Takeuchi Mini excavator TB225 (No.122500005~). Operator's Manual (2019)

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

Area

Diesel fuel specification

Area

ASTM D975

No.1-D S15

No.2-D S15

USA

ISO 8217DMX

International

Bio-diesel fuel

Canada

Biodiesel blends up to B7

ASTM D6751

EN590: 2009

Bio-diesel fuel

European union BS2869-A1 or A2

United kingdom

Biodiesel blends up to B7

EN14214

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 (21.6°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 0.5 % by volume.

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

should be used.

Fuel tank

Diesel fuel

A higher sulfur content fuel may cause sulfuric acid corrosion

in the cylinders of the engines.

• 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.

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

SAE 10W-30

Engine oil pan

API: CD class

Every 250 hrs.

SAE 15W-40

ACEA: E-3, E-4 or E-5

Takeuchi genuine

Every 4000

ISO VG46

hydraulic oil 46

hrs.***

Hydraulic oil

ISO VG32

tank

Every 2000

Anti-wear hydraulic oil

ISO VG46

hrs.***

ISOVG68

Every 2000 hrs.

Cooling water (water +

Engine cooling

Mixture of 50% coolant

or every two

coolant)**

system

Mixture of 30% coolant

years (whichever

SAE: J814C or J1034

comes first)

Every 1000 hrs

Travel reduction

Gear oil

SAE 90

after the initial

gear

API: GL-4

250 hrs*.

Slew motor

Every 50 hrs.

pinion

Lithium based grease

Slew bearing

Every 50 hrs.

EP-2

—

Working

Daily or every

NLGI No.2

equipment

10 hrs.

Levers

When required

* : 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

SAE standard: Society of Automotive Engineers

5-6

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

15511-04300

Every 1000 hrs

return filter

Element

after the initial 250

Hydraulic system

hrs.

Pilot line filter

15512-00703

Air breather (if equipped)

15520-03000

Every 1000 hrs.

Engine lubrication

Engine oil filter

Cartridge

Y129150-35153

Every 250 hrs.

system

Fuel system

Fuel filter

Cartridge

Y119802-55801

Every 500 hrs.

Every 1000 hrs. or

Primary

after 6 cleanings

(Outer)

Y119808-12520

(whichever comes

element

Air cleaner system

Air cleaner

first)

Secondary

When the primary

(Inner)

19111-02772

elements are

element

replaced.

Ventilation filter

03445-00034

Once a year or if

Heater system

Element

clogging remains

Circulation filter

03445-00021

after cleaning

5-9

MAINTENANCE

SERVICE DATA

LIST OF TOOLS

Code

Part name

Part No.

Remarks

Spanner

19100-47081

10 - 12

Spanner

19100-47082

14 - 17

Screwdriver

19100-06112

(+) (-) replaceable shank

Filter wrench

19100-65081

Filter wrench

19104-01082

Monkey wrench

16904-00250

250 mm

Pliers

16905-00200

200 mm

Spanner

16901-00013

Spanner

16909-00019

Spanner

16900-01922

19 - 22

Tool case

16914-00005

Grease gun

16910-60600

600 cc

Drain connector

15545-12201

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±0.8

7.2±0.6

12, 13

M8 x 1.25

23±1.8

17±1.4

14, 17

M10 x 1.5

47±3.8

35±2.8

Coarse

17, 19

M12 x 1.75

83±6.6

62±5

19, 22

M14 x 2.0

134±10.7

99±7.9

22, 24

M16 x 2.0

208±16.6

153±12.2

27, 30

M20 x 2.5

411±32.9

303±24.2

12, 13

M8 x 1.0

25±2

18±1.4

14, 17

M10 x 1.25

50±4

37±3

17, 19

M12 x 1.5

87±7

64±5.1

Fine

19, 22

M14 x 1.5

135±10.8

100±8

22, 24

M16 x 1.5

221±17.7

163±13

27, 30

M20 x 1.5

452±36.2

333±26.6

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

Heater hoses

Cooling system

Rubber 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 (span cylinder)

