Takeuchi TB175W Workshop Manual
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Takeuchi TB175W Workshop Manual

Takeuchi TB175W Workshop Manual

Hydraulic excavator
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Table Of Contents
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Table of Contents

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See also: Operator's Manual
TB175W
Hydraulic Excavator
CW3E001
BOOK No.
WORKSHOP MANUAL
17540001~
Serial No.

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Summary of Contents for Takeuchi TB175W

  • Page 1 TB175W Hydraulic Excavator CW3E001 BOOK No. WORKSHOP MANUAL 17540001~ Serial No.
  • Page 2 FOREWORD This manual is intended for persons who engage in maintenance operations, and explains procedures for dis- assembly and reassembly of the machine, check and maintenance procedures, maintenance reference values, troubleshooting and outline specifications, etc. Please use this manual as a reference in service activities to improve maintenance techniques.
  • Page 3 I . GENERAL II . SPECIFICATIONS III . MACHINE CONFIGURATION IV . HYDRAULIC UNITS V . TROUBLESHOOTING VI . ENGINE...
  • Page 5 I . GENERAL...
  • Page 6 GENERAL CONTENTS Safety Precautions ..............................Cautions during Disassembly and Assembly ......................Cautions during Removal and Installation of the Hydraulic Units ...............10 Cautions during Removal and Installation of Piping ....................11 Handling of Seals ..........................................................
  • Page 7 GENERAL SAFETY PRECAUTIONS SAFETY ALERT SYMBOL This symbol means Attention! Be Alert! Your Safety Is Involved. The message that follows the symbol contains important information about safety. Read and understand the message to avoid personal injury or death. ■ SIGNAL WORDS Safety messages appearing in this manual and on machine decals are identified by the words “DANGER”, “WARNING”...
  • Page 8 GENERAL Provide a fire extinguisher and first aid Anti-explosive lighting Use anti-explosive electrical fixtures and lights • Know where a fire extinguisher and first aid kit when inspecting fuel, oil, coolant, battery fluid, etc. are located and understand how to use them. If lighting that is not anti-explosive should break, •...
  • Page 9 GENERAL Always clean the machine Securely block the machine or any com- ponent that may fall • Clean the machine before performing mainte- nance. • Before performing maintenance or repairs under • Cover electrical parts when washing the machine. the machine, set all working equipment against Water on electrical parts could cause short-cir- the ground or in the lowermost position.
  • Page 10 GENERAL Cautions on working on the machine Handling of hoses Fuel, oil or hydraulic fluid leaks can cause a fire. • Do not twist, bend or hit the hoses. • Never use twisted, bent or cracked hoses, tubes and pipes. They may burst. •...
  • Page 11 • Do not make hole, weld, or fuse. • Do not subject to shock such as hitting or rolling. • At time of disposal, it will be necessary to release the enclosed gas. Please contact a Takeuchi sales or service agent. Be careful with grease under pressure Pressure can be maintained in the hydraulic circuit long after the engine has been shut down.
  • Page 12 Have a Takeuchi service agent repair welding cracks 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 qualified person in a •...
  • Page 13 GENERAL • When adding air to a tire, do so from a distance. Use a long hose with self-attaching chuck. Always stand behind tread when adjusting tire pressure. • Do not inflate tires with flammable gases or from systems utilizing an alcohol injector. •...
  • Page 14 GENERAL CAUTIONS DURING DISASSEMBLY AND CAUTIONS DURING REMOVAL AND INSTALLA- ASSEMBLY TION OF THE HYDRAULIC UNITS 1. Clean the machine before disassembly opera- 1. Make sure that the temperature of the hydraulic tion. oil has dropped. 2. Before disassembly, check the machine condi- 2.
  • Page 15 GENERAL CAUTIONS DURING REMOVAL AND INSTAL- HANDLING OF SEALS LATION OF PIPING 1. Clean the grooves for O-rings and if there is any 1. When hydraulic hoses are installed, tighten them burr, etc., remove it. once to the prescribed torque, then loosen them slightly and retighten them to the prescribed torque.
  • Page 16 GENERAL TIGHTENING TORQUES Hydraulic Hoses Torque Hose Fitting Size Union Nut (G) Taper Thread (R) N·m ft-lb N·m ft-lb +4.9 +3.5 11.8 ±1.2 8.7 ±0.8 +4.9 +3.5 24.5 18.1 29.4 ±2.9 21.7 ±2.1 +4.9 36.2 +3.5 53.9 ±5.4 39.8 ±3.9 58.8 +4.9 43.4...
  • Page 17 GENERAL Joints for Piping Torque Nominal Thread Diameter Steel Cast Steel N·m ft-lb N·m ft-lb 11.8 ±1.2 8.7 ±0.8 10.8 ±1.1 8.0 ±0.7 29.4 ±2.9 21.7 ±2.1 24.5 ±2.5 18.1 ±1.7 53.9 ±5.4 39.8 ±3.9 49 ±4.9 36.2 ±3.5 88.3 ±8.8 65.1 ±6.4 73.5 ±7.4 54.3 ±5.3...
  • Page 18 GENERAL Bolts and Nuts (for ISO Strength Category 10.9) Torque Thread Size × Pitch General Tightening Points Special Tightening Points N·m kgf·m ft-lb N·m kgf·m ft-lb M 6 × 1.0 9.8 ±0.5 1.0 ±0.05 7.2 ±0.4 11.8 ±0.6 1.2 ±0.06 8.7 ±0.4 M 8 ×...
  • Page 19 II . SPECIFICATIONS II-1...

  • Page 20: Table Of Contents

    SPECIFICATIONS CONTENTS Names of C ........................................................................................Specifications T Recommended Lubricants ............................ Standards for Judging Performance ........................Reference Value Table ............................ Methods for Inspecting Performance ......................Hydraulic Circuit Diagram ............................ Electrical Wiring Diagram ............................ In regard to Standard Values and Allowable Values The terms used in the items “Servicing Standards”...
  • Page 21 SPECIFICATIONS NAMES OF COMPONENTS NAMES OF COMPONENTS 1. Cab 10. Axle Lock Cylinder 19. Dozer Blade Cylinder 20. Swivel Joint 2. Engine Hood 11. Engine 3. Fuel Tank 21. Bucket 12. Tire 4. Hydraulic Tank 13. Axle 22. Bucket Cylinder 23.

  • Page 22: Table Of Contents

    SPECIFICATIONS DIMENSIONS DIMENSIONS Machine Dimensions Unit: mm 2-Piece Boom Mono-Boom 6260 6320 2110 ← 2925 ← 1720 ← 1715 ← 2100 ← 2330 ← 2300 ← ← ← 2505 2620 1955 2060 2385 2495 ← ← 1815 ← ← 4380 4445 2895 2645...

  • Page 23: Table Of Contents

    SPECIFICATIONS DIMENSIONS Mono-Boom Operating Range Unit: mm Mono-Boom 6945 6700 4055 3220 6780 4765 1330 4270 II-5...
  • Page 24 SPECIFICATIONS SPECIFICATIONS TABLES SPECIFICATIONS TABLES SPECIFICATIONS Serial Number 17540095 or later Machine Type 2-Pice Boom Mono-Boom Machine Mass (not including operator) 8130 7905 –1 49.3/2300 Engine Rated Output kW/min ← Bucket Capacity (Standard Bucket) 0.245 Rated Capacity ← 0.185 Struck Capacity ←...
  • Page 25 SPECIFICATIONS STANDARDS FOR JUDGING PERFORMANCE Serial Number 17540095 or later Machine Type 2-Pice Boom Mono-Boom Working Equipment (Hoe Attachment) Boom Swing Angle: L.H. degree ← R.H. degree ← Maximum Reach 7650 6945 Maximum Reach at GRP 7430 6700 Minimum Level Cut Radius with Bucket Flat on GRP 1700 Maximum Digging Depth 4085...
  • Page 26 SPECIFICATIONS SPECIFICATIONS TABLES SPECIFICATIONS OF DEVIDES Serial Number 17540095 or later Engine Model Yanmar 4TNV98T-ZSTBW Type 4-cycle, vertical, water-cooled, in-line, 4-cylinder diesel engine Number of Cylinders – Bore × Stroke 4-98 × 110 Total Displacement 3318 Compression Ratio Performance Maximum Torque N·m/min 271.3 to 295.8/1650 ±100 Maximum No-load R.P.M.
  • Page 27 SPECIFICATIONS SPECIFICATIONS TABLES Control Valve (4-Section) Model KVSE31-4 Number of Circuits Main Relief Valve Pressure Setting 24.0 Port Relief Valve Pressure Setting 26.9 20.6 Solenoid Valve Model 16521-00010 Number of Solenoids Solenoid Rated Voltage Relief Valve Set Pressure Solenoid Valve Model 16545-00000 Number of Solenoids...
  • Page 28 SPECIFICATIONS SPECIFICATIONS TABLES Boom Cylinder 120 × 75 Bore Diameter × Rod Diameter Stroke Fully Retracted Length (Pitch) 1207 Cushion Mechanism Rod Side Arm Cylinder Bore Diameter × Rod Diameter 100 × 65 Stroke Fully Retracted Length (Pitch) 1327 Cushion Mechanism Both Ends Bucket Cylinder Bore Diameter ×...
  • Page 29 SPECIFICATIONS SPECIFICATIONS TABLES Tire Front Tire: Qty. Size 8.25-20-12PR Tire Pressure 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 Brake Type Rear wheel braking disk Outrigger (Option) Type...

  • Page 30: Recommended Lubricants

    Takeuchi genuine hydraulic oil 46. This manual describes when to replace the hydraulic oil assuming that this Takeuchi oil 46 is used. When a conventional antiwear hydraulic oil is used, replace it every 2000 hours.
  • Page 31 SPECIFICATIONS RECOMMENDED LUBRICANTS Diesel fuel standards Use the diesel fuel that is compliant with any of the standards below. The table below shows the stan- dards from the various countries. Diesel fuel standards Region No. 2-D, No. 1-D, ASTM D975-94 EN590:96 Part Type...

