012 495hr2 Hyd Serv Proc
Short Description
Descripción: HYD CROW...
Description
495 HR2 / HF2 SHOVELS HYDRAULIC CROWD SERVICE PROCEDURES
Hydraulic System Cleanliness
Cleanliness in the hydraulic crowd system is extremely important. Fluid cleanliness is of primary importance because contaminants can cause component malfunction, prevent proper valve seating, and cause wear in components.
The inside of a hydraulic system can only be kept as clean as the fluid added to it.
Initial fluid cleanliness can be achieved by observing stringent cleanliness
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requirements or by filtering all fluid added to the system. Maintaining hydraulic fluid within allowable contamination limits for both water and particulate matter is crucial to the care and protection of hydraulic equipment.
Filters provide adequate control of the particular contamination problem during all normal hydraulic system operations if the filtration system is installed properly and filter maintenance is performed properly.
Filter maintenance includes changing elements at proper intervals.
During installation, maintenance and repair, cleanliness is of paramount importance.
Hydraulic System Cleanliness
The following maintenance and servicing procedures should be adhered to at all times to provide proper contamination control:
1. All tools and the work area (workbenches and test equipment) should be kept in a clean, dirt-free condition. 2. A suitable container should always be provided to receive the hydraulic liquid during component removal or disassembly. NOTE: The reuse of drained hydraulic liquid is prohibited in most hydraulic systems. In some large-capacity systems the reuse of fluid is permitted. When liquid is drained from these systems for reuse, it must be stored in a clean and suitable container. The liquid must be filtered when it is returned to the system reservoir. 3. Before hydraulic lines or fittings are disconnected, the affected area should be cleaned with an approved dry-cleaning solvent.
4. All hydraulic lines and fittings should be capped or plugged immediately after disconnection. 5. Before any hydraulic components are assembled, their parts should be washed with an approved dry-cleaning solvent.
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Hydraulic System Cleanliness 6. After the parts have been cleaned in dry-cleaning solvent, they should be dried thoroughly with clean, lint-free cloths and lubricated with the recommended preservative or hydraulic liquid before assembly. 7. All hoses and tubes used in the hydraulic crowd system must be cleaned internally using hose cleaning projectiles. Hose cleaning kit is shipped with the machine. Refer to the manufacturer's documentation for instructions. 8. All packings, o-rings and gaskets should be replaced during the assembly
procedures. 9. All parts should be connected with care to avoid stripping metal slivers from threaded areas. 10. All hydraulic servicing equipment should be kept clean and in good operating condition.
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Hydraulic System Oil Contamination Guide
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When oil contaminants are found in the hydraulic circulation filter or the upper tank return filters, refer to the chart below to help determine the possible source or sources of the contamination.
Hydraulic System Oil Contamination Guide
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Crowd Machinery Overview
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The majority of the hydraulic crowd machinery is located in the front of the machine.
The system consists of a hydraulic cylinder assembly, power module, upper hydraulic tank, isolators, oil circulation pump, pump control manifold and oil cooler (not shown).
Hydraulic Crowd Cylinder Overview
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The hydraulic crowd cylinder is located inside the sleeve assembly which is assembled to the rear of the saddle block.
The hydraulic cylinder is equipped with a control manifold that straddles the cap end of the cylinder.
The cylinder measures approximately 34 ft. when retracted and approximately 54 ft. when extended.
Hydraulic Crowd Cylinder Overview
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The dry weight of the cylinder and manifold is approximately 21,000 lbs.
The cylinder itself is a non-serviceable component and should only be rebuilt by the manufacturer.
However, the cylinder has a "static" or spare rod seal.
The guide bushing can be rotated to extend the bushing life. Refer to SERVICE PROCEDURES section for the appropriate procedure.
Cylinder Control Manifold Overview
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The hydraulic crowd cylinder control manifold is assembled around the stationary rod end of the cylinder.
The primary manifold block straddles the cylinder. Inlet and outlet blocks are assembled at opposite sides of the manifold.
Several valve blocks control the flow of fluid to and from the hydraulic cylinder.
Access holes in the sleeve assembly allow periodic visual inspection of the cylinder control manifold and the attached hydraulic lines.
Access to any serviceable components is very limited.
Cylinder Control Manifold Overview
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Two quick-disconnect couplings are located on the top face of the manifold which can be used to extend or retract the hydraulic cylinder.
Serviceable components are limited to valve cartridges, control valves and replacement coils.
The manifold also has three test couplings to take pressure readings of various hydraulic circuits.
Cylinder Control Manifold Overview
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Cylinder Control Manifold Overview
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Auxiliary Power Unit Overview
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The auxiliary power unit is located inside the lube room.
The unit consists of a 120 gallon hydraulic reservoir, 20HP electric pump motor, pressure compensated piston pump, single stage manifold with pressure gauge and shutoff valve.
A separate control box contains the starter switch.
A control pendant with 50 feet of cord can be used for remote control of the power unit.
Continued…
Auxiliary Power Unit Overview
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Two hoses pass through the lube room bulkhead and extend up to the roof. These hoses are used to extend and retract the hydraulic cylinder during service procedures.
The hoses can also be connected to filter the oil to meet the minimum oil cleanliness specifications.
An oil level sight gauge is located on the reservoir wall.
Oil filtration is achieved through two filters located below the reservoir. The
pressure filter has a 10-micron element. The return filter has a 6-micron element and a gauge indicator is located at the base of the filter housing.
Replace filter as indicated. Oil samples can be taken from an oil line next to the lube room door (not shown).
The unit is equipped with a hydraulic contamination monitor with a display. The output switch (normally closed) will open when a level of ISO 18/16/14 is reached.
The cleanliness target level is ISO 16/14/12.
To fill the power unit reservoir, replace filter elements or draw oil samples from the auxiliary power unit, refer to AUXILIARY POWER UNIT FILL & FILTER REPLACEMENT.
