Takeuchi TL230 Track Loader Service Repair Workshop Manual (Serial No. 223000001 and up).pdf

FOREWORD
This manual, which is written for engineers who service the machine, describes procedures for disassembly and assembly,
inspection and maintenance, and troubleshooting, as well as maintenance reference values and an outline of the specifica-
tions. Refer to this manual during daily work to improve your services. Note that the information is subject to change without
notice due to design modifications made to the machine from time to time by the manufacturer.
Directional terms: front, rear, left, right
In this manual, the “front” refers to the end of the machine where the bucket is mounted, while the “rear” refers to the other
end where the travel motor is mounted. The “right” or “left” refers to the side viewed by a person sitting in the operator’s
seat.
Machine serial number
The machine serial number is stamped on the identification plate. Be sure to include this number when sending a report or
inquiry or when ordering parts.
Control of manual
Appoint a person in charge of keeping the manuals up to date in your company and inform us of the person’s name for our
records. Any revisions or additions to this manual will be sent to the person.
Symbols used in this manual
The symbols used in this manual have the following meanings.
Indicates the machine serial number.
Means “Refer to the section quoted.”
Indicates the mass of the equipment or machine.
Means “Tighten to the torque specified here.”
Indicates the use of thread-locking compound.
Indicates the use of grease.
Manual structure
This manual consists of the following parts.
1. Safety
2. Service data
3. Function
4. Disassembly and assembly
5. Troubleshooting
6. Engine

1-1
SAFETY 1
Safety alert symbol ...................................................... 1-2
Safety precautions....................................................... 1-3
Cautions when working ............................................... 1-9

1-2
1
SAFETY
SAFETY ALERT SYMBOL
This symbol represents the safety alert.
The message that follows the symbol
contains important information regard-
ing human safety.
Read and understand the message to
avoid personal injury or death.
Safety label
Safety labels are used to alert operators or other people
exposed to the risks of injury or damage. There are the fol-
lowing three types of labels.
Read the labels carefully as they are important for your
safety.
DANGER
The word “DANGER” indicates an imminently hazard-
ous situation which, if not avoided, is likely to result in
serious injury or death.
WARNING
The word “WARNING” indicates a potentially hazard-
ous situation which, if not avoided, could result in seri-
ous injury or death.
CAUTION
The word “CAUTION” indicates a potentially hazard-
ous situation which, if not avoided, may result in minor
or moderate injury.
IMPORTANT: The word “IMPORTANT” is used to alert
operators and maintenance personnel about situations
which could result in 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. It is also impossible
to cover all hazards and risks which may be associated
with the maintenance of the machine in every environment.
For maintenance work, each person must take adequate
safety precautions against possible hazards in the respec-
tive working environment.
SAFETY ALERT SYMBOL

1-3
1
SAFETY PRECAUTIONS
SAFETY
SAFETY PRECAUTIONS
Observe all safety rules
• Operation, inspection and maintenance of this machine
must be performed only by a trained and qualified per-
son.
• All rules, regulations, precautions and safety procedures
must be understood and followed when performing op-
eration, inspection and maintenance of this machine.
• Do not perform any operation, inspection or mainte-
nance of this machine when under the influence of alco-
hol, drugs, medication, fatigue or insufficient sleep.
Wear safe clothing and protective gear
• Do not wear loose clothing or any accessory that can
catch on the controls or the moving parts of the ma-
chine.
• Do not wear clothing stained with oil or grease that can
easily catch fire.
• Wear protective gear such as helmet, safety shoes, pro-
tective goggles, respirator, gloves and earmuffs, as ap-
propriate, depending on the work involved. Especially
make sure to wear protective eye-wear and mask when
working with a grinding/polishing/sanding machine,
hammer or compressed air, as metal fragments or other
objects could scatter in such an environment.
• Wear hearing protectors when operating the machine.
Loud and prolonged noise can damage or destroy your
hearing.
Install an extinguisher and a first aid kit
• Install an extinguisher to fight a fire, and learn how to use
it.
• Prepare a first aid kit and keep it at a designated place.
• Decide on the procedures to be used in case of fire or
other hazards.
