5080 SUPPLEMENT FOR HYDRAULIC EXCAVATORS Transportation Information Caterpillar

Shipping Dimension

Ultra High Demolition Configuration

Due to the big size of the front parts, it is not possible to ship the machine with front parts (Boom-Foot, Boom-Nose, Fore-Boom, Stick and Linkage) completely assembled on the machine.

The base machine must be on a separate trailer. Boom-Nose and Fore-Boom can be shipped assembled. Stick and Linkage can be shipped assembled. Refer to Operation and Maintenance Manual, "Operation Section / Transportation Information - Machine Loading on a trailer".

Shipping dimension of the Base Machine:

The Base Machine includes the following components:

5080 basic machine,

14 tons counterweight,

Demolition Cab,

Falling Object Guard,

375 L undercarriage,

Hydraulic Adjustable Track Frame (if equipped),

Boom-Foot

Illustration 61

Table 13

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¹This configuration includes: 5080 basic machine, 14 tons counterweight, Demolition Cab, Falling Object Guard, 375 L undercarriage, Boom-Foot, Boom Cylinders and 7500 mm Track Shoes.

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²With the Tiltable Cab.

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³ With the 375L undercarriage in shipping position.

Shipping dimension of the Boom-Nose and Fore-Boom assembled (3m Fore Boom):

This configuration includes: Boom-Nose, Fore-Boom (3m), Fore-Boom Cylinder, transportation supports and hydraulic lines.

Illustration 62

Table 14

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¹This configuration includes: Boom-Nose, Fore-Boom (3m), Fore-Boom Cylinder, transportation supports and hydraulic lines.

Shipping dimension of the Boom-Nose and Fore-Boom assembled (7m Fore Boom):

This configuration includes: Boom-Nose, Fore-Boom (7m), Fore-Boom Cylinder, transportation supports and hydraulic lines.

Illustration 63

Table 15

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¹This configuration includes: Boom-Nose, Fore-Boom (7m), Fore-Boom Cylinder, transportation supports and hydraulic lines.

Shipping dimension of the Stick, Stick Cylinder, Linkage and Linkage Cylinder assembled:

These configuration includes: Stick, Stick Cylinder, Linkage, Linkage Cylinder and the hydraulic lines without tool.

Illustration 64

Table 16

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¹ This configuration includes: Stick, Stick Cylinder, Linkage, Linkage Cylinder and the hydraulic lines without tool.

Machine Loading onto a Trailer

Ultra High Demolition Configuration (If Equipped)

Due to the big size of the front parts, it is not possible to ship the machine with front parts (Boom-Foot, Boom-Nose, Fore-Boom, Stick and Linkage) completely assembled on the machine.

The base machine must be on a separate trailer. Boom-Nose and Fore-Boom can be shipped assembled. Stick and Linkage can be shipped assembled.

The Boom-Nose and the Stick can be shipped on the same trailer.

Refer to Operation and Maintenance Manual, "Operation Section / Transportation Information - Disassembly/Assembly Front Parts".

Illustration 65

(A) Base Machine;

(B) Boom-Foot;

(C) Boom-Nose;

(D) Fore-Boom;

(E) Stick and Linkage.

Once the Front Parts are completely installed on the first trailer, disconnect the base machine and the boom-foot from the rest of the front parts by removing the two Expandable Pins. Refer to Operation and Maintenance Manual, "Operation Section / Transportation Information - Disassembly/Assembly Front Parts".

For the shipping of the base machine (with the boom-foot) on a second trailer, refer to the standard Operation and Maintenance Manual, "Operation Section / Transportation Information - Machine Loading onto a Trailer" for the basic transportation instructions. Follow the procedure when using the loading plates.

Machine Lifting - Tiedown Information

Ultra High Demolition Configuration (If Equipped)

Refer to the standard Operation Maintenance Manual for the basic instructions of lifting segments and to the Assembly/Disassembly section of this Operation and Maintenance Manual.

Illustration 66

1. It is not allowed to lift the base machine with all Fronts Parts assembled.

Illustration 67

2. It is not allowed to lift the all Fronts Parts assembled (Boom-Nose, Fore-Boom and Stick).

Illustration 68
Lifting cables length: A = 4800 mm and B = 4600 mm

3. Boom-Nose, Fore-Boom, Fore-Boom Cylinder and transportation support can be lift together.

Use the 4 special lifting eyes located on the top plate of the boom-nose and identified with the lifting decal. Do not use any other lifting points.