Power Module/Lower Tank Overview The power module and lower hydraulic tank are located in the front of the machine on the revolving frame between the boom foot pin lugs. It consists of the following components:
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Lower hydraulic tank/crowd motor mounting platform,
Crowd motor,
Pump-drive transmission (PDT),
Main pumps,
Flushing/PDT lube motor,
Circulation filter,
Manifolds.
Lower Tank / Crowd Motor / Transmission and Pumps Overview
IMPORTANT! NEVER weld on hydraulic oil tank.
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The lower hydraulic tank also acts as the mounting base for the crowd motor and pump-driven transmission (PDT). The motor is air cooled with a crowd blower located on the motor's right side.
A grid coupling transmits power from the motor to the transmission which in turn drives the 4 main pumps. The crowd tachometer is mounted to the PDT and is driven by the input shaft.
Flushing/PDT Lube Motor Overview
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The Flushing/PDT Lube Motor is located on the right side of the power module.
Flushing/PDT Lube Motor Overview
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The flushing/PDT lube motor consists of a 5-HP electric motor, flex-drive coupling, vane pump and gear pump.
The gear pump circulates transmission oil through the cooler assembly.
The vane pump circulates hydraulic oil from the suction manifold to the flushing manifold then through the main pumps, for cooling.
Circulation Filter Overview
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The circulation filter and adjoining parts measure and clean the hydraulic oil passing through the filter.
Oil returning from the oil cooler travels up through the flow meter, then into the filter housing.
Oil flows through the element from outside to inside of the element.
The filtered oil then returns to the lower tank.
A check valve, located below the filter assembly, only allows filtered oil to travel into the tank.
Manifolds Overview The power module contains 3 manifold assemblies:
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Pump flushing manifold
Tank return header manifold
Oil circulation manifold
Oil Circulation Manifold Overview
The oil circulation manifold is located on the left side of the power module.
When hydraulic oil reaches operating temperature, the cooler control valve routes oil through the hydraulic cooler before returning it to the lower
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tank. The manifold is fitted with two relief valves, a directional control valve and three pressure test couplings. Serviceable components are limited to valve cartridges and control valves.
Pump Control Manifold Overview
The pump control manifold is located on the utility room wall and controls oil flow from each of the four main pumps.
The pump control manifold requires no routine service outside of periodic inspection of the
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attached hydraulic lines. Serviceable components are limited to valve cartridges, control valves and replacement coils. The manifold is equipped with several test couplings for diagnostic purposes.
Upper Hydraulic Tank Overview IMPORTANT! NEVER weld on hydraulic oil tank.
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The upper hydraulic tank is located inside the lube room.
An oil level sight gauge is located above the three immersion heaters.
Located underneath the tank is a 10 inch butterfly valve and transfer tube which passes through the wall of the lube room and connects to the lower hydraulic tank.
Also located underneath the tank is a ball valve and 3.00 inch hose which connects to the oil circulation pump located on the lube room floor.
Upper Hydraulic Tank Overview
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A 4.00 inch return line hose is also connected to the tank, routed through the upper wall of the lube room (above the power module) and connects to the pump control manifold mounted to the upper wall of the utility room.
Upper Hydraulic Tank Overview
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Oil Circulation Pump Overview
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The oil circulation pump is located on the house floor next to the lube room.
Driven by a 30-HP electric motor, the attached gear pump circulates hydraulic oil from the upper tank to the oil circulation manifold mounted on the left side of the power module.
The oil circulation pump requires no routine service outside of periodic inspection of the attached hydraulic lines.
Oil Circulation Pump Overview
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To remove and replace the oil circulation pump, refer to OIL CIRCULATION PUMP REMOVAL & REPLACEMENT in SERVICE PROCEDURES section.
For more information about proper coupling alignment, refer to CIRCULATION PUMP COUPLING ALIGNMENT in BRAKES AND COUPLINGS section.
Isolator Tank Overview
Six isolator tanks are clamped into to a welded support which is mounted to the lube room wall.
Each isolator contains an internal bladder that expands and contracts during cylinder operation.
The bladders can be inspected by looking through the inspection holes.
The isolator hoses all attach to the isolation manifold which is fitted with a vacuum breaker.
IMPORTANT! The isolator tanks are an essential component of the hydraulic crowd system. The internal bladders need to be routinely inspected for proper operation. Refer to ISOLATOR TANK INSPECTION in this manual.
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Isolator Tank Overview
Six isolator tanks are clamped into to a welded support which is mounted to the lube room wall.
Each isolator contains an internal bladder that expands and contracts during cylinder operation. The bladders can be inspected by looking through the inspection holes.
The isolator hoses all attach to the isolation manifold which is fitted with a vacuum breaker.
IMPORTANT! The isolator tanks are an essential component of the hydraulic crowd system. The internal bladders need to be routinely inspected for proper operation.
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Oil Cooler and Plumbing Overview
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The dual-core oil coolers are located below the right-hand side deck extension. The secondary (outboard) cores are used to cool gear oil from the pump drive transmission (PDT).
The primary (inboard) cores are used to cool hydraulic oil.
Hydraulic Crowd Sensor Locations
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The hydraulic crowd system has numerous sensors throughout the system components.
These sensors, transducers and switches provide essential data to operate and maintain the machine properly.
Cylinder Sensors
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Power Module Sensors
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Power Module Sensors
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Power Module Sensors
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Power Module Sensors
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Upper Hydraulic Tank Sensors
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Pump Control Manifold Sensor
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Auxiliary Power Unit Sensor
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INSPECTION
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PDT Leak Inspection
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Leak inspection for the pump driven transmission (PDT) involves visually inspecting the transmission housing and all the PDT gear oil circulation plumbing (hose and tubing) connecting the transmission with the hydraulic coolers.
Inspect the transmission housing and any oil supply line connected directly to the PDT housing.