• Decide on and take note of the contact(s) in case of
emergency.
Place a “Do not operate” alert sign
Serious injury or death may result if an unauthorized person
starts the engine or touches the controls during inspection
or maintenance.
• Before performing maintenance, stop the engine, re-
move the key and store it in a safe place.
• Prominently display a “Do not operate” alert sign on
places such as the starter switch and the control lever.
Place another sign outside of the machine as neces-
sary.
Use the correct tools
Do not use damaged or weakened tools or tools designed
for other purposes. Use only the correct tools for the work
involved.
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1-4
1
SAFETY PRECAUTIONS
SAFETY
Regularly replace the safety-critical parts
• Regularly replace fuel hoses to prevent a fire hazard.
Hoses wear out over time, even if they do not show any
symptom of wear.
• Regardless of the replacement schedule, replace imme-
diately if a symptom of wear is found.
Explosionproof lighting
To prevent an ignition or explosion, use explosion-proof
lights when inspecting fuel, oil, coolant or battery fluid.
Prohibit access by unauthorized persons
Do not allow unauthorized personnel in the work area while
working.
Take particular care that no unauthorized person is present
when grinding, welding or using a hammer.
Prepare the work area
• Select a level and firm ground on which to perform
maintenance work. Make sure that the work area is light
enough and well ventilated.
• Straighten any obstacle or dangerous object, remove
any spill of oil or grease and clean the work area.
When the canopy is tilted up
• If the canopy is raised or lowered while the engine is
moving, the machine may accidentally start moving, re-
sulting in severe injury to the maintenance personnel.
Make sure that the working equipment has been low-
ered to the ground and the engine has been turned off
before raising/lowering the canopy.
• When the canopy is tilted up, firmly secure the canopy
with a stopper to prevent it from falling.
Keep the machine clean
• Clean the machine before performing maintenance and
try to keep it clean.
• Before washing, cover the electrical parts with vinyl to
prevent water from entering, as this could cause a short-
circuit or malfunction. Do not use water or steam to
wash the battery, sensors, connectors or the operator’s
seat area.
Stop the engine before performing maintenance
Make sure the engine is stopped before starting inspection
or maintenance. If maintenance must be performed with
the engine running, always work as a 2-person team, com-
municating with each other.
• One of them must sit at the operator’s seat and stop the
engine whenever necessary. He/she must take care not
to touch the lever or pedal unless necessary.
• The one who performs maintenance must make sure to
keep his/her body or clothing away from the moving part
of the machine.
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1-5
1
SAFETY PRECAUTIONS
SAFETY
Keep clear of the moving fan and belt
• Any object that can be easily caught in moving parts
must be kept away.
• If a hand or tool becomes trapped in the fan or fan belt,
you could lose your ﬁnger. Do not touch the fan or belt
while they are moving.
When working under the machine
• Before performing maintenance or repairs under the
machine, set all movable equipment against the ground
or in the lowermost position.
• Place chocks under the crawler tracks to secure the
machine.
• If it is unavoidably necessary to work under the raised
machine or working equipment, be sure to ﬁrmly sup-
port it by using an arm stopper, wooden block, stand
or safety brace. Never go under the raised machine or
working equipment without such protection measures.
When working on the machine
• To prevent slipping/falling from machine, clear the foot-
ing and observe the following:
a. Do not spill oil or grease on the machine.
b. Keep the machine tidy and clean.
c. Be careful when walking around the machine.
• Never jump down from the machine. Climb up/down
the ladder (steps) holding the handrail to support your
weight in a three point secure stance (hand and feet).
• Wear protective gear according to the work involved.
Securing the working equipment
When replacing/repairing the bucket teeth or side cutter,
secure the relevant equipment to prevent any accidental
movement.
Secure the engine hood and guard when they are
open
Firmly secure the machine when the engine hood or guard
is left open. Do not keep the hood or guard open on a
windy day or if the machine is parked on a slope.
Place heavy components in a stable position
When it is necessary to temporally place a heavy compo-
nent, such as the hoe attachment, on the ground during
removal or installation, be sure to place it in a stable posi-
tion.
