Service Manual - TiltRotators UK
Contents
1. Fig 10 Hydraulic connections valve block Page 14 engcon Service Manual Tiltrotator Rotator EC02 Directional valve valve block tilt cylinder 4 Undo the two screws that are screwed into the valve package applies to protective plate without type plate Fig 11 Screws for protective plate without type plate 5 Remove the protective plate with a type plate 6 Disconnect the three power plugs 7 Remove the valve block from the tilt cylinder making sure that the O rings come away with it 8 Remove the directional valve from the valve block 9 Plug all open connections 10 Remove the plastic nuts on the electromagnets and pull the electromag nets off the directional valve NOTE Reserve the O rings for later Fig 12 Directional valve 11 Replace any damaged parts engcon Page 15 Service Manual Tiltrotator Rotator EC02 Directional valve valve block tilt cylinder Attachment a BR U N Oo Attach the electromagnets on the directional valve Lubricate the O rings and thread them onto the directional valves Attach the plastic nuts Connect the directional valve to the valve block Attach the valve block to the tilt cylinder Check that the O rings are cor rectly in place Connect the three power plugs Make sure that the cables are positioned correctly and are not rubbing against any edges Attach the protective plate and tig2. 6 Install the dial indicator and tool 1004806 in one of the screw holes for the hydraulic motor Set the dial indicator to zero Fig 18 Installation dial indicator NOTE When checking the play make sure that the lower part and frame do not rotate in relation to each other 7 Turn the lower part anti clockwise Check that the play is within the specified tolerance If there is too much play the worm screw must be reshimmed 8 Reinstall the hydraulic motor according to the instructions in the section Hydraulic motor Attachment Page 22 engcon Service Manual Tiltrotator Rotator EC02 Worm wheel Worm wheel Removal 1 Remove the tilt cylinder according to the instructions in the section Tilt cylinder Removal steps 1 9 2 Remove the lock screws from the tilt shafts on the head and remove the tilt shafts Remove the head Remove the indicator rod on the quick hitch Use an iron bar and a spacer to hold the locking wedge in place Remove the reamed bolt for the lock cylinder N QD oO AS WO Carefully allow the iron bar to slide forwards until the tool springs are free from pressure Remove the locking wedge and the tool springs Fig 19 Jig tool springs 8 Mark the positions of the two tubes on the lock cylinder 9 Remove the two tubes from the lock cylinder on the swivel engcon Page 23 Service Manual Tiltrotator Rotator EC02 Worm wheel Fig 20 Tubes
3. NZ YN engcon Service Manual Tiltrotator Rotator EC ECRO2 The noble art of digging Service Manual Tiltrotator Rotator EC02 Table of contents Safety regulations General INfFOMMation eee 4 Gautionsis sciare E 4 Technical data General information eene 6 TGS TANG acia cocto ias nn bx Raub cda 7 PCPA refecit 7 Tiltrotator rotator ECO2 seen 8 Tilt cylinde Removal aaa 9 Dismantlittya canina i e i o Rx 10 jorge 11 Attachments cr o ete er p ER P Fee ee S Eph 12 Directional valve valve block tilt cylinder Removals rrr ioa ERR EE 14 ATLACIIMG INE ai ie eire etie Fr oiv tv E Es 16 Directional valve valve block frame Removala c irit eire ee tian e Doer ew retis 17 Attachment iene 17 Head Removal cetero DOM ERE CE CU ERR RHET ERR 18 Attachment iee arne ct enn ie er tere rrr c Peces 18 Hydraulic motor Removal 20 Attachment iscncl liana 20 Worm screw Removal izle ia 21 Attachment anioni 22 Worm wheel Removal aria 23 Attachment erre rien reina 28 Checking of axial play Axial play worm Whedlsiscsnccicnia ian 33 Axial play WONT SONG W rr 35 engcon Page 3 Service Manual Tiltrotator Rotator EC02 Safety regulations Safety regulations General information Cautions In this service manual the terms CAUTION NB and NOTE are used as follows CAUTION The term CAUTION
4. 4 Check the head for cracks and other damage Replace or repair if necessary 1 Lubricate the bushes for the tilt shafts 2 Lift the head into place and attach the tilt shaft that is turned away from the base machine 3 Attach the tilt shaft that is turned towards the machine and push it in until it reaches the inner edge of the shaft hole on the head Do not use shims on the front end Risk of material damage 4 Shim the head into place positioning the shims on the inside at the rear end NOTE There must be no perceivable play after attachment and shimming Page 18 engcon Service Manual Tiltrotator Rotator EC02 Head Fig 14 Shimming head 5 Attach the lock screw for the tilt shafts 6 Lubricate the bushes for the tilt cylinder 7 Attach the tilt cylinder according to the instructions in the section Tilt cylinder Attachment steps 5 11 engcon Page 19 Service Manual Tiltrotator Rotator EC02 Hydraulic motor Hydraulic motor CAUTION Make sure that the hydraulic system is free of pressure before starting work Risk of personal injury All work that involves opening up connections to hydraulic parts requires a high degree of cleanness NOTE Dismantling instructions for each type of hydraulic motor are included with the seal kit when spare parts are ordered Removal 1 Remove the motor guard 2 Clean the motor and connections 3 Mark the positions o
