Tb175w Electric Diagram

TB175W
Hydraulic Excavator
BOOK No. CW3E001
WORKSHOP MANUAL
Serial No. 17540001~

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.
0-2
I . GENERAL
II . SPECIFICATIONS
III . MACHINE CONFIGURATION
IV . HYDRAULIC UNITS
V . TROUBLESHOOTING
VI . ENGINE
0-3
0-4
I . GENERAL
1-1
GENERAL
CONTENTS
Safety Precautions ........................................................................................................ ........................................ 3

Cautions during Disassembly and Assembly ........................................................................................................ 10
Cautions during Removal and Installation of the Hydraulic Units .......................................................................10
Cautions during Removal and Installation of Piping ............................................................................................11
Handling of Seals ..................................................................................................................................................11
................................................................................................................................................12
I-2
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:
DANGER WARNING CAUTION

The word “DANGER” indi- The word “WARNING” indi- The word “CAUTION” indi-
cates an imminently hazard- cates a potentially hazardous cates a potentially hazardous
ous situation which, if not situation which, if not avoided, situation which, if not avoided,
avoided, can result in serious could result in serious injury may result in minor or moder-
injury or death. or death. ate injury.
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 • Wear a hard hat, safety shoes, safety glasses, filter
protective equipment mask, heavy gloves, ear protection and other pro-
• Do not wear loose clothing or any accessory that tective equipment as required by job conditions.
can catch on controls or in moving parts. Wear required appropriate equipment such as
• Do not wear oily or fuel stained clothing that can safety glasses and filter mask when using grind-
catch fire. 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-3
GENERAL
Provide a fire extinguisher and first aid Anti-explosive lighting

kit
Use anti-explosive electrical fixtures and lights

• Know where a fire extinguisher and first aid kit when inspecting fuel, oil, coolant, battery fluid, etc.
are located and understand how to use them. If lighting that is not anti-explosive should break,
• Know how to contact emergency assistance and the substance could ignite, resulting in serious injury
first aid help. or death.
Attach a “DO NOT OPERATE” tag Do not allow unauthorized personnel in

the work area
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 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
Do not use damaged or weakened tools or tools de- slippery areas.
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.
I-4
GENERAL
Always clean the machine Securely block the machine or any com-
ponent that may fall
• Clean the machine before performing mainte-

nance. • Before performing maintenance or repairs under
• Cover electrical parts when washing the machine. the machine, set all working equipment against
Water on electrical parts could cause short-cir- the ground or in the lowermost position.
cuits or malfunctions. • Securely block the tracks.
Do not use water or steam to wash the battery, • If you must work beneath the raised machine or
sensors, connectors or the operatorʼs seat area. 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
Stop the engine before performing main-
especially important when working on hydraulic
tenance
cylinders.
• Avoid lubrication or mechanical adjustments with
the machine in motion or with the engine running
while stationary.
Securely block the working equipment
• If maintenance must be performed with the engine
running, always work as a 2-person team with To prevent unexpected movement, securely block
one person sitting in the operatorʼs seat while the the working equipment when repairing or replacing
other works on the machine. the cutting edges or bucket teeth.
• When performing maintenance, be sure to
keep your body and clothing away from mov-
ing parts.
Secure the engine hood or cover when
opened
Be sure to secure the engine hood or cover when
Stay clear of moving parts
opening it. Do not open the engine hood or cover on
slopes or in strong wind.
Place heavy objects in a stable position
• 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.
When removing or installing the hoe attachment,
place it in a stable position so that it does not tip
over.
I-5
GENERAL
Cautions on working on the machine 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
• 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- Stop the engine and allow the machine to cool down
ditions. before performing inspection and maintenance.
• The engine, muffler, radiator, hydraulic lines,
sliding parts and many other parts of the machine
Use caution when fueling
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 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. Do not remove the radiator cap or drain plugs when
• Clean up spilled fuel immediately. the coolant is hot. Stop the engine, let the engine
• Tighten the fuel tank cap securely. Should the and radiator cool and loosen the radiator cap or drain
fuel cap be lost, replace it only with the original plugs slowly.
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.
I-6
GENERAL
High pressure nitrogen gas is enclosed in the accu-
Be careful with fluids under pressure
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

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 The track adjuster contains highly pressurized
within a few hours by a doctor familiar with this grease. If the tension is adjusted without following
type of injury. 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.
Release all pressure before working on
• Do not put your face, arms, legs or body in front
the hydraulic system
of the grease discharge valve.
Oil may spurt out if caps or filters are removed or
pipes disconnected before releasing the pressure in
the hydraulic system.
Disconnect the battery
• 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.
Disconnect the battery before working on the electri-
cal system or doing any welding. Remove the nega-
Handling of the Accumulator
tive (–) battery cable first. When reconnecting the
battery, connect the negative (–) battery cable last.
I-7
GENERAL
Avoid battery hazards Checks after maintenance

• Batteries contain sulfuric acid which will damage • Gradually raise the engine speed from a low idle
eyes or skin on contact. to maximum speed and check that no oil or air is
• If acid contacts eyes, flush immediately with leaking from serviced parts.
clean water and get prompt medical attention. • Move the controls and check that the machine is
• If acid is accidentally swallowed, drink large operating properly.
quantities of water or milk and call a physician
immediately.
• If acid contacts skin or clothing, wash off im-
Disposing of wastes
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 • Funnel spent fluids from the machine into con-
items. tainers. Disposing of fluids improperly destroys
• Always unfasten the negative (–) battery cable the environment.
first when disconnecting the battery cable. Al- • Follow the prescribed regulations when disposing
ways connect the negative (–) battery cable last of oil, fuel, engine coolant, refrigerant, solvents,
when fastening the battery cable. filters, batteries or other harmful substances.
• Loose battery terminals may result in sparks. Be
sure to fasten terminals tightly.
• Make sure the vent caps are tightened securely.
Tire Maintenance
• 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 • Explosive separation of a tire and/or rim parts can
properly equipped workplace. 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-
Safety signs
rectly.
• Keep all safety signs clean and legible. Changing tires is a job better done by your tire
• Replace all missing, illegible or damaged safety service company.
and warning signs. • 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-8
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-9
GENERAL
CAUTIONS DURING DISASSEMBLY AND CAUTIONS DURING REMOVAL AND INSTALLA-
ASSEMBLY TION OF THE HYDRAULIC UNITS
1. Clean the machine before disassembly opera- 1. Make sure that the temperature of the hydraulic
tion. oil has dropped.
2. Before disassembly, check the machine condi- 2. To prevent a loss of flow of the hydraulic oil,
tions and record them. the residual pressure in the piping and the in-
• Model, Machine Serial Number, Hourmeter ternal pressure in the hydraulic tank should be
• Reason for Repairs, Repair History released.
• Dirtiness of Filters
• Fuel and Oil Conditions 3. Be sure to install caps or plugs on all openings
• Damage to each parts, etc. in the hydraulic unit to prevent dirt from getting
into the unit through the openings.
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, 4. It is easy to mistake hydraulic oil adhering to the
as a rule, use a press. When a hammer, etc., is hydraulic unit for an oil leak, so wipe the unit
used, it leaves bruises. off thoroughly.
8. Wipe all joining surfaces clean so that there is 5. Be sure that no damage is done to the plating on
no dirt or dust adhering to them. the rod in the hydraulic cylinder.
9. Wrap seal tape from the front end, Wrapping it 6. As a rule, removal and installation of the hy-
tight and leaving 1 or 2 threads bare, Overlap the draulic cylinder should be done with the rod
tape by about 10 mm. 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”
10. When fitting the snap rings, the bigger, rounder

side of their circumferences should face the
mating surfaces.
I-10
GENERAL
CAUTIONS DURING REMOVAL AND INSTAL- HANDLING OF SEALS

LATION OF PIPING
1. Clean the grooves for O-rings and if there is any
1. When hydraulic hoses are installed, tighten them burr, etc., remove it.
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.
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
3. After installation of hydraulic hoses or steel get it to fit snugly.
pipes, apply the maximum working pressure 5
or 6 times and confirm that there is no leakage. 5. Apply grease to the lip of the oil seal.
• This is to prevent wear when it is first started
up after assembly.
I-11
GENERAL
TIGHTENING TORQUES
Hydraulic Hoses
Torque
Hose Fitting Size Union Nut (G) Taper Thread (R)
N·m ft-lb N·m ft-lb
1/8 9.8 +4.9
0 7.3 +3.5
0 11.8 ±1.2 8.7 ±0.8
+4.9 +3.5
1/4 24.5 0 18.1 0 29.4 ±2.9 21.7 ±2.1
+4.9 +3.5
3/8 49 0 36.2 0 53.9 ±5.4 39.8 ±3.9
+4.9 +3.5
1/2 58.8 0 43.4 0 88.3 ±8.8 65.1 ±6.4
3/4 117.7 +4.9
0 86.8 +3.5
0 147.1 ±14.7 108.5 ±10.7
+4.9 +3.5
1 137.3 0 101.3 0 196.1 ±19.6 144.7 ±14.3
Bite Type Pipe Fitting for Steel Pipe

Pipe Outer Diameter Torque
(mm) 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
I-12
GENERAL
Joints for Piping
Nominal Thread Torque

Diameter Steel Cast Steel
(R) 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
Joints for Piping (O-ring Seal Type)

Diameter
(G) 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

Diameter
(UNF) 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
I-13
GENERAL
Bolts and Nuts (for ISO Strength Category 10.9)

Torque
Thread Size × Pitch General Tightening Points Special Tightening Points
N·m kgf·m ft-lb N·m kgf·m ft-lb
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
Coarse 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
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
Fine
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
1. General Tightening Points (Non-lubricated) 4. If tightening torque values are provided in this
• All securing points other than the special manual, then tightening should be done accord-
tightening points. ing to those values.
(This indicates that the tightening torque differs
2. Special Tightening Points (Grease with molyb- from the values given in this table.)
denum disulfide applied.)
• Points where particularly necessary due to 5. In order to tighten bolts and nuts evenly, they
function. should be tightened alternately top, bottom, left,
Special tightening positions and associated right.
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.
I-14
II . SPECIFICATIONS
II-1
SPECIFICATIONS
CONTENTS
Names of C .......................................................................................................................................... 3
D ............................................................................................................................................................ 4
Specifications T ...................................................................................................................... ........................ 6
Recommended Lubricants ...................................................................................................................... ..............12
Standards for Judging Performance ...................................................................................................................... 14
Reference Value Table ....................................................................................................................................14
Methods for Inspecting Performance ............................................................................................................. 15
Hydraulic Circuit Diagram .................................................................................................................................... 23
Electrical Wiring Diagram .................................................................................................................................... 25
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
estimated value indicating the use limit for the respective part. It is decided under refer-
ence 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.
II-2
NAMES OF COMPONENTS SPECIFICATIONS
NAMES OF COMPONENTS
1. Cab 10. Axle Lock Cylinder 19. Dozer Blade Cylinder

2. Engine Hood 11. Engine 20. Swivel Joint
3. Fuel Tank 12. Tire 21. Bucket
4. Hydraulic Tank 13. Axle 22. Bucket Cylinder
5. Hydraulic Pump 14. Hub 23. Arm
6. Slew Motor 15. Swing Cylinder 24. Arm Cylinder
7. Pilot Valve 16. Undercarriage 25. Boom
8. Battery 17. Dozer Blade 26. Boom Cylinder
9. Control Valve 18. Steering Wheel 27. Swing Bracket
II-3
DIMENSIONS SPECIFICATIONS
DIMENSIONS Machine Dimensions
Unit: mm
2-Piece Boom Mono-Boom
A 6260 6320
B 2110 ←
C 2925 ←
D 1720 ←
E 1715 ←
F 2100 ←
G 2330 ←
H 2300 ←
J 515 ←
K 335 ←
L 2505 2620
M 1955 2060
N 2385 2495
P 690 ←
Q 730 ←
R 1815 ←
S 600 ←
T 4380 4445
U 2895 2645
V 80° ←
W 50° ←
2-Piece Boom Operating Range

Unit: mm
2-Piece Boom
A 7650
B 7430
C 4085
D 3600
E 8325
F 6355
G 2665
H 4360
J 335
K 145
II-4
DIMENSIONS SPECIFICATIONS
Mono-Boom Operating Range
Unit: mm
Mono-Boom
A 6945
B 6700
C 4055
D 3220
E 6780
F 4765
G 1330
H 4270
J 335
K 145
II-5
SPECIFICATIONS TABLES SPECIFICATIONS
SPECIFICATIONS TABLES
SPECIFICATIONS
Serial Number 17540095 or later

Machine Type 2-Pice Boom Mono-Boom
Machine Mass (not including operator) kg 8130 7905
Engine Rated Output kW/min–1 49.3/2300 ←
Bucket Capacity (Standard Bucket)
Rated Capacity m3 0.245 ←
Struck Capacity m3 0.185 ←
Performance
Slew Speed: Slow Speed min–1 4.1 to 7.6 ←
Normal Speed min–1 10.7 ←
Travel Speed:
Forward: Creep km/h 0 to 4.5 ←
Site km/h 0 to 9.0 ←
Road km/h 0 to 20 ←
Reverse: Creep km/h 0 to 4.5 ←
Site km/h 0 to 9.0 ←
Road km/h 0 to 20 ←
Gradeability % (degree) 70 (35) ←
Minimum Turning Radius mm 5855 ←
Minimum Turning Clearance Radius mm 5615 ←
Noise Level: Sound-power level dB (A) LWA 99 ←
Sound-pressure level dB (A) LPA 77 ←
Auxiliary Hydraulic Flow Rate 1st L/min 69 ←
2nd L/min 53.6 ←
3nd L/min 11.3 ←
Dimensions
Overall Length mm 5685 ←
Overall Width mm 2330 ←
Overall Height mm 3990 ←
Dimensions of Base Machine
Tail Swing Radius mm 1720 ←
Distance of Rearmost Upper Structure from Axis of Rotation mm 1715 ←
Clearance Height under Upperstructure mm 1140 ←
Wheel Base mm 1815 ←
Rear Overhang mm 765 ←
Minimum Ground Clearance mm 335 ←
II-6
STANDARDS FOR JUDGING PERFORMANCE SPECIFICATIONS

Machine Type 2-Pice Boom Mono-Boom
Working Equipment (Hoe Attachment)
Boom Swing Angle: L.H. degree 80 ←
R.H. degree 50 ←
Maximum Reach mm 7650 6945
Maximum Reach at GRP mm 7430 6700
Minimum Level Cut Radius with Bucket Flat on GRP mm 905 1700
Maximum Digging Depth mm 4085 4055
Radius at Maximum Digging Depth mm 2665 2425
Vertical Digging Depth mm 3660 3220
Maximum Digging Height mm 8325 6780
Radius at Maximum Digging Height mm 1335 3985
Maximum Dumping Height mm 6355 4765
Radius at Maximum Dumping Height mm 2090 4345
Minimum Dumping Height mm 2665 1330
Minimum Front Swing Radius mm 2505 2620
Minimum Front Swing Radius at Boom Offset mm 1955 2060
Overall Height at Minimum Front Swing Radius mm 5180 4975
Overall Height at Minimum Front Swing Radius at Boom Offset mm 5395 4975
Maximum Bucket Offset Volume: Left mm 690 ←
Right mm 730 ←
Digging Force: Bucket kN 52.7 ←
Arm kN 36.0 ←
Working Equipment (Dozer Blade)
Dozer Blade: Width mm 2300 ←
Height mm 600 ←
Dozer Blade: Lift Height mm 335 ←
Depth of Cut mm 145 ←
II-7
SPECIFICATIONS OF DEVIDES

Engine
Model Yanmar 4TNV98T-ZSTBW
Type 4-cycle, vertical, water-cooled, in-line, 4-cylinder diesel engine
Number of Cylinders – Bore × Stroke mm 4-98 × 110
Total Displacement mL 3318
Compression Ratio 18
Performance
Maximum Torque N·m/min-1 271.3 to 295.8/1650 ±100
Maximum No-load R.P.M. min–1 2350 ±10
Minimum No-load R.P.M. min–1 1100 ±10
Specific Fuel Consumption g/kW·h <
=249
Starter V – kW 12 – 3.0
Generator V – kW 12 – 0.96
Battery V – A·h 12 – 90
Hydraulic Pump
Model K3SP36C-1CFR-9002-2
Type Variable displacement type double axial piston
Delivery: P1 L/min 72.6
P2 L/min 72.6
Rated Pressure: P1 MPa 27.4/31.0*
P2 MPa 27.4/31.0*
Hydraulic Pump (Gear)
Model SDYA259.5F1H1-R473
Type Double gear
P4 L/min 20.9
Rated Pressure: P3 MPa 24.0
P4 MPa 17.5
Hydraulic Pump (Gear)
Model GPW1-C-4A
Type Gear
Rated Pressure: P5 MPa 3.4
Control Valve (Mono-Block)
Model KVMM-80-TB
Number of Circuits Mono-Block
Main Relief Valve Pressure Setting MPa 27.4/31.0*
Port Relief Valve Pressure Setting MPa 33.3
MPa 20.6
*: In Case of raise
II-8
Control Valve (4-Section)

Model KVSE31-4
Number of Circuits 4
Main Relief Valve Pressure Setting MPa 24.0
Port Relief Valve Pressure Setting MPa 26.9
MPa 20.6
Solenoid Valve
Model 16521-00010
Number of Solenoids 4
Solenoid Rated Voltage V 12
Relief Valve Set Pressure MPa 3.4
Solenoid Valve
Model 16545-00000
Solenoid Valve (2-Piece Boom)
Model 16522-00000
Proportional Control Solenoid
Model 2KWE5A-30/G12R-269
Solenoid Rated Voltage 12
Pilot Valve
Model PV48M2
Secondary Side Pressure (Ports 1, 3) MPa 0.54 to 2.06
(Ports 2, 4) MPa 0.64 to 1.86
Operating Angle: Single (Ports 1, 3) degree 19
Single (Ports 2, 4) degree 25
Pilot Valve (Swing)
Model PV6P1013A
Secondary Side Pressure MPa 0.49 to 2.06
II-9
Boom Cylinder
Bore Diameter × Rod Diameter mm 120 × 75
Stroke mm 725
Fully Retracted Length (Pitch) mm 1207
Cushion Mechanism Rod Side
Arm Cylinder
Stroke mm 875
Cushion Mechanism Both Ends
Bucket Cylinder
Stroke mm 660
Cushion Mechanism ––
Boom Adjustment Cylinder
Stroke mm 580
Cushion Mechanism ––
Slew Motor
Model MSG-44P-21
Type Piston Motor
Total Displacement cm3/rev 702.4
Motor Displacement cm3/rev 34.1
Redution Gear Ratio 1/20.615
Relief Valve Pressure Setting MPa 23.5
Parking Brake Torque N·m 177.9
Parking Brake Release Pressure MPa 1.5
Travel Motor
Model A6VM80HA1TA
Motor Displacement: Low cm3/rev 80
Hi cm3/rev 27.2
Front Axle
Type 212
Rear Axle
Type 112
Drop Box Type 357
Reduction Gear Ratio: Low 1:3.28
Hi 1:1.43
Reduction Gear ––
Differential 11.35
Hub 1:6.00
II-10
Tire
Front Tire: Qty. 4
Size 8.25-20-12PR
Tire Pressure kpa 600
Steering System
Type Front Setting System
Operation Type Hydraulically-Operated
Breake Device
Travel Brake Type Front and rear wheel braking, direct acting hydraulic
disk with brake lock
Parking Brake Type Rear wheel braking disk
Outrigger (Option)
Type Hinge
II-11
RECOMMENDED LUBRICANTS SPECIFICATIONS
RECOMMENDED LUBRICANTS
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.
Type by air temperature When to change/

Part Type -20 -10 0 10 20 30 40°C Capacity
replenish
Every 250 hrs

Diesel engine oil SAE 10W-30 Upper limit 10.2 L
Engine oil pan after the first 50
API: CF class SAE 15W-40 Lower limit 5.7 L
hrs
Takeuchi genuine
ISO VG46 Every 4000 hrs**
hydraulic oil 46
Total amount of
Hydraulic oil oil: 135 L
tank ISO VG32 Tank capacity:
Anti-wear hydrau- 68 L
ISO VG46 Every 2000 hrs**
lic oil
ISO VG68
Engine cooling Cooling water Mixture of 50% coolant

Every 1000 hrs 12.0 L
system (water + coolant)* Mixture of 30% coolant
Gear oil
Hub SAE 90 Every 1500 hrs 1.0 L
API: GL-4
Gear oil
Transmission SAE 90 Every 1500 hrs 1.3 L
API: GL-4
Gear oil
Differential SAE 90 Every 1500 hrs 8.5 L
API: GL-4
Undercarriage Every 250 hrs
Slew bearing Lithium grease Every 50 hrs
Working equip- EP-2 –– Daily or every As required
ment NLGI No.2 10 hrs
Levers When required
*: 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 manufacturerʼs
instructions to determine the mixture ratio.
**: The replacement interval for hydraulic oil depends on the oil type being used. New machines are shipped
from the factory with the Takeuchi genuine hydraulic oil 46. This manual describes when to replace the
hydraulic oil assuming that this Takeuchi oil 46 is used. When a conventional antiwear hydraulic oil is used,
replace it every 2000 hours.
II-12
RECOMMENDED LUBRICANTS SPECIFICATIONS
Diesel fuel standards
Use the diesel fuel that is compliant with any of the
standards below. The table below shows the stan-
dards from the various countries.
Diesel fuel standards Region

No. 2-D, No. 1-D, ASTM D975-94 USA
EN590:96 EU
Part Type Capacity

To keep the performance and service life of the engine, al-
ways use the clean and high-quality fuel.
• To avoid freezing in cold climates, use a light oil that still
functions when the temperature is at least 12°C below the
lowest expected ambient temperature.
• Use a light oil that has a cetane number of 45 or higher.
When operating at a very low temperature or at a high
altitude, a higher cetane number fuel will be required.
• The sulfur content must be less than 0.5% by volume. he
recommended value, however, is less than 0.05%. The
Fuel tank Desel fuel 120 L
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 sulfu-
ric acid corrosion inside the cylinder.
• Do not mix diesel 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.
II-13
STANDARDS FOR JUDGING PERFORMANCE
REFERENCE VALUE TABLE

Machine Type 2-Piece Boom Mono-Boom
Item Unit Standard Values Allowable Values Standard Values Allowable Values
Hydraulic Oil Pressure
Travel MPa 31.00 31.00
Boom MPa 27.46 27.46
Arm MPa 27.46 27.46
Dozer Blade MPa 24.0 24.0
Slew MPa 23.54 23.54
Pilot Pressure MPa 3.43 3.43
Brake, Steering MPa 17.16 17.16
Slew
Slew Time Normal Speed s 10.82 10.82
Slow Speed s 14.53 14.53
Overrun When Slewing Stops mm 498.5 380
Natural Slew Drop mm 0 0
Cylinders
Cylinder Speed
Boom Extended s 3.10 2.20
Retracted s 3.65 2.65
Arm Extended s 3.43 3.43
Bucket Extended s 3.36 3.36
Dozer Blade Extended s 1.91 1.91
Swing Extended s 8.38 8.1
Adjust Extended s 7.81 ––
Retracted s 7.42 ––
Cylinders
Natural Cylinder Drop
Boom mm 3 2
Arm mm 2 2
Bucket mm 2 2
Dozer Blade mm 0 0
Swing mm 5 5
Adjust mm 6 ––
Bucket Tip mm 100 60
Slew Bearing
Backlash mm 30 ±10 30 ±10
II-14
METHODS FOR INSPECTING PERFOR-
MANCE
Hydraulic Oil Pressure (Main Relief Valve

Set Pressure)
Travel, Boom, Arm
Measuring Method
• Engine : Maximum r.p.m.
• Hydraulic Oil Temp. : 50~60°C
• Mount the pressure gauge on the pressure detec-
tion port, operate the desired hydraulic circuit and
measure the relief pressure.
Pressure Detection Port Relief
Circuit
Port Position Size Valve
Boom P1 G1/4
Arm P2 G1/4 R1
Travel P1 G1/4
Adjusting Method
Travel circuit (High pressure set)
1. Loosen the lock nut (1).
2. Fasten the plug (2) until the piston (3) contacts
the surface A of the plug (4).
• Be sure that the plug (4) does not turn together
with the plug (2). 4
A 5
• The tightening torque of the plug (2) is B
19.6N·m or less.
• The size B is 4 mm or more.
3. Turn the plug (4) and adjust the set pressure.
• Turn the plug slowly by referring to the pres-
sure gauge.
• The pressure increases by 21.3 MPa at one
turn of the plug.
4. Upon completion of the pressure adjustment,
hold the plug (4) to prevent it from turning and 3 1 2
fasten it with the lock nut (5). W2B010
Boom and Arm Circuits (Low pressure set)

5. First, set the travel circuit (high pressure set),
then loosen the plug (2) and adjust the set pres-
sure.
• Turn the plug slowly by referring to the pres-
sure gauge.
• The pressure decreases by 21.3 MPa at one
turn of the plug
hold the plug (2) to prevent it from turning and
fasten it with the lock nut (1).
7. Actuate the relief valve again and confirm that
the set pressure is stable.
II-15
Dozer Blade
Measuring Method
• Mount the pressure gauge on the pressure detec-
tion port, operate the desired hydraulic circuit and
measure the relief pressure.

Circuit
Dozer Blade P3 G1/4 R3
Adjusting Method
1. Loosen locknut (2), then begin adjusting pres-
sure by turning setting screw (1).
Turning clockwise................ raises the set pressure.
Turning counterclockwise.... lowers the set pressure.
2. In order to keep the setting screw from turning
after pressure has been adjusted, tighten the
locknut while at the same time holding the set-
ting screw firmly in place.
3. Operate the relief valve once more to confirm
that the pressure that has been set it stabilized.
II-16
Hydraulic Oil Pressure (Slewing Relief Valve
Set Pressure)
Measuring Method
• Mount the pressure gauge on the pressure de-
tection port and set a solid obstacle so that the
upperstructure cannot slew in the direction to be
measured. Next, operate the circuit to be mea-
sured and measure the relief pressure.

Circuit
Right Slew D G1/4 SR1
Left Slew E G1/4 SR2
Adjusting Method
1. Loosen locknut (2), then begin adjusting pres-
sure by turning setting screw (1).
Turning clockwise................ raises the set pressure.
Turning counterclockwise.... lowers the set pressure.
2. In order to keep the setting screw from turning
after pressure has been adjusted, tighten the
locknut while at the same time holding the set-
ting screw firmly in place.
3. Operate the relief valve once more to confirm
that the pressure that has been set it stabilized.
II-17
Hydraulic Oil Pressure (Pilot Relief Valve
Set Pressure)
Measuring Method
• Hydraulic Oil Temp. : 50~60˚C
• Mount pressure gauge on the pressure detection
port and measure the pilot relief pressure.
Pressure Detection Port

Relief Valve
Port Position Size
P5 G1/4 PR
Pressure Adjustment
The relief valve pressure is set at the factory. Do not
adjust it unless necessary.
1. Remove the cap screws, and then remove the
cover (1).
2. Remove the spring (2) and the plunger (3).
3. Adjust the pressure with the shims (4)
Shim thickness ..........0.2 mm
Shim thickness ..........0.5mm
0.2 mm Remove Decrease of approx. 0.13 MPa

Add Increase of approx. 0.13 MPa
0.5 mm Remove Decrease of approx. 0.31 MPa
Add Increase of approx. 0.31 MPa

assemble the relief valve and confirm that the
relief valve set pressure is stable.
Cap Screw: 3.92 N·m
Hydraulic Oil Pressure (Steering Relief Valve

Set Pressure)
Measuring Method
• Mount pressure gauge on the pressure detection
port and measure the pilot relief pressure.
Pressure Detection Port

Relief Valve
Port Position Size
P4 G1/4 ––
II-18
Slew Time
• Measurement Posture : Completely retract the
arm cylinder, fully extend the bucket cylinder and
adjust so that boom foot pin and bucket pin are
at matching height. Rest the dozer blade on the
ground.
• With the hoe attachment in a no-load state, wait
1 rotation, then measure the time required for the
next 2 rotations.
Overrun When Slewing Stops

• Measurement Posture : Same as that for measur-
ing slew time.
• Draw matching marks on the outer race of the
slew bearing and lower frame at an exactly 180
degrees rotation from the starting point. With the
hoe attachment in a no-load state, rotate 180 de-
grees at, which point return the operation lever
to neutral. Measure the differential between the
position marks and the point the hoe attachment
stops.
Natural Slew Drop

• Engine : Stopped
• Grade : 15°
ing slew time.
• Rotate the upper machinery so that it is directly
abeam of the grade, then draw positional marks
on the slew bearingʼs outer race and the lower
frame. Then measure the distance that develops
between the marks after 5 minutes.
Boom Cylinder Speed

arm cylinder, fully extend the bucket cylinder and
rest the dozer blade on the ground.
• Then measure the time required for the bucket to
reach its highest elevation point (lowest point)
from its lowest point (highest point) resting on the
ground. (Do not include the cushioning time.)
II-19
Arm Cylinder Speed
arm cylinder, fully extend the bucket cylinder,
position the arm horizontally and rest the dozer
blade on the ground.
• Then measure the time required for the arm cyl-
inder to completely retract (extend) from a fully
extended state (retracted state).
Bucket Cylinder Speed

arm cylinder, position the arm horizontally and
rest the dozer blade on the ground.
• Then measure the time required for the bucket
cylinder to completely retract (extend) from a
fully extended state (retracted state).
Dozer Blade Cylinder Speed

• Measurement Posture : Using the hoe attachment,
lift up the dozer blade end of the excavator.
• Then, raising and lowering the dozer blade full
stroke, measure the time required per stroke in
each direction.
Swing Cylinder Speed

ing slew time.
• While swinging the boom left (right) to right
(left), measure the time required for a full stroke
each way.
(Do not include the cushioning time.)
II-20
Adjust Cylinder Speed
arm cylinder, fully extend the bucket and boom
cylinders, position the arm horizontally and rest
the dozer blade on the ground.
• Then measure the time required for the adjust cyl-
inder to completely retract (extend) from a fully
extended state (retracted state).
Natural Cylinder Drop

Boom, Arm, Bucket, Dozer Blade, Bucket Tip
dozer blade and arm cylinders, fully extend the
bucket cylinder and adjust the bucket pin position
to the same height as the boom foot pin.
• Maintain this position for 10 minutes, then mea-
sure the change in rod length and the distance the
bucket tip falls.
Swing Cylinder
• Engine : Stopped
• Grade : 15˚
ing slew time.
• Rotate the upper machinery so that it is directly
abeam of the grade, then measure the change in
rod length after 5 minutes.
II-21
II-22
III . MACHINE CONFIGURATION
III- TB175W
MACHINE CONFIGURATION
CONTENTS
Drive System............................................................................................................................................................3
Slew System.............................................................................................................................................................9
Travel System........................................................................................................................................................ 11
Upper Frame..........................................................................................................................................................13
Control System......................................................................................................................................................21
Attachments...........................................................................................................................................................27
Hydraulic System...................................................................................................................................................33
Electrical System...................................................................................................................................................37
Air Conditioner System.........................................................................................................................................44
TB175W III-
DRIVE SYSTEM MACHINE CONFIGURATION
DRIVE SYSTEM
CONSTRUCTION
Engine Mount 1/2
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B: 241 N·m 1. Engine Foot FL 9. Ground Cable

C: 193 N·m 2. Engine Foot FR 10. Bracket
D: 55 N·m 3. Engine Foot RL 11. Exhaust Pipe
Apply thread-locking compound. 12. Pipe
4. Engine Foot RR
E: “A” Mark
F: 23 N·m 5. Stopper 13. Bracket
G: 3.9 N·m 6. Stopper 14. Silencer
7. Cushion Rubber 15. Gasket
8. Cushion Rubber 16. Gasket
III-3
III- TB175W
MACHINE CONFIGURATION DRIVE SYSTEM
Engine Mount 2/2
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A: 3.9 N·m
A: 4.9 N·m
1. Bracket 12. Hose
2. Air Cleaner 13. Hose
3. Hose 14. Hose
4. Hose 15. Sub Tank
5. Pipe 16. Bracket
6. Pipe 17. Plate
7. Pipe 18. Hose
8. Pipe 19. Sensor
9. Hose 20. Joint
10. Hose 21. Hose
11. Drain Vave
TB175W III-
III-4
DRIVE SYSTEM MACHINE CONFIGURATION
Radiator and Oil Cooler

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1. Stay 8. Bracket
2. Stay 9. Bracket
3. Shroud 10. Guard
4. Plate 11. Cushion Rubber
5. Plate 12. Radiator and Oil Cooler
6. Plate 13. Cushion Rubber
7. Net 14. Guard
III-5
III- TB175W
Pump Coupling

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A: Supply molybdenum disulfide grease.

B: 86 N·m
C: 54.9 N·m 1. Engine Housing
D: 255.8 N·m
2. Hydraulic Pump
3. Hab
4. Gear Pump
The pump coupling connects the engine flywheel

and the hydraulic pump’s drive shaft. It is construct-
ed so that it absorbs vibrations, torsions, impact and
out of center of the engine and hydraulic pump.
P1 P3 P4
• Refer to the table concerning the responsibility
of each of the pumps shown in the drawing at
right.
P1 Travel, Bucket, Boom[1], Arm[2]
P2 Travel, Auxiliary, Boom[2], Arm[1], Swing
P3 Outrigger, Slew, Auxiliary P2
P4 Steering, Brake P5
W2C104
P5 Pilot Pressure
TB175W III-
III-6
Fuel Supply Pump

:&
A: 0.78 N·m
B: “Red” Mark
C:Upon assembling, inspect the continuity using a 1. Box 8. Hose
tester when the level switch float (13) is at ON and 2. Resistor 9. Plug
OFF positions. 3. Switch 10. Level Switch
Float is at OFF (upper) position There is no continuity. 11. Strainer
4. Relay
Float is at ON (upper) position There is no continuity.
5. Wire Harness 12. Pump
6. Diode (3A, yellow) 13. Float
7. Hose
TB175W III-
III-8
MACHINE CONFIGURATION TRAVEL SYSTEM
TB175W III-12
MACHINE CONFIGURATION Upper frame
Floor Plate
3 2 1 4
6
6 5
8
7
8
10 W2C401
1. Floor Plate
2. Floor Mat
3. Cover
4. Stage
5. Tube
6. Tube
7. Rubber
8. Cover
9. Cover
10. Pipe
TB175W III-14
Upper frame MACHINE CONFIGURATION
Heater

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D: Grease with molybdenum disulfide applied.
B: 23.5 N·m
1. Cover 9. Filter
2. Plate 10. Cover
3. Selector Damper 11. Hose
4. Bracket 12. Hose
5. Panel 13. Heater Assembly
6. Cover 14. Switch
7. Wire 15. Valve
8. Wire
III-15 TB175W

:&
1. Bracket 9. Hazard Switch

2. Box 10. Pilot Lamp
3. Louver 11. Pilot Lamp
4. Defroster Hose 12. Pilot Lamp
5. Parking Brake Switch 13. Pilot Lamp
6. Site Travel Switch 14. Creeping Travel Switch
7. Axle Lock Switch 15. Ornament
8. Light Switch
TB175W III-16
D

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A: ACC Relay 1. Clamp 9. Cable

B: Air Heat Relay 2. Box 10. Battery Cable
C: Actuator Relay 3. Plate 11. Terminal
D: Main Relay
E: Starter Relay
4. Relay 12. Clamp
5. Relay 13. Cover
F: 12.3 N·m 6. Sheet 14. Battery Switch
G: 9.8 N·m 7. Battery 15. ECU
8. Bracket 16. Ground Cable
III-17 TB175W
Radio

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1. Cover R
2. Cover L
3. Bracket
4. AM/FM Radio
5. Speaker R
6. Speaker L
TB175W III-18
Covers

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A: 54.9 N·m
Apply thread-locking compound.
B: 26.5 N·m
1. Engine Food 9. Under Cover Assembly 17. Lock Plate

2. Engine Cover [Front] 10. Under Cover Assembly 18. Link
3. Side Cover L 11. Handrail 19. Yoke
4. Side Cover R 12. Plate 20. Hinge
5. Front Cover 13. Stay 21. Gas Spring
6. Center Cover F 14. Stay 22. Under Cover
7. Center Cover T 15. Hook 23. Plate
8. Under Cover 16. Wire 24. Under Cover
III-19 TB175W
TB175W III-20
Control SYSTEM MACHINE CONFIGURATION
Control SYSTEM
CONSTRUCTION
Steering Unit
4
1
8
3
29
30
31
32
9
11
12 2
13 5
16 10
22
14 23 25 27
20
7 6
24
15
28
21
19
18 26
17
W2C500
1. Washer 9. Shaft 17. Pin 25. Support

2. Telescopic Device 10. Bracket 18. Pin 26. Half Bowl
3. Woodruff Key 11. Ring 19. Collar 27. Clamp
4. Nut 12. Covering 20. Substructure, Compl. 28. Pedal
5. Spring 13. Washer 21. Plate 29. Steering Wheel
6. Shield 14. Half Bowl 22. Stop 30. Turning Handle
7. Covering 15. Substructure 23. Spring 31. Cap
8. Spring 16. Segment 24. Shaft 32. Switch
III-21 TB175W
MACHINE CONFIGURATION Control SYSTEM
11 3A2
1
24 4Pb2
5Pb2
10
a2
4Pb3
2 20
b2
21
RP T7
R4
R3
4Pa2
5Pa2
R1
R2
RT 4Pa3
SH
A LP
L4
16
L3
3ST
L1
L2
LT
9 C1 SSP
C2 B1
MONO BOOM D
B2
A1
A2
PM3
PM4
PM5
4
AST PM1
7
TM3
PM2
3ST TM5
BSP BST TM1
TM2
8
5 A TM6
TM4
13 W2C504E
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TB175W III-22

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♦ Table of Connections ♦
1 R1 ↔ 4Pb2 10 5 BS1 ↔ 5Pa1 12 PP ↔ 5Pb3 10
10 　　
1. Right Pilot Valve
1 R2 ↔ 4Pa3 10 5 BST ↔ TM4 8 12 PT ↔ T13 11 2. Left Pilot Valve
1 R3 ↔ 4Pa2 10 5 BSP ↔ PM1 7 13 3SA ↔ MPp 22 3. Steering Valve
4. Accelerator Valve
1 R4 ↔ 4Pb3 10 6 S1 ↔ AC1 18 13 3SB ↔ ③ 17
5. Pilot Valve (Swing)
1 RP ↔ PM2 7 6 S2 ↔ AC2 19 13 3ST ↔ TM6 8 6. Brake Valve
1 RT ↔ TM2 8 6 BR1 ↔ ② 17 13 3SP ↔ Pp 20 7. Manifold
8. Manifold
2 L1 ↔ B2 9 6 BR2 ↔ ④ 17 13 4SD ↔ ① 17 9. Shuttle Valve
2 L2 ↔ 5Pb2 10 6 P ↔ A4 14 13 3SC ↔ ⑤ 17 10. Control Valve (Mono-Block)
2 L3 ↔ A2 9 6 T ↔ T4 11 23 P5 ↔ A 15 11. Hydraulic Tank
12. Pilot Selector
2 L4 ↔ C2 9 7 PM3 ↔ 3A2 24 15 B ↔ Pp 10 13. Solenoid Valve (Mono-Boom)
2 LP ↔ PM4 7 9 B1 ↔ a2 20 10 4Pa1 ↔ 5Pb5 10 Solenoid Valve (2-Piece Boom)
2 LT ↔ TM5 8 9 A1 ↔ b2 20 10 5Pa5 ↔ 4Pb1 10 14. Hydraulic Pump
15. Line Filter
3 STR ↔ 5 17 9 C1 ↔ 5Pa2 10 15 B ↔ P 24 16. Proportional Control Solenoid Valve
3 STL ↔ 6 17 9 D ↔ SH 21 10 Pp ↔ PP 20 17. Swivel Joint
18. Accumulator
3 STT ↔ T10 11 10 5Pb4 ↔ SSA2 16 10 Pp ↔ Pd 21
19. Accumulator
3 STP ↔ N 6 10 5Pa4 ↔ SSA1 16 8 TM3 ↔ T7 11 20. Control Valve
4 AS1 ↔ 4Pa1 10 11 T6 ↔ SST 16 1S SSP ↔ PM5 7 21. Slew Motor
22. Selector Valve (2-Piece Boom)
4 AS2 ↔ 5Pa5 10 10 Dr ↔ T5 11
23. Pipe
4 AST ↔ TM1 8 10 PDB ↔ 5Pa3 10 24. Solenoid Valve
4 ASP ↔ A5 24 12 PA ↔ 4Pa2a 10
5 BS2 ↔ 5Pb1 10 12 PPL ↔ 4Pa4 10
III-23 TB175W
Control Box R
7 13
8 9 10 11 12
6
14 12
13 3 4 VIEW A
VIEW B
A
1
5 2
14 B
W2C506E
1. Panel Cover R 5. Clamp 9. Light Switch 13. Fuse Box

2. Cover 6. Cluster Gauge 10. Wiper Switch 14. Safety Relay
3. Cover 7. Starter Switch 11. Safety Lock Button
4. Panel Cover R 8. Slew Speed Switch 12. Fuse Box
Control Box L
1 2
Air Conditioner
W2C507E
1. Panel Cover L
2. Cover
3. Clamp
TB175W III-24
Dozer Blade Lever
3 5
1
7
6
2
4
W2C508
1. Dozer Blade Lever 4. Control Cable 7. Hinge

2. Bracket 5. Yoke
3. Cover 6. Cigarette Lighter
Swing Pedal
4
5
1
3 2 B
6
VIEW B W2C509E
1. Bracket 3. Cover 5. Elbow

2. Swing Pedal 4. Bushing 6. Pilot Valve (Swing)
III-25 TB175W
Pilot Valve (Brake)
2
1
3
2 4
W2C510
1. Pilot Valve (Brake) 3. Elbow

2. Adapter 4. Adapter
Pilot Valve (Travel)
4 2 1
A 3
2, 4
2, 3
VIEW A
W2C511E
1. Pilot Valve (Travel) 3. Elbow

2. Bushing 4. Elbow
TB175W III-26
Attachments MACHINE CONFIGURATION
Attachments
CONSTRUCTION
2-Piece Boom 1
D
$

D

; ;

D

F
E F

E
%
%

$ :&
A: 26 N·m
B: 31.5 ±5.88 N·m
• Keep the clearance at the pin connecting section
(excluding the bucket connecting section) to 0.5 mm
or less by using the shim.
• When fastening the lock bolt with double nuts, main-
tain a clearance between the nuts and the bushing
of 0.5~1.0 mm when tightening the double nuts.
1. Boom 12. Pin 23. Shim 34. Tube

2. Bushing 13. Pin 24. O-ring 35. Tube
3. Dust Seal 14. Pin 25. Pin 36. Clamp
4. Intermediate Boom 15. Pin 26. Pin 37. Band
5. Plate 16. Shim 27. Shim 38. Band
6. Protector 17. Grease Nipple 28. Protector 39. Cap
7. Clamp 18. Boom Light 29. Pin
8. Cover 19. Bulb 30. Plate
9. Wire Harness 20. Boom Cylinder 31. Grease Nipple
10. Rubber 21. Arm Cylinder 32. Elbow
11. Bracket 22. Boom adjustment Cylinder 33. Elbow
III-27 TB175W
MACHINE CONFIGURATION Attachments
2-Piece Boom 2

;

;

:&

tain a clearance between the nuts and the bushing 1. Pipe L 10. Pipe L
of 0.5~1.0 mm when tightening the double nuts. 2. Pipe R 11. Pipe
3. Clamp 12. Cap
4. Hose 13. Grease Nipple
5. Pipe 14. Hose
6. Hose 15. Hose
7. Clamp 16. Hose
8. Adapter 17. Cap
9. Pipe R
TB175W III-28
Mono-Boom

;

;

D
D E

E
%

%
$ :&
A: 26 N·m
B: 31.5 ±5.88 N·m
1. Boom 11. Rubber 21. Adapter 31. Tube

2. Bushing 12. Bracket 22. Grease Nipple 32. Protector
3. Dust Seal 13. Clamp 23. Boom Light 33. Gauge
4. Cover 14. Clamp 24. Bulb 34. Plate
5. Plate 15. Pin 25. Boom Cylinder 35. Cap
6. Protector 16. Pin 26. Arm Cylinder 36. Band
7. Pipe R 17. Pin 27. Hose 37. Band
8. Pipe L 18. Pin 28. Hose 38. Band
9. Pipe 19. Pin 29. O-ring
10. Wire Harness 20. Shim 30. Tube
III-29 TB175W
Arm

&

&
'
:

:

:

<

:,7+5'
7+$8;/,1(

:,7+5'
' 7+$8;/,1( <

' ;
'

&

& '

;
3,(&(%220

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A: 26 N·m
1. Arm 12. Pin 23. Shim

2. Bushing 13. Pin 24. Shim
3. Bushing 14. Pin 25. Shim
4. Dust Seal 15. Pin 26. Cap
5. Dust Seal 16. Pin 27. Gauge
6. Bucket Link 17. Grease Nipple 28. Plate
7. Bushing 18. Elbow 29. Cap
8. Bushing 19. Elbow 30. O-ring
9. Dust Seal 20. O-ring 31. Elbow
10. Guide Link L 21. Bucket Cylinder
11. Guide Link R 22. Hose
TB175W III-30
inspection and adjustment
Adjusting the Clearance Between the Buck-

et and Arm
Adjust the clearance between the bucket and arm so
that it is 0.5 mm.
1. Clean the bucket mount and the area around it

thoroughly.
2. Slide the O-ring (1).
3. Measure the clearance (X).

