Complete service repair manual for Komatsu/DEMAG Hydraulic Shovels, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
DEMAG Hydraulic Shovels workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
DEMAG Hydraulic Shovel Repair Manual (serial numbers DEMAG ALL).pdf
H285S78139OMM – DEMAG Komatsu Hydraulic Mining Shovels Parts & Service.pdf
Total Pages: 2,827 + 498 pages
File Format: PDF
Language: English
TABLE OF CONTENTS
1. CYLINDER
2. HYDRAULIC PUMP
3. HYDRAULIC MOTOR
4. VALVES
5. PUMP DISTRIBUTOR GEAR & DRIVE SHAFT
6. SLEWING GEAR
7. TRAVEL GEAR
8. SLEW RING
9. ROTARY JOINT
10. BOTTOM ROLLER/TRACK ROLLER
11. TOP ROLLER
12. IDLER
13. SPROCKET
14. WELDING INSTRUCTIONS FOR STEEL STRUCTUREAL PARTS AND STEEL CASTINGS
DEMAG Hydraulic Shovel Repair Manual…2
COVER…2
CONTENTS…6
1. CYLINDER…8
1-1 CYLINDERS H 241…11
1. TABLE OF SERVICEABLE CYLINDER…12
2. TABLE OF DRAWINGS…13
3. CYLINDER FEATURES AND DATA…14
4. WORK AIDS…15
5. SEALING…28
6. WEAR AND TEAR LIMITS…40
7. TORQUING REQUIREMENTS…66
8. SPACE MEASUREMENT OF GUIDE RINGS…68
9. MEASURE TABLES REBUILDING OF CYLINDERS…72
10. DRAWINGS, ORIGINAL PARTS, PISTON AND FLANGE BUSHING…79
11. REBUILDING OF CYLINDER PISTON ROD BY GRINDING OFF AND CHROMIUM PLATING…111
1-2 CYLINDERS H 185…116
1. TABLE OF SERVICEABLE CYLINDERS…118
2. TABLE OF DRAWINGS…13
3. CYLINDER MARKINGS…14
4. WORK AIDS…120
5. SEALING…28
6. WEAR AND TEAR LIMIT…140
7. TORQUES…144
1-3 CYLINDERS H 121…148
1. TABLE OF SERVICEABLE CYLINDERS…150
2. TABLE OF DRAWINGS…13
3. CYLINDER MARKING…14
4. WORK AIDS…152
5. SEALING…28
6. WEAR AND TEAR LIMIT…163
7. TORQUES…167
1-4 CYLINDERS H 285…170
1. TABLE OF SERVICEABLE CYLINDERS…172
2. TABLE OF DRAWINGS…13
3. CYLINDER MARKING…14
4. WORK AIDS…174
5. SEALING…28
6. WEAR AND TEAR LIMITS…194
7. TORQUES…197
8. REWORK BY HONING…200
1-5 CYLINDER H485…202
1-5.1 CYLINDER H485/655 AND PC8000…203
1. TABLE OF SERVICEABLE CYLINDERS…205
2. CYLINDER WEIGHT…211
3. DESIGN, CUT VIEW…217
4. WORK AIDS…225
5. WEAR AND TEAR LIMITS…269
6. ASSEMBLY…307
7. TIGHTENING TORQUES…315
1-6 CYLINDERS H 185 S FROM SERIAL NO. 06078 – UP…321
1. TABLE OF SERVICEABLE CYLINDERS…322
2. DESIGN, CUT VIEW…323
3. WORK AIDS…327
4. WEAR AND TEAR LIMITS…348
5. ASSEMBLY…359
6. BOLT TIGHTENING TORQUES…361
1-6.1 CYLINDERS H 185 S…363
1. TABLE OF SERVICEABLE CYLINDERS…365
