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Takeuchi TB175W, Workshop Manual

The Takeuchi TB175W Workshop Manual is a comprehensive guide for maintaining and repairing your excavator. This manual covers all aspects of the TB175W, providing detailed instructions and diagrams to assist with proper maintenance. Download your free copy from our website today.

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TB

175

W

Hydraulic Excavator

BOOK No.

 CW3E001

WORK

SHOP MANUAL

Serial No.

 17540001~

Summary of Contents for TB175W

Page 1: ...TB175W Hydraulic Excavator BOOK No CW3E001 WORKSHOP MANUAL Serial No 17540001...

Page 2: ...as the rear The left and right sides of the operator when seated in the operator s seat are the left and right sides of the machine MACHINE SERIAL NUMBER The machine serial number is stamped on the i...

Page 3: ...0 3 I GENERAL II SPECIFICATIONS III MACHINE CONFIGURATION IV HYDRAULIC UNITS V TROUBLESHOOTING VI ENGINE...

Page 4: ...0 4...

Page 5: ...1 1 I GENERAL...

Page 6: ...TENTS Safety Precautions 3 Cautions during Disassembly and Assembly 10 Cautions during Removal and Installation of the Hydraulic Units 10 Cautions during Removal and Installation of Piping 11 Handling...

Page 7: ...ssarily cover all safety measures For maintenance work each person must take adequate safety precautions against possible hazards present in the respective working environment Observe all safety rules...

Page 8: ...y parts periodi cally Replace fuel hoses periodically Fuel hoses be come weaker over time even if they appear to be in good shape Replace important safety parts whenever an ir regularity is found even...

Page 9: ...ands clothing and tools away from the rotating fan and running fan belts Securely block the machine or any com ponent that may fall Before performing maintenance or repairs under the machine set all w...

Page 10: ...rer s approved cap Use of a non ap proved cap without proper venting may result in pressurization of the tank Never use fuel for cleaning purposes Use the correct fuel grade for the operating sea son...

Page 11: ...s or disconnect ing hoses stand to the side and loosen slowly to gradually release the internal pressure before removing Handling of the Accumulator High pressure nitrogen gas is enclosed in the accu...

Page 12: ...s or other damage Ask a Takeuchi service agent to repair any welding problems which are detected If not feasible make sure the welding is done by a quali ed person in a properly equipped workplace Saf...

Page 13: ...s utilizing an alcohol injector Never cut or weld on a wheel with an in ated tire mounted on it This could cause explosive decompression Tires are to be repaired only by an authorized person using the...

Page 14: ...eal tape from the front end Wrapping it tight and leaving 1 or 2 threads bare Overlap the tape by about 10 mm 10 When tting the snap rings the bigger rounder side of their circumferences should face t...

Page 15: ...ses or steel pipes apply the maximum working pressure 5 or 6 times and con rm that there is no leakage HANDLING OF SEALS 1 Clean the grooves for O rings and if there is any burr etc remove it 2 Be car...

Page 16: ...5 9 9 8 151 8 7 2 27 2 245 2 9 8 181 0 7 2 28 313 8 19 6 231 4 14 3 32 313 8 19 6 231 4 14 3 35 411 9 19 6 303 7 14 3 Hose Fitting Size Torque Union Nut G Taper Thread R N m ft lb N m ft lb 1 8 9 8 4...

Page 17: ...5 12 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 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 3 4 93...

Page 18: ...7 5 6 0 28 40 5 2 0 M12 1 75 83 4 4 1 8 5 0 42 61 5 3 0 97 1 4 8 9 9 0 49 71 6 3 5 M14 2 0 134 4 6 7 13 7 0 68 99 1 4 9 155 9 7 7 15 9 0 79 115 0 5 7 M16 2 0 207 9 10 4 21 2 1 06 153 3 7 7 241 2 12 1...

Page 19: ...II 1 II SPECIFICATIONS...

Page 20: ...ydraulic equipment drops and this is the estimated value indicating the use limit for the respective part It is decided under refer ence to the standard at the time of shipping the results of various...

Page 21: ...7 Pilot Valve 8 Battery 9 Control Valve 10 Axle Lock Cylinder 11 Engine 12 Tire 13 Axle 14 Hub 15 Swing Cylinder 16 Undercarriage 17 Dozer Blade 18 Steering Wheel 19 Dozer Blade Cylinder 20 Swivel Jo...

Page 22: ...Unit mm 2 Piece Boom Mono Boom A 6260 6320 B 2110 C 2925 D 1720 E 1715 F 2100 G 2330 H 2300 J 515 K 335 L 2505 2620 M 1955 2060 N 2385 2495 P 690 Q 730 R 1815 S 600 T 4380 4445 U 2895 2645 V 80 W 50...

Page 23: ...II 5 SPECIFICATIONS Mono Boom DIMENSIONS Operating Range Unit mm Mono Boom A 6945 B 6700 C 4055 D 3220 E 6780 F 4765 G 1330 H 4270 J 335 K 145...

Page 24: ...0 Road km h 0 to 20 Reverse Creep km h 0 to 4 5 Site km h 0 to 9 0 Road km h 0 to 20 Gradeability degree 70 35 Minimum Turning Radius mm 5855 Minimum Turning Clearance Radius mm 5615 Noise Level Soun...

Page 25: ...ximum Digging Height mm 8325 6780 Radius at Maximum Digging Height mm 1335 3985 Maximum Dumping Height mm 6355 4765 Radius at Maximum Dumping Height mm 2090 4345 Minimum Dumping Height mm 2665 1330 Mi...

Page 26: ...tarter V kW 12 3 0 Generator V kW 12 0 96 Battery V A h 12 90 Hydraulic Pump Model K3SP36C 1CFR 9002 2 Type Variable displacement type double axial piston Delivery P1 L min 72 6 P2 L min 72 6 Rated Pr...

Page 27: ...d Valve Model 16545 00000 Number of Solenoids 3 Solenoid Rated Voltage V 12 Solenoid Valve 2 Piece Boom Model 16522 00000 Number of Solenoids 4 Solenoid Rated Voltage V 12 Proportional Control Solenoi...

Page 28: ...Mechanism Boom Adjustment Cylinder Bore Diameter Rod Diameter mm 90 55 Stroke mm 580 Fully Retracted Length Pitch mm 955 Cushion Mechanism Slew Motor Model MSG 44P 21 Type Piston Motor Total Displacem...

Page 29: ...0 Steering System Type Front Setting System Operation Type Hydraulically Operated Breake Device Travel Brake Type Front and rear wheel braking direct acting hydraulic disk with brake lock Parking Brak...

Page 30: ...Takeuchi oil 46 is used When a conventional antiwear hydraulic oil is used replace it every 2000 hours Part Type Type by air temperature 20 10 0 10 20 30 40 C When to change replenish Capacity Engine...

Page 31: ...xpected 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 altitude a higher cetane number fuel will be required The sul...

Page 32: ...MPa 17 16 17 16 Slew Slew Time Normal Speed s 10 82 10 82 Slow Speed s 14 53 14 53 Overrun When Slewing Stops mm 498 5 380 Natural Slew Drop mm 0 0 Cylinders Cylinder Speed Boom Extended s 3 10 2 20...

Page 33: ...e plug 4 and adjust the set pressure Turn the plug slowly by referring to the pres sure gauge The pressure increases by 21 3 MPa at one turn of the plug 4 Upon completion of the pressure adjustment ho...

Page 34: ...en begin adjusting pres sure by turning setting screw 1 Turning clockwise raises the set pressure Turning counterclockwise lowers the set pressure 2 In order to keep the setting screw from turning aft...

Page 35: ...ure the relief pressure Adjusting Method 1 Loosen locknut 2 then begin adjusting pres sure by turning setting screw 1 Turning clockwise raises the set pressure Turning counterclockwise lowers the set...

Page 36: ...shims 4 Shim thickness 0 2 mm Shim thickness 0 5mm 4 Upon completion of the pressure adjustment assemble the relief valve and con rm that the relief valve set pressure is stable Cap Screw 3 92 N m Hy...

Page 37: ...a no load state rotate 180 de grees at which point return the operation lever to neutral Measure the differential between the position marks and the point the hoe attachment stops Natural Slew Drop E...

Page 38: ...osition the arm horizontally and rest the dozer blade on the ground Then measure the time required for the bucket cylinder to completely retract extend from a fully extended state retracted state Doze...

Page 39: ...r Drop Boom Arm Bucket Dozer Blade Bucket Tip Engine Maximum r p m Hydraulic Oil Temp 50 60 C Measurement Posture Completely retract the dozer blade and arm cylinders fully extend the bucket cylinder...

Page 40: ...II 22 SPECIFICATIONS STANDARDS FOR JUDGING PERFORMANCE...

Page 41: ...III TB175W III MACHINE CONFIGURATION...

Page 42: ...II MACHINE CONFIGURATION TB175W CONTENTS Drive System 3 Slew System 9 Travel System 11 Upper Frame 13 Control System 21 Attachments 27 Hydraulic System 33 Electrical System 37 Air Conditioner System 4...

Page 43: ...Engine Foot RR 5 Stopper 6 Stopper 7 Cushion Rubber 8 Cushion Rubber 9 Ground Cable 10 Bracket 11 Exhaust Pipe 12 Pipe 13 Bracket 14 Silencer 15 Gasket 16 Gasket B 241 N m C 193 N m D 55 N m Apply th...

Page 44: ...I TB175W Engine Mount 2 2 A 3 9 N m A 4 9 N m 1 Bracket 2 Air Cleaner 3 Hose 4 Hose 5 Pipe 6 Pipe 7 Pipe 8 Pipe 9 Hose 10 Hose 11 Drain Vave 12 Hose 13 Hose 14 Hose 15 Sub Tank 16 Bracket 17 Plate 18...

Page 45: ...RATION DRIVE SYSTEM III TB175W III 5 Radiator and Oil Cooler 1 Stay 2 Stay 3 Shroud 4 Plate 5 Plate 6 Plate 7 Net 8 Bracket 9 Bracket 10 Guard 11 Cushion Rubber 12 Radiator and Oil Cooler 13 Cushion R...

Page 46: ...ary Boom 2 Arm 1 Swing Outrigger Slew Auxiliary Steering Brake Pilot Pressure P1 P2 P3 P4 P5 The pump coupling connects the engine flywheel and the hydraulic pump s drive shaft It is construct ed so t...

Page 47: ......

Page 48: ...ire Harness 6 Diode 3A yellow 7 Hose 8 Hose 9 Plug 10 Level Switch 11 Strainer 12 Pump 13 Float III 8 C Upon assembling inspect the continuity using a tester when the level switch float 13 is at ON an...

Page 49: ......

Page 50: ......

Page 51: ......

Page 52: ...III 12 MACHINE CONFIGURATION TRAVEL SYSTEM TB175W...

Page 53: ......

Page 54: ...MACHINE CONFIGURATION Upper frame III 14 TB175W Floor Plate 1 Floor Plate 2 Floor Mat 3 Cover 4 Stage 5 Tube 6 Tube 7 Rubber 8 Cover 9 Cover 10 Pipe W2C401 10 6 5 6 8 8 7 3 2 4 1 9...

