Usage:
Start By:
a. remove bucket
1. Start the engine. Extend the stick, and lower it to the ground.
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At operating temperature, the hydraulic oil tank is hot and under pressure. Hot oil can cause burns. To prevent possible personal injury, release the pressure in the implement hydraulic circuits (boom, stick and bucket) before any hydraulic lines or components are disconnected or removed. |
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- a. Shut off the engine, and put the hydraulic activation control lever in the "Lock" position.
- b. Move the control levers for the boom, bucket, stick and swing through their full travel strokes. This will relieve any pressure that may be present in the pilot system.
- c. Slowly loosen the air breather cap on the hydraulic oil tank to release the pressure.
- d. Tighten the air breather cap on the hydraulic oil tank.
- e. The pressure in the hydraulic system has now been released. Lines and components can now be removed.
- b. Move the control levers for the boom, bucket, stick and swing through their full travel strokes. This will relieve any pressure that may be present in the pilot system.
2. Release the pressure in the hydraulic system as follows:
3. Install tool (A) under the front of the boom to support it.
4. Fasten a lifting strap and a hoist to the rod end of the stick cylinder as shown.
5. Remove pin assembly retaining bolt (1) and the washer.
6. Using tooling (B), remove pin assembly (2) and spacer (3). Put a small wood block under the rod end of the stick cylinder, and lower the cylinder onto the wood block. Tie the rod in the stick cylinder back so it can not extend.
7. Reinstall pin assembly (2) and pin assembly retaining bolt (1) and the washer back in the stick pin bore.
8. Fasten lifting straps and a hoist to the stick. Fasten the hoist at pin assembly (2) and the bucket link assembly for the bucket as shown.
9. Disconnect two hose assemblies (4) from the stick.
10. Remove pin assembly retaining bolt (5) and the washer from pin assembly (6).
11. Be sure the threaded puller hole in pin assembly (6) is clean prior to installation of tooling (F). Fasten tooling (F) to pin assembly (6). Fasten a lifting strap and a hoist to tooling (F) to support it.
12. Using tooling (F), remove pin assembly (6) far enough until the stick is free of the boom. Do not remove pin assembly (6) completely out of the boom.
13. Remove tooling (F) from pin assembly (6). Remove pin assembly (6) by hand. The weight of the pin assembly is 41 kg (90 lb).
NOTE: Stick weights can range from approximately 963 to 1324 kg (2123 to 2919 lb).
14. Carefully separate the stick from the boom. The combined weight of the stick, bucket cylinder and bucket linkage group is approximately 1633 kg (3600 lb).
NOTE: Some machines may be equipped with shims between the stick and boom at the stick-to-boom pin joint. For assembly purposes, put identification marks on the shims as to their location.
15. Remove the shims (if so equipped) at the stick-to-boom pin joint.
16. Remove two lip-type seals (7) from the stick at the stick-to-bucket pin joint.
17. Remove two lip-type seals (8) from the stick at the stick-to-boom pin joint.
NOTE: For the removal of the lip-type seals and bearings from the stick at the stick-to-bucket linkage pin joint, see the topic "Remove & Install Bucket Linkage Group" in this module.
18. Remove the two bearings from the stick at the stick-to-boom pin joint and the stick-to-bucket pin joint with tooling (C). Fasten tooling (C) to the stick as shown. Fasten a hoist to tooling (C) to support it; then remove the bearing. Remove the other bearings in the stick the same way.
NOTE: The following steps are for the installation of the stick.
| NOTICE |
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Be sure the pin bores in the stick are clean prior to installation of the bearings and lip-type seals. |
19. Install the two bearings in the stick at the stick-to-boom pin joint. Lower the temperature of the bearings, and install them in the pin bore until each one is 9.5 ± 0.8 mm (0.37 ± 0.03 in) below the outside surface of the stick.
20. Install the two bearings in the stick at the stick-to-bucket pin joint. Lower the temperature of the bearings, and install them in the pin bore until each one is 9.5 ± 0.8 mm (0.37 ± 0.03 in) below the outside surface of the stick.
| NOTICE |
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To prevent dirt and debris from entering the pin bores in the stick, install lip-type seals (7) and (8) with the sealing lip facing toward the outside of the pin bores. |
21. Using tool (D), install the two lip-type seals (8) in the stick at the stick-to-boom pin joint. Install the seals with the sealing lip facing toward the outside of the pin bores and until each one makes contact with the bearing.
22. Using tool (D), install the two lip-type seals (7) in the stick at the stick-to-bucket pin joint. Install the seals with the sealing lip facing toward the outside of the pin bores and until each one makes contact with a bearing.
23. Put a thin coat of 5P0960 Multipurpose Grease on the bearings and seals in the stick.
| NOTICE |
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Be sure the pin bores in the stick and boom are clean and free of dirt prior to installation of the stick. |
24. Fasten a hoist to the stick, and put it in position in the boom. Put the pin bores of the two components in alignment with each other. It may be necessary to move the stick and boom to align the pin bores. Be sure the threaded puller hole in pin assembly (6) is clean. Put a thin coat of 5P0960 Multipurpose Grease on pin assembly (6). Install tool (G) in the end of the pin assembly. Temporarily install pin assembly (6) with a hammer. Remove tool (G) from the end of the pin assembly. Do not remove the hoist from the stick at this time.
25. Slide the stick to one side until it makes contact with the boom. Measure the total clearance between the stick and boom at the pin bore. The total clearance must not be more than 1.6 mm (0.06 in). If the total clearance is less than 1.6 mm (0.06 in), the addition of shims between the stick and boom will not be required. If the total clearance is more than 1.6 mm (0.06 in), add the correct thickness of shims to obtain the necessary clearance.
26. If it has been determined that shims need to be installed between the stick and boom, remove pin assembly (6). Install the shims between the stick and boom on the side opposite pin assembly retaining bolt (5); then reinstall pin assembly (6). Install the washer and pin assembly retaining bolt (5). Tighten the pin assembly retaining bolt to a torque of 325 ± 40 N·m (240 ± 30 lb ft). Remove the hoist from the stick.
27. Check the condition of the O-ring seals in the ends of hose assemblies (4). If any of the seals are worn or damaged, use new parts for replacement. Reconnect two hose assemblies (4) in their original locations.
28. Remove pin assembly (2) from the stick.
29. Fasten a hoist to the rod end of the stick cylinder. Raise the stick cylinder, and remove the wood block from under it. Align the pin bore in the rod end of the stick cylinder with the pin bore in the stick. Using tool (E), install spacer (3) and pin assembly (2). Install the washer and pin assembly retaining bolt (1). Tighten the pin assembly retaining bolt to a torque of 325 ± 40 N·m (240 ± 30 lb ft).
30. Fill the hydraulic oil tank with oil to the correct level. Lubricate the stick and stick cylinder mounting pins. See the Operation & Maintenance Manual for the correct procedure.
End By:
a. install bucket