Hydraulic hoses (pilot valve)

Hydraulic hoses (auxiliary piping)

Seat belt

Every 3 years

Non-slip sheet

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

*: Cab parts No. 03486-00028

*: Canopy parts No.(1) 03484-00003

*: Canopy parts No.(2) 03484-00027

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

5-20

Inspecting the hydraulic oil tank level and replenishing

5-21

Lubricating the working equipment

5-22

After the initial 50 hours (only for new machines)

Inspecting and adjusting the fan belt

5-24

Every 50 hours

Inspecting and adjusting the crawler tension

5-26

Lubricating the slew bearing

5-28

Lubricating the slew motor pinion

5-28

Draining the water from the fuel tank

5-29

Inspecting the battery fluid level and replenishing

5-30

Every 100 hours

Cleaning the water separator

5-32

After the initial 250 hours (only for new machines)

Replacing the hydraulic oil return filter

5-33

Replacing the pilot line filter

5-34

Replacing the travel motor gear oil*

5-35

Every 250 hours

Inspecting and adjusting the fan belt

5-36

Replacing the engine oil and the oil filter

5-36

Cleaning the air cleaner

5-38

Inspecting the throttle control system

5-39

Cleaning the radiator fins and the oil cooler fins

5-40

Cleaning the air filters

5-41

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

oil earlier than the specified time.

5-14

MAINTENANCE

MAINTENANCE LIST

Inspection and maintenance item

Page

Every 500 hours

Replacing the fuel filter

5-42

Every 1000 hours

Replacing the hydraulic oil return filter

5-44

Replacing the travel motor gear oil*

5-44

Replacing the air cleaner element

5-44

Replacing the air breather

5-45

Inspecting and adjusting the engine valve clearance

5-46

Replacing the pilot line filter

5-46

Every 1500 hours

Inspecting and cleaning the engine fuel injectors

5-47

Inspecting the crankcase breather system

5-47

Every 2000 hours

Cleaning the engine cooling system

5-48

Lapping the engine valve seats

5-49

Every 4000 hours

Replacing the hydraulic oil and cleaning the suction strainer

5-50

When required

Replacing the bucket teeth and the side cutters

5-53

Replacing the bucket

5-56

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

5-58

Lubricating the levers and pedals

5-60

Inspecting the rubber crawlers

5-61

Replacing the rubber crawlers

5-62

Inspecting and replenishing the windshield washer fluid

5-63

*: 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, bolts or electric

wiring are loosened or damaged.

INSPECTING BY OPENING THE ENGINE

3. Check for oil leakage from the hydraulic oil

HOOD AND COVERS

tank, hydraulic devices, hoses or

connections.

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.

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, shoe slides, track

rollers, idlers and sprockets for damage,

wear and loose bolts.

10. Check for oil leakage from the travel

motor.

11. Check the canopy/cab and guard for

damage and the nuts and bolts for

looseness.

12. Check the rearview mirror and the interior

rearview mirror for dirt or damage, and

adjust them if necessary.

13. Check the labels for dirt and damage.

5-17

MAINTENANCE

DAILY INSPECTION (EVERY 10 HOURS)

INSPECTING AND REPLENISHING THE

DAILY INSPECTION

COOLANT

(EVERY 10 HOURS)

Perform the following inspections every day

before starting the engine for the first time.

• Do not remove the radiator cap or the

drain plug when the cooling water is

hot. Stop the engine and wait until the

• Before operating, perform the daily

engine and the radiator cool before

inspections and make repairs

slowly loosening the radiator cap and

immediately where necessary.

the drain plug to remove them.

• Be sure to secure the engine hood or

• Always wear the protective goggle and

cover before working the inside. Do not

gloves when handling coolant

keep the hood or cover open on a windy

(antifreeze). If any coolant (antifreeze)

day or if the machine is parked on a

comes in contact with eyes or skin,

slope.

wash it off with clean water. Otherwise,

it could result in injures.

