Page 1 TB53FR...
Page 2 TB53FR...
Page 3 TB53FR...
Page 4 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. TB53FR...
Page 5 Indicates the revision of this manual. This number is printed on the page that reflects this revision. 3. Model (s) 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. TB53FR...
Page 6 TB53FR...
Page 7 I . GENERAL II . SPECIFICATIONS III . MACHINE CONFIGURATION IV . HYDRAULIC UNITS V . TROUBLESHOOTING VI . ENGINE TB53FR...
Page 8 TB53FR...
Page 9 I . GENERAL TB53FR...
Page 10: Table Of Contents
Safety Precautions ..............................3 Cautions during Disassembly and Assembly ......................9 Cautions during Removal and Installation of the Hydraulic Units ..............10 Cautions during Removal and Installation of Piping ..................11 Handling of Seals ..............................12 Tightening Torques ............................. 13 TB53FR...
Page 11: Safety Precautions
• Do not wear oily or fuel stained clothing that can other objects can fly and cause serious personal catch fire. injury. • Use hearing protection when operating the ma- chine. Loud prolonged noise can cause hearing impairments, even the total loss of hearing. TB53FR...
Page 12 • 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. TB53FR...
Page 13 Stop the engine before raising or lowering the platform. • When the floor is tilted up, support it firmly with the stopper to prevent it from falling. TB53FR...
Page 14 • Use the correct fuel grade for the operating season. Do not remove the radiator cap or drain plugs when the coolant is hot. Stop the engine, let the engine and radiator cool and loosen the radiator cap or drain plugs slowly. TB53FR...
Page 15 (For link type controls) • When removing plugs or screws or disconnecting hoses, stand to the side and loosen slowly to gradu- ally release the internal pressure before removing. TB53FR...
Page 16 Have a Takeuchi service agent repair welding cracks or other damage Ask a Takeuchi service agent to repair any welding problems which are detected. If not feasible, make sure the welding is done by a qualified person in a properly equipped workplace.
Page 17: Cautions During Disassembly And Assembly
1 or 2 threads bare, Overlap the tape by about 10 mm. LEAVE 1 OR 2 THREAD MARGIN 10. When fitting the snap rings, the bigger, rounder side of their circumferences should face the mat- ing surfaces. TB53FR...
Page 18: Cautions During Removal And Installation Of The Hydraulic Units
If this operation is forgotten, it could cause cavitation of the hy- draulic pump. Also, it could have a drastic effect on the life of the hydraulic pump. “III. Machine Configuration, Hydraulic Sys- tem” I-10 TB53FR...
Page 19: Cautions During Removal And Installation Of Piping
3. After installation of hydraulic hoses or steel pipes, apply the maximum working pressure 5 or 6 times and confirm that there is no leakage. I-11 TB53FR...
Page 20: Handling Of Seals
• After assembly, turn the seal 2 or 3 times to get it to fit snugly. 5. Apply grease to the lip of the oil seal. • This is to prevent wear when it is first started up after assembly. GREASE I-12 TB53FR...
Page 21: Tightening Torques
30.7 ±1.7 58.8 ±4.9 43.4 ±3.5 88.3 ±4.9 65.1 ±3.5 93.2 ±4.9 68.7 ±3.5 132.4 ±4.9 97.6 ±3.5 205.9 ±9.8 151.8 ±7.2 27.2 245.2 ±9.8 181.0 ±7.2 313.8 ±19.6 231.4 ±14.3 313.8 ±19.6 231.4 ±14.3 411.9 ±19.6 303.7 ±14.3 I-13 TB53FR...
Page 22 (UNF) N·m 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-14 TB53FR...
Page 23 (This indicates that the tightening torque differs from the values given in this table.) 5. In order to tighten bolts and nuts evenly, they should be tightened alternately top, bottom, left, right. I-15 TB53FR...
Page 24 GENERAL I-16 TB53FR...
Page 25 II . SPECIFICATIONS I-17 II-1 TB53FR...
Page 26 * Do not use the standard values and the allowable values as standards for customer claims. I-18 II-2 TB53FR...
Page 27: Names Of Components
7. Pilot valve 17. Right link arm 27. Boom bracket 8. Battery 18. Track adjuster 28. Offset cylinder 9. Control valve 19. Solenoid valve 29. Dozer blade 10. Left link arm 20. Swivel joint 30. Dozer blade cylinder II-3 TB53FR...
Page 28: Dimensions
← ← 2000 ← 4085 ← J1K001A 1520 ← ← 30° ← 15° ← Operating Range Unit: mm Canopy 5905 ← 5765 ← 3590 ← 2780 ← 5535 ← 3880 ← 1515 ← 3885 ← ← ← J1K002A II-4 TB53FR...
Page 29: Lifting Capacities
The operator and other personnel should fully acquaint themselves with the operator’s manual furnished by the manufacturer before operating this machine, and rules for safe operation of equipment shall be adhered to at all times. II-5 TB53FR...
Page 30 SPECIFICATIONS LIFTING CAPACITIES Equipped with Standard Arm Unit: kg (lbs.) Over Front; Dozer Blade Down Over Front; Dozer Blade Up J1K003A Over Rear Over Side J1K004A II-6 TB53FR...
Page 31: Specification Tables
Distance of Rearmost Upper Structure from Axis of Rotation 1000 ← Clearance Height under Upper Structure ← Crawler Base 1985 ← Crawler: Overall Length 2500 ← Overall Width 2000 ← Crawler Shoe Width ← Minimum Ground Clearance ← II-7 TB53FR...
Page 32 Overall Height at Minimum Front Swing Radius at Boom Offset 4400 ← Maximum Bucket Offset Volume: Left ← Right ← Digging Force: Bucket 36.3 ← 25.2 ← Working Equipment (Dozer Blade) Dozer Blade: Width 2000 ← Height ← Dozer Blade: Lift Height ← Depth of Cut ← II-8 TB53FR...
Page 33 Number of Circuits Main Relief Valve Pressure Setting: P1 20.6 20.6 19.6 Port Relief Valve Pressure Setting: 23.5 25.5 Solenoid Valve Model 07706-00000 Rated Pressure Rated Flow Rate: Flow through Spool mL/min Pressure Reducing Valve Pressure Setting MPa 1.18 II-9 TB53FR...
Page 34 Bore Diameter × Rod Diameter 100 × 55 Stroke Fully Retracted Length (Pitch) 750/783* Cushion Mechanism  Dozer Blade Cylinder Bore Diameter × Rod Diameter: Standard 110 × 60 Stroke Fully Retracted Length (Pitch) Cushion Mechanism  * Serial No. 15810019~ II-10 TB53FR...
Page 35 Model MSG-33P-19-5 Type Piston Total Displacement /rev Motor Displacement /rev 29.4 Reduction Gear Ratio 18.9 Relief Valve Pressure Setting 18.6 Parking Brake Torque N·m 1863 or more Parking Brake Release Pressure 2.0 or more Swivel Joint Model YV-7095A II-11 TB53FR...
Page 36: Mass Tables
Crawler Belt: Rubber/Steel 219/245 Travel Motor Carrier Roller Track Roller: Rubber/Steel 11.6/12.1 Idler 42.3 Sprocket 15.4 Track Adjuster 23.9 Dozer Blade Dozer Blade Cylinder Hoe Attachment Boom Bucket: Standard Boom Cylinder Arm Cylinder Bucket Cylinder * Serial No. 15810019~ II-12 TB53FR...
Page 37: Recommended Lubricants
If the percentage of the traveling time within the total operating time is high, replace the gear oil earlier than the specified time. ** For water, use tap water (soft). Do not use well or river water. *** When the ambient temperature drops below 0°C, add coolant (antifreeze). Follow the coolant manufacture’s instructions to determine the mixture ratio. II-13 TB53FR...
Page 38: Servicing Standards
Track Roller Unit: mm Code Designated Standard Basic Dimension Allowable Value  F4B002 Drive Sprocket Unit: mm Code Designated Standard Basic Dimension Allowable Value 380.4 ."*! Idler Unit: mm Code Designated Standard Basic Dimension Allowable Value  ."*" II-14 TB53FR...
Page 39 SPECIFICATIONS SERVICING STANDARDS ATTACHMENTS Pin and Bushing Clearances L2B010 II-15 TB53FR...
Page 40 Right Link Arm & Boom Bracket 0.2~0.28 -0.05 +0.18 +0.23 -0.02 0.2~0.28 Right Link Arm & Turntable +0.18 -0.05 +0.23 -0.02 Left Link Arm & Boom Bracket 0.2~0.28 +0.18 -0.05 +0.23 -0.02 0.2~0.28 Left Link Arm & Turntable +0.18 -0.05 II-16 TB53FR...
Page 41: Standards For Judging Performance
Cylinders Cylinder Speed Boom Extended 4.2 ±0.6 Retracted 4.1 ±0.6 Extended 3.3 ±0.6 Retracted 2.5 ±0.6 Bucket Extended 3.1 ±0.6 Retracted 2.2 ±0.6 Dozer Blade Extended 2.9 ±0.6 Retracted 2.3 ±0.6 Offset Extended 3.5 ±0.6 Retracted 2.6 ±0.6 II-17 TB53FR...
