VARIOUSPRODUCTPARTS&SERVICEPUBLICATIONSAREAVAILABLETOALLCONSTRUCTION EQUIPMENTOWNERS,INCLUDINGOPERATION&MAINTENANCEMANUALS,PARTSBOOKSANDSHOP MANUALS.
SPECIALPUBLICATIONSSUCHASSERVICETOOL,AIRCONDITIONING,ANDTURBOCHARGERSHOP MANUALSAREALSOAVAILABLEASWELLASSELECTEDOPERATION&MAINTENANCEANDSHOPMANUALS INFOREIGNLANGUAGES.
THEPUBLICATIONSLISTEDBELOWAREAVAILABLEFORTHISPARTICULARMACHINE(S).
440NorthFairwayDrive
VernonHills,IL60061-8112U.S.A.
Attn:TechnicalPublications
FaxNo.(847)970-4186
TelNo.(847)970-5887
COMPANYNAME
ATTN.
STREETADDRESS
PURCHASEORDERNO.
ORDERDATE
QTY.PUBLICATIONFORMNO.P-Paper
MODELNUMBERSERIALNUMBER
Properserviceandrepairisextremelyimportantforthesafeoperationofyourmachine.Theserviceandrepairtechniques recommendedanddescribedinthismanualarebotheffectiveandsafemethodsofoperation.Someoftheseoperations requiretheuseoftoolsspeciallydesignedforthepurpose.
Topreventinjurytoworkers,thesymbolsandareusedtomarksafetyprecautionsinthismanual.Thecautions accompanyingthesesymbolsshouldalwaysbefollowedcarefully.Ifanydangeroussituationarisesormaypossiblyarise, firstconsidersafety,andtakethenecessaryactionstodealwiththesituation.
Mistakesinoperationareextremelydangerous.Readthe7.Beforeaddingoilormakingrepairs,parkthemachineon OPERATION&MAINTENANCEMANUALcarefullyBEFOREhard,levelground,andblockthewheelsortracksto operatingthemachine.preventthemachinefrommoving.
1.Beforecarryingoutanygreasingorrepairs,readallthe8.Beforestartingwork,lowerblade,ripper,bucketorany precautionsgivenonthedecalswhicharefixedtotheotherworkequipmenttotheground.Ifthisisnot machine.possible,insertthesafetypinoruseblockstopreventthe
workequipmentfromfalling.Inaddition,besuretolock
2.Whencarryingoutanyoperation,alwayswearsafetyallthecontrolleversandhangwarningsignsonthem. shoesandhelmet.Donotwearlooseworkclothes,or clotheswithbuttonsmissing.
Alwayswearsafetyglasseswhenhittingpartswitha hammer.
Alwayswearsafetyglasseswhengrindingpartswitha grinder,etc.
3.Ifweldingrepairsareneeded,alwayshaveatrained, experiencedweldercarryoutthework.Whencarrying outweldingwork,alwayswearweldinggloves,apron, glasses,capandotherclothessuitedforweldingwork.
4.Whencarryingoutanyoperationwithtwoormore workers,alwaysagreeontheoperatingprocedurebefore starting.Alwaysinformyourfellowworkersbeforestarting anystepoftheoperation.Beforestartingwork,hang UNDERREPAIRsignsonthecontrolsintheoperator's compartment.
5.Keepalltoolsingoodconditionandlearnthecorrectway tousethem.
6.Decideaplaceintherepairworkshoptokeeptoolsand removedparts.Alwayskeepthetoolsandpartsintheir correctplaces.Alwayskeeptheworkareacleanand makesurethatthereisnodirtoroilonthefloor.Smoke onlyintheareasprovidedforsmoking.Neversmoke whileworking.
9.Whendisassemblingorassembling,supportthemachine withblocks,jacksorstandsbeforestartingwork.
10.Removeallmudandoilfromthestepsorotherplaces usedtogetonandoffthemachine.Alwaysusethe handrails,laddersorstepswhengettingonoroffthe machine.Neverjumponoroffthemachine.Ifitis impossibletousethehandrails,laddersorsteps,usea standtoprovidesafefooting.