Page 55: ...rame III 15 TB175W Heater D Grease with molybdenum disulfide applied B 23 5 N m 1 Cover 2 Plate 3 Selector Damper 4 Bracket 5 Panel 6 Cover 7 Wire 8 Wire 9 Filter 10 Cover 11 Hose 12 Hose 13 Heater As...

Page 56: ...6 TB175W 1 Bracket 2 Box 3 Louver 4 Defroster Hose 5 Parking Brake Switch 6 Site Travel Switch 7 Axle Lock Switch 8 Light Switch 9 Hazard Switch 10 Pilot Lamp 11 Pilot Lamp 12 Pilot Lamp 13 Pilot Lamp...

Page 57: ...2 Box 3 Plate 4 Relay 5 Relay 6 Sheet 7 Battery 8 Bracket 9 Cable 10 Battery Cable 11 Terminal 12 Clamp 13 Cover 14 Battery Switch 15 ECU 16 Ground Cable A ACC Relay B Air Heat Relay C Actuator Relay...

Page 58: ...MACHINE CONFIGURATION Upper frame III 18 TB175W Radio 1 Cover R 2 Cover L 3 Bracket 4 AM FM Radio 5 Speaker R 6 Speaker L...

Page 59: ...d Covers 1 Engine Food 2 Engine Cover Front 3 Side Cover L 4 Side Cover R 5 Front Cover 6 Center Cover F 7 Center Cover T 8 Under Cover 17 Lock Plate 18 Link 19 Yoke 20 Hinge 21 Gas Spring 22 Under Co...

Page 60: ...MACHINE CONFIGURATION Upper frame III 20 TB175W...

Page 61: ...g 8 Spring 9 Shaft 10 Bracket 11 Ring 12 Covering 13 Washer 14 Half Bowl 15 Substructure 16 Segment 17 Pin 18 Pin 19 Collar 20 Substructure Compl 21 Plate 22 Stop 23 Spring 24 Shaft 25 Support 26 Half...

Page 62: ...TM1 PM1 A2 B2 C2 C1 SH T7 3A2 a2 b2 B1 A1 D PM2 3ST 3ST BST BSP AST PM5 PM4 PM3 TM3 TM5 SSP 5Pa2 4Pa3 4Pa2 R1 R2 R3 R4 RT RP L1 L2 L3 L4 LT LP A MONO BOOM 5Pb2 4Pb3 4Pb2 W2C504E 11 21 1 13 A 4 5 8 7...

Page 63: ...ator 19 Accumulator 20 Control Valve 21 Slew Motor 22 Selector Valve 2 Piece Boom 23 Pipe 24 Solenoid Valve 1 1 1 1 1 1 2 2 2 2 2 2 3 3 3 3 4 4 4 4 5 5 5 5 6 6 6 6 6 6 7 9 9 9 9 10 10 11 10 10 12 12 1...

Page 64: ...Cover R 5 Clamp 6 Cluster Gauge 7 Starter Switch 8 Slew Speed Switch 9 Light Switch 10 Wiper Switch 11 Safety Lock Button 12 Fuse Box 13 Fuse Box 14 Safety Relay 1 Panel Cover L 2 Cover 3 Clamp Contro...

Page 65: ...B175W Dozer Blade Lever 1 Dozer Blade Lever 2 Bracket 3 Cover 4 Control Cable 5 Yoke 6 Cigarette Lighter Swing Pedal 7 Hinge 1 Bracket 2 Swing Pedal 3 Cover 4 Bushing 5 Elbow 6 Pilot Valve Swing W2C50...

Page 66: ...ION Control SYSTEM III 26 TB175W Pilot Valve Brake 1 Pilot Valve Brake 2 Adapter 3 Elbow 4 Adapter Pilot Valve Travel 1 Pilot Valve Travel 2 Bushing 3 Elbow 4 Elbow W2C510 2 1 2 3 3 4 2 W2C511E 2 1 4...

Page 67: ...Arm Cylinder 22 Boom adjustment Cylinder 23 Shim 24 O ring 25 Pin 26 Pin 27 Shim 28 Protector 29 Pin 30 Plate 31 Grease Nipple 32 Elbow 33 Elbow 34 Tube 35 Tube 36 Clamp 37 Band 38 Band 39 Cap A 26 N...

Page 68: ...ipe L 11 Pipe 12 Cap 13 Grease Nipple 14 Hose 15 Hose 16 Hose 17 Cap Keep the clearance at the pin connecting section excluding the bucket connecting section to 0 5 mm or less by using the shim When f...

Page 69: ...23 Boom Light 24 Bulb 25 Boom Cylinder 26 Arm Cylinder 27 Hose 28 Hose 29 O ring 30 Tube 31 Tube 32 Protector 33 Gauge 34 Plate 35 Cap 36 Band 37 Band 38 Band A 26 N m B 31 5 5 88 N m Keep the cleara...

Page 70: ...Elbow 19 Elbow 20 O ring 21 Bucket Cylinder 22 Hose 23 Shim 24 Shim 25 Shim 26 Cap 27 Gauge 28 Plate 29 Cap 30 O ring 31 Elbow A 26 N m Keep the clearance at the pin connecting section excluding the...

Page 71: ...he value calculated above clear ance X However since the thickness of the adjustment shims is 0 5 mm the actual clearance will be a value near 0 5 Example If the clearance X is 1 8 mm 1 8 0 5 1 3 mm S...

Page 72: ...III 32 MACHINE CONFIGURATION Attachments TB175W...

Page 73: ...HYDRAULIC SYSTEM HYDRAULIC SYSTEM HYDRAULIC CIRCUIT DIAGRAM MACHINE CONFIGURATION III 33 TB175W 2 Piece Boom...

Page 74: ...Mono Boom III 34 TB175W HYDRAULIC SYSTEM MACHINE CONFIGURATION...

Page 75: ...raulic Tank 1 Tank 2 Air Breather 3 Cover 4 Cover 5 Spring 6 Filter Element 7 Check Valve 8 Suction Filter 9 O ring 10 O ring 11 Sight Gauge 12 Plug 13 O ring 14 Check Valve 15 Snap Ring 16 Adapter 17...

Page 76: ...1 Loosen the bolts and remove the center cover 1 2 Remove the plug 2 3 Once hydraulic oil overflows from the plug hole tighten the plug 2 4 Install the center cover 1 Cylinders 1 Start the engine and...

Page 77: ...ELECTRICAL SYSTEM ELECTRICAL SYSTEM ELECTRICAL WIRING DIAGRAM 1 3 MACHINE CONFIGURATION III 37 TB175W...

Page 78: ...III 38 TB175W ELECTRICAL SYSTEM MACHINE CONFIGURATION 2 3...

Page 79: ...ELECTRICAL SYSTEM 3 3 MACHINE CONFIGURATION III 39 TB175W...

Page 80: ...III 40 TB175W ELECTRICAL SYSTEM MACHINE CONFIGURATION...

Page 81: ...rness 5 Diode 3A yellow 6 Plate 7 Resistor 8 Detector a H I J K D E F G 9 Relay 10 Controller 11 Flasher Relay 12 Box 13 Buzzer 14 Fuse Box 15 Bracket 16 Hour Meter a Horn relay b Wiper relay c Light...

Page 82: ...W3C802 a a b b c b c 17540001 17540134 17540001 17540134 17540135 2 17540001 17540094 6 2 5 3 4 9 1 7 10 8 1 Wire Harness 2 Fusible Link 3 Short Connector 4 Diode 3A yellow 5 Short Connector 6 Wire Ha...

Page 83: ...MACHINE CONFIGURATION ELECTRICAL SYSTEM III 43 TB175W 9 5 1 9 5 6 7 1 0 7 6 7...

Page 84: ...III 44 MACHINE CONFIGURATION ELECTRICAL SYSTEM TB175W...

Page 85: ...Guard 3 Shaft 4 Collar 5 Compressor 6 Pulley 7 Hose 8 Hose 9 Bushing 10 Valve 11 Adaptor 12 Bushing 13 Elbow 14 V Belt A Allow a clearance B Press on the center of the belt with a finger The belt s t...

Page 86: ...MACHINE CONFIGURATION Air Conditioner System III 46 TB175W Air Conditioner 1 2 1 Bracket 2 Cover 3 Condenser 4 Fun 5 Dryer 6 Bracket 7 Hose 8 Hose 9 Switch 10 Connector...

Page 87: ...Conditioner System III 47 TB175W Air Conditioner 2 2 1 Hose 2 Guard 3 Wire Harness 4 Air Conditioner Unit 5 Wire 6 Wire Harness 7 Relay 8 Valve 9 Tube 10 Cover 11 Panel 12 Hose 13 Hose 14 Hose 15 Lou...

Page 88: ...ser Air Conditioner Unit Panel Assembly 1 Adaptor 2 Evaporato 3 Heater Core 4 Filter 5 Blowier Motor 6 O Ring 7 O Ring 8 Expansion Valve 9 Thermo Stat 10 Air Condiitioner Switch 11 Knob 12 Cable Contr...

Page 89: ...ystem advantages and disadvantages explained in the paragraphs that follow The HVAC system includes both heater and air conditioner components usu ally a common control and air ducts The system cools...

Page 90: ...stem Operation We have described the movement of heat energy and basic HVAC system function in Chapter 1 Now we will go into some detail on how an air conditioner operates The system is sealed to keep...

Page 91: ...es a liquid The compressor also sucks the va porized refrigerant out of the evaporator and back inside itself in the form of gas One way valves inside the compressor separate the compressed gas high p...

Page 92: ...water at 212 degrees Fahrenheit Heat energy was involved in the change of state but the temperature did not change The same kind of action happens inside the AC sys tem The refrigerant gas gives up a...

Page 93: ...ver drier Figure 2 6 also separates gas bubbles from the liquid with a pick up tube as shown in this illustration Some receiver driers have a spring to preload the desiccant pack Figure 2 5 As the ref...

Page 94: ...using and sensing tube expands when it gets warmer and forces the expansion valve open at the metering orifice 5 Evaporator Coil The expansion valve or other type of metering device bleeds high pressu...

Page 95: ...perating range settings automatically cycle the clutch on and off The operation of the expansion valve or other refrigerant metering device at the inlet to the evaporator is automatic Individual syste...

Page 96: ...side of the water pump or to the radiator A control cable attached to a water valve between the water pump and the heater inlet is used to control the flow of coolant to the heater The heater fan or...

Page 97: ...ushed or pulled through the core depending on system design Blower or fan speed is usually selected by the operator Environmental Effects on System Operation The environment outside the cab involves m...

Page 98: ...e sealed pressurized systems The normal air conditioner operat ing pressure ranges from 150 to 250 pounds per square inch some times higher with a different refrigerant Air conditioners have a high an...

Page 99: ...are serviced every six months or less and another 62 are serviced at least once a year The survey also covered how often the different components required mainte nance Figure 7 1 below shows survey f...

