TABLE OF CONTENTS

SECTION

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I

Power Trein .........................................................................

Hoist System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Attechments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crowd Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Swing Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Propel Systems .......................................................................

Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubricetion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mqintenance Welding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I

HOW TO USE THIS SHOP MANUAL

This Shop Manual is divided into the major sections shown above. Each major
section can be located using the margin tab marks on the right edge of this page as
shown in sketch. At the beginning of each major section is a Table of Contents
which identifies the topics covered iti that section.

This manual has been planned to allow new information to be added as design changes occur. Therefore, this manual may
contain information not applicable to your machine.
 SECTION I

INTRODUCTION

Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l-l
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l-l
Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l-l
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l-2
Tabulated Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l-3
 SECTION I
INTRODUCTION

SCOPE shown must not be used when ordering repair parts.

Always obtain part numbers from.the Repair Parts Manual
This manual provides suggested methods and procedures for your machine serial number.
for the overhaul and repair of the mechanical components
of this excavator. All dimensions, without tolerances given in this publica-
A review of the table of contents will indicate that the tion are to be considered non-critical. These dimensions are
manual has been divided into a number of major sections. the nominal value desired and any deviation should be
Each major section has, in turn, been divided into sub-sec- within reason. In cases where a question may arise on non-
tions covering the overhaul, repair, and inspection of each critical dimensions consult your Harnischfeger represen-
component. tative.

SERIAL NUMBER
Figure l-1 illustrates the machine serial number which is
located on the front of the operator’s cab. Always indicate
The size and weight of most ot the excavators the machine serial number in all correspondence to prop-
components necessitates the uee ot lifting and erly identify the machine.
jacking equipment, and the uee of repair pro-
cedures not common to smaller excavetors.
Thoretoro. service personnel should read and
thoroughly understand the procedure before
beginning the job, and determine what pra
cautions must bo taken to prevent unexpected
movement of the component being serviced.
Figure l-l. Excavator Serial Number
In most cases, the method of performing a repairwill bede-
termined by the tools and equipment available at the mine WARRANTY
site. The methods and procedures described in this manual The terms under which this machine is guaranteed are
are therefore only one suggested method of performing a clearly defined under the warranty which accompanies
repair. every HARNISCHFEGER product. This warranty, while
generous, will be voided if the machine is operated under
GENERAL INFORMATION unsafe operating conditions, or with accessories or attach-
ments not designed and furnished or approved by the
The information, specifications and illustrations in this HARNISCHFEGER CORPORATION. Modifications made
publication are based on the information for U.S. built ma- upon the machine which will affect its operation or capac-
chines in effect at the time this manual was printed. Con- ity will void the warranty.
tinuing improvement and advancement of product design
may cause changes to your machine which may not be in- DESCRIPTION
cluded in this publication. Each publication is reviewed and
revised, as required, to update and include these changes in This excavator is powered and controlled electrically. All
later editions. working functions of the excavator are driven by electrical
motors connected to mechanical transmissions which are
Whenever a question arises regarding your machine, or this used to drive the various motions of this machine.
publication, please consult your Harnischfeger represen- Alternating Current (AC), is supplied to the excavator
tative for the latest available information. through the tail cable, which is connected to the electrical
Part numbers are used occasionally in this manual to distribution system of the mine. Power from the tail cable is
identify various parts and assemblies. The part numbers supplied to the transformers, various electrical control cabi-

l-l
SECTION I INTROOUCTION

nets, and the main motor through slip rings on the under- MACHINERY DECK: This is the platform of the upper on
side of the revolving frame. which the machinery is mounted.
The main motor sewes two functions. namely; supplying LOWER MACHINE FRONT: This is the end of the lower op-
power to lift the dipper and to drive the swing and posite the propel machinery.
crowd/propel generators. The MagnetorquerxS are directly UPPER MACHINE FRONT The front of the upper is the at-
connected to the left of the motor, while the generators are tachment end.
connected to the right of the mein motor bv a chain drive.
LOWER MACHINE REAR: This is the end of the lower which
The MagnetorquesQB are eddy current clutches which al- has the propel machinery.
low the operator to control the amount of digging power bv
varying the current through the clutches. When the cper- UPPER MACHINE REAR: The rear of the upper is the
ator applies excitation to the MegnetoquesS, magnetic at- counterweight end.
traction between the inner and outer members causes the RIGHT SIDE: The right side of the machine is to the oper-
inner member to rotate with the outer member. ator’s right when he is seated at his controls and is facing
The swing and crowd/propel genemtors are used to con- forward.
vert rotating mechanical energy, supplied bv the main LEFT SIDE: The left side of the machine is to the operator’s
motor, into Direct Current (DC) which is used to w the left when he is seeted at his controls and is facing forward.
swing and crowd/propel motions. These motions are con-
ATTACHMENT: An alternate designation for front end
trolled bv varying the power supplied to the motors.
equipment. In the case of this excavator, it includes the
Auxiliary machinery such as the air compressor iadriven bv gamry, boom, dipper and crowd machinery.
individual AC motors.
HOIST The process of lifting the dipper.
TERMINOLOGY SWING: Swing is defined as the function of revolving the
Certain terms are frequently used in this manual. For bet- upper of the mechine.
ter understanding, severe1 are defined below and illus- CROWD: Outwerd movement of the dipper sticks in rela-
treted in Figure 1-2. tion to its axis on the boom.
CAR8ODY: The traveling base upon which the upper and TABULATED DATA
side frame are mounted.
METRIC CONVERSIONS. Use Table l-l to convert the
SIDE FRAME: A frame attached to the csrbodv which aup- English units in this manual to metric units.
ports the crawler tracks.
TORQUE VALUES. Unless otherwise specified torque all
LOWER: The portion of the machine on which the upper is - common bolts and screws on_this machine to the values
mounted. shown in Table l-2. The torques provided are to be used
UPPER: The upper is defined as the revolving portion of the with dry threads. The use of thread lubricant or plated
excavator. threeds will substantially lower the torque values required.

BOOM POINT
BOOM SHEAVES
SUSPENSION CROW0 -I
GANTRY CABLES TRANSMISSION m
COMPRESSION A
MEMBER

- HOIST
CABLES

UP
t DIPPER

Figure l-2. Excavator Terminology

l-2
INTRODUCTION SECTION I

Table l-1. English to Metric Conversions

to get equivalent to get equivalent

Multiply by number of: Multiply number of:

LENGTH TORQUE
Inch 25.4 millimetres (mm) in-lbs 0.11298 newton-metres (N.m)
Foot 0.3048 metres (m) ft-lbs 1.3558 newton-metres
Yard 0.9144 metres ft-lbs 0.1383 kg-m
Mile (Statute) 1.609 kilometres (km)

AREA POWER
Inch2 645.2 millimetres2 (mm2) Horsepower 0.746 kilowatts (kW)
6.45 centimetres2 (cm2)
Foot2 0.0929 metres’ (m2)
Yard2 0.8361 metres’
PRESSURE OR STRESS
Inches of
VOLUME mercury 3.377 kilopascals (kPa)
Inch” 16 387. mm3 Inches of
16.387 cm3 water 0.2491 kilopascals
0.0164 litres (I) Pounds/sq.
Quart 0.9464 litres in. (psi) 6.895 kilopascals
Gallon 3.7854 litres Pounds/sq.
Yards 0.7646 metres3 (mJ) in. (psi) 0.069 bars

MASS ENERGY OR WORK

Pound 0.4536 kilograms (kg) BTU 1 055. joules (J)
Ton (Short) 907.18 kilograms Foot-pound 1.3558 joules
Ton (Short) 0.907 tonne (t) Kilowatt-
hour 3.6 x lo6 or joules (J = one W.s)
3600000
FORCE
Kilogram 9.807 newtons (N) VELOCITY
Ounce 0.278 newtons Miles/hour 1 . 6 0 9 3 kilometres/hr (km/h)
Pound 4.448 newtons

TEMPERATURE CONVERSION CHART

F
,‘F
OF.! oC+32 .40 0 32 4050 59 90 _ 120 140 160 200 212

II,‘~l’~‘!lI!,I1,lIIIIIIIIIIillllll
1015 40 60 60 100
oc = ; (“F -32) .40 .20 0 20
“C
“C

PI51

l-3
SECTION I lNTROOUCllON

Table l-2. Recommended Torque Values in Foot-Pounds (Dry Threads)’

Screw, Stud
or Bolt Studs
Diameter (in)
Onrv D Q @
Coarse
Threads UNC Grade 2 Grade 4 Grade 5 Grade 7 Grade 8

l/4 6 10 9 11 12
5116 11 20 17 21 25
318 20 36 31 38 44
7116 32 58 50 61 70
l/2 49 90 75 93 106
9/16 70 130 109 135 154
518 97 180 150 185 212
314 172 315 266 330 380
718 170 505 430 530 610
1 250 750 650 800 910
l-118 355 1075 800 1130 1290
l-1/4 500 1520 1120 1590 1820
l-318 660 1990 1470 2090 2390
l-1/2 870 2640 1950 2770 3160
l-3/4 1370 4160 3080 4370 4990
2 2060 6250 4630 6570 7500
2-l/4 3020 9140 6770 9600 10970
2-l/2 4130 12500 9250 13130 15000
2-3/4 5590 16950 12540 17800 20400
3 7390 22390 16570 23500 26900
3-l/4 9520 28850 21350 30230 34600
3-l/2 12030 36450 26970 38300 43800
3-314 14940 45300 33500 47500 54400
4 18280 55400 41000 58200 66500

Fine
Threads UNF

l/4 6 11 9 11 13
5116 12 22 18 23 26
318 22 39 33 41 47
7116 34 62 52 65 74
l/2 53 95 81 100 114
S/l6 75 136 115 142 163
518 105 190 162 200 228
314 183 332 282 350 400
718 180 530 450 560 635
1 260 790 670 830 945
l-118 380 1150 850 1200 1380
l-1/4 525 1600 1180 1680 1910
l-3/8 710 2150 1590 2260 2580
l-112 930 2820 2090 2960 3380
l-3/4 1500 4540 3360 4770 5450
2 2270 6860 5080 7210 8240
2-l/4 3260 9860 7300 10360 11830
2-l/2 4500 13630 10100 14310 16360
2-314 6030 18260 13500 19170 21910
3 7860 23600 17600 25010 28600
3-l/4 10040 30400 22500 32000 36500
3-l/2 12600 38200 28200 40100 45800
3-314 15500 47100 34800 49400 56500
P13S 4 18900 57300 42400 60100 68700
l The use of thread lubricant or plated threads will substantially lower the recommended torque VSlUeS.

1-4
 SECTION II

POWER TRAIN

PAGE

2A. INTRODUCTION
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .,........ 2A-1
Alignment ,.......................... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-1

2B. MAIN MOTORS AND GENERATORS

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28-1
Main Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28-1
Generators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28-2

2C. CHAIN CASE ASSEMBLIES

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2c-1
Chain Case (1 OOJ3139) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2c-1

2D. COUPLINGS
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-1
Couplings (18P2721, 182529 & 182553) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-1
 SUBSECTION 2A
INTRODUCTION

ALIGNMENT
GENERAL
GENERAL: Alignment of the power train is critical to the
This section covers the main motors, clutch assemblies,
total operation of the excavator. Alignment checks re-
and generators. Service for each major assembly is covered
quired, when removing individual assemblies, is detailed in
in an individual subsection. Removal, disassembly, repair,
the subsection for each assembly. Complete alignment
assembly, installation and adjustments are covered in each
must be rechecked when a condition is changed that may
subsection. Alignment of the power train components is
alter the stress on the housing frame, such as a change in
covered in Subsection 2A.
counterweights.
The main motor provides constant rotational power to the The hoist gear case and clutch shaft assemoly is the refer-
clutch assembly and to the swing and crowd/propel gener- ence point in alignment of the power train. The main motor
ator. The swing and crowd/propel generators are driven is aligned to the clutch shaft assemblv. The chain case is
through the chain case (see Figure 2A-1). then aligned, by use of the chain sprockets, to the main

SWINQ
GENERATOR

CLUTCH
ASSEMBLY

CROWD
PROPEL
QENERATOR

Figure 2A-1. Power Train Relationships

2A-1
SUBSECTION 2A INTRODUCTION

motor. The crowd/propel generator is aligned to the chain It is suggested that the following tools be acquired for these
case and the swing generator is aligned to the alignments (See Figure 2A-3):
crowd/propel generator (See Figure 2A-2).
MOTOR AND GENERATOR ALIGNMENT. The main motor
to the clutch shaft, the crowd/propel generator to the chain Aligning Tool . . . . . . . . . . . . . . . . . . . . . . . . 1089Jl
case, and the swing generator to the crowd/propef gener- ‘7” Bar Tool . . . . . . . . . . . . . . . . . . . . . . Fabricated
ator alignments are all accomplished using the same pro- Aligning Tool Post.. . . . . . . . . . , . . . . . . ._-
Fabricated
cedure. Aligning Clamp . . . . . . . . . . . . . . . . . . . . Fabricated

ALIGNMENT
DIRECTION

SWING
GENERATOR

CLIJTCII SHAFT
AND CLUTCll ASSE

AUGNMENT
REFERENCE

CROWD
PROPEL
GENERATOR
HOIST
MOTOR

01. CLUTCH SHAR TO MAIN MOTOR

02. CHAIN CASE
03. CROWD/PROPEL GENERATOR TO CHAIN CASE
04. SWING GENERATOR TO CROWD/PROPEL GENERATOR

Figure 2A-2. Power Train Alignment

2A-2
INTRODUCTION SUBSECTION 2A

ALIGNING TOOL (1088Jl)

RECORDED FACIAL GAP
t

INDICATOR
TOOL POST

AUGNING

,++

AUGNMENT ROD TAP Y,,” -1s UNC \

Figure 2A-3. Alignment Tools

1. Attach the proper tool posts to the shaft nuts of assem- D. Rotate the aligning tool posts 180 degrees and read dial
blies being aligned (See Figure 2A-4). indicator #2. Divide the reading by 2. This indicates the
amount the opposite end of the assembly must be
NOTE moved side ways to correct the misalignment.
When aligning the main motor to the clutch shaft, E. Repeat step 4 until a Total Indicator Runout (T.I.R.) mis-
tack weld fabricated alignment rod to the clutch shaft alignment of 0.010 inches is achieved.
as shown on Figure 2A-4. 5. Set the facial gap by positioning the assemblies being
aligned so the gap is the distance recorded in removal. The
2. Install dial indicators on aligning posts as illustrated on use of a 7” bar tool is recommended (See Figure 2A-3).
Figure 2A-4.
6. Align the shafts vertical position as follows (See Figure
3. Shafts of the components must be aligned for face par- 2A-5):
allelism, vertical and horizontal position, and proper facial
gap (See Figure 2A-5). A. Position the aligning posts in a vertical plane. Set dial
indicator #l to 0.0 inches.
4. Align shafts facial parallelism as follows:
8. Rotate the aligning posts 180 degrees and read indi-
A. Position the aligning tool posts in the vertical plane and cator 171. Divide the reading bv 2. This indicates the
set dial indicator #2 to 0.0 inches. amount of vertical misalignment.
0. Rotate the aligning tool posts 180 degrees and read dial C. If shaft of assembly being aligned is low, install shims
indicator #2. Divide the reading by 2. This indicates the equal to the amount of misalignment under each
shim value required to correct the misalignment. mounting leg. If shaft is high, remove mounting pad on
C. Place aligning tool posts in a horizontal’ plane and set the revolving frame and remove material equal to the
dial indicator #2 to 0.0 inches. misalignment from each pad.

2A-3
SUBSECTION 2A INTROOUCTlON

DIAL INDICATOR dl DIAL INDICATOR #l

L!
-

v
INDICATOR #2
AUGNMENT
ROD 1 PUGNMENT
TOOL POST

lNDl&TOR
TOOL POST

I
TAC
WE1
-_-- -_ L
-
-.-. - -__ -
-
GENERATOR
SHAR
___ CROWD/PROPEL
GENERATOROR
MAIN MOTOR POWER TAKE-OFF
IL
SHAPT -
- SHAFT
II

--
_------
---_
TAC B --__-
\ MAIN M O T O R
WEL SHAFT NUT

a
\ ALIGNMENT
TOOL ,
CLAMP
POST - BOLT
CLAMP I

Figure 2A4. Alignment Connections

7. Align the shafts horizontal position aa folbwa (See Fig- CHAIN CASE ALIGNMENT. Alignment of the chain case
ure 2A-5): must be checked and adjusted whenever the main motor is
A. Position the aligning posts in a horizontal plane. Set dial changed and/or if a change has been made in the align-
ment of the main motor to the clutch shaft.
indicator #l to 0.0 inches.
8. Rotate the aligning posts 180 degrees and read indi- Check and adjust the alignment of the chain case as fol-
cator #l. Divide the reading bv 2. This indicates the lows (See Figure 2A-8):
amount of horizontal misalignment.
1. Upper cover of the chain case must be removed to check
C. Move assembly being aligned side ways a distance alignment (refer to Subsection 2C).
equal to the amount of horizontal misalignment.
2. Attach an indicator on the parting face of the chain case
8. Repeat alignment steps 8 and 7 until the vertical and and check chain sprocket for face runout (T.I.R.). Tolerance
horizontal alignment isO.Oto0.003 inches(0.0-0.008 mm). of T.I.R. is 0.0-0.010 inches (0.0-0.025 mm).
9. Repeat all four alignment checks to insure adjustments 3. Rotate the sprocket until the twc lowest indicator read-
have not moved ‘and assembly is properly aligned to spec- ings are in a parallel plane and in line with the power take-
ified tolerances. off shaft (P.T.O.).

2A-4
INTRODUCTION SUBSECTION 2A

PARALLELISM
ALIGNMENT

VERTICAL
ALIGNMENT

Figure 2A-5. Alignments

CROWD
PROPEL
GENERATOR HOIST
MOTOR

SILK LINE OR
STRAIGHTEDGE

Figure 2A-6. Chain Case Alignment

4. Place a silk line or an accurate straight edge along the 5. Move the P.T.O. shaft end of the chain case sideways
chain sprocket, using the point on the sprocket of the low until the P.T.O. shaft is aligned to the chain sprocket along
indicator readings as a reference. the silk line or straight edge. Tighten chain case mounting
bolts.

2A-5
 SUBSECTION 2B

MAIN MOTORS AND GENERATORS

GENERAL MEASURE
GAP MAGNETORQUE
The main motor and two generators, swing and MAIN MOTOR
CLUTCH
Crowd/Propel, are located in the rear portion of the upper
housing. The removal and installation of these assemblies
are covered in this subsection. Electrical maintenance of
these components is not covered in this manual.

Disconnect the power from the excavator at

thq tail-cable before performing any work on
the main motor or generator.

MAIN MOTOR
Figure 28-l. Measuring Facial Gap
DESCRIPTION. The main motor is a constant speed unidi-
rectional, squirrel cage induction type motor. The main
motor drives the hoist from the left hand side and the gen-
erators from the right hand side. The main motor has no slip
rings, commutator brushes or brush holders. The part
number of the main motor varies with excitation power.
Short all capacitor leads to ground to insure
REMOVAL. To remove the main motor, proceed as follows: electrical charge has been bled off.
1. Mark and disconnect the electrical wiring to the main
motor.
7. Insert two lifting eyebolts in tapped holes provided and
2. Remove the bolts from the coupling between the main lift the main motor from the revolving framedeck. The main
motor and clutch shaft. Place a pan under the coupling and motor weighs approximately 10,900 Ibs (4944.2 kg).
slide the coupling halves apart.
INSTALLATION. To install the main motor, proceed as fol-
3. Remove the chain case cover and drive chain as de- lows:
scribed in Subsection 2C.
1. Position the main motor on the revolving frame deck. Be
4. Measure the facial gap as shown on Figure 28-l and sure to locate the dowel pins.
record for use in alignment.
2. Install the shim paks in the location from which they
were removed if the same motor is being replaced.
3. Align the main motor to the clutch shaft assembly asde-
NOTE scribed in Subsection 2A.
Mark the location of the shim packs on the motor 4. Install the main motor mounting bolt and tighten them.
mounting blocks. If the same motor is to be reinstal-
led, shims must be retained for reinstallation. 5. Install the chain case cover as described in Subsection
2c.
6. hrstall the coupling bolts.
5. Remove the motor mounting bolts.
7. Install capacitor cabinet to top of the main motor, if
6. Remove capacitor cabinet from top of motor if required. removed.

25-l
SUBSECTION 26 MAIN MOTORS AND GENERATORS

8. Connect the electrical wiring to the main motor. 4. Remove the mounting bolts and tapered dowel pins con-
nected to the eyebolts. Lift the generator from the excava-
GENERATORS tor. The generators weight approximately 2187 Ibs (991 kg).

DESCRIPTION. The generators have split housing and an all NOTE

welded frame without any internal connections between
the upper and lower half. Large covers provide easy access When the same generator is to be reinstalled, mark
the location of the shim pack on the generator
to commutators and brushes. The armature shaft assembly
mounting blocks and shims. Retain these shims for
is easiiy removed without disturbing the field windings.
reinstallation.
Large internal f&s draw in air and provideforcaventilation
through windings and’over the commutator.
REMOVAL To remove the Crowd/Propel or Swing gener- INSTALLATION. To install the Crowd/Propel or Swing gen-
ator, proceed as follows: erator, proceed as follows:

1. Mark and disconnect the generator electrical wiring. 1. Place the generator on the mounting pads. Be sure to lo-
cate the dowel pins. The generator weighs approximately
2. Place a pan under the generator coupling. Remove the 2187 Ibs (991 kg).
bolts of the coupling and slide the coupling halves apart.
The Crowd/Propel generator has a coupling on each side of 2. If the same generator is being reinstalled, place the
the generator, one for the power taka-off shaft and one from shims on the mounting pad from which they were re-
the swing generator. moved.
3. Measure the facial gap as shown on Figure 26-2 and re- 3. Align the generator as described in the topic Alignment,
cord for use in alignment. in Subsection 2A. The installation of a new Swing gener-
ator may require an adjustment of the Crowd/Propel gen-
FACIAL erator alignment to the power take-off shaft. Check the
GAP alignment of the Swing generator to the Crowd/Propel gen-
AUGNMENT erator, adjust as required using the shims installed under
each mounting leg.
4. Install and tighten the generator mounting bolts.
5. Install the coupling bolts.
6. Connect the electrical wiring to the generator.

Figure 29-2. Facial Gap Alignment

29-2
 SUBSECTION 2C

CHAIN CASE ASSEMBLIES

2. Disconnect vent hoses (01) from the chain case cover.

GENERAL
3. On the power take-off end of the chain case, remove
The chain case assembly consists of the chain case cover,
three top bearing capsule capscrews (02) on each side.
drive chain, motor sprocket, power take-off shaft and the
chain case lubrication pump and strainer. This subsection 4. Remove the top row of capscrews from outer side cover
covers chain case inspection, removal of major compo- (03) on the main motor end of the chain case.
nents and repair of the power take-off shaft and lubrication
5. Remove the chain case cover bolts (04). Remove cover
pump. Alignment of the chain case is covered in Subsec-
(05).
tion 2A and must be checked when the chain case is re-
paired. DRIVE CHAIN. Refer to Figure 2C-1 and remove the drive
chain as follows:
CHAIN CASE (10053139) 1. Remove the master chain link pin. The chain must be
DESCRIPTION held firmly during this operation.

The chain case assembly consists of the drive sprocket, 2. Slowly allow the chain to fall from the motor sprocket.
drive chain and power take-off shaft. Power from the main
motor is transferred through thechain to the powertake-off
POWER TAKE-OFF SHAFT. Refer to Figure 2C-1 and re-
shaft. The power take-off shaft transfers this power to turn
move the P.T.O. shaft as follows:
the generators.
1. Remove the gear case cover.
The chain case containsoil to lubricate the moving parts. An 2. Remove three lower left and right bearing capsule cap-
oil strainer is installed in the lubrication pump suction line screws (02).
and a flow switch in the discharge line. If the flow switch
senses an insufficient oil flow, the excavator will shut 3. Place a guide approximately 3/4 inch (19.1 mm) thick,
down. This flow switch is inoperative when the excavator is between the bearing capsule and sprocket. This will keep
in the propel mode. the capsule.from tipping.
4. Place a sling around the P.T.O. shaft sprocket and re-
PERIODIC INSPECTION move the P.T.O. assembly.

DRIVE CHAIN. The drive chain should be inspected every MOTOR SPROCKET. Refer to Figure 2C-2 and remove the
10,DDD hours. motor sprocket as described below:
A repair link (P&H Part Number 20283304) can be used if it 1. Remove the chain case covers and drive chain.
is necessary to shorten the chain one pitch.
2. Remove capscrews (11) from the lower portion of outer
MOTOR SPROCKET. The motor sprocket nut should be tor- side cover (10).
qued to 4,DDD ft-lbs (553.2 m-kg) every 10,DDO hours.
3. Remove drive chain (10) and support the motor sprocket
POWER TAKE-OFF SHAFT. The condition of the power with a suitable lifting device.
take-off shaft bearings should be inspected at 20,CCO
hours. The shaft and component parts should be checked
for proper tolerance when disassembled (See Figure 2C-4).

REMOVAL OF MAJOR COMPONENTS Never remove a taper fit component with a pul-
CHAIN CASE COVER. Refer to Figure 2C-1 and remove the ler and jack. Parts could snap off explosively
chain case cover as follows: and cause injury to personnel.

1. Drain the oil from the chain case. The drain tube ex- 4. Remove the sprocket from the tapered motor shaft as fol-
tends from the chain case through the revolving frame. lows:

2c-1
 CHAIN CASE ASSEMBLIES

VENT HOSE
CAPSCREW b WASHER
SIDE COVER
CAPSCREW b WASHER
COVER
SPROCKET
PTO SHAFT
GASKkT
GEAR CASE COVER
SIDE COVER
CAPSCREWS
DRIVE CHAIN

Figure X-1. Chain Case Components

CHAIN CASE ASSEMBLIES SUBSECTION 2C

thoroughly with compressed air. All gasket material must

be cleaned from all surfaces. Do not spin bearings with
compressed air.
Inspect all components for wear, cracks and other damage.
Check the P.T.O. shaft component parts for proper dimen-
sion per Figure 2C-3.
ASSEMBLY. Refer to Figure 2C-3 and assemble the P.T.O.
shaft as follows:

1. Install key (15) in chain sprocket (13) and press the

sprocket on shaft (14).
2. Press spacer (12) and the inner race of bearing (09) on
shaft (14). Install snap ring (08).

3. Install bearing (09). spacer (10) and snap ring (1 1) in

bearing capsule (06). Install a new O-ring (07) on the bear-
ing capsule.

4. Install bearing capsule (06). oil seal (05) and seal re-
Figure 2C-2. Motor Sprocket tainer (04) on the left end of shaft (14).
5. Install key (03) to coupling half (02) and press coupling
half on shaft (14).
A. Screw a blank nut on the motor shaft threads.
6. Press bearing (18) into bearing capsule (17). Install a
6. Drive wedges behind the sprocket hub. new O-ring (16) and press bearing capsule (17) on the
C. Strike the blank nut with a solid hammer blow which will threaded end of shaft (14).
loosen the sprocket. 7. Install star .washer (19) and locknut (20). Place a new
gasket (21) on end cap (22) and attach the end cap to bear-
P.T.O. SHAFT REPAIR ing capsule (17).
DISASSEMBLY. Refer to Figure 2C-3 and disassemble the CHAIN CASE PUMP TROUBLESHOOTING AND REPAIR
P.T.O. shaft as follows:
GENERAL. The chain case is provided with a positive dis-
1. Remove coupling half (02) and shaft key (03). placement gear pump. The pump supplies the chain case
components with lubricating oil taken from the chain case
2. Pull bearing capsule (06) from shaft (14). Oil seal re- sump (see Figure 2C-4). The pump suction line contains a
tainer (04). oil seal (05). bearing (09). and spacer (10) will be strainer to insure a clean supply of oil to the pump. A fac-
removed with the bearing capsule. tory set relief valve is an integral part of the pump.

NOTE Table 2C-1 provides troubleshooting information to help lo-

cate specific chain case lubrication system problems. Pump
The inner race of bearing (10) will remain on shaft (14) repair consists of pump and relief valve disassembly and the
when removing bearing capsule (06). replacement of worn or broken parts.
3. Remove snap ring (11). spacer (10) and bearing tO9)from DISASSEMBLY. To disassemble the lubrication pump, pro-
the bearing capsule, as required. ceed as follows (see Figure 2C-5):
NOTE
4. Remove snap ring (08) from shaft (14) and removechain
sprocket (13). Two threaded holes are provided in the chain The seal assembly may be changed without disas-
sprocket for removal. The inner race of bearing (09) and sembling the entire pump.
spacer (12) will be removed with the sprocket. 1. Place the pump in a vise, shaft facing up, so that one jaw
5. Remove key (15) from shaft (14). grips across the two ports. Do not tighten the vise exces-
sively as the pump housing may be distorted.
6. Remove bearing end cap (22) and gasket (21) from the
right end of shaft (14).
2. Inspect the shaft at the drive tang. Any burrs will inter-
7. Remove lock nut (20) and star washer (19). Pull bearing fere with the removal of the housing plug bearing assem-
capsule (17) and bearing (18) from shaft (14). bly.
8. Remove bearing (18) from bearing capsule (17). 3. Remove the housing plug with a face type spanner
wrench.
CLEANING, INSPECTION AND REPAIR. Clean all parts of 4. Pull the seal from the shaft. The rubber boot will be
the P.T.O. shaft with a suitable cleaning solvent and dry bonded to the shaft, so it is necessary to push down on the

2C-3
SUBSECTION 2C CHAIN CASE ASSEMBLIES

01. LEm COUWNQ HALF

02. RIGHT COUPUNG HALF
03. KEY
04. OIL SEAL RETAINER
OS. OIL SEAL
06. SEARING CAPSULE
07. O-RING
OS. SNAP RING
09. ROLLER SEARING
10. SPACER
11. SNAP RING
12. SPACER
13. SPROCKEI’
14. SHAFT
15. KEY
16. 0-RINQ
17. SEARINQ CAPSULE
10. SPHERICAL ROLLfR SEARINQ
19. STAR WASHER
20. LOCKNUT
21. GASKID
22. END CAPS

Q CHAIN 2.933” DIA. FOR

2.922” 12 PITCH THO

Figure 2C-3. Power Take-Off Shaft (lOW2206)

2c-4
CHAIN CASE ASSEMBLIES SUBSECTION 2 c

OIL seal to break this bond. Grasp the metal outer shell with any
SPRAY LEVEL suitable device and pull the seal assembly upwards. The
ESSUAE PIPE STRAINER DI llr, spring and washer should also be removed.
5. Press the staponary seal face from the housing plug.
6. Discard the O-ring from the housing plug assembly.
7. Mark the cover and body of the pump to assure proper re-
assembly. Remove the capscrews, cover, idler and rotor
from the housing.
6. Remove the relief valve components from the pump
housing.

NSPECTION. Inspect the parts of the pump as follows:

1. Check all parts for wear, cracks and chipping.
2. The housing bore and rotor O.D. are checked for wear by
positioning the rotor in the housing and slowly turning the
rotor. The shaft must turn freely without any detectable side
CASE
play. Side play indicates that the housing and/or rotor must
COCK be replaced.
Figure 2C-4. Chain Case Lubrication NOTE
If both the housing and rotor require replacement, it is
HOUSING economically advisable to replace the pump.
CAPSCREWS
SEAL ASSEMBLY. To assemble the pump, proceed as follows (see
ASSEMBLY yRING Figure 2C-5):
NOTE
If only the seal is being replaced, proceed to step 6.
1. Clean all parts thoroughly, taking care to eliminate all
dirt.
2. Install the rotor in the pump body.
3. Place the idler gear on the cover pin.
4. Set the gasket on the cover and install the cover on the
housing with the match marks aligned.
,LJ \ HOUSING
PLUG
ROTOR 5. Install the cover capscrews. Tighten the capscrews
>LER
CAPSCREWS \
gradually and alternate from a capscrew on one side to one
PIN
on the opposite side.
COVER
6. Oil the rotor shaft and the inside of the new seal with a
light lubricating oil.
NOTE
Installation of the seal requires the use of a tapered
sleeve with a maximum O.D. equal to the rotor shaft
O.D.
7. Lubricate the tapered seal assembly sleeve.
8. Slide the seal onto the tapered end of the sleeve, spring
end first.
9. Press the seal about half-way on the tapered sleeve.
GAiKET 10. Place the tapered sleeve over the pump shaft tang. Line
up the outside diameters of the sleeve and shaft by eye.
RELIEF VALVE SECTION
11. Pull the seal down so that it passes from the assembly
sleeve to a position half-way down the shaft.
12. Press the stationary face into the housing plug with the
Figure 2C-5. Chain Case Lubrication Pump lapped surface up. Protect the lapped surface by covering it

2C-5
SUBSECTION 2C CHAIN CASE ASSEMBLIES

with a piece of paper when pressing down on the face. Use 20. Remove and clean the oil strainer prior to starting the
finger pressure only for this operation. machine.
13. Lubricate the carbon face liberally with oil. 21. Start the machine and check the oil pressure. The oil
pressure should stabilize around 15 to 25 psi after the oil
14. Assemble the housing plug intothe pump housing. Use
has warmed.
care when placing the housing plug into position over the
pump shaft not to nick the seal face by hitting the pump
shaft.
15. Tighten the housing plug with a spanner wrench. The INSTAUATION OF MAJOR COMPONENTS
seal will be positioned during this operation. MOTOR SPAOCKET.‘Prior to installing the motor sprocket it
16. Check the pump for free rotation by turning the shaft must be lapped to the motor shaft. Lapand install the motor
with a wrench. There will be a definite resistance to turn- sprocket as follows (see Figure 2C-2):
ing because of the seal load. The pump must turn freely 1. Remove all nicks and/or burrs from the parts,
without binding.
2. File the keyway and prefit the key. The key must be a
17. Install the parts of the relief valve assembly just aa they hand slida fit into the sprocket bore keyway. Remove the
were removed. key.
18. Fill the ports of the pump with chain case lubricant and 3. Apply lapping compound at four places along the length
connect the suction and output lines to the pump. of the motor shaft and in the sprocket bore.
19. Anach the pump to the motor with the mounting hard- 4. Engage the shaft in the bore and rotate the shaft in both
ware. directions.

Tablo 2C-1. Chain Cam Pump Troublo8boting

PROBLEM POSSIBLE CAUSES SOLUTIONS

No oil output. Bad leaks in suction line. Submerge preaaure line from discharge

I side of pump into a pail of oil, air

leakage will be indicated by bubbles.
1 Replace any faulty lines.
I
Pump shaft not rotating because Replace the coupling.
of a defective coupling.
Low oil output. Air leaks in suction line. Replace the suction line.
Pump speed too slow. Replace the defective pump motor.
Obstructed strainer. 1 Clean debris from strainer.
I Excessive clearance in pump. 1 Repair or replace the pump.
Intermittent pumping action. 1 Leaky suction lines. 1 Replace the suction line.
Pump us83 excessive power. Pressure too high. Check for obstruction in the
suction or discharge lines. Clean
lines and nozzles.
Oil more viscous than required. Change the chain case oil. See
Section X.
Driving shaft and pump shaft Check and correct shaft alignment.
misaligned.
Pump shaft bent. Replace shaft and seal.
Pump is noisy. Pump cavitation. Check for air leaks on suction side
of pump. Check chain case oil
IlWel.
Pump vibration. Repair or replace pump.
Pump leaks. Loose cover bolts or defective Check gasket and torque bolts.
cover gasket. See Pump Repair.

I Leaky shaft seal. Replace seal. See Pump Repair.

I

2C-6
CHAIN CASE ASSEMBLIES SUBSECTION 2C

5. Separate the parts and clean them with solvent. Ex- DRIVE CHAIN. Refer to Figure 2C-1 and install the drive
amine the shaft surface for fit. A true lapped fit will show a chain as follows:
gray color over the entire length of the shaft. If there are 1, Lay chain across motor sprocket and P.T.O. shaft.
bright spots on the shaft, repeat the procedure until they
disappear. A bearing surface of 90% or more is acceptable. 2. Install master chain link pin and spacers.
6. When lapping is complete, clean the parts with solvent.
The parts must be dry and free of oil film. CHAIN CHASE COVER. Refer to Figure 2C-1 and install the
7. Fit the key into the shaft keyway. Do not use a lubricant chain case as follows:
on the mating parts. 1. Install the gasket to the side cover of the gear case. using
8. Assemble the two components and check for clearance a suitable gasket compound. Install the side cover to the
between the top of the key and the bottom of the keyway. motor end of the gear case.
Some clearance must be present: if not, file the top of the 2. Install the six body fitted bolts if previously removed (see
key. Figure 2C-6).
3. Install the gasket on the flange of the gear case and lift
m the gear case cover on to the gear case.
Do not heat thesprocketwhen assembling it to 4. Install the capscrews on the side cover and the power
the shaft. take-off bearing capsules.
9. Set the sprocket on the shaft by using a block of hard- 5. Torque the body fitted cover bolts to 170 ft-lbs (23.5 kg-
wood and a light bar. m). Torquetheremainingcoverboltsto lOOft-lbs(13.83 kg-
10. Install the lock ring and large hex nut and torque nut t0 m).
4,000 ft-tbs. 6. Torque the bearing capsule capscrews to 50 ft-lbs (7.0
kg-m).
POWER TAKE-OFF SHAFT. Refer to Figure 2C-1 and install 7. Torque the side cover capscrews to 20 ft-lbs (2.5 kg-m).
the P.T.O. shaft as follows:
8. Install the vent hoses to the gear case cover.
1. Lift the P.T.O. shaft assembly into the bores of the chain
case. 9. Fill the chain case with the proper lubricant.
2. Install the three lower capscrews in the bearing 10. Connect the power take-off coupling as described in
capsules. Do not tighten at this time. Subsection 2D.

5/8-l 1 x 2-l/2 BODY FITTED BOLTS

BOLT 314-10 x 2-l/2

Figure 2C-6. Body Fitted Bolts

2C-7
 SUBSECTION 2D
COUPLINGS

GENERAL
The couplings used are flanged sleeve flexible couplings.
The couplings are filled with grease for lubrication and Never remove a taper fit component with a
sealed with O-rings and a gasket (see Figure 20-l ). puller and jack. Parts could snap off explo-
sively and cause injury to personnel.
The coupling half on the clutch shaft has a splined hub. The
flange is a male flange having a ridge on the inside diame- TAPERED. Couplings having a tapered hub are lapped and
ter of the flange. This connects to the main motor coupling keyed to the shaft and fastened by a hex nut. Remove the
half which has a tapered hub and a female flange having a coupling from the tapered shaft as follows:
groove in the inside diameter of the flange. The main motor
1. Screw a blank nut on the shaft threads.
coupling half is keyed to the motor shaft and fastened with a
hex nut. 2. Drive wedges behind the coupling.
The coupling half on the power take-off shaft has a splined 3. Strike the blank nutwith a solid hammer blowwhich will
hub. The generator coupling half has a tapered hub and is loosen the coupling.
keyed to the generator shaft. It is held on the shaft with a
hex nut. REPAIRS
The coupling halves which connect the two generators to- The O-ring can be replaced by separating the flange from
gether, both have tapered hubs and are keyed to the gener- the hub and removing the O-ring from the flange.
ator shafts. The coupling halves are held in place with hex
The gasket which is installed when the coupling halves are
nuts.
fastened together, can also be replaced when necessary.
COUPLINGS (18P2721, 182529 & 182553)
INSTALLATION
REMOVAL
SPLINED. Couplings having a splined hub are installed by
SPLINED. Couplings having a splined hub are not fastened sliding over the splines of the shaft.
to the shaft and can be pulled off by hand or with the aid of a
suitable puller. TAPERED. Install couplings as follows:

FLANGE\ , COUPLING BOLTS

O-RING

TAPERED
HUB

GREASE

Figure 20-l. Coupling

2D-1
SUBSECTION 20 COUPLINGS

1. Remove all nicks and/or burrs from the parts. 7. Fit the key into the shaft keyway. Do not use a lubricant
on the mating parts.
2. File the keyway and prefit the key. The key must be a
hand slide fit into the sprocket bore keyway. Remove the 8. Assemble the two components and check for clearance
key. between the top of the key and the bottom of the keyway.
Some clearance must be present: if not. file the top of the
3. Apply lapping compound at four places along the length
of the motor shaft and in the coupling bore. key.

4. Engage the shaft in the bore and rotate the shaft in both
directions.
5. Separate the parts and clean them with solvent. Exam-
ine the shaft surface for fit. A true lapped fit will show a gray Do not hoot the coupling when auombling it to
color over the entire length of the shaft. If there are bright the &oft.
spots on the shaft. repeat the procedure until they disap-
pear. A bearing surface of SD96 or more is acceptable.
9. Set the coupling on the shaft bv using a block of hard-
6. When lapping is complete, clean the parts with solvent. wood and a light bar. Install the washer and nut on the
The parts must be dry and free of oil film. shaft. Tighten the nut securely.

20-2
 SECTION III
HOIST SYSTEM

SUBSECTION PAGE

3A. INTRODUCTION
General ........................................................................................ 3A-1
Reeving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A- 1
Cab Assembly .................................................................................... 3A-2
Gear Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-2
Gear Case Lubrication Pump ..................................................................... 3A-7

38. MAGNETORQUEO CLUTCHES

General ........................................................................................ 38-l
Magnetorque Clutch Shaft (91DJ323) ............................................................. 38-l

3 C . INTERMEDIATE.SHAFTS
General ........................................................................................ 3c-1
intermediate Shaft (1 ODN1091) ................................................................... 3c-1

30. HOIST BRAKE SHAFTS

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D-1
Brake Shaft (91ffl246) ~ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D-1

3E. HOIST DRUM ASSEMBLIES

General ........................................................................................ 3E-1
Hoist Drum Assembly (91 DJ310 & 91 DJ460) ...................................................... 3E- 1

3F. HOIST BRAKES

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F-1
Hoist Brake (1 DDJ3150) .......................................................................... 3F-1
 SUBSECTION 3A
INTRODUCTION

GENERAL REEVING
SCOPE. This section describes the removal, repair and re- The hoist reeving of the excavator is iilustrated in Figure
assembly of all major components of the hoist system. 3A-1. The hoist drum, boom point, and equalizer areviewed
Cable reeving and removal and installation of assemblies from the top looking down.
within the hoist gear case will becovered in Subsection 3A.
Disassembly, repair and reassembly will be covered in a
subsection devoted to the individual main assembly.

DESCRIPTION. The hoist system consists of the main drive

motor, the Magnetorque clutch unit, the hoist gearing, and
the hoist drum. The hoist system is used to lift the dipper.
The dipper is lowered bv gravity (see Figure 3A-3).
The main drive motor, a unit directional, constant speed
motor, provides power for hoisting. The field members of
the clutch unit are rotated bv main motor through a
mechanical coupling and when excitation is applied to the
field coils of the rotating members, the clutch pinion sleeve
drives the intermediate hoist gear.
The intermediate hoist gear is mounted on the intermedi- BOOM POINT
ate hoist pinion shaft. The intermediate hoist pinion is ma-
chined integrally with the shaft. The pinion is spur cut and
transmits hoist torque to the main hoist gear.
The main hoist gear meshes with and is driven by the inter-
mediate hoist pinion. The main hoist gear is a spur cut gear
bolted to a spider which is mounted directly on the hoist
drum.
The main hoist gear is driven through the gear train. The
hoist drum then rotates and the dipper is raised. CABLE
Ul
Gearing in the hoist machinery is enclosed in an oil tight
gear case. Gear case joints, horizontal or vertical, are bolted
to provide rigidity and protection against leakage. Large
breathers are installed to prevent excessive pressures from
developing within the gear case.

A holding brake is incorporated on the first reduction gear of CAeLE CABLE

the hoist transmission. This brake is a holding brake only x2 rtl
and should only be applied when motion is stopped and the
transmission is to remain stopped for an extended period of
time. It is a spring set, air released brake. Figure 3A-1. Reeving

3A-1
SUBSECTION 3A INTROOUCTION

CAB ASSEMBLY A. Remove upper four capscrews (01, Figure 3A-5) from
DESCRIPTION. The cab assembly cover (canopy) is sec- both bearing retainers of the intermediate shaft aaaem-
tionally designed with removable hatch covers, for easy re- bly.
moval of major assemblies enclosed in the cab. Refer to Fii- 6. Remove upper four capscrews (02) from the left bearing
ure 3A-2 or 3A-3 and remove the hatch covers or sections retainer of the drumshaft assembly.
necessary forthe individual assembly being removed. Large
C. Remove upper six capscrews (03) from seal retainer
major assemblies may require removal of one or more sec-
(04). Remove upper half of the split retainer ring.
tions of the canopy on standard cabs (see Figure 3A-2).
D. Remove four cap bolts (05) from the intermediate shaft
bearing caps.
GEAR CASE
DESCRIPTION. The hoist gear case contains the gearing E. Remove cover mounting bolts (06,07. and 08) from two
which transmits power from the clutch shaft pinion to the piece cover.
hoist drum. The location of major components of the hoist
system are shown in Figure 3A-4.
NOTE
DISASSEMBLY. The hoist gear case is disassembled bv re-
moving the major assemblies as described in the following Cover mounting bolts should be kept separate as
steps: coupling bolts (C6) must be reassembled in thecoupl-
ing holes.
1. Place the dipper on the ground and remove the hoist F. Remove two coupling bolts (OS) and fifteen mounting
cables from the drum. bolts (10).

2. Remove the required canopy sections. G. Using a suitable crane, lift hoist gear case covers
through the canopy and place it on blocks.
3. Remove the hoist gear case covers as described in the H. If required the two piece cover can be separated bv re-
following: moving coupling bolts (121 and mounting bolts (11).

GENERATOR

OPERATORS

Figure 3A-2. Standard Cab Assembly

3A-2
lNTRODlJCTlON SUBSECTION 3A

HATCH
CANOPY
SAFETY
ARFH
WALK

MAIN HATCH CO

PLENUM
DOORS

Figure 3A-3. Modular Cab Assembly

A. Remove canopy section as required per instructions in

NOTE
this subsection.
It is only necessary to remove the clutch shaft cover
and bearing cap when the clutch assembly is to be re- B. Remove gear case covers as described in step 3.
moved. C. On the left end of the intermediate shaft, remove the
overspeed switch flange capscrews.
J. Drain the gear case oil. D. Remove bearing retainer from the right end of the inter-
K. Remove two guards from the outer members. Support mediate shaft.
clutch shaft assembly by placing tapered wooden E. Using a crane, remove the intermediate shaft assem-
wedges under the outer members. Remove four cap- bly. This assembly weighs approximately 4400 Ibs
screws (13, Figure 3A-5) on bearing cap. (1996 kg).
L. Remove remaining coupling bolts (09) and mounting
bolts (10). Lift bearing cap off case and place on blocks.
4. Refer to Figure 3A-4 and remove the intermediate shaft 5. Remove the brake shaft assembly as follows (see Figure
.
assembly as follows: 3A-4):

3A-3
 ‘A\ INTERMEDIATE HOIST

COUPUNG

Figure 3A-4. Hoist Machinery

A. Remove required canopy sections, gear case covers and

I intermediate shaft assembly as described in this sub-

section.
IUeuer rmmvo a taper fit oomponont with a 9. Remove hex nuts and bearing caps from the left and
pullor 8nd jack Pam could anap off l xplo- right drum shaft bearing blocks.
siwly and cauw injury to porsonnd.
C. Loosen capscrews from the lower seal retaining ring.
D. Using a crane, remove the drum shaft assembly. This as-
A. Screw a blank nut on the shaft threads.
sembly weighs approximately 26DDD Ibs (11793 kg).
9. Drive wedges behind the brake drum hub.
7. Remove the clutch shaft assembly as described in the
C. Strike the blank nut with a solid hammer blowwhich will
loosen the drum. following steps (see Figure 3A-4):

0. Remove the capscrews from the brake shaft bearing re- A. Disconnect and tag all electrical leads to the clutch and
tainer. slip rings.
E. Using a puller, remove the brake shaft assembly from 6. Remove the bolts from the coupling between the clutch
the gear case as a unit. This assembly weighs approxi- shaft and the main motor. Place a pan under the
mately 500 Ibs. coupling, slide the coupling halves apart.
6. Remove drum and drum shaft assembly as described in C. Remove required canopy sections, outer guard and
the following steps (see Figure 3A-4): bearing cap as described in this section.

