Content      ..     4      5      6      7     ..

Takeuchi Mini excavator TB225 (No.122500005~). Operator's Manual (2019) - page 6

MAINTENANCE

EVERY 2000 HOURS

Then, slowly loosen the radiator cap

EVERY 2000 HOURS

and the drain plug to remove them.

CLEANING THE ENGINE COOLING

SYSTEM

When cleaning, if the temperature of the

coolant is low, the thermostat will be closed

Replace the coolant after the two-year

and the coolant will not circulate in the

operation even if the running time is less than

radiator. Heat the coolant water to at least

2000 hours.

90°C (194°F) before cleaning.

1. Open the engine hood.

• 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 these parts will

cause burns.

· The engine coolant is also hot and

under high pressure immediately after

the engine is stopped. Be careful

when loosening the caps or plugs.

2. Gradually loosen the radiator cap (3) to

Working on the machine under these

release the internal pressure, and then

conditions could result in burns or

remove the cap.

injuries due to the hot coolant spurting

out.

• If maintenance must be performed with

the engine running, always work as a

two person team communicating each

other.

· One person must sit in the operator’s

seat so that he/she can immediately

stop the engine when 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

3. Loosen the bolts and open the cover (5).

or clothing away from the moving part

4. Place a pan for catching the waste coolant

of the machine.

under the drain plug (4), and then loosen

• Standing at the back of the machine

the drain plug (4) to drain the coolant.

while the engine is running is extremely

5. Tighten the drain plug (4).

dangerous, as the machine could move

6. Add tap water to the radiator through the

suddenly. Never stand at the back of the

coolant fill port up to the top of the port.

machine while the engine is running.

Take time and slowly add water, so that no

• Do not remove the radiator cap or the

air enters the radiator.

drain plug when the cooling water is

7. Close the radiator cap (3).

hot. Stop the engine and wait until the

engine and the cooling water cool.

5-48

MAINTENANCE

EVERY 4000 HOURS

EVERY 4000 HOURS

REPLACING THE HYDRAULIC OIL AND

CLEANING THE SUCTION STRAINER

• 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

3. Open the side cover.

are hot immediately after the engine is

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

stopped. Touching these parts will

relieve the internal pressure, and then

cause burns.

remove the plug.

· The hydraulic oil is also hot and under

high pressure immediately after the

engine is stopped.

Be careful when loosening the caps or

plugs. 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.

· When removing plugs or screws, or

when disconnecting hoses, stand to

the side and loosen them slowly to

gradually release the internal pressure

before removing.

1. Set the machine to the hydraulic oil level

inspection posture.

Refer to “Inspecting the hydraulic oil tank

level and replenishing” on page 5-21.

2. Raise the safety lock lever to the locked

position.

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

6. Remove the return filter (3).

5-50

MAINTENANCE

EVERY 4000 HOURS

20. Add hydraulic oil from the hole of plug (1)

up to the level between the upper limit

(H) and the lower limit (L) in the sight

gauge (4).

21. Tighten the plug (1).

22. Bleed air from the hydraulic oil circuit

following “Bleeding air” below.

23. Set the machine to the hydraulic oil level

inspection posture and inspect the oil

level when the oil temperature drops.

Refer to “Inspecting the hydraulic oil tank

7. Loosen the bolts and remove the under

level and replenishing” on page 5-21.

cover (5).

24. Install the under cover (5).

8. Place a pan for catching the waste oil

under the drain plug (6).

Bleeding air

9. Loosen the drain plug (6) and drain the

hydraulic oil.

IMPORTANT: After replacing the hydraulic

oil or hydraulic devices, or after

performing maintenance of the hydraulic

devices, bleed air from the hydraulic

circuits and hydraulic devices. Failure to

do so may damage the hydraulic devices.

• Hydraulic pump

10. Loosen the hose bands and remove the

hoses (7) and (8).

11. Loosen the bolts and remove the flange

(9).

12. Remove the suction strainer (10) and

clean it.

13. Clean the inside of the hydraulic oil tank.

14. Replace the air breather (if equipped).

1. Open the engine hood.

Refer to “Replacing the air breather” on

2. Loosen the vent plug (1) on the hydraulic

page 5-45.

pump.

15. Install the suction strainer (10) to the

3. Once hydraulic oil overflows from the vent

flange (9).

plug hole (1), tighten the vent plug (1).

16. Reinstall the flange (9) and the hoses (7)

and (8) on their original positions.

17. Install a new return filter to the flange (2).

18. Reinstall the flange (2) to their original

positions.

19. Tighten the drain plug (6).

5-51

MAINTENANCE

EVERY 4000 HOURS

• Cylinders

Boom

1. Start the engine, let it run at a low-idling

speed for 10 minutes.

