Page 1
TL150
Track Loader
BOOK No.
WORKSHOP MANUAL
CT7E901
Serial No.
21500004~
Page 2
FOREWORD
This manual is intended for persons who engage in maintenance operations, and explains procedures for disassembly 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.
Further, please be advised that items contained in this manual are subject to change without notice due to design
modifications, etc.
MACHINE FRONT AND REAR, LEFT AND RIGHT
The end where the bucket is mounted is the front and the end with the travel motors is the rear. Also the right and
left sides of the operator when he is seated in the driver·s seat are the right and left sides of the machine.
MACHINE SERIAL NUMBER
The machine serial number is stamped on the identification plate. When sending reports and inquiries, and when
ordering parts, etc., be sure to include this number.
MANUAL CONTROL
Information on those to whom this manual is distributed is recorded in the ledger in the section in charge at this
company, so please decide on a person to be in charge of it and control it. When there are updates or additions,
etc., we will notify the person in charge.
SYMBOLS
means “Please refer to the section quoted.”
Indicates the tightening torque at the specific section that requires special attention in designing.
Indicates the mass of a part or device.
0-2
Page 3
I . GENERAL
II . SPECIFICATIONS
III . MACHINE CONFIGURATION
IV . HYDRAULIC UNITS
V . TROUBLESHOOTING
VI . ENGINE
0-3
Page 4
0-4
Page 5
I . GENERAL
I-1
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
I-2
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.
Q SIGNAL WORDS
Safety messages appearing in this manual and on machine decals are identified by the words “DANGER”,
“WARNING” and “CAUTION”. These signal words mean the following:
DANGER
The word “DANGER” indicates an imminently hazardous situation which, if not
avoided, can result in serious
injury or death.
IMPORTANT: The word “IMPORTANT” is used to alert against operators and maintenance personnel
about situations which can result in possible damage to the machine and its components.
This manual is intended for trained and qualified personnel only. Warnings or cautions described in this manual
do not necessarily cover all safety measures. For maintenance work, each person must take adequate safety
precautions against possible hazards present in the respective working environment.
Observe all safety rules
• Operation, inspection and maintenance of this
machine must be performed only by a trained and
qualified person.
• All rules, regulations, precautions and safety pro
cedures must be understood and followed when
performing operation, inspection and maintenance of this machine.
• Do not perform any operation, inspection and
maintenance of this machine when under the
adverse influence of alcohol, drugs, medication,
fatigue, or insufficient sleep.
The word “WARNING” indicates a potentially hazardous
situation which, if not avoided, could result in serious
injury or death.
WARNING
The word “CAUTION” indicates a potentially hazardous situation which, if not
avoided, may result in minor
or moderate injury.
-
CAUTION
Wear appropriate clothing and personal
protective equipment
• Do not wear loose clothing or any accessory that
can catch on controls or in moving parts.
• Do not wear oily or fuel stained clothing that can
catch fire.
• Wear a hard hat, safety shoes, safety glasses, filter
mask, heavy gloves, ear protection and other protective equipment as required by job conditions.
Wear required appropriate equipment such as
safety glasses and filter mask when using grinders, hammers or compressed air, as metal fragments or other objects can fly and cause serious
personal injury.
• Use hearing protection when operating the ma
chine. Loud prolonged noise can cause hearing
impairments, even the total loss of hearing.
I-3
-
Page 8
GENERAL
Provide a fire extinguisher and first aid
kit
• Know where a fire extinguisher and first aid kit
are located and understand how to use them.
• Know how to contact emergency assistance and
first aid help.
Attach a “DO NOT OPERATE” tag
Severe injury could result if an unauthorized person
should start the engine or touch controls during
inspection or maintenance.
• Stop the engine and remove the key before per
forming maintenance.
• Attach a “DO NOT OPERATE” tag to the starter
switch or control lever.
Anti-explosive lighting
Use anti-explosive electrical fixtures and lights
when inspecting fuel, oil, coolant, battery fluid, etc.
If lighting that is not anti-explosive should break,
the substance could ignite, resulting in serious injury
or death.
Do not allow unauthorized personnel in
the work area
-
Use the correct tools
Do not use damaged or weakened tools or tools designed for other purposes. Use tools suited for the
operation at hand.
Replace important safety parts periodically
• Replace fuel hoses periodically. Fuel hoses become weaker over time, even if they appear to be
in good shape.
• Replace important safety parts whenever an ir
regularity is found, even if it is before the normal
time for replacement.
Do not allow unauthorized personnel in the work
area. Chips or other debris can fly off machine parts
when grinding, welding or using a hammer.
Prepare the work area
• Select a firm, level work area. Make sure there is
adequate light and, if indoors, ventilation.
• Clear obstacles and dangerous objects. Eliminate
slippery areas.
-
I-4
Page 9
GENERAL
Always clean the machine
• Clean the machine before performing maintenance.
• Cover electrical parts when washing the machine.
Water on electrical parts could cause short-circuits or malfunctions.
Do not use water or steam to wash the battery,
sensors, connectors or the operator·s seat area.
Stop the engine before performing maintenance
• Avoid lubrication or mechanical adjustments with
the machine in motion or with the engine running
while stationary.
• If maintenance must be performed with the engine
running, always work as a 2-person team with
one person sitting in the operator·s seat while the
other works on the machine.
• When performing maintenance, be sure to
keep your body and clothing away from moving parts.
Securely block the machine or any component that may fall
• Before performing maintenance or repairs under
the machine, set all working equipment against
the ground or in the lowermost position.
• Securely block the tracks.
• If you must work beneath the raised machine or
equipment, always use wood blocks, jack-stands
or other rigid and stable supports. Never get under the machine or working equipment if they
are not sufficiently supported. This procedure is
especially important when working on hydraulic
cylinders.
Securely block the working equipment
To prevent unexpected movement, securely block
the working equipment when repairing or replacing
the cutting edges or bucket teeth.
Secure the engine hood or cover when
opened
Stay clear of moving parts
• Stay clear of all rotating and moving parts. Wrapping or entanglement may result in serious injury
or death.
• Keep hands, clothing and tools away from the
rotating fan and running fan belts.
Be sure to secure the engine hood or cover when
opening it. Do not open the engine hood or cover on
slopes or in strong wind.
Place heavy objects in a stable position
When removing or installing the hoe attachment,
place it in a stable position so that it does not tip
over.
I-5
Page 10
GENERAL
Cautions on working on the machine
• When performing maintenance on the machine,
clean up the foot area and strictly observe the following so as not to fall:
• Do not spill oil or grease.
• Do not leave tools laying around.
• When walking, watch your step.
• Never jump off the machine. Use the steps and
handrails when climbing on and off the machine,
and always support your body at three points with
your hands and feet.
• Use protective equipment as required by job con
ditions.
Use caution when fueling
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.
• Retighten loose connections.
Be careful with hot and pressurized
components
-
Stop the engine and allow the machine to cool down
before performing inspection and maintenance.
• The engine, muffler, radiator, hydraulic lines,
sliding parts and many other parts of the machine
are hot directly after the engine is stopped. Touching these parts will cause burns.
• The engine coolant, oil and hydraulic fluid are
also hot and under high pressure.
Be careful when loosening caps and plugs. Work
ing on the machine under these conditions could
result in burns or injuries due to the hot oil spurting out.
• Do not smoke or permit open flames while fueling or near fueling operations.
• Never remove the fuel cap or refuel with the en
gine running or hot. Never allow fuel to spill on
hot machine components.
• Maintain control of the fuel filler nozzle when
filling the tank.
• Do not fill the fuel tank to capacity. Allow room
for expansion.
• Clean up spilled fuel immediately.
• Tighten the fuel tank cap securely. Should the
fuel cap be lost, replace it only with the original
manufacturer·s approved cap. Use of a non-approved cap without proper venting may result in
pressurization of the tank.
• Never use fuel for cleaning purposes.
• Use the correct fuel grade for the operating sea
son.
Be careful with hot cooling systems
-
Do not remove the radiator cap or drain plugs when
the coolant is hot. Stop the engine, let the engine
and radiator cool and loosen the radiator cap or drain
plugs slowly.
-
I-6
Page 11
GENERAL
Be careful with fluids under pressure
Pressure can be maintained in the hydraulic circuit
long after the engine has been shut down.
• Release all pressure before working on the hy
draulic system.
• Hydraulic fluid under pressure can penetrate the
skin or eyes and cause injury, blindness or death.
Fluid escaping from a small hole can be almost
invisible. Wear a safety goggles and heavy gloves
and use a piece of cardboard or wood to search
for suspected leaks.
If fluid is injected into the skin, it must be removed
within a few hours by a doctor familiar with this
type of injury.
Release all pressure before working on
the hydraulic system
Oil may spurt out if caps or filters are removed or
pipes disconnected before releasing the pressure in
the hydraulic system.
• Gradually loosen the vent plug to relieve tank
pressure.
• Move all the control levers and pedals several
times in all directions to release the pressure from
the working equipment circuitry. (For link type
controls)
• When removing plugs or screws or disconnect
ing hoses, stand to the side and loosen slowly
to gradually release the internal pressure before
removing.
Handling of the Accumulator
High pressure nitrogen gas is enclosed in the accumulator and incorrect handling could possibly bring
about serious injury due to explosion. The following
matters should be strictly observed:
• Do not disassemble.
• Do not bring close to fire or throw into a fire.
• 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 sales or service
agent.
Be careful with grease under pressure
-
E3A6201
The track adjuster contains highly pressurized
grease. If the tension is adjusted without following
the prescribed procedure, the grease discharge valve
may fly off, resulting in injury.
• Loosen the grease discharge valve slowly. Do not
unfasten it more than one full turn.
• Do not put your face, arms, legs or body in front
of the grease discharge valve.
Disconnect the battery
-
Disconnect the battery before working on the electrical system or doing any welding. Remove the negative (–) battery cable first. When reconnecting the
battery, connect the negative (–) battery cable last.
I-7
Page 12
GENERAL
Avoid battery hazards
• Batteries contain sulfuric acid which will damage
eyes or skin on contact.
• If acid contacts eyes, flush immediately with
clean water and get prompt medical attention.
• If acid is accidentally swallowed, drink large
quantities of water or milk and call a physician
immediately.