3A-4
INTRODUCTION SUBSECTION 3A

(OS) 1-8 N.C. x 5”

COUPLING BOLT (6)
/
8 oflo
( I
0 $
0
tl
1 0

(06) 1-8 N.C. x 4” I!

COUPLING BOLTS (3) 0 ii

I’

0i F
00;
0 0
0

L;,
l-2-13 UNC x l-112 (12)
.--__ 0 0
q
(07)1xl4UNCx3”(41) .o

VIEW SS

(08) 1-8 N.C. x 2” (12) l-8 N.C. x 4”

SOCKET HEAO CAPSCREWS COUPLING BOLTS (0)

(OS) SPECIAL (4)

F
0000
0

VIEW AA

Figure 3A-5. Hoist Gear Case Covers

3A-5
SUBSECTiON 3A INTROOUCTlON

D. Install linesof identical length overthefirstgrooveofthe

outer members and using a crane apply sufficient ten-
sion to releese the wooden wedges.
E. Lift shaft assembly slowly until shaft clears bearing
bore, then remove assembly and place on blocks.
ASSEMBLY. Assemble the hoist gear case by installing the
major assemblies as described in the following steps (See
Figure 3A-4):
1. Install the clutch shaft assembly as follows:
A. Attach lines of identical length over the first groove of
the outer members and using a crane position clutch
shaft assembly in bearing bore.
8. Support clutch shaft assembly with wooden wedges
placed under the two outer members.
C. Position bearing cap OMI clutch shaft and install beer- Figure 3A-6. O-Ring Installation
ing cap bolts (13, Figure3A-5). Install coupling bolts(D6)
and cover mounting bolts (10).
M. Pull the seals back slightly so the cover can be installed
NOTE without it resting on the seals.
Coupling bolts (06) must be installed in the holes 3. Install the brake shaft assembly in the hoist gear case as
shown on Figure 3A-5. follows (see Figure 3A4):
2. Install the hoist drum shaft assembly as follows(see Fig- A. Position the hoist brake shaft assemblv in the left side of
ure 3A-4): the gear case. This assembly weighs approximately 500
Ibs (227 kg).
A. Install the springs of the drum seels in the slotted side of
the seals. There ere two seals used on the geer case.
NOTE
8. In the lower half of the gear case, instell one of the seals
tine up the roller bearing with the inside gear case
in the seal groove. The slotted side of the seal should
searing bore.
face the inside of the gear case.
8. Use 5/8-l 1 NC x 3-l/2 inch capscrews installed
C. Install the lower half of the split ring against the seal. through the bearing capsuleand into the tapped holes in
D. Install the remaining seal in the seal groove. Install the the geer case as jacking screws. Begin to tighten the
lower half of the seal retaining plate and capscrews. jacking screws pulling the brake assembly in position in
to gear case (see Figure 3A-7):
E. Lubricete the seals in the lower half of the gear case.
F. Lower the hoist drum shaft assembly into position on NOTE
the bearing blocks while holding the top portion of the
When the capscrews bottom and can no longer be
seals awey from the drum. This assembly weighs ap
turned, remove them and install a spacer between the
proximately 26DW Ibs (11793 kg).
capscrew heed and bearing capsule.
G. Install the fastening studs so the short threededend is to
the bottom of the pillow block. C. When the bearing capsule is against the gear case, re-
piece the 5/8-l 1 NC x 3-l 12 inch capscrews with the
H. Install new O-rings in the two special hex nuts. Install proper 5/8-l 1 NC x l-7/8 inch hex head capscrews and
these nuts on the bottom of the left pillow block studs. lock weshers.
Fasten with cotter pins (see Figure 3A-6).
J. Install two hex nuts to the bottom of the right pillow 4. Install the brake drum on the tapered shaft as follows:
block studs and fasten with cotter pins. A. Remove all nicks and/or burrs from the parts.

K. Thread the hex nuts on the top of the pillow studs, torque 8. File the keyway and prefit the key. The key must be a
to 7,DW ft-lbs (968 m-kg). hand slide fit into the drum bore keyway. Remove the
key.
L Fasten the ends of the drum seal spring together. Push
the springs into the split side of the seal, C. Apply lapping compound at four places along the length
of the brake shaft and in the drum bore.
0. Engage the shaft in the bore and rotate the shaft in both
NOTE directions.
It may be necessary to cut the ends of the seal to ob- E. Separate the parts and clean them with solvent. 5x-
tain the correct length, never cut the spring. amine theshaft surfaceforfit. A true lappedfitwill show

3A-6
INTRODUCTION SUBSECTION 3A

a gray color over the entire length of the shaft. If there 7. Install guards over the outer members of the clutch shaft
are bright spots on the shaft, repeat the procedure until assembly.
they disappear. A bearing surface of 90% or more is ac-
8. Refill the gear case wrth recommended gear oil
ceptable.
F. When lapping is complete, clean the parts with solvent.
The parts must be dry and free of oil film.
I t-7,

A-
G. Fit the key into the shaft keyway. Do not use a lubricant
on the mating parts.
H. Assemble the two components and check for clearance ---
between the top of the key and the bottom of the key-
way. Some clearance must be present; if not, file the top
of the key.

Do not heat the brake drum when assembling it

to the shaft.
J. Set the drum on the shaft by using a block of hardwood
and a light bar. Install the washer and nut on the shaft.
Tighten the nut securely. I ] JACKSCREW
I
SPACER
‘I
5. Assemble the intermediate shaft to the hoist gear case
as follows (see Figure 3A-4): Figure 3A-7. Brake Assembly Jacking Screws

A. Lower the intermediate shaft assembly into the gear

case using a suitable lifting device. This assembly GEAR CASE LUBRICATION PUMP
weighs approximately 4400 Ibs (1996 kg). GENERAL. The hoist gear case is provided with a positive
NOTE displacement gear pump. The pump supplies the gear case
components with lubricating oil taken from the gear case
Both intermediate two row bearings have a hole sump (see Figure 3A-8). The output line of the pump con-
which must line up with the locating dowels in the tains a bypass type of filter to assure a clean supply of oil to
bearing bore of the gear case. the hoist gears and bearings.
8. Insure the intermediate gear meshes properly with the
brake shaft pinion and the clutch quill pinion. The inter-
mediate pinion must mesh with the hoist drum shaft
gear.

6. Install the two piece gear case cover as follows (see Fig-
ure 3A-4):
A. The two top covers should be installed together as one
piece. If they were separated, clean the O-ring grooves
and install a new O-ring gasket. Fasten the two covers
together using capscrews, (11 and 12). lockwashers and
nuts (see Figure 3A-5).
8. Clean the O-ring grooveson the gear case flange and in-
stall a new O-ring.
C. Using a suitable lifting device, carefully lower the two
piece cover as one part on the gear case.
D. Install coupling bolts (06) and mounting bolts (07 and
08). Do not tighten.
E. Push the first seal in the seal ring groove and install the Figure 3A-8. Hoist Gear Case Lubrication Pump
upper half of the split seal ring.
F. Push the second seal in the seal groove and install the
upper half of seal retaining plate (04) secure with cap- The efficiency indicator on the filter should be periodically
screws (03). Tighten coupling bolts (06) and mounting checked to determine if cleaning is necessary. The filter can
bolts (07 and 08). easily be cleaned by removing the endcover and pulling the

3A-7
SUBSECTION 3A INTRODUCTION

element out. Wash the filter in solvent and air dry (see Fig- DISASSEMBLY. To disassemble the lubrication pump, pro-
ure 3A-9). Replace the element and end cover gasket. ceed as follows (see Figure 3A-11):
Check the unit for leaks.
1. Clean the outside of the pump with a solvent and dry it
CLEAN OUT thoroughly.
FILTERING COVER
ELEMENT 2. Pull key (02) out of the shaft end. Remove the sharp
CAATRIOGE
edges and burrs from the kevway and shaft end.
REAR CAP
P’sTor R’NG \ \ I 3. Match mark the sections of the pump with a prick punch
for proper reassembly.
4. Bolt the adapter end of the pump to a bench mounted as-
semblv plate (see Figura 3A-10).

INOICAT ‘OR
ARM l/2” HOLE

MECHANICAL
INDICATOR
BELTER HOUSING

PRESSURE DROP
CONTROL SPRING
Figure 3A-9. Hoist Gear Case Oil Filter

fable 3A-1 lists troubleshooting information to help isolate

specific hoist gear case lubrication system problems. Pump
repair consists of pump disassembly and the replacement of
worn or broken parts. Figure 3A- 10. Pump Assembly Plate

Table 3A-1. Lubrication Pump Troubleshooting

noisy.

raspond or fails to
respond.

3A-8
INTRODUCTION SUBSECTION 3A

-18

01. SHAFT 07. DOWEL PIN 13. CAPSCREW 19. SHIM. ,001 INCH, AMBER
02. KEY 08. GEAR 14. BEARING 19. SHIM. .002 INCH. RED
03. ADAPTER 09. O-RING 15. WEAR PLATE 19. SHIM, .0015 INCH. PURPLE
04. SEAT SEAL 10. WOODRUFF KEY 15. SHAFT 20. HOUSING
05. SEAL ASSEMBLY 11. SNAP RING 17. COVER 21. SNAP RING
05. WASHER 12. LOCKWASHER 19. GEAR

Figure 3A- 11. Hoist Lubrication Pump

5. Removefourcapscrews(l3), lockwashers(l2)andcover 10. Remove seal assembly (05) and snap ring (23) freeing
(17). the shaft and wear plate.
NOTE 11. Pull dowel pins (07) from the adapter and cover ends
with pliers or-a lever jaw wrench.
To prevent the possibility of leakage, avoid scoring or
nicking the machined surfaces of the pump section. DRIVE DRIVEN
Do not use a screwdriver to pry the sections apart. Tap
with a fiber hammer, if necessary, to loosen.

6. Note the position of the relief pocket and drilled holes in

wear plates (15) for proper reassembly. Mark drive and
driven gears (08 and 18) for proper reassembly (see Figure
3A-12).
7. Remove shims (19) noting the location and number.
8. Lift out shaft (16) and gear (18).
9. Unbolt the adapter from the bench plate. Coat the endof
the shaft with white lead or other lubricant and press on the
keyed end of the shaft to press out bearing (14). Figure 3A-12. Gear Marking

3A-9
SUBSECTION 3A

INSPECTION AND REPAIR. Clean all pump parts in solvent 3. Inspect the seal seat for excessive wear or damage. The
and air dry. Inspect and repair the pump as follows: seal seat should not be removed unless it is going to be re-
placed. To remove the seal seat, invert adapter (03) and
1. Check bearings (14) for freeness of rollers and pitted, drive out the seat with a wooden block. Press a new seat
broken or excessively worn rollers. Replace the bearing if it into the adapter using a seal seat driver (see Figure 3A- 15).
is possible to insert a 0.020 inch feeler gauge between
ropers.
2. Replace an excessively worn roller bearing as follows:
A. Insert the bearing removal tool under the bearing and
into the cored hole between the bearing bores (see Fig-
ure 3A- 13).

l/18” UNOERCUT
+.008”
l/18” x 4S” MATERIAL C.R.S.

Figure 3A-15. Seal Seat Driver

4. Inspect the gears for excessive wear, pitting or chipping

and replace as necessary.

5. Inspect the wear plates for scorimg or excessive wear.

Even though only slight wear is shown on the gear pattern,
3/8” check for an erosion path in the vicinity of the relief pocket
and replace the wear plate if wear exists(see Figure 3A- 16).

NOTE
The wear plate cannot be turned, as the counter-
bored relief pocket is on the gear side only. If the wear
plate is steel backed, the bronze side should be next to
the gears.

Figure 3A-13. Bearing Removal

6. Check the following wear tolerances:

6. Complete the removal of the bearing using a puller (see A. Replace the housing if the gear bores measure greater
Figure 3A- 14). than 3.259 inches through the dowel pin hole center-
line.

9. Replace both gears if the differential between the hous-

ing width and the gears, with no gaskets in the pump, is
8” in excess of 0.0035 inch.

C. Assembled, the total end clearance between the gear

faces and the housing width should be 0.0025 inch
minimum and 0.0035 inch maximum.
-7
lW32” 0. Replace the shaft and bearing if wear at the roller pat-
terns exceeds 0.001 inch from that of the major
diameter.

Figure 3A-14. Bearing Puller 7. Always replace the housing gaskets and all seal rings.

3A-10
INTROOUCTION SUBSECTION 3A

4. Put a wear plate (15) over the shaft, makrng sure the
WEAR EROSION
counterbored relief pocket is facing the gear. Place a bear-
PLATE PATH
rng (14) on the shaft and install snap ring (21).
5. Install the oil seal as follows:
A. Place washer (06) on first followed by the coil spring,
synthetic rubber rrng (lubricate this ring wrth light
grease or oil) and the seal cup with the lapped surface
up. Be sure the rubber ring is seated in the cup.

NOTE
Make sure the rubber ring is not cut when placing it
on the shaft and when passing it over the key slot or
Figure 3A-16. Wear Plate Erosion spline.

8. Press the entire seat assembly down against the spring

ASSEMBLY. To assemble the lubrication pump, proceed as and compress it. When released, the spring should re-
follows (see Figure 3A-11): turn the cup to the position held beforec mpressing. If it
sticks on the shaft, replace the oil sea Passembly.
1. Lubricate bearings (14) with light grease. Coat the I.D. of
the bearing bore with white lead and install the bearing 6. Wipe off any foreign matter from the seal seat. Lubri-
with the lettering facing up. Press the bearings into the cate the lapped surfaces of the seal seat and seal cup with
bearing bores using the tool shown in Figure 3A-17. light oil.
7. Turn the entire drive shaft assembly over and install it in
the adapter end using a composition hammer to drive the
entire assembly down, driving the bearing into the bearing
bore.
8. Place O-ring (09) around the wear plate and lubricate It
with light oil.
9. Using a micrometer, determine thewidth of housing (20)
and gears (08 and 18). Clearance between the gear faces
and wear plates is provided by plastic shim gaskets be-
tween the housing, adapter and cover. See Table 3A-2 to
determine the number and location of shim gaskets to use
to provide the proper clearance.

NOTE
If the gears are so worn that the housing width be-
comes more than 0.005 inch greater than gearwidth,
both gears should be replaced.

DIA.

Table 3A-2. Pump Shimming

Figure 3A-17. Bearing Driver

2. Install dowel pins (07) in adapter (03).

3. 8olt the adapter to the bench plate with the bearing side
up. Temporarily insert shaft (01) with gear (08) into adapter
bearing (14).

3A-11
SUBSECTION 3A lNlROOUCflON

10. Insert the driven gear and shaft into the adapter end. 14. Place O-ring (09) around the wear plate and position it
Line up the marks previously made on thegear faces if the on the wear plate with an equal air gap around each shaft.
original gears are reinstalled. If new gears are used, keep 15. Install dowel pins (07) in the cover. Line up the punch
the keyways 1 80° apart. Lubricate the faceof the gears with marks previously made on the housing and cover and in-
light oil. stall. Tap the cover down on the dowel pins being careful
11. Place proper gasket as selected by Table 3A-2 over the not to pinch the O-ring seal around the wear plate.
gears and on the face of thewear plate. If it is not practical to 16. Install capscrews (13) and washers (12). Gradually
use micrometers to measure the gears and housing, use a tighten opposite capscrews. with a final torque of 55 ft-lbs.
gasket that measures 0.002 inch.
17. After assembly is complete, turn the shaft with a 6 inch
wrench. If the shaft will turn with a slight drag and not too
12 Line up the punch marks and place the pump housing
freely, proper clearances are assured between the gears
over the gears and gasket. Tap down with a fiber hammer.
and the wear plate. If the shaft is too tight or too free add or
remove as many gaskets as necessary for proper clear-
13. Place the gasket selected for the cover side on the
ance.
pump housing and install the wear plate, making sure that
the 1 / 16 inch deep counterbored relief pocket is in its ori- 18. Fill the pump with hoist gear case lubricant prior to re-
ginal position facing the gears and is rotated 1800 from the installing the pump hoses. 8e sure the filter is operating
pocket of the adapter wear plate. properly and clean it if necessary.

3A-12
MAGNETORQUEB CLUTCHES SUBSECTION 36

SUBSECTION 38

MAGNETORQUEB CLUTCHES

GENERAL SLIP RING FIELD

ASSEMBLY MEMBERS COUPLING
This subsection covers Magnetorque hoist drive operation,
preventive maintenance and overhaul. The hoist drive unit
is located at the rear of the hoist gear case and is coupled di-
rectly to the main motor. The unit consists of two pairs of
concentric rotating members and a clutch shaft (see Figure
36-l ).
MAGNETORQUE CLUTCH SHAFT (91 OJ323)
DESCRIPTION
The MagnetorqueB hoist drive (see Figure 38-l ) consists of
two pairs of concentric rotating members and the clutch
shaft. ’ FIELD COILS’ MOTOR
Each pair of concentric rotating members consists of an Figure 36-2. Field Member
outer member, also called the field member, and an inner ure 39-2). Carbon brushes contact the slip rings. The oper-
member, also called the rotor member. The field and rotor ator controls the electrical current flowing through the
members are separated by a uniform but specific air gap. brushes and slip rings through the field windings. This cur-
The field member consists of a drum carried on a spider. The rent is DC current, which generates a magnetic field when
spider is mounted on the clutch shaft which is driven by the flowing through the field coils. The current flow through the
main AC motor. field windings is called excitation.
The inner member rotates inside the field member. The low
inertia rotor member is of all welded construction with steel
rims of magnetic alloy composition. Sturdy welded fins sup-
port the rims (see Figure 38-3). There are no coils or other
electrical wiring in the rotor members.

RIM
SEGMENT

EABLE
Y RIM
Figure 36-l. Magnetorque Hoist Drive

Field coils are embedded in the field member. The ends of

these field coils (or windings) are connected to slip rings
which are mounted on the clutch shaft at each end (see Fig- Figure 39-3. Rotor Member

38-l
SUBSECTION 38 MAGNETORQUEO CLUTCHES

The clutch shaft holds the spiders which hold the field SUP. As the slip increases the primary field lines of force
members. The clutch shaft also holds the bearings on which move through the inner member faster. This produces more
the pinion sleeve runs. The rotor members are mounted on and stronger eddy currents which react with the primary
the pinion sleeve. The pinion sleeve, or quill pinion, is field to produce more torque at the Magnetorque pinion
coupled to the hoist drum through a gear train. sleeve. When the field member excitation is varied by
manipulation of the hoist controller, the eddy currents will
lo better understand the design and function of the Magne-
be proportionately affected, and the torque produced at the
torque clutch it is important to relate the basic principles of pinion sleeve will be similarly changed.
an eddy current clutch as they apply to the excavator hoist
motion. The Magnetorque requires slip to function. Otherwise, eddy
currents would not be generated and torque transmitting
When direct current flows through the field coils of the field ability would not exist (see Figure 38-6).
member, which is constantly rotating, it becomes a rotating
magnet. The inner surface of the Magnetorque field
member is composed of many pole pieces which alternate FIELD MEMBER
in polarity (N-S-N-S) (see Figure 38-4). ROTATING AT NEAR
SYNCHRONOUS SPEED
FIELD

POLE flECES
ALTERNATE
IN POLAAlTY

EDDY CURRENTS
BEING GENERATED

Figure 38-4. Field Member Poles Figure 38-5. Eddy Current Generation

_ FIELD ROTATION .._._ AT

ROTOR R0TATu-r -.
The strength of the field memper magneuc .’ roux
*’ 1 field, or pri- AT NEAR q msanrn SPEED
.._._..___
mary field, is determined bv the amount of excitation (cur- SYNCHRONOUS
rrti*b r-lid mtk- firlrl rnilr This amliad am&4tin#l isr&
‘W..., .qqe...a” .” .I.” S.“... “W..... . . .._ --..-- -__~7‘~_~.
--_

gulated or varied bv the manipulation of the hoist controller

bv the operator.
With excitation applied to the coils of the rotating field
member a primary magnetic flux is set up between adjacent
poles of unlike polar&v This primary field induces voltages
in the permeable steel rim of the rotor member. These in-
duced voltages cause eddy currents to flow in the rotor rim.
The eddy current flow establishes a secondary magnetic
field in the rotor member (see Figure 38-6).
Its strength is determined bv the strength of the primary
field and the relative speed between the two members. In
the eddy current coupling, the attraction of the primary and
secondary fields causes the rotor to follow the field magnets SUP SPEED = SPEED DIFFERENTIAL BETWEEN THE
in the same direction of rotation. Thus the attraction of FIELD AND ROTOR UNDER LOAO
these two fields causes the rotor member to follow the di-
rection of rotation of the field member. Figure 38-6. Field and Rotor Rotation

A force tending to retard the motion of the inner member, PREVENTIVE MAINTENANCE. Periodic preventive mainte-
such as bank resistance, increases the magnitude of addv nance and inspection will reduce down-time and increase
currents generated as the difference in speed becomes the service life of the Magnetoqueclutch. The following in-
greater. The difference in speed between the field member formation is provided as a preventive maintenance guide.
and inner member is referred to as SLIP SPEED or merely The service procedures and inspections should be per-

38-2
MAGNETORQUEB CLUTCHES SUBSECTION 38

formed mmhly or every 500 hours. Additional items A. Spray perchlorethylene into the fins and shoes of the
should be added as required. Table 38-l is intended to be rotor and allow it to stand for a maximum of two or three
used as an inspection and preventive maintenance record. minutes.
To inspect and maintain the Magnetorque clutch, proceed
B. Blow the material off of the rotor with compressed air.
as follows:
Rotate the clutch and finish removing any of the
1. Lubrication. Check the lubrication record for the ma- accumulated debris that remains.
chine. Left and right clutch shaft bearings (18 and 67, Fig-
NOTE
ure 38-17) must be lubricated with .50 cubic inch of
lithium-soap base grease (P&H 472) every 24 hours. The A completely plugged clutch may not get properly
clutch bearings are greased manually through fittings on cleaned in the machine using the above procedure. If
the rotors. this is the case, it is necessary to remove, clean and
reinstall the clutch. A maintenance schedule should
2. General Condition and Cleanliness. Check the overall then be established to clean the unit on a more fre-
condition and cleanliness of the clutch and housing. Check quent basis.
capscrews for tightness and be sure all guards are in place.
Remove any oil or dirt that may have accumulated on the 4. Counterweights. Check the counterweights on the
machinery deck below the clutch housing. rotors, fields and fans. The counterweights must be se-
3. Cooling Fins. Dirt accumulationson the rotor cooling fins curely fastened in place without danger of rubbing on
cause unnecessary overheating, loss of hoist power and guards or covers.
premature bearing failure due to lubricant breakdown. 5. Pinion. Remove the inspection cover and inspect the
Blow all accumulated dirt off of the rotor cooling fins. Dirt condition of the clutch pinion. Note any chipped or un-
and/or oil collected on the fins greatly reduces heat trans- evenly worn teeth. Check to see that lubricant has been,
fer from the fins to the cooling air Figure 38-7 illustrates the flowing onto the pinion.
,-,/GUARD
6. Air Gap. Measure the air gap between the rotor and field
at several locations (see Figue 38-8). A minimum gap of
,033 inch should exist around the rotor (cool clutch). Note
any large differences from one side of the rotor to the other.
IELD

AIR INLET.

Figure 38-8. Checking the Air Gap

Figure 38-7. Hoist Clutch Air Flow
normal air flow through the Magnetorque clutch. The
importance of keeping the air intake porting open is ap-
7. Brush Assembly. Remove theguard over the slip ring as-
parent in that if the inlet ports for the air are reduced, it will
sembly and check the condition of the brushes and brush
affect the air flow through the clutch. Reducing air flow
riggings. Repeat for the opposite side.
leads to overheating which in turn reduces the eff iciency of
the clutch causing further overheating. Repeated over- 8. Fans. Note the overall condition of the fans. Check and
heating reduces the operating life expectancy cf the tighten all fan capscrews. Rotate the clutch unit by hand
Magnetorque rotor. If the dirt deposits cannot be removed and check for vertical and horizontal runout. Excessive
with compressed air, proceed as follows: runout must be corrected as this will lead to vibration and

38-3
SUBSECTION 38 MAGNETORQUEO CLUTCHES

possible interference with guards and covers. With all OVERHAUL

guards in place and tools clear, staR the machine. Check the Overhaul of the Magnetoque hoist drive includes disas-
vibration levels with a portable vibration meter. Set the sembly, inspection, field member resin repair and assem-
hoist controller in the OFF position and also in the full ON bly. The entire overhaul procedure should be read before
position for meter readings (see Figure 38-9). Record and proceeding to assure that all necessary tools are avaiiable.
compare the meter readings with previous readings.
Significant changes indicate that a problem may exist in the
fan system.
DISASSEMBLY. To disassemble the Magnetorque clutch,
proceed as follows (see Figure 38-l 7).
1. Remove the clutch assembly as described in Subsection
3A.
2. Remove fan assemblies (09 and 89) from field members
(11 and 79).
3. Remove the end plates and shims from both shaft ends.
Remove coupling half (82) from the right end of the clutch
shaft.
4. Disconnect and remove slip ring assemblies (08 and 81)
from shaft (24).

5. Use a 50 ton center hole jack and puller to remove field

members (11 and 79) from each end of the shaft. as shown
in Figure 35-11.

8. Remove oii seal retainers (18 and 74) from rotors (21 and
54). Remove retaining rings (17 and 73) and all shims from
the pinion sleeve.
Figure 38-9. Checking Fan Vibration
7. Slide clutch shaft (24) out of the left end of the pinion as-
9. Operation. While the machine is running, observe the sembly.
general operation of the Magnetoque clutch. Check vibra- 8. Use the 80 ton center hole jack and puller to remove
tion !evels on the bearing housings with the excavator rotor members (21 and 84) from the ends of pinion sleeve
under full load and no load conditions (see Figure 36-10). (45) as shown in Figure 38-l 2.
Compare current readings with previous readings and note
changes as in step 8. 9. Remove all remaining seals, bearings and O-rings from
shaft (24) and pinion sleeve (45).
INSPECTION AND REPAIR. All components should be in-
spected carefully each time the Magnetorque clutch is dis-
assembled. See Figure 38-17 for clutch component di-
mensions.
1. All wldments should be inspected. Any suspected
+NIIAAT~~K / cracks or defects should be tested and certified sound be-
fore reassembly.
2. Inspect the bore surfaces of the field member poles for
burrs or damage.

Do not machina the ineido diemetr of the field

memkre or pinion aleeve (45) to remove bum
or scrub merIte.
3. Inspect the bores and surfaces of all parts. Remove all
burrs and irregularities prior to assembly.
4. It is recommended that all O-rings, oil seals and bear-
ings be replaced whenever the clutch shaft assembly is dis-
Figure 39- 10. Checking Bearing Vibration assembled.

39-4
SUBSECTTON 38 MAGNETORQUE@ CLUTCHES

OIL SEAL
BORE
RETAINER\
HUB
CENTER-HOLE
JACK
(60 TON)

HEAVY
PLATE

kigure 38-l 1. Field Member Removal

PINION PIATE
l-1 12 INCH HYDRAULIC

/ i””

PULLER

ROD
BOLT

RIM
SEGMENTS
Figure 38-t 2. Rotor Removal

5. Repair of the clutch assembly is limited to the repair of

Table 38-2. Repair Muterida
any cracked spin cast resin found in the field members. This
repair procedure is not intended for the repair of any Injection Kit . . . . . . . . . . . . . . . . . . . . . . . . . P&H P/N 212752
cracked or fractured metal components. Repair the field as- Sealant Gun . . . . . . . . . . . . . . . . .-. . . . . . . .P&H P/N 212753
sembly as follows:
OPTIONAL
Air Operated Gun . . . . . . . . . . . . . . . . . . . . P&H P/N 212754
Materials required to perform this repair procedure are Slim Point Nozzle . . . . . . . . . . . . . . . . P&H P/N 212755-01
listed in Table 38-2. Duck Bill Nozzle . . . . . . . . . . . . . . . . . . P&H P/N 212755-02

38-6
MAGNETORQUEB CLUTCHES SUBSECTION 3B

6. Prepare clutch assembly for repair as listed in the fol- 13. Check the field member for proper balance prror to re-
lowing steps: assembling.
A. Disassemble the clutch assembly as described in this
ASSEMBLY. The assembly of the clutch shaft will require
subsection.
some parts to be heated. These parts should be heated to
8. Check winding resistances of the field members elec- approximately 3tXYF. To ease assembly apply light clean oil
trically with a Kelvin or a Wheatstone Bridge. This re- or grease to parts.
sistance must be 5% of the ohmic value stamped on the
To assemble the clutch shaft, proceed as follows (see Fig-
part.
ure 3B 17):
c. Check the resistance from the field winding to ground
using a 500 volt megometer. Prior to cleaning, a mini- NOTE
mum of 1 megohm is required. Do not interchange bearing parts. Each bearing is
D. Thoroughly steam clean the clutch assembly field mem- individually numbered and fitted to close tolerances.
bers. Assembly time can be reduced by placing the bear-
ings in a thermostatically controlled oven or oil bath at
E. Place the field member in an air circulating, exhausting the start of assembly.
type oven. The oven temperature should be set at 225 to
250 degrees F. 1. Place pinion sleeve (45) on blocking.
7. Remove the field member after it has dried a minimum of 2. Install spacer (46) over the end of the pinion sleeve. The
12 hours. Place the field member on the floor where it can spacer should fit tight against the pinion gear (see Figure
be manually rolled. 38-g).
3. Slide heated bearing (47) over the end of the pinion
sleeve so that it is tight against spacer (46).
\ WARNING 1
4. After the bearing has cooled, place spacer (48) and O-
ring (49) over the outside diameter of the pinion sleeve.
Care must be taken whan handling the hot f ield
members. 5. Press seals (57 and 58) into retainer (53) and fasten
them in place with retaining ring (61) and capscrews (63).

8. Thoroughly mix the sealant as described in the instruc-

tion supplied with the injection kit. Only mix one sealant
cartridge at a time as mixed resin pot life is only 30 minutes.
9. Place the mixed resin cartridge in the sealant gun and at-
tach the plastic nozzle. Cut the nozzle to establish the de-
sired nozzle opening.
SPACER
10. Apply the sealant mix as follows:
A. Starting with the slot opening at the 6 o’clock position, PINION SLEEVE
apply the mixed patch resin carefully and slowly. Resin
should be applied, working from one end to the other,
Figure 38-l 3. Spacer Installation
across the entire slot opening.

NOTE 6. Slide the retainer on the right end of the pinion sleeve
over bearing (47).
Field member must be hot and the resin “puddled”
when applied. This will insure the patch resin will 7. Carefully slide spacer (50) over the pinion sleeve until it
penetrate all cracks or the spin cast or cured resin is tight against spacer (48).
without excessive build-up.
8. Apply resin to the adjacent slot as described in step A. NOTE

C. Roll the field assembly as required, such that the slots Spacer (50) should be heated to approximately 1 20°F.
being coated are at.the 6 o’clock position. This should allow the spacer to be positioned without
damaging the O-ring or seals.
NOTE 8. Install heated bearing (43) on the left side of the pinion
The applied patch resin must start to gel on the heated sleeve.
field assembly prior to rolling the unit. 9. Place spacer (42) and O-ring (41) over the outside dia-
11. Clean off all excess cured resin in the air gap. meter of the pinion sleeve.
12. Repeat megohm minimum ground resistance as de-
scribed in step 1 C. Reading must be a minimum of 10 meg- 10. Press seals (27 and 30) into retainer (31) and fasten
ohms. them in place with retaining ring (26) and capscrews (28)

38-7
 S U BSECTION 38 MAGNETOAQUEO CLUTCHES

ROTOR MEMBER
CENTER-HOLE

DAM RING

Figure 38-l 4. Rotor Installation

11. Slide the reiainer over the left end of the pinion sleeve 21. Repeat step 20 for retainer segments (17) and rotor
up to bearing (43). (21).
12. Carefully slide spacer (40)overthe pinion sleeve until it 22. Install the seals in retainers (16 and 74). Assemble the
is tight against spacer (42). retainers to rotors (21 and 64).

NOTE 23. Place clutch shaft (24) on blocking. Slide spacers (19
and 68) on clutch shaft (24).
Spacer (40) should be heated to approximately 1 20°F.
This should allow the spacer to be positioned without 24. Install heated bearing (18) and the heated race of bear-
damaging the O-ring or seals. ing (67) on the splined end of the clutch shaft. Begin heat-
ing rings (14 and 76).
13. Lubricate each end of the pinion sleeve and install
sleeve keys (44). 25. Check to be sure there are no burrs remaining on the
clutch shaft. especially in the area of the key slots.
14. Install dam rings (20 and 65) in the ends of the pinion
sleeve. 28. Screw a rod approximately three feet long and threaded
on both ends, into the splined end of theclutch shaft. Guide
15. Lubricate the inside bore of rotor members(21 and 64). the clutch shaft into the pinion assembly from the outboard
16. Position rotor member (64) at the end of, the pinion end.
sleeve. With a 60 ton center hole jack, pull the rotor member 27. Using the tool illustrated in Figure 38-15 drive the
onto the pinion sleeve (see Figure 38-l 4). clutch shaft into the pinion sleeve until it bottoms.
NOTE l-1/2” 4-l /4”
. --
Be sure to line up the keyway of rotor member (64) b I_
with the key in the pinion sleeve. -A-
17. Repeat step 16 for rotor member (21). T i
8-l /4”
0
18. Install the roller assembly of bearing (67) into the right
end of the pinion sleeve. -f

19. Press spacer (69) into the pinion sleeve. 1 .-

20. Install the three segments of retainer (73). With a feeler
gauge, measure the clearance between the retainer seg-
L 7-l/2” -
ments and the face of rotor (64). Install the necessary shims
to take up all clearance. Figure 38-15. Assembly Tool

38-8
MAGNETOAQUEO CLUTCHES SUBSECTION 38

28. Press seal (15) into retainer (16) and seal (75) into re- 33. Position the field member and clutch shaft as shown in
tainer (74). Install the retainers and torque tospecifications. Figure 38-16 and carefully line up the key on the clutch
shaft with the keyway in the field member.
29. Lubricate bearings (18 and 67) until grease appears on
seals (15 and 75). Also, lubricate the pinion sleeve seals at
34. Using a 60 ton center hole jack, press the field member
this time.
onto the clutch shaft.
30. Install heated rings (14 and 76) on the field member
35. Repeat steps 32 through 34 at the opposrte end.
hubs. The rings are chamfered on the inside to ease instal-
lation. 36. Insert drive pins (10 and 80) over the ends of the clutch
shaft and rotate the slip rings until the drive pins engage in
31. The fit of slip ring assemblies (08 and 81) should be the rings.
checked at this time. Slide the assemblies onto shaft (24)
and remove them. There should be no binding during in- 37. Insert shims on the left end of the shaft, as necessary.
stallation or removal. to take up any excess space between the clutch shaft and
the bore face of slip ring assembly (08).
32. Insert keys (23 and 25) in the key groove on each end of
shaft (24). 38. Fasten end plate (04) with capscrews and tie wrre.
39. Slide coupling half (82) on the splines of the clutch
THREADED ROD 3’ LONG shaft. Insert shims to take up the excass space between the
FIELD MEMBER clutch shaft and the bore face of the coupling hub.
PIPE SPACER
\
ROTOR MEMBER
NOTE
If the clutch shaft protrudes beyond thecoupling hub.
insert a suitable spacer behind the coupling hub.
40. Shim between the clutch shaft and end plate (86) as
necessary and secure with capscrews and tie wire.
41. Install fan assemblies (09 and 89) on field members (1 1
and 79).
42. Install the clutch assembly as described in Subsectlon
CLUTCH SHAn 3A.
I ASSY
HYDRAULIC JACK
60 TON CAPACITY
Figure 38-l 6. Field Member Installation

38-9/1o
MAGNETORQUEO CLUTCHES SUBSECllON 38

Figure 38- 17. Clutch Shaft Assembly (91 oJ323)

 48. SPACER
49. G-RING
50. SPACER
51. GASKET
52. PLUG
53. RETAINER
54. LUBE FITnNG
55 CGUPUNG
56. NIPPLE
57. GIL SEAL
58. GIL SEAL
59. WASHER
1 2.880” BORE 60. CAPSCREW
.I 6.125” DIA. 61. RETAINING RING
BORE 62. WASHER
63. CAP.$CREW
K 5.50” SHAFT 64. RGTGR MEMBER
0.0. 65. DAM RING
L 9.254” SHAFT 66. SPACER
9.253” G.D. 67. BEARING
68. SPACER
M 14.567” RETAINER 69. SPACER
14.665” DIA. 70. SHIM. ,020”
71. SHIM. .005”
72. SHIM. .0075”
73. RETAiNING RING
El 74.
75.
76.
77.
78.
RETAINER
SEAL
RING
WASHER
CAPSCREW
79. FlELD MEMBER
80. DRWE PIN
81. SLIP RING ASSEMBLY
82. CGUPUNG HALF
83. SHIM. .005”
84. SHIM. .007”
85. SHIM. .020”
86. END PLPITE
87. CIPSCREW
88. WASHER
89. FAN
90. COUPLING HALF
91. CAPSCREW
45. PINION SLEEVE 92. WASHER
46. SPACER 93. CAPSCREW
47. BEARlNG
 SUBSECTION 3C
INTERMEDIATE SHAFTS

GENERAL 1. Place the intermediate shaft assembly on a wooden

base. Secure it so it will not fall. The shaft assembly weighs
The intermediate hoist gear is mounted on the intermedi- approximately 4400 Ibs. (1996 kg).
ate hoist pinion shaft. The intermediate hoist pinion is ma-
chined integrally with the shaft. This pinion is spur cut and 2. Remove the two bearing retainer plates.
transmits hoist torque to the main hoist gear. 3. Remove the bearings from each end of the shaft.

INTERMEDIATE SHAFT (lOON 091) 4. Remove the spacer on the left end of the shaft.
DISASSEMBLY. To disassemble the intermediate shaft as- 6. The large helical cut gear can be removed by pressing it
sembly, proceed as follows (See Figure 3C-1): from the shaft.

BEARING
RETAINER
PLATE

RETAINER
PLATE

Figure 3C-1. Intermediate Hoist Pinion Shaft Assembly (lOON1091)

3c-1
SUSSECTION 3C lNT5RMEDlATE SHAFTS

NOTE NOTE
The large helical cut gear should not be turned around The entire gearing, including cones and cup should be
in an attempt to prolong gear life. heated. If the cones are heated and expanded and put
INSPECTION AND REPAIR. The helical cut gear and pinion in cold cups. the bearing will be excessively tight. It is
should be inspected annually for cracks and fractures. In- possible that there will be no clearance and it may be
spection covers have been provided to gain access to both impossible to get the two cones butted against each
the gear and pinion. other. By heating the cup and cones the entire unit
will be expanded uniformly, seat properly. cool uni-
ASSEMBLY. To assemble the intermediate shaft assem- formly and have the proper setting.
bly, proceed as follows (See Figure 3C-1):
5. Repeat step 4 for the bearing on the right end of the
1. Install the key in the pinion shaft groove. shaft.
2. Press the helical gear on the pinon shaft. 6. Install the bearing retainers to both ends of the shaft. Se-
3. On the gear end. left end of the shaft, slide the spacer cure them in place using the capscrews. Torque the cap-
against the gear. screws to 600 ft-lbs (83 kg-m).
4. Install the two row bearing on the left side of the shaft. 7. Install the lo&wire through the capscrews.

__ _
>- -- -mm.

%
t
I
?

‘:
c

-J -
8vr t
'

-_z -. --a-.

__ ;_

Figure 3C-2. Intermediate Shaft Assembly Dimensions

3C-2
 SUBSECTION 30

HOIST BRAKE SHAFTS

GENERAL 3. Pull gear (16). spacer (18) and bearing (17) from the right
end of hoist shaft (14).
The hoist holding brake is located in the hoist gear case on
the first reduction gear. This brake is a holding brake that is 4. Remove bearing retainer (07) from bearing capsule (11).
spring set, air released. It is designed to be set only after all Remove capsule (11) from the left end of the hoist shaft.
motion of the hoist system has stopped. 5. Pull cup and cones of bearing (10) off the left end of shaft
(14). Spacers (06 and 09) will come off with the bearing.
BRAKE SHAFT (91OJ248)
INSPECTIDN. The brake drum surface should be inspected
DISASSEMBLY. Refer to Figure 30-l and disassemble the each 1,000 hours for fractures. The drum life is greatly ex-
hoist brake shaft assembly as follows: tended by maintaining the proper brake adjustments. It is
1. Place the hoist shaft assembly on a wooden base with recommended that the brake shaft bearings be inspected at
sufficient support to keep assembly from rolling or falling. 25,000 hours.
The brake shaft assembly weighs approximately 500 Ibs.
Figure 3D-3 is provided as a guide to allowable tolerances of
(227 kg).
the brake shaft assembly.
2. Remove retaining ring (19) from the right end of hoist
shaft (14). 19
18 \
17 \ \

07. BEARING RETAINER

08. GASKET
OS. FLAT SPACER
10. BEARING
11. BEARING CAPSULE
12. O-RING
13. KEY
14. SHAFT
15. KEY
01. SHAFT END NUT 16. GEAR
02. WASHER 17. SPACER
03. BRAKE WHEEL 18. ROLLER BEARING
04. BEARING LOCKNUT 19. RETAINING RING
OS. SEAL 20. RETAINING RING
06. SPACER 21. CAPSCREW
Figure 3D-1. Hoist Brake Shaft Assembly

3D-1
SuBSECTlON 30 HOIST BRAKE SHAFTS

ASSEMBLY. Refer to 30-l and 30-3 and assemble the hoist

C A
brake shaft assembly as follows:
1. lnstallkeY(15)inkeywayofshaft(l4)andpressgear(l6)
on right end of the brake shaft.
2. Heat spacer (17) and slide it against gear (16). Press
bearing (18) tight against spacer (17) and secure with re-
taining ring (19).
CONE 3. Install new O-ring (12) in bearing capsule (1 1) and in-
SPACUI
stall double tapered bearing (10) in the following method:

I NOTE
The components of bearing (10) are matched and are
not interchangeable with other identical bearings
. during installation. Special care must be taken to
‘ C O N E insure that the etched letters A and C of the bearing
CONE
cup and cone are matched as shown on Figure 30-2.

A. Heat one cone of bearing (10) and slide it on shaft (14)

with the stamped letter “C” ag&nst the shaftshoulder.
Figure 30-2. Double Tapered Roller Bearings Install bearing spacer against cone.

- Cl/Z”

Figure 30-3. Brake Shaft Assembly Dimensions

30-2
HOIST BRAKE SHAFTS SUBSECTION 3D

B. Press the bearing cup in bearing capsule (1 1 ), with the 4. Heat spacer (06) and install it against spacer (OS). Install
stamped letter “A’ facing the flange side. gasket (08) and retainer (07).
5. Install oil seal (05) after spacer (06) has cooled. Secure
oil seal with retaining ring (20).
C. Positiqn bearing capsule (11) over the installed bearing
cone. The flanged side of bearing capsule (1 1) must be 6. Install bearing lock nut (04) on shaft (14). Tighten the
toward the end of shaft (14). lock nut securely.
7. Lap brake wheel (03) to shaft (14).

D. Heat the remaining cone and slide it over shaft (14) into NOTE
the bearing cup. The etched letter, on the bearing cone Brake wheel (03) will be assembled to the brake shaft
and cup, facing the end of shaft (14) must match. during the installation procedure in Subsection 3A.

30-3
 SUBSECTION 3E
HOIST DRUM ASSEMBLIES

GENERAL 1. Clean the area to be repaired of all flaked and mashed

material by grinding. In the area of thedrum grooves, main-
The hoist drum assembly is supported by the hoist gear case
tain the original rope groove contour as much as possible to
and a side stand. Power is supplied to the hoist drum from
eliminate extensive final grinding (see Figure 3E-1).
the Magnetorque hoist drive through the intermediate
shaft. Power is only supplied to the hoist drum to lift the dip- NOTE
per. The gravitational lowering of the dipper and rotation of
It is suggested that a template be made of the rope
the drum hoist is controlled by the retarding action of the
grooves prior to rework.
Magnetorque unit.
HOIST DRUM ASSEMBLIES
(SlOJ310 & SlOJSSO)
INSPECTION. Inspection covers are provided for inspection
of the spur gear. The spur gear teeth faces should be in-
spected annually for cracks and fractures. It is recom-
mended that the hoist drum bearings be inspected at
25,000 hours.
DISASSEMBLY. Remove the hoist drum assembly as de-
scribed in Subsection 3A. Refer to Figure 3E-3 and disas-
semble the hoist drum assembly as follows:
1. Remove locknuts (02 and 04) and pull bearings (05.06
and 07) from drum shaft (10).
2. Press drum shaft (10) from drum (12). The shaft must be
pressed from the end opposite the shaft key.
3. If it is necessary to remove hoist gear (14) from spider
(15) the bolts securing these items together will have to be
pressed out. Place jackscrews in the four relief holes in
spider (15) and remove the spider. Figure 3E-1. Hoist Drum Groove Dimensions
NOTE
The coupling bolts should be replaced whenever the 2. Any area where the original flame hardening remains
hoist gear and spider are separated. must be heated to 800°F to avoid cracking when these
areas are welded over. These areas should then be slow
REPAIR. Repair consists of replacing worn or broken parts
cooled. Use asbestos blankets or other suitable material.
and. a weld build-up procedure for the hoist drum and/or
grooves. 3. Preheat the worn area to approximately 400°F.
Figure 3E-3 is provided as a guide to allowable tolerances
for the hoist drum.assembly. NOTE
If repairs by welding are of a local nature, the drum may be If the build-up required is over 3116 inch in depth,
repaired in place, otherwise remove the drum for better ac- then the area of the rope grooves should be built up to
cessibility. To weld on the hoist drum, proceed as follows: this dimension using AWS E-10019 electrodes be-
fore proceeding.
NOTE
Attach the welding ground cable to the drum to avoid 4. Weld as close to the original groove contour as possible,
passing the welding current through the drum shaft using hard surface electrodes that can be deposited in
bearings. multi-layers that give RC47-52 as deposited. Never build up

3E-1
SUBSECTION 3E HOIST DRUM ASSEMBLIES

CUP ASSEMBLY. Refer to Figure 3E-3 and reassemble the hoist

CO?E / I drum assembly as follows:
1. Press hub( 11) on shaft (10). if the hub was removed from
the drum.
2. Press shaft assembly (10) into hoist drum (12). Insert the
drum shaft from the end opposite the gear end.
3. Weld hub (11) to drum (12) (see Section X).
4. Assemble gear (14) to spider (15). The fitted bolts which
secure the hoist gear to the spider must be packed in dry ice
prior to assembly.
NOTE
When installing a naw hoist gear to the spider, ream
any mismatched holes to 1.500-l .501 inch (38.10-
38.1 3 mm) diameter.
5. Block the hoist drum in a horizontal position with the
drum hub at the bottom.
6. Install keys (13) in drum (12). Press the spider and gear
on the hoist drum. Keyways in spider (15) must be aligned
Figure 3E-2. Searing Position with kevs (13).
7. Install spacers (18 and 19) on both endsof shaft (10). the
flat side of spacers against the shaft collar.
more than three passes in depth with hard surfacing elec-
trodes. If the build-up required is less than l/8 inch, then 8. Install bearings (06.06 and 07) on ends of drum shaft
grind the contour to allow for the thickness of one hard sur- (10). Bearing cones must butt together (see Figure 3E-2).
facing weld pass. NOTE
5. Once the job is started, welding should be continuous Bearing cups and cones should be heated prior to in-
until it is completed. 90 not allow the area to cool. Care stalling on the drum shaft.
must be used to avoid all undercutting and aaaure smooth
blending of weld metal and parent metal at the beginning 9. Install locknuts (02 and 04) in ends of shaft (10). Tighten
and end of the build-up area. locknuts fully and insert roll pins (01). If dowel holes in the
6. Grind the weld deposit smooth (only grinding abrasions shaft and locknut are not aligned, tighten locknut until
visible) and to the proper rope groove contour after it is aligned to thenext hole in shaft( 10). Never back off the lock-
cooled. nut.

