- Material Handler
- MH3022 (S/N: FM21-UP; FB31-UP)
- MH3024 (S/N: FM41-UP; FB51-UP; FB71-UP)
- MH3026 (S/N: FB91-UP)
- MH3024 (S/N: FM41-UP; FB51-UP; FB71-UP)
Introduction
The lower swing drive mounting bore in the upper carriage of certain Material Handlers can wear out and become oval shaped. The following information will show how to check and repair the bore.
Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.
Reference Section
Reference: Specifications, SENR3130, "Torque Specifications"
Safety Section
Use only proper tools and observe all precautions that pertain to the use of those tools. Failure to follow these procedures can result in personal injury. The following procedures should be observed.
Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.
A person must be alert to potential hazards. This person must also have the necessary training, skills, and tools to perform these functions properly.
Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. AVSpare cannot anticipate every possible circumstance of a potential hazard.
Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. Avoid using a tool, a procedure, a work method, or operating technique that is not recommended by AVSpare.
Ensure that the product will not be damaged or the product will be made unsafe by the operation, lubrication, maintenance, or the repair procedures.
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Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility. |
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Failure to follow all safety guidelines prescribed in this document and by governing authorities and regulatory agencies may result in severe injury or death of personnel or machine damage. |
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When removing a major component or attachment, ensure that it is properly blocked or secured before removing mounting hardware. An assembly that is disconnected without proper blocking may shift or fall, resulting in serious injury or death of personnel or machine damage. |
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Personal injury or death can result from improper maintenance procedures. To avoid injury or death, follow the procedures exactly as stated below. |
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Personal injury or death can result from sudden movement. Prevent possible injury by performing the following procedures before work begins: Move the product or equipment to a smooth, level surface. When applicable, lower equipment/work tools to the ground. Engage the parking brake, system brakes and/or hydraulic lockout control. When applicable, stop the engine and remove the ignition key. Release system pressure from pressurized systems. If applicable, block the wheels/tracks. Turn the battery disconnect switch to the OFF position and if applicable, remove the battery disconnect key. If not equipped with a battery disconnect switch, disconnect the battery cables from the battery and tape the battery clamps. Attach a “Do Not Operate” or similar warning tag at the battery disconnect switch location and as defined by site rules and/or local regulations. |
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| Illustration 1 | g06276183 |
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Personal injury or death can result from fumes, gases and ultraviolet rays from the weld arc. Welding can cause fumes, burn skin and produce ultraviolet rays. Keep your head out of the fumes. Use ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing area. Wear eye, ear and body protection before working. Protect yourself and others; read and understand this warning. Fumes and gases can be dangerous to your health. Ultraviolet rays from the weld arc can injure eyes and burn skin. Electric shock can cause death. Read and understand the manufacturer's instructions and your employer's safety practices. Do not touch live electrical parts. See "American National Standard Z49.1, Safety in Welding and Cutting" published by the American Welding Society. American Welding Society2501 N.W. 7th Street Miami, Florida 33125 See "OSHA Safety and Health Standards, 29 CFR 1910", available from U.S. Department of Labor. U.S. Department of LaborWashington, D.C. 20210 |
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Personal injury can result from flame cutting or welding on painted areas. The effect of gasses from burned paint is a hazard to the person doing the cutting or welding. Do not flame cut or weld on painted areas. |
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Before carrying out arc welding on the machine or on any equipment attached to the machine, disconnect all power and ground leads from the batteries in order to avoid possible damage to electronic components. |
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Access to this service point may require climbing on the equipment. Slipping or falling while climbing on the equipment could result in personal injury or death. Refer to the Operation and Maintenance Manual, Mounting and Dismounting topic for safety information. |
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Failure to use an approved access system during installation and removal of components could result in slipping and falling which could result in personal injury or death. To prevent injury or death, use an approved access system to reach the appropriate mounting locations of the components. Do not climb on the machine. Maintain three-points of contact and/or use a safety harness. |
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Personal injury can result from improper handling of chemicals. Make sure you use all the necessary protective equipment required to do the job. Make sure that you read and understand all directions and hazards described on the labels and material safety data sheet of any chemical that is used. Observe all safety precautions recommended by the chemical manufacturer for handling, storage, and disposal of chemicals. |
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Do not operate the machine if any guards or covers are missing or inadequately secured. Personnel could be seriously injured or machine damage may occur. |
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Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended/blocked loads. Personnel may be seriously injured or killed by falling loads. |
Welding Specifications and Qualifications
Preparing the Metal for Welding
Cover all finished bores and threads. Finished bores and threads must be protected from all the following items like foreign materials, gouging, and paint spatters. Do not remove the covers until the component is painted.
