
bern.
Clean all parts before assembly of the gearbox.
Bild / fig. 5.1-01
Wellenmutter (Pos.18) vorab auf Tragach-
se (Pos. 1) testen.
Achtung!
Schrauben Sie zur Überprüfung des Ge-
windes an der Tragachse die Wellenmutter
einmal über die gesamte Gewindelänge
auf. Danach entfernen Sie die Wellenmut-
ter. Eventuell mit Gewindefeile nacharbei-
ten.
Test in advance the Shaft nut (item 18) on
the Spindle (item 1).
Attention!
In order to check the Spindle thread, screw
the Shaft nut the whole length of the
thread. Then remove the Shaft nut. Even-
tually touching up with a Thread file.
Bild / fig. 5.1-02
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 46/84
5. Montage • 5. Assembly
5.2 Montage Stirnradstufe (Teilmontage I)
5.2 Assembly Spur Gear Stages (Partial Assembly I)
Wellendichtringe (Pos. 44) am Außendurchmesser
gleichmäßig mit LOCTITE 128068 bestreichen.
Evenly apply coat of LOCTITE 128068 to the outer ring
of radial sealing (item 44).
Bild / fig. 5.2-01
Neue Wellendichtringe (Pos. 44) einsetzen und mit
ensprechendem Hilfswerkzeug (Bild 1.3-01) zur Anlage
bringen.
Auf richtige Einbaulage der Dichtlippen achten!
Insert new radial shaft sealing rings (item 44) and mount
them with an adequate device (fig. 1.3-01) for proper
axial seat.
Observe correct mounting position of sealing lips!
Bild / fig. 5.2-02
Einbauraum zwischen den Dichtlippen mit Wälzlagerfett
(K3N-30 DIN 51502) füllen.
Fill mounting space between sealing lips with roller
bearing grease (K3N-30 DIN 51502).
Bild / fig. 5.2-03
Neuen O-Ring (Pos. 75) in entsprechende O-Ring Nut
von Mitnehmer (Pos. 19) einsetzen.
O-Ring fetten.
Insert a new o-ring (item 75) into the adequate o-ring
groove of coupler (item 19).
Grease the o-ring.
Bild / fig. 5.2-04
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 47/84
5. Montage • 5. Assembly
5.2 Montage Stirnradstufe (Teilmontage I)
5.2 Assembly Spur Gear Stages (Partial Assembly I)
Anlaufscheibe (Pos. 24) am Außendurchmesser mit
LOCTITE 480 bestreichen.
Evenly apply coat of LOCTITE 480 to the outer ring of
locating ring (item 24).
Bild / fig. 5.2-05
Anlaufscheibe (Pos. 24) in Mitnehmer (Pos. 19) einset-
zen.
Auf richtige Einbaulage der Fase achten!
Insert locating ring (item 24) into coupler (item 19).
Observe correct mounting position of chamfer!
Bild / fig. 5.2-06
Neuen Sicherungsring (Pos. 61) in entsprechende Nut
von Mitnehmer (Pos. 19) einsetzen.
Insert a new snap ring (item 61) into suitable groove of
spindle (item 19).
Bild / fig. 5.2-07
Rillenkugellager (Pos. 37) auf 120°-130°C erwärmen
und auf Mitnehmer (Pos. 19) montieren.
Abkühlzeit von ca. 60 min beachten.
Achtung!
Entsprechende Sicherheitshandschuhe tragen.
Heat ball bearing (item 37) to approx. 120°-130°C and
mount it onto coupler (item 19) Observe a time of re-
frigation of approx. 60 min.
Caution!
Wear suitable safety gloves.
Bild / fig. 5.2-08
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 48/84
5. Montage • 5. Assembly
5.2 Montage Stirnradstufe (Teilmontage I)
5.2 Assembly Spur Gear Stages (Partial Assembly I)
Rillenkugellager (Pos. 34) mit neuem Sicherungsring
(Pos. 61) sichern.
Secure ball bearing (item 34) with a new snap ring (item
61).
Bild / fig. 5.2-09
Stirnrad (Pos. 17) vormontieren:
Rillenkugellager (2x Pos. 34) auf ca. 120°-130°C er-
wärmen und auf Stirnrad (Pos. 17) montieren.
Achtung!
Entsprechende Sicherheitshandschuhe tragen.
Pre-assembling of spur wheel (item 20):
Heat ball bearing (2x item 34) to approx. 120°-130°C
and mount onto coupler.
Caution!
Wear suitable safety gloves.
Bild / fig. 5.2-10
Neuen Sicherungsring (Pos. 63) in entsprechende Nut
von Stirnrad (Pos. 17) einsetzen.
Mount a new snap ring (item 63) into the suitable groove
of spur wheel (item 17).
Bild / fig. 5.2-11
Vormontierten Mitnehmer (Pos. 19) mit Hilfswerkzeug
(siehe Bild 1.3-06) in Getriebe einsetzen.
Insert pre-assembled coupler (item 19) with mounting
tool (note fig. 1.3-06) into drive.
Bild / fig. 5.2-12
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 49/84
5. Montage • 5. Assembly
5.2 Montage Stirnradstufe (Teilmontage I)
5.2 Assembly Spur Gear Stages (Partial Assembly I)
Hilfswerkzeug aus Bild 1.3-01 entfernen und Mitnehmer
mit Hilfswerkzeug z.B. Kupferdorn eintreiben.
Remove mounting tool from fig. 1.3-01 and drive in
coupler with mounting tool.
Bild / fig. 5.2-13
Neuen Sicherungsring (Pos. 62) in entsprechende Nut
von Tragachse (Pos. 1) einsetzen.
Insert a new snap ring (item 62) into suitable groove of
spindle (item 1).
Bild / fig. 5.2-14
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 50/84
5. Montage • 5. Assembly
5.3 Montage Plantenstufen und Dichtungen /
5.3 Assembly Planetary Stages and Seals
Gleitringdichtungs – O-Ring mit Spiritus benetzen.
Wet face seal o-ring with spirit of wine cleaner.
Bild / fig. 5.3-01
Gleitringdichtungshälfte (Pos. 43) unter gleichmäßigen
Druck auf die Dichtfläche in die Aufnahmebohrung der
Tragachse (Pos. 1) einsetzen und mit geeignetem
Hilfsmittel (Bild 1.3-04) O-Ring der Gleitringdichtung in
die entsprechende Aufnahmebohrung einpressen.
Install one half of the face seal (item 43) into cavity of
spindle (item 1) with even pressure around it´s circum-
ference. Use a suitable device (fig. 1.3-04) to press the
face seal o-ring into cavity of spindle.
Bild / fig. 5.3-02
Scheibe (Pos. 88) auf Tragachse (Pos. 1) montieren
(auf richtige Einbaulage „Fase“ achten / Scheibe bei
Bedarf erwärmen.
Mount disk (item 88) onto spindle (item 1).
Observe correct installation position “chamfer” / heat
disk if necessary.
Bild / fig. 5.3-03
Dichtung (Pos. 94) auf Tragachse (Pos. 1) montieren.
Dichtung spannen.
Mount gasket (item 94) onto spindle (item 1).
Tension the gasket.
Bild / fig. 5.3-04
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 51/84
5. Montage • 5. Assembly
5.3 Montage Plantenstufen und Dichtungen /
5.3 Assembly Planetary Stages and Seals
Dichtung (Pos. 94) einfetten.
Grease gasket (item 94).
Bild / fig. 5.3-05
Die 2 Außenringe der Kegelrollenlager (Pos. 30) in flüs-
sigen Stickstoff auf -180°C abkühlen.
Use nitrogen to cool down the two outer rings of tapered
roller bearings (item 30) to aprox. -180°C.
Bild / fig. 5.3-06
Außenring von unteren Kegelrollenlager in Stützring
(Pos. 2) montieren (auf richtige axiale Anlage prüfen)
Achtung!
Entsprechende Sicherheitshandschuhe tragen.
Insert outer ring of lower tapered roller bearing into
supporting ring (item 2) (check for proper axial seat).
Caution!
Wear suitable safety gloves.
Bild / fig. 5.3-07
Gleitringdichtungs – O-Ring mit Spiritus benetzen.
Wet face seal o-ring with spirit of wine cleaner.
Bild / fig. 5.3-08
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 52/84
5. Montage • 5. Assembly
5.3 Montage Plantenstufen und Dichtungen /
5.3 Assembly Planetary Stages and Seals
Obere Gleitringdichtungshälfte in Stützring (Pos. 2)
einsetzen.
Install upper half of the face seal (item 43) into cavity of
supporting ring (item 2).
Bild / fig. 5.3-09
Mit geeignetem Hilfsmittel (Bild 1.3-04) O-Ring der
Gleitringdichtung in die entsprechende Aufnahmeboh-
rung einpressen.
Use a suitable device (Fig. 1.3-04) to press the face
seal o-ring into cavity of spindle.
Bild / fig. 5.3-10
Innenring und Rollenkäfig vom unteren Kegelrollenlager
(Pos. 30) auf ca. 120-130°C erwärmen und auf Trag-
achse (Pos. 1) montieren (auf richtige axiale Anlage
prüfen).
Achtung!
Entsprechende Sicherheitshandschuhe tragen.
Heat inner ring and roller cage of below tapered roller
bearing to approx. 120°-130°C and mount onto spindle
(item 1) (check for proper axial seat).
Caution!
Wear suitable safety gloves.
Bild / fig. 5.3-11
Gleitflächen der Gleitringdichtung (Pos. 43) mit ölge-
tränktem Wildledertuch säubern
Gleitflächen der Gleitringdichtung (Pos. 43) mit Ölfilm
versehen.
Clean the sliding surfaces of the face seal (item 21) with
an oil tinctured suede towel.
Wet the sliding surfaces of the seal (item 20) with oil.
Bild / fig. 5.3-12
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 53/84
5. Montage • 5. Assembly
5.3 Montage Plantenstufen und Dichtungen /
5.3 Assembly Planetary Stages and Seals
Vormontierten Stützring auf Tragachse (Pos. 1) montie-
ren.
Install pre-assembled supporting ring onto spindle
(item 1).
Bild / fig. 5.3-13
Oberen Außenring von Kegelrollenlager (Pos. 30) in
Stützring (Pos. 2) montieren (auf richtige axiale Anlage
prüfen).
Insert outer ring of lower upper roller bearing (item 30)
into supporting ring (item 2) (check for proper axial seat.
Bild / fig. 5.3-14
Oberen Innenring mit Rollenkranz von Kegelrollenlager
(Pos. 30) auf ca. 120°-130°C erwärmen und auf Trag-
achse (Pos. 1) montieren.
Vor weiterer Montage Abkühlzeit von ca. 15min. einhal-
ten.
Achtung!
Entsprechende Sicherheitshandschuhe tragen.
Heat upper rin with roller cage of tapered roller bearing
(item 30) to approx. 120°-130°C and mount onto spindle
(item 1).
Allow cooling time of approx. 15 minutes before contin-
ning assembly.
Caution!
Wear suitable safety gloves.
Bild / fig. 5.3-15
Rundschnur (Pos. 78) in die entsprechende Nut von
Stützring (Pos. 2) einlegen.
Rundschnurenden mit LOCTITE 480 verkleben.
Rundschnur fetten.
Insert a new chord (item 78) into the suitable groove of
supporting ring (item 2).
Stick the endings of chord with LOCTITE 480.
Grease the chord.
Bild / fig. 5.3-16
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 54/84
5. Montage • 5. Assembly
5.3 Montage Plantenstufen und Dichtungen /
5.3 Assembly Planetary Stages and Seals
Gewinde der Tragachse (Pos. 1) und der Wellenmutter
(Pos. 18) entfetten (z.B. LOCTITE 7061 oder „Liqui moly
Artikel Nr: 3333“).
Degrease threads of spindle (item 1) and shaft nut (item
18) (e.g. with LOCTITE 7061 or „Liqui moly Article Nr:
3333“).
Bild / fig. 5.3-17
Gewinde der Wellenmutter (Pos. 18) gleichmäßig mit
LOCTITE 270 bestreichen.
Evenly apply coat of LOCTITE 270 to thread of shut nut
(item 18).
Bild / fig. 5.3-18
Wellenmutter (Pos. 18) mit Ringkerbe nach oben (sicht-
bar) montieren.
Mount shaft nut (item 18) with groove on upper side
(visible).
Bild / fig. 5.3-19
Aufnahmebohrung von Gehäusescheibe (Pos. 22) mit
LOCTITE 480 bestreichen.
Apply coat of LOCTITE 480 to the cavity of housing
washer (item 22).
Bild / fig. 5.3-20
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 55/84
5. Montage • 5. Assembly
5.3 Montage Plantenstufen und Dichtungen /
5.3 Assembly Planetary Stages and Seals
Scheibe (Pos. 22) mit sichtbarer Ölschmiernut montie-
ren.
Mount washer (item 22) with the lubrication groove on
upper side (visible).
Bild / fig. 5.3-21
Wellenmutter (Pos. 18) von Hand bis Anlage voranzie-
hen.
Pretighten shaft nut (item 18) by hand up to the contact
surface.
Bild / fig. 5.3-22
CAT Montage Werkzeug 6003533 zum Anziehen der
Wellenmutter aufsetzen.
Die Nabe muss während des Anziehvorganges fest
gehalten werden.
Ein Hydraulik Aggregat ist Vorraussetzung.
Mount CAT mounting Tool 6003533 to tighten the shaft
nut.
The hub must restrain during the tightening process.
A hydraulic power aggregate is provided.
Bild / fig. 5.3-23
ACHTUNG!
Das Hohlrad ist während des Anziehvorganges der
Wellenmutter mehrfach in eine Richtung zu drehen.
- Wellenmutter (Pos. 18) mittels Vorrichtung mit ei
nem Anziehdrehmoment von 65000 Nm anziehen.
- Die anschließende Aushärtezeit für den Kleber be
trägt 24 Std.
ATTENTION!
While adjusting the bearing unit via the shaft nut the
ring gear has to be turned in one direction several
times!
- Tighten shaft nut (item 18) by using an adequate
device with a tightening torque of 65000 Nm.
- The LOCTITE setting time equals 24 hours at room
temperature.
Bild / fig. 5.3-24
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 56/84
5. Montage • 5. Assembly
5.3 Montage Plantenstufen und Dichtungen /
5.3 Assembly Planetary Stages and Seals
Zylinderstift (Pos. 87) einsetzen.
Insert cylindrical dowel pin (item 87).
Bild / fig. 5.3-25
Planetensteg (Pos. 6) in Kran einhängen und auf Steck-
verzahnung von Tragachse (Pos. 1) montieren.
Hang planet carrier (item 6) onto crane and mount it
onto the shaft spline of spindle (item 1).
Bild / fig. 5.3-26
Scheibe (Pos. 23) einlegen.
Insert disk (item 23).
Bild / fig. 5.3-27
Neuen Sicherungsring (Pos. 68) montieren.
Mount a new snap ring (item 68).
Bild / fig. 5.3-28
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 57/84
5. Montage • 5. Assembly
5.3 Montage Plantenstufen und Dichtungen /
5.3 Assembly Planetary Stages and Seals
Dichtfläche Stützring / Hohlrad mit Flächendichtung
LOCTITE 128068 bestreichen.
Apply sealing surface of supporting ring / ring gear with
LOCTITE 128068.
Bild / fig. 5.3-29
Das auf ca. 70°C erwärmte Hohlrad (Pos. 3) auf Zent-
riersitz von Stützring (Pos. 2) montieren.
Achtung!
Entsprechende Sicherheitshandschuhe tragen.
Heat the ring gear (item 3) to approx. 70°C and mount it
onto the centering of supporting ring (item 2).
Caution!
Wear suitable safety gloves.
Bild / fig. 5.3-30
Zylinderschrauben (Pos. 48) in Gewindebohrung von
Stützring (Pos. 2) einsetzen und mit erforderlichem
Anzugsmoment anziehen.
Insert socket head cap srews (item 48) into threaded
holes of supporting ring (item 2) and tighten them to a
proper torque.
Bild / fig. 5.3-31
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 58/84
5. Montage • 5. Assembly
5.3 Montage Plantenstufen und Dichtungen /
5.3 Assembly Planetary Stages and Seals
Montage Zylinderrollenlager (Pos. 31) Hauptstufe
- Zylinderrollenlager (Pos. 31) aus der Transportverpa-
ckung direkt in die Aufnahmebohrung von Planetenrad
(Pos. 9) drücken.
Achtung!
- Kontrollieren Sie ob der Sicherungsring vom Zylinder-
rollenlager in die entsprechende Nut eingeschnappt ist.
Assembly of cylindrical roller bearing (item 31) main-
stage:
- push cylindrical roller bearing (item 31) directly out of
the transport packing into the locating hole of the planet
gear (item 9).
Attention!
- Make sure that the snap ring is in the right position of
the snap ring groove.
Bild / fig. 5.3-32
Achtung!
Bei der Montage der vormontierten Planetenräder ist
darauf zu achten das der größere Planetenlagerradius
zum Planetensteg zeigt.
Attention!
Observe during assembly of the pre-assembled planet
gears that the larger radius on the bearing bore is orien-
tated towards the planet carrier.
Bild / fig. 5.3-33
Vormontierte Planetenräder (Pos. 9) auf ca. 120°-130°C
erwärmen und auf die Planetenbolzen von Planetensteg
(Pos. 6) montieren.
Achtung!
Entsprechende Sicherheitshandschuhe tragen.
Heat pre-assembled planet gears (item 9) to approx.
120°-130°C and mount onto the planetary pins of planet
carrier (item 6).
Caution!
Wear suitable safety gloves.
Bild / fig. 5.3-34
Planetenräder mit neuen Sicherungsringen (Pos. 74)
sichern.
Secure the planet gears with new snap rings (item 74).
Bild / fig. 5.3-35
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 59/84
5. Montage • 5. Assembly
5.3 Montage Plantenstufen und Dichtungen /
5.3 Assembly Planetary Stages and Seals
Sonnenrad (Pos. 13) mit neuem Sicherungsring (Pos.
72) auf Planetensteg (Pos. 7) fixieren.
Fasten the sun gear (item 13) with a new snap ring (item
72) to the planet carrier (item 7).
Bild / fig. 5.3-36
Vormontierten Planetensteg der Vorstufe inclusive Son-
nenrad (Pos. 13) in das Getriebe einsetzen.
st
Install pre-assembled 1 planet stage including sun gear
(item 13) into gear drive.
Bild / fig. 5.3-37
Montage Zylinderrollenlager (Pos. 32) Vorstufe
- Zylinderrollenlager (Pos. 32) aus der Transportverpa-
ckung direkt in die Aufnahmebohrung von Planetenrad
(Pos. 10) drücken.
Achtung!
- Kontrollieren Sie ob der Sicherungsring vom Zylinder-
rollenlager in die entsprechende Nut eingeschnappt ist.
Assembly of cylindrical roller bearing (item 31) pre-
stage:
- push cylindrical roller bearing (item 32) directly out of
the transport packing into the locating hole of the planet
gear (item 10).
Attention!
- Make sure that the snap ring is in the right position of
the snap ring groove.
Bild / fig. 5.3-38
Achtung!
Bei der Montage der vormontierten Planetenräder ist
darauf zu achten das der größere Planetenlagerradius
zum Planetensteg zeigt.
Attention!
Observe during assembly of the pre-assembled planet
gears that the larger radius on the bearing bore is orien-
tated towards the planet carrier.
Bild / fig. 5.3-39
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 60/84
5. Montage • 5. Assembly
5.3 Montage Plantenstufen und Dichtungen /
5.3 Assembly Planetary Stages and Seals
Vormontierte Planetenräder (Pos. 102) auf ca. 120°-
130°C erwärmen und auf die Planetenbolzen von Plane-
tensteg (Pos. 7) montieren.
Achtung!
Entsprechende Sicherheitshandschuhe tragen.
Heat pre-assembled planet gears (item 10) to approx.
120°-130°C and mount onto the planetary pins of planet
carrier (item 7).
Caution!
Wear suitable safety gloves.
Bild / fig. 5.3-40
Planetenräder mit neuen Sicherungsringen (Pos. 71)
sichern.
Secure the planet gears with new snap rings (item 71).
Bild / fig. 5.3-41
Aufnahmebohrung von Zwischenring (Pos. 29) mit
LOCTITE 480 bestreichen.
Apply coat of LOCTITE 480 to the cavity of spacer ring
(item29).
Bild / fig. 5.3-42
Den in flüssigenStickstoff auf – 180°C abgekühlten
Zwischenring (Pos. 29) mit sichtbarer Ölschmiernut
montieren.
Achtung!
Entsprechende Sicherheitshandschuhe tragen.
Use nitrogen to cool down (-180°C) the spacer ring and
mount it with the lubrication groove on upper side (visi-
ble).
Caution!
Wear suitable safety gloves.
Bild / fig. 5.3-43
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 61/84
5. Montage • 5. Assembly
5.3 Montage Plantenstufen und Dichtungen /
5.3 Assembly Planetary Stages and Seals
Rundschnur (Pos. 76) in entsprechende Nut des De-
ckels (Pos. 5) einlegen und auf Länge zuschneiden.
Rundschnurenden mit LOCTITE 480 verkleben.
Insert a new chord (item 76) into the suitable groove of
supporting ring (item 2) and cut it on length.
Stick the endings of chord with LOCTITE 480.
Bild / fig. 5.3-44
Sonnenradwelle (Pos. 15) einsetzen.
Install sun gear shaft (item 15)
Bild / fig. 5.3-45
Axialspiel prüfen:
Spiel zwischen Anlauffläche der Sonnenradwelle (Pos.
15) und dem Zwischenring (Pos. 29) vor der Montage
des Deckels (Pos. 5) prüfen.
Sollwert “S”1-2mm
Checking of axial clearance:
Determine clearance between contact face of sun gear
shaft (item 15) and spacer ring (item 29) by measuring
parts prior to assembly of cover (item 5)
Recommended clearance “S”1-2mm
Bild / fig. 5.3-46
Dichtfläche Deckel / Hohlrad mit Flächendichtung
LOCTITE 128068 bestreichen.
Apply sealing surface of cover / ring gear with LOCTITE
128068.
Bild / fig. 5.3-47
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 62/84
5. Montage • 5. Assembly
5.3 Montage Plantenstufen und Dichtungen /
5.3 Assembly Planetary Stages and Seals
Deckel (Pos. 5) mit neuer Rundschnur (Pos. 76) in den
Einpaß des Hohlrades (Pos. 3) einsetzen.
Assemble cover (item 5) with a new chord (item 76) into
fit of ring gear (item 3).
Bild / fig. 5.3-48
Gewinde der Sechskantschrauben (Pos. 49) gleichmä-
ßig mit LOCTITE 270 bestreichen.
Evenly apply coat of LOCTITE 270 to threads of hex
head bolts (item 49).
Bild / fig. 5.3-49
Deckelbefestigungsschrauben (Pos. 49) in Gewindeboh-
rungen von Hohlrad (Pos. 3) einsetzen und mit erforder-
lichem Anzugsmoment anziehen.
Insert cover mounting bolts (item 49) into threaded holes
of ring gear (item 3) and tighten them to a proper torque.
Bild / fig. 5.3-50
Vor Inbetriebnahme Planetengetriebe mit Öl auffüllen
(siehe hierzu Betriebsanleitung).
ACHTUNG!
Öl erst nach Anbau der Stirnradstufe einfüllen.
Prior to putting into operation fill the planet gear with
new oil (see operating instructions)
CAUTION!
Fill in oil after assembly of spur gear stage.
Bild / fig. 5.3-51
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 63/84
5. Montage • 5. Assembly
5.3 Montage Plantenstufen und Dichtungen /
5.3 Assembly Planetary Stages and Seals
Verschlußschrauben (Pos. 81) mit neuen Dichtungen
(Pos. 82) in Deckel (Pos. 5) einschrauben.
