Takeuchi TB215R, Workshop Manual

Page 1: ...CC8E005 WETB215R_A XI Seral No 215000003...

Page 2: ...the blade be ing at the front Machine serial number The machine serial number is stamped on the identification plate Be sure to include this number when sending a report or inquiry or when ordering p...

Page 3: ...SAFETY 1...

Page 4: ...arily cover all safety measures It is also im possible to cover all hazards and risks which may be as sociated with the maintenance of the machine in every environment For maintenance work each person...

Page 5: ...hen working with a grinding polishing sanding machine hammer or compressed air as metal frag ments or other objects could scatter in such an envi ronment Wear hearing protectors when operating the mac...

Page 6: ...oving the machine may accidentally start moving resulting in severe injury to the maintenance person nel Make sure that the working equipment has been lowered to the ground and the engine has been tur...

Page 7: ...event slipping falling from machine clear the footing and observe the following a Do not spill oil or grease on the machine b Keep the machine tidy and clean c Be careful when walking around the machi...

Page 8: ...rade of fuel for the operating season Handling of hoses Oil leak or fuel leak can cause a fire Do not twist bend or hit the hoses Never use twisted bent or cracked pipes tubes or hoses otherwise they...

Page 9: ...re from the circuit of the working equipment for link type controls When removing plugs or screws or when disconnect ing hoses stand to the side and loosen them slowly to gradually release the interna...

Page 10: ...When disconnecting the battery wiring always discon nect it from the earth side When connecting con nect the earth side last Loose battery terminals may result in sparks Be sure to fasten terminals t...

Page 11: ...id damage Wipe all joining surfaces clean until there is no dirt or dust adhering to them Wrap the thread tight with seal tape starting 1 or 2 threads away from the thread end The tape should be overl...

Page 12: ...s are not contacting sharp objects or each other This could cause surface flaws on the hoses resulting in breakage Handling of seals Clean the grooves for O rings and remove any burrs Be careful not t...

Page 13: ...SERVICE DATA 2...

Page 14: ...SERVICE DATA DIMENSIONAL DRAWING 1 2 DIMENSIONAL DRAWING 2A0AX001 DIMENSIONAL DRAWING Machine dimensions 2A0AX03...

Page 15: ...8 1 F 1155 45 6 1205 47 4 1155 45 6 1205 47 4 G 1520 59 9 1570 61 8 1520 59 9 1570 61 8 H 1300 51 2 1300 51 2 1300 51 2 1300 51 2 H2 980 38 6 980 38 6 980 38 6 980 38 6 J 230 9 1 230 9 1 230 9 1 230 9...

Page 16: ...SERVICE DATA DIMENSIONAL DRAWING 3 2 DIMENSIONAL DRAWING 2A0AX001 Operating range 2A0AX02...

Page 17: ...r A 3815 150 2 3815 150 2 4000 157 5 4000 157 5 B 3760 148 0 3760 148 0 3945 155 4 3945 155 4 C 2190 86 2 2190 86 2 2390 94 1 2390 94 1 D 1780 70 1 1780 70 1 1970 77 6 1970 77 6 E 2705 106 5 2705 106...

Page 18: ...eed min 1 rpm 9 2 9 2 Travel speed Rubber crawler 1st km h mph 2 2 1 37 2nd km h mph 4 2 2 61 Steel crawler 1st km h mph 2 1 1 3 2nd km h mph 4 2 49 Maximum tractive force kN lbf 19 4 4360 Gradeabilit...

Page 19: ...720 28 3 Upper structure rearmost distance from axis of rotation mm in 720 28 3 Clearance height under upper structure Rubber crawler mm in 460 18 1 Steel crawler mm in 450 17 7 Crawler base 21500000...

Page 20: ...8 Battery Voltage V 12 Capacity A h 38 Quantity 1 Hydraulic pump drive system Engine direct coupling Hydraulic pump Type Variable displacement type double axial piston double gear Quantity 1 Delivery...

Page 21: ...ulic pilot operated pedal operated system Other Blade spanner function operation Mechanical lever operated system Auxiliary line piping operation Mechanical pedal operated system Instruments switches...

Page 22: ...ne side Quantity 68 Shoe width mm in 230 9 06 Lug height mm in 25 0 91 Type Steel crawler double grouser Number of shoes on one side Quantity 35 Shoe width mm in 230 9 06 Grouser height mm in 15 0 65...

Page 23: ...l crawler mm in 2200 86 6 Reach at maximum digging depth mm in 1840 72 4 Maximum vertical digging depth Rubber crawler mm in 1780 70 1 Steel crawler mm in 1790 70 5 Maximum height of cutting edge Rubb...

Page 24: ...er Number of cylinders Quantity 1 Bore mm in 60 2 4 Stroke mm in 385 15 2 Bucket cylinder Number of cylinders Quantity 1 Bore mm in 50 2 Stroke mm in 355 14 Swing cylinder Number of cylinders Quantity...

Page 25: ...ler 300 11 8 Cutting angle deg 55 Distance between the front end of the dozer blade and the axis of rotation mm in Standard blade 855 33 6 mm in Long blade 1200 47 2 Dozer blade maximum lifting mm in...

Page 26: ...h roof attached 48 105 Counterweight 100 220 Counterweight with added weight Boom bracket 30 65 Swing cylinder 17 37 Lower structure kg lb Part name Remarks Mass Swivel joint 12 27 Slew bearing 18 40...

Page 27: ...e it every 2000 hours API Standards American Petroleum Institute ACEA Standards European Automobile Manufacturers Association SAE Standard SAE International Society of Automotive Engineers JASO Standa...

Page 28: ...s use a light oil that still functions when the temperature is at least 12 C 54 F be low the lowest expected ambient temperature Use a light oil with a cetane number of 45 or higher When operating at...

Page 29: ...ed s 0 4 2 9 0 4 3 6 Bucket cylin der Retracted s 0 4 1 8 0 4 2 4 Extended s 0 4 2 5 0 4 3 2 Swing cylinder Retracted s 0 7 5 3 0 7 6 5 Extended s 0 7 5 0 0 7 6 2 Retracted s Extended s Dozer blade cy...

Page 30: ...lade cylinder mm in 0 2 2 0 0 0 1 0 1 4 0 2 Bucket tip mm in 0 70 70 0 0 2 8 2 8 140 5 5 Backlash mm in 15 20 15 0 6 0 8 0 6 40 1 6 Lever play Right control lever mm in 0 4 4 0 0 0 2 0 2 Left control...

Page 31: ...045 PSI Test port A1 Right travel Pressure 21 0 MPa 3045 PSI Test port A1 Boom Pressure 21 0 MPa 3045 PSI Test port A1 Bucket Pressure 21 0 MPa 3045 PSI Test port A1 Boom swing Pressure 21 0 MPa 3045...

Page 32: ...sen the locknut 2 and turn the setscrew 1 to adjust the set pressure Turn the setscrew clockwise to increase the set pressure Turn the setscrew counterclockwise to decrease the set pressure 2 In order...

Page 33: ...ement method Engine Maximum R P M Hydraulic oil temp 50 C to 60 C 122 F to 140 F Install a pressure gauge on the pressure detection port to measure the relief pressure Adjustment method 1 Loosen the l...

Page 34: ...ive 5 meters 16 4 ft first and then start measuring the time required for the machine to travel another 10 meters 32 8 ft Do this on level ground Traveling attitude With the bucket in a no load state...

Page 35: ...ired for the next 2 rotations Overrun when slewing stops Engine Maximum R P M Hydraulic oil temp 50 C to 60 C 122 F to 140 F Measuring attitude Same as that for measuring slew time Draw matching marks...

Page 36: ...ontally and rest the dozer blade on the ground Measure the time required for the arm cylinder to move from the fully retracted position to the fully extended position and vice versa Bucket cylinder sp...

Page 37: ...cylinder and make adjustments so that the boom foot pin and bucket pin are at the same height Maintain this attitude for 5 minutes and then measure the change in rod length and the distance that the...

Page 38: ...der and fully extend the bucket cylinder Move the tips of the bucket teeth from side to side left and right and measure the amount of play Slew bearing play 1 With the bucket in a no load state comple...

Page 39: ...using both the hoe attachment and the dozer blade For models with rubber crawlers line up the crawler seam joint marked with an M or symbol with the upper center of the upper structure Measure the wi...

