Takeuchi Mini Excavator TB260 (S/N 126000002~, S/N 126100003~). Operator's Manual

OPERATION

HANDLING RUBBER CRAWLERS

CAUTIONS

Observe the following cautions when

operating the machine:

• Rubber crawler belts are not as stable as

steel crawler belts since the entire lugs are

made of rubber. Be very careful when

slewing and swinging sideways.

• Do not turn the undercarriage with the front

of the machine body lifted using the hoe

PREVENTING THE RUBBER CRAWLERS

attachment (the upperstructure is not

FROM COMING OFF

turned). Doing so will twist the crawlers

with the load concentrated on a single

Observe the following cautions to prevent

point on the crawler belt, causing rapid

the crawler from coming off:

damage to the crawlers.

• Always keep the crawlers at the proper

• Avoid changing course abruptly or spin-

tension.

turning on concrete surfaces whenever

possible. Doing so may wear or damage

the rubber crawlers.

• Avoid drops that may expose the rubber

crawlers to strong shocks.

• Salt, potassium chloride, ammonium

sulfate, potassium sulfate, and triple

superphosphate of lime can damage the

crawler belts. If any of these substances

gets on the crawler belts, wash if off

thoroughly with water.

• Do not let the sides of the rubber crawlers

rub against concrete or walls.

• When traveling over a large step such as a

• Do not damage the rubber crawlers by

cobblestone or rock (20 cm (8 in.) or

hitting the bucket against them.

deeper), climb up the step at the right

• Be especially careful on snowy or frozen

angle and do not change courses on top of

surfaces in winter, as the crawler belts tend

the step.

to slip in such conditions.

• Use rubber crawler belts at temperatures

between -25°C to +55°C (-14°F to 131°F).

• When storing the rubber crawlers for long

periods of time (three months or more), do

so indoors in a place not exposed to direct

sunlight or rain.

3-27

OPERATION

HANDLING RUBBER CRAWLERS

• When climbing in reverse, do not change

• Do not change directions when the crawler

directions at the point where the slope

belts are slack as shown in the figure.

starts.

• The rubber crawler belts will come off if the

• Avoid traveling by setting one crawler on a

machine travels backward in this condition.

slope or projecting portion and the other

crawler on a flat surface (with the machine

at a tilt of 10° or more). Travel with both

crawlers set on flat surfaces.

• The rubber crawler belts will come off if the

machine turns in this condition.

3-28

TRANSPORT

LOADING AND UNLOADING

The machine may roll or tip over or fall

while being loaded or unloaded. Take the

following precautions:

• Select a firm, level surface and keep

sufficient distance from road shoulders.

• Secure the ramps of adequate strength

and size to the truck bed. The slope of

the ramps must not exceed 15°. If the

1. Set the parking brake on the transporter

rumps are bowed down too low,

and chock the wheels.

support them with poles or blocks.

2. Fix the ramps securely to the truck bed.

• Never use the working equipment to

The slope of the ramps must not exceed

load or unload the machine. Doing so

15°.

may result in tipping over or falling

3. Align the center of the truck bed with the

down of the machine.

center of the machine, and of the ramp

• Keep the truck bed and loading ramps

with the center of the crawler.

clean of oil, soil, ice, snow, and other

4. Make sure the dozer blade does not hit

materials to prevent the machine from

the ramps.

sliding sideways. Clean the crawlers.

5. Lower the hoe attachment as far as

• Chock the transporter wheels to prevent

possible without letting it touch the

movement.

transporter.

• Turn off the deceleration switch and

6. Decrease the engine speed.

auto-deceleration switch. Otherwise,

the engine speed may suddenly

increase to cause troubles.

• When being loaded or unloaded, travel

slowly in 1st (low) gear by following the

signal from the signal person.

• Never change courses on the ramps.

• Do not slew/swing on the ramps. The

machine may tip over.

• When slewing/swinging on the truck

bed, do it slowly as the footing should

be unstable.

• Lock the cab door after being loaded, if

applicable. Otherwise, the door may

open during transport.

• Chock the tracks and secure the

machine to the truck bed with wire rope

or chain.

When loading or unloading the machine, be

sure to use ramps or a platform and follow

the procedure below.

4-2

TRANSPORT

HOISTING THE MACHINE

Hoisting

HOISTING THE MACHINE

1. Slew the upperstructure so that the dozer

blade is at the rear of the machine (set the

upperstructure parallel to the track frame).

• Know and use the correct crane signals.

2. Raise the dozer blade fully.

• Check the hoisting equipment for

3. Extend the bucket cylinder and arm

damaged or missing parts on a daily

cylinder fully to raise the boom to its

basis and replace as necessary.

uppermost position.

• When hoisting, use a wire rope capable

4. If the boom is swung to either the left or

of lifting the machine mass.

right side, set it in the neutral position.

• Hoist the machine in such a manner

5. Raise the safety lock lever to the locked

described in the procedure below. Do

position.

not do it in any other manner. Doing so

6. Stop the engine, remove the starter key

is dangerous as it may result in the

and get off the machine.

machine losing its balance.

7. Install the wire ropes as shown on the

• Do not hoist the machine with an

figure below. Install the wire ropes and

operator on it.

hoisting attachment without letting them

• When hoisting, hoist slowly so that the

touch the machine body.

machine does not tip.

8. Hoist the machine slowly until it leaves the

• Keep everyone out of the area when

ground.

hoisting. Do not move the machine over

9. Stop hoisting until the machine becomes

the heads of the persons.

stable, and then start hoisting the machine

slowly again.

IMPORTANT: This hoisting method

applies to machines with standard

specifications. The center of gravity

differs according to the attachments and

optional equipment installed.

Contact your Takeuchi service agent for

details.

4-4

TRANSPORT

SECURING THE MACHINE

After loading the machine at the specified position, secure it as described below.