Page 100: ...HVAC system been in use Did the operator or work order explain or describe any prob lems about the system Did someone else work on the system yesterday 700 miles down the road Your first inspection s...

Page 101: ...Look to see if the sight glass has a moisture indicator that is showing moisture in the system B Components Under the Hood Tip the cab or raise the hood Look at the compressor mounting bracket compre...

Page 102: ...should be often near the condenser All of these spots are potential leak or damage points Tighten re fasten add or replace as indi cated by your inspection 4 Check for Refrigerant Leaks System refrige...

Page 103: ...is at rest Electrical System Inspection The two stages of an electrical inspection are explained in more detail below 1 Inspect Electrical Connections 2 Check Electrical Current Flow and Device Funct...

Page 104: ...not sure the clutch is engaged look for the lead wire connector near the clutch Break and close that connection The clutch will disengage and engage again E Test Blower Speed Operation Some systems h...

Page 105: ...stem performance testing will be much faster if all doors and windows in the cab are closed The cab air must cool down to thermostat control setting levels before system components will cycle on and o...

Page 106: ...ly feel the suction and discharge lines and note their change in temperature The discharge line will get hot after a while it may be to hot to touch and the suction line will get cooler 3 Check Sight...

Page 107: ...ipment before refilling with clean water and anti freeze Coolant must be hot when using the hydrometer to check protection freeze up level The following inspection procedures are explained in more det...

Page 108: ...e checked with the pressure and thermostat testers as described in Chapter 6 A hand pump pressure tester can also be used to check for coolant leaks This is done by using the pump to raise the pressur...

Page 109: ...not take more than 15 to 20 minutes unless com ponent replacement and or complete system evacuation and recharging is war ranted The survey results shown in Figure 7 1 indicate belts compressor clutch...

Page 110: ...III 69 TB175W...

Page 111: ...repaired right Wrong What you did is add refrigerant and the problem went away You did not find and fix the cause of the problem Component failure in an air conditioning system may be the result of a...

Page 112: ...they do and are not too proud to ask for help or suggestions when needed The key understanding system function The Key Understanding System Function Your complete understanding of AC and heater syste...

Page 113: ...s heat energy from the cab to the outside air for occupant comfort The automatic functions of the thermostat or the pressure valve on some ac cumulators and the expansion valve help maintain pressures...

Page 114: ...ow about these possibilities and others when you talk to the operator before he has the chance to leave The right kind of questions can speed up troubleshooting and your service work by pinpointing th...

Page 115: ...ponents that should be serviced You could fix the probable causes and the system might work and then break down again as the rig drives out of your place From your knowledge and what the operator has...

Page 116: ...re all the valves on the manifold are closed all the way turn them clockwise Check the hose connections on the manifold for tightness Locate the low and high side system service fittings and remove th...

Page 117: ...read system pressure when the hand valves are closed if the hose end valves and the stem type service valves if included are open 2 Adding Refrigerant to the System Now that the gauges are connected y...

Page 118: ...frigerant to the system For your safety and to prevent system damage use the following procedure 1 Turn on the engine and set the idle at 1200 to 1500 RPM and then turn on the air conditioner Do not o...

Page 119: ...ore than that amount you should stop and check again for leaks Then recover all of the refrigerant repair evacuate and recharge the air conditioner See Chapter 9 You may want to add dry nitrogen gas t...

Page 120: ...air flow found under normal operating conditions When a vehicle has a tilt cab or hood and the condenser is part of the grill you must use the floor fan to get air to the condenser You could tilt the...

Page 121: ...e air from vents in the cab seems warm If there is a low pressure or Trinary switch in the system it may have shut off the compressor clutch Cause Extremely low or no refrigerant in the system There i...

Page 122: ...witch may not cycle the clutch on and off so the low pressure gauge will not fluctuate Cause Air and or moisture in the system RepairProcedure Test for leaks especially around the compressor shaft sea...

Page 123: ...f system re place the receiver drier or accumulator The desiccant is saturated with moisture Check and replace any com pressor oil lost due to leakage Evacuate and recharge the system then check AC op...

Page 124: ...suction pressure on the gauge This indicates the valve was part way open and that your action closed it Repeat the test but first warm the valve diaphragm or cap illary with your hand If the low side...

Page 125: ...id refrigerant may be flooding the evaporator making it impossible for the refrigerant to vaporize and absorb heat normally In vehicles where the TXV and sensing bulb are accessible check the capillar...

Page 126: ...Recover all refrigerant from the system and re place the expansion valve and the receiver drier Evacu ate and recharge the system with refrigerant then check AC operation and performance System High P...

Page 127: ...e may be a worn or loose compressor clutch drive belt Repair Procedure If you find the belt worn or loose replace or tighten it and recheck system performance and gauge readings To inspect and service...

Page 128: ...even if you install a new or rebuilt unit Tighten all connections and evacuate the system Recharge the air conditioner with refrigerant and check system operation and performance Note Rotary compresso...

Page 129: ...ator shutter assembly Re place any defective parts and then recheck AC system operation gauge readings and performance If the problem continues the system may be over charged have too much refrigerant...

Page 130: ...ube not inserted between the evaporator fins in the proper position Cause The thermostatic switch is not functioning properly or at all Repair Procedure Replace the thermostatic switch When you remove...

Page 131: ...ing problems are discussed in more detail in this section 1 Belts and Compressor Clutch 2 Condenser 3 Refrigerant Lines Hoses and Fittings 4 Refrigerant Metering Valves 5 Other Problems 1 Belts and Co...

Page 132: ...attacked by ozone oxygen in the air Rub ber parts break down slowly and become more vulnerable to the effects of vibration with the passage of time Heavy duty vehicle vibration causes stress on all li...

Page 133: ...p the leak The shaft rotation exerts force all around the seal and puts life back into it To prevent this from happening manufactur ers recommend regular AC system operation a minimum of every couple...

Page 134: ...MACHINE CONFIGURATION III 93 TB175W...

Page 135: ...IV 1 TB175W IV HYDRAULIC UNITS...

Page 136: ...oportional Control Solenoid 75 Selector Valve 77 Port Relief Valve 79 Shut Off Valve 81 Pilot Valve S N 17520003 17520208 83 Pilot Valve S N 17520209 94 1 Pilot Valve Swing 95 Cylinders 99 Dozer Blade...

Page 137: ...tem 34 Nut 35 Cover 36 Sleeve 37 Spool 38 Pin 39 Pin 40 Piston 41 Pin 42 Case 43 Adjusting Screw 44 Adjusting Screw 45 Piston 46 O ring 47 O ring 48 O ring 49 O ring 50 O ring 51 O ring 52 O ring 53 O...

Page 138: ...e 3 operateasthepumpP1 whilethe pistons in contact with the discharge port B operate as the pump P2 Inthisway thetenpistons 2 executeonesuctionand discharge stroke with each revolution of the cylinder...

Page 139: ...is closed When the discharge pressure from pumps P1 and P2 is reduced the spool 6 is pushed back to the left by the force exerted by the springs 7 and 8 and the hydraulic oil passage 11 connected to...

Page 140: ...ill be assembled in the same positions when assembled Replace all seals with new ones each time the hydraulic units is disassembled Check each part to make sure there is no abnormal wear or seizing an...

Page 141: ...er block a Remove the cylinder block from the shaft b Remove the guide 3 the springs 4 the holder 5 andthepistons 6 fromthecylinder block 7 Disassembletheinsideofthecylinderblock 7 only when required...

Page 142: ...rear end with a plastic hammer 10 Remove the cap screws and remove the cover 11 Remove the two springs inside outside 12 Remove the spring seat 13 Remove the cap screws and remove the cover 14 Remove...

Page 143: ...e piston Screw the bolt into the screw hole M4 at the end face of the piston and grab the bolt to pull out the piston 18 Loosen the lock nut 3 and remove the adjusting screw 2 Record the length of the...

Page 144: ...length as previously assembled using the lock nut 3 Lock nut 98 N m 2 Install the piston 3 Install the drain plug 1 4 Install the oil seal 5 Install the shaft in the housing Tap the spline end with a...

Page 145: ...ash plate 7 Install the swash plate in the housing Insert the bushing into the swash plate Apply grease on the sliding surfaces of the swash plate pin R and pin L 8 Mount the pin and tighten the plug...

Page 146: ...eat Apply grease to the spherical part of the spring seat 14 Install the two springs inside outside 15 Assemble the cylinder block a Install the springs in the cylinder block b Install the guide 3 in...

Page 147: ...valve plate and install it to the cover matching the knock hole 18 Install a large and a small O ring in the cover 19 Install the cover and install the cap screws Install the cover parallel to the hou...

Page 148: ...rt of shaft and oil seal Noabnormalscratches 0 02mmor more wear orstickingfortheslid ing surfaces Exchange Exchange Exchange Exchange Correctbylapping or exchange No abnormal wear or harmful scratches...

Page 149: ...erthanthepumpisincreasing Operatetheengineatthespecifiedspeed Stopthemachineandlettheoilcooloff then check again Replace the hydraulic oil with oil of the proper viscosity Replace the pump Reset the s...

Page 150: ...HYDRAULIC UNITS HYDRAULIC PUMP IV 16 TB175W...

Page 151: ...asket 14 Gasket 15 BuckupRing 16 Gasket 17 Gasket 18 Oil Seal 19 Snap Ring Gear Pump Thegearpumpconsistsofasinglegearcase insideof whichisadrivegear 1 andadrivengear 2 engaged with each other By turni...

Page 152: ...laceallsealswithnewoneseachtimethepump is disassembled coating them lightly with grease Check each part to make sure there is no abnormal wear or seizing and use sandpaper etc to remove any burrs shar...

Page 153: ...driven gear 10 from the housing Be careful to keep the bushings separated and in their original places Be careful not to scratch or otherwise damage the inside of the housing 7 Remove the gasket 2 fro...

Page 154: ...the drive gear 15 and the driven gear 16 Be careful to keep the bushings separated and in their original places Be careful not to scratch or otherwise damage the inside of the rear cover 12 Remove the...

Page 155: ...the sliding surfaces to have no roughness and for the suction side half to be lustrous Also it is satisfactory if strong contact marks can be seen on the side surface on the suction side and minute co...

Page 156: ...scaling and cutting If it is abnormal replace it Test Operation Thebestmethodfortestingthepump soperationisto mount it in a test stand However if that cannot be done testitundertheconditionsitwouldbes...

Page 157: ...a tester 1 to the discharge side of the pump 2 There should be no mistakes made in the tester s pipe installation 2 Open the tester s loading valve and start the engine 3 Run the engine at the rated...

Page 158: ...vitation is occurring Pump and engine are out of center with respect to each other There are bubbles in the hydraulic oil Removethedirtoreliminatethecrushed condition of the hose Tighten all the joint...

Page 159: ...O BLOCK CONSTRUCTION 1 Right Travel Section 2 Bucket Section 3 Boom 1 Section 4 Arm 2 Section 5 Left Travel Section 6 Auxiliary Section 7 Boom 2 Section 8 Arm 1 Section 9 Swing Section W2D200E A A B C...