Page 42 8.8 ±3.9 Travel 22.6 ±9.8 37.3 ±9.8 Dozer Blade 41.8 ±9.8 Offset Lever Play Boom Bucket Slew Travel Dozer Blade Slew Bearing 20 ±13 Backlash Slew Bearing Play 0.6 ±0.5 Crawler 172~192 Crawler Tension Steel  108~118 Rubber  II-18 TB53FR...
Page 43: Methods For Inspecting Performance
3. Operate the relief valve once more to confirm that the pressure that has been set it stabilized. II-19 TB53FR...
Page 44 3. Operate the relief valve once more to confirm that the pressure that has been set it stabilized. II-20 TB53FR...
Page 45 J1B007 3. Operate the relief valve once more to confirm that the pressure that has been set it stabilized. II-21 TB53FR...
Page 46 3. Operate the relief valve once more to confirm that the pressure that has been set it stabilized. J1B009 II-22 TB53FR...
Page 47 • Hydraulic Oil Temp. : 50~60°C • Measurement Posture : Travel Posture • Starting after an approach of 5 meters, drive the excavator in a turn for 10 meters, then measure the distance of X (5 m point). Do this on level ground. II-23 TB53FR...
Page 48 • Rotate the upper machinery so that it is directly abeam of the grade, then draw positional marks on the slew bearing’s outer race and the lower frame. Then measure the distance that develops between the marks after 5 minutes. II-24 TB53FR...
Page 49 • Measurement Posture : Using the hoe attach- ment, lift up the dozer blade end of the excava- tor. • Then, raising and lowering the dozer blade full stroke, measure the time required per stroke in each direction. II-25 TB53FR...
Page 50 : 15˚ • Measurement Posture : Same as that for mea- suring 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. L2B023 II-26 TB53FR...
Page 51 1. Attach a dial gauge to the bot- off the ground and set the dial crawler and read the dial tom face of the slew bearing’s gauge to zero. gauge. race located near the front of the upper machinery. II-27 TB53FR...
Page 52 Then measure the distance (of droop) between the center point on the crawler frame and top of the crawler shoe. Note: For the rubber crawler, the measuring should be performed after placing the joint portion with “M” mark to the top center. II-28 TB53FR...
Page 53 III . MACHINE CONFIGURATION II-29 III-1 TB53FR...
Page 54 CONTENTS Drive System ................................. 3 Slew System ................................9 Travel System ..............................11 Upper Frame ................................ 17 Control System ..............................23 Attachments ................................. 29 Hydraulic System ..............................35 Electrical System ..............................39 Interference Prevention System ........................... 43 II-30 III-2 TB53FR...
Page 55: Drive System
• Remove the filler cap with hose attached and put it on the fuel tank. 13. Remove the water separator (7) and the feed pump (9) together with the bracket (11). 14. Remove the hydraulic pump. “Removing the Hydraulic Pump” J1C103 III-3 TB53FR...
Page 56 17. Disconnect the engine ground cable (15). 18. Disconnect the exhaust pipe (16). 19. Remove the cushion rubber tightening double nuts (17) and the engine assembly. Installing the Engine Follow the same procedure as for removal in the reverse order. III-4 TB53FR...
Page 57 Installing the Radiator and Oil Cooler Follow the same procedure as for removal in the reverse order. • The radiator should be mounted at right angles to the main body frame and parallel to the cooling fan. A: parallel B: right angle L2C114 III-5 TB53FR...
Page 58 • Loosen the air release plug (7), fill in the oil through the opening until the oil overflows, and fasten the plug. 2. After starting the engine, let it run at a low idling speed for a while to completely bleed out the air within the circuit. J1C108 III-6 TB53FR...
Page 59 8. Suspend the fuel tank (3) and remove it. • Suspend the tank by sliding it to avoid hitting the floor frame. Fuel tank: 32 kg Installing the Fuel Tank Follow the same procedure as for removal in the reverse order. III-7 TB53FR...
Page 60 MACHINE CONFIGURATION DRIVE SYSTEM III-8 TB53FR...
Page 61: Slew System
Bolt: 256 ±12.7 N·m • Apply thread lock to the bolts. 9. Suspend the slew motor (7) and remove it. Slew motor: 56 kg Installing the Slew Motor Follow the same procedure as for removal in the reverse order. III-9 TB53FR...
Page 62 • When mounting the swivel joint, tighten it tempo- rarily with the fixing bolts, and center the swivel joint by using a dial gauge (4). • Adjust the centering so that the deviation from the center is within 0.25 mm. L2C207 III-10 TB53FR...
Page 63: Travel System
4. Slide the crawler to a position where it will fit snugly with the idler. 5. Engage the crawler fully with the sprocket and the idler, then adjust the crawler tension. “II. Specifications, Standards for Judging Performance” III-11 TB53FR...
Page 64 3. After lowering the body, install the master pin to join the ends of the crawle. • After aligning the pin holes, insert a temporary pin before inserting the master pin. 4. Raise the body and adjust the crawler tension. “II, Specifications, Standards for judging performance” III-12 TB53FR...
Page 65 Bolt: 102 ±5.1 N·m • Apply thread lock to the threads of the bolt. 3. Raise the machine body, then adjust the tension of the crawler. Raise the machine body, then adjust the tension of the crawler. III-13 TB53FR...
Page 66 Bolt: 155.9 ±7.7 N·m • Apply thread lock to the bolts. 5. Suspend the travel motor (3) and remove it. Travel motor: 57 kg Installing the Travel Motor Follow the procedure used for removal in reverse order. G4C309 III-14 TB53FR...
Page 67 “Installing the Track Roller” 3. Attach the guide (5) to the bottom of the frame on the idler side, and fix them with a washer (7) and a bolt (6). J1C311 III-15 TB53FR...
Page 68 MACHINE CONFIGURATION TRAVEL SYSTEM III-16 TB53FR...
Page 69: Upper Frame
• Apply molybdenum disulfide grease to the threads and the bolt holes. 9. Suspend the upper frame temporarily and remove J1C405 the remaining fixing bolts while keeping the frame well balanced. 10. Suspend the upper frame and remove it. L2C407 III-17 TB53FR...
Page 70 MACHINE CONFIGURATION UPPER FRAME Installing the Upper Frame Follow the same procedure as for removal in the reverse order. L2C408 III-18 TB53FR...
Page 71 11. Disengage the safety stopper (3) and lower the floor frame. 12. Remove the bolt and the shaft (11). 13. Suspend the floor frame and remove it. L2C412 Installing the Floor Frame Follow the procedure used for removal in reverse order. III-19 TB53FR...
Page 72 2. Take out the 3 caps and the bolts and remove the side cover (3). 3. Take out the 5 bolts and remove the center cover (4). F4C409 Installing the Covers Follow the same procedure as for removal in the reverse order. J1C408 III-20 TB53FR...
Page 73 Follow the same procedure as for removal in the reverse order. • Be sure to mount the fixing bolts and cushion rubber on the frame in advance. • Suspend the cab on the level and fix it in the temporarily suspended state. L2C419 III-21 TB53FR...
Page 74 MACHINE CONFIGURATION UPPER FRAME III-22 TB53FR...
Page 75: Control System
L2 ↔ B7 6. Shuttle Valve L3 ↔ WC 7. Slew Motor Shuttle Valve L4 ↔ WA Control Valve LP ↔ P1 Tank LT ↔ T Solenoid Valve B2 ↔ B2 Control Valve Shuttle Valve WA ↔ A7 III-23 TB53FR...
Page 76 Solenoid Valve T ↔ T Tank B1 ↔ A5 Control Valve Slew Motor Dr ↔ T Tank Swivel Joint G ↔ T Tank Control Valve P1 ↔ P Solenoid Valve Slew Motor PG ↔ OP Pilot Valve (Offset) III-24 TB53FR...
Page 77 2. Left Pilot Valve 6. Shuttle Valve WB ↔ A8 Control Valve 3. Solenoid Valve 7. Slew Motor Shuttle Valve WC ↔ B8 4. Control Valve 8. Selector Valve WD ↔ SH Slew Motor Solenoid Valve B2 ↔ B2 Control Valve III-25 TB53FR...
Page 78 Solenoid Valve T ↔ T Tank B1 ↔ A5 Control Valve Slew Motor Dr ↔ T Tank Swivel Joint G ↔ T Tank Control Valve P1 ↔ P Solenoid Valve Slew Motor PG ↔ OP Pilot Valve (Offset) III-26 TB53FR...
Page 79 2. Position lever (3) at the center of the stroke by turning nut (2), then fasten the control cable (4) with nut (5). 3. Move the lever (3) and hold it at the stroke end of the valve spool. 4. Set the setscrew (6). III-27 TB53FR...
Page 80 MACHINE CONFIGURATION CONTROL SYSTEM III-28 TB53FR...
