This document is a shop manual for Komatsu hydraulic excavators that provides information on general specifications, structure and function of components, testing and adjustment procedures, disassembly and assembly instructions, and maintenance standards. It is divided into sections for general information, structure/function, testing/adjustment, disassembly/assembly, and maintenance standards. The safety section emphasizes the importance of following safety precautions when servicing equipment to prevent injuries. The document also provides installation and removal instructions for components like the radiator and hydraulic oil cooler.
Komatsu pc200 6 hydraulic excavator service repair manual sn a82001 and upufjjdjkkskemmd
This document provides specifications for the Komatsu PC200-6 and PC200LC-6 hydraulic excavators, including operating weight, dimensions, performance capabilities, and other technical details. Key specifications listed include a 0.8 m3 bucket capacity, maximum digging depths of 6.62 meters, maximum digging reaches of 9.88 meters, and travel speeds up to 4 km/h. Component weights, fuel/coolant types, and maintenance standards are also outlined.
Caterpillar cat 320 d lrr excavator (prefix zgb) service repair manual (zgb00...fjjsekkdmme
This document provides instructions for removing and installing the valve mechanism cover base on a 320D LRR excavator with a C6.4 engine. The removal procedure involves removing clips and disconnecting harnesses from the electronic unit injectors, then removing bolts to take off the cover base. The installation procedure specifies tightening bolts and reconnecting harnesses in the reverse order. Precautions are given to keep parts clean and prevent damage from contaminants.
Caterpillar cat 320 d lrr excavator (prefix tae) service repair manual (tae00...fjjsekkdmme
This document provides instructions for removing and installing inlet and exhaust valve springs on a Caterpillar 320D LRR excavator engine. The procedure involves using specialty tools to compress the valve springs so that the valves, springs, and related components can be safely accessed and removed or installed one at a time. Safety precautions are outlined to prevent injury from parts under spring pressure.
Caterpillar cat 320 d lrr excavator (prefix ejt) service repair manual (ejt00...fjjsekkdmme
This document provides instructions for removing and installing the flywheel and crankshaft pulley on a 320D LRR excavator with a C6.4 engine. The flywheel removal procedure involves using link brackets and forcing bolts to lift the flywheel off the crankshaft. The crankshaft pulley is removed using a combination puller tool. Both components are installed by reversing the removal process and tightening to the specified torques.
Caterpillar cat 320 d lrr excavator (prefix dhe) service repair manual (dhe00...fjjsekkdmme
This document provides instructions for removing, disassembling, assembling, and installing the engine oil pump and water pump on a Caterpillar 320D LRR excavator with a C6.4 engine. The oil pump removal instructions describe removing gears, covers, and other components. The water pump instructions describe removing the pump, pulley, and O-ring seal, as well as disassembling, inspecting, and reassembling the pump components. Precautions are provided regarding cleaning parts and containing fluids.
Caterpillar cat 318 c excavator (prefix faa) service repair manual (faa00001 ...fjjsekkdmme
This document provides instructions for installing pistons and connecting rods, removing and installing connecting rod bearings, and removing crankshaft main bearings for Caterpillar 3064 and 3066 engines. The procedures describe cleaning and lubricating parts, aligning identification marks, using specific tools, and torquing fasteners to the proper specifications.
Caterpillar cat 318 c excavator (prefix btg) service repair manual (btg00001 ...fjjsekkdmme
This document provides instructions for disassembling and assembling the final drive of a 318C excavator. The disassembly procedure involves using various tools to remove 31 parts from the final drive including the cover, planetary assembly, retaining rings, gears, bearings, seals and housing components. The assembly procedure instructs installing these 31 parts in reverse order and provides details on cleaning, lubricating and setting torque specifications.
Caterpillar cat 316 f l excavator (prefix ydl) service repair manual (ydl0000...fjjsekkdmme
This document provides service and repair instructions for the final drive and related components of a 316F L excavator. It includes specifications, illustrations, removal and disassembly procedures, and assembly instructions. The procedures involve using various tools to remove, disassemble, and replace components like gears, bearings, seals, and housings. Precautions are outlined for cleaning parts and applying lubricants and sealants during assembly.
Komatsu pc200 6 hydraulic excavator service repair manual sn a82001 and upufjjdjkkskemmd
This document provides specifications for the Komatsu PC200-6 and PC200LC-6 hydraulic excavators, including operating weight, dimensions, performance capabilities, and other technical details. Key specifications listed include a 0.8 m3 bucket capacity, maximum digging depths of 6.62 meters, maximum digging reaches of 9.88 meters, and travel speeds up to 4 km/h. Component weights, fuel/coolant types, and maintenance standards are also outlined.
Caterpillar cat 320 d lrr excavator (prefix zgb) service repair manual (zgb00...fjjsekkdmme
This document provides instructions for removing and installing the valve mechanism cover base on a 320D LRR excavator with a C6.4 engine. The removal procedure involves removing clips and disconnecting harnesses from the electronic unit injectors, then removing bolts to take off the cover base. The installation procedure specifies tightening bolts and reconnecting harnesses in the reverse order. Precautions are given to keep parts clean and prevent damage from contaminants.
Caterpillar cat 320 d lrr excavator (prefix tae) service repair manual (tae00...fjjsekkdmme
This document provides instructions for removing and installing inlet and exhaust valve springs on a Caterpillar 320D LRR excavator engine. The procedure involves using specialty tools to compress the valve springs so that the valves, springs, and related components can be safely accessed and removed or installed one at a time. Safety precautions are outlined to prevent injury from parts under spring pressure.
Caterpillar cat 320 d lrr excavator (prefix ejt) service repair manual (ejt00...fjjsekkdmme
This document provides instructions for removing and installing the flywheel and crankshaft pulley on a 320D LRR excavator with a C6.4 engine. The flywheel removal procedure involves using link brackets and forcing bolts to lift the flywheel off the crankshaft. The crankshaft pulley is removed using a combination puller tool. Both components are installed by reversing the removal process and tightening to the specified torques.
Caterpillar cat 320 d lrr excavator (prefix dhe) service repair manual (dhe00...fjjsekkdmme
This document provides instructions for removing, disassembling, assembling, and installing the engine oil pump and water pump on a Caterpillar 320D LRR excavator with a C6.4 engine. The oil pump removal instructions describe removing gears, covers, and other components. The water pump instructions describe removing the pump, pulley, and O-ring seal, as well as disassembling, inspecting, and reassembling the pump components. Precautions are provided regarding cleaning parts and containing fluids.
Caterpillar cat 318 c excavator (prefix faa) service repair manual (faa00001 ...fjjsekkdmme
This document provides instructions for installing pistons and connecting rods, removing and installing connecting rod bearings, and removing crankshaft main bearings for Caterpillar 3064 and 3066 engines. The procedures describe cleaning and lubricating parts, aligning identification marks, using specific tools, and torquing fasteners to the proper specifications.