Page 40: ...1 1 2 4 9 255 0 3 6 188 0 Nominal thread diameter Tightening torque UNF internal thread flat face sealing union joint N m ft lb 9 16 18 UNF 4 9 25 0 3 6 18 0 11 16 16 UN 4 9 37 0 3 6 27 0 13 16 16 UN...

Page 41: ...2 144 7 14 3 171 6 17 2 126 6 12 5 Nominal thread diameter Tightening torque Port material Steel Port material Aluminum N m ft lb N m ft lb G1 8 19 6 2 0 14 5 1 5 19 6 2 0 14 5 1 45 G1 4 34 3 4 9 25...

Page 42: ...he table above follow the specification in the manual 5 To tighten multiple bolts and nuts evenly tighten op posite bolts nuts alternately as a pair Thread Size pitch Tightening torque General tighten...

Page 43: ...2 7 94 1 9 3 1 196 1 19 2 144 7 14 3 171 6 17 2 126 6 12 5 Nominal thread diameter G Tightening torque N m ft lb 1 8 19 6 2 0 14 5 1 4 1 4 34 3 4 9 25 3 3 5 3 8 53 9 4 9 39 8 3 5 1 2 63 7 4 9 47 0 3 5...

Page 44: ...e table above follow the specification in the manual 5 To tighten multiple bolts and nuts evenly tighten op posite bolts nuts alternately as a pair Thread Size pitch Tightening torque General tighteni...

Page 45: ...SERVICE DATA HYDRAULIC CIRCUIT DIAGRAM 1 2 HYDRAULIC CIRCUIT DIAGRAM 2F0AX001 HYDRAULIC CIRCUIT DIAGRAM...

Page 46: ...Pa at L min psi at US gal min 25 9 at 5 0 3756 at 1 3 Part number 19020 28700 Type PVD00B 14D 5G3 Engine RPM min 1 rpm 2400 2400 Displacement P1 P2 cm3 rev cu in rev 7 0 0 4 P3 cm3 rev cu in rev 4 5 0...

Page 47: ...in rev 232 14 2 Motor displacement 1st cm3 rev cu in rev 11 4 0 7 2nd cm3 rev cu in rev 5 8 0 3 Reduction gear ratio 1 36 96 2nd speed switching speed MPa psi 3 4 493 Parking brake torque N m ft lb 2...

Page 48: ...9001 13900 Type Bore diameter rod diameter mm in 60 35 2 4 1 4 Stroke mm in 120 4 7 Maximum retraction length mm in Part number 19001 14000 Type Bore diameter rod diameter mm in 50 25 2 0 1 0 Stroke m...

Page 49: ...RCUIT DIAGRAM 2F0AX001 Travel lever lock cylinder Overall length Solenoid valve 3rd auxiliary line piping Part number 19000 74800 Type Stroke mm in 320 12 6 Maximum retraction length mm in Part number...

Page 50: ...e used in low voltage circuits 80 C 176 F AVX Heat resistant cross linked vinyl insulated low voltage cables A wire with dramatically improved heat resistance over that of AV wire enabling it to provi...

Page 51: ...SERVICE DATA ELECTRICAL CIRCUIT DIAGRAM 2 2 ELECTRICAL CIRCUIT DIAGRAM 2G0AX00 Electrical Schematic Diagram...

Page 52: ...SERVICE DATA WIRE HARNESS DIAGRAM 1 2 WIRE HARNESS DIAGRAM 2H0AX00 WIRE HARNESS DIAGRAM Wiring diagram...

Page 53: ...SERVICE DATA WIRE HARNESS DIAGRAM 2 2 WIRE HARNESS DIAGRAM 2H0AX00 Body harness 03342 68000...

Page 54: ...SERVICE DATA WIRE HARNESS DIAGRAM 3 2 WIRE HARNESS DIAGRAM 2H0AX00...

Page 55: ...SERVICE DATA WIRE HARNESS DIAGRAM 4 2 WIRE HARNESS DIAGRAM 2H0AX00...

Page 56: ...SERVICE DATA WIRE HARNESS DIAGRAM 5 2 WIRE HARNESS DIAGRAM 2H0AX00...

Page 57: ...SERVICE DATA WIRE HARNESS DIAGRAM 6 2 WIRE HARNESS DIAGRAM 2H0AX00...

Page 58: ...FUNCTION 3...

Page 59: ...plate 3 operates as the pump P1 while the piston in contact with the discharge port B operates as the pump P2 As thus described the pistons 2 complete one stroke of intake and exhaust for every stroke...

Page 60: ...rm length a which is determined by the action of the net force on the piston F1 becomes small er represented by a resulting in a larger force F1 being needed to act against the inclination of the swas...

Page 61: ...discharge the pilot pressure oil The gear pump 1 is connected by the hydraulic pump piston 2 and coupling 3 and the hydraulic pump 2 is connected by the engine 4 and coupling 5 with the drive gear 6 o...

Page 62: ...n example in which the spool 2 is moved to the right When the spool 2 is moved to the right the center by pass passage 1 is closed and the oil that has flowed into the valve from the pump passes throu...

Page 63: ...cated by the arrows F P A F1 P A1 P Pressure A and A1 Cross sectional ar eas The cross sectional area A1 is larger than the cross sec tional area A which causes the main poppet 2 to be pushed to the l...

Page 64: ...of the main poppet 6 as indicated by the arrows F P A F1 P A1 P Pressure A and A1 Cross sectional ar eas The cross sectional area A1 is larger than the cross sec tional area A which causes the main po...

Page 65: ...ction opera tion If the cylinder is operated at a speed too fast for the oil supply to keep up and thus the pressure of the chamber B becomes almost negative oil is supplied from the tank to prevent c...

Page 66: ...l conditions a pressure is applied to the cyl inder port P which causes the poppet 1 to remain closed A negative pressure arises in the cylinder port P When the pressure drops below that in the tank p...

Page 67: ...ed up This allows the oil that entered the port P to flow through the parallel passage 2 as well as the spool head and the second parallel passages A and B The second par allel passage A is connected...

Page 68: ...d to the port PiA which causes the spool 1 to be pushed up This results in the oil from the pump being supplied to the head side of the arm cylinder through the port A Meanwhile the return oil from th...

Page 69: ...utput ports A and B located below the vertical shaft hole The secondary pressure functions as the pilot pressure to ac tivate the spool of the control valve When the lever 3 is in the neutral position...

Page 70: ...ssure is balanced with the spring force When the pressure in the output port A becomes higher than the set spring force the out put port A is disconnected from the input port P and then becomes connec...

Page 71: ...the pressure Pa of the port A The pressure Pa acts on the differential area S between the cross section A1 and cross section B1 of the spool 6 and the spool 6 is pushed to the solenoid side by the oi...

Page 72: ...in the port P pump side is blocked by the spool 1 The oil flows through the port A on the pilot circuit side of the 3rd auxiliary section and port T on the tank side which means that the pressure of...

Page 73: ...re of the downstream pilot circuit is the same as the tank pres sure In addition the pressure in port C is the same as that in port P under normal conditions as port C is connected to port P When the...

Page 74: ...When the pressure in port P exceeds the force applied by the spring 2 the plunger 1 moves to the right al lowing the pressure oil to flow from port P to port PAC Port PAC J Port P The plunger 1 is re...

Page 75: ...ector valve is connected between the control valve and the pilot valve control lever Turn the selector valve lever to switch the connection port to switch the control lever pattern 1 Position A ISO 2...

Page 76: ...ISO Port A Port 1 Port B Port 2 Port C Port 3 Port D Port 4 Position G JCB Port A Port 3 Port B Port 4 Port C Port 1 Port D Port 2 1 Position A ISO 2 Position G JCB 3 Rotation of 90 1 Position A ISO 2...

Page 77: ...m the hole in the body 2 2 Turn the lever 3 counterclockwise 90 3 Tighten the wing bolt 1 by hand The end of the wing bolt 1 should go into the anti rotation hole in the body 2 Switching from Position...

Page 78: ...ELECTOR VALVE 4 3 SELECTOR VALVE 3K8AQ00 2 Turn the lever 3 clockwise 90 3 Tighten the wing bolt 1 by hand The end of the wing bolt 1 should go into the anti rotation hole in the body 2 3K8AQ07Z 3 3K8...

Page 79: ...olliding with the cover at the stroke end is dampened by the mechanism Cushion mechanism When the piston 1 approaches the stroke end and ap pears likely to bump into the cover 2 the cushion bear ing 3...

