Case 50 Crawler D Series User manual

50 Crawler Series D
Service Manual
S 406236M2
IReprinted I

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GENERAL
TABLE OF CONTENTS
GENERAL
Safety Precautions ................................................................... 3,4
Introduction .......................................................................... 5
Nomenclatureand General Description
.................................................. 6,7
Specifications ........................................................................ 8
SECTION 1 • SCHEDULED PREVENTIVE MAINTENANCE
Introduction .......................................................................... 9
Hydraulic Oil Recommendations
........................................................ 10
Hydraulic System Operating Pressures .................................................. 10
Component Capacities ................................................................ 11
Rated Pump Output ............................... · .................................... 11
Maintenance Chart ................................................................. 12, 13
Illustrated Listing of Grease Fittings .................................................. 14,15
Itemized Maintenance
Instructions ................................................ 16 thru 21
SECTION 2 · MECHANICAL SYSTEM
Undercarriage ......................... : ....................................... 22 thru 30
Engine and Related Parts ................................... : .................... 31 thru 34
Turntable Swing .............. , ....................... ; ....... , .......... , ...... 34 thru 39
aoom and Attachments ........................................ : ................ 39 thru 42
SECTION 3 • ELECTRICAL SYSTEM
Introduction ,; ........................................................................ 43
12/24 Volt System (Machines through PIN 6280344) ... , .............................. 44 thru 52
24 Volt System (Machines with PIN 6280345 and After) ................................ 53 thru 60
Control Circuits ... · ................................................................... 61
Lights and Instrumentation Circuits ..................................................... 62
SECTION 4 · HYDRAULIC SYSTEM (For pressures, see page 10)
Introduction ......................................................................... 63
System Maintenance ........................................................... 64 thru 66
Main Hydraulic System .......................................................... 66 thru 80
General Description ................................................................. 66
Hydraulic Pump .................................................................... 68
Main Control Valves ................................................................. 70
Port Relief Valves ................................................................... 73
Explanation of "Summated" System ................................................... 76
Power Sensing Valve .............................................................. 76
Main Relief Valves ................................................................ 78
Track Drive Hydraulics .......................................................... 81 thru 87
Drive Motor Circuits ................................................................. 81
Digging Brake Release Circuit ........................................................ 85
Solenoid Control Valve .............................................................. 85
Hydraulic Swivel
................................................................... 86
Swing Hydraulics
..................................................................... 88
Hoist Hydraulics ..................................................................... 90
Hydraulic Circuits to Crowd Cylinderand Tool Cylinder ..................................... 92
Leveler Hydraulics .................................................................... 93
PilotControl System ............................................................ 94 thru 97
1
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GENERAL
TABLE OF CONTENTS (CON'T)
SECTION 5 - TROUBLESHOOTING
Introduction ......................................................................... 98
Engine
............................................................................. 100
Undercarriage
....................................................................... 100
Electrical System .................................................................... 102
Pilot Control System ................................................................. 107
Main
Hydraulic System ............................................................... 107
Track Drive System
.................................................................. 109
Swing System ....................................................................... 110
Cylinder Circuits .................................................................... 111
Main Pump ......................................................................... 112
Main
Control Valves .................................................................. 113
Relief Valves
........................................................................ 114
SECTION 6 - DISASSEMBLY AND REPAIR
General Cleaning Instructions ......................................................... 115
leveler Assembly .................................................................... 116
Track Chain
......................................................................... 117
Track
Adjustment Cylinder ............................................................ 118
Track Rollers
........................................................................ 119
Idler Wheel ........................................................................ . 121
Digging Brake ....................................................................... 123
Final Drive
Transmission ........... · .................................................. 125
Engine and Pump Drive
............................................................... 131
House Brake ........................................................................ 133
Swing Gearbox .................................................................. , ... 135
Turntable Bearing Replacement
........................................................ 143
Boom
.............................................................................. 149
Wiring Harness Replacement .......................................................... 150
Main
Hydraulic Pump ................................................................ 150
Pilot Hydraulic Pump ................................................................. 159
Main
Control Valves ................................................................... 160
Power
Sensing Valve ................................................................. 165
Pilot
Control (Modulator) Valves ........................................................ 166
Track Drive
Motor .................................................................... 172
Swing Motor ........................................................................ 180
Swing Cushion Valve ................................................................. 191
Leveler Lock Valve ................................................................... 192
Hydraulic Swivel .................................................................... 194
Hydraulic Cylinders .................................................................. 197
Hydraulic Oil Tank .................................................................. .202
Solenoid Control Valve ............................................................... 203
TORQUE CHARTS AND SCHEMATICS ................................................. 204 thru 208
2
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A SAFETY
THIS SAFETY
ALERT
SYMBOL INDICATES
IMPORTANT SAFETY MESSAGES
IN
THIS
MANUAL, WHEN
YOU SEE THIS
SYMBOL,
CAREFULLY
READ
THE
MESSAGE THAT
FOLLOWS
AND
BE
ALERT TO THE
POSSIBILITY OF PERSONAL INJURY
OR
DEATH.
