7/23/2019 Front Susp Recon Guidelines http://slidepdf.com/reader/full/front-susp-recon-guidelines 1/16 - Norm Item code Index DatePlant PreparedChecked ApprovedNo 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. 1/16 Reconditioning Guidelines in accordance with a Life Cycle Management for a LHB front shock absorber 1148554500109.10.2013 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 Id.no.10814570 is superseded by Id.no.11651418!
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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Index 001: New LH-Repair manual Id.no.11651418 added.Id.no.10814570 is superseded by Id.no.11651418!
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
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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.
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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
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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.
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Rebuild:
Reuse part without rebuild work, as is
Use new VSTI Plugs and seals
Cleaning and strip paint, if necessary
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