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ALL CYLINDERS
MAINTENANCE MANUAL MANUAL
SANDVIK MINING AND CONSTRUCTION CONSTRUCTION LYON S.A.S. 19, av. De Lattre de Tassigny B.P. 46 - 69881 LYON cedex, FRANCE Tel: +33 (0)4 72 45 22 00 Fax: +33 (0)4 (0)4 78 31 79 80
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ALL CYLINDERS
03-10-2003 EZ-JCB-FL
1) PRELIMINARY REMARKS 1/1) SAFETY The information contained in this manual must be studied and thoroughly assimilated before undertaking any maintenance work on the equipment Remember: SAFETY FIRST!
Always observe the warnings accompanied by the following symbols.
WARNING
WARNING
WARNING
WARNING: Before starting any maintenance operation ensure that the machine is in a safe location with good safety, ventilation and lighting conditions. Ensure that lifting equipments and pedestals are compatible with elements’ weight. Follow all the safety instructions and ware safety protections as gloves, goggle, helmet, safety boots, ear protectors.
WARNING: Before any operation stabilize and fix steadily all the elements on suitable pedestals. Stop the power pack, switch the general power breaker and the battery switch OFF. Place a tag or a board to warn other members of the personnel that maintenance work on the machine is in progress.
WARNING: Pressurized oil jets could cause severe injuries. Before any operation on hydraulic circuit, STOP the power pack and release remaining pressure in components by operating hydraulic control levers several times. Always release the static pressure in cylinders before disassemble them. WARNING: NEVER WORK ON AN OPERATING CIRCUIT. WARNING: While tests are in progress, do not allow any other member of the personnel to stand in the area surrounding the moving parts. Stay at the control station to be able to stop the movement and switch off the power pack.
WARNING
WARNING: Maintenance, adjustment and repairs are restricted to qualified personnel with special training for the particular equipment. Always read the instructions carefully before starting any maintenance work. WARNING
CAUTION: Always use suitable tools and work in a clean place when dismantling and assembling hydraulic components. After removing cylinders the hydraulic inlet/outlet ports must be plugged to prevent dirt and air intrusion during operation. CAUTION
1/2) ABOUT THIS BOOKLET The present manual is destined for the use of personnel in charge of carrying out servicing and maintenance operations on the ALL CYLINDERS. It contains maintenance operations schedule and operating methods for the main elements of the ALL CYLINDERS. Note that servicing and maintenance operations must be carried out by personnel with the required qualifications, technical knowledge, and proper training on the machine.
SANDVIK MINING AND CONSTRUCTION LYON S.A.S. 19, av. De Lattre de Tassigny B.P. 46 - 69881 LYON cedex, FRANCE Tel: +33 (0)4 72 45 22 00 Fax: +33 (0)4 78 31 79 80
ALL CYLINDERS
03-10-2003 EZ-JCB-FL
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2) RELEASE PRESSURE
WARNING
WARNING: Pressurized oil jets could cause severe injuries. Before any operation on hydraulic circuit, STOP the power pack and release remaining pressure in components by operating hydraulic control levers several times. Always release the static pressure in cylinders before disassemble them.
NEVER WORK ON AN OPERATING CIRCUIT .
RELEASING PRESSURE 1
1
• Place the moving part on adapted support to prevent a sudden fall of moving parts when releasing the pressure trap in the cylinder chambers. • Release remaining pressure in hydraulic components and hoses by operating control levers several times.
1
• WARNING: Cover the bleed plug 1 with a cloth and thoroughly undo the plug in order to avoid unexpected oil jet.
1
• Slowly loosen remaining static pressure. • Same operation on the other end of the cylinder or rotary actuator. NOTE: Do not fully untighten bleed plugs and retighten them after operation to keep free translation of the piston and the rod.
BLEEDING A CYLINDER 1
1
After installing a cylinder, bleed the air in the chambers.
• Tighten bleed plugs 1. • Start up the power pack. • Operate control levers several times and carry out movement from stop to stop. • Stop the power pack. 1
1
• Thoroughly untighten bleed plugs and breeze the air. WARNING: While tests are in progress, do not allow any other member of the personnel to stand in the area surrounding the moving parts. Stay at the control station to be able to stop the movement and switch off the power pack.
