Takeuchi TB215R - Disassembly and Assembly

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DISASSEMBLY AND ASSEMBLY

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Directional Terms: Front, Rear, Left, Right2
Manual Structure2
Machine Serial Number2
Symbols Used in this Manual2
Safety3
Safety Alert Symbol4
Safety Label4
Safety Precautions5
Explosionproof Lighting6
When the Canopy Is Tilted up6
Prepare the Work Area6
Stop the Engine before Performing Maintenance6
Handling of the Accumulator9
Disconnect the Battery9
Disposing of Wastes10
Checks after Maintenance10
Cautions When Working11
When Disassembling or Assembling11
When Removing/Installing the Hydraulic Unit11
Pressure Adjustment for Hydraulic Devices12
Handling of Seals12
Service Data13
Dimensional Drawing14
Machine Dimensions14
Operating Range16
Specification Tables18
Lubricant and Fuel Chart27
Diesel Fuel Standards28
Performance Criteria29
Standard Values Table29
Hydraulic Pump Assignment Table31
Methods for Inspecting Performance32
Hydraulic Oil Pressure (Boom, Arm, Dozer Blade)32
Measurement Method32
Hydraulic Oil Pressure (Slew)33
Hydraulic Oil Pressure (Pilot Pressure)33
Traveling Attitude34
Travel Speed (5 Revs.)34
Straight-Ahead Traveling34
Travel Speed (10 M)34
Natural Travel Drop35
Slew Time35
Overrun When Slewing Stops35
Natural Slew Drop35
Boom Cylinder Speed36
Arm Cylinder Speed36
Bucket Cylinder Speed36
Dozer Blade Cylinder Speed36
Swing Cylinder Speed37
Natural Cylinder Drop37
Swing37
Spanner Cylinder Speed37
Slew Bearing Play38
Backlash38
Lever Play38
Lever Operating Force38
Track Tension39
Tightening Torque40
Hydraulic Hose40
Bite-Type Pipe Fitting for Steel Pipe40
Joint for Piping41
Joint for Piping (O-Ring Seal Type)41
Bolts and Nuts (JIS Strength Category 10.9)42
Hydraulic Circuit Diagram45
Control Valve46
Main Pump46
Slew Motor46
Travel Motor47
Solenoid Valve (Lever Lock and Travel Speed Switching)47
Boom Cylinder47
Wiring/Cable Colors50
Wire/Cable Color Symbols50
Types of Wire to Use50
Electrical Circuit Diagram50
Electrical Schematic Diagram51
Wire Harness Diagram52
Wiring Diagram52
Body Harness: 03342-6800053
Hydraulic Pump (Piston)59
Discharge Volume Control Mechanism59
Gear Pump61
When the Spools Are in the Neutral Position62
Load Check Valve62
When the Spool Is Being Operated62
Main Relief Valves63
The Relief Valve Is Activated63
Port Relief Valve64
The Relief Valve Is Subjected to the Relief Operation64
Anti-Cavitation Valve66
Anti-Drift Valve66
When the Switch Valve Is Not Activated67
Switch Valve67
When the Switch Valve Is Activated67
Arm in Regeneration68
Pilot Valve (Control Lever)69
Proportional Control Solenoid Valve71
Solenoid Valve(3Rd Auxiliary Line Piping)72
Solenoid Valve72
When the Solenoid Is Energized72
Solenoid Valve (Lever Lock)73
Solenoid Switching and Relief Function73
When the Solenoid Is Not Energized73
Check Function74
Selector Valve75
Switching from Position a (ISO) to Position G (JCB)77
Cylinders79
Cushion Mechanism79
Counterbalance Valve80
Hydraulic Motor80
2-Speed Mechanism81
2-Speed Control Valve81
Swash Plate82
Automatic 2-Speed Switching82
Parking Brake83
Reduction Gears83
Hydraulic Motor 184
Hydraulic Motor 285
Brake Valve86
Swivel Joint87
Selector87
Disassembly and Assembly88
Service Standards89
Track Roller89
Shoe Slider89
Sprocket89
Clearance for Pin and Bushing90
Drive System92
Engine92
Removing the Engine95
Installing the Engine95
Removing the Hydraulic Pump97
Installing the Hydraulic Pump97
Cautions on Starting the Hydraulic Pump97
Fuel Tank98
Installing the Fuel Tank99
Removing the Fuel Tank99
Battery100
Removing the Battery101
Installing the Battery101
Throttle Lever102
Adjusting the Throttle Lever103
Engine Speed103
Control Force103
Installing the Crawler104
Travel System104
Removing the Crawler104
Removing the Track Roller105
Installing the Track Roller105
Removing the Idler and Track Adjuster105
Installing the Idler and Track Adjuster105
