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III-48

MACHINE CONFIGURATION

HYDRAULIC SYSTEM

Function

1. This tank stores the quantity of hydraulic oil

necessary to operate the cylinders and hydraulic
motors.

2. It keeps air, moisture and dirt out of the hydrau-

lic oil.

3. It dissipates heat and lowers the oil tempera-

ture.

4. Volume of Hydraulic Oil.

Check the oil level with the arm cylinders and
bucket cylinders fully retracted and with the
bucket cutting edge lowered to the ground.

Reference

If the amount of hydraulic oil is insufﬁcient, the dis-
turbances in the ﬂow of oil can not be calmed, and
this will result in air bubbles getting in the hydraulic
oil.  If  these  bubbles  are  sucked  into  the  hydraulic
pumps, they could cause cavitation. Heat  dissipation
time would also become shorter and would result in
a rise in the oil temperature.
If more than the speciﬁed amount of hydraulic oil is
supplied, the amount of air in the tank will become
small  and  changes  in  the  oil  level  could  cause  the
pressure ﬂuctuation in the tank to become severe.

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Summary of Contents for TL150

Page 1: ...TL150 Track Loader BOOK No CT7E901 WORKSHOP MANUAL Serial No 21500004...

Page 2: ...vel motors is the rear Also the right and left sides of the operator when he is seated in the driver s seat are the right and left sides of the machine MACHINE SERIAL NUMBER The machine serial number...

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

Page 4: ...0 4...

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

Page 6: ...ety Precautions 3 Cautions during Disassembly and Assembly 9 Cautions during Removal and Installation of the Hydraulic Units 9 Cautions during Removal and Installation of Piping 10 Handling of Seals 1...

Page 7: ...cessarily 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 rul...

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: ...ws 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: ...cable Loose battery terminals may result in sparks Be sure to fasten terminals tightly Make sure the vent caps are tightened securely Do not charge a battery or jump start the engine if the battery i...

Page 13: ...g it tight and leaving 1 or 2 threads bare Overlap the tape by about 10 mm SEALING TAPE LEAVE 1 OR 2 THREAD MARGIN Y2 A102E 10 When tting the snap rings the bigger rounder side of their circumferences...

Page 14: ...s 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 BURR DIRT Y2 A105E 2 Be c...

Page 15: ...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 9 7 3 3 5 11 8 1...

Page 16: ...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 2 4 9 6...

Page 17: ...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 18: ...I 14 GENERAL...

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

Page 20: ...ic 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 tests...

Page 21: ...Safety Bar 6 Pilot Valve L H 7 Pilot Valve R H 8 HST Pump 9 Bucket Cylinder 10 Fuel Tank 11 Arm Cylinder 12 Travel Motor 13 Track Roller 14 Track 15 Idler 16 Quick Hitch 17 Bucket 18 Control Valve Sub...

Page 22: ...85 B 3135 C 1555 D 2350 E 355 F 1860 G 450 H 1570 J 985 K 1960 L 580 M 31 Machine Dimensions L M D J H K C F G A E B T7K001A D H K C F A E B J G T7K002A Unit mm Standard Bucket Steel Tracks A 4255 B 3...

Page 23: ...555 D 2350 E 355 F 1860 G 450 H 1570 J 985 K 1960 L 580 M 31 Machine Dimensions L M D J H K C F G A E B T7K001A D H K C F A E B J G T7K002A Unit mm Standard Bucket Steel Tracks A 4255 B 3210 C 2440 D...

Page 24: ...bucket mm 1560 Rear Clearance Radius mm 1755 Overall Width of Crawler mm 1860 Overall Length of Crawler mm 2150 Bucket Width mm 1960 Angle of Departure degree 31 Working Range Maximum Lift Height to B...

Page 25: ...Clearance Radius mm 1755 Overall Width of Crawler mm 1860 Overall Length of Crawler mm 2150 Bucket Width mm 1960 Angle of Departure degree 31 Working Range Maximum Lift Height to Bucket Pin mm 3210 Ma...

Page 26: ...1 Type Variable displacement type double axial piston Displacement cm3 rev 41 0 41 0 Delivery L min 90 2 90 2 Relief Valve Pressure Setting MPa 34 5 Charge Relief Valve Pressure Setting MPa 2 26 0 02...

Page 27: ...cient Ports D 63 Ports B 37 Rated Flow L min 88 0 Rated Pressure MPa 20 6 Maximum Working Pressure MPa 24 5 Cylinder Arm Bore Diameter Rod Diameter mm 75 45 Stroke mm 760 Fully Retracted Length Pitch...

Page 28: ...c Tank Assembly 51 Fuel Tank Assembly 28 Control Valve 10 Control Valve High Flow 12 Control Valve Sub 12 Pilot Valve R H 2 3 L H 2 3 Self Level Valve 4 5 Canopy Cab 220 270 Lift Arm 420 Quick Hitch 8...

Page 29: ...o prevent fuel ow problems in cold weather use die sel fuel with a pour point of at least 12 C 10 F below the lowest expected ambient temperature Minimum cetane number is 45 Low temperature or high al...

Page 30: ...ension Allowable Value Replace A Tread Outer Diameter 188 180 B Width of Tread 36 5 40 5 Basic Dimension Allowable Tolerance Standard Allowable Shaft Hole C Shaft and Bushing Bore Diameter Clearance 4...

Page 31: ...Value Replace A Tread Outer Diameter 188 180 B Width of Tread 37 5 45 5 Basic Dimension Allowable Tolerance Standard Allowable Shaft Hole C Shaft and Bushing Bore Diameter Clearance 40 0 050 0 075 D...

Page 32: ...meter 300 292 B Width of Tread 36 5 40 5 Basic Dimension Allowable Tolerance Standard Fit Allowable Fit Shaft Hole C Shaft and Bearing Bore Diameter Interference 40 0 0 016 0 0 012 0 016 0 012 D Rolle...

Page 33: ...ocket Unit mm Code Item Designated Standard Servicing Procedure Basic Dimension Allowable Value Replace A Sprocket Teeth Pro le Wear 14 4 6 4 B Sprocket Teeth Width 45 41 C Sprocket Outer Diameter 432...

Page 34: ...er Tread 390 380 B Width of Tread 33 4 38 4 Basic Dimension Allowable Tolerance Standard Allowable Shaft Hole C Shaft and Bearing Bore Diameter Clearance 45 0 0 011 0 0 012 0 011 0 012 D Idler and Bea...

Page 35: ...ack Adjuster Unit mm Code Item Designated Standard Servicing Procedure Basic Value Allowable Value Length when Free mm 270 A Coil Spring Length when Installed mm 224 5 Replace Set Load kN 41 5 B Check...

Page 36: ...A Lift Arm Frame 45 0 06 0 09 0 17 0 12 0 18 0 26 1 0 B Arm Cylinder Frame 45 0 06 0 09 0 20 0 05 0 11 0 29 1 0 C Arm Cylinder Lift Arm 45 0 06 0 09 0 20 0 05 0 11 0 29 1 0 D Bucket Cylinder Lift Arm...

Page 37: ...ght Speed s 10 1 0 5 12 0 Travel Speed 10 m Low Speed s 6 4 0 5 7 5 Hight Speed s 4 4 0 4 5 4 Travel Curve mm 125 0 500 Natural Travel Drop Engages Parking Brake mm 0 Releases Parking Brake mm Cylinde...

Page 38: ...art up the hydraulic circuit to be tested and measure the re lief pressure Circuit Pressure Detection Port Relief Valve Port Position Size Left Travel forward P1 G1 4 R1 Right Trav el forward P2 G1 4...

Page 39: ...e relief valve once more to con rm that the pressure that has been set it stabilized Charge pressure Measuring Method Engine Idling Maximum R P M Hydraulic Oil Temp 50 60 C Insert the pressure gauge i...

