Chapter 17 - Attachment Mechanical: Service Manual

Service Manual
Chapter 17 - Attachment mechanical

Attachment - Mechanical.................................................................................................................................. 17-3
1 Installation / Removal ....................................................................................................................... 17-3
1.1 Boom ...................................................................................................................................... 17-3
1.2 Stick........................................................................................................................................ 17-11
1.3 Bucket..................................................................................................................................... 17-16
2 Condition monitoring......................................................................................................................... 17-21
2.1 Condition monitoring of the boom........................................................................................... 17-22
2.2 Condition monitoring of the stick ............................................................................................ 17-22
2.3 Condition monitoring of the bucket ......................................................................................... 17-22
3 Pins / bushes .................................................................................................................................... 17-22
3.1 Component location................................................................................................................ 17-22
3.2 Technical data ........................................................................................................................ 17-27
3.3 Installation / Removal ............................................................................................................. 17-27
LFR/en/version: 09 / 2007
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Service Manual
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Service Manual Attachment - Mechanical
Installation / Removal
17 Attachment - Mechanical
17.1Installation / Removal
17.1.1Boom
17.1.1.1Component location
Boom for an excavator with a shovel attachment Boom for an excavator with a back bucket attachment
Boom for an excavator with a shovel attachment

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Attachment - Mechanical Service Manual
Boom for an excavator with a back bucket attachment
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17.1.1.2Shovel attachment
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Installation
For the installation of the boom, use appropriate jacking equipment.
– Park the machine in level flat ground, and check if the excavator is in a blast area.
– Shut off the engine.
– Turn ignition key on, safety lever down and activate joysticks in all directions to expel stored energy in the
hydraulic cylinders and in the servo accumulator.
– Isolate the machine by disconnecting the safety switch S9.1.
– Lift the boom with a crane and lay it on blocks. The boom cylinders and the stick cylinders must now be fixed
on the boom.
– Align the boom cylinders extremity with the boom (axis 42) and fit the pin 1 and the washer kits 5. Install the
covers 2 and their O-ring 4 with the screws 3.
– Align the stick cylinders extremity with the boom (axis 43) and fit the pin 1, washer kits 5. Install the distance
rings 6, the covers 2 and their O-ring 4 with the screws 3.
– Lift the boom and the cylinders with a crane. Use chains to secure the cylinders to the boom, so they won’t
hang when the boom is installed.
– Install grease lines between boom and uppercarriage, plug all grease lines.
– Install all electrical wiring.
– Install and plug hydraulic lines between uppercarriage and boom, and between the upperdeck and the
boom cylinders.
– Put the rod of the boom cylinder out until the base bushings (axis 80) are aligned to the rod bushings. Fit
the pins 1 and the washer kits 5.
– Install covers 2 and their O-ring 4 with screws 3 at the connections between the boom base and the upper-
carriage (axis 80) and between the boom cylinders and the uppercarriage (axis 81).
– Install the cam of the proximity transmitters on the cover of the right connection (axis 80).
– Reconnect the safety switch S9.1.
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Removal
Before the removal of the boom, the bucket and the stick must have been already dismounted.
– Drive boom down, as far as possible and be sure that the attachment is in a rested position.
– Then shut off the engine.
– Turn ignition key on, safety lever down and activate joysticks in all directions to expel stored energy in hy-
draulic cylinders and servo accumulators.
– Isolate machine by disconnecting the safety switch S9.1.
– Remove all grease lines between boom and the upperdeck. Plug all grease lines.
– Remove all electrical wiring.
– Remove and plug hydraulic lines between boom and uppercarriage.
– Remove covers 2 and their O-ring 4 with screws 3 on the connections between boom cylinders and the up-
percarriage (axis 81) and between the boom and the upperdeck (axis 80).
– Use chains to secure boom cylinders and stick cylinders to boom, so they won’t hang when the boom is
removed.
– Set crane to front of boom to take weight.
– Remove the pins 1 and the washer kits 5 of the connections between boom cylinders and uppercarriage
(axis 81).
– Attach another crane to rear of the boom.
– Take some weight on the cranes and remove the pins 1 and the washer kits 5 of the connections between
boom and uppercarriage (axis 80).
– Lift boom away from machine.
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17.1.1.3Backhoe attachment
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Installation
For the installation of the boom, use appropriate jacking equipment.
– Isolate the machine by disconnecting the safety switch S9.1.
– Lift the boom with a crane and lay it on blocks. The boom cylinders must now be fixed on the boom.
– Align the boom cylinders extremity with the boom (axis 42) and fit the pin 1 and the washers kit 5. Install the
covers 2 and their O-ring 4 with the screws 3.
– Lift the boom and the cylinders with a crane. Use chains to secure the cylinders to the boom, so they won’t
hang when the boom is installed.
– Install grease lines between boom and uppercarriage, plug all grease lines.
– Install all electrical wiring.
– Install and plug hydraulic lines between uppercarriage and boom, and between the upperdeck and the
boom cylinders.
– Put the rod of the boom cylinder out until the base bushings (axis 80) are aligned to the rod bushings. Fit
the pins 1 and the washer kits 5.
– Install covers 2 and their O-ring 4 with screws 3 at the connections between the boom base and the upper-
carriage (axis 80) and between the boom cylinders and the uppercarriage (axis 81).
– Install the cam of the proximity transmitters on the cover of the right connection (axis 80).
– Reconnect the the safety switch S9.1.
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Removal
Before the removal of the boom, the bucket and the stick must have been already dismounted.
– Drive boom down, as far as possible and be sure that the attachment is in a rested position.
– Then shut off the engine.
– Remove all grease lines between boom and the upperdeck. Plug all grease lines.
– Remove all electrical wiring.
– Remove and plug hydraulic lines between boom and uppercarriage.
– Remove covers 2 on the connections between boom cylinders and the uppercarriage (axis 81) and between
the boom and the upperdeck (axis 80).
– Use chains to secure boom cylinders to boom, so they won’t hang when the boom is removed.
– Set crane to front of boom to take weight.
– Remove the pins 1 and the washer kits 5 of the connections between boom cylinders and uppercarriage
(axis 81).
– Attach another crane to rear of the boom.
– Take some weight on the cranes and remove the pins 1 and the washer kits 5 of the connections between
boom and uppercarriage (axis 80).
– Lift boom away from machine.
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17.1.2Stick
Stick for an excavator with a shovel attachment Stick for an excavator with a back bucket attachment
Stick for an excavator with a shovel attachment

