INTRODUCTION
Basic instructions - Precaution for disassembly and assembly
Preparations for disassembly
• Thoroughly wash the machine before bringing it into the shop. Bringing a dirty machine into the shop may cause
machine components to be contaminated during disassembling/assembling, resulting in damage to machine com-
ponents, as well as decreased efficiency in service work.
• Be sure to thoroughly understand all disassembling/assembling procedures beforehand, to help avoid incorrect
disassembling of components as well as personal injury.
• Check and record the items listed below to prevent problems from occurring in the future.
1. The machine model, machine serial number, and hour meter reading.
2. Reason for disassembly (symptoms, failed parts, and causes).
3. Clogging of filters and oil, water or air leaks, if any.
4. Capacities and condition of lubricants.
5. Loose or damaged parts.
• Prepare the necessary tools to be used and the area for disassembling work.
• Wear appropriate clothing, safety shoes, safety helmet, goggles, and clothes with long sleeves.
• Confirm ready access to a first-aid kit and fire extinguisher, as well as appropriate emergency personnel contacts
in the case of a medical accident or fire.
• Before performing any work on the machine, follow lockout/tagout procedures by attaching a “maintenance in
progress tag”. This tag can be applied on the left-hand control lever, safety lever or cab door. Notify those with
access to the machine that you will be performing the maintenance.
Disassembling and assembling hydraulic equipment
• Before removing lines, release the pressure of hydraulic oil tank, or open the cover on the return side to tank, and
take out the filter.
• Drain the oil in removed lines into an appropriate container to prevent oil contamination.
• Protect open connections with plugs or caps to prevent oil from leaking and debris from contaminating the system.
• Thoroughly clean the outside of components before disassembling, and drain hydraulic oil and gear oil before dis-
assembly.
Disassembling hydraulic equipment
• Impaired performance and function of hydraulic equipment after unauthorized service may not be covered under
warranty by the manufacturer. Consult your local dealer for service.
• If it is unavoidably necessary to disassemble and modify, it should be carried out by experts or personnel qualified
through service training.
• Make match mark on parts for reassembling.
• Before disassembling, read instructions in advance, and determine if the service is required to be performed by an
authorized dealer.
• Use appropriate specialty tools and jigs if required.
• If parts can not be removed as specified by the procedure, never force removal. Check for other failures that may
be causing binding or interference.
• Inspect parts for wear and clearance; record the measured values. Replace components if the values fall outside
of the recommended range.
• If an abnormality is detected, repair or replace the parts.
• When removing parts, use appropriate markings or labels to ensure they can be reinstalled in the correct order and
location without confusion.
• For common parts, pay attention to the quantity and locations of each group of components.
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