Takeuchi TB53FR, Workshop Manual

Page 1: ...0 1 TB53FR...

Page 2: ...0 2 TB53FR...

Page 3: ...0 3 TB53FR...

Page 4: ...LEFT AND RIGHT The end where the dozer blade is mounted is the front and the end with the travel motors is the rear Also the right and left sides of the operator when he is seated in the driver s seat...

Page 5: ...A page is added between page 9 and page 10 II 10 If a page has been revised it is to be used in place of the page used before revision and it is not necessary to keep the old page 2 Revision number I...

Page 6: ...0 6 TB53FR...

Page 7: ...0 7 TB53FR I GENERAL II SPECIFICATIONS III MACHINE CONFIGURATION IV HYDRAULIC UNITS V TROUBLESHOOTING VI ENGINE...

Page 8: ...0 8 TB53FR...

Page 9: ...I 1 TB53FR I GENERAL...

Page 10: ...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 Sea...

Page 11: ...ANT 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 qualifie...

Page 12: ...safety parts periodically 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...

Page 13: ...ly block the machine or any component that may fall Before performing maintenance or repairs under the machine set all working equipment against the ground or in the lowermost position Securely block...

Page 14: ...correct fuel grade for the operating season Handling of hoses Fuel oil or hydraulic fluid leaks can cause a fire Do not twist bend or hit the hoses Neverusetwisted bentorcrackedhoses tubesand pipes Th...

Page 15: ...aulic system Gradually loosen the vent plug to relieve tank pressure Move all the control levers and pedals several times in all directions to release the pressure from the working equipment circuitry...

Page 16: ...veswhenworkingwith batteries Batteries generate flammable and explosive gases Keep arcs sparks flames and lighted tobacco away Use a flashlight to check battery electrolyte level Stop the engine and s...

Page 17: ...er sequence 5 Be sure to replace all seals and cotter pins etc with new parts 6 Keeppartswhichshouldnotcomeincontactwith oilandwaterseparatefrompartswithoilonthem Electrical Parts Rubber V Belts etc 7...

Page 18: ...hydraulic unit for an oil leak so wipe the unit off thoroughly 5 Be sure that no damage is done to the plating on the rod in the hydraulic cylinder 6 As a rule removal and installation of the hydrau...

Page 19: ...hem 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 an...

Page 20: ...ring 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 conta...

Page 21: ...5 1 6 4 108 5 10 7 144 7 14 3 9 8 4 9 24 5 4 9 49 4 9 58 8 4 9 117 7 4 9 137 3 4 9 7 3 3 5 18 1 3 5 36 2 3 5 43 4 3 5 86 8 3 5 101 3 3 5 8 10 12 15 16 18 22 27 2 28 32 35 Pipe Outer Diameter mm Torque...

Page 22: ...6 17 2 8 0 0 7 18 1 1 7 36 2 3 5 54 3 5 3 94 1 9 3 126 6 12 5 Nominal Thread Diameter G Torque N m ft lb 1 8 1 4 3 8 1 2 3 4 1 1 1 4 1 1 2 19 6 2 0 34 3 4 9 53 9 4 9 63 7 4 9 93 2 4 9 107 9 9 8 117 7...

Page 23: ...tely top bottom left right Thread Size Pitch Torque General Tightening Points Special Tightening Points N m kgf m ft lb N m kgf m ft lb Coarse Fine M 6 1 0 M 8 1 25 M10 1 5 M12 1 75 M14 2 0 M16 2 0 M2...

Page 24: ...GENERAL I 16 TB53FR...

Page 25: ...I 17 TB53FR II SPECIFICATIONS II 1...

Page 26: ...ofshippingfromthefactory 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 p...

Page 27: ...arm 11 Engine 12 Crawler belt 13 Idler 14 Track roller 15 Carrier roller 16 Travel motor 17 Right link arm 18 Track adjuster 19 Solenoid valve 20 Swivel joint 21 Bucket 22 Bucket cylinder 23 Arm 24 A...

Page 28: ...N P Q R S T U 5330 1860 2580 1000 615 1985 2500 2000 400 300 1285 720 825 2000 4085 1520 430 30 15 DIMENSIONS Cab 2565 Operating Range Unit mm Canopy A B C D E F G H J K 5905 5765 3590 2780 5535 3880...

Page 29: ...tion the load is applied 2 Asysteminwhichthereisnoriskoftheliftedload falling from the hooking device for example one equippedwithahookslippagepreventiondevice 3 A system in which there is no risk of...

Page 30: ...SPECIFICATIONS LIFTING CAPACITIES II 6 TB53FR Equipped with Standard Arm Unit kg lbs Over Front Dozer Blade Down Over Rear Over Front Dozer Blade Up Over Side J1K003A J1K004A...

Page 31: ...oise Level Sound power dB A Sound pressure level dB A Auxiliary Hydraulic Flow Rate L min Dimensions Overall Length in Transport Position mm Overall Width mm Overall Height mm Dimensions of Base Machi...

Page 32: ...aximum Dumping Height mm Radius at Maximum Dumping Height mm Minimum Dumping Height mm Minimum Front Swing Radius mm Minimum Front Swing Radius at Boom Offset mm Overall Height at Minimum Front Swing...

Page 33: ...Bore Stroke mm Total Displacement mL Compression Ratio Performance Maximum Torque N m min 1 Maximum No load R P M min 1 Minimum No load R P M min 1 Specific Fuel Consumption g kW h Starter V kW Genera...

Page 34: ...ameter Rod Diameter mm Stroke mm Fully Retracted Length Pitch mm Cushion Mechanism Bucket Cylinder Bore Diameter Rod Diameter mm Stroke mm Fully Retracted Length Pitch mm Cushion Mechanism Offset Cyli...

Page 35: ...Torque N m Parking Brake Release Pressure MPa Amount of Reduction Gear Lubricant L Slew Motor Model Type Total Displacement cm3 rev Motor Displacement cm3 rev Reduction Gear Ratio Relief Valve Pressu...

Page 36: ...er Left link arm Right link arm Lower Machinery Swivel Joint Slew Bearing Crawler Belt Rubber Steel Travel Motor Carrier Roller Track Roller Rubber Steel Idler Sprocket Track Adjuster Dozer Blade Doze...

Page 37: ...ype Type by temperature Replacement interval 22 4 14 32 50 68 86 104 F 30 20 10 0 10 20 30 40 C SAE 5W 20 SAE 10W 30 SAE 15W 40 ISO VG68 ISO VG46 ISO VG32 Hydraulic tank Fuel tank Engine cooling syste...

Page 38: ...Basic Dimension Allowable Value 84 30 B 78 Track Roller Unit mm Code Designated Standard A Basic Dimension Allowable Value 110 35 B 106 Drive Sprocket Unit mm Code Designated Standard A Basic Dimensio...

Page 39: ...SPECIFICATIONS SERVICING STANDARDS II 15 TB53FR ATTACHMENTS Pin and Bushing Clearances L2B010 T U N W M V G F H E C A J D B I L K R S P O Q...

Page 40: ...15 0 14 0 22 0 07 0 30 0 07 0 30 0 2 0 28 0 07 0 30 0 07 0 30 0 2 0 28 0 07 0 30 0 07 0 30 0 07 0 30 0 07 0 30 0 14 0 22 0 2 0 28 0 2 0 28 0 2 0 28 0 2 0 28 0 2 0 28 0 2 0 28 1 0 1 0 1 0 1 0 1 0 1 0...

Page 41: ...er Blade Slew Pilot Pressure Travel Travel Speed 5 rev Steel Crawler Low Speed High Speed Rubber Crawler Low Speed High Speed Travel Speed 10m Steel Crawler Low Speed High Speed Rubber Crawler Low Spe...

Page 42: ...andard Values Allowable Values Cylinders Natural Cylinder Drop Boom Arm Bucket Dozer Blade Offset Bucket Tip Levers Lever Operating Force Boom Raise Lower Arm Dump Load Bucket Dump Load Slew Right Lef...

