SERVICE MANUAL EC 240 + Remove the bolts (6, Fig. 6) of ball-bearing ‘swing bearing at the superstructure. Keep the spacers (7) for re-use. The superstructure is now detached from the undercarriage. ‘Lift the superstructure carefully until the swing ‘gearbox pinion is free. Swing the superstruc- ture away from the undercarriage. ‘+ Take the swing bearing into the lifting tackle (Fig. 5) by inserting three lifting eye bolts at 120 degree intervals through the drilled holes and holding them in place with nuts. ‘+ Remove the bolts (4, Fig. 6). Keep the spacers (3) for re-use. ‘+ Lift the swing bearing from the undercarriage. * Check the housing (1, Fig. 1) and seal (5) of the swing bearing. Repair or replace if damag- gt XS S WES Fae 73179387,00 usSERVICE MANUAL EC 240 Installing the swing bearing + Ifa new swing bearing is to be installed, first remove the anti-corrosion coating, * Clean all contact surfaces on the superstruc- ture and the undercarriage thoroughly. The contact surfaces must be bright, dry and ‘grease-tree. Remove any roughness and burrs, Clean drilled holes in the undercarriage. Clean the threaded holes on the superstructure care- fully, checking threads and recutting them if damaged. ‘+ Apply a bonding agent (PIN 73171476) to the ‘contact surface on the undercarriage, using a paint roller, a hard brush or a plastic spatula, A WARNING Keep the bonding agent away from the drilled holes. Any bonding agent in the threads causes increased friction and con- ‘sequently to invalidates the tightening torque data. ‘+ Take the new swing bearing into the iting tackle. Tum inner and outer raceway until the *S'-mark on the outer raceway is at 90 degrees to the travelling direction, and the "S'-mark on the inner raceway is opposite (Fig. 7) Fa? ‘Swing bearings are hardened inductively. The 'S'-mark marks those points between start and fend of raceway hardening, which, due to the hardening process - could not be hardened. The swing bearing is therefore deliberately installed in such a way that those points are outside the main stress zone, ‘Swing the bearing above the undercarriage, swing It above the contact surface without set- ting it down. Screw in at least three new screws (4, Fig. 6) with spacers (8) as a guide. Set down slewing ring caretuly. Remove iting tackle from slewing ring, Screw in the other new screws with the spac- fers and tighten crosswise with a torque wrench {806 table for tightening torque). Mark tightened screws. ‘Apply the bonding agent to the contact surface ff the superstructure, as daseribed above Apply grease generously to the teeth of the ‘swing bearing until the gaps between the teeth are filed with grease. ‘Swing the superstructure above the undercar- fiage and swing it above the swing bearing without setting it down, Continue to lower the superstructure carefully, uiding the pinion into the teeth. Screw in at least three new screws (6, Fig. 6) with spacers (7) as a guide, Lower the superstructure carefully, Screw in the other new screws with spacers and tighten crosswise with a torque wrench {see table for tightening torque). Mark tightened screws. (A screw cannot be ‘mounted in the slewing gearbox area for struc- tural reasons). Re-install the rotor locking element (Fig. 4). Connect all hydraulic lines to the rotor. Remove the liting tackle from the superstruc- ture. Start up the machine and check all hydraulic lines at the rotor for tightness. The bonding agent between slewing ring and undercarriage | superstructure increases the load capacity of the screwed connection while sealing the joint gaps. The bonding agent hardens without exposure to air. The ultimate strength is attained after six hours. Only then may the machine be fully loaded, a 73179387,00 us 3SERVICE MANUAL EC 240 ‘Swing gearbox pinion / Checking the tooth flank clearance on the swing ring ‘This work must be done only if the tooth flank clearance between the swing gearbox pinion and the swing bearing teeth are believed to be insulti- cient ‘This may be the case, for example, if problems have occurred in setting down the superstructure and securing it to