All grease, water, paint, rust, dirt, and scale must be removed before welding. Any of these materials will discharge gas which will cause porosity in the weld deposit. Water and rust will cause hydrogen embrittlement. Hydrogen embrittlement causes cracks in the weld deposit.
Remove foreign objects with a wire brush, a buffer, or a grinder. Shot blasting the appropriate areas will also remove foreign material.
Remove any oil or grease with a AVSpare approved solvent.
Welding Requirements
Welding quality is critical to the success of the installation procedures. Welds must be smooth and continuous. Do not undercut the welds. No overlap is allowed. Grind the ends of the welds to a smooth radius.
Prepare the metal for welding. Refer to "Preparing the Metal for Welding". Further instructions for welding are stated within the installation.
Use LB-26 Electrodes (AWS E7016 or AWS E7018) or equivalent electrodes to weld the reinforcement plates to the machine. Basic welding wire ESAB OK tubrod 15.00 with a
All electrodes must be dried. The electrodes can be dried by heating the electrodes to
Do not weld in windy conditions. Do not weld when temperatures are below
Penetration characteristics may vary greatly depending on the following conditions:
- electrode diameter
- shielding gas
- welding current
- plate thickness
The following items also affect the welds:
- geometry of welded joints
- surface conditions
- composition of the base metal and of the electrode
A root pass should be applied before each weld is finished.
Maintain a
All welds to the stick must be welded in the direction from the rear of the stick toward the front of the stick.
Refer to Special Instruction REHS1841 General Welding Procedures.
Weld Inspection
The weld should not have any of the conditions that follow:
- Cracks
- Porosity
- Undercut
- Incomplete Fusion
To verify the quality of the weld, refer to"American National Standards Institute (ANSI)/American Welding Society (AWS) Specification D14.3".
Refer to Special publications, SEBD0512, "AVSpare Service Welding Guide" for the correct welding procedures.
Required Parts
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| Illustration 2 | g06612680 |
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(B) Adjust inner geometry as required
(D1) (D2) (D3) 4 X 17.5-C (D4) 15° (D5) (D6) (D7) | |
Note A: Steel ENI0025–2–S235JR+AR or GB/T 700 Q235B
Note B: Use ISO 2768M for dimension without tolerances
| Required Parts | ||
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| Qty | Part Name | Note |
| 1 | Plate | Dealer Fabricated Part |
Rework Procedure for the Upper Carriage Swing Drive Mounting Bore
- Check the diameter and shape of the lower bore for tolerances. Also inspect the bore for plastic deformation. The bore size should be
200 ± 0.013 mm (7.87 ± 0.0005 inch) .- If the bore diameter is within the correct tolerance, the swing drive can be assembled.
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Illustration 5 g06613080 Upper carriage swing drive mounting bore - If the bore diameter exceeds the tolerance, then repair welding is required.
Separate the upper and lower frame to access the damaged area. Follow all safety guidelines when removing the upper carriage with installed boom and stick as one unit. The complete unit which includes the upper frame, boom, and stick, can have a max weight of
18000 kg (39683 lbs) in the heaviest configuration. Add material by building-up the welding at damaged bore surface. Build up the welding around the entire bore surface. See Illustration 5.
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Illustration 6 g06613229 Mobile lathe attachment points Show/hide table
Illustration 7 g06614602 Alternative attachment method - If the bore diameter is within the correct tolerance, the swing drive can be assembled.
- Machine the lower bore diameter to meet the required tolerances.
Weld the mobile lathe on the top and the bottom of the upper frame. Welding is only allowed on non-machined surfaces. Welding the mobile lathe will ensure proper attachment, which will prevent the drill rod from bending. Refer to Illustration 6 for attachment points. Align new machine surfaces by using the upper bore
259 - 0/+1 mm (10.2 - 0.04 inch) . Use a plate with an outside diameter fitting to the upper bore to align the mobile lathe.An alternative mobile lathe attachment method is to align the hole pattern of the swing drive on the upper frame. The plate should align to the new machined surface by using the upper bore
259 - 0/+1 mm (10.2 - 0.04 inch) . Refer to Illustration 7. Attach the mobile lathe to the top and bottom of the upper frame to ensure that the drill rod will not bend.
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| Illustration 3 | g06612622 |
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Upper carriage swing drive mounting bore | |
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| Illustration 4 | g06620687 |
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Points of reference (C) Swing drive (D) Upper frame structure (E) Upper bore (F) Lower bore | |