Page 40: ...e tracks rotate a total of ve revolutions This test should be performed at the same speed in which the machine was last oper ated Travel Speed 10m Engine Maximum R P M Hydraulic Oil Temp 50 60 C Measu...

Page 41: ...ion This time should not include the time allowed for op eration of the cushion Bucket Cylinder Speed Engine Maximum R P M Hydraulic Oil Temp 50 60 C Measurement Posture Make sure that the bucket pin...

Page 42: ...ly extended position This time should not include the time allowed for op eration of the cushion Bucket Cylinder Speed Engine Maximum R P M Hydraulic Oil Temp 50 60 C Measurement Posture Make sure tha...

Page 43: ...er pedal Track Tension In a stable level location lower the lift arm tilt the bucket forward and lift the front of the tracks slightly off the ground Measure the distance be tween the bottom surface o...

Page 44: ...III 1 III MACHINE CONFIGURATION...

Page 45: ...III 2 MACHINE CONFIGURATION CONTENTS Drive System 3 Travel System 16 Frame 22 Control System 34 Attachments 37 Hydraulic System 46 Electrical System 51 Air Conditioner System 54...

Page 46: ...gine Mount A 256 N m Apply thread locking compound B 110 N m Apply thread locking compound C 5 9 N m D 3 9 N m 1 Engine Foot FL 2 Engine Foot FR 3 Engine Foot RL 4 Engine Foot RR 5 Exhaust Pipe 6 Brac...

Page 47: ...CONFIGURATION DRIVE SYSTEM Radiator A 4 9 N m B 39 2 N m 1 Radiator 2 Radiator Hose Upper 3 Radiator Hose Lower 4 Sub Tank 5 Sensor 6 Oil Cooler 7 Drain Valve 8 Drain Hose 9 Drain Hose 10 Hose 11 Joi...

Page 48: ...501587 A 256 N m Apply thread locking compound B 110 N m Apply thread locking compound C 5 9 N m D 3 9 N m 1 Engine Foot FL 2 Engine Foot FR 3 Engine Foot RL 4 Engine Foot RR 5 Exhaust Pipe 6 Bracket...

Page 49: ...URATION DRIVE SYSTEM Radiator High Flow Serial No 21501587 A 4 9 N m B 39 2 N m 1 Radiator 2 Radiator Hose Upper 3 Radiator Hose Lower 4 Sub Tank 5 Sensor 6 Drain Valve 7 Drain Hose 8 Drain Hose 9 Hos...

Page 50: ...ump coupling connects the engine ywheel and the hydraulic pump s drive shaft It is constructed so that it absorbs vibrations torsions impact and out of center of the engine and hydraulic pump Refer to...

Page 51: ...III 8 MACHINE CONFIGURATION DRIVE SYSTEM 1 Fuel Tank 2 Cap 3 Strainer 4 Drain Plug 5 Fuel Sender 6 Water Separator 7 Feed Pump Fuel Tank and Lines...

Page 52: ...III 9 MACHINE CONFIGURATION DRIVE SYSTEM 1 Lever 2 Bracket 3 Accelerator Wire 4 Wire Stopper 5 Wire Stopper 6 Conical Washer 7 Washer 8 Washer Engine Control A Apply molybdenum disul de grease...

Page 53: ...and the lter 4 9 Remove the fuel inlet pipe 5 10 Disconnect the fuel hoses 6 11 Disconnect the battery cable 7 and all the con nections on the engine side of the electric wir ings 8 Attach identi cati...

Page 54: ...lts 2 and open the radiator 3 3 Disconnect the radiator hoses upper 4 and lower 5 and hoses 6 from the radiator 4 Remove the R pins and pull out the pins 7 5 Remove the radiator 3 Installing the Radia...

Page 55: ...enum disul de grease to the spline section Installing the Hydraulic Pump Follow the same procedure as for removal in the reverse order Purging Air from the HST Pump WARNING When re tting the HST pump...

Page 56: ...e the oil ow from only the pilot valves into the tank 4 Remove the plugs in the pilot ports X1 and X11 and immediately connect the respective hoses to those ports to prevent unnecessary loss of hydrau...

Page 57: ...he Hydraulic Pump 5 Remove the suction pipe 2 6 Loosen the drain cock 3 to drain out the fuel Fuel tank capacity 108 L 7 Disconnect the fuel sender connector 4 8 Disconnect the fuel hoses 5 and the ho...

Page 58: ...with the wire lock pin 6 4 Move the throttle lever 1 to the B full throttle position and the governor control 4 to the D full throttle position Adjust the stopper 7 so that the throttle lever 1 hits...

Page 59: ...Track Roller A 1 Roller 2 Shaft 3 Cover 4 Floating Seal 5 Snap Ring 6 O ring 7 Oil Filler Plug A 241 N m Apply thread locking compound Track Roller B 1 Roller 2 Shaft 3 Cover 4 Floating Seal 5 Snap Ri...

Page 60: ...ing 6 Floating Seal 7 Oil Filler Plug A 156 N m Apply thread locking compound B 55 N m Apply thread locking compound C 20 N m Idler 1 Idler 2 Shaft 3 Cover A 4 Cover B 5 Bearing 6 Floating Seal 7 Oil...

Page 61: ...CHINE CONFIGURATION TRAVEL SYSTEM Track Adjuster 1 Yoke 2 Reach Rod 3 Spring 4 Piston 5 Cylinder 6 Grease DischargeValve A 59 N m Travel Motor 1 Travel Motor 2 Sprocket A 241 N m Apply thread locking...

Page 62: ...der the machine rear 5 Rotate the travel motor slowly in the reverse direction to remove the track Track 401 kg Installing the Steel Track 1 Place the wooden blocks 3 with a height of 20 cm under the...

Page 63: ...with the ground then tighten the bolts Bolt 241 N m track rollers A and B Bolt 156 N m track roller C Apply thread locking compound 3 Raise the machine body then adjust the track tension Removing the...

Page 64: ...41 N m Apply thread locking com pound 3 Remove the cover and disconnect the hydraulic hoses 4 4 Suspend the travel motor 3 temporarily and remove the bolts 5 Bolt 241 N m Apply thread locking com poun...

Page 65: ...III 22 MACHINE CONFIGURATION FRAME FRAME CONSTRUCTION Frame 1 Frame 2 Under Cover A 3 Under Cover B 4 Cover L 5 Cover R 6 Under Cover C 7 Cover 8 Cover...

Page 66: ...III 23 MACHINE CONFIGURATION FRAME 1 Floor Plate 2 Floor Mat 3 Cover R 4 Cover L 5 Foot Rest 6 Cover C 7 Floor Stay 8 Cover 9 Floor Stay Floor Frame...

Page 67: ...III 24 MACHINE CONFIGURATION FRAME 1 Safety Bar 2 Bracket L 3 Bracket R 4 Stopper 5 Proximity Switch 6 Cover L 7 Cover R 8 Gas Spring Safety Bar...

Page 68: ...III 25 MACHINE CONFIGURATION FRAME 1 Rear Door 2 Engine Hood 3 Bracket 4 Plate 5 Plate 6 Plate 7 Pin Cover 8 Gas Spring 9 Rod 10 Side Cover L 11 Side Cover R 12 Center Cover 13 Plate...

Page 69: ...III 26 MACHINE CONFIGURATION FRAME 1 Canopy 2 Bolt Assembly 3 Cushion Rubber 4 Pin Assembly 5 Collar Canopy 6 Washer 7 Cushion Rubber 8 Washer 9 Gas Spring 10 Cushion Rubber...

Page 70: ...III 27 MACHINE CONFIGURATION FRAME 1 Cab 2 Bolt Assembly 3 Cushion Rubber 4 Pin Assembly 5 Collar Cab 6 Washer 7 Cushion Rubber 8 Washer 9 Gas Spring 10 Cushion Rubber...

