Takeuchi Mini Excavator TB215R (No.215000003~). Operator's Manual

0B0BZ00

FOREWORD

This manual, which is written for engineers who service the machine, describes procedures for disassembly and assem-
bly, inspection and maintenance, and troubleshooting, as well as maintenance reference values and an outline of the
specifications. Refer to this manual during daily work to improve your services. Note that the information is subject to
change without notice due to design modifications made to the machine from time to time by the manufacturer.

Directional terms: front, rear, left, right

In this manual, front and back/left and right are based on ori-
entations when sitting in the driver’s seat with the blade be-
ing at the front.

Machine serial number

The machine serial number is stamped on the identification
plate. Be sure to include this number when sending a report
or inquiry or when ordering parts.

Symbols used in this manual

The symbols used in this manual have the following mean-
ings.

Indicates the machine serial number.
Means “Refer to the section quoted.”
Indicates the mass of the equipment or machine.
Means “Tighten to the torque specified here.”
Indicates the use of thread-locking compound. (Three-
Bond #1324, or an equivalent)
Indicates the use of grease. (Lithium grease EP2/NLGI
No.2)

Manual structure

This manual consists of the following parts.
1.

Safety

Service data

Function

Disassembly and assembly

Troubleshooting

Other

0B0BZ01

FRONT

VORN

AVANT

๓

RIGHT

RECHTS

DROITE

ྑ

LEFT

LINKS

GAUCHE

ᕥ

REAR

HINTEN

ARRIERE

ྡྷ

SAFETY

SAFETY ALERT SYMBOL

SAFETY ALERT SYMBOL

1A0BO001

SAFETY ALERT SYMBOL

Safety label

Safety labels are used to alert operators or other people
exposed to the risks of injury or damage. There are the
following three types of labels.
Read the labels carefully as they are important for your
safety.

IMPORTANT: The word “IMPORTANT” is used to alert
operators and maintenance personnel about any in-
formation which requires special attention or guid-
ance; information that needs to be highlighted; and
situations which could result in damage to the ma-
chine and its components.

This manual is intended for trained and qualified person-
nel only. Warnings or cautions described in this manual
do not necessarily cover all safety measures. It is also im-
possible to cover all hazards and risks which may be as-
sociated with the maintenance of the machine in every
environment. For maintenance work, each person must
take adequate safety precautions against possible haz-
ards in the respective working environment.

This symbol represents the safety
alert.
The message that follows the sym-
bol contains important information
regarding human safety.
Read and understand the message
to avoid personal injury or death.

DANGER

The word “DANGER” indicates an imminently hazard-
ous situation which, if not avoided, is likely to result
in serious injury or death.

WARNING

The word “WARNING” indicates a potentially hazard-
ous situation which, if not avoided, could result in se-
rious injury or death.

CAUTION

The word “CAUTION” indicates a potentially hazard-
ous situation which, if not avoided, may result in mi-
nor or moderate injury.

SAFETY

SAFETY PRECAUTIONS

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SAFETY PRECAUTIONS

Observe all safety rules

• Operation, inspection and maintenance of this ma-

chine must be performed only by a trained and quali-
fied person.

• All rules, regulations, precautions and safety proce-

dures must be understood and followed when per-
forming operation, inspection and maintenance of this
machine.

• Do not perform any operation, inspection or mainte-

nance of this machine when under the influence of al-
cohol, drugs, medication, fatigue or insufficient sleep.

Wear safe clothing and protective gear

• Do not wear loose clothing or any accessory that can

catch on the controls or the moving parts of the ma-
chine.

• Do not wear clothing stained with oil or grease that can

easily catch fire.

• Wear protective gear such as helmet, safety shoes,

protective goggles, respirator, gloves and earmuffs,
as appropriate, depending on the work involved. Es-
pecially make sure to wear protective eye-wear and
mask when working with a grinding/polishing/sanding
machine, hammer or compressed air, as metal frag-
ments or other objects could scatter in such an envi-
ronment.

• Wear hearing protectors when operating the machine.