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1-6
1
SAFETY PRECAUTIONS
SAFETY
Caution when filling with fuel or oil
• Keep away from heat, sparks and flame while filling with
fuel or oil.
• Never remove the fuel cap or try to fuel when the engine
is running or still hot.
• Maintain control of the fuel filler nozzle when filling the
tank.
• Refill with fuel or oil outdoors or in a well ventilated place,
with the engine turned off.
• Clean up spilled fuel or oil immediately.
• Do not overfill the tank.
• Firmly tighten the fuel cap or oil cap. If the fuel cap is
lost, replace it only with the original manufacturer’s ap-
proved cap. Use of a non-approved cap without proper
venting may result in pressurization of the tank.
• Never use fuel for cleaning.
• Use the correct grade of fuel for the operating season.
Handling of hoses
Oil leak or fuel leak can cause a fire.
• Do not twist, bend or hit the hoses.
• Never use twisted, bent or cracked pipes, tubes or hos-
es; otherwise, they may burst.
• Retighten loose connections.
Be careful with hot and pressurized components
Before performing inspection and maintenance, stop the
engine and allow the machine to cool down.
• The engine, muffler, radiator, hydraulic lines, sliding parts
and many other parts of the machine are hot immediate-
ly after the engine is stopped. Wait until it cools before
making any inspection or adjustments.
• The engine coolant, hydraulic oil and other oils are also
hot and under high pressure. Touching these liquids will
cause burns.
Handling of radiator
Do not remove the radiator cap when the coolant is hot.
Wait until it cools down, and then remove the radiator cap
by loosening it slowly to release the internal pressure.
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1-7
1
SAFETY PRECAUTIONS
SAFETY
Be careful with oils under pressure
Pressure is maintained in the hydraulic circuit long after the
engine has been shut down.
• Do not fill with, dispose of fuel/oil, or perform the in-
spection and maintenance until the internal pressure is
completely released.
• The hydraulic oil escaping from a small hole can be haz-
ardous if contacted. It is under high enough pressure to
penetrate the skin or eyes and cause serious injury. If
leak is suspected, protect your eyes and skin by wear-
ing protective glasses and thick gloves to search for a
leak. Also use a paperboard or plywood to keep your
skin from oil spurting. If oil penetrates the skin, it must
be surgically removed within a few hours by a doctor
familiar with this type of injury.
Release internal pressure before working on the
hydraulic system
Oil may spurt out if caps or filters are removed or pipes are
disconnected before releasing the pressure in the hydraulic
system.
• Gradually loosen the vent plug to release the internal
pressure of the hydraulic oil tank.
• Move all the control levers and pedals several times in all
directions to release the pressure from the circuit of the
working equipment (for link type controls).
• When removing plugs or screws, or when disconnect-
ing hoses, stand to the side and loosen them slowly to
gradually release the internal pressure before removing.
Be careful with grease under pressure
In the track adjuster, the grease has been injected under
high pressure. 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 put your face, arms, legs or body in front of the
grease discharge valve.
Handling of the accumulator
Be sure to handle the high-pressure nitrogen gas enclosed
in the accumulator with care according to procedure. If
handled incorrectly, it could explode and cause serious in-
jury. Strictly observe the following precautions:
• Do not disassemble.
• Do not allow flame near it or throw it into a fire.
• Do not drill, weld or fuse.
• Do not subject it to physical shock such as hitting, rolling
or dropping.
• Before disposing of the unit, the sealed gas must be
drained. Contact your sales or service dealer for help
with this.
Disconnect the battery
Disconnect the wiring from the both terminals (+ and -) on
the battery before working on the electrical system or doing
electric welding. Otherwise, short-circuit and explosion of
the battery can result.
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1-8
1
SAFETY PRECAUTIONS
SAFETY
Use caution when handling batteries
• Batteries contain sulfuric acid which will damage eyes or
skin if contacted.
• If eye contact occurs, flush immediately with clean
water and get prompt medical attention.
• If accidentally swallowed, drink large quantities of
water or milk and call a physician immediately.
• If acid contacts skin or clothing, wash off immediately
with a lot of water.
• Wear protective glasses and gloves when working with
batteries.
• Batteries generate flammable hydrogen gas which may
explode. Keep away from flame and sparks.