Page 80: ...he oil pushes the check valve 6 upward and then flows into both the motor port M1 and the chamber B in the pilot section The pressure oil flows into the motor from the motor port M1 By contrast the re...

Page 81: ...connected to the tank passage via the 2 speed solenoid valve 1 This causes the spool 2 to be pushed to the left by the spring 4 and the piston chamber 3 that controls the swash plate to become connec...

Page 82: ...springs 9 10 and the force of the 2 speed control piston 11 resulting in the swash plate being oriented at an angle which en ables the motor to run in 2nd speed high speed When the engine is stopped...

Page 83: ...rt 7 and the parking brake force is operated by the spring 4 Reduction gears The reduction gears consist of simple two stage plane tary gear assemblies connected in series Each plane tary gear assembl...

Page 84: ...holes which are connected to the seven chambers in the gerolor 4 The circuit to the gerolor 4 is then opened when the seven oil holes in the valve plate 3 are con nected to some of the twelve oil hole...

Page 85: ...fted to the chambers A G and F At this time the center point Y of the rotor 6 is shifted to the point Y around the point X This point Y is further shifted to Y as shown in Figure 3 In other words the...

Page 86: ...ncreases in pro portion to the distance traveled by the piston 5 which causes the relief pressure to increase The spring 4 is compressed the most when the piston 5 is moved left to the stroke end At t...

Page 87: ...ressure chan nel 5 between the hub 1 and shaft 2 to enable con tinued connection of the circuit located between the slew assemblies without being blocked due to rotation Selector The swivel joint is e...

Page 88: ...DISASSEMBLY AND ASSEMBLY 4...

Page 89: ...Code Criteria mm in Standard dimension Allowable value A 75 3 0 69 2 7 B 25 1 0 Code Criteria mm in Standard dimension Allowable value A 9 0 4 4 5 0 2 Code Criteria mm in Standard dimension Allowable...

Page 90: ...DISASSEMBLY AND ASSEMBLY SERVICE STANDARDS 2 4 SERVICE STANDARDS 4A0AX00 Clearance for pin and bushing...

Page 91: ...0 1 18 6 Arm and boom 35 1 38 7 Arm cylinder and arm 35 1 38 8 Arm cylinder and boom 35 1 38 9 Boom and swing bracket 35 1 38 10 Boom cylinder and boom 35 1 38 11 Boom cylinder and swing bracket 35 1...

Page 92: ...w 1 Use a shim to adjust the clearance between the en gine hood and stopper Clearance a 5 mm 0 2 in Clearance b 6 mm 0 24 in 1 Radiator assembly 8 Drain valve 2 Fan guard 9 Tank 3 Air cleaner assembly...

Page 93: ...h have been coated to prevent them from becoming loose 54 9 N m 40 5 ft lb Press fit the three included spring pins into the assembly to insert them 2 Clearance a 19 mm 0 75 in 15 Coupling 21 Hose 16...

Page 94: ...DISASSEMBLY AND ASSEMBLY DRIVE SYSTEM 3 4 DRIVE SYSTEM 4B0AX00 27 RAD HOC 32 Cushion rubber 28 Plate 33 Plate 29 Elbow 34 Shroud assembly 30 Pipe 35 Nipple 31 Plate...

Page 95: ...move the radiator assembly 1 Slowly hoist up the radiator assembly while slowly pulling it forward so that the shroud does not strike the cooling fan 13 kg 28 lbs 12 Remove the hydraulic pump Removing...

Page 96: ...bdenum disulfide grease on the spline Applying a large amount of grease on the spline hole in the coupling assembly may cause the grease to drip down onto rubber parts and cause the rubber to dete rio...

Page 97: ...ide grease on the spline Bolt 102 N m 75 2 ft lb Pump 13 kg 29 lb Installing the hydraulic pump For installation follow the same procedures as for remov al but in the reverse order Cautions on startin...

Page 98: ...4 DRIVE SYSTEM 4B0AX00 Fuel tank 1 To engine 1 Fuel tank 9 Drain plug 2 Plate 10 Fuel hose 3 Plate 11 Fuel hose 4 Fuel sender 12 Fuel hose 5 Sedimenter 13 Fuel hose 6 Feed pump 14 Fuel hose 7 Air bre...

Page 99: ...the drain plug 9 and let the fuel drain out Fuel tank capacity 22 L 5 8 US gal 4 Disconnect the fuel hoses from the fuel tank sedi menter and fuel pump 5 Take out the bolts holding the fuel tank 1 in...

Page 100: ...DISASSEMBLY AND ASSEMBLY DRIVE SYSTEM 9 4 DRIVE SYSTEM 4B0AX00 Battery 1 Body earth point 1 Earth ground cable 4 Battery 2 Connection to the starter 2 Battery cable 5 Hook bolt 3 Battery clamp...

Page 101: ...rocedures as for remov al but in the reverse order WARNING Wear protective glasses and gloves when working with batteries Batteries generate flammable hydrogen gas which may explode Keep away from fla...

Page 102: ...ttle lever Apply molybdenum disulfide grease to both surfac es of the lever Line up the conical washers 3 so that the indented sides are all on the same side ThreeBond 1324 1 Lever 6 Stopper 2 Wire 7...

Page 103: ...7 4 Pull the throttle lever 1 out to the full throttle side B and position the governor 10 to the full throttle po sition D Adjust the stopper 6 so that the throttle lever 1 makes contact with the st...

Page 104: ...he sprocket once the pipe reaches the side of the idler 5 Slide the crawler over to the side and remove it Rubber crawler One side 55 kg 120 lb Installing the crawler 1 Lift up the machine and insert...

Page 105: ...n ing down the bolt 1 2 Tighten the bolt 1 to the stipulated torque Bolt ThreeBond 1324 Bolt 102 N m 75 2 ft lb 3 Lift up the machine and adjust the crawler tension Removing the idler and track adjust...

Page 106: ...e cover and disconnect the hydraulic hoses 4 Make sure to attach identification labels to each of the hoses and the joints before dis connecting the hoses 4 Hoist up the travel motor 3 temporarily and...

Page 107: ...DISASSEMBLY AND ASSEMBLY SLEW EQUIPMENT 1 4 SLEW EQUIPMENT 4D0AX00 SLEW EQUIPMENT Slew motor Construction ThreeBond 1324 1 Slew motor 2 Cover...

Page 108: ...onnect the hydraulic hoses from the slew motor 1 2 Remove the bolts from the slew motor Bolt ThreeBond 1324 Bolt 102 N m 75 2 ft lb 3 Raise the slew motor 1 and remove it Slew motor 22 kg 49 lb Instal...

Page 109: ...3 4 SLEW EQUIPMENT 4D0AX00 Slew bearing Construction ThreeBond 1324 Grease the tooth surfaces and grease bus with lithium grease EP 2 1 Supply port hole 2 Use a reamer bolt at this position only 3 S...

Page 110: ...for the inner race Bolt ThreeBond 1324 Bolt 102 N m 75 2 ft lb 4 Raise the slew bearing 2 and remove it Slew bearing 18 kg 40 lb Installing the slew bearing To install follow the same procedures as fo...

Page 111: ...DISASSEMBLY AND ASSEMBLY SLEW EQUIPMENT 5 4 SLEW EQUIPMENT 4D0AX00 Swivel joint Construction ThreeBond 1324 1 Swivel joint 2 Stopper...

Page 112: ...2 ft lb 4 Take out the bolts holding the swivel joint 1 in place and remove the swivel joint 1 Bolt ThreeBond 1324 Bolt 26 N m 19 2 ft lb 5 Raise the swivel joint 1 and remove it Swivel joint 12 kg 2...

Page 113: ...ASSEMBLY UPPER FRAME 1 4 UPPER FRAME 4E0AX00 UPPER FRAME Upper frame Construction Apply molybdenum disulfide grease ThreeBond 1324 1 Upper frame 5 Cover 2 Counterweight 6 Cover 3 Bushing 7 Cover 4 Shi...

Page 114: ...0AX00 1 To the slew motor 2 To the slew bearing 3 To the swing cylinder 4 Use the spiral tube to keep the hoses and machine body from coming into contact with each other 8 Grease fitting 12 Hose 9 Ada...

Page 115: ...Bond 1324 6 Disconnect the adapter 15 from the slew bearing 7 Remove all of the fixing bolts for the outer race of the slew bearing except for two at the front of the ma chine and two at the rear When...