• The opposite side (Y) should be fitting tight-
ly with no clearance.
4. Calculate the amount of the clearance adjust-

ment (the number of shims which need to be
moved).
• Subtract the recommended clearance, 0.5
mm from the value calculated above [clear-
ance (X)]. However, since the thickness of
the adjustment shims is 0.5 mm, the actual
clearance will be a value near 0.5.
Example: If the clearance (X) is 1.8 mm,
1.8 – 0.5 = 1.3 mm
Shims to be moved: 2 shims
5. Loosen the bolts (2), leave one and take out the
other 2.
6. With the bolt remaining in the end plate (3),

flange (4) and shim (5), remove the parts so that
their assembly order is not destroyed.
7. Take out only the number of shims required for

clearance adjustment from between the bushing
(6) and flange.
8. Insert the shims which were just removed be-

tween the flange and the end plate, then reas-
semble the parts.
Tighten the 3 bolts uniformly.
Bolt: 83 N·m
9. Return the O-ring to its proper position.
III-31 TB175W
TB175W III-32
HYDRAULIC SYSTEM MACHINE CONFIGURATION
HYDRAULIC SYSTEM
HYDRAULIC CIRCUIT DIAGRAM
2 Piece Boom
:&
III-33 TB175W
MACHINE CONFIGURATION HYDRAULIC SYSTEM
Mono-Boom
:&
TB175W III-34
Hydraulic SYSTEM MACHINE CONFIGURATION
CONSTRUCTION
Hydraulic Tank

'(7$,/%
%

6(&7,21&&

&
$

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A: 54.9 N·m
1. Tank 10. O-ring

2. Air Breather 11. Sight Gauge
3. Cover 12. Plug
4. Cover 13. O-ring
5. Spring 14. Check Valve
6. Filter Element 15. Snap Ring
7. Check Valve 16. Adapter
8. Suction Filter 17. Washer
9. O-ring 18. Bushing
III-35 TB175W
MACHINE CONFIGURATION Hydraulic SYSTEM
Bleeding the air

IMPORTANT: After replacing the hydraulic oil,
bleed the air from the hydraulic circuit and hy-
draulic devices. Failure to do so may damage
the hydraulic devices.
Hydraulic pump
1. Open the engine hood.
2. Disconnect the drain hose (1) from the hydrau- 1 2

lic pump.
3. Once hydraulic oil overflows from the elbow (2),

connect the drain hose (1).
W2C705
Slew motor
1. Loosen the bolts and remove the center cover (1).
2. Remove the plug (2).
3. Once hydraulic oil overflows from the plug

hole, tighten the plug (2).
4. Install the center cover (1).
Cylinders
1. Start the engine and run it at low idle for 10
minutes.
2. Set the engine to a low idle, then extend and

contract all the cylinders 4 or 5 times, without
going to the stroke end. 2
3. Run the engine at high speed, then extend and
contract all the cylinders 4 or 5 times, without
1
going to the stroke end.
4. Set the engine back to a low idle, then extend

and contract all the cylinders 4 or 5 times to the
W2C706
stroke ends.
TB175W III-36
ELECTRICAL SYSTEM MACHINE CONFIGURATION
ELECTRICAL SYSTEM
ELECTRICAL WIRING DIAGRAM
1/3
:&
III-37 TB175W
MACHINE CONFIGURATION ELECTRICAL SYSTEM
2/3
:&
TB175W III-38
3/3
:&
III-39 TB175W
TB175W III-40

$ %

a

% $
D
E
F
G
H
I
J

K

:&
a: Horn relay
b: Wiper relay 1. Wire Harness 9. Relay
c: Light relay 2. Short Connector 10. Controller
d: Lift alarm relay 3. Cap 11. Flasher Relay
e: Parking light relay
4. Wire Harness 12. Box
f: Head light relay
5. Diode (3A yellow) 13. Buzzer
g: Change speed relay
h: Hazard relay 6. Plate 14. Fuse Box
7. Resistor 15. Bracket
8. Detector 16. Hour Meter
III-41 TB175W
9
3 2
a b
a
1
c
17540001~17540134
2 b
10 17540001~17540134
c 8 b
17540001~17540094 17540135~
W3C802
1. Wire Harness
2. Fusible Link
3. Short Connector
4. Diode (3A yellow)
5. Short Connector
6. Wire Harness
7. Wire Harness
8. Diode (3A yellow)
9. Guard
10. Horn
TB175W III-42
/(9(5/,1.
/(9(56:,7&+$1'/,0,76:,7&+
:&
III-43 TB175W
:&
TB175W III-44
Air Conditioner System MACHINE CONFIGURATION
Air Conditioner system

Construction
Compressor Assembly
B 2
10 7
1mm
12
A
13 5
11
3 1
4
6
14
W3C805
A: Allow a clearance. 1. Bracket 8. Hose

B: Press on the center of the belt with a finger. The 2. Guard 9. Bushing
belt’s tension is normal if it bends about 8 mm when
3. Shaft 10. Valve
pressed with a force of about 98N.
4. Collar 11. Adaptor
5. Compressor 12. Bushing
6. Pulley 13. Elbow
7. Hose 14. V-Belt
III-45 TB175W
MACHINE CONFIGURATION Air Conditioner System
Air Conditioner 1/2

;

:&
1. Bracket
2. Cover
3. Condenser
4. Fun
5. Dryer
6. Bracket
7. Hose
8. Hose
9. Switch
10. Connector
TB175W III-46
Air Conditioner System MACHINE CONFIGURATION
Air Conditioner 2/2

:&
1. Hose
2. Guard
3. Wire Harness
4. Air Conditioner Unit
5. Wire
6. Wire Harness
7. Relay
8. Valve
9. Tube
10. Cover
11. Panel
12. Hose
13. Hose
14. Hose
15. Louver
16. Adaptor
17. Louver
III-47 TB175W
MACHINE CONFIGURATION Air Conditioner System
Condenser, Air Conditioner Unit, Panel Assembly

:&
1. Adaptor
2. Evaporato
3. Heater Core
4. Filter
5. Blowier Motor
6. O-Ring
7. O-Ring
8. Expansion Valve
9. Thermo Stat
10. Air Condiitioner Switch
11. Knob
12. Cable Control Converter
13. Cable Control Converter
14. 3-Speed Rotary Switch
TB175W III-48
Overview of System Operation
• Truck and Heavy Equipment Systems
Click on any of these
subject headings to go
• Air Conditioner-System Operation
directly to the page • Heater System Operation
• Environmental Effects on System Operation
• Chapter Review
Truck and Heavy Equipment Systems

A variety of HVAC systems are in use today, some old and some new. There are:
• Vehicle manufacturer installed systems
• Owner specified systems
• Add-on systems
• Retrofit systems
The system components come in different colors, shapes, and sizes. They may be
mounted in or on the cab in varied locations. Owners or fleet maintenance people
can modify systems by adding controls, auxiliary units or ducts. Major compo-
nents are sometimes replaced due to damage or failure. All systems were, at least
originally, designed and installed to meet the needs of an operator. Figure 2-1
includes illustrations of various AC and Heater systems. They illustrate system
advantages and disadvantages explained in the paragraphs that follow.
The HVAC system includes both heater and air conditioner components, usu-
ally a common control, and air ducts. The system cools the cab by removing heat
energy. It removes moisture from damp air in the cab and adds fresh outside air to
the cab. In this way, the operator can work comfortably in all kinds of weather.
A sleeper unit, built in or added on, increases the air volumes in the cab. The
air conditioner or heater must circulate and cool or heat a larger amount of air.
This is accomplished by routing ducts and controls to the sleeper compartment as
part of system design. Components may be increased in size to handle the larger
cab air volume. A bigger heater core, air conditioning evaporator coil, condenser,
blower or fan may be included. Often, on long haul trucks, auxiliary air condi-
tioning and heater components and controls are added. The objective remains the
same, to move heat energy and maintain occupant comfort.
TB175W III-48
Air Conditioner—System Operation
Figure 2-1
These illustrations show a
basic heater, HVAC system,
the combo system with
sleeper unit, add on AC roof
top and in cab units, roof
mounted condenser and
auxiliary units.
By law, all trucks have a heater/defroster as part of the standard equipment. When there
is a reason to add air conditioning, there are options to meet different needs. The avail-
able space in the cab, operating environment, and owner preference can all play a part
in the type of AC unit selected. You will probably encounter roof-mounted and in-cab
add on systems, and even systems where the condenser is mounted on the roof and the
evaporator is attached to the back panel or mounted under the dash. In cooler climates
you may come across a cab with two heaters, the original and an auxiliary unit.

We have described the movement of heat energy and basic HVAC system function in
Chapter 1. Now we will go into some detail on how an air conditioner operates. The
system is sealed to keep out air and moisture. To operate properly, the inside of the sys-
tem contains a measured amount of refrigerant and special refrigerant oil that keeps the
system lubricated. Figure 2-2 is an illustration of system components without the cab
outline, in-cab controls, component housing, and air ducts or vents. Please study it for a
moment. Note the information printed next to each component. Remember that the com-
ponents may be positioned and attached to the truck in various locations.
III-49 TB175W
System Operation
The following AC components are discussed in detail in this section:

1. Compressor/Clutch Assembly
2. Condenser
3. Receiver-Drier
4. Expansion Valve
5. Evaporator Coil
Figure 2-2
Air Conditioner components
are connected together to
illustrate system operation.
The components shown are
not to scale. The refrigerant
and refrigerant oil are clear
in color and not visible in
this drawing. The small ar-
rows inside the components
and connecting hoses show
the direction of refrigerant
flow (refrigerant circuit).
1. Compressor/Clutch Assembly
The compressor/clutch assembly is the heart of the system. When the clutch is
engaged, the compressor pumps refrigerant and oil around the system. It raises
the temperature and pressure of the refrigerant gas, and forces it to the condenser
where it changes state and becomes a liquid. The compressor also sucks the va-
porized refrigerant out of the evaporator and back inside itself in the form of gas.
One way valves inside the compressor separate the compressed gas (high pres-
sure) side of the system from the suction (low pressure) side. Figure 2-3 shows a
cutaway view of a compressor with the high and low pressure sides noted.
TB175W III-50
Figure 2-3
The compressor inlet is
low pressure and the outlet
is high pressure. The reed
valves are one way. They
open to allow refrigerant gas
to enter the compressor on
the down stroke and exit on
the upstroke. Note the open
valves in the illustrations.
The clutch is mounted on the shaft of the compressor and is engaged by electromag-
netic action. Part of the clutch assembly is an electromagnetic wire coil. The coil is
energized through a thermostat that senses the temperature in the evaporator coil. If
the evaporator is too warm the electrical contacts close and allows power to flow to
the clutch. The compressor shaft is engaged and moves the refrigerant around inside
the system. Figure 2-4 is a cutaway view of the clutch mounted on the compressor.
Figure 2-4
The clutch shown here has
its electromagnetic coil
mounted on the compressor
body. When the coil is ener-
gized, magnetic force pulls
the clutch drive plate into
the pulley. This action locks
the pulley to the compressor
drive shaft and drives the
compressor.
2. Condenser
The refrigerant gas leaves the compressor and moves through a high pressure hose to
the condenser. Inside the condenser the gas “changes state” and becomes a liquid. It
is still hot and under pressure. Remember in Chapter 1 when we talked about water
at 212 degrees Fahrenheit? Heat energy was involved in the “change of state,” but
the temperature did not change. The same kind of action happens inside the AC sys-
tem. The refrigerant gas gives up a lot of heat energy to the outside air as it “changes
state” in the condenser. Figure 2-5 illustrates a condenser. Air moving through the
condenser absorbs heat from the refrigerant. The amount of air flow through the con-
denser is the major factor in how well the condenser functions.
III-51 TB175W
System Operation
Figure 2-5
As the refrigerant gas moves
through the tubing coil from
top to bottom, it condenses
(changes state) into a liquid.
For ease of installation,
condenser fittings are often
routed close together.
3. Receiver-Drier
The liquid refrigerant continues to move inside the system, out of the condenser
through a tube or hose to the receiver-drier. The receiver-drier serves as a small stor-
age tank and filter for the refrigerant. It is also a good location to mount pressure
switches and often contains a sight glass (small window) used to view activity inside
the system. The receiver-drier, Figure 2-6, also separates gas (bubbles) from the
liquid with a pick-up tube as shown in this illustration. Some receiver-driers have a
spring to preload the desiccant pack.
Figure 2-6
This cutaway view of a
receiver-drier shows the fil-
ter elements, inlet, outlet and
refrigerant path. The sight
glass is a small window into
the system used in diagnosis
and when adding refrigerant
(charging the system).
TB175W III-52
4. Expansion Valve (Refrigerant Metering Device)

When refrigerant moves from the receiver-drier, it travels through another high pres-
sure hose to a metering device at the inlet of the evaporator coil. The metering device
can be an expansion valve, an expansion tube or a combination (multiple function)
valve. Between the compressor and this point inside the system, the pressure is high
and can range from 150 to 250 pounds per square inch. The expansion valve (TXV)
is closely connected to the evaporator. A diaphragm opens the valve by exerting pres-
sure on the spring. Pressure comes from gas inside the diaphragm housing on top of
the valve and in the sealed sensing bulb. The sensing tube is located in the outlet of
the evaporator and picks up heat from warm refrigerant leaving the evaporator. The
gas in the valve diaphragm housing and sensing tube expands when it gets warmer
and forces the expansion valve open at the metering orifice.
Figure 2-7
This block type expansion
valve cutaway view will give
you a better idea how these
valves work. Spring pressure
holds the valve closed.
5. Evaporator Coil
The expansion valve or other type of metering device bleeds high pressure refrigerant
into the evaporator coil, where the pressure is low. The refrigerant expands rapidly in
this low pressure environment. When it expands it “changes state”. The sudden drop
in pressure brings the refrigerant temperature down quickly inside the evaporator
coil. Figure 2-8 shows an evaporator coil and thermostat. Refrigerant is sprayed into
the evaporator by the high side pressure when the expansion valve opens. The refrig-
erant absorbs heat from the air when the blower forces the air through the fins. When
the thermostat probe senses the upper limit of the thermostat heat setting, a circuit
closes. The compressor clutch engages and the compressor operates and moves more
refrigerant to the high side of the system.
III-53 TB175W
System Operation
Figure 2-8
The evaporator coil as shown
is of fin and tube construc-
tion. The thermostat probe
is positioned in between the
evaporator fins and senses
the temperature.
Note: Moisture in the air (humidity) condenses on the fins of the

evaporator as water droplets which drain out of the evapora-
tor through a drain hose. This action dehumidifies the air in
the cab as part of system operation, and contributes to opera-
tor comfort.
Cab air forced across the evaporator coil gives up heat energy to the cold
refrigerant inside the coil. The cooled air circulates in the cab for occupant
comfort. Refrigerant continues to expand and absorb heat energy in the
evaporator coil. Refrigerant changes from liquid to gas before it leaves the
evaporator on the way back to the compressor. The refrigerant gas moves to
the compressor through a low pressure (suction) hose. When the compressor
is operating, it sucks the refrigerant gas back inside, compressing and rais-
ing its temperature and pressure.
Some of AC system operation is controlled by the operator, and some is auto-
matic. The operator can turn the system on and off, regulate the air velocity with
the blower control, and in some designs adjust the thermostat control. The system
and component operating range settings automatically cycle the clutch on and off.
The operation of the expansion valve or other refrigerant metering device at the
inlet to the evaporator is automatic.
Individual system features may differ, but the basic system function remains
the same. Variations in components and controls are described in Chapters 4 and
5. The engine provides the power for both air conditioner and heater operation. It
drives the AC compressor and the cooling system water pump. Engine RPM af-
fects the efficiency of both the heater and air conditioner. The slower the engine
RPM, the less capacity a heater or AC system will have.
WARNING When an AC system is operating, the high pressure side

components, fittings and high pressure lines or hoses can
be hot enough to burn your skin if you touch them. This in-
cludes the compressor, clutch, hoses, condenser, receiver-
drier, and any control devices or metal tubing. The low
pressure side will be cool to the touch. In operation the
AC system is under load and high side pressures normally
range between 150 and 250 pounds per square inch for
R-12 and higher for some other refrigerants.
TB175W III-54
System Operation
Heater System Operation

Heater and air conditioner systems both have the same basic function of mov-
ing heat. They take advantage of nature’s laws where heat energy always moves
from a warmer to a cooler area. In a heater system there is no “change of state”
involved in system operation. The system is sealed and operates under pressure,
but the pressure is low when compared to an air conditioner.
A heater system uses the engine coolant to carry excess heat energy to the cab
air. The heart of the system is the water pump. The water pump forces hot coolant
through a hose from the engine block and through the heater core. The coolant is
returned to the engine cooling system either at the suction side of the water pump
or to the radiator.
A control cable, attached to a water valve between the water pump and the
heater inlet, is used to control the flow of coolant to the heater. The heater fan or
blower forces cab air through the heater core where heat energy moves from the
engine coolant to the air in the cab. Figure 2-9 illustrates the main heater system
components. In-cab controls, component housing and air vents are not shown.
The following heater components are discussed in detail in this section:
1. Heater Core
2. Water Valves
3. Defrosters and Ducts
4. Blowers and Fans
Figure 2-9
This view of a heater system
shows the main components
and how they are connected.
Additional heater controls, ducts, air vents, blend-air doors, temperature regu-
lating devices and auxiliary heaters may be installed as part of a heater system.
These may be air, vacuum, electrical or mechanically operated.
III-55 TB175W
Environmental Effects
1. Heater Core
Heater cores are like small radiators. The fin and tube construction is de-
signed to route coolant flow for the best possible heat energy transfer from
coolant to cab air. Hoses from and to the engine are connected to the core
with clamps. The core outlet may be larger or the same size as the inlet.
2. Water Valves
Water valves may be cable, vacuum or air controlled. The valve can be ei-
ther open, closed or set part way open. Some valves have a bypass design
to return coolant to the engine. Most are manually controlled although elec-
tronic systems are now being installed.
3. Defrosters and Ducts

Defrosting is accomplished by directing heated dry air through ducts to the
windshield. The heater system serves the dual purpose of defrosting and
heating. Controls are used to route the air flow to the windshield and occu-
pant areas by opening and closing duct doors. Controls may be manual, air
or vacuum.
Many vehicles use a “defrost interlock” system which utilizes the air con-
ditioner to dry the defrost air and clear the cab windows more quickly.
4. Blowers and Fans

Blowers or fans are used in the system to move cab air through the heater
core and evaporator. Air can be pushed or pulled through the core depending
on system design. Blower or fan speed is usually selected by the operator.
Environmental Effects on System Operation

The environment outside the cab involves more than the weather. It may be hot
and humid or cold and dry. That is only part of the condition the HVAC system
must handle to maintain an ideal comfort range. A truck can be at idle, in traffic
or moving along for hours on the Interstate at 65 M.P.H. The load condition on a
trip can include going out full, coming home empty, or driving across the Rockies
or Kansas plains during the day or night. The truck color and shape, the windows
and angle of the sun are all variables that can increase or decrease the “load” on
the system. The following are a few examples of environmental effect:
• A black cab-over (COE) with a dark color interior will be more
difficult to cool than the same vehicle with white paint and a light
colored interior. The black cab picks up and holds the radiant heat
from the sun more easily than the white one.
• In Florida or Houston the humidity in mid summer can be very
high with the temperature in the high 90’s or low 100’s. The AC
unit must remove a lot of moisture from the air in the cab as the air
moves through the evaporator fins. The more moisture on the fins,
the less effective the transfer of heat is to the refrigerant inside the
evaporator coil.
TB175W III-56
System Operation
• On a cold day the temperature can drop below zero. The engine may
run cooler so the engine coolant is cooler when it circulates through
the heater. The heat in the cab moves out of the cab faster (remember
heat always moves to a cooler area until both are the same tempera-
ture—nature’s law). To maintain cab comfort you have to increase the
flow of coolant through the heater, increase coolant temperature, and/
or move more air through the heater core.
• On a hot day, an off-road vehicle experiences cooling at a slower rate
than an on-road vehicle. This is a result of high sun-load, large window
area and often less insulation.
It is important for you to keep environmental effects in mind when you are servicing
or diagnosing heater or air conditioner systems. If you work in Denver the altitude
will affect system function and pressure. In Houston the heat and humidity may lower
heat transfer to the air at the condenser and increase system operating pressures.
Chapter Review
• HVAC systems range from simple cab heaters to multi-function com-
bination systems. The multi-function system can heat and cool the cab
and sleeper unit, and have separate auxiliary components and controls
for driver and passenger comfort.
• Both heater (engine) coolant and air conditioner refrigerant circulate
inside sealed, pressurized systems. The normal air conditioner operat-
ing pressure ranges from 150 to 250 pounds per square inch, some-
times higher with a different refrigerant.
• Air conditioners have a high and a low pressure side within the system.
The compressor is the starting point of the high side. Pressure drops at
the expansion valve opening to the evaporator.
• The basic components of an AC system are the compressorclutch as-
sembly, high pressure lines, condenser, receiver-drier, expansion valve,
evaporator, thermostat, blower assembly, and suction lines. There may
be other controls installed for more complex systems.
• The basic components of a heater system are the inlet and outlet hoses,
a water valve and valve control, heater core and fan or blower assem-
bly. There may be other controls for more complex systems.
• An air conditioner system uses the “change of state” of refrigerant in-
side the system to move heat from the cab air to the outside air. Refrig-
erant changes from a gas to a liquid in the condenser, and back to a gas
in the evaporator.
• A heater system uses the heat from the engine, carried to the heater
core by the action of the water pump, to warm the air in the cab. There
is no change of state within the heater system.
• Environmental conditions affect how both heaters and air conditioners
work. Weather, driving conditions, color of the vehicle are factors. All
contribute to heat gain or loss inside a cab and how much heat energy
must be moved to maintain occupant comfort.
III-57 TB175W
Inspection and Maintenance-
without gauges
Click on any of these • Discussion of Inspection & Maintenance Survey Results
directly to the page • Visual Inspection - System Off
• Electrical System Inspection
• Performance Inspection - Engine Running
• Heater System Inspection
• Preventive Maintenance Worksheet
• Chapter Review
Discussion of Inspection & Maintenance Survey Results

There are three reasons for regular inspection and maintenance procedures:
1. They save money in the long run by reducing down time and often
prevent more costly repairs.
2. They help to insure driver comfort and safety.
3. They add to your store of knowledge about these systems and main-
tain your level of efficiency.
About half of all heavy duty vehicles have air conditioners. Surveys of AC system
owners find that over 30% of the systems are serviced every six months or less,
and another 62% are serviced at least once a year.
The survey also covered how often the different components required mainte-
nance. Figure 7.1 below shows survey finding percentages. Failure of any of the
AC components listed in the survey could cause a system to malfunction or stop
cooling.
Figure 7-1
This chart shows mainte- INSPECTION & MAINTENANCE SURVEY
nance frequency, lists key
parts and how often they
require maintenance.
Note: The above survey results may not apply to your situation. Ac-
tual operating conditions for the vehicles you service will de-
termine or influence maintenance frequency and requirements.
The following inspection procedures should take about 15 to 20 minutes, longer
if corrective steps, part replacement or adding refrigerant is necessary. There is
a “Preventive Maintenance Worksheet” you may use at the end of this chapter,
Figure 7-9
TB175W III-58
Inspection & Maintenance
Visual Inspection - System Off

Your observations and the corrective measures you take may be different depend-
ing on circumstances. The following inspection procedures are explained in more
detail below:
1. Observe the System
2. Inspect Parts
3. Check Hoses and Fittings
4. Check for Refrigerant Leaks
Use the following procedures as a general rule in performing a visual inspection

with the AC system off:
1. Observe the System

Your first inspection step is to answer the following question if you can:
• Has the vehicle just come in off the road and has the HVAC
system been in use?
• Did the operator or work order explain or describe any prob-
lems about the system?
• Did someone else work on the system yesterday, 700 miles
down the road? Your first inspection step is to answer these
questions if you can.
CAUTION Even when someone has told you what is wrong with an
HVAC system, you should perform a visual inspection.
Always make a visual inspection before you hook up the
manifold gauge set. Never add refrigerant to a system until
you have made a complete visual and performance inspec-
tion.
2. Inspect Parts
Look at the system for what might come loose, leak, wear out or become
dirty and not function the way it should. The main points for visual inspec-
tion of the system are emphasized in Figure 7-2.
III-59 TB175W
Visual Inspection
Figure 7-2
This system illustration notes
the main points for visual
inspection.
A. Condenser – Is it free of leaves, bugs, bird feathers or mud? The con-

denser must be relatively clean to work well as a heat exchanger. How you
clean the condenser depends on where it is mounted. The condenser fin
comb, air hose and nozzle, or soap and water may be used. Where possible,
check condenser mounting bolts or screws and tighten them if necessary.
Condenser failure often results from loose hoses. Hose movement will
cause fatigue failure of condenser tubing adjacent to the fittings. Make sure
the hoses are securely clamped.
While inspecting the condenser check the receiver-drier sight glass and
connections. Look to see if the sight glass has a moisture indicator that is
showing moisture in the system.
B. Components Under the Hood – Tip the cab or raise the hood. Look at
the compressor mounting bracket, compressor clutch assembly, drive belt
and pulley alignment. The mounting bracket, compressor, clutch and drive
pulley should be fastened securely, and a clutch groove (there may be two
groves) should be in line with the drive pulley. Tighten all bolts shown in
Figure 7-3, as you inspect.
Figure 7-3
Engine and compressor
vibration can work mount-
ing bolts loose. Tighten all
mounting bolts as you in-
spect the system. Slots in the
mounting bracket are used to
move the compressor clutch
assembly in order to adjust
belt tension or alignment.
TB175W III-60
C. Drive Belt – The drive belt should be tight and in good condition. Use
a belt tension gauge to check tension (120 pounds maximum). With experi-
ence, you can feel belt tension by twisting the belt. Try feeling belt tension
after using the gauge, when you know the tension is correct. Replace belts if
they are frayed or look worn.
If the clutch pulley/belt alignment is obviously off, you need to loosen
the compressor or mounting bracket, or both—and use the alignment bar to
line up the clutch pulley with the drive pulley. Tighten compressor mounting
bolts first, then the bolts holding the bracket. The mounting bracket should
have slots or other means of adjustment to allow you to adjust the tension of
the drive belt. When you use a pry bar to apply tension, be sure you do not
pry against the compressor. Pry against the mounting bracket.
3. Check Hoses and Fittings

Check all hoses and fittings. Look for places where hoses flex when the cab is
tilted. Any places the hoses or fittings are fastened, clamped, connected, bent or
secured are potential wear points. This also applies to places where hoses are not
clamped or supported but should be (often near the condenser). All of these spots
are potential leak or damage points. Tighten, re-fasten, add, or replace as indi-
cated by your inspection.
4. Check for Refrigerant Leaks

System refrigerant leaks can be anywhere but there are obvious places. You can
spot some by looking for signs of refrigerant oil forced out with refrigerant leak-
age. One location leaks frequently occur is the compressor shaft seal. The shaft
and seal are hidden behind the clutch assembly, but centrifugal force will throw
the oil off the shaft and against the engine, bracket or whatever is close. Check
these points when you examine the compressor clutch and mounting bracket. A
solution of soap and water applied around potential leak points works well for
detecting leaks. A leak in the evaporator may be indicated if you feel around the
condensate drain hole and find oil present.
Note: You can add inexpensive dry nitrogen gas to the system instead
of R-12 if system pressures are low. Dispense the gas at no more
than 200-250 PSI as this is sufficient pressure to cause or indicate
a leak point in the AC system. AC service procedures for complete
system recovering of refrigerant, evacuating, and recharging are
covered and illustrated in Chapter 9.
Note: A leaking heater core could also result in coolant at the condensate
drain.
III-61 TB175W
Electrical System Inspection
You can feel for oil at the bottom of all connections (see Figure 7-4) if the
system is not too hot. Of course, a few minutes with an electronic leak de-
tector is the best way to check for leaks. Keep in mind that pressure is dif-
ferent in a system at rest, so small leaks may be hard to find. Pressure in a
system at rest, will equalize at from 60 to 95 PSI, depending on outside air
temperature. This means there is more pressure in the low side of the system
at rest than during normal system operation. Just the opposite is true of the
high side; at rest, high side pressure is lower. You may want to use the detec-
tor to check for leaks in the high side when the air conditioner is operating,
if you suspect a leak and can’t find it when the system is at rest.
Figure 7-4
This illustration shows a po-
tential refrigerant leak point
at the condenser fitting.

The two stages of an electrical inspection are explained in more detail below:
1. Inspect Electrical Connections
2. Check Electrical Current Flow and Device Functions
Use the following procedures to perform an electrical system inspection:
1. Inspect Electrical Connections

First, while you are making your visual inspection under the hood (cab)
and/or at the roof top condenser, take a moment and check all electrical con-
nections visually and by feel. Look for any corrosion on leads or connectors
and clean them. Make sure all leads and wires are properly supported and
securely connected.
2. Check Electrical Current Flow and Device Functions

Perform the following steps to check current flow and electrical device func-
tions:
A. Turn the Ignition On – To check current flow the ignition must be

on.
TB175W III-62
B. Turn the AC System On – This will power the thermostat and

clutch. If it does not come on, use the AC mode switch to check the
leads to the switch. You should be able to hear a “click” from the ther-
mostat and hear the clutch drive plate “snap” against the clutch pul-
ley. You can not check thermostat cycling on and off until you do the
performance inspection. Figure 7-5 illustrates a typical AC electrical
system and the places you should inspect.
Figure 7-5
The electrical system inspec-
tion points are noted with
check marks (✔) on this
wiring diagram (electrical
schematic).
C. Check Fuses – If there is a failure and you have made sure all con-
nections are clean and tight, you need to check fuses—in-cab as well as
in-line.
D. Check Clutch Engagement – Since you can’t see and may not hear
the clutch engage, get out and look at the clutch. If it’s engaged, you
will see that the drive plate is against the pulley and not slightly spaced
from it. If you are not sure the clutch is engaged, look for the lead wire
connector near the clutch. Break and close that connection. The clutch
will disengage and engage again.
E. Test Blower Speed Operation – Some systems have a common

switch that turns on the air conditioner and powers the blower motor.
Test blower speed operation by adjusting this or the separate blower
control switch. Feeling the air flow from the ducts or note blower
sound (speed) changes.
F. Inspect Roof Mounted Condensers – Don’t forget to inspect roof

mounted condensers and AC systems for dirt and debris. Be sure the
condenser fan(s) are working properly and all parts and electrical con-
nections are securely fastened. The roof mounted condenser fans may
come on when the system is turned on. Like the thermostat and most
clutches, the normal on-off cycling action can not be observed until the
engine is running with the AC system on.
III-63 TB175W
Performance Inspection – Engine Running

The purpose of visual and electrical inspection is to detect obvious problems and
assure AC system function for an accurate performance inspection. If you do the
performance inspection first, you could be mislead. Problem areas discovered
during the performance inspection can give you false clues or symptoms, and re-
sult in repair errors and come-backs. The following performance inspection pro-
cedures are explained in more detail below:
1. Inspect System Component Cycling and
Cab Temperature Levels
2. Check Clutch Cycling Under Load
3. Check Sight Glass
The performance inspection does not cover pressure and temperature sensitive
safety devices (cutout switches, fan control, Trinary etc.). Testing these devices
requires the use of the manifold gauge set for observation of internal system pres-
sures during tests. These are explained in Chapter 8.
Use the following procedures as a general rule in a performance inspection:
1. Inspect System Component Cycling and Cab

Temperature Levels
A. Turn On the Engine and Air Conditioner – Inspect for system
component cycling and cab temperature levels.
Note: System performance testing will be much faster if all

doors and windows in the cab are closed.
The cab air must cool down to thermostat control setting
levels before system components will cycle on and off, indi-
cating correct function. This is called ‘stabilizing the system’
and takes about five minutes of operation. In very hot weather
the system may not cycle.
B. Check Thermometer Readings – In the cab you can use your ther-
mometer to measure air temperature at the vents. When the evaporator
is easy to reach with a thermometer probe without removing some of
the dash or duct work, use the probe to measure evaporator tempera-
ture. When the AC unit is on and working correctly, you can see the
thermometer dial needle move down to about 32 degrees, then rise six
to ten degrees and move back down again. The movement up and down
indicates that the cycling clutch and thermostat, or orifice tube and ac-
cumulator pressure switch (to the clutch) are functioning correctly. In
systems with a non-cycling clutch, this movement indicates correct
function of the refrigerant metering device.
The needle movement is called “temperature swing.” When you can
adjust the thermostat setting, the range of swing should change. For ex-
ample, from full cooling (cold) to moderate (between cold and warm),
the swing may change from 32-38 to 32-42 degrees.
TB175W III-64
These readings at the vents will be higher and temperature swing slow-
er and not as obvious. Also blower speed will cause the temperature,
levels to read higher (high air speed) or lower (low air speed) at the
same thermostat setting. When you measure air temperature, an elec-
tronic thermometer/pyrometer is a great tool to have. You can easily
measure cab air temperature at several locations quickly.
Swing temperatures vary depending on where you measure tem-
perature, and on outside temperature, humidity and altitude. The chart
in Figure 7-6, shows some examples of typical temperature variables.
Don’t forget that cab and sleeper area temperatures can vary within the
same vehicle. Also, electronic controls used in newer HVAC systems
often keep the temperature spread within a narrower range.
air temp. 70° 80° 90° 100°

Figure 7-6
degrees f. The chart of AC system and
air quality humid dry humid dry humid dry humid dry cab temperature range shows
you typical variables.
center outlet 43° 40° 44° 40° 47° 40° 52° 41°
air temp. to to to to to to to to
degrees f. 47° 44° 48° 44° 51° 44° 56° 45°
left & right air outlet temperature will vary
left right left right left right left right
outlet air temp. 40° 41° 41° 43° 46° 47° 48° 50°
range degrees f. to to to to to to to to
41° 44° 45° 47° 52° 54° 55° 56°
2. Check Clutch Cycling Under Load

The following operating inspections, visual and by feel, are done outside the
cab while you wait for the system to stabilize.
A. Lift hood – With the hood up (or cab tilted) observe the clutch cy-
cling under load.
Note: If the condenser is hood mounted you may not have adequate
air flow through it.
B. Touch suction and discharge lines – Soon after system start up you
can safely feel the suction and discharge lines and note their change in
temperature. The discharge line will get hot (after a while it may be to
hot to touch) and the suction line will get cooler.
3. Check Sight Glass

The sight glass is the only point where you can actually see inside the air
conditioner during operation. Check the sight glass through the window on
the top of the receiver-drier (or the separate in-line sight glass). If the sys-
tem is functioning properly and cooling the cab adequately, the sight glass
should be clear (you will not see anything in it). If it is not clear when the
system is first turned on, wait a few minutes for the system to stabilize, then
look again. Figure 7-7 illustrates and explains what you may observe in the
sight glass. Roof mounted condenser fans may run continuously or cycle on
and off. If you can’t tell by sound you may have to climb a ladder and ob-
serve the fan blades.
III-65 TB175W
Performance Inspection
Figure 7-7
These drawings illustrate
conditions you may observe
in the sight glass window.
Note: A roof mounted condenser or AC unit assembly often in-

cludes a roof mounted receiver-drier (and sight glass) close to
the condenser.
Heater System Inspection

A heater system inspection is really a combination engine cooling system and
heater inspection. All heater/cooling system rubber parts deteriorate due to the
air (ozone), heat, coolant and oils. They should be replaced at regular intervals to
prevent breakdown on the road. Metal parts and gaskets are subject to malfunc-
tion or breakdown due to fatigue and corrosion.
Coolant has a limited life and should be replaced regularly. If it is dirty, the
cooling system should be drained and flushed or back flushed (using special
equipment) before refilling with clean water and anti-freeze. Coolant must be hot
when using the hydrometer to check protection (freeze-up) level. The following
inspection procedures are explained in more detail below:
1. Check Heater Control Valve Function
2. Inspect Other Functions
1. Check Heater Control Valve Function

Many air conditioner/heater systems depend on the heater control valve for
temperature control and positive closure. You can easily check heater con-
trol valve function as follows.
A. Cool engine – Start with the engine cool, set the temperature to cold
and leave the fan off. As the engine warms up, feel the heater return
hose. If the hose feels warm or hot, the heater control valve is leaking
internally. This type of leak can seriously reduce air conditioning per-
formance.
TB175W III-66
B. Warm up engine – Next, let the engine warm up to normal operat-

ing temperature and set both fan and temperature on high. Feel both
heater supply and return hoses. If there is a noticeable difference in
their temperature, it indicates a low flow of coolant through the heater
core (a partially closed or blocked heater control valve). This could re-
sult in poor heating performance during cold weather conditions.
Figure 7-8
Heater/cooling system
potential problem areas and
checks are indicated in this
drawing.
2. Inspect Other Functions

There are some things you can’t see or feel when you inspect the thermostat,
heater core, radiator pressure cap, electrical switch and control valve func-
tions. Some of these can be checked with the pressure and thermostat testers
as described in Chapter 6. A hand pump pressure tester can also be used to
check for coolant leaks. This is done by using the pump to raise the pressure
inside the system above normal operating pressure to force small suspected
leaks to show up.
Heater/cooling electrical and valve component inspection is the same as
air conditioner inspection. The controls are operated to see if they function
correctly to maintain or vary cab temperature and air flow.
Preventive Maintenance Worksheet

Please feel free to modify or copy the worksheet in Figure 7-9. Actual vehicle
use, mileage, operating conditions and maintenance budget may influence service
frequency.
III-67 TB175W
Chapter Review
Chapter Review
The purpose of these brief inspection procedures is for vehicle system mainte-
nance and to determine if further, more detailed service is required. The uses of
a manifold gauge set, system troubleshooting, recovery, flushing, evacuating and
charging are explained in the next chapter.
High usage and operating condition variations are tough on air conditioning
and heater components. You should establish and follow regular inspection and
maintenance procedures to improve overall system function and component ser-
vice life.
The typical inspection should not take more than 15 to 20 minutes unless com-
ponent replacement and/or complete system evacuation and recharging is war-
ranted. The survey results shown in Figure 7-1, indicate belts, compressor clutch
assembly, condenser and the refrigerant lines are the most frequent problem ar-
eas. However, your own experience with service and maintenance may vary from
survey results.
Inspection should first be visual and by feel. Some of your electrical system
inspection will be done as you inspect other components (checking leads, connec-
tions and for loose wires). When you check the electrical circuit, begin with the
engine off but ignition on. A system performance inspection with the engine run-
ning and system on really combines electrical and AC or heater system function.
TB175W III-68
III-69 TB175W
Troubleshooting
& Service Procedures
Click on any of these • Troubleshooting Overview
directly to the page • Understanding System Function
• A Troubleshooting Example
• Manifold Gauge Set Installation
• Troubleshooting by Manifold Gauge Set Readings
• Review of Frequent Problem Areas
• Conclusion
Can you fix an air conditioner or heater system without finding and correcting
the cause of the problem? You bet you can! It happens every day and it’s not good
for business. Here is an example. A truck pulls in off the road and the operator asks
to have his rig serviced in a hurry. He tells you the air conditioner isn’t cooling like
it should and dashes into the restaurant for lunch.
You tip the hood, and check the sight glass on top of the receiver-drier. You see
bubbles, not a lot but a fairly constant stream of them. It is obvious the system is
low on refrigerant so you hook up the manifold gauge set, purge the gauge set hoses
of air, and add refrigerant until the sight glass clears. Then you check evaporator
temperature and it’s OK. The air conditioner is repaired right? Wrong! What you
did is add refrigerant and the problem went away. You did not find and fix the cause
of the problem.
Component failure in an air conditioning system may be the result of a problem
elsewhere in the system. For example, a belt or clutch failure might be caused by a
dirty condenser restricting air flow and increasing head pressures. High head pres-
sures commonly create problems with other system components. Take time to look
beyond the obvious for a potential hidden problem.
Troubleshooting Overview
Troubleshooting includes collecting enough information to locate the cause of the
problem, then correcting the problem and its cause by replacement, adjustment, and/
or repairing. You begin by gathering information from the most to the least impor-
tant sources.
Starting with the most important:
1. Your personal knowledge and experience with AC systems.
2. The vehicle operator's knowledge and experience—question him or her.
3. The work order.
4. Good test equipment and the HVAC system
The routine you follow when troubleshooting should proceed from the most to least
productive way of locating the problem and fixing the cause.
TB175W III-70
Troubleshooting & Service Procedures
Experienced troubleshooters talk to the operator if they can, then personally verify
the symptoms of the problem whenever possible. They attempt quick fixes on the
basis of their knowledge of common system problems and causes when appropriate.
They know where components are located, and make repairs when they have a good
idea of what the problem is. They fix the cause or causes as well as the problem.
They are confident of their knowledge and ability.
Note: The best troubleshooters all know who to call when they get
stuck. They know someone who knows more than they do and
are not too proud to ask for help or suggestions when needed.
The key—understanding system function
The Key–Understanding System Function

Your complete understanding of AC and heater systems and how they work,
plus what can go wrong, is the key to troubleshooting and repair. We have talked
about components and system function before. Now let’s take a little different ap-
proach in describing what happens when the air conditioner is turned on. In Figure
8-1 we have used numbers on the illustration to track normal air conditioner func-
tion.
Figure 8-1
An illustration of the typical
HVAC system. The numbers
follow the action when the
AC part of the system is
working properly (moving
heat out of the cab and into
the outside air).
III-71 TB175W
Understanding System Function
When you turn on the air conditioner at the control panel (1), the thermostat (2),
is supposed to sense a warm temperature at the evaporator. A circuit in the ther-
mostat should close, allowing current to flow through the thermostat to the com-
pressor clutch field coil (3). When this happens, the clutch field coil becomes an
electromagnet and pulls the clutch drive plate (4) tight against the clutch pulley (5).
Note: The same AC switch (1) may also turn on the fan or blower
motor (2a) to circulate air in the cab. The air feels warm at
first but will cool quickly.
A belt connects the clutch pulley to a drive pulley (6) on the engine. The engine
provides the power to turn the clutch pulley and drive the compressor (7) when
the clutch is engaged. When operating, the compressor compresses and pushes
refrigerant gas to the condenser (8), through the receiver-drier (9), and to the ex-
pansion valve (10) orifice. When it does, it puts a lot of pressure on the gas. The
compressor raises the temperature and pressure of the refrigerant inside the high
side of the system.
At the same time, the compressor is also sucking in low pressure refrigerant
gas from the expansion valve orifice, evaporator and through the low side of the
system. The movement of the refrigerant inside the system transfers heat energy
from the cab to the outside air for occupant comfort.
The automatic functions of the thermostat (or the pressure valve on some ac-
cumulators), and the expansion valve, help maintain pressures and temperatures
inside the system at safe and efficient operating levels. Pressure and tempera-
ture are constantly changing due to compressor and expansion valve action, the
amount of heat energy being moved and the environment or weather conditions.
The engine cooling system fan and clutch (11), and the evaporator blower mo-
tor (2a), move a sufficient amount of air through the condenser and evaporator.
On the road, vehicle speed provides most of the (ram) air required for the con-
denser to work right. In a parked or slow moving vehicle the engine fan (or roof
or remote mounted condenser and fans) moves sufficient air through the condens-
er fins.
Note: Clean refrigerant and refrigeration oil should be inside the

system in the amount specified by the manufacturer. Mois-
ture, sludge (moisture combined with refrigerant oil or desic-
cant), or desiccant particles will prevent the correct perfor-
mance of the system and may cause component damage.
A Troubleshooting Example
Remember the story at the beginning of this chapter? The vehicle operator pulled
in off the road and asked you to repair the rig. He was in such a hurry he didn’t
tell you anything except that the air conditioner wasn’t cooling. Here is the best
way to handle that kind of situation.
TB175W III-72
Use your knowledge and experience. Ask yourself what could have caused a lack
of cooling in that rig! Did the compressor drive belt break? Did a pressure switch
or relief valve cutout the compressor because of high or low system pressure?
Does the switch or valve in this type of system reset itself? Could there be a su-
perheat switch and thermal limiter with a melted fuse. Did someone else service
the system recently and put in too much refrigerant?
Could there be contaminants in the system blocking the expansion valve (ex-
pansion tube)? If there is a leak, why and how did refrigerant get out of the sys-
tem? You know if refrigerant can get out, air and moisture may get inside as well,
especially if the leak is on the suction side of the system. Could there be a restric-
tion to refrigerant flow in one of the high pressure lines because of a kink? From
your knowledge and experience, you already know about these possibilities and
others when you talk to the operator (before he has the chance to leave).
The right kind of questions can speed up troubleshooting and your service
work by pinpointing the problem(s) that needs fixing. Your conversation with the
operator might be as follows:
• How long ago did the AC system stop cooling?

Answer: About an hour ago.
• What steps did you take when you noticed the lack of cooling?
Answer: I put it on maximum cool.
• Then what did you do?

Answer: When it wouldn’t cool, I opened the window and
turned the air conditioner off.
• Is this problem new or has it happened before, and when?

Answer: In the last few days I’ve had problems with cool-
ing off and on—this is the first time it’s happened when I was
close to a place that did AC service.
• Do you get any cooling at all?

Answer: Yes but it seems to quit after a while.
• Do you still get air flow at the vents from the blower?
Answer: Yes.
• When was your air conditioner checked thoroughly?

Answer: Before I bought the rig last May (a year ago).
• Has the heater been used recently and did it work OK?
Answer: Yes.
III-73 TB175W
A Troubleshooting Example
• Have you had other service problems in the last few months?
Answer: No.
• (If the answer was yes, you should ask—When? Where?