Inspection

1. Open the engine hood.

2. Inspect the cooling water level in the

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.

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).

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

inspection, check for water leakage and

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

water to the radiator (3) as required, and

then to the reserve tank (1).

3. Install the cap (2).

5-18

MAINTENANCE

DAILY INSPECTION (EVERY 10 HOURS)

Note: Use only clean water (soft water) to

INSPECTING AND REPLENISHING THE

replenish the cooling water loss due to

ENGINE OIL

evaporation. Use coolant (antifreeze) and

clean water (soft water) of the specified

mixing ratio to replenish the cooling water

loss due to leaking.

Stop the engine and allow the machine to

cool down before performing

maintenance.

Inspection

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.

Replenishing

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

too low or too high.

3. Tighten the oil filler cap (2).

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

5 minutes, then stop it.

5. After about 10 minutes, inspect the oil

level.

5-19

MAINTENANCE

DAILY INSPECTION (EVERY 10 HOURS)

INSPECTING THE WATER SEPARATOR

INSPECTING THE FUEL LEVEL

• Do not smoke or permit open flames

while handling fuel or working on the

fuel system.

• Stop the engine in a well-ventilated

• Never remove the fuel cap or add fuel

place and allow it to cool down before

when the engine is running or still hot.

performing maintenance.

Do not spill fuel on the hot surface of

• Clean up spilled fuel immediately.

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. Inspect the water separator (1).

If the red indicator ring (6) is sunk to the

bottom of case (4), no water is mixed in.

If the red indicator ring (6) is floating, there

is water up to the ring. Drain the water

and clean.

Refer to “Cleaning the water separator” on

page 5-32.

Refer to “Bleeding air from the fuel

1. Check the fuel level using the fuel gauge

system” on page 6-9.

(1).

F: Tank is full.

E: Tank is empty.

2. If the fuel level is low, open the side cover.

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

watching the sight gauge (3).

Use this gauge (3) to check the full state

when adding fuel. For checking the

remaining amount, use the gauge in the

instrument cluster.

Refer to “Fuel filler port” on page 2-7.

5-20

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.

• Gradually loosen the vent plug to relieve

tank pressure.

Inspection

The oil level changes with the oil

IMPORTANT: Do not fill up to the level

temperature. Inspect the oil by maintaining

higher than the upper limit (H). It will

the machine at posture shown in the figure at

damage the hydraulic circuits or result in

the next.

oil spurting. If accidentally done, stop the

• Machine posture for inspecting the

engine and wait the hydraulic oil to cool,

hydraulic oil level

and then let the excessive oil to drain

from the drain plug.

1. Open the side cover.

2. Slowly loosen the plug (2) to relieve the

internal pressure, and then remove the

plug.

3. Add the hydraulic oil up to the middle of

the sight gauge (1).

4. Tighten the plug (2).

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

2. Fully extend the crawler width.

3. Fully retract the cylinders (arm and

bucket), and lower the bucket to the

ground.

4. Lower the dozer blade, and then stop the

engine.

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).

5-21

MAINTENANCE

AFTER THE INITIAL 50 HOURS (ONLY FOR NEW MACHINES)

Inspection

AFTER THE INITIAL 50 HOURS

(ONLY FOR NEW MACHINES)

INSPECTING AND ADJUSTING THE FAN

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

1. Move the sheet all the way forward.

of the machine are hot immediately after

2. Take out four bolts and remove the cover

the engine is stopped. Touching these

(1).

parts will cause burns.

IMPORTANT: The loose belts could result

in bad battery charge, overheat of engine

or early wear of belt. Too tight belts could

damage the water pump or bearing and

belt used to drive the alternator.

IMPORTANT: Do not let any oil or grease

get on the belt.

3. Press at the center of the fan pulley (1)

and alternator pulley (2) 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).

4. Inspect the fan belt (3) 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.

5-24

MAINTENANCE

AFTER THE INITIAL 50 HOURS (ONLY FOR NEW MACHINES)

Adjustment

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

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

alternator (7) and to adjust the tension of

the fan belt (1).

