SERVICE MANUAL EC 240 Fitting of idler For fitting of the idler, the following sequence must be observed Pat Fas 1. Press or drive both bushes (3) down to the 5. Slide one half of the duo-cone seal (9) over limit stop into the idler (8) the shaft (5) and insert into the slider (2) (see ‘Duo-cone seals") Foe Fo 2. Insert an O-ring (4) into the slider (2)so that 6. Insert the other part of the duo-cone seal (9) the O-ring is in the groove inside the slider. Into the idler (8) 3. Insert shaft (S)carefully into the slider (2), pay- ing attention not to damage the O-ring (4), 4, Secure shaft (6) with clamping bush (1) in slider (2). Drive in olamping bush (1) K5> so that the gap of the bush faces the shaft, 8 a 73179387,00 usSERVICE MANUAL EC 240 Fas 7. Slide the pre-assembled slider (2) with shaft (6) and duo-cone seal (9) into the idler (8). Before assembling the duo-cone seal clean the contact surface carefully and cover the contact surface slightly with olf. Do not oll the other areas of the duo-cone seals. Fas 8, Insert one half of the second duo-cone seal (9) into the idler (8). Fo7 9. Insert the second O-ring (4) and the other halt of the second duo-cone seal (9) into the sec- fond slider (2). The O-ring (4) must be in the groove of the slider (2) Foe 10.Slide the the pre-assembled slider (2) with (O-ring and duo-cone seal over the pre-assem- bled shaft (5) in the idler (8) and secure on shaft (5) with clamping bush (1). The gap of the clamping bush must face the shatt. Before assembling the duo-cone seal clean the contact surface carefully and cover the contact surface slightly with oll. Do not oll the other areas of the duo-cone seals. 73179387,00 us 19SERVICE MANUAL EC 240 Fae 11.Fill in lubricating oll through the bores in the sliders (2), The type of oil and the quantity are ‘et out in the Operator's Manual Close the bores after filing using the plugs ©). Fig. 10 12.Attach the fork (7) with hex screws (10) to the sliders (2) fitled to the idler (8) (tightening torques see table), 3 73179387,00 usSERVICE MANUAL EC 240 This page intentionally left blank. 73179387,00 us o aASERVICE MANUAL EC 240 Bottom rollers Bottom rollers have lifetime lubrication. They do ot require any maintenance until the wear limits The roller can be made fully operational by re- moving and cleaning it, and then filing it with have been reached fresh ol ‘The rollers are sealed with duo-cone seals (8, Fig. 1). Function and assembly of duo-cone seals. - see chapter "Duo-cone seal" The majority of roller leaks is due to dit that enters through the labyrinth (see arrow, Fig. 2) and penetrates into the duo-cone seals. Components of the bottom roller om] Quan. | Description ‘Weight Torque kg/lb | Thread |Material |Wrench| M, |Torque size | grade | size | Nm | Ibft. mm 1 | 1 [Bottom roller 36/80 2 | 2 | Bearing 3/10 3 | 2 [Locking pin 4 5 | 1 | Screwplug 6 | 1 | Bearing 3/10 7 | 2 [Bushing & | 2 | Duo-cone seal @ | 2 [ORing 10] 1 [Axe 9/20 11 | 1 [Roller 22/50 2 a 73179387,00 usSERVICE MANUAL EC 240SERVICE MANUAL EC 240 Top roller (On each track frame 2 top rollers are installed Top rollers have lifetime lubrication. They do not require any maintenance until the wear limits have been reached The majority of roller leaks is due to din that enters through the labyrinth (see arrow, Fig. 2) land penetrates into the duo-cone seals, The roller can be made fully operational by re- moving and cleaning it, and then filing it with ‘The rollers are sealed with duo-cone seals (11, fresh oil Fig. 1). Function and assembly of duo-cone seals. - see chapter ‘Duo-cone seal" Components of the top roller (Fig. 1) tem | Quan. | Description Weight Torque kg/tb | Thread |Material |Wrench| M, |Torque size | grade | size | Nm | IDft. mm 1 | 1 [Toprotier 14731 2 3 | 1 [Cover 4] 1 [oRing 5 | 2 | Hex.bott fps-10 65-7 4 6 | 2 | Washer 7 | 2 [Bushing @ | 1 | Roller 8/18 @ | 1 | Scewplug jao-61] 36-45 10] 2 [O-Ring 11 | 1 | Duo-cone seal 12| 1 [Bearing 13] 1 [axe 3/10 2a a 73179387,00 usSERVICE MANUAL EC 240 9 3 56 7 8 10 