the swing bearing. Insuificient tooth flank clearance may cause dam- age to the swing bearing and swing gearbox. A WARNING Risk of injury ‘One person is under the machine while the superstructure is being swing. ‘The following operations must be execut- ed with extreme caution. ‘Three persons are needed: one sits on the operator's seat, one is under the su- Perstructure, and one acts as a manager. All these persons must be within sight of ‘one another and be able to give and re- ceive hand signals. ‘+ Remove the cover of the swing gearbox pinion, ‘+ Swing the superstructure until the teeth marked with green paint are in front of the swing gear- box pinion, ‘These green teeth mark the point where the internal ring deviates most from the ideal circle, le. the part of the ring where the diameter is smallest, + The person below the superstructure forces a 30 centimeter(12 inchs) long strip of flat lead between the teeth of the pinion and of the slewing ring. The lead stip must run through the toothing when the pinion engages in the green-marked teeth (see Fig. 8). + IF it does 0, the manager signals to the oper- ator that he should swing the superstructure at ‘minimum speed. + As soon as the lead strip is contacted by the teeth, it must be released so that the hand is ‘not caught in the teeth. + Swing the superstructure only until the lead strip has passed through the teeth (Fig. 8). Foe * Switch off the engine, + Measure the thickness of the lead strip; it should be at least 0.3°? mm. a 7 73179387,00 usSERVICE MANUAL EC 240 This page intentionally left blank. 73179387,00 us 6SERVICE MANUAL EC 240 rT 6 73179387,00 usSERVICE MANUAL EC 240 ENGINE, INSTALLATION Removing and installing the diesel engine Legend to Fig. 1 tem | Quan. | Description Waight Torque kg/lb | Thread |Material |Wrench| M, |Torque size | grade | size | Nm | Ibft. mm 1 | 1 [Bracket 2 | 1 | Bracket 3 | 1 | Bracket a [1 [Bracket 5 | 4 | Spacer 6 | 13 | Spacer 7 | 16 | Spacer 8 | 1 | Spacer 9 | 4 | Bearing 10 | 4 |Hexscrow mie | 109 | 24 | 250] 185 11 | 14. [Hex screw wiz | too | 19 | 104] 77 12 | 16 |Hexscrew mioxso| to9 | 17 | 60 | 44 13 | 1 | Engine with pumps fa50/ 1439 General information The diesel engine with the flange-mounted hy- draulic pumps is resiliently mounted at three points (Fig. 1): two brackets are bolted laterally fon the hydraulic pump side, and one bracket on the opposite end face. (Repair work on the engine is described in the technical manual issued by the engine manufac- turer). 73179387,00 us 6 7SERVICE MANUAL EC 240 Removing the diesel engine The following aids must be available: ‘a crane and lifting tackle with a load-bearing capacity of at least 1000 kg (1.5 tons) for lifting and moving the engine, «lifting tackle matching the engine (see technical manual issued by engine manufacturer), ‘+ wrench / socket wrench, width across flats 17, 19 mm and 24 mm, ‘+ a torque wrench designed for a tightening torque of 250 Nm (185ibf) ‘Also needed: ‘+ a container to catch hydraulic oil (min. 200 1 / 55 gal), ‘+ a container to catch coolant (min, 351 / 10 gal), ‘+ a standard tool kit for dismantling lines at the hydraulic pumps, A WARNING Risk of injury from rotating fan blades and V-belts. Stop the engine before opening the engine compartment. Risk of burns from hot parts of the en- gine, exhaust system, hydraulic pumps and coolers. Never start work until all components in the engine compartment have cooled off. A CAUTION Escaping consumables such as fuel, hy- draulic oil, engine oil or coolant are an environmental hazard. Put adequately large containers in place to catch them. Catch drained-off fluids for re-use or dis- card in accordance with environmental regulations. Close openings, lines and hoses. This prevents contaminants from penetrat- ing and damaging the engine and hydrau- lic system. Disconnect the batteries. Unscrew the holder for the compression springs of the engine cover and fold the cover back towards the counterweight. (Attention: the compression springs are preten- sioned). Remove the housing plates from below the en- gine and the pump compartment, Clean the engine. ‘Mount lifting tackle for the engine (see tech- nical manual issued by engine manufacturer). Drain the hydraulic oll out of the hydraulic oll reservoir and combi-cooler. Drain the coolant out of the engine and the combi-cooler. Disconnect the intake, pressure and control lines from the hydraulic pumps. Disconnect the fuel, air and exhaust lines from the engine. Disconnect all the electrical connections and ‘grounding wires from the engine. Disconnect all the connections to the combi- cooler. Remove the bolts (10, 13, Fig. 1) from the engine bearings. Lift the engine out carefully. 