WARNING:
Always use a non-flammable
A
solvent for cleaning parts.
DO
NOT use
~
gasoline
or
other
flammable
substances.
Whenever
servicing
the machine,
A
always ta§ mark the ignition switch to
~
alert
other
operators
and prevent
accidental start-ups.
A
WARNING:
To help prevent eye injury,
wear eye protection when servicing this
machine.
A
CAUTION:
When checking coolant level,
remove cap on radiator slowly to relieve
pressure within the system.
CAUTION:
Disconnect both leads from
A the
batteries
when
working
on
the
engine
or
electrical
system.
Always
disconnect the Ground lead first.
WARNING:
Use
extreme
care
when
A handling the track. Never insert fingers
between track shoes when removing
track.
GENERAL
A
DANGER:
Exhaust
fumes
can
kill.
If
necessary
to
start
engine
in
an
enclosed
area, be sure
to
provide
adequate ventilation.
A
CAUTION:
ENGINE FAN AND BELTS ·
To prevent possible serious injury avoid
contact with rotating fan and belts.
A
DO
NOT wear loose clothing which may
~
catch in moving parts.
3
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GENERAL
'4
CAUTION:
The
idler
wheel
spring
is
A
under
tension.
If
for
any reason
this
~
spring
must
be removed, use EXTREME
caution.
I
A
WARNING:
To
avoid personal
injury,
keep hands clear
of
turntable
ring gear
w,hile
turntable
is
being rotated.
Keep a fire extinguisher on hand and
A
KNOW
HOW
TO USE IT. Check
it
regul~rly to ensure
it
is in good working
order.
A
WARNING:
Any changes to the
controls
must be clearly noted and posted in the
Operator's Cab.
If
any
control
changes
are made, a new
Operator's
Control
Pattern decal
must
be installed in the
cab
to
warn
other
operators
of
the
changes.
A
Wipe oil spills, immediately and keep
work
area as
clean
as
possible.
A
cluttered work area invites accidents.
A
A
WA
RN
I
NG:
Never operate the
alternator
on
an
open
circuit.
With
no
battery
or
other electrical load on the
circuit,
a
voltage
buildup
will
occur
within
the
alternator. This voltage
buildup
could
be
extremely dangerous
to
anyone
touching
the alternator
"BAT"
terminal.
CAUTION:
When releasing grease from
the track
adjustment
cylinder, loosen
the
adapter
SLOWLY. Very
high
pressure can
exist
in the
adjustment
cylinder
when
under
tension.
The
adapter
fitting
could fly loose and cause
personal injury.
When
bleeding
brakes,
loosen
bleeder
A
plug
approximately
one-half
to
three-
quarter
turn
or
until
oil
just
starts
to
flow.
If
plug
is
loosened
too
far,
it
may
be
blown
out
under
pressure.
A
CAUTION:
Engage Digging Brake
whenever the
unit
is
not
"crawling."
Accidental engagement
of
the Drive
Lock
Switch
will
cause
the machine
to
immediately
move in the
forward
direction.
A
Never smoke
while
refueling, servicing
the
fuel
system
or
working
with
batteries.
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GENERAL
GENERAL INFORMATION
INTRODUCTION
This manual provides instructions for maintenance
and service
of the DROTT 50 series "D" Crawler. All
components and systems are included, with the
exception
of the engine which is covered in the
engine manufacturer's manual supplied with each
machine.
The manual is divided into six sections, preceded by
a general section on safety, machine description and
specifications.
