7. ADJUSTMENT AND REPAIR

4)Reassembly

Reassemble the hydraulic cylinder in the reverse order of the disassembly procedure.

Notes :

•Take care not to install the cushion plunger 12 of the boom cylinder in the wrong direction.

•Replace the O-rings, packings and seals with new ones.

U-nut Size end Tightening Torque

No.CylinderU-nut sizeU-nut tightening torqueAdhesive

2.Removal and Reinstallation of Hydraulic Oil Tank 1)Removal

Procedure

(1)Swing the upperstructure so that the drain plug 1 of the hydraulic oil tank is positioned halfway between the right and left crawlers. Then, lower the bucket to the ground and stop the engine.

(2)Remove the drain plug 1 from the hydraulic oil tank and drain the hydraulic oil.

Hydraulic oil quantity4.36 Gals. (16.5L)

(3)Remove the step 3, the panel L 4, and the panel R 5

(4)Remove the panel R 5, and then disconnect the harness connectors.

(5)Disconnect the battery cable (negative) 6 and the battery cable (positive) 7 and remove the battery clamp 8, and then remove the battery 9

Procedure

(6)Remove the cover R 10 and the cover L 11

(7)Remove the plates in the left and right (the cover 12 and 13).

(8)Remove the operator’s seat bracket 14 (with the operator’s seat), and then remove the operator’s seat plate 15

(9)Remove the snap pin 17 and disconnect the accelerator cable 16 from the accelerator lever 18

(10)Remove the snap pin 20 and disconnect the blade cable 19 from the blade lever 21.

(11)Remove the nut 23 and disconnect the adjustable leg lever 22 from the link.

(12)Remove the pilot valve 24 and 25 in the left and right with the hydraulic hose attached.

(13)Disconnect the harness 26 from the fuel gauge unit.

(14)Disconnect the connecting coupler 29 of the harness A 27 and harness B 28

(15)Disconnect the body ground terminal 30

(16)Disconnect the connections of the dual speed travel switch 31, the horn 32 and working lamp 33

(17)Remove the canopy 34

: Take care that the harnesses and clamps do not catch on any other parts when lifting up the operator’s seat mount.

Procedure

(18)Loosen the hose clip 36 on the air cleaner side and remove the air cleaner hose B 35

(19)Remove the water separator 38 from the operator’s seat mount 43 and disconnect the fuel hose 37 on the water separator 38 side.

(20)Remove the fuel hose 39, 40, 41, 46 on the fuel filter 42 side.

(21)Rope the operator’s seat mount 43 (with the bonnet and the air cleaner 44 ) and lift it up, to remove it.

Note : Take care that the harnesses and clamps do not catch on any other parts when lifting up the operator’s seat mount.

(22)Remove the hoses connected to the reservoir tank 46 a. Suction hose b. Return hose (control valve to reservoir tank) c. Return hose (control valve to reservoir tank) d. Return hose (remote control valve to reservoir tank)

(23)Remove the joint 47 from the reservoir tank 46, and then remove the reservoir tank 46

2)Reinstallation

Reinstall the hydraulic oil tank in the reverse order of the removal procedure.

Notes :

[1]Completely drain the oil from the hydraulic oil tank and wipe off the deposits from the bottom of the tank.

[2]Replace the return filter 3 with a new one.

[3]Clean the strainer 10. Replace it if the wire gauze is damaged.

[4]Replace the oil when it reaches the replacement time or it has been deteriorated. If reusing the oil, maintain the oil quality so that it has no impurities.

[5]Check the O-rings 8 of the oil level gauge 6 for oil leak. If any oil leak is found, replace the O-ring.

[6]Hydraulic oil to be used :

TypeVG 46 class or its equivalent

3)Oil Level Check

(1)Place the machine on firm and flat ground when checking the hydraulic oil level.

(2)Check the hydraulic oil level with the oil level gauge when the oil temperature is between 32 °F (0°C) and 86°F (30°C).

(3)The proper oil level is 0.394 in. (10 mm) above the middle of the oil level gauge. The hydraulic oil level increases or decreases depending on the hydraulic oil temperature due to its nature; therefore, check it when the oil is cooled.

4)Machine Position for Oil Level Check

(1)Retract the bucket and arm cylinder rods fully to lower the bucket to the ground.

(2)Lower the blade to the ground.