Mannesmann Demag Hydraulic Shovel Service Repair Manual (DEMAG ALL) – PDF Download

Description

Mannesmann Demag Hydraulic Shovel Service Repair Manual (DEMAG ALL)

Description:

Mannesmann Demag Hydraulic Shovel Service Repair Manual (DEMAG ALL)

This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in accordance with written authorization from Komatsu America Corp. It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or improvements at any time without incurring any obligation to install such changes on products sold previously. Due to this continuous program of research and development, revisions may be made to this publication. It is recommended that customers contact their distributor for information on the latest revision.

Table of Contents:

Mannesmann Demag Hydraulic Shovel Service Repair Manual (DEMAG ALL)

MAIN MENU......................................................................................................   0
COVER..........................................................................................................   1
CONTENTS.......................................................................................................   5
1. CYLINDER....................................................................................................   7
	1-1 CYLINDERS H 241........................................................................................  10
		1. TABLE OF SERVICEABLE CYLINDER.......................................................................  11
		2. TABLE OF DRAWINGS...................................................................................  12
		3. CYLINDER FEATURES AND DATA..........................................................................  13
		4. WORK AIDS...........................................................................................  14
		5. SEALING.............................................................................................  27
		6. WEAR AND TEAR LIMITS................................................................................  39
		7. TORQUING REQUIREMENTS...............................................................................  65
		8. SPACE MEASUREMENT OF GUIDE RINGS....................................................................  67
		9. MEASURE TABLES REBUILDING OF CYLINDERS..............................................................  71
		10. DRAWINGS, ORIGINAL PARTS, PISTON AND FLANGE BUSHING................................................  78
		11. REBUILDING OF CYLINDER PISTON ROD BY GRINDING OFF AND CHROMIUM PLATING............................. 110
	1-2 CYLINDERS H 185........................................................................................ 115
		1. TABLE OF SERVICEABLE CYLINDERS...................................................................... 117
		2. TABLE OF DRAWINGS...................................................................................  12
		3. CYLINDER MARKINGS...................................................................................  13
		4. WORK AIDS........................................................................................... 119
		5. SEALING.............................................................................................  27
		6. WEAR AND TEAR LIMIT................................................................................. 139
		7. TORQUES............................................................................................. 143
	1-3 CYLINDERS H 121........................................................................................ 147
		1. TABLE OF SERVICEABLE CYLINDERS...................................................................... 149
		2. TABLE OF DRAWINGS...................................................................................  12
		3. CYLINDER MARKING....................................................................................  13
		4. WORK AIDS........................................................................................... 151
		5. SEALING.............................................................................................  27
		6. WEAR AND TEAR LIMIT................................................................................. 162
		7. TORQUES............................................................................................. 166
	1-4 CYLINDERS H 285........................................................................................ 169
		1. TABLE OF SERVICEABLE CYLINDERS...................................................................... 171
		2. TABLE OF DRAWINGS...................................................................................  12
		3. CYLINDER MARKING....................................................................................  13
		4. WORK AIDS........................................................................................... 173
		5. SEALING.............................................................................................  27
		6. WEAR AND TEAR LIMITS................................................................................ 193
		7. TORQUES............................................................................................. 196
		8. REWORK BY HONING.................................................................................... 199
	1-5 CYLINDER H485.......................................................................................... 201
	1-5.1 CYLINDER H485/655 AND PC8000......................................................................... 202
		1. TABLE OF SERVICEABLE CYLINDERS...................................................................... 204
		2. CYLINDER WEIGHT..................................................................................... 210
		3. DESIGN, CUT VIEW.................................................................................... 216
		4. WORK AIDS........................................................................................... 224
		5. WEAR AND TEAR LIMITS................................................................................ 268
		6. ASSEMBLY............................................................................................ 306
