Page 1 TL150 Track Loader CT7E901 BOOK No. WORKSHOP MANUAL 21500004~ 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 ..............................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 ..............................10 Tightening Torques ............................... 11...
Page 7: Safety Precautions
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 GENERAL High pressure nitrogen gas is enclosed in the accu- Be careful with ﬂuids under pressure mulator and incorrect handling could possibly bring about serious injury due to explosion. The following matters should be strictly observed: • Do not disassemble. •...
Page 12 GENERAL Avoid battery hazards Checks after maintenance • Batteries contain sulfuric acid which will damage • Gradually raise the engine speed from a low idle eyes or skin on contact. to maximum speed and check that no oil or air is •...
Page 13: Cautions During Disassembly And Assembly
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 14: Handling Of Seals
GENERAL CAUTIONS DURING REMOVAL AND IN- HANDLING OF SEALS STALLATION 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 15: Tightening Torques
GENERAL TIGHTENING TORQUES Hydraulic Hoses Torque UNION NUT Union Nut (G) Taper Thread (R) Hose Fitting Size N·m ft-lb N·m ft-lb +4.9 +3.5 11.8 ±1.2 8.7 ±0.8 +4.9 +3.5 TAPER THREAD 24.5 18.1 29.4 ±2.9 21.7 ±2.1 +4.9 +3.5 36.2 53.9 ±5.4 39.8 ±3.9 58.8...
Page 16 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 17 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 18 GENERAL I-14...
Page 19 II . SPECIFICATIONS II-1...
Page 20: Table Of Contents
SPECIFICATIONS CONTENTS Names of Components ............................3 Speciﬁcation Diagrams ............................4 Speciﬁcations Tables ...............................6 Mass Tables ................................10 Recommended Lubricants ............................ 11 Service Standards ..............................12 Standards for Judging Performance ........................19 Reference Value Table ............................19 Methods for Inspecting Performance ......................20 In regard to Standard Values and Allowable Values The terms used in the items “Servicing Standards”...
Page 21: Names Of Components
SPECIFICATIONS NAMES OF COMPONENTS NAMES OF COMPONENTS T7B001 1. Lift Arm 11. Arm Cylinder 2. Control Valve 12. Travel Motor 3. Hydraulic Tank 13. Track Roller 4. Canopy 14. Track 5. Safety Bar 15. Idler 6. Pilot Valve (L. H.) 16.
Page 22: Table Of Contents
SPECIFICATIONS SPECIFICATION DIAGRAMS SPECIFICATION DIAGRAMS Canopy Type Machine Dimensions Unit: mm Standard Bucket Steel Tracks 3985 3135 1555 2350 1860 1570 1960 31° T7K001A Operating Range Unit: mm Standard Bucket Steel Tracks 4255 3210 2440 1005 3865 2435 1560 1755 31°...
Page 23: Table Of Contents
SPECIFICATIONS SPECIFICATION DIAGRAMS Cab Type Machine Dimensions Unit: mm Standard Bucket Steel Tracks 3985 3135 1555 2350 1860 1570 1960 31° T7K001A Operating Range Unit: mm Standard Bucket Steel Tracks 4255 3210 2440 1005 3865 2435 1560 1755 31° T7K002A II-5...
Page 24: Standard Bucket
SPECIFICATIONS SPECIFICATIONS TABLES SPECIFICATIONS TABLES SPECIFICATIONS Type Canopy Standard Bucket Capacity Rated Capacity 0.579 Struck Capacity 0.426 Machine Mass (not including operator) 5485 Dimensions Overall Lenght: with bucket 3985 without bucket 3135 Overall Width: with bucket 1960 without bucket 1860 Overall Height 2350 Minimum Ground Clearance...
Page 25 SPECIFICATIONS SPECIFICATIONS TABLES Type Standard Bucket Capacity Rated Capacity 0.579 Struck Capacity 0.426 Machine Mass (not including operator) 5575 Dimensions Overall Lenght: with bucket 3985 without bucket 3135 Overall Width: with bucket 1960 without bucket 1860 Overall Height 2350 Minimum Ground Clearance Front Clearance Radius: with bucket 2435...
Page 26 SPECIFICATIONS SPECIFICATIONS TABLES SPECIFICATIONS OF DEVICES Engine Model Yanmar 4TNV106T-XTBL Type 4-Cycle, vertical, water-cooled, in-line, 4-cylinder diesel engine Number of Cylinders-Bore × Stroke 4-106 × 125 Total Displacement 4412 Compression Ratio 18.0 Performance Rated Output kW/min 72.0/2200 Maximum Torque N·m/min 361.6~394.0/1400 ±100 Maximum No-load R.P.M.
Page 27 SPECIFICATIONS SPECIFICATIONS TABLES Pilot Valve (R. H.) Model PV48K1262 Secondary Side Pressure 0.49~1.96 Operating Angle : Single (Ports 1, 3) degree : Single (Ports 2, 4) degree Pilot Valve (L. H.) Model PV48K1261 Secondary Side Pressure 0.49~1.91 Operating Angle : Single degree : Simultaneous degree...
Page 28: Mass Tables
SPECIFICATIONS MASS TABLES MASS TABLES UNIT WEIGHT (DRY MASS) Unit: kg Engine Radiator Radiator (High Flow) Oil Cooler Oil Cooler (High Flow) HST Pump Gear Pump Gear Pump (High Flow) Hydraulic Tank Assembly Fuel Tank Assembly Control Valve Control Valve (High Flow) Control Valve (Sub) Pilot Valve :R.
Page 29: Recommended Lubricants
SPECIFICATIONS RECOMMENDED LUBRICANTS RECOMMENDED LUBRICANTS Use different fuels, lubricants and greases according to the temperature, referring to the chart below. • Change the lubricant earlier than as show in the table if it is extremely dirty or its performance has deteriorated severely. •...
Page 30: Service Standards
SPECIFICATIONS SERVICE STANDARDS SERVICE STANDARDS TRAVEL SYSTEM Track Roller A Unit: mm Servicing Code Item Designated Standard Procedure Basic Dimension Allowable Value Tread Outer Diameter Width of Tread 36.5 40.5 Allowable Tolerance Basic Standard Allowable Dimension Shaft Hole Replace Shaft and Bushing Bore -0.050 Diameter Clearance -0.075...
Page 31 SPECIFICATIONS SERVICE STANDARDS Track Roller B Unit: mm Servicing Code Item Designated Standard Procedure Basic Dimension Allowable Value Tread Outer Diameter Width of Tread 37.5 45.5 Allowable Tolerance Basic Standard Allowable Dimension Shaft Hole Replace Shaft and Bushing Bore -0.050 Diameter Clearance -0.075 Roller and Bushing Outer...
Page 32 SPECIFICATIONS SERVICE STANDARDS Track Roller C Unit: mm Servicing Code Item Designated Standard Procedure Basic Dimension Allowable Value Tread Outer Diameter Width of Tread 36.5 40.5 Allowable Tolerance Basic Standard Allowable Dimension Shaft Hole Replace Shaft and Bearing Bore 0.016 -0.016 -0.012 Diameter Interference...
Page 33 SPECIFICATIONS SERVICE STANDARDS Drive Sprocket Unit: mm Servicing Code Item Designated Standard Procedure Basic Dimension Allowable Value Sprocket Teeth Proﬁle Wear 14.4 Sprocket Teeth Width Replace Sprocket Outer Diameter Sprocket Teeth Lower Diameter 378.6 370.6 II-15...
Page 34 SPECIFICATIONS SERVICE STANDARDS Idler Unit: mm Servicing Code Item Designated Standard Procedure Basic Dimension Allowable Value Outer Diameter Tread Width of Tread 33.4 38.4 Basic Allowable Tolerance Standard Allowable Dimension Shaft Hole Replace Shaft and Bearing Bore 0.011 Diameter Clearance -0.011 -0.012 0.012...
Page 35 SPECIFICATIONS SERVICE STANDARDS Track Adjuster Unit: mm Servicing Code Item Designated Standard Procedure Basic Value Allowable Value Length when Free Coil Spring Length when Installed 224.5 Replace Set Load 41.5 Check Valve Tightening Torque N·m Retighten II-17...
Page 36 SPECIFICATIONS SERVICE STANDARDS Pin and Bushing Clearance Unit: mm Servicing Code Item Designated Standard Procedure Basic Allowable Tolerance Standard Allowable Dimension Clearance Clearance Shaft Hole -0.06 +0.17 Lift Arm & Frame 0.18~0.26 -0.09 +0.12 -0.06 +0.20 Arm Cylinder & Frame 0.11~0.29 -0.09 +0.05...
Page 37: Standards For Judging Performance
SPECIFICATIONS STANDARDS FOR JUDGING PERFORMANCE STANDARDS FOR JUDGING PERFORMANCE REFERENCE VALUE TABLE Item Unit Standard Values Allowable Values Engine Speed 1130 ±70 High 2330 ±60 Hydraulic Oil Pressure Travel 34.3 +5.9 Lift Arm +1.1 Bucket 20.6 -0.3 Charge Pressure 2.0 ±0.3 Hight 2.4 ±0.2 Pilot Pressure...
Page 38 SPECIFICATIONS STANDARDS FOR JUDGING PERFORMANCE METHODS FOR INSPECTING PERFOR- MANCE Hydraulic Oil Pressure Travel Measuring Method • Engine : Maximum R.P.M. • Hydraulic Oil Temp. : 50~60°C • Insert the pressure gauge into the pressure detec- tion port and ﬁt pipe (1) over the travel motor sprocket to disable the motor.
Page 39 SPECIFICATIONS STANDARDS FOR JUDGING PERFORMANCE Adjusting Method 1. Loosen locknut (2), then begin adjusting pres- sure by turning setting screw (1). Turning clockwise ....raises the set pressure. Turning counterclockwise ... lowers the set pressure. 2. 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 ﬁrmly in place.
Page 40 SPECIFICATIONS STANDARDS FOR JUDGING PERFORMANCE Travel Speed (5 Revolutions) • Engine : Maximum R.P.M. • Hydraulic Oil Temp. : 50~60°C • Measurement Posture : Place blocks (1) under the rear of the body of the machine and use the lift arm and bucket to raise the machine up from the ground.
Page 41 SPECIFICATIONS STANDARDS FOR JUDGING PERFORMANCE Natural Travel Drop • Engine : Idling R.P.M. • Hydraulic Oil Temp. : 50~60°C • Grade : 15° • Measurement Posture : Travel Posture • Park the machine with the parking brake applied, and wait for one minute. Then, measure the amount of spontaneous travel drop.
Page 42 SPECIFICATIONS STANDARDS FOR JUDGING PERFORMANCE Natural Travel Drop • Engine : Idling R.P.M. • Hydraulic Oil Temp. : 50~60°C • Grade : 15° • Measurement Posture : Travel Posture • Release the parking brake with the machine lo- cated on a slope to measure the distance by which it descends in one minute under the force of grav- ity alone.
Page 43 SPECIFICATIONS STANDARDS FOR JUDGING PERFORMANCE Lever Operating Force • With the engine stopped, attach a push-pull scale to the center of the operation lever s handle grip, or in the case of a pedal, position a push-pull scale to its tip and record the measurement at the point the lever/pedal reaches full stroke.
