GB Workshop manual

DXR 310
From serial no 1
 Technical data
Category Technical feature Specification
General Model DXR310
Rotation speed of pivot [rpm] 6
Transport speed max. [km/h] / [mph] 3 / 1.9
Hydraulic Volume hydraulic system [l] / [gal] 50 / 13
system
Pump type Load sensing axial piston pump
with variable displacement.
Pump flow max.* [l/min] / [gal/min] 65 / 17
Variable flow to tool and system 0—65 / 0—17
System pressure (nom. Max) [Bar] / [psi] 200 / 2900
System pressure (boosted) [Bar] / [psi] 250 / 3630
Electric motor Type Siemens 1LA9166—4LA66—Z
Frequency [Hz] 50 60
Voltage [V] 380—420 440—480
Power [kW] 22 24
Speed [rpm] 1455 1750
Current [A] 44
Control system Control type Remote control
Signal transmission Bluetooth® / cable
Working range, radio [m] [y] ≤ 100 / ≤ 109
Battery [mAh] High capacity Li-Ion 1600
Weight Without tool [kg] / [lb] 1963 / 4328
Tools Rec. max. weight [kg] / [lb] 230 / 507
Dimensions Length without tool [mm] / [in] 2594 / 102
Width with track widener [mm] / [in] 1110 / 44
Width without track widener [mm] / [in] 780 / 31
Min. height [mm] / [in] 1484 / 58
Clearance height [mm] / [in] 185 / 7
Folding outrigger [mm] / [in] 2056 / 81
Telescopic arm [mm] / [in] 550 / 22
Rubber track width (mm/in) 230 / 9
Work radius around the machine [mm] / [in] 5200 / 205
*Maximum pump flow and system pressure cannot be taken out at the same time, the engine will be over­
loaded. 60 Hz has limited displacement.

Noise emissions
Machine without tool Sound power level, measured [dB(A)] 87
Sound power level, guaranteed [LWA dB(A)] 92
Machine with tool (hydraulic ham­ Sound power level, measured [dB(A)]
mer) 118
Sound power level, guaranteed [LWA dB(A)]
Noise emissions in the environment measured as sound power [L WA] in conformity with EC directive
2000/14/EC.

Sound power level

Sound level 10m from the machine's tools* [dB(A)] 90
*The stated value refers to work with a hydraulic hammer.
Other types of recommended tools create a considerably lower noise level.
HUSQVARNA CONTENTS Page

DXR 310 1. Introduction

Spare parts
1
1
2. Safety symbols 3
3. Checks | Troubleshooting | Specifications 5
Important precautions 5
Cleaning 6
Service schedules 7
Lubrication 8
Mountings & Tightening torque 9
Level checks 9
Checking for wear and damage - welding 10
Functional inspections 11
Change or Replace 12
Troubleshooting – error messages 13
Troubleshooting guide 15
Guide values and specifications 16
4. Components – orientation 19
Undercarriage 19
Turret 20
Boom—stick 21
Remote control 21
5. Functional components 23
Drive line and hydraulics 23
Hydraulic system 24
6. Common service tasks 25
Shafts of joints and cylinders 25
Hydraulic lines/couplings 26
Positioning and supporting the machine 27
Positioning and securing boom and stick 28
7. Outriggers 29
8. Traction system 31
Replacing a rubber track 31
Dismantling the track unit 32
Removing drive motor and tensioning cylinder 33
Drive motor service 33
9. Frame manifold valve 35
10. Tipping machine | Frame interior 37
11. Turret coverings / counterweight 39
Dismantling the housing 39
The counterweight 40
Rear stop button 41
12. Radio and Control modules 43
13. The hydraulic pump 45
Removing the hydraulic pump 45
 CONTENTS Page
14. Cooling system 47
Removing the cooler 47
Remove the fan hub assembly 48
15. Main electric motor 49
Remove the motor 49
16. Hydraulic fluid tank 51
Draining and filling 52
Complete change of hydraulic fluid 53
17. Hydraulic manifolds (turret) 55
Remove front valve block 56
Remove rear manifold 57
Disassembling a valve 58
18. Slewing system 59
Slewing motor 59
Slewing ring 60
Adjusting gear backlash 61
Swivel 62
19. Electric cabinet 63
Fuse table 64
20. Dismantling the stick 67
Tool link/hitch – disassembling 68
21. Telescope 69
Shimming the telescope 69
22. Boom and boom extension 73
23. Hydraulic pressure tuning 75
Pressure levels 75
24. Remote control 77
25. Grease pump 79
26. Diagrams 81
Electric diagram components 81
Electric circuit 83
Hydraulic circuit 96
27. Software 99
28. Adjust to changed frequency (~50/~60Hz) 101
Adjust pump output flow 101
Adjustment of mains voltage range 102
29. Tools 103
Service tools – supplied 103
Recommended tools – not supplied 103
 Introduction 1

1.Introduction
Workshop Manual
The Workshop Manual includes the most im­
portant workshop procedures that can come into
question on the demolition robot DXR310.
Some very simple and self-evident repairs have
been omitted.
OUTLINE
This workshop manual start with the introduct­
ory sections “Safety” (important safety
guidelines), “Service” (frequently occurring ser­
vice items), “Functional components” (illustrat­
ing the basic design and functionality of the ma­
chine) and “Components orientation” with over­
views of the location of various components and
the corresponding terminology.
The manual goes on to describe in detail
through the different chapters how work on the
basic modules should be carried out, starting
with the undercarriage frame followed by the
pivoting platform and last the Boom—stick.
The last chapters refer to the electric and the
hydraulic system, the remote control, software
1. maintenance and tools recommendations.
×2 10mm Many of the service steps include manoeuv­
ring the hydraulic system when positioning the
machine. This means that as a mechanic, you
will have to carefully read the operator's manual
and make yourself familiar with the remote con­
trolled manoeuvring system.
LAYOUT – PICTURES AND TEXT
The pictures are mostly enough to guide the
mechanic through the various procedures. The
text on the right hand column has further refer­
ences and explanations for the repair work as
well as various warnings involved.
The general principle is that the mounting
procedure is the dismantling procedure in re­
verse.
CONTENTS
The manual is divided into numbered chapters
with chapter headings in bold at the top of each
page.
The list of contents also has page references to
the start of each chapter.

Spare parts
SPARE PARTS DXR310
Article No: 523 02 91–02
The catalogue includes all spare parts for
Husqvarna DXR310.
It contains complete exploded views of the en­
tire machine where each component's position,
spare part number and appearance can be easily
identified.

1
1 Introduction

2
 Safety symbols 2

2.Safety symbols General precautions concerning service on the DXR310

Chemical substances
When performing service READ THE OPERATOR'S MANUAL
tasks involving the use of
• Familiarise yourself with the machine. Read the operator's manual, especially the
chemical substances (such as
sections involving manoeuvring with the remote control system.
hydraulic fluids or retainer
compounds), please refer to • The user's manual contains much information concerning basic service and main­
the instructions from the tenance, which is important in order to keep the machine safe and reliable.
manufacturer.

WARNING
• This symbol indicates that hazardous safety risks to persons must be avoided.

• This symbol indicates when risk of machine damage should be avoided.

HIGH VOLTAGE
• Risk of electric shock. Service work on the machine should be performed with the
power cable disconnected.

RISK OF FIRE
• The machine contains flammable liquids and components.
• Ensure that there is a fire-extinguisher on site at the workplace.

HEAV Y WEIGHT
• Lifting or movement of heavy objects may be required. Take proper precautions to
prevent accidents.

SECURE WORK PIECE

• Secure parts carried by the hydraulic system, especially when standing or reaching
in under machine parts. A faulty machine may loose hydraulic pressure and sink
or tip!
• Use jack stands, lifting straps from a traverse or a forklift of sufficient capability.
– Once secured – never rotate turret; otherwise the weight balance is
compromised!

HIGH PRESSURE HAZARDOUS FLUID

This machine has a complex hydraulic system. Most service points therefore involve a
risk of exposure to hydraulic fluid, often with high pressure.
• Protect eyes, hands and skin from hydraulic fluids.
• Take proper precautions to carefully reduce pressure and collect spills.

AVOID POLLUTING HYDRAULIC SYSTEM

• Dust particles must never reach inside the hydraulic system!
• Before service, clean the area concerned thoroughly.
• Pay extra attention before exposing the interior of any hydraulic parts.
Wipe clean with a solvent and use compressed air to remove any dust or debris.
• Always plug openings to reduce spill and exposure to dust.

3
2 Safety symbols

4
 Checks | Troubleshooting | Specifications 3

3.Checks | Troubleshooting | Specifications INTRODUCTION

This chapter comprises various systematic check lists as well as troubleshooting and
service components specifications and recommendations.

Important precautions
Warning! Reduce risks, avoid accidents
Plan and prepare the work to prevent accidents. Most accidents occur during trouble shooting, service and
maintenance as staff have to locate themselves within the ma­
chine's risk area.
Disconnect power cable and position it so that it If service operations or trouble shooting does not require the
cannot be connected by mistake. machine to be switched on.
Be aware of risks When working with or in the vicinity of moving parts if servi­
cing operations require the motor to be in operation.

Area of precautions Measures to take in advance of maintenance, service and trouble shooting
General • Ensure that the machine is situated in a safe area.
• Place the machine on a flat surface with the boom—stick secured and the outriggers down.
• Do not commence any servicing or maintenance tasks if the machine has been in use. Several components heat
up during work with the machine.
• Set out clear signs to inform persons in the vicinity that maintenance work is in progress.
• Ascertain the location of fire-extinguishers, medical supplies and emergency telephone.
Protective equipment • Wear personal protective equipment.
• Use approved lifting devices to secure and lift heavy machine parts.
• Ensure that there is equipment to secure machine parts mechanically.
Working environment • Ensure sufficiently illuminated in the working area to create a safe working environment.
• The area around the machine must be free of dirt in order to minimize the risk of slipping.
• Ensure that there is a sufficiently large working area.
• Clean the machine.
Discharge pressure and • Discharge pressure in the hydraulic cylinders by taking the load off the boom--stick by resting it on the ground.
stored energy in the hydraul­ • Undo the air filter so that the overpressure in the reservoir is discharged.
ic system • Wait until pressure has decreased via internal leakage.
• When maintaining the track unit, discharge the pressure in the accumulator. Refer to the directions under “Func­
tional inspection” in the “Maintenance and service” section.
Reduce risk of electric chock • Turn off the motor.
• Put the main switch in the OFF position (0).
• Disconnect the power cable and place it so that it cannot be connected by mistake.
Dismantling • Secure moving parts mechanically before loosening screw joints or hydraulic hoses.
• Pipe and hose couplings can remain pressurised despite the motor being switched off.
Take great care when undoing connections and use appropriate personal protective equipment.
• Mark all cables and hoses that are undone in conjunction with service and maintenance in order to ensure cor­
rect reassembly.
Test running the machine • The machine's movements can be defective if a terminal, cable or hose is incorrectly mounted.
Be prepared to turn the machine off immediately in the event of a fault.

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3 Checks | Troubleshooting | Specifications

Cleaning
Precautions
Turn off the motor Disconnect the power cable and place it so that it cannot be connected by mistake.
Minimize the risk of slipping The area around the machine must be free of dirt.
Use suitable personal protective equip­ • There is a risk of getting dirt and harmful substances sprayed into the eyes.
ment • Dirt and harmful substances can be released from the machine when using high pressure equip­
ment.
• High-pressure jetting using water or air can permeate into the skin and cause serious injury.
Never aim a high-pressure jet towards the skin!

CLEANING METHOD
The cleaning method varies depending on type of contaminants and how dirty the machine is. A mild degreasing agent can be used. Avoid skin
contact.
Bear the following in mind when using high-pressure washing:
• High-pressure washing with the wrong nozzle or high pressure can damage electrical components, electrical cables and hydraulic hoses.
• The high pressure jet can damage seals and lead to water and dirt permeating into the machine, resulting in serious damage.
• Stickers can be washed away.
• The surface finish can be damaged.
NB! High-pressure washing and compressed air should be used with extreme caution. Incorrect use can damage the machine.

CLEANING OF COMPONENTS
Several components require special consideration when cleaning:
Component Precautions
Hydraulic tank • Place a plastic bag over the tank's air filter and seal it with a rubber band to avoid water getting into the tank.
Cooler • Allow the cooler to cool down before cleaning. Use compressed air to clean the air fins. If necessary, use high-pressure
washing and degreasing agent.
• Incorrect use of high-pressure washing or compressed air can distort the cooler's fins and thereby impair the cooling
capacity.
– Max. pressure: 100 Bar.
– Spray directly towards the cooler, in parallel with the fins.
– Keep a distance of about 40 cm between the cooler and the nozzle.
Electric components • Clean electric motor, electric cabinet, terminals and other electrical components with a cloth or with compressed air.
• Do not spray water at electric components.
• Wipe the remote control with a damp cloth.
• Never use high-pressure washing.
• Blow clean internally using compressed air.

AFTER WASHING
• Lubricate all the machine's lubrication points.
• Blow electrical terminals dry using compressed air.
• Exercise caution when the machine is started after washing. If any components have been damaged due to moisture, the machine's move­
ments can be defective.

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 Checks | Troubleshooting | Specifications 3

Service schedules
The service schedules are based on the machine's operating time. More frequent service intervals might be necessary when working in dusty or hot
environments and in conjunction with work that generates high temperatures. A description of how the operations are to be performed is to be
found in the relevant section of this manual and in the operator's manual.
Check Daily service* Weekly service*
Lubrication • Cylinders and shafts of boom—stick and tool attachment. • Outrigger cylinders and shafts, and slewing ring.
• Tools. • Grease nipples and Slewing gear ring.
Cracks • Cylinders and shafts in lower part and outriggers. • Boom—stick.
• Cylinders and shafts of boom—stick and tool attachment.
• Tools.
Mountings • Cylinders and shafts in lower part and outriggers. • Bolts, fasteners and shafts.
(Re-tighten) • Cylinders and shafts of boom—stick and tool attachment. • Drive, track unit sides and track tensioning.
• Tool and adapter plate. • Power unit (motor, fan, fan housing).
Level check • Hydraulic fluid. • Hydraulic fluid.
• Hammer lubrication. • Hammer lubrication.
Wear and damage • Cylinder and shafts of boom—stick and tool attachment. • Outrigger shafts and cylinders, slewing ring.
• Visible hoses (boom—stick, outriggers, etc.). • Drive, track slides and track tensioning.
• Power cable, connectors and sockets. • Hoses.
Leakage • Outrigger cylinders. • Hoses.
• Cylinders of boom—stick. • Other hydraulic components.
• Visible hoses (boom—stick, outriggers, etc.).
• Tool.
Function • Outrigger cylinders and shafts. • Drive, track slides and track tensioning.
• Cylinders and shafts of boom—stick and tool attachment. • Cooler.
• Power cable, connectors and sockets. • Slew motor.
• Tool. • Hammer lubrication.
• Emergency stop/machine stop.
Cleaning • Clean the entire machine and the cooler.
*Daily maintenance must also be carried out after transportation as well as before the weekly service

FIRST 100 HOURS SERVICE 500 HOURS SERVICE

After the first 100 hours, the following maintenance should be carried Carry out the 250 hours service as per the service schedule before you
out, subsequently every 1,000 hours. perform the 500 hours service.
Hydraulic motors Change Reference Item Action References
Slew motor, slew re­ • Oil See chapter 18, “Slewing motor ser­ Hydraulic fluid • Change See chapter 15, “Draining/Filling the
duction gear unit vice” reservoir”
Drive motor, drive • Oil See chapter 6, “Drive motor service” Fluid filter • Replace See chapter 15, “Hydraulic fluid fil­
gear ter”
Air filter • Replace See chapter 15, “Air filter”
250 HOURS SERVICE
Carry out the weekly service as per the service schedule before you per­
form the 250 hours service. 1,000 HOURS SERVICE
Carry out the 500 hours service as per the service schedule before you
Item Checks
perform the 1,000 hours service.
Mountings • Drive motor
Hydraulic motors Change References
(Re-tighten) • Slewing motor.
Slew motor, slew re­ • Oil See chapter 18, “Slewing motor ser­
• Slewing gear ring.
duction gear unit vice”
• Check / re-tighten slewing ring bolts:
• Frame, Base-plate Drive motor, drive • Oil See chapter 6, “Drive motor service”
gear
Level check • Slewing motor, see chapter 18.
Function • Track drive motor.
• Slewing motor.
• Slewing ring (also lubricate).
Miscel­ • Hydraulic pump. Check for unusual sounds.
laneous
• Hydraulic hammer. Check bushing and wrecking bar.

