Chapter 17 - Attachment Mechanical: Service Manual
Chapter 17 - Attachment Mechanical: Service Manual
Chapter 17 - Attachment Mechanical: Service Manual
LFR/en/version: 09 / 2007
17 Attachment - Mechanical
17.1Installation / Removal
17.1.1Boom
17.1.1.1Component location
Boom for an excavator with a shovel attachment Boom for an excavator with a back bucket attachment
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17.1.1.2Shovel attachment
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Installation
For the installation of the boom, use appropriate jacking equipment.
– Park the machine in level flat ground, and check if the excavator is in a blast area.
– Shut off the engine.
– Turn ignition key on, safety lever down and activate joysticks in all directions to expel stored energy in the
hydraulic cylinders and in the servo accumulator.
– Isolate the machine by disconnecting the safety switch S9.1.
– Lift the boom with a crane and lay it on blocks. The boom cylinders and the stick cylinders must now be fixed
on the boom.
– Align the boom cylinders extremity with the boom (axis 42) and fit the pin 1 and the washer kits 5. Install the
covers 2 and their O-ring 4 with the screws 3.
– Align the stick cylinders extremity with the boom (axis 43) and fit the pin 1, washer kits 5. Install the distance
rings 6, the covers 2 and their O-ring 4 with the screws 3.
– Lift the boom and the cylinders with a crane. Use chains to secure the cylinders to the boom, so they won’t
hang when the boom is installed.
– Install grease lines between boom and uppercarriage, plug all grease lines.
– Install all electrical wiring.
– Install and plug hydraulic lines between uppercarriage and boom, and between the upperdeck and the
boom cylinders.
– Put the rod of the boom cylinder out until the base bushings (axis 80) are aligned to the rod bushings. Fit
the pins 1 and the washer kits 5.
– Install covers 2 and their O-ring 4 with screws 3 at the connections between the boom base and the upper-
carriage (axis 80) and between the boom cylinders and the uppercarriage (axis 81).
– Install the cam of the proximity transmitters on the cover of the right connection (axis 80).
– Reconnect the safety switch S9.1.
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Removal
Before the removal of the boom, the bucket and the stick must have been already dismounted.
– Park the machine in level flat ground, and check if the excavator is in a blast area.
– Drive boom down, as far as possible and be sure that the attachment is in a rested position.
– Then shut off the engine.
– Turn ignition key on, safety lever down and activate joysticks in all directions to expel stored energy in hy-
draulic cylinders and servo accumulators.
– Isolate machine by disconnecting the safety switch S9.1.
– Remove all grease lines between boom and the upperdeck. Plug all grease lines.
– Remove all electrical wiring.
– Remove and plug hydraulic lines between boom and uppercarriage.
– Remove covers 2 and their O-ring 4 with screws 3 on the connections between boom cylinders and the up-
percarriage (axis 81) and between the boom and the upperdeck (axis 80).
– Use chains to secure boom cylinders and stick cylinders to boom, so they won’t hang when the boom is
removed.
– Set crane to front of boom to take weight.
– Remove the pins 1 and the washer kits 5 of the connections between boom cylinders and uppercarriage
(axis 81).
– Attach another crane to rear of the boom.
– Take some weight on the cranes and remove the pins 1 and the washer kits 5 of the connections between
boom and uppercarriage (axis 80).
– Lift boom away from machine.
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17.1.1.3Backhoe attachment
LFR/en/version: 09 / 2007
Installation
For the installation of the boom, use appropriate jacking equipment.
– Park the machine in level flat ground, and check if the excavator is in a blast area.
– Shut off the engine.
– Turn ignition key on, safety lever down and activate joysticks in all directions to expel stored energy in the
hydraulic cylinders and in the servo accumulator.
– Isolate the machine by disconnecting the safety switch S9.1.
– Lift the boom with a crane and lay it on blocks. The boom cylinders must now be fixed on the boom.
– Align the boom cylinders extremity with the boom (axis 42) and fit the pin 1 and the washers kit 5. Install the
covers 2 and their O-ring 4 with the screws 3.
– Lift the boom and the cylinders with a crane. Use chains to secure the cylinders to the boom, so they won’t
hang when the boom is installed.
– Install grease lines between boom and uppercarriage, plug all grease lines.
– Install all electrical wiring.
– Install and plug hydraulic lines between uppercarriage and boom, and between the upperdeck and the
boom cylinders.
– Put the rod of the boom cylinder out until the base bushings (axis 80) are aligned to the rod bushings. Fit
the pins 1 and the washer kits 5.