2. Maintain the engine at low idle, then

extend and retract each cylinder 4 or 5

times, without let them reach the stroke

end.

3. Run the engine at high speed, then extend

and retract each cylinder 4 or 5 times,

without let them reach the stroke end.

4. Set the engine back to a low idle, then

extend and contract all the cylinders 4 or 5

times to the stroke ends.

4. Hold the hose fitting (A) in place with a

• Emergency shut-off valve (If equipped)

wrench and slowly loosen the hose nut (1).

This operation is dangerous and requires

5. Slowly move the boom in the “Boom

experience. Ask your sales or service

lower” direction a little until there are no

dealer for help.

more air bubbles coming from the hose

If air is not released, the working

nut (1) joint.

equipment could become slow in reacting

6. Hold the hose fitting (A) in place with a

to the operation of the operator and show

wrench and tighten the hose nut (1).

unexpected behavior.

Arm

When removing plugs or screws, or when

disconnecting hoses, stand to the side

and loosen them slowly to gradually

release the internal pressure before

removing.

1. Place a pan under the hose (A) or (B) to

catch the waste oil.

2. Start the engine and run it at low idle.

3. Fully lower the safety lock lever to the

unlock position.

4. Hold the hose fitting (B) in place with a

wrench and slowly loosen the hose nut (2).

5. Slowly move the arm in the “Arm lower”

direction a little until there are no more air

bubbles coming from the hose nut (2)

joint.

6. Hold the hose fitting (B) in place with a

wrench and tighten the hose nut (2).

5-52

MAINTENANCE

WHEN REQUIRED

• Bucket tooth <V13SY or V17S>

WHEN REQUIRED

Removal

REPLACING THE BUCKET TEETH AND

1. Clean the bucket and park the machine in

THE SIDE CUTTERS

a flat, safe place where the ground is hard.

Replace the bucket teeth and the side

cutters when the tooth points or the side

cutters are worn. Do not wait until the

adapter or bucket is damaged.

• Before performing maintenance or

repairs under the machine, lower all

moveable working equipment to the

ground or in the lowermost position.

• To prevent unexpected movement,

firmly secure the working equipment

2. Set the bottom surface of the bucket flat

when repairing or replacing the bucket

and lower it on a block so that the locking

teeth or side cutter.

pin (1) can be knocked out.

• When using a hammer, pins may fly out

3. Remove the key, then check that the

or metal particles may be scattered.

bucket is stable.

This may lead to serious injury.

· If hard metal parts such as pins,

bucket teeth, side cutter or bearings

are hit with a hammer, wear protective

gear such as safety goggles and

gloves.

· When hitting pins or bucket teeth,

always check that there is no one in

the surrounding area.

• Do not allow unauthorized personnel in

the work area while working.

4. Place a rod against the locking pin (1) and

knock the locking pin out by hammering

against the rod.

The rod should be round and thinner than

the locking pin.

5-53

MAINTENANCE

WHEN REQUIRED

5. Remove the tooth point (2). Some tooth

2. Put the tooth point (2) in the adapter nose

points (2) are of the type that are removed

(3).

by turning (twisting) them

Push in firmly until the tooth point (2)

counterclockwise.

touches the tip of the adapter nose(3).

The same procedure can be used to

Some tooth points (2) are of the type that

remove the other tooth points.

are installed by turning (twisting) them

clockwise.

Installation

3. Insert the locking pin (1), making sure it is

1. Clean the adapter nose (3). If there is

in the right direction.

gravel or mud on the adapter nose, the

tooth point will not go in all the way and

the pin cannot be driven in.

5-54

MAINTENANCE

WHEN REQUIRED

• Side cutter

Installation

4. Drive in the locking pin (1) with a hammer

until it is flush with the tip of the tooth

point (2) ear.

1. Insert the bolts from the inner of the

bucket and tighten the side cutterwith

nuts.

Tightening torque: 241 N·m (178 ft-lb)

2. Caulk the bolts with a punch at three

spots along the periphery of the screw to

prevent the nuts from coming loose.

5. The locking pin (1) is now driven in.

The same procedure can be used to install

the other tooth points.

5-55

MAINTENANCE

WHEN REQUIRED

REPLACING THE BUCKET

Removing

• Before performing maintenance or

repairs under the machine, lower all

working equipment to the ground or in

the lowermost position.

• If maintenance must be performed with

the engine running, always work as a

two person team communicating each

other.

· One person must sit in the operator’s

seat so that he/she can immediately

1. Lower the bucket to the ground as shown

stop the engine when necessary. He/

on the figure above in a stable position.

she must take care not to touch the

lever or pedal unless necessary.