Loud and prolonged noise can damage or destroy
your hearing.

Install an extinguisher and a first aid kit

• Install an extinguisher to fight a fire, and learn how to

use it.

• Prepare a first aid kit and keep it at a designated

place.

• Decide on the procedures to be used in case of fire or

other hazards.

• Decide on and take note of the contact(s) in case of

emergency.

Place a “Do not operate” alert sign

Serious injury or death may result if an unauthorized per-
son starts the engine or touches the controls during in-
spection or maintenance.
• Before performing maintenance, stop the engine, re-

move the key and store it in a safe place.

• Prominently display a “Do not operate” alert sign on

places such as the starter switch and the control lever.
Place another sign outside of the machine as neces-
sary.

Use the correct tools

Do not use damaged or weakened tools or tools de-
signed for other purposes. Use only the correct tools for
the work involved.

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SAFETY

SAFETY PRECAUTIONS

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Regularly replace the safety-critical parts

• Regularly replace fuel hoses to prevent a fire hazard.

Hoses wear out over time, even if they do not show any
symptom of wear.

• Regardless of the replacement schedule, replace im-

mediately if a symptom of wear is found.

Explosionproof lighting

To prevent an ignition or explosion, use explosion-proof
lights when inspecting fuel, oil, coolant or battery fluid.

Prohibit access by unauthorized persons

Do not allow unauthorized personnel in the work area
while working.
Take particular care that no unauthorized person is pres-
ent when grinding, welding or using a hammer.

Prepare the work area

• Select a level and firm ground on which to perform

maintenance work. Make sure that the work area is
light enough and well ventilated.

• Straighten any obstacle or dangerous object, remove

any spill of oil or grease and clean the work area.

When the canopy is tilted up

• If the canopy is raised or lowered while the engine is

moving, the machine may accidentally start moving,
resulting in severe injury to the maintenance person-
nel. Make sure that the working equipment has been
lowered to the ground and the engine has been turned
off before raising/lowering the canopy.

• When the canopy is tilted up, firmly secure the canopy

with a stopper to prevent it from falling.

Keep the machine clean

• Clean the machine before performing maintenance

and try to keep it clean.

• Before washing, cover the electrical parts with vinyl to

prevent water from entering, as this could cause a
short-circuit or malfunction. Do not use water or steam
to wash the battery, sensors, connectors or the opera-
tor’s seat area.

Stop the engine before performing maintenance

Make sure the engine is stopped before starting inspec-
tion or maintenance. If maintenance must be performed
with the engine running, always work as a 2-person team,
communicating with each other.
• One of them must sit at the operator’s seat and stop

the engine whenever necessary. He/she must take
care not to touch the lever or pedal unless necessary.

• The one who performs maintenance must make sure to

keep his/her body or clothing away from the moving
part of the machine.

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SAFETY

SAFETY PRECAUTIONS

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Keep clear of the moving fan and belt

• Any object that can be easily caught in moving parts

must be kept away.

• If a hand or tool becomes trapped in the fan or fan belt,

you could lose your finger. Do not touch the fan or belt
while they are moving.

When working under the machine

• Before performing maintenance or repairs under the

machine, set all movable equipment against the
ground or in the lowermost position.

• Place chocks under the crawler tracks to secure the

machine.

• If it is unavoidably necessary to work under the raised

machine or working equipment, be sure to firmly sup-
port it by using an arm stopper, wooden block, stand
or safety brace. Never go under the raised machine or
working equipment without such protection measures.

When working on the machine

• To prevent slipping/falling from machine, clear the

footing and observe the following:
a. Do not spill oil or grease on the machine.
b. Keep the machine tidy and clean.
c. Be careful when walking around the machine.

• Never jump down from the machine. Climb up/down

the ladder (steps) holding the handrail to support your
weight in a three point secure stance (hand and feet).

• Wear protective gear according to the work involved.

Securing the working equipment

When replacing/repairing the bucket teeth or side cutter,
secure the relevant equipment to prevent any accidental
movement.

