10STRUCTURE,FUNCTIONANDMAINTENANCESTANDARD
20STANDARDVALUETABLES
30TESTINGANDADJUSTING.
40TROUBLESHOOTING.
50DISASSEMBLYANDASSEMBLY.
90DIAGRAMSANDSCHEMATICS.
FOREWORD
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FOREWORD
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SAFETYNOTICE
IMPORTANTSAFETYNOTICE
Properserviceandrepairisextremelyimportantforthesafeoperationofyourmachine.Theserviceandrepairtechniques recommendedanddescribedinthismanualarebotheffectiveandsafemethodsofoperation.Someoftheseoperations requiretheuseoftoolsspeciallydesignedforthepurpose.
Topreventinjurytoworkers,thesymbolisusedtomarksafetyprecautionsinthismanual.Thecautions accompanyingthesesymbolsshouldalwaysbefollowedcarefully.Ifanydangeroussituationarisesormaypossiblyarise, firstconsidersafety,andtakethenecessaryactionstodealwiththesituation.
GENERALPRECAUTIONS
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Mistakesinoperationareextremelydangerous.ReadtheOPERATION&MAINTENANCEMANUALcarefullyBEFORE operatingthemachine.
1.Beforecarryingoutanygreasingorrepairs,readalltheprecautionsgivenonthedecalswhicharefixedtothemachine.
2.Whencarryingoutanyoperation,alwayswearsafetyshoesandhelmet.Donotwearlooseworkclothes,orclotheswith buttonsmissing.
•Alwayswearsafetyglasseswhenhittingpartswithahammer.
•Alwayswearsafetyglasseswhengrindingpartswithagrinder,etc.
3.Ifweldingrepairsareneeded,alwayshaveatrained,experiencedweldercarryoutthework.Whencarryingoutwelding work,alwayswearweldinggloves,apron,glasses,capandotherclothessuitedforweldingwork.
WARNING!Nevermodify,weld,cut,ordrillonanypartofaROPSstructure.Doingsomayweakenthe structurewhichcouldleadtopossiblefailureinarolloversituation
4.Whencarryingoutanyoperationwithtwoormoreworkers,alwaysagreeontheoperatingprocedurebeforestarting. Alwaysinformyourfellowworkersbeforestartinganystepoftheoperation.Beforestartingwork,hang"UNDER REPAIR"signsonthecontrolsintheoperator'scompartment.
5.Keepalltoolsingoodconditionandlearnthecorrectwaytousethem.
6.Decideaplaceintherepairworkshoptokeeptoolsandremovedparts.Alwayskeepthetoolsandpartsintheircorrect places.Alwayskeeptheworkareacleanandmakesurethatthereisnodirtoroilonthefloor.Smokeonlyintheareas providedforsmoking.Neversmokewhileworking.
PREPARATIONSFORWORK
1.Beforeaddingoilormakingrepairs,parkthemachineonhard,levelground,andblockthewheelsortrackstopreventthe machinefrommoving.
2.Beforestartingwork,lowerblade,ripper,bucketoranyotherworkequipmenttotheground.Ifthisisnotpossible,insert thesafetypinoruseblockstopreventtheworkequipmentfromfalling.Inaddition,besuretolockallthecontrollevers andhangwarningsignsonthem.
3.Whendisassemblingorassembling,supportthemachinewithblocks,jacksorstandsbeforestartingwork.
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4.Removeallmudandoilfromthestepsorotherplacesusedtogetonandoffthemachine.Alwaysusethehandrails,laddersorstepswhengettingonoroffthemachine.Neverjumponoroffthemachine.Ifitisimpossibletousethehandrails, laddersorsteps,useastandtoprovidesafefooting.
PRECAUTIONSDURINGWORK
1.Whenremovingtheoilfillercap,drainplugorhydraulicpressuremeasuringplugs,loosenthemslowlytopreventtheoil fromspurtingout.Beforedisconnectingorremovingcomponentsoftheoil,wateroraircircuits,firstremovethepressure completelyfromthecircuit.