Page 71: ...nt to the ground and stop the engine 2 Set the safety bar to the lock position 3 Remove a R pin and remove the sopper pin B 4 Remove the lock bolts A 5 Solwly raise the canopy 6 Insert the stopper pin...

Page 72: ...e oor mat 4 Remove the auxiliary pedal a Remove the screws 2 and the pedal 3 Apply thread locking compound b Remove the bolts 4 and pilot valve c Remove the bolts and plate 5 5 Remove the bolts and oo...

Page 73: ...hoses 6 and electrical wiring 7 Drain the oil from the tank Remove the Hydraulic Tank 5 Loosen the drain cock to drain out the fuel Removing the Fuel Tank 6 Disconnect the fuel hoses 8 7 Lift up the r...

Page 74: ...the electric wiring 1 for the cano py 6 Remove the gas springs 2 and installation pins 7 Lower the canopy and the lift arms to the ground 8 Remove the xing bolts on the 2 rear positions B 9 Suspend th...

Page 75: ...el ground and remove the bucket 2 Lower the lift arms to the ground and stop the engine 3 Remove the rear R pin 4 from the locking pin 1 4 Support the lift arm stop 2 by hand and pull out the locking...

Page 76: ...Sit in the seat fasten the seat belt start the en gine and lower the safety bar 5 Raise the lift arms slowly until the spring 3 will lift the lift arm stop 2 off the cylinder rod 6 Lower the lift arm...

Page 77: ...ve 4 Control Valve Sub 5 Solenoid Valve 6 HST Pump 7 Hydraulic Tank 8 Pilot Valve Auxiliary 9 Shuttle Valve CONTROL SYSTEM CONSTRUCTION Hydraulic Pilot Unit 1 2 zTable of Connectionsz 1 1 Pa2 3 1 2 Pb...

Page 78: ...ft Pilot Valve 3 Control Valve 4 Control Valve Sub 5 Solenoid Valve 6 HST Pump 7 Hydraulic Tank 8 Pilot Valve Auxiliary 9 Shuttle Valve Hydraulic Pilot Unit 2 2 zTable of Connectionsz 5 A B 9 5 B Pb32...

Page 79: ...Attach identi cation labels to individual hoses for correct reassembling c Disconnect the electric wiring 3 e Remove the bolts and bracket L 4 4 Remove the lever stand R a Remove the cover 5 b Disconn...

Page 80: ...III 37 MACHINE CONFIGURATION ATTACHMENTS ATTACHMENTS CONSTRUCTION 1 Bucket 2 Quick Hitch 3 Lift Arm 4 Bucket Cylinder 5 Arm Cylinder T7C600 5 3 2 1 4...

Page 81: ...MENTS 1 Bracket 2 Bracket 3 Bracket 4 Bracket 5 Pipe Bucket Piping 1 2 Piping 2 2 6 Pipe Bucket 7 Pipe Auxiliary 8 Pipe Auxiliary 9 Control Valve 10 Self Level Valve 11 Solenoid Valve 12 Stop Valve 13...

Page 82: ...racket 4 Bracket 5 Pipe Bucket 6 Pipe Bucket Piping High Flow 1 2 Piping High Flow 2 2 7 Pipe Auxiliary 8 Pipe Auxiliary 9 Control Valve 10 Self Level Valve 11 Solenoid Valve 12 Stop Valve 13 Hydrauli...

Page 83: ...operated for the rst time after reassembly be sure the bleed the air out of the hydraulic circuits by the following procedure Air Bleeding Operation 1 Start the engine and let it idle for about 5 min...

Page 84: ...e pins 8 from the rod side of the arm cylinders 6 Set the arm cylinders onto a crosstie before removing the pillow blocks 9 4 Remove the arm foot pins 10 use a cable to lift up the lift arms 7 and rem...

Page 85: ...19 63750 1 Lock Pin 3 Part Number Quantity 08816 02700 1 Installing the Arm Stopper Install the arm stopper 2 to support the lift arm in place for adjusting the bucket stopper 1 Park the machine on a...

Page 86: ...alling off Adjusting the Bucket Stoppers Loosen the lock nuts 7 and screw in the stopper bolts 8 fully 1 Start the engine slowly extend the bucket cylin ders to the maximum length and then stop the en...

Page 87: ...that the frame presses against the right and left stoppers 1 at the same time when it is lowered 1 Raise the lift arm and securely lock it with the lift arm stopper 2 III 28 28 2 2 Remove the Allen bo...

Page 88: ...e note of the clearance A on the right and the left side 7 Install the stopper 1 and the shim 3 to each of the right and left frames and fasten them with the Allen bolts The shim must be such that the...

Page 89: ...4 3 3 5 3 3 6 5 1 5 4 45 1 5 5 3 44 0 00 3 7 7 1B 1B 1 1 1 1 1B BU NJO 1B BU NJO 1B BU NJO 1B BU NJO 1B BU NJO 0 9 9 9 9 0 3 16 1 NJO 150 9 3 5 7 5 L8 NJO 5 53 7 0503 3 5 53 7 0503 8 3 038 3 8 3 038 3...

Page 90: ...ION HYDRAULIC SYSTEM CONSTRUCTION Hydraulic Tank 1 Hydraulic Tank 2 Suction Pipe 3 Bracket 4 Bracket 5 Suction Strainer 6 Air Breather 7 Sight Gauge 8 O ring 9 O ring 10 Plug 11 Flange A 47 1 N m Appl...

Page 91: ...ket cutting edge lowered to the ground Reference If the amount of hydraulic oil is insuf cient the dis turbances in the ow of oil can not be calmed and this will result in air bubbles getting in the h...

Page 92: ...oses 3 from hydrau lic tank Next remove the bushings 6 hoses 4 Disconnect the suction hoses 4 from the hy draulic tank 5 Remove the plug 5 6 Remove the bolts suction pipe 6 and ange 7 7 Remove the sig...

Page 93: ...is about 50 to 80 C The level should be near the upper limit H Bleeding the air After replacing the hydraulic oil bleed the air from the hydraulic circuit and hydraulic devic es Failure to do so may...

Page 94: ...III 51 MACHINE CONFIGURATION ELECTRICAL SYSTEM ELECTRICAL SYSTEM ELECTRICAL WIRING DIAGRAM...

Page 95: ...RATION ELECTRICAL SYSTEM Electricals 1 Relay Assembly 2 Wire Harness Assembly 3 Fusible Link 4 Diode 5 Fuse 10A 6 Fuse 20A 7 Fuse 30A 8 Fuse 80A 9 Wire Harness 10 Resistor 11 Horn 12 Buzzer 13 Heater...

Page 96: ...III 53 MACHINE CONFIGURATION ELECTRICAL SYSTEM Relay Assembly 1 Box 2 Resistor 3 Relay Assy 4 Timer Unit 5 Timer Unit 6 Relay 7 Detector 8 Relay...

Page 97: ...ulley 2 Valve 3 Bracket 4 Shaft 5 Collar 6 Compressor 7 Pulley A Allow a clearance B Press on the center of the belt with a nger The belt s tension is normal if it bends about 8 mm when pressed with a...

Page 98: ...III 55 MACHINE CONFIGURATION AIR CONDITIONER SYSTEM 1 Hose 2 Hose 3 Hose 4 Hose 5 Bracket 6 Receiver Dryer 7 Pressure Switch 8 Condenser 9 Wire Harness Compressor Assembly 2 4...

Page 99: ...ONER SYSTEM 1 Cover 2 Cover 3 Cover 4 Bracket 5 Bracket 6 Bracket 7 Air Conditioner Unit 8 Panel Compressor Assembly 3 4 A 1 8 N m B Apply thread locking compound 9 Control Cable 10 Tube 11 Box 12 Tub...