11.Whenremovingtheoilfillercap,drainplugorhydraulic pressuremeasuringplugs,loosenthemslowlytoprevent theoilfromspurtingout.Beforedisconnectingor removingcomponentsoftheoil,wateroraircircuits,first removethepressurecompletelyfromthecircuit.
12.Thewaterandoilinthecircuitsarehotwhentheengine isstopped,sobecarefulnottogetburned.Waitforthe oilandwatertocoolbeforecarryingoutanyworkonthe oilorwatercircuits.
13.Beforestartingwork,removetheleadsfromthebattery. ALWAYSremovetheleadfromthenegative()terminal first.
14.Whenraisingheavycomponents,useahoistorcrane. Checkthatthewirerope,chainsandhooksarefreefrom damage.Alwaysuseliftingequipmentwhichhasample capacity.Installtheliftingequipmentatthecorrectplaces. Useahoistorcraneandoperateslowlytopreventthe componentfromhittinganyotherpart.Donotworkwith anypartstillraisedbythehoistorcrane.
15.Whenremovingcoverswhichareunderinternalpressure orunderpressurefromaspring,alwaysleavetwobolts inpositiononoppositesides.Slowlyreleasethepressure, thenslowlyloosentheboltstoremove.
16.Whenremovingcomponents,becarefulnottobreakor damagethewiring,Damagedwiringmaycauseelectrical fires.
17.Whenremovingpiping,stopthefueloroilfromspilling out.Ifanyfueloroildripsontothefloor,wipeitup immediately.Fueloroilonthefloorcancauseyoutoslip, orcanevenstartfires.
18.Asageneralrule,donotusegasolinetowashparts.In particular,useonlytheminimumofgasolinewhen washingelectricalparts.
19.Besuretoassembleallpartsagainintheiroriginalplaces. Replaceanydamagedpartwithnewparts.
Wheninstallinghosesandwires,besurethatthey willnotbedamagedbycontactwithotherparts whenthemachineisbeingoperated.
20.Wheninstallinghighpressurehoses,makesurethatthey arenottwisted.Damagedtubesaredangerous,sobe extremelycarefulwheninstallingtubesforhighpressure circuits.Alsocheckthatconnectingpartsarecorrectly installed.
21.Whenassemblingorinstallingparts,alwaysusethe specifiedtighteningtorques.Wheninstallingprotective partssuchasguards,orpartswhichvibrateviolentlyor rotateathighspeed,beparticularlycarefultocheckthat theyareinstalledcorrectly.
22.Whenaligningtwoholes,neverinsertyourfingersor hand.Becarefulnottogetyourfingerscaughtinahole.
23.Whenmeasuringhydraulicpressure,checkthatthe measuringtooliscorrectlyassembledbeforetakingany measurements.
24.Takecarewhenremovingorinstallingthetracksoftracktypemachines.Whenremovingthetrack,thetrack separatessuddenly,soneverletanyonestandateither endofthetrack.
Thisshopmanualhasbeenpreparedasanaidtoimprovethequalityofrepairsbygivingtheservicemananaccurateunderstanding oftheproductandbyshowinghimthecorrectwaytoperformrepairsandmakejudgements.Makesureyouunderstandthecontents ofthismanualanduseittofulleffectateveryopportunity.
Thisshopmanualmainlycontainsthenecessarytechnicalinformationforoperationsperformedinaserviceworkshop.Foreaseof understanding,themanualisdividedintothefollowingsections.Thesesectionsarefurtherdividedintoeachmaingroupofcomponents.
Thissectionliststhegeneralmachinedimensions,performancespecifications,componentweights,andfuel,coolantandlubricant specificationcharts.
Thissectionexplainsthestructureandfunctionofeachcomponent.Itservesnotonlytogiveanunderstandingofthestructure, butalsoservesasreferencematerialfortroubleshooting.