Circulation Plumbing Inspection
The circulation plumbing includes several main components:
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Upper Hydraulic Tank
Oil Circulation Pump
Oil Circulation Manifold
In-line Hydraulic Coolers
Circulation Plumbing Inspection 1. Visually inspect the circulation plumbing (hoses, fittings, split flanges, etc.) and coolers for leaks. 2. Tighten, repair or replace components where necessary.
IMPORTANT! When replacing hoses, contamination of the hydraulic system is always possible. It is important to install caps/plugs immediately after opening the hydraulic system to prevent contamination. When replacing o-rings and flange mounted hoses, clean the fitting ends and mounting surfaces prior to installation. Clean all new hoses with air projectiles prior to installation.
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Circulation Plumbing Inspection
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When installing flange mounted hoses, refer to SPLIT FLANGE ASSEMBLY procedure in ENGINEERING DATA section for proper tightening sequence and torque specifications.
Oil Circulation Pump Inspection
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Inspect the inlet and output hose connections at the gear pump.
Inspect hoses; ensure any hose clamps are tight.
Repair or replace as needed. When replacing split flanges, refer to ENGINEERING DATA for proper assembly procedure and torque specification.
For more information on the flexible drive coupling and proper alignment procedures, refer to BRAKES AND COUPLINGS section.
Isolator Troubleshooting
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Isolator Tank Inspection
To verify correct operation of the isolators, they must be inspected while the crowd cylinder is cycled in and out.
Using a flashlight, look through the isolator inspection holes in the support.
Inspect each individual isolator to verify correct operation of the bladder. All six bladders should be expanding and contracting during cylinder operation.
If any of the isolation bladders does not move, inspect the isolator plumbing for leaks. If no leaks are found, refer to ISOLATOR REMOVAL AND REPLACEMENT.
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Isolator Manifold Inspection 1. Remove the drain plug from the isolator manifold. With an oil receptacle underneath, open the cock valve. 2. If any amount of oil is drained from the isolator manifold, inspect each individual isolator. Refer to ISOLATOR INSPECTION procedure. 3. Allow oil to thoroughly drain from isolator manifold, close cock valve and reinstall drain plug.
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Vacuum Breaker Inspection The vacuum breaker must be inspected while the cylinder is being cycled. 1. Place a plastic bag over the vacuum breaker and use a rubber band to create an air tight seal at the connection. Observe the plastic bag while the hydraulic cylinder is being cycled. 2. If the plastic bag expands or contracts, the system is not functioning properly. Refer to ISOLATOR MANIFOLD INSPECTION procedure.
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Isolator Plumbing Inspection
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The isolator plumbing must be air tight.
Visually inspect tubing, hoses and fittings for damage and leaks.
Tighten any loose hose clamps.
Replace damaged hoses.
Repair all leaks.
Service Procedures
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Hydraulic Crowd Start Up Procedure The following procedure applies to Start-Up of either new or rebuilt systems.
IMPORTANT!
Before performing this procedure, read through the entire procedure. DO NOT continue this procedure until you have read and fully understand the process.
NOTE: The system will not operate with a low oil level or with the hydraulic oil below 0° F (-18°C) at which time the system will require filling or enter the heating cycle respectively. 1. To ensure the validity of oil level measurements throughout the start-up procedure, make sure the machine is sitting on level ground. 2. Fill and filter the auxiliary power unit with hydraulic oil. Refer to AUXILIARY POWER UNIT FILL & FILTER REPLACEMENT procedure. 3. Fill and filter the main hydraulic system with oil (approximately 950 gallons). Refer to INITIAL SYSTEM OIL FILL procedure.
NOTE: Ensure lower tank vent lines (located at the corners of the tank) are routed with a constant rising gradient to eliminate potential trapped air bubbles. 4. Fill the pump drive transmission (PDT) with gear oil. Refer to PDT-INITIAL OIL FILL procedure.
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Hydraulic Crowd Start Up Procedure 5. Purge the main pumps. Refer to PURGING THE MAIN PUMPS procedure.
6. Top off the pump drive transmission (PDT) oil level. Refer to PDT-OIL TOP OFF procedure. 7. Flush and filter the main hydraulic circulation plumbing and oil cooler. Refer to STANDARD SYSTEM FLUSHING & FILTRATION procedure. 8. Thoroughly flush and filter the hydraulic oil in the boom plumbing. Refer to COMPLETE SYSTEM FLUSHING & FILTRATION procedure. 9. Check the oil level at the upper tank oil level sight gauge. Verify the hydraulic oil is within the correct operating range with handle fully extended. Refer to SYSTEM TOP OFF procedure. The hydraulic crowd system is now ready to operate.
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Standard System Flushing and Filtration
PURPOSE: The purpose of this procedure is to flush oil through the boom plumbing WITHOUT circulating potentially contaminated oil into the cylinder.
This procedure should be performed after any boom hoses or tubing have been replaced between the power module and the crowd cylinder.
NOTE: In the case of major component failure, refer to COMPLETE SYSTEM FLUSHING & FILTRATION in this section of the manual.
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To flush the boom plumbing, the hose flushing program is to be used.
Standard System Flushing and Filtration 1. On the operator's display, navigate to the HyrdaCrowd maintenance screen and press the “Flushing" button. Press the “On” button to activate the flushing process. HANDLE MOTION MAY OCCUR DURING THE HOSE FLUSHING PROCESS!
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Standard System Flushing and Filtration NOTE : If the warm-up mode is operating, the hose flushing program will not initiate. When the initial warm-up cycle is complete, hose flushing will begin. The amount of time remaining to complete the warm-up cycle is displayed on the warm-up screen. 2. Allow circulation loop to run and filter oil for 1 hour.
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Standard System Flushing and Filtration 3. Turn the crowd switch to the ON position. After 15 minutes check the contamination monitor (HOCM1), located on the power module. The cleanliness reading should be 16/14/12 or better. If not, turn the crowd switch OFF. Allow circulation loop to run until the desired reading is obtained.