– Install covers 2 and their O-ring 4 with screws 3 at the connections between the boom base and the upper-
carriage (axis 80) and between the boom cylinders and the uppercarriage (axis 81).
– Install the cam of the proximity transmitters on the cover of the right connection (axis 80).
– Reconnect the the safety switch S9.1.
LFR/en/version: 09 / 2007
Removal
Before the removal of the boom, the bucket and the stick must have been already dismounted.
– Park the machine in level flat ground, and check if the excavator is in a blast area.
– Drive boom down, as far as possible and be sure that the attachment is in a rested position.
– Then shut off the engine.
– Turn ignition key on, safety lever down and activate joysticks in all directions to expel stored energy in hy-
draulic cylinders and servo accumulators.
– Isolate machine by disconnecting the safety switch S9.1.
– Remove all grease lines between boom and the upperdeck. Plug all grease lines.
– Remove all electrical wiring.
– Remove and plug hydraulic lines between boom and uppercarriage.
– Remove covers 2 on the connections between boom cylinders and the uppercarriage (axis 81) and between
the boom and the upperdeck (axis 80).
– Use chains to secure boom cylinders to boom, so they won’t hang when the boom is removed.
– Set crane to front of boom to take weight.
– Remove the pins 1 and the washer kits 5 of the connections between boom cylinders and uppercarriage
(axis 81).
– Attach another crane to rear of the boom.
– Take some weight on the cranes and remove the pins 1 and the washer kits 5 of the connections between
boom and uppercarriage (axis 80).
– Lift boom away from machine.
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17.1.2Stick
17.1.2.1Component location
Stick for an excavator with a shovel attachment Stick for an excavator with a back bucket attachment
17.1.2.2Shovel attachment
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Installation
– Park the machine in level flat ground, and check if the excavator is in a blast area.
– Drive boom down as far as possible.
– Locate crane in suitable position to support stick, lift the stick.
– With crane, align stick to boom bushings (axis 41) and fit the pin 1.
– With another crane, align the stick cylinders to the stick (axis 44), and put the rod of the cylinders out, fit the
pins 1, the washers kit 5 and the distance ring 6.
– Shut off the engine.
– Turn ignition key on, safety lever down and activate joysticks in all directions to expel stored energy in the
hydraulic cylinders and in the servo accumulator.
– Isolate machine by disconnecting the safety switch S9.1.
– Install the covers 2 and the O-rings 4 with the screws 3 to the connections between stick cylinders and stick
(axis 44), and to the connections between the boom and the stick (axis 41).
– Install grease lines between boom and stick, plug all lines.
– Install bucket cutout wiring between boom and stick.
– Install and plug hydraulic lines between stick and boom.
Removal
Before the removal of the stick, the bucket must be removed.
– Park the machine in level flat ground, and check if the excavator is in a blast area.
– Put the attachment in rested position, lay boom down with stick out.
– Turn ignition key on, safety lever down and activate joysticks in all directions to expel stored energy in cy-
linders and servo accumulators.
– Isolate machine by disconnecting the safety switch S9.1.
– Remove grease lines between boom and stick, plug all lines.
– Remove bucket cutout wiring between boom and stick.
– Remove and plug hydraulic lines between stick and boom.
– Remove covers 2 from stick cylinders (axis 44) and from the connections between boom and stick (axis 41).
– Remove stick pins 1 between stick cylinders and stick (axis 44) using mobile crane.
– Restart machine and suck stick cylinders in.
– Locate crane in suitable position to support stick, connect to stick.
– Remove pins 1 between stick and boom (axis 41) securing stick to boom with crane.
– Remove stick from machine.
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17.1.2.3Backhoe attachment
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Installation
– Park the machine in level flat ground, and check if the excavator is in a blast area.
– Drive boom down as fas as possible.
– Lift the stick cylinders with a crane.
– Align stick cylinders extremities to boom bushings (axis 43) and fit the pin 1 and washers kit 5. Install the
covers 2 and the O-rings 4 with the screws 3.
– Locate crane in suitable position to support stick, lift the stick.
– With crane, align stick to boom bushings (axis 41) and fit the pin 1 and washers kit 5.
– With another crane, align the stick cylinders to the stick (axis 44), and put the rod of the cylinders out, fit the
pins 1.
– Shut off the engine.
– Turn ignition key on, safety lever down and activate joysticks in all directions to expel stored energy in the
hydraulic cylinders and in the servo accumulator.