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3 Checks | Troubleshooting | Specifications

Lubrication
Warning!
Ensure that nobody starts the machine while service is taking place.
•Turn off the motor when the machine has been moved to the desired location.
•Disconnect the power cable and place it so that it cannot be connected by mistake.
Lubrication Note
General • Position the machine to allow access to all grease nipples • Always apply lubrication in the same order to easily remember all
(as illustrated). lubrication points.
• Clean nipples before greasing. • Use lubricating grease according to the “Hydraulic fluid and lub­
• Replace broken or blocked nipples. rication” table in the “Technical data” section.
• Grease type: See under “Guide values and specifications”
• Connect grease gun and pump 3—5 strokes, until grease
penetrates through shims area.
Outriggers and • Lubricate all joints and cylinder mountings. 1. Rear outrigger joints (2) 9. Extension cylinder (2)
boom—stick 2. Rear outrigger cylinders (4) 10. Stick cylinder (2)
3. Front outrigger joints (2) 11. Stick joint
4. Front outrigger cylinders (4) 12. Tool cylinder (2)
5. Boom cylinder (2) 13. Lever joint
6. Boom joint 14. Tool joints (2)
7. Extension joint 15. Link joint
8. Telescope cylinder (2)
Slewing ring Three of the four slewing ring grease nipples are accessible at
a time. 16. Slewing gear (×1 nipple) 17. Slewing ring bearings (×4
To distribute the grease evenly; apply, rotate and then nipples)
apply again:
• Connect a grease gun and grease the nipples:
I. Stand at a safe distance Caution! – Follow lubrication instructions!
II. Start the machine Risk of displacing the gear ring's seals:
III. Rotate the turret 90° • A displaced gear ring seal will expose the bear­
IV. Switch off the motor ings to dirt and slewing ring must then be re­
• Repeat this procedure three times in order to lubricate the placed.
gear ring's bearings and teeth throughout a 360° circle.

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 Checks | Troubleshooting | Specifications 3

Mountings & Tightening torque

Mountings Tightening torque
General • All components must be properly secured and tightened General Use abutment when torquing through shafts to avoid the
to avoid wear damage. shaft rotating.
• A bolted joint that is secured with adhesive should not be Position Component(s) [Nm]
re-tightened. Simply check that it is firm. If it has come
A Slewing ring, ring—frame bolts (see chap. 18) 81
loose, clean the threads before applying new adhesive.
• Check shafts for proper mounting/locking by re-tighten­ B Slewing ring, turret—ring bolts (see chap. 18) 81
ing with a torque wrench. C (1—15) Outriggers, Boom—stick shafts (see chap. 6, 7) 175
• Check lock pins for damage or faulty mounting. D Track sides (see chap. 8) 500
Shafts • New shafts and tapered lock rings must be re-tightened E Tool against adapter plate 197
frequently until they have bedded in.
• Centre shaft and re-tighten evenly (See chapter 6). Torque for occurring metric fasteners
– Wear damage on the tapered lock rings is a typical SS—ISO 8981/1 rating
sign of insufficient tightening.
Type 8.8 [Nm] 10.9 [Nm] 12.9 [Nm]
SHAFT CHECK LIST: 8. Telescope cylinder (2) M5 5,7 8,1 9,7
1. Rear outrigger joints (2) 9. Extension cylinder (2)
Coarse M6 9,8 14 17
2. Rear outrigger cylinders (4) 10. Stick cylinder (2)
3. Front outrigger joints (2) 11. Stick joint pitch M8 24 33 40
4. Front outrigger cylinders (4) 12. Tool cylinder (2) threads M10 47 65 79
5. Boom cylinder (2) 13. Lever joint M12 81 114 136
6. Boom joint 14. Tool joints (2)
M16 197 277 333
7. Extension joint 15. Link joint
M20 385 541 649

Level checks
General • Position the machine on a flat surface.
• Clean the component before opening for reading or filling. Always prevent dirt entering the sys­
tem.
• If the hydraulic fluid level is low, refill with the type and quality given under “Guide values and
specifications” in this chapter.

Item Check level

Hydraulic fluid • Retract all boom—stick cylinders and fully fold the outriggers. (See chapter 16)
• Refill if the level is more than one cm below the max. mark.
Slew motor gear unit • Locate and loosen the dipstick. Wipe it clean, lower it and check the level. (See chapter 18)
Drive motor gear • Rotate drive track until one of the plugs is in level with the hub centre and the other one is at the
top position. (See chapter 8)
• Unscrew the lower plug. The oil level should reach up to the hole.
Hammer lubrication • Check if there is grease in the tube container. (See chapter 25)

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3 Checks | Troubleshooting | Specifications

Checking for wear and damage - welding

Important!
Deal with worn components as quickly as possible. There is
an increased risk of mechanical breakdown if the machine is
used despite damaged or worn components.
Wear and damage
Shafts • Bearings and any shafts must be replaced in the event of
and slides play in joints and cylinder mountings.
bearings • Replace or repair damaged components:
– Replace bearings if there is play in joints.
– Replace shafts if they have wear damage.
– Wear damage on a tapered lock ring indicates
that it has not been sufficiently tightened.
– Swing joints must be kept lubricated so that any
dirt that have entered is pressed out, and to re­
duce wear on shafts and bearings.
Rubber • Check that rubber tracks and outrigger feet are intact.
compon­
– Replace if metal has worn through.
ents
Hydraulic • Do not use hoses that are distorted, worn or damaged.
hoses • Make sure that the cords are not visible.
• Always have a spare hose at hand.
– Replace damaged hoses immediately.
• Check that none of the hoses are rubbing against sharp
edges. Be aware of the risk of abrasive jets.
• Adjust the length of hydraulic hoses. They must never be
stretched.
• Ensure that the hose is not twisted while coupling it.
• Avoid sharp bends in the hose.
Hydraulic • Check that the couplings are not damaged. Damaged
couplings couplings may deteriorate hoses with the result that they
come off.
– Replace damaged couplings immediately.
• The hydraulic couplings should be lubricated before
tightening to reduce friction.
Electric • The power cable must be disconnected when electric
cables cables are checked!
– Check that the cables' insulating casings are not
damaged.
– Replace damaged cables immediately.
Important!
Leakage can cause serious mechanical breakdowns and an
increased risk of slipping. Wash the machine regularly to in­
crease the chance of defecting leakage at an early stage. Deal with leaks
as quickly as possible and refill when necessary.
Leakage
Hydraulic • Leakage of hydraulic fluid leads to an increased risk of
fluid dirt getting into the hydraulic system, which can lead to
breakdowns and mechanical damage.
• Any hydraulic fluid underneath the machine or on the
base plate it is probably due to leakage.
• Check for leakage at the hose connectors, couplings and
cylinders. Leakage can also occur at other hydraulic com­
ponents and can manifest itself with a strip of dirt.
• Increase temperature to find leak:
– Cover cooler and run outriggers up/down.
• Check O-rings and replace if damaged.
Cracks
General A clean machine makes it easier to detect cracks.
• The greatest risks of crack formations are:
– Weld seams.
– Holes or sharp corners.
Check in particular for cracks:
Undercar­ • Around outrigger mountings, both on the undercarriage
riage frame and on the outriggers, gear ring mounting and
frame weld seams between the frame and the track units.
Boom-- • Boom—stick joints, cylinder mountings and weld seams.
stick

Welding work on the machine

General Only qualified welders should carry out welding operations on the machine.
Important! Risk of fire. The machine contains flammable liquids and components.
– Do not undertake any welding in direct connection with flammable liquids, e.g. in the vicinity of tanks,
fuel lines or hydraulic pipes.
– Ensure that there is a fire-extinguisher on site at the workplace.
Risk of inhaling harmful substances. Toxic gases can be formed.
– When welding indoors, use equipment to extract welding fumes.
– Never weld in the vicinity of rubber or plastic material. Use a breathing mask.
Components that should The following components should not be repaired but replaced:
not be welded – Tool hitch – Adaptor plates – Hydraulic reservoir
– Tool link and lever – Cylinders – Cast parts
– Cotters
Recommended welding wire Flex cored wire • Esab OK 14.03 Tubrod, Class: AWS A5.28 E110C-G
Solid • Elgamatic 100, Class: AWS A5.18 ER70S-6
Rod • Esab OK 75.75, Class: AWS A5.5 E11018-G

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 Checks | Troubleshooting | Specifications 3

Functional inspections
Functional inspections ensure that the machine's functions are intact.
Item Functional inspection
Brake functions Check the drive brake's function by operating the machine on a slope.
– Release the joysticks.
– The machine should then be braked and remain stationary.
Check the slew brake's function by rotating the boom—stick on a slope.
– Release the joysticks.
– The boom—stick should then be braked and stop gently.
Cooler Clean the cooler when necessary. Overheating has a negative effect on the service life of the machine's components.
Refer to “Cleaning the machine” in the “Maintenance and service” section.
Cylinders Checking cylinder barrels and piston rods must be done with the cylinders extended to the end position. Replace
damaged components immediately.
– Check that the cylinder barrels are not dented or cracked.
– Check that the piston rods are undamaged and straight. A damaged piston rod causes contamination in
the hydraulic system, resulting in mechanical damage.
Tool attachment Warning! The tool hitch cotter and pin are important safety components. A worn or damaged cotter must be re­
placed with an original spare part; manufacturing your own cotter is not permitted.
• Check that the tool hitch is complete and that all parts are intact and correctly mounted.
Automatic track tensioning • The rubber tracks are tensioned automatically when the outriggers are lifted.
• If demolition material or suchlike enter into the side of the tracks during operation, their spring function should
prevent breakdowns and stoppages.
• The spring function consists of a hydraulic accumulator.
Checking track tension The track must not slacken by more than 10—15 mm.
– Operate the outriggers up and then down.
– Wait 15 minutes and then check.
– The tracks can become slack due to one of the track tensioning function's non-return valves being
blocked or broken.
Cleaning check valves The check valves can be cleaned by discharging the pressure in the accumulator and thus loosening the tension of
the tracks.
– Pull out the valve knob and rotate it a ¼-turn to lock it in an opened position.
– Operate the outriggers up and down.
– Hydraulic fluid is then pumped around, cleaning the non-return valve.
– Rotate and release the valve back into position.
– Operate the outriggers up and down to tension the track.
Hammer lubrication • Check that grease is reaching the hammer by dismantling the grease hose at the hammer.
• Start the machine and activate the hammer function.
• Exercise great caution during the inspection to ensure that nobody is injured.
Tools • Check that the tool can be used in such a way that neither the operator nor people in the vicinity are exposed to
unnecessary risks.
• Refer to the supplier's Operator's Manual for other checks.

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3 Checks | Troubleshooting | Specifications

Change or Replace

Important! • Chemicals such as degreasing agent, grease, glycol and hydraulic fluid can cause allergies in conjunction with re­
peated skin contact. Use protective equipment!

General • Changing liquids and replacing filters must be done in such a way that the machine's hydraulic system and the sur­
rounding environment are not damaged.
– Dispose of residual products according to local laws.
• Position the machine on a flat surface.
– Discharge the machine and allow it to cool.
• Clean the component before opening it for refilling in order to prevent dirt getting in.
• If the level is low, fill in according with the instructions
Item Change or Replace (For further reference: See chapter 15)
Hydraulic fluid Important! Allow the machine to cool. Hot fluid can cause severe burn injuries.
• Check which quality of hydraulic fluid the machine's hydraulic system contains before refilling or changing.
– The machine's hydraulic fluid quality is indicated on the sticker on the machine's hydraulic tank.
– Mixing different types of hydraulic fluid can damage the machine.
• Refer also to “Guide values and specifications” for choice of suitable hydraulic oils.
Draining hydraulic fluid • Manoeuvre the machine with the boom—stick cylinders fully retracted and the outriggers completely folded.
• Undo the air filter so that the overpressure in the tank is discharged.
• Place a collecting vessel under the tank's drain plug and open the plug.
• Screw on the drain plug when all the liquid has drained out.
• Changing oil filters – refer to “Oil filter” in the “Maintenance and service” section.
• Tighten the air filter.
• NB! Do not start the motor when the hydraulic tank is empty. Otherwise the hydraulic pump will be damaged.
Replenishing Hydraulic The machine is equipped with a refill pump.
fluid • Manoeuvre the machine with the boom—stick cylinders fully retracted and the outriggers completely folded.
• Clean the refill pump suction hose. Remove the plug and put the hose into the fluid container.
• Push the refilling button to activate the pump.
• Use the fluid level sight gauge when refilling.
• Start the machine and operate the cylinders between outer and inner end position a number of times to remove
air that might have entered the hydraulic system while refilling.
Oil filter Important! Allow the machine to cool. Hot oil can cause severe burn injuries.
• Undo the air filter to discharge any tank pressure.
• Thoroughly clean the outside of the filter and the surrounding parts.
• Remove the filter cover. Lift up the sealing ring, the spring and the filter holder together with the filter cartridge.
• Remove the filter cartridge from the filter holder.
• Check whether there is an unusually large amount of the large metal particles or sealing compound in the filter
holder. If this is the case, the machine's hydraulic system must be checked for faults.
• Clean the filter holder with degreasing agent. Rinse with warm water and blow dry using compressed air.
• Install the new filter in the filter holder and put it in the tank. Install a new sealing ring.
• Install the spring and the filter cover.
Air filter • Thoroughly clean the outside of the filter and the surrounding parts.
• Replace the filter.

12
 Checks | Troubleshooting | Specifications 3

Troubleshooting – error messages

Error messages – operation

!
Error messages
Service message Information without direct danger for the operator or the machine.

▲ Warning Faults or safety defects that can cause personal or mechanical damage.
• All error messages that have been acknowledged remain as small yellow red warning triangles in the field for service.
– To overview all warnings: Bring up the service menu and select “Warnings”.
– The messages are listed in order of priority, highest priority first.
• When a fault that has in some way restricted the machine's functions ceases, a message appears on the display. This mes­
sage must be acknowledged for the machine to return to full functionality.
Service messages • When service messages appear on the display, the operator is informed by the work light flashing three times.

! • The service message remains on the display until the operator has acknowledged it.
– The message disappears from the display and is replaced by a yellow warning triangle in the field for service.
– The triangle symbol remains for as long as the message is current.
Actions Oil temperature is above T_high1 • Hydraulic fluid temperature is above 80°C (176°F).
• Put the machine into circular pumping mode to cool the hydraulic fluid.
! Oil filter needs to be changed • Change the hydraulic fluid filter at once.
Low battery • Approx. 30 min. operating time left.
• It is not possible to activate the remote control if the battery capacity is too low.
• Change/recharge the battery.
Warnings • When an error message appears on the display, the operator is made aware of it through the work light flashing continu­
ously.
– The machine is put into idling mode in connection with the warning.
– If message is not acknowledged within 10 seconds, the horn signals thrice and the motor is turned off.
▲ • The operator acknowledges the warning message by selecting override.
– The light stops flashing and the message disappears from the display and is replaced by a red warning triangle in
the field for service.
– The triangle symbol remains for as long as the message is current.
– In override mode, the tool is blocked, but machine movements can be carried out at 50% speed. This function
is intended for moving the machine away from hazardous areas.
Actions Oil temperature above Thigh2 • Hydraulic fluid temperature over 90°C (194°F).
• Put the machine into circular pumping mode to cool the hydraulic fluid.
Oil temperature below Tlow • Oil temperature below 10°C (50°F).
• Cover cooler, lift machine and run tracks until fluid reaches 40°C (104°F).
Phase error • Voltage too high/low or out of phase.
• Check incoming voltage or if a phase has been lost.
▲ Motor Over Temperature • Turn off the machine and wait until the temperature has dropped.
• Normal operation can be resumed when the temperature has normalised.
NO OIL PRESSURE • Fault in the phase sequence relay resulting in motor and pump running in the wrong
direction.
– Check that the motor is running in the right direction.
• If the problem persists, contact service.
IDLE PRESSURE TOO • The hydraulic fluid pressure does not fall when the machine is put into circulation
HIGH pumping mode.
– Check the circulation valve: Cable / contact LED
Machine stop • A message will appear in the display at start up:
– if machine stop on remote control is pressed
• Check and confirm the message.

