WI PN 19 005-02 Modification of Control Block For Slewing

WORK INSTRUCTIONS WI_TDG PN 19 005-02
MODIFICATION OF CONTROL BLOCK FOR SLEWING
RELATED BULLETIN
TDG PN 19 005-01
ASSOCIATED MODELS
AC 45City SN 71301 to 71324 (except 71320)

AC 55-3 SN 51301 to 51327 (except 51324)
AC 60-3 SN 54301 to 54312
AC 100-4L SN 10551 to 10652 (except 10624; 10625; 10630; 10646)
AC 130-5 SN 35300 to 35388 (except 35375; 35385; 35387)
AC 160-5 SN 38400 to 38491 (except 38485; 38487)
AC 220-5 SN 82350 to 82535 (except 82507; 82518; 82523)
AC 250-5 SN 82350 to 82535 (except 82507; 82518; 82523)
AC 300-6 SN 85401 to 85427 (except 85424; 85426)
ALLOWABLE LABOR HOURS

4h
REQUIRED TOOLS / SKILLS:
Item Description Size

1 Standard Tools
REQUIRED PARTS FOR:
AC 100-4L BN 10551 bis 10559

AC 130-5 BN 35300 bis 35357
AC 160-5 BN 38400 bis 38457
AC 220-5/250-5 BN 82350 bis 82466
AC 300-6 BN 85401 bis 85416
Item Qty. Description Spare part no.

1 1 Mod kit (Bucher Ident.Nr. 485 778 12
100117957)
For enquiries or comments about Tadano Demag GmbH

this notice, please contact:
Europaallee 2, 66482 Zweibrücken, Germany
Department: Customer support
Phone: + 49 (0) 6332 83 1111 ; Email: zwb.customersupport@tadano.com
Page 1 / 33
REQUIRED PARTS FOR:
AC 100-4L BN 10560 to 10652

AC 130-5 BN 35358 to 35388
AC 160-5 BN 38458 to 38491
AC 220-5/250-5 BN 82467 to 82535
AC 300-6 BN 85417 to 85427

100117958)
REQUIRED PARTS FOR:
AC 45City SN 71301 to 71324

AC 55-3 SN 51301 to 51327
AC 60-3 SN 54301 to 54312

100117959)

Page 2 / 33
PROCEDURE
Contents
Introduction ................................................................................................................................
Basic Instruction ....................................................................................................................
Icons .....................................................................................................................................
Parts list ................................................................................................................................
Component identification ......................................................................................................
Work Instructions .......................................................................................................................
Overview ...............................................................................................................................
Section 2 – Outlet .................................................................................................................
Section 1 – Intake .................................................................................................................
End plate ...............................................................................................................................
Type plate .............................................................................................................................
2.6 Software Update…………………………………………………………………………………….
2.7 Running in the spools…………………………………………………………………………….…
2.8 Speed adjustment of slewing…..…………………………………………………………………..
LOCATION ON THE MACHINE (Exemple AC 160-5)


Page 3 / 33
Introduction
Basic Instruction
- Generally, the above side of the control block is shown. The conversion steps shown are for
the A- and B-side of the control block.
- In this instruction the conversion is described step by step per section. To avoid confusion, it is
not recommended to rebuild the entire control block in parallel.
- Before opening the block in the field, the block must be thoroughly cleaned when installed.
Thus, the risk of contamination during disassembly / assembly is reduced.
- The seat of the O-rings must always be checked before installation!
- Before mounting, remove any dirt on the flange surfaces of the valve sections and pilot heads
(Paint, dirt etc.).

Icons
Attention
!
Danger
Damage possible
Will be reused
Will not be reused

Page 4 / 33
Partslist
AC 100-4L SN 10551 to 10559

AC 130-5 SN 35300 to 35357
AC 160-5 SN 38400 to 38457
AC 220-5/250-5 SN 82350 to 82466
AC 300-6 SN 85401 to 85416

Item. Designation 1 Designation 1 Oty. Bucher ID Notice
1 Pilot head LVS12.....F....0000D 2 100236825

2 Nozzle B M040,8 DST 2 100231921 Already mounted
3 Pilot head LVS12.....F....0126D 2 100154768
4 Piston LVS-E-CF*-G.J.A110 WCC 1 100238133
6 Spool LVS12-063-6V*...0569D 2 100117940
7 Spool LVS12-080-6AB...0568D 2 100117939
8 Screw DIN912 M4X12 8.8 VZ 8 100202187
9 Screw DIN912 M5X45 8.8 VZ 1 100238670 Removal aid
10 Screw DIN912 M6X55 12.9 16 100220776
11 O-Ring 6x1,5 NBR90 10 100247350
12 O-Ring 35x2,5 NBR90 4 100232465
13 Type plate 32X20 TEREX 1 100237788