Use the adequate lifting cable length

Illustration 69
Lifting cables length: A = 5200 mm and B = 5700 mm

4. Stick, Stick cylinder, Linkage and Linkage Cylinder and transportation support can be lift together.

Use the 2 special lifting eyes located on the bottom plate of the stick and 2 on the side plate. All of the lifting eyes are identified with the lifting decal. Do not use any other lifting points.

Use the adequate lifting cable length

The separate segments (Boom-Foot, Boom-Nose, Fore-Boom and Stick) can be lifted separately.

Illustration 70

4. To lift the boom-foot, use the indicated lifting points as shown in Illustration 70. Use the lifting points (A) located on one side of the boom and use a pin (B) thru the bore for the other side of the boom.

Table 16

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¹These dimensions include the boom-foot and the hydraulic lines.

Illustration 71

5. To lift the boom-nose, use the indicated lifting points (A) as shown in illustration 71.

NOTE: The short Boom Nose doesn't own lifting points.

Table 17

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¹These dimensions include the short Boom-Nose (11m) and the hydraulic lines.

Table 18

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¹These dimensions include the long boom-nose (13m) and the hydraulic lines.

Illustration 72

6. Lift Cylinder - Fasten two proper rated wire rope cable to the cylinder and secure the piston rod to the cylinder tube.

Table 19

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¹These weights include: cylinder and hydraulic lines.

Illustration 73

7. To lift the fore-boom, use the indicated lifting points (A) as shown in illustration 73.

Table 20

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¹These dimensions include the Fore-boom (3m) and the hydraulic lines.

Illustration 74

Table 21

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¹ These dimensions include the Fore-boom (7 m) and the hydraulic lines.

Illustration 75

8. To lift the stick, use the indicated lifting points (A) as shown in illustration 75.

Table 22

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¹These dimensions include the stick and the hydraulic lines.

Displacement of the Machine

Ultra High Demolition Configuration (If Equipped)

Illustration 76

(A) Angle of the Boom;

(B) Link;

(C) Ground clearance.

Maintain the angle of the boom (A) within 45 degrees of the ground or raise the front parts and the tool enough in order to provide sufficient ground clearance (C).

During the displacement of the machine, do not connect a link (B) between boom and stick.

Move the implements control levers in order to correct the drift of the front parts.

Guard on the Linkage cylinder (If Equipped)

Illustration 77

(1) Channel;

(2) Bolts and Nuts;

(A) Stick Nose;

(B) Power Link.

If the machine is equipped with guard on the linkage cylinder and without tool installed at the stick nose, a channel (1) must be installed between the stick nose (A) and the power link (B) to avoid to damage the guard.

Disassembly / Assembly Front Parts

Ultra High Demolition Configuration (If Equipped)

This procedure will explain how to ship the machine.

As explained previously, it is not practically feasible to ship the machine with the front parts installed.

It is necessary to use two trailers for the transportation of the machine and its front parts.

The first trailer will include the base machine with boom-foot and boom cylinders installed.

The second trailer will include the boom-nose, the fore-boom and the stick. The second trailer must have a flat surface where the transportations stands are located.

The following illustrations show the location of the stand on the trailer and the way of fastening the front parts for the transportation.

It is needed to locate prior these transportation stands as accurately as possible.

A second mechanic will be useful to guide the machine movements.

NOTE: For the transportation, the tool must be removed.

Illustration 78

(1) Stick and Linkage;

(2) Stick Cylinder;

(3) Stand 1;

(4) Stand 2;

(5) Boom-Nose (long);

(6) Fore-Boom (3m);

(7) Fore-Boom Cylinder;

(8) Stand 3

(9) Stand 4.

Table 23

The support (3) and the support (8) must be bolted together.

The stand (4) and the stand (9) must be also bolted together.

The transportation stand of the boom must be installed on the trailer.

The stand of the stick must be located on a flat ground level.

Illustration 79

(1) Stick

(2) Stick Cylinder;

(3) Stand 1;

(4) Stand 2;

(5) Boom-Nose (long);

(6) Fore-Boom (7 m);

(8) Stand 3;

(9) Stand 4.

Table 24

The support (3) and the support (8) must be bolted together.

The stand (4) and the stand (9) must be also bolted together.

