STRUCTURALS 5540F/YB5515 SERVICE MANUAL
11-54
4. Disconnect the hydraulic lines from the lower swivel
ports. Put caps or plugs on the fittings and hydraulic
lines.
5. Using an overhead crane, remove the two
counterweights 2 and 4 from the mast.
6. Refer to winch removal in this section and remove the
winch assembly.
7. Connect a hoist to the mast capable of handling the
weight of the mast. Remove the 26 bolts 9 and flat
washers 10, which fasten the mast to the mast bearing.
8. Remove the mast and place it on blocks.
9. Remove the 26 bolts 23 and structural washers 7 and
remove the mast bearing 11 from the frame.
Installation
1. Using a suitable solvent, clean the holes in the bearing
plate on the main frame. Remove the residue with
compressed air. Clean all dirt from the bearing plate.
2. Locate the mast bearing (11, Figure 11-125) in place on
the bearing plate.
3. Install the bolts 26 and structural washers 7 to fasten the
mast bearing to the bearing plate.
4. Figure 11-123 shows order of tightening the bolts. Each
bolt must first be tightened to a torque of 282 lb-ft. (384
Nm) and then loosened slightly. After which, each bolt
must again be torqued to 282 lb-ft. (384 Nm).
5. Make sure the top surface of the mast bearing and the
bottom surface of the mast base are clean.
6. With a hoist, raise and the lower the mast into position
over the mast bearing. Install bolts (9, Figure 11-125)
and washers 10.
7. Figure 11-123 shows the order for tightening the bolts.
Each bolt must first be tightened to a torque of 159 lb-ft.
(216 Nm), and then loosened slightly. After which, each
bolt must again be tightened to a torque of 158 lb- ft.(215
Nm).
8. Install swivel stop (25, Figure 11-125) to hydraulic swivel
26.
9. Connect the hydraulic lines to the hydraulic swivel.
10. Install counterweights 2 and 4 into the mast.
11. Install the winch assembly to the mast.
12. Install the boom assembly.
Swing Gearbox And Pinion
Maintenance
Gearbox
The swing gearbox has a worm gear set which rotates on
taper roller bearings. The gears and bearings are given
lubrication by the grease in the gearbox. Gaskets inhibit
external leakage from the gearbox.Keep the gear case filled
with grease.
Swing Gear/Pinion
The swing pinion and gear must be lubricated at regular
intervals.
Adjustment
Checking Backlash
Check the backlash between the swing gear and the swing
gearbox pinion every six months or after 1500 hours of
operation, whichever occurs first.
1. Remove the swing gear pinion cover.
2. Start the engine and rotate the mast until the high point
on the swing gear is engaged with the pinion
(Figure 11-126). The high point is punch-marked on the
edge of the metal base plate.
3. Using a feeler gauge, check the backlash between the
gear and pinion. There should be no clearance between
the swing gear tooth the pinion tooth. If there is any
clearance, adjust the backlash.
Backlash Adjustment
NOTE: Be sure the swing gear and pinion are aligned at
the high spot of the swing gear.
1. Slightly loosen the four bolts securing the gearbox
(Figure 11-126).
Reference Only
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