HyDRAULIC EXCAVATOR SPM#9308128
Contents
1. 9 gt 9 9 e 8 o 9 4 4 e gt a o a 4 4 o 9 9 9 9 o ORINE 0233 E73 SAP Des uio e 9 o 9 5 9 Quantity BM RM k Fa Ka ki KC Ka k ka ka Ka ka M Ka ka Kad m ME 27 WHEN ORDERING PARTS FOLLOW THE INSTRUCTIONS OUTLINED ON PAGE ii Figure 28 Hydraulic Reservoir and Filters 28 n n Q ERROREM WHEN ORDERING PARTS FOLLOW THE INSTRUCTIONS OUTLINED ON PAGE ii Index Part AER Number Number Quantity HYDRAULIC RESERVOIR AND FILTERS 1 020101 Plu E ute T ze TESI 2 2 020151 oou x EE EEN 1 3 240013 Breather a DRY a o2. a 4 o e eps 44 9 9 4 o 4 330068 Control Shaft Assembly s 330139 Control v oec te wore G 330059 Travel Lever or Outrigger Lever 330028 Per de gra Shs 120039 Handlo eX Tim 330042 Boom and Swing 330070 Bucket and Dipstick 330017 Control Base Assembly 120176 Machinery Platf rm 555 CC Quantity BPE DN DO R IND KA 25 WHEN ORDERING PARTS FOLLOW THE INSTRUCTIONS OUTLINED ON PAGE ii Figure 27 Typical Cylinder Assembly Index Part Number Number Description Quantity BUCKET CYLINDER ASSEMBLY 040100 040090 Packing Nut 242255546 oy 010032 Rod Packing Set 040041 Cylinder Tube 010027 Piston Ring gp cal M UR RR CL 220000 B Shing ES s 400011 BUE 040080 PISTON o 010013 EE ER Eh EE 040032 Rod 040091 Ham Head uou wx SCA 010014
3. 12 020023 TIE a RR 13 030194 oon Mer pure 14 030212 ovo wo Tesi se door ee ey i ambo t efe 15 400101 coxa x ee eor SOS EE 16 050006 Reservoir c w wv cd ame ae e 17 030180 eh 18 030177 2 A a ecg 19 030179 EIE SR as ee eee c 20 030140 IPube e E T IN RN S ud 21 020147 BIDON ER Sere Ss 22 020148 UTR UR UE URN Xov 23 000015 5 usen eset mn 5 ITE RR 24 020149 ds 25 030127 26 020132 Adapter Elbow 9599 9 4 EL eS Ow RV 27 020122 Connector Acc de at e 28 000033 Control Valve s 255 asa woes D a eae 29 020157 TOW crop the Foe Ao OS Qe og er 30 020009 Connector e e 9 9 o 5 020126
4. ut NU Se 1 4 230102 Bearing E 1 5 220044 Bearing 1 6 230104 Equalizer 2255254 AP E RTA Tae esae Ca Ro 1 7 220046 Bearing Washer 1 8 400182 Bearing N La a R Ske ENT RIS i a 1 9 230113 Cable Lower 2 10 230118 Propel Gear Box Bracket AS ee Be 1 230117 Propel Gear Box Bracket 1 11 240057 Propel Gear Box RH 999 49 oe 5 1 240056 Propel Gear Box LH 1 12 230101 Cable Mounting Bracket Turntable bce gs er e 1 13 230091 Brake Handle Assembly 1 14 230087 Brake Handle Mounting 1 33 ii GE TIONS OUTLINED ON PA WHEN ORDERING PARTS FOLLOW THE INSTRUC E s 22 cu Figure 31 Machinery Housing and Cab 34 Index WHEN ORDERING PARTS FOLLOW THE INSTRUCTIONS OUTLINED ON PAGE ii Part Number Number Beseripuen Quantity MACHINERY HOUSING AND CAB 1 120230 Top Secon Rear lt uc wey e R ee deca NS 1 2 120232 Top Section Front SL 1 3 120238 End Panel R H i SR
5. 4 230105 Propel Drive Chain 2 pitch 70 pitches 2 130062 Turntable s xl an NT ALCUNE qe oss 1 400280 Engine Mounting Bushing Vk e AUN NE am e De Ce eim e RR ae 4 400281 Cupped Washer Engine Mount 4 120264 Engine Mount Spacer 1 2 Thick 4 g RMY IM 8 65 AVOID ACCIDENTS OST ACCIDENTS WHETHER THEY OCCUR IN INDUSTRY ON THE HOME OR ON THE HIGHWAY ARE CAUSED BY THE FAILURE VIDUAL TO FOLLOW SIMPLE AND FUNDAMENTAL SAFETY PRECAUTIONS FOR 5 REASON MOST ACCIDENTS CAN BE D BY RECOGNIZING THE REAL CAUSE AND DOING SOME G ABOUT IT BEFORE THE ACCIDENT OCCURS REGARDLESS OF THE CARE USED IN THE DESIGN AND CONSTRUC TION OF ANY TYPE OF EQUIPMENT THERE ARE MANY CONDITIONS THAT CANNOT BE COMPLETELY SAFEGUARDED AGAINST WITHOUT INTERFER ING WITH REASONABLE ACCESSIBILITY AND EFFICIENT OPERATION A careful operator is the best insurance against an accident The complete observance of one simple rule would prevent many thousand seri ous injuries each year That rule is Never attempt to clean oil or adjust a machine while iti is in motion NATIONAL SAFETY COUNCIL
6. EE 010010 Wiper Seal 220026 Bushing 20 3 ka ka 60 0 i N ra NRE Fa ka DIPSTICK CYLINDER ASSEMBLY 040098 040090 Packing Nut lt lt 010032 Rod Packing Set 040044 Cylinder so so a s 010027 Piston Ring 4 55 220000 Bushings 24 400011 INGE 040080 Pisto 010013 O Ring 040030 Rod 040091 Ram Head ea ow oU 010014 ORIDE 3 RT AE R T Se 010010 Wiper Seal 53 DOR Mi ka bo e 2 2 4 n bt ka ka ka 26 Fear erg err en rea ner ey EE EEN mic at eem etn ates seem eet e rem a Th ene ima EE DEER n a a RTH B A VETERES R ae ec a RR oga TAXI AT SURREY MTM S Index Number C5 ta kA kad ka b RS CO sl CO H C5 N ES CO I1 gt WHEN ORDERING PARTS FOLLOW THE INSTRUCTION OUTLINED ON PAGE ii Part Number 040090 010032 040043 010027 220000 400011 040080 010013 040018 040091 010014 010010 040082 010033 040042 010026 7 220000
7. 1 4 120240 Side DOOR eS Per ats gd En 5 1 5 120237 End Posts Re He ss eee RRR R Ss eee Se 1 6 120236 Rear Post R H DEED eet hy Wr bo i Es 1 7 120235 Rear Post L H UT 1 8 120239 Rear and L H Door C d posee ute i 4 9 120233 Access Door 1 4 4 1 10 120231 Top Assembly T 1 11 120234 End Panel L H Era a sete dod No UN UE ES ET 1 12 120283 End Post LLH 4 4 oem Sew 2 1 13 120281 Cab Complete aeneo Ronde AT 1 35 36 WHEN ORDERING PARTS FOLLOW THE INSTRUCTIONS OUTLINED ON PAGE ii Figure 32 Swing Circuit Hydraulic System Number Index ond Q d i 2 gt c 17 18 19 20 WHEN ORDERING PARTS FOLLOW THE INSTRUCTIONS OUTLINED ON PAGE ii Part Number 030175 030191 030036 020150 000025 020025 020122 020023 020009 030141 020000 020003 000029 030035 020013 000016 030232 030164 020200 020154 SWING Adapter Control Valve Adapter Connector Connector Tube Plug s Adapter Elbow Swing Motor Tee Description CIRCUIT HYDRAULIC SYSTEM 9
8. 030039 Bucket Cylinder Hose C 10 1HD T 10 1HD E 030166 Bucket Cylinder Hose T 12 1 C 12 bus I 10 210002 Dipstick Rod Pin boars 11 040098 Dipstick Cylinder bez NO gi it EC 12 100006 Boom Assembly C 10 1 T 10 1 ee 100081 Boom Assembly C 10 1HD T 10 1HD MR Re SE N COE r E 100081 Assembly 12 1 C 12 1HD 030022 Boom Tube 030023 030024 Boom Tube To Bucket Cylinder Hose 10 1 T 10 1 NOE 030162 Boom Tube To Bucket Cylinder Hose 10 1HD T 10 1HD 030162 Boom Tube To Bucket Cylinder Hose C 10 1HD T 10 1HD 400254 Boom Double Tube Clamps and re tae A 400043 Boom Single Tube Clamps x i ATN M 220000 Boom and Dipstick Pivot Bushing 13 N 0210028 Dipstick Cylinder Base Pin 14 030036 Dipstick Cylinder Hose 10 1 T 10 1 QOL DINERS 030164 Dipstick Cylinder Hose C 10 1HD T 10 1HD 030164 Dipstick Cylinder Hose e 12 1HD T 12 1 15 210003 Boom Lift Pin e R a EE RI AU 210004 Lift Pin Coliar EE E sd 16 040101 Boom Cylinder Assembly 10 1 10 1 040102 Boom Cylinder Assembly
9. 1 22 1562 Housing Oe ee ri 1 23 1575 Center Post Seal s 5 NI m p cg 1 24 1561 Center eu Het de i 1 een Ee A ee Ee SEENEN AN EE EES e WHEN ORDERING PARTS FOLLOW THE INSTRUCTIONS OUTLINED ON PAGE ii PUMP MOUNTING STUD 4 A SORS AAAS X ZA T DRIVE SHAFT SY b MOUNTING BOLTS IN NN D A ZA BEARING X N XY DRIVE SHAFT Figure 29 Typical Pump Drive 30 WHEN ORDERING PARTS FOLLOW THE INSTRUCTIONS OUTLINED ON PAGE ii _ Index Part Number Number Quantity __________________ ________ SWING BRAKE INSTALLATION NOT ILLUSTRATED Description 230087 Brake Handle Mounting Bracket 1 230093 Brake Cable Mounting Bracket Gear Box 1 230090 Brake Cable A ONE SE MOI 1 230091 Brake Handle Assembly 1 HYDRA SWIVEL ASSEMBLY CRAWLER NOT ILLUSTRATED 020206 Tee Drain Eines 5 2 4 OR apud ee ee ORC EE 1 030245 Hydraulic Tube Upper 2 020198 Connector Top Body 5 4
10. 4 SECTION II OPERATION 5 2 1 Preparation for Use Ae pee ea ea ya ar ve 5 2 2 Initial Checks me 9 2 3 Starting the AIR DV EO a 5 2 4 Operating Controls npe 5 2 5 Digging Hints E AE We 8 2 6 Stopping th Engine Aor Ve deese pre i aar reos 8 2 1 Preparation for Storage EE Xu 8 SECTION IH MAINTENANCE AND REPAR 9 1 Preventive Maintenance oe a Gree 9 2 Lubricant Recommendations 3 Maintenance EECH 9 4 LIubrication 2 2 2 22 5 Lubrication Crawler y Mor dax red 12 5 6 Lubrication Pra PEE gt 7 gt Propel Drive Chain Adjustment ee OM c oca ee a deos 12 8 Crawler Track Adjustment E 120 9 Hydraulic Circuit Pressure 18 10 Swing and Propel Brake Adjustment 14 11 TOOL an qs d EIE FIDE 190 12 Gear Box Removal ee ee 13 Propel and Swing Gear Box Bener nr aides eee Ue Ge 14 Shaft Bearing Adjustment