Page 160: ...HYDRAULIC UNITS CONTROL VALVE IV 26 TB175W 1 Cover 2 Spool End 3 Holder 4 Spring 5 Spring 6 O ring 7 Cover 8 O ring 9 Shuttle 10 Spring 11 O ring 12 Plug 13 Poppet 14 O ring 15 Plug 16 Spring...

Page 161: ...HYDRAULIC UNITS CONTROL VALVE IV 27 TB175W 1 Housing 2 O ring 3 Spring Holder 4 Spring 5 Spool End 6 Port Relief Valve 7 O ring 8 Plug 9 Spring 10 Poppet...

Page 162: ...1 O ring 2 Plug 3 Spring 4 Poppet 5 Spring 6 Poppet 7 Sleeve 8 Port Relief Valve 9 O ring 10 Plug 11 Backup Ring 12 O ring 13 Spring 14 Poppet 15 Sleeve 16 Plug 17 O ring 18 Spring 19 Poppet 20 Anti...

Page 163: ...IC UNITS CONTROL VALVE IV 29 TB175W 1 Port Relief Valve 2 Plug 3 O ring 4 Spring 5 Poppet 6 Port Relief Valve 7 Poppet 8 Spring 9 O ring 10 Backup Ring 11 Plug 12 O ring 13 Plug 14 Sleeve 15 Spring 16...

Page 164: ...HYDRAULIC UNITS CONTROL VALVE IV 30 TB175W 1 Plug 2 O ring 3 Poppet 4 Spring 5 Plug 6 Main Relief Valve W2D205E 6 2 1 3 4 5 SECTION J J SECTION K K...

Page 165: ...2 Plug 3 Poppet 4 Poppet 5 Piston 6 Needle Valve 7 Spring 8 Spring 9 Spring 10 AdjustingScrew 11 Washer 12 Nut 13 O ring 14 O ring 15 Backup Ring 16 O ring 17 O ring 18 Backup Ring 1 Body 2 Poppet 3 P...

Page 166: ...heoilsuppliedfromtheportPPofthesignalpassage passes through the filter 5 orifice 6 passage 7 and flows into the pilot chamber 9 of the straight travel spool 8 At the same time the oil from the signal...

Page 167: ...fromtheport5B5tothetank passage 4 Part of the oil from the pump P2 passes through the orifice 10 raises the poppet 11 passes through the passage 3 and flows into the port 5A5 Bucket spool switching Sw...

Page 168: ...es 8 load check valve 9 passage 10 and the head of the spool 6 Then the oil raises thepoppet 1 oftheanti driftvalveandflowsintothe port 4B3 Concurrently thespool 12 oftheboom 2 isswitched by the passa...

Page 169: ...reducesthepressureinthespringchamber 5 through the drain port Dr1 to open the poppet 1 The return oilflowsthroughtheheadofthespool 6 oftheboom 1 orifice notch and back to the tank passage 20 Swing sp...

Page 170: ...spool 1 ofthearm 1 causesthespool 17 of the arm 2 to be switched by the passage 8 to close the center bypass passage 9 The oil sup plied from the pump P1 flows through the center bypass passage 9 pass...

Page 171: ...ilfromtheorifice 14 ofthespoolreturns to the tank The return oil flows from the port 5B2 through the orificeandnotchoftheheadofthespool 1 ofthearm 1 and back to the tank passage 18 Compound Operations...

Page 172: ...ool 3 passage 4 and to the spring chamber 5 Due to the spring force and the force produced by the difference in the poppet areas the poppet 1 is firmly seated 2 Raise The oil supplied from the pump op...

Page 173: ...at surface on the left side If the pressure in the circuit becomes higher than the force of the spring 7 the needle valve 5 is pushed to the right by hydraulic pressure opening Oil then flows around t...

Page 174: ...on the left side If the pressure in the circuit becomes higher than the force of the spring 7 the needle valve 5 is pushed to the right by hydraulic pressure opening Oil then flows around the circumf...

Page 175: ...atingavacuum in chamber B oil is supplied from the tank side preventing the occurrence of cavitation When the pressure in chamber B is lower than the pressure in the tank passage T the differences in...

Page 176: ...ace the section assembly as a unit Be sure to number each section and spool to avoid mistakes during assembly Do not turn adjusting screws if not required Following is an explanation of the control va...

Page 177: ...1 and 2 auxiliary bucket offset and the load check valves at the three common check valves a Remove the plug 13 then remove the O ring from the plug Plug 88 98 N m b Remove the spring 14 and poppet 15...

Page 178: ...Hold the spool with two pieces of wood so that the spool will not be damaged Locktite is applied to the thread so heat the section around the thread to approximately 200 C a Removethescrew 27 thenremo...

Page 179: ...spontaneously 5 Remove the poppet 7 spring seat 12 and spring 13 When reassembling be sure to apply grease to the edge of the poppet 7 to prevent the spring seat and the spring from being displaced 6...

Page 180: ...Remove the O ring 8 and backup rings 9 from the main poppet 4 4 Loosenthelocknut 10 andremovetheplug 11 and piston 12 When assembling after installing the plug first partially tighten the lock nut the...

Page 181: ...d the outer cir cumference sliding portion Scratches on the portion that slides against the seals on both ends Spool not operating smoothly Imperfect sealing due to damage to the valve or spring Does...

Page 182: ...sure bearing on one side only Spool is bent from externally applied pressure Entire valve is strained due to strain in the installation face Valve was used at a pressure or a flow volume which was out...

Page 183: ...ssing Or a seat is damaged Spool stroke is not the specified stroke Pump is damaged and no oil is dis charged Disassemble and check then overhaul or replace Try tightening the adjustment screw If itis...

Page 184: ...HYDRAULIC UNITS CONTROL VALVE IV 50 TB175W...

Page 185: ...Control Section Assembly 4 Dozer Blade Section Assembly 5 Slew Section Assembly 6 Outlet Housing 7 Main Relief Valve 8 Port Relief Valve 9 Spacer Section 10 Slow Slew Speed Adjusting Valve 11 Auxilia...

Page 186: ...O ring 10 Cover 11 O ring 12 Cap Screw 13 O ring Dozer Blade Section 1 Cover 2 Screw 3 Spring Holder 4 Spring 5 Cover 6 Load Check Valve 7 Spring 8 O ring 9 O ring 1 Screw 2 Spring Holder 3 Spring 4 C...

Page 187: ...Filter 2 Orifice Spacer Section 1 Plug 2 Adjusting Screw 3 Nut 4 O ring 5 O ring 6 O ring L3D253 1 2 L3D254 6 3 4 1 2 5 1 Cover 2 Screw 3 Spring Holder 4 Spring 5 Cover 6 Load Check Valve 7 Spring 8 O...

Page 188: ...15 O ring 16 O ring Main Relief Valve 1 Housing 2 Plug 3 Sleeve 4 Main Poppet 5 Seat 6 Needle Valve 7 Adjusting Screw 8 Washer 1 Housing 2 AdjustingScrew 3 Poppet 4 Spring 5 Lock Nut 6 O ring 7 O rin...

Page 189: ...he right When the spool 2 is moved to the right the center bypasspassage 3 isclosedandhydraulicoilentering from the pump passes through the load check valve 5 from the parallel passage 4 flowing from...

Page 190: ...ke pressure P1 and post choke pressure P2 at spool 1 works to maintain a constant pressure PC Part of the hydrau lic oil supplied from port P3 passes through the controlorifice 7 andflowstotheslewmoto...

Page 191: ...s of the main poppet 2 F P A Fl P A1 P Pressure A A1 Cross Sectional Area Since the cross sectional area of A is less than that of A1 the main poppet 2 is pushed by the force F1 F to the seat surface...

Page 192: ...Pressure A A1 Sectional Area SincethesectionalareaofAislessthanthatofA1 the main poppet 6 is pushed by the force F1 F to the seat surface on the left side If the pressure in the circuit becomes highe...

Page 193: ...than the pressure in the tank passage T the differences in the sectional areas A and A1 cause the main poppet 6 to open Thus sufficient oil from the tank passage T enters chamber B filling the empty...

Page 194: ...section assembly as a unit Be sure to number each section and spool to avoid mistakes during assembly Do not turn adjusting screws if not required Following is an explanation of the control valve disa...

Page 195: ...valve Removethespring 3 thenremovethepoppet 4 Manually Operated Section 1 Remove the cap screws 5 the cover 6 and the spool assembly 7 Cap screw 7 3 N m 2 Loosenthescrew 8 fromthespoolassembly 7 Screw...

Page 196: ...ng 14 5 Remove the screws on the spool yoke end side of the section then remove the seal holder backup ring and O ring Screw 2 5 N m Pilot Operated Section 1 Take out the cap screw 5 and remove the co...

Page 197: ...16 from the cover 21 Cap screw 7 3 N m Disassembling the Slew Flow Control Block 1 Remove cap screws 1 then remove cover 2 spring 3 spring holder 4 and spool 5 Cap screw 9 8 N m 2 Remove O ring 6 fro...

Page 198: ...eeve 4 4 Remove the O ring 7 and backup ring 8 from the seat 9 5 Removethelocknut 10 washer 11 andadjust ing screw 12 from the plug 1 then remove the O ring 13 from the adjusting screw 12 During assem...

Page 199: ...ng clawed around the outer cir cumference sliding portion Scratches on the portion that slides against the seals on both ends Spool not operating smoothly Imperfect sealing due to damage to the valve...

Page 200: ...owsthesettingatthe factory Adjustable distance A 3 mm 1 Loosen the lock nut 2 and turn the set screw 1 to fine adjust the slew speed Turning to the left will reduce the speed Turning to the right will...

Page 201: ...TRUCTION Solenoid Valve 3 Section Ram Lock Lever Lock and Speed Shift 1 Body 2 O ring 3 Spool 4 Spring 5 Cover 6 Solenoid Valve 7 Relief Valve W2H100E 7 1 3 T T A4 A4 P P P1 P1 A3 A3 A2 A2 A1 A1 4 2 5...

Page 202: ...and Parking Brake 1 Spring 2 Sleeve 3 Body 4 Rod 5 Plate 6 Solenoid Valve 7 Spool 8 Stopper 9 Plug 10 Washer 11 O ring 12 O ring HYDRAULIC SYMBOL W2H101E C B A A P T B C PARKING BRAKE SWING ADJUST CH...

Page 203: ...1 Spring 2 Sleeve 3 Body 4 Rod 5 Plate 6 Solenoid Valve 7 Spool 8 Stopper 9 Plug 10 Washer 11 O ring 12 O ring HYDRAULIC SYMBOL W2H102E C D B A A P T B C D SWING ADJUST CHANGE SPEED SHIFT LOW SPEED SH...

Page 204: ...T are connected the pressure in the pilot circuit downstream becomes the same as the tank pressure When current is flowing A magnetic field is generated around the coil and the plunger 2 is pulled do...

Page 205: ...and a thin coating of grease to seals when assembling them Replace seals with new parts each time disassem bly is done Do not turn adjusting screws if not required Following is a description of the s...