· Tighten: Clockwise

· Loosen: Counterclockwise

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

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.

5-25

MAINTENANCE

EVERY 50 HOURS

Inspection

EVERY 50 HOURS

INSPECTING AND ADJUSTING THE

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

1. For rubber crawlers, move the machine so

important when working on hydraulic

that the “M” mark at the joint is at the top

cylinders.

center of the crawler frame.

• Be careful with the high-pressure grease

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

turns.

· Do not put your face, arms, legs or

body in front of the grease discharge

2. Use the working equipment to lift the

valve.

machine body. Operate the levers slowly.

· If grease does not come out when the

grease discharge valve is loosened,

the valve is faulty. Ask a Takeuchi

service agent for repair.

5-26

MAINTENANCE

EVERY 50 HOURS

Adjustment

Increasing the tension

3. Inspect the gap (A) between the bottom

surface of the frame at the center of the

crawler frame and the top surface of the

crawler.

The gap (A) must be within the following

1. Remove the cover (1).

range:

2. Inject grease through the grease fitting (3)

of the grease discharge valve (2) with a

(A) Rubber crawler

grease gun.

55 to 60 mm (2.2 to 2.4 in.)

3. Inspect the crawler tension.

Decreasing the tension

1. Remove the cover (1).

2. Slowly loosen (one turn) the grease

discharge valve (2) with a spanner to

discharge grease. If grease does not

come out well, move the machine back-

and-forth.

3. Tighten the grease discharge valve (2).

· Tightening torque:

59 to 88 N·m (43.5 to 64.9 ft-lb.)

5-27

MAINTENANCE

EVERY 50 HOURS

LUBRICATING THE SLEW BEARING

LUBRICATING THE SLEW MOTOR PINION

Do not slew while lubricating. Doing so is

dangerous, as you may get caught in the

machine.

1. Use the grease gun to lubricate the grease

fitting (2).

2. Wipe off the excess grease.

1. Stop the engine with the machine in the

posture shown on the figure above.

2. Use the grease gun to grease the grease

fitting (1).

3. Start the engine, lift the bucket and slew

clockwise 90°.

4. Lower the bucket to the ground, and then

stop the engine.

5. Repeat the steps 2 to 4 above three

times.

6. Wipe off the grease expelled from the slew

bearing and grease fitting.

5-28

MAINTENANCE

EVERY 50 HOURS

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

the machine.

3. Loosen the bolts and remove the under

• Fill the fuel tank in a well ventilated

cover (3).

place.

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

• Do not fill the fuel tank to capacity.

5. Loosen the drain plug (4) to drain water

Allow room for oil expansion.

and sediment buildup in the bottom of the

• Clean up spilled fuel immediately.

tank.

• Securely tighten the fuel filler cap.

6. Tighten the drain plug (4).

• Use the correct grade of fuel for the

7. Install the under cover (3).

operating season.

8. Add fuel while watching the sight gauge

(1).

Do the draining operation before starting the

9. Tighten the fuel filler cap (2).

machine.

10. Close the side cover and lock it with the

key.

11. Bleed air.

Bleeding air from the fuel system

Refer to “Bleeding air from the fuel system”

on page 6-9.

Note: Air in the fuel system causes the

engine to fail to start or to have problems.

Bleed air when the fuel tank is emptied,

using the same procedure above.

1. Open the side cover.

2. Remove the fuel filler cap (2).

5-29

MAINTENANCE

EVERY 50 HOURS

INSPECTING THE BATTERY FLUID LEVEL

AND REPLENISHING

• Wear protective goggle and clothing

when working with batteries.

• Do not add the distilled water above the

• Do not use the battery when the fluid

upper level limit. Doing so could cause

level is below the lower level limit. Doing

the fluid to leak. This fluid can cause

so will hasten the deterioration of the

skin damage if contacted, or can cause

internal portions of the battery and

the machine components to corrode.

shorten the battery life. It also can

• Batteries contain sulfuric acid which will

cause rupturing (explosion).

damage eyes or skin if contacted.