Page 116: ...ASSEMBLY UPPER FRAME 4 4 UPPER FRAME 4E0AX00 Covers Construction 1 Engine hood 8 Bracket 2 Side cover L 9 Pin 3 Side cover R 10 Rod 4 Side frame L 11 Plate 5 Side frame R 12 Plate 6 Cover 13 Plate 7...

Page 117: ...e mounting bolts in the hinge and re move the pins Engine hood 11 kg 26 5 lb 2 Take out the mounting bolts holding the side covers L and R in place and remove the side covers 3 Take out the mounting b...

Page 118: ...DISASSEMBLY AND ASSEMBLY UPPER FRAME 6 4 UPPER FRAME 4E0AX00 CANOPY Construction 1 Canopy 2 Roof...

Page 119: ...4E0AX00 Removing the canopy 1 Remove the battery ground cable from the battery terminal 2 Disconnect the electrical wiring from the canopy 3 Take out the mounting bolts Bolt 135 N m 99 6 ft lb 4 Suspe...

Page 120: ...DISASSEMBLY AND ASSEMBLY OPERATING DEVICE 1 4 OPERATING DEVICE 4F0AX00 OPERATING DEVICE Control levers Construction...

Page 121: ...e lever so that it is oriented at a right angle when set to neutral 1 Bracket 17 Bracket 33 Lever 2 Mini pillow bearing unit 18 Lock cylinder 34 Bracket 3 Lever 19 Plate 35 Elbow 4 Lever 20 Plate 36 E...

Page 122: ...EMBLY OPERATING DEVICE 3 4 OPERATING DEVICE 4F0AX00 Dozer blade lever Construction Apply grease to the inside surfaces of the DU bushing during assembly 1 Lever control force 28 N 6 31 lbf 1 Control c...

Page 123: ...limit switch When the limit switch is in the ON posi tion the tip of the switch should be visible from the boot Apply rubber grease 9106 for natural rubber Apply grease to the inside of the bushing du...

Page 124: ...DISASSEMBLY AND ASSEMBLY OPERATING DEVICE 5 4 OPERATING DEVICE 4F0AX00 Pilot valve Right 1 Control box R 2 Bracket 3 Plate 4 Pilot valve Right...

Page 125: ...DISASSEMBLY AND ASSEMBLY OPERATING DEVICE 6 4 OPERATING DEVICE 4F0AX00 Hydraulic piping...

Page 126: ...Table of Connections 1 R1 Pa1 4 1 Pilot valve Right 1 R2 Pb2 4 2 Pilot valve Left 1 R3 Pb1 4 3 Solenoid valve Lever lock 1 R4 Pa2 4 4 Control valve 1 RP SOL B1 3 5 Hydraulic tank 1 RT T1 5 2 L1 Pb8 4...

Page 127: ...DISASSEMBLY AND ASSEMBLY ATTACHMENTS 1 4 ATTACHMENTS 4G0AX001 ATTACHMENTS Hoe attachment Construction...

Page 128: ...g NEVER SEEZ NS Regular grade or an equivalent anti seizing lubricant put the parts together During assembly grease the pins using lithium grease EP 2 supplied from the grease nipples 1 Arm 9 Bucket c...

Page 129: ...4G0AX001 3 After applying NEVER SEEZ NS Regular grade or an equivalent anti seizing lubricant put the parts together 4 Position with the grooved side facing upward 27 Boom bracket 28 Pin 29 Pin 30 Pi...

Page 130: ...DISASSEMBLY AND ASSEMBLY ATTACHMENTS 4 4 ATTACHMENTS 4G0AX001 34 Blade 35 Blade cylinder 36 Pin 37 Plate R 38 Plate L...

Page 131: ...es listed after the names of parts throughout this document are used to refer to the same parts as the numbers listed in the construction di agram and parts lists Removing the bucket 1 Orient the back...

Page 132: ...the hydraulic hoses from the auxil iary line ports 2 Suspend the bucket cylinder 9 temporarily and then pull out the pin and remove the bucket cylinder Bucket cylinder 9 kg 20 lb 3 Place a skid under...

Page 133: ...r the cylinder to the ground d Suspend the boom cylinder 17 temporarily dis connect the rod side from the rod pin 21 and raise the cylinder Boom cylinder 20 kg 44 lb 4 Disconnect the electrical wiring...

Page 134: ...lubricant an anti seizing lubricant to the fixing pin holes on the boom bracket and then insert the pins into the appro priate holes Attach the washer 33 with the side with the grease groove facing up...

Page 135: ...Y HYDRAULIC TANK 1 4 HYDRAULIC TANK 4H0AX00 HYDRAULIC TANK ThreeBond 1324 1 Hydraulic tank 6 Oil plug 11 O ring 2 Lid 7 Suction filter 12 Sight gauge 3 Pipe 8 Return filter 13 Drain plug 4 Bushing 9 O...

Page 136: ...release the inter nal pressure in the hydraulic tank b Drain out the oil from the drain plug 13 Tank level capacity 16 1 L 4 3 US gal 3 Disconnect the low pressure hoses from the hydrau lic tank 4 Di...

Page 137: ...bove the H mark Doing so may cause damage to the hydraulic circuit or cause oil to spurt out If the oil level is accidentally filled to above the H mark stop the engine and allow the hydraulic oil to...

Page 138: ...n the piping Continue bleeding off the air from the piping until the cylinders begin running as directed 3 Release the air in each cylinder With the engine running at slow speed extend and retract the...

Page 139: ...Spring T1 27 Snap ring 39 Coupling 4 Cylinder block 16 Spring holder 28 Snap ring 40 Collar 5 Valve plate 17 Spring guide 29 O ring 41 Bolt 6 Piston 18 Pin 30 O ring 42 O ring 7 Shoe 19 Piston 31 Cap...

Page 140: ...re move coating or thread locking compound on the joints with a wire brush Clean disassembled parts with dedicated cleaning oil Apply hydraulic oil on the sliding surfaces and thin lay er of grease o...

Page 141: ...e cylinder block 4 from the body S 1 6 Remove the swash plate 10 and the oscillating pin 12 from the body S 1 7 Remove the stopper pin A 21 belleville spring 26 and piston 19 from the body S 1 To avoi...

Page 142: ...Y HYDRAULIC PUMP 4 4 HYDRAULIC PUMP 4I0AY001 9 Remove the shaft 3 and oil seal 25 from the body S 1 Tap the shaft with the bearing attached with a plastic hammer to remove it 10 Remove the spring guid...

Page 143: ...the shaft 3 into the body S 1 and secure it in place using the snap ring 27 Be careful not to damage the lip on the oil seal while inserting the part 3 Place the four belleville springs 26 onto the st...

Page 144: ...ing guide 17 and O ring 30 into the body H 2 9 Align the valve plate 5 with the spring pin on the body H and attach it carefully The side of the valve plate with the barbs is the sliding surface that...

Page 145: ...y assembly and replace them with the cap screws M10 40 and tighten those screws down to secure the parts in place Cap screws 51 0 to 64 7 N m 37 6 to 47 7 ft lb 14 Attach the collar 40 and the couplin...

Page 146: ...e Replace Shaft and oil seal mount When the amount of wear on the shaft and oil seal mount is 0 025 mm 0 00098 in deep or more Replace Valve plate When there are abnormal scratches measuring more than...

Page 147: ...od 2 Nut 3 Outlet housing 4 Bucket section 5 Boom section 6 Right travel section 7 Inlet housing 8 Left travel section 9 Arm section 10 Auxiliary section 11 Swing section 12 Switch valve 13 Slew secti...

Page 148: ...ction 5 Boom section 6 Right travel section 7 Inlet housing 8 Left travel section 9 Arm section 10 Auxiliary section 11 Swing section 12 Switch valve 13 Slew section 14 Dozer blade section 15 2nd Auxi...

Page 149: ...ight travel section 7 Inlet housing 8 Left travel section 9 Arm section 10 Auxiliary section 11 Swing section 12 Switch valve 13 Slew section 14 Dozer blade section 15 2nd Auxiliary section 16 3rd Aux...

Page 150: ...1 Screw 12 Plug 13 Poppet 14 Spring 15 O ring Left travel section Swing section 1 Housing 2 Spool 3 O ring 4 Wiper 5 Seal holder 6 Spring holder 7 Spring 8 Screw 9 Cover 10 Cap screw 11 Screw 12 Plug...