11 10 2 13 Fae a 73179387,00 us a 2SERVICE MANUAL EC 240 Sprocket ‘The sprocket is bolted to the travel gearbox + Assembly requirements Removal and installation of the sprocket is pos- sible with installed travel gearbox. ‘+ Tightening bolts ‘The thread and the contact surface of the bolt head are to be slightly oiled + Contact surface ‘Check the contact surface of sprocket and trav- ‘1 gearbox for damage and clean with thinner (Part-no, 73171477) from paint and grease. All contact surfaces must be cleaned down to the bright metal and be dry and free from grease, + Thread holes All thread holes in the travel gearbox have to be cleaned with compressed air, carefully ‘checked for paint, rust and damage. If required the threads are to be taped again + Adhesive ‘When the sprocket is prepared for installation apply a thin layer of adhesive (Part-no 73176144) onto one of the contact surfaces. ‘Apply the adhesive appr. 10 mm clear of the thread holes, When assembling the sprocket no adhesive must reach the thread holes, The Penetration of adhesive into the thread hole Fesults in increased friction and thus in wrong tightening of the botts. * Installation A CAUTION Start assembly immediately after applica- tion of the adhesive. Hardening of the adhesive begins after joining the metal surfaces under the ex- clusion of air and is generally completed after approx. 48 hours at an ambient tem- perature of 68°F. The hardening process begins only after a considerable initial delay so that the fit- ting operations may extend over a period of 8 hours maximum. At temperatures of -50’F it is necessary to spray an activator (Part no. 73176145) ‘onto the second contact surface, i.e. the one without adhesive. ‘The bolts have to be tightened crosswise with the required torque. 26 73179387,00 usSERVICE MANUAL EC 240 Ft Components of the sprocket (Fig. 1) tem | Quan. | Description ‘Weight Torque kg/tb | Thread |Material |Wrench| M, |Torque size | grade | size | Nm | Ibft. mm 1 | 1 [Sprocket 42/93 2 | 2 | Travelgearbox 167/368 3 | 20 |Hex.bott Ma0x15°| 109 | 30 | 750] 53 "| with tiquid locking a 73179387,00 us a aSERVICE MANUAL EC 240 This page intentionally left blank. 28 a 73179387,00 usSERVICE MANUAL EC 240 Travel gearbox aroosse Removal and installation ‘The removal and installation of the travel gearbox is described in chapter 07. a 73179387,00 us a 29SERVICE MANUAL EC 240 This page intentionally left blank. 30 a 73179387,00 usSERVICE MANUAL EC 240 Track pads 2100899 Replacing track pads Fat Fg? Replace wom or damaged crawler shoes imme: * Screw new crawler shoe on. Ensure that the diately to prevent damage to the crawler unit ruts are correct seated in the grooves in the chain lnk (Fig. 2). + Screw out screws (Fig. 1) and remove damag- ed craviler shoe. + Tighten the fastening screws of the crawler shoe using a torque wrench a ‘+ Smooth and clean bearing surfaces of crawler chain and new crawler shoe. ‘+ Apply paratfine oil to bearing surfaces and then ‘apply silicon corundum powder, grain 120 - 150, 73179387,00 us a aSERVICE MANUAL EC 240 This page intentionally left blank. 2 a 73179387,00 usSERVICE MANUAL EC 240 Duo-cone seals Duo-cone seals (also referred to as steel-on-stee! seals) are used as shaft seals. The arrangement of the seal is such that one steel ring, elastically mounted in the fixed component, lies/runs axially against a second steel ring that is also elastically ‘mounted, but this time in the rotating component. Duo-cone seals are used in the excavator's bot- ‘tom rollers, support rollers and idlers. Leakages In such components are usually due to damaged duo-cone seals. In case of leakages, the duo-cone seals are to be changed imme: diately Observe the following points when assembling duo-cone seals: + The running surfaces "A" of the steel rings (1 Fig. 1) must be completely free of scratches land scores. Clean all traces of oil and dust from running surfaces "A" and seating bevels. All surfaces must be dry and free of rust, slag and scale. if 2 Place one complete half (1) and (2) of the duo-cone seal into/onto the rigid component ‘and one complete half into/onto the rotating ‘component (Fig. 3) - but without using any oil Make sure that distance "C’ Is equal all the way around the seal Fat ‘+ Draw rubber seal (2) onto steel ring (1, Fig. 2) ‘The rubber ring (2) is correctly positioned when it sits twist-ree parallel to the surface of the steel ring (1), . 