Takeuchi tb180 fr hydraulic excavator service repair workshop manual (serial no. 17830004 and up)
- 2. 0-2 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 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 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.
- 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. GENERAL I-3 Observe all safety rules • Operation, inspection and maintenance of this ma- chine must be performed only by a trained and qualified person. • All rules, regulations, precautions and safety pro- cedures must be understood and followed when performingoperation,inspectionandmaintenance of this machine. • Do not perform any operation, inspection and maintenance of this machine when under the ad- verse influence of alcohol, drugs, medication, fa- tigue, 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. 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: 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 notnecessarilycoverallsafetymeasures.Formaintenancework,eachpersonmusttakeadequatesafetyprecautions against possible hazards present in the respective working environment. Theword“DANGER”indicates an imminently hazardous situ- ationwhich,ifnotavoided,can resultinseriousinjuryordeath. DANGER The word “WARNING” indi- cates a potentially hazardous situation which, if not avoided, could result in serious injury or death. The word “CAUTION” indi- cates a potentially hazardous situation which, if not avoided, may result in minor or moder- ate injury. CAUTIONWARNING • Wear a hard hat, safety shoes, safety glasses, filter mask, heavy gloves, ear protection and other pro- tective equipment as required by job conditions. Wearrequiredappropriateequipmentsuchassafety glasses and filter mask when using grinders, ham- mers 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. SAFETY PRECAUTIONS
- 7. GENERAL I-4 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 in- spection 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 designed for other purposes. Use tools suited for the operation at hand. Replace important safety parts periodically • 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. GENERAL I-5 Always clean the machine • Cleanthemachinebeforeperformingmaintenance. • 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. 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 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 espe- cially important when working on hydraulic cylin- ders. Securely block the working equipment Topreventunexpectedmovement,securelyblockthe 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. Cautions on tilting up the platform • Raising or lowering the platform 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 platform. • When the floor is tilted up, support it firmly with the stopper to prevent it from falling.
- 9. GENERAL I-6 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. Use caution when fueling • Do not smoke or permit open flames while fueling or near fueling operations. • Neverremovethefuelcaporrefuelwiththeengine running or hot. Never allow fuel to spill on hot machine components. • Maintain control of the fuel filler nozzle when filling the tank. • Donotfillthefueltanktocapacity.Allowroomfor 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-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 season. Handling of hoses Fuel, oil or hydraulic fluid leaks can cause a fire. • Do not twist, bend or hit the hoses. • Neverusetwisted,bentorcrackedhoses,tubesand 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, slid- ing 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. 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 radiatorcoolandloosentheradiatorcapordrainplugs slowly.