Page 151: ...der 6 Cover 7 O ring 8 Cap screw 9 Poppet 10 Spring 11 Plug 12 O ring 13 Poppet 14 Spring 15 Spacer 16 Backup ring 17 Plug 18 Poppet 19 Cap screw 20 O ring 21 Anti drift valve Slew section 1 Housing 2...

Page 152: ...p screw 15 Poppet 16 Spring Bucket section 1 Housing 2 Spool 3 Spring holder 4 Spring 5 Spring holder 6 Cover 7 O ring 8 Cap screw 9 Poppet 10 Spring 11 Plug 12 O ring 13 Poppet 14 O ring 15 Cover Doz...

Page 153: ...1 Spring 12 O ring 13 Backup ring 14 O ring 15 O ring 16 O ring Switch valve 1 Housing 2 Spool 3 Spring holder 4 Spring 5 Spring holder 6 Cover 7 O ring 8 Cap screw 9 Cover 10 Filter 11 Washer 12 Plug...

Page 154: ...Housing 2 Plug 3 Sleeve 4 Main poppet 5 Piston 6 Needle valve 7 Spring 8 Spring 9 Set screw 10 Washer 11 Lock nut 12 O ring 13 Backup ring 14 O ring 15 Backup ring 16 O ring 17 O ring 18 Spring 19 O...

Page 155: ...ring The contact surface is of a metal seal Pay attention not to damage or make a dent on it 3 Remove the main relief valve and the port relief valve and then remove the O ring from the relief valve D...

Page 156: ...ve the O ring 8 from the plug Manually operated section 1 Remove the cap screws the cover 1 and the spool assembly 2 Cap screw 7 3 N m 5 4 ft lb 2 Take out the seal holder and remove the wiper and the...

Page 157: ...hen re move the O ring from the cover Cap screw 7 3 N m 5 4 ft lb 2 Remove the spring holder 2 spring 3 and spring holder 4 3 Take out the cap screws and housing 5 and then re move the O ring from the...

Page 158: ...ring 5 and the main poppet 6 from the sleeve 4 4 Remove the O ring 7 and the backup ring 8 from the seat 9 5 Remove the lock nut 10 the washer 11 and the set screw 12 from the plug 1 and then remove t...

Page 159: ...atches on parts that slide against the seals at both ends Spool does not move smoothly Replace Replace Repair or replace Load check valve Imperfect sealing due to damage to the valve or spring Operate...

Page 160: ...E 1 4 PILOT VALVE 4K2AQ00 PILOT VALVE Construction 1 Casing 7 Seal 13 Spring 2 Plate 8 O ring 14 Spring 3 Spool 9 Spring seat 15 Spring 4 Plug 10 Spring seat 16 Joint 5 Push rod 11 Washer 2 17 Cam 6 P...

Page 161: ...and assembly work in a clean place Provide clean containers to hold parts during disassembly Clean around the ports before disassembly Remove paint around connectors with a wire brush Clean the disas...

Page 162: ...sheet 2 Remove the joint 16 and then remove the plate 2 Use the installation jigs A and B 3 Take out the plugs 4 and remove the push rods 5 6 from the plugs 4 If it is hard to remove use a flathead s...

Page 163: ...e pressure reducing valves and casing holes to ensure the same po sition during reassembly 6 Disassemble the pressure reducing valve a Push in the spring seats 9 10 to compress the springs 14 15 Move...

Page 164: ...ol 3 b Push in the spring seats 9 10 to compress the springs 14 15 Move the spool 3 from the large hole side to the small hole side of the spring seats 9 10 Do not push down the spring seat more than...

Page 165: ...joint Use the installation jigs A and B to install the joint Joint 47 1 2 9 N m 6 Install the cam 17 and the adjusting nut 18 Tighten the adjusting nut 18 to uniformly contact all four push rods When...

Page 166: ...ip is worn 1 mm or more Scratches on the sliding surfaces Replace Replace Plug Imperfect sealing due to damage Repair or replace Controls Looseness in the pin shaft or joint of the controls results in...

Page 167: ...DISASSEMBLY AND ASSEMBLY PROPORTIONAL CONTROL SOLENOID VALVE 1 4 PROPORTIONAL CONTROL SOLENOID VALVE 4K4AQ00 PROPORTIONAL CONTROL SOLENOID VALVE Construction 1 Proportional control solenoid 2 Bolt...

Page 168: ...r abnormal wear or seizing Re move any burrs with sandpaper Do not move adjusting screws unless absolutely nec essary Disassembly 1 Remove the bolts 2 and remove the proportional control solenoid 1 Bo...

Page 169: ...SOLENOID VALVE 3RD AUXILIARY LINE PIPING 1 4 SOLENOID VALVE 3RD AUXILIARY LINE PIPING 4K6AV01 SOLENOID VALVE 3RD AUXILIARY LINE PIPING Construction 1 Plug 5 Spring 2 Solenoid coil 6 Spool 3 O ring 7 B...

Page 170: ...ions After each disassembly replace all seals and apply a thin layer of grease to them Check each part for abnormal wear or seizing Re move any burrs with sandpaper Do not move adjusting screws unless...

Page 171: ...ce Replace Replace Push rod Tip is worn 1 mm or more Scratches on the sliding surfaces Replace Replace Plug Imperfect sealing due to damage Repair or replace Controls Looseness in the pin shaft or joi...

Page 172: ...VE LEVER LOCK 1 Plunger 2 Spring 3 Plug 4 Spring 5 Spool 7 Adjust screw 8 Cover 9 Plug 10 Plunger 11 Spring 12 Solenoid 13 Body 15 Plug 16 Plug 17 Cap screw 18 Cap screw 19 Washer 20 Nut 22 O ring 23...

Page 173: ...o let the push rod drop out When assembling be sure to fit the O rings 22 to the solenoids 12 before installing them on the body 13 3 Take out the plugs 15 and remove the O rings 24 Plug 26 5 N m 19 5...

Page 174: ...n and adjustment Checking the parts Parts Judgment criteria Treatment Coil When the solenoid is burned or short circuited or has a wire break Wiring short circuit or wire break Replace Replace Body Sc...

Page 175: ...SEMBLY AND ASSEMBLY SELECTOR VALVE 1 4 SELECTOR VALVE 4K8AQ00 SELECTOR VALVE Construction 1 Body 2 Rotor 3 Lever 4 Bolt 5 O ring 6 O ring 7 O ring 8 O ring 9 Spring pin 10 Snap ring 11 Cap screw 12 Wa...

Page 176: ...ld parts during disassembly Clean around the ports before disassembly Remove paint around connectors with a wire brush Clean the disassembled parts with wash oil Put alignment marks on all parts to re...

Page 177: ...ELECTOR VALVE 3 4 SELECTOR VALVE 4K8AQ00 3 Remove the rotor 2 with the lever 3 attached from the body 1 4 Remove the cap screws 11 and remove the lever 3 from the rotor 2 5 Remove the spring pins 9 fr...

Page 178: ...DISASSEMBLY AND ASSEMBLY SELECTOR VALVE 4 4 SELECTOR VALVE 4K8AQ00 6 Remove the O rings 5 6 7 8 from the body 1 and rotor 2...

Page 179: ...4 SELECTOR VALVE 4K8AQ00 Assembly 1 Install the spring pins 9 in the body 1 Lightly tap with a hammer 2 Fit the O rings 5 6 to the body 1 3 Install the spring pin 9 in the rotor 2 Lightly tap with a h...

Page 180: ...OR VALVE 6 4 SELECTOR VALVE 4K8AQ00 5 Attach the lever 3 to the rotor 2 Tighten the cap screws 11 Cap screw 4 9 to 6 86 N m 6 Install the rotor 2 to the body 1 7 Fit the snap ring 10 8 Attach the bolt...

Page 181: ...d Tip is worn 1 mm or more Scratches on the sliding surfaces Replace Replace Plug Imperfect sealing due to damage Repair or replace Controls Looseness in the pin shaft or joint of the controls results...

Page 182: ...12 Piston packing 13 Wear ring 14 Set screw 15 Ball 16 Cushion bearing 17 Cushion seal 18 Stopper 19 Snap ring 20 Plug 21 O ring 22 Dust seal 23 Grease fitting 24 Grease fitting Arm cylinder 1 Tube 2...