Install plugs (item 81) with new seal rings (item 82) into
cover (item 5).
Bild / fig. 5.3-52
Abdrückgewindebohrungen im Deckel (Pos. 5) mit Fett
(z.B.K3N-30 DIN 51502) füllen.
Grease the forcing threaded holes at the cover (item 5)
with e.g. K3N-30 DIN 51502.
Bild / fig. 5.3-53
Zur weiteren Montage Getriebe auf Deckel (Pos. 5)
abstellen.
For further assembly turn the gearbox and place it on
cover (item 5).
Bild / fig. 5.3-54
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 64/84
5. Montage • 5. Assembly
5.4 Montage Stirnradstufe (Teilmontage II)
5.4 Assembly Spur Gear Stages (Partial Assembly II)
Planetensteg (Pos. 8) in Kran einhängen und auf Steck-
verzahnung von Mitnehmer (Pos. 19) montieren.
Hang planet carrier (item 8) onto crane and mount it
onto the shaft spline of coupler (item 19).
Bild / fig. 5.4-01
Planetensteg (Pos. 8) mit neuem Sicherungsring (Pos.
61) sichern.
Secure planet carrier (item 8) with a new snap ring (item
61).
Bild / fig. 5.4-02
Montage Zylinderrollenlager (Pos. 12):
- Sicherungsring (Pos. 64) einsetzen
- Anlaufscheibe (Pos. 40) einlegen
- Zylinderrollenlager (Pos. 33) aus der Transportverpa-
ckung direkt in die Aufnahmebohrung von Planetenrad
(Pos. 12) drücken
- 2te Anlaufscheibe einlegen
- Mit Sicherungsring (Pos. 64) sichern
Assembly of cylindrical roller bearing (item 12):
- install a new snap ring (item 64)
- insert a new locating ring (item 40)
- push cylindrical roller bearing (item 33) directly out of
the transport packing into the locating hole of the planet
gear (item 12)
- insert 2nd new locating ring
- secure with a new snap ring (item 64)
Bild / fig. 5.4-03
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 65/84
5. Montage • 5. Assembly
5.4 Montage Stirnradstufe (Teilmontage II)
5.4 Assembly Spur Gear Stages (Partial Assembly II)
Achtung!
Bei der Montage der vormontierten Planetenräder ist
darauf zu achten das der größere Planetenlagerradius
zum Planetensteg zeigt.
Attention!
Observe during assembly of the pre-assembled planet
gears that the larger radius on the bearing bore is orien-
tated towards the planet carrier.
Bild / fig. 5.4-04
Vormontierte Planetenräder (Pos. 12) auf ca. 120°-
130°C erwärmen und auf die Planetenbolzen von Plane-
tensteg (Pos. 8) montieren.
Achtung!
Entsprechende Sicherheitshandschuhe tragen.
Heat pre-assembled planet gears (item 12) to approx.
120°-130°C and mount them onto the planetary pins of
planet carrier (item 8).
Caution!
Wear suitable safety gloves.
Bild / fig. 5.4-05
Planetenrad (Pos. 12) mit neuem Sicherungsring (Pos.
73) sichern.
Secure planet gear (item 12) with a new snap ring (item
73).
Bild / fig. 5.4-06
Neuen O-Ring (Pos. 76) auf Zentriersitz von Tragachse
(Pos. 1) aufziehen.
Mount a new o-ring (item 76) on the centering of spindle
(item 1).
Bild / fig. 5.4-07
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 66/84
5. Montage • 5. Assembly
5.4 Montage Stirnradstufe (Teilmontage II)
5.4 Assembly Spur Gear Stages (Partial Assembly II)
Dichtfläche Hohlrad / Tragachse mit Flächendichtung
LOCTITE 128068 bestreichen.
Apply sealing surface of ring gear / spindle with
LOCTITE 128068.
Bild / fig. 5.4-08
Hohlrad (Pos. 4) in entsprechende Aufnahmebohrung
von Tragachse (Pos. 1) einsetzen.
Install ring gear (item 4) into suitable fit of spindle (item
1).
Bild / fig. 5.4-09
Gewinde der Zylinderschrauben (Pos. 48) gleichmäßig
mit LOCTITE 270 bestreichen.
Evenly apply coat of LOCTITE 270 to threads of socket
head cap screws (item 48).
Bild / fig. 5.4-10
Zylinderschrauben (Pos. 48) in entsprechende Gewin-
debohrungen von Tragachse (Pos. 1) einsetzen und mit
erforderlichem Anzugsmoment anziehen.
Install socket head cap screws (item 48) into threaded
holes of spindle (item 1) and tighten them to a proper
torque.
Bild / fig. 5.4-11
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 67/84
5. Montage • 5. Assembly
5.4 Montage Stirnradstufe (Teilmontage II)
5.4 Assembly Spur Gear Stages (Partial Assembly II)
Sonnenrad (Pos. 14) einsetzen.
Insert sun gear (item 14).
Bild / fig. 5.4-12
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 68/84
5. Montage • 5. Assembly
5.5 Montage Vorstufe 5.5 Assembly Input Stage
Dichtungsring (Pos. 20) vormontieren:
Aussenring der Wellendichtringe (Pos. 45) gleichmäßig
mit LOCTITE 128068 bestreichen.
Pre-assembling of seal ring (item 20):
Evenly apply coat of LOCTITE 128068 to outer ring of
radial sealings (item 45).
Bild / fig. 5.5-01
Dichtungsring (Pos. 20) vormontieren:
Mit entsprechendem Hilfsmittel (siehe Bild 1.3-02) Wel-
lendichtringe (Pos. 45) in Aufnahmebohrung von Dich-
tungsring (Pos. 20) einsetzen.
Achtung!
Auf richtige Einbaulage der Dichtlipe achten.
Pre-assembling of seal ring (item 20):
Insert radial shaft sealing rings (item 45) with mounting
tool (note fig. 1.3-02) into suitable fit of seal ring (item
20).
Caution!
Observe correct mounting position of sealing lip.
Bild / fig. 5.5-02
Dichtungsring (Pos. 20) vormontieren:
Einbauraum zwischen den Dichtlippen mit Wälzlagerfett
(K3N-30 DIN 51502) füllen.
Pre-assembling of seal ring (item 20):
Fill mounting space between sealing lips with roller
bearing grease (K3N-30 DIN 51502).
Bild / fig. 5.5-03
Zylinderrollenlager (Pos. 36) in entsprechende Aufnah-
mebohrung von Flansch (Pos. 28) einsetzen.
Insert cylindrical roller bearing (item 36) into cavity of
flange (item 28).
Bild / fig. 5.5-04
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 69/84
5. Montage • 5. Assembly
5.5 Montage Vorstufe 5.5 Assembly Input Stage
Zylinderrollenlager (Pos. 36) verstemmen.
Caulk cylindrical roller bearing (item 36).
Bild / fig. 5.5-05
Innenring von Zylinderrollenlager (Pos. 36) einlegen.
Insert inner ring of cylindrical roller bearing (item 36).
Bild / fig. 5.5-06
Komplett vormontiertes Stirnrad (Pos. 17) in Gehäuse
(Pos. 27) einsetzen.
Install pre-assembled spur wheel (item 17) into housing
(item 27).
Bild / fig. 5.5-07
Zylinderrollenlager (Pos. 36) mit Flamme erwärmen.
Heat up cylindrical roller bearing (item 36) with flame.
Bild / fig. 5.5-08
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 70/84
5. Montage • 5. Assembly
5.5 Montage Vorstufe 5.5 Assembly Input Stage
Antriebswelle (Pos. 16) in Zylinderrollenlager (Pos. 36)
einsetzen.
Install the input shaft (item 16) into the cylindrical roller
bearing (item 36).
Bild / fig. 5.5-09
Innenring von Zylinderrollenlager (Pos. 35) mit Flamme
erwärmen.
Heat up inner ring of cylindrical roller bearing (item 35)
with flame.
Bild / fig. 5.5-10
Lagerinnenring von Zylinderrollenlager (Pos. 35) auf den
entsprechenden Paßsitz von Antriebswelle (Pos. 16)
montieren.
Achtung!
Entsprechende Sicherheitshandschuhe tragen.
Heat bearing inner ring of cylindrical roller bearing (item
35) and mount onto the equivalent fit of input shaft (item
16).
Caution!
Wear suitable safety gloves.
Bild / fig. 5.5-11
Neuen Sicherungsring (Pos. 60) in entsprechende Nut
von Gehäuse (Pos. 27) montieren.
Mount a new snap ring (item 60) into the suitable groove
of housing (item 27).
Bild / fig. 5.5-12
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 71/84
5. Montage • 5. Assembly
5.5 Montage Vorstufe 5.5 Assembly Input Stage
Neuen O-Ring (Pos. 75) in entsprechende O-Ring Nut
von Gehäuse (Pos. 27) einsetzen. O-Ring fetten.
Insert a new o-ring (item 75) into the suitable o-ring
groove of housing (item 27). Grease o-ring.
Bild / fig. 5.5-13
Vormontierten Dichtungsring (Pos. 20) in entsprechende
Aufnahmebohrung von Gehäuse (Pos. 27) einsetzen.
Mount the pre-assembled seal ring (item 20) into the
suitable cavity of housing (item 27).
Bild / fig. 5.5-14
Mit entsprechendem Hilfsmittel (siehe Bild 1.3-05) Dich-
tungsring (Pos. 20) zur Anlage bringen.
Mount seal ring (item 20) with a suitable mounting tool
(note fig. 1.3-05) for proper axial seat.
Bild / fig. 5.5-15
Zylinderrollenlager (Pos. 35) in Gehäusebohrung ein-
setzen.
Zylinderrollenlager (Pos. 35) verstemmen.
Insert cylindrical roller bearing (item 35) into suitable
boring of housing.
Caulk cylindrical roller bearing (item 35).
Bild / fig. 5.5-16
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 72/84
5. Montage • 5. Assembly
5.5 Montage Vorstufe 5.5 Assembly Input Stage
Neuen O-Ring (Pos. 76) auf Zentriersitz von Flansch
(Pos. 28) aufziehen.
Mount a new o-ring (item 76) on the centering of flange
(item 28).
Bild / fig. 5.5-17
Dichtfläche Gehäuse / Flansch mit Flächendichtung
LOCTITE 128068 bestreichen.
Apply sealing surface of housing / flange with LOCTITE
128068.
Bild / fig. 5.5-18
Zylinderrollenlager (Pos. 35) mit Flamme erwärmen.
Heat up cylindrical roller bearing (item 35) with flame.
Bild / fig. 5.5-19
Gehäuse (Pos. 27) auf Zentrierung von Flansch (Pos.
28) montieren.
Mount housing (item 27) onto fit of flange (item 28).
Bild / fig. 5.5-20
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 73/84
5. Montage • 5. Assembly
5.5 Montage Vorstufe 5.5 Assembly Input Stage
Flansch (Pos. 28) und Gehäuse (Pos. 27) mit Zylinder-
stift (Pos. 41) fixieren.
Fasten flange (item 28) and housing (item 27) with cy-
lindrical dowel pin (item 41).
Bild / fig. 5.5-21
Zylinderschrauben (Pos. 42) in Gewindebohrungen von
Gehäuse (Pos. 27) einsetzen und mit erforderlichem
Anzugsmoment anziehen.
Insert socket head cap screws (item 42) into threaded
holes of housing (item 27) and tighten them to a proper
torque.
Bild / fig. 5.5-22
Neuen Sicherungsring (Pos. 70) auf Antriebswelle (Pos.
16) montieren.
Mount a new snap ring (item 70) onto input shaft (item
16).
Bild / fig. 5.5-23
Mitnehmer (Pos. 25) auf Steckverzahnung von An-
triebswelle (Pos. 16) aufschieben.
Slide on coupler (item 25) onto shaft spline of input shaft
(item 16).
Bild / fig. 5.5-24
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 74/84
5. Montage • 5. Assembly
5.5 Montage Vorstufe 5.5 Assembly Input Stage
Mit 2ten neuem Sicherungsring (Pos. 70) Mitnehmer
sichern.
nd
Secure coupler with 2 new snap ring (item 70).
Bild / fig. 5.5-25
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 75/84
5. Montage • 5. Assembly
5.6 Montage Bremse 5.6 Assembly Brake
Federn, Dichtelemente und Gegenflächen der Dichtele-
mente sind für die Montage leicht einzuölen.
Bevor die Quadringe montiert werden müssen beide
Stützringe eingebaut werden.
Lubricate springs, piston seals, supporting rings as well
as their contact areas lightly with gear oil. Assemble
supporting rings prior to piston seals.
Bild / fig. 5.6-01
Scheibe (Pos. 504) in Lamellenträger (Pos. 501) einle-
gen.
Insert disk (item 504) into the disk housing (item 501).
Bild / fig. 5.6-02
Scheibe mit neuem Sicherungsring (Pos. 508) sichern.
Secure disk with a new snap ring (item 508).
Bild / fig. 5.6-03
Neuen O-Ring (Pos. 89) auf Zentriersitz von Lamellen-
träger (Pos. 501) aufziehen.
Mount a new o-ring (item 89) on the centering of disk
housing (item 501).
Bild / fig. 5.6-04
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 76/84
5. Montage • 5. Assembly
5.6 Montage Bremse 5.6 Assembly Brake
Lamellenträger zur weiteren Montage drehen.
For further assembly turn the disk housing.
Bild / fig. 5.6-05
Neue Stützringe (Pos. 513+515) in die Lamellenträger-
nuten einsetzen. Neue Quadringe (Pos. 512+514) zwi-
schen die Stützringe montieren.
Quadringe vor Montage dehnen.
Assemble new supporting rings (item 513+515) into disk
housing groove prior to assembly of new piston seals
(item 512+514) between supporting rings.
Prior assembly dilate the piston seals.
Bild / fig. 5.6-06
Neue Lamellen (Pos. 505+506) in richtiger Reihenfolge
einlegen (siehe Zeichnung).
Insert new brake disks (item 505+506) in correct order
(note drawing).
Bild / fig. 5.6-07
Kolben (Pos. 502) in den Lamellenträger (Pos. 501)
einsetzen.
Insert piston (item 502) into disk housing (item 501)
Bild / fig. 5.6-08
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 77/84
5. Montage • 5. Assembly
5.6 Montage Bremse 5.6 Assembly Brake
Vormontierten Lamellenträger (Pos. 501) in Einpaß von
Stirnradgehäuse einsetzen.
Mount pre-assembled disk housing (item 501) into the fit
of spur gear wheel housing.
Bild / fig. 5.6-09
Zylinderschrauben (Pos. 519) in Gewindebohrung von
Gehäuse (Pos. 27) einsetzen und mit erforderlichem
Anzugsmoment anziehen.
Insert socket head cap screws (item 519) into threaded
holes of housing (item 27) and tighten them to proper
torque.
Bild / fig. 5.6-10
Neue Druckfedern (Pos. 507+509) in richtiger Anord-
nung in Kolben (Pos. 502) einsetzen.
Insert new pressure springs (item 507+509) in correct
order into piston (item 502).
Bild / fig. 5.6-11
Scheibe (Pos. 503) einlegen.
Install disk (item 503).
Bild / fig. 5.6-12
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 78/84
5. Montage • 5. Assembly
5.6 Montage Bremse 5.6 Assembly Brake
Mit geeigneter Vorrichtung Scheibe (Pos. 503) bis zum
Anschlag gegen die Federn (Pos. 507+509) drücken.
Press disk (item 503) with a suitable device firmly
against the pressure springs (item 507+509).
Bild / fig. 5.6-13
Neuen Sicherungsring (Pos. 520) montieren und auf
richtigen Sitz prüfen. Vorrichtung entfernen
Assemble a new snap ring (item 520) and check for
proper seat. Remove fixture.
Bild / fig. 5.6-14
Funktionsprüfung der Bremse
Kolben (Pos. 502) mit max. 50 bar Druck beaufschla-
gen. Bremslüftanschluß „Z“ M16x1,5. Prüfdauer min. 15
Minuten. Verwenden Sie hierzu eine Pumpe ähnlich
Bild 5.6-16.
Functional check of brake
Release piston (item 502) with a max. release pressure
of 725 psi. Testing time 15 minutes minimum. Brake
release port M16x1,5. for this use a pump like in
fig. 5.6-16
Bild / fig. 5.6-15
Pumpe.
Pump.
Bild / fig. 5.6-16
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 79/84
5. Montage • 5. Assembly
5.6 Montage Bremse 5.6 Assembly Brake
Bremslüftanschluß mit Stopfen (Pos. 517) verschließen.
Lock brake release port with plug (item 517).
Bild / fig. 5.6-17
Diverse Verschlußschrauben, Entlüfter, Ölstandsauge
an Bremse bzw. Stirnradgehäuse montieren.
Assemble of diverse screw plugs, vent and oil level
gauge at brake and spur gear housing.
Bild / fig. 5.6-18
Hydromotor mit neuem O-Ring (Pos. 511) am Getriebe
anbauen.
Motor gehört nicht zum Lieferumfang Bosch Rexroth.
Assemble hydraulic motor with a new snap ring (item
511). The motor is not scope of supply of Bosch
Rexroth.
Bild / fig. 5.6-19
Motorbefestigungsschrauben einschrauben und mit
erforderlichem Anzugsmoment anziehen.
Insert the motor mounting bolts and tighten them to
proper torque.
Bild / fig. 5.6-20
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 80/84
5. Montage • 5. Assembly
5.6 Montage Bremse 5.6 Assembly Brake
Vor Inbetriebnahme Bremse mit Öl befallen.
Hinweise auf der Einbauzeichnung beachten!
Prior to putting into operation fill the brake with new oil.
Observe details given on the installtion drawing
Bild / fig. 5.6-21
Dichtfläche Stirnradstufe / Tragachse mit LOCTITE
128068 bestreichen.
Apply sealing surface of spur gear stage / spindle with
LOCTITE 128068.
Bild / fig. 5.6-22
Komplett vormontierte Stirnradstufe (mit montierter
Bremse) in Kran einhängen und O-Ring (Pos. 76) in
entsprechende Nut von Flansch (Pos. 28) einlegen.
Hang complete pre-assembled spur gear stage (with
mounted brake) onto crane and insert o-ring (item 76)
into suitable o-ring flange (item 28) groove.
Bild / fig. 5.6-23
O-Ring einfetten.
Grease o-ring.
Bild / fig. 5.6-24
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 81/84
5. Montage • 5. Assembly
5.6 Montage Bremse 5.6 Assembly Brake
Komplett vormontierte Stirnradstufe (mit Bremse) in
entsprechende Aufnahmebohrung von Hohlrad (Pos. 4)
einsetzen.
Install complete pre-assembled spur gear stage (with
brake) into suitable fit of ring gear (item 4).
Bild / fig. 5.6-25
11x 6kt-Schraube (Pos. 50) in Gewindebohrungen von
Hohlrad (Pos. 4) einsetzen und mit erforderlichem An-
zugsmoment anziehen.
Install 11x hex head bolt (item 50) into threaded holes of
ring gear (item 4) and tighten them to a proper torque.
Bild / fig. 5.6-26
2x 6kt-Schraube (Pos. 90) in Gewindebohrungen von
Tragachse (Pos. 1) einsetzen und mit erforderlichem
Anzugsmoment anziehen.
Install 2x hex head bolt (item 90) into threaded holes of
spindle (item 1) and tighten them to a proper torque.
Bild / fig. 5.6-27
Entlüfter (Pos. 83) mit neuem Dichtring (Pos. 84) mon-
tieren.
Mount vent (item 83) with a new seal ring (item 84).
Bild / fig. 5.6-28
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 82/84
5. Montage • 5. Assembly
5.6 Montage Bremse 5.6 Assembly Brake
Verschlußschraube (Pos. 85) mit neuem Dichtring (Pos.
86) einsetzen.
Insert screw plug (item 85) with a new seal ring (item
86).
Bild / fig. 5.6-29
Vor Inbetriebnahme Stirnradstufe mit Öl befüllen (siehe
hierzu Betriebsanleitung).
Prior to putting into operation fill the spur gear stage with
new oil (note operating instructions)
Bild / fig. 5.6-30
Verschlußschrauben (Pos. 81) mit neuen Dichtungen
(Pos. 82) in Gehäuse (Pos. 27) einschrauben.
Screw into housing (item 27) screw plugs (item 81) with
new seal rings (item 82).
Bild / fig. 5.6-31
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 83/84
6. Probelauf • 6. Test Run
6.1 Prüfstandsaufbau 6.1 Test set up
Das Getriebe wird in der vorgesehenen Einbaulage auf- The gearbox shall be mounted in its intended installation
gebaut und mit einem geeigneten Antriebsmotor angetrie- position and connected to a suitable driving motor. If the
ben. Wenn das Betriebsverhalten des Getriebetyps be- operating performance of the gearbox type is known, it
kannt ist, kann eine andere Prüflage gewählt werden, is possible to mount the gearbox in another test position
wobei die Radialwellendichtringe, bzw. Gleitringdichtun- under the condition that the radial face seals and the
gen unter Öl stehen müssen (Luftkammerbildung beach- axial seal are submerged in oil (check for air cham-
ten!). bers!).
6.2 Ölversorgung 6.2 Lubrication
Die Getriebe werden wie in der Einbauzeichnung vorge- The gear units are to be filled with oil as shown on the
sehen mit Öl gefüllt. Bremsen mit seperater Ölfüllung sind installation drawing. Brakes which have separate oil
vor dem Probelauf gemäß Einbauzeichnung ebenfalls mit fillings shall be filled with oil before test run.
Öl zu befüllen. For oil fill, please use the lubricants listed in the operat-
Zur Ölbefüllung verwenden Sie bitte die in der Betriebsan- ing instructions.
leitung angebenen Schmierstoffe.
6.3 Drehzahl, Laufzeit und 6.3 Speed, Running Time,
Prüflast Test Load
Die Getriebe sind mit Höchstdrehzahl (nmax Getriebe bzw. The gear units are to be operated at max. speed (nmax of
nmax Prüfstand) über 1 Stunde (je ½ Stunde pro Drehrich- gearbox or nmax test bed) under no load for one hour
tung bei Getrieben mit wechselnder Drehrichtung) ohne (half an hour in each direction of rotation in case of
Last zu fahren. reverse gears).
Hierbei ist die Ölsumpftemperatur am Außendurchmesser Measure oil sump temperatures at outside diameter of
des Hohlrades nach 30, 45 und 60 Minuten zu messen ring gear and note them down after 30, 45 and 60 min-
und zu protokollieren. utes of operation.
6.4 Thermische Werte 6.4 Thermal Parameters
Die Ölsumpftemperatur soll nach Abschluß des The oil sump temperature measured after the 1-hour
1-stündigen Probelaufs 70°C nicht übersteigen. Die Tem- test run shall not exceed 70°C.
peratur nach 30 Minuten bei reduzierter Laufzeit soll die The temperature measured after 30 minutes reduced
Temperatur der Temperaturaufschreibung des ersten operating time shall not exceed the temperature records
Getriebes um nicht mehr als 4°C überschreiten. of the first gearbox by more than 4°C.
Die Temperaturen an außenliegenden Lagerstellen (so- The temperatures measured at the external bearing
weit zutreffend) sollen die Ölsumpftemperaturen um nicht areas (if applicable) must be not exceed the oil sump
mehr als 10°C übersteigen. temperature by more than 10°C.
6.5 Laufgeräusch 6.5 Running Noise
Das Laufgeräusch soll weich und gleichmäßig sein. The running noise under test conditions should be
Es dürfen keine harten, schlagenden oder pfeifende Ge- smooth and steady.
räusche vorhanden sein. Hard, knocking or howling noise produced by the unit
are inadmissible.