2. TABLE OF DRAWINGS…366
3. CYLINDER MARKING…371
4. WORK AIDS…373
5. WEAR AND TEAR LIMIT…397
6. TIGHTENING TORQUES FOR MOUNTING BOLTS…415
7. ASSEMBLY…417
1-7 CYLINDERS H 95…419
1. TABLE OF SERVICEABLE CYLINDERS…421
2. DESIGN, CUT VIEW…422
3. WORK AIDS…429
4. WEAR AND TEAR LIMITS…444
5. ASSEMBLY…461
6. TIGHTENING TORQUES…463
1-8 MACHINING OF THE FLANGE BUSHING AFTER FREEZING IN THE BUSHING (ALL CYLINDERS)…465
1-9 CYLINDERS H 135…471
1. TABLE OF SERVICEABLE CYLINDERS…473
2. DESIGN, CUT VIEW…474
3. WORK AIDS…479
4. WEAR AND TEAR LIMITS…494
5. ASSEMBLY…506
6. TIGHTENING TORQUES…508
1-10 HOOK WRENCH FOR PISTN NUT…511
1-11 CYLINDERS H 285 S…515
1. TABLE OF SERVICEABLE CYLINDERS…517
2. DESIGN, CUT VIEW…521
3. WORK AIDS…527
4. WEAR AND TEAR LIMITS…555
5. SEALING OF THE CYLINDER…581
6. ASSEMBLY…583
7. TIGHTENING TORQUES…591
1-12 CYLINDER H 255 S…595
1. TABLE OF SERVICEABLE CYLINDERS…597
2. DESIGN, SECTIONAL DRAWING…599
3. WORK AIDS…605
4. WEAR AND TEAR LIMITS…629
5. ASSEMBLY…649
6. TIGHTENING TORQUES…653
1-12.1 CYLINDER PC3000…655
1. TABLE OF SERVICEABLE CYLINDERS…657
2. DESIGN, SECTIONAL DRAWING…659
3. WORK AIDS…665
4. WEAR AND TEAR LIMITS…693
5. ASSEMBLY…711
6. TIGHTENING TORQUES…715
1-13 CYLINDERS H 455 S…716
1. TABLE OF SERVICEABLE CYLINDERS…718
2. DESIGN, CUT VIEW…720
3. WORK AIDS…734
4. WEAR AND TEAR LIMITS…758
5. SEALING OF THE CYLINDER…780
6. TIGHTENING TORQUES…782
1-14 CYLINDER PC1800…786
1. TABLE OF SERVICEABLE CYLINDERS…788
2. DESIGN, SECTIONAL VIEW…790
3. WORK AIDS…794
4. WEAR AND TEAR LIMITS…808
5. ASSEMBLY…826
6. DISASSEMBLY OF CYLINDER DAMPING SYSTEM…832
7. INSTALLATION OF ROD SEAL AND DUST SEAL…834
8. MOUNTING OF DAMPING PISTION AND SEAL…838
9. TIGHTENING TORQUES…846
1-15 CYLINDER (CYLINDER, BARREL AND ROD)…848
1-16 CYLINDER – GENERAL REBUILD PROCEDURES…850
2. HYDRAULIC PUMP…852
2-1 HYDRAULIC PUMP…858
MANNESMANN REXROTH RDE 92210-04R…858
SLIPPER BEARING …920
CONTENTS…922
TECHNICAL DESCRIPTION…924
ADJUSTING OF ASSEMBLY DIMENSIONS…936
ASSEMBLY-DISASSEMBLY…940
MOBILE ADJUSTMENT…948
MAIN PUMP CATALOGE PAGE ON 90-1560…962
MAIN PUMP CATALOGUE PAGE NO. 90-1490…966
2-2 LUBE OIL PUMP…970
2-3 GEAR LUBE OIL PUMP…976
2-4 MEASURING AND CONTROL OIL PUMP…982
2-5 FAN PUMP…990
2-6 SLEWING PUMP…996
2-7 COOLING CIRCUIT PUMP…1000
3. HYDRAULIC MOTOR…1006
3-1 HYDRAULIC MOTOR…1010