Page 43: ...ng Method 1 Loosenlocknut 2 thenbeginadjustingpressure by turning setting screw 1 Turning clockwise raises the set pressure Turning counterclockwise lowers the set pressure 2 In order to keep the sett...

Page 44: ...ustingpressure 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 ha...

Page 45: ...cannot slew in the direction to be measured Next operate the circuit to be mea sured and measure the relief pressure Adjusting Method 1 Loosenlocknut 2 thenbeginadjustingpressure by turning setting s...

Page 46: ...ilot relief pressure Adjusting Method 1 Loosenlocknut 2 thenbeginadjustingpressure by turning setting screw 1 Turning clockwise raises the set pressure Turning counterclockwise lowers the set pressure...

Page 47: ...n Startingafteradistance of 5 meters measure the time required to travel 10 meters Do this on level ground Travel Posture Fully extend the arm and bucket cylinders and adjust the hoe attachment so tha...

Page 48: ...Overrun When Slewing Stops Engine Rated r p m Hydraulic Oil Temp 50 60 C Measurement Posture Same as that for mea suring slew time Draw matching marks on the outer race of the slew bearing and lower f...

Page 49: ...r position the arm horizontally and rest the dozer blade on the ground Then measure the time required for the arm cylinder to completely retract extend from a fully extended state retracted state Buck...

Page 50: ...Rated r p m Hydraulic Oil Temp 50 60 C Measurement Posture Completely retract the dozer blade and arm cylinders fully extend the bucket cylinder and adjust the bucket pin posi tion to the same height...

Page 51: ...r Play Measure any discernible play at the tip of the lever pedal Backlash Measurement Posture Completely retract the arm cylinder and fully extend the bucket cylin der Move the tips of the bucket tee...

Page 52: ...ompletely off the ground using the hoe attachment and dozer blade Then measure the distance of droop between the center point on the crawler frame and top of the crawler shoe Note For the rubber crawl...

Page 53: ...II 29 TB53FR III MACHINE CONFIGURATION III 1...

Page 54: ...ONFIGURATION II 30 TB53FR 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...

Page 55: ...air hose 2 from the engine 7 Disconnect the coolant drain hose 3 8 Close the valves 4 and disconnect two heater hoses 9 Disconnect the fuel hoses 5 and 6 from the engine 10 Disconnect the fuel hoses...

Page 56: ...lectric wirings 14 Attach identification labels to individual wir ings for correct reassembling Disconnect the wirings from the clamps and the bands 17 Disconnect the engine ground cable 15 18 Disconn...

Page 57: ...ct the 2 oil cooler hoses Prepare a plate to catch drips of the hydraulic oil 13 Remove the fan guard 8 14 Remove the brackets and fan ring 9 15 Remove the cushion rubber tightening double nuts 10 16...

Page 58: ...ump 6 9 Disconnect the 3 discharge hoses from the sole noid valve 1 10 Remove the fixing bolts and take out the hydrau lic pump 6 Bolt 102 N m Apply molybdenum disulfide grease to the spline section I...

Page 59: ...the fuel hoses 4 5 6 and 7 from the fuel tank 6 Disconnect the electric wiring 8 from the fuel tank 3 7 Suspendthefueltank 3 temporarilyandremove the 4 fixing bolts Remove2boltsfromtheupperpartoftheta...

Page 60: ...MACHINE CONFIGURATION DRIVE SYSTEM III 8 TB53FR...

Page 61: ...assembling them 4 Disconnect the hydraulic hoses 4 from shuttle valve 5 Attach ID labels to the various hoses for when reassembling them 5 Remove the bolts from bracket 6 6 Remove the control valve an...

Page 62: ...rated in the right figure Apply grease to the inner teeth of the slew bearing Removing the Swivel Joint 1 Remove the upper frame Removing the Upper Frame 2 Disconnect the hoses 1 from the hub side Mak...

Page 63: ...e iron pipes reach a point just to the side of the idler 4 stop rotating the sprocket 4 Slide the crawler to the side to remove it Rubber crawler 219 kg Installing the Rubber Crawler 1 Raise the machi...

Page 64: ...ile running the travel motor slowly in reverse Use the dozer blade and hoe attachment to raise the body It should be kept level as it is raised Steel Crawler 245 kg Installing the Steel Crawler 1 Rais...

Page 65: ...ead lock to the threads Installation nut 256 12 7 N m Removing the Track Roller 1 Loosen the crawler tension 2 Loosen the roller installation bolt 1 slightly approximately 1 turn 3 Raise the machine b...

Page 66: ...er piston and cylinder Removing the Travel Motor 1 Remove the crawler Removing the Crawler 2 Remove the installation bolts 1 and remove the sprocket 2 Bolt 155 9 7 7 N m Apply thread lock to the bolts...

Page 67: ...00 11010 41230 11400 20012 Item Part Number Description Quantity 3 4 5 6 7 20 40 4 12 12 Refer to the previous pages for removing and install ing the crawler belts 1 Remove the track roller Removing t...

Page 68: ...MACHINE CONFIGURATION TRAVEL SYSTEM III 16 TB53FR...

Page 69: ...them 6 Take out the fixing bolts and remove the stopper Bolt 102 5 1 N m Apply thread lock to the bolts 7 Disconnect the grease pipe 5 from the slew bearing 8 Remove the fixing bolts 4 from the outer...

Page 70: ...MACHINE CONFIGURATION UPPER FRAME III 18 TB53FR L2C408 Installing the Upper Frame Follow the same procedure as for removal in the reverse order...

Page 71: ...the identi fication labels to individual hydraulic hoses 6 Disconnect the two control cables 5 connected to the travel levers 7 Disconnecttheelectricwiring 6 fortravelspeed switching 8 Disconnect the...

Page 72: ...the engine hood and suspend it tempo rarily b Remove the hinge fixing bolts 2 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 Inst...

Page 73: ...movethecastlenutsonthe2rearpositions B a Remove the fixing bolts and the cover 2 b Remove the castle nuts 5 Suspend the cab and remove it Cab 185 kg Installing the Cab Follow the same procedure as for...

Page 74: ...MACHINE CONFIGURATION UPPER FRAME III 22 TB53FR...

Page 75: ...2 WA A7 Solenoid Valve 1 Right Pilot Valve 2 Left Pilot Valve 3 Solenoid Valve 4 Control Valve 5 Hydraulic Tank 6 Shuttle Valve 7 Slew Motor Shuttle Valve Control Valve Tank Control Valve Solenoid Val...

Page 76: ...k Cylinder Tank Slew Motor Control Valve Swivel Joint 1 Pilot Valve Offset 2 Pump 3 Solenoid Valve 4 Control Valve 5 Hydraulic Tank 6 Slew Motor 7 Lock Cylinder 8 Swivel Joint Control Valve Tank Tank...

Page 77: ...uttle Valve Selector Valve Selector Valve Position A Type ISO Position G Type JCB Right Pilot Valve Boom Bucket Arm Slew Lower Raise Load Dump Dump Load Left Right Arm Bucket Boom Slew Dump Load Load...

Page 78: ...ve Lock Cylinder Tank Slew Motor Control Valve Swivel Joint 1 Pilot Valve Offset 2 Pump 3 Solenoid Valve 4 Control Valve 5 Hydraulic Tank 6 Slew Motor 7 Lock Cylinder 8 Swivel Joint Control Valve Tank...

Page 79: ...respond to the control valve spool stroke using the setscrew 1 The spool of the control valve 1 should be in the neutral position 2 Position lever 3 at the center of the stroke by turning nut 2 then f...

Page 80: ...MACHINE CONFIGURATION CONTROL SYSTEM III 28 TB53FR...