  • Page 32: Standards For Judging Performance

    SPECIFICATIONS STANDARDS FOR JUDGING PERFORMANCE STANDARDS FOR JUDGING PERFORMANCE REFERENCE VALUE TABLE Serial Number 17540095 or later Machine Type 2-Piece Boom Mono-Boom Item Unit Standard Values Allowable Values Standard Values Allowable Values Hydraulic Oil Pressure Travel 31.00 31.00 Boom 27.46 27.46 27.46 27.46...
  • Page 33 SPECIFICATIONS STANDARDS FOR JUDGING PERFORMANCE METHODS FOR INSPECTING PERFOR- MANCE Hydraulic Oil Pressure (Main Relief Valve Set Pressure) Travel, Boom, Arm Measuring Method • Engine : Maximum r.p.m. • Hydraulic Oil Temp. : 50~60°C • Mount the pressure gauge on the pressure detec- tion port, operate the desired hydraulic circuit and measure the relief pressure.
  • Page 34 SPECIFICATIONS STANDARDS FOR JUDGING PERFORMANCE Dozer Blade Measuring Method • Engine : Maximum r.p.m. • Hydraulic Oil Temp. : 50~60°C • Mount the pressure gauge on the pressure detec- tion port, operate the desired hydraulic circuit and measure the relief pressure. Pressure Detection Port Relief Circuit...
  • Page 35 SPECIFICATIONS STANDARDS FOR JUDGING PERFORMANCE Hydraulic Oil Pressure (Slewing Relief Valve Set Pressure) Measuring Method • Engine : Maximum r.p.m. • Hydraulic Oil Temp. : 50~60°C • Mount the pressure gauge on the pressure de- tection port and set a solid obstacle so that the upperstructure cannot slew in the direction to be measured.
  • Page 36 SPECIFICATIONS STANDARDS FOR JUDGING PERFORMANCE Hydraulic Oil Pressure (Pilot Relief Valve Set Pressure) Measuring Method • Engine : Maximum r.p.m. • Hydraulic Oil Temp. : 50~60˚C • Mount pressure gauge on the pressure detection port and measure the pilot relief pressure. Pressure Detection Port Relief Valve Port Position...
  • Page 37 SPECIFICATIONS STANDARDS FOR JUDGING PERFORMANCE Slew Time • Engine : Maximum r.p.m. • Hydraulic Oil Temp. : 50~60°C • Measurement Posture : Completely retract the arm cylinder, fully extend the bucket cylinder and adjust so that boom foot pin and bucket pin are at matching height.
  • Page 38 SPECIFICATIONS STANDARDS FOR JUDGING PERFORMANCE Arm Cylinder Speed • Engine : Maximum r.p.m. • Hydraulic Oil Temp. : 50~60°C • Measurement Posture : Completely retract the arm cylinder, fully extend the bucket cylinder, position the arm horizontally and rest the dozer blade on the ground.
  • Page 39 SPECIFICATIONS STANDARDS FOR JUDGING PERFORMANCE Adjust Cylinder Speed • Engine : Maximum r.p.m. • Hydraulic Oil Temp. : 50~60°C • Measurement Posture : Completely retract the arm cylinder, fully extend the bucket and boom cylinders, position the arm horizontally and rest the dozer blade on the ground.
  • Page 40 SPECIFICATIONS STANDARDS FOR JUDGING PERFORMANCE II-22...
  • Page 41 III . MACHINE CONFIGURATION III- TB175W...
  • Page 42 MACHINE CONFIGURATION 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 ............................44 TB175W III-...
  • Page 43 3. Engine Foot RL Apply thread-locking compound. 12. Pipe 4. Engine Foot RR E: “A” Mark 13. Bracket 5. Stopper  N·m 14. Silencer 6. Stopper .9 N·m 15. Gasket 7. Cushion Rubber 16. Gasket 8. Cushion Rubber III- III- TB175W...
  • Page 44 13. Hose 3. Hose 14. Hose 4. Hose 15. Sub Tank 5. Pipe 16. Bracket 17. Plate 6. Pipe 7. Pipe 18. Hose 8. Pipe 19. Sensor 9. Hose 20. Joint 10. Hose 21. Hose 11. Drain Vave TB175W III-4 III-4...
  • Page 45 Radiator and Oil Cooler 8. Bracket 1. Stay 9. Bracket 2. Stay 10. Guard 3. Shroud 11. Cushion Rubber 4. Plate 12. Radiator and Oil Cooler 5. Plate 13. Cushion Rubber 6. Plate 14. Guard 7. Net III-5 III-5 TB175W...
  • Page 46 P3 P4 • Refer to the table concerning the responsibility of each of the pumps shown in the drawing at right. Travel, Bucket, Boom[1], Arm[2] Travel, Auxiliary, Boom[2], Arm[1], Swing Outrigger, Slew, Auxiliary Steering, Brake W2C104 Pilot Pressure TB175W III- III-...
  • Page 48 C:Upon assembling, inspect the continuity using a 9. Plug 2. Resistor tester when the level switch float (13) is at ON and 10. Level Switch OFF positions. 3. Switch Float is at OFF (upper) position There is no continuity. 11. Strainer 4. Relay Float is at ON (upper) position There is no continuity. 12. Pump 5. Wire Harness 13. Float 6. Diode (3A, yellow) 7. Hose TB175W III-8 III-8...
  • Page 52 MACHINE CONFIGURATION TRAVEL SYSTEM TB175W III-12...
  • Page 54 MACHINE CONFIGURATION UPPER FRAME Floor Plate W2C401 1. Floor Plate 2. Floor Mat 3. Cover 4. Stage 5. Tube 6. Tube 7. Rubber 8. Cover 9. Cover 10. Pipe TB175W III-14...
  • Page 55 D: Grease with molybdenum disulfide applied. 23.5 N·m 1. Cover 9. Filter 2. Plate 10. Cover 3. Selector Damper 11. Hose 4. Bracket 12. Hose 5. Panel 13. Heater Assembly 6. Cover 14. Switch 7. Wire 15. Valve 8. Wire III-15 TB175W...
  • Page 56 10. Pilot Lamp 3. Louver 11. Pilot Lamp 4. Defroster Hose 12. Pilot Lamp 5. Parking Brake Switch 13. Pilot Lamp 6. Site Travel Switch 14. Creeping Travel Switch 7. Axle Lock Switch 15. Ornament 8. Light Switch TB175W III-16...
  • Page 57 C: Actuator Relay 3. Plate 11. Terminal D: Main Relay 4. Relay 12. Clamp E: Starter Relay 5. Relay 13. Cover 14. Battery Switch 6. Sheet 12.3 N·m 7. Battery 15. ECU .8 N·m 8. Bracket 16. Ground Cable III-17 TB175W...
  • Page 58 MACHINE CONFIGURATION UPPER FRAME Radio 1. Cover R 2. Cover L 3. Bracket 4. AM/FM Radio 5. Speaker R 6. Speaker L TB175W III-18...
  • Page 59 4. Side Cover R 12. Plate 20. Hinge 5. Front Cover 13. Stay 21. Gas Spring 6. Center Cover F 14. Stay 22. Under Cover 15. Hook 7. Center Cover T 23. Plate 8. Under Cover 16. Wire 24. Under Cover III-1 TB175W...
  • Page 60 MACHINE CONFIGURATION UPPER FRAME TB175W III-20...
  • Page 61 20. Substructure, Compl. 28. Pedal 5. Spring 13. Washer 21. Plate 29. Steering Wheel 6. Shield 14. Half Bowl 22. Stop 30. Turning Handle 31. Cap 7. Covering 15. Substructure 23. Spring 8. Spring 16. Segment 24. Shaft 32. Switch III-21 TB175W...
  • Page 62 MACHINE CONFIGURATION CONTROl SYSTEM 4Pb2 5Pb2 4Pb3 4Pa2 5Pa2 4Pa3 MONO BOOM W2C504E TB175W III-22...
  • Page 63 T6 ↔ SST SSP ↔ PM5 22. Selector Valve (2-Piece Boom) AS2 ↔ 5Pa5 Dr ↔ T5 23. Pipe AST ↔ TM1 PDB ↔ 5Pa3 24. Solenoid Valve ASP ↔ A5 PA ↔ 4Pa2a BS2 ↔ 5Pb1 PPL ↔ 4Pa4 III-23 TB175W...
  • Page 64 2. Cover 6. Cluster Gauge 11. Safety Lock Button 3. Cover 7. Starter Switch 4. Panel Cover R 8. Slew Speed Switch 12. Fuse Box Control Box l Air Conditioner W2C507E 1. Panel Cover L 2. Cover 3. Clamp TB175W III-24...
  • Page 65 1. Dozer Blade Lever 4. Control Cable 7. Hinge 2. Bracket 5. Yoke 3. Cover 6. Cigarette Lighter Swing Pedal VIEW B W2C509E 1. Bracket 3. Cover 5. Elbow 2. Swing Pedal 4. Bushing 6. Pilot Valve (Swing) III-25 TB175W...
  • Page 66 MACHINE CONFIGURATION CONTROl SYSTEM Pilot Valve (Brake) W2C510 1. Pilot Valve (Brake) 3. Elbow 2. Adapter 4. Adapter Pilot Valve (Travel) 2, 4 2, 3 VIEW A W2C511E 1. Pilot Valve (Travel) 3. Elbow 2. Bushing 4. Elbow TB175W III-26...
  • Page 67 17. Grease Nipple 29. Pin 7. Clamp 18. Boom Light 30. Plate 8. Cover 19. Bulb 31. Grease Nipple 9. Wire Harness 20. Boom Cylinder 32. Elbow 21. Arm Cylinder 10. Rubber 33. Elbow 11. Bracket 22. Boom adjustment Cylinder III-27 TB175W...
  • Page 68 11. Pipe of 0.5~1.0 mm when tightening the double nuts. 3. Clamp 12. Cap 4. Hose 13. Grease Nipple 5. Pipe 14. Hose 6. Hose 15. Hose 7. Clamp 16. Hose 8. Adapter 17. Cap 9. Pipe R TB175W III-28...
  • Page 69 6. Protector 26. Arm Cylinder 36. Band 17. Pin 7. Pipe R 27. Hose 37. Band 18. Pin 8. Pipe L 28. Hose 38. Band 19. Pin 9. Pipe 29. O-ring 20. Shim 30. Tube 10. Wire Harness III-29 TB175W...
  • Page 70 6. Bucket Link 28. Plate 17. Grease Nipple 7. Bushing 29. Cap 18. Elbow 8. Bushing 30. O-ring 19. Elbow 31. Elbow 9. Dust Seal 20. O-ring 10. Guide Link L 21. Bucket Cylinder 11. Guide Link R 22. Hose TB175W III-30...
  • Page 71 (6) and flange. 8. Insert the shims which were just removed be- tween the flange and the end plate, then reas- semble the parts. Tighten the 3 bolts uniformly. Bolt: 83 N·m 9. Return the O-ring to its proper position. III-31 TB175W...
  • Page 72 MACHINE CONFIGURATION ATTACHMENTS TB175W III-32...

  • Page 73: Hydraulic Circuit Diagram

    MACHINE CONFIGURATION HYDRAULIC SYSTEM HYDRAULIC SYSTEM HYDRAULIC CIRCUIT DIAGRAM 2 Piece Boom III-33 TB175W...
  • Page 74 MACHINE CONFIGURATION HYDRAULIC SYSTEM Mono-Boom TB175W III-34...
  • Page 75 2. Air Breather 11. Sight Gauge 3. Cover 12. Plug 4. Cover 13. O-ring 5. Spring 14. Check Valve 6. Filter Element 15. Snap Ring 7. Check Valve 16. Adapter 8. Suction Filter 17. Washer 9. O-ring 18. Bushing III-35 TB175W...

  • Page 76: Hydraulic Pump

    3. Run the engine at high speed, then extend and contract all the cylinders 4 or 5 times, without going to the stroke end. 4. Set the engine back to a low idle, then extend and contract all the cylinders 4 or 5 times to the W2C706 stroke ends. TB175W III-36...

