Takeuchi's own Workshop Manual for the TB153FR compact excavator, document CJ3E004, sets out across 431 pages the disassembly, assembly, maintenance reference values and troubleshooting for this machine. Hydraulic schematics in this Takeuchi TB153FR service manual PDF trace oil from the pump through the control valve and pilot circuit out to the travel motor, slew motor and swivel joint, while the wiring and controller connection diagrams let you follow a dead circuit back to its source. Troubleshooting is laid out by symptom (travel, slewing, boom, arm, bucket, dozer blade and auxiliary hydraulics), ending with a Yanmar engine error code table. Change the hydraulic oil at 4000 hours on Takeuchi genuine 46, or 2000 hours on conventional antiwear oil, and pull a 1/2 hose union nut to 58.8 +4.9/0 N·m. Bookmarked and text-searchable, this file keeps the reference values a page away.
What's Inside This Takeuchi TB153FR Manual
| System | Pages | Key Topics |
|---|---|---|
| Safety Precautions | 3-8 | Safety Alert Symbol, Signal Words, Clothing and Personal Protective Equipment, Fire Extinguisher and First Aid Kit, Anti-Explosive Lighting, Unauthorized Personnel |
| Cautions During Disassembly and Assembly | 9 | |
| Cautions During Removal and Installation of the Hydraulic Units | 9 | |
| Cautions During Removal and Installation of Piping | 10 | Hydraulic Hoses, Fittings, Maximum Working Pressure |
| Handling of Seals | 10 | O-Rings, Floating Seals, Oil Seals |
| General Safety and Maintenance Cautions | 11-18 | Safety Symbols, Fire Safety, Battery Hazards, Disassembly/Assembly Cautions, Tightening Torques, Bolt/Nut Specifications |
| Specifications | 19-46 | Machine Dimensions, Operating Range, Component Specifications, Mass Tables, Recommended Lubricants, Servicing Standards, Performance Inspection Methods |
| Machine Configuration | 47-180 | Drive System, Slew System, Travel System, Upper Frame, Control System, Attachments, Hydraulic System, Electrical System |
| Hydraulic Units | 181-182 | |
| Hydraulic Pump | 183-212 | Piston Pump, Gear Pump, Discharge Volume Control, Pilot Relief Valve and Solenoid Valve, Operation, Disassembly and Assembly, Inspection and Adjustment, Troubleshooting |
| Control Valve | 213-234 | Main Relief Valve, Port Relief Valve, Anti-Cavitation Valve, Load Check Valve, Boom Block, Travel Block, Operation, Disassembly and Assembly, Inspection and Adjustment, Troubleshooting |
| Pilot Valve | 235-258 | Pilot Valve (Travel), Pilot Valve (Offset), Operation, Disassembly and Assembly, Inspection and Adjustment, Troubleshooting |
| Solenoid Valve | 259-284 | Solenoid Valve (Interference Prevention), Proportional Control Solenoid Valve, Shut-Off Valve, Disassembly and Assembly, Inspection and Adjustment, Troubleshooting |
| Cylinders | 285-302 | Operation, Inspection and Adjustment, Troubleshooting, Table of Special Tools |
| Travel Motor | 303-324 | Operation, Counterbalance Valve, Parking Brake, Disassembly and Assembly, Inspection and Adjustment, Troubleshooting |
| Slew Motor | 325-348 | Operation, Disassembly and Assembly, Inspection and Adjustment |
| Swivel Joint | 349-354 | Operation, Disassembly and Assembly, Troubleshooting |
| Troubleshooting | 355-400 | Troubleshooting Cautions, Overall Machine Issues, Travel Issues, Slewing Issues, Boom/Arm/Bucket/Dozer Blade Issues, Auxiliary Hydraulics |
| Engine and Maintenance Tools | 401-431 | Yanmar Diesel Engine, Engine Trouble Diagnostics Tool, Maintenance Software, Controller Connection Diagrams, Error Code Table |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Hydraulic Hoses Union Nut (G) Torque 1/8 | 9.8 +4.9/0 N·m | p. 15 |
| Hydraulic Hoses Union Nut (G) Torque 1/4 | 24.5 +4.9/0 N·m | p. 15 |
| Hydraulic oil replacement interval (Takeuchi genuine hydraulic oil 46) | 4000 hrs | p. 29 |
| Hydraulic oil replacement interval (conventional antiwear hydraulic oil) | 2000 hrs | p. 29 |
| V-belt tension adjustment slack | 8 mm | p. 55 |
| Belt deflection | approx. 8 mm/98 N | p. 129 |
| Boom raise solenoid valve pressure | 0-3.4 MPa | p. 366 |
| Left offset solenoid valve pressure | 0-3.4 MPa | p. 366 |
| Hydraulic Tank Total System Capacity | 110 L | p. 29 |
| Hydraulic Tank Level Capacity | 68 L | p. 29 |
| Fuel Tank Capacity | 65 L | p. 29 |
| Engine Cooling System Capacity | 8.8 L | p. 29 |
Takeuchi TB153FR Common Problems This Manual Covers
Takeuchi TB153FR hydraulic oil level low or pump coupling faulty, no machine operations can be done
Inspect the hydraulic oil level first and top up with the same brand already in the tank. Tank level capacity is 68 L per page 29. If the level is right, release all hydraulic pressure (page 11), then disconnect and plug the pump discharge hose. Unplug the engine stop solenoid wiring and crank on the starter. No oil discharged means the pump or coupling is faulty (page 358).