The transportation stand of the boom must be installed on the trailer.

The stand of the stick must be located on a flat ground level.

Illustration 80

(1) Fore-Boom (7 m);

(2) Fore-Boom Stand;

(3) Boom Nose (short);

(4) Boom Nose Stand (rear);

(5) Boom Nose Stand (front)

Table 25

Disassembly Front Parts

36 m UHD Configuration

Illustration 81

(3) Front Stand;

(4) Rear stand.

1. Install the front (3) and rear (4) transportation stand of the stick located on the ground level, distant of ... 11150 mm (F). Do not install them on the trailer.

Illustration 82

(A) Stick Nose;

(B) Power Link;

(1) Pin

2. Disconnect and remove the tool of the stick nose (A) and tie the power link (B) to the stick nose.

Illustration 83

(A) Stick Nose;

(1) Pin;

(3) Support;

(10) Block;

(11) Bolts and washers

3. Insert the Pin (1) into the stick nose (A).

4. Place the machine in front of the stand. Put down the stick nose on the front support (3).

5. Install 2 blocks (10) on each side of the stick nose and tighten the 8 bolts and washers (11).

6. Slowly lower the boom to position the stick on the rear stand (4).

Illustration 84

(4) Rear stand transportation;

(5) Support on the stick;

(6) Pin;

(7) Lock pin.

7. Align the hole of the support on the stick (5) and the holes of the rear stand transportation (4). When the holes are aligned, introduce a pin (6) in the holes. Block the pin (6) with a lock pin (7). Repeat the same operation for the other side of the stick.

8. Stop the engine and move the implements control levers to release the pressure.

Illustration 85

(A) Stick;

(C) Fore-Boom;

(D) Boom-Nose;

(E) Stick Cylinder;

(F) Ball Valve;

(G) Tie;

(H)

Quick-Connector.

9. Tie the Stick Cylinder (E) to the Boom-Nose (D). Close the 3 Ball-Valves (F) located on the sides of the Fore-Boom (C) (2 valves are located on one side and 1 is located to the other side) and disconnect the Quick-Connector (H).

10. Remove bolts, clamps and hydraulic hoses of each Ball-Valve. Disconnect the grease lines. Plug the hydraulic hoses.

Illustration 86

(1) Bolt;

(2) Pin;

(A) Stick;

(C) Fore-Boom;

(E) Stick Cylinder;

(G) Tie;

(I) Piece of wood.

11. Install a piece of wood (I) between the Stick cylinder (E) and the Stick (A). Remove the bolt (1) and the pin (2). Slowly lower the Stick Cylinder (E) to the Stick (A) by removing the Tie (G). Tie the Stick Cylinder on the Stick.

Illustration 87

(A) Stick;

(C) Fore-Boom;

(F) Ball-Valve;

(H) Quick Connector.

12. Close the 4 Ball-Valves (F) located on the Fore-Boom (C). Remove the bolts, clamps and hydraulic hoses of the ball-valves. Plug the hydraulic hoses. Disconnect the Quick-Connector (H) located on the Fore-Boom (C). Disconnect the grease lines and the electrical wiring.

Illustration 88

(A) Stick;

(C) Fore-Boom;

(1) Bolt and Washer;

(2) Pin;

(3) Spacer.

13. Remove the Bolt (1), the Pin (2) and the Spacer (3) located between the stick (A) and the fore-boom (C).

14. Start the engine running. Boom up. Drive the machine backwards.

15. Lift the Stick and the transportation stand by using the 4 lifting eyes located on the Stick. Refer to the Operation and Maintenance Manual, "Operation Section / Transportation Information - Machine lifting".

16. Install the stick and support on the trailer.

Illustration 89

(A) Stick;

(1) Bolts, Washers and Nuts;

(3) Front Stick Transportation Stand;

(4) Rear Stick Transportation Stand;

(8) Front Boom Transportation Stand;

(9) Rear Boom Transportation Stand.

17. Tighten the front stick transportation stand (3) to the front boom transportation stand (8) with bolts, washers and nuts (1). Repeat the operation for the rear transportation stand (stick and boom).

NOTE: The Boom transportation stands are already installed on the trailer.

Illustration 90

(8)

Front Boom Transportation Stand;

(9) Rear Boom Transportation Stand;

(10) Trailer;

(J) Fore-Boom Cylinder;

(K) Front Parts.