  • Page 77: Electrical Wiring Diagram

    ELECTRICAL SYSTEM MACHINE CONFIGURATION ELECTRICAL SYSTEM ELECTRICAL WIRING DIAGRAM TB175W III-37...
  • Page 78 MACHINE CONFIGURATION ELECTRICAL SYSTEM TB175W III-38...
  • Page 79 MACHINE CONFIGURATION ELECTRICAL SYSTEM TB175W III-39...
  • Page 80 MACHINE CONFIGURATION ELECTRICAL SYSTEM TB175W III-40...
  • Page 81 Parking light relay 4. Wire Harness f: Head light relay 13. Buzzer 5. Diode (3A yellow) g: Change speed relay 14. Fuse Box 6. Plate h: Hazard relay 15. Bracket 7. Resistor 16. Hour Meter 8. Detector III-41 TB175W...
  • Page 82 MACHINE CONFIGURATION ELECTRICAL SYSTEM 17540001~17540134 17540001~17540134 17540001~17540094 17540135~ W3C802 1. Wire Harness 2. Fusible Link 3. Short Connector 4. Diode (3A yellow) 5. Short Connector 6. Wire Harness 7. Wire Harness 8. Diode (3A yellow) 9. Guard 10. Horn TB175W III-42...
  • Page 83 MACHINE CONFIGURATION ELECTRICAL SYSTEM III-43 TB175W...
  • Page 84 MACHINE CONFIGURATION ELECTRICAL SYSTEM TB175W III-44...
  • Page 85 8 mm when 3. Shaft 10. Valve pressed with a force of about 98N. 4. Collar 11. Adaptor 5. Compressor 12. Bushing 6. Pulley 13. Elbow 7. Hose 14. V-Belt III-45 TB175W...
  • Page 86 MACHINE CONFIGURATION AIR CONdITIONER SYSTEM Air Conditioner 1/2 1. Bracket 2. Cover 3. Condenser 4. Fun 5. Dryer 6. Bracket 7. Hose 8. Hose 9. Switch 10. Connector TB175W III-46...
  • Page 87 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. Louver 16. Adaptor 17. Louver III-47 TB175W...
  • Page 88 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 Control Converter 13. Cable Control Converter 14. 3-Speed Rotary Switch TB175W III-48...
  • Page 89 A bigger heater core, air conditioning evaporator coil, condenser, blower or fan may be included. Often, on long haul trucks, auxiliary air condi- tioning and heater components and controls are added. The objective remains the same, to move heat energy and maintain occupant comfort. TB175W III-48...
  • Page 90 Please study it for a moment. Note the information printed next to each component. Remember that the com- ponents may be positioned and attached to the truck in various locations. III-49 TB175W...
  • Page 91 One way valves inside the compressor separate the compressed gas (high pres- sure) side of the system from the suction (low pressure) side. Figure 2-3 shows a cutaway view of a compressor with the high and low pressure sides noted. TB175W III-50...
  • Page 92 The refrigerant gas gives up a lot of heat energy to the outside air as it “changes state” in the condenser. Figure 2-5 illustrates a condenser. Air moving through the condenser absorbs heat from the refrigerant. The amount of air flow through the con- denser is the major factor in how well the condenser functions. III-51 TB175W...
  • Page 93 Figure 2-6 This cutaway view of a receiver-drier shows the fil- ter elements, inlet, outlet and refrigerant path. The sight glass is a small window into the system used in diagnosis and when adding refrigerant (charging the system). TB175W III-52...
  • Page 94 The refrig- erant absorbs heat from the air when the blower forces the air through the fins. When the thermostat probe senses the upper limit of the thermostat heat setting, a circuit closes. The compressor clutch engages and the compressor operates and moves more refrigerant to the high side of the system. III-53 TB175W...
  • Page 95 In operation the AC system is under load and high side pressures normally range between 150 and 250 pounds per square inch for R-12 and higher for some other refrigerants. TB175W III-54...
  • Page 96 Additional heater controls, ducts, air vents, blend-air doors, temperature regu- lating devices and auxiliary heaters may be installed as part of a heater system. These may be air, vacuum, electrical or mechanically operated. III-55 TB175W...
  • Page 97 90’s or low 100’s. The AC unit must remove a lot of moisture from the air in the cab as the air moves through the evaporator fins. The more moisture on the fins, the less effective the transfer of heat is to the refrigerant inside the evaporator coil. TB175W III-56...
  • Page 98 • Environmental conditions affect how both heaters and air conditioners work. Weather, driving conditions, color of the vehicle are factors. All contribute to heat gain or loss inside a cab and how much heat energy must be moved to maintain occupant comfort. III-57 TB175W...
  • Page 99 The following inspection procedures should take about 15 to 20 minutes, longer if corrective steps, part replacement or adding refrigerant is necessary. There is a “Preventive Maintenance Worksheet” you may use at the end of this chapter, Figure 7-9 TB175W III-58...
  • Page 100 2. Inspect Parts Look at the system for what might come loose, leak, wear out or become dirty and not function the way it should. The main points for visual inspec- tion of the system are emphasized in Figure 7-2. III-59 TB175W...
  • Page 101 Tighten all mounting bolts as you in- spect the system. Slots in the mounting bracket are used to move the compressor clutch assembly in order to adjust belt tension or alignment. TB175W III-60...
  • Page 102 AC system. AC service procedures for complete system recovering of refrigerant, evacuating, and recharging are covered and illustrated in Chapter 9. Note: A leaking heater core could also result in coolant at the condensate drain. III-61 TB175W...
  • Page 103 Look for any corrosion on leads or connectors and clean them. Make sure all leads and wires are properly supported and securely connected. 2. Check Electrical Current Flow and Device Functions Perform the following steps to check current flow and electrical device func- tions: A. Turn the Ignition On – To check current flow the ignition must be TB175W III-62...
  • Page 104 The roof mounted condenser fans may come on when the system is turned on. Like the thermostat and most clutches, the normal on-off cycling action can not be observed until the engine is running with the AC system on. III-63 TB175W...
  • Page 105 The needle movement is called “temperature swing.” When you can adjust the thermostat setting, the range of swing should change. For ex- ample, from full cooling (cold) to moderate (between cold and warm), the swing may change from 32-38 to 32-42 degrees. TB175W III-64...
  • Page 106 Figure 7-7 illustrates and explains what you may observe in the sight glass. Roof mounted condenser fans may run continuously or cycle on and off. If you can’t tell by sound you may have to climb a ladder and ob- serve the fan blades. III-65 TB175W...
  • Page 107 As the engine warms up, feel the heater return hose. If the hose feels warm or hot, the heater control valve is leaking internally. This type of leak can seriously reduce air conditioning per- formance. TB175W III-66...
  • Page 108 Heater/cooling electrical and valve component inspection is the same as air conditioner inspection. The controls are operated to see if they function correctly to maintain or vary cab temperature and air flow. Preventive Maintenance Worksheet Please feel free to modify or copy the worksheet in Figure 7-9. Actual vehicle use, mileage, operating conditions and maintenance budget may influence service frequency. III-67 TB175W...
  • Page 109 When you check the electrical circuit, begin with the engine off but ignition on. A system performance inspection with the engine run- ning and system on really combines electrical and AC or heater system function. TB175W III-68...
  • Page 110 III-69 TB175W...
  • Page 111 2. The vehicle operator's knowledge and experience—question him or her. 3. The work order. 4. Good test equipment and the HVAC system The routine you follow when troubleshooting should proceed from the most to least productive way of locating the problem and fixing the cause. TB175W III-70...
  • Page 112 8-1 we have used numbers on the illustration to track normal air conditioner func- tion. Figure 8-1 An illustration of the typical HVAC system. The numbers follow the action when the AC part of the system is working properly (moving heat out of the cab and into the outside air). III-71 TB175W...
  • Page 113 He was in such a hurry he didn’t tell you anything except that the air conditioner wasn’t cooling. Here is the best way to handle that kind of situation. TB175W III-72...
  • Page 114 AC service. • Do you get any cooling at all? Answer: Yes but it seems to quit after a while. • Do you still get air flow at the vents from the blower? Answer: Yes. • When was your air conditioner checked thoroughly? Answer: Before I bought the rig last May (a year ago). • Has the heater been used recently and did it work OK? Answer: Yes. III-73 TB175W...
  • Page 115 The result would be the appearance of an AC problem. TB175W III-74...
  • Page 116 The manifold gauge set is a necessary tool in troubleshooting AC system prob- lems. The following steps are performed during and after installing the manifold gauge set: 1. Purging Air from the Gauge Set Hoses 2. Adding Refrigerant to the System 3. Stabilizing the AC System. III-75 TB175W...
  • Page 117 AC system is maintained on a regular basis. When adding refrigerant to the system, connect the center hose from the manifold gauge set to the refrigerant dispensing valve on the container. Fig- ure 8-4 illustrates this connection. TB175W III-76...
  • Page 118 2. Open the refrigerant dispensing valve on the container and then the low pressure hand valve on the manifold. This allows refrig- erant to enter the system as a gas on the low pressure or suction side of the compressor. The compressor will pull refrigerant into the system. III-77 TB175W...
  • Page 119 3. Stabilizing The AC System For reliable gauge readings as an aid in troubleshooting, the AC system must be stabilized. Be sure your tools and test equipment are clear of all mov- CAUTION ing parts of the engine and air conditioner. TB175W III-78...
  • Page 120 Low Refrigerant Charge in the System Figure 8-5 Gauge reading, low refriger- ant charge in the system. Tip: You see bubbles in the sight glass. The air from vents in the cab is only slightly cool. Cause: Insufficient refrigerant (charge) in the system. III-79 TB175W...
  • Page 121 Note: It may be necessary to use a jumper wire to bypass some types of low pressure cutout switches to operate the compressor (clutch) when you add refrigerant to the system. TB175W III-80...
  • Page 122 (there is no way to tell). Check the compressor and replace any refrigeration oil lost due to leakage. Evacuate and recharge the system with refrigerant, then check AC operation and performance. III-81 TB175W...
  • Page 123 AC operation and performance. Figure 8-9 Expansion Valve (TXV) Stuck Closed or Plugged Gauge reading, expansion valve (TXV) stuck closed. Tip: Air from vents in the cab is only slightly cool. The ex- pansion valve body is frosted or sweating. TB175W III-82...
  • Page 124 Remove, clean and replace the screen, then reconnect the hose. Any signs of contamination will require flushing the system. Next, replace the re- ceiverdrier. Then evacuate and recharge the system with refrigerant, and check AC operation and performance. III-83 TB175W...