Page 81: ...d etc from getting in Duringassembly besuretoadjustallthepartswith shims so that there will be no looseness in the mounts When aligning pin hole positions absolutely do not insert a finger in any pin...

Page 82: ...3 Take out the pin 4 then remove the guide link L 5 R 6 Installing the Link Follow the procedure used for removal in reverse order Removing the Arm 1 Disconnectthehydraulichoses 1 fromthebucket cylin...

Page 83: ...der 7 5 Suspend the boom cylinder 7 temporarily and take out the pin 8 The disconnected end of the cylinder head should be resting on the ground 6 Disconnect the electric wiring to the boom light 9 an...

Page 84: ...the clamps 8 5 Remove the bushing 10 and the guard 11 6 Remove the fixing bolts and disconnect the right guide 12 and the left guide 13 from the boom bracket 3 7 Remove the pin 14 and disconnect the...

Page 85: ...thedozer blade cylinder 2 2 Suspendthedozerbladecylinder 2 temporarily take out the pins 3 4 and remove the cylinder Dozer blade cylinder 44 kg 3 Suspend the dozer blade 5 temporarily take out the pin...

Page 86: ...MACHINE CONFIGURATION ATTACHMENTS III 34 TB53FR...

Page 87: ...TB53FR HYDRAULIC SYSTEM III 35 HYDRAULIC SYSTEM HYDRAULIC CIRCUIT DIAGRAM MACHINE CONFIGURATION J1C700...

Page 88: ...III 36 TB53FR HYDRAULIC SYSTEM MACHINE CONFIGURATION...

Page 89: ...the tank 5 Loosen the drain plug 2 and drain out the oil Tank level capacity 79 L 6 Disconnect the 3 low pressure hoses 4 from the tank 7 Disconnect the hydraulic hoses 5 from stop valve 8 Disconnect...

Page 90: ...after replacing the hydraulic oil or reassembling hydraulic devices or hoses 1 Removetheventplug 7 onthehydraulicpump bleed the air from the housing and tighten plug 7 once hydraulic oil begins to co...

Page 91: ...TB53FR ELECTRICAL SYSTEM III 39 ELECTRICAL SYSTEM ELECTRICAL WIRING DIAGRAM MACHINE CONFIGURATION J1C802...

Page 92: ...TB53FR MACHINE CONFIGURATION ELECTRICAL SYSTEM III 40...

Page 93: ...de 14 Resistor 15 Relay Assembly 16 Relay 17 Relay 18 Angle 19 Wire Harness 20 Engine Harness 21 Engine Harness 22 Wire 23 Wire 24 Wire 25 Horn 26 Relay 27 Maintenance Light Socket 28 Rotary Switch b...

Page 94: ...MACHINE CONFIGURATION ELECTRICAL SYSTEM III 42 TB53FR...

Page 95: ...to prevent interference between boom and cab C to prevent interference between bucket and cab D Boom deceleration detection position E Boom interference detection position F Bucket interference detec...

Page 96: ...ON INTERFERENCE PREVENTION SYSTEM III 44 TB53FR Offset switch A Apply thread locking compound B Apply molybdenum disulfide grease 1 Bracket 2 Link plate 3 Roller 4 Collar 5 Offset Switch 6 Spring F4C9...

Page 97: ...decelerated and stopped and the left offset of the offset cylinder 8 is stopped thus preventing inter ference between the attachment and the cab Structure and operations of the solenoid valve IV Hydr...

Page 98: ...the sole noids 1 2 and 3 of the solenoid valve are turned on Thesolenoid1connectstheportA1andportB1ofthe solenoidvalvetosupplythepilotpressuretotheoffset section 6 of the control valve This enables op...

Page 99: ...et and the cab is prevented Right offset the boom so that the boom becomes parallel to the body and so that the boom and the cab will not interfere with each other by providing the clearanceHbetweenth...

Page 100: ...n position F When the boom raising is stopped When the boom is raised to the bucket interference detection position F the boom switch C is turned off the solenoids 1 2 and 3 are turned off and the pil...

Page 101: ...d 1 connects the ports A1 and B1 of the solenoidvalvetosupplythepilotpressuretotheoffset section 6 of the control valve The solenoids 2 and 3 connect the ports A2 and B2 to supply the pilot pressure t...

Page 102: ...ned off and the solenoids 1 2 and 3 are turned off At this time the solenoid valve operates as the flow control valve to relieve the shock when the boom stops Also the port B1 and the tank port are co...

Page 103: ...e be tween the cab and the bucket When the boom is in normal operation The boom switches A B and C are turned on the offset switches R and L are turned on and the sole noids 1 2 and 3 are turned on Th...

Page 104: ...pressure to the boom section 5 is shut off to stop the boom raising At this time the port B1 and the tank port are connected to shut off the pilot pressure and the left offset cannot be operated Boom...

Page 105: ...peration The solenoid 1 connects the ports A1 and B1 of the solenoidvalvetosupplythepilotpressuretotheoffset section 6 of the control valve The solenoids 2 and 3 connect the ports A2 and B2 to supply...

Page 106: ...turned off and the solenoids 1 2 and 3 are turned off At this time the solenoid valve operates as the flow control valve to relieve the shock when the boom stops Also the port B1 and the tank port ar...

Page 107: ...nd the cab Engine Rated r p m Hydraulic Oil Temp 50 60 C Attachment interference switch Standard bucket Fully extend the arm and bucket cylinders 1 Raise the boom that is parallel to the body and in t...

Page 108: ...alues If the interference prevention device is faulty and the boom cannot be stopped the swing bracket s link mechanism enables the stopper pin to move to the boom stopper position stopping the boom A...

Page 109: ...eadjusted atthepositionwherethecamroller 3 isonthe angle 1 and the switch stroke is shortened by 4 mm from the free position and set 3 Adjust the angle 1 and confirm that the clear ance H between the...

Page 110: ...MACHINE CONFIGURATION INTERFERENCE PREVENTION SYSTEM III 58 TB53FR...

Page 111: ...III 59 TB53FR IV HYDRAULIC UNITS IV 1...

Page 112: ...HYDRAULIC UNITS III 60 TB53FR 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 IV 2...

Page 113: ...IC PUMP IV 3 TB53FR HYDRAULIC PUMP CONSTRUCTION 1 Shaft 2 Swash Plate 3 Cylinder Block 4 Cover 5 Control Spring 6 Control Piston 7 Gear Pump 8 Housing 9 Solenoid Valve 10 Relief Valve 11 Valve K3D100...

Page 114: ...g 5 Oil Seal 6 O ring 7 Snap Ring 8 Snap Ring Swash Plate 1 Swash Plate 2 Plate 3 Distance Piece 4 Bearing 5 O ring Cylinder Block 1 Piston 2 Cylinder Block 3 Retainer 4 Plate 5 Guide 6 Spring 7 Pin 8...

Page 115: ...ing 11 O ring Control Spring 1 Spring Seat 2 Spring Seat 3 Cover 4 Spring 5 O ring 6 Adjusting Screw 7 Spring 8 Nut 9 Shim K3D104 7 3 5 1 11 2 10 5 9 6 4 8 9 8 9 5 6 4 6 K3D105 1 4 7 9 2 5 8 6 3 1 Cyl...

Page 116: ...oupling 10 Bushing 11 O ring 12 O ring 13 Seal Ring 14 Angular Ring 15 Pin 16 O ring 17 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...

Page 117: ...7 TB53FR Solenoid Valve 1 Body 2 Spool 3 O ring 4 O ring 5 Spring 6 Filter Element 7 Solenoid A 8 Solenoid B Relief Valve 1 Spool 2 Screw 3 O ring 4 Spring 5 Nut 6 Shim K3D109 4 6 4 X X Y Y 7 3 2 8 3...

Page 118: ...1 whilethe pistons in contact with the discharge port B operate as the pump P2 Inthisway thetenpistons 2 executeonesuctionand discharge stroke with each revolution of the cylinder block 1 so that suct...