18. Place the machine in front of Boom Transportation Stand located on the trailer (10). Slowly extend to the maximum the Fore-Boom Cylinder (J) and lower the Front Parts (K).

Illustration 91

(8) Front Boom Transportation Stand;

(9) Rear Boom Transportation Stand;

(C) Fore-Boom;

(D) Boom-Nose;

(L) Boom-Foot;

(M) Bracket of the Boom-Nose.

19. Place the Boom-Nose (D) on the Front Boom Transportation Stand (8) and on the Rear Boom Transportation Stand (9). Align the holes of the bracket of the Boom-Nose (M) with the holes of the Front Stand (8) Lower the Fore-Boom onto the stand.

Illustration 92

(8) Front Boom Transportation Stand;

(M) Bracket of the Boom-Nose;

(N) Pin;

(O) Lock-Pin.

20. When the holes are aligned, introduce a Pin (N) in the Front Boom Transportation Stand (8) and in the Bracket of the Boom-Nose (M) located on both side of the Boom-Nose. Lock Pins (N) with a Lock-pin (O).

Illustration 93

(9) Rear Boom Transportation Stand;

(D)

Boom-Nose;

(M) Bracket of the Boom-Nose;

(P) Block;

(Q) Bolts and Washers.

21. Block the other extremity of the Boom-Nose (D) on the Rear Boom Transportation Stand (9). Place the Bracket of the Boom-Nose (M) on the Rear Boom Transportation Stand (9). Tie the Bracket (M) on the Stand (9) with the Block (P), Bolts and Washers (Q) on both sides of the Boom-Nose.

Illustration 94

(9) Rear Boom Transportation Stand;

(C) Fore-Boom;

(D) Boom-Nose;

(P) Block;

(Q)

Bolts and Washers;

(R) Pin.

22. Introduce a Pin (R) into the Fore-Boom (C). Slowly lower the Fore-Boom (C) and place the Pin (R) on the Rear Boom Transportation Stand (9). Tie the Pin (R) on the Stand (9) with Block (P), Bolts and Washers (R) on both sides of the Fore-Boom.

23. Stop the engine and move the implement control levers to release the pressure.

Illustration 95

(D) Boom-Nose;

(F) Ball-Valve;

(H) Quick Connector;

(S) Boom-Foot.

24. Close the 9 Ball-Valves (F) located on the Boom-Foot (S) and the 8 Ball-Valves on the Boom-Nose (D). Remove bolts, clamps and hydraulic hoses of the Ball-Valves located on the Boom-Foot. Plug the hydraulic hoses. Disconnect the Quick-Connector (H) located on the Boom-Foot (S). Disconnect the grease lines and the electrical wiring.

Illustration 96

(D) Boom-Nose;

(S) Boom-Foot;

(T) Expandable Pin.

25. Remove the two Expandable Pins (T). Refer to Operation and Maintenance Manual, "Operation Section / Transportation Information - Disassembly and Assembly Expandable Pins".

26. Start the engine and drive the machine backwards.

27. Place the machine on the second trailer. Refer to Standard Operation and Maintenance Manual, "Operation Section / Transportation Information - Machine Loading onto a Trailer".

3 m Fore-Boom Storage.

Illustration 97

(1) Storage Stand;

(A) Cross bar;

(B) Lock pins.

1. Install the Storage stand (1) on a flat ground. Lock the Cross bar (A) in transverse position with the lock pins (B).

Illustration 98

(1) Storage Stand;

(C) Boom-Nose;

(D) Fore-Boom cylinder.

2. Place the machine in front of the Storage stand (1). Slowly extend to the maximum the Fore-Boom cylinder (D) and lower the front parts (C).

Illustration 99

(1) Storage stand;

(2) 3m Fore-Boom;

(E) Pin

3. Place the Fore-Boom (2) on its Storage stand (1). Align the holes of the Fore-Boom (2) with the holes of the stand (1). Introduce a pin (E) into the Fore-Boom (2).

4. Stop the engine and move the implement control levers to release the pressure.

Illustration 100

(2) 3m Fore-boom;

(C) Boom-Nose;

(F) Pin;

(G) Ball Valves;

(H) Quick connectors.