Page 81: Attachments
Follow the procedure used for removal in reverse order. • Position the O-ring at the “A” position on the outer perimeter of the bucket bush before mounting the bucket. Upon completion of the mounting, move the O-ring to the prescribed “B” position. L2C603 III-29 TB53FR...
Page 82 4. Take out the split pin and remove the castle nut (7). 5. Suspend the arm (8) temporarily, take out the pin (9) and remove the arm. Arm mass: 95 kg Installing the Arm Follow the procedure used for removal in reverse order. C4C606 III-30 TB53FR...
Page 83 (13), pin (14) and remove the boom. Boom: 227 kg 9. Suspend the boom cylinder (7) temporarily, take out the pin (15) and remove the boom cylinder. Boom cylinder: 65 kg Installing the Boom Follow the procedure used for removal in reverse order. J1C606 III-31 TB53FR...
Page 84 8. Suspend the boom bracket (3) temporarily, and pull out the two pins (16) and remove the boom 10,14 bracket (3). Boom bracket: 117 kg L2C611 Installing the Boom Bracket Follow the same procedure as for removal in the reverse order. L2C612 III-32 TB53FR...
Page 85 Dozer blade cylinder: 44 kg 3. Suspend the dozer blade (5) temporarily, take out the pins (6), and remove the dozer blade. Dozer blade: 197 kg J1C607 Installing the Dozer Blade Follow the procedure used for removal in reverse order. III-33 TB53FR...
Page 86 MACHINE CONFIGURATION ATTACHMENTS III-34 TB53FR...
Page 87 MACHINE CONFIGURATION HYDRAULIC SYSTEM HYDRAULIC SYSTEM HYDRAULIC CIRCUIT DIAGRAM J1C700 III-35 TB53FR...
Page 88 MACHINE CONFIGURATION HYDRAULIC SYSTEM III-36 TB53FR...
Page 89: Hydraulic System
9. Remove the exhaust pipe fixing bolts (7). 10. Take out the fixing bolts (8), and suspend the tank and remove it. Tank: 57 kg Installing the Hydraulic Tank Follow the same procedure as for removal in the reverse order. III-37 TB53FR...
Page 90 • Move the piston rods to 100 mm before the stroke end. DO NOT extend them com- pletely. b. Repeat step “a” above with the engine running at full, then run it at slow and extend the piston rods completely to the stroke end. III-38 TB53FR...
Page 91 MACHINE CONFIGURATION ELECTRICAL SYSTEM ELECTRICAL SYSTEM ELECTRICAL WIRING DIAGRAM J1C802 III-39 TB53FR...
Page 92 MACHINE CONFIGURATION ELECTRICAL SYSTEM III-40 TB53FR...
Page 93: Electrical System
21. Engine Harness 8. Diode 22. Wire 9. Battery Harness 23. Wire 10. Fusible Link 24. Wire 11. Box Assembly 25. Horn 12. Wire Harness 26. Relay 13. Diode 27. Maintenance Light Socket 14. Resistor 28. Rotary Switch III-41 TB53FR...
Page 94 MACHINE CONFIGURATION ELECTRICAL SYSTEM III-42 TB53FR...
Page 95: Interference Prevention System
C: to prevent interference between bucket and cab 2. Cover 8. Collar D: Boom deceleration detection position E: Boom interference detection position 3. Cam Plate 9. Collar F: Bucket interference detection position 4. Link Plate 10. Spring 5. Collar 11. Switch 6. Rubber Plate III-43 TB53FR...
Page 96 MACHINE CONFIGURATION INTERFERENCE PREVENTION SYSTEM Offset switch F4C901 A: Apply thread-locking compound. B: Apply molybdenum disulfide grease. 1. Bracket 2. Link plate 3. Roller 4. Collar 5. Offset Switch 6. Spring III-44 TB53FR...
Page 97 Offset switch R Prevents interference between bucket and cab. Offset switch L Prevents interference between J1C902 boom and cab. Solenoids Solenoid 1 Stops left offset. Solenoid 2 Stops boom raise. Solenoid 3 Decelerates boom raise. III-45 TB53FR...
Page 98 This will raise the boom to the top position at a normal ÒONÓ speed. ÒONÓ SOL2 ÒOFFÓ Boom switch A Solenoid 1 Solenoid 2 ÒOFFÓ Boom switch B ÒONÓ Solenoid 3 ÒONÓ SOL1 Boom switch C Offset switch R Offset switch L J1C904 III-46 TB53FR...
Page 99 H between them. Then raise the boom to the position where the bucket and the cab will not inter- fere (allow the clearance G between them). The clearance G is determined by the boom raise stop position. L2C906 III-47 TB53FR...
Page 100 Boom switch A Solenoid 1 ÒOFFÓ Solenoid 2 Boom switch B ÒOFFÓ ÒOFFÓ SOL2 Solenoid 3 Boom switch C ÒOFFÓ Offset switch R ÒOFFÓ ÒONÓ Offset switch L SOL1 ÒOFFÓ J1C905 III-48 TB53FR...
Page 101 ÒONÓ to the boom deceleration detection position D. ÒOFFÓ Solenoid 1 Boom switch A ÒONÓ SOL2 ÒONÓ Solenoid 2 Boom switch B ÒONÓ ÒOFFÓ Solenoid 3 Boom switch C ÒONÓ SOL1 Offset switch R Offset switch L J1C911 III-49 TB53FR...
Page 102 Solenoid 1 ÒOFFÓ Boom switch A Solenoid 2 ÒOFFÓ Boom switch B SOL2 ÒOFFÓ Boom switch C Solenoid 3 ÒOFFÓ Offset switch R ÒONÓ ÒOFFÓ Offset switch L ÒOFFÓ SOL1 J1C913 III-50 TB53FR...
Page 103 (5) of the control valve. Solenoid 1 Boom switch A ÒONÓ Solenoid 2 Boom switch B ÒONÓ ÒONÓ SOL2 Boom switch C Solenoid 3 ÒONÓ Offset switch R ÒONÓ ÒONÓ Offset switch L ÒONÓ SOL1 J1C916 III-51 TB53FR...
Page 104 Boom switch A Solenoid 1 Solenoid 2 “OFF” Boom switch B Solenoid 3 “ON” Boom switch C “OFF” SOL2 Offset switch R “OFF” Offset switch L “OFF” “ON” SOL1 “OFF” J1C918 III-52 TB53FR...
Page 105 D. Boom switch A Solenoid 1 ÒONÓ Boom switch B Solenoid 2 ÒONÓ Solenoid 3 Boom switch C ÒONÓ SOL2 Offset switch R ÒONÓ Offset switch L ÒONÓ ÒONÓ SOL1 ÒONÓ J1C920 III-53 TB53FR...
Page 106 Solenoid 1 Boom switch A ÒOFFÓ Boom switch B Solenoid 2 ÒONÓ Boom switch C Solenoid 3 ÒOFFÓ SOL2 ÒOFFÓ Offset switch R ÒONÓ ÒONÓ Offset switch L SOL1 ÒOFFÓ J1C922 III-54 TB53FR...
Page 107 5. Operate the left offset and confirm that the boom will stop at the position (clearance H) where the boom will not interfere with the cab. J1C906 • H: 90~100 mm III-55 TB53FR...
Page 108 J becomes equal to the set value when the boom stops. For the inspection of the height J, see the former section “Inspect the boom raise stop position.” L2C916 III-56 TB53FR...
Page 109 Confirm the clearance H again at the engine’s rated rotational speed. • After adjustment, if the clearance H is still less than 90 to 100 mm, place a shim (4) such as a washer between the angle (1) and the link arm (2). F4C918 III-57 TB53FR...
Page 110 MACHINE CONFIGURATION INTERFERENCE PREVENTION SYSTEM III-58 TB53FR...
Page 111 IV . HYDRAULIC UNITS III-59 IV-1 TB53FR...
Page 112 CONTENTS Hydraulic Pump ..............................3 Control Valve ..............................35 Solenoid Valve ..............................57 Pilot Valve ................................65 Pilot Valve (Offset) ............................. 73 Cylinders ................................77 Travel Motor ................................ 95 Slew Motor ................................ 119 Swivel Joint ............................... 151 III-60 IV-2 TB53FR...
Page 113: Hydraulic Pump
HYDRAULIC UNITS HYDRAULIC PUMP HYDRAULIC PUMP CONSTRUCTION K3D100 1. Shaft 7. Gear Pump 2. Swash Plate 8. Housing 3. Cylinder Block 9. Solenoid Valve 4. Cover 10. Relief Valve 5. Control Spring 11. Valve 6. Control Piston IV-3 TB53FR...
Page 114 Swash Plate 1. Swash Plate 2. Plate 3. Distance Piece 4. Bearing 5. O-ring K3D102 Cylinder Block 1. Piston 2. Cylinder Block 3. Retainer 4. Plate 5. Guide 6. Spring 7. Pin 8. Spring Seat K3D103 9. Snap Ring IV-4 TB53FR...