Transporting posture

1. Lower the dozer blade.

Precautions to be taken during

2. Extend the bucket cylinder and arm

transportation

cylinder fully, and then lower the boom.

3. Raise the safety lock lever to the locked

position.

• Know and follow the applicable safety

4. Stop the engine, remove the starter key

rules, vehicle code and traffic laws

and lock all locks.

when transporting the machine.

5. Place the stoppers (chocks) in front and

• Select the best transport route by

behind the crawlers.

considering the length, width, height

6. Install a chain or wire rope over the lower

and weight of the truck with the

frame of the machine and fasten it

machine loaded on it.

securely to prevent the machine from

• Never abruptly start or stop or run at a

slipping sideways.

high speed at the sharp curves during

7. Secure the bucket with a chain or wire

transport. Doing so will move or lose the

rope.

balance of the loaded machine.

IMPORTANT: Place a wooden block under

the bucket to protect the floor from

damage caused by the bucket.

4-6

MAINTENANCE

GENERAL

CAUTIONS ON MAINTENANCE

GENERAL

MAINTENANCE OVERVIEW

Do not perform any other inspection and

maintenance works than those listed in this

To keep the machine in good condition and

manual.

use if for a long period, perform the

For works not listed in this manual, ask your

inspection and maintenance properly and

sales or a service dealer for help.

safely following the procedures

recommended by this manual.

Keep the machine clean

• Clean the machine before performing

The inspection and maintenance items are

inspection and maintenance and try to

divided into groups according to the

keep it clean.

machine’s total operating time: every 10

• Stop the engine before washing the

hours (walk-around and daily inspection),

machine. Cover the electrical parts so that

every 50 hours, every 250 hours, etc. Refer

water cannot enter. Water on electrical

to the hour meter readings to determine

parts could cause short-circuits or

when to schedule an inspection and

malfunctions. Do not use water or steam to

maintenance. Items for which it is not

wash the battery, electronic control

possible to determine the inspection and

components, sensors, connectors or the

maintenance interval are included under

operator’s compartment.

“When Required”.

Fuel, lubricant and grease

When operating the machine in extremely

• Choose fuel, lubricant and grease by

harsh environments (with high dust levels or

following to the “Fuel and lubricant table”.

high temperatures), inspection and

• Use fuels, lubricants and greases which do

maintenance should be performed earlier

not contain water, and be careful to keep

than the times specified on the Maintenance

dirt out when changing or replenishing fuel,

List.

lubricant or grease.

• Store fuels, lubricants and greases in the

prescribed places and in such a way that

no water or dirt can get in them.

Cautions on refueling

• If the port includes a strainer, do not

remove the strainer when fueling.

• After fueling, be sure to securely tighten the

fuel filler cap.

• Do not add more than the specified

amount of fuel.

Do not use fuel to clean parts

Do not use fuel to clean parts. Use a non-

combustible cleaning agent.

Keep dirt out

When mounting and removing parts, do so in

a place where there is no dust, clean the

working area and the part, and keep dirt out.

5-2

MAINTENANCE

GENERAL

Clean the installation surfaces

Cautions on handling of battery wiring

When installing and removing parts, be sure

• Disconnect the wiring from the both

that the surfaces of contact of the parts are

terminals (+ and -) on the battery before

clean. If the sealing grooves of the surface of

working on the electrical system or doing

contact are damaged, consult your sales or

electric welding.

service dealer for repair or release.

Always disconnect it from the earth side

(-). When connecting, connect the earth

Seals and split pins

side last.

• Be sure to replace all seals and cotter pins

• Do not disconnect the battery wiring while

with new ones.

the engine is moving. Otherwise, the

• When installing, be careful not to damage

electric circuits of the rotary converter or

or twist the seal.

others may be damaged.

Sealing tape

• When wrapping the plug with sealing tape,

remove any old sealing tape from the

threads and clean the threads.

• Wrap the thread tight with seal tape

starting 1 or 2 threads away from the

thread end.

Disposing of wastes

• Always collect oil that is drained from the

machine in containers. Improperly

disposed waste oil can cause

environmental harm.

• Follow appropriate laws and regulations

when disposing of harmful objects such as

oil, fuel, cooling water, coolant, filters and

batteries.

Check after maintenance

• Gradually increase the engine speed from a

low idle to maximum speed and check that

there is no oil or water leaking from

serviced parts.

• Operate each control lever and check that

the machine is operating properly.

5-3

MAINTENANCE

SERVICE DATA

FUEL AND LUBRICANT TABLE

Select the appropriate fuel, lubricant and grease according to the temperature by referring to

the table below.

• Regardless of the specified time, change the oil if it becomes too dirty or degraded.

• When refilling, never mix oils of different brands. If a brand is to be changed, replace the

whole fuel/oil.

Fuel

Diesel fuel specifications

Diesel fuel should comply with the following specifications. The table lists several worldwide

specifications for diesel fuels.

Diesel fuel specification

Location

Diesel fuel specification

Location

ASTM D975

No.1-D S15

No.2-D S15

USA

ISO 8217DMX

International

Bio-diesel fuel

Canada

Biodiesel blends up to B5

ASTM D6751, D7467

EN590: 2009

Bio-diesel fuel

European union BS2869-A1 or A2

United kingdom

Biodiesel blends up to B5

EN14214, EN590

5-4

MAINTENANCE

SERVICE DATA

To maintain the performance and service life of the engine,

always use clean and high-quality fuel.

• To avoid freezing in cold climates, use a diesel fuel that still

functions when the temperature is at least 12°C (53.6°F) below

the lowest expected ambient temperature.

• Use a diesel fuel that has a cetane number of 45 or higher.

When operating at a very low temperature or at a high altitude,

a higher cetane number fuel will be required.

• Use fuel with sulfur content of less than 15 ppm by volume.

Especially in the U.S.A. and Canada, ultra-low sulfur fuel

should be used.

A higher sulfur content fuel may cause sulfuric acid corrosion

in the cylinders of the engines.