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Standard System Flushing and Filtration
NOTE : If at anytime the low oil level warning appears, use the auxiliary power unit in the lube room to add oil to the system until the correct oil height is reached. Refer to SYSTEM TOP OFF procedure.
IMPORTANT! DO NOT use the crowd function until the oil has reached the proper cleanliness level. Using the crowd function under these conditions could contaminate the cylinder and cylinder control manifold causing cylinder malfunction, premature wear or failure!
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Complete System Flushing and Filtration
PURPOSE: The purpose of this procedure is to purge the hydraulic crowd cylinder of contaminants after major component failure or major system contamination.
IMPORTANT! The following steps 1-4 should be performed a minimum of 3 times, regardless of cleanliness reading obtained in step 4. Continue these steps until two consecutive oil sample readings are at 16/14/12 or better.
Purging a severely contaminated hydraulic system is time-consuming. BE PATIENT!
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Complete System Flushing and Filtration 1. Run the circulation pump for approximately 30 minutes. Turn the crowd control switch to the ON position. After 15 minutes check the contamination monitor located on the power module. If the reading is better than 16/14/12 turn the crowd control switch OFF and proceed to Step 2. Otherwise turn the crowd control switch to the OFF position and allow the circulation pump to run for another 30 minutes or until the desired reading is obtained.
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Complete System Flushing and Filtration
2. On the operator's display, navigate to the HyrdaCrowd maintenance screen and press the “Flushing" button. Press the “On” button to activate the flushing process. HANDLE MOTION MAY OCCUR DURING THE HOSE FLUSHING PROCESS!
NOTE : If the warm-up mode is operating, the hose flushing program will not initiate. When the initial warm-up cycle is complete, hose flushing will begin. The amount of time remaining to complete the warm-up cycle is displayed on the warm-up screen. 3. With the dipper handle horizontal and the dipper fully extended, retract the crowd at full speed up to the electrical stop limit. Lower the handle until vertical and extend the dipper at full speed downward until it is just above the ground. Hoist the dipper and extend at full speed up to the electrical stop limit. Repeat three times.
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Complete System Flushing and Filtration 4. After cycling the crowd in Step 3, wait 15 minutes. Check reading on the contamination monitor located on the power module. If the cleanliness level is above 16/14/12, repeat steps 1-3. If the reading is 16/14/12 or better and this is the second consecutive reading at this level after cycling the crowd, as in step 3, proceed to Step 5. 5. Clean or replace all four return filter elements. For detailed procedure, refer to UPPER TANK RETURN FILTER CLEANING & REPLACEMENT. 6. Replace the circulation filter element. Refer to CIRCULATION FILTER REPLACEMENT 7. Run the circulation pump for one hour to filter out any contaminants that may have entered the system during filter maintenance (Steps 5 & 6). The hydraulic crowd system is now ready to operate.
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Complete System Flushing and Filtration
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Initial System Oil Fill NOTE : Use only hydraulic oil recommended by Bucyrus International, Inc. The initial fill will require approximately 1,000 gallons of oil. 1. Ensure that all four isolation valves are OPEN. If the valve is in the open
position, the handle will run parallel to the hydraulic line or tube.
NOTE : Two of the four isolation valves (shown below) are located inside the lube room, below the auxiliary hydraulic tank. The remaining two isolation valves are located at the base of the power module (not shown).
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Initial System Oil Fill 2. Connect the oil supply line to the system prefill quick connect located in the lube room, below the upper hydraulic tank.
NOTE : An alternate prefill connection is located below the supplied quickconnection. Customer specific quick-connect fittings can be installed in this location. 3. Begin filling the system. Continually monitor the prefill filter indicator and replace filters if required. Monitor the oil level through the tank's sight gauge until it reaches the oil level label.
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Initial System Oil Fill 4. Continue filling the system until oil level reaches the top edge of the label. The additional oil above the normal operating level will account for empty hydraulic hose and cooler assembly.
NOTE : The hydraulic oil system may require additional oil during initial start-up. This can be done with oil from the auxiliary oil tank. Refer to SYSTEM TOP OFF procedure.
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System Top Off IMPORTANT! Measure oil level with cylinder handle fully extended and machine on level ground.
NOTE: Check the auxiliary power unit oil level prior to performing this procedure. If the reservoir is low, refill as instructed in AUXILIARY POWER UNIT FILL AND FILTER REPLACEMENT. To top off the hydraulic crowd oil level:
1. Locate the CYLINDER POSITION quick-connect coupling located on the lube room front wall bulkhead panel. Disconnect the coupling and reconnect to the system pre-fill coupling. 69
System Top Off 2. Using the hand-held pendant, activate the EXTEND function to raise the oil level in the upper tank. Fill until desired oil level is reached.
NOTE : Monitor the auxiliary power unit oil level to avoid completely emptying the reservoir. To refill the auxiliary power unit reservoir, refer to AUXILIARY POWER UNIT FILL AND FILTER REPLACEMENT procedure in this section of the manual. 3. When the desired oil level is reached, deactivate the EXTEND function. Return the quick connect coupling to the CYLINDER POSITION quick-connect coupling located on the lube room front wall bulkhead.
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System Oil Drain Partial
If the hydraulic system contains too much oil, small amounts of oil can be drained from the upper tank to achieve the proper oil level. See View A. Four drain cocks are located on the under side of the upper tank. A suitable container will be required to catch the drained hydraulic oil.
To drain off hydr aulic oil to the proper oi l level : 1. Locate one of the drain cocks on the under side of the upper tank. Place a suitable container on the floor of the lube room. 2. Replace the pipe plug with an end fitting with an attached hose. Use the hose to direct hydraulic oil into container.
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System Oil Drain Partial 3. Open the drain cock valve and monitor the hydraulic oil level (with the dipper handle fully extended) at the upper hydraulic tank sight glass. 4. Close the drain cock valve when the proper oil level is reached. 5. Remove the drain hose from the drain cock valve and re-install pipe plug. NOTE: Apply pipe joint compound to all NPT threads.