5. Service Manual Tiltrotator Rotator EC02 Tilt cylinder Removal Tilt cylinder CAUTION Make sure that the hydraulic system is free of pressure before starting work Risk of personal injury All work that involves opening up connections to hydraulic parts requires a high degree of cleanness 1 Clean the tilt cylinder and its hydraulic connections 2 Mark the positions of the two hydraulic tubes 3 Disconnect the hydraulic tubes attached to connection A and connection B on the tilt cylinder s valve block 4 Plug all open connections Fig 4 Hydraulic connections valve block Remove the cable ties around the tubes Remove the two power plugs from the rotator s valve block Remove the cylinder coupling that is turned towards the base machine Remove the lock screw for the cylinder shaft and remove the shaft DON OA engcon Page 9 Service Manual Tiltrotator Rotator EC02 Tilt cylinder Fig 5 Cylinder shaft CAUTION Risk of catching in moving parts 9 Lift off the tilt cylinder with the valve package from the cylinder coupling that is turned away from the machine 10 Remove the protective plates covering the tilt cylinder s valve package 11 Remove the valve block from the tilt cylinder making sure that O rings come away with it Dismantling All work that involves dismantling of hydraulic parts requires a high degree of cleanness 1 Clean the outside of the cy
6. anual Tiltrotator Rotator EC02 Worm wheel Fig 32 Tubes lock cylinder 30 Attach the lock cylinder with spacers Do not tighten the fastenings 31 Attach the tool springs and the locking wedge Use an iron bar with a spacer to compress the springs 32 Attach the reamed bolt for the lock cylinder 33 Tighten the hex screws on the lock cylinder Fig 33 Jig tool springs 34 Attach the indicator rod to the quick hitch 35 Attach the head 36 Attach the tilt shaft that is turned away from the machine engcon Page 31 Service Manual Tiltrotator Rotator EC02 Worm wheel 37 Attach the tilt shaft that is turned towards the machine and push it in until it reaches the inner edge of the shaft hole on the head Do not use shims on the front end Risk of material damage 38 Shim the head into place on the inside at the rear end NOTE There must be no perceivable play after attachment and shimming Fig 34 Shimming head 39 Attach the lock screws for the tilt shafts 40 Attach the tilt cylinder according to the instructions in the section Tilt cylinder Attachment steps 5 11 Page 32 engcon Service Manual Tiltrotator Rotator EC02 Checking of axial play Checking of axial play Axial play worm wheel If there is no hole for mounting the gauge 1 Drill a hole measuring 8 5 mm in the cover plate as shown in fig 38 2 Probe with the tool R1 8 NOTE Plug
7. crew can be turned in the screw bush then attach the worm screw in the frame 18 Attach the screw housing for the worm screw 19 Turn the lower part clockwise to make sure that the worm screw reaches the bottom 20 Install the dial indicator and tool 1004806 in one of the screw holes for the hydraulic motor Set the dial indicator to zero Fig 29 Dial indicator engcon Page 29 Service Manual Tiltrotator Rotator EC02 Worm wheel NOTE When checking the play make sure that the lower part and frame do not rotate in relation to each other 21 Turn the lower part anti clockwise Check that the play is within the specified tolerance If there is too much play the worm screw must be reshimmed 22 Attach the hydraulic motor and tighten the screws 23 Attach the valve block with the swivel Check that the pin on the swivel fits the notch on the hitch F OO Fig 30 Swivel pin fitted correctly in notch 24 Check that all the O rings are correctly in place on the directional valves 25 Attach the directional valves 26 Attach the tubes on the hydraulic motor following the markings made earlier 27 Attach the motor guard 28 Attach the tubes for extra equipment following the markings made earlier Fig 31 Tubes extra equipment 29 Attach the tubes to the lock cylinder following the markings made earlier Page 30 engcon Service M
