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Takeuchi TB 250, Workshop Manual, Page: 294 / 352

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Takeuchi TB 250 Workshop Manual Download Page 294

5-3

5

OVERALL MACHINE

TROUBLESHOOTING

OVERALL MACHINE

No operation is possible.

1

Check  the  hydraulic  oil 
level

Insufficient

Add hydraulic oil.

Sufficient

2

Check 

the 

hydraulic 

pump

Faulty

• Repair  or  replace  the  hy-

draulic pump.

• Replace the coupling.

  1.  Check the 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”

  2.  Check the hydraulic pump.

 •  Check the discharge pressure of the pumps P1 and 

P2 (piston pumps).

 “2. Service data, Performance criteria”
 “5. Troubleshooting, Piston pump”

 •  Check the pumps P3 and P4 (gear pumps).

 “2. Service data, Performance criteria”
 “5. Troubleshooting, Piston pump”

2DAA01Z

P1

P2

P3

P4

Summary of Contents for TB 250

Page 1: ......

Page 2: ...by a person sitting in the operator s seat Machine serial number The machine serial number is stamped on the identi cation plate Be sure to include this number when sending a report or inquiry or whe...

Page 3: ...1 1 SAFETY 1 Safety alert symbol 1 2 Safety precautions 1 3 Cautions when working 1 9...

Page 4: ...tentially hazard ous situation which if not avoided could result in seri ous injury or death CAUTION The word CAUTION indicates a potentially hazard ous situation which if not avoided may result in mi...

Page 5: ...ing with a grinding polishing sanding machine hammer or compressed air as metal fragments or other objects could scatter in such an environment Wear hearing protectors when operating the machine Loud...

Page 6: ...ne may accidentally start moving re sulting in severe injury to the maintenance personnel Make sure that the working equipment has been low ered to the ground and the engine has been turned off before...

Page 7: ...falling from machine clear the foot ing 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 machine Never jump...

Page 8: ...he operating season Handling of hoses Oil leak or fuel leak can cause a re Do not twist bend or hit the hoses Never use twisted bent or cracked pipes tubes or hos es otherwise they may burst Retighten...

Page 9: ...he 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 internal pressur...

Page 10: ...cting the battery wiring always discon nect it from the earth side When connecting connect the earth side last Loose battery terminals may result in sparks Be sure to fasten terminals tightly Make sur...

Page 11: ...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 overlapped by about 10 mm When removing instal...

Page 12: ...twist ed hose oil leak hose breakage or damage to the hose tting can result Be sure that the hydraulic hoses are not contacting sharp objects or each other This could cause surface aws on the hoses re...

Page 13: ...imensional drawing 2 2 Speci cations tables 2 4 Lubricant and Fuel chart 2 9 Performance criteria 2 11 Tightening torque 2 21 Hydraulic circuit diagram 2 25 Electric circuit diagram 2 33 Wire harness...

Page 14: ...0 1690 C 2515 2520 2515 2515 D 1435 1435 1435 1435 E 630 625 630 630 F 1985 1920 1985 1985 G 2500 2425 2500 2500 H 1840 1840 1840 1840 J 400 400 400 400 K 335 330 335 335 L 2170 2170 2195 2235 M 1680...

Page 15: ...Unit mm Standard arm Middle arm Long arm Rubber crawlers Rubber crawlers Rubber crawlers A 5850 5990 6135 B 5705 5850 5995 C 3475 3625 3785 D 2725 2860 2990 E 3935 3985 4055 F 5625 5715 5800 G 3990 4...

Page 16: ...rking equipment height in transept position Cab mm 2515 Canopy mm 2515 Dimensions of base machine Overall length of base machine mm 2965 Overall width of base machine mm 1840 Overall width of base mac...

Page 17: ...control valve 10 valves in series standard spec Operation type Hydraulic oil lter Type Glass ber lter type Filter precision BETA10 6 Installing position Return Circuit In Hydraulic tank Hydraulic oil...

Page 18: ...h a counter balance valve Parking brake Type Wet friction plate type Undercarriage Track shoe Type Rubber track Steel crawler with triple grouser Number of shoes One side Qty 74 38 Shoe width mm 400 4...

Page 19: ...ont offset mm 1680 Overall height at minimum radius of equipment and attachment mm 4320 Overall height of equipment at maximum front offset mm 4320 Offset distance of bucket Left mm 715 Right mm 710 7...

Page 20: ...r Number of cylinders Qty 1 Bore mm 110 Stroke mm 175 Dimensions Dozer blade dimensions Width mm 1840 Height mm 430 Cutting angle degree 69 Distance between the front end of dozer blade and the axis o...

Page 21: ...50 hrs As required Working equip ment Daily or every 10 hrs Levers When required LUBRICANT AND FUEL CHART Select the appropriate fuel lubricant and grease according to the temperature by referring to...

Page 22: ...least 12 C below the lowest expected ambient temperature Use a light oil that has a cetane number of 45 or higher When operating at a very low temperature or at a high alti tude a higher cetane numbe...

Page 23: ...tracted s Extended s Dozer blade cylinder Retracted s 2 5 0 4 3 2 Extended s 2 7 0 4 3 4 Retracted s Extended s Slew time Normal speed s 12 0 1 0 14 2 Slow speed s Overrun when slewing stops mm 120 50...

Page 24: ...p mm 110 0 220 Bucket tip With emergency shut off valve mm 80 0 160 Backlash mm 17 10 34 Lever play Right operating lever mm 4 0 Left operating lever mm 4 0 Travel mm 4 0 5 0 Dozer blade mm 25 0 Lever...

Page 25: ...ht travel Pressure 21 0 MPa Test port P2 Boom Pressure 21 0 MPa Test port P2 Bucket Pressure 21 0 MPa Test port P2 Pump P2 Left travel Pressure 21 0 MPa Test port P1 Arm Pressure 21 0 MPa Test port P1...

Page 26: ...relief pressure Adjusting method 1 Loosen the locknut 2 and turn the setscrew 1 to adjust the set pressure To increase the set pressure turn the setscrew clockwise To decrease the set pressure turn th...

Page 27: ...sure Pilot pressure Measuring method Engine Maximum R P M Hydraulic oil temp 50 60 C Mount pressure gauge on the pressure detection port and measure the pilot relief pressure Adjusting Method 1 Loosen...

Page 28: ...r in motion Starting after a distance of 5 meters measure the time required to travel 10 meters Do this on level ground Travel posture Fully extend the arm and bucket cylinders and adjust the hoe atta...

Page 29: ...ired for the next 2 rota tions Overrun when slewing stops Engine Maximum R P M Hydraulic oil temp 50 60 C Measurement posture Same as that for measuring slew time Draw matching marks on the outer race...

Page 30: ...ition the arm horizontally and rest the dozer blade on the ground Then measure the time required for the arm cylinder to completely retract extend from a fully extended state retracted state Bucket cy...

Page 31: ...cylinder and adjust the bucket pin position to the same height as the boom foot pin Maintain this position for 10 minutes then measure the change in rod length and the distance the bucket tip falls S...

Page 32: ...hen adjust the boom foot pin and the bucket pin so that they are the same height 2 Place the dial gauge on the undersurface of the slew bearing outer teeth located forward of the machine and then set...

Page 33: ...4 24 5 4 9 29 4 2 9 3 8 49 0 4 9 53 9 5 4 1 2 58 8 4 9 88 3 8 8 3 4 117 7 4 9 147 1 14 7 1 137 3 4 9 196 1 19 6 Pipe outer diameter mm Tightening torque N m 8 34 3 4 9 10 41 7 2 5 12 58 8 4 9 15 88 3...

Page 34: ...4 7 127 5 12 7 1 196 1 19 2 171 6 17 2 Nominal thread diameter G Tightening torque N m 1 8 19 6 2 0 1 4 34 3 4 9 3 8 53 9 4 9 1 2 63 7 4 9 3 4 93 2 4 9 1 107 9 9 8 1 1 4 117 7 9 8 1 1 2 137 3 9 8 Nomi...

Page 35: ...7 9 7 8 M16 1 5 220 6 11 0 256 0 12 7 M20 1 5 452 1 22 6 524 7 26 1 1 General tightening points non lubricated All securing points that have no special tightening torque speci ed in this manual and th...

Page 36: ...2 24 2 TIGHTENING TORQUE SERVICE DATA...

Page 37: ...2 25 2 SERVICE DATA HYDRAULIC CIRCUIT DIAGRAM HYDRAULIC CIRCUIT DIAGRAM Equipped with options 1 2...

Page 38: ...2 26 2 HYDRAULIC CIRCUIT DIAGRAM SERVICE DATA Equipped with options 2 2...

Page 39: ...2 27 2 HYDRAULIC CIRCUIT DIAGRAM SERVICE DATA Equipped with angle blade and blade oat 1 2...

Page 40: ...2 28 2 HYDRAULIC CIRCUIT DIAGRAM SERVICE DATA Equipped with angle blade and blade oat 2 2...