Fuel tank

Diesel fuel

• Never mix kerosene, used engine oil, or residual fuel with the

diesel fuel. Use of kerosene is prohibited.

• Poor quality fuel can reduce engine performance and / or

cause engine damage.

• Fuel additives are not recommended. Some fuel additives may

cause poor engine performance.

• The content of metal, such as zinc, sodium, magnesium,

silicon and aluminum, must be 1 mass ppm or less. (JPI-

5S-44-95 test analysis method)

Precautions when using bio-diesel fuel

The warranty of the engine manufacturer may be voided by

using a bio-diesel fuel that does not meet the standard or that is

deteriorated.

5-5

MAINTENANCE

SERVICE DATA

Lubricant

Type by air temperature

Location

Type

-4

86 104°F

When to replace

-20

-10

30 40°C

Diesel engine oil

<Applicable machine

models 126000002 or

later>

API: CD class

ACEA: E3/E4/E5 class

Every 250 hrs

Engine oil pan

JASO: DH1 class

SAE 10W-30

after the initial

<Applicable machine

50 hrs.

SAE 15W-40

models 126100003 or

later>

API: CJ-4 class

ACEA: E6 class

JASO: DH2 class

Takeuchi genuine

Every 4000

ISO VG46

hydraulic oil 46

hrs.***

Hydraulic oil

ISO VG32

tank

Every 2000

Anti-wear hydraulic oil

ISO VG46

hrs.***

ISO VG68

Cooling water

Engine cooling

Mixture of 50% coolant

(water + coolant)**

Every 1000 hrs.

system

Mixture of 30% coolant

SAE: J814C or J1034

Every 1000 hrs

Travel reduction

Gear oil

SAE 90

after the initial

gear

API: GL-4

250 hrs*.

Slew bearing

Lithium based grease

Every 50 hrs.

Working

EP-2

—

Daily or every

equipment

NLGI No.2

10 hrs.

5-6

MAINTENANCE

SERVICE DATA

* : If the ratio of traveling time to 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 (32°F), add coolant (antifreeze). Follow the coolant

manufacturer’s instructions to determine the mixture ratio.

*** :The hydraulic oil replacement interval depends on the type of hydraulic oil being used. New

machine are delivered with Takeuchi genuine hydraulic oil 46, and the hydraulic oil

replacement intervals indicated in this manual assume that Takeuchi genuine hydraulic oil

46 is being used. When using conventional antiwear hydraulic oil, the hydraulic oil should

be replaced every 2000 hours.

API standard: American Petroleum Institute

ACEA standard: Association des Constructeurs Européens d’Automobiles

JASO standard: Japanese Automobile Standards Organization

SAE standard: Society of Automotive Engineers

Volume

Engine cooling

Hydraulic oil

Travel reduction

Engine oil pan

Fuel tank

system

tank

gear

Upper limit

11 L (11.6 US qt.)

System

Level capacity

0.8L X 2

7.4 L (7.8 US qt.)

90 L (23.8 US gal.)

81 L (21.3 US gal.)

(0.85 US qt.) X 2

Lower limit

Tank

76 L (20.1 US gal.)*

4.0 L (4.2 US qt.)

49 L (12.9 US gal.)

*: When the auto fuel supply pump is stopped

5-7

MAINTENANCE

SERVICE DATA

REGULARLY REPLACE THE HYDRAULIC

OIL

When a hydraulic breaker is used, the oil

deteriorates more quickly than that used for

a usual excavation operation. Be sure to

replace the hydraulic oil and the return filter

elements.

• Failure to replace these in time can lead to

damage to the machine and the breaker

hydraulic system. To prolong the service life

of the hydraulic devices, properly replace

the hydraulic oil and the return filter

elements according to the table below.

• When replacing the hydraulic oil, clean the

suction strainer.

Replacement interval (hours)

( ):

When a conventional antiwear hydraulic

oil is used.

Item

Hydraulic oil

Filter element

1st time

—

2nd time

—

100

Periodically

1200 (600)

200

When the breaker operating ratio is 100%.

Refer to “Hydraulic breaker” on page 8-6.

5-8

MAINTENANCE

SERVICE DATA

LIST OF CONSUMABLES

Periodically replace consumables such as filters and elements according to the table below.

System

Item

Part name

Part No.

When to replace

Hydraulic oil

15511-03900

Every 1000 hrs

return filter

after the initial 250

Hydraulic system

Element

hrs.

Pilot line filter

15512-00601

Air breather filter

15520-02715

Every 1000 hrs.

Engine lubrication

Every 250 hrs after

Engine oil filter

Cartridge

Y129150-35153

system

the initial 50 hrs.

<Applicable machine

models 126000002

or later>

Y129907-55801

Fuel filter

Cartridge

<Applicable machine

models 126100003

or later>

Y129A00-55800

<Applicable machine

Fuel system

Every 500 hrs.

models 126000002

or later>

If equipped with filter

Water separator

for high sulfur fuel

Element

filter

Y41650-550800

<Applicable machine

models 126100003

or later>

Y129A00-55730

Every 1000 hrs. or

Primary

after 6 cleanings

(Outer)

19111-12001

(whichever comes

Air cleaner

element

Air cleaner

first)

system

Secondary

When the primary

(Inner)

19111-12002

elements are

element

replaced.

Receiver dryer

19115-14513

Every 2 years

AC system

Ventilation filter

Element

05546-00025

Every year

Circulation filter

Element

05546-03101

Every year

5-9

MAINTENANCE

SERVICE DATA

LIST OF TOOLS (IF EQUIPPED)

Code

Part name

Part No.