Page 183: ...O ring 10 Backup ring 11 O ring 12 Piston 13 Wear ring 14 Piston packing 15 Set screw 16 Ball 17 Plug 18 O ring 19 Dust seal 20 Grease fitting 21 Grease fitting Dozer blade cylinder 1 Tube 2 Bushing 3...

Page 184: ...ng 3 Piston rod 4 Rod cover 5 Bushing 6 Rod packing 7 Backup ring 8 Dust seal 9 O ring 10 Backup ring 11 O ring 12 Backup ring 13 O ring 14 Cushing ring 15 Spacer 16 Stopper 17 Piston 18 Piston packin...

Page 185: ...STKM13C A B C D E Boom 35 45 54 5 35 Arm 35 45 54 5 35 Bucket 30 40 49 5 30 Blade 30 40 49 5 30 Swing 30 40 49 5 30 A B C D E F Boom 60 5 58 3 40 20 8 12 3 20 Arm 60 5 58 3 40 20 8 12 3 20 Bucket 50 5...

Page 186: ...m spurting out 3 Disengage the anti rotation lock of the rod cover Since the anti rotation lock is built into the cylinder tube take care not to damage the tube when disen gaging the lock 4 Loosen the...

Page 187: ...bearing 4 Boom cylinder swing cylinder Only for boom cylinder c to f c Remove the snap ring 4 When removing lightly tap the ring with a plastic hammer while taking care not to damage the pis ton rod o...

Page 188: ...e piston packing from the piston Rod cover 1 Remove the O rings 20 and 21 and the backup ring 22 from the outer diameter section of the rod cover Only for swing cylinder 2 Remove the cushion ring a Re...

Page 189: ...dust seal 26 Tap alternately on several points around the inner circumference of the metal ring gradually pushing the seal out of the groove Clevis 1 Remove the dust seals from the tube and the piston...

Page 190: ...ngs 28 into the piston rod and tube 2 Install the dust seal by using the supporting metal 29 Rod cover 1 Install the rod packing a Install the backup ring 16 Bucket cylinder Swing cylinder b Install t...

Page 191: ...the backup ring 22 and the O rings 20 and 21 Make sure that the cut portion of the backup ring does not get out of place Piston 1 Install the piston packing on the piston a Install the O ring 34 If th...

Page 192: ...ng 10 just enough so that it can be installed on the piston in axial direction Piston rod assembly 1 Install the rod cover assembly on the piston rod Only for swing cylinder 2 Install the cushion bear...

Page 193: ...the ball 2 tighten the set screw 1 and caulk at two points with a punch Piston setscrew Cylinder assembly 1 Secure the tube in a level position and insert the piston rod assembly into the tube When i...

Page 194: ...13 4 Cylinders Disassembly and assembly 4L0AX00 Cylinders 3 Bend down the lock rib on the tube and fit it into the notch of the rod cover to lock it...

Page 195: ...diam eter at both ends on V blocks b Set a dial gauge at the center between the two blocks c Rotate the rod and take a reading of the maximum and minimum run out indicated by the dial gauge If the be...

Page 196: ...Disconnect the extension side hose 2 Apply test pressure to the retraction side for 3 min utes 3 Measure the amount of oil that has leaked from the extension side The amount of leakage should be 1 mL...

Page 197: ...c 2 Flange holder 13 Retainer 24 Center disc 3 Shaft 14 Bearing 25 Oil seal 4 Cylinder block 15 Bearing 26 Spring pin 5 Valve plate 16 Break piston 27 Ball 6 Piston 17 Spring 28 Pin 7 Shoe 18 Snap rin...

Page 198: ...2 Cover 12 Needle 22 O ring 3 Carrier 2 13 Floating seal 23 O ring 4 Planet gear B1 14 O ring 24 Plug 5 Planet gear B2 15 Bearing 25 Thrust washer 6 Sun gear S1 16 Thrust washer 26 Plug 7 Pin 17 Snap...

Page 199: ...Y TRAVEL MOTOR 3 4 TRAVEL MOTOR 4M0AX00 Valves 1 Spool 7 Shuttle spool 13 Plug 2 Check valve 8 Spring 14 O ring 3 Spring guide 9 Spring 15 O ring 4 Spool 10 Plug 16 O ring 5 Spool 11 Plug 17 O ring 6...

Page 200: ...and hydraulic motor 1 Secure the valve body in a vise and insert the spool into the valve body Insert an aluminum plate or the like between the motor and the vise to prevent the outer surface of the...

Page 201: ...ring 5 into the valve body 5 Attach the O rings to the plugs and tighten the plugs on each end of the body Plug 46 to 51 N m 33 9 to 37 6 ft lb 6 Insert the shuttle and the needles on both sides 7 Att...

Page 202: ...4M0AX00 8 Attach the O rings large and small to the valve body 9 Press fit the oil seal into the flange holder Do not disassemble the oil seal unless necessary Add grease between the lips of the oil...

Page 203: ...sassembled Be careful not to damage the oil seal with the shaft 13 Place the balls and the swash plate in the flange holder Apply hydraulic oil to the sliding surfaces of the swash plate 14 Mount the...

Page 204: ...hoe holder assembly 17 Place the shoe holder assembly into the cylinder block to form the cylinder block assembly 18 Insert the cylinder block assembly into the flange holder Insert the cylinder block...

Page 205: ...side 22 Attach the brake piston assembly to the flange hold er Apply grease to the O rings and make sure that the seal material does not get caught in the parts 23 Attach the valve plate to the flange...

Page 206: ...and tighten the screws Screw 28 4 to 30 4 N m 20 9 to 22 4 ft lb Insert an aluminum plate or the like between the motor and the vise to prevent the outer surface of the valve body from becoming damage...

Page 207: ...e seal ring pin with the pin hole on the housing Apply grease to the O ring 4 Attach the housing and insert the hydraulic motor Tighten the housing and the hydraulic motor flanges with a C clamp or a...

Page 208: ...l diame ter must be on the motor side 8 Attach the thrust washer and secure it in place with the snap rings Do not spread the snap ring open more than nec essary Insert the snap ring with the edge fac...

Page 209: ...ASSEMBLY TRAVEL MOTOR 13 4 TRAVEL MOTOR 4M0AX00 11 Insert the carrier 2 assembly into the housing 12 Attach the O ring to the housing 13 Place the ring on the cover Apply grease 14 Add 330 ml 11 2 fl...

Page 210: ...the notch on the housing with the drain plug hole 16 Attach the snap ring to secure the cover in place Set a flat head screwdriver against the edge of the snap ring to hammer it in around its circumfe...

Page 211: ...plate Sliding surface If there are abnormal scratches wear or seizure on the surface Replace O rings Replace Shaft Oil seal surface If there are abnormal scratches wear or seizure on the surface Repl...

Page 212: ...ve body If there are abnormal scratches wear or seizure on the surface Sliding surface with the check valve If there are abnormal scratches wear or seizure on the surface Replace both the spool and ch...

Page 213: ...O ring 14 Pinion gear 25 Rear bearing 36 Ball 4 Shaft face seal 15 Plug 26 Socket bolt 37 Plug 5 Inner face seal 16 Break piston 27 Gerolor 38 Spring 6 Outer face seal 17 Ring 28 Drive gear 39 Plug 7...

Page 214: ...DISASSEMBLY AND ASSEMBLY SLEW MOTOR 2 4 SLEW MOTOR 4N0AX00 Brake valve 1 Plunger 2 Pinion 3 Spring 4 Timer orifice 5 Damper orifice...

Page 215: ...ly hydraulic oil on the sliding surfaces and thin lay er of grease on the seals before assembly Replace seals with new ones after each disassembly Check each part for abnormal wear or seizing Re move...

Page 216: ...OTOR 4 4 SLEW MOTOR 4N0AX00 4 Remove the valve plate and the valve drive gear 5 Remove the gerolor 6 Remove the drive 7 Take out the socket bolts and remove the flange mounting Do not disassemble the...

Page 217: ...EMBLY AND ASSEMBLY SLEW MOTOR 5 4 SLEW MOTOR 4N0AX00 8 Remove the spring from the flange mounting 9 Remove the brake piston 10 Remove the ring 11 Remove the center disc 20 the friction disc 19 and the...

Page 218: ...e the snap ring 13 Remove the pinion gear Pull out the shaft assembly with a press using a support Do not disassemble the ball bearing and collar unless necessary 14 Remove the X ring from the bearing...