Thissectionexplainscheckstobemadebeforeandafterperformingrepairs,aswellasadjustmentstobemadeatcompletion ofthechecksandrepairs.Troubleshootingchartscorrelating"Problems"to"Causes"arealsoincludedinthissection.
Thissectionexplainstheordertobefollowedwhenremoving,installing,disassemblingorassemblingeachcomponent,aswell asprecautionstobetakenfortheseoperations.
Thissectiongivesthejudgementstandardswheninspectingdisassembledparts.
Thespecificationscontainedinthisshopmanualaresubjecttochangeatanytimeandwithoutanyadvancenotice.Contact yourdistributorforthelatestinformation.
Shopmanualsareissuedasaguidetocarryingoutrepairs. Theyaredividedasfollows:
Issuedforeverymachinemodel
Issuedforeachengineseries
Eachissuedasonetocoverallmodels
Eachissuedasonetocoverallmodels
Thesevariousvolumesaredesignedtoavoidduplicationof information.Thereforetodealwithallrepairsforanymodel,itis necessarythatchassis,engineelectricalandattachmentbe available.
Anyadditions,amendmentsorotherchangeswillbesenttoyour distributors.Getthemostup-to-dateinformationbeforeyoustart anywork.
1.Seethepagenumberonthebottomofthepage.Filethe pagesincorrectorder.
2.Followingexamplesshowhowtoreadthepagenumber: Example1(Chassisvolume): 10-3
Itemnumber(10.StructureandFunction)
Consecutivepagenumberforeach item
Example2(Enginevolume): Refertothepertinentenginemanual.
3.Additionalpages:Additionalpagesareindicatedbya hyphen(-)andnumberedafterthepagenumber.Fileasin theexample. Example: 10-4
10-4-1Addedpages 10-4-2 10-5
Whenamanualisrevised,aneditionmark(....)is recordedonthebottomoutsidecornerofthepages.
RevisedpagesareshownattheLISTOFREVISEDPAGES betweenthetitlepageandSAFETYpage.
Sothattheshopmanualcanbeofamplepracticaluse, importantplacesforsafetyandqualityaremarkedwiththe followingsymbols.
SymbolItemRemarks
Safetynecessarywhenperformingthe
Caution
Weight
Tighteningtorque
Specialsafetyprecautionsare work.
Specialtechnicalprecautionsor otherprecautionsforpreserving standardsarenecessarywhen performingthework.
Weightofpartsorsystems. Cautionnecessarywhenselecting hoistingwireorwhenworking postureisimportant,etc.
Placesthatrequirespecial attentionfortighteningtorque duringassembly.
CoatPlacestobecoatedwithadhesives andlubricantsetc.
Oil,waterPlaceswhereoil,waterorfuelmustbeadded,andthecapacity.
Draindrained,andquantitytobe
Placeswhereoilorwatermustbe drained.
Heavyparts(25kgormore)mustbeliftedwitha hoistetc.Inthe section,everypartweighing25kgormoreisindicated clearlywiththesymbol
Ifapartcannotbesmoothlyremovedfromthemachineby hoisting,thefollowingchecksshouldbemade:
1)Checkforremovalofallboltsfasteningtheparttothe relativeparts.
2)Checkforexistenceofanotherpartcausinginterface withtheparttoberemoved.
1)Useadequateropesdependingontheweightofpartsto behoisted,referringtothetablebelow:
Wireropes (Standard"Z"or"S"twistropeswithoutgalvanizing Ropediameter(mm)Allowableload(tons)
3)Donotslingaheavyloadwithoneropealone,butsling withtwoormoreropessymmetricallywoundontothe load.
Slingingwithoneropemaycauseturningofthe loadduringhoisting,untwistingoftherope,or slippingoftheropefromitsoriginalwindingpositiononthe load,whichcanresultinadangerousaccident.