Note: When removing pins, set the bucket

· The one who performs maintenance

so that it is barely touching the ground. If the

must make sure to keep his/her body

bucket is firmly touching the ground, the

or clothing away from the moving part

resistance will be great and it will be difficult

of the machine.

to remove the pin.

• When using a hammer, pins may fly out

or metal particles may be scattered.

2. Set the safety lock lever to the locked

This may lead to serious injury.

position and stop the engine.

· If hard metal parts such as pins,

bucket teeth, side cutter or bearings

are hit with a hammer, wear protective

gear such as safety goggles and

gloves.

· When hitting pins or bucket teeth,

always check that there is no one in

the surrounding area.

• When aligning the pin holes, always do

so by checking them visually. Do not

insert your finger in the pin hole, or you

could lose your finger.

3. Remove the bolt (1).

4. Hammer the pin (2) out of the bucket.

5. Remove the bucket.

Inspect the pin seal (3) and replace it if it is

deformed or damaged. (See next page.)

5-56

MAINTENANCE

WHEN REQUIRED

Installation

5. Adjust the gap between the bucket and

the arm.

1. Set the O-ring (4) on the bucket as shown

Refer to “Adjusting the gap between the

on the figure above.

bucket and arm (If equipped)” on page

5-58.

6. Slide the O-ring (4).

Replacing the pin seal

2. Align the pin hole (A) on the bucket with

the pin hole on the arm (5), and install the

pin (2).

3. Operate the cylinder, align the pin hole (B)

on the bucket with the pin hole on the link

1. Set the pin seal (3) in the direction shown

arm (6), and install the pin (2).

on the figure above.

2. Use a mallet to slowly press the pin seal

in. Be careful not to damage the seal.

4. Align the turn prevention holes, and then

install the bolt (1) and the nut. Be sure to

leave a gap of about 0.5 to 1 mm (0.02 to

0.04 in.) between the nut and bucket

bush, or the nut will come loose.

5-57

MAINTENANCE

WHEN REQUIRED

ADJUSTING THE GAP BETWEEN THE

BUCKET AND ARM (IF EQUIPPED)

• Before performing maintenance or

repairs under the machine, lower all

working equipment to the ground or in

the lowermost position.

• To prevent unexpected movement,

securely block the working equipment

when adjusting the gap.

3. Move the O-ring (1) to bring the gap (A)

into view and measure the width of the

gap (A).

The gap (A) should be 0.5 mm (0.02 in.).

Swing the upperstructure slightly to the left

and lightly press the arm point to the left

side of the bucket (the side without an

adjuster).

1. Lower the bucket to the ground as shown

on the figure above in a stable position.

2. Check that the bucket dose not move,

and then set the safety lock lever to the

locked position and stop the engine.

4. Remove the three bolts (2), the end plate

(3) and flange (4).

5-58

MAINTENANCE

WHEN REQUIRED

5. Pull out the adjustment shim(s) (5)

corresponding to the gap (A) from

between the flange (4) and the bucket

body.

Adjustment shim thickness : 0.5 mm (0.02

in.)

Be careful that the gap is no less than 0.5

mm (0.02 in.) after adjustment.

Note:

Example (for a gap of 2 mm or 0.08 in.):

2 mm - 0.5 mm (standard value)= 1.5 mm

(0.06 in.)

In the above example, three shims (5) should

be removed.

6. Insert the adjustment shim(s) (5) removed

in step 5 above between the end plate (3)

and the flange (4), and then fasten it in

place with the three bolts (2).

· Tightening torque for bolts (2): 83 N·m

(61.5 ft-lb.)

7. Return the O-ring (1) to the original

position.

5-59

MAINTENANCE

WHEN REQUIRED

LUBRICATING THE LEVERS AND PEDALS

Boom swing pedal

Set the machine to the parking posture,

stop the engine, remove the starter key

and store it. Failure to do so may result in

the machine moving abruptly, leading to

serious injury or death.

If the levers or pedals no longer move

smoothly, grease them.

Operating levers

1. Remove the lower mount section of the

boot (1) and turn it upward.

2. Wipe off the old grease.

3. Apply grease to points (A) and (B).

4. Set the boot (1) back as it was.

Travel levers/pedals

5-60

MAINTENANCE

WHEN REQUIRED

INSPECTING THE RUBBER CRAWLERS

(3) Metal core

Repair or replace the rubber crawlers if their

condition becomes as described below.

Consult your sales or service dealer for repair

or replacement.

Rubber crawler

Replace the crawler if the entire crawler is

stretched and cannot be adjusted.