  • Page 125 2. The low pressure (suction) side gauge needle should now drop on the gauge. This indicates the valve has closed and is not stuck open. Repeat the test, but first warm the valve diaphragm with your hand. TB175W III-84...
  • Page 126 The hose or line may be cool to the touch near the restriction. Cause: There could be a kink in a line, or other restriction in the high side of the system. III-85 TB175W...
  • Page 127 R-12 from systems containing Schrader valves. Remove the compressor cylinder head and check the appearance of the reed valve plate assembly. If defective, replace the valve plate and install with new gaskets, or replace the com- pressor assembly. TB175W III-86...
  • Page 128 The high pressure hoses and lines will be very hot. Don’ t forget to check the engine cooling system compo- nents—fan and drive belt, fan clutch operation, and the radiator shutter. III-87 TB175W...
  • Page 129 (it may be par- tially plugged) or replace the condenser. Also replace the receiver-drier or accumulator. Then connect the components and evacuate the system. Recharge the air conditioner with refrigerant and check system operation and performance. TB175W III-88...
  • Page 130 Don’t kink or break the tube. Position the new thermostat capillary tube at or close to the same location and seating depth between the evapo- rator coil fins as the old one. Connect the electrical leads. III-89 TB175W...
  • Page 131 When refrigerant and refrigera- tion oil leaks out of a system or there is contamination blocking oil flow, the compressor will be starved for oil and seize. TB175W III-90...
  • Page 132 When the system is charged with refrigerant, the pressure goes from minus (a vacuum) to plus pressure inside the hoses and all components. The refrigerant and refrigera- tion oil are trying to escape from the system at all times. III-91 TB175W...
  • Page 133 But there was no way to tell without using your knowledge and experience. By now you are pretty familiar with AC system problems, the reasons for some of them, troubleshooting and repair. In Chapter 9 we will describe com- plete system purging, evacuation, flushing and recharging. TB175W III-92...
  • Page 134 MACHINE CONFIGURATION TB175W III-93...
  • Page 135 IV . HYDRAULIC UNITS IV-1 TB175W...
  • Page 136 Cylinders ................................99 Dozer Blade Cylinder ............................115 Ram Lock Cylinder ............................117 Slew Motor ................................ 123 Axle Type: 279/172 Axle Type: 212 (Front) Axle Type: 112 (Rear) Travel Motor Type: A6VM Drop Box Type: 357 Swivel Joint Type: 532 IV-2 TB175W...
  • Page 137 66. Spring Pin 11. Spring 25. Ball 39. Pin 53. O-ring 67. Adjusting Screw 12. Swash Plate 26. Pin 40. Piston 54. O-ring 13. Bushing 27. Lever 41. Pin 55. O-ring 14. Pin 28. Piston 42. Case 56. O-ring IV-3 TB175W...
  • Page 138 P1 and P2 and discharge pressure from pump P3 act on the piston (9). Also, the discharge pressure selected by the shuttle valve (11) and transmitted through the sleeve (2) and spool (6) acts on the servo piston (10). L3D103 IV-4 TB175W...
  • Page 139 P1 and P2 but also by the pump P3. Thus, the P-Q curve for the piston pumps shows that the engine's power is fully utilized (full horse power control). L3D124E IV-5 TB175W...
  • Page 140 1. Loosen the drain plug (1) and drain out the oil. L3D106 2. Remove the cap screws and remove the gear pump. 3. Remove the coupling. L3D107 4. Remove the cap screws and remove the cover. • Remove the cover in horizontal condition. L3D108 IV-6 TB175W...
  • Page 141 (5), and the pistons (6) from the cylinder block (7). • Disassemble the inside of the cylinder block (7) only when required. L3D111 7. Remove the swash plate. 8. Remove the pin R and pin L. L3D112 IV-7 TB175W...
  • Page 142 10. Remove the cap screws and remove the cover. 11. Remove the two springs [inside, outside]. 12. Remove the spring seat. L3D114 13. Remove the cap screws and remove the cover. 14. Remove the lever. L3D115 15. Remove the sleeve, the spool and piston. L3D116 IV-8 TB175W...
  • Page 143 L3D118 18. Loosen the lock nut (3) and remove the adjusting screw (2). • Record the length of the adjusting screw pro- trusion before starting the disassembly. L3D119 IV-9 TB175W...
  • Page 144 3. Install the drain plug (1). L3D106 4. Install the oil seal. 5. Install the shaft in the housing. • Tap the spline end with a plastic hammer to positively install the outer race of the bearing in the housing hole. L3D120 IV-10 TB175W...
  • Page 145 • Insert the bushing into the swash plate. • Apply grease on the sliding surfaces of the swash plate, pin R and pin L. L3D122 8. Mount the pin and tighten the plug. Plug: 29.4 N·m L3D117 9. Mount the piston in the housing. L3D123 IV-11 TB175W...
  • Page 146 Install the guide (3) in the cylinder block. • Apply grease to the spherical part of the guide. c. Attach the pistons (6) to the shoe holder (5), and install the shoe holder (5) in the cylinder block. L3D111 IV-12 TB175W...
  • Page 147 Cap screw: 235 N·m L3D108 20. Install the coupling on the end of the main pump shaft. 21. Unite the main pump and gear pump and fix them with the cap screws. Cap screw: 56.9 N·m L3D107 IV-13 TB175W...
  • Page 148 • No abnormal scratches, wear, or • Exchange driven gear flaking of the tooth surfaces Ball bearings and • No abnormal scratches, wear, or • Exchange the shaft needle bearings flaking of the rolling surfaces and the assembly. IV-14 TB175W...
  • Page 149 • Replace the seals. • The shaft surface which slides against • Replace the shaft or replace the pump. the oil seal is worn. • The plug or bolts are loose. • Tighten them or replace the seals. IV-15 TB175W...
  • Page 150 HYDRAULIC UNITS HYDRAULIC PUMP IV-16 TB175W...
  • Page 151 By turning the drive shaft (3), the space between the case and the gears is filled with oil. This oil is thus sent through the pump from the inlet to the outlet. INLET OUTLET Y1-D101E IV-17 TB175W...
  • Page 152 3. Remove the snap ring (3) and the oil seal (4) from the flange (1). • Be careful not to scratch or otherwise damage the flange. • When re-assembling, install the oil seal using the jigs A and B. L4D151 T7D152 IV-18 TB175W...
  • Page 153 • Be careful not to scratch or otherwise damage the inside of the housing. L4D154 7. Remove the gasket (2) from the adapter plate (11). DISCHARGE SIDE 8. Remove the backup ring (5) and gasket (6) from the adapter plate (11). SUCTION SIDE L4D155E IV-19 TB175W...
  • Page 154 • Be careful not to scratch or otherwise damage the inside of the rear cover. 12. Remove the gasket (18), (19) from the bushing (13) and the bushing (14). L4D156 • Be careful to keep the bushings separated and in their original places. IV-20 TB175W...
  • Page 155 • There are marks from foreign matter biting into the sliding surface of the bearing inner diameter and the side surface. Dirty hydraulic oil is one likely cause of such wear. In such a case, replace the hydraulic oil and flush out affected hydraulic circuit completely. IV-21 TB175W...
  • Page 156 3. Run the pump for 10 minutes under the conditions the test. in (2), then increase the engine’s speed to 1,500~2,000 rpm and run it for another 10 min- utes. IV-22 TB175W...
  • Page 157 2. Open the tester’s loading valve and start the engine. 3. Run the engine at the rated speed. 4. Gradually close the loading valve and apply the rated pressure to the pump (2). 5. Measure the discharge volume and the pump’s speed (engine speed). IV-23 TB175W...
  • Page 158 • Clean the suction filter and suction side piping. • Aeration is occurring. • Check for insufficient tightening of pipes, etc. and repair. • Viscosity of the hydraulic oil is too • Replace the hydraulic oil with oil of the low. proper viscosity. IV-24 TB175W...
  • Page 159 CONTROL VALVE (MONO-BLOCK) CONSTRUCTION VIEW Z W2D200E 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 IV-25 TB175W...
  • Page 160 SECTION ÒB-BÓ SECTION ÒA-AÓ L3D201E 1. Cover 7. Cover 13. Poppet 2. Spool End 8. O-ring 14. O-ring 3. Holder 9. Shuttle 15. Plug 4. Spring 10. Spring 16. Spring 5. Spring 11. O-ring 6. O-ring 12. Plug IV-26 TB175W...
  • Page 161 CONTROL VALVE 8 910 2 3 4 3 5 SECTION ÒD-DÓ SECTION ÒC-CÓ L3D202E 1. Housing 6. Port Relief Valve 2. O-ring 7. O-ring 3. Spring Holder 8. Plug 4. Spring 9. Spring 5. Spool End 10. Poppet IV-27 TB175W...
  • Page 162 3. Spring 11. Backup Ring 19. Poppet 4. Poppet 12. O-ring 20. Anti-Drift Valve 5. Spring 13. Spring 21. Spacer 6. Poppet 14. Poppet 22. Spring 7. Sleeve 15. Sleeve 23. Poppet 8. Port Relief Valve 16. Plug IV-28 TB175W...
  • Page 163 L3D204E 1. Port Relief Valve 9. O-ring 2. Plug 10. Backup Ring 3. O-ring 11. Plug 4. Spring 12. O-ring 5. Poppet 13. Plug 6. Port Relief Valve 14. Sleeve 7. Poppet 15. Spring 8. Spring 16. Poppet IV-29 TB175W...
  • Page 164 HYDRAULIC UNITS CONTROL VALVE SECTION “J-J” SECTION “K-K” W2D205E 1. Plug 2. O-ring 3. Poppet 4. Spring 5. Plug 6. Main Relief Valve IV-30 TB175W...
  • Page 165 Anti-Drift Valve 1. Body 2. Poppet 3. Plug 4. Piston 5. Spool 6. Sleeve 7. Spring 8. Spring 9. O-ring 10. O-ring 11. Backup Ring 12. Backup Ring 13. O-ring 14. Plug 15. O-ring 16. Spring Holder L2D208 IV-31 TB175W...
  • Page 166 5-section part passes through the passage (10), signal lands of indi- vidual spools of the 4-section part, signal land (11) of the bucket spool, and then flows into the tank passage IV-32 TB175W...
  • Page 167 (4). Then the oil flows through left travel operations. the passage (5) and the head of the spool (1), and enters the port 4A2. The return oil flows from the port 4B2 through the head of the spool (1), and back to the IV-33 TB175W...
  • Page 168 (11) to close the center bypass valve (13). The oil supplied from the pump P2 passes through the parallel passages (14), load check valve (15), passage (16), the head of the spool (12), and the IV-34 TB175W...
  • Page 169 (3), load check valve (4), passage (5), and the head of the spool (1), and then flows into the port 5B1. The return oil flows from the port 5A1 through the head of the spool (1), and back to the tank passage (6). IV-35 TB175W...
  • Page 170 Switching the spool (1) of the arm [1] causes the spool head of the spool (1) of the arm [1], and back to the (17) of the arm [2] to be switched by the passage (8) tank passage (15). 2. Load L2D217 IV-36 TB175W...
  • Page 171 Part of the oil from the pump P2 flows through the parallel passages (4), orifice (10), and load check valve (11), and is supplied to the travel section to relieve the deceleration shock at the time of switching of the straight travel spool (3). IV-37 TB175W...
  • Page 172 (5) to flow through the passage (4) into the tank port Dr1. This opens the poppet (1), and the return oil from the cylinder port 4B3 flows through the spool of the boom [1] and back to the tank. L2D221 IV-38 TB175W...