9-8 Before fitting the two machine components (ig- id and rotating) together, carefully wipe the sur- faces "A" of the steel rings (1) to remove any foreign bodies or even finger-prints. Then apply a drop of thin oil between the running surfaces, but without allowing oil to get onto the other parts, A CAUTION NEVER fit a new half of a duo-cone seal to aused half. When re-assembling used duocone seals, make sure that pairs that were previously installed together are kept together. 73179387,00 us 33Bottom rollers c Closing the track chain Components ofthe bottom roller Components ofthe idler Components ofthe sprocket (Fig 1) Components ofthe top roller (Fig. 1). Components ofthe travel system Crawler chain - Checking tension D Danger in the event of non-obser-vance of the safety instructions Duo-cone seals F Fitting of idler. Foreword G General. ler ° (Opening the track chain, R Releasing track chain tension .... Removal and installation Repair preparations, Replacing track links Replacing track pads. Flues for safety at work 1" 7 27 24 15 18 16 10 12 12 31 s Safety Instructions Sprocket T Tensioning the track chain Top roller ‘Track - direction of travel Track chain ‘Track pads. Travel gearbox. Travel system u UNDERCARRIAGE, w Wear limits. 26 16 24 “4 31 29SUPERSTRUCTURE Foreword. Safety Instructions. Danger in the event of non-obser-vance of the salety InstFUCtions. nn: aot ules for safety at work 2 BALL-BEARING SWING BEARING General information a Dismantling / installing the ball-bearing swing ring Tools and aids oe sonnei sow 10. Dismantiing the swing bearing nnn . soon V1 Installing the swing bearing 13 ‘Swing gearbox pinion / Checking the tooth flank clearance on the swing ring “ ENGINE, INSTALLATION. Removing and installing the diesel engine General information nn sonnei a wo WT Removing the diesel engine 18 Instaling the diesel engine. 19 ENGINE, COUPLING General information ... son sev soon 20 Removing the coupling, 22 Instaling the coupling 23SERVICE MANUAL EC 240 SUPERSTRUCTURE Foreword The "Technical Specifications’ manual contains important information for personnel servicing the machine, Machine specifications listed elsewhere in the machine documents are not always re- peated in this book. ‘The documentation includes: + the operator's manual + the parts catalog ‘the dimension table with the technical data of the machine. ‘The present brochure does not contain the speci- fications of auxiliary units for the operation of additional or optional equipment or the specifica- tions of individual machines. ‘The refiling quantities specified for consumables are approximate quantities which are intended as {help for planning consumable requirements. Each unit is equipped with a suitable checking devices, e.g. dipstick or checking plugs, permit- ting the operator to check proper filing of the units. Safety Instructions Danger in the event of non-obser-vance of the safety instructions A WARNING This hydraulic excavator has been built in accordance with state-of-the-art standards and the recognized safety rules. However, operating the machine when a fault is suspected or has occurred, or car- rying out repair work inexpertly may = endanger the lives of persons In con- tact with it + damage the machine and other prop- erty. The hydraulic excavator must be stopped immediately when any damage is suspect- ed or occurring, to ensure that the safety of the operator, other persons at the place of use or other material property is not ‘compromised. All components are carefully coordinated. Trouble-free operation and a long service life can only be achieved with original spare parts. 