• If acid contacts skin or clothing, wash off im
mediately with clean water.
• Wear safety glasses and gloves when working
with batteries.
• Batteries generate flammable and explosive gas
es. Keep arcs, sparks, flames and lighted tobacco
away.
• Use a flashlight to check battery electrolyte lev
el.
• Stop the engine and shut off electrical equipment
while inspecting or handling the battery.
• Do not short circuit the battery posts with metal
items.
• Always unfasten the negative (–) battery cable
first when disconnecting the battery cable. Always connect the negative (–) battery cable last
when fastening the battery cable.
• Loose battery terminals may result in sparks. Be
sure to fasten terminals tightly.
• Make sure the vent caps are tightened securely.
• Do not charge a battery or jump-start the engine if
the battery is frozen. Warm to 15°C (60°F) or the
battery may explode.
Checks after maintenance
• Gradually raise the engine speed from a low idle
to maximum speed and check that no oil or air is
leaking from serviced parts.
• Move the controls and check that the machine is
operating properly.
-
-
-
Disposing of wastes
• Funnel spent fluids from the machine into containers. Disposing of fluids improperly destroys
the environment.
• Follow the prescribed regulations when disposing
of oil, fuel, engine coolant, refrigerant, solvents,
filters, batteries or other harmful substances.
Have a service agent repair welding
cracks or other damage
Ask a 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 properly
equipped workplace.
Safety signs
• Keep all safety signs clean and legible.
• Replace all missing, illegible or damaged safety
and warning signs.
I-8
Page 13
GENERAL
CAUTIONS DURING DISASSEMBLY AND
ASSEMBLY
1. Clean the machine before disassembly opera
-
tion.
2. Before disassembly, check the machine condi-
tions and record them.
• Model, Machine Serial Number, Hourmeter
• Reason for Repairs, Repair History
• Dirtiness of Filters
• Fuel and Oil Conditions
• Damage to each parts, etc.
3. To make reassembly operations easy, make
matching marks at the necessary points.
4. Clean all disassembled parts and new parts, then
arrange them in the proper sequence.
5. Be sure to replace all seals and cotter pins, etc.,
with new parts.
6. Keep parts which should not come in contact
with oil and water separate from parts with oil
on them.
• Electrical Parts, Rubber, V-Belts, etc.
CAUTIONS DURING REMOVAL AND INSTALLATION OF THE HYDRAULIC UNITS
1. Make sure that the temperature of the hydraulic
oil has dropped.
2. To prevent a loss of flow of the hydraulic oil,
the residual pressure in the piping and the internal pressure in the hydraulic tank should be
released.
3. Be sure to install caps or plugs on all openings
in the hydraulic unit to prevent dirt from getting
into the unit through the openings.
PLUG
PLUG
Y2-A103E
7. When installing bearings, bushings and oil seals,
as a rule, use a press. When a hammer, etc., is
used, it leaves bruises.
8. Wipe all joining surfaces clean so that there is
no dirt or dust adhering to them.
9. Wrap seal tape from the front end, Wrapping it
tight and leaving 1 or 2 threads bare, Overlap the
tape by about 10 mm.
SEALING TAPE
LEAVE 1 OR 2 THREAD MARGIN
Y2-A102E
10. When fitting the snap rings, the bigger, rounder
side of their circumferences should face the
mating surfaces.
4. It is easy to mistake hydraulic oil adhering to the
hydraulic unit for an oil leak, so wipe the unit
off thoroughly.
5. Be sure that no damage is done to the plating on
the rod in the hydraulic cylinder.
6. As a rule, removal and installation of the hydraulic cylinder should be done with the rod
fully retracted.
7. Be sure to bleed the air after replacing the hydraulic oil or removing any of the hydraulic
devices.
“III. Machine Configuration, Hydraulic
System”
I-9
Page 14
GENERAL
CAUTIONS DURING REMOVAL AND INSTALLATION OF PIPING
1. When hydraulic hoses are installed, tighten them
once to the prescribed torque, then loosen them
slightly and retighten them to the prescribed
torque.
• Tighten the fittings after the installation sur
faces fit snugly together.
• Pieces wrapped with seal tape are excluded.
2. Use 2 spanners, each on an opposite side, to
remove and tighten fittings so that the hoses or
steel pipes are not twisted.
3. After installation of hydraulic hoses or steel
pipes, apply the maximum working pressure 5
or 6 times and confirm that there is no leakage.
HANDLING OF SEALS
1. Clean the grooves for O-rings and if there is any
burr, etc., remove it.
-
BURR
DIRT
Y2-A105E
2. Be careful not to twist O-rings. If an O-ring is
twisted, remove the twist with the fingertips.
3. During insertion, be careful not to damage the
seal.
4. Handling of Floating Seals
• Wipe all oil off the O-ring and housing of the
floating seal.
• When assembling, apply a thin coating of
gear oil to the contact surface of the housing.
• After assembly, turn the seal 2 or 3 times to
get it to fit snugly.
5. Apply grease to the lip of the oil seal.
• This is to prevent wear when it is first started
up after assembly.
I-10
GREASE
Y2-A106E
Page 15
TIGHTENING TORQUES
Hydraulic Hoses
Hose Fitting Size
N·m ft-lb N·m ft-lb
1/8 9.8
1/4 24.5
3/8 49
1/2 58.8
3/4 117.7
1 137.3
Torque
Union Nut (G) Taper Thread (R)
+4.9
+4.9
0
+4.9
0
+4.9
+4.9
+4.9
0
0
0
0
7.3
18.1
36.2
43.4
86.8
101.3
+3.5
+3.5
+3.5
+3.5
+3.5
11.8 ±1.2 8.7 ±0.8
0
29.4 ±2.9 21.7 ±2.1
0
53.9 ±5.4 39.8 ±3.9
0
88.3 ±8.8 65.1 ±6.4
0
147.1 ±14.7 108.5 ±10.7
0
+3.5
196.1 ±19.6 144.7 ±14.3
0
GENERAL
UNION NUT
TAPER THREAD
Y2-A107E
Bite Type Pipe Fitting for Steel Pipe
Pipe Outer Diameter
(mm)
N·m ft-lb
8 34.3 ±4.9 25.3 ±3.5
10 41.7 ±2.5 30.7 ±1.7
12 58.8 ±4.9 43.4 ±3.5
15 88.3 ±4.9 65.1 ±3.5
16 93.2 ±4.9 68.7 ±3.5
18 132.4 ±4.9 97.6 ±3.5
22 205.9 ±9.8 151.8 ±7.2
27.2 245.2 ±9.8 181.0 ±7.2
28 313.8 ±19.6 231.4 ±14.3
32 313.8 ±19.6 231.4 ±14.3
35 411.9 ±19.6 303.7 ±14.3
Torque
I-11
Page 16
Joints for Piping
GENERAL
Nominal Thread
Diameter
(R)
Steel Cast Steel
N·m ft-lb N·m ft-lb
1/8 11.8 ±1.2 8.7 ±0.8 10.8 ±1.1 8.0 ±0.7
1/4 29.4 ±2.9 21.7 ±2.1 24.5 ±2.5 18.1 ±1.7
3/8 53.9 ±5.4 39.8 ±3.9 49 ±4.9 36.2 ±3.5
1/2 88.3 ±8.8 65.1 ±6.4 73.5 ±7.4 54.3 ±5.3
3/4 147.1 ±14.7 108.5 ±10.7 127.5 ±12.7 94.1 ±9.3
1 196.1 ±19.2 144.7 ±14.3 171.6 ±17.2 126.6 ±12.5
Joints for Piping (O-ring Seal Type)
Nominal Thread
Diameter
(G)
N·m ft-lb
1/8 19.6 ±2.0 14.5 ±1.4
1/4 34.3 ±4.9 25.3 ±3.5
3/8 53.9 ±4.9 39.8 ±3.5
1/2 63.7 ±4.9 47.0 ±3.5
3/4 93.2 ±4.9 68.7 ±3.5
1 107.9 ±9.8 79.5 ±7.2
1-1/4 117.7 ±9.8 86.8 ±7.2
1-1/2 137.3 ±9.8 101.2 ±7.2
Torque
Torque
O-RING
Nominal Thread
Diameter
(UNF)
N·m ft-lb
Torque
7/16–20 16.7 ±2.0 12.3 ±1.4
1/2–20 22.6 ±2.0 16.6 ±1.4
9/16–18 31.4 ±2.9 23.1 ±2.1
3/4–16 59.8 ±4.9 44.1 ±3.5
1-1/16–12 102.0 ±5.9 75.2 ±4.4
1-5/16–12 135.3 ±7.8 99.8 ±5.8
1-5/8–12 181.4 ±9.8 133.8 ±7.2
I-12
Y2-A110
Page 17
Bolts and Nuts (for ISO Strength Category 10.9)
Thread Size × Pitch
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 × 1.25 22.6 ±1.1 2.3 ±0.11 16.6 ±0.8 26.5 ±1.3 2.7 ±0.13 19.5 ±0.9
M10 × 1.5 47.1 ±2.4 4.8 ±0.24 34.7 ±1.7 54.9 ±2.7 5.6 ±0.28 40.5 ±2.0
Coarse
Fine
M12 × 1.75 83.4 ±4.1 8.5 ±0.42 61.5 ±3.0 97.1 ±4.8 9.9 ±0.49 71.6 ±3.5
M14 × 2.0 134.4 ±6.7 13.7 ±0.68 99.1 ±4.9 155.9 ±7.7 15.9 ±0.79 115.0 ±5.7
M16 × 2.0 207.9 ±10.4 21.2 ±1.06 153.3 ±7.7 241.2 ±12.1 24.6 ±1.23 177.9 ±8.9
M20 × 2.5 410.9 ±20.5 41.9 ±2.09 303.1 ±15.1 475.6 ±23.7 48.5 ±2.42 350.8 ±17.5
M 8 × 1.0 24.5 ±1.2 2.5 ±0.12 18.1 ±0.9 28.4 ±1.4 2.9 ±0.14 21.0 ±1.0
M10 × 1.25 50.0 ±2.5 5.1 ±0.25 36.9 ±1.8 58.8 ±2.9 6.0 ±0.30 43.4 ±2.2
M12 × 1.5 87.3 ±4.3 8.9 ±0.44 64.4 ±3.2 102.0 ±5.1 10.4 ±0.52 75.2 ±3.8
M14 × 1.5 135.3 ±6.8 13.8 ±0.69 99.9 ±5.0 157.9 ±7.8 16.1 ±0.80 116.5 ±5.8
M16 × 1.5 220.6 ±11.0 22.5 ±1.12 162.7 ±8.1 256.0 ±12.7 26.1 ±1.30 188.8 ±9.4
M20 × 1.5 452.1 ±22.6 46.1 ±2.30 333.4 ±16.6 524.7 ±26.1 53.5 ±2.66 387.0 ±19.2
General Tightening Points Special Tightening Points
N·m kgf·m ft-lb N·m kgf·m ft-lb
GENERAL
Torque
1. General Tightening Points (Non-lubricated)
• All securing points other than the special
tightening points.