Remarks

Spanner

Y28110-100120

10 - 12

Spanner

Y28110-140170

14 - 17

Screwdriver

Y104200-92350

(+) (-) replaceable shank

Filter wrench

Y119640-92750

ø80

for water separator filter

Filter wrench

Y129A00-92750

<Applicable machine models

126100003 or later>

Hammer

16903-00330

3/4

Monkey wrench

16904-00250

250 mm

Pliers

16905-00200

200 mm

Spanner

16900-01922

19-22

Spanner

16900-02427

24-27

Single-ended wrench

16901-00013

Single-ended wrench

16901-00041

Combination wrench

16909-00026

Hex. wrench

16906-00400

4 mm

Hex. wrench

16906-00500

5 mm

Hex. wrench

16906-00600

6 mm

Hex. wrench

16906-00800

8 mm

Hex. wrench

16906-01000

10 mm

Hex. wrench

16906-01400

14 mm

Tool case

16914-00005

Case

16919-00001

Grease gun

16910-60610

600 cc

Drain connector

15545-12601

5-10

MAINTENANCE

SERVICE DATA

LIST OF TIGHTENING TORQUES

Nuts and Bolts (for ISO strength category 10.9)

Tighten nuts and bolts at the torques shown on the table below, unless otherwise specified.

• The tightening torques used for the mounted plastic covers are not listed in the table below.

Consult your sales or service dealer for details. They will be damaged if over tightened.

• When replacing nuts and bolts, replace them with nuts and bolts of the same size and

standards.

• Tighten nuts and bolts alternately (top, bottom, left then right) or in 2 or 3 times so that they

are evenly tightened.

Tightening torque

Head width (b)

Size (a) x pitch

Classification

General connection points

N·m

ft-lb.

M6 x 1.0

9.8±0.5

7.2±0.4

12, 13

M8 x 1.25

22.6±1.1

16.6±0.8

14, 17

M10 x 1.5

47.1±2.4

34.7±1.7

Coarse

17, 19

M12 x 1.75

83.4±4.1

61.5±3.0

19, 22

M14 x 2.0

134.4±6.7

99.1±4.9

22, 24

M16 x 2.0

207.9±10.4

153.3±7.7

27, 30

M20 x 2.5

410.9±20.5

303.1±15.1

12, 13

M8 x 1.0

24.5±1.2

18.1±0.9

14, 17

M10 x 1.25

50±2.5

36.9±1.8

17, 19

M12 x 1.5

87.3±4.3

64.4±3.2

Fine

19, 22

M14 x 1.5

135.3±6.8

99.8±5.0

22, 24

M16 x 1.5

220.6±11

162.7±8.1

27, 30

M20 x 1.5

452.1±22.6

333.4±16.6

5-11

MAINTENANCE

SAFETY-CRITICAL PARTS

To use the machine safely, periodically perform inspection and maintenance. The safety-critical

parts listed below must be periodically replaced for an increased safety.

Serious injury or a fire could result if they are worn or damaged.

List of safety-critical parts

Unit

Safety-critical parts to be replaced periodically

When to replace

Fuel hoses

Fuel system

Packing on fuel filler cap

Heater hoses

Heater & AC systems

Air conditioner hoses

Hydraulic hoses (pump - delivery)

Hydraulic hoses (pump - suction)

Main body

Hydraulic hoses (slew motor)

Hydraulic hoses (travel motor)

Every 2 years

Hydraulic hoses (boom cylinder piping)

Hydraulic hoses (arm cylinder piping)

Hydraulic

system

Hydraulic hoses (bucket cylinder piping)

Hydraulic hoses (swing cylinder)

Working

equipment

Hydraulic hoses (blade cylinder)

Hydraulic hoses (angle blade cylinder)

Hydraulic hoses (pilot valve)

Hydraulic hoses (auxiliary piping)

Seat belt

Every 3 years

5-12

MAINTENANCE

SAFETY-CRITICAL PARTS

The material of the safety-critical part listed above tends to change over time and cause wear

or deterioration. It is difficult to determine the degree of deterioration at the periodic inspection,

and thus they need to be replaced with new ones after a certain time to maintain their proper

performance even if they appear in good condition. Note that regardless of the replacement

schedule, replacement must be performed immediately if a symptom of wear is found. If a

hose clamp is deformed or cracked, replace it together with the hose immediately. When

replacing the safety-critical parts, ask your sales or service dealer.

In addition to the safety-critical parts, inspect the hydraulic hoses and retighten or replace as

necessary. When replacing the hydraulic hoses, replace the O-rings and seals at the same

time.

Check the fuel and hydraulic hoses according to the periodic schedule described below.

Refer to “Maintenance”.

Type of inspection

Inspection item

Leakage from the connecting parts of hydraulic or fuel hoses

Daily inspection

Damage to cab or canopy - replace*

Leakage from the connecting parts of hydraulic or fuel hoses

Monthly inspection

Damaged hydraulic or fuel hoses (cracks, wear and tear)

Leakage from the connecting parts of hydraulic or fuel hoses

Annual inspection

Deteriorated, twisted, damaged hydraulic or fuel hoses (cracks, wear

and tear) or hoses in contact with other parts of the machine

*: Canopy parts No. 05584-00085

*: Cab parts No. 05586-03100

5-13

MAINTENANCE

MAINTENANCE LIST

Inspection and maintenance item

Page

Walk-around inspection

Inspecting by opening the engine hood and covers

5-16

Inspecting by walking around the machine

5-17

Inspecting while sitting in the operator’s seat

5-17

Daily inspection (every 10 hours)

Inspecting and replenishing the coolant

5-18

Inspecting and replenishing the engine oil

5-19

Inspecting the water separator

5-20

Inspecting the fuel level

5-21

Inspecting the hydraulic oil tank level and replenishing

5-22

Lubricating the working equipment

5-23

After the initial 50 hours (only for new machines)

Replacing the engine oil and the oil filter

5-24

Inspecting and adjusting the fan belt

5-26

Inspecting and adjusting the compressor belt (AC)

