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Global Service Training

6050 Hydraulic Mining Shovel


Swing System
Module 10 - Text Reference

SERV2021

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trade dress, as well as corporate and product identity used herein, are trademarks of Caterpillar
and may not be used without permission. © 2014 Caterpillar Inc. All Rights Reserved.
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SERV2021 - 08/14 -2- Module 10 - Swing System

TABLE OF CONTENTS
Safety Briefing��������������������������������������������������������������������������������������������������������������������� 4
Purpose����������������������������������������������������������������������������������������������������������������������������������� 5
Reason������������������������������������������������������������������������������������������������������������������������������������� 6
Competency Statement����������������������������������������������������������������������������������������������������� 7
Learning Outcomes������������������������������������������������������������������������������������������������������������ 8
swing system overview���������������������������������������������������������������������������������������������������� 9
swing pumps������������������������������������������������������������������������������������������������������������������������� 10
swing pump����������������������������������������������������������������������������������������������������������������������������11
swing pump schematic����������������������������������������������������������������������������������������������������� 13
swing motors���������������������������������������������������������������������������������������������������������������������� 14
swing charge pump and oil filters���������������������������������������������������������������������������� 15
swing filters����������������������������������������������������������������������������������������������������������������������� 16
twin engine operation - swing right������������������������������������������������������������������������� 17
single engine operation - swing right��������������������������������������������������������������������� 18
swing control circuit - swing left��������������������������������������������������������������������������� 19
swing control circuit - swing right������������������������������������������������������������������������� 20
swing balance valve�������������������������������������������������������������������������������������������������������� 21
swing system - balance��������������������������������������������������������������������������������������������������� 23
swing system - swing left��������������������������������������������������������������������������������������������� 24
swing system - swing right������������������������������������������������������������������������������������������� 25
swing system - swing left (Swing pressure increasing)���������������������������������� 26
flushing valve�������������������������������������������������������������������������������������������������������������������� 27
swing park brake��������������������������������������������������������������������������������������������������������������� 28
swing park brake schematic����������������������������������������������������������������������������������������� 29
swing motor and swing bearing��������������������������������������������������������������������������������� 30
swing bearing��������������������������������������������������������������������������������������������������������������������� 32
swing bearing soft spot������������������������������������������������������������������������������������������������ 33
swing motor - rexroth��������������������������������������������������������������������������������������������������� 34
swing charge (45-50 bar)������������������������������������������������������������������������������������������������� 35
swing blocking valves���������������������������������������������������������������������������������������������������� 36

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TABLE OF CONTENTS
closed circuit with blocking valves������������������������������������������������������������������������ 37
swing proportional valves������������������������������������������������������������������������������������������ 38
servo lines��������������������������������������������������������������������������������������������������������������������������� 39
Purpose review������������������������������������������������������������������������������������������������������������������ 40
Reason review�������������������������������������������������������������������������������������������������������������������� 41
Competency Statement review������������������������������������������������������������������������������������ 42
Learning Outcomes Review������������������������������������������������������������������������������������������� 43
Module Conclusion���������������������������������������������������������������������������������������������������������� 44

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Safety Briefing
• Emergency Phone Numbers
• First Aid Responders
• Location of Exits
• Location of Fire Extinguisher
• Room Alerts or Hazards
• Designated Location for Evacuation
• Storm Shelter
• Hazardous Material

Safely Home. Everyone. Every Day.™

4
Safety Briefing

Before beginning this module, the following topics will be reviewed:


• Emergency Phone Numbers
• First Aid Responders
• Location of Exits
• Location of Fire Extinguisher
• Room Alerts or Hazards
• Designated Location for Evacuation
• Storm Shelter
• Hazardous Material

Safely Home. Everyone. Every Day.™

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PURPOSE

This module is designed to familiarize you with the


components and operation of the 6050 Hydraulic
Mining Shovel swing system.

5
Purpose

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REASON

This training is necessary for you to accurately


diagnose and repair the 6050 swing system
components.

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Reason

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COMPETENCY Statement

At the completion of this module, you will be required to


successfully complete a summative group assessment
by answering five oral questions at an accuracy rate of
at least 80%.

At the completion of this module, you will be required


to successfully complete a written assessment at an
accuracy rate of at least 80%.