4)Donotslingaheavyloadwithropesformingawide hanginganglefromthehook.Whenhoistingaloadwith twoormoreropes,theforcesubjectedtoeachropewill increasewiththehangingangles.Thetablebelowshows thevariationofallowableload(kg)whenhoistingismade withtworopes,eachofwhichisallowedtoslingupto 1000kgvertically,atvarioushangingangles.Whentwo ropesslingaloadvertically,upto2000kgoftotalweight canbesuspended.Thisweightbecomes1000kgwhen tworopesmakea120hangingangle.Ontheother hand,tworopesaresubjecttoanexcessiveforceas largeas4000kgiftheyslinga2000kgloadatalifting angleof150
Theallowableloadvalueisestimatedtobe1/6or1/7of thebreakingstrengthoftheropeused.
2)Slingwireropesfromthemiddleportionofthehook. Slingingneartheedgeofthehookmaycausetherope toslipoffthehookduringhoisting,andaseriousaccident canresult.Hookshavemaximumstrengthatthemiddle portion.
Therecommendedcoatingmaterialsprescribedintheshopmanualsarelistedbelow.
CategoryCodePartNo.QtyContainerMainapplications,features
LT-1A790-129-9030150gTubeUsedtopreventrubbergaskets,rubbercushionsandcorkplugsfrom comingout
LT-1B790-129-905020g(x2)Usedforplastics(exceptpolyethylene,polypropylene, Plastic container
Usedinplacesrequiringanimmediatelyeffective,strongadhesive. tetrafluoroethylene,andvinylchloride),rubber,metalandnon-metal.
LT-209940-0003050gPlasticFeatures:Resistancetoheat,chemicalscontainerUsedforanti-looseningandsealantpurposesforboltsandplugs.
Adhesive
Gasketsealant
LT-3HardagtCanUsedasadhesiveorsealantformetal,glassorplastic.
790-129-9060 Setofadhesive andhardening agent Adh1kg 500kg
LT-4790-129-9040250gUsedassealantformachinedholes. Plastic container
Loctite
Features:Resistancetoheat,chemicals 648-50 Usedatjointportionssubjecttohightemperature.
79A-129-911050cc---
LG-1790-129-9010200gTubeUsedasadhesiveorsealantforgasketsandpackingofpowertrain case,etc.
LG-3790-129-90701kgCanlocations;usedtopreventseizure.
Features:Resistancetoheat Usedassealantforflangesurfacesandboltsathightemperature Usedassealantforheatresistantgasketforathightemperature locationssuchasenginepre-combustionchamber,exhaustpipe.
Features:Resistancetowater,oil Usedassealantforflangesurface,thread.
LG-4790-129-9020200gTubeAlsopossibletouseassealantforflangeswithlargeclearance.
Usedassealantformatingsurfacesoffinaldrivecase,transmission case.
LG-5790-129-90801kg
Usedassealantfortaperedplugs,elbows,nipplesofhydraulic Plastic container
Usedassealantforvariousthreads,pipejoints,flanges. piping.
LG-609940-00011250gTubeUsedassealantforflangesurface,thread.
Features:Siliconbased,resistanttoheat,cold. Usedassealantforoilpan,finaldrivecase,etc.
LG-709920-00150150gTubeUsedassealantforflywheelhousing,intakemanifold,oilpan, Features:Siliconbased,quickhardeningtype. thermostathousing,etc.
Rustpreventionlubricant---09940-0005160gCanUsedaslubricantforslidingparts(topreventsqueaking).
Molybdenum disulfidelubricant---09940-00040200gTubeshrinkfitting.
Usedtopreventseizureorscuffingofthethreadwhenpressfittingor Usedaslubricantforlinkage,bearings,etc.
SYG-350Ll
SYG-400Ll
LithiumgreaseG2-L1SYG-400Ll-AVariousVariousGeneralpurposetype
SYG-160Ll
SYGA-160CNLl
SSG2-400CA
SYG2-350CA
CalciumgreaseG2-CASYG2-400CA-AVariousVarious
SYG2-160CA
SYGA-16CNCA
Usedfornormaltemperature,lightloadbearingatplacesincontact withwaterorsteam.
Molybdenum400g disulfidegrease(10/case)---SYG2-400MBellowstypeUsedforplaceswithheavyload.