Secure the engine hood and guard when they are
open

Firmly secure the machine when the engine hood or
guard is left open. Do not keep the hood or guard open
on a windy day or if the machine is parked on a slope.

Place heavy components in a stable position

When it is necessary to temporally place a heavy compo-
nent, such as the hoe attachment, on the ground during
removal or installation, be sure to place it in a stable po-
sition.

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SAFETY

SAFETY PRECAUTIONS

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Caution when filling with fuel or oil

• Keep away from heat, sparks and flame while filling

with fuel or oil.

• Never remove the fuel cap or try to fuel when the en-

gine is running or still hot.

• Maintain control of the fuel filler nozzle when filling the

tank.

• Refill with fuel or oil outdoors or in a well ventilated

place, with the engine turned off.

• Clean up spilled fuel or oil immediately.
• Do not overfill the tank.
• Firmly tighten the fuel cap or oil cap. If the fuel cap is

lost, replace it only with the original manufacturer’s ap-
proved cap. Use of a non-approved cap without prop-
er venting may result in pressurization of the tank.

• Never use fuel for cleaning.
• Use the correct grade of fuel for the operating season.

Handling of hoses

Oil leak or fuel leak can cause a fire.
• Do not twist, bend or hit the hoses.
• Never use twisted, bent or cracked pipes, tubes or

hoses; otherwise, they may burst.

• Retighten loose connections.

Be careful with hot and pressurized components

Before performing inspection and maintenance, stop the
engine and allow the machine to cool down.
• The engine, muffler, radiator, hydraulic lines, sliding

parts and many other parts of the machine are hot im-
mediately after the engine is stopped. Wait until it
cools before making any inspection or adjustments.

• The engine coolant, hydraulic oil and other oils are

also hot and under high pressure. Touching these liq-
uids will cause burns.

Handling of radiator

Do not remove the radiator cap when the coolant is hot.
Wait until it cools down, and then remove the radiator cap
by loosening it slowly to release the internal pressure.

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SAFETY

SAFETY PRECAUTIONS

1B0BF00

Be careful with oils under pressure

Pressure is maintained in the hydraulic circuit long after
the engine has been shut down.
• Do not fill with, dispose of fuel/oil, or perform the in-

spection and maintenance until the internal pressure is
completely released.

• The hydraulic oil escaping from a small hole can be

hazardous if contacted. It is under high enough pres-
sure to penetrate the skin or eyes and cause serious
injury. If leak is suspected, protect your eyes and skin
by wearing protective glasses and thick gloves to
search for a leak. Also use a paperboard or plywood
to keep your skin from oil spurting. If oil penetrates the
skin, it must be surgically removed within a few hours
by a doctor familiar with this type of injury.

Release internal pressure before working on the
hydraulic system

Oil may spurt out if caps or filters are removed or pipes
are disconnected before releasing the pressure in the
hydraulic system.
• Gradually loosen the vent plug to release the internal

pressure of the hydraulic oil tank.

• Move all the control levers and pedals several times in

all directions to release the pressure from the circuit of
the working equipment (for link type controls).

• When removing plugs or screws, or when disconnect-

ing hoses, stand to the side and loosen them slowly to
gradually release the internal pressure before remov-
ing.

Be careful with grease under pressure

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.
• Loosen the grease discharge valve slowly.
• Do not put your face, arms, legs or body in front of the

grease discharge valve.

Handling of the accumulator

Be sure to handle the high-pressure nitrogen gas en-
closed in the accumulator with care according to proce-
dure. If handled incorrectly, it could explode and cause
serious injury. Strictly observe the following precautions:
• Do not disassemble.
• Do not allow flame near it or throw it into a fire.
• Do not drill, weld or fuse.
• Do not subject it to physical shock such as hitting, roll-

ing or dropping.

• Before disposing of the unit, the sealed gas must be

drained. Contact your sales or service dealer for help
with this.

Disconnect the battery

Disconnect the wiring from the both terminals (+ and -)
on the battery before working on the electrical system or
doing electric welding. Otherwise, short-circuit and ex-
plosion of the battery can result.