Caterpillar cat 318 c excavator (prefix btg) service repair manual (btg00001 ...fjjsekkdmme
This document provides instructions for disassembling and assembling the final drive of a 318C excavator. The disassembly procedure involves using various tools to remove 31 parts from the final drive including the cover, planetary assembly, retaining rings, gears, bearings, seals and housing components. The assembly procedure instructs installing these 31 parts in reverse order and provides details on cleaning, lubricating and setting torque specifications.
Caterpillar cat 316 f l excavator (prefix ydl) service repair manual (ydl0000...fjjsekkdmme
This document provides service and repair instructions for the final drive and related components of a 316F L excavator. It includes specifications, illustrations, removal and disassembly procedures, and assembly instructions. The procedures involve using various tools to remove, disassemble, and replace components like gears, bearings, seals, and housings. Precautions are outlined for cleaning parts and applying lubricants and sealants during assembly.
Caterpillar cat 316 f l excavator (prefix ecz) service repair manual (ecz0000...fjjsekkdmme
This document provides service and repair instructions for the final drive and related components of a 316F L excavator. It includes specifications, illustrations, removal and disassembly procedures, and assembly instructions. The procedures involve using various tools to remove, disassemble, and replace components like gears, bearings, seals, and housings. Precautions are outlined for cleaning parts and applying lubricants and sealants during assembly.
Caterpillar cat 315 d l excavator (prefix ncm) service repair manual (ncm0000...fjjsekkdmme
This document provides instructions for disassembling and assembling a 315D L excavator final drive. The disassembly process involves removing 33 parts from the final drive assembly including the cover, carrier assembly, ring gears, and housing components. The assembly process describes installing 33 parts back into the final drive in reverse order and includes steps for preloading the bearings and determining the correct shim thickness. Cleanliness is emphasized throughout to prevent contamination.
Caterpillar cat 315 d l excavator (prefix jha) service repair manual (jha0000...fjjsekkdmme
The document provides instructions for disassembling and assembling a travel motor. It lists 27 steps for disassembly that include removing the head, check valves, fittings, brake piston, friction plates, and other components. It then lists 26 steps for assembly that describe cleaning and installing components like the shaft assembly, cam plate, barrel assembly, brake piston, and seals in the reverse order of disassembly. Precise alignment of parts and use of identification marks are emphasized to ensure correct reassembly.
Caterpillar cat 315 d l excavator (prefix cjn) service repair manual (cjn0000...fjjsekkdmme
The document provides instructions for disassembling and assembling a travel motor. It lists 27 steps for disassembly that include removing bolts, seals, plates, and other components. It then lists 26 steps for assembly, which involves cleaning components, applying seals and lubricants, and reinstalling components in reverse order of disassembly. Special care must be taken to align parts properly and not damage surfaces.
Caterpillar cat 315 c l excavator (prefix cjc) service repair manual (cjc0000...fjjsekkdmme
The document provides step-by-step instructions for disassembling and assembling the travel motor of 315C and 315C L excavators. It lists 28 steps for disassembly, which include removing bolts, valves, seals, pistons, springs and other components. The 27 steps for assembly describe installing these same components in reverse order, making sure to clean parts, replace seals, and apply lubricants. Special tools and safety precautions are noted throughout the process.
Caterpillar cat 315 c l excavator (prefix cft) service repair manual (cft0000...fjjsekkdmme
The document provides instructions for disassembling and assembling the travel motor of an excavator model 315C. It describes 27 steps to disassemble the travel motor by removing components like bolts, seals, bearings, pistons, and plates. It then describes 26 steps for reassembling the travel motor by installing these components in the reverse order. Precautions are provided to mark parts, clean them, apply lubricants, and take care when installing spring-loaded or sealed components.
Caterpillar cat 315 c l excavator (prefix cfb) service repair manual (cfb0000...fjjsekkdmme
1) The document provides step-by-step instructions for disassembling and assembling the final drive of a 315C excavator.
2) Disassembly includes removing 21 components from the final drive housing.
3) Assembly requires determining the proper shim thickness to set the rolling torque and installing components in reverse order of disassembly. Cleanliness and applying oil to components is emphasized.
Caterpillar cat 315 c l excavator (prefix anf) service repair manual (anf0000...fjjsekkdmme
The document provides instructions for removing and installing a cylinder head on a Caterpillar 3054E engine. The removal process involves draining fluids, removing accessories like the exhaust manifold and fuel lines, and then loosening and removing cylinder head bolts. For installation, the cylinder head gasket is placed on dowels on the cylinder block and the head is positioned using guide bolts before reinstalling the bolts and tightening them in stages.
Caterpillar cat 315 c l excavator (prefix ake) service repair manual (ake0000...fjjsekkdmme
The document provides instructions for disassembling and assembling the travel motor of a 315C excavator. It lists 28 steps for disassembly, which include removing bolts, seals, plates, pistons, springs and other components. It then lists 25 steps for assembly, which involve cleaning parts, applying lubricants, and reinstalling components in reverse order using various tools. Proper cleaning and lubrication of parts is emphasized for both disassembly and assembly.
Caterpillar cat 315 c excavator (prefix cjc) service repair manual (cjc00001 ...fjjsekkdmme
The document provides step-by-step instructions for disassembling and assembling the travel motor of 315C and 315C L excavators. It lists 28 steps for disassembly, which include removing bolts, valves, seals, pistons, springs and other components. It then lists 25 steps for reassembly, instructing technicians to clean parts, replace seals, apply lubricants, and reinstall components in reverse order using various tools. Technicians are advised to mark parts for orientation and take precautions when working with pressurized or spring-loaded components.
Caterpillar cat 315 c excavator (prefix cft) service repair manual (cft00001 ...fjjsekkdmme
The document provides instructions for disassembling and assembling the travel motor of an excavator model 315C. It describes 27 steps to disassemble the travel motor by removing components like bolts, seals, bearings, pistons, and plates. It then describes 26 steps for reassembling the travel motor by installing these components in the reverse order. Precautions are provided to mark parts, clean them, apply lubricants, and take care when installing spring-loaded or sealed components.
Caterpillar cat 315 c excavator (prefix cfb) service repair manual (cfb00001 ...fjjsekkdmme
1) The document provides step-by-step instructions for disassembling and assembling the final drive of a 315C excavator.
2) Disassembly includes removing 21 components from the final drive housing. Assembly is the reverse of disassembly and requires determining the proper shim thickness to set the rolling torque.
3) Special tools are required and components must be cleaned and lubricated before assembly to ensure proper operation of the final drive.
