COMPONENT CODE: K100

REF NO.: Ah00504A

PARTS & SERVICE NEWS DATE: April 1st, 2000
Page 1 of 5

This PARTS & SERVICE NEWS supercedes the previous issue No. 21 – 506a
dated Aug. 1998 which should be discarded.

SUBJECT: Cleaning and Flushing the Hydraulic System

in Case of Damages with Chips

PURPOSE: Damages creating chips on components such as

hydraulic pumps and motors

APPLICATION: All Types

FAILURE CODE: K100ZB

DESCRIPTION:

In case of damages creating chips on components such as pumps, motors and

cylinders the replacement of the defective part and the cleaning of the return filter
alone are not sufficient to work again with the machine.

.
Since this kind of damage of a component is rarely noticed at the
beginning, this failure may contaminate the complete hydraulic cir-
cuit to which the component concerned belongs, or even the entire
hydraulic system.

For this reason, we recommend to clean the hydraulic system thoroughly after the
replacement of a defective component, to avoid expensive consequential damages.

. If during inspection and cleaning, damage to other components is

found, these parts too must be repaired or replaced.

If, in case of commissionings or repairs the hydraulic oil level decreases in the
suction pipe and the pump runs empty, it is very important to bleed the system ac-
cording to Service Bulletin 21-491.
The cleaning of the system is subdivided as follows:

A General page 2 - 4
B Systems with high-pressure filter page 4 - 5
C Systems without high-pressure filter page 5

Ah00504A
Page 2 of 5

A - General Þ Damages creating chips on components such as hydraulic pumps

and motors

• Short-circuit pressure lines of the defective component and flush approx. 30

minutes by actuating the corresponding motion (see ill., page 3). With hydraulic
cylinders coupled in parallel, the pressure lines of both cylinders must be short-
circuited. The flow direction must be inversed appr. every 5 minutes during
the flushing procedure.

flushing bridge. connector [inch] diameter of pipe [mm]

864 070 40 ¾ ’’ 25x3
864 068 40 1 ’’ 30x4
864 066 40 1 ’’ 38x5
826 154 40 1 ¼ ‘’ 38x5
826 155 40 1 ½ ‘’ 50x6
826 156 40 2 ’’ 65x8

• With cylinders coupled in parallel (e.g. cylinders of basic boom, stick, etc.)
both cylinders must be removed, opened, cleaned, and inspected for possi-
ble damage.

• Dismount, disassemble, inspect, and readjust correctly the outlet pressure

relief valve(s) of the circuit concerned.

• Pull spool out of control block, check for scratches and smooth fit in control
block.

• Flush control block housing.

• Remove, disassemble, clean, and inspect all other valves in the circuit, e.g.
throttles, throttle check valves, solenoid valves, etc.

• In case of damage of the hydraulic motors of the travel gear, pull out pivot
from rotary joint. Clean and inspect all parts.

• Remove, disassemble, clean, and inspect back pressure valves in front of the
return filters.

• In case of damage of hydraulic motors of slew gear and travel gear, of cooler
motors etc., the leak oil line must be cleaned. Disconnect line(s) from tank and/or
leak oil filter.

• Drain hydraulic oil into clean barrels.

Ah00504A
Page 3 of 5

• Before the installation of the flushing

bridge, a suitable oil pan has to be
placed, to avoid environment contami-
B Control block

nation.

Oil pan

• Remove pressure lines from cylinder. Remove lines

from cylinder
• Protect cylinder against contamination.
• Mount flushing bridge to both line ends.

Replace cylinder against a flushing bridge

• Start engine / motor.

• Actuate movement with hand lever, to tion
start flushing procedure. irec
gd
hin
flus
• The flushing should be performed for at
least 30 min. The changing of the
flushing direction should be changed
every 5 min. (see below).

• Reverse flushing direction

tion
irec
gd
• After the flushing procedure, the en- flus
hin

gine/ motor has to be stopped and the

pressure lines connected to the cylin-
der, if disassembly is not required.

Ah00504A
Page 4 of 5

• Dismount all return-line and leak-oil filters, inspect filter screens.

Þ damaged: replace filter screens
Þ not damaged: clean filter screens. Check especially for chips in by-
pass valves and flow regulator valves. Check function
of by-pass valve.
• Clean carefully filter chamber and suction area in tank.
• Install new or cleaned filter cartridges.
• Close oil tank.
• Fill tank with hydraulic oil.
• Fill in new or drained and most finely filtered oil (20 micron absolute) only
through return line filter.
• After commissioning of the machine, the pressure of the filter chamber has to be
checked with a pressure gauge at the measuring point. The permissible pressure
is 2 bar, if the pressure exceeds this value, the control system in the operators
cab will give a signal. Over 2,3 bar, the by-pass valve opens automatically to
avoid bursting of the filter element.
• Furthermore, the return-line filters have to be checked after 1 hour and then
every 2 or 3 hours for contamination (chips). If necessary, clean or replace.
These inspections must be repeated until no contamination (chips) can be found.

ã If an increased contamination (chips) is detected, stop machine

immediately, determine the cause and rectify.

B- Systems with high-pressure filter ÞDamages creating chips on components

such as hydraulic pumps

The high-pressure filters mounted in almost all new machines between pumps and
control blocks, protect all hydraulic components of the respective circuit against
chips.
Nevertheless, if pump defects are detected or restricted high-pressure filters are in-
dicated, proceed as follows.

• Open high-pressure filter of the pump circuit concerned.

• Remove filter cartridge.

Ah00504A
Page 5 of 5

ã
When dismounting the filter cartridge, make sure no chips from the
contaminated filter chamber penetrate into the circuit through the
filter outlet.

• Clean housing.
• Check filter cartridge for damage (holes, ruptures).

ã If the filter cartridge is damaged, the hydraulic system must be

cleaned according to example "A".

• If the filter cartridge is o.k., clean cartridge and remount (observe flow direction).
• Drain suction reservoir and clean if installed, check suction strainer.
In this case we recommend to perform the same jobs on all high-pressure filters.

C- Systems without high-pressure filter ÞDamages creating chips on compo-

nents such as hydraulic pumps

• Remove all hydraulic cylinders, disassemble, clean, and inspect.

• Check for scratches in cylinder tube, at piston rod and piston.
• Remove all hydraulic motors and send to an authorized shop or to KMG for in-
spection.
• This kind of job can only be done at your end, if specially trained personnel and
the necessary tools are available.
• Remove rotary joint, disassemble, clean, and check.
• Remove, disassemble, clean, and check pilot oil unit, pressure relief valves, pilot
units, three circuit control valves, etc.
• Open pilot oil filters, clean or replace filter cartridge.
• Disassemble nitrogen accumulator, flush hydraulic unit and check nitrogen pres-
sure.
• Perform all other jobs as described in example "A".

Ah00504A