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SAFETY

SAFETY PRECAUTIONS

1B0BF00

Use caution when handling batteries

• Batteries contain sulfuric acid which will damage eyes

or skin if contacted.

• If eye contact occurs, flush immediately with clean

water and get prompt medical attention.

• If accidentally swallowed, drink large quantities of

water or milk and call a physician immediately.

• If acid contacts skin or clothing, wash off immedi-

ately with a lot of water.

• Wear protective glasses and gloves when working with

batteries.

• Batteries generate flammable hydrogen gas which

may explode. Keep away from flame and sparks.

• Do not use or charge the battery when the electrolyte

level is lower than the lower limit: otherwise, it could
cause an explosion.

• Be sure to stop the engine by turning off the starter

switch before inspecting or handling the battery.

• Be careful not to let metal tools (or any metal objects)

such as a hammer or spanner come into contact with
the battery terminals.

• When disconnecting the battery wiring, always discon-

nect it from the earth side (-). When connecting, con-
nect the earth side last.

• Loose battery terminals may result in sparks. Be sure

to fasten terminals tightly.

• Make sure the battery caps are tightened securely.
• Do not charge a battery or jump-start the engine if the

battery is frozen; otherwise it may explode.
Warm the frozen battery to 15°C (59°F) before use.

Have a service agent repair welding cracks or
other damage

Ask a service agent to make any repairs that require
welding. If the agent is unavailable, make sure the weld-
ing is done by a qualified person in a properly equipped
workplace.

Checks after maintenance

• Gradually raise the engine speed from low idle to max-

imum and check that no oil or water is leaking from the
parts serviced.

• Move the controls and check that the machine is oper-

ating properly.

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 dispos-

ing of harmful objects such as oil, fuel, coolant, sol-
vent, filters and batteries.

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SAFETY

CAUTIONS WHEN WORKING

1C0BF001

CAUTIONS WHEN WORKING

When disassembling or assembling

• Clean the machine before disassembly.
• Check the following items and record the results:

a. Model, machine serial number, hour meter.
b. Reason for repair, repair history.
c. Are the filters dirty?
d. The conditions of the fuel and oil.
e. Any damage or looseness to any part?

• Where necessary, draw alignment indicators to avoid

assembly errors. To avoid misconnection, place indi-
cators such as reference tags on pipes.

• Clean all disassembled parts and new parts, arrange

them neatly, and place indicators as necessary.

• Be sure to replace all seals and cotter pins with new

ones.

• Keep those parts that should not come in contact with

water or oil away from those with oil on the surface.

• When installing bearings, bushings and oil seals, a

press tool should be used. If a hammer is used, use a
cushioning material to avoid damage.

• Wipe all joining surfaces clean until there is no dirt or

dust adhering to them.

• Wrap the thread tight with seal tape starting 1 or 2

threads away from the thread end. The tape should be
overlapped by about 10 mm (0.39 in).

When removing/installing the hydraulic unit

• Make sure that the temperature of the hydraulic oil has

dropped and is cool enough to work with.

• To prevent the hydraulic oil from escaping under pres-

sure, release the residual pressure in the piping.

• Be sure to install caps or plugs on all openings in the

hydraulic unit to prevent dirt from getting into the unit
through them.

• The hydraulic oil adhering to the unit is often mistaken

for an oil leak, so wipe off the unit thoroughly.

• Be sure that no damage is caused to the plating on the

rod in the hydraulic cylinder.

• Removal and installation of the hydraulic cylinder

should be done with the rod fully retracted.

• Be sure to bleed the air after installing the hydraulic

cylinder. (

“4. Disassembly and assembly: Cylin-

der”)

• Always bleed the air when hydraulic oil is changed or

a hydraulic device is replaced. (

“4. Disassembly

and assembly: Drive system”)

SAFETY

CAUTIONS WHEN WORKING

1C0BF001

When connecting/disconnecting the hoses or
pipes

• When hydraulic hoses or pipes are connected, tighten

them once to the prescribed torque, then loosen them
slightly and retighten them to the prescribed torque.
a. Tighten the fittings after the installation surfaces fit

snugly together.

b. The above procedures do not apply to fittings with

seal tape.