Page 5 / 33

AC 100-4L BN 10560 to 10652

AC 130-5 BN 35358 to 35388
AC 160-5 BN 38458 to 38491
AC 220-5/250-5 BN 82467 to 82535
AC 300-6 BN 85417 to 85427

1 Pilot head LVS12.....F....0000D 2 100236825

3 Pilot head LVS12.....F....0126D 2 100154768
6 Spool LVS12-063-6V*...1569D 2 100117942
7 Spool LVS12-080-6AB...1568D 2 100117941
8 Screw DIN912 M4X12 8.8 VZ 8 100202187
10 Screw DIN912 M6X55 12.9 16 100220776
11 O-Ring 6x1,5 NBR90 10 100247350
12 O-Ring 35x2,5 NBR90 4 100232465


Page 6 / 33

AC 45City SN 71301 to 71324

AC 55-3 SN 51301 to 51327
AC 60-3 SN 54301 to 54312

1 Pilot head LVS12.....F....0000D 2 100236825

3 Pilot head LVS12.....F....0126D 2 100154768
6 Spool LVS12-050-6V*...1569D(T1) 2 100117944
7 Spool LVS12-050-6AB...1500D 2 100117943
8 Screw DIN912 M4X12 8.8 VZ 8 100202187
10 Screw DIN912 M6X55 12.9 16 100220776
11 O-Ring 6x1,5 NBR90 10 100247350
12 O-Ring 35x2,5 NBR90 4 100232465


Page 7 / 33
Component identification

Section 2 ‐ Outlet Section 1 ‐ Intake
Pilot head
Pos. 3 Pos. 1
Description: LVS12.....F....0126D Description: LVS12.....F....0000D

Spool
Pos. 6 (…6V*…) Pos. 7 (…6AB…)


Page 8 / 33
Work Instructions
Overview
Section 2 – Outlet Section 1 – Intake
B-Side B-Side
(chapter 2.2) (chapter 2.3)

Pos. 6 Pos. 3 Pos. 7 Pos. 1

Type plate
End plate (chapter 2.5)
(chapter 2.4)

Pos. 13

Pos. 4

Section 2 – Outlet
Section 1 – Intake
A-Side
A-Side
(chapter 2.2)
(chapter 2.3)

Pos. 6 Pos. 3 Pos. 7 Pos. 1

Page 9 / 33
2.2 Section 2 – Outlet


Page 10 / 33
Dismantling
1. Remove screws M4.
2. Remove pilot valves.
3. Remove screws M6.
4. Remove pilot head housing.
2
1
3 4

Page 11 / 33
5. Dismantle spool (avoid tilting).

6. If necessary remove O-Rings of the valve section.
! Oil leakage possible
6 1
3
4

Page 12 / 33
Assembly
Avoid any pollution on the flange surface of the valve sections and pilot heads (Paint, dirt, etc.)
7. New O-Ring (Pos. 12) in Valve section.

8. New O-Rings (Pos. 11) in new pilot head.
Pos. 12
7
8 Pos. 1
Pos. 11 (3x)

Page 13 / 33
9. Install Slider in Pilot Head Housing.

10. Put pilot head housing onto valve section.
11. Fix pilot head housing with screws M6.
9 10
Use correct pilot head!
!
Use correct Spool! !
Pos. 3
Pos. 6
Use correct pilot head!

Pos. 6 !
Use correct Spool! !
Pos. 3
11
Pos. 10 (4x)
5
MA = 10 Nm
Pos. 10 (4x)
5
MA = 10 Nm

Page 14 / 33
Avoid any pollution on the flange surface of the valve sections and pilot heads (Paint, dirt, etc.)
12. Insert the pilot valves dismantled into the new pilot head housing.
13. Fix pilot valve with screws M4.
12
13
Pos. 8 (4x)
3
MA = 3 Nm

Page 15 / 33
Section 1 – Intake

Page 16 / 33
Installation is carried out in the same way as described under 2.2 Section 2 „Outlet“.
Particularity:
pay attention to correct Spool and number of O-Rings (Pos. 1 to 3)
Use correct Spool!

Pos. 7 !
2
3
Use correct Spool!