A separate section entitled "Scheduled Preventive
Maintenance" is provided to cover all components
which require periodic maintenance. Refer
to this
section whenever performing normal maintenance.
It
includes a Maintenance Schedule, Component
Capacities, Hydraulic System Operating Pressures,
MaintenanceChart and Maintenance Details.
The Service section is divided
into three general
areas -
Mechanical, Electrical and Hydraulic.
Included in the Service section is general descriptive
and
operational information to provide a basic
understanding of each system and its components.
All disassembly and repair information is contained
in the last section
of the manual and arranged in the
general sequence established in the service section,
i.e. Mechanical, Electrical and Hydraulic.
Troubleshooting charts for all the systems are
contained in a separate section (See Section
5).
Torque Charts and Schematic Drawings of the
Electrical and Hydraulic systems are located in back
of this manual for easy reference when
troubleshooting the machine.
If further service information is required, contact
your nearest DROTT dealer or Service
Representative forassistance.
EXPLANATION OF INTERNATIONAL SYMBOLS
Symbols are a universal language. International
symbols are used in
this manual to help identify
components requiring service.
PARTS AND SERVICE
When writing to the dealer or manufacturer about
your DROTT machine, always give reference to the
model and
PIN (Product Identification Number) in
addition to the part name and location. The
PIN plate
is on the lower right corner
of the cab (Figure 1).
All main components of the machine have an
identification plate or number on the component
housing. The location
of the engine serial plate is
shown in Figure
2.
PRODUCTIDENTIFICATION Al
NUMBER PLATE
~=====[___===== ... -~
Figure 1. Machine Identification
- ~·'€'---
. J cg
.
11
1
~CASE
rr~,----- ENGINE TROIT DIESEL
---
- ---~-
~--
~~
Figure 2. Engine Serial Plate
EQ]
rll
♦
(f)
GIAR BOK
HYQt,h111l 1(
HYDRAULIC
NI ",f MVOUI
FILTER
FIL TIii AUi
9 © JI)
....--...
0
COOI.Afllf
IIIIGIIII OIL
OIISIL fUIL
LUBRICATE•••"
MwlhpurlhJkG•,.••
5
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GENERAL
NOMENCLATURE
I
~
6
1.
Backhoe Bucket {Tool)
2.
Tool Link
3.
Side Levers
4.
Tool Cylinder ·
5.
Dipperstick
6.
Crowd Cylinder
7.
Main Boom
8.
Hoist
Cylinder
9.
Operator's Cab w/Controls
10.
Location
of
Main Control Valves
and Hydraulic Oil Tank
8
NOTE: Machine shown
in
Digging
Position (front of turntable over
rear
of
undercarriage).
'II/A
·•
®-t~~~~~·=;;;:;:::::l.
Figure
3.
Nomenclature
11.
Engine Compartment and Location
of
Hydraulic Pumps
12.
Counterweight
13.
Idler
Wheel
14.
Location
of
Track Adjuster
Cylinder
15.
Leveler Assembly (Optional)
16.
Turntable Bearing
17.
Final Drive Transmission
18.
Location
of
Fuel Tank and
Swing Mechanism
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GENERAL
DIRECTIONAL REFERENCE
The turntable on this machine rotates through a full
360 degrees. The normal
driving posi.tion is with the
Boom over the front of the undercarriage (track drive
transmission to the rear), as shown in figureA. In this
position, directional callouts for both the turntable
and the undercarriageare the same. All references to
Front, Rear, Right and Left will be made with respect
to this position. RIGHT is the Operator's right; LEFT
is the
Operator's left.
~I
V
E
L
LEFT m FRONT
RIGHT I"".~
IDLER
REAR
!UNDERCARRIAGE)
OPERATOR
SI TS
HERE
LEFT RIGHT
{TURNTABLE)
Figure 4. Directional Referer:ce
GENERAL DESCRIPTION
FRONT
REAR
The Drott 50 Crawler is a fully hydraulic excavator.
Engine
power is converted to hydraulic energy, then
reconverted
to mechanical force by means of
cylinders and motors.
single spool valve (optional) to the machine's
functions. To get maximum use of the engine's
power, a "Power Sensing" valve is connected
between the two main pumping circuits.