Manual Section: Overall Machine Troubleshooting p. 358Hydraulic pump suction hose pinched, suction filter clogged or suction joint loose, with loud abnormal pump noise
Stop the engine and let the machine cool before touching hot oil lines (page 10), then release all hydraulic pressure (page 11). Check the suction hose for pinching, clean a clogged suction filter, and retighten each suction side joint to stop air ingress. If the noise persists, check oil viscosity, look for bubbles in the oil, verify engine speed and check the drain piping per page 210.
Manual Section: Hydraulic Pump Troubleshooting p. 210Control valve cannot hold boom, arm or bucket cylinder in spool neutral position, cylinder drops
Lower all working equipment to the ground before working under the machine (page 9). Check whether it is only the cylinder's natural drop; if the cylinder itself leaks, disassemble and repair it. On pilot operated spools, check pilot pressure in case the spool is not returning to neutral. Release all hydraulic pressure (page 11), then disassemble and check the port relief and anti-cavitation valve seats for trapped foreign matter (page 233).
Manual Section: Control Valve Troubleshooting p. 233Travel motor sliding parts or bearings worn, motor won't speed up and rotational speed changes greatly
Check that proper pressure is reached at the motor inlet port side. If it is not, trace the hydraulic pump and control valve and repair as needed (page 322). Release all hydraulic pressure before opening the motor (page 11). Inspect the motor sliding parts for abnormal wear and replace any worn parts. Replace bearings that are abnormally worn, and replace damaged oil seals and O-rings if the motor is leaking.
Manual Section: Travel Motor Troubleshooting p. 322Travel motor 2-speed control spool doesn't switch over, machine veers during travel
Release all hydraulic pressure before opening the 2-speed control function (page 11). Inspect the spool for caught foreign matter, remove it, and repair or replace any damaged parts. Check that the spring is present and install it if missing. Replace a damaged spring. Work through the 2-speed control checks on page 323 before chasing other travel components.
Manual Section: Travel Motor Troubleshooting p. 323Solenoid valve coil or wiring short-circuited or broken, or spool catching foreign matter, valve does not operate
Disconnect the battery before working on the electrical system (page 11). Check the wiring and solenoid coil for a short circuit or wire break and replace whichever has failed. If the wiring and coil check out, release all hydraulic pressure (page 11), then overhaul the valve. Inspect the spool and plunger for foreign matter or outer circumference damage, and repair or replace following page 266.
Manual Section: Solenoid Valve Troubleshooting p. 266Frequently Asked Questions
How do I bleed the air from the hydraulic cylinder?
To bleed air from the hydraulic cylinder, start the engine and let it idle for approximately 5 minutes. With the engine running at slow speed, extend and retract the cylinder 4 or 5 times, moving the piston rod to a position 100 mm before the end of the stroke. Finally, with the engine at top speed, repeat the operation and move the piston rod to the stroke end, applying relief. p. 299
What is the tightening torque for the hydraulic hose union nut with a 1/4 inch fitting size on the Takeuchi TB153FR?
The tightening torque for a 1/4 inch hydraulic hose union nut (G) is 24.5 +4.9/0 N·m (18.1 +3.5/0 ft-lb). p. 15
What is the replacement interval for the engine oil in the Takeuchi TB153FR engine oil pan?
The engine oil in the engine oil pan should be changed after the first 50 hours of operation, and then every 500 hours thereafter. p. 29
What is the procedure for adjusting the control force of the throttle lever?
To adjust the control force of the throttle lever, loosen the lock nut (9) and turn the nut (10) until the control force is 29.4 N. Once the adjustment is complete, tighten the lock nut (9) while holding the nut (10) to prevent it from turning. p. 61
What is the standard clearance for the bucket and arm connection pin on a Takeuchi TB153FR?
The standard clearance for the connection between the bucket and the arm is 0.14 to 0.22 mm, with an allowable clearance limit of 1.0 mm before replacement is required. p. 33
How will I receive this Takeuchi TB153FR Service Manual?
A 431-page Service Manual in searchable PDF format, available the moment you complete checkout. View on computer, tablet, or phone, with no shipping wait.
Is this Takeuchi TB153FR manual print-friendly?
Yes. Print the sections you need to take out to the shop for your own use. Standard letter or A4 paper works.
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