MHL360 Remove / Install Dipper Stick / xxxx en

Transcription

1 MHL360

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3 Foreword 1 1 Foreword Contents Target group Introduction Safety Hazard Classification Notes General instructions Description of symbols and hazard pictorials Technical Data Technical Data Torque information for screws, bolts and nuts Labour time involved, Equipment Labour time involved Equipment (Special Tools and Operating Resources) To be performed before conversion Park the machine Overview Parts Dipper Stick 7,0m / 23 ft Loose Parts Hydraulic Installation Dipper Stick 7,8m / 25,5ft Loose Parts Hydraulic Installation Electric Installation Loading Equipment Remove Dipper Stick Dismount Cylinders from Dipper Stick Release excess pressure from the hydraulic system Dismount electrical System Disconnect hydraulic pipes/ hoses Remove Dipper Stick Disassembly and Reassembly of Dipper Stick Loose Parts Hydraulic System Reinstall Dipper Stick Connect Dipper Stick with Boom Reconnect Dipper Stick Cylinders Bleeding air from the hydraulic system SA10602-en Edition

4 1 Foreword 1 Foreword 1.1 Contents This document describes removal, Installation and changing all parts of: Dipper Stick 7,0m / 23ft Dipper Stick 7,8m / 25,5ft for MHL360D 1.2 Target group This document is written for trained workshop specialists. 1.3 Introduction Only if the user / staff is familiar with the Operation and Service Manual errors can be prevented and trouble-free operation / working can be assured. It is therefore very important that those persons who are actually responsible for operation / working are familiar with the Operating and Service Manual. They must be thoroughly read and understood, as the manufacturer will not assume liability for damages and malfunctions arising as a result of noncompliance with the Operating and Service manual. If you require additional information or if any point is unclear, please contact your dealer or our Customer Service immediately: We reserve the right to modify the machine within the scope of technical developments without changing the operating instructions. All drawings and pictures must not necessarily match with the machine type described in this manual. TEREX Fuchs GmbH Industriestraße Bad Schönborn GERMANY 2 Edition SA10602-en

5 Foreword Safety Hazard Classification DANGER DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. WARNING WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. CAUTION CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. CAUTION CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage Notes This symbol is employed for information containing important notes about the correct use and/or how to proceed. Non-compliance may lead to malfunction General instructions These instructions must be observed without exception during every step of assembly. Failure to do so may result in injury to persons and damage to property. CAUTION Never install hoses crosswise or twisted. This will prevent contact points which may subsequently lead to damage. 1000Nm WARNING Shows Torque information! Torque instructions for bolts must be observed without exception! Danger of accident if bolt threads are striped! CAUTION Always tighten bolts that form a rectangular or round pattern in stages, alternating back and forth around a circle WARNING SAG1001 Keep a safe step on the machine because of the big height Make sure that no parts get lost! Keep smaller screws, bolts, washers etc. in a box or another suitable container. Measures in drawings and pictures, if not special marked, are always given in Millimetres and inches SA10602-en Edition

6 1 Foreword Description of symbols and hazard pictorials The symbols used in this Service manual and on the machine identify the following hazards: Symbol Description Symbol Description Electrical hazard Death or serious injury can result from contacting electric power lines. Always contact the electric power line owner. The electric power shall be disconnected or the power lines moved or insulated before machine operation begin. Entanglement hazard Death or serious injury can result from contact with rotating drivelines. Keep clear of rotating drivelines. Switch off engine before to performing service. Explosion / burn hazard Will cause death, burns, or blindness due to ignition of explosive gases or corrosive acid. Keep all open flames and sparks away. Wear personal protective equipment, including face shield, gloves and long sleeve shirt. Consult operation and maintenance manual for jump starting instructions. Explosion / burn hazard Release of hot pressurized fluids can cause burns or blindness. Allow system to cool and always open carefully. Crush hazard Death or serious injury can result from leaving the operators station without securing the machine. Always turn off the engine and set the parking brake before leaving the operators station. Crush hazard Death or serious injury can result from people riding on this machine other than at the operators station. No passengers are permitted to ride on this machine. Only operate this machine from the operators station. Crush hazard Death or serious injury can result from contact with moving outriggers. Keep clear of moving outriggers. Skin injection hazard Use a piece of cardboard to check for hydraulic hose leaks. Do not use your hand. If fluid is injected under the skin, it can cause gangrene. Get medical help immediately. 4 Edition SA10602-en