• Do not use or charge the battery when the electrolyte
level is lower than the lower limit: otherwise, it could
cause an explosion.
• Be sure to stop the engine by turning off the starter
switch before inspecting or handling the battery.
• Be careful not to let metal tools (or any metal objects)
such as a hammer or spanner come into contact with
the battery terminals.
• When disconnecting the battery wiring, always discon-
nect it from the earth side (-). When connecting, connect
the earth side last.
• Loose battery terminals may result in sparks. Be sure to
fasten terminals tightly.
• Make sure the battery caps are tightened securely.
• Do not charge a battery or jump-start the engine if the
battery is frozen; otherwise it may explode.
Warm the frozen battery to 15°C (60°F) before use.
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Have a service agent repair welding cracks or
other damage
Ask a service agent to make any repairs that require weld-
ing. If the agent is unavailable, make sure the welding is
done by a qualified person in a properly equipped work-
place.
Checks after maintenance
• Gradually raise the engine speed from low idle to maxi-
mum and check that no oil or water is leaking from the
parts serviced.
• Move the controls and check that the machine is oper-
ating properly.
Disposing of wastes
• Always collect oil that is drained from the machine in
containers. Improperly disposed waste oil can cause
environmental harm.
• Follow appropriate laws and regulations when dispos-
ing of harmful objects such as oil, fuel, coolant, solvent,
filters and batteries.
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1-9
1
SAFETY
CAUTIONS WHEN WORKING
When disassembling or assembling
• Clean the machine before disassembly.
• Check the following items and record the results:
a. Model, machine serial number, hour meter.
b. Reason for repair, repair history.
c. Are the ﬁlters dirty?
d. The conditions of the fuel and oil.
e. Any damage or looseness to any part?
• Where necessary, draw alignment indicators to avoid
assembly errors. To avoid misconnection, place indica-
tors such as reference tags on pipes.
• Clean all disassembled parts and new parts, arrange
them neatly, and place indicators as necessary.
• Be sure to replace all seals and cotter pins with new
ones.
• Keep those parts that should not come in contact with
water or oil away from those with oil on the surface.
• When installing bearings, bushings and oil seals, a press
tool should be used. If a hammer is used, use a cushion-
ing material to avoid damage.
• Wipe all joining surfaces clean until there is no dirt or
dust adhering to them.
• Wrap the thread tight with seal tape starting 1 or 2
threads away from the thread end. The tape should be
overlapped by about 10 mm.
When removing/installing the hydraulic unit
• Make sure that the temperature of the hydraulic oil has
dropped and is cool enough to work with.
• To prevent the hydraulic oil from escaping under pres-
sure, release the residual pressure in the piping.
• Be sure to install caps or plugs on all openings in the
hydraulic unit to prevent dirt from getting into the unit
through them.
• The hydraulic oil adhering to the unit is often mistaken
for an oil leak, so wipe off the unit thoroughly.
• Be sure that no damage is caused to the plating on the
rod in the hydraulic cylinder.
• Removal and installation of the hydraulic cylinder should
be done with the rod fully retracted.
• Be sure to bleed the air after installing the hydraulic cyl-
inder. ( “4. Disassembly and assembly: Cylinder”)
• Always bleed the air when hydraulic oil is changed or a
hydraulic device is replaced.( “4. Disassembly and
assembly: Drive system”)
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1-10
1
SAFETY
When connecting/disconnecting the hoses or
pipes
• When hydraulic hoses or pipes are connected, tighten
them once to the prescribed torque, then loosen them
slightly and retighten them to the prescribed torque.
a. Tighten the fittings after the installation surfaces fit
snugly together.
b. The above procedures do not apply to fittings with
seal tape.
• Use two spanners, one to tighten/loosen and the other
to secure the mating hose/pipe to ensure that the hose
is not twisted.
• After connecting the hydraulic hoses or pipes, apply the
maximum working pressure five or six times to check for
leakage.
• If high pressure, vibration or shock is applied to a twist-
ed hose, oil leak, hose breakage or damage to the hose
fitting can result.
