GENERAL / Precautions for Dissembling and Assembling PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING Precautions for Disassembling Clean the Machine Thoroughly wash the machine before bringing it into the shop. Bringing a dirty machine into the shop may cause machine components to be contaminated during disassembling / assembling, resulting in damage to machine components, as well as decreased efficiency in service work. Inspect the Machine Be sure to thoroughly understand all disassembling / assembling procedures beforehand to help avoid incorrect disassembling of components as well as personal injury. Check and record the items listed below to prevent problems from occurring in the future.
The machine model, machine serial number, and hour meter reading. Reason for disassembly (symptoms, failed parts, and causes). Clogging of filters and oil, water or air leaks, if any. Capacities and condition of lubricants. Loose or damaged parts. Prepare and Clean Tools and Disassembly Area Prepare the necessary tools to be used and the area for disassembling work. Precautions for Disassembling and Assembling Precautions for Disassembling Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach an identification tag onto the connectors, hoses, and pipes for assembling. Before disassembling, clean the exterior of the components and place on a workbench.
Drain hydraulic oil and gear oil from the hydraulic components and reduction gear. Be sure to provide appropriate containers for draining fluids. Use matching marks for easier reassembling if necessary. Be sure to use the specified special tools when instructed. If a part or component cannot be removed after removing its securing nuts and bolts, do not attempt to remove it forcibly. Find the cause (s), then take the appropriate measures to remove it. Orderly arrange disassembled parts. Mark and tag them if necessary. Store common parts, such as bolts and nuts with reference to where they are to be used and in a manner that will prevent loss.
Inspect the contact or sliding surfaces of disassembled parts for abnormal wear, sticking, or other damage. Measure and record the degree of wear and clearances. Precautions for Assembling Be sure to clean all parts and inspect them for any damage. If any damage is found, repair or replace part. Dirt or debris on the contact or sliding surfaces may shorten the service life of the machine. Take care not to contaminate any contact or sliding surfaces. Apply appropriate lubricant oil onto parts in order to prevent them from seizing. Be sure to replace O-rings, backup rings, oil seals, and floating seals with new ones once they have been disassembled. Apply grease before installing.
Be sure that liquid-gasket-applied surfaces are clean and dry. If an anti-corrosive agent has been used on a new part, be sure to thoroughly clean the part to remove the agent. Fit the matching marks made when disassembling and assemble them. Be sure to use the designated tools to assemble bearings, bushings, and oil seals. Keep a record of the number of tools used for disassembly / assembly. After assembling is completed, count the number of tools so as to make sure that no forgotten tools remain in the assembled machine. W1-1-1