Page 119: ...te 4 changes not only according to the operation pressure of the pumps P1 and P2 but also according to the operation pres sure of the pump P3 the P Q curve of the piston pump becomes a curve with effe...

Page 120: ...onnected the pressure in the pilot circuit downstream becomes the same as the tank pressure When Current is Flowing A magnetic field is generated around the coil and the plunger 2 is pulled down This...

Page 121: ...so that they will be assembled in the same positions when assembled Unit mm NAME DIMENSIONS NAME DIMENSIONS JIG A JIG B 1 2 K3D117 A Replaceallsealswithnewoneseachtimethepump is disassembled coating...

Page 122: ...Remove the cover in horizontal condition Use care as the valve plate is installed on the rear When the cover is difficult to remove tap it with a plastic hammer 5 Remove the two springs inside outside...

Page 123: ...and the piston 6 from the cylinder block 7 Disassembletheinsideofthecylinderblock 7 only when required 8 Removethesnapringandremovetheoilsealcase 8 and the O ring Use two flat screwdrivers as shown in...

Page 124: ...e the cap screws and remove the plate 9 b Remove the distance piece 10 c Remove the bearing 11 d Remove the swash plate 11 Disassemble the cover part a Remove the valve plate b Removethecapscrewsandre...

Page 125: ...12 piston 13 from the cylinder 14 d Remove the piston 15 for the air conditioner if equipped e Remove the piston 16 f Remove the three conical spring washers and the spring seat g Remove the cap screw...

Page 126: ...tapping it with a plas tic hammer 13 Remove the relief valve The parts inside the relief valve should not be disassembled unless absolutely necessary a Remove the nut Record the length of the adjusti...

Page 127: ...emble the hy draulic pump into the pump P3 and the pump P4 15 Disassemble the pump P4 a Remove the plate backup ring and seal ring while pulling the drive gear b Remove the driven gear 16 Disassemble...

Page 128: ...HYDRAULIC UNITS HYDRAULIC PUMP IV 18 TB53FR K3D134 b Remove the frame c Remove the seal ring d Remove the plate guide and O ring e Remove the plate K3D132 K3D133...

Page 129: ...move the drive gear driven gear and bush ing 17 Disassemble the solenoid valve a Removethecapscrewsandthenthesolenoids Be careful not to miss the push rod in the solenoid valve b Remove the spool and...

Page 130: ...e 9 e Attach the plate 9 and fix it with the cap screws Cap screw 12 15 N m 2 Assemble the shaft part a Use the jig B to install the bearing on the shaft Use the bearing as the base and use a press or...

Page 131: ...he pin 4 in the cylinder block Apply grease to the pin 4 to prevent its dropping off b Install the guide 3 in the cylinder block Apply grease to the spherical part of the guide c Attach the piston 6 t...

Page 132: ...es of the piston shoes and the plate 10 Install the spring seat 1 Apply grease to the spherical part of the spring seat 11 Install the two springs inside outside 12 Assemble the cover unit a Install t...

Page 133: ...grease to the two pins 12 the piston 13 and install them in the cylinder 14 f Put the cylinder 14 in position and install the cap screws Cap screw 28 35 N m Apply Loctite 270 g Fit the O ring to the...

Page 134: ...arge and a small O ring in the cover 13 Install the relief valve a Install the spool 19 b Install the spring 18 c Fit the shim to the adjusting screw 17 and install it in the cover d Install the nut 1...

Page 135: ...t 17 Assemble the gear pump a Match the bushing and install the rectangular ring 20 Pay attention to the installation direction b Install the bushings assembled as described above on both sides of the...

Page 136: ...should come to the largely rounded side of the plate circumfer ence d Install the plate assembled as described above in the housing e Install two plates in the housing Be careful of the installation...

Page 137: ...and mount them on the pump 18 Assemble the pump P4 a Install the drive gear in the housing b Install the driven gear in the housing c Fit the seal ring and backup ring to the plate Apply grease to th...

Page 138: ...PUMP IV 28 TB53FR K3D151 d Install the plate in the housing e Fit the pins and O ring to the frame f Install the frame in the housing g Fix the frame and the housing with the cap screws Cap screw 29...

Page 139: ...nd mount the cou pling on the shaft end on the side of the pump P3 19 Unite the pump P3 and the pump P4 and fix them with the bolt Bolt 59 N m 20 Fit the O ring to the frame 21 Assemble the solenoid v...

Page 140: ...unt the O ring on the body c Mount the solenoids on the body and fix them with the cap screws Cap screw 3 4 4 4 N m d Fit the O ring to the body 22 Unite the main pump and gear pump and fix them with...

Page 141: ...HYDRAULIC UNITS HYDRAULIC PUMP IV 31 TB53FR 23 Mount the solenoid valve on the pump and fix it with the cap screws Cap screw 28 35 N m K3D117 A...

Page 142: ...rt of shaft and oil seal Noabnormalscratches 0 02mmor more wear orstickingfortheslid ing surfaces Exchange Exchange Exchange Exchange Correctbylapping or exchange No abnormal wear or harmful scratches...

Page 143: ...erthanthepumpisincreasing Operatetheengineatthespecifiedspeed Stopthemachineandlettheoilcooloff then check again Replace the hydraulic oil with oil of the proper viscosity Replace the pump Reset the s...

Page 144: ...HYDRAULIC UNITS HYDRAULIC PUMP IV 34 TB53FR...

Page 145: ...ght Travel Block Assembly 7 Swing Block Assembly 8 Arm Block Assembly 9 Outlet Housing 10 Dozer Blade Block Assembly 11 Slew Block Assembly 12 Inlet Housing 13 Port Relief Valve 14 Plug Assembly 15 An...

Page 146: ...Cover 5 Seal Holder 6 Backup Ring 7 O ring 8 Poppet 9 Spring 1 Screw 2 Spring Holder 3 Spring 4 Cover 5 Seal Holder 6 Backup Ring 7 O ring 8 Poppet 9 Spring 1 Cover 2 Screw 3 Spring Holder 4 Spring 5...

Page 147: ...pet 7 Spring 8 O ring 9 Spring Holder 1 Cover 2 Screw 3 Spring Holder 4 Spring 5 Cover 6 Poppet 7 Spring 8 O ring 9 Spring Holder 1 Cover 2 Screw 3 Spring Holder 4 Spring 5 Cover 6 Poppet 7 Spring 8 O...

Page 148: ...ring 5 Cover 6 Poppet 7 Spring 8 O ring 9 Spring Holder 10 Poppet 1 Cover 2 Screw 3 Spring Holder 4 Spring 5 Seal Holder 6 Poppet 7 Spring 8 O ring 9 Backup Ring 1 Cover 2 Screw 3 Spring Holder 4 Spri...

Page 149: ...3 Sleeve 4 Main Poppet 5 Piston 6 Needle Valve 7 Set Screw 8 Washer 9 Lock Nut 10 Spring 11 Spring 12 O ring 13 Backup Ring 14 O ring 15 O ring 16 O ring 17 Washer 1 Housing 2 Plug 3 Sleeve 4 Main Po...

Page 150: ...NTROL VALVE IV 40 TB53FR Anti Cavitation Valve 1 Housing 2 Plug 3 Poppet 4 Poppet 5 Piston 6 Spring 7 O ring 8 Backup Ring 9 O ring 10 Backup Ring 11 O ring 12 O ring 13 Wave Washer K3D211 4 5 8 7 12...

Page 151: ...e right When the spool 2 is moved to the right the center bypasspassage 3 isclosedandhydraulicoilentering from the pump passes through the load check valve 5 from the parallel passage 4 flowing from t...

Page 152: ...ctions 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 F1 F t...

Page 153: ...on the left side If the pressure in the circuit becomes higher than the force of the spring 7 the needle valve 5 is pushed to the right by hydraulic pressure opening Oil then flows around the circumf...