Stick for an excavator with a backhoe attachment
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Installation
– Drive boom down as far as possible.
– Locate crane in suitable position to support stick, lift the stick.
– With crane, align stick to boom bushings (axis 41) and fit the pin 1.
– With another crane, align the stick cylinders to the stick (axis 44), and put the rod of the cylinders out, fit the
pins 1, the washers kit 5 and the distance ring 6.
– Install the covers 2 and the O-rings 4 with the screws 3 to the connections between stick cylinders and stick
(axis 44), and to the connections between the boom and the stick (axis 41).
– Install grease lines between boom and stick, plug all lines.
– Install bucket cutout wiring between boom and stick.
– Install and plug hydraulic lines between stick and boom.
Removal
Before the removal of the stick, the bucket must be removed.
– Put the attachment in rested position, lay boom down with stick out.
– Turn ignition key on, safety lever down and activate joysticks in all directions to expel stored energy in cy-
linders and servo accumulators.
– Remove grease lines between boom and stick, plug all lines.
– Remove bucket cutout wiring between boom and stick.
– Remove and plug hydraulic lines between stick and boom.
– Remove covers 2 from stick cylinders (axis 44) and from the connections between boom and stick (axis 41).
– Remove stick pins 1 between stick cylinders and stick (axis 44) using mobile crane.
– Restart machine and suck stick cylinders in.
– Locate crane in suitable position to support stick, connect to stick.
– Remove pins 1 between stick and boom (axis 41) securing stick to boom with crane.
– Remove stick from machine.
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Installation
– Drive boom down as fas as possible.
– Lift the stick cylinders with a crane.
– Align stick cylinders extremities to boom bushings (axis 43) and fit the pin 1 and washers kit 5. Install the
covers 2 and the O-rings 4 with the screws 3.
– Locate crane in suitable position to support stick, lift the stick.
– With crane, align stick to boom bushings (axis 41) and fit the pin 1 and washers kit 5.
– With another crane, align the stick cylinders to the stick (axis 44), and put the rod of the cylinders out, fit the
pins 1.
– Install the distance ring 6, the covers 2 and the O-rings 4 with the screws 3 to the connections between stick
cylinders and stick (axis 44).
– Install the covers 2 and the O-rings 4 with the screws 3 to the connections between the boom and the stick
(axis 41).
– Install grease lines between boom and stick, plug all lines.
– Install bucket cutout wiring between boom and stick.
– Install and plug hydraulic lines between stick and boom.
Removal
Before the removal of the stick, the bucket must be removed.
– Put the attachment in rested position, lay boom down with stick out.
– Turn ignition key on, safety lever down and activate joystickes in all directions to expel stored energy in cy-
linders and servo accumulators.
– Isolate machine by disconnecting the safety switches S9.1.
– Remove grease lines between boom and stick, plug all lines.
– Remove bucket cutout wiring between boom and stick.
– Remove and plug hydraulic lines between stick and boom.
– Remove covers 2 from stick cylinders (axis 44) and from the connections between boom and stick (axis 41).
– Remove stickes pins 1 between stick cylinders and stick (axis 44) using mobile crane.
– Restart machine and suck stick cylinders in.
– Locate crane in suitable position to support stick, connect to stick.
– Remove pins 1 between stick and boom (axis 41) securing stick to boom with crane.