3-2 SLEW MOTOR…1037
SLEWING MOTOR CATALOGUE PAGE NO. 90-1363…1038
SLEWING MOTOR CATALOGUE PAGE NO. 90-1370…1040
SLEWING MOTOR TRAVEL MOTOR CATALOG PAGE NO. 90-1349…1042
3-3 FAN MOTOR DRIVE…1045
4. VALVES…1009
5. PUMP DISTRIBUTOR GEAR & DRIVE SHAFT…1053
5-1 PUMP DISTRIBUTOR GEAR H 241…1056
1. GENERAL VIEW…1057
2. DISASSEMBLING…1060
3. DETERMINATION OF WEAR AND TEAR…1076
4. ASSEMBLING…1102
5. PREASSEMBLING OF DRIVE SHAFT ASSY…1112
5-2 DRIVE SHAFT…1126
5-3 PUMP DISTRIBUTOR GEAR H 285 CONDITION MONITORING GATALOGUE PAGE NO. 90-2060A…1167
1. DESIGN…1168
2.DISASSEMBLY…1187
3. WEAR AND TEAR DETERMINATION…1206
4. PREASSEMBLY OF INPUT SHAFT AND MOUNTING IT IN THE GEAR…1219
5. ASSEMBLY OF THE OTHER SHAFT SETS…1239
5-4 PUMP DISTRIBUTOR GEAR H 85…1257
1. GENERAL VIEW…1259
2. DISASSEMBLY…1268
3. DETERMINATION OF WEAR AND TEAR…1280
4. ASSEMBLY AND ADJUSTMENT OF AXIAL PLAY…1306
5. CONDITION MONITORING PUMP DISTRIBUTOR GEAR…1324
5-5 PUMP DISTRIBUTOR GEAR H 285 CONDITION MONITORING CATALOGUE PAGE NO. 90-2079B …1328
5-6 PUMP DISTRIBUTOR GEAR H 485…1338
ASSEMBLY DRAWING…1340
CONDITION MONITORING CATALOGUE PAGE NO. 90-2076…1344
CONDITION MONITORING CATALOGUE PAGE NO. 90-0558…1352
5-6.1 PUMP DISTRIBUTOR GEAR H 485 CONDITION MONITORING…1357
5-6.2 PUMP DISTRIBUTOR GEAR H 485 DETERMINATION OF WEAR AND TEAR …1364
5-7 PUMP DISTRIBUTOR GEAR H 285…1378
5-8 PUMP DISTRIBUTOR GEAR H 685 SP…1468
1. GENERAL VIEW…1469
2. DISASSEMBLY…1483
3. DETERMINATION OF WEAR AND TEAR…1486
4. ASSEMBLY…1491
5-9 PUMP DISTRIBUTOR GEAR H 285 S…1528
1. GENERAL VIEW…1528
2. DISASSEMBLY…1546
3. DETERMINATION OF WEAR AND TEAR…1562
4. ASSEMBLY…1564
5-10 PUMP DISTRIBUTOR GEAR H 455…1612
1. GENERAL VIEW…1612
2. DISASSEMBLY…1627
3. DETERMINATION OF WEAR AND TEAR…1638
4. ASSEMBLY…1639
5-10.1 PUMP DISTRIBUTOR GEAR H 455 (PC5500) WEAR DIMENSIONS…1686
5-11 PUMP DISTRIBUTOR GEAR H 158 E + H225 E…1695
1. GENERAL VIEW…1695
2. DISASSEMBLY…1707
3. DETERMINATION OF WEAR AND TEAR…1712
4. ASSEMBLY…1715
5-12 PUMP DISTRIBUTOR GEAR H 655 WEAR DIMENSIONS…1771
6. SLEWING GEAR…1774
6-1 SLEWING GEAR H 241…1777
GENERAL VIEW…1778
DISASSEMBLING…1782
DETERMINATION OF WEAR AND TEAR…1829
ASSEMBLING…1847
TORQUES…1869
6-2 SLEWING GEAR H 285…1871
1. GENERAL VIEW…1872
2. DISASSEMBLING…1879
3. DETERMINATION OF WEAR AND TEAR…1897
4. ASSEMBLY…1921