6.6 Dichtigkeitsprüfung 6.6 Leakage Testing
Während des Probelaufs sind alle Dichtungen auf Undich- During the test run, make sure to check all seals for
tigkeiten hin zu beobachten, z.B.: leakages, e.g.:
- Ein- und Auslaßschrauben - Inlet and drain plugs
- Entlüfter - Vent
- Dichtflächen an Hohlrädern und Deckeln - Sealing faces at ring gears and covers
- Wellendichtungen - Shaft seals
RDE 77958-02-R/02.13 Sach-Nr. / Part-No. 3683483 84/84
6. Probelauf • 6. Test Run
6.7 Funktionsprüfung der 6.7 Functional Test of
Bremsen Hydraulic Brakes
Rexroth Bremsen werden durch eine pulsierende Prüfung A pulsating pressure test shall be performed on the
auf Funktion und Dichtigkeit geprüft: Rexroth brakes to check the tightness and function:
- Prüfdruck: 60-80 bar - Test pressure: 60-80 bar
- Lüftzeit: 6-10 sek pro Kolbenhub - Releasing time: 6-10 sec. per piston stroke
- Prüfdauer:min. 15 Minuten - Testing time: 15 minutes minimum
Die hier beschriebene Funktionsprüfung gilt nicht für in The descriped functional test of hydraulic brakes is not
Motoren integrierte Bremsen. valid for motor integrated brakes.
6.8 Fremdkörper 6.8 Oil Contamination Test
Nach Durchführung des Probelaufs ist das ablaufende After completing the test run, the oil shall be inspected
Getriebeöl auf Späne, Zunder, übermäßigen Abrieb zu for scraps, scales and wear particles and other impuri-
beobachten. Auf Fremdkörper an Magnetstopfen und ggf. ties. The magnetic plug and, if necessary, the oil filter
am Ölfilter ist zu achten. shall be checked.
7.3 SWING GEARBOX
7.3 Swing gearbox Dimensions of the swing gearbox
This section is valid for the swing gearbox
part no. 3 689 117
3 692 960
3 692 970
3 692 990
7.3.1 General
The swing gearbox forms one structural unit to-
gether with the swing motor and the parking brake.
It is designed as a 2-stage planetary gear system.
Technical data
Gearbox type: GFB 144 T2 2006
Transmission ratio: i = 49,28
Oil capacity: approx. 38 l
Table 1
Fig. 1 Swing gearbox – Dimensions – 2806400b-01
mm
A 1 172
B 294
D 562
Table 2
3721489en - (01) – 01.12 Page 7.3 - 1
7.3 SWING GEARBOX
Components of swing gearbox mounting
Ref. No. Tightening torque Weight
Quantity Designation [Nm] [kg]
1 1 Swing gearbox with motor 1 060
9 1 Connector
11 24 Washer
16 1 O-ring
18 1 Oil drain plug
19 1 Chip indicator
20 1 Sealing ring
21 1 Extension pipe
22 1 Sealing ring
32 24 Hex. bolt M 24 x 700 – 10.9 Md = 850 Nm
Table 2 Quantities are valid for one gearbox.
32
Fig. 2 Components of swing gearbox mounting – 3720802a-02
Page 7.3 - 2 3721489en - (01) – 01.12
7.3 SWING GEARBOX
7.3.2 Dismantling and installing the Installing the swing gearbox
swing gearbox
The toothing of the sleewing device must be filled
Dismantling the swing gearbox with roller-bearing grease about 10 mm above
tooth-tips.
1. Remove swing motor as described in attached
gearbox manual (see chapter 7.3.3). 1. Remove all traces of paint and grease from
contact surfaces of swing gearbox and super-
The motor can be deposited on the frame with structure frame with thinner. Check surfaces
the hydraulic lines connected. It is not neces- for damage.
sary to open the hydraulic system.
Contact surfaces must be cleaned down to
2. Remove brake line at brake unit and close line the bright metal and be dry and free from
with plug. grease.
3. Drain oil according to the operating instruc- 2. Install O-ring (16) onto gearbox housing.
tions.
3. Pick up gearbox in lifting tackle, bring into
4. Remove oil drain assembly (9, 18, 20, 21, 22). installation position and set down without dis-
placement.
5. Loosen fastening bolts (32).
4. Screw in bolts with washers (11 & 32) and
6. Lift up gearbox with lifting eye bolts (4 x M 20) tighten crosswise, mark tightened bolts.
in lifting tackle and remove.
Tightening torque = 850 Nm
5. Coat the drive pinion of the swing motor with
The gearbox may suddenly break lubricating paste and install the motor as de-
free! scribed in attached gearbox manual (see
chapter 7.3.3).
The hydraulic motors with the brakes must be
rotated as shown in fig. 4. The angle of rota-
tion (see table 3) refers to delivery condition.
6. Connect brake line and bleed air from the
brake system.
7. Fill in oil according to the Operating Instruc-
tions.
3721489en - (01) – 01.12 Page 7.3 - 3
7.3 SWING GEARBOX
32
Fig. 3 Swing gearbox - removal and installation – 3695152b-02
Page 7.3 - 4 3721489en - (01) – 01.12
7.3 SWING GEARBOX
Fig. 4 T: travel direction 3716544-01
a, b: The hydraulic motors with the brakes must be rotated in the shown direction.
The angle of rotation is listed in table 3.
Item Angle of rotation
a + / - 1 boring (30°)
b + / - 5 borings (150°)
Table 3
3721489en - (01) – 01.12 Page 7.3 - 5
7.3 SWING GEARBOX
7.3.3 Disassembly & Assembly
instructions
Please refer to the attached manual.
Swing gearbox part no.
3 689 117
Swing gearbox part no.
3 692 960
3 692 970
3 692 990
Page 7.3 - 6 3721489en - (01) – 01.12
7.4 PUMP GEARBOX
7.4 Pump gearbox Weight
This section is valid for Pump gearbox without pumps approx. 1 790 kg
Pump gearbox with pumps approx. 3 700 kg
engine Caterpillar 3512 C Table 2
with pump gearbox part no. 3 705 643.
Dimensions of the pump gearbox (fig. 1)
7.4.1 General
The pump gearbox forms one structural unit to- [mm]
gether with the main-, swing-, cooling-, and servo A 1 690
pumps. It is designed as a spur gear system.
B 1 540
C 565
Technical data Table 3
Gearbox type: 4549.XX
Input RPM: 1 800
RPM of main pumps: 1 457
RPM of swing pumps: 1 953
Ratio for cooling pumps: 1 956
Direction of rotation: right
(view onto input shaft)
Oil capacity: approx. 75 l
Table 1
Fig. 1 Dimensions of the pump gearbox – 2710369a
3721434en - (00) – 12.11 Page 7.4 - 1
7.4 PUMP GEARBOX
7.4.2 Dismantling and installing the 2. Support diesel engine on superstructure
pump gearbox frame, e.g. with timber or bracket.
Diesel engine and pump gearbox are resiliently The engine must be securely sup-
mounted together on the superstructure frame by ported on the frame.
means of the bearing (1, fig 2).
Dismantling the pump gearbox 3. Unscrew bolts (2, fig. 1) between gearbox
flange and diesel engine.
1. Remove hydraulic lines and pumps, collecting
escaping hydraulic oil in suitable vessels. 4. Unscrew bolts between engine coupling and
flywheel (see chapter 5.4 – Coupling assem-
Close exposed hose and pipe connections, bly).
open bores and housing carefully to prevent
dirt from penetrating. 5. Connect gearbox at eyes with appropriate
lifting tackle (crane).
Disconnect electric cables from gearbox and
pumps and secure to prevent short-circuiting. 6. Unscrew bolts (12, fig. 2).
7. Remove gearbox with coupling from engine
and lift out.
Components for pump gearbox mounting (fig. 1 & 2)
Weight
Ref. no. Quantity Designation Further remarks
[kg]
2 16 Hex. bolt ½ - 13 UNC x 75 - 8.8 Tightening torque Md = 71 Nm
3 16 Disc
9 4 Pair of lock washer
12 4 Hex. bolt M 20 X 130 - 10.9 – A3B Tightening torque Md = 490 Nm
Table 1 Quantities are valid for 1 pump gearbox.
Page 7.4 - 2 3721434en - (00) – 12.11
7.4 PUMP GEARBOX
Fig. 1 Pump gearbox – dismantling and assembly – 3721782-01
12
Fig. 2 Pump gearbox – dismantling and assembly – 3720974-01
3721434en - (00) – 12.11 Page 7.4 - 3
7.4 PUMP GEARBOX
12
Fig. 3 Pump gearbox – dismantling and assembly – 3695545-02
Page 7.4 - 4 3721434en - (00) – 12.11
7.4 PUMP GEARBOX
Fig. 4 Pump gearbox – dismantling and assembly – 3695549-01
3721434en - (00) – 12.11 Page 7.4 - 5
7.4 PUMP GEARBOX
Installation of the pump gearbox 7.4.3 Disassembly & Assembly in-
structions
1. Clean the contact surface of pump gearbox
and superstructure carefully. The surfaces Please refer to the attached manual:
must be metallically clean (no rust), dry and
grease-free. SN3691273 - 4549.01.09900
2. Check Megiflex-discs (5, fig. 1), replace if
necessary (see chapter 5.3 – Engine installa-
tion).
3. Install coupling into the input shaft of the
pump gearbox (see chapter 5.4 – Engine
coupling).
4. Position the pump gearbox on the superstruc-
ture. Fasten the slightly oiled bolts (12, fig. 2)
finger tight.
5. Tighten bolts between engine coupling and
flywheel (see chapter 5.4).
6. Connect engine and pump gearbox with
slightly oiled bolts (2, fig. 1) and tighten with
the required torque.
Tightening torque = 71 Nm
7. Tighten the pump gearbox on the superstruc-
ture (12, fig. 2) with the required torque:
Tightening torque = 490 Nm
6. Connect hydraulic lines and electric cables.
Remove support parts.
7. Check oil level in pump gearbox.
8. Bleed air from the hydraulic pumps (see
chapter 8.2).
On completion of assembly work,
all installation inspections pre-
scribed by the engine manufac-
turer (e.g. measurement of axial
play of crank shaft) must be car-
ried out.
Page 7.4 - 6 3721434en - (00) – 12.11
SERVICE MANUAL
Pumpenverteilergetriebe Typ 4549.01
SN 3691273 RH 340B
Service Manual 4549.01 SN3691273 RH340B
Inhaltsverzeichnis – Contents
Inhaltsverzeichnis – Contents .................................................................................................. 2
Technische Daten – Technical Data ........................................................................................ 3
Einleitung – Introduction........................................................................................................... 4
Einführung – Introduction ......................................................................................................... 5
Sicherheit – Safety................................................................................................................... 6
Anziehdrehmomente – Tightening torques............................................................................... 7
Werkzeuge – Tools .................................................................................................................. 8
Montageanleitung allgemein – General assembly instructions ................................................12
Montageanleitung Getriebe – Typ 4549.01 Assembly instructions gearbox type 4549.01 .......12
Demontageanleitung allgemein – General disassembly instructions .......................................28
Demontageanleitung Getriebe Typ 4549.01 – Disassembly instructions type 4549.01............28
Problemanalyse – Troubleshooting.........................................................................................39
Probelauf – Test run ...............................................................................................................40
Anlagen – Enclosures .............................................................................................................41
2
Service Manual 4549.01 SN3691273 RH340B
Technische Daten – Technical Data
Verteilergetriebe – Pump drive type 4549.01 RH 340B
Pmax=1600 kW n1= 1800 min-1
i1= 1,2353 n2= 1457 min-1 Hauptpumpen / main pumps
i2= 1,1569 n3= 1556 min-1 Schmierölpumpe / oil pump
i3= 0,9216 n4= 1953 min-1 Schwenk – Hilfspumpen / swing – auxiliary
pumps
1. Lebensdauer – Service life
Lh>25000 h bei Pumpenvollast mit P=900 kW (Hauptpumpen)
Lh>25000 h at pumps full load with P=900 kW (main pumps)
2. Sicherheitsfaktoren – Safety factors
Bei Stirnradsatz – at spur gear set
Mindest- Sicherheiten nach DIN 3990: dauerfest bei T2max=6555 Nm
Minimum safeties according to DIN 3990: fatigue endurable at T2max=6555 Nm
SHdyn/SHstat = 1,54 / 2,34
SFdyn/SFstat = 1,78 / 5,96
3. Werkstoffe – Material
Gehäuse - Housing = EN-GJL-250
Stirnräder – Spur gears = 16MnCr5
Zahnwelle – Splined shaft = 42CrMo4V
Kupplungsstücke – coupling pieces = C45
4. Verzahnung – Gearing
Stirnräder – Spur gears: einsatzgehärtet und zahnflankengeschliffen
case – hardened and gear flank ground
Kupplungsstücke – coupling pieces: nitrated
3
Service Manual 4549.01 SN3691273 RH340B
Einleitung – Introduction
Urheberrecht Copyright
Das Urheberrecht an Zeichnungen und Bildern The copyright at drawings and pictures remains
verbleibt bei uns. Eine Zeichnung (Bild) darf nur zu with us. A drawing (picture) may be used only for
den Zwecken benutzt werden, zu denen sie dem the purposes, for which it is entrusted to the recipi-
Empfänger anvertraut ist. Ohne unsere ausdrückli- ent. Without our written permission drawings and
che schriftliche Genehmigung dürfen Zeichnungen pictures must not be made available to third per-
und Bilder nicht an Dritte weitergegeben oder die- sons. Each duplication – also of details – is forbid-
sen zugänglich gemacht werden. Jede Vervielfälti- den.
gung – auch von Einzelheiten – ist untersagt.
Contravention will be prosecuted. Spare parts must
Zuwiderhandlungen werden gerichtlich verfolgt. meet the technical requirements committed by.
Ersatzteile müssen den von festgelegten techni- This is always secured with original spare parts.
schen Anforderungen genügen. Dies ist bei -
Indicate the following data when placing an order:
Originalersatzteilen immer gewährleistet.
Geben Sie bei einer Bestellung folgende Daten an: the article no. / drawing no. (DIN no.)
the gearbox serial no.
die Artikel-Nr. / Zeichnungs-DIN-Nr.
You find these numbers on the nameplate
die Getriebe-Nr. which is attached to each product.
Sie finden diese Nummern auf dem Typen the drawing no.
schild, das an jedem Produkt angebracht ist.
the item no.
die Zeichnungsnummer
the exact description
die Positionsnummer
the part no.
die genaue Benennung
You find these numbers in the parts list.
die Teil-Nr.
the number of pieces of the requested spare
Sie finden diese Nummern in der Teileliste. parts
die Stückzahl der gewünschten Ersatzteile the requested way of dispatch (e.g. express
die gewünschte Versandart (z.B. Expressgut, shipment, freight, aifreight, courier service, etc.)
Frachtgut, Luftfracht, Kurierdienst, usw.)
4
Service Manual 4549.01 SN3691273 RH340B
Einführung – Introduction
Einführung Introduction
Die vorliegende Anleitung beschreibt die Montage The available instructions describe the assembly
bzw. Demontage des Pumpenverteilergetriebes and disassembly of pump drive type 4549.01.
4549.01.
Observe the references on the assembly drawing
Beachten Sie die Hinweise auf der Anbauzeich- A4549.01.
nung A4549.01.
All items and their positions are shown on the
Alle Einzelpositionen und deren Lage sind auf der spare part drawing E4549.01.
Ersatzteilzeichnung E4549.01 dargestellt.
The drawings shown in this manual are intended
Die in dieser Anleitung enthaltenen Zeichnungen only for the assembly and disassembly of gearbox
dienen nur dem Zweck der Montage und Demon- type 4549.
tage des Getriebes Typ 4549.
The drawings cannot be used for mounting the
Die Zeichnungen sind nicht geeignet für den An- gearbox
bau des Getriebes.
With this symbol dangers for bodies and
Mit diesem Symbol sind Gefahren für health are characterized.
Körper und Gesundheit gekennzeichnet.
With this symobl dangers for the product
Mit diesem Symbol sind Gefahren für and the entire plant are characterized.
das Produkt und die Gesamtanlage
gekennzeichnet.
Absolutely consider the safety regulations and the
Beachten Sie unbedingt die Sicherheitsbestim-
relevant rules for the prevention of accidents! Con-
mungen und die einschlägigen Unfallverhütungs-
sider for this the operating instructions for pump
vorschriften! Beachten Sie hierzu die allgemeine
drives.
Bedienungsanleitung für Pumpenverteilergetriebe.
Bauen Sie nur Originalersatzteile ein.
Attach only original spare parts.
Verwenden Sie geeignete Auffangge-
Use suitable collection receptacles
when draining oil.
fäße beim Ölablassen.
Mark before the separation bolted and
Markieren Sie vor dem Trennen ver-
toothed parts on their positions.
schraubte und verzahnte Teile auf de-
ren Lage und Position. Make sure that no dirt or foreign sub-
stance gets into the gearbox.
Achten Sie darauf, dass kein Schmutz
oder Fremdkörper in das Getriebe ge- Replace damaged parts, O-rings, seal
langt. rings and end caps by new parts.
Ersetzen Sie beschädigte Teile, O- Warm up bearings and gear wheels
Ringe, Dichtringe und Verschlusskap- before assembling only on hot plates
pen durch neue Teile. or in the furnace. Never warm up with
direct flame.
Erwärmen Sie Lager und Zahnräder
vor der Montage nur auf Heizplatten Before the installation all movably
bzw. im Wärmeofen. Niemals mit di- parts and seal rings are to be oiled.
rekter Flamme erwärmen.
Sometimes the coat of paint of the
Vor dem Einbau sind alle beweglichen gearbox is damaged by dismantling
Teile sowie Dichtringe einzuölen. and re-assembling. Renew therefore
the coat of paint in order to protect the
Unter Umständen ist der Farbanstrich
gearbox from corrosion.
des Getriebes durch das Zerlegen und
Zusammenbauen beschädigt. Erneu- Carry out a test run of the gearbox.
ern Sie deshalb den Farbanstrich, um
das Getriebe gegen Korrosion zu
schützen.
Führen Sie einen Probelauf des Ge-
triebes durch.
5
Service Manual 4549.01 SN3691273 RH340B
Sicherheit – Safety
Bei der Montage bzw. Demontage des Pumpenverteilergetriebes Typ 4549 sind die folgenden Si-
cherheitshinweise zur Vermeidung von Personen-, Sach- und Umweltschäden unbedingt zu be-
achten:
During assembly and disassembly of pump drive type 4549 the following safety instructions to pre-
vent personal injury, damage to property and environmental damage or loss must be absolutely
observed:
Mögliche Gefahr(en) / Maßnahmen
Potential Danger(s)
Beschreibung / Description
/ Measures
Gefahr von Verbrennungen durch den Umgang mit erhitzten Bauteilen.
Tragen Sie beim Umgang mit heißen Teilen immer geeignete Schutz-
handschuhe.
Danger of burns due to the handling of heated components. Always wear
Warnung vor heißen Ober-
flächen suitable protective gloves when handling hot parts.
Beware of hot surfaces
Gefahr von Handverletzungen z.B. durch scharfe Kanten, herab- und/
oder herunterfallende Bauteile. Tragen Sie geeignete Schutzhandschuhe
zum Schutz vor Handverletzungen.
Danger of hand injury e.g. due to sharp edges, falling down components.
Gefahr von Handverlet-
zungen Wear suitable protective gloves as a protection against hand injury.
Beware of hand injury
Quetschgefahr durch umstürzendes Getriebes. Sichern Sie das Getriebe
gegen Umfallen. Tragen Sie Schutzschuhe.
Danger of being crushed due to upset of the gearbox. Secure the gearbox
aginst tipping over. Wear protective gloves.
Quetschgefahr
Danger of being crushed
Achten Sie beim Transport des Getriebes mittels Kran darauf, dass der
Kran und die verwendeten Anschlagmittel über ausreichende Tragfähig-
keit verfügen und in einwandfreiem Zustand sind. Halten Sie sich nicht
unter schwebenden Lasten auf.
Pay attention during transportation of the gearbox by means of a crane
Gefahr durch schwebende
Lasten
that the crane and the used lifting accessories hava a sufficient lifting
capacity. Do not remain under suspended loads.
Overhead load hazard
Beim Umgang mit hydraulischen Vorrichtungen bestehen Quetschgefah-
ren und Gefahren durch platzende Hydraulikschläuche. Verwenden Sie
nur einwandfreie hydraulische Vorrichtungen und beachten Sie die Be-
dienungsanleitung des Herstellers. When handling hydraulic devices there
is danger due to hydraulic oil. Only use correct devices and observe the
Gefahrstelle manufacturer’s instructions.
Hazard area
6
Service Manual 4549.01 SN3691273 RH340B
Beachten Sie die beim Umgang mit Chemikalien (Fett, Kleber, Öle, etc.)
üblichen Sicherheitshinweise und tragen Sie ggf. geforderte Persönliche
Schutzausrüstung.
When handling chemicals (fat, adhesive, oil, etc.) observe the usual
Gesundheitsschädliche safety instructions and wear the demanded personal protection equip-
Stoffe ment, if necessary.
Materials harmful to health
Gefährdung der Umwelt durch auslaufendes Getriebeöl. Verwenden Sie
geeignete Auffangwannen. Nehmen Sie verschüttetes oder ausgelaufe-
nes Öl mit flüssigkeitsbindendem Material auf und führen Sie es der
sachgerechten Entsorgung zu.
Endangerment of the environment by leaking gear oil. Use suitable col-
lecting trays. Take up burie or run out oil with liquid-binding material and
arrange for proper disposal.
Rutschgefahr durch ausgelaufenes Getriebeöl. Nehmen Sie verschüttetes
oder ausgelaufenes Öl mit flüssigkeitsbindendem Material auf und führen
Sie es der sachgerechten Entsorgung zu.
Slip hazard by leaking gear oil. Take up buried or run-out oil with liquid-
Rutschgefahr binding material and arrange for proper disposal.
Slip hazard
Anziehdrehmomente – Tightening torques
= 0,13 bis 0,17)
Standard-Anziehdrehmomente MA in Nm für ungeschmierte Schaftschrauben (
mit Regelgewinde ohne zusätzliche Einzelangaben (s. LSN 945 0201)
Standard-tightening torque MA in Nm for unlubricated shoulder stud ( = 0,13 bis 0,17) with standard thread
without additional details (LSN 945 0201)
Schraube
M6 M8 M 10 M 12 M 14 M 16 M 20 M 24 M 27 M 30 M 33 M 36 M 39 M 42
Screw
8.8 Dr. 8,5 21,1 42,2 73,6 114,8 176,6 358 618 903 1216 1687 2129 2757 3394
10.9 Dr. 12,4 30,4 60,8 104,0 166,8 255,1 510 873 1285 1736 2364 3021 3924 4836
Dr. = Drehmomentschlüssel (torque wrench)
7
Service Manual 4549.01 SN3691273 RH340B
Werkzeuge – Tools
Werkzeuge und Zubehör Tools and accessories
Drehmomentschlüssel: SW17; Torque wrench: SW17; SW19; SW22;
SW19; SW22; SW24; SW27; SW30 SW24; SW27; SW30
Maulschlüssel: SW17; SW19; SW22; Combination wrench: SW17; SW19;
SW24; SW27; SW30; SW41 SW22; SW24; SW27; SW30; SW41
Imbus: SW 10; SW 12; SW14; SW17 Imbus: SW 10; SW 12; SW14; SW17
Durchschlag: 6; 8; 10; 12 Punch: 6; 8; 10; 12
Gasbrenner Gas burner
Mittelfester Kleber Medium strength adhesive
Hochfester Kleber Higth strength adhesive
Anaerobe Dichtmasse anaerobic sealing compound Detergent
Reiniger Degreaser
Rissprüfung Check for cracks e.g.:
Spezialreiniger Special detergent
Eindringmittel Penetration substance
Entwickler Developer
Gewindestange M24x1000mm threaded rod M24x1000mm
Montagepaste Mounting paste
1. Einpressplatte
Disc for fitting
Ø D1 D1/ mm E / mm Montagehilfe für
Position
175 15 370
200 15 350,360,340,330
220 15 380
E
D2 2. Schlaghülse für RWDR
Striker sleeve for radial oil seals
D1
D1/ mm D2/mm Montagehilfe für
Position
107 114 400
30mm 50mm 127 144 410
8
Service Manual 4549.01 SN3691273 RH340B
3. Montagehilfe für Kugellager
D2 Fit up aid for ball bearings
D1 D1 / mm D2 / mm Montagehilfe für
Position
110 120 370
60mm
100mm
4. Abziehvorrichtung
Ø230mm Extractor device
Ø200mm
Demontagevorrichtung für Zwischenwelle Pos. 180
Disassembly device for intermediate shaft item 180
150mm
5. Hydraulikzylinder 250 KN + 400 KN
Hydraulic cylinder 250 KN + 400 KN
Hydraulikzylinder zum demontieren von Pos. 180
Hydraulic cylinder for disassembly of item 180.