- 10. GENERAL I-7 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 hydrau- lic 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 disconnecting hoses, stand to the side and loosen slowly to gradu- ally release the internal pressure before removing. Handling of the Accumulator Highpressurenitrogengasisenclosedintheaccumu- lator 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 theenclosedgas.PleasecontactaTakeuchisalesor service agent. Be careful with grease under pressure Thetrackadjustercontainshighlypressurizedgrease. If the tension is adjusted without following the pre- scribedprocedure,thegreasedischargevalvemayfly 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. N0A005
- 11. GENERAL I-8 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. • Ifacidcontactsskinorclothing,washoffimme- diately with clean water. • Wearsafetyglassesandgloveswhenworkingwith batteries. • Batteries generate flammable and explosive gases. Keep arcs, sparks, flames and lighted tobacco away. • Use a flashlight to check battery electrolyte level. • Stop the engine and shut off electrical equipment while inspecting or handling the battery. • Do not short circuit the battery posts with metal items. • Alwaysunfastenthenegative(–)batterycablefirst whendisconnectingthebatterycable.Alwayscon- nectthenegative(–)batterycablelastwhenfasten- ing 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 contain- ers. 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. GENERAL I-9 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 thehydraulicunittopreventdirtfromgettinginto 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 hydrau- lic cylinder should be done with the rod fully retracted. 7. Besuretobleedtheairafterreplacingthehydrau- lic oil or removing any of the hydraulic devices. “III.MachineConfiguration,HydraulicSys- tem” CAUTIONS DURING DISASSEMBLY AND ASSEMBLY 1. Clean the machine before disassembly operation. 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. Tomakereassemblyoperationseasy,makematch- ing 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. Keeppartswhichshouldnotcomeincontactwith oilandwaterseparatefrompartswithoilonthem. • 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 mat- ing surfaces. SEALING TAPE LEAVE 1 OR 2 THREAD MARGIN PLUG PLUG
- 13. GENERAL I-10 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. • Thisistopreventwearwhenitisfirststartedup after assembly. GREASE 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. Afterinstallationofhydraulichosesorsteelpipes, applythemaximumworkingpressure5or6times and confirm that there is no leakage. BURR DIRT
- 14. GENERAL I-11 1/8 1/4 3/8 1/2 3/4 1 Hose Fitting Size Torque Union Nut (G) Taper Thread (R) N·m ft-lb N·m ft-lb 11.8 ±1.2 29.4 ±2.9 53.9 ±5.4 88.3 ±8.8 147.1 ±14.7 196.1 ±19.6 8.7 ±0.8 21.7 ±2.1 39.8 ±3.9 65.1 ±6.4 108.5 ±10.7 144.7 ±14.3 9.8 +4.9 24.5 +4.9 49 +4.9 58.8 +4.9 117.7 +4.9 137.3 +4.9 7.3 +3.5 18.1 +3.5 36.2 +3.5 43.4 +3.5 86.8 +3.5 101.3 +3.5 8 10 12 15 16 18 22 27.2 28 32 35 Pipe Outer Diameter (mm) Torque N·m ft-lb 34.3 ±4.9 41.7 ±2.5 58.8 ±4.9 88.3 ±4.9 93.2 ±4.9 132.4 ±4.9 205.9 ±9.8 245.2 ±9.8 313.8 ±19.6 313.8 ±19.6 411.9 ±19.6 25.3 ±3.5 30.7 ±1.7 43.4 ±3.5 65.1 ±3.5 68.7 ±3.5 97.6 ±3.5 151.8 ±7.2 181.0 ±7.2 231.4 ±14.3 231.4 ±14.3 303.7 ±14.3 0 0 0 0 0 0 0 0 0 0 0 0 UNION NUT TAPER THREAD TIGHTENING TORQUES Hydraulic Hoses Bite Type Pipe Fitting for Steel Pipe
- 15. GENERAL I-12 1/8 1/4 3/8 1/2 3/4 1 Nominal Thread Diameter (R) Torque Steel Cast Steel N·m ft-lb N·m ft-lb 11.8 ±1.2 29.4 ±2.9 53.9 ±5.4 88.3 ±8.8 147.1 ±14.7 196.1 ±19.2 8.7 ±0.8 21.7 ±2.1 39.8 ±3.9 65.1 ±6.4 108.5 ±10.7 144.7 ±14.3 10.8 ±1.1 24.5 ±2.5 49 ±4.9 73.5 ±7.4 127.5 ±12.7 171.6 ±17.2 8.0 ±0.7 18.1 ±1.7 36.2 ±3.5 54.3 ±5.3 94.1 ±9.3 126.6 ±12.5 Nominal Thread Diameter (G) Torque N·m ft-lb 1/8 1/4 3/8 1/2 3/4 1 1-1/4 1-1/2 19.6 ±2.0 34.3 ±4.9 53.9 ±4.9 63.7 ±4.9 93.2 ±4.9 107.9 ±9.8 117.7 ±9.8 137.3 ±9.8 14.5 ±1.4 25.3 ±3.5 39.8 ±3.5 47.0 ±3.5 68.7 ±3.5 79.5 ±7.2 86.8 ±7.2 101.2 ±7.2 Nominal Thread Diameter (UNF) Torque N·m ft-lb 7/16–20 1/2–20 9/16–18 3/4–16 1-1/16–12 1-5/16–12 1-5/8–12 16.7 ±2.0 22.6 ±2.0 31.4 ±2.9 59.8 ±4.9 102.0 ±5.9 135.3 ±7.8 181.4 ±9.8 12.3 ±1.4 16.6 ±1.4 23.1 ±2.1 44.1 ±3.5 75.2 ±4.4 99.8 ±5.8 133.8 ±7.2 O-RING Joints for Piping Joints for Piping (O-ring Seal Type)