Page 41: ...2 29 2 HYDRAULIC CIRCUIT DIAGRAM SERVICE DATA Equipped with high ow option 1 2...

Page 42: ...2 30 2 HYDRAULIC CIRCUIT DIAGRAM SERVICE DATA Equipped with high ow option 2 2...

Page 43: ...2 31 2 HYDRAULIC CIRCUIT DIAGRAM SERVICE DATA Equipped with high ow angle blade blade oat option 1 2...

Page 44: ...2 32 2 HYDRAULIC CIRCUIT DIAGRAM SERVICE DATA Equipped with high ow angle blade blade oat option 2 2...

Page 45: ...2 33 2 ELECTRIC CIRCUIT DIAGRAM SERVICE DATA ELECTRIC CIRCUIT DIAGRAM First auxiliary hydraulic piping with on off switch...

Page 46: ...2 34 2 ELECTRIC CIRCUIT DIAGRAM SERVICE DATA First auxiliary hydraulic piping with proportional control...

Page 47: ...2 35 2 ELECTRIC CIRCUIT DIAGRAM SERVICE DATA First auxiliary hydraulic piping with on off switch second auxiliary hydraulic piping with bucket select switch...

Page 48: ...2 36 2 ELECTRIC CIRCUIT DIAGRAM SERVICE DATA First auxiliary hydraulic piping with proportional control second auxiliary hydraulic piping with bucket select switch...

Page 49: ......

Page 50: ...2 26630 3 Fusible link 4 Diode 5 Fuse box 6 Short connector 7 Wire harness 03742 17070 8 Plate 9 Short connector 10 Horn 11 Relay 12 Wire harness 03742 05600 1 Plate 2 Flip op unit 3 Relay 4 Relay 5 R...

Page 51: ...E HARNESS WIRING DIAGRAM SERVICE DATA 1 Plate 2 Flip op unit 3 Relay 4 Relay 5 Resistance 6 Relay 7 Controller 8 Buzzer 9 Timer 10 Safety relay 11 Diode unit Upper frame wiring 2 2 Serial No 125000850...

Page 52: ...ring rst auxiliary hydraulic piping with proportional control 1 Wire harness 03942 26910 2 Wire harness 03742 17510 Upper frame wiring rst auxiliary hydraulic piping with proportional control and foot...

Page 53: ...SERVICE DATA Upper frame wiring rst auxiliary hydraulic piping with on off switch and foot switch 1 Wire harness 03742 19310 Upper frame wiring equipped with angle blade 1 Wire harness 03742 23010 2 D...

Page 54: ...TA Control unit second auxiliary hydraulic piping with bucket select switch 1 Wire harness 03570 15570 2 Diode 3 Relay 4 Flip op unit Control unit rst auxiliary hydraulic piping with on off switch 1 R...

Page 55: ...conditioner 3 Relay Compressor 4 Wire harness 03946 21310 Serial No 125000001 to 125000939 Wire harness 03946 21320 Serial No 125000940 or later 5 Short connector 6 Compressor 7 Control box 8 Air cond...

Page 56: ...S WIRING DIAGRAM SERVICE DATA Control unit arm holding limit 1 Relay 2 Wire harness 03760 15590 3 Diode Control unit automatic deceleration 1 Wire harness 03742 17710 2 Diode 3 Relay 4 Timer unit 5 Fl...

Page 57: ...SERVICE DATA Control unit heater for cold climate 1 Control amplifier 2 Relay 3 Wire harness 03745 08250 Serial No 125000001 to 125000939 Wire harness 03745 08260 Serial No 125000940 or later 4 Short...

Page 58: ...iliary piping detent rst auxiliary hydraulic piping with on off switch 1 Wire harness 03742 19450 2 Relay 3 Flip op unit Auxiliary piping detent rst auxiliary hydraulic piping with proportional contro...

Page 59: ...2 46 2 WIRE HARNESS WIRING DIAGRAM SERVICE DATA...

Page 60: ...2 47 2 WIRE HARNESS WIRING DIAGRAM SERVICE DATA...

Page 61: ...2 48 2 WIRE HARNESS WIRING DIAGRAM SERVICE DATA...

Page 62: ...2 49 2 WIRE HARNESS WIRING DIAGRAM SERVICE DATA...

Page 63: ...2 50 2 WIRE HARNESS WIRING DIAGRAM SERVICE DATA...

Page 64: ...2 51 2 WIRE HARNESS WIRING DIAGRAM SERVICE DATA...

Page 65: ...2 52 2 WIRE HARNESS WIRING DIAGRAM SERVICE DATA...

Page 66: ...2 53 2 WIRE HARNESS WIRING DIAGRAM SERVICE DATA...

Page 67: ...2 54 2 WIRE HARNESS WIRING DIAGRAM SERVICE DATA...

Page 68: ...2 55 2 WIRE HARNESS WIRING DIAGRAM SERVICE DATA...

Page 69: ...2 56 2 WIRE HARNESS WIRING DIAGRAM SERVICE DATA...

Page 70: ...2 57 2 WIRE HARNESS WIRING DIAGRAM SERVICE DATA...

Page 71: ...2 58 2 WIRE HARNESS WIRING DIAGRAM SERVICE DATA...

Page 72: ...2 59 2 WIRE HARNESS WIRING DIAGRAM SERVICE DATA...

Page 73: ...2 60 2 WIRE HARNESS WIRING DIAGRAM SERVICE DATA NAME STANDARD NO...

Page 74: ...2 61 2 WIRE HARNESS WIRING DIAGRAM SERVICE DATA...

Page 75: ...2 62 2 WIRE HARNESS WIRING DIAGRAM SERVICE DATA...

Page 76: ...2 63 2 WIRE HARNESS WIRING DIAGRAM SERVICE DATA...

Page 77: ...2 64 2 WIRE HARNESS WIRING DIAGRAM SERVICE DATA...

Page 78: ...2 65 2 WIRE HARNESS WIRING DIAGRAM SERVICE DATA...

Page 79: ...2 66 2 WIRE HARNESS WIRING DIAGRAM SERVICE DATA...

Page 80: ...2 67 2 WIRE HARNESS WIRING DIAGRAM SERVICE DATA...

Page 81: ...2 68 2 WIRE HARNESS WIRING DIAGRAM SERVICE DATA...

Page 82: ...ION 3 Piston pump 3 2 Gear pump 3 5 Control valve 3 6 Pilot valve 3 12 Proportional control solenoid valve 3 13 Emergency shut off valve 3 14 CylinderS 3 15 Travel motor 3 16 Slew motor 3 20 Swivel jo...

Page 83: ...3 operate as the pump P1 while the pistons in contact with the discharge port B oper ate as the pump P2 In this way the ten pistons 2 execute one suction and discharge stroke with each revolution of t...

Page 84: ...inactive spring 8 also becomes active and a still higher discharge pressure will be required to coun teract this spring force In this way the inclination of the swash plate 4 is changed the discharge...

Page 85: ...nd speed and the solenoid valve B used to switch the lever lock Solenoid valve When the solenoid valve is not energized The oil in the port P is blocked by the spool 1 Since the port A is connected wi...

Page 86: ...d of two mutually engaging gears drive gear 1 and driven gear 2 contained in a gear case When the drive shaft 3 is rotated the space be tween the case and the gears is lled with oil that is owing from...

Page 87: ...spool 2 is moved to the right the center bypass passage 1 is closed and the oil that has owed into the valve from the pump passes through the parallel passage 4 the load check valve 5 the port A and t...

Page 88: ...nto the tank passage T When this happens a pressure differential is generated between the two ends of the ori ce of the main poppet 2 and the main poppet is pushed to the right by the hydraulic pressu...

Page 89: ...c oil owing from the chamber B to the chamber C resulting in a low pressure in the chamber C If the pressure of the chamber C becomes lower than that of the chamber B equilibrium cannot be maintained...

Page 90: ...ough the tank passage T into the cylinder port P Anti drift valve This valve is installed in the head side of the cylinder cir cuit of the boom section and it prevents oil leakage in the cylinder head...

Page 91: ...tivated When the traveling operation and other operation are per formed at the same time the pilot pressure is directed tot the port P1 to push up the spool 1 This allows the oil entered the port P to...

Page 92: ...3 11 3 CONTROL VALVE FUNCTION...

Page 93: ...nected with the tank port T making the pressures in the ports A and B equal to the pressure in the tank port T When the lever 1 is tilted When the lever 1 is tilted and the push rod 6 is pushed the sp...

Page 94: ...sections A1 and B1 of the spool 1 and the spool 1 is pushed to the solenoid side by the oil pressure Pa x S The spool 1 stops at the position where the sum of the oil pressure Pa x S and the force Fk...

Page 95: ...and then through the port C into the boom or arm cylinder When the boom or arm is lowered the pilot pressure from the pilot valve 2 is led to the port Pi The pilot pressure from the port Pi works on t...