In the hydraulic system, oil from a 2-section gear
pump is routed through two 4-spool valves and a Figure 5
shows the distribution of the engine power
to the
hydraulic and electrical systems. The machine
has a
pilot·operated hydraulic control system.
SWING
MOTOR
BRAKE
GEARBOX
SWING· CROWD
LEFT TRACK -FAST HOIST
CONTROL
VAL VE
CYLINDER
CIRCUIT
GEARBOX
HOIST-TOOL
AUX
RIGHT TRACK -AUXILIARY
----; VALVE
CONTROL VALVE (OPT.)
LEVELER
- - •
-.: CYLINDERS
CIRCUIT
2 SECTION
HYO. PUMP
HOIST
CYLINDER
CIRCUIT
AUXILIARY
CIRCUIT
L
-· r' _____ T _______ _
I I
I I
GEARBOX
,-
1
I
I ---~ I
I
I
I L - - - - - - - - - - - - - -
-.J
L- - - - - - - - - - - - - - - - -- - - - - - - - - -
Figure 5. Block Diagram - SOD Crawler
30LENOIO
CONTROL
VALVE
MODULATOR
VALVES
ENGINE
CHARGE
PUMP
I
I
I
J
7
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GENERAL
SPECIFICATIONS
ENGINE:
Detroit Diesel 6V-53N
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diesel, 2 stroke cycle,
Case
504
BOT
Diesel, 4 stroke cycle,
turbocharged
Number
of
cylinders
..........................
.
Bore
........................................
.
Stroke
......................................
.
Displacement
................................
.
Compression Ratio
...........................
.
Horsepower
SAE
Net
..........................
.
Horsepowerat Gov. Speed
.....................
.
High (no load) rpm
............................
.
Load rpm
..................................
.
Idle speed
.................................
.
Undercarriage:
naturally aspirated
6
3.875 in (98.4 mm)
4.5
in (114 mm)
318
cu in (5.2 litre)
21
to
1
174
(129.8 kW)
190
(141.7 kW)
2530
2400
550-600
6
4.625 in (117.5 mm)
5 in
(127
mm)
504 cu in (8.2 litre)
15.8
to
1
189 (140.9 kW)
206
(153.6 kW)
2230-2270
2100
725-775
Track Frame
.........................................
,
...
,.
.........
Rigid, welded
constrution
Track Idlers
........................................
Sealed hub, spring cushion, hydraulic adjust
Crawler Drive
.........................................
Hydraulic gear motor, spurgear final drive
Track Brake
....................................
Hydraulically released disc, on
input
to
final drive
Track Rollers
......................................
Cast and machined construction, sealed hub
Carrier Rollers
................................
Cast and machined
construction,
sealed, 2 perside
Track Gauge -Narrow Position
....................................................
8
ft
(2.43
m)
Track Gauge
-Wide
Position
......................................................
9
ft
(2.74
m)
Electrical System:
Machines through
PIN
6280344
........................
24
volt start,
12
volt operating,
direct
current
negative ground;
72
amp alternator
Machines
with
PIN
6280345 and
After
.......................
24
volt,
direct
current, negative ground
42
amp alternator
Hydraulic System:
Type
..........................................................
Two pump circuits, summated
Pump (Main)
.........................................
Two section gear, driven
off
rear
of
engine
Main Control Valves
.......................
Two 4-spool valves, single spool auxiliary valve optional;
Series and parallel spool
for
simultaneous operation
of
two
or
more
functions
Filters
.........
Two 100 mesh·screens and
two
10
micron full
flow
filters
in return lines; four 140 mesh
screens in
summator
system;
two
screen
diffusers
and
filler
screen in tank
Cylinders
.........
Double-acting type for hoist, crowd, tool and auxiliary
functions,
·single-acting type
for optional leveler
Motors
............................
Gear type
for
swing and track drive functions, internally-valved,
two-speed
motor
for
track drive
Turntable
Swing:
Single race ball bearing
with
integral ring gear; powered by hydraulic gear
motor
through DROTT gearbox. Mei::hanicalry actuated
disc
brake on input to gearbox (for
holding
brake
only).
Boom Options:
"E"
Main Boom
with
9 ft. (2.7
m),
10
ft.
5 in.