11. 33 Dipstick and Upper Propel or Outrigger Hydraulic Circuit TN T NO GHNITLOO SNOLLOQHLSNI SLHVd NHHM WHEN ORDERING PARTS FOLLOW THE INSTRUCTIONS OUTLINED ON PAGE ii Index Part 4244 Number Number Dene Tipton Quantity DIPSTICK AND UPPER PROPEL OR OUTRIGGER HYDRAULIC CIRCUIT 1 020199 Elbow 2 030036 Hose 3 030239 Tube a a 9 o 9 a e 0 e 4 9 9 o 4 8 e 9 4 030237 Tube 5 030234 Tube 6 030125 Tube 7 8 9 9 8 8 e a 9 9 o o 9 9 o 030238 Tube 030193 Tube 9 o 9 e 5 o 5 9 030175 HOS Gg rne Aux Me Your Wo SE te x See ae 10 030124 Tubes 11 030232 Be
12. Po ue duele aos 1 4 400251 x m rA RONDA CU od E eg 1 5 050006 Reservoir s s a o e cge Ue UR 1 6 400222 COD 6 7 400223 Washer n tos dw Rosy Ee es 6 8 120218 Angle d ELM 1 400228 Pump Supply Lines Hose Clamp 4 9 030182 Nipple K Seo pce CUR Roa ral eu e e RETI ae rae 1 10 000019 Drain Valves 6 eb GRO o ELE 6 ced 1 400200 Drain Valve Handle 1 11 020105 PipB PIUE cta yu d 1 12 050007 Filter Assembly EUR Sb ca 3 13 015 PLUG 20x46 63649 9 3 14 1568 Backpressure Gage o 5 3 15 020163 Street Ell E Me a a ue os Sub X aes 3 16 1560 Head lt a le 5 Oi A E eed 1 17 1576 O Ring how cR rip ET 1 18 1564 Backup Washer OPER EE 2 19 1565 Gasket NEE Ba ON Ce 2 20 1566 Element 1 1567 Element Disposable 1 21 1563 BDPIUB C EN teme oh al TR
13. 9 a o 44 4 o o o 9 a 44 4 o o o e 9 a 0 9 44 44 9 oak o o o y o o o o on 9 k o e 9 4 9 9 o o o o gt b o o o gt 4 9 4 4 gt o 9 o gt o o o e 6s o o 9 4 9 s gt e o o o 9 o o e 4 ee 4 s e 9 9 6 e H U e e o 5 c s 4 9 4 9 DREES ee o Quantity SNK k RA NOR BO B2 BO BO CO KA KA DO KA KA 37
14. ww ABE PRINTED IN U S A BULLETIN CED 26 service manual model serial no This manual contains operating instructions service information and repair parts lists for all models unless otherwise noted Almost half a century of design and manufacturing experience has gone into your new Hein Werner machine It is the finest equipment that this know how and modern technology can produce We congratulate you on your selection We recommend that you become familiar with this manual and the maintenance pro cedures outlined herein Following these instr ctions andoperating the machine in a proper manner will assure you of long dependable and profitable service mmm CORPORATION CONSTRUCTION EQUIPMENT DIVISION WAUKESHA WISCONSIN 53187 A EE EE SPALT EET OTTEN EEEE ATS EEEE EDS ATE SETS TO S INSTRUCTIONS FOR ORDERING REPLACEMENT PARTS To assure prompt and accurate service include the following data with each parts order Model and Serial number of machine Part numbers Part descriptions Quantity of each part desired Correct shipping destination Method of transportation Engine Serial number Confirm all telephone and telegraph orders in writing Be sure these orders are marked Confirmation to avoid duplication of orders WHERE TO ORDER PARTS Hein Werner Dealers are conveniently located throughout the United States and Canada These Deale
15. E NES leen Gah eh cae Weiter cR EE 1 14 030002 Tube s woe pg x e N e s 1 15 020009 Connector 6224 du It n 1 16 030006 PDG Sc udi uod DEER 1 17 020159 sex a 4 1 18 020157 RIDOW Ae ta et Ar e del C 1 19 030009 ap CCP ee ey Ge dow Si tees a 1 20 030001 pos R RR aT a ee Oe 1 21 020122 CONNECION oov Von Ww os CR CI 4 22 000032 Control Valve 1 23 020132 Adapter BIDOW DR 1 24 030165 PLI 1 25 020149 Adapter im LE 1 26 020204 7 EIBOW a 16 ch COLOCAR RT A 1 21 020003 PIG scan Ue re s I isole acta cde 1 020101 Plg sigs Seams ais Weavers ty CEPR 1 28 000037 Pressure Compensating 1 43 sso MUR necu Umm e WHEN ORDERING PARTS FOLLOW THE INSTRUCTIONS OUTLINED ON PAGE ii Figure 37 Swing System 44 Index Number N WHEN ORDERING PARTS FOLLOW INSTRUCTIONS OUTLINED ON PAGE
16. Figure 9 Lubrication Diagram Crawler 3 4 LUBRICATION UPPERSTRUCTURE Lubricate the upperstructure at the points shown in Figures 7 and 8 Always remove excess grease after lubrication or dirt and dust will accumulate and work into bearings and bushings 3 5 LUBRICATION CRAWLER Lubricate the crawler assembly at the points specified in Figure 9 Be sure to lubricate crawler daily even though the machine has not been travel ing since there is movement when swinging and digging DO NOT lubricate propel drive chain 3 6 LUBRICATION CARRIER AND OUTRIGGERS Lubricate carrier as specified in the carrier manual shipped with your machine Lubricate the outriggers at the points indicated in Figure 10 3 7 PROPEL DRIVE CHAIN ADJUSTMENT Check propel drive chain for 3 4 to 1 deflection on the slack side of chain If necessary to adjust proceed as follows 1 Loosen the four propel box mounting bolts Figure 11 which attach gear box to side frame 12 SWING BEARING FITTINGS 4 RH TUMBLER SHAFT FITTINGS 2 LH TUMBLER SHAFT FITTINGS 2 2 Loosen the four adjusting bolt lock nuts and tighten both adjusting bolts equally to adjust chain until deflection is 3 4 to 1 3 Tighten lock nuts and gear box mounting bolts and recheck deflection 3 8 CRAWLER TRACK ADJUSTMENT The erawler tracks should be adjusted until some slack exists When there is no slack or excessive slack adjust
17. Part Number 400193 400055 400056 400212 400188 240039 400185 400182 400097 400184 400183 240042 200014 240041 400187 400191 400180 400190 400203 220025 400202 400189 250020 250019 250018 250024 Description Quantity SWING SYSTEM D RIBE VOL OR 1 Jam lt Led te sero eee as TRITT VE VR N A ew de CEU 4 L ckwasher SOLO OU dO E 4 Stud PER bora dt 4 Cap SOLOW wy wn No er D I CAT BAG cm 2 Swing Gear BOX s e inter e Ie er a io 1 sp MMC PME Rear o oet pe rio UA 2 Rte der TRE 6 Lockwasler e g RR m ec mes EE TC 4 St d ws Wow Ge os er 3 2 Coler Pin 5 25 8 4 Spacer Rod X I UD NR REN LM 1 Swing Pinion RT R 5 5 ES 4 1 e eaa 1 Cap BCTOW uo de uisa de ie toe a o 2 N ee Wy 1 LODEWIED RE EORUM Re we Rede SEET 18 Cap Screw o p e ege ge VU e MU UA ON CIR rt e 36 Washer ecs em RE 5 Ru 36 Swing Bearing 5 tal ig ake al a
18. and the operator Table 2 Preventive Maintenance and Inspection Schedule Upperstructure Models Service or Inspection to be Performed ily Lubricate as required See paragraph 3 4 Inspect for and correct any fuel oil coolant or hydraulic system leaks Check oil level in swing gear box If necessary add oil as specified in Table 1 Check oil in hydraulic reservoir If necessary add oil as specified in Table 1 Check back pressure indication of filter gages If gage registers in red zone clean or replace filter element Check engine for crankcase oil level coolant level engine belt tension and level of electrolyte in pattery s engine manual f r complete Specifications Check swing bearing bolt to 2400 inch pounds if necessary as ee en BY Table 2 Preventive Maintenance and Inspection Schedule Cont Upperstructure All Models Service or Inspection to be Performed Monthly Check hydraulic system pressures See paragraph 3 9 for detailed instructions Monthly Check swing brake adjustment See paragraph 3 10 Monthly Monthly Check all mechanical linkage connections Check all mounting and assembly bolts Tighten if necessary Refer to Table 4 Check all hydraulic system hoses lines and fittings for signs of possible trouble Monthly As required Inspect bucket teeth and replace as necessary Do