Page 154: ...ng the empty space Anti Cavitation Valve The anti cavitation valves are incorporated between the cylinder ports of the swing and bucket sections and the tank circuit When a cylinder is operated at hig...

Page 155: ...ded on the spool 3 As the passage 4 is connected to the boom and bucket block while the passage 5 is connected to the auxiliary block and swing block the hoe attachment can be operated except for arm...

Page 156: ...nd pump P3 The returning oil from the cylinder port 6 flows into the tank passage and returns to the tank When Moving the Arm Out Whenthepilotport 7 ispressurizedandthespool 2 is switched the hydrauli...

Page 157: ...s replace the section assembly as a unit Be sure to number each section and spool to avoid mistakes during assembly Following is an explanation of the control valve disassembly procedure Follow the pr...

Page 158: ...ove the O ring 2 from the valve Plug 69 78 N m 5 Remove the load check valve Removethespring 3 thenremovethepoppet 4 Manually Operated Section 1 Remove the cap screws 5 the cover 6 and the spool assem...

Page 159: ...der 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 2 9 N m Pilot Operated Se...

Page 160: ...section 3 Take out the screw 17 and remove the spring holder 18 spring 19 and spring holder 20 Screw 19 22 N m 4 a Take out the cap screws 5 and remove the cover 21 b Remove the O ring 16 from the co...

Page 161: ...During assembly after installing the set screw 5 lock the lock nut 3 temporarily then tighten it after adjusting the pressure Lock nut 27 5 31 4 N m b Remove the needle valve 8 and spring 9 then remov...

Page 162: ...pocket portion of the part that enters the spool Scratches rust corrosion of the port seal portion which is in contact with the O ring Scratches rust corrosionofthesealportionoftherelief valve etc Oth...

Page 163: ...sure bearing on one side only Spool is bent from externally applied pressure Entire valve is strained due to strain in the installation face Valve was used at a pressure or a flow volume which was out...

Page 164: ...is biting into the port relief valve seat or the anti cavitation valveseatandoilisbypassing Oraseat is damaged Spool stroke is not the specified stroke Pump is damaged and no oil is dis charged Disas...

Page 165: ...3FR Symptom Probable Causes Remedy 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 Loaddoesn tmove Pres sure rises Sp...

Page 166: ...HYDRAULIC UNITS CONTROL VALVE IV 56 TB53FR...

Page 167: ...LIC UNITS SOLENOID VALVE IV 57 TB53FR SOLENOID VALVE CONSTRUCTION 1 Shim 2 Spring 3 Plug 4 Spool 5 Sleeve 6 Spring 7 Orifice 8 Solenoid 9 Body 10 Spool 11 Spool 12 Ring 13 Plug 14 O ring 15 O ring 16...

Page 168: ...actuate the flow control valve in the boom stop area to relieve the shock when the boom is stopped Solenoids A B 1 When the solenoid is not electrified The oil in the port P is blocked by the spool 1...

Page 169: ...cing valve When the boom advances further into the boom raise stop area the solenoid 2 is also turned off to actuate the flow control valve When the boom is raised The spools 1 and 2 of the solenoids...

Page 170: ...oil to be supplied from the port A2 to the port B2 flows from the chamber B through the pas sage 7 and enters the passage of the tank 8 When the pressure in the chamber B is reduced to the setting val...

Page 171: ...ce 12 passing resistance pressure is generated This pressure tries to shift the plunger downward When the plunger 11 is shifted downward the side holeoftheplunger 11 isthrottledbythelandsection 14 Thi...

Page 172: ...n coating of hydraulic oil to sliding surfaces and a thin coating of grease to seals when assembling them Replace seals with new parts each time disassem bly is done The following describes the disass...

Page 173: ...re not to miss the push rod Cap screw 3 92 N m 2 Remove the O ring from the solenoid coil 5 3 Remove the spool 6 and sleeve 7 from the body Record the positions of the spool sleeve and the body hole s...

Page 174: ...ted or has a wire break Wiring short circuit or wire break Judgment Criteria Treatment Scratches rust or corrosion at the sliding parts with the spool Scratches rust or corrosion of the seal part in c...

Page 175: ...Casing PILOT VALVE CONSTRUCTION 10 Port Plate 11 Push Rod 12 Spring Holder 13 Piston 14 Spool 15 Wire Ring 16 Spring 17 Spring 18 Spring 19 Spring 20 Nut 21 Sleeve 22 Cap Screw 23 Cap Screw 24 U Pack...

Page 176: ...e spool Therefore the spool is pushed up by the return spring and is in the output port C position shown above with oil not flowing between port P and the output port C but flowing between the T port...

Page 177: ...ke sure there are no burrs bruises using or other marks on them Remove all burrs and bruises using an oil stone Apply thin coating of grease to seals when assem bling them Disassembly 1 Removethenut 1...

Page 178: ...pool assemblies and springs for port 1 and port 3 are different from those for port 2 andport4 Storethemcarefullysothattheycan be restored at the same positions when assem bling 9 Disassemble the spoo...

Page 179: ...hole up B Make the side with the shallow hole down b Push down the spring holder 15 and fit the retainer 17 to the spool 18 Be careful of the direction of the retainer C Make the side with the sharp c...

Page 180: ...bepositionedinthe back of the holes 7 Install one O ring 6 six O rings 7 and the port plate 4 in the casing and tighten them with the cap screws Cap screw 23 5 2 N m 8 Reverse the casing again to the...

Page 181: ...mage Tightening is loose at the pin shaft or joint of the operating portion with looseness of 2 mm or greater Due to wear etc tightening is loose at the pin shaft or joint of the operating portion wit...

Page 182: ...and casing assem bly Disassemble and reassemble or re place the handle TROUBLESHOOTING Symptom Probable Causes Remedy Sliding parts are catching Tank line pressure fluctuates Air gets mixed into the p...

Page 183: ...CTION 1 O ring 2 O ring 3 Cover 4 Push Rod 5 Shim 6 Cam 7 Pin 8 Spring 9 Boot 10 Shim 11 Shim 12 Shim 13 Spring Holder 14 Spring 15 Cap Screw 16 Set Screw 17 Washer 18 Washer 19 Spring Pin 20 Ball 21...

Page 184: ...r 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 g...

Page 185: ...cover and casing so that they can be reassembled in the same positions Cap screw 23 5 N m 5 Remove the O rings from the casing 3 6 Remove the push rods 4 together with the cover 5 7 Remove the O ring...

Page 186: ...HYDRAULIC UNITS PILOT VALVE IV 76 TB53FR INSPECTION AND ADJUSTMENT IV 71 TROUBLESHOOTING IV 72...

Page 187: ...iston 16 Wear Ring 17 Nut 18 Set Screw 19 Ball 20 Dust Seal 21 Pipe 22 Bolt 23 Washer 24 Grease Nipple Arm Cylinder 9 Bushing 10 Piston Rod 11 Bushing 12 Rod Cover 13 Bushing 14 Cushion Bearing 15 Spa...

Page 188: ...Bushing 19 Grease Nipple 20 Grease Nipple 21 Dust Seal 1 Tube 2 Piston Rod 3 Rod Cover 4 Bushing 5 Rod Packing 6 Backup Ring 7 Dust Seal 8 O ring 9 Packing Holder 10 O ring 11 Piston 12 Wear Ring 13 P...

Page 189: ...13 Bushing 14 Piston 15 Wear Ring 16 Set Screw 17 Ball Serial No 15810019 1 Rod Packing 2 Dust Seal 3 O ring 4 O ring 5 O ring 6 Backup Ring 7 Piston Packing 8 Tube 9 Bushing 10 Piston Rod 11 Bushing...

Page 190: ...the piston colliding with the cover at the stroke end acts on that mechanism and is dampened by it Cushion Mechanism When the piston 1 nears the stroke end just before itcollideswiththecover 2 ifthec...