8. f the two hydraulic tubes so that they can be replaced in the same position 4 Disconnect the tubes from the hydraulic motor 5 Plug all open connections Fig 15 Hydraulic connections hydraulic motor 6 Remove the screws from the hydraulic motor and remove the motor Attachment 1 Attach the hydraulic motor and tighten the screws 2 Connect the tubes for the hydraulic motor following the markings made earlier 3 Attach the motor guard Page 20 engcon Service Manual Tiltrotator Rotator EC02 Worm screw Removal Worm screw 1 Remove the hydraulic motor according to the instructions in the section Hydraulic motor Removal 2 Remove the screw housing for the worm screw 3 Remove the worm screw washer along with the corresponding shims A jig is required for this operation Fig 16 Worm screw 4 Remove the screw bush 5 Remove the worm screw 6 Check all seals and wear parts for damage and wear Replace any damaged or worn parts engcon Page 21 Service Manual Tiltrotator Rotator EC02 Worm screw Attachment 1 Lubricate the worm screw bushes 2 Put together the worm screw screw bush and screw washer with shims Fig 17 Worm screw 3 Check that the screw can be turned in the screw bush then attach the worm screw in the frame 4 Attach the screw housing for the worm screw 5 Turn the lower part clockwise to make sure that the worm screw reaches the bottom
9. hecking the play make sure that the lower part and the frame do not rotate in relation to each other 4 Turn the lower part anti clockwise and check that the play is within the specified tolerance If there is too much play the worm screw must be reshimmed Reshim according to the instructions in the section Worm screw Removal Attachment Attach the hydraulic motor according to the instructions in the section Hydraulic motor Attachment engcon Page 35 engcon Nordic engcon Finland engcon Denmark engcon UK engcon Germany engcon Poland engcon The noble art of digging engcon Sweden Nordic Holding PO Box 111 SE 833 22 Str msund Sweden Phone 46 670 178 00 Fax 46 670 178 28 info engcon com www engcon com Z wy Production Syre Print Berndtssons Tryckeri 2010
10. hten the screws Connect the two hydraulic tubes to the valve block following the markings made earlier Page 16 engcon Service Manual Tiltrotator Rotator EC02 Directional valve valve block frame Directional valve valve block frame Removal Attachment Undo the two power plugs on the directional valves Remove the directional valves from the valve block Plug all open connections WON Remove the plastic nut for each electromagnet and pull them off the directional valve NOTE Reserve the O rings for later 5 Replace any damaged parts Fig 13 Directional valve Attach the electromagnets on the directional valve Lubricate the O rings and thread them onto the directional valves Attach the plastic nuts Attach the directional valves on the valve block a BR U N Connect the power plugs to the directional valves engcon Page 17 Service Manual Tiltrotator Rotator EC02 Head Head Removal Attachment CAUTION Make sure that the hydraulic system is free of pressure before starting work Risk of personal injury All work that involves opening up connections to hydraulic parts requires a high degree of cleanness 1 Remove the tilt cylinder according to the instructions in the section Tilt cylinder Removal steps 1 9 2 Remove the lock screws for the tilt shafts on the head and remove the tilt shafts 3 Remove the head
11. late with a type plate 5 Lubricate the bushes for the tilt cylinder 6 Install the cylinder in the hitch that is turned away from the base machine Page 12 engcon Service Manual Tiltrotator Rotator EC02 Tilt cylinder 7 Attach the hitch that is turned towards the base machine Fig 9 Tilt cylinder 8 Attach the cylinder shaft and the lock screw 9 Connect the two hydraulic tubes to the tilt cylinder s valve block following the markings made earlier 10 Connect the two power plugs to the rotator s valve block 11 Fasten the power cable firmly to the hydraulic tubes using cable ties 12 Lubricate the tiltrotator See the lubrication schedule in the instruction manual engcon Page 13 Service Manual Tiltrotator Rotator EC02 Directional valve valve block tilt cylinder Directional valve valve block tilt cylinder CAUTION Make sure that the hydraulic system is free of pressure before starting work Risk of personal injury All work that involves opening up connections to hydraulic parts requires a high degree of cleanness All work on the hydraulic system that involves dismantling of parts requires a high degree of cleanness Removal 1 Mark the positions of the two hydraulic tubes so that they can be replaced in the same position 2 Disconnect the hydraulic tubes attached to connection A and connection B on the tilt cylinder s valve block 3 Plug all open connections