Page 44 III . MACHINE CONFIGURATION III-1...
Page 45 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 III-2...
Page 46 MACHINE CONFIGURATION DRIVE SYSTEM DRIVE SYSTEM CONSTRUCTION Engine Mount 256 N·m; Apply thread-locking compound. 110 N·m; Apply thread-locking compound. 5.9 N·m 1. Engine Foot FL 7. Silencer 3.9 N·m 2. Engine Foot FR 8. Air Cleaner 3. Engine Foot RL 9.
Page 47 MACHINE CONFIGURATION DRIVE SYSTEM Radiator 4.9 N·m 39.2 N·m 1. Radiator 7. Drain Valve 2. Radiator Hose (Upper) 8. Drain Hose 3. Radiator Hose (Lower) 9. Drain Hose 4. Sub Tank 10. Hose 5. Sensor 11. Joint 6. Oil Cooler 12.
Page 48 MACHINE CONFIGURATION DRIVE SYSTEM Engine Mount (High Flow) Serial No. 21501587~ 256 N·m; Apply thread-locking compound. 1. Engine Foot FL 7. Silencer 110 N·m; Apply thread-locking compound. 5.9 N·m 2. Engine Foot FR 8. Air Cleaner 3.9 N·m 3. Engine Foot RL 9.
Page 49 MACHINE CONFIGURATION DRIVE SYSTEM Radiator (High Flow) Serial No. 21501587~ 4.9 N·m 39.2 N·m 1. Radiator 7. Drain Hose 2. Radiator Hose (Upper) 8. Drain Hose 3. Radiator Hose (Lower) 9. Hose 4. Sub Tank 10. Joint 5. Sensor 11. O-Ring 6.
Page 50 MACHINE CONFIGURATION DRIVE SYSTEM Pump Coupling T7C102 Apply molybdenum disulﬁde grease. 210~230 N·m 55 N·m 1. Engine Housing 116 N·m 2. Coupling 47.1 N·m; Apply thread-locking compound 3. HST Pump 132 N·m 4. Gear Pump 69 N·m The pump coupling connects the engine ﬂywheel and the hydraulic pump s drive shaft.
Page 51 MACHINE CONFIGURATION DRIVE SYSTEM Fuel Tank and Lines 1. Fuel Tank 2. Cap 3. Strainer 4. Drain Plug 5. Fuel Sender 6. Water Separator 7. Feed Pump III-8...
Page 52 MACHINE CONFIGURATION DRIVE SYSTEM Engine Control A: Apply molybdenum disulﬁde grease. 1. Lever 2. Bracket 3. Accelerator Wire 4. Wire Stopper 5. Wire Stopper 6. Conical Washer 7. Washer 8. Washer III-9...
Page 53 MACHINE CONFIGURATION DRIVE SYSTEM DISASSEMBLY AND ASSEMBLY Removing the Engine 1. Disconnect the negative battery cable from the battery. 2. Remove the canopy. “Removing the Canopy” 3. Remove the ﬂoor frame. “Removing the Floor Frame” 4. Disconnect the electrical wiring from the air cleaner.
Page 54 MACHINE CONFIGURATION DRIVE SYSTEM Removing the Radiator 1. Remove the radiator cap and loosen the drain cock (1) to drain the engine coolant. • Coolant volume: 15 L 2. Remove the bolts (2) and open the radiator (3). 3. Disconnect the radiator hoses [upper] (4) and [lower] (5) and hoses (6) from the radiator.
Page 55 MACHINE CONFIGURATION DRIVE SYSTEM Removing the Hydraulic Pump 1. Drain out the oil from the hydraulic tank. “Removing the Hydraulic Tank” 2. Disconnect the drain hoses (1) and HST hoses (2). 3. Disconnect the pressure switch connectors (3). 4. Disconnect the pilot hoses (4). 5.
Page 56 MACHINE CONFIGURATION DRIVE SYSTEM 2. Install the HST pump on the machine 3. Fill the hoses which are connected to the pilot ports (X1) and (X11) with hydraulic oil. • To ﬁll, hold the hose openings at the same level as the pilot valves. Pouring oil with the hose openings held below the pilot valves may result in insufﬁcient air purge, while pouring oil with the hose open-...
Page 57 MACHINE CONFIGURATION DRIVE SYSTEM Removing the Fuel Tank 1. Remove the ﬂoor frame. “Removing the Floor Frame” 2. Remove the lever stands. “Removing the Lever Stands” 3. Remove the hose cramp (1). 4. Remove the hydraulic pump. “Removing the Hydraulic Pump” 5.
Page 58 MACHINE CONFIGURATION DRIVE SYSTEM INSPECTION AND ADJUSTMENT Adjusting the Throttle Lever Engine Speed 1. Fasten the wire (2) to the throttle lever (1) by using the wire lock pin (3). 2. Move the throttle lever (1) to the A (low idle) position and the governor control (4) to the C position (idle).
Page 59 MACHINE CONFIGURATION TRAVEL SYSTEM TRAVEL SYSTEM CONSTRUCTION Track Roller A 1. Roller 2. Shaft 3. Cover 4. Floating Seal 5. Snap Ring 6. O-ring 7. Oil Filler Plug 241 N·m; Apply thread-locking compound. Track Roller B 1. Roller 2. Shaft 3.
Page 60 MACHINE CONFIGURATION TRAVEL SYSTEM Track Roller C 1. Idler 2. Shaft 3. Cover A 4. Cover B 5. Bearing 6. Floating Seal 7. Oil Filler Plug 156 N·m; Apply thread-locking compound. 55 N·m; Apply thread-locking compound. 20 N·m Idler 1. Idler 2.
Page 61 MACHINE CONFIGURATION TRAVEL SYSTEM Track Adjuster 1. Yoke 2. Reach Rod 3. Spring 4. Piston 5. Cylinder 6. Grease DischargeValve 59 N·m Travel Motor 1. Travel Motor 2. Sprocket 241 N·m; Apply thread-locking compound. III-18...
Page 62 MACHINE CONFIGURATION TRAVEL SYSTEM DISASSEMBLY AND ASSEMBLY Removing the Steel Track Stop the machine so that the master links are positioned at the top of the idler. 1. Loosen the track tension. When loosening the grease discharge valve (1), turn it slowly. Do not loosen it beyond the point where grease starts to ooze out.
Page 63 MACHINE CONFIGURATION TRAVEL SYSTEM Removing the Track Roller 1. Loosen the track tension. 2. Loosen the roller installation bolts (1) slightly (approximately 1 turn). 3. Raise the machine body, take out the installation bolts (1) and remove the roller (2). Installing the Track Roller 1.
Page 64 MACHINE CONFIGURATION TRAVEL SYSTEM Removing the Travel Motor 1. Remove the track. “Removing the Steel Track” 2. Remove the bolts (1) and remove the sprocket (2). Bolt: 241 N·m; Apply thread-locking com- pound. 3. Remove the cover and disconnect the hydraulic hoses (4).
Page 65 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 III-22...
Page 66 MACHINE CONFIGURATION FRAME Floor 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 III-23...
Page 67 MACHINE CONFIGURATION FRAME Safety Bar 1. Safety Bar 2. Bracket L 3. Bracket R 4. Stopper 5. Proximity Switch 6. Cover L 7. Cover R 8. Gas Spring III-24...
Page 68 MACHINE CONFIGURATION FRAME Cover 1. Rear Door 8. Gas Spring 2. Engine Hood 9. Rod 3. Bracket 10. Side Cover L 4. Plate 11. Side Cover R 5. Plate 12. Center Cover 6. Plate 13. Plate 7. Pin III-25...
Page 69 MACHINE CONFIGURATION FRAME Canopy 1. Canopy 6. Washer 2. Bolt Assembly 7. Cushion Rubber 3. Cushion Rubber 8. Washer 4. Pin Assembly 9. Gas Spring 5. Collar 10. Cushion Rubber III-26...
Page 70 MACHINE CONFIGURATION FRAME 1. Cab 6. Washer 2. Bolt Assembly 7. Cushion Rubber 3. Cushion Rubber 8. Washer 4. Pin Assembly 9. Gas Spring 5. Collar 10. Cushion Rubber III-27...
Page 71 MACHINE CONFIGURATION FRAME Tilting Up the Canopy For inspection and maintenance, the canopy is de- signed so that it can be tilted up. WARNING • Raising or lowering the canopy while the engine is running may cause the machine to move, and cause serious injury or death. Stop the engine before raising or lowering the canopy.
Page 72 MACHINE CONFIGURATION FRAME DISASSEMBLY AND ASSEMBLY Removing the ﬂoor Frame 1. Tilt up the Canopy. “Tilting Up the Canopy” 2. Remove the cover (1). 3. Remove the ﬂoor mat. 4. Remove the auxiliary pedal. a. Remove the screws (2) and the pedal (3). •...
Page 73 MACHINE CONFIGURATION FRAME Removing the Covers 1. Disconnect the negative battery cable from the battery. 2. Tilt up the canopy. “Tilting up the Canopy” 3. Open the engine hood (1), lifting it up with cables. Remove the gas spring (2), plate (3) and hinges (4) to remove the engine hood (1).
Page 74 MACHINE CONFIGURATION FRAME Removing the Canopy. 1. Disconnect the negative battery cable from the battery. 2. Raise the lift arms. “Lift Arm Stop” 3. Remove the ﬁxing bolts on the 2 front positions (A). 4. Suspend the canopy. • Hook the suspender on the handrail ahead of the canopy.
Page 75 MACHINE CONFIGURATION FRAME Lift Arm Stop WARNING • If you must work beneath the raised lift arms, securely engage the lift arm stop. Never get under the lift arms and bucket if they are not sufﬁciently supported. • Service the lift arm stop if damaged or if parts are missing.
Page 76 MACHINE CONFIGURATION FRAME Disengagement 1. Remove the rear R-pin (4) from the locking pin (1). 2. Pull out the locking pin (1) from the lift arm stop (2). 3. Hook the end part of the spring (3) onto the hook (5) of the lift arm stop (2).
Page 77 MACHINE CONFIGURATION CONTROL SYSTEM CONTROL SYSTEM CONSTRUCTION Hydraulic Pilot Unit (1/2) Table of Connections 1. Right Pilot Valve 2. Left Pilot Valve 3. Control Valve 4. Control Valve (Sub) 5. Solenoid Valve 6. HST Pump 7. Hydraulic Tank 8. Pilot Valve (Auxiliary) 9.
Page 78 MACHINE CONFIGURATION CONTROL SYSTEM Hydraulic Pilot Unit (2/2) Table of Connections 1. Right Pilot Valve 2. Left Pilot Valve 3. Control Valve Pb32 4. Control Valve (Sub) 5. Solenoid Valve 6. HST Pump Pb31 7. Hydraulic Tank 8. Pilot Valve (Auxiliary) 9.
Page 79 MACHINE CONFIGURATION CONTROL SYSTEM DISASSEMBLY AND ASSEMBLY Removing the lever Stands 1. Tilt up the canopy. “Tilting Up the Canopy” 2. Remove the ﬂoor. “Removing the Floor Frame” 3. Remove the lever stand L. a. Remove the cover (1). b. Disconnect the hydraulic hoses (2) from the pilot valve.