13

14
Display message
Oil temperature is above
T_high1
Oil temperature is above
T_high2
Oil temperature is below
T_low
Oil temperature is above
measurable range
Oil temperature is below
measurable range
Oil pressure in idle mode
too high
Oil pressure too low
Oil pressure is above al -
lowed maximum
Oil filter need to be
changed
No hydraulic pressure de -
tected Please check:- Motor
rotation - Oil level
Phase error
Motor over temperature
Check if Emergency Stop is
pressed or contact
Husqvarna Service Center
Terminal lost for more than
120 seconds
ServiceRequest
Warning State2 no longer
active Machine will return
to normal operation
Cause
oil temperature exceeds first limit
▲ value: 80°C
oil temperature exceeds second lim - Put machine into circulation pump -
▲ it value: 90°C ing mode.
oil temperature below lowest limit
▲ value: 10°C
oil temperature exceeds thermal
▲ sensor range
oil temperature below thermal
▲ sensor range
pressure during circulation pump -
▲ ing too high
pressure during circulation pump -
▲ ing too low
oil pressure exceeds pressure sensor
▲ range
hydraulic fluid filter needs to be re -
▲ placed
Warns if pressure falls below 2 Bar
▲ with running motor
Phase error on inbound 3-phase
▲ if a phase is gone
motor temperature too high
▲ temperature has dropped
Pressed emergency stop on ma -
▲ chine. Or faulty safety relay, or soft
starter. Or faulty PLC 1 or radio
module
Machine has not been linked with
▲ terminal for 2 minutes
All machine warnings have disap -
peared
! full functionality
Error messages – service
Suggested action
Put machine into circular pumping
mode
Run tracks in the air. Optionally,
raise and lower outriggers repeatedly.
Check if thermal sensor is faulty
Check if thermal sensor is faulty
Check circulation pump valve
1) Check if pump generates pressure
2) Check if pressure sensor is faulty
3) Check motor rotation
1) Check HP valve
2) Check if pressure sensor is faulty
replace oil filter
1) Check if pump generates pressure
2) Check if pressure sensor is faulty
3) Check motor rotation
check voltage on inbound phases or
switch off machine and wait until the
1) Check emergency stop of machine
2) Check phase sequence relay
3) Check safety relay
4) Check PLC 1 and radio modules
After acknowledging the message, the
work-light flashes three times
After acknowledgement the machine
will regain full functionality
3
Effect on machine after
How fault is detected Machine indication acknowledgement
Continuously checked from 2 seconds after start up of Work-lights flashes 3 times
primary PLC module (PLC 1 or Epec 2024)
Continuously checked from 2 seconds after start up of If message is not acknowledged within 10 Inactivates tool, machine
primary PLC module (Epec 2024) seconds: Motor stops, circulation pumping movement speed reduced
mode, 3 horn signals, work-lights flashing by 50%
Continuously checked from 2 seconds after start up of If message is not acknowledged within 10 Inactivates tool, machine
primary PLC module (Epec 2024) seconds: Motor stops, circulation pumping movement speed reduced
mode, 3 horn signals, work-lights flashing by 50%
Continuously checked from 2 seconds after start up of If message is not acknowledged within 10 Inactivates tool, machine
primary PLC module (Epec 2024) seconds: Motor stops, circulation pumping movement speed reduced
mode, 3 horn signals, work-lights flashing by 50%
Continuously checked from 2 seconds after start up of If message is not acknowledged within 10 Inactivates tool, machine
primary PLC module (Epec 2024) seconds: Motor stops, circulation pumping movement speed reduced
mode, 3 horn signals, work-lights flashing by 50%
Continuously checked from 5 seconds after activation of Work-lights flashes 3 times
machine circulation pumping mode
Continuously checked from 5 seconds after activation of Work-lights flashes 3 times
machine circulation pumping mode
Activated when oil pressure has exceeded pressure sensor If message is not acknowledged within 10 Inactivates tool, machine
range for 0.1 seconds seconds: Motor stops, circulation pumping movement speed reduced
mode, 3 horn signals, work-lights flashing by 50%
Activates when the filter sensor, during 20 seconds, de - Work-lights flashes 3 times
tects that the fluid filter needs to be replaced. The warn -
ing is inactivated when the filter sensor, during 60
seconds, detects that the filter is OK.
Checked once when soft-start indicates start of electric Work-lights flashes 3 times
motor
Continuously checked from 2 seconds after start up of If message is not acknowledged within 10 Inactivates tool, machine
primary PLC module (Epec 2024) seconds: Motor stops, circulation pumping movement speed reduced
mode, 3 horn signals, work-lights flashing by 50%
Continuously checked from 2 seconds after start up of If message is not acknowledged within 10 Inactivates tool, machine
primary PLC module (Epec 2024) seconds: Motor stops, circulation pumping movement speed reduced
mode, 3 horn signals, work-lights flashing by 50%
1) No indication from soft-start relay that motor has Activates motor stop relay after 10 seconds
started within 10 seconds from release of soft-start relay.
2) Oil pressure is below 2 Bar, 10 seconds after release of
start relay.
Checks | Troubleshooting | Specifications
Activates if machine has not received correct increment - Prevents start of machine
al signals from terminal during 120 seconds
Work-lights flashes 3 times
Work-lights flashes 2 times After acknowledgement
the machine will regain
 Checks | Troubleshooting | Specifications 3

Troubleshooting guide
Troubleshooting guide
Fault Possible cause Suggested action
• Most accidents involving machines occur during trouble shooting, • This troubleshooting guide will provide tips to facilitate the trouble
service and function
An individual maintenance as staff have
is running to locate in
Restriction themselves within
a hydraulic hose. shooting• process.
Extend an unloaded cylinder to its end position and
slowly.
the machine's risk area. Prevent accidents by being alert and by check
• Always start the pump
by checking anypressure in the display
error messages on the(under
remote“Service”).
control.
planning and preparing the work. Please refer to “Important pre­ • Ifinstructions
Follow the you do notforgetthe
maximum pressure
respective messagethis
in indicates a re­
accordance
parations” in the beginning of this chapter. striction
with the error in the
messages hose. Change hose.
section.
• If service operations or trouble shooting does not require the ma­
Valve spool runs with friction. Clean valve spool (see chapter 17).
chine to be switched on, the power cable must be removed and po­
Faultby
sitioned so that it cannot be connected in mistake.
the pilot control valve. Check visually. Replace if spool is scratched or deformed.
An individual function is not Joystick in an operative position when start­ Restart the remote control with the joystick in neutral posi­
working. ing the remote control. tion.
Fault Fault in thePossible
pilot control
causevalve or the spool Check visually. Replace if spool
Suggested is scratched or deformed.
action
in the valve is stuck or damaged.
Electric motor does not start. Emergency stop/machine stop is Check that the emergency stop or machine stop button are not
The machine sinks on the blades. pressed.
Leaking check valve (pilot controlled) pressed
on the byCheck
turning them
valve clockwise.
on cylinder housing.
blade cylinder.
A fuse has blown. Check that the mains voltage is compatible with the machine and that
Jerky movements of boom—stick The hydraulic fluid has been heated up theincorrect
a Wait fuses
forare used. to heat up machine.
machine
Too
coldlow mains voltage to machine. Check power supply on phase relay and ensure correct voltage.
machine.
Fuses for the mains connection The rating
A valve of the
piston machine's
is seizing duefuses is Check that
to contamina­ the valve
Clean mainsthoroughly.
voltage is compatible with the machine and that
blow when starting. too
tion.low. the correct fuses are
Replace used.with visible scratches.
pistons
Electric motor blown (sharp smell). Replace electric motor (see chapter 15).
Broken O-rings in the pilot control valve. Replace old/faulty O-rings.
The hydraulic pump has cut out . Fluid filter full of debris is a good indicator. Replace hydraulic pump
Fault in the servo circuit. Replace
(see chapter 13). servo circuit.
Machine works but the motor Too
Faultlow
in mains
the LS voltage to thesystem.
load sensing ma­ Check power
Check supply and Should
pressure. ensure correct
be 20±1voltage.
Bar (see chapter 22).
speed decreases substantially dur­ chine.
Cylinder
ing sinks*
operation. Contamination in the hydraulic system. • Check for possible leaks.
Incorrectly dimensioned power Ensure that the power cable is correctly dimensioned. Refer to “Mains
• Change hydraulic fluid and replace fluid filter.
cable. connection” in next section “Guide values and specifications”.
Motor runs but the hydraulic func­ Not Leakage in the
enough cylinder.fluid in the • Stop the
hydraulic Locate
motor theatleak
once.and replace any damaged components.
tions have no power or do not work tank. (Knocking
Defective valve. noise coming from • Investigate
Check and rectify
valve any leakshousing.
on cylinder there might be.
at all. the pump). • Replenish hydraulic fluid (see chapter 16).
Faulty counter balance valve. Clean with pressured air or replace if necessary.
Circulation valve open. • Check diode on valve cap at the bottom of front manifold valve.
* If cylinder 3 (stick) or 4 (tool) slowly sink (aprox.
(see 1chapter
cm/min),17)
this is entirely normal as they do not have any counter balance valves.
• If the circulation valve is open, the diode does not light up.
Overheating in the hydraulic Cooler blocked or obstructed. –Clean
Check thecable
cooler.
to the control module.
system. –UseCheck forcooling.
magnetic field (feel with small screw driver).
Too high ambient temperature. forced
Fault in the pump regulator. • Extend an unloaded cylinder to its end position and check the
Maximum pressure or pressure at rest set Check pressure values (see chapter 22).
pump pressure in the display (see chapter 22).
too high in the pump.
• If you get maximum pressure the pump regulator is OK.
Defectiveathose
Pressure or coupling.
rest set too low. Replace faulty component.
• Activate the remote control without running any functions and
Restriction in main line or line to tool. check the setting
Replace for pressure
faulty component. at rest in the display.
• The pressure should be 20±1 Bar.
Power extraction too high due to faulty or Check that tool pressure and flow are compatible with the
unsuitable tool. For accurate
–machine's reading; remove and plug LS hose from pump
specifications.
while checking pressure (see chapter 22).
Boom—stick movements and tool Tool Defective
speedhydraulic
adjustment pump.
and Slow mo­ • AdjustReplace hydraulic pump (see chapter 13).
speed settings of the two remote control knobs. (See chapter
function run slowly. tion
Check control
the fanononthetheremote control
radiator. 4, “Remote
Replace control”:
fan with item 28—29) if faulty (see chapter 14)
DC-motor
have been set too low.
Knocking noise in the hydraulic Not enough hydraulic fluid in the tank. • Stop the motor at once.
system Pressure at rest is set too low. • Activate the remote control without running any functions and
• Investigate and rectify any leaks there might be.
check the setting for idle pressure in the display.
• Check level of hydraulic fluid (see chapter 16).
• The pressure should be 20±1 Bar (see chapter 22).
Remote control terminal does not •AirFlat in battery.
the hydraulic fluid. Run thesymbol
• If the display machine without
is red, checka load untilbattery
that the air andforfluid have sep­
the remote
work. arated.
control is charged and correctly inserted.
•Defective hydraulic pump.
No communication between re­ • Green Replace symbol in hydraulic pump
the display (see chapter
indicates 13).
contact.
Discoloured hydraulic fluid. mote control and machine. • Ensure that the correct remote
Cloudy grey fluid indicates water in the sys­ • Investigate and rectify the cause of water control is being used.
entering.
tem. • Check•that Change hydraulic fluid and replace the cable
the communication cable and aerial filter. on the ma­
chine are properly secured – test run the machine.
Black fluid indicates coke formation due to •that
• Check Investigate
diodes ofand rectifyBluetooth
machine the cause of overheating.
radio module are on.
too high operating temperature. • Change hydraulic fluid
– Check fuse F6 (see chapter 19) and replace the filter.
– Replace radio module

15
3 Checks | Troubleshooting | Specifications

Guide values and specifications

MAINS CONNECTION
The power cable must be dimensioned by a qualified person in accordance with national and local regulations. The mains socket must be dimen­
sioned for the same amperage as the machine's electrical socket and extension cable, e.g. a 63A electrical socket must be preceded by a 63A fuse.
Nominal voltage Min. voltage Cable Max. cable length Starting Motor Setting thermal over­
Frequency
from power at machine area during operation* current** output load relay
[Hz]
source [V] [V] [mm2] [m] [A] [kW] [A]
400 380 50 6 55 90* 22.0 44
10 90
16 145
460 440 60 6 55 90* 25.3 44
10 90
16 145
* Lengths are estimated. Limiting factor is the current required for starting the machine.
** Two phases soft start. The directly related phase can be loaded up to 30% more.

HYDRAULIC SYSTEM PRESSURE

Type of pressure Pressure [Bar]
Pump pressure Tool, max 250
• The pressure in the pipes between pump and main stop valve. Rotating function 170
• The pressure varies between pressure at rest and max. pressure depend­
Outrigger down/up 250/200
ing on which hydraulic functions are being used.
Other functions 200
Pressure cut-off • Functions equipped with pressure cut-off can never be run at a higher Telescopic arm 180
pressure than that indicated.
• The following functions are equipped with pressure cut-off for the re­ (External hand tool
140
spective pressure level. – option)
Pressure at rest The pressure that the pump deliveries when no function is activated and
20 ± 1
the pump around valves is shut.

HYDRAULIC FLUID
Quality Min. starting temp. [°C/°F] Max. temp. [°C/°F] Ideal working temp. [°C/°F]
Mineral oil ISO VG32 -20 / -4 75 / 167 35—60 / 95—140
Mineral oil ISO VG46 -13 / 9 87 / 189 50—75 / 122—167
Mineral oil ISO VG68 -10 / 14 97 / 207 55—80 / 131—176
Always ask the machine manufacturer before using a type of hydraulic fluid other than those mentioned above.
The quality of hydraulic fluid that the machine was supplied with is indicated on the sticker on the machine's hydraulic tank.
Do not mix different types of hydraulic fluid! The hydraulic system may clog and damage the machine.
Check which quality of hydraulic fluid the machine's hydraulic system contains before refilling or changing.

LUBRICANTS
Component Quality Standard
Slewing ring
SAE 80W—90 API GL 5
Drive motor, drive gear
All lubrication points with grease nipples NLGI 2
Tool grease: See Husqvarna Spare Parts

PRE-SET LIMIT VALUES

Description Temperature [°C/°F]
Oil Temperature Hight threshold 1 (Thigh1) 80/176
Oil Temperature Hight threshold 2 (Thigh2) 90/194
Oil Temperature Low (Tlow) 10/50

16
Checks | Troubleshooting | Specifications 3

17
 Components – orientation 4

4.Components – orientation
General exterior
BOOM—STICK
The “mechanical arm” which comprises
boom, boom extension, stick, joints, cyl­
inders and tool hitch with optional tool.
TURRET
Rotates on the chassis with the base of
the boom. Its housing contains the
main motor, hydraulic pump, the main
hydraulic system, the control and elec­
tric system.
UNDERCARRIAGE
Comprises the frame with traction sys­
tem and outriggers for stability.