(1) Lug

Replace if even one metal core is off.

(4) Rubber

Replace if the height of (A) is 5 mm (0.2 in.)

or below.

(2) Steel cord

Repair if there are cracks of 60 mm (2.4 in.)

or greater in length.

If the steel cord is visible, repair as soon as

possible, regardless of the length of the

crack.

Replace if the steel cord is exposed for two

links or more.

Replace if the half or more of the steel cords

on one side are cut.

5-61

MAINTENANCE

WHEN REQUIRED

REPLACING THE RUBBER CRAWLERS

Removal

1. Fully release the tension of the rubber

crawler.

Refer to “Inspecting and adjusting the

• If you must work beneath the raised

crawler tension” on page 5-26.

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.

• If maintenance must be performed with

the engine running, always work as a

two person team communicating each

other.

· One person must sit in the operator’s

seat so that he/she can immediately

stop the engine when necessary. He/

2. Use the working equipment to lift the

she must take care not to touch the

body.

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.

3. Set an iron pipe (1) in the rubber crawler

and turn the sprocket slowly in the reverse

direction.

4. Turn until the iron pipe (1) is directly next to

the idler and the rubber crawler lifts away

from the idler, then stop turning the

sprocket.

5. Slide the rubber crawler sideways and

remove it from the crawler frame.

Remove the other rubber crawler using

the same procedure.

5-62

MAINTENANCE

WHEN REQUIRED

Installation

INSPECTING AND REPLENISHING THE

1. Use the working equipment to lift the

WINDSHIELD WASHER FLUID

body.

Choose ethyl alcohol as washer solution.

Do not use methyl alcohol as washer

solution. It could damage the eyes.

Use a windshield washer fluid designed

specifically for motor vehicles. Follow the

instructions included with the washer fluid.

2. Set the rubber crawler on the sprocket.

3. Set an iron pipe (1) in the rubber crawler

and turn the sprocket slowly in the reverse

direction.

4. Turn until the iron pipe (1) is directly next to

the idler and the rubber crawler lifts away

from the idler, then stop turning the

sprocket.

5. Slide the rubber crawler inward, engage it

on the idler, then pull out the iron pipe.

6. Check that the rubber crawler is securely

Inspection

engaged on the sprocket and idler.

1. Open the cab door.

7. Tighten the rubber crawler to the standard

2. Inspect the washer tank (1) and add

tension.

washer fluid if the level is low.

Refer to “Inspecting and adjusting the

crawler tension” on page 5-26.

Replenishing

8. Install the other rubber crawler using the

1. Mix the washer fluid to the prescribed

same procedure.

concentration.

2. Remove the cap (2) and add washer fluid.

Keep the dust away while replenishing the

washer fluid.

3. Install the cap (2).

5-63

TROUBLESHOOTING

SYMPTOMS THAT ARE NOT MALFUNCTIONS

• It becomes less easy to operate the

SYMPTOMS THAT ARE NOT

machine when an attachment weighing

more than a standard arm or bucket is

MALFUNCTIONS

installed.

The symptoms listed below are not

malfunctions.

• The arm retracting speed momentarily

slows down when it reaches an almost

vertical position while the engine is running

at low speed.

• The bucket teeth moving speed

momentarily slows down when it reaches

an almost horizontal position while the

engine is running at low speed.

• The slew motor produces noise at the

beginning and end of the slewing.

• The travel motor produces noise when

stopped suddenly from its high speed

traveling.

• The control valve produces noise if

excessive force is applied to the working

equipment or when it moved to the stroke

end.

6-2

TROUBLESHOOTING

IF THE ENGINE OVERHEATS

Remedy procedure

IF THE ENGINE OVERHEATS

1. Park the machine in a safe place.

2. Check if steam is coming out of the closed

engine hood and covers.

• Do not open the engine hood and

3. If there is steam, stop the engine

covers when steam is coming from it.

immediately and contact your sales or

The steam or hot water may spurt out

service dealer for repair. If steam, is not

and cause burns.

coming out run the engine at low idle and

• Do not try to remove the radiator cap or

let the water temperature cool down.

the drain plug when the cooling water is

4. When the water temperature gauge LED

hot. Stop the engine, wait until the

drops in the green zone, stop the engine.

engine and the radiator cool, and then

5. Perform the inspections and the remedies

slowly loosen the radiator cap to release

listed below once the engine cools down.

the internal pressure.

· Fan belt slack

Adjust

• Before performing maintenance, stop

Refer to page 5-24.

the engine and allow the machine to

· Coolant level

Add

cool down.

Refer to page 5-18.