3E-2
f

x
8t
 SUBSECTION 3F
HOIST BRAKES

GENERAL HOIST BRAKE (lOOJ3150)

INSPECTION. Refer to Figure 3F-1 and inspect the wear of
The hoist brake is a spring set and air released holding the brake shoe linings and the drum surface for fractures
brake. When the operator presses the hoist brake release every 5000 hours. Replace linings when worn to l/4 inch.
button, a solenoid valve is operated, applying air pressure to NOTE
the brake rotochamber. If air pressure should be lost, the
brake will be applied automatically by spring force. Life of the brake shoe linings can be greatly extended
by maintaining proper brake linkage adjustment.

ROTOCHAMSER BRAKE
JAW

SPRING

BASE

Figure 3F-1. Hoist Brake (lOOJ3150)

3F-1
SUBSECTION 3F HOIST BRAKES

REMOVAL Major components such as the rotochamber

and the brake shoes can be removed without detaching the
complete assembly from the mounting bracket. Spring prauura must ba ralaaaad from the
Refer to Figure 3F-1 and remove the brake assembly from braka jawa prior to diaconnacting the jaws
the mounting bracket as follows: from the bra&o baaa.

1. Apply air pressure to the rotochamber. If the excavator’s 5. Disassemble the remainder of the brake assembly as il-
air’supply is not available, use a portable air supply capable lustrated in Figure 3F-3.
of at least 110 psi air pressure. REPAIR. Repair of the brake assemblies includes the re-
2. Hold the brake in the released position by turning the placement of worn or damaged parts, overhaul of the roto-
stop nut tight against the brake jaw. chamber, and replacement of the brake linings. Inspect and
repair the brake components as follows:
3. Loosen the air line connection at the rotochamber and
tap the fitting gently to break the seal. This will allow any 1. If necessary, overhaul the rotochamber as described in
pressure trapped in the system to escape. Disconnect the Section VIII. Air System Components.
air line. 2. Replace all broken, damaged or corroded springs.
4. Remove the four mounting nuts, lockwashers and bolts. 3. Replaca the brake linings if they are worn to a thickness
Support the brake assembly and slide it off of the brake of l/4 inch or less. Refer to Figure 3F-2 and raplace the
drum. brake linings as follows:
BRAKE SHOE REMOVAL Refer to Figure 3F-3 and remove
the brake shoe assemblies as follows:
1. Perform steps 1 and 2 of the brake assembly removal
procedure.

Friction pluga (10) an com~saad against the

ineido of braIro jam (06 and 18) by spring (11).
The brako shoaa should bm romovad carefully
to prwant t)lo friction plug8 from popping out
with forca.

2. Remove eye pins (32) and retaining pins(31). Lift the two
brake shoe assemblies (26) from brake jaws (06 and 18).

ROTOCHAMBER REMOVAL Refer to Figure 3F-3 and re-

move the rotochamber as follows:
1. Perform steps 1,2 and 3 of the brake assembly removal
procedure.
2. Remove nuts (03 and 04). Remove the mounting nuts for Figure 3F-2. Brake Lining Installation
rotochamber (13) and pull the rotochamber away from
brake jaw (18) until nut (04) can be removed from rod (12).
3. Loosen the rotochamber jam nut and remove rod (12).
A. Remove the rivet hole plugs and existing rivets from the
4. Remove the rotochamber mounting nuts and remove the
brake shoe and linings.
rotochamber from the brake jaw.
8. Remove the old linings from the brake shoe and place
DISASSEMBLY. If complete disassembly of the brake is re-
the new linings in position on the faceof the shoe. Align
quired, refer to Figure 3F-3 and disassemble as follows:
the holes in the new linings with the rivet holes in the
1. Remove the brake assembly as described in the removal brake shoes.
procedure in this subsection.
C. Install new rivets to secure the new linings to the brake
2. Perform step 2 of the brake shoe removal procedure. shoe Place new rivet hole plugs in the linings.
3. Perform steps 2 and 3 of the rotochamber removal pro- 4. Check the wear of friction plugs (10). Refer to Figure 3F-
cedure. 4 for plug dimensions.
4. Remove nut (01) and slowly remove nuts (01 and 08). 5. Check the bushings in the brake base and the brake
This removes all spring pressure from jaws (06 and 18). shoes for excessive wear. Install new bushings if required.

3F-2
HOIST BRAKES SUBSECTION 3F

01. NUT 13. ROTOCHAMBER 25. BUSHING

02. SNAP RING 14. ROD GUIDE 26. BRAKE SHOE
03. JAM NUT 15. SPRING 27. LINING
04. JAM NUT 18. JAM NUT 28. RIVET
OS. PIN 17. PRSSURE BLOCK 29. PLUG
08. BRAKE JAW 18. BRAKE JAW 30. PIN
07. SNAP RING 19. BOLT 31. PIN
08. STOP NUT 20. LOCKWASHER 32. EYE PIN
08. SPRING ROD 21. CAPSCREW 33. LOCKWASHER
10. FRICTION PLUG 22. JAM NUT 34. CAPSCREW
11. SPRING 23. NUT 35. PIN
l’2. TIE ROD 24. BASE

Figure 3F-3. Hoist Brake Assembly

3F-3
SUBSECTION 3F HOIST BRAKES

1” DIA. 10. Install nut (04) on rod (12). Slide the rod through pin
,750” DIA. ? I/84” 314” DIA. (11) then install nuts (03 and 04) on the end of the rod.

INSTALLATION. Refer ta Figure 3F-1 and install the brake

assembly as follows:
1. Lift the brake assembly over the brake drum and posi-
tion it on the support bracket.
2. Install the four mounting bolts, lockwashers and nuts.

BRAKE SHOE INSTALIATION. If the brake shoes were re-

moved without disassembling the brake, they may be rein-
stalled by performing steps 4 and 5 of the assembly proce-
dure in this subsection.
Figure 3F-4. Friction Plug (19H1093)

ROTOCHAMEER INSTAUATION. If the rotochamber was

removed without disassembling the brake, it may be rein-
ASSEMBLY. Refer to Figure 3F-3 and assemblethe brake stalled by performing steps 10 and 11 of the assembly pro-
after complete disassembly as follows: cedure in this subsection.
1. Install centering screws (21) in the brake base.
2. Assemble brake jaws (06 and 18) to the brake base. Se-
ADJUSTMENT. Adjust the hoist brake for normal lining
cure with retaining pins (30).
wear, or after lining replacement, asfollowsfsee Figure 3F-
3. Assemble friction plugs (10) and springs (11) to brake 5):
shoes (26).
1. Insure that there is no air applied to the rotochamber.
4. Assemble brake shoes (26) to brake jaws (06 and 18).
2. Adjust the spring length to 16-3/8 inch using nuts (08
Secure with retaining pins (31).
and 10). Tighten nuts (09 and 11).
5. install pins (05 and 35) into brake jaw (06). Secure with
3. Tighten stop nut (12) against nut (11).
snap rings (02 and 07).
6. Turn nuts (01 and 16) onto spring rod (09). Install wash-
er (36). pressure block (17). spring (15). and spring guide
(14) on spring rod (09). NOTE
Stop nut (12) must be securely tightened against nut
(11). Loosening of stop nut (12) will prevent a full
NOTE brake application.
Lubricate rod (09) and the bore of guide (14), during
assemblv. 4. Adjust nuts (02 and 03) to obtain a 13/16 inch clear-
ance between the brake jaw and the collar on the tie rod.
7. Slide the spring rod assembly through brake jaw (18) and Tighten nuts (01. 02 and 03).
install nuts (01 and 08) on the spring rod. 5. Loosen jam nuts (16) and adjust capscrews (15) so that
there is l/l6 inch clearance between the capscrew head
and the stop block as shown in Figure 3F-5. Thisdimension
NOTE
may be adjusted to ensure proper release, but clearance be-
Do not compress spring (15) when installing nuts (01 tween each capscrew head and stop block must never ex-
and 08). ceed l/8 inch and must be adjusted along with the spring
length as noted above.
6. Apply air pressure to the rotochamber releasing the
8. Slide spring rod (09) through pin (35) and install nut (01) hoist brake. Check to see that Mere is equal clearance be-
on the end of the spring rod. tween the brake drum and each brake shoe. Tighten jam
9. Position rod (12) and the rotochamber on brake jaw( 18). nuts (16).
Screw the rod onto the rotochamber rod and tighten the jam 7. Reset the hoist brake and check the spring length and
nut on the rod. Securely fasten the rotochamber to the clearance dimensions. Readjust if these dimensions have
brake jaw. changed.

3F-4
HOIST BRAKES SUBSECTION 3F

01

09 /lo

\l2”

-13

l/8” MAX.

Figure 3F-5. Hoist Brake Adjustment

01. JAM NUT 09. JAM NUT

02. ADJUSTING NUT 10. ADJUSTING NUT
03. ADJUSTING NUT 11. NUT
04. TIE ROD 12. STOP NUT
OS. BRAKE JAW 13. BRAKE SHOE
06. ROTOCHAMBER 14. STOP BLOCK
07. SPRING 15. CAPSCREW
08. NUT 16. JAM NUT

3F-5
 SECTION IV
AlTACHMENTS

SUBSECTION PAGE

4A. GANTRY
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-1
inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-2
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-2
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-2

46. SHOVEL BOOM

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46-l
Boom Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46-l
Boom Foot Cushion and Pin Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B 1
Boom Point Assembly (919N 19) .................................................................. 48-2

4C. BOOM LIMIT SWITCHES

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4c-1
Boom Limit Switch (1 ODJ4105) ................................................................... 4c-1
Boom Limit Switch (lDDJ5311) ................................................................... 4C-2

40. DIPPER COMPONENTS

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-l
Dipper Maintenance ............................................................................. 4D-2
Dipper Trip Assembly (lDDJ1563-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-3
 SUBSECTION 4A
GANTRY

GENERAL
The rear section or tension member is pinned on the ma-
The gantry is built of welded structural steel members, pin
chinery deck and to the top of the compression member (see
connected to the revolving frame. The front, or compression
Figure 4A-1). The approximate weight of the gantry with
member is of strong box sections braced and welded into a
single unit. legs and equalizer is 17,000 Ibs. (7711 kg).

COYMtSSlON MCYIfR

Figure 4A-1. Gantry

4A- 1
 SUBSECTION 4A GANTRY

INSPECTtON 1. Opma the excavator and bagin to fill the dipper. Hold
Inspect the gantry assembly st regular intervah as follows: the dim in the bank.

1. Check the aquaker pin for waar and retention. 2. Loosen the support lodcnut.
2. Inspect the squaker and spmeder bar for structural 3. Adjurt the support bolt & it has a dearanca of l/32 inch
damaga (fadguo CracksL (0.79 mm) bstwesn the gamry spreader bar and head of the
3. Check the retention of the corirpmssion membsr and -bolt
tension mornbar pins (top and bottom), spiit pina nuts and 4. liqhtan the support locknut.
cthw perts in the assembly.
5. Ramova the digpar from the bank

REPAIRS
The gantry assembly has two bushings that are rspke-
able. These bushings am Icosted at the point where the
compression member pins to the tension member. The ten-
sion member mrut be unpinned from the coqression
mefnber in order to rsviace then bushings (Ses figure4A-
2).

ADJUSTMENT
There is one adjurmmt anthesxawtorgentw.Thereis
anedjusmbiesuworrMtforthe~spreedubsr,lo-
cetedneerthetopofthe~mentbu.Toad~urt
this support bolt pmcesd as foitows (ses Figurn 4A-3): Rgum 4A-3. Gm Support Adjustment
 SUBSECTION 46
SHOVEL BOOM

GENERAL eyebolt, it is necessary to jack the boom and remove the

boom pin as follows (see Figure 49-l):
For purposes of this manual the boom is considered to in-
clude all structural members. The boom point assembly and
the boom foot cushion and pin assembly are included with
the boom.

BOOM ASSEMBLY
DESCRIPTION. The boom is of welded box girder construc-
tion with diaphragms to provide torsional strength. The
boom feet are wide spread heavy steel castings welded to
the body of the boom. The feet incorporate stacked rubber
disc shock absorbers. This boom foot cushion assembly,
absorbs stresses from swing acceleration and deceler-
ation. Four boom suspension lines are attached to an
equalizer which is pinned to the boom.
REPAIR. There is no recommended repair for the structural WELDED PLATE
boom of the excavator. In case a problem arises with the
boom assembly, consult your area HARNISCHFEGER re-
presentative.

Figure 48-l. Hydraulic Jack Positioning

1. Weld a plate to the boom, near the boom foot.

When adding compomnts to the boom auem-
bly that requirea welding, the wolde must be 2. Build cribbing 3 feet (91 cm) by 3 feet (91 cm) to the
longitudinal to the boom. Any crone mfde will proper height so a jack can be installed between the
weaken the boom and cauea cracking at the cribbing and the plate welded to the boom.
weld. 3. Refer to Figure 46-2 and loosen the jam nut and boom
foot cushion adjustment nut.
BOOM FOOT CUSHION AND
PIN ASSEMBLY 4. Jack the boom so it is free from the roller. Support the
roller and boom foot eyeboit and drive the boom foot pin out.
GENERAL The boom foot rollers support the boom. The
Remove the roller and boom foot eyeboit.
boom foot cushion aids the rollers and acts as a shock
absorber. This protects the boom components and revoiv- INSTALLATION. lo install tha boom foot cushion eyeboit
ing frame from stresses developed through side thrust from and roller. proceed as follows:
accelerating and decelerating of the swinging motion.
1. Position the roller and eyebolt so the bores of each are in
line with the bore in the revolving frame lugs.
The boom foot cushion assembly and roller are held in place
by the boom foot pin. 2. Determine the amount of shims needed to center the
roller with the boom foot.

AEMOVAL When removal is limited to the removal of the 3. Hold the shims in place and install the boom foot pin.
boom foot cushion, remove the jam nut and adjustment nut 4. Install the split collars 0~ both sides of the boom foot pin.
and lift the washer, steel discs and rubber cushions from
the eyebolts. lo remove the roller and boom foot cushion 5. Lower the jack and remove.

49-l
SUSSECTION 40

c JAM1NUT
IER
SHI DCK
ABBO RBER

SPHERICAL
SURfACe
ROLLER AffROXlMATELY 20 FT. (609.6 CM) LONG
Figure 48-3. Adjusting Pipe

JAM NUTS

Figure 48-2. Boom Foot Cushion

6. Alternate@ install nine steel washers and eight rubber

washers. Start with a steei washer and end with a steel
washer.

NOTE
The concave surfaca of the stool washer should face
upward and the convert surface of the rubber washer
downwardsoitfiiinthesteetwasher.

7. Install the adjustment and jam nuts.

ADJUSTMENT. To adjust the boom foot cushion assem-
blies, proceed as followsz
1. Obtain a suitsble pips 20 feet(6D9.6 cm) in length and of Figure 484. Rubber Discs
suitable diameter to fit the end of the adjusting wrench (part
number 2DlW556) provided. place on a sleeve with two retaining rings. A boom point pin
holds the sheaves and sleeve on the boom,
2. Flatten the end of the pipe so it fur the wrench snug (see
Figure 46-3). REMOVAL To rsmove the boom point assembly, proceed as
follows (see Figure 48-5):
3. Position the wrench in the flat end of the pipe. Drill and
pin the wrench to the pipe. 1. Remove the sppllt collar from each end of the shaft.
4. Using the wrench. turn the adjusting nut until all the 2. Attach a crane to both boom point sheaves. Support the
slaclt is removed from bath boom foot cushion assemblies. sheave so the boom point pin can be removed. The sheave
assembly weighs approximately 5000 lb (2265 kg).
5. Tighten the adjustment nut until you get a visual bulge in
the rubber washer (see Figure 48-4). 3, l’ha boom point pin must be removed from the right side
of the boom point Using a crane, support the boom point pin
6. Measure the length of the compressed rubber washers. as it is being removed.

7. Tighten the remaining side to the same measured

length. 1 WARNING b
ti locating km may bo looso whan the pin is
BOOM POINT ASSEMELY (919N19)
romovod. If the keys arm looso, they could fall
GENERAL. The boom point assembly consists of two and uusa injury to pwsonnol or damrga to
sheaves on tapered roller bearings. The sheaves are held in equipment.

40-2
SHOVEL BOOM
S U B S E C T I O N 48

6.505’~
s DIA 9OOM BORE
6.508”
6.500”
c DIA. PIN
6.502”
12.496” 07. BEARING RETAlNER
D DIA. SHEAVE SORE 01. SPUT COLLAR 08. SLEEVE 14. KEEPER PLATE
12.498”
02. SPLIT COLLAR 09. SEARING 19. SHEAVE
7.877” 03. KEY 10. SEARING 16. SHEAVE
E DIA. SPACER BORE
7.882” 04. LOCKING RING 11. SPACER 17. BOOM POlNT PIN
09. LOCKING RING 12. SEARING 19. LUBE FlTTlNG
12.870”
F DIA. SHEAVE BORE 06. BEARING RETAtNER 13. SEARlNG 19. LUBE FllTlNG
12.975-
7.874”
G DIA. SLEEVE 0 D.
7.875”
A640
6.515’~
H DIA. SLEEVE BORE
6.630”

48-S
SUBSECTION 48 SHOVEL BOOM

4. Pull the boom point sheave from the throat of the boom 1. Install the cups of all four bearings in the sheave hubs.
point.
2. Preheat and install the cone of bearing (09) on the left
DISASSEMBLY. Refer to Figure 48-2 and disassemble the end of sleeve (08). Screw bearing retainer (06) on the sleeve
boom point sheave assembly as follows: until the face of the retainer is flush with the end of the
1. Remove locking ring (04) and unscrew bearing re- sleeve. Install locking ring (04).
tainers (06 and 07) from sleeve (08). 3. Stand sleeve (08) on end with the installed retainer and
2. Support the sheaves and pull sheaves (15 and 16) and bearing cone down. Lift one sheave and place it over sleeve
bearings (12 and 13) from sleeve. Remove spacer (11) and (08) on the installed bearing cone.
inner race of bearings, if they remained on the sleeve. 4. Preheat the cone of bearing (12) and spacer (11). Install
INSPECTION AND REPAIR. Inspection consists of measur- the bearing cone over sleeve (08) onto the hub of sheave
ing the sheave bores and boom point pin diameter. Proper (15). Install spacer (1l)over thesleeveagainst bearing(12).
dimensions are shown on Figure 48-5. 5. Preheat and install the cone of bearing (13) over the
sleeve against spacer (11). Lift sheave (16)and position it on
Repair is limited to the replacement of bearings and the cone of bearing (13).
sheaves.
6. Preheat and install the cone of bearing (10) into the hub
of sheave (16). Screw bearing retainer (07) on sleeve until
ASSEMBLY. Refer to Figure 48-5 and assemble the boom the bearings have no appreciable end play or preload. In-
point assembly as follows: stall locking ring (05).

48-4
 SUBSECTION 4C
BOOM LIMIT SWITCHES

GENERAL BOOM LIMIT SWITCH (1 OOJ4105)

The boom limit switch is mounted behind the front cab wall. DESCRIPTION. This limit switch utilizes a double plunger to
The activating plunger protrudes from the cab wall. The activate the first and second stage switches. The inner
plunger is in line with a bracket welded to the boom. plunger activates the first stage switch while the outer
As the boom is jacked slightly, the limit switch will be acti-
plunger activates the second stage switch (see Figure 4C-
vated and cause the crowd motor to reverse or produce a 1).
zero torque condition. If the boom is jacked severely the MAINTENANCE. To prevent rust and corrosion the plunger
limit switch will shut the machine down electrically. and spring assembly should bedisassembled once a year or

SPRING

PROXIMITY
SWITCH
I 1 si STAGE
ROLLER AND
PLUNGER
2ND STAGE
\
BOOM
BAACKET
ROLLER AND
I ST STAGE
PLUNGER

- BASE

Figure 4C-1. Boom Limit Switch

4C-1
SUBSECTlON 4C BOOM LIMIT SWITCHES

every 5DDD hours. Clean the spring and plunger and repack 1. Loosen the two adjusting capscrews on the end of the
the cavities with grease (P&H 472). center rod.
REPAIR. Repair of this boom limit switch is limited to the re- 2. Slide the sensing plate so its edge is even with the front
placement of damaged parts. Removal and installation of of the switch.
these parts is apparent (see Figure 4C-1). 3. Tighten the mounting capscraws and test the action of
ADJUSTMENT. The action of the first stage switch should the switch bv jacking the boom. Readjust the sensing plate
be adjusted to operate with approximately 2 degrees of as necessary.
boom movement. Adjust the first stage switch as follows Activation of the second stage switch should take place
(see Figure 4C-2): when the boom is jacked approximtely 4 degrees. The ac-
tion of the switch is adjustable bv locating the switch arm
connection pin through the hole which allows the switch to
open at a 4 degree boom movement (see Figure 4C-2).

BOOM UMrr SWITCH (1 OoJ6311)

DESCRIPTION. This assembly contains two magnetic
proximity switches. One switch either reverses or shuts off
the crowd motor when the boom is jacked up slightly, the
other switch shuts down the machine if the boom is jacked
up severely. Each switch can be adjusted independently of
the other. This switch utilizes a single plunger to activate
both proximity switches (see Figue 4C-3).
MAINTENANCE. To prevent rust and corrosion the plunger
and spring assembly should bedisassembled once a year or
every 5DDD hours. Clean the spring and plunger and repack
the cavity with grease (P&H 472).
REPAIR. Repair of the boom limit switch is limited to the re-
placement of worn or damaged parts. Removal and instal-
Figure 4C-2. Second Stage Adjustment lation of these pam is apparent as shown in Figure 4C-4.

Figure 4C-3. Boom Limit Switch Assembly 1)

4C-2
SUBSECTION 4C BOOM LIMIT SWITCHES

BRACKET
CROW0
SENSINQ ARIUSllNQ MOTOR
AREA SCREWS SWKCW /

\ MACHINE
SHUTDOWN
SWITCII

SENSING TERMINAL
AREA BLOCK

Figure 4C-5. Limit Switch Adjustment

NOTE
4. If it becomes necessary to change the location of the
The plunger bottoms out at approximately 8”. switch assembly or boom bracket. retain the0.03-0.09 inch
3. Repeat steps 1 and 2 for the shutdown switch. gap shown in Figure 4C-3.

4c-4
SUBSECTION 40 DIPPER COMPONENTS

DIPPER MAINTENANCE 8. Check the latch bar engagement in the latch keeper. It
INSPECTION should be approximately l/4 inch (0.635 cm) (see Figure
40-l).
LATCH BAA. Periodicallycheckthe latch bar engagement in
the keeper. The proper engagement is l/4 inch (0.635 cm)
(see Figure 40-l ). LATCH BAR ’ ,, :,*%,
_..:,,,”>.-
WEAR PLATES. Inspect the dipper latch bar wear plates and I“’ LATCH LEVER
cushions periodically. The nominal clearance between the iHlM SPACER
latch bar and wear plate should be l/4 inch (0.635 cm).
There are no adjustments for the wear plate and cushions.
The wear plates and cushions should ba replaced when the
clearance reaches l/2 inch (1.27 cm) (see Figure 40-2).
DIPPER DOOR SNUBBERS. The dipper door snubbers
should be inspected periodically for friction disc weer. It is
recommended that the dipper door snubber friction discs ba
replaced when worn to a thickness of l/8 inch (0.318 cm).
Periodic dipper door snubber adjustments are necessary to
prevent the dipper door from slamming shut so rapidly that
damage could result.

ADJUSTMENTS
DIPPER DOOR LATCH. The dipper door latch bar must be
adjusted occasionally to compensate for wear. As the latch
bar wears, remova shims from beneath the latch lever to ob-
tain a l/4 inch (0.835) latch bar engagement in the latch
keeper. Refer to Figure 4D-3 and remove shims as follows:

1. Place the dipper on the ground to gain access to the latch

mechanism.
2. Raise the latch lever as far as it will go.
3. Place blocking b&ween the latch lever and dipper door
frame to prevent the latch lever from lowering.
4. Remove the cotter pins from the shim locating pins.
5. Raise the shim spacer and remove a shim.
6. Lower the spacer and install the cotter pins.
7. Remove the blocking from the latch lever. Figure 40-3. Dipper Door Latch

WEAR DIPPER
PLATE DOOR

I LATCH
CUSHION BAR

Figure 40-2. Dipper Latch

4D-2
DIPPER COMPONENTS SUBSECTION 40

DIPPER DOOR SNUBBERS. There are two adjustment pro- DIPPER TRIP ASSEMBLY (1 OOJl563-3)
cedures for the dipper snubbers. One, when the friction GENERAL. The dipper trip motor and drum are mounted on
discs are replaced and two, a periodic adjustment to pre- the right side of the boom near the boom base (see Figure
vent the dipper door from slamming shut.
40-5). The cable from the drum is routed over the dipper trip
When the dipper door friction discs are replaced, adjust the sheave on the saddle block to the boom dippertrip lever and
snubber as follows (see Figure 40-4): dipper.
1. Remove the cotter pin from the snubber pin. A constant voltage is applied to the motor. This voltage al-
lows the motor to keep slack out of the trip cable. When the
2. Tighten the adjusting nut until it is snug against the fiat
operator pulls the dipper trip lever, he shorts out resistance
washer.
in series with the motor field and the dipper trip lever with-
3. Measure the distance the snubber pin protrudes from draws the dipper latch bar allowing the dipper door to open.
the nut.
REMOVAL. Thedippertrip motor and drum assembly can be
4. Tighten the adjustment nut approximately 3/4 inch disassembled without removal from the machine. When re-
(1.91 cm). moval of the dipper trip anddrum assembly is required, pro-
5. Replace the cotter pin in the snubber pin. ceed as follows:

6. Repeat steps 1, 2 and 3 for the opposite snubber. 1. Shut off the electrical power to thedippertrip motor. Tag
and mark the electrical wiring connections to the motor. Re-
If during operation there is a noticeable slamming of the move the electrical wires.
dipper door, adjust the snubbers as follows (see Figure 4D-
2. Remove the dipper trip cable from the drum.
4):
1. Remove the cotter pin from the snubber pin. 3. Attach a lifting device to the dipper trip motor and drum.
This assembly weighs approximately 400 Ibs.
2. Tighten the adjusting nut as required to prevent slam-
ming. 4. ‘Remove the mounting bolts and lift the assembly from
the machine.
NOTE DISASSEMBLY. Refer to Figure 4D-8 and disassemble the
The adjustment nuts on each dipper snubber must be dipper trip motor and drum as follows:.
adjusted uniformly. 1. Secure the dipper trip motor and drum on a sturdy base.
3. Replace the cotter pin in the snubber pin. 2. Remove nuts (24), lockwashers (23) and washers (22).
4. Repeat steps 1, 2 and 3 to the opposite snubber. 3. Pull drum guard (25) from bracket (20).

ADJUSTMENT
WASliER
SNUBBER NUT /
_-__
ARM

I SPRING
\ yTER /

T----@a--- -
LOCK PIN SNUBBER
PIN
I
FRICTION
DISCS
SN"kER
PIN
SNUBBER
ARM
I
LOCK PIN
\
SNUBBER
PIN

Figure 40-4. Dipper Door Snubber

40-3
SUBSECTION 4D DIPPER COMPONENTS

SHEAVE SADDLE
A BLOCK

DIPPER TRIP
MOTOR AND
DRUM
_ DIPPER
HANDLE

Figure 40-5. Dipper Trip Assembly

4. Remove setscrews (14), springs (13) and spring caps To replace the ring gear, proceed as follows (see Figure 4D-
(12). 6):
5. Remove washer (28) and slide drum (32) off of pin (16). 1. Using an arc air torch, torch out the skip welds on the
Both bearings (30) should come off with the drum. ring gear. The skip welds are approximately l/4 inch deep.
8y using the arc air torch it will prepare thedrum groove for
6. Attach a lifting device to the dipper trip motor and re- the new ring gear weld.
move capscrews (02).
2. Lightly grind the drum weld edge. Do not remove more
7. Pull the motor away from the mounting bracket. than l/32 inch of metal.
8. Compress snap ring (OS) and remove it from the mount- 3. Clean the drum and ring gear of all dirt, rust and con-
ing bracket. Pinion (08) and bearing (07) can now be re- taminants.
moved.
4. Preheat the ring gear to 400°F. Position the ring gear in
9. Remove snap ring (06) and pull bearing (07) from the the drum so the face of the ring gear is flush with the face of
pinion.
the drum.
10. Remove keeper plate (17) and pull pin (16) out of the NOTE
motor bracket.
The preheat temperature must be maintained during
INSPECTION. Inspect all parts per the dimensional mea- welding.
surements shown in Figure 40-8. Check parts visually for
cracks, breaks or excessive wear. 5. Use AWS-E-7018 dry low hydrogen type electrodes.
REPAIR. Repair of this assembly consists of the replace- Tack weld in two places 180 degrees apart. Check to see
that the ring gear face is flush with the drum face.
mentpf all parts found to be damaged or which do not meet
the requirements as shown in Figure 40-8. The dipper trip 6. Skip weld 3 inches long, 180 degrees apart alternately
drum ring gear is a replaceable item. with 12 inch pitch.

40-4
DIPPER COMPONENTS SUBSECTION 40

DIPPER TRIP DRUM

/ r9

RING
GEAR

Figure 40-6. Welding Ring Gear to Drum

ASSEMBLY. To assemble the dipper trip motor and drum, 8. Install washer (28), lockwashers (23) and capscrews
proceed as follows (see Figure 40-8): (26). Use wire to lock the capscrews in place.
1. Slide pin (16) into bracket (20) and secure it with keeper 9. tine up the holes in drum guard (25) with rods (21). Slide
plate (17). the drum guard over the drum and fasten it in place with
washers and nuts (22. 23 and 24).
2. Press bearing (07) onto pinion (08) and secure with snap
ring (06). 10. Install springcaps(l2),springs(l3)andsetscrews(l4).
3. Install the pinion assembly into bracket (20). Secure with 11. Pump sufficient lubricant through fitting (15) to fill the
snap ring (05). ring gear cavity.
4. Clean the motor shaft splines with a degreasing sol-
vent.
5. Apply enough locking compound (P&H 212772) to fill the
INSTALLATION. Install the dipper trip motor and drum as
voids between the shaft splines and the pinion.
follows:
NOTE 1. Position the motor and drum on the mounting bracket at-
tached to the boom.
Hardening of the sealant begins within 20 minutes of
application. 2. Fasten the assembly in place using capscrews (09). lock-
washers (10) and nuts (11).
6. Assemble the motor to bracket (20)and secure with cap-
screws (02). 3. Attach the dipper trip cable to the drum (see Figure 4D-
7. Press prelubricated bearings (30) into drum (32). Slide 7).
the drum onto pin (16). 4. Connect the electrical wiring to the motor.

40-5
SUBSECTION 40 DIPPER COMPONENTS

DIPPER TRIP
MOTOR AN0
DRUM

CABLE

Figure 40-7. Cable Installation

4D-6
DIPPER COMPONENTS SUBSECTION 40

01. MOTOR
02. CAPSCREW
03. l.OCKWASHER
04 NUT
05. SNAP RlNG
06. SNAP RING
07. BEARlNG
08. PlNlclN
09. CAPSCREW
10. LOCKWASHER
Il. NVT
12. SPRING CAP
13. SPRING
14. SETSCREW
15 FITTING
16 PIN
17. KEEPER PLATE
18. LOCKWASHER
19. C*PSCREW
20. BRACKET
21. ROD
22. WASHER
23. LOCKWASHER
24. NUT
25. DRUM GVARD
26. CAPSCREW
27. LOCKWASHER
28. WISHER
29. WlRE
30. BEARING
31. WEDGE
32. DRUM

CODE
LETTER DIMENSION
A 3.543 DIA.
3.544 BORE
6 2.1655 DIA.
2.1660 PlNlON
c 1.550 DIA.
1.555 PIN
0 1.500 DIA
1 502 BORE
El3
E

F
1 5738
1 5744
3.1484
DIA.
PIN
DIA.
i’ 3.1496 BORE

F,gure 40-B D,pper Tr,p Drum Assembly (lOOJ1563-3)1

4D-7
 SECTION V
CROWD SYSTEM

SUBSECTION

5A. INTRODUCTION
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A- 1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-2

5B. CROWD DRIVE SYSTEM

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56-l
Torque Tube Drive (1 OOJ2995) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-l I

5C. CROWD TRANSMISSION

General . . . . . . . , , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ......... 5c-1
.Transmissiog (1 CKN2182) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5c-1

5D. SADDLE BLOCKS

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5D-1
Saddle Blocks (33J75 & 33J98) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-l

5E. CROWD BRAKES

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5E-1
Crowd Brake (1 OOJ1247-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5E-1

5F. CROWD LIMIT SWITCHES

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5F-1
Crowd Limit Switch (lOOJ3946) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5F-1

56. DIPPER HANDLES

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5G-1
Dipper Handle (11 J2849) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5G-1
 SUBSECTION 5A
INTRODUCTION

GENERAL system consists of the crowd motor, torque tube, crowd

transmission. shipper shaft, saddle blocks and the crowd
This section provides maintenance and repair information brakes (see Figure 5A- 1).
about the crowd system used on this excavator. The crowd

SHIPPER
SHAFT GEAR

STOP BLOCK
I-GREEN HORN”) I

GEARED / /
LIMIT
SWITCH

FIRST REDUCTION
WORM AND PINION

HOIST ROPE
GUARD ASSEMBLY

WORM
GEAR CASE

TOROUE TUBE

COVER

CROW0
MOTOR
DIAPER
STICK
- 7 L9’“1tJN

’ BOOM

/
Figure 5A-1. Crowd Machinery

5A-1
SUBSECTION 5A INTRODUCTION

DESCRIPTION engage the pinion racks welded to the underside of the

The crowd machinery is mounted on the boom. The pur- dipper handle. Rotation of the shipper shaft causes the
pose of the crowd system is to crowd or thrust the dipper dipper handles to extend or retract.
into the bank to assist in filling the dipper. The saddle blocks mounted on the ends of theshipper shaft
guide and hold the dipper handles. The saddle blocks re-
The crowd motor is mounted near the base of the boom to quire periodic adjustments to assure proper operation and
minimize the rotating inertia of the upper rotating system. maximum service life. The crowd brake is a spring set, air
Power from the crowd motor is transmitted to the crowd released holding brake which will apply automatically if
transmission through the torque tube. The crowd trans- system air pressure falls below a preset level. The brake
mission gearing drives the shipper shaft which is mounted should be set whenever the crowd machinery is in an idle
inside the boom. Pinions near the ends of the shipper shaft state.

5A-2
 SUBSECTION 58
CROWD DRIVE SYSTEM

GENERAL 4. Pry the grid members out of the hub grooves. Work
around the coupling hub, prying a little at a time to prevent
Power for the crowd drive is provided by a horizontally excessive force on the grid members (see Figure 56-2).
mounted, fast response, direct current motor. The crowd
motor is ventilated by a separate motor driven blower which NOTE
draws filtered air from within the machinery housing. The When the grid members are removed do not lose the
continuously turning blower forces clean filtered air di- ball which is between the coupling hubson the motor
rectly into the commutator end of the crowd motor, across end of the torque tube.
the armature and out the upper end of the motor.
OUTER GRID
TORQUE TUBE DRIVE (lOOJ299S)
DESCRIPTION. The torque tube transmits power from the
crowd motor to the worm shaft of the first reduction gear-
ing. The torque tube is coupled to the crowd motor and the
worm shaft by two flexible couplings.
REMOVAL. Refer to Figure 55-l and remove the torque
tube and coupling as follows:
1. Remove the crowd brake cover.
2. Attach a crane to the torque tube and remove the cou- -HUB
pling capscrews on each end of the torque tube. GRID MEMBER
3. Slide the coupling covers back. Be careful not to dam-
age the cover seal. Figure 58-2. Removing Grid Members

CAPSCREWS COUPLING COUPLING

COVER COVER
TORQUE TUBE CAYSCREWS
SEAL \

MOTOR WORM’DRIVE
SHAFT l/4” KEY SHAFT

Figure 55-l. Torque Tube and Coupling (1 OOJ29953

55-l
SUBSECTION 5B CROWD DRIVE S Y S T E M

5. Remove the torque tube. INSTALLATION. To install the same crowd motor and
torque tube assembly proceed as follows (see Figure 56-l ):
[V]
1. Remove the positioning dowels before mounting a new
crowd motor. The dowels should be used to position the
Never remove taper fit components with a pui-
crowd motor when reinstalling the same motor base.
Ier and jack. Pa-r could come off explosively
and cause injuy to personnel. 2. Position the motor on its mounting pads on the boom.
The motor weighs approximately 4UDD Ibs (1812 kg).
6. If it is necessary to remove the coupling half from either
the motor shaft or the worm drive shaft, proceed as follows: 3. If previously shimmed, replace the shims in their proper
locations.
A. Screw a blank nut on the shaft threads.
4. Install the mounting bolts.
6. Drive wedges behind the coupling half.
5. If the coupling and/or torque tube are to be replaced,
C. Strike the blank nut with a solid hammer blow which will
check the key in the coupling hub keyway. It should be
loosen the coupling half.
possible to push the key through the keyway by hand.
7. Support the crowd motor. The crowd motor weighs ap-
6. Measure the width and depth of the keyway in the hub
proximately 4DDD tbs.
and shaft. Compare key measurements to make sure the
[ W A R N I N G ) key will fit snugly, without binding. If necessary, file the key
until it is slightly smaller than the combined keywaydimen-
Be certain that all electrical Power is off be- sions.
fore removing the crowd motor wires.
7. If the tapered coupling hubs were removed from the
8. Tag and mark the crowd motor electrical wires and then motor shaft or worm drive shaft. the hubs must be lap fit to
remove them. the respective shaft as follows:
9. Remove the two brackets between the crowd brake base
and top of the boom.
10. Remove the four crowd motor mounting bolts. Do not heat the hubs when assembling them to
NOTE the shafts.

If shims are installed between the motor mounting A. Remove all nicks and/or burrs from parts.
pads and base, mark their location and the amount of 8. File all keyuays and prefit the keys. The keys must be a
shims in each location. . hand slide fit into the bore keyway. Remove the key.
11. Remove the crowd motor. C. Apply lapping compound at four places along the length
INSPECTION. Figure 55-3 is provided as a guide to the of the shaft and in the mating component bore.
proper torque tube assembly dimensions. These dimen- D. Engage the shaft in the bore and rotate the shaft in both
sions should be checked before assembly. directions.

BRAKE TORQUE
WHEEL TUBE HUE COVER
I I I

3.4985 I.D.
3.4975 CPLG.

3.4979 CPLG.

3.499 SHAFT

Figure 58-3. Torque Tube Assembly Dimensions

58-2
CROWD DRIVE SYSTEM SUBSECTION 56

E. Separate the parts and clean them with solvent. Ex- 13. Set the torque tube on “V” blocks and jacks in line with
amine the shaft surface for fit. A true lapped fit will show the crowd motor shaft and the worm shaft.
a gray color over the entire length of the shaft. If there
14. When installing a new crowd motor proceed to step 15.
are bright spots on the shaft, repeat the procedure until
When installing the same motor base that was removed
they disappear. A bearing surface of 90% or more is ac-
perform the following steps.
ceptable.
A. Check the gap between the coupling hub faces. The gap
F. When lapping is complete, clean the parts with solvent.
should be between l/16 and l/2 inch (1.59 and 12.7
The parts must be dry and free of oil film.
mm), with l/4 inch (6.35 mm) preferred. Make at least
G. Fit the key into the shaft keyway. Do not use a lubricant four measurements around the hub diameters to insure
on the mating parts. that the gap is the same around the circumference.
H. Assemble the two components and check for clearance 8. Add or delete shims as necessary under the motor
between the top of the key and the bottom of the key- mounting pads to obtain the clearance in step A.
way. Some clearance must be present, if not, file the top
of the key.
15. Proceed to step 17 when installing the same motor that
8. Install the coupling cover seal in the rear edge of the
was removed. Align the torque tube coupling hub face to the
cover (see Figure 58-4).
worm gear hub as follows when installing a new motor.
9. Before mounting the coupling hub, slide the cover and A. Place four l/4 inch (6.35 mm) spacer blocks at 90°
cover gasket over the torque tube. intervals, between the hub faces.
10. Install the key and coupling hub. B. Adjust jacks under torque tube at the crowd motor end to
11. Repeat steps 4 through 9 for the opposite end. maintain l/l 6 to l/2 inch (159 to 12.7 mm) gap when
spacer blocks are removed.
12. Weld jackscrew blocks to the boom when installing a
new motor. Blocks should be placed so the jack screws will C. Mark a spot on the torque tube and using a dial indica-
n.eet milled surfaces of the motor feet. Distances between tor as shown on Figure 58-5, place the torque tube so
ths worm shaft coupling hub and crowd motor hub must in- the dial indicator is placed at the top of the coupling hub.
clude a l/2 inch (12~7 mm) gap for each coupling. Set the dial indicator to a reading of 0.0 inches.

GRIO MEMBERS

COVER COVER
GASKET

COVER
SEAL -

CAPSCREWS GRID IDENTIFICATION

INNER LAYER PAINTED
ALUMINUM, STAMPED “IN”
OUTER LAYER PAINTED
BRONZE, STAMPED “OUT”

Figure 56-4. Coupling Assembly

58-3
SUBSECTION 50 CROWD DRIVE SYSTEM

16. Align the coupling hub face to the crowd motor hub
using the same proceduredescribed in step 15. Properindi-
cator readings should be achieved by moving the crowd
motor sideways and adding or removing shims from under
the motor as required.

17. Using a soft headed hammer, tap the inner and outer
grid members into position in the hub grooves. lap the grid
members part way into their grooves first, and then com-
plete installation bv tapping grid members into final posi-
tion.

Figure 555. Alignment Check NOTE

These couplings have inner and outer grid members.
NOTE Be sure that the ends of the inner and outer grid
members are pointing in the same direction and are
The dial indicator must remain on the spot marked on directly above and below each other.
the torque tube until the check is completed.

0. Rotate the torque tube so the indicator is positioned at

18. Slide the hub flange gasket into position and pack more
the bottom of the hub. Read the indicator and divide the
lubricant into the spaces around the grid members.
reading bv 2. This will indicate the amount to change the
jack at the worm end of the torque tube.
E. Rotate the torque tube so the indicator is positioned 90’
NOTE
from the top of the hub. Set indicator to 0.0 inches.
The importance of proper grease cannot be overem-
F. Again rotate ihe torque tube until the indicator is 1 SC0
phasized. If the coupling is not properly packed with
from position in step E. Read the indicator and move the
lubricant, centrifugal force will throw grease out-
torque tube sideways until reading on indicator is re-
ward, leaving the grid members dry.
duced by one-half.
G. Repeat steps C, 0, E and F until dial indicator deflection
is minimal at all four positions.
19. Slide the cover into position and tighten the cover cap-
H. Recheck l/4 inch (6.35 mm) gap setting between hubs screws. Then fill the coupling with more grease, using a
as described in steps A and 8. grease gun. Be sure the coupling is completely filled with
grease. The manufacturer suggests using a nail or small
NOTE screwdriver under the seal ring at the rear of the coupling
Using a puttv knife or similar tool, pack the coupling cover while the cover is being installed to allow air to vent.
hubs with proper grease. Be sure to force grease 20. Remove the blocking from beneath the torque tube and
down into the _aao. between the hubs. check the final alignment (Step 14).

50-4
 SUBSECTION 5C
CROWD TRANSMISSION

GENERAL which serves as the second speed reduction and the drive
for the crowd motion of the dipper stick. The gears are
The purpose of the crowd transmission is to reduce the
splash lubricated with oil contained in the bottom of the en-
speed and increase the torque output of the rack pinions.
closed gear case.
The transmission is enclosed in a gear case, which fits into
a fabricated box in the boom.
REMOVAL OF MAJOR COMPONENTS
TRANSMISSION (1 OGJ2182)
WORM DRIVE.. Refer to Figure 5C-1 and remove the drive
DESCRIPTION gear case as follows:
The crowd transmission consists of a first reduction worm 1. Operate the excavator to lower the dipper to the ground.
and worm pinion arrangement, and the shipper shaft. Slack off on the hoist cables.