7
Competency statement

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LEARNING OUTCOMES

You will meet the following learning outcomes during


this Swing System module for the 6050 Hydraulic
Mining Shovel course:
• Identify the main swing system components.
• Identify the function of the swing system components
during a Post-Assessment.

8
Learning outcomes

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SERV2021 - 08/14 -9- Module 10 - Swing System

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3

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Swing System Overview

• Identify the swing system The swing system consists of four bidirectional, variable displacement piston pumps
components. (1) that drive four bent-axis piston motors (2). The motors rotate the swing drive gear
to swing the machine left or right. The swing hydraulic circuit is a closed loop system.

Oil from one of the high pressure loops (red) flows to the swing blocking valves (3),
which direct the oil to the swing motors to rotate the motors. Oil returns to the pump
through the low pressure loops (blue). Each drive loop contains a high pressure oil
filter (4). The blocking valves prevent high pressure oil from the driven pumps from
flowing to the non-driven pumps when only one engine is operating. The oil filters
protect the pump and motor from contamination in one circuit if the pump or motor
in the other circuit fails.

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SERV2021 - 08/14 -10- Module 10 - Swing System

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4

1
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Swing Pumps

• Identify the swing pumps and the This image shows the location of the left swing pumps (1), which are attached to the
swing charge pumps. left pump gear box (2).

This image shows the location of the right swing pumps (3), which are attached to
the right pump gear box (4).

The left swing charge pump (5) and the right swing charge pump (6) are also shown.

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2

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Swing Pump

The above illustration shows the following components:


• Rotary group (1)
• Temperature switch (2)
• Contamination switch (3)
• Shock relief valve - 2 (400 bar) (4)
• Swing charge adjustment (cooling) (5) (factory set)
• Pressure cut-off valve (6) (not used)

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1 2 4

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Swing Pump (cont.)

The above illustration shows the following components:


• Contamination switch S72 (1)
• Temperature switch S70 (2)
• Swing charge pump (45 bar) and Filter (3)
• Shock relief valves (4)
• Cooling orifice (5) (factory set)
• Swing pump main pump element (6)
• Control piston (7)

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SERV2021 - 08/14 -13- Module 10 - Swing System

SWING PUMP SCHEMATIC


Contamination Temperature
Switch (6) Switch (7) Swing Charge
Pump (1)

Shock Relief
Valves (3)

Cooling
Orifice (2)

Pump
Actuator
Cooling (5)
Relief
Valve (4)

13_1

Swing Pump Schematic

• Explain the operation of the swing This schematic shows the components and oil flow in the swing pump. Oil from the
pump. swing charge pump (1) supplies charge oil to the swing pump. The charge oil
replaces oil lost due to internal leakage and flushing and provides cooling via the
cooling orifice (2). The shock (crossover) relief valves (3) limit pressure spikes in the
swing circuit to 400 bar (5800 psi). The cooling relief valve (4) and a cooling orifice
cool the swing pump oil. The cooling relief valve is factory set at
17 bar (250 psi). The cooling orifice provides a restriction in the charge circuit, which
maintains the charge oil pressure at approximately 40 bar (580 psi).

The pump actuator (5) controls the pump swashplate angle, which determines the
pump output flow and direction.

The swing pump is also equipped with a contamination switch (6) and an oil
temperature switch (7).

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14_1

Swing Motors

• Identify the swing motors. The swing motors drive the swing gear, which rotates the machine. The swing motors
are bidirectional, fixed displacement piston motors.

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15_1

Swing Charge Pump and Oil Filters

• Identify the swing charge pump Each swing charge pump (1) provides charge oil to two swing pumps (2). This image
and oil filters. shows the left swing charge pump and the left swing pumps.

Oil flow from each charge pump splits and flows separately through a charge oil
filter (3) to each swing pump. The swing charge pumps are fixed displacement
pumps that are mounted to swing pumps 1 and 4.

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Swing Filters

Oil from the swing charge pumps flows through charge oil filters to the swing
pumps.