· Water leakage

Repair

The symptoms listed below indicate

· Radiator fins

Clean

overheating.

Refer to page 5-40.

· Sediment in cooling system

............................... Clean

Refer to page 5-48.

If the problem persists after the above

remedies, contact your sales or service

dealer for repair.

• An alarm is sounded and the engine

emergency lamp and the coolant

temperature warning lamp start flashing.

• The water temperature gauge LED is in the

red zone.

• Steam comes from the engine room.

6-3

TROUBLESHOOTING

IF THE BATTERY GOES DEAD

Connecting the jumper cables

IF THE BATTERY GOES DEAD

The symptoms below indicate that the

IMPORTANT: Set the starter keys of the

battery is dead.

booster vehicle and the dead machine to

• The starter motor does not turn or fails to

the OFF position.

start the engine.

• The horn is too weak.

Remedy procedure

Start the engine using the booster battery on

the other vehicle (booster vehicle) and the

jumper cables.

• When starting the engine using the

jumper cables, be sure to connect the

cables by following the proper steps.

Improper use of jumper cables can

1. Connect the clip of jumper cable (R) to the

result in battery explosion or

positive (+) battery terminal of the dead

unexpected machine motion.

machine.

· Do not allow the booster vehicle and

2. Connect the other clip of jumper cable (R)

the machine with a dead battery (dead

to the positive (+) battery terminal of the

machine) to touch each other.

booster vehicle.

· Do not allow the positive (+) and the

3. Connect the clip of jumper cable (B) to the

negative (-) clips of the jumper cables

negative (-) battery terminal of the booster

to touch each other.

vehicle.

· When connecting, attach the jumper

4. Connect the other clip of jumper cable (B)

cable to the positive (+) terminals first.

to the engine block of the dead machine.

When disconnecting, remove the

Connect the clip to a place as far from the

cable from the negative (-) terminal

battery as possible.

(ground) first.

· Connect the last clip of the jumper

Starting the engine

cable to a point as far away from the

1. Check that the clips are securely

battery as possible.

connected to the terminals.

• Always wear the protective goggle when

2. Start the engine of the booster vehicle and

jump starting the engine by using the

run it at high speed.

jumper cables.

3. Start the engine of the dead machine.

IMPORTANT: Use the jumper cables and

clips of a size suited to the capacity of

battery. Do not use damaged or corroded

jumper cables and clips.

IMPORTANT: Be sure that the battery of

the booster vehicle has the same

capacity as the battery of the dead

machine.

IMPORTANT: Be sure to connect the clips

securely.

6-4

TROUBLESHOOTING

IF THE BATTERY GOES DEAD

Disconnecting the jumper cables

Once the dead machine is successfully

running, remove the jumper cables by

following the same steps as for connection in

the reverse order.

1. Disconnect the clip of jumper cable (B)

from the engine block of the dead

machine.

2. Disconnect the other clip of jumper cable

(B) from the negative (-) battery terminal of

the booster vehicle.

3. Disconnect the clip of jumper cable (R)

from the positive (+) battery terminal of the

booster vehicle.

4. Disconnect the clip of jumper cable (R)

from the positive (+) battery terminal of the

dead machine.

Recharging

Ask your sales or service dealer for

recharging the dead battery.

6-5

TROUBLESHOOTING

IF A FUSE BLOWS

Fuse layout and circuits protected

IF A FUSE BLOWS

If a light does not come on or the electrical

system does not work, a fuse may be blown.

Inspect the fuses.

INSPECTING AND REPLACING THE FUSE

If the fuse blows again soon after

replacement, then the electric system is

likely faulty. It may pose a fire hazard if

not properly repaired. Contact your sales

or service dealer for advice.

1. Turn the starter key to the OFF position to

stop the engine.

2. Open the fuse box cover (1).

3. Check for any blown fuses.

4. If a fuse is blown, replace it with a spare

fuse of the same capacity.

6-6

TROUBLESHOOTING

IF A FUSE BLOWS

No.

Capacity

Symbol

Protected circuit

Fuse No.

1

15A

Lights

F1

2*

15A

Wiper

F2

3

10A

Safety lock lever

F3

4*

10A

Heater

F4

5

15A

Beacon

F5

6

15A

CAB

00

Cab

F6

7

10A

Alternator relay

F7

8

15A

OPT

Option

F8

9

−

F9

10

5A

Switch lighting

F10

11

20A

CTL 00

Controller power supply

F11

12

10A

ACC relay

F12

13

30A

Engine

F13

14

5A

Feed pump

F14

15

5A

CTL 00

Controller power supply

F15

16

20A

Starter switch

F16

17

10A

Horn

F17

18

10A

Cluster

F18

*: Only for cab

6-7

TROUBLESHOOTING

IF A FUSE BLOWS

INSPECTING THE FUSIBLE LINK

If the machine is not turned on after turning

the starter switch to the ON position, the

cartridge type fusible link (1) is likely blown.