Page 80 MACHINE CONFIGURATION ATTACHMENTS ATTACHMENTS CONSTRUCTION T7C600 1. Bucket 2. Quick-Hitch 3. Lift Arm 4. Bucket Cylinder 5. Arm Cylinder III-37...
Page 81 MACHINE CONFIGURATION ATTACHMENTS Piping 1/2 Piping 2/2 1. Bracket 6. Pipe [Bucket] 11. Solenoid Valve 2. Bracket 7. Pipe [Auxiliary] 12. Stop Valve 3. Bracket 8. Pipe [Auxiliary] 13. Hydraulic Tank 4. Bracket 9. Control Valve 14. Coupler 5. Pipe [Bucket] 10.
Page 82 MACHINE CONFIGURATION ATTACHMENTS Piping (High Flow) 1/2 Piping (High Flow) 2/2 1. Bracket 7. Pipe [Auxiliary] 13. Hydraulic Tank 2. Bracket 8. Pipe [Auxiliary] 14. Control Valve (High Flow) 3. Bracket 9. Control Valve 15. Gear Pump (High Flow) 4. Bracket 10.
Page 83 MACHINE CONFIGURATION ATTACHMENTS DISASSEMBLY AND ASSEMBLY General Cautions • Always be sure to work on a stable, level sur- • When all the hydraulic equipment such as hydrau- face. lic cylinders and piping have been removed and • When disconnecting hydraulic hoses, be sure to the hydraulic cylinders are being operated for the bleed off any residual pressure in the hoses.
Page 84 MACHINE CONFIGURATION ATTACHMENTS Removing the Lift Arm 1. Remove hydraulic hoses (1) from pipes [bucket] (2). 2. Remove hydraulic hoses (3) from the pipes [auxiliary] (4) and then remove hydraulic hoses (5) from the arm cylinders (6). 3. Use cables to lift up the lift arms (7) and then remove the pins (8) from the rod side of the arm cylinders (6).
Page 85 MACHINE CONFIGURATION ATTACHMENTS INSPECTION AND ADJUSTMENT Adjusting the Bucket Stopper DANGER WARNING When the lift arm is raised, never position your- • Park the machine on a ﬂat and solid ground self under it without making sure that the lift for work.
Page 86 MACHINE CONFIGURATION ATTACHMENTS 5. Lower the lift arm until the arm stopper (2) hits against the edge of the cylinder tube and be- comes ﬁxed, and stop the engine. 6. Insert the lock pin (3) in the front hole of the arm stopper (2) and pass it through under the cylinder rod to the back hole.
Page 87 MACHINE CONFIGURATION ATTACHMENTS Adjusting the Arm Stopper DANGER WARNING When the lift arm is raised, never position your- • Park the machine on a ﬂat and solid ground self under it without making sure that the lift for work. arm is securely supported by the lift arm stop- •...
Page 88 MACHINE CONFIGURATION ATTACHMENTS 3. Remove the lift arm stopper (2). “III-28~28-2” 4. Start the engine, and lower the lift arm. • The lift arm must be positioned at the height of approximately 500 mm above the ground. 5. Press the ﬂoat switch of the right control lever to lower the lift arm, and stop the engine.
Page 89 MACHINE CONFIGURATION HYDRAULIC SYSTEM HYDRAULIC SYSTEM HYDRAULIC CIRCUIT DIAGRAM ф ф ф ф μ ф ф μ μ μ III-46...
Page 90 MACHINE CONFIGURATION HYDRAULIC SYSTEM CONSTRUCTION Hydraulic Tank 47.1 N·m Apply thread-locking compound. 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 III-47...
Page 91 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.
Page 92 MACHINE CONFIGURATION HYDRAULIC SYSTEM DISASSEMBLY AND ASSEMBLY Removing the Hydraulic Tank 1. Remove the radiator. “Removing the Radiator” 2. Drain the oil from the tank. a. Remove the plug (1). b. Loosen the drain plug (2) and drain out the oil.
Page 93 MACHINE CONFIGURATION HYDRAULIC SYSTEM Filling with Hydraulic Oil The oil level changes according to the oil tempera- ture. Inspect the oil level in the hydraulic oil level inspection posture shown in the diagram. Hydraulic oil level inspection posture 1. Start the engine and run it at low speed. 2.
Page 94 MACHINE CONFIGURATION ELECTRICAL SYSTEM ELECTRICAL SYSTEM ELECTRICAL WIRING DIAGRAM III-51...
Page 95 MACHINE CONFIGURATION ELECTRICAL SYSTEM Electricals 1. Relay Assembly 8. Fuse (80A) 2. Wire Harness Assembly 9. Wire Harness 3. Fusible Link 10. Resistor 4. Diode 11. Horn 5. Fuse (10A) 12. Buzzer 6. Fuse (20A) 13. Heater Relay 7. Fuse (30A) 14.
Page 96 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 III-53...
Page 97 MACHINE CONFIGURATION AIR CONDITIONER SYSTEM AIR CONDITIONER SYSTEM Compressor Assembly (1/4) A: Allow a clearance. B: Press on the center of the belt with a ﬁnger. The belt’s tension is normal if it bends about 8 mm when 1. Pulley 8.
Page 98 MACHINE CONFIGURATION AIR CONDITIONER SYSTEM Compressor Assembly (2/4) 1. Hose 2. Hose 3. Hose 4. Hose 5. Bracket 6. Receiver-Dryer 7. Pressure Switch 8. Condenser 9. Wire Harness III-55...
Page 99 MACHINE CONFIGURATION AIR CONDITIONER SYSTEM Compressor Assembly (3/4) 1.8 N·m B: Apply thread-locking compound. 1. Cover 9. Control Cable 2. Cover 10. Tube 3. Cover 11. Box 4. Bracket 12. Tube 5. Bracket 13. Louver 6. Bracket 14. Adapter 7. Air Conditioner Unit 15.
Page 100 MACHINE CONFIGURATION AIR CONDITIONER SYSTEM Compressor Assembly (4/4) 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 III-57...
Page 101 Overview of System Operation • Truck and Heavy Equipment Systems • Air Conditioner-System Operation • Heater System Operation • Environmental Effects on System Operation • Chapter Review Truck and Heavy Equipment Systems A variety of HVAC systems are in use today, some old and some new. There are: •...
Page 102 Air Conditioner—System Operation Figure 2-1 These illustrations show a basic heater, HVAC system, the combo system with sleeper unit, add on AC roof top and in cab units, roof mounted condenser and auxiliary units. By law, all trucks have a heater/defroster as part of the standard equipment. When there is a reason to add air conditioning, there are options to meet different needs.
Page 103 System Operation The following AC components are discussed in detail in this section: 1. Compressor/Clutch Assembly 2. Condenser 3. Receiver-Drier 4. Expansion Valve 5. Evaporator Coil Figure 2-2 Air Conditioner components are connected together to illustrate system operation. The components shown are not to scale.
Page 104 Air Conditioner—System Operation Figure 2-3 The compressor inlet is low pressure and the outlet is high pressure. The reed valves are one way. They open to allow refrigerant gas to enter the compressor on the down stroke and exit on the upstroke.
Page 105 System Operation Figure 2-5 As the refrigerant gas moves through the tubing coil from top to bottom, it condenses (changes state) into a liquid. For ease of installation, condenser ﬁttings are often routed close together. 3. Receiver-Drier The liquid refrigerant continues to move inside the system, out of the condenser through a tube or hose to the receiver-drier.
Page 106 Air Conditioner—System Operation 4. Expansion Valve (Refrigerant Metering Device) When refrigerant moves from the receiver-drier, it travels through another high pres- sure hose to a metering device at the inlet of the evaporator coil. The metering device can be an expansion valve, an expansion tube or a combination (multiple function) valve.
Page 107: Operating Range
System Operation Figure 2-8 The evaporator coil as shown is of ﬁn and tube construction. The thermostat probe is positioned in between the evaporator ﬁns and senses the temperature. Note: Moisture in the air (humidity) condenses on the ﬁns of the evapo- rator as water droplets which drain out of the evaporator through a drain hose.
Page 108 System Operation Heater System Operation Heater and air conditioner systems both have the same basic function of moving heat. They take advantage of nature s laws where heat energy always moves from a warmer to a cooler area. In a heater system there is no “change of state” involved in system operation.
Page 109 Environmental Effects 1. Heater Core Heater cores are like small radiators. The ﬁn and tube construction is designed to route coolant ﬂow for the best possible heat energy transfer from coolant to cab air. Hoses from and to the engine are connected to the core with clamps. The core outlet may be larger or the same size as the inlet.
Page 110 System Operation • On a cold day the temperature can drop below zero. The engine may run cooler so the engine coolant is cooler when it circulates through the heater. The heat in the cab moves out of the cab faster (remember heat always moves to a cooler area until both are the same tempera- ture—nature s law).
Page 111 Inspection and Maintenance- without gauges • Discussion of Inspection & Maintenance Survey Results • Visual Inspection - System Off • Electrical System Inspection • Performance Inspection - Engine Running • Heater System Inspection • Preventive Maintenance Worksheet • Chapter Review Discussion of Inspection &...
Page 112 Inspection & Maintenance Visual Inspection - System Off Your observations and the corrective measures you take may be different depending on circumstances. The following inspection procedures are explained in more detail below: 1. Observe the System 2. Inspect Parts 3. Check Hoses and Fittings 4.
Page 113 Visual Inspection Figure 7-2 This system illustration notes the main points for visual inspection. A. Condenser – Is it free of leaves, bugs, bird feathers or mud? The condenser must be relatively clean to work well as a heat exchanger. How you clean the condenser depends on where it is mounted.
Page 114 Inspection & Maintenance C. Drive Belt – The drive belt should be tight and in good condition. Use a belt ten- sion gauge to check tension (120 pounds maximum). With experience, you can feel belt tension by twisting the belt. Try feeling belt tension after using the gauge, when you know the tension is correct.
Page 115 Electrical System Inspection You can feel for oil at the bottom of all connections (see Figure 7-4) if the system is not too hot. Of course, a few minutes with an electronic leak detector is the best way to check for leaks. Keep in mind that pressure is different in a system at rest, so small leaks may be hard to ﬁnd.
Page 116 Inspection & Maintenance B. Turn the AC System On – This will power the thermostat and clutch. If it does not come on, use the AC mode switch to check the leads to the switch. You should be able to hear a “click” from the thermostat and hear the clutch drive plate “snap”...
Page 117 Electrical System Inspection Performance Inspection – Engine Running The purpose of visual and electrical inspection is to detect obvious problems and assure AC system function for an accurate performance inspection. If you do the performance inspection ﬁrst, you could be mislead. Problem areas discovered during the perfor- mance inspection can give you false clues or symptoms, and result in repair errors and come-backs.
Page 118 Inspection & Maintenance These readings at the vents will be higher and temperature swing slower and not as obvious. Also blower speed will cause the temperature, levels to read higher (high air speed) or lower (low air speed) at the same thermostat setting.
Page 119 Performance Inspection Figure 7-7 These drawings illustrate conditions you may observe in the sight glass window. Note: A roof mounted condenser or AC unit assembly often includes a roof mounted receiver-drier (and sight glass) close to the con- denser. Heater System Inspection A heater system inspection is really a combination engine cooling system and heater inspection.