Page 191: ...d Applyathincoatingofhydraulicoiltosealsbefore fitting them in place Afterfitting makesuretheO ringsarenottwisted Apply clean hydraulic oil to each sliding portion before assembling them In this manua...

Page 192: ...ton a Take out the set screw 2 and remove the steel ball 3 The set screw is staked at 2 places with a punch sogrindoffthestakedportionsusing a hand drill b Loosen the piston nut 6 and remove it Use a...

Page 193: ...he wear ring at the cut portion the minimum amount necessary for it to be re moved Remove it in the direction of the shaft Either cut the piston packing off or use a flat bladed screwdriver etc to tak...

Page 194: ...to remove it 4 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 t...

Page 195: ...rod and tube 2 Using a setting tool 45 install the dust seals Rod Cover 1 Using an installation jig A pressure fit the bushing Hydraulic fluid should be applied to the inside surface of the rod cover...

Page 196: ...ting tool 46 to install it 4 Installthebackupring 35 andfittheO ring 34 The cut portions of the backup ring should overlap correctly Piston 1 Assemble the piston assembly a Fit the O ring 50 If the O...

Page 197: ...minimum amount necessary installing it on the piston from the shaft direction Piston in two pieces 1 Install the back ring 30 the backup ring 31 and the slipper ring 32 on the piston 13 2 Install the...

Page 198: ...Install the snap ring 9 3 Install the spacer 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 th...

Page 199: ...he 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...

Page 200: ...makes a squeaking sound in the operation test after reas sembly or if it catches during movement If the inner diameter of the clevis bushing is worn replace the bushing Tube If there are cracks in th...

Page 201: ...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...

Page 202: ...g and other seals If it leaks after the seals have been replaced replace the piston rod Repair the hardened chrome plating O ring is damaged Backup ring is damaged Replace the affected parts Replace t...

Page 203: ...1 46 30 51 46 F 60 50 48 5 60 55 A 74 59 54 67 67 B 59 5 49 8 44 8 54 8 54 8 C 10 10 10 10 10 D 5 5 5 5 5 E 30 30 30 30 30 F 80 64 60 73 73 Sliding Jig C Fitting Jig D MATERIAL STKM13C MATERIAL NYLON...

Page 204: ...HYDRAULIC UNITS CYLINDERS IV 94 TB53FR Corrective Jig E Unit mm Boom Arm Bucket Dozer Blade Offset A 123 103 123 113 B 110 90 110 100 MATERIAL STKM13C...

Page 205: ...der Block 5 Valve Plate 6 Piston 7 Shoe 8 Shoe Holder 9 Guide 10 Swash Plate 11 Pin 12 Spring 13 Retainer 14 Bearing 15 Bearing 16 2 Speed Piston 17 Brake Piston 18 Spring 19 Snap Ring 20 O ring 21 O...

Page 206: ...ange Holder 11 Snap Ring 12 Carrier 1 13 Needle 14 Needle 15 Floating Seal 16 O ring 17 Bearing 18 Thrust Washer 19 Snap Ring 20 Snap Ring 21 Snap Ring 22 Ring 23 Ring 24 Pin 25 Pin 26 Plug 27 Thrust...

Page 207: ...ng Guide 8 Spring 9 Cap 10 O ring 11 Orifice 12 Spool 13 Spring 14 Plug 15 O ring 16 Plug 17 Plug 18 Orifice 19 Valve Body 20 Relief Valve Assembly 21 Relief Housing 22 Poppet 23 Seat 24 Spring Seat 2...

Page 208: ...e oil is introduced to port C rotation is the reverse of the above Counterbalance Valve If high pressure oil is introduced to port P1 the oil pushes the check valve 6 up This causes oil to flow throug...

Page 209: ...the shock during stopping is absorbed Relief Valve 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 r...

Page 210: ...me 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 2 Speed Mechanism 2 speed control valve When high press...

Page 211: ...pressure of the 2 speed control valve is cut off so the swash plate 5 is stabilized at the swash plate a plane A by the force of the springs 9 10 changing to the 1st speed side For this reason when st...

Page 212: ...orque and rotates the case The output shaft of the hydraulic motor is connected to the gear S2 via the spline The rotation of the gear S2 is decelerated by one stage among the gears S2 B2 and a2 This...

Page 213: ...sassembled coating them lightly with grease Check each part to make sure there is no abnormal wear or seizing and use sandpaper etc to remove any burrs sharp edges etc The following describes the asse...

Page 214: ...he second speed spool 4 and spring 5 on the body 5 Fit the O ring to the plug and tighten the plug to the body Plug 46 51 N m 6 Mount the shuttle on the body 7 Fit the O ring to the plug and tighten t...

Page 215: ...it the oil seal into the flange holder As the oil seal is to be inserted do not disas semble it unless necessary Fill between the lips of the oil seal with grease 10 Fit the O ring to the plug and ins...

Page 216: ...to damage the oil seal by the shaft 14 Mount the balls and swash plate Apply hydraulic oil to the sliding surfaces of the swash plate 15 Mount the retainer 6 spring 8 and retainer 7 on the cylinder b...

Page 217: ...ssemble the shoe holder assembly 19 Mount the shoe holder assembly on the cylinder block to assemble the cylinder block assembly 20 Install the center disc in the groove of the flange holder 21 Instal...

Page 218: ...ston assembly on the flange holder Apply grease to the O ring and be careful not to let it bite the seal 25 Mount the valve plate on the flange holder and insert the springs into the spring holes The...

Page 219: ...vise and tighten it with the screws Screw 51 65 N m Insert a protector such as an aluminum plate between the flange holder and the vise to prevent the outer surface of the body from being damaged 28 I...

Page 220: ...ighten them with the cap screws Cap screw 25 32 N m Reduction Gears 1 Install the bearing 17 snap ring 18 and bear ing 17 in the housing Be careful of the installation direction of the bearings 2 Fit...

Page 221: ...ar and the flange of the hydraulic motor with a C clamporhydraulicpress andfixthemwiththe snap ring 5 Press fit the ring 1 to the gear B 6 Install the needles 2 in the gear B Apply grease to the needl...

Page 222: ...hemwith the snap ring 11 Mount the thrust washer gear B2 needle and thrust washer on the carrier 2 and fix them with the snap ring 12 Install the carrier 1 assembly in the housing 13 Install the thrus...

Page 223: ...the gear S2 15 Fit the O ring to the housing 16 Supply 0 8 L of lubricant 17 Install the ring on the cover Apply grease to secure 18 Install the cover on the housing Line up the plug holes G 3 8 with...

Page 224: ...secure the cover Put the blade of a screwdriver on the snap ring end and push it into position 20 FittheO ringstotheplugsandinstalltheplugson the cover Plug 46 51 N m 21 Fit the O ring to the plug and...

Page 225: ...Front of Gear Tooth Sur faces Thereshouldbenoabnormalscratches 0 02 mm or greater wear or seizing etc Front of sliding surface There should be no scratches or abnor mal wear Surface of oil seal There...

Page 226: ...seizing Thereshouldbenoabnormalscratches wear or seizing Front of the surface which slides with the base plate Thereshouldbenoabnormalscratches wear or seizing Front of the surface which slideswiththe...

Page 227: ...worn parts High pressure hydraulic oil is leaking and flowing out of the drain port due to wear of the motor s sliding parts Bearings are worn Replace the abnormally worn parts Replacethebearingsifthe...

Page 228: ...auses Remedy Remove the foreign matter and repair or replace the damaged parts Install the spring Replace the spring 2 speed Control Function Machine veers during travel Spool doesn t switch over Fore...

Page 229: ...g 9 Shaft SLEW MOTOR CONSTRUCTION Hydraulic Motor 10 Retainer 11 Spring 12 Retainer 13 Guide 14 Pin 15 Valve Plate 16 Bearing 17 Snap Ring 18 Collar 19 Shoe Holder 20 Pin 21 O ring 22 Center Disc 23 S...

