FOREWORD
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SAFETYNOTICE
IMPORTANTSAFETYNOTICE
Properserviceandrepairisextremelyimportantforthesafeoperationofyourmachine.Theserviceandrepairtechniques recommendedanddescribedinthismanualarebotheffectiveandsafemethodsofoperation.Someoftheseoperations requiretheuseoftoolsspeciallydesignedforthepurpose.
Topreventinjurytoworkers,thesymbolsandareusedtomarksafetyprecautionsinthismanual.Thecautions accompanyingthesesymbolsshouldalwaysbefollowedcarefully.Ifanydangeroussituationarisesormaypossiblyarise, firstconsidersafety,andtakethenecessaryactionstodealwiththesituation.
GENERALPRECAUTIONS
Mistakesinoperationareextremelydangerous.Readthe OPERATION&MAINTENANCEMANUALcarefully BEFOREoperatingthemachine.
1.Beforecarryingoutanygreasingorrepairs,readallthe precautionsgivenonthedecalswhicharefixedtothe machine.
2.Whencarryingoutanyoperation,alwayswearsafety shoesandhelmet.Donotwearlooseworkclothes,or clotheswithbuttonsmissing.
Alwayswearsafetyglasseswhenhittingpartswitha hammer.
Alwayswearsafetyglasseswhengrindingpartswitha grinder,etc.
3.Ifweldingrepairsareneeded,alwayshaveatrained, experiencedweldercarryoutthework.Whencarrying outweldingwork,alwayswearweldinggloves,apron, glasses,capandotherclothessuitedforweldingwork.
4.Whencarryingoutanyoperationwithtwoormore workers,alwaysagreeontheoperatingprocedure beforestarting.Alwaysinformyourfellowworkers beforestartinganystepoftheoperation.Beforestarting work,hangUNDERREPAIRsignsonthecontrolsin theoperator'scompartment.
5.Keepalltoolsingoodconditionandlearnthecorrect waytousethem.
6.Decideaplaceintherepairworkshoptokeeptoolsand removedparts.Alwayskeepthetoolsandpartsintheir correctplaces.Alwayskeeptheworkareacleanand makesurethatthereisnodirtoroilonthefloor.Smoke onlyintheareasprovidedforsmoking.Neversmoke whileworking.
PREPARATIONSFORWORK
1.Beforeaddingoilormakingrepairs,parkthemachine onhard,levelground,andblockthewheelsortracksto preventthemachinefrommoving.
2.Beforestartingwork,lowerblade,ripper,bucketorany otherworkequipmenttotheground.Ifthisisnot possible,insertthesafetypinoruseblockstoprevent theworkequipmentfromfalling.Inaddition,besureto lockallthecontrolleversandhangwarningsignson them.
3.Whendisassemblingorassembling,supportthe machinewithblocks,jacksorstandsbeforestarting work.
4.Removeallmudandoilfromthestepsorotherplaces usedtogetonandoffthemachine.Alwaysusethe handrails,laddersorstepswhengettingonoroffthe machine.Neverjumponoroffthemachine.Ifitis impossibletousethehandrails,laddersorsteps,usea standtoprovidesafefooting.
PRECAUTIONSDURINGWORK
1.Whenremovingtheoilfillercap,drainplugor hydraulicpressuremeasuringplugs,loosenthemslowly topreventtheoilfromspurtingout.Beforedisconnectingorremovingcomponentsoftheoil,waterorair circuits,firstremovethepressurecompletelyfromthe circuit.
2.Thewaterandoilinthecircuitsarehotwhentheengine isstopped,sobecarefulnottogetburned.Waitforthe oilandwatertocoolbeforecarryingoutanyworkon theoilorwatercircuits.
3.Beforestartingwork,removetheleadsfromthebattery. ALWAYSremovetheleadfromthenegative(-) terminalfirst.
12 4.Whenraisingheavycomponents,useahoistorcrane.Checkthatthewirerope,chainsandhooksarefreefromdamage. Alwaysuseliftingequipmentwhichhasamplecapacity.Installtheliftingequipmentatthecorrectplaces.Useahoistor craneandoperateslowlytopreventthecomponentfromhittinganyotherpart.Donotworkwithanypartstillraisedby thehoistorcrane.