Caterpillar cat 315 c excavator (prefix anf) service repair manual (anf00001 ...fjjsekkdmme
The document provides instructions for removing and installing a cylinder head on a Caterpillar 3054E engine. The removal process involves draining fluids, removing accessories like the exhaust manifold and fuel lines, and then loosening and removing cylinder head bolts. For installation, the cylinder head gasket is placed on dowels, the head is positioned and bolts are lubricated, installed, and tightened in stages to the specified torques. Tools like guide bolts and a torque wrench are required to correctly perform the work.
Caterpillar cat 315 c excavator (prefix ake) service repair manual (ake00001 ...fjjsekkdmme
The document provides instructions for disassembling and assembling the travel motor of a 315C excavator. It lists 28 steps for disassembly, which include removing bolts, seals, plates, pistons, springs and other components. It then lists 25 steps for assembly, which involve cleaning parts, applying lubricants, and reinstalling components in reverse order using various tools. Proper cleaning and lubrication of parts is emphasized for both preventing damage and ensuring smooth operation.
Caterpillar cat 315 b fm l excavator (prefix 7rz) service repair manual (7rz0...fjjsekkdmme
The document provides instructions for disassembling and assembling track rollers on a 315B excavator. It describes:
1) Removing the track rollers and draining oil from the roller before disassembly.
2) Using presses and tools to remove internal components like seals, shafts, and bearings.
3) Checking shaft end play and installing new internal components in reverse order.
4) Filling the roller with the specified oil and reinstalling it along with the track guide.
Caterpillar cat 311 d lrr excavator (prefix lka) service repair manual (lka00...fjjsekkdmme
This document provides instructions for removing and installing inlet and exhaust valve springs on a Caterpillar C4.2 engine. It describes the required tools and gives step-by-step procedures for removing valve springs safely while ensuring the piston is at top-dead-center. Proper installation of new valve springs and related components is also outlined. Safety notices are included to prevent injury from parts propelled by spring forces.
Caterpillar cat 311 d lrr excavator (prefix dwr) service repair manual (dwr00...fjjsekkdmme
This document provides instructions for removing and installing pistons, connecting rods, connecting rod bearings, and the crankshaft on a Caterpillar C4.2 engine. It outlines the required tools and steps to take the components out and put them back in. Key steps include using a piston ring compressor and socket wrench, cleaning and lubricating parts, aligning marks, and torquing connecting rod nuts. The crankshaft removal involves taking off the oil supply tube, installing a nut to turn the crank, and removing main bearing caps.
Caterpillar cat 311 d lrr excavator (prefix cla) service repair manual (cla00...fjjsekkdmme
This document provides instructions for removing and installing inlet and exhaust valves, valve guides, and the engine oil cooler on a Caterpillar C4.2 engine. It describes the required tools and steps to remove the cylinder head to access the valves. Procedures are provided for removing and installing the valves, guides, and oil cooler. Precautions are outlined to prevent contamination and contain fluids.
Caterpillar cat 215 d excavator (prefix 9tf) service repair manual (9tf00001 ...fjjsekkdmme
This document provides instructions for disassembling and assembling the fuel injection pump housing of a Caterpillar 3304B engine. The disassembly process involves removing various parts like the fuel rack, lifters, camshaft and bearings. The assembly process details installing these parts in reverse order and setting proper clearances. Tools needed include retaining ring pliers and a driver group. Precautions like keeping parts clean and applying oil before assembly are also specified.
Caterpillar cat 130 g motor grader (prefix 74v) service repair manual (74v023...fjjsekkdmme
The document provides instructions for removing and installing the flywheel housing on a 130G motor grader with a 3304 engine. It describes using link brackets and a hoist to remove the housing, which weighs 37 kg. Installation involves placing a gasket and bolting the housing back onto the engine, then reinstalling components like the oil drain line and crankshaft rear seal.
Caterpillar cat 316 f l excavator (prefix ecz) service repair manual (ecz0000...fjjsekkdmme
This document provides service and repair instructions for the final drive and related components of a 316F L excavator. It includes specifications, illustrations, removal and disassembly procedures, and assembly instructions. The procedures involve using various tools to remove, disassemble, and replace components like gears, bearings, seals, and housings. Precautions are outlined for cleaning parts and applying lubricants and sealants during assembly.
Caterpillar cat 315 d l excavator (prefix ncm) service repair manual (ncm0000...fjjsekkdmme
This document provides instructions for disassembling and assembling a 315D L excavator final drive. The disassembly process involves removing 33 parts from the final drive assembly including the cover, carrier assembly, ring gears, and housing components. The assembly process describes installing 33 parts back into the final drive in reverse order and includes steps for preloading the bearings and determining the correct shim thickness. Cleanliness is emphasized throughout to prevent contamination.
Caterpillar cat 315 d l excavator (prefix jha) service repair manual (jha0000...fjjsekkdmme
The document provides instructions for disassembling and assembling a travel motor. It lists 27 steps for disassembly that include removing the head, check valves, fittings, brake piston, friction plates, and other components. It then lists 26 steps for assembly that describe cleaning and installing components like the shaft assembly, cam plate, barrel assembly, brake piston, and seals in the reverse order of disassembly. Precise alignment of parts and use of identification marks are emphasized to ensure correct reassembly.
Caterpillar cat 315 d l excavator (prefix cjn) service repair manual (cjn0000...fjjsekkdmme
The document provides instructions for disassembling and assembling a travel motor. It lists 27 steps for disassembly that include removing bolts, seals, plates, and other components. It then lists 26 steps for assembly, which involves cleaning components, applying seals and lubricants, and reinstalling components in reverse order of disassembly. Special care must be taken to align parts properly and not damage surfaces.
Caterpillar cat 315 c l excavator (prefix cjc) service repair manual (cjc0000...fjjsekkdmme
The document provides step-by-step instructions for disassembling and assembling the travel motor of 315C and 315C L excavators. It lists 28 steps for disassembly, which include removing bolts, valves, seals, pistons, springs and other components. The 27 steps for assembly describe installing these same components in reverse order, making sure to clean parts, replace seals, and apply lubricants. Special tools and safety precautions are noted throughout the process.
Caterpillar cat 315 c l excavator (prefix cft) service repair manual (cft0000...fjjsekkdmme
The document provides instructions for disassembling and assembling the travel motor of an excavator model 315C. It describes 27 steps to disassemble the travel motor by removing components like bolts, seals, bearings, pistons, and plates. It then describes 26 steps for reassembling the travel motor by installing these components in the reverse order. Precautions are provided to mark parts, clean them, apply lubricants, and take care when installing spring-loaded or sealed components.
Caterpillar cat 315 c l excavator (prefix cfb) service repair manual (cfb0000...fjjsekkdmme
1) The document provides step-by-step instructions for disassembling and assembling the final drive of a 315C excavator.
2) Disassembly includes removing 21 components from the final drive housing.