Undercarriage
Frame and outriggers
1. Undercarriage frame
2. Frame service cover plate
(outrigger/belt tensioning valve block
with tension accumulator)
3. Rubber cover (outrigger cylinders)
4. Belt tension release cover plate
5. Outrigger joint with axis/pin
6. Steel cover (outrigger cylinder)
7. Outrigger for stability
8. Outer cylinder axis/pin
9. Foot with rubber padding
Traction system
10. Traction drive
11. Hydraulic traction motor
12. Rubber track
13. Screw bond for track system unit
14. Track rollers
15. Forward direction indication
16. Track system unit (containing belt ten­
sioning cylinder)
17. Rubber track tension idler
(pushed forwards by belt tensioning cyl­
inder)

19
4 Components – orientation

Turret
RIGHT SIDE
1. Control panel
(a) MOTOR START: Main electric motor
(b) Manoeuvring mode switch
Remote control — Control panel
(c) ON/OFF: Hand tool hydraulics
(d) Hydraulic fluid tank fill pump
(e) STOP: Emergency stop button
(f) ON/OFF switch: Mains power
(g) Hour counter
2. Right hand bonnet/hood lock
3. Front valve (pivot motor and chassis hy­
draulics)
4. Headlight
5. Front lifting lug
6. Rear lifting lug
7. Hydraulic fluid reservoir with filter (lid)
8. Electric cabinet (fuses, wiring etc.)
9. Rear valve (boom and stick assembly hy­
draulics)
10. Automatic tool lubrication pump with
grease tube
LEFT SIDE
11. Left hand bonnet/(hood) lock
12. Horn
13. Hydraulic fluid cooler system
14. Cooling fan (see 25)
15. Counter-weights
• cast part of the pivoting platform
housing comprising the grille
• flat weight bolted underneath the
rear of the platform
16. Front lifting lug
17. Hydraulic pump
18. Manoeuvring signal receiver and elec­
tronics assembly
19. Hydraulic fluid fill pump
20. Hydraulic pump drive axis coupling
tunnel
21. Main electric motor
22. Retractable hydraulic fluid fill hose
23. Rear lifting lug
REAR VIEW
24. Power mains cable
25. Grille for cooling system comprising
electric motor, fan and fluid cooler
26. Indicator lamp for motor on
27. Radio antenna
28. Power mains swivel
29. Emergency stop button
30. Hydraulic fluid level scale
TOP VIEW (FROM FRONT)
31. Slewing motor
32. Hydraulic line swivel (through pivoting
centre)

20
Components – orientation
“Arm-system”
The “mechanical arm” (fixed to the
turret) comprises a two-piece fold­
able/extendable and telescopic
boom with a dipstick (stick). The
two-piece boom with stick is here
referred to as the Boom—stick.
4
Boom—stick
1. Boom (section No 1)
2. Boom extension (section No 2)
3. Inner bulkhead, hydraulic couplings and
bracket with guard
4. Telescope with stick cylinder attachment
5. Outer bulkhead, hydraulic couplings
6. Stick (section No 3)
7. Tool lever
8. Tool hitch
9. Adapter plate
10. Tool
Assembly base attachments
11. Boom cylinder joint at pivoting plat­
form base plate
12. Boom joint integrated in base plate
Cylinders
13. Boom cylinder (No 1)
14. Boom extension cylinder (No 2)
15. Telescope cylinder (No 5)
inside extension tube and telescope
16. Stick cylinder (No 3)
17. Tool cylinder covered with shield (No 4)
Remote control
18. Battery pack
19. Cable signal/power connector
(overrides radio and battery power sup­
ply)
20. Left hand joy stick (with two thumb
function buttons)
21. Left hand operational mode buttons
22. [START] button; main electric motor
23. Display:
Status—Mode options—Fault indication
24. STOP button for main electric motor
25. Right hand operational mode buttons
26. Left hand joy stick (with dual function
thumb switch)
27. Shoulder harness for carrying remote
control
28. [STOP] button
29. Remote control slide on fitting
30. On/Off remote control switch “0—1“
Diode indicating active terminal
31. Tool speed adjustment knob
32. Slow motion control
21
4 Components – orientation

22
 Functional components 5

5.Functional
Functional components
Drive line and hydraulics
MAIN ELECTRIC MOTOR
The electric motor runs at constant speed. It
is the power source for the hydraulic axial
Electric motor piston pump. The motor and pump shafts
50 Hz: 1455 rpm inter-connect by a claw coupling.
60 Hz: 1750 rpm
The hydraulic flow is controlled by the load
sensing pump.

LOAD SENSING HYDRAULIC

CIRCUIT
The pump responds to imbalance detec­
ted by the Load Sensors (LS) whenever
the control valve is altered.

Example:
Extend Retract The operator wishes to remote control an item:
LS Spool
Spool

Control valve
Cooler

1. The joy-stick movement is

translated into a radio signal.

Hydraulic piston pump

Filter
• The signal is transmitted to
the machine's Bluetooth®
receiver.

Reservoir
Swashplate

2. The robot's control module

Load Sensing (LS) Hydraulic Circuit (PLC) activates an accurate cur­
rent to the specific solenoid.
• The current will correspond
to the joystick angle.

3. The precise solenoid induced

spool movement will adjust
the valve.
• This alters the load balance
between the retraction and
extension side of the cylin­
der.

4. The Load Sensors (LS) will de­

tect any imbalance and:
• The hydraulic pump will
build up flow to com­
pensate for the load differ­
ence.
• The swashplate angle (a) will
adapt the pump piston
stroke to achieve ideal hy­
draulic flow.

23
5 Functional components

Hydraulic system
The hydraulic fluid flow/pressure is induced
1 by the pump (c) and then distributed to the
front manifold (d), which in conjunction
with the rear manifold, control various actu­
ators following these principles:
1. TURRET AND
UNDERCARRIAGE
Turret
(a) Hydraulic fluid cooler (return flow)
(b) Hydraulic fluid filter and tank
(c) Hydraulic pump (axial piston)
(powered by main electric motor)
(d) Front manifold
(e) Slewing motor (fixed to pivoting plat­
form with sprocket in slewing ring
(fixed to chassis)
(f) Hydraulic line swivel through pivot­
ing centre
Undercarriage
(g) Traction motor (two lines to each
side)
(h) Belt tension cylinder (each side)
(powered by blade cylinder pressure)
(i) Frame manifold with belt tension ac­
cumulator
(j) Outrigger cylinder (two lines to each
cylinder)

2. THE BOOM—STICK
(a) Hydraulic fluid cooler (return flow)
(b) Hydraulic fluid filter and tank
(c) Hydraulic pump (powered by main electric motor)
(d) Rear manifold
(e) Tool hydraulics
(f) Boom cylinder
(g) Boom extension cylinder
(h) Stick cylinder
(i) Tool lever cylinder
(j) Telescope cylinder

24
 Common service tasks 6

6.Common service tasks This chapter describes some frequently occurring service tasks. Also described are
some general recommendations on safe positioning of the demolishing robot for
good and ergonomic reach, when performing various service work.

Shafts of joints and

cylinders
Prepare disassembling by checking that the
weight of concerned structure is safely bal­
anced and hydraulic hoses are properly re­
moved or tied up in a secure manner as de­
scribed further on in this chapter.
REMOVE THE SHAFT
×2 24mm
1. Remove the bolt and washer on both
sides of the shaft
2. Fit in a bolt and use a socket with an ex­
tension that matches the length of the
shaft
(a) Use a mallet to knock out the tapered
lock ring
– change side to knock out the other
lock ring and knock shaft through
– if shaft seems stuck, try again
from the other side
3. Try to reduce the load on the shaft when
taking it out
ASSEMBLING A JOINT SHAFT
WITH SHIMS
Due to heavy intermittent loads, all joints
should be fitted as firmly as possible. This al­
lows for high precision when operating the
machine
4. Insert the axis partially as illustrated
• Check the amount of shims needed
to achieve a firm fit
• Fit in half of the shims and fit the
axis shaft through
5. Position the axis shaft to the other side,
as illustrated
• Fit in the remaining shims

6. Centre the axis shaft accurately

Fit in on each side:
(a) the tapered lock ring, greased inside
(b) the washer
(c) the axis bolt
• Tighten the two bolts evenly at
175Nm. Both lock rings
should be equally visible
(d) Lubricate the shaft by pressing in
grease through the axis nipple
• Excess grease should penetrate
out through the shims area
ASSEMBLING A CYLINDER SHAFT
×2 24mm Assemble in the same manner as a joint
shaft (see above).
• No shims are needed for cylinders

τ =175Nm
TIGHTENING TORQUE
Tighten all shaft bolts by 175Nm.

25
6 Common service tasks

Hydraulic lines/couplings
Preparation
Position the machine into a
pressure free state.
Balance and secure structure in
a safe manner!
Make sure hydraulic coupling
areas are absolutely clean before
opening!
• Take care of the spill; put a vessel or an ab­
sorbent sheet under the coupling
THREADED COUPLINGS
1. Mark lines and hoses for your own refer­
ence and gently loosen the coupling.
Use two spanners not to twist hose
Avoid hazardous spray! Use eye-
protection. Check that hoses
are pressure free.
2. Keep clean and reduce spill by plugging
the openings
(a) a tight fit plastic hat
(b) a nylon line plug
Maintaining hydraulic pressure
3. Use a metal PO-plug (c) when
maintaining operability of the hydraulic
system is desired
Reassembling threaded couplings
4. Check that the O-ring is positioned
correctly in its slot
– Replace O-rings with cracks or
signs of wear
Reverse the steps as in 1—2 above.
QUICK COUPLING (WEO)
5. Use a slotted screw driver or suitable
players to pull off the red WEO-clip
6. Release coupling
I. Press in the coupling to detach
II. Pull out hose coupling
7. Reassembling quick coupling (WEO)
I. Fit WEO-clip in its' slot
II. Press in hose coupling until WEO-
clip is in contact with female
coupler

HOSES
8. Check that hoses are in good condition
– Replace worn or damaged hoses
– Check that hoses run smoothly
without kinks, twists or contact to
sharp edges

26
Common service tasks 6

Positioning and supporting the machine

USING JACK STANDS
Jack stands are useful as a safety measure when performing various service tasks:
They stop the machine from sinking down due to reduced hydraulic pressure

With the outriggers fully down:

1. Fit in a jack stand under the outrigger
joint tube and close the gap as illus­
trated
• Avoid damaging the grease nipple in
the centre
• With the jack stand in proper place,
the outrigger may be raised
Limited sideways balance. Nev­
er rotate turret on jack stands!
2. With jack stands under each pair of out­
riggers, they may be moved independ­
ently

PLACING THE MACHINE ON A

PALLET
This method will considerably improve ergo­
nomics when performing time consuming
service tasks, e.g. dismantling the hydraulic
valve blocks.
3. Press down all outriggers

(a) Position the boom, stick and

tool as illustrated and fit a
wooden piece under the tool
hitch
• Let the tool hitch rest on
the wooden piece
(b) Pull in the boom and straight­
en the stick
• As the tool hitch slides
in, the front outriggers
will raise
(c) Extend the telescope and fur­
ther retract the stick until the
front outriggers reach their
highest position
(d) Fit in two pallets under the
tracks as illustrated
(e) Raise the boom extension and
let the tool/bracket slide away
• The front will lower un­
til the tracks rest on the
pallet
(f) Pull back the boom and re­
trieve the telescope to achieve
better balance

27
6 Common service tasks

Positioning and securing boom

and stick
There are various means to secure the boom and
stick while performing service tasks. The aim is to re­
duce the risks of heavy pieces collapsing or tipping
due to reduced hydraulic pressure:
• Position machine in such a way that the
boom—stick is mechanically locked. In the il­
lustration, three cylinders are in their end pos­
itions:
(a) Boom cylinder: fully extended
(b) Telescope: fully retrieved
(c) Tool cylinder: fully retracted
(d) The hitch rests on the flat surface,
forming a stable triangle with the
stick joint
• Use straps to increase stability
• Secure a position with a capable lift or ceiling
beams
• Rest boom--stick on a stable surface, a sturdy
bench or a trestle

28
 Outriggers 7

7.Outriggers OUTRIGGERS FOR SUPPORT

The outriggers in each corner of the machine are controlled independently to supply
maximum stability. All four outriggers have the same design comprising attachment
to the undercarriage, joints, cylinders and hydraulic lines.

PREPARATION
Let the machine stand on its rubber tracks:
1. Lower the outrigger to be serviced until
it almost touches the ground.
×2 __mm
Removing the cylinder covers
2. Remove the rubber cover steel strip
3. Remove the cylinder shield (a)
×2 24mm The outrigger cylinder
The outermost cylinder axis
4. Lift up the outrigger to its end position
using the remote control. This will
empty the cylinder from hydraulic li­
quid
• Remove the two shaft bolts with wash­
ers

×2 __mm

5. Insert a shaft bolt, fit a key extension

over it and us a mallet to knock the
shaft in both directions:
(b) Neutralise shaft pressure with your
hip
(c) Remove the cone ring on either side
• Remove the shaft

6. Lower the outrigger manually:

(d) Use a crowbar to clear the passage of
the cylinder shaft nipple
×2
7. Mark the lines for your own reference
and gently loosen the coupling:
Thoroughly clean areas around
hydraulic openings!
See chapter 6 for reference on
hydraulic lines

The innermost cylinder shaft

×2 __mm 8. Remove the cylinder shaft bolts follow­
ing the procedure described in step 5
above
• Remove the cylinder

×2 24mm

29
7 Outriggers

The outrigger
The joint shaft
1. Remove the two shaft bolts with washers
• Remove the cone rings as described in
step 5 in previous page
2. Due to lack of space in front of the
track unit:
(a) Use the mallet sideways and use key
extensions of various lengths to work
the shaft through the joint

3. Hold the outrigger as you pull out the

shaft
(b) Optionally, use a glide hammer on
the shaft bolt
• Remove the shaft
• Collect shims

REASSEMBLING
joint and shims
• Due to heavy intermittent loads all joints
should be fitted as firmly as possible, ac­
cording to torque recommendations (See
Chapter 6, Joints). This ensures highest
precision when operating the machine
• Reassemble by following the above steps
in reversed order

30
 Traction system 8

8.Traction system THE TRACTION SYSTEM

The two traction units are attached to each
side of the undercarriage frame. They have
one independent hydraulic drive motor
each, for short distance driving and position­
ing the machine.

Replacing a rubber track

Preparations
1. Position the machine:
(a) Lower the outriggers. The traction
units should be well above the ground
• It is recommended to fill most of
the gap under the rubber track, e.g.
with a pallet
(b) Rotate turret slightly to give access to
tension release lid (e)
Identify the following parts:
(c) Drive wheel (fitted on motor)
(d) Idler (pushing rubber track)
(e) Belt tension release knob accessed
through service hole
REMOVING A RUBBER TRACK
2. Remove the cover plate of the track ten­
sion release service hole
(e) Locate the puller for the belt tension
release valve
×1 14mm
Release rubber track tension
3. Pull the tension release knob
• Lock the released position by twisting
a ¼-turn
• Make sure the idler wheel slides in all
the way
– If necessary, apply pressure on the
track tensioning wheel by means
of a crowbar
Lift off rubber track
4. Reduce slack by means of a crowbar or
a pallet (to keep the drive gears inside
the rubber track)

5. Remove the rubber track from the idler

6. Remove the rubber track from the drive
wheel

FIT ON A NEW RUBBER TRACK

7. Make sure to fit new rubber track with
pattern as illustrated; top view with ar­
rows forwards
• Fit on the new belt by reversing step
6, 4 and 5
• Check that the rubber track
tension knob is released (re­
verse step 3)
• The tension cylinders activate
whenever the outriggers are lif­
ted

31
8 Traction system

Overview
Two track units comprising:
(a) Hydraulic drive motor with drive wheel
(b) Screw bond plate secures track unit to chassis tube
(c) Rubber track tensioning cylinder
(d) Idler (pushing rubber track)
(e) Three rollers

Dismantling the track unit

Preparations
×2 18mm
• Remove rubber track (see previous page)
• All rollers should be clear off the ground. The machine
may stand on it's outriggers. (Here illustrated using jack
stands to maximise accessibility – see chapter 6)
REMOVE THE TENSION IDLER
1. Pull out the tension idler
• Lifting the outrigger will increase accessibility

TRACK ROLLERS
2. Use an Allen key to remove the axis
screws on either side of the roller
3. Remove the track roller
• Note the axis notch and its corresponding
support inside the track unit
REMOVE THE DRIVE WHEEL
4. Remove the eight drive wheel bolts with
a hex key
5. Pull off the drive wheel

×8 8mm DETACH THE TRACK UNIT

6. Insert a pallet, preferably on a lift, under
the track unit

7. Use illustrated keys to loosen the two

×2 8mm track unit bolts and the two screw bond
bolts
• When reassembling; tighten by 500Nm

τ =500Nm ×2 19mm 8. Slide the screw bond plate (b) forwards

and carefully remove the track unit
bolts.
(f) Observe the two track unit position­
ing pins when reassembling

9. Tilt down the track unit and pull it out

slightly on the pallet

REASSEMBLING
Reverse the steps described above.