What was fixed or replaced?).
• Finally, ask the operator if he or she has a wiring diagram for

the system.
Now let’s look at the information you have gathered from the operator and what
you know from experience. He believes the problem is that the AC system quits
cooling after it has been on for a while! You know that the AC system has not
been maintained since the rig was purchased a year ago. Because of that, there
could be several causes for the problem (lack of cooling) and there may be other
potential problems about to develop.
It is possible that some refrigerant has leaked. Moisture and other contamina-
tion may be inside the system. You have been told there are no heater problems,
but that doesn’t mean there are none that might affect AC system operation. The
AC system has quit cooling several times in the last few days. The problem may
have become more severe than when it quit cooling the first time.
If enough refrigerant or oil has leaked out, a low pressure cutout switch may
have cut the circuit to the clutch, protecting the compressor. Because the system
has not been maintained in a year, there may be other components that should be
serviced. You could fix the probable causes, and the system might work and then
break down again as the rig drives out of your place. From your knowledge and
what the operator has just told you, you know this may not be a quick fix prob-
lem.
It’s up to you to describe the service situation to the operator. Tell him you
need to do a complete system maintenance inspection to find and correct the
problem or other potential problems. He can give you the go ahead for full ser-
vice and repair now, wait till you have inspected the system to determine cause
and cost, or delay repair until he has some down time available.
Normally when the operator can tell you what the problem is, you would first
operate the system to verify the problem. In this situation your troubleshooting (your
own knowledge added to what the operator told you), indicates the next step.
You need to do a complete maintenance inspection instead! Proceed as described
in Chapter 7. Correct any obvious problems and check carefully for leaks. Leak
testing should be visual, by feel and with a leak detector. Next, do your perfor-
mance test with the engine running and the AC system on.
Note: Don’t forget to check the heater system too! If the water valve
is not closed, then hot engine coolant flowing through the
heater core would warm the air at the same time the evapora-
tor was trying to cool it. The result would be the appearance
of an AC problem.
TB175W III-74
If your AC and heater visual, electrical and leak inspections don’t turn up any
problems, save time by hooking up the manifold gauge set before you make the
performance test. If you find a leak and can correct it easily by tightening a con-
nection, do so. But if too much refrigerant leaked out, you may have to add some
refrigerant to the system for an effective performance test. We will get into detail
on troubleshooting with gauges after we explain manifold gauge set installation
and adding refrigerant.
Manifold Gauge Set Installation
CAUTION Never hook up the gauge set when the engine and air con-
ditioner are running. Be sure all the valves on the manifold
are closed all the way (turn them clockwise). Check the
hose connections on the manifold for tightness.
Locate the low and high side system service fittings and remove their protective
caps. Position or hang the manifold gauge set in a convenient location. Figure 8-2
illustrates a good example of manifold gauge set hookup in one service situation.
Figure 8-2
A typical manifold gauge
set hookup is shown in this
illustration. The center hose
on the gauge set is connected
to the vacuum pump.
The manifold gauge set is a necessary tool in troubleshooting AC system prob-

lems. The following steps are performed during and after installing the manifold
gauge set:
1. Purging Air from the Gauge Set Hoses
2. Adding Refrigerant to the System
3. Stabilizing the AC System.
III-75 TB175W
1. Purging Air From Gauge Set Hoses

Environmental regulations require that all service hoses have a shutoff valve
within 12 inches of the service end. These valves are required to ensure only
a minimal amount of refrigerant is lost to the atmosphere. R-12 gauge set
hoses have a valve near the end of all three hoses. R-134a gauge sets have a
combination quick disconnect and shutoff valve on the high and low sides.
The utility (center) hose also requires a valve.
The initial purging is best accomplished when connected to recovery or
recycle equipment. Figure 8-3 illustrates the gauge set connections for purg-
ing and refrigeration recovery.
Figure 8-3
The purging setup for mani-
fold gauge set and compres-
sor service valves are shown
here.
Note: The manifold gauges read system pressure when the hand
valves are closed if the hose end valves, and the stem type
service valves (if included) are open.
2. Adding Refrigerant to the System

Now that the gauges are connected, you may need to add some refrigerant to
the AC system before you can do an effective performance inspection. How-
ever, if leaks are obvious they should be repaired prior to adding refrigerant.
Note: Loss of some refrigerant is not unusual over an extended pe-

riod of time. Adding refrigerant is a typical procedure when
the AC system is maintained on a regular basis.
When adding refrigerant to the system, connect the center hose from the
manifold gauge set to the refrigerant dispensing valve on the container. Fig-
ure 8-4 illustrates this connection.
TB175W III-76
Figure 8-4
In this illustration we have
noted how refrigerant is
added to the air conditioner.
Before adding refrigerant to the system you should study the sight glass
while the engine is running and the air conditioner is on. Even if you found
a leak during the system inspection and corrected it, you have no way of
knowing how much refrigerant has leaked. You will not be able to tell how
much refrigerant is in there, but you can see if bubbles are present.
Then check the gauges for unusually high or low readings, or a lack of
pressure. Following this procedure, and using your knowledge and experi-
ence, decide if it is safe and makes sense to add refrigerant in order to make
your full performance inspection.
You are now ready to add refrigerant to the system. For your safety and to
prevent system damage use the following procedure.
1. Turn on the engine and set the idle at 1200 to 1500 RPM and
then turn on the air conditioner.
CAUTION Do not open the high pressure hand valve on the manifold
gauge set. The compressor could pump refrigerant into
the container and cause it to BURST. Be sure to keep the
refrigerant container upright to prevent liquid refrigerant
from entering the compressor.
2. Open the refrigerant dispensing valve on the container and then

the low pressure hand valve on the manifold. This allows refrig-
erant to enter the system as a gas on the low pressure or suction
side of the compressor. The compressor will pull refrigerant into
the system.
III-77 TB175W
3. Add refrigerant until the gauges read in the normal range and the
sight glass appears clear. The sight glass may not be clear for a
moment just before or after the clutch cycles on and off but should
generally be clear. Gauge readings will fluctuate as the compres-
sor cycles on and off.
Note: Pressures within the air conditioning system vary with ambient
temperature. A normal pressure range is defined as follows:
Low side 15–30 PSIG
High side 150–280 PSIG
If R-134a is used in place of R-12 the high side readings will
be about 20 PSI higher. For this reason many OEMs are rec-
ommending an increase in condenser capacity when retrofit-
ting to the new refrigerant, R-134a.
CAUTION If the gauges show any abnormally high or low pressures as

you are adding refrigerant, stop and investigate for probable
cause. Never add more than one pound of refrigerant. If the
system is low enough on refrigerant to require more than
that amount you should stop and check again for leaks. Then
recover all of the refrigerant, repair, evacuate and recharge
the air conditioner. (See Chapter 9). You may want to add
dry nitrogen gas to the AC system instead of R-12 if pres-
sures are below normal and a leak is suspected. Nitrogen
gas is sold in cylinders under high pressure, 1800 to 2000
PSI. Be sure the cylinder has a pressure regulating valve to
control the pressure when dispensing nitrogen gas. Dispose
the gas at no more than 200-250 psi, as this is sufficient
pressure to cause or indicate a leak point. See note under
Troubleshooting by Manifold Gauge Set Readings in this
chapter.
4. When the gauges show normal, close the hand valve on the mani-
fold, the hose end shutoff valve, and the valve on the refrigerant
container. You can now proceed with the performance inspection.
3. Stabilizing The AC System

For reliable gauge readings as an aid in troubleshooting, the AC system must
be stabilized.
CAUTION Be sure your tools and test equipment are clear of all mov-
ing parts of the engine and air conditioner.
TB175W III-78
Start the engine and set to a fast idle of 1200 to 1500 RPM. Turn on the air
conditioner. After a quick in-cab performance test of control function, blow-
er speeds and air flow, set the AC system controls to maximum cooling and
blower speed on high. All windows must be closed. If cab temperature is hot (rig
has been sitting in the sun with the windows closed), open the windows for
a minute or so to let the hot air out. Run the engine and air conditioner about
five minutes for the system to stabilize. In hot humid weather or where the
AC condenser can’t receive adequate air flow from the engine fan you may
have to use a floor mounted fan to force sufficient air flow through condens-
er fins. This helps to stabilize the system by simulating ram air flow found
under normal operating conditions.
When a vehicle has a tilt cab or hood and the condenser is part of the
grill, you must use the floor fan to get air to the condenser. You could tilt the
cab or hood back to normal position, carefully routing the manifold gauge
set and hoses away from moving parts. Then place the gauges so you can
read system pressure.
Troubleshooting by Manifold Gauge Set Readings

The series of figures that follow (Figures 8-6 through 8-15) show gauges with
typical readings indicating AC system problems. Each figure is followed by trou-
bleshooting tips, probable causes for the gauge readings shown, and appropriate
service and repair procedures.
Low Refrigerant Charge in the System Figure 8-5

Gauge reading, low refriger-
ant charge in the system.
Tip: You see bubbles in the sight glass. The air from vents in
the cab is only slightly cool.
Cause: Insufficient refrigerant (charge) in the system.
III-79 TB175W
Manifold Gauge Set Readings
Repair Procedure:
Check for leaks with your leak detector. If you find a
leak at a connection, tighten it then add refrigerant as
necessary. If a component or line is leaking (defective),
recover all refrigerant from the system. Replace the de-
fective part and then check the compressor oil level and
replace missing oil. Evacuate and recharge with refrig-
erant, then check AC operation and performance.
Figure 8-6
Gauge reading, extremely Extremely Low Refrigerant Charge in the System
low refrigerant charge in
system.
Tip: The sight glass is clear or shows oil streaks. The air
from vents in the cab seems warm. If there is a low
pressure or Trinary™ switch in the system it may have
shut off the compressor (clutch).
Cause: Extremely low or no refrigerant in the system. There is

a leak in the system.
Repair Procedure:
Add refrigerant to the system, at least half of the normal
full charge amount. Then perform your leak test. As an
alternative to a refrigerant, add dry nitrogen gas to the
system and then test for leaks.
Note: It may be necessary to use a jumper wire to bypass

some types of low pressure cutout switches to operate
the compressor (clutch) when you add refrigerant to
the system.
TB175W III-80
After finding a leak, recover all refrigerant from the

system and repair the leak. Check the compressor and
replace any refrigeration oil lost due to leakage. Evacu-
ate and recharge the system with refrigerant, then check
AC operation and performance.
Air and/or Moisture in the System Figure 8-7

Gauge reading, air and/or
moisture in the system.
Tip: The sight glass may be clear or show some bubbles.

The air from vents in the cab is only slightly cool. In a
cycling clutch type system with a thermostatic switch,
the switch may not cycle the clutch on and off, so the
low pressure gauge will not fluctuate.
Cause: Air and/or moisture in the system.
RepairProcedure:
Test for leaks, especially around the compressor shaft
seal area. When the leak is found, recover refrigerant
from the system and repair the leak. Replace the receiv-
er-drier or accumulator because the desiccant may be
saturated with moisture (there is no way to tell). Check
the compressor and replace any refrigeration oil lost
due to leakage. Evacuate and recharge the system with
refrigerant, then check AC operation and performance.
III-81 TB175W
Figure 8-8 Excessive Air and/or Moisture in the System

Gauge reading, excessive
air and/or moisture in the
system.
Tip: There may be occasional bubbles in the sight glass. Air

from vents in the cab is only slightly cool.
Cause: System contains excessive air and/or moisture.
Repair Procedure:
Test for leaks, recover refrigerant from the system and
repair the leak. Depending on the type of system, re-
place the receiver-drier or accumulator. The desiccant
is saturated with moisture. Check and replace any com-
pressor oil lost due to leakage. Evacuate and recharge
the system, then check AC operation and performance.
Figure 8-9 Expansion Valve (TXV) Stuck Closed or Plugged

Gauge reading, expansion
valve (TXV) stuck closed.
Tip: Air from vents in the cab is only slightly cool. The ex-
pansion valve body is frosted or sweating.
TB175W III-82
Cause: An expansion valve malfunction could mean the

valve is stuck in the closed position, the filter screen
is clogged (block type expansion valves do not have
filter screens), moisture in the system has frozen at the
expansion valve orifice, or the sensing bulb is not oper-
ating. In vehicles where the TXV and sensing bulb are
accessible, perform the following test. If not accessible,
then proceed to Repair Procedure.
Test: 1. Warm diaphragm and valve body in your hand or

carefully with a heat gun. Activate system and watch
to see if the low pressure gauge rises.
2. Next, carefully spray a little nitrogen, or any sub-

stance below 32 degrees Fahrenheit, on the capillary
coil (bulb) or valve diaphragm. The low side gauge
needle should drop and read at a lower (suction)
pressure on the gauge. This indicates the valve was
part way open and that your action closed it. Repeat
the test, but first warm the valve diaphragm or cap-
illary with your hand. If the low side gauge drops
again, the valve is not stuck.
3. Clean the surfaces of the evaporator outlet and the

capillary coil or bulb. Make sure the coil or bulb is
securely clamped to the evaporator outlet tube and
the insulation is in place. Next proceed with recover-
ing refrigerant from the system.
Repair Procedure:
Inspect the expansion valve screen (except block type
valves). To do this you must recover all refrigerant from
the system. Disconnect the inlet hose fitting from the
expansion valve. Remove, clean and replace the screen,
then reconnect the hose. Any signs of contamination
will require flushing the system. Next, replace the re-
ceiverdrier. Then evacuate and recharge the system with
refrigerant, and check AC operation and performance.
III-83 TB175W
Note: If the expansion valve tests did not cause the low
pressure gauge needle to rise and drop, and if the oth-
er procedures described did not correct the problem,
the expansion valve is defective. You must recover
all refrigerant from the system again, and replace
the expansion valve and receiver-drier. Evacuate and
recharge the system with refrigerant, then check AC
operation and performance.
Figure 8-10 Expansion Valve (TXV) Stuck Open

Gauge reading, expansion
valve (TXV) stuck open.
Tip: Air from vents in the cab is warm or only slightly cool.
Cause: The expansion valve is stuck open and/or the capillary

tube (bulb) is not making proper contact with the evap-
orator outlet tube. Liquid refrigerant may be flooding
the evaporator making it impossible for the refrigerant
to vaporize and absorb heat normally. In vehicles where
the TXV and sensing bulb are accessible, check the
capillary tube for proper mounting and contact with the
evaporator outlet tube. Then perform the following test.
If the TXV is not accessible, then proceed to Repair
Procedure.
Test: 1. Operate the AC system on it’s coldest setting for

a few minutes. Carefully spray a little nitrogen or
other cold substance, on to the capillary tube coil (bulb)
or head of the valve.
2. The low pressure (suction) side gauge needle should

now drop on the gauge. This indicates the valve has
closed and is not stuck open. Repeat the test, but
first warm the valve diaphragm with your hand.
TB175W III-84
3. If the low side gauge shows a drop again, the valve

is not stuck. Clean the surfaces of the evaporator
outlet and the capillary coil or bulb. Make sure the
coil or bulb is securely fastened to the evaporator
outlet and covered with insulation material. Operate
the system and check performance.
Repair Procedure:
If the test did not result in proper operation of the ex-
pansion valve, the valve is defective and must be re-
placed. Recover all refrigerant from the system and re-
place the expansion valve and the receiver-drier. Evacu-
System High Pressure Side Restriction Figure 8-11

Gauge reading, system high
pressure side restriction.
Tip: Air from vents in the cab is only slightly cool. Look for
sweat or frost on high side hoses and tubing, and frost
appearing right after the point of restriction. The hose
or line may be cool to the touch near the restriction.
Cause: There could be a kink in a line, or other restriction in

the high side of the system.
III-85 TB175W
Repair Procedure:
After you locate the defective component containing
the restriction, recover all of the refrigerant. Replace
the defective component and the receiver-drier. Evacu-
Figure 8-12 Compressor Malfunction

Gauge reading, compressor
malfunction.
Tip: The compressor may be noisy when it operates.
Cause: Defective reed valves or other compressor components.

If the compressor is not noisy, there may be a worn or
loose compressor clutch drive belt.
Repair Procedure:
If you find the belt worn or loose, replace or tighten it
and recheck system performance and gauge readings.
To inspect and service the compressor, you must isolate
(front seat the stem type compressor service valves) and
recover refrigerant, or fully recover R-12 from systems
containing Schrader valves. Remove the compressor
cylinder head and check the appearance of the reed
valve plate assembly. If defective, replace the valve
plate and install with new gaskets, or replace the com-
pressor assembly.
TB175W III-86
If you find particles of desiccant in the compressor,

remove and replace it and the receiver-drier. Before do-
ing so, back flush other system components (except the
expansion valve) using a flushing kit. If there are stem
type valves and you isolate the compressor, the rest of
the system must be purged of refrigerant before you
can disconnect and flush system components (Chapter
9 describes the flushing procedure). After flushing, re-
assemble the components. Always check the oil level
in the compressor, even if you install a new or rebuilt
unit. Tighten all connections and evacuate the system.
Recharge the air conditioner with refrigerant and check
system operation and performance.
Note: Rotary compressors have a limited oil reservoir. Extra

oil must be added for all truck installations
Condenser Malfunction or System Overcharge Figure 8-13

Gauge reading, condenser
malfunction or system over-
charge.
Tip: The air from vents in the cab may be warm. In R-12
systems there can be bubbles in the sight glass. The
high pressure hoses and lines will be very hot. Don’
t forget to check the engine cooling system compo-
nents—fan and drive belt, fan clutch operation, and the
radiator shutter.
III-87 TB175W
Cause: The condenser is not functioning correctly or there may

be an overcharge of refrigerant inside the system. An-
other possibility is lack of (ram) air flow through the
condenser fins during testing. Engine cooling system
component malfunction can cause high pressure by
blocking air flow (radiator shutter) or not providing air
flow (fan clutch) in sufficient quantity.
Repair Procedure:
Inspect the condenser for dirt, bugs or other debris and
clean if necessary. Be sure the condenser is securely
mounted and there is adequate clearance (about 1-1/2
inches) between it and the radiator. Check the radiator
pressure cap and cooling system, including the fan, fan
clutch, drive belts and radiator shutter assembly. Re-
place any defective parts and then recheck AC system
operation, gauge readings and performance.
If the problem continues, the system may be over-

charged (have too much refrigerant inside). Recover the
system slowly until low and high pressure gauges read
below normal, and bubbles appear in the sight glass.
Then add refrigerant (charge the system) until pressures
are normal and the bubbles disappear. Add another
quarter to half pound of refrigerant and recheck AC sys-
tem operation, gauge readings and performance.
If the high gauge readings do not change, you should

recover all of the refrigerant and flush (it may be par-
tially plugged) or replace the condenser. Also replace
the receiver-drier or accumulator. Then connect the
components and evacuate the system. Recharge the air
conditioner with refrigerant and check system operation
and performance.
TB175W III-88
Thermostatic Switch Malfunction Figure 8-14

Gauge reading, thermostatic
switch malfunction.
Tip: The low side gauge needle may fluctuate in a very nar-
row range compared to a normal range. The compressor
clutch may be cycling on and off more frequently than
it should.
The low side gauge needle may fluctuate in an above

normal range as the clutch cycles. This may be an indi-
cation that the thermostat is set too high (someone may
have attempted to adjust the factory setting). A new
thermostat may have been installed incorrectly (capil-
lary tube not inserted between the evaporator fins in the
proper position).
Cause: The thermostatic switch is not functioning properly or

at all.
Repair Procedure:
Replace the thermostatic switch. When you remove the
old thermostat, replace it with one of the same type.
(They operate in a factory preset temperature range.)
Take care in removing and handling the thermostat and
thin capillary tube attached to it. Don’t kink or break
the tube.
Position the new thermostat capillary tube at or close to

the same location and seating depth between the evapo-
rator coil fins as the old one. Connect the electrical
leads.
III-89 TB175W
Review of Frequent Problem Areas
Note: See the Thermostat section in Chapter 10. Fan clutch,

radiator shutter, condenser, compressor, and the new-
er air and water valve control systems are covered in
Chapter 10.
Review of Frequent Problem Areas

In HVAC systems a limited number of things can go wrong. Moving parts of the
compressor, clutch, and expansion valve or refrigerant metering device can mal-
function or break down from metal fatigue, contamination, abnormal pressure or
lack of lubrication. Electrical connections may corrode, become disconnected or
break. Fuses blow from shorts or overload. Belts slip or break.
Vibration from the engine or road surface can work bolts and air or vacuum
lines loose, or rub and break or wear parts out. Motors may burn out. The inside
of the system can become contaminated from moisture, air or desiccant material
breakdown. Refrigerant may leak out of the system quickly or very slowly. Mois-
ture in the system can combine with refrigerant to form acid and attack (corrode)
metal parts from the inside. Moisture and refrigeration oil can combine to form
sludge that may block refrigerant flow.
The following problems are discussed in more detail in this section:
1. Belts and Compressor Clutch
2. Condenser
3. Refrigerant Lines, Hoses, and Fittings
4. Refrigerant Metering Valves
5. Other Problems
1. Belts and Compressor Clutch

Let’s review problem areas listed at the beginning of Chapter 7. The most
frequent repairs are replacing belts and servicing or replacing the compres-
sor or clutch. Heavy duty vehicle operation puts a lot of stress on these parts.
There are several main reasons.
There is often continuous operation for long periods of time. There may
be frequent sudden RPM variations when shifting gears up or down. For
this reason the AC clutches used in heavy duty systems usually have double
row ball bearings. Vibration and road shock contribute to loose or broken
mounting brackets, electrical connections and fittings. Belts, bearings and
compressor reed valves wear out.
Various compressor clutch cutout switches are used because the AC de-
signers know about compressor operating conditions. System leaks, high
operating pressures, malfunctioning engine cooling system components—
all cause compressor problems and failures. When refrigerant and refrigera-
tion oil leaks out of a system or there is contamination blocking oil flow, the
compressor will be starved for oil and seize.
TB175W III-90
2. Condenser
Condensers get dirty and the dirt reduces heat movement by insulating the
condenser. The fittings come loose or break from stress if the condenser or
connecting hoses are not secured properly to keep the effects of vibration at
a minimum.
Heat transfer efficiency and pressure in the condenser are affected by the
amount of outside air flowing through condenser fins. A lack of air flow can
mean the refrigerant doesn’t give up enough heat energy to the outside air (it
doesn’t change state). The refrigerant arrives at the evaporator as a gas and
can’t pick up any heat energy from cab air. In the cab, air from the vents is
only slightly cool or warm.
One possible cause of condenser malfunction could be the engine cooling
system. This is why fan clutches and radiator shutters are often controlled or
overridden by AC switch function. In fact, we can add fan clutch, radiator
shutters and also fan motors to condenser problems. If they don’t function
to allow sufficient air through the condenser, pressure inside the system may
become dangerously high. A lack of air through the condenser fins can raise
high side pressure and blow out the weakest point in a system, or damage
the compressor.
3. Refrigerant Lines, Hoses and Fittings

Problems with these parts may be caused by normal deterioration, vibration
damage, lack of maintenance or human error (improper installation or re-
placement). All rubber parts are attacked by ozone (oxygen) in the air. Rub-
ber parts break down slowly and become more vulnerable to the effects of
vibration with the passage of time.
Heavy duty vehicle vibration causes stress on all lines, fittings and connec-
tions. Regular maintenance includes checking and tightening any suspect
line, or hose retainers, or grommet position where the grommet is protecting
a line or hose from abrasion. Any insulating material wrapped around hoses
must be in place and securely fastened.
4. Refrigerant Metering Valves

When you consider valve problems there are obvious differences in valve
construction and what can go wrong. If a valve is clogged with sludge or
other obstruction, the result is a valve problem but the cause is contamina-
tion in the system. Valves get stuck open or closed, although most often
closed when the gas charge is lost from the diaphragm housing in a tradi-
tional TXV. The capillary tube can vibrate loose from the evaporator outlet
tube. The capillary can break and the small quantity of temperature sensitive
gas can escape. The diagnosis of a valve as defective calls for replacement.
5. Other Problems—Leaks, Moisture, and Adding

Refrigerant
Before any refrigerant was put inside the AC system, someone used a vacu-
um pump to evacuate any air and moisture. Vacuum is really a force pulling
against all hoses, fittings and components from the inside. When the system
is charged with refrigerant, the pressure goes from minus (a vacuum) to plus
pressure inside the hoses and all components. The refrigerant and refrigera-
tion oil are trying to escape from the system at all times.
III-91 TB175W
Conclusion
Technicians frequently add refrigerant to a system, replacing refrigerant

seepage through system connections or fittings. If the system has been main-
tained regularly (every three to six months), adding a small amount of re-
frigerant may result in normal system function. However, the best procedure
is to check all connections and look for, find and repair any leaks before
adding refrigerant.
When your leak detector indicates the presence of a leak, you can’t tell
how long the system has been leaking. Finding one leak doesn’t mean there
are not others. Until you have some AC system work experience, it will be
hard to guess how much refrigerant may have leaked. If you have to top a
system off with a half pound of refrigerant or more, adding refrigerant is not
the answer.
Find the leak. Recover all of the refrigerant and repair the system. The
moisture absorbing capacity of any desiccant material is limited and can-
not be measured. For that reason, replace the receiver-drier or accumulator.
Then evacuate the system for an hour and recharge with refrigerant.
When a compressor shaft seal has leaked oil and the refrigerant charge is
a little low, the shaft seal may have leaked because the air conditioner was
not used. The seal can get a little out of round from the weight of the crank-
shaft and leak above the shaft. Running the compressor may cause the seal
to swell and close up the leak. The shaft rotation exerts force all around the
seal and puts life back into it. To prevent this from happening, manufactur-
ers recommend regular AC system operation a minimum of every couple of
weeks even in cool weather.
Keep in mind that the compressor can cause a vacuum inside the system if
there is a restriction in the system. That means it can suck air and moisture
inside under some conditions. It will pull these contaminants in through the
same space where refrigerant and refrigerant oil has leaked out.
Conclusion
What could the air conditioning problem and it’s cause have been at the begin-
ning of this chapter? The operator was in a hurry, but you were able to start your
troubleshooting with the answers he gave you. Problems your inspection may
have turned up are a very low refrigerant charge, a contaminated system or defec-
tive compressor. Those are not quick fix jobs.
On the other hand, you might have found enough debris on the condenser fin
surface to boost high side pressures to an abnormal level during the hottest part of
the day. So the Trinary™ or high pressure switch would cut out from high pres-
sure—but reset itself. You cleaned the condenser, added a half pound of refriger-
ant and AC system pressures and function returned to normal. Service and repair
took a half hour. But there was no way to tell without using your knowledge and
experience. By now you are pretty familiar with AC system problems, the reasons
for some of them, troubleshooting and repair. In Chapter 9 we will describe com-
plete system purging, evacuation, flushing and recharging.
TB175W III-92
MACHINE CONFIGURATION
TB175W III-93
IV . HYDRAULIC UNITS
IV-1 TB175W
HYDRAULIC UNITS
CONTENTS
Hydraulic Pump (Piston) ....................................................................................................................................... 3

Hydraulic Pump (Gear) ....................................................................................................................................... 17
Control Valve (Mono-Block) .............................................................................................................................. 25
Control Valves (3-Section/4-Section) ................................................................................................................. 51
Solenoid Valves ................................................................................................................................................... 67
Proportional Control Solenoid ............................................................................................................................. 75
Selector Valve ..................................................................................................................................................... 77
Port Relief Valve ................................................................................................................................................. 79
Shut-Off Valve .................................................................................................................................................... 81
Pilot Valve: S/N 17520003~17520208................................................................................................................ 83
Pilot Valve: S/N 17520209~............................................................................................................................. 94-1
Pilot Valve (Swing) ............................................................................................................................................. 95
Cylinders .............................................................................................................................................................. 99
Dozer Blade Cylinder ........................................................................................................................................ 115
Ram Lock Cylinder ........................................................................................................................................... 117
Slew Motor ........................................................................................................................................................ 123
Axle Type: 279/172
Axle Type: 212 (Front)
Axle Type: 112 (Rear)
Travel Motor Type: A6VM
Drop Box Type: 357
Swivel Joint Type: 532
TB175W IV-2
HYDRAULIC PUMP HYDRAULIC UNITS
HYDRAULIC PUMP (PISTON)
CONSTRUCTION
40 49 28 29 39 38 36 37 46 33 31 54 32 51 50 43
42
45
52
44
61
V V
34
35
52 30
27 26
13 20 17 41 57 21 22 53 60 47 66 62 67
48
9 15
10
5 56
4 18
SECTION “V-V”
63 55 59
X X 14
SECTION “X-X”
24 23
58
W W
14 25 51
2 SECTION “W-W”
3 64 12 8 7 16 11 6 19 66 65
L3D100E
1. Shaft 15. Pin 29. Case 43. Adjusting Screw 57. Packing
2. Coupling 16. Housing 30. Spring Seat 44. Adjusting Screw 58. Oil Seal
3. Collar Bearing 17. Cover 31. Spring 45. Piston 59. Backup Ring
4. Needle Bearing 18. Cover 32. Spring 46. O-ring 60. Backup Ring
5. Spacer 19. Valve Plate 33. Stem 47. O-ring 61. Nut
6. Cylinder Block 20. Pin 34. Nut 48. O-ring 62. Nut
7. Piston 21. Piston 35. Cover 49. O-ring 63. Ring
8. Shoe 22. Stopper 36. Sleeve 50. O-ring 64. Ring
9. Shoe Holder 23. Seat 37. Spool 51. O-ring 65. Ring
10. Guide 24. Stopper 38. Pin 52. O-ring 66. Spring Pin
11. Spring 25. Ball 39. Pin 53. O-ring 67. Adjusting Screw
12. Swash Plate 26. Pin 40. Piston 54. O-ring
13. Bushing 27. Lever 41. Pin 55. O-ring
14. Pin 28. Piston 42. Case 56. O-ring
IV-3 TB175W
HYDRAULIC UNITS HYDRAULIC PUMP
OPERATION
4 2 1
Piston Pump
This pump is a variable displacement piston pump
with a single cylinder block, which discharges two 5
equal volumes.
3
Ten pistons (2) are installed in the cylinder block (1),
and the end surface is in contact with the valve plate
(3). The suction port C and the discharge port A of the
pump P1 and the discharge port B of the pump P2 are
arranged in the valve plate (3). On the other hand, the
swash plate (4) is fastened to the housing at a given
inclination, and the pistons (2) rotate along this swash
plate (4). L3D101
When the shaft (5) is rotated, the cylinder block (1)

rotates, the pistons (2) in the cylinder block execute

reciprocating movement along the swash plate (4),
and the pump executes suction and discharge. At this

time, the pistons in contact with the discharge port A
of the valve plate (3) operate as the pump P1, while the
pistons in contact with the discharge port B operate as
the pump P2.
In this way, the ten pistons (2) execute one suction and

discharge stroke with each revolution of the cylinder

block (1), so that suction and discharge are executed
continuously when the shaft (5) is rotated continu-

ously.
As the piston stroke displacement depends on the
inclination of the swash plate (4), the discharge flow

quantity can be changed by changing the inclination
of the awash plate (4).
Discharge volume control

The lever (1) can pivot on the pin and is linked with 11 8
the sleeve (2) and pin (3). The pin (3) is linked with the 2
swash plate (4) to change the inclination of the swash
plate.
P3 7
The force exerted by the springs (7) and (8) acts on the 6 P2
spool (6) while the average discharge pressure from 1 P1
pumps P1 and P2 and discharge pressure from pump
P3 act on the piston (9). Also, the discharge pressure 10
selected by the shuttle valve (11) and transmitted 3
9
through the sleeve (2) and spool (6) acts on the servo
piston (10). 4
L3D103
TB175W IV-4
When the discharge pressure from pump P1 or P2
exceeds the setting value, the average pressure of the P2 2 7 8
discharges from pumps P1 and P2, (P1 + P2)/2, acts P1
on the piston (9). Then, the spool (6) is pushed and
moved to the right until this operating pressure bal- 9
ances the force exerted by the springs (7) and (8).
When the spool (6) moves, the hydraulic oil passes 1
6
through the sleeve (2), spool (6), and hydraulic pas-
3 10
sage (11), and is supplied to the large bore of the servo 11
piston (10). This pushes the servo piston (10) to the
left, decreasing the inclination of the swash plate (4). 4
The movement of the servo piston (10) is conveyed
via the piston (3) to the lever (1). The lever (1) pivots
on the pin fixed on the housing and moves the sleeve L3D104
(2) to the right. The sleeve (2) continues to move until

the hydraulic oil passage (11) connected to the large P2 2 7 8
bore is closed. P1
When the discharge pressure from pumps P1 and P2

is reduced, the spool (6) is pushed back to the left by 1
the force exerted by the springs (7) and (8), and the 6
hydraulic oil passage (11) connected to the large bore
3 10 11
is connected to the tank passage. Then the servo
piston (10) moves to the right by pressure from the
small bore on its own, increasing the inclination of the 4
swash plate (4). The lever (1) pivots on the pin and
moves the sleeve (2) to the left. This operation contin-
ues until the openings of the sleeve (2) and spool (6) L3D105
are closed.
Thus, by changing the inclination of the swash plate

(4) the discharge is controlled and only minimum
pressure and flow required for the load are supplied
from the pump. This minimizes the pressure loss of
the pump. The inclination of the swash plate (4) varies
depending on the operating pressures not only by the
pumps P1 and P2 but also by the pump P3. Thus, the
P-Q curve for the piston pumps shows that the engine's
power is fully utilized (full horse power control).
L3D124E
IV-5 TB175W
DISASSEMBLY AND ASSEMBLY
General Cautions
• Carry out disassembly and assembly operations in • Replace all seals with new ones each time the
a clean place and provide clean containers to place hydraulic units is disassembled.
the disassembled parts in. • Check each part to make sure there is no abnormal
• Before disassembly, clean around the ports and wear or seizing and use sandpaper, etc. to remove
remove the paint from each joint using a wire any burrs, sharp edges, etc.
brush. • Do not turn adjusting screws if not required.
• Clean all disassembled parts in cleaning solvent. • Apply hydraulic oil to sliding surfaces and apply a
Use a lint free cloth, or air dry the parts. thin coating of grease to seals when assembling
• Make match marks on each part so that they will be them.
assembled in the same positions when assembled.
Disassembly
1. Loosen the drain plug (1) and drain out the oil.
1 L3D106
2. Remove the cap screws and remove the gear

pump.
3. Remove the coupling.
L3D107
4. Remove the cap screws and remove the cover.

• Remove the cover in horizontal condition.
L3D108
TB175W IV-6
5. Remove the valve plate.
L3D109
6. Disassemble the cylinder block.

a. Remove the cylinder block from the shaft.
L3D110
b. Remove the guide (3), the springs (4), the 5 7 6

holder (5), and the pistons (6) from the cylinder
3
block (7).
• Disassemble the inside of the cylinder block
(7) only when required.
4 L3D111
7. Remove the swash plate.
8. Remove the pin R and pin L.
L3D112
IV-7 TB175W
9. Remove the shaft while tapping its rear end with

a plastic hammer.
L3D113
11. Remove the two springs [inside, outside].
12. Remove the spring seat.
L3D114
14. Remove the lever.
L3D115
15. Remove the sleeve, the spool and piston.
L3D116
TB175W IV-8
16. Remove the plug and the pin.
L3D117
17. Remove the piston.

• Screw the bolt into the screw hole (M4) at the
end face of the piston, and grab the bolt to pull
out the piston.
L3D118
18. Loosen the lock nut (3) and remove the adjusting
screw (2).
• Record the length of the adjusting screw pro-
trusion before starting the disassembly.
3
2 L3D119
IV-9 TB175W
Assembly
1. Install the adjusting screw (2).
• Fix the adjusting screw (2) to the same length
as previously assembled using the lock nut (3).
Lock nut: 98 N·m
3
2 L3D119
2. Install the piston.
L3D118
3. Install the drain plug (1).
1 L3D106
4. Install the oil seal.
5. Install the shaft in the housing.

• Tap the spline end with a plastic hammer to
positively install the outer race of the bearing
in the housing hole.
L3D120
TB175W IV-10
6. Fit the pin R and L on the swash plate.
L3D121
7. Install the swash plate in the housing.

• Insert the bushing into the swash plate.
• Apply grease on the sliding surfaces of the
swash plate, pin R and pin L.
L3D122
8. Mount the pin and tighten the plug.

Plug: 29.4 N·m
L3D117
9. Mount the piston in the housing.
L3D123
IV-11 TB175W
10. Mount the sleeve and spool.
L3D116
11. Install the lever on the housing.
12. Install the cover and install the cap screws.

Cap screw: 29.4 N·m
L3D115
13. Install the spring seat.

• Apply grease to the spherical part of the spring
seat.
14. Install the two springs [inside, outside].
L3D114
15. Assemble the cylinder block. 5 7 6

a. Install the springs in the cylinder block.
3
b. Install the guide (3) in the cylinder block.
• Apply grease to the spherical part of the
guide.
c. Attach the pistons (6) to the shoe holder (5),
and install the shoe holder (5) in the cylinder
block.
4 L3D111
TB175W IV-12
16. Install the cylinder block matching the spline of
the shaft.
• Apply grease to the sliding surfaces of the
piston shoes and the plate.
L3D110
17. Apply grease to the rear of the valve plate and

install it to the cover, matching the knock hole.
18. Install a large and a small O-ring in the cover.
19. Install the cover and install the cap screws.

• Install the cover parallel to the housing instal-
lation surface.
Cap screw: 235 N·m
L3D108
20. Install the coupling on the end of the main pump

shaft.
21. Unite the main pump and gear pump and fix them
with the cap screws.
Cap screw: 56.9 N·m
L3D107
IV-13 TB175W
INSPECTION AND ADJUSTMENT
Checking the Parts
Parts Judgment Criteria Treatment

Piston and cylinder • A clearance S of 0.05 mm or more • Exchange
block assembly between the piston and the cylinder
block
• Occurrence of scratches, scoring, • Exchange.
abnormal wear, etc. on sliding parts
Slack of the piston • A slack S of 0.2 mm or more for the • Exchange

shoe piston shoe
Shaft and oil seal OIL SEAL MOUNT • A wear amount of 0.025 mm at the • Exchange
installation part installation part of shaft and oil seal
STANDARD DIMENSION
Valve plate • No abnormal scratches (0.02 mm or • Correct by lapping

more), wear, or sticking for the slid- or exchange.
ing surfaces
Bushing • No abnormal wear or harmful • Exchange
scratches of the sliding surfaces
Seals and O-rings • At the time of reassembly after dis- • Exchange
assembly
Drive gear and • No abnormal scratches, wear, or • Exchange
driven gear flaking of the tooth surfaces
Ball bearings and • No abnormal scratches, wear, or • Exchange the shaft
needle bearings flaking of the rolling surfaces and the assembly.
TB175W IV-14
TROUBLESHOOTING
Symptom Probable Causes Remedy

Noise is loud. Abnormal • The suction hose is pinched or the suc- • Remove the dirt or eliminate the pinched
noise is generated. tion filter is clogged. condition of the hose.
• The suction side joint is loose and air is • Retighten each joint.
being sucked in.
• The hydraulic oil’s viscosity is too high • Replace the hydraulic oil with oil of the
and cavitation is occurring. proper viscosity.
• The pump is off center with respect to • Center the pump with respect to the
the engine. engine.
• There are bubbles in the hydraulic oil. • Investigate the cause of the bubbles and
repair it.
• The engine’s speed is higher than the • Operate the engine at the specified speed.
specified speed.
• The drain back pressure is higher than • Check and replace the drain piping.
the specified pressure.
• The bearing, etc. is mechanically dam- • Replace the damaged parts or replace
aged. the pump.
Discharge is insufficient. • The engine’s speed is too low. • Operate the engine at the specified speed.
• The oil temperature is abnormally high. • Stop the machine and let the oil cool off,
then check again.
• The hydraulic oil’s viscosity is too high. • Replace the hydraulic oil with oil of the
proper viscosity.
• The pump’s volumetric efficiency has • Replace the pump.
dropped.
• The horsepower setting adjustment • Reset the screw and lock it.
screw is loose.
• The oil level in the tank is low. • Replenish the tank with hydraulic oil to
the specified level.
• The suction side pipe or the suction • Clean the piping.
filter is clogged.
• The amount of leakage from hydraulic • Repair the hydraulic device or replace
devices other than the pump is increasing. it.
Pressure doesn’t rise. • The relief valve setting has dropped. • Reset the relief valve setting.
• The amount of leakage from hydraulic • Repair the hydraulic device or replace
devices other than the pump is increasing. it.
• The pump’s volumetric efficiency has
dropped. • Replace the pump.
The rotational speed drops • The peak pressure is generated due to a • Repair the relief valve or replace it.
when there is a dynamic drop in the relief valve’s response.
load. • There is foreign matter trapped in the • Remove the foreign matter and repair or
pilot line or foreign matter is caught in replace the scratched parts.
the sliding parts of the control equip-
ment.
Abnormal heat is gener- • Leakage from the pump is increasing. • Replace the pump.
ated. • The bearings, etc. are mechanically dam- • Replace the damaged parts or replace
aged. the pump.
• There is seizing of sliding parts. • Replace the damaged parts or replace
the pump.
Hydraulic oil is leaking. • Seals are damaged. • Replace the seals.
• The shaft surface which slides against • Replace the shaft or replace the pump.
the oil seal is worn.
• The plug or bolts are loose. • Tighten them or replace the seals.
IV-15 TB175W
TB175W IV-16
HYDRAULIC PUMP (GEAR)
CONSTRUCTION
3 19 18 1 14 2 6 8 17 7 16 12
11 5 4 15 13 10 9
L4D150
1. Flange 6. Adapter Plate 11. Bushing 16. Gasket

2. Housing 7. Rear Cover 12. Bushing 17. Gasket
3. Drive Gear 8. Drive Gear 13. Gasket 18. Oil Seal
4. Driven Gear 9. Driven Gear 14. Gasket 19. Snap Ring
5. Bushing 10. Bushing 15. Buckup Ring
Gear Pump
The gear pump consists of a single gear case, inside of
which is a drive gear (1) and a driven gear (2) engaged
with each other. By turning the drive shaft (3), the
space between the case and the gears is filled with oil.
This oil is thus sent through the pump from the inlet
to the outlet.
INLET OUTLET
Y1-D101E
IV-17 TB175W
General Cautions
• Carry out disassembly and assembly operations in • Replace all seals with new ones each time the pump
a clean place and provide clean containers to place is disassembled, coating them lightly with grease.
brush. • Adjust adjustment screws only when required.
• Clean each of the disassembled parts with a clean-
ing oil such as diesel fuel.
• Make match marks on each part so that they will be
Following is an explanation of the gear pump disas-

sembly procedure.
Follow the procedure used to disassemble the gear
pump in reverse order when reassembling it.
1. Remove the cap screws.

Screw: 98~108 N·m
2. Remove the flange (1).

1
3. Remove the snap ring (3) and the oil seal (4) from 4
the flange (1).
• Be careful not to scratch or otherwise damage 3
the flange.
• When re-assembling, install the oil seal using
the jigs A and B.
L4D151
4 1
T7D152
TB175W IV-18
4. Remove the gasket (2) from the flange (1).
5. Remove the backup ring (5) and gasket (6) from

the flange (1).
6
5
2
1
L4D153
SUCTION SIDE
DISCHARGE SIDE
6
5 L4D152E
6. Remove the bushing (7), the bushing (8), the

drive gear (9), and the driven gear (10) from the
housing. 9
• Be careful to keep the bushings separated and
in their original places.
• Be careful not to scratch or otherwise damage 7
the inside of the housing.
8
10
L4D154
7. Remove the gasket (2) from the adapter plate

(11). DISCHARGE SIDE
8. Remove the backup ring (5) and gasket (6) from

the adapter plate (11).
5
6
SUCTION SIDE
11
2 L4D155E
IV-19 TB175W
9. Remove the rear cover (17).

14
10. Remove the gasket (12) from the adapter plate
(11). 15
13
18
11. Remove the bushing (13), bushing (14), the drive 12 11
gear (15), and the driven gear (16).
in their original places. 17 19
• Be careful not to scratch or otherwise damage
the inside of the rear cover.
16
12. Remove the gasket (18), (19) from the bushing
(13) and the bushing (14). L4D156
in their original places.
TB175W IV-20
Checking Parts
After checking the disassembled parts for dirt or
discoloration, clean them with diesel fuel. However,
do not let diesel fuel get on rubber parts. Check each
part for the following points and if there is any trouble,
repair or replace the part.
Housing
SUCTION SIDE
SUCTION SIDE DISCHARGE SIDE

CONTACT MARKS
DISCHARGE SIDE DEPTH OF CONTACT MARKS:

CONTACT MARKS T7D157E A 0.15mm T7D158E
The gear pump is made so that the crests of the gear

teeth make light contact with the housing walls as a
means of increasing its efficiency. Therefore, contact
marks can be seen near the suction port in any pump
that has been operated.
It is normal if the depth of the contact marks is within
0.1 mm. If the depth exceeds the use limit in the above
figure, replace the pump assembly.
Bushing
The ideal situation is for the sliding surfaces to have
no roughness and for the suction side half to be
lustrous. Also, it is satisfactory if strong contact
marks can be seen on the side surface on the suction
side and minute contact marks can be seen on the
discharge side.
• Contact marks can be seen on the sliding surface of
the entire bearing inner diameter and it is so rough
that it looks like it has been clawed.
• There is a large number of scratches around the
circumference of the side surface and it is so rough
that it looks like it has been clawed.
• There are marks from foreign matter biting into the
sliding surface of the bearing inner diameter and
the side surface.
Dirty hydraulic oil is one likely cause of such wear. In
such a case, replace the hydraulic oil and flush out
affected hydraulic circuit completely.
IV-21 TB175W
Other likely causes are as follows.

• Excessive load due to damage to the relief valve.
• Cavitaion or aeration.
• Hydraulic oil temperature is too high.
• Hydraulic oil is deteriorated.
• Hydraulic oil’s viscosity is low.
If it is necessary to replace the bushings, this means
that the gear shaft and gear side surfaces are also
rough or worn severely, so replace the gears at the
same time as the bushings are replaced.
Gear
Replace a gear if it is in the following condition.
1. The shaft or the gear side surfaces ar so rough that
they look like they have been clawed.
2. There are cracks in the tooth roots and there is
extreme abnormal wear in the tooth surfaces.
3. None of the points coming into contact with the
oil seal should be abraded to a depth in excess of
0.1 mm.
Seals
• Check oil seals for scratches in the seal surface,
wear, deformation or deterioration of the rubber’s
elasticity. If a seal is abnormal, replace it.
• Replace seals when the hydraulic pump is disas-
sembled.
• Check the backup ring for scaling and cutting. If it
is abnormal, replace it.
Test Operation
The best method for testing the pump’s operation is to 4. Next, run the pump so that it reaches the rated
mount it in a test stand. However, if that cannot be pressure ( “II. Specifications, Specification
done, test it under the conditions it would be subjected Tables”) for 5 minutes at a time for each addi-
to if it were installed in the machine. tional 1.96~2.94 kPa of pressure.
Also, if any abnormal wear is discovered during Afterward, after operating each ciruit for about 5
disassembly, be sure to replace the hydraulic oil and minutes, replace the return filter or clean it.
return filter. In addition, during the process of raising the pressure,
1. Install a pressure gauge in the high pressure pay careful attention to the oil temperature, the pump’s
piping near the pump. surface temperature and the operating noise. If the oil
2. Run the engine at 500~1,000 rpm and set the temperature or the pump’s surface temperature be-
control valve in the neutral position. come abnormally high, eliminate the load from the
3. Run the pump for 10 minutes under the conditions pump and let the temperature drop before resuming
in (2), then increase the engine’s speed to the test.
1,500~2,000 rpm and run it for another 10 min-
utes.
TB175W IV-22
Measuring the Discharge Volume
After completing the test operation, measure the
discharge volume.
1. Connect a tester (1) to the discharge side of the
pump (2).
• There should be no mistakes made in the
tester’s pipe installation.
2. Open the tester’s loading valve and start the
engine.
3. Run the engine at the rated speed.
4. Gradually close the loading valve and apply the
rated pressure to the pump (2).
5. Measure the discharge volume and the pump’s
speed (engine speed).
IV-23 TB175W
TROUBLESHOOTING

Pump won’t discharge. • Direction of rotation is reversed. • Run the pump in the specified direc-
tion.
• Oil level in the tank is low. • Replenish the oil to the specified level.
• Suction side pipe or suction filter is • Clean the pipes.
clogged.
• Hydraulic oil’s viscosity is too high. • Replace the hydraulic oil with oil of the
proper viscosity.
• Speed is low. • Run the pump at the specified speed.
Noise level is high. • Suction side hose is crushed, the suc- • Remove the dirt or eliminate the crushed
Abnormal noise is tion filter is clogged or cavitation is condition of the hose.
generated. occurring.
• Suction side joint is loose and air is • Tighten all the joint.
being sucked in.
• Hydraulic oil’s viscosity is too high, • Replace the hydraulic oil with oil of the
and cavitation is occurring. proper viscosity.
• Pump and engine are out of center with • Correct the centering between the pump
respect to each other. and engine.
• There are bubbles in the hydraulic oil. • Investigate the cause of the bubbles
and correct it.
Oil leaks from oil seals. • Oil seal is worn, damaged or deformed. • Replace the oil seal.
Oil leaks from mating sur- • Body seal is damaged or worn by rub- • Replace with a new part.
faces between housing and bing.
flange and between hous-
ing and cover.
Discharge volume is low. • Bushing seal is damaged. • Replace the bushing.
• Cavitation is occurring. • Clean the suction filter and suction side
piping.
• Aeration is occurring. • Check for insufficient tightening of
pipes, etc. and repair.
• Viscosity of the hydraulic oil is too • Replace the hydraulic oil with oil of the
low. proper viscosity.
TB175W IV-24
CONTROL VALVE HYDRAULIC UNITS
CONTROL VALVE (MONO-BLOCK)
CONSTRUCTION
8 9
C B A
Z
D D
E E
F F
G G
H H
K
J K
J
C B A
7 65
4 3
VIEW Z 1 2 W2D200E
1. Right Travel Section

2. Bucket Section
3. Boom [1] Section
4. Arm [2] Section
5. Left Travel Section
6. Auxiliary Section
7. Boom [2] Section
8. Arm [1] Section
9. Swing Section
IV-25 TB175W
HYDRAULIC UNITS CONTROL VALVE

1. Cover 7. Cover 13. Poppet

2. Spool End 8. O-ring 14. O-ring
3. Holder 9. Shuttle 15. Plug
4. Spring 10. Spring 16. Spring
5. Spring 11. O-ring
6. O-ring 12. Plug
TB175W IV-26

1. Housing 6. Port Relief Valve

2. O-ring 7. O-ring
3. Spring Holder 8. Plug
4. Spring 9. Spring
5. Spool End 10. Poppet
IV-27 TB175W

1. O-ring 9. O-ring 17. O-ring

2. Plug 10. Plug 18. Spring
3. Spring 11. Backup Ring 19. Poppet
4. Poppet 12. O-ring 20. Anti-Drift Valve
5. Spring 13. Spring 21. Spacer
6. Poppet 14. Poppet 22. Spring
7. Sleeve 15. Sleeve 23. Poppet
8. Port Relief Valve 16. Plug
TB175W IV-28

1. Port Relief Valve 9. O-ring

2. Plug 10. Backup Ring
3. O-ring 11. Plug
5. Poppet 13. Plug
6. Port Relief Valve 14. Sleeve
7. Poppet 15. Spring
8. Spring 16. Poppet
IV-29 TB175W
2
3
4
5
SECTION “J-J”
1
SECTION “K-K”
W2D205E
1. Plug
2. O-ring
3. Poppet
4. Spring
5. Plug
6. Main Relief Valve
TB175W IV-30
Main Relief Valve
1. Plug 11. Plug
2. Sleeve 12. O-ring
15 17 11 16 14 12 10 7 6 4 32 3. Main Poppet 13. Nut
4. Spring 14. Piston
5. Seat 15. Plug
6. Needle Valve 16. O-ring
7. Spring 17. Nut
8. O-ring 18. O-ring
9. Backup Ring 19. Backup Ring
10. O-ring
13 1 5 9 8 18 19
W2D206
Port Relief Valve

1. Housing 10. Adjusting Screw
5 3 16 7 6 1 8 9 2 1112 10 2. Plug 11. Washer
3. Poppet 12. Nut
4. Poppet 13. O-ring
5. Piston 14. O-ring
6. Needle Valve 15. Backup Ring
9. Spring 18. Backup Ring
4 18 17 14 15 13
L2D207
Anti-Drift Valve
1. Body
14
2. Poppet
3 3. Plug
4 4. Piston
5 5. Spool
7 6. Sleeve
13 7. Spring
8. Spring
11
9. O-ring
15
10 10. O-ring
15 9 11. Backup Ring
12. Backup Ring
12 13. O-ring
14. Plug
16 15. O-ring
6 2 8 1 L2D208 16. Spring Holder
IV-31 TB175W
OPERATION
This control valve has a structure incorporating a 4-

section and a 5-section part.
10
P2 2
T1 T2
5P
3
14
12 1 11
13 4P 16
PH PT
9 8 4 15 7
P1
5
PP
6
L3D209
When All Spools are in the Neutral Positions (2).