Page 96: ...troke end is dampened by the mechanism Cushion mechanism 3LAA01Z 1 2 3 4 3LAA02Z 1 2 3 4 When the piston 1 approaches the stroke end and is likely to bump into the cover 2 the cushion bearing 3 that i...

Page 97: ...M1 and the chamber B in the pilot section The pres sure oil ows into the motor from the motor port M1 On the other hand the return oil from the motor does not ow into the port P2 because the passage b...

Page 98: ...solenoid valve 1 For this reason the spool 2 is pushed to the left by the spring 4 and the piston chamber 3 that controls the swash plate becomes connected to the tank port T There is no force pushes...

Page 99: ...ue to the equilibrium between the force of the springs 9 10 and the force of the 2nd speed control piston 11 resulting in the angle of that can run the motor at the 2nd speed When the engine is stoppe...

Page 100: ...ke release port 7 and the parking brake force is operated by the spring 4 Reduction gears The reduction gears consist of 2 stage simple planetary gears connected in series Each planetary gear consists...

Page 101: ...shaft 4 turning it Conversely if high pressure oil is introduced to the port C the rotation is the reverse of the above Relief valve This relief valve is equipped with shockless function and works in...

Page 102: ...lve is closed as in braking the oil from the motor drain as well as the leak from the valve is replenished through the makeup valve 1 to prevent a vacuum from being generated in the circuit Anti rebou...

Page 103: ...ssage from the port Pv2 to the port Cv is closed Parking brake The cylinder block 1 and the disc 1 are connected through the spline The disc 2 is pushed between the brake piston 4 and the case 5 by th...

Page 104: ...ht by the spring 2 force the port PG is closed and the oil in the brake piston cham ber 3 is blocked This enclosed oil gradually ows into the drain port dr from the ori ce located at the outer circum...

Page 105: ...hub and shaft can be turned separately The num ber of ports is the number of the uid circuits There are grooves formed in the inner circumference surface of the hub 1 and the outer circumference surfa...

Page 106: ...Attachments 4 39 Hydraulic tank 4 45 Hydraulic pump 4 50 Control valve 4 74 Pilot valve 4 86 Proportional control solenoid valve 4 93 Pilot valve auxiliary 4 95 Pilot valve travel 4 106 Solenoid valv...

Page 107: ...r Drive sproket Idler Code Criteria mm Standard dimension Allowable value A 84 80 B 30 Code Criteria mm Standard dimension Allowable value A 110 106 B 35 Code Criteria mm Standard dimension Allowable...

Page 108: ...4 3 4 SERVICE STANDARDS DISASSEMBLY AND ASSEMBLY Clearance for pin and bushing...

Page 109: ...nd arm 50 0 02 0 05 0 25 0 05 0 07 to 0 30 1 0 H Arm cylinder and boom 50 0 02 0 05 0 25 0 05 0 07 to 0 30 1 0 I Boom and swing bracket 60 0 02 0 05 0 001 0 059 0 021 to 0 109 1 0 J Boom cylinder and...

Page 110: ...he engine 1 Engine foot FR 2 Engine foot FL 3 Engine foot RR 4 Engine foot RL 5 Air hose 6 Air hose 7 Air hose 8 Cushion rubber 9 Cushion rubber 10 Tail pipe 11 Ground cable 12 Stopper 13 Exhaust pipe...

Page 111: ...ng the hydraulic pump 9 Disconnect the fuel hoses Removing the fuel tank 10 Disconnect the battery cable and the electrical wirings from the engine side Attach an identi cation label to each wiring 11...

Page 112: ...guard 3 Shroud 4 Plate 5 Cushion rubber 6 Cushion rubber 7 Radiator and oil cooler 8 Radiator hose upper 9 Radiator hose lower 10 Sub tank Removing the radiator and oil cooler 11 Drain valve 12 Hose 1...

Page 113: ...sembly 7 together with the radiator bracket and remove it Lift it slowly sliding it out forward so that the shroud does not come in contact with the cooling fan 7 Disconnect the oil cooler hoses Prepa...

Page 114: ...4 9 4 DRIVE SYSTEM DISASSEMBLY AND ASSEMBLY Removing the hydraulic pump Apply molybdenum disul de grease to the spline 1 Engine housing 2 Hydraulic pump 3 Coupling 4 Air bleeding plug 5 Solenoid valve...

Page 115: ...lic pump 7 Disconnect the hoses from the solenoid valve 8 Remove the xing bolts and then remove the hydraulic pump 2 Apply molybdenum disul de grease to the spline Bolt 102 N m Installing the hydrauli...

Page 116: ...VE SYSTEM DISASSEMBLY AND ASSEMBLY Removing the fuel tank 1 Fuel tank 2 Flange 3 Fuel sender 4 Cover 5 Drain valve 6 Band 7 Band 8 Fuel hose 9 Fuel hose 10 Fuel hose 11 Fuel hose 12 Feed pump 13 Float...

Page 117: ...n the fuel Fuel tank capacity 73 L 4 Disconnect the electrical wiring from the fuel sender 3 5 Disconnect the fuel hoses 8 and 11 6 Take out the bolts and remove the plate 14 7 Take out the nuts and r...

Page 118: ...1 to the B full throttle side and set the governor 4 to the D full throttle posi tion Adjust the stopper 7 so that the throttle lever 1 hits against the stopper 7 and secure the stopper with the lock...

Page 119: ...e of the idler stop the rotation of the sprocket 4 Slide the crawler to the side and remove it Crawler belt 219 kg Installing the crawler belt 1 Raise the machine and place the crawler on the frame Se...

Page 120: ...e and the hoe attachment and then gradually remove the crawl er 1 while running the travel motor slowly in reverse Crawler 259 kg Installing the steel crawler 1 If using the blade and hoe attachment r...

Page 121: ...the same proce dure as for removal in the reverse order Bolt ThreeBond 1324 Bolt 256 N m Removing the track roller 1 Loosen the tension of the crawler 2 Slightly loosen the roller xing bolt 1 about o...

Page 122: ...o the previous page for removing and installing the crawler belt 1 Remove the track roller Removing the track roller 2 Insert the spacer 1 between the carrier roller bracket and the frame and then ins...

Page 123: ...liding surfaces of the track adjuster piston and the cylinder Removing the travel motor 1 Remove the crawler Removing the crawler belt 2 Take out the xing bolts 1 and remove the sprocket 2 Bolt ThreeB...

Page 124: ...e 2 Disconnect the hydraulic hoses from the slew motor 1 3 Remove the bolts xing the slew motor Bolt ThreeBond 1324 Bolt 256 N m 4 Suspend the slew motor 1 and then remove it Slew motor 50 kg Installi...

Page 125: ...olt ThreeBond 1324 Bolt 256 N m 4 Suspend the slew bearing and remove it Slew bearing 84 kg Installing the slew bearing For installation of the slew bearing follow the same proce dure as for removal i...

Page 126: ...vel joint xing bolts Bolt ThreeBond 1324 Bolt 102 N m 4 Suspend the swivel joint 1 and remove it Installing the swivel joint For installation of the swivel joint follow the same proce dure as for remo...

Page 127: ...4 22 4 UPPER FRAME DISASSEMBLY AND ASSEMBLY UPPER FRAME Removing the upper frame 1 Upper frame 2 Counterweight 3 Grease pipe...

Page 128: ...the xing bolts from the outer race of the slew bearing leaving only two bolts each on the front and the rear of the machine When installing the slew bearing be careful to align it with the positions o...

Page 129: ...ISASSEMBLY AND ASSEMBLY Removing the covers 1 2 1 Engine hood 2 Front cover 3 Side cover R 4 Side cover L 5 Tank cover 6 Front cover 7 Center cover 8 Hinge 9 Plate 10 Cover 11 Bracket 12 Stay damper 1...

Page 130: ...4 25 4 UPPER FRAME DISASSEMBLY AND ASSEMBLY 15 Side frame R 16 Side frame L 17 Tool box 18 Cover 19 Bracket 20 Cover 2 2...

Page 131: ...ve the center cover 7 4 Remove the side covers R 3 and L 4 5 Remove the xing bolts Remove the rod 14 discon nect the light wiring and detach the front cover 6 6 Remove the tool box 17 7 Remove the sid...

Page 132: ...erminal 2 Disconnect the electric wiring from the cab 3 Remove the xing bolts 4 Suspend the cab and remove it Cab 240 kg Installing the cab For installation of the cab follow the same procedure as for...

Page 133: ...ISASSEMBLY AND ASSEMBLY CONTROL SYSTEM Removing the lever stand Control lever 1 Pedal assembly L 2 Pedal assembly R 3 Lever L 4 Lever R 5 Pilot valve 1st auxiliary 6 Pedal assembly swing 7 Control cab...

Page 134: ...M DISASSEMBLY AND ASSEMBLY Control lever pedal Aux 1 proportional control 1 Pedal assembly L 2 Pedal assembly R 3 Lever L 4 Lever R 5 Proportional control valve 6 Pedal assembly swing 7 Control cable...