2. Special Tightening Points (Grease with molybdenum disulfide applied.)
• Points where particularly necessary due to
function.
Special tightening positions and associated
instructions are given in the text.
3. Points where thread-locking compound is used
(Three Bond #1324 is applied.)
Thread-locking compound positions and associ
ated instructions are given in the text.
4. If tightening torque values are provided in this
manual, then tightening should be done according to those values.
(This indicates that the tightening torque differs
from the values given in this table.)
5. In order to tighten bolts and nuts evenly, they
should be tightened alternately top, bottom, left,
right.
-
I-13
Page 18
GENERAL
I-14
Page 19
II . SPECIFICATIONS
II-1
Page 20
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” and “Standards for Judging Performance” have the following
meanings.
Standard Value ............ This indicates the standard value for the new machine at the time of shipping from the
factory. It should be used as the target value for maintenance work after operation.
Allowable Value .......... The dimensions of parts change during use because of wear and deformation. Also, the
performance of pumps, motors, and other hydraulic equipment drops, and this is the
estimated value indicating the use limit for the respective part. It is decided under reference to the standard at the time of shipping, the results of various tests, etc. As the use
conditions, the degree of repairs, etc., differ for each machine, these should be combined
and used as reference for servicing standards and standards for judging performance.
* Do not use the standard values and the allowable values as standards for customer
claims.
II-2
Page 21
NAMES OF COMPONENTS
NAMES OF COMPONENTS
SPECIFICATIONS
4
5
1
7
6
9
2
3
12
19
17
16
14
15
10
1. Lift Arm
2. Control Valve
3. Hydraulic Tank
4. Canopy
5. Safety Bar
6. Pilot Valve (L. H.)
7. Pilot Valve (R. H.)
8. HST Pump
9. Bucket Cylinder
10. Fuel Tank
11
8
18
13
T7B001
11. Arm Cylinder
12. Travel Motor
13. Track Roller
14. Track
15. Idler
16. Quick-Hitch
17. Bucket
18. Control Valve (Sub)
19. Self-Level Valve
II-3
Page 22
SPECIFICATION DIAGRAMS
SPECIFICATION DIAGRAMS
Canopy Type
D
C
B
A
SPECIFICATIONS
Machine Dimensions
Unit: mm
Standard Bucket
Steel Tracks
L
K
H
J
M
E
G
F
T7K001A
A 3985
B 3135
C 1555
D 2350
E 355
F 1860
G 450
H 1570
J 985
K 1960
L 580
M 31°
G
Operating Range
Unit: mm
Standard Bucket
Steel Tracks
H
F
J
A 4255
B 3210
C 2440
D 795
E 1005
F 3865
G 2435
H 1560
E
J 1755
K 31°
A
C
B
K
D
T7K002A
II-4
Page 23
SPECIFICATION DIAGRAMS
Cab Type
C
B
A
SPECIFICATIONS
Machine Dimensions
Unit: mm
D
L
K
H
J
A 3985
B 3135
C 1555
D 2350
E 355
F 1860
G 450
H 1570
J 985
K 1960
M
E
G
F
T7K001A
L 580
M 31°
Standard Bucket
Steel Tracks
G
Operating Range
Unit: mm
Standard Bucket
Steel Tracks
H
F
J
A 4255
B 3210
C 2440
D 795
E 1005
F 3865
G 2435
H 1560
E
J 1755
K 31°
A
C
B
K
D
T7K002A
II-5
Page 24
SPECIFICATIONS TABLES
SPECIFICATIONS
Type Canopy
Standard Bucket Capacity
Rated Capacity m
Struck Capacity m
Machine Mass (not including operator) kg 5485
Dimensions
Overall Lenght: with bucket mm 3985
without bucket mm 3135
Overall Width: with bucket mm 1960
without bucket mm 1860
Overall Height mm 2350
Minimum Ground Clearance mm 355
Front Clearance Radius: with bucket mm 2435
without bucket mm 1560
Rear Clearance Radius mm 1755
Overall Width of Crawler mm 1860
Overall Length of Crawler mm 2150
Bucket Width mm 1960
Angle of Departure
Working Range
Maximum Lift Height to Bucket Pin mm 3210
Maximum Dumping Height mm 2440
Maximum Dump Angle Fully Raised
Maximum Bucket Rollback at Ground Level
Reach Fully Raised mm 1005
Performance
Breakout Force kN 38.5
Travel Speed 1st / 2nd km/h 5.8 / 8.3
Gradeability
Ground Pressure kPa 39.0
Tipping Load kg 3300
Cycle Time
Raise-Full Load (Lift Arm) Sec. 4.8
Lower-No Load (Lift Arm) Sec. 3.1
Dump-Full Load (Bucket) Sec. 3.3
Curl-Full Load (Bucket) Sec. 2.4
degree
degree
degree
degree
3
3
0.579
0.426
SPECIFICATIONSSPECIFICATIONS TABLES
31
39
31
30
II-6
Page 25
Type Cab
Standard Bucket Capacity
Rated Capacity m
Struck Capacity m
3
3
0.579
0.426
Machine Mass (not including operator) kg 5575
Dimensions
Overall Lenght: with bucket mm 3985
without bucket mm 3135
Overall Width: with bucket mm 1960
without bucket mm 1860
Overall Height mm 2350
Minimum Ground Clearance mm 355
Front Clearance Radius: with bucket mm 2435
without bucket mm 1560
Rear Clearance Radius mm 1755
Overall Width of Crawler mm 1860
Overall Length of Crawler mm 2150
Bucket Width mm 1960
Angle of Departure
degree
31
Working Range
Maximum Lift Height to Bucket Pin mm 3210
Maximum Dumping Height mm 2440
Maximum Dump Angle Fully Raised
Maximum Bucket Rollback at Ground Level
degree
degree
39
31
Reach Fully Raised mm 1005
Performance
Breakout Force kN 38.5
Travel Speed 1st / 2nd km/h 5.8 / 8.3
Gradeability
degree
30
Ground Pressure kPa 39.6
Tipping Load kg 3300
Cycle Time
Raise-Full Load (Lift Arm) Sec. 4.8
Lower-No Load (Lift Arm) Sec. 3.1
Dump-Full Load (Bucket) Sec. 3.3
Curl-Full Load (Bucket) Sec. 2.4
SPECIFICATIONSSPECIFICATIONS TABLES
II-7
Page 26
SPECIFICATIONSSPECIFICATIONS TABLES
SPECIFICATIONS OF DEVICES
Engine
Model Yanmar 4TNV106T-XTBL
Type
Number of Cylinders-Bore × Stroke
Total Displacement mL 4412
Compression Ratio 18.0
Performance
Rated Output kW/min
Maximum Torque N·m/min
Maximum No-load R.P.M.
Minimum No-load R.P.M.
Specific Fuel Consumption
min
min
g/kW·h 252 or less
Starter V–kW 12–3.0
Generator V–kW 12–0.72
Battery V–A·h 12–92
HST Pump
Model PVM4141
Type Variable displacement type double axial piston
Displacement cm
3
Delivery L/min 90.2 + 90.2
Relief Valve Pressure Setting MPa 34.5
Charge Relief Valve Pressure Setting
MPa 2.26 ±0.02
Gear Pump
Model SD1A4018E2H1-R211M
Type
Displacement cm
3
Delivery L/min 88.7 + 40.3
Gear Pump (High Flow)
Model KFP 2223ASFSX
Type Gear
Displacement cm
3
Delivery L/min 62
Control Valve
Model 07813-00010
Number of Circuits 3
Main Relief Valve Pressure Setting
Port Relief Valve Pressure Setting
MPa@L/min
MPa@L/min
Control Valve (High Flow)
Model 07930-0000A
Relief Valve Pressure Setting
MPa@L/min
Control Valve (Sub)
Model 07903-0000
Rated Flow L/min 41.6
Relief Valve Pressure Setting
MPa@L/min
4-Cycle, vertical, water-cooled, in-line, 4-cylinder diesel engine
mm 4-106 × 125
-1
-1
-1
-1
72.0/2200
361.6~394.0/1400 ±100
2380 ±25
1150 ±25
/rev 41.0 + 41.0
Tandem gear
/rev
40.3 + 18.3
/rev 22.9
20.6 @88
23.1 @88
20.6 @60
3.3 @40
II-8
Page 27
Pilot Valve (R. H.)
Model PV48K1262
Secondary Side Pressure MPa 0.49~1.96
Operating Angle
Pilot Valve (L. H.)