Thefollowingchartsgivethestandardtorquesvaluesofboltsandnuts.Exceptionsaregiveninsectionsof
ThreaddiameterofboltWidthacrossflat
Thistorquetabledoesnotapplytotheboltswithwhichnylonpackingorothernon-ferrousmetalwashersareto beused,orwhichrequiretorquingtootherwisespecifiedvalues.
Usethesetorquesvaluesforsplitflangebolts.
ThreaddiameterofboltWidthacrossflattorquerequirementvalues
Usethesetorquevaluesforflairedpartofnut.
ThreaddiameterofboltWidthacrossflattorquerequirementvalues
Inthewiringdiagrams,variouscolorsandsymbolsareemployedtoindicatethethicknessofwires.Thiswirecode tablewillhelpyouunderstandWIRINGDIAGRAMS. Example:05WBindicatesacablehavinganominalnumber05andwhitecoatingwithblackstripe.
strands(mm)tion(mm²) 0.85110.320.882.412Starting,lighting,signaletc.
TheConversionTableinthissectionisprovidedtoenablesimpleconversionoffigures.Fordetailsofthemethodof usingtheConversionTable,seetheexamplegivenbelow.
MethodofusingtheConversionTabletoconvertfrommillimeterstoinches.
1.Convert55mmintoinches.
(1)Locatethenumber50intheverticalcolumnattheleftside,takethisas,thendrawahorizontallinefrom
(2)Locatethenumber5intherowacrossthetop,takethisas,thendrawaperpendicularlinedownfrom.
(3)Takethepointwherethetwolinescrossas.Thispointgivesthevaluewhenconvertingfrommillimeters toinches.Therefore,55millimeters=2.165inches.
2.Convert550mmintoinches.
(1)Thenumber550doesnotappearinthetable,sodivideby10(movethedecimaloneplacetotheleft)to convertitto55mm.
(2)Carryoutthesameprocedureasabovetoconvert55mmto2.165inches.
(3)Theoriginalvalue(550mm)wasdividedby10,somultiply2.165inchesby10(movethedecimaloneplace totheright)toreturntotheoriginalvalue.Thisgives550mm=21.65inches.
1mm=0.03937in
803.1503.1893.2283.2683.3073.3463.4253.4653.504 903.5433.5833.6223.6613.7013.7403.8193.8583.898
1mm=0.03937in mm0123456789
000.0390.0790.1180.1570.1970.2360.2760.3150.354 100.3940.4330.4720.5120.5510.5910.6300.6690.7090.748 200.7870.8270.8660.9060.9450.9841.0241.0631.1021.142 301.1811.2201.2601.2991.3391.3781.4171.4571.4961.536 401.5751.6141.6541.6931.7321.7721.8111.8501.8901.929
501.9692.0082.0472.0872.1262.1652.2052.2442.2832.323 602.3622.4022.4412.4802.5202.5592.5982.6382.6772.717 702.7562.7952.8352.8742.9132.9532.9923.0323.0713.110 803.1503.1893.2283.2683.3073.3463.3863.4253.4653.504 903.5433.5833.6223.6613.7013.7403.7803.8193.8583.898
1kg=2.2046lb kg0123456789
002.204.416.618.8211.0213.2315.4317.6419.84 1022.0524.2526.4628.6630.8633.0735.2737.4839.6841.89 2044.0946.3048.5050.7151.9155.1257.3259.5361.7363.93 3066.1468.3470.5572.7574.9677.1679.3781.5783.7885.98 4088.1890.3992.5994.8097.0099.21101.41103.62105.82108.03
50110.23112.44114.64116.85119.05121.25123.46125.66127.87130.07 60132.28134.48136.69138.89141.10143.30145.51147.71149.91152.12 70154.32156.53158.73160.94163.14165.35167.55169.76171.96174.17 80176.37178.57180.78182.98185.19187.39189.60191.80194.01196.21 90198.42200.62202.83205.03207.24209.44211.64213.85216.05218.26