3) Assembly requires determining the proper shim thickness to set the rolling torque and installing components in reverse order of disassembly. Cleanliness and applying oil to components is emphasized.
Caterpillar cat 315 c l excavator (prefix anf) service repair manual (anf0000...fjjsekkdmme
The document provides instructions for removing and installing a cylinder head on a Caterpillar 3054E engine. The removal process involves draining fluids, removing accessories like the exhaust manifold and fuel lines, and then loosening and removing cylinder head bolts. For installation, the cylinder head gasket is placed on dowels on the cylinder block and the head is positioned using guide bolts before reinstalling the bolts and tightening them in stages.
Caterpillar cat 315 c l excavator (prefix ake) service repair manual (ake0000...fjjsekkdmme
The document provides instructions for disassembling and assembling the travel motor of a 315C excavator. It lists 28 steps for disassembly, which include removing bolts, seals, plates, pistons, springs and other components. It then lists 25 steps for assembly, which involve cleaning parts, applying lubricants, and reinstalling components in reverse order using various tools. Proper cleaning and lubrication of parts is emphasized for both disassembly and assembly.
Caterpillar cat 315 c excavator (prefix cjc) service repair manual (cjc00001 ...fjjsekkdmme
The document provides step-by-step instructions for disassembling and assembling the travel motor of 315C and 315C L excavators. It lists 28 steps for disassembly, which include removing bolts, valves, seals, pistons, springs and other components. It then lists 25 steps for reassembly, instructing technicians to clean parts, replace seals, apply lubricants, and reinstall components in reverse order using various tools. Technicians are advised to mark parts for orientation and take precautions when working with pressurized or spring-loaded components.
Caterpillar cat 315 c excavator (prefix cft) service repair manual (cft00001 ...fjjsekkdmme
The document provides instructions for disassembling and assembling the travel motor of an excavator model 315C. It describes 27 steps to disassemble the travel motor by removing components like bolts, seals, bearings, pistons, and plates. It then describes 26 steps for reassembling the travel motor by installing these components in the reverse order. Precautions are provided to mark parts, clean them, apply lubricants, and take care when installing spring-loaded or sealed components.
Caterpillar cat 315 c excavator (prefix cfb) service repair manual (cfb00001 ...fjjsekkdmme
1) The document provides step-by-step instructions for disassembling and assembling the final drive of a 315C excavator.
2) Disassembly includes removing 21 components from the final drive housing. Assembly is the reverse of disassembly and requires determining the proper shim thickness to set the rolling torque.
3) Special tools are required and components must be cleaned and lubricated before assembly to ensure proper operation of the final drive.
Caterpillar cat 315 c excavator (prefix anf) service repair manual (anf00001 ...fjjsekkdmme
The document provides instructions for removing and installing a cylinder head on a Caterpillar 3054E engine. The removal process involves draining fluids, removing accessories like the exhaust manifold and fuel lines, and then loosening and removing cylinder head bolts. For installation, the cylinder head gasket is placed on dowels, the head is positioned and bolts are lubricated, installed, and tightened in stages to the specified torques. Tools like guide bolts and a torque wrench are required to correctly perform the work.
Caterpillar cat 315 c excavator (prefix ake) service repair manual (ake00001 ...fjjsekkdmme
The document provides instructions for disassembling and assembling the travel motor of a 315C excavator. It lists 28 steps for disassembly, which include removing bolts, seals, plates, pistons, springs and other components. It then lists 25 steps for assembly, which involve cleaning parts, applying lubricants, and reinstalling components in reverse order using various tools. Proper cleaning and lubrication of parts is emphasized for both preventing damage and ensuring smooth operation.
Caterpillar cat 315 b fm l excavator (prefix 7rz) service repair manual (7rz0...fjjsekkdmme
The document provides instructions for disassembling and assembling track rollers on a 315B excavator. It describes:
1) Removing the track rollers and draining oil from the roller before disassembly.
2) Using presses and tools to remove internal components like seals, shafts, and bearings.
3) Checking shaft end play and installing new internal components in reverse order.
4) Filling the roller with the specified oil and reinstalling it along with the track guide.
Caterpillar cat 311 d lrr excavator (prefix lka) service repair manual (lka00...fjjsekkdmme
This document provides instructions for removing and installing inlet and exhaust valve springs on a Caterpillar C4.2 engine. It describes the required tools and gives step-by-step procedures for removing valve springs safely while ensuring the piston is at top-dead-center. Proper installation of new valve springs and related components is also outlined. Safety notices are included to prevent injury from parts propelled by spring forces.
Caterpillar cat 311 d lrr excavator (prefix dwr) service repair manual (dwr00...fjjsekkdmme
This document provides instructions for removing and installing pistons, connecting rods, connecting rod bearings, and the crankshaft on a Caterpillar C4.2 engine. It outlines the required tools and steps to take the components out and put them back in. Key steps include using a piston ring compressor and socket wrench, cleaning and lubricating parts, aligning marks, and torquing connecting rod nuts. The crankshaft removal involves taking off the oil supply tube, installing a nut to turn the crank, and removing main bearing caps.
Caterpillar cat 311 d lrr excavator (prefix cla) service repair manual (cla00...fjjsekkdmme
This document provides instructions for removing and installing inlet and exhaust valves, valve guides, and the engine oil cooler on a Caterpillar C4.2 engine. It describes the required tools and steps to remove the cylinder head to access the valves. Procedures are provided for removing and installing the valves, guides, and oil cooler. Precautions are outlined to prevent contamination and contain fluids.
Caterpillar cat 215 d excavator (prefix 9tf) service repair manual (9tf00001 ...fjjsekkdmme
This document provides instructions for disassembling and assembling the fuel injection pump housing of a Caterpillar 3304B engine. The disassembly process involves removing various parts like the fuel rack, lifters, camshaft and bearings. The assembly process details installing these parts in reverse order and setting proper clearances. Tools needed include retaining ring pliers and a driver group. Precautions like keeping parts clean and applying oil before assembly are also specified.
Caterpillar cat 130 g motor grader (prefix 74v) service repair manual (74v023...fjjsekkdmme
The document provides instructions for removing and installing the flywheel housing on a 130G motor grader with a 3304 engine. It describes using link brackets and a hoist to remove the housing, which weighs 37 kg. Installation involves placing a gasket and bolting the housing back onto the engine, then reinstalling components like the oil drain line and crankshaft rear seal.
Understanding Catalytic Converter Theft:
What is a Catalytic Converter?: Learn about the function of catalytic converters in vehicles and why they are targeted by thieves.
Why are They Stolen?: Discover the valuable metals inside catalytic converters (such as platinum, palladium, and rhodium) that make them attractive to criminals.
Steps to Prevent Catalytic Converter Theft:
Parking Strategies: Tips on where and how to park your vehicle to reduce the risk of theft, such as parking in well-lit areas or secure garages.