5-27

Every 50 hours

Inspecting and adjusting the crawler tension

5-28

Lubricating the slew bearing

5-30

Draining the water from the fuel tank

5-30

Inspecting the battery fluid level and replenishing

5-31

Every 100 hours

Cleaning the water separator <Applicable machine models 126000002 or

5-33

later>

After the initial 250 hours (only for new machines)

Replacing the hydraulic oil return filter

5-34

Replacing the pilot line filter

5-35

Replacing the travel motor gear oil*

5-36

Every 250 hours

Replacing the engine oil and the oil filter

5-37

Inspecting and adjusting the fan belt

5-37

Inspecting and adjusting the compressor belt (AC)

5-37

Cleaning the air cleaner

5-38

Cleaning the radiator fins and the oil cooler fins

5-39

Cleaning the air filters (AC)

5-40

Cleaning the condenser (AC)

5-41

Inspecting the refrigerant (gas) level (AC)

5-42

Every 500 hours

Replacing the fuel filter

5-44

Replacing the water separator filter

5-45

*: If the percentage of the traveling time within the total operating time is high, replace the gear

oil earlier than the specified time.

(AC): Air conditioner

5-14

MAINTENANCE

MAINTENANCE LIST

Inspection and maintenance item

Page

Every 1000 hours

Replacing the hydraulic oil return filter

5-46

Replacing the pilot line filter

5-46

Replacing the travel motor gear oil *

5-46

Cleaning the engine cooling system

5-46

Replacing the air cleaner element

5-48

Replacing the air breather filter

5-49

Inspecting and adjusting the engine valve clearance

5-49

Inspecting the engine compression pressure

5-49

Inspecting and cleaning the engine starter and the alternator

5-49

Every 1500 hours

Inspecting, cleaning and checking operation of the engine fuel injectors

5-50

Inspecting the crankcase breather system

5-50

Cleaning the EGR cooler (cleaning the water side and exhaust air passage

5-50

blower) <Applicable machine models: 126100003 or later>

Every 2000 hours

Lapping the engine valve seats

5-51

Every 3000 hours

Inspecting the turbocharger (blow wash as necessary)

5-52

Inspecting, cleaning and checking operation of the EGR valve <Applicable

5-52

machine models: 126100003 or later>

Cleaning the EGR lead valve <Applicable machine models: 126100003 or

5-52

later>

Inspecting and cleaning the DPF soot filter <Applicable machine models:

5-52

126100003 or later>

Inspecting the operation of the air intake throttle valve

5-52

Inspecting and cleaning the injector <Applicable machine models:

5-52

126100003 or later>

Every 4000 hours

Replacing the hydraulic oil and cleaning the suction strainer

5-53

When required

Replacing the bucket teeth and the side cutters

5-56

Replacing the bucket

5-58

Adjusting the gap between the bucket and arm (If equipped)

5-60

Inspecting and replenishing the windshield washer fluid

5-61

Draining the water from the water separator

5-61

Lubricating the levers and pedals

5-62

Inspecting the rubber crawlers

5-63

Replacing the rubber crawlers

5-64

Every 2 years

Replacing the receiver dryer

5-66

*: If the percentage of the traveling time within the total operating time is high, replace the gear

oil earlier than the specified time.

5-15

MAINTENANCE

WALK-AROUND INSPECTION

Perform the following inspections every day before starting the engine for the first time.

• Before operating, perform the walk-around inspections and make repairs immediately

where necessary.

• Be sure to secure the engine hood or cover before working the inside. Do not keep the

hood or cover open on a windy day or if the machine is parked on a slope.

Before starting the engine, look around the machine and clean any combustibles from the

surroundings of the engine. Also, inspect if oil or water is leaking and any nuts or bolts are

loosened.

INSPECTING BY OPENING THE ENGINE

HOOD AND COVERS

1. Check for any twigs, leaves, oil or other

combustible materials around the engine

and battery.

2. Check for oil or engine coolant water

leakage around the engine.

3. Check for oil leakage from the hydraulic oil

tank, hydraulic devices, hoses or

connections.

5-16

MAINTENANCE

WALK-AROUND INSPECTION

INSPECTING BY WALKING AROUND THE

INSPECTING WHILE SITTING IN THE

MACHINE

OPERATOR’S SEAT

4. Check lights for dirt, damage and burnt

14. Check the windshield for dirt or damage.

out bulbs.

15. Check the seat and seat belt for dirt or

5. Check attachments and hoses for

damage.

Check the operator’s seat for dirt, oil or

6. Check the bucket, bucket teeth and side

other combustible materials.

cutter for wear, damage and looseness.

16. Check the monitor, instruments and

7. Check the hook, slip stopper and hook

switches for dirt or damage.

mount of buckets with hooks for damage.

(Option)

8. Check the handrail, the steps and the

slip-resistant surfaces for damage and

loose bolts.

9. Check the crawlers, carrier rollers, track

rollers, idlers and sprockets for damage,

wear and loose bolts.

10. Check for oil leakage from the travel

motor, carrier rollers, track rollers and

idlers.

11. Check the cab and guard for damage

and loose nuts and bolts.

12. Check the mirrors for dirt or damage,

and adjust them.

13. Check the labels for dirt and damage.

5-17

MAINTENANCE

DAILY INSPECTION (EVERY 10 HOURS)

Inspection

DAILY INSPECTION

(EVERY 10 HOURS)

Perform the following inspections every day

before starting the engine for the first time.

• Before operating, perform the daily

inspections and make repairs

immediately where necessary.

• Be sure to secure the engine hood or

cover before working the inside. Do not

keep the hood or cover open on a windy

1. Open the engine hood.

day or if the machine is parked on a

2. Inspect the cooling water level in the

slope.

reserve tank (1).

The level should be between the upper

limit (H) and the lower limit (L).

If it is below the lower limit (L), replenish.

INSPECTING AND REPLENISHING THE

COOLANT

Replenishing

1. Remove the cap (2) of the reserve tank (1).

2. Add cooling water up to the upper limit (H)

of the reserve tank (1).

