FOREWORD
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SAFETYNOTICE
IMPORTANTSAFETYNOTICE
Properserviceandrepairisextremelyimportantforthesafeoperationofyourmachine.Theserviceandrepairtechniques recommendedanddescribedinthismanualarebotheffectiveandsafemethodsofoperation.Someoftheseoperations requiretheuseoftoolsspeciallydesignedforthepurpose.
Topreventinjurytoworkers,thesymbolsandareusedtomarksafetyprecautionsinthismanual.Thecautionsaccompanyingthesesymbolsshouldalwaysbefollowedcarefully.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.Ifthisisnotpossible,insertthesafetypinoruseblockstopreventthe workequipmentfromfalling.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,drainplugorhydraulicpressuremeasuringplugs,loosenthemslowlytopreventtheoilfromspurtingout.Beforedisconnectingor removingcomponentsoftheoil,wateroraircircuits, firstremovethepressurecompletelyfromthecircuit.
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,alwaysleavetwoboltsinpositiononoppositesides.Slowlyreleasethepressure,thenslowlyloosentheboltstoremove.
6.Whenremovingcomponents,becarefulnottobreakordamagethewiring,Damagedwiringmaycauseelectricalfires.
7.Whenremovingpiping,stopthefueloroilfromspillingout.Ifanyfueloroildripsontothefloor,wipeitupimmediately. Fueloroilonthefloorcancauseyoutoslip,orcanevenstartfires.
8.Gasolineorotherfuelsshouldneverbeusedtocleanparts.Cleanpartwithappropriatesolvents.
9.Besuretoassembleallpartsagainintheiroriginalplaces.Replaceanydamagedpartwithnewparts. Wheninstallinghosesandwires,besurethattheywillnotbedamagedbycontactwithotherpartswhenthemachineis beingoperated.
10.Wheninstallinghighpressurehoses,makesurethattheyarenottwisted.Damagedtubesaredangerous,sobeextremely carefulwheninstallingtubesforhighpressurecircuits.Alsocheckthatconnectingpartsarecorrectlyinstalled.
11.Whenassemblingorinstallingparts,alwaysusethespecifiedtighteningtorques.Wheninstallingprotectivepartssuchas guards,orpartswhichvibrateviolentlyorrotateathighspeed,beparticularlycarefultocheckthattheyareinstalledcorrectly.
12.Whenaligningtwoholes,neverinsertyourfingersorhand.Becarefulnottogetyourfingerscaughtinahole.
13.Whenmeasuringhydraulicpressure,checkthatthemeasuringtooliscorrectlyassembledbeforetakinganymeasurements.
14.Takecarewhenremovingorinstallingthetracksoftrack-typemachines.Whenremovingthetrack,thetrackseparates suddenly,soneverletanyonestandateitherendofthetrack.
15.Whenjumpstartingthemachine,onlyuseamachineofsimilarsizeandvoltage.Neveruseaarcwelderorotherelectrical generatingequipmenttojumpstartthemachine.Carefullyreviewthesafetyandproceduresforjumpstartingthe machine.
Thisshopmanualhasbeenpreparedasanaidtoimprovethequalityofrepairsbygivingtheservicemananaccurateunderstandingoftheproductandbyshowinghimthecorrectwaytoperformrepairsandmakejudgements.Makesureyouunderstandthecontentsofthismanualanduseittofulleffectateveryopportunity.
Thisshopmanualmainlycontainsthenecessarytechnicalinformationforoperationsperformedinaserviceworkshop.For easeofunderstanding,themanualisdividedintothefollowingsections.Thesesectionsarefurtherdividedintoeachmain groupofcomponents.
GENERAL
Thissectionliststhegeneralmachinedimensions,performancespecifications,componentweights,andfuel,coolantand lubricantspecificationcharts.
STRUCTURE,FUNCTIONANDMAINTENANCESTANDARD
Thissectionexplainsthestructureandfunctionofeachcomponent.Itservesnotonlytogiveanunderstandingofthe structure,butalsoservesasreferencematerialfortroubleshooting.
TESTING,ADJUSTINGANDTROUBLESHOOTING
Thissectionexplainscheckstobemadebeforeandafterperformingrepairs,aswellasadjustmentstobemadeatcompletionofthechecksandrepairs.Troubleshootingchartscorrelating“Problems”to“Causes”arealsoincludedinthissection.
DISASSEMBLYANDASSEMBLY
Thissectionexplainstheordertobefollowedwhenremoving,installing,disassemblingorassemblingeachcomponent, aswellasprecautionstobetakenfortheseoperations.
NOTICE
Thespecificationscontainedinthisshopmanualaresubjecttochangeatanytimeandwithoutanyadvancenotice.Contact yourdistributorforthelatestinformation.