Center bypass passage Concurrently, the oil that passed through the signal
The oil supplied from the pump P1 flows through the land (12) passes through the signal land (13) and
center bypass passage (1) and the tank passage (2) of flows into the tank passage (14).
the 4-section part, and through the ports T1 and T2, On the other hand, the oil that passed through the
and then back to the tank. passage (15) and entered the signal passage of the
The oil supplied from the pump P2 flows through the travel spool of the 4-section part flows through the
center bypass passage (3) and the passage (4) of the 5- signal land (16) to the tank passage (2).
section part, the tank passage (2) of the 4-section part,
the ports T1 and T2, and then back to the tank.
Signal passage
The oil supplied from the port PP of the signal passage
passes through the filter (5), orifice (6), passage (7),
and flows into the pilot chamber (9) of the straight
travel spool (8). At the same time, the oil from the
signal land of individual spools of the 5-section part
passes through the passage (10), signal lands of indi-
vidual spools of the 4-section part, signal land (11) of
the bucket spool, and then flows into the tank passage
TB175W IV-32
Independent Operation
Travel spool switching
11 10
6
P2 8
9
7
4 2 5
1
3
2
L3D210
Switching the spool (1) on the right travel lever closes the oil supplied from the pump P2 to pass through the
the center bypass passage (2), and the oil supplied parallel passages (6), the head of straight travel spool
from the pump P1 passes through the center bypass (7), the passages (8) and (9), and to flow into the port
passage (2) and bridge passage (3), and flows into the 5A5. The return oil flows from the port 5B5 to the tank
port 4A1. The return oil flows from the port 4B1 passage (4). Part of the oil from the pump P2 passes
through the head of the spool (1) and back to the tank through the orifice (10), raises the poppet (11), passes
passage (4). through the passage (3), and flows into the port 5A5.
Switching the spool (5) on the left travel lever allows
Bucket spool switching

5B4 5A4
5Pb4 5Pa4
4Pb2 4Pa2
4Pa2
4B2 4A2 7 1
5
2 3 4 L3D211
Switching the spool (1) by pressurizing the port 4Pa2 tank passage (6). Also, part of the oil is supplied from
closes the center bypass passage (2). The oil supplied the orifice (7) to the left travel section, enabling
from the pump P1 raises the parallel passages (3) and concurrent operations of the buckets during right and
the load check valve (4). Then the oil flows through left travel operations.
the passage (5) and the head of the spool (1), and
enters the port 4A2. The return oil flows from the port
4B2 through the head of the spool (1), and back to the
IV-33 TB175W
Boom spool switching

1. When the spool is in the neutral position
4 2 5 1
3
L2D212
The poppet (1) of the anti-drift valve mounted on the the passage (2), spool (3), passage (4), and spring
cylinder head of the boom [1] is seated by the pressure chamber (5).
from the port 4B3. This pressure is applied through
2. Raise
16 18 15
12
14
13 19
11 17 7
8
1 6 10 9
L2D213
Switching the spool (6) of the boom [1] by pressuriz- passage (17), and then joins into the port 4B3. Part of
ing the port 4Pb3 closes the center bypass passage (7). the oil through the orifice (18) of the spool (12)
The oil supplied from the pump P1 passes through the returns to the tank.
parallel passages (8), load check valve (9), passage The return oil flows from the port 4A3 through the
(10), and the head of the spool (6). Then the oil raises head of the spool (6) of the boom [1], and back to the
the poppet (1) of the anti-drift valve and flows into the tank passage (19).
port 4B3.
Concurrently, the spool (12) of the boom [2] is switched
by the passage (11) to close the center bypass valve
(13). The oil supplied from the pump P2 passes
through the parallel passages (14), load check valve
(15), passage (16), the head of the spool (12), and the
TB175W IV-34
3. Lower
20
8
3 5 1 6 9 10
L2D214
Switching the spool (6) of the boom [1] by pressuriz- Pressurizing the ports 4Pa3 and PLc1 at the same time
ing the port 4Pa3 closes the center bypass passage (7). switches the spool (3) of the anti-drift valve. This
The oil supplied from the pump P1 passes through the reduces the pressure in the spring chamber (5) through
parallel passages (8), load check valve (9), passage the drain port Dr1 to open the poppet (1). The return
(10), and the head of the spool (6), and then flows into oil flows through the head of the spool (6) of the boom
the port 4A3. [1], orifice, notch, and back to the tank passage (20).
Swing spool switching

5 4
2
6
L2D215
Switching the spool (1) by pressurizing the port 5Pb1

closes the center bypass passage (2). The oil supplied
from the pump P2 passes through the parallel pas-
sages (3), load check valve (4), passage (5), and the
head of the spool (1), and then flows into the port 5B1.
The return oil flows from the port 5A1 through the
head of the spool (1), and back to the tank passage (6).
IV-35 TB175W
Arm spool switching

1. Dump
1 46 7 3
5 15
2
8 13
9
17 11 10 14 12
L2D216
Switching the spool (1) of the arm [1] by pressurizing to close the center bypass passage (9). The oil sup-
the port 5Pb2 closes the center bypass passage (2). plied from the pump P1 flows through the center
The oil supplied from the pump P2 passes through the bypass passage (9), passage (10), and check valve
center bypass passage (2), tandem check valve (3), (11), and joins into the port 5B2. Part of the oil from
passage (4), and the head of the spool (1), and then the pump P1 also, flows through the tandem check
flows into the port 5B2. valve (12), the passages (13) and (4), and the head of
Concurrently, part of the oil from the pump P2 flows the spool of the arm [1], and then joins into the port
through the parallel passages (5), orifice (6), load 5B2. Part of the oil from the orifice (14) of the spool
check valve (7), and the passage (4), and then enters flows into the tank.
the port 5B2. The return oil flows from the port 5A2 through the
Switching the spool (1) of the arm [1] causes the spool head of the spool (1) of the arm [1], and back to the
(17) of the arm [2] to be switched by the passage (8) tank passage (15).
2. Load
1 18 7 3 4
5
2 13 16
9
17 11 10 14 12 L2D217
TB175W IV-36
Switching the spool (1) of the arm [1] by pressurizing to close the center bypass passage (9). The oil sup-
the port 5Pa2 closes the center bypass passage (2). plied from the pump P1 flows through the center
The oil supplied from the pump P2 passes through the bypass passage (9), passage (10), check valve (11),
center bypass passage (2), tandem check valve (3), passage (4), and the head of the spool (1) of the arm
passage (4), and the head of the spool (1) of the arm [1], and then joins into the port 5A2.
[1], and then flows into the port 5A2. The oil from the pump P1 raises the tandem check
Also, part of the oil from the pump P2 flows through valve (12) and from the passage (13) joins into the
the parallel passages (5), orifice (6), load check valve port 5A2.
(7), and passage (4), and then enters the port 5A2. The Part of the oil from the orifice (14) of the spool returns
orifice (6) is provided as a priority throttle for the to the tank.
concurrent operation with the boom offset operation. The return oil flows from the port 5B2 through the
Switching the spool (1) of the arm [1] causes the spool orifice and notch of the head of the spool (1) of the arm
(17) of the arm [2] to be switched by the passage (16) [1], and back to the tank passage (18).
Compound Operations during Traveling
10 11
5
6
2 3
4
4
7 9
1 8
P1
L3D216
When the attachment is operated while traveling, the

passages (1) and (2) are closed, causing the pressure
of the port PP to switch the straight travel spool (3) to
block the flow from the parallel passages (4) of the 5-
section part to the passage (5). This stops the oil
supply from the pump P2 to the left travel spool (6),
and the hydraulic oil from the pump P2 is supplied to
the sections for the attachment. Concurrently, the
hydraulic oil from the pump P1 is separated into two
flows: one flow is from the center bypass (7) of the 4-
section part to the right travel spool (8); and the other
flow raises the poppet (9), passes through the head of
the straight travel spool (3) and passage (5), and
reaches the left travel spool. This keeps the travel
straight.
Part of the oil from the pump P2 flows through the
parallel passages (4), orifice (10), and load check
valve (11), and is supplied to the travel section to
relieve the deceleration shock at the time of switching
of the straight travel spool (3).
IV-37 TB175W
Anti-Drift Valve
This valve is installed in the boom cylinder head line
to prevent the oil from leaking at the boom cylinder
head line so that the boom will not fall down sponta-
neously when the boom spool is in the neutral posi- 3 2
tion.
5 1
1. Neutral
The pressure from the cylinder port is applied through
the passage (2), hollow in the spool (3), passage (4),
and to the spring chamber (5). Due to the spring force
and the force produced by the difference in the poppet
areas, the poppet (1) is firmly seated.
4 L2D219
2. Raise
The oil supplied from the pump opens the poppet (1)
and flows into the cylinder port.
L2D220
3. Lower
Switching the spool (3) by pressurizing the port PLc1
causes the oil from the spring chamber (5) to flow
through the passage (4) into the tank port Dr1. This 3
opens the poppet (1), and the return oil from the
5 1
cylinder port 4B3 flows through the spool of the boom
[1] and back to the tank.
4 L2D221
TB175W IV-38
Main Relief Valve
Relieving Operation
When the pressure in the circuit is low with respect to
the set value, the relief valve is maintained at equilib- B A
rium. Hydraulic oil from the pump passes through the
orifice from chamber B and arrives at the spring
chamber C and the needle valve (5). On the other
hand, forces F and F1 are acting in the arrow direc- F
tions on both sides of the main poppet (6). F1
F = P × A F1 = P × A1
P: Pressure A,A1: Sectional Area
Since the sectional area of A is less than that of A1, the 6 C A1 5
main poppet (6) is pushed by the force “F1-F” to the
seat surface on the left side. W2D207
If the pressure in the circuit becomes higher than the

force of the spring (7), the needle valve (5) is pushed T 7
to the right by hydraulic pressure, opening. Oil then
flows around the circumference of the needle valve
(5) and passes through the slits, flowing into the tank
passage (T).
W2D208
Compared to the chamber B side, the pressure in

chamber C is low and there is no equilibrium in B T
pressure. For this reason, the main poppet (6) opens
and pressurized oil flows to the tank passage (T).
6 C
W2D209
Pressure Increase Operation

When the pressure is applied to the pilot port PH, the
piston (8) is pushed to the left to hit the plug (9). Then, B 7
the spring force of the spring (7) becomes larger,
increasing the pressure in chamber B.
PH
8 9
W2D210
IV-39 TB175W
Port Relief Valve

Relieving Operation
the set value, the relief valve is maintained at equilib-
rium. Pressure from the pump passes from chamber B
to the orifice in piston (4), then reaches chamber C and
the needle valve (5). On the other hand, forces F and
F1 are acting in the arrow directions on both sides of
the main poppet (6).
F = P × A F1 = P × A1
P: Pressure A, A1: Sectional Area
Since the sectional area of A is less than that of A1, the
seat surface on the left side.

force of the spring (7), the needle valve (5) is pushed
passage (T).
When the needle valve (5) opens, the pressure drops

on the back side of the piston (4), pushing the piston
(4) to be pushed to the right, seating with the needle
valve (5). This shuts off the flow of hydraulic oil to the
rear of the main poppet (6). As a result, the pressure
in chamber C on the inside drops.

chamber C is low and there is no equilibrium in
TB175W IV-40
Suction Operation
When the cylinder is operated at high speed, and the
supply of oil cannot keep up with it, creating a vacuum
in chamber B, oil is supplied from the tank side,
preventing the occurrence of cavitation.
When the pressure in chamber B is lower than the
pressure in the tank passage (T), the differences in the
sectional areas A and A1 cause the main poppet (6) to
open. Thus, sufficient oil from the tank passage (T)
enters chamber B, filling the empty space.
IV-41 TB175W
General Cautions
• Since all parts in control valves are precision • Replace all seals with new ones each time the
machined, carry out disassembly and assembly valves are disassembled.
operations in a clean place. • Spools and section bodies are specially selected for
• Before disassembly, clean the outside surfaces a precise fit. Therefore, if any damage is found in
around the valves. either of these parts, replace the section assembly
• Clean all disassembled parts in cleaning solvent. as a unit.
Use a lint free cloth, or air dry the parts. • Be sure to number each section and spool to avoid
• Apply hydraulic oil to sliding surfaces and apply a mistakes during assembly.
thin coating of grease to seals when assembling • Do not turn adjusting screws if not required.
them.
Following is an explanation of the control valve

disassembly procedure.
Follow the procedure used to disassemble the control
valve in reverse order when reassembling it.
• Before disassembly, number each section and spool.
Disassembly
1. Remove the main relief valve (2), then remove 3
the O-ring from the valve.
Valve: 49~54 N·m 2
2. Remove the port relief valve (3), then remove the
O-ring from the valve.
• Do not disassemble the port relief valve, as the
pressure cannot be adjusted after it is reas-
sembled.
• Install the valve in the same position as it was
in before disassembly.
Valve: 59~69 N·m 3 W2D211
3. Remove the plug (4), then remove spring (5) and

spool (6). Next, remove the O-ring from the plug.
Plug: 78~88 N·m
4
6
5
4 W2D212
TB175W IV-42
4. Disassemble the arm [1] and [2] and load check
valve.
87
a. Remove the plug (7), then remove the O-ring 9
from the plug. 1
Plug: 167~196 N·m
b. Remove the spring (8) and poppet (9).
c. <Arm [1]> Remove the sleeve (10), spring
(11) and poppet (12). 12
11
<Arm [2]> Remove the sleeve (1). 10
9
8
7
L3D226
5. Disassemble the booms [1] and [2], auxiliary,

bucket, offset and the load check valves at the
three common check valves.
a. Remove the plug (13), then remove the O-ring
from the plug.
Plug: 88~98 N·m
b. Remove the spring (14) and poppet (15).
15 15
14 14
13 13
L3D227
6. Disassemble the left travel load check valve.

a. Remove the plug (16), then remove the O-ring
from the plug.
16
Plug: 167~196 N·m 17
18
b. Remove the sleeve (17), spring (18) and pop- 19
pet (19).
7. Disassemble the right travel plug (20). Next,

remove the O-ring from the plug.
Plug: 105.9~141.2 N·m 20
L3D228
8. Remove the cap screws, then remove cover (21).

Next, remove the O-ring from the cover. 21
Cap screw: 8.8~10.8 N·m
L3D229
IV-43 TB175W
9. Remove the individual spool assemblies from the

valve housing.
• Pull out the spool straight so that the spool
surface will not be damaged.
L3D230
10. Remove the cap screws, then remove cover (23).

Next, remove the O-ring from the cover.
23
L3D231
11. Disassemble the spool.

• Hold the spool with two pieces of wood so that 27
the spool will not be damaged.
28
• Locktite is applied to the thread, so heat the
section around the thread to approximately
200°C. 29
a. Remove the screw (27), then remove the spools.
Cap screw: 19~22 N·m
28
b. Remove the spring holder (28), spring (29) and
spring holder (28).
L2D232
12. Pull out the plug (33) and remove the spring (34)
and poppet (35). Then remove the O-ring and
backup ring from the plug (33).
• Screw the bolt into the screw hole (M6 × 1.0)
at the end face of the plug, and grab the bolt to
pull out the plug.
35
35 34
34 33
33 L3D236
TB175W IV-44
Anti-Drift Valve
1. Remove the plug (1), then remove the O-ring
from the plug.
Plug: 69~78 N·m
4
3
2. Remove the piston (2), spool (3) and spring (4).
2
1
L2D237
3. Remove the plug (5), then remove the O-ring

from the plug.
Plug: 69~78 N·m 13
12
4. Remove the sleeve (6). Then remove the O-rings 11 7
9
10 8
(8) and (9), and the backup rings (10) and (11)
from the sleeve (6). 6
• When reassembling, be sure to put the O-rings
and the backup rings in place. Otherwise the 5
boom can fall spontaneously.
5. Remove the poppet (7), spring seat (12), and

spring (13). L2D238
• When reassembling, be sure to apply grease to

the edge of the poppet (7) to prevent the spring
seat and the spring from being displaced. 14
6. Remove the cap screws, then remove the body

(14) from the housing.
7. Remove the O-ring from the body (14).
L2D239
8. Remove the spacer (15).

• Screw the bolt into the screw hole (M4 × 0.7) 15
at the end face of the spacer, and grab the bolt 17
to pull out the spacer. 16
18
9. Remove the O-ring (16) and backup ring (17)
from the spacer (15).
19
10. Remove the spring (18) and poppet (19) from the
body (14).
L2D240
IV-45 TB175W
Main Relief Valve

1. Remove the sleeve (2), spring (3) and main pop-
pet (4) from the plug assembly (1). 9 2
• The pilot seat (5) is caulked by the tip of the 4 8
3
plug and cannot be disassembled. 6
7
2. Remove the O-ring (6) and backup ring (7) from 1
the pilot seat (5).
3. Remove the O-ring (8) and backup rings (9) from

5
W2D213
4. Loosen the lock nut (10) and remove the plug (11) 18
and piston (12).
17
• When assembling, after installing the plug, 14
first partially tighten the lock nut, then fully 16
tighten it after adjusting the pressure.
15
5. Remove the O-ring (13) from the plug (11). 12
10
6. Loosen the lock nut (14) and remove the plug 13
11
(15).
7. Remove the O-ring (16) from the plug (15).

W2D214
8. Remove the spring (17) and needle valve (18).
TB175W IV-46
Checking the Parts

Housing • Scratches, rust, corrosion of the portion which slides • Replace
against the spool.
• Scratches, rust, corrosion of the seal pocket portion of • Replace
the part that enters the spool.
• Scratches, rust, corrosion of the port seal portion which • Replace
is in contact with the O-ring.
• Scratches, rust, corrosion of the seal portion of the relief • Replace
valve, etc.
• Other damage which could be a hindrance to correct • Replace
function.
Spool • Scratch marks like being clawed around the outer cir- • Replace
cumference sliding portion.
• Scratches on the portion that slides against the seals on • Replace
both ends.
• Spool not operating smoothly. • Repair or replace.
Load Check Valve • Imperfect sealing due to damage to the valve or spring. • Repair or replace.
• Does not catch, but operates lightly when inserted in the • Normal
section body and operated.
Around Springs • Rust, corrosion, deformation, breakage or other marked • Replace
damage to the spring, holder or cover.
Around Spool Seal • Oil leaking to the outside. • Repair or replace.
• Rust, corrosion or deformation of the seal holder. • Repair or replace.
Main Relief Valve, • External rust, damage. • Replace
Port Relief Valve, • Damage to valve seat contact surface. • Replace
Anti-Drift Valve • Damage to poppet contact surface. • Replace
• Abnormality in the spring. • Replace
• O-rings, backup rings, seals • As a rule, all these
should be replaced.
Adjusting the Main Relief Valve Pressure

“II. Specifications, Standards for Judging Per-
formance”
IV-47 TB175W
TROUBLESHOOTING
The following items are a list of all the problems that compound the trouble. It is therefore desirable to
might occur individually, but in actual practice, 2 or proceed so that the causes can be eliminated one at a
3 of these problems might occur simultaneously to time.

Oil leaks from spool seal. • Seal is scratched or the seal lip is worn • Replace with a new part.
due to long use.
• Spool’s seal sliding portion was dam- • Repair or replace the spool.
aged by some external cause (bruise,
scratch, etc.).
• Seal bulged out and the cover was in- • Return to the correct shape and check
stalled in a warped state. for eccentric wear of the seal lip.
• Paint adhered to the sliding portion of • Remove paint with paint thinner or re-
the spool’s seal portion during painting. move it mechanically. However, at this
time, be careful not to damage the spool
surface or the seal lip.
• Tank circuit’s pressure became high • Eliminate the factors causing excessive
and exceeded the pressure level that the flow resistance.
seal was capable of withstanding.
Spool’s sliding is not • Foreign matter is biting into the spool’s • Overhaul and repair or replace.
smooth. sliding surface.
• Oil film between the spool and body • Use some method to lower the oil tem-
disappears due to abnormally high oil perature or if the relief valve is operat-
temperature. ing frequently, investigate the cause
and reduce the frequency.
• Lubrication is improper due to deterio- • This could be alleviated by simply re-
rating oil. placing the hydraulic oil, or it could
require an overhaul of the circuit.
• Spool is worn from long use or due to • Check the spool’s diameter and con-
pressure bearing on one side only. sider the necessity of replacement.
• Spool is bent from externally applied • Check the spool’s straightness and other
pressure. factors, then repair or replace.
• Entire valve is strained due to strain in • Loosen the installation bolts, then cut
the installation face. the installation face and edge and check.
• Valve was used at a pressure or a flow • In the case of pressure, check with a
volume which was out of specification. pressure gauge. In the case of flow
volume, check by the actuator’s speed
of movement and the capacity.
• Bolts used to assemble the valve were • Check if the assembly bolts are tight-
tightened excessively. ened to the specified torque. If the torque
deviates markedly from the specified
torque, tighten them again.
• Oil is accumulating in the cover (the • The spool is leaking oil, so when the
side with a spring or a detent) opposite spool moves, oil leaks from the cover.
the side where the spool operates. After confirming this, replace the seal.
Cylinder drops while • Foreign matter is biting into the load • Disassemble and check, then overhaul
shifting to a lift operation. check valve seat or large scratches were or replace.
made by foreign matter biting into the
valve's seat previously.
TB175W IV-48

Can’t be held in the spool • Could be mistaken for a great amount of • Check if it isn't just the cylinder’s natu-
neutral position (cylinder leakage in the cylinder. ral drop when the cylinder is held. If the
drops). problem is in the cylinder, disassemble
and repair it.
• The gap between the spool and body is • Replace the spool or replace the valve
large, so the amount of oil leaking from block assembly.
the spool is great.
• Spool won’t return completely to the • Manually Operated :
neutral position. Check if there is something interfering
with the link mechanism.
Pilot Operated:
Check the pilot pressure.
• Foreign matter is biting into the port • Disassemble and check, then overhaul
relief valve seat or the anti-cavitation or replace.
valve seat and oil is bypassing. Or a seat
is damaged.
The load won’t move. • Foreign matter is biting into the relief • Disassemble and check, then overhaul
(Pressure won’t increase.) valve seat and oil is bypassing. Or the or replace.
seat is damaged.
• The relief valve’s adjustment screw is • Try tightening the adjustment screw. If
loose. it is loose, correct the setting and tighten
the lock nut securely.
• Foreign matter is biting into the port • Disassemble and check, then overhaul
relief valve seat or the anti-drift valve or replace.
seat and oil is bypassing. Or a seat is
damaged.
• Spool stroke is not the specified stroke. • Manually Operated:
Check if there is something interfering
with the link mechanism. Check if a pin
or a pin hole in the link connection is
worn.
Pilot Operated:
Check the pilot pressure.
• Pump is damaged and no oil is dis- • Check if the pump is abnormal or not. If
charged. the pump is bad, replace it. Check if the
cause of the abnormality is air being
sucked in, deterioration of hydraulic oil
or shafts not centered, etc.
Load doesn’t move. (Pres- • The load is too heavy. • Compare with an object of the specified
sure rises.) weight.
• Mechanical resistance of connecting • Check and replenish hydraulic oil, etc.,
parts is great regardless of the hydraulic modify or repair.
pressure in the operating unit.
• A large piece of foreign matter is trapped • Find the affected place and repair it.
in the circuit or a pipe is bent, causing
great resistance.
• Spool stroke is not the specified stroke. • Check if there is something interfering
with the link mechanism. Check if a pin
or a pin hole in the link connection is
worn or not.
IV-49 TB175W
TB175W IV-50
CONTROL VALVES HYDRAULIC UNITS
CONTROL VALVES (3-SECTION/4-SECTION)
CONSTRUCTION
3-Section 4-Section
5 10 12 11 5
10
4 4
6
6
1 2
9 1 2
9
3
12 3
8 8
7 7
W2D215E
1. Nut
2. Tie Rod
3. Slew Flow Control Section Assembly
4. Dozer Blade Section Assembly
5. Slew Section Assembly
6. Outlet Housing
7. Main Relief Valve
8. Port Relief Valve
9. Spacer Section
10. Slow Slew Speed Adjusting Valve
11. Auxiliary Section Assembly
12. Port Relief Valve
IV-51 TB175W
HYDRAULIC UNITS CONTROL VALVES
Slew Flow Control Section

1. Screw
2. Sleeve
3. Pin
4. O-ring
5. Piston
6. Spring Holder
7. Spring
8. Cover
9. O-ring
10. Cover
11. O-ring
12. Cap Screw
13. O-ring
Dozer Blade Section

1. Screw
2. Spring Holder
3. Spring
4. Cover
10 7 6 5. Seal Holder
6. Load Check Valve
2 3 4 5 7. Spring
8. Wiper
9. O-ring
10. O-ring
1 5 8 9 L3D251
Slew Section
1. Cover
2. Screw
3. Spring Holder
4. Spring
5. Cover
8 7 6 6. Load Check Valve
7. Spring
1 8. O-ring
9. O-ring
3 4 2 3 9 9 5 L3D252
TB175W IV-52
Auxiliary Section
1. Cover
2. Screw
3. Spring Holder
4. Spring
5. Cover
8 7 6 6. Load Check Valve
7. Spring
9 5
3 4 3 8. O-ring
9. O-ring
1 2 9 W2D217
Outlet Housing
1. Filter
2. Orifice
2 1
L3D253
Spacer Section
1. Plug
2. Adjusting Screw
3. Nut
4. O-ring
5. O-ring
6 6. O-ring
2
1
4 L3D254
IV-53 TB175W
Main Relief Valve
1. Housing 9. Lock Nut

9 2 1 10 6 5 11 4 3 2. Plug 10. Spring
3. Sleeve 11. Spring
4. Main Poppet 12. O-ring
5. Seat 13. Backup Ring
7. Adjusting Screw 15. O-ring
8. Washer 16. O-ring
7 8 15 14 13 12 16
W2D216
Port Relief Valve
1. Housing 11. Lock Nut

2. Plug 12. O-ring
3. Sleeve 13. Backup Ring
4. Main Poppet 14. O-ring
5. Piston 15. Backup Ring
8. Spring 18. Wave Washer
9. Adjusting Screw 19. O-ring
10. Washer
Port Relief Valve

2 5 7 1 7 4 6 3 1. Housing
2. Adjusting Screw
3. Poppet
4. Spring
5. Lock Nut
6. O-ring
7. O-ring
C4D205
TB175W IV-54
OPERATION
When the Spool is in the Neutral Position

When the control valve spool is not moving, hydrau-
lic oil flows through the center bypass passage (1) and
then through the tank passage (T) in the arrow direc-
tion, returning to the tank.
When the Spool is Actuated

Explanation is given for the case where the spool is
moved to the right.
When the spool (2) is moved to the right, the center
bypass passage (3) is closed and hydraulic oil entering
from the pump passes through the load check valve
(5) from the parallel passage (4), flowing from the A
port to the actuator. On the other hand, oil returning
from the B port flows through the tank circuit (T) and
returns to the tank.
Load Check Valve

A load check valve (5) is included in each section
except the travel (right, left) sections.
This valve prevents oil from flowing backward due to
the load pressure (C) from the actuator port during
switching of the spool.
IV-55 TB175W
Slew Flow Control Function

This function switches the quantity of hydraulic oil
flowing to the slew motor to change the slewing speed
between normal and slow. It also keeps the flow to the
motor steady even when the supply pressure changes
during slow speed slewing.
Normal speed mode

When there is no pilot pressure at port FC, spool (1),
push rod (2) and piston (3) are positioned at the left
side by spring (4). In addition, pre-choke pressure P1
is led to the left side of spool (1) through pilot hole (5)
and post-choke pressure P2 is led to the right side of
spool (1) through pilot hole (6). At this time, all the oil
supplied from port P3 flows to the slew motor.
Slow speed mode

When the pilot pressure reaches port FC, piston (3)
moves to the right side, push rod (2) and spool (1) also
move, and the difference between pre-choke pressure
P1 and post-choke pressure P2 at spool (1) works to
maintain a constant pressure (PC). Part of the hydrau-
lic oil supplied from port P3 passes through the
control orifice (7) and flows to the slew motor, and the
remaining oil flows to tank port T2. The pressure at
port P3 (PS) at this time increases, and when the flow
increases, the difference in pressure between P1 and
P2 increases, so spool (1) moves to the right side, the
control orifice (7) is choked, the pressure difference
[P1 – P2] is kept at PC, and the flow to the slew motor
does not increase.
Inversely, when the pressure (PS) at port P3 de-

creases, the difference in pressure between P1 and P2
decreases, so spool (1) is moved to the left side by
spring (4) until the pressure difference reaches PC and
orifice (7) opens, so the flow to the slew motor does
not decrease.
In this way, only a specific quantity of the oil supplied
flows to the slew motor even when the supply pres-
sure changes, the remaining being release to tank port
T2. This makes it possible to slew in the slow speed
mode with a slow flow.
TB175W IV-56
Main Relief Valve
A main relief valve is mounted between the pump
circuit and tank circuit of each inlet housing and
serves to maintain the circuit pressure at the set value.
When the Relief Valve is NOT Operating

When the pressure in the circuit is low with respect to C 2 D 1
the set value, the relief valve maintains equilibrium.
Hydraulic oil from the pump passes through the
orifice from chamber (C) and arrives at the spring
chamber (D) and the needle valve (1). On the other
hand, forces F and F1 are acting in the respective F F1
arrow directions on both sides of the main poppet (2).
F = P × A Fl = P × A1
P: Pressure A, A1: Cross Sectional Area
Since the cross sectional area of A is less than that of
A1, the main poppet (2) is pushed by the force A A1
“F1 - F” to the seat surface on the left side. S3F611
When the Relief Valve is Operating

If the circuit's pressure becomes greater than the set
value of the spring (3), the needle valve (1) is pushed 2 3 1
to the right by hydraulic pressure and oil flows to the
tank passage (T). When this happens, a pressure
differential is generated between the two ends of
orifice of the main poppet (2), and this hydraulic
pressure pushes the main poppet toward the right. As
a result, the pressurized oil in the circuit flows to the
tank passage.
This operation maintains the pressure in the circuit at
the set value.
T
S3F612
IV-57 TB175W
Port Relief Valve

A port relief valve is located between the actuator port
and the tank circuit and when abnormal pressure due
to shock pressure or external pressure generated when
the actuator port is suddenly blocked by the spool or
when there is an overload occurs, these valves act to
protect the actuator.
Relieving Operation
the set value, the relief valve is maintained at equilib-
rium. Pressure from the pump passes from chamber B
to the orifice in piston (4), then reaches chamber C and
the needle valve (5). On the other hand, forces F and
F1 are acting in the arrow directions on both sides of
F = P × A F1 = P × A1
P: Pressure A, A1: Sectional Area
Since the sectional area of A is less than that of A1, the
seat surface on the left side.

force of the spring (7), the needle valve (5) is pushed
passage (T).
When the needle valve (5) opens, the pressure drops

on the back side of the piston (4), pushing the piston
(4) to be pushed to the right, seating with the needle
valve (5). This shuts off the flow of hydraulic oil to the
rear of the main poppet (6). As a result, the pressure
in chamber C on the inside drops.

chamber C is low and there is no equilibrium in
TB175W IV-58
Suction Operation
When the cylinder is operated at high speed, and the
supply of oil cannot keep up with it, creating a vacuum
in chamber B, oil is supplied from the tank side,
preventing the occurrence of cavitation.
When the pressure in chamber B is lower than the
pressure in the tank passage (T), the differences in the
sectional areas A and A1 cause the main poppet (6) to
open. Thus, sufficient oil from the tank passage (T)
enters chamber B, filling the empty space.
For Auxiliary
The figure at right shows when hydraulic pressure
arrives at chamber A from the actuator port. If this
pressure becomes stronger than the set value of the
spring (1), it pushes the poppet (2) to the right side and
pressurized fluid from the actuator port flows to the
tank passage.
IV-59 TB175W
General Cautions
• Since all parts in control valves are precision • Replace all seals with new ones each time the
machined, carry out disassembly and assembly valves are disassembled.
operations in a clean place. • Spools and section bodies are specially selected for
• Before disassembly, clean the outside surfaces a precise fit. Therefore, if any damage is found in
around the valves. either of these parts, replace the section assembly
• Clean all disassembled parts in cleaning solvent. as a unit.
Use a lint free cloth, or air dry the parts. • Be sure to number each section and spool to avoid
• Apply hydraulic oil to sliding surfaces and apply a mistakes during assembly.
thin coating of grease to seals when assembling • Do not turn adjusting screws if not required.
them.
Following is an explanation of the control valve

disassembly procedure.
Follow the procedure used to disassemble the control
• Before disassembly, number each section and spool.
Disassembly
Valve Assembly
1. Loosen the nuts and remove the tie rods, then
remove the sections.
Nut: 19.0 N·m
2. Remove the O-ring.

• The mating surfaces are metal seals, so be
careful not to scratch, bruise or otherwise dam-
age them.
3. Remove the main relief valves and the port relief

valves, then remove the O-rings from the relief
valves.
• Do not disassemble the relief valves unless it is
necessary.
• When using a spanner or adjustable wrench, be
sure to attach it in the place shown in the figure
at right.
Relief valve: 68~78.5 N·m
G4D223
TB175W IV-60
4. Remove the load check valve.
• Remove the spring (3), then remove the poppet
(4).
Manually Operated Section

1. Remove the cap screws (5), the cover (6) and the
spool assembly (7).
Cap screw: 7.3 N·m
2. Loosen the screw (8) from the spool assembly (7).

Screw: 5.2 N·m
3. Remove the spring holder (9), spring (10), and

spring holder (9).
IV-61 TB175W
4. Remove the seal holder (12), then remove the

backup ring (13) and O-ring (14).
5. Remove the screws on the spool yoke end side of

the section, then remove the seal holder, backup
ring and O-ring.
Screw: 2.5 N·m
Pilot Operated Section

1. Take out the cap screw (5) and remove the cover
(15), then remove the O-ring (16) from the cover
(15).
Cap screw: 7.3 N·m
2. Remove the spool from the section.
K3D217
TB175W IV-62
3. Take out the screw (17) and remove the spring
holder (18), spring (19) and spring holder (18).
Screw: 4.9 N·m
4. Take out the cap screws (5) and remove the cover
(21).
5. Remove the O-ring (16) from the cover (21). 16

Cap screw: 7.3 N·m 21
5
K3D219
Disassembling the Slew Flow Control Block

1. Remove cap screws (1), then remove cover (2),
spring (3), spring holder (4) and spool (5).
Cap screw: 9.8 N·m
2. Remove O-ring (6) from cover (2).
3. From the opposite side of the block, remove cap

screws (7), then remove cover (8), piston (9), pin
(10) and sleeve (11).
Cap screw: 9.8 N·m
4. Remove O-ring (12) from cover (8).
5. Remove O-ring (13) from sleeve (11).
IV-63 TB175W
Main Relief Valve

1. Remove the plug (1) from the housing (2).
Plug: 49~54 N·m 2
2. Remove the O-ring (3) from the plug (1).
3
1
W2D218
3. Remove the sleeve (4) from the plug (1) and

remove the spring (5) and main poppet (6) from
the sleeve (4).
5
4. Remove the O-ring (7) and backup ring (8) from 7
8
the seat (9).
1 4
9
W2D219
5. Remove the lock nut (10), washer (11) and adjust-

ing screw (12) from the plug (1), then remove the 1
O-ring (13) from the adjusting screw (12).
• During assembly, after installing the adjusting
screw (12), lock the lock nut (10) temporarily,
then tighten it after adjusting the pressure. 13
12
Lock nut: 27~31 N·m
6. Remove the spring (14) and needle valve (15). 15

14
11
10 W2D220
TB175W IV-64
Checking the Parts

Housing, • Scratches, rust, corrosion of the portion which slides • Replace
Section Body against the spool.
• Scratches, rust, corrosion of the seal pocket portion of • Replace
the part that enters the spool.
• Scratches, rust, corrosion of the port seal portion which • Replace
is in contact with the O-ring.
• Scratches, rust, corrosion of the seal portion of the relief • Replace
valve, etc.
• Other damage which could be a hindrance to correct • Replace
function.
Spool • Scratch marks like being clawed around the outer cir- • Replace
cumference sliding portion.
• Scratches on the portion that slides against the seals on • Replace
both ends.
• Spool not operating smoothly. • Repair or replace.
Load Check Valve • Imperfect sealing due to damage to the valve or spring. • Repair or replace.
• Does not catch, but operates lightly when inserted in the • Normal
section body and operated.
Around Springs • Rust, corrosion, deformation, breakage or other marked • Replace
damage to the spring, holder or cover.
Around Spool Seal • Oil leaking to the outside. • Repair or replace.
• Rust, corrosion or deformation of the seal holder. • Repair or replace.
Main Relief Valve, • External rust, damage. • Replace
Port Relief Valve • Damage to valve seat contact surface. • Replace
• Damage to poppet contact surface. • Replace
• Abnormality in the spring. • Replace
• O-rings, backup rings, seals • As a rule, all these
should be replaced.
Adjusting the Main Relief Valve Pressure

“II. Specifications, Standards for Judging Per-
formance”
IV-65 TB175W
Adjusting The Slow Slew Speed Adjusting

Valve
The slow slew speed can be adjusted in the range of
38% to 71%. The slow slew speed has been set to 71%
at the factory. (The right figure shows the setting at the
factory.)
• Adjustable distance A: 3 mm
1. Loosen the lock nut (2) and turn the set screw (1)
to fine adjust the slew speed. 2
Turning to the left will reduce the speed.
Turning to the right will increase the speed. 1
2. Upon completion of the adjustment, tighten the
lock nut while holding down the set screw to
prevent it from turning.
3. Operate the valve again to confirm that the set 84.4 A
screw is stable.
L3D255
TROUBLESHOOTING
“IV-48~49”
TB175W IV-66
SOLENOID VALVES HYDRAULIC UNITS
SOLENOID VALVES
CONSTRUCTION
Solenoid Valve (3-Section)

Ram Lock, Lever Lock and Speed Shift
SPEED
OUTRIGGER LEVER SHIFT
/RAMLOCK LOCK (SLEW)
6
7
T
A1 A2
A3
P A4
P1
A1 A2 A3
4
2
P
P1
5
T
A4
HYDRAULIC SYMBOL 3
W2H100E
1. Body
2. O-ring
3. Spool
4. Spring
5. Cover
6. Solenoid Valve
7. Relief Valve
IV-67 TB175W
HYDRAULIC UNITS SOLENOID VALVES

Change, Speed Shift and Parking Brake
C B A
C B A
PARKING SPEED SWING/ADJUST

P BRAKE SHIFT CHANGE
(LOW)
T Y Y X X X
HYDRAULIC SYMBOL
11 5
4 12 9
6
11 2 7 10 1 8 3
SECTION “Y”
ACC
T
P
SECTION “X”
W2H101E
1. Spring 7. Spool
2. Sleeve 8. Stopper
3. Body 9. Plug
4. Rod 10. Washer
5. Plate 11. O-ring
6. Solenoid Valve 12. O-ring
TB175W IV-68
Change and Speed Shift
D C B A
D C B A
SPEED SPEED SPEED SWING/ADJUST

P SHIFT SHIFT SHIFT CHANGE
(HIGH) (LOW) (INCH)
T Y X X X X
HYDRAULIC SYMBOL
11 5
4 12 9
6
11 2 7 10 1 8 3
SECTION “Y”
ACC
T
P
SECTION “X”
W2H102E
1. Spring 7. Spool
2. Sleeve 8. Stopper
3. Body 9. Plug
4. Rod 10. Washer
5. Plate 11. O-ring
6. Solenoid Valve 12. O-ring
IV-69 TB175W
OPERATION
Solenoid Valve
When current is not flowing T
Oil at port P is blocked by the spool (1). Also, since A
port A and port T are connected, the pressure in the
pilot circuit downstream becomes the same as the
tank pressure. 1
9 0!
When current is flowing

A magnetic field is generated around the coil and the 2
plunger (2) is pulled down. This pushes the spool (1)
down. As a result, oil at port P flows into port A and A
pressure is transmitted to the pilot circuit at the T
bottom.
1
9 0"
TB175W IV-70
General Cautions
• Carry out disassembly and assembly operations in • The spool and body are selectively fitted, so if one
a clean place and place disassembled parts in clean is found to be damaged, replace the valve assem-
containers. bly.
• Before disassembly, clean thoroughly around the • Apply a thin coating of hydraulic oil to sliding
ports and remove paint or thread lock, etc. from all surfaces and a thin coating of grease to seals when
joints with a wire brush. assembling them.
• Clean all disassembled parts in cleaning solvent. • Replace seals with new parts each time disassem-
Use a lint free cloth, or air dry the parts. bly is done.
• Do not turn adjusting screws if not required.
Following is a description of the solenoid valve block

disassembly procedure. Reassemble the solenoid valve
block by following this procedure in reverse order.

Ram Lock, Lever Lock and Slew Shift
1. Fix the housing and remove the solenoid valve
(1).
Solenoid valve: 44 ±5 N·m
2. Remove the socket bolt, and then remove the

cover (2).
Cap screw: 3.4 ±0.5 N·m
3. Remove the spring (3) and the spool (4).

• Pull out the spool slowly, and take care not to
scratch or dent the circumference.
• At the time of reassembly, the spool must be
installed in the same housing hole.
4. Remove the relief valve.

Relief valve: 44 ±5 N·m
IV-71 TB175W

Change, Speed Shift and Parking Brake
1. Loosen the cap screws and remove the solenoid
coil (5). 5
• Put matching marks on the solenoid and the
body so that they can be aligned when assem-
bling.
• Take care not to miss the push rod.
Cap screw: 3.9 N·m
2. Remove the O-ring from the solenoid coil (5).
W2H105
3. Remove the spool (6) and sleeve (7) from the

body.
• Record the positions of the spool, sleeve and
the body hole so that they can be aligned when
assembling.
6
• To take out the spool, hook the small orifice at
the end of the spool using a tool such as a
scriber.
• To remove the sleeve, turn the body upside 7
down and lightly tap it.
W2H106

Change and Speed Shift
1. Loosen the cap screws and remove the solenoid 5
coil (5).
• Put matching marks on the solenoid and the
body so that they can be aligned when assem-
bling.
• Take care not to miss the push rod.
Cap screw: 3.9 N·m
2. Remove the O-ring from the solenoid coil (5).
W2H107
3. Remove the spool (6) and sleeve (7) from the

body.
• Record the positions of the spool, sleeve and
the body hole so that they can be aligned when
assembling.
6
• To take out the spool, hook the small orifice at
the end of the spool using a tool such as a
scriber.
• To remove the sleeve, turn the body upside 7
down and lightly tap it.
W2H108
TB175W IV-72
Checking the Parts

Solenoid coil • When the solenoid is burned, short-circuited, or has a wire • Replace
break
• Wiring short-circuit or wire break • Replace
Body • Scratches, rust, or corrosion at the sliding parts with the spool • Replace
• Scratches, rust, or corrosion of the seal part in contact with the • Replace
O-ring
• Other damage considered to impair the normal functions • Replace
Spool, plunger • Damage on the outer circumference which catches a fingernail • Replace
• No smooth movement • Adjust or replace
Spring • Rust, corrosion, deformation, breakage, or other notable dam- • Replace
age
O-Ring  • Replace
TROUBLESHOOTING

Solenoid valve does not • Wiring short-circuit or wire break • Replace
operate. • Solenoid coil short-circuit or wire break • Replace
• Catching of foreign matter by the spool • Overhaul and repair or replace.
• Damage on the outer circumference of the spool • Overhaul and repair or replace.
• Catching of foreign matter by the plunger • Overhaul and repair or replace.
• Damage on the outer circumference of the plunger • Overhaul and repair or replace.
Oil leakage from solenoid • Damaged O-ring • Replace
valve, cover, or relief • Damaged O-ring at the emergency manual but- • Replace
valve to the outside. ton of the solenoid valve
Pressure does not rise. • Catching of foreign matter by the relief valve • Clean or replace.
IV-73 TB175W
TB175W IV-74
PROPORTIONAL CONTROL SOLENOID VALVE HYDRAULIC UNITS
PROPORTIONAL CONTROL SOLENOID VALVE
CONSTRUCTION
A: 7 ±0.5 N·m
1. Proportional Control Solenoid

2. Bolt
3. Spool
IV-75 TB175W
HYDRAULIC UNITS PROPORTIONAL CONTROL SOLENOID VALVE
OPERATION PRINCIPLE
This valve controls the secondary pressure by using S 1

the built-in proportional pressure reducing valve. The
2 4
S=A1-B1
secondary pressure of this valve is proportional to the
magnitude of electric current flowing in the valve,
B1 A1
because the force to generate the secondary pressure
Fk
is applied by the solenoid based on the current passing Fs Fks
through the coil. Paxs
When a current flows in the solenoid, a thrust force

proportional to the current is generated and moves the
spool (1) so that the oil supplied from Port P is led to P A T
the secondary pressure side Port A, thus increasing
Paxs Fk Fs Fks
pressure Pa of Port A. T9H201
Pressure Pa is a function of the differential area S

between the cross sections A1 and B1 of the spool (1),
and the spool (1) is pushed to the solenoid side by the
oil pressure Pa × S. The spool (1) stops at a position
where the sum of the oil pressure Pa × S and the force
Fk exerted by the springs (2) is balanced with the
thrust force Fs generated by the solenoid. The weight
Fks of the spring (4) for fine adjustment of the
secondary pressure acts in the direction (left) to help
the thrust force from the solenoid.
When the thrust force is larger than the set value, the
spool (1) is moved to the left, connecting Port P 5 1
(primary, supply side) and Port A (secondary, dis-
charge side) through the notch (5).
P A T
T9H202
When the thrust force is smaller than the set value, the
spool (1) is moved to the right, connecting Port A 1 6
(secondary, discharge side) and Port T (outlet to tank)
through the notch (6).
Therefore, the opening areas of the supply side notch
(5) and discharge side notch (6) are controlled by the
movement of the spool (1), and secondary (pilot)
pressure created by the thrust force generated by the
solenoid can be provided.
P A T
T9H203
TB175W IV-76
PROPORTIONAL CONTROL SOLENOID VALVE HYDRAULIC UNITS
General Cautions
• Carry out disassembly and assembly operations in • Apply a thin coating of hydraulic oil to sliding
a clean place and place disassembled parts in clean surfaces and a thin coating of grease to seals when
containers. assembling them.
• Before disassembly, clean thoroughly around the • Replace seals with new parts each time disassem-
ports and remove paint or thread lock, etc. from all bly is done.
joints with a wire brush.
• Clean disassembled parts with light oil or other
cleaning oil.
• The spool and body are selectively fitted, so if one
is found to be damaged, replace the valve assem-
bly.
The following describes the disassembly procedure.