		7. TIGHTENING TORQUES.................................................................................. 314
	1-6 CYLINDERS H 185 S FROM SERIAL NO. 06078 - UP........................................................... 320
		1. TABLE OF SERVICEABLE CYLINDERS...................................................................... 321
		2. DESIGN, CUT VIEW.................................................................................... 322
		3. WORK AIDS........................................................................................... 326
		4. WEAR AND TEAR LIMITS................................................................................ 347
		5. ASSEMBLY............................................................................................ 358
		6. BOLT TIGHTENING TORQUES............................................................................. 360
	1-6.1 CYLINDERS H 185 S.................................................................................... 362
		1. TABLE OF SERVICEABLE CYLINDERS...................................................................... 364
		2. TABLE OF DRAWINGS................................................................................... 365
		3. CYLINDER MARKING.................................................................................... 370
		4. WORK AIDS........................................................................................... 372
		5. WEAR AND TEAR LIMIT................................................................................. 396
		6. TIGHTENING TORQUES FOR MOUNTING BOLTS............................................................... 414
		7. ASSEMBLY............................................................................................ 416
	1-7 CYLINDERS H 95......................................................................................... 418
		1. TABLE OF SERVICEABLE CYLINDERS...................................................................... 420
		2. DESIGN, CUT VIEW.................................................................................... 421
		3. WORK AIDS........................................................................................... 428
		4. WEAR AND TEAR LIMITS................................................................................ 443
		5. ASSEMBLY............................................................................................ 460
		6. TIGHTENING TORQUES.................................................................................. 462
	1-8 MACHINING OF THE FLANGE BUSHING AFTER FREEZING IN THE BUSHING (ALL CYLINDERS).......................... 464
	1-9 CYLINDERS H 135........................................................................................ 470
		1. TABLE OF SERVICEABLE CYLINDERS...................................................................... 472
		2. DESIGN, CUT VIEW.................................................................................... 473
		3. WORK AIDS........................................................................................... 478
		4. WEAR AND TEAR LIMITS................................................................................ 493
		5. ASSEMBLY............................................................................................ 505
		6. TIGHTENING TORQUES.................................................................................. 507
	1-10 HOOK WRENCH FOR PISTN NUT............................................................................. 510
	1-11 CYLINDERS H 285 S..................................................................................... 514
		1. TABLE OF SERVICEABLE CYLINDERS...................................................................... 516
		2. DESIGN, CUT VIEW.................................................................................... 520
		3. WORK AIDS........................................................................................... 526
		4. WEAR AND TEAR LIMITS................................................................................ 554
		5. SEALING OF THE CYLINDER............................................................................. 580
		6. ASSEMBLY............................................................................................ 582
		7. TIGHTENING TORQUES.................................................................................. 590
	1-12 CYLINDER H 255 S...................................................................................... 594
		1. TABLE OF SERVICEABLE CYLINDERS...................................................................... 596
		2. DESIGN, SECTIONAL DRAWING........................................................................... 598
		3. WORK AIDS........................................................................................... 604
		4. WEAR AND TEAR LIMITS................................................................................ 628
		5. ASSEMBLY............................................................................................ 648
		6. TIGHTENING TORQUES.................................................................................. 652
	1-12.1 CYLINDER PC3000..................................................................................... 654
		1. TABLE OF SERVICEABLE CYLINDERS...................................................................... 656
		2. DESIGN, SECTIONAL DRAWING........................................................................... 658
		3. WORK AIDS........................................................................................... 664
		4. WEAR AND TEAR LIMITS................................................................................ 692
		5. ASSEMBLY............................................................................................ 710
		6. TIGHTENING TORQUES.................................................................................. 714
	1-13 CYLINDERS H 455 S..................................................................................... 715
		1. TABLE OF SERVICEABLE CYLINDERS...................................................................... 717