12. linder 2 Clamp the cylinder in a vice 3 Remove the cylinder nut and empty any remaining oil from the cylinder 4 Pull out the piston rod along with its seals NOTE The piston is fixed with Loctite If necessary heat gently to facilitate removal 5 Remove the piston from the piston rod 6 Remove the cylinder nut from the piston rod Page 10 engcon Service Manual Tiltrotator Rotator EC02 Tilt cylinder Assembly 1 Check the piston rod piston and cylinder for damage or scratches 2 Replace all seals Fig 6 Tilt cylinder assembly diagram 3 Lubricate the seals in the cylinder nut with clean hydraulic oil and thread it onto the piston rod 4 Apply lock solution to the piston and mount it on the piston rod 5 Make a punch mark on the bottom between the piston and the piston rod to secure the piston 6 Lubricate the new seals on the piston with clean hydraulic oil and push the piston rod into the cylinder 7 Screw the cylinder nut into place engcon Page 11 Service Manual Tiltrotator Rotator EC02 Tilt cylinder Attachment 1 Attach the valve block with the directional valve Check that the O rings are correctly in place Fig 7 O rings 2 Attach the protective plate without a type plate to the valve block Fig 8 Protective plate without type plate 3 Make sure that the cables are not rubbing against any sharp edges 4 Attach the protective p
13. lock cylinder 10 Remove the cylinder 11 Plug all open connections 12 Mark the positions of the tubes for extra equipment 13 Remove the tubes Fig 21 Tubes extra equipment 14 Plug all open connections 15 Mark the positions of the two hydraulic tubes connected to the hydraulic motor so that they can be replaced in the same position 16 Disconnect the tubes from the hydraulic motor Page 24 engcon Service Manual Tiltrotator Rotator EC02 Worm wheel 17 Plug all open connections Fig 22 Hydraulic connections hydraulic motor 18 Remove the screws from the hydraulic motor and remove the motor 19 Remove the directional valves making sure that the O rings remain in place 20 Undo the screws for the cover plate and remove the valve block with the swivel Fig 23 Removal of swivel 21 Remove the screw housing for the worm screw engcon Page 25 Service Manual Tiltrotator Rotator EC02 Worm wheel 22 Remove the washer for the worm screw with the shim A jig is required for this operation Fig 24 Worm screw 23 Remove the screw bush and the worm screw 24 Remove the screws for the worm wheel quick hitch 25 Remove the quick hitch 26 Remove the scraper for the quick hitch 27 Undo the two hex screws for the centre ring Fig 25 Hex screws centre ring 28 Lift out the worm wheel Page 26 engcon Service Manual Ti
14. lock function number of couplings 2 Rotation Infinite Tilt angle 2x40 Tilt time hydraulic flow 2s 10 l min Rotation time for one rotation hydraulic flow 4 6 s 35 l min Hydraulic motor Char Lynn J lin 50 cm Standard mountings S30 S40 Depends on mountin p g A g From machine Fig 1 Measurement table Page 6 engcon Service Manual Tiltrotator Rotator EC02 Tightening Permitted play Technical data The rotator is dimensioned to withstand heavy strain from breakout and rotation Tightening of certain screw joints is vital to ensure optimum durability Screws and thread holes must be kept very clean and the threads well lubricated Screw dimension 8 8 Type 12 9 Typ M5 5 7 Nm 9 7 Nm M10 47 Nm 80 Nm M12 81 Nm 140 Nm The screws for the hitch centre ring and yoke couplings must be replaced during servicing The replacement screws should be of the same type as the previous screws Axial play worm screw A Axial play worm wheel B Max 0 4 mm Max 0 3 mm NOTE After shimming the values should be between 0 1 mm and 0 2 mm Fig 2 Overview play Axial play worm screw A Axial play worm wheel B engcon Page 7 Service Manual Tiltrotator Rotator EC02 Tiltrotator rotator EC02 Tiltrotator Rotator EC02 Tilt cylinder Valve block swivel Worm screw Hydraulic motor Worm wheel Fig 3 Assembly diagram rotator EC02 Page 8 engcon
15. ltrotator Rotator EC02 Worm wheel 29 Remove the shims Fig 26 Shims worm wheel 30 Remove the centre ring 31 Remove the wear washer wear ring guide bush and scraper for the centre ring 32 Check all seals and wear parts for damage and wear Replace if necessary engcon Page 27 Service Manual Tiltrotator Rotator EC02 Worm wheel Attachment 1 Attach the wear washer checking that it is aligned with the lubrication groove Fig 27 Wear washer 2 Attach the wear ring Check that the guide pin is not protruding above the wear washer Attach the scraper for the centre ring and the guide bush Attach the centre ring Attach the shim and lubricate the wear washer wear ring Attach the worm wheel Tighten the worm wheel centre ring with the two hex screws M6 ON OO 2 OO Insert two screws through the holes in the worm wheel and put a flat bar between them to keep the iron bar in place Page 28 engcon Service Manual Tiltrotator Rotator EC02 Worm wheel 9 Measure the axial play around the worm wheel using a dial indicator and iron bar Fig 28 Measurement play 10 Max play 0 3 mm If the play exceeds the tolerance the rotor must be reshimmed NOTE Make sure that the groove for the scraper is clean so that the new scraper can be positioned correctly 16 Put together the worm screw screw bush and screw washer with shims 17 Check that the s