Page 100: ...CONFIGURATION AIR CONDITIONER SYSTEM 1 Condenser Assembly 2 Condenser 3 Motor 4 Guard 5 Air Conditioner Unit 6 Core 7 Core 8 Filter 9 Louver 10 Motor 11 Thermostat 12 Valve 13 Box 14 Filter Compresso...

Page 101: ...er systems They illustrate system advantages and disadvantages explained in the paragraphs that follow The HVAC system includes both heater and air conditioner components usually a common control and...

Page 102: ...em 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 o...

Page 103: ...s a liquid The compressor also sucks the vaporized 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 pre...

Page 104: ...ter 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 system The refrigerant gas gives up a lot...

Page 105: ...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 refrig...

Page 106: ...ng and sensing tube expands when it gets warmer and forces the expansion valve open at the metering ori ce 5 Evaporator Coil The expansion valve or other type of metering device bleeds high pressure r...

Page 107: ...or can turn the system on and off regulate the air velocity with the blower control and in some designs adjust the thermostat control The system and component operating range settings automatically cy...

Page 108: ...ide 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 ow of coolant to the heater The heater fan or blow...

Page 109: ...or pulled through the core depending on sys tem design Blower or fan speed is usually selected by the operator Environmental Effects on System Operation The environment outside the cab involves more t...

Page 110: ...sealed pressurized systems The normal air conditioner operat ing pressure ranges from 150 to 250 pounds per square inch sometimes higher with a different refrigerant Air conditioners have a high and a...

Page 111: ...e 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 maintenance Figure 7 1 below shows survey nding...

Page 112: ...AC system been in use Did the operator or work order explain or describe any problems about the system Did someone else work on the system yesterday 700 miles down the road Your rst inspection step is...

Page 113: ...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 compressor...

Page 114: ...ld be often near the condenser All of these spots are potential leak or damage points Tighten re fasten add or replace as indicated by your inspection 4 Check for Refrigerant Leaks System refrigerant...

Page 115: ...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 Functions...

Page 116: ...t 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 have...

Page 117: ...m 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 lev els before system components will cycle on and off...

Page 118: ...eel the suction and discharge lines and note their change in tempera ture 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 Gla...

Page 119: ...nt before re lling 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 detail b...

Page 120: ...cked with the pressure and thermostat testers as de scribed 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 pressure in...

Page 121: ...t take more than 15 to 20 minutes unless com ponent replacement and or complete system evacuation and recharging is warranted The survey results shown in Figure 7 1 indicate belts compressor clutch as...

Page 122: ...III 79...

Page 123: ...nd it s OK The air conditioner is repaired right Wrong What you did is add refrigerant and the problem went away You did not nd and x the cause of the problem Component failure in an air conditioning...

Page 124: ...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 systems an...

Page 125: ...eat energy from the cab to the outside air for occupant comfort The automatic functions of the thermostat or the pressure valve on some accumu lators and the expansion valve help maintain pressures an...

Page 126: ...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 the p...

Page 127: ...mponents that should be serviced You could x 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 j...

Page 128: ...l 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 ttings and remove their pro...

Page 129: ...ead 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 yo...

Page 130: ...erant 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 open...

Page 131: ...han that amount you should stop and check again for leaks Then re cover all of the refrigerant repair evacuate and recharge the air conditioner See Chapter 9 You may want to add dry nitrogen gas to th...

Page 132: ...ow 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 oor fan to get air to the condenser You could tilt the cab or...

Page 133: ...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 is a le...

Page 134: ...ch may not cycle the clutch on and off so the low pressure gauge will not uctuate Cause Air and or moisture in the system RepairProcedure Test for leaks especially around the compressor shaft seal are...

Page 135: ...system replace the receiver drier or accumulator The desiccant is saturated with moisture Check and replace any compressor oil lost due to leakage Evacuate and recharge the system then check AC operat...

Page 136: ...tion pressure on the gauge This indicates the valve was part way open and that your action closed it Repeat the test but rst warm the valve diaphragm or capillary with your hand If the low side gauge...

Page 137: ...refrigerant may be ooding the evapora tor making it impossible for the refrigerant to vaporize and absorb heat normally In vehicles where the TXV and sens ing bulb are accessible check the capillary t...

Page 138: ...er all refrigerant from the system and replace the expansion valve and the receiver drier Evacuate and recharge the system with refrigerant then check AC operation and per formance System High Pressur...

Page 139: ...may be a worn or loose compressor clutch drive belt Repair Procedure If you nd the belt worn or loose replace or tighten it and recheck system performance and gauge readings To in spect and service th...

Page 140: ...ou install a new or rebuilt unit Tighten all connections and evacuate the system Recharge the air conditioner with re frigerant and check system operation and performance Note Rotary compressors have...

Page 141: ...tter assembly Replace 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 inside R...

Page 142: ...not inserted between the evaporator ns in the proper position Cause The thermostatic switch is not functioning properly or at all Repair Procedure Replace the thermostatic switch When you remove the o...

Page 143: ...g 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 Comp...

Page 144: ...cked by ozone oxygen in the air Rubber 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 lines t...

Page 145: ...the leak The shaft rotation exerts force all around the seal and puts life back into it To prevent this from happening manufacturers recommend regular AC system operation a minimum of every couple of...

Page 146: ...MACHINE CONFIGURATION III 103...

Page 147: ...IV 1 IV HYDRAULIC UNITS...

Page 148: ...S CONTENTS HST Pump 3 Gear Pump 33 Gear Pump High Flow 40 Control Valve 44 Control Valve High Flow 56 Control Valve Sub 64 Pilot Valve 71 Pilot Valve Auxiliary 81 Self level Valve 85 Cylinders 92 Trav...

Page 149: ...ring 8 O ring 9 Swash Plate 10 Seal Carrier HST PUMP CONSTRUCTION Pump Assembly 1 4 11 Seal Carrier 12 Cover 13 Pin 14 Gasket 15 Plug 16 Ring 17 Cylinder Block 18 Valve Plate 19 Coupling 20 Coupling...

Page 150: ...IV 4 HYDRAULIC UNITS HST PUMP Pump Assembly 2 4 1 Plug 2 Pin 3 Adjuster 4 O ring 5 Spring 6 Poppet 7 Nut T7D101E 2 3 7 5 6 4 A A L L SECTION L L SECTION E E E E 1...

Page 151: ...T PUMP 1 Ori ce 2 Gasket 3 Plug 4 Valve 5 Spring 6 O ring 7 Backup Ring 8 O ring 9 Plug 10 Plug 11 Cover Pump Assembly 3 4 12 Screw 13 Seal Nut 14 Plug 15 Cover 16 Plug 17 Plug 18 Backup Ring 19 Pisto...

Page 152: ...IV 6 HYDRAULIC UNITS HST PUMP 1 Plug 2 Plug 3 Plug 4 Screw 5 Seal Nut 6 Plug Pump Assembly 4 4...

Page 153: ...piston 2 connection to cylinder block 1 to follow along with swash plate 7 to move in a back and forth motion and causes the intake and exhaust pumps to begin working Thus the nine pistons 2 perform a...

Page 154: ...1 is connected by piston 2 to control cylin der 3 the mechanism tilts to match the degree of stroke for control cylinder 3 and the pump begins to exhaust Thus the pumping capacity of the pump may be...

Page 155: ...If the pressure in the charge circuit 1 becomes higher than that in the closed circuit 2 a gap is generated between the check valve 4 and the spring holder 3 and so the oil ows into the closed circuit...

Page 156: ...o 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 them Disassembly Pum...

Page 157: ...he shaft assembly Grasp the spline of the shaft assembly and pull it up 6 Remove the side cover a Remove the six cap screws b Remove the side cover 9 Press down the swash plate 10 by the handle of a r...

Page 158: ...te is hard to remove use a at head driver Take care not to damage the valve plate 11 Remove the timing pin 14 of the valve plate 12 Remove the servo cover 15 a Remove the ve cap screws b Remove the se...