CONDITION MONITORING SLEWING GEAR…1953
6-3 SLEWING GEAR CONDITION MONITORING H 485…1958
1. ASSEMBLY DRAWING SLEWING GEAR …1960
2. CONDITION MONITORING SLEWING GEAR …1962
3. ASSEMBLY MONITORING SLEWING GEAR…1968
6-3.1 SLEWING GEAR H 485 CONDITION MONITORING CATALOGUE PAGE NO. 90-0910…1970
6-3.2 SLEWING GEAR H 485 WEAR AND TEAR DETERMINATION CATALOGUE PAGE NO. 90-0910…1972
6-3.3 SLEWING GEAR H 485 CONDITION MONITORING CATALOGUE PAGE NO. 90-0560…1976
6-3.4 SLEWING GEAR H 485/H 655 WEAR AND TEAR DETERMINATION…1978
6-4 SLEWING GEAR H 85…1985
6-5 SLEWING GEAR H 455…1989
1. GENERAL VIEW…1991
2. DISASSEMBLY…1997
3. DETEMINATION OF WEAR AND TEAR…2001
4. ASSEMBLY…2005
5. TORQUES…2048
6-6 SLEWING GEAR H 285 S CATALOGUE NO. 90-1978D…2050
1. GENERAL VIEW …2051
2. DISASSEMBLY…2064
3. DETERMINATION OF WEAR AND TEAR…2065
4. ASSEMBLY…2067
5. TORQUES…2108
6-6.1 SLEWING GEAR H 285 S CONDITION MONITORING CATALOGUE PAGE NO. 90-1978 & 90-1978B…2110
6-7 SLEWING GEAR H 255 CATALOGUE PAGE NO. 991-0119…2120
1. GENERAL VIEW…2121
2. DISASSEMBLY…2131
3. DETERMINATION OF WEAR AND TEAR…2137
4. ASSEMBLY…2139
5. TORQUES…2184
6-8 SLEWING GEAR PC4000…2186
1. GENERAL VIEW…2187
2. DISASSEMBLY…2193
3. DETERMINATION OF WEAR AND TEAR…2201
4. ASSEMBLY…2203
6-10 SLEWING GEAR DISC BRAKE PC3000/4000/5500/8000…2288
1. PARTS REQUIRED FOR REPAIR…2289
2. DISASSEMBLY…2291
3. ASSEMBLY…2303
7. TRAVEL GEAR…2324
7-7.1 TRAVEL GEAR H 455/PC5500 EXCHANGE OF: PLANETARY CARRIER…2325
5. DISASSEMBLY OF PLANETARY GEARBOX, EXCHANGE OF PLANETARY CARRIER…2327
7-10 TRAVEL GEAR H 255/PC3000…2329
1. GENERAL VIEW…2330
2. DISASSMELBY…2337
3. DETERMINATION OF WEAR AND TEAR…2358
4. ASSEMBLY…2360
8. SLEW RING…2493
9. ROTARY JOINT…2494
10. BOTTOM ROLLER/TRACK ROLLER…2495
11. TOP ROLLER…2496
12. IDLER…2497
13. SPROCKET…2498
14. WELDING INSTRUCTIONS FOR STEEL STRUCTURAL PARTS AND STEEL CASTINGS…2501
14-4 WELDING INSTRUCTIONS, REBUILD OF TRACK PADS, BOTTOM ROLLERS, SPROCKETS AND IDLERS OF CASTING STEEL…2503
1. COMPONENTS SUITABLE FOR REBUILD…2505
1.1 TRACK PADS…2505
1.2 BOTTOM ROLLERS…2507
1.3 SPROCKET…2509
1.4 IDLERS…2511
2. DETERMINATION OF WEAR…2519
3. WELDING PROCESS…2523
4. RE-MACHINING THE ORIGINAL CONTOUR…2527
H285S78139OMM – DEMAG Komatsu Hydraulic Mining Shovels Parts & Service…2529
Komatsu/DEMAG Hydraulic Shovels H285S Repair Service Manuals