1 General Purpose Contents Target group Entire documentation In case of questions...

Transcription

1 MHL350 D

2

3 Contents General Purpose Contents Target group Entire documentation In case of questions... 3 Safety Requirements for the service staff General safety notes for service work Special notes Information on installation and removal Assembly overview, employment of personnel Lifting equipment and devices Special tools and aids Definition of views... 4 Preparations Placing the machine in service position Letting off residual pressure in hydraulic system Switching off and securing the machine Allowing the machine to cool down Removing the main hydraulic pump Structure of the description Creating/closing accesses Cleaning the assembly area Discharging and holding back the hydraulic oil Disconnecting/connecting the hydraulic connections of the hydraulic oil tank Disconnecting/connecting electrical connections Lifting out/inserting the hydraulic oil tank Disconnecting/connecting the hydraulic connections of the main hydraulic pump Lifting out/inserting the main hydraulic pump Modifications Installing or modifying small parts Modifying the engine/main hydraulic pump coupling Installation main hydraulic pump Structure of the description Procedure Fill and vent main hydraulic pump SA0503-en Version (44)

4 Contents 8 Placing the machine into operation again Checks before switching on Start operation of main hydraulic pump Appendix Technical data Tightening torques for screw connections Vacuum pump Eyebolts Fittings, flanges Index...44 (44) Version SA0503-en

5 General General. Purpose These Service Instructions describe the individual steps to be followed for removing and installing components. They do not contain information on troubleshooting and diagnostics. The texts, photographs and graphic depictions have been kept as general as possible for reasons of clarity. In your interest, TEREX Fuchs continues developing the products further. For this reason, we reserve the right to implement technical changes without prior notice that might deviate from the information contained in these Service Instructions.. Contents These Service Instructions describe the following service work: Replacement of main hydraulic pump with a new main hydraulic pump or a replacement hydraulic pump. The description is valid for the following machines: MHL350 D as of Vehicle Identity No / Target group These Service Instructions are exclusively intended for authorized service staff of the contract dealers and service partners of TE- REX Fuchs..4 Entire documentation These Service Instructions represent one part of the entire documentation for the machine. The entire documentation comprises Operating instructions Service Instructions for the individual components (if provided). Service CD Documentations of the various component manufacturers (if applicable). Note The Operating Instructions and the instructions on the service work to be carried out must be read and understood before beginning with the work. Depending on the type of service work, the documentation of the respective component manufacturer must also be known..5 In case of questions These Service Instructions contain basic information. However, they cannot answer all questions. Should you have any specific questions regarding your machine, please contact the service department that is responsible for you. Terex Deutschland GmbH Geschäftsbereich Terex Fuchs Industriestraße 3 D Bad Schönborn GERMANY Phone: +49 (0) Fax: +49 (0) For USA and Canada TCA 8800 Rostin Rd Southaven, MS3867 Phone: + (66) Fax: + (66) SA0503-en Version (44)

6 Safety Safety. Requirements for the service staff Any service work on the machine requires comprehensive knowledge of the mode of operation and dangers of the machine as a whole and its components. Therefore, the service staff must have certain minimum qualifications depending on the task. For the required qualification, a distinction is made between installation/removal of components on the one hand and diagnostics on the other hand. Activities Disassembly and installation of components Diagnostic work Qualifications Must be 8 years old (6 years is sufficient for assistant work under supervision of an authorized service technician). Must have the physical and mental abilities to carry out the responsibilities, tasks and actions. Must be trained in First Aid and also capable of providing it. Must have the respective national permission for operating this loading machine. Must know the danger potential of repair work on loading machines. Knowledge and understanding of all safety-related notes, sources of danger and safety measures. Must have been trained and instructed in rules of conduct in the event of a fault. Must have read and understood the entire documentation, in particular these Service Instructions, and must be able to apply it. Must be qualified to work on the mechanical, electrical, control and hydraulic system of loading machines by a corresponding nationally recognized training for service work and must be up-to-date with the latest state of knowledge. Must be able to read and understand circuit diagrams and hydraulic diagrams. Must have attended a work-specific training organized by TEREX Fuchs or a person authorized by TEREX Fuchs for carrying out the required service work. 4 (44) Version SA0503-en