For assembly, follow the disassembly procedure in 1
the reverse order.
Disassembly
1. Remove the bolts, and then remove the propor-
tional control solenoid (1).
Bolt: 6.9 ±1 N·m
T9H204
2. Remove the O-rings from the proportional con-

trol solenoid (1).
• Do not disassemble the sleeve (2) that is swaged
onto the solenoid (4) with the retaining ring
(3).
• Make sure that the spool (5) moves a little if
pushed from the sleeve (2) end.
4
3
2
5 T9H205
IV-77
IV-76-1 TB175W
HYDRAULIC UNITS PROPORTIONAL CONTROL SOLENOID VALVE
Checking the Parts
Part Judgment Criteria Treatment

Coil assembly • When the solenoid is burned, short-circuited, or has a wire • Replace
break
• Wiring short-circuit or wire break • Replace
Housing • Scratches, rust, or corrosion at the sliding parts with the • Replace
spool
• Scratches, rust, or corrosion of the seal part in contact with • Replace
the O-ring
• Other damage considered to impair the normal functions • Replace
Spool • Damage on the outer circumference which catches a finger- • Replace
nail
• No smooth movement • Adjust or replace
Spring • Rust, corrosion, deformation, breakage, or other notable • Replace
damage
O-ring  • Replace
TROUBLESHOOTING
Symptom Main Causes Remedy

Solenoid valve does • Wiring short-circuit or wire break • Replace
not operate • Coil assembly short-circuit or wire break • Replace
• Catching of foreign matter by the spool • Overhaul and repair or re-
place
• Damage on the outer circumference of the spool • Overhaul and repair or re-
place
• Defective the proportional controller • Repair or replace
• Primary pressure is insufficient • Keep the primary pressure
Oil leakage from sole- • Damaged O-ring • Replace
noid valve • Damaged seal nut • Replace
TB175W IV-76-2
IV-78
SELECTOR VALVE HYDRAULIC UNITS
SELECTOR VALVE
CONSTRUCTION
Pilot Change
PL
A T
P
HYDRAULIC SYMBOL
A
3 PL
1
T
4 P
6
5
8
2
B
W2H300
A: 26.5 N·m
B: 70.6 N·m
1. Body 5. Spring
2. Plug 6. Retainer
3. Connector 7. O-ring
4. Spool 8. O-ring
IV-77 TB175W
HYDRAULIC UNITS SELECTOR VALVE
Swing/Adjust Change
B1 A1 B2 A2
2 4 1 4 3
PP T
P1 P2
HYDRAULIC SYMBOL
SECTION “X-X”
2 2
22 * *
6
6
A ) ) A
X X
9 0!-
A: 9.8 N·m
1. Spring
2. Cover
3. Cover
4. O-ring
TB175W IV-78
PORT RELIEF VALVE HYDRAULIC UNITS
PORT RELIEF VALVE
CONSTRUCTION
P1 P2
HYDRAULIC SYMBOL
X X
11 3
9 17
4
16
5 18
10
6 1 13
16 8
2 7
15 14 12
SECTION “X-X”
W2H400E
1. Housing 10. Backup Ring

2. Plug 11. Pin
3. Sleeve 12. Adjusting Screw
4. Main Poppet 13. Body
5. Spring 14. Lock Nut
9. Backup Ring 18. O-ring
IV-79 TB175W
HYDRAULIC UNITS PORT RELIEF VALVE
OPERATION
“IV-58~59”
Genaral Cautions
“IV-60”
Following is an explanation of the relief valve disas-

sembly procedure.
Follow the procedure used to disassemble the relief
Disassembly
1. Remove the port relief valves, then remove the O-
rings from the relief valves.
• Do not disassemble the relief valves unless it is
necessary.
• When using a spanner or adjustable wrench, be
sure to attach it in the place shown in the figure
at right.
Relief valve: 58.84 N·m
W2H401
TB175W IV-80
SHUT-OFF VALVES HYDRAULIC UNITS
SHUT-OFF VALVES
CONSTRUCTION
1. Body 6. Plug
2. Relief Valve 7. Lock Nut
3. Plug 8. Adjusting Screw
4. Screw 9. Spring
5. Plug 10. Spool
IV-81 TB175W
HYDRAULIC UNITS SHUT-OFF VALVES
OPERATION
The isolation valve prevents the boom or arm being

raised from falling. If the hydraulic hose breaks, the
valve blocks and isolates the hydraulic oil flowing to
the cylinder head.
When the boom or arm is raised, the pressure oil from

the hydraulic pump flows through the port V2 to push
up the check valve (1) and then through the port C2
into the boom or arm cylinder.
When the boom or arm is lowered, the pilot pressure

from the pilot valve (2) is led to the port PDB. The
pilot pressure in the port PDB moves the spool (3) to
the left. The return oil from the cylinder flows from
the port C2 to the passage through the spool (3) and
the check valve (1), the port V2 and into the tank
passage.
The boom or arm does not fall in case of hydraulic

hose breakage, because the oil flow leading to the
boom or arm is blocked and isolated in the passage
through the check valve (1) and the spool (3) if a hose
breaks.
TB175W IV-82
SHUT-OFF VALVES HYDRAULIC UNITS
Never adjust the adjuster screws on the isolation

valve. Otherwise, the valve may not work properly, or
the boom or arm may fall.
IV-83
IV-83 TB175W
HYDRAULIC UNITS SHUT-OFF VALVES
TROUBLE SHOOTING
When the hose of the boom or arm cylinders are

ruptured and the boom or arm falls, the emergency
shut-off valve is activated and stops the boom or arm
part way through the fall.
WARNING
If the boom or arm drops and the emergency
shut-off valves are activated, immediately move
away from the suspended object.
If the engine can be started, the boom or arm can be

lowered with the operating lever. Check for safety,
then slowly lower the boom or arm.
If the engine cannot be started, the boom or arm can
be lowered using the procedure described below.
1. Check for safety in the working area and for

stability of the machine and lifted load.
2. Remove the cap (2).
3. Loosen the lock nut (3).
4. Tighten the stem (4) to lower the boom or arm.
5. Check for stability of the hoe attachment and

load.
6. Loosen the stem (4) secure it with the lock nut (3).
TB175W IV-84
IV-84
PILOT VALVE HYDRAULIC UNITS
PILOT VALVE
CONSTRUCTION
1. Casing 11. Washer 2

2. Plate 12. Spring
3. Spool 13. Spring
4. Plug 14. Spring
5. Push Rod 15. Spring
6. Push Rod 16. Joint
7. Seal 17. Disc
8. O-ring 18. Adjusting Nut
9. Spring Seat 19. Lock Nut
10. Spring Seat
IV-85
IV-97 TB175W
OPERATION
The pilot valve casing contains a vertical shaft hole The casing also contains an inlet port for hydraulic oil
with a reducing valve incorporated into it. When the port P (primary pressure) and an outlet port, port T
handle is tilted, the push rod and spring seat are (tank) and secondary pressure is taken from 4 ports,
pushed down changing the secondary pressure spring’s port 1, port 2, port 3 and port 4, on the bottom of the
pressure. vertical shaft hole.
When the Handle is in Neutral When the Handle is Tilted

In this case, the force of the secondary pressure setting When the handle (1) is tilted and the push rod is
spring, which determines the pilot valve’s output pushed, the spool moves downward and port P and
pressure (secondary pressure), is not transmitted to port A are joined. The oil in the pilot valve pump flows
the spool. Therefore, the spool is pushed up by the out to port A, generating pressure.
return spring and is in the output port C position a. When the pressure in port A is the same as the set
shown above, with oil not flowing between port P and force of the spring (set pressure), there is a balance
the output port C but flowing between the T port and between the hydraulic pressure and the spring
output port C. force.
b. When the pressure in port A is greater than the set
pressure, port A and port P close and port A and
port T open.
c. When the pressure at port A is lower than the set
pressure, port A and port P open and port A and port
T close.
In this way, the secondary pressure is kept constant.
IV-87
IV-86 TB175W
HYDRAULIC UNITS PILOT VALVE
Table of Special Tools

NAME, DIMENSION Q’ty NAME, DIMENSION Q’ty
INSTALLATION JIG (A) INSTALLATION JIG (B)
1 2
MATERIAL A; S45C
MATERIAL B; SCM415N WITH CEMENTATION HARDENING MATERIAL B; SCM415N WITH CEMENTATION HARDENING
General Cautions
• Since all parts in the pilot valve are precision • Replace all seals with new ones each time the pilot
machined, carry out disassembly and reassembly valve is disassembled.
operations in a clean place and take special care not • During assembly, remove all the foreign matter
to scratch the parts. from each part and check them to make sure there
• Before disassembly, clean the outside surfaces of are no burrs, bruises using or other marks on them.
the pilot valve. Remove all burrs and bruises using an oil stone.
• Clean each of the disassembled parts and apply • Apply thin coating of grease to seals when assem-
clean hydraulic oil to them. bling them.
Disassembly
1. Remove the lock nut and the adjust nut (1), then
remove the disc (2).
• Using copper or lead plates, fasten the valve in
a vise.
2. Remove the joint (3), then remove the plate (4).

• Use installation jigs (A) and (B).
TB175W IV-87
IV-98
3. Take out the plug (5) then remove the push rod (6)
from the plug (5).
• If the plug is difficult to remove, use (–) screw
driver to remove it.
• Be careful not to let the plug fly out from the
spring’s force.
4. Remove the O-ring (7) and seal (8) from the plug.
5. Remove the reducing valve (12) and spring (13).

• Make match marks on the reducing valve and
casing hole so they can be placed in the same
position when they are reassembled.
6. Disassemble the reducing valve.

a. Push in the spring sheet (14) to contract the
spring (15), and move the spool (17) from the
small hole to the large hole of the spring sheet
(14).
• Do not push in the spring sheet too far (at
most 6 mm).
IV-88
IV-99 TB175W
b. Remove the spring seat (14), spring (15) and

washer 2 (16) from the spool (17).
Assembly
1. Assemble the reducing valve (12).
a. Install the washer 2 (16), spring (15) and spring
seat (14) on the spool (17).
b. Push in the spring sheet (14) to contract the

spring (15), and move the spool (17) from the
large hole to the small hole of the spring sheet
(14).
• Do not push in the spring sheet too far (at
most 6 mm).
TB175W IV-89
IV-100
2. Install the spring (13) and reducing valve (12).
• Install them in the positions they were in be-
fore disassembly.
3. Install the O-ring (7) and seal (8) in the plug (5).
4. Install the push rod (9) in the plug (5).

• Apply hydraulic oil to the push rod.
5. Install the plug (5) and plate (4), then install the
joint.
• Use installation jigs (A) and (B) to install the
joint.
Joint: 47.1 ±2.9 N·m
IV-90
IV-101 TB175W
6. Install the disc (2), the adjust nut (1) and the lock
nut.
• Tighten the adjust nut to the point where all 4
push rods are uniformly making contact.
• During tightening, the disc should not be
moved.
Adjust Nut: 68.6 ±4.9 N·m
7. Apply grease to the contact surfaces of the joint

rotating portion, the disc and the push rod.
TB175W IV-91
IV-102
Checking the Parts

O-ring ⎯⎯ • Replace
Seal ⎯⎯ • Replace
Seal Washer ⎯⎯ • Replace
Spool • Wear on sliding portions is 10 μm or greater compared to non- • Replace
sliding portions
• Scratches on sliding portions • Replace
• Spool doesn’t move smoothly • Repair or replace
Push Rod • Front end is worn 1 mm or more • Replace
• Scratches in the sliding portion • Replace

Plug • Seal is imperfect due to damage • Repair or replace
Operating Portion • Tightening is loose at the pin, shaft or joint of the operating • Tighten to the speci-
portion, with looseness of 2 mm or greater fied torque
• Due to wear, etc. tightening is loose at the pin, shaft or joint of • Replace
the operating portion, with looseness of 2 mm or greater
Casing, • Scratches, rust or corrosion on the spool and sliding portion • Replace
Port Plate • Scratches, rust or corrosion on seal portions which come in • Repair or replace
contact with the O-ring
TROUBLESHOOTING

Secondary pressure doesn’t • Primary pressure is insufficient • Keep the primary pressure
rise • Spring is damaged or permanently • Replace the spring
deformed
• The clearance between the spool and • Replace the spool and casing assem-
casing is abnormally large bly
• There is looseness in the handle • Disassemble and reassemble, or re-
place the handle
Secondary pressure doesn’t • Sliding parts are catching • Repair or replace
stabilize • Tank line pressure fluctuates • Remove the abnormal portions of the
tank line
• Air gets mixed into the piping • Operate the machine several times
and bleed out the air
Secondary pressure is high • Tank line pressure is high • Remove the abnormal portions of the
tank line
• Sliding parts are catching • Repair or replace
TB175W IV-94
IV-92
PILOT VALVE (SWING)
CONSTRUCTION
13
16 14
6 15
9
12
11
10
L3D350
1. Casing 9. Spring Seat

2. Cover 10. Washer
3. Plug 11. Spring
4. Seal 12. Spring
5. O-ring 13. Shaft
6. Push Rod 14. Bushing
7. Shim 15. Cam
8. Spool 16. Ball
IV-93
IV-10
IV 3 TB175W
OPERATION
“IV-86”
General Cautions
“IV-87”
The following describes the disassembly procedure.

For assembly, refer to the construction diagram and
follow the disassembly procedure in the reverse or-
der.
Disassembly
1. Remove the boot from the cover.
• Use a copper or iron sheet to fasten the valve to
the vice.
• Apply grease to the cam and push rods.
2. Remove the set screw.

Set screw: 6.9 N·m
• Apply Loctite #241 to the set screw.
3. Remove the cam pin, then remove the cam (1).
TB175W IV-104
IV-94
4. Loosen the cap screws and remove the cover (2).
• The cover and plug will rise from the surface if
the rebound spring is too strong, so loosen the
cap screws alternately so that the cover is flat.
• Mark the cover and casing so that they can be
reassembled in the same positions.
Cap screw: 8.8 N·m
5. Remove the push rods (4) together with the plug

(5). 4
L3D351
6. Remove the O-rings and seal (6) from the plug.
L3D352
7. Remove the spool assembly (7) and spring (8)

from the casing.
• Never disassemble the spool assembly as the
pressure has been adjusted by the shim.
IV-105
IV-95 TB175W
Checking the Parts

O-ring ⎯⎯ • Replace
Seal ⎯⎯ • Replace
Seal Washer ⎯⎯ • Replace
Spool • Wear on sliding portions is 10 μm or greater compared to non- • Replace
sliding portions
• Scratches on sliding portions • Replace
• Spool doesn’t move smoothly • Repair or replace
Push Rod • Front end is worn 1 mm or more • Replace
• Scratches in the sliding portion • Replace

Plug • Seal is imperfect due to damage • Repair or replace
Operating Portion • Tightening is loose at the pin, shaft or joint of the operating • Tighten to the speci-
portion, with looseness of 2 mm or greater fied torque
• Due to wear, etc. tightening is loose at the pin, shaft or joint of • Replace
the operating portion, with looseness of 2 mm or greater
Casing, • Scratches, rust or corrosion on the spool and sliding portion • Replace
Port Plate • Scratches, rust or corrosion on seal portions which come in • Repair or replace
contact with the O-ring
TB175W IV-96
TROUBLESHOOTING

Secondary pressure doesn’t • Primary pressure is insufficient • Keep the primary pressure
rise • Spring is damaged or permanently • Replace the spring
deformed
• The clearance between the spool and • Replace the spool and casing assem-
casing is abnormally large bly
• There is looseness in the handle • Disassemble and reassemble, or re-
place the handle
Secondary pressure doesn’t • Sliding parts are catching • Repair or replace
stabilize • Tank line pressure fluctuates • Remove the abnormal portions of the
tank line
• Air gets mixed into the piping • Operate the machine several times
and bleed out the air
Secondary pressure is high • Tank line pressure is high • Remove the abnormal portions of the
tank line
• Sliding parts are catching • Repair or replace
IV-95
IV-97 TB175W
TB175W IV-106
IV-98
CYLINDERS HYDRAULIC UNITS
CYLINDERS
CONSTRUCTION
Boom Cylinder
3 14 2 6 1 16 5 4 17 15 2122 8 23 24 25 18 20 7 4 19
DETAIL "S"
26 26 28
9
13 27 11 DETAIL "T"
12 10
29
30
W2D400E
1. Buffer Ring 9. O-ring 17. Snap Ring 25. Ball

2. Rod Packing 10. Tube 18. Holder 26. Dust Seal
3. Dust Seal 11. Bushing 19. Cushion Seal 27. Nipple
4. O-ring 12. Piston Rod 20. Collar 28. Plug
5. Backup Ring 13. Bushing 21. Piston 29. Grease Nipple
6. O-ring 14. Rod Cover 22. Wear Ring 30. Grease Nipple
7. Backup Ring 15. Cushion Bearing 23. Nut
8. Piston Packing 16. Bushing 24. Set Screw
IV-99 TB175W
HYDRAULIC UNITS CYLINDERS
Arm Cylinder
4 5 17 23 27 26 25 28
3 2 14 6 1 16 15 22 8 2124 18 20 7 4 19
DETAIL "A"
12 10
32
13 11 9
29 29 DETAIL "B"
31
34 33
30
35
W2D401E
1. Buffer Ring 10. Tube 19. Cushion Seal 28. Stopper

2. Rod Packing 11. Bushing 20. Collar 29. Dust Seal
3. Dust Seal 12. Piston Rod 21. Piston 30. Nipple
4. Backup Ring 13. Bushing 22. Wear Ring 31. Pipe
5. O-ring 14. Rod Cover 23. Set Screw 32. Plug
6. O-ring 15. Cushion Bearing 24. Ball 33. Holder
7. Backup Ring 16. Bushing 25. Cushion Bearing 34. Bolt
8. Piston Packing 17. Snap Ring 26. Cushion Seal 35. Grease Nipple
9. O-ring 18. Holder 27. Snap Ring
TB175W IV-100
Bucket Cylinder
11
4 13 7 1 6 5 15 14 17 8 17 19 20 18 22
12
21 18 3 2 16 9 10
W2D402
1. Buffer Ring 7. O-ring 13. Rod Cover 19. Set Screw

2. Rod Packing 8. Piston Packing 14. Piston 20. Ball
3. Backup Ring 9. Tube 15. Snap Ring 21. Grease Nipple
4. Dust Seal 10. Bushing 16. Bushing 22. Grease Nipple
5. O-ring 11. Piston Rod 17. Wear Ring
6. Backup Ring 12. Bushing 18. Dust Seal
Swing Cylinder
26 29 4 14 7 6 5 6 8 6 15 20 16 22 9 22 17 27 28 25 23 21 24
26
13 11
3 2 1 18 19
12 10 W2D403
1. Buffer Ring 9. Piston Packing 17. Nut 25. Snap Ring

2. Rod Packing 10. Tube 18. Bushing 26. Dust Seal
3. Backup Ring 11. Bushing 19. Snap Ring 27. Set Screw
4. Dust Seal 12. Piston Rod 20. Cushion Seal 28. Ball
5. O-ring 13. Bushing 21. Cushion Bearing 29. Grease Nipple
6. Backup Ring 14. Rod Cover 22. Wear Ring
7. O-ring 15. Cushion Bearing 23. Cushion Seal
8. O-ring 16. Piston 24. Stopper
IV-101 TB175W
Boom Adjustment Cylinder
3 13 2 6 1 14 5 4 15 23 7 16 18 17 20
8
DETAIL "A"
19 19
12 10
11 9
21
22 22
W2D404
1. Buffer Ring 7. Piston Packing 13. Rod Cover 19. Dust Seal
2. Rod Packing 8. O-ring 14. Bushing 20. Plug
3. Dust Seal 9. Tube 15. Snap Ring 21. Holder
4. O-ring 10. Bushing 16. Piston 22. Grease Nipple
5. Backup Ring 11. Piston Rod 17. Set Screw 23. Wear Ring
6. O-ring 12. Bushing 18. Ball
TB175W IV-102
OPERATION
Hydraulic oil flowing alternately in and out of the oil

outlet and inlet on both sides (head and rod sides) of
the piston acts on the piston and its force causes the
piston to move back and forth.
In cylinders equipped with a cushion mechanism, the
shock resulting from the piston colliding with the
cover at the stroke end acts on that mechanism and is
dampened by it.
Cushion Mechanism
1 3 2
A
4
DETAIL PORTION "A"
L1-D406E
When the piston (1) nears the stroke end, just before
it collides with the cover (2), if the cushion bearing (3)
that precedes it enters the inner diameter portion of the
cover, the oil in the back of the piston is restricted by
the cushion bearing (3) and the clearance (4) of the
cover inner diameter portion. This causes the piston’s
(1) back pressure to rise and slows the piston’s speed.
IV-103 TB175W
Special Tools
See the table of special tools at the back of this section
for the jigs and tools used for disassembly and assem-
bly.
General Cautions
• Carry out disassembly and assembly operations in • Replace all seals with new ones each time the
a clean place and provide clean containers to place hydraulic units is disassembled.
brush. • Do not turn adjusting screws if not required.
• Clean all disassembled parts in cleaning solvent. • Apply hydraulic oil to sliding surfaces and apply a
Use a lint free cloth, or air dry the parts. thin coating of grease to seals when assembling
• Make match marks on each part so that they will be them.
In this manual, the procedure for the arm cylinder is

described. When necessary, the points which are
different in other cylinders are mentioned.
Disassembly
Cylinder Assembly
1. Fasten the clevis of the tube in a vice and place the
other end on a support block made of wood to
fasten the cylinder in a horizontal condition.
2. Drain out hydraulic oil remaining in the cylinder.

• Move the piston rod gently to prevent the
hydraulic oil from spraying out and scattering
all over.
3. Free the locked portion of the rod cover.

• Since the lock is integrated with the cylinder
tube, be careful not to bend it or to scratch it
when the lock is being freed.
4. Loosen the rod cover.

• The piston rod should be pulled out approxi-
mately 200 mm beforehand.
• Measures should be taken to prevent the piston
rod from being hit.
TB175W IV-104
5. Pull the piston rod assembly out of the tube.
• Use a wooden block (1) so as not to scratch the
sliding surface, and pull the assembly straight
out.
Piston Rod Assembly

1. Fasten the piston rod assembly securely in a level
position.
2. Remove the piston.

a. Take out the set screw (2) and remove the steel
ball (3).
• The set screw is staked at 2 places with a
punch, so grind off the staked portions using
a hand drill.
b. Loosen the piston nut (4) and remove it.
• Use a wrench with a hydraulic jack (5).
c. Remove the piston (6).
3. Remove the cushion bearing (7) and cushion seal

(8).
4. Remove the cushion bearing.

a. Remove the snap ring (9).
b. Move the cushion bearing (10) and remove the
stopper (11).
c. Pull out the cushion bearing (10).
d. Remove the cushion seal (12).
5. Remove the rod cover from the piston rod.
IV-105 TB175W
Piston
1. Remove the wear ring (13) from the piston.
• Spread the wear ring the minimum amount
necessary and remove it in the axial direction.
2. Remove the piston packing (14).

• Remove the piston packing by cutting it or
using a screwdriver.
Rod Cover
1. Remove the O-ring (17) and the backup rings (18)
from holder. 22 21 15 19 24 23 20 16 18 17 30 29
2. Remove the collar (30) and cushion seals (29).
3. Remove the O-rings (15), (16) and the backup

rings (20).
4. Remove the buffer ring (19) and rod packing (21).

• Extract using a eyeleteer with a pointed tip.
5. Remove the dust seal (22). W2D405
• Extract by raising the rubber part with a screw-

driver, etc., and striking.
6. Remove the snap ring (23).
7. Remove the bushing

• Since the bushing has been pressure fitted
tightly in the rod cover, it is impossible to take
it out. First use a lathe to grind down the inside
portion until only a thin piece remains, then
insert a copper spatula strongly and pry it out
to removed it.
Clevis
1. Remove the dust seal from the tube and piston
rod.
2. Remove the bushing using a setting tool (43).
TB175W IV-106
Assembly
Clevis
1. Using installation jig (B), pressure fit the bushing
(44) in the piston rod and tube.
2. Using a setting tool, install the dust seal.
Rod Cover
1. Using an installation jig (A), pressure fit the
bushing.
• Hydraulic oil should be applied to the inside
surface of the rod cover before assembly.
• After installation, make sure there are no level
differences with the bushing.
2. Install the O-rings (15), (16) and the backup rings

(20).
3. Using setting tool (G), pressure fit the dust seal

(22). 22 21 15 19 24 23 20 16
4. Install the rod packing (21).

W2D406
5. Install the buffer ring (19). < Swing >

<Swing>
23
• Attach the seal ring (25), bend the buffer ring
(26) into a U shape with your fingers, then set 19
it in the groove. Make sure it is bent with a
radius of 6mm or greater to prevent wrinkles. 25 (PROJECTION)
• Be sure to install it in the proper direction.
6. Install the snap ring (23).

26 (SLIT)
W2D407E
IV-107 TB175W
7. Install the collar (30) and the cushion seals (29).
8. Install the O-ring (17) and the backup rings (18).

18 17 30 29
W2D408
Piston
1. Install the O-ring (27) on the piston.
2. Cover the piston with the sliding jig (C), then,

using the fitting jig (D), insert the slipper ring (28)
rapidly.
3. Since the slipper ring (28) is extended when it is

installed, correct it using the corrective jig (E).
4. Install the wear ring (13).

• Spread the wear ring at the cut portion the
minimum amount necessary, installing it on
the piston from the shaft direction.
Piston Rod Assembly

1. Fasten the piston rod so that it is flat and install the
rod cover.
• Cover the piston rod thread with tape, etc., to
protect the seals from being scratched.
2. Install the cushion bearing (10).

a. Install the cushion seal (12).
• Set the side with the slits facing the screw
side.
b. Install the cushion bearing (10).
• Be sure to set with the flat side (A) in the
proper direction.
c. Install the stopper (11) on the piston rod, and
move the cushion bearing (10).
d. Install the snap ring (9).
TB175W IV-108
3. Install the cushion seal (8) and cushion bearing
(7).
• Set the side of the cushion seal with the slits
facing the screw side.
• Be sure to set with the flat side (A) of the
cushion seal in the proper direction.
4. Install the piston.

a. Install the piston (6).
b. Install the piston nut (4) and tighten it.
Piston nut: Refer to the table below.
c. Insert the steel ball (3).
d. Tighten the set screw (2) and caulk it at two
places with a punch.
Set screw: Refer to the table below.
Piston Nut, Set Screw Unit: N·m

Place Piston Nut Set Screw
Boom 3500 56.9
Arm 3100 31.5
Bucket 1540 31.5
Boom Adjustment 1470 31.5
Swing 4410 56.9
Cylinder Assembly
1. Fasten the tube in a horizontal position, then
insert the piston rod assembly in the tube.
• During insertion, align the center of the piston
rod with the center of the tube, inserting it
straight so the seals will not be scratched.
2. Tighten the rod cover.

• Apply Three Bond #1901 or the equivalent to
the rod cover tread.
Rod cover Unit: N·m
Boom 1060
Arm 647
Bucket 490
Boom Adjustment 530
Swing 1060
3. Bend the lock rib on the tube down in a notch of

the rod cover to lock it.
IV-109 TB175W
Inspection after Disassembly

Clean each part thoroughly with cleaning oil, then
carry out the following checks. When a cylinder has
been disassembled, replace all the seals with new
ones.
Piston Rod
• Replace the rod if there are cracks. Measuring the Bend
• If the threads are damaged, repair them or replace
it.
• If the plating layer of the plated portion is broken,
rusted or scratched, replace it.
• If the rod is bent more than the limit of 1 mm in 1
m, replace it. (Measure by the method shown in the
figure at right.
If the bending of the rod is within the above limit,
yet is bent a lot in a small distance so that it won’t a. Support the portion of the rod with the same
move smoothly, replace the rod if it makes a diameter at both ends on V-blocks.
squeaking sound in the operation test after reas- b. Set a dial gauge at the center between the two
sembly or if it catches during movement. blocks.
• If the inner diameter of the clevis bushing is worn, c. Rotate the rod and take a reading of the maximum
replace the bushing. and minimum runout indicated by the dial gauge.
Tube
• If there are cracks in the welded portion, replace it.
• Replace the tube if the inside surface is scratched
or if it leaks hydraulic oil.
• If the inner diameter of the clevis bushing is worn,
replace the bushing.
Rod Cover
• If the bushing inner diameter is worn and the
clearance with the piston rod is greater than 0.25
mm, replace the bushing.
• If the inside surface of the bushing is scratched, and
the scratches are deeper than the depth of the
coating layer, replace the bushing.
TB175W IV-110
Inspection after Assembly
No Load Operation Test
1. Place the cylinder in a horizontal position with no
load.
2. Apply gentle pressure alternately to the ports at
both ends, operating the piston rod 5 or 6 times.
3. Make sure there is no abnormality in the operat-
ing condition.
Leak Test
External Leakage
1. Apply test pressure for 3 minutes each to the
retraction side and the extension side.
2. Make sure there are no abnormalities such as
external leakage or permanent deformation, etc.
in the rod seal, the rod cover mount, or in any
welded portion.
Internal Leakage
1. Disconnect the extension side hose.
2. Apply test pressure to the retraction side for 3
minutes.
3. Measure the amount of oil that has leaked from
the extension side.
• The amount of leakage should be 1 cm3 / 3min
or less.
Bleeding Air from the Hydraulic Cylinder

Bleed the air out of the cylinder when the cylinder is
removed or when the hydraulic piping, etc. is discon-
nected.
1. Start the engine and let it idle for approximately
5 minutes.
2. With the engine running at slow speed, extend
and retract the cylinder 4 or 5 times.
• Move the piston rod to a position 100 mm
before the end of the stroke, being careful not
to apply any relief at all.
3. With the engine at top speed, repeat the operation
in (2), then with the engine running at slow speed,
move the piston rod to the stroke end and apply
relief.
IV-111 TB175W
TROUBLESHOOTING

Oil leaks from piston rod • Foreign matter is caught in the inner • Remove the foreign matter.
sliding surface (an oil ring diameter portion of the rod packing,
forms on the piston and backup ring or dust seal.
this enlarges and drips off). • The inner diameter lip of the rod packing, • Replace the affected parts.
backup ring or dust seal is damaged or
abnormal.
• Piston rod sliding surface is scratched. • Smooth the sliding surface with an oil
stone (1.6 S or lower)
• If it leaks after the sliding surface has
been smoothed, replace the rod pack-
ing and other seals.
• If it leaks after the seals have been
replaced, replace the piston rod.
• The hardened chrome plating is separat- • Repair the hardened chrome plating.
ing from the piston rod.
Oil leaks from the outer • O-ring is damaged. • Replace the affected parts.
circumference of the rod • Backup ring is damaged. • Replace the affected parts.
cover.
Oil leaks from welded por- • The tube’s welds are damaged. • Replace the affected parts.
tion.
Cylinder natural drop (this • Foreign matter is caught in the wear ring • Remove the foreign matter.
is the maximum amount sliding surface.
of movement of the piston • The sliding surface of the wear ring is • Replace the affected parts.
in 10 minutes when a static scratched or abnormal.
weight corresponding to • The piston packing sliding surface is • Replace the affected parts.
the maximum use pressure scratched.
multiplied by the • The O-ring is damaged. • Replace the affected parts.
cylinder’s surface area) is
0.5 mm or greater.
TB175W IV-112
TABLE OF SPECIAL TOOLS
Installation Jig (A) Installation Jig (B)
MATERIAL: SS41 MATERIAL: SS41

Unit: mm
Installation Jig (A) Installation Jig (B)
A B C D E F A B C D E F
Boom 79 75 43 12 75 75 89 74.5 10 5 30 95
Arm 69 65 43 12 75 65 79 64.5 10 5 30 90
Bucket 59 55 32 12 46 55 59 49.5 10 5 30 70
Boom Adjustment 59 55 32 12 46 55 89 74.5 10 5 30 95
Swing 79 75 43 12 75 75 89 74.5 10 5 30 95
Sliding Jig (C) Fitting Jig (D)
MATERIAL: STKM13C MATERIAL: NYLON

Unit: mm
Sliding Jig (C) Fitting Jig (D)
A B C D E F A B C D E F
Boom 121.0 119.7 101 107.3 23.5 97 13 71 97 110 117 120
Arm 101.0 99.7 84 90.7 22.5 77 10 57 77 95 99 102
Bucket 85.7 84.7 70 75.7 19.5 75 10 55 75 80 84 87
Boom Adjustment 90.7 89.7 75 80.7 19.5 75 10 55 75 85 89 92
Swing 121.0 119.7 101 107.3 23.5 97 13 71 97 110 117 120
IV-113 TB175W
Corrective Jig (E)
MATERIAL: STKM13C
Unit: mm
A B
Boom 133 120
Arm 113 100
Bucket 98 85
Boom Adjustment 103 90
Swing 133 120
TB175W IV-114
DOZER BLADE CYLINDER HYDRAULIC UNITS
DOZER BLADE CYLINDER
CONSTRUCTION
12 13 1 2 8 5 4 3 7 6 9 10
11
W2D409
1. Dust Seal 8. Rod Cover

2. Joint 9. Piston
3. Guide Band 10. Nut
4. O-ring 11. Screw
5. Backup Ring 12. Bearing
6. Pipe 13. Ring
7. Piston Rod
IV-115 TB175W
HYDRAULIC UNITS DOZER BLADE CYLINDER
TB175W IV-116
RAM LOCK CYLINDER HYDRAULIC UNITS
RAM LOCK CYLINDER
Contents
1. Functional description
2. Hydraulic connection plan
3. Start-up and bleeding
4. Fault-finding
5. Repair instructions
1. Functional description
Designed as plunger cylinder with integrated non-return valve.

The non-return valve is designed as an oil-tight round-seat valve which can be opened via a control piston.
Surface ratio ψ = 16:1

Control volume 1.4 cm3
Control pressure Pst = 30-50 bars
Blockable internal cylinder pressure Pi= (Pst-4.5) ✕ ψ
Example: 30 bar control pressure Pi = (30-4.5) ✕ 16 = 408 bars
The control line is attached to the connecting line of both cylinders, i.e. the control pressure which can be applied to the
non-return valve in the cylinder head is also the initial pressure for the cylinder during reciprocating motion, i.e., only one
line is needed to the cylinder.
Note:
• The pressure in the tank line must be less than 2 bars when blockage occurs.
• The axle mounting should be level, hardened and greased (see Fig. 1).
• Larger stroke differences in the axle design should be avoided.
• Pay particular attention to the central position of the axle’s point of rotation in relation to the cylinders.
• The securing surfaces of the cylinder to the sub-assembly must be flat in order to avoid distorting the cylinder housing
when bolting together.
IV-117 TB175W
HYDRAULIC UNITS RAM LOCK CYLINDER
Figs 1-6
2. Hydraulic switching diagram
Fig. 2
TB175W IV-118
3. Start-up and bleeding
At start-up, all components must be filled with oil and bled of air.
This is done as follows:
• Remove lock bolts from cylinder (pos. 10).

• Press rod down as far as bearing.
WARNING! Regardless of cylinder type, the check valve case projects fairly far into the oil filler bore. Be careful
not to damage the valve case when pressing down on the rod.
• The rod can also be pressed down hydraulically.
• Fill the cylinder area with oil and re-insert the lock bolts.
• To bleed both cylinders, undo the bleed screws at Pos. 11 and fill with oil until no more air comes out.
• Do up bleed screws but do not tighten. The screws should be easy to loosen.
• Apply control pressure to cylinder and tighten bleed screws until oil comes out without air bubbles. Bleeding is now
complete.
The entire bleeding operation should be carried out under clean conditions.
4. Fault-finding
a) If the rigid axle fails to support a cylinder, the rod seal, Pos. 7, and the tightness of the check valve case, Pos. 3, should
be checked and the parts replaced if necessary.
b) If the axle cannot be brought to a variable position after switching off and on several times, the following should be
checked:
• At very high cylinder loads the internal cylinder pressure cannot be released (see Functional Description)
• The unit needs bleeding (see Start-up)
• If the operation of the axle is not rectified by bleeding, check whether there is adequate control pressure (see Functional
Description)
• If the previous points do not reveal any fault, the smooth operation of the control piston, Pos. 5, of the non-return valve
must also be checked (see Repair Instructions).
5. Repair Instructions
a) Changing the rod seal
• Remove lock bolt, Pos. 10.

• Push down and remove rod, Pos. 2.
WARNING! Do not damage rod surface.
• Remove grooved ring using a round-edged tool.
WARNING! Do not damage the recess surface.
• Check scraper, Pos. 6, for damage and replace if necessary.
• Grease seals.
• Re-insert rod.
IV-119 TB175W
b) Demounting the non-return valve

• Remove cylinder bolts, Pos. 9.
• Remove cylinder, Pos. 4.
• Remove piston, Pos. 5. The piston should move freely in the non-return valve and in the cylinder.
• Remove non-return valve, Pos. 3, from the inside via the filler bore, Pos. 10.
• Check seals, Pos. 8, 14, 15, 16 and 17 for damage and replace if necessary.
• The non-return valve case cannot be dismounted any further.
• Reassemble components in reverse order above. Grease seals before assembly.
• Torque cylinder bolts, Pos. 9, to 16 Nm.
WARNING! Use only 12.9 Nm cylinder bolts.
Before start-up, bleed again as per Point 3 above.
WARNING! All checking and repair work should be carried out under clean conditions.
Fig. 3
TB175W IV-120
Torque: D = be longing to seal set

Pos. MA (Nm) 1 Seal set D 0640.00.000
9 16
∗∗ If part in Pos. 10 Supply separately only for seal set
10 180 1 O-ring ∗∗ D 18 410236
11 10
12 40 ∗ If part in Pos. 3 Supply separately only for seal set
1 O-ring ∗ D 17 410019
1 Back-up ring ∗ D 16 410391
1 O-ring ∗ D 15 410027
1 O-ring ∗ D 14 410401
1 Lock bolt 12 310182

1 Lock bolt 11 310180
1 Lock bolt 10 310154
5 Cylinder bolt 9 310200
1 O-ring D 8 410403
1 Grooved ring D 7 430079
1 Scraper ring D 6 440029
1 Piston 5 0620.00.003
1 Cylinder 4 0620.00.002
1 Non-return valve case, complete 3 0620.01.000
1 Rod 2 0640.00.002
1 Cylinder housing 1 0640.00.001
No. Name Part Dwg no.
IV-121 TB175W
TB175W IV-122
SLEW MOTOR HYDRAULIC UNITS
SLEW MOTOR
CONSTRUCTION
Hydraulic Motor
3 2 1 23 25 9 16
14
26
11
17
10
12
24
20
15
8
29
7
18
28 21 5 22 13 27 19
L3D600
1. O-ring 11. Spring 21. O-ring

2. O-ring 12. Retainer 22. Center Disc
3. O-ring 13. Guide 23. Swash Plate
4. O-ring 14. Pin 24. Bearing
5. Friction Disc 15. Valve Plate 25. Case
6. Cylinder Block 16. Bearing 26. Pin
7. Brake Piston 17. Snap Ring 27. Piston
8. Spring 18. Collar 28. O-ring
9. Shaft 19. Shoe Holder 29. Spring
10. Retainer 20. Pin
IV-123 TB175W
HYDRAULIC UNITS SLEW MOTOR
Reduction Gears
26 16 13 14 12 18 10
4
1
8
11
24 23 17 25 9 21 15 19 27 20 22
L3D601
1. Plate 10. Carrier 2 19. Screw

2. Oil Seal 11. Plate 20. Sun Gear
3. Shaft 12. Race 21. Carrier 1
4. Collar 13. Needle 22. Collar
5. Bearing 14. Planetary Gear 23. Race
6. Case 15. Thrust Plate 24. Needle
7. Bearing 16. Drive Gear 25. Planetary Gear A
8. Plate 17. O-ring 26. Thrust Plate
9. Thrust Washer 18. Thrust Washer 27. Snap Ring
TB175W IV-124
Brake Valve
33 32 31
34
2 4
1
C 3
23 22 25 24 21
27 29 17 18 12 14 13 14 11 10 16
15
28 6 5 20 19 8 9
26 30
L3D602
A: Relief Valve
B: Timer Valve
C: Check Valve
D: Anti-rebound Valve
1. Cover 10. Plug 19. O-ring 28. Washer

2. Poppet 11. O-ring 20. Backup ring 29. Orifice
3. O-ring 12. Piston 21. Body 30. O-ring
4. Spring 13. O-ring 22. Check Valve Assembly 31. Body
5. Housing 14. Backup ring 23. Spring 32. Spool
6. Poppet 15. Guide 24. Sleeve 33. Spring
7. Seat 16. O-ring 25. Orifice 34. O-ring
8. Seat 17. O-ring 26. O-ring
9. Spring 18. Backup ring 27. Filter
IV-125 TB175W
OPERATION
3 2 1
Hydraulic Motor
9 pistons (2) are fitted in the cylinder block (1) and
there is a valve plate (3) with two half moon ports, B
and C in the end. Also, the cylinder block (1) rotates
freely and is joined to the shaft (4) via the spline. On
the other band, the swash plate (5) is fastened to the
housing. A
When high pressure oil is introduced into port B, one
piston (2) makes contact and force F bears on the
swash plate (5).
F = P × A P: Pressure A: Piston Sectional Area
The force F which the piston (2) applies to the swash
plate (5) is divided into force F1, which pushes the F1
plate, and force F2, which rotates the cylinder block F2 5 4
F
(1). The total sum of the components in the direction
of rotation of the high pressure side piston generates
F
a rotational force in the cylinder block (1) and via the
spline, torque is transmitted to the shaft (4), turning it.
F2
Conversely, if high pressure oil is introduced to port
C, rotation is the reverse of the above.
F
F2
B C
E5D603
Relief Valve M2 M1
Operation 1
When the Motor is Started
When the motor is started, since the inertial load is
great, the pressure of the oil required to accelerate it
rises. If this pressure reaches the relief valve set
pressure, the relief valve operates and oil returns to
port M2.
In this way, the motor begins to turn as it relieves the
relief valve, and as the rotational speed increases, the
amount of relief decreases until it stops.
In this way, the shock during starting is absorbed. T
E5D605
When the Motor is Stopped M2 M1

When the motor is stopped, the return circuit is closed
off.
However, since the motor tends to want to continue
rotating due to inertial energy, the pressure in port M2
rises. When this pressure reaches the relief valve’s set
pressure, the relief valve operates and oil flows to port
M1. In this way, the flow of oil to port M1 prevents
cavitation from occurring as it absorbs the shock
during stopping.
T
E5D606
TB175W IV-126
Operation 2
Since this relief valve has a shockless mechanism, it
operates in 2 steps.

1st Step
When relief valve operation starts, the pressure in

chamber B (P1) is kept at a pressure which is lower

than that in chamber C while the pressure in chamber
A (P) becomes higher than the pressure of the oil
flowing in.
At this time, there are two forces acting on the poppet
(10), force (F), which attempts to move the poppet
(10) to the left and force (F1) which pushes against the
seat on the right side. Since F = P × A, F1 = P1 × A1,
P > P1 and A > A1, the poppet (10) is moved to the left
by this force “F – F1”.
This opens a supply side circuit from chamber A and
lets the pressure escape. That is, during the time piston 10 A
(11) is moving to its stroke end, the relief valve
operates at low pressure (about 1/3 the set pressure).
2nd Step
When the piston (11) reaches the stroke end, the P1 P
pressure in chamber B rises and the pressures in
chamber A and chamber B equalize. At this time, the
force moving the poppet (10) to the left side becomes
“P = P1”, so this becomes “A – A1” and the relief
valve operates at the specified set pressure. B 11
L3D604
Anti-rebound Valve 2 B
When the motor stops, this valve will connect the
motor main circuit to the makeup circuit for a pre-
scribed time to prevent motor rebound due to the
pressure in the main circuit.
When the Brake is Actuated

The braking pressure generated at the port Pv1 will
move the check valve (2) to the right until it is seated
at section B. Pv1 Cv Pv2
G4D604
When the Motor Rebounds

When the motor is stopped by braking operation of the
brake valve, it starts to rebound due to the pressure in
the main circuit. This rebound pressure generated at
the port Pv2 will move the sleeve (3) to the left to open
the passage. This then releases the rebound pressure
to the port Cv.
Pv1 Cv Pv2
B 3
G4D605
IV-127 TB175W
The rebound pressure also pushes the check valve (1)

to the left, which is the opposite direction of pushing 2 1
at the time of braking. The flux control valve built in
the check valve (2) (that is now on the lower pressure
side) releases the oil in the damper chamber (4) at a
constant flux. Therefore, the check valve (1) moves at
a constant speed. When the check valve reaches its
stroke end, the passage from the port Pv2 to the port
Cv is closed.
Pv1 Cv Pv2
4
G4D606
Timer Valve 2 1 PG
This function is used to prevent sudden operation of
the parking brake when the motor is stopped.
At the time of parking brake operation, pressure oil
from the port P4 is supplied at all times to the port PG, SH
the valve spool (1) is pushed to the right by the force
of the spring (2), and the port PG is closed. PB
When turning pilot pressure or arm pilot pressure is
led to the port SH, the spool (1) is moved to the left
against the force of the spring (2), and the port PG is
opened. The pressure oil from the port PG passes
through the hole at the center of the spool (1) and is led
to the parking brake release port (PB), so that the L3D605
parking brake is released.