		2. DESIGN, CUT VIEW.................................................................................... 719
		3. WORK AIDS........................................................................................... 733
		4. WEAR AND TEAR LIMITS................................................................................ 757
		5. SEALING OF THE CYLINDER............................................................................. 779
		6. TIGHTENING TORQUES.................................................................................. 781
	1-14 CYLINDER PC1800....................................................................................... 785
		1. TABLE OF SERVICEABLE CYLINDERS...................................................................... 787
		2. DESIGN, SECTIONAL VIEW.............................................................................. 789
		3. WORK AIDS........................................................................................... 793
		4. WEAR AND TEAR LIMITS................................................................................ 807
		5. ASSEMBLY............................................................................................ 825
		6. DISASSEMBLY OF CYLINDER DAMPING SYSTEM.............................................................. 831
		7. INSTALLATION OF ROD SEAL AND DUST SEAL.............................................................. 833
		8. MOUNTING OF DAMPING PISTION AND SEAL................................................................ 837
		9. TIGHTENING TORQUES.................................................................................. 845
	1-15 CYLINDER (CYLINDER, BARREL AND ROD)................................................................... 847
	1-16 CYLINDER - GENERAL REBUILD PROCEDURES................................................................. 849
2. HYDRAULIC PUMP.............................................................................................. 851
	2-1 HYDRAULIC PUMP......................................................................................... 857
		MANNESMANN REXROTH RDE 92210-04R....................................................................... 857
		SLIPPER BEARING ....................................................................................... 919
			CONTENTS........................................................................................... 921
			TECHNICAL DESCRIPTION.............................................................................. 923
			ADJUSTING OF ASSEMBLY DIMENSIONS................................................................... 935
			ASSEMBLY-DISASSEMBLY............................................................................... 939
		MOBILE ADJUSTMENT...................................................................................... 947
		MAIN PUMP CATALOGE PAGE ON 90-1560..................................................................... 961
		MAIN PUMP CATALOGUE PAGE NO. 90-1490................................................................... 965
	2-2 LUBE OIL PUMP.......................................................................................... 969
	2-3 GEAR LUBE OIL PUMP..................................................................................... 975
	2-4 MEASURING AND CONTROL OIL PUMP......................................................................... 981
	2-5 FAN PUMP............................................................................................... 989
	2-6 SLEWING PUMP........................................................................................... 995
	2-7 COOLING CIRCUIT PUMP................................................................................... 999
3. HYDRAULIC MOTOR.............................................................................................1005
	3-1 HYDRAULIC MOTOR........................................................................................1009
	3-2 SLEW MOTOR.............................................................................................1036
		SLEWING MOTOR CATALOGUE PAGE NO. 90-1363...............................................................1037
		SLEWING MOTOR CATALOGUE PAGE NO. 90-1370...............................................................1039
		SLEWING MOTOR TRAVEL MOTOR CATALOG PAGE NO. 90-1349....................................................1041
	3-3 FAN MOTOR DRIVE........................................................................................1044
4. VALVES......................................................................................................1008
5. PUMP DISTRIBUTOR GEAR & DRIVE SHAFT.........................................................................1052
	5-1 PUMP DISTRIBUTOR GEAR H 241............................................................................1055
		1. GENERAL VIEW........................................................................................1056
		2. DISASSEMBLING.......................................................................................1059
		3. DETERMINATION OF WEAR AND TEAR......................................................................1075
		4. ASSEMBLING..........................................................................................1101
		5. PREASSEMBLING OF DRIVE SHAFT ASSY...................................................................1111
	5-2 DRIVE SHAFT............................................................................................1125
	5-3 PUMP DISTRIBUTOR GEAR H 285 CONDITION MONITORING GATALOGUE PAGE NO. 90-2060A...........................1166
		1. DESIGN..............................................................................................1167
		2.DISASSEMBLY..........................................................................................1186
		3. WEAR AND TEAR DETERMINATION.........................................................................1205
		4. PREASSEMBLY OF INPUT SHAFT AND MOUNTING IT IN THE GEAR..............................................1218
		5. ASSEMBLY OF THE OTHER SHAFT SETS....................................................................1238