Page 135: ...MBLY AND ASSEMBLY Control lever pedal 1st auxiliary ON OFF 1 Pedal assembly L 2 Pedal assembly R 3 Lever L 4 Lever R 5 Pilot valve 1st auxiliary 6 Pedal assembly swing 7 Control cable 8 Pilot valve tr...

Page 136: ...trol valve 5 Pilot valve 6 Shuttle valve 7 Hydraulic tank Table of connection 1 R1 pb1 4 1 R2 pa2 4 1 R3 pa1 4 1 R4 pb2 4 1 RP TRP 3 1 RT TRT 3 2 L1 SHAA 6 2 L2 pb7 4 2 L3 pb8 4 2 L4 SHAB 6 2 LP 1SSP...

Page 137: ...L2 3 8 2 L3 pb8 4 2 L4 4 8 2 LP 1SSP 5 2 LT 1SST 5 3 TR1 pa4 4 3 TR2 pb4 4 3 TR3 pa3 4 3 TR4 pb3 4 3 TRP 1SSP 5 3 TRT 1SST 5 3 TRT T2 7 5 L pb6 4 5 R pa6 4 6 SHAA pa8 4 6 SHAB pa7 4 8 A pa2 4 8 B pb2...

Page 138: ...ONTROL SYSTEM DISASSEMBLY AND ASSEMBLY Blade lever When assembling be sure to apply NEVER SEEZ anti seize and lubricating agent to the inner surfaces of the DU bush 1 Base plate 2 Lever 3 Control cabl...

Page 139: ...4 34 4 CONTROL SYSTEM DISASSEMBLY AND ASSEMBLY Lever stand 1 Bracket 2 Lever 3 Lever 4 Bracket 5 Control box 6 Plate 7 Pilot valve 8 Limit switch 9 Stay damper 10 Pin...

Page 140: ...ver R 2 Cover 3 Starter switch 4 Light switch 5 Cluster gauge 6 Valve 7 Hour meter Control box R Canopy 1 Cover R 2 Plate 3 Cover 4 Starter switch 5 Light switch 6 Cluster gauge 7 Valve 8 Hour meter 9...

Page 141: ...ency shut off valve B Emergency shut off valve arm holding limit Control box L with air conditioner and heater for cold climates 1 Cover L 2 Air conditioner blower fan switch 3 Attenuator thermal 4 Co...

Page 142: ...n identi cation label to each hydraulic hose for easy reassembly d Disconnect the electrical wiring of the limit switch e Take out the stay damper and the pin and then re move the control box 4 Remove...

Page 143: ...it is long enough for the spool stroke on the control valve 1 The control valve 1 spool should be in the neutral po sition 2 Turn the nut 2 and position the lever 3 in the center of the stroke and th...

Page 144: ...ND ASSEMBLY ATTACHMENTS Removing the attachments 1 Bucket 2 Bucket link 3 Guide link R 4 Guide link L 5 Bucket cylinder 6 Arm 7 Arm cylinder 8 Boom 9 Boom cylinder 10 Swing bracket 11 Swing cylinder 1...

Page 145: ...an not be inserted by hand Be sure to bleed the air from the cylinder before starting for the rst time after reassembling hydrau lic devices such as the hydraulic cylinder or hydrau lic piping Removin...

Page 146: ...rom the bucket cyl inder 2 Next disconnect the hydraulic hoses from the auxiliary ports 3 2 Suspend the bucket cylinder 1 temporarily pull out the pin 4 and then remove the bucket cylinder Bucket cyli...

Page 147: ...the boom 4 and then dis connect the hydraulic hoses 5 from the boom cylinder 6 4 Suspend the boom cylinder 6 temporarily and remove the pin 7 Lower the boom so that the side where the cylinder rod was...

Page 148: ...der 6 from the swing bracket 4 4 Suspend the swing bracket 4 temporarily pull out the pins 7 and 8 and then remove the swing bracket Be careful not to damage the hoses Swing bracket 135 kg Installing...

Page 149: ...to the ground 1 Disconnect the hydraulic hoses 1 from the blade cyl inder 2 2 Suspend the blade cylinder 2 temporarily pull out the pins 3 and 4 and then remove the blade cylinder 2 Blade cylinder 41...

Page 150: ...ther 1 Tank 2 Pipe assembly 3 Pipe 4 Pipe 5 O ring 6 Check valve 7 Pipe 8 Elbow 9 Check valve 10 Stop valve 11 Elbow 12 Elbow 13 O ring 14 Plate 15 Hose 16 O ring 17 Drain plug 18 Plug 19 Hose 20 Hose...

Page 151: ...ehand b Loosen the drain plug 6 and drain out the oil Tank capacity 52 L 4 Disconnect the low pressure hoses from the tank 5 Disconnect the hydraulic hoses from the tank Attach an identi cation label...

Page 152: ...ton to relieve the tank pres sure models with air breather Machine setup for inspecting the hydraulic oil level 1 Start the engine and run it at low speed 2 Fully retract the arm cylinder and bucket c...

Page 153: ...with air breather Open the side cover press the button 3 to relieve the internal pressure from the tank 3 Add hydraulic oil up to the middle of the sight gauge 1 4 Pressurize the hydraulic oil tank a...

Page 154: ...plug 1 once the hydraulic oil over ows from the hole Cylinders 1 Start the engine and let it run at a low idling speed for 10 minutes 2 While the engine runs at low idle extend and retract each cylin...

Page 155: ...P DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP Construction 1 Shaft 2 Swash plate 3 Cylinder block 4 Cover 5 Spring seat 6 Piston control 7 Gear pump 8 Housing 9 Solenoid valve 10 Relief valve 11 Spring ou...

Page 156: ...Take out the cap screws and remove the solenoid valve from the pump Hold the pump upright with the shaft side on the bottom and place the pump onto the jig A so that the shaft end does not come in con...

Page 157: ...e the cover When removing keep the cover in a level position Do not damage the valve plate tted on the back If it is hard to remove lightly tap the cover with a plastic hammer 5 Remove the two springs...

Page 158: ...and pis tons 6 from the cylinder block 7 Do not disassemble the cylinder block 7 unless necessary 8 Take out the snap ring and remove the oil seal case 8 and the O ring When removing the oil seal case...

Page 159: ...plate 9 b Remove the distance piece 10 c Remove the bearing 11 d Remove the swash plate 11 Disassemble the cover section a Remove the valve plate b Take out the cap screw and remove the piston con tr...

Page 160: ...the piston 13 from the cylinder 14 d For the machine with an air conditioner remove the piston 15 Only the machine with an air condition er e Remove the piston 16 f Remove the three conical spring was...

Page 161: ...tion a Remove the snap ring b Tap the shaft with a plastic hammer and remove the shaft 13 Remove the relief valve Do not assemble the relief valve unless necessary a Remove the nut Note down the free...

Page 162: ...the assembly into the hydraulic pump and the pumps P3 and P4 15 Disassemble the pump P4 a Pull up the drive gear and remove the seal ring the backup ring and the plate b Remove the driven gear 16 Disa...

Page 163: ...4 58 4 HYDRAULIC PUMP DISASSEMBLY AND ASSEMBLY c Remove the frame d Remove the seal ring e Remove the plate the guide and the O rings f Remove the drive gear the driven gear and the bushing...

Page 164: ...DISASSEMBLY AND ASSEMBLY 17 Disassemble the solenoid valve a Remove the lter and the O rings b Remove the nut c Remove the solenoid d Remove the base Be careful not to drop the push rod e Remove the...

Page 165: ...4 60 4 HYDRAULIC PUMP DISASSEMBLY AND ASSEMBLY f Remove the plug g Remove the spring and the ball...

Page 166: ...secure it with cap screws Cap screw 12 to 15 N m 2 Assemble the shaft section a Install the bearing on the shaft using the jig B Use the bearing as a bed and press t the shaft using a press or a plas...

Page 167: ...l the pins 4 on the cylinder block Apply grease on the pins 4 to prevent it from dropping out b Install the guide 3 on the cylinder block Apply grease on the spherical part of the guide c Install the...

Page 168: ...herical part of the spring seat 11 Install the two springs inner and outer 12 Assemble the cover section a Install the spring seat 18 and the conical spring washers 17 Be sure to install the washers i...

Page 169: ...o 35 N m Apply Loctite 270 g Fit the O ring to the spring seat and install the spring seat h Place the cover in the speci ed position and secure it using the cap screws Cap screw 28 to 35 N m i Apply...

Page 170: ...setscrew 17 and install it on the cover d Install the nut After assembly set the pressure and secure the valve Nut 9 8 N m 14 Install the cover and secure it using the cap screws When installing keep...

Page 171: ...ng 20 Be sure to install it in the correct direction A Discharge side B Suction side b Install the bushings that were set as above on both sides of the drive gear and driven gear and then install them...