32
 Traction system 8

Removing drive motor and tensioning cylinder

Preparations
• Dismantle the track unit (see previous page)
• Clean all areas around hydraulic couplings and keep plugs available

HYDRAULIC DRIVE MOTOR

1. Remove and plug the two hydraulic
hose couplings from the motor
Follow the advice on hydraulic
couplings (see chapter 6)
2. Remove the 8 motor fasteners
×2 8mm
(a) The motor valve should be removed
to access hidden fasteners
• Lift out the motor
×2 __mm ×8 8mm
TENSIONING CYLINDER
3. Remove the hydraulic line coupling
from the cylinder and plug the lines
Follow the advice on hydraulic
line couplings (see chapter 6)
• Slide out the cylinder as illustrated

REASSEMBLING
Simply reverse the steps above

×1 17mm
Drive motor service
The gear oil should be changed after the first
100 hours and then every 1000 hours. This
procedure may be carried out without any
dismantling.
Preparations
• Lift up the machine with the outriggers
CHANGE GEAR OIL
1. Rotate drive motor until one plug is
pointing straight down
2. Remove the two plugs with an Allen key
3. Collect the gear oil as it pours out

CHECK OIL LEVEL

×2 5mm 4. Rotate drive motor until one
plug is pointing straight up
• Remove plugs (as step 2)
• Fill up with new oil to level
with lower hole and refit
plugs

33
8 Traction system

34
 Frame manifold valve 9

9.Frame manifold valve
This manifold is supplied via the front manifold (see chapter 17).
RUBBER TRACK TENSIONING
The tensioning valve uses hydraulic pressure for the outrigger cylinders as
means to keep the rubber tracks well tensioned. A gas accumulator (a) serves
as suspension.
Pull the tension release knob (d), to slacken the rubber tracks. The ten ­
sion will return as soon as an outrigger is lifted. Slack will remain if the
pulled out knob position is locked by a ¼-turn (see chapter 8).

FRONT VIEW
(c) Counter pressure valve
(d) Track tension release valve knob
4. Return | outrigger front left
5. Return | outrigger front right
REAR VIEW
(a) Accumulator (track suspension)
1. To: outrigger front right
2. To: outrigger front left
3. Return: outrigger rear right/left
6. To: Outriggers (all) |from swivel (5)
7. Drain accumulator| to swivel (D)
REACHING THE MANIFOLD
Preparations
• Rotate turret 90°
• Fix the release tension knob in it's pulled
out position with a ¼-turn
• Lower the outriggers just above the
ground and switch off power
×4 14mm I. Remove the service lid with a socket key
II. Locate the various components.
• The manifold is attached to the frame
wall with spacers (b)
REMOVING ACCUMULATOR
Preparations
Clean all areas thoroughly be­
fore exposing hydraulic open­
ings and keep plugs at hand
III. Disconnect and plug the hose coup­
×2 __mm lings (1) and (7) (see chapter 6) to access
the gas accumulator (a)
IV. Loosen the gas accumulator
V. Remove the two tube valve block fasten­
ers
(b) Take care of the two spacers between
frame wall and the manifold
×1 27mm VI. Slide manifold forwards and take out
the accumulator
REMOVING VALVE BLOCK
• Remove the accumulator as in III—VI
• Disconnect and plug the couplings (2), (3)
and (6) and take out the valve block
×2 __mm
• Disconnect and plug the remaining hose
couplings (4) and (5)

REASSEMBLING
Reverse the steps as described above.

35
 Tipping machine | Frame interior 10

10.Tipping machine | Frame interior TIPPING MACHINE

This is handy for easy access to and overview
of frame interior.

Preparations
• Lift machine on all four outrig­
gers
• Rotate turret 90°
1. Tipping procedure
(a) Boom forwards
(b) Telescope maximum out
(c) Stick straight with tool rest­
ing on board (to slide on)
as illustrated
(d) Lift up both outriggers on
the boom side
(e) Lift boom extension
(f) Fully retract boom
(g) The tool assembly will slide
on the board
(h) When machine is fully tipped, press
down outriggers slightly to support
the rubber track
(i) As a safety measure:
• Fit a strap between rear lifting lugs
and the boom extension
2. Removing the tube plate
Use a socket key to remove the four
tube plate screws
×4 14mm INTERIOR VIEW
3. Bottom view of the hydraulic swivel
(see chapter 18)
×4 17mm (j) 4 Swivel bolts
(k) 4 Swivel bracket
bolts
Two service slots just be­
hind and in front of the
rectangular frame service
opening:
(l) Each service slot
×4 __mm gives access to
three bolts that
complete the
circle of gear ring
×3 18mm ×3 18mm bolts
– Move hydraulic hoses aside to
access all bolt heads

4. Turret slewing base

(m) 32 slewing ring bolts with nyloc nuts
×32 19mm
– securing turret to frame
• Holes larger than bolts allow for
optimised gear fit before tighten­
ing
(n) 32 slewing gear ring fastening bolts
(Six bolts are accessible as illustrated
in 3 (l) above) – see chapter 18
(o) Slewing base plate, fixed to frame
×32 18mm

37
 Turret coverings / counterweight 11

11.Turret coverings / counterweight On each side of the turret there is a bonnet

(hood), a side plate and a cast front piece.
×2 Two top plates are fitted around the power
cable swivel. The cast counterweight forms
the back part of the coverings.

×2 10mm Dismantling the housing

THE SIDE PLATE
1. Open the bonnet/(hood) and:
(a) Remove the side plate fasteners with a
socket key
(b) Lift out the positioning tabs and re­
move the plate

THE BONNET/(HOOD)
2. Detach the bonnet/(hood) gas spring
• Remove the nut and washer
• The other end of the gas spring is at­
tached to the centre frame.
• For most service cases the gas
springs may remain inside

×1 13mm

3. Remove the innermost bolt pairs from

the bonnet/(hood) hinges
• Remove the bonnet/(hood)

Reassembling
• To assure accurate fit; do not fully tighten
these bolts until the lock is properly closed
• To trim alignment of hinges for proper fit
– see “Adjusting hinges”, last page of this
chapter

×4 4mm

THE ROOF PLATES

4. Remove the front roof plate
• Overlaps under the rear roof plate
5. Remove the rear roof plate

39
11 Turret coverings / counterweight

THE CAST FRONT PIECE

1. Locate the three fasteners

2. Use a socket key to remove the three

fasteners

×3 15mm
3. Remove the front piece

The counterweight
The cast counterweight (80kg) comprises the
grille for the hydraulic fluid cooler and
forms the rear part of the coverings that en­
close the turret.
PREPARATIONS
×4 17mm • Remove the coverings as described on
previous page
• Have lifting aids available, capable of at
least 100kg
4. Remove the top bracket and stop but­
ton:
(a) Loosen the two front side nyloc nuts
for the power cable swivel. And com­
pletely remove the two rear side nuts
(that also fasten the top bracket)
(b) Remove the two rear fasteners for the
top bracket, lift it off the threaded
pins and move it aside
(c) Remove the two stop button bracket
fasteners

×4 17mm Lifting
5. Secure the counterweight with a lifting
hook
• Fit an eye bolt in each stop bracket
M12 hole with a loop strap through
×2 – It is possible to use the stop button
bracket – first remove the button, see
next page, step 3.

6. Remove the four fasteners located at the

bottom side of the counterweight

×2 10mm
7. Remove two fasteners located at each
rear lifting lug
×2 10mm

40
Turret coverings / counterweight 11

THE COUNTER-WEIGHT
1. Use a lifting device to safely re­
move the counter-weight
Take precautions! The
counterweight is heavy
(80kg)
(a) Note the two positioning tabs
when reassembling

2. Lower the counter-weight on a

pallet and secure it by placing it
on its backside

REASSEMBLING HOUSING AND

COUNTER-WEIGHT
Simply reverse all steps above.
• Pay attention to not tightening the bon­
net (hood) hinges until the locks fit prop­
erly.

Rear stop button

For proper access, remove the rear top cover.
DISASSEMBLING
3. Use a bladed screwdriver to loosen the
lock tabs of each contact module

4. Move the OFF—ON lever to the OFF-

position as illustrated

5. Unscrew the mounting ring and remove

the stop button

REASSEMBLING STOP BUTTON

Reverse the steps 3—5 above.

41
11 Turret coverings / counterweight

×1 7mm ×1 7mm ADJUSTING BONNET HINGES

1. The holes of the outer hinges are larger
than the fasteners. This allows for fine
adjustment before tightening. (see first
page of this chapter)
2. The hinge bracket
(a) hinge bracket fastener
– the oval hole for this fastener al­
lows for forwards—backwards ad­
×4 4mm ×1 8mm justment
– Loosen—adjust—re-tighten
(b) hinge fastener nuts, welded to pivot­
ing bar
(c) pivoting lock screw for inner hinge
fastener. Remove hinge bracket fasten­
er (a) before adjusting the angle.
– For adjusting to the angle of the
hinge fasteners
– Loosen—adjust—re-tighten

42
 Radio and Control modules 12

12.Radio and Control modules Location

1. With the left side plate removed (see chapter 11) you find
the electronics console mounted on top of the the axis
coupling tunnel of the main motor and hydraulic pump.
(a) The Bluetooth® communication module with an­
tenna and signal cable
(b) The primary Control module (PLC)
(c) The secondary Control module
Disassembling
UNDOING THE CABLE
CONNECTORS
The communication module (a)
2. Unscrew the lock cylinder of the larger
signal cable and pull out the connector
• Repeat the process with the antenna
connector
The primary control module (b)
3. Use a bladed screw driver to release the
lock tab of each one of the four con­
nectors.
• Pull the contact – not the cable!

The secondary control module (c)

4. Use a bladed screw driver to release the
lock tab of each one of the two connect­
ors and pull them out

REMOVING THE CONSOLE

5. Remove the three fasteners with washers
as illustrated

REMOVING THE INDIVIDUAL

RADIO AND PLC MODULES
6. Use Allen keys to remove the screws
• 4 fasteners of the communication
Bluetooth® module
Comprising two plugs:
• 8-pin signal contact
• 1-pin antenna
• 2 Allen fasteners for the primary con­
trol module
×3 __mm Comprising four plugs:
• Blue 23-pin
• Black 23-pin

×4 __mm
• White 23-pin
• Black 8-pin
7. Use an Allen key to remove the two
×2 __mm fasteners of the secondary control mod­
ule
Comprising two plugs:
×2 __mm • White 23-pin
• Black 8-pin

REASSEMBLING
Simply reverse the steps described above.

43
12 Radio and Control modules

REMOVING A CABLE PIN

The connector is gathering up to 23 (or 8)
individual female pins. The grid numbering
is engraved on the connector sides as illus­
trated; 1—8, 9—15 and 16—23.
Remove the pin grid protector
1. Release the first tab lock by inserting a
small bladed screwdriver
• Repeat on the other side of the con­
nector and slide grid out to next stage

2. Release the second tab lock by inserting

a small bladed screwdriver
• Repeat on the other side of the con­
nector and remove the grid protector
Disengage the cable pin
3. Select the desired cable
(a) cable pin (e.g. No. 1)
I. Gently twist cable until a quiet click
is heard
II. Pull out cable with pin

INDIVIDUAL CABLE WITH PIN

4. Cable with pin end (a)

REASSEMBLING
Reverse the steps described above. No twist­
ing is needed at step 3, simply insert until it
clicks in place.

44
 The hydraulic pump 13

13.The
The hydraulic pump The pump is powered by the main electric motor via a claw coupling. The
hydraulic fluid intake on top (c) comes from the tank. (d) is a drain flow
to tank. The main pressure line exit is underneath (g) and feeds the mani­
fold valves on the right side of the turret. (f) is for load sensing function­
ality.

Removing the hydraulic

pump
Preparations
• Remove the turret coverings (see chapter
11). Removal of counterweight is not needed.
• Remove the console for radio and control
modules (see chapter 12)
• Carefully clean areas around hydraulic
parts to be opened. (see chapter 2)
• Have available hydraulic fluid absorbents
and plugs for hydraulic openings
1. Discharge tank pressure:
(a) Loosen the tank air filter by 2—3
turns, or
(b) unscrew the upper fluid level gauge
fastener by 2—3 turns
×1 17mm THE FLUID FEED HOSE
2. Use a socket and loosen the four fasten­
ing bolts
• Place absorbent sheets under the
coupling
3. Reduce spill by keeping the coupling
pressed down in position while remov­
ing the last bolts

4. Quickly raise the feed line (c) to a high­

er level and plug it. Use absorbent to re­
duce any spill and secure it with a strap
×4 10mm
THE DRAIN RETURN HOSE
5. Use a spanner to undo the coupling
(d) Avoid spill and quickly raise and se­
cure the hose out of the way
(e) Plug all openings to minimise expos­
ure to dust

THE RADIO/PLC CONSOLE

×1 24mm SUPPORT
6. Use a socket and remove the two con­
sole support bolts
THE FILL HOSE AND FILTER
This should be removed for better access un­
derneath the pump.
7. Remove the filter from the hydraulic flu­
id fill pump. (See chapter 15)
• Plug the hydraulic openings

×2 13mm

45
13 The hydraulic pump

LOAD SENSOR HOSE

1. Place an absorbent underneath and use
spanners to undo the coupling
• Plug the openings

×1 17mm LARGE PRESSURE HOSE

2. Use a spanner to loosen the four fasten­
ers (as in step 2 on previous page)
3. Plug the pressure hose as soon as it is
free and plug the motor opening

REMOVING THE HYDRAULIC

×2 17mm PUMP
4. Use an Allen key to remove the upper
pump fastener with washer
×1 10mm
5. Remove the lower fastener and washer
• Fit the long end of the hex key in the
bolt head and use extensions as a
lever

Release axis coupling and remove the

×1 10mm
pump
6. Turn the pump a fraction in either dir­
ection around its axis
• Pull out the coupling
7. The coupling claws fit on the electric
motor axis
• A cushioning ring allows for a tight
but pliable fit

Remove axis coupling unit from pump

8. Release the axis lock screw
• Use an Allen key to loosen it
9. Pull the axis coupling unit straight off

REASSEMBLING THE HYDRAULIC

PUMP
Reverse the steps described above.

×1 4mm

46
 Cooling system 14

14.Cooling system The primary function is to cool the hy­

draulic fluid. The secondary function is
to cool the main electric motor.
Components
(a) Coupling: Return flow
(b) By-pass valve
(c) Coupling: From fill pump
(d) Coupling: To reservoir
(e) Fan shield with ventilation grille
(f) Fan: Rotates with motor axis
(g) Cooler grid. Should be kept clean
×1 22mm
with compressed air

Removing the cooler

Preparations
• Remove turret coverings and counter­
weight to access the cooler area (see
chapter 11)
×1 36mm • Discharge tank pressure by slightly un­
screwing the air filter (see chapter 16)
Clean areas around hydraulic
couplings and keep plugs at
hand

UNCOUPLE HOSES
1. Remove and plug the hoses (c) and (d)
×2 13mm by disconnecting their couplings
• See chapter 6 for reference
2. Remove and plug openings for the re­
turn flow hose (a)
Loosen fan shield
×1 36mm
3. Remove the outer fan shield fasteners
4. Use extensions to reach and remove the
inner fasteners

Remove the cooler

5. Remove the outer cooler fasteners
6. Remove the inner fasteners

×2 13mm

×2 5mm

7. Remove the cooler from the fan shield

and gently lift off as illustrated
• Slightly press in the outer fan shield
bottom corner (e) to increase space
for disengaging the cooler

REASSEMBLING
Simply reverse the steps above

×2 5mm

47
14 Cooling system

Remove the fan hub

assembly
Preparations
First remove the cooler as described on pre­
vious page.