6. Abziehvorrichtung
Detaching device
D1 D1/ mm D2 / mm t/ mm Demontagehilfe
für Position
25 85 25 180
D2
9
Service Manual 4549.01 SN3691273 RH340B
7. Abziehvorrichtung
D2 Detaching device
D1/ mm D2 / mm t/ mm Demontagehilfe
für Position
D1 25 230 25 180
8. Hydraulischer Dreiarmabzieher
Hydraulic-three-armed extractor
Demontagevorrichtung für Zwischenwelle Pos. 180
Disassembly device for intermediate shaft item 180
9. Augenschraube M16 x 150 mm
Eye bolt M16 x 150 mm
Augenschraube zum anheben von Profilhohlwellen
und Baugruppen.
Eye bolt for lifting profile hollow shafts and assembly
groups.
10. Zweiarmabzieher
Two-armed extractor
L1 / mm L2 / mm L3 / mm Demontagehilfe
für Position
13 340 220 340, 350, 360,
330, 360
L3
L1
L2
10
Service Manual 4549.01 SN3691273 RH340B
37mm 11. Montagedorn
Fit-up aid
Montagedorn zum eintreiben der Radialwellendicht-
ringe Pos. 390
60mm Fit-up aid for radial oil seals item 390.
20mm
79mm
12. Heizplatte
Heating plate
Heizofen zum Erwärmen der Innenringe der Kugella-
ger Pos. 360.
Heating furnace for heating the inner rings of the ball
bearings item 360.
13. Heizofen
Heating furnace
Heizofen zum Erwärmen der Innenringe der Kugella-
ger Pos.340, 350, 370.
Heating furnace for heating the inner rings of the ball
bearings item 340, 350, 370.
Sonderwerkzeuge können beim Hersteller bestellt werden.
Special tools can be ordered from the manufacturer.
Der Hersteller empfiehlt die Verwendung von Loctite.
Für die anaerobe Dichtmasse Loctite 573.
The manufacturer recommends using of Loctite.
For the anaerobic sealing compound Loctite 573.
11
Service Manual 4549.01 SN3691273 RH340B
Montageanleitung allgemein – General assembly instructions
ACHTUNG ! ATTENTION !
Unsachgemäße Handhabung beim Öffnen, Zerle- Inappropriate handling when opening, dismantling
gen und Zusammenbauen kann zur Gefährdung and assembling can lead to the endangerment of
von Personen, der Anlage und des Produktes füh- persons, the system and the product.
ren.
Therefore only technical personnel may execute
Derartige Arbeiten darf deshalb nur Fachpersonal such work, who was authorized and particularly
durchführen, das von Hersteller ermächtigt und trained by the manufacturer.
besonders ausgebildet wurde.
For damage, regardless of which type, which re-
Für Schäden, gleich welcher Art, die durch Nicht- sults from neglect of this regulation, the manufac-
beachtung dieser Vorschrift entstehen, übernimmt turer does not take over liability.
der Hersteller keine Haftung.
Montageanleitung Getriebe – Typ 4549.01 Assembly instructions gearbox type
4549.01
1. Zahnwelle Pos. 180 am Durchmesser mit Öl ein-
streichen.
Paste splined shaft item 180 with oil at the diameter
_
Innenring des Pendelrollenlagers Pos. 380 mittels
Wärmeofen auf ca. 100°C erwärmen und auf die
Zahnwelle aufziehen.
Heat inner ring of self-aligning roller bearing item
380 to approx. 100 °C using a heating furnace and
fit onto the splined shaft.
Stützscheibe Pos. 550 auflegen und mit dem Siche-
rungsring Pos. 490 sichern.
Apply supporting disc item 550 and secure with
circlip item 490.
Werkzeug / Tools:
- Wärmeofen / Heating furnace
- Sicherungsringzange A4 / circlip pliers A4
2. Lagerträger Pos. 030 aufstellen, im Lagerträger den
Lagersitz mit Öl einstreichen und die Zahnwelle
mittels Augenschraube und S-Haken in den Lager-
träger einfügen.
Set up bearing carrier item 030, paste the bearing
seat within bearing carrier with oil and insert the
splined shaft and the S-hook into the bearing
carrier.
Werkzeug / Tools:
- Öl / oil
- Augenschraube M24 / eye bolt M24
- S-Haken bis 150Kg / S-hook up to 150 kg
12
Service Manual 4549.01 SN3691273 RH340B
3. Laufring Pos. 240 und Zahnwelle mit Reiniger ent-
fetten.
Degrease ball race item 240 and splined shaft using
purifier.
Laufring mittels Wärmeofen auf ca. 60° erwärmen,
Innenflächen des Ringes mit mittelfestem Kleber
einstreichen und auf die Zahnwelle aufschrumpfen.
Heat the ball race up to approx. 60 °C using a heat -
ing furnace, paste the inner surfaces of the ball race
with medium strength adhesive and fit onto the
splined shaft.
Werkzeug / Tools:
- Wärmeofen / heating furnace
- Mittelfester Kleber / medium strength adhesive
- Reiniger / purifier
4. Die Differenz zwischen dem Lagerträger Pos. 030
und dem Dichtringdeckel Pos. 020 vermessen.
Measure the difference between bearing carrier
item 030 and the seal ring cover item 020.
Achtung! Es gilt: + 0mm – 0,2mm
Attention! It is imperative: + 0 mm – 0,2 mm
Es darf keine Vorspannung vorhanden sein.
There must not be any prestress.
Das maximale Axialspiel beträgt 0,2mm.
The maximum axial play is 0,2 mm.
Werkzeug / Tools:
- Digitaler Tiefenmesschieber / digital depth gauge
Messbereich: 150 mm / measurement
range: 150 mm
Ablesung: 0,01mm / readout: 0,01 mm
5. Radialwellendichtring Pos. 460 mittels Einpressplat-
te (Werkzeug Nr.1) eintreiben und mit Fett einstrei-
chen.
Drive in radial oil seal item 460 using a press-in
plate (see tool no.1) and paste with grease.
Dichtflächen des Dichtringdeckels Pos. 020 sowie
die Dichtflächen des Lagerträgers mit Reiniger
entfetten und mit anaerober Dichtmasse eindichten.
Degrease sealing surfaces of sealing ring cover
item 020 and bearing carrier using purifier and seal
with anaerobic sealing compound.
Werkzeug / Tools:
- Einpressplatte (Werkzeug Nr.1) / press-in plate
(see tool no.1)
- Anaerobe Dichtmasse / anaerobic sealing com-
pound
- Reiniger / purifier
13
Service Manual 4549.01 SN3691273 RH340B
6. Dichtringdeckel Pos. 020 am Lagerträger Pos. 030
befestigen.
Attach seal ring cover item 020 to the bearing car-
rier item 030.
Achtung! Darauf achten, dass der Radialwellen-
dichtring nicht beschädigt wird.
Attention! Pls. observe the radial oil seal not being
damaged.
Achtung! Die Schmiernuten im Dichtringdeckel
müssen mit den Schmiernuten im Lagerträger über-
einander liegen. (Siehe Markierungen Bild 5)
Attention! The oil grooves within the seal ring cover
must be on top of each other (see markings photo
no. 5).
Dichtringdeckel mit den Schrauben Pos. 595 ver-
schrauben (210Nm).
Screw together seal ring cover and screws item 595
(210 Nm).
Werkzeug / Tools:
- Stechschlüssel für Innensechskant SW 14 /
socket wrench for hexagon socket size 14
7. Baugruppe Lagerträger wenden und die Passfeder
Pos. 580 mittels Kupferhammer eintreiben.
Turn bearing carrier assembly and drive in the key
item 580 using a copper hammer.
Zahnwelle am Durchmesser mit Öl einstreichen
Paste the splined with oil.
Stirnrad Pos. 140 mittels Wärmeofen oder Indukti-
onswärmer auf ca. 100°C erwärmen und mittels
Augenschrauben und S-Haken auf die Zahnwelle
aufziehen.
Heat the spur gear item 140 to approx. 100 °C using
a heating furnace or induction heater and fit to the
splined shaft by means of eye bolts and S-hook.
Stirnrad mit Sicherungsring Pos. 510 sichern.
Secure the spur gear with circlip item 510.
Werkzeug / Tools:
- 2x Augenschrauben M12 / 2x eye bolt M12
- 2x S-Haken bis 150Kg / 2x S-hook up to 150 kg
- Wärmeofen oder Induktionswärmer / heating fur-
nace or induction heater
- Kupferhammer (500 Gr) / copper hammer (500 gr)
- Öl / oil
- Sicherungsringzange A4 / circlip pliers A4
14
Service Manual 4549.01 SN3691273 RH340B
8. Alle Laufringe Pos. 230 und 220 mittels Reiniger
entfetten.
Degreas all ball races item 230 and 220 using
purifier.
Laufringe auf ca. 60°C erwärmen, Innenseiten mit
mittelfestem Kleber einstreichen und auf die Zahn-
wellen Pos. 210 aufziehen. Kleberrückstände ent-
fernen.
Heat ball races to approx. 60 °C, paste the inner
surfaces with medium strength adhesive and fit onto
the splined shafts item 210. Remove adhesive resi-
dues.
Laufringe mit den Sprengringen Pos. 530, 540 si-
chern.
Secure ball races with snap rings item 530, 540.
Passfedern Pos. 560, 570 mittels Kupferhammer
eintreiben und mit Öl einstreichen.
Drive in keys item 560, 570 using a copper hammer
and paste with oil.
Werkzeug / Tools:
- Reiniger / purifier
- Wärmeofen / heating furnace
- Mittelfester Kleber / medium strength adhesive
- Kupferhammer (500 Gr) / copper hammer (500 gr)
- Öl / oil
9. Alle Stirnräder Pos. 170 und 150 mittels Wärmeofen
oder Induktionswärmer auf ca. 140°C erwärmen
und auf die Zahnwellen Pos. 210 und 190 aufzie-
hen.
Heat all spur gears item 170 and 150 to approx. 140
°C using a heating furnace or induction heater and
fit onto splined shafts item 210 and 190.
Stirnräder mit den Sicherungsringen Pos. 480 und
500 sichern.
Secure spur gears with circlips item 480 and 500.
Werkzeug / Tools:
- Wärmeofen oder Induktionswärmer / heating fur-
nace or induction heater
- Sicherungsringzange A4 / circlip pliers A4
15
Service Manual 4549.01 SN3691273 RH340B
10. Dichtflächen am Gehäuse und am Lagerträger mit-
tels Reiniger entfetten und mit anaerober Dichtmas-
se eindichten.
Degrease the housing and bearing carrier sealing
surfaces using purifier and seal with anaerobic seal-
ing compound.
Baugruppe Lagerträger mittels Augenschraube und
S- Haken in das Gehäuse einfügen.
Insert the bearing carrier assembly into the housing
using eye bolt and S-hook.
Achtung! Die Schmiertasche im Lagerträger muss
über der Nut im Gehäuse liegen!
Attention! The lubrication slot in the bearing carrier
must be on top of the groove within the housing!
Werkzeug / Tools:
- Reiniger / purifier
- Anaerobe Dichtmasse / anaerobic sealing com-
pound
- Augenschraube M24 / eye bolt M24
- S-Haken bis 150Kg / S-hook up to 150 kg
11. Baugruppe Lagerträger mittels Pos. 595 am Ge-
häuse befestigen (210Nm).
Attach the bearing carrier assembly item 595 to the
housing (210 Nm).
Werkzeug / Tools:
- Steckschlüssel für Innensechskant SW 14 / so-
cket wrench for hexagon socket size 14
12. Dichtflächen am Deckel Pos. 090 und am Gehäuse
mittels Reiniger entfetten und mit anaerober Dicht-
masse eindichten.
Degrease sealing surfaces of cover item 090 and
housing using purifier and seal with anaerobic seal-
ing compound.
Deckel mit Pos. 090 mit Schrauben Pos. 640 befes-
tigen (49Nm).
Fix cover item 090 with screws item 640 (49 Nm).
Werkzeug / Tools:
- Reiniger / purifier
- Anaerobe Dichtamsse / anaerobic sealing com-
pound
- Steckschlüssel für Außensechskant SW 19 / so-
cket wrench for hexagon head size 19
16
Service Manual 4549.01 SN3691273 RH340B
13. Radialwellendichtringe Pos. 390 in die Dichtringde-
ckel Pos. 070 mittels Vorrichtung und Hammer ein-
treiben.
Drive radial oil seals item 390 into seal ring cover
item 070 using device and a hammer.
Werkzeug / Tools:
- Vorrichtung (Werkzeug Nr.11)/ device (pls. see
tool no. 11)
- Hammer / hammer
14. Entlüftungsfilter Pos. 790 und Verschlussschraube
Pos. 700 in den Dichtringdeckel einfügen.
Insert vent filter item 790 and locking screw item
700 into the seal ring cover.
Dichtflächen am Dichtringdeckel Pos. 070 und am
Gehäuse mittels Reiniger entfetten und mit anaero-
ber Dichtmasse eindichten.
Degrease sealing surfaces of seal ring cover item
070 and of housing using purifier and seal with an-
aerobic sealing.
Dichtringdeckel in das Gehäuse einfügen.
Insert seal ring cover into the housing.
Achtung! Die Schmiernut muss nach oben zeigen!
Attention! The oil groove must face upwards!
Werkzeug/ Tools:
- Steckschlüssel für Außensechskant SW 14 / so-
cket wrench for hexagon head size 14
- Steckschlüssel für Innensechskant SW 6 / socket
wrench for hexagon socket size 6
- Anaerobe Dichtmasse / anaerobic sealing com-
pound
- Reiniger / purifier
15. Dichtringdeckel Pos. 070 mit Pos. 670 befestigen
(210Nm).
Fix seal ring cover item 070 (210 Nm).
Werkzeug / Tools:
- Steckschlüsse für Außensechskant SW 24 / so-
cket wrench for hexagon head size 24
17
Service Manual 4549.01 SN3691273 RH340B
16. Gehäuse auf die Antriebsseite ablegen, sodass es
seine Lage nicht verändern kann.
Deposit the housing onto its drive side so that it
cannot change position.
Sämtliche Pendelrollenlager Pos. 350 und Rillenku-
gellager Pos. 340 mittels Einpressplatte in das Ge-
häuse einfügen.
Insert all self-aligning roller bearings item 350 and
grooved ball bearings item 340 into the housing
using a press-in plate.
Sämtliche Verschlussschrauben Pos. 770, 730,
Magnetstopfen Pos. 780 und die Einsteck -
winkelverschraubung Pos. 900 in das Gehäuse
einfügen.
Insert all locking screws item 770, 730, magnet
plugs item 780 and plug-in elbow item 900 into the
housing.
Werkzeug / Tools:
- Einpressplatte (Werkzueg Nr.1)/ press-in plate
(see tool no.1)
- Steckschlüssel für Außensechskant SW 30, 27,
22 / socket wrench for hexagon head
size 30, 27, 22
17. O-Ring Pos. 435 mit Fett einstreichen und in die
O-Ringnut einfügen.
Grease O-ring item 435 and insert into the groove.
18. Lagersitz der Zahnwelle Pos. 180 und Bohrung mit
Öl einstreichen.
Paste bearing carrier of splined shaft item 180 with
oil as well as the bore.
Innenring des Pendelrollenlagers Pos. 370 mittels
Heizplatte auf ca. 100°C erwärmen und mittels Ein-
pressplatte bis zum Grund eintreiben.
Heat inner ring of self-aligning roller bearing item
370 to approx. 100 °C using a heating furnace and
drive in to the bottom using a press-in plate.
Werkzeug / Tools:
- Öl / oil
- Einpressplatte (Werkzueg Nr.1)/ press-in plate
(see tool no.1)
- Heizplatte (Werkzeug Nr. 12/ heating furnace (see
tool no.12)
18
Service Manual 4549.01 SN3691273 RH340B
19. Deckel Pos. 100 mittels Reiniger entfetten und mit
anaerober Dichtmasse eindichten.
Degrease cover item 100 using purifier and seal
with anaerobic sealing compound.
Deckel aufsetzten und mit Pos. 660 verschrauben
( 210Nm).
Attach cover and screw together with item 660 (210
Nm).
Werkzeug / Tools:
- Reiniger / purifier
- Anaerobe Dichtmasse / anaerobic sealing com-
pound
- Steckschlüssel für Außensechskant SW 24 / so-
cket wrench for hexagon head size 24
20. Pendelrollenlager Pos. 370 mittels Einpressplatte in
das Gehäuse eintreiben.
Drive self-aligning roller bearing item 370 into the
housing using a press-in plate.
Bohrung mit Öl einstreichen.
Oil the bore.
Werkzeug / Tools:
- Einpressplatte (Werkzueg Nr.1)/ press-in plate
(see tool no.1)
- Hammer / hammer
- Öl / oil
21. Stirnrad Pos. 160 mittels Heizofen oder Induktions-
wärmer auf ca. 140°C erwärmen.
Heat spur gear item 160 to approx. 140 °C using a
heating furnace or an induction heater.
Innenring des Pendelrollenlagers Pos. 370 mittels
Heizofen auf ca. 100°C erwärmen.
Heat the inner ring of self-aligning roller bearing item
370 to approx. 100 °C using a heating furnace.
Werkzeug / Tools:
- Wärmeofen oder Induktinswärmer / heating fur-
nace or induction heater
- Heizofen (Werkzeug Nr.13) / heating furnace (see
tool no.13)
19
Service Manual 4549.01 SN3691273 RH340B
22. Distanzring Pos. 270 auf das Pendelrollenlager Pos.
370 auflegen.
Attach spacer item 270 onto self-aligning roller bear-
ing item 370.
Das erwärmte Stirnrad Pos. 160 auf den Distanzring
legen und ausrichten.
Attach the heated spur gear item 160 onto the
spacer and adjust.
23. Zahnwelle Pos. 200 mittels Augenschraube einset-
zen und eintreiben.
Insert splined shaft item 200 using an eye bolt and
drive in.
Werkzeug / Tools:
- Hammer / hammer
- Augenschraube M16x150mm / eye bolt M16x150
mm
24. Innenring des Pendelrollenlagers Pos. 370 auf ca.
100°C erwärmen und mittels Buchse auf die Welle
eintreiben.
Heat the inner ring of self-aligning roller bearing item
370 to approx. 100 °C and force onto the shaft by
means of a sleeve.
Werkzeug / Tools:
- Hammer / hammer
- Buchse (Werkzueg Nr.3)/ sleeve (see tool no.3)
20
Service Manual 4549.01 SN3691273 RH340B
25. Dichtflächen der Anbauflansch Pos. 050 mittels
Reiniger entfetten, mit anaerober Dichtmasse ein-
dichten und mit Pos. 660 befestigen (210Nm).
Degrease surfaces of mounting flange item 050
using purifier and seal with anaerobic sealing com-
pound and fix with item 660 (210 Nm).
Werkzeug / Tools:
- Reiniger / purifier
- Anaerobe Dichtmasse / anaerobic sealing com-
pound
- Steckschlüssel für Außensechskant SW 24 / so-
cket wrench for hexagon head size 24
26. Innenringe der Pendelrollenlager Pos. 350 und In-
nenringe der Rillenkugellager Pos. 340 mittels Heiz-
ofen auf ca. 100°C erwärmen und die Baugruppen
mittels Augenschraube und S-Haken in das Gehäu-
se einfügen.
Heat inner rings of self-aligning roller beaing item
350 and inner rings of grooved ball bearing item 340
to approx. 100 °C using a heating furnace and inser t
the assemblies into the housing using eye bolt and
S-hook.
Werkzeug / Tools:
- Heizofen (Werkzeug Nr.13) / heating furnace (see
tool no.13)
- Augenschraube M16x150mm / eye bolt M16 x150
mm
- S-Haken bis 150Kg / S-hook up to 150 kg
27. Anbauflansch Pos. 040 Vorbereiten.
Pendelrollenlager Pos. 360 mittels Einpressplatte in
die Anbauflansch Pos. 040 eintreiben.
O-Ring Pos. 450 aufsetzen.
Entlüftungsfilter Pos. 790 und Verschlussschrauben
Pos. 700 einschrauben.
Prepare mounting flange item 040.
Drive self-aligning roller bearing into the mounting
flange item 040 using a press-in plate.
Attach O-ring item 450.
Werkzeug / Tools:
- Einpressplatte (Werkzueg Nr.1)/ press-in plate
(see tool no.1)
- Steckschlüssel für Außensechskant SW 14 / so-
cket wrench for hexagon head size 14
- Steckschlüssel für Innensechskant SW 6 / socket
wrench for hexagon socket size 6
21
Service Manual 4549.01 SN3691273 RH340B
28. Anbauflansch Pos. 060 Vorbereiten.
Prepare mounting flange item 060.
Rillenkugellager Pos. 330 in die Anbauflansch Pos.
060 eintreiben.
Drive ball bearing item 330 into mounting flange
item 060.
O-Ring Pos. 440 einsetzen.
Insert O-ring item 440.
Entlüftungsfilter Pos. 790 und Verschlussschrauben
Pos. 700 einschrauben.
Screw vent filter item 790 and plugs item 700.
Werkzeug / Tools:
- Einpressplatte (Werkzeug Nr.1)/ press-in plate
(see tool no.1)
- Steckschlüssel für Außensechskant SW 14 / so-
cket wrench for hexagon head size 14
- Steckschlüssel für Innensechskant SW 6 / socket
wrench for hexagon socket size 6
29. Innenring des Pendelrollenlagers Pos. 360 mittels
Heizofen auf ca. 100°C erwärmen.
Heat the inner ring of self-aligning roller bearing item
360 to approx. 100 °C using a heating furnace.
Werkzeug / Tools:
- Heizplatte (Werkzeug Nr. 12) / heating furnace
(see tool no. 12)
30. Anbauflansch Pos. 040 mittels Augenschrauben und
S-Haken in das Gehäuse einfügen.
Insert mounting flange item 040 into the housing
using eye bolts and S-hook.
Achtung! Anbauflansch wird während des einfü-
gens mit einem Bolzen gegen Verdrehen gesichert.
Attention! The mounting flange is to be secured
against distortion by means of a bolt during inser-
tion.
Werkzeug / Tools:
- 2x Augenschrauben M20 / 2x eye bolt M20
- 2x S-Haken bis 150Kg / 2x S-hook up to 150 kg
- Bolzen M16x100mm / bolt M16x100 mm
22
Service Manual 4549.01 SN3691273 RH340B
31. Anbauflansch Pos. 040 mit Pos. 600 Befestigen
(210Nm).
Fix mounting flange item 040 by means of item 600
(210 Nm).
Innenring der Pendelrollenlager Pos. 360 mittels
Durchschlag und Hammer nachsetzen.
Adjust inner ring of self-aligning roller bearing item
360 using a punch and a hammer.
Werkzeug / Tools:
- Hammer / hammer
- Durchschlag / punch
- Steckschlüssel für Außensechskant SW 24 / so-
cket wrench for hexagon head size 24
32. Radialwellendichring Pos. 410 mittels Vorrichtung
und Hammer eintreiben.