HOIST ROPE
GUARD ASSEMBLY

WORM DRIVE
ANDGEARCASE
COVER AGSEMBLY

/ I

Figure 5C-1. Worm Drive Gear Case

5c-1
SUBSECTION 5C CROWD TRANSMISSION

2. Remove the hoist rope guard and drain the oil in the gear 4. Drive shaft (31) out of the worm housing. All parts
case into a container. mounted on the shaft will now be free, and should be re-
moved.
3. Remove the torque tube and crowd limit switch as de-
scribed in Subsection 56 and Subsection 5E. 5. Separate worm wheel (33) from spider (34) by removing
bolts (36).
4. Remove the capscrews which secure the worm drive
gear case to the crowd boom gear case. 6. Pinion (32) is keyed to shaft (31). The pinion can be
pressed from shaft (31) as required.
5. Remove the shear plugs and the shear plug O-rings.
6. Using a hoist, lift the worm gear case off the boom gear 7. Pull the cup of bearing (30) from the side of the gear case
from which the shaft was driven out. Remove the remain-
case. This assembly weighs approximately 3000 Ibs (1361
ing parts of bearing (30) from shaft (31).
kg).
8. Remove bearing retainer (15). Cut lockwire (19) and re-
SHIPPER SHAFT. Refer to Figure 5C-2 and remove the ship-
move capscrews (20) and adapter shaft (21).
per shaft as follows:
9. Remove nut (01) and the coupling hub from the end of
1. Remove the torque tube as described in Subsection 56.
the worm shaft. Remove key (02).
Remove the worm drive asdescribed in previous procedure.
10. Loosen the bolts which hold split bearing retainer nut
2. Remove split collar (01), shims (02), and spacer (03).
(04) together to remove the nut.
3. Attach a crane to the lifting eye of saddle block (04) and
slide the saddle block off shipper shaft (05). The saddle block 11. Unscrew bearing retainer nut (04). Bearing retainer
weighs approximately 2.900 Ibs (1270 kg). (10). seals (07). and spacer (08) can now be removed from
the end of the worm shaft as a unit.
4. Remove O-ring (06) and bushings (07 and 08) from the
saddle block. 12. Remove any shims which may be located adjacent to
gasket (11) and keep them together. These shims are used
5. Repeat steps 2, 3 and 4 on the opposite end of the to maintain proper sealing action of gasket (11). The same
shipper shaft. shims should be used during reassembly.
6. Attach a crane to the dipper handles and raise them off 13. Worm shaft (23) must now be driven out the rear of the
the shipper shaft pinions. Propel the excavator in reverse worm housing (toward the base of the boom). Double bear-
so the dipper will clear the shipper shaft pinions. Lowerthe ings remain in the worm housing and must be removed by
dipper handles onto suitable cribbing. means of a bearing puller.
7. Pull shipper shaft pinions (OS and 10). spacers (11 and 14. Bearing (13) may now be removed from the worm shaft,
12) will also be pulled from the shipper shaft. The shaft if necessary.
pinions weigh approximately 700 Ibs (317 kg).
6. The shipper shaft can be pushed or pulled from either NOTE
side of the boom. It is necessary to support shipper shaft Do not remove seal (18) unless it must be replaced.
gear (13) to relieve some weight from the shipper shaft
when removing the shipper shaft. Gear (13) weighs ap-
proximately 1500 Ibs (680 kg). SHIPPER SHAFT. It is necessary to disassemble the shipper
shaft to remove it from the crowd boom gear case. Refer to
9. Remove shipper shaft gear (13). Thrust washers (14 and Removal of Major Components, Shipper Shaft.
15) on each side of the gear are loose fitting and care must
be taken to keep these washers from falling. INSPECTION AND REPAIR
DISASSEMBLY OF MAJOR COMPONENTS WORM DRIVE ASSEMBLY. The pinion teeth should be
checked annually for surface fractures. An inspection cover
WORM DRIVE. Refer to Figure 5C-3 and disassemble the
is provided in the top of the worm drive gear case. It is
worm drive assembly as follows:
recommended that the bearings in the worm drive be in-
1. Turn the gear case upside down for ease of disassem- spected after 10,ODC hours.
bly.
Repairs of the worm drive assembly consist of replacing
2. Remove bearing spacers (28). Shims (29) will now be
worn or broken parts. Figure 5C-3 is provided as a guide to
free.
the proper dimensions of the worm drive assembly.
NOTE
SHIPPER SHAFT ASSEMBLY. The shipper shaft gear can be
All G-rings, gaskets, and shims in the crowd trans- inspected through the oil fill pipe plate, bolted on the front of
mission should be replaced whenever the gear case is the gear box. Inspection of teeth for fracture should be made
disassembled. It is also recommended that bearings annually.
be replaced.
Visually inspect the shipper shaft pinions for tooth defor-
3. Block pinion (32) and worm wheel (33) to prevent them mation after 10,DOD hours.
from falling when shaft (31) is driven out of the housing. Cut
lockwires (24) and remove capscrews (25) and keeper plate The boom bushings should be inspected after 10,000 hours
(26). along with the shipper shaft gear thrust washers.

5C-2
CROWD TRANSMISSION SUBSECTION 5C

19

I‘.
I ’ ‘.

-. ‘.
‘.
‘.
‘.
.‘- I
‘-J

,’
<

01. SPLIT COLLAR 09. KEY 17. SHtM 25. LOCKWASHER

02. SHIM 10. KEY 18. SPACER 26. CAPSCREW
03. SPACER 11. PlNlON 19. LH SADDLE B L O C K 27. LOCKWASHER
04. RH SADDLE BLOCK 12. PINION 20. O-RING 28. CAPSCREW
05. SHIPPER SHAFT 13. GEAR 21. B”.sHiNG 29. SLIDE PLATE
114.1/16”(~-6.1,16”)
05. O-RING 14. THRVST WASHER 22. B”SHlNG 30. LOCKWASHER
07. WSHlNG 15. THRVSTWASHER 23. DOWEL PIN 31. CAPSCREW
08. BUSWNG 16. SPUT COUAR 24. NUT 32. TIE WRE

Fagure 5C-2 Shpper Shaft A! isembly (910N4711

 SUBSECTION 5C

Repairs to the shipper shaft assembly consist of replacing 7. Install bearing retainer (10) with gasket (11) and the ori-
worn or broken parts and a weld build-up procedure for the ginal shims. Tighten capscrews (09) to firmly seat the cups
shipper shaft pinion shroud. Figure K-2 is provided as a or bearing (13).
guide to the proper dimensions of the shipper shaft assem-
bly.
To build-up the shipper shaft pinion with weld, proceed as
follows (see Figure 5C-4):
1. Clean the pinion. It must be free of oil, dirt and rust.
2. Grind out any surface cracks. Preheat the pinion to
800°F (426OC) and maintain this heat during welding.
3. Use 5/32 inch (3.97 mm) AWS-E-F3-MN-A electrodes
(Chemetron Wear Arc Ni-MN typical) in the welding
sequence shown in Figure 58-4. Height of build-up should
be approximately 3/l 6 inch (4.76 mm). Make a maximum of
three passes.

ASSEMBLY OF MAJOR COMPONENTS

WORM DRIVE. To assemble the worm drive assembly, pro-
ceed as follows (see Figure 5C-3):
1. Turn the worm gear case right side up for the first por-
tion of assembly.
2. Install seal (18) in the housing of the gear case.
3. Install outer race of bearing (17). seating it firmly against
its locating shoulder in the gear case bore.
4. Assemble bearing (13) on the drive end of the shaft (23).
5. Insert shaft (23) through the bores in the gear case,
using care to avoid dislodging of damaging seal (18). Block
shaft (23) in the gear case to prevent its weight from rest-
ing on seal (18).
6. If removed, install seals (07) and spacer (08) in the bore
of bearing retainer (10). Install lock plate (06)on bearing re-
tainer (10). Figure 5C-4. Pinion Weld Build-Up

5c-5
 SUBSECTION SD
SADDLE BLOCKS

GENERAL 4. Repeat steps 3 and 4 on the other end of the shipper

shaft.
The saddle blocks are of extra heavy welded construction of
liberal length to eliminate stick chatter and provided with 5. Adjust the saddle blocks as described below.
cast bronze wearing bars backed by shims for easy adjust-
ment.
SADDLE BLOCKS (33J75 & 33598)
ADJUSTMENT. Refer to Figure 5D-2 and adjust the lateral
DESCRIPTIGN. The saddle blocks are of one piece con-
clearance between the dipper handles and the saddle
struction. The saddle block uses a split bushing arrange-
ment which is doweled to the saddle block frame. The slide blocks as follows:
plates are engaged with the shipper shaft pinion. 1. Hoist the dipper handles into the horizontal position. Po-
sition the handles so that the hoist ropes are vertical. Set all
INSPECTION. The saddle block bushings should be checked
brakes.
for excessive clearance every 3,000 hours. The bushing
should be replaced when the clearance between the bush- 2. Pry either of the saddle blocks away from the dipper
ing and shaft approaches l/8 inch. Saddle block slide handle. Measure the clearance between the dipper handle
plates should be inspected at 5,OOC hours. Slide plate clear- and the saddle block. Mark this clearance down so it can be
ance should be checked monthly. referred to when adding or deleting the shims.
REMOVAL AND DISASSEMBLY. To remove and disassem- 3. Repeat step 2 for the opposite saddle block.
ble the saddle blocks, proceed as follows (seeFigure 50-l ):
4. Loosen the capscrew attaching the split collar to the
1. Operate the excavator to lower the dipper to the ground. spacer. To each saddle block, add or delete shims between
the split collar and the spacer to obtain a l/8 inch maxi-
2. Allow ample slack in the hoist cable. Remove cap- mum clearance between the dipper sticks and saddle block
screws (01) and bolts (03) from the right side of the shipper lateral surface.
shaft.
5. Tighten the split collar capscrews.
3. Remove the halvesof split collar (06). Pull shims(07)and
spacer (08) from shaft (09). Refer to Figure 5D-2 and adjust the slide plates as follows:
1. Hoist the dipper handles into the horizontal position.
4. Attach a crane to the lifting eye of saddle block(11). Slide
the saddle block off of the shipper shaft. Saddle block (11) 2. Divide the dipper stick rack into three approximately
yighs approximately 2800 Ibs. equal lengths using chalk or paint marks.
5. Repeat steps 2 through 4 for the left side of the shipper 3. Move the dipper handles in and out a few times to in-
shaft. sure that they are free in the saddle blocks and mating nor-
mally with the shipper shaft pinions.
6. Remove the saddle block bushings. These bushings are
doweled in four locations through the bushing flange. 4. Position the dipper handles so that the outer third of the
dipper handle racks (torsion box end) is in the saddle blocks.
ASSEMBLY AND INSTALLATION. Assemble and install the
Measure the clearance between the slide plate and the
saddle blocks as follows (see Figure 50-l ):
upper side of the dipper handles at both the front and rear of
1. Install the split bushing in the saddle block bore being the saddle blocks.
careful to locate the dowel pins.
5. Repeat step 4 for each of the other two sections of the
2. Attach a crane to the lifting eye of saddle block (16). Slide dipper handle.
the saddle block on the shipper shaft. The saddle block
6. Loosen the capscrews which secure the saddle block
weighs approximately 2800 Ibs.
slide plates to the saddle blocks and insert shims between
3. Install spacer (08). shims (07) and split collar (06). Se- the slide plates and saddle blocks until the clearance be-
cure the assembly with bolts (03) and capscrews (01). tween the top of the dipper stick and the slide plates is re-

50-l
SUBSECTION 50 SADDLE BLOCKS

duced to 1 /16 inch (at the point of the dipper handle that 7. If slide Plate wear is greatest on the end of the slide plate
shows the least wear). It is not necessary to remove the toward the base of the boom, check the shipper shaft and
slide plate to insert shims since the shims are slotted to saddle block bushings for excessive wear and replace them
pass around the capscrews. if necessary.

01. CAPSCREW
02. LOCKWASHER
03. BOLT
64. LOCKWASHER
06. NUT
06. COLLAR
07. SHIMS
06. SPACER
09. SHAFT
10. KEY
11. SAOOLE BLOCK
12. O-RING
13. PlNlON
14. THRUST WASHER
IS. GEAR
16. SAOOLE BLOCK Figure 50-l. Saddle Blocks (33J96)

50-2
1.H. SADDLE
BLOCK \ MEASURE SLIDE PLATE SLIDE
TO DIPPER HANDLE PLATE
CLEARANCE HERE

l/8” LATERAL
C L E A R A N C E 1‘1

BUSHINGS u I 1 II I SHIPPER
SHAFT

LATERAL SADDLE
BLOCK ADJUSTMENT

Figure 502. Shipper Shaft and Saddle Block Adjustment

-.
 SUBSECTION 5E
CROWD BRAKES

GENERAL CROWD BRAKE (1 OOJl247-3)

The crowd brake is mounted on its own base, just forward of INSPECTION. Refer to Figure 5E-1 and inspect the brake
the crowd motor. The base is bolted to the crowd motor shoe linings and the condition of drum surfaces every 5CCC
frame. The brake is a spring set air released holding brake. hours. Replace the brake shoe linings when worn to l/4
In the event that air pressure is lost, the brake will be inch. Check the adjustment of the brake and adjust if nec-
applied automatically. essary.

YOKE SPRING ROTOCHAMBER

ASSEMBLY ROD
LOCKNUT

JAW

’ BASE

Figure 5E-1. Crowd Brake (loOJ1247-3)

5E-1
SUSSECTlON 5E CROWD BRAKES

NOTE 1. Check all springs for cracks, warping and distortion.

Check the free length of the brake spring. This dimension
Life of the brake shoe linings can be greatly extended
should be 9-l/2 inches.
by maintaining proper brake linkage adjustment
REMOVAL The brake assembly should only be removed 2. Measure the thickness of the brake linings. The linings
from the mounting bracket if complete disassembly is re- should be replaced when worn to a thickness of l/4 inch or
quired. The rotochamber can be removed without detach-
ing the complete assembly from the crowd motor fram0.
Refer to Figure 5E- 1 and remove the brake assembly from
the crowd motor frame as follows:
1. Remove the brake cover. Release the spring pressure by
backing off the locknut on the spring rod until thebrake jaw
is released.
2. Loosen the air line connection at the rotochamber and
tap the fitting gently to break the seal. This will allow any
pressure trapped in the system to escape. Disconnect the
air line.
3. Remove the torque tube (see Subsection 55).
4. Remove the mounting bolts and lo&washers. Lift the
brake assembly straight up off of the brake drum.
ROTOCHAMBER REMOVAL To remove the rotochamber
without removing the brake assembly, proceed as follows
(see Figure 5E-3):
1. Perform stepa 1 and 2 of the brake aaaembly removal
procedure. Figure 5E-2. Brake Lining Replacement
2. Loosen jam nut (09) andunscrew the cylinder rod of the less. Refer to Figure 5E-2 and replace the brake linings as
rotochamber from spring rod (14). follows:
3. Remove the mounting hardware for the rotochamber 3. Check the friction plugs for excessive wear. Friction plug
and lift the rotochamber from yoke (08). dimensions are shown in Figure 554.
DISASSEMBLY. If completedisassemblyof thecrowd brake A. Remove the rivet hole plugs and remove existing rivets
is required, remove the brake assembly per the removal pro- from the brake shoes and linings.
cedure and disassemble as follows (see Figure 5E-3): 5. Remove the old linings from the brake shoes and place
1. Loosenstopjamnut(lO)andbackoffstop(ll). nm linings in position on the face of the shoes. Align
the holes in the new linings with the rivet holes in the
2. Loosen nuts (12) to relieve spring tension. brake shoes.
3. Perform steps 2 and 3 of the rotochamber removal pro- C. Install new rivets to secure the new linings to the brake
cedure. shoes. Place new rivet hole plugs in the linings.
4. Remove nuts (29 and 30) and washer (07). Lift the spring
4. Check all bushings for excessive wear. Replace as nec-
rod assembly from the yoke.
5. Remove spring rod guide (16) from the yoke.
6. Remove capscrews (17). eve pins (19) and retaining pins
(20). Remove the brake jaw assembly from brake base (23). ASSEMBLY. To assemble the brake mechanism, proceed as
follows (see Figure 5E-3):
7. Remove capscrews (17). eve pins (19) and retaining pins
(31). Separate brake shoes (03) from the brake jaws. 1. Install retaining pins (05) into Yoke (06) and brake jaws
(21). Secure with snap rings (22).
8. Remove snap rings (22) and pull retaining pins (28)from
brake jaw (21). 2. Compress friction plugs (01) on the friction plug springs
and install them in the brake shoes.
9. Remove friction plugs (01) and friction plug springs (02)
from the brake shoes. 3. Install the brake shoes on the brake jaws and secure
with retaining pins (31). Lock the retaining pins with eve
pins (19) and capscrews (17).
REPAIR. Repair of the brake assembly includes the re-
placement of damaged or worn parts, overhaul of the roto- 4. Install the brake shoes and brake jaw assembly on base
chamber and the replacement of brake linings. Inspect and (23). Secure with retaining pins(20). Lock the retainmg Pins
repair the brake assembly as follows: with eye pins (19) and capscrews (17).

5E-2
CROWD BRAKES SUBSECTION 5E

11
10
/
,
/

9
0

01. FRICTION PLUG 09. NUT 17. CAPSCREW 25. JAM NUT
02. SPRING 10. JAM NUT 18. LOCKWASHER 26. CAPSCREW
03. SHOE 11. STOP 19. EYE PIN 27. NUT
04. LINING 12. JAM NUTS 20. PIN 28. PIN
OS. PIN 13. WASHER 21. BRAKE JAW 29. NUT
06. YOKE 14. SPRING ROD 22. SNAP RING 30. JAM NUT
07: WASHER 15. SPRING 23. BASE 31. PIN
08. ROTOCHAMBER 16. SPRING ROD GUIDE 24. BUSHING

Figure 5E-3. Crowd Brake Assembly

5E-3
SUBSECTION 5E CROWD BRAKES

I I 4. Install the torque tube and brake cover (see Subsection

ROTOCHAMBER INSTALLATION. If the rotochamber was

removed without disassembling the brake, it may be rein-
stalled by performing steps 8 and 9 of the assembly proce-
dure and steps 3 and 4 of the installation procedure.

ADJUSTMENT. Maintaining the proper brake adjustments

will prolong the life of the brake drum and linings. To adjust
the brake after repair, proceed as follows (see Figure 5E-5):
NOTE
Stepa 1 and 2 must be performed at any initial brake
assembly or lining replacement to prevent bottoming
of the,air chamber piston. FuRher adjustmentwill not
be necessary throughout the life of the linings.
Figure 5E-4. Friction Plug Dimensions (19H970) 1. With the brake applied. loosen jam nut (02) and adjust
spring shaft nut (01) to obtain the 2-3/4 inch dimension be-
tween rotoohamber (09) and rotochamber rod end.

5. Install spring rod guide (16) in the yoke. 2. Tighten jam nuts (02) against the brake jaw pin and re-
check the 2-3/4 inch dimension. Repeat step 1 if this di-
6. Assemble jam nut (lo), stop (11). jam nuts (12). waaher mension has changed.
(13) and spring (15) on spring rod (14).

7. Install the spring rod assembly, through rod guide (1% 3. Adjust nut (04) to obtain a spring length of 8- l/2 inches
into the yoke. with the brake applied. Tighten jam nut (05).

8. Position jam nut (09) one inch from the end of the roto- NOTE
chamber rod and assemble the rotoohamber to the yoke.
This spring length must be checked periodically and
Secure with the mounting hardware.
maintained throughout the life of the brake linings to
9. With no air applied to the brake air chamber, screw the insure brake operation at rated capacitv.
spring rod onto the rotochamber rod until it reaches jam nut
(09). Tighten jam nut (09). 4. Adjust stop (06) so there is 518 inch maximum clear-
ance between the stop and yoke frame. Tighten stop jam nut
10. Position nuts (29 and 30) on spring rod (14) until a suf- (07).
ficient length of rod extends to allow installation of retain-
ing pin (28) and locknut (27). 5. Apply air pressure to the rotoohamber releasing the
crowd brake. The brakes should be equally released with a
gap of l/64 inch between the top of capscrew (11) and the
bottom of block (10). Adjust the height of capscrew (1 1) if
INSTALLATION. Install the brake assembly as follows:
necessary and tighten jam nut (12).

1. Lift the brake assembly and position it over the brake

drum. 6. Reset the crowd brake and check the spring length and
clearance dimensions. Readjust if these dimensions have
2. Install the mounting bolts and securely fasten the crowd changed.
brake to the crowd motor frame.

7. Release the crowd brake and recheck the gap between

3. Attach and tighten the air line to the rotochamber. capscrews (11) and block (10). Readjust if necessary.

5E-4
 SUBSECTION 5E
CROWD BRAKES

\
03
1 \
OS Lo7

01. NUT
02. JAM NUTS
03. SPRING
10 04. NUT
OS. JAM NUT
06. STOP
11
07. JAM NUT
12 06. JAM NUT
09. ROTOCHAMBER
10. BLOCK
11. CAPSCREW
12. JAM NUT
SHOE

Figure 5E-5. Crowd Brake Adjustment (1 OOJ1247-3)

5E-5
 SUBSECTION 5F
CROWD LIMIT SWITCHES

GENERAL 1. Loosen the cam hub setscrew and the allen head
setscrew on the top cam. Rotate both cams so they are di-
The crowd limit switch is a protective device which pre-
rectly over one another.
vents the dipper handles from being operated beyond their
limits. In the event that the operator crowds or retracts the 2. Retract the dipper handles slowly until seven dipper
dipper handles beyond their limits, the switch will close. handle rack teeth are counted between the shipper shaft
When the switch is actuated two circuits are simultaneous- pinion and the last rack tooth at the torsion box end of the
ly energized. One circuit will ring the crowd limit bell dipper handles. Set the crowd brake.
located in the operators cab, thesecondcircuit reverses the 3. Rotate the lower cam very slowly toward the retract
function of the crowd controller which will automatically re- proximity switch. When the crowd signal bell sounds in the
turn the dipper handles to their operational limits. operator’s cab the retract limit switch will close. Tighten the
cam hub setscrew. This completes the retract limit adjust-
CROWD LIMIT SWITCH (10053946) ment.

DESCRIPTION. The crowd limit switch is a proximity type 4. Extend the dipper handles slowly until seven dipper
switch, actuated bv two cams attached to the reducer out- handle rack teeth are counted between the shipper shaft
put shaft. This switch is located on the front of the trans- pinion and the last rack tooth at the greenhorn end of the
mission gear case (see Figue 5F-1). . dipper handles. Set the crowd brake.
ADJUSTMENT. The crowd limit switch will require an ad- 5. Rotate the upper cam very slowly toward the crowd
justment if the dipper. handles are replaced or if the crowd proximity switch. When the crowd signal bell sounds in the
motion mechanical assembly is reconditioned. The recom- operator’s cab the crowd limit switch will close. Tighten the
mended adjustment procedure may vary with circum- cam hub setscrew. This completes the crowd limit adjust-
stances. To adjust the crowd limit switch, proceed as ment.
follows (see Figure 5F-I): 6. Extend and retract the dipper handles several times in
each direction at full motion speed to check the limit switch
adjustments. It may be necessary to readjust either or both
cams.

NOTE
The crowd limit switch circuitry should be en- The crowd limit switch may be set and adjusted using
ergized. Caution should be exercised when a continuity tester. In this case it would be necessary
working near live circuit% to isolate the switches from the electrical circuits.

5F-1
SUBSECTION 5F

INSPECTION PLATE

SENSING AREA \

\ I
LOWER CAM AND
\.
HUS SETSCREW

Figure 5F-1. Crowd Limit Switch

5F-2
 SUBSECTION 5G
DIPPER HANDLES

GENERAL
The dipper handle consists of two legs joined at the dipper
end (see Figure 5G-1). The dipper handle rack sections are
welded to the handle legs. The handle sits on the shipper
shaft pinions and is held in place by a saddle block sus- DIPPER RACK
pended from each end of the shipper shaft.
DIPPER HANDLE (1152848)
REMOVAL
Remove the dipper handles as described in Subsection 5C.
INSPECTION
Inspect the dipper handles as follows (see Figure 5G-2):
1. Place the handle on parallels or blockswith the racks up. DIPPER TRIP
Level the torsion box end and shim the opposite end until it BRACKET
is also level.
2. Stretch a line along the entire length of the inside of the /
handle legs. With the line held straight, check the legs to in-
sure that they are straight within l/8 inch.
3. Check the spread or distance between the legs. This
distance must be 42.00-42.125 inches (see Figure 5G-3). AlTACHMENT
END
4. Check the twist of each leg. Each side must be straight
within 0.12 inches. /
5. Place a straightedge across the two racks betwen the
teeth as shown in Figure 5G-4. Place a square on the
straightedge and check the out-of-square condition of the
racks. The racks must be square within 0.12 inch. Figure 5G-1. Dipper Handle (11 J2849)
6. Check the parallelism c( !he handle surfaces as indi-
cated in Figure 5G-4.
7. Magnetic particle inspect all external welds as required.
REPAIRING CRACKS. Repair dipper handle cracks by weld-
8. Magnetic particle inspect all rack splice welds. ing as follows:
9. Weld all faulty welds using the procedure detailed in the -1. After the dipper handle is removed from the excavator,
following repair topic. place a heavy spacer bar or pipe between the dipper legs as
close to the open end as possible. This will maintain the
10. Check to be sure that all welds in the handle front area,
proper spacing of 42.00-42.125 inches.
particularly between the torsion box and legs, and at the for-
ward rack termination are ground free of obvious imperfec- 2. Clean the handle of all grease and dirt.
tions and blended into plates. 3. Magnetic particle inspect the handle to be sureof the lo-
11. Recheck all dimensions as shown in Figure 5G-2. cation of the cracks.
REPAIR 4. Preheat the cracked areas to 200°F
Repair of the dipper handles consists of welding proce- 5. Remove cracks bv the arc-air process. If possible, start
dures for repairing handle cracks and replacing handle rack two inches beyond the end of the crack to prevent further
sections. cracking.

5G-1
SUBSECTION 5G DIPPER HANDLES

CODE
LEITER I DIMENSION INCH
A I HANDLE WlDTH
I OUTSlOE (12.00
S INSIDE DISTANCE I

Figure 5G-2. Dipper Handle Dimensions (11 J2849)

5G-2
DIPPER HANDLES SUBSECTION 5G

THESE SURFACES NOTE

MUST BE PARALLEL
Make sure the electrodes are from a fresh dry can.
Once opened, the electrodes should be kept in a hold-
ing oven at 250°F.
END
REPLACING RACKS. Replace dipper handle racks as fol-
lows:

This procedure is for standard dipper handles

equipped with manganese racks. Do not use
thi, procedure for alloy racks.
1. Place a heavy spacer bar or pipe between the dipper
handle legs as close to the open end as possible to main-
Figure 5G-3. Checking Handle Spread tain the proper spacing of 42.00-42.125 inches.
2. Clean the handle of all grease and dirt.
NOTE 3. Remove the old racks using the arc-air process being
careful not to gouge into the dipper handle legs.
Arc-air in such a manner as to form a “J” groove. Do
not burn through if the opposite side of the member is 4. Grind the dipper handle leg surfaces smooth to prepare
inaccessible. for the installation of the new racks.

6. Grind all of the surfaces which have been arc-aired to a 5. Magnetic particle inspect the entire handle to be sure it
depth of l/32 inch. is free of cracks. If any cracks are found, they should be cor-
rected as outlined in the repair topic.
7. Magnetic particle inspect the cracked areas to make sure
the crack is completely removed. 6. Line up one set of rack sectionswith theteeth up using a
straightedge along the rack rails.
8. Preheat to 200°F soaking heat before rewelding. Hold
the interpass temperature below 400°F. 7. Place the second set of rack sections with teeth down on
top of the first set mating the teeth but offsetting the splice
NOTE by approximately five teeth. This will insure proper tooth
If the welding area is adjacent to the rack, a 6OOOF spacing across the splice joints (see Figure 5G-5).
preheat may be required. 8. Clamp both sets of racks together using a fabricated
9. Weld with a small 5/32 inch and 3/16 inch AWS E- clamp as shown in Figure 5G-6.
7018 electrode using the stringer bead technique. See Sec- 9. Preheat all joints to lOOoF soaking heat. Use a stringer
tion IX for maintenance welding procedures. bead technique for all welding.

RACK MUST NOT PROJECT

STRAIGHT EDGE OVER INSIDE OF STICK (L.H. 8 R.H.)
\ ENTIRE LENGTH

THESE SURFACES
TO BE PARALLEL
WITHIN 0.12”
ENTIRE LENGTH

SIDES MUST BE STRAIGHT

WITHIN 0.12” ENTIRE LENGTH

SIDES-TO BE PARALLEL
WITHIN to.1 2”

Figure 5G-4. Checking Dipper Handles

5G-3
 SECTION VI
SWING SYSTEM

SUBSECTION PAGE

6A. INTRODUCTION
General ........................................................................................6A- 1

6B. SWING MOTORS

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-1
Swing Motor Assembly (lDDJ1931) ............................................................... 6B-1

6C. SWING TRANSMISSIONS

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-1
Swing Transmission (lDDJ4242 81 lDDJ5122) ..................................................... 6C-1

6D. SWING SHAFT ASSEMBLY

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D-1
Swing Sahft Assembly (1 DDN2416 & 1 DDN28D8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D-1

6E. SWING BRAKE

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..% . . . . . . . . . . . . . . . . . . . . . . . . . 6E-1
Swing Brake (lDDJ1247-5) ....................................................................... 6E-1

6F. SWING CIRCLE COMPONENTS

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-1
Swing Gear (1 N1036 & 1 N1294) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-1
Roller Circle (lODN1622) ......................................................................... 6F-4
Roller Circle (1 DDP751) .......................................................................... 6F-6
Roller Path (182891, lDDJ2638-1, 29117 81 lDDJ3716-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-9
Center Gudgeon (91 ON501 81 91 DJ493) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-9
 SUBSECTION 6A
INTRODUCTION

GENERAL reduction gear. The swing shaft pinion meshes with the
large swing gear to revolve the upper (See Figure 6A-1).
The swing system as detailed in this section consists of two
direct current reversible swing motors, swing brakes, swing The swing system is supplied with spring set, air released
transmission, and all swing circle components. Removal, holding brakes on each swing motor. These brakes hold the
repair, installation, and adjustments of the various swing upper in the desired position.
system components are covered in their specific subsec- The revolving frame rotates on the carbody through the
tion. swing circle components. Rollers are installed between an
inner and outer segment to provide a roller circle. The roller
The two direct current reversible motors are mounted di- circle then acts as a bearing between the revolving frame
rectly above a swing gear case, which contains three stage and the carbody. The rollers of the roller circle ride between
reduction gearing operating in an oil bath. The motor pinion an upper roller path and a lower roller path. The upper roller
meshes with and drives the first reduction gear. The trans- is attached to the underside of the revolving frame by clips
mission transmits the power from the swing motor to the welded to the frame. The lower roller path is welded to the
swing shaft which is spline fitted to the bore of the third ring gear on the carbody.

6A- 1
SUBSECTION 6A INTRODUCTION

SECOND
REDUCTION

SWINQ
BRAKE
WEAR CASE
SWINQ SHAm /

AEDUCTION

SWINQ
SWING SHAFT PtNlON
I

Figure 6A-1. Swing System

6A-2
 SUBSECTION 6B
SWING MOTORS

GENERAL 1. Remove cab and roof panels as necessary for motor as-
sembly removal.
Swing power is provided by two vertically mounted, fast
response, direct current motors. The swing motors are lo- 2. Tag and disconnect all electrical wiring to the motor.
cated on top of the transmission. Each swing motor has a
spring set. air released brake, bolted to the motor. The* 3. Remove the air supply line from the brake rotochamber.
brakes are holding brakes and should be set after the upper
4. Remove the motor mounting bolts.
is in desired position. They are also automatically set if air
pressure is lost. 5. Lift the motor assembly straight up off the gear case. The
motor weighs approximately 3000 Ibs (1361 kg).
This subsection covers the removal and installation of the
swing motors. Actual motor repair is covered in an electri- DISASSEMBLY. Disassembly of the motor assembly is,
cal maintenance manual. Repair and adjustment of the limited to the disassembly of the motor pinion and mounting
swing brakes are covered in this subsection. assembly and removal of the swing brake mounting as-
sembly as follows (See Figure 68-2):
1. Remove lockwire (01) and four mounting capscrews
SWING MOTOR ASSEMBLY (1 OOJl931)
(02). Remove impeller housing (03).
REMOVAL. Remove the swing motor and brake assembly NOTE
as follows (See Figure 66-l ): Retain shims (04) between the motor and impeller
housing (03).
2. Remove cotter pin (05) and unscrew impeller (06) from
the motor shaft.
3. Using a suitable puller remove motor pinion (07). Re-
move key (08).
4. Remove brake mounting bracket assembly by removing
mounting hardware and lifting entire brake assembly from
the swing motor (See Figure SB-1).
ASSEMBLY. Reassemble the motor pinion and pump as-
sembly and the brake mounting bracket as follows (See Fig-
ure 68-2):
1. Install pinion key (08) in the groove of the motor shaft.
2. Install motor pinion (07) and screw impeller (06) on the
motor shaft.
3. On a new motor, drill a 3/8 inch (9.53 mm) holethrough
the motor shaft, using the hole in the impeller asa guide. In-
stall cotter pin (05).
4. Install impeller housing (03) in the proper relation to the
flat surface of the motor flange. Secure with four cap-
screws (02) and install lockwire (01).

NOTE
Check impeller for free rotation. If impeller does not
rotate freely place shims (04) between impeller
Figure 6B-1. Swing Motor and Brake Assembly housing and the motor.

6B-1
SUBSECTlON 66 SWING MOTORS

5. Install brake mounting bracket assembly and secure

B- 00 with mounting hardware (See Figure 65-l ).

INSTALLATION. Install the swing motor assembly as fol-

lows (See Figure 68-l ):

1. Place the adapter ring on the swing transmission in a

position so that the flat side of the adapter ring will coincide
with the flat side of the motor flange.

Spa&i owe should ba taken not to damage the

motor pinion and pump assmmblywhorn install-
ing tha swing motor.

2. Using a suitable lifting device lift the motor assembly

into position over the gear case. The swing motor assembly
weighs approximately 3,000 Ibs (1361 kg).

3. Secure the motor assembly in place with the mounting

bolts.

4. Connect the air line to the rotochamber.

01. LOCKWIRE g6. COmR PIN 5. Connect the electrical wiring to the motor as tagged in
02. CAPSCREWS 06. PUMP IMPm.ER the removal procedure.
03. iMPEU.ER HOUSING 07. MOTOR PINION
04. SHIMS 08. KEY
Figure 68-2. Motor Pinion and Mounting Assembly

68-2
 SUBSECTION 6C
SWING TRANSMISSIONS

GENERAL DISASSEMBLY. Figure 6C-4 is provided as a fold-out to be

used while performing the assembly and disassembly pro-
The swing transmission transmits power from the swing
cedures. All parts are keyed to Figure 6C-4 unless other-
motor to the swing shaft to rotate the upper. The excavator
wise stated. Disassemble the swing transmission as
is supplied with two swing transmissions. Each swing
follows:
transmission contains a triple reduction gear arrangement
as shown in Figure 6A-1. 1. Place the swing transmission on suitable blocking SC

The swing transmission contains lubricant sufficient to that cover (01) is sitting on the blocks.
submerge the second and third reduction gearing. The first 2. Remove bearing retainers (56) and shims (53, 54 and
reduction gear is lubricated by a bearingless pump mounted 55). Shims must be saved for reassembly. Remove oil seals
on the swing motor armature shaft. The case is built in three (52) from retainer (56).
sections, lower section, middle section, and cover section.
3. Remove bearing retainer (44) and gasket (42).
These three sections are connected with coupling bolts,
bolts,-and dowels. All case sections are provided with NOTE
mounting flanges.
Oil pipes and inspection covers should only be re-
moved if damaged and replacement is necessary.
SWING TRANSMISSION (WDJ4242 & lOOJ5122) 4. Remove the lower section mounting hardware and lift
PERIODIC INSPECTION. The swing transmission should be lower section (06) from the center section. Care must be
inspected for cracks in the gear teeth faces. taken as sections are doweled at the rear of thecase flange.

The cover section has two inspection openings for viewing 5. Remove cups of bearings (51 and 41) from lower section
the condition of the first and second reduction gear teeth. (06). Remove cones of bearings (51 and 41) from the third
reduction gear and the second reduction pinion.
The center section has a side inspection cover for viewing
the condition of the second reduction gear and pinion teeth. 6. Remove third reduction gear (50) and remove cone of
bearing (46) from the gear.
The base section has a side inspection opening tocheck the
third reduction pinion and gear teeth. NOTE

REMOVAL. Remove the swing transmission from the Do not remove snap ring (47). O-ring (48) or baffle (49)
excavator as follows: unless parts are damaged or worn.
7. Remove the middle section mounting hardware and lift
1. Remove roof panels as necessary to lift the transmis- the middle section from the cover section. Care must be
sion from the shovel. taken as the section is doweled at the rear of the case
2. Remove the swing motor and brake assembly as de- flange.
scribed in subsection 66. NOTE
3. Drain the oil from the swing transmission into suitable Coupling bolt (08) located on the front of the case is a
containers. body fitted bolt and should be removed using a soft
4. Remove the transmission mounting bolts and using a drift and hammer.
suitable device lift the transmission from the revolving 8. Remove bearing retainer (29) and cup of bearings (46
frame. The swing transmission weighs approximately 4DDD and 28). Lift second reduction pinion shaft (39) from the
Ibs (1812 kg). middle section.
9. Remove cone of bearing (36) from retainer (37). Remove
reduction gear (38) from pinion shaft (39).
NOTE 10. Lift reduction pinion shaft (26) from cover sectIon and
Check to be sure that nothing will interfere with the remove cones of bearings (28 and 23). retainer (24) and
swing transmission as it is lifted from the excavator. gear (25).

6C- 1
SUBSECTION 0C SWING TRANSMISSIONS

11. Remove cups of bearings (23 and 36) from cover SECOND
section (01). REDUCTION
12. Turn cover section (01) on blocks and remove bearing FIRST
retainers (32 and 15). Remove shims (33, 34 and 35). REDUCTION,
CLEANING, INSPECTION AND &PAIR. Clean all compo- COVER SECTION
nents of the swing transmission with a suitable cleaning (INVERTED)
solvent and dry thoroughly with compressed air. All gasket
material must ba removed from all surfaces of the case sao-
tions.

Beeringa mue never k spun when drying with

compfma8od air.
Figure 6C-1. Gear Assemblies, Installation
Figure 6C4 provides installed dimensions of the wansmis-
sion. Inspect all parts for wear, cracks and other damage. , OOWEL
PIN
Repair of the swing transmission is limited to the replace-
ment of all seals, O-rings, and worn or damaged patts. it is
recommended that all bearings be replaced when this
transmission is disassembled for repair.
ASSEMBLY. Assemble the swing transmission as follows
(See Figure 6C-4):
NOTE
All bearing cones must bet preheated prior to installa-
tion on shafts. Extreme cam must ba taken to assure
bearings are never heated over 3OOOF (1469OC).
Freezing of the bearing cups is acceptable to aid in COVER SEC-DO _
their installation. Figure 6C-2. Center Section, Installation
1. Place cover section (01) on b&king with the top up. In- 11. Install cup of bearing (46) in center section and press
stall cones of bearings (23 and 36) and retainers (32 and cones of bearings (46 and 51) on reduction gear (SO).
15). Do not install shims(33.34and 3S)at thistime. Mount- 12. If removed, install baffle (49). O-ring (46) and snap ring
ing capscrews for retainers must be loose. (47) in the bore of reduction gear (SO).
2. Press reduction gear (25) firmly against the shoulder of 13. Install third reduction gear assembly in the center sec-
shaft (20). Check condition and fit of key (27) before tion and install the cone of bearing (41).
installing the gear. 14. Place gasket (OS) on the center section. Gasket thick-
3. Press reduction gear (38) firmly against the shoulder of ness must be 0.016 inch (0.41 mm).
shaft (39). Check condition and fit of key (40) before 15. Install cups of bearings (5 1 and 41) in lower section (06)
installing the gear. and install the lower section on thecenter section. Align the
4. Install grease retainers (24 and 37) on their respective lower section using a dowel pin and coupling bolt as shown
shafts with the flat side of the retainers against the gear in Figure 6C-3.
hub. 16. Install bearing retainer (56) without seals (52). Do not
5. Press cones of bearings (28 and 23) on reduction shaft tighten the retainer mounting bolts.
(26). tapered end of bearing to the outside.
6. install cone of bearing (36) on reduction shaft (39).
tapered end of bearing cone to the outside.
7. Turn cover section (01) over on blocking and install first
and second reduction assemblies in the cover section as
shown on Figure 6C-1.
6. Install the cup of bearing (28) in retainer (29) and install
retainer on center section (04).
9. Install gasket (03) on flange of cover section (01). The
gasket must be 0.016 inch (0.41 mm) thick.
10. (nstall center section (04) on cover section (01 ), prop-
erly lining up the dowel pin and coupling bolt as shown in
Figure 6C-2. Figure 6C-3. Lower Section, Installation

6C-2
SWING TRANSMISSIONS

SUBSECTION 6C

17. SHIM
18. SWM
19. CAPSCREW
20. LOCKWASHER
2 1 . FITTING
2 2 . FITTING
23. BEARING
24. RETAINER
25. GEAR
25. SHAFT
27. KEY
26. BEARING
29. RETAINER
30. CAPSCREW
31. TIE WRE
32. RETAINER
33. SHlM
34. SHIM
36. SHIP.4
35. BEARING
37. RETAINER
36. REDUCTION GEAR
39. SHAFT
40. KEY
41. BEARING
42. GASKET
43. O-RING
44. RETAlNER
45. CAPSCREW
45. BEARING
47. SNAP ICING
48. ~-RING
49. BAFFLE
50. REOUCTlON GE A R
51. BEARING
52. OIL SEAL
53. SHIM
54. 6WM
CODE
55. SHIM
LEITER DIMENSION 55. RETA,NER
L 6.374 R E T A IN E R 57. WASHER
5.375 I.D. 56. CAPSCREW
59. PLATE
M 3.6025 SHAFT 60. WASHE R
3.5015 0.0. 61. CAPSCREW
N 6.0025 SHAFT 52. COVER
8.0015 0.0. 53. GASKET
54. CAPSCREW 25-
0 11.125 BORE 01. COVER 55. WASHER
11.127 I.D. 02. COUPLING BOLT 56. COVER
P 6.75 P.D. 03. GASKET 67. GASKET
W8 O.P.: 23 T 04. MlDDLE SECTION 66. PLATE
05. GASKET 69. TUBE
(1 8.ooO P.O. 06. LOWER SECTION 70. CAP
l-112 D.P. 12 T 07. 6”LT 71. OIL 5TlCK
R 24.000 P.O. 06. COUPUNG BOLT 72. TVBE
2-112 O.P. 60 T 09. N”T 73. ELBOW
10. WASHER 74. TV66
S 21 .Joo P.O. 11. BOLT 75. TUBE
3 O.P. 63 T 12. WASHER 76. CAP
T 22.000 P.D. 13. NUT 77. PLUG
l-l/2 O.P. 33 T 14. PIN 76. BOLT
15. RETAINER 79. LOCKWASHER
,a SHIM 90. NUT 58’ 8
I I A637

bwe 6C-4. Swrq Transmtsslon (loOJ4242 & lCO~5122j

6C-3
SUBSECTION 6C SWING TRANSMISSIONS

17. Install gasket (42) and retainer (44). Torque retainer 20. Install oil seals (52) in retainer (56). The seals must be
capscrews (45) to 100 ft-lbs (13.83 kg-m). installed from the flat side of the retainer. Install the re-
tainer on the gear case and tighten the capscrews.
18. Torque all case section mounting bolts to 100 ft-lbs
(13.83 kg-m). 21. Turn the case on the blocking and set the end play of re-
duction shaft (39) and (26) as described in step (19). using
19. Set third reduction gear (50) end play as follows:
the proper retainer. Do not repeat step A.
A Tighten all retainer capscrews (58 and 19) until snug.
22. Install all piping and inspection covers if previously re-
Strike gear case sufficiently with a heavy object, while
moved.
rotating first reduction gear (25). to insure all bearings
are properly seated. Loosen all capscrews (58 and 19).
8. Tighten retainer (56) mounting capscrews equally in INSTALLATION. Installation of the swing transmission is
small increments. After each increment that the cap- basically the reverse of removal with the following excep-
screws are tightened, spin reduction gear (25) to check tions:
bearing preload. When reduction gear (25) rotates one
revolution when spun, the bearing preload is correct. 1. Anew gear case will require the reaming of eight mount-
When the correct bearing preload is attained, measure ing holes to 1.250 inch (3.2 cm) and two motor mounting
C
the gap between bearing retainer (56)and thegear case. holes to 1 .125 inch (2.86 cm) at assembly.
The measured gap plus 0.005 inch (0.13 mm) repre- 2. Fill the gear case with approximately 40 gallons of lubri-
sents the shim thickness required to provide proper end cant (see Section IX).
Wv.

6C-4
 SUBSECTION 6D
SWING SHAFT ASSEMBLY

GENERAL 1. Slide the spacer onto the shaft until it is tight against the
shaft shoulder.
The swing shaft assembly consists of the swing shaft, bear-
ing spacer, bearing, bearing retainer and swing pinion. The 2. Press the bearing on the shaft. The bearing must be tight
swing shaft transfers torque from the swing transmission against the bearing spacer.
to the swing gear.
3. Install a new seal in the bearing retainer and place the
The shaft assembly should be inspected periodically for ex- retainer over the shaft.
cessive wear and chipped or broken teeth.
4. Install the swing pinion on the shaft.
SWING SHAFT ASSEMBLY (lOON 6 & 1 OON2808)
REMOVAL. To remove the swing shaft assembly, proceed NOTE
as follows (see Figure 60-l or Figure 60-2): Do not damage the seal when installing the pinion.
1. Swing the machine upper so that the swing shaft to be The seal lip fits on the hub of the pinion.
removed is over the front of the carbody.
5. Install the flat washer and nut. Tighten this nut securely
2. Lower the dipper to the ground to relieve strain on the
on the shaft and secure with a cotter pin.
front of the revolving frame.
6. Lift the swing shaft in position under the revolving
3. Remove the sheet metal guard which protects the swing
frame.
shaft pinion.
7. While holding the swing shaft tightly in place, use a pry
4. Place blocking beneath the swing shaft to prevent the bar to raise the bearing retainer near the revolving frame.
shaft from falling when the shaft retainer is removed. The There must be a minimum gap of 0.03 inch between the
shaft and pinion weigh approximately loo0 Ibs. bearing retainer and the revolving frame before the cap-
5. Remove the tie wire and retainer capscrews. Lower the screws are tightened. See point “A” in Figure 60-l or
swing shaft assembly from the excavator frame. If the shaft Figure 60-2.
is broken on the upper end, it may be necessary to remove NOTE
the swing transmission to extract the broken piece.
The gap is necessary to assure that the outer bearing
6. Pull the bearing and bearing spacer from the shaft. race is secured between the revolving frame and the
retainer flange. This prevents the outer race from ro-
tating in the bearing bore.
INSPECTION AND REPAIR. Inspect all parts for proper di-
mensions as shown in Figure 60-l or Figure 60-2. Repair is
limited to the replacement of worn and broken parts. 8. Install the retainer capscrews, fastening the bearing re-
tainer and swing shaft in place. Torque the capscrews to
150 ft-lbs. Secure the capscrews with wire.
ASSEMBLY AND INSTALLATION. Assemble and install the
swing shaft as follows (see Figure 60-l or Figure 60-2): 9. Replace the swing shaft pinion guard.

60-l
SUBSECTION 60 SWING SHAFT ASSEMBLY

SWING
SHAFT

_d+_-?
0
s
I
I
I
I
I
I
I
I
I
me -__-
_-- -

1
SPACER

RETAINER
-___
__--
L
PlNlON

CAPSCREW

COTiER
PIN

Figure 6D-1. Swing Shaft (lOON 6)

6D-2
SWING SHAFT ASSEMBLY SUBSECTION 6D

SWING
SHAFT

~spAcE” 46

ACE

a -NUT
- W A S H E R

@!a\.

COl-rER
PIN
Figure 60-2. Swing Shaft (lOON2808)

60-3
 SUBSECTION 6E
SWING BRAKES

GENERAL SWING BRAKE (1 OOJl247-5)

Two swing brakes are used, one on the armature shaft of INSPECTION. Refer to Figure 6E-1 and Inspect the brake
each swing motor The brakes are sprmg set, air released. shoe llnmgs and the condition of drum surfaces every 5000
When the operator presses the release button on the con- hours. Replace the brake shoe linings when worn to l/4
trol console a solenoid valve IS operated applying air pres- Inch. Check the adlustment of the brake and adjust If nec-
sure IO the brake air chamber. If air pressure should be lost essary.
the brakes WIII be applied automatically by spring force

ROTOCHAMBER
YOKE SPRING
ASSEMBLY ROD

LOCKNUT

_ LINING

DRUM

\ BASE

Figure 6E-1. Swing Brake (lOOJ1247-5)

6E-1
SUBSECTION 6E SWING BRAKES

NOTE 1. Check all springs for cracks, warping and distortion.

Life of the brake shoe linings can be greatly extended Check the free length of the brake spring. This dimension
by maintaining proper brake linkage adjustment. should be g-112 inches.