(3.2
m),
or
12
ft. (3.65 m)
dipperstick
Attachment
Options:
Standard and Severe Duty
backhoe buckets,
Ditch
Bucket, Front Loading
Bucket, Ripper Tooth, Wrist-O-Twist, Turntable
Leveler.
8
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PREVENTIVE MAINTENANCE
SECTION 1
SCHEDULED PREVENTIVE MAINTENANCE
INTRODUCTION
Scheduled preventive maintenance is necessary to
keep the machine in top operating condition. Decide
from the start upon a maintenance schedule that
will
best suit your particular needs. The type of work
being done, the size
of loads, and ground and
weather conditions should all be taken into
consideration when establishing a schedule.
Use the engine hourmeteralong
with a calendar and
checklist to ensure that all recommended
maintenance is performed at the prescribed
intervals. Recommendations contained in this
manual are based upon average operating
conditions, and should be considered as MINIMUM
maintenance requirements for the CRAWLER.
Depart from recommended intervals only when
conditions warrant shortening them, or when
changes in ambient temperature require it.
Recommended intervals should be shortened
whenever the machine is operated under extreme
conditions, such as on a
dusty job site, in extreme
heat
or cold, under intermittent operation or
extremely heavy loads.
LUBRICANTS
It is not the policy of J I Case, Drott Division, to
publish lists of approved lubricants or to guarantee
lubricant performance. The responsibility
for the
quality of any lubricant rests solely with the distributor
ormanufacturer
of the lubricant.
In various paragraphs
of this manual, you will find
the statement "Use (lubricant brand name) or
functional equivalent". This statement does not
constitute an unconditional guarantee of the
performance of the brand of oil mentioned; it is
intended only as a guide
to the type of lubricant
recommended fora given application.
SOUNDPROOFING INSULATION
Care must be taken when cleaning the cab interiors
that have soundproofing insulation. To clean the
insulating material, use
only a vacuum cleaner or
damp cloth
with plain water or mild detergent
solution.
DO NOT steam clean, wash or rinse with a water
hose, etc., since only
slight wetting of the insulation
will substantially reduce its soundproofing
capabilities.
SPARK ARRESTOR
Laws of some states or provinces may require that
this unit be equipped with a spark arrestor or spark
arresting muffler. The State
of California, as an
example, is one state which has such regulations
for
agricultural and forestry applications, plus a
regulation for
construction applications in forest-
covered, brush-covered orgrass-covered lands.
Typically, such laws and regulations require spark
arresting devices
to be maintained in good working
order and
typically to be attached to the exhaust
system on naturally aspirated engines (engines
without aturbo-charger).
IMPORTANT: Always Install new decals whenever the old decals are
destroyed, lost, painted over, or Illegible. When Individual parts are replaced
that have dec3ls attached, be sure to Install a new decal with the new part.
Replacement decals are available from your Drott dealer.
9

PREVENTIVE MAINTENANCE
HYDRAULIC OIL RECOMMENDATIONS
Drott DHF Fluid is recommended for year-around
use in the hydraulic system; or as alternate, use
oils
listed below:
SYSTEM
OIL WEIGHT OPERATING TEMPERATURE
SAE20-20W 50°
to 210° F (10° to 99° C)
SAE 10W 0° to 180° F
(-18° to 82° C)
SAE 5W or5W-20 Arctic Conditions
Viscosity: The viscosity
of the oil at starting should
not exceed 9000 SSU or drop below 60 SSU for
sustained high temperature operation. The
optimum
operating conditions are between 80 SSU and 180
SSU. The viscosity index should not be less than 90
(for this service).
Arctic Conditions: The use of an auxiliary heater, a
warm-up period avoiding high speed operation
of
hydraulic components until the system is warm, and
the use
of SAE 5W or SAE 5W-20 oils may be
necessary, provided the viscosity requirements for
sustained high temperature operation are not
exceeded at maximum operation temperatures. See
preceding paragraph on Viscosity.
HYDRAULIC SYSTEM
OPERATING PRESSURES
VALVE
PRESSURE SETTING
PSI
kPa
Main Reliefs 3300 22 700
Hoist Port Reliefs 3400 23 400
Crowd Port Reliefs 3400 23 400
Tool Port Reliefs 3400 23 400
SwinQ Port Reliefs 2500
17 200
Track Port Reliefs 2500
17 200
Power Sensing Reliefs
Case
2800
19 300
D.D.