Page 172: ...plate that was set as above on the hous ing Be sure to install the plate in the correct direc tion A Discharge side B Suction side e Install the seal ring 18 Assemble the pump P4 a Install the drive...

Page 173: ...Y c Install the seal ring 21 and the backup ring 22 on the plate 23 Apply grease on the rings to prevent them from dropping out d Install the plate on the housing e Install the two pins and O ring on...

Page 174: ...ousing using the cap screws Cap screw 28 to 35 N m h Fit the two pins to the frame and install the coupling on the shaft end of the pump P3 side 19 Connect the pumps P3 and P4 and secure them using th...

Page 175: ...SSEMBLY AND ASSEMBLY 21 Assemble the solenoid valve a Install the ball and the spring on the body b Install the plug Plug 13 2 to 17 6 N m c Install the springs and the spools on the body d Install th...

Page 176: ...in pump and the gear pump and se cure them using the cap screws Hold the pump upright with the shaft side on the bottom and place the pump onto the jig A so that the shaft end does not come in contact...

Page 177: ...nd oil seal mount e Oil seal mount f Standard dimen sion A wear amount of 0 025 mm or more at the shaft and oil seal mount Replace Valve plate Abnormal scratches 0 02 mm or more wear or scorching on t...

Page 178: ...he guide and retainer as a set if repair is im possible Repair a small scoring or scratch by lapping Solenoid valves A and B Measure the clearance between the body and the spool D d 0 015 mm Replace R...

Page 179: ...ucket section 4 Boom section 5 Right travel section 6 Inlet housing 7 Left travel section 8 Swing section 9 1st auxiliary section 10 Arm section 11 Slew section 12 Dozer blade section 13 Switch valve...

Page 180: ...7 Poppet 8 Spring 9 O ring 10 Plug 11 Housing 12 Spool Right travel section 1 Spring holder 2 Spring 3 Spring holder 4 Cover 5 O ring 6 Cover 7 Poppet 8 Spring 9 O ring 10 Plug 11 Housing 12 Spool Swi...

Page 181: ...ng 11 Spacer 12 Backup ring 13 O ring 14 Spring 15 Poppet 16 Spring holder 17 Sleeve 18 Backup ring 19 O ring 20 O ring 21 Backup ring 22 Spool 23 O ring 24 Spring 25 Piston 26 O ring 27 Housing 28 Sp...

Page 182: ...Cover 5 O ring 6 Poppet 7 Spring 8 O ring Bucket section 1 Spring holder 2 Spring 3 Spring holder 4 Cover 5 O ring 6 Cover 7 Poppet 8 Spring 9 O ring 10 Poppet Dozer blade section 1 O ring 2 Wiper 3 S...

Page 183: ...Poppet 9 Spring 10 O ring 11 O ring 12 Housing 13 Spool 1st auxiliary section 1 Cover 2 Spring holder 3 Spring holder 4 Spring 5 Poppet 6 Spring 7 O ring 8 O ring 9 O ring 10 Housing 11 Spool 1st auxi...

Page 184: ...Spring 7 O ring 8 O ring 9 O ring 10 Housing 11 Spool Inlet housing 1 Cover 2 Filter 3 O ring 4 Cover 5 O ring 6 Housing 7 Spool Main relief valve 1 Housing 2 Plug 3 Sleeve 4 Main poppet 5 Piston 6 N...

Page 185: ...Poppet 3 Spring 4 O ring 5 Backup ring 6 O ring Port relief valve 1 Housing 2 Plug 3 Sleeve 4 Main poppet 5 Piston 6 Needle valve 7 Spring 8 Spring 9 Setscrew 10 Washer 11 Lock nut 12 O ring 13 Backu...

Page 186: ...ove the O 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 reli...

Page 187: ...he plug Manually operated section 1 Remove the cap screws the cover 1 and the spool assembly 2 Cap screw 8 8 to 10 8 N m 2 Take out the seal holder and remove the wiper and the O ring 3 Take out the s...

Page 188: ...move the O ring from the cover Cap screw 8 8 to 10 8 N m 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 housing...

Page 189: ...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 the O ring...

Page 190: ...hat 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 Operates smoothly when i...

Page 191: ...VE Construction 1 Casing 2 Plate 3 Spool 4 Plug 5 Push rod 6 Push rod 7 Seal 8 O ring 9 Spring seat 10 Spring seat 11 Washer 2 12 Spring 13 Spring 14 Spring 15 Spring 16 Joint 17 Cam 18 Adjusting nut...

Page 192: ...sembly 1 Take out the adjusting nut 1 and remove the cam 2 from the joint Secure the valve to the vice by using a copper or lead plate 2 Take out the joint 3 and then remove the plate 4 Use the instal...

Page 193: ...5 Remove the reducing valve 12 and the spring 13 To avoid misconnection when reassembling place indicators showing the matching positions for the reducing valve and the casing hole 6 Disassemble the r...

Page 194: ...spring 15 and the spring seat 14 on the spool 17 b Push in the spring seat 14 to compress the spring 15 and to move the spool 17 from the large hole side to the small hole side of the spring seat 14 T...

Page 195: ...ug 5 the plate 4 and the joint Use the installation jigs A and B to install the joint Joint 41 7 2 9 N m 6 Install the cam 2 and the adjusting nut 1 Tighten the adjusting nut 1 to the point where it u...

Page 196: ...4 91 4 PILOT VALVE DISASSEMBLY AND ASSEMBLY Grease the rotating part of the joint and its contact surfaces with the disc and the push rod 4KAC15Z...

Page 197: ...or more Scratches on the sliding portions Replace Replace Plug Seal is imperfect due to damage Repair or replace Controls Tightening is loose at the pin shaft or joint of the con trols with looseness...

Page 198: ...4 93 4 PROPORTIONAL CONTROL SOLENOID VALVE DISASSEMBLY AND ASSEMBLY PROPORTIONAL CONTROL SOLENOID VALVE Construction 1 Proportional control solenoid 2 Spool...

Page 199: ...ng 3 Make sure that the spool 5 moves a little if pushed from the sleeve 2 end 4KAD02Z 1 4KAD03Z 2 3 4 5 Inspection and adjustment Checking the parts Part Criteria Action Coil assembly When the soleno...

Page 200: ...VE AUXILIARY DISASSEMBLY AND ASSEMBLY PILOT VALVE AUXILIARY Construction 1 Case 2 Cover 3 Plug 4 Seal 5 O ring 6 Push rod 7 Shim 8 Spool 9 Spring seat 10 Washer 11 Spring 12 Spring 13 Shaft 14 Bushing...

Page 201: ...h a blank plug 2 Insert a cushion plate between the pilot valve and the vise and secure the pilot valve Remove the bellows from the cover by pulling it up ward 3 Loosen the hexagon setscrew with a hex...

Page 202: ...cam relative to the cover 6 Loosen the cap screws with a hexagon spanner and remove them 7 Remove the cover WARNING When removing the cover be careful as the push rod or the plug may be ejected Note d...

Page 203: ...d remove the bush by applying the special jig and tapping it light ly with a hammer 11 To disassemble the pressure reducing valve push down the spring seat to compress the secondary pressure spring an...

Page 204: ...er is for adjusting the preset value of the secondary pressure spring and its thickness differs for each spool assembly In some cases this washer is omitted 13 Remove the push rod from the plug 14 Rem...

Page 205: ...eat to com press the secondary pressure spring move the spring seat sideways to install it Take care not to scratch the spool surface Do not push down the spring seat by 4 mm or more 3 Secure the casi...

Page 206: ...installed in the wrong way around Apply a thin layer of grease to the packing before installation 7 Install the push rod on the plug Apply hydraulic oil to the push rod before installa tion Do not us...

Page 207: ...bush does not pop out of the cover 10 Install the cover in the casing Install the cover in the position it was in before dis assembly Take care that the cover is not lifted by the return springs 11 Ti...

Page 208: ...aring 14 Apply Loctite to the hexagon setscrew Hexagon setscrew Loctite 241 or equivalent 15 Tighten the hexagon setscrew with the speci ed torque Hexagon set screw 6 9 1 0 N m 16 Tilt the cam and app...

Page 209: ...the groove of the cover Before inserting the lower end of the bellows into the groove of the cover spray the inside of the bellows with rust inhibiting oil Make sure to attach the bellows correctly Th...

Page 210: ...1 mm or more Scratches on the sliding portions Replace Replace Plug Seal is imperfect due to damage Repair or replace Controls Tightening is loose at the pin shaft or joint of the con trols with loose...

Page 211: ...PILOT VALVE TRAVEL Construction 1 Case 2 Cover 3 Plug 4 Seal 5 O ring 6 Push rod 7 Shim 8 Spool 9 Spring seat 10 Washer 11 Spring 12 Spring 13 Shaft 14 Bushing 15 Cam 16 Ball 17 O ring 18 Grease cup 1...

Page 212: ...g 2 Insert a cushion plate between the pilot valve and the vise and then secure the pilot valve Remove the bellows from the cover by pulling it up ward 3 Loosen the hexagon setscrew with a hexagon wre...