7 Safety. General safety notes for service work Increased danger of injury Service work always involves a high danger potential. Serious and permanent injuries may occur, which might, under extreme circumstances, even result in death. Safety through information Not all dangers can be prevented by design measures and safety devices. The service staff must therefore obtain extensive information and keep up-to-date with the latest state of technology. National safety regulations and regulations regarding the protection of the environment provide basic information on safe work and environmentally friendly behavior. The operating instructions contain detailed notes on the permissible machine operation and the correct behavior during service work on the machine. The operating instructions can be found behind the driver s seat and must be valid for the machine. Safe workplace The workplace must be selected and occupied carefully. Make sure that means of escape exist for the event of danger. Check that stability is sufficient. Clean slippery areas before beginning with the work. Remove any obstacles, if possible. When climbing on machine parts, always watch them carefully and make sure that your hands and feet have safe contact at least at three points. Do not choose the shortest, but the safest way. Place down parts and components so that these cannot fall. Use a scaffold when working at high altitudes. If this is not possible, secure yourself with ropes. People wearing medical devices (pace makers) may not enter machines with installed magnets (option). Safe handling of the machine Safety-aware behavior before, during and after service work is of vital importance. The following notes are examples only and not complete. Position the machine at a suitable place. Consider the condition of the ground and weather influences. Keep a sufficient safety distance to overhead electrical lines and obstacles in the range of travel of machine parts. Operate the parking brake and switch off the machine prior to any service work. Remove the ignition key and battery disconnect switch. Place a sign with the note "Service work in progress" in the cab. Wear personal protective equipment. Safety devices may only be removed during standstill and after drive has been secured. Prior to switching on, reattach all safety devices and check their function. Machine parts may move even when switched off. Secure machine parts using suitable tools (for example supports). Always consider the possibility that coupled machine parts can move. Release energies before commencing work (hydraulics, electricity, tanks with fuels, lubricants and coolants, tightening of machine parts). Only seal leakages after the hydraulic pressure has been relieved. Do not walk through the jet of hydraulic oil splashing out. Use tools (for example cardboard) when searching for leaks. Do not check the hydraulic components with your hands! When switching the machine on, expect unforeseeable machine behavior. Take suitable safety measures..50-sa0503-en Version (44)

8 Safety.3 Special notes Safety instructions Safety instructions that refer to a described action are indicated at the beginning of such action or sequence of actions. They explain a danger and how to avoid it in brief. Their format makes them stand out from the rest of the text. Used symbols Symbol Description General warning of a danger area or dangerous situation. Symbol n Signal word Information on the source and the consequences Information on how to avoid it In emergency: Behavior if danger occurs. Danger because of electric current. Danger because of suspended loads. The signal word identifies the danger level. The following signal words are used: DANGER for notes the non compliance with which will result in death or serious permanent injuries. WARNING for notes the non compliance with which might result in death or serious permanent injuries. CAUTION for notes the non compliance with which might result in minor injuries. Symbols clarify a danger by a simplified illustration and are used for severe dangers. In this regard, the illustration does not depict the actual situation but signalizes the type of danger in a clear manner. General notes Notes the non compliance with which might result in environmental hazards or machine damage, that refer to regulations and manufacturer's guidelines, or that are particularly important to ensure that the work to be carried out is successful, are represented as follows: Note Text of a note with or without symbol on the side. Danger because of fire. Danger because of hot surfaces. Danger because of hot liquids. Danger because of slipping. Danger because of tripping. Danger because of falling. Danger by crushing and strikes on the entire body. Danger of crushing and strikes on body parts. 6 (44) Version SA0503-en

9 Safety Danger for body parts by cutting or separating. Danger that objects might be pulled into machine parts. Danger because of automatic start. Danger because of poisonous substances. Danger because of corrosive substances. Ecologically harmful substances. Wear ear and eye protection. Read safety-relevant information..50-sa0503-en Version (44)

10 3 Information on installation and removal 3 Information on installation and removal 3. Assembly overview, employment of personnel The following data are based on experiences. They might differ depending on the local situation. Staff Duration Modifications 0 hours Depending on the customer s requirement, a main hydraulic pump engine is replaced by a new hydraulic pump or a replacement hydraulic pump. The procedure is the same in both cases. The following components from the removed hydraulic pump must be mounted to the new one. Coupling for the connection to the engine. Must be replaced if worn. Small parts (connections for the hydraulic lines) 8 (44) Version SA0503-en

11 3 Information on installation and removal 3. Lifting equipment and devices j WARNING Risk of bruising when using incorrect lifting equipment Observe component weight. Consider additional weight of auxiliary agents, for example tank filling. Do not guide cables and chains over edges. In emergency: Provide first aid. Consult a doctor immediately. j WARNING Risk of bruising due to incorrect storage places Secure components lowered down against toppling over. Provide sufficient free space. In emergency: Provide first aid. Consult a doctor immediately. Assembly option Assembly stand or similar that securely holds the main hydraulic pump during modification work and collects any escaping hydraulic oil. It is purposeful to use a coupling part () on the side of the engine for blocking the drive shaft during assembly work Assembly stand (example) Lifting equipment for hydraulic oil tank and small parts Lifting equipment with lug () and at least three chains () and load hooks (3). The load hooks must be secured so that they cannot slip out. h Weights on page Lifting equipment for diverse parts (examples).50-sa0503-en Version (44)

12 3 Information on installation and removal Lifting equipment for the main hydraulic pump Cable () or the like h Weights on page Cable for holding the main hydraulic pump 0 (44) Version SA0503-en