Open the maintenance cover and inspect. If

the fusible link is blown, please contact your

sales or service dealer.

Note: Fusible links are large type fuses used

in high current applications. Like a regular

fuse, they act as fuses by protecting the

electric components and wirings from

damage caused by excessive current draw.

6-8

TROUBLESHOOTING

RESTARTING AFTER ADDING FUEL

Note: Air in the fuel system causes the

RESTARTING AFTER ADDING

engine to fail to start or to have other

problems. Always bleed air when the fuel

FUEL

tank is emptied or when there is air in the

BLEEDING AIR FROM THE FUEL SYSTEM

fuel system.

IMPORTANT: NEVER use the starter

motor to crank the engine in order to

prime the fuel system. This may cause the

starter motor to overheat and damage the

coils, pinion gear and/or ring gear.

IMPORTANT: If the engine stalls due to

fuel shortage, add fuel, turn the key to the

ON position for 60 seconds, and then turn

it to the START position. Running the

starter for a long time before there is

enough fuel is going through can cause

the starter to fail.

1. Add fuel.

2. Turn the starter key to the ON position and

hold it for about 60 seconds.

The automatic air bleeder bleeds air from

the fuel system.

6-9

TROUBLESHOOTING

IF A WARNING LAMP FLASHES

IF A WARNING LAMP FLASHES

If an alarm is sounded or a warning lamp starts flashing during operation, park the machine in

a safe place and perform the remedy procedures described below.

Warning lamp

Lamp name

Causes and remedies

Vehicle and

There is a problem in the machine.

engine

Refer to the respective warning lamp below.

emergency

Get the vehicle error code number from the instrument

lamp

cluster, and then consult your sales or service dealer

referring to the “Vehicle error code list”.

Refer to “Instrument cluster” on page 2-16.

Refer to “Vehicle error code list” on pages 6-12 and

6-13.

Battery charge

There is a problem with the fan belt or charger.

warning lamp

Check the fan belt for slack or breakage and adjust as

necessary.

If the lamp continues flashing after maintenance, there is

likely a problem with the charger. Consult your sales or

service dealer for help.

Refer to “Inspecting and adjusting the fan belt” on page

5-24.

Engine oil

There is a problem in the engine lubrication system.

pressure

warning lamp

Check the engine oil level. If the lamp is flashing when

the level is normal or even after replenishment of oil or

coolant, consult your sales or service dealer.

Refer to “Inspecting and replenishing the engine oil” on

page 5-19.

6-10

TROUBLESHOOTING

IF A WARNING LAMP FLASHES

Warning lamp

Lamp name

Causes and remedies

Coolant

The coolant temperature is too high and the engine is

temperature

overheating.

warning lamp

Refer to “If the engine overheats” on page 6-3.

Air cleaner

The air cleaner is clogged. Clean it.

warning lamp

Refer to “Cleaning the air cleaner” on page 5-38.

Fuel level

The fuel level is too low. Add fuel.

warning lamp

Refer to “Inspecting the fuel level” on page 5-20.

Third auxiliary

Pressure in the third auxiliary hydraulic line is too low

hydraulic

warning lamp

Consult your sales or service dealer for help.

Lift overload

This lamp starts flashing if the overload warning device is

warning

activated. If it occurs, reduce the load to be lifted.

indicator lamp

Refer to “Lift overload warning switch (If equipped)” on

page 2-45.

6-11

TROUBLESHOOTING

VEHICLE ERROR CODE LIST

VEHICLE ERROR CODE LIST

If an error code appears on the display, consult your sales or service dealer.

Error code

Error details

9

Impossible to sense ACC key

402

CAN 0 communication error

602

CAN communication error (cluster gauge)

612

CAN communication error (OX024)

1703

Main power supply voltage error (too high)

1704

Main power supply voltage error (too low)

1713

OX024 power supply voltage error (too high)

1714

OX024 power supply voltage error (too low)

2503

Sensor voltage error (too high) MMC

2504

Sensor voltage error (too low) MMC

3300

Alternator charge faulty

3401

Engine oil pressure error

3500

Overheat

3600

Air cleaner clogged

5303

Accelerator sensor error (too high)

5304

Accelerator sensor error (too low)

5353

Governor position sensor error (high pressure)

5354

Governor position sensor error (low pressure)

5505

Fuel gauge resistance value error (cable break)

5603

Lift alarm sensor error (too high)