Page 213: ...te down the position of the cam relative to the cover WARNING When removing the cam there is a risk that the push rod 214 may pop out 6 Loosen the cap screws with a hexagon spanner 7 Remove the cover...

Page 214: ...od so that it can be installed in the position it was in before disassembly WARNING When removing the push rod there is a risk that the plug may pop out Take care not to scratch the push rod surface 1...

Page 215: ...la tive to the casing hole 13 Pull out the spring seats from the casing by using twee zers or the like Note down the position of the spring seat relative to the casing hole 14 Remove the balls by usin...

Page 216: ...remove the bushing by applying the special jig and tapping it lightly with a hammer 18 To disassemble the pressure reducing valve push down the spring seat to compress the secondary pressure spring a...

Page 217: ...ss differs for each spool assembly In some cases this washer is omitted 20 Remove the grease cup from the plug 21 Remove the packing from the plug Use a small at head screwdriver or the like for re mo...

Page 218: ...ng seat to com press the secondary pressure spring move the spring seat sideways to install it Take care not to scratch the spool surface Do not push down the spring seat 4 mm or more 3 Fix the casing...

Page 219: ...e balls 7 Install the spring seats with tweezers or the like in the casing Install the spring seats in the positions they were in before disassembly 8 Install the damping springs in the casing Install...

Page 220: ...pistons in the positions they were in be fore disassembly 10 Install the O ring on the plug 11 Install the packing on the plug Be sure to install the packing in the correct direc tion Apply a thin lay...

Page 221: ...blies assembled in steps 10 11 12 and 13 in the casing 15 Place the cover sideways on a at surface and press t the bushing by using the special jig and tapping it lightly with a hammer Take care that...

Page 222: ...s not lifted by the damping spring 18 Tighten the cap screws with the speci ed torque Make sure that the cover is in a level position Cap screw 8 8 0 8 N m 19 Install the cam in the casing Install the...

Page 223: ...ite 241 22 Tighten the hexagon setscrew with the speci ed torque Hexagon setscrew 6 9 1 N m 23 Tilt the cam and apply grease to the head of the push road and ll grease into the grease cup of the plug...

Page 224: ...the groove of the cover Before inserting the lower end of the bellows into the groove of the cover spray the inside of the bellows with rust inhibiting oil Make sure to attach the bellows correctly T...

Page 225: ...mm or more Scratches on the sliding portions Replace Replace Plug Seal is imperfect due to damage Repair or replace Controls Tightening is loose at the pin shaft or joint of the con trols with loosen...

Page 226: ...4 121 4 SOLENOID VALVE 1 SECTION DISASSEMBLY AND ASSEMBLY SOLENOID VALVE 1 SECTION Construction 1 Plug 2 Solenoid valve 3 O ring 4 O ring 5 Spring 6 Spool 7 Body...

Page 227: ...w 4 9 N m 2 Remove the O ring from the solenoid coil 1 3 Remove the plug 2 and then remove the O ring from the plug 2 Plug 23 5 N m 4 Remove the spring 4 and the spool 3 from the body Note down the po...

Page 228: ...Replace Body Scratches rust or corrosion at the sliding parts and the spool Scratches rust or corrosion of the seal part in contact with the O ring Other damage considered to impair normal function R...

Page 229: ...4 124 4 SOLENOID VALVE 2 SECTION DISASSEMBLY AND ASSEMBLY SOLENOID VALVE 2 SECTION Construction 1 Plug 2 Solenoid valve 3 O ring 4 O ring 5 Spring 6 Spool 7 Body...

Page 230: ...w 3 92 N m 2 Remove the O ring from the solenoid coil 1 3 Remove the plug 2 and then remove the O ring from the plug 2 Plug 26 5 N m 4 Remove the spring 4 and the spool 3 from the body Note down the p...

Page 231: ...eplace Body Scratches rust or corrosion at the sliding parts and the spool Scratches rust or corrosion of the seal part in contact with the O ring Other damage considered to impair normal function Rep...

Page 232: ...hion bearing 19 Piston 20 Wear ring 21 Setscrew 22 Ball 23 Dust seal 24 Dust seal 25 Grease tting 26 Grease tting Arm cylinder 1 Rod Packing 2 Dust seal 3 O ring 4 Backup ring 5 O ring 6 Backup ring 7...

Page 233: ...acking holder 15 Bushing 16 Setscrew 17 Bushing 18 Snap ring 19 Grease tting 20 Grease tting 21 Wear ring 22 Dust seal Dozer blade cylinder 1 Piston packing 2 Rod packing 3 Backup ring 4 Dust seal 5 O...

Page 234: ...ring 6 O ring 7 Piston packing 8 Tube 9 Bushing 10 Piston rod 11 Bushing 12 Rod cover 13 Bushing 14 Connector 15 Stopper 16 Retainer 17 Cushion seal 18 Spacer 19 Stopper 20 Piston 21 Wear ring 22 Ball...

Page 235: ...side Sliding jig C Quantity 1 Material STKM13C Fitting jig D Quantity 1 Material Nylon Corrective jig E Quantity 1 Material STKM13C A B C D E F Boom 64 74 49 8 59 8 15 6 30 70 80 Arm 59 49 8 15 5 30...

Page 236: ...draulic oil from the cylinder Move the piston rod slowly to prevent the hydraulic oil from spurting out 3 Disengage the anti rotation lock of the rod cover Since the anti rotation lock is built into t...

Page 237: ...with a hand drill b Remove the piston 3 c Pull out the cushion bearing 4 Arm cylinder d Remove the snap ring 5 e Push in the cushion bearing 6 to release the stop per 7 and then remove the cushion be...

Page 238: ...ng cylinder 5 Separate the retainer 9 from the rod cover a Remove the stopper 10 b Remove the connector 11 and then disconnect the retainer 8 from the rod cover Piston piston packing holder 1 Remove t...

Page 239: ...ion seal 4 and spacer 5 Retainer Swing cylinder 1 Remove the O ring 1 and the backup ring 2 2 Remove the stopper 3 spacer 4 and cushion seal 5 Rod cover 1 Remove the O rings 20 and 21 and the backup r...

Page 240: ...he backup ring 23 3 Remove the 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 sea...

Page 241: ...gs 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 Boom cylinder arm cylinder swing cylinder a Install the rod packing Buck...

Page 242: ...gs 20 and 21 Make sure that the cut portion of the backup ring does not get out of place Retainer Swing cylinder 1 Install the cushion seal 5 spacer 4 and stopper 3 on the retainer 2 Install the backu...

Page 243: ...after tted correct it b Cover the piston with the sliding jig C and then using the tting jig D quickly insert the slipper ring 35 c Since the slipper ring 35 has been extended when it is installed cor...

Page 244: ...od assembly Swing cylinder 1 Install the retainer 9 on the rod cover a Insert the retainer 9 into the rod cover b Install the connector 11 at the joining surfaces of the retainer 9 and the rod cover I...

Page 245: ...back again c Install the snap ring 5 Swing cylinder a Install the cushion bearing 6 b Install the washer c Install the screw 5 Screw 41 2 N m Bucket cylinder blade cylinder a Install the piston packin...

Page 246: ...tube When inserting align the center of the piston rod with the center of the tube Insert the assembly straight so as not to damage the seal 2 Tighten the rod cover Rod cover 3 Bend down the lock rib...

Page 247: ...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 bending of th...

Page 248: ...1 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...

Page 249: ...der block 5 Valve plate 6 Piston 7 Shoe holder 8 Guide 9 Swash plate 10 Pin 11 Spring 12 Retainer 13 Bearing 14 Bearing 15 2nd speed piston 16 Brake piston 17 Spring 18 Snap ring 19 O ring 20 O ring 2...

Page 250: ...ar B1 5 Gear B2 6 Gear S1 7 Gear S2 8 Pin 9 Flange holder 10 Snap ring 11 Needle 12 Needle 13 Floating seal 14 O ring 15 Bearing 16 Thrust washer 17 Snap ring 18 Snap ring 19 Snap ring 20 Ring 21 Plat...

Page 251: ...Y Counterbalance valve 2nd speed control valve relief block assembly 1 Valve body 2 Spool 3 Check valve 4 Spring 5 O ring 6 Spring guide 7 Spring 8 Cap 9 O ring 10 Spool 11 Spring 12 Plug 13 O ring 14...

Page 252: ...Counter balance valve and hydraulic motor 1 Secure the valve body in a vise and install the spool in the valve body Insert an aluminum plate or the like between the motor and the vise to prevent the...

Page 253: ...spool 4 5 Install the 2nd speed spool 4 on the body 6 Install the O ring on the plug and then attach the plug to the valve body by tightening it Plug 46 to 51 N m 7 Install the shuttle 8 Install the...

Page 254: ...Y 9 Install the O rings large and small on the valve body 10 Press t the oil seal in the ange holder Do not disassemble the oil seal unless necessary Add grease between the lips of the oil seal 11 Ins...