REMOVAL The brake assembly should only be removed 2. Measure the thickness of the brake linings. The linings
from the mounting bracket if complete disassembly is re- should be replaced when worn to a thicknessof l/4 inch or
quired. The rotochambar can be removed without detach-
ing the complete assembly from the crowd motor frame.
Refer to Figure 6E-1 and remove the brake assembly from
the swing motor frame as follows:
1. Refease the spring pressure bY backing off the locknut on
the spring rod untii the brake jaw is released.
2. Loosen the air line connection at the.rotochamber and
tap the fitting gently to break the seal. This will allow any
pressure trapped in the system to escape. Disconnect the
air line.
3. Remove the mounting bolts and lockwashers. Lift the
brake assembly straight up off of the brake drum.

ROTOCIIAMSER REMOVAL To remove the rotochamber

without removing the brake assembly, proceed as follows
(see Figure 6E-3):
1. Perform steps 1 and 2 of the brake assembly removal
procedure.
2. Loosen jam nut (09) and unscrew the cylinder rod of the Figure 6E-2. Brake Lining Replacement
rotochamber from spring rod (14). less. Refer to Figure 6E-2 and replace the brake linings as
3. Remove thq mounting hardware for the rotochamber follows:
and lift the rotochamber from Yoke (06). 3. Check the friction plugs for excassive wear. Friction plug
dimensions are shown in Figure 6E-4.

DISASSEMBLY. If complete disassembly of the swing brake A. Remove the rivet hole plugs and remove existing rivets
is required, remove the brake assembly per the remove1 pro- from the brake shoas and linings..
cedure and disassemble as follows (see Figure 6E-3): 8. Remove the old linings from the brake shoes and place
1. Loosenstopjamnut(lO)andbackoffstop(ll). new linings in position on the face of the shoes. Align
the holes in the new linings with the rivet holes in the
2. Loosen nuts (12) to relieve spring tension. brake shoes.
3. Perform steps 2 and 3 of the rotochamber removal pro- C. Install new rivets to secure the new linings to the brake
cedure. shoes. Place new rivet hole,plugs in the linings.
4. Remove nuts (29 and 30) and washer (07). Lift the spring
rod assembly from the yoke. 4. Check all bushings for excessive wear. Replace as nec-

5. Remove spring rod guide (16) from the Yoke.

6. Remove capscrews (17). eye pins (19) and retaining pins
(20). Remove the brake jaw assembly from brake base (23). ASSEMBLY. To assemble the brake mechanism, proceed as
follows (see Figure 6E-3):
7. Remove capscrews (17). eye pins (19) and retaining pins
(31). Separate brake shoes (03) from the brake jaws. 1. Install retaining pins (05) into yoke (06) and brake jaws
‘(21). Secure with snap rings (22).
8. Remove snap rings (22) and pull retaining pins (28)from
brake jaw (21). 2. Compress friction plugs (01) on the friction plug springs
and install them in the brake shoes.
9. Remove friction plugs (01) and friction plug springs (02)
from the brake shoes. 3. Install the brake shoes on the brake jawa and secure
with retaining pins (31). Lock the retaining pms with eye
pins ( 19) and capscrews (17).
REPAIR. Repair of the brake assembly includes the re-
placement of damaged or worn parts, overhaul of the roto- 4. Install the brake shoes and brake jaw assembly on base
chamber and the replacement of brake linings. Inspect and (23). Secure with retaining pins(20). Lock the retaining pins
repair the brake assembly as follows: with eve pins (19) and capscrews (17).

6E-2
 ,06

01. FRICTION PLUG OS. NUT 17. CAPSCREW 26. JAM NUT
02. SPRING 10. JAM NUT 18. LOCKWASHER 26. CAPSCREW
03. SHOE 11. STOP 19. EYE PIN 27. kUT
04. LINING 12. JAM NUTS 20. PIN 28. PIN
05. PIN 13. WASHER 21. BRAKE JAW 29. NUT
06. YOKE 14. SPRING ROD 22. SNAP RING 30. JAM NUT
07. WASHER 16. SPRING 23. BASE 31. PIN
08. ROTOCHAMBER 16. SPRING ROD GUIDE 24. BUSHING

Figure 6E-3. Swing Brake Assembly

SUBSECTION 6E SWING BRAKES

3. Attach and tighten the air line to the rotochamber

AOTOCHAMBER INSTALLATION. If the rotochamber was

removed without disassembling the brake, it may be rein-
stalled by performing steps 8 and 9 of the preceding as-
sembly procedure.

ADJUSTMENT. Maintaining the proper brake adjustments

will prolong the life of the brake drum and linings. To adjust
the brake after repair, proceed as follows (see Figure 6E-5):

NOTE
Steps 1 and 2 must be performed at any initial brake
assembly or lining replacement to prevent bottoming
Figure 6E-4. Friction Plug Dimensions ( 19H970) of the air chamber piston. Further adjustment will not
be necessary throughout the life of the linings.

5. install spring rod guide (16) in the yoke. 1. With the brake applied, loosen jam nut (02) and adjust
spring shaft nut (01) toobtain the 2-314 inch dimension be-
tween rotochamber (09) and rotochamber rod end.
6. Assemble lam nut (10). stop (1 1). jpm nuts (12). washer
(13) and spring (15) on spring rod (14).
2. Tighten jam nuts (02) against the brake jaw pin and re-
7. Install the spring rod assembly, through rod guide (16). check the 2-314 inch dimension. Repeat step 1 if this di-
Into the yoke. mension has changed.

3. Adjust nut (04) to obtain a spring length of 8-l/2 inches

8. Posmon lam nut (09) one inch from the end of the roto- with the brake applied. Tighten jam nut (05).
chamber rod and assemble the rotochamber to the yoke.
Secure with the mountmg hardware.
NOTE

9. With no air applied to the brake air chamber. screw the This spring length must be checked periodically and
sprmg rod onto the rotochamber rod until It reaches jam nut maintained throughout the life of the brake linmgs to
(09). Tighten jam nut (09). insure brake operation at rated capacity.

10. Positlon nuts (29 and 30) on sprmg rod (14) until a suf- 4. Adjust stop (06) so there is 5/8 Inch maximum clear-
ficlent length of rod extends to allow mstallation of retain- ance between the stop and yoke frame. Tighten stop lam nut
mg pm (28) and locknut (27). (07).

5. Apply air pressure. to the rotochamber releasing the

swing brake. The brakes should be equally released with a
gap of l/64 inch between the top of capscrew (11) and the
bottom of block (10). Adjust the height of capscrew (1 1) if
necessary and tighten jam nut (12).

INSTALLATION. Install the brake assembly as follows: 6. Reset the swing brake and check the spring length and
clearance dimensions. Readjust if these dimensions have
1 Lift the brake assembly and posmon tt over the brake changed.
drum.

2. Install the mounting bolts and securely fasten the swmg 7 Release the swmg brake and recheck the gap between
brake to the swung motor frame. capscrews (11 j and block (10). Readjust If necessary.

6E-4
SWING BRAKES SUBSECTION 6E

c-_- 8-l/2”

I
2-3/4”

I
5/8” MAX. +

08

01. NUT
02. JAM NUTS
03. SPRING

05. JAM NUT

06. STOP
07. JAM NUT
08. JAM NUT
09. AOTOCHAMBER
10. BLOCK
11. CAPSCREW
12. JAM NUT
13. SHOE

Figure 6E-5. Swing Brake Adjustment (lOOJ1247-5)

6E-5
 SUBSECTION 6F
SWING CIRCLE COMPONENTS

GENERAL BROKEN TOOTH

The swing circle components include the mechanical com-
ponents, of the carbody and lower assemblies, utilized to
rotate the upper. Included are the swing gears, roller paths,
roller circles, and center gudgeon.

SWING GEAR (lN1036 & lN1294)

DESCRIPTION. The swing gear is the large stationary gear
between the revolving frame and the carbody. This gear is
bolted to the carbody. The swing pinion engages the swing
gear to revolve the upper. It also is the seat or mounting sur- USE TRI-TEN
face for the lower roller path. OR Tl ON TOP
AN0 BOTTOM
A two piece ring gear is available if a replacement is neces- OF GEAR
sary. The following instructions cover the installation of the
split type ring gear. Figure 6F-1. Tooth Reinforcement
INSPECTION. The swing gear should be inspectedannually
for surface fractures at the tooth faces.
1. Clean and inspect the teeth on each side of the broken
REPAIR. Repair of the ring gear consists of welding cracks tooth for cracks (use dye penetrant method).
in the ring gear, replacing broken teeth and building up a
2. Preheat the gear to 600°F before burning or welding on
new tooth where a tooth is completely lost.
the gear.
To repair the ring gear when a tooth is broken off and lost,
3. “V” out both sides of the tooth to provide space for the
proceed as follows:
weld but leave a small “land” for fitting. Grind the arced
1. Clean and inspect the teeth on each side of the broken surfaces clean and smooth.
tooth for cracks (use dye penetrant method).
4. Butter weld both sides of the joint before welding the
2. Make a template out of sheet metal to help form the new center.
tooth. This template should span 5 teeth.
5. Make a sheet metal template to accurately space the
3. Preheat the area to 6DD°F; protect this area from wind to broken teeth. The template should span 5 teeth.
prevent cooling of the weld metal. Do not allow the weld or
6. Reheat to 600°F and place the broken tooth back into the
welded area to cool until all welding is completed.
main ring gear, and tack it in place with an E-l 0016 or E-
4. Use a low hydrogen AWS E-1001 6 or E-1001 8 elec- 10018 electrode.
trode. Build a new tooth with stringer beads. Chipandclean
7. Maintain preheat at 6OOOF. Keep welding until finished,
each weld.
protected from the wind, and peen each weld. Grind smooth
5. Do not stop welding until the tooth is finished. Grind the when finished welding.
top, bottom and sides of the finished tooth flush.
8. Reinforce the top and bottom of the tooth, as shown in
6. After the tooth has been built up, the top and bottom of Figure 6F-1.
this area should be reinfored with a 3/8”plate. asshown in
Figure 6F-1. If the gear has cooled, warm the plate and gear
to 6DD°F again before welding the plate in place. Finish REMOVAL. Because of the variety of tools available and
grinding the tooth contour. methdds that can be employed. this section will not at-
To repair the ring gear when a tooth is broken off and is tempt to describe how to jack the revolving frame. To re-
found at the site, proceed as follows: move the swing gear, proceed as follows:

6F-1
SUBSECTION 6F SWING ClRCtE COMPONENTS

1. Secure the power and remove the tail cable. INSTALLATION. To install the split swing gear, proceed as
follows:
2. Loosen and remove the center gudgeon nut.
1. Place the two halves of the new gear in place so that the
3. Jack the revolving frame up to allow ample room to work. welded splices will fall near the midpoints on the sides of
the carbody.
(WARNlNG( 2. Line up the gear halveswith several shear pinsanddrive
the spacer shims in place making sure they are bottomed
and located as shown in Figure 6F-2.
After ti ravohring frmno i8 jacked. block it
with suitable cribbing to pme it from
tilling 3. Check the alignment of the teeth across each splice joint.
or shifting. 4. Drill and ream two new 2 inch (5.1 cm) dowel pin holes
into the carbodv, locating these holes from extra holes in
each segment of the swing gear half. lnsen extra locating
4. Remove the roller circle as described in the topic Roller
dowels and install remaining shear pins (see Figure 6F-3).
Circle, Removal.
5. Build a suitable shield around the working area to pre-
5. Remove the swing gear mounting bolts. vent any draft or sudden chilling of the preheated area.
6. Using a torch, cut the welds of the lower roller path. 6. Preheat splice area at least 12 inches (30.5 cm) on each
7. Remove the roller path. The roller path weighs approxi- side of the splice joint to 6DD°F (315.2OC) soaking heat. Do
mately 1,900 Ibs (861.9 kg). not allow preheat to cool below 4ODOF (204.2OC).
NOTE
8. lf a new swing gear is to be installed, cut’the old geer in Once welding has started, it must be continued until
two pieces to ease the removal. entire splice joint is completed.

GEAR OVERHANG
SECflGN “A” _ “A”

Figure 6F-2. Swing Gear Installation

6F-2
SWING CIRCLE COMPONENTS SUBSECTION 6F

7. Usea 1/8inchelectrodetypeA.W.S.E1~16orEl~18 11. Finish welding the vertical portion in the root of the
for tacking, stringer beads and out of position welds. Tack gear tooth.
and stringer bead one pass of weld on the bottom restricted
12. Cover with asbestos and slow cool.
area of the gear (see Figure 6F-4).
13. Grind the flat surface of the ring gear flush for proper
8. Run stringer beads all around the top, back and front fill of the roller path.
securely holding shim in place. Put in approximately l/4
inch (6.4 mm) of weld metal all around including the root of 14. Grind all the areas to proper contour.
the tooth. 15. Repeat the above welding procedure on the opposite
side.
9. Finish all welding under and up in the back restricted
area of the tooth root (see Figure 6F-4). 16. Check the final gear tooth profile and spacing.
10. Finish all welding on the flat and inside vertical por- 17. Install the lower roller track as described in the topic
tions of the weld joint using 5/32 inch A.W.S. El001 6 or -Roller Path, Installation.
El0018 electrodes. All passes should be of the bead type
and thoroughly chipped between passes.

700”
MOUNTING BOLT 2-12 EQUALLY SPACED

PATH

- SWING GEAR

StRAlGliT ROLLER PATH

SECTION “A”--“A”

II

I
I MOUNTING
BOLT
\

TAPERED ROLLER
MOUNTING PATH
BOLT /

SECTION 3”--“B”

- CARSODY
CAP

1
TAPERED ROLLER PATH
SECTION “A”--“A”

Figure 6F-3. Shear Pins

6F-3
SUBSECTION 6F SWING ClACLE COMPONENTS

1. Swing the upper so the roller to be removed is at the side

of the revolving frame, below the point where the upper
peth is open.

\ RiRTRICT5D AREA

It is suggostod th8t tha powar k 8hut off at the

powor station. This will pnvont injury if then
Figure 6F-4. Restricted Area of Tooth Root io contact with tha high voitaga rings.

2. Remove the nearest splice plate on the outside roller

segment.
ROLLER CIRCLE (lOON 622) 3. Remove the necessary pin nuts to allow the opening of
DESCRIPTION. Two types of roller circlea have been used the outer segment to the roller being removed.
on this machine. This writeup is for “straight” rollers. 4. Using a suitable punch, drive the roller pin out.
Tapered roller circlea are covered later in this subsection.
5, Remove the roller.
The rollers act aa bearings between the revolving frame and
carbody. They ride between the upper roller path and~lower NOTE
roller path. The upper roller path is held to the underside of
the revolving frame by clips welded to the frame. The lower The roller pin spacer is loose and could fall when the
roller path is welded to the ring gear in the carbody (SW Fig- roller is removed.
ure 6F-5). INSPECTION. The roller circle assembly should be inspec-
ted annually for worn or cracked inner and outer segments.
REMOVAL. Refeno Figure 6F-6 and remove the roller circle lf worn, it will be apparent on the inside surface adjacent to
as follows: the roller hubs.

RO.LLER PATH

Figure 6F-5. Straight Roller Path

SWING CIRCLE COMPONENTS SUBSECTION 6F

LOCKWASHER

GREASE FllTlNG

\
\ NUT

ROLLER

INNER /
SEGMENT
’ PIN
SPLICE / -
PLATES

OUTER SEGMENT

SPLICE

Figure 6F-6. Rollers

When a roller is removed, inspect the amount of wear the Annually check the roller assembly bolts for trghtness.
roller has caused on the segment. If there are indications of
excessive wear, replace the segment (see Figure 6F-7). lNSTALL4TION. To install the rollers in the roller circle, pro-
ceed as follows (see Figure 6F-6):
It is recommended that the segments and spacers be
1. Insert the roller spacer in the roller.
changed after 15,000 hours. The rollers should be re-
placed after 25,000 hours. Roller outside diameter wear is 2. Place the roller between the roller segments.
not a problem if wear is uniform with all the rollers. 3. Insert the roller pin from the inside of the roller circle
NOTE 4. Bend the outer segment into place and screw the roller
pin nut on the roller pin.
Always replace all the rollers when one needs re-
placing. If one roller is replaced, it will run higher than 5. Repeat steps 1 through 4 for the remarnrng rollers.
the rest and could cause excessive wear and/or 6. Install the segment splice and fasten it with lockwash-
damage. ers and nuts.

6F-5
SUBSECTlON 6F

eouiooed with an automatic lubrication system. insert the

grease fining in each roller pin and lubricate.
9. Check to see that the roller turns free. The roller spacer
should be tight between the segments and should not turn.

ROUJER CIRCLE (100p781)

DESCRIPTION. The tapered rollers of the roller circle act as
bearings between the revolving frame and carbody.
The rollers ride between the upper roller path and lower
roller path. The upper roller path is held to the underside of
the revolving frame bv clips welded to the frame. The lower
sPAc6n roller path is welded to the ring gear on the carbodv (See
Figure 6F-8).
REMOVAL Refer to Figure 6F-9 and remove the tapered
StamNT rollera from the roller circle as follows:
Figure 6F-7. Segment Wear 1. Swing the upper so the tapered roller to be removed is at
the side of the revolving frame, below the point where the
NOTE upper roller path is open.

The concave surface of the compreaaion tvpe lock-

washer must be toward the segment to function prop-
erlv
7. Retighten the roller pin nuts.
It i8 8uggntmd that th8 power k shut off at thm
8. If the excavatdr is equipped with an automatic lubrica- poww swtion. Thk will pravont injury if t h m
tion svstem, connect the lubrication lines to the roller. If not is co- with tha high vokaga rings.

REVOLVING FRAME

PlNlON

Figure 6F-8. Tapered Roller Path

6F-6
SWING CIRCLE COMPONENTS SUBSECTION 6F

ROLLER
COTTER PIN

TAPER
ROLLER
ASSEMBLY

Figure 6F-9. Roller Removal

2. Remove the cotter pin from the top of the roller retaining ASSEMBLY. Refer to Figure 6F-10 and assemble the tap-
pin. ered roller as follows:
3. Pull the roller retaining pin from the top of the roller 1. Wash all the roller parts in a suitable non-flammable sol-
retaining pin. vent and dry thoroughly.
4. The tapered roller can not be pulled out from the roller 2. If the bushing was not removed from the roller pin, pro-
circle. ceed with step 3. To install the bushing, proceed as follows:
DISASSEMBLY. Refer to Figure 6F-1 D anddisassemble the
tapered roller as follows: A. Heat the bushing under a heat lamp for approximately
1. Remove the’pipe plugs and drain the oil. 30 minutes.
2. Using a punch, drive out the roller pin from the seal 6. While the bushing is hot, slide it on the pin and position
retainer. the bushing so the inside oil groove is in line with theoil
hole of the roller pin.
3. Remove the seal retainer from the roller.
3. Insert the roller pin with bushing into the roller.
4. Remove the roller retainer cap. The thrust washer will
now be loose. 4. Place the thrust washer on the head of the pin. The
tapered edge of the thrust washer must be up.
5. Remove the roller pin and bushing.
5. Place the O-ring in the O-ring groove of the retainer cap.
NOTE Apply a small amount of grease to hold this O-ring in place.

The bushing is shrunk fitted to the pin. If it is neces- 6. Place the retainer cap on the roller and fasten with cap-
sary to remove the bushing, replace it with a new one. screws.
7. Install the pipe plug in the retainer cap.

8. Using seal ring installation tool (Caterpillar No. 5M160

INSPECTION AND REPAIR, The tapered roller should be in- Figure 6F-11). Install one half of the seal ring in the roller.
spected annually for lubricant leaks from the roller seals. Install the other half of the seal ring in the seal retainer.
Repairs to the roller are limited to the replacing of the roller Take care to avoid scratching or nicking the sealing faces of
seals and O-rings. the metal rings.

6F-7
SUBSECTION 6F SWING CIRCLE COMPONENTS

PIPE
PLUG
SKAL RETAINER

THRUST WASHER

RETAINER

ROLLKR PIN

CAPSCREW
Figure 6F-10. Taper Roller Assembly AND LOCKWASHER

11. Place the seal retainer over the roller pin, lining up the
hole in the pin with the hole in the seal retainer.
12 Push down on the seal retainer so it slides over the
shoulder of the pin. While holding it down, insert a punch
through a seal retainer hole so it engages the pin. This will
hold the seal retainer down while inserting a roll pin
through the opposite retainer hole (see Figure 6F-12).

RETAINER

Figure 6F-11. Seal Ring Installation Tool

NOTE
Special care should be taken to wipe the seal ring in-
stallation tool edges and surfaces that will come in
contact with the seal, using tissue paper. Se careful
that the rubber ring or its seat does not come in con-
tact with any oil.
9. Insert O-ring in the inside O-ring groove of the seal
retainer.
10. Place a few drops of clean oil on the metal seal rings
and wipe it off. A light coat of oil should remain on seal
rings. Figure 6F-12. Seal Retainer Assembly

6F-8
SWING CIRCLE COMPONENTS SUBSECTION 6F

13. Insert a roll pin in the opposite seal retainer hole. Using u-1
a punch, drive the pin in place so half of the roll pin engages
the hole of the roller pin.
After the revolving frame is jacked, block it
14. Remove the punch which is holding the seal retainer.
with suitable cribbing to prevent it from falling
15. Insert a roll pin in the hole of the seal retainer. Using a or shifting.
punch, drive the pin in place so half of the roll pin engages
the hole of the roller pin.
4. Remove the roller circle as described in the topic Roller
16. Insert a pipe plug in one hole of the seal retainer. Circle, Removal.
17. Using a pressure regulator which has been previously 5. Using a torch cut the welds and remove the roller path or
regulated to 20 psi (1.37 bars), insert it in the opposite seal pat“s. Each roller path weighs approximatly 1,900 Ibs
retainer hole. (861.9 kg).
18. Apply air, check to see that it is not more or less than 20 INSTALLATION. Refer to Figure 6F-13 and install thelower
psi (1.37 bars). roller path as follows:
19. Submerge the entire roller in a clean non-flammable, 1. Clean the ring gear groove using a suitable grinder.
non-corrosive solution. 2. Preheat the ends of the split roller paths to 500°F
20. Check to see that the roller is free of leaks. Any leaks (259.7%).
must be corrected. 3. Weld the spacers in place on the ends of the split roller
21. Remove pressure regulator from roller assembly and paths.
fill roller with 1 OW-30 oil (Approximately l/2 pint). 4. Grind the parting lines on the top of the split roller paths
22. Install pipe plug in hole of seal retainer. until they are smooth.

INSTALLATION. Refer to Figure 6F-8 and install the tap- 5. Set the split roller paths in the ring seat groove.
ered roller in the roller circle as follows: 6. Weld the split roller path in place using a heavy tack weld
1. Insert the roller pin in the roller circle. in six places equally spaced.
UPPER ROLLER PATH. Install the upper roller path as
follows:
1. Position one section of the split roller path so it has a 70
inch (17.28 m) radius from the center of the gudgeon to the
It is suggested that the power be shut off at the inside of the roller path (see Figure 6F-14).
power station. This will prevent injury if there
is contact with the high voltage rings. 2. Weld the clips in place as indicated in Figure 6F-14. Be
sure to maintain the 70 inch (17.78 m) radius.
3. Cut the ends of the split roller paths to the dimensions
2. Rotate the roller pin while pushing the roller retaining shown in Figure 6F-15.
pin up from the bottom of the roller circle.
4. Weld the inside and outside shear bars in place as
3. When the retaining pin is inserted through the roller pin, shown in Figure 6F-14.
insert a cotter pin at the top of the retaining pin.
5. Weld a l-l 12 inch x 1 inch x 3 inch (3.81 cm x 2.54 cm x
7.62 cm) bar stock to the revolving frame at the ends of the
ROLLER PATH (182891, lOOJ2638-1, 29U7 split roller paths.
81 lOOJ3718-1) 6. Grind a bevel on the ends of the split roller path as shown
GENERAL. The roller path consists of an upper and lower in Figure 6F-16.
path. The upper is held in place by shear bars and clips 7. Install the roller circle as described In the topic Roller
welded to the underside of the revolving frame. The lower Circle, Installation.
roller path is welded in the groove of the ring gear.
8. Lower the revolving frame on the roller circle.
Because of the vast variety of tools available and methods
that can be employed, this section will not attempt to de- 9. Install the center gudgeon nut and adjust it as described
scribe howto jack the revolving frame. It will concentrate on in the topic Center Gudgeon, Adjustment.
the positioning of the roller paths, clips, shear bars, and the
welding necessary to secure the roller paths.
REMOVAL. Remove the upper and lower paths as follows: CENTER GUOGEON (910N501 81 91OJ493)
1. Secure the power and remove the tail cable. GENERAL. Removal and repair of the center gudgeon is not
covered in this subsectron. In case a problem occurs with
2. Loosen and remove the center gudgeon nut.
the center gudgeon notify your area HARNISCHFEGER
3. Jack the revolving frame up to allow ample room to work. representatrve.

6F-9
SUBSECTION 6F SWING CIRCLE COMPONENTS

LOWER ROLLER

n PATH

SPACER

Figure 6F-13. Split Roller Path installation

An adjusting nut is provided at the top of the center gudgeon

to compensate for wear between the upper and lower roller
paths, roller, and the thrustwasher undertheadjusting nut.
The oparator should not hold the dipper in a
stalled condition when applying a load to the
It is recommended that the wear be checked at least once machine, as dascribad above.
every three months and if necessary adjusted.

2. If the clearance is l/4 inch (6.4 mm) or greater, take up

the excess clearance by tightening the center gudgeon nut.
ADJUSTMENT. The following procedure describes a
method of checking and adjusting the center gudgeon nut 3. Manipulate the dipper until the clearance is zero
(see Figure 6F-17). between the upper roller path and the rollers. This will
balance the revolving frame. Maintain this balance until the
(WARNING) adjustment is made.
4. Expose the adjusting nut by opening the access cover on
the left side of the base plate under the low voltage
As this procedure requiras that tha machine is collectors.
swung periodically during the adjustmant pro-
cedura, it is recommandad that the operator 5. Swing the machine to locate the lock key under the
and maintenance parsonnel establish a means opening.
of communitcating with each other bafore
beginning the procedure.

1. Have the operator take a deep cut in the work face, while Extreme care must be exercised while adjust-
the maintenance man is positioned at the rear of the ma- ing the center gudgeon nut, as the low voltage
chine in a location to observe if any clearance exists be- collector is located just above the adjusting
tween the upper roller path and rollers. Repeat this pro- nut. These collectors are electrified during the
cedure several times. procedure.

6F-10
SWING CIRCLE COMPONENTS SUBSECTION 6F

ROLLER PATH

VIEW A-A

CENTER POINT OF
CENTER GUDGEON

ROLLER PATH

THIS IS THE RIGHT SIDE.

THE LEFT SIDE HAS THE SAME
OIMENSIONS AN0 LOCATIONS.

IPS
/

Figure 6F-14. Upper Roller Path Installation

6F-11
SirSSECTION 6F

~-30-l/1-
Figure 6F-15. Roller Path Ends

6. Loosen the key retaining strap and remove the capscrew

which secures the strap to the adjusting nut. Pry out the
lock key by placing a screwdriver under the strap.

7. There are four keyways in the adjusting nut and three in

the center gudgeon. so the nut can be locked in 30 degree
increments. With the key removed, turn the nut clockwise
until it is as tight as possible.

NOTE
One method of turning the nut would be to drive the
nut with a suitable bar and sledge hammer.
INSIDE
SHEAR
BAA
8. Swing the machine clockwise to locate the nearest set of
matched keyways.

9. Install the lock key and secure the lock key with the key
Figure 6F-16. Bevel Edge retaining strap.

6F-12
 SECTION VII

PROPEL SYSTEMS

SUBSECTION PAGE

7A. INTRODUCTION
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-1

78. PROPEL DRIVE SYSTEMS

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B- 1
Propel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78-l
Propel Motor Base (100J3976) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78-5
Propel Motor Couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78-8

7C. PROPEL TRANSMISSION

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C-1
Transmission (1 DDJ3944) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7c-1

7D. PROPEL BRAKES

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7D-1
Propel Brake (lDDJ4516) ......................................................................... 7D-1

7E. STEERING SYSTEM

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7E-1
Steering Linkage Assembly (1 DDJ4683) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7E-4

7F. FINAL DRIVES

General ........................................................................................ 7F-1
Final Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7F-1

7G. CRAWLER COMPONENTS

General ........................................................................................ 7G-1
Crawler Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7G-1
Crawler Belt Roller (910N516) .................................................................... 7Gr4
Crawler Belt Idler Assembly (91 DJ322) ............................................................ 7G-6
 SUBSECTION 7A
INTRODUCTION

GENERAL propel brake area. One clutch is driven directly and the op-
posite clutch is driven through the horizontal propel shaft
This section covers the maintenance and repair of the
which passes through the propel motor base and extends
propel components used on this machine. The basic propel
across the carbody. When the steering jaw clutches are en-
machinery consists of the reversible propel motor, propel
gaged in the propel clutches, the corresponding final drive
transmission, horizontal propel shaft, and the crawler drive
reduction pinions propel the crawler drive tumblers and
shafts and tumblers which propel the machine on the
tracks.
crawler tracks. The complete propel machinery is shown in
Figure 7A-1.
DESCRIPTION The propel brakes and steering system are shown in Figure
Propel power is provided by a reversible, direct-current 7A-2. The propel brakes and the steering system are
motor. The output of the propel motor is transmitted pneumatically operated; the air control components are
through the power take-off shaft to a triple reduction trans- housed on a cabinet in the carbody. Maintenance proce-
mission. The transmission output shaft drives the female dures for components of the propel air system are covered
half of the propel clutches. These clutches are located in the in Section VIII.
BRAKE AIR
CYLINDER

PROPEL
HORIZONTAL I\ \ /

BRAKE WHEEL

TRANSMISSION

R TAKE-OFF SHAFT

DRIVE TUMBLER

Figure 7A-1. Propel Machinery

7A-1
SUBSECTION 7A INTROOUCllON

PROPEL FLANGE
w SPRING
(DAIVING)
\

- -T--.7_ .7 \

/’ ENoAaEo’
POSITION i
/
./A
,---
r

i--- i..,
\-
FINAL DRIVE
PINION
PROPEL BRAKE
WHEEL

Figure 7A-2. Propel and Brake Clutch Assembly

Two V-type propel brakes are used, one at each final reduc- The jaw clutches are operated through a lever and yoke sys-
tion pinion shaft. The brakes are released automatically, tem bv means of double acting air cylinders. When a jaw
when the PROPEL button on the operator’s control console clutch engages the propel flange, propel power can be
is depressed. transmitted from the flange, through the jaw clutch, to the
propel brake wheel and final drive.
Each propel brake wheel is slotted to accept a male jaw
clutch member which rides on the brake wheel hub. The This subsection covers the maintenance and repair of the
jaw clutch members are always engaged in the brake crawler components. Other propel system component
wheels and move on the brake wheel hubs to engage the maintenance and repairs will be covered in their specific
propel flanges. subsection.

7A-2
 SUBSECTION 78

PROPEL DRIVE SYSTEMS

GENERAL 2. Remove the motor coupling bolts and slide the spacer
For purposes of this manual the propel drive system in- from between the coupling halves.
cludes the propel motor bases, and the propel motors. 3. Remove the motor blower.
Maintenance of these subassemblies will be discussed in
4. Attach suitable lifting slings around the motor and sup-
this subsection.
port it. This motor weighs approximatly 4.000 Ibs.
The propel motor is accurately mounted to the motor base
5. Remove the four mounting bolts. Do not disturb the
on a shear ledge. The motor base has a machined surface
motor adjustment screws. Lift up on the motor slightly and
which is mounted on thecarbody. Because of this machined
pull it away from the base.
surface, alignment of the motor base to carbody is not re-
quired. The motor base is also the bearing block for the hori- NOTE
zontal propel shaft.
Do not lose the twowedge plates located on the shear
The propel motor coupling is located between the propel ledge of the motor base.
motor and propel transmission input shaft. This is a flexible
INSTALLATION. To install the propel motor, proceed as fol-
type coupling that transmits torque from the propel motor to
lows:
the propel transmission. The coupling is filled with grease
to lubricate the free floating coupling sleeves on the 1. Attach suitable lifting slings around the motor. Raise It
coupling hubs. into position on the motor base.
2. If the two wedge plates were removed, replace them on
the shear ledge.
PROPEL MOTOR
3. Install the mounting bolts. Do not tighten the bolts com-
REMOVAL. To remove the propel motor, proceed as fol- pletely. These bolts should be loose to align the motor with
lows: the propel transmission.
1. Remove the motor coupling guard. 4. Install the motor blower

HOAtZONTAL ADJUSTING SCREWS

VERTICAL ADJUSTING SCREWS

Figure 78-T. Adjustment Screws

78-l
SUBSECTION 78 PROPEL MOTORS

AUGNMENT. The propel motor must be aligned with the in-

put shaft of the propel transmission. The motor base and
propel transmission need not be aligned to the carbody due Block tracks with suitablm blocking to prevent
to the machined mounting surfaces. There are five align- thm l xcavatoe from rolling fredy.
ment procedures.
If the shims have been retained when the motor was re- 2. Place the propel steer switch in the operators cab in the
moved, replace each shim pack in the location from which it RlOL?T steer position. This will disengage the right jaw
was removed. clutch.
The four adjustment screws located under the motor on the 3. Attach the aligning tool, with the C clamp, to the nut of
motor base, are used to align the motor with the propel the propel motor shaft (see Figure 78-4).
transmission. 4. Attach the aligning tool post to the propel transmission
It is suggested that the following tools be acquired for align- input shaft (see Figure 78-4). Secure it with the jam nut.
ing:

Aligning Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . lD88Jl

‘7” Ear Tool . . . . . . . . . . . . . (Fabricated, see Figure 78-2)
Aligning Tool Post . . . . . . . . (Fabricated, see Figure 78-3)
INDICATORS
k 2.00 INCH A

ALIGNING
TOOL
PORT

Figure 76-2. ‘T’ Bar Tool

-Iv l/2” DIA. x 14” LONG

PROPEL TRANSMISSION
10 JAM NUT COUPLtNG HALF

Figure 78-4. Position of Dial Indicators

5. Fasten the dial indicators to the aligning tool post. Ad-

just the dial indicators so they just touch the aligning tool on
3/4 - 10 x 4” CAPSCREW the motor, one at the top and one on the side.
The first procedure is the horizontal alignment of the motor
Figure 78-3. Aligning Tool Post shaft to the propel transmission shaft (see Figure 78-5):
1. Set both aligning posts so they are pointed in toward the
To align the propel motor shaft to the propel transmission carbody.
input shaft, proceed as follows: 2. Set the dial indicator touching the side of the motor
1. Remove the split collar from the right side of the hori- alignment post to O.DDD inch.
zontal propel shaft coupling. See Figure 7A-1. Move the 3. Rotate both adjustment posts 1 80°. Thev should now be
male jaw clutch member to the right. pointing out from the carbody.

78-2
PROPEL MOTORS SUBSECTION 78

4. Read the dial indicator and divide the reading by 2. This 4. Read the dial indicator and divide the reading by 2. This
will indicate the amount of shims required. will indicate the distance the motor must be moved.
5. If there is a minus (-) reading, the shims should be added 5. Move the wedge plates using the adjustment screws.
to the rear mountings of the motor. If there is a plus (+) read- These screws are located at the front and rear of the lower
ing the shims should be removed from the rear mountings motor mounts (see Figure 78-l ).
of the motor. Maximum misalignment is 0.003 inch.
6. The front wedge adjustment screw will either raise or
The second procedure is the vertical alignment of the motor lower the front of the motor. The rear wedge adjustment
shaft to the propel transmission shaft (see Figure 78-6): screw will either raise or lower the rear of the motor.
1. Set both adjustment posts so they are pointed straight 7. Repeat steps 1 through 6 as necessary to obtain a toler-
up. ance of f 0.003 inch.
2. Set the dial indicator which touches the side of the motor The third procedure is the horizontal axial alignment of the
alignment post to 0.000 inch. motor shaft to the transmission shaft (see Figure 78-7).

3. Rotate both adjustment posts 1 80°. They should now be 1. Rotate both alignment tool posts so they are pointing in,
pointing toward the ground. toward the carbody.

CARBOOY
PROPEL
TRANSMISSION
/.

VIEWED FROM
>
TOP REAR
I i OF CARSODY
PROPEL le ’ ’ ’ ’ ’
TRANSMISSION
SHAFT

Figure 78-5. Horizontal Alignment

-.-_-____.-
PROPEL
TRANSMISSION -
VIEWED FROM
THE REAR OF
CARBODY

Figure 78-6. Vertical Alignment

78-3
SUSSECTlON 78 PROPEL MOTORS

CARBOOY

_-.-mm ___-_ -_-m-m

0
VIEWED FROM
0
TOP OF
CARBOOY

Figure 78-7. Horizontal Axial Alignment

2. Set the top dial indicator on O.ooO inch. Rotate both 2. Set the dial indicator on the end of the alignment post to
posts 1 80°. They should now be pointihg away from the car- 0.000 inch.
body. 3. Rotate the alignment posts 180”. They should now be
pointing toward the ground.
3. Resd the top dial indicator and divide the reading by 2.
This will indicate the amount of shims required. 4. Read the dial indicator and divide the reading by 2. This
will indicate the distance the motor must be moved.
4. If it has a minus (-) reading, add shims. If it has .a plus (+)
reading remove shims. Add or remove shims between the 5. If you have a plus (+) reading the motor must be raised. If
motor and motor base at the mounting bolt locstions. you have a minus (-1 reading the motor must be lowered.

5. Repeat steps 1 through 4 as necessary to obtain a toler- 6. Turn both wedge plate adjustment screws equally. Turn-
ants of t 0.003 inch. ing them to the right will raise the motor and turnmg them
The fourth adjustment is the vertical axial alignment of the to the left will lower the motor.
motor shaft to the propel transmission shaft.
1. Set both alignment tool posts so they are pointed straight 7. Repeat steps 1 through 6 as necessary to obtain a toler-
UP. ance of f 0.003 inch.

I-l
PROPEL
TRANSMISSION

El+
PROPEL
MOTOR
--_ .-- . . .

VIEWED FROM
REAR OF
CARBODY

Figure 788. Vertical Axial Alignment

78-4
PROPEL DRIVE SYSTEMS SUBSECTION 78

PROPEL
TRANSMISSION

“T” BAR
TOOL

Figure 78-9. Distance Between Couplings

The fifth adjustment is to obtain the distance between the PROPEL MOTOR BASE (1 OOJ3976)
motor coupling and transmission coupling (see Figure 7B-
INSPECTION. The horizontal propel shaft should be m-
9).
spected for bushing wear every 15,000 hours. To inspect for
bushing wear, proceed as follows:
1. Move the motor to the right or left to obtain a 2.00 inch
1. Remove the split .collar from the right side of the
clearance between coupling hubs. Measure the distance
horizontal propel shaft coupling. Move the male jaw clutch
with the ‘7” bar tool.
member to the right (see Figure 78-10).
2. The two adjustment screws mounted above the wedge
plate screws are used to slide the motor to the right or left.

NOTE
Block the tracks to prevent the excavator from
If one is screwed tn the other must be screwed out. rolling freely.

FEMALE HORIZONTAL
PROPEL SHAFT

PROPEL MOTOR

KEEPER PROPEL TRANSMISSION

PLATE

Figure 78-10. Horizontal Propel Shaft and Coupling

78-5
 PROPEL DRIVE SYSTEMS

2 . On the left propel steering linkage, remove thetwoclevis 6. Lower the jack until it no longer contacts the female jaw
pins from the air cylinder and return spring assembly (see clutch. Read the dial indicator. Maximum allowable bush-
Figure 7B- 11). ing wear is l/8 inch (3.1 B mm).
3. Move the male jaw clutch to the left, disengaging it. 7. Perform steps 4,5 and 6 on the right end of the shaft. Re-
Block it so it will not engage. place bushings worn beyond l/8 inch (3.18 mm).
4. Place a hydraulic jack under the female jaw clutch on the 8. Check the dogs of the male clutches and the female
left end of the horizontal propel shaft. Slowly jack the shsft clutches for any fractures or broken teeth. Replace the
up. clutch member if necessary.
5. Place a dial indicator so the indiitor pin touchesthe top If the horizontal propel shaft is removed from the base,
of the female jaw clutch. Set the indiior at 0.00 inch. check the dimensions of the shaft. Refer to Figure 78-12.

--
r--
/
PINU. DAtVL
PINION _--

POSITtON

PROPEL BRAKE
WHEEL \ PROPEL
BRAKE

Figure 78-l 1. Propel Steering and Clutch Arrangement

78-6
PROPEL DRIVE SYSTEMS SUBSECTION 76

Figure 78-l 2. Horizontal Propel Shaft (91OJ405)

REMOVAL. Remove the propel motor base assembly as 8. Remove the motor base mounting bolts. Carefully move
follows: the motor base away from the carbody.
1. Remove the propel motor as described in this subsec- DISASSEMBLY. Remove the horizontal propel shaft and
tion. Install four l-112-6 UNC lifting eyes on top of the bushings from the motor base assembly as follows:
motor base assembly. 1. Place a piece of plywood flat on the floor. Position the
motor base so the machined surface is falt on the plywood.
2. Remove the split collar on the right side of the horizontal
propel shaft coupling. Move the male jaw clutch memberto 2. Using a nylon sling and a suitable hoist, wrap the sling
the right. around the shaft through the access hole of the motor base.
Take up the slack in the sling. The shaft weighs approxi-
mately 1400 Ibs (630 kg).
3. Remove-the keeper plates from both ends of the shaft.
4. Using a puller, pull the female clutch. As each female
Block the tracks to prevent the excavator from clutch is removed, protect the bushings with wood inserts
rolling freely. (see Figure 78-13).
3. On the left propel steering linkage, remove the clevis HORIZONTAL
PROPEL SHAFT
pins from both the air cylinder and return spring assembly
(see Figure 78-l 1).
4. Move the male jaw clutch to the left, disengaging it.
Block so it will not engage.
5. Separate the motor coupling bv removing the bolts and
slide the spacer from between the coupling halves as de-
scribed in this subsection.
6. Remove the oil slinger shield from the right side of the USHING
left brake wheel (see Figure 78-l 1).
7. Using a lifting device attached to the lifting eyes, sup-
port the motor base. This assembly weighs approximately
48OC Ibs (2177 kg). Figure 78-l 3. Wood Inserts

78-7
SUBSECTION 78 PROPEL DRIVE SYSTEMS

5. After the female clutches have been removed, remove 5. On the horizontal propel shaft coupling, slide the male
the shaft from the motor base. jaw clutch member to the left, engaging the coupling. In-
stall the split collar on the right sideof thecoupling (see Fig-
ASSEMBLY. Assemble the bushings and horizontal propel
ure 78- 10).
shaft to the motor base as follows:
6. Install and align the propel motor as described in this
1. To install a new bushing break all sharp edges and
subsection.
deburr the grease grooves.
2. Align the three dowel pin holes in the bushing flange PROPEL MOTOR COUPUNGS
with the dowel pins in the motor base. Press the bushing GENERAL
into the motor base.
The propel motor coupling is located between the propel
3. Using a sling and hoist, slide the shaft through either of motor and propel transmission input shaft This is a flexible
the bushing bores. type coupling thattransmitstoquefrom the propel motorto
the propel transmission.
NOTE
The coupling is filled with grease to lubricate the free float-
8e sure the wood inserts (Figure 78-l 3) are in place to ing coupling slekves on the coupling hubs. O-rings instal-
protect the bushings from damage. led in the coupling sleeves form a grease seal.
4. Support the shaft through the motor base access holes COUWNG (18Q82)
with a hoist and nylon slings.
REMOVAL To remove the coupling, proceed as follows (sea
5. Remove the wood inserts and install the female Figure 78-15):
clutches. The female clutch on the right side has a flat ma- COUPUNG BOLTS
chined face. The female clutch on the left does not have a RmAINING
flat machined face.
6. Install the keeper plates. Toque the capsorews to 1 ,COC lNG
ft-lbs (138.3 kg-m).
INSTALLATION. Install the propel motor basa assembly to
the carbody as follows:
1. Attach a lifting device to the four lifting eyes on the motor
base, and lift it into position on the carbodv.
2. Install the mounting bolts and tighten.
3. Install the oil slinger shield on the right side of the left
brake wheel (see Figure 78-l 1).
4, Connect the steering linkage to the air cylinder and re-
turn spring assembly (see Figure 76-14).

I TRANSMISSIbN
MOTOR ‘COUPLlNG /
SPACER SLEEVE COUPLING
HUB HUB
Figure 78-l 5. Propel Motor Coupling (18Q62)

1. Remove the coupling bolts. The coupling spacer is now

free.
2. The transmission coupling half is a splined fit. Using a
suitable puller,
_ remove the coupling half.
3. Remove the transmission coupling by pushing it out the
flanged end of the coupling sleeve.
4. Remove the retaining nut from the motor shaft.
5. The motor coupling half is fitted on a tapered shaft. Re-
move the sprocket from the tapered motor shaft as follows:

[WPlRNlNO)

Never remove a taper fit component with a

puller and jack. Parts could snap off explo-
Figure 78-l 4. Steering Linkage sively and cause injury to personnel.
PROPEL DRIVE SYSTEMS SUBSECTION. 78

A. Screw a blank nut on the motor shaft threads. 7. Apply lapping compound at four places along the length
of the motor shaft and in the sprocket bore.
0. Drive wedges behind the sprocket hub.
C. Strike the blank nut with a solid hammer blowwhich will 8. Engage the shaft in the bore and rotate the shaft in both
directions.
loosen the sprocket.
6. The coupling hub can be removed from the coupling 9. Separate the parts and clean them with solvent. Ex-
sleeve by pushing it out the flanged end of the coupling amine the shaft surfaces for fit. A true lapped fit will show a
sleeve. gray color over the entire length of the shaft. If there are
bright spots on the shaft, repeat the procedure until they
REPAIRS. Repairs of the coupling are limited to replacing disappear. A bearing surface of 90% or more is acceptable.
the coupling sleeve O-rings. 10. When lapping is complete, clean the parts with sol-
ASSEMBLY. To assemble the propel motor coupling, pro- vent. The parts must be dry and free of oil film.
ceed as follows (see Figure 76-l 5): 11. Fit the key into the shaft keyway. Do not use a lubricant
1. Install the sleeve O-rings, one in each sleeve. on the mating parts.
2. Install the coupling hub with the splined bore in a cou- 12. Assemble the two components and check for clear-
pling sleeve. The end with the tapped holes must be toward ance between the top of the key and the bottom of the key-
the flanged end of the coupling sleeve. way. Some clearance must be present; if not, file the top of
the key.
3. Install the coupling half on the propel transmission in-
put shaft.
4. Clean the propel motor shaft.
NOTE
Do not heat thosprockstwhsn assembling it to
If a new coupling or motor is to be installed, proceed the shaft.
with step 5. If the old coupling is being installed on the
motor from which removed, proceed with step 7.
5. Remove all nicks a.nd/or burrs from the parts. 13. Set the sprocket on the shaft by using a block of hard-
wood and a light bar. Install the retaining nut on the shaft.
6. File the keyway and prefit the key. The key must be a
Tighten the nut securely.
hand slide fit into the sprocket bore keyway. Remove the
key. 14. Install the spacer and coupling bolts.

70-9
 SUBSECTION 7C

PROPEL TRANSMISSION

GENERAL 5. With the right propel brake released, loosen the upper
brake adjustment nut (6) and the two nuts on the lower
The propel transmission, through gear reduction, trans- brake arm support (See Figure 7C-1).
mits power from the propel motor to the horizontal propel
shaft on the left and the final propel drive on the right. There
are three reductions in the propel transmission. All gearing
is supported on anti-friction tapered roller bearings. The
first reduction gear and second reduction pinion are quill
mounted on the output shaft.