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1
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4
6

3 1
5

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17_1

Twin Engine Operation – SWING RIGHT

• Explain the flow of oil through This schematic shows the oil flow in the swing system with both engines running and
the swing system in twin engine the joystick moved to the SWING RIGHT position.
operation during SWING RIGHT.
High pressure oil from the swing pumps (1) flows to the blocking valves (2). Oil from
the servo pumps (3) flows to the blocking valves and opens the pilot valve inside the
blocking valves. With the pilot valves open, the swing pump oil flow is allowed to flow
through the blocking valves to the swing motors (4). The swing motors rotate and
drive the swing gear.

Low pressure oil from the swing motors returns to the swing pumps through the open
blocking valves.

Balance lines (5) ensure that the pressure in all four swing motors is the same to
compensate for flow variations between the left and right pumps. The oil filters (6)
are located in the balance lines to filter the oil flowing between the pumps.

The check valves in the oil filters prevent contaminants from flowing between the left
and right pumps if contaminants are present in the left or right swing oil circuit.

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18_1

Single Engine Operation – SWING RIGHT

• Explain the flow of oil through the This schematic shows the oil flow in the swing system with the right engine running
swing system in single engine and the joystick moved to the SWING RIGHT position.
operation during SWING RIGHT.
High pressure oil from the right swing pumps (1) flows to the right blocking
valves (2). Oil from the right servo pump (3) flows to the right blocking valves and
opens the pilot valve inside each blocking valve. With the pilot valves open, the swing
pump oil flow is allowed to flow through the blocking valves to the swing motors (4)
via the balance lines (5) and oil filters (6). The right swing motors rotate and drive
the swing gear.

Low pressure oil from the right swing motors returns to the right swing pumps through
the open right blocking valves.

Since the left engine is not running, the left swing pumps (7) and the left servo
pump (8) are not producing oil flow. The pilot valve in the left blocking valves (9) is
closed, which will not allow the left blocking valves to open. The left blocking valves
block the high pressure and low pressure oil from flowing to the left swing pumps.

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19_1

Swing Control Circuit – SWING LEFT

• Explain the flow of oil in the swing This schematic shows the oil flow in the swing control circuit when the joystick is
control circuit during SWING moved to the SWING LEFT position. When the joystick is moved to the left, a signal
LEFT. is sent to the CMS. The CMS sends a corresponding signal to the swing left
proportional valve (1) and the switching safety valve (2), which are located on the
proportional valve block. The energized switching safety valve allows oil at a pressure
of 40 bar (580 psi) to flow to the left swing proportional valve, provided the operator
is seated and the ladder and service station are in the raised position.
All of the servo proportional and safety valves are mounted in a manifold located in
the room below the operator’s cab. Each proportional valve has a matching safety
valve.
For the function, swing left, the operator moves the joystick in the desired direction.
This supplies a 0 - 650 mA signal to the proportional valve, which then opens and
allows 0 -31 bar hydraulic pressure to the corresponding side of the swing balance
valve control valve.
Providing the operator is seated, and the ladder and service arm are up, the matching
safety valve will be open and allow servo oil to travel through to the proportional
valve.

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20_1

Swing Control Circuit – SWING RIGHT

• Explain the flow of oil in the swing This schematic shows the oil flow in the swing control circuit when the joystick is
control circuit during SWING moved to the SWING RIGHT position. When the joystick is moved to the right, a
RIGHT. signal is sent to the CMS. The CMS sends a corresponding signal to the right swing
proportional valve (1) and the switching safety valve (2), which are located on the
proportional valve block. The energized switching safety valve allows oil at a pressure
of 40 bar (580 psi) to flow to the right swing proportional valve, provided the operator
is seated and the ladder and service station are in the raised position.

All of the servo proportional and safety valves are mounted in a manifold located in
the room below the operator’s cab. Each Proportional valve has a matching safety
valve.

For the function swing right, the operator moves the joystick in the desired direction.
This supplies a 0 - 650 mA signal to the proportional valve, which then opens and
allows 0 - 31 bar hydraulic pressure to the corresponding side of the swing balance
valve control valve. Proportional valve Y109.1 and safety valve Y92 control the LH
swing function, and proportional valve Y108.1 and safety valve Y92.1 control the RH
swing function.

Providing the operator is seated, and the ladder and service arm are up, the matching
safety valve will be open and allow servo oil to travel through to the proportional
valve.