Page 230: ...Carrier 2 Reduction Gears 11 Ring Gear 12 Race 13 Needle 14 Planetary Gear 15 Thrust Plate 16 Drive Gear 17 O ring 18 O ring 19 Screw 20 Sun Gear 21 Carrier 1 22 Pin 23 Race 24 Needle 25 Planetary Gea...

Page 231: ...r 24 Spring 25 Body 26 Check Valve Assembly 27 Spring 28 Sleeve 29 Orifice 30 O ring 31 Body 32 O ring 33 Filter 34 Washer 35 Orifice 36 Backup ring A Relief Valve B Timer Valve C Check Valve D Anti r...

Page 232: ...t Conversely if high pressure oil is introduced to port C rotation is the reverse of the above Relief Valve Operation 1 When the Motor is Started When the motor is started since the inertial load is g...

Page 233: ...ure 2nd Step When the piston 11 reaches the stroke end the 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 sid...

Page 234: ...e valve spool 1 is pushed to the right by the force of the spring 2 and the port PG is closed When turning pilot pressure or arm pilot pressure is led to the port SH the spool 1 is moved to the left a...

Page 235: ...atesaclearancebetweenthe 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...

Page 236: ...ULIC UNITS SLEW MOTOR IV 126 TB53FR DISASSEMBLY AND ASSEMBLY Table of Special Tools JIG A NAME DIMENSIONS NAME DIMENSIONS JIG F 1 6 JIG B JIG G 2 7 JIG C JIG H 3 8 JIG D JIG I 4 9 JIG E JIG J 5 10 Uni...

Page 237: ...angle No of teeth A Adjust the internal gear so that a clearance of 0 3 to 0 5 mm is produced when the male gear shown in the table is inserted B Width across flat Profile shifted gear Standard gear t...

Page 238: ...ace all seals with new ones each time the unit is disassembled coating them lightly with grease Check each part to make sure there is no abnormal wear or seizing and use sandpaper etc to remove any bu...

Page 239: ...cover 2 Fix the hydraulic motor with a vise Be careful not to let the valve plate drop off 3 Remove the valve plate 3 from the cover 4 Remove the bearing 4 5 Remove the orifice 5 The orifice is caulk...

Page 240: ...e the spring 7 and check valve 8 7 Remove the relief valve a Remove the plug 9 and piston 10 Do not loosen the set screw nut 11 b Remove the springs 12 and 13 and piston guide 14 Use a pair of tweezer...

Page 241: ...6 Blow the air from the brake release port PB with care such that the brake piston does not protrude 9 Remove the collar 17 Use the jig B 10 Remove the cylinder block 18 friction discs 19 and center d...

Page 242: ...24 retainer 25 spring 26 and retainer 27 from the cylinder block 18 To remove the snap ring push up the retainer 25 by using the press and jig C 14 Remove the swash plate 28 Use the jig B 15 Remove th...

Page 243: ...valve Be careful not to damage or deform the contact surface a Remove the plug 31 b Remove the spring 32 and valve 33 Use a pair of tweezers c Remove the orifice 34 from the valve 33 Adhesive has been...

Page 244: ...4 needles 5 and inner race 6 5 Remove the carrier 1 7 6 Remove the snap ring 8 and then the sun gear 9 7 Remove the carrier 2 assembly 10 8 Loosen the screw and remove the thrust plate 11 Loctite has...

Page 245: ...N and Q in the pinion section of the shaft 19 to hold down the collar 20 Do not remove the shaft unless necessary 12 Put the jig E on the upper part of the shaft and pull out the shaft by using the p...

Page 246: ...ve a Mount the filter 37 washer 36 and orifice 35 on the valve 33 Positiontheholeoftheorifice 35 asshown in the figure b Mount the orifice 34 on the valve 33 Apply adhesive to section A of the orifice...

Page 247: ...iner 25 by using the press and jig C Position the retainer 27 so that its tapered side A faces the cylinder block 3 Fit the pins 23 to the cylinder block Apply grease to the pins 4 Mount the guide 22...

Page 248: ...the cylinder block 18 in the housing Be careful not to let the shoe holder or other parts drop off 10 Mount three center discs 20 and three friction discs 19 Total number of friction discs 3 Total num...

Page 249: ...g 17 14 Assemble the relief valve assembly a Fit the O ring and backup ring to the piston 10 b Fit the backup ring and O ring to the plug 9 c Fit the backup ring and O ring to the relief housing 15 d...

Page 250: ...11 15 Mount the check valve a Mount the spring 7 and poppet 8 on the cover b Fit the O ring to the plug 6 and mount them on the cover Plug 157 10 N m 16 Insert the bearing 4 into the cover Use the ji...

Page 251: ...on the cover Applygreaseonthebackofthevalveplate the sidefacingthecover inadvancetopreventthe plate from dropping off 20 Mount the cover 2 on the case and fix them with the cap screws Be careful not t...

Page 252: ...e shaft Use the jig I and the press to insert 3 Fit the O ring to the shaft and mount the collar 18 Be careful of the mounting direction of the collar 18 Use the jig I and the press to mount 4 Insert...

Page 253: ...plug 25 on the case Theshaft 19 shouldbemountedbeforemount ing the plug 25 8 Mount the inner race 27 of the taper roller bearing to the shaft Use the jig M and the press to mount 9 Mount the U nut 15...

Page 254: ...ry gear B 12 on the carrier 2 Be careful of the mounting direction of the planetary gear B 12 Mount the thrust plate 11 and fix it with the cap screws Apply Loctite 242 to the cap screws in ad vance C...

Page 255: ...re the depth A from the case end to the 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 th...

Page 256: ...HYDRAULIC UNITS SLEW MOTOR IV 146 TB53FR 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...

Page 257: ...d vibration occurs There is a lot of leakage due to faulty seating etc Damaged or severely deformed Replace Replace Replace Replace Replace Replace Replace Replace Replace Parts Standard Dimension Rec...

Page 258: ...tary shaft is large Clearance with pinion is large due to spline wear Amount of wear is great Rotation is abnormal abnormal noise rotation not smooth etc Flaking separation etc on rolling surfaces Pre...

Page 259: ...from oil seals Oil is leaking from mat ing surfaces Noise in piping Lubricating oil Gear unit Relief valve s set pressure is low Pump is broken down Control valve is broken down The load is excessive...

Page 260: ...ed prop erly Foreign matter is trapped The tightening torque of the anti rebound valve mounting bolt exceeds the prescribed value Remove the foreign matter Repair or replace the faulty parts Use the p...

Page 261: ...ame s slew angle Above the hub 1 and shaft 2 which are capable of rotating together ports 3 are included for oil for the necessary number of circuits only The inner circum ference surface of the hub a...

Page 262: ...with sandpa per or by a similar method Check for foreign matter or dirt etc in the seal grooves The following describes the disassembly procedure For assembly follow the disassembly procedure in the...

Page 263: ...eals from the inside diameter of the hub Check the positions of the seals in the struc tural drawing Use an O ring tooth or eyeleteer with a sharp point on the end etc Donotdeformorbendtheslipperseals...

Page 264: ...gone ultrasonic tempering and parts which come off due to seizing biting in of foreign matter etc Replace with new parts Parts with abnormal wear or with scratches 0 1 mm deep or deeper due to seizing...

Page 265: ...justing the relief valve 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 R...

Page 266: ...s Thrust ring is defective Great wear on sliding surfaces Shaft and hub are stuck together Replace all the seal parts Replace the assembly Carry out polishing and honing If looseness and oil leakage a...

Page 267: ...IV 157 TB53FR V TROUBLESHOOTING V 1...

Page 268: ...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 d...

Page 269: ...ne 21 Right or left slewing cannot be done 24 Slewing speed is low or there is no power 25 The machine slews but overrun when slewing stops is great or it cannot be stopped 27 BOOM The boom cylinder d...