Page 115 4. Spring 5. O-ring 6. Adjusting Screw K3D105 7. Spring 8. Nut 9. Shim Control Piston 1. Cylinder 2. Piston 3. Pin 4. Pin 5. O-ring 6. Conical Spring Washer J1D106 7. Spring Seat 8. O-ring 9. O-ring IV-5 TB53FR...
Page 116 6. Bushing 12. O-ring 18. O-ring Gear Pump (P4) 1. Frame 2. Housing 3. Drive Gear 4. Driven Gear 5. Plate 6. Metal 7. Backup Ring 8. Pin 9. Seal Ring 10. Coupling 11. Snap Ring K3D108 12. O-ring IV-6 TB53FR...
Page 117 HYDRAULIC PUMP Solenoid Valve 1. Body 2. Spool 3. O-ring 4. O-ring 5. Spring 6. Filter Element 7. Solenoid A K3D109 8. Solenoid B Relief Valve 1. Spool 2. Screw 3. O-ring 4. Spring 5. Nut K3D110 6. Shim IV-7 TB53FR...
Page 118 P3 works on the piston (10). When the discharge pressure is below the value preset for the spring (7), the inclination of the swash plate (4) is fixed to the maximum value by the spring (7). IV-8 TB53FR...
Page 119 P4 (2) exceeds the preset value. This pilot pressure is switched by the solenoid valve A (that switches the second travel speed) and the solenoid valve B (that switches the lever lock). G4D103 IV-9 TB53FR...
Page 120 A magnetic field is generated around the coil and the plunger (2) is pulled down. This pushes the spool (1) down. As a result, oil at port P flows into port A and pressure is transmitted to the pilot circuit at the bottom. G4D108 IV-10 TB53FR...
Page 121 Place the pump with the shaft facing down onto the jig (A) so that the shaft end is not in contact with anything. K3D117 2. Remove the cap screws and remove the gear pump. K3D118 IV-11 TB53FR...
Page 122 • When the cover is difficult to remove, tap it with a plastic hammer. 5. Remove the two springs [inside, outside]. 6. Remove the spring seat (1). 7. Disassemble the cylinder block. a. Remove the cylinder block from the shaft. IV-12 TB53FR...
Page 123 8. Remove the snap ring and remove the oil seal case (8) and the O-ring. • Use two flat screwdrivers as shown in the figure to remove the oil seal case. 9. Remove the shaft while tapping its rear end with a plastic hammer. IV-13 TB53FR...
Page 124 Remove the bearing (11). K3D121 d. Remove the swash plate. 11. Disassemble the cover part. a. Remove the valve plate. b. Remove the cap screws and remove the control piston part. • Disassemble the control piston part only when required. K3D122 IV-14 TB53FR...
Page 125 Remove the piston (15) for the air-conditioner (if equipped). K3D123 e. Remove the piston (16). K3D124 f. Remove the three conical spring washers and the spring seat. K3D125 g. Remove the cap screws and remove the cover. IV-15 TB53FR...
Page 126 • Record the length of the adjusting screw protrusion before starting the disassembly. K3D126 b. Remove the adjusting screw (17). • Be careful not to miss the shim. c. Remove the spring (18). d. Remove the spool (19). K3D127 IV-16 TB53FR...
Page 127 15. Disassemble the pump P4. a. Remove the plate, backup ring and seal ring while pulling the drive gear. K3D129 b. Remove the driven gear. K3D130 16. Disassemble the pump P3. a. Remove the bolts and then the flange. K3D131 IV-17 TB53FR...
Page 128 HYDRAULIC UNITS HYDRAULIC PUMP b. Remove the frame. K3D132 c. Remove the seal ring. d. Remove the plate, guide and O-ring. K3D133 e. Remove the plate. K3D134 IV-18 TB53FR...
Page 129 17. Disassemble the solenoid valve. a. Remove the cap screws and then the solenoids. • Be careful not to miss the push rod in the solenoid valve. K3D136 b. Remove the spool and spring. c. Remove the O-ring. K3D137 IV-19 TB53FR...
Page 130 Install the snap ring to fix the bearing. 3. 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. 4. Install the O-ring. IV-20 TB53FR...
Page 131 (5) in the cylinder block. 8. Install the plate on the swash plate. • In order to prevent dropping off, apply grease at the rear (A) of the plate on the swash plate side. K3D138 IV-21 TB53FR...
Page 132 11. Install the two springs [inside, outside]. 12. Assemble the cover unit. a. Install the spring seat (18), the three conical spring washers (17). • Be careful of the installation direction of the washers. K3D139 K3D125 b. Install the piston (16). K3D124 IV-22 TB53FR...
Page 133 Cap screw: 28~35 N·m • Apply Loctite #270. K3D122 g. Fit the O-ring to the spring seat and install the spring seat. h. Put the cover in place and install the cap screws. Cap screw: 28~35 N·m IV-23 TB53FR...
Page 134 Fit the shim to the adjusting screw (17) and install it in the cover. K3D127 d. Install the nut. K3D126 14. Install the cover and install the cap screws. • Install the cover parallel to the housing instal- lation surface. Cap screw: 98~123 N·m IV-24 TB53FR...
Page 135 • Pay attention to the installation direction. K3D141 A: DISCHARGE SIDE B: SUCTION SIDE b. Install the bushings assembled as described above on both sides of the drive gear and the driven gear, and install them in the housing. K3D135 IV-25 TB53FR...
Page 136 Install the plate assembled as described above in the housing. K3D133 e. Install two plates in the housing. • Be careful of the installation directions of the plates. A: DISCHARGE SIDE B: SUCTION SIDE K3D144 K3D134 f. Mount the seal ring. IV-26 TB53FR...
Page 137 Install the drive gear in the housing. K3D146 b. Install the driven gear in the housing. K3D147 c. Fit the seal ring and backup ring to the plate. • Apply grease to the rings in advance to prevent them from dropping off. K3D148 IV-27 TB53FR...
Page 138 Install the plate in the housing. K3D149 e. Fit the pins and O-ring to the frame. K3D150 f. Install the frame in the housing. K3D132 g. Fix the frame and the housing with the cap screws. Cap screw: 29 N·m K3D151 IV-28 TB53FR...
Page 139 19. Unite the pump P3 and the pump P4 and fix them with the bolt. Bolt: 59 N·m K3D153 20. Fit the O-ring to the frame. K3D154 21. Assemble the solenoid valve. a. Mount the spring and spool on the body. K3D137 IV-29 TB53FR...
Page 140 Mount the solenoids on the body and fix them with the cap screws. Cap screw: 3.4~4.4 N·m K3D136 d. Fit the O-ring to the body. K3D156 22. Unite the main pump and gear pump and fix them with the cap screws. Cap screw: 55~69 N·m K3D118 IV-30 TB53FR...
Page 141 HYDRAULIC UNITS HYDRAULIC PUMP 23. Mount the solenoid valve on the pump and fix it with the cap screws. Cap screw: 28~35 N·m K3D117 IV-31 TB53FR...
Page 142 • 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. IV-32 TB53FR...
Page 143 • 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-33 TB53FR...
Page 144 HYDRAULIC UNITS HYDRAULIC PUMP IV-34 TB53FR...
Page 145: Control Valve
6. Right Travel Block Assembly 17. Main Relief Valve 7. Swing Block Assembly 18. Tie Rod 8. Arm Block Assembly 19. Nut 9. Outlet Housing 20. Main Relief Valve 10. Dozer Blade Block Assembly 21. Switch Valve 11. Slew Block Assembly IV-35 TB53FR...
Page 146 4. Cover 5. Seal Holder 6. Backup Ring 7. O-ring 8. Poppet 9. Spring K3D202 Swing Block 1. Cover 2. Screw 3. Spring Holder 4. Spring 5. Cover 6. Poppet 7. Spring 8. O-ring 9. Spring Holder J1D201 IV-36 TB53FR...
Page 147 5. Cover 6. Poppet 7. Spring 8. O-ring K3D205 9. Spring Holder Arm Block 1. Cover 2. Screw 3. Spring Holder 4. Spring 5. Cover 6. Poppet 7. Spring 8. O-ring 9. Poppet 10. Poppet 11. Spring Holder K3D206 IV-37 TB53FR...
Page 148 3. Spring Holder 4. Spring 5. Seal Holder 6. Poppet 7. Spring 8. O-ring K3D208 9. Backup Ring Switch Valve 1. Cover 2. Screw 3. Spring Holder 4. Spring 5. Cover 6. Spring Holder 7. O-ring 8. O-ring K3D209 IV-38 TB53FR...
Page 149 12. O-ring 3. Sleeve 13. Backup Ring 4. Main Poppet 14. O-ring 5. Piston 15. Backup Ring 6. Needle Valve 16. O-ring 7. Spring 17. O-ring 8. Spring 18. Wave Washer 9. Set Screw 19. O-ring 10. Washer IV-39 TB53FR...