Page 120 Inspection & Maintenance B. Warm up engine – Next, let the engine warm up to normal operating temperature and set both fan and temperature on high. Feel both heater sup- ply and return hoses. If there is a noticeable difference in their temperature, it indicates a low ﬂow of coolant through the heater core (a partially closed or blocked heater control valve).
Page 121 Chapter Review Chapter Review The purpose of these brief inspection procedures is for vehicle system maintenance and to determine if further, more detailed service is required. The uses of a manifold gauge set, system troubleshooting, recovery, ﬂushing, evacuating and charging are explained in the next chapter.
Page 122 III-79...
Page 123 Troubleshooting & Service Procedures • Troubleshooting Overview • Understanding System Function • A Troubleshooting Example • Manifold Gauge Set Installation • Troubleshooting by Manifold Gauge Set Readings • Review of Frequent Problem Areas • Conclusion Can you ﬁx an air conditioner or heater system without ﬁnding and correcting the cause of the problem? You bet you can! It happens every day and it s not good for business.
Page 124 Troubleshooting & Service Procedures Experienced troubleshooters talk to the operator if they can, then personally verify the symptoms of the problem whenever possible. They attempt quick ﬁxes on the basis of their knowledge of common system problems and causes when appropriate. They know where components are located, and make repairs when they have a good idea of what the problem is.
Page 125 Understanding System Function When you turn on the air conditioner at the control panel (1), the thermostat (2), is supposed to sense a warm temperature at the evaporator. A circuit in the thermostat should close, allowing current to ﬂow through the thermostat to the compressor clutch ﬁeld coil (3).
Page 126 Troubleshooting & Service Procedures Use your knowledge and experience. Ask yourself what could have caused a lack of cooling in that rig! Did the compressor drive belt break? Did a pressure switch or relief valve cutout the compressor because of high or low system pressure? Does the switch or valve in this type of system reset itself? Could there be a superheat switch and thermal limiter with a melted fuse.
Page 127 A Troubleshooting Example • Answer: No. • (If the answer was yes, you should ask—When? Where? What was ﬁxed or replaced?). • Finally, ask the operator if he or she has a wiring diagram for the system. Now let s look at the information you have gathered from the operator and what you know from experience.
Page 128 Troubleshooting & Service Procedures If your AC and heater visual, electrical and leak inspections don t turn up any problems, save time by hooking up the manifold gauge set before you make the performance test. If you ﬁnd a leak and can correct it easily by tightening a connection, do so. But if too much refrigerant leaked out, you may have to add some refrigerant to the system for an effective performance test.
Page 129 Manifold Gauge Set Installation 1. Purging Air From Gauge Set Hoses Environmental regulations require that all service hoses have a shutoff valve within 12 inches of the service end. These valves are required to ensure only a minimal amount of refrigerant is lost to the atmosphere. R-12 gauge set hoses have a valve near the end of all three hoses.
Page 130 Troubleshooting & Service Procedures Figure 8-4 In this illustration we have noted how refrigerant is added to the air conditioner. Before adding refrigerant to the system you should study the sight glass while the engine is running and the air conditioner is on. Even if you found a leak during the system inspection and corrected it, you have no way of knowing how much refriger- ant has leaked.
Page 131 Manifold Gauge Set Installation 3. Add refrigerant until the gauges read in the normal range and the sight glass appears clear. The sight glass may not be clear for a moment just before or after the clutch cycles on and off but should generally be clear.
Page 132 Troubleshooting & Service Procedures Start the engine and set to a fast idle of 1200 to 1500 RPM. Turn on the air con- ditioner. After a quick in-cab performance test of control function, blower speeds and air ﬂow, set the AC system controls to maximum cooling and blower speed on high.
Page 133 Manifold Gauge Set Readings Repair Procedure: Check for leaks with your leak detector. If you ﬁnd a leak at a connection, tighten it then add refrigerant as necessary. If a component or line is leaking (defective), recover all refrigerant from the system. Replace the defective part and then check the compressor oil level and replace missing oil.
Page 134 Troubleshooting & Service Procedures After ﬁnding a leak, recover all refrigerant from the system and repair the leak. 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.
Page 135 Manifold Gauge Set Readings Excessive Air and/or Moisture in the System Figure 8-8 Gauge reading, excessive air and/or moisture in the system. Tip: There may be occasional bubbles in the sight glass. Air from vents in the cab is only slightly cool. Cause: System contains excessive air and/or moisture.
Page 136 Troubleshooting & Service Procedures Cause: An expansion valve malfunction could mean the valve is stuck in the closed position, the ﬁlter screen is clogged (block type expansion valves do not have ﬁlter screens), moisture in the system has frozen at the expansion valve oriﬁce, or the sensing bulb is not operating.
Page 137 Manifold Gauge Set Readings Note: If the expansion valve tests did not cause the low pressure gauge needle to rise and drop, and if the other procedures described did not correct the problem, the expansion valve is defective. You must recover all refrigerant from the system again, and replace the expansion valve and receiver-drier.
Page 138 Troubleshooting & Service Procedures 3. If the low side gauge shows a drop again, the valve is not stuck. Clean the surfaces of the evaporator outlet and the capillary coil or bulb. Make sure the coil or bulb is securely fastened to the evaporator outlet and covered with insulation material.
Page 139 Manifold Gauge Set Readings Repair Procedure: After you locate the defective component containing the restriction, recover all of the refrigerant. Replace the de- fective component and the receiver-drier. Evacuate and recharge the system with refrigerant, then check AC opera- tion and performance. Compressor Malfunction Figure 8-12 Gauge reading, compressor...
Page 140 Troubleshooting & Service Procedures If you ﬁnd particles of desiccant in the compressor, remove and replace it and the receiver-drier. Before doing so, back ﬂush other system components (except the expansion valve) using a ﬂushing kit. If there are stem type valves and you isolate the compressor, the rest of the system must be purged of refrigerant before you can disconnect and ﬂush system components (Chapter 9 describes the ﬂush-...
Page 141 Manifold Gauge Set Readings Cause: The condenser is not functioning correctly or there may be an overcharge of refrigerant inside the system. Another possibility is lack of (ram) air ﬂow through the condenser ﬁns during testing. Engine cooling system component malfunction can cause high pressure by blocking air ﬂow (radiator shutter) or not providing air ﬂow (fan clutch) in sufﬁcient quantity.
Page 142 Troubleshooting & Service Procedures Thermostatic Switch Malfunction Figure 8-14 Gauge reading, thermostatic switch malfunction. Tip: The low side gauge needle may ﬂuctuate in a very narrow range compared to a normal range. The compressor clutch may be cycling on and off more frequently than it should. The low side gauge needle may ﬂuctuate in an above nor- mal range as the clutch cycles.
Page 143 Review of Frequent Problem Areas Note: See the Thermostat section in Chapter 10. Fan clutch, ra- diator shutter, condenser, compressor, and the newer air and water valve control systems are covered in Chapter Review of Frequent Problem Areas In HVAC systems a limited number of things can go wrong. Moving parts of the com- pressor, clutch, and expansion valve or refrigerant metering device can malfunction or break down from metal fatigue, contamination, abnormal pressure or lack of lubrica- tion.
Page 144 Troubleshooting & Service Procedures 2. Condenser Condensers get dirty and the dirt reduces heat movement by insulating the con- denser. The ﬁttings come loose or break from stress if the condenser or connecting hoses are not secured properly to keep the effects of vibration at a minimum. Heat transfer efﬁciency and pressure in the condenser are affected by the amount of outside air ﬂowing through condenser ﬁns.
Page 145 Conclusion Technicians frequently add refrigerant to a system, replacing refrigerant seep- age through system connections or ﬁttings. If the system has been maintained regularly (every three to six months), adding a small amount of refrigerant may result in normal system function. However, the best procedure is to check all connections and look for, ﬁnd and repair any leaks before adding refrigerant.
Page 146 MACHINE CONFIGURATION III-103...
Page 147 IV . HYDRAULIC UNITS IV-1...
Page 148 HYDRAULIC UNITS 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 Travel Motor (Daikin) ............................109 IV-2...
Page 149 HYDRAULIC UNITS HST PUMP HST PUMP CONSTRUCTION Pump Assembly (1/4) 21. Shaft 1. O-ring 11. Seal Carrier 2. Seal 12. Cover 22. Pad A 3. Gasket 13. Pin 23. Pad B 4. O-ring 14. Gasket 24. Shaft 5. O-ring 15. Plug 25.
Page 150 HYDRAULIC UNITS HST PUMP Pump Assembly (2/4) SECTION "L-L" SECTION "E-E" T7D101E 1. Plug 2. Pin 3. Adjuster 4. O-ring 5. Spring 6. Poppet 7. Nut IV-4...
Page 151 HYDRAULIC UNITS HST PUMP Pump Assembly (3/4) 1. Oriﬁce 12. Screw 2. Gasket 13. Seal Nut 3. Plug 14. Plug 4. Valve 15. Cover 5. Spring 16. Plug 6. O-ring 17. Plug 7. Backup Ring 18. Backup Ring 8. O-ring 19.
Page 152 HYDRAULIC UNITS HST PUMP Pump Assembly (4/4) 1. Plug 2. Plug 3. Plug 4. Screw 5. Seal Nut 6. Plug IV-6...
Page 153 HYDRAULIC UNITS HST PUMP OPERATION The pump covered here is a tandem pump for hy- drostatic transmission. When combined together with an HST travel motor, the speed of the motor may be controlled from a speed of 0 to the speciﬁed maximum, in smooth gradations and without the switching of gears.
Page 154 HYDRAULIC UNITS HST PUMP Once directed to chamber (4), the pilot pressure moves control cylinder (3) to the left. Since swash plate (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.
Page 155 HYDRAULIC UNITS HST PUMP Charge Check and High Pressure Relief Valve This valve has two functions: a charge check valve and a high-pressure relief valve. The charge check valve function supplies the closed circuit with the oil from the charge pump to replenish the oil ﬂushed into the tank by the ﬂushing valve.
Page 156 HYDRAULIC UNITS HST PUMP DISASSEMBLY AND ASSEMBLY General Cautions • Carry out disassembly and assembly operations • Replace all seals with new ones each time the in a clean place and provide clean containers to hydraulic units is disassembled. place the disassembled parts in. •...
Page 157 HYDRAULIC UNITS HST PUMP 3. Remove the retaining ring (6). • Use a ﬂat head driver. 4. Remove the seal carrier. a. Pull up the shaft and remove the seal carrier (7). • If the seal carrier is hard to remove, insert the ﬂat head driver under the convex part (A) of the seal carrier and try again.
Page 158 HYDRAULIC UNITS HST PUMP 8. Remove the swash plate (10). • Take care not to damage the sliding surface of the swash plate. 9. Remove the needle bearing assembly (12) from the servo piston. 10. Remove the valve plate (13) from the housing. •...
Page 159 HYDRAULIC UNITS HST PUMP 14. Remove the servo cover (19). a. Remove the ﬁve cap screws. b. Remove the servo cover (19) and the gasket (17). c. Remove the servo cover (19) from the tie bolt (16). S3F313 15. Remove the servo piston (20). Mark S3F314E 16.