19. eg NE 777772 NL 22222222227 2 2222 LEVITZ 7X g Figure 42 Idler Section Index Part SE Number Number SE Quantity IDLER SECTION 1 800003 SEE Sw d 2 2 800075 Dio e ccr 2 3 800072 Thrust Washer 8 e x ala Te 4 4 800009 Bearing Block cene STR es 4 5 800007 Shaft d da e a Te eC 8 6 800064 Shaft Bushing 2252225 Ee Ye d 4 7 800099 Shaft D as reqd 800100 Shaft Shim Sr decus det ci vt eie as reqd 8 800065 Shaft uec do ce RORIS EUR 6 42242521 2 9 800014 End Plate 21 wok owe pu c PII 4 400319 Grease Fittings not illustrated 50 WHEN ORDERING PARTS FOLLOW THE INSTRUCTIONS OUTLINED ON PAGE ii MISCELLANEOUS PARTS NOT ILLUSTRATED Index Part Number Number DERE Quantity 050008 Fuer Tank EP 5 Sw eek es Soba 1 120253 Fuel Tank Mounting 1 120252 Fuel Tank Mounting 1 400293 Gear Box Adjusting Bolts ss s s s ce we ee eee rrr n 4 400301 Side Frame to Cross Tube Hex Head Bolts
20. 400012 040081 010011 040031 040083 010012 010009 040090 010032 040063 010027 220000 400011 040080 010013 040058 040091 010014 010010 Description OUTRIGGER CYLINDER ASSEMBLY 040099 Packing Nub 0x ud e ail den Rod Packing Set s e a uox oe scr Beats we SS ree AS Cylinder Tube RING Sev ALKON UE BOOM CYLINDER ASSEMBLY 4 INCH 040101 Packing Nut LT cher ed M Rod Packing Set Cylinder Tube Piston Ring Bushing log eo Ge m Wiper Seal gt s sa e dt eA S BOOM CYLINDER ASSEMBLY 5 1 4 INCH 040102 Packing Nut ence xy Ao de NO arto vd Bal ee ea a Hod Packinp Set vo TRU IR Cylinder rude n og Ug Ee ao Beer eae s Piston Ring Wiper Seal e a 9 Piston RING 5 4 aa 3 9 WOO De e m Bushing R T er TIE Rod Nut wed Aaa Beweise ET dir PISO e Sa uu 9 9 9 9 4 9 8 9 9 9 9 c o 9 55
21. NOTE Be sure gage is indicating correctly before proceeding K 1 BOOM CIRCUIT PRESSURE CHECK Install 0 3000 psi pressure gage in boom cylinder testing port as shown in Figure 13 Run engine at full throttle and pressurize boom cylinder rod end by pushing boom control lever forward Boom cylinder pressure gage should indicate 1850 to 1900 psi 2 BUCKET CIRCUIT PRESSURE CHECK Install 0 3000 psi pressure gage in bucket cylinder testing port as shown in Figure 14 Run engine at full throttle and pressurize bucket cylinder rod end by pushing bucket control lever forward Bucket cylinder pressure gage should indicate 2050 to 2100 psi 3 DIPSTICK CIRCUIT PRESSURE CHECK In stall 0 3000 psi pressure gage in dipstick cylinder testing port as shown in Figure 15 at base end of the cylinder Run engine at full throttle and pres surize dipstick cylinder rod by pulling dipstick control lever back Dipstick cylinder pressure gage should indicate 2050 2100 psi 4 PROPEL CIRCUIT PRESSURE CHECK Place machine so that forward and backward travel are 13 te A M o SE OUNTING BOLTS 4 us T ADJUSTING BOLTS LOCKNUTS 4 PERMA Figure 11 Propel Drive Chain Adjustment completely blocked Install 0 3000 psi pressure gage in each propel crossover valve as shown in Figure 16 With engine at full throttle push both propel control levers forward The gages should indicate 2050 210
22. use the bucket teeth to loosen the material so that the bucket can be filled on the next cycle When digging in clay or hard soil use the bucket ina flat position and shave or peel the soil by moving the boom and dipstick The bucket can be removed reattached in an inverted position to use the machine for shovel operation 2 6 STOPPING THE ENGINE 1 Reduce engine speed to idle Allow engine to m operate at idle speed for approximately five minutes to normalize engine temperature then place the ON OFF switch or fuel shut off lever in OFF position Do not stop the engine suddenly unless itis absolutely necessary 2 If the engine continues to run after fuel shut off lever is placed in OFF position pull emer oil gency stop knob located on back wall of cab This will shut off the air supply to the engine by tripping the air shut off valve If air shut off valve has been tripped it must be reset before the engine will operate To reset the air shut off valve first push the emergency stop knob all the way in and then manually reset the air shut off valve latch Refer to the engine manual for detailed instructions 2 1 PREPARATION FOR STORAGE If the machine is to be stored for an indefinite length of time perform the following procedures subject to the length of the anticipated storage period 1 Drain fuel system and refill with Valvoline Oil Company 503 C rust preve
23. 030244 Hydraulic Tube Lower 2 010036 jon es Re 6 040105 Hydra swivel Body v 1 040104 Hydra swivel Housing COACHES Ka e W Er 1 040107 End SD rasce ue prar URS m 1 HYDRA SWIVEL ASSEMBLY TRUCK NOT ILLUSTRATED 020198 Connector Top Ports eoo A X 4 040105 Hydra swivel 1 010036 ORINE 6 020101 PII seus as DELE Ae M 1 040104 Hydra swivel Housing eu e e 1 040107 End Plate COR AS Gee 1 030252 Tube Lower Porte 2 030251 Tube POFlS amp Jj 9 amp 9 2 020158 Elbow AMNEM 4 31 WHEN ORDERING PARTS FOLLOW THE INSTRUCTIONS OUTLINED ON PAGE ii es Ce ENN S E Ge 222222 2727 ESSE 2 Figure 30 Propel Brake Installation Sheet 1 WHEN ORDERING PARTS FOLLOW THE INSTRUCTIONS OUTLINED ON PAGE ii 9 Figure 30 Propel Brake Installation Sheet 2 Index Part Number Number Quantity PROPEL BRAKE INSTALLATION 1 230107 Upper Brake 1 2 400290 Snap 2 3 230103 Block Brake Cable jede og S
24. OUTRIGGER CYLINDER LOOKING TOWARD FRONT OF CARRIER Figure 4 Lower Circuitry Carrier by the use of a series of ported grooves which are sealed with rings The two propel motors are mounted directly to the propel gear boxes Each track of the crawler is driven by a separate motor and gear box This independent drive results in greatly increased ma neuverability The crawler track assemblies and carbody are designed for long trouble free service The carbody and side frames are rugged steel fabrications which are reinforced at all points of stress concentration The components of the track assemblies such as the track shoes tumblers idlers rollers and sprockets are made from high grade heat treated alloy steel with excellent durability characteristics These parts are designed to provide good dirt shedding qualities The 20 track rollers are equipped with pre greased ball bearings with armor shields to protect the seal from dirt branches and other foreign matter The use of these bearings also results in reduced day to day maintenances of the track assembly 1 2 CARRIER The standard Hein Werner Carrier is of rugged job proven design The carrier can be equipped with a remote control unit which enables the operator to steer shift brake and accelerate the carrier from within the excavator cab 1 3 ACCESSORIES Accessories include a log grapple a clam shell bucket frost point and a special 60 di
25. WHEN ORDERING PARTS FOLLOW THE INSTRUCTIONS OUTLINED ON PAGE tick ips Bucket and D igure 25 Boom F Eo py 4 1 t WHEN ORDERING PARTS FOLLOW THE INSTRUCTIONS OUTLINED ON PAGE ii BOOM BUCKET AND DIPSTICK Index Part sic 2 Number Number Quantity 1 400033 Bucket Tooth P int 3 06263 Oe de UE as reqd 400034 Bucket Tooth Shank A ere V oin 400035 Bucket Tooth x ROME as 2 210024 Bucket and Linkage Pin Tr Em 3 150003 Bucket Link Assembly TT Brig ae 4 4 140027 Bell Crank Link 220028 Bell Crank Bushing Not Grooved ix od wears M PE 22002 Bell Crank Bushing Grooved 5 040100 Bucket Cylinder Assembly acte ue Thor dw RC eae 6 400018 Lock Pin osa RE AU wee Vl AC 1 400026 Cotter Pin xov haec 6S Ge ok GS 1 7 110045 Dipstick 10 1 T 10 1 Sa qe e TEE 110045 Dipstick C 10 1HD T 10 IHD CRX oec ogy te d Ais V 110052 Dipstick T 12 1 C 12 1HD xd eub o eue M MC ee 220028 Dipstick Pivot Bushing Saws FUSS Sora 8 210002 Bucket Cylinder Base Pin ea 6 9 030039 Bucket Cylinder Hose 10 1 10 1