• Be sure that the hydraulic hoses are not contacting
sharp objects or each other. This could cause surface
flaws on the hoses, resulting in breakage.
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Handling of seals
• Clean the grooves for O-rings and remove any burrs.
• Be careful not to twist the O-rings. If twisted, remove it
with your fingertips.
• When inserting, be careful not to damage the seal.
• Handling of the floating seal
a. After removal, wipe all oil off the O-ring and housing
of the floating seal.
b. When assembling, apply a thin coating of gear oil to
the contact surface of the housing,
c. After assembly, turn the seal two or three times to get
it to fit snugly.
• Apply grease to the lip of the oil seal.
a. This is to prevent wear from occurring upon first start
up after assembly.
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2-1
SERVICE DATA 2
Dimensional drawing ................................................... 2-2
Speciﬁcations tables.................................................... 2-3
Lubricant and Fuel chart.............................................. 2-6
Performance criteria .................................................... 2-8
Tightening torque ...................................................... 2-16
Hydraulic circuit diagram ........................................... 2-19
Electrical wiring diagram ............................................ 2-23
Wire harness diagram................................................ 2-25

2-2
2
SERVICE DATA
DIMENSIONAL DRAWING
Unit: mm
Standard bucket
Rubber crawler
Canopy Cab
A 3430 ←
B 2740 ←
C 1390 ←
D 2235 2130
E 310 ←
F 1580 ←
G 320 ←
H 1430 ←
J 985 980
K 1675 ←
L 510 ←
M 30° ←
Unit: mm
Standard bucket
Rubber crawler
Canopy Cab
A 3905 ←
B 3030 ←
C 2370 ←
D 730 ←
E 2080 ←
F 1375 ←
G 1590 ←
H 30° ←
Machine dimensions Operating range
DIMENSIONAL DRAWING
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2-3
2
SERVICE DATA
SPECIFICATIONS TABLES
Performance
Bucket type Standard bucket
Bucket capacity m3
0.351
Tipping load kg 2380
Rated loading mass kg 735
Breakout force kN 29.9
Raising time (load) s 4.0
Lowering time s 2.6
Bucket forward tilting time s 2.6
Travel speed
Forward 1st km/h 7.3
Forward 2nd km/h 10.9
Reverse 1st km/h 7.3
Reverse 2nd km/h 10.9
Maximum tractive force kN 40.6
Gradeability degree (°) 30
Minimum turning radius Bucket outside m 2.082
Dimensions
Overall length in transport
condition
Without teeth mm 3430
With teeth mm −
Overall width (body) mm 1580
Bucket width mm 1675
Overall height
Bucket on ground
Canopy mm 2130
Cab mm 2235
Max. raised height of bucket mm 3905
Crawler bearing length mm 1390
Track gauge mm 1260
Shoe width mm 320
Crawler bearing area m2
0.890
Ground clearance of undercarriage mm 310
Bucket hinge pin height mm 3030
Dumping clearance (at 45-
degree forward tipping)
With teeth mm −
Dumping reach (at 45-degree
forward tipping)
With teeth mm −
Bucket roll back angle On ground degree (°) 29.3
Bucket dumping angle Maximum height position degree (°) 38.6
Maximum digging depth mm 0
Mass
Gross machine mass
Canopy kg 4270
Cab kg 4360
Operating mass
Canopy kg 3710
Cab kg 3800
Machine mass
Canopy kg 3635
Cab kg 3725
Shipping mass
Canopy kg 3580
Cab kg 3670

2-4
2
SERVICE DATA
Engine
Model Yanmar 4TNV98-ZNTBL
Type
4-cycle, vertical, water-cooled,
in-line, 4-cylinder, direct-injection
Number of cylinders – Internal diameter x stroke 4 – 98 × 110
Total displacement L 3.318
Performance
Rated engine speed min-1
2500
Rated horsepower kW 50.1
Maximum torque N·m 222.7 to 242.5/1600 min-1
Speciﬁc fuel consumption (at rated
output)
g/kW·h 250 (184)