Page 219: ...o the bearing housing 2 Insert the shaft into the bearing housing Using a support press fit the shaft with a press 3 Attach the snap ring to secure the front bearing in place 4 Insert the center disc...

Page 220: ...to the bearing housing 6 Fit the O ring to the piston and then insert them into the housing 7 Fit the O ring to the flange mounting and insert the spring Apply grease to the spring and avoid dropping...

Page 221: ...Fit the O rings large and small to the flange mount ing and attach them to the gerolor When installing be sure to align the flange mount ing with the gerolor drain hole 12 Insert the valve drive into...

Page 222: ...alve Important The valve timing determines the rotation direc tion of the motor Carefully attach the valve by referring to the figure below 15 Insert the plug spring and ball into the valve hous ing P...

Page 223: ...ach the O rings large and small to the housing 20 Attach the valve housing to the valve while prevent ing the balancing plate from becoming disconnect ed by pushing against it with a thin bar such as...

Page 224: ...ASSEMBLY AND ASSEMBLY SLEW MOTOR 12 4 SLEW MOTOR 4N0AX00 22 Insert the O ring into the housing 23 Attach the brake valve to the hydraulic motor and tighten with socket bolts Socket bolt 54 N m 39 3 ft...

Page 225: ...Shaft If there is pitting abrasion etc occurring on the surfaces of the gear teeth Replace If there is flaking or pitting occurring on rolling surfaces Replace Ball bearing If there are abnormalities...

Page 226: ...WIVEL JOINT CONSTRUCTION 1 Slipper Seal 2 O ring 3 O ring 4 O ring 5 O ring 6 Backup Ring 7 Dust Seal 8 Cover 9 Cover 10 Spring 11 O ring 12 O ring 13 Backup Ring 14 Washer 15 Hub 16 Shaft 17 Flange 1...

Page 227: ...mal wear or seizing and use sandpaper etc to remove any burrs sharp edges etc Do not turn adjusting screws if not required Apply hydraulic oil to sliding surfaces and apply a thin coating of grease to...

Page 228: ...if the shaft rotates 2 Remove the O ring 2 snap ring 3 and thrust ring 4 During assembly make sure the snap ring fist securely in the groove 3 Remove the shaft 5 from the hub Place a knock pin 6 agai...

Page 229: ...inside diameter of the hub Check the positions of the seals in the struc tural drawing Use an O ring tooth or eyeleteer with a sharp point on the end etc Do not deform or bend the slipper seal strong...

Page 230: ......

Page 231: ...nnect the pipe 3 from the hydraulic pump 2 to the shaft 1 side port 2 Connect the pressure gauge 5 to the hub 4 side Increasethepressuregraduallyto20 6MPa 2900PSI while adjusting the relief valve 6 Pe...

Page 232: ...TROUBLESHOOTING 5...

Page 233: ...rive the machine yourself and confirm the faulty condition Determine if it is really faulty by referring to the performance criteria Note that such determination may differ depending on the person Imp...

Page 234: ...hydraulic oil level Check the hydraulic oil tank level 4 Disassembly and assembly Hydraulic oil tank When adding use the same brand of oil currently being used 2 Service data Fuel and lubricant table...

Page 235: ...Normal 5 Piston pump is faulty Repair or replace the faulty piston pump 1 Check the hydraulic oil level 4 Disassembly and assembly Hydraulic oil tank 2 Add hydraulic oil No operation is possible 1 Ch...

Page 236: ...adually tightening the set screw If the pressure does not increase after tightening the setscrew by 1 4 turn the relief valve is faulty 5 Piston pump is faulty If the inside of the pump is excessively...

Page 237: ...the lever lock sole noid valve Faulty Repair or replace the lever lock solenoid valve Normal 5 Check the pilot relief valve Faulty Repair or replace the pilot re lief valve Normal 6 Check the pilot va...

Page 238: ...ck solenoid valve Check according to the following procedure a Turn the starter switch to the ON position b Lightly press down the protruding part on the sole noid valve c Move the lever stand to turn...

Page 239: ...e Fit the pressure gauge to the hose just disconnected to measure the pilot pressure Fit the plug to the cylinder port from which the hose was disconnected If the measured value is within the specific...

Page 240: ...avel motor Faulty Repair or replace the travel motor 1 Check the operation of actuators other than of the travel motor If the right or left travel is impossible operate each ac tuator of the devices l...

Page 241: ...measured value is within specifications the swivel joint is normal 2 Service data Performance criteria 5 Check the counter balance valve If neither forward nor reverse travel is possible the spool 1 o...

Page 242: ...ol opera tion Faulty Repair or replace the housing block Normal 4 Switch the discharge hos es between the pumps Veering is changed to the opposite side Repair or replace the pumps Replace the hydrauli...

Page 243: ...ck the pump 4 Disassembly and assembly Hydraulic pump 5 Test by switching the main relief valves Switch the main relief valves between the right travel circuit and the left travel circuit and operate...

Page 244: ...Repair or replace the 2nd speed solenoid valve Normal 5 Check the swivel joint Faulty Repair or replace the swivel joint Normal 6 Check the 2nd speed control valve Faulty Repair or replace the 2nd sp...

Page 245: ...part on the sole noid end c Move the lever stand to turn on the limit switch d If you feel vibration under your fingers when the spool is moved and the circuit is switched the sole noid valve is norma...

Page 246: ...e set pressure Normal Pressure does not rise Repair or replace the relief valve 5 Check the slew motor Faulty Repair or replace the slew motor Normal Slew bearing is faulty Replace 1 Check the operati...

Page 247: ...uge to the discharge port on the con trol valve Operate the lever slew and measure the pressure If the measured value is as below the spool is nor mal Supply pressure 20 0 MPa 2901 PSI 4 Check the sle...

Page 248: ...the slew motor 1 Check the pilot valve It is likely that only the pilot valve spool on the side where slewing is not possible is faulty No slewing is possible 2 Check the pilot valve 2 Check the spoo...

Page 249: ...sure Adjust to set pressure Normal Pressure does not rise Repair or replace the relief valve 5 Check the slew motor Faulty Repair or replace the slew motor Normal Slew bearing is faulty Replace 1 Is t...

Page 250: ...lew relief valve pressure Adjust to set pressure Pressure does not rise Repair or replace the relief valve 1 Is the amount of overrun when slewing stops within specs 2 Service data Performance criteri...

Page 251: ...is released after operation Disconnect the hose connecting the control valve slew block and the slew motor from the control valve Fit the pressure gauge to the discharge port on the control valve Oper...

Page 252: ...w Adjust the relief valve pressure of the slew brake valve Adjust to set pressure Normal Pressure does not rise Repair or replace the slew re lief valve 3 Check the slew motor Faulty Repair or replace...

Page 253: ...hooting Overall machine All sys tems working but insufficient force 1 Check the operation of actuators other than of the boom cylinder Normal 2 Check the pilot valve Faulty Repair or replace the pilot...

Page 254: ...the pres sure Supply pressure 21 0 MPa 3045 PSI 4 Test by replacing the port relief valve Replace the port relief valve in question with a normal port relief valve If the boom cylinder operates with...

Page 255: ...replacing the port relief valve The boom cylinder does not move 4 Test by replacing the port relief valve 1 Is the speed of the boom cylinder within specs Within specs Normal Out of specs 2 Check the...

Page 256: ...only and drain oil from the piping Insert a plug 1 into the disconnected hose c Retract the arm cylinder to lift the bucket off the ground If oil leaks from the cylinder piping from which the hose was...

Page 257: ...t to raise the machine body If oil leaks from the cylinder piping from which the hose was disconnected and the boom cylinder rod extends the cylinder is leaking internally If no oil leaks from the cyl...

Page 258: ...pressure is low and the flow rate is low If the load check valve is faulty the oil will temporarily flow backward due to the load applied to the boom cylinder As a result the boom temporarily drops 2...

Page 259: ...st by replacing the port relief valve The boom cylinder does not move 4 Test by replacing the port relief valve 1 Is the spontaneous drop of the boom cylinder with in specs Within specs Normal Out of...

Page 260: ...tuators other than of the arm cylinder Determine if only the arm cylinder is faulty by checking the operation of actuators for the devices listed in the table on the right If it is faulty check the ma...

Page 261: ...e in question with a normal port relief valve If the arm cylinder operates with the re placement valve the port relief valve used on the boom side is faulty Make sure to return the port relief valve t...