Pos. 7 !
Pos. 1
Pos. 11 (2x)

Page 17 / 33
End plate

Page 18 / 33
Dismantling
1. Unscrew the long screw plug to relieve the spring by 5 turns.
2. Unscrew sealing plug (C)
3. If need be dismantle piston with auxiliary screw (Pos. 9)
32
5 turns
A
B
Pos. 9
3
12

Page 19 / 33
Assembly
4. Mount new piston (Pos. 4)
5. (C) Attach sealing plug (2 turns)
6. Tighten the long screw plug (A)
7. Tighten the sealing plug (C)
4 5
Pos. 4
32
6 2 turns 7
12
MA = 70 Nm

Page 20 / 33
12
MA = 65 Nm
Type plate
1. Stick on self-adhesive Type plate.
Adhesive surface fat. Oil and pollution free.
No. modificion kit Fa. Bucher

Indication modification kit Fa. Bucher
No. modification kit Fa. Terex
Serial No. Fa. Bucher
Software update
Software for MTC must be min:
AC 45City: V 1.11 or higher
AC 55-3; AC 60-3: V 1.9 or higher
AC 100-4L: V 1.8 or higher
AC 130-5; AC 160-5; AC 220-5; AC 250-5: V 1.30 or higher
AC 300-6: V 1.15 or higher

Page 21 / 33
Running in the spools

1. For running in the spools set control currents to maximum piston stroke in the menu “Control
currents”.
Adjust Pmin to 0mA and Pmax to 900mA for Adjust Pmax to 900mA for slewing right and
slewing right and left in the open circle. left in the closed circle.
2. Drive the slew movement against the static slew brake in the open circle alternately to the right
and to the left for about 2 – 3 minutes.
Open circle; static slew brake closed In the function diagnosis menu, the deflection of
the control piston can be observed
.

Page 22 / 33

2.8 Speed adjustment of slewing
Current values and speeds of the individual crane types must be set again after the conversion.
Please find them in the appendix.
1. For setting the pressure of Slewing connect a gauge or two Pressure transducer on the inlet
and outlet side of the slewing block.
2. Change to pressure of Slewing in the settings menu.
With a motor speed of

1000 min-1 a rotational speed of 0.1
min-1 to the right and drive to the left.

Page 23 / 33
3. Adjustment „Pressure log“
The lower value of the two pressures is in

each case the clamping to be set depending
on the direction of rotation.
By reducing or increasing the preset 100%
(e.g., to 98%), the restraint is set to 14-18
bar.

Page 24 / 33
Setting values AC 45City

Page 25 / 33
Setting values AC 55-3, AC 60-3

Page 26 / 33
Setting values AC 100-4 >10551

Page 27 / 33
Setting values AC 130-5

Page 28 / 33

Page 29 / 33
Setting values AC 220-5, AC 250-5

Page 30 / 33

Page 31 / 33
RISK ASSESSMENT
People performing maintenance and repair work on cranes can become exposed to health and safety
risks. These risks can be identified and prevented in accordance with the provisions of occupational
safety and accident prevention directives through the vigilance and actions of appropriately trained
and experienced personnel. Terex therefore provides its employees with regular instruction compliant
with statutory health and safety regulations. Terex employees are mandated to take all necessary
precautions and comply with all associated procedures. Terex requires that work covered by this WI is
only ever performed by appropriately trained and experienced personnel.
 Prior to commencement of each repair and maintenance job, and particularly following any
interruption to the work, it is essential to check or recheck that all the safety prerequisites are
properly satisfied.
To enable the safe execution of the work described above, we specifically instruct personnel with
respect to the following potential risks and recommended precautionary procedures.
Item Risk Protective purpose Precaution / Instruction
1 Workplace-related - To ensure safety when working with - Machines to be explained at the point of use, with
operating unfamiliar machinery possible language problems being taken into due
instructions account
2 Work coordination - To eliminate possible endangerment - Take precautions against possible endangerment
of others on site of others on site
3 Hazardous work - To ensure safety under all - Make full use of personnel protection measures
(e.g. due to tight circumstances and personal protective equipment (PPE)
spaces, great
- To facilitate rapid rescue and aid, - Working under conditions of elevated risk only
heights)
should the need arise permitted in the presence of a reliable second
person
4 Falling over on flat - To prevent risk of falling over - Examine working environment for risks to safety
surfaces (slipping or
- Identify unevenness, puddles, tripping points and
tripping over, ankle
obstacles, and implement appropriate measures
twist, toppling)
5 Falling from a - To prevent accidents when working - Use suitable climbing aids (steps, scaffolding) and
height from heights of more than 1m above appropriate safety harnesses or other securing
ground level equipment
6 Tight spaces - To prevent hazards arising from - Apply electrical safety measures, use PPE and,
electricity, poor air and confined where necessary, wear a mask
working conditions
- Only work in the presence of a reliable second
person
7 Heavy physical - To prevent injury and illness arising - Lift and carry in a manner that avoids back injury
work from the lifting and carrying of heavy
- Use appropriate load-lifting devices
materials