5. Close the 7 Ball-Valves (G) located on the Boom-Nose (C). Disconnect the quick-connectors (H) located on the Fore-Boom (2). Remove bolts, clamps and hydraulic hoses. Disconnect the grease lines and the electrical wiring. Remove the Fore-Boom pin (F).

6. Remove the Fore-Boom cylinder.

7. Start the engine and drive the machine backwards.

Illustration 101

(1) Storage Stand;

(I) Fore-boom bore.

8. The 3m Fore-Boom can be stocked in the position shown on the illustration 101. In order to stock the Fore-Boom in the horizontal position follow the procedure described below.

9. Use the Fore-Boom bore (I) to take it off slightly from the cross bar. Use an appropriate lifting device in order not to make the bearing worse.

Illustration 102

(1) Storage Stand;

(A) cross bar;

(B) Lock pin.

10. Remove the lock pin (B). Rotate the cross bar (A) round the second pin axis.

11. Lower the Fore-Boom into its storage stand.

Illustration 103

(1) Storage Stand;

(A) Cross Bar;

(B) Lock pin.

12. Put the removed lock pin (B) in the hole of the cross-bar (A).

7 m Fore-Boom Disassembled.

Illustration 104

(1) Fore-Boom Stand;

(A) Storage position;

(B) Transportation position;

(C) Stop Pin;

(D) Central Tube.

1. Install the Fore-Boom stand on a flat ground in its storage position by sliding the central tube (D) from its transportation position (B) to its storage position (A). Lock the central lube (D) by using the stop pin (C).

2. Disconnect and remove the tool of the Fore-Boom.

3. Remove the tool cylinder.

Illustration 105

(1) Fore-Boom Stand;

(E) Boom-Nose;

(F) Fore-Boom cylinder.

4. Place the machine in front of the Fore-Boom stand. Slowly extend to the maximum the Fore-Boom cylinder (F) and lower the front parts (E).

Illustration 106

(1) Fore-Boom Stand;

(H) Fore-Boom Bracket;

(I) Pin.

5. Place the Fore-Boom on its support. Align the holes of the bracket of the Fore-Boom (H) with the holes of the stand (1). Introduce a pin (I) into the Fore-Boom.

6. Stop the engine and move the implement control levers to release the pressure.

Illustration 107

(E) Boom-Nose;

(J) Quick Connectors;

(K) Pin;

(L) Ball Valves;

(M) Fore-Boom.

7. Close the 7 Ball-Valves (L) located on the Boom-Nose (E). Disconnect the quick-connectors (J) located on the Fore-Boom (M). Remove bolts, clamps and hydraulic hoses. Plug the hydraulic hoses. Disconnect the grease lines and the electrical wiring. Remove the Fore-Boom pin (K).

8. Remove the Fore-Boom cylinder.

9. Start the engine and drive the machine backwards.

Illustration 108

(E) Boom-nose;

(2) Boom-Nose Stand (front);

(3) Boom Nose Stand (rear).

10. Place the machine in front of the Boom-Nose transportation stands located on the trailer. Lower the front parts (E).

Illustration 109

(E) Boom-Nose;

(2) Boom-Nose Stand (front);

(3) Boom-Nose Stand (rear)

11. Place the Boom-Nose on the Boom-Nose transportation stands. Follow the same procedure described in "Disassembly Front Parts 36 m UHD Configuration", steps 19 to 21, 23 to 27.

Illustration 110

(C) Stop pin; (I); - Pin; Cables length : P = Q - 40 cm.

12. Remove the pin (I). Lift the fore-Boom by using the lifting points (N).

Illustration 111

(1) Fore-Boom Stand;

(2) Storage position;

(B) Transportation position;

(C) Stop pin;

(M) Fore-Boom

(N) Lifting points.

13. Unlock the central tube by removing it from the stop pin (C). Slide the central tube from its storage position (A) to its transportation position (B).

NOTE: To avoid any injury don't let the Fore-Boom above the stand during the operation.

Illustration 112

(1) Fore-Boom stand;

(H) Fore-Boom bracket;

(I) Pin;

(N) Lifting points;

(O) Turnbuckle.

14. Use the lifting points (N) to put down the Fore-Boom on its stand (1). Align the holes of the bracket of the Fore-Boom (H) with the holes of the stand (1). Introduce a pin (I) into the Fore-Boom. Use turnbuckles on both side of the Fore-Boom in order to fix it on the stand.