Removing the Travel Motor106
Installing the Travel Motor106
Slew Equipment107
Removing the Slew Motor108
Installing the Slew Motor108
Removing the Slew Bearing110
Installing the Slew Bearing110
Upper Frame113
Removing the Upper Frame115
Installing the Upper Frame115
Covers116
Removing the Covers117
Installing the Covers117
Removing the Canopy119
Operating Device120
Control Levers120
Attachments127
Hoe Attachment127
Removing the Hoe Attachment131
Removing the Bucket131
Installing the Bucket131
Removing the Link132
Installing the Link132
Removing the Arm132
Installing the Arm132
Removing the Boom133
Installing the Boom133
Installing the Blade134
Removing the Blade134
Installing the Boom Bracket134
Removing the Boom Bracket134
Hydraulic Tank135
Removing the Hydraulic Tank136
Installing the Hydraulic Tank136
Inspecting and Refilling the Oil in the Hydraulic Tank137
Refilling the Oil137
Tank Pressure137
Bleeding off the Air138
Hydraulic Pump139
General Precautions140
Inspection and Adjustments146
Checking the Parts146
Boom Section151
Arm Section152
Bucket Section152
Dozer Blade Section152
Auxiliary Section153
Valve Assembly155
Manually Operated Section156
Pilot Operated Section157
Main Relief Valve158
Pilot Valve160
Solenoid Valve (3Rd Auxiliary Line Piping)169
Inspection after Disassembly195
Piston Rod195
Measuring the Bend195
Tube195
No Load Operation Test196
Leak Test196
External Leak196
Bleeding Air from the Hydraulic Cylinder196
Counter Balance Valve and Hydraulic Motor200
General Cautions227
Thrust Ring230
Flange230
Use Limit for Parts230
About the Troubleshooting Section233
Notes on Troubleshooting and Servicing233
Overall Machine234
All Systems Working, but Insufficient Force235
Boom, Bucket, Slew and Arm Fail to Move or Are too Slow237
Check the Pilot Relief Valve238
Check the Limit Switch238
Check the Lever Lock Solenoid Valve238
Check the Fuse238
Traveling239
Check the Linkage239
The Travel Lever Lock Cylinder Is Faulty239
Right or Left Travel Is Impossible240
Check the Spool Operation240
Check the Counter Balance Valve243
Check the Swivel Joint243
Test by Switching the Main Relief Valves243
Is the Veering Within Specs?243
2Nd Speed Travel Is Not Possible244
Check the Gear Pump244
Check the 2Nd Speed Solenoid Valve245
2Nd Speed Control Valve Is Faulty245
Slewing246
No Slewing Is Possible246
Check the Slew Motor247
Check the Slew Pressure247
Check the Pilot Valve247
Slew Right or Left Is Not Possible248
Slewing Is Slow or Lacks Force249
When Stopped on Slope, the Upperstructure Cannot Maintain Its Posture252
Boom253
The Boom Cylinder Does Not Move253
Boom Cylinder Operation Is Slow or Lacks Force255
Spontaneous Drop of the Boom Cylinder Is too Large259
Arm260
Arm Cylinder Does Not Move260
Arm Cylinder Operation Is Slow or Lacks Force262
Spontaneous Drop of the Arm Is too Large264
Bucket Cylinder Does Not Move or Lacks Force265
Test by Replacing the Port Relief Valve266
Check the Bucket Cylinder266
Spontaneous Drop of the Bucket Is too Large267
Swing Cylinder Does Not Move268
Boom Swing268
Dozer Blade270
Dozer Blade Cylinder Does Not Move or Lacks Force270
Prescribed Pressure Is Not Supplied to the Auxiliary Lines274
Spanner Cylinder Does Not Move or Lacks Force275
Piston Pump277
Monochrome LCD Cluster288
Panel Display and LCD Specifications288
Table of Contents289
Normal Panel Display/Lcd Screen290
Panel Display: Water Temperature Gauge291
Panel Display: Fuel Gauge292
- Overheating Warning Light293
- Engine Oil Pressure Warning Light293
- Charge Warning Light293
Panel Display: Function/Warning Lamps293
1 Hour Meter294
Normal Screen294
Main Menu Screen295
Data Selection Screen296
Data Screen (TRIP METER)297
Data Screen (Water Temp.)298
Settings Selection Screen299
Setting Screen (Clock)300
Setting Screen (Alarm)-1301
Setting Screen (ALARM)-2302
Setting Screen (CONTRAST ADJ.)303

Takeuchi TB215R - Disassembly and Assembly

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