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System Oil Drain Complete
In the event that a complete system oil drain (approximately 1,000 gallons) is required, ensure that an adequate supply of storage containers (approximately 20 fifty-five gallon drums or equivalent) are readily available. The upper tank must be drained prior to draining the lower.
To c ompletely drain the s ys tem's hydraulic oil: 1. Locate the four drain ports in the upper hydraulic tank. Move oil storage containers into place. 2. Replace the pipe plug with a 1.0 inchNPT end fitting with an attached hose. Use the hose to direct hydraulic oil into the containers.
NOTE : The upper hydraulic tank has four internal chambers that must be drained individually. 73
System Oil Drain Complete 3. Drain all four chambers. Remove drain hose and close all drain valves.
NOTE : Apply pipe joint compound to all NPT threads. 4. Verify that all four isolation valves in the OPEN position (the handle
running parallel with the respective hydraulic line). 5. Locate the four drain ports in the lower hydraulic tank. Move oil storage containers into place. 6. Replace the pipe plug with a 1.0 inch-NPT end fitting with an attached hose. Use the hose to direct hydraulic oil into the containers.
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System Oil Drain Complete 7. Open the drain cock valve, allowing the hydraulic oil to drain into the containers. Repeat for all four tank chambers. 8. Locate the vent line T-fitting located on the left side of the power module. 9. Temporarily remove the vent hose before draining the lower hydraulic tank. This will allow for a complete system drain. 10. Remove the drain hose from each drain cock valve and re-install pipe plug.
NOTE: Apply pipe joint compound to all NPT threads.
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System Oil Drain Complete 11. Re-connect and tighten the vent line at the T-fitting located on the left side of the power module.
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Auxiliary Power Unit Fill and Filter Replacement
The auxiliary power unit has a capacity of approximately 120 gallons of hydraulic oil and should be filled with clean, new oil through the
auxiliary power unit fill line.
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The fill line is located next to the control box.
Incoming oil is routed for a single pass through the return filter before entering the reservoir.
Auxiliary Power Unit Fill and Filter Replacement
To fill the auxiliary power unit with oil and then to multi-pass (prefilter) the oil:
1. Connect oil source to the auxiliary reservoir fill line. Begin filling the reservoir. 2. Monitor the oil level at the reservoir's sight gauge. Fill the reservoir to capacity. 3. Connect the A & B hoses to gether using the quick-connect fittings. With the A & B hoses connected to each other, the pump will circulate oil through the hoses and filters and back to the unit's reservoir. Run the power unit by energizing the retract solenoid on the pendant. Allow the power unit to circulate and filter the oil. Check the contamination monitor (located on the auxiliary unit) until a reading of 16/14/12 is obtained.
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Auxiliary Power Unit Fill and Filter Replacement To replace the return filter: 1. Place a suitable container below the filter. Remove the element and dispose of properly.
2. Apply a small amount of clean oil to the new element seal and install. 3. Tighten to manufacturer's specifications. To replace the pressure filter: 1. Place a suitable container below the filter. Remove the pressure filter bowl. 2. Remove the element and dispose of properly. 3. Install new element onto filter and reinstall bowl.
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Auxiliary Power Unit Fill and Filter Replacement Oil samples can be drawn from a dedicated line routed along the lube room door. To draw oil samples: 1. Place a suitable container below the oil sampling line. Before taking any oil samples, drain approximately 1 quart (0.25 gallon) of stagnant oil into the container.
2. Take consecutive readings to verify oil cleanliness. NOTE: New oil cleanliness is 19/17/14. A reading of 16/14/12 is 8 times cleaner. Monitor both pressure and return filter element visual indicators, replace the filter elements as required.
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Auxiliary Power Unit Fill and Filter Replacement
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PDT - Initial Oil Fill To fill the pump drive transmission (PDT) follow the procedures below.
1. Remove any dirt or debris from the fill cap located on the top, right side of the transmission. 2. Remove the oil fill cap. 3. Using a clean funnel, pour clean gear oil into the transm ission. The transmission volume alone is 5.75 gallons.
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PDT - Initial Oil Fill NOTE: An additional 3.25 gallons of gear oil will be required to fill the transmission if the PDT cooler core, circulating pump and lines are empty. 4. Reinstall the fill cap. 5. Energize the Flushing/PDT Lube Motor by turning the Crow d Control Switch (CCS) to the ON position. Allow the motor to run for 3 minutes to ensure that the oil lines and cooler are filled. 6. De-energize the Flushing/Lube Motor. Allow the transmission oil to settle. 7. Check the oil level again and add (or drain) oil as needed to attain the proper oil level. To add oil, refer to PDT-OIL TOP OFF procedure . To drain oil, refer to PDT-OIL DRAIN procedure. NOTE: For recommended gearcase oil and change intervals, refer to LUBRICATION section.
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PDT Oil Top Off If gear oil needs to be added to the transmission, follow the procedure listed below. 1. Remove any dirt or debris from the fill cap located on the top, right side of the transmission. 2. Remove the oil fill cap. 3. Pour clean gear oil into the tra nsmission until the oil level on the dipstick reaches the FULL mark. 4. Reinstall the fill cap.
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PDT Oil Level Check
NOTE: The transmission oil level is to be checked with the Crowd Motor and the Flushing/PDT Lube Motor "OFF". The Crowd Control Switch (CCS) must be in the OFF position and the Flushing/PDT Lube Motor must be allowed to run until both the time delay and oil temperature requirements are satisfied and the Flushing/PDT Lube Motor stops. 85
PDT Oil Level Check 1. With the machine on level ground, remove the PDT dipstick from the transmission and wipe clean with a clean shop rag. Reinsert the dipstick into tube until it seats properly. 2. Remove the dipstick again and visually inspect the oil level. 3. The oil level should appear at the FULL mark on the dipstick. 4. Add (or drain) oil as needed to attain the proper oil level. To add oil, refer to PDT-OIL TOP OFF procedure. To drain oil, refer to PDT-OIL DRAIN procedure. 5. Reinsert the dipstick into tube until it seats properly.