• Batteries generate flammable hydrogen

· If eye contact occurs, flush

gas which may explode. Keep away

immediately with clean water and get

from flame, sparks, fire or lighted

prompt medical attention.

cigarettes.

· If accidentally swallowed, drink large

• Use a dampened cloth to clean above

quantities of water or milk and call a

the fluid level line and check the fluid

physician immediately.

level. Do not clean with a dry cloth;

· If acid contacts skin or clothing, wash

otherwise it can cause static electricity

off immediately with a lot of water.

to build up, resulting in ignition or

explosion.

Inspection

• Do not use the cable if it’s connecting

terminal is loose or corroded. If used,

IMPORTANT: Check the fluid level of all

ignition or explosion may occur.

cells following the steps below, even

• Do not block the exhaust hole of the

when the fluid level can be checked using

battery. An explosion could result, if

the indicator.

blocked.

Note: Under normal operating conditions,

the maintenance-free battery does not

require addition of water because of the

special plate designed to minimize fluid loss.

However, for those machines that are heavily

used or operated under severe conditions

(for example, in high ambient temperature),

the fluid level often becomes low. If that is

the case, check the fluid level of the

maintenance-free battery and add water as

needed.

Note: The warranty will be void if the label on

the battery is removed during the warranty

period. If the indicator displays “Insufficient

battery fluid” during the warranty period,

contact your sales or service dealer without

doing anything to the battery.

5-30

MAINTENANCE

EVERY 50 HOURS

1. Open the side cover.

2. Inspect the indicator (1).

· Blue: Good

· White: Charging needed

· Red: Insufficient battery fluid

3. Inspect the fluid level.

The fluid level must be between the upper

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

add distilled water up to the line (H).

4. Check the battery terminal for looseness,

dirt and corrosion.

5. Check the exhaust holes (2) for dirt.

Replenishing

When adding distilled water, do so before

starting operations in order to prevent

freezing.

1. Upon expiration of the warranty period,

remove the label from the sealing plugs

(3).

2. Loosen the sealing plugs (3) and add

distilled water up to the highest level line

(H).

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

4. Securely tighten the sealing plugs (3).

Note: For the replacement battery, a semi-

sealed type is recommended.

5-31

MAINTENANCE

EVERY 100 HOURS

CLEANING THE WATER SEPARATOR

• 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.

1. Close the valve (2).

2. Loosen the ring (3), and then remove and

clean the case (4), element (5) indicator

ring (6) and spring (7).

3. Inspect the O-ring and the element (5). If

there are any scratches or other

irregularities, replace them.

4. Install the indicator ring (6), spring (7),

element (5) and case (4), and then tighten

the ring (3).

5. Open the valve (2) to bleed air.

Refer to “Bleeding air from the fuel

system” on page 6-9.

5-32

MAINTENANCE

AFTER THE INITIAL 250 HOURS (ONLY FOR NEW MACHINES)

2. Slowly loosen the air bleeding plug (1) to

AFTER THE INITIAL 250 HOURS

relieve the internal pressure, and then

remove the plug.

(ONLY FOR NEW MACHINES)

REPLACING THE HYDRAULIC OIL

RETURN FILTER

• Stop the engine and allow the machine

to cool down before performing

maintenance.

· The engine and the hydraulic system

and many other parts of the machine

are hot immediately after the engine is

stopped. Touching these parts will

cause burns.

· The hydraulic oil is also hot and under

high pressure.

Be careful not to touch the hydraulic

oil when loosening the cap or plug.

Working on the machine under these

conditions could result in burns or

injuries due to the hot oil spurting out.

• 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

relieve tank pressure.

3. Loosen the bolts to take out the flange (2).

· When removing plugs or screws, or

4. Remove the return filter (3).

when disconnecting hoses, stand to

5. Install a new return filter.

the side and loosen them slowly to

6. Reinstall the flange (2) on its original

gradually release the internal pressure

position.

before removing.