5604

Lift alarm sensor error (too low)

6503

AUX1 slide switch voltage value error (too high)

6504

AUX1 slide switch voltage value error (too low)

6509

AUX1 slide switch neutral error

6-12

TROUBLESHOOTING

VEHICLE ERROR CODE LIST

Error code

Error details

6519

AUX1 (L) switch error

6529

AUX1 (R) switch error

6603

AUX2 slide switch voltage value error (too high)

6604

AUX2 slide switch voltage value error (too low)

6609

AUX2 slide switch neutral error

6709

AUX3 button error (Foot)

6719

AUX3 switch error (Grip)

8015

AUX1 (L) PWM output voltage error (too low)

8016

AUX1 (L) PWM output voltage error (too high)

8025

AUX1 (R) PWM output voltage error (too low)

8026

AUX1 (R) PWM output voltage error (too high)

8035

AUX2 (L) PWM output voltage error (too low)

8036

AUX2 (L) PWM output voltage error (too high)

8045

AUX2 (R) PWM output voltage error (too low)

8046

AUX2 (R) PWM output voltage error (too high)

8054

Throttle motor A (too low)

8064

Throttle motor B (too low)

PWM = Pulse width modulation

6-13

TROUBLESHOOTING

OTHER SYMPTOMS

OTHER SYMPTOMS

For symptoms not included in the table below or if the problem persists after the proper

remedies have been taken, consult your sales or service dealer.

Symptoms

Major causes

Remedies

Left and right operating levers

• Insufficient grease on the

• Grease the levers.

do not move smoothly

left and right operating

Refer to page 5-60.

levers

Blade lever and throttle lever

• Wire is stretched too lose

• Adjust or replace (ask your

do not move smoothly

sales or service dealer).

Hoe attachment, slewing or

• Safety lock lever is raised

• Lower (release) the safety

traveling operation not

(locked)

lock lever.

possible

Refer to page 2-46.

• Fuse is blown

• Replace the fuse.

Refer to page 6-6.

Digging force is insufficient

• Hydraulic oil level too low

• Add to the specified level.

Refer to page 5-21.

• Hydraulic oil is not warm

• Perform the warm-up.

enough

Refer to page 3-8.

• Air cleaner is clogged

• Clean the air cleaner.

Refer to page 5-38.

• Hydraulic oil is not of

• Replace the hydraulic oil.

suitable type

Refer to page 5-50.

Traveling is not possible or

• Stones or foreign objects

• Remove the foreign object.

not smooth

are stuck

Machine veers to the right/left

• Stones or foreign objects

• Remove the foreign object.

are stuck

• Faulty crawler tension

• Adjust the crawler to the

adjustment

prescribed tension.

Refer to page 5-26.

Travel speed cannot be

• Fuse is blown

• Replace the fuse.

changed

Refer to page 6-6.

6-14

TROUBLESHOOTING

OTHER SYMPTOMS

Symptoms

Major causes

Remedies

Slewing is not possible or not

• Insufficient grease on slew

• Grease the bearing.

smooth

bearing

Refer to page 5-28.

Hydraulic oil temperature is

• Hydraulic oil level too low

• Add up to the specified

too high

level.

Refer to page 5-21.

Starter motor turns but

• Insufficient fuel

• Add fuel.

engine does not start

Refer to page 5-20.

• Air in fuel system

• Bleed air.

Refer to page 6-9.

• Water in fuel system

• Drain water.

Refer to page 5-29.

Crawlers come off

• Crawlers too loose

• Increase the tension.

Refer to page 5-26.

Engine exhaust is white or

• Excessive engine oil

• Adjust to the specified level.

bluish

Refer to page 5-19.

• Poor fuel

• Replace the fuel.

Engine exhaust is

• Air cleaner is clogged

• Clean the air cleaner.

occasionally black

Refer to page 5-38.

Irregular noise is produced

• Low quality fuel is being

• Replace the fuel.

from the engine

used

(combustion or mechanical

• Engine is overheating

• Refer to “If the engine

noise)

overheats” on page 6-3.

• Damage inside the muffler

• Replace the muffler.

For replacement, ask your

sales or service dealer.

6-15

TROUBLESHOOTING

LOWERING THE BOOM TO THE GROUND

Equipped with emergency shut-off valve

Without emergency shut-off valve

1. Place a pan under the hose to catch the

1. Take out the bolt and remove the cover

waste oil.

(1).

2. Hold the hose fitting (1) with a wrench and

slowly loosen the hose nut (2) with another

wrench.

3. The oil in the boom cylinder is drained and

the hoe attachment is lowered.

4. After the hoe attachment is lowered to the

ground, check the safety and stability of

the machine.