13 3 Information on installation and removal 3.3 Special tools and aids Designation Units Remark Standard equipment Vacuum pump Vacuum pump on page 39 Eyebolts with nuts M0 : Eyebolts on page 39 Fittings, flanges Fittings, flanges on page 40 Swivel nuts with dummy plug 8S: 4 0L: 4 L: 5L: 6 8L: 4 L: 6 8L: 35L Straight-through connector 8S: 0L: L: 5L: 3 8L: L: 6 8L: 35L Flanges 6000 PSI ¼ 4 Loctite 70 Assembly spray ASA 400 Hydraulic oil Discharging the hydraulic oil on page 7 Clean containers for catching the hydraulic oil to be discharged Cloth and absorbing agent for spilled liquids and oils.50-sa0503-en Version (44)

14 3 Information on installation and removal 3.4 Definition of views The descriptions include depictions of the work steps. For orientation purposes, the caption of the pictures indicates the viewpoint of the viewer. The following designations are used: Lateral view : Starter side : Operator s side Front view 3: Service ladder 4: Coupling side 5: Main hydraulic pump side (44) Version SA0503-en

15 4 Preparations 4 Preparations 4. Placing the machine in service position Unload machine and place it at an even place that is protected against weather influences and offers sufficient work area. 4 Swivel the uppercarriage () until it stands crosswise to the undercarriage () so that you can reach the access holes on the bottom of the uppercarriage Lower the dipperstick (4) with the loading equipment and the 4-point outrigger (3) down to the ground. Service position 4. Letting off residual pressure in hydraulic system Turn the ignition key to position "" (ignition on) Repeatedly move (min. 5 times) both control levers (4) and (5) in all directions and move the toggle switch on the control lever (5) in both directions (min. 3 times) to relieve the remaining pressure of the hydraulic system Control lever in the cab.50-sa0503-en Version (44)

16 4 Preparations 4.3 Switching off and securing the machine Apply parking brake. Switch off the machine. Place a sign at the machine reading "Repair work". Turn the key () at the battery disconnect switch by 90 to the left and pull off. Keep the key at a safe place where it is protected against unauthorized access, but can easily be found Battery disconnect switch 4.4 Allowing the machine to cool down j WARNING Danger of burning by hot engine parts. Let the machine cool down for a sufficient time. Do not touch hot surfaces. Before loosening any connections, always make sure that fuels, lubricants, coolants and liquids contained in these have cooled down. In emergency: Provide first aid. Consult a doctor. 4 (44) Version SA0503-en

17 5 Removing the main hydraulic pump 5 Removing the main hydraulic pump 5. Structure of the description The removal of the main hydraulic pump is described step-by-step. The steps are summarized in groups for purposes of clarity. In the individual case, a different order might therefore be quicker. Basically, the removal is always described first. Additional notes are given for the installation at the end of the work step description. 5. Creating/closing accesses Removing covers at the bottom Remove plates () and (). Cover (view from the bottom of the uppercarriage) Removing covers at the top Remove the cover () Cover (view from starter side) Turning the engine hood down Open the engine hood and secure with the catch () Engine hood (view from starter side).50-sa0503-en Version (44)

18 5 Removing the main hydraulic pump j WARNING Danger of injury because of rotating parts, scattered parts, spurting liquids Reattach all covers prior to switching on the machine. Hoods and doors must be closed. In emergency: Switch off machine. Provide first aid. Consult a doctor. Notes on closing the accesses On principle, close the accesses in reverse sequence. 5.3 Cleaning the assembly area j WARNING Danger of injury to the eyes from liquid jet and scattering dirt Always wear protective goggles. No other people may stand within the area. In emergency: Rinse eyes with clean water and consult a doctor immediately. Note When cleaning with a high-pressure cleaner, never direct the jet onto electric components and connections or the cooler fins. Do not use corrosive cleaning additives! Thoroughly clean the work area around the cooler, engine and main hydraulic pump. 5.4 Discharging and holding back the hydraulic oil j WARNING Danger of serious injuries because of slipping Immediately remove discharged hydraulic oil. Cordon off area. In emergency: Provide first aid. Consult a doctor immediately. Note Hydraulic oil may not be discharged into the environment. It must be disposed of in the correct manner! Hydraulic oil that escapes must be bound with binding agent! General Information The hydraulic oil should be discharged from the hydraulic oil tank for the following work. It is thus ensured that only a minimum amount of hydraulic oil can escape (Discharging the hydraulic oil on page 7). However, if the hydraulic oil is to remain in the hydraulic oil tank, a vacuum pump must be used. It will hold back the hydraulic oil when detaching the hydraulic connections until all hydraulic connections have been sealed (Holding the hydraulic oil back with the vacuum pump on page 8). If the hydraulic oil has been used for more than,000 operating hours, it should be replaced together with the hydraulic and the ventilation filter. h Hydraulic oil specification: Operating Instructions Chapter 3 6 (44) Version SA0503-en

19 5 Removing the main hydraulic pump Ventilation filter (view onto the hydraulic tank) Discharging the hydraulic oil Provide large container. Remove ventilation filter () at the hydraulic oil tank. Remove cap () from the drain valve. Screw straight drain hose from the onboard tool kit to the drain valve (). Screwing will open the drain valve and the hydraulic oil will flow out. Collect hydraulic oil. Close drain valve. Remove ventilation filter at the hydraulic oil tank. Note Collect the hydraulic oil and, if it cannot be used again for filling, dispose of it properly! Drain valve (view onto hydraulic oil tank) SA0503-en Version (44)