Protective Devices: Overview of various anti-theft devices available, including catalytic converter locks, shields, and alarms.
Etching and Marking: The benefits of etching your vehicle’s VIN on the catalytic converter or using a catalytic converter marking kit to make it traceable and less appealing to thieves.
Surveillance and Monitoring: Recommendations for using security cameras and motion-sensor lights to deter thieves.
Statistics and Insights:
Theft Rates by Borough: Analysis of data to determine which borough in NYC experiences the highest rate of catalytic converter thefts.
Recent Trends: Current trends and patterns in catalytic converter thefts to help you stay aware of emerging hotspots and tactics used by thieves.
Benefits of This Presentation:
Awareness: Increase your awareness about catalytic converter theft and its impact on vehicle owners.
Practical Tips: Gain actionable insights and tips to effectively prevent catalytic converter theft.
Local Insights: Understand the specific risks in different NYC boroughs, helping you take targeted preventive measures.
This presentation aims to equip you with the knowledge and tools needed to protect your vehicle from catalytic converter theft, ensuring you are prepared and proactive in safeguarding your property.
Welcome to ASP Cranes, your trusted partner for crane solutions in Raipur, Chhattisgarh! With years of experience and a commitment to excellence, we offer a comprehensive range of crane services tailored to meet your lifting and material handling needs.
At ASP Cranes, we understand the importance of reliable and efficient crane operations in various industries, from construction and manufacturing to logistics and infrastructure development. That's why we strive to deliver top-notch solutions that enhance productivity, safety, and cost-effectiveness for our clients.
Our services include:
Crane Rental: Whether you need a crawler crane for heavy lifting or a hydraulic crane for versatile operations, we have a diverse fleet of well-maintained cranes available for rent. Our rental options are flexible and can be customized to suit your project requirements.
Crane Sales: Looking to invest in a crane for your business? We offer a wide selection of new and used cranes from leading manufacturers, ensuring you find the perfect equipment to match your needs and budget.
Crane Maintenance and Repair: To ensure optimal performance and safety, regular maintenance and timely repairs are essential for cranes. Our team of skilled technicians provides comprehensive maintenance and repair services to keep your equipment running smoothly and minimize downtime.
Crane Operator Training: Proper training is crucial for safe and efficient crane operation. We offer specialized training programs conducted by certified instructors to equip operators with the skills and knowledge they need to handle cranes effectively.
Custom Solutions: We understand that every project is unique, which is why we offer custom crane solutions tailored to your specific requirements. Whether you need modifications, attachments, or specialized equipment, we can design and implement solutions that meet your needs.
At ASP Cranes, customer satisfaction is our top priority. We are dedicated to delivering reliable, cost-effective, and innovative crane solutions that exceed expectations. Contact us today to learn more about our services and how we can support your project in Raipur, Chhattisgarh, and beyond. Let ASP Cranes be your trusted partner for all your crane needs!
Implementing ELDs or Electronic Logging Devices is slowly but surely becoming the norm in fleet management. Why? Well, integrating ELDs and associated connected vehicle solutions like fleet tracking devices lets businesses and their in-house fleet managers reap several benefits. Check out the post below to learn more.
EV Charging at MFH Properties by Whitaker JamiesonForth
Whitaker Jamieson, Senior Specialist at Forth, gave this presentation at the Forth Addressing The Challenges of Charging at Multi-Family Housing webinar on June 11, 2024.
Ever been troubled by the blinking sign and didn’t know what to do?
Here’s a handy guide to dashboard symbols so that you’ll never be confused again!
Save them for later and save the trouble!
What Could Be Behind Your Mercedes Sprinter's Power Loss on Uphill RoadsSprinter Gurus
Unlock the secrets behind your Mercedes Sprinter's uphill power loss with our comprehensive presentation. From fuel filter blockages to turbocharger troubles, we uncover the culprits and empower you to reclaim your vehicle's peak performance. Conquer every ascent with confidence and ensure a thrilling journey every time.
Expanding Access to Affordable At-Home EV Charging by Vanessa WarheitForth
Vanessa Warheit, Co-Founder of EV Charging for All, gave this presentation at the Forth Addressing The Challenges of Charging at Multi-Family Housing webinar on June 11, 2024.
Expanding Access to Affordable At-Home EV Charging by Vanessa Warheit
Komatsu pc210 lc 6 hydraulic excavator service repair manual (a82001 and up)
1. Shop
Manual
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Pc2002001c4
PC21OLC=li
PC22OlLli
PC25OlbiHYDRAULIC EXCAVATOR
PC200-6 - A82001
PC2OOLC-6 - A82001
PC21OLC-6 n A82001
SERIAL NUMBERS PC22OLC-6 n A82001 andup
PC25OLC-6 - A82001
This material is proprietary to Komatsu America lnternational Company and is not to be reproduced, used, or
disclosed except in accordance with written authorization from Komatsu America International Company.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make
changes or add improvements at any time without incurring any obligation to install such changes on products sold
previously.
Due to this continuous program of research and development, periodic revisions may be made to this publication.
It is recommended that customers contact their distributor for information on the latest revision.
00-l
October 1996 Copyright 1996 Komatsu America International Company 0
2. CONTENTS
01 GENERAL ............................................. 01-I
IO STRUCTURE AND FUNCTION ............................ IO-I
20 TESTING AND ADJUSTMENT ............................. 20-I
30 DISASSEMBLY AND ASSEMBLY .......................... 30-I
40 MAINTENANCE STANDARD .............................. 40-I
00-2
3. SAFETY SAFETY NOTICE
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for the safe operation of your machine. The service and repair
techniques recommended and described in this manual are both effective and safe methods of operation.
Some of these operations require the use of tools specially designed for the purpose.
To prevent injury to workers, the symbols A and *$ are used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises
or may possibly arise, first consider safety, and take the necessary actions to deal with the situation.
GENERAL PRECAUTIONS clean and make sure that there is no dirt or oil on the
floor. Smoke only in the areas provided for smoking.
Mistakes in operation are extremely dangerous. Read the Never smoke while working.
OPERATION & MAINTENANCE MANUAL carefully
BEFORE operating the machine. PREPARATIONS FOR WORK
1.
2.
l
l
3.
4.
5.
6.
I
I
i
3efore carrying out any greasing or repairs, read all
:he precautions given on the decals which are fixed to
:he machine.
7.
When carrying out any operation, always wear safety
shoes and helmet. Do not wear loose work clothes,
)r clothes with buttons missing.
Always wear safety glasses when hitting parts with
a hammer.
8.
Always wear safety glasses when grinding parts
with a grinder, etc. 9.
f welding repairs are needed, always have a trained,
experienced welder carry out the work. When carry-
ng out welding work, always wear welding gloves, 10,
apron, glasses, cap and other clothes suited for
Melding work.