26. 18 15 Gear Box 18 16 Hydraulic Cylinder 18 17 Crawler Drive Sprocket Removal 20 18 Tumbler or Idler Shaft Bushing Thrust Washer and Seal 20 Replacement SECTION IV REPAIR PARTS 2 2 2 21 dii 1 2 3 4 5 6 7 8 9 Hydraulic Reservoir Return Lines Filters Hydraulic Swing Motor House Brake Drum Swing Gear Box Hydra Swivel Ball Bearing Ring Gear Levers 10 11 12 13 14 15 Foot Pedals Machinery Platform Pressure Compensating Inline Pressure Compen sating Unit Swing System Control Valve Boom Bucket and Propel or Outrigger Control Valve Figure 1 Machinery Platform 16 17 18 19 20 21 Dipstick and Out rigger Control Valve Swing System Pump System Dipstick and Propel or Out rigger Pump Section Boom Bucket and Propel or Outrigger Pump Section Clutch Engine SECTION I DESCRIPTION 1 1 HYDRAULIC CIRCUITS AND CONTROLS The information in this section is designed to furnish the owner and operator of Hein Werner excavators with the basic information neededto under Stand the operation of the machine An understanding of the various systems is essentialto proper opera tion and service and we suggest this description be read thoroughly Power for the unit is supplied by either a gaso line or
27. PACKING SET Figure 20 Hydraulic Cylinder Disassembly 18 n Figure 21 Removing the Crawler Drive Sprocket 2 Pivot the cylinder to allow clearance for re moving the cylinder rod and piston assembly 3 Remove hoses from base end of cylinder to release any suction Remove rod assembly from cylinder tubes 4 Disassemble the cylinder rod and piston assem bly as indicated in Figure 20 Replace packings piston rings O rings wiper seal and rod nut Lubricate all parts with hydraulic oil Reassemble the cylinder rod and piston assembly 5 Replace the cylinder rod and piston assembly in the cylinder and screw the ram head into the end of the cylinder until it is tight Replace hoses 6 Slowly pivot the cylinder into position Use control lever to apply slight hydraulic pressure to align the rod end with the cylinder rod end pivot point 7 Insert the pivot pin Lock the pivot pin in place 8 Use the control levers to slowly apply hydraulic pressure alternately to both ends of the repaired cylinder until the cylinder is completely filled with oil i 9 After 4 to 8 hours of operation with a cylinder which has been repacked tighten the cylinder packing nut to prevent excessive escape of hydraulic oil around the cylinder rods Do not overtighten as a small seepage of oil at this point is necessary for cylinder rod lubrication The packing nut should be tightened snug and then backed off 1 4 to 1 2 turn for
28. diesel engine 21 Figure 1 the make of which is optional For service parts and information refer to the engine manual supplied with your machine The engine is coupled to the hydraulic pump by either a direct drive shaft or a clutch 20 The clutch is extremely useful as a starting aid in cold weather If your machine is equipped with a clutch refer to the separate section included with this manual The pump is a gear type with three sections in tandem mounted directly to the engine clutch housing Each pump section is fitted with a separate Supply line from the reservoir to assure proper oil flow The pump section 19 closest to the engine delivers power to the boom bucket and propel control valve 15 on the crawler mounted machine and to the boom bucket and outrigger system on the carrier mounted machine The center pump section 18 supplies power to the dipstick and propel circuit valve 16 on the crawler mounted machine and to the dipstick and outrigger system on the carrier mounted machine The pump section 17 furthest from the engine delivers power to operate the swing circuit on all models The three pump sections are completely independent of each other enabling simultaneous use of all three circuits The oil flows from the pump to the three control valves When the control valves are in aneutral posi tion the oil flows without restriction through the control valve and return lines 2 to the filters 3 which
29. not use shanks without teeth for digging AS required Remove filter screen from hydraulic reservoir Clean screen thoroughly with cleaning solvent Be sure filter screen is in place when adding oil ASK BOOM LIFT PIN DIPSTICK CYLINDER BASE PIN BOOM CYLINDER DIR CYLINDERS ROD END BUCKET CYLINDER BASE PIN DIPSTICK PIVOT PIN BOOM CYLINDERS BASE END BELL CRANK PIVOT PIN BUCKET PIVOT PIN BUCKET LINK AND BUCKET CYLINDER ROD END BUCKET LINK Zei Figure 7 Lubrication Diagram Sheet 1 Table 3 Preventive Maintenance and Inspection Schedule Crawler Frequency Service or Inspection to be Performed Daily Check level of lubricant in propel box See paragraph 3 15 Daily Lubricate as required See paragraph 3 5 Weekly Check propel drive chain adjustment See paragraph 3 7 Weekly Check crawler track adjustment See paragraph 3 8 Monthly Check propel brake adjustment See paragraph 3 10 Monthly Check all mounting and assembly bolts Tighten if necessary Refer to Table 4 Monthly Check all mechanical linkage connections Monthly Check all hydraulie system hoses lines and fittings for signs of possible trouble PUMP DRIVE 7 BEARING QUTPUT SHAFT LEVER FITTINGS CONTROL LEVER FITTINGS 2 Figure 8 Lubrication Diagram Upperstructure Sheet 2 11 DENS is PR PROPEL GEAR RH IDLER SHAFT FITTINGS 2 LH IDLER SHAFT FITTINGS 2
30. the proper setting 3 17 CRAWLER DRIVE SPROCKET REMOVAL Use the Pushmaster Unit supplied with the craw ler tool kit to remove the crawler drive sprocket Attach a chain to the sprocket as shown in Figure 21 Replace the standard Pushmaster head with the 90 concave head adapter Remove the shaft end plate Install the Pushmaster as shown and pull the sprocket out until the drive chain will clear the track shoes The drive chain can now be removed and the sprocket pulled completely off T SHAFT END PLATE SIDE FRAME END PLATE TRACK SHOE PIN BEARING BLOCK DRIVE LOCK PIN Figure 22 Removing Idler or Tumbler Bearing Blocks 3 18 TUMBLER OR IDLER SHAFT BUSHING THRUST WASHER AND SEAL REPLACEMENT To replace the shaft bushings thrust washers and seals loosen the track by removing all adjusting shims See paragraph 3 8 To remove either the idler or tumbler bearing blocks remove track shoe pin Figure 22 by driving out first the drive lock pin shown and then the track shoe pin from the opposite side If the tumbler is to be removed the drive chain must also be disconnected Remove the side frame end plate and then the tumbler or idler and shaft assembly Next remove the shaft the shaft end plate and the bearing blocks When replacing bushings and seals press the bushings in and install the seal in a reverse position Figure 23 to allow the bushing to be flushed of dirt when being greased Reassemble
31. the tracks at the idler end of the side frame Figure 12 as follows 1 Remove shim cover plate 2 Insert Hein Werner Pushmaster unit supplied with tool kit as shown 3 Turn the relief knob clockwise and jack out the idler bearing block until correct slack exists 4 Install the 1 4 and 1 8 thick shims furnished in the tool kit as required to take up play 9 Release the pressure on the Pushmaster Unit by turning relief valve knob counterclockwise 6 Replace the shim cover plate This adjustment must be performed on both the inside and the outside of the side frame The two idler bearing blocks must be adjusted equally to keep the idler from becoming cocked EN Jem 1 Outrigger Cylinder Rod Pin 2 Outrigger Foot Pivot Pin 3 Outrigger Arm Pivot Pin 4 Outrigger Cylinder Base Pin 5 Outrigger Arm Pivot Pin 6 Outrigger Cylinder Rod Pin 7 Outrigger Foot Pivot Pin Figure 10 Lubrication Diagram Outriggers 3 9 HYDRAULIC CIRCUIT PRESSURE CHECK The correct control valve and pressure compen sating unit adjustments have been made before shipping from the factory Only factory and dealer represen tatives are authorized to adjust valve pressure settings TAMPERING WITH PRESSURE SETTINGS WILL RESULT IN VOIDING THEWARRANTY OF THE MACHINE However at the intervals specified in the maintenance schedule or in the event of malfunction check the pressure settings as follows