15. Use the lifting points to put down the set on the trailer.

Assembly Front Parts

For the assembly procedure, follow Steps 27to 1.for the 36 m UHD configuration and steps 15to 1for the 7 m Fore-Boom Configuration.

NOTE: Connect hydraulic hoses before opening Ball-Valves.

NOTE: For the assembly of the Expandable Pins refer to Operation and Maintenance Manual, "Operation Section / Transportation Information - Disassembly and Assembly Expandable Pins."

NOTE: After the assembly of the front parts and reconnection of all hydraulic lines, grease lines and electrical wirings. It is necessary to purge the hydraulic circuits. Refer to Operation and Maintenance Manual, "Operation Section / Transportation Information - Purge of Hydraulic Lines Circuit".

Disassembly Front Parts 40 m UHD Configuration

Except for steps9 to 11, follow the same procedure described in "Disassembly Front Parts 36 m UHD Configuration".

Illustration 113

(A) Stick;

(B) Fore-Boom;

(1) Stick Cylinder;

(2) Piece of Wood.

1. Close the 3 Ball-Valves located on the sides of the Fore-Boom (B).

2. Remove bolts, clamps and hydraulic hoses of each Ball-Valve. Disconnect the grease lines. Plug the hydraulic hoses.

3. Use an appropriate lifting device to support the stick cylinder. Install a piece of wood between the stick cylinder and the stick.

Illustration 114

(A) Stick;

(B) Fore-Boom;

(1) Stick Cylinder;

(2) Piece of Wood.

4. Slowly lower the stick cylinder to the stick.

Disassembly and Assembly Expandable Pins

Illustration 115

(D) Boom-Nose;

(S) Boom-Foot;

(T) Expandable Pins.

Table 26

Table 27

Illustration 116

(1) Pin;

(2) Bolt (M12);

(3) Washer;

(4) Bolt (M42);

(5) Sleeve;

(6) Dismantling Bolt (M42).

Assembly Expandable Pins

Illustration 117

(A) Front Parts;

(B) Support Equipment

1. Front Parts (A) are supported by the Support Equipment (B) supplied with the boom (transportation support or stand support).

2. Drive the machine towards the Boom-Nose to join the Boom-Foot and the Boom-Nose.

Illustration 118

(B) Support Equipment;

(C) Bores to align;

(D) Boom-Foot;

(E) Boom-Nose;

(3) Screw.

Illustration 119

(C) Bore;

(D) Boom-Nose;

(E) Boom-Foot.

3. Prior to the actual assembly, ensure that the bores (C) of the Boom-Nose (D) and Boom-Foot (E) are properly aligned. Use the screw (3) located on each support (B) to align the holes.

4. Before mounting the sleeves in the Boom-Nose, grease or oil them by using our recommended products (see Table 27). Grease or oil the bolts ends and the ends of the Expandable pin before to assemble them by using our recommended products (see Table 27).

5. Introduce the Pin inside the higher holes of the Boom-Foot and the Boom-Nose.

Illustration 120

(1) Expandable Pin;

(2) Bolt (M12);

(3) Washer;

(4) Bolt (M42);

(5) Sleeve;

(D) Boom-Nose;

(E) Boom-Foot.

6. Mount the sleeves (5) inside the Boom-Nose (D) bores. On each face of the sleeves (5), tighten a washer (3) with 4 bolts (2). Repeat the operation for the other side of the pin.

7. Tighten the Expandable Pin (1) on the washer (3) with bolt (4). Repeat the operation for the other side of the pin.

8. Apply the right torque on each bolt (4). See Table 26.

9. Repeat from Step 6 to 8 for the lower bores.

10. Operate the machine during 1 hour. Check the torque of the bolts (4).

Illustration 121

(3) Washer;

(D) Boom-Nose;

(L) Distance between Washer and Boom-Nose.

11. Check the distance (L) between the face of the washer (3) and the face of the Boom-Nose (D). The distance (L) must be larger than 0 (L > 0).

12. Operate the machine during 2 or 3 hours and check the torque.

13. If the torque is not correct, adjust it and repeat Step 11 & 12. If the torque is correct, check the torque at normal maintenance interval schedule. Refer to Operation and Maintenance Manual, "Maintenance Section / Maintenance Interval Schedule".

Disassembly Expandable Pins

1. Lower the boom onto the supplied support.

2. When the boom is resting on the support, lift the boom lightly to ensure the force and weight are not pushing it downwards.