Fuel system Speed governor Electronic governor
Lubrication system
Type Trochoid pump
Filter system Filter paper
Cooling system Water cooling
Air cleaner Cyclone ﬁlter
Cooling system
Fan Pusher type
Radiator Pressurized
Generator
AC/DC Three-phase alternating current, self-rectifying
Voltage V 12
Output kW 0.48
Starting system
Voltage V 12
Output kW 3
Battery
Type 130E41R
Voltage V 12
Capacity A·h 80
Quantity 1
Hydraulic drive system
Pump
Model Sauer-Danfoss-Daikin PVM2828
Type Variable displacement piston
Displacement cm3
/rev 0 to 28
Quantity 2
Travel motor
Model Sauer-Danfoss-Daikin BMVT32C
Type Variable displacement piston
Motor displacement cm3
/rev 20.6/31.5
Quantity 2
Set pressure Effective differential pressure MPa 34.5
Reduction gears Epicycle reduction gear
Brake device
Parking brake Spring-loaded, wet type disc brake
Undercarriage
Suspension system Rigid type
Roller, Idler
Seal system Floating seal
Carrier roller (one side) Q’ty ––
Track roller (one side) Q’ty 5
Crawler
Track adjuster By injecting grease
Type One-piece design, single groucer, rubber crawler
Grouser height mm 30
Number of shoes (one side) Q’ty 52 (lugs)
Pitch mm 86
Shoe width mm 320

2-5
2
SERVICE DATA
Operating device
Cab/canopy
Location Center of machine
Type ROPS/FOPS canopy & cab
Operator's seat Suspension seat, adjustable
Control lever and pedal
Lever Travel, attachments
Pedal Accelerator
Instruments
Cluster gauge (12 V):
Water temperature gauge, Fuel gauge, Hourmeter,
Charge, Oil, Air cleaner, Line ﬁlter, Glow, 2nd-speed pilot
Lighting device
Front light 12 V, 55 W x 2
Rear light 12 V, 55 W x 2
Others
Horn Q’ty 1
Back-up buzzer Q’ty 1
Inside rear view mirror Q’ty 2
Rear view mirror Q’ty 1
Working equipment
Bucket blade type Without teeth
Bucket teeth
Type ––
Quantity ––
Auto adjustment mechanism Hydraulic leveling device for bucket raising
Hydraulic system
Arm cylinder
Type Independent piston
Quantity 2
Internal diameter mm 65
Stroke mm 705
Bucket cylinder
Type Independent piston
Quantity 2
Internal diameter mm 65
Stroke mm 475
Hydraulic pump
Type Double gear pump
Displacement cm3
/rev 27.8 + 16.2
Control valve
Type Hydraulic pilot operated
Set pressure MPa 3.3

2-6
2
SERVICE DATA
LUBRICANT AND FUEL CHART
Select the appropriate fuel, lubricant and grease according to the temperature by referring to the table below.
• Regardless of the specified time, change the oil if it becomes too dirty or degraded.
• When refilling, never mix oils of different brands. If a brand is to be changed, replace the whole fuel/oil.
Part Type
Type by air temperature
-30 -20 -10 0 10 20 30 40°C
When to change/
replenish
Capacity
Engine oil pan
Diesel engine oil
API: CF class or
more
Every 250 hrs
after the first 50
hrs
Upper limit 10.2 L
SAE 10W-30
SAE 15W-40
Hydraulic oil tank
Diesel engine oil
API: CD class
Every 1000 hrs
Total amount of
oil: 58 L
Tank capacity:
39 L
SAE 10W-30
SAE 10W-40
Engine cooling
system
**Cooling water
(water + coolant)
Every 1000 hrs 16.5 L
Mixture of 50% coolant
Mixture of 30% coolant
Travel reduction
gear
Gear oil
API: GL-4
SAE 90
Every 500 hrs af-
ter the first 250*
hrs
1.0 L
Track roller A
Diesel engine oil
API: CD class
SAE 30 –– 0.18 L
Track roller B
Mobilgear
SHC680
–– –– 0.14 L
Idler
Diesel engine oil
API: CD class
SAE 30 –– 0.12 L
Working equip-
ment
Lithium grease
EP-2
NLGI No.2
––
Daily or every
10 hrs As required
Lever/pedal When required
* If the ratio of traveling time to total operating time is high, replace the gear oil earlier than 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 manufacturer’s instruc-
tions to determine the mixture ratio.