7 Foreword 1 Symbol Description Symbol Description Crush hazard Death or serious injury can result from contact with moving parts. Keep clear of elevated components. Support components before performing service. Crush hazard Death or serious injury can result from contact with moving parts. Keep clear of swinging upper structure. Falling hazard Death or serious injury can result from an elevated cab. When the cab is elevated, keep the door to the cabin closed. Only exit when the cab is in the lowered position. Always use seat belt Death or serious injury can result from failure to wear seat belt. Always adjust seat and fasten seat belt before starting engine. Hand Crush Hazard Serious injury can result from contact with moving parts. Keep clear from moving parts! Falling hazard Death or serious injury can result from falling from the machine. Always face the machine and maintain three point contact when using the access system. Do not allow riders on the steps during operations. Falling hazard Death or serious injury can result from falling from the machine. Do not climb onto moving or working machinery. Do not use deck as walking surface. Read and understand operators manual and all safety signs before using or maintaining machine. If you do not understand the information in the manuals consult your supervisor, the owner, or the manufacturer. Lifting lug Refer to the operators manual for procedures for lifting the machine. Operating manuals behind drivers seat SA10602-en Edition

8 2 Technical Data 2 Technical Data 2.1 Technical Data Loading equipment 16,5m / 54,1ft Length of dipper stick 7,0 m / 23 ft Weight of dipper stick kg / lb Loading equipment 18m / 59ft Length of dipper stick 7,8m / 25,5ft Weight of dipper stick kg / 4.012,5 lb Weight of dipper stick cylinder (2x) 300 kg / 661,4 lb (hydraulic oil not included) 2.2 Torque information for screws, bolts and nuts If there are no special torque information for bolts and nuts in the manual, the following list instructs you how to tighten them. Torque M A [Nm] M 4 x 0,7 3,0 4,4 5,1 M 5 x 0,8 5,9 8,7 10 M 6 x 1, M 8 x 1, M10 x 1, M12 x 1, M14 x 2, M16 x 2, M18 x 2, M20 x 2, M22 x 2, M24 x 3, M27 x 3, M30 x 3, Edition SA10602-en

9 Labour time involved, Equipment 3 3 Labour time involved, Equipment 3.1 Labour time involved Labour time ca. 8 hours Qualified Personnel 2 Persons 3.2 Equipment (Special Tools and Operating Resources) crane or other loading equipment with suitable capacity lubricating grease Hydraulic oil (look in Operating Instructions, Chapter 7 for sort and quantity) To seal hydraulic hoses and pipes you need following parts: M M D1 D1 M L L 0.20-SAG1006 Denomination Qty. Union nut (1) Union nut (2) Blind fitting (3) Blind fitting (4) Connection (5) Connection (6) PN (bar) PN (PSI) D1 (mm) D1 (in) M L (mm) L (in) Walterscheid denomination Fuchs-Part- No ,59 M22x1,5 17 0,67 M15L ,18 M42x2 29 1,14 M30S ,59 / 20 0,79 VSD-15L M.MB ,18 / 34 1,34 VSD-30S M.MB / / M22x1,5 30 1,18 P-GS- 15L / / M42x2 54 2,13 P-GS- 30S SA10602-en Edition

10 3 Labour time involved, Equipment The following pictures of the hoists / devices are only examples, if you have other equivalent solutions it is possible to use them, if they match with the needed parameters. DANGER Be sure to use a crane with suitable capacity and the hoist / device you are using is designed for the load. flat lifting sling(s) for securing dipper stick / boom CAUTION Use sling with reinforced bordering because of the sharp edges! Dipper stick could fall down! SAG1012 other lifting slings for securing cylinders / boom SAG Edition SA10602-en

11 4 To be performed before conversion To be performed before conversion Park the machine 0.10-SAG1007 The armrest contact switch must be active by lowering the armrest, the driver must be sitting on the seat and the service ladder must be locked. Toggle switch (2) "Travel and work functions enabled" must be in the center position. Indicator (3) "Travel and work functions disabled" must not be lit (yellow background against message) 0.10-SAG1006 remove work attachments Park machine off on level ground rotate the upper carriage in travel direction lift the stabilizers up Set the parking brake by activating the toggle switch (1). Extend the Dipper Stick completely. Lower the boom until the Stick rests on the ground Switch off the engine. turn the disconnector (1) 90 to the left side and pull it out Make sure that the disconnector does not get lost! 0.10-SAG SA10602-en Edition