Drive in radial oil seal item 410 using a device and a
hammer.
Für die Montage der Abtriebe 3 und 4 siehe
Schritte 29 bis 32.
Pls. see step 29-32 for the assembly of output 3
and 4.
Werkzeug / Tools:
- Hammer / hammer
- Vorrichtung (Werkzeug Nr. 2) / device (see tool no.
2)
33. Sicherungsring Pos. 520 mittels Sicherungsringzan-
ge in die Zahnwelle Pos. 200 einfügen.
Insert circlip item 520 into splined shaft item 200
using circlip pliers.
Werkzeug / Tools:
- Sicherungsringzange J2 / circlip pliers J2
23
Service Manual 4549.01 SN3691273 RH340B
34. Kupplungsstück Pos. 300 mit Montagepaste ein-
streichen und in die Zahnwelle Pos. 200 einfügen.
Paste coupling piece item 300 with fitting grease
and insert into the splined shaft item 200.
O-Ring Pos. 420 auf die Schmierölpumpe Pos. 870
auflegen.
Attach the O-ring item 420 to the lube oil pump item
870.
Werkzeug / Tools:
- Montagepaste / Mounting paste
35. Schmierölpumpe Pos. 870 aufsetzen und mit Pos.
590 befestigen (49Nm).
Attach lube oil pump item 870 and fix with item 590
(49 Nm).
Gerade-Flansch-Verschraubung Pos. 910 anbrin-
gen.
Fix straight flanged connection item 910.
Werkzeug / Tools:
- Steckschlüssel für Innensechskant SW 10 / socket
wrench for hexagon socket size 10
- Steckschlüssel für Innensechskant SW 6 / socket
wrench for hexagon socket size 6
36. Rohr Pos. 280 einfügen, ausrichten und Überwurf-
muttern befestigen.
Insert tube item 280, adjust ist and fix sleeve nuts.
Werkzeug / Tools:
- Maulschlüssel SW 32 / wrench size 32
24
Service Manual 4549.01 SN3691273 RH340B
37. Zwischendeckel Pos. 110 vorbereiten.
Prepare intermediate cover item 110.
Abdeckblech Pos. 250 mit zwei Schrauben Pos. 620
befestigen (mit hochfestem Kleber sichern).
Secure the metal cover item 250 using two screws
item 620 (secure with Higth strength adhesive).
Drei Schrauben Pos. 260 einschrauben (mit hoch-
festem Kleber sichern).
Screw three screws item 260 (secure with Higth
strength adhesive).
Werkzeug / Tools:
- Steckschlüssel für Außensechskant SW 19 / so-
cket wrench for hexagon head
- Maulschlüssel SW 10 / wrench size 10
- Hochfester Kleber/ High strength adhesive
38. Deckel Pos. 120 und Zwischendeckel Pos. 110 mit-
tels Reiniger entfetten und mit anaerober Dichtmas-
se eindichten.
Degrease cover item 120 and intermediate cover
item 110 using purifier and seal with anaerobic seal-
ing compound.
Werkzeug / Tools:
- Anaerobe Dichtmasse / anaerobic sealing com-
pound
- Reiniger / purifier
39. Deckel Pos. 120 und Zwischendeckel Pos. 110 auf-
legen und mit Pos. 600 befestigen (210Nm).
Attach cover item 120 and intermediate cover item
110 and fix with item 600 (210 Nm).
Werkzeug / Tools:
- Steckschlüssel für Aussensechskant SW 24 /
wrench for hexagon head
25
Service Manual 4549.01 SN3691273 RH340B
40. Gehäuse auf die Pumpenseite ablegen, sodass es
seine Lage nicht verändern kann.
Put the housing down onto the pump side so that
the position cannot be changed.
Pendelrollenlager Pos. 370 mit dem Sicherungsring
Pos. 470 sichern.
Secure self-aligning roller bearing item 370 using
circlip item 470.
O-Ring Pos. 430 mit Fett einstreichen und in die Nut
einfügen.
Grease the O-ring item 430 and insert into the
groove.
Werkzeug / Tools:
- Sicherungsringzange A4 / circlip pliers A4
41. Deckel Pos. 130 eintreiben.
Achtung! Auf die Lage der Schmiernuten achten.
Drive in cover item 130.
Attention! Observe the position of the oil grooves.
Scheiben Pos. 680 auflegen und Schrauben Pos.
630 befestigen (49Nm) (mit mittelfestem Kleber
sichern).
Attach disks item 680 and fix with screws item 630
(49 Nm) (secure with Higth strength adhesive).
Ger.-Einschr.Verschraubung Pos. 880 einschrau-
ben.
Screw in the straight screwed coupling item 880.
Werkzeug / Tools:
- Steckschlüssel für Aussensechskant SW 19 / so-
cket wrench for hexagon head size 19
- Mittelfester Kleber / medium strength adhesive
- Maulschlüssel SW 22 / wrench size 22
42. Rohr Pos. 290 einfügen, ausrichten und Überwurf-
muttern befestigen.
Insert tube item 290, adjust it and fix with sleeve nut.
Werkzeug / Tools:
- Maulschlüssel SW 32 / wrench size 32
26
Service Manual 4549.01 SN3691273 RH340B
43. Lochscheibe Pos. 310 mittels Sechskantschrauben
Pos. 650 an der Welle befestigen.
Attach the perforated disk item 310 to the shaft us-
ing hexagon screws item 650.
Werkzeug / Tools:
- Steckschlüssel für Aussensechskant SW 24 /
wrench for hexagon head bolts size 24
Getriebe anhand der Anbauzeichnung überprü-
fen!
Inspect the gearbox by means of the assembly
drawing!
27
Service Manual 4549.01 SN3691273 RH340B
Demontageanleitung allgemein – General disassembly instructions
Für die Demontage des Getriebes sind folgende For the disassembly of the gearbox the following
Vorarbeiten erforderlich: preliminary work is necessary:
Getriebe nur in ausgebautem Zustand Dismantle gearbox only in removed
demontieren. condition.
Alle nicht zum Getriebe gehörenden All parts not belonging to the gearbox
Teile müssen abgebaut werden. must be removed.
Getriebeöl ablassen. Lösen Sie dafür Drain gear oil. For that purpose loosen
Verschlussschraube Pos. 760. plug item 760
Verwenden Sie dabei geeignete Auf- Use suitable collection receptacles oil
fanggefäße Ölinhalt ca. 80 l. content approx. 80 l.
Pumpenleitungen abbauen. Remove pump pipes.
Öl aus den Pumpenanschlusskammern Drain oil out of the pump connection
ablassen. chambers.
Pumpen vom Getriebe abbauen. Remove pumps from the gearbox.
Achten Sie beim Transport auf eine Pay attention in the case of transport to
ausreichende Tragkraft des Kranes. a sufficient carrying capacity of the
Getriebegewicht ohne Pumpen ca. crane. Gearbox weight without pumps
2000 kg. approx. 2000 kg.
Zur Demontage/Montage legen Sie das For disassembly/re-assembly place the
Getriebe auf den SAE-Flansch bzw. auf gearbox onto the SAE flange or onto
der Pumpenseite ab. the pump side.
Stellen Sie sicher, dass das abgesetzte Guarantee that the put down gearbox
Getriebe seine Lage nicht ändern kann. cannot change its position.
Beachten Sie die Hinweise auf der Er- Observe the information on the spare
satzteilzeichnung E4549 und auf der part drawing E4549 and on the assem-
Anbauzeichnung A4549. bly drawing A4549.
Demontageanleitung Getriebe Typ 4549.01 – Disassembly instructions type 4549.01
1. Getriebe abtriebsseitig ablegen, sodass es seine
Lage nicht verändern kann.
Put the gearbox onto the output side so that the
position cannot be changed.
Überwurfmuttern des Rohres Pos. 290 lösen und
das Rohr entfernen.
Loosen sleeve nuts of tube item 290 and remove
the tube.
Werkzeug / Tools:
- Maulschlüssel SW 32 / wrench size 32
28
Service Manual 4549.01 SN3691273 RH340B
2. Zwei Schrauben Pos. 630 lösen und die Scheiben
Pos. 680 entfernen.
Loosen two screws item 630 and remove the disks
item 680.
Zwei Augenschrauben in den Deckel Pos. 130 ein-
schrauben und diesen mittels zwei Montierhebel
herausziehen.
Screw two eye bolts into the cover item 130 and pull
it off using two mounting levers.
Werkzeug / Tools:
- Steckschlüssel für Außensechskant SW19 /
wrench for hexagon head size 19
- 2x Augenschrauben M8 / 2x eye bolt M8
- 2x Montierhebel / 2x mounting lever
3. Sicherungsring Pos. 470 mittels Sicherungsring-
zange entfernen.
Remove circlip item 470 using circlip pliers.
O-Ring Pos. 430 entnehmen.
Take out the O-ring item 430.
Werkzeug / Tools:
- Sicherungsringzange A4 / circlip pliers A4
4. Schrauben Pos. 640 lösen und Deckel Pos. 080
entfernen.
Loosen screws item 640 and remove cover item
080.
Werkzeug / Tools:
- Steckschlüssel für Außensechskant SW 19 /
wrench for hexagon head size19
29
Service Manual 4549.01 SN3691273 RH340B
5. Schrauben Pos. 670 lösen und Anbauflansch Pos.
070 mit zwei Abdruckschrauben entfernen.
Loosen screws item 670 and remove mounting
flanges item 070 using two jack screws.
Werkzeug / Tools:
- Steckschlüssel für Außensechskant SW 24 /
wrench for hexagon head size 24
- 2x Abdruckschrauben M16x150mm /
2x jack screws M16x150 mm
6. Baugruppe Zahnwelle der Abtriebe 5 und 6 mittels
Augenschraube und S-Haken herausziehen.
Pull out the splined shaft assembly of output 5 and
6 using an eye bolt and an S-hook.
Werkzeug / Tools:
- S-Haken bis 150Kg / S-hook up to 150 kg
- Augenschraube M16x150mm(Werkzueg Nr.9)/
eye bolt M16x150 mm (see tool no.9)
7. Befestigungsschrauben Pos. 595 des Lagerträgers
Pos. 030 lösen und entfernen.
Loosen fixing bolts item 595 of bearing carrier item
030 and remove.
Werkzeug / Tools:
- Steckschlüssel für Innensechskant SW 14 /
wrench for hexagon socket size 14
30
Service Manual 4549.01 SN3691273 RH340B
8. Baugruppe Lagerträger mittels Augenschraube und
Kran herausziehen. Gegebenenfalls mit einem
Hammer nachsetzen, um den Dichtfilm zu lösen.
Pull out the bearing carrier assembly using an eye
bolt and a crane. If necessary, adjust with a ham-
mer in order to loosen the sealing film.
Werkzeug / Tools:
- Augenschraube M24 / eye bolt M24
- S-Haken bis 500 Kg / S-hook up to 500 kg
9. Befestigungsschrauben Pos. 595 lösen und Dicht-
ringdeckel Pos. 020 mit zwei Abdruckschrauben
abdrücken.
Loosen fixing bolts item 595 and force off the seal
ring cover item 020 using two jack screws.
Werkzeug / Tools:
- Steckschlüssel für Innensechskant SW 14 /
wrench for hexagon socket size 14
- 2x Abdruckschrauben M16x150mm /
2x jack screws M16x150 mm
10. Baugruppe Lagerträger wenden.
Turn the bearing carrier assembly.
Pendelrollenlager Pos. 370 mittels Zweiarmabzieher
abziehen.
Pull of the self-aligning roller bearing item 370 using
a two-armed extracto.
Werkzeug / Tools:
- Zweiarmabzieher Größe 4 (Werkzeug Nr.10)/ two-
armed extractor size 4 (see tool no.10)
31
Service Manual 4549.01 SN3691273 RH340B
11. Sicherungsring Pos. 510 mittels Sicherungsring-
zange entfernen.
Remove circlips item 510 using circlip pliers.
Werkzeug / Tools:
- Sicherungsringzange A4 / circlip pliers A4
12. Stirnrad Pos. 140 mittels Hydraulischem Dreiarm-
abzieher abziehen.
Pull off the spur gear ite 140 using a hydraulic thre-
armed extractor.
Gegebenenfalls Stirnrad mittels Gas –
Sauerstoffbrenner erwärmen.
If necessary. heat the spur gear by means of a gas-
oxygen burner.
Werkzeug / Tools:
- Hydraulischer Dreiarmabzieher (Werkzeugliste Nr.
8) / hydraulic three-armed extractor (see tool no.8)
- Gas –Sauerstoffbrenner / gas-oxygen
burner
13. Lagerträger Pos. 030 mittels Schonhammer entfer-
nen.
Remove the bearing carrier item 030 using a soft
hammer.
Sicherungsring Pos. 490 entfernen und Distanz-
scheibe Pos. 550 entnehmen.
Remove the circlip item 490 and take out the spacer
item 550.
Werkzeug / Tools:
- Sicherungsringzange A4 / circlip pliers A4
32
Service Manual 4549.01 SN3691273 RH340B
14. Pendelrollenlager Pos. 380 mittels Hydraulischem
Dreiarmabzieher abziehen.
Remove the self-aligning roller bearing item 380
using a hydraulic three-armed extractor.
Gegebenenfalls muss der Innenring des Pendelrol-
lenlagers mittels Gas –Sauerstoffbrenner erwärmt
werden.
If necessary, the inner ring of the self-aligning roller
bearing must be heated by means of a gas-oxygen
burner.
Werkzeug / Tools:
- Hydraulischer Dreiarmabzieher (Werkzeug Nr. 8) /
hydraulic three-armed extractor (see tool no. 8)
- Gas –Sauerstoffbrenner / gas-oxygen
burner
15. Getriebe antriebsseitig ablegen, sodass es seine
Lage nicht verändern kann.
Put the gearbox onto the input side so that the
position cannot be changed.
Überwurfmuttern des Rohres Pos. 280 lösen und
Rohr entfernen.
Loosen sleeve nuts of the tube item 280 and
remove the tube.
Werkzeug / Tools:
- Maulschlüssel SW 32 / wrench size 32
16. Gerade Ringverschraubung Pos. 910 entfernen.
Befestigungsschrauben Pos. 590 lösen und die
Schmierölpumpe Pos. 870 entnehmen.
Remove the straight screw connect item 910,
loosen the fixing bolts item 590 and take out the
lube oil pump item 870.
Das in der Zahnwelle befindliche Kupplungsstück
Pos. 300 entnehmen.
Take out the coupling piece item 300 remaining in
the splined shaft.
Werkzeug / Tools:
- Steckschlüssel für Innensechskant SW 8, 6 /
wrench for hexagon socket size 8, 6
33
Service Manual 4549.01 SN3691273 RH340B
17. Befestigungsschrauben Pos. 600 von den Abtrieben
1 und 2 lösen und entfernen.
Loosen and remove fixing bolts item 600 from the
output 1 and 2.
Werkzeug / Tools:
- Steckschlüssel für Außensechskant SW 24 /
wrench for hexagon head size 24
18. Anbauflansche Pos. 040 mittels Abdruckschrauben
abdrücken.
Remove the mounting flanges item 040 by means of
jack screws.
Werkzeug / Tools:
- 2x Abdruckschrauben M16x150mm /
2x jack screws M16x150 mm
19. Anbauflansche Pos. 040 mittels Augenschrauben
und S-Haken entfernen.
Remove the mounting flanges item 040 by means of
eye bolts and an S-hook.
Gegebenenfalls kommen beim demontieren der
Anbauflansche die Zahnwellen schon mit.
Maybe the splined shafts become already loose
when disassembling the mounting flanges.
Baugruppe Zahnwelle der Abtriebe 1 und 2 mittels
Augenschraube und S-Haken herausziehen.
Pull out the splined shaft assembly of output 1 and 2
using an eye bolt and an S-hook.
Werkzeug / Tools:
- 2x Augenschrauben M20 / 2x eye bolts M20
- 2x S-Haken bis 150Kg / 2x S-hook up to 150 kg
- Augenschraube M16x150mm(Werkzueg Nr.9)/ eye
bolt M16x150 mm (see tool no.9)
- S-Haken bis 150Kg / S-hook up to 150 kg
34
Service Manual 4549.01 SN3691273 RH340B
20. Befestigungsschrauben Pos. 610 der Abtriebe 3 und
4 lösen.
Loosen fixing bolts item 610 of the output 3 and 4.
Anbauflansche Pos. 060 mittels zwei Augenschrau-
ben und S-Haken entfernen.
Remove the mounting flanges item 060 by means of
two eye bolts and an S-hook.
Werkzeug / Tools:
- Steckschlüssel für Außensechskant SW 24 /
wrench for hexagon head size 24
- 2x Augenschrauben M16 / 2x eye bolt M16
- 2x S-Haken bis 150Kg / 2x S-hook up to 150 kg
21. Befestigungsschrauben Pos. 660 lösen und Deckel
Pos. 100 mittels Montierhebel entnehmen.
O-Ring Pos. 370 aus der Nut entfernen.
Loosen fixing bolts item 660 and take out the cover
item 100 using a mounting lever.
Remove the O-ring item 370 from the groove.
Werkzeug / Tools:
- Steckschlüssel für Außensechskant SW 24 /
wrench for hexagon head size 24
- 2x Montierhebel / 2x mounting lever
22. Befestigungsschrauben Pos. 660 lösen und Anbau-
flansch Pos. 050 mittels zwei Abdruckschrauben
abdrücken.
Loosen fixing bolts item 660 and remove the mount-
ing flange item 050 by means of two jack screws.
Werkzeug / Tools:
- Steckschlüssel für Außensechskant SW 24 /
wrench for hexagon head size 24
- 2x Abdruckschrauben M16x150mm / 2x jack screw
M16x150 mm
35
Service Manual 4549.01 SN3691273 RH340B
23. Sicherungsring Pos. 520 mittels Sicherungsringzan-
ge aus der Zahnwelle Pos. 200 entfernen.
Remove circlip item 520 from the splined shaft item
200 using circlip pliers.
Werkzeug / Tools:
- Sicherungsringzange J3 / circlip pliers J3
24. M16x500mm Gewindestange in die Zahnwelle Pos.
1 200 bis zum Anschlag einschrauben und diese mit-
2
3 tels Hydraulischem Zylinder aus dem Zahnrad Pos.
160 herausziehen.
Screw a threaded rod M16x500 mm into the splined
4 shaft item 200 as far as it will go and pull it out of the
gear item 160 by means of a hydraulic cylinder.
5
Werkzeug / Tools:
- 1 Gewindestange M16x800mm / threaded rod
6
M24x800 mm
- 2 M16 Mutter / M16 screw nut
- 3 Scheibe (Werkzeug Nr. 6) / disc (see tool no. 6)
- 4 Hydraulikzylinder (Werkzeug Nr. 5) / hydraulic
cylinder (see tool no.5)
- 5 Scheibe (Werkzeug Nr. 7/ Plate (see tool no. 7)
- 6 Hülse (Werkzeug Nr. 4)/ bushing (see tool no. 4)
25. Sämtliche Verschlussschrauben Pos. 730, 770, 710,
760 und 780 aus dem Gehäuse entfernen.
Remove all locking screws item 730, 770, 710, 760
and 780 from the housing.
Werkzeug / Tools:
- Steckschlüssel für Außensechskant SW 30, 22, 27
/ wrench for hexagon head size 30, 22, 27
36
Service Manual 4549.01 SN3691273 RH340B
26. Getriebe Senkrecht aufstellen, sodass es seine
Lage nicht verändern kann.
Put the gearbox upright so that the position cannot
be changed.
Befestigungsschrauben Pos. 600 lösen und Deckel
Pos. 120 sowie Zwischendeckel Pos. 110 mittels
vier Abdruckschrauben abdrücken.
Loosen fixing bolts item 600 and remove the cover
item 120 as well as the intermediate cover item 110
using four jack screws.
Deckel und Zwischendeckel mittels Augenschrau-
ben und Kran entfernen.
Remove the cover and the intermediate cover using
eye bolts and a crane.
Werkzeug / Tools:
- Steckschlüssel für Außensechskant SW 24 /
wrench for hexagon head size 24
- 4x Abdruckschrauben M16x150mm /
4x jack screw M16x150 mm
27. Sämtliche Pendelrollenlager Pos. 350, 360 und Ril-
lenkugellager Pos. 330, 340 mittels Zweiarmabzie-
her abziehen.
Pull off all self-aligning roller bearings item 350, 360
as well as grooved ball bearings item 330, 340
using a two-armed extractor.
Sicherungsringe Pos. 480 und Pos. 500 entfernen.
Remove circlips item 480 and 500.
Stirnräder Pos. 170 und 150 mittels Hydraulikpresse
abpressen.
Press of the spur gears item 170 and 150 by means
of a hydraulic press.
Gegebenenfalls Stirnräder mittels Gas –
Sauerstoffbrenner erhitzen.
If necessary, heat the spur gears by means of a
gas-oxygen burner.
Werkzeug / Tools:
- Zweiarmabzieher Größe 4 / two-armed extractor
size 4
- Sicherungsringzange A4 / circlip pliers A4
- Hydraulikpresse bis 10 Tonnen / hydraulic press
up to 10 t
- Gas –Sauerstoffbrenner / gas-oxygen
burner
37
Service Manual 4549.01 SN3691273 RH340B
28. Alle Radialwellendichtringe Pos. 400, 390, 460 und
410 mittels Durchschlag und Hammer entfernen.
Remove all radial oil seals item 400, 390, 460 and
410 using a punch and a hammer.
Alle Verschlussschrauben Pos. 700 und Entlüf-
tungsfilter Pos. 790 entfernen.
Remove all locking screws item 700 and the vent
filter item 790.
Alle O-Ringe Pos. 440 und 450 entfernen.
Remove all O-rings item 440 and 450.
Werkzeug / Tools:
- Durchschlag / punch
- Hammer / hammer
- Steckschlüssel für Außensechskant SW14,13 /
wrench for hexagon head size 14, 13
29. Sämtliche Ölleitbleche entfernen und den Zwi-
schendeckel Pos. 110 sowie Deckel Pos. 120 Rei-
nigen und überprüfen.
Remove all oil baffles as well as the intermediate
cover item 110. Clean and inspect the cover item
120.
Werkzeug / Tools:
- Mauschlüssel SW 8 / wrench size 8
- Steckschlüssel für Außensechskant SW 19 /
wrench for hexagon head size 19
Alle Getriebekomponenten reinigen.
Clean all the gearbox components.
- siehe Prüfbericht / see the test report
38
Service Manual 4549.01 SN3691273 RH340B
Problemanalyse – Troubleshooting
Ölstandskontrolle – Ölwechsel Oil level control – Oil change
Ölstandskontrollen und Ölwechsel sind der Be- Oil level checks and oil changes are to be learnt
triebsanleitung zu entnehmen. from the operating instructions.
Undichtigkeit Leakage
Undichtigkeiten lokalisieren. Locate leakage.
Bei beschädigtem Radialwellendichtring Pos. 460 If the radial shaft sealing ring item 460 is damaget
muss dieser getauscht werden. Beim Wechseln it must be replaced. When changing the radial
des Radialwellendichtringes ist darauf zu achten, shaft sealing ring, make sure that the gasket seats
dass die Dichtringsitze an der Zahnwelle nicht on the gear shaft is not damaged. In case of dam-
beschädigt wird. Bei Beschädigungen sind auch age, these must be changed too.
diese zu wechseln.
With damaged radial seals item 390, 400, 410
Bei beschädigten Radialwellendichtringen Pos. these must be exchanged. When changing the
390, 400, 410 müssen diese getauscht werden. radial seals it is to be made certain that the seal
Beim Wechseln der Radialwellendichtringe ist dar- seats at the profile hollow shafts and the ball races
auf zu achten, dass die Dichtringsitze an den Pro- are not damaged. When damaged also these have
filhohlwellen und an den Laufringen nicht beschä- to be exchanged.
digt sind. Bei Beschädigungen sind auch diese zu
With leakage between pump flange and housing it
wechseln.
is to be examined whether the O-ring is still alright.