5.Whenremovingcoverswhichareunderinternalpressureorunderpressurefromaspring,alwaysleavetwoboltsin positiononoppositesides.Slowlyreleasethepressure,thenslowlyloosentheboltstoremove.
6.Whenremovingcomponents,becarefulnottobreakordamagethewiring,Damagedwiringmaycauseelectricalfires.
7.Whenremovingpiping,stopthefueloroilfromspillingout.Ifanyfueloroildripsontothefloor,wipeitupimmediately. Fueloroilonthefloorcancauseyoutoslip,orcanevenstartfires.
8.Asageneralrule,donotusegasolinetowashparts.
9.Besuretoassembleallpartsagainintheiroriginalplaces.Replaceanydamagedpartwithnewparts.
•Wheninstallinghosesandwires,besurethattheywillnotbedamagedbycontactwithotherpartswhenthemachine isbeingoperated.
10.Wheninstallinghighpressurehoses,makesurethattheyarenottwisted.Damagedtubesaredangerous,sobeextremely carefulwheninstallingtubesforhighpressurecircuits.Alsocheckthatconnectingpartsarecorrectlyinstalled.
11.Whenassemblingorinstallingparts,alwaysusethespecifiedtighteningtorques.Wheninstallingprotectivepartssuchas guards,orpartswhichvibrateviolentlyorrotateathighspeed,beparticularlycarefultocheckthattheyareinstalled correctly.
12.Whenaligningtwoholes,neverinsertyourfingersorhand.Becarefulnottogetyourfingerscaughtinahole.
13.Whenmeasuringhydraulicpressure,checkthatthemeasuringtooliscorrectlyassembledbeforetakingany measurements.
14.Takecarewhenremovingorinstallingthetracksoftrack-typemachines.Whenremovingthetrack,thetrackseparates suddenly,soneverletanyonestandateitherendofthetrack.
Thisshopmanualhasbeenpreparedasanaidtoimprovethequalityofrepairsbygivingtheservicemananaccurate understandingoftheproductandbyshowinghimthecorrectwaytoperformrepairsandmakejudgements.Makesureyou understandthecontentsofthismanualanduseittofulleffectateveryopportunity.
Thisshopmanualmainlycontainsthenecessarytechnicalinformationforoperationsperformedinaserviceworkshop.For easeofunderstanding,themanualisdividedintothefollowingsections.Thesesectionsarefurtherdividedintoeachmain groupofcomponents.
GENERAL
Thissectionliststhegeneralmachinedimensions,performancespecifications,componentweights,andfuel,coolantand lubricantspecificationcharts.
STRUCTURE,FUNCTIONANDMAINTENANCESTANDARD
Thissectionexplainsthestructure,functionandmaintenancestandardofeachcomponent.Itservesnotonlytogivean understandingofthestructure,butalsoservesasreferencematerialfortroubleshooting.
TESTING,ADJUSTINGANDTROUBLESHOOTING
Thissectionexplainscheckstobemadebeforeandafterperformingrepairs,aswellasadjustmentstobemade completionofthechecksandrepairs.Troubleshootingchartscorrelating“Problems”to“Causes”arealsoincludedinthis section.
DISASSEMBLYANDASSEMBLY
Thissectionexplainstheordertobefollowedwhenremoving,installing,disassemblingorassemblingeachcomponent, aswellasprecautionstobetakenfortheseoperations.
OTHER
Thissectionmainlygiveshydrauliccircuitdiagramsandelectriccircuitdiagrams. Inaddition,thissectionmaygivethespecificationsofattachmentsandoptionstogether.
NOTICE
Thespecificationscontainedinthisshopmanualaresubjecttochangeatanytimeandwithoutanyadvancenotice.Contact yourdistributorforthelatestinformation.