• Do not remove the radiator cap or the

If the reserve tank (1) is found empty at the

drain plug when the cooling water is

inspection, check for water leakage and

hot. Stop the engine and wait until the

then the water level in the radiator (3). Add

engine and the radiator cool before

water to the radiator (3) as required, and

slowly loosening the radiator cap and

then to the reserve tank (1).

the drain plug to remove them.

3. Install the cap (2).

• Always wear the protective goggle and

gloves when handling coolant

Note: Use only clean water (soft water), such

(antifreeze). If any coolant (antifreeze)

as tap water, to replenish the coolant loss

comes in contact with eyes or skin,

due to evaporation. If the coolant loss is due

wash it off with clean water. Otherwise,

to leakage, replenish the mixture of antifreeze

it could result in injures.

and clean water (soft water) prepared using

the same mixing ratio used for the current

coolant.

5-18

MAINTENANCE

DAILY INSPECTION (EVERY 10 HOURS)

INSPECTING AND REPLENISHING THE

Replenishing

ENGINE OIL

1. Remove the oil filler cap (2).

2. Add oil up to between the upper limit (H)

and the lower limit (L) of the dipstick (1).

Problems could arise if the oil level is either

Stop the engine and allow the machine to

too low or too high.

cool down before performing

3. Tighten the oil filler cap (2).

maintenance.

4. Start the engine, run it at low idle for about

5 minutes, then stop it.

5. After about 10 to 20 minutes, inspect the

Inspection

oil level.

1. Open the engine hood.

2. Take out the dipstick (1) and wipe the oil

off with a rag.

3. Fully reinsert the dipstick (1), and then pull

it back out.

4. Check the oil on the dipstick (1).

The level should be between the upper

limit (H) and the lower limit (L).

If it is below the lower limit (L), replenish.

5-19

MAINTENANCE

DAILY INSPECTION (EVERY 10 HOURS)

INSPECTING THE WATER SEPARATOR

<Applicable machine models 126100003

or later>

• Do not smoke or permit open flames

while handling fuel or working on the

fuel system.

• Stop the engine in a well-ventilated

place and allow it to cool down before

performing maintenance.

• Clean up spilled fuel immediately.

<Applicable machine models 126000002

or later>

1. Turn the starter switch to the ON position.

2. Inspect the water separator warning lamp.

3. If the warning lamp is flashing, drain the

water.

Refer to “Draining the water from the

water separator” on page 5-61.

1. Open the engine hood.

2. Check if there is water in the water

separator (1).

If water collects in the separator, the float

(red ring) (6) goes up. Be sure to drain

water before the float goes up to the

element (5),

3. Loose the vent plug (8) and then the drain

plug (7) to discharge water collected

inside.

4. After drainage of water, tighten each plug

and bleed air from the fuel system.

Refer to “Bleeding air from the fuel

system” on page 6-8.

5-20

MAINTENANCE

DAILY INSPECTION (EVERY 10 HOURS)

INSPECTING THE FUEL LEVEL

• Do not smoke or permit open flames

while handling fuel or working on the

fuel system.

• Never remove the fuel cap or add fuel

when the engine is running or still hot.

Do not spill fuel on the hot surface of

the machine.

• Fill the fuel tank in a well ventilated

place.

• Clean up spilled fuel immediately.

• Do not fill the fuel tank to capacity.

Allow room for oil expansion.

• Securely tighten the fuel filler cap.

• Use the correct grade of fuel for the

operating season.

1. Check the fuel level using the fuel gauge

(1).

F: Tank is full.

E: Tank is empty.

2. If the fuel level is low, open the fuel lid.

3. Add fuel from the fuel filler port (2) while

watching the sight gauge (3).

Refer to “Fuel filler port” on page 2-8.

5-21

MAINTENANCE

DAILY INSPECTION (EVERY 10 HOURS)

INSPECTING THE HYDRAULIC OIL TANK

Replenishing

LEVEL AND REPLENISHING

Oil may spurt out if caps or filters are

removed or pipes are disconnected

before releasing the pressure in the

hydraulic system.

• Press the air breather button to relieve

the internal pressure from the tank.

Inspection

IMPORTANT: Do not fill up to the level

The oil level changes with the oil

higher than the upper limit (H). It will

temperature. Inspect the oil by maintaining

damage the hydraulic circuits or result in

the machine at posture shown in the figure at

oil spurting. If accidentally done, stop the

the next.

engine and wait the hydraulic oil to cool,

• Machine posture for inspecting the

and then let the excessive oil to drain

hydraulic oil level

from the drain plug.

1. Open the right side cover.

2. Press the air breather button (2) to relieve

the internal pressure from the tank.

3. Remove the plug (3).

4. Add the hydraulic oil up to the middle

point of the sight gauge (1).

5. Tighten the plug (3).

1. Start the engine and run it at low speed.

2. Fully retract the cylinders (arm and

bucket), and lower the bucket to the

ground.

3. Lower the dozer blade, and then stop the

engine.

4. Open the right side cover.

5. Inspect the oil level using the sight gauge

(1).

· When the oil temperature is about 20°C

(68°F):

The level should be between the upper

limit (H) and the lower limit (L).

If it is below the lower limit (L), replenish.

· When the oil temperature is about 50 to

80°C (122 to 176°F):

The level should be slightly below the

upper limit (H).

5-22

MAINTENANCE

AFTER THE INITIAL 50 HOURS (ONLY FOR NEW MACHINES)

AFTER THE INITIAL 50

HOURS (ONLY FOR NEW

MACHINES)

REPLACING THE ENGINE OIL AND THE

OIL FILTER

Stop the engine and allow the machine to

2. Loosen the bolts and remove the under

cool down before performing

cover (3).

maintenance.

3. Place a pan for catching the waste oil

• The engine, muffler, radiator, hydraulic

under the drain plug (4).

lines, sliding parts and many other parts

4. Remove the cap (A), install connector (B)

of the machine are hot immediately after

and drain the oil. (The oil comes out when

the engine is stopped. Touching these

the screw is tightened.)

parts will cause burns.