32. will help to insure proper operation and extended 3 3 MAINTENANCE SCHEDULES life of the machine Follow the maintenance schedules and procedures This section outlines suggested maintenance sched as outlined in Tables 2 and 3 ules lubrication guides andminor adjustments which should be made to maintain optimum performance from your machine These schedules and the pre Table 1 Recommended Lubricants ventive maintenance record sheets included with this manual will help you organize a good system Lubricant of daily care which best suits your particular opera tion Gear Boxes EP 80 90 oil The maintenance requirements listed are for aver Open Gears Crater compound age working conditions If your machine is subject Swing bearing Mobilux GR 2 or to adverse conditions such as extreme dust mois 4 fittings equivalent ture the frequency and extent ofthe maintenance 8 4 Gear box bearing Mobil No 5 grease precedures should be increased accordingly grease fittings or equivalent A one year supply of Preventive Maintenance All other grease Moly type grease Record forms is included at the end of this manual fittings such as Mobiloil A sample copy with several typical entries made special or equivalent has also been included to show how these records Hydraulic reservoir Premium grade SAE may be maintained These records when kept com 20 oil plete and up to date will benefit both the owner
33. 0 psi If the gages do indicate no pressure reading repeat same procedure except pull both levers back The two gages should read 2050 to 2100 psi Figure 13 Pressure Gage Installed in Boom Cylinder Testing Port 14 IDLER BEARING BLOCKS SHIM COVER Figure 12 Crawler Track Adjustment 5 SWING CIRCUIT PRESSURE CHECK Place unit so that swing is completely blocked in both direc tions Install 0 3000 psi pressure gages in pressure compensating unit counterclockwise and clockwise swing testing ports as shown in Figure 17 Run engine at full throttle and pressurize swing circuit for clockwise swing by pushing swing control lever forward Pressure gage in clockwise swing testing port should indicate 1650 to 1700 psi Run engine at full throttle and pressurize swing circuit for counterclockwise swing by pulling swing controllever back Pressure gage in counterclockwise swingtesting port should indicate 1650 to 1700 psi 3 10 SWING AND PROPEL BRAKE ADJUSTMENT The swing brake is commonto all models Crawler mounted machines in addition are equipped with a Figure 14 Pressure Gage Installed in Bucket Cylinder Testing Port T S Figure 15 Pressure Gage Installed in Dipstick Cylinder Testing Port brake on each propel gear box The adjusting proce dures are identical for both propel and swing brake assemblies The brakes be adjusted at three points 1 In the handle itself 2 At eith
34. 1 040109 Hydra Swivel Assembly 1 12 000035 Pressure Compensating 2 41 WHEN ORDERING PARTS FOLLOW THE INSTRUCTIONS OUTLINED ON PAGE ii Figure 36 Boom Bucket and Upper Propel Outrigger Hydraulic Circuit 42 WHEN ORDERING PARTS FOLLOW THE INSTRUCTIONS OUTLINED ON PAGE ii Index Part Number Number Description Quantity BOOM BUCKET AND UPPER PROPEL OR OUTRIGGER HYDRAULIC CIRCUIT 030038 Hose d 030038 Hoses ts n EO uem CUERO Ew RECS 4 2 030036 HOBG Orbe Sates a 2 3 030010 Tubes Oe me wore Oeo D ue we 2 4 030008 FEUD Cid ice ne Ww ERU TUO 1 5 030007 Tubes E TP cei RI a 1 6 030240 T b6 owe dice eO Uude Mose rw ENT 1 7 030235 reg Deu ars BE ecu ey GAS 1 8 030236 Kure ce ca 1 9 020024 Connector Tee EOE 1 10 030194 BIbOW 275 Siw s Ra els won eS pu E 1 11 030212 eter fg URL nale GR RS 1 12 400101 Clamp X x3 USD RI qe IUS ACA 2 13 030192 i woe
35. Adapter Ee 000034 Pressure Compensating Unit 010019 O Ring 020003 Plug 020211 Plugs ced he BASE 31 020121 Connector Tee 32 020152 Elbow 020110 Nipple 020205 TEG us RUE cu UR HET AA 020112 INI Sea dica AT ta e d atr 050007 Filter Complete 020153 Tee RTE TRUE WO TR WES 0 CIE ae eo ec 020154 Elbow e gt o o 9 9 9 5 9 e e 89 o 9 gt 9 e 8 e 9 o o 9 9 8 9 gt 4 x La ko ka Ka Ka Ka RA a ROR Ka Ka ka KA KA KA KA IND KA KA 33 020101 Plug lt Ser EE CUIUS N 34 020156 Nipple s EE CR Ye OO mot 000019 v uade meo carm 400200 Handle lt s
36. C 10 1HD T 10 1HD 040102 Boom Cylinder Assembly C 12 1HD T 12 1 ONE gt HS BO BO ka BO CO PO DO PO NH HH KA BO BO Oe ha KA qi BO DO KA 17 030038 Boom Cylinder T TE 18 030036 Boom Foot Hose TEM ERE PEE REX 19 21002 Boom Foot Pin lt lt 20 210002 Boom Cylinder oup PEE 400015 Grease Fitting ke AUR WHEN ORDERING PARTS FOLLOW THE INSTRUCTIONS OUTLINED ON PAGE ii Figure 26 Machinery Platform and Controls 24 Number WHEN ORDERING PARTS FOLLOW THE INSTRUCTIONS OUTLINED ON PAGE ii Part I Number Description MACHINERY PLATFORM AND CONTROLS 330024 aeterne V v 330023 EXC IE e a UR ON qu eden os ote Te 330140 Control Rod lt cet ee exe e rio Race EC 330077 Control Rod amp ee oss dox c 330141 Control Rod 330080 Control Rod v xc WO ONE EROR ae SOS 000025 Control Valve Single Spool 000033 Control Valve 1 000032 Control Valve Three Spool 330142 Control Rod a o o
37. CONTROL PEDAL Figure 6 Operating Controls SEAT ADJUSTMENT CONTROLS The seat height can be adjusted by pulling out the height adjustment pin setting the seat to the desired height and then reinserting the pin The seat can be moved forward and backward by pulling out the pin under the seat sliding the seat cushion to the desired position and then reinserting the pin 2 5 DIGGING HINTS 1 Keep the machine as close to the work as pos Sible This results in a greater mechanical advantage and also cuts down the cycle time Start a cut with the dipstick at right angles to the boom point this will decrease cycle time because the boom does not have to be repositioned as often 2 Tuck in the dipstick as the boom is raised out of a cut this will permit clearing the top of the cut sooner and reduce the cycle time Square cuts for manholes etc can be made easier by moving the machine in line with each bank rather than using the swing to get from bank to bank 3 Make straight down end cuts by extending the dipstick and bucket and movingthe machine forward or back to reach the bottom of the cut To decrease cycle time especially a deep cut shave offa layer at a time rather than going to the bottom of the cut on every cycle Rocks and stumps can be uncovered undermined and pried out Meine the bucket 4 For faster dumping open both the bucket and the dipstick When digging in gravel stones or shale
38. To hold bucket in position move the pedal or lever to center position neutral 4 To place bucket in open position push down with toe of left foot on the pedal or push the lever forward DIPSTICK PEDAL OR LEVER 1 For normal operation use the foot pedal to control the dipstick However for very close work when speed is not a factor use the lever to control critical movement of dipstick 2 To tuck dipstick in push down with heel of right foot on the pedal or pullthe lever back 3 To hold dipstick in place move the pedal or lever to center position neutral 6 4 To open dipstick push down with toe of the right foot on the pedal or push the control lever forward SWING CONTROL LEVER 1 To swing platform in a clockwise direction push lever forward 2 To swing platform counterclockwise pulllever back The swingofthe platform is controlled by revers ing the control lever Slight overcontrol allows the machine to be operated with a high degree of smooth ness with no abrupt or dead stops For example if the machine is rotating clockwise lever pushed forward feather the lever back toward the operator until the rotation stops If one particular position is desired lock the platform in place with the swing brake control lever SWING BRAKE OR PROPEL BRAKE LEVER 1 To engage brake pull up on the lever The lever will snap into an overcenter lock position 2 To release brake push the lever dow