Page 159: ...ic pump P1 a Remove the six cap screws and take out the B pad adapter 22 If the adapter is hard to remove slightly tap on the adapter with a rubber hammer b Remove the O rings 17 Remove the A pad adap...

Page 160: ...and the retainer 32 from the cylinder block 36 b Remove the ball guide 33 and take out three hold down pins 35 c Remove the retainer ring 34 from the cylin der block 36 21 Disassemble the cylinder blo...

Page 161: ...re vent it from turning Tighten the nut until no load is applied to the snap ring 48 d Remove the snap ring 48 e Remove the spring assembly f Remove the nut 49 g Remove the spring guide 51 the spring...

Page 162: ...ve plug mark the plug lock nut 5 and housing so as to approximately maintain the original adjustment when assembling a Remove the screw adjustable charge relief valve plug 6 by loosening the lock nut...

Page 163: ...ng 48 and the tie bolt 16 rotates freely f Adjust the rotational torque of the servo pis ton IV 24 2 Assemble the cylinder block Lubricate individual components of the cyl inder block with hydraulic o...

Page 164: ...vidual components are assembled in place 4 Install the positioning pins 29 5 Install the drive coupling 27 6 Install the B pad adapter on the side of the hy draulic pump P1 as follows a Install the O...

Page 165: ...utes and let the piston ring 21 contract c Install the servo piston 20 in such a way that the tie bolt 16 is installed at the marker side Make sure that the hole for installing the swash plate bearing...

Page 166: ...cover 15 d Tighten them manually with the ve cap screws e Tighten the cap screws on both sides of the tie bolt to the stipulated torque by using a torque wrench Cap Screw 15 17 5 N m 10 Install the ad...

Page 167: ...ing into the carrier 12 Make sure the surface attached with the bearing number projects 0 00 to 0 38 mm out of the carrier surface b Install the carrier 12 to the swash plate 10 14 Install the swash p...

Page 168: ...t corner counterclock wise Make sure the swash plate does not in terfere with the side cover and the needle bearing Cap Screw 15 17 5 N m 17 Install the shaft assembly to the housing Make sure the cyl...

Page 169: ...le securing the pump with a vise If the turning is not smooth reassemble it again Idle run torque 12 4 N m or less 23 Assemble the pumps P1 and P2 and the gear pump a Attach the O ring to the B pad ad...

Page 170: ...es sure relief valve assemblies 2 into the pump housing The conical springs MUST be correctly positioned on the check poppets or relief valves after installation for proper pump operation c Install th...

Page 171: ...e valve plate must be at least 0 152 in 3 86 mm The sliding surface and the rear surface must be smooth The parallel accuracy must be at least 0 00098 in 0 0249 mm The atness of the valve plate must b...

Page 172: ...laced as a cover assembly or a housing assem bly The bearings must rotate smoothly If the presence of foreign matter is suspected clean the bearing and lubricate it with hydraulic oil When reassemblin...

Page 173: ...orque Nut 20 27 N m Measurement of the Servo Piston s Rota tional Torque Check whether the servo piston s rotational torque is properly adjusted 1 Secure the servo piston 20 with your hand to prevent...

Page 174: ...c hoses to the gauge ports to make the pressures on both sides of the servo piston equal Hydraulic pump P1 M4 and M5 Hydraulic pump P2 M14 and M15 2 Install the pressure gauges to the ports to mea sur...

Page 175: ...above Make sure the readings on the two pressure gauges are equal 8 Tighten the tie bolt 16 by the adjusting seal nut 18 Do not allow the tie bolt to rotate Adjusting seal nut 28 51 N m 9 Stop the eng...

Page 176: ...ng traveling Improper adjustment of the displacement limiter may cause track deviation By adjusting the displacement limiter limit the maximum gradient of the swash plate and control the discharge vol...

Page 177: ...replace Repair or replace Machine operates neither in forward nor reverse Fails to move in a straight line in for ward The level in the hydraulic tank is low Bad pilot valve Insuf cient pressure being...

Page 178: ...oil level in the tank is low The suction side pipe or the suction lter is clogged The amount of leakage from hydraulic devices other than the pump is increas ing Operate the engine at the speci ed spe...

Page 179: ...hich is a drive gear 1 and a driven gear 2 engaged with each other By turning the drive shaft 3 the space between the case and the gears is lled with oil This oil is thus sent through the pump from th...

Page 180: ...with new ones each time the pump 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 sharp edge...

Page 181: ...riginal places Be careful not to scratch or otherwise damage the inside of the housing 7 Disassemble the rear housing according to the same procedure as followed for the front hous ing 8 Remove the ga...

Page 182: ...ave 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 contact marks can be seen o...

Page 183: ...it is abnormal replace it Test Operation The best method for testing the pump s operation is to mount it in a test stand However if that cannot be done test it under the conditions it would be sub je...

Page 184: ...er 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 en gine 3 Run the engine at the rated speed...

Page 185: ...e are out of center with respect to each other There are bubbles in the hydraulic oil Remove the dirt or eliminate the crushed condition of the hose Tighten all the joint Replace the hydraulic oil wit...

Page 186: ...rive gear 1 and a driven gear 2 engaged with each other By turning the drive shaft 3 the space between the case and the gears is lled with oil This oil is thus sent through the pump from the inlet to...

Page 187: ...r 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 them Followin...

Page 188: ...not to scratch or otherwise damage the ange When reassembling install the oil seal using the jigs A and B 5 Remove the rear cover 6 6 Remove the seal 2 and the backup ring 3 from the cover 6 7 Remove...

Page 189: ...IV 43 HYDRAULIC UNITS GEAR PUMP INSPECTION AND ADJUSTMENT IV 36 38 TROUBLESHOOTING IV 39...

Page 190: ...ing 3 Port Relief Valve 4 O ring 5 Nut 6 Main Relief Valve 7 O ring 8 O ring 9 Inlet Housing 10 Lift Arm Section Assembly 11 Bucket Section Assembly 12 Auxiliary Section Assembly CONTROL VALVE CONSTRU...

Page 191: ...1 7 2 T7D203E Lift Arm Section Bucket Section Auxiliary Section 1 Load Check Valve 2 Spring 3 Cover 4 Screw 5 Spring Holder 6 Spring 7 Cap Screw 8 O ring 9 O ring 10 O ring 1 Load Check Valve 2 Sprin...

Page 192: ...ket T7D204 9 7 2 10 6 1 11 4 3 14 15 5 12 13 8 T7D205 10 9 2 7 6 1 8 4 3 5 17 15 11 14 16 12 13 9 Lock Nut 10 Spring 11 Spring 12 O ring 13 O ring 14 O ring 15 O ring 1 Housing 2 Plug 3 Poppet 4 Main...

Page 193: ...ctuator On the other hand the oil returned from the actuator ows into port A and runs through the inner passage of the spool 2 to be supplied to the next section When the spool 2 is moved to the left...

Page 194: ...ther hand forces F and F1 are acting in the respective ar row directions on both sides 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 le...

Page 195: ...he 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 ows around the circumference of the needle valve 5 and passes...

Page 196: ...ace the section assem bly as a unit Be sure to number each section and spool to avoid mistakes during assembly Following is an explanation of the control valve dis assembly procedure Follow the proced...

Page 197: ...Operated Section 1 Take out the cap screw 5 and remove the cover 15 then remove the O ring 16 from the cover 15 Cap screw 3 92 0 98 N m 2 Remove the spool from the section 3 Take out the screw 17 and...

Page 198: ...e 49 04 4 90 N m 2 Remove the O rings from sleeve 1 3 Remove the plug 2 Plug 42 17 3 92 N m 4 Remove the spring 3 and main poppet 4 5 Remove the Lock nut 5 Lock nut 23 54 1 96 N m 6 Remove the gasket...