Bei Undichtigkeiten zwischen Pumpenanbau- Exchange of the O-ring is described in the disas-
flansch und Gehäuse ist zu prüfen, ob der O-Ring sembly instructions.
noch i. O. ist. Austausch des O-Rings in der De-
Operational noise
montageanleitung beschrieben.
The operational noise should be smooth and regu-
Laufgeräusche
lar. If indefinable strong (high) operational noise
Das Laufgeräusch soll weich und gleichmäßig comes up you have to try to locate it. With damage
sein. Falls undefinierbare starke (hohe) Laufgeräu- at the gear wheels or ball bearings the gearbox
sche auftreten, muss versucht werden, diese zu must be dismantled and the defective unit must be
lokalisieren. Bei Beschädigungen an Zahnrädern exchanged in accordance with the disassembly
oder Kugellagern muss das Getriebe demontiert instructions.
und die defekte Einheit nach der Demontageanlei-
Wear determination
tung ausgetauscht werden.
After having removed the shaft sets all compo-
Verschleißermittlung
nents have to be cleaned carefully. Check the oil
Nach Ausbau der Wellensätze alle Bauteile sorg- deposits for impurities and solid particles. Control
fältig reinigen. Ölablagerungen auf Verunreinigun- all components regarding cracks by means of a
gen und Feststoffpartikel prüfen. Alle Bauteile mit suitable procedure. Control all components regard-
geeigneten Verfahren auf Risse kontrollieren. Alle ing wear.
Bauteile auf Verschleiß kontrollieren.
39
Service Manual 4549.01 SN3691273 RH340B
Probelauf – Test run
Prüfstandsaufbau Test-bench setup
Das Getriebe wird in der vorgesehenen Einbaula- The gearbox is assembled in the planned installation
ge aufgebaut und mit einem geeigneten Antriebs- position and is driven by a suitable drive motor.
motor angetrieben. Oiling system
Ölversorgung The gearbox is filled up to the upper dipstick marking
Das Getriebe wird bis zur oberen Peilstabmarkie- and/or up to the lower edge of the overflow bore. For
rung bzw. bis zur Unterkante der Überlaufbohrung the oil filling please use the lubricants mentioned in
gefüllt. Zur Ölbefüllung verwenden Sie bitte die in the operating instructions.
der Betriebsanleitung angegebenen Schmierstoffe. Speed, running time and test load
Drehzahl, Laufzeit und Prüflast The gearbox is to be operated with maximum speed
Das Getriebe ist mit Höchstdrehzahl (nmax Getrie- (nmax gearbox and/or. nmax test-bench) in the indicated
be bzw. nmax Prüfstand) in der angegebenen direction of rotation without load. The duration of test
Drehrichtung ohne Last zu fahren. Die Probelauf- run is one hour. Here the sump temperature and the
dauer beträgt 1 Stunde. Hierbei ist als Tempera- highest temperature measured at the bearing points
turaufschreibung die Ölsumpftemperatur und die after 30, 45 and 60 minutes is to be recorded.
höchste der an den Lagerstellen gemessenen Thermal values
Temperaturen nach 30, 45 und 60 Minuten zu The oil sump temperature measured on the housing
protokollieren. exterior surface should not exceed 80 °C after term i-
Thermische Werte nation of the one-hour test run. The temperatures at
Die Ölsumpftemperatur, gemessen an der Gehäu- the bearing points should not exceed the soil sump
se-Außenfläche, soll nach Abschluss des 1- temperature more than 10 °C.
stündigen Probelaufs 80 °C nicht übersteigen. Die Operational noise
Temperaturen an den Lagerstellen sollen die Öl- The running noise should be smooth and regular.
sumpftemperatur um nicht mehr als 10 °C über-
steigen. Leakage test
Laufgeräusch During the test run all seals are to be observed on
leakage, e. g.:
Das Laufgeräusch soll weich und gleichmäßig
sein. Intake and outlet screws
Dichtigkeitsprüfung Breather
Während des Probelaufs sind alle Dichtungen auf Sealing surfaces on housing and covers
Undichtigkeiten hin zu beobachten, z. B.: Shaft sealings
Ein- und Auslassschrauben
Entlüfter Foreign objects
Dichtflächen an Gehäuse und Deckeln Examine after the test run the gear oil for splinters,
Wellendichtungen scale, excessive abrasion and other foreign objects at
the draining oil, at the magnetic drain plugs and, if
Fremdkörper necessary, at the oil filter.
Überprüfen Sie nach Durchführung des Probelaufs
das Getriebeöl auf Späne, Zunder, übermäßigen
Abrieb und auf sonstige Fremdkörper am ablau-
fenden Öl, an Magnetstopfen und ggf. am Ölfilter.
40
Service Manual 4549.01 SN3691273 RH340B
Anlagen – Enclosures
Zeichnungen - Drawings
41
03.2019
8. Hydraulic system
CONTENTS
8. HYDRAULIC SYSTEM
8.1 Introduction ..................................................................................... 8.1 - 1
8.1.1 Foreword................................................................................8.1 - 1
8.1.2 Safety..................................................................................... 8.1 - 1
8.1.3 General .................................................................................. 8.1 - 5
8.2 Depressurizing, bleeding, flushing .................................................8.2 - 1
8.2.1 Depressurizing the hydraulic system .....................................8.2 - 1
8.2.2 Bleeding air from the hydraulic system .................................. 8.2 - 7
8.2.3 Flushing the hydraulic system.............................................. 8.2 - 14
8.3 Description of hydraulic system ..................................................... 8.3 - 1
8.3.1 Technical data .......................................................................8.3 - 1
8.3.2 Components of hydraulic schematic ...................................... 8.3 - 1
8.3.3 Hydraulic schematic ......................................................... …8.3 - 13
8.4 Hydraulic components ..................................................................... 8.4 - 1
8.4.1 Main pumps ........................................................................... 8.4 - 1
8.4.2 Swing pumps ......................................................................... 8.4 - 1
8.4.3 Pilot pumps ........................................................................... 8.4 – 1
8.4.4 Charge pumps ...................................................................... 8.4 – 1
8.4.5 Hydraulic oil cooling fan pumps ............................................ 8.4 – 1
8.4.6 Engine cooling fan pumps..................................................... 8.4 – 1
8.4.7 Gear oil pumps ..................................................................... 8.4 – 1
8.4.8 Lubrication pumps ................................................................ 8.4 – 1
3849398en – (00) Page 8 - 1
CONTENTS
8.4.9 Rotor ..................................................................................... 8.4 – 1
8.4.10 Hydraulic valves ..................................................................... 8.4 - 1
8.5 Description of hydraulic circuits ..................................................... 8.5 - 1
8.5.1 Load limit regulation ............................................................ 8.5.1 - 1
8.5.2 Pressure cut off ...................................................................8.5.2 - 1
8.5.3 Pilot system ........................................................................ 8.5.3 - 1
8.5.4 Attachment functions .......................................................... 8.5.4 - 1
8.5.5 Travel system ..................................................................... 8.5.5 - 1
8.5.6 Swing system ...................................................................... 8.5.6 - 1
8.5.7 Track tension system .......................................................... 8.5.7 - 1
8.5.8 Cooling system for hydraulic oil .......................................... 8.5.8 - 1
8.5.9 Cooling system for engines.................................................8.5.9 - 1
8.5.10 Cooling system for pump gearboxes ............................... 8.5.10 – 1
8.5.11 Bearing flushing system for main pumps .......................... 8.5.11 - 1
8.6 Pressure checking and setting........................................................ 8.6 - 1
8.6.1 Introduction ............................................................................ 8.6 - 1
8.6.2 Pressure setting ..................................................................... 8.6 - 4
8.6.3 Tools ...................................................................................... 8.6 - 6
8.6.4 Hydraulic circuits .................................................................... 8.6 - 7
8.7 Installation of hydraulic pumps.......................................................8.7 - 1
8.8 Hydraulic cylinders (Face shovel)....................................................8.8 -1
8.8.1 Boom cylinder ..................................................................... 8.8.1 - 1
8.8.1.1 Introduction ......................................................... 8.8.1 -1
8.8.1.2 Safety................................................................. 8.8.1 - 2
Page 8 - 2 3849398en – (00)
CONTENTS
8.8.1.3 Design configuration ......................................... 8.8.1 - 3
8.8.1.4 Assembly ........................................................... 8.8.1 - 5
8.8.1.5 Tightening torques ........................................... 8.8.1 - 12
8.8.2 Stick cylinder ...................................................................... 8.8.1 - 1
8.8.2.1 Introduction ......................................................... 8.8.2 -1
8.8.2.2 Safety................................................................. 8.8.2 - 2
8.8.2.3 Design configuration .......................................... 8.8.2 - 3
8.8.2.4 Assembly ........................................................... 8.8.2 - 5
8.8.2.5 Tightening torques ........................................... 8.8.2 - 12
8.8.3 Bucket cylinder ................................................................... 8.8.3 - 1
8.8.3.1 Introduction ......................................................... 8.8.3 -1
8.8.3.2 Safety................................................................. 8.8.3 - 2
8.8.3.3 Design configuration .......................................... 8.8.3 - 3
8.8.3.4 Assembly ........................................................... 8.8.3 - 5
8.8.3.5 Tightening torques ........................................... 8.8.3 - 12
8.8.4 Clam cylinder ...................................................................... 8.8.4 - 1
8.8.4.1 Introduction ......................................................... 8.8.4 -1
8.8.4.2 Safety................................................................. 8.8.4 - 2
8.8.4.3 Design configuration .......................................... 8.8.4 - 3
8.8.4.4 Assembly ........................................................... 8.8.4 - 5
8.8.4.5 Tightening torques ........................................... 8.8.4 - 12
3849398en – (00) Page 8 - 3
CONTENTS
Page 8 - 4 3849398en – (00)
8.1 HYDRAULIC SYSTEM
8.1 Introduction
8.1.1 Foreword 8.1.2 Safety Instructions
The Service Manual contains important infor- Danger in case of non-observance of safety
mation for personnel servicing the machine. Ma- instructions
chine technical data listed in other machine docu-
ments are not always repeated in this book.
This CAT hydraulic excavator has
The documentation of a CAT mining machine in- been built in accordance with
cludes: state-of-the-art standards and the
recognized safety rules.
Operation and Maintenance Manual However, operating the machine if
a fault is suspected or has oc-
Spare Parts Catalog curred, or carrying out repair work
inexpertly
Service Manual
endangers the lives of people in
contact with it
The service manual does not contain technical
data on auxiliary units for the operation of specific damages the machine and other
or optional equipment or data of individual devices. property.
The refilling quantities specified for consumables Stop the hydraulic excavator im-
are approximate quantities which are intended as a mediately if you suspect or notice
help for planning consumable requirements. any damage to ensure the safety of
the operator, other people or mate-
Each component is equipped with suitable check- rial property at the application area
ing devices, e.g. a dipstick or checking plugs, per- of the excavator.
mitting the operator to check exactly the filling of All components of CAT machines
the components. are perfectly tuned to each other.
Trouble-free operation and a long
service life can only be achieved
with original CAT spare parts.
2440575en – (03) Page 8.1 - 1
8.1 HYDRAULIC SYSTEM
Rules for safety at work
Personnel Personnel
The machine must not be started Personal protective equipment and
by unauthorized people. safety working clothing:
Therefore secure and lock it. Wear a safety helmet, safety foot-
wear and safety gloves.
Follow the accident prevention
regulations. Wear closely fitting working cloth-
ing when working on the machine.
Only specially trained and qualified
Loose, wide garments can catch
personnel with the appropriate
on machine parts and result in
technical knowledge can operate,
injury.
service or repair the hydraulic ex-
cavator. Personnel carrying out work at
greater heights must wear safety
If you lack such knowledge, expe-
harnesses. Always put on a tested
rienced personnel, e.g. from Cater-
harness which is equipped with fall
pillar Global Mining HMS, are to
arrestors and safety lines.
give you detailed instructions.
If you need assistance to carry out
The personnel must have read and
the work, e.g. marshallers, clearly
understood the Operation and
define the responsibilities of each
Maintenance Manual and in partic-
assistant beforehand. The individ-
ular the chapter
ual responsibilities are to be care-
‘Fundamental Safety Instructions.’ fully observed to ensure safety.
Only such people can start up the
machine after assembly work to
adjust the attachment.
Incorrect operation of the machine
or the equipment can result in life-
threatening situations.
During all works, always observe
the start and shut down proce-
dures described in the Operation
and Maintenance Manual.
Page 8.1 - 2 2440575en – (03)
8.1 HYDRAULIC SYSTEM
Tools and devices Before opening systems and units
(e.g. pipes, coolers, hydraulic res-
Tools, hoists, slings, trestles and ervoirs and accumulators) depres-
other devices must be in a reliable, surize them properly.
safe state.
Open or remove protective devices
Metal splinters may cause injury on moving machine parts only
when you take in or out attachment when the drive unit is shut down
bolts. Therefore during this proce- and secured against inadvertent
dure use a brass or copper man- start.
drel and wear safety glasses.
Before re-commissioning install all
When climbing onto or off the ma- protective devices.
chine use only ladders, steps, plat-
forms and handrails provided for Before carrying out assembly
this purpose. work, the machine and the equip-
ment must be secured against in-
Always keep ladders, steps and advertent movement, e.g. by plac-
platforms in a non-slip state. Re- ing the working equipment on the
move any oil, grease, earth, clay, ground.
snow, ice and other foreign matter
immediately.
Hydraulic and lubricating sys-
tem:
Securing the working equip-
ment Always observe the safety regula-
tions applicable to the product
Secure the machine and the work- when handling oils, greases and
ing equipment against inadvertent other chemical substances.
and unauthorized start. Position
working equipment on the ground Close open unused bores, pipe
in such a way that it cannot move and hose connections so that they
when mechanical or hydraulic are impermeable to pressure.
connections become detached. Refill the hydraulic system with
Use hoists or other appropriate collected drain hydraulic oil only
support devices when you install, through the return flow filters. Dis-
remove or displace any equipment pose of waste oil without polluting
or component. Thus you prevent the environment.
them from inadvertent movements, Observe the correct working se-
slip or fall. quence when fitting or replacing
components or equipment.
2440575en – (03) Page 8.1 - 3
8.1 HYDRAULIC SYSTEM
Modifications of the machine
Before carrying out works, espe-
cially on the electrical system, dur- Unauthorized conversions or modi-
ing which tools, spare parts, etc. fications of the hydraulic excavator
can contact electric cables, always are forbidden for reasons of safety.
disconnect the battery: first the
Never modify the nominal pressure
negative pole and then the positive
value of pressure relief valves
pole. When reconnecting the bat-
without explicit approval from Cat-
tery, connect first the positive and
erpillar Global Mining HMS. Do not
then the negative pole.
remove the lead seals from pres-
Always replace defective, mechan- sure relief valves and hydraulic
ically prestressed components. accumulators.
Never open them! The Service
Manual contains no information on
such work.
Re-commissioning
The operating temperature of the
machine is high and the consuma-
bles have at least the same tem-
perature. Therefore take care to Before re-commissioning:
avoid burns or scalds.
Grease all lubricating points.
Be careful when handling acids,
e.g. battery acid. Acid splashes Check all oil levels and correct
may injure the eyes and the skin. them if necessary.
If the acid is splashed onto your
skin, rinse it with plenty of clean
Carry out function checks of all
repaired components.
running water and seek medical
care immediately. Check all functions of the exca-
If the acid is splashed in your eyes, vator including brakes during a
rinse thoroughly with running wa- test run. Release the hydraulic
ter and seek medical care immedi- excavator for re-commissioning
ately. only if all its functions operate
properly.
Never smoke when handling flam-
mable liquids.
Be careful with open flames and
unprotected light. Not only fuel but
also other consumables often have
a low flash point and catch fire
easily.
Page 8.1 - 4 2440575en – (03)
8.1 HYDRAULIC SYSTEM
8.1.3 General
This Service Manual contains information in addi- The Service Manual covers the information you
tion to the Operation and Maintenance Manual need when handling your excavator. However,
and the Spare Parts Catalog, to familiarize the Caterpillar Global Mining HMS will be pleased to
personnel with the designated use, maintenance answer any questions you have on its products.
and repair of the CAT excavator. Please contact your local CAT dealer or your Cat-
erpillar subsidiary.
The information in the Service Manual corre-
sponds to the standard technical specification of
the machine when it was delivered.
All sketches and drawings show general principles.
They do not represent the actual design of the
machine and are not to be used for manufacturing.
Special equipment is normally not considered.
Technical modifications, which are introduced after
delivery of the machine, may also be incorporated
in machines which are already in operation.
In this case, you can find the updated version of
the Service Manual on the Caterpillar website.
2440575en – (03) Page 8.1 - 5
8.1 HYDRAULIC SYSTEM
Page 8.1 - 6 2440575en – (03)
8.2 DEPRESSURIZING, BLEEDING, FLUSHING
8.2 Depressurizing, bleeding 8.2.1 Depressurizing the hydraulic
and flushing the hydraulic system
system Always open hydraulic systems only when they are
free of pressure. Hydraulic systems can contain
considerable back pressure, e.g. primary pressure
Before starting any work all from the last movement, even when the excavator
personnel carrying out is parked on a level surface with its working
commissioning, operation, equipment on the ground (Fig. 1).
inspection, service and repair are
to read and understand “Operation Residual pressure drops only gradually. If you are
and maintenance manual” and in to work on the hydraulic system immediately after
particular the chapter stopping the excavator, first depressurize the
system.
‘Fundamental safety instructions.’
Before working on the hydraulic
system ensure that the system is
depressurized and remaining
pressure is relieved.
Shut off the engine.
Components (e.g. hydraulic tank,
cylinders and valves) may be hot
and cause severe burns.
Secure the machine before
working on it.
Avoid contact of hydraulic oil with
the skin. It can be dangerous.
Fig. 1 Parking position of FS machine – 630213
Always wear safety glasses, safety
gloves and firm protective Release pressure in one system section (if
clothing. required, combine several depressurization
steps).
Open carefully the system section.
Be extremely careful when working Examples of system sections:
on hydraulic cylinders or pressure
lines of the attachment. 1) Attachment circuits
Some amount of pressure may still 2) Track tension circuit
remain in the system even after the
depressurization. Therefore check 3) Swing circuit
pressure before starting any
maintenance tasks using the 4) Travel circuit
information of chapter 8.6 Pressure
checking and setting of this 5) Access ladder circuit
Service Manual.
6) Engine off lowering accumulator circuit
7) Service arm circuit.
3746515en – (01) Page 8.2 - 1
8.2 DEPRESSURIZING, BLEEDING, FLUSHING
Depressurization of the attachment circuits Hold switch (65, Fig. 3) for at least 5
seconds, then release it. Depressurization
Before depressurization: mode is activated.
Ensure that the accumulator in
the engine off lowering circuit has
10L capacity and is charged to 17
bar.
Ensure that the updated software
is installed.
If the E stop was hit, reset it.
Park the excavator on a level
ground.
Lower the working equipment to
the ground.
Shut off the engine.
Fig. 3 Activation of depressurization mode –108223
Caution! Attachment components
may move.
The following screen appears in BCS
display:
Sit in the operator seat to activate the seat
switch (105, Fig. 2).
Switch on the electric system with the key
(32, Fig. 2).
Activate the hydraulic system with the
switch (71, Fig. 2)
Fig. 4 Depressurization mode is active – 647324
To continue depressurization mode move
a joystick (115 or 116, Fig. 3 & Fig. 5 ), or
a pedal (111, Fig. 5), or a thumbwheel
Fig. 2 Location of switches – 108224 (118) within the next 15 seconds.
Otherwise depressurization mode will be
deactivated.
Page 8.2 - 2 3746515en - (01)
8.2 DEPRESSURIZING, BLEEDING, FLUSHING
Connect a pressure gauge with a range of
400 bar to the test coupling and check the
pressure value.
Check the pressure value.
When the system is depressurized, close
the valves, remove the pressure gauge
and close the protection cap of the test
coupling.
You can also use a test hose:
Open the protection cap (1, Fig. 6) of the
test coupling.
Connect a special connector, e.g. a test
Fig. 5 Continuation of depressurization mode –107633a hose (Fig. 7) to the test coupling.
Hold the boom and stick lower (float down) while
actuating the following functions:
bucket curl function;
In 1 second actuate clam close function.
In 1 second release bucket curl function.
In 1 second actuate bucket dump function.
In 1 second release clam close function.
In 1 second actuate clam open function.
In 1 second release bucket dump function.
In 1 second actuate bucket curl function.
In 1 second release all the functions.
The attachment circuits are depressurized.
To check pressure, use the information of chapter
8.6 Pressure checking and setting of this Service Fig. 7 Test hose – 644696
Manual. In case test couplings are not installed,
install them to the ports illustrated below. Connect
pressure gauges to the test couplings as follows Collect the oil coming out of the hose in a
and carry out checks: container. When the oil flow stops, the
circuit is depressurized.
Open the protection cap (1, Fig. 6) of the Remove the connector, connect a pressure
test coupling. Replace the cap after use. gauge and check the pressure value in the
circuit. Repeat the depressurization
procedure if necessary.
Close the protection cap of the test
coupling.
To check if the boom cylinders are depressurized,
use ports TP of boom float valve 164 (Fig. 8).
To check if the stick cylinders are depressurized,
use ports TP of stick float valve 165 (Fig. 8).
To check if the clam cylinders are depressurized,
use ports TP of clam valve 169 (Fig. 8).
Fig. 6 Test coupling – 644695 To check if the bucket cylinders are depressurized,
use ports TP of distributors 188 (Fig. 9).
3746515en – (01) Page 8.2 - 3
8.2 DEPRESSURIZING, BLEEDING, FLUSHING
Fig. 8 Ports for boom, stick and clam cylinders pressure check – 647294d
Fig. 9 Ports for bucket cylinder pressure check – 647325
Page 8.2 - 4 3746515en - (01)
8.2 DEPRESSURIZING, BLEEDING, FLUSHING
Depressurization of the engine off lowering Depressurization of track tension, swing, travel
accumulator access ladder and service arm circuits
Before depressurization: To depressurize track tension circuit use pressure
relief valves (134, Fig. 11) in the undercarriage.
If the E stop was hit, reset it. For depressurization check use test coupling
Park the excavator on a level connections (MP, Fig. 11).
ground.
Lower the working equipment to
the ground.
Shut off the engine.
Caution! Attachment components
may move.
Sit in the operator seat to activate the seat
switch (105, Fig. 2).
Switch on the electric system with the key
(32, Fig. 2).
Fig. 11 Depressurization check of track tension circuit –
647024a
Activate the hydraulic system with the Swing and travel circuits are depressurized when
switch (71, Fig. 2) the machine is off. To check depressurization of
the swing circuit use pressure sensors -2B17 and -
2B18 at swing motor 102/4 (Fig. 12).
Hold switch (65, Fig. 3) for at least 5
seconds, then release it. Depressurization
mode is activated.
To depressurize the engine off lowering
accumulator (52, Fig. 10) move a joystick
(115 or 116, Fig. 3 & Fig. 5 ) repeatedly 40
– 45 times to lower the boom or stick.
To check depressurization of the
accumulator use a charging and testing
unit. You can find more information on it in
chapter 8.6 of this Service Manual.
Fig. 12 Depressurization check of swing circuit – 646971a
Fig. 10 Location of engine off lowering accumulator –
647004
3746515en – (01) Page 8.2 - 5
8.2 DEPRESSURIZING, BLEEDING, FLUSHING
To check depressurization of the travel circuit use
test points TP1 – TP4 at secondary pressure relief
manifold 125 in the undercarriage (Fig. 13).