• Use two spanners, one to tighten/loosen and the other

to secure the mating hose/pipe to ensure that the hose
is not twisted.

• After connecting the hydraulic hoses or pipes, apply

the maximum working pressure five or six times to
check for leakage.

• If high pressure, vibration or shock is applied to a twist-

ed hose, oil leak, hose breakage or damage to the
hose fitting can result.

• Be sure that the hydraulic hoses are not contacting

sharp objects or each other. This could cause surface
flaws on the hoses, resulting in breakage.

Handling of seals

• Clean the grooves for O-rings and remove any burrs.

• Be careful not to twist the O-rings. If twisted, remove it

with your fingertips.

• When inserting, be careful not to damage the seal.
• Handling of the floating seal

a. After removal, wipe all oil off the O-ring and housing

of the floating seal.

b. When assembling, apply a thin coating of gear oil to

the contact surface of the housing.

c. After assembly, turn the seal two or three times to

get it to fit snugly.

• Apply grease to the lip of the oil seal.

a. This is to prevent wear from occurring upon first

start up after assembly.

Pressure adjustment for hydraulic devices

• The pressure for hydraulic devices is adjusted by

Takeuchi Mfg. to optimal conditions before products
are shipped for delivery to the customer. The pressure
will not need to be adjusted again except in products
that undergo disassembly and assembly procedures.

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SERVICE DATA

DIMENSIONAL DRAWING

DIMENSIONAL DRAWING

2A0AX001

: With the crawler extended

: Side plate attached

: Long blade specifications

Unit: mm (in.)

Standard arm

Long arm

215000003 to

215002407

from 215002408

215000003 to

215002407

from 215002408

Rubber crawler

3445 (135.6)

3455 (136.1)

3440 (135.5)

3450 (135.9)

980 (38.5)

2345 (92.2)

720 (28.3)

460 (18.1)

1155 (45.6)

1205 (47.4)

1155 (45.6)

1205 (47.4)

1520 (59.9)

1570 (61.8)

1520 (59.9)

1570 (61.8)

1300 (51.2)

980 (38.6)

230 (9.1)

205 (8.0)

1450 (57.0)

1470 (57.9)

1185 (46.7)

1210 (47.6)

395 (15.6)

555 (21.9)

980 (38.6)

1300 (51.2)

250 (9.8)

310 (12.1)

2725 (107.3)

2720 (107.1)

855 (33.6)

1200 (47.2)

3585 (141.1)

3580 (140.9)

3970 (156.2)

3965 (156.1)

SERVICE DATA

DIMENSIONAL DRAWING

DIMENSIONAL DRAWING

2A0AX001

: Long blade specifications

Unit: mm (in.)

Standard arm

Long arm

215000003 to

215002407

from 215002408

215000003 to

215002407

from 215002408

Rubber crawler

3815 (150.2)

4000 (157.5)

3760 (148.0)

3945 (155.4)

2190 (86.2)

2390 (94.1)

1780 (70.1)

1970 (77.6)

2705 (106.5)

2760 (108.7)

3430 (135.1)

3570 (140.6)

2400 (94.6)

2545 (100.2)

835 (32.9)

635 (25)

215 (8.4)

310 (12.1)

210 (8.3)

365 (14.3)

SERVICE DATA

SPECIFICATION TABLES

SPECIFICATION TABLES

2B0AX003

SPECIFICATION TABLES

Performance

*: At the operator location as stipulated by ISO 6396: 2008.