5. Hold the hose fitting (1) with a wrench and

tighten the hose nut (2) with another

wrench.

· Tightening torque: 31.4 N·m (23.1 ft-lb.)

2. Remove the fitting (2).

3. Loosen the lock nut (3) while holding the

adjust screw (4) in place with a hexagonal

wrench so that the adjust screw (4) will not

be loosened together with the lock nut (3).

4. Turn the adjust screw (4) slowly 1/4 turn to

lower the boom.

5. Check for safety and stability of the

machine.

6. Return the adjust screw (4) to the original

position.

7. Tighten the lock nut (3) while holding the

adjust screw (4) in place with a hexagonal

wrench so that the adjust screw (4) will not

be loosened together with the lock nut (3).

8. Install the fitting (2).

9. Reinstall the side cover (1).

6-17

TROUBLESHOOTING

TOWING

Towing the machine

TOWING

Use the procedure described below to tow

heavy objects or the machine itself if it

should get stuck in the mud and not be able

When towing, serious injury or death

to get out on its own.

could result, if performed incorrectly or

the wire rope being used is inappropriate

or not properly inspected.

• It becomes dangerous if the wire rope

breaks or becomes disengaged. Use a

wire rope appropriate for the required

tractive force.

• Do not use a wire rope that is kinked,

twisted or otherwise damaged.

• Do not apply heavy loads abruptly to

the wire rope.

• Wear safety gloves when handling the

wire rope.

• Permissible force: 35.2 KN (7913 lbf)

• Make sure there is an operator on the

machine being towed as well as on the

1. Attach the wire rope to the shackle (1).

machine that is towing.

2. Fasten the shackle (1) to the towing holes

• Never tow on slopes.

(2).

• Do not let anyone come near to the wire

3. Make sure that the wire rope is at a cone

rope while towing.

angle of 20° or less to the travel frame.

4. Move the machine to tension the wire

IMPORTANT: Do not tow a machine if its

rope.

engine does not start or if the machine

5. Move the machine at a low speed of 2

does not run. Doing so could damage the

km/h (1.24 mph) or less to a place

machine being towed.

(convenient location for repair) a short

IMPORTANT: Be sure to follow the steps

distance from the site.

below closely when using the towing hole

to tow. Failure to heed even one of the

steps may cause damage to the towing

hole or other parts of the frame.

6-18

TROUBLESHOOTING

IF THE CAB OR CANOPY IS DAMAGED

IF THE CAB OR CANOPY IS

DAMAGED

Immediately replace the damaged cab or

canopy. Serious injury or death may occur

if the machine is operated with damaged

cab/canopy.

Do not operate the machine until the

replacement is complete. Do not try to

repair the damaged cab or canopy by

welding. Doing so could endanger the

safety of the cab/canopy.

· Cab parts No. 03486-00028

· Canopy parts No.(1) 03484-00003

· Canopy parts No.(2) 03484-00027

6-19

SPECIFICATIONS

BASIC SPECIFICATIONS

BASIC SPECIFICATIONS

Type

Cab

Canopy

MASS

Operating mass

kg (lb)

Rubber crawlers

2400 (5290)

2265 (4995)

PERFORMANCE

Heaped

0.064

(2.26)

Bucket capacity

m³ (cu. ft.)

(Standard bucket)

Struck

0.047

(1.66)

Slew speed

min^-1 (rpm)

9.7

(9.7)

1st

2.5

(1.55)

Travel speed

km/h (mph)

Rubber crawlers

2nd

4.2

(2.61)

Gradeability

(degrees)

30

Ground pressure

kPa (psi)

Rubber crawlers

30.4

(4.41)

28.7

(4.16)

Sound power level

LWA 93

Noise level dB (A)

Emission sound pressure level at the

LpA 79

operator’s position (ISO 6396,2008:)

ENGINE

Manufacturer and model

Yanmar 3TNV82A

Net (ISO 14396)

kW/min^-1 (hp/rpm)

16.5/2200 (22.1/2200)

Rated output

Net (ISO 9249/

kW/min^-1 (hp/rpm)

15.8/2200 (21.2/2200)

SAEJ1349)

Displacement

ml (cu.in.)

1330 (81.2)

Amount of CO² emission*

g/kWh

774

Starter

V-kW

12-1.7

Alternator

V-kW

12-0.48

Battery (IEC 60095-1)

V-A·h

12-58

CCA

A

490

*: The amount of CO² emission refers to the value obtained by testing the parent engine

representing the engine type (engine family member) being used; it shall not guarantee the

performance of the machine.

7-2

Content      ..     4      5      6      7     ..