Fig. 14 Depressurization check of access ladder circuit –
Fig. 13 647649
Depressurization check of travel circuit – 646995a
To check depressurization of the service arm
To check depressurization of the access ladder
circuit read the value at test port TP (Fig. 15).
circuit use test point TP of the access ladder
control valve (152, Fig. 14).
Ensure that the access ladder is down.
Attach a test coupling with the pressure
gauge to the test point (TP, Fig. 14).
Caution! Access ladder may move
when you shift its control valve
lever.
Shift the lever of the control valve (152) in
the ladder up position and check the
pressure.
Fig. 15 Depressurization check of service arm circuit –
Shift the lever of the control valve in the
646847c
ladder down position and check the
pressure.
If there is pressure in the system, repeat
the lever shifting process until the pressure
is released.
Page 8.2 - 6 3746515en - (01)
8.2 DEPRESSURIZING, BLEEDING, FLUSHING
8.2.2 Bleeding air from the hydraulic To ensure long operation of your machine follow
system the air bleeding procedures described below.
Bleed air from hydraulic pumps, Bleeding air from the main pumps
hydraulic motors, hydraulic cylinders
and pilot pressure circuits 1) Open slowly the gate valve (67/1, Fig. 18)
between the hydraulic oil tank (60) and the
before machine re- suction line of LH main pumps (3/1 & 3/2,
commissioning, e.g. after Fig. 19). The oil flows to the suction line
overhauls or repairs of the and fills hydraulic hoses.
hydraulic system, or after a long
standstill; 2) Open the port (A1, Fig. 21) on the case
after every oil change. drain collector for LH pumps. The oil flows
Otherwise you affect the intake and to the case drain hose. The air escapes
operation of the hydraulic components. through the open port.
Hydraulic oil serves also as a lubricant
for these components. A “dry run” 3) When the system is free from air, open
causes a complete breakdown of the slowly ports R(L1) and R(L2) (Fig. 16) on
system in very short time. LH main pumps and check the oil level.
After bleeding air check the hydraulic system under
load. Listen for noises in the pumps and motors.
Jerky movements indicate air pockets in the
4) As soon as the oil comes out, close the
pump ports and port A1 of the case drain
collector.
system. To eliminate the air pockets actuate all 5) Open slowly the gate valve (67/2, Fig. 18)
hydraulic functions several times. between the hydraulic oil tank (60) and the
suction line of RH main pumps (3/3 & 3/4,
Bleeding air from suction headers Fig. 20). The oil flows to the suction line
and fills hydraulic hoses.
1) Open the plug (P, Fig. 18) on the top of the
suction header. 6) Open the port (A2, Fig. 21) on the case
drain collector for RH pumps. The oil flows
2) Open slowly shut off valve 68 (Fig. 18). to the case drain hose. The air escapes
through the open port.
3) The air escapes through the open port
during air bleeding procedure for hydraulic
7) When the system is free from air, open
pumps. slowly ports R(L1) and R(L2) (Fig. 16) on
RH main pumps and check the oil level.
4) Close the shut off valve and the plug.
8) As soon as the oil comes out, close the
Bleeding air from hydraulic pumps pump ports and port A2 of the case drain
collector.
Bleed air from hydraulic pumps after every oil
change. Fill clean oil and bleed the axial piston Bleeding air from the swing pumps
units through the ports shown in Fig. 16 - Fig. 17.
1) Remove case drain lines from the swing
Main pumps: pumps (4/1 – 4/4, Fig. 21).
8 times through ports R(L1) and R(L2).
2) Open ports R (Fig. 17) of the swing pumps
Swing pumps: and wait till hydraulic oil fills them.
4 times through ports R
3) Install the case drain lines to ports R of the
Charge pumps: swing pumps.
2 times through ports L1
4) When the swing pumps start up, swing
Engine cooling fan pumps: charge pumps fill lines A and B with
2 times through ports L hydraulic oil and the air escapes through
3746515en – (01) Page 8.2 - 7
8.2 DEPRESSURIZING, BLEEDING, FLUSHING
the blocking valves to the hydraulic oil Bleeding air from hydraulic motors
tank.
Before starting with the following procedures, drain
Bleeding air from the charge pumps hydraulic oil from the motors in a special reservoir
and dispose of it in compliance with local
1) Remove case drain lines from the charge environmental regulations. Ensure that no oil is
pumps (16/1 & 16/2, Fig. 21). Ports L1 available to fill the motor cases from the hydraulic
(Fig. 17) are open. lines.
2) Open shut off valve 68 (Fig. 18). Bleeding air from travel motors
3) When hydraulic oil comes out of ports L1, 1) Disconnect case drain lines from travel
close the ports and the shut off valve. motors (121, Fig. 22).
4) Install the case drain lines. 2) Fill the cases of the travel motors with
hydraulic oil through the highest case drain
Bleeding air from the engine cooling fan pumps ports (C, Fig. 22). When the oil rises to the
level of the ports, connect the case drain
1) Remove case drain lines from the engine lines to the motors.
cooling fan pumps (11/1 – 11/2, Fig. 21).
Ports L (Fig. 17) are open.
2) Open shut off valve 68 (Fig. 18).
3) To bleed air form the working lines of the
travel motors let the machine idle and
slowly actuate the travel pedal.
3) When hydraulic oil comes out of ports L, Bleeding air from swing motors
close the ports and the shut off valve.
1) Disconnect case drain lines from swing
4) Install the case drain lines. motors (102/1 – 102/4, Fig. 23).
Bleeding air from the pilot pumps 2) Fill the cases of the swing motors with
hydraulic oil through the highest case drain
1) Open ports A1 and A2, (Fig. 21) on the ports. When the oil rises to the level of the
case drain collectors. ports, connect the case drain lines to the
motors.
2) Open shut off valve 68 (Fig. 18).
3) To bleed air form the working lines of the
3) Hydraulic oil flows to the case drain hose. swing motors let the machine idle, so that
The air escapes through the open ports. the swing charge pumps supply oil to the
working ports.
4) As soon as the oil comes out of ports A1
and A2, close the ports and the shut off
valve.
Bleeding air from the oil cooling fan pumps
1) Open pressure ports of the oil cooling fan
pumps (10/1 – 10/4, Fig. 19 - Fig. 20).
2) Open shut off valve 68 (Fig. 18).
3) When hydraulic oil comes out of the
pressure ports, close the ports and the
shut off valve.
Page 8.2 - 8 3746515en - (01)
8.2 DEPRESSURIZING, BLEEDING, FLUSHING
Fig. 16 Ports for bleeding air from main pumps – 647220
Fig. 17 Ports for bleeding air from swing, charge and engine cooling fan pumps – 647228
3746515en – (01) Page 8.2 - 9
8.2 DEPRESSURIZING, BLEEDING, FLUSHING
Fig. 18 Location of gate valves – 647115a
Fig. 19 Suction lines of LH pumps to gate valves – 647116
Page 8.2 - 10 3746515en - (01)
8.2 DEPRESSURIZING, BLEEDING, FLUSHING
Fig. 20 Suction lines of RH pumps to gate valves – 647117
Fig. 21 Case drain collectors – 647234
3746515en – (01) Page 8.2 - 11
8.2 DEPRESSURIZING, BLEEDING, FLUSHING
Fig. 22 Bleeding air from travel motors – 647275
Fig. 23 Bleeding air from swing motors – 646963a
Page 8.2 - 12 3746515en - (01)
8.2 DEPRESSURIZING, BLEEDING, FLUSHING
Bleeding air from hydraulic cylinders
1
Before the hydraulic oil fills a cylinder for the first
time, its head (2, Fig. 24 - Fig. 25) is to be in one of
the two end positions, i.e. the rod (1) is to be either 4
fully extended or fully retracted.
Note: 2
Always fill that end of the cylinder with hydraulic oil,
where its head is positioned.
When the cylinder is retracted (Fig. 24), fill the
head end (3) with the oil.
630255.SKD
When the cylinder is extended (Fig. 25), fill the Fig. 25 Extended cylinder – 630255.SKD
rod end (4) with the oil.
If the rod (1, Fig. 24 - Fig. 25) is in the half-way
position for installation reasons, let the oil flow to Bleeding air from pilot pressure circuit
the rod end (4) first.
If the pilot pressure lines are connected to one side
The first filling of the cylinders has to be carried out of the attachment control manifolds, open the
with a reduced oil flow. Therefore extend or retract bleed plugs (P, Fig. 26) and start the engine. Keep
the rod as slowly as possible. the plugs open and the engine running until the oil
comes out without bubbles.
The items of Table 1 refer Fig. 24 - Fig. 25.
Item Designation
1 Rod
2 Head
3 Head end
4 Rod end
Table 1
Fig. 26
3 Bleed plugs – 647266
630254.SKD
Fig. 24 Retracted cylinder – 630254.SKD If the pilot pressure lines are connected to the
upper ports of the pilot caps the system bleeds air
automatically.
3746515en – (01) Page 8.2 - 13
8.2 DEPRESSURIZING, BLEEDING, FLUSHING
8.2.3 Flushing the hydraulic system Types and sources of contamination
During flushing procedure the machine remains on Type Source
site. Repair or exchange hydraulic components
(e.g. cylinders) only in a closed clean workshop. Shiny metal particles or Damaged bearings
debris of pumps or the
If a hydraulic component (e.g. a pump or a hydraulic motor
cylinder) is damaged, check the system for any
chips of the component. For this purpose remove Steel particles looking like Seized inner
and inspect magnetic rods M and return flow filters turnings, in the filter pieces components of a
62 of hydraulic oil tank 60 (Fig. 27). of guide bands, O-rings hydraulic cylinder
and seals
Individual parts, such as Damaged valves
pieces of springs or of
valve plates
Table 2
When the damage is extensive, all these
symptoms can appear at once.
Steps in case of pump damage
Identify the damaged pump. Typical symptoms of
damage are:
chip indicator for a main or a swing
pump is ON;
vibrating hydraulic hoses;
Fig. 27 Location of magnetic rods and return flow filters –
647344 fluctuating pressure value on the
pressure gauges;
Flushing is necessary in the following cases:
abnormal noise;
The quantity, size and shape of the metal
particles on the magnetic rod look different considerable power output loss;
than usual.
excessively high temperature;
The quantity of magnetic and non-
magnetic debris in the return flow filters is engine overload.
larger than usual.
If the damaged pump is not connected to high
After every change of a defect hydraulic pressure filters:
component. You can limit flushing to the
circuit connected to the component, if you 1) Remove return flow filters and check them
can isolate it completely. for contamination.
2) Empty the oil tank and clean it.
3) Remove the damaged pump.
4) Remove the pump intake line and clean it.
Page 8.2 - 14 3746515en - (01)
8.2 DEPRESSURIZING, BLEEDING, FLUSHING
5) Install a new pump and bleed the air from clean them and check thoroughly all the
it. components.
6) If the hydraulic system is contaminated 8) Empty the hydraulic oil tank and clean it.
with metal particles of the pump, carry out
all the following procedures, even if you 9) Install the cylinders.
cannot identify the damage on other
components. Steps in case of valve damage
If the damaged pump is connected to high 1) Identify the damaged valve.
pressure filters:
2) If you have found all its parts, the only
1) Remove the damaged pump. thing you need is to change the valve.
2) Remove the high pressure filters and clean 3) If you cannot find all the parts, search them
them. in return flow filters, hydraulic oil tank,
components connected downstream of the
3) Remove the line between the pump and valve, e.g. cylinders, valves, motors.
the high pressure filters and clean it.
Steps in case of excessive contamination of
4) Install a new pump, the clean high
pressure filters and the line. Bleed the air
from the pump.
hydraulic system
If the hydraulic system is excessively contaminated
with chips, take the following steps:
5) Install new return oil filters.
1) Remove the primary relief valves, separate
6) Fill the circuit with oil through the return their components, clean, reassembly them
flow filters. and install the valves again.
7) Start the excavator. 2) Remove the secondary relief valves,
separate their components, clean,
Steps in case of cylinder damage reassembly them and install the valves
again.
1) Remove return flow filters and check them.
3) If the hydraulic oil tank is contaminated,
2) Identify the damaged cylinder. Remove it, clean the oil cooling circuit and check it.
separate its components, clean and check
them thoroughly. Remove the oil cooler. Clean it outside and
flush it thoroughly inside in both flow
3) If the cylinders work in pairs, also remove directions. If the contamination chips
them, separate their components, clean cannot be removed from the cooling fins
them and check thoroughly all the completely, change the oil cooler.
components.
Flush hydraulic lines or blow compressed
4) During the reassembly always provide the air through them.
cylinders with new seals and guides.
4) Check the pilot pressure control valves and
5) Install the cylinders without connecting clean them if necessary.
hydraulic lines.
5) If you installed hydraulically driven
6) Carry out the flushing procedure and the equipment, check its systems as well,
operation check as described below. especially if you cannot find the source of
contamination. Follow the manufacturer
7) If you still see particles during the flushing instructions.
procedure, remove all the hydraulic
cylinders, separate their components,
3746515en – (01) Page 8.2 - 15
8.2 DEPRESSURIZING, BLEEDING, FLUSHING
Flushing procedure 3) In case of the contamination clean the
magnetic rod.
The extent of flushing procedure depends upon the
contaminated point. You have to flush the 4) Check it again in increasing intervals.
downstream hydraulic line with all connected
sublines to the filters. Check the filters thoroughly
for proper operation. If the cylinder is damaged:
If the damaged pump is not connected to high 1) Install a new return flow filter.
pressure filters:
2) Change the cylinder and connect its lines
1) Install a new return flow element. directly in a short circuit.
2) Fill the circuit with fresh hydraulic oil 3) Run the engine at its maximal speed. After
through the return flow filter. the filter control light is off actuate the
cylinder function.
3) Disconnect consumer lines and connect
the consumers directly in a short circuit. 4) Extend and retract the cylinder for
approximately one minute in each
4) Run the engine at its maximal speed. After direction. Switch the functions to the
the filter control light is off actuate the
control valve.
5) Actuate each hydraulic function separately
neutral position for several times.
5) Change the return flow filter and clean the
magnetic rod.
and let it run for approximately one minute
in each direction. Switch the function to the 6) Repeat the flushing procedure. Actuate
neutral position for several times. Carry out each consumer separately for short time.
the procedure for each consumer for at
least 5 minutes. 7) Check the return flow filter and the
magnetic rod.
6) Change the return flow filter and clean the
magnetic rod. 8) Connect the cylinder correctly and bleed
the air from the circuit.
7) Repeat the flushing procedure. Actuate
each consumer separately for short time. 9) Check the oil level in the hydraulic tank.
8) Check the return flow filter and the 10) Start the excavator.
magnetic rod.
9) Connect all the consumers correctly and If the hydraulic motor is damaged:
bleed the air from the circuit.
1) Install a new return flow filter.
10) Check the oil level in the hydraulic tank.
2) Change the hydraulic motor and connect
11) Start the excavator. all its lines directly in a short circuit.
3) Run the motor for approximately one
If the damaged pump is connected to high minute in each direction. Switch the
pressure filters: functions to the neutral position for several
times.
1) Flushing is not required. Start the
excavator and run it for approximately one 4) Change the return flow filter and clean the
minute. magnetic rod.
2) Check the magnetic rod. 5) Repeat the flushing procedure. Actuate
each consumer separately for short time.
Page 8.2 - 16 3746515en - (01)
8.2 DEPRESSURIZING, BLEEDING, FLUSHING
6) Check the return flow filter and the
magnetic rod.
7) Connect the motor correctly and bleed the
air from the circuit.
8) Check the oil level in the hydraulic tank.
9) Start the excavator.
Operation monitoring
1) Start the machine and run it for
approximately one minute.
2) Check the magnetic rod.
3) In case of the contamination clean the
magnetic rod.
4) Check it again in increasing intervals.
The same or even increased
amount of contamination means
that you have not eliminated its
source.
Check and flush the system again.
3746515en – (01) Page 8.2 - 17
8.2 DEPRESSURIZING, BLEEDING, FLUSHING
Page 8.2 - 18 3746515en - (01)
8.3 DESCRIPTION OF HYDRAULIC SYSTEM - FS
8.3 Description of hydraulic
system
8.3.2 Components of hydraulic
8.3.1 Technical data schematic
The technical data of the hydraulic system are The item numbers refer to hydraulic schematic No.
listed in chapter 2 ‘Technical Data’. 3 758 597 (00). Free item numbers are not listed.
Item Quantity Designation Location
1 2 Diesel engine Engine module
2 2 Pump gearbox Engine module
3 4 Main pump A 20 VO Pump gearbox
4 4 Swing pump A 4 VG Pump gearbox
6 4 Pilot pump KP 1/22 Pump gearbox
10 4 Hydraulic oil cooling fan pump KP 5/250 Pump gearbox
11 2 Engine cooling fan pump A 10 VO Pump gearbox
16 2 Charge pump A 10 VO Pump gearbox
19 1 Lubrication system Superstructure
Proportional pressure reducing valve for main pump
23 2 Engine module
control
25 2 Control manifold Engine module
26 1 Valve block Engine module
27 1 Valve block Engine module
29 1 Control block Engine module
32 1 High pressure filter and control block Engine module
34 4 Filter Engine module
36 4 Filter Engine module
38 2 Bladder accumulator Cab module
39 2 Check valve Engine module
43 4 Check valve Engine module
44 1 Check valve Engine module
48 2 Filter Engine module
50 1 Mounting plate assembly with control valves Engine module
51 1 Check valve Engine module
52 1 Diaphragm accumulator Engine module
53 1 Solenoid operated on-off valve Engine module
56 2 SIL valve Engine module
57 1 Distributor Engine module
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8.3 DESCRIPTION OF HYDRAULIC SYSTEM - FS
Item Quantity Designation Location
60 1 Hydraulic oil tank Superstructure
62 2 Return flow filter Hydraulic oil tank
63 6 Bypass valve Hydraulic oil tank
64 4 Tank line pressurizing valve Hydraulic oil tank
67 2 Gate valve Hydraulic oil tank
68 1 Gate valve Hydraulic oil tank
72 2 Drain oil manifold Engine module
80 4 Hydraulic oil cooler Oil cooler module
81 4 Fan motor Oil cooler module
85 2 Fan control manifold Oil cooler module
91 1 Rotor Superstructure
92 1 RH travel valve Rotor
93 1 LH travel valve Rotor
95 1 RH travel retarder valve RH travel valve
96 1 LH travel retarder valve LH travel valve
97 4 Anti-cavitation valve Travel valves
100 4 Swing gearbox Main frame
101 3 Shuttle valve Engine module
102 4 Swing motor A2F 180 Swing gearbox
103 4 Swing circuit blocking valve Engine module
105 1 Swing balance valve Engine module
106 1 Swing flushing valve Engine module
107 2 High pressure filter Superstructure
109 2 Pressure reducing valve Engine module
111 1 Orifice, 2.2 mm Swing flushing valve
120 2 Travel gearbox Undercarriage
121 4 Travel motor A6VM 250 Undercarriage
123 4 Check valve Travel motors
125 1 Secondary pressure relief manifold Undercarriage
130 2 Track tension cylinder Undercarriage
131 2 Piston accumulator Undercarriage
132 2 Ball valve Undercarriage
133 1 Track tension control manifold Undercarriage
134 2 Pressure relief valve Undercarriage
140 2 Fan motor A2FM 200 Counterweight
141 2 Anti-cavitation valve block Counterweight
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8.3 DESCRIPTION OF HYDRAULIC SYSTEM - FS
Item Quantity Designation Location
145 1 Hydraulic cylinder Service arm
146 1 Control valve Service arm
147 1 Check valve Service arm
148 1 Diaphragm accumulator Service arm
150 1 Hydraulic cylinder Access ladder
151 1 Bladder accumulator Cab module
152 1 Control valve Superstructure
153 1 Check valve Cab module
160 2 LH attachment control manifold Boom
161 2 RH attachment control manifold Boom
164 1 Boom float valve Boom
165 1 Stick float valve Boom
166 3 Auxiliary control block Boom
169 1 Clam valve block Boom
Between Tripower link
182 2 Boom cylinder
& superstructure
Between Tripower link
183 2 Stick cylinder
& stick
Between Tripower link
184 2 Bucket cylinder
& bucket
186 2 Clam cylinder Bucket rear wall
187 1 Distributor Bucket rear wall
188 2 Distributor Boom
191 2 Filter Engine module
192 2 Bypass valve Engine module
193 2 Gear oil cooler Oil cooling module
194 2 Distributor Engine module
3849405en – (00) Page 8.3 - 3
8.3 DESCRIPTION OF HYDRAULIC SYSTEM - FS
Diesel engine Pos. 1 flows into the low pressure side lines to protect the
engine and pumps from overload.
Two water cooled diesel engines with turbo The pumps are equipped with temperature
charging are used as a drive unit. switches and contamination switches. If the
hydraulic oil is contaminated with metal particles or
its temperature exceeds the set value, the relevant
Pump gearbox Pos. 2 switches initiate a corresponding error message on
the BCS screen.
Two pump gearboxes are driven with two engines
through two couplings. The pump gearboxes
distribute engine output to the hydraulic pumps
Pilot pump KP 1/22 Pos. 6
installed in them.
Four pilot pumps are external gear pumps of fluid
bearing type.
Main pump A 20 VO Pos. 3 The pumps supply the machine pilot system with
pilot pressure oil.
Four double variable displacement axial piston
pumps in a swash plate design enable attachment
and travel functions.
Hydraulic oil cooling fan pump
The pump flow rate is steplessly variable and KP 5/250 Pos. 10
increases from zero to maximum flow with the
increase of the swash plate displacement. Four external gear pumps provide machine
hydraulic oil cooling module with oil.
The pumps are equipped with pressure cut off
valves which maintain the system pressure at 320
bar. During travel boost mode the cut off pressure Engine cooling fan pump
of the valves on main pumps 3/1 and 3/4 increases
A 10 VO Pos. 11
to 360 bar.
The pumps are equipped with temperature Two variable displacement axial piston pumps in a
switches and contamination switches. If the swash plate design feed hydraulic oil to the engine
hydraulic oil is contaminated with metal particles or cooling fan motors.
its temperature exceeds the set value, the relevant The pump oil flow changes in dependence of the
switches initiate a corresponding error message on engine coolant or air intake temperature.
the BCS screen.
Each pump is equipped with a pressure cut off and
a proportional valve which carry out its electro-
Swing pump A 4 VG Pos. 4 hydraulic control. When the solenoid current signal
drops towards 150 mA, the maximal oil flow is
Four variable displacement axial piston pumps in a limited to Q max. The cut off valves set at 250 bar
swash plate design enable superstructure protect the system from pressure peaks. When the
movement. pressure in the system reaches this value, the
The pump oil flow is proportional to the inclination valve shifts the pump swash plate back. So the
angle of pump swash plate displacement.The oil pumps deliver as much oil as required to maintain
flow is bidirectional. Its direction changes smoothly the maximal pressure of 250 bar.
when the swash plate moves from 15° inclination
angle through the neutral position (0°) to 15° in
Charge pump A 10 VO Pos. 16
another direction.
The swing pumps change the rotation direction and
the torque of the swing motors. Two variable displacement axial piston pumps in a
swash plate design supply hydraulic oil to the swing
Each swing pump is equipped with two pressure pumps and compensate oil losses in the swing
relief valves with 410 bar setting for its two high system with clean cool hydraulic oil.
pressure sides. When the system pressure
increases to 410 bar, the valves open and the oil Each pump is equipped with a cut off valve set at
50 bar. The valve ensures constant oil pressure in
3849405en – (00) Page 8.3 - 4
8.3 DESCRIPTION OF HYDRAULIC SYSTEM - FS
the charge pump line. When the oil pressure in the test couplings serve for pressure checks and
line reaches 50 bar, the valve opens and shifts the adjustments.
pump swash plate back. So the pump delivers only
as much oil flow as required to maintain the oil
pressure in the swing charge line at 50 bar. Valve block Pos. 27
Lubrication system Pos. 19 An assembly group comprising five solenoid
operated on-off valves and six pressure relief
valves ensures pilot pressure supply for different
The lubrication system is operated by the machine machine functions. Five measurement ports with
hydraulic system and ensures lubrication of the test couplings serve for pressure checks and
relevant machine components. adjustments.