12 5 Overview Parts 5 Overview Parts 5.1 Dipper Stick 7,0m / 23 ft Loose Parts Dipper Stick 7,0m / 23ft SAG Edition SA10602-en

13 Overview Parts 5 Loose Parts Dipper Stick 7,0m / 23ft Position Benennung Denomination Anzahl Fig. Qty. 1 Ladestiel 7,0 m Dipper stick 7.0 m Buchse Bushing Einspannbuchse Bushing Buchse Bushing Buchse Bushing Deckel Cover Sechskantschraube Hexagon bolt Scheibe Washer 4 2 Bolzen kpl. Pin cpl. 2 3 Scheibe Washer 2 4 Kronenmutter Castle nut 2 5 Splint Cotter pin 2 6 Scheibe Washer? 6 Scheibe Washer? 10 Halter Bracket 2 11 Sechskantschraube Hexagon bolt 6 12 Scheibe Washer 6 For more information about spare parts / required parts please look into the current Parts Catalog for your machine! SA10602-en Edition

14 5 Overview Parts Hydraulic Installation Dipper Stick 7,0m / 23ft SAG Edition SA10602-en

15 Overview Parts 5 Hydraulic Installation Dipper Stick 7,0m / 23ft Position Benennung Denomination Anzahl Fig. Qty. 1 Reduzierverschraubung Fitting 2 2 Leitung Pipe 2 3 Verbindungsstutzen Connection 2 4 Leitung Pipe 2 5 Kupplungsstecker Coupler Connector 1 6 Schutzstopfen Protection connector 1 7 Kupplungsmuffe Coupling sleeve 1 8 Schutzkappe Cover 1 10 Leitung Pipe 2 11 Verbindungsstutzen Connection 2 12 Leitung Pipe 2 13 Kupplungsstecker Coupler Connector 1 14 Verschlussschraube Screw plug 1 15 Kupplungsmuffe Coupling sleeve 1 16 Verschlussmutter Lock nut 1 20 Schlauchhalter Hose bracket 2 21 Sechskantschraube Hexagon bolt Sechskantmutter Hexagon nut Schlauchhalter Hose bracket Lasche Bracket 1 31 Senkschraube Bolt 1 For more information about spare parts / required parts please look into the current Parts Catalog for your machine! SA10602-en Edition

16 5 Overview Parts 5.2 Dipper Stick 7,8m / 25,5ft Loose Parts Dipper Stick 7,8m / 25,5ft SAG Edition SA10602-en

17 Overview Parts 5 Loose Parts Dipper Stick 7,8m / 25,5ft Position Benennung Denomination Anzahl Fig. Qty. 1 Ladestiel 7,8 m Dipper stick 7.8 m Buchse Bushing Einspannbuchse Bushing Buchse Bushing Buchse Bushing Deckel Cover Sechskantschraube Hexagon bolt Scheibe Washer 4 2 Bolzen kpl. Pin cpl. 2 3 Scheibe Washer 2 4 Kronenmutter Castle nut 2 5 Splint Cotter pin 2 6 Scheibe Washer? 6 Scheibe Washer? 10 Halter Bracket 2 11 Sechskantschraube Hexagon bolt 6 12 Scheibe Washer 6 For more information about spare parts / required parts please look into the current Parts Catalog for your machine! SA10602-en Edition

18 5 Overview Parts Hydraulic Installation Dipper Stick 7,8m / 25,5ft SAG Edition SA10602-en

19 Overview Parts 5 Hydraulic Installation Dipper Stick 7,8m / 25,5ft Position Benennung Denomination Anzahl Fig. Qty. 1 Reduzierverschraubung Fitting 2 2 Leitung Pipe 2 3 Verbindungsstutzen Connection 2 4 Leitung Pipe 2 5 Kupplungsstecker Coupler Connector 1 6 Schutzstopfen Protection connector 1 7 Kupplungsmuffe Coupling sleeve 1 8 Schutzkappe Cover 1 10 Leitung Pipe 2 11 Verbindungsstutzen Connection 2 12 Leitung Pipe 2 13 Kupplungsstecker Coupler Connector 1 14 Verschlussschraube Screw plug 1 15 Kupplungsmuffe Coupling sleeve 1 16 Verschlussmutter Lock nut 1 20 Schlauchhalter Hose bracket 2 21 Sechskantschraube Hexagon bolt Sechskantmutter Hexagon nut Schlauchhalter Hose bracket Lasche Bracket 1 31 Senkschraube Bolt 1 For more information about spare parts / required parts please look into the current Parts Catalog for your machine! SA10602-en Edition