  • Page 173 When the pressure is applied to the pilot port PH, the piston (8) is pushed to the left to hit the plug (9). Then, the spring force of the spring (7) becomes larger, increasing the pressure in chamber B. W2D210 IV-39 TB175W...
  • Page 174 C on the inside drops. Compared to the chamber B side, the pressure in chamber C is low and there is no equilibrium in pressure. For this reason, the main poppet (6) opens and pressurized oil flows to the tank passage (T). TB175W IV-40...
  • Page 175 When the pressure in chamber B is lower 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 space. IV-41 TB175W...
  • Page 176 • Install the valve in the same position as it was in before disassembly. Valve: 59~69 N·m W2D211 3. Remove the plug (4), then remove spring (5) and spool (6). Next, remove the O-ring from the plug. Plug: 78~88 N·m W2D212 IV-42 TB175W...
  • Page 177 7. Disassemble the right travel plug (20). Next, remove the O-ring from the plug. Plug: 105.9~141.2 N·m L3D228 8. Remove the cap screws, then remove cover (21). Next, remove the O-ring from the cover. Cap screw: 8.8~10.8 N·m L3D229 IV-43 TB175W...
  • Page 178 (35). Then remove the O-ring and backup ring from the plug (33). • Screw the bolt into the screw hole (M6 × 1.0) at the end face of the plug, and grab the bolt to pull out the plug. L3D236 IV-44 TB175W...
  • Page 179 9. Remove the O-ring (16) and backup ring (17) from the spacer (15). 10. Remove the spring (18) and poppet (19) from the body (14). L2D240 IV-45 TB175W...
  • Page 180 5. Remove the O-ring (13) from the plug (11). 6. Loosen the lock nut (14) and remove the plug (15). 7. Remove the O-ring (16) from the plug (15). W2D214 8. Remove the spring (17) and needle valve (18). IV-46 TB175W...
  • Page 181 • Damage to poppet contact surface. • Replace • Abnormality in the spring. • Replace • O-rings, backup rings, seals • As a rule, all these should be replaced. Adjusting the Main Relief Valve Pressure “II. Specifications, Standards for Judging Per- formance” IV-47 TB175W...
  • Page 182 • Foreign matter is biting into the load • Disassemble and check, then overhaul shifting to a lift operation. check valve seat or large scratches were or replace. made by foreign matter biting into the valve's seat previously. IV-48 TB175W...
  • Page 183 • Spool stroke is not the specified stroke. • Check if there is something interfering with the link mechanism. Check if a pin or a pin hole in the link connection is worn or not. IV-49 TB175W...
  • Page 184 HYDRAULIC UNITS CONTROL VALVE IV-50 TB175W...
  • Page 185 3. Slew Flow 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. Auxiliary Section Assembly 12. Port Relief Valve IV-51 TB175W...
  • Page 186 10 7 6. Load Check Valve 7. Spring 8. Wiper 9. O-ring 10. O-ring L3D251 Slew Section 1. Cover 2. Screw 3. Spring Holder 4. Spring 5. Cover 6. Load Check Valve 7. Spring 8. O-ring 9. O-ring L3D252 IV-52 TB175W...
  • Page 187 4. Spring 5. Cover 6. Load Check Valve 7. Spring 8. O-ring 9. O-ring W2D217 Outlet Housing 1. Filter 2. Orifice L3D253 Spacer Section 1. Plug 2. Adjusting Screw 3. Nut 4. O-ring 5. O-ring 6. O-ring L3D254 IV-53 TB175W...
  • Page 188 16. O-ring 7. Spring 17. O-ring 8. Spring 18. Wave Washer 9. Adjusting Screw 19. O-ring 10. Washer Port Relief Valve 1. Housing 2. Adjusting Screw 3. Poppet 4. Spring 5. Lock Nut 6. O-ring 7. O-ring C4D205 IV-54 TB175W...
  • Page 189 A load check valve (5) is included in each section except the travel (right, left) sections. This valve prevents oil from flowing backward due to the load pressure (C) from the actuator port during switching of the spool. IV-55 TB175W...
  • Page 190 In this way, only a specific quantity of the oil supplied flows to the slew motor even when the supply pres- sure changes, the remaining being release to tank port T2. This makes it possible to slew in the slow speed mode with a slow flow. IV-56 TB175W...
  • Page 191 (2), and this hydraulic pressure pushes the main poppet toward the right. As a result, the pressurized oil in the circuit flows to the tank passage. This operation maintains the pressure in the circuit at the set value. S3F612 IV-57 TB175W...
  • Page 192 C on the inside drops. Compared to the chamber B side, the pressure in chamber C is low and there is no equilibrium in pressure. For this reason, the main poppet (6) opens and pressurized oil flows to the tank passage (T). IV-58 TB175W...
  • Page 193 A from the actuator port. If this pressure becomes stronger than the set value of the spring (1), it pushes the poppet (2) to the right side and pressurized fluid from the actuator port flows to the tank passage. IV-59 TB175W...
  • Page 194 • Do not disassemble the relief valves unless it is necessary. • When using a spanner or adjustable wrench, be sure to attach it in the place shown in the figure at right. Relief valve: 68~78.5 N·m G4D223 IV-60 TB175W...
  • Page 195 1. Remove the cap screws (5), the cover (6) and the spool assembly (7). Cap screw: 7.3 N·m 2. Loosen the screw (8) from the spool assembly (7). Screw: 5.2 N·m 3. Remove the spring holder (9), spring (10), and spring holder (9). IV-61 TB175W...
  • Page 196 Screw: 2.5 N·m Pilot 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: 7.3 N·m 2. Remove the spool from the section. K3D217 IV-62 TB175W...
  • Page 197 3. From the opposite side of the block, remove cap screws (7), then remove cover (8), piston (9), pin (10) and sleeve (11). Cap screw: 9.8 N·m 4. Remove O-ring (12) from cover (8). 5. Remove O-ring (13) from sleeve (11). IV-63 TB175W...
  • Page 198 O-ring (13) from the adjusting screw (12). • During assembly, after installing the adjusting screw (12), lock the lock nut (10) temporarily, then tighten it after adjusting the pressure. Lock nut: 27~31 N·m 6. Remove the spring (14) and needle valve (15). W2D220 IV-64 TB175W...
  • Page 199 • Damage to poppet contact surface. • Replace • Abnormality in the spring. • Replace • O-rings, backup rings, seals • As a rule, all these should be replaced. Adjusting the Main Relief Valve Pressure “II. Specifications, Standards for Judging Per- formance” IV-65 TB175W...
  • Page 200 2. Upon completion of the adjustment, tighten the lock nut while holding down the set screw to prevent it from turning. 3. Operate the valve again to confirm that the set 84.4 screw is stable. L3D255 TROUBLESHOOTING “IV-48~49” IV-66 TB175W...
  • Page 201 SOLENOID VALVES CONSTRUCTION Solenoid Valve (3-Section) Ram Lock, Lever Lock and Speed Shift SPEED OUTRIGGER LEVER SHIFT /RAMLOCK LOCK (SLEW) HYDRAULIC SYMBOL W2H100E 1. Body 2. O-ring 3. Spool 4. Spring 5. Cover 6. Solenoid Valve 7. Relief Valve IV-67 TB175W...
  • Page 202 11 2 7 10 1 8 3 SECTION “Y” A C C SECTION “X” W2H101E 1. Spring 7. Spool 2. Sleeve 8. Stopper 3. Body 9. Plug 4. Rod 10. Washer 5. Plate 11. O-ring 6. Solenoid Valve 12. O-ring IV-68 TB175W...
  • Page 203 11 2 7 10 1 8 3 SECTION “Y” A C C SECTION “X” W2H102E 1. Spring 7. Spool 2. Sleeve 8. Stopper 3. Body 9. Plug 4. Rod 10. Washer 5. Plate 11. O-ring 6. Solenoid Valve 12. O-ring IV-69 TB175W...
  • Page 204 A magnetic field is generated around the coil and the plunger (2) is pulled down. This pushes the spool (1) down. As a result, oil at port P flows into port A and pressure is transmitted to the pilot circuit at the bottom. 9 0" IV-70 TB175W...
  • Page 205 • Pull out the spool slowly, and take care not to scratch or dent the circumference. • At the time of reassembly, the spool must be installed in the same housing hole. 4. Remove the relief valve. Relief valve: 44 ±5 N·m IV-71 TB175W...
  • Page 206 • To take out the spool, hook the small orifice at the end of the spool using a tool such as a scriber. • To remove the sleeve, turn the body upside down and lightly tap it. W2H108 IV-72 TB175W...
  • Page 207 • Damaged O-ring at the emergency manual but- • Replace valve, cover, or relief valve to the outside. ton of the solenoid valve Pressure does not rise. • Catching of foreign matter by the relief valve • Clean or replace. IV-73 TB175W...
  • Page 208 HYDRAULIC UNITS SOLENOID VALVES IV-74 TB175W...
  • Page 209 HYDRAULIC UNITS PROPORTIONAL CONTROL SOLENOID VALVE PROPORTIONAL CONTROL SOLENOID VALVE CONSTRUCTION 7 ±0.5 N·m 1. Proportional Control Solenoid 2. Bolt 3. Spool IV-75 TB175W...
  • Page 210 Therefore, the opening areas of the supply side notch (5) and discharge side notch (6) are controlled by the movement of the spool (1), and secondary (pilot) pressure created by the thrust force generated by the solenoid can be provided. T9H203 IV-76 TB175W...
  • Page 211 • Do not disassemble the sleeve (2) that is swaged onto the solenoid (4) with the retaining ring (3). • Make sure that the spool (5) moves a little if pushed from the sleeve (2) end. T9H205 IV-76-1 IV-77 TB175W...
  • Page 212 • Defective the proportional controller • Repair or replace • Primary pressure is insufficient • Keep the primary pressure Oil leakage from sole- • Damaged O-ring • Replace noid valve • Damaged seal nut • Replace IV-76-2 IV-78 TB175W...
  • Page 213 HYDRAULIC UNITS SELECTOR VALVE SELECTOR VALVE CONSTRUCTION Pilot Change HYDRAULIC SYMBOL W2H300 26.5 N·m 70.6 N·m 1. Body 5. Spring 2. Plug 6. Retainer 3. Connector 7. O-ring 4. Spool 8. O-ring IV-77 TB175W...
  • Page 214 HYDRAULIC UNITS SELECTOR VALVE Swing/Adjust Change HYDRAULIC SYMBOL SECTION “X-X” 9 0!- 9.8 N·m 1. Spring 2. Cover 3. Cover 4. O-ring IV-78 TB175W...
  • Page 215 10. Backup Ring 2. Plug 11. Pin 3. Sleeve 12. Adjusting Screw 4. Main Poppet 13. Body 5. Spring 14. Lock Nut 6. Spring 15. O-ring 7. Spring 16. O-ring 8. Needle Valve 17. O-ring 9. Backup Ring 18. O-ring IV-79 TB175W...
  • Page 216 • Do not disassemble the relief valves unless it is necessary. • When using a spanner or adjustable wrench, be sure to attach it in the place shown in the figure at right. Relief valve: 58.84 N·m W2H401 IV-80 TB175W...
  • Page 217 HYDRAULIC UNITS SHUT-OFF VALVES SHUT-OFF VALVES CONSTRUCTION 1. Body 6. Plug 2. Relief Valve 7. Lock Nut 3. Plug 8. Adjusting Screw 4. Screw 9. Spring 5. Plug 10. Spool IV-81 TB175W...
  • Page 218 The boom or arm does not fall in case of hydraulic hose breakage, because the oil flow leading to the boom or arm is blocked and isolated in the passage through the check valve (1) and the spool (3) if a hose breaks. IV-82 TB175W...
  • Page 219 HYDRAULIC UNITS SHUT-OFF VALVES INSPECTION AND ADJUSTMENT Never adjust the adjuster screws on the isolation valve. Otherwise, the valve may not work properly, or the boom or arm may fall. IV-83 IV-83 TB175W...
  • Page 220 3. Loosen the lock nut (3). 4. Tighten the stem (4) to lower the boom or arm. 5. Check for stability of the hoe attachment and load. 6. Loosen the stem (4) secure it with the lock nut (3). IV-84 IV-84 TB175W...
  • Page 221 12. Spring 3. Spool 13. Spring 4. Plug 14. Spring 5. Push Rod 15. Spring 6. Push Rod 16. Joint 7. Seal 17. Disc 8. O-ring 18. Adjusting Nut 9. Spring Seat 19. Lock Nut 10. Spring Seat IV-85 IV-97 TB175W...
  • Page 222 T open. c. When the pressure at port A is lower than the set pressure, port A and port P open and port A and port T close. In this way, the secondary pressure is kept constant. IV-87 IV-86 TB175W...