Page 206: ...of the spool using a tool such as a scriber To remove the sleeve turn the body upside down and lightly tap it Solenoid Valve 4 Section Change and Speed Shift 1 Loosen the cap screws and remove the sol...

Page 207: ...ted or has a wire break Wiring short circuit or wire break Judgment Criteria Treatment Scratches rust or corrosion at the sliding parts with the spool Scratches rust or corrosion of the seal part in c...

Page 208: ...HYDRAULIC UNITS SOLENOID VALVES IV 74 TB175W...

Page 209: ...HYDRAULIC UNITS PROPORTIONAL CONTROL SOLENOID VALVE IV 75 TB175W PROPORTIONAL CONTROL SOLENOID VALVE CONSTRUCTION A 7 0 5 N m 1 Proportional Control Solenoid 2 Bolt 3 Spool...

Page 210: ...sectionsA1andB1ofthespool 1 and the spool 1 is pushed to the solenoid side by the oil pressure Pa S The spool 1 stops at a position where the sum of the oil pressure Pa S and the force Fk exerted by t...

Page 211: ...damaged replace the valve assem bly Apply a thin coating of hydraulic oil to sliding surfaces and a thin coating of grease to seals when assembling them Replace seals with new parts each time disasse...

Page 212: ...Rust corrosion deformation breakage or other notable damage Coil assembly Housing Spool Spring O ring Replace Replace Replace Replace Replace Replace Adjust or replace Replace Replace Symptom Main Ca...

Page 213: ...CTOR VALVE IV 77 TB175W SELECTOR VALVE CONSTRUCTION Pilot Change 1 Body 2 Plug 3 Connector 4 Spool 5 Spring 6 Retainer 7 O ring 8 O ring W2H300 PL T P HYDRAULIC SYMBOL A 3 7 1 4 6 5 8 2 A B PL T P A A...

Page 214: ...HYDRAULIC UNITS SELECTOR VALVE IV 78 TB175W Swing Adjust Change 1 Spring 2 Cover 3 Cover 4 O ring 22 6 6 2 2 X X 9 0 HYDRAULIC SYMBOL A A 1 2 3 4 4 SECTION X X PP T P1 B1 A1 B2 A2 P2 A 9 8 N m...

Page 215: ...ng 2 Plug 3 Sleeve 4 Main Poppet 5 Spring 6 Spring 7 Spring 8 Needle Valve 9 Backup Ring 10 Backup Ring 11 Pin 12 AdjustingScrew 13 Body 14 Lock Nut 15 O ring 16 O ring 17 O ring 18 O ring W2H400E SEC...

Page 216: ...y procedure Follow the procedure used to disassemble the relief valve in reverse order when reassembling it Disassembly 1 Removetheportreliefvalves thenremovetheO rings from the relief valves Donotdis...

Page 217: ...HYDRAULIC UNITS SHUT OFF VALVES IV 81 TB175W 1 Body 2 Relief Valve 3 Plug 4 Screw 5 Plug 6 Plug 7 Lock Nut 8 AdjustingScrew 9 Spring 10 Spool SHUT OFF VALVES CONSTRUCTION...

Page 218: ...ough the port C2 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 PDB The pilot pressure in the port PDB moves the spool 3 to...

Page 219: ...HYDRAULIC UNITS SHUT OFF VALVES IV 83 TB175W INSPECTION AND ADJUSTMENT Never adjust the adjuster screws on the isolation valve Otherwise thevalvemaynotworkproperly or the boom or arm may fall IV 83...

Page 220: ...rom the suspended object If the engine can be started the boom or arm can be lowered with the operating lever Check for safety then slowly lower the boom or arm If the engine cannot be started the boo...

Page 221: ...TB175W PILOT VALVE 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 Disc...

Page 222: ...mitted to the spool Therefore the spool is pushed up by the return spring and is in the output port C position shown above with oil not flowing between port P and the output port C but flowing between...

Page 223: ...IG A INSTALLATION JIG B Replace all seals with new ones each time the pilot valve is disassembled During assembly remove all the foreign matter from each part and check them to make sure there are no...

Page 224: ...he O ring 7 and seal 8 from the plug 5 Remove the reducing valve 12 and spring 13 Make match marks on the reducing valve and casing hole so they can be placed in the same position when they are reasse...

Page 225: ...17 Assembly 1 Assemble the reducing valve 12 a Installthewasher2 16 spring 15 andspring seat 14 on the spool 17 b Push in the spring sheet 14 to contract the spring 15 and move the spool 17 from the...

Page 226: ...the positions they were in be fore disassembly 3 Install the O ring 7 and seal 8 in the plug 5 4 Install the push rod 9 in the plug 5 Apply hydraulic oil to the push rod 5 Install the plug 5 and plat...

Page 227: ...1 and the lock nut Tighten the adjust nut to the point where all 4 push rods are uniformly making contact During tightening the disc should not be moved Adjust Nut 68 6 4 9 N m 7 Apply grease to the c...

Page 228: ...Plug Operating Portion Casing Port Plate Replace Replace Replace Replace Repair or replace Replace Replace Repair or replace Tightentothespeci fied torque Replace Replace Repair or replace IV 92 Seco...

Page 229: ...75W PILOT VALVE SWING CONSTRUCTION 1 Casing 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 L3D350 16 6 4 3 2 5...

Page 230: ...mbly refer to the construction diagram and follow the disassembly procedure in the reverse or der Disassembly 1 Remove the boot from the cover Use a copper or iron sheet to fasten the valve to the vic...

Page 231: ...ternately so that the cover is flat Mark the cover and casing so that they can be reassembled in the same positions Cap screw 8 8 N m 5 Remove the push rods 4 together with the plug 5 6 Remove the O r...

Page 232: ...due to damage Tightening is loose at the pin shaft or joint of the operating portion with looseness of 2 mm or greater Due to wear etc tightening is loose at the pin shaft or joint of the operating p...

Page 233: ...m bly Disassemble and reassemble or re place the handle TROUBLESHOOTING y d e m e R s e s u a C e l b a b o r P m o t p m y S Sliding parts are catching Tank line pressure fluctuates Air gets mixed in...

Page 234: ...HYDRAULIC UNITS PILOT VALVE IV 106 TB175W IV 98...

Page 235: ...ing 9 O ring 10 Tube 11 Bushing 12 Piston Rod 13 Bushing 14 Rod Cover 15 Cushion Bearing 16 Bushing 17 Snap Ring 18 Holder 19 Cushion Seal 20 Collar 21 Piston 22 Wear Ring 23 Nut 24 Set Screw 25 Ball...

Page 236: ...Bushing 14 Rod Cover 15 Cushion Bearing 16 Bushing 17 Snap Ring 18 Holder 19 Cushion Seal 20 Collar 21 Piston 22 Wear Ring 23 Set Screw 24 Ball 25 CushionBearing 26 Cushion Seal 27 Snap Ring 28 Stoppe...

Page 237: ...Snap Ring 16 Bushing 17 Wear Ring 18 Dust Seal 19 Set Screw 20 Ball 21 Grease Nipple 22 Grease Nipple 9 Piston Packing 10 Tube 11 Bushing 12 Piston Rod 13 Bushing 14 Rod Cover 15 Cushion Bearing 16 Pi...

Page 238: ...ring 5 Backup Ring 6 O ring 7 Piston Packing 8 O ring 9 Tube 10 Bushing 11 Piston Rod 12 Bushing 13 Rod Cover 14 Bushing 15 Snap Ring 16 Piston 17 Set Screw 18 Ball 19 Dust Seal 20 Plug 21 Holder 22...

Page 239: ...m the piston colliding with the cover at the stroke end acts on that mechanism and is dampened by it Cushion Mechanism When the piston 1 nears the stroke end just before itcollideswiththecover 2 ifthe...

Page 240: ...e 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 seals when assembling the...

Page 241: ...set screw 2 and remove the steel ball 3 The set screw is staked at 2 places with a punch sogrindoffthestakedportionsusing a hand drill b Loosen the piston nut 4 and remove it Use a wrench with a hydr...

Page 242: ...4 Removethebufferring 19 androdpacking 21 Extract using a eyeleteer with a pointed tip 5 Remove the dust seal 22 Extract by raising the rubber part with a screw driver etc and striking 6 Remove the s...

Page 243: ...make sure there are no level differences with the bushing 2 Install the O rings 15 16 and the backup rings 20 3 Using setting tool G pressure fit the dust seal 22 4 Install the rod packing 21 5 Insta...

Page 244: ...pread the wear ring at the cut portion the minimum amount necessary installing it on the piston from the shaft direction Piston Rod Assembly 1 Fastenthepistonrodsothatitisflatandinstallthe rod cover C...

Page 245: ...rew Refer to the table below Piston Nut Set Screw Cylinder Assembly 1 Fasten the tube in a horizontal position then insert the piston rod assembly in the tube During insertion align the center of the...

Page 246: ...he rod is bent more than the limit of 1 mm in 1 m replace it Measure by the method shown in the figure at right If the bending of the rod is within the above limit yet is bent a lot in a small distanc...

Page 247: ...Leakage 1 Disconnect the extension side hose 2 Apply test pressure to the retraction side for 3 minutes 3 Measure the amount of oil that has leaked from the extension side The amount of leakage shoul...

Page 248: ...ng and other seals If it leaks after the seals have been replaced replace the piston rod Repair the hardened chrome plating O ring is damaged Backup ring is damaged Replace the affected parts Replace...

Page 249: ...55 75 A 89 79 59 89 89 B 74 5 64 5 49 5 74 5 74 5 C 10 10 10 10 10 D 5 5 5 5 5 E 30 30 30 30 30 F 95 90 70 95 95 Sliding Jig C Fitting Jig D MATERIAL STKM13C MATERIAL NYLON Unit mm Sliding Jig C Fitt...

Page 250: ...HYDRAULIC UNITS CYLINDERS IV 114 TB175W Corrective Jig E Unit mm Boom Arm Bucket Boom Adjustment Swing A 133 113 98 103 133 B 120 100 85 90 120 MATERIAL STKM13C...

Page 251: ...CYLINDER IV 115 TB175W DOZER BLADE CYLINDER CONSTRUCTION 1 Dust Seal 2 Joint 3 Guide Band 4 O ring 5 Backup Ring 6 Pipe 7 Piston Rod 8 Rod Cover 9 Piston 10 Nut 11 Screw 12 Bearing 13 Ring W2D409 12...

Page 252: ...HYDRAULIC UNITS DOZER BLADE CYLINDER IV 116 TB175W...

Page 253: ...408 bars The control line is attached to the connecting line of both cylinders i e the control pressure which can be applied to the non return valve in the cylinder head is also the initial pressure...

Page 254: ...HYDRAULIC UNITS RAM LOCK CYLINDER IV 118 TB175W Figs 1 6 2 Hydraulic switching diagram Fig 2...

Page 255: ...clean conditions 4 Fault finding a If the rigid axle fails to support a cylinder the rod seal Pos 7 and the tightness of the check valve case Pos 3 should be checked and the parts replaced if necessar...