1. Remove the centre bolt

Use an Allen key
×2 __mm
– Stop rotation by holding on to
the fan blades
×1 __mm
2. Loosen the lock screws
Unscrew the two hub locking Allen
screws approximately 3 turns each

3. Pull off the fan with hub

4. Lift off the fan shield with frame

REASSEMBLING
Simply reverse the steps as described above.

48
 Main electric motor 15

15.Main electric motor CABLE CONNECTIONS

Unscrew the four corner screws to open up the elec­
tric box on top of the motor.
Wires entering the box
(a) PLC cable, thermal bi-metal relay*:
I. Signal from control module
II. Signal to control module
(b) Power cable:
1—3: Phases L1, L2, L3
E: Protective Earth
*When the coils reach approx. 150°C the thermal bi-met­
al relay open with a display warning. The relay recon­
nect when motor temperature drop 10°C from max. and
×4 the warning disappears.

MOTOR AND PUMP PACKAGE

The motor (e) and pump (c) should be lifted
out as one package, connected by the axis
coupling tube (d) as illustrated.

Remove the motor

Preparations
• Remove the Radio and control modules
assembly (see chapter 12)
• Uncouple and plug the hydraulic pump
hose couplings (see chapter 13)
• Remove the cooler and fan assembly (see
chapter 14)
• Disconnect from mains power and pre­
vent accidental power connection
• Disconnect the wires of the two cables (a)
and (b) as illustrated above
REMOVE THE MOTOR FASTENERS
4. Remove the two outer motor fasteners

5. Remove the two inner motor fasteners

• Use an extension and a crow foot for
×2 16mm reaching
×2 16mm

LIFT OUT THE MOTOR

The motor and pump package
is heavy. Take proper safety pre­
cautions!
6. Use a lifting device capable of 200kg
and a heavy duty lifting strap
• Lift up motor and pump package and
place it on a sturdy work bench
REMOVE THE HYDRAULIC PUMP
(See chapter 13 for reference)
7. Remove the axis coupling tube (d)
• Remove the four bolts with nuts and
lift off the tube

REASSEMBLING
Simply reverse the steps as described above.
×4 24mm

49
15 Main electric motor

50
 Hydraulic fluid tank
16.Hydraulic f luid tank OVERVIEW (REAR)
(a) Thermal sensor
(b) To hydraulic sensing pump
(hose clamp)
(c) From hydraulic cooler com­
prising a pressure guard
(d) Drain return from pump
(e) Service opening for flush
cleaning the reservoir
(f) Air filter (valve)
(g) Lid for hydraulic fluid filter
(h) Sight gauge for hydraulic
fluid level
(i) Attachment tabs
(j) Drain plug
×6 10mm
×2 5mm
×2 6mm
×2 10mm
×6 10mm
16
The hydraulic reservoir receives cooled fluid
from the cooler and supplies fluid to the
pump. Depending to the state of the con­
nected hydraulic cylinders, the surface level
may vary substantially. With all cylinders
fully retracted, the level of the scale (h)
should be just below the upper line.
It is paramount to keep all
openings and the interior abso­
lutely free from debris or dust
that can compromise the clean­
ness of the hydraulic system.
AIR FILTER
The air filter (f) of the tank work as a valve
to allow airflow in and out, to compensate
for a variable volume of hydraulic fluid as
hydraulic cylinders expand or retract.
• Change filter every 500 hours, or
more often if used in a closed and
heavily dusty environment
1. Remove the air valve with filter
• Unscrew 3 turns to discharge tank
pressure
• Fully unscrew air filter to remove it
HYDRAULIC HOSE COUPLINGS
2. Remove hoses as follows:
• Two hoses (d) and (c) – See chapter 6
“hydraulic couplings”
• The hose to the hydraulic pump (b) is
clamped on the tube – use an Allen
key
REMOVING THE RESERVOIR
Preparations
• Empty the hydraulic fluid through the
drain plug: see next page
• Remove the counter-weight: see chapter
11
• Remove the hose couplings (step 2 above)
3. Remove the two inner fasteners
• Use a long extension to remove the
innermost fasteners (i)
4. Remove the two fasteners on the side
HYDRAULIC FLUID FILTER
Many hydraulic components are lubricated
by the fluid with small tolerances. Grades
and particles are collected in the filter, which
must be replaced at 500 hours service.
5. Open the lid
• Remove the six screws of the lid
• Take care of the spring
• Check O-ring (k) for kinks or cracks
– Replace if damaged
6. Lift out the filter with plastic sleeve
• Disengage bayonet fitting and replace
the filter
51
16 Hydraulic fluid tank

Draining and filling

Preparations
• Remove left side plate (see chapter 11)

1. DRAINING
• Position turret rotated at 90°, as illustrated
• Retract all cylinders of hydraulic system; boom—stick and blades.
Release rubber track tensioners (see chapter 7, step 1—2)
• Place a vessel capable of 30 litres straight below the tank
• Remove the drain plug with a socket key and let the tank drain
• Replace the air filter and fluid filter (see previous page, step 1 and 5)
• Fit in and tighten the drain plug

×1 8mm 2. FILLING UP
Replacing hydraulic fluid of tank requires
approximately 30 litres of new fluid.
• Check fill pump filter (see step 1—2 last
page of this chapter).
• Place container of new hydraulic fluid be­
low the fill pump hose.
Make sure to use the same quality
of hydraulic fluid (see chapter 3).
This will minimise risk of clogging.
• Unplug fill hose end and fit it deep inside
a new hydraulic fluid container.
• Position yourself where you can reach the
control panel, and read the sight gauge
(a) Press fill button (ON)
(b) Press fill button (OFF) when level
is 15—20mm below the high level
≈10mm mark
– Step 11, 500-hour service, (see
next page): only fill to 15—
20mm above low level mark
The level will raise another 5—10mm
after you press the button

IF FILL PUMP CAVITATES

(Pump spins with no result)
Try the following:
I. Discharge pressure (air filter)
• Run fill pump temporarily until the
filter unit is full of hydraulic fluid
II. If necessary, loosen the check valve
coupling to reduce pump resistance
• Run fill pump temporarily until the
filter unit is full of hydraulic fluid
– Re-tighten air filter
– Re-tighten check valve coupling

×1 24mm

52
 Hydraulic fluid tank 16

Complete change of hydraulic fluid

The hydraulic fluid should be fully replaced at 500 hours interval, or in case the system has been contaminated. The following procedure requires
approximately 60 litres of new fluid and the following recommended tools; an adaptor coupler (a—b)* and a drain hose (c)*.
Hydraulic fluid – 500-hour service Note Controls
1. Position machine:
CONTROLLING PUMP FLOW: – Retract all cylinders
Select mode (Set-up or Work) – Rotate turret 90° MODE:
– press [START] + activate: – Switch machine OFF Work+Set-up

– within 4 sec: [Run function(s)] See previous

2. Drain tank
– within 4 sec: press [STOP] page, step 1
Change air and fluid filter.
Run speed: If not otherwise stated, perform all man­ Fit back the drain plug!
oeuvring at slow speed!
3. Reconnect hoses – Service set-up See illustr. II.
4. Switch ON. Fill up with new fluid See previous page, step 2
Reconnect hoses 5. Press [START] + activate:
NORMAL CONNECTION: • Fully lower blades. Confirm any pres­ MODE: Set-up
sure warnings and restart. Press
[STOP]
6. Fill up with new fluid See previous page, (a)—(b)
7. Press [START] + activate:
• Slowly rotate turret 90° to normal po­
sition MODE: Set-up
• Run both track drives 5 seconds at
full speed. Press [STOP]
SERVICE SET-UP – RECONNECTED HOSES: 8. Fill up with new fluid See previous page, (a)—(b)
• Remove fill hose (a) from check valve (V)
9. Press [START] + activate: MODE: Work
• Remove return hose (b) from cooler exit • Fully extend all cylinders of boom—­
(OUT) stick. Press [STOP]

10. Reconnect hoses to Normal See illustr. I.

11. Fill up with new fluid NB! Fill to just above lower level
See previous page, (a)—(b)
12. Press [START] + activate:
• Fully retract all cylinders of boom-- MODE: Work
stick. Press [STOP]
See previous
• Check fluid level – fill up if needed page, step 2

• Use an adaptor coupler (a—b)* to connect fill

hose (a) and return hose (b)
• Fit on a drain hose (c)* on cooler exit (OUT)
• When performing step 7, it is practical to place
fluid containers on a pallet or rollers

*Service tool, see chapter 29

Keep hose area absolutely clean!

Take precautions. Avoid hazardous spray.

Full pump pressure will result in powerful
bursts!

53
16 Hydraulic fluid tank

CLEANING THE FILL PUMP FILTER

1. Remove the filter unit with fill hose
• Unscrew from pump as illustrated

2. Open the filter unit by turning the bay­

onet coupling as illustrated
(a) Check that the O-ring seal is undam­
aged

(b) Use a brush and compressed air to re­

move all dirt or debris from the filter

Reassembling the filter unit

• Check that the O-ring (2a) is evenly seal­
ing the contact surfaces without any kinks
• Reverse step 1—2 above

REMOVING THE FILL PUMP

Remove the filter with the hydraulic fluid
fill hose (as above)
3. Use a bladed screw driver to undo the
hose clamp for the the internal fill hose
• Remove and plug the hose
4. Use a spanner to remove the four fasten­
ing bolts

5. Disconnect the DC power connector

located behind the motor
×4 13mm (c) Depress the lock tab

Mounting the fill pump

• Reverse step 3—5 above

REPLACE THE SIGHT GAUGE

Preparations
• Remove counterweight (see chap. 11)
• Lower fluid level well below lower
×2 17mm gauge fastener.
6. Remove the two hollow fasteners and re­
place the sight-gauge
• Fit in the new gauge and reverse the
above steps

54
 Hydraulic manifolds (turret) 17

17.Hydraulic
Hydraulic manifolds (turret) The two major hydraulic manifolds are mounted on the right side of
the turret base plate.
FRONT MANIFOLD
The front manifold is the principal one. It supplies the feed and return
lines to the other manifold; the rear manifold and the frame manifold
(see chapter 9).

1. Valve 1 – Track drive motor, Right

A: to Swivel (1) B: to Swivel (4)
2. Valve 2 – Track drive motor, Left
A: to Swivel (3) B: to Swivel (2)
3. Valve 3 – to Outriggers
A: Outrigger speed control
B: Outriggers + Track tension return,
to Swivel (5) – (see chapter 18)
4. Valve 4 – to Slewing motor
A: to Slewing motor, Port (A)
B: to Slewing motor, Port (B)
Outrigger ports
5. Port 1: Left/Front, to Swivel (7)
6. Port 2: Left/Rear, to Swivel (6)
7. Port 3: Right/Rear, to Swivel (9)
8. Port 4: Right/Front, to Swivel (8)
Miscellaneous ports
9. “LS block”: from Connection block
10. “P to block”: to Connection block
11. “T from block”: from Connection block
12. “T to cooler”: to Cooler
13. Circulation pumping valve
14. “P from pump”: from hydraulic pump
15. LS pump “P”: Load Sensor to pump
16. System pressure limiter

REAR MANIFOLD
Boom—stick
C5: Proportional directional spool
17. Telescope (cyl. 5) A: (+) | B: (-)
C4: Proportional directional spool
18. Tool (cyl. 4) A: (+) | B: (-)
C3: Proportional directional spool
19. Stick (cyl. 3) A: (+) | B: (-)
C2: Proportional directional spool
20. Extension (cyl. 2) A: (+) | B: (-)
C1: Proportional directional spool
21. Boom (cyl. 1) A: (+) | B: (-)
22. A: T tool B: P tool
(and grease pump)
tool: Proportional directional spool
Connection block
23. A: T to front manifold
B: P from front manifold
24. “LS”: Load Sensor to front manifold

55
17 Hydraulic manifolds (turret)

1. REMOVE SOLENOID CONTACTS

Mark each cable contact for quick reassembling
• Use a Phillips screw driver
• Gently pull off the female contacts and put the cables aside

2. REMOVE HYDRAULIC HOSES

Keep work area clean and pre­
vent dirt or debris to enter any
valve opening using plugs.
• Mark and remove all connected hoses, see
chapter 6 for reference

3. REMOVE THE WORK LIGHT

The right side work light has to be re­
moved to remove the front valve block
• Unscrew the four headlight fasteners
using an Allen key
• Take out the head light an disconnect
the electric connector by pressing
down the locking tab

×4 __mm

Remove front valve block

Remove solenoid contacts, hydraulic hoses
and right side work light as in 1—3 above.
4. Remove the valve block front fastener
(a) Use a socket key and an extension to
remove the valve block fastener
(b) The valve block bracket is secured to
the valve block with two bolts

5. Remove the valve block side fasteners

×1 14mm
(c) Continue to remove the remaining
two front valve block fasteners along
the side

REASSEMBLING
×2 14mm Simply reverse the steps above.

56
 Hydraulic manifolds (turret) 17

Remove rear manifold

Preparations
• Remove the hydraulic hoses (as described
on previous page, step 2)

1. Locate the 3 front fasteners: a, b and c

2. Remove the manifold fasteners

×3 14mm
• Use a socket with long extension(s) to
access fasteners (a) and (b)

(c) Use a crow foot to loosen the rear

side fastener

3. Remove the solenoid contacts

Manoeuvre the manifold slightly to bet­
ter access the solenoid contacts.
• See previous page, step 1

REASSEMBLING
Simply reverse the steps above.
×1 14mm

57
17 Hydraulic manifolds (turret)

Disassembling a valve
The valve spools (c) are secured by one spool
limiter block (a) at each end. To remove the
spool, the spring end (b) must be cleared.
Keep work area clean and pre­
vent dirt or debris to enter any
valve opening.
1. Remove the four Allen fasteners of
the spool limiter block
(a) Lift off the limiter block
×4 3mm
(b) Pull out the valve spool by its spring
end
– a spool with visible scratches
should be replaced
2. DISASSEMBLING THE SPOOL
SPRING PACKAGE
I. Loosen the spring fastener
×1 __mm
– Hold it by fitting a fine screw
driver through the spool end
II. Unscrew the spring fastener
– Control the process by compress­
ing the spring package

FITTING SPOOL INTO VALVE

3. Insert the valve spool, but not all the
way

4. The other spool limiter block (here il­

lustrated disassembled) comprises a
seal bracket (d) and an integrated
spool axis lock pin (e)
– Gently rotate the valve spool as
you carefully push in to fit its end
on the axis lock pin (e)

5. Fit on the spool spring end lim­

iter block and secure it with the
four fasteners, reversing step 1
as above

58
 Slewing system 18

18.Slewing system
Slewing motor
REMOVING THE SLEWING MOTOR
Preparations
1. To access the slewing motor (a), the fol­
lowing should be prepared:
(b) The tool grease pump should be de­
tached and moved aside (or removed)
(c) All hydraulic lines that otherwise
block access to the slewing motor or
its fasteners, should be removed and
plugged (see chapter 6)

Detaching grease pump bracket

2. Remove the two bracket fasteners
• Use an Allen key, a universal joint and
an extension
– To completely remove the grease
pump; uncouple and plug the hy­
draulic lines and the grease line
(see chapter 24 and 6)

REMOVING ALL FASTENERS

3. Use a spanner to remove the seven
reachable fasteners around the slewing
motor base plate
• Take care of the two-piece wedge cam
lock washers

×2 __mm 4. If the grease pump is not fully removed;

push it aside and
(d) Remove the remaining fasteners
– Use a crow foot with an extension
bar

×7 17mm

×1 17mm

59
18 Slewing system

INSERTING THE SLEWING MOTOR

1. Lift the motor straight up
(a) To fit the sprocket back in, turn the
motor slightly until the sprocket fits
in the cog ring
• Align the fastening bolt holes and
reverse the steps on the previous
page
Hydraulic Couplings
(See chapter 17 for reference)
(b) A: to front valve block (1A)
(c) B: to front valve block (1B)

CHANGING GEAR OIL

Gear oil should be changed every 500 hrs
and may be done with motor in place.
Remove hoses if necessary to reach. (See
chapter 6)
(d) Remove gear oil: Unscrew plug to
drain the gear oil
(e) On rear side, use a crowfoot or a
spanner to remove the oil stick
– Fill up to max level and plug it
GEAR RING ATTACHMENT
(f) Slewing ring fasteners (×32) – secures
×1 14mm pivoting platform to the cog ring (see
chapter 10)

τ =81Nm

Slewing ring
2. The bare slewing ring.
(a) The slewing ring gears
Should be cleaned and inspected for
wear and damage
(f) The slewing ring bolts, with nyloc
nuts – see 1 (e) as above and chapter
10: 4 (m)
Bearings lubrication
(g) Grease nipple (×4) (see chapter 3)

LUBRICATING GEAR RING AND

SPROCKET
The gear ring and sprocket should be lubric­
ated at a weekly basis.
3. Use the lubrication hose nipple to press
down grease
• Distribute evenly by applying 4
times. Rotate 90° between each
time.