20 5 Overview Parts 5.3 Electric Installation Loading Equipment X H H23 Overload warning 20 S B40 B28 B40 S65 overload shut-off system Upper Carriage X SAG Edition SA10602-en

21 Overview Parts 5 Electric Installation Loading Equipment Position Benennung Denomination Anzahl Fig. Qty. 1 Arbeitsscheinwerfer Working floodlights Glühlampe Filament lamp 1 2 Halter Bracket 1 3 Zylinderschraube Cylinder head bolt 4 4 Scheibe Washer 4 1 Arbeitsscheinwerfer Working floodlights Glühlampe Xenon Filament lamp Xenon 1 2 Halter Bracket 1 3 Zylinderschraube Cylinder head bolt 4 4 Scheibe Washer 4 5 Näherungsschalter Proximity switch 1 6 Schlauchschelle Hose clamp? 7 Wellschlauchhalter Corrugated hose holder? 8 Deckel (Wellschlauchhalter) Cover (corrugated hose holder)? 9 Zylinderschraube Cylinder head bolt? 10 Scheibe Washer? 20 Kabelbaum (Ladeeinrichtung) Wire harness (loading equipment) Steckhülsengehäuse Casing of receptacle for tabs 1 21 Gummikappe Rubber sheet 1 For more information about spare parts / required parts please look into the current Parts Catalog for your machine! SA10602-en Edition

22 6 Remove Dipper Stick 6 Remove Dipper Stick 6.1 Dismount Cylinders from Dipper Stick secure dipper stick cylinders with suitable slings CAUTION Pay attention! Do not scratch the piston rods! SAG1007 It s not necessary to hang the cylinder on a crane! The cylinders only have to be secured! WARNING Don t remove the mounting of the dipper stick cylinders on the boom side (B)! remove the Cotter pins, Castle nuts, washers and the pins on both sides of the Stick (A) (leave the bushings inside of the dipper stick) B A SAG Edition SA10602-en

23 Remove Dipper Stick 6 plug in the disconnector (1) turn around 90 to the right The operating voltage is now reconnected! 0.10-SAG start the engine retract dipper stick cylinders completely SAG Release excess pressure from the hydraulic system DANGER Danger of injury due to loading equipment suddenly dropping. Danger due to hot hydraulic oil under pressure. Before converting the loading equipment, set it down on the ground and release residual pressure from the system! 0.10-SAG1005 Turn the engine off Turn the ignition key to position "1" (ignition on). Reduce the pressure in the hydraulic system by activating both control levers (4 and 5) at least 5 times in all directions and press the toggle swith on top of the right control lever (5) at least 3 times to both sides SA10602-en Edition

24 6 Remove Dipper Stick turn the disconnector (1) 90 to the left side and pull it out Make sure that the disconnector does not get lost! 0.10-SAG screw out the ventilation filter wait a few seconds until there is now more pressure on the tank screw in the ventilation filter SAG1006 push a suitable object ( for example thin tube or a screw driver) in the couplings for the work attachments to release the rest hydraulic oil in the lines SAG Edition SA10602-en

25 Remove Dipper Stick 6 Upper carriage 6.3 Dismount electrical System disconnect plugs of headlights remove headlights remove all electric connections from the dipper stick and fix them on the boom CAUTION Protect the electrical Connections from moisture and dirt, if necessary cover them with tape! SAG SA10602-en Edition

26 6 Remove Dipper Stick Collect the hydraulic oil and dispose of it properly! Clear up any spilt oil! 6.4 Disconnect hydraulic pipes/ hoses disconnect pipes, hoses and grease lines between stick and boom seal the connections as shown See Chapter 3.2 for drawing of fittings! Denomination Qty. PN (bar) Union nut (1) Union nut (2) Blind fitting (3) Blind fitting (4) Connection (5) Connection (6) PN (PSI) D1 (mm) D1 (in) M L (mm) L (in) ,59 M22x1,5 17 0,67 M15L ,18 M42x2 29 1,14 M30S Walterscheid denomination ,59 / 20 0,79 VSD-15L M.MB ,18 / 34 1,34 VSD-30S M.MB / / M22x1,5 30 1,18 P-GS- 15L / / M42x2 54 2,13 P-GS- 30S Fuchs-Part- No A SAG Edition SA10602-en