SANDVIK MINING AND CONSTRUCTION LYON S.A.S. 19, av. De Lattre de Tassigny B.P. 46 - 69881 LYON cedex, FRANCE Tel: +33 (0)4 72 45 22 00 Fax: +33 (0)4 78 31 79 80
WARNING
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ALL CYLINDERS
03-10-2003 EZ-JCB-FL
3) DESCRIPTION See page 4 Each cylinder consists essentially of:
2
• a body (1) with a ball joint (2) attached, 8
• a rod (3) with the other ball joint (2) attached, • a piston (4) screwed to the rod and fitted with seals (*),
5
*
• a pin (5) to prevent the piston unscrewing,
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• a guide (6) screwed to the body and fitted with seals (*). 7
Some cylinders are also fitted with spacers rings (7) or have yokes or threaded housings instead of ball joints. Grease nipples (8) are sometimes mounted directly on the ball joint yokes and not on the taper pins. Disassembly and reassembly are the same for all types of cylinder.
4
*
1
3
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6
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8
2
Figure 1
SANDVIK MINING AND CONSTRUCTION LYON S.A.S. 19, av. De Lattre de Tassigny B.P. 46 - 69881 LYON cedex, FRANCE Tel: +33 (0)4 72 45 22 00 Fax: +33 (0)4 78 31 79 80
ALL CYLINDERS
03-10-2003 EZ-JCB-FL
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4) TIGHTENING TORQUES / LUBRICANTS For basic genuine TAMROCK SECOMA™ screws and nut use the following tightening torque: metric dimension
M6 M8 M10 M12 M14 M16 M18 M20 M22 M24 M27 M33 M36 M39 M42
HEX BOLTS
“ALLEN” BOLTS
GRADE 8.8
GRADE 12.9
10Nm (7.37ft.lbs) 25Nm (18.43ft.lbs) 50Nm (36.85ft.lbs) 85Nm (62.64ft.lbs) 130Nm (95.81ft.lbs) 200Nm (147.4ft.lbs) 280Nm (206.36ft.lbs) 400Nm (294.8ft.lbs) 530Nm (390.61ft.lbs) 670Nm (493.79ft.lbs) 1000Nm (737ft.lbs) 1780Nm (1311.86ft.lbs) 2300Nm (1695.1ft.lbs) 3000Nm (2211ft.lbs) 3700Nm (2726.9ft.lbs)
16Nm (11.79ft.lbs) 40Nm (29.48ft.lbs) 80Nm (58.96ft.lbs) 140Nm (103.18ft.lbs) 210Nm (154.77ft.lbs) 330Nm (243.21ft.lbs) 460Nm (339.02ft.lbs) 650Nm (479.05ft.lbs) 880Nm (648.56ft.lbs) 1130Nm (832.81ft.lbs) 1650Nm (1216.05ft.lbs) 2200Nm (1621.4ft.lbs) 3850Nm (2837.45ft.lbs) 5050Nm (3721.85ft.lbs) 6250Nm (4606.25ft.lbs)
LUBRICANTS: Recommended grease: Mobilith SHC 220, Mobilgrease HP 222 or equivalent. Recommended oil: Mobilfluid 316M, Mobil DTE 15M. Refer to lubricant dedicated booklet in section 1 of the maintenance manual.
SANDVIK MINING AND CONSTRUCTION LYON S.A.S. 19, av. De Lattre de Tassigny B.P. 46 - 69881 LYON cedex, FRANCE Tel: +33 (0)4 72 45 22 00 Fax: +33 (0)4 78 31 79 80
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ALL CYLINDERS
03-10-2003 EZ-JCB-FL
5) MAINTENANCE OPERATIONS CAUTION: the safety of users, the reliability of the Cylinder, and therefore the efficiency of operation, depend on the proper use of the machine, on its maintenance and the use of genuine TAMROCK SECOMA spare parts. All damaged parts must be replaced.
5/1) STARTING OR DAILY OPERATIONS • Before starting up: Grease the ball joints at the level of the taper pins. • After starting up: Check for oil leakage.