5. Remove the connector (B) and install the

• The engine oil is also hot.

cap (A).

Be careful not to touch the hydraulic oil

6. Install the under cover (3).

when loosening the cap or plug.

Working on the machine under these

IMPORTANT: Check the waste oil for

conditions could result in burns or

metal powder. If it contains large amounts

injuries.

of metal powder, consult your sales or

service dealer.

Engine oil

1. Open the engine hood and remove the oil

filler cap (2).

5-24

MAINTENANCE

AFTER THE INITIAL 50 HOURS (ONLY FOR NEW MACHINES)

Engine oil filter

7. Turn the filter (5) counterclockwise with the

filter wrench and remove it.

8. Clean the surface of installation of the filter

stand.

9. Apply a thin layer of oil on the packing of

the new filter.

10. Install the new filter by hand.

11. Tighten one more turn (with the filter

wrench) after the filter packing comes in

contact with the surface of installation.

(Torque when tightening with filter

wrench: 19.6 to 23.5 N·m or14 to 17

ft-lb.)

12. Add oil up to between the upper limit (H)

and the lower limit (L) of the dipstick (1).

Problems could arise if the oil level is

either too low or too high. It takes around

10 to 20 minutes for all of the added oil

to go down to the oil pan.

13. Tighten the oil filler cap (2).

14. Start the engine, run it at low idle for

about 5 minutes, then stop it.

15. After about 10 minutes, inspect the oil

level.

5-25

MAINTENANCE

AFTER THE INITIAL 50 HOURS (ONLY FOR NEW MACHINES)

INSPECTING AND ADJUSTING THE FAN

Adjustment

BELT

Stop the engine and allow the machine to

cool down before performing

maintenance.

• The engine, muffler, radiator, hydraulic

lines, sliding parts and many other parts

of the machine are hot immediately after

the engine is stopped. Touching these

parts will cause burns.

1. Loosen the bolt (5) and locking nut (4).

IMPORTANT: The loose belts could result

2. Turn the adjustment bolt (6) to move the

in bad battery charge, overheat of engine

alternator (7) and to adjust the tension of

or early wear of belt. Too tight belts could

the fan belt (1).

damage the water pump or bearing and

· Tighten: Clockwise

belt used to drive the alternator.

· Loosen: Counterclockwise

IMPORTANT: Do not let any oil or grease

3. Tighten the bolt (5) and locking nut (4).

get on the belt.

Note: When replacing with a new belt, run

the engine at low idle speed for about 3 to 5

Inspection

minutes to break in the new belt, before

1. Open the engine hood.

adjusting the tension.

2. Press the fan belt (1) at the midpoint

between the fan pulley (2) and alternator

pulley (3) to check the tension (approx. 98

N or 22 lbf).

The slack (A) should be 7 to 10 mm (0.28

to 0.4 in).

3. Inspect the fan belt (1) and replace if it is

as follows.

· There are cuts or cracks.

· The belt is worn and touches the bottom

of the V groove in the pulley.

· The belt stretched too loose to be

adjusted.

5-26

MAINTENANCE

AFTER THE INITIAL 50 HOURS (ONLY FOR NEW MACHINES)

INSPECTING AND ADJUSTING THE

Inspection

COMPRESSOR BELT (AC)

• Stop the engine and allow the machine

to cool down before performing

maintenance.

· The engine, muffler, radiator, hydraulic

lines, sliding parts and many other

parts of the machine are hot

immediately after the engine is

stopped. Touching these parts will

cause burns.

1. Open the engine hood.

• The high-pressure pipes of the air

2. Measure the belt (1) tension using the belt

conditioner can be very hot (80 to 120°C

tension gauge. The belt tension is normal

or 176 to 248°F). Be careful not to burn

if the belt tension gauge indicates the

yourself.

following values.

294 to 392 N or 66 to 88 lbf.

IMPORTANT: Do not let any oil or grease

get on the belt. It will cause the belt to

Adjustment

slip, decrease the cooling capacity or

If the belt tension is not normal, adjust it with

shorten the service life of the air

the adjuster bolt (2).

conditioner.

1. Loosen the locking nut (3).

2. Turn the adjuster bolt (2) as follows.

If the belt is too slack, it will slip and vibrate,

· Tighten: Clockwise

resulting in decreased cooling capacity. The

· Loosen: Counterclockwise

service life of the air conditioner also will be

3. Tighten the locking nut (3) after

shortened. Adjust the belt tension to the

adjustment.

standard value.

Tightening torque:

· Locking nut (3) 31.4 to 45.1 N·m (23.2

to 33.3 ft-lb.)

Note: When replacing with a new belt, run

the engine at low idle speed for about 3 to 5

minutes to break in the new belt, before

adjusting the tension again.

Replacing

Replace the belt in the following cases:

· There are cuts or cracks.

· The belt is worn and touches the bottom of

the V groove in the pulley.

· The belt stretched too loose to be

adjusted.

5-27

MAINTENANCE

EVERY 50 HOURS

1. For rubber crawlers, move the machine so

EVERY 50 HOURS

that the “M”, “J” or “∞” mark at the joint is

INSPECTING AND ADJUSTING THE

at the top center of the crawler frame.

CRAWLER TENSION

• If you must work beneath the raised

machine or working equipment, always

use wood blocks, jack-stands or other

rigid and stable supports. Never get

under the machine or working

equipment if they are not sufficiently

supported. This procedure is especially

important when working on hydraulic

cylinders.

2. Use the working equipment to lift the

• Be careful with the high-pressure grease

machine body. Operate the levers slowly.

In the track adjuster, the grease has

been injected under high pressure. If the

tension is adjusted without following the

prescribed procedure, the grease

discharge valve may fly off, resulting in

injury.

· Never loosen the grease fitting.