2 1 PG
When the pilot pressure at the port SH disappears, the
spool (1) is moved by the force of the spring (2) to the
right, the port PG is closed, and the oil in the brake
piston chamber (3) is prevented from escaping. The
oil in the chamber flows gradually through the orifice
(4) at the outer circumference of the spool (1) to the
drain port dr, so that the parking brake is not applied
rapidly, but after a certain time, just as if a timer were
used. 4
3 L3D606
Parking Brake
The center discs (1) are connected to the housing and
the friction discs (2) are connected to the cylinder
block (3) via the spline, respectively. The center discs
(1) and friction discs (2) are pressed against the
housing (6) by the springs (4) via the brake piston (5).
The friction force between these discs generates the
6
brake torque to prevent the cylinder block (3) from 5
rotating. 2
4
When the pressure oil is introduced into the motor, the 1 3
oil flows from the parking brake release port (7) into
the brake piston chamber (8). The oil pressure over- L3D607
TB175W IV-128
powers the spring force and moves the brake piston
(5) to the right. This generates a clearance between the
center discs (1) and friction discs (2) to release the
parking brake. When the motor stops, the spool re-
turns to the neutral position to close the parking brake
release port (7). The pressure oil in the brake piston
chamber (8) is introduced into the motor case and the
spring (4) operates the parking brake. 7 8
2
5
1
4
L3D608
Reduction Gears
The reduction gear is composed of a 2-stage planetary
gear mechanism, and it converts the high-speed op-
eration of the motor to low speed torque for operation
of the pinion shaft (1).
In the figure on the right, the drive force transmitted
from the motor output shaft is transmitted to the
second stage sun gear (5) via the first stage drive gear
(2), the planetary gear (3) and the carrier 1 (4). Drive
force is transmitted in the same way to the pinion shaft
(1) via the second stage sun gear (5), the planetary
gear (6), and the carrier 2 (7), and this becomes the
slewing drive force.
IV-129 TB175W
Table of Special Tools

Unit: mm
NAME, DIMENSIONS NAME, DIMENSIONS
JIG (A) JIG (C)
70 150
1 3
¿95 -0.1
-0.2
¿30
¿45
L3D609 L3D611
JIG (B) JIG (D)
50
100
40
2 4 ¿63.2 +0.2
0
100
10
¿35
¿47
63
L3D610
¿78.2 +0.2
0
L3D612
General Cautions
• Carry out disassembly and assembly operations in • Replace all seals with new ones each time the unit
a clean place and provide clean containers to place is disassembled, coating them lightly with grease.
brush.
• Wash the disassembled parts and dry them with
compressed air. Do not use a rag, as this could
cause clogging of dirt.
• Make match marks on each part so that they will be
assembled in the same positions when reassembled.
Disassembly
Slew Motor
1. Remove the cap screws and then the anti-rebound
valve.
K3D626
TB175W IV-130
2. Remove the cap screws to disassemble the motor
into the hydraulic motor (1) and the reduction
gear (2).
• Mark the mating position on both the hydraulic 1
motor and the reduction gear so that they can
be mated correctly when reassembling.
• Fix the hydraulic motor with a vise.
2
K3D627
Brake Valve and Hydraulic Motor

1. Remove the cap screws and then the timer valve
(1).
• Be careful not to miss the O-ring.
L3D613
2. Remove the cap screws and then the cover (2).

• Fix the hydraulic motor with a vise. 2
• Be careful not to let the valve plate drop off.
K3D629
3. Remove the valve plate (3) from the cover.
L3D614
IV-131 TB175W
4. Remove the bearing (4).
L3D615
5. Remove the orifice (5).

• The orifice is caulked. Do not remove it unless
necessary.
L3D616
6. Remove the check valve.

9
a. Remove the plug (9). 10
b. Remove the spring (10) and check valve (11). 11
11
10
9
L3D617
7. Remove the relief valve (12).

• Do not loosen the set screw nut (13).
• Do not disassemble the relief valve.
13
12
L3D618
TB175W IV-132
8. Remove the brake piston (15).
• Blow the air from the brake release port PB
with care such that the brake piston does not PB
protrude.
15
PB
L3D619
9. Remove the collar (17).

17
L3D620
10. Remove the cylinder block (18), friction discs

(19) and center discs (20). 18
19
20
L3D621
11. Remove the shoe holder (14) and piston assembly 14 21 22 23

(21) from the cylinder block.
12. Remove the guide (22) and pins (23) from the
cylinder block.
L3D622
IV-133 TB175W
13. Remove the snap ring (24), retainer (25), spring

(26) and retainer (27) from the cylinder block 24
(18). 25
• Do not disassemble these parts unless neces- 26
sary. 27
These parts should be replaced as one assem- 18
bly.
A
E5D622
14. Remove the swash plate (28).
28
L3D623
15. Remove the shaft (29).

• Lightly tap the end face with a plastic hammer.
29
L3D624
16. Remove the bearing (30) from the shaft (29).

• Do not disassemble these parts unless neces- 29
sary. The removed bearing cannot be used
again.
30
K3D643
TB175W IV-134
17. Disassemble the timer valve.
• Be careful not to damage or deform the contact 31
surface. 32
a. Remove the plug (31). 33
b. Remove the spring (32) and spool (33).
• Use a pair of tweezers.
K3D644
Reduction Gears 7 4 6 5 3 2 1
1. Remove the O-ring (1).
2. Remove the thrust plate (2).
3. Remove the drive gear (3). 8
4. Remove the planetary gear A (4), needles (5) and

inner race (6).
5. Remove the thrust washer (7).
6. Remove the carrier 1 (8). L3D625
7. Remove the sun gear (9).

10 9
8. Remove the carrier 2 assembly (10).
L3D626
9. Loosen the screw and remove the thrust plate

(11).
• Loctite has been applied to the screw. Warm- 11
ing the screw screws (for example, using a 14 13 12
portable drier) will make its removal much
easier.
10. Remove the planetary gear B (12), needle (13),

inner race (14) and the thrust washer (15).
15
L3D627
IV-135 TB175W
11. Remove the collar (9) and plate (10).

• Do not disassemble these parts unless neces-
10 9
sary.
These parts should be replaced as one assem-
bly.
11
L3D628
12. Remove the shaft (11) from the case.

• Be careful not to miss the shaft.
• If the shaft will not come out easily, lightly tap
it with a plastic hammer.
• To replace the taper roller bearing or collar, the
case assembly should be replaced.
25
11
L3D629
13. Remove the inner race (24) of the taper roller

bearing.
24
L3D630
14. Remove the oil seal (23).

• Use a flat blade screwdriver.
• The oil seal should be replaced with a new one
every time it is disassembled.
• Be careful not to damage the outer race of the
taper roller bearing.
23 L3D631
TB175W IV-136
15. Remove the plug (25) from the case.
25
L3D632
Anti-rebound Valve 1
1. Remove the plug (1) and then the spring (2). 2
3
2. Remove the check valve assembly (3).
3. Remove the sleeve (4).
4
3
2
1 G4D613
4. Remove the plug (5) and then the orifice (6). 5
G4D614
5. Remove the orifice (7), washer (8) and filter (9). 7

• The filter should be replaced with a new one 8
every time the anti-rebound valve is disas- 9
sembled.
G4D615
IV-137 TB175W
Assembly
Anti-rebound Valve 7
1. Mount the filter (9), washer (8) and orifice (7) on 8
the body. 9
• Use a new filter.
Orifice: 4.9 N·m
G4D615
2. Mount the orifice (6) on the body. 5

Orifice: 2.45 N·m
6
3. Fit the O-ring to the plug (5), and mount them on
the body.
Plug: 61.8 N·m
G4D614
4. Mount the sleeve (4) on the body. 1

2
5. Mount the check valve assembly (3) and the 3
spring (2) on the body.
6. Fit the O-ring to the plug (1), and mount them on

the body.
Plug: 61.8 N·m
4
3
2
1 G4D613
Brake Valve and Hydraulic Motor 31

1. Assemble the timer valve. 32
• Be careful not to damage the rotation section of 33
the valve.
a. Mount the spool (33) and spring (32) on the
body.
b. Fit the O-ring to the plug (31) and mount them
on the body.
Plug: 39.2 ±2.0 N·m
K3D644
TB175W IV-138
2. Mount the retainer (27), spring (26), retainer (25)
and snap ring (24) on the cylinder block (18). 24
• To mount the snap ring, push the retainer (25) 25
by using the press and jig (C). 26
• Position the retainer (27) so that its tapered 27
side (A) faces the cylinder block. 18
A
E5D622
3. Fit the pins (23) to the cylinder block. 14 21 22 23

• Apply grease to the pins.
4. Mount the guide (22).
5. Fit the shoe holder (14) to the piston assembly

(21) and mount them on the cylinder block.
• Apply the hydraulic oil to the rotation section.
L3D622
6. Insert the bearing (30) into the shaft (29).

• Insert the bearing by using the press and jig 29
(A).
30
K3D643
7. Install the shaft (29) in the housing.

• Lightly tap with a plastic hammer to install. 29
L3D633
IV-139 TB175W
8. Install the switch plate (28) in the housing.

• Apply grease to the side (A) of the swash plate.
28
L3D623
9. Install the cylinder block (18) in the housing.

• Be careful not to let the shoe holder or other 18
parts drop off.
19
• Use the press to insert.
10. Mount the center discs (20) and the friction discs
(19).
• Total number of friction discs: 2
• Total number of center discs: 3
• Be careful of the mounting order.
20
L3D621
11. Fit the O-ring to the collar (17) and insert them in
the housing.
17
L3D620
12. Fit the O-ring to the brake piston (15) and insert 22.5¡
them in the housing. 15
• Use the press to insert.
• Make sure that the pin hole (A) of 8.5 mm in
diameter is positioned as shown in this figure.
A
L3D634
TB175W IV-140
13. Install twelve large springs (16), eight small
springs (17), and the O-ring.
• Make sure that the eight small springs (17) are
positioned as shown in this figure.
17 16
17
L3D635
14. Fit the O-rings and backup rings to the relief valve
(12).
15. Mount the relief valve assembly on the cover.

• Be careful not to let the spring jump out.
Plug: 37 ±20 N·m
• Do not loosen the lock nut (13). 13
12
L3D618
16. Mount the check valve.

9
a. Mount the spring (10) and poppet (11) on the 10
cover. 11
b. Fit the O-ring to the plug (9) and mount them
on the cover.
Plug: 157 ±10 N·m
11
10
9
L3D617
17. Insert the bearing (4) into the cover.

• Use the jig (B) and the press to insert.
L3D615
IV-141 TB175W
18. Fit the pin to the cover.
19. Mount the orifice (5) on the cover.

• Caulk the circumference of the orifice female 4 5
screw by using a punch.
L3D636
20. Mount the pin and valve plate (3) on the cover.
A 6mm
• Apply grease on the back of the valve plate (the
side facing the cover) in advance to prevent the
plate from dropping off. 3
• Upon mounting the pin, caulk the position (A)
using the punch as shown in this figure.
L3D637
21. Mount the cover (2) on the case and fix them with
the cap screws. 2
• Be careful not to let the valve plate drop off.
Cap screw: 127 ±10 N·m
K3D629
22. Mount the timer valve (1).

a. Fit the O-ring to the case.
b. Mount the timer valve and fix it with the screw.
Screw: 39.2 ±2.0 N·m
L3D613
TB175W IV-142
Reduction Gears
1. Insert the oil seal (23) into the case.
• Use the jig (C) and the press to insert. 23
• The oil seal diameter (A) after insertion should
be 4.25 mm.
A
L3D638
2. Put grease into the inner race of the taper roller

bearing.
• Grease type: Shell ALVANIA Grease
• Grease volume: 80~90 mL
E5D629
3. Mount the shaft (11) and plug (25) on the case.

• The shaft (11) should be mounted before mount-
ing the plug (25).
Plug: 15.7 ±0.8 N·m
25
11
L3D629
4. Mount the plate (10) and collar (9).

10 9
• Mount the collar while loading the 11770 N on
the inner race using the jig (D).
11
L3D628
IV-143 TB175W
5. Mount the thrust washer (15), inner race (14),

needles (13) and planetary gear B (12) on the
carrier 2 (10). 14 13 12
15
10
L3D639
6. Mount the thrust plate (11) on the carrier 2 (10)

and fix them with the cap screws.
• Apply Loctite #242 to the cap screws. 11
Cap screw: 24.5 ±4.9 N·m 14 13 12
15
L3D627
7. Mount the carrier 2 (10) on the case.
10
L3D640
8. Fit the snap ring on the sun gear (9).
L3D641
TB175W IV-144
9. Mount the sun gear (9).
10 9
L3D626
10. Mount the carrier 1 (8). 7 4 6 5 3 2 1
11. Mount the thrust washer (7), inner race (6), needles
(5), planetary gear A (4), drive gear (3) and thrust
plate (2) on the carrier 1 (8).
• Measure the depth (A) from the case end to the 8
carrier 1 and select a proper thickness for the
thrust plate by referring to the table.
• The largely-rounded side of the thrust plate
circumference should face the planetary gear.
From 5.3 to less From 5.8 to less

Depth (A) From 6.5 to 7.0 L3D625
than 5.8 mm than 6.5 mm
Thrust plate
2.8 ±0.14 mm 2.3 ±0.12 mm 1.8 ±0.10 mm
thickness
12. Fit the O-ring (1) to the case. A
L3D642
Slew Motor
1. Unite the hydraulic motor (1) and the reduction
gear (2) and fix them with the cap screws. 1
Cap screw: 177 ±10 N·m
K3D627
IV-145 TB175W
2. Fit the O-ring to the cover.
3. Fit the anti-rebound valve to the cover and mount

the washer, seal and screws.
Screw: 32.4 ±2.0 N·m
K3D626
TB175W IV-146
Checking the Parts

Brake Valve
Parts Judgement Criteria Treatment
Check Valve, • Scratches in sliding portions are deep or roughness is severe. • Replace
Piston • The clearance with the body is large. • Replace
• Scratches in sliding portions are deep or seating is uneven. • Replace
Housing • Scratches in sliding portions are deep or roughness is severe. • Replace
• There are scratches where oil leakage occurs. • Replace
Relief Valve • The set pressure drops abnormally low. • Replace
Assembly • The set pressure is unstable and vibration occurs. • Replace
• There is a lot of leakage due to faulty seating, etc. • Replace
Spring • Damaged or severely deformed. • Replace
Hydraulic Motor
Recommended
Standard
Parts Replacement Treatment
Dimension
Value
Clearance (S) be- Replace cylinder
tween piston and block, swash plate
D
d
cylinder bore assembly.

0.02 mm 0.04 mm
S=D-d
E5D632
Clearance (S) be- Replace cylinder

tween piston and block, swash plate
shoe assembly.
0.15 mm 0.4 mm
S
E5D633
Shaft and needle Flaking or pitting Replace shaft, port

bearing rolling sur- in the rolling sur- block assembly.
face face.
E5D634
Cylinder block Sliding surface is Carry out lap re-

sliding surface (1) 1 rough. pairs (#1000 Pow-
der) or replace.
Valve plate sliding Replace
surface (2) 2
E5D635
IV-147 TB175W
Reduction Gears
Drive Gear • Gear tooth surfaces are pitted or separating, etc. • Replace
• Clearance with motor joint is large due to spline wear. • Replace
Housing, • Gear tooth surfaces are pitted or separating, etc. • Replace
Internal Gear
Planetary Gear • Gear tooth surfaces are pitted or separating, etc. • Replace
• Needle rolling surfaces are pitted or separating, etc. • Replace
Needle Bearing, • Needle and shaft rolling surfaces are pitted or separating, etc. • Replace
Planetary Shaft • Pressure marks, etc. on needle and shaft rolling surfaces. • Replace
• Bearing rotation is abnormal (abnormal noise, rotation not smooth, • Replace
etc.).
Carrier, Shaft • Clearance with planetary shaft is large. • Replace
Shaft • Clearance with pinion is large due to spline wear. • Replace
Thrust Wasyer • Amount of wear is great. • Replace
Ball Bearing, • Rotation is abnormal (abnormal noise, rotation not smooth, etc.). • Replace
Roller Bearing • Flaking, separation, etc. on rolling surfaces. • Replace
• Pressure marks, etc. on rolling surfaces. • Replace
Collar, Oil Seal, • Scratches, etc. exist which cause leaks. • Replace
O-ring
Anti-rebound Valve
Check Valve • Scratches in sliding portions are deep or roughness is severe. • Replace
• The clearance with the body is large. • Replace
• Scratches in sliding portions are deep or seating is uneven. • Replace
Body • Scratches in sliding portions are deep or roughness is severe. • Replace
• There are scratches where oil leakage occurs. • Replace
Spring, Sleeve • Damaged or severely deformed. • Replace
TB175W IV-148
TROUBLESHOOTING
If there is an abnormal increase in noise or heat, this The following table shows a number of causes of
is an indication that trouble has occurred. When this general breakdowns that can be seen in the hydraulic
type of condition is manifested, stop the machine circuits and indicates coutermeasures to take in each
immediately and search out the source of the trouble. case.
Symptom How/Where? Probable Causes Remedy

Motor does not start. Pressure doesn’t rise at the • Relief valve’s set pressure • Set the pressure at the cor-
motor’s inlet port. is low. rect level.
• Pump is broken down. • Repair or replace the
pump.
• Control valve is broken • Repair or replace the con-
down. trol valve.
Pressure rises at the motor’s • The load is excessive. • Lighten the load.
inlet port. • Hydraulic motor is broken • Repair or replace the hy-
down. draulic motor.
• Reduction gears are bro- • Repair or replace the re-
ken down. duction gears.
Motor’s speed won’t • Pump’s discharge vol- • Pump’s drain amount is • Repair or replace the
increase. ume is insufficient. large. pump.
• Depends on the motor’s • The motor’s volumetric ca- • Replace the motor.
function. pacity is dropping.
Oil is leaking. • Oil is leaking from oil • Lip is cut or damaged. • Replace the oil seal.
seals.
• Oil is leaking from mat- • Bolts are loose. • Tighten the bolts.
ing surfaces. • O-ring is cut or damaged. • Replace the O-ring.
• Mating surface is scratched. • Repair the surface with a
grind stone or sand paper.
Motor makes abnor- • Noise in piping. • Piping support is faulty. • Clamp the piping.
mal noise.
(The surface tempera- • Lubricating oil • Oil level is low. • Replenish the oil.
ture of the reduction • Hydraulic oil is getting in. • Replace the reduction gears.
gears case becomes • Gear unit • Bearings are damaged. • Replace the reduction gears.
high.) • Gear surfaces are damaged. • Replace the reduction gears.
IV-149 TB175W
Anit-rebound Valve
The motor does not Something other than the piston motor, valve Inspect the pressure at the entrance of the
rotate or its rota- unit or anti-rebound valve is malfunctioning. valve. Or, inspect individual units and ser-
tion speed is slow. vice as necessary.
The check valve assembly is not seated prop-
erly.
• Foreign matter is trapped. • Remove the foreign matter. Repair or
replace the faulty parts.
• The tightening torque of the anti-rebound • Use the prescribed tightening torque.
valve mounting bolt exceeds the prescribed
value.
The sleeve is malfunctioning.
The motor does not The check valve assembly is not seated prop-
stop or its stopping erly.
speed is slow. • Foreign matter is trapped. • Remove the foreign matter. Repair or
• The tightening torque of the anti-rebound • Use the prescribed tightening torque.
valve mounting bolt exceeds the prescribed
value.
The valve within the check valve assembly is
malfunctioning.
• Foreign matter is in the orifice of the valve. • Remove the foreign matter.
The sleeve is malfunctioning.
Slewing stops with The valve within the check valve assembly is
a great shock. malfunctioning.
• Foreign matter is in the orifice of the valve. • Remove the foreign matter.
The orifice is choked.
• Foreign matter is in the orifice of the anti- • Remove the foreign matter.
rebound valve body.
• Foreign matter is in the orifice of the valve • Remove the foreign matter.
unit.
TB175W IV-150
AXLE TYPE: 212 (FRONT)
TB175W
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AXLE TYPE: 112 (REAR)
TB175W
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GEAR BOX TYPE: 357
TB175W
TB175W REV. 1
Service Manual
Gear Box
357A10
GSM-0012
January 1998
PRINTED IN ITALY
Copyright By DANA SPICER CLARK-HURTH
Vietata la riproduzione anche parziale di testo ed illustrazioni
Realizzazione a cura dell'Ufficio PubblicitaÁ e dell'Ufficio Post Vendita della DANA SPICER CLARK-HURTH
Impaginazione: TEMAS s.r.l. - Gallarate (Va)
Stampa: Gennaio 1998 (N.L. 7309)
Data subject to change without notice. We decline all responsability for the use of non-original components, or accessories which have
not been tested and submitted for approval.
Dati soggetti a modifiche senza impegno di preavviso. Si declina ogni responsabilitaÁ per l'utilizzo di componenti non originali o accessori
non collaudatied apporvati.
AÈnderungen ohne vorherige AnkuÈndingung vorbehalten. Es wird jede Verantwortung fuÈr die Verwendung von Nichtoriginalteilen oder
nicht abgenommenem und genehmigtem ZubehoÈr abgelehnt.
Los datos pueden ser modificados sin aviso previo. Se declina toda responsabilidad en el caso de uso de componentes no originales o
bien de accesorios no ensayados y aprobados.
Le constructeur se reÂserve le droit d'apporter des modifications aÁ sa production, sans pour cela eÃtre tenu d'en donner preÂavis. Nous
deÂclinons toute responsabiliteÂ pour l'utilisation de pieÁces non originales ou d'accessoires non testeÂs et homologueÂs.
2
INDEX - INDICE - INHALTSVERZEICHNIS - INDICE - INDEX
GB
INTRODUCTION..................................................................................................................................................................................................... 4
MAINTENANCE AND LUBRICANT .......................................................................................................................................................................... 6
CONVERSION TABLES .......................................................................................................................................................................................... 7
TIGHTENING TORQUES ........................................................................................................................................................................................ 7
DIAGRAMS OF REDUCTION UNIT AND EXPLODED VIEWS ................................................................................................................................... 8
DISASSEMBLY OF DIRECTLY FLANGED REDUCTION GEAR 357........................................................................................................................ 10
REMOVAL OF HYDRAULIC GEAR CONTROL....................................................................................................................................................... 12
ASSEMBLY OF DIRECTLY FLANGED REDUCTION GEAR 357 ............................................................................................................................. 28
INSTALLATION OF HYDRAULIC GEAR CONTROL ............................................................................................................................................... 44
INTRODUZIONE .......................................................4 VORAUSSETZUNG .................................................. 4

ITA D
MANUTENZIONE E LUBRIFICANTI...........................6 WARTUNG UND SCHMIERSTOFFE ......................... 6
TABELLE DI CONVERSIONE....................................7 UMRECHNUNGSTABELLEN .................................... 7
COPPIE DI SERRAGGIO .............................................................7 ANZIEHDREHMOMENTE ............................................................ 7
SCHEMI RIDUTTORE ED ESPLOSI .............................................8 SCHEMAS FUÈR UNTERSETZUNGSGETRIEBE
SMONTAGGIO GRUPPO RIDUTTORE 357 AFFLANGIATO ........10 UND ZUSAMMENSTELLUNGSZEICHNUNGEN ........................... 8
RIMOZIONE COMANDO MARCIA IDRAULICO ...........................12 DIREKT GEFLANSCHTER REDUZIERER 357 ZERLEGEN ......... 10
ASSEMBLAGGIO GRUPPO RIDUTTORE 357 AFFLANGIATO.....28 HYDRAULISCHER GANGSCHALTUNG ENFERNEN.................. 12
INSTALLAZIONE COMANDO MARCIA IDRAULICO ....................44 DIREKT GEFLANSCHTER REDUZIERER 357 MONTIEREN ....... 28
HYDRAULISCHER GANGSCHALTUNG MONTIEREN ................ 44
PROLOGO ...............................................................4 INTRODUCTION....................................................... 4

ESP MANTENIMIENTO Y LUBRICANTES .........................6 F ENTRETIEN ET LUBRIFIANTS ................................. 6
TABLAS DE CONVERSION.......................................7 TABLEAUX DE CONVERSION.................................. 7
PARES DE TORSION ..................................................................7 COUPLES DE SERRAGE ............................................................ 7
DIAGRAMAS REDUCTOR Y VISTAS PORMENORIZADAS ...........8 TRACES REDUCTEUR ET EXPLOSIFS....................................... 8
DESMONTAJE GRUPO REDUCTOR 357 CON BRIDA ...............10 DEMONTAGE DU GROUPE REDUCTEUR BRIDE 357............... 10
REMOCION MANDO MARCHA HIDRAULICO.............................12 DEPLACEMENT DE LA COMMANDE DE VITESSES
MONTAJE GRUPO REDUCTOR 357 CON BRIDA ......................28 HYDRAULIQUE ........................................................................ 12
MONTAJE MANDO MARCHA HIDRAULICO...............................44 ASSEMBLAGE DU GROUPE REDUCTEUR BRIDE 357 ............. 28
INSTALLATION DE LA COMMANDE DE VITESSES
HYDRAULIQUE ........................................................................ 44
3
INTRODUCTION - INTRODUZIONE - VORAUSSETZUNG - PROLOGO - INTRODUCTION
The efficiency and continued operation of mechan- martelli in plastica o rame, leve appropriate estrattori e chiavi
GB ical units depend on constant, correct maintenance specifiche, al fine di facilitare il lavoro salvaguardando nel
and also on efficient repair work, should there be a contempo le superfici lavorate e la sicurezza degli operatori.
break-down or malfunction. The instructions contained in this Prima di procedere al disassemblaggio delle parti e scaricare
manual have been based on a complete overhaul of the unit. l'olio, eÁ opportuno eseguire un'accurata pulizia del ponte,
However, it is up to the mechanic to decide whether or not it is asportando incrostazioni ed accumuli di grasso.
necessary to assemble only individual components, when
partial repair work is needed. The manual provides a quick PREMESSA: Tutti gli organi meccanici smontati, devono
and sure guide which, with the use of photographs and essere accuratamente puliti con prodotti appropriati, quindi
diagrams illustrating the various phases of the operations, ripristinati o sostituiti nel caso presentino danni, usura,
allows accurate work to be performed. incrinature, grippaggi, ecc. In particolare, verificare l'integritaÁ
All the information needed for correct disassembly, checks and di tutte quelle parti in movimento (cuscinetti, ingranaggi, coppia
assembly of each individual component is set out below. In conica, alberi) e di tenuta (anelli OR, paraolio), soggette a
order to remove the differential unit from the vehicle, the maggiori sollecitazioni ed usura. EÁ consigliabile, comunque, la
manuals provided by the vehicle manufacturer should be sostituzione degli organi di tenuta ogni qualvolta si proceda alla
consulted. In describing the following operations it is presumed revisione o riparazione dei componenti. Al momento del
that the unit has already been removed from the vehicle.
montaggio, gli anelli di tenuta devono essere lubrificati sui
IMPORTANT: In order to facilitate work and protect both bordi di tenuta. Nel caso della coppia conica, la sostituzione di
working surfaces and operators, it is advisable to use proper uno dei suoi ingranaggi comporta anche la sostituzione
equipment such as: trestles or supporting benches, plastic or dell'altro. In fase di montaggio sono da rispettare scrupolosa-
copper hammers, appropriate levers, extractors and specific mente i giochi, i precarichi e le coppie prescritte.
spanners or wrenches. Á : Il manuale fornisce le validitaÁ dei gruppi sotto forma
VALIDITA
Before going on to disassemble the parts and drain the oil, it is
di matricola. Al fine di una corretta interpretazione, le validitaÁ
best to thoroughly clean the unit, removing any encrusted or
sono indicate come:
accumulated grease.
= fino alla matricola
INTRODUCTORY REMARKS: All the disassembled mechan-
ical units should be thoroughly cleaned with appropriate = dalla matricola
products and restored or replaced if damage, wear, cracking or
seizing have occurred. Se non sono indicate validitaÁ, le operazioni di smontaggio ed
In particular, thoroughly check the condition of all moving parts assemblaggio sono comuni a tutte le versioni.
(bearings, gears, crown wheel and pinion, shafts) and sealing
parts (O-rings, oil shields) which are subject to major stress and MANUTENZIONE E RIPARAZIONE: Al fine di facilitare
wear. In any case, it is advisable to replace the seals every time interventi sui gruppi ponte differenziali e cambi di velocitaÁ la
a component is overhauled or repaired. During assembly, the SPICER CLARK-HURTH, ha ritenuto opportuno compilare
sealing rings must be lubricated on the sealing edge. In the queste istruzioni di manutenzione e riparazione. I disegni delle
case of the crown wheel and pinion, replacement of one attrezzature specifiche eventualmente necessarie per l'esecu-
component requires the replacement of the other one. During zione di interventi di manutenzione e riparazione possono
assembly, the prescribed pre-loading, backlash and torque of essere acquistati direttamente presso il costruttore; i ricambi
parts must be maintained. possono essere ordinati tramite il costruttore della macchina o
direttamente presso la SPICER CLARK-HURTH.
CLASSIFICATION: This manual classifies units according to
part numbers. For a correct interpretation, classification is
indicated as follows:
= up to the part number Die Leistung und Lebensdauer der mechanischen
D Teile haÈngt nicht nur von einer staÈndigen und
= from the part number on richtig durchgefuÈhrten Wartung sondern auch von
einem sofortigen Eingriff im StoÈrungsfall ab. Um dieses
When no classification is given, disassembly and assembly Handbuch zu erstellen sind wir von einer allgemeinen U È ber-
operations are the same for all versions. pruÈfung der Einheit ausgegangen, doch entscheidet der
Mechaniker ob die einzelnen Teile bei Reparaturen montiert
SPECIFIC EQUIPMENT AND SPARE PARTS: The drawings of werden muÈssen oder nicht. Das Handbuch ist schnell und
all specific tools required for maintenance and repair work can einfach nachzuschlagen und ermoÈglicht es anhand der Abbild-
be found at the end of this manual ; spare parts may be ordered ungen und der Zeichnungen, die die verschiedenen VorgaÈnge
either from the vehicle manufacturer or directly from the darstellen, gezielt einzugreifen. Nachstehend sind alle Infor-
Service Centers or Authorised Distributors of SPICER mationen und Hinweise aufgefuÈhrt, die zur Zerlegung, PruÈfung
CLARK-HURTH. und Montage der Einzelteile noÈtig sind. Um die Differentia-
lachse des Fahrzeugs abzumontieren, lesen Sie bitte die
Anweisungen in den HandbuÈchern des Fahrzeugherstellers.
Die nachstehenden Beschreibungen gehen davon aus, daû die
Il rendimento e la continuitaÁ degli organi meccanici Fahrzeugachse schon abmontiert worden ist.
ITA dipendono oltre che da una costante e corretta
manutenzione, anche dal tempestivo intervento, WICHTIG: Um die Arbeit zu erleichtern und gleichzeitig die
nell'eventualitaÁ di guasti o anomalie. verarbeiteten FlaÈchen zu schuÈtzen und die Sicherheit der
Nel proporre questo manuale si eÁ considerata l'ipotesi di una Arbeiter zu gewaÈhrleisten, empfehlen wir geeignete Werk-
revisione generale del gruppo ma eÁ il meccanico a valutare la zeuge wie BoÈcke, Tisch, Gummi- oder Kupferhammer, geeig-
necessitaÁ di montare solo i singoli componenti nel caso di nete Auszieher und SchluÈssel zu verwenden.
Bevor mit der Zerlegung der Teile begonnen und das O Èl
riparazione. Il manuale eÁ una guida rapida e sicura che
consente interventi precisi, tramite le fotografie ed i disegni abgelassen wird, muû die Achse sorgfaÈltig gereinigt und
prospettici che illustrano le varie fasi delle operazioni. Di Verkrustungen und Fettablagen abgetragen werden.
seguito sono riportate tutte quelle informazioni ed avvertenze VORAUSSETZUNG: Alle abmontierten mechanischen Teile
necessarie al corretto disassemblaggio, alle relative verifiche muÈssen sorgfaÈltig mit geeigneten Reinigungsmitteln gereinigt
ed all'assemblaggio dei singoli componenti. Per la rimozione oder, wenn beschaÈdigt, verschleiût, gerissen, festgefressen
del ponte differenziale dal veicolo, eÁ necessario consultare i usw. ausgewechselt werden. Insbesondere muû der einwand-
manuali forniti dal costruttore del veicolo. Nel descrivere le freie Zustand aller beweglichen Teile (Lager, ZahnraÈder,
operazioni seguenti, si presuppone che il ponte sia giaÁ stato Kegelradpaare, Wellen) und der Dichtungen (O-Ringe, O È lab-
rimosso dal veicolo. dichtungen), die am meisten beansprucht werden und ver-
schleiûen, kontrolliert werden. Wir empfehlen auf jeden Fall die
IMPORTANTE: In tutte le operazioni, eÁ consigliabile usare Abdichtungselemente immer auszuwechseln, wenn eine U È ber-
attrezzature idonee quali cavalletti o banchi di sostegno, holung oder eine Reparatur der Teile vorgenommen wird. Bei
4
der Montage muÈssen die RaÈnder der Dichtringe geschmiert Si no ha sido indicada validez, las operacioÂn de desmontaje y
werden. Wenn beim Kegelradpaar ein Zahnrad ausgewechselt montaje son comunes a todas las versiones.
werden muû, muû auch das andere Zahnrad ausgewechselt
werden. Bei der Montage muÈssen die vorgeschriebenen HERRAMIENTAS ESPECIFICAS Y RECAMBIOS: Los planos
Spiele, Vorspannungen und Drehmomente strengstens ein- de las herramientas especificas necesarias para la ejecucioÂn
gehalten werden. de las intervenciones de mantenimiento figuran al final del
manual; los recambios se pueden pedir al fabricante de la
GUÈ LTIGKEIT: Das Handbuch gibt an zu welchen Kennummern maÂquina o directamente al Service Center o a Distribuidores
die Einheiten gehoÈren. Der Einfachheit halber sind die autorizados de SPICER CLARK-HURTH.
AngehoÈrigkeiten folgendermaûen aufgefuÈhrt:
= bis Kennummer
= ab Kennummer Le rendement et la continuiteÂ des organes meÂca-

F niques deÂpendent, non seulement d'une mainte-
Wenn keine AngehoÈrigkeit angegeben ist, verstehen sich die nance correcte et constante, mais eÂgalement de la
Arbeiten zur Zerlegung und Montage fuÈr alle AusfuÈhrungen rapiditeÂ d'intervention en cas de pannes ou d'anomalies. En
guÈltig. vous proposant ce manuel, on envisage l'hypotheÁse d'une
reÂvision geÂneÂrale du groupe, mais c'est au meÂcanicien
SPEZIFISCHE WERKZEUGE UND ERSATZTEILE: die Zeich- d'eÂvaluer la neÂ cessiteÂ de monter ou non chacun des
nungen der fuÈr Wartungsarbeiten erforderlichen spezifischen composants en cas de reÂparation. Le manuel est un guide
Werkzeuge, sind am Ende des Handbuchs aufgefuÈhrt; Ersatz- rapide et suÃr consentant des interventions preÂcises, au travers
teile koÈnnen beim Fahrzeughersteller oder direkt bei der de photographies et de dessins prospectifs qui illustrent les
Kundendienststelle oder bei einem zugelassenen HaÈndler der diffeÂrentes phases des opeÂrations. Ensuite, sont reporteÂes
SPICER CLARK-HURTH bezogen werden. toutes les informations et preÂcautions neÂcessaires pour un
deÂmontage correct et les veÂrifications et assemblage de
chaque composant. En ce qui concerne le deÂplacement du
pont d'eÂtai du veÂhicule, il est neÂcessaire consulter les manuels
fournis par le constructeur du veÂhicule. En deÂcrivant les
El rendimiento y la duracioÂn de los oÂrganos
ESP opeÂrations suivantes, on preÂsume que le pont ait deÂjaÁ eÂteÂ
mecaÂnicos depende, ademaÂs que del constante y
enleveÂ du veÂhicule.
correcto mantenimiento, tambieÂn de la interven-
cioÂn inmediata en caso de averõÂas o anomalõÂas. IMPORTANT: Pour faciliter le travail en sauvegardant en
Al proponer este manual, ha sido considerada la suposicioÂn de meÃme temps les surfaces usineÂes et la seÂcuriteÂ des opeÂra-
una revisioÂn general del grupo, pero es el mecaÂnico quien tiene teurs, il est preÂconiseÂ d'utiliser des installations approprieÂes
que valorar la necesidad de montar cada uno de los telles que des eÂtais ou banc de support, maillets en plastique
componentes en caso de reparacioÂn. El manual es una guõÂa ou cuivre, leviers approprieÂs, extracteurs et cleÂs speÂcifiques.
raÂpida y segura que permite intervenciones precisas por medio Avant de proceÂder au deÂmontage des parties et vidanger
de fotografõÂas y de planos que muestran las distintas fases de l'huile, il vaut mieux nettoyer soigneusement le pont, en
las operaciones. A continuacioÂn figuran todas las informacio- enlevant incrustations et blocs de gras.
nes y advertencias necesarias para ejecutar un montaje
correcto, para las comprobaciones y el montaje de cada uno PRELIMINAIRE: Tous les organes meÂcaniques deÂmonteÂs
de los componentes. Para remover el puente diferencial del doivent eÃtre soigneusement nettoyeÂs aÁ l'aide de produits
vehõÂculo hay que consultar los manuales de los fabricantes del approprieÂs et reÂpareÂs ou remplaceÂs dans le cas ouÁ ils seraient
vehõÂculo. En la descripcioÂn de las operaciones siguientes se abõÃmeÂs, useÂs, feÃleÂs, grippeÂs, etc. VeÂrifier, l'inteÂgriteÂ, en
supone que el puente ya ha sido sacado del vahõÂculo. particulier, de toutes les parties en mouvement (paliers,
engrenages, couple conique, arbres) et l'eÂtancheÂiteÂ des
IMPORTANTE: Para facilitar el trabajo salvaguardando al bagues (bagues OR, parahuile), qui sont sujettes aÁ plus de
mismo tiempo las superficies mecanizadas y la seguridad de sollicitations et aÁ l'usure. Il est preÂconiseÂ, de toute facËon, de
los operadores, se aconseja que se usen equipos y herra- substituer les organes d'eÂtancheÂiteÂ, chaque fois que l'on
mientas adecuados como caballetes y bancos de soporte, effectue une reÂvision ou une reÂparation des composants. Au
martillos de plaÂstico o de cobre, palancas adecuadas, moment du montage, les bagues d'eÂtancheÂiteÂ doivent eÃtre
extractores y llaves especõÂficas. lubrifieÂes sur les bords eÂtanches. Dans le cas du couple
Antes de desmontar las partes y descargar el aceite, es conique, la substitution de l'un de ses engrenages comporte
conveniente que se haga una limpieza minuciosa del puente eÂgalement la substitution de l'autre. En phase de montage, il
sacando las incrustaciones y acumulaciones de grasa. faut respecter scrupuleusement les jeux, les preÂcharges et les
couples prescrits.
INTRODUCCION: Todos los oÂrganos mecaÂnicos desmontados
tienen que ser limpiados minuciosamente con productos VALIDITE: Le manuel fournit la validiteÂ des groupes sous
adecuados y restaurados o sustituidos en el caso de que forme de matricule. Pour une meilleure interpreÂtation, les
presenten danÄos, desgaste, rajaduras, agarrotamientos, etc. validiteÂs sont indiqueÂes comme:
En particular, comprobar la integridad de todas las partes en
movimiento (cojinetes, engranajes, par coÂnico, ejes) y de = jusqu'aÁ l'immatriculation
estanqueidad (anillos OR, detenedor de aceite) sujetas a
mayores solicitaciones y desgaste. = aÁ partir de l'immatriculation et apreÁs
Se aconseja, de todas formas, que se sustituyan los oÂrganos
de estanqueidad cada vez que se ejecute la revisioÂn o Si les validiteÂs ne sont pas indiqueÂes, les opeÂrations de
reparacioÂn de los componentes. deÂmontage et d'assemblage sont pareilles dans toutes les
Al volver a montar, los segmentos de compresioÂn tienen que versions.
estar lubricados en los bordes de estanqueidad. En el caso del
par coÂnico, la sustitucioÂn de uno de sus engranajes comporta INSTALLATIONS SPECIFIQUES ET PIECES DETACHEES:
tambieÂn la sustitucioÂn del otro. Al montar hay que tener en Les dessins des installations speÂcifiques neÂcessaires pour
cuenta escrupulosamente los juegos, las precargas y los pares effectuer des interventions d'entretien sont reporteÂes aÁ la fin du
descriptos. manuel, les pieÁces deÂtacheÂes peuvent eÃtre commandeÂes au
constructeur de la machine ou directement aux Centres de
VALIDEZ: El manual suministra la validez de los grupos en Services, ou Distributeurs agreÂeÂs de la SocieÂteÂ SPICER
forma de matrõÂcula. Para poder tener una interpretacioÂn CLARK-HURTH.
correcta, la validez estaÂ indicada:
= hasta la matrõÂcula
= desde la matrõÂcula en adelante
5
MAINTENANCE AND LUBRICANT - MANUTENZIONE E LUBRIFICANTI - WARTUNG UND SCHMIERSTOFFE
MANTENIMIENTO Y LUBRICANTES - ENTRETIEN ET LUBRIFIANTS
D1240009
Oil fill and level plug Oil drain plug
1 2
Tappo carico e livello olio Tappo scarico olio
È leinfu
O È lstandschraube
Èll- und O È leinfu
O È lablaûschraube
Èll- und O
Tapo Â n de relleno y nivel aceite Tapo Â n de vaciado nivel aceite
Bouchon de remplissage et jauge d'huile Bouchon de vidage huile
1 2
3
MFG. BY CLARK-HURTH COMPONENTS S.P.A.
38062 Arco (Trento)
MADE IN ITALY
D1240011
Type and model unit Serial number Lubrificant
1 2 3
Tipo e modello gruppo Numero di serie Lubrificante
Type und modell Antriebes Seriennummer Schmieroel
Tipo y modelo unidad Â mero de serie
Nu Lubricante
Â le de ensemble
Type et mode Numero de serie Lubrificant
OPERATION FREQUENCY LUBRICANTS

OPERAZIONE Á
PERIODICITA LUBRIFICANTI
ARBEITSVORGANG ZEITABSTAND SCHMIERSTOFFE
OPERACION FRECUENCIA LUBRICANTES
OPERATION PERIODICITE LUBRIFIANTS
. Check levels: monthly
. Controllo livelli: mensile
. È lstandkontrolle:
O monatlich
. Control niveles: cada mes
. ControÃle niveaux: mensuel
SAE85W90 API GL3
. Oil change: every 1000 hours ]
. Cambio olio: ogni 1000 ore
. È lwechsel:
O alle 1000 Std.
. Cambio aceite: cada 1000 horas
. Vidange huile: toutes les 1000 hours
] Initially after 100 working hours - Inizialmente dopo 100 ore di lavoro - Erstmals nach 100 Betriebstunden - Al principio, despueÂs de
100 horas de trabajo - Initialement apreÁs 100 heures de travail
6
CONVERSION TABLES - TABELLE DI CONVERSIONE - UMRECHNUNGSTABELLEN
TABLAS DE CONVERSION - TABLEAUX DE CONVERSION
1 Atm%1 bar%105 PA%14.4 PSi

Pa
N daN kN kg lbs Nm daNm kNm kgm lb-in
1N 1 0,1 0,001 0,102 0,225 1Nm 1 0,1 0,001 0,102 8,854
1daN 10 1 0,01 1,02 2,25 1daNm 10 1 0,01 1,02 88,54
1kN 1000 100 1 102 225 1kNm 1000 100 1 102 8854
1kg 9,81 0,981 0,00981 1 2,205 1kgm 9,81 0,981 0,00981 1 86,8
1lb-in 0,1129 0,01129 0,0001129 0,01152 1
TIGHTENING TORQUES - COPPIE DI SERRAGGIO - ANZIEHDREHMOMENTE

PARES DE TORSION - COUPLES DE SERRAGE
TYPE OF BOLT - TIPO VITE - GEWINDE - TIPO DE TORNILLO - TYPE DE VIS

SIZE OF BOLT
MISURA VITE
SCHRAUBENMASS
TAMAN Ä O TORNILLO
8G/8,8 10k/10,9 12k/10,9
MESURE VIS Nm Nm Nm
M4 2,9 4,1 Ð
M6 10,0 14,0 Ð
M8 25,0 35,0 Ð
M10 49,0 69,0 Ð
M10x1,25 52,0 73,0 88,0
M12 86,0 120,0 Ð
M14 135,0 190,0 Ð
M14x1,5 150,0 210,0 250,0
M16 210,0 295,0 Ð
M18x1,5 325,0 460,0 550,0
A22 550
7
DIAGRAMS OF REDUCTION UNIT AND EXPLODED VIEWS - SCHEMI RIDUTTORE ED ESPLOSI - SCHEMAS FUÈR UNTERSETZUNGSGETRIEBE
UND ZUSAMMENSTELLUNGSZEICHNUNGEN - DIAGRAMAS REDUCTOR Y VISTAS PORMENORIZADAS - TRACES REDUCTEUR ET EXPLOSIFS
DIAGRAM
SCHEMA
SCHEMAS
DIAGRAMAS
TRACES
D1240001
TECHNICAL DATA - CARATTERISTICHE TECNICHE - TECHNISCHE DATEN - CARACTERI-

STICAS TECNICAS - CARACTERISTIQUES TECHNIQUES
A- Connector for hydraulic gear control - Pressure required 15±30 bar
Raccordi comando marce idraulico - Pressione di comando 15±30 bar
Anschluss fuÈr hydraulischer BetaÈtigung der Gangschaltung Schaltdruck 15±30 bar
ConexioÂn mando marcha hydraulico - PresioÂn de mando 15±30 bar
Raccord commande des vitesses hydraulique - Pression de commande 15±30 bar
REDUCTION GEAR
RIDUTTORE
UNTERSETZUNGSGETRIEBE
REDUCTOR
REDUCTEUR
D1240012
] OPTIONAL
8
Ist GEAR
Ië MARCIA
Ië GANG
Ië MARCHA
Ië VITESSE
D1240002
IInd GEAR
IIë MARCIA
IIë GANG
IIë MARCHA
IIë VITESSE
D1240003
9
SYMBOLS - SIMBOLI - SYMBOLS DISASSEMBLY OF DIRECTLY FLANGED REDUCTION GEAR 357- SMONTAGGIO GRUPPO RIDUTTORE 357 AFFLANGIATO - DIREKT GEFLANSCHTER
SIMBOLOS - SYMBOLES REDUZIERER 357 ZERLEGEN - DESMONTAJE GRUPO REDUCTOR 357 CON BRIDA - DEMONTAGE DU GROUPE REDUCTEUR BRIDE 357
Disassembly of assembly groups

Smontaggio di sottogruppi
Zerlegen von Baugruppen
Desmontaje de subgrupos
Demontage des sous-groupes
Reassemble to from assembly groups
Montaggio di sottogruppi
Zusasmmenbauen von Baugruppen
Ensamblaje de subgrupos
Montage des sous-groupes
Remove obstruction parts
Smontaggio di particolari ingombri
Abbauen-Ausbauen
Desmontaje de componentes abultados
Demontage des pieces encombrante
Reinstall-remount parts which had obstructed disassembly
Montaggio di particolari ingombri
Einbauen-Ausbauen
Montaje de componentes abultados
Montage des pieces encombrante
Attention ! Important notice
Attenzione, indicazione importante F1240069 F1240070
Achtung, wichtiger Hinweis
¡ Cuidado ! IndicacioÂn importante
Attention, indication importante GB a GB b
Check - adjust e.g. torque, dimensions, pressures, etc.
Controllare - regolare p.e. coppie, misure, pressioni ecc. Reduction gear directly flanged on the axle with mechanic gear Reduction gear directly flanged on the axle with hydraulic gear
PruÈfen - Einstellen z.B. Momente, Maûe, Drucke u.s.cs. control. control.
Controlar y ajustar, por ej. pares, medidas, presiones, etc.
Controler, regler p.e. couples, mesures, pressions ecc.
T=Special tool P=page
T=Attrezzature speciali P=Pagina
T=Spezialwerkzeug P=Seite
T=Herramientas especiales P=PaÂgina
T=Outils P=Page
Note direction of installation
Rispettare direzione di montaggio
Einbaurichtung beachten
Respetar la direccioÂn de ensamblaje
Respecter direction de montage
Visual inspection
Esaminare con controllo visuale
Kontrollieren -PruÈfen
Examinar mediante inspeccioÂn visual
Controler, examiner, controle visuel
Possibly still serviceable, renew if necessary
Eventualmente riutilizzare (sostituire se necessario)
Bedingt weiderverwendbar
Puede volver a utilizarse (reemplazar, si es preciso)
Eventuellement a utiliser a noveau (remplacer si neÂcessaire)
Renew at each reassembly
Sostituire con ogni montaggio
Beim Zusammenbau immer erneuern
Puede reemplazarse a cada ensamblaje
Remplacer avec chaque montage F1240071
Unlock - lock e.g. split pin, locking plate, etc.