- 16. GENERAL I-13 Thread Size × Pitch Torque General Tightening Points Special Tightening Points N·m kgf·m ft-lb N·m kgf·m ft-lb Coarse Fine M 6 × 1.0 M 8 × 1.25 M10 × 1.5 M12 × 1.75 M14 × 2.0 M16 × 2.0 M20 × 2.5 M 8 × 1.0 M10 × 1.25 M12 × 1.5 M14 × 1.5 M16 × 1.5 M20 × 1.5 9.8 ±0.5 22.6 ±1.1 47.1 ±2.4 83.4 ±4.1 134.4 ±6.7 207.9 ±10.4 410.9 ±20.5 24.5 ±1.2 50.0 ±2.5 87.3 ±4.3 135.3 ±6.8 220.6 ±11.0 452.1 ±22.6 1.0 ±0.05 2.3 ±0.11 4.8 ±0.24 8.5 ±0.42 13.7 ±0.68 21.2 ±1.06 41.9 ±2.09 2.5 ±0.12 5.1 ±0.25 8.9 ±0.44 13.8 ±0.69 22.5 ±1.12 46.1 ±2.30 7.2 ±0.4 16.6 ±0.8 34.7 ±1.7 61.5 ±3.0 99.1 ±4.9 153.3 ±7.7 303.1 ±15.1 18.1 ±0.9 36.9 ±1.8 64.4 ±3.2 99.9 ±5.0 162.7 ±8.1 333.4 ±16.6 11.8 ±0.6 26.5 ±1.3 54.9 ±2.7 97.1 ±4.8 155.9 ±7.7 241.2 ±12.1 475.6 ±23.7 28.4 ±1.4 58.8 ±2.9 102.0 ±5.1 157.9 ±7.8 256.0 ±12.7 524.7 ±26.1 1.2 ±0.06 2.7 ±0.13 5.6 ±0.28 9.9 ±0.49 15.9 ±0.79 24.6 ±1.23 48.5 ±2.42 2.9 ±0.14 6.0 ±0.30 10.4 ±0.52 16.1 ±0.80 26.1 ±1.30 53.5 ±2.66 8.7 ±0.4 19.5 ±0.9 40.5 ±2.0 71.6 ±3.5 115.0 ±5.7 177.9 ±8.9 350.8 ±17.5 21.0 ±1.0 43.4 ±2.2 75.2 ±3.8 116.5 ±5.8 188.8 ±9.4 387.0 ±19.2 1. General Tightening Points (Non-lubricated) • Allsecuringpointsotherthanthespecialtight- ening 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. 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. Bolts and Nuts (for ISO Strength Category 10.9)
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- 19. SPECIFICATIONS II-2 CONTENTS Names of Components .......................................................................................................................................... 3 Specification Diagrams ......................................................................................................................................... 4 Specification Tables .............................................................................................................................................. 5 Mass Tables ......................................................................................................................................................... 11 Recommended Lubricants ................................................................................................................................... 12 Servicing Standards ............................................................................................................................................. 13 Standards for Judging Performance..................................................................................................................... 16 Reference Value Table .................................................................................................................................. 16 Methods for Inspecting Performance ............................................................................................................ 18 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 ......... Thisindicatesthestandardvalueforthenewmachineatthetimeofshippingfromthefactory. 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.
- 20. SPECIFICATIONS II-3 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. Pilotvalve(Offset) 20. Swivel joint 21. Bucket 22. Bucket cylinder 23. Arm 24. Arm cylinder 25. Boom 26. Boom cylinder 27. Boom bracket 28. Offset cylinder 29. Dozer blade 30. Dozer blade cylinder 31. Pilot valve (Travel)