20 5 Removing the main hydraulic pump 3 Holding the hydraulic oil back with the vacuum pump Remove ventilation filter (3). Wait for a short time until the pressure in the tank has been relieved. Connect vacuum pump () to the nozzle for the ventilation filter (). Turn on the vacuum pump and generate a vacuum (min bar) / (-. psi) Vacuum pump (view onto hydraulic oil tank) Remove the fillister-head screws () and washers on the retaining fixture (). Remove the retaining fixture (). Turn the square by 90 using a fork wrench from the open position (3) to the shut-off position (4). The shut-off flap is now closed. Note The marking on the end face of the square must be at right angles with the passage. Fasten the safety cover () with the fillister-head screws (). Notes for removing the vacuum pump and closing the shut-off flap Removal of the vacuum pump is always in reverse sequence. 3 4 The shut-off flap is closed and secured after venting the main hydraulic pump. h Fill and vent main hydraulic pump on page 34 Shut-off flap (view from operator s side, left) (44) Version SA0503-en

21 5 Removing the main hydraulic pump 5.5 Disconnecting/connecting the hydraulic connections of the hydraulic oil tank 3 Disconnecting the hydraulic connections Note Hydraulic oil may be discharged from the lines. Therefore have cloth, container and caps ready. Pos. : one swivel nut with dummy plug 35L for the tank connection as well as a straightthrough connector with swivel nut and dummy plug 35L for the hose. Pos. : As above, but in 0L. Pos. 3: As above, but in L. Pos. 4: As above, but in 8L. Pos. 5,, 9: As above, but in 5L. Pos. 6, 8: As above, but in 8L. Pos. 4, 5, 6, 8: As above, but in L. Pos. 7, 9, 0,, 3, 7: remain closed or are sealed with electronic components. Pos. 0: seal with clean film. Connections on the hydraulic oil tank Remove extraction pipe (). Take out O-ring and keep separate. Seal openings on the main hydraulic pump and on the tank. If no cover plate is available for the aperture on the main hydraulic pump it may be dismantled from the new hydraulic pump. Mark and disconnect all other hydraulic connections () on the hydraulic oil tank. Close openings and hoses. If a vacuum pump was used, switch it off. Check the tightness of the closed hydraulic connections Hydraulic connections (view from operator s side).50-sa0503-en Version (44)

22 5 Removing the main hydraulic pump Notes for connecting the hydraulic connections on the hydraulic oil tank On principle, connection is to be carried out in the reverse sequence of disconnection. 3 In particular, check the connection of the intake pipe. Note Use a new O-ring. Dispose of the old one! Slightly screw in the two bottom fastening screws () at the main hydraulic pump. Hydraulic connection for extraction pipe (view from operator s side) At the intake pipe, insert the new O-ring (3) into the groove of the sealing surface (). Hook the intake pipe with the two bottom attachment points (4) in the fastening screws () at the main hydraulic pump. Slowly rest the intake pipe against the sealing surface of the main hydraulic pump while observing the O-ring. If the O-ring has not moved out of the groove, screw in and fasten all fastening screws. 0 (44) Version SA0503-en

23 5 Removing the main hydraulic pump 5.6 Disconnecting/connecting electrical connections Disconnecting electrical connections Note Possible damage to electric components due to residual voltages. - Detach battery disconnect switch. - Ensure potential equalization Electrical connections (view from operator s side, from the top) Mark and disconnect the electrical connections (). Detach connecting cable () from the supports and lead away from the hydraulic tank and the main hydraulic pump. Subsequently fasten so that they are not in the way when the hydraulic oil tank and the main hydraulic pump are lifted out later. If the hydraulic oil tank is equipped with optional components (such as hydraulic oil pre-heating), disconnect these as well Electrical connections (view from starter side) Notes for connecting the electric connections On principle, connection is to be carried out in the reverse sequence of disconnection. Check that the following precautions are taken: Note Make sure that installation of cables corresponds to as-delivered state. Cables may not chafe against any components or contact hot components. Ensure that the seals for the plug-type connectors are seated properly..50-sa0503-en Version (44)

24 5 Removing the main hydraulic pump 5.7 Lifting out/inserting the hydraulic oil tank 3 Removing fastenings The hydraulic oil tank () is screwed to the uppercarriage (). Remove fastenings (3) (4 pieces). Hydraulic tank fastening (view onto hydraulic oil tank) Lifting out the hydraulic oil tank j WARNING Risk of bruising by falling hydraulic oil tank Only use lifting equipment that is suitable for the weight (for information on the lifting equipment refer to 9). Do not step or put your hands beneath the lifted hydraulic oil tank. In emergency: Provide first aid. Consult a doctor immediately. Transport lugs on the hydraulic oil tank Attach lifting equipment at the transport lugs (). On the freely suspended hydraulic oil tank (), check whether all joints and connections have been detached. Slowly lift the hydraulic oil tank upwards and out of the machine. Place the hydraulic oil tank down outside the assembly area so that it does not rest on the drain valve. Secure it against toppling over. Make sure that all apertures on the hydraulic oil tank have been closed. (44) Version SA0503-en