Page 270: ...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 1 from the pump side Also fit a plug in the di...

Page 271: ...he bubbling Repair or replace the main relief valve Repair or replace the pump Flush with hydraulic oil 1 Inspect the hydraulic oil level III Machine Configuration Hydraulic Tank 2 Replenish the hydra...

Page 272: ...4 turn of the screw the main relief valve is faulty 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...

Page 273: ...Normal Normal Normal Faulty Faulty Faulty Faulty Faulty Faulty Repair or replace the hydrau lic pump P4 Replace the fuse Adjust or replace the limit switch Repairorreplacetheleverlock solenoid valve...

Page 274: ...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 lim...

Page 275: ...f the interference prevention area Replace the fuse Adjust repair or replace the parts Adjust repair or replace the pilot relief valve Repair or replace the pilot valve Repair or replace the control v...

Page 276: ...25B and ground the test prodonthenegative sideofthetester Then turnthestarterswitchtothe ON positionand check the voltage If the voltage is 12 V the wiring is in the normal state If not inspect the w...

Page 277: ...mthatthecamroller 3 movessmoothly along with the angle 1 pushing the offset switch Confirm that the offset switch is set in the state with the stroke reduced by 4 mm from the free statewhenthecamrolle...

Page 278: ...hetesterandgroundthe test prod on the negative 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 wiri...

Page 279: ...e and the travel lever lock cylinder on the cylinder side Connect a pressure gauge to the discon nected hose and measure the pilot pressure Keep the plug assembled on the port of the disconnected cyli...

Page 280: ...r or replace the travel motor 1 Inspect the operation of actuators other than the travel motor If operation of the right or left travel motor is impossible operate each respective actuator in accordan...

Page 281: ...the pres sure Theswiveljointisnormalifthepressuregauge reading indicates the standard value Standard value Approx 20 6 MPa 5 Inspect the counterbalance valve If neither forward nor reverse travel is...

Page 282: ...tter Repair or replace the housing block Repair the pump or replace it Replace the hydraulic oil and filter Repair or replace the swivel joint Repair or replace the counter balance valve Repair or rep...

Page 283: ...V Hydraulic Units Hydraulic Pump 5 Switch the left and right main relief valves and test Switch the left and right main relief valves and test If the direction in which the machine curves during trave...

Page 284: ...rmal Faulty Faulty Faulty Faulty Faulty Faulty Faulty Faulty Repair or replace the hydrau lic pump P4 Adjust repair or replace the pilot relief valve Replace the fuse Replace the travel speed switch R...

Page 285: ...nd speed solenoid valve and check the fuse for the power supply circuit 4 Inspect the travel speed switch Press the switch to turn it ON While it is in this condition check if there is continuity with...

Page 286: ...e circuit changes then it is normal 7 Inspect the swivel joint Disconnect the hose between the swivel joint and the 2nd speed control valve at the 2nd speed control valve side Set a pressure gauge in...

Page 287: ...ulty Pressure is low Faulty Repair or replace the pilot valve Repair or replace the housing block Adjust the set pressure Repair or replace the slew re lief valve Repair or replace the slew motor Repl...

Page 288: ...e The shuttle valve is normal if between 0 and 3 4 MPa corresponding to the operation angle 4 Inspect the operation of the spool Disconnectthehosethatgoesbetweenthecontrol valve slew section and the s...

Page 289: ...23 TB53FR 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 H...

Page 290: ...t the spool for only the side of the pilot valve for which slewing is impossible will not operate V 22 2 Inspect the operation of the spool It could be that the spool will not move only in the directi...

Page 291: ...re Not within the standard 2 Inspect the pilot valve Normal Normal Normal Faulty Faulty Pressureislow Repair or replace the slew re lief valve Adjust the pressure of the slew relief valve Pressuredoes...

Page 292: ...the slew motor under the following con ditions and measure the amount of oil which drains out in 1 minute a Disconnect the drain hose 1 connected to the motor and insert a plug 2 in the end of the di...

Page 293: ...Pressureislow Adjust the pressure of the slew relief valve Pressure doesn t rise 1 Is the amount of overrun when slewing stops within the standard II Specifications Standards for Judging Performance 2...

Page 294: ...gauge in its supply port Read the pressure gauge after operating the lever slew then releasing it Ifthepressureiszero thepilotvalveisnormal 4 Inspect the check valve of the slew brake valve Iftheslew...

Page 295: ...he pilot valve Normal Normal Does not change Faulty Faulty Operation became normal Repair or replace the boom cylinder Inspect the boom cylin der Faulty THE BOOM CYLINDER DOESN T MOVE The port relief...

Page 296: ...boom lever and measure the pressure A pressure of 20 6 MPa is normal 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 c...

Page 297: ...5 Inspect the pilot valve Normal Normal Does not change Faulty Faulty Operation became normal Repair or replace the boom cylinder Inspect the boom cylin der Faulty The port relief valve is faulty Wit...

Page 298: ...NATURAL DROP IS GREAT 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 reli...

Page 299: ...f valve Normal 2 5 Inspect the pilot valve Normal Normal Does not change Faulty Faulty Operation became normal Repair or replace the arm cyl inder Inspect the arm cylinder Faulty The port relief valve...

Page 300: ...the port relief valve with that of the normal boom If the arm cylinder then operates the port relief valve is faulty 5 Inspect the arm cylinder Switchthearmhosesandbuckethosesconnected to the pipes at...

Page 301: ...lve Not within the standard 2 5 Inspect the pilot valve Normal Normal Does not change Faulty Faulty Operation became normal Repair or replace the arm cyl inder Inspect the arm cylinder Faulty The port...

Page 302: ...nd lower the bucket to the ground b Disconnect the two hoses connected to the cylinder Insert plugs 1 in the disconnected hoses and the cylinder piping c Raisetheboomandraisethehoeattachmentso it floa...

Page 303: ...rm cylinder Repair or replace the arm cyl inder Replace the housing block Not within the standard Normal Faulty 3 There is leakage inside the control valve THE AMOUNT OF ARM NATURAL DROP IS GREAT 1 Is...

Page 304: ...5 Inspect the pilot valve Normal Normal Does not change Faulty Faulty Operation became normal Repair or replace the bucket cylinder Inspect the bucket cylin der Faulty The port relief valve is faulty...

Page 305: ...ort relief valve was faulty 5 Inspect the bucket cylinder At the boom foot exchange the arm hose with the bucket hose that is connected to the pipe Move the lever arm and check whether the bucket cyli...

Page 306: ...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...

Page 307: ...t pedal and measure the pres sure Depending the operation angle if the pressure is normal it will range between 0 3 4 MPa Left Travel Relief Valve R2 Pump P2 Lever Operated Places inspected THE OFFSET...

Page 308: ...ference prevention system is faulty V 10 12 4 Inspect the operation of the spool Disconnect the hose between the control valve offset section and the cylinder on the cylinder side thensetapressuregaug...

Page 309: ...the linkage Normal Faulty Faulty Repair or replace the housing block Normal Faulty Adjust repair or replace the parts Normal Faulty The dozer blade cylinder is faulty Repair or replace the dozer blade...

Page 310: ...ver and inspect the supply pres sure If the pressure indicated is not the value below the housing block is faulty Supply Pressure 19 6 MPa 5 Inspect the swivel joint Disconnect the hose between the sw...

Page 311: ...NATURAL DROP IS GREAT OR THE DOZER BLADE WON T HOLD THE MACHINE UP Faulty Repair or replace the swivel joint or replace the control valve 1 Is the dozer blade s natural drop within the standard II Spe...

Page 312: ...placing the port relief valve with a normal one If the dozer blade can support the machine s body after this then the port relief valve is faulty 3 Inspect the swivel joint and control valve Disconnec...

Page 313: ...V 47 TB53FR VI ENGINE...

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