60
Slewing system 18

Adjusting gear backlash

Improper gear backlash affects efficiency of
power transmission and precision in man­
oeuvring the machine.
Jerky slewing operation, or replacement of
slewing ring or motor, are reasons to re-
check the backlash between motor sprocket
and slewing ring gears.
To perform a proper backlash adjustment,
the turret must be separated from the under­
carriage.
Preparations
• Optionally, remove the boom—stick (for
more balance and control)
– See chapter 21
• Disconnect all WEO quick couplings
from swivel (from inside the pivoting plat­
form)
– See chapter 6 (couplings) and
chapter 18 (swivel)
• Secure turret before removing all 32 slew­
ing gear ring bolts
– See chapter 10 (4n)
• Use a capable lifting device to lift off the
pivoting platform

Principle; the motor sprocket is fixed and

the hole play of the slewing ring fasteners
will allow for a certain adjustment (a).
SET BACKLASH TO 0.2mm
1. Position pivoting platform securely,
ideally in a vertical position as illustrated
(view from below)
(x) Place the three green marked teeth in
the sprocket contact area
(a) Allow for increasing/decreasing the
distance (a) by loosening all 32 slew­
ing ring fasteners, except for either of
the 8th nut counting from the sprock­
et (indicated with )
2. Position the sprocket in proper gear pos­
ition for backlash reading
– Fit in a slewing gear ring bolt to
knock the gears in position by
means of a mallet
(d) Check proper backlash setting with a
0.2mm feeler blade
3. Adjust the slewing ring in the desired
direction by means of a heavy mallet
– Check backlash with feeler blade
– Fine tune (a)-adjustment by al­
ternating tightening/loosening
the two No. 8 bolts ( )
Proper backlash distance (d) is 0.2mm

REASSEMBLING
Re-tighten all bolts evenly according to re­
commended torque and fit back turret on
the undercarriage.

61
18 Slewing system

Swivel
The swivel permits hydraulic lines to pass
through from the turret to and from the un­
dercarriage. The hydraulic hoses are connec­
ted to a cast female unit (a) that is freely ro­
tating over the male pivot centre (b) which is
fixed to the tube chassis – see chapter 10,
step 3(d).
A hose from the front valve (see chap. 17)
connects to a specific port number on the
female pivot side of the swivel (a) and con­
tinues from the corresponding number on
the male chassis tube side (b).
SEPARATING TURRET FROM
UNDERCARRIAGE
When separating the turret and undercar­
riage for major service jobs, such as backlash
adjustment, only the WEO couplings inside
the turret should be uncoupled, thus leaving
the swivel intact on the undercarriage.

FEMALE AND MALE SWIVEL HOSE

PORTS
Female unit facing backwards.
Male unit from below, with port number 9
in the forwards direction.

D. Drain return

Track drive motor

1. Forwards/Right
2. Forwards/Left
3. Backwards/Left
4. Backwards/Right

Outriggers
5. Outriggers & Track tension return (-)
6. Rear/Left (+)
7. Front/Left (+)
8. Front/Right (+)
9. Rear/Right (+)

MALE SWIVEL BASE

The male swivel unit is attached by it's base
to the swivel bracket:
(c) 4 fasteners attached from the inside
of the chassis tube.

62
 Electric cabinet
19.Electric
Electric cabinet OPEN ELECTRIC CABINET
Fault searching should
only be performed by a
qualified electrician!
• Use a bladed screwdriver to turn
the two locking screws and open
the lid
Interior modules
1. Main motor contactor combin­
ation (QM1, QM2)
2. Internal power supply (T1)
24V, 20A from power mains
3×400V~
3. Emergency stop relay (B1)
3-diode status
indication
4. Soft start/stop relay with built
in motor protection (T2)
Automatic reset at temperature
decrease
19
5. Phase sequence relay (K1)
Compensates for phase sequence faults
caused by e.g. extension cables. Checks
voltage on all phases. Displays “Phase er­
ror” if fault due to over/under voltage
6. 3-phase fuse for the 24V power supply
and phase sequence relay.
A blown fuse will halt power supply and
phase sequence relay
7. Fuse for optional 230V power socket
8. Terminal blocks
9. 24V-relay for multiple functions: (K10)
as indicated in electric diagram
10. Relays marked in accordance with K-
numbers in electric diagram
11. Relay
12. Fuse rack. Replace fuse if blown.
Qualified electrician should perform
fault search if fuse blows repeatedly
63
19 Electric cabinet

SOFT START/STOP RELAY

Reset buttons and diode
RESET TO FACTORY DEFAULT:
A. Reset mode
• Press RESET/TEST button (B) repeatedly
B. Reset test until the RESET MODE diode (C) goes
C. Reset mode indication yellow, then adjust screws 1—6:
Adjustment screws Default setting
1. Protection class ▷ 10
2. Overcurrent time limit ▷ 44
3. Ramp down time ▷ 2
4. Starting torque ▷ 40
5. Ramp up time ▷ 5
6. Current start limit ▷ 3.5

Diodes (LED) I. II. III.

STATE BYPASSED OVER­
DEVICE
Operating indications FAILURE LOAD
Off Green 0 0
Start (ramp up) Green – Green – 0
By-pass (normal) Green Green 0
Ramp down Green – Green – 0
Alarm signals
Ie/Class setting not permissible Green × – Red –
Start inhibited/thyristors too hot – Yellow – × 0
Error signals
24V: U<0.75×Us or U>1.25×Us 0 Red 0
Non-permissible Ie/Class setting for edge 01 on Green Red – Red –
input IN
Thermal overloading of thyristors Yellow Red 0
Missing mains voltage, phase failure, missing load Green Red 0
Device fault Red Red 0
Indicators: 0 (Off), × (Not relevant), – _ – (flashing)

EMERGENCY STOP RELAY

Fuse table This safety relay has three diode indicatiors that goes ON or
No Related items/functions OFF corresponding to the operating states of the machine:
F1 Transformer 400V—24V Operating states
LED Operation
F2 — not in use — Release
Power Chan. 1 Chan. 2 PS Emergency stop ON
circuits
F3 Working lights
☼ ☼ ☼ not activated activated closed
F4 Rear safety light (orange) | Horn
☼ • • ON activated not activated open
F5 Fill pump for hydraulic fluid
☼ • • not activated not activated
open
F6 Radio and control modules Faults
F7 Safety relay | Soft start | Start ☼ ☼ • – Relay fusion-welded
functions – Motor contactor fusion-welded
☼ • ☼
– Defect in electronics
☼ • • – Short-circuit in ON circuit open
Cross or ground faults in EMER­
• • • GENCY STOP circuit (min fault cur­
rent IKmin=0.5A; PTC fuse trips)

64
 Electric cabinet 19

AUTOMATIC PHASE RELAY

Standard power supply is 400V~50Hz (for
460V~60Hz, see chapter 28). This phase relay
protects the machine from under/over cur­
rent by generating an error message at pre-set
minimum and maximum values:
– U▿ Minimum default: 380V
– U▵ Maximum default: 420V
Reset to factory default setting
• Press repeatedly to select:
U▿ Min. ↔ U▵ Max.
• Press + to increase or decrease
the displayed value:
Changes are saved automatically.

AVAILABLE DISPLAY OPTIONS

The diagram below illustrates the sequence of available
functionality:
I. Display voltage over phases: U1—2, U2—3, U3—1
– Press + to display voltage between pairs
of phases (e.g. U2—3=401V)
II. Display adjustable voltage limits (160V—690V)
(a) Upper voltage limit: Press once
(b) Lower voltage limit: Press twice

65
 Dismantling the stick 20

20.Dismantling the stick PREPARATION

1. Position boom—stick according to the il­
lustration:
• Outriggers down
• Turret rotated 90°
• Boom—stick stretched out with the
stick at desired working hight
• Tool cylinder fully withdrawn

THE CYLINDER SHIELD

2. Remove the four tool cylinder bolts
with washers
• Remove the cylinder shield

×2 24mm
THE OUTER CYLINDER SHAFT
×2 24mm 3. Remove the outer tool cylinder shaft
from the tool lever (see general guide;
chapter 6).
REMOVE THE TOOL CYLINDER
4. To remove the cylinder, follow these
×2 24mm steps:
(a) To completely remove the cylinder:
• Undo the hydraulic couplings
and plug the lines (see chap. 6)
(b) Remove the inner shaft in the same
manner as the outer (see 3 above)

TIE UP THE LINES/CYLINDER

5. Use a strap to tie up the lines and/or the
cylinder along the boom extension.

67
20 Dismantling the stick

×2 6mm
Tool link/hitch –
disassembling
1. Remove the tool link shaft from the
stick
• (see chapter 6 for reference)

THE INNER TOOL HITCH SHAFT

2. Use a marker to indicate the position of
the shaft (useful when mounting)
(a) Use an Allen key to remove the lock
×2 24mm screws
• Use a mallet to knock out the
shaft and take care of the
shims. (see chapter 6)

TOOL LINK/HITCH ASSEMBLY

3. Overview of the joints:
(a) Inner tool hitch shaft screws
(b) Outer tool hitch shaft screws
• Disassemble: as in step 2 above
(c) Joint between tool link and hitch
×2 24mm
lever.
×2 6mm
• Disassemble as standard
shimmed joint, (see chapter 6)

REMOVING THE STICK

4. Position the stick on a suitable surface:
(d) Remove the stick cylinder shaft
(e) Remove the joint between stick and
boom extension

REASSEMBLING
Reverse the steps above. See chapter 6 for ref­
erence.

×4 24mm

68
 Telescope 21

21.Telescope The boom extension (a) contains the tele­

scope (b), which can be extended or re­
trieved with the integrated stick cylinder at­
tachment (c).
Preparation
1. Position the boom—stick as illustrated:
• Outriggers down
• Turret rotated 90°
• Boom maximum back, boom exten­
sion horizontal, telescope extended
with cylinder bolt (d) accessible and
keep stick vertically
THE TELESCOPE CYLINDER
For shimming, only the outermost shaft must be
removed (see Chapter 6 for shaft service)
×1 __mm
(d) Remove the outer cylinder shaft
(e) Use the remote control to retrieve the
cylinder before removing the inner
cylinder shaft
Removing the cylinder
2. Guide the cylinder out through the back
of the boom extension
3. Uncouple the first hydraulic line (see
Chapter 6, hydraulic couplings)
×1 22mm
4. Disengage the cylinder and secure the
outer end by means of a thin shaft
through the cylinder eye (e)
5. Uncouple the second hydraulic line (see
Chapter 6, hydraulic couplings)
• Remove the telescope cylinder

×1 22mm Shimming the telescope

This method will minimise the amount of
steps needed to perform proper shimming
of the telescope, while preserving all func­
tionality of the hydraulic system.
SUGGESTED PREPARATIONS
×4 __mm
Detaching hydraulic hoses and stick
Let the stick rest on a pallet as illustrated
(f) Remove the bulkhead coupling brack­
×4 __mm ets on each side and the guard piece
(g) Remove the bulkhead coupling brack­
ets on each side of the telescope end
(h) Remove the shaft of the telescope
stick cylinder attachment, (see
Chapter 6 for pin service)
• Lower the cylinder end
(i) Remove the shaft of the stick joint,
(see Chapter 6 for shaft service)
×2 24mm
The stick is heavy, secure it well
so that it does not tip, e.g. by
means of a strap!

Continue on next page...

×2 24mm

69
21 Telescope

Shimming the telescope

1. Putting hose package and stick aside
The boom extension stripped from stick with hydraulic hoses,
maintaining hydraulic functionality (see Suggested preparations,
previous page)
(a) By means of a strap, the stick assembly may be moved in a safe man­
ner simply using the remote controlled boom and extension
(b) Place the stick on a pallet
• The balance of the stick may be controlled by trimming the
tool lever cylinder

2. Removing the telescope

(c) Remove the outer telescope cylinder
shaft (see previous page, 1d)
(d) Remove the four slot bolts
(e) Take care of the iron distance block
(f) Remove the four exit shims cover
bolts
– Allows for sliding the telescope's stick
cylinder attachment out through the
slot

×1 __mm

3. Remove the exit shims assembly

This allows for passage (in/out) of the inner
shims package.
(f) Shims cover/bracket bolts (×4)
(g) Shims covers (×2)
(h) Shims brackets (×4)
(i) Gliding pad (×4)
• Each pad is attached with two
pad screws (see also inner
shims, next page)
• Replace pads if no wear toler­
ance remain to the bolt heads
(j) Shims
When reassembling:
• Fit in as many shims as pos­
sible, without jamming the tele­
scope
• To fit them in more easily, see
method to widen exit, next page, I.
—II.

70
 Telescope 21

Shimming the telescope

4. Check the gap over the shims
– Pull out the telescope until the in­
ner gliding pads are in the exit
(rest the outer end on a bench)
(a) Check the gliding pads
– Measure how much the telescope
should be shimmed (b) under
each gliding pad
×8 __mm 5. Lift out the telescope
– Use method I.—II. below if needed
The telescope is heavy!
×8 __mm Take proper precautions!
– Remove the two counter sunk
screws with nuts (from the inside)
from each of the four gliding
pads
– Replace the pads if no wear toler­
ance remain to the bolt heads
(c) Fit in as many shims (b) as needed
and reattach the inner shims package
– Insert the shimmed telescope
through the boom extension exit
Use method I.—II. below if needed
6. Secure the telescope cylinder
• Fit in the outer cylinder shaft (see
Chapter 6, shaft/joint service)
7. Check that telescope will pull in all
the way
• If not; refit with slightly less shims

REASSEMBLING
Once the telescope operates with a tight fit.
Reverse step 1—3 (previous page). Pay atten­
tion to exit shimming in a likewise manner
as the inner shims.
Finally reattach stick, hoses and bulkhead
coupling brackets.