Page 160 HYDRAULIC UNITS HST PUMP 18. Remove the coupling (27). S3F317 19. Remove the two pins (29) for positioning the pump. • Take care not to drop the pins inside the hous- ing. T7D105 20. Disassemble the cylinder block assembly. The cylinder block assembly should not be disassembled unless required for cleaning up foreign matter or replacing damaged components.
Page 161 HYDRAULIC UNITS HST PUMP 22. Disassemble the servo piston. The servo piston should not be disassem- bled unless required for cleaning up foreign matter or replacing damaged components. a. Remove the piston rings (21) from the servo piston (20). b. Remove the nuts (49 and 50) from the tie bolt (16).
Page 162 HYDRAULIC UNITS HST PUMP 2. Remove the charge relief valve. • Before removing the screw adjustable relief valve 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 (5) and unscrewing the plug.
Page 163 HYDRAULIC UNITS HST PUMP Assembly Pump 1. Assemble the servo piston. a. Install the spring guide (53), the spring (52) and the spring guide (51) to the tie bolt (16). b. Attach the nut (50), and tighten it manually until it contacts the spring guide (51). c.
Page 164 HYDRAULIC UNITS HST PUMP d. Insert the pistons (31) in the retainer (32), and install them to the cylinder block (36). • Make sure that individual components are assembled in place. S3F323 4. Install the positioning pins (29). T7D105 5. Install the drive coupling (27). S3F317 6.
Page 165 HYDRAULIC UNITS HST PUMP 7. Install the A pad adapter (on the side of the hy- draulic pump P2). < Pump P2 > a. Install the gasket (23). • Use a new gasket. b. Install the A pad adapter (24), and tighten it with the seven cap screws.
Page 166 HYDRAULIC UNITS HST PUMP 9. Install the servo cover and the gasket. • Use a new gasket. a. Install the gasket (17) and the servo cover (19). • Take care not to damage the servo cover while installing it on the tie bolt. b.
Page 167 HYDRAULIC UNITS HST PUMP 12. Install the valve plate (13) over the needle bear- ing of the housing. • Foreign matter under the valve plate could cause a pump failure. • Make sure that the valve plate can be pushed in by hand and engages with the timing pin.
Page 168 HYDRAULIC UNITS HST PUMP 16. Install the side cover. a. Push down the swash plate to mate with the Push bearing of the side cover (9). b. Install the gasket (55) and the side cover (9). • Install the two bolts (that are longer than Rubber mallet the Allen screws for securing the side cov- er) temporarily as the positioning guides.
Page 169 HYDRAULIC UNITS HST PUMP 20. Install the seal carrier (7) to the housing, and at- tach the retaining ring (6). • Take care not to pinch or damage the O-ring. • Make sure the retaining ring is installed in the installation slot of the housing.
Page 170 HYDRAULIC UNITS HST PUMP Valves 1. Replace the charge check and high pressure re- lief valve. a. Install outer O-ring, backup ring, and inner O-ring on each valve seat plug. b. Check that the conical springs (3) are prop- erly retained on the check poppets or relief valves.
Page 171 HYDRAULIC UNITS HST PUMP INSPECTION AND ADJUSTMENT Checking the Parts If abnormal components are found, never reuse them; always replace with new ones. Cylinder Block Minimum cylinder • The sliding surface or the surface that contacts block height : 2.200 in. (55.88 mm) the valve plate must be smooth and free from any damage or burrs.
Page 172 HYDRAULIC UNITS HST PUMP Input Shaft • The shaft and its spline must be straight and free from any damage or wear. • No annular groove should be found on the shaft surface that contacts the shaft seal. • No spalling should be found on the surface where the shaft and the bearing contact.
Page 173 HYDRAULIC UNITS HST PUMP Adjustment of Rotational Torque of the Servo Piston The adjustment should be performed so that the load of the spring (52) is applied to the snap ring (48), and the tie bolt (16) rotates freely. 1. Secure the nut (50) with a wrench, and tighten the tie bolt (16) manually by turning it to the left until ﬁrm.
Page 174 HYDRAULIC UNITS HST PUMP Neutral Adjustment of the Pump WARNING • Be sure to do these adjustments on the level ground. • The hydraulic oil and the tank are hot and under pressure at operating temperature. • Never adjust the pump immediately after the engine stops to prevent bodily injuly, be- cause all the components are hot.
Page 175 HYDRAULIC UNITS HST PUMP 7. Turn the tie bolt (16) until it is positioned at the middle of the two positions recorded in 5 and 6 above. • Make sure the readings on the two pressure gauges are equal. 8. Tighten the tie bolt (16) by the adjusting seal nut (18).
Page 176 HYDRAULIC UNITS HST PUMP Adjustment of Displacement Limiter of the Remote Hydraulic Control WARNING • Be sure to do these adjustments on the level ground. • The hydraulic oil and the tank are hot and under pressure at operating temperature. •...
Page 177 HYDRAULIC UNITS HST PUMP TROUBLESHOOTING HST System Sympotom Probable Causes Remedy Difﬁcult or impos- • Pilot valve out of line. • Repair or replace. sible to ﬁnd neutral • HST pump adjustment screws have been • Tighten or loosen the HST pump adjust- position.
Page 178 HYDRAULIC UNITS HST PUMP Hydraulic Pump Trouble Probable Causes Remedy Noise is loud. Ab- • The suction hose is pinched or the suction • Remove the dirt or eliminate the pinched normal noise ﬁlter is clogged. condition of the hose. generated.
Page 179: Gear Pump
HYDRAULIC UNITS GEAR PUMP GEAR PUMP CONSTRUCTION 1. Flange 5. Driven Gear 9. Drive Gear 13. Oil Seal 2. Rear Cover 6. Bushing 10. Driven Gear 14. Snap Ring 3. Housing 7. Adapter Plate 11. Gasket 4. Drive Gear 8. Housing 12.
Page 180 HYDRAULIC UNITS GEAR PUMP DISASSEMBLY AND ASSEMBLY General Cautions • Carry out disassembly and assembly operations • Replace all seals with new ones each time the in a clean place and provide clean containers to pump is disassembled, coating them lightly with place the disassembled parts in.
Page 181 HYDRAULIC UNITS GEAR PUMP 5. Separate the mechanism into its individual com- ponents: housing (5), adapter plate (6), housing MATCH MARK (7), and rear cover (8). T7D153E 6. Remove bushing A (9), bushing B (10), drive gear (11), and driven gear (12) from the front SUCTION SIDE housing.
Page 182 HYDRAULIC UNITS GEAR PUMP INSPECTION AND ADJUSTMENT Checking Parts After checking the disassembled parts for dirt or dis- coloration, clean them with cleaning oil. However, do not let cleaning oil get on rubber parts. Check each part for the following points and if there is any trouble, repair or replace the part.
Page 183 HYDRAULIC UNITS GEAR PUMP Other likely causes are as follows. • Excessive load due to damage to the relief valve. • Cavitaion or aeration. • Hydraulic oil temperature is too high. • Hydraulic oil is deteriorated. • Hydraulic oil s viscosity is low. If it is necessary to replace the bushings, this means that the gear shaft and gear side surfaces are also rough or worn severely, so replace the gears at the...
Page 184 HYDRAULIC UNITS GEAR PUMP Measuring the Discharge Volume After completing the test operation, measure the discharge volume. 1. Connect a tester (1) to the discharge side of the pump (2). • There should be no mistakes made in the tester s pipe installation. 2.
Page 185 HYDRAULIC UNITS GEAR PUMP TROUBLESHOOTING Symptom Probable Causes Remedy Pump won t discharge. • Direction of rotation is reversed. • Run the pump in the speciﬁed direc- tion. • Oil level in the tank is low. • Replenish the oil to the speciﬁed level. •...
Page 186 HYDRAULIC UNITS GEAR PUMP GEAR PUMP (HIGH FLOW) CONSTRUCTION 1. Housing 6. Bushing 2. Drive Gear 7. Seal 3. Driven Gear 8. Backup Ring 4. Flange 9. Oil Seal 5. Cover 10. Snap Ring Gear Pump The gear pump consists of a single gear case, inside of which is a drive gear (1) and a driven gear (2) engaged with each other.
Page 187 HYDRAULIC UNITS GEAR PUMP DISASSEMBLY AND ASSEMBLY General Cautions • Carry out disassembly and assembly operations • Replace all seals with new ones each time the in a clean place and provide clean containers to hydraulic units is disassembled. place the disassembled parts in. •...
Page 188 HYDRAULIC UNITS GEAR PUMP 4. Remove the snap ring (4) and the oil seal (5) from the ﬂange (1). • Use a (–) screw driver to remove the oil seal. • Be careful not to scratch or otherwise damage the ﬂange. •...
Page 189 HYDRAULIC UNITS GEAR PUMP INSPECTION AND ADJUSTMENT “IV-36~38” TROUBLESHOOTING “IV-39” IV-43...
Page 190 HYDRAULIC UNITS CONTROL VALVE CONTROL VALVE CONSTRUCTION T7D200 1. Tie Rod 2. Outlet Housing 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.
Page 191 HYDRAULIC UNITS CONTROL VALVE Lift Arm 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 SECTION "X-X" T7D201E Bucket Section 1. Load Check Valve 2.
Page 192 HYDRAULIC UNITS CONTROL VALVE Main Relief Valve 1. Housing 9. Lock Nut 2. Plug 10. Spring 3. Sleeve 11. Spring 4. Main Poppet 12. O-ring 5. O-ring 13. O-ring 6. Needle Valve 14. O-ring 7. Set Screw 15. O-ring 8. Gasket T7D204 Port Relief Valve 1.
Page 193 HYDRAULIC UNITS CONTROL VALVE OPERATION When the Spool is in the Neutral Position When the spool is not moved (in the neutral posi- tion), the oil supplied from the pump ﬂows into the valve through port P and ﬂows via the bypass pas- sage (1) to port T to return to the tank.
Page 194 HYDRAULIC UNITS CONTROL VALVE Load Check Valve This valve prevents oil from ﬂowing backward due to the load pressure C from the actuator port (6) dur- ing switching of the spool. T9D204 Main Relief Valve A main relief valve is mounted between the pump circuit and tank circuit of each inlet housing and serves to maintain the circuit pressure at the set value.
Page 195 HYDRAULIC UNITS CONTROL VALVE Port Relief Valve Relieving Operation When the pressure in the circuit is low with respect to the set value, the relief valve is maintained at equilibrium. Pressure from the pump passes from chamber B to the oriﬁce in piston (4), then reaches chamber C and the needle valve (5).
Page 196 HYDRAULIC UNITS CONTROL VALVE DISASSEMBLY AND ASSEMBLY General Cautions • Since all parts in control valves are precision • Replace all seals with new ones each time the machined, carry out disassembly and assembly valves are disassembled. operations in a clean place. •...
Page 197 HYDRAULIC UNITS CONTROL VALVE 4. Remove the load check valve. a. Remove the spring (3), then remove the pop- pet (4). 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).
Page 198 HYDRAULIC UNITS CONTROL VALVE Main Relief Valve 1. Remove the sleeve (1). Sleeve: 49.04 ±4.90 N·m 2. Remove the O-rings from sleeve (1). T7D210 3. Remove the plug (2). Plug: 42.17 ±3.92 N·m 4. Remove the spring (3) and main poppet (4). T7D211 5.