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PDT Oil Drain To drain the transmission oil: 1. Assemble a drain hose and with a 0.50 inch NPT connector to route oil into a suitable container.
2. Position the container (10 gallon capacity) to catch the drained oil. Route the end of the drain hose into the container. 3. Remove the temperature sensor and immediately replace with the drain hose. Allow time for the housing to fully drain (approximately 5.75 gallons).
4. Remove drain hose. Wipe threads of sensor clean and replace in PDT housing. 87
Hydraulic Crowd Cooler Cleaning
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Dirt on oil cooler core, fan or motor can reduce cooling capacity.
Every 1000 hours, clean the unit's electric motor and fan blades with a wire brush or rag. Spray wash the cooler core.
Clean the cooler core as follows:
Hydraulic Crowd Cooler Cleaning 1. Using compressed air, blow away any dry dirt or debris before washing the core with a high- pressure hot water wash. NOTE:
When using a high-pressure spray wash, avoid using alkaline soap or caustic soda additives. Do not use spray washes that exceed 1200 psi. Never spray cooling fins from an angle! If access is limited, use an offset angled spray nozzle so you can spray directly into the core.
2. Start by spraying into the air exit side of the cooler. With the spray nozzle at least
6 inches away, spray straight into the fins from top to bottom. Concentrate on small areas and work slowly. Wash until the water exiting the opposite side is free of dirt and debris.
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Purging The Main Pumps IMPORTANT! The main pumps MUST be purged of air after many hydraulic service procedures or upon initial start-up. Failure to remove the air from the pumps before start-up will cause pump cavitation and premature pump failure.
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Purging The Main Pumps To purge the main pumps:
1. Open ALL four isolation valves. 2. SLOWLY loosen the test plug in the suction side test port, or install a quickconnect test hose onto the test coupling, to act as an air bleed. See View AA. Gravity feed from the upper hydraulic tank will expel air from the suction hose as it fills with hydraulic oil. Allow air to bleed out until oil has filled the entire suction line.
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Purging The Main Pumps 3. Repeat Step 2 for the remaining suction hoses. 4. Fill each of the main pumps w ith clean hydraulic oil by removing the flushing hose from the top port of each pump and filling with clean (prefiltered to 16/14/12 cleanliness specification) hydraulic oil. Reassemble flushing hoses and run the case flushing pump for five minutes.
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Hydraulic System Prefill Filter Replacement 1. Position a five gallon bucket under the oil filter. 2. Remove the filter and dispose of properly. 3. Allow any hydraulic oil to drain into the bucket. 4. Clean the mounting surface of the
filter base. a small clean oil to Apply the new filter'samount seal. of 5. Install and tighten the new filter. : There is no need to replace any hydraulic oil drained during filter replacement
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Upper Tank Return Filter Cleaning and Replacement
! When cleaning or replacing filter, contamination of the hydraulic system is always possible.
It is important to thoroughly clean the filter cover and surrounding area before disassembly to prevent contamination. For guidelines and specifications, refer to HYDRAULIC SYSTEM CLEANLINESS.
The return filters are located inside the upper hydraulic tank . Access to return filters is located on top of the machinery house, above the lube room. If
the filter elements appear to be clean, with no visible signs of contamination, do not remove the filter assembly. The risk of system contamination during filter removal if the element is clean is not warranted. Only remove one cover at a time for filter maintenance to minimize potential system contamination.
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The upper tank return filters have removable stainless steel mesh filter elements that can be cleaned and reused. If the filter element is physically damaged, it should be replaced.
Continued….
Upper Tank Return Filter Cleaning and Replacement
1. Clean the filter cover and surrounding area of the tank surface. 2. Remove the 12 screws securing the cover to the tank. The filters are spring loaded. 3. Remove the filter cover o-ring and clean the mating surface. Remove the top spring. 4. Lift the filter assembly from the tank. The diffuser can remain in place.
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Upper Tank Return Filter Cleaning and Replacement
5. 6. 7. 8.
Remove the lower nut & spring from the filter assembly. Remove the mesh filter element from cover/magnetic core. Clean the magnetic core assembly. Remove any steel particles. Clean any coarse dirt from the pressure side of the element with normal cleaning solvents and a smooth bristled brush (not a wire brush). This process can be done under a jet-stream, not a bath, to help prevent the removed particles from reaching the clean side of the element.
9. After cleaning, use compressed air to blow through the element fromuse theaclean side. The filter elements are filtered from inside to outside and must dirt pan as shown in the figure.
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Upper Tank Return Filter Cleaning and Replacement
10. Next dip the cleaned element in cleaning fluid to pick up any remaining dirt particles. Use compressed air to blow out the element as in step 2 above. 11. Repeat the above steps until all dirt particles have been removed from the filter element. NOTES:
Filter seals should be inspected and replaced as required during filter cleaning and maintenance.
Handle the mesh of the element carefully to avoid damage through improper handling.
12. Lower the cleaned (or replacement) filter assembly into the diffuser cavity. Make sure the integral o-ring seal seats properly. 13. Replace the top spring making sure it sits outside the guide located on top of the filter. 14. Replace the filter cover with a new o-ring to the tank surface. Ensure the filter spring is properly seated over the cover plate spring guide. Secure the filter cover to the tank base with existing screws and flat washers. Tighten the 12 screws per bolt tightening procedure.
15. Repeat steps 1-14 for three remaining filters. 97
Isolator Removal and Replacement To remove an isolator:
1.
Remove hose assembly. Install cap/plug immediately after cleaning to prevent contamination. Also cap off open fitting at the isolator manifold.
2. 3.
Remove the 4 screws securing the cushioned clamp to the isolator support. With a suitable lifting device, remove the isolator (approximately 60 lbs). : To remove an isolator behind another, the front isolator must be removed first.