Illustration 122

(2) Bolt (M12);

(3) Washer;

(4) Bolt (M42).

3. Loosen and remove the 4 bolts (2) and the bolt (4). Remove the washer (3).

Illustration 123
(2) - Bolt (M12); (3) - Washer; (6) - Dismounting Bolt.

4. Turn the washer (3) of 180° and mount the 4 bolts (2). Tighten them to a torque of approximately 90 N·m. Mount the Dismounting Bolt (6).

5. Repeat Step 4 for the other side of the Expandable-Pin.

6. Move the Boom up and down and hit the Dismounting Bolt (6) alternatively with a (sledge-) hammer at the same time, to relieve the Expandable-Pin from pressure, until the sleeves loosen. Check the torque of the M12 Bolts (2) during the procedure.

7. Remove the Dismounting Bolt (6), Bolts (2), Washers (3) and Sleeves (5).

8. Remove the Expandable-Pin.

9. Repeat from Step 3to8for the other Expandable-Pin.

Purge of Hydraulic Lines Circuit

After the assembly of the Front Parts and reconnection of the hydraulic lines, it is necessary to purge all the hydraulic lines.

Special attention should be drawn on:

- The Load Sensing Line from the Fore-Boom Valve.

- The 2 Pilot Lines from the Fore-Boom Valve.

- The Pilot Line from the Stick Lowering Control Device.

In order to facilitate and improve the purge, nipples have been installed on some hydraulic lines.

Purge after transportation of Front Parts on the trailer

Illustration 124

(A) Boom-Foot;

(1) Purge of the Load Sensing line.

Illustration 125

(A) Boom-Foot;

(B) Boom-Nose;

(2) Ball-Valve;

(3) Plug.

1. When the Boom-Foot is connected to the Boom-Nose, loosen the bolts located on each Ball-Valves (9 on the Boom-Foot and 8 on the Boom-Nose), loosen the Nipple (1) of the Load Sensing lines located at the foot of the Boom-Foot (A).

Illustration 126

(B) Boom-Nose;

(C) Fore-Boom Cylinder;

(D) Valve;

(2) Ball-Valve;

(3) Plug;

(4) Nipples of the Pilot Lines.

2. Loosen the Plug (3) of the Valve (D) located on the Fore-Boom Cylinder (C). Loosen the 2 Nipples (4) of the Pilot Lines.

Illustration 127

(B) Boom-Nose;

(E) Fore-Boom;

(2) Ball-Valve;

(3) Plug.

3. Loosen the Plug (3) on all Ball-Valves (2) (4 on the top plate of the Fore-Boom and 3 on the side plate of the Fore-Boom) located on the Fore-Boom (E).

4. Slowly, extend and retract the Fore-Boom Cylinder and raise and lower the Boom. When hydraulic oil starts to leak through the plugs and nipples, screw all of them.

5. After assembly of the Stick on the Fore-Boom, the Stick-Cylinder on the Fore-Boom and reconnection of all lines (hydraulic, grease and electrical), purge the rest of the hydraulic lines.

Illustration 128

(E) Fore-Boom;

(F) Stick Cylinder;

(4) Nipple;

(5) Stick Lowering Valve.

Illustration 129

(G) Stick;

(H) Tool Cylinder;

(2) Ball-Valve;

(3) Plug; Nipple;

(6) Tool Lowering Valve.

6. Loosen the nipple (4) located on the Stick Lowering Valve (5). Loosen the plug (3) located on the Tool Lowering Valve (6) and the plug (3) of the 2 Ball-Valves (2) located on each side of the Stick (G).

7. Slowly raise the Boom, extend and retract the Stick Cylinder and the Tool Cylinder. When hydraulic oil start to leak thru the plugs and nipples, screw all of them.

Purge after Switching Front Parts

After connection of the Boom-Foot with the Boom-Nose, reconnection of all lines, the hydraulic lines must be purged.

For Illustration, refer to the Section "Purge after transportation of Front Parts on the trailer".

1. Loosen the nipple of the Load Sensing line (See Illustration 124).

2. Loosen plug located on each Ball-Valve (See Illustration 125, 126, 127 and 128) and nipples (See Illustration 126 and 128).

3. Slowly start to raise the boom and extend all cylinders. When hydraulic oil starts to leak, screw all of the plugs and nipples.