Page 199 HYDRAULIC UNITS CONTROL VALVE INSPECTION AND ADJUSTMENT Checking the Parts Parts Judgment Criteria Treatment Housing, • Scratches, rust, corrosion of the portion which slides • Replace Section Body against the spool. • Scratches, rust, corrosion of the seal pocket portion of •...
Page 200 HYDRAULIC UNITS CONTROL VALVE TROUBLESHOOTING The following items are a list of all the problems to compound the trouble. It is therefore desirable to that might occur individually, but in actual practice, proceed so that the causes can be eliminated one at 2 or 3 of these problems might occur simultaneously a time.
Page 201 HYDRAULIC UNITS CONTROL VALVE Symptom Probable Causes Remedy Can t be held in the • Could be mistaken for a great amount of • Check if it isn t just the cylinder s natu- spool neutral position leakage in the cylinder. ral drop when the cylinder is held.
Page 202 HYDRAULIC UNITS CONTROL VALVE (HIGH FLOW) CONTROL VALVE (HIGH FLOW) CONSTRUCTION 1. Spring 11. Plug 21. Plug 2. Plug 12. Plunger 22. O-ring 3. Valve Seat 13. Relief Valve 23. O-ring 4. Spring 14. O-ring 24. O-ring 5. Solenoid 15. O-ring 25.
Page 203 HYDRAULIC UNITS CONTROL VALVE (HIGH FLOW) OPERATION When the solenoid (2) of the control valve (high hydraulics (A). This will combine the hydraulic oil ﬂow) (1) is powered on, the pilot pressure from the ﬂows from the pump P3 and the pump PTO together. pilot valve (3) operates the spool of the auxiliary hy- Also, the unload valve (6) of the control valve (high draulic section of the control valve (4) to let the hy-...
Page 204 HYDRAULIC UNITS CONTROL VALVE (HIGH FLOW) Unload Relief Valve When Unloading (When the Solenoid Valve is Not Powered On): The hydraulic oil from the port P partially ﬂows through the small hole (2) of the plunger (1) and from the solenoid valve switching section into the port T.
Page 205 HYDRAULIC UNITS CONTROL VALVE (HIGH FLOW) DISASSEMBLY AND ASSEMBLY General Cautions • Since all parts in control valves are precision • Replace all seals with new ones each time the machined, carry out disassembly and assembly valves are disassembled. operations in a clean place. •...
Page 206 HYDRAULIC UNITS CONTROL VALVE (HIGH FLOW) 6. Remove the cap screws and the solenoid valve, then remove the O-ring from 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. •...
Page 207 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. IV-61...
Page 208 HYDRAULIC UNITS CONTROL VALVE (HIGH FLOW) INSPECTION AND ADJUSTMENT Checking the Parts Parts Judgment Criteria Treatment Solenoid coil • When the solenoid is burned, short-circuited, or has a wire • Replace break • Wiring short-circuit or wire break • Replace Body •...
Page 209 HYDRAULIC UNITS CONTROL VALVE (HIGH FLOW) TROUBLESHOOTING Symptom Probable Causes Remedy High ﬂow does not oper- • The high ﬂow is unloaded (The coil or wiring is • Replace the coil. ate. broken.) • A foreign matter which entered the spool of •...
Page 210 HYDRAULIC UNITS CONTROL VALVE (SUB) CONTROL VALVE (SUB) CONSTRUCTION 30 2 10 9 15 20 27 4 12 12 SECTION "X-X" 30 2 SECTION "Z-Z" 19 5 25 26 6 24 SECTION "Y-Y" T7D900E 25. Spring 1. O-ring 9. Spring 17.
Page 211 HYDRAULIC UNITS CONTROL VALVE (SUB) OPERATION When the solenoid A is not electriﬁed The port P and the circuit of the port 3 are connected through the spool (4). The hydraulic oil from the port P ﬂows into the port 3, while the port P and the circuit (5) of the port 1 are shut off.
Page 212 HYDRAULIC UNITS CONTROL VALVE (SUB) The hydraulic oil from the port 1 ﬂows through the bore on the side panel of the spool (11) and through the wire clearance into the chamber D, which consists of the spool (11) and piston (12). When the pressure in the chamber D becomes higher than the set pres- sure, the spool (11) moves downward, releasing the oil from the port 1 to port 2, keeping the pressure in...
Page 213 HYDRAULIC UNITS CONTROL VALVE (SUB) DISASSEMBLY AND ASSEMBLY General Cautions • Carry out disassembly and reassembly operations • The spool and body are selectively ﬁtted, so if in a clean place and place disassembled parts in one is found to be damaged, replace the valve as- clean containers.
Page 214 HYDRAULIC UNITS CONTROL VALVE (SUB) Solenoid Valve A 1. Loosen the nut and remove the solenoid coil (1). Nut: 29.4 ±2.94 N·m 2. Remove the shaft (2) from the body. • Take care not to miss the push rod. Shaft: 37.3 ±3.92 N·m 3.
Page 215 HYDRAULIC UNITS CONTROL VALVE (SUB) 4. Loosen the plug (12) from the body. Plug: 49.0 ±4.9 N·m 5. Remove the O-ring from the plug (12). 6. Remove the spool (13) from the body. 7. Remove the piston (14) from the spool (13). Check Valve 1.
Page 216 HYDRAULIC UNITS CONTROL VALVE (SUB) INSPECTION AND ADJUSTMENT Checking the Parts Parts Judgment Criteria Treatment Solenoid coil • When the solenoid is burned, short-circuited, or has a • Replace wire break • Wiring short-circuit or wire break • Replace Body •...
Page 217 HYDRAULIC UNITS PILOT VALVE PILOT VALVE CONSTRUCTION T7D300 1. Casing 10. Spool 18. Spring Seat 2. Port Plate 11. Plug 19. Washer 2 3. Seal Washer 12. Push Rod 20. Spring 4. O-ring 13. Push Rod 21. Spring 5. Cap Screw 14.
Page 218 HYDRAULIC UNITS PILOT VALVE OPERATION The casing also contains an inlet port for hydrau- The pilot valve casing contains a vertical shaft hole with a reducing valve incorporated into it. When lic oil port P (primary pressure) and an outlet port, the handle is tilted, the push rod and spring seat port T (tank) and secondary pressure is taken from 4 ports, port 1, port 2, port 3 and port 4, on the bottom...
Page 219 HYDRAULIC UNITS PILOT VALVE DISASSEMBLY AND ASSEMBLY Table of Special Tools Q ty Q ty NAME, DIMENSION NAME, DIMENSION INSTALLATION JIG (A) INSTALLATION JIG (B) C0.5 C0.5 10.4 14.5 MATERIAL A; S45C MATERIAL B; SCM415N WITH CEMENTATION HARDENING MATERIAL B; SCM415N WITH CEMENTATION HARDENING Y1-D302E Y1-D303E General Cautions...
Page 220 HYDRAULIC UNITS PILOT VALVE 3. Take out the plug (5) then remove the push rod (6) from the plug (5). • If the plug is difﬁcult to remove, use (–) screw driver to remove it. • Be careful not to let the plug ﬂy out from the spring s force.
Page 221 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. IV-75...
Page 222 HYDRAULIC UNITS PILOT VALVE Assembly 1. Fit the bushing (20) and O-ring (19), then install the port plate (18). • Align the positions of the spring pin (21) and the casing hole. 2. Install the seal washer and cap screws. Cap screw: 20.6 ±1.5 N·m 3.
Page 223 HYDRAULIC UNITS PILOT VALVE 4. Install the spring (13) and reducing valve (12). • Install 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). •...
Page 224 HYDRAULIC UNITS PILOT VALVE Joint: 47.1 ±2.9 N·m 8. Install the disc (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.
Page 225 HYDRAULIC UNITS PILOT VALVE INSPECTION AND ADJUSTMENT Checking the Parts Parts Judgment Criteria Treatment O-ring • Replace Seal • Replace Seal Washer • Replace Spool • Wear on sliding portions is 10 m or greater compared • Replace to non-sliding portions •...
Page 226 HYDRAULIC UNITS PILOT VALVE TROUBLESHOOTING Symptom Probable Causes Remedy Secondary pressure • Primary pressure is insufﬁcient • Keep the primary pressure doesn t rise • Spring is damaged or permanently de- • Replace the spring formed • The clearance between the spool and •...
Page 227 HYDRAULIC UNITS PILOT VALVE PILOT VALVE (AUXILIARY) CONSTRUCTION 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.
Page 228 HYDRAULIC UNITS PILOT VALVE OPERATION “IV-72” DISASSEMBLY AND ASSEMBLY General Cautions “IV-73” The following describes the disassembly procedure. For assembly, refer to the construction diagram and follow the disassembly procedure in the reverse or- der. Disassembly 1. Remove the boot from the cover. •...
Page 229 HYDRAULIC UNITS PILOT VALVE 4. Loosen the cap screws and remove the cover (2). • The cover and plug will rise from the surface if the rebound spring is too strong, so loosen the cap screws alternately so that the cover is ﬂat.
Page 230 HYDRAULIC UNITS PILOT VALVE INSPECTION AND ADJUSTMENT “IV-79” TROUBLESHOOTING “IV-80” IV-84...
Page 231 HYDRAULIC UNITS SELF-LEVEL VALVE SELF-LEVEL VALVE CONSTRUCTION SECTION “A-A” T7D950E 1. Valve Assembly 10. Spring 19. Spring 20. Plunger 2. Ring 11. Plunger 3. Cover 12. Pin 21. Plug 4. O-ring 13. Cap 22. Spring 5. O-ring 14. Nut 23. Housing 6.
Page 232 HYDRAULIC UNITS SELF-LEVEL VALVE OPERATION This valve causes the bucket to tip forward as the lift arms rise, ensuring that the bucket always remain horizontal to the ground. Self-Leveling Operation <Arm Spool Out, Bucket Spool Neutral> Oil ejected from the rod side of the arm cylinder (1) ﬂows into port A of the self-leveling valve, where the difference in the area of adjust double oriﬁce A1 (2) and ﬁxed oriﬁce A2 (3) causes the oil to split and...
Page 233 HYDRAULIC UNITS SELF-LEVEL VALVE At Lowering of the Arm <Arm Spool In, Bucket Spool Neutral> Oil ejected from port B opens up plunger (8) and ﬂows out from port A to go into the rod side of arm cylinder (1). The oil ﬂowing out from the head side returns to the tank.
Page 234 HYDRAULIC UNITS SELF-LEVEL VALVE DISASSEMBLY AND ASSEMBLY General Cautions • Carry out disassembly and reassembly operations • Apply a thin coating of hydraulic oil to sliding in a clean place and place disassembled parts in surfaces and a thin coating of grease to seals when clean containers.
Page 235 HYDRAULIC UNITS SELF-LEVEL VALVE 4. Remove cover (18), nut (17), and set screw (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.
Page 236 HYDRAULIC UNITS SELF-LEVEL VALVE INSPECTION AND ADJUSTMENT Checking the Parts Part Judgment Criteria Treatment Housing • Scratches, rust, or corrosion at the sliding parts with the • Replace spool. • Scratches, rust, or corrosion of the seal part in contact •...
Page 237 HYDRAULIC UNITS SELF-LEVEL VALVE TROUBLESHOOTING Symptom Probable Causes Remedy Arm delay at start of self-level • Air in system. • Cycle Arm and bucket slowly to rid or unstable self-level. system of air. Loaded bucket dumps or un- • Unloading spool is leaking. •...