TRANSMISSION (lOOJ3944)
GENERAL
The propel transmission should be inspected once each
year todetermine suitability for continued service. Three in-
spection covers are provided on the gear case top for gear
inspection. Remove the covers and inspect the gears for
cracks at the gear teeth faces and for broken teeth.
Transmission overhaul consists of replacing worn or broken
parts and all bearings. Overhaul should be done asdictated
by the annual transmission inspection.

REMOVAL
Remove the propel transmission from the carbody as
follows:
1. Position the upper at right angles to the carbody. This
allows sufficient clearance to remove the transmission.
2. Remove the propel motor coupling guard. Remove the
propel motor coupling spacer.

NOTE
It is not necessary to loosen the propel motor mount- Figure 7C-1. Right Propel Brake
ing bolts to remove the coupling.
6. Set the propel brake by placing the steer switch in the op-
3. Remove the-split collar on the right side of the horizontal
erator’s cab in the OFF position.
propel shaft and move the male jaw clutch member to the
right. 7. Attach a lifting device to the lower brake arm to support
it. Remove the upper brake adjustment nut (B) and the two
nuts on the lower brake arm support.
8. Lower the lower brake arm to the ground and remove the
capscrews and slinger shield from the left side of the brake
Block the tracks to prevent the excavator from wheel.
rolling freely. 9. Attach a lifting device to the lifting eyes on the propel
4. Release the right propel brake by placing the propel steer transmission. The transmission assembly weighs approxi-
switch in the operator’s cab in the LEFT steer position. mately 18000 Ibs (8182 kg).

7c-1
SUSSEcllON 7c PROPEL TRANSMISSION

10. The transmission should be removed so that it is rea- 3. Lift the upper cover from the assembly. This assembly
sonably square with the milled edge of the carbody. This can weighs approximately 3800 Ibs (1727 kg).
be accomplished by installing two lifting eye&Its in the
OUTPUT SHAFT ASSEMBLY. Remove the output shaft as-
place of two propel transmission flange bolts on the rear of sembly as follows (7C-3):
the transmission case. Attach suitable slings and puller
hoist (come along) between the lifting eyes and hook of the 1. Remove the capscrews and lockwashers from the
primary lifting device. The puller hoist can then be used to bearing retainers.
tilt the transmission, squaring it with the carbody’s milled 2. Lift the Output shaft assembly from the gear case. This
edge (See Figure 7C-2). assembly weighs approximately 6790 Ibs (3086 kg). Place
assembly on a wooden base to prevent damage to the gear
11. Remove the transmission mounting bolts and care- teeth. Place wooden wedges against the assembly to keep it
fully remove the transmission from the carbody. from rolling.
THIRD REDUCTION PlNlON ASSEMBLY. Remove the third
DISASSEMBLY reduction pinion assembly as follows (See Figure 7C-3):

The propel transmission is disassembled by removing the 1. Attach a lifting device to the third reduction pinion as-
major components. Each major component can then be sembly and apply a slight tension to the assembly. Remove
repaired as needed (See Figure 7C-3). The procedures fol- the bearing cap from the assembly.
lowing are complete disassembly procedures for each 2. Lift the third reduction pinion assembly from the gear
major component. If an overhaul is not being performed. case. This assembly weighs appoximately 2185 Ibs (993
disassembly should be limited to that which is reguired for kg).
the specific repair.
FIRST REDUCTION ASSEMBLY. Remove the first reduc-
GEAR CASE COVERS. Remove the transmission gear case tion assembly as follows (See Figure 7C-3):
cover as follows: 1. Remove the bearing carrier from the assembly.
1. Remove the top four capscrews on each of the four shaft 2. Lift the first reduction assembly from the gear case. This
bearing retainers.
assembly weighs approximately 240 Ibs (109 kg).
2. Remove the cover nuts, bolts and lockwashers.
DISASSEMBLY OF MAJOR COMPONENTS
NOTE OUTPUT SHAFT. Figure 7C-20 is provided as a guidato dis-
Two special fitted coupling bolts are installed. These assemble the output shaft. This Figure is on a fold-out to be
bolts should not be driven out. They serve as posi- used aa a reference while reading the disassembly proce-
tioning bobs when reassembled. dure. Disassemble the output shaft as follows:

PROPEL TRANSMISSION

Figure 7C-2. Propel Transmission Removal

7C-2
PROPEL TRANSMISSION SUBSECTION 7C

I 4
0 0 0 0 0 0 0
A

FIRST REDUCTION
, 0 ASSEMBLY
V
THIRD
REDUCTION
PINION ’
ASSEMBLY

SEARING
CAP -

CAPSCREWS

SEARING
CARRIER

CAPSCREW

\
ASSEMBLY SEARING
/ RETAINER
CAPSCREW
I
SEARING
RETAINER

\ /
MILLED SURFACE TO CARSOOY

Figure 7C-3. Propel Transmission

7c-3
SUBSECTION 7C PROPEL TRANSMISSION

7 999” DIA
8:002” ’
t-i-

l/8” @ 46” CHAM.

Figure 7C-4. Gear Case Dimensions (914J186)

7c-4
 PROPEL TRANSMISSION SUBSECTION 7C

1. Remove tie wire (01). capscrews (02). and keeper plate 4. Pull cones of bearings (36 and 38) from first reduction
(03) from both ends of shaft (06). pinion shaft (39).
2. Pull femaleclutch (04) and coupling half (05)from output 5. Pull bearing cap (40) from the gear case and remove the
shaft (06). cup of bearing (38) from the bearing cap.
3. Remove seal earner (07). Seal (08) will be removed with
CLEANING AND INSPECTION
carrier (07). Remove seal (08) from the seal carrier. Re-
, move bearing retainer (09) and seal (10). Remove seal (10) CLEANING. Clean all parts of the disassembled major com-
from bearing retainer (09). ponents with a suitable commercial solvent and dry thor-
oughly. Never use a hot alkaline solution on finished parts
4. Remove bearing carrier (11). Bearing cup and one cone
or bearings.
of bearing (12) and spacer (13) will be removed with carrier
(11). Remove dowel (14) from carrier (11) and pull the bear- INSPECTION. All parts of disassembled major components
ing cone out of the carrier. Remove the remaining bearing should be inspected for wear or damage. Particular atten-
cone from shaft (06). tion should be paid to the following items:
5. Remove bearing carrier (15). Spacer (16). O-ring (18), 1. Inspect all gears for wear, cracks and/or broken teeth.
and the cup and one cone of bearing (17) will be removed
2. Inspect all spacers for wear, scoring or galling.
with the carrier. Remove O-ring (18). dowel (19). and the
bearing cup and cone from carrier (15). Remove the re- 3. Inspect all anti-friction bearings for excessive play, dis-
maining bearing cone of bearing (17) from shaft (06). torted races, and ball or roller wear or damage.
6. Thread rods into the two holes of the first reduction gear 4. Inspect all surfaces on which seal lips seat. These sur-
hub (20) and pull gear and pinion assembly (20) from shaft faces must be very smooth to prevent wearing away the
(06). The cup and cone of bearing (21) will be removed with seal lips, which will cause oil leaks.
the gear and pinion assembly. 5. Inspect all other parts for any evidence of damage. All
parts that are questionable should be replaced.
NOTE ’
6. Inspect all parts of the major components as shown on
Any shimming between the cone of bearing (21) and Figures 7C-4 through 7C-7.
spacer (22) should be noted and the shims should be
saved. These shims will be reused during reassem- REPAIRS
bly of the output sheft.
Repairs are limited to replacing worn or broken parts. The
7. The first reduction gear is pressed and keyed to the inspection is intended to determine if the parts are within
pinion of assembly (20). If required press the reduction gear allowable tolerances.
off the pinion and remove key (25). When the transmission is disassembled for overhaul, the .
8. Remove spacer (22) and cup and cone of bearing (24) roller bearings must be renewed at assembly. When any
from shaft (06). major assembly is disassembled, replace the oil seals.
9. Remove third reduction gear (23) from shaft (06). ASSEMBLY OF MAJOR COMPONENTS
THIRD REDUCTION PINION ASSEMBLY. Refer to Figure GENERAL. Each major assembly must be assembled
7C-20 and disassemble the third reduction pinion assembly separately before installation in the gear case. The follow-
as follows: ing are suggestions that should be adhered to when reas-
1. Remove bearings (27 and 28) and spacer (29) from third sembling the transmission.
reduction pinion (31). 1. When the torque values are specified. be sure to use a
2. Press second reduction gear (30) from the third reduc- torque wrench and tighten as directed.
tion pinion. Remove the cup of bearing (27) from bearing 2. Always prelubricate anti-friction bearings with a suit-
cap (26). able lubricant before final assembly.

FIRST REDUCTION PINION ASSEMBLY. Refer to Figure 7C- 3. If a bearing is to be heated for assembly purposes, the
20 and disassemble the first reduction pinion shaft entire bearing should be immersed in an oil bath, or heated
assembly as follows: in an oven, for sufficient time to ensure that it is heated’
throughout.
1. Pull coupling half (33) from the first reduction pinion
assembly. NOTE
2. Remove bearing and seal housing (34) from shaft (39). When heating a bearing in an oil bath, place a rack at
Remove the cup of bearing (36) and seal (35) from the the bottom of the container to set the bearing on. This
bearing and seal housing. will prevent the bearing from touching the hot bot-
tom. Never heat the bearing above 225OF.
3. Remove spacer (37) from shaft (39). Spacer should be
heated sufficiently so it will slide off the shaft. Do not over- 4. Smooth out all nicks, burrs or galled spots on shafts,
heat and damage the spacer. bores or bushings.

7c-5
 PROPEL TRANSMISSION

5. If the old bearing is to be used. the spacers must be re- 1. Place third reduction gear (23) on a wood base. Block the
assembled in the bearings from which they were removed. gear so it will not roll or fall.
New bearings are recommended.
2. Lift shaft (06) and slide it in the bore of gear (23). Posi-
OUTPUT SHAFT. Refer to Figure 7C-20 and assemble the tion the shaft so there is an eoual overlap of the gear hub on
output shaft assembly as follows: the shaft splines.

--CD4

COOE 1 I CODE I I CODE I

ILEGI DIMENSION

4-4
N 14.667” P.D.
3 OP U T
0 5.0” GEAR
FACE
13.743” I.D.
I ------
K P 9.5” GEAR
E 2.928” 13.746” COUNTERBORE FACE
F 0.375” L 9.506” R
0.0. 52.000 P.D.
0 2.125” 9.501” SHAFT 4 DP 208f
I I I M 1 9.5312” 1.0. S 44.000 P.O.
9.5466” SLEEVE 1 DP 44T
1
Figure 7C-5. Output Shaft Assembly Dimensions (91 DJ399)

7C-6
 42.333 P.D. 3 D.P.
M
127 TEETH

i 13.000 P.D., 1 D.P. !

1 13TEETH I
I I ti 3rd RED.
_---
1 6.373” DIA. 1 -I-- --tl
1 6.374” BORE ’
I .-f
I I
- -

14.999” DIA. BORE

15.003”
6.373” DIA. BORE
SUBSECTION 7C PROPEL TRANSMISSION

3. Two row bearing (12) is a matched bearing. The parts of 9. Install the bearing cups of bearing (21 and 24) into the
this bearing are not interchangeable with other identical first reduction gear assembly.
bearings. Each side of the bearing parts has an etched
10. Slide spacer (22) on shaft (06). Spacer should be
letter. It is not important if the Asideor C side is installedon
against the cone of bearing(24). Care should be taken notto
the shaft first. The important thing is that an A side of the
damage the ends of the spacer when handling.
bearing cone match the A sideof thebearing cup. The same
applies to the matched bearing cone and cup with the letter 11. Lift the first reduction gear assembly into place on shaft
C as shown on Figure 7C-8. (06). Be sure the reduction assembly is tight against bear-
ing (24).

C A 12. Place shims (2lA) removed in the removal procedure

against the sleeve and slide the cone of bearing (21) against
the shims. To ease in assembly a spacer tool can be
fabricated (See Figure 7C-9).

13. Measure and adjust the end play of the first reduction
gear assembly as follows:
A. Place the spacer tool over the shaft against the bearing.
The spacer tool should be held in place by the end piate
and capscrews screwed to the end of the shaft.
8. Clamp a dial indicator to the spacer tool with the
indicator against first reduction gear (20). Check the end
play of the first reduction gear assembly. A pry bar may
be necessary to insure that the proper end play is being
reed (See Figure 7C-10).
C. The end play of the first reduction gear assembly must
be 0.007 to 0.010 inch (0.177 to 0.254 mm). If the end
play is within the prescribed tolerance proceed to step
14. If shims are to be added or removed to achieve
Figure 7C-8. Two Row Bearing, Installation proper end play continue with step D.
D. Remove spacer tool from the end of shaft (06). Place
Install bearing (12) on shaft (06) as follows: jacks between the first and third reduction gear assem-
blies. Jack the first reduction gear assembly to the right
A. Slide a heated cone over the right end of the shaft tight just far enough to remove the cone of bearing (21).
against gear (23). Note which etched letter is against
gear (23). E. Add or delete shims between spacer (22) and the cone of
bearing (21) as required to obtain the proper end play.
8. Slide the spacer for the bearing against the installed Repeat steps 12 and 13 until end play iswithin the spec-
cone. Place the bearing cup over the installed cone so ified tolerance. Remove the spacer tool.
the etched letters are matched as shown on Figure 7C-
8. 14. Bearing (17) is an identical bearing to bearing (12) de-
scribed in step 3. Install bearing (17) as follows:
C. Slide the remaining cone over the shaft into the bearing
cup. Insure that the etched letters on the cone and cup A. Slide a heated cone of bearing (17) over shaft (06) tight
match. against the cone of bearing (21). !&xe which etched
letter is against the bearing cone.
4. Install oil seal (08) into seal carrier (07). Place a gasket on
bearing retainer (11) and install retainer over bearing (12). 8. Slide the bearing spacer against the installed bearing
cone.
5. Install seal carrier (07) to the bearing retainer. Slide
heated spacer (13) over shaft (06) against bearing (12). Take C. Install the cup of bearing (17) into bearing carrier (19).
care not to damage the oil seal by overheating the spacer. Care should be taken so the etched letters on the
installed cone and the bearing cup will match when the
6. Slide female clutch (04) over the shaft and secure with carrier is installed.
keeper plate (03). Keeper plate capscraws should be only
snug tightened at this time.
7. Install the heated cone of bearing (24) on shaft (06) NOTE
against the left side of the third reduction gear. The taper of Dowel holes in the bearing cup and the bearing
the cone should be away from gear (23). carrier must be properly aligned at cup installation.
8. If the first reduction gear has been removed from the
Pinion assembly, press it on the pinion. Be sure the key had D. Place gasket (15A) on bearing carrier (10) and install the
been installed in the pinion prior to installation of the re- carrier on shaft (06) properly seated on the installed
duction gear. bearing cone.

7C-8
PROPEL TRANSMISSION SUBSECTION 76

NOTE: THE LENGTH OF THIS TOOL

WILL FIT THE OUTPUT SHAFT FOR
MODELS 1900AL. 2100812300 AND
2800. THE BOLT LENGTH WILL VARY
DEPENDING ON EACH MODEL

11”

Figure 7C-9. Spacer Tool

Figure 7C-10. First Reduction Gear End Play

E. Slide the remaining heated cone of bearing (17) over

shaft (06) into the bearing carrier assembly.
F. Tap the bearing with a mold steel bar to assure the bear-
ing is properly seated (See Figure 7C-11). Figure 7C-11. Seating Searing Cone

7c-9
SUBSECTION 7C PROPEL TRANSMISSION

15. install O-ring (18) and oil seal (10) on bearing retainer ASSEMBLY
(09). Lift the retainer assembly on shaft (06) against the
bearing carrier. Secure with two temporary bolts and nuts. The PrOPel transmission is reassembled by installing the as-
sembled major components as follows:
16. Slide heated spacer (16)on the shaft tight against bear-
ing (17). Care should be taken not to damage the oil seal by 1. Lift the third reduction gear assembly and position it in
the gear case as shown on Figure 7C-13. Lower the
overheating spacer.
assembly until it is level, taking care that the outside bear-
THIRD REDUCTION PINION. Refer to Figure 7C-20 and as- ins cone does not rest on the aear case edae.
semble the third reduction pinion assembly as follows:

of
2. Slide the heated cone bearing (27) on the end of pinion
shaft (31), taper away from pinion. lap the bearing cone
slightly with a soft metal bar to properly seat the cone.
3. Install spacer (29) and slide the heated cone of bearing
(28) on the end of pinion shaft (31). taper away from the re-
duction gear. Tap the bearing cone slightly with a soft metal
bar to properly seat the cone.
4. Install the cup of bearing (27) into bearing retainer (26).
Install the cup of bearing (28) into the gear case bearing re-
miner (Sea Figure 7C-12).

1
Figure 7C-13. Third Reduction Assembly, Installation

2. Install the bearing carrier and fasten with four cap-

I screws. Remove the lifting device.
L-
. -w!zg
3. Measure and adjust the end play of the third reduction
assembly as follows:
A. Place a dial indicator on the gear case flange with the
indicator head against a tooth face of the pinion. Move
the assembly to one side and set the dial indicator to zero
(See Figure 7C-14).
iEAR CASE BEARING A=AINER’

Figure 7C-12. Bearing Cup Installation

FIRST REDUCTION PINION. Refer to Figure 7C-20 and as-

semble the first reduction pinion as follows:
1. Install the heated cones of bearings (36 and 38) on shaft
(39). one on each side of the pinion with the tapers away
from the pinion. Slightly tap the bearing cones with a mold
steel bar to properly seat them.

NOTE
The small diameter of spacer (37) must be against the
cone of bearing (36).
2. Slide the heated spacer on shaft (39).
3. Install the cup of bearing (36) in bearing and seal hous-
ing (34). Install the cup of bearing (38) in the gear case
bearing retainer (40). Figure 7C-14. Third Reduction Assembly End Play

7c-10
PROPEL TRANSMISSION SUBSECTION 7C

8. Move the assembly to the opposite side and note the

reading of the dial indicator. Loosen or tighten the four
capscrews of the bearing retainer until a reading of
0.003 to 0.005 inch (0.076 to 0.127 mm) is achieved.
C. Measure the clearance between the bearing carrier and
the gear case with a feeler gauge.
D. Support the reduction assembly with a lifting device and
remove the bearing carrier.
E. Install shims equal to the amount of clearance mea-
sured between the bearing carrier and gear case. Shims
consist of three thicknesses which are color coded. Use
any combination to equal the amount needed.

Blue ........................ .0.005 inch (0.127 mm)

Transmatte ................ 0.0075 inch (0.1905 mm)
Yellow ...................... .0.020 inch (0.508 mm)

F. Install the bearing carrier and fasten with four cap-

screws. Torque to 150 ft-lbs (20.75 kg-m). Recheck end Figure 7C-16. First Reduction Pinion End Play
play. If the end play does not fail within the tolerance
specified, add or remove shims as necessary. 7. Lift the output shaft assembly into the gear case as
shown on Figure 7C-17. The output shaft must be level dur-
4. Lift the first reduction pinion and position it in the gear
ing the installation into the gear case.
case as shown on Figure 7C-15. Do not allowthe bearing to
rest on gear case edge.

JTPUT SHAFT

Figure 7C-17. Output Shaft, Installation

NOTE
When lowering the output shaft assembly into the
Figure 7C-15. gear case, special care must be taken not to damage
First Reduction Pinion Assembly, Installation the gaskets on the bearing retainers.
8. Align the holes of the bearing retainers and install four
5. Install the bearing and seal housing over the cone and capscrews on each side. Torque these capscrews to 200 ft-
secure to the gear case with four capscrews. Ibs (27.66 kg-m).
6. Measure and adjust the first reduction pinion assembly 9. Check the gear backlash as follows:
end play using the same procedure as described on step #3.
Dial indicator should be mounted as shoinrn on Figure 7C- A. Place a wooden wedge between either the first reduc-
16. End play shall equal 0.003 too.005 inch (0.076 too.1 27 tion or third reduction gear and the gear case. This will
mm). keep the gear train from rotating.

7c-11
SUBSECTION 7C PROPEL TRANSMISSION

6. Place a dial indicator on the gear case edge and the in- 1. Clean the milled faces of the carbody and the propel
dicator head against a tooth of the gear to be checked. transmission.
Move the gear back and forth. The backlash should be as 2. Attach the lifting device to the four lifting eyes on the
follows: propel transmission. The transmission should be installed
First Reduction Assembly.. . . . 0.012 inch (0.305 mm) so that it is reasonably square with the milled edge of the
Maximum carbody. Refer to Figure 7C-19 and install the transmission
Second Reduction Assembly.. 0.020 inch (0.508 mm) as follows:
Maximum A. Install two lifting eyebolts in place of two flange bolts at
Third Reduction Assembly . . . .0.028 inch (0.711 mm) the rear of the transmission.
Maximum 5. Attach a sling and puller hoist between the lifting eyes
and hook of the primary lifting device. The puller hoist
10. Check the flange of the gear case and cover. Be sure it
can then be used to tiltthe transmission squaring it with
is clean and free of burrs.
the carbody’s milled edge (See Figure 7C-2).
11. Install new O-ring seal on the gear case flange and lift 3. Position the transmission in place on the carbody. In-
the upper cover on to the gear case. stall the mounting bolts and tighten securely.
12. There are 25 bolts that hold the cover to the gear case NOTE
(See Figure 7C-18).
Mounting bolts should be installed so the nuts are to
NOTE the outside wherever possible.
The twocoupling boltsarespeciallyfittedtothecover. 4. Install the slinger shield on the left side of the right brake
These act as positioning bolts when the cover is as- wheel.
sembled to the gear case. 5. Lift the lower brake arm of the right brake. Replace brake
adjustment nut (6) and the two brake support nuts (See
13. Install and torque the mounting bolts as shown on Fig-
Figure 7C-19).
ure 7C-18.
6. Adjust the brake as detailed in Propel Brake Adjust-
14. Refer to Figure 7C-20 and install coupling half (05) on ment.
output shaft (06). Secure with keeper plate (03) and cap- 7. Align the propel motor shaft with the propel transmis-
screws (02). Torque capscrews (02) on both ends of the out- sion shaft as described under Propel Motor Alignment.
put shaft to 325 ft-lbs (44.95 kg-m).
8. Install the motor coupling guard.
9. Slide the male jaw clutch member on the output shaft
coupling to the left, so it engages the female jaw clutch. In-
stall the split collar on the right side of the male jaw clutch
coupling.

@ COUPUNG BOLT

Figure 7C- 18. Propel Gear Case Cover Bolt Location

INSTALLATION
Install the propel transmission to the carbody as follows: Figure 7C-19. Right Propel Brake

7C-12
PROPEL TRANSMISSION SUBSECTION 7C

32. KEY
33. COUPUNG HALF
34. SEAL HO”S,NG
39. SEAL
36. SEARlNG
37. SPACER
38. SEARING
39. FIRST REDUCTlON PlNlcw SHAFT
40. BEARING CAP
41. TRANSMISSION CASE
42. GASKET
43. BREATHER

Fqure 7C-20. Propel Transmission (loOJ39‘W

 SUBSECTION 7D
PROPEL BRAKES

GENERAL
When the propel steer switch is placed in the RIGHT steer
Two propel brake assemblies are used on this excavator. position the air supplied to the right propel brake cylinder is
The brakes are spring set, air released. The brake lever exhausted to atmosphere setting the brake. Simul-
action is of the toggle type. Quick exhaust valves are pro- taneously, air is introduced to the left propel brakecylinder.
vided at the air cylinders to insure fast setting of the brakes. releasing it. With the steer switch in the center position, air
The propel brakes are placed on the driven side of the propel is introduced to both propel brake cylinders releasing the
gear train and are actually part of the crawler assembly. brakes. When the propel crowd transfer switch is placed in
This provides positive braking of the crawler motion, re- the CROWD position, air to both propel brake cylinders is
gardless of the positions of the steering jaw clutches. Also, exhausted to atmosphere, setting both brakes.
the propel transmission is freed from the rocking motion in- PROPEL BRAKE (lOOJ4516)
duced by rapid swing reversals of the upper.
DISASSEMBLY. Complete disassembly of the propel brake
Both brake assemblies in the excavator have two func- assemblies should not be necessary. Major components,
tions; braking and steering. When the propel/crowd lever, such as the air cylinder and lining assemblies can be re-
in the operator’s cab, is in the PROPEL position the brakes
moved without detaching the complete assembly from the
are used to steer the machine. If the propel steer switch is
mounting bracket. Disassemble the brake assembly as
placed in the LEFT position, the air supplied to the left propel follows (see Figures 70-l and 70-3):
brake cylinder is exhausted to atmosphere, setting the
brake. Simultaneously, air is introduced to the right propel 1. Loosen the air line connections at the brake air cylinder.
brake cylinder releasing it. Do not disconnect it.

I _ 29.75”

FRAME ASSEMBLY

TENSION ROD

AIR CYLINDER

I SPRING TENSION NUT

TENSION ROD
ADJUSTING NUT

Figure 70-l. Spring Frame Assembly

7D-1
SUBSECTION 70 PROPEL BRAKES

NOTE
2. lap the fitting gently to break the seal. Thiswill allow any
pressure trapped in the system to escape. Maximum allowable heat applied to the brake linings
for removal is 50D°F. Do not exceed this heat.
3. Disconnect the air line and remove the spring frame
guard. 4. The surface of the lining and shoes must be free from
4. Back off on the spring tension nut and locknut. paint, rust, oil, grease, or wax. Sand the surfaces and wipe
with a suitable solvent (P&H part number 212679).
5. Remove the cotter pin and retaining pin from the toggle 5. Mix equal parts of Scotch-weld brand structural
tension rod to brake linkage. adhesive, (P&H part number 212675) manufactured by
Minnesota Mining and Manufacturing. (3M part number
N O T E EC21 58 8/A).
Support the brake linkage before unpinning the tog- Mix thoroughly equal parts. by volume or weight of 8 (Base)
gle tension rod. When the linkage is unpinned swing and A (Accelerator).
it down out of the way. NOTE
6. Attach a hoist to the spring frame and remove the spring Bonding of 2 linings to shoes requires approximately
frame assembly by removing the cotter and retaining pins l/6 quart of A and l/6 quart of 8. Mixed color should
from the mounting bracket. be a uniform gray.
7. Remove the air cylinder by removing the cylinder mount- 8. Apply evenly on the bonding surfaces of both the shoes
ing bracket. Remove the spring assembly. and lining.
8. The brake linkage and upper and lower brake arms can 7. Join the adhesive coated surfaces. Install the screws to
be removed using a hoist and unpinning the components hold them in place. Allow them to cure at 6D°F or above
from the frame. until completely firm. Heat up to 350°F will speed curing.
When using heat, cure only until firm. Pressure is not nec-
REPAIRS. Repairs to the brake assembly are limited to two
areas: air cylinder and brake linings. Air cylinder overhaul is essary.
covered in Subsection 85 8. Position the brake arms on the sides of the brake shoe
The brake linings should be replaced when worn to a thick- assembly and install the assembly bolts and nuts. Torque
ness of 3/8 inch. To replace the brake linings, proceed as these nuts to 500 ft-lbs.
follows (see Figure 70-2):
ASSEMBLY. Assemble the propel brake asfollowsfsee Fig-
1. Remove the brake arm assembly nuts and bolts. ures 70-l and 7D-3):
2. Remove the lining’s brass mounting screws. 1. Install the upper and lower brake arms by pinning them
3. Apply heat to the linings. This will melt the bonding and to the mounting bracket.
the lining can be removed. 2. Pin the brake linkage to the upper and lower brakearms.
3. Raise the lower brake arm and pin the support bolt in
place on the lower brake arm.
TOGGLE SPRING
TENSION FRAME 4. Clean all oil, grease, wax, dirt, paint and rust inhibitors
ROD \ from the internal thread at the end of the tension rod and
the thread on the end of the cylinder rod.
5. Apply locking compound (P&H #21Z772) to the threads
of the tension rod and cylinder rod.
6. Install the air cylinder by threading the screw toggle ten-
sion rod onto the air cylinder as far as it will go, approxi-
mately 1.63 inches.
7. Mount the air cylinder to the spring frame and fasten
with the four mounting bolts.
8. Measure the total length of the frame assembly. Mea-
sure from the center of the mounting bracket pin to the
center of the pin hole on the toggle tension rod.. This di-
mension must be 61.25 f 0.125 inches.
NOTE
SLEEVE The 61.25 inch frame dimension shoulddraw theql-
NUT inder rod out 0.25 inch. This 0.25 inch is necessary to
prevent the cylinder from bottoming due to lining
Figure 7D-2. Tension Rod Flat Welding wear.

7D-2
PROPEL BRAKES SUBSECTION 90

9. If the dimension measured in step 8 is not within re- after repair and the second to adjust the brake for normal
quirements, it must be adjusted as follows: lining wear. To adjust the brake after repair, complete the
A. Remove the welded flat between the tension rod toggle entire procedure, to adjust the brakes for normal lining
and the rod adjustment nut. Some machines may not be wear start with step 4 (see Figure 7D-3):
equipped with this flat. 1. Loosen both adjustment nuts (A and 6). Loosen the two
B. Turn the tension adjusting nut until the total length of support bracket nuts (C and D).
the frame assembly is 61.25 f inches. The adjusting nut 2. Set the propel brakes and turn nut “B” until both brake
should be turned clockwise to lengthen this dimension shoes are tight against the brake wheel. Tighten nut “A”.
and turned counterclockwise to shorten it. 3. Release brakes and loosen nut “A” approximately 2
C. Weld a flat l/4 x l-1 14 x 5 inches long between the turns. Tighten nut “B”.
toggle of the tension rod and the tension rod adjusting 4. Reset the brakes and measure the gap between the
nut (see Figure 7D-2). spring frame and tension adjusting nut. This dimension
10. Adjust the spring length to 29.75 inches with the should be 0.75 +0.06 inch. If thts dimension is out of toler-
spring tension nut and tighten the locknut. ance, release the brake and adjust nut “A” and “B” as re-
quired. Recheck the dimension and repeat the procedure
11. Refer to Figure 7D-3 and lift the spring frame intoposi- until the gap dimension is within the specified tolerance.
tion on the mounting frame, secure into position with a pin
and cotter pin. NOTE
Loosening nut “A” and tightening nut “B” will in-
12. Raise the brake linkage and pin it to the toggle tension crease the gap between the spring frame and the ten-
rod of the spring frame. sion rod adjusting nut. Loosening nut “8” and tight-
13. Connect the air line to the brake air cylinder. ening nut “A” will decrease this gap.
NOTE 5. With the propel brake set, measure the spring length.
The spring must measure 29.00 inches end to end. Adjust
Check all of the retaining pins to be sure cotter pins the spring length to meek this requirement with the spring
have been installed. tension adjustment nut.
ADJUSTMENT. When the propel brakes are set, they should 6. Set the propel brake and adjust the clearance between
be capable of stalling the propel motor. There are two ad- the support washer and nut “C” to 0.25 inch.
justment procedures; one to cover the adjustment required 7. Tighten nut “D” against nut “C”

TENSION ROD

ARM

Figure 7D-3. Propel Brake Adjustment (lOOJ4516)

70-3
 SUBSECTION 7E
STEERING SYSTEM

GENERAL FORWARD PROPEL. Placing the steering toaale switch in

.,e--

the center position with the excavator In the propel mode,

The excavator steering is controlled by the movement of the
steer toggle switch in the operator’s cab. This three posi- automatically engages both jaw clutches and releases the
tion switch is functional only when the excavator is in the right and left propel brakes. In this mode the excavator will
propel straight forward or backward (see Figure 7E-1).
propel mode of operation. Basic operation of the three oper-
ating modes; forward propel, right steer and left steer is as RIGHT STEER. Placing the steering toggle switch in the
follows: RIGHT steer position automatically disengages the right

QUICK RELEASE
4 t - 7 VALVES 4 t --,
LIMIT
SWITCHES

Released Released Engage

Propel Brakes Steering Clutches

CYLINDER
AlR \

BRAKE
ELEASED RETURN
SPRING
RETURN EXTENDED
SPRING
EXTENDED
/
LIMIT LIMIT
SWITCH SWITCH

ENGAGED
Figure 7E-1. Forward Propel i!‘ CLUTCH
ENGAGED

7E-1
SUBSECTION 7E STEERING SYSTEM

jaw clutch and sets the right brake. The left jaw clutch. in leased. The excavator will turn to the right while propelling
this mod& will be engaged and the left propel brake re- forward (see Figure 7E-2).

Released set ngaged Disengaged

Propel Bra&es Steering Clutches

_ MOVES TO THE LEFT

RETRACTED PISTON

UMIT COMPRESSED
SWITCH

LEFT JAW
CLUTCH
ENGAGED
Y \ RIGHT JAW
CLUTCH
DISENGAGED

Figure 7E-2. Right Steer

7E-2
STEERING SYSTEM SUBSECTION 7E

LEFT STEER. Placing the steering toggle switch in the LEFT will be engaged and the right brake released. The exca-
steer position automatically disengages the left jaw clutch vator will turn left while propelling forward (see Figure
and sets the left brake. The right jaw clutch, in this mode, 7E-3).

Released Disengaged Engaged

Propel Brakes Steering Clutches

MOVES TO THE RIGHT _

PISTON
RETRACTED

- LEFT

SPRING
COMPRESSED EXTENDED

SWITCH

CLUTCH CLUTCH
DISENGAGED ENGAGED

Figure 7E-3. Left Steer

7E-3
 STEERING SYSTEM

LEGEND FOR FIGURE 7E-5:

A pipe interlock is provided to prevent both jaw clutches
CAPSCREW
from disengaging at the same time. When the right jaw LOCKWASHER
clutch is disengaged, the right portion of the pipe interlock COVER (A.H.)
slides to the left and prevents the left jaw clutch from dis- COVER (L.H.)
PIN ASSEMBLY
engaging. When the left jaw clutch is disengaged, the left CAPSCREW
portion of the interlock slides to the right and prevents the LOCKWASHER
PLAIN WASHER
right jaw clutch from disengaging. /U$$RLOCK LEVER (R J-l.)
CAPSCREW
JAM NUT
STEERING UNKAGE ASSEMBLY (10054683) INTERLOCK LEVER IL. f-f.1
HUB
DISASSEMBLY. The disassembly of the right and left steer- CAPSCREW
JAM NUT
ing linkage assemblies is the same. Disassemble the steer- SPRING ASSEMBLY
ing linkage as follows (see Figure 7E-5): SPRING
HOUSING
PULL ROD
1. Remove covers (03 and 04) to gain access to the linkage EB%TPLATE
connections. NUT
.__.
LOCKWASHER
RETAINING PIN
PIN
2. Relieve the air pressure from the excavator air system. CLEVIS
JAM NUT
AIR CYUNOER
3. Loosen the air line connections on the air cylinder. Tap RETAINING PIN
the connection with a soft hammer to break the seal. . .._
Remove the air line (see Figure 7E-4). CLEWS
JAM NUT
RETAINING PIN

CAPSCREW
LOCKWASHER
p$f+Sl$;SEMSLY (R.H.)
BUSHING
:Az;,i;SEMSLY (L.H.)
BUSHING
CAPSCREW
LOCKWASHER
COTTER PIN
WASHER
g;zEEEVER ( R.H.)
b;$KWASHER
Figure 7E-4. Air Connections
N..H.)

4. Disconnect spring assembly (17) from the interlock lever

by removing retaining pin (25) and pin (26).
5. Disconnect air cylinder (29) from the interlock lever bv
removing retaining pin (30) and pin (31).
6. Remove capscrew (06). lockwasher (07)and washer (08)
from the top of steering pin (05).
7. Match mark the interlock lever to the steering pin.
8. Gain access to the interlock pipe by crawling through the
manhole in the rear corner of the carbody. Remove retain-
ing pin (34) and pin (35) which connects interlock pipe (36)
to lever (09 and 13).

7E-4
STEERING SYSTEM SUBSECTION 7E

_.’

c_ 55 54

Figure 7E-5. Steering Lmkage Assembly (1 COJ4682)

7E-5
SUBSECTION 7E STEERING SYSTEM

NOTE To adjust the steering limit switches, proceed as follows

The interlock pipe should not be disassembled. It is (see Figure 7E-6):
adjusted during erection and should not bedisturbed. 1. Place the jaw clutches in the engaged position. This is
9. Pull interlock lever (09 or 13) from steering pin (05). done bv placing the steer switch in the operator’s cab in the
center position.
10. Install a 518 inch evebolt to the top center of steering
pin (05) and support the steering pin with a lifting device. 2. Be sure the capscrew on the interlock lever is tight.

11. Remove shifter lever (09 or 13). Remove shifter yoke 3. Loosen the bolts that hold the limit switch to the base.
(68) bv removing special capscrews (66) and lockwasher Slide the switch so the roller just touches the head of the
(67) on the top and bottom of the yoke. capscrew on the interlock lever.

12. Disassemble the spring assembly, if required, as fol- 4. Repeat steps 2 and 3 for the opposite side if necessary.
lows:
A. Clamp the spring assembly in a vise.
8. Remove two bolts (22). lockwasher (24) and nuts (23)
from end plate (21).
C. Spring (18) and pull rod (20) can now be removed.

INSPECTION AND REPAIR. Inspect and repair the steering

linkage as follows:
1. inspect all parts for cracks, warpage or excessive wear.
2. Check the bushings in the base for wear and replace if
necessary.
3. Repair the air cylinder as described in Subsection 8E.

ASSEMBLY AND INSTALLATION. Assembly and installa-

tion is the reverse of disassembly. Bushings(49.50,52and
53) should be lubricated during the assembly procedure.

ADJUSTMENT. There is no adjustment necessary to the

steering linkage. The pipe interlock should never be read-
justed. In case the interlock pipe is damaged, notify theerea
HARNISCHFEGER service representative for replacement
and adjustment procedures. Figure 7E-6. Limit Switch Adjustment

7E-6
 SUBSECTION 7F
FINAL DRIVES

GENERAL the bushing using a feeler gauge. Bushing should be re-

placed if the clearance is l/8” or greater.
The final drive assembly consists of the final drive pinion,
gear final drive, shaft and drive tumbler. The pinion and 3. Insure that there is ample grease in the bushings.
final drive shaft are supported by bushings. DISASSEMBLY. Disassemble the final drive assembly as
follows:
FINAL DRIVE
1. Using the excavator, dig a hole approximately 1 foot
INSPECTION. The teeth on the final drive pinion and final deep. The hole should be in the path of the crawler belt
drive gear should be inspected every 5DDD hours. The bush- when propelled forward.
ings of the final drive shaft every 3DDC hours.
2. Propel the machine forward over the hole (see Figure 7F-
To check bushing wear of the final drive pinion shaft, re- 1).
move the cover from the gear case and proceed as follows 3. Block the idler assembly and split the crawler belt at a
(see Figure 7F-10): convenient spot above the drive tumbler as follows:
1. Remove the gear case cover nuts and remove the cover. A. Remove the crawler shoe link pin retaining bolt on the
2. Check the clearance between the pinion shaft and the belt shoe at the desired split point.
bushing using a feeler gauge. The bushing should be re- 8. Remove the shoe link pins and spacer pin.
placed if clearance is l/8” or greater.
3. Insure that there is ample grease in the bushings.
Inspect wear of the final drive shaft bushing as follows(see
Figure 7F-5):
1. Remove the final drive shaft end plates on both sides of Do not stand under the crawler shoe when re-
the crawler frame. moving the link pin and spacer pin.
2. Check the clearance between the bottom of the shaft and C. Remove the crawler belt from the drive tumbler.

ee 0
D_.D
I. c
; o .o-. L
.co ,a* coccc,
c,
f”,&
A’, L _.
C-I? -.

Figure 7F- 1. Excavator Position

761
SUBSECTION 7F FINAL DRIVES

4. Disassemble the propel brake as described in Subsec- 8. Check that the shifter lever is free to slide up and down.
tion 70. 9. Remove the final drive gear case cover.
5. Remove the slinger shield on the propel transmission
10. Lift the final drive pinion from the machine. The final
side of the brake wheel.
drive pinion weighs approximately 3,270 tbs. The steering
6. Remove the two special screws which fasten thesteer- lever must be raised at the same time the final drive pinion
ing lever to the steering yoke (Figure 7F-2). Remove the is raised.
steering yoke. NOTE
Do not lose the steering pin key when the steering
lever is raised.
11. Remove the end plates from the final drive shaft.
12. Block the final drive gear so it will not drop when the
final drive shaft is removed.
13. Block the drive tumbler so most of the weight is re-
moved from the shaft. Block it so it will not roll when the
final drive shaft is removed.

14. Pull the final drive shaft from the drive tumbler side of
the side frame. The shaft weighs approximately 1,330 Ibs.
15. Lift the drive tumbler from the machine. The tumbler
weighs approximately 2,700 tbs. Remove the final drive
gear. The gear weighs approximately 1,621 Ibs.

16. Pull the male jaw clutch and spacer from the pinion
shaft.
17. Slide the bushings off the shaft. Remove thrust
washers from the shaft.
18. Pull the two final drive shaft bushings from the bores of
the side frame.
Figure 7F-2. Steering Yoke
REPAIRS. Repairs to the components of the final drive as-
7. Loosen the clamp bolt on the rod end of the steering lever sembly except the drive tumbler are limited to measuring to
(See Figure 7F-3). assure that they are within allowable tolerances. To check
the tolerance of each component refer to Figures 7F-5 and
7F-6. Replace as required.
lhe drive tumbler can be repaired by weld build-up applied
to the driving lugs. The recommendedweld build-up should
be performed at approximately 10,000 hours. To build-up
the drive tumbler lugs, proceed as follows (See Figure 7F-6):
1. Cut out a template as indicated in Figure 7F-7. The tem-
plate can be made of sheet metal, wood, or template paper.
2. Clean the tumbler of all spalled or loose material, grease
and contaminants. Use a grinder to remove imperfections.
Do not use a torch.
3. Preheat the entire tumbler to 5OOOF soaking. Maintain
this temperature during welding.
4. Hold a medium arc length -slight weaving permitted but
keep to a minimum to prevent local overheating. Beads
must be applied adjacent to each other without removing
the slag. This will result in a smooth overlay. Remove the
slag between layers. maximum of 3 layers permitted.
5. Weld up to within 3/16 inch of the final contour with
weld rod that conforms to Harnischfeger specification 112
or AWS E-l 0018. Use only new low hydrogen electrodes.
Figure 7F-3. Steering Lever Allow the drive tumbler to cool slowly.

7F-2
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SUBSECTION FINAL DRIVES

7F-4
FINAL DRIVES SUBSECTION 7F

6. The template can be inserted in the drive tumbler to be

sure the drive tumbler lugs are built up to the original con-
tour (See Figure 7F-8).

VIEW A-A

Figure 7F-8. Template Between Drive Tumbler Lugs

7. Finish welding to a final contour with Harnischfeger

HARTOP-F Electrode, Airco 364, Hobart’s Top-n-Hard 400.
or Stoody 1105.

NOTE
The final welding will give a 50to 55 Rockwell C scale
hardness.

ASSEMBLY. Refer to Figure 7F-4 and assemble the final

drive assembly as follows:
1. Break the sharp edges on the final drive pinion bush-
ings. Slide the bushings in place on the shaft.
Figure 7F-6. Drive Tumbler Weld Build-Up (100NlC) 2. Mount the jaw clutch in the brake wheel and slide the
brake wheel and jaw clutch assembly on the shaft so it is
tight against the bushing.
3. Break the sharp edges on the final drive shaft bushings.
f Install each of the three final drive bushings in the bores of
11/(#” the gear case.
i
4. Apply a small amount of grease to the thrust washer
grooves on the drive tumbler. Fit the thrust washer on the
drive tumbler. The grease will hold the thrustwashersin
place during assembly.
5. Position the final drive gear and drive tumbler on block-
ing in thegear case. The chamfered end of the tumbler must
be inboard. Line the bores of these two components with
the bores of the gear case.
6. Install the final drive shaft. Shaft must be installed from
the outside or the drive tumbler end of the gear case.

NOTE
Do not damage the final drive shaft bushings when
Figure 7F-7. Template installing the final drive shaft.

7F-5
SUBSECTION 7F FINAL DRIVES

7. After the shaft is in place install the two end plates, one
on each end of the final drive shaft. Torque the capscrews to
600 ft-(bs.
8. Turn the drive tumbler and final drivegear bv hand to as-
sure it is free to turn.
9. mr the final drive pinion in the bore of the final drive
gear case. As the final drive pinion is being positioned, line
up the holes of the final drive pinion bushmgs with the lo-
cating dowels in the bottom bore of the final drive gear case
(See Figure 7F-9).
10. Apply a liquid gasket materiai (Hamischfeger part
number 212587-02) on the milled final drive gear case
cover surface of the gear case.
11. Positionthegearcasecoverontopofthegearcaseand
install the cover bolts (See Figure 7F-10).
12. Torque the cover bolts as follows: I I w CAPSCREW

3-12 UN . . . . . . . . . . . . . . . . . . . . . . . torque to 12OOOft-lbs

q--__-p;[;‘.,,‘::d.“““”
2-3/4-12 . . . . . . . . . . . . . . . . . . . . . . Torque to 32OOOft-lbs FRAME
l-1/2-6 UN . . . . . . . . . . . . . . . . . . . . . Torque to 17OOfGlbs Figure 7F-10. Bolt Location Final Drive Gear Case Cover

FINAL
. DRIVE
PINION

FINAL DRIVE
PtNION BUSHINGS

FINAL REDUCTION

Figure 7F-9. Final Drive Pinion Bushing Locating Dowels

7F-6
 SUBSECTION 7G
CRAWLER COMPONENTS

GENERAL
This subsection describes the maintenance and repair of
the crawler components. items covered include the crawler
belt, belt rollers and idler assembly.

CRAWLER BELT
GENERAL The crawler belt is made up of crawler shoes
pinned to each other which makes up a movable track on
which the excavator rides. The crawler belt evenly
distributes the weight of the excavator on the ground.
Crawler shoes are made of manganese steel. Thewidth and
quantity used will vary, depending on the model of excava-
tor.
Figure 7G-1. Crawler Positioning
REMOVAL. Remove the crawler belt assembly as follows:
1. Dig a hole approximately 1 foot (2.54 cm)deep in front of
the crawler track. vehicle and pull the crawler belt toward the rear of the
excavator.
2. Propel the excavator forward until the front idler roller is
over the hole (see Figure 7G-1).
3. Disconnect the lubrication line from the idler roller shatt.
4. On both sides of the idler assembly, remove the shim re-
taining pins and forward set of shims.
5. Install a hydraulic jack on each side of the crawler frame. The crawler belt may begin to slide freely due
Wsing the jacks force the idler shaft forward until the rear to its weight, when it is pulled off the crawler
set of shims are loose. Be sure to move the idler shaft the frame. Be sure that all personnel are clear of
same distance on both sides of the crawler frame (see Fig- the crawler belt when it is being pulled.
ure 7G-2).
6. Remove the rear set of shims and back off the two hv-
draulic jacks to allow the idler roller to retract fully.
10. Position the crawler belt so it is lying flat along the
7. Remove the crawler shoe link pin retaining bolt of the ground.
shoe nearest the bottom of the idler roller. REPAIRS. The crawler belt can be repaired without jacking
8. Remove the shoe link pins and spacer pin (see Figure or removing. One half of the crawler belt should be re-
7G-3). paired at a time.
Repairing the crawler belt assembly is limited to replacing
( WARNING 1 worn or broken shoe retaining pins and building up of the
crawler shoe driving lugs,
Do not atand under the crawler shoe when re- Refer to Figure 7G-4and repair the crawler shoe lugs as fol-
moving the link pin rpacer pin. lows:

9. Attach a sling near the top front portion of the crawler

belt. Position a pulling vehicle at the rear of the excavator in 1. Clean the crawler belt shoes of all spalled. loose ma-
line with the crawler belt. Attach the sling to the pulling terial, grease, contaminants and grind imperfections.