Page 32 / 33
8 Heavy lop-sided - To prevent injury and illness arising - Avoid lengthy periods in a lop-sided, cramped or
physical work from incorrect body posture confined position
- Regularly change activities
- Take regular rests
9 Unprotected moving - To prevent hazards arising from - Always use unimpaired tools, jigs, fixtures and
machine parts unprotected machine parts safety equipment
10 Components with - To prevent endangerment from hot - Allow motors, engines and exhaust systems to
dangerous surfaces surfaces or sharp edges cool
- When welding and torch-cutting, use appropriate
PPE, insulators and guards.
- Pack sharp-edged components for handling and
transport
- Always deburr sharps
11 Materials handling - To prevent handling and - Ensure safe location, unrestricted view, even load
equipment transportation accidents distribution and sufficient load clearance
- Do not work under suspended loads
12 Basic electrical - To ensure safety when working on - Disconnect components from electrical supply
hazards crane electrics
- If necessary, disconnect battery (negative
terminal first, then positive terminal)
- Avoid short-circuiting
13 Hazardous body - To prevent shock hazard due to - Insulate or cover live electrical equipment
currents contact with live electrical equipment
- Stay in cab in a storm
- To prevent risk of being struck by
- Take precautions against possible electrostatic
lightning or other storm-related
discharge
hazards
14 Effects arising from - To prevent injury from the escape of - Depressurise system and ensure that no pressure
gases, vapours, pressurised fluids build-ups can occur while work is ongoing
aerosols, liquid and
- To protect eyes, respiratory - Use PPE, skin protection and skin care products
solid media
passages, skin against e.g. welding
- Use oil binders (absorbing agents) as appropriate
gases, solvent vapours and oil
- To prevent environmental damage
15 Skin irritation - To prevent skin contact with - Wear PPE and regularly change protective items
hazardous substances (in accordance with the resistance of the PPE
materials)
- Use skin protection and skin care products
16 Noise - To avoid damage to hearing - Wear ear protectors
17 Contact with hot or - To prevent hazards arising from hot - Prevent escape of hot media, allow fluids to cool
cold / cryogenic or cold / cryogenic media prior to performing maintenance and repair work
media
- Wear PPE when working with liquid nitrogen

Page 33 / 33

WI PN 19 005-02 Modification of Control Block For Slewing

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WORK INSTRUCTIONS WI_TDG PN 19 005-02

MODIFICATION OF CONTROL BLOCK FOR SLEWING

AC 45City SN 71301 to 71324 (except 71320)

ALLOWABLE LABOR HOURS

REQUIRED TOOLS / SKILLS:

Item Description Size

REQUIRED PARTS FOR:

AC 100-4L BN 10551 bis 10559

Item Qty. Description Spare part no.

For enquiries or comments about Tadano Demag GmbH

REQUIRED PARTS FOR:

AC 100-4L BN 10560 to 10652

Item Qty. Description Spare part no.

REQUIRED PARTS FOR:

AC 45City SN 71301 to 71324

Item Qty. Description Spare part no.

For enquiries or comments about Tadano Demag GmbH

LOCATION ON THE MACHINE (Exemple AC 160-5)

For enquiries or comments about Tadano Demag GmbH

Will not be reused

AC 100-4L SN 10551 to 10559

Item. Designation 1 Designation 1 Oty. Bucher ID Notice

1 Pilot head LVS12.....F....0000D 2 100236825

For enquiries or comments about Tadano Demag GmbH

AC 100-4L BN 10560 to 10652

Item. Designation 1 Designation 1 Oty. Bucher ID Notice

1 Pilot head LVS12.....F....0000D 2 100236825

For enquiries or comments about Tadano Demag GmbH

AC 45City SN 71301 to 71324

Item. Designation 1 Designation 1 Oty. Bucher ID Notice

1 Pilot head LVS12.....F....0000D 2 100236825

For enquiries or comments about Tadano Demag GmbH

For enquiries or comments about Tadano Demag GmbH

For enquiries or comments about Tadano Demag GmbH

2.2 Section 2 – Outlet

For enquiries or comments about Tadano Demag GmbH

For enquiries or comments about Tadano Demag GmbH

5. Dismantle spool (avoid tilting).

! Oil leakage possible

For enquiries or comments about Tadano Demag GmbH

7. New O-Ring (Pos. 12) in Valve section.

For enquiries or comments about Tadano Demag GmbH

9. Install Slider in Pilot Head Housing.

Use correct pilot head!

For enquiries or comments about Tadano Demag GmbH

For enquiries or comments about Tadano Demag GmbH

For enquiries or comments about Tadano Demag GmbH

Use correct Spool!

Use correct Spool!

For enquiries or comments about Tadano Demag GmbH

For enquiries or comments about Tadano Demag GmbH

For enquiries or comments about Tadano Demag GmbH

For enquiries or comments about Tadano Demag GmbH

No. modificion kit Fa. Bucher

For enquiries or comments about Tadano Demag GmbH

Running in the spools

For enquiries or comments about Tadano Demag GmbH

2. Change to pressure of Slewing in the settings menu.

With a motor speed of

For enquiries or comments about Tadano Demag GmbH

3. Adjustment „Pressure log“

The lower value of the two pressures is in