7. Inspect the level with the sight gauge (4),

and replenish if the level is too low.

Refer to “Inspecting the hydraulic oil tank

level and replenishing” on page 5-21.

1. Open the side cover.

5-33

MAINTENANCE

AFTER THE INITIAL 250 HOURS (ONLY FOR NEW MACHINES)

REPLACING THE PILOT LINE FILTER

• Stop the engine and allow each part of

the machine to cool down before

performing maintenance.

· The engine, the hydraulic system and

many other parts of the machine are

hot immediately after the engine is

stopped. Touching these parts will

cause burns.

3. Open the engine hood.

· The hydraulic oil is also hot and under

4. Turn the case (4) counterclockwise and

high pressure immediately after the

remove it.

engine is stopped.

5. Remove the element (5) and O-ring (6).

Be careful not to touch the oil when

6. Clean the inside of the case (4).

loosening the cap or plug. Working on

7. Apply a thin layer of oil on the O-ring of the

the machine under these conditions

new filter.

could result in burns or injuries due to

8. Install the new element on the filter stand

the hot oil spurting out.

(7).

• Oil may spurt out if caps or filters are

9. Apply a thin layer of oil on the new O-ring

removed or pipes are disconnected

(6).

before releasing the pressure in the

10. Install the new O-ring (6) and the case (4)

hydraulic system.

on the filter stand (7).

· Gradually loosen the vent plug to

· Case (4) tightening torque: 25 to 35 N·m

relieve tank pressure.

(18.4 to 25.8 ft-lb)

· When removing plugs or screws, or

11. Inspect the level with the sight gauge (1)

when disconnecting hoses, stand to

and replenish if the level is too low.

the side and loosen them slowly to

Refer to “Inspecting the hydraulic oil tank

gradually release the internal pressure

level and replenishing” on page 5-21.

before removing.

1. Open the side cover.

2. Slowly turn the vent plug (2) to relieve tank

pressure, then remove.

5-34

MAINTENANCE

AFTER THE INITIAL 250 HOURS (ONLY FOR NEW MACHINES)

REPLACING THE TRAVEL MOTOR GEAR

6. Add oil through the hole of the plug (3)

OIL

until oil flows out of the hole of the plug

(2).

7. Tighten the plugs (2) and (3).

Plug (2) tightening torque: 12 to 18 N·m

• Stop the engine and allow the machine

(8.8 to 13.3 ft-lb)

to cool down before performing

Plug (3) tightening torque: 46 to 51 N·m

maintenance.

(34 to 37.6 ft-lb)

· The travel motor is hot immediately

after the engine is stopped. Touching

it will cause burns.

· The gear oil is also hot and under high

pressure immediately after the engine

is stopped.

Be careful when loosening the plugs.

Working on the machine under these

conditions could result in burns or

injuries.

• The pressure in the reduction gear case

of travel motor may cause oil or the plug

to fly out. Loosen the plug slowly to

release the pressure.

IMPORTANT: If the percentage of the

traveling time within the total operating

time is high, replace the gear oil earlier

than the specified time.

AG7G051

1. Set the travel motor so that plug (1) is at

the very bottom.

2. Place a pan under the plug (1).

3. Remove the plugs (1), (2) and (3) and drain

the oil.

4. Rewrap the plugs with new sealing tape.

5. Tighten the plug (1).

· Plug (1) tightening torque: 46 to 51 N·m

(34 to 37.6 ft-lb)

5-35

MAINTENANCE

EVERY 250 HOURS

REPLACING THE ENGINE OIL AND THE

EVERY 250 HOURS

OIL FILTER

INSPECTING AND ADJUSTING THE FAN

BELT

Refer to “Inspecting and adjusting the fan

Stop the engine and allow the machine to

belt” on page 5-24.

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.

• The engine oil is also hot.

Be careful not to touch the hydraulic oil

when loosening the cap or plug.