25 5 Removing the main hydraulic pump Notes for installing the hydraulic oil tank Insertion is to be carried out in the reverse sequence of detaching. Check that the following precautions are taken: Clean hydraulic oil tank and replace filter. h More information: Operating Instructions Chapter Filter (view from starter side, right) j WARNING Risk of bruising by falling hydraulic oil tank Only use lifting equipment that is suitable for the weight (for information on the lifting equipment refer to 9). If possible, drain hydraulic oil beforehand. Otherwise consider filling weight. Do not step or put your hands beneath the lifted hydraulic oil tank. In emergency: Provide first aid. Consult a doctor immediately. Transport lugs on the hydraulic oil tank. Attach lifting equipment at the three transport lugs (), but do not lift yet Place the spacer plates (4) on the uppercarriage () on the left side at the two fastening places (). Slowly lift the hydraulic oil tank and carry to assembly site. Lower it there until it is suspended just above the uppercarriage. Screw in fastening screws (3) left () and right (5), but do not fasten yet Hydraulic oil tank fastening (view from main hydraulic pump side).50-sa0503-en Version (44)

26 5 Removing the main hydraulic pump Place down hydraulic oil tank () and align towards the uppercarriage (): right side (3) flush with uppercarriage; front side (4) offset by 30 mm (. in) behind the uppercarriage Positioning of hydraulic oil tank (view from corner operator s side/main hydraulic pump side) 85 Nm Tighten fastening screws () and (). Tightening torque for both bolts (): 85 Nm (63 lbf ft) Hydraulic oil tank fastening (view from the top) 4 (44) Version SA0503-en

27 5 Removing the main hydraulic pump 5.8 Disconnecting/connecting the hydraulic connections of the main hydraulic pump 3 Disconnecting the hydraulic connections Note Hydraulic connections (view from main hydraulic pump side) Hydraulic oil may be discharged from the lines. Therefore have cloth, container and dummy plugs ready. Pos. : four flanges 6000 PSI ¼ with retaining screws for the two main hydraulic pump connections and the hoses. Pos. : one swivel nut with dummy plug 0L for the main hydraulic pump connection as well as one straight-through connector with swivel nut and dummy plug 0L for the hose. Pos. 3: As above, but x in 8S. Pos. 4: As above, but x in L. Remove flanges (). Close openings and hoses. Mark and disconnect all hydraulic connections () (4) on the main hydraulic pump. Close openings and hoses. Lead connecting lines away from the main hydraulic pump. Subsequently fasten so that they are not in the way when lifting out the main hydraulic pump later. j WARNING Danger of fractures, cuts and bruises because of slipping Clean the entire work area and the machine of discharged hydraulic oil. In emergency: Provide first aid, consult a doctor..50-sa0503-en Version (44)

28 5 Removing the main hydraulic pump Notes for connecting the hydraulic connections Hydraulic connections of control block (view from main hydraulic pump side) j WARNING Danger of injury because of spurting hydraulic oil A high pressure is created at the flange connections. Therefore proceed with special care when connecting. Do not check for leakages when hydraulic system is switched on. Use tools. In emergency: Switch off the machine. Provide first aid. Consult a doctor immediately. On principle, connection is to be carried out in the reverse sequence of disconnection. In particular, check the connection of the control block flange connection. Note New sealing rings must be used. Dispose of the old ones! Insert new sealing rings () in the two flanges (). Slowly rest the flange against the sealing surface of the main hydraulic pump while observing the sealing ring. If the sealing ring has not moved out of the groove, screw in and fasten all fastening screws. h For connecting the intake pipe see Notes for connecting the hydraulic connections on the hydraulic oil tank on page 0 6 (44) Version SA0503-en

29 5.9 Lifting out/inserting the main hydraulic pump 5 Removing the main hydraulic pump Marking the coupling In the view hole (), mark the joint of the coupling halves () so that these can be fitted into each other at the same place when rejoining them later. h Inspecting the coupling on page 3 Note If the joint of the coupling is not accessible, mark the position of the coupling halves to each other immediately after removing them Main hydraulic pump (view from operator s side) 3 Detaching fastening Main hydraulic pump (view from operator s side) j WARNING Risk of bruising by falling or toppling over main hydraulic pump Only use lifting equipment that is suitable for the weight (for information on the lifting equipment refer to 0). Fasten main hydraulic pump so that it cannot topple over when subsequently pulling it out of the engine. Do not put your hands in between main hydraulic pump and cladding (4) when detaching main hydraulic pump from engine. In emergency: Provide first aid. Consult a doctor immediately. Arrange rope or similar (3) around the main hydraulic pump (), as depicted. Make sure that no components can be pinched. Slightly tension rope with the main hydraulic pump. Remove all fastening screws () of the main hydraulic pump on the engine..50-sa0503-en Version (44)