39. able and bracket and the hydraulic lines To refill propel gear box remove the top filler plug and fill the gear box with EP 80 90 oil until the oil begins to run out the upper level checking plug located at the side of the gear box Replace the plugs and check the gear box for oil leaks ______ Table 4 Torque Values Gear Box intermediate shaft cover bolts 106 113 ft Ibs Gear Box output shaft cover bolts 69 73 ft lbs 106 113 ft 108 Gear Box cover to case bolts Swing bearing to bearing adapter 200 ft 108 and platform bolts Swing bearing adapter to carbody bolts 300 ft Ibs Carbody to cross tube bolts 556 ft Ibs 3 16 HYDRAULIC CYLINDER REPAIR Cylinder repair kits contain ram head and cylinder rod O rings rod packings and wiper piston rings and rod nut Use all parts of the repair kit when a cylinder is repaired even though some of the parts being replaced may not appear to be worn It is not necessary to remove a cylinder assembly from the unit in order to repair it with a cylinder repair kit but be extremely careful to prevent the entry of any dirt or foreign particles into the cylinder Proceed as follows to service a cylinder NOTE Use only factory approved parts to insure proper fit and operation 1 Use the spanner wrench supplied in the tool kit to remove the cylinder ram head CYLINDER TUBE ASSEMBLY RAM HEAD HEAD O RING CYLINDER ROD ROD
40. anism holds the valve spool in either position to allow the operator to perform other operations whiletravel ing The control levers must be manually returned to the neutral position to stop the crawler travel When the propel circuit is in operation the oil flows from the control valve through the hydra swivel 7 to the propel motors The hydra swivel is used on both the carrier and the crawler mounted machines Its purpose is to allow oil to flow from the upper structure to the propel motor or the outrigger cylinders which are located on the non rotating portion on the machine This is accomplished 1 RESERVOIR ED G9 FILTERS Li BOOM CYLINDER L H J BUCKET CYLINDER 5 7 d BOOM CYLINDER Tm BOOM BUCKET AND PROPEL OR 1 24 OUTRIGGER VALVE CLUTCH PUM DIPSTICK SWING VALVE INLINE AND PROPEL OR RELIEF OUTRIGGER VALVE Figure 2 Upper Circuitry Cum ym ek VU PRESSURE COMPENSATING UNIT PROPEL X N MOTO 3 Bn FRONT OF MACHINE REVERSE TRAVEL PRESSURE FORWARD TRAVEL S HOSES PRESSURE HOSES G m DC DRAIN HOSE SA 2209 ER OH Dn PRESSURE COMPENSATING 7 O PROPEL Figure 3 Lower Circuitry Crawler OUTRIGGER CYLINDER HYDRA SWIVEL ASSEMBLY
41. ard 3 4 Drive C3 Track Adjusting Shims 1 4 16 C6 Track Shoe Groove Pins 6 Figure 19 ToolKit Crawler Mounted Machine 17 6 Carefully clean and inspect all parts for signs of wear or future failure 3 14 SHAFT BEARING ADJUSTMENT The intermediate shaft bearings are adjusted by means of shims under the shaft cover Use shims as required to obtain 002 inch end play to 002 inch preload on the bearing The output shaft bearings are adjusted by positioning the nut on the upper end of the shaft Tighten and secure nut as required to ob tain 002 inch end play to 002 inch b aring preload Pack the grease cavity of the Shaft covers with Mobil 15 grease or equivalent 3 15 GEAR BOX REPLACEMENT No adjustment is necessary when replacing the swing gear box When the gear box is in position on the mounting studs the output pinion is in correct mesh with the swing bearing Install the propel box and adjust the drive chain see paragraph 3 7 while the side frame is removed Tip the side frame back to the norma position by inserting the bucket teeth below the track shoes and tucking the bucket Replace the side frame on the carbody cross tube by inserting a large pipe or timber between the bucket and the side frame and using the dipstick carefully push the side frames back in position Replace the four locking bolts which hold the side frame to the carbody cross tubes Connect the safety chain brake c
42. are mounted on the hydraulic reservoir 1 Each circuit is equipped with a filter which con tains a cleanable filtering element Disposable ele ments also are available as a replacement part After being filtered the oil flows directly into the reservoir The control valves are operated by levers 9 and foot pedals 10 in the operator s cab The cab is also equipped with a complete set of engine gages and controls The engine gage set consists of an ammeter individual gages for fuel level oil pressure and water temperature and a combin ation tachometer and engine revolution hour meter When a typical cylinder circuit is put into operation by moving the control lever or foot pedal in either direction from the neutral position the valve spool moves within the control valve This spool reroutes the oil flow from the return line port to the port which supplies oil to the cylinder being used This spool is spring loaded to return to neutral position when the control lever or pedal is released The control valves have excellent feathering charac teristics to assure smooth and precise operation of all components The control valves contain a relief valve which is adjusted at the factory toa specified limit If the pressure demanded by the circuit being used exceeds this pre set limit the relief valve will bypass the oil to the reservoir until the pressure demanded by the circuit drops to the specified pressure setting The digging m
43. de frame assembly checks a Tightness of all mounting bolts see Table 4 b Track adjustment see paragraph 3 8 c Drive chain adjustment see paragraph 3 7 2 When the crawler mounted machines are ship ped from the factory they are assembled to the legal 96 inch shipping width They may be operated at this width or extended to 104 inch width for greater stability To extend the tracks proceed as follows a Swing the boom see Figure 5 over the side of the tracks and with the bucket tucked apply down pressure with the boom to lift the track off the ground b Block up the machine and release pressure on the boom c Remove the four locking bolts Attach a chain to the side frame and the bucket Use the bucket to pull the tracks out until the side frame is flush with the cross tube d Replace and tighten the locking bolts in the second set of holes Extend the opposite track in a similar manner Each track will move out four inches to give 104 inch overall width 2 2 INITIAL CHECKS SWING BEARING After six to eight hours of running time check the swing bearing mounting bolts for tightness Torque the bolts to 2400 inch pounds CYLINDERS After four to eight hours of initial operation tighten the hydraulic cylinder packing nuts to pre vent excessive escape of hydraulic oil around the cylinder rods Tighten the nuts until they are snug and then back them off 1 4 to 1 2 turn Do not overtighten a small seepage
44. em bers are also protected from overload by an inline pressure compensating unit 13 This unit relieves the pressure in the boom and dipstick circuits when external forces cause the pressure to exceed the maximum allowable The swing circuit is controlled by the single spool control valve 14 This valve and its built in relief valve are identical in design and purpose to the typical cylinder control valve already described The swing circuit is also further protected by a pressure compensating unit 12 which minimizes shock loads The double rotation positive displacement hydraulic motor 4 provides unlimited swing in either direction The motor is directly coupled to the swing gear box 6 which is mounted to the machinery platform 11 with specially ground alloy steel studs This mounting assures perfect mesh between the output pinion and the ball bearing ring gear at alltimes All gears and shafts in the swing system are pre cision machined and hardened to give maximum life The shafts are carried by tapered roller bearings The cover and case are precision bored and milled to assure precise gear mesh The use of a double row ball bearing ring gear 8 results in reduced maintenance smoother rotation and longer life The bearing requires no day to day maintenance other than lubrication The crawler propel control valve is essentially the same as the other control valves except for an added detent feature This detent mech