7G-1
SUBSECTION 7G CRAWLER COMPONENTS

CRAWLER
BELT -

HYOAAUU

FRONT y
SMMS

Figure 7G-2. Removing Crawler Shims

A6TAlNINQ SOLT. NUT

AND LOCKWASHER
uNK\p’N /

Figure 7G-4. Crawler Shoe Weld Build-Up (1OCNl 1)

Figure 7G-3. Crawler Shoe Assembly (24J257)

3. Build up the surface to within 3/l 6 inch (4.6 mm)of final

NOTE
contour with AWS-E-F3 Mn-A (Chemetron Wear-Arc Ni
Clean-up should be accomplished by grinding or Mn) electrode. Use the lowest heat possible for the rod size.
some means other than a cutting torch or flame.
2. In ambient temperatures less than 60°F (9.99OC) NOTE
crawler belt shoes should be pre-heated to loOoF For an alternate rod use (AWS E) 306 stainless. Use
(37.74OC). only new low hydrogen electrodes.

NOTE 4. Finish welding to a final contour with a hard surface

At no time permit the interpass temperatureto build electrode such as Airco 364, Hobart’s Tuf n’ Hard 400. or
up beyond 9CO°F (259.74OC) maximum. Stoodv 1105.

7G-2
CRAWLER COMPONENTS SUBSECTION 7G

5. Hold a medium arc length, slight weaving is permitted 4. Stop the pulling vehicle and excavator when the idler
but keep to a minimum to prevent local overheating. Beads tumbler is over the hole.
should be applied adjacent to each other without removing 5. Slack off on the towing cable and remove it from the
the slag. This will result in a smooth overlay. Remove the crawler belt.
slag between layers. A maximum of 3 layers is permitted.
6. Lift the lower portion of the crawler belt and join it with
The overlay deposited hardness is 50 to 55 Rockwell C the upper portion. Secure it using the spacer and link pins.
scale.
7. Install the link pin retainer bolt, lockwasher and nut.
INSTALLATION. Install the crawler belt as follows:
8. Adjust the crawler belt tension as described-in this sub-
1. Propel the excavator in reverse until the drive tumbler is section.
near the end of the crawler (see Figure 7G-5).
ADJUSTMENT. Adjust the crawler belt tension as follows:
2. Attach a cable to thecrawler belt atthedrive tumbler end
of the excavator. Run the cable over the top of the crawler 1. Remove the cotter pin and shim retaining pin, one on
frame to the front of the excavator. each side of the idler assembly (see Figure 7G-6).
3. Attach the end to a pulling vehicle and pull the crawler 2. Remove the forward set of shims and install a hydraulic
belt. Simultaneously propel the excavator slowly forward jack on each side of the idler assembly.
(see Figure 7G-5).

Figure 7G-5. Crawler Belt Installation

7G-3
SUBSECTION 70 CRAWLER COMPONENTS

REMOVAL To remove the crawler belt rollers it is neces-

sary to have ample slack in the crawler belt and the rollers
(see Figure 7G-6).
REMOVAL Refer to Figure 7G-6 and insure there is suf-
ficient slack in the crawler belt to gain clearance between
the crawler belt and the rollers to remove the crawler belt
rollers.

Figure 7G-6. Hydraulic Jack Positioning

NOT6
Be sure to move the idler roller the same distance on
both sides of the idler assembly.
3. Jack the hydraulic jack until the crawler belt appears to
be tight. Fill the space behind the roller bearing Mock with
shims. Use the shims that were removed from the front of
the bearing block.
4. Back off on the jack. Install the remaining shims in the
space in the front of the bearing block.
5. Slide the retainer pins on each side into position and in-
stall a cotter pin. Remove the hydraulic jack and clear all
tools and equipment from the crawfer tracks.
6. Propel the excavator forward while watching the crawler
pads leave the top of the drive tumbler. lf the crawler pads
form a peak the track is too I-. If the crawfer pads come
straight off the drive tumbler, check the slope of the crawler
belt on the top center of the crawler frame. If the belt is loose
it will slide over the top craw(er frame rail. If it is too tight it
will stretch across the slope on the side frame. The crawler
belt should have a gentle slope as it croaaes the side frame Figure 7G-7. Track Tension
rail slope.

CRAWLER BELT ROLLER (91ON616)

GENERAL The weight of the excavator is transmitted to the
crawfer shoes through the crawler belt rollers. The rollers
are held in place bv a pin.. bolt, lusher. and nut.
INSPECTION. The roller bushing clearance should be in-
spected each 3,CCC hours. Inspect the roller as follows:
1. Dig a hole approximately 1 foot (30.5 cm) deep. Propel
the excavator until the rollerto be inspected is over the hole.
2. Using a pry bar under the roller, lift the roller and
measure the movement of the roller.
3. The roller bushings must be replaced if the movement
approaches 3/l 6 inch (4.76 mm). Figure 7G-8. Crawler Belt Slack

7G-4
CRAWLER COMPONENTS SUBSECTION 7G

The shims on the idler roller assembly can be removed as NOTE

descried in Crawler Belt Idler Assembly in this subsection to The roller pin must be removed toward the outside of
allow additional crawler belt slack. the crawler side frame.
Remove the rollers as follows: 6. Lower the roller from the crawler side frame. This roller
1. Remove the grease line guard from the outside of the weighs approximately 900 Ibs (408.2 kg).
side crawler frame (see Figure 7G-9).
NOTE
2. Disconnect the grease hose and remove the grease pipe
from the roller shaft. The thrust washers on each side of the roller are loose
fitting. Care should be taken to keep these washers
3. Remove the retaining bolt, nut and lockwasher (see Fig- from falling when the roller is being removed.
ure 7G-10).
7. Using a suitable puller, remove the split roller bushings.
4. Support the roller so it will not fall or roll when the roller
pin is removed. REPAIRS. Repairs to the thrust washers and roller bush-
ings are limited to measuring them for proper dimensions. If
5. Remove the roller pin by driving it out from the inside of the thrust washer or bushings do not meet the allowable
the crawler side frame. This pin weighs approximately 200 tolerances, they must be replaced (see Figure 7G-11).
Ibs (90 kg).

11/16” -
1
I r

Figure 7G-9. Side Frame Grease Line Guard

Figure 7G-11. Thrust Washer and Bushing Dimension

If inspection reveals that the roller is worn, the following

welding procedure may be used to build up the roller’s out-
side diameter. To build up the roller with weldment, pro-
ceed as follows (see Figure 7G- 12).
1. Clean the roller and remove all cracked, spalled or work
hardened surface material.

NOTE
The clean-up should be accomplished by grinding or
some means other than a cutting torch or flame.
2. Preheat the entire roller to 600°F (315%) and maintain
this temperature during welding.

Once started, the welding must be completed

without permitting the roller to cool to room
Figure 7G-10. Retaining Bolt Removal temperature.

7G-5
SUBSECTION 7G CRAWLER COMPONENTS

Figure 7G-12. Crawler Roller Dimensions (910N516)

3. Utilizing an automatic submerged arc welding’proce- INSTALLATION. To install the crawler roller, proceedasfol-
dure build up the roller while it is rotating under the arc. lows (see Figure 7G-13):
4. Use a 4130 wire and a neutral flux with a stringer beak 1. Install the two split bushings in the bore of the roller and
technique. Build up the roller diameter to within l/2 inch position the roller under the side frame so it can be raised
(12.7 mm) of the final diameter. into position.
5. Complete the last 2 Iavers of weld metal using 2. Apply grease to the thrust washers and install them on
Chemetron Wear-0-Matic 4 automatic wire with a neutral each side of the roller.
flux. Use l/8 inch (3.18 mm) to S/32 inch (3.97 mm) size
wire with 25 to 30 volts. 3. The roller pin must be installed so the grease hole is
pointing up when the pin is in position. Install the roller pin.
With l/8 inch (3.18 mm) wireuse3OOampsandwith 5/32
inch (3.97 mm) wire use 375 amps for hardtough surfaces 4. Install the retaining bolt, lockwasher, and nut through
the pin on the inside of the side frame.
5. Connect the grease line to the roller pin. Install the
grease line guard on the outside of the side crawler frame.

Do not use more than 3 layers of this win.

Build up to within this 3 layor love1 with 4130
win.

6. After the welding is completed, allow the roller to cool CRAWLER BELT IDLER ASSEMBLY (91 OJ322)
slowly in still air to prevent cracking.
GENERAL The idler roller is of double web construction.
This combination of weld wires and process will provide a The idler shaft is of large diameter to tolerate maximum
hard wearing surface supported with a relatively tough tipping loads, and of uniform diameter to avoid stress con-
base. A surface hardness in excess of 350 8.H.N. will be ob- centration. Shims between the idle bearing and thecrawler
tained. side frames provide for crawler track adjustment.

7G-6
CRAWLER COMPONENTS SUBSECTION 7G

SIDE FRAME

COUNTER SUNK
PIPE PLUG

LOCKWASHER

Figure 7G-13. Crawler Roller Assembly

DISASSEMBLY. To disassemble the crawler belt idler 7. Remove the idler roller bushing.
assembly, proceed as follows: INSPECTION AND REPAIR. It is recommended that the
1. Perform the first 9 steps of the crawler belt removal as bushing and thrust washers be replaced when the bushing
detailed in this subsection. clearance approaches 3/l 6 inch (4.76 mm).
2. Attach a sling to the front portion of the crawler belt, pull The idler assembly should be inspected for cracks and
the crawler belt toward the rear of the carbody until the distortion. The idler assembly should also be inspected for
lshoes just clear the idler roller. proper dimensions. (See Figure 7G-14).
3. Secure the top crawler track to the side frame. This will If necessary the idler roller can be built up by welding. To
prevent it from sliding off the crawler track guide post. build up the roller, proceed as follows (see Figure 7G-15).
4. Block the idler roller to prevent it from rolling and re- 1. Clean the roller and remove all cracked, spalled or work
move the cotter pins and the bearing retainer pins. Remove hardened surface material.
the bearings on each side of the shaft.
NOTE
5. Pull the roller shaft. This shaft weighs approximately
400 Ibs (1043 kg). The clean-up should be accomplished by grinding or
some means other than a cutting torch or flame.
6. Using a suitable lifting device, lift the idler roller from the
machine. This roller weighs approximately 2,300 Ibs 2. Preheat the entire roller to 5DD°F (259.7OC) and main-
(1043.3 kg). tain this temperature during welding.

m
NOTE
The thrust washers on the idler roller are loose fitting Once started, the welding must be completed
to prevent them from falling when the idler roller is re- without permitting the roller to cool to room
moved. temperature.

7G-7
SUBSECTION 76 CRAWLER COMPONENTS

-1132” BEARING

Figure 7G- 14. Idler Shaft Assembly Dimensions (91 DJ322)

3. Utilizing an automatic submerged arc welding process m

Do not uu mon thm 3 Ieyera of thi8 wire.
build up the roller while it is rotating under the arc.
4. Use a 4130 wire and a neutral flux with a stringer bead Build up to within this 3 Iay~ Ievol with 4130
technique. Build up the roller diameter to within l/2 inch wire.
(12.7 mm) of the final diameter.
6. After the welding is completed, allow the roller to cool
5. Complete the last 2 layers of weld metal using Cheme- slowly in still air to prevent cracking.
tron Wear-0-Matic 4 automatic wire with a neutral flux.
Use l/8 inch (3.18 mm) to 5/32 inch (3.97 mm) size wire This combination of weld wires and process will provide a
with 25 to 30 volts. hard wearing surface supported with a relatively tough
base.
With l/8 inch (3.18 mm) wire use 300 amps andwith 5132 A surface hardness of 4245 Rockwell “C” Scale will be ob-
inch (3.97 mm) wire use 375 amps for hard tough surfaces. tained.

7G-8
CRAWLER COMPONENTS SUBSECTION 76

ASSEMBLY. Refer to Figure 7G-16 and assemble the

crawler belt idler assembly as follows:
to"
12"- -l/16"'

- 6” - 1. Install the idler roller bushing in the bore of the idler

roller.

2. Apply a small amount of grease to the thrust washer

grooves on the idler roller. Fit the thrust washer on the idler
roller. The grease will hold the thrust washers in placedur-
ing assembly.

3. Using a lifting device, position the idler roller in place in

the side frame.

4. Using a suitable lifting device, install the idler shaft.

5. Install the bearing blocks, one on each side of the shaft.

Install the bearing retainer pins and cotter pins.

6. Install two link pins in the crawler shoe of the top por-
tion of the crawler belt. Position a pulling vehicle at the front
of the excavator, in line with the crawler belt shoe and to the
pulling vehicle.

7. Take up the tension of the sling. Remove the previously

installed securing device which is holding the crawler belt
in place. ,

8. Pull the crawler belt until it is tight. Secure the belt to

prevent it from becoming slack.

9. Release the tension and disconnect the sling attached.

Allow the crawler belt to hang down over the idler roller.

10. Raise the lower crawler shoe. Mate the end of the
crawler shoes and install the spacer pin and two link pins.
R. Install the link pin retaining bolts on both sides of the
crawler shoe.

11. Remove the device which is holding the crawler belt

tight.

Figure 7G-15. Idler Roller Weld Build-Up 12. Adjust the crawler belt as described in this subsection.

7G-9
SUBSECTION 76 CRAWLER COMPONENTS

3/4” SHIMS
I

BEARING
RETAINING
PIN

SEARING
BLOCK
PIN

SIDE FR:ME
REAR SET FORWARO SET
OF SHIMS OF SHIMS
VIEWED AT THE
INSIDE LEFT IDLER
SHAFT ASSEMBLY

Figure 7G-16. Crawler Idler Assembly

7G-10
 SECTION VIII

AIR SYSTEM

SUBSECTION PAGE

BA. INTRODUCTION
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-1

88. AIR COMPRESSORS

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88-l
Air Compressors (51 U3-Dl ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B- 1

8C. AIR SYSTEM VALVES

General ....................................................................................... 8C- 1
Quick Release Valve (362240) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C-1
Solenoid Air Valve (36Zl 151) ................................................................... 8C- 1
Shut-Off Valve (3621152) ........................................................................ 8C-2
Pressure Switch (7923138) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C-3
Air Valves (360282) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C-3
Solenoid Air Valve (36Z1037-Dl, 3621038-01 & 36Z1058-Dl) . . . . . . . . . . . . . . . . . . . . . . . . . . . .. ... . . 8C-4
Safety Valve (3621140) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C-5

8D. AIR SYSTEM CONDITIONERS

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-1
Air Regulator (89Z182 & 892428) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-1
Air Lubricator (462405) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-2
Air Lubricator (46Q16-D9 & 462237) ............................................................. 8D-3
Air Filter (46017-09 81 462236-D3) .............................................................. 80-5

8E. AIR SYSTEM CYLINDERS

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-1
Rotochamber (38Ul -Dl & 38U2-06) .............................................................. 8E-1
Propel Brake Cylinder (38U88) .................................................................... 8E-2
Steering Cylinder (38Q13) ....................................................................... BE-3

8F. AIR FILTRATION SYSTEM

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-2
Purging the Air System .......................................................................... 8F-4
 SUBSECTION 8A
INTRODUCTION

GENERAL the reservoir air pressure drops to approximately 120 psi

This machine incorporates pneumatic controls for oper- (8.3 bars), the governor permits the compressor to continue
ation of the swing, hoist, crowd, propel brakes, and the pumping, thus maintaining reservoir pressure at the de-
propel steering mechanism. Compressed air is also used in sired level.
the operation of the automatic lubrication system.
A pressure switch mounted on the air reservoir, will not al-
This section covers the maintenance and repair of the air low the excavator to be started until a safe operating pres-
components used on this excavator. The components in- sure of 105 psi (7.2 bars) is reached in the air system. The
clude the air compressor, air filters, regulators, lubricators, pressure switch will remain closed and the excavator will
solenoid valves, rotochambers and the air filtration sys- operate normally only as long as the system pressure re-
mains above 105 psi (7.2 bars). If at any time during the op-
tem.
eration of the excavator the reservoir pressure drops below
A description and schematic diagram of the air system are 105 psi (7.2 bars), the pressure switch opens and the ma-
provided in this subsection (see Figure 8A-1). The locations chine shuts down electrically.
of the air control panels varies. Earlier machines have the
air controls located on separate panels on the upper (see
Figure 8A-2). On current machines the upper air controls One drain cock (vent) is provided at the end of the air reser-
are located in the lube room. The lower air on all machines voir. In addition, a main line condensate drain dumps col-
is contro[led by a panel located nearthecenter of the lower. lected moisture without loss of air from ‘the system.

DESCRIPltON NOTE
Compressed air for all pneumatic controls is furnished by An air system drain schedule should be set up to in-
the electric motor driven air compressor. A pilot line re- sure that moisture will be removed from the air sys-
turns air from the reservoir to the compressor governor. tem. Serious component malfunctions will result if
When pressure in the reservoir reaches 175 psi (12.1 bars), excessive moisture is allowed to collect in the sys-
the governor stops the output of the air compressor. When tem.

8A- 1
SUBSECTION 8A INTRODUCTION
INTRODUCTION SUBSECTION 8A

LUSRlCAtlON AIR CONTROL

PANEL

Hlld-th I IL:--JII

I”_... -...-

CONDENSATE

HOIST BRAKE
PANEL

PLENUM CHAMBER CONTROL

PANEL

& ___--____‘__--r

/I _____
1. - c q 1 ‘,,
( ; COMPRESSORD , , AIR COMPRESSOR
I.--J , ,
‘c________-__Y

Figure 8A-2. Compressor and Air Panel Locations (Early Machines)

8A-3
 SUBSECTION 88
AIR COMPRESSORS

GENERAL
This subsection covers the lubrication, pressure adjust-
ment, maintenance and troubleshooting of the air com-
The lubrication system of this compressor is
pressor.
designed to operate at a minimum speed of 400
rpm. Operation at lower speeds will cause
rapid wear and failure of the compressor.
AIR COMPRESSOR (51 U3-01)
DESCRIPTION. The air compressor located at the front of
the machine provides compressed air for all of the
pneumatic controls. Thecompressor requires regular main- LUBRICATION. Drain and refill the crankcase every 500
tenance and inspection to assure continuous service. hours, or whenever the oil becomes diluted or dirty. Cl,ean
the crankcase thoroughly at the time the oil is changed.
Check the oil level with the dipstick oil gauge. Keep the 011
level between the marks on the gauge at all times. The
UNLOADING crankcase capacity is 6 quarts.
VALVES
AIR
FILTER The recommended oil viscosities for use at different
ambient temperatures are shown in Table 88-l.

TABLE 88-l

OIL LEVEL I I I

OIL PRESSURE ADJUSTMENT. The 011 pressure is regu-

lated bv a spring loaded ball, mounted on the bearing car-
rier. Spring pressure is controlled by an adjusting screw.
Turning the screw inward will increase the oil pressure,
- .- JRE whereas turning the screw outward will decrease the pres-
PRESSURE ’ GAUGE
sure. Be sure to loosen the locknut before making any ad-
ADJUSTING DRAIN
justment, and to turn the adjustment screw slowly until the
SCREW CAP
oil gauge registers approximately 15 to 18 psi. After the ad-
justment has been made, tighten the locknut.
Figure 88-l. Compressor (51 U3-01)

88-l
SUBSECTION 80 AIR COMPRESSORS

MAINTENANCE AND TROUBLESHOOTING. Refer to Tables

88-2 and 88-3 for compressor maintenance and trouble-
shooting.

TABLE 88-2. COMPRESSOR MAINTENANCE CHART

I CHECK 1 DAILY 1 W E E K L Y 1 M O N T H L Y 1 Y E A R L Y
I 1. Check oil oressure - maintain at 15 pounds I x I I I
2. Check oil level - maintain between high and low
X
level marka on bayonet oil gauge
CAUTION: DO NOT OVERFILL
3. Drain drop legs and traps in air distribution system X
4. Give compressor overall visual check X
5. Drain moisture accumulation from air receiver X
I 8. Check air distribution svstem for air leaks 11x1 I
7. Clean cooling surfaces of compressor intercaoler
and aftercooler
8. Operate safety valves
9. Reolace or clean intake filter element

18. Lubricate electri

manufacturer’s

“Check more often if extremely dirtv conditions exist.

l **Everv 6 months.

68-2
AIR COMPRESSORS

TABLE 88-3. COMPRESSOR TROUBLESHOOTING

PROBABLE CAUSE SUGGESTED REMEDY

LOW DISCHARGE PRESSURE

1. Air leaks. 1. Listen for escaping air. Apply soap solution to all
fittings and connections; bubbles will appear at
points of leakage. Tighten or replace leaking
connections or fittings.
2. Leaking valves. 2. Remove valve assemblies from head, disassemble,
and inspect components for valve breakage, worn
valve springs, scarred valve seats, etc. Replace
defective parts and reassemble.
CAUTION: Be sure that old valve assembly gaskets are removed from the head valve pockets, and that
they are replaced with new ones each time the valve assemblies are removed from the head.
3. Restricted air intake. 3. Clean the air filter.

4. Remove belts, mark a line at the present position

of the motor feet wrth a scratch awl, pencil or
4. Slipping belts.
chalk. Loosen motor clampmg bolts and move
the motor 1116” to l/4” away from the compres-
sor, being sure that the motor shaft is perfectly
parallel to the scribed line. Tighten motor clamping
bolts and reinstall belts. Proper tension of the belts
should be gauged by flexing the belt with the hand
a distance equal to the overall thickness of the belt.

5. Unloading mechanism not operating properly. 5. Check the operation of the oil pump and pressure
gauge by unscrewing the pressure gauge until oil
seeps around the threads when the compressor is
running. This indicates that oil pressure is reaching
the system. and also indicates whether the pressure
gauge is operating. If no 011 appears at the threads
of the oil gauge, this IS an indication of possible
oil pump failure. If oil appears at the threads of
the gauge, and the oil pressure gauge indicates
little or no pressure, suspect that the oil gauge
may be faulty and replace. After determining that
the oil pump and gauge are in good operating
order, if the unloading mechanism of the compres-
sor continues to be inoperative, remove the copper
tube that leads from the hydraulic unloader to
the unloading arrangement on the head. There
should be no leakage of arr at thus pomt when the
compressor is running. When the compressor is
stopped, air should leak from the disconnected
tube. This test tells whether the hydraulic unloader
is functioning properly. If, after testing the oil
pump and the hydraulic unloader by the above
methods, the unloading mechanism continues to
be inoperative, remove the unloader arrangement,
and the valve assemblies from the head, and inspect.
6. Blown gaskets. 6. Replace any gaskets proven faulty on inspection.
7. Low compression. 7. Low pressure can be due to worn rings and
cylinder walls. CorrectIon is made by replacing
the rings or by rebormg the cylinder to an over-
size and installing new piston assemblies

88-3
SUBSECTION 88 AIR COMPRESSORS

TABLE 88-3. COMPRESSOR TROUBLESHOOlWG (Cont.1

PROBABLE CAUSE SUGGESTED REMEDY

KNOCKING

1. Loose motor or compressor pulley. 1. Loose motor or compressor pulleys are a very
common cause of compressor knocking. Tighten
pulley clamp bolts and setscrews.
2. Lack of oil in crankcase. 2. Check bayonet oil gauge for proper oil level; if
low. check for possible damage to bearings.
3. Oil pump not functioning. 3. Check as in paragraph on “unloading mechanism
not properly operating.”
4. Worn connecting rod in-. 4. Remove connecting rod cap and inspect inserts: tf
worn or damaged, replace.
CAUTION: Before installing now connecting rod insorb, chock crankshaft oil ch8nnels for th?
possibility of king pluggod with moltm Babbitt.
5. Worn piston pin bushing. 6. Remove rod and piston assemblies from the
compressor and inspect for excess wear. Replace
excessively worn piston pin or bushing.
6. Burned out Timken bearing. 6. Replace worn or burned out bearings and remedv
cause of failure.
7. Excessive crankshaft end play. 7. Remove the cylinder and head assemblies from the
running gear, and check crankshaft for end play.
If end play can be felt. remove one thin bearing
adjustment shim at a time, and recheck end play
after each removal. The bearing, when properly
adjusted, should have a very slight drag when
turned over by hand. This adjustment should never
be made while the rods are still connected to the
crankshaft.
8. Loose valve assemblies. 8. Remove valve assembly and valve assembly gasket
from the heed, replace valve assembly gasket with
a new one, and reinstall valve assembly after
examining the valve pockets in the head and the
valve assemblies for possible damage. Carefully
tighten valve assembly holddown screws suf-
ficiently to hold the valve solidly in place.
9. Loose piston. 9. Bore cylinder to .OlO” or ,020” oversize, and
install oversized pistons and rings.
10. Piston hitting the head. 10. Remove the compressor head and inspect for
carbon deposits or other forecgn matter on top of
the piston. Replace head with new head gasket
and intercooler gaskets as the case may be.

HEATING

1. Dirty cooling surfaces. 1. Clean the cooling surfaces of the cylinder. Inter-
cooler and aftercooler.
2. Incorrect pulley rotation. 2. Check the arrow on the pulley for correct rotation.
If incorrect. have a competent electrictan check for
the possibility of the motor leads bemg reversed.
AIR COMPRESSORS SUBSECTION 86

TABLE 88-3. COMPRESSOR TROUBLESHOOTING (Cont.)

PROBABLE CAUSE SUGGESTED REMEDY I

I

STALL

1. Overloaded motor. 1. Have competent electrician examme the motor

and wiring, then proceed wrth his recommen-
dations.

EXCESSIVE BELT WEAR

1. Pulley out of alignment. 1. Realign motor pulley with compressor pulley.

2. Belt too loose or too tight. 2. Adjust tension. Refer to Slipping Belts under
Low Discharge Pressure.

3. Belt slipping. 3. Adjust tensron.

4. Pulley wobble. 4. Check for worn crankshaft, keyway, or pulley bore,

resulting from runnmg the compressor or motor
with loose pulleys. Check for bent pulleys or bent
crankshaft.

OIL IN THE DISCHARGE AIR

1. Worn piston rings. 1. Replace wrth new rings.

2. Compressor air intake restricted. 2. Clean filtering media in non-flammable solvent,

and check for other restrtcttons m the Intake
svstem.

I 3. Restricted breather valve. I 3. Clean and check breather valve for free operation. 1
4. Excessive oil in compressor. 4. Drain down to full mark on bayonet 011 gauge.

5. Wrona oil viscositv. 5. Check Table 8B-1 for correct viscositv.

6. Connecting rod out of alignment. 6. Have rod with piston attached checked and re-
aligned. Most automotive engine rebuilding houses
have equipment available to make this test.
I

88-5
 SUBSECTION 8C
AIR SYSTEM VALVES

GENERAL MAINTENANCE AND REPAIR. No adjustment is required on

the quick release valves. To check the operation of a valve,
For purposes of this manual theair system valves include all
release the brakes and make certain that air is exhausted
valves not mounted on the air compressor. The air valves
quickly when the brakes are applied.
used in the lubrication system are not covered in this
manual. The valves should be tested periodically for leaks. To test a
valve, release the brakes and coat the exhaust port with a
QUICK RELEASE VALVE (362240)
soap solution. Leakage should not exceed a one inch bubble
DESCRIPTION. The quick release valves are provided to in one second.
allow rapid venting of air from the brake air cylinders. by
If a valve is defective, disassemble the valve as shown in
venting pressure locally from the cylinders. Venting air
Figure 8C-1. Wash all metal parts with a suitable solvent.
pressure locally eliminates any delay which would be
Wash the diaphragm and gasket with soap and water. Flex
caused bv exhausting the air from the cylinders back
the diaphragm,and examine it carefully for cracks or worn
through the lines to the solenoid valves.
spots, and replace it if necessary.
The quick release valve has three ports, as shown in Figure
8C-1. Air pressure entering the inlet port forces the SOLENOID AIR VALVE (3621151)
diaphragm to seal off the exhaust port. The deflected DESCRIPTION. This valve is solenoid operated with an op-
diaphragm also opens a passage between the inlet and out- tional manual operator. The valve is teed into the receiver
let ports. and is electrically activated for a specific time when a com-
When air pressure at the inlet port is reduced, air pressure pressor is energized. Activation of the solenoid valve ex-
from the outlet port lifts the diaphragm off the exhaust port hausts airfrom the shut-off valve located at the bottom of
and seals the inlet port. This opens a passage between the the receiver. As air is bled from the shut-off valve, the valve
outlet and exhaust ports, exhausting air rapidly from the opens and allows collected moisture and air to bleed from
cylinder. the receiver.

EXllAiJST PORT

Figure 8C-1. Quick Release Valve (362240)

ac-i
SUBSECTION 8C AIR SYSTEM VALVES

MAINTENANCE AND REPAIR. Periodically, theoperation of

the valve should be checked. Observe the drain line at the
bottom of the receiver as a compressor staRs up. Air should
blow out of the line until all moisture is eliminated from the
receiver. If the valve does not stay open long enough to ex-
---
F7=
iilLLr
pel all of the moisture. the timer located on the compressor COIL II
deck should be adjusted as necessary. If the solenoid wlw
is not operating property it should be repaired. Repairs are
limited to the replacement of the O-rings, valve body and
solenoid assembly. Remow and repair the valve as fol-
lows: RETAINING -
RING

Shut off the eioctrical pawor and air prsssuro

supplies. Blood all linas bofors attampting ro-
pairs. SPOOL O-RING
1. Tag and remow the electrical wiring from the valve.
2. Disconnect the two air lines to the valw.
3. Remove the capscrews that attach the valw to the re-
ceiver. Remow the valve from the receiver.
4. Disassemble the valve and clean all parts (see Fig- SPRING
ure 8C-2).
5. Replace the O-rings on the spool assembly. E- FILTER
NOTE
If the spool or valve body is worn or damaged. the en-
tire valve body assembly should ba replaced.
-6. Assemble and install the valw on the receiver.
-7. Activate the air system and check the operation of the
valve.

SHUT-OFF VALVE (3821152)

Figure 8C-2. Solenoid Air Valve (36211511
DESCRIFTION. This is a pilot operated valw located at the
bottom of the receiver. The valve is normally held closed bv
pilot pressure from solenoid air valw (3821151). When the DIAPHRAGM
compressors are energized the pilot preaaure is exhausted CAPSCREW I SONNET
and the valve opens to drain moist air from the receiwr.
The valve consi,sts of two aluminum housings and a poly-
urethane diaphragm (see Figure 8C-3). Due to a larger
working surface area on the pilot side of the diaphragm, the
diaphragm is deflected owr the receiver and exhaust ports.
When air is exhausted on the pilot pressure side of the
valve. the diaphragm will return to the center position thus
allowing the receiver to wnt.

MAlNT5NANCE AND REPAIR. No adjustment is required for

the shut-off valve. To check the operation of the valve, ob-
serve the valve at compressor start-up to be sure that the re-
ceiver is venting properly.
The valve should be tested periodically for leaks. With the
receiver up to operating pressure, test the valve by coating
the valve with a soap solution. Leakage should not exceeda
one inch bubble in one second. Figure 8C-3. Shut-Off Valve (3621 152)

8C-2
AIR SYSTEM VALVES SUBSECTION 8C

If a valve is defective, disassemble the valve as shown in AIR VALVES (38Q282)

Figure 8C-3. Wash all metal parts with a suitable solvent. DESCRIPTION. These valves are located on the upper and
Wash the diaphragm with soap and water. Flex the lower air control panels. The valves located on the upper
diaphragm and examine it carefully for cracks or worn panel control the air to the crowd brakes, hoist brakes,
spots, and replace it if necessary. swing brakes and plenum. The four valves located on the
lower panel control the air to the propel brakes and steer-
PRESSURE SWITCH (7923138) ing cylinders. Each brake is independently controlled by a
DESCRIPTION. There are four pressure switches located in valve.
the lubrication room. Three of the switches are for the upper
brakes and one switch is for the receiver. The pressure The valves are solenoid pilot operated. When a brake is to be
switches shut the excavator down electrically if the air pres- released, electrical current is transmitted to a brake valve.
sure is not within oreset limits. The valve allows air to flow to the brake. The air compres-
ses the brake chamber spring and releases the brake. When
ADJUSTMENT. Adjust the pressure switches as follows: the current is removed from the solenoid, the valve ex-
1. Remove the covers from the pressure switches. hausts the air from the brake line, which in turn exhausts
air from the brake chamberthrough thequick releasevalve.
2. Set the air regulator located on the lube room control
The brake will then be set by the brake chamber spring. If
panel to 90 psi.
power should fail on the excavator, all of the brakes will
3. Adjust the regulated air pressure upward until the automatically be set due to the action of the air valves.
brakes open just short of dragging.
MAINTENANCE AND REPAIR. Test the valves periodically
4. Set the brake and receiver pressure switches to the pres-
for leaks. To test a valve, release the brakes and coat all
sure now registered on the regulator.
ports with a soap solution. Leakage should not exceed a one
5. Adjust the regulator upward until all brakes are fully inch bubble in one second. If a valve isdefective. disassem-
open. ble the valve as shown in Figure 8C-4. Wash all metal parts
with a suitable solvent. Inspect all parts and replace worn or
NOTE
damaged parts as necessary.
Do not exceed 150 psi on the air regulator.
NOTE
6. Set all pressure switches to a 5 psi differential.
A repair kit is available for these valves. Refer to the
7. Replace the covers on the pressure switches. replacement parts manual provided for this machine.

CHECK
PLUG VALVE
SOLENOIO
ASSEMBLY COVER
\ /

COVER O-RING RETAINER

CONNECTOR

FILTER GASKET GASKET

Figure 8C-4. Air Valve (36Q282)

8C-3
 SU6SEcTlON 8C AIR SYSTEM VALVES

ADJUSTMENT. No adjustment is required on the air valves.

To check the operation of a valve, release and set the brakes
a number of times. The brakes should release and apply
quickly and smoothly.

SOLENOID AIR VALVE (3621037-01,

3621038-01, 3621068-01)
GENERAL
These brake valves, used on early machines, consist of a
valve body, sub-plate, pilot plate with a manual override
button, and coil assembly (see Figure 8C-5).
These valves can be repaired without removing the sub-
I

,w I

SLEEVE ASSY.

/
plate from the air line. The coil csn also be replaced without
removing the valve body from the sub-plate. _ SEAL

OIL AssEYeLY
PLUNGER
WITH -ill
RRlOE
Figure 8C-6. Coil Assembly
VALVE
BOGY BODY COVER
VALVE BODY. Refer to Figure 8C-7 and disassemble the
valve bodv as follows:
BASE SUB-PLATE
PILOT

3 WAY EOOY
CAPSCREWS

BOOY
COVER
VALVE BOW

4OOY COVER
VALVE SEAT
CARTRIOGE

4 WAY

Figure 8C-5. Solenoid Valves

VALVE SOOY

DISASSEMBLY
COIL. Refer to Figure 8C-6 and remove the coil as follows: BASE SUB-PLATE

Figure 8C-7. Valve Assembly

Shut off the electrical and air pressure supply.

Bleed all lines before attempting repairs. 1. Locate the match marks on the valve body, sub-plate,
1. Tag and mark the electrical wiring to the coil. body cover, and pilot plate (see Figure K-8). If there are no
match marks, make a mark using a suitable punch. Locate
2. Remove the hex nut on the top of the coil assembly.
the marks in the approximate locations shown in Figure
3. Lift the coil from the pilot plate. 8C-8.

8C-4
AIR SYSTEM VALVES SUBSECTION 8C

2. Place the name tag on the coil top

3. Fasten the coil in place with the hex nut. Do not over
tighten this nut.
4. Connect the wires of the coil to the electrical system.
ATCH MARKS
VALVE BODY. Refer to Figure 8C-7 and assemble the valve
body as follows:
1. Clean all parts carefully to remove all foreign particles.
Lightly lubricate all moving parts with a suitable lubricant.
2. Insert the poppet cartridge assembly in the side bore of
the valve body from which it was removed.
3 WAY. 3. Insert the valve seat cartridge in the valve bore.
4. Replace both cover gaskets and fasten both covers to the
valve body. Tighten all the screws systematically to obtain
an even pull-down of the covers.
5. Replace the sub-plate gasket. Place the body assembly
on the sub-plate, being careful to locate the dowel pin of the
body in the hole of the sub-plate.
6. Fasten the body to the sub-plate using four socket head
capscrews.
7. Connect the wiring of the coil to the electrical system.

4 WAY

Figure 8C-8. Match Marks SAFETY VALVE (3621140)

The safety valve is mounted on the reservoir, and limits the
2. Remove the four bodY socket head capscrews Remove maximum pressure in the air system. No maintenance is
the body assembly from the base sub-plate. ordinarily required. Occasionally, the exposed valve stem
should be pulled to allow the valve to “blow off”. If the valve
NOTE stem cannot be moved, remove and disassemble the valve
Cover the base sub-plate to prevent entry of dirt and for cleaning. Always match mark the adjusting cap and
foreign particles. locknut to the valve stem before disassembly so that the
valve can be returned to the same adjustment (see Figure
3. Remove the bodycoversfrom thevalve body. Note the lo- 8C-9).
cation of the valve poppet assembly in relation to the match
marks.
4. Push a wooden dowel through the hole in the valve seat
cartridge and push the poppet cartridge assembly out.
5. Insert a wooden dowel through the exposed opening of
the poppet assembly and push out the seat cartridge.
6. The O-rings and poppet can now be removed.
REPAIRS
It is good practice to replace all the O-rings and gaskets
when thevalve has been disassembled. A reconditioning kit
and coil are available for this solenoid valve. Consult Your
parts book for the correct part numbers.

ASSEMBLY
COIL. Refer to Figure 8C-6 and assemble the coil assembly
as follows:
1. Insert the coil on the top of the valve pilot plate. Place the
coil housing over the coil. Figure 8C-9. Safety Valve (3621 140)

8C-5
 SUBSECTION 8D
AIR SYSTEM CONDlTlONERS

GENERAL air at a constant preset pressure to insure smooth release of

the brakes. Regulators are also located on the plenum and
This subsection includes all components used for the pur- tugger motor control panels.
pose of conditioning the upper and lower air supply. Regu-
lators, lubricators and filters are all considered to be air con- The regulator consists of a diaphragm and spring arrange-
ditioning components. The repair, troubleshooting, and ment which reduces incoming pressure to preset levels. An
description of each of the applicable components are cov- adjusting screw on the regulator provides for adjustment of
ered in this subsection. air pressure output.

TROUBLESHOOTING. Table 8D-1 is provrded to help deter-

AIR REGUlATOR (892182 & 892428) mine the cause of regulator problems. If the cause of the
DESCRIPTION: The excavator is equipped with air regula- problem can be located, use the remedies suggested in the
tors located in the air supply lines. The regulators provide table.

Table 80-l. Troubleshooting Regulators

PROBLEM PROBABLE CAUSE REMEDY

Regulator creep (increase in Dirty or cut valve elastomers. Replace or clean valve. If valve seat
secondary pressure due to leak Nick in valve seat. is damaged it can be replaced on
from primary). most models. On others it may re-
quire replacement of complete
regulator.
Excessive leak from relief Damaged relief seat. Replace diaphragm assembly.
hole in bonnet. Ruptured diaphragm.
Leakage past valve causing Replace or clean valve.
secondary to increase somewhat
and open relief seat. ,
Regulator chatter. A resonant condition. Reorientation of the regulating
spring helps.
Regulator difficult to adjust. Adjusting screw or knob locking Threaded adjusting screws, loosen
device in locked position. locknut.
Contaminants in adjusting screw Remove adjusting screw, clean
threads. thread, and lubricate with
Lubriplate 110 or equivalent.
Place some lubricant on tip of
screw.

8D-1
SUBSECTION 80 AIR SYSTEM CONOITIONERS

DISASSEMBLY. The regulator can be disassembled with- 6. Inspect each part carefully. Replace any damaged or
out removing it from the pipe line. Disassemble the regula- worn parts.
tor as follows (see Figure 80-l ): ASSEMBLY. Assemble the regulator as follows (see Figure
8D-1):

AOJU8l’lNG 1. Apply a small amount of grease on the rubber seat of the

SCREW valve pin.
LOCKNUT 2. Assemble the bottom valve assembly as shown in Fig-
BONNET ure 80-l.
3. Place the washer on the center hole of the baffle.
4. Stack the diaphragm assembly, regulating spring, inter-

COM WNENT
- IsPERRESTSPR’NG mediate spring rest, component, spring and upper spring
rest on the baffle.
5. Place the bonnet over these parts. Fasten with the body
screws.
8. Screw the adjusting screw with the locknut into the bon-
net.

REGULATING
ADJUSTMENTS. Adjust the air pressure regulators as fol-
lows:
1. Build system air pressure up to normal.
OIAPHRAGM
2. Starting at 90 psi, adjust the pressure upward until all
brakes are fully released. Do not exceed 150 psi.
3. Set and release the brakes several times. If the brakes do
not fully release. increase the pressure slightly and re-
-tiASHEir check.
AIR LUBRICATOR (482405)
DESCRIPTION. This air lubricator is located in the lube
u room. The lubricator metersoil into the air line to provide lu-
+--VALVE SEAT bricant to the moving parts of the air valves and cylinders.

Oil is metered into the air line only when there is a flow of
air through the lubricator. Variations in air flow through the
-WASHER lubricator will csuse more or less oil to be metered into the
air streem. As a result, a nearly constant oil density ratio
STRAINER over a wide range of air flow is provided.
VALVE SPRING MAINTENANCE AND REPAIR. All of the working parts of the
lubricator can be disassembled without removal from the
-GASKET
air line. To service the lubricator, proceed as follows (see
@__/- BOTTOM PLUG Figure 80-2):

1. Shut off the air supply to the lubricator.

Figure 8D- 1. Air Regulator (892182 & 892428) 2. Remove the reservoir mounting strap, reservoir, gasket
and check valve.
NOTE
7. Shut off the air pressure in the system. Do not remove the siphon tube unless replacement is
necessary.
2. Turn the adjusting screw counterclockwise to relieve
compression on the spring. 3. Remove the dome assembly, seal, fill plug and O-ring.
3. Remove the body screws and remove the bonnet. 4. The flow sensor should be removed only if it is obviously
4. Remove the upper spring rest, intermediate spring rest, damaged. If removal is necessary, insert an extra long
spring and diaphragm assembly. needle nose pliers into the inlet port in the body and grasp
the point of the sensor. Rotate the sensor approximately
5. The valve assembly can be removed by removing the hot: one-quarter turn either direction and push it through the
tom plug. outlet port in the body.

80-2
AIR SYSTEM CONDITIONERS SUBSECTION 80

DOME ADJUSTMENT. Drip rate adjustments should only be made

l/ ASSEMBLY under a normal steady flow condition. Once established,
the lubricator will automatically adjust the drip rate propor-
FILL tionally to variations in the air flow. To adjust the drip rate,
/ PLUG proceed as follows:
SEAL’ - 1. Fill the reservoir with air lubricating oil.
2. Open the air supply valve to the lubricator.
3. With the air flowing at a normal rate, turn the adjusting

\
FLOW
SENSOR
knob counterclockwise to increase the drip rate. Turn the
knob clockwise to decrease the drip rate.
4. Push the green lock ring downward to lock the setting
after the final adjustment.

AIR LUBRICATOR (46Q16-OS & 462237)

BODY
TROUBLESHOOTING. If problems arise, consult Trouble-
SIPHON/U 1 shooting Table 80-2 first before disassembling the lubrica-
tor. If the problem can be located, use the suggested
remedy. If necessary, proceed with maintenance and/or
disassembly procedures.
MAINTENANCE. All of the working parts of the lubricator
are contained in the capsule assembly. If cleaning or repair
is necessary, the capsule assembly may be removed from
the body without disconnecting any piping as follows (see
Figure 8D-3):

1. ,Turn off the air supply to the lubricator.

2. Press vent valve button (03) to vent the pressure in the
system.
‘SERVICE 3. Remove top cap (04) by turning it counterclockwise.
KIT ITEMS
4. Back off capsule screws (05) until they no longer en-
gage the threads in body (02). The screws WIII remain with
the capsule assembly.
Figure BD-2. Air Lubricator (462405)

When cleaning parts of the lubricator, use only

5. Clean all parts with soap and water. clear, warm water or kerosene.

6. Dry the parts and blow out the internal passages in the 5. If it is necessary to clean siphon tube (06). do not lose
body using clean, dry compressed air. check ball (07) which is installed between the siphon tube
7. Make certain the check ball in the siphon tube fitting in fitting (11) and the capsule body.
the body moves freely.
8. Inspect each part and replace any parts that are dam-
aged.
9. Install the flow sensor if it was removed. The pointed end Make certain that the bowl is not cross-
must face in the opposite direction to the flow arrow on the threaded when reassembling, and that the
body. bowl is turned in until all threads are no longer
visible.
10. Install the dome assembly and the check valve. Torque
them to 30-35 inch-pounds.
6. When reassembling, tighten capsule screws (05) evenly,
11. Apply a coat of grease to the reservoir gasket.
a l/32” Allen wrench is requrred to remove and tighten
12. Attach the reservoir to the body. pressurizing valve (08).

80-3
SUBSECTION 80 AIR SYSTEM CONDlTlONERS

Table 80-Z. Troublesbooting Air Lubricators (46416-09 & 462236-03)

PROBLEM PROBABLE CAUSE REMEDY

Unable to depressurire Vent button may be restricting Replace vent button.

bowl using vent button. flow. This is indicated by a low,
steady flow.
Bowl pressurizing valve may ba Replace capsule assembly.
defective. This will result in a
high continuous flow.
. Capsule seals may be extruded Reposition seals. If seals are
into the bowl cavity. This will damaged, replace with capsule
result in a high continuous flow. assembly repair kit.
Oil feed not adjustable. Leakage in threads around oil Replace capsule assembly.
adjusting screw.
Partially blocked oil passage. Clean passageways by running the
oil adjusting screw in and out
several times. If unable to clean,
replace capsule assembly.
Unable to pressurize bowl. External leaks. Check for leaks to atmosphere.
Replace defective seals.
Defective charge valve. Clean orifice in charge valve.
Unable to produce a drip External leakage past the Check for damaged O-ring.
rate. O-ring seal between cap and Make certain the capsule has
capsule. baen properly installed. Replace
defective parts.
External leakage through the cap Check for damaged or improperly
or bowl threads. installed seals. Check for insuf-
ficient tightening of cap or
bowl. Make necessary cortec-
tion and replace damaged seals.
Internal leakage between body Check for damaged or improp-
cavity and secondary side of erly installed seals. Replace
capsule. any defective seals and care-
fully reinstall capsule.
Bowl is not being pressurized Replace capsule assembly.
due to defective charge valve.
Canbedetectedbylackof
flow when depressing vent
button.
Blocked oil feed passage. This is generally in the oil feed
adjusting screw threads. Running
the adjusting screw in and “out”
several times normally clears
this passage.
Air leak between siphon tube Siphon tube may be loose in
and capsule. capsule. Tighten as required
being careful not to damage
threads in capsule. If unable to
seal, replace capsule assembly.
Defective siphon tube check Replace capsule assembly.
valve which allows reverse
flow during cyclic
applications.

