FOREWORD
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SafetyNotice
ImportantSafetyNotice
Properserviceandrepairisextremelyimportantforthesafeoperationofyourmachine.Theserviceandrepairtechniques recommendedanddescribedinthismanualarebotheffectiveandsafemethodsofoperation.Someoftheseoperations requiretheuseoftoolsspeciallydesignedforthepurpose.
Topreventinjurytoworkers,thesymbolisusedtomarksafetyprecautionsinthismanual.Thecautionsaccompanying thesesymbolsshouldalwaysbefollowedcarefully.Ifanydangeroussituationarisesormaypossiblyarise,firstconsider safety,andtakethenecessaryactionstodealwiththesituation.
GeneralPrecautions
Mistakesinoperationareextremelydangerous.Readthe OPERATION&MAINTENANCEMANUALcarefully BEFOREoperatingthemachine.
1.Beforecarryingoutanygreasingorrepairs,readallthe precautionsgivenonthedecalswhicharefixedtothe machine.
2.Whencarryingoutanyoperation,alwayswearsafety shoesandhelmet.Donotwearlooseworkclothes,or clotheswithbuttonsmissing.
Alwayswearsafetyglasseswhenhittingpartswith ahammer.
Alwayswearsafetyglasseswhengrindingparts withagrinder,etc.
3.Ifweldingrepairsareneeded,alwayshaveatrained, experiencedweldercarryoutthework.Whencarrying outweldingwork,alwayswearweldinggloves,apron, glasses,capandotherclothessuitedforweldingwork.
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WARNING!Nevermodify,weld,cut,or drillonanypartofaROPS structure.Doingsomay weakenthestructurewhich couldleadtopossiblefailure inarolloversituation.
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.Before disconnectingorremovingcomponentsoftheoil,water oraircircuits,firstremovethepressurecompletelyfrom thecircuit.
2.Thewaterandoilinthecircuitsarehotwhentheengineisstopped,sobecarefulnottogetburned.Waitfortheoiland watertocoolbeforecarryingoutanyworkontheoilorwatercircuits.
3.Beforestartingwork,removetheleadsfromthebattery.ALWAYSremovetheleadfromthenegative(-) terminalfirst.
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.Neveruseflammableliquidstocleanparts,useonlynon-flammableapprovedcleaningsolutionstocleanparts.
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.
15.Precautionsfordisconnectingandconnectinghosesandtubesinairconditionercircuit.
A.Disconnection
WARNING!Collecttheairconditionerrefrigerantgas(R134a). Iftherefrigerantgas(R134a)getsinyoureyes,youmayloseyoursight.Accordingly, whencollectingoraddingit,youmustbequalifiedforhandlingtherefrigerantandputon protectivegoggles.
B.Connection
i.Wheninstallingtheairconditionercircuithosesandtubes,takecarethatdirt,dust,water,etc.willnotenter them.
ii.Whenconnectingtheairconditionerhosesandtubes,checkthatO-rings(1)arefittedtotheirjoints.
iii.CheckthateachO-ringisnotdamagedordeteriorated.
iv.Whenconnectingtherefrigerantpiping,applycompressoroilforrefrigerant(R134a)(DENSO:ND-OIL8, ZEXEL:ZXL100PG(equivalenttoPAG46))toitsO-rings.
ExampleofO-ring(Fittedtoeveryjointofhosesandtubes) Fortighteningtorque,seetheprecautionsforinstallationineach sectionof"Disassemblyandassembly".