Model PV48K1261
Secondary Side Pressure MPa 0.49~1.91
Operating Angle
Pilot Valve (Auxiliary)
Model PV6P1013A
Secondary Side Pressure MPa 0.49~2.06
Self-Level Valve
Model 39055-EBV
Flow coefficient
Rated Flow L/min 88.0
Rated Pressure MPa 20.6
Maximum Working Pressure MPa 24.5
Cylinder
Arm
Bore Diameter × Rod Diameter
Stroke mm 760
Fully Retracted Length (Pitch)
Cushion Mechanism Both Ends
Bucket
Bore Diameter × Rod Diameter
Stroke mm 530
Fully Retracted Length (Pitch)
Cushion Mechanism
Travel Motor (DAIKIN)
Model BMVT51G
Type Piston Motor
Total Displacement
Motor Displacement
Reduction Gear Ratio 24.362
Parking Brake Torque N·m 363
Parking Brake Release Pressure MPa 1.5
Amount of Reduction Gear Lubricant
: Single (Ports 1, 3)
: Single (Ports 2, 4)
: Single degree 19
: Simultaneous degree 25
: Ports D 63%
: Ports B 37%
:1st / 2nd
:1st / 2nd
degree 19
degree 25
mm 75 × 45
mm 1185
mm 75 × 40
mm 850
cm3/rev 1242 / 848
cm3/rev 51.0 / 34.8
L 2.2
SPECIFICATIONSSPECIFICATIONS TABLES
±
II-9
Page 28
MASS TABLES
MASS TABLES
UNIT WEIGHT (DRY MASS)
Engine 340
Radiator 20
Radiator (High Flow) 38
Oil Cooler 23
Oil Cooler (High Flow)
HST Pump 84
Gear Pump 8
Gear Pump (High Flow) 5
Hydraulic Tank Assembly 51
Fuel Tank Assembly 28
Control Valve 10
Control Valve (High Flow) 12
Control Valve (Sub) 12
Pilot Valve :R. H. 2.3
:L. H. 2.3
Self-Level Valve 4.5
Canopy / Cab 220 / 270
Lift Arm 420
Quick-Hitch 81
Bucket 272
Arm Cylinder 39 × 2
Bucket Cylinder 28 × 2
Track 401 × 2
Travel Motor 86 × 2
Sprocket 15.5 × 2
Track Roller A 21.4 × 2
Track Roller B 28.8 × 8
Track Roller C 41.1 × 2
Idler Assembly 54.4 × 2
Track Adjuster 39.7 × 2
±
SPECIFICATIONS
Unit: kg
II-10
Page 29
RECOMMENDED LUBRICANTS
SPECIFICATIONS
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.
• Whenever possible, use the same brand of lubricant as before. If changing with a different brand, replace the
entire quantity – do not mix different brands.
Part Type
Engine oil pan
Hydlaulic tank
Diesel engine oil
API service CD
Diesel engine oil
API service CD
Fuel tank Diesel fuel
Engine cooling
system
Travel reduction gear
Track Roller A
Track Roller B
Coolant
(water+Coolant
Gear oil
API-GL-4
Diesel engine oil
API service CD
Type by temperature
-22 -4 14 32 50 68 86
-30 -20 -10 0 10 20 30
SAE 5W-20
SAE 10W-30
SAE 15W-40
SAE 10W-30
104°F
40°C
Replacement
interval
After first 50 hrs.
Every 250 hrs.
Every 1000 hrs.
Use a clean, Quality fuel for performance and optimum engine life.
• To prevent fuel flow problems in cold weather, use diesel fuel with a pour point of at least -12°C (10°F) below
the lowest expected ambient temperature.
• Minimum cetane number is 45. Low temperature or
high altitude operation may require the use of fuel with
a higher cetane number.
30% coolant mixture
)
50% coolant mixture
SAE 90
Every 1000 hrs.
After first 250 hrs.
Every 500 hrs.
SAE 30
±
Capacity
Upper limit:
14 L
Lower limit:
7 L
Total system:
95 L
Tank level:
64 L
Tank level:
108 L
15 L
2.2 L
180 mL
Track Roller C
Idler
Working equipment
Levers
If the percentage of the traveling time within the total operating time is high, replace the gear oil earlier than
Mobil gear
SHC 680
Lithium grease
EP-2
NLGI No. 2
±± ±
±± ±
±±
±±
Daily or erery
10 hrs.
When required
170 mL
170 mL
As required
the specified time.
For water, use tap water (soft). Do not use well or river water.
When the ambient temperature drops below 0°C, add coolant (antifreeze). Follow the coolant manufacture·s
instructions to determine the mixture ratio.
II-11
Page 30
SERVICE STANDARDS
TRAVEL SYSTEM
Track Roller A
SPECIFICATIONSSERVICE STANDARDS
Code Item Designated Standard
Basic Dimension Allowable Value
A Tread Outer Diameter 188 180
B Width of Tread 36.5 40.5
Basic
Dimension
Shaft and Bushing Bore
C
Diameter Clearance
Roller and Bushing Outer
D
Diameter Interference
Shaft End Play 0.7 1.2
40
44
Allowable Tolerance
Shaft Hole
-0.050
-0.075
+0.15
+0.10
Standard Value Allowable Value
±±±
+0.025
-0.020
Standard Allowable
0.075~
II-12
0.170
Unit: mm
Servicing
Procedure
Replace
±
Page 31
Track Roller B
SPECIFICATIONSSERVICE STANDARDS
Code Item Designated Standard
Basic Dimension Allowable Value
A Tread Outer Diameter 188 180
B Width of Tread 37.5 45.5
Allowable Tolerance
Shaft Hole
-0.050
-0.075
+0.15
+0.10
±±±
+0.025
-0.020
Standard Allowable
0.075~
Shaft and Bushing Bore
C
Diameter Clearance
Roller and Bushing Outer
D
Diameter Interference
Basic
Dimension
40
44
Standard Value Allowable Value
Shaft End Play 0.7 1.2
0.170
Unit: mm
Servicing
Procedure
Replace
±
II-13
Page 32
SERVICE STANDARDS
Track Roller C
SPECIFICATIONS
Code Item Designated Standard
Basic Dimension Allowable Value
A Tread Outer Diameter 300 292
B Width of Tread 36.5 40.5
Shaft and Bearing Bore
C
Diameter Interference
Roller and Bearing Outer
D
Diameter Interference
Basic
Dimension
40
68
Allowable Tolerance
Shaft Hole
0
-0.016
0
-0.016
0
-0.012
-0.014
-0.033
Standard
0.016
0.012
0.002
0.033
Standard Value Allowable Value
Shaft End Play 0.7 1.2
*: Maximum clearance **: Maximum interference
Fit
Allowable
Fit
±
±
Unit: mm
Servicing
Procedure
Replace
II-14
Page 33
SERVICE STANDARDS
Drive Sprocket
SPECIFICATIONS
Code Item Designated Standard
Basic Dimension Allowable Value
A Sprocket Teeth Profile Wear 14.4 6.4
B Sprocket Teeth Width 45 41
Unit: mm
Servicing
Procedure
Replace
C Sprocket Outer Diameter
Sprocket Teeth Lower Diameter
D
432
378.6 370.6
424
II-15
Page 34
Idler
SPECIFICATIONSSERVICE STANDARDS
Code Item Designated Standard
Basic Dimension Allowable Value
A Outer Diameter Tread 390 380
B Width of Tread 33.4 38.4
Allowable Tolerance
Shaft Hole
0
-0.011
0
-0.018
Standard Value Allowable Value
Shaft and Bearing Bore
C
Diameter Clearance
Idler and Bearing Outer
D
Diameter Interference
Basic
Dimension
45
85
0
-0.012
0
-0.035
Standard Allowable
0.011
0.012
0.018
0.035
Unit: mm
Servicing
Procedure
Replace
±
±
Shaft End Play 0.9 1.4
*: Maximum clearance **: Maximum interference
II-16
Page 35
Track Adjuster
SPECIFICATIONSSERVICE STANDARDS
Code Item Designated Standard
Basic Value Allowable Value
Length when Free mm 270
A Coil Spring Length when Installed mm 224.5
Set Load kN
41.5
B Check Valve Tightening Torque N·m 59
±
±
±
±
Unit: mm
Servicing
Procedure
Replace
Retighten
II-17
Page 36
SERVICE STANDARDS
Pin and Bushing Clearance
SPECIFICATIONS
Code Item Designated Standard
Basic
Dimension
A Lift Arm & Frame 45
B Arm Cylinder & Frame 45
C Arm Cylinder & Lift Arm 45
D Bucket Cylinder & Lift Arm 45
Bucket Cylinder & Quick-
E
Hitch
F Lift Arm & Quick-Hitch 45
45
Allowable Tolerance
Shaft Hole
-0.06
-0.09
-0.06
-0.09
-0.06
-0.09
-0.06
-0.09
-0.06
-0.09
-0.06
-0.09
+0.17
+0.12
+0.20
+0.05
+0.20
+0.05
+0.20
+0.05
+0.20
+0.05
+0.17
+0.12
Clearance
0.18~0.26 1.0
0.11~0.29 1.0
0.11~0.29 1.0
0.11~0.29 1.0
0.11~0.29 1.0
0.18~0.26 1.0
II-18
Standard
Unit: mm
Servicing
Procedure
Allowable
Clearance
Replace
Page 37
STANDARDS FOR JUDGING PERFORMANCE
STANDARDS FOR JUDGING PERFORMANCE
REFERENCE VALUE TABLE
Item Unit Standard Values Allowable Values
Engine Speed
Low min
High min
Hydraulic Oil Pressure
Travel MPa 34.3
Lift Arm MPa
Bucket MPa 20.6
Charge Pressure
Low MPa 2.0 ±0.3
Hight MPa 2.4 ±0.2
Pilot Pressure MPa 3.2 ±0.5
Travel
Travel Speed (5 rev.)
Low Speed s 14.8 ±0.6 16.9
Hight Speed s 10.1 ±0.5 12.0
Travel Speed (10 m)
Low Speed s 6.4 ±0.5 7.5
Hight Speed s 4.4 ±0.4 5.4
Travel Curve mm 125
Natural Travel Drop
Engages Parking Brake mm 0
Releases Parking Brake mm
Cylinders
Cylinder Speed
Arm Extended s 4.5 ±0.4 5.4
Retracted s 3.0 ±0.4 3.7
Bucket Extended s 3.2 ±0.4 3.9
Retracted s 2.5 ±0.4 3.2
Natural Cylinder Drop
Arm mm 8
Bucket mm 6
Bucket Tip mm 70
Levers
Lever Operating Force
Arm N 10 ±4
Bucket N 10 ±4
Travel N 10 ±4
Lever Play
Arm mm 4
Bucket mm 4
Travel mm 4
Track
Track Tension mm 175~195
Level of Front Edge of Bucket mm 10
-1
-1
SPECIFICATIONS
1130 ±70
2330 ±60
+5.9
0
±±
+1.1
-0.3
0
-125
±±
0
-8
0
-6
0
-70
0
-4
0
-4
0
-4
0
-10
±
±
±
±
±
±
±
500
±
16
12
200
±
±
II-19
Page 38
STANDARDS FOR JUDGING PERFORMANCE
METHODS FOR INSPECTING PERFORMANCE
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. Next start up the
hydraulic circuit to be tested and measure the relief pressure.