8 73179387,00 usSERVICE MANUAL EC 240 Installing the diesel engine Prior to installation: Check the rubber bearings (9, Fig. 1) in the brackets and the bolts of engine bearing; replace if damaged. Installation of the diesel engine is done in the reverse sequence as the removal ‘+ Align the engine. ‘Tighten the engine bearing bolts with a torque wrench (86 table for tightening torques). After installation: Check the fuel, engine oil, coolant and hydraulic cil level; top up if necessary. Only then may the engine be started up. Check all connections for tightness. o 73179387,00 us 19SERVICE MANUAL EC 240 ENGINE, COUPLING General information ‘The diesel engine output is transmitted to the hydraulic pumps by means of a resilient coupling. The coupling (4, Fig, flywheel of the engine 1) is fastened to the The hub (1, Fig. 2) is pushed onto the splined shaft of the dual pump and secured with a clamp- ing wedge (5). The clamping wedge is pressed conto the splining with a stud (4). Pot tem | Quan. | Description ‘Weight Torque kg/tb | Thread |Material |Wrench| M, |Torque size | grade | size | Nm | IDft. mm + [1 [ Pumps unit 165/364 2 | 9 |Hexscrew mioxs5| 109 | 17 | 60 | 44 3 | 8 | Hexsocket-head screw ae- 16 [8Grade | we [55 | 40 4 | 1 [Coupling 23/51 5 | 1 Engine 453/999 20 6 73179387,00 usSERVICE MANUAL EC 240 Fig? tem | Quan. | Description ‘Weight Torque kg/tb | Thread {Material |Wrench) M, |Torque size | grade | size | Nm | Ibft. mm + | + [coupling nub 2 | 1 | intermediate ring 3 | 1 [Coupling flange 4 | 1 [Setscrew wizx25| 45H | 6 | 46 | 34 5 | 1 | Clamping wedge 73179387,00 us 6 2SERVICE MANUAL EC 240 Removing the coupling The following aids must be available: ‘a crane and lifting tackle with a load-bearing capacity of at least 200 kg (600Ib) for lifting ‘and moving the engine, ‘+ a wrench / socket wrench, width across flats 17 ‘+ @ hexagon-socket-screw key / hexagon-socket- ‘screw wrenches, width across flats 6 mm and om ‘+ a torque wrench designed for a tightening toraue of 60 Nem (45 Ibft Also needed: ‘a container to catch hydraulic oil (min. 200 1 / 55 gal), ‘+ a standard too! kit for dismantling lines at hy- mT Fae Reassembling the Swing Gearbox * Thorougly remove any paint and grease from the seating surfaces (A, Fig. 1) of the swing gearbox and the superstructure frame with thin- nner (PINo. 73171477). Then check for damage. ‘Seating surfaces must be bright, dry and free of grease. + Apply a ring of adhesive (P/No. 73171476) of about 1 mm in thickness around each tapped bolt hole (seating surface A of the superstruc- ture frame) A CAUTION ‘Apply the adhesive at some distance to the holes so that no adhesive can get to the threads when the parts are joined. Do not apply the adhesive before the gearbox is ready for assembling. * Attach lifting tackle to the gearbox, bring to fitting position and set down without displace- ment. + Tum in and tighten the bolts (6). Proceed crosswise, mark tightened bolts. + Re-connect the line (1, Fig. 1) of the expansion reservoir (2) and top up the gearbox with oil according to the Operator's Manual + Brush some lubricating paste (P/No. 73171484) over the driving pinion of the swing motor and fit the motor. + Secure the bolts (5) with liquid stew locking agent (PINo. 73171473) and tighten. + Re-connect the brake line (4) and bleed the superstructure holding brake. 73179387,00 us 1SERVICE MANUAL EC 240 This page intentionally left blank. 2 7 73179387,00 usSERVICE MANUAL EC 240 Technical handbook "Traveling Gearbox" 73179387,00 us 7