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. Never use flamable liquids to clean parts, always use approved non-flamable solvents to clean parts. Be sure to assemble all parts in their original locations.
Replace any damaged part with new parts. When installing high pressure hoses, be sure that they are not twisted. Damaged tubbing is dangerous, be extremely careful when installing tubes for high pressure circuits. Also make sure parts are correctly installed.
When assembling or installing parts, always use the specified tightening torques and sequences. When installing protective parts such as guards, or parts that may vibrate or rotate at high speeds, be particularly careful to check ther installation carefully.
When aligning two holes, never insert your fingers or hand. Use approperate tools to alighn parts. When measuring hydraulic pressure, be sure the measuring tool is correctly assembled before taking any measurements. Take care when removing or installing the tracks on track-type machines.
When removing the track, the track separates suddenly, never let anyone stand at either end of the track. Make sure you under- stand 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. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. Troubleshooting charts correlating Problems to Causes are also included in this section.
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. Open the engine right side cover. Disconnect fuel control cable 1 from the fuel injection pump. Disconnect fuel supply hoses 2 and 3.
Disconnect fuel filter 4. Disconnect fuel return hose 5. Component Symbol Part No. Lower the work equipment to the ground and stop the engine. Disconnect the cable from the negative - terminal of the battery.
Remove six fuel injection tubes 6. Remove cotter pin 10 and nut 11 , and then remove engine stop solenoid rod 12 from the fuel injection pump. Remove engine stop solenoid 13 and bracket 14 together.
Remove fuel tubes 15 and Remove lubrication tubes 17 and Remove boost compensator tube Using timing pin 20 , match the timing gear to the fuel injection timing. Remove cap Remove fuel injection pump nut 22 and washer Using tool A, disconnect the fuel injection pump shaft and pump drive gear.
Remove fuel injection pump bracket Remove four fuel injection pump mounting nuts 25 and fuel injection pump assembly Check that the timing pin is matched to the injection timing. Remove plug 27 and turn over timing pin 28 of the fuel injection pump, and then reinstall them to the fuel injection pump.
Install fuel injection pump assembly 26 and tighten 4 nuts Install fuel injection pump bracket Install washer 23 and temporarily tighten fuel injection pump nut Disengage the timing pin of the fuel injection pump on the timing gear side from projection a and return it to the original position. Tighten fuel injection pump nut 22 permanently. Fuel injection pump mounting nut: 9. Temporarily tighten the nut to the following torque so that it will not damage the timing pin. Temporary tightening torque of fuel injection pump nut: Open the engine right and left side covers.
Remove fuel injection tubes 1. Remove spill tube 2. Loosen and remove nozzle holder assembly 3. Remove engine assembly. For details, see Removal, Installation of engine assembly.
Drain the coolant. Remove the air conditioner compressor according to the following procedure. Disconnect wiring connector E16 1 and ground terminal E22 2. Remove cover 3. Loosen 2 mounting bolts 4 and 2 mounting bolts 5. Loosen 2 locknuts 6 and 2 adjustment bolts 7. Remove air conditioner compressor belt 8. Remove 2 mounting bolts 4 , 2 mounting bolts 5 , and air conditioner compressor and bracket assembly Stop the vehicle on a level place and set the safety bar to the frame.
Lower the work equipment to the ground, stop the engine, apply the parking brake, and put chocks under the tires. Coolant: 17 liters 4. Disconnect the following wiring connectors and terminals, also the wiring harness clamps.
Remove the mounting bolts of heater relay Remove air hose 17 between the air cleaner and turbocharger. Disconnect radiator inlet hose Disconnect aftercooler upper hose Remove air cleaner and bracket assembly Remove the muffler according to the following procedure.
Remove mounting bolts 21 , two pieces on each side. Remove one mounting bolt Remove four mounting bolts from the inside of rear side a. Raise muffler 23 and disconnect drain tube Remove the turbocharger and exhaust manifold assembly according to the following procedure.
Disconnect turbocharger lubrication tubes 25 and Remove bracket Remove muffler drain tube mounting bolt Remove exhaust manifold heat insulation cover Remove muffler brackets Lift off turbocharger and exhaust manifold assembly Remove 6 fuel injection tubes Turbocharger and exhaust manifold assembly: 40 kg 88 lbs Remove alternator belt cover Disconnect wiring connectors E02 35 and terminal E11 Remove mounting bolts 37 and 38 and alternator.
Remove alternator bracket Remove engine sling and thermostat housing assembly Remove air conditioner compressor bracket Remove engine stop solenoid bracket mounting bolts and nuts Disconnect air hose Remove air intake connector 45 and heater Remove fuel tubes 48 and Remove fuel filter Disconnect spill hose Disconnect heater hose Remove spill tube Mclanahan has designed the dairy stall filler specifically to handle sand bedding.
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