Page 238 HYDRAULIC UNITS CYLINDERS CYLINDERS CONSTRUCTION Arm Cylinder 21. Wear Ring 1. Rod Packing 11. Bushing 22. Ball 2. Dust Seal 12. Rod Cover 23. Set Screw 3. O-ring 13. Bushing 24. Cushion Bearing 4. Backup Ring 14. Connector 25. Cushion Bearing 5.
Page 239 HYDRAULIC UNITS CYLINDERS OPERATION Hydraulic oil ﬂowing alternately in and out of the oil outlet and inlet on both sides (head and rod sides) of the piston acts on the piston and its force causes the piston to move back and forth. In cylinders equipped with a cushion mechanism, the shock resulting from the piston colliding with the cover at the stroke end acts on that mechanism...
Page 240 HYDRAULIC UNITS CYLINDERS DISASSEMBLY AND ASSEMBLY Special Tools See the table of special tools at the back of this sec- tion for the jigs and tools used for disassembly and assembly. General Cautions • Carry out disassembly and assembly in a clean •...
Page 241 HYDRAULIC UNITS CYLINDERS 4. Loosen the rod cover. • The piston rod should be pulled out approxi- mately 200 mm beforehand. • Measures should be taken to prevent the pis- ton rod from being hit. 5. Take the piston rod assembly out of the tube. •...
Page 242 HYDRAULIC UNITS CYLINDERS 4. Separate the rod cover assembly (6) and retainer assembly (7). a. Remove the stopper (8) and separate the con- nector (9) into two to separate it from the rod cover assembly. E5D412 Retainer 1. Remove the O-ring (14) and backup ring (15). E5D416 2.
Page 243 HYDRAULIC UNITS CYLINDERS Rod Cover 1. Remove the O-ring (34) from the outer diameter of the rod cover, then remove the backup ring (35). 2. Remove the rod packing. K3D409 a. Remove the stopper (37). b. Remove the spacer (38). c.
Page 244 HYDRAULIC UNITS CYLINDERS 4. Remove the bushing. • Since the bushing has been pressure ﬁtted tightly in 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.
Page 245 HYDRAULIC UNITS CYLINDERS Assembly Clevis 1. Using installation jig (B), pressure ﬁt the bush- ings (44) in the piston rod and tube. 2. Using a setting tool (45), install the dust seals. Rod Cover 1. Using an installation jig (A), pressure ﬁt the bushing.
Page 246 HYDRAULIC UNITS CYLINDERS a. Install the backup ring (41). b. Install the rod packing (40), being careful of its installation direction. c. Install the cushion seal (39). d. Install the spacer (38). e. Install the stopper (37). 3. Install the dust seal (42). •...
Page 247 HYDRAULIC UNITS CYLINDERS 2. Install the O-ring (14) and the backup ring (15) on the outer circumference of the retainer. E5D428 Piston 1. Assemble the piston assembly. a. Fit the O-ring (50). • If the O-ring is twisted after it is ﬁtted, cor- rect it.
Page 248 HYDRAULIC UNITS CYLINDERS 2. Install the wear ring (27). a. Spread the wear ring (27) at the cut portion the minimum amount necessary, installing it on the piston from the shaft direction. Piston Rod Assembly 1. Assemble the rod cover assembly (6) and re- tainer assembly (7).
Page 249 HYDRAULIC UNITS CYLINDERS Piston Nut, Set Screw Unit: N·m Place Piston Nut Set Screw Arm Cylinder Bucket Cylinder Cylinder Assembly 1. Fasten the tube in a horizontal position, then insert the piston rod assembly in the tube. • During insertion, align the center of the piston rod with the center of the tube, insert- ing it straight so that the seals will not be scratched.
Page 250 HYDRAULIC UNITS CYLINDERS INSPECTION AND ADJUSTMENT Inspection after Disassembly Clean each part thoroughly with cleaning oil, then carry out the following checks. When a cylinder has been disassembled, replace all the seals with new ones. Piston Rod • Replace the rod if there are cracks. Measuring the Bend •...
Page 251 HYDRAULIC UNITS CYLINDERS Inspection after Assembly No Load Operation Test 1. Place the cylinder in a horizontal position with no load. 2. Apply gentle pressure alternately to the ports at both ends, operating the piston rod 5 or 6 times. 3.
Page 252 HYDRAULIC UNITS CYLINDERS TROUBLESHOOTING Symptom Probable Causes Remedy Oil leaks from piston rod slid- • Foreign matter is caught in the • Remove the foreign matter. ing surface (an oil ring forms on inner diameter portion of the rod the piston and this enlarges and packing, backup ring or dust seal.
Page 253 HYDRAULIC UNITS CYLINDERS TABLE OF SPECIAL TOOLS Installation Jig (A) Installation Jig (B) MATERIAL: SS41 MATERIAL: SS41 Unit: mm Installation Jig (A) Installation Jig (B) 49.0 45.0 28.0 22.0 15.0 60.0 54.0 45.0 40.0 15.0 65.0 Bucket 43.0 40.0 28.0 34.0 15.0 55.0...
Page 254 HYDRAULIC UNITS CYLINDERS Corrective Jig (E) Unit: mm Corrective Jig (E) Bucket MATERIAL: STKM13C IV-108...
Page 255 HYDRAULIC UNITS TRAVEL MOTOR TRAVEL MOTOR (DAIKIN) CONSTRUCTION Hydraulic motor 1/2 1. Flange Holder 9. O-ring 31. Brake Piston 2. Pin 10. Cylinder Block Assembly 33. O-ring 3. Bearing Assembly 25. Plug 34. O-ring 26. O-ring 35. O-ring 4. Snap Ring 5.
Page 256 HYDRAULIC UNITS TRAVEL MOTOR Hydraulic motor 2/2 6. Bearing 20. Plug 44. Plug 21. Plug 45. Spool 11. Valve Plate 12. Pin 27. Plug 46. Spring Guide 13. Valve Body 32. Pin 47. Plug 14. Cap Screw 40. Plug 48. O-ring 15.
Page 257 HYDRAULIC UNITS TRAVEL MOTOR Reduction gears 1. Housing 8. Ring Nut 18. Floating Seal 2. Cover 9. Thrust Plate 19. Screw 3. Carrier 10. Thrust Plate 20. Bolt 4. Sun Gear 11. Snap Ring 21. Bolt 5. Sun Gear 13. Bearing 22.
Page 258 HYDRAULIC UNITS TRAVEL MOTOR OPERATION Hydraulic motor The cylinder block (1) is constructed with the pis- tons (2), and its end surface comes in contact with the valve plate (3) containing two half-moon-shaped ports (B) and (C). The cylinder block (1) rotates freely and is connected to the drive shaft (4) via the spline.
Page 259 HYDRAULIC UNITS TRAVEL MOTOR Parking brake The friction disc (2) and the disc (1) are connected through the spline. The friction disc (2) and the disc (1) are pressed against the ﬂange holder (6) by the springs (4) via the brake piston (5). The friction force between these discs generates the brake torque to prevent the cylinder block (3) from rotating.
Page 260 HYDRAULIC UNITS TRAVEL MOTOR Reduction gears The reduction gears consist of two simple planetary stages connected in series. Each planetary stage consists of a sun (input) gear, an internal tooth ring gear and planet gears mounted on a carrier. The sun gear “ﬂoats”...
Page 261 HYDRAULIC UNITS TRAVEL MOTOR DISASSEMBLY AND ASSEMBLY Special tools IV-115...
Page 262 HYDRAULIC UNITS TRAVEL MOTOR JIG D VORRICHTUNG D OUTIL D 4 x1 3 x2 25.5 22.4 2 x1 Cap Screw M6x2 40.5 Inbusschraube M6x2 Vis M6x2 1 x1 ø20 ø35 ø42.3 4MAA05Z IV-116...
Page 263 HYDRAULIC UNITS TRAVEL MOTOR IV-117...
Page 264 HYDRAULIC UNITS TRAVEL MOTOR The part numbers contained in the “Disassembly and Assembly” section of this manual correspond to the numbers listed in the construction diagram. Work should be performed by referring to the diagram, as necessary. Disassembly Reduction gears 1.
Page 265 HYDRAULIC UNITS TRAVEL MOTOR 5. Take out the screws 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.
Page 266 HYDRAULIC UNITS TRAVEL MOTOR 3. Remove the springs (28), pin (2), O-rings (8, 9, and 35) and the valve plate (11). 4. Place several blocks between the valve body (13) and the ﬂange holder (1). • The block must be thin enough so that the cap screw M10 ×...
Page 267 HYDRAULIC UNITS TRAVEL MOTOR 7. Remove the cylinder block (10). • Be sure not to damage the sliding surface. 8. Remove the shaft (7) and the swash plate (37). 9. Remove the balls (39) and the control piston (38). Floating Seal 1.
Page 268 HYDRAULIC UNITS TRAVEL MOTOR 2. Remove the plugs (23). 4MAA20Z 3. Remove the ring nut (8). • Use the jig (C). 4MAA21Z 4. Remove the housing (1) from the ﬂange holder. • Use the jig (D). 5. Remove the ﬂoating seal (18) from the housing (1) of the ﬂange holder.
Page 269 HYDRAULIC UNITS TRAVEL MOTOR Assembly Floating seal 1. Place the ﬂoating seal (18) in the housing. • Apply gear oil on the O-ring. 2. Place the guide jig (E). 4MAA23Z 3. Fit the ﬂoating seal (18) by pressing the guide jig (E) with the jig (F).
Page 270 HYDRAULIC UNITS TRAVEL MOTOR 6. Press-ﬁt the guide jig (G) with the jig (H), and then install the ﬂoating seal (18). • Apply gear oil on the sliding surface. Do not apply grease. Important: • Be sure not to damage the sliding surface. •...
Page 271 HYDRAULIC UNITS TRAVEL MOTOR 10. Fit the plugs (23). Plug: 30 N·m 4MAA20Z 11. Install the inner races (16). • Use the jig (I) and a hammer to install the in- ner races. • After assembly, the dimension “X” must be between 0 and 1 mm.
Page 272 HYDRAULIC UNITS TRAVEL MOTOR 4. Install the shaft (7) and the swash plate (37). • Apply hydraulic oil on the sliding surface of the swash plate. 5. Install the cylinder block assembly (10). • Use the spline of the shaft as a guide. 6.
Page 273 HYDRAULIC UNITS TRAVEL MOTOR 8. Install the brake piston (31) on the ﬂange hold- • Apply hydraulic oil on the sliding surface of the cylinder block. • Be sure that no foreign matter is present in the cylinder block port. •...
Page 274 HYDRAULIC UNITS TRAVEL MOTOR 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).
Page 275 HYDRAULIC UNITS TRAVEL MOTOR 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.
Page 276 HYDRAULIC UNITS TRAVEL MOTOR Reduction gears 1. Install the needle bearings (16) and the planet gears (7). • Clean the inner surface of the gears and lightly apply oil on them. • Do not tap on the bearing or gear. 2.
Page 277 HYDRAULIC UNITS TRAVEL MOTOR 5. Install the planet gears (6) and the needle bear- ings (14) on the carrier (3), and then install them on the housing (1). 6. Install the sun gear (4). 7. Measure the depth “A” from the housing end face to the holder (pin).