– Remove stick from machine.
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17.1.3Bucket
Bucket for an excavator with a back Bucket for an excavator with a back
shovel attachment bucket attachment
Shovel Bucket LFR/en/version: 09 / 2007
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Installation
– Park the machine on level flat ground, and check if the excavator is in a blast area.
– Lift the bucket cylinders with a crane.
– Align bucket cylinders extremities to boom bushings (axis 45) and fit the pins 1 and washer kits 5. Install the
distance rings 6, the covers 2 and the O-rings 4 with the screws 3.
– Locate the crane in suitable position to support the bucket, lift the bucket.
– With the crane, align the bucket to stick bushings (axis 47) and fit the pins 1.
– Put the rod of the bucket cylinders out and align the cylinders extremities with the bucket bushings (axis 46).
Fit the pins 1 and the washer kits 5.
– Install the covers 2 and the O-rings 4 with the screws 3 to the connections between the stick and the bucket
(axis 47).
– Install the distance rings 6, the covers 2 and the O-rings 4 with the screws 3 to the connections between
the bucket cylinders and the bucket (axis 47).
– Install grease lines between the stick and the bucket, plug all lines.
– Install bucket cutout wiring between stick and bucket.
– Install and plug hydraulic lines between stick and bucket.
Removal
– Put the attachment rested on the floor in a stable position.
– Turn the engine off.
– Remove grease lines.
– Remove the distance rings 6, the covers 2 and the O-rings 4 with the screws 3 from the bucket cylinders
(axis 46).
– Remove the covers 2 and the O-rings 4 with the screws 3 from the connections between the stick and the
bucket (axis 47).
– Put the bucket in upright position.
– Remove stick pins 1 and washers kits 5 between the bucket cylinders and bucket (axis 46).
– Restart the machine and retract bucket cylinders.
– Remove pins 1 and washer kits 5 between the bucket and the stick (axis 47).
– Lift stick out of the bucket.
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Installation
– Lift the bucket cylinders with a crane.
– Locate the crane in suitable position to support the bucket, lift the bucket.
– With the crane, align the bucket to stick bushings (axis 47) and fit the pins 1 and the guard rings 7.
– Put the rod of the bucket cylinders out and align the shift levers with the bucket bushings (axis 46). Fit the
pins 1 and the guard rings 7.
– Install the covers 2 and the O-rings 4 with the screws 3 to the connections between the stick and the bucket
(axis 47).
– Install the covers 2 and the O-rings 4 with the screws 3 to the connections between the shift levers and the
bucket (axis 46).
– Install grease lines between the stick and the bucket plug all lines.
– Install bucket cutout wiring between stick and bucket.
– Install and plug hydraulic lines between stick and bucket.
Removal
– Put the attachment rested on the floor in a stable position.
– Turn the engine off.
– Remove grease lines.
– Remove the covers 2 and the O-rings 4 with the screws 3 from the connections between the shift levers and
the bucket (axis 46).
– Remove the covers 2 and the O-rings 4 with the screws 3 from the connections between the stick and the
bucket (axis 47).
– Put the bucket in upright position.
– Remove the pins 1 and the guard rings 7 between the bucket cylinders and bucket (axis 46).
– Restart the machine and retract bucket cylinders.
– Remove pins 1 and the guard rings 7 between the bucket and the stick (axis 47).
– Lift stick out of the bucket.
17.1.3.4Installation and removal of the bucket teeth