73179387,00 usSERVICE MANUAL EC 240 Rules for safety at work A WARNING Personnel ‘The machine must not be started by un- authorized persons. It must therefore be secured. Observe the accident prevention regula: tions. ‘The hydraulic excavator may be operated, serviced or repaired only by specially trained and authorized personnel with the appropriate technical know-how. If such know-how is lacking, meticulous Instruction must be given by experienced personnel. ‘The personnel must have read and under- stood the operator's manual and in par- ticular the chapter “Fundamental Safety Instructions". ‘Only such persons may start up the ma- chine during assembly work in order to adjust the attachments. Incorrect operation of the machine or the attachments may give rise to life-threaten- ing situations. During all works, always observe the start-up and shut-down procedures pre- scribed in the operator's manual. A WARNING Personnel Personal protective gear and working clothing: Wear a safety helmet, safety footwear, gloves and safety glasses. Wear closely fitting working clothing when working on the machin Loose, wide garments may catch on ma- chine parts and result in injury. the work to be carried out requires aux- 6, @.g. operators, the competences of each individual helper must be clearly defined beforehand. The idual responsibilities must be meticulously observed to avoid unclear ‘competences endangering safety. Tools, hoists, slings, stands and other de- vices must be in a reliable, safe state. Metal splinters may cause injury when at- tachment bolts are being driven in or out. A brass or copper drift should therefore be used for this purpose, and safety glasses must be worn. For climbing onto or off the machine, use only the ladders, steps, platforms and handrails provided for this purpose. ‘Always keep ladders, steps and platforms in a non-slip state. Remove any oil, grease, dirt, clay, snow, ice and other foreign matter immediately. 73179387,00 usSERVICE MANUAL EC 240 A WARNING Securing the working equipment Before carrying out assembly work, the machine and the attachments must be se- cured against inadvertent and unauthoriz- ed starting, e.g. by placing chocks under the wheels or tracks and by setting the working equipment on the ground. Set the working equipment on the ground in such a way that no movements can be made when mechanical or hydraulic con- nections become detached. Secure any equipment or component which Is to be mounted or dismantled or whose position is to be changed using hoists or appropriate slinging/supporting devices to prevent them from moving, Systems and units (e.g. pipes, accumula- tors, etc.) must be properly depressurized before being opened. Protective devices on moving mact parts may be opened or removed only when the drive unit is stationary and pro- tected against inadvertent starting. Before recommissioning, all protective de- vices must be refitted. A WARNING Hydraulic and lubricating system Always observe the safety regulations ap- plicable to the product when handling oils, greases and other chemical sub- stances. Unused but open bores, pipelines and hose connections must be closed in a Refill collected hydraulic oil back into the hydraulic system only through the return- flow filters. Dispose of waste oil without pol environment. Observe the correct working sequence when fitting or replacing components or equipment. The working sequence has been specified and tested by qualified experts. Replace defective, mechanically prestres- sed units only as an entirety. Never open them. In exceptional cases, open only when the system and the operating sequence are precisely known. The Technical Manual contains no information on such work. When the machine is at operating tem- perature, the consumables are at least at the same temperature. Precautions must therefore be taken to prevent burning or scalding. Be careful when handling acids, e.g. bat- tery acid, Acid splashes may injure the eyes and the skin. Do not smoke when handling flammable