Takeuchi TB138FR Compact Excavator Service Repair Workshop Manual (Serial No. 138200001 and up)
- 2. 0-2 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 im- prove 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 dozer blade 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 operatorʼs 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.
- 3. 0-3 I . GENERAL II . SPECIFICATIONS III. MACHINE CONFIGURATION IV. HYDRAULIC UNITS V . TROUBLESHOOTING VI. ENGINE
- 5. GENERAL I-2 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
- 6. I-3 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” and “CAUTION”. These signal words mean the following: The word “DANGER” indi- cates an imminently hazard- ous situation which, if not avoided, can result in serious injury or death. DANGER The word “WARNING” indi- cates a potentially hazardous situation which, if not avoided, could result in serious injury or death. WARNING The word “CAUTION” indi- cates a potentially hazardous situation which, if not avoided, may result in minor or moder- ate injury. CAUTION 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 mainte- nance 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. 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 pro- tective equipment as required by job conditions. Wear required appropriate equipment such as safety glasses and filter mask when using grind- ers, hammers or compressed air, as metal frag- ments 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.
- 7. I-4 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. Use the correct tools Do not use damaged or weakened tools or tools de- signed for other purposes. Use tools suited for the operation at hand. Replace important safety parts periodi- cally • Replace fuel hoses periodically. Fuel hoses be- come weaker over time, even if they appear to be in good shape. • Replace important safety parts whenever an ir- regularity is found, even if it is before the normal time for replacement. 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 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.
- 8. I-5 GENERAL Always clean the machine • Clean the machine before performing mainte- nance. • Cover electrical parts when washing the machine. Water on electrical parts could cause short-cir- cuits or malfunctions. Do not use water or steam to wash the battery, sensors, connectors or the operatorʼs seat area. Stop the engine before performing main- tenance • 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 operatorʼs seat while the other works on the machine. • When performing maintenance, be sure to keep your body and clothing away from mov- ing parts. Stay clear of moving parts • Stay clear of all rotating and moving parts. Wrap- ping or entanglement may result in serious injury or death. • Keep hands, clothing and tools away from the rotating fan and running fan belts. Securely block the machine or any com- ponent that may fall • Before performing maintenance or repairs under the machine, set all 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 un- der 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 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.
- 9. I-6 GENERAL Cautions on working on the machine • When performing maintenance on the machine, clean up the foot area and strictly observe the fol- lowing 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 • Do not smoke or permit open flames while fuel- ing 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 manufacturerʼs approved cap. Use of a non-ap- proved cap without proper venting may result in pressurization of the tank. • Never use fuel for cleaning purposes. • Use the correct fuel grade for the operating sea- son. 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. Touch- ing 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 spurt- ing out. 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.
- 10. I-7 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 accu- mulator 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 Takeuchi sales or service agent. Be careful with grease under pressure 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 electri- cal system or doing any welding. Remove the nega- tive (–) battery cable first. When reconnecting the battery, connect the negative (–) battery cable last.
- 11. I-8 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. Al- ways 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. Have a Takeuchi service agent repair welding cracks or other damage Ask a Takeuchi service agent to repair any welding problems which are detected. If not feasible, make sure the welding is done by a qualified person in a properly equipped workplace. Safety signs • Keep all safety signs clean and legible. • Replace all missing, illegible or damaged safety and warning signs. 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 con- tainers. 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.
- 12. I-9 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. 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. 10. When fitting the snap rings, the bigger, rounder side of their circumferences should face the mating surfaces. CAUTIONS DURING REMOVAL AND INSTALLA- TION 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 in- ternal 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. 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 hy- draulic cylinder should be done with the rod fully retracted. 7. Be sure to bleed the air after replacing the hy- draulic oil or removing any of the hydraulic devices. “III. Machine Configuration, Hydraulic System”
- 13. I-10 GENERAL CAUTIONS DURING REMOVALAND INSTAL- LATION 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. 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.
- 14. GENERAL I-11 TIGHTENING TORQUES Hydraulic Hoses Bite Type Pipe Fitting for Steel Pipe Pipe Outer Diameter (mm) Torque 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 Hose Fitting Size Torque Union Nut (G) Taper Thread (R) N·m ft-lb N·m ft-lb 1/8 9.8 +4.9 7.3 +3.5 11.8 ±1.2 8.7 ±0.8 1/4 24.5 +4.9 18.1 +3.5 29.4 ±2.9 21.7 ±2.1 3/8 49 +4.9 36.2 +3.5 53.9 ±5.4 39.8 ±3.9 1/2 58.8 +4.9 43.4 +3.5 88.3 ±8.8 65.1 ±6.4 3/4 117.7 +4.9 86.8 +3.5 147.1 ±14.7 108.5 ±10.7 1 137.3 +4.9 101.3 +3.5 196.1 ±19.6 144.7 ±14.3 0 0 0 0 0 0 0 0 0 0 0 0
- 15. GENERAL I-12 Joints for Piping Joints for Piping (O-ring Seal Type) Nominal Thread Diameter (R) Torque 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 Nominal Thread Diameter (G) Torque N·m ft-lb 1/8 19.6 ±2.0 14.5 ±1.4 1/4 34.3 ±4.9 25.3 ±3.5 3/8 53.9 ±4.9 39.8 ±3.5 1/2 63.7 ±4.9 47.0 ±3.5 3/4 93.2 ±4.9 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 Nominal Thread Diameter (UNF) Torque N·m ft-lb 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
- 16. I-13 GENERAL Bolts and Nuts (for ISO Strength Category 10.9) 1. General Tightening Points (Non-lubricated) • All securing points other than the special tightening points. 2. Special Tightening Points (Grease with molyb- denum 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. Thread Size × Pitch Torque General Tightening Points Special Tightening Points N·m kgf·m ft-lb N·m kgf·m ft-lb Coarse 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 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 Fine 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 4. If tightening torque values are provided in this manual, then tightening should be done accord- ing 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.
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- 19. II-2 SPECIFICATIONS 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 esti- mated 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. CONTENTS Names of components..............................................................................................................................................3 Dimensions ..............................................................................................................................................................4 Specifications tables.................................................................................................................................................5 Mass tables.............................................................................................................................................................10 Recommended lubricants.......................................................................................................................................11 Servicing standards................................................................................................................................................13 Standards for judging performance........................................................................................................................16 Reference value table ......................................................................................................................................16 Methods for inspecting performance...............................................................................................................18 Hydraulic Circuit diagram .....................................................................................................................................29 Electrical wiring diagram.......................................................................................................................................30
- 20. II-3 SPECIFICATIONS NAMES OF COMPONENTS NAMES OF COMPONENTS 1. Cab 2. Engine hood 3. Fuel tank 4. Hydraulic tank 5. Hydraulic pump 6. Slew motor 7. Pilot valve 8. Battery 9. Control valve 10. Left link arm 11. Engine 12. Crawler belt 13. Idler 14. Track roller 15. Carrier roller 16. Travel motor 17. Right link arm 18. Track adjuster 19. Swivel joint 20. Bucket 21. Bucket cylinder 22. Arm 23. Arm cylinder 24. Boom 25. Boom cylinder 26. Boom bracket 27. Offset cylinder 28. Dozer blade 29. Dozer blade cylinder