Page 150 HYDRAULIC UNITS CONTROL VALVE Anti-Cavitation Valve 1. Housing 8. Backup Ring 2. Plug 9. O-ring 3. Poppet 10. Backup Ring 4. Poppet 11. O-ring 5. Piston 12. O-ring 6. Spring 13. Wave Washer 7. O-ring K3D211 IV-40 TB53FR...
Page 151 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-41 TB53FR...
Page 152 (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. IV-42 TB53FR...
Page 153 C on the inside drops. Compared to the chamber B side, the pressure in chamber C is low and there is no equilibrium in pressure. For this reason, the main poppet (6) opens and pressurized oil flows to the tank passage (T). IV-43 TB53FR...
Page 154 (1) is closed. If a vacuum is generated at the cylinder port (P) and the pressure in the tank passage K3D212 (T) drops as a result, it pushes on the poppet (1) and oil flows from the tank passage to the cylinder port. IV-44 TB53FR...
Page 155 (3) is not switched. Therefore, the oil that has flowed into the switch valve from the pump P3 returns to the tank from the passage (6) through the center bypass passage of the arm block. K3D214 IV-45 TB53FR...
Page 156 (6). The resulting oil flow equals the total oil flow from the pump P2 and pump P3. The returning oil from the cylinder port (4) flows into the tank passage and returns to the tank. K3D216 IV-46 TB53FR...
Page 157 • 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: 69~78 N·m G4D223 IV-47 TB53FR...
Page 158 • 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: 8.8~10.8 N·m 2. Loosen the screw (8) from the spool assembly (7). Screw: 19~22 N·m IV-48 TB53FR...
Page 159 O-ring. Screw: 2.5~2.9 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: 8.8~10.8 N·m IV-49 TB53FR...
Page 160 (18), spring (19) and spring holder (20). Screw: 19~22 N·m K3D218 4. a. Take out the cap screws (5) and remove the cover (21). b. Remove the O-ring (16) from the cover (21). Cap screw: 8.8~10.8 N·m K3D219 IV-50 TB53FR...
Page 161 Remove the sleeve (12) and O-ring (13) from the housing (14). b. Remove the piston (15), spring (16) and main poppet (17) from the sleeve (12), then remove the O-ring (18) and backup ring (19) from the piston (15). IV-51 TB53FR...
Page 162 Turning it to the left decreases the set pressure. 5. After completing the pressure adjustment, tighten the lock nut (2) while holding the set screw (1) so it won’t turn. Operate the relief valve again and check if the pressure is stabilized. L2B017 IV-52 TB53FR...
Page 163 • 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. IV-53 TB53FR...
Page 164 • 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. IV-54 TB53FR...
Page 165 Load doesn’t move. (Pres- • Spool stroke is not the specified stroke. • Check if there is something interfering sure rises.) with the link mechanism. Check if a pin or a pin hole in the link connection is worn or not. IV-55 TB53FR...
Page 166 HYDRAULIC UNITS CONTROL VALVE IV-56 TB53FR...
Page 167: Solenoid Valve
SECTION T-T SECTION Y-Y SECTION X-X F4D900E 1. Shim 9. Body 2. Spring 10. Spool 3. Plug 11. Spool 4. Spool 12. Ring 5. Sleeve 13. Plug 6. Spring 14. O-ring 7. Orifice 15. O-ring 8. Solenoid 16. O-ring IV-57 TB53FR...
Page 168 A magnetic field is generated around the coil. The push rod (2) is pulled down to press down the spool (1), then the oil in port P flows into port A and conveys the pressure to the downstream pilot circuit. C4D902 IV-58 TB53FR...
Page 169 The pilot pressure from the pilot valve (3) is applied through the port A2, passages (4) and (5), port B2 and to the boom section (6) of the control valve. This causes the boom to be raised. IV-59 TB53FR...
Page 170 (6). This pushes back the spool of the control valve (6) to the same position as where the set pressure is applied, and reduces the flow of the hydraulic oil to decelerate the boom raise. IV-60 TB53FR...
Page 171 (12), passing resistance (pressure) is generated. This gradually reduced by the flow control, and the pos- pressure tries to shift the plunger downward. sible shock at the time of the boom stop is relieved. When the plunger (11) is shifted downward, the side IV-61 TB53FR...
Page 172 " .",' Flow Control Valve & 1. Remove the plugs (8) from both sides of the body. Plug: 23.5 N·m 2. Remove the O-ring from the plug (8). 3. Remove the springs (9) and plunger (10). & .",'! IV-62 TB53FR...
Page 173 • 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 down and lightly tap it. .",'# IV-63 TB53FR...
Page 174 • 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-64 TB53FR...
Page 175: Pilot Valve
4. Joint 13. Piston 22. Cap Screw 5. Cam 14. Spool 23. Cap Screw 6. Plate 15. Wire Ring 24. U-Packing 7. Shim 16. Spring 25. O-ring 8. Shim 17. Spring 26. O-ring 9. Casing 18. Spring 27. O-ring IV-65 TB53FR...
Page 176 A and port P close and port A and port T open. 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-66 TB53FR...
Page 177 6. Remove the push rods (9) together with the sleeves (10). • The push rods for port 1 and port 3 are different from those for port 2 and port 4. Store them carefully so that they can be restored at the same positions when assembling. C4D303 IV-67 TB53FR...
Page 178 Push down the spring holder (15) and remove the retainer (17) from the spool (18). b. Remove the spring holder (15) and spring (19) from the spool (18). • Be careful not to lose the pressure adjusting shim (20) if assembled. C4D306 IV-68 TB53FR...
Page 179 • Install them at the same positions as previously assembled. • Be careful not to damage the spool hole. C4D305 3. Install the O-ring (11) and U-packing (12) in the sleeve (10). • Be careful of the direction of the U-packing. C4D304 IV-69 TB53FR...
Page 180 C4D301 with the nut, keeping the push rods pressed. This will generate secondary pressure in the neutral position that might cause erroneous operation. 10. Apply grease to the cam, push rods and joint rotating section. IV-70 TB53FR...
Page 181 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 IV-71 TB53FR...
Page 182 • 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-72 TB53FR...
Page 183: Pilot Valve (Offset)
9. Boot 16. Set Screw 3. Cover 10. Shim 17. Washer 4. Push Rod 11. Shim 18. Washer 5. Shim 12. Shim 19. Spring Pin 6. Cam 13. Spring Holder 20. Ball 7. Pin 14. Spring 21. Spool IV-73 TB53FR...
Page 184 • Apply grease to the cam and push rods. L2D301 2. Remove the set screw. Set screw 4.9 N·m • Apply Loctite #262 to the set screw. L2D302 3. Remove the cam pin, then remove the cam (1). L2D303 IV-74 TB53FR...
Page 185 • Be careful not to damage the push rod hole. L2D305 8. 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. L2D306 IV-75 TB53FR...
Page 186 HYDRAULIC UNITS PILOT VALVE INSPECTION AND ADJUSTMENT “IV-71” TROUBLESHOOTING “IV-72” IV-76 TB53FR...
Page 187: Cylinders
12. Rod Cover 20. Cushion Bearing 28. Washer 5. O-ring 13. Bushing 21. Cushion Seal 29. Grease Nipple 6. O-ring 14. Cushion Bearing 22. Snap Ring 7. Piston Packing 15. Spacer 23. Stopper 8. Tube 16. Piston 24. Dust Seal IV-77 TB53FR...
Page 188 14. Nut 20. Grease Nipple 3. Rod Cover 9. O-ring 15. Set Screw 21. Dust Seal 4. Bushing 10. Lock Washer 16. Ball 5. Rod Packing 11. Piston 17. Shim 6. Dust Seal 12. Piston Packing 18. Bushing IV-78 TB53FR...
Page 189 2. Dust Seal 7. Piston Packing 12. Rod Cover 17. Wear Ring 3. O-ring 8. Tube 13. Bushing 18. Set Screw 4. O-ring 9. Bushing 14. Cushion Bearing 19. Ball 5. O-ring 10. Piston Rod 15. Spacer 20. Dust Seal IV-79 TB53FR...
Page 190 (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-80 TB53FR...
Page 191 4. Loosen the rod cover. • The piston rod should be pulled out approxi- mately 200mm beforehand. • Measures should be taken to prevent the piston rod from being hit. IV-81 TB53FR...
Page 192 3. Remove the cushion bearing (7) and spacer (8). J1D406 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). IV-82 TB53FR...
Page 193 • Either cut the piston packing off or use a flat bladed screwdriver, etc. to take it off. Rod Cover 1. Remove the O-ring (34) from the outer diameter of the rod cover, then remove the backup ring (35). 2. Remove the rod packing. K3D409 IV-83 TB53FR...
Page 194 Clevis 1. Remove the dust seals from the tube and piston rod. 2. Remove the bushings using a setting tool (43). IV-84 TB53FR...
Page 195 1. Using an installation jig (A), pressure fit the bushing. • Hydraulic fluid 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 rod packing. K3D409 IV-85 TB53FR...