Page 199: ...rs the spool Scratches rust corrosion of the port seal portion which is in contact with the O ring Scratches rust corrosion of the seal portion of the relief valve etc Other damage which could be a hi...

Page 200: ...rained due to strain in the installation face Valve was used at a pressure or a ow volume which was out of speci cation Bolts used to assemble the valve were tightened excessively Oil is accumulating...

Page 201: ...cavitation valve seat and oil is bypassing Or a seat is damaged Spool stroke is not the speci ed stroke Pump is damaged and no oil is dis charged Disassemble and check then overhaul or replace Try ti...

Page 202: ...g 5 Solenoid 6 Plug 7 O ring 8 O ring 9 O ring 10 O ring CONTROL VALVE HIGH FLOW CONSTRUCTION 11 Plug 12 Plunger 13 Relief Valve 14 O ring 15 O ring 16 Plug 17 Cover 18 Spool End 19 Holder 20 Spring 2...

Page 203: ...ill combine the hydraulic oil ows from the pump P3 and the pump PTO together Also the unload valve 6 of the control valve high ow 1 keeps the pressure from the pump PTO constant When the solenoid 2 is...

Page 204: ...1 is moved to the right by the spring force and pressed against the seat F1 force to the right direction A1 P spring force F2 force to the left direction A2 P Therefore F1 F2 is established and this m...

Page 205: ...ly as a unit Be sure to number each section and spool to avoid mistakes during assembly Following is an explanation of the control valve dis assembly procedure Follow the procedure used to disassemble...

Page 206: ...om the solenoid valve Cap Screw 3 92 0 98 N m 7 Remove the spool 4 the sleeve 5 and the spring 6 from the body To remove the sleeve turn the body upside down and lightly tap it 8 Remove the cap screw...

Page 207: ...IV 61 HYDRAULIC UNITS CONTROL VALVE HIGH FLOW 10 Remove the screw 6 and remove the spring holder 7 spring 8 and spring holder 7 Screw 23 5 1 96 N m Apply Locktite 242 to the screw...

Page 208: ...9 MPa 4 In order to keep the setting screw from turning after pressure has been adjusted tighten the locknut while at the same time holding the set ting screw rmly in place 5 Operate the relief valve...

Page 209: ...e cannot be unloaded The solenoid coil is switched on A foreign matter which entered the spool of the solenoid switching section is blocking the switching the spool does not return A foreign matter wh...

Page 210: ...X 30 2 12 12 11 11 20 27 4 29 21 22 1 23 3 31 17 3 18 16 30 2 19 5 25 26 6 24 7 28 10 9 15 14 13 8 14 SECTION X X SECTION Y Y SECTION Z Z 9 Spring 10 Plug 11 Cap Screw 12 Cap Screw 13 O ring 14 O ring...

Page 211: ...ppet 6 The hydraulic oil from the port 2 pushes up the plunger 7 ows into the circuit of the port 1 and enters together with the oil from the port 1 into port T When the solenoid A is electri ed A mag...

Page 212: ...ng the pressure in the port 1 at the set pressure The hydraulic oil in the port 2 pushes up the poppet 5 and ows into the port 3 When the solenoid B is not electri ed The hydraulic oil from the port P...

Page 213: ...ting of hydraulic oil to sliding surfaces and a thin coating of grease to seals when assembling them Replace seals with new parts each time disassem bly is done The following describes the disassembly...

Page 214: ...e 4 from the body To remove the sleeve turn the body upside down and lightly tap it Control Valve 1 Loosen the plug 5 from the body Plug 98 1 9 81 N m 2 Remove the O ring from the plug 5 3 Remove the...

Page 215: ...13 from the body 7 Remove the piston 14 from the spool 13 Check Valve 1 Loosen the plug 15 from the body Plug 49 0 4 9 N m 2 Remove the O ring from the plug 15 3 Remove the spring 16 4 Remove the popp...

Page 216: ...sion deformation breakage or other notable damage Replace O Ring Replace TROUBLESHOOTING Symptom Probable Causes Remedy Solenoid valve does not operate Wiring short circuit or wire break Solenoid coil...

Page 217: ...9 Spool PILOT VALVE CONSTRUCTION 23 26 24 25 12 8 16 17 21 20 9 19 1 4 2 3 5 13 11 14 15 18 22 10 7 6 T7D300 10 Spool 11 Plug 12 Push Rod 13 Push Rod 14 Seal 15 O ring 16 Washer 1 S N 21500004 215034...

Page 218: ...smitted 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 owing between port P and the output port C but owing between th...

Page 219: ...from each part and check them to make sure there are no burrs bruises using or other marks on them Remove all burrs and bruises using an oil stone Apply thin coating of grease to seals when assem bli...

Page 220: ...e the 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 rea...

Page 221: ...IV 75 HYDRAULIC UNITS PILOT VALVE b Remove the spring seat 14 spring 15 and washer 2 16 from the spool 17 7 Take out the cap screws 8 Remove the port plate 18 O ring 19 and bushing 20 from the casing...

Page 222: ...g hole 2 Install the seal washer and cap screws Cap screw 20 6 1 5 N m 3 Assemble the reducing valve 12 a Install the washer 2 16 spring 15 and spring seat 14 on the spool 17 b Push in the spring seat...

Page 223: ...l them in the positions they were in be fore disassembly 5 Install the O ring 7 and seal 8 in the plug 5 6 Install the push rod 9 in the plug 5 Apply hydraulic oil to the push rod 7 Install the plug 5...

Page 224: ...sc 2 the adjust nut 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 Loc...

Page 225: ...Scratches in the sliding portion Replace Replace Plug Seal is imperfect due to damage Repair or replace Operating Portion Tightening is loose at the pin shaft or joint of the oper ating portion with l...

Page 226: ...ressure Replace the spring Replace the spool and casing assembly Disassemble and reassemble or replace the handle Secondary pressure doesn t stabilize Sliding parts are catching Tank line pressure uct...

Page 227: ...LVE 1 Casing 2 Cover 3 Plug 4 Seal 5 O ring 6 Push Rod 7 Shim 8 Spool PILOT VALVE AUXILIARY CONSTRUCTION L3D350 16 6 4 3 2 5 9 12 11 7 10 8 1 13 15 14 9 Spring Seat 10 Washer 11 Spring 12 Spring 13 Sh...

Page 228: ...bly 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 vice...

Page 229: ...nately so that the cover is at 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 rings...

Page 230: ...IV 84 HYDRAULIC UNITS PILOT VALVE INSPECTION AND ADJUSTMENT IV 79 TROUBLESHOOTING IV 80...

Page 231: ...ring 7 O ring 8 O ring 9 O ring SELF LEVEL VALVE CONSTRUCTION T7D950E 4 5 6 7 2 16 17 24 23 21 22 20 12 13 14 19 25 10 11 9 3 15 8 18 SECTION A A 10 Spring 11 Plunger 12 Pin 13 Cap 14 Nut 15 Set Screw...

Page 232: ...e point where it exceeds the force exerted by spring 6 the oil which has been ejected from the rod side of bucket cylinder 4 ows out of port B coming out of port C and passing along the surface of unl...

Page 233: ...unger 9 and instead all oil from the pump ows into the head side of bucket cylinder 4 The oil owing out from the rod side returns to the tank At Bucket Tilt Rear Bucket Spool In Arm Spool Neutral The...

Page 234: ...f hydraulic oil to sliding surfaces and a thin coating of grease to seals when assembling them Replace seals with new parts each time disassem bly is done Following is an explanation of the self level...

Page 235: ...16 from cap Make a record of the measurements for A see diagram below and make sure that these measurements do not change during assem bly Nut 5 4 7 8 N m 5 Remove cap 15 and then take O ring 14 off...