5/2) 50-HOUR OR WEEKLY OPERATIONS • Check the tubes and hydraulic connections.
5/3) 100-HOUR OR MONTHLY OPERATIONS • Carry out the 50-hour or weekly operations.
5/4) 200-HOUR OPERATIONS • Carry out the 100-hour or monthly operations.
5/5) 600-HOUR OPERATIONS • Carry out the 200-hour operations.
5/6) 1200-HOUR OR ANNUAL OPERATIONS • Carry out the 600-hour operations.
5/7) 3600-HOUR OPERATIONS General inspection or reconditioning. • Strip and reassemble the cylinders. • Replace damaged parts.
SANDVIK MINING AND CONSTRUCTION LYON S.A.S. 19, av. De Lattre de Tassigny B.P. 46 - 69881 LYON cedex, FRANCE Tel: +33 (0)4 72 45 22 00 Fax: +33 (0)4 78 31 79 80
03-10-2003 EZ-JCB-FL
ALL CYLINDERS
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6) DISASSEMBLY - REASSEMBLY 6/1) DISASSEMBLY The greatest cleanliness must be observed when disassembling and reassembling to avoid rapid deterioration of the seals and scratches on the moving parts. Use non fluffy cloths and products without solvent for cleaning. Always carry out disassembly and reassembly operations in properly equipped, dust free premises. Assembly products, recommended lubricants and the required tools must also be available. 6/1/1) DISASSEMBLING A CYLINDER Three major types of cylinder can be found out on the machine see page 8 . • Hold the body (1) firmly at the level of the ball joint (2) or fixing plate (2). • Unblock and unscrew the guide (3). • Extract the fitted rod assembly (4) from the body. • Hold the rod (4) firmly at the level of the ball joint (5) or the yoke (5). • Drive out the pin (6) or remove the screw (6). • Unscrew the piston (7) from the rod. • Remove the spacer ring (8) if fitted. • Remove the guide (3) from the rod (4). • Remove the grease nipples (9) if fitted. • Remove all the seals, rings and/or scrapers (*), noting their position and mounting direction.
SANDVIK MINING AND CONSTRUCTION LYON S.A.S. 19, av. De Lattre de Tassigny B.P. 46 - 69881 LYON cedex, FRANCE Tel: +33 (0)4 72 45 22 00 Fax: +33 (0)4 78 31 79 80
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ALL CYLINDERS
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Figure 2 6/1/2) disassembling a ball joint Liquid nitrogen-mounted ball joints: see page 9
SANDVIK MINING AND CONSTRUCTION LYON S.A.S. 19, av. De Lattre de Tassigny B.P. 46 - 69881 LYON cedex, FRANCE Tel: +33 (0)4 72 45 22 00 Fax: +33 (0)4 78 31 79 80
ALL CYLINDERS
03-10-2003 EZ-JCB-FL
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• Extract the ball joint (1) using a press. 1
Figure 3 Ball joint mounted with circlips: see page 9 • Extract the dust protector (1). • Remove the circlips (2). • Extract the ball joint (3) using a press.
1 2 3
Figure 4 Welded ball joint or yoke: see page 9 • Grind the welding (1) to the level of the cylinder body or the rod (2). • Remove the ball joint (3) or unscrew the yoke (4). • Smooth off the parts. 2 2
1
1
4
3
Figure 5
6/2) REASSEMBLY 6/2/1) reassembling a ball joint It is strongly recommended to use liquid nitrogen instead of a press for assembling a new ball joint. WARNING: Handling of nitrogen-cooled objects requires great caution and proper protection (gloves and safety glasses). Ball joints must be installed prior to reassemble the cylinder itself. Nitrogen-mounted ball joint: see page 10 • Cool the ball joint (1) with nitrogen. SANDVIK MINING AND CONSTRUCTION LYON S.A.S. 19, av. De Lattre de Tassigny B.P. 46 - 69881 LYON cedex, FRANCE Tel: +33 (0)4 72 45 22 00 Fax: +33 (0)4 78 31 79 80
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ALL CYLINDERS
03-10-2003 EZ-JCB-FL
• Remount the ball joint in its housing until it stops at the shoulder and allow the assembly to warm to ambient temperature.