JVhen carrying out any operation with two or more
Norkers, always agree on the operating procedure
oefore starting. Always inform your fellow workers
Before adding oil or making repairs, park the ma-
chine on hard, level ground, and block the wheels or
tracks to prevent the machine from moving.
Before starting work, lower blade, ripper, bucket or
any otherwork equipment to the ground. If this is not
possible, insert the safety pin or use blocks to prevent
the work equipment from falling. In addition, be sure
to lock all the control levers and hang warning signs
on them.
When disassembling or assembling, support the
machine with blocks, jacks or stands before starting
work.
Remove all mud and oil from the steps or other
places used to get on and off the machine. Always
use the handrails, ladders or steps when getting on or
off the machine. Never jump on or off the machine.
If it is impossible to use the handrails, ladders or
steps, use a stand to provide safe footing.
sefore starting any step of the operation. Before PRECAUTIONS DURING WORK
starting work, hang UNDER REPAIR signs on the
zontrols in the operator’s compartment. 11.
<eep all tools in good condition and learn the correct
Nay to use them.
Decide a place in the repair workshop to keep tools
and removed parts. Always keep the tools and parts
n their correct places. Always keep the work area 12.
When removing the oil filler cap, drain plug or hy-
draulic pressure measuring plugs, loosen them
slowly to prevent the oil from spurting out. Before
disconnecting or removing components of the oil,
water or air circuits, first remove the pressure com-
pletely from the circuit.
The water and oil in the circuits are hot when the
00-3
4. SAFETY SAFETY NOTICE
13.
14.
15.
16.
17.
18.
engine is stopped, so be careful not to get burned.
Wait for the oil and water to cool before carrying out
any work on the oil or water circuits.
Before starting work, remove the leads from the
battery. ALWAYS remove the lead from the negative
(-) terminal first.
When raising heavy components, use a hoist or
crane. Check that the wire rope, chains and hooks
are free from damage. Always use lifting equipment
which has ample capacity. Install the lifting equip
ment at the correct places. Use a hoist or crane and
operate slowly to prevent the component from hitting
any other part. Do not work with any part still raised
by the hoist or crane.
When removing covers which are under internal
pressure or under pressure from a spring, always
leave two bolts in position on opposite sides. Slowly
release the pressure, then slowly loosen the bolts to
remove.
When removing components, be careful not to break
or damage the wiring, Damaged wiring may cause
electrical fires.
When removing piping, stop the fuel or oil from
spilling out. If any fuel or oil drips on to the floor, wipe
it up immediately. Fuel or oil on the floor can cause
you to slip, or can even start fires.
As a general rule, do not use gasoline to wash parts.
In particular, use only the minimum of gasoline when
19.
20.
21.
22.
23.
24.
washing electrical parts.
Be sure to assemble all parts again in their original
places. Replace any damaged part with new parts.
l When installing hoses and wires, be sure that
they will not be damaged by contact with other
parts when the machine is being operated.
When installing high pressure hoses, make sure that
they are nottwisted. Damaged tubes are dangerous,
so be extremely careful when installing tubes for high
pressure circuits. Also check that connecting parts
are correctly installed.
When assembling or installing parts, always use the
specified tightening torques. When installing protec-
tive parts such as guards, or parts which vibrate
violently or rotate at high speed, be particularly
careful to check that they are installed correctly.
When aligning two holes, never insert your fingers or
hand. Be careful not to get your fingers caught in a
hole.
When measuring hydraulic pressure, check that the
measuring tool is correctly assembled before taking
any measurements.
Take care when removing or installing the tracks of
track-type machines. When removing the track, the
track separates suddenly, so never let anyone stand
at either end of the track.
00-4
5. FOREWARD GENERAL
FOREWARD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate
understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure
you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop.
For ease of understanding, the manual is divided into the following sections. These sections are further divided into each
main group of components.
GENERAL
This section lists the general machine dimensions, performance specifications, component weights, and fuel,
coolant and lubricant specification charts.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding of
the structure, but also serves as reference material for troubleshooting.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made
at completion of the checks and repairs. Troubleshooting charts correlating “Problems” to “Causes” are also
included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling each
component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any advance
notice. Contact your distributor for the latest information.
00-5
6. DISASSEMBLY AND ASSEMBLY RADIATOR. HYDRAULIC OIL COOLER
6. Disconnect radiator support rods (12) and (13).
* Loosen the mounting bolts, then remove the
top mounting bolts and move the rods toward
the rear of the engine.
7. Disconnect radiator lower hose (14) and heater
hose (15).
* The radiator lower hose is fixed by a clamp to
the radiator, so always disconnect the clamp.
8. Sling radiator and hydraulic oil cooler assembly
(16) remove 4 bottom mounting bolts, then lift off
radiator and hydraulic oil cooler assembly.
* When raising the radiator and hydraulic oil
cooler assembly, check the position carefully
and do not let it hit the fan when removing it.
Radiator l hydraulic oil cooler
assembly: 125 kg
INSTALLATION OF RADIATOR.
HYDRAULIC OIL COOLER
ASSEMBLY
Carry out installation in the reverse order to
removal.
Refilling with coolant.
* Add coolant through the water filler to the
specified level. Run the engine to circulate the
coolant through the system. Then check the
coolant level again.
Refilling with oil (hydraulic tank)
* Add oil through the oil filler to the specified
level. Run the engine to circulate the oil through
the system. Then check the oil level again.
30-16
0
7. DISASSEMBLY AND ASSEMBLY ENGINE. HYDRAULIC PUMP
REMOVAL OF ENGINE.
HYDRAULIC PUMP ASSEMBLY
A
A
l
*
0
1.
2.
3.
Disconnect the cable from the negative (-) terminal
of the battery.
Lower the work equipment completely to the g
round and stop the engine. Then loosen the oil filler
cap slowly to release the pressure inside the
hydraulic tank.
Remove the hydraulic tank strainer, and using tool
B, stop the oil.
l When not using tool B, remove the drain plug,
and drain the oil from the hydraulic tank and
inside the system.
Hydraulic tank: Approx. 170 P
Mark all the piping with tags to prevent mistakes in
the mounting position when installing.
Drain engine coolant.
Remove cotter pin (1) of stopper, then remove
engine hood (2).
Remove side cover and mounting frame (3).
Remove engine hood mounting bracket (4), cover
(5) and engine room partition plate (6).
XiOARO14
30-I 7
0
8. DISASSEMBLY AND ASSEMBLY ENGINE. HYDRAULIC PUMP
4. Disconnect hoses (7) (8) and (9) from NC l LS
valve.
5. Pull out connectors (10) and (11) from holder and
disconnect.
* Remove the connector wiring clamps
completely.