Page 236: ...th the spool Scratches rust or corrosion of the seal part in contact with the O ring Other damage considered to impair the normal func tions Replace Replace Replace Spool Pin Plunger Damage on the out...

Page 237: ...much self level Pin is out of adjustment Flow divider spool is stuck towards port B Flow divider spool installed wrong Re adjust pin to achieve proper ow split Remove ow divider spool and inspect for...

Page 238: ...ner 17 Cushion Seal 18 Spacer 19 Stopper 20 Piston 21 Wear Ring 22 Ball 23 Set Screw 24 Cushion Bearing 25 Cushion Bearing 26 Washer 27 Screw 28 Dust Seal 29 Grease Nipple 30 Grease Nipple Bucket Cyli...

Page 239: ...colliding with the cover at the stroke end acts on that mechanism and is dampened by it Cushion Mechanism Before the piston 1 nears the stroke end and col lides with the cover 2 the cushion bearing 3...

Page 240: ...rts Apply a thin coating of hydraulic oil to seals be fore tting them in place After tting make sure the O rings are not twist ed Apply clean hydraulic oil to each sliding portion before assembling th...

Page 241: ...e Pull it out straight to prevent the sliding sur face from being scratched Piston Rod Assembly 1 Fasten the piston rod assembly securely in a level position 2 Remove the piston a Take out the set scr...

Page 242: ...the O ring 14 and backup ring 15 2 Remove the stopper 16 spacer 17 and cush ion seal 18 Piston 1 Remove the wear ring 27 then remove the piston packing 28 Spread the wear ring at the cut portion the m...

Page 243: ...g 35 2 Remove the rod packing a Remove the stopper 37 b Remove the spacer 38 c Remove the cushion seal 39 d Remove the rod packing 40 e Remove the backup ring 41 3 Remove the dust seal 42 Tap alternat...

Page 244: ...n the rod cover it is impossible to take it out First use a lathe to grind down the inside portion until only a thin piece remains then insert a copper spatula strongly and pry it out to remove it Cle...

Page 245: ...d and tube 2 Using a setting tool 45 install the dust seals Rod Cover 1 Using an installation jig A pressure t the bushing Hydraulic uid should be applied to the inside surface of the rod cover before...

Page 246: ...er 38 e Install the stopper 37 3 Install the dust seal 42 In the case of a dust seal with a metal ring around the outer circumference use a setting tool 46 to install it 4 Install the backup ring 35 a...

Page 247: ...ston 1 Assemble the piston assembly a Fit the O ring 50 If the O ring is twisted after it is tted cor rect it b Cover the piston with the sliding jig C then using the tting jig D insert the slipper ri...

Page 248: ...ssembly 7 and rod cover 6 t the divided connector 9 around both sides then fasten it with the stopper 8 b Assemble the retainer assembly 7 with ref erence to the item IV 87 88 2 Insert the rod cover a...

Page 249: ...in a horizontal position then insert the piston rod assembly in the tube During insertion align the center of the piston rod with the center of the tube insert ing it straight so that the seals will n...

Page 250: ...squeaking sound in the operation test after reas sembly or if it catches during movement If the inner diameter of the clevis bushing is worn replace the bushing Tube If there are cracks in the welded...

Page 251: ...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 should be 1 c...

Page 252: ...nd other seals If it leaks after the seals have been replaced replace the piston rod Repair the hardened chrome plat ing Oil leaks from the outer circum ference of the rod cover O ring is damaged Back...

Page 253: ...Jig B A B C D E F A B C D E F Arm 49 0 45 0 28 0 22 0 15 0 60 0 54 0 45 0 40 0 5 0 15 0 65 0 Bucket 43 0 40 0 28 0 34 0 15 0 55 0 54 0 45 0 40 0 5 0 15 0 65 0 Sliding Jig C MATERIAL STKM13C Fitting Ji...

Page 254: ...IV 108 HYDRAULIC UNITS CYLINDERS Corrective Jig E MATERIAL STKM13C Unit mm Corrective Jig E A B Arm 90 75 Bucket 90 75...

Page 255: ...raulic motor 1 2 1 Flange Holder 2 Pin 3 Bearing Assembly 4 Snap Ring 5 Oil Seal 7 Shaft 8 O ring 9 O ring 10 Cylinder Block Assembly 25 Plug 26 O ring 28 Spring 29 Center Disc 30 Friction Disc 31 Bra...

Page 256: ...ic motor 2 2 6 Bearing 11 Valve Plate 12 Pin 13 Valve Body 14 Cap Screw 15 Cap Screw 18 Plug 19 Plug 20 Plug 21 Plug 27 Plug 32 Pin 40 Plug 41 Ball 42 Spool 43 Spring 44 Plug 45 Spool 46 Spring Guide...

Page 257: ...s 1 Housing 2 Cover 3 Carrier 4 Sun Gear 5 Sun Gear 6 Planet Gear 7 Planet Gear 8 Ring Nut 9 Thrust Plate 10 Thrust Plate 11 Snap Ring 13 Bearing 14 Needle Bearing 16 Needle Bearing 18 Floating Seal 1...

Page 258: ...and via the spline the torque is transmit ted to the shaft 4 turning it Conversely if high pressure oil is introduced to the port C the rotation is the reverse of the above 2 Speed mechanism 1st spee...

Page 259: ...l to prevent the oil temperature from increasing and to remove contaminants from the circuit When the machine is stopped no pressure is gener ated in the motor port and thus the plunger 1 is held at t...

Page 260: ...ple gear mesh points The motor drives the 1st stage sun gear 1 which in turn drives the 1st planet gears 2 Since these planet gears 2 are engaged with the ring gear 3 the rota tion is transmitted to t...

Page 261: ...IV 115 HYDRAULIC UNITS TRAVEL MOTOR DISASSEMBLY AND ASSEMBLY Special tools...

Page 262: ...AVEL MOTOR 4MAA05Z Cap Screw M6x2 Inbusschraube M6x2 Vis M6x2 3 x2 2 x1 4 x1 1 x1 25 5 40 22 4 190 70 18 27 8 25 5 40 5 30 20 35 42 3 5 5 20 20 70 9 45 60 12x2 25 70 25 260 M16 56 3 20 40 25 5 25 4 JI...

Page 263: ...IV 117 HYDRAULIC UNITS TRAVEL MOTOR...

Page 264: ...ram as necessary Disassembly Reduction gears 1 Take out the plugs 24 and drain out the gear oil 2 Take out the bolts and remove the cover 2 If it is hard to remove lightly tap on the side of the cover...

Page 265: ...ews and remove the thrust plate 10 6 Remove the planet gears 7 Remove the planet gears 7 together with the needle bearing 16 mounted within Hydraulic motor 1 Remove the relief valve 50 2 Take out the...

Page 266: ...lder 1 The block must be thin enough so that the cap screw M10 100 can be tightened to the brake piston 31 in the next step Be sure that the valve body is horizontal 5 Take out the plugs and tighten t...

Page 267: ...ve the shaft 7 and the swash plate 37 9 Remove the balls 39 and the control piston 38 Floating Seal 1 Remove the inner race 16 Use the jig A to hook the inner race and then use the jig B to hold the j...

Page 268: ...NITS TRAVEL MOTOR 4MAA20Z 4MAA21Z 2 Remove the plugs 23 3 Remove the ring nut 8 Use the jig C 4 Remove the housing 1 from the ange holder Use the jig D 5 Remove the oating seal 18 from the housing 1 o...

Page 269: ...it the oating seal 18 by pressing the guide jig E with the jig F Apply gear oil on the sliding surface Important Be sure not to damage the sliding surface The oating seal must be mounted horizon tally...

Page 270: ...ing surface Do not apply grease Important Be sure not to damage the sliding surface The oating seal must be mounted horizon tally 7 Install the housing 1 on the ange holder 8 Fit the ring nut 8 Use th...