· Loosen the grease discharge valve

slowly. Do not turn it more than one

turn.

· Do not put your face, arms, legs or

body in front of the grease discharge

valve.

3. Inspect the gap (A or B) between the

· If grease does not come out when the

bottom surface of the frame at the center

grease discharge valve is loosened,

of the crawler frame and the top surface of

the valve is faulty. Ask a Takeuchi

the crawler.

service agent for repair.

The gap (A or B) must be within the

following range:

Inspection

(A) Rubber crawler

83 to 93mm (3.3 to 3.7 in.)

(B) Steel crawler

150 to 170mm (5.9 to 6.7 in.)

(B) Segmental rubber crawler

150 to 170 mm (5.9 to 6.7 in.)

5-28

MAINTENANCE

EVERY 50 HOURS

Adjustment

Increasing the tension

1. Remove the cover (1).

2. Using the grease gun, insert grease

through the grease fitting (3) in the grease

discharge valve (2).

3. Inspect the crawler tension.

Decreasing the tension

1. Remove the cover (1).

2. Using the spanner, slowly loosen the

grease discharge valve (2) (one turn) and

drain the grease.

If the grease does not drain easily, move

the machine forward or backward.

3. Tighten the grease discharge valve (2).

· Tightening torque: 60 to 80 N·m (44.3 to

59 ft-lb.)

5-29

MAINTENANCE

EVERY 50 HOURS

LUBRICATING THE SLEW BEARING

4. Lower the bucket to the ground, and then

stop the engine.

5. Repeat the steps 2 to 4 above three

times.

Do not slew while lubricating. Doing so is

6. Wipe off the grease expelled from the slew

dangerous, as you may get caught in the

bearing and grease fitting.

machine.

DRAINING THE WATER FROM THE FUEL

TANK

• Do not smoke or permit open flames

while handling fuel or working on the

fuel system.

• Never remove the fuel cap or add fuel

when the engine is running or still hot.

Do not spill fuel on the hot surface of

1. Stop the engine with the machine in the

the machine.

posture shown on the figure above.

• Fill the fuel tank in a well ventilated

place.

• Do not fill the fuel tank to capacity.

Allow room for oil expansion.

• Clean up spilled fuel immediately.

• Securely tighten the fuel filler cap.

• Use the correct grade of fuel for the

operating season.

Do the draining operation before starting the

machine.

2. Use the grease gun to grease the grease

fitting (1).

3. Start the engine, lift the bucket and slew

clockwise 90°.

5-30

MAINTENANCE

EVERY 50 HOURS

INSPECTING THE BATTERY FLUID LEVEL

AND REPLENISHING

• Do not use the battery when the fluid

level is below the lower level limit. Doing

so will hasten the deterioration of the

internal portions of the battery and

shorten the battery life. It also can

cause rupturing (explosion).

1. Open the fuel lid.

• Batteries generate flammable hydrogen

2. Remove the fuel filler cap (2).

gas which may explode. Keep away

3. Loosen the bolts and remove the under

from flame, sparks, fire or lighted

cover (3).

cigarettes.

4. Place a pan under the drain valve (4).

• Use a dampened cloth to clean above

5. Remove the cap (A), install the connector

the fluid level line and check the fluid

(B), and then drain the water and sediment

level. Do not clean with a dry cloth;

buildup in the bottom of the tank (the

otherwise it can cause static electricity

water comes out when the screw is

to build up, resulting in ignition or

tightened).

explosion.

6. Remove the connector (B) and install the

cap (A).

7. Install the under cover (3).

8. Add fuel while watching the sight gauge

• Wear protective goggle and clothing

(1).

when working with batteries.

9. Tighten the fuel filler cap (2).

• Do not add the distilled water above the

10. Close the fuel lid and lock it with the key.

upper level limit. Doing so could cause

11. Bleed air.

the fluid to leak. This fluid can cause

skin damage if contacted, or can cause

Bleeding air from the fuel system

the machine components to corrode.

Refer to “Bleeding air from the fuel system”

• Batteries contain sulfuric acid which will

on page 6-8.

damage eyes or skin if contacted.

· If eye contact occurs, flush

Note: Air in the fuel system causes the

immediately with clean water and get

engine to fail to start or to have problems.

prompt medical attention.

Bleed air when the fuel tank is emptied,

· If accidentally swallowed, drink large

using the same procedure above.

quantities of water or milk and call a

physician immediately.

· If acid contacts skin or clothing, wash

off immediately with a lot of water.

5-31

MAINTENANCE

EVERY 50 HOURS

Inspection

• If the fluid level cannot be checked by fluid

level lines:

IMPORTANT: Check the fluid level of all

cells following the steps below, even

when the fluid level can be checked using

the indicator.

1. Open the right side cover.

Remove the caps (2) and look into the

fluid filler holes to check the fluid level. If

the fluid is below the sleeve (3), be sure to

add distilled water up to the bottom edge

of the sleeve (3).

2. Inspect the indicator (1).

Proper level (A)

· Blue: Good

If the fluid reaches up to the bottom edge

· White: Charging needed

of the sleeve (3), the surface tension

· Red: Insufficient battery fluid

causes the fluid to swell and the plate

3. Inspect the fluid level.

appears as if it is distorted.

The fluid level must be between the upper

level line (H) and lower level line (L). If not,

Level too low (B)

add distilled water up to the line (H).

If fluid does not reach up to the bottom

edge of the sleeve (3), the plate looks

laminar, not distorted.

4. Check the terminals for looseness and

dirt.

Replenishing

When adding distilled water, do so before

starting operations in order to prevent

freezing.

1. Remove the caps (2), and add distilled

water until the upper level (H).

2. Check that the indicator (1) turns blue.

3. Clean the exhaust hole on the cap, then

tighten the caps (2) securely.

5-32

Takeuchi Mini Excavator TB260 (S/N 126000002~, S/N 126100003~). Operator's Manual - page 5