Page 196 Fit the O-ring (50). • If the O-ring is twisted after it is fitted, correct it. b. Cover the piston with the sliding jig (C), then using the fitting jig (D), insert the slipper ring (51) rapidly. IV-86 TB53FR...
Page 197 2. Install the wear ring (11) on the piston (13) and the packing holder (5). • Widen the cut part of the wear ring (11) only as far as required, and install it from the axial direction on the piston. E5D415 IV-87 TB53FR...
Page 198 Set screw: Refer to the table below. Piston Nut, Set Screw Unit: N·m Place Piston Nut Set Screw Boom Cylinder 2650 31.5 Arm Cylinder 1510 16.2 Bucket Cylinder 15.6 Dozer Blade Cylinder 2256 31.5 Offset Cylinder 2060/1960* 31.5/16.2* * Serial No. 15810019~ IV-88 TB53FR...
Page 199 Rod cover Unit: N·m Boom Cylinder Arm Cylinder Bucket Cylinder Dozer Blade Cylinder 834 ±191.2 Offset Cylinder 3. Bend the lock rib on the tube down in a notch of the rod cover to lock it. IV-89 TB53FR...
Page 200 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. IV-90 TB53FR...
Page 201 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-91 TB53FR...
Page 202 • The piston packing sliding surface is • Replace the affected parts. the maximum use pressure scratched. multiplied • The O-ring is damaged. • Replace the affected parts. cylinder’s surface area) is 0.5 mm or greater. IV-92 TB53FR...
Page 203 Sliding Jig (C) Fitting Jig (D) Boom 111.0 109.7 97.3 23.5 90.7 89.7 80.7 19.5 Bucket             Dozer Blade 111.0 109.7 97.3 23.5 Offset 101.0 99.7 90.7 22.5 IV-93 TB53FR...
Page 204 HYDRAULIC UNITS CYLINDERS Corrective Jig (E) MATERIAL: STKM13C Unit: mm Boom Bucket   Dozer Blade Offset IV-94 TB53FR...
Page 205: Travel Motor
6. Piston 16. 2-Speed Piston 26. Oil Seal 7. Shoe 17. Brake Piston 27. Spring Pin 8. Shoe Holder 18. Spring 28. Pin 9. Guide 19. Snap Ring 29. Backup Ring 10. Swash Plate 20. O-ring 30. Plug IV-95 TB53FR...
Page 206 28. Plug 5. Gear B2 13. Needle 21. Snap Ring 29. O-ring 6. Gear S1 14. Needle 22. Ring 30. Snap Ring 7. Gear S2 15. Floating Seal 23. Ring 31. O-ring 8. Pin 16. O-ring 24. Pin IV-96 TB53FR...
Page 207 7. Spring Guide 18. Orifice 29. Backup Ring 40. Shuttle 8. Spring 19. Valve Body 30. Piston 41. Spacer 9. Cap 20. Relief Valve Assembly 31. O-ring 10. O-ring 21. Relief Housing 32. Stopper 11. Orifice 22. Poppet 33. Spacer IV-97 TB53FR...
Page 208 B drops below the set valve of the spring (7), the spool (8) attempts to return to the right side. As a result, since the resuming oil is constricted at portion D, back pressure is generated at port M2 and the motor’s turning is slowed. C4D555 IV-98 TB53FR...
Page 209 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. G4D504 IV-99 TB53FR...
Page 210 (3). This causes operation of the control piston (11), and the swash plate (5) is pushed At the time of engine stop, no pressure oil is supplied any longer, and the spring (4) returns the spool (2) to G4D508 the speed 1 position. IV-100 TB53FR...
Page 211 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. C4D558 IV-101 TB53FR...
Page 212 S1, B1 and a1 that are connected to the carrier 2 (1) via the spline. This rotation is conveyed to the rotary main body via the inner gears a1 and a2 as the driving force of the motor. K3D502 IV-102 TB53FR...
Page 213 • Do not disassemble the spool assembly into parts. 2. Mount the rings (1) and springs (2) on both sides of the spool. C4D562 3. Fit the O-ring to the plug, and tighten the plug on both sides of the body. Plug: 196~245 N·m C4D563 IV-103 TB53FR...
Page 214 5. Fit the O-ring to the plug and tighten the plug to the body. Plug: 46~51 N·m C4D565 6. Mount the shuttle on the body. 7. Fit the O-ring to the plug and tighten the plug to the body. Plug: 12~23 N·m IV-104 TB53FR...
Page 215 • Fill between the lips of the oil seal with grease. 10. Fit the O-ring to the plug and install the plug on the flange holder. Plug: 12~13 N·m K3D503 11. Mount the pin. 12. Mount the 2-speed piston. G4D516 IV-105 TB53FR...
Page 216 15. Mount the retainer (6), spring (8) and retainer (7) on the cylinder block and fix them with the snap ring (9). K3D504 K3D505 16. Fit the three pins to the cylinder block. 17. Install the friction disc. K3D506 IV-106 TB53FR...
Page 217 19. Mount the shoe holder assembly on the cylinder block to assemble the cylinder block assembly. K3D507 20. Install the center disc in the groove of the flange holder. K3D508 21. Install the cylinder block assembly. a. Install the shaft splinge in the guide. K3D509 IV-107 TB53FR...
Page 218 • Assemble the valve plate in such a manner that the copper surface is on the cylinder block side. • Apply grease to the valve plate and springs, and be careful not to drop them. K3D511 IV-108 TB53FR...
Page 219 C4D582 28. Install the plug. • Seal tape should be wound around the threads of the plug. Plug: 26~31 N·m 29. Mount the relief valve on the valve body. Relief valve: 196~245 N·m G4D518 IV-109 TB53FR...
Page 220 (17) in the housing. • Be careful of the installation direction of the bearings. C4D583 C4D584 2. Fit the O-ring to the floating seal and install them in the housing. • Apply grease to the O-ring. C4D585 IV-110 TB53FR...
Page 221 7. Press fit the ring (1) to the other end of the gear B. K3D514 8. Install the thrust washer, the gear B assembly (3), the thrust washer and the pin (4). 9. Press fit the spring pins to secure the pins (4). K3D515 IV-111 TB53FR...
Page 222 2 and fix them with the snap ring. C4D591 12. Install the carrier 1 assembly in the housing. K3D516 13. Install the thrust washer and the carrier 2 assem- bly in the housing. K3D517 IV-112 TB53FR...
Page 223 16. Supply 0.8 L of lubricant. C4D595 17. Install the ring on the cover. • Apply grease to secure. G4D524 18. Install the cover on the housing. • Line up the plug holes (G 3/8) with the cuts in the housing. G4D525 IV-113 TB53FR...
Page 224 G4D526 20. Fit the O-rings to the plugs and install the plugs on the cover. Plug: 46~51 N·m G4D527 21. Fit the O-ring to the plug and install the plug on the cover. Plug: 12~13 N·m G4D528 IV-114 TB53FR...
Page 225 0.04 mm or greater time. block Front of the surface which There should be no abnormal scratches slides with the swash plate. (0.02 mm or greater), wear or seizing. Clearance between piston 0.4 mm or greater Replace and shoe. IV-115 TB53FR...
Page 226 Check Valve Front of the surface which There should be no abnormal scratches, time. slides with the spool. wear or seizing. Surface of spool and seat. There should be contact with the seat around the entire circumference. IV-116 TB53FR...
Page 227 The spool does not return. noise. • Foreign matter gets caught. • Remove the foreign matter and repair or replace the damaged parts. • A spring is damaged. • Replace the spring. • The orifice is clogged up. • Clean it. IV-117 TB53FR...
Page 228 Machine veers during travel. Spool doesn’t switch over. • Foreign matter is caught. • Remove the foreign matter and repair or replace the damaged parts. • A spring is missing. • Install the spring. • A spring is damaged. • Replace the spring. IV-118 TB53FR...
Page 229: Slew Motor
22. Center Disc 5. Friction Disc 14. Pin 23. Swash Plate 6. Cylinder Block 15. Valve Plate 24. Bearing 7. Brake Piston 16. Bearing 25. Housing 8. Spring 17. Snap Ring 26. Pin 9. Shaft 18. Collar 27. Piston IV-119 TB53FR...
Page 230 15. Thrust Plate 25. Planetary Gear A 6. Housing 16. Drive Gear 26. Thrust Plate 7. Bearing 17. O-ring 27. Snap Ring 8. Plate 18. O-ring 28. Collar 9. Nut 19. Screw 10. Carrier 2 20. Sun Gear IV-120 TB53FR...
Page 231 8. O-ring 20. O-ring 32. O-ring 44. Filter 9. Backup ring 21. O-ring 33. Filter 45. Orifice 10. Sleeve 22. Guide 34. Washer 46. Orifice 11. Seat 23. Washer 35. Orifice 12. Seat 24. Spring 36. Backup ring IV-121 TB53FR...
Page 232 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. E5D606 IV-122 TB53FR...
Page 233 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. G4D605 IV-123 TB53FR...