– Isolate machine by disconnecting the safety switch S9.1.
– Install the distance ring 6, the covers 2 and the O-rings 4 with the screws 3 to the connections between stick
cylinders and stick (axis 44).
– Install the covers 2 and the O-rings 4 with the screws 3 to the connections between the boom and the stick
(axis 41).
– Install grease lines between boom and stick, plug all lines.
– Install bucket cutout wiring between boom and stick.
– Install and plug hydraulic lines between stick and boom.
Removal
Before the removal of the stick, the bucket must be removed.
– Park the machine in level flat ground, and check if the excavator is in a blast area.
– Put the attachment in rested position, lay boom down with stick out.
– Turn ignition key on, safety lever down and activate joystickes in all directions to expel stored energy in cy-
linders and servo accumulators.
– Isolate machine by disconnecting the safety switches S9.1.
– Remove grease lines between boom and stick, plug all lines.
– Remove bucket cutout wiring between boom and stick.
– Remove and plug hydraulic lines between stick and boom.
– Remove covers 2 from stick cylinders (axis 44) and from the connections between boom and stick (axis 41).
– Remove stickes pins 1 between stick cylinders and stick (axis 44) using mobile crane.
– Restart machine and suck stick cylinders in.
– Locate crane in suitable position to support stick, connect to stick.
– Remove pins 1 between stick and boom (axis 41) securing stick to boom with crane.
– Remove stick from machine.
LFR/en/version: 09 / 2007
17.1.3Bucket
17.1.3.1Component location
Bucket for an excavator with a back Bucket for an excavator with a back
shovel attachment bucket attachment
17.1.3.2Shovel attachment
LFR/en/version: 09 / 2007
Installation
– Park the machine on level flat ground, and check if the excavator is in a blast area.
– Lift the bucket cylinders with a crane.
– Align bucket cylinders extremities to boom bushings (axis 45) and fit the pins 1 and washer kits 5. Install the
distance rings 6, the covers 2 and the O-rings 4 with the screws 3.
– Locate the crane in suitable position to support the bucket, lift the bucket.
– With the crane, align the bucket to stick bushings (axis 47) and fit the pins 1.
– Put the rod of the bucket cylinders out and align the cylinders extremities with the bucket bushings (axis 46).
Fit the pins 1 and the washer kits 5.
– Shut off the engine.
– Turn ignition key on, safety lever down and activate joysticks in all directions to expel stored energy in the
hydraulic cylinders and in the servo accumulator.
– Isolate machine by disconnecting the safety switch S9.1.
– Install the covers 2 and the O-rings 4 with the screws 3 to the connections between the stick and the bucket
(axis 47).
– Install the distance rings 6, the covers 2 and the O-rings 4 with the screws 3 to the connections between
the bucket cylinders and the bucket (axis 47).
– Install grease lines between the stick and the bucket, plug all lines.
– Install bucket cutout wiring between stick and bucket.
– Install and plug hydraulic lines between stick and bucket.
Removal
– Park the machine on level flat ground, and check if the excavator is in a blast area.
– Put the attachment rested on the floor in a stable position.
– Turn the engine off.
– Turn ignition key on, safety lever down and activate joysticks in all directions to expel stored energy in hy-
draulic cylinders and servo accumulators.
– Isolate machine by disconnecting the safety switch S9.1.
– Remove grease lines.
– Remove the distance rings 6, the covers 2 and the O-rings 4 with the screws 3 from the bucket cylinders
(axis 46).
– Remove the covers 2 and the O-rings 4 with the screws 3 from the connections between the stick and the
bucket (axis 47).
– Put the bucket in upright position.
– Remove stick pins 1 and washers kits 5 between the bucket cylinders and bucket (axis 46).
– Restart the machine and retract bucket cylinders.
– Remove pins 1 and washer kits 5 between the bucket and the stick (axis 47).
– Lift stick out of the bucket.
LFR/en/version: 09 / 2007
17.1.3.3Backhoe attachment
LFR/en/version: 09 / 2007
Installation
– Park the machine on level flat ground, and check if the excavator is in a blast area.
– Lift the bucket cylinders with a crane.
– Locate the crane in suitable position to support the bucket, lift the bucket.
– With the crane, align the bucket to stick bushings (axis 47) and fit the pins 1 and the guard rings 7.
– Put the rod of the bucket cylinders out and align the shift levers with the bucket bushings (axis 46). Fit the
pins 1 and the guard rings 7.
– Shut off the engine.