SPECIFICATIONS
-
Circuit
Pressure Detection Port
Port Position
Left Travel
(forward)
Right Travel (forward)
Lift Arm, Bucket
Relief
Size
Valve
P1 G1/4 R1
P2 G1/4 R2
P1
P2
C
T7B007
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.
Circuit
Arm, bucket
Pressure Detection Port
Port Position
P3
Size
9/16-
18UNF
Relief
Valve
R3
-
II-20
Page 39
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.
3. Operate the relief valve once more to confirm
that the pressure that has been set it stabilized.
Charge pressure
Measuring Method
• Engine : Idling/Maximum R.P.M.
• Hydraulic Oil Temp. : 50~60˚C
• Insert the pressure gauge into the pressure detec
tion port to measure the charge pressure.
SPECIFICATIONS
-
P1
C
-
Pressure Detection Port
Port Position
Size
CG1/4
Measuring the pilot pressure
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 pilot pressure.
Circuit
Bucket dump
Pressure Detection Port
Port Position
Size
P4 G1/4
P2
T7B007
-
II-21
Page 40
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. Be sure that you always perform this
operation in a stable, level location.
• Begin rotating the tracks of both right and left side
and count from the second rotation to measure the
time required until the tracks rotate a total of five
revolutions. (This test should be performed at the
same speed in which the machine was last operated.)
Travel Speed (10m)
• Engine : Maximum R.P.M.
• Hydraulic Oil Temp. : 50~60°C
• Measurement Posture : Travel Posture
• Set the machine in motion. Starting after a dis
tance of 5 meters, measure the time required to
travel 10 meters. Do this on level ground.
SPECIFICATIONS
-
Q Travel Posture
The arm and bucket cylinders should be retracted
as far as possible.
Travel Curve
• Engine : 1500 ±100 R.P.M.
• Hydraulic Oil Temp. : 50~60°C
• Measurement Posture : Travel Posture
• Starting after an approach of 5 meters, drive the
machine in a turn for 10 meters, then measure
the distance of X (5 m point). Do this on level
ground.
10m
X
II-22
2DAA12Z
Page 41
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.
Arm Cylinder Speed
• Engine : Maximum R.P.M.
• Hydraulic Oil Temp. : 50~60°C
• Measurement Posture : The bucket cylinders
should be retracted as far as possible.
• Measure the time required to raise the arm from a
fully retracted to a fully extended position. (This
time should not include the time allowed for operation of the cushion.)
SPECIFICATIONSSTANDARDS FOR JUDGING PERFORMANCE
Bucket Cylinder Speed
• Engine : Maximum R.P.M.
• Hydraulic Oil Temp. : 50~60°C
• Measurement Posture : Make sure that the bucket
pin (1) and the arm foot pin (2) are at the same
height.
• Then measure the time required for the bucket
cylinder to completely retract (extend) from a
fully extended state (retracted state).
Natural Cylinder Drop
Lift Arm, Bucket, Bucket Tip
• Engine : Maximum R.P.M.
• Hydraulic Oil Temp. : 50~60˚C
• Measurement Posture : Make sure that the bucket
pin (1) and the arm foot pin (2) are at the same
height and bring the bucket to a level position.
• Maintain this position for 10 minutes, then mea
sure the change in rod length and the distance the
bucket tip falls.
-
II-23
Page 42
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 gravity alone.
Arm Cylinder Speed
• Engine : Maximum R.P.M.
• Hydraulic Oil Temp. : 50~60°C
• Measurement Posture : The bucket cylinders
should be retracted as far as possible.
• Measure the time required to raise the arm from a
fully retracted to a fully extended position. (This
time should not include the time allowed for operation of the cushion.)
SPECIFICATIONS
-
Bucket Cylinder Speed
• Engine : Maximum R.P.M.
• Hydraulic Oil Temp. : 50~60°C
• Measurement Posture : Make sure that the bucket
pin (1) and the arm foot pin (2) are at the same
height.
• Then measure the time required for the bucket
cylinder to completely retract (extend) from a
fully extended state (retracted state).
Natural Cylinder Drop
Lift Arm, Bucket, Bucket Tip
• Engine : Maximum R.P.M.
• Hydraulic Oil Temp. : 50~60˚C
• Measurement Posture : Make sure that the bucket
pin (1) and the arm foot pin (2) are at the same
height and bring the bucket to a level position.
• Maintain this position for 10 minutes, then mea
sure the change in rod length and the distance the
bucket tip falls.
-
II-23
Page 43
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.
Lever Play
• Measure any discernible play at the tip of the le-
ver (pedal).
SPECIFICATIONSSTANDARDS FOR JUDGING PERFORMANCE
Track Tension
• In a stable, level location, lower the lift arm, tilt
the bucket forward, and lift the front of the tracks
slightly off the ground. Measure the distance between the bottom surface of the frame at the center track roller and the top surface of the track.
Level of Front Edge of Bucket
• Measurement Posture: The bucket should be in
a level position and the front edge of the bucket
should be fixed so that it is approximately 20 centimeters above the ground.
• Measure the difference “C” between the height of
the left and right front edges of the bucket from
the ground.
II-24
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
DRIVE SYSTEM
CONSTRUCTION
Engine Mount
MACHINE CONFIGURATIONDRIVE SYSTEM
A: 256 N·m; Apply thread-locking compound.
110 N·m; Apply thread-locking compound.
B:
C:
5.9 N·m
3.9 N·m
D:
III-3
1. Engine Foot FL
2. Engine Foot FR
3. Engine Foot RL
4. Engine Foot RR
5. Exhaust Pipe
6. Bracket
7. Silencer
8. Air Cleaner
9. Hose
10. Cushion Rubber
11. Ground Cable
Page 47
Radiator
MACHINE CONFIGURATIONDRIVE SYSTEM
A: 4.9 N·m
39.2 N·m
B:
III-4
1. Radiator
2. Radiator Hose (Upper)
3. Radiator Hose (Lower)
4. Sub Tank
5. Sensor
6. Oil Cooler
7. Drain Valve
8. Drain Hose
9. Drain Hose
10. Hose
11. Joint
12. O-Ring
Page 48
Engine Mount (High Flow)
Serial No. 21501587~
MACHINE CONFIGURATIONDRIVE SYSTEM
A: 256 N·m; Apply thread-locking compound.
110 N·m; Apply thread-locking compound.
B:
C:
5.9 N·m
3.9 N·m
D:
III-5
1. Engine Foot FL
2. Engine Foot FR
3. Engine Foot RL
4. Engine Foot RR
5. Exhaust Pipe
6. Bracket
7. Silencer
8. Air Cleaner
9. Hose
10. Cushion Rubber
11. Ground Cable
12. Bracket
Page 49
Radiator (High Flow)
Serial No. 21501587~
MACHINE CONFIGURATIONDRIVE SYSTEM
A: 4.9 N·m
39.2 N·m
B:
III-6
1. Radiator
2. Radiator Hose (Upper)
3. Radiator Hose (Lower)
4. Sub Tank
5. Sensor
6. Drain Valve
7. Drain Hose
8. Drain Hose
9. Hose
10. Joint
11. O-Ring
Page 50
Pump Coupling
MACHINE CONFIGURATIONDRIVE SYSTEM
1
X
C
G
A: Apply molybdenum disulfide grease.
210~230 N·m
B:
55 N·m
C:
116 N·m
D:
47.1 N·m; Apply thread-locking compound
E:
132 N·m
F:
69 N·m
G:
B
F
F
2
B
A
G
4
3
E
X
D
T7C102
1. Engine Housing
2. Coupling
3. HST Pump
4. Gear Pump
The pump coupling connects the engine flywheel and
the hydraulic pump·s drive shaft. It is constructed so
that it absorbs vibrations, torsions, impact and out of
center of the engine and hydraulic pump.
• Refer to the table concerning the responsibility of
each of the pumps shown in the drawing at right.
P1 Left Travel
P2 Right Travel
P3 Lift Arm, Bucket, Auxiliary
P4 Charge Pressure, Pilot Pressure
PTO High Flow
III-7
Page 51
Fuel Tank and Lines
MACHINE CONFIGURATIONDRIVE SYSTEM
III-8
1. Fuel Tank
2. Cap
3. Strainer
4. Drain Plug
5. Fuel Sender
6. Water Separator
7. Feed Pump
Page 52
Engine Control
MACHINE CONFIGURATIONDRIVE SYSTEM
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
DISASSEMBLY AND ASSEMBLY
MACHINE CONFIGURATIONDRIVE SYSTEM
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. Next, remove the bracket (1) together
with the air cleaner.
5. Remove the radiator.
“Removing the Radiator”
6. Disconnect the coolant drain hose (2).
7. Remove the hydraulic pump.
“Removing the Hydraulic Pump”
8. Remove the valves (3) and the filter (4).
9. Remove the fuel inlet pipe (5).
10. Disconnect the fuel hoses (6).
1
5
3
8
6
10
2
11
3
4
T7C105
6
T7C106
11. Disconnect the battery cable (7) and all the con-
nections on the engine side of the electric wir-
ings (8).
• Attach identification labels to individual wir
ings.
• Disconnect the wirings from the clamp and
the band.
12. Disconnect the engine ground cable (9).
13. Remove the bracket (10) and accelerator wire
(11) from the engine.
14. Remove the bolts (12) and then the cushion rubbers.
Bolt: 256N·m; Apply thread-locking com-
pound.
15. Suspend the engine temporarily, and remove the
engine.
Engine: 340 kg
Installing the Engine
Follow the same procedure as for removal in the
reverse order.
-
8
7
9
12
12
8
T7C107
T7C108
III-10
Page 54
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.
4. Remove the R-pins and pull out the pins (7).
MACHINE CONFIGURATIONDRIVE SYSTEM
2
5. Remove the radiator (3).
Installing the Radiator
Follow the same procedure as for removal in the
reverse order.
• The radiator should be mounted at right angles to
the main body frame and parallel to the cooling
fan.
3
1
T7C109
III-11
Page 55
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).