Page 234 (4), (5) in 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. K3D608 IV-124 TB53FR...
Page 235 (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-125 TB53FR...
Page 236 HYDRAULIC UNITS SLEW MOTOR DISASSEMBLY AND ASSEMBLY Table of Special Tools Unit: mm NAME, DIMENSIONS NAME, DIMENSIONS JIG (A) JIG (F) JIG (B) JIG (G) JIG (C) JIG (H) JIG (D) JIG ( I ) JIG (E) JIG (J) IV-126 TB53FR...
Page 237 Standard gear tooth Amount of addendum modification 1.95 (shown in the table) is inserted. Module Height of tooth 14.625 B: Width across flat Pressure angle 20° Addendum circle diameter ø 107.9 No. of teeth Dedendum circle diameter ø 78.65 IV-127 TB53FR...
Page 238 • Fix the hydraulic motor with a vise. 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. K3D628 IV-128 TB53FR...
Page 239 • Be careful not to let the valve plate drop off. K3D629 3. Remove the valve plate (3) from the cover. K3D630 4. Remove the bearing (4). K3D631 5. Remove the orifice (5). • The orifice is caulked. Do not remove it unless necessary. K3D632 IV-129 TB53FR...
Page 240 • Use a pair of tweezers. • Be careful not to damage the piston guide. K3D635 c. Remove the relief housing (15). • Pinch section A with a pair of pliers. • Be careful not to damage the pinched sec- tion. K3D637 K3D636 IV-130 TB53FR...
Page 241 10. Remove the cylinder block (18), friction discs (19) and center discs (20). K3D640 11. Remove the shoe holder (20) and piston assembly (21) from the cylinder block. 12. Remove the guide (22) and pins (23) from the cylinder block. E5D621 IV-131 TB53FR...
Page 242 • Use the jig (B). K3D641 15. Remove the shaft (29). • Lightly tap the end face with a plastic hammer. K3D642 16. Remove the bearing (30) from the shaft (29). • Use the press and jig (D). K3D643 IV-132 TB53FR...
Page 243 Remove the orifice (34) from the valve (33). • Adhesive has been applied to the orifice. K3D645 d. Remove the washer (35), orifice (36) and filter (37) from the valve (33). K3D646 Reduction Gears 1. Remove the ring gear (1). K3D647 IV-133 TB53FR...
Page 244 • Loctite has been applied to the screw. Warm- ing the screw screws (for example, using a 13 12 portable drier) will make its removal much easier. 9. Remove the planetary gear B (12), needle (13) and inner race (14). K3D651 IV-134 TB53FR...
Page 245 • Be careful not to damage the outer race of the taper roller bearing. K3D654 14. Remove the outer race (24) of the taper roller bearing. • Use the pulley remover (for pulleys of ø85 mm in diameter) and jig (A). K3D655 IV-135 TB53FR...
Page 246 • Position the hole of the orifice (35) as shown in the figure. K3D646 b. Mount the orifice (34) on the valve (33). • Apply adhesive to section A of the orifice in advance. Excessive application may clog the hole. Orifice: 4.9 ±1.0 N·m K3D645 IV-136 TB53FR...
Page 247 (21) and mount them on the cylinder block. • Apply the hydraulic oil to the rotation section. E5D621 6. Insert the bearing (30) into the shaft (29). • Insert the bearing by using the press and jig (F). K3D643 IV-137 TB53FR...
Page 248 • Total number of center discs: 3 • Be careful of the mounting order. K3D640 11. Fit the O-ring to the collar (17) and insert them in the housing. • Use the jig (G) and the press to insert. K3D639 IV-138 TB53FR...
Page 249 Install the spring sheet (38) and spring (13) in the relief housing (15). • Be careful of the mounting direction of the spring sheet (38). e. Install the guide (14) in the relief housing (15). f. Mount the spring (12) on the guide(14). K3D661 IV-139 TB53FR...
Page 250 • Use the jig (H) and the press to insert. K3D631 17. Fit the pin (39) to the cover. • Caulk the pin at two positions by using a punch. Protrusion due to caulking should not be more than 1 mm. K3D663 K3D662 IV-140 TB53FR...
Page 251 • Be careful not to let the valve plate drop off. Cap screw: 128 ±7 N·m K3D629 21. 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: 10 ±1 N·m K3D628 IV-141 TB53FR...
Page 252 • The oil seal diameter (A) after insertion should be 4.25 mm. K3D654 5. Insert the outer race (24) of the taper roller bear- ing into the case. • Use the jig (L) and the press to insert. IV-142 TB53FR...
Page 253 • Be careful of the mounting direction of the U nut. • Fix the shaft with the jig (P) and tighten it with the jig (O). • Be sure to use a new U nut. U nut: 933 ±49 N·m K3D652 IV-143 TB53FR...
Page 254 14. Fit the snap ring (8) to the sun gear (9) and mount them. 15. Fit the spring pin to the carrier 1. • Let the slit section of the spring face outside as shown in the figure. IV-144 TB53FR...
Page 255 14.5 mm Thrust plate 1.8 mm 2.3 mm 2.8 mm thickness Slew Motor 1. Unite the hydraulic motor (1) and the reduction gear (2) and fix them with the cap screws. Cap screw: 128 ±7 N·m K3D627 IV-145 TB53FR...
Page 256 HYDRAULIC UNITS SLEW MOTOR 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: 29.4 ±2 N·m K3D626 IV-146 TB53FR...
Page 257 E5D634 Cylinder block Sliding surface is Carry out lap re- sliding surface (1) rough. pairs (#1000 Pow- der) or replace. Valve plate sliding Replace surface (2) E5D635 IV-147 TB53FR...
Page 258 • Scratches in sliding portions are deep or roughness is severe. • There are scratches where oil leakage occurs. • Replace Spring, Sleeve • Damaged or severely deformed. • Replace Brake Valve Adjusting the Relief Valve Pressure “II, Specifications, Performance Judgment Stan- dards” IV-148 TB53FR...
Page 259 • 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 TB53FR...
Page 260 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. IV-150 TB53FR...
Page 261: Swivel Joint
Oil flowing in from a port flows constantly through this hydraulic passage (5) between the hub and shaft and the circuits can be connected without a break when the upper frame is slewing. IV-151 TB53FR...
Page 262 • Place a knock pin (6) against the shaft end and tap with a hammer. Select a knock pin (6) made of copper or plastic, etc. • Apply a thin coating of hydraulic oil or grease to the outer circumference of the shaft. IV-152 TB53FR...
Page 263 • Use an O-ring tooth or eyeleteer with a sharp point on the end, etc. • Do not deform or bend the slipper seal strongly in any one place. • During assembly, O-rings should not be twisted when they are fitted in place. IV-153 TB53FR...
Page 264 Repair so that it is smooth • Parts with scratches due to seizing, biting in or Repair so that it is smooth foreign matter, etc., which are within the wear limit of 0.5 mm and which can be repaired IV-154 TB53FR...
Page 265 (6), then perform a 1 minute leak test. • Release the neighboring ports on both sides and check visually for leakage from the ports. • Check for external leakage, etc., by a color check. IV-155 TB53FR...
Page 266 • Shaft and hub are stuck together • Carry out polishing and honing. If looseness and oil leakage are great, replace the assem- Flange looseness • Socket bolt tightening is insuffi- • Retighten to the specified torque cient IV-156 TB53FR...
Page 267 V . TROUBLESHOOTING IV-157 TB53FR...
Page 268 (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. IV-158 TB53FR...
Page 269 The offset cylinder doesn’t move........................41 DOZER BLADE The dozer blade cylinder doesn’t move, or there is no power................43 The amount of dozer blade natural drop is great or the dozer blade won’t hold the machine up....... 45 TB53FR...
Page 270: Overall Machine
• The throttle lever should be in the engine stop position. If the pump is normal, hydraulic oil will be C4E001 discharged from it. If hydraulic oil is not dis- charged, the pump or the coupling is faulty. J1E002 TB53FR...
Page 271: All Operations Can Be Done, But There Is No Power
• 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. TB53FR...
Page 272 Caution : When replacing the hydraulic oil, be sure to clean the inside of the Hydraulic Tank and the suction strainer. “III. Machine Configuration, Hydraulic Tank” If the pump seal is damaged, replace the seal. “IV. Hydraulic Units, Hydraulic Pump” TB53FR...
Page 273: The Boom, Bucket, Slew And Arm Do Not Move At All, Or The Speed Is Low
1. Inspect the hydraulic pump P4. Inspect the hydraulic pump P4 (1) 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. ."-! TB53FR...
Page 274 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. “II. Specifications, Standards for Judging Performance” 6. Inspect the pilot valve. “IV. Hydraulic Units, Pilot Valve” TB53FR...
Page 275: The Boom Cannot Be Raised Or The Left Offset Cannot Be Operated. The Interference Prevention System Does Not Operate Normally
“III. Machine Configuration, Interference Prevention System” If the attachment is within the interference pre- vention area, set the offset to the right and move the attachment out of that area. TB53FR...