– Turn ignition key on, safety lever down and activate joysticks in all directions to expel stored energy in the
hydraulic cylinders and in the servo accumulator.
– Isolate machine by disconnecting the safety switch S9.1.
– Install the covers 2 and the O-rings 4 with the screws 3 to the connections between the stick and the bucket
(axis 47).
– Install the covers 2 and the O-rings 4 with the screws 3 to the connections between the shift levers and the
bucket (axis 46).
– Install grease lines between the stick and the bucket plug all lines.
– Install bucket cutout wiring between stick and bucket.
– Install and plug hydraulic lines between stick and bucket.
Removal
– Park the machine on level flat ground, and check if the excavator is in a blast area.
– Put the attachment rested on the floor in a stable position.
– Turn the engine off.
– Turn ignition key on, safety lever down and activate joysticks in all directions to expel stored energy in hy-
draulic cylinders and servo accumulators.
– Isolate machine by disconnecting the safety switch S9.1.
– Remove grease lines.
– Remove the covers 2 and the O-rings 4 with the screws 3 from the connections between the shift levers and
the bucket (axis 46).
– Remove the covers 2 and the O-rings 4 with the screws 3 from the connections between the stick and the
bucket (axis 47).
– Put the bucket in upright position.
– Remove the pins 1 and the guard rings 7 between the bucket cylinders and bucket (axis 46).
– Restart the machine and retract bucket cylinders.
– Remove pins 1 and the guard rings 7 between the bucket and the stick (axis 47).
– Lift stick out of the bucket.
17.2Condition monitoring
The attachment is the part of the hydraulic excavator, which is the most request. This part is directly in contact
with the handling material; the excavator with the standard backhoe, grapple or bucket attachment may only
be used to loosen, pick up, move, load and dump soil, gravel, rock or other material and to load trucks, barges,
conveyor, belts, or rock crushing systems. So the shocks, the vibrations, the requests and the stresses on the
attachment are more important than on the other parts of the excavator. The wear of this part is consequently
faster, especially for the bucket. You have to be very careful during the inspection of the attachment.
17.3Pins / bushes
17.3.1Component location
The following figures indicate the location of pins and bushes on the attachment (surrounded parts).
Rotating deck
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Boom
Stick
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Bucket
Rotating deck
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Boom
Stick
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Bucket
17.3.2Technical data
On the hydraulic excavator R9250, there are different sizes of pins and bushes, but the principal technical data
are the same.
Steel (type) 42 Cr Mo 4
Chromium (type) Chromium plating to size 0,03 mm
Hardening (type) Induction hardening
Depth of hardening (finished part) 1,5+0,5
Hardness (HRC) 58±2
Heat treated to (N/mm²V) 900 / 1050
External diameter adjustment (type) f7
Steel (type) 18 M 5
Treatment (type) SURSULF SDA 0
Heat treated to (daN/mm²V) 65 / 80
Internal diameter adjustment (type) D8
External diameter adjustment (type) s6
17.3.3Installation / Removal
Central lubrication
Lubrication by a cover
– It is imperative to verify the axis alignment of the bore. For this operation, use a control axis of adjustment f7.
– Check after the mounting of the bushing that the bores are without impurity, with control pieces. The verifi-
cation will be done with compressed air. Put a stub in rubber at the end of the bellows before engaging it in
the greasing hole. This inspection can be done with a grease pump too.
M 14 x 1,5 4901359
M 10 x 1 7743242
• Screw lubricator :
Screw the lubricator, which is tightening with a key, and put the protecting cap.
• Self threading lubricator :
Engage the lubricator in the bore. Intrude the lubricator with a hammer (800 g) thanks to an appropriate
drawer. Just one thread must stay apparent. Then the screw of a quarter of turn thanks to a key.
– Safety rules :
It seems here very useful to remind the elementary cautions to take during the using of liquid nitrogen.
Caution!
C
LFR/en/version: 09 / 2007
For the installation of the pins use an appropriate tool. The tool required is the mounting device for pins (Ident.
Number : 9826013). Fix the front flange (see pos. 2) on the housing where you want to install the pin, thanks
to hexagonal head screws. Then put the pin in the mounting device, exactly on the supports (see pos. 12, 14
and 15). A hydraulic cylinder permit to push correctly the pin in its housing, but before pushing the pin in its
housing put the distributor in «pushing position». According to the length of the pin and to the stroke of the hy-
draulic cylinder, you can adjust the position of the hydraulic cylinder thanks to mechanical stop.
LFR/en/version: 09 / 2007