Page 255: ...mbled Be careful not to damage the oil seal with the shaft 14 Install the balls and the swash plate on the ange hold er Apply hydraulic oil to the sliding surfaces of the swash plate 15 Install the re...

Page 256: ...der block to make the cylinder block assembly 19 Install the cylinder block assembly on the ange hold er Install the cylinder block assembly in such a manner that the shoe will touch the swash plate 2...

Page 257: ...pply grease to the O rings and make sure that the seal material is not caught 23 Install the valve plate 21 and the retainer 22 on the valve body and install the springs in the spring holes Install th...

Page 258: ...d the vise to prevent the outer sur face of the valve body from being damaged Reduction gears 1 Install the bearing 17 snap ring 18 and bearing 17 on the housing Be careful not to install the bearing...

Page 259: ...hrust plate 3 ring 4 gear B1 5 needle 6 and thrust plate 7 on the pin and then secure them with a snap ring 8 Do not spread the snap ring more than necessary Install the snap ring with the edge facing...

Page 260: ...9 Install the carrier 2 assembly on the housing 10 Install the O ring on the housing 11 Add 1 0 L lubricant 12 Mount the ring on the cover Apply grease 13 Install the cover on the housing Align the no...

Page 261: ...ure the cover Set a at head screwdriver to the edge of the snap ring and hammer it in around its circumference 15 Mount an O ring on the plug G3 8 and install it on the cover Plug 46 to 51 N m 16 Atta...

Page 262: ...surface Replace Thrust plate Sliding surfaces Abnormal scratches wear or scorch ing on the surface Replace O ring Replace Shaft Oil seal surface Abnormal scratches wear or scorch ing on the surface Re...

Page 263: ...dy and spool Spool Sliding surface with the valve body Abnormal scratches wear or scorch ing on the surfaces Sliding surface with the check valve Abnormal scratches wear or scorch ing on the surfaces...

Page 264: ...ng 2 O ring 3 O ring 4 O ring 5 Disc 6 Cylinder block 7 Brake piston 8 Spring 9 Shaft 10 Retainer 11 Disc spring 12 Retainer 13 Guide 14 Pin 15 Valve plate 16 Bearing 17 Snap ring 18 Spring seat 19 Sh...

Page 265: ...4 Collar 5 Bearing 6 Housing 7 Bearing 8 Plate 9 Collar 10 Carrier 11 Thrust wire 12 Race 13 Needle 14 Planetary gear B 15 Thrust plate 16 Drive gear 17 O ring 18 O ring 19 Screw 20 Sun gear 21 Carrie...

Page 266: ...ng 6 O ring 7 O ring 8 O ring 9 Backup ring 10 Sleeve 11 Seat 12 Seat 13 Spring 14 Cap 15 Piston 16 Housing 17 Backup ring 18 Shim 19 Shim 20 O ring 21 O ring 22 Spring 23 O ring 24 Sleeve 25 O ring 2...

Page 267: ...4 162 4 SLEW MOTOR DISASSEMBLY AND ASSEMBLY Special tools Oil seal press tting jig A Collar installation jig B...

Page 268: ...tor 1 and the reduction gears 2 Place alignment marks on the hydraulic motor and the reduction gears for easy reassembly Secure the hydraulic motor in a vise Brake valve and hydraulic motor 1 Remove t...

Page 269: ...sassemble the relief valve 6 Remove the O ring 14 disc spring 15 and spring seat 16 7 Remove the brake piston 17 WARNING In a work area where compressed air is used metal fragments or other objects co...

Page 270: ...and pin 23 from the cylinder block 11 Take out the snap ring 24 and remove the retainer 25 springs 26 and retainer 27 from the cylinder block WARNING Components may pop out Wear protective gear such a...

Page 271: ...asher 32 and the spool 33 c Remove the sleeve 34 Reduction gears 1 Remove the O ring 1 and the thrust plate 2 2 Remove the drive gear 3 3 Remove the planetary gear 4 needle 5 inner race 6 and thrust w...

Page 272: ...easy removal using a portable dryer for example 8 Remove the planetary gear 15 needle 16 inner race 17 and thrust washer 18 from carrier 2 13 9 Remove the collar 9 and plate 10 10 Remove the shaft 11...

Page 273: ...race of the bear ing 12 Remove the oil seal 21 Removed oil seal cannot be reused Anti rebound valve 1 Take out the plug 1 and remove the plug 2 2 Remove the check valve assembly 3 3 Remove the sleeve...

Page 274: ...new lter Ori ce 4 9 N m 2 Install the ori ce 6 on the body Ori ce 2 45 N m 3 Attach the O ring on the plug 5 and install them on the valve body Plug 61 8 N m 4 Install the sleeve 4 on the body 5 Inst...

Page 275: ...the timing valve a Attach the O ring on the sleeve 34 and install them on the housing b Fit the spool 33 washer 32 and spring 31 into the hole of the sleeve c Install the plug 30 Plug 84 5 N m 5 Insta...

Page 276: ...Apply hydraulic oil to the sliding surfaces before hand 9 Press t the shaft 29 into the housing 10 Install the swash plate 28 on the housing Apply grease to surface A of the swash plate 11 Install th...

Page 277: ...O ring 7 on the cov er Apply grease to the pin beforehand 16 Install the pin 5 and the valve plate 4 on the cover Apply grease on the back of the valve plate the side facing the cover in advance to p...

Page 278: ...tting jig A Dimension of the oil seal press tted 4 25 mm 2 Press t the bearing 12 3 Fill grease into the inner race of the taper roller bear ing Brand Shell Albania Grease 2 Filling volume 62 to 72 mL...

Page 279: ...16 and planetary gear B 15 on the carrier 2 13 7 Install the thrust plate 14 on the carrier 2 13 and secure it with the cap screws Apply Loctite 242 to the cap screws Cap screw 6 1 2 0 N m 8 Install...

Page 280: ...ive gear 4 and thrust plate 2 on the carrier 1 8 12 Install the O ring 1 on the housing Slew motor 1 Assemble the hydraulic motor 1 and the reduction gears 2 and secure them with the cap screws Cap sc...

Page 281: ...sembly Abnormal drop in set pressure Unstable set pressure causes vibration Strong leakage due to faulty seating Replace Replace Replace Spring Damaged or severely deformed Replace Hydraulic motor Par...

Page 282: ...e Carrier shaft Clearance with planetary shaft is too large Replace Shaft Excessive clearance with the pinion due to wear of the spline Replace Thrust washer Excessive wear Replace Ball bearing roller...

Page 283: ...8 4 SWIVEL JOINT DISASSEMBLY AND ASSEMBLY SWIVEL JOINT Construction 1 Shaft 2 Hub 3 Flange 4 Thrust ring 5 Pin 6 Slipper seal 7 O ring 8 O ring 9 Backup ring 10 Dust seal 11 Snap ring 12 Plug 13 Dust...

Page 284: ...ing place a pipe on the stopper pin of the shaft and check if the shaft smoothly rotates Bolt 24 5 to 39 2 N m 2 Remove the O ring 2 the snap ring 3 and the thrust ring 4 When assembling make sure the...

Page 285: ...er of the hub Check the positions of the seals in the construction diagram Remove the O rings with an eyeleteer or similar tool with a sharp point on the end Do not strongly deform or bend localized p...

Page 286: ...ing of foreign matter etc Replace Sliding portion of hub and shaft other than the seals Abnormal wear or scratches of 0 1 mm depth or more due to scorching trapping of foreign matter etc Scratches of...

Page 287: ...e pipe 3 coming from the hydraulic pump 2 to the shaft 1 side port 2 Connect the pressure gauge 5 to the hub 4 side Increase the pressure gradually to 20 6 MPa while adjusting the relief valve 6 and t...

Page 288: ...LY AIR CONDITIONER Construction 1 Upper case 2 Heater core 3 Retainer 4 Clamp 5 Blower motor 6 Blower fan 7 Evaporator 8 Unit case 9 Sensor holder 10 Thermistor 11 Expansion valve 12 Temperature senso...

Page 289: ...installation location shown on the gure on the right and to observe the followings The clearance A between the fan 6 and the case must be 2 mm or more on both sides Align the center of the blower fan...

Page 290: ...valve 11 from the evaporator c Install a new expansion valve 11 on the evaporator 7 using the prescribed tightening torque Expansion valve inlet C 13 2 0 15 N m Evaporator inlet D 17 7 0 2 N m d Inst...

Page 291: ...air conditioner 2 to 3 times a month during the season when it is not in use to prevent the oil from drying up in the compressor Check for refrigerant gas leaks at the same time Leaving the air condit...

Page 292: ...4 Boom cylinder operation is slow or lacks power 5 26 When the boom control lever is pulled slowly the boom drops at rst 5 29 Spontaneous drop of the bucket is too large 5 30 Arm 5 31 Arm cylinder doe...