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8 6 3 6 8

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21_1

Swing Balance Valve

• Identify the components of the The swing balance valve (1), located on the assembly plate, controls the swing
swing balance valve. direction and the maximum swing system oil pressure. Oil from the
40 bar (580 psi) pressure reducing valve (2) flows to the main spool (3) in the swing
balance valve. With the spool held in the balance position by the centering springs
(4), the servo oil flows through the balance valve and to the swing pump actuator
piston ports (5) to the swing pump actuator piston.

When the joystick is moved to the SWING LEFT or SWING RIGHT position, oil
flows from the corresponding swing proportional valve through the ports (6) and
to the large surface of the balance valve spool. When the spool shifts, servo oil is
directed to one side of the swing pump actuator piston. Oil from the other side of the
swing pump actuator piston returns to the tank through the tank port (7) in the swing
balance valve.

High pressure oil (8) from the left and right swing circuits flows to the small
surface (piston) (9) of the balance valve spool to keep the valve spool balanced. If
the swing pressure increases, the pressure acts on the small piston. The pressure
acting on the small piston is 12 times the joystick signal pressure of 31 bar (450 psi).
The pressure limiting valve limits the joystick signal pressure to 31 bar (450 psi). The
high pressure acting on the small piston stops the swing pump from producing oil
flow, and the swing movement is stopped.

The swing balance valve can be adjusted (centered) with the adjustment
screw (10).
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Swing Balance Valve (cont.)

The above graphic illustrates the 12:1 (1) ratio between the small piston and the
large piston.

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Swing System - Balance

The above graphic illustrates the swing balance valve in the neutral position. 40
bar is applied to both X1 and X2 in the swing pumps, which keeps the swing pumps
in neutral.
• Joystick signal swing left (1)
• Joystick signal swing right (2)
• 40 bar pressure (3)

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1 3 2

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Swing System - Swing Left

The above graphic illustrates the swing balance valve in the swing left position. 40
bar is applied to X2 while the oil in X1 is returned to the tank from the swing pumps.
• Joystick signal swing left (1)
• Joystick signal swing right (2)
• 40 bar pressure (3)

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1 3 2

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Swing System - Swing Right

The above graphic illustrates the swing balance valve in the swing right position.
40 bar is applied to X1 while the oil in X2 is returned to the tank from the swing
pumps.
• Joystick signal swing left (1)
• Joystick signal swing right (2)
• 40 bar pressure (3)

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1 3 2

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Swing System - Swing Left (Swing Pressure Increasing)

The above graphic illustrates the swing balance valve in the swing left position with
pressure increasing.

40 bar is applied to both X1 and X2 because the high pressure from the swing
system is applied to the small piston area, which moves the spool back to the
neutral position.
• Joystick signal swing left (1)
• Joystick signal swing right (2)
• 40 bar pressure (3)

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4

27_1

Flushing Valve

• Identify the components of the The flushing valve (1), located on the assembly plate, directs oil from the low pressure
flushing valve. side of the swing circuit to the tank. The corresponding amount of cool filtered oil is
sent back into the swing circuit by the swing charge pump. During swing operation,
high pressure oil is sensed at the end of the spool (2), which shifts the spool and
directs oil in the low pressure circuit to the tank through an orifice (3) and relief valve
(4). When the swing direction changes, high pressure shifts the spool in the opposite
direction.

The top image shows the oil flow through the flushing valve during both a SWING
RIGHT and a SWING LEFT condition.

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2

28_1

Swing Parking Brake

• Identify the swing parking brakes. The swing parking brakes are wet multi-disc brakes, designed as a parking or holding
brake, not a slowing brake. The swing brakes are spring applied (1) and released
with hydraulic pressure (2).

Maximum swing brake release pressure should be 70 bar (1015 psi).

NOTE: The swing brakes should be engaged only when the machine is in a
stationary position.

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Swing Parking Brake Schematic

• Explain the operation of the When the swing function is activated by the operator, the joystick (1) sends a signal
swing parking brake. to the CMS (2). The CMS sends a current to the swing brake solenoid (3). The
swing brake solenoid is energized and directs oil from the servo valve block (4) to
the swing brake (5). The oil pressure releases the swing brake, which allows the
swing motor (6) to rotate.

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2

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Swing Motor and Swing Bearing

• Identify the swing motor and This image shows the location of one of the swing motors (3), swing gear box (4),
swing bearing. and components of the swing bearing (5).