12 HOWTOREADTHESHOPMANUAL
VOLUMES
Shopmanualsareissuedasaguidetocarryingoutrepairs. Theyaredividedasfollows:
Chassisvolume:Issuedforeverymachinemodel Enginevolume:Issuedforeachengineseries
Electricalvolume:Eachissuedasonetocoverallmodels Attachmentvolume:Eachissuedasonetocoverallmodels
Thesevariousvolumesaredesignedtoavoidduplicationof information.Thereforetodealwithallrepairsforanymodel, itisnecessarythatchassis,engine,electricalandattachment beavailable.
DISTRIBUTIONANDUPDATING
Anyadditions,amendmentsorotherchangeswillbesentto yourdistributors.Getthemostup-to-dateinformationbefore youstartanywork.
FILINGMETHOD
1.Seethepagenumberonthebottomofthepage.Filethe pagesincorrectorder.
2.Followingexamplesshowhowtoreadthepagenumber: Example: 10-3
Itemnumber(10.StructureandFunction)
Consecutivepagenumberforeachitem
3.Additionalpages:Additionalpagesareindicatedbya hyphen(-)andnumberedafterthepagenumber.Fileas intheexample. Example:
REVISIONS
RevisedpagesareshownattheLISTOFREVISEDPAGES betweenthetitlepageandSAFETYpage.
SYMBOLS
Sothattheshopmanualcanbeofamplepracticaluse, importantplacesforsafetyandqualityaremarkedwiththe followingsymbols.
SymbolItemRemarks
Safety
Caution
Weight
Tightening torque
Specialsafetyprecautionsare necessarywhenperformingthe work.
Specialtechnicalprecautionsor otherprecautionsforpreserving standardsarenecessarywhen performingthework.
Weightofpartsorsystems. Cautionnecessarywhenselecting hoistingwireorwhenworking postureisimportant,etc.
Placesthatrequirespecialattention fortighteningtorqueduring assembly.
CoatPlacestobecoatedwithadhesives andlubricantsetc.
Oil,waterPlaceswhereoil,waterorfuelmust beadded,andthecapacity.
DrainPlaceswhereoilorwatermustbe drained,andquantitytobedrained.
Whenamanualisrevised,aneditionmark(…)is recordedonthebottomoutsidecornerofthepages.
12 HOISTINGINSTRUCTIONS
HOISTING
WARNING!Heavyparts(25kgormore) mustbeliftedwithahoistetc. IntheDISASSEMBLYAND ASSEMBLYsection,every partweighing25kgormoreis indicatedclearlywiththesymbol
Ifapartcannotbesmoothlyremovedfromthemachine byhoisting,thefollowingchecksshouldbemade:
1.Checkforremovalofallboltsfasteningtheparttothe relativeparts.
2.Checkforexistenceofanotherpartcausinginterface withtheparttoberemoved.
WIREROPES
1.Useadequateropesdependingontheweightofpartsto behoisted,referringtothetablebelow:
Wireropes (Standard“Z”or“S”twistropeswithoutgalvanizing)
canresult.Hookshavemaximumstrengthatthemiddle portion.
3.Donotslingaheavyloadwithoneropealone,butsling withtwoormoreropessymmetricallywoundontothe load.
Theallowableloadvalueisestimatedtobe1/6or1/7of thebreakingstrengthoftheropeused.
2.Slingwireropesfromthemiddleportionofthehook. Slingingneartheedgeofthehookmaycausetheropeto slipoffthehookduringhoisting,andaseriousaccident
00
WARNING!Slingingwithoneropemay causeturningoftheloadduringhoisting,untwistingofthe rope,orslippingoftherope fromitsoriginalwindingpositionontheload,whichcan resultina dangerousaccident
4.Donotslingaheavyloadwithropesformingawide hanginganglefromthehook.Whenhoistingaloadwith twoormoreropes,theforcesubjectedtoeachropewill increasewiththehangingangles.Thetablebelow showsthevariationofallowableload(kg)when hoistingismadewithtworopes,eachofwhichis allowedtoslingupto1000kgvertically,atvarious hangingangles.Whentworopesslingaloadvertically, upto2000kgoftotalweightcanbesuspended.This weightbecomes1000kgwhentworopesmakea120° hangingangle.Ontheotherhand,tworopesaresubject toanexcessiveforceaslargeas4000kgiftheyslinga 2000kgloadataliftingangleof150°