16. signifies that incorrect procedures can cause personal injury The term NB signifies that incorrect procedures can cause material damage NOTE The term NOTE highlights important user instructions The service manual describes the repair and inspection operations that can be performed on tiltrotator rotator ec 02 The safety regulations apply regardless of which base machine is used Also see the safety instructions for the base machine and other equipment used as well as the safety information in the instruction manual Make sure you have read and understood all the cautions before undertaking any maintenance operations The cautions explain potential risks and how to avoid them If in any doubt contact your employer or the supplier Expert advice can eliminate many unnecessary risks CAUTION Incorrect installation can pose a safety risk If in any doubt contact an engcon dealer or engcon Nordic AB CAUTION Make sure that the hydraulic system is free of pressure before starting work on the system Risk of personal injury CAUTION Switch off the power when working with the electrical system and remove rings watches etc before starting work Risk of personal injury Page 4 engcon Service Manual Tiltrotator Rotator EC02 gt gt bD BPE Safety regulations CAUTION Never use your hands to check for leaks in the hydraulic system Hydraulic oil under pressure can penetrate your skin ca
17. the hole after finishing the operation Fig 36 Measurement table engcon Page 33 Service Manual Tiltrotator Rotator EC02 Checking of axial play Checking of play 1 Remove the directional valve for rotation Fig 37 Directional valve for rotation removed 2 Attach the tool for checking the axial play 1 1004707 2 610906 3 1004720 4 1004809 Fig 38 Tool for checking play 3 Set the gauge to zero against one of the flat surfaces with the rotor resting flat against the ground Page 34 engcon Service Manual Tiltrotator Rotator EC02 Checking of axial play NOTE Check the play by lifting the rotor up from the ground 4 Probe with an iron bar between the hitch and frame to make sure that there is room for maximum play Check that the play is within the indicated tole rance If there is too much play the rotator must be reshimmed Reshim according to the instructions in the section Worm wheel Removal Attachment Attach the directional valve for rotation Axial play worm screw Checking of play 1 2 3 Remove the hydraulic motor according to the instructions in the section Hydraulic motor Removal Turn the lower part clockwise to make sure that the worm screw reaches the bottom Attach the gauge and tool 1004806 and reset it to zero against one of the flat surfaces De Fig 39 Gauge NOTE When c
18. using serious injury CAUTION Implements connected to the tiltrotator rotator may not be used under any circumstances unless correctly locked into place ALWAYS make sure that the lock bolts protrude according to the specifications for the relevant quick hitch CAUTION Never attempt to upgrade the equipment s maximum capacity by making modifications without the supplier s approval CAUTION Short circuits in electrical cables can cause injury and burning Insulate electrical conductors and parts carefully when installing electrical equipment CAUTION Risk of burn injuries from hot hydraulic oil CAUTION The machine must never be operated with the implement lock switch turned on except when attaching or detaching a bucket or implement CAUTION If in any doubt regarding the machinery or the safety features contact an engcon dealer or engcon Nordic AB CAUTION Risk of catching in moving parts engcon Page 5 Service Manual Tiltrotator Rotator EC02 Technical data Technical data General information Max machine size 3 000 kg Max breakout 20 kNm Max bucket width 800 mm Max hydraulic pressure 22 5 MPa Min max hydraulic flow 15 35 l min Max rec pressure in return line 2 5 MPa Weight 65 kg Width A 180 mm Width B 155 mm Width C 160 mm Total length D 435 mm Build height E 245 mm Max width 385 mm Swivel channel extra function number of couplings 2 Swivel channel
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