30 5 Removing the main hydraulic pump Lifting out the main hydraulic pump Main hydraulic pump at the lifting equipment j WARNING Risk of bruising by falling main hydraulic pump Always wear safety gloves when pulling out the main hydraulic pump. Do not step or put your hands beneath the lifted main hydraulic pump. Place main hydraulic pump down immediately. In emergency: Provide first aid. Consult a doctor immediately. Slightly lift main hydraulic pump at the rear () and pull it out of the engine with vibrating movements. On the freely suspended main hydraulic pump, check whether all joints and connections have been detached and are closed. Slowly lift the main hydraulic pump upwards and out of the machine. Place main hydraulic pump down outside the assembly area and secure against toppling over. j WARNING Danger of fractures, cuts and bruises because of slipping Clean the entire work area and the machine of discharged hydraulic oil. In emergency: Provide first aid, consult a doctor. 8 (44) Version SA0503-en

31 5 Removing the main hydraulic pump Notes for inserting the main hydraulic pump Insertion is to be carried out in the reverse sequence of lifting out. Check that the following precautions are taken: j WARNING Engine coupling place Risk of bruising by falling main hydraulic pump and edges Observe the notes Lifting out/inserting the main hydraulic pump on page 7. Always wear safety gloves when pushing in the main hydraulic pump. Do not touch the flange surfaces of engine and main hydraulic pump when joining them. In emergency: Provide first aid. Consult a doctor immediately. Clean the area around the toothing () and check for damage. Subsequently wet with assembly spray ASA 400. h Inspecting the coupling on page Clean fastening flanges on main hydraulic pump and engine (). Main hydraulic pump coupling place Note Do not use force or striking tools when inserting the pump. Otherwise, this will damage the plastic coupling on the engine. Main hydraulic pump (view from operator s side) 49 Nm Thread coupling driven member of main hydraulic pump in coupling flange of the engine. Make sure that the toothing of the coupling halves engage at the places marked during disassembly. Use the view holes () for this. h Inspecting the coupling on page 3 Insert main hydraulic pump until it rests against the engine flange. While doing this, jolt main hydraulic pump a little bit. Align hole circles to each other and screw in all fastening screws (). Fasten the fastening screws at the flange. Torque: 49 Nm (36 lbf ft)..50-sa0503-en Version (44)

32 6 Modifications 6 Modifications 6. Installing or modifying small parts Note Hydraulic oil may be discharged from the lines. Therefore have cloth, container and dummy plugs ready. Pos.,, and 3: three union nuts with dummy plug L Connections in the lower area of the main hydraulic pump Remove screw-in fittings (), () and (3) from the removed main hydraulic pump and install. Close opening. Note 5 3 Hydraulic oil may be discharged from the lines. Therefore have cloth and container ready. If it has not already been done during disassembly, provide the following dummy plugs. Pos. : Union nuts with dummy plug 0L. Pos. and 5: As above, but 8S. Pos. 4: As above, but L Connections in the upper area of the main hydraulic pump Remove dummy plug Pos. () at the new main hydraulic pump and install in Pos. (3). Remove screw-in fittings and elbow sockets (), (4) and (5) from the removed main hydraulic pump and install. Remove screw-in fittings () from the removed main hydraulic pump and install. Close opening. j WARNING Danger of fractures, cuts and bruises because of slipping Clean the entire work area and the main hydraulic pump of discharged hydraulic oil. In emergency: Provide first aid, consult a doctor. 30 (44) Version SA0503-en

33 6 Modifications 6. Modifying the engine/main hydraulic pump coupling Inspecting the coupling The coupling has a two-part design and is subject to wear and tear. It consists of a metal hub () on the side of the main hydraulic pump, and a plastic flange () on the side of the engine. Main hydraulic pump/drive engine coupling Note If operating time exceeds 4,000 hours, always replace the complete coupling (hub and flange). Y X S Wear measurement on toothing S=.70 mm: Gear teeth thickness in new condition up to Y=0.65 mm: normal wear range between Y and X: Coupling should be replaced from X=.30 mm: Replace coupling immediately Check coupling parts. The toothing may not be worn, broken or cracked. Inspect the gear teeth on the engine side () particularly thoroughly. Measure wear on toothing (3). Evaluate based on bottom left drawing. If coupling is still used, the toothing () and () must mesh at the same place when reassembled. If this is not observed, another run-in process is required. This will result in a greater play. 0 Nm Installing clutch hub If no new coupling is installed, loosen clamping screw (3), take out clutch hub and clean. 3 Push new or used clutch hub () on drive shaft of the new main hydraulic pump until stop. Make sure that the collar () faces the engine. Coat terminal screw (3) with Loctite 70 and screw in. Tightening torque: 0 Nm (55 lbf ft) Clutch hub (view from engine side).50-sa0503-en Version (44)

34 6 Modifications Installing the coupling flange (only for new coupling) Remove () fastenings on the coupling flange. Coupling flange (view from main hydraulic pump side) Clean flywheel (). Wet the fastening screw thread for the coupling flange () and for the main hydraulic pump (3) with Loctite Flywheel (view from main hydraulic pump side) 3 (44) Version SA0503-en