45. er end of the conduit 3 At the gear box connection The swing and propel brake is a static brake only Therefore the amount of wear should be very small However if the brakes do need adjusting proceed as follows ie 1 Make the initialadjustment in the handle itself by turning the knurled adjusting knob at the tip of the handle until the handle snaps into overcenter lock position when pulled up 2 If for some reason the adjustment can not sufficiently be made in the handle make the remaining adjustment at either of the other two points 3 11 TOOL KITS The tool kit for the carrier mounted machines Figure 18 includes the tools necessary for all maintenance and adjustments of the upperstructure The tool kit supplied with crawler mounted machines Figure 19 includes the tools for the upper structure plus the extra tools necessary for adjust ments and maintenance of the crawler This kit also includes shims and groove pins for the crawler tracks 3 12 GEAR BOX REMOVAL To remove the propel gear box swing the boom over the side frame which is to be removed Dis connect the safety chain from the carbody Raise Figure 16 Pressure Gage Installed in Propel Circuit Cross over Relief Valve and block the machine as described in paragraph 2 1 and Figure 5 Disconnect the hydraulic lines from the propel motor remove the brake cable and mounting bracket from the gear box Disconnect the four lockin
46. g bolts which attach the side frame to the carbody cross tubes Attach chain as shown in Figure 5 and pull the entire side frame off The side frame assembly can now be tipped flat to facilitate the removal of the drive chain and gear box The swing gear box is easily removed by un screwing the four retaining nuts and lifting off the gear box Figure 17 Pressure Gage Installed in Swing Circuit Pressure Compensating Unit Testing Port 15 Grease Spanner Wrench Cylinder Heads Open End Wrench 7 8 and 1 Open End Wrench 1 1 4 Universal Joint 3 4 Drive Socket 1 1 16 Deep Throat 3 4 Drive Socket 1 1 8 Deep Throat 3 4 Drive Socket 15 16 Standard 3 4 Drive Extension 1 12 3 4 Drive PP RRP SSD 10 Crescent Wrench 15 11 Special Tube Wrench 1 1 2 12 Sliding Handle 3 4 Drive 13 Open End Wrench 3 8 14 Drain Valve Handle Oil Reservoir 15 Plugs 1 1 4 Supply Lines 2 16 Plug 1 Supply Lines 17 Tool Box 18 Tee Handle Machinery Housing Doors Figure 18 Tool Kit Carrier Mounted Machine 3 13 PROPEL AND SWING GEAR BOX REPAIR The gear boxes are of relatively simple construc tion and therefore detailed disassembly and repair instructions are not necessary However for ease of disassembly and repair and also to guard against unnecessary damage to the gear box components we recommend that the following list of general hints and p
47. n PROPEL OR OUTRIGGER CONTROL LEVERS PROPEL LEVERS When in the normal traveling position drive sprockets to the rear follow the instructions below When in reversed position drive sprockets to the front reverse all directional instructions The speed of travel is governed by the engine speed 1 To propel machine forward push both levers forward i 2 To propel machine backward pull both levers back 3 make right hand turn use any ofthe following procedures Push the left lever forward and leave the right lever in neutral PRO PEL CONTROL LEVERS CRAWLER OUTRIGGER CONTROL LEVERS TRUCK SWING BRAKE CONTROL LEVER DIPSTICK CONTROL PEDAL b Pull the right lever back and leave the left lever in neutral c When working in close quarters or when speed is required a right hand spin turn may be made by simultaneously pushing the left hand lever forward and the right hand lever back 4 To make a left hand turn reverse the above directions OUTRIGGER LEVERS 1 To set outriggers push both levers forward 2 To raise outriggers pull both levers back When in the digging position boom extended over the rear of the carrier the left outrigger is con trolled by the left lever INSTRUMENT PANEL CHOKE LEVER THROTTLE LEVER EMERGENCY STOP KNOB SWING CONTROE LEVER BUCKET CONTROL LEVER PROPEL BRAKE CONTROL LEVER CRAWLER BUCKET
48. ng 8 a8 reqd 800098 Shim Retainer Plate 800024 Groove Pin sl gt 48 WHEN ORDERING PARTS FOLLOW THE INSTRUCTIONS OUTLINED ON PAGE ii 4 2 22222222 SS SENS 364 SDN MA B gg T EN Sy gt NOT T A C 59 2 CNN T d cmm 2 om IS Zim Figure 41 Tumbler Section Index Part Number Number Description TUMBLER SECTION 1 800001 22 lt TT 2 800013 Sprocket E 3 800075 OVS i xd deu Ib EE EE 4 80007 2 Thrust Washer 5 800009 Bearing BlOcK 6 800007 Shaft Seal St ee 1 800064 Shaft Bus bingy oa iee a a R R 8 800099 Shaft Shim 800100 Shaft SIN ewe We ee ee ke 9 800066 tTumbler Shaft s vu woe ee US 10 800014 End cas aes 45 400319 Grease Fittings not illustrated SE SCH ANN Quantity 49 WHEN ORDERING PARTS FOLLOW THE INSTRUCTIONS OUTLINED ON PAGE ii 5
49. ntative com pound or its equivalent 2 Drain engine lubricant and refill with engine preservative oil 3 Drain engine cooling system and refill with corrosion inhibitor 4 Crank engine to circulate preservative oils through fuel and lubricating systems 9 Drain lubricant from swing and propel gear and refill with preservative oil Wherever fluid systems have been drained attach a waterproof tag to the tank or engine to warn the operator not to operate the machine until the system s have been drained and refilled with correct fluid 6 Rem move battery ER Relieve engine belt tensi n Tag the belts to indicate that belt tension must be adjusted before Starting engine 8 Wipe machine to remove all film and dirt Apply preservative to any exposed metal surfaces subject to corrosion through prolonged non usage such as valve spools cylinder rods etc ER Close and secure all doors Seal all openings with waterproof paper 10 Fill hydraulic system completely with hydraulic SECTION HI MAINTENANCE AND REPAIR 3 1 PREVENTIVE MAINTENANCE 3 2 LUBRICANT RECOMMENDATIONS It is impossible to overstress the importance of To insure maximum efficiency and long life use preventive maintenance well organized day to day the lubricants recommended in Table 1 or their preventive maintenance schedule will save you ex equivalent pensive downtime and costly repairs In addition it
50. of oil at these points is necessary for cylinder rod lubrication 2 3 STARTING THE ENGINE Leave all control levers in neutral Place throttle in approximately half fuel position Place ON OFF switch in ON position or place fuel shut off lever in RUN position Depress starter button to crank engine If engine fails to start after two or three attempts refer to engine manual for cause of trouble and instructions to correct it 2 4 OPERATING CONTROLS See Figure 6 Operators not familiar with hydraulic machines may tend to over control and thereby cause rough operation of the machine It is recommended that the machine be operated at half throttle or less until the operator gets the feel of the controls The throttle setting may then be gradually increased to fully governed speed The operation of each control is as follows BOOM CONTROL LEVER 1 To raise boom pull boom control lever back 2 To hold boom in position move control lever to center position neutral 3 To lower boom push boom control lever forward rece n Figure 9 Extending Crawler Tracks BUCKET CONTROL PEDAL OR LEVER 1 For normal operation use the foot pedal to control the bucket However for very close work when speed is not a factor use the lever to control critical movement of bucket 2 To place bucket in closed position push down with heel of leftfoot onthe pedalor pull the lever back 3