2600
17 900
Pilot System Relief 550 3 800
Swing Cushion Relief 1550 10 700
Leveler (optional)
2500
17 200
10

PREVENTIVE MAINTENANCE
COMPONENT CAPACITIES
Component Lubricant/Fluid Capacity
Engine Cooling System ½ ethylene
glycol base anti-freeze,
8½ gal. (32 L)
½ water
Engine Crankcase See Engine Manufacturer's Manual See Specifications, page 8
Fuel Tank No. 2 Diesel Fuel, See Engine Manual
75 gal. (284 L)
Hydraulic System (Complete) DROTT 65 gal. (246
L)
DHF Fluid
or
Hydraulic Oil Tank See Page
10
25 gal. (95 L)
Final Drive Transmissions
HD80-90 Gearlube 14 qts. (13.2 L)
Swing Gearbox HD80-90 Gearlube
11 pts. (5.2 L)
Turntable Bearing Ring Gear Open Gear Lubricant, such as Mobil Apply liberal amount. Rotate
Mobitac
E, Texaco CraterCompound, turntable so pinion spreads the
or functional equivalent lubricant
Pressure Grease
Fittings
Multipurpose E.P. No. 2 lithium
Use sufficient amount to remove
grease,
molydisulfide grease, or the old, contaminated grease at
functional equivalent each location (See
List of
Grease Fittings)
RATED PUMP OUTPUT® GOV. RPM
OUTPUT PER SECTION
ENGINE GPM L/MIN
Detroit Diesel 6V-53
65
246
Case504 BOT
67
253
11

PREVENTIVE
MAINTENANCE
MAINTENANCE CHART
Figure
6.
Maintenance
Chart
12

RE_F.
COMPONENT/SYSTEM
1 ENGINE X X
2 RADIATOR, COOLING X
SYSTEM
X X
3 AIR CLEANER X X
4 BATTERIES X
5 FUEL
TANK
X X
6 SWING GEARBOX
X
7 TURNTABLE BEARING X X
8 TURNTABLE X
CAPSCREWS
9 TRACK X X
10 LUBRICATION X X
FITTINGS
11 HYDRAULIC FILTERS X
12 HYDRAULIC OIL TANK
X X
13
FINAL DRIVE TRANS. X
14 CAB and CONTROLS X X
15
BOOM and X
ATTACHMENT
X
X
X
X
X
PREVENTIVE MAINTENANCE
PREVENTIVE
MAINTENANCE CHART
SERVICE/CHECK INSTRUCTION
Check oil, drain fuel filter
See Engine Manual
Change oil and
filters See Engine Manual
Check coolant level See page 16
Clean fins, remove
obstruction, check fan belts
See page32
Check specific gravity, add corrosion inhibitor See page 31
Drain and flush system See Engine Manual
Check restriction indicator, empty dust cup See page 17
Clean or replace element See page 17
Check electrolyte level (except "Maintenance Free"
See page 17
type)
Clean battery case,
posts and connections See page 17
Fill at end of shift, drain water from tank See page 17
Clea~ br-eather See page
17
Check oil level See page
18
Change oil, clean breather See page
18
Lubricate the ring gear See page 18
Lubricate the bearing race (thru Central Lube) See Illustrated Listing
Check torque (See also "Special Maintenance" See page36
below)
Grease
pillow blocks, clean tracks See Illustrated Listing
Check and adjust track tension See page25
Apply grease per intervals in Illustrated Listing
See page 14
Clean 100 mesh screens, replace paperelements See page 19
Check oil level See page 19
Replace breather See page 19
Change oil, clean screens See page 19
Check oil level, look for damage or leaks See page
20
Change oil
See page 20
Clean cab, check operation of controls
See page9
Check condition and adjustment of the controls
See page 94
Lubricate thoroughly See page39
SPECIAL MAINTENANCE
End of First Day or First 10 Hours of Operation
Hydraulic Filters ................................... Replace paper elements, clean 100 mesh screens
After First 20 Hours of Operation
Case engine ........................................ Change run-in oil and filters. See Engine Manual
After First Week or 50 Hours of Operation
Turntable Capscrews ...................................................... Check for correct torque
13

PREVENTIVE MAINTENANCE
ILLUSTRATED LISTING OF GREASE FITTINGS
LUBRICATION FITTING CHART
Figure No. Location/Title
7
8
9
10
11
12
Turntable Bearing
Control Pedals
Turntable Leveler
Drive
Sprocket Pillow Block
Fan Pulley (Detroit Diesel Engine)
Boom and Bucket
Machines through PIN 6280344
I~
~
. ~
~
I --- 0
. ~
Qty.