Dimensions of completed machine

Operating mass

215000003 to
215002407

Rubber
crawler

kg (lb)

1575 (3470)

Steel
crawler

kg (lb)

1670 (3680)

from

215002408

Rubber
crawler

kg (lb)

1610 (3550)

Steel
crawler

kg (lb)

1675 (3695)

Rated output

Net (ISO 14396) kW/min

-1

(hp/rpm)

11.5/2400 (15.4/2400)

Net (ISO 9249/SAEJ 1349)
kW/min

-1

(hp/rpm)

11/2400 (14.8/2400)

Bucket capacity

Heaped capacity

(ft

)

0.038 (1.34)

Struck capacity

(ft

)

0.028 (0.99)

Standard loading mass

kg (lb)

70 (150)

Slew speed

min

-1

(rpm)

9.2 (9.2)

Travel speed

Rubber
crawler

1st

km/h (mph)

2.2 (1.37)

2nd

km/h (mph)

4.2 (2.61)

Steel crawler

1st

km/h (mph)

2.1 (1.3)

2nd

km/h (mph)

4 (2.49)

Maximum tractive force

kN (lbf)

19.4 (4360)

Gradeability

deg.

Ground pressure

215000003 to
215002407

Rubber
crawler

kPa (psi)

26.2 (3.8)

Steel
crawler

kPa (psi)

28.2 (4.09)

from

215002408

Rubber
crawler

kPa (psi)

26 (3.77)

Steel
crawler

kPa (psi)

27.3 (3.96)

Noise level

Sound-power level

dB (A)

Sound-pressure level*

dB (A)

Overall length

215000003 to
215002407

Standard
arm

Rubber
crawler

mm (in.)

3445 (135.6)

Steel
crawler

mm (in.)

3445 (135.6)

from

215002408

Rubber
crawler

mm (in.)

3455 (136)

Steel
crawler

mm (in.)

3445 (135.6)

Overall width

During normal operation

mm (in.)

1300 (51.2)

Track retracted

mm (in.)

980 (38.6)

Overall height

Rubber crawler

mm (in.)

2345 (92.3)

Steel crawler

mm (in.)

2350 (92.5)

SERVICE DATA

SPECIFICATION TABLES

SPECIFICATION TABLES

2B0AX003

Dimensions of base machine

Overall length of base
machine

215000003 to
215002407

Rubber
crawler

mm (in.)

1560 (61.4)

Steel
crawler

mm (in.)

1565 (61.6)

from

215002408

Rubber
crawler

mm (in.)

1570 (61.8)

Steel
crawler

mm (in.)

1565 (61.6)

Overall width of base
machine

During normal operation

mm (in.)

1300 (51.2)

Track retracted

mm (in.)

980 (38.6)

Upper structure overall width

mm (in.)

980 (38.6)

Upper structure overall
width

Left

mm (in.)

490 (19.3)

Right

mm (in.)

490 (19.3)

Cab overall width

mm (in.)

Overall height of base
machine

Rubber crawler

mm (in.)

2345 (92.3)

Steel crawler

mm (in.)

2350 (92.5)

Swing radius

mm (in.)

720 (28.3)

Upper structure rearmost distance from axis of rotation

mm (in.)

720 (28.3)

Clearance height under
upper structure

Rubber crawler

mm (in.)

460 (18.1)

Steel crawler

mm (in.)

450 (17.7)

Crawler base

215000003 to
215002407

Rubber
crawler

mm (in.)

1155 (45.5)

Steel
crawler

mm (in.)

1135 (44.6)

from

215002408

Rubber
crawler

mm (in.)

1205 (47.4)

Steel
crawler

mm (in.)

1180 (46.5)

Crawler overall length

215000003 to
215002407

Rubber
crawler

mm (in.)

1520 (59.8)

Steel
crawler

mm (in.)

1500 (59.1)

from

215002408

Rubber
crawler

mm (in.)

1570 (61.8)

Steel
crawler

mm (in.)

1550 (61)

Undercarriage overall
width

During normal operation

mm (in.)

1300 (51.2)

Track retracted

mm (in.)

980 (38.6)

Track gauge

During normal operation

mm (in.)

1070 (42.1)

Track retracted

mm (in.)

750 (29.5)

Track shoe width

mm (in.)

230 (9.1)

Ground clearance of
undercarriage

Rubber crawler

mm (in.)

205 (8.1)

Steel crawler

mm (in.)

195 (7.7)

Takeuchi Mini Excavator TB215R (No.215000003~). Operator's Manual - page 1