Working on the machine under these

conditions could result in burns or

injuries.

1. Open the engine hood and remove the oil

filler cap (2).

2. Loosen the bolts and remove the under

cover (3).

3. Place a pan for catching the waste oil

under the drain plug (4).

5-36

MAINTENANCE

EVERY 250 HOURS

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

and drain the oil. (The oil comes out when

the screw is tightened.)

5. Remove the connector (B) and install the

cap (A).

IMPORTANT: Check the waste oil for

metal powder. If it contains large amounts

of metal powder, consult your sales or

service dealer.

6. Turn the filter (4) counterclockwise with the

filter wrench and remove it.

7. Clean the surface of installation of the filter

stand.

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

the new filter.

9. Install the new filter by hand.

10. 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)

11. 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.

12. Tighten the oil filler cap (2).

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

about 5 minutes, then stop it.

14. After about 10 minutes, inspect the oil

level.

5-37

MAINTENANCE

EVERY 250 HOURS

CLEANING THE AIR CLEANER

• Stop the engine and allow the machine

to cool down before performing

maintenance.

· The engine, muffler, radiator and many

other parts of the machine are hot

immediately after the engine is

stopped. Touching it will cause burns.

• Wear required appropriate equipment

3. Clean the inside of the dust cup (2).

such as protective goggle and filter

4. Remove the primary element (3).

mask when using compressed air, as

5. Cover the intake hole at the back of the

metal fragments or other objects can fly

body (4) with cloth or tape to prevent dirt

and cause serious injury.

from getting in.

IMPORTANT: Be careful not to scratch the

To prevent dirt from getting inside the

element. Do not use an element if it is

engine, do not remove the secondary

damaged.

element (5).

IMPORTANT: When operating the

6. Clean the inside of the body (4).

machine in very dusty places, perform

inspection and maintenance operations

every day.

IMPORTANT: Be sure to install the

element and dust cap securely. If not,

dust could be drawn into the cylinder,

damaging the engine.

1. Open the engine hood.

7. Clean the primary element (3) with dried

compressed air (294 to 490 kPa or 43 to

71 psi).

First blow the air from the inside of the

element along the pleats. Then blow the

air from the outside and finally from the

inside again.

8. Light up the inside of the primary element

(3) with a light bulb, inspect it, and replace

2. Loosen the clamps (1) and remove the

it if there are small holes or thin spots.

dust cup (2).

9. Remove the cloth or tape applied in step

10. Install the primary element (3).

11. Install the dust cup (2) with its

“ TOP

” mark facing up, and then

fasten it with the clamps (1).

5-38

MAINTENANCE

EVERY 250 HOURS

INSPECTING THE THROTTLE CONTROL

SYSTEM

Operate the throttle controller to check for

stretch in the wire and looseness of it at the

fixing portion.

If the wire is stretched or loosened at the

fixing portion, malfunction could result.

The operation of wire replacement or

adjustment requires experience. Ask your

sales or service dealer for it.

1. Turn the starter switch to the ON position.

Check that the governor lever (1) is

contacting the low-speed limit bolt (2).

2. Press the Deceleration button to cancel

the deceleration mode. Turn the throttle

controller to the maximum speed position,

and check that the governor lever (1) is

contacting the high-speed limit bolt (3).

If the governor lever is not contacting

either the limit bolt (1) or (2), contact your

sales or service dealer for help.

5-39

MAINTENANCE

EVERY 250 HOURS

CLEANING THE RADIATOR FINS AND

THE OIL COOLER FINS

Wear required appropriate equipment

such as protective goggle and filter mask

when using compressed air, as metal

fragments or other objects can fly and

cause serious injury.

IMPORTANT: Be careful not to damage

the fins when cleaning.

• When using compressed air or

pressurized water, make sure the

pressure is no higher than 200 kPa (28

psi) and hold the nozzle sufficiently

away from the fins.

IMPORTANT: When using water, cover the

electrical system to prevent water from

getting in.