  • Page 223 1. Remove the lock nut and the adjust nut (1), then remove the disc (2). • Using copper or lead plates, fasten the valve in a vise. 2. Remove the joint (3), then remove the plate (4). • Use installation jigs (A) and (B). IV-87 IV-98 TB175W...
  • Page 224 Push in the spring sheet (14) to contract the spring (15), and move the spool (17) from the small hole to the large hole of the spring sheet (14). • Do not push in the spring sheet too far (at most 6 mm). IV-88 IV-99 TB175W...
  • Page 225 Push in the spring sheet (14) to contract the spring (15), and move the spool (17) from the large hole to the small hole of the spring sheet (14). • Do not push in the spring sheet too far (at most 6 mm). IV-89 IV-100 TB175W...
  • Page 226 4. Install the push rod (9) in the plug (5). • Apply hydraulic oil to the push rod. 5. Install the plug (5) and plate (4), then install the joint. • Use installation jigs (A) and (B) to install the joint. Joint: 47.1 ±2.9 N·m IV-90 IV-101 TB175W...
  • Page 227 • During tightening, the disc should not be moved. Adjust Nut: 68.6 ±4.9 N·m 7. Apply grease to the contact surfaces of the joint rotating portion, the disc and the push rod. IV-91 IV-102 TB175W...
  • Page 228 • Operate the machine several times and bleed out the air Secondary pressure is high • Tank line pressure is high • Remove the abnormal portions of the tank line • Sliding parts are catching • Repair or replace IV-94 IV-92 TB175W...
  • Page 229 L3D350 1. Casing 9. Spring Seat 2. Cover 10. Washer 3. Plug 11. Spring 4. Seal 12. Spring 5. O-ring 13. Shaft 6. Push Rod 14. Bushing 7. Shim 15. Cam 8. Spool 16. Ball IV-93 IV-10 IV 3 TB175W...
  • Page 230 • Apply grease to the cam and push rods. 2. Remove the set screw. Set screw: 6.9 N·m • Apply Loctite #241 to the set screw. 3. Remove the cam pin, then remove the cam (1). IV-104 IV-94 TB175W...
  • Page 231 6. Remove the O-rings and seal (6) from the plug. L3D352 7. Remove the spool assembly (7) and spring (8) from the casing. • Never disassemble the spool assembly as the pressure has been adjusted by the shim. IV-105 IV-95 TB175W...
  • Page 232 2 mm or greater Casing, • Scratches, rust or corrosion on the spool and sliding portion • Replace Port Plate • Scratches, rust or corrosion on seal portions which come in • Repair or replace contact with the O-ring IV-96 IV-96 TB175W...
  • Page 233 • Operate the machine several times and bleed out the air Secondary pressure is high • Tank line pressure is high • Remove the abnormal portions of the tank line • Sliding parts are catching • Repair or replace IV-95 IV-97 TB175W...
  • Page 234 HYDRAULIC UNITS PILOT VALVE IV-106 IV-98 TB175W...
  • Page 235 28. Plug 5. Backup Ring 13. Bushing 21. Piston 29. Grease Nipple 6. O-ring 14. Rod Cover 22. Wear Ring 30. Grease Nipple 7. Backup Ring 15. Cushion Bearing 23. Nut 8. Piston Packing 16. Bushing 24. Set Screw IV-99 TB175W...
  • Page 236 6. O-ring 15. Cushion Bearing 24. Ball 33. Holder 7. Backup Ring 16. Bushing 25. Cushion Bearing 34. Bolt 8. Piston Packing 17. Snap Ring 26. Cushion Seal 35. Grease Nipple 9. O-ring 18. Holder 27. Snap Ring IV-100 TB175W...
  • Page 237 20. Cushion Seal 28. Ball 5. O-ring 13. Bushing 21. Cushion Bearing 29. Grease Nipple 6. Backup Ring 14. Rod Cover 22. Wear Ring 7. O-ring 15. Cushion Bearing 23. Cushion Seal 8. O-ring 16. Piston 24. Stopper IV-101 TB175W...
  • Page 238 20. Plug 3. Dust Seal 9. Tube 15. Snap Ring 21. Holder 4. O-ring 10. Bushing 16. Piston 22. Grease Nipple 5. Backup Ring 11. Piston Rod 17. Set Screw 23. Wear Ring 6. O-ring 12. Bushing 18. Ball IV-102 TB175W...
  • Page 239 (3) and the clearance (4) of the cover inner diameter portion. This causes the piston’s (1) back pressure to rise and slows the piston’s speed. IV-103 TB175W...
  • Page 240 4. Loosen the rod cover. • The piston rod should be pulled out approxi- mately 200 mm beforehand. • Measures should be taken to prevent the piston rod from being hit. IV-104 TB175W...
  • Page 241 Remove the snap ring (9). b. Move the cushion bearing (10) and remove the stopper (11). c. Pull out the cushion bearing (10). d. Remove the cushion seal (12). 5. Remove the rod cover from the piston rod. IV-105 TB175W...
  • Page 242 Clevis 1. Remove the dust seal from the tube and piston rod. 2. Remove the bushing using a setting tool (43). IV-106 TB175W...
  • Page 243 Make sure it is bent with a (PROJECTION) radius of 6mm or greater to prevent wrinkles. • Be sure to install it in the proper direction. 6. Install the snap ring (23). (SLIT) W2D407E IV-107 TB175W...
  • Page 244 Install the cushion bearing (10). • Be sure to set with the flat side (A) in the proper direction. c. Install the stopper (11) on the piston rod, and move the cushion bearing (10). d. Install the snap ring (9). IV-108 TB175W...
  • Page 245 • Apply Three Bond #1901 or the equivalent to the rod cover tread. Rod cover Unit: N·m Boom 1060 Bucket Boom Adjustment Swing 1060 3. Bend the lock rib on the tube down in a notch of the rod cover to lock it. IV-109 TB175W...
  • Page 246 0.25 mm, replace the bushing. • If the inside surface of the bushing is scratched, and the scratches are deeper than the depth of the coating layer, replace the bushing. IV-110 TB175W...
  • Page 247 3. With the engine at top speed, repeat the operation in (2), then with the engine running at slow speed, move the piston rod to the stroke end and apply relief. IV-111 TB175W...
  • Page 248 • The piston packing sliding surface is • Replace the affected parts. the maximum use pressure scratched. multiplied • The O-ring is damaged. • Replace the affected parts. cylinder’s surface area) is 0.5 mm or greater. IV-112 TB175W...
  • Page 249 Fitting Jig (D) MATERIAL: STKM13C MATERIAL: NYLON Unit: mm Sliding Jig (C) Fitting Jig (D) Boom 121.0 119.7 107.3 23.5 101.0 99.7 90.7 22.5 Bucket 85.7 84.7 75.7 19.5 Boom Adjustment 90.7 89.7 80.7 19.5 Swing 121.0 119.7 107.3 23.5 IV-113 TB175W...
  • Page 250 HYDRAULIC UNITS CYLINDERS Corrective Jig (E) MATERIAL: STKM13C Unit: mm Boom Bucket Boom Adjustment Swing IV-114 TB175W...
  • Page 251 1 2 8 5 4 3 W2D409 1. Dust Seal 8. Rod Cover 2. Joint 9. Piston 3. Guide Band 10. Nut 4. O-ring 11. Screw 5. Backup Ring 12. Bearing 6. Pipe 13. Ring 7. Piston Rod IV-115 TB175W...
  • Page 252 HYDRAULIC UNITS DOZER BLADE CYLINDER IV-116 TB175W...
  • Page 253 • Pay particular attention to the central position of the axle’s point of rotation in relation to the cylinders. • The securing surfaces of the cylinder to the sub-assembly must be flat in order to avoid distorting the cylinder housing when bolting together. IV-117 TB175W...
  • Page 254 HYDRAULIC UNITS RAM LOCK CYLINDER Figs 1-6 2. Hydraulic switching diagram Fig. 2 IV-118 TB175W...
  • Page 255 WARNING! Do not damage rod surface. • Remove grooved ring using a round-edged tool. WARNING! Do not damage the recess surface. • Check scraper, Pos. 6, for damage and replace if necessary. • Grease seals. • Re-insert rod. IV-119 TB175W...
  • Page 256 • Torque cylinder bolts, Pos. 9, to 16 Nm. WARNING! Use only 12.9 Nm cylinder bolts. Before start-up, bleed again as per Point 3 above. WARNING! All checking and repair work should be carried out under clean conditions. Fig. 3 IV-120 TB175W...
  • Page 257 O-ring 310182 Lock bolt 310180 Lock bolt 310154 Lock bolt 310200 Cylinder bolt 410403 O-ring Grooved ring 430079 Scraper ring 440029 Piston 0620.00.003 Cylinder 0620.00.002 Non-return valve case, complete 0620.01.000 0640.00.002 Cylinder housing 0640.00.001 Name Part Dwg no. IV-121 TB175W...
  • Page 258 HYDRAULIC UNITS RAM LOCK CYLINDER IV-122 TB175W...
  • Page 259 5. Friction Disc 15. Valve Plate 25. Case 6. Cylinder Block 16. Bearing 26. Pin 7. Brake Piston 17. Snap Ring 27. Piston 8. Spring 18. Collar 28. O-ring 9. Shaft 19. Shoe Holder 29. Spring 10. Retainer 20. Pin IV-123 TB175W...
  • Page 260 5. Bearing 14. Planetary Gear 23. Race 6. Case 15. Thrust Plate 24. Needle 7. Bearing 16. Drive Gear 25. Planetary Gear A 8. Plate 17. O-ring 26. Thrust Plate 9. Thrust Washer 18. Thrust Washer 27. Snap Ring IV-124 TB175W...
  • Page 261 32. Spool 5. Housing 14. Backup ring 23. Spring 6. Poppet 15. Guide 24. Sleeve 33. Spring 7. Seat 16. O-ring 25. Orifice 34. O-ring 8. Seat 17. O-ring 26. O-ring 9. Spring 18. Backup ring 27. Filter IV-125 TB175W...
  • Page 262 When this pressure reaches the relief valve’s set pressure, the relief valve operates and oil flows to port M1. In this way, the flow of oil to port M1 prevents cavitation from occurring as it absorbs the shock during stopping. E5D606 IV-126 TB175W...
  • Page 263 This rebound pressure generated at the port Pv2 will move the sleeve (3) to the left to open the passage. This then releases the rebound pressure to the port Cv. G4D605 IV-127 TB175W...
  • Page 264 (3) from rotating. When the pressure oil is introduced into the motor, the oil flows from the parking brake release port (7) into the brake piston chamber (8). The oil pressure over- L3D607 IV-128 TB175W...
  • Page 265 (2), the planetary gear (3) and the carrier 1 (4). Drive force is transmitted in the same way to the pinion shaft (1) via the second stage sun gear (5), the planetary gear (6), and the carrier 2 (7), and this becomes the slewing drive force. IV-129 TB175W...
  • Page 266 Do not use a rag, as this could cause clogging of dirt. • Make match marks on each part so that they will be assembled in the same positions when reassembled. Disassembly Slew Motor 1. Remove the cap screws and then the anti-rebound valve. K3D626 IV-130 TB175W...
  • Page 267 2. Remove the cap screws and then the cover (2). • Fix the hydraulic motor with a vise. • Be careful not to let the valve plate drop off. K3D629 3. Remove the valve plate (3) from the cover. L3D614 IV-131 TB175W...
  • Page 268 Remove the plug (9). b. Remove the spring (10) and check valve (11). L3D617 7. Remove the relief valve (12). • Do not loosen the set screw nut (13). • Do not disassemble the relief valve. L3D618 IV-132 TB175W...
  • Page 269 10. Remove the cylinder block (18), friction discs (19) and center discs (20). L3D621 11. Remove the shoe holder (14) and piston assembly (21) from the cylinder block. 12. Remove the guide (22) and pins (23) from the cylinder block. L3D622 IV-133 TB175W...
  • Page 270 15. Remove the shaft (29). • Lightly tap the end face with a plastic hammer. L3D624 16. Remove the bearing (30) from the shaft (29). • Do not disassemble these parts unless neces- sary. The removed bearing cannot be used again. K3D643 IV-134 TB175W...
  • Page 271 • Loctite has been applied to the screw. Warm- ing the screw screws (for example, using a portable drier) will make its removal much easier. 10. Remove the planetary gear B (12), needle (13), inner race (14) and the thrust washer (15). L3D627 IV-135 TB175W...
  • Page 272 14. Remove the oil seal (23). • Use a flat blade screwdriver. • The oil seal should be replaced with a new one every time it is disassembled. • Be careful not to damage the outer race of the taper roller bearing. L3D631 IV-136 TB175W...