Page 271: ...ner races After assembly the dimension X must be between 0 and 1 mm Hydraulic motor 1 Install the oil seal 5 Press t the seal with its metal edge posi tioned upside Grease the lip part of the oil sea...

Page 272: ...he swash plate 5 Install the cylinder block assembly 10 Use the spline of the shaft as a guide 6 Install the center discs 29 and the friction discs 30 alternately The friction discs must be engaged wi...

Page 273: ...l the O rings 8 9 and 35 and the pins 2 on the ange holder 11 Install the pin 12 on the valve body 13 12 Install the valve plate 11 on the valve body 13 Grease the backside of the valve plate The pins...

Page 274: ...R 16 Install the ball 41 and the plug 40 Degrease the hole before installing the plug 40 Plug 30 N m 17 Install the plug 22 Plug 35 N m 18 Install the plug 22 spool 42 and the springs 43 Plug 35 N m 1...

Page 275: ...R 20 Mount the spring guide 46 and the spring 49 to the spool 45 and then install it Be sure to mount the spring guide 46 in the correct direction 21 Install the plugs 47 Plug 35 N m 22 Install the re...

Page 276: ...7 Clean the inner surface of the gears and lightly apply oil on them Do not tap on the bearing or gear 2 Install the thrust plate 10 and t the screws Screw 20 N m 3 Install the sun gear 5 4 Install t...

Page 277: ...on the housing 1 6 Install the sun gear 4 7 Measure the depth A from the housing end face to the holder pin 8 Measure the dimension B of the cover 9 The thrust plate must be such that its thickness X...

Page 278: ...he bolts Apply either Loctite 515 or ThreeBond 1215 to the cover surface on which the housing is mounted Bolt 16 N m 12 Add the gear oil through the plug hole and at tach the plug 24 Be sure to wrap s...

Page 279: ...ace of the sliding part with the piston assembly No abnormal scratches wear or sei zure on the surface Repair with a lap ping tool 1000 or replace Cylinder block Surface of the sliding part with the v...

Page 280: ...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 and O rin...

Page 281: ...ally released the piston motor loses its mechanical braking ca pability The mechanical braking capability of the vehicle must be maintained by means of a vehicle brake or for stationary equipment must...

Page 282: ...IV 136 HYDRAULIC UNITS TRAVEL MOTOR...

Page 283: ...V 1 V TROUBLESHOOTING...

Page 284: ...ether 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 not...

Page 285: ...erature 14 Machine will not travel in second speed 16 LIFT ARMS Lift arm cylinders fail to move 18 Movement of the lift arm cylinders is slow or lacks power 20 Slowly pulling the control lever of the...

Page 286: ...r or replace hydraulic pump Replace the coupling mechanism Repair or replace hydraulic pump Replace fuse Replace proximity switch Normal Normal Normal Faulty Faulty Faulty Not enough oil Normal Faulty...

Page 287: ...ndards for Judging Performance Check pumps P3 and P4 gear pumps a Remove the delivery hoses 2 from the pump b Crank the engine If everything is working properly hydrau lic oil will be ejected from the...

Page 288: ...lock solenoid Check the solenoid according to the following procedure a Turn the starter switch to the on position b Lightly press down on the protruding part on the end of the solenoid c Move the sa...

Page 289: ...ect the hydraulic oil level 1 Replace seal tape O ring hose Take proper action in accor dance with the cause of the problem Replace the lter element Repair or replace the control valve sub Normal No N...

Page 290: ...strainer is clogged 3 Inspect the line lter Remove the case take out the lter element and check to see if the lter is clogged 4 Inspect the control valve sub V 6 5 Hydraulic pump at fault When the ins...

Page 291: ...essure is too low adjust it by tightening the valve set screw gradu ally If the pressure does not rise even after the screw has been turned onequarter of a full rotation the relief valve may be judged...

Page 292: ...mal Normal Pressure low Inspect the output pres sure of the HST pump 3 Repair or replace HST pump Repair or replace travel mo tor Travel motor fault Repair or replace pilot valve Faulty Perform replac...

Page 293: ...pect the charge pressure II Speci cations Standards for Judging Performance 3 Inspect the output pressure of the HST pump II Speci cations Standards for Judging Performance 4 Perform replacement test...

Page 294: ...curve within standard 1 Normal Adjust to speci ed tension or remove foreign matter Repair or replace pilot valve Repair or replace high pres sure relief valve Repair or replace HST pump Problem due to...

Page 295: ...Speci cations Standards for Judging Performance 2 Inspect the crawler tension and inspect for foreign matter biting in etc II Speci cations Standards for Judging Performance 3 Inspect the pilot valve...

Page 296: ...or the parking brake 4 Inspect high pressure relief valves 3 Inspect oil cooler 2 Inspect hydraulic oil level 1 Add hydraulic oil Clean the oil cooler and radiator Repair or replace the oil cooler Rep...

Page 297: ...worked their way in and clogged the cooling system 3 Inspect the high pressure relief valves V 11 4 Inspect the release pressure for the parking brake a Disconnect the hose running from the control v...

Page 298: ...ard value the valve is normal II Speci cations Standards for Judging Performance MACHINE WILL NOT TRAVEL IN SECOND SPEED The 2nd speed control valve is faulty 5 Inspect the 2nd speed solenoid valve 4...

Page 299: ...start switch ON b Press the protruding portion of the solenoid valve lightly c Turn the travel speed switch ON d If the spool moves and vibration can be felt with the ngertip when the circuit changes...

Page 300: ...ef valve Repair or replace pilot valve Normal Faulty 1 Inspect the operation of actuators other than the lift arm cylinders Check the table at right to see if the problem lies with the lift arms alone...

Page 301: ...or the lift arms may be judged to be at fault 5 Inspect the arm oat solenoid valve Foreign particles working their way onto the surface of the valve sheet or the locking of the poppet in a xed positio...

Page 302: ...port relief valves 4 Repair or replace arm oat solenoid valve Repair or replace lift arm cylinder Normal Faulty Repair or replace port relief valve No change Operation be came normal Port relief valve...

Page 303: ...ot being checked and insert a plug in place of the removed hose c Disconnect the hose to the rod end from the cylinder to be checked and release the oil in the pipes within Be sure to insert a plug in...

Page 304: ...to contact with the ground before beginning the above procedure Reference The quantity of oil and its pressure is low when the spool begins operation This places a heavy load on the lift arm cylinders...

Page 305: ...lief valves 4 Replace control valve Repair or replace port relief valve No change Operation be came normal Problem lies with port relief valve Repair or replace lift arm cylinder Outside the standard...

Page 306: ...1 Inspect operation of actuators other than the bucket cylinders Check the table at right to see if the problem lies with the bucket cylinders alone If the problem does lie with the bucket cylinders t...

Page 307: ...e port relief valve for the lift arms with a working one and see if the bucket cylin ders then operates properly If they do the port relief valve for the bucket may be judged to be at fault 5 Inspect...

Page 308: ...l Faulty Perform replacement test for the port relief valves 4 Repair or replace port relief valve Operation be came normal Problem lies with port relief valve Repair or replace pilot valve Outside th...

Page 309: ...ct with the ground b Check the left and right bucket cylinders individually Disconnect the hose from the cylinder not being checked and insert a plug in place of the removed hose c Disconnect two hose...

Page 310: ...air or replace valve Normal Repair or replace bucket cylinder Outside the standard Faulty 1 Is the amount of natural fall within the stan dard II Speci cations Standards for Judging Performance 2 Insp...

Page 311: ...spect the ow selector switch Set the safety bar to the driving position and turn the proximity switch and the starter switch to the ON position Push the ow selector switch to ON If the green lamp ligh...

Page 312: ...r solenoid a Turn the proximity switch and start switch ON b Press the protruding portion of the solenoid valve lightly c Turn the ow selector switch ON d If the spool moves and vibration can be felt...

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