IMPORTANT: When operating the

machine in very dusty places, perform

inspection and maintenance operations

every day.

Blow compressed air on the fins to remove

mud and dirt stuck on them.

5-40

MAINTENANCE

EVERY 250 HOURS

CLEANING THE AIR FILTERS

Cleaning

1. Blow dry, compressed air (138 kPa or 20

psi or less) directly on the filters from the

inside, moving up and down along the

Wear required appropriate equipment

pleats.

such as protective goggle and filter mask

Be sure to keep the nozzle at an adequate

when using compressed air, as metal

distance from the filters.

fragments or other objects can fly and

2. Wash the filter with neutral detergent if it is

cause serious injury.

very dirty. Dry the filter completely after

washing it.

Clean the filters immediately after operating

in dusty places.

Replacing

If the filters are clogged, the air flow is

Replace the filter with a new one once a year

reduced and a booming sound is heard from

or if it is still clogged after blow-drying with

the air conditioner unit.

compressed air and washing.

Removing the filters

1. Take out two screws and open the cover

(1).

2. Remove the air filters (2) and (3).

Air filter (2): Part No. 03445-00021

Air filter (3): Part No. 03445-00034

3. Use compressed air or water to clean

each filter, depending on how dirty it is.

5-41

MAINTENANCE

EVERY 500 HOURS

REPLACING THE FUEL FILTER

• 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.

1. Open the engine hood.

2. Turn the filter (1) counterclockwise with the

filter wrench and remove it.

3. Clean the surface of installation of the filter

stand.

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

the new filter.

5. Install the new filter by hand.

6. Tighten one more turn after the filter

packing comes in contact with the surface

of installation. (Torque when tightening

with filter wrench: 20 to 24 N·m or 15 to

18 ft-lb.)

7. Bleed the air.

Refer to “Bleeding air from the fuel

system” on page 6-9.

5-42

MAINTENANCE

EVERY 1000 HOURS

REPLACING THE AIR CLEANER ELEMENT

EVERY 1000 HOURS

REPLACING THE HYDRAULIC OIL

RETURN FILTER

Stop the engine and allow the machine to

Refer to “Replacing the hydraulic oil return

cool down before performing

filter” on page 5-33.

maintenance.

• The engine, muffler, radiator and many

other parts of the machine are hot

REPLACING THE TRAVEL MOTOR GEAR

immediately after the engine is stopped.

OIL

Touching these parts will cause burns.

Refer to “Replacing the travel motor gear oil”

IMPORTANT: Do not use an element if its

on page 5-35.

pleats, gaskets or seals are damaged.

IMPORTANT: Be sure to install the

element and dust cap securely. If not,

dust could be drain into the cylinder,

damaging the engine.

1. Open the engine hood.

2. Loosen the clamps (1) and remove the

dust cup (2).

3. Clean the inside of the dust cup (2).

4. Remove the primary element (3).

5-44

MAINTENANCE

EVERY 1000 HOURS

5. Cover the intake hole at the back of the

REPLACING THE AIR BREATHER

body (4) with cloth or tape to prevent dirt

from getting in.

Do not yet remove the secondary element

Oil may spurt out if caps or filters are

(5).

removed or pipes are disconnected

6. Clean the inside of the body (4).

before releasing the pressure in the

7. Remove the cloth or tape applied in step

hydraulic system.

• Gradually loosen the vent plug to relieve

tank pressure.

Remove the secondary element (5).

8. Install the new elements.

9. Install the dust cup (2) with its “ TOP

”

mark facing up, and then fasten it with the

clamps (1).

1. Open the engine hood.

2. Slowly loosen the air bleeding plug (1) to

relieve the internal pressure, and then

remove the plug.

3. Turn the air breather (2) counterclockwise

by hand or with the wrench and remove it.

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

the new air breather.

5. Install the new air breather by hand.

· Tightening torque: Max. 5 N·m (3.7 ft-lb)

5-45

Takeuchi Mini excavator TB225 (No.122500005~). Operator's Manual (2019) - page 5