Page 256: ...s 3 from the inside via the filler bore Pos 10 Check seals Pos 8 14 15 16 and 17 for damage and replace if necessary The non return valve case cannot be dismounted any further Reassemble components in...

Page 257: ...g D Scraper ring D Piston Cylinder Non returnvalvecase complete Rod Cylinder housing Name D be longing to seal set D 0640 00 000 Supply separately only for seal set 410236 Supply separately only for s...

Page 258: ...HYDRAULIC UNITS RAM LOCK CYLINDER IV 122 TB175W...

Page 259: ...10 Retainer SLEW MOTOR CONSTRUCTION Hydraulic Motor 11 Spring 12 Retainer 13 Guide 14 Pin 15 Valve Plate 16 Bearing 17 Snap Ring 18 Collar 19 Shoe Holder 20 Pin 21 O ring 22 Center Disc 23 Swash Plate...

Page 260: ...her Reduction Gears 10 Carrier 2 11 Plate 12 Race 13 Needle 14 Planetary Gear 15 Thrust Plate 16 Drive Gear 17 O ring 18 Thrust Washer 19 Screw 20 Sun Gear 21 Carrier 1 22 Collar 23 Race 24 Needle 25...

Page 261: ...de 16 O ring 17 O ring 18 Backup ring 19 O ring 20 Backup ring 21 Body 22 Check Valve Assembly 23 Spring 24 Sleeve 25 Orifice 26 O ring 27 Filter 28 Washer 29 Orifice 30 O ring 31 Body 32 Spool 33 Spr...

Page 262: ...ning it Conversely if high pressure oil is introduced to port C rotation is the reverse of the above Relief Valve Operation 1 When the Motor is Started When the motor is started since the inertial loa...

Page 263: ...ure 2nd Step When the piston 11 reaches the stroke end the pressure in chamber B rises and the pressures in chamber A and chamber B equalize At this time the force moving the poppet 10 to the left sid...

Page 264: ...rt PG passes throughtheholeatthecenterofthespool 1 andis led to the parking brake release port PB so that the parking brake is released When the pilot pressure at the port SH disappears the spool 1 is...

Page 265: ...operates the parking brake Reduction Gears Thereductiongeariscomposedofa2 stageplanetary gear mechanism and it converts the high speed op eration of the motor to low speed torque for operation of the...

Page 266: ...the disassembled parts and dry them with compressed air Do not use a rag as this could cause clogging of dirt Make match marks on each part so that they will be assembledinthesamepositionswhenreassem...

Page 267: ...that they can be mated correctly when reassembling Fix the hydraulic motor with a vise Brake Valve and Hydraulic Motor 1 Remove the cap screws and then the timer valve 1 Be careful not to miss the O...

Page 268: ...rifice is caulked Do not remove it unless necessary 6 Remove the check valve a Remove the plug 9 b Remove the spring 10 and check valve 11 7 Remove the relief valve 12 Do not loosen the set screw nut...

Page 269: ...ch that the brake piston does not protrude 9 Remove the collar 17 10 Remove the cylinder block 18 friction discs 19 and center discs 20 11 Removetheshoeholder 14 andpistonassembly 21 from the cylinder...

Page 270: ...rts unless neces sary These parts should be replaced as one assem bly 14 Remove the swash plate 28 15 Remove the shaft 29 Lightly tap the end face with a plastic hammer 16 Remove the bearing 30 from t...

Page 271: ...ve the planetary gear A 4 needles 5 and inner race 6 5 Remove the thrust washer 7 6 Remove the carrier 1 8 7 Remove the sun gear 9 8 Remove the carrier 2 assembly 10 9 Loosen the screw and remove the...

Page 272: ...e shaft will not come out easily lightly tap it with a plastic hammer Toreplacethetaperrollerbearingorcollar the case assembly should be replaced 13 Remove the inner race 24 of the taper roller bearin...

Page 273: ...nd then the spring 2 2 Remove the check valve assembly 3 3 Remove the sleeve 4 4 Remove the plug 5 and then the orifice 6 5 Remove the orifice 7 washer 8 and filter 9 The filter should be replaced wit...

Page 274: ...61 8 N m 4 Mount the sleeve 4 on the body 5 Mount the check valve assembly 3 and the spring 2 on the body 6 Fit the O ring to the plug 1 and mount them on the body Plug 61 8 N m Brake Valve and Hydrau...

Page 275: ...er block 3 Fit the pins 23 to the cylinder block Apply grease to the pins 4 Mount the guide 22 5 Fit the shoe holder 14 to the piston assembly 21 and mount them on the cylinder block Apply the hydraul...

Page 276: ...10 Mount the center discs 20 and the friction discs 19 Total number of friction discs 2 Total number of center discs 3 Be careful of the mounting order 11 Fit the O ring to the collar 17 and insert th...

Page 277: ...iefvalve 12 15 Mount the relief valve assembly on the cover Be careful not to let the spring jump out Plug 37 20 N m Do not loosen the lock nut 13 16 Mount the check valve a Mount the spring 10 and po...

Page 278: ...plate the sidefacingthecover inadvancetopreventthe plate from dropping off Upon mounting the pin caulk the position A using the punch as shown in this figure 21 Mount the cover 2 on the case and fix t...

Page 279: ...ut grease into the inner race of the taper roller bearing Grease type Shell ALVANIA Grease Grease volume 80 90 mL 3 Mount the shaft 11 and plug 25 on the case Theshaft 11 shouldbemountedbeforemount in...

Page 280: ...gear B 12 on the carrier 2 10 6 Mount the thrust plate 11 on the carrier 2 10 and fix them with the cap screws Apply Loctite 242 to the cap screws Cap screw 24 5 4 9 N m 7 Mount the carrier 2 10 on t...

Page 281: ...ess for the thrust plate by referring to the table The largely rounded side of the thrust plate circumference should face the planetary gear 12 Fit the O ring 1 to the case Slew Motor 1 Unite the hydr...

Page 282: ...HYDRAULIC UNITS SLEW MOTOR IV 146 TB175W 2 Fit the O ring to the cover 3 Fit the anti rebound valve to the cover and mount the washer seal and screws Screw 32 4 2 0 N m K3D626...

Page 283: ...d vibration occurs There is a lot of leakage due to faulty seating etc Damaged or severely deformed Replace Replace Replace Replace Replace Replace Replace Replace Replace Parts Standard Dimension Rec...

Page 284: ...ise rotation not smooth etc Clearance with planetary shaft is large Clearance with pinion is large due to spline wear Amount of wear is great Rotation is abnormal abnormal noise rotation not smooth et...

Page 285: ...from oil seals Oil is leaking from mat ing surfaces Noise in piping Lubricating oil Gear unit Relief valve s set pressure is low Pump is broken down Control valve is broken down The load is excessive...

Page 286: ...ed prop erly Foreign matter is trapped The tightening torque of the anti rebound valve mounting bolt exceeds the prescribed value Remove the foreign matter Repair or replace the faulty parts Use the p...

Page 287: ...TB175W AXLE TYPE 212 FRONT...

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Page 511: ...TB175W AXLE TYPE 112 REAR...

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Page 718: ...TB175W GEAR BOX TYPE 357...

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Page 720: ...Service Manual Gear Box 357A10 GSM 0012 January 1998...

Page 721: ...declina ogni responsabilita per l utilizzo di componenti non originali o accessori non collaudatied apporvati A nderungen ohne vorherige Anku ndingung vorbehalten Es wird jede Verantwortung fu r die...

Page 722: ...FFE 6 UMRECHNUNGSTABELLEN 7 ANZIEHDREHMOMENTE 7 SCHEMAS FU R UNTERSETZUNGSGETRIEBE UND ZUSAMMENSTELLUNGSZEICHNUNGEN 8 DIREKT GEFLANSCHTER REDUZIERER 357 ZERLEGEN 10 HYDRAULISCHER GANGSCHALTUNG ENFERNE...

Page 723: ...Pru fung und Montage der Einzelteile no tig sind Um die Differentia lachse des Fahrzeugs abzumontieren lesen Sie bitte die Anweisungen in den Handbu chern des Fahrzeugherstellers Die nachstehenden Bes...

Page 724: ...z esta indicada hasta la matr cula desde la matr cula en adelante Si no ha sido indicada validez las operacio n de desmontaje y montaje son comunes a todas las versiones HERRAMIENTAS ESPECIFICAS Y REC...

Page 725: ...ery 1000 hours ogni 1000 ore alle 1000 Std cada 1000 horas toutes les 1000 hours Initially after 100 working hours Inizialmente dopo 100 ore di lavoro Erstmals nach 100 Betriebstunden Al principio des...

Page 726: ...9 4 1 M6 10 0 14 0 M8 25 0 35 0 M10 49 0 69 0 M10x1 25 52 0 73 0 88 0 M12 86 0 120 0 M14 135 0 190 0 M14x1 5 150 0 210 0 250 0 M16 210 0 295 0 M18x1 5 325 0 460 0 550 0 A22 550 8G 8 8 Nm 10k 10 9 Nm 1...

Page 727: ...HE TECHNISCHE DATEN CARACTERI STICAS TECNICAS CARACTERISTIQUES TECHNIQUES A Connector for hydraulic gear control Pressure required 15 30 bar Raccordi comando marce idraulico Pressione di comando 15 30...

Page 728: ...9 D1240002 Ist GEAR I MARCIA I GANG I MARCHA I VITESSE D1240003 IInd GEAR II MARCIA II GANG II MARCHA II VITESSE...

Page 729: ...on Esaminare con controllo visuale Kontrollieren Pru fen Examinar mediante inspeccio n visual Controler examiner controle visuel Possibly still serviceable renew if necessary Eventualmente riutilizzar...

Page 730: ...aulico Direkt an der Triebachse geflanscht mit hydraulischer Gangschaltung Versio n con brida en el puente con mando hidra ulico de la marcha Mode le bride au pont a commande de vitesses hydraulique V...

Page 731: ...the position of the O rings Remove the protection plate Re assembly arrangement of gear control cylinder parts GB GB GB GB GB GB a b c d f e 12 REMOVAL OF HYDRAULIC GEAR CONTROL RIMOZIONE COMANDO IDRA...

Page 732: ...Estrarre il cilindro comando marce Prestare attenzione alla posizione degli anelli OR Rimuovere la lamiera di protezione Zylinder des Gangschalters herausziehen Auf die Position der O Ringe achten Sc...

Page 733: ...e screw spring together with gear and neutral position spindle mechanical version Remove screw spring and neutral position ball hydraulic version GB GB GB GB GB GB a b c d f e 14 DISASSEMBLY OF DIRECT...

Page 734: ...Position der Gangschaltung mit O Ring und Unterlegscheibe entfernen Remover el interruptor de posicio n de marcha em bragada con el anillo OR y la roseta Enlever l interrupteur de la position vitesses...