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.Gasolineorotherfuelsshouldneverbeusedtocleanparts.Cleanpartwithappropriatesolvents.
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.Whenjumpstartingthemachine,onlyuseamachineofsimilarsizeandvoltage.Neveruseaarcwelderorotherelectrical generatingequipmenttojumpstartthemachine.Carefullyreviewthesafetyandproceduresforjumpstartingthe machine.
12 GENERAL
Thisshopmanualhasbeenpreparedasanaidtoimprovethequalityofrepairsbygivingtheservicemananaccurate understandingoftheproductandbyshowinghimthecorrectwaytoperformrepairsandmakejudgements.Makesureyou understandthecontentsofthismanualanduseittofulleffectateveryopportunity.
Thisshopmanualmainlycontainsthenecessarytechnicalinformationforoperationsperformedinaserviceworkshop.For easeofunderstanding,themanualisdividedintothefollowingsections.Thesesectionsarefurtherdividedintoeachmain groupofcomponents.
GENERAL
Thissectionliststhegeneralmachinedimensions,performancespecifications,componentweights,andfuel,coolantand lubricantspecificationcharts.
STRUCTURE,FUNCTIONANDMAINTENANCESTANDARD
Thissectionexplainsthestructureandfunctionofeachcomponent.Itservesnotonlytogiveanunderstandingofthe structure,butalsoservesasreferencematerialfortroubleshooting.Inaddition,thissectiongivesthejudgementstandards wheninspectingdisassembledparts.
STANDARDVALUETABLE
Thissectionexplainsthestandardvaluesfornewmachineandjudgementcriteriafortesting,adjustingand troubleshooting.Thisstandardvaluetableisusedtocheckthestandardvaluesintestingandadjustingandtojudgeparts introubleshooting.
TESTINGANDADJUSTING
Thissectionexplainscheckstobemadebeforeandafterperformingrepairs,aswellasadjustmentstobemadeat completionofthechecksandrepairs.
TROUBLESHOOTING
Troubleshootingchartscorrelating“Problems”to“Causes”areincludedinthissection.
DISASSEMBLYANDASSEMBLY
Thissectionexplainstheordertobefollowedwhenremoving,installing,disassemblingorassemblingeachcomponent, aswellasprecautionstobetakenfortheseoperations.
DIAGRAMSANDSCHEMATICS
Thissectionhasthefoldoutdrawingsforthemachine.
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. Cautionnecessarywhen selectinghoistingwireorwhen workingpostureisimportant, etc.
Placesthatrequirespecial attentionfortighteningtorque duringassembly.
CoatPlacestobecoatedwithadhesivesandlubricantsetc.
Oil,waterPlaceswhereoil,waterorfuel mustbeadded,andthecapacity.
Drain
Placeswhereoilorwatermust bedrained,andquantitytobe drained.
RevisedEditionMark
Whenamanualisrevised,aneditionmark(…)is recordedonthebottomoutsidecornerofthepages.
12 HOISTINGINSTRUCTIONS
Hoisting
WARNING!Heavyparts(25kgormore) mustbeliftedwithahoistetc. IntheDISASSEMBLYAND ASSEMBLYsection,every partweighing25kgormoreis indicatedclearlywiththe symbol
•Ifapartcannotbesmoothlyremovedfromthemachine byhoisting,thefollowingchecksshouldbemade:
1.Checkforremovalofallboltsfasteningtheparttothe relativeparts.
2.Checkforexistenceofanotherpartcausinginterface withtheparttoberemoved.
WireRopes
1.Useadequateropesdependingontheweightofpartsto behoisted,referringtothetablebelow:
Wireropes (Standard“Z”or“S”twistropeswithoutgalvanizing)
3.Donotslingaheavyloadwithoneropealone,butsling withtwoormoreropessymmetricallywoundontothe load.
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Theallowableloadvalueisestimatedtobe1/6or 1/7ofthebreakingstrengthoftheropeused.
2.Slingwireropesfromthemiddleportionofthehook. Slingingneartheedgeofthehookmaycausetheropeto slipoffthehookduringhoisting,andaseriousaccident canresult.Hookshavemaximumstrengthatthemiddle portion.