See Posilok Tooth System with Sidewinder Pin.
See ESCO Super V Locking Pins.
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Condition monitoring
17.2Condition monitoring
The attachment is the part of the hydraulic excavator, which is the most request. This part is directly in contact
with the handling material; the excavator with the standard backhoe, grapple or bucket attachment may only
be used to loosen, pick up, move, load and dump soil, gravel, rock or other material and to load trucks, barges,
conveyor, belts, or rock crushing systems. So the shocks, the vibrations, the requests and the stresses on the
attachment are more important than on the other parts of the excavator. The wear of this part is consequently
faster, especially for the bucket. You have to be very careful during the inspection of the attachment.
17.2.1Condition monitoring of the boom

• Floodlights : check if the floodlights of the boom light up and if they are not broken.
• Handrails : verify the fixing of the handrails on the boom, and do a visual check for good conditions of the
handrails.
• Hydraulic pipes clamps and hoses : verify if the hydraulic pipes clamps and hoses are well fixing on the
boom, and check visually the good conditions of the hoses.
• Cracks : check if there are no cracks on the boom.
• Pins and bushes : verify if the pins and bushes permit a good rotation of the boom’s axis.
• Hydraulic cylinders : check if they are in service conditions and well fixed on the boom.
17.2.2Condition monitoring of the stick

stick, and check visually the good conditions of the hoses.
• Cracks : check if there are no cracks on the stick.
• Pins and buches : verify if the pins and bushes permit a good rotation of the stick’s axis.
• Hydraulic cylinders : check if they are in service conditions and well fixed on the stick.
17.2.3Condition monitoring of the bucket

bucket, and check visually the good conditions of the hoses.
• Cracks : check if there are no cracks on the bucket.
• Pins and bushes : verify if the pins and bushes permit a good rotation of the bucket’s axis.
• Hydraulic cylinders : check if they are in service conditions and well fixed on the bucket.
• Knife of the bucket : check the state of wear of the shrouds and of the teeth.
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Pins / bushes
17.3Pins / bushes
17.3.1Component location
The following figures indicate the location of pins and bushes on the attachment (surrounded parts).
17.3.1.1For an excavator with shovel attachment
Rotating deck
Boom
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Pins / bushes
Stick
Bucket
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Pins / bushes
17.3.1.2For an excavator with a backhoe attachment
Rotating deck
Boom
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Pins / bushes
Stick
Bucket
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Pins / bushes
17.3.2Technical data
On the hydraulic excavator R9250, there are different sizes of pins and bushes, but the principal technical data
are the same.
17.3.2.1For the pins
Steel (type) 42 Cr Mo 4
Chromium (type) Chromium plating to size 0,03 mm
Hardening (type) Induction hardening
Depth of hardening (finished part) 1,5+0,5
Hardness (HRC) 58±2
Heat treated to (N/mm²V) 900 / 1050
External diameter adjustment (type) f7
17.3.2.2For the bushes
Steel (type) 18 M 5
Treatment (type) SURSULF SDA 0
Heat treated to (daN/mm²V) 65 / 80
Internal diameter adjustment (type) D8
External diameter adjustment (type) s6
17.3.3Installation / Removal
17.3.3.1Installation of the bushes

– First, make you sure that the bore, its extremities and the eventual relieves of the bushes are free of impurity
(cutting and oil). If there are always impurities aspirate them or take them off with a magnet. The bores and
the holes must be blown with compressed air.
– Check that the bushes you want to mount are the good one, for this, verify the Ident. No. on the bushes.
– The bushes must submerge in a bath of liquid nitrogen between 5 and 15 minutes; it depends from the di-
mensions of the bushes. Be very careful the nitrogen is a chemically dangerous. You must always wear
safety glasses and protective gloves when you are manipulating nitrogen.
– There are several types of grooves in the bushes you will have to mount :
• Smooth bushes without lubricating groove.
• Bushes with an unoutcoming lubricating groove.
• Bushes with lubricating groove which bore is coming out at the two sides.
• Bushes with lubricating groove which bore is coming out only at one side.
– For the mounting direction, see the following drawings.
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Pins / bushes
Central lubrication
Groove which is coming out at the inner side.
Lubrication at the middle of the bushing.
Groove which is coming out at the outer side.
Central lubrication by central bracing
Groove which is coming out at the inner side.
Lubrication by a cover
Groove which is coming out at the outer side.

