Front Susp Recon Guidelines

7/23/2019 Front Susp Recon Guidelines

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- NormItem code

Index

Date Plant Prepared Checked Approved

No copying or duplication of this document without the permission of Liebherr. Liebherr-Norm_000_ENThis document has been issued electronically and is valid without signature.

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Reconditioning Guidelines in accordance with a

Life Cycle Management for a LHB front shock absorber

11485545

001

09.10.2013 LHB M.Stucke H.P.Lavergne H.P.Lavergne

Index Changes Reconditioning Guideline

Index 001: New LH-Repair manual Id.no.11651418 added.Id.no.10814570 is superseded by Id.no.11651418!



- NormItem code 11485545

Index 001

No copying or duplication of this document without the permission of Liebherr. Liebherr-Norm_000_EN

This document has been issued electronically and is valid without signature.

2/16

LIEBHERR Reconditioning Guidelines in accordance with a

Kirchdorf LHB Life Cycle Management for a suspension

Overhaul1. Disassembly of the shock absorber, according to LH-Repair manual Id.no.11651418.2. Evaluation, assessment and measurement of the part.3. Separate regeneration, of the items according to the evaluation.3a. When the tube is scored or damaged, the tube can be repeatedly honed. For the following

sizes LH pistons are available:+0.25 mm nominal size+0.50 mm nominal size+0.75 mm nominal sizeExample: Ø425 H8 originalØ425, 25 H8 new diameter According to the new diameter, the appropriate spare piston has to be used. In

the spare parts list, you can find the ID number to order. Pos.3025, 3050 and 3075.3b. When the cylinder surface is damaged (scoring), it can be unchromed several times andthen rechromed up to a maximum thickness of 0.12 mm. For greater thicknesses,authorized HVOF or thermal spray processes can be used.

4. Using a new seal kit (seals and guides) + attachments.

Mounting the shock absorber, according to LH-Repair manual Id.no.116514185. Function test of the shock absorber, see LH-specification Id.No.103360786. Marking of the shock absorber7. Reconditioning can be performed, depending on the needs, up to the maximum operating

hours.

Evaluation criteria and controlling:

• Visual inspection and photographic documentation (beats, scratches, damaged areas of therod coating, ...).

• Surface crack testing of welds and the bearing bore, according to LH-specification Id.no.11651418• Remove the un-cleaned Seals and send them to LHB. Fill out the extra sheet “Evaluating of

the seals and guide rings”.

Following the scheduled inspections (refer also to to LH-Repair manual Id.no.11651418):

Check 1, no later than 20.000 hours of operation

Dismantling of suspension

Expert’s report, assessment and survey of components

Separate reconditioning according to assessment Usage of a new seal kit (seals and guide rings), bolts, washers, orifices, bearings and snap rings

Re-hone with +0,25mm, +0,50mm or +0,75mm, when needed

Re-chrome piston rod, when needed

Spare part piston with Indication H / HH / HHH, when needed Re-assembly of suspension

Hydraulic pressure test of suspension

Check 2, no later than 20.000 hours after check 1

Overhaul, as with check 1

Check 3, no later than 20.000 hours after check 2

Overhaul, as with check 1




Index 001



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Next is the structure of the individual processing steps:

The reconditioning work must be completed in a workshop, which possesses the respective expertknowledge and also have the necessary qualified staff available. As far as possible, it should have

certification according to ISO 9002.

1. Dismantling Procedures :

Follow LH-Repair manual Id.no.11651418

2. Expert’s Report, Assessment and Survey of Components All components must be carefully cleaned. The expert’s reports, assessments and surveys must berecorded in a log book.

Log complete shock absorber

Log outer cylinder tube

Log cylinder for Log head bottom

Log piston Log piston rod bearing

The decision, what reconditioning work is needed for the individual components, is made according to thesurvey‘s log book. Documentation stored, until the end of the component lifespan is reached.

3. Usage of a new Seal kitWhen a shock absorber is reconditioned, basically a new seal kit, consisting of sealing and guideelements, should be installed. Please make sure that the sealing elements are not damaged duringassembly. Please follow the system drawing of the cylinder and the assembly instructions for sealing

when installing the sealing elements, according to LH-Repair manual Id.no.11651418.