	5-4 PUMP DISTRIBUTOR GEAR H 85.............................................................................1256
		1. GENERAL VIEW........................................................................................1258
		2. DISASSEMBLY.........................................................................................1267
		3. DETERMINATION OF WEAR AND TEAR......................................................................1279
		4. ASSEMBLY AND ADJUSTMENT OF AXIAL PLAY...............................................................1305
		5. CONDITION MONITORING PUMP DISTRIBUTOR GEAR..........................................................1323
	5-5 PUMP DISTRIBUTOR GEAR H 285 CONDITION MONITORING CATALOGUE PAGE NO. 90-2079B ..........................1327
	5-6 PUMP DISTRIBUTOR GEAR H 485............................................................................1337
		ASSEMBLY DRAWING.......................................................................................1339
		CONDITION MONITORING CATALOGUE PAGE NO. 90-2076........................................................1343
		CONDITION MONITORING CATALOGUE PAGE NO. 90-0558........................................................1351
	5-6.1 PUMP DISTRIBUTOR GEAR H 485 CONDITION MONITORING.....................................................1356
	5-6.2 PUMP DISTRIBUTOR GEAR H 485 DETERMINATION OF WEAR AND TEAR ..........................................1363
	5-7 PUMP DISTRIBUTOR GEAR H 285............................................................................1377
	5-8 PUMP DISTRIBUTOR GEAR H 685 SP.........................................................................1467
		1. GENERAL VIEW........................................................................................1468
		2. DISASSEMBLY.........................................................................................1482
		3. DETERMINATION OF WEAR AND TEAR......................................................................1485
		4. ASSEMBLY............................................................................................1490
	5-9 PUMP DISTRIBUTOR GEAR H 285 S..........................................................................1527
		1. GENERAL VIEW........................................................................................1527
		2. DISASSEMBLY.........................................................................................1545
		3. DETERMINATION OF WEAR AND TEAR......................................................................1561
		4. ASSEMBLY............................................................................................1563
	5-10 PUMP DISTRIBUTOR GEAR H 455...........................................................................1611
		1. GENERAL VIEW........................................................................................1611
		2. DISASSEMBLY.........................................................................................1626
		3. DETERMINATION OF WEAR AND TEAR......................................................................1637
		4. ASSEMBLY............................................................................................1638
	5-10.1 PUMP DISTRIBUTOR GEAR H 455 (PC5500) WEAR DIMENSIONS................................................1685
	5-11 PUMP DISTRIBUTOR GEAR H 158 E + H225 E................................................................1694
		1. GENERAL VIEW........................................................................................1694
		2. DISASSEMBLY.........................................................................................1706
		3. DETERMINATION OF WEAR AND TEAR......................................................................1711
		4. ASSEMBLY............................................................................................1714
	5-12 PUMP DISTRIBUTOR GEAR H 655 WEAR DIMENSIONS...........................................................1770
6. SLEWING GEAR................................................................................................1773
	6-1 SLEWING GEAR H 241.....................................................................................1776
		GENERAL VIEW...........................................................................................1777
		DISASSEMBLING..........................................................................................1781
		DETERMINATION OF WEAR AND TEAR.........................................................................1828
		ASSEMBLING.............................................................................................1846
		TORQUES................................................................................................1868
	6-2 SLEWING GEAR H 285.....................................................................................1870
		1. GENERAL VIEW........................................................................................1871
		2. DISASSEMBLING.......................................................................................1878
		3. DETERMINATION OF WEAR AND TEAR......................................................................1896
		4. ASSEMBLY............................................................................................1920
		CONDITION MONITORING SLEWING GEAR......................................................................1952
	6-3 SLEWING GEAR CONDITION MONITORING H 485................................................................1957
		1. ASSEMBLY DRAWING SLEWING GEAR ......................................................................1959
		2. CONDITION MONITORING SLEWING GEAR ..................................................................1961
		3. ASSEMBLY MONITORING SLEWING GEAR....................................................................1967
	6-3.1 SLEWING GEAR H 485 CONDITION MONITORING CATALOGUE PAGE NO. 90-0910...................................1969
	6-3.2 SLEWING GEAR H 485 WEAR AND TEAR DETERMINATION CATALOGUE PAGE NO. 90-0910............................1971
	6-3.3 SLEWING GEAR H 485 CONDITION MONITORING CATALOGUE PAGE NO. 90-0560...................................1975