6. Disconnect hoses (12) and (13) from control pump.
7. Remove suction tubes (14) and (15).
8. Disconnect hoses (16) and (17) installed to top of
main pump assembly.
9. Remove cover (18) and disconnect hose bracket
(19) from pump.
10. Remove bracket (20) at counterweight end.
30-18
0
9. DISASSEMBLY AND ASSEMBLY ENGINE l HYDRAULIC PUMP
11. Disconnect connector (21).
12.
13.
14.
15.
16.
Disconnect governor motor connectors (22) and
remove wiring clamp (23).
Disconnect starting motor wiring (24). Disconnect
intake heat wiring (24A) and engine earth (24B).
Disconnect air conditioner compressor hoses (25)
and (26). (If fitted)
* Loosen the sleeve nut slightly and release the
refrigerant (gas) completely before
disconnecting the hoses.
* Fit blind plugs to prevent the entry of moisture,
dust or dirt into the hoses.
Disconnect fuel hoses (27) and ground connection
(26).
Remove radiator upper hose (29), heater hose (30)
air cleaner connector (31) and fan guard (32).
XlOAR022
30-I9
0
10. DISASSEMBLY AND ASSEMBLY ENGINE. HYDRAULIC PUMP
17. Remove fan (33), and disconnect radiator lower
hose (34).
18. Remove mount bolt, and raise engine and hydraulic
pump assembly (36) slowly, then move to right side
of chassis and lift off.
j, When removing the engine and hydraulic pump
assembly, check that all the wiring and piping
has been disconnected.
Engine l hydraulic pump assembly:
750 kg
INSTALLATION OF ENGINE.
HYDRAULIC PUMP ASSEMBLY
0 Carry out installation in the reverse order to
removal.
Engine mount bolt: 276.9 f 31.9 Nm
I r.,J XlOARO25
m
(28.3 f 3.3 kgm)
Refilling with coolant.
* Add coolant through the water filler to specified
level. Run the engine to circulate the coolant
through the system. Then check the coolant
level again.
Refilling with oil (hydraulic tank)
j, Add oil through the oil filler to the specified
level. Run the engine to circulate the oil through
the system. Then check the oil level again.
Bleeding air
* Bleed air from the hydraulic pump. For details,
see TESTING AND ADJUSTING, Bleeding air.
30-20
0
11. DISASSEMBLY AND ASSEMBLY
DAMPER
REMOVAL OF DAMPER
ASSEMBLY
1. Remove main pump assembly. For details, see
REMOVAL OF MAIN PUMP ASSEMBLY.
2. Remove damper assembly (1).
INSTALLATION OF DAMPER
ASSEMBLY
0 Carry out installation in the reverse order to
removal.
30-21
0
12. DISASSEMBLY AND ASSEMBLY FUEL TANK
REMOVAL OF FUEL TANK
ASSEMBLY
1.
2.
3.
4.
5.
6.
Disconnect the cable from the negative (-) terminal
of the battery.
Loosen drain valve (1) of fuel tank and drain fuel.
t
Fuel tank: Approx. 315 0 (when tank is
u full)
Disconnect fuel supply hose (2) and return hose
(3).
Remove handrail (4) battery case (5) and cover
(6).
Remove connector (7) from holder, and disconnect
it.
* Remove the wiring from the clamp, then
disconnect from the fuel tank.
If refueling pump is fitted, disconnect hose (9) from
tank tube.
Remove mounting bolts and lift off fuel tank
assembly (8). j-%q
el Fuel tank assembly: 120 kg
kg
INSTALLATION OF FUEL TANK
ASSEMBLY
a Carry out installation in the reverse order to
removal.
Fuel tank mounting bolt: 276.9 + 31.9
Nm (28.25 f 3.25 kgm)
0 Refilling with oil (fuel tank)
Add fuel.
X12BD009
XlZBDOH
30-22
0
13. DISASSEMBLY AND ASSEMBLY CENTER SWIVEL JOINT
REMOVAL OF CENTER SWIVEL
JOINT ASSEMBLY
A
*
1.
2.
3.
4.
5.
6.
7.
8.
Release the remaining pressure in the hydraulic
circuit. For details, see TESTING AND
ADJUSTING, Releasing remaining pressure from
hydraulic circuit.
Mark all the piping with tags to prevent mistakes in
the mounting position when installing.
Disconnect hoses (I), (2) (3) and (4) and tubes (5)
and (6), and remove filter and bracket assembly.
* Machines equipped with additional attachment
circuit.
&
Filter, bracket assembly: 95 kg
kg
Disconnect hoses (7) (8) (9) and (10) between
travel motor and swivel joint.
Remove elbow (11).
Disconnect drain hose (12).
Disconnect hoses (13) and (14) between control
valve and swivel joint.
Disconnect travel speed selector hose (15).
Disconnect plate (16).
Remove center swivel joint assembly (17).
Center swivel joint assembly: 45 kg
INSTALLATION OF CENTER
SWIVEL JOINT ASSEMBLY
0 Carry out installation in the reverse order to
removal.
* Assemble the center swivel as shown in the
diagram below.
Center swivel ’
+ s-6
2PSprocket
@@
X09DDO23
Refilling with oil (hydraulic tank)
* Add oil through the oil filler to the specified
level. Run the engine to circulate the oil through
the system. Then check the oil level again.
Bleeding air
Jr Bleed the air from the travel motor. For details,
see TESTING AND ADJUSTING, Bleeding air.
30-23
0
14. DISASSEMBLY AND ASSEMBLY CENTER SWIVEL JOINT
DISASSEMBLY OF CENTER
SWIVEL JOINT ASSEMBLY
1. Remove cover (1).
2. Remove snap ring (2).
3. Using tool D, pull out swivel rotor (4) and ring (3)
from swivel shaft (5).
4. Remove O-ring (6) and slipper seal (7) from swivel
rotor.
ASSEMBLY OF CENTER SWIVEL
JOINT ASSEMBLY
1. Assembly slipper seal (7) and O-ring (6) to swivel
rotor.
2. Set swivel shaft (5) to block, then using push tool,
tap swivel rotor (4) with a plastic hammer to install.
Contact surface of rotor, shaft: Grease
- (G2-LI)
!
XOSDDO28
* When installing the rotor, be extremely careful
not to damage the slipper seal and the O-ring.
3. Install ring (3) and secure with snap ring (2).
4. Fit O-ring and install cover (1).
Mounting bolt: 31.4 + 2.9 Nm (3.2 + 0.3
kgm)
30-24
0
15. DISASSEMBLY AND ASSEMBLY FINAL DRIVE
REMOVAL OF FINAL DRIVE
ASSEMBLY
1.
a
2.
3.
Remove sprocket. For details, see REMOVAL OF
SPROCKET.