80-4
AIR SYSTEM CONDITIONERS SUBSECTION BD

OIL FEED
ADJUSTMENT

l iI
- It II
II
BUTTON
Figure 80-4. Lubricator Adjustment

AIR FILTER (46017-09 81 462236-03)

DESCRIPTION. The automatic drain filter dumps collected
moisture without loss of air from the system. The air enters
the filter through louvers which force the air into a circular
pattern. Liquid particles are thrown against the inside wall
of the bowl by centrifugal force, and run down to the bot-
tom of the bowl. The air leaves the bowl through a filter ele-
ment which removes any remaining solid impurities. A float
opens a valve at the bottom of the bowl when accumulated
liquid reaches a certain level, and the liquid is dumped. The
float allows the valve to close before air is lost through the
valve. Liquid may be dumped manually by depressing the
needle inside the drain outlet (see Figure 80-5).

FLOAT
) ASSEMBLY

STRAIN
AUTOMATIC
DRAIN

01. CAPSULE ASSEMBLY

02. BODY L GASKET
03. VENT VALVE SUTTON
04. TOP CAP
05. SCREWS
06. SIPHON TUBE NEEDLE KNURLED
07. CHECK BALL % RETAINING RING
08. PRESSURIZING VALVE
09. PRESSURIZING RESERVOIR Figure 80-5. Air Filter Drain
10. SIGHT-FEED DOME
11. FIrrING
Figure 80-3. Air Lubricator (46Q16-09 & 462237)
DISASSEMBLY. It is not necessary to remove the filter from
the air line to service it. To disassemble the filter for clean-
ADJUSTMENT. The drip rate is adjusted by turnmg the oil ing and servicing, proceed as follows (see Figure 80-6):
feed adjusting screw (see Figure 80-4) clockwise to de- 1. Shut off the arr supply and bleed the pressure from tn-
crease and counterclockwise to increase the drip rate. side the filter assembly.

8D-5
SUBSECTION 80 AIR SYSTEM CONOlTlONERS

2. Remove the threaded bowl by unscrewing it counter-

clockwise.

3. Unscrew the baffle. The filter element and filter shield

will drop off with the baffle. The louver deflector assembly
can be removed by first unscrewing the filter guide. A l/2
inch open wrench is required to remove the filter guide.

4. The strainer and float assembly are not attached and will
drop out when the bowl is turned upside down. The float
and automatic drain assemblies are not considered repair-
able items.

u-- LoUVER - DEFLECTOR ASSEMBLY

FILTER GUIDE
5. Remove the automatic drain by loosening the knurled re-
taining ring.

6. Clean and inspect each part carefully, with the excep-

tion of the automatic drain mechanism and float assembly,
use only clean, warm water or kerosene.
GASKET

FILTER ELEMENT ASSEMBLY. Care should be taken when reassembling the

filter to install the gasket on the bottom of the automatic
drain before placing it in the bowl. If the strainer has a
flLTER SHIELD flanged end, the flanged end should be down.

When replacing the bowl, take special care to avoid cross

threading.

To assemble the air filter, proceed as follows (see Figure

80-6):

FLOAT ASSEMBLY 1. Place the gasket on the bottom of the automatic drain as-
sembly.

2. Place the automatic drain assembly in the bowl. Fasten it

AUTOMATIC DRAIN in place with the knurled retaining ring.

3. Drop the strainer and float assembly on the automatic

GASKET
drain.

4. Place the O-ring on top of the louver-deflector assem-

bly. Put the filter guide in the louver-deflector and screw it
on the bodv.
KNURLED
RETAINING RING 9. Place the gasket fiter element. gasket. and filter shield
on the filter guide. Screw the baffle on the filter guide.

Figure 8D-6. Air Filter (46Q17-09 & 462236-03) 6. Screw the bowl on the body. Do not over trghten.

80-6
 SUBSECTION 8E
AIR SYSTEM CYLINDERS

GENERAL air pressure to equalize on both sides of the piston, and the
brake will remain applied.
For purposes of this manual air system cylinders include all
rotochambers and air cylinders used in the air brake and To check for a ruptured diaphragm, loosen the air connec-
steering systems. Operation, troubleshooting, repair, dis- tion at the rotochamber and determine whether air es-
assembly, and assembly as required by the individual item capes when the operator releases the brake. If air is avail-
will be covered in this subsection. able and escapes through the loosened connection, the
rotochamber must be removed and repaired, or replaced.
ROTOCHAMBER (38Ul -Dl & 38U2-06)
REMOVAL. To remove the rotochamber, refer to the sub-
section covering the specific brake affected.
DESCRIPTION. The rotochambers consist basically of a pis-
ton, the movement of which is opposed by a spring. Air is DISASSEMBLY. Refer to Figure 8E-1 and disassemble the
applied to one side of the piston, driving it forward against rotochamber as described in the following steps:
spring pressure to release the brake. A flexible diaphragm is 1. Remove the rubber foot.
connected between the outer diameter of the piston and the
inner diameter of the housing, as shown in Figure 8E-1. 2. Remove the capscrews which secure the housing to the
base.
TESTING. In the event that a brake cannot be released, and
air is available at the rotochamber, the most probable cause 3. Remove the housing from the base, and remove the
is a ruptured diaphragm. A ruptured diaphragm will allow spring.

OUTER
DIAPHRAGM CLAMP HOUSING BASE MOUNTING
STUD
NUTS
STUO
NUTS (01) aw
\

, RUBBER SOOT

PUSH PLATE PUSH ROD

NOTE: THESE ITEMS

COMPRISE THE PISTON

RELEASE SPRING CAPSCREW (02)

Figure 8E-1. Rotochamber Assembly

8E-1
SUBSECTION 8E AIR SYSTETvl CYLINOERS

4. Remove stud nuts (01). Pull and wiggle the push rod and 5. Place the assembly, consisting of the push rod, push
the entire internal assembly out of the housing. plate, diaphragm guide, diaphragm, and inner clamp, on the
inside of the outer clamp.
5. Straighten the rolled diaphragm, and remove the outer
clamp. Remove nuts (03). and remove the remaining parts 6. Roll the free end of the diaphragm back and over the end
from the push rod. of the outer diaphragm clamp. Coat the inside of the hous-
ing and the diaphragm with a good grade of air brake cylin-
INSPECTION. Clean and inspect the disassembled parts as der grease.
follows:
7. Slide the completed subassembly into the housing, mak-
1. Clean all metal parts in a suitable cleaning solvent. ing sure the end of the diaphragm fits snugly against the
2. Inspect the body, inner and outer diaphragm clamps, and shoulder in the housing by positioning the outer dia-
diaphragm guide for cracks or damage. Replace any dam- phragm clamp studs through the holes at the end of the
aged parts. housing. Install stud nuts (01).

3. Inspect the push rod for cracks, bends, or wear. Replace 8. Install the release spring over the push rod, and against
the diaphragm guide and push rod as an assembly if dam- the push plate. Install the base and secure it in position with
age is found. capscrews (02).

4. Always replace the diaphragm and rubber boot when the INSTALLATION. After reassembly, install the rotochamber
rotochamber is disassembled. as described in the specific subsection covering the af-
fected brake.
5. Inspect the release spring for cracks or damage. If the
spring must be replaced, be sure to order the correct spring PROPEL BRAKE CYLINDER (38U88)
by giving the model number and sirs of the rotochamber. DESCRIPTION. The air cylinder consists of the body, end
covers, piston, piston rod, O-ring, and packings. The piston
ASSEMBLY. Assemble the rotochamber asdescribed in the is of the single piece type using two packing rings. The pis-
following steps: ton rod is held to the piston by a self locking nut. ’
1. Stand the tubular diaphragm on end on the inner dia- DISASSEMBLY. Refer to Figures 8E-2 and 8E-3 and disas-
phragm clamp. The small diameter end of the diaphragm semble the air cylinder as follows:
should be against the inner diaphragm clamp. 1. Remove the air cylinder from the propel brake as de-
2. Position and install the diaphragm guide within the dia- scribed in Section VII.
phragm and over the inner diaphragm clamp studs. 2. Push the piston rod into the cylinder as far as it will go.
3. Install the push plate and push rod assembly within the Remove the breather from the rod end of the cylinder.
diaphragm guide and over the diaphragm clamp studs. 3. Remove the rod packing nut. In the case of the round
4. Install nuts(03) on the inner diaphragm clamp studs, and gland, use a pin type spanner wrench. For hex head pack-
tighten the nuts securely. ing gland. use an open end wrench of the proper size.

BOOY PACKING NUT

PISTON ROD
EN0 COVER

PISTON A00 PACKING

ROD NUT

VENT PORT
TlE ROD
NUTS
PISTON U-CUP
PACKINGS
SUPPLY PORT

Figure 8E-2. Air Cylinder (381188)

8E-2
AIR SYSTEM CYLINDERS SUBSECTION 8E

STEERING CYLINDER (38013)

DESCRIPTION. There are two steering cylinders on the ex-
cavator. One cylinder is provided with each steering link-
age assembly. When activated, the steenng cylinder acts
against the force of the steering spring to disengage 6 jaw
clutch. If air is lost at any time the cylinder is automatically
vented and the jaw clutch will be spring engaged.
Repair of this cylinder is limited to disassembly, cleaning
and replacement of seals and packings.

DISASSEMBLY. If the air cylinder requiresdisassemb(y and

repair, proceed as follows (see Figure 8E-4):
1. Remove the air cylinder from the steering linkage as de-
scribed in Subsection 7G.
2. Remove nuts (01) from one end of tie rods (16).
3. Pull rod head (14) off of tube (04) and remove piston as-
sembly (07) from the tube.
4. Remove gland (12). packings (13) and wiper (11) from the
head. Note how the packings come out of the cylinder head.
INSPECTION. Clean and inspect the disassembled parts as
follows:
Figure 8E-3. Packing Installation
1. Discard all seals and O-rings. Clean all metal parts in a
suitable cleaning solvent.
4. Slide the packing nut to the end of the piston rod, but do
NOTE
not remove it from the rod, apply air pressure to the rod end
port to blow the rod packing out. The packing nut will be A seal repair kit is available for this cylinder. See the
used to catch the packing as it leaves the head. Remove the replacement parts manual.
packing and packing nut.
2. Inspect the piston, tube and heads for damage and ex-
5. Remove the tie rod nuts and end cover. cessive wear.
6. Push the piston out the back of the cylinder body. 3. Inspect the push rod for cracks or bends.
ASSEMBLY. Assemble the air cylinder as follows (see Fig-
ASSEMBLY. Refer to Figures 8E-2 and 8E-3 and assemble ure 8E-4):
the air cylinder as follows:
1. Coat the O-rings and seals with a light seal grease prior
1. Coat the piston packingswith a light clean oil. Slide them to assembly.
in the piston grooves. Be sure the flat sides of the packings
are against the center piston ring as shown in Figure 8E-3 2. Install the U-cups and washers on the piston.
2. Coat the piston O-ring with a light clean oil and slide it on 3. Assemble sleeve (09). O-ring (08) and the piston assem-
the piston rod against the rod shoulder. bly onto rod (15).
3. Place the piston rod through the piston and fasten it in 4. Carefully slide the piston assembly into tube(04). Do not
place with the piston rod nut. allow the U-cups to roll back on the prston.
4. Carefully insert the piston and piston rod in the body of 5. Place tube seals (03) into heads (02 and 14) and assem-
the cylinder by hand. ble the heads to the tube with rod bolts (16).
5. Place the end cover on the body and fasten itwith the tie 6. Install nuts (01) and tighten diametrically opposite rod
rods and tie rod nuts. nuts in pairs, working around the succeeding pair of rod
nuts until all have been tightened a reasonable amount.
6. Coat the rod packing with light clean oil and slide it over Then follow with an additional tightening to 15 foot-pounds
the rod followed by the packing nut. Do not over tighten the of torque.
packing nut.
7. Install the seal assembly in the same order as it was re-
NOTE moved during disassembly.
It may be necessary to retighten the rod packing nut 8. With wrper (1 1) in place, securely fasten packing gland
after a few hours of operation. (12) to the head with capscrews ( 10).
9. Install the air cylinder on the steering linkage. See Sub-
7 Install the brake cylinder as described in Sectron VII. section 7G.

8E-3
SUBSECTION 8E AIR SYSTEM CYLINDERS

.Ol. NUT 09. SLEEVE

02. MEAD 10. CAPSCKEW
‘03. TUBE SEAL ‘11. WIPER
04. TUSE 12. PACKING GIAND
l os. U-CUP l 13. SEAL ASSEMBLY
‘OS. SACK-UP WASHER 14. HEAO
07. PISTON 1s. PISTON ROD
‘OS. O-RINO 16. TIE ROD
‘SERVICE KIT ITEMS

Figure 8E-4. Steering Cylimr (38Q13)

s-4
 SUBSECTION 8F

AIR FILTRATION SYSTEM

OIRT'Y AIR

DIRTY AIR

CLEAN AIR

DIRT AN0 BLEED AIR

AND BLEED AIR

‘U
Figure 8F-1 Air Filter System

GENERAL through the hoist cable opening and vents. This pressur-
ization assures that all air drawn into the cab is filtered.
The entrance of dust into the electrical equipment could
cause damage to electrical components. For this reason, all This method offers protection to DC motors and gener-
air entering the cab of the excavator is forced through the ators which have commutators and carbon brushes, pro-
filters mounted in the filter box above the generators (See viding better commutators and longer commutator life than
Figure 8F-1). Enough air is supplied by the blowers to conventional systems. Better air circulation and reduced
maintain a pressure of about three-eighths of an inch dust accumulation also result in lower operating temper-
(water gauge) above atmospheric pressure within the cab. atures of all electrical equipment.
A separate blower on the controi cabinet provides air to cool Dirty air enters through the inlet located at the face or wide
the force-ventilated resistor in the control circuit. If a cab end of the wedge shaped cell (see Figure 8F-2). Most of the
door is left open, cab pressure cannot be maintained. air (90%) must change direction abruptly as it ‘passes
To insure adequate cooling of the propel and swing motors through the narrow side passages. The dirt particles, be-
auxiliary blowers are mounted on each motor to draw fil- cause of their greater mass, tend to continue in a straight
tered air from the cab and force it through the motor. line (inertial separation) and are carried on into the bleed
duct by the bleed air flow (10%).
DESCRiPTlON
The dirt laden bleed air continuously “sweeps” the bleed
In operation, the slight pressurization of cab air reverses duct. The dirt particles and bleed air are returned to atmos-
any potential inflow through momentarily opened doors or phere.

8F-1
 AIR FILTRATION SYSTEM

DIRTY AIR 3. Grasp each of the blade packs and pull it forward out of
its cell (see Figure 8F-4).

DIRT AND BLEED AIR

Figure 8F-2. Air Flow

MAINTENANCE
DESCRIPTION. The cab ventilation system consists of two
blowers and either two or four filters. The ventilation sys-
tern is generally considered a low maintenance item, how-
ever, there are a few maintenance procedures which must
be observed to insure optimum performance.
INSPECTION. A periodic visual inspection should be made
4
to assure that the air inlet screens are free of large debris
”
J‘SIAOE -

which might impair air flow. The filters are designed to re- PACK
move dusr from the air, not largedebris such as rags, leaves Figure 8F-3. Removing the Bullnose Strip
or pieces of paper.
A more detailed inspection should be made at intervals de-
pending upon the circumstances at each particular site. In
most cases twice a year is sufficient. At this inspection the
bleed slots of each cell should bechecked to make sure they
have not become plugged with large debris. At the same
time the blades of the filter cell should be examined for a
build-up of deposits. A light coating of dust is normal and
will not impair the operation or efficiency of the cells. In
some installations, however, the cell blades may occasion-
ally accumulate a thicker deposit of surface dirt due to the
sticky character of an unusual dust, or due to the presence
of oil mist or similar vapors in the air. When the accumulat-
ed deposit reaches a thickness of l/8 inch, the cell blades 3
should be cleaned.

CLEANING. Depending upon the type and stickiness of the

dust deposits, there are two ways in which the filter blades
may be cleaned. For light dirt deposits, clean by brushing
the surface of the blade and/or blowing down with com-
pressed air. For heavy deposits, completely remove and
clean the blade packs as follows:

1. Gain access to the blade pack through the plenum

chamber.
a
2. Loosen the nuts which hold the blade pack clamp bars In I
place, rotate the clamp bars 90° and remove the bullnose
strips (see Figure 8F-3). Figure 8F-4. Blade Pack Removal

8F-2
AIR FILTRATION SYSTEM SUBSECTION 8F

4. Thoroughly clean the blade packs in a detergent or other but the setting should be checked when the filters are ser-
suitable solvent. viced. To adjust the blower blades, proceed as follows:

NOTE 1. Check the setting of each blade as indicated by the line

If the cleaning process removes paint from the blades, on the blade housing (see Figure 8F-5). See Table 8F-1 for
they should be rinsed, dried and repainted prior to In- the correct blade setting.
stallation. 2. If the blade setting is incorrect, remove the top cover to
5 After cleaning and drying the filter blade, coat the out- gain access to the adjusting nuts (see Figure 8F-6).
srde surfaces of the channels to which the blades are weld-
ed and the inside surfaces of the channels to which each 3. Loosen the hex nut and adjust each blade mdivrdually
blade pack slides with grease. This grease not only lubrr- until all blades are properly adjusted.
cates to make insertion and removal easier but also pre- 4. Tighten the hex nuts and recheck the settrngs on all of
vents corrosion and serves as a seal to prevent arr and dirt the blades. Install and tighten the top cover.
bypass.
6. Check bleed ducts for dirt build-up and clean if neces-
sary.
BLADE HEX NUT BLADE
ADJUSTMENTS. In addition to filter efficiency, the amount \ I HOUSING
of air supplied to thecab is highly dependent upon the blade
setting of the blower. The blower blades are preadjusted,

TOP
COVER
I

Figure 8F-5. Checking Blade Setting Figure 8F-6. Fan Blade Adjustment

Table 8F-1

Low Alt. (o-7000 Ft.) High Alt. (7000-l 2000 Ft.)

Number Number Number Number
Number Cab of of of of
of H.P. Pressure Filter Blade Blade Filter Blade Blade
M a c h i n e C y c l e B l o w e r s B l o w e r s ( i n . o f H,O) Units Packs Setting Units Packs Setting

19oOAL 50 2 15 .5 2 56 4 4 72 8
60 2 15 .5 2 56 7 4 72 4-l/2

8F-3
SUBSECTlON 8F AIR FILTRATION SYSTEM

PURGING THE AIR SYSTEM 2. 60 seconds after blower reverse contactor (153A) is en-
ergized, the normally closed contacts of timer (151 A) open
The air filtration system is purged of dust and foreign ma- to de-energize blower reverse contactor (153A) and air
terial automatically esch time the machine is started by re-
valve solenoid (154A). and the normally open contacts of
versing the csb blowers and blowing compressed air timer (151A) close to start timer (152A). This gives the
through the blowers and bleed ducts figure 8F-7 is a
blower SO seconds to slow down from the reverse direction
schematic diagram of both the air piping system and the and shuts off the air to the plenum chambers.
electrical system involved.
3. 120 seconds after the machine has started, the nor-
The operation of the air filtration purging system is as fol-
malty open contacts of timer (152A) close energizing blower
lows:
forward contactor (88A). When the blower forward contac-
1. When the machine is started, blower reverse contsctor tar is energized, power is applied to the blower motors to
(153A) is energized, causing the blowers to run in the re- cause them to run in the normal forward direction.
verse direction. At the same time, the air solenoid valve
(154A) is energized allowing compressed air to be blown
through the plenum chambers to loosen any foreign ma- 4. The interlocks in series with the forward and reverse
terial 50 that it can be blown out of the machine by the re- contactor coils prevent any possibility of the reversing con-
versed blowers. tactors connecting conflicting phases to the blower motors.

TIMEn rrELAY COIL

c

“ON DELAY- (so EEC.)

bLOWOff NOZZLES (MOUNYEO NEAR FANS)

SOLENOID
faCSSuAI AIR VALVE
REGULATOR \

I ’
4

TO OYHER SYSYEMS

COMPitESSOR
TAM

PNEUMATIC SYSTEM

Figure 8F-7. Dust Removal System (100J2771)

8F-4
 SECTION IX

LUBRICATION

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-l
Lubrication Specifications ...................................................................................9-l
Chain Case Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Electric Motor and Generator Lubrication ..................................................................... 9-l
 SECTION IX
LUBRICATION

GENERAL a lubricant from this list does not mean that it is unsuitable.
An automatic lubrication system is provided on this ma- It means only that, as of the date of this writing, the lubri-
chine. Greasing of the upper machinery, lower machinery, cant has not been tested by P&H. The order in which the Iu-
and boom machinery is accomplished by meansof a central bricants appear on any list is of no significance. No superi-
greasing station located in the upper of the machine. ority of any brand listed should be read into the order of
appearance on a list. The listing is purely random and all
The system has been designed to grease all machinery, products on the list are equally acceptable.
while digging, once every 45 to 60 minutes. When propel-
ling, it is possible to apply grease to the lower machinery
much more frequently, while the upper and boom ma-
chinery receive no lubrication at all.
The operation of the automatic lubrication is covered in a CHAIN CASE LUBRICATION
separate manual for that equipment. Refer to the manufac- For ambient temperatures between +40°F and +90°F, use
turer’s manual for maintenance and adjustment informa- SAE 10 or SAE 20 oil. For ambient temperatures below
tion. +40°F, use SAE 5 oil. For ambient temperatures above
90°F, use SAE 30 oil.

Make certain that any grease added to the

grease drum is compatible with the grease al- NOTE
ready being used in the system. Do not use oils heavier than SAE 30.
LUBRICATION SPECIFICATIONS
The following list identifies suitable lubricants for points Anti-rust and anti-foam additives may be used, but deter-
shown in the lubrication chart by three methods. They are: gent oils are not recommended for initial fill or for tempera-
1. BY P&H SPECIFICATION NUMBER. This lubrication tures up to 90°F.
specification classified by internal Harnischfeger Corpora- The sump capacity is 13 gallons.
tion Standards.
2. BY MILITARY SPECIFICATION NUMBER. If the lubricant
classified by P&H Specification Number has a known mili- ELECTRIC MOTOR AND
tary specification equivalent number, this equivalent num- GENERATOR LUBRICATION
ber is also listed in the individual lubricant description.
A lubrication instruction plate is mounted on each major
NOTE electric motor and generator. Use multi-purpose grease of
the type listed in the lubrication section. Before lubricating
The absence of an entry in the Military Specification any of the large motors or generators, check to see if a Iu-
Column in a lubricant description does not mean that bricant sump plug or a relief fitting is furnished. If it is a
the lubricant recommended does not meet any equiv- sump plug, the plug must be removed to allow the old lubri-
alent military specification. It may mean, for in- cant to be forced out by the new. A relief fitting will open
stance, that the lubricant has not been tested and automatically.
qualified by the military because it is relatively new.
For that reason, it is not certified as meeting the stan- NOTE
dards of a particular military specification, even
though it may be perfectly capable of so doing. If temperatures considerably lower than 20 degrees
below zero Fahrenheit are encountered in service
3. BY EQUIVALENT LUBRICANT. Equivalent lubricants conditions, it is recommended strongly that all mo-
presently conformed as meeting the requirements of the tors and generators be equipped with heaters.
P&H specification are listed by trade names. The absence of

9-1
 -

SECTION IX LUBRICATION

MULTIPURPOSE GREASE

PRW MILITARY EOUIVALENT

SPEC. NO. AMBIENT RANGE SPEC. NO. LUBRICANTS MANUFACTURERS

472A ‘Wow-1WF Not Avaiieble Lithdine Atlantic Richfield Oil Co.

(NLGI #ID EPI (-12oc) industrial 0
EP “Sindrir”
Lithdine H EP 0
Conolith EP #o Continental Oil Compeny
Aolubricent 0 or ~~mwv
LidokEP#O
Amoiith Greece Amoco Oil Compeny
No.OEP
Mobiiux EP #o Mobil Oil Corpomtion
Ahmnir EPRO Shell Oil Company
Prestige 740 EP Sun Oil Co. - OX Dii.
Multifak EP #o Texaco, incorporated
Unoba EP NLGI #O Union Oil Company of Calif.
Dun-Lith Grease EP #o Chevron Oil Compeny
4728 ‘-20 to +4O“F Not AvailaM Litholine H EP 1 Atlantic Richfield Compeny
(NLGI #l EPj (-2Sto4w camdth EP 111 Continental Oil Company
Rofubricant 1 Goam Company (AI
OrLidOkEP#l
Mobiiux EP #l Mobil Oil Corporation
Ahmnia EP 11 Shell Oil compel
Fmntige741 EP Sun Oil Co. - OX Div.
Mdtif8kEP#1 lexaco, Incorpomted
AmolithGreaso#l EP Amoco Oil Compnny
Unoba EP NLGI It1 Union Oil Company of Calif.
Dumdth Gmase EP #l Chovron Oil C0mpary
472 l +20 to 125OF Not Aveilabfo Lithofine H EP 2 or Athntic Richfield Company
(NLGI #2 EF) (4 to SZ=C) ArcoEPMdyD
CanoiithEP(12 Continentel Oil Compeny
Rdubricant2 or ~~nv(A~
Liddt#2
MoMuxEP#2 Mobil Oil Corporation
AhmniaEP#2 Shell Oil Company
Prestige 742 EP Sun Oil Company
MultifakEP#2 Texaco, incorporated
Amolith Grease #2 EP Amoco Oil Company
UnokEPNLGi#2 Union Oil Compsny of Calif.
Duradth Greue EP#2 Chevron Oil Company

‘Pumpability tests also required when u8ed in centralized lubrbtion systems. Consult manufectursr of system.

(Al Rolubricent for steel mill applications.

bsueNo.e,1-76 Pl11

9-2
LUBRICATION SECTION IX

PETROLEUM GEAR OIL

P&H AMBIENT MILITARY BAE

SPEC. NO. RANGE SPEC. NO. EQUIVALENT LUBRICANTS GRADE MANUFACTURERS

497A Below +l O°F MIL-L- Multipurpose Gear Lube 80 Amoco Oil Company
21058 Conoco Universal Gear Lube 80 Continental Oil Company
Gear Oil GX 80 Exxon Company
Mobilube HO 80 Mobil Oil Corporation
Spirax Heavy Outy 80 Shell Oil Company
Sunfleet GL-5 80 Sun Oil Company
Multigear Lube 80 Texaco, Incorporated
Union MP Gear Lube 80 Union Oil Company of Calif.
Citgo Premium Gear Oil (MP) 80 Cities Service Oil Company
4978 +l O” to +9D°F MIL-L- Multipurpose Gear Lube 90 Amoco Oil Company
21058 Arco HD Gear Oil 90 Atlantic Richfield Company
Conoco Universal Gear Lube 90 Continental Oil Company
Gear Oil GX Exxon Company
Mobilube HD z Mobil Oil Company
Spirax Heavy Duty 90 Shell Oil Company
Sunfleet GL-5 90 Sun Oil Company
Multigear Lube 90 Texaco, Incorporated
Citgo Premium Gear Oil (MP) 90 Cities Service Oil Co.
497c Above +9D°F MIL-L- Multipurpose Gear Lube 140 Amoco Oil Company
21058 Arco HD Gear Oil 140 Atlantic Richfield Company
Conoco Universal Gear Lube 140 Continental Oil Company
Gear Oil GX 140 Exxon Company
Mobilube HD 140 Mobil Corporation
Sunfleet GL-5 140 Sun Oil Company
Union MP Gear Lube 140 Union Oil Company of Calif.
Citgo Premium Gear Oil (MP) 140 Cities Service Oil Co.

P-lo4
Issue No. 5,2-75

9-3
SECTION IX LUBRICATION

OPEN GEAR AND WIRE ROPE LUBRICANT

AMBIENT
P&H RANGE (or MILITARY SAE
SPEC. NO. appli~) SPEC. NO. EQUlVALENT LUBRICANTS GRADE MANUFACTURERS
l
464 Open gears and W-L-751 Amovis Lubricant or American Oil Company
racks under latest Amoco Compounds
vaF/ing weather isaw .
Richcote Lubricants Atlantic Richfield Company
conditions.
Peripheral Onyx Lubricants
Atlantic Lubricants, 36
““9z; thru 40
fwt par min.
l
(366.8 m/min.) Coal_ Continental Oil Company
l
Suratt Exxon Company
.
MCbit0C Mobil Oil Corporation
l
Pinion Greasa MS Chevron Oil Company
Union Gearshield . Union Oil Company of Calif.
Crater 2X . Texaco. Incorporated
Liquid Gear Composition . Whitmore Mfg. Company

*Consult lubricant manufactumr for proper viscosity gmde, which will depend on application and climate.

P108
Iasue No. 5.2-76

INSULATlNG OIL - TRANSFORMER OIL

P&H MILKARY
SPEC. AMBIENT SPEC. EQUIVALENT SAE
SYMBOL NO. RANGE NO. LUBRICANTS GRADE MANUFACTURERS
IO 483 All Not Available Transformer Oil Does Not Continental Oil Co.
APPIY
Univolt N-34 Does Not Exxon Co.
ApPrV
Mobilect 33 Does Not Mobil Oil Corp.
APPfY
Shell Diala Does Not Shell Oil Co.
Oil AX APPfY
Sunelect AH Does Not Sun Oil Co.
APPIY
Transformer Oil 55 Does Not Texaco, Inc.
Inhibited APPIY
Union Transformer Does Not Union Oil Co. of Calif.
Oil #1 (Poco APPLY Union 76 Division
Transformer)
Chevron Inhibited Does Not Chevron Oil Co.
Insulating Oil APPLY
Pl56
Issue No. 4, 2-75

9-4
LUBRICATION SECTION IX

HEAVY DUTY MOTOR OIL

P&H AMBIENT MILITARY SAE

SPEC. NO. RANGE SPEC. NO. EQUIVALENT LUBRICANTS GRADE MANUFACTURERS

451A Below +l O°F MIL-L- Conoco Fleet Motor Oils 1 CW Continental Oil Company
45152 (or XD-3 Motor Oils 1CW Exxon Company
latest issue Delvac 1200 Series 1 CW Mobil Oil Corporation
in effect) Rotella T Oils 1 CW Shell Oil Company
Sunfleet HP Motor Oils 1CW Sun Oil Co. - DX Div.
Ursa Oils - Extra Duty 1 CW Texaco, Incorporated
Arco Fleet HD Motor Oils 1CW Atlantic Richfield Company
Amoco 200 Motor Oils 1 CW American Oil Company
Union Heavy Duty Motor Oils 1 CW Union Oil Company of Calif.
Citgo C-300 Motor Oils 1 OW Cities Service Oil Company
Delco 200 Motor Oils 1 CW Chevron Oil Company
4518 +l O” to 32OF MIL-L- NOTE: Equivalent lubricants and manufacturers are the same as for
46152 (or P&H Spec. 451 A Motor Oil as described above. The only differ-
latest issue ence, insofar as this description is concerned, is that P&H Spec-
in effect) ification 451 B is an SAE 20-20W grade oil.
451c +32O to 9ooF MIL-L- NOTE: Equivalent lubricants and manufacturers are the same as for
48152 (or P&H Spec. 451 A Motor Oil as described above. The only differ-
latest issue ence, insofar as this description is concerned, is that P&H Spec-
in effect) ification 451 C is an SAE 30 grade oil.
4SlD Above +k’F MIL-L- NOTE: Equivalent lubricants and manufacturers are the same as for
45152 (or P&H Spec. 451 A Motor Oil as described above. The only differ-
latest iSSU6 ence, insofar as this description is concerned, is that P&H Spec-
in effect) ification 461 D is an SAE 40 grade oil.
451E Above +90°F MIL-L- NOTE: Equivalent lubricants and manufacturers are the same as for
45152 (or P&H Spec. 451 A Motor Oil as described above. The only differ-
latest issue ence, insofar as this description is concerned, is that P&H Spec-
in effect) ification 461 E is an SAE 50 grade oil.
Pl 09

Issue No. 5,2-75

9-5
 PROPEL MOTOR COUPLINQ
2 POINTS EVERY 2000 HOURS

SYMBOLS
THE LUBRICATION RECOMMENDED
MPq - MULTIPURPOSE QREASE
IS BABED ON OPERATION OF THE
99 - QEAR OIL
MACHINE EIQHT HOURS EACH DAY,
$& - QEAR LUBRICANT
FIVE DAYS PER WEEK. LUBRICATION
m - MOTOR OIL
1 SCHEDULES SHOULD BE ADJUSTED ON
THIS BASIS.
1 CABLES

FINAL DRIVE
PROPEL TRANBMISSION

LUBRICATE MOTORB AND DIPPER HANDLES

GENERATORS ACCORDINQ
TO INSTRUCTIONB ON HOUBE ROLLERS
4 POINTS EVERY 120 HOURB

DIPPER BNUBBERS
0 POINTS EVERY 40 HOURS
MPO

HOUSE BLOWERB \
4 POINTS EVERY
600 HOURB
MPO
GENERATOR DRI HOUSE ROLLERS
CHAIN CASE INTERNAL AND EXTERNAL PENDULUM
13 OALLONB EVERY 24 HOURS 1 POINT EVERY 40 HOURS
CHECK 8 HOURS SWINO GE:R AND PINION MPO
MO
- EVERY 4 HOURS
Go
Figure 9-2. Excavator Lubrication
 AUTO-LUBE SYSTEM - UPPER GREASE - 30 MINUTE INTERVAL
UPPER GEAR OIL - 30 MlNUTE INTERVAL E
m
LOWER GREASE - 16 MINUTE INTERVAL P

THE LUBRICATION RECOMMENDED 5

IS BASED ON OPERATION OF THE
MACHINE EIGHT HOURS PER DAY. E
LUBRICATE MOTORS AND HOIST GEAR CASE FIVE DAYS PER WEEK. LUBRICATION
GENERATORS ACCORDING 80 GALLONS SCHEDULES SHOULD BE ADJUSTED ON
TO INSTRUCTIONS ON THIS BASIS.
MOTOR OR GENERATOR. SYMBOLS
MPG - MULTIPURPOSE GREASE
HOIST DRUM SEALS
SWING GEAR Ep - GEAR OIL .
CASE LH g - GEAR LUBRICANT
EVERY 200 HOURS
40 GALLONS m - MOTOR OIL
lo - INSULATING OIL

MAGNETORQUE WORM SHAFT SEAL

SHAFT BEARINGS 1 POINT EVERY 120 HOURS
2 POINTS

COUPLINGS
2000 HOURS

4 HOURS

EVERY 1000 HOURS

CHANGE EVERY 2000 HOURS

45 GALLONS

Figure 9-l. Excavator Lubrication

 SECTION X
MAINTENANCE WELDING

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-l
Repair and Welding Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-l
Repair Welding Recommendations ..........................................................................10-l
Carbody Fatigue Cracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
 SECTION X
MAINTENANCE WELDING

GENERAL inches, a 200°F indicating crayon should melt.

Thus sectron covers repatr welding procedures that have not 4. Rod - When preheat temperature is reached, begin
been covered tn the specific sectron of the manual desig- welding immediately. Use low hydrogen electrodes of a
nated for the. item bemg repaired. Included is Harnisch- good quality. Unless extremely high strength is a must, the
feger Corporation Field Repair Welding Recommendations best general recommendation is to weld both joining sur-
as to proper preheat and weld Information. faces of the prepared joint with AWS E-701 8 low hydrogen
REPAIR AND WELDING PROCEDURE electrodes. The rod must be new and clean.

The following is a summary of practices that should be em- Before using the electrodes, they should be baked at 700°F
ployed when making any structural repair. This procedure for a period of one hour to assure dryness and then held in
does not apply to any welding of the manganese racking to hot boxes or holding ovens at 200°F until used. Any elec-
the dipper handle bottom plate, dipper lip, propel drive trode exposed to air for over two hours should be rebaked
tumbler or crawler shoe. before use.
5. Buttering - Use the stringer bead technique with no
1. Cleaning - Remove all mill scale, dirt. grease and any
weaving. Weld only the sides. Put a single layer of weld
other contaminants from the area that is to be repaired.
metal on each side of the weld joint. This layer should be ap-
After cleaning, the entire area should bechecked with a dye
proximately 3/32 inch to l/8 inch thick. The bottom or root
penetrant or any other means of magnetic particle inspec- of the joint should be open far enough that the joint is not
tion to determine the extent of cracking. joined when the buttering passes are made. The buttering
2. Grinding - Grind the weld surface to get it smooth and as weld passes should extend up over the top edge of the joint
reasonably level as possrble so that there are no areas for and onto the surface of the plate for approximately l/4 inch
trapping slag during the welding operation. on each side of the joint.
3. Preheating - Depending upon the alloy, always preheat 6. Peening - The first two passes put into the root of the
and maintain a temperature of at least 200°F in the weld- weld should not be peened. These passes must be thor-
ment during welding, The entire structure usually doesn’t oughly cleaned. This should give approximately l/2 inch
require preheating, but fan the heat around with a torch to thickness of weld. All passes of the weld from there to the
cover the adjacent areas. Obtain a reasonable amount of final pass or layers must be peened with a well rounded
soaking heat for 3 inches to each side of the weld joint. At 3 chisel.

Figure 10-l. Weld Cross Sections

10-l
SECTION X MAINTENANCE WELDING

NOTE pass. After air-arcing, a dye penetrant should again be used

to assure that the crack has been completely removed.
Take care to avoid overweld. The weld deposit should
be above the original thickness of the plate and then Air-arcing should be to the full thickness of the plate. Toas-
ground flush. On joint welds the deposits should ba sure that a full thickness weld is employed. a back-up bar
well blended. Whenever possible. all welds should be should be placed under the crack to be welded. The arc
made in the flat position. Refer to Figure 10-l for groove should be ground out by the use of a hand grinder to
typical weld joint cross sections with the weld a depth of l/32 inch to remove all carbon deposits left by
sequence. the air-arcing operation.
7. Cooling - Protect the weld area from rapid cooling. Pro-
REPAIR WELDING RECOMMENDATIONS
vide an area free of wind and drafts to ensure slow even
cooling of the weld material. The following table provides weld information specifically
designed for all field rework. This table provides the P&H
8. Finishing - Grind and blend the weld corners to elimin-
Material Specification Numbers, the Specification Refer-
ate sharp notches and severe corners.
ence, the P&H Weld Symbols used on the drawings, the
9. Air-arcing - Preheat the material to 2OOOF. Limit the re- AWS Weld Rod Classification and the Recommended Mini-
moval of material to a maximum of 3/l 6 inch depth per arc mum Preheat required in three categories.

Table 10-l. Fiid Re~tir Welding Recommendations

PIH P&H AWS

Rocanmwded MInimum Preheet
MelI. sfseo.Aefuenw wddaesei-
Se= C.S. = cut SteeI Svmbd f i a t & n 3/4In&andUnder 7/8lnchte2lncb OverZlnch
1 C.S. - Med Carbon n E-7018 7oOF ( 21°C) 2OO“F ( 93°C) 3ooOF (149OC)
2 C.S. - Med Carbon N E-10018 3OO“F (149°C) 4oooF (204%1 5OO-‘F (260°C)
6 C.S. -CR-MO H E-701 8 6000F (316%) 7OO“F (371°C) 8oooF l427’C)
7 C.S. - AUST. MN. (He&old) AA E-307 70°F ( 21%) 7oOF ( 21°C) 70°F ( 2lOC)
a C.S. - Low Carbon H E-7016 7O“F ( 21°C) 7oOF ( 21°C) 70°F( 21°C)
11 C.S. - MN-MO N E-10016 300°F (149%) 4oooF (204%) 5ooOF (26OOC)
13 C.S. - NI-CR-MO Consult 8oooF (316°C) 700°F (371 “Cl eooOF (427Y)
16 C.S. - NI-CR-MO WeMing 500°F (26ooC) 55ooF (266YZ) 600°F (316OC)
19 C.S. - NI-CR-MO Engineer !%O’=F (28ooCI 5500F (2W°C) 600°F (31 B°C)
20 C.S. - CR-MO-8 sooOF (260%) 55O“F (288%) 600°F (316°C)
21 C.S. - Low Carbon H E-701 6 200°F ( 93OC) 250°F (121 OC) WOOF (149°C)
22 C.S. - NI-CA-MO Consult Welding 5oooF (260%) 6oooF (31 a°CI 7W°F (371OC)
23 C.S. - NI-CR-MO Engineer 5004F (260%) 600°F (316V 7W°F (371 “C)
50 Steer Carbon Plate Ht. n E-7016 70°F ( 2VCl 7oOF f 21Or.Z) 1 W°F ( 36V)
90 Steer H.S.L.A. H E-701 6 7oOF ( 21%) 70°F ( 21V 1 W°F ( 36“‘J
97 St4 - H.R. Alloy H E-701 a 55ooF (296’C) 6oooF (316Y) 7W°F (371 “C)
100 Stael - Carb. Plate H E-701 6 7oOF( 21%) 150°F ( 66OCI 250°F (121 ‘YI)
104 662OH Carbunted Steel E-6620 2ooOF ( 93“CI 3W°F (149VI 4oooF (204Y)
106A A441 H.S.LA. (fri Ten Type) H E-7016 70°F ( 21°C) 1 50°F ( 66OC) 2W°F ( 93°C)
108 Alloy Stwl Abrasron H E-7018 350°F (177Y) 4W°F (204V 450°F (232.Y)
109 Nitrallov 135 HR. H E-7016 sooOF (26O=C1 55ooF (288V) 6W°F (316Y)
112 4340 Alloy Stwl E-4340 8oooF (316V) 700°F (371 OC) 800°F (427OC)
113 lW0 H.R. Carbon Ban H E-7018 5W°F (26O“Cl 6oooF (316’CI 700°F (371 “Cl
119 414OH Alloy Sree( C.F P E-41 30 500°F (260°C) 600°F (316OC) 7W°F (371 OC)
120 4142.4750 Allov Steel P E-41 30 SW°F (260°Cl 600°F (316OC1 7W°F (371 OC)
121 4130H Alloy Steel P E-41 30 3W°F (149VI 350°F (177Y) 40C°F (2W’V
123 1010 Carbon Steel H E-7016 7oOF ( 21%) 70°F ( 21V 70°F I 21°C)
125L 12t.14 C.F. Steel H E-7018 70°F ( 21°CI 70°F ( 21 “C) 70°F ( 2 1 OC)
126 1117C.F St& H E-7018 7oOF ( 21OC) 70°F ( 21 “C) 1 W°F ( 36VI
127 1118 C.F. Steel H E-7016 70°F ( 21°C) 70°F ( 21%) 1 W°F ( 36“C)
128 1045 C.F. Steel H 5-7018 4W°F (204%) 5W°F (260°C) 6W°F (31 a°CI
129 1020 H.R. Steel H E-7016 7O“F ( 2 1 OC) 70°F ( 21OC) 1 W°F I 3&‘Cl
130 1035 H.R. Stee( H E-701 9 2WoF ( 93“C) 3W°F (149O C) 4W°F (204°C)
131 1040 H.R. Steel H E-701 8 3W°F (149OC) 400°F (204VI 5W°F (260°C)
132 1045 H.R. Steel H E-701 6 300°F (149V) 40C°F (204°C~ 5W°F (260°C)
133 M-27 Elec Sheet Steel H E-7016 70°F ( 21°CI
134 Steel Back Pipe H E-7018 70°F ( 21OC)
136 1015 Carbon Steel H.R. H E-7016 7O“F ( 21°CI
139 A-36 Carbon Stw( H.R. H E-701 8 70°F ( 21 “C)
140 4130 Allcv Tubq N E-10016 300°F (1 40°C)

1 o-2
 SECTlON X

Table 1 O-l. Field Repair Welding Recommendations (Cont.)

P&H P&H AWS Recommmded Minimum Preheat
MNl. !+ec. Reference Weld Ci8Ssi-
SP=. C.S. = cast Steel Symbol fication 3/4 Inch and Under 718 Inch to 2 Inch Over 2 Inch

142 1141 Cold Drawn Str Ael H E-701 8 300°F (149Y) 4OO“F (204V) 5OOOF (260°C)
142A&H 1144 Cold Drawn Str Ael H E-701 6 30C°F (149%) 400°F (204°C) 500°F (260°C)
143 1018 Seamless Tubing H E-701 8 70°F ( 21 OC)
146 4320H Bars and Billets H E-7018 300°F (149°C) 350°F (177OC) 400°F (204OC)
148 C.R. Stamping Steel H E-701 6 7O’=F ( 21“C)
150 1045 Cold Finished H E-701 6 3OtYF (149“C) 400°F (204°C) 5oO°F (26oOCI
151 H.S.L.A. Struct Shapes H E-701 6 7O’=F ( 21°C) 1 50°F ( 66V) 250°F (1 21°C)
153 4142-47-51H H.R. Alloy N E-lCOl6 5OOOF (260°C) 6OO’=F (316°C) 7OO“F (371 ‘XI
155 1015 Welded Tubing H E-701 6 70°F I 21°C)
161 ingot Iron H E-7018 70°F ( 21OC)
162 303 Stamless AA E-308 70°F ( 21°C)
163 Ingot Iron C. Fin. H E-7018 70°F ( 21OC)
164 1053 Steel H.R. Bars H E-701 6 400°F 1204°C) 5CO°F (260°C) 600°F (316Yl
165 1070 H.R. Steel H E-7018 500°F (260°C) 6OOOF (316OC) 7OO’=F (371 “C)
‘166 A-514 H.S.L.A. Tl Type H E-701 8 70°F ( 21°C) 1 SOoF ( 66OC) 200°F I 93YX
167 Hyd. Tubmg
172 1095 HT. High Carbon H E-701 8 6W°F (316V 7OO“F (371OC) 8OO’=F (427°C)
173 Carbon Steel Expanded H E-701 6 Room Temp.
160 A-36 H.R. Carbon H E-7018 7O“F ( 21°C) 70°F ( 21°C) 1 50°F ( 66’=C)
234 Galvanued Pipe H E-7018 70°F f 2 1 OCI
286 Low Carbon H E-701 8 70°F ( 21 VI
281 Cold Drawn Tubmg E E-901 8 70°F ( 21°C)
285 Black Pipe H E-7018 Room Temp.
334 1040 Seamless H R. Pipe H E-701 8 300°F 1149Y) 4OO’=F (204’X)
394 Sleel Car&n Plate H E.7018 70°F I 21°C) 1 SOoF I 66V 300°F (149°C)
395 A-36 Structural Tubmg H E-701 8 70°F ( 21”CI
396 4130 Steel H.R P E-41 30 300°F (149’X) 35O’=F (177OC) 4OO’=F (204V)
l 397 Steel H.R.H.T H E-7018 lOO’=F I 38OC) 2OO=‘F ( 93OC) 3OO“F (149V)
398 Steel H R.H.T H E-701 8 100°F i 38°C) 200°F ( 93°C) 3OO’=F (149V)
399 1048 Sreel H A. Carbon PI. H E-701 8 400°F (204OC) 5C@F (260°C) 600°F (316°C)

CARBOOY FATIGUE CRACKS

The carbody should be inpsected on a routine schedule for
fatigue cracks as shown on Figure 10-2. If any cracks are Prior to making any inspection on the carbody,
found on the carbody structure they should be weld re- the tail cable must be disconnected from the
paired as described in the Repair and Welding procedure. excavator.

1 o-3
SECTION X MAINTENANCE WELDING

POINT 1: WELD AROUNO POINT 4: WELDS

CENTER HUB ON GYSSETS

POINT 2: WELDS POINT 5: HOLES IN

ON GUSSETS / SOnOM PLATE
I /

0 0
TOP VIEW BOl-rOM VIEW

POINT 6: WELD AROUNO

POINT 3: HOLES TUB SECTION
IN REAR PLATE
I

SIOE VIEW
REAR VIEW

NOTE: IT IS SUGGESTED THAT THE

AREAS SHOWN SE PERIOOICAUY
CHECKED FOR CRACKS SO THAT
REPAIRS CAN BE MAOE IF NECESSARY

Figure 10-2. Carbody Inspection Points

1 o-4