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Isolator Removal and Replacement To replace an isolator:
1.
2.
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With a suitable lifting device, raise the isolator (with cushioned clamps) into position. Assemble the 4 screws securing the isolator to the support assembly. Remove caps/plug and connect hose assembly to fitting on isolator manifold.
Isolator Draining :
1. Remove the isolator. Refer to ISOLATOR REMOVAL AND REPLACEMENT procedure. 2. With a suitable lifting device, tip the isolator (approx. 60 lbs) upside down into an oil receptacle. Allow isolator to drain. 3. Shake the isolator to ensure all fluid is completely
drained. 4. Reinstall the isolator. Refer to ISOLATOR REMOVAL AND REPLACEMENT procedure.
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Circulation Filter Replacement 1. Place a suitable container (minimum 6 gallon capacity) under the drain plug. 2. Remove the drain plug and open (or remove) vent port allowing the hydraulic oil to drain into the container. 3. When the hydraulic oil has thoroughly drained, replace and tighten the drain plug. 4. Clean the top area around the filter cap. Loosen retaining hardware and remove cap. 5. Remove the used filter element and dispose of properly. Install new filter element being careful not to introduce any debris or contaminants into the filter housing. 6. Reinstall cap and tighten. If removed, reinstall the vent port on top of the canister and tighten. 7. Reset the clogged circulation filter fault on the maintenance screen. 8. Allow the circulation pump to run for at least 5 minutes prior to machine operation to purge air from system. 101
Boom Pressure Hose Removal and Installation
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It is recommended that pressure and/or return hoses are replaced in pairs.
Boom Pressure Hose Removal and Installation
To remove a boom pressure hose:
1. Place a suitable container (25 gallon capacity) on the right front outside walkway, below the pump control manifold located on the utility room wall. 2. Relieve any stored pressure from both pressure lines. Carefully remove the test coupling and install a drain hose to the pump control manifold as shown in View A. 3. At the saddle block-sleeve connection, loosen both vent ports on the conn ection plate shown in View B. This will allow hydraulic oil (approximately 21 gallons) to drain through the drain hose, into the container. 4. Remove the hose clamps securing the pressure hoses in place. 5. Remove the 4 - 0.75 inch socket head screws and belleville washers from each hose. Remove the flange halves and o-ring. 6. Remove each hose from the connection plate port. In their place, insert a hose cleaning projectile into the exposed port to temporarily block any contaminants from entering the hydraulic system.
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Boom Pressure Hose Removal and Installation
1. Strap both hoses together. Refer to the PRESSURE HOSE POSITIONING procedure. 2. Place the new hoses in the rough location and install one clamp on each hose. 3. Discard the cleaning projectile from the port in the connection plate. Shoot a clean projectile though the hose using the projectile gun supplied with the machine.
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Boom Pressure Hose Removal and Installation
4. 5. 6. 7.
Ensure the new hose is free of debris or any possible contaminants on the internal walls prior to assembly. Slide a washer onto each of the 0.75 inch socket head screws before applying retaining compound to the threads. Lubricate the new o-ring with light grease or oil and insert into groove. Position the hose end in place and loosely assemble by inserting the mounting screws through flange halves. Hand tighten the screws, ensuring a
proper seal. : Refer to the appropriate torque specified in SPLIT FLANGE ASSEMBLY procedure in ENGINEERING DATA section. 8. Repeat steps 4 & 5 for the remaining hose end. 9. Tighten both vent plugs at the connection plate. 10. Remove the drain hose from the pump control manifold (see View A) and replace with the test coupling. 11. Carefully follow the PRESSURE HOSE POSITIONING procedure. Ensure that the proper hose lengths exist between the hose clamps before proceeding. Damage will occur during operation if proper lengths between the hose clamps is not maintained.
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Boom Pressure Hose Removal and Installation
12. On the operator's display, navigate to the HyrdaCrowd maintenance screen and press the “Flushing" button. Press the “On” button to activate the flushing process. HANDLE MOTION MAY OCCUR DURING THE HOSE FLUSHING PROCESS! For more information, refer to STANDARD SYSTEM FLUSHING & FILTRATION. NOTE: If the hydraulic system is in the process of warming up, hose flushing will not begin until the warm-up cycle is complete. 13. Ensure that the main system hydraulic oil as required. Refer to SYSTEM TOP OFF
procedure in this section of the manual.
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Boom Pressure Hose Removal and Installation
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Pressure Hose Positioning
IMPORTANT! Maintain proper hose and cable lengths specified below. Damage will occur during operation if proper lengths between hose clamps is not maintained.
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The two pressure hoses are located on the right side of the saddle block.
To allow the dipper handle its full range of movement without damaging the pressure hoses or the transition cable, both the pressure hoses and the transition cable must be secured as shown.
Pressure Hose Positioning
1. Ensure there is 74 inches of unrestricted boom/cylinder transition cable between the clamp located adjacent to the saddle block pivot and the clamp located parallel to the elbow block on the boom. 2. From the hose clamps mounted to the saddle block, ensure that no straps are installed more that 60 inches from the hose clamps as shown. 3. From the hose clamps mounted at the boom hose guard, ensure that the next strap is located at a length of 55 inches. No other straps should be installed.
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Boom Return Hose Removal and Installation It is recommended that pressure and/or return hoses are replaced in pairs. To remove a boom return hose: 1. At the saddle block-sleeve connection, connect a drain hose to the test coupling to relieve the stored pressure (approximately 30 psi). Pressure return lines. is relieved from both 2. Remove the hose clamps securing the return hoses in place.
3. Remove the four 0.63 inch socket head screws and Belleville washers from each hose. Remove the flange halves and o-ring.
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Boom Return Hose Removal and Installation 4. Remove each hose from the connection plate port. In their place, insert a hose cleaning projectile into the exposed port to temporarily block any contaminants from entering the hydraulic system. To install a boom return hose : 1. Strap both hoses together. Refer to the RE TURN HOSE POSITIONING procedure in this section of the manual. 2. Place the new hoses in the rough location and install one clamp on each hose.