27 Remove Dipper Stick Remove Dipper Stick secure dipper stick with flat lifting sling like shown (sling as near as possible to the cylinder mounting brackets) or with round lifting slings around the brackets for the cylinders WARNING Pay attention that dipper stick does not slide out of the slings! SAG1012 CAUTION The Dipper Stick Cylinders are still secured and retracted! Be careful not to damage the cylinders! remove the stick / boom connection (cotter pins, castle nuts, washers, pins and all other loose parts) on both sides of the stick / boom (leave the bushings inside) let the Dipper Stick slowly down to the ground and rest on blocks SAG SA10602-en Edition

28 6 Remove Dipper Stick secure boom with suitable support so it can not lower while the dipper stick is being dismounted WARNING Pay attention that the boom does not slide out of the sling! 26 Edition SA10602-en

29 7 Disassembly and Reassembly of Dipper Stick Disassembly and Reassembly of Dipper Stick Loose Parts remove all covers and loose parts SAG1014 Collect the hydraulic oil and dispose of it properly! Hydraulic oil that escapes must be bound with binding agent! Leave all Pipes, Hoses and other Hydraulic Components sealed or respectivly connected with each other! There may be Hydraulic oil inside! 7.2 Hydraulic System remove all upper parts of brackets remove pipes and hoses remove all other components if present disassemble pipes and hoses When dismounting pipes be careful to collect rest hydraulic oil! reassemble in reverse order SAG SA10602-en Edition

30 8 Reinstall Dipper Stick 8 Reinstall Dipper Stick 8.1 Connect Dipper Stick with Boom remove the support from the boom SAG1017 WARNING Pay attention that Dipper Stick does not slide out of the sling! lift up dipper stick carefully with a suitable hoist position it to the boom until the drillings for the connection of stick to boom match SAG Edition SA10602-en

31 Reinstall Dipper Stick 8 CAUTION The Dipper Stick Cylinders are still secured and retracted!! Take care to line up the bearing holes exactly and keep dipper stick parallel to boom prepare the pins with lubricating grease position the washers, insert the pins and secure them with the castle nuts and cotter pins mount all other loose parts if present WARNING Do not use your fingers to check the alignment of the holes! SAG SA10602-en Edition

32 8 Reinstall Dipper Stick Collect the hydraulic oil and dispose of it properly! Clear up any spilt oil! remove the sealings from the pipes and hoses reconnect the hydraulic lines between dipper stick and boom A SAG1011 Upper carriage install headlights and all other electrical components if present remove protection tape from electric connections connect all plugs and other electric connections fix all not needed connections on the dipper stick so that they can t be damaged later SAG Edition SA10602-en

33 Reinstall Dipper Stick Reconnect Dipper Stick Cylinders plug in the disconnector (1) and turn around 90 to the right side The operating voltage is reconnected now! 0.10-SAG turn off the vacuum pump remove the plug of the pump (1) screw in the cap of the ventilation filter (2) SAG1025 start the engine drive out the dipper stick cylinders until the bearing holes are aligned SAG SA10602-en Edition

34 8 Reinstall Dipper Stick The drillings have to match perfectly together and the dipper stick has to be exact parallel to the boom, anywise it is not possible to get the pins in! turn off the engine position the washers, insert the pins and secure them with the castle nuts and cotter pins (A) mount any other loose parts remove all support and slings B A SAG Bleeding air from the hydraulic system start the engine move the loading equipment by operating both control levers (4) and (5) in all directions until the air is bled from the system 0.10-SAG1005 The Installation of the dipper stick is finished now, you can work with the machine again! After installing a work attachment you also have to bleed the air from the hydraulic lines of the work attachment (open and close it on low engine speed a few times) 32 Edition SA10602-en

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36 Hauptverwaltung / Verkauf / Kundendienst Head Office / Sales / After Sales Service Sièges Administratif / Vente / Service Après-Vente TEREX Fuchs GmbH Industriestraße Bad Schönborn GERMANY Fon.: ++49 (0) / 84-0 Fax: ++49 (0) / Info@fuchs-terex.de