1
4
(See
Figure 9)
2 per side
1
15
Interval
Weekly/50 hours
Weekly/50 hours
Weekly/50 hours
Daily/10 hours
Weekly/50 hours
Daily/10 hours
Machines with PIN 6280345 and After
Figure 7. Lubrication Point for Turntable Bearing Figure 8. Controls and Linkages
TOT AL OF 8 (Machines
through PIN 6280344)
TOTAL OF 6 (Machines with
PIN 6280345 and After)
0
Figure 9. Turntable Leveler
14
0
. /J<
~ ~, ~.-===~
✓- ~
•
......_______ ' -
·-
TOTAL OF 4 /
,
y,;
Figure 1 O. Drive Sprocket PIiiow Block Figure 11. Fan Pulley
(Detroit Diesel Engine)

PREVENTIVE MAINTENANCE
BOOM LUBRICATION
NOTE: Grease at least every 4 hours for first 20 hours
of operation. Continue to grease every 4 hours
A
if working conditions are severe.
Detail C Detail D
Detail F Detail G
Figure 12.
Lubrication Fittings on Boom
Detail A
Detail B
lJ,.lAJJ
~ /rf t! i ;c.
,', .
'
,1
Detail E
Detail H
15

PREVENTIVE MAINTENANCE
ITEMIZED INSTRUCTIONS
1. ENGINE -See separate engine manual for
required engine maintenance.
Lubrication System: Engine oil should be
checked daily before operation. See engine
manual
for oil recommendations, oil and filter
change procedures.
DIPSTICK
FILTERS
I11
16
-io,
Figure 13. Oil Filters (Case Engine)
Fuel System: Before operation, drain water and
sediment from fuel filters. This helps prevent
condensation and sediment buildup in the fuel
system. See engine manual
for additional
maintenance.
HAND
BLEED SCREWS
\
DRAIN
PLUG
- ~I
-=--------~I
SEDIMENT
BOWL
Figure 14. Fuel Filters
on Case Engine
Figure 15. Fuel Filters on Detroit Diesel Engine
2. RADIATOR AND OIL COOLER - Check Radiator
coolant level daily. When freezing temperatures
threaten,
fill with solution of 50% ethylene
glycol base antifreeze and 50% water.
NOTE: Antifreeze with sealant additives Is NOT
recommended in Detroit Diesel Engines due
to the
possibility of plugging cooling system ports.
A CAUTION: When checking coolant level,
remove cap on radiator
slowly to relieve
pressure
within the system.
Blow foreign matter from Radiator and Oil Cooler
fins weekly. Inspect hoses and connections for
leaks and cracks at the same time. Be sure the
engine is
shut off when using compressed air. If
overheating occurs in hot weather, the following
suggestions are offered to help ensure maximum
cooling system efficiency:
A CAUTION: ENGINE FAN AND BELTS ·
To prevent possible serious injury avoid
contact with rotating fan and belts.
a. Keep radiatorand oil cooler fins clean.
b. Check the radiator pressure cap.
It must main-
tain 7 psi
(48 kPa) on the Radiator. Either
high or low pressure can cause overheating.

3. AIR CLEANER -Check Air Restriction Indicator
on air cleaner inlet line daily. Remove and clean
(or replace) the element when the red
indicator
band remains in full view with the engineoff.
Remove
the dust cup daily or every 10 hours
and clean
out accumulated dust.
Clean and inspect (or replace) the element every
500 hours or two months whichever occurs first.
To service the element, remove and tap
it
against your hand. Blow out from inside with
compressed air. Then wash in a solution of non-
sudsing detergent (DO NOT use HOT water).
Shake
out excess water and let dry.
NOTE: Never run an engine with the Air Cleaner or Dust
Collector removed.
ELEMENT
HOUSING
Figure 16. Engine Air Cleaner(typical)
Test element by holding a lighted bulb inside. If
light shows through unevenly, replace the
element. Keep an extra element on hand for
quick replacement.