liquids. Be careful with open flames and unprotec- ted light. Not only fuel but also other consumables often have a low flash point and catch fire easily. ing the 73179387,00 usSERVICE MANUAL EC 240 A WARNING Conversions or modifications to the machine Unauthorized conversions or modifica tions of the hydraulic excavator are for- bidden for reasons of safety. ‘The nominal pressure of the pressure re- lief valves must not be modified. Do not remove the lead seals from pressure-relief valves and pressure accu- mulators. A CAUTION Recommissioning Prior to recommissioning: = Grease all lubricating points. = Check all oll levels and make the nec- essary corrections. = Carry out function checks of all re Paired components. = Check all functions of the excavator including the brakes during a test run. Release the hydraulic excavator for re- commissioning only after all functions have been found to work perfectly. 73179387,00 usSERVICE MANUAL EC 240 This page intentionally left blank. 73179387,00 us 6SERVICE MANUAL EC 240 BALL-BEARING SWING BEARING \\ lm, Fat 73179387,00 usSERVICE MANUAL EC 240 tem | Quan. | Description ‘Weight Torque kg/Ib | Thread |Material |Wrench) M, |Torque size | grade | size | Nm | Ibft. mm 1 | 1 [Covering 18/33 2 | 1 | Swing bearing 367/809 3 | 36 | Spacer 4 [36 [Hex screw IMzaxt.sx- 109 | 92 | 720] 631 100) 5 | 1 [Seal 6 | 36 | Hoxsorow waaxtt0| 108 | 92 | 680 | S02 7 | 36 | Spacer ut glue on the connecting surface of superstructure and undercarriage (omni) 73179387,00 usSERVICE MANUAL EC 240 General information The swing bearing of this machine is a single- race ball bearing. It comprises a toothed inner raceway (1, Fig. 2), the outer raceway (2) and the balls running between them. ‘The toothed inner raceway is secured to the un- dercarriage with 36 screws, and the outer raceway to the superstructure with 36 screws. The pinion of the swing gearbox engages in the teeth, allowing the superstructure to be swing on the undercarriage. Six lubricating nipples (3) are located on the cir- ‘cumference of the swing bearing for lubrication of the slewing ring bearing. The teeth are lubricated through a lubricating nipple at the A-frame (see ‘Owner's Machine Manual). Fig? 73179387,00 usSERVICE MANUAL EC 240 This page intentionally left blank. 73179387,00 us 6SERVICE MANUAL EC 240 Dismantling / installing the ball-bearing swing ring aa08e10 Tools and aids Before the swing bearing can be replaced, the superstructure of the machine must be removed. ‘The following aids must be available for this pur- pose: ‘+ two cranes (each with a load-bearing capacity ‘of 20.000 kg / 25 tons), support as in Fig. 3 Using lifting belts with a load-bearing capacity ‘of 20.000 kg (25 tons) to liftoff the machine superstructure, ‘a crane and lifting tackle with a load-bearing capacity of at least 260 kg (600 Ib) to lift and move the ball-bearing slewing ring, ‘+ wrench / socket wrench, width across flats 30 + torque wrench designed for a tightening torque ‘of 540 Nm (200 Ibft Also needed: * a spatula / three-square scraper to clean the contact surfaces, * cleaning agent * bonding agent (P/N 73171476) for bonding the ball-bearing slewing ring, * lubricating grease (P/N 73175845), ‘+ new fastening screws for the slewing ring (see parts catalog) Fas 0 73179387,00 usSERVICE MANUAL EC 240 Dismantling the swing bearing A WARNING Risk of accidents Lifting eyes are welded to some machine components (e.g. to the counterweight ‘and to the boom). Never lift the entire machine by means of these eyes. They fare not designed for loads on this scale and may break. ‘The eyes may be used only for lifting the respective component when installing it. Depressurize hydraulic system. Secure the undercarriage from inadvertent ‘movement by chocking the tracks. Take superstructure into the lifting tackle (Fig. 3) and tighten lifting tackle, but do not lift superstructure, Disconnect all hydraulic lines to the undercar- ‘lage at the rotor. Dismantie the rotor locking element (Fig. 4). Fad 73179387,00 us 1