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Takeuchi Hydraulic Excavator TB175W (S/N 17540001~). WORKSHOP MANUAL - page 1

175

Hydraulic Excavator

BOOK No. CW3E001

WORKSHOP MANUAL

Serial No. 17540001~

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 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 side on which the blade is mounted is referred to as the rear. The left and right sides of the operator when seated

in the operatorʼs seat are the left and right sides of the machine.

MACHINE SERIAL NUMBER

The machine serial number is stamped on the identiﬁcation plate. When sending reports and inquiries, and when

ordering parts, etc., be sure to include this number.

MANUAL CONTROL

Information on those to whom this manual is distributed is recorded in the ledger in the section in charge at this

company, so please decide on a person to be in charge of it and control it. When there are updates or additions, etc.,

we will notify the person in charge.

SYMBOLS

means “Please refer to the section quoted.”

Indicates the tightening torque at the speciﬁc section that requires special attention in designing.

Indicates the mass of a part or device.

0-3

I .

GENERAL

II .

SPECIFICATIONS

III .

MACHINE CONFIGURATION

IV .

HYDRAULIC UNITS

V .

TROUBLESHOOTING

VI .

ENGINE

1-1

I .

GENERAL

GENERAL

I-2

CONTENTS

Safety Precautions

Cautions during Disassembly and Assembly ........................................................................................................

........................................................................................................

................................................................................................................................................

..........................................

........................................

Cautions during Removal and Installation of the Hydraulic Units .......................................................................10

Cautions during Removal and Installation of Piping ............................................................................................11

Handling of Seals

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.

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.

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.

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.

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.

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.

Tire Maintenance

• Explosive separation of a tire and/or rim parts can

cause serious injury or death. Always follow the

service outlet or see your tire supplier.

• Special tools and procedures are required to

change tires. To do it safely, it must be done cor-

rectly.

Changing tires is a job better done by your tire

service company.

• Always maintain the correct tire pressure. Do not

inﬂate the tires above the recommended pres-

sure.

• Inspect tires and wheels daily. Do not operate

with low pressure, cuts, bubbles, damaged rims.

• A rise in tire pressure during operation is normal,

and should NOT be reduced.

I-9

GENERAL

• When adding air to a tire, do so from a distance.

Use a long hose with self-attaching chuck. Always

stand behind tread when adjusting tire pressure.

• Do not inﬂate tires with ﬂammable gases or from

systems utilizing an alcohol injector.

• Never cut or weld on a wheel with an inﬂated

tire mounted on it. This could cause explosive

decompression.

• Tires are to be repaired only by an authorized

person using the proper procedures and safety

equipment. New or replacement tires and wheels

should always be checked for proper size before

mounting.

• Always use a safety cage or cable restraints when

reinﬂating a repaired tire.

I-10

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”

I-11

GENERAL

CAUTIONS DURING REMOVAL AND 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.

GENERAL

I-12

TIGHTENING TORQUES

Hydraulic Hoses

Bite Type Pipe Fitting for Steel Pipe

Pipe Outer Diameter

(mm)

Torque

N·m

ft-lb

34.3 ±4.9

25.3 ±3.5

41.7 ±2.5

30.7 ±1.7

58.8 ±4.9

43.4 ±3.5

88.3 ±4.9

65.1 ±3.5

93.2 ±4.9

68.7 ±3.5

132.4 ±4.9

97.6 ±3.5

205.9 ±9.8

151.8 ±7.2

27.2

245.2 ±9.8

181.0 ±7.2

313.8 ±19.6

231.4 ±14.3

313.8 ±19.6

231.4 ±14.3

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

+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

137.3

+4.9

101.3

+3.5

196.1 ±19.6 144.7 ±14.3

GENERAL

I-13

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

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

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

Content .. 1 2 ..

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