Page 735: ...the flange Remove screws from the cover GB GB GB GB GB GB a b c d f e 16 DISASSEMBLY OF DIRECTLY FLANGED REDUCTION GEAR 357 SMONTAGGIO GRUPPO RIDUTTORE 357 AFFLANGIATO DIREKT GEFLANSCHTER REDUZIERER...

Page 736: ...del movimiento De crocher le couvercle d entre e du mouvement Rimuovere il dado della flangia Flanschmutter abschrauben Remover la tuerca de la brida Enlever l e crou de la flasque Asportare l anello...

Page 737: ...o damage planes Take away the cover Pay attention to the position of the pins GB GB GB GB GB GB a b c d f e 18 DISASSEMBLY OF DIRECTLY FLANGED REDUCTION GEAR 357 SMONTAGGIO GRUPPO RIDUTTORE 357 AFFLAN...

Page 738: ...le haut Rimuovere le viti Schrauben abschrauben Remover los tornillos Enlever les vis Rimuovere il coperchio Prestare attenzione per non danneggiare i piani Deckel abnehmen Darauf achten die Fla chen...

Page 739: ...l shield plate with oil inlet facing upwards Apply LOCTITE 510 on the outside Fit the oil shield plate into position 5 5 5 mm from box plane GB GB GB GB GB GB a b c d f e 20 DISASSEMBLY OF DIRECTLY FL...

Page 740: ...ngang mu nach oben gerichtet sein Remover el sello de aceite si fuera necesario Cuidado la entrada del aceite tiene que estar dirigida hacia arriba Enlever la to le pare huile seulement si besoin Atte...

Page 741: ...orn Remove the lower shaft Remove the entire shaft and the flow regulator plate GB GB GB GB GB GB a b c d f e 22 DISASSEMBLY OF DIRECTLY FLANGED REDUCTION GEAR 357 SMONTAGGIO GRUPPO RIDUTTORE 357 AFFL...

Page 742: ...et la fourchette Verificare pattini spina e manicotto scorrevole Sostituirli se sono usurati Zu kontrollieren Gleitschuhe Stift und Gleithu lse Wenn verschlei t auswechseln Comprobar patines clavija y...

Page 743: ...plied already assembled Pull out the sealing ring Re insert a new sealing ring GB GB GB GB GB GB a b c d f e 24 DISASSEMBLY OF DIRECTLY FLANGED REDUCTION GEAR 357 SMONTAGGIO GRUPPO RIDUTTORE 357 AFFLA...

Page 744: ...del eje de salida Assemblage de l arbre de sortie Rimuovere l albero di entrata Nel caso di sostituzione viene fornito premontato Eingangswelle entfernen Bei Ersatz wird sie schon montiert geliefert...

Page 745: ...bearing from the cover of the reduction unit GB GB GB GB GB GB a b c d f e 26 DISASSEMBLY OF DIRECTLY FLANGED REDUCTION GEAR 357 SMONTAGGIO GRUPPO RIDUTTORE 357 AFFLANGIATO DIREKT GEFLANSCHTER REDUZIE...

Page 746: ...e tanche ite neuve Estrarre l anello di tenuta dal coperchio di ingresso del moto Dichtungsring am Anfang der Bewegung herauszie hen Extraer el segmento de compresio n de la tapa de entrada del movim...

Page 747: ...ghten screws using a torque wrench setting of 49 51 Nm Lubricate the lip of the sealing ring with grease GB GB GB GB GB GB a b c d f e 28 ASSEMBLY OF DIRECTLY FLANGED REDUCTION GEAR 357 ASSEMBLAGGIO G...

Page 748: ...mouvement Rimontare il coperchio spalmando sui piani e sulle viti LOCTITE 510 Deckelfla chen und schrauben mit LOCTITE 510 schmieren und montieren Volver a montar la tapa engrasando las superficies y...

Page 749: ...e sure that the niche faces upwards Simultaneously insert fork and sliding blocks coupling and flow regulator plate Re insert screws and tighten GB GB GB GB GB GB a b c d f e 30 ASSEMBLY OF DIRECTLY F...

Page 750: ...provvisoriamente il coperchio con le viti Attenzione alla nicchia che deve essere rivolta verso l alto Voru bergehend den Deckel mit den Schrauben montieren Achtung die Nische mu nach oben gerichtet...

Page 751: ...10 on the surface and assemble the cover Fasten the cover GB GB GB GB GB GB a b c d f e 32 ASSEMBLY OF DIRECTLY FLANGED REDUCTION GEAR 357 ASSEMBLAGGIO GRUPPO RIDUTTORE 357 AFFLANGIATO DIREKT GEFLANSC...

Page 752: ...er les paliers a rouleaux l engrenage et l entretoise Verificare l inserimento delle spine Einsatz der Stifte kontrollieren Comprobar la insercio n de las clavijas Ve rifier l introduction des broches...

Page 753: ...ch setting of 80 100 Nm Fix the gear in position switch with washer and O ring Tighten with torque wrench setting of max 54 2 Nm Assemble the sealing cover with washer and revolution indicator Tighten...

Page 754: ...n hydraulische Ausfu hrung Mit einem An ziehdrehmoment zu 80v100 Nm anziehen Engrasar los componentes y volver a colocar la bola el muelle y el tornillos versio n hidra ulica Apretar a un par ma x dei...

Page 755: ...relation to the axis Tighten screws using a torque wrench setting of 49 51 Nm Extract screws and remove the temporarily assembled cover GB GB GB GB GB GB a b c d f e 36 ASSEMBLY OF DIRECTLY FLANGED R...

Page 756: ...os tornillos engrasa ndolos con LOCTITE 510 Introduire les vis en les enduisant d abord de LOCTITE 510 Avvitare le viti posizionando il riduttore in modo verticale rispetto l asse Schrauben festschrau...

Page 757: ...A Es B 5 2 A 4 6 mm Backlash 0 2 0 3 Distance washer required 0 4 0 3 Apply LOCTITE 510 on the surface lubricate the sealing ring insert the distance washers and re assemble the cover with niche faci...

Page 758: ...Di stanzstu cke ausrechnen S Ma B Ma A Bsp B 5 2 A 4 6 mm Spiel 0 2v0 3 einzusetzende Distanz stu cke 0 4v0 3 Registrar la cota B en la tapa entre la superficie y el soporte del cojinete Calcular los...

Page 759: ...rotection plate after applying LOCTITE 510 Complete flanged reduction gear 357 with mechanical gear control GB GB GB GB GB GB a b c d f e 40 ASSEMBLY OF DIRECTLY FLANGED REDUCTION GEAR 357 ASSEMBLAGGI...

Page 760: ...coppia di serraggio di 260v280 Nm Mutter mit einem Anziehdrehmoment zu 260v280 Nm anziehen Apretar la tuerca a un par de torsio n de 260v280 Nm Serrer l e crou a un couple de serrage de 260v280 Nm Ri...

Page 761: ...O ring Re fit screws and screw down Re introduce the gear control rod after applying LOCTITE 242 on it GB GB GB GB GB GB a b c d f e 42 ASSEMBLY OF DIRECTLY FLANGED REDUCTION GEAR 357 ASSEMBLAGGIO GR...

Page 762: ...oir enduite de LOCTITE 510 Rimontare il cilindro comando marcia completo di anello OR Zylinder des Gangschalters mit O Ring montieren Volver a montar el cilindro mando marcha completo de anillo OR Rem...

Page 763: ...screws using a torque wrench setting of 49 51 Nm GB GB GB GB GB GB a b c d f e 44 INSTALLATION OF HYDRAULIC GEAR CONTROL INSTALLAZIONE COMANDO MARCIA IDRAULICO HYDRAULISCHER GANGSCHALTUNG MONTIEREN M...

Page 764: ...e vitesses a un couple de serrage de 25v26 Nm Serrare le viti cilindro comando marcia con una coppia di serraggio di 49v51 Nm Die Zylinderschrauben des Gangschalters mit einem Anziehdrehmoment zu 49v5...

Page 765: ...ne service parts ordering visit www SpicerParts com order asp Copyright 2010 Dana Holding Corporation All content is subject to copyright by Dana and may not be reproduced in whole or in part by any m...

Page 766: ...TB175W SWIVEL JOINT TYPE 532...

Page 767: ...TB175W REV 1...

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Page 771: ...The introduction of dust and spray interferes with labyrinths 9 and 2 at the interface between housing 12 and rotor 11 Cover 8 has a seat for fitting a rotating connector This makes it possible to in...

Page 772: ...aulic system must be bled before start up Service If the operating instructions in the installation drawings are observed no maintenance will be necessary Installation drawing 532 044 000 2 INSTALLATI...

Page 773: ...ases fixing threads are located in the cover for a slip ring mount OPERATION The rotatable bearing supported rotor 2 in the housing is held in the axial plane by cover 5 Connectors 6 in the housing ar...

Page 774: ...nectors Make sure there is sufficient play between the housing mount and the counter piece There must be no tension when the tubes are connected preferably with hose connectors Additional lateral load...

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Page 778: ...V 1 TB175W V TROUBLESHOOTING...

Page 779: ...whether the machine has broken down may differ between individu als IMPORTANT When running the machine it is possible that moving the machine could make the breakdown worse than it already is so do n...

Page 780: ...ped 16 Slewing in slow gear is not possible 18 BOOM The boom cylinder doesn t move 20 Boom cylinder operation is slow or there is no power 22 When the boom operation lever is pulled gently the boom dr...

Page 781: ...c oil supplied should be the same brand as the oil currently in the tank II Specifications Fluid Capacities 3 Pump or coupling is faulty a Disconnect the discharge hose from the pump side Also fit a p...

Page 782: ...ng at the source of the bubbling Repair or replace the main relief valve Repair or replace the pump Flush with hydraulic oil 1 Inspect the hydraulic oil level 2 Replenish the hydraulic oil V 4 3 Noise...

Page 783: ...ly II Specifications Standards for Judging Performance 5 Pump is faulty If the pump is abnormally worn internally or if it is damaged it is possible that pieces of metal are mixed into the hydraulic o...

Page 784: ...ormal Normal Normal Normal Faulty Faulty Faulty Faulty Faulty Faulty Repair or replace the hydrau lic pump P5 Replace the fuse Adjust or replace the limit switch Repairorreplacetheleverlock solenoid v...

Page 785: ...and female for emergency use 4 Inspect the lever lock solenoid valve Inspect by the following procedure a Turn the starter switch to the ON position b Push lightly on the projection on the front end o...

Page 786: ...ulty Pressure is low Faulty Repair or replace the pilot valve Repair or replace the housing block Adjust the set pressure Repair or replace the slew re lief valve Repair or replace the slew motor Repl...

Page 787: ...he shuttle valve is normal if between 0 and 3 4 MPa corresponding to the operation angle 4 Inspect the operation of the spool Disconnectthehosethatgoesbetweenthecontrol valve slew section and the slew...

Page 788: ...11 TB175W 6 Inspect the slew motor Separate the slew motor 1 and the turntable 2 then try turning the turntable 2 Turntable doesn t turn Faulty slew bearing 3 Turntable turns Faulty slew motor 1 IV H...