  • Page 273 4. Remove the plug (5) and then the orifice (6). G4D614 5. Remove the orifice (7), washer (8) and filter (9). • The filter should be replaced with a new one every time the anti-rebound valve is disas- sembled. G4D615 IV-137 TB175W...
  • Page 274 • Be careful not to damage the rotation section of the valve. a. Mount the spool (33) and spring (32) on the body. b. Fit the O-ring to the plug (31) and mount them on the body. Plug: 39.2 ±2.0 N·m K3D644 IV-138 TB175W...
  • Page 275 6. Insert the bearing (30) into the shaft (29). • Insert the bearing by using the press and jig (A). K3D643 7. Install the shaft (29) in the housing. • Lightly tap with a plastic hammer to install. L3D633 IV-139 TB175W...
  • Page 276 12. Fit the O-ring to the brake piston (15) and insert them in the housing. • Use the press to insert. • Make sure that the pin hole (A) of 8.5 mm in diameter is positioned as shown in this figure. L3D634 IV-140 TB175W...
  • Page 277 Fit the O-ring to the plug (9) and mount them on the cover. Plug: 157 ±10 N·m L3D617 17. Insert the bearing (4) into the cover. • Use the jig (B) and the press to insert. L3D615 IV-141 TB175W...
  • Page 278 • Be careful not to let the valve plate drop off. Cap screw: 127 ±10 N·m K3D629 22. Mount the timer valve (1). a. Fit the O-ring to the case. b. Mount the timer valve and fix it with the screw. Screw: 39.2 ±2.0 N·m L3D613 IV-142 TB175W...
  • Page 279 • The shaft (11) should be mounted before mount- ing the plug (25). Plug: 15.7 ±0.8 N·m L3D629 4. Mount the plate (10) and collar (9). • Mount the collar while loading the 11770 N on the inner race using the jig (D). L3D628 IV-143 TB175W...
  • Page 280 • Apply Loctite #242 to the cap screws. Cap screw: 24.5 ±4.9 N·m L3D627 7. Mount the carrier 2 (10) on the case. L3D640 8. Fit the snap ring on the sun gear (9). L3D641 IV-144 TB175W...
  • Page 281 1.8 ±0.10 mm thickness 12. Fit the O-ring (1) to the case. L3D642 Slew Motor 1. Unite the hydraulic motor (1) and the reduction gear (2) and fix them with the cap screws. Cap screw: 177 ±10 N·m K3D627 IV-145 TB175W...
  • Page 282 HYDRAULIC UNITS SLEW MOTOR 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 IV-146 TB175W...
  • Page 283 E5D634 Cylinder block Sliding surface is Carry out lap re- sliding surface (1) rough. pairs (#1000 Pow- der) or replace. Valve plate sliding Replace surface (2) E5D635 IV-147 TB175W...
  • Page 284 • Scratches in sliding portions are deep or seating is uneven. • Replace Body • Scratches in sliding portions are deep or roughness is severe. • Replace • There are scratches where oil leakage occurs. Spring, Sleeve • Damaged or severely deformed. • Replace IV-148 TB175W...
  • Page 285 • Hydraulic oil is getting in. • Replace the reduction gears. gears case becomes • Gear unit • Bearings are damaged. • Replace the reduction gears. high.) • Gear surfaces are damaged. • Replace the reduction gears. IV-149 TB175W...
  • Page 286 The orifice is choked. • Foreign matter is in the orifice of the anti- • Remove the foreign matter. rebound valve body. • Foreign matter is in the orifice of the valve • Remove the foreign matter. unit. IV-150 TB175W...
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  • Page 718 GEAR BOX TYPE: 357 TB175W...
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  • Page 720 Service Manual Gear Box 357A10 GSM-0012 January 1998...
  • Page 725 D1240009 MFG. BY CLARK-HURTH COMPONENTS S.P.A. 38062 Arco (Trento) MADE IN ITALY D1240011...
  • Page 727 D1240001 D1240012...
  • Page 728 D1240002 D1240003...
  • Page 729 F1240069 F1240070 F1240071...
  • Page 731 F1240072 F1240073 F1240074 F1240075 F1240076 F1240077...
  • Page 733 F1240078 F1240079 F1240080 F1240081 F1240082 F1240083...
  • Page 735 F1240084 F1240085 F1240086 F1240087 F1240088...
  • Page 737 F1240089 F1240090 F1240091 F1240092 F1240093...
  • Page 739 F1240094 F1240095 F1240096 F1240097 F1240098 F1240099...
  • Page 741 F1240100 F1240101 F1240102 F1240103 F1240104...
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  • Page 745 F1240111 F1240112 F1240113 F1240114...
  • Page 747 F1240115 F1240116 F1240117 F1240118 F1240119...
  • Page 749 F1240120 F1240104 F1240121 F1240122 F1240101 F1240100...
  • Page 751 F1240123 F1240124 F1240125 F1240126 F1240127...
  • Page 753 F1240128 F1240082 F1240083 F1240081 F1240080...
  • Page 755 F1240129 F1240130 F1240131 F1240132 F1240133 F1240134...
  • Page 757 F1240135 F1240136 F1240137 F1240138 F1240139...
  • Page 759 F1240140 F1240141 F1240142 F1240143 F1240144 F1240069...
  • Page 761 F1240145 F1240144 F1240146 F1240147 F1240148...
  • Page 763 F1240149 F1240150...
  • Page 765 Copyright 2010 Dana Holding Corporation For product inquiries or support, All content is subject to copyright by Dana and may not visit www.dana.com or call 419-887-6445 be reproduced in whole or in part by any means, For other service publications, electronic or otherwise, without prior written approval.
  • Page 766 SWIVEL JOINT TYPE: 532 TB175W...
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  • Page 771 3. Slight leakage is possible between toroidal chambers when no pressure is present. This drains away in a common leakage channel. If the hydraulic circuits are separate, a common oil container will be needed. TB175W REV. 1...
  • Page 772 Special consultation is required in these cases. Changes in accordance with technical progress are reserved. Changes, even with our consent, must be authorized by our modification department. REV. 1 TB175W...
  • Page 773 7 and intermediate piece 9 to connectors 11 in the connector unit. There is a seal between toroidal chambers 4 by means of gaskets 3, by gaskets 8 between rotor 2 and intermediate piece 9, and by gaskets 10 between rotor 10 and connector 13. TB175W REV. 1...
  • Page 774 Special consultation is required in these cases. Changes in accordance with technical progress are reserved. Changes, even with our consent, must be authorized by our modification department. REV. 1 TB175W...
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  • Page 778 V . TROUBLESHOOTING TB175W...
  • Page 779 (2) When it is thought that the trouble has more than one cause, begin investigating from the simplest cause. (3) Think over why the trouble could have occurred and try to correct the root cause of that problem. TB175W...
  • Page 780 The amount of arm natural drop is great......................34 BUCKET The bucket cylinder doesn’t move, or there is no power..................35 The amount of bucket natural drop is great......................37 BOOM SWING The swing cylinder doesn’t move........................38 TB175W...
  • Page 781 Check that the hydraulic oil is dis- charged from the pump at this time. If the pump is normal, hydraulic oil will be discharged from it. If hydraulic oil is not dis- charged, the pump or the coupling is faulty. TB175W...
  • Page 782 • Apply grease or oil to the part which appears to be making the noise and inspect if there is any change. (Inspect if it is sucking in air or not.) b. Inspect for clogging of the suction filter. TB175W...
  • Page 783 (Up to NAS Class 9) Caution : When replacing the hydraulic oil, be sure to clean the inside of the Hydraulic Tank and the suction strainer. If the pump seal is damaged, replace the seal. “IV. Hydraulic Units, Hydraulic Pump” TB175W...
  • Page 784 1. Inspect the hydraulic pump P5. Inspect the hydraulic pump P5 which is the source of the hydraulic pressure for the pilot valve. “V-4” Since clogging of the line filter can also be con- sidered, inspect and clean the filter. TB175W...
  • Page 785 5. Inspect the pilot relief valve. Measure the relief pressure of the pilot relief valve. • If the pressure is the standard value, the valve is normal. “II. Specifications, Standards for Judging Performance” 6. Inspect the pilot valve. “IV. Hydraulic Units, Pilot Valve” TB175W...
  • Page 786 Inspect if the operation of the slew motor only is Lever Operated Places inspected faulty by the table at right. If its operation is Dozer Blade Relief Valve R3 Pump P3 faulty, inspect the main relief valve and the hy- draulic pump. “V-6” TB175W...
  • Page 787 • The pressure is normal if it is the standard value. “II. Specifications, Standards for Judging Performance” If adjustment of the pressure is possible, the slew relief valve’s adjustment is faulty. Also, if the pressure adjustment is impossible, the slew relief valve is faulty. V-10 TB175W...
  • Page 788 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. Hydraulic Units, Slew Motor” V-11 TB175W...
  • Page 789 It could be that the spool for only the side of the pilot valve for which slewing is impossible will not operate. “V-10” 2. Inspect the operation of the spool. It could be that the spool will not move only in the direction in which slewing is impossible. “V-10” V-12 TB175W...
  • Page 790 • If foreign matter is caught in one of the check valves, the hydraulic oil returns to the tank from the check valve. L3E005 5. The slew motor is faulty. “IV. Hydraulic Units, Slew Motor” V-13 TB175W...
  • Page 791 Faulty Inspect the check valve Repair or replace the slew of the slew brake valve. brake valve. Normal Repair or replace the slew Faulty Inspect the slew motor. motor. Normal The slew bearing is faulty. Replace. V-14 TB175W...
  • Page 792 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 brake valve. “IV. Hydraulic Units, Slew Motor” 6. Inspect the slew motor. “IV. Hydraulic Units, Slew Motor” V-15 TB175W...
  • Page 793 (slew section) on the control valve side, then set a pressure gauge in the disconnected hose. • Read the pressure gauge after operating the lever (slew), then releasing it. • If the pressure is zero, the pilot valve is normal. V-16 TB175W...
  • Page 794 • Read the pressure gauge after operating the lever (slew), then releasing it. • If the pressure is zero, the pilot valve is normal. 4. Inspect the slew hydraulic pressure. “V-10” 5. Inspect the slew brake valve. “IV. Hydraulic Units, Slew Motor” V-17 TB175W...
  • Page 795 • If the pressure is the standard value, the valve is normal. “II. Specifications Standards for Judging Performance” 3. Inspect the slow slew switch. Press the switch to obtain “ON” condition. The switch is normal when the lamp lights in this condition. V-18 TB175W...
  • Page 796 Inspect if the spool of the slew flow control valve moves smoothly. • Remove the spool cover at the FC port and try pushing the spool with a finger. It is normal if it moves smoothly about 9 mm. V-19 TB175W...
  • Page 797 Inspect if the operation of the boom cylinder only Lever Operated Places inspected is faulty by the table at right. If its operation is Bucket Relief Valve R1 Pump P1 faulty, inspect the main relief valve and the hy- draulic pump. “V-6” V-20 TB175W...
  • Page 798 When performing the operation in “a~c” above, the bucket cylinder should be fully W1-E004 extended, the arm cylinder should be fully retracted and the bucket should be lowered to the ground. V-21 TB175W...