35 7 Installation main hydraulic pump 7 Installation main hydraulic pump 7. Structure of the description As the installation of many components is done in reverse order of disassembly, we refer to the respective disassembly description for these work steps. 7. Procedure Installation of the main hydraulic pump is done in the following order: Insert main hydraulic pump. h Lifting out/inserting the main hydraulic pump on page 7 If a vacuum pump is used, switch it on again. h Vacuum pump on page 39 Provide hydraulic connection for main hydraulic pump (except for intake pipe). h Disconnecting/connecting the hydraulic connections of the main hydraulic pump on page 5 Insert the hydraulic oil tank h Lifting out/inserting the hydraulic oil tank on page Provide electrical connections for hydraulic oil tank. h Disconnecting/connecting electrical connections on page Provide hydraulic connection for hydraulic oil tank (including intake pipe). h Disconnecting/connecting the hydraulic connections of the hydraulic oil tank on page 9 Switch off vacuum pump and remove. h Vacuum pump on page 39 Open shut-off flap once again. h Discharging the hydraulic oil on page 7 If it has not been done, detach ventilation filter. h Vacuum pump on page 39 Fill in hydraulic oil. h More information: Operating Instructions Chapter 7 h Discharging the hydraulic oil on page 4 Vent hydraulic system and main hydraulic pump. Note Failure to vent may destroy the main hydraulic pump. h More information: Operating Instructions Chapter 7 Reattach ventilation filter. h Vacuum pump on page 39 Close accesses. h Creating/closing accesses on page 5.50-SA0503-en Version (44)

36 7 Installation main hydraulic pump 7.3 Fill and vent main hydraulic pump Opening venting place Note Hydraulic oil may be discharged from the line. Therefore have cloth, container and cap ready. Pos. : one straight through connector with swivel nut and dummy plug L for the hose. Venting place (view from operator s side, left) If a vacuum pump is available, connect it and switch it on. h Holding the hydraulic oil back with the vacuum pump on page 8 Disconnect and seal hose () from elbow socket (). Filling main hydraulic pump with hydraulic oil Switch off vacuum pump Remove the fillister-head screws () and washers on the retaining fixture (). Remove the retaining fixture (). Turn the square by 90 using a fork wrench from the shut-off position (4) to the open position (3). The shut-off flap is now open and oil flows into the pump. Note The marking on the end face of the square must parallel to the passage. 3 4 Shut-off flap (view from operator s side, left) (44) Version SA0503-en

37 7 Installation main hydraulic pump Venting place (view from operator s side, left) Hold collecting container against the socket elbow () and wait until hydraulic oil escapes. If no hydraulic oil escapes, the hydraulic oil tank must be topped up. Close shut-off flap. Switch on vacuum pump. Remove cover from hose (). Reconnect hose to the main hydraulic pump. Switch off vacuum pump and remove. Open shut-off flap. Check hydraulic oil level. Top up if necessary. h More information: Operating Instructions Chapter 7 The hydraulic pump is filled and thus vented. Any residual air in the lines will be relieved when placing the machine into operation again. h Start operation of main hydraulic pump on page 36 Note The main hydraulic pump may not be operated until completely filled with oil! Attaching the safety cover Coat the fastening screws () with Loctite 70. Attach the safety cover () Safety cover (view from operator s side, left).50-sa0503-en Version (44)

38 8 Placing the machine into operation again 8 Placing the machine into operation again 8. Checks before switching on Check hydraulic oil level. Check safety devices. 8. Start operation of main hydraulic pump j WARNING Danger of injury by uncontrolled machine movements Personally make sure that no other people stand in the area. Always expect that the machine operates faulty or incorrectly after repair work. In the event of any abnormal machine movements, switch off machine immediately and identify cause. In emergency: Provide first aid. Consult a doctor immediately. Reinstall battery disconnect switch and ensure power supply. j WARNING Risk that body parts might be separated by hydraulic jet at high pressure. Personally make sure that no other people stand in the area. Only start machine from inside the closed cab. In emergency: Provide first aid. Consult a doctor immediately. Start engine. Let engine warm up at idle. Switch off engine and check the tightness of all connections. Check hydraulic oil level. Top up if necessary. Restart the engine if there are no leaks. Check settings of the main hydraulic pump and correct if necessary: - Basic settings - Δp - VD3 valve h More information: Service documentation Use the control levers to carry out all work functions with small movements and at low load. The machine will vent automatically during this. WARNING! Unpredictable movements are possible. Increase the load slowly. Note If you hear any strange noises, briefly reduce the load. Subsequently, increase load once again. If the problem has not been corrected by this, switch machine off and inform TEREX / Fuchs. Switch off engine and check once again the tightness of all connections. Check hydraulic oil level. 36 (44) Version SA0503-en