NOTE: Air Cleaner elements should be replaced after
five cleanings.
CAUTION: Disconoect both leads from
A the
batteries when working on the
engine or electrical system. Always
disconnect the Ground lead first.
PREVENTIVE MAINTENANCE
4. BATTERIES -Clean Battery terminals and other
metal parts with soda water solution and rinse
with clean water every 1500 hours or six
months. Brighten terminal posts and inside of
connectors with a wire brush. After connecting
terminals, coat them with petroleum jelly or
STP oil treatment to help prevent corrosion. On
units not equipped with "Maintenance-free"
batteries, check the electrolyte level weekly or
every 50 hours. Add distilled water as
necessary
to keep the electrolyte level above
the
cell plates.
5. FUEL TANK -Keep the Fuel Tank filled to prevent
condensation when the machine is not being
used. Refer
to Engine Manufacturer's Manuals
for fuel .recommendations. Drain water trap in
bottom of tank daily or every 10 hours.
RETURN
WA
TEA TRAP LINE
------
INLET LINE
Figure 17. Fuel Tank Water Trap
A Never smo,ke while refueling, servicing
the fuel system or working with
batteries.
17

PREVENTIVE MAINTENANCE
6. SWING GEARBOX · Check oil level weekly or
every 50 hours whichever comes first. Drain and
refill every 6
months or 1500 hours, whichever
comes first. FILL, CHECK and DRAIN plugs are
shown in Figure 18.
Check and adjust house brake monthly, every
250 hours,
or as necessary. See page 36.
BREATHER(FILL 'i/ / ',~ \
rl
'·, ; J~SWING' MOTOR
r
,....,._.__ ' ,, / \'
!J.~.>t_r~ : -.- - ; \
~- ]·-if . ~~-HOUSE BRAKE
~~-;/.· h l;r',
" ..~ .;;.! 11 -SWINGG~A~BOX
~\ '--'' ',' I;· I
'\ , I '• , I . "-.,
DRAIN ON -( :- ; I,' ~ ACCESS TO
BOTT?M
,,-< ~~iiK /1~1f -:;-; OPEN GEAR
Figure 18. Turntable
Ring Gear Access Hole
and Swing Mechanism
7. TURNTABLE BEARING RING GEAR - Lubricate
daily or every 10 hours, whichever occurs first.
Use a spray-on open gear
lubricant such as
Mobiltac E, Sohio Sohitac No. 1, Sunoco 407
Compound B, Texaco Crater Compound or
functional equivalent.
I
Figure 19. Lubricating the Ring Gear
18
Remove the access cover and spray or brush on the
lubricant while the Turntable is slowly rotating
through 360°. (See Figure 19.)
NOTE: Rotate turntable so that Pinion helps spread the
lubricant.
A
WARNING: To avoid personal injury,
keep hands clear of turntable ring gear
while turntable is being rotated.
8. TURNTABLE CAPSCREWS -The capscrews which
hold the
turntable to bearing and bearing to
carbody
should be checked for proper torque
after the first
50 hours or first week of operation.
Thereafter they
should be checked every 250
hours
or monthly (see page 37).
9. TRACK -Track Rollers are pre-lubricated and
sealed. They require
no periodic lubrication.
Check the Rollers
for leaks. Grease the Drive
Sprocket Pillow Block Bearings daily or every
10 hours
with a general purpose lithium base
grease. See
Illustrated Listing.
Check the Track for proper tension every 50
hours or weekly, whichever comes first. See
page
25.
10. LUBRICATION (GREASE) FITTINGS· Lubricate all
grease
fittings at the intervals indicated in the
LUBRICATION FITTING CHART.
Lubrication
points in high wear areas such as the boom
and
bucket must be greased at least every
4 hours
for the first 20 hours of operation
and
daily or every 10 hours thereafter. If working
conditions are severe, contin1,Je to grease these
areas
after every 4 hours. Use a multipurpose
lithium base grease, unless otherwise noted.
When
working in wet or swampy areas, grease
those components exposed to water every 4
hours.
If grease fitting will not accept lubricant,
remove
it and clean out the obstruction or
replace the fitting. Apply sufficient grease to
force
out the old grease.