Lower the work equipment completely to the g
round and stop the engine. Then loosen the oil filler
cap slowly to release the pressure inside the
hydraulic tank.
Remove cover (1).
Disconnect 4 travel motor hoses (2) and lift off final
drive assembly (3).
jr Be extremely careful not to damage the
tool surface of the hose mount.
Final drive assembly: 425 kg
INSTALLATION OF FINAL DRIVE
ASSEMBLY
0 Carry out installation in the reverse order to
removal.
m
Final drive mounting bolt: 276.9 f
31.9 Nm (28.25 f 3.25 kgm)
Bleeding air
* Bleed the air from the travel motor. For details,
see TESTING AND ADJUSTING, Bleeding air.
Refilling with oil (hydraulic tank)
* Add oil through the oil filler to the specified
level.
Run the engine to circulate the oil through the
system. Then check the oil level again.
.---I
X07HH034
30-25
0
16. DISASSEMBLY AND ASSEMBLY FINAL DRIVE
DISASSEMBLY OF FINAL DRIVE
ASSEMBLY
PC200-6, PC2OOLC-6, PC21 OLC-6, PC22OLC-6
1.
2.
3.
4.
Draining oil
Remove drain plug and drain oil from final drive
case.
Final drive case: Approx. 5.5 I?
Cover
Remove mounting bolts, then remove cover (1)
using eyebolts 0.
X07HH037
Spacer
Remove spacer (2).
No. 1 sun gear shaft
Remove No. 1 sun gear shaft (3).
5. No. 1 carrier assembly
1) Remove No. 1 carrier assembly (4).
X07HH039
2) Disassembly No. 1 carrier assembly as follows.
i) Push in pin (5) and pull out shaft (6) from
carrier (7).
9
j, After removing the shaft, remove pin
(5).
ii) Remove thrust washer (8) gear (9),
bearing (IO), and thrust washer (11). 6
XO7HHO40
30-26
0
17. DISASSEMBLY AND ASSEMBLY FINAL DRIVE
6. Ring gear
Using eyebolts 0, remove ring gear (12).
7. No. 2 sun gear
Remove No. 2 sun gear (13).
8. Thrust washer
Remove thrust washer (14).
9. No. 2 carrier assembly
1) Remove No. 2 carrier assembly (15).
2) Disassemble No. 2 carrier assembly as follows.
i) Push in pin (16) and pull out shaft (17) from
carrier (18).
* After removing the shaft, remove pin
(16).
ii) Remove thrust washer (19) gear (20)
bearing (21), and thrust washer (22).
10. Nut
1) Remove lock plate (23).
2) Using tool G,, remove nut (24).
12
XO7HHO41
19 17 21 18
20
---_---
22
30-27
0
18. DISASSEMBLY AND ASSEMBLY FINAL DRIVE
11. Hub assembly
1) Using eyebolts 0, remove hub assembly (25)
from travel motor.
2) Disassemble hub assembly as follows.
i) Remove floating seal (26).
ii) Remove bearings (27) and (28) from hub
(2%
3) Remove floating seal (30) from travel motor
(31).
X07HH045
26 XO7HHO46
X07HH047
30-28
0
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20. DISASSEMBLY AND ASSEMBLY FINAL DRIVE
ASSEMBLY OF FINAL DRIVE
ASSEMBLY
PC200-6, PC2OOLC6, PC21OLC-6, PC22OLC-6
*
1.
2.
Clean all parts, and check for dirt or damage. Coat
the sliding surfaces of all parts with engine oil
before installing.
Hub assembly
1) Using push tool, press fit bearings (27) and (28)
to hub (29).
2) Using tool Gq, install floating seal (26).
G4.
*
*
*
X07HH049
Remove all oil and grease from the O-ring
and O-ring contact surface, and dry the
parts before installing the floating seal.
After installing the floating seal, check that
the angle of the floating seal is within 1mm.
After installing the floating seal, coat the
sliding surface thinly with engine oil.
3)
4)
Using tool G,, install floating seal (30) to travel
motor (31).
* The procedure for installation is the same
as in Step 2) above.
Using eyebolts 0, set hub assembly (25) to
travel motor, then using push tool, tap to press
fit bearing portion.
Nut
1) Install nut as follows.
i) Using tool G,, push bearing inner race
portion.
* Pushing force: 8.82 - 12.74 kN (0.9 -
1.3 ton)
j, Rotate the hub 2 - 3 times before
applying the pushing force to the
bearing inner race.
ii) Measure dimension “a” in the condition in
Step i) above.
&II
X07HH047
I
25
X07HH045
a
-.-.. --__- _ XO7HHO45
30-29
0
21. DISASSEMBLY AND ASSEMBLY FINAL DRIVE
iii) Measure thickness “b” of nut itself.
iv) Calculate a - b = c.
v) Using tool G,, tighten nut (24) to a point
where dimension “d” is cj,,
vi) Using push-pull scale 8, measure
tangential force in direction of rotation of
hub in relation to motor case.
* Tangential force: Max. 294.2 N (30 kg)
* The tangential force is the maximum
force when starting rotation.
vii) Install lock plate (23).
* Install the lock plate as shown in the
diagram below.
Casting notch
X07HHOSO
Thread of mounting bolt: Thread
- tightener (LT-2)
* Do not coat the tap portion of the nut
with thread tightener (LT-2).
3. No. 2 carrier assembly
1) Assemble No. 2 carrier assembly as follows.
* There are the remains of the caulking when
the pin is inserted at the end face of hole h
at the side of the carrier, so remove the
caulked metal from the inside diameter of
the hole before starting to assemble.
i) Assemble bearing (21) to gear (20) fit top
and bottom thrust washers (19) and (20)
and set gear assembly in carrier (18).
30-30
0
22. DISASSEMBLY AND ASSEMBLY FINAL DRIVE
ii) Align position of pin holes of shaft and
carrier, then tap with a plastic hammer to
install shaft (17).
* When installing the shaft, rotate the
planetary gear. Be careful not to
damage the thrust washer.
iii) Insert pin (16).
* After inserting the pin, caulk the pin
portion of the carrier.
* After assembling the carrier assembly,
check that gear (20) rotates smoothly.
2) Install No. 2 carrier assembly (15).
4. Thrust washer
Install thrust washer (14).
5. No. 2 sun gear
Install No. 2 sun gear (13).
6. No. 1 carrier assembly
1) Assemble No. 1 carrier assembly as follows.
* There are the remains of the caulking when
the pin is inserted at the end face of hole h
at the side of the carrier, so remove the
caulked metal from the inside diameter of
the hole before starting to assemble.
i) Assemble bearing (10) to gear (9) fit top
and bottom thrust washers (8) and (11) and
set gear assembly to carrier (7).
Ii - X07HH056
h
9
XO7HHOS
30-3 1
0