Page 278 HYDRAULIC UNITS TRAVEL MOTOR 11. Install the cover and ﬁt the 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).
Page 279 HYDRAULIC UNITS TRAVEL MOTOR INSPECTION AND ADJUSTMENT Use Limit for Parts Part Location Criteria Action Planet gear Gear tooth surface No abnormal scratches, wear or ﬂak- Replace ing on the tooth surface Rolling surface of the No abnormal scratches, wear or ﬂak- Replace needle bearing ing on the rolling surface...
Page 280 HYDRAULIC UNITS TRAVEL MOTOR TROUBLESHOOTING Hydraulic motor Symptoms Major causes Remedies Motor fails to start • All the devices other than the motor and the • Check whether the speciﬁed pressure reduction gears are not working correctly is generated in the inlet port, and then check and repair each device.
Page 281 HYDRAULIC UNITS TRAVEL MOTOR Parking brake Symptoms Major causes Remedies Braking force • The total thickness of three friction discs • Replace the discs. insufﬁcient or not and four center discs is 13.5 mm or less evenly applied • Disc surface is faulty •...
Page 282 HYDRAULIC UNITS TRAVEL MOTOR IV-136...
Page 283 V . TROUBLESHOOTING...
Page 284 TROUBLESHOOTING CAUTIONS IN TROUBLESHOOTING AND REPAIRS (1) Do not begin disassembling the equipment immediately just because it has broken down. Conduct a thorough preliminary check before attempting disassembly. a. Ask the user the following questions. • What were the conditions when the machine broke down? •...
Page 285 TROUBLESHOOTING CONTENTS OVERALL MACHINE Complete failure of all systems..........................4 All systems working, but with insufﬁcient power....................7 Lift arms and bucket fail to move/speed of operation poor..................9 MACHINE TRAVEL Travel train fault..............................10 Speed falls and machine veers to one side......................12 The travel system is operating at an unusually high temperature.
Page 286 TROUBLESHOOTING OVERALL MACHINE COMPLETE FAILURE OF ALL SYSTEMS. Not enough oil Inspect the hydraulic Add hydraulic oil. oil level. Normal Faulty Inspect the hydraulic • Repair or replace hydraulic pump. pump. • Replace the coupling mechanism. Normal Faulty Inspect hydraulic pump Repair or replace hydraulic pump.
Page 287 TROUBLESHOOTING OVERALL MACHINE 1. Inspect the hydraulic oil level. “III. Machine Conﬁguration, Hydraulic Tank” Always be sure to use the same brand as that currently being used when adding hydraulic oil. “Speciﬁcations, Fluid Capacities” 2. Inspect the hydraulic pump. • Inspect the delivery pressure of pumps P1 and P2 (HST pumps).
Page 288 TROUBLESHOOTING OVERALL MACHINE 5. Inspect the proximity switch. The proximity switch (4) should be switched on by moving the safety bar (3) into the driving position. Use a tester to check to see whether the power running from the lever lock solenoid (5) at this time is being cut off or not.
Page 289 TROUBLESHOOTING OVERALL MACHINE ALL SYSTEMS WORKING, BUT WITH INSUFFICIENT POWER. Not enough oil Inspect the hydraulic Add hydraulic oil. oil level. Normal Hydraulic pump is emit- Noise Problem in the suc- Replace seal tape, O-ring, ting an unusual level of tion line hose.
Page 290 TROUBLESHOOTING OVERALL MACHINE 1. Inspect the hydraulic oil level. “III. Machine Conﬁguration, Hydraulic Tank” 2. Hydraulic pump is emitting an unusual level of noise. The cause of the problem is probably a fault in the suction line which has caused the pump to dry out.
Page 291 TROUBLESHOOTING OVERALL MACHINE LIFT ARMS AND BUCKET FAIL TO MOVE/SPEED OF OPERATION POOR. Faulty Inspect hydraulic pump Repair or replace hydraulic pump P3. Normal Faulty Inspect the main relief Repair or replace the main valve. relief valve. Normal Faulty Repair or replace the pilot Inspect the pilot valve.
Page 292 TROUBLESHOOTING MACHINE TRAVEL TRAVEL TRAIN FAULT. Faulty Repair replace pilot Inspect the pilot valve. valve. Normal Pressure low Inspect the charge pres- Repair or replace HST pump sure. charge relief valve. Normal Normal Inspect the output pres- Repair or replace travel mo- Travel motor fault.
Page 293 TROUBLESHOOTING MACHINE TRAVEL 1. Inspect the pilot valve. Measure the secondary pressure of the pilot valve. a. Disconnect the hose connecting the HST pump (P1, P2) and the pilot valve at the pump. b. Fit a pressure gauge to the hose. c.
Page 294 TROUBLESHOOTING MACHINE TRAVEL SPEED FALLS AND MACHINE VEERS TO ONE SIDE. Problem due to com- Within standard Is the amount of travel bination of equip- Normal curve within standard? ment. Outside the standard Inspect the crawler ten- Faulty Adjust to speciﬁed tension sion and inspect for for- or remove foreign matter.
Page 295 TROUBLESHOOTING MACHINE TRAVEL 1. Is the amount of travel curve within stan- dard? If the amount of travel curve is within standards, then operation is normal and the variation de- pends on the combination of equipment. “II. Speciﬁcations, Standards for Judging Performance”...
Page 296 TROUBLESHOOTING MACHINE TRAVEL THE TRAVEL SYSTEM IS OPERATING AT AN UNUSUALLY HIGH TEMPERATURE. Level low Inspect hydraulic oil Add hydraulic oil. level. Level normal Faulty • Clean the oil cooler and radiator. Inspect oil cooler. • Repair or replace the oil cooler. Normal Faulty Inspect high pressure...
Page 297 TROUBLESHOOTING MACHINE TRAVEL 1. Inspect the hydraulic oil level. Check the oil level in the hydraulic tank. “III. Machine Conﬁguration, Hydraulic System” 2. Inspect the oil cooler. Check the oil cooler to see if it has been clogged up or if there is anything else the matter with it. Also check the oil cooler and the cooling fan in the radiator to see if dust or other foreign par- ticles have worked their way in and clogged the...
Page 298 TROUBLESHOOTING MACHINE TRAVEL MACHINE WILL NOT TRAVEL IN SECOND SPEED. Faulty Inspect the hydraulic Repair or replace the hy- pump P4. draulic pump P4. Normal Faulty Inspect the pilot relief Adjust, repair or replace the valve. pilot relief valve. Normal Faulty Inspect the travel speed Replace the travel speed...
Page 299 TROUBLESHOOTING MACHINE TRAVEL 3. Inspect the travel speed switch. Press the switch to turn it “ON”. While it is in this condition, check if there is continuity with a tester. T7E005 4. Inspect the 2nd speed solenoid valve. a. Turn the start switch “ON”. b.
Page 300 TROUBLESHOOTING LIFT ARMS LIFT ARM CYLINDERS FAIL TO MOVE. Inspect the operation of actuators other than the lift arm cylinders. Normal Faulty Repair replace pilot Inspect the pilot valve. valve. Normal Faulty Inspect movement of Repair or replace control the spool. valve.
Page 301 TROUBLESHOOTING LIFT ARMS 3. Inspect movement of the spool. a. Disconnect one of the hoses connected to the lift arm section of the control valve. b. Fit a pressure gauge to the lift arm section. c. Engage the lever to operate the lift arms and measure the pressure.
Page 302 TROUBLESHOOTING LIFT ARMS MOVEMENT OF THE LIFT ARM CYLINDERS IS SLOW OR LACKS POWER. Are the lift arm cylinders Within standard moving within the speci- Normal ﬁed range of speed? Outside the standard Faulty Repair replace pilot Inspect the pilot valve. valve.
Page 303 TROUBLESHOOTING LIFT ARMS 6. Inspect for leaks within the lift arm cylin- ders. a. Tilt the bucket slightly forward (about 10 de- grees) and bring the front edge of the bucket down and into contact with the ground. b. Check the left and right lift arm cylinders individually.
Page 304 TROUBLESHOOTING LIFT ARMS SLOWLY PULLING THE CONTROL LEVER OF THE LIFT ARMS CAUSES THE LIFT ARMS TO DROP MOMENTARILY. Inspect the load check Faulty Repair or replace control valve of the control valve. valve. Normal Faulty Inspect for leaks inside Repair or replace lift arm the lift arm cylinders.
Page 305 TROUBLESHOOTING LIFT ARMS THE AMOUNT OF LIFT ARMS NATURAL DROP IS GREAT. Is the amount of natural Within standard drop within the stan- Normal dard? Outside the standard Faulty Inspect for leaks within Repair or replace lift arm the lift arm cylinders. cylinder.
Page 306 TROUBLESHOOTING BUCKET BUCKET CYLINDERS FAIL TO MOVE. Inspect operation of actuators other than the bucket cylinders. Normal Faulty Repair replace pilot Inspect the pilot valve. valve. Normal Faulty Inspect movement of Repair or replace control the spool. valve. Normal Operation be- Perform replacement came normal.
Page 307 TROUBLESHOOTING BUCKET 3. Inspect movement of the spool. a. Disconnect one of the hoses connected to the bucket section of the control valve. b. Fit a pressure gauge to the bucket section. c. Engage the lever to operate the bucket cylin- ders and measure the pressure.
Page 308 TROUBLESHOOTING BUCKET MOVEMENT OF THE BUCKET CYLINDERS IS SLOW OR LACKS POWER. Is the speed of the Within standard bucket cylinders within Normal the speciﬁed range? Outside the standard Faulty Repair replace pilot Inspect the pilot valve. valve. Normal Faulty Inspect movement of Repair or replace control the spool.
Page 309 TROUBLESHOOTING BUCKET 1. Is the speed of the bucket cylinders within the speciﬁed range? “II. Speciﬁcations, Standards for Judging Performance” 2. Inspect the pilot valve. “V-24” 3. Inspect movement of the spool. “V-25” 4. Perform replacement test for the port relief valves.
Page 310 TROUBLESHOOTING BUCKET THE AMOUNT OF BUCKET NATURAL DROP IS GREAT. Is the amount of natural Within standard fall within the stan- Normal dard? Outside the standard Faulty Inspect for leaks within Repair or replace bucket the bucket cylinders. cylinder. Normal Inspect for leaks within the control valve or Repair or replace valve.
Page 311 TROUBLESHOOTING AUXILIARY HYDRAULICS SWITCHING BETWEEN 2-WAY FLOW AND 1-WAY FLOW IS IMPOSSIBLE. Faulty Inspect the ﬂow selec- Repair or replace the selec- tor switch. tor switch. Faulty Inspect the resistor. Replace the resistor. Faulty Inspect the ﬂow selec- Repair or replace the ﬂow tor solenoid.
Page 312 TROUBLESHOOTING AUXILIARY HYDRAULICS 3. Inspect the ﬂow selector solenoid. a. Turn the proximity switch and start switch “ON”. b. Press the protruding portion of the solenoid valve lightly. c. Turn the ﬂow selector switch “ON”. d. If the spool moves and vibration can be felt with the ﬁngertip when the circuit changes, then it is normal.

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