METHOD
Widening the telescope exit
It can be useful to temporarily widen the
boom extension exit, to facilitate passage
of a thicker shims package.
I. Fit one slot bolt through the outer­
most slot hole
• Fit on a nut inside the slot
(e) Insert the distance block sideways
×1 __mm II. Hold the nut inside the gap with a
spanner while tightening the bolt,
until the exit is wide enough

71
21 Telescope

72
 Boom and boom extension 22

22.Boom and boom extension DISASSEMBLING

Take proper precaution! The boom, extension and stick are heavy; use
proper means to support weight and structure!
1. REMOVING BOOM EXTENSION
Suggested preparations
• Remove stick (see chapter 20);
• Fully retract cylinders as illustrated
Procedure:
(a) Secure boom extension by means of a strong tied bridle and a cap­
able hoisting device
(b) Remove and disengage hydraulic hoses (see chapter 6)
– Guide the hoses out through the frame structure
(c) Remove the extension cylinder (see chapter 6)
(d) Remove extension joint shaft and lift away the boom extension
(e) Secure the boom by the extension joint (d)
– Carry out remaining dismantling as you secure the parts involved

2. REMOVING THE BASE PLATE

BOOM CYLINDER SHAFT
– Access right side shaft bolt with a
glide hammer, threading it
through the hoses

3. Remove the left side shaft bolt and

loosen the right side shaft bolt
(f) Remove the shaft by means of a glide
hammer
– Move boom forwards for better
access to shaft bolt

REASSEMBLING
Reverse the steps described above.

73
22 Boom and boom extension

74
 Hydraulic pressure tuning 23

23.Hydraulic pressure tuning This chapter describes how to fine tune the
system pressure;
Preparations
• Remove left sideplate and front shield
from the turret, see chap. 11.
• Remove LS hose from pump and plug it
with a PO-plug, see chap. 6
REMOTE TERMINAL DISPLAY
• Select Service mode
– Standby-mode will stay active for 3—4
seconds
• To maintain machine active:
– Press and hold left button of right
hand joy-stick
ADJUST TUNING SCREWS
In circulation pumping mode
1. Access the tuning screws
Low down at the front of the hydraulic
pump. locate the two tuning screws:
(a) Maximum pressure level
(b) LS (LoadSensing) pressure level
To access the screws:
– Remove the cap nuts and washers
2. Unlock the tuning screw
– Loosen the nut 3 turns while hold­
ing the adjustment screw in place
with an Allen key
3. Tune the pressure level
– Use the Allen key
• Decrease pressure: Turn anticlockwise
• Increase pressure: Turn clockwise

Pressure levels
×1 13mm
INCREASED LOAD – 250 BAR
×1 4mm Achieve increased load pressure level:
• Keep pressing down the outriggers.
The original sensors have a maximum reading of
249 Bar.
Adjust screw (a):
• Decrease pressure level reading to well
below 248 Bar
• Then increase gradually until the dis­
play reads 248—249 Bar
LOAD SENSING (LS) PRESSURE
LEVEL
Uncouple LS-hose from pump and plug
hose and opening for maximum accuracy.
Adjust screw (b) as described under “Adjust
tuning screws” above.
– Press and hold left button of right
×1 13mm hand joy-stick, while keeping joystick
in neutral position:
LS pressure level should be: 20±1 Bar

REASSEMBLING
Reverse steps 1—2 and reassemble front
shield and side plate.

75
23 Hydraulic pressure tuning

NORMAL MAXIMUM SYSTEM

LOAD LEVEL
The principle is similar to that of “Increased
load pressure level” described on previous
page. The adjustment however is done with
the system pressure limiter located on the in­
side of the pivot front valve as illustrated (a).

TERMINAL DISPLAY
Achieve remote terminal display service win­
dow as described on previous page:
• Keep extending one boom assembly cylin­
der (any one except for the telescope)
• Reading on remote terminal dis­
play should be 200 Bar

TUNING THE LOAD LEVEL

1. Unlock the tuning screw
– Loosen the 19mm nut 3 turns
×1 6mm while holding the adjustment screw
in place with a 6mm Allen key
2. Tune the pressure level
– Use the Allen key
• Decrease pressure: Turn anticlockwise
×1 19mm • Increase pressure: Turn clockwise

REASSEMBLING
Reverse step 1 and fit on the side plate.

76
 Remote control 24

24.Remote control See also exterior overview, chapter 4.

RADIO CONNECTION
The Bluetooth® (microwave) signal from
the remote control is programmed to com­
municate only with the machine it was de­
livered with. This is to secure that no extern­
al signals may ever compromise safety while
operating the machine.
Only one remote control can be paired with
a specific machine. A replacement remote
control has to be specifically programmed
before it can be used – see chapter 27.
CABLE CONNECTION
Each new machine is equipped with an or­
ange remote control cable as a convenience
measure in case of failure with radio trans­
mission or flat batteries.
Through cable connection, any Husqvarna
DMX310 remote control can operate the
machine, even if the original Bluetooth®
system is failing or the remote control de­
livered with the machine is otherwise out of
order.

INTERIOR OVERVIEW
Expose the interior of the remote control by
opening up the 9 Phillips screws (1)
1. Mounting screws (×9 Phillips)
2. Cable connection contact
3. Bluetooth radio link
4. Electronic circuit board comprising con­
trol terminal with display and control
buttons
5. Left hand joystick
– Four Phillips fasteners are access­
ible as illustrated (a)
6. Emergency button
7. Motor On/Off switch
8. Tool speed adjustment control
9. Slow motion control
10. JST connector for firmware upgrades
(see chapter 27)
11. Right hand joystick
– Four Phillips fasteners are access­
ible as illustrated (a)

×4

77
24 Remote control

78
 Grease pump 25

25.Grease pump The grease pump supplies a continuous flow of grease (d)
to the attached hydraulic breaker.
The grease pump (1) is mounted on a console under
the right side pivot bonnet/(hood). The console is se­
cured to the innermost slewing motor fasteners (see
chapter 18). The breaker mode will automatically activate
the grease pump by means of the T-valve (2), which is fit­
ted behind the console.
Accumulation of grease under the overpressure relief valve (e)
indicates blockage of grease flow to tool.

OVERVIEW
1. Grease pump
(a) Hydraulic fluid flow
(from T-valve, see (i) below)
×1 __mm
×2 __mm (b) Hydraulic return flow
(c) Cover cap for flow adjustment screw
(d) Tube attachment for tool grease
(e) Overpressure relief valve
(f) Grease exit – hose to tool
(g) Nipple for grease pump chamber
(h) Air release hole with Allen screw
(i) Grease pump Allen key fasteners
2. Grease pump L-valve
(j) Hydraulic pressure supply
(from Rear valve block, see chap. 17)
(k) Valve piston control spool
(l) Hydraulic pressure to grease pump
REPLACE TOOL GREASE TUBE
(Available as Spare Part)
• Remove empty tube by turning it anti­
clockwise
• Cut end of nuzzle to open new tube
• Attach new tube by fitting it inside (d)
– turn clockwise until tube is
firmly secured
Check that grease pump works
• Remove hose from grease exit (f)
• Remove the air release screw (h)
– Gently press tube (d) by hand,
until grease appears through (h)
• Press in tool grease through nipple (g),
until grease is pressed out through exit (f)
• Test run tool briefly to check that grease
is pumped out through exit (f)
• Secure grease hose to exit (f)
ADJUST PUMP CAPACITY
3. Remove the cover cap (c) by means of a
bladed screw driver
4. Reach in to adjust the pump capacity as
follows:
I. Turn screw clockwise until it reaches
its' innermost position (minimum
pump capacity)
II. Increase pump capacity from minim­
um:
– 3 turns = default factory setting
– 6 turns = maximum pump capa­
city

79
25 Grease pump

80
 Diagrams 26

26.Diagrams
Electric and hydraulic circuits
This chapter comprises diagrams of the electric and hydraulic circuits.
Before the 13 sheets of electric circuits, each electric component is described in the following reference tables:

Electric diagram components

81
26 Diagrams

Electric Diagram components

82
Diagrams 26

Electric circuit

83
26 Diagrams

ELECTRIC CIRCUIT

84
Diagrams 26

ELECTRIC CIRCUIT

85
26 Diagrams

ELECTRIC CIRCUIT

86
Diagrams 26

ELECTRIC CIRCUIT

87
26 Diagrams

ELECTRIC CIRCUIT

88
Diagrams 26

ELECTRIC CIRCUIT

89
26 Diagrams

ELECTRIC CIRCUIT

90
Diagrams 26

ELECTRIC CIRCUIT

91
26 Diagrams

ELECTRIC CIRCUIT

92
Diagrams 26

ELECTRIC CIRCUIT

93
26 Diagrams

ELECTRIC CIRCUIT

94
Diagrams 26

ELECTRIC CIRCUIT

95
26 Diagrams

Hydraulic circuit
BOOM—STICK

96
Diagrams 26

Hydraulic circuit
TURRET &
UNDERCARRIAGE

97
26 Diagrams

98
 Software 27

27.Sof
Sof tware INTRODUCTION
The control system of a Husqvarna DXR-machine comprises three main units:
• Machine with two control modules (PLCs) that control the machine functions,
e.g. all hydraulic functions, electric motor, grease pump, working light, horn etc.
• Control Terminal for the operator to remote control the machine by means of
joysticks, knobs and buttons and a TFT display to access machine functionality
and to monitor its status.
• Bluetooth® radio link comprising two Bluetooth® radio modules that transfer
CAN messages between Machine and Control Terminal.
– One Bluetooth® radio module is connected to the Machine's two control
modules through the machine CAN bus (see chapter 12)
– The other Bluetooth® radio module is located inside the remote Control
Terminal (see chapter 24)
Parameters of the control and Bluetooth® radio modules can be updated or edited
from a PC by means of special software and firmware. Descriptions, procedures on
how to connect to the control modules can be found in the Husqvarna service kit.
Please refer to your Husqvarna Service Center for further information.

99
27 Software

100
 Adjust to changed frequency (~50/~60Hz) 28

28.Adjust to changed frequency (~50/~60Hz)
ADJUSTMENT OF PUMP FLOW AND MAINS VOLTAGE
DXR 310 is factory set for power mains of 3×400V ~50Hz. When used with 3×460V
~60Hz some minor adjustments are necessary.
If any other power mains supply is required please contact your Husqvarna Service
Center for further advice.
This adjustment is applicable from S/N 3100007.

Adjust pump output flow

The pump capacity must be adjusted in ac­
cordance with the higher motor rotation
speed due to increased alternating current,
from 50Hz to 60Hz.
Preparations
• On the left side, remove the side plate and
the front cast piece (see chapter 11)
PROCEDURE
1. Locate the adjustment screw for maxim­
um pump flow
(a) Remove the cap nut and washer

×1 13mm
2. Loosen the 13mm nut 3 turns while
holding the adjustment screw in place
with an Allen key
×1 4mm
3. Turn the adjustment screw 2¾ turns
(990°) clockwise
– Use a 4mm Allen key
– If you are to adjust the DXR 310
from 60Hz to 50Hz the adjustment
screw must be turned 2¾ turns anti­
clockwise instead.
Reassembling
• While still holding the adjustment screw
in place with the Allen key
– Tighten the nut with the socket key
(reversing step 2)
• Put the cap nut with washer back on, re­
versing step 1a
FLOW METER READING
If a flow meter is available you can use this
to achieve the exact flow:
×1 13mm • Connect the flow meter to the hydraulic
tool connections on the stick
• Activate crusher mode and run function
• Read value and adjust if necessary
– The flow should be 65 l/m
(17.16 US gallons/minute)

! The remote control tool speed adjust­

ment knob must be set to max!
Increase flow: Adjust screw anticlockwise.
Reduce flow: Adjust screw clockwise.

101
28 Adjust to changed frequency (~50/~60Hz)

Adjustment of mains voltage range

The voltage range should be set according to the mains supply ±20V.
Preparations
• On the right side, remove the side plate (see chapter 11), open up the electric cab­
inet and locate the automatic phase relay (see chapter 19)

AUTOMATIC PHASE RELAY

Adjustment to nominal
460V~60Hz ±20V.
(for factory default 400V~50Hz,
see chapter 19)
– U▿ Minimum: 440V
– U▵ Maximum: 480V
Adjust to 460V~60Hz:
• Press repeatedly to select
U▿ Min. ↔ U▵ Max.
• Press + to increase or decrease
the displayed value:
AVAILABLE DISPLAY OPTIONS Changes are saved automatically.
The diagram below illustrates the sequence of available
functionality:
I. Display voltage over phases: U1—2, U2—3, U3—1
– Press + to display voltage between pairs
of phases (e.g. U2—3=461V)
II. Display adjustable voltage limits (160V—690V)
(a) Lower voltage limit: Press once
(b) Upper voltage limit: Press twice

102
 Tools 29
● = Service action

29.Tools
Service tools – supplied
Kit for Fluid change Kit of PO-plugs
Article No. 576 94 52–01 Article No. 576 94 53–01
Male—male (13—19) ORFS coupler Pressure proof metal plugs
+ Drain hose (2m) with female (19)
● Selection of hose plugs of occur­
ORFS coupler
ring sizes.
● Used for change of hydraulic fluid
and for flushing hydraulic system
(see chapter 16). Kit of plastic plugs and caps

Kit of O-rings Article No. 576 94 55–01

Article No. 576 94 54–01 ● Selection of male and female ser­
vice plugs. Prevent leakage, or con­
● Selection of replacement hydraulic tamination of hydraulic system.
O-rings of occurring sizes.

Kit of NOP-plugs Kit of VSTI-plugs

Article No. 576 94 56–01 Article No. 576 94 57–01
Pressure proof metal caps Pressure proof metal plugs
● Selection of occurring sizes. ● Selection of male plugs of occur­
ring sizes for e.g. manifold ports.

Recommended tools – not supplied

Absorbents
● Absorbent sheets to collect spill from hydraulic fluid.

WRENCH TOOLS AND SPANNERS

Extra extension shaft ● Added extension needed when re­
moving cooler, main motor, hy­
draulic reservoir and rear manifold
(see chapter 14—17)
¾” Allen
19mm, +500Nm
● For tightening track sides (see
chapter 7).
Crow foot wrench
14, 16, 17mm
● Rear manifold fastener, slewing
motor dipstick and fasteners, main
motor (see chapter 15, 17 and 18).
Spanner kit + short kit
10—19mm
● Covers basic service.
Standard and short length.
Large size spanners ● Occurring larger dimensions.
30, 32, 36, 41mm Standard and short length.
½” Allen keys ● Various bolts and screws.
Standard kit
Ratchet wrenches
Large+small
● Various bolts and screws.

TOOLS FOR MEASURING

Torque wrench Torque wrench, Large
20—200Nm 500Nm, 3/4”
● Tightening torque of various ● Tightening torque of track units
mountings (see chapter 3). (see chapter 3 and 8).

Flow meter
Feeler blade
65l/m
0.2mm
● Useful for complementary meas­
urement of actual hydraulic flow ● Backlash measurement (see chapter
(see chapter 27). 18)

103
29 Tools
● = Service action

Recommended tools – not supplied

HOIST AND SUPPORT

Pulley hoist (or equiv.) Ratchet strap

2500kg 2000kg
● All heavy lifting jobs, including ● For securing or lifting – e.g.
loading entire machine. chapter 11 and 15.

Sling strap ×2
1000kg, 1m
● For securing or lifting – e.g.
Motor hoist chapter 11 and 15.
200kg
● Lifting counterweight and main
motor (see chapter 11 and 15)
Eye bolt ×2
M12
● For lifting counterweight (see
chapter 11).

Pallet lift (with pallets)

1500kg Jack stands ×4
—80cm, 2ton
● Various tasks involving moving
heavy pieces. ● For positioning.

Lift jack
1500kg
● Various lifting tasks.

MISCELLANEOUS TOOLS
Crowbar Grease gun ×3
Medium ● 1 gun for multi-purpose grease
● Various tasks. (joints, cylinder shafts, slewing
ring) – see chapter 3
● 1 gun for hammer grease (grease
Glide hammer pump service) – see chapter 25
Medium ● 1 gun for crusher grease. Manually
applied directly to tool
● Lower boom cylinder shaft (see
chapter 22).
Mallet – hard plastic Oil can
Medium ≥ 0,7l
● Various tasks such as joint shafts. ● Track drive and slewing motor oil
(see chapter 8 and 18).

104
 Tools 29
● = Service action

105
 Endoc AB

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