Page 276 Confirm that the offset switch is set in the state with the stroke reduced by 4 mm from the free state when the cam roller is on the cam plate (2). “III. Machine Configuration, Interfer- ence Prevention System” J1C923 V-10 TB53FR...
Page 277 (-) side of the tester. Then turn on the starter switch and check the voltage. • If the voltage is 12 V, the wiring is in the normal state. If not, inspect the wiring for the fault location. J1E011 V-11 TB53FR...
Page 278 • If the measured pressure is a reference value, the valve is in the normal state. “II. Specifications, Standards for Judging Performance” 6. Inspect the pilot valve “IV. Hydraulic Units, Pilot Valve and Pilot Valve (Offset)” 7. Inspect the control valve “IV. Hydraulic Units, Control Valve” V-12 TB53FR...
Page 279: Machine Travel
• Inspect the operating status of the lever lock cylinder and arm. Also, check whether the fixing bolt or nut is loose. 3. Inspect the travel lever lock cylinder. The travel lever lock cylinder cannot be disas- sembled. If it is faulty, replace it. L2E015 V-13 TB53FR...
Page 280: Right Or Left Travel Is Impossible
• If the spool is sticking, take it out and inspect it. If it can’t be taken out, or if it is scratched, replace the housing block. Another cause of the spool not operating prop- erly could be that the return spring installation bolt is loose. V-14 TB53FR...
Page 281 • Disconnect the counterbalance valve plug (2) and try pushing the spool (1) with a finger. It is normal if it moves smoothly about 6 mm. 6. Inspect the travel motor. “IV. Hydraulic Units, Travel Motor” V-15 TB53FR...
Page 282: Speed Drops In The Left Or Right Travel, Causing The Machine To Travel In A Curve
If the amount of travel curve is within standards, then operation is normal and the variation de- pends on the combination of equipment. “II. Specifications, Standards for Judging Performance” 2. Adjust the tension of the crawler belt. “II. Specifications, Standards for Judging Performance” V-16 TB53FR...
Page 283 • Inspect the main relief valve “V-6” J1E014 6. Inspect the swivel joint. “V-15” 7. Inspect the counterbalance valve. Inspect if the counterbalance valve’s plunger moves smoothly. “V-15” 8. The travel motor’s speed reducer unit is faulty. “IV. Hydraulic Units, Hydraulic Pump” V-17 TB53FR...
Page 284: Machine Won't Accelerate During Travel
1. Inspect the hydraulic pump P4. Inspect the hydraulic pump P4 which is the source of the hydraulic pressure for switching to second gear. “V-7” Since clogging of the line filter can also be considered, inspect and clean the filter. V-18 TB53FR...
Page 285 Press the travel speed switch to turn the second speed relays (1) to “ON.” Check whether the voltage is applied to the second speed solenoid valve by using a tester. Be sure to stop the engine before starting the inspection. 0.85RY J1E015 V-19 TB53FR...
Page 286 • A pressure of 3.4 MPa is normal. C4E013 8. The 2nd speed control valve is faulty. Check if the plunger of the 2nd speed control valve is sticking or if foreign matter is caught in “IV. Hydraulic Units, Travel Motor” V-20 TB53FR...
Page 287: Slewing
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-21 TB53FR...
Page 288 • The pressure is normal if it is the standard value. “II. Specifications, Standards for Judging 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. V-22 TB53FR...
Page 289 6. Inspect the slew motor. Separate the slew motor (1) and the turntable (2), then try turning the turntable (2). • Turntable turns....Faulty slew motor (1). • Turntable doesn’t turn ..Faulty slew bearing (3). “IV. Hydraulic Units, Slew Motor” V-23 TB53FR...
Page 290: Right Or Left Slewing Cannot Be Done
• If foreign matter is caught in one of the check valves, the hydraulic oil returns to the tank from the check valve. 5. The slew motor is faulty. “IV. Hydraulic Units, Sew Motor” V-24 TB53FR...
Page 291: Slewing Speed Is Low, Or There Is No Power
Normal Inspect the slew motor Faulty Repair or replace the slew drainage amount. motor. Normal Faulty Inspect the slew reduc- Repair or replace the slew re- tion gear. duction gear. Normal The slew bearing is faulty. Replace. V-25 TB53FR...
Page 292 If it is as follows, the drainage amount is normal. Hydraulic Oil Temp.: 50~60°C Engine Speed: Rated Speed Drainage Amount: 0.5 L/min or less 7. Inspect the slew reduction gear. “IV. Hydraulic Units, Slew Motor” V-26 TB53FR...
Page 293: The Machine Slews, But Overrun When Slewing Stops Is Great, Or It Cannot Be Stopped
(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. V-27 TB53FR...
Page 294 For that reason, the amount of overrun when slewing stops is great during slew stopping. 5. Inspect the slew hydraulic pressure. “V-22” V-28 TB53FR...
Page 295: Boom
Inspect if the operation of the boom cylinder only Lever Operated Places inspected is faulty by the table at right. If its operation is Right Travel Relief Valve R1 Pump P1 faulty, inspect the main relief valve and the hy- draulic pump. “V-6” V-29 TB53FR...
Page 296 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 extended, the arm cylinder should be fully retracted and the bucket should be lowered to the ground. V-30 TB53FR...
Page 297: Boom Cylinder Operation Is Slow, Or There Is No Power
“II. Specifications, Standards for Judging Performance” 2. Inspect the pilot valve. “V-30” 3. Inspect the operation of the spool. “V-30” 4. Perform a port relief valve switching test. “V-30” 5. Inspect the boom cylinder. “IV. Hydraulic Units, Cylinders” V-31 TB53FR...
Page 298: The Amount Of Boom Natural Drop Is Great
Replace the housing block. internally. 1. Is the amount of natural drop within the standard? “II. Specifications, Standards for Judging Performance” 2. Inspect for internal leakage in the boom cylinder. 3. Perform a port relief valve switching test. “V-30” V-32 TB53FR...
Page 299: Arm
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 Left Travel Relief Valve R2 Pump P2 main relief valve and the hydraulic pump. “V-6” 2. Inspect the pilot valve. “V-30” V-33 TB53FR...
Page 300 • 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. V-34 TB53FR...
Page 301: Arm Cylinder Operation Is Slow, Or There Is No Power
1. Is the arm cylinder’s speed within the stan- dard? “II. Specifications, Standards for Judging Performance” 2. Inspect the pilot valve. “V-30” 3. Inspect the operation of the spool. “V-34” 4. Perform a port relief valve switching test. “V-34” V-35 TB53FR...
Page 302 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. V-36 TB53FR...
Page 303: The Amount Of Arm Natural Drop Is Great
Inspect the arm cylinder. inder. Normal There is leakage inside Replace the housing block. the control valve. 1. Is the amount of natural fall within the stan- dard? “II. Specifications, Standards for Judging Performance” 2. Inspect the arm cylinder. “V-36” V-37 TB53FR...
Page 304: Bucket
If operation is faulty, inspect Right Travel Relief Valve R1 Pump P1 the main relief valve and the hydraulic pump. “V-6” 2. Inspect the pilot valve. “V-30” 3. Inspect the operation of the spool. “V-34” V-38 TB53FR...
Page 305 • 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. V-39 TB53FR...
Page 306: The Amount Of Bucket Natural Drop Is Great
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-40 TB53FR...
Page 307: Offset
• Operate the offset pedal and measure the pres- sure. • Depending the operation angle, if the pressure is normal, it will range between 0~3.4 MPa L2E028 V-41 TB53FR...
Page 308 (offset section) and the cylinder on the cylinder side, then set a pressure gauge in the disconnected hose. • Operate the offset pedal and measure the pres- sure. • A pressure of 20.6 MPa is normal. 5. Inspect the offset cylinder. “IV. Hydraulic Units, Cylinders” V-42 TB53FR...
Page 309: Dozer Blade
If operation is faulty, Slew Relief Valve R3 Pump P3 inspect the main relief valve and the hydraulic pump. “V-6” 2. Inspect the operation of the spool. “V-14” 3. Inspect the linkage. “V-15” V-43 TB53FR...
Page 310 Connect a pressure gauge to the disconnected hose and operate the lever (blade). • If the measured pressure is not the following value, the swivel joint is faulty. Supply pressure: 19.6 MPa V-44 TB53FR...
Page 311: The Amount Of Dozer Blade Natural Drop Is Great Or The Dozer Blade Won'thold The Machine Up
Using the hoe attachment, raise the machine’s body, then lower the dozer blade fully. b. Disconnect the dozer blade cylinder’s rod side hose and drain out the oil in the piping. Insert a plug (1) in the disconnected hose. V-45 TB53FR...
Page 312 Apply a load to the dozer blade by the procedure in the previous item 2, a~c. If the machine’s body drops, the swivel joint is faulty. If the machine’s body does not drop, there is internal leakage in the control valve. V-46 TB53FR...
Page 313 VI . ENGINE V-47 TB53FR...

Takeuchi TB53FR Workshop Manual

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