Figure 6 Ball joint mounted with circlips: see page 10 • Remount a circlip (2) in its groove. • Cool the ball joint (3) with nitrogen. • Remount the ball joint in its housing until it stops at the circlip and allow the assembly to warm to ambient temperature. • Remount the other circlip. • Remount and crimp the protecting hoods (1). 1 2 3
Figure 7 Welded ball joint or yoke: see page 10 • Engage the centering pin (1) of the ball joint (2) or screw the yoke (3) to the rod (4). • Place a line of solder (5) round the ball joint or yoke. • Allow time for welding to cool down. 4 4
5
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Figure 8 6/2/2) reassembling of the cylinder CAUTION: All seals must be replaced when reassembling of the cylinder, use genuine Tamrock Secoma seal kits. Replace all damaged par ts. Lubricate the seals using hydraulic oil prior to reinstall. REASSEMBLE THE ROD FIRST: see page 12 • hold the rod (4) firmly at the level of the ball joint or the yoke (5). • Remount the notched nut guide (3) or ball joint side pin housing (5). • Install the spacer ring (8) if used. • Retighten the piston (7) on the rod to a maximum and check that the piston and rod holes are aligned (unscrew slightly to do this if necessary) for pin-equipped pistons. SANDVIK MINING AND CONSTRUCTION LYON S.A.S. 19, av. De Lattre de Tassigny B.P. 46 - 69881 LYON cedex, FRANCE Tel: +33 (0)4 72 45 22 00 Fax: +33 (0)4 78 31 79 80
03-10-2003 EZ-JCB-FL
ALL CYLINDERS
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• Re-insert the pin (6). • For pistons equipped with lock screws: tighten the piston (7) on the rod to a maximum, mount and tighten the screw (6). • On guide (3) and on cylinder (7): Reassemble all the seals (*), rings and/or scrapers, taking care of their respective positions and assembly direction. ASSEMBLING OF THE ROD INTO THE BODY • Hold the body (1) firmly at the level of the ball joint or fixing plate (2). • Insert the fitted rod, taking care not to damage the seals on insertion. • Retighten the guide (3) after coating the threads with "LOCTITE 270". • Mount the grease nipples (9) if fitted. FINAL TEST: • Place the cylinder on a hydraulic bench and connect up. • Bleed the cylinder. • Increase the pressure and check for tightness and correct operation.
SANDVIK MINING AND CONSTRUCTION LYON S.A.S. 19, av. De Lattre de Tassigny B.P. 46 - 69881 LYON cedex, FRANCE Tel: +33 (0)4 72 45 22 00 Fax: +33 (0)4 78 31 79 80
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ALL CYLINDERS
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Figure 9
SANDVIK MINING AND CONSTRUCTION LYON S.A.S. 19, av. De Lattre de Tassigny B.P. 46 - 69881 LYON cedex, FRANCE Tel: +33 (0)4 72 45 22 00 Fax: +33 (0)4 78 31 79 80
ALL CYLINDERS
03-10-2003 EZ-JCB-FL
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7) - PERIODIC MAINTENANCE TABLE - ALL CYLINDERS Machine serial number:
Percussion hours (PH):
Name:
Date:
Diesel hours (DH):
Signature:
o m
Check Adjust Clean
s l
Replace Lubricate PERIODS
Each 50 PH 200
600
1200 1800 2400 3600
shift
PH
PH
PH
PH
PH
DONE. ALL CYLINDERS
PH
o
o
o
o
o
Leakage detection
o
o
o
o
o
Check all equipments condition
o
o
o
o
o
Check hose, unions and fitting condition
l
l
l
l
l
l
l
l
Lubricate all joints
m
Overall inspection and tests Removal and check of all assembly Replace damaged parts
s l
SANDVIK MINING AND CONSTRUCTION LYON S.A.S. 19, av. De Lattre de Tassigny B.P. 46 - 69881 LYON cedex, FRANCE Tel: +33 (0)4 72 45 22 00 Fax: +33 (0)4 78 31 79 80
YES
NO