Togliere-mettere la sicura
Entsichern-Sichern GB c GB d
Quitar-colocar el seguro
Enlever-mettre la securite Reduction gear directly flanged on the axle with or without
Lock-adhere (liquid sealant) revolution indicator.
Mettere la sicura, incollare (mastice liquido)
Sichern-Kleben (fluÈssige Dichtung)
Colocar el seguro, pegar (mastique lõÂquido)
Mettre la securite, coller (mastic liquide)
Guard against material damage, damage to parts
Evitare danni materiali, danni a pezzi
Materialschaden verhuÈten
Evitar danÄar los materials o las piezas
Eviter dommages au materiaux, dommages au pieces
Mark before disassembly, observe marks when reassembly
Marchiare prima dello smontaggio (per il montaggio)
Vor dem Ausbau markieren (fuÈr den Zusammenbau)
Marcar antes de desmontar (para facilitar el ensamblaje)
Marquer avant le demontage (pour le montage)
Filling - topping up - refilling e.g. oil, cooling water, etc.
Caricare - riempire (olio - lubrificante)
EinfuÈllen - AuffuÈllen - NachfuÈllen (OÈl-Schmiermittel)
Cargar - llenar (aceite lubricante)
Charger - remplir (huile - lubrifiant)
Drain off oil, lubricant
Scaricare olio, lubrificante
OÈl, bzw. Schmiermittel Ablassen
Descargar aceite lubricante
Vidanger, lubrifiant
Tighten
Tendere
Spannen
Tensar
Tendre
Apply pressure into hydraulic circuit
GB e GB f
Inserire pressione nel circuito idraulico
Leitung unter Druck setzen
Introducir presioÂn en el circuito hidraÂulico
Inserer pression dans le circuit hydraulique
To clean
Pulire
Reinigen
Limpiar
Nettoyer 10
Versione afflangiata al ponte con comando marcia Versione afflangiata al ponte con comando marcia
ITA meccanico. ITA idraulico.
Direkt an der Triebachse geflanscht mit mechanischer Direkt an der Triebachse geflanscht mit hydraulischer
D Gangschaltung. D Gangschaltung.
a b
VersioÂn con brida en el puente con mando mecaÂnico VersioÂn con brida en el puente con mando hidraÂulico
ESP de la marcha. ESP de la marcha.
ModeÁle brideÂ au pont aÁ commande de vitesses ModeÁle brideÂ au pont aÁ commande de vitesses
F meÂcanique. F hydraulique.
Versione afflangiata al ponte con o senza rilevatore di

ITA giri. ITA
Direkt an der Triebachse geflanscht mit oder ohne

D Drehzahlmesser. D
c d
VersioÂn con brida en el puente con o sin detector de
ESP revoluciones. ESP
ModeÁle brideÂ pont avec ou sans compteur de tours.

F F
ITA ITA
D D
e f
ESP ESP
F F
11
REMOVAL OF HYDRAULIC GEAR CONTROL - RIMOZIONE COMANDO IDRAULICO - HYDRAULISCHER GANGSCHALTUNG ENFERNEN -
REMOCION MANDO MARCHA HIDRAULICO - DEPLACEMENT DE LA COMMANDE DE VITESSES HYDRAULIQUE
F1240072 F1240073
GB a GB b
Remove the gear control rod. Pull out the control rod.
F1240074 F1240075
GB c GB d
Remove screws on the gear control cylinder. Remove the gear control cylinder.
F1240076 F1240077
GB e GB f
Pull out the gear control cylinder. Re-assembly arrangement of gear control cylinder parts.
Pay attention to the position of the O-rings. Remove the protection
plate.
12
Rimuovere l'asta di comando marce. Estrarre l'asta comando.
ITA ITA
Gangschalterhebel abnehmen. Hebel herausziehen.

D D
a b
Remover la varilla de mando de las marchas. Extraer la varilla de mando.
ESP ESP
Enlever la tringle de commande de vitesses. Extraire la tringle de commande.

F F
Rimuovere le viti del cilindro comando marce. Rimuovere il cilindro comando marce.
ITA ITA
Die Schrauben vom Zylinder des Gangschalters Zylinder des Gangschalters abnehmen.
D abnehmen. D
c d
Remover los tornillos del cilindro de mando de las Remover el cilindro de mando de las marchas.
ESP marchas. ESP
Enlever les vis du cylindre de commande de vitesses. Enlever le cylindre de commande de vitesses.
F F
Estrarre il cilindro comando marce. Ordine di rimontaggio dei particolari del cilindro di
ITA Prestare attenzione alla posizione degli anelli OR. ITA comando marce.
Rimuovere la lamiera di protezione.
Zylinder des Gangschalters herausziehen. Reihenfolge zur Montage der Einzelteile des Gangs-
D Auf die Position der O-Ringe achten. Schutzblech D chalterzylinders.
abnehmen.
e f
Extraer le cilindro de mando de las marchas. Orden para volver a montar las piezas del cilindro de
ESP Tener cuidado con la posicioÂn de los anillos OR. ESP mando de las marchas.
Remover la placa de proteccioÂn.
Extraire le cylindre de commande de vitesses Placer les pieÁces en ordre en vue du remontage du
F Faire attention au positionnement des bagues OR F cylindre de commande de vitesses.
Enlever la toÃle de protection.
13
DISASSEMBLY OF DIRECTLY FLANGED REDUCTION GEAR 357- SMONTAGGIO GRUPPO RIDUTTORE 357 AFFLANGIATO - DIREKT GEFLANSCHTER
REDUZIERER 357 ZERLEGEN - DESMONTAJE GRUPO REDUCTOR 357 CON BRIDA - DEMONTAGE DU GROUPE REDUCTEUR BRIDE 357
F1240078 F1240079
GB a GB b
Remove fastening screws from the reduction unit. Disjoin the entire reduction unit from the axle and place it on a
bench.
F1240080 F1240081
GB c GB d
Remove the sealing cover with the relative washer or the revolution Remove gear-in position switch, O-ring and washer.
indicator.
F1240082 F1240083
GB e GB f
Remove screw, spring, together with gear-and-neutral position Remove screw, spring and neutral position ball (hydraulic version).
spindle (mechanical version).
14
Rimuovere le viti di fissaggio del riduttore. Staccare il riduttore completo dal ponte e posizionarlo
ITA ITA su un banco.
Reduziererbefestigungsschrauben abschrauben. Den gesamten Reduzierer von der Triebachse neh-

D D men und einen Tisch legen.
a b
Remover los tornillos de fijacioÂn de reductor. Desprender el reductor completo del puente y posi-
ESP ESP cionarlo en un banco.
Enlever les vis de fixation du reÂducteur. DeÂtacher le reÂducteur tout entier du pont et le mettre
F F sur le banc.
Rimuovere il tappo di chiusura con rosetta oppure il Rimuovere l'interruttore di posizione marcia inserita
ITA rilevatore di giri. ITA con anello OR e rosetta.
Stopfen mit Unterlegscheibe oder Drehzahlmesser Schalter fuÈr die Position der Gangschaltung mit O-
D entfernen. D Ring und Unterlegscheibe entfernen.
c d
Remover el tapoÂn de cierre con la roseta o bien el Remover el interruptor de posicioÂn de marcha em-
ESP detector de revoluciones. ESP bragada con el anillo OR y la roseta.
Enlever le bouchon de verrouillage aÁ rondelle ou bien Enlever l'interrupteur de la position vitesses incorporeÂ
F le compteur de tours. F avec la bague OR et la rondelle.
Rimuovere la vite, la molla ed il puntalino di posizione Rimuovere la vite, la molla e la sfera di posizone folle
ITA marcia e folle (versione meccanica). ITA (versione idraulica).
Schraube, Feder und Stift fuÈr die Position der Gangs- Schraube, Feder und Kugel fuÈr die Position des
D chaltung und des Leerlaufs entfernen (mechanische D Leerlaufs entfernen (hydraulische AusfuÈhrung).
AusfuÈhrung).
e f
Remover el tornillo, el muelle y el pasador de posicioÂn Remover el tornillo, el muelle y la bola de posicioÂn de
ESP de marcha y punto neutro (versioÂn mecaÂnica). ESP punto neutro (versioÂn hidraÂulica).
Enlever la vis, le ressort et la buteÂe de position Enlever la vis, le ressort et la spheÁre de position point
F vitesses et point mort (modeÁle meÂcanique). F mort (modeÁle hydraulique).
15
F1240084 F1240085
GB a GB b
Remove screws from the motion input cover. Disjoin the motion entrance cover.
F1240086 F1240087
GB c GB d
Remove the nut from the flange. Remove the O-ring and pull out the flange.
F1240088
GB e GB f
Remove screws from the cover.
16
Rimuovere le viti del coperchio di entrata del moto. Staccare il coperchio di entrata del moto.
ITA ITA
Die Deckelschrauben am Anfang der Bewegung Deckel am Eingang des Bewegung abnehmen.
D abschrauben. D
a b
Remover los tornillos de la tapa de entrada del Desprender la tapa de entrada del movimiento.
ESP movimiento. ESP
Enlever les vis du couvercle d'entreÂe du mouvement. DeÂcrocher le couvercle d'entreÂe du mouvement.
F F
Rimuovere il dado della flangia. Asportare l'anello OR ed estrarre la flangia.

ITA ITA
Flanschmutter abschrauben. O-Ring abnehmen und Flansch herausziehen.

D D
c d
Remover la tuerca de la brida. Quitar el anillo OR y extraer la brida.
ESP ESP
Enlever l'eÂcrou de la flasque. Enlever la bague OR et extraire la flasque.

F F
Rimuovere le viti del coperchio.

ITA ITA
Deckelschrauben abschrauben.
D D
e f
Remover los tornillos de la tapa.
ESP ESP
Enlever les vis du couvercle.

F F
17
F1240089 F1240090
GB a GB b
Disjoin the cover. Remove the cover by fixing the distance washers onto the cover
itself.
Caution: the niche must be facing upwards.
F1240091 F1240092
GB c GB d
Remove screws. Remove the cover.
Take care not to damage planes.
F1240093
GB e GB f
Take away the cover.
Pay attention to the position of the pins.
18
Staccare il coperchio. Rimuovere il coperchio fissando gli spessori allo
ITA ITA stesso.
Attenzione: nicchia rivolta verso l'alto.
Deckel abnehmen. Deckel abnehmen und DistanzstuÈcke am Deckel

D D befestigen.
Achtung: die Nische ist nach oben gerichtet.
a b
Desprender la tapa. Remover la tapa fijando los espesores en la misma.
ESP ESP Cuidado: el hueco tiene que estar dirigido hacia
arriba.
DeÂcrocher le couvercle. Enlever le couvercle en fixant les cales aÁ ce dernier.

F F Attention: au logement tourneÂ vers le haut.
Rimuovere le viti. Rimuovere il coperchio.

ITA ITA Prestare attenzione per non danneggiare i piani.
Schrauben abschrauben. Deckel abnehmen.

D D Darauf achten, die FlaÈchen nicht zu beschaÈdigen.
c d
Remover los tornillos. Remover la tapa.
ESP ESP Poner mucho cuidado a fin de no danÄar las superfi-
cies.
Enlever les vis. Enlever le couvercle.

F F Faire attention aÁ ne pas endommager les surfaces.
Togliere il coperchio.
ITA Prestare attenzione alla posizione delle spine. ITA
Deckel abnehmen.
D Auf die Position der Stifte achten. D
e f
Sacar la tapa.
ESP Tener mucho cuidado con la posicioÂn de las clavijas. ESP
Enlever le couvercle.
F Faire attention aÁ la position des broches. F
19
F1240094 F1240095
GB a GB b
Pull out gear, needle bearings and distance piece form the box. Remove the bearing if it needs replacing.
F1240096 F1240097
GB c GB d
Re-introduce the bearing into the box. Remove the oil shield plate only if necessary.
Caution: the oil inlet must face upwards.
F1240098 F1240099
GB e GB f
Re-introduce the oil shield plate with oil inlet facing upwards. Fit the oil shield plate into position 5±5.5 mm from box plane.
Apply LOCTITE 510 on the outside.
20
Estrarre dalla scatola l'ingranaggio, i cuscinetti a Rimuovere il cuscinetto se eÁ da sostituire.
ITA rullini ed il distanziale. ITA
Aus der Schachtel das Zahnrad, die Kugellager und Lager herausnehmen, wenn es ausgewechselt wer-
D das DistanzstuÈck nehmen. D den soll.
a b
Extraer de la caja el engranaje, los cojinetes de agujas Remover el cojinete si hay que sustituirlo.
ESP y el separador. ESP
Extraire la boõÃte d'engrenage, les paliers aÁ rouleaux et Enlever le palier s'il est aÁ remplacer.
F l'entretoise. F
Reinserire il cuscinetto nella scatola. Rimuovere la lamiera paraolio solo se necessario.

ITA ITA Attenzione: l'entrata dell'olio deve essere rivolta verso
l'alto.
Lager in die Schachtel einsetzen. È labdichtung nur abnehmen, wenn es noÈtig sein
O
D D sollte.
È leingang muû nach oben gerichtet sein.
Achtung: der O
c d
Volver a colocar el cojinete en la caja. Remover el sello de aceite si fuera necesario.
ESP ESP Cuidado: la entrada del aceite tiene que estar dirigida
hacia arriba.
ReÂinseÂrer le palier dans la boõÃte. Enlever la toÃle pare-huile seulement si besoin.

F F Attention: l'orifice de huile doit eÃtre tourneÂe vers le
haut.
Reinserire lamiera paraolio con l'entrata dell'olio verso Posizionare la lamiera paraolio a 5v5,5 mm dal piano
ITA l'alto. ITA scatola.
Spalmare sull'esterno LOCTITE 510.
È labdichtung mit dem Eingang nach oben wieder

O È labdichtung in einem Abstand von 5v5,5 mm von
O
D einsetzen. D der SchachtelflaÈche einsetzen.
Auûen mit LOCTITE 510 schmieren.
e f
Volver a colocar el sello de aceite con la entrada del Posicionar el sello de aceite a 5v5,5 mm de la
ESP aceite hacia arriba. ESP superficie de la caja.
Engrasar por fuera con LOCTITE 510.
ReÂinseÂrer la toÃle pare-huile avec l'orifice de l'huile Placer la toÃle pare-huile aÁ 5v5,5 mm de la surface de
F tourneÂe vers le haut. F la boõÃte.
Enduire du LOCTITE 510 aÁ l'exteÂrieur.
21
F1240100 F1240101
GB a GB b
Remove the check screws from the flow regulator plate. Remove the plate and pull out coupling and fork at the same time.
F1240102 F1240103
GB c GB d
Check: sliding blocks, pin, and sliding coupling. Remove the lower shaft.
Replace if worn.
F1240104
GB e GB f
Remove the entire shaft and the flow regulator plate.
22
Rimuovere le viti di ritegno lamiera frangiflusso. Asportare la lamiera ed estrarre contemporaneamente
ITA ITA il manicotto e la forcella.
Befestigungsschrauben des Strahlreglers abschrau- Strahlregler abnehmen und gleichzeitig HuÈlse und
D ben. D Gabel herausziehen.
a b
Remover los tornillos de retencioÂn de la placa Sacar la placa y extraer contemporaÂneamente el
ESP deflectora. ESP manguito y la horquilla.
Enlever les vis de fixation de la toÃle brise-jet. Enlever la toÃle et extraire, en meÃme temps, le
F F manchon et la fourchette.
Verificare: pattini, spina e manicotto scorrevole. Rimuovere l'albero di uscita.

ITA Sostituirli se sono usurati. ITA
Zu kontrollieren: Gleitschuhe, Stift und GleithuÈlse. Ausgangswelle abnehmen.

D Wenn verschleiût, auswechseln. D
c d
Comprobar: patines, clavija y manguito corredizo. Remover el eje de salida.
ESP Sustituirlos si estaÂn gastados. ESP
VeÂrifier: pattes, broches et manchon coulissant. DeÂplacer l'arbre de sortie.

F Remplacer s'ils sont useÂs. F
Asportare l'albero completo e la lamiera frangiflusso.

ITA ITA
Die ganze Welle und den Strahlregler abnehmen.

D D
e f
Sacar el eje completo y la placa deflectora.
ESP ESP
Enlever l'arbre au complet ainsi que la toÃle brise-jet.

F F
23
F1240105 F1240106
GB a GB b
Disassembly of the entire lower shaft. Progressive arrangement of parts fitted onto the lower shaft.
F1240107 F1240108
GB c GB d
Assembly of lower shaft. Removal of upper shaft.
(In case of replacement, the shaft is supplied already assembled).
F1240109 F1240110
GB e GB f
Pull out the sealing ring. Re-insert a new sealing ring.
24
Smontaggio dell'albero di uscita completo. Disposizione progressiva dei particolari montati su
ITA ITA albero di uscita.
Ganze Ausgangswelle abmontieren. Reihenfolge der auf der Ausgangswelle montierten

D D Einzelteile.
a b
Desmontaje del eje de salida completo. DisposicioÂn progresiva de las piezas montadas en el
ESP ESP eje de salida.
DeÂmontage complet de l'arbre de sortie. Mise en place progressive des pieÁces monteÂes sur
F F l'arbre de sortie.
Assemblaggio dell'albero di uscita. Rimuovere l'albero di entrata.

ITA ITA (Nel caso di sostituzione, viene fornito premontato).
Zusammenbau der Ausgangswelle. Eingangswelle entfernen.

D D (Bei Ersatz, wird sie schon montiert geliefert).
c d
Montaje del eje de salida. Remover el eje de entrada.
ESP ESP (En el caso de sustitucioÂn, se entrega ya premontado).
Assemblage de l'arbre de sortie. DeÂplacer l'arbre d'entreÂe.

F F (En cas de substitution, il est fourni preÂmonteÂ).
Estrarre l'anello di tenuta. Reinserire il nuovo anello di tenuta.

ITA ITA
Dichtungsring herausziehen. Den neuen Dichtungsring einsetzen.

D D
e f
Extraer el segmento de compresioÂn. Volver a insertar el segmento de compresioÂn.
ESP ESP
Extraire la bague d'eÂtancheÂiteÂ. Introduire la bague d'eÂtancheÂiteÂ neuve.

F F
25
F1240111 F1240112
GB a GB b
Pull out the sealing ring of the cover. Re-insert a new sealing ring.
F1240113 F1240114
GB c GB d
Pull out the sealing ring from the motion input cover. Remove the bearing from the cover of the reduction unit.
GB e GB f
26
Estrarre l'anello di tenuta del coperchio. Reinserire il nuovo anello di tenuta.
ITA ITA
Dichtungsring des Deckels herausziehen. Den neuen Dichtungsring einsetzen.

D D
a b
Extraer el segmento de compresioÂn de la tapa. Insertar el nuevo segmento de compresioÂn.
ESP ESP
Extraire la bague d'eÂtancheÂiteÂ du couvercle. Introduire la bague d'eÂtancheÂiteÂ neuve.

F F
Estrarre l'anello di tenuta dal coperchio di ingresso del Rimuovere il cuscinetto dal coperchio riduttore.
ITA moto. ITA
Dichtungsring am Anfang der Bewegung herauszie- Lager des Reduziererdeckels entfernen.

D hen. D
c d
Extraer el segmento de compresioÂn de la tapa de Remover el cojinete de la tapa del reductor.
ESP entrada del movimiento. ESP
Extraire la bague d'eÂtancheÂiteÂ du couvercle d'entreÂe Enlever le palier du couvercle du reÂducteur.

F du mouvement. F
ITA ITA
D D
e f
ESP ESP
F F
27
ASSEMBLY OF DIRECTLY FLANGED REDUCTION GEAR 357 - ASSEMBLAGGIO GRUPPO RIDUTTORE 357 AFFLANGIATO - DIREKT GEFLANSCHTER
REDUZIERER 357 MONTIEREN - MONTAJE GRUPO REDUCTOR 357 CON BRIDA - ASSEMBLAGE DU GROUPE REDUCTEUR BRIDE 357
F1240115 F1240116
GB a GB b
Re-fit the bearing in the cover of the reduction unit using ordinary Re-insert the new sealing ring in the motion input cover.
tools.
F1240117 F1240118
GB c GB d
Re-assemble the cover, spreading LOCTITE 510 on planes and Tighten screws using a torque wrench setting of 49±51 Nm.
screws.
F1240119
GB e GB f
Lubricate the lip of the sealing ring with grease.
28
Rimontare il cuscinetto nel coperchio riduttore con i Reinserire il nuovo anello di tenuta coperchio di
ITA normali attrezzi. ITA ingresso del moto.
Lager in den Reduziererdeckel mit gewoÈhnlichen Den neuen Dichtungsring in den Deckel am Eingang
D Werkzeugen montieren. D der Bewegung montieren.
a b
Volver a montar el cojinete en la tapa del reductor con Volver a insertar el nuevo segmento de compresioÂn en
ESP las herramientas normales. ESP la tapa de entrada del movimiento.
Remonter le palier du couvercle reÂducteur aÁ l'aide Introduire la bague d'eÂtancheÂiteÂ neuve dans le
F d'outils habituels. F couvercle d'entreÂe du mouvement.
Rimontare il coperchio spalmando sui piani e sulle viti Serrare le viti con una coppia di serraggio di
ITA LOCTITE 510. ITA 49v51 Nm.
DeckelflaÈchen und -schrauben mit LOCTITE 510 Schrauben mit einem Anziehdrehmoment zu
D schmieren und montieren. D 49v51 Nm anziehen.
c d
Volver a montar la tapa engrasando las superficies y Apretar los tornillos a un par de torsioÂn de di
ESP los tornillos con LOCTITE 510. ESP 49v51 Nm.
Remonter le couvercle en eÂtalant du LOCTITE 510 sur Serrer les vis aÁ un couple de serrage de
F les surfaces et sur les vis. F 49v51 Nm.
Lubrificare con grasso il labbro dell'anello di tenuta.

ITA ITA
Dichtlippe mit Fett schmieren.

D D
e f
Lubricar con grasa el labio del segmento de compre-
ESP sioÂn. ESP
Lubrifier avec du gras la leÁvre de la bague d'eÂtan-

F cheÂiteÂ. F
29
F1240120 F1240104
GB a GB b
Re-assemble the motion upper shaft. Re-assemble the full lower shaft and the flow regulator plate.
F1240121 F1240122
GB c GB d
Position the shaft so that the bearing juts out approximately 5 mm Temporarily re-assemble the cover with screws.
from the cover of the reduction unit. (Be sure that the niche faces upwards).
F1240101 F1240100
GB e GB f
Simultaneously insert: fork and sliding blocks, coupling and flow Re-insert screws and tighten.
regulator plate.
30
Rimontare l'albero di entrata del moto. Rimontare l'albero uscita completo e la lamiera
ITA ITA frangiflusso.
Welle am Eingang der Bewegung montieren. Ganze Ausgangswelle und Strahlregler montieren.
D D
a b
Volver a montar el eje de entrada del movimiento. Volver a montar el eje de salida completo y la placa
ESP ESP deflectora.
Remonter l'arbre d'entreÂe du mouvement. Remonter l'arbre de sortie tout entier et la toÃle brise-
F F jet.
Posizionare l'albero in modo che il cuscinetto sporga Rimontare provvisoriamente il coperchio con le viti.
ITA dal coperchio riduttore circa 5 mm. ITA (Attenzione alla nicchia che deve essere rivolta verso
l'alto).
Die Welle so positionieren, daû das Lager vom VoruÈ bergehend den Deckel mit den Schrauben
D Reduziererdeckel ca. 5 mm herausragt. D montieren.
(Achtung, die Nische muû nach oben gerichtet sein).
c d
Posicionar el eje de manera que el cojinete sobresalga Volver a montar provisionalmente la tapa con los
ESP de la tapa del reductor en unos 5 mm aproximada- ESP tornillos. (Cuidado con el hueco que tiene que estar
mente. dirigido hacia arriba).
Positionner l'arbre de telle sorte que le palier saillisse Remonter provisoirement le couvercle avec les vis.
F du couvercle du reÂducteur d'environ 5 mm. F (Attention le logement doit eÃtre tourneÂ vers le haut).
Reinserire contemporaneamente: la forcella con patti- Reinserire le viti ed avvitarle.

ITA ni, il manicotto e la lamiera frangiflusso. ITA
Gleichzeitig Gabel mit Gleitschuh, HuÈlse und Strahl- Schrauben anbringen und festschrauben.
D regler montieren. D
e f
Volver a insertar contemporaÂneamente la horquilla Volver a introducir los tornillos y atornillarlos.
ESP con los patines, el manguito y la placa deflectora. ESP
ReÂinseÂrer en meÃme temps: la fourchette avec les Introduire les vis et visser.
F pattes, le manchon et la toÃle brise-jet. F
31
F1240123 F1240124
GB a GB b
Tighten screws using a torque wrench setting of 25±26 Nm. Re-assemble needle bearings, gear and distance piece.
F1240125 F1240126
GB c GB d
Check the insertion of pins. Spread LOCTITE 510 on the surface and assemble the cover.
F1240127
GB e GB f
Fasten the cover.
32
Serrare le viti con una coppia di serraggio di Rimontare i cuscinetti a rullini, l'ingranaggio ed il
ITA 25v26 Nm. ITA distanziale.
Schrauben mit einem Anziehdrehmoment zu Kugellager, Zahnrad und DistanzstuÈck montieren.

D 25v26 Nm anziehen. D
a b
Apretar los tornillos a un par de torsioÂn de Volver a montar los cojinetes de agujas, el engranaje y
ESP 25v26 Nm. ESP el separador.
Serrer les vis aÁ un couple de serrage de Remonter les paliers aÁ rouleaux, l'engrenage et
F 25v26 Nm. F l'entretoise.
Verificare l'inserimento delle spine. Spalmare la superficie con LOCTITE 510 e montare il
ITA ITA coperchio.
Einsatz der Stifte kontrollieren. FlaÈche mit LOCTITE 510 schmieren und Deckel
D D montieren.
c d
Comprobar la insercioÂn de las clavijas. Engrasar la superficie con LOCTITE 510 y montar la
ESP ESP tapa.
VeÂrifier l'introduction des broches. Enduire la surface avec du LOCTITE 510 et monter le
F F couvercle.
Mandare il coperchio in battuta.

ITA ITA
Den Deckel zum Anschlag bringen.

D D
e f
Llevar la tapa a tope.
ESP ESP
Lancer le couvercle buteÂe.

F F
33
F1240128 F1240082
GB a GB b
Tighten screws using a torque wrench setting of 49±51 Nm. Grease components and re-introduce spindle, spring and screw
Caution: tighten using the crossed method. (mechanical version).
Tighten using a max. torque wrench setting of 80±100 Nm.
F1240083 F1240081
GB c GB d
Grease components and re-introduce ball, spring and screw Fix the gear-in position switch with washer and O-ring.
(hydraulic version). Tighten with torque wrench setting of max. 54.2 Nm.
Tighten using a max. torque wrench setting of 80±100 Nm.
F1240080
GB e GB f
Assemble the sealing cover with washer and revolution indicator.
Tighten using a torque wrench setting of max. 25 Nm.
34
Serrare le viti con una coppia di serraggio di Ingrassare i componenti e reinserire il puntalino, la
ITA 49v51 Nm. ITA molla, la vite (versione meccanica). Serrare con una
Attenzione: serrare con il metodo incrociato. coppia di serraggio max. di 80v100 Nm.
Schrauben mit einem Anziehdrehmoment zu Einzelteile schmieren und Stift, Feder und Schraube
D 49v51 Nm anziehen. D einsetzen (mechanische AusfuÈhrung). Mit einem An-
Achtung: Schrauben abwechselnd im Kreuz anziehen. ziehdrehmoment zu max. 80v100 Nm anziehen.
a b
Apretar los tornillos a un par de torsioÂn de Engrasar los componentes y volver a insertar el
ESP 49v51 Nm. ESP pasador, el muelle, el tornillo (versioÂn mecaÂnica).
Cuidado: apretar con el meÂtodo cruzado. Apretar a un par de torsioÂn maÂx. dei 80v100 Nm.
Serrer les vis aÁ un couple de serrage de Graisser les composants et reÂinseÂrer la buteÂe, le
F 49v51 Nm. F ressort, la vis (modeÁle meÂcanique).
Attention: serrer avec la meÂthode croiseÂe. Serrer aÁ un couple de serrage max. de 80(100 Nm.
Ingrassare i componenti e reinserire la sfera, la molla e Montare l'interruttore di posizione marcia inserita con
ITA la vite (versione idraulica). ITA rosetta e anello OR.
Serrare con una coppia max. di 80v100 Nm. Serrare con una coppia di serraggio max. di 54,2 Nm.
Einzelteile schmieren und Kugel, Feder und Schraube Schalter fuÈr die Position der Gangschaltung mit
D einsetzen (hydraulische AusfuÈhrung). Mit einem An- D Unterlegscheibe und O-Ring montieren. Mit einem
ziehdrehmoment zu 80v100 Nm anziehen. Anziehdrehmoment zu max. 54,2 Nm anziehen.
c d
Engrasar los componentes y volver a colocar la bola, Montar el interruptor de posicioÂn marcha embragada
ESP el muelle y el tornillos (versioÂn hidraÂulica). ESP con roseta y anillo OR.
Apretar a un par maÂx. dei 80v100 Nm. Apretar a un par de torsioÂn maÂx. de 54,2 Nm.
Graisser les composants et reÂinseÂrer la spheÁre, le Monter l'interrupteur de position de vitesses incorporeÂ
F ressort et la vis (modeÁle hydraulique). F avec la rondelle et la bague OR.
Serrer aÁ un couple max. de 80v100 Nm. Serrer aÁ un couple de serrage max. de 54,2 Nm.
Montare tappo di chiusura con rosetta e rilevatore di

ITA giri. Serrare con una coppia max. di 25 Nm. ITA
Stopfen mit Unterlegscheibe und Drehzahlmesser

D montieren. Mit einem Anziehdrehmoment zu max. 25 D
Nm anziehen.
e f
Montar el tapoÂn de cierre con la roseta y el detector de
ESP revoluciones. Apretar a un par maÂx. de 25 Nm. ESP
Monter le bouchon de verrouilllage accompagneÂ de la

F rondelle et du compteur de tours. Serrer aÁ un couple F
max. de 25 Nm.
35
F1240129 F1240130
GB a GB b
Re-fit the reduction unit onto the axle by spreading LOCTITE 510 Fasten the support planes (turn flange to assist assembly).
on the planes.
F1240131 F1240132
GB c GB d
Insert screws by applying LOCTITE 510. Screw down by placing the reduction unit in a vertical position in
relation to the axis.
F1240133 F1240134
GB e GB f
Tighten screws using a torque wrench setting of 49±51 Nm. Extract screws and remove the temporarily assembled cover.
36
Rimontare il riduttore sul ponte spalmando i piani con Mandare in battuta i piani di appoggio (ruotare la
ITA LOCTITE 510. ITA flangia per facilitare il montaggio).
Reduzierer auf die Triebachse montieren; zuvor die AuflageflaÈchen bis zum Anschlag bringen (Flansch
D FlaÈchen mit LOCTITE 510 schmieren. D drehen um die Montage zu erleichtern).
a b
Volver a montar el reductor en el puente engrasando Llevar a tope las superficies de apoyo (girar la brida
ESP las superficies con LOCTITE 510. ESP para facilitar el montaje).
Remonter le reÂducteur au pont en eÂtalant sur les Lancer les surfaces d'appui en buteÂe (tourner la
F surfaces du LOCTITE 510. F flasque pour faciliter le montage).
Inserire le viti spalmandole con LOCTITE 510. Avvitare le viti posizionando il riduttore in modo
ITA ITA verticale rispetto l'asse.
Schrauben mit LOCTITE 510 schmieren und ein- Schrauben festschrauben; dabei den Reduzierer
D setzen. D senkrecht zur Achse halten.
c d
Insertar los tornillos engrasaÂndolos con LOCTITE 510. Atornillar los tornillos posicionando el reductor de
ESP ESP manera vertical con respecto al eje.
Introduire les vis en les enduisant d'abord de Visser les vis en placËant le reÂducteur verticalement par
F LOCTITE 510. F rapport aÁ l'axe.
Serrare le viti con una coppia di serraggio di Asportare le viti e rimuovere il coperchio montato
ITA 49v51 Nm. ITA provvisoriamente
Schrauben mit einem Anziehdrehmoment zu Schrauben abschrauben und voruÈbergehend montier-

D 49v51 Nm anziehen. D ter Deckel abnehmen.
e f
Apretar los tornillos a un par de torsioÂn de Sacar los tornillos y remover la tapa montada
ESP 49v51 Nm. ESP provisionalmente.
Serrer les vis aÁ un couple de serrage de Enlever les vis et enlever le couvercle provisoirement
F 49v51 Nm. F monteÂ.
37
F1240135 F1240136
GB a GB b
Fasten the bearing by using a standard tool. Measure dimension "A" between the bearing and the box plane
using an ordinary depth gauge (if parts are not replaced, use
disassembled distance washers).
S
F1240137 F1240138
GB c GB d
Measure dimension "B" on the cover, between the bearing plane Apply LOCTITE 510 on the surface, lubricate the sealing ring,
and bearing support. Calculate the dimension of the distance insert the distance washers and re-assemble the cover with niche
washers required: facing upwards.
S=Dimension B Ð Dimension A
Es: B=5.2±A=4.6 mm ± Backlash 0.2±0.3=Distance washer
required=0.4±0.3.
F1240139
GB e GB f
Fit screws after applying LOCTITE 510.
38
Mandare in battuta il cuscinetto utilizzando un Rilevare la quota "A" fra cuscinetto e piano scatola
ITA normale attrezzo. ITA usando un normale calibro di profonditaÁ.
(Se non vengono sostituiti pezzi, utilizzare gli spessori
smontati).
Das Lager bis zum Anschlag bringen; dazu ein Maû "A" zwischen Lager und SchachtelflaÈche mit
D gewoÈhnliches Werkzeug verwenden. D einem gewoÈhnlichen Kaliber messen (wenn keine
Teile ausgewechselt werden, die abmontierten Di-
stanzstuÈcke verwenden).
a b
Llevar a tope el cojinete utilizando una herramienta Registrar la cota "A" entre el cojinete y la superficie de
ESP normal. ESP la caja utilizando un normal calibre de profundidad.
(Si no se sustituyen las piezas, utilizar los espesores
desmontados).
Lancer en buteÂe le palier aÁ l'aide d'un outil normal. Relever la cote "A" entre palier et surface de la boõÃte aÁ
F F l'aide d'un calibre de profondeur normal (S'il n'y a pas
de pieÁces aÁ remplacer, utiliser les cales deÂmonteÂes).
Rilevare la quota "B" sul coperchio fra piano e Spalmare la superficie con LOCTITE 510, lubrificare
ITA appoggio cuscinetto. Calcolare gli spessori da inserire ITA l'anello di tenuta, inserire gli spessori e rimontare il
S=Quota B±Quota A coperchio con la nicchia rivolta verso l'alto.
Es: B=5,2±A=4,6 mm ± Gioco 0,2v0,3= Spessore da inseri-
re=0,4v0,3
Maû "B" am Deckel zwischen FlaÈche und Auflage- FlaÈche mit LOCTITE 510 schmieren; Dichtungsring
D flaÈche des Lagers messen. Die einzulegenden Di- D schmieren; DistanzstuÈcke einsetzen und Deckel mit
stanzstuÈcke ausrechnen. S=Maû B±Maû A Nische nach oben gerichtet, montieren.
Bsp: B=5,2±A=4,6 mm ± Spiel 0,2v0,3=einzusetzende Distanz-
c stuÈcke=0,4v0,3 d
Registrar la cota "B" en la tapa entre la superficie y el Engrasar la superficie con LOCTITE 510, lubricar el
ESP soporte del cojinete. Calcular los espesores que hay ESP segmento de compresioÂn, insertar los espesores y
que insertar S = Cota B±Cota A volver a montar la tapa con el hueco dirigido hacia
Es: B=5,2±A=4,6 mm ± Juego 0,2v0,3= Espesor a inser- arriba.
tar=0,4v0,3
Relever la cote "B" sur le couvercle entre surface et Enduire la surface de LOCTITE 510, lubrifier la bague
F support palier. Calculer le nombre de cales aÁ F d'eÂtancheÂiteÂ, introduire les cales et remonter ensuite
introduire S=Cote B±Cote A le couvercle avec le logement tourneÂ vers le haut.
Exp: B=5,2±A=4,6 mm ± Jeu 0,2v0,3=Cales aÁ introduire
=0,4v0,3
Inseire le viti dopo everle spalmate con

ITA LOCTITE 510. ITA
Schrauben einsetzen; zuvor mit LOCTITE 510

D schmieren. D
e f
Introducir los tornillos despueÂs de engrasarlos con
ESP LOCTITE 510. ESP
Introduire les vis apreÁs les avoir enduites de

F LOCTITE 510. F
39
F1240140 F1240141
GB a GB b
Tighten screws using a torque wrench setting of 49±51 Nm. Assemble flange, O-ring and nut using LOCTITE 242.
F1240142 F1240143
GB c GB d
Screw down the nut of the flange. Tighten the nut using a torque wrench setting of 260±280 Nm.
F1240144 F1240069
GB e GB f
Re-fix the protection plate after applying LOCTITE 510. Complete flanged reduction gear 357 with mechanical gear control.
40
Serrare le viti con una coppia di serraggio di Montare la flangia, l'anello OR e il dado con
ITA 49v51 Nm. ITA LOCTITE 242.
Schrauben mit einem Anziehdrehmoment zu Flansch, O-Ring und Mutter mit LOCTITE 242
D 49v51 Nm anziehen. D schmieren und montieren.
a b
Apretar los tornillos a un par de torsioÂn de Montar la brida, el anillo OR y la tuerca con
ESP 49v51 Nm. ESP LOCTITE 242.
Serrer les vis aÁ un couple de serrage de Monter la flasque, la bague OR et l'eÂcrou enduit de
F 49v51 Nm. F LOCTITE 242.
Avvitare il dado della flangia. Serrare il dado con una coppia di serraggio di
ITA ITA 260v280 Nm.
Flanschmutter festschrauben. Mutter mit einem Anziehdrehmoment zu

D D 260v280 Nm anziehen.
c d
Atornillar la tuerca de la brida. Apretar la tuerca a un par de torsioÂn de
ESP ESP 260v280 Nm.
Visser l'eÂcrou de la flasque. Serrer l'eÂcrou aÁ un couple de serrage de

F F 260v280 Nm.
Rimontare lamiera di protezione dopo everla spalmata Gruppo riduttore 357 afflangiato con comando marcia
ITA con LOCTITE 510. ITA meccanico completo.
Schutzblech mit LOCTITE 510 schmieren und mon- Ganzes direkt geflanschter Reduzierer 357 mit me-
D tieren. D chanischer Gangschaltung.
e f
Volver a montar la placa de proteccioÂn despueÂs de Grupo reductor 357 con brida con mando de marcha
ESP engrasarla con LOCTITE 510. ESP mecaÂnico completo.
Remonter la toÃle de protection apreÁs l'avoir enduite de Groupe reÂducteur brideÂ 357 aÁ commande de vitesses
F LOCTITE 510. F meÂcanique complet.
41
F1240145 F1240144
GB a GB b
Re-assemble all the parts of the gear control cylinder, according to Re-fix the protection plate after applying LOCTITE 510 on it.
their arrangement.
F1240146 F1240147
GB c GB d
Re-fit the gear control cylinder into place with its O-ring. Re-fit screws and screw down.
F1240148
GB e GB f
Re-introduce the gear control rod after applying LOCTITE 242 on it.
42
Rimontare tutti i particolari del cilindro comando Rimontare lamiera di protezione dopo averla spalmata
ITA marcia come disposti in ordine. ITA con LOCTITE 510.
Alle Einzelteile des Zylinders des Gangschalters der Schutzblech mit LOCTITE 510 schmieren und mon-
D Reihenfolge nach montieren. D tieren.
a b
Volver a montar todas las piezas del cilindro mando Volver a montar la placa de proteccioÂn despueÂs de
ESP marcha dispuestos en su orden. ESP engrasarla con LOCTITE 510.
Remonter toutes les pieÁces du cylindre de commande Remonter la toÃle de protection apreÁs l'avoir enduite de
F de vitesses placeÂ dans l'ordre. F LOCTITE 510.
Rimontare il cilindro comando marcia completo di Reinserire le viti ed avvitarle.

ITA anello OR. ITA
Zylinder des Gangschalters mit O-Ring montieren. Schrauben einsetzen und festschrauben.
D D
c d
Volver a montar el cilindro mando marcha completo de Volver a introducir los tornillos y atornillarlos.
ESP anillo OR. ESP
Remonter le cylindre de commande de vitesses Introduire les vis et visser.

F complet de bague OR. F
Reinserire asta di comando marcia dopo averla

ITA spalmata con LOCTITE 242. ITA
Gangschalterhebel mit LOCTITE 242 schmieren und

D montieren. D
e f
Volver a insertar la varilla de mando de la marcha
ESP despueÂs de engrasarla con LOCTITE 242. ESP
Introduire la tringle de commande de vitesses apreÁs

F l'avoir enduite de LOCTITE 242. F
43
INSTALLATION OF HYDRAULIC GEAR CONTROL - INSTALLAZIONE COMANDO MARCIA IDRAULICO - HYDRAULISCHER GANGSCHALTUNG
MONTIEREN - MONTAJE MANDO MARCHA HIDRAULICO - INSTALLATION DE LA COMMANDE DE VITESSES HYDRAULIQUE
F1240149 F1240150
GB a GB b
Tighten the gear control rod using a torque wrench setting of Tighten gear control cylinder screws using a torque wrench setting
25±26 Nm. of 49±51 Nm.
GB c GB d
GB e GB f
44
Serrare asta di comando marcia con una coppia di Serrare le viti cilindro comando marcia con una coppia
ITA serraggio di 25v26 Nm. ITA di serraggio di 49v51 Nm.
Den Gangschalterhebel mit einem Anziehdrehmoment Die Zylinderschrauben des Gangschalters mit einem
D zu 25v26 Nm anziehen. D Anziehdrehmoment zu 49v51 Nm anziehen.
a b
Apretar la varilla de mando a un par de torsioÂn de Apretar los tornillos de mando de la marcha a un par
ESP 25v26 Nm. ESP de torsioÂn de 49v51 Nm.
Serrer la tringle de commande de vitesses aÁ un couple Serrer les vis du cylindre de commande de vitesses aÁ
F de serrage de 25v26 Nm. F un couple de serrage de 49v51 Nm.
ITA ITA
D D
c d
ESP ESP
F F
ITA ITA
D D
e f
ESP ESP
F F
45
Copyright 2010 Dana Holding Corporation For product inquiries or support,
All content is subject to copyright by Dana and may not visit www.dana.com or call 419-887-6445
be reproduced in whole or in part by any means, For other service publications,
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THIS INFORMATION IS NOT INTENDED FOR SALE OR For online service parts ordering,
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COPIES.
SWIVEL JOINT TYPE: 532
TB175W
TB175W REV. 1
REV. 1 1 TB175W
TB175W 2 REV. 1
REV. 1 3 TB175W
INSTALLATION INSTRUCTIONS
532 044 001
7-way swivel joint for hydrau-
lic applications
Application The introduction of dust and spray interferes with labyrinths

As rotating line connector for introducing hydraulic fluid 9 and 2 at the interface between housing 12 and rotor 11.
from at-rest to rotating machine parts. Example: in hydrau-
lic excavators to transfer energy from the rotatable upper Cover 8 has a seat for fitting a rotating connector. This
assembly with pumps and control blocks to the lower makes it possible to introduce hydraulic and compressed air
assembly with hydraulic motors for driving and hydrostatic with a perfect separation of media within the swivel joint.
linkages.
Installation instructions
Other applications upon request. The swivel joint is attached to flange 13 with adapter 14 and
fastened with three M16 bolts. The line connectors can then
Principles of operation attach to the tubes.
Rotor 11 in housing 12 is maintained in the axial direction
by cover 8. Channels 5 run from connectors 7 on the upper In the housing, there should be adequate play between
side of the housing to toroidal chambers 4 which are sealed connector 6 and the fork. Line connectors must be flexible,
from each other by special gaskets 10. Each toroidal cham- i.e., hoses. Additional sideways loads on the swivel joint
ber 4 is connected to a radial connector 1 in rotor 11 by an must be avoided.
axial bore 3.
Slight leakage is possible between toroidal chambers when
no pressure is present. This drains away in a common
leakage channel. If the hydraulic circuits are separate, a
common oil container will be needed.
TB175W 4 REV. 1
532 044 001
The oil which leaks provides continuous lubrication for the
bearing between the rotor and the housing and must be filled
with oil before start-up. The swivel joint is installed verti-
cally, with the axial connectors facing upwards. Contact the
company for information on horizontal installation.
Warning!
During assembly, the oil line (no. 0) must be filled with
hydraulic oil.
The swivel joint and the attached hydraulic system must be

bled before start-up.
Service
If the operating instructions in the installation drawings are
observed, no maintenance will be necessary.
Installation drawing
532 044 000 2
These installation instructions correspond to the present state of knowledge and are subject to revision. Grau accepts no
responsibility for application beyond those covered n these installation instructions. Special consultation is required in these
cases.
Changes in accordance with technical progress are reserved. Changes, even with our consent, must be authorized by our
modification department.
REV. 1 5 TB175W
APPLICATION
As swivel joint between moving and rotating machine parts.
Use preferably as part of a Grau combination swivel joint for

independent support of different circuits such as work and pre-control
hydraulics.
Some designs have a central bore for a cable. In these cases, fixing threads
are located in the cover for a slip ring mount.
OPERATION
The rotatable bearing supported rotor 2 in the housing is held in the
axial plane by cover 5.
Connectors 6 in the housing are connected by toroidal chambers 4,

axial bores 7 and intermediate piece 9 to connectors 11 in the
connector unit.
There is a seal between toroidal chambers 4 by means of gaskets 3, by

gaskets 8 between rotor 2 and intermediate piece 9, and by gaskets 10
between rotor 10 and connector 13.
TB175W 6 REV. 1
Before mounting the swivel joint on a Grau swivel joint for hydraulic applications, connector 13 must be removed by loosening
bolts 12 (by about 2 turns). The swivel joint mount is then placed with intermediate piece 9 through the central bore of the swivel
joint for hydraulic applications and fastened with the flange bolts.
Finally, connector 13 is slid with seals held in place by bolts 12 over the protruding intermediate piece 9, with the locator pin
sitting in the correct position in the connector.
Bolts 12 are tightened again to secure connector piece 13 and to seal the connectors.
Make sure there is sufficient play between the housing mount and the counter-piece.
There must be no tension when the tubes are connected, preferably with hose connectors. Additional lateral loads on the rotating
connector induced by too short or inflexible hoses must be avoided.
MAINTENANCE
If the installation instructions are observed to the letter, no maintenance will be required.
INSTALLATION DRAWING
532 124 000 2
These installation instructions correspond to the present state of knowledge and are subject to revision. Grau accepts no
responsibility for application beyond those covered n these installation instructions. Special consultation is required in these
cases.
Changes in accordance with technical progress are reserved. Changes, even with our consent, must be authorized by our
modification department.
REV. 1 7 TB175W
TB175W 8 REV. 1
REV. 1 9 TB175W
TB175W 10 REV. 1
V . TROUBLESHOOTING
V-1 TB175W
TROUBLESHOOTINTG
CAUTIONS IN TROUBLESHOOTING AND REPAIRS
(1) Do not begin disassembling the equipment immediately just because it has broken down.
Conduct a thorough preliminary check before attempting disassembly.
a. Ask the user the following questions.
• What were the conditions when the machine broke down?
• Did anything abnormal happen before breakdown occurred?
• Are there any other places which were functioning poorly other than the part that broke
down?
• Are there any parts which have been repaired previous to the breakdown? What were
they?
• Has the same thing happened before?
b. Run the machine yourself and confirm the breakdown conditions.
• Judge whether the machine is really broken down or not following the judgment
standards.
The judgment on whether the machine has broken down may differ between individu-
als.
IMPORTANT: When running the machine, it is possible that moving the machine could
make the breakdown worse than it already is, so do not forget to ask the user if there is
anything to prevent your operating the machine.
c. Based on the information that you have gathered from the user and the information
obtained from running the machine yourself, judge the cause of the trouble. Also keep in
mind that it is difficult to reproduce the conditions of the breakdown again once the
machine has been disassembled, and early disassembly may make it impossible to
determine the true cause of the trouble. Therefore be sure to find the true cause of the
trouble before attempting disassembly.
(2) When it is thought that the trouble has more than one cause, begin investigating from the
simplest cause.
(3) Think over why the trouble could have occurred and try to correct the root cause of that
problem.
TB175W V-2
TROUBLESHOOTINTG
CONTENTS
OVERALL MACHINE
No operations can be done. ................................................................................................................................... 4
All operations can be done, but there is no power. ............................................................................................... 5
The boom, bucket, slew and arm do not move at all, or the speed is low. ............................................................ 7
SLEWING
No slewing can be done. ........................................................................................................................................ 9
Right or left slewing cannot be done. .................................................................................................................. 12
Slewing speed is low, or there is no power. ........................................................................................................ 14
The machine slews, but overrun when slewing stops is great, or it cannot be stopped. ..................................... 16
Slewing in slow gear is not possible .................................................................................................................... 18
BOOM
The boom cylinder doesn’t move. ....................................................................................................................... 20
Boom cylinder operation is slow, or there is no power. ...................................................................................... 22
When the boom operation lever is pulled gently, the boom drops temporarily. ................................................. 25
The amount of boom natural drop is great. ......................................................................................................... 26
The boom adjustment cylinder doesn’t move ..................................................................................................... 27
ARM
The arm cylinder doesn’t move. .......................................................................................................................... 30
Arm cylinder operation is slow, or there is no power. ........................................................................................ 32
The amount of arm natural drop is great. ............................................................................................................ 34
BUCKET
The bucket cylinder doesn’t move, or there is no power. ................................................................................... 35
The amount of bucket natural drop is great. ........................................................................................................ 37
BOOM SWING
The swing cylinder doesn’t move. ....................................................................................................................... 38
V-3 TB175W
TROUBLESHOOTINTG OVERALL MACHINE
NO OPERATIONS CAN BE DONE.
Inspect the hydraulic oil Insufficient Replenish the hydraulic

1 2
level. oil.
Proper Amount
• Repair the pump or replace

Pump or coupling is
3 the pump.
faulty.
• Replace the coupling.
1. Inspect the hydraulic oil level.