4. Assembly of shock absorberRe-assembly per to LH-Repair manual Id.no.11651418.Cleanliness must be applied during all work procedures. Components must not get damaged. Inparticular, attention must be paid to the running surface of the piston rod and outer tube. The interiorgrooves of the parts must not come into contact with splinters and dust particles. All Bolts, washers, snap-rings, spherical bearings and fill valves have to be changed out and replacedwith new ones, according to the parts replacement guidance sheet. For lubrication and easier assembly,use lubricants (LH Hydraulic Plus).

5. Testing of shock absorber After re-assembly of the shock absorber, a pressure and leak test has to be carried out.See LH-specification Id.No.10336078, for more details.




Index 001



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Customer Info:

Contact person: Substitution:

Customer:

Address:

Email:

Plant / Division:

Details:

Used as:

Job site

Equipment(such as: T282B)

Used as(shock absorber left front)

Type of mine(Coal, Oil… )

Article code shock absorber

Revision Index

Serial-No. shock absorber

Operating hourshock absorber (in h)

Operating hourequipment (in h)

Oil temperature (in °C)

Why changed(Service or damaged)

http://www.dict.cc/englisch-deutsch/substitution.html





Index 001



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Liebherr-No. Liebherr-No. on partTyp ID.-No. Drawing-No. Ident-No. with

IndexSerial-No.

Supplementary sheet „Cylinder“ for LH-Specification Id.no.11651418

Evaluation criteria:

Inspection points Specified Measured Tolerance Decision Comment

Optical inspection and photodocumentation when scratches,damages, ... are visible

(1) Outside diameter Ø380 f7O.K.Rework

(2) Length 1165 +0,3 / -0,2O.K.Rework

(3) Spherical diameter bore Ø259,92 +0,05O.K.Rework

Orifice M20x1.5 & Chamfer118°-140°, only early versions

O.K.Rework

Thread M20O.K.Rework

Surface (1) diameterO.K.Rework

Crack testingO.K.Rework

Comments:

Early versions still have 12 orifice seats!

http://www.dict.cc/englisch-deutsch/supplementary.html

http://www.dict.cc/englisch-deutsch/sheet.html






Index 001



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Rebuild:

Reuse part without rebuild work, as is

New Spherical bearing and snap ring

Cleaning and strip paint, if necessary

Rework part

Polish surface, within the tolerance f7

Rechrome surface with tolerance f780NiCr / 80BrCr or 150µm HVOF Coat “TLS415.060 from TeroLab”

Install new Spherical bearing and snap ringInstall new oversize-Spherical bearing and snap ring (+2mm in Ø) Rework orifices seat or check ball seatRework spherical bearing seat to Ø261,92+0,05 for oversize bearing

Part is reused in original suspension

Part is stored for spare

Preserve and seal up part

Scrap part

Statement:

Coating definition:




Index 001



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Surface definition:

Rework check ball seat:

If excessive wear, in the check ball seat area has occurred (see fig.1):

Figure 1

Figure 2

Machining repair procedure:

Support, and secure the suspension rod on a mill table and center the tool chuck to the bottom ofthe 24 mm diameter of the ball seat, shown in figure 2.

Using a 24mm end mill in the machine tool, remove just enough material to clean off excessmaterial on top of the seat. Max depth of this 24mm bore is 21mm, for the rework.

Remove any burrs from machined surfaces and make sure all surfaces are free from loosematerial. No other machining is required. A contour of the ball will remain when machining iscomplete. This contour is acceptable for reassembly of the suspension.

Validator Date Place




Index 001



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IndexSerial-No.

Supplementary sheet „Outer tube“ for LH-Specification Id.no.11651418




(1) Inner diameter 425 H8O.K.Rework

(2) Length 440 ±0,5

O.K.