Roller bearings (1) are shown in the image above. The larger roller bearings are
located at the top for supporting the load.

The inspection plate (2) is also shown in the image.

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31_1

Swing Motor and Swing Bearing (cont.)

• Identify the swing motor and This image shows one of the swing motors (1), the swing gear box (2), the swing
swing bearing. motor drive gear (3), the swing bearing (4), and the swing bearing gear (5).

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32_1

Swing Bearing

• Identify the location of the swing The above images show the swing bearing installed on the lower frame.
bearing.

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33_1

Swing Bearing Soft Spot

• Identify the swing bearing soft A soft spot on the swing bearing is indicated by an S (arrow).
spot.
The S mark on the undercarriage should be located at 90° on the right side.

The S mark on the upper carriage should be located at 30° from the rear on the left
side of the machine.

Refer to the technical manual for the proper assembly procedure.

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4

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Swing Motor - Rexroth

• Identify the gears and brakes in This image shows the gears (1) and brakes (2) in the Rexroth swing motor.
the Rexroth swing motor.
• Pistons (3)
• Brake - spring applied (4)
• Brake - hydraulically released (5)
• Auto lube connection (grease) (6)
• Oil drain (7)

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35
Swing Charge (45 to 50 Bar)

The above illustration shows the oil flow from the LH swing charge pump (1) to the
swing charge filters (2).

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1 4
4

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Swing Blocking Valves

Pilot oil (70 bar) supplied at port (1) from the servo block keeps the blocking valves
in the OPEN position when the machine is operating with both engines.

When only one engine is operating, the signal is not applied to the blocking valve,
thus moving the blocking valve to the CLOSED position.
• Oil back to tank (2)
• From swing pumps (3)
• Out to swing system (4)

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4

10 9 8

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11
11 5
2

10 9 8

1
7
37
Closed Circuit with Blocking Valves

The illustration above shows the following components:


• Swing pump 1 (1)
• Swing pump 2 (2)
• Swing pump 3 (3)
• Swing pump 4 (4)
• LH servo pump (5)
• RH servo pump (6)
• Swing park brake solenoid Y11 (7)
• Blocking valves (8)
• Swing motors (9)
• Gear boxes (10)
• Filters (11)

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SERV2021 - 08/14 -38- Module 10 - Swing System

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Swing Proportional Valves

This illustration shows the Swing limiting relief valve (1) that is used to adjust the
swing system maximum pressure of 31 bar.

The swing limiting relief valve is supplied by oil (40 bar) from the swing proportional
valve block (2). The swing limiting valve regulates the oil to 31 bar for supply to the
swing balance valve (3) at Y1 and Y2.

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1 2

39
Servo Lines

The illustration above shows the following components:


• Flushing valve (1)
• Balance valve (2)
• Blocking valves (3)
• Servo adjustment block (4)
• Swing pumps (5)

All four swing pumps are controlled at the same time by the X1 and X2 connections
in the swing balance valve.

In single engine operation, all four swing pumps are still fully operating.

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PURPOSE

This module was designed to familiarize you with


the components and operation of the 6050 Hydraulic
Mining Shovel swing system.

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Purpose review

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REASON

This training was necessary for you to accurately


diagnose and repair the 6050 swing system
components.

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Reason review

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COMPETENCY Statement

At the completion of this module, you will be required to


successfully complete a summative group assessment
by answering five oral questions at an accuracy rate of
at least 80%.

At the completion of this module, you will be required


to successfully complete a written assessment at an
accuracy rate of at least 80%.

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Competency statement REVIEW

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LEARNING OUTCOMES

You have met the following learning outcomes during


this Swing System module for the 6050 Hydraulic
Mining Shovel course:
• Identified the main swing system components.
• Identified the function of the swing system components
during a Post-Assessment.

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Learning outcomes REVIEW

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44
Module Conclusion

This presentation has provided information for the swing system of the 6050
Hydraulic Mining Shovel.

When used in conjunction with the service manual, the information in this package
should permit the technician to do a thorough job of analyzing a problem in these
systems.

For service repairs, adjustments, and maintenance, always refer to the Operation
and Maintenance Manual, Service Manuals, and other related service publications.

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