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Takeuchi Mini excavator TB230 (No.130000003~). Operator's Manual (2014) - page 5

MAINTENANCE

GENERAL

Clean the installation surfaces

Cautions on handling of battery wiring

When installing and removing parts, be sure

• Disconnect the wiring from the both

that the surfaces of contact of the parts are

terminals (+ and -) on the battery before

clean. If the sealing grooves of the surface of

working on the electrical system or doing

contact are damaged, consult your sales or

electric welding.

service dealer for repair or release.

Always disconnect it from the earth side

(-). When connecting, connect the earth

Seals and split pins

side last.

• Be sure to replace all seals and cotter pins

• Do not disconnect the battery wiring while

with new ones.

the engine is moving. Otherwise, the

• When installing, be careful not to damage

electric circuits of the rotary converter or

or twist the seal.

others may be damaged.

Sealing tape

• When wrapping the plug with sealing tape,

remove any old sealing tape from the

threads and clean the threads.

• Wrap the thread tight with seal tape

starting 1 or 2 threads away from the

thread end.

Disposing of wastes

• Always collect oil that is drained from the

machine in containers. Improperly

disposed waste oil can cause

environmental harm.

• Follow appropriate laws and regulations

when disposing of harmful objects such as

oil, fuel, cooling water, coolant, filters and

batteries.

Check after maintenance

• Gradually increase the engine speed from a

low idle to maximum speed and check that

there is no oil or water leaking from

serviced parts.

• Operate each control lever and check that

the machine is operating properly.

5-3

MAINTENANCE

SERVICE DATA

SERVICE DATA

FUEL AND LUBRICANT TABLE

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

the table below.

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

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

whole fuel/oil.

Fuel

Diesel fuel specifications

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

specifications for diesel fuels.

Diesel fuel specification

Location

Diesel fuel specification

Location

ASTM D975

No.1-D S15

No.2-D S15

USA

ISO 8217DMX

International

Bio-diesel fuel

Canada

Biodiesel blends up to B5

ASTM D6751, D7467

EN590: 2009

Bio-diesel fuel

European union BS2869-A1 or A2

United kingdom

Biodiesel blends up to B5

EN14214, EN590

5-4

MAINTENANCE

SERVICE DATA

To maintain the performance and service life of the engine,

always use clean and high-quality fuel.

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

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

the lowest expected ambient temperature.

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

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

a higher cetane number fuel will be required.

• Use fuel with sulfur content of less than 0.5% by volume.

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

should be used.

A higher sulfur content fuel may cause sulfuric acid corrosion

in the cylinders of the engines.

Fuel tank

Diesel fuel

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

diesel fuel. Use of kerosene is prohibited.

• Poor quality fuel can reduce engine performance and / or

cause engine damage.

• Fuel additives are not recommended. Some fuel additives may

cause poor engine performance.

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

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

5S-44-95 test analysis method)

Precautions when using bio-diesel fuel

The warranty of the engine manufacturer may be voided by

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

deteriorated.

5-5

MAINTENANCE

SERVICE DATA

Lubricant

Type by air temperature

Location

Type

-4

14

32

50

68

86 104°F

When to replace

-20 -10

0

10

20

30 40°C

API: CF class or higher

Every 250 hrs

SAE 10W-30

Engine oil pan

ACEA: E6 class

after the initial

SAE 15W-40

JASO: DH2 class

50 hrs.

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

Cooling water

Engine cooling

Mixture of 50% coolant

(water + coolant)**

Every 1000 hrs.

system

Mixture of 30% coolant

SAE: J814C or J1034

Every 1000 hrs

Travel reduction

Gear oil

SAE 90

after the initial

gear

API: GL-4

250 hrs*.

Slew bearing

Lithium based grease

Every 50 hrs.

Working

EP-2

—

Daily or every

equipment

NLGI No