39 9 Appendix 9 Appendix 9. Technical data Designation Weight [kg] Remark Engine with add-on parts Engine approx. 750 kg (654 lbs) Without engine oil Cooler cover Engine cooler approx. 00 kg ( lbs) approx. 00 kg ( lbs) Main hydraulic pump approx. 00 kg (44 lbs) Without filled hydraulic oil Uppercarriage Hydraulic oil tank approx. 300 kg (66 lbs) Without filled hydraulic oil.50-sa0503-en Version (44)

40 9 Appendix 9. Tightening torques for screw connections Tightening torques TM A M 4 x 0.7 3,0 Nm (. lbf ft) 4,4 Nm (3. lbf ft) 5, Nm (3.8 lbf ft) M 5 x 0.8 5,9 Nm (4.4 lbf ft) 8,7 Nm (6.4 lbf ft) 0 Nm (7.5 lbf ft) M 6 x.0 0 Nm (7.5 lbf ft) 5 Nm ( lbf ft) 8 Nm (3.5 lbf ft) M 8 x.5 5 Nm (8.5 lbf ft) 36 Nm (6.5 lbf ft) 43 Nm (3.5 lbf ft) M 0 x.5 49 Nm (36 lbf ft) 7 Nm (53 lbf ft) 84 Nm (6 lbf ft) M x Nm (63 lbf ft) 5 Nm (9 lbf ft) 45 Nm (07 lbf ft) M 4 x.0 35 Nm (00 lbf ft) 00 Nm (48 lbf ft) 35 Nm (73 lbf ft) M 6 x.0 0 Nm (55 lbf ft) 30 Nm (9 lbf ft) 365 Nm (69 lbf ft) M 8 x Nm ( lbf ft) 430 Nm (37 lbf ft) 500 Nm (369 lbf ft) M 0 x.5 45 Nm (34 lbf ft) 60 Nm (450 lbf ft) 70 Nm (54 lbf ft) M x Nm (48 lbf ft) 830 Nm (6 lbf ft) 970 Nm (76 lbf ft) M 4 x Nm (538 lbf ft) 050 Nm (774 lbf ft) 0 Nm (900 lbf ft) M 7 x Nm (8 lbf ft) 550 Nm (43 lbf ft) 800 Nm (38 lbf ft) M 30 x Nm (070 lbf ft) 00 Nm (549 lbf ft) 450 Nm (807 lbf ft) Note The specified tightening torques apply for screwed connections for which no values have been indicated in the Service Instructions, Operating Instructions or the documentation of the component manufacturer. 38 (44) Version SA0503-en

41 9 Appendix 9.3 Vacuum pump Vacuum pump for generating a low pressure for disassembly of the toothed wheel pumps: Generation of low pressure of at least -0.5 bar (-. psi) Connecting thread M40 mm When using the vacuum pump, the hydraulic oil can remain in the tank. If no vacuum pump is used, it must be discharged Vacuum pump (example) 9.4 Eyebolts Eyebolts M0 with nuts for lifting small components, such as engine cooler and housing Eyebolts (example).50-sa0503-en Version (44)

42 9 Appendix 9.5 Fittings, flanges part number size thread part number size LL M0x L/S LL Mx L/S L Mx, L/S L M4x, L L M6x, L L M8x, L L Mx, L L M6x, L L M30x L L M36x S L M45x S L M5x S S M4x, S S M6x, S S M8x, S M0x, S M4x, S M30x S M36x S M4x S M5x part number size L L L L L L L L L S 8S S S S S S S S 40 (44) Version SA0503-en

43 part number size part number size L L L L L L 8L L L L L L L L 8S L 0S L S L 6S S S S S S S S S S S S S 9 Appendix part number size L L L L L L L L L S S S S S S S L L 8S.50-SA0503-en Version (44)

44 9 Appendix part number size part number size L L L L L L L L L L L L L L L L L L S S S S S S S S S S S S S S 38S S part number size part number size L L L L L L L L L L L L L L L L L L 8S S S S S S S S S S S S S S S 4 (44) Version SA0503-en

45 9 Appendix part number size part number size L L L L S S L-8S S L S L S-L L S-5L S S-8L L S-L L L L L L L S L S L S S L S L S L L L L S L S L S S S-L S S-5L L S-8L L L L L L L part number size 3/4" 3000PSI " 3000PSI /4" 3000PSI /" 3000PSI /" 6000PSI 3/4" 6000PSI " 6000PSI /4" 6000PSI bolt M0x35 M0x35 M0x40 Mx45 M8x30 M0x35 Mx45 M4x45.50-SA0503-en Version (44)

46 0 Index 0 Index Links to the operating instructions change hydraulics filter 3 fill in hydraulic oil 34 filling in hydraulics oil 36 hydraulic oil 6 venting hydraulics und main hydraulic pump 34 Links to the service documentation Settings main hydraulic pump (44) Version SA0503-en

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48 Hauptverwaltung / Verkauf / Kundendienst Head Office / Sales / After Sales Service Sièges Administratif / Vente / Service Après-Vente Terex Deutschland GmbH Geschäftsbereich Terex Fuchs Bad Schönborn GERMANY Fon.: ++49 (0) 7 53 / 84-0 Fax: ++49 (0) 7 53 / Info@fuchs-terex.de