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ALL CYLINDERS
MAINTENANCE MANUAL
Page 2
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: 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
WARNING 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
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
ALL CYLINDERS
03-10-2003 EZ-JCB-FL
Page 3
2) RELEASE PRESSURE
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
WARNING cylinders before disassemble them.
NEVER WORK ON AN OPERATING CIRCUIT
.
RELEASING PRESSURE
BLEEDING A CYLINDER
Page 4
ALL CYLINDERS
03-10-2003 EZ-JCB-FL
3) DESCRIPTION
See page 4
Each cylinder consists essentially of:
4
*
1
3
*
6
*
*
8
2
Figure 1
ALL CYLINDERS
03-10-2003 EZ-JCB-FL
Page 5
HEX BOLTS
GRADE 8.8
ALLEN BOLTS
GRADE 12.9
M6
M8
M10
M12
M14
M16
M18
M20
M22
M24
M27
M33
M36
M39
M42
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.
Page 6
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.
03-10-2003 EZ-JCB-FL
ALL CYLINDERS
Page 7
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.
Page 8
ALL CYLINDERS
03-10-2003 EZ-JCB-FL
6
8
*
*
3
4
Figure 2
6/1/2) disassembling a ball joint
Liquid nitrogen-mounted ball joints: see page 9
ALL CYLINDERS
03-10-2003 EZ-JCB-FL
Page 9
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
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
Page 10
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
1
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 parts.
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
Page 11
Page 12
ALL CYLINDERS
9 *
03-10-2003 EZ-JCB-FL
2
2
7
*
*
3
1
Figure 9
ALL CYLINDERS
03-10-2003 EZ-JCB-FL
Page 13
Name:
Date:
Signature:
o Check Adjust
m Clean
s Replace
l Lubricate
PERIODS
DONE.
Each 50 PH 200
shift
PH
600
PH
Leakage detection
ALL CYLINDERS
m
s
l
YES
NO