Page 262: ...ment valve Problem solved The port relief valve faulty Repair or replace the port re lief valve No change 5 Check for leak inside the arm cylinder Faulty Repair or replace the arm cyl inder 1 Is the s...

Page 263: ...rm cylin der and then lower the bucket to the ground b Disconnect the two hoses connected to the cylin der Insert plugs 1 into the disconnected hoses and the cylinder piping c Raise the boom and lift...

Page 264: ...within specs Within specs Normal Out of specs 2 Check the arm cylinder Faulty Repair or replace the arm cyl inder 1 Is the spontaneous drop of the arm cylinder within specs 2 Service data Performance...

Page 265: ...listed in the table on the right If one of them is faulty check the main relief valve and the hydraulic pump main 5 Troubleshooting Overall machine All systems working but insufficient force 2 Check t...

Page 266: ...replacement valve the port relief valve used on the bucket side is faulty 5 Check the bucket cylinder Switch between the arm hose and the bucket hose connected to the piping at the boom foot Move the...

Page 267: ...e housing block 1 Is the spontaneous drop of the bucket cylinder within specs 2 Service data Performance criteria 2 Check the bucket cylinder a Fully extend the bucket cylinder completely re tract the...

Page 268: ...roke 7 mm 0 3 in If the spool is sticking try to take it out If it can t be taken out or is scratched replace the housing block Note that the faulty spool operation could be caused by the loosened bol...

Page 269: ...ng is inoperable it is likely that for eign matter is caught in the anti cavitation valve or the valve is sticking 5 Check the swing cylinder Disconnect the hose connecting the swing cylinder and the...

Page 270: ...roubleshooting Boom swing Swing cylin der does not move 2 Check the spool opera tion 3 Check the linkage 5 Troubleshooting Boom swing Swing cylin der does not move 3 Check the linkage 1 Check the oper...

Page 271: ...in question with a port relief valve used for a normal arm If the dozer blade cylinder operates normally with the re placement valve the port relief valve used on the dozer blade side is faulty 5 Che...

Page 272: ...ttachments raise the machine then lower the blade fully b Disconnect the hose from the rod side of the doz er blade cylinder and drain oil from the piping Install the plug 1 on the hose just disconnec...

Page 273: ...lade try replacing the port relief valve with a normal one If the blade can support the ma chine after this replacement then the port relief valve is faulty 3 Inspect the swivel joint and the control...

Page 274: ...he hydraulic pump main 5 Troubleshooting Overall machine All systems working but insufficient force 2 Check the spool operation 5 Troubleshooting Traveling Right or left travel is impossible 2 Check t...

Page 275: ...inder operation can be done by operating the lever Therefore checking procedure for the spanner cylin der is similar to that for the blade cylinder 5 Troubleshooting Dozer blade 1 Check the operation...

Page 276: ...rrectly switched to the blade side Spool stroke A 6 mm 0 2 in b Disconnect the hose between the swivel joint and the spanner cylinder from the cylinder side Install a pressure gauge on the hose just d...

Page 277: ...s too high Replace with hydraulic oil of proper viscos ity Pump volume efficiency becomes low Replace the pump Hydraulic oil tank level is too low Add oil to the specified level Clogging in the suctio...

Page 278: ...ide is loose and sucking air Retighten each joint Cavitation is being produced due to too high viscosity of the hydraulic oil Replace with hydraulic oil of proper viscos ity Pump and engine are not ce...

Page 279: ...e to the increased oil temperature Try to decrease the oil temperature If the relief valve is started often find the cause and correct it Lubrication is disabled due to deterio rated oil Oil should be...

Page 280: ...rew in the adjuster screw If loose set the adjustment again and fasten with a lock nut Foreign matter is caught in the seat of the port relief valve or of the anti cavita tion valve and thus the oil i...

Page 281: ...g is too large Replace the spool and the casing assem bly Too much play in the handle Disassemble and assemble or replace The secondary pressure is unstable The sliding part is not smooth Repair or re...

Page 282: ...break Replace Coil assembly short circuit or wire break Replace Foreign matter is caught in the spool Overhaul and repair or replace Damage on the outer circumference of the spool Overhaul and repair...

Page 283: ...the leak persists after replacing the seals replace the piston rod Peeling of the hard chromium plated surface Re plate the hard chromium plating Oil leaking around the rod cover O ring is damaged Rep...

Page 284: ...are large High pressure oil is leaking from the drain port because the motor s sliding part is worn out Replace the abnormally worn part if any Bearing is worn out Replace the abnormally worn part if...

Page 285: ...the spring Bolt for manual releasing is being fitted Remove the bolt for manual release and fit the plug Abnormal heat generation due to brake drag Release of braking is faulty Oil leak due to O ring...

Page 286: ...e motor Direction of rota tion is incorrect Piping Motor valve timing Piping is incorrectly connected Motor valve timing is incorrect Correct the piping Set the valve timing correctly Oil is leaking L...

Page 287: ...Other 6...

Page 288: ...MONOCHROME LCD CLUSTER PANEL DISPLAY AND LCD SPECIFICATIONS WITHOUT A CAN 1 6 6S3AY00 Monochrome LCD Cluster Panel Display and LCD Specifications Without a CAN...

Page 289: ...en 3 Panel Display Water Temperature Gauge 4 Panel Display Fuel Gauge 5 Panel Display Function Warning Lamps 6 Normal Screen 7 Main Menu Screen 8 Data Selection Screen 9 Data Screen TRIP METER 10 Data...

Page 290: ...amps Water temperature warning light Charge warning light 2nd speed travel light Engine oil warning light Glow light Low fuel level warning light System warning light LCD 1 Hour meter 2 Clock 3 Switch...

Page 291: ...10 50 3 7 20 68 2 45 30 86 1 66 40 104 1 15 50 122 0 811 60 140 0 584 70 158 0 428 80 176 0 318 90 194 0 24 95 203 0 2118 100 212 0 1836 105 221 0 1627 110 230 0 1417 120 248 0 1108 80 C t 95 C 95 C...

Page 292: ...e values are used for the output values The average amount of movement over a span of 120 seconds mea sured in 100 ms intervals Float position FULL 3 4 1 2 1 4 EMPTY Resistance 10 17 7 38 61 7 90 Allo...

Page 293: ...Turns ON for 3 s when ACC is ON Turns ON when the glow relay is ON turns OFF if a Start signal is received within 3 s of being ON Turns ON when the glow relay is ON OFF when the glow relay is OFF and...

Page 294: ...n 2 for a short while Turns on the work light Pressing and holding down Button 2 for 2 seconds Toggles the display to the trip meter In Normal screen mode Pressing Button 3 for a short while Moves the...

Page 295: ...Menu screen Pressing Button 3 on the Main Menu screen for a short while moves the display to the Normal screen Pressing Button 2 on the Main Menu screen for a short while moves the bar to the next opt...

Page 296: ...splay to the Data Selection screen Pressing Button 3 on the Data Selection screen for a short while moves the display to the Main Menu screen Pressing Button 2 on the Data Selection screen for a short...

Page 297: ...r Pressing Button 2 on the DATA screen TRIP METER for a short while moves the bar to the next option The setting value for the highlighted option flashes Pressing and holding down Button 1 on the DATA...

Page 298: ...8 80 176 0 318 90 194 0 24 100 212 0 1836 110 230 0 1417 120 248 0 1108 Pressing Button 1 while WATER TEMP is highlighted moves the display to the DATA screen WATER TEMP Pressing Button 3 on the Data...

Page 299: ...play to the Settings Selection screen Pressing Button 3 on the Settings Selection screen for a short while moves the display to the Main Menu screen Pressing Button 2 on the Settings Selection screen...

Page 300: ...hile causes the setting value of the highlighted option to increase Pressing and holding down Button 2 for 1 second causes the setting value of the highlighted option to increase at high speed Setting...

Page 301: ...he highlighted option between being checked and not checked Pressing and holding down Button 1 on the Setting screen for 2 seconds completes configuration of the alarm and moves the display to the Set...

Page 302: ...g value of the highlighted option to increase at high speed Setting range for hours 1 to 24 Toggles from 1 to 2 to 24 and back to 1 where it starts start over Setting range for minutes 00 to 59 Toggle...

Page 303: ...Button 2 for 1 second causes the setting value of the highlighted option to increase at high speed The contrast changes as the setting value of the bar increases The contrast can be set to any of the...