Page 789: ...aulty Faulty Faulty Repair or replace the pilot valve Repair or replace the housing block Repair or replace the slew re lief valve Repair or replace the slew brake valve Repair or replace the slew mot...

Page 790: ...s faulty 4 Inspect the check valve of the slew brake valve If foreign matter is caught in one end of the check valve 1 or if the valve is sticking right or left slewing will be impossible If foreign m...

Page 791: ...pair or replace the housing block Adjust the set pressure Not within the standard 2 Inspect the pilot valve Normal Normal Normal Faulty Faulty Pressureislow Repair or replace the slew re lief valve Ad...

Page 792: ...cifications Standards for Judging Performance 2 Inspect the pilot valve V 10 3 Inspect the operation of the spool V 10 4 Inspect the slew hydraulic pressure V 10 5 Inspect the check valve of the slew...

Page 793: ...t the slew brake valve Normal Normal Faulty Pressureislow Repair replace the slew brake valve Adjust the pressure of the slew relief valve Pressure doesn t rise 1 Is the amount of overrun when slewing...

Page 794: ...ration lever slew is released after operation Disconnect the line from the slew section of the control valve then set a pressure gauge in its supply port Read the pressure gauge after operating the le...

Page 795: ...pairorreplacetheslowslew solenoid valve Repairorreplacetheslewflow control valve 1 Inspect the hydraulic pump P5 InspectthehydraulicpumpP5whichisthesource of the hydraulic pressure for switching to sl...

Page 796: ...Turn the slow slew switch ON d If the spool moves and vibration can be felt with the fingertip when the circuit changes then it is normal 5 Inspect the slew flow control valve Inspect if the spool of...

Page 797: ...he pilot valve Normal Normal Does not change Faulty Faulty Operation became normal Repair or replace the boom cylinder Inspect the boom cylin der Faulty THE BOOM CYLINDER DOESN T MOVE The port relief...

Page 798: ...and measure the pressure A pressure of 27 5 MPa is normal 4 Perform a port relief valve switching test Switch the port relief valve for the port relief valve of the normal arm If the boom cylinder ope...

Page 799: ...ulty Faulty Operation became normal Repair or replace the boom cylinder Inspect the boom cylin der Faulty The port relief valve is faulty Within the standard Repair or replace the pilot valve 1 Is the...

Page 800: ...emove both hoses from the cylinder that is not being inspected at this time and plug the disconnected hoses c Retract the arm cylinder and lift the bucket so it is floating above the ground At this ti...

Page 801: ...e disconnected hoses c Operate the bucket and raise the machine s body At this time if there is oil leaking from the piping of the cylinder where the hose was disconnected and if the boom cylinder s r...

Page 802: ...formingtheoperationin a c above The bucket cylinder should be fully ex tended the arm cylinder should be fully retracted and the bucket should be low ered to the ground Reference When the spool first...

Page 803: ...ot within the standard Normal Does not change Within the standard Faulty Operation be came normal The control valve is leaking internally The port relief valve is faulty Normal THE AMOUNT OF BOOM NATU...

Page 804: ...place the pilot valve swing Normal Faulty Repair or replace the housing block Faulty 6 Normal Faulty Inspect the boom adjust ment cylinder Repair or replace the boom adjustment cylinder 1 Inspect the...

Page 805: ...ly circuit b Inspect the selector switch Presstheselectorswitchtoturnit ON While it is this condition check if there is continuity with a tester c Inspect the relay Press the selector switch to turn t...

Page 806: ...eside then set a pressure gauge in the disconnected hose Operate the boom swing pedal and measure the pressure A pressure of 33 3 MPa is normal 5 Inspect the port relief valve IV Hydraulic Units Port...

Page 807: ...f valve Normal 2 5 Inspect the pilot valve Normal Normal Does not change Faulty Faulty Operation became normal Repair or replace the arm cyl inder Inspect the arm cylinder Faulty The port relief valve...

Page 808: ...that of the normal boom If the arm cylinder then operates the port relief valve is faulty 5 Inspect the arm cylinder Switchthearmhosesandbuckethosesconnected to the pipes at the boom foot Try operati...

Page 809: ...ulty Faulty Operation became normal Repair or replace the arm cyl inder Inspect the arm cylinder Faulty The port relief valve is faulty Within the standard Repair or replace the pilot valve 1 Is the a...

Page 810: ...the bucket to the ground b Disconnect the two hoses connected to the cylinder Insert plugs 1 in the disconnected hoses and the cylinder piping c Raisetheboomandraisethehoeattachmentso it floats above...

Page 811: ...cylinder Repair or replace the arm cyl inder Replace the housing block Not within the standard Normal Faulty 3 There is leakage inside the control valve THE AMOUNT OF ARM NATURAL DROP IS GREAT 1 Is th...

Page 812: ...al 2 5 Inspect the pilot valve Normal Normal Does not change Faulty Faulty Operation became normal Repair or replace the bucket cylinder Inspect the bucket cylin der Faulty The port relief valve is fa...

Page 813: ...as faulty 5 Inspect the bucket cylinder At the boom foot exchange the arm hose with the bucket hose that is connected to the pipe Move the lever arm and check whether the bucket cylinder operates If t...

Page 814: ...1 Is the amount of natural drop within the standard II Specifications Standards for Judging Performance 2 Inspect the bucket cylinder a Fully extend the bucket cylinder fully retract the arm cylinder...

Page 815: ...ector valve Repair or replace the swing cylinder Normal Normal 3 Inspect the operation of the spool Normal Faulty Faulty Repair or replace the pilot valve swing Normal Faulty Repair or replace the hou...

Page 816: ...of the spool Normal Faulty Faulty Repair or replace the pilot valve swing Normal Faulty Repair or replace the housing block Faulty 1 Inspect the supply pressure to the pilot valve swing V 7 8 2 Inspec...

Page 817: ...OOM SWING V 40 TB175W 4 Inspect the check valve If right swing cannot be done then foreign matter is caught in the check valve or the valve is sticking 5 Inspect the swing cylinder IV Hydraulic Units...

Page 818: ...V 41 TB175W VI ENGINE Machine Serial No Mounted Engine Machine Model TB175W 17540001 4TNV98T...

Page 819: ...ompliant and regulation approved engines and the trouble diagnostic tool is speci cally designed for them regular maintenance software for the controller intended for the whole machine cannot be used...

Page 820: ...r Yanmar EDT TB180FR T 3 F14E 17840001 or later Yanmar EDT 17301 42820 17301 42690 T ECU maintenance soft ware TB175 T 3 A14E 17530001 or later Yanmar EDT 17301 42830 17301 42680 T ECU maintenance sof...

Page 821: ...uchi Electrical Control Unit Takeuchi maintenance tool Con guration Maintenance software CD Part No 17301 42700 Dedicated USB cable Part No 17301 42720 Excavator TB180FR F14C T 2 Serial No 178300001 o...

Page 822: ...1 42660 Dedicated USB cable Part No 17301 42720 Excavator TB1140 A25B Serial No 51410001 or later TB1140 A25D Serial No 51430001 or later Laptop computer Engine Isuzu Takeuchi Interface box Proportion...

Page 823: ...40 L8B Serial No 22400001 or later TL230 L6B Serial No 22300001 or later TL220 L5B Serial No 22200001 or later Engine model 4TNV98T ZNTBL Compliant with Tier 3 emission standards Laptop computer Inter...

Page 824: ...ar Engine Diagnostic Tool EDT Con guration Software CD Interface cable Interface box Takeuchi maintenance tool Con guration Maintenance software CD Part No 17301 42690 Dedicated USB cable Part No 1730...

Page 825: ...al No 17540001 or later Engine model 4TNV98T ZNTBL Compliant with Tier 3 emission standards Engine Yanmar Takeuchi Laptop computer Interface box Interface box Yanmar Engine Diagnostic Tool EDT Con gur...

Page 826: ...zu Compliant with Tier 3 emission standards Excavator TB1140 A25C T 3 Serial No 514200001 or later Isuzu Selector Laptop computer Data link connector Engine Engine module programming system EMPS III I...

Page 827: ......

Page 828: ...keuchi Proportional ampli er for the service port Takeuchi Cluster panel Takeuchi Isuzu Engine Fuel sender CAN unit Takeuchi Fuel tank Data link connector Takeuchi maintenance tool Con guration Mainte...

Page 829: ...r and the connector on the machine Cap NJC 16 RCa Nanaboshi Transducer unit USB on computer Red RS232C TX White RS232C TX Black GND Yellow CTL Orange Vctol Wiring 232 TX 232 RX GND Part No Plug NJC 16...

Page 830: ...Isuzu Engine Maintenance tool...

Page 831: ...omputer screen after software installation Start menu con guration The start menu con guration of maintenance software after installation is illustrated as follows Model Maintenance software Start men...

Page 832: ...Model Maintenance software Start menu 2...

Page 833: ...d time the error occurred Error code State of the emergency re lease 00 Off 01 On If the 01 state is displayed when the engine is overheat ing or seizing it indicates that the emergency release has be...

Page 834: ...6 Maintenance software for A25B and A25D executed 1 Maintenance software is selected...

Page 835: ...2 A25B and A25D Maintenance Software for Proportion Output Ampli er Refer to each manual for further information...

Page 836: ...7 F14E maintenance software executed...

Page 837: ...8 A14E and A14EW maintenance software executed 1 A14E Maintenance software is selected 2 A14EW Maintenance software is selected...

Page 838: ...9 A25C maintenance software executed 1 Maintenance software is selected 2 Management software is selected...

Page 839: ...3 Maintenance Software for Proportion Output Ampli er is selected...

Page 840: ...10 Maintenance tool executed on the A14E Isuzu monitor machine 1 Management software is selected...

Page 841: ...2 ECM data browse is selected 3 Management software is selected...

Page 842: ...4 Maintenance Software for Proportion Output Ampli er is selected...

Page 843: ...nnect cable to USB port of PC Note Please check COM port number of Serial to USB cable See Control panel in start menu Hit Performance and maintenance and then hit System Hit Hard ware tag on System p...

Page 844: ...2...

Page 845: ...3...

Page 846: ...4...

Page 847: ...5 The personal computer displayed what TB175W Maintenance software could use in COM4 of the Universal Serial Bus port hoose this COM port number at the time of initial setting page...

Page 848: ...6 2 Maintenance software setting Start TB175W MAINTENACE SOFTWARE Ver1 0 from start menu Hit Option Setting Choose COM port number on the list...

Page 849: ...om machine to PC Turn key switch ON of machine Hit Log Load on the menu Note Don t forget turn machine key switch off after loading the data 4 Delete Log When hitting Log Delete log data in the contro...

Page 850: ...read the file by Excel 6 Open saved Log file Hit Log Open Choose CSV file 7 Print Log Hit Log Print The log now you opened will be printed 8 See Serial number of Controller Hit Option Version and Ser...

Page 851: ...e upper bound of voltage of the battery is abnormal Voltage as over 29V had been measured over 0 5 second after ACC power was supplied or engine was started 13 the lower bound of voltage of the batter...

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