Proportional pressure-reducing valve Control block Pos. 29
for main pump control Pos. 23
The control block contains two blocking valves, a
Two proportional pressure-reducing valves control toggle travel valve and two measurement ports with
the oil flow of the main pumps proportionally to test couplings for pressure checks and
operator joystick commands. The valves get adjustments.
electric current within the range of 250 – 850 mA The control block ensures that hydraulic oil flows
from the electronic system and supply control from main single pump pairs P1 & P7 and P2 & P8
pressure between 11 and 42 bar to the main pump either to attachment control manifolds to operate
swashplate regulators, stroking the main pumps attachment functions, or to travel valves to operate
between 30 cc and 446 cc. If the engine speed lugs travel function, which has always priority: When the
down, the valves limit the main pump oil flow below operator activates both attachment and travel
joystick demand to reduce engine power. If the functions, hydraulic oil of pump pairs P1 & P7 and
temperature in the hydraulic system or the engine P2 & P8 flows to the travel motors. The hydraulic
gets too high, the valves also limit the main pump oil flow to the attachment is supplied only with main
oil flow. single pump pairs P4 & P6 and P3 & P5.
Control manifold Pos. 25 HP filter & control block Pos. 32
Two control manifolds contain proportional High pressure filter and control block contains eight
pressure reducing valves for swing and travel high pressure filters, eight blocking valves, four
functions and filter elements. primary pressure relief valves, eighteen measuring
Control manifold ports with test couplings for pressure checks and
adjustments and eight pressure sensors. The high
25/1 contains four proportional pressure pressure oil from the main pumps flows through
reducing valves for left forward travel, left the high pressure filter and control block to the
reverse travel, right forward travel and right control block (29) and attachment control manifolds
reverse travel. (160 & 161) to operate travel and attachment
functions.
25/2 contains two proportional pressure
reducing valves for left and right swing High pressure filters protect the down line
functions. components from metal chips and other
contaminants coming from the main pumps.
The blocking valves isolate oil flow of LH main
Valve block Pos. 26 pumps from RH main pumps during single engine
operation.
The primary pressure relief valves with a 370 bar
An assembly group comprising five solenoid
setting limit main pump pressure to 370 bar to
operated on-off valves and seven pressure relief
prevent pressure peaks.
valves ensures pilot pressure supply for different
The pressure sensors with a 400 bar range monitor
machine functions. Seven measurement ports with
pressure in the main pump lines.
3849405en – (00) Page 8.3 - 5
8.3 DESCRIPTION OF HYDRAULIC SYSTEM - FS
Filter Pos. 34 Check valve Pos. 44
Four filters in the oil supply line of the charge The check valve ensures proper operation of
pumps protect the swing pumps from engine off lower function. The valve prevents the
contamination. accumulator (52) from draining down back through
the valve block (26).
Filter Pos. 36
Filter Pos. 48
Four filters installed in the pilot circuit between pilot
pumps (6) and valve blocks (26 – 27) protect the Two filters clean cool oil returning from the
pilot circuit oil from contamination. hydraulic oil coolers (80) to the lines between
flushing ports of the main pumps (3) and the
hydraulic oil tank.
Bladder accumulator Pos. 38
Mounting plate assembly with control
Two hydro-pneumatic accumulators consist of a
gas and a fluid part separated with a bladder. The valves Pos. 50
gas compressibility is used to accumulate fluid.
The fluid part around the bladder is connected to The mounting plate assembly contains valve
the hydraulic track tension circuit. So with hydraulic blocks and control valves for different machine
pressure increase the accumulator gas part – the functions.
bladder filled with nitrogen – is compressed and the
hydraulic oil is accumulated. When hydraulic oil
pressure in the circuit decreases, the compressed Check valve Pos. 51
nitrogen expands and pushes the accumulated
hydraulic oil into the circuit. So the bladder
accumulators charged at 80 and 50 bar The check valve ensures proper operation of
compensate pressure drops in the pilot circuit. engine off lower function. The valve prevents
draining of the accumulator (52) through auxiliary
control blocks (166) until the solenoid operated on-
Check valve Pos. 39 off valve (53) is activated.
Two check valves resolve the higher of the two Diaphragm accumulator Pos. 52
pressure values of main single pump pairs for
travel and direct this higher travel pressure to the
spring chambers of blocking valves in the control The hydro-pneumatic accumulator consists of a
block (29). They ensure that both blocking valves gas and a fluid part separated with a diaphragm.
remain closed during travel operation. The gas compressibility is used to accumulate
fluid. The fluid part is connected to the hydraulic
boom lower circuit. So with hydraulic pressure
Check valve Pos. 43 increase the accumulator gas part filled with
nitrogen is compressed and the hydraulic oil is
accumulated. When hydraulic oil pressure in the
Four check valves separate pilot oil flow from the circuit decreases, the compressed nitrogen
pumps in standstill during single engine operation expands and pushes the accumulated hydraulic oil
mode. into the circuit. So the diaphragm accumulator
Otherwise the oil from the spinning pumps on the provides pressure for boom lowering when the
running engine would flow to the pumps in engines (1) are off.
standstill on the idle engine and spin them
backwards.
Solenoid operated on-off valve Pos. 53
The valve ensures proper operation of engine off
boom lower function. When the engines are off and
the operator has activated boom lower function, the
3849405en – (00) Page 8.3 - 6
8.3 DESCRIPTION OF HYDRAULIC SYSTEM - FS
solenoid operated on-off valve directs the pressure Tank line pressurizing valve Pos. 64
from the diaphragm accumulator (52) to auxiliary
control blocks (166) of the attachment to lower the
boom. The activated valve prevents draining of the Four tank line pressurizing valves direct return oil
accumulator through the auxiliary control blocks. flow from the attachment control valves and travel
valves to the hydraulic tank. The tank line
pressurizing valves consist of pressure relief valves
SIL valve Pos. 56 with 15 bar setting and flow control valves. This
pressure activates anti-cavitation valves for travel
and attachment functions to prevent voiding
Two SIL (Safety Integrity Level) solenoid valves conditions and cavitation damage to travel motors,
ensure safe operation of the swing circuit when any attachment valves, cylinders and other hydraulic
control function (electrical, hydraulic or mechanical) components. If the pressure in the line to the
fails. cylinders or travel motors drops below 15 bar, the
anti-cavitation valves open and direct the oil that
Distributor Pos. 57 otherwise would have returned to the hydraulic tank
to the corresponding hydraulic components. It
protects the components from cavitation damage
The distributor on the mounting plate assembly that otherwise could be caused by too low inlet oil
(50) connects return oil lines of control valves to pressure.
the hydraulic oil tank.
Gate valve Pos. 67
Hydraulic oil tank Pos. 60
Two gate valves separate the hydraulic oil tank
The hydraulic oil tank comprises following from hydraulic oil lines of main pumps (3). So they
components: enable replacement of the main pumps without
2 return flow filter chambers (62); draining hydraulic oil out of the tank.
6 bypass valves (63); Gate valve
4 tank line pressurizing valve blocks (64);
3 gate valves (67/1, 67/2 and 68). 67/1 separates hydraulic oil lines of LH main
pumps (3/1 and 3/2);
Return flow filter Pos. 62 67/2 separates hydraulic oil lines of RH main
pumps (3/3 and 3/4).
Two return flow filters, or filter chambers, – each
containing 7 filter elements – are installed in the Gate valve Pos. 68
hydraulic oil tank to clean the oil returning from the
consumers. The oil passes through the filter
elements from the inside to the outside. Metal The gate valve separates the hydraulic oil tank
particles are collected on the magnetic rod located from suction lines of pilot pumps (6), hydraulic oil
above the filters. cooling fan pumps (10), engine cooling fan pumps
(11) and charge pumps (16). So the valve enables
replacement of all these pumps without draining
Bypass valve Pos. 63 hydraulic oil out of the tank.
Six bypass valves protect return flow filters (62). Drain oil manifold Pos. 72
When the filters get contaminated, the oil pressure
in the filter chambers exceeds 1.5 bar. The bypass
valves which are set to 1.5 bar open and let the Two drain oil manifolds collect the drain oil from the
unfiltered oil flow directly into the hydraulic oil tank. pumps and pressure relief valves and direct it to
the hydraulic oil tank.
3849405en – (00) Page 8.3 - 7
8.3 DESCRIPTION OF HYDRAULIC SYSTEM - FS
Hydraulic oil cooler Pos. 80 channels 7 and 9 are for return oil line;
channel 8 is plugged.
Four hydraulic oil coolers transfer the heat
generated in the hydraulic system to the
atmosphere. Cooling is achieved through the air
flow produced by the fans. RH travel valve Pos. 92
Fan motor Pos. 81 The pilot controlled single-spool valve directs the
hydraulic oil flow through the rotor (91) to RH travel
motors (121) and other travel circuit components to
Four high pressure gear motors are driven with enable travel function.
hydraulic oil cooling fan pumps (10) and drive the
fans of the hydraulic oil coolers (80).
LH travel valve Pos. 93
Fan control manifold Pos. 85
The pilot controlled single-spool valve directs the
hydraulic oil flow through the rotor (91) to LH travel
Two fan control manifolds ensure proper operation motors (121) and other travel circuit components to
of the whole hydraulic oil cooling system. Each fan enable travel function.
control manifold includes two pressure relief
valves, two thermostats and two anti-cavitation
(check) valves for the corresponding fan motors. RH travel retarder valve Pos. 95
The pressure relief valves with 65 bar setting limit
pressure in the oil cooling lines to each fan motor.
The thermostats installed on 2/2-way directional The valve gets return hydraulic oil from travel
valves control the oil flow through the coolers motors (121) and directs it to the hydraulic oil tank.
proportionally to hydraulic oil temperature between The valve decelerates the rotation speed of the
40 and 52°C. When the oil temperature is below travel motors to protect them from cavitation and
40°C, the valves bypass the oil flow to the tank. damage. It is especially important when the
When the oil temperature rises above 40°C, the machine travels downhill and its weight forces the
thermostats gradually close the valve ports to the travel motors to rotate at a higher speed and
tank line. So the valves direct the oil flow to the oil consume more hydraulic oil than the main pumps
coolers and fan motors, and the oil temperature in supply. When traveling downhill, the travel retarder
the lines decreases. When the oil temperature valves partially close building braking torque on the
rises to 52°C, the tank ports of the valves close travel motors. The machine slows and the pump
completely and the whole oil flows to the coolers. pressure recovers.
The anti-cavitation valves protect oil cooling fan
motors. When the operator switches off the engine,
the anti-cavitation valves direct the oil flow from the
LH travel retarder valve Pos. 96
fan motors outlets to their inlets to protect them
from cavitation. The valve gets return hydraulic oil from travel
motors (121) and directs it to the hydraulic oil tank.
The valve decelerates the rotation speed of the
Rotor Pos. 91 travel motors to protect them from cavitation and
damage. It is especially important when the
The rotor connects the hydraulic systems of the machine travels downhill and its weight forces the
superstructure and the undercarriage. travel motors to rotate at a higher speed and
It has 9 channels for the following functions: consume more hydraulic oil than the main pumps
supply. When traveling downhill, the travel retarder
channels 1 – 4 are for travel; valves partially close building braking torque on the
travel motors. The machine slows and the pump
channel 5 is for track tension system; pressure recovers.
channel 6 is for travel park brake and
second speed travel;
3849405en – (00) Page 8.3 - 8
8.3 DESCRIPTION OF HYDRAULIC SYSTEM - FS
Anti-cavitation valve Pos. 97 Swing motor A2F 180 Pos. 102
Four anti-cavitation valves designed as check Two swing motors are fixed displacement axial
valves protect travel motors from cavitation piston motors in a bent axis design. The output
damage. When the machine stops, the travel speed is proportional to the pump oil flow and the
motors continue to rotate for some time due to motor displacement volume. The output torque
inertia, but the main pumps destroke and may not increases with the pressure difference between the
supply sufficient oil quantity to the travel motor high and low pressure sides of the motors and with
inlets. The oil returning to the hydraulic tank from the increasing displacement volume.
the corresponding ports of the motors passes
through tank line pressurizing valves (64) with 15
bar setting and reaches the tank. Therefore the Blocking valve Pos. 103
anti-cavitation valves have a pressure supply of 15
bar on the tank line side. If the pressure drops Four swing circuit blocking valves ensure safe
below 15 bar, the valves open and the oil that machine function during single engine operation
otherwise would have returned to the hydraulic oil mode. In such cases the corresponding blocking
tank passes through the anti-cavitation valves and valves are closed, so the high and low pressure oil
flows to the low pressure ports of the motors. So flow to the swing pumps on the corresponding side
the travel motors do not run “dry” avoiding is blocked to prevent the pressurized oil from
cavitation erosion. flowing to the engine in standstill and to avoid
power losses.
Swing gearbox Pos. 100
Swing balance valve Pos. 105
Four swing gearboxes designed as a 2-stage
planetary gear system enable superstructure The swing balance valve controls swing torque,
movement.The spring applied multidisc brakes, a swing direction and swing system oil pressure.
part of the the swing gearboxes, serve to hold the
superstructure stationary.
Swing flushing valve Pos. 106
Shuttle valve Pos. 101
The swing flushing valve directs hydraulic oil flow
Three shuttle (changeover) valves permit hydraulic from the low pressure side of the closed loop swing
oil flow from either of two inlet ports to a common circuit to the hydraulic oil tank. This heated oil is
outlet according to the relative pressure at the two replaced with cooler filtered oil from the tank
inlets. The higher pressure inlet oil flows through supplied with swing charge pumps (16).
the valve to the joint outlet while the other inlet is
blocked. When the higher pressure oil flows
through the other inlet, the valve lets the oil flow to High pressure filter Pos. 107
the outlet in the reverse direction and relieves
system pressure.
Shuttle valve Two high pressure filters for swing motors (102)
protect both sides of the swing circuit from
101/1 directs pressure from the higher pressure contamination. The check valves in the filter heads
port Y1 or Y2 of swing balance valve 105 ensure that the oil flows through the filters only in
towards pressure relief valve 109/1; one direction. It is necessary because high
pressure and low pressure sides of the swing
101/2 releases the travel park brake and circuit change depending on the swing direction.
determines whether the travel motor operates in
low speed or 2nd speed mode;
Pressure relief valve Pos. 109
101/3 directs pressure to track tension relief
control manifold 133 and blocks the other inlet Two pressure relief valves with different settings
for normal track tension pressure. limit pressure in different hydraulic circuits.
Pressure relief valve
3849405en – (00) Page 8.3 - 9
8.3 DESCRIPTION OF HYDRAULIC SYSTEM - FS
Track tension cylinder Pos. 130
109/1 limits inlet control pressure of the
swing balance valve (105) for RH and LH
swing to 22 bar. Two single acting hydraulic cylinders keep the
crawler tracks tensed.
109/2 limits pressure in the track tension
pilot supply circuit to 100 bar.
Piston accumulator Pos. 131
Orifice Pos. 111 Two hydro-pneumatic accumulators consist of a
gas and a fluid part separated with a piston. The
The orifice (111) limits the oil flow from the swing gas compressibility is used to accumulate fluid.
flushing valve (106) to the hydraulic oil tank. The fluid part is connected to the hydraulic track
tension circuit. So with hydraulic pressure increase
the accumulator gas part filled with nitrogen is
Travel gearbox Pos. 120 compressed and the hydraulic oil is accumulated.
When hydraulic oil pressure in the track tension
circuit decreases, the compressed nitrogen
Two travel gearboxes with integrated brakes are of expands and pushes the accumulated hydraulic oil
three-stage planetary design. into the circuit. So the piston accumulators
A mechanical multiple disk park brake integrated in compensate pressure drops in the track tension
each travel gearbox is applied by springs and circuit and absorb shocks caused to the tracks by
released by 53 bar pilot pressure. external forces.
Travel motor A6VM 250 Pos. 121 Ball valve Pos. 132
Four travel motors are variable displacement axial Two ball valves separate track tension cylinders
piston units in bent axis design. Due to their wide (130) and hydraulic accumulators (131) from other
control range the travel motors produce high torque components of track tension system for removal,
and speed. The displacement volume can vary installation, service and transport of the crawlers.
steplessly from 0 to maximum. The output speed of
the travel motors depends on their displacement
volume and on the main pump oil supply. The Track tension control manifold Pos. 133
output torque increases with the increasing
pressure difference between high and low pressure
sides and with the increasing displacement volume. The track tension control manifold consisting of a
3/2-way directional switch valve and two check
valves ensures proper operation of track tension
Check valve Pos. 123 circuit.
Four check valves with 6 bar setting protect the Pressure relief valve Pos. 134
shaft seals of the travel motors (121) from damage
caused by high pressure oil.
Two pressure relief valves with 330 bar setting
protect the track tension circuit in each crawler
Secondary pressure relief frame separately from too high pressure increase.
manifold Pos. 125
Fan motor A2FM 200 Pos. 140
The secondary pressure relief manifold comprises
four pressure relief valves with 370 bar setting
Two fixed displacement axial piston motors in a
arranged in two cross-over pairs. The manifold
bent axis design are driven by engine cooling fan
protects travel motors (121) and hydraulic hoses
pumps (11) and drive the fans for the engine
from excessive pressure that could cause them to
cooling. The output speed of the motors is
fail prematurely. The valves become active during
proportional to the pump oil flow.
travel brake and reverse travel.
3849405en – (00) Page 8.3 - 10
8.3 DESCRIPTION OF HYDRAULIC SYSTEM - FS
Anti-cavitation valve block Pos. 141 Bladder accumulator Pos. 151
Two anti-cavitation valve blocks for engine cooling The hydro-pneumatic accumulator consists of a
fan motors (140) consist of check valves with 0.2 gas and a fluid part separated with a bladder. The
bar spring setting. The valve blocks protect the gas compressibility is used to accumulate fluid.
engine cooling fan motors from damage when the The fluid part around the bladder is connected to
engines stop. the hydraulic access ladder circuit. So with
hydraulic pressure increase the accumulator gas
part – the bladder filled with nitrogen – is
Hydraulic cylinder Pos. 145 compressed and the hydraulic oil is accumulated.
When hydraulic oil pressure in the circuit
The double acting hydraulic cylinder operates the decreases, the compressed nitrogen expands and
fast fill station (service arm). pushes the accumulated hydraulic oil into the
circuit. So the bladder accumulator charged at 65
bar ensures proper operation of the access ladder
Control valve Pos. 146 when the engines are off.
The control valve for the fast fill station (service Control valve Pos. 152
arm) is designed as a 3/3-way seat valve with two
solenoid operated on-off elements. The valve
ensures proper operation of the service arm. The 6/3-way seat valve with a pressure relief
element and a lever enables proper operation of
the access ladder.
Check valve Pos. 147
Check valve Pos. 153
The check valve for the fast fill station (service
arm) enables service arm operation with the The check valve enables access ladder operation
pressure of the accumulator (148) when the with the pressure of the hydraulic accumulator
engines are off. (151) when the engines are off.
Diaphragm accumulator Pos. 148
LH & RH attachment control manifolds
Pos. 160 – 161
The hydro-pneumatic accumulator consists of a
gas and a fluid part separated with a diaphragm.
The gas compressibility is used to accumulate Four pilot controlled valve manifolds consist of 3
fluid. The fluid part is connected to the hydraulic control spools for boom, bucket and stick cylinders
boom lower circuit. So with hydraulic pressure and 6 secondary pressure relief valves with 350
increase the accumulator gas part filled with bar setting to limit pressure in the cylinders. The
nitrogen is compressed and the hydraulic oil is manifolds control the cylinders to enable proper
accumulated. When hydraulic oil pressure in the operation of attachment functions.
circuit decreases, the compressed nitrogen
expands and pushes the accumulated hydraulic oil
into the circuit. The accumulator ensures proper Boom & stick float valves Pos. 164 – 165
operation of the fast fill station (service arm) when
the engines are off. The float valves allow lowering of the boom and
stick under the power of gravity without using main
pump oil. Each float valve contains three identical
Hydraulic cylinder Pos. 150 control spools which shift against their closing
springs when the operator commands the boom or
The double-acting hydraulic cylinder ensures stick to lower. As the spools shift, the boom or stick
proper operation of the access ladder. cylinder head ends connect through the spools to
the boom or stick cylinder rod ends. The boom or
stick cylinders retract with some of the oil from the
3849405en – (00) Page 8.3 - 11
8.3 DESCRIPTION OF HYDRAULIC SYSTEM - FS
head ends filling the rod ends and the rest oil Distributor Pos. 187
returns to the hydraulic oil tank.
The distributor is installed on the bucket rear wall
Auxiliary control block Pos. 166 between clam cylinders (186). The distributor
contains a secondary pressure relief valve with 330
bar setting which protects the clam cylinders from
Each of three auxiliary control blocks contains four too high pressure. The distributor connects the
proportional pressure reducing valves to control hydraulic lines from the rod ends of the clam
pressure for attachment functions, one preheating cylinder to their head ends and protects the
valve and one sieve to prevent contamination. hydraulic system from pressure peaks.
Clam valve block Pos. 169 Distributor Pos. 188
The clam valve block controls clam cylinders (186). Two distributors installed on the boom connect high
The block contains one control spool which directs pressure oil lines from four attachment control
oil pressure to operate the clam cylinders. Two manifolds (160 – 161) to bucket cylinders (184).
secondary pressure relief valves with 365 bar
setting installed in the block limit system pressure
to protect the clam cylinders. Two check valves in Filter Pos. 191
the clam valve block protect the clam cylinders
from voiding. If the cylinders are moved by external
forces, the check valves let the hydraulic oil from Two filters with optical indicators are installed in the
the tank line to fill the cylinders. gear oil cooling circuit for pump gearboxes (2)
between gear pumps and gear oil coolers (193).
The pumps suck hot gear oil from the bottom of the
Boom cylinder Pos. 182 pump gearboxes and send it through filters to the
gear oil coolers. The filters keep gear oil clean.
Two double acting hydraulic cylinders are installed
between the superstructure and the boom Tripower Bypass valve Pos. 192
link. They lift or lower the boom and thus the
complete attachment.
Two bypass valves designed as check valves with
6 bar setting protect the gear oil cooling circuit from
Stick cylinder Pos. 183 pressure peaks. If there is a restriction in the gear
oil filters or coolers, or the gear oil is cold, the
bypass valves direct the gear oil from gear pumps
Two double acting hydraulic cylinders are installed back into the pump gearboxes (2).
between the boom Tripower link and the stick.
They enable to lift or lower the stick.
Gear oil cooler Pos. 193
Bucket cylinder Pos. 184 Two gear oil coolers installed in the oil cooling
module cool gear oil of two pump gearboxes.
Two double acting hydraulic cylinders are installed
between the boom Tripower link and the bucket
rear wall and are used to lift or lower the bucket. Distributor Pos. 194
Two distributors are installed into the
Clam cylinder Pos. 186 corresponding pump gearbox cooling circuit in the
engine module. Each distributor contains a check
Two double acting hydraulic cylinders are installed valve with 1 bar setting and a 3 mm orifice to
on the bucket rear wall and are used to open and maintain back pressure in the gear oil cooling
close the bucket. circuit. The cooled gear oil returns from the gear oil
coolers (193) to the pump gearboxes (2) through
the distributors.
3849405en – (00) Page 8.3 - 12
8.3 DESCRIPTION OF HYDRAULIC SYSTEM - FS
8.3.3 Hydraulic schematic
The hydraulic schematic of 6060 FS Batch has part
no. 3 758 597 (00).
3849405en – (00) Page 8.3 - 13
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