  • Page 799 Stroke the spools of the boom [1] and boom [2] sections and inspect whether they move smoothly, or remove the spools and check whether there is any foreign matter engaged in them. 4. Perform a port relief valve switching test. “V-21” L3E007 V-22 TB175W...
  • Page 800 Also, if there is no leakage of oil from the cylinder’s piping, if the boom cylinder’s rod is retracted, the control valve is leaking inter- nally. W1-E006 Boom Cylinder Internal Leakage Inspect (2) a. Place the machine in the posture shown in the figure. W1-E008 V-23 TB175W...
  • Page 801 Also, if there is no leakage of oil from the cylinder’s piping, if the boom cylinder’s rod is extended, the control valve is leaking inter- nally. If the cylinder is damaged internally, the system should be flushed out to remove any W1-E008 broken pieces (NAS Class 9). V-24 TB175W...
  • Page 802 Also, the cylinder will have inadequate driving force. However, in this case as well, the amount of natural drop will be great. • Cylinder Inspect “V-23~24” V-25 TB175W...
  • Page 803 Replace the housing block. internally. 1. Is the amount of natural drop within the standard? “II. Specifications, Standards for Judging Performance” 2. Inspect for internal leakage in the boom cylinder. “V-23~24” 3. Perform a port relief valve switching test. “V-21” V-26 TB175W...
  • Page 804 5Pa1 side, then set a pressure gauge in the disconnected hose. • Operate the boom swing pedal and measure the pressure. • Depending the operation angle, if the pressure is normal, it will range between 0~3.4 MPa. W2E007 V-27 TB175W...
  • Page 805 “ON”. Check whether the voltage is applied to the solenoid valve by using a tester. Be sure to stop the engine before starting the inspection. d. Inspect the solenoid valve. “IV. Hydraulic Units, Solenoid Valves, Swing/Adjust Cange” W2E010E V-28 TB175W...
  • Page 806 • Operate the boom swing pedal and measure the pressure. • A pressure of 33.3 MPa is normal. W2E011 5. Inspect the port relief valve. “IV. Hydraulic Units, Port Relief Valve” 6. Inspect the boom adjustment cylinder. “IV. Hydraulic Units, Cylinders” V-29 TB175W...
  • Page 807 Inspect if the operation of the arm only is faulty by Lever Operated Places inspected the table at right. If operation is faulty, inspect the Swing Relief Valve R1 Pump P2 main relief valve and the hydraulic pump. “V-6” 2. Inspect the pilot valve. “V-21” V-30 TB175W...
  • Page 808 • If the cylinder doesn’t operate, the cylinder is faulty. When performing the operation above, the bucket cylinder should be fully extended, the arm cylinder should be fully retracted, and the bucket should be lowered to the ground. L3E011E V-31 TB175W...
  • Page 809 Stroke the spools of the boom [1] and boom [2] sections and inspect whether they move smoothly, or remove the spools and check whether there is any foreign matter engaged in them. 4. Perform a port relief valve switching test. “V-21” L3E012 V-32 TB175W...
  • Page 810 Raise the boom and raise the hoe attachment so it floats above the ground. If the arm dorps, the cylinder is faulty. If the arm does not drop, there is leakage inside the control valve. W1-E006 V-33 TB175W...
  • Page 811 Inspect the arm cylinder. inder. Normal There is leakage inside Replace the housing block. the control valve. 1. Is the amount of natural fall within the stan- dard? “II. Specifications, Standards for Judging Performance” 2. Inspect the arm cylinder. “V-31” V-34 TB175W...
  • Page 812 If operation is faulty, inspect Boom Relief Valve R1 Pump P1 the main relief valve and the hydraulic pump. “V-6” 2. Inspect the pilot valve. “V-21” 3. Inspect the operation of the spool. “V-21” V-35 TB175W...
  • Page 813 • If the bucket cylinder does not operate, the bucket cylinder is faulty. This inspection should be done with the bucket cylinder fully extended and the arm cylinder fully retracted. Also, the bucket must be lowered to the ground. L3E011E V-36 TB175W...
  • Page 814 Raise the boom and raise the hoe attachment so that it floats above the ground, If the bucket drops, the cylinder is faulty, If the bucket does not drop, there is leakage inside the control valve. V-37 TB175W...
  • Page 815 1. Inspect the supply pressure to the pilot valve 4. Inspect the selector valve. (swing). “V-28~29” “V-7~8” 5. Inspect the swing cylinder. 2. Inspect the pilot valve (swing). “IV. Hydraulic Units, Cylinders” “V-27” 3. Inspect the operation of the spool. “V-28” V-38 TB175W...
  • Page 816 Disconnect the hose between the control valve (swing section) and the cylinder on the cylinder side, then set a pressure gauge in the disconnected hose. • Operate the boom swing pedal and measure the pressure. • A pressure of 27.5 MPa is normal. L3E016 V-39 TB175W...
  • Page 817 TROUBLESHOOTING BOOM SWING 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, Cylinders” W2E013 V-40 TB175W...
  • Page 818 VI . ENGINE Mounted Engine Machine Serial No. Machine Model 17540001~ 4TNV98T TB175W V-41 TB175W...
  • Page 819 There are two main tools for maintenance: the engine trouble diagnostic tool provided by the engine manufacturer and the maintenance tool provided by Takeuchi. Some of our machines have a control computer which can be connected to a personal computer for communications, allowing computers to read or write data.
  • Page 820 *1 The kit includes the USB cable assembly to be used to connect to the controller. (Part No.: 17301-42720) T-ECU: Takeuchi-Electrical Control Unit (Takeuchi) EDT: Engine Diagnostic Tool (Yanmar) EMPS-3: Engine Module Programming System (Isuzu)
  • Page 821 3. Controller connection diagram and system requirements � �������������������� 3.1 Machines with standard engines (1) Connection diagram for F14C, F10C and F10B ���� ������������� T-ECU: Takeuchi-Electrical Control Unit �������������������������������������� ��� ������������������� ������������������ Excavator TB180FR (F14C) T-2 Serial No. 178300001 or later TB153FR (F10C) T-3 Serial No.
  • Page 822 (2) Connection diagram for A25B and A25D �������������������������������������� ��� �������������� T-ECU: Takeuchi-Electrical Control Unit Excavator Engine model: 4BG1TRE (Isuzu) TB1140 (A25B) Compliant with Tier 2 emission standards Serial No. 51410001 or later TB1140 (A25D) Serial No. 51430001 or later Laptop computer...
  • Page 823 3.2 Machines with standard engines ���� ���������������� (1) Connection diagram for TL240, TL230, and TL220 ��� ����������������������� Track loader Engine model: 4TNV98T-ZNTBL TL240 (L8B) Compliant with Tier 3 emission standards Serial No. 22400001 or later TL230 (L6B) Serial No. 22300001 or later TL220 (L5B) Serial No.
  • Page 824 (2) Connection diagram for TB180FR T-ECU: Takeuchi-Electrical Control Unit �������������������������������������� ��� ������������ Excavator Engine model: 4TNV98T-ZNTBL Compliant with Tier 3 emission standards TB180FR (F14E) T-3 Serial No. 17840001 or later Laptop computer Interface box (Yanmar) Yanmar Engine Diagnostic Tool (EDT) Configuration...
  • Page 825 (3) Connection diagram for TB175 and TB175W T-ECU: Takeuchi-Electrical Control Unit �������������������������������������� ��� ����������������� Excavator Engine model: 4TNV98T-ZNTBL TB175 (A14E) T-3 Compliant with Tier 3 emission standards Serial No. 17530001 or later TB175W (A14EW) T-3 Serial No. 17540001 or later...
  • Page 826 (4) Connection diagram for TB1140 �������������������������������������� ��� ����������� T-ECU: Takeuchi-Electrical Control Unit Excavator Engine model: 4JJ1X (Isuzu) TB1140 (A25C) T-3 Compliant with Tier 3 emission standards Serial No. 514200001 Laptop computer or later Selector (Isuzu) Data link connector Engine Engine module programming system (EMPS-III), Isuzu Configuration ①...
  • Page 827 ����...
  • Page 828 (5) Connection diagram for TB175 with an Isuzu engine �������������������������������������� ��� �������������� T-ECU: Takeuchi-Electrical Control Unit Excavator Engine model: 4JJ1X (Isuzu) TB175 (A14E Isuzu) Compliant with Tier 3 emission standards Monitor machine Laptop computer Selector (Isuzu) Data link connector Engine...
  • Page 829 Dedicated USB cable connecting the computer and the connector on the machine � �� � � � � �� �� �� ��� � � � �� � � � � �� � � � �����...
  • Page 830 Isuzu Engine Maintenance tool � �� �� � � � �� �� �� ��� �����...
  • Page 831 4. Computer screen after software installation � ��� � � � � �� �� �� ��� � � � �� � � � � �� Model Start menu 1 Maintenance software Start menu configuration The start menu configuration of maintenance software after installation is illustrated as follows.
  • Page 832 Model Start menu 2 Maintenance software �����...
  • Page 833 5. Maintenance software for F14C, F10C and F10B executed � ��� � � � � �� �� �� ��� � � � �� � � � � �� � ������������� T-ECU serial number Version of the software installed ����������� Date and time the Error code ������...
  • 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 Amplifier (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 Amplifier 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 Amplifier is selected ��������������������� �����...
  • Page 843 TB175W Maintenance software Ver1.0 SerNO. 17540001~ 1. Connecting -TB175W CABIN. -Connect Maintenance cable as shown as picture. TAKEUCHI Original USB Cable Maintenance Connecter LAPTOP -Connect cable to USB port of PC. Note: Please check COM port number of Serial to USB cable.
  • Page 845 〔Ｐｅｒｆｏｒｍａｎｎｃｅ
 ａｎｄ
 Ｍａｉｎｔｅｎａｎｃｅ〕
 ＯＰＥＮ...
  • Page 846 〔Ｓｙｓｔｅｍ〕
 ＯＰＥＮ 〔Ｄｅｖｉｃｅ
 Ｍａｎｅｇｅｒ〕
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  • Page 847 The personal computer displayed what TB175W Maintenance software could use in COM4 of the Universal Serial Bus port. Ｃhoose this COM port number at the time of initial setting. Ｓｅｅ
 ６
 page...
  • Page 848 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 3. Monitor Error Log -Verify connection from 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 controller will be deleted. Basically, DON’T DO IT.
  • Page 850 5. Save Log -Hit [Log] → [Save] -Chose location of file, and enter the file name. -Log will be saved as CSV file. We can read the file by Excel. 6. Open saved Log file. -Hit [Log] → [Open] -Choose CSV file. 7.
  • Page 851 TB175W
Maintenance
software
Ver1.0,
Error
Code
Table 
 Error
Code Discription Note Key
switch
starter
signal
was
entered
in
less
than
2
seconds
 Key
SW
starter
signal
and
start
 interval.
 01
 operation
for
a
short
time.
 PULL
action
of
Engine
Stop
solenoid
was
repeated
in
short
 interval.
 Engine
oil
pressure
decrease
 02
 after
 
 engine
starts
 After
the
engine
starts,
 03
 Alternator
 
 charge
is
defective
 04
 Overheating
 Signal
from
water
temperature
switch
 06
 Air
cleaner
stopped
up
 
 Lifting
overload
appeared
(more
than
1second)
after
ACC
power
 07
 Lift
over
load
 supply
 Glow
key
SW
turning
on
for
a
long
 10
 Glow
key
switch
had
connected
more
than
10
seconds.
 Time
 11
 Ignition
at
time
of
head
Glow
 Glow
had
ignited
more
than
10
seconds.
 The
upper
bound
of
voltage
of
the
...

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