Rework

(3) Inner diameter steps 430 H7O.K.Rework

(4) Thread M20O.K.Rework

Inner surface (1)O.K.Rework

Comments:








Index 001



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Rebuild:


Use new VSTI Plugs and seals


Rework part

Polish inner surface, within the tolerance H8

Refurbish inner diameter. Depending on the scratches, damages three steps with0,25mm, 0,50mm or 0,75mm can be completed. According to the stage of rebuild, thecorrect spare piston has to be ordered, for the suspension.

Label the tube, after the tube identification number withH = reworked 0,25mm, HH = reworked 0,50mm or HHH = reworked 0,75mm




Rework step marked (H / HH / HHH)

Scrap part

Statement:

Surface definition:





Index 001



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IndexSerial-No.

Supplementary sheet „lower head“ for LH-Specification Id.no.11651418




(1) Diameter Sphericalbearing bore

Ø259,92 +0,05 O.K.Rework

(2) Thread M16x1.5O.K.Rework

(3) Outside diameter Ø430 -0,02 / -0,08 O.K.Rework

Crack testingO.K.Rework

Comments:

Crack testing Head /Radius area, all around

LH-Specification 11651418








Index 001



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Rebuild:


New static seal

New Spherical bearing and snap rings

Store without static seal


Rework part

Complete part with new Spherical bearing and snap ring

Install new oversize-Spherical bearing and snap ring (+2mm in Ø)

Refinish plain surface, of the M20 bolt area, when needed (max. 1mm)

Rework spherical bearing seat to Ø261,92+0,05 for oversize bearing




Scrap part

Statement:





Index 001



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IndexSerial-No.

Supplementary sheet „Piston rod bearing“ for LH-Specification Id.no.11651418




(1) Outer diameter Ø430 -0,02 / -0,08 O.K.Rework

(2) Inner diameter Ø381,6 +0,3O.K.

Rework

(3) Inner diameter guiderings

Ø385 +0,03 / -0,02O.K.Rework

(4) Inner diameter groovedivider

Ø380,6 +0,3O.K.Rework

(4) Inner diameter groovedivider

Ø380,6 +0,3O.K.Rework

Comments:








Index 001



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Rebuild:


New seal kit


Store without seals

Rework part

Refinish plain surface, of the M20 bolt area, when needed (max. 1mm)

Reassemble with a new seal kit




Scrap part

Statement:





Index 001



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IndexSerial-No.

Supplementary sheet „Piston“ for LH-Specification Id.no.11651418




(1) Width 112 ±0,2 O.K.Rework

(2) Diameter guide rings Ø417 -0,05 / -0,1 O.K.Rework

(3) Maximum outside diameter Ø424,3 -0,2 O.K.Rework

(4) Thread G3/4“ & chamfer118°-140°, if still present.When already closed, leave it.

O.K.Rework

Comments:

New Version, since Q1/2012with fixed bore.

Closed orifice seat in piston, accordingto SIC / LME / 2012 - 04 - 0001








Index 001



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Rebuild:


Cleaning

Store

Order spare part with correct oversize

(Tube reworked to H = 0,25mm; HH = 0,50mm; HHH = 0,75mm)

Close orifice seat, according to SIC / LME / 2012 - 04 - 0001




Scrap part

Statement:





Index 001



Supplementary sheet „Return delivery and Evaluation of the seals and guideelements“ for LH-Specification Id.no.11651418

Current management number:

Shipping address:

Company: Liebherr Mining Equipment Co.

Street: 4100 Chestnut Ave

City: Newport News, VA

Country: 23607, USA

Contact:

E-Mail / Phone:

Customer :

Contact person: Substitution:

Name:

Location:

Email:

Plant / Division:

Details:

Used as:

Equipment(such as: T282B)

Used as(shock absorber left front)

Type of mine(Coal, Oil… )

Article code shock absorber

Revision Index

Serial-No. shock absorber

Operating hourshock absorber (in h)

Miscellaneous, like why wasthe suspension removed?

If the shock absorber failed, due to aseal kit leakage, send the un-cleaned

seals to the address listed below:




http://www.dict.cc/englisch-deutsch/miscellaneous.html

http://www.dict.cc/englisch-deutsch/miscellaneous.html




Documents

Front Susp Recon Guidelines