WARNING!Slingingwithoneropemay causeturningoftheload duringhoisting,untwistingof therope,orslippingofthe ropefromitsoriginalwinding positionontheload,which canresultinadangerous accident.
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°.
12 MAINTENANCESTANDARDTERMINOLOGY
Themaintenancestandardchapterexplainsthecriteriaforreplacingorreusingproductsandpartsinthemachinemaintenance work.Thefollowingtermsareusedtoexplainthecriteria.
1.Standardsizeandtolerance
•Tobeaccurate,thefinishingsizeofpartsisalittledifferentfromonetoanother.
•Tospecifyafinishingsizeofapart,atemporarystandardsizeissetandanallowabledifferencefromthatsizeisindicated.
•Theabovesizesettemporarilyiscalledthe“standardsize”andtherangeofdifferencefromthestandardsizeiscalled the“tolerance”.
•Thetolerancewiththesymbolsof+or–isindicatedontherightsideofthestandardsize.
•
Example:
•Thetolerancemaybeindicatedinthetextandatableas[standardsize(upperlimitoftolerance/lowerlimitoftolerance)].
Example)120(–0.022/–0.126)
•Usually,thesizeofaholeandthesizeoftheshafttobefittedto thatholeareindicatedbythesamestandardsizeanddifferent tolerancesoftheholeandshaft.Thetightnessoffitisdecided bythetolerance.
•Indicationofsizeofrotatingshaftandholeandrelationship drawingofthem.
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12 2.Standardclearanceandstandardvalue
•Theclearancemadewhennewpartsareassemblediscalledthe“standardclearance“,whichisindicatedbytherange fromtheminimumclearancetothemaximumclearance.
•Whensomepartsarerepaired,theclearanceisgenerallyadjustedtothestandardclearance.
•Avalueofperformanceandfunctionofnewproductsorequivalentiscalledthe“standardvalue“,whichisindicated byarangeoratargetvalue.
•Whensomepartsarerepaired,thevalueofperformance/functionissettothestandardvalue.
3.Standardinterference
•Whenthediameterofaholeofapartshowninthegivenstandardsizeandtolerancetableissmallerthanthatofthe matingshaft,thedifferencebetweenthosediametersiscalledthe“interference”.
•Therange(A–B)fromthedifference(A)betweentheminimumsizeoftheshaftandthemaximumsizeofthehole tothedifference(B)betweenthemaximumsizeoftheshaftandtheminimumsizeoftheholeisthe“standardinterference”.
•Afterrepairingorreplacingsomeparts,measurethesizeoftheirholeandshaftandcheckthattheinterferenceisin thestandardrange.
4.Repairlimitandallowablevalueorallowabledimension
•Thesizeofapartchangesbecauseofwearanddeformationwhileitisused.Thelimitofchangedsizeiscalledthe “repairlimit”.
•Ifapartisworntotherepairlimit,itmustbereplacedorrepaired.
•Theperformanceandfunctionofaproductlowerswhileitisused.Avaluewhichtheproductcanbeusedwithout causingaproblemiscalledthe“allowablevalue”or“allowabledimension”.
•Ifaproductisworntotheallowablevalue,itmustbecheckedorrepaired.Sincethepermissiblevalueisestimated fromvarioustestsorexperiencesinmostcases,however,itmustbejudgedafterconsideringtheoperatingcondition andcustomer'srequirement.
5.Clearancelimit
•Partscanbeuseduntiltheclearancebetweenthemisincreasedtoacertainlimit.Thelimitatwhichthosepartscannotbeusediscalledthe“clearancelimit”.
•Iftheclearancebetweenthepartsexceedstheclearancelimit,theymustbereplacedorrepaired.
6.Interferencelimit
•Theallowablemaximuminterferencebetweentheholeofapartandtheshaftofanotherparttobeassemblediscalled the“interferencelimit”.
•Theinterferencelimitshowstherepairlimitofthepartofsmallertolerance.
•Iftheinterferencebetweenthepartsexceedstheinterferencelimit,theymustbereplacedorrepaired.