MACHINE CONFIGURATIONDRIVE SYSTEM
5
2
1
7
3. Disconnect the pressure switch connectors (3).
4. Disconnect the pilot hoses (4).
5. Disconnect the charge hose (5).
6. Disconnect the discharge hoses (6) and suction
hoses (7) from the gear pumps.
7. Remove the cap screws (8) and take out the hydraulic pump.
Cap Screw: 116 N·m
Apply molybdenum disulfide grease to the
spline section.
Installing the Hydraulic Pump
Follow the same procedure as for removal in the
reverse order.
2
6
3
4
4
5
7
T7C111
8
T7C112
Purging Air from the HST Pump
WARNING
When refitting the HST pump after repair or replacement, be sure to purge air before starting
the operation. Failure to do so can cause injury
or death due to unexpected machine movement.
1. Before installing the HST pump on the machine,
fill the servo control chambers with hydraulic
oil.
a. Plug the pilot ports (X1), (X2), (X11) and
(X12) temporarily.
b. Supply hydraulic oil through the servo pres
sure gauge ports (M4), (M5), (M14) and
(M15) to fill the servo control chambers.
-
III-12
Page 56
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 openings held above the pilot valves will make the
oil flow from only the pilot valves into the
tank.
4. Remove the plugs in the pilot ports (X1) and
(X11) and immediately connect the respective
hoses to those ports to prevent unnecessary loss
of hydraulic oil.
5. Remove the plugs in the pilot ports (X2) and
(X12) and connect the respective hoses to those
ports.
6. Connect the all remaining hoses to the pump.
X1
MACHINE CONFIGURATIONDRIVE SYSTEM
X1
X11
21
X11
T6C102
7. Supply hydraulic oil through the plug hole (1) to
fill the pump casing.
8. Start and run the engine at idle for about 5 minutes to purge air from the pump casing.
9. Slowly move the control levers to purge air from
the main and pilot lines.
III-13
Page 57
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”
MACHINE CONFIGURATION
3
5
5. Remove the suction pipe (2).
6. Loosen the drain cock (3) to drain out the fuel.
• Fuel tank capacity: 108 L
7. Disconnect the fuel sender connector (4).
8. Disconnect the fuel hoses (5) and the hose (6).
9. Loosen the bolts and nuts and remove the bands
(7).
10. Remove the fuel tank (8).
Fuel tank: 14 kg
Installing the Fuel Tank
Follow the same procedure as for removal in the
reverse order.
T7C113
5
651
2
7
4
7
8
T7C114
7
III-14
T7C115
Page 58
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).
• Make sure that the throttle lever (1) hits
against the stopper (5).
3. Secure the wire (2) with the wire lock pin (6).
4. Move the throttle lever (1) to the B (full throttle)
position and the governor control (4) to the D
(full throttle) position.
• Adjust the stopper (7) so that the throttle lever
(1) hits against the stopper (7), and tighten the
lock nut (8) to fasten the stopper.
MACHINE CONFIGURATION
Control Force
1. Loosen the lock nut (9), and turn the nut (10) to
adjust the control force.
Control force: 44.1 N
2. Upon completion of the adjustment, tighten the
lock nut (9) by holding the nut (10) to prevent it
from turning.
3. Operate the throttle lever (1) again, and make
sure that the control force is stable.
III-15
Page 59
TRAVEL SYSTEM
CONSTRUCTION
Track Roller A
MACHINE CONFIGURATIONTRAVEL SYSTEM
A: 241 N·m; Apply thread-locking compound.
Track Roller B
1. Roller
2. Shaft
3. Cover
4. Floating Seal
5. Snap Ring
6. O-ring
7. Oil Filler Plug
A: 241 N·m; Apply thread-locking compound.
1. Roller
2. Shaft
3. Cover
4. Floating Seal
5. Snap Ring
6. O-ring
7. Oil Filler Plug
III-16
Page 60
Track Roller C
MACHINE CONFIGURATIONTRAVEL SYSTEM
1. Idler
2. Shaft
3. Cover A
4. Cover B
5. Bearing
6. Floating Seal
7. Oil Filler Plug
A: 156 N·m; Apply thread-locking compound.
55 N·m; Apply thread-locking compound.
B:
C:
20 N·m
Idler
1. Idler
2. Shaft
3. Cover A
4. Cover B
5. Bearing
6. Floating Seal
7. Oil Filler Plug
A: 158 N·m; Apply thread-locking compound.
55 N·m; Apply thread-locking compound.
B:
20 N·m
C:
III-17
Page 61
TRAVEL SYSTEM
Track Adjuster
MACHINE CONFIGURATION
1. Yoke
2. Reach Rod
3. Spring
4. Piston
5. Cylinder
6.
Grease DischargeValve
A: 59 N·m
Travel Motor
1. Travel Motor
2. Sprocket
A: 241 N·m; Apply thread-locking compound.
III-18
Page 62
TRAVEL SYSTEM
DISASSEMBLY AND ASSEMBLY
MACHINE CONFIGURATION
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. If it is difficult
for the grease to come out, move the machine
forward and in reverse.
Grease discharge valve: 59 N·m
2. Remove the master bolts (2) and disconnect the
master links (3).
3. Place the wooden blocks (4) with a height of 20
cm under the cutting edge of the bucket and tilt
the bucket forward and lower the lift arms to
raise the machine front.
4. Suspend the machine rear and place a block (5)
under the machine rear.
5. Rotate the travel motor slowly in the reverse
direction to remove the track
Track: 401 kg
Installing the Steel Track
1. Place the wooden blocks (3) with a height of 20
cm under the cutting edge of the bucket and tilt
the bucket forward and lower the lift arms to
raise the machine front.
2. Suspend the machine rear and place a block (4)
under the machine rear.
3. Position the track beneath the frame.
• Be careful not to mistake the installation di-
rection of the track.
4. Engage the links in the sprocket, then rotate the
travel motor slowly in the forward direction to
wrap the track around the frame.
5. When the master link reachs a point just to the
top of the idler, stop rotating the sprocket and
lower the machine to the ground.
6. Connect the master links and install the shoe
plate and the master bolts.
Master bolt: 225±10 N·m
7. Adjust the track tension.
“II. Specifications, Standards for Judging
Performance”
III-19
Page 63
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. Tighten the roller (2) installation bolts (1) tem
porarily.
2. Bring the machine body in full contact with the
ground, then tighten the bolts.
Bolt: 241 N·m (track rollers A and B)
Bolt: 156 N·m (track roller C)
Apply thread-locking compound.
3. Raise the machine body, then adjust the track
tension.
MACHINE CONFIGURATION
-
Removing the Idler and Track Adjuster
1. Remove the track.
“Removing the Steel Track”
2. Pull out the idler (1).
Idler: 55 kg
3. Pull out the track adjuster·s track spring (2) and
the tensioning cylinder (3).
Track adjuster: 40 kg
Installing the Idler and Track Adjuster
Follow the procedure used for removal in reverse
order.
• Apply grease to the rubbing surfaces of the track
adjuster piston and cylinder.
III-20
Page 64
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).
4. Suspend the travel motor (3) temporarily and
remove the bolts (5).
Bolt: 241 N·m; Apply thread-locking com-
pound.
5. Suspend the travel motor (3) and remove it.
Travel motor: 86 kg
Installing the Travel Motor
Follow the procedure used for removal in reverse
order.
MACHINE CONFIGURATION
4
4
2
5
1
3
T7C307
III-21
Page 65
FRAME
CONSTRUCTION
Frame
MACHINE CONFIGURATIONFRAME
III-22
1. Frame
2. Under Cover A
3. Under Cover B
4. Cover L
5. Cover R
6. Under Cover C
7. Cover
8. Cover
Page 66
Floor Frame
MACHINE CONFIGURATIONFRAME
III-23
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
Page 67
Safety Bar
MACHINE CONFIGURATIONFRAME
III-24
1. Safety Bar
2. Bracket L
3. Bracket R
4. Stopper
5. Proximity Switch
6. Cover L
7. Cover R
8. Gas Spring
Page 68
Cover
MACHINE CONFIGURATIONFRAME
III-25
1. Rear Door
2. Engine Hood
3. Bracket
4. Plate
5. Plate
6. Plate
7. Pin
8. Gas Spring
9. Rod
10. Side Cover L
11. Side Cover R
12. Center Cover
13. Plate
Page 69
Canopy
MACHINE CONFIGURATIONFRAME
III-26
1. Canopy
2. Bolt Assembly
3. Cushion Rubber
4. Pin Assembly
5. Collar
6. Washer
7. Cushion Rubber
8. Washer
9. Gas Spring
10. Cushion Rubber
Page 70
Cab
MACHINE CONFIGURATIONFRAME
III-27
1. Cab
2. Bolt Assembly
3. Cushion Rubber
4. Pin Assembly
5. Collar
6. Washer
7. Cushion Rubber
8. Washer
9. Gas Spring
10. Cushion Rubber
Page 71
Tilting Up the Canopy
For inspection and maintenance, the canopy is designed 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.
• When the canopy is tilted up, support it firmly
with the stopper to prevent it from falling.
Raising (Tilt up)
1. Select a firm, level surface, lower the working
equipment to the ground, and stop the engine.
2. Set the safety bar to the lock position.
3. Remove a R-pin and remove the sopper pin
(B).
B
MACHINE CONFIGURATIONFRAME
A
4. Remove the lock bolts (A).
5. Solwly raise the canopy.
6. Insert the stopper pin (B) into the body·s holder
and insert a R-pin into the stopper pin·s hole to
fasten it in place.
If you need to run the engine while the canopy is
raised follow these steps.
7. Make sure that all levers and pedal are in neutral
positions.
8. Push the throttle lever to the low idling position.
9. Start the engine.
10. Be sure to stop the engine after inspection and
maintenance.
Lowering
1. Remove the sopper pin (B).
T9C407
B
2. Lower the canopy.
3. Tighten the lock bolts (A).
4. Reinsert the stopper pin (B) into the body·s
holder.
T9C408
III-28
Page 72
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).
• Apply thread-locking compound.
b. Remove the bolts (4) and pilot valve.
c. Remove the bolts and plate (5).