LUBRICANT AND FUEL CHART
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2-7
2
SERVICE DATA
LUBRICANT FUEL AND CHART
Diesel fuel standards
Use the diesel fuel that is compliant with any of the standards below. The table below shows the standards from the various
countries.
Diesel fuel standards Region
No. 2-D, No. 1-D, ASTM D975-94 USA
EN590:96 EU
ISO 8217 DMX International standard
BS 2869-A1 (or A2) UK
JIS K2204 Grade, 2-go Japan
KSM-2610 Korea
GB252 China
Part Type Capacity
Fuel tank Desel fuel
• The sulfur content must be less than 0.5% by volume. The recommended
value, however, is less than 0.05%. The electronically-controlled engine with
an EGR system should use fuel containing less than 0.05% sulfur.
Fuel containing a high content of sulfur may cause sulfuric acid corrosion
inside the cylinder.
• Do not mix fuel with any kerosene, used engine oil or leftover fuel.
• Poor quality fuel can degrade the engine performance. It also can damage
the engine.
• Avoid using additives to fuel. Some fuel additives can degrade the engine
performance
75 L
Bio-diesel fuel
In various European countries and the US, fuel sources such as rapeseed oil methyl ester (RME) and soybean oil methyl
ester (SOME) are used as extenders for diesel fuel made from mineral oil. These RME and SOME are collectively called fatty
acid methyl ester (FAME).
Bio-diesel fuel is permitted to be used provided its total mixing rate by volume is at least 95% approved mineral oil and no
more than 5% FAME. Note that bio-diesel fuel containing 5% SOME is referred to as B5 diesel fuel.
This B5 diesel fuel must meet certain standards:
• It must meet the minimum standard requirements of the country in which it is used.
In Europe, bio-diesel fuel must meet the European standard EN14214.
In the US, bio-diesel fuel must meet the US standard ASTM D6751.
• It must be purchased from a certified diesel fuel store.
Precautions when using bio-diesel fuel
• There is a risk that the free methanol in FAME could cause corrosion of some parts of the fuel injection equipment (FIE)
made from aluminum or zinc.
• The free water in FAME may cause clogging of the fuel filter or increased growth of bacteria.
• The fuel viscosity may increase and the fuel may become difficult to flow at low temperature. Also, operation of the injec-
tion pump may become faulty or the spray performance of the injection nozzle may decrease.
• FAME may damage some rubber materials (seals), causing fuel to leak or the engine oil to become thinner.
• Even when the bio-diesel fuel meets the appropriate standard, care should be taken to maintain the quality of the equip-
ment and the fuel in the fuel tank. It is important always to add clean new fuel. It may become necessary to regularly
wash out the dirt from the fuel line and fuel tank.
• The warranty of the engine manufacturer may be voided by using a bio-diesel fuel that does not meet the standard of
the diesel engine manufacturer or diesel fuel injection equipment, or deteriorated fuel as described in the above precau-
tions.

Item Standard value Allowable value
Engine speed
Low min-1
1130 ±70 ––
High min-1
2650 ±60 ––
Hydraulic oil pressure
Travel
Right MPa 34.3 +5.9
––
Left MPa 34.3 +5.9
––
Charge
Low MPa 1.5 ±0.2 ––
High MPa 2.0 ±0.2 ––
Bucket MPa 20.6 +1.2
––
Pilot MPa 3.1 ±0.4 ––
High ﬂow MPa 20.6 ±1.0 ––
Cylinder speed
Lowering speed when the lift arm is in ﬂoat s 4.4 ±1.4 6.2
Lift arm
Raising s 4.0 ±0.4 4.8
Lowering s 2.7 ±0.4 3.4
Bucket
Roll back s 2.0 ±0.4 2.6
Dump s 2.8 ±0.4 3.5
Travel speed (10 m)
1st
Forward s 4.9 ±0.5 5.9
Reverse s 4.9 ±0.5 5.9
2nd
Forward s 3.3 ±0.4 4.2
Reverse s 3.3 ±0.4 4.2
Track shoe (5 revs.)