– It is imperative to verify the axis alignment of the bore. For this operation, use a control axis of adjustment f7.
– Check after the mounting of the bushing that the bores are without impurity, with control pieces. The verifi-
cation will be done with compressed air. Put a stub in rubber at the end of the bellows before engaging it in
the greasing hole. This inspection can be done with a grease pump too.
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Pins / bushes
– Mouting of the joints :

Engage the joint in the bore. This mounting must be done with appropriate tool.
– Mounting direction of the joints :

Inner side joint.
Inner and outer side joints

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Pins / bushes
– Mounting of the lubricator :

• Existing lubricator :
The Ident. Number is defined in the parts list of the development department.
M 14 x 1,5 4901359
M 10 x 1 7743242
M 10 x 1 7001026 Self threading
8500251 Protecting cap
• Screw lubricator :
Screw the lubricator, which is tightening with a key, and put the protecting cap.
• Self threading lubricator :
Engage the lubricator in the bore. Intrude the lubricator with a hammer (800 g) thanks to an appropriate
drawer. Just one thread must stay apparent. Then the screw of a quarter of turn thanks to a key.
– Safety rules :
It seems here very useful to remind the elementary cautions to take during the using of liquid nitrogen.
Caution!
C
The liquid nitrogen is chemically very dangerous!!! : -196°C.

Risks of burns with projections and contact.
The wear of work gloves and of safety glasses is obligatory.
Manipulate the bushes (entry and coming out of the nitrogen tray) with appropriate pliers.
Do not heat the cooled bushes directly with a hammer (risks of blowout and metal particles pro-
jections).
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Pins / bushes
17.3.3.2Installation of the pins
2 front flange 22 pipe

3 back flange 24 central pin
4 pin 25 handle
5 cylinder support 26 handle
7 washer 27 fairlead bush
8 washer 28 fairlead bush
9 limit stop 29 cylinder block
10 pin 30 locking pin
12 support 31 locking pin
14 support 32 lifting screw
15 support 33 socket head screw
16 stop screw 34 hexagonal head screw
18 stop screw 35 hexagonal head nut
19 stop screw 36 handle
20 end connection
For the installation of the pins use an appropriate tool. The tool required is the mounting device for pins (Ident.
Number : 9826013). Fix the front flange (see pos. 2) on the housing where you want to install the pin, thanks
to hexagonal head screws. Then put the pin in the mounting device, exactly on the supports (see pos. 12, 14
and 15). A hydraulic cylinder permit to push correctly the pin in its housing, but before pushing the pin in its
housing put the distributor in «pushing position». According to the length of the pin and to the stroke of the hy-
draulic cylinder, you can adjust the position of the hydraulic cylinder thanks to mechanical stop.
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Pins / bushes
17.3.3.3Removal of the bushes

For the removal of the bushes, use a grinding machine to cut the bushes and the put them off.
17.3.3.4Removal of the pins

The tool use for the removal of the pins is the same as this one use for the installation of the pins.
Fix the front flange (see pos. 2) on the housing where you have to remove the pin, thanks to hexagonal screws.
Screw the threaded stub on the pin, they are threaded. Add the end connection (pos. 20), which permits to the
threaded stub to be linked to the hydraulic cylinder. Put the distributor in «pulling position». According to the
length of the pin and to the stroke of the hydraulic cylinder, you can adjust the position of the hydraulic cylinder
thanks to mechanical stop.
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Chapter 17 - Attachment Mechanical: Service Manual

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Service Manual

Chapter 17 - Attachment mechanical

R 9250 from 13466 17 - 1

17 - 2 R 9250 from 13466

Boom for an excavator with a shovel attachment

R 9250 from 13466 17 - 3

Boom for an excavator with a back bucket attachment

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17 - 6 R 9250 from 13466

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17 - 10 R 9250 from 13466

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Stick for an excavator with a shovel attachment

Stick for an excavator with a backhoe attachment

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Shovel Bucket LFR/en/version: 09 / 2007

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17.1.3.4Installation and removal of the bucket teeth

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17.2.1Condition monitoring of the boom

17.2.2Condition monitoring of the stick

17.2.3Condition monitoring of the bucket

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17.3.1.1For an excavator with shovel attachment

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17.3.1.2For an excavator with a backhoe attachment

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17.3.2.1For the pins

17.3.2.2For the bushes

17.3.3.1Installation of the bushes

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Groove which is coming out at the inner side.

Lubrication at the middle of the bushing.

Groove which is coming out at the outer side.

Central lubrication by central bracing

Groove which is coming out at the inner side.

Groove which is coming out at the outer side.

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– Mouting of the joints :

– Mounting direction of the joints :

Inner and outer side joints

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– Mounting of the lubricator :

M 10 x 1 7001026 Self threading

8500251 Protecting cap

The liquid nitrogen is chemically very dangerous!!! : -196°C.

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17.3.3.2Installation of the pins

2 front flange 22 pipe