51. recautions be followed NOTE Use only genuine Hein Werner parts to insure proper fit and operation Sm 1 Use a soft hammer when assembling or dis assembling any parts which may become nicked or marred 2 Use a press wherever possible to remove and replace gears and bearings 3 Use care when removing seals and bearing cups to avoid damaging the case or cover in which the components are seated 4 Replace hex nuts and bolts with rounded cor ners all lockwashers oil seals and gaskets 5 Clean the threads of all bolts studs and nuts to assure proper torque and adjustment fe i 5 Upperstructure Tools 1 Grease Gun 10 Crescent Wrench 15 2 Spanner Wrench Cylinder Heads 11 Tube Wrench 1 1 2 Special 3 Open End Wrench 7 8 and 1 12 Sliding Handle 3 4 Drive 4 Open End Wrench 1 1 4 13 Open End Wrench 3 8 5 Universal Joint 3 4 Drive 14 Drain Valve Handle Oil Reservoir 6 Socket 1 1 16 Deep Throat 3 4 Drive 15 Plugs 1 1 4 Supply Lines 2 1 Socket 1 1 8 Deep Throat 3 4 Drive 16 Plug 1 Supply Lines 8 Socket 15 16 Standard 3 4 Drive 17 Tool Box 9 Extension 12 3 4 Drive 18 Tee Handle Machinery Housing Doors Crawler Tools Hein Werner Pushmaster Unit Track Adjustment C4 Track Adjusting Shims 1 8 20 C2 Chain Adapter Sprocket Removal C5 Socket 1 5 16 Stand
52. rs maintain a stock of genuine Hein Werner replacement parts Always order parts from your nearest Hein Werner Dealer INSPECTION OF SHIPMENTS Carefully inspect all shipments upon arrival In the event of loss or damage do not accept the shipment until the transportation company either makes a notation on the freight bill or gives you an inspection report covering said damage or loss In the event of concealed damage or loss notify the carrier at once within 20 days requesting that an inspection be made and damage or loss be acknowledged ADJUSTMENTS AND RETURNS Refer to the written Warranty in this manual for an explanation of Warranty policy If you feel a Warranty claim is in order consult your Dealer Claims must be made through your Dealer within a 15 day period from the time a failure occurs Parts returned directly to the factory without Dealer Authorization will not be accepted USE ONLY GENUINE HEIN WERNER PARTS FOR MAXIMUM PERFORMANCE ii nrc E EE Ed Y M RT AEN 5 3 3 3 3 3 3 3 3 8 3 3 3 3 3 3 3 3 3 Page SECTION I DESCRIPTION 1 1 1 Hydraulic Circuits and 1 1 9 Carriers e V wc Bose E R wn 4 1 3 Accessories im M an auia
53. s Bh ee GR a 42 1 r 36 Cap SCrEW ane eed iod de eo ates Sad he 34 Swing Bearing Shim No 31 as reqd Swing Bearing Shim No 22 as reqd Swing Bearing Shim No 16 gage as reqd Swing Bearing Shim 0 005 in as reqd 45 oL a aa a rea EE WHEN ORDERING PARTS FOLLOW THE INSTRUCTIONS OUTLINED ON PAGE ii Figure 38 Outrigger System Hein Werner Carrier Index Part Number Number Deserpion Quantity OUTRIGGER SYSTEM HEIN WERNER CARRIER 1 210029 Cylinder Pin s 5 2 4 3 ais a ee 2 2 210023 Arm Pivot PIN s a wu 3 26 7 3 4 290 URL e 2 3 210025 Cylnd r Rod Pin 222 Fea x ee ae 2 4 210022 FOOL PIVOL PIN X xk a BOE Oe CER LRE 2 5 140014 Foot Pade rus C Deoa e ao eo Ce Cas 2 6 140001 Foot Assembly qo UV AC BU 2 7 140024 Arm Assembly uu ote we I 2 8 140038 Outrigger Frame 1 9 140041 Mounting Colar A TER TENE Y e 8 10 210085 Mounting PN 4 uus HE dede T 4 11 400332 Mounting Bol
54. t rea ers oe ode R DI K ER AU rs 8 12 400062 Lock Nut Mounting Bolt 8 13 040099 Cylinder Assembly 5 2 2 NOTE Outriggers are available for mounting commercial trucks These outriggers are identical except that they are welded rather than bolted Allparts are identical 46 WHEN ORDERING PARTS FOLLOW THE INSTRUCTIONS OUTLINED ON PAGE ii L d 922 Figure 39 Roller and RUE Shaft Assemblies Boer P Description Number Number Quantity ROLLER AND SHAFT ASSEMBLIES 1 800005 os SG cwm M 20 2 800004 Bearing 5x10 A Ca 40 3 800010 Roher Shaft v Gey ERE da 20 4 800035 Us BOI E ake Et WO SS x 40 5 800034 Bevel Washers sw e A a EE Te RUE e 80 47 WHEN ORDERING PARTS FOLLOW THE INSTRUCTIONS OUTLINED ON PAGE ii Figure 40 Crawler Drive Parts Index Fan Description Number Number Quantity CRAWLER DRIVE PARTS 1 800081 24 Track Shoes Wow ovk COE oe OUR a LM avs dE s CV o 86 800079 32 Track Shoe 800019 Track Shoe Pin 800023 Drive Lock 800032 Bearing Adjuster 800012 1 4 Track Adjusting reqd 800085 1 8 Track Adjusti
55. tch cleaning bucket Various standard buckets are also available These buckets range in size from 16 to 48 widths If your machine is equipped with any of the above mentioned accessories refer to the special section in this manual for service and parts information The following basic schematics will be useful in tracing the hydraulic circuitry 1 Upper circuitry Figure 2 2 Lower circuitry crawler Figure 3 3 Lower circuitry carrier Figure 4 SECTION Il OPERATION 2 1 PREPARATION FOR USE Before operating the machine make the following checks and adjustments ALL MODELS 1 Engine checks see engine manual for detailed instructions Crankcase oil level Fan belt tension Coolant level Air cleaner Level of electrolyte in battery Battery and terminals for corrosion Tightness of mounting bolts cg n Fuel level 2 Upperstructure checks a Security of fuel oil and electrical con nections b Freedom of operation of all controls c Oil level in hydraulic reservoir Remove the high level plug and check that the oil level is between the high level plug and the low level plug If necessary add pre mium grade SAE 20 oil d Damage which may have occurred in ship ment e Level of lubricant in gear boxes If neces add EP 80 90 oil f Lubricate entire machine as required see paragraphs 3 4 3 5 and 3 6 CRAWLER MODELS 1 Carbody and si
56. the thrust washers and bearing blocks to the shaft See Figures 41 and 42 To adjust the shaft end plate clearance bolt one end plate tight Add shims as required to obtain 020 030 inch total clearance between the bearing block and the shaft end plate When shimming the tumbler end place the shims on the drive sprocket end of the shaft Adjust the idler at either end of the shaft Re place the shaft and tumbler or idler assembly in the side frame by reversing the disassembly pro cedure Adjust the track as instructed in para graph 3 8 Figure 23 Replacing Bushings and Seals WHEN ORDERING PARTS FOLLOW THE INSTRUCTIONS OUTLINED ON PAGE ii SECTION IV REPAIR PARTS LIST When ordering parts always give the model number machine serial number and engine serialnumber as shown on the Serial Number Plate Figure 24 part numbers preceded by an asterisk in the following lists are dealer serviced assemblies Contact your dealer for informa tion concerning these parts When ordering parts for engine drive packages engine mounting packages or any other assemblies for which part numbers are not listed include the name of the part and the make of the engine in addition to the above information CONSTRUCTION EQUIPMENT a ____ REFER TO MANUAL FOR LUBRICATION AND OPERATING INSTRUCTIONS HEIN WERNER CORPORATION WAUKESHA WISCONSIN U S A Figure 24 Serial Number Plate 21 11
57. u 0 020105 DIS 2 E N e vo RS Gl ong 85 020151 E 040013 Breather CHE WHEN ORDERING PARTS FOLLOW THE INSTRUCTIONS OUTLINED ON PAGE ii Figure 34 Lower Outrigger Hydraulic Circuit Index Part we Number Number Description Quantity LOWER OUTRIGGER HYDRAULIC CIRCUIT 1 020113 45 R bOW ue uds 4 2 030254 QE TN QC 4 3 040113 Hydra Swivel Assembly E 1 40 lm m eer MN WHEN ORDERING PARTS FOLLOW THE INSTRUCTIONS OUTLINED ON PAGE Wr 1 Figure 35 Lower Propel Hydraulic Circuit Index Part Number Number Quantity LOWER PROPEL HYDRAULIC CIRCUIT 1 020101 aS E 4 2 020154 Elbow cona GUERRE 2 3 020155 ElDOW AI Je ac a 4 4 000036 Propel 2 5 030246 Drain 242 ___ a ei 2 6 030243 E E UO 2 7 020111 vn sc ante ORE pc rq 2 8 030242 HOSE ae ES ER 2 9 020009 PER STR TO ee Se we CT 4 10 030241 OP 4 1
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