	6-3.4 SLEWING GEAR H 485/H 655 WEAR AND TEAR DETERMINATION.................................................1977
	6-4 SLEWING GEAR H 85......................................................................................1984
	6-5 SLEWING GEAR H 455.....................................................................................1988
		1. GENERAL VIEW........................................................................................1990
		2. DISASSEMBLY.........................................................................................1996
		3. DETEMINATION OF WEAR AND TEAR.......................................................................2000
		4. ASSEMBLY............................................................................................2004
		5. TORQUES.............................................................................................2047
	6-6 SLEWING GEAR H 285 S CATALOGUE NO. 90-1978D............................................................2049
		1. GENERAL VIEW .......................................................................................2050
		2. DISASSEMBLY.........................................................................................2063
		3. DETERMINATION OF WEAR AND TEAR......................................................................2064
		4. ASSEMBLY............................................................................................2066
		5. TORQUES.............................................................................................2107
	6-6.1 SLEWING GEAR  H 285 S CONDITION MONITORING CATALOGUE PAGE NO. 90-1978 & 90-1978B.....................2109
	6-7 SLEWING GEAR H 255 CATALOGUE PAGE NO. 991-0119.........................................................2119
		1. GENERAL VIEW........................................................................................2120
		2. DISASSEMBLY.........................................................................................2130
		3. DETERMINATION OF WEAR AND TEAR......................................................................2136
		4. ASSEMBLY............................................................................................2138
		5. TORQUES.............................................................................................2183
	6-8 SLEWING GEAR PC4000....................................................................................2185
		1. GENERAL VIEW........................................................................................2186
		2. DISASSEMBLY.........................................................................................2192
		3. DETERMINATION OF WEAR AND TEAR......................................................................2200
		4. ASSEMBLY............................................................................................2202
	6-10 SLEWING GEAR DISC BRAKE PC3000/4000/5500/8000.........................................................2287
		1. PARTS REQUIRED FOR REPAIR...........................................................................2288
		2. DISASSEMBLY.........................................................................................2290
		3. ASSEMBLY............................................................................................2302
7. TRAVEL GEAR.................................................................................................2323
	7-7.1 TRAVEL GEAR H 455/PC5500 EXCHANGE OF: PLANETARY CARRIER..............................................2324
		5. DISASSEMBLY OF PLANETARY GEARBOX, EXCHANGE OF PLANETARY CARRIER.....................................2326
	7-10 TRAVEL GEAR H 255/PC3000..............................................................................2328
		1. GENERAL VIEW........................................................................................2329
		2. DISASSMELBY.........................................................................................2336
		3. DETERMINATION OF WEAR AND TEAR......................................................................2357
		4. ASSEMBLY............................................................................................2359
8. SLEW RING...................................................................................................2492
9. ROTARY JOINT................................................................................................2493
10. BOTTOM ROLLER/TRACK ROLLER.................................................................................2494
11. TOP ROLLER.................................................................................................2495
12. IDLER......................................................................................................2496
13. SPROCKET...................................................................................................2497
14. WELDING INSTRUCTIONS FOR STEEL STRUCTURAL PARTS AND STEEL CASTINGS.........................................2500
	14-4 WELDING INSTRUCTIONS, REBUILD OF TRACK PADS, BOTTOM ROLLERS, SPROCKETS AND IDLERS OF CASTING STEEL....2502
		1. COMPONENTS SUITABLE FOR REBUILD.....................................................................2504
			1.1 TRACK PADS.....................................................................................2504
			1.2 BOTTOM ROLLERS.................................................................................2506
			1.3 SPROCKET.......................................................................................2508
			1.4 IDLERS.........................................................................................2510
		2. DETERMINATION OF WEAR...............................................................................2518
		3. WELDING PROCESS.....................................................................................2522
		4. RE-MACHINING THE ORIGINAL CONTOUR...................................................................2526

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MANNESMANN DEMAG HYDRAULIC SHOVEL SERVICE REPAIR MANUAL (DEMAG ALL) – PDF DOWNLOAD:

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