“III. Machine Configuration, Hydraulic
Tank”
2. Replenish the hydraulic oil.

Take out the plug and replenish the hydraulic oil.
• The hydraulic oil supplied should be the same
brand as the oil currently in the tank.
“II. Specifications, Fluid Capacities”
3. Pump or coupling is faulty.

a. Disconnect the discharge hose from the pump
side.
Also fit a plug in the disconnected hose to keep
the hydraulic oil from pouring out.
b. With the engine emergency stop knob pulled
out all the way, turn the start switch to the
“START” position to cause the engine to begin
cranking. Check that the hydraulic oil is dis-
charged from the pump at this time.
If the pump is normal, hydraulic oil will be
discharged from it. If hydraulic oil is not dis-
charged, the pump or the coupling is faulty.
TB175W V-4
OVERALL MACHINE TROUBLESHOOTINTG
ALL OPERATIONS CAN BE DONE, BUT THERE IS NO POWER.
Inspect the hydraulic oil Insufficient Replenish the hydraulic

1 2
level. oil.
Proper Amount
Noise generated by the Noise Replace the seal tape, O-rings,

3 Suction line is faulty.
pump. hose.
No Noise
Bubbles from inside Treat beginning at the source

the tank. of the bubbling.
Inspect the main relief Faulty Repair or replace the main

4
valve. relief valve.
Normal
• Repair or replace the pump.

5 Pump is faulty.
• Flush with hydraulic oil.
1. Inspect the hydraulic oil level.
2. Replenish the hydraulic oil.

“V-4”
3. Noise generated by the pump.

A faulty suction line can make it easy for cavita-
tion to occur in the pump and for noise to be
generated. Carry out the following inspect.
a. Inspect the piping used for suction of hydraulic
oil.
• Apply grease or oil to the part which appears
to be making the noise and inspect if there is
any change. (Inspect if it is sucking in air or
not.)
b. Inspect for clogging of the suction filter.
V-5 TB175W
4. Inspect the main relief valve.

Measure the relief pressure of the main relief
valve.
• The valve is normal if the pressure gauge
reading is the standard value.
“ II. Specifications, Standards for Judging
Performance”
If the main relief valve’s set pressure is too low,

adjust it by tightening the valve set screw gradu-
ally.
“II. Specifications, Standards for Judging
Performance”
5. Pump is faulty.
If the pump is abnormally worn internally, or if it
is damaged, it is possible that pieces of metal are
mixed into the hydraulic oil. Therefore, carry out
the following treatment.
• Replace the spin filter cartridge.
• Replace the hydraulic oil or flush out the
hydraulic circuit.
(Up to NAS Class 9)
Caution : When replacing the hydraulic oil, be

sure to clean the inside of the Hydraulic Tank and
the suction strainer.
If the pump seal is damaged, replace the seal.

“IV. Hydraulic Units, Hydraulic Pump”
TB175W V-6
OVERALL MACHINE TROUBLESHOOTINTG
THE BOOM, BUCKET, SLEW AND ARM DO NOT MOVE AT ALL, OR THE SPEED IS LOW.
Inspect the hydraulic Faulty Repair or replace the hydrau-

1
pump P5. lic pump P5.
Normal
Faulty
2 Inspect the fuse. Replace the fuse.
Normal
Faulty Adjust or replace the limit

3 Inspect the limit switch.
switch.
Normal
Inspect the lever lock so- Faulty Repair or replace the lever lock
4
lenoid valve. solenoid valve.
Normal
Inspect the pilot relief Faulty Adjust, repair or replace the

5
valve. pilot relief valve.
Normal
Faulty Repair or replace the pilot

6 Inspect the pilot valve.
valve.
1. Inspect the hydraulic pump P5.

Inspect the hydraulic pump P5 which is the source
of the hydraulic pressure for the pilot valve.
“V-4”
Since clogging of the line filter can also be con-
sidered, inspect and clean the filter.
V-7 TB175W
2. Inspect the fuse.

Inspect the fuse for the electric power circuit that
operates the pilot solenoid valve.
10
10
20
10
10
20
10
20
10
5
10
5
20
20
10
20
W2E003
3. Inspect the limit switch.

Set the lever stand to the operation position to turn
on the limit switch. Check the voltage at the lever
lock solenoid valve by using a tester.
• The limit switch is normal if the voltage is
being applied.
Reference: If the limit switch is found to be faulty
and the attachment must be moved, connect the
lever lock release connectors (male) and (female)
for emergency use.
4. Inspect the lever lock solenoid valve.

Inspect by the following procedure.
a. Turn the starter switch to the “ON” position.
b. Push lightly on the projection on the front end
of the solenoid valve.
c. Move the lever stand and change the limit
switch from “OFF” to “ON”.
d. If the spool moves and vibration can be felt
with the fingertip when the circuit changes,
then it is normal.
5. Inspect the pilot relief valve.

Measure the relief pressure of the pilot relief
valve.
• If the pressure is the standard value, the valve
is normal.
Performance”
6. Inspect the pilot valve.

“IV. Hydraulic Units, Pilot Valve”
TB175W V-8
SLEWING TROUBLESHOOTINTG
NO SLEWING CAN BE DONE.
Inspect the operation of

1 actuators other than the
slew motor.
Normal

valve.
Normal
Faulty Repair or replace the shuttle

3 Inspect the shuttle valve.
valve.
Normal
Inspect the operation of Faulty Repair or replace the housing

4
the spool. block.
Normal
Inspect the slew hydrau- Pressure is low. Adjust the slew relief
5 Adjust the set pressure.
lic pressure. valve pressure.
Normal
Pressure does not rise Repair or replace the slew re-

lief valve.
Faulty Repair or replace the slew

6 Inspect the slew motor.
motor.
Normal
The slew bearing is faulty. Replace.
1. Inspect the operation of actuators other than

the slew motor.
Inspect if the operation of the slew motor only is Lever Operated Places inspected
faulty by the table at right. If its operation is
Dozer Blade Relief Valve R3 Pump P3
faulty, inspect the main relief valve and the hy-
draulic pump.
“V-6”
V-9 TB175W
TROUBLESHOOTINTG SLEWING

Disconnect the hose between the pilot valve and
control valve (slew section) at the control valve
side, then set a pressure gauge in the disconnected
hose.
• A plug should be inserted in the control valve
port.
• Operate the lever (slew) and measure the pres-
sure.
• Depending on the operating angle, a pressure
in the 0~3.4 MPa range is normal.
3. Inspect the shuttle valve.

Disconnect the hose that goes between the shuttle
valve and the slew motor at the slew motor side
and set a pressure gauge to the disconnected hose.
sure.
• The shuttle valve is normal if between 0 and
3.4 MPa corresponding to the operation angle.
L3E004
4. Inspect the operation of the spool.

Disconnect the hose that goes between the control
valve (slew section) and the slew motor at the
valve side and set a pressure gauge to the dis-
charge port of the valve.
sure.
• The operation of the spool is normal if it agrees
with the following value of supply pressure:
23.5 MPa
5. Inspect the slew hydraulic pressure.

Measure the pressure at the left and right slew
relief valves.
• The pressure is normal if it is the standard
value.
Performance”
If adjustment of the pressure is possible, the slew
relief valve’s adjustment is faulty. Also, if the
pressure adjustment is impossible, the slew relief
valve is faulty.
TB175W V-10
6. Inspect the slew motor.
Separate the slew motor (1) and the turntable (2),
then try turning the turntable (2).
• Turntable doesn’t turn .... Faulty slew bearing (3).
• Turntable turns................ Faulty slew motor (1).
“IV. Hydraulic Units, Slew Motor”
V-11 TB175W
RIGHT OR LEFT SLEWING CANNOT BE DONE.

valve.
Normal

2
the spool. block.
Normal
Inspect the slew relief Faulty Repair or replace the slew re-
3
valve. lief valve.
Normal
Inspect the check valve Faulty Repair or replace the slew

4
of the slew brake valve. brake valve.
Normal
Repair or replace the slew

5 The slew motor is faulty.
motor.

It could be that the spool for only the side of the
pilot valve for which slewing is impossible will
not operate.
“V-10”

It could be that the spool will not move only in the
direction in which slewing is impossible.
“V-10”
TB175W V-12
3. Inspect the slew relief valve.
Try switching the left and right slew relief valves.
If slewing becomes possible, the relief valve is
faulty.
4. Inspect the check valve of the slew brake

valve.
If foreign matter is caught in one end of the check
valve (1), or if the valve is sticking, right or left
slewing will be impossible.
• If foreign matter is caught in one of the check
valves, the hydraulic oil returns to the tank
from the check valve.
1 L3E005
5. The slew motor is faulty.

V-13 TB175W
SLEWING SPEED IS LOW, OR THERE IS NO POWER.
Is the time needed for Within the standard.

1 slewing within the stan- Normal
dard?
Not within the standard

valve.
Normal

3
the spool. block.
Normal
Inspect the slew hydrau- Pressure is low. Adjust the pressure of

lic pressure. the slew relief valve.
Normal
Pressure does not rise. Repair or replace the slew re-

lief valve.
Inspect the check valve Faulty Repair or replace the slew

5
of the slew brake valve. brake valve.
Normal
Faulty Repair or replace the slew

6 Inspect the slew motor.
motor.
Normal
The slew bearing is faulty. Replace.
TB175W V-14
1. Is the time needed for slewing within the
standard?
Performance”

“V-10”

“V-10”

“V-10”
5. Inspect the check valve of the slew brake

valve.
6. Inspect the slew motor.

V-15 TB175W
THE MACHINE SLEWS, BUT OVERRUN WHEN SLEWING STOPS IS GREAT, OR IT CANNOT BE STOPPED.
Is the amount of overrun Within the standard.

1 when slewing stops Normal.
within the standard?
Not within the standard.

valve.
Normal

3
the spool. block.
Normal
Inspect the slew hydrau- Pressure is low. Adjust the pressure of

lic pressure. the slew relief valve.
Normal
Pressure doesn’t rise Repair or replace the slew re-

lief valve.
Inspect the slew brake Repair replace the slew brake

5
valve. valve.
1. Is the amount of overrun when slewing stops

within the standard?
Performance”

Inspect if the spool of the pilot valve returns to the
neutral position when the operation lever (slew)
is released after operation. Disconnect the hose
between the pilot valve and the control valve
(slew section) on the control valve side, then set
a pressure gauge in the disconnected hose.
• Read the pressure gauge after operating the
lever (slew), then releasing it.
• If the pressure is zero, the pilot valve is normal.
TB175W V-16
Inspect if the spool of the control valve (slew
section) returns to the neutral position when the
operation lever (slew) is released after operation.
Disconnect the line from the slew section of the
control valve, then set a pressure gauge in its
supply port.
• Read the pressure gauge after operating the
lever (slew), then releasing it.
• If the pressure is zero, the pilot valve is normal.

“V-10”
5. Inspect the slew brake valve.

V-17 TB175W
SLEWING IN SLOW GEAR IS NOT POSSIBLE.
Inspect the hydraulic Faulty Repair or replace the hydrau-

1
pump P5. lic pump P5.
Normal
Inspect the pilot relief Faulty Adjust, repair or replace the

2
valve. pilot relief valve.
Normal
Inspect the slow slew Faulty Replace the slow slew switch.
3
switch
Normal
Inspect the slow slew Faulty Repair or replace the slow slew
4
solenoid valve. solenoid valve.
Normal
Inspect the slew flow Faulty Repair or replace the slew flow
5
control valve. control valve.
1. Inspect the hydraulic pump P5.

Inspect the hydraulic pump P5 which is the source
of the hydraulic pressure for switching to slow
gear.
“V-4”
Since clogging of the line filter can also be con-
sidered, inspect and clean the filter.
2. Inspect the pilot relief valve.

Measure the relief pressure of the pilot relief
valve.
• If the pressure is the standard value, the valve
is normal.
“II. Specifications Standards for Judging
Performance”
3. Inspect the slow slew switch.

Press the switch to obtain “ON” condition. The
switch is normal when the lamp lights in this
condition.
TB175W V-18
4. Inspect the slow slew solenoid valve.
a. Turn the start switch “ON”.
b. Press the protruding portion of the solenoid
valve lightly.
c. Turn the slow slew switch “ON”.
d. If the spool moves and vibration can be felt
with the fingertip when the circuit changes,
then it is normal.
5. Inspect the slew flow control valve.

Inspect if the spool of the slew flow control valve
moves smoothly.
• Remove the spool cover at the FC port and try
pushing the spool with a finger. It is normal if
it moves smoothly about 9 mm.
V-19 TB175W
TROUBLESHOOTINTG BOOM
THE BOOM CYLINDER DOESN’T MOVE.

boom cylinder.
Normal

valve.
Normal

3
the spool. block.
Normal
Operation
Perform a port relief became normal. The port relief valve is Repair or replace the port re-
4
valve switching test. faulty. lief valve.
Does not change.
Inspect the boom cylin- Faulty Repair or replace the boom

5
der. cylinder.

the boom cylinder.
Inspect if the operation of the boom cylinder only Lever Operated Places inspected
is faulty by the table at right. If its operation is
faulty, inspect the main relief valve and the hy- Bucket Relief Valve R1 Pump P1
draulic pump.
“V-6”
TB175W V-20
BOOM TROUBLESHOOTINTG
Disconnect the hose between the pilot valve and
control valve (boom section) on the control valve
hose.
• Operate the (boom) lever and measure the
pressure.
• Depending the operation angle, if the pressure
is normal, it will range between 0~3.4 MPa.
W2E004

Disconnect the hose between the control valve
(boom section) and the cylinder on the cylinder
hose.
• Operate the (boom) lever and measure the
pressure.
• A pressure of 27.5 MPa is normal.
W2E005
4. Perform a port relief valve switching test.

Switch the port relief valve for the port relief
valve of the normal arm. If the boom cylinder
operates, the boom side port relief valve is faulty.
W2E006
5. Inspect the boom cylinder.

a. Disconnect the hose between the control valve
and the boom cylinder on the control valve
side.
b. Connect the disconnected hose to the arm
section or the bucket section.
c. Try operating the boom cylinder. If the cylin-
der doesn’t operate, the cylinder is faulty.
When performing the operation in “a~c”
above, the bucket cylinder should be fully W1-E004
extended, the arm cylinder should be fully

retracted and the bucket should be lowered
to the ground.
V-21 TB175W
BOOM CYLINDER OPERATION IS SLOW, OR THERE IS NO POWER.
Is the boom cylinder’s Within the standard.

1 speed within the stan- Normal
dard?

valve.
Normal

3
the spool. block.
Normal
Operation
4
Does not change
Inspect the boom cylin- Faulty Repair or replace the boom

5
der. cylinder.
1. Is the boom cylinder’s speed within the stan-

dard?
Performance”

“V-21”

Stroke the spools of the boom [1] and boom [2]
sections and inspect whether they move smoothly,
or remove the spools and check whether there is
any foreign matter engaged in them.

“V-21”
L3E007
TB175W V-22
BOOM TROUBLESHOOTINTG
5. Inspect the boom cylinder.
Boom Cylinder internal Leakage Inspect (1)
a. With the bucket cylinder fully retracted and
with the rod of the arm cylinder a little ex-
tended from the fully retracted position, lower
the bucket front end to the ground.
W1-E005
b. Disconnect the rod side hose (A) only and let

the oil in the piping run out.
Insert a plug (1) in the disconnected hose.
• Test the left and right cylinders one at a
time. Remove both hoses from the cylinder
that is not being inspected at this time and
plug the disconnected hoses.
1
A
L3E008
c. Retract the arm cylinder and lift the bucket so

it is floating above the ground.
At this time, if there is oil leaking from the
piping of the cylinder where the hose was
disconnected, and if the boom cylinder’s rod is
retracted, the cylinder is leaking internally.
Also, if there is no leakage of oil from the
cylinder’s piping, if the boom cylinder’s rod is
retracted, the control valve is leaking inter-
nally. W1-E006
Boom Cylinder Internal Leakage Inspect (2)

a. Place the machine in the posture shown in the
figure.
W1-E008
V-23 TB175W
b. Disconnect the head side hose (B) and let the

hydraulic oil out of the cylinder’s piping.
Insert a plug (2) in the disconnected hose.
• Test the left and right cylinders one at a
time. Remove both hoses from the cylinder
that is not being inspected at this time and
plug the disconnected hoses.
L3E009
c. Operate the bucket and raise the machine’s

body.
At this time, if there is oil leaking from the
piping of the cylinder where the hose was
disconnected, and if the boom cylinder’s rod is
extended, the cylinder is leaking internally.
Also, if there is no leakage of oil from the
cylinder’s piping, if the boom cylinder’s rod is
extended, the control valve is leaking inter-
nally.
If the cylinder is damaged internally, the

system should be flushed out to remove any W1-E008
broken pieces (NAS Class 9).
TB175W V-24
BOOM TROUBLESHOOTING
WHEN THE BOOM OPERATION LEVER IS PULLED GENTLY, THE BOOM DROPS TEMPORARILY.
Inspect the load check Faulty Repair or replace the housing

1
valve of the control valve. block.
Normal
Inspect for internal leak- Faulty Repair or replace the boom

2
age in the boom cylinder. cylinder.
1. Inspect the load check valve of the control

valve.
a. Disconnect the hose between the control valve
and boom cylinder at the control valve side.
b. Connect the disconnected hose to the arm or
bucket section.
c. Try operating the boom cylinder.
If operation is normal, the load check valve is
faulty.
Place the machine in the following posture

when performing the operation in “a~c” above.
• The bucket cylinder should be fully ex-
tended, the arm cylinder should be fully
retracted and the bucket should be low-
ered to the ground.
Reference: When the spool first starts to pull, the

oil’s pressure and flow are small, so if the load
check valve is faulty, it causes a load to bear on the
boom cylinder, which causes the oil to flow
backwards for a time. For this reason, the boom
will drop temporarily.
2. Inspect for internal leakage in the boom

cylinder.
When the boom cylinder’s piston or tube is faulty,
if oil is leaking from the head side (A) to the rod
side (B), since the oil’s pressure and flow are low
when the spool first starts pulling, the boom
cylinder will drop temporarily. Also, the cylinder
will have inadequate driving force. However, in
this case as well, the amount of natural drop will
be great.
• Cylinder Inspect
“V-23~24”
V-25 TB175W
TROUBLESHOOTING BOOM
THE AMOUNT OF BOOM NATURAL DROP IS GREAT.
Is the amount of natural Within the standard.

1 Normal
fall within the standard?
Inspect for internal leak- Faulty Repair or replace the boom

2
age in the boom cylinder. cylinder.
Normal
Operation be-
Perform a port relief came normal. The port relief valve is Repair or replace the port re-
3
Does not change.
The control valve is leaking

Replace the housing block.
internally.
1. Is the amount of natural drop within the

standard?
Performance”
2. Inspect for internal leakage in the boom

cylinder.
“V-23~24”

“V-21”
TB175W V-26
THE BOOM ADJUSTMENT CYLINDER DOESN’T MOVE.
Inspect the supply pres-

1 sure to the pilot valve
(swing).
Normal
Inspect the pilot valve Faulty Repair or replace the pilot

2
(swing). valve (swing).
Normal

3
the spool. block.
Normal
Faulty Repair or replace the selector

4 Inspect the selector valve.
valve.
Normal
Inspect the port relief Faulty Repair or replace the port rerief
5
valve. valve.
Normal
Inspect the boom adjust- Faulty Repair or replace the boom

6
ment cylinder. adjustment cylinder.
1. Inspect the supply pressure to the pilot valve 5Pb1
(swing).
“V-7~8”
2. Inspect the pilot valve (swing).

Disconnect the hose between the pilot valve
(swing) and control valve on the control valve 5Pa1

hose.
• Operate the boom swing pedal and measure the
pressure. BS2
• Depending the operation angle, if the pressure

BS1
is normal, it will range between 0~3.4 MPa. W2E007
V-27 TB175W
TROUBLESHOOTING BOOM

Disconnect the hose between the control valve SH
(swing section) and the selector valve on the

selector valve side, then set a pressure gauge in
the disconnected hose. 5B1
• Operate the boom swing pedal and measure the 5A1
SR
pressure. OP2
• A pressure of 27.5 MPa is normal. MA1

MA2
OP1
MA1
MP1
MA2
MB1
MP2
MB2
W2E008
4. Inspect the selector valve.

a. Inspect the fuse.
Operate the solenoid valve and check the fuse
for the power supply circuit. 10
10
20
10
10
20
10
20
10
5
10
5
20
20
10
20
L3E020
b. Inspect the selector switch.

Press the selector switch to turn it “ON”. While GRAY YELLOW
it is this condition, check if there is continuity
with a tester.
W2E009E
c. Inspect the relay. Solenoid Valve (4-Section)

Press the selector switch to turn the relay to Change and Speed Shift
“ON”. Check whether the voltage is applied to
the solenoid valve by using a tester. Be sure to
stop the engine before starting the inspection.
d. Inspect the solenoid valve.
“IV. Hydraulic Units, Solenoid Valves,
Swing/Adjust Cange”
W2E010E
TB175W V-28
e. Inspect the operation of the spool.
Disconnect the hose between the selector valve SH
and the cylinder on the selector valve side, then

set a pressure gauge in the disconnected hose.
• Operate the boom swing pedal and measure 5B1
the pressure. 5A1
SR
• A pressure of 33.3 MPa is normal. OP2
MA1
OP1
MA2
MA1
MP1
MB1 MA2
MP2
MB2
W2E011
5. Inspect the port relief valve.

“IV. Hydraulic Units, Port Relief Valve”
6. Inspect the boom adjustment cylinder.

“IV. Hydraulic Units, Cylinders”
V-29 TB175W
TROUBLESHOOTING ARM
THE ARM CYLINDER DOESN’T MOVE.

arm cylinder.
Normal

valve.
Normal

3
the spool. block.
Normal
Operation
4
Does not change.
Faulty Repair or replace the arm cyl-

5 Inspect the arm cylinder.
inder.

the arm cylinder.
Inspect if the operation of the arm only is faulty by Lever Operated Places inspected
the table at right. If operation is faulty, inspect the
main relief valve and the hydraulic pump. Swing Relief Valve R1 Pump P2
“V-6”

“V-21”
TB175W V-30
ARM TROUBLESHOOTING
Disconnect the arm hose connected to the pipe at
BUCKET
BUCKET
the boom foot, then set a pressure gauge in the
ARM
ARM
disconnected hose.
• Operate the (arm) lever and measure the pres-
sure.
• If the pressure is 27.5 MPa, it is normal.
L3E010E

Switch the port relief valve with that of the
normal boom. If the arm cylinder then operates,
the port relief valve is faulty.
W2E006
5. Inspect the arm cylinder.

BUCKET
BUCKET
Switch the arm hoses and bucket hoses connected

ARM
ARM
to the pipes at the boom foot.

• Try operating the (bucket) operation lever to
operate the arm cylinder.
• If the cylinder doesn’t operate, the cylinder is
faulty.
When performing the operation above, the
bucket cylinder should be fully extended, the
arm cylinder should be fully retracted, and
the bucket should be lowered to the ground.
L3E011E
V-31 TB175W
TROUBLESHOOTING ARM
ARM CYLINDER OPERATION IS SLOW, OR THERE IS NO POWER.
Is the arm cylinder’s Within the standard.

1 speed within the stan- Normal
dard?

valve.
Normal

3
the spool. block.
Normal
Operation
4
Does not change

inder.
1. Is the arm cylinder’s speed within the stan-

dard?
Performance”

“V-21”

Stroke the spools of the boom [1] and boom [2]
sections and inspect whether they move smoothly,
or remove the spools and check whether there is
any foreign matter engaged in them.

“V-21”
L3E012
TB175W V-32
ARM TROUBLESHOOTING
a. Fully retract the bucket cylinder, fully retract
the arm cylinder and lower the bucket to the
ground.
W1-E005
b. Disconnect the two hoses connected to the

cylinder. Insert plugs (1) in the disconnected
hoses and the cylinder piping.
c. Raise the boom and raise the hoe attachment so

it floats above the ground. If the arm dorps, the
cylinder is faulty. If the arm does not drop,
there is leakage inside the control valve.
W1-E006
V-33 TB175W
TROUBLESHOOTING ARM
THE AMOUNT OF ARM NATURAL DROP IS GREAT.

1 Normal

inder.
Normal
There is leakage inside

3 Replace the housing block.
the control valve.
1. Is the amount of natural fall within the stan-

dard?
Performance”

“V-31”
TB175W V-34
BUCKET TROUBLESHOOTING
THE BUCKET CYLINDER DOESN’T MOVE, OR THERE IS NO POWER.

bucket cylinder.
Normal

valve.
Normal

3
the spool. block.
Normal
Operation
4
Does not change.
Inspect the bucket cylin- Faulty Repair or replace the bucket

5
der. cylinder.

the bucket cylinder.
Inspect if the operation of the bucket only is faulty Lever Operated Places inspected
by the table at right. If operation is faulty, inspect
the main relief valve and the hydraulic pump. Boom Relief Valve R1 Pump P1
“V-6”

“V-21”

“V-21”
V-35 TB175W
TROUBLESHOOTING BUCKET

When only “bucket load” side is inoperable:
Replace the port relief valve with that of the
normal boom, and test. If the bucket cylinder
operates, the replaced old port relief valve was
faulty.
W2E012
5. Inspect the bucket cylinder.
BUCKET
BUCKET
At the boom foot, exchange the arm hose with the
ARM
ARM
bucket hose that is connected to the pipe.
• Move the lever (arm) and check whether the
bucket cylinder operates.
• If the bucket cylinder does not operate, the
bucket cylinder is faulty.
This inspection should be done with the

bucket cylinder fully extended and the arm
cylinder fully retracted. Also, the bucket must
be lowered to the ground.
L3E011E
TB175W V-36
BUCKET TROUBLESHOOTING
THE AMOUNT OF BUCKET NATURAL DROP IS GREAT.

1 Normal
Inspect the bucket cylin- Faulty Repair or replace the bucket

2
der. cylinder.
Normal
There is leakage inside

3 Replace the housing block.
the control valve.
1. Is the amount of natural drop within the

standard?
“II, Specifications, Standards for Judging
Performance”
2. Inspect the bucket cylinder.

a. Fully extend the bucket cylinder, fully retract
the arm cylinder and lower the bucket to the
ground,
b. Disconnect the 2 hoses connected to the cylin-
der.
Insert the plugs (1) in the disconnected hoses
and the piping.
c. Raise the boom and raise the hoe attachment so

that it floats above the ground, If the bucket
drops, the cylinder is faulty, If the bucket does
not drop, there is leakage inside the control
valve.
V-37 TB175W
TROUBLESHOOTING BOOM SWING
THE SWING CYLINDER DOESN’T MOVE.
2-Piece Boom

(swing).
Normal

2
Normal

3
the spool. block.
Normal
Faulty Repair or replace the selector

4 Inspect the selector valve.
valve.
Normal
Inspect the swing cylin- Faulty Repair or replace the swing

5
der. cylinder.
1. Inspect the supply pressure to the pilot valve 4. Inspect the selector valve.
(swing). “V-28~29”
“V-7~8”
5. Inspect the swing cylinder.
2. Inspect the pilot valve (swing). “IV. Hydraulic Units, Cylinders”
“V-27”

“V-28”
TB175W V-38
BOOM SWING TROUBLESHOOTING
Mono Boom

(swing).
Normal

2
Normal

3
the spool. block.
Normal
Faulty Repair or replace the check

4 Inspect the check valve.
valve.
Normal
Inspect the swing cylin- Faulty Repair or replace the swing

5
der. cylinder.
1. Inspect the supply pressure to the pilot valve

(swing).
“V-7~8”
2. Inspect the pilot valve (swing).

“V-27”

Disconnect the hose between the control valve
(swing section) and the cylinder on the cylinder
hose.
• Operate the boom swing pedal and measure
the pressure.
• A pressure of 27.5 MPa is normal. L3E016
V-39 TB175W
TROUBLESHOOTING BOOM SWING
4. Inspect the check valve.

If right swing cannot be done, then foreign matter
is caught in the check valve or the valve is
sticking.
5. Inspect the swing cylinder.

“IV. Hydraulic Units, Cylinders”
W2E013
TB175W V-40
VI . ENGINE
Machine Model Machine Serial No. Mounted Engine
TB175W 17540001~ 4TNV98T
V-41 TB175W
ENGINE TROUBLE DIAGNOSTICS TOOL AND MAINTENANCE TOOL
1. Introduction
Our maintenance tools are designed to identify the causes of troubles so that machines can be quickly returned to
normal. We also offer a tool to adjust the quantity of oil in the service port for machines with an optional attachment,
to ensure safer maintenance work. These tools are offered only to the designated dealers, and are to be used by main-
tenance technicians with knowledge of computers, so the basic computer operations are not explained.
2. System overview
There are two main tools for maintenance: the engine trouble diagnostic tool provided by the engine manufacturer and
the maintenance tool provided by Takeuchi. Some of our machines have a control computer which can be connected
to a personal computer for communications, allowing computers to read or write data.
(1) Engine trouble diagnostic tool

This tool is used to diagnose troubles with the engine controller of machines with Tier 3-compliant engines and to
flash the engine control data. It can be purchased from the engine manufacturer, Isuzu or Yanmar. Tier 3-compliant
engines are electronically controlled by the Engine Control Unit (ECU) or Engine Control Module (ECM). These
controllers use data specific to Tier 3-compliant and regulation-approved engines, and the trouble diagnostic tool
is specifically designed for them; regular maintenance software for the controller intended for the whole machine
cannot be used.
In case of trouble, the engine trouble diagnostic tool is used to display the error codes and states, from which the
cause of trouble can be identified and action taken according to the engine manufacturerʼs manual.
To purchase the tool, contact our Sales or Parts department.
For details of the tool, read the userʼs manual of the manufacturer.
The maintenance software is permitted to be used only by licensed manufacturers and service dealers.
(2) Maintenance tool and maintenance software

This tool is used to read data from the machine controller and to adjust peripheral devices.
• Reading the error codes stored in the Takeuchi Electrical Control Unit (T-ECU)
Past trouble details can be read or deleted.
∗ For the details of error codes, refer to the manual included in the software CD and the maintenance manual.
• Reading the parameters and writing the modified data in the proportional amplifier for the service port
The proportional output for the first/second auxiliary line can be modified.
The operation speed of various attachments can be modified.
• It is possible to read each serial number and the software version of the controller connected to the device.
The serial number of the controller is necessary for manufacturing management or for troubleshooting.
Machine maintenance tool and trouble analysis tool
Engine manufacturer
Takeuchi maintenance tool
Emission D e v e l o p - Machine Ser. maintenance tool
Model
standards ment code No. Software CD
Engine Name Kit part No. *1 Description of software
part No.
17830001 or
TB180FR F14C
later
15830001 or • T-ECU maintenance soft-
F10C 17301-42800 17301-42700
later ware
TB153FR
15820001 or
F10B
later
TB1140 A25B
later ware
17301-42810 17301-42660 • Maintenance software for
51430001 or the proportional amplifier
TB1140 A25D
later of the service port
22400001 or
TL240 T-3 L8B Yanmar EDT
later
22300001 or
later
22200001 or
later
TB180FR T-3 F14E Yanmar EDT 17301-42820 17301-42690
later ware
17530001 or
TB175 T-3 A14E
later • T-ECU maintenance soft-
Yanmar EDT 17301-42830 17301-42680
17540001 or ware
TB175W T-3 A14EW
later
• T-ECU maintenance soft-
ware
• Controller management
51420001 or
TB1140 T-3 A25C Isuzu EMPS-3 17301-42840 17301-42670 software
later
• Maintenance software for
the proportional amplifier
of the service port
• T-ECU maintenance soft-
ware
• Controller management
A14E Monitor ma-
TB175 T-3 Isuzu EMPS-3 17301-42850 17301-42710 software
Isuzu chines
• Maintenance software for
the proportional amplifier
of the service port
*1 The kit includes the USB cable assembly to be used to connect to the controller. (Part No.: 17301-42720)
T-ECU: Takeuchi-Electrical Control Unit (Takeuchi)
EDT: Engine Diagnostic Tool (Yanmar)
EMPS-3: Engine Module Programming System (Isuzu)
3. Controller connection diagram and system requirements
� ��
3.1 Machines with standard engines
(1) ��
Connection diagram for F14C, F10C and F10B
��
�� T-ECU: Takeuchi-Electrical Control Unit
��
��
Excavator
TB180FR (F14C) T-2
Serial No. 178300001 or later
TB153FR (F10C) T-3
TB153FR (F10B) T-2
Serial No. 158200001 or later Laptop computer
Interface box
(Takeuchi)
Engine
Configuration
① Maintenance software CD (Part No. 17301-42700)
② Dedicated USB cable (Part No. 17301-42720)
��
(2) Connection diagram for A25B and A25D
��
T-ECU: Takeuchi-Electrical Control Unit
Excavator Engine model: 4BG1TRE (Isuzu)

TB1140 (A25B) Compliant with Tier 2 emission standards
TB1140 (A25D)
Laptop computer
Engine
(Isuzu)
(Takeuchi) Interface box
Proportional ampli-
fier for the service Connection
port (Takeuchi) upon selection
Optional for A25D Takeuchi maintenance tool
Configuration
① Maintenance software CD (Part No. 17301-42660)
② Dedicated USB cable (Part No. 17301-42720)
��
3.2 Machines with standard engines
��
(1) Connection diagram for TL240, TL230, and TL220
��
Track loader Engine model: 4TNV98T-ZNTBL

TL240 (L8B) Compliant with Tier 3 emission standards
TL230 (L6B)
TL220 (L5B)
Laptop computer
Interface box
(Yanmar)
Yanmar Engine Diagnostic Tool (EDT)

Engine Configuration
① Software CD
② Interface cable
��
(2)��
Connection diagram for TB180FR
��
Excavator Engine model: 4TNV98T-ZNTBL
TB180FR (F14E) T-3 Compliant with Tier 3 emission standards
Serial No. 17840001 or later Laptop computer
Interface box
(Yanmar)

① Software CD
② Interface cable
Interface box
(Takeuchi)

Configuration
③ Maintenance software CD (Part No. 17301-42690)
④ Dedicated USB cable (Part No. 17301-42720)
��
(3)��Connection diagram for TB175 and TB175W ��
Excavator Engine model: 4TNV98T-ZNTBL

TB175 (A14E) T-3 Compliant with Tier 3 emission standards
TB175W (A14EW) T-3
Laptop computer
Interface box
(Yanmar)

① Software CD
② Interface cable
Interface box
(Takeuchi)

Configuration
④ Dedicated USB cable (Part No. 17301-42720)
��
(4) Connection
�� diagram for TB1140
��
Excavator Engine model: 4JJ1X (Isuzu)

TB1140 (A25C) T-3 Compliant with Tier 3 emission standards
Serial No. 514200001
or later Selector Laptop computer
(Isuzu)
Engine Data link connector
Engine module programming system

(EMPS-III), Isuzu
Configuration ① Software CD
② Interface cable (six types)
Refer to the EMPS manual for details.
(Takeuchi)
Interface box
Proportional ampli-
fier for the service
Connection upon selection
port (Takeuchi)

Configuration
Cluster panel ④ Dedicated USB cable (Part No. 17301-42720)
(Takeuchi)
��
��
(5) Connection diagram for TB175 with an Isuzu engine
��
Excavator Engine model: 4JJ1X (Isuzu)

TB175 (A14E Isuzu) Compliant with Tier 3 emission standards
Monitor machine
Selector Laptop computer
(Isuzu)
Data link connector

Engine
Engine module programming system

(EMPS-III), Isuzu
Configuration ① Software CD
② Interface cable (six types)
Refer to the EMPS manual for details.
Interface box
(Takeuchi)

Proportional ampli- Configuration
fier for the service ③ Maintenance software CD (Part No. 17301-42710)
port (Takeuchi) ④ Dedicated USB cable (Part No. 17301-42720)
Cluster panel
(Takeuchi)
Fuel tank
Fuel sender
CAN unit
(Takeuchi)
��
Dedicated USB
�� cable
� ��
Transducer unit
USB on computer
connecting
�� the��
① Red (RS232C-TX) ⑦
② White (RS232C-TX) ⑧ Orange (Vctol)
computer
③ Black (GND) ⑨
⑩
��
④ Yellow (CTL)
⑤ ⑪
and
⑥ ⑫
��
��
the
��connector
Plug: NJC-165-PM
��on
Adapter: NJC-165-RF
(Nanaboshi) (Nanaboshi)
��
Cap: NJC-16-RCa
��
(Nanaboshi)
Part No.
the�machine
Wiring ① 232-TX
② 232-RX
③ GND
Isuzu Engine
�� Maintenance
��tool��
��
4. Computer screen
�� after
�� software
��installation
��
Model
Start menu 1
Maintenance software
Start menu configuration
The start menu configuration of maintenance software after installation is

illustrated as follows.
��
Model
Start menu 2
Maintenance software
��
5. Maintenance software
�� for
��F14C,
��F10C
��and
��F10B
� executed
��
T-ECU serial number Version of the software installed
��
Date��
and time the Error code
�� State of the emergency re-
��
error��
occurred Display of errors or abnormal
lease
��
states
00:��
Off ��
01:��
On
If ��
the “01” state is displayed
when the engine is overheat-
��
ing��
or seizing, it indicates that
the��
emergency release has
��
been turned on to force en-
��
gine operation. (It is not due
to a defect in the machine.)
��
6. Maintenance
��software
��for ��A25B�� and
��A25D
� executed
(1) Maintenance software
�� is selected
��
(2) A25B and A25D Maintenance Software for Proportion Output
�� Amplifier (Refer to each manual for further
��
information.)
��
7. F14E maintenance
�� software
�� executed
�
��
8. A14E and
�� A14EW
�� maintenance
�� software
��executed
�
(1) A14E Maintenance software
�� is selected
(2) A14EW Maintenance software is selected

��
��
9. A25C
��maintenance
�� software
�� executed
�
(1) Maintenance software is selected
��
(2) Management software is selected

��
��
(3) Maintenance Software for Proportion Output Amplifier is selected
��
��
10. Maintenance
�� tool��
executed
�� on the
��A14E
�� Isuzu
��monitor
�� machine
(1) Management software is selected.
��
��
(2) ECM data browse is selected
��
(3) Management software is selected

��
��
(4) Maintenance Software for Proportion Output Amplifier is selected
��
��
TB175W Maintenance software Ver1.0
SerNO. 17540001~
1. Connecting
-TB175W CABIN.
-Connect Maintenance cable as shown as picture.
TAKEUCHI Original USB Cable
Maintenance Connecter
LAPTOP
-Connect cable to USB port of PC.
Note: Please check COM port number of Serial to USB cable.

See [Control panel] in start menu.
Hit [Performance and maintenance], and then hit [System].
Hit [Hard ware] tag on [System property], and then hit [Device manager].
Check COM Port number on the tree.
〔Ｃｏｎｔｒｏｌ  Ｐａｎｅｌ  〕ＯＰＥＮ
1
2
〔Ｐｅｒｆｏｒｍａｎｎｃｅ  ａｎｄ  Ｍａｉｎｔｅｎａｎｃｅ〕  ＯＰＥＮ
3
〔Ｓｙｓｔｅｍ〕  ＯＰＥＮ
〔Ｄｅｖｉｃｅ  Ｍａｎｅｇｅｒ〕  ＯＰＥＮ
4
The personal computer displayed what TB175W Maintenance software could use in COM4 of the
Universal Serial Bus port.
Ｃhoose this COM port number at the time of initial setting.

Ｓｅｅ  ６  page
5
2. Maintenance software setting.
-Start [TB175W MAINTENACE SOFTWARE Ver1.0] from start menu.
-Hit [Option] → [Setting]
-Choose COM port number on the list.
6
3. Monitor Error Log
-Verify connection from machine to PC.
-Turn key switch ON of machine.
-Hit [Log] → [Load] on the menu.
Note: Don’t forget turn machine key switch off after loading the data.
4. Delete Log.
-When hitting [Log] → [Delete], log data in the controller will be deleted.
Basically, DON’T DO IT.
7
5. Save Log
-Hit [Log] → [Save]
-Chose location of file, and enter the file name.
-Log will be saved as CSV file. We can read the file by Excel.
6. Open saved Log file.

-Hit [Log] → [Open]
-Choose CSV file.
7. Print Log
-Hit [Log] → [Print].
-The log now you opened will be printed.
8. See Serial number of Controller.

-Hit [Option] → [Version and Serial]
-Current Version of software, Serial number of controller and manufactured date of controller
will be shown.
8
TB175W Maintenance software Ver1.0, Error Code Table 
Error Code Discription Note
Key switch starter signal was entered in less than 2 seconds 
Key SW starter signal and start  interval. 
01 
operation for a short time.  PULL action of Engine Stop solenoid was repeated in short 
interval. 
Engine oil pressure decrease 
02  after   
engine starts 
After the engine starts, 
03  Alternator   
charge is defective 
04  Overheating  Signal from water temperature switch 
06  Air cleaner stopped up   
Lifting overload appeared (more than 1second) after ACC power 
07  Lift over load 
supply 
Glow key SW turning on for a long 
10  Glow key switch had connected more than 10 seconds. 
Time 
11  Ignition at time of head Glow  Glow had ignited more than 10 seconds. 
The upper bound of voltage of the  Voltage as over 29V had been measured over 0.5 second, after ACC 
12 
battery is abnormal  power was supplied or engine was started. 
the lower bound of voltage of the  Voltage as under 16V had been measured over 2 second, after ACC 
13 
battery is abnormal  power was supplied or engine was started. 
Clock in the controller had been reset. 
15  Clock initialization  For example, It will happen when Battery have abnormal lower 
voltage in 
Engine oil pressure switch condition was OFF, when key switch was 
16  Engine oil disconnection 
turned on . 
17  Alternator charge disconnection  Charge signal was ON, when key switch was turned on . 
The upper bound of the voltage of 
31  the accelerator sensor is  Voltage as over 4.8V had been measured over 1.5 second 
abnormal 
The lower bound of the voltage of 
32  the accelerator sensor is  Voltage as under 0.2V had been measured over 1.5 second 
abnormal 
33  CAN Communication Error   

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TB175W

BOOK No. CW3E001

Serial No. 17540001~

MACHINE FRONT AND REAR, LEFT AND RIGHT

MACHINE SERIAL NUMBER

Indicates the mass of a part or device.

Safety Precautions ........................................................................................................ ........................................ 3

SAFETY ALERT SYMBOL

DANGER WARNING CAUTION

Observe all safety rules

Provide a ﬁre extinguisher and ﬁrst aid Anti-explosive lighting

Use anti-explosive electrical ﬁxtures and lights

Attach a “DO NOT OPERATE” tag Do not allow unauthorized personnel in

Use the correct tools

Prepare the work area

Replace important safety parts periodi-

• Clean the machine before performing mainte-

Place heavy objects in a stable position

• Stay clear of all rotating and moving parts. Wrap-

Cautions on working on the machine Handling of hoses

Be careful with hot and pressurized

Be careful with hot cooling systems

• Do not smoke or permit open ﬂames while fuel-

Be careful with grease under pressure

Avoid battery hazards Checks after maintenance

Have a Takeuchi service agent repair

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

4. Clean all disassembled parts and new parts, then

5. Be sure to replace all seals and cotter pins, etc.,

6. Keep parts which should not come in contact

7. Be sure to bleed the air after replacing the hy-

10. When ﬁtting the snap rings, the bigger, rounder

CAUTIONS DURING REMOVAL AND INSTAL- HANDLING OF SEALS

2. Use 2 spanners, each on an opposite side, to

2. Be careful not to twist O-rings. If an O-ring is

3. During insertion, be careful not to damage the

4. Handling of Floating Seals

Bite Type Pipe Fitting for Steel Pipe

Joints for Piping

Nominal Thread Torque

Joints for Piping (O-ring Seal Type)

Nominal Thread Torque

Nominal Thread Torque

Bolts and Nuts (for ISO Strength Category 10.9)

3. Points where thread-locking compound is used

In regard to Standard Values and Allowable Values

1. Cab 10. Axle Lock Cylinder 19. Dozer Blade Cylinder

2-Piece Boom Operating Range

Serial Number 17540095 or later

Serial Number 17540095 or later

Serial Number 17540095 or later

Control Valve (4-Section)

Type by air temperature When to change/

Every 250 hrs

Engine cooling Cooling water Mixture of 50% coolant

Diesel fuel standards Region

Part Type Capacity

Serial Number 17540095 or later

Hydraulic Oil Pressure (Main Relief Valve