1st
Light
Forward s 11.1 ±0.6 12.8
Reverse s 11.1 ±0.6 12.8
Left
Forward s 11.1 ±0.6 12.8
Reverse s 11.1 ±0.6 12.8
2nd
Light
Forward s 7.3 ±0.5 8.8
Reverse s 7.3 ±0.5 8.8
Left
Forward s 7.3 ±0.5 8.8
Reverse s 7.3 ±0.5 8.8
Straight-ahead traveling
Forward mm 125 0
500
Reverse mm 125 0
500
Cylinder spontaneous drop
Lift arm mm 5 +0
10
Bucket mm 5 +0
10
Natural travel drop Engages parking brake
Forward mm 0 ––
Reverse mm 0 ––
Bucket front edge
Difference between
right and left
mm 10 0
20
Lever
Lever operating force
Arm N 10 ±4 ––
Bucket N 10 ±4 ––
Travel N 10 ±4 ––
Lever play
Arm mm 4 0
––
Bucket mm 4 0
––
Travel mm 4 0
––
Crawler tension mm 25 to 50 ––
2-8
2
PERFORMANCE CRITERIA
SERVICE DATA
Standard values table
-0.5
-0.5
-0.5
-125
-125
-5
-5
-10
-4
-4
-4

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2-9
2
SERVICE DATA
Hydraulic pump assignment table
P1 Left travel 70.0 L/min
P2 Right travel 70.0 L/min
P3 Arm, bucket, auxiliary 69.5 L/min
P4 Charge pressure, pilot pressure 40.5 L/min
Left travel Pressure: 34.3 MPa Test port P1
Right travel Pressure: 34.3 MPa Test port P2
Arm Pressure: 20.6 MPa Test port P3
Bucket Pressure: 20.6 MPa Test port P3
Auxiliary Pressure: 20.6 MPa Test port P3
Charge pressure:Low/
high
Pressure: 1.6/2.1 MPa Test port C
Pilot pressure Pressure: 3.1 MPa Test port P4
Pump P1
Pump P2
Pump P3
Pump P4
2DAA01Z
P1
P2
P3
P4

2-10
2
SERVICE DATA
Methods for inspecting performance
Hydraulic oil pressure
Travel
Measuring method
• Engine: Maximum RPM
• Hydraulic oil temp.: 50 to 60°C
• Install a pressure gauge on the pressure detection port.
Fit the pipe (1) on the travel motor sprocket to deacti-
vate the motor. Then, start up the hydraulic circuit to be
tested and measure the relief pressure.
Lift arm, bucket
Measuring method
• Engine: Maximum RPM
Operate the hydraulic circuit to be tested and measure
the relief pressure.
Circuit
Pressure detection port
Relief valve
Port location Size
Left travel
(forward)
P1 G1/4 R1
Right travel
(forward)
P2 G1/4 R2
2DAA02Z
1
2DAA04Z
R1
R2
A
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Circuit
Relief valve
Port location Size
Arm, bucket P3 G1/4 R3
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2-11
2
SERVICE DATA
Adjusting method
1. Loosen the locknut (2), and turn the setscrew (1) to
adjust the set pressure.
• To increase the set pressure, turn the setscrew
clockwise.
• To decrease the set pressure, turn the setscrew
counterclockwise.
2. Upon completion of the adjustment, tighten the lock
nut (2) by holding the setscrew (1) to prevent it from
turning.
3. Operate the relief valve again to conﬁrm that the newly
set pressure is stabilized.
Charge pressure
Measuring method
• Engine: Idling/Maximum RPM
Adjusting method
1. Loosen the locknut (2), and turn the setscrew (1) to
adjust the set pressure.
• To increase the set pressure, turn the setscrew
clockwise.
• To decrease the set pressure, turn the setscrew
counterclockwise.
2. Upon completion of the adjustment, tighten the lock
nut (2) by holding the setscrew (1) to prevent it from
turning.
3. Operate the relief valve again to conﬁrm that the newly
set pressure is stabilized.
1
2
2DAA06Z
CR
2DAA07Z
1 2
2DAA08Z
Relief valve
Port location Size
C G1/4 CR
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