Page 293: ...tion Determine if it is really faulty by referring to the performance criteria Note that such determination may differ de pending on the person Important By operating the user s machine you could make...

Page 294: ...l 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 2 Check the...

Page 295: ...n re lief valve 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 5 3 3 Abnormal...

Page 296: ...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 worn or...

Page 297: ...itch Normal 4 Check 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...

Page 298: ...d 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 on the li...

Page 299: ...uators other than of the travel motor If the right or left travel is impossible operate each ac tuator of the devices listed in the table on the right If operation is faulty inspect the main relief va...

Page 300: ...alve Fit the pressure gauge to the hose just dis connected If the measured value is within speci cations the swivel joint is normal 2 Service data Performance criteria 5 Check the counter balance valv...

Page 301: ...ulty Repair or replace the housing block Normal 4 Switch the discharge hos es between the pumps Veering is changed to the op posite side Repair or replace the pumps Replace the hydraulic oil or the lt...

Page 302: ...tion is changed to the op posite side the pumps are faulty Disassemble and check the pump 4 Disassembly and assembly Hydraulic pump 5 Test by switching the main relief valves Switch the main relief va...

Page 303: ...d speed switch Normal 5 Check the 2nd speed re lay Faulty Replace the 2nd speed relay Normal 6 Check the 2nd speed so lenoid valve Faulty Repair or replace the 2nd speed solenoid valve Normal 7 Check...

Page 304: ...rformance criteria 3 Check the fuse Check the fuse in the power supply circuit that acti vates the 2nd speed solenoid valve 4 Check the 2nd speed switch Press the switch to turn it on Then check for c...

Page 305: ...nd the circuit is switched the sole noid valve is normal 7 Check the swivel joint Disconnect the hose connecting the swivel joint and the 2nd speed control valve from the 2nd speed con trol valve Fit...

Page 306: ...slew relief valve Adjust to the 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 faul...

Page 307: ...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 19 6 MPa 4 Check the slew pressure Measu...

Page 308: ...ve of the slew brake valve Faulty Repair or replace the brake valve Normal 5 The slew motor is faulty Repair or replace the slew motor 1 Check the pilot valve It is likely that only the pilot valve sp...

Page 309: ...matter is caught in one of the check valves 1 or if the valve is sticking right or left slewing does not work If foreign matter is caught in one of the check valves the hydraulic oil returns from the...

Page 310: ...y Repair or replace the housing block Normal 4 Check the slew pressure Pressure too low Adjust the slew relief valve pressure Adjust to set pressure Normal Pressure does not rise Repair or replace the...

Page 311: ...eci ca tions 2 Service data Performance criteria 2 Check the pilot valve 5 16 3 Check the spool operation 5 16 4 Check the slew pressure 5 16 5 Check the check valve of the slew brake valve 5 18 6 Ins...

Page 312: ...ew pressure Pressure too low Adjust the slew 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...

Page 313: ...d 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 Operate the le...

Page 314: ...Pressure too low 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 R...

Page 315: ...The port relief valve is faulty Repair or replace the port re lief valve No change 5 Check the boom cylinder Faulty Repair or replace the boom cylinder 1 Check the operation of actuators other than of...

Page 316: ...e pres sure Supply pressure 21 0 MPa 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 the replacem...

Page 317: ...on Faulty Repair or replace the housing block Normal 4 Test by replacing the port relief valve Problem solved The port relief valve is faulty Repair or replace the port re lief valve No change 5 Check...

Page 318: ...the piping Insert a plug 1 into the hose just disconnected c Retract the arm cylinder and lift the bucket off the ground If oil leaks from the cylinder piping that the hose was disconnected from and...

Page 319: ...machine body If oil leaks from the cylinder piping the hose was dis connected from while the boom cylinder rod is ex tended the cylinder is leaking internally If there is no oil leak from the cylinde...

Page 320: ...eps a through c above set the machine as follows Fully extend the bucket cylinder completely re tract the arm cylinder and lower the bucket to the ground When the spool rst starts to pull the oil s pr...

Page 321: ...or replace the boom cylinder Normal 3 Test by replacing the port relief valve Problem solved The port relief valve is faulty Repair or replace the port re lief valve No change Oil leak inside the cont...

Page 322: ...the operation of actuators 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...

Page 323: ...ion 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 to its regu...

Page 324: ...replace the housing block Normal 4 Test the port relief valve with a replacement valve Problem solved The port relief valve faulty Repair or replace the port re lief valve No change 5 Check for leak i...

Page 325: ...ylin 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 the...

Page 326: ...spontaneous drop of the arm cylinder 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 wi...

Page 327: ...on of actuators other than of the bucket cylinder Determine if only the bucket cylinder is faulty by check ing the operation of actuators for the devices listed in the table on the right If one of the...

Page 328: ...ement 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 lever...

Page 329: ...ing 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 arm c...

Page 330: ...heck the operation of actuators other than of the swing cylinder Determine if only the boom swing cylinder is faulty by checking the operation of actuators for the devices listed in the table on the r...

Page 331: ...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 con...

Page 332: ...he housing block Normal 5 Check the swivel joint Faulty Repair or replace the swivel joint Normal Dozer blade cylinder is faulty Repair or replace the dozer blade cylinder 1 Check the operation of act...

Page 333: ...19 6 MPa When only Dozer Blade Lower is impossible Replace the port relief valve in question with a port relief valve used for a normal arm If the dozer blade cylinder operates normally with the repl...

Page 334: ...e the housing block Normal 3 Inspect the swivel joint and the control valve Faulty Repair or replace the swivel joint or control valve 1 Is the spontaneous drop of the dozer blade within specs 2 Servi...

Page 335: ...try replacing the port relief valve with a normal one If the blade can support the machine af ter this replacement then the port relief valve is faulty 3 Inspect the swivel joint and the control valve...

Page 336: ...actuators for the devices listed in the table on the right If one of them is faulty check the main relief valve and the hydraulic pump P3 5 8 2 Check the proportional controller 4 Disassembly and asse...

Page 337: ...g or the suction lter Leak volume of hydraulic devices other than the pump is increased Run at the rated RPM Stop running and check the temperature again after the oil cools down Replace with hydrauli...

Page 338: ...ue to too high viscosity of the hydraulic oil Pump and engine are not center aligned Frothing of hydraulic oil Remove the dirt and correct the crushing Retighten each joint Replace with hydraulic oil...

Page 339: ...disabled due to deteriorated oil Spool is worn out because of prolonged use or of the unbalanced force applied Spool is bent by the external force Whole Valve is distorted due to the distortion of th...

Page 340: ...semble overhaul or replace Screw in the adjuster screw If loose set the adjustment again and fasten with a lock nut Disassemble overhaul or replace Manual Check if the link mechanism is inter fering w...

Page 341: ...ient primary pressure Replace Replace the spool and the casing assembly Disassemble and assemble or replace The secondary pressure is unstable The sliding part is not smooth The tank line pressure uct...

Page 342: ...e Coil assembly short circuit or wire break Replace Catching of foreign matter by the spool Overhaul and repair or replace Damage on the outer circumference of the spool Overhaul and repair or replace...

Page 343: ...eak still persists after replacing the seals replace the piston rod Redo the hard chromium plating Oil leak from the rod cover perimeter O ring is damaged Backup ring is damaged Replace the faulty par...

Page 344: ...n port because the motor s sliding part is worn out Bearing is worn out Replace the abnormally worn part if any Replace the abnormally worn part if any Oil leak Oil leak due to breakage of oil seal an...

Page 345: ...ual releasing is being tted Replace the discs Repair or replace Replace the spring Remove the bolt for manual release and t the plug Abnormal heat generation due to brake drag Release of braking is fa...

Page 346: ...faulty Reduction gears are faulty Reduce the load Repair or replace Replace the reduc tion gears Motor does not speed up Pump discharge is insuf cient Too much drain from the pump Repair or replace t...

Page 347: ...for clogging and repair If drain from the motor is too large check and repair the mo tor Timing valve does not change over Sliding parts are worn or dam aged Foreign matter is caught A spring is brok...

Page 348: ...ES Water valve is faulty Remove Connectors 1 and 2 Check for continuity of the wires yel low white yellow black green white green black of Connector 1 and Con nector 2 NO NO Repair the wire break disc...

Page 349: ...compressor Is it 10 15V YES C o m p r e s s o r clutch is faulty Repair or replace the compressor NO Turn off the starter switch and remove Connector 12 Check the pressure switch of the receiver drye...

Page 350: ...nk to black of Connector 12 YES Turn off the starter switch and remove the blower motor Any foreign matter in the blower motor YES The blower motor is locked by a foreign matter Remove the foreign mat...

Page 351: ...hanged be tween 2 and 3 Cannot be changed between 1 2 and 3 Check for short circuits in the blue white and blue yellow Short circuited YES Check for short circuits in the blue black and blue white Sho...

Page 352: ...ENGINE 6 Machine model Mounted engine TB250 4TNV88...

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