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Boom Return Hose Removal and Installation 4. Remove each hose from the connection plate port. In their place, insert a hose cleaning projectile into the exposed port to temporarily block any contaminants from entering the hydraulic system. To install a boom return hose : 1. Strap both hoses together. Refer to the RE TURN HOSE POSITIONING procedure in this section of the manual. 2. Place the new hoses in the rough location and install one clamp on each hose. 3. Discard the cleaning projectile from the port in the connection plate. Shoot a clean projectile though the hose using the projectile gun supplied with the machine.
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Boom Return Hose Removal and Installation 4. Ensure the new hose is free of debris or any possible contaminants on the internal walls prior to assembly. 5. Slide a washer onto each of the 0.63 inch socket head screws before applying retaining compound to the threads. 6. Lubricate the new o-ring with light grease or oil and insert into groove. 7. Position the hose end in place and loosely assemble by inserting the mounting screws through flange halves. Hand tighten the screws, ensuring a proper seal. NOTE:
Refer to the appropriate torque specified in SPLIT FLANGE ASSEMBLY procedure in ENGINEERING DATA section.
8. Repeat steps 4 & 5 for the remaining hose end. 9. Tighten both vent plugs at the connection plate.
10. Carefully follow the RETURN HOSE POSITIONING procedure in this section of the manual. Ensure that the proper hose lengths exist between the hose clamps before proceeding. Damage will occur during operation if proper lengths between the hose clamps is not maintained.
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Boom Return Hose Removal and Installation 11. On the operator's display, navigate to the HyrdaCrowd maintenance screen and press the “Flushing" button. Press the “On” button to activate the flushing process. HANDLE MOTION MAY OCCUR DURING THE HOSE FLUSHING PROCESS! For more information, refer to STANDARD SYSTEM FLUSHING & FILTRATION.
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NOTE: If the hydraulic system is in the process of warming up, hose flushing will not begin until the warm-up cycle is complete.
Return Hose Positioning
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IMPORTANT! Maintain proper hose and cable lengths specified below. Damage will occur during operation if proper lengths between hose clamps is not maintained.
The two return hoses are located on the left side of the saddle block.
To allow the dipper handle its full range of movement without damaging hoses, both the return hoses and the vent hose must be secured as shown.
Return Hose Positioning 1. Ensure there is 74 inches of unrestricted vent hose between the clamp located adjacent to the saddle block pivot and the clamp located parallel to the elbow block on the boom. 2. From the hose clamps mounted to the saddle block, ensure that no straps are installed more that 60 inches from the hose clamps as shown. 3. From the hose clamps mounted at the boom hose guard, ensure that the next strap is located at a length of 55 inches. No other straps should be installed.
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Main Pump Pressure Hose Removal and Installation
NOTE: The four pressure hoses vary in length. Mark hoses if necessary to ensure correct installation. To remove pressure hose (s): 1. CLOSE the isolation valve located below the suction manifold. 2. Place a suitable container below the four main pumps. 3. Remove the 4 - M16 hex screws, belleville washers and 2 flange halves from the main pump as shown. Let the hose drain any hydraulic oil into the container.
4. Remove the o-ring. 5. Remove the 4 - 0.63 inch hex screws, belleville washers and 2 flange halves from the pump control manifold as shown.
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Main Pump Pressure Hose Removal and Installation
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Main Pump Pressure Hose Removal and Installation
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Main Pump Pressure Hose Removal and Installation
6. Remove the hose and o-ring.
7. Clean hose mounting surface before assembly. Seal off exposed ports to prevent contamination if hose will not be replaced immediately after removal. 8. Repeat steps 3 - 7 for remaining hoses. 9. Dispose of drained oil properly. Do not reuse unfiltered
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Main Pump Pressure Hose Removal and Installation To install pressure hose : 1. Ensure hose mounting surfaces are clean prior to installation.
2. Ensure new hose is free of debris or any possible contaminants on the internal walls prior to assembly. Use hose cleaning projectiles to clean the hoses internally. Use the hose cleaning equipment and supplies supplied with the machine. For instruction, refer to equipment manufacturer's documentation. 3. Slide a washer onto each of the flange mounting screws before applying retaining compound to the threads. 4. Lubricate the new o-ring with light grease or oil and insert into groove.
5. Starting at the pump control manifold, position the new hose end in place and loosely assemble by inserting screws through flange halves. Hand tighten screws ensuring a proper o-ring seal. Do not tighten screws. 121
Main Pump Pressure Hose Removal and Installation
6. Repeat steps for pump end of the hose.
7. Secure flange halves by tightening screws in a diagonal sequence in three incremental steps. Refer to the appropriate torque specified in SPLIT FLANGE ASSEMBLY procedure in ENGINEERING DATA section. 8. Repeat steps for remaining flange assemblies. 9. OPEN the isolation valve located below the suction manifold. IMPORTANT! If any other hoses were removed from the main pumps, the pumps MUST be purged of air BEFORE flushing the system! To purge the main pumps of air, refer to PURGING THE MAIN PUMPS. 10. On the operator's display, navigate to the HyrdaCrowd maintenance screen and press the “Flushing" button. Press the “On” button to activate the flushing process. HANDLE MOTION MAY OCCUR DURING THE HOSE FLUSHING PROCESS! For more information, refer to STANDARD SYSTEM FLUSHING & FILTRATION. NOTE: If the hydraulic system is in the process of warming up, hose flushing will not begin until the warm-up cycle is complete. 11. Verify main system hydraulic oil level. Refer to SYSTEM TOP OFF procedure if oil level is low when measured with the cylinder handle fully extended. 122
Main Pump Pressure Hose Removal and Installation
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Hydraulic Crowd Service Schedule
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Hydraulic Crowd Service Schedule
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