MACHINE CONFIGURATIONFRAME
1
3
5
2
4
T7C405
5. Remove the bolts and floor plate (6).
6. Remove the bolts and cover C (7).
7. Remove the bolts and cover R (8).
8. Remove the bolts and cover L (9).
Installing the Floor Frame
Follow the procedure used for removal in reverse
order.
7
8
9
6
T7C406
III-29
Page 73
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).
4. Open the rear door (5) to remove the oil cooler
hoses (6) and electrical wiring (7).
• Drain the oil from the tank.
“Remove the Hydraulic Tank”
5. Loosen the drain cock to drain out the fuel.
“Removing the Fuel Tank”
6. Disconnect the fuel hoses (8).
7. Lift up the rear door (5) with cables to remove
the pins and remove the rear door (5).
MACHINE CONFIGURATIONFRAME
1
4
2
3
T7C407
8. Remove the bolts and the center cover (9).
9. Remove the bolts and the side cover L (10).
10. Remove the bolts and the side cover R (11).
Installing the Covers
Follow the same procedure as for removal in the
reverse order
5
8
7
6
9
11
T7C408
10
T7C409
III-30
Page 74
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.
5. Disconnect the electric wiring (1) for the canopy.
6. Remove the gas springs (2) and installation
pins.
7. Lower the canopy and the lift arms to the
ground.
8. Remove the fixing bolts on the 2 rear positions
(B).
MACHINE CONFIGURATIONFRAME
A
B
T7C410
1
2
9. Suspend the canopy and remove it.
• Re-hook the suspender on the center of the
canopy to suspend the canopy at level.
Canopy: Approx. 150 kg
10. Remove the cushion rubber between the canopy.
Installing the Canopy
Follow the same procedure as for removal in the
reverse order.
T7C411
B
T7C412
III-31
Page 75
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. Using a damaged lift arm
stop or with missing parts can cause the lift
arms to drop causing injury or death.
Maintenance and service work can be done with the
lift arms lowered. If the lift arms are raised, use the
following procedures to engage and disengage an
approved lift arm stop.
Engagement
1. Park the machine on level ground and remove
the bucket.
2. Lower the lift arms to the ground and stop the
engine.
3. Remove the rear R-pin (4) from the locking pin
(1).
4. Support the lift arm stop (2) by hand and pull out
the locking pin (1).
MACHINE CONFIGURATIONFRAME
3
2
4
1
T9C409
5. Check that the spring (3) moves freely (i.e., is
disengaged from the hook (5)) and place the lift
arm stop (2) on the cylinder.
6. Sit in the seat, fasten the seat belt, start the engine and lower the safety bar.
7. Raise the lift arms slowly until the lift arm stop
(2) drops onto the cylinder rod.
8. Lower the lift arms slowly until the lift arm stop
is held between the lift arm and the end of the
cylinder tube.
9. Stop the engine.
10. Install the locking pin (1) into the rear of the lift
arm stop (2) below the cylinder rod.
11. Install the R-pin (4) to the locking pin (1).
5
3
2
T9C410
2
4
1
T9C411
III-32
Page 76
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).
MACHINE CONFIGURATIONFRAME
2
1
3. Hook the end part of the spring (3) onto the hook
(5) of the lift arm stop (2).
4. Sit in the seat, fasten the seat belt, start the engine and lower the safety bar.
5. Raise the lift arms slowly until the spring (3)
will lift the lift arm stop (2) off the cylinder
rod.
6. Lower the lift arms slowly to the ground and
stop the engine.
7. Raise the lift arm stop (2) into storage position
and insert the locking pin (1) through lift arm
stop and bracket.
8. Install the R-pin (4) to the locking pin (1).
5
3
4
T9C412
2
1
4
T9C413
III-33
Page 77
CONTROL SYSTEM
CONSTRUCTION
Hydraulic Pilot Unit (1/2)
MACHINE CONFIGURATIONCONTROL SYSTEM
zTable of Connectionsz
11
12
13
14
1P
Pa2 3
㲗
Pb1 3
㲗
Pb2 3
㲗
Pa1 3
㲗
11 4
㲗
1T㲗T2 5
21
22
23
24
2P
X1 6
㲗
X11 6
㲗
X2 6
㲗
X12 6
㲗
24
㲗
2T㲗T4 7
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. Shuttle Valve
III-34
Page 78
Hydraulic Pilot Unit (2/2)
MACHINE CONFIGURATIONCONTROL SYSTEM
zTable of Connectionsz
5A㲗B9
5B㲗Pb32 3
5P㲗12 4
5T1㲗T5 7
81㲗Pb31 3
82㲗A9
8P㲗13 4
8T㲗T2 4
9C㲗Pa3 3
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. Shuttle Valve
III-35
Page 79
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”
MACHINE CONFIGURATION
1
4
3. Remove the lever stand L.
a. Remove the cover (1).
b. Disconnect the hydraulic hoses (2) from the
pilot valve.
• Attach identification labels to individual
hoses for correct reassembling.
c. Disconnect the electric wiring (3).
e. Remove the bolts and bracket L (4).
4. Remove the lever stand R.
a. Remove the cover (5).
b. Disconnect the electric wiring (6).
c. Disconnect the hydraulic hoses (7) from the
pilot valve.
• Attach identification labels to individual
hoses for correct reassembling.
d. Disconnect the accelerator wire (8).
e. Remove the bolts and bracket R (9).
Installing the Lever Stands
Follow the same procedure as for removal in the
reverse order.
2
3
T7C502
8
5
6
9
7
T7C503
III-36
Page 80
ATTACHMENTS
ATTACHMENTS
CONSTRUCTION
4
MACHINE CONFIGURATION
5
1
2
3
T7C600
1. Bucket
2. Quick-Hitch
3. Lift Arm
4. Bucket Cylinder
5. Arm Cylinder
III-37
Page 81
Piping 1/2
MACHINE CONFIGURATIONATTACHMENTS
Piping 2/2
1. Bracket
2. Bracket
3. Bracket
4. Bracket
5. Pipe [Bucket]
6. Pipe [Bucket]
7. Pipe [Auxiliary]
8. Pipe [Auxiliary]
9. Control Valve
10. Self-Level Valve
11. Solenoid Valve
12. Stop Valve
13. Hydraulic Tank
14. Coupler
15. Pipe
III-38
Page 82
Piping (High Flow) 1/2
MACHINE CONFIGURATIONATTACHMENTS
Piping (High Flow) 2/2
1. Bracket
2. Bracket
3. Bracket
4. Bracket
5. Pipe [Bucket]
6. Pipe [Bucket]
7. Pipe [Auxiliary]
8. Pipe [Auxiliary]
9. Control Valve
10. Self-Level Valve
11. Solenoid Valve
12. Stop Valve
13. Hydraulic Tank
14. Control Valve (High Flow)
15. Gear Pump (High Flow)
16. Pipe
III-39
Page 83
ATTACHMENTS
DISASSEMBLY AND ASSEMBLY
General Cautions
• Always be sure to work on a stable, level sur
face.
• When disconnecting hydraulic hoses, be sure to
bleed off any residual pressure in the hoses.
• Plug openings which are opened up when piping
is disconnected to prevent dust and mud, etc. from
getting in.
• During assembly, be sure to adjust all the parts
with shims so that there will be no looseness in
the mounts.
• When aligning pin hole positions, absolutely do
not insert a finger in any pin holes.
• When fastening the lock bolt with double nuts,
maintain a clearance between the nuts and the
bushing of 0.5~1.0mm when tightening the double nuts.
MACHINE CONFIGURATION
-
• When all the hydraulic equipment such as hydraulic cylinders and piping have been removed and
the hydraulic cylinders are being operated for the
first time after reassembly, be sure the bleed the
air out of the hydraulic circuits by the following
procedure.
Air Bleeding Operation
1. Start the engine and let it idle for about 5 min
utes.
2. With the engine running at slow speed, extend
and retract the cylinders 4 or 5 times.
• Move the piston rods to a position 100 mm
before the end of the stroke, taking care not
to allow any relief whatsoever.
3. Perform the operation in (2) with the engine at
top speed, then with the engine at slow speed,
move the piston rods to the stroke end, allowing
relief.
-
0.5~1.0mm
C4C601
Removing the Quick-Hitch
• Bring the side of the quick-hitch that comes into
contact with the bucket down and into contact
with the ground.
1. Remove bucket pins (1) and (2) to remove the
quick-hitch (3).
Quik-Hitch: Approx. 81 kg
2. Remove the hydraulic hoses (4) from the bucket
cylinders (5).
3. Suspend the bucket cylinder (5) temporarily,
take out the pin (6) and remove the bucket cylinder.
Bucket Cylinder: Approx. 28 kg
Installing the Quick-Hitch
Follow the procedure used for removal in reverse
order.
1
2
1
2
3
T7C604
6
III-40
4
5
T7C605
Page 84
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).
• Set the arm cylinders onto a crosstie before
removing the pillow blocks (9).
4. Remove the arm foot pins (10), use a cable to lift
up the lift arms (7), and remove.
Lift Arm: Approx. 420 kg
5. Remove the head side pins (11) from the arm
cylinders (6) and the use a cable to lift up and
remove the lift arms.
Arm Cylinder: Approx. 39 kg
10
MACHINE CONFIGURATION
2
3
5
1
T7C606
4
7
Installing the Lift Arm
Follow the procedure used for removal in reverse
order.
11
6
9
8
T7C607
III-41
Page 85
ATTACHMENTS
INSPECTION AND ADJUSTMENT
Adjusting the Bucket Stopper
MACHINE CONFIGURATION
DANGER
When the lift arm is raised, never position yourself under it without making sure that the lift
arm is securely supported by the lift arm stopper.
For the adjustment, the pin hole (1) of the lift arm
must be supported by the arm stopper (2) at the
height of approximately 1600 mm above the ground.
The following arm stopper (2) and lock pin (3) must
be prepared for safety operation.
Arm Stopper (2)
Part Number Quantity
08819-63750 1
Lock Pin (3)
Part Number Quantity
08816-02700 1
WARNING
• Park the machine on a flat and solid ground
for work.
• Be sure to be seated on the cab when oper
ating the machine, including the starting and
stopping the engine.
• Set the engine speed to low when operating
the control lever.
-
Installing the Arm Stopper
Install the arm stopper (2) to support the lift arm in
place for adjusting the bucket stopper.
1. Park the machine on a flat and rigid ground, and
remove the bucket.
2. Lower the lift arm to its lowest position, and
stop the engine.
3. Hook the arm stopper (2) on the steel bar (4) of
the lift arm, and place it on the cylinder.
4. Start the engine, and raise the lift arm until the
arm stopper (2) falls on the cylinder rod.
III-42
Page 86
ATTACHMENTS
5. Lower the lift arm until the arm stopper (2) hits
against the edge of the cylinder tube and becomes 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.
7. Attach the R pin (5) to prevent the lock pin (3)
from falling off.
Adjusting the Bucket Stoppers
• Loosen the lock nuts (7) and screw in the stopper
bolts (8) fully.
1. Start the engine, slowly extend the bucket cylinders to the maximum length, and then stop the
engine.
MACHINE CONFIGURATION
2. Adjust the stopper bolts (8) so that their heads
touch the quick-hitch evenly.
3. Start the engine, retract the bucket cylinders to
the minimum length, and then stop the engine.
4. Turn the stopper bolts (8) counterclockwise (2/3
turns) to take their heads 1 mm out and tighten
the lock nuts (7).
• Stopper Bolt, Lock Nut: Apply thread-lock
ing compound.
-
III-43
Page 87
ATTACHMENTS
Adjusting the Arm Stopper
MACHINE CONFIGURATION
DANGER
When the lift arm is raised, never position yourself under it without making sure that the lift
arm is securely supported by the lift arm stopper.
The lift arm must be adjusted so that the frame
presses against the right and left stoppers (1) at the
same time when it is lowered.
WARNING
• Park the machine on a flat and solid ground
for work.
• Be sure to be seated on the cab when oper
ating the machine, including the starting and
stopping the engine.
• Set the engine speed to low when operating
the control lever.
-
1. Raise the lift arm, and securely lock it with the
lift arm stopper (2).
“III-28~28-2”
2. Remove the Allen bolts and then the stoppers
(1).
III-44
Page 88
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.
MACHINE CONFIGURATION
6. Measure and take note of the clearance A on the
right and the left side.
7. Install the stopper (1) and the shim (3) to each
of the right and left frames, and fasten them with
the Allen bolts.
• The shim must be such that the thickness of
the section B (27 mm thick) of the stopper (1)
plus the shim is one millimeter larger than the
clearance A measured in Step 3.
• Make sure that the lift arm presses against the
right and left stoppers at the same time.
• Allen bolts: Apply the thread-locking com
pound (ThreeBond #1324).
• Allen bolt tightening torque: 476 N·m
-
III-45
Page 89
HYDRAULIC SYSTEM
HYDRAULIC CIRCUIT DIAGRAM
.1B
BU-NJO
"
5
$0/530-7-7&
46#
-*/&'*-5&3
μ
MACHINE CONFIGURATIONHYDRAULIC SYSTEM
$0/530-7"-7&
."*/3&-*&'7"-7&4&513&4463&.1BBU-NJO
1*-057"-7&
"69
4)655-&
"
#
15
7"-7&
40-&/0*%
7"-7&
4)655-&
7"-7&
#1
"3. #6$,&5
1J 1J 1J
%6.1
-08&3
-0"%
3"*4&
" 1J 1J1J # #"
"69*-*"3:
"69"
"69#
3*()51*-057"-7&
10353&-*&'7"-7&4&513&4463&.1BBU-NJO
#
"
#5"
40-&/0*%7"-7&
)*()'-08
"69
-08'-08
$)&$,7"-7&
-NJO
-NJO
.1BBU-NJO
1
$0/530-7"-7&
5"1-
4&-'-&7&-7"-7&
"
#
$
#6$,&5$:-*/%&3
%
фYфYTU
3-
"3.$:-*/%&3
фYфYTU
40-&/0*%7"-7&
"%"15&3
-*/&'*-5&3
μ
.&4)
-&'51*-057"-7&
1 1
(&"316.1
1-NJO
1-NJO
9 9 ..9 9" ". .
/0
ф ф
.1B
BU-NJO
.1B
BU-NJO
.1B
BU-NJO
)4516.1
1-NJO
1-NJO
/0
.1B
BU-NJO
11
.1B
BU-NJO
##
"*3#3&"5)&3
46$5*0/453"*/&3
μ.&4)
(&"316.1
-NJO
&/(*/&
:"/."35/75
L8NJO
#"$,8"3%
"
3&%
3*()5
53"7&-.0503
#
'038"3%
53"7&-.0503
45
9
150
'038"3%
#"$,8"3%
/%DNYDN
"
#
DNYDN
3&%
-&'5
53"7&-.0503
0*-$00-&3
.1B
'*-5&3"44&.#-:
μ
III-46
5$
.1B
$)&$,7"-7&
):%3"6-*$5"/,
$"1"$*5:-
4:45&.$"1"$*5:-
Page 90
CONSTRUCTION
Hydraulic Tank
MACHINE CONFIGURATIONHYDRAULIC SYSTEM
A: 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
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 hydraulic oil.
3. It dissipates heat and lowers the oil temperature.
4. Volume of Hydraulic Oil.
Check the oil level with the arm cylinders and
bucket cylinders fully retracted and with the
bucket cutting edge lowered to the ground.
MACHINE CONFIGURATIONHYDRAULIC SYSTEM
Reference
If the amount of hydraulic oil is insufficient, the disturbances in the flow of oil can not be calmed, and
this will result in air bubbles getting in the hydraulic
oil. If these bubbles are sucked into the hydraulic
pumps, they could cause cavitation. Heat dissipation
time would also become shorter and would result in
a rise in the oil temperature.
If more than the specified amount of hydraulic oil is
supplied, the amount of air in the tank will become
small and changes in the oil level could cause the
pressure fluctuation in the tank to become severe.
III-48
Page 92
DISASSEMBLY AND ASSEMBLY
MACHINE CONFIGURATIONHYDRAULIC SYSTEM
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.
• Tank level capacity: 64 L
3. Disconnect the hydraulic hoses (3) from hydrau
lic tank.
Next remove the bushings.
• 6 hoses.
4. Disconnect the suction hoses (4) from the hy
draulic tank.
5. Remove the plug (5).
6. Remove the bolts, suction pipe (6) and flange
(7).
7. Remove the sight gauge (8).
1
8
9
-
T7C702
-
8. Remove the bolts (9).
Bolt: 47.1 N·m
Apply thread-locking compound.
9. Remove the bolts (10).
Bolt: 47.1 N·m
Apply thread-locking compound.
10. Suspend the tank (11) and remove it.
Tank: 51 kg
Installing the Hydraulic Tank
Follow the same procedure as for removal in the
reverse order.
III-49
Page 93
Filling with Hydraulic Oil
The oil level changes according to the oil temperature. 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. Fully retract the lift arm and bucket cylinders
and ground the bucket.
3. Stop the engine.
4. Inspect the oil level using the sight gauge (2).
• When the oil temperature is about 20°C:
The level should be halfway between the up
per limit (H) and lower limit (L).
If it is below the lower limit (L), replenish.
• When the oil temperature is about 50 to
80°C:
The level should be near the upper limit (H).
MACHINE CONFIGURATIONHYDRAULIC SYSTEM
2
H
L
-
T7G008A
Bleeding the air
After replacing the hydraulic oil, bleed the air
from the hydraulic circuit and hydraulic devices. Failure to do so may damage the hydraulic
devices.
Hydraulic pump
1. Tilt up the canopy.
2. Remove the plug (1) from the hydraulic pump.
3. Once hydraulic oil overflows from the plug hole,
connect the plug (1).
Cylinders
1. Start the engine and run it at low idle for 10 min
utes.
2. Set the engine to a low idle, then extend and
contract all the cylinders 4 or 5 times, without
going to the stroke end.
3. Run the engine at high speed, then extend and
contract all the cylinders 4 or 5 times, without
going to the stroke end.
1
T7G024A
-
4. Set the engine back to a low idle, then extend
and contract all the cylinders 4 or 5 times to the
stroke ends.
III-50
Page 94
ELECTRICAL SYSTEM
ELECTRICAL WIRING DIAGRAM
MACHINE CONFIGURATIONELECTRICAL SYSTEM
III-51
Page 95
Electricals
MACHINE CONFIGURATIONELECTRICAL SYSTEM
1. Relay Assembly
2. Wire Harness Assembly
3. Fusible Link
4. Diode
5. Fuse (10A)
6. Fuse (20A)
7. Fuse (30A)
III-52
8. Fuse (80A)
9. Wire Harness
10. Resistor
11. Horn
12. Buzzer
13. Heater Relay
14. Safety Relay
Page 96
Relay Assembly
MACHINE CONFIGURATIONELECTRICAL SYSTEM
III-53
1. Box
2. Resistor
3. Relay Assy
4. Timer Unit
5. Timer Unit
6. Relay
7. Detector
8. Relay
Page 97
AIR CONDITIONER SYSTEM
Compressor Assembly (1/4)
MACHINE CONFIGURATIONAIR CONDITIONER SYSTEM
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
pressed with a force of about 98N.
C: Apply thread-locking compound.
III-54
1. Pulley
2. Valve
3. Bracket
4. Shaft
5. Collar
6. Compressor
7. Pulley
8. Belt
9. Hose
10. Adapter
11. Elbow
12. Valve
13. Shim
Page 98
Compressor Assembly (2/4)
MACHINE CONFIGURATIONAIR CONDITIONER SYSTEM
III-55
1. Hose
2. Hose
3. Hose
4. Hose
5. Bracket
6. Receiver-Dryer
7. Pressure Switch
8. Condenser
9. Wire Harness
Page 99
Compressor Assembly (3/4)
MACHINE CONFIGURATIONAIR CONDITIONER SYSTEM
A: 1.8 N·m
B: Apply thread-locking compound.
1. Cover
2. Cover
3. Cover
4. Bracket
5. Bracket
6. Bracket
7. Air Conditioner Unit
8. Panel
III-56
9. Control Cable
10. Tube
11. Box
12. Tube
13. Louver
14. Adapter
15. Cushion Rubber
Page 100
Compressor Assembly (4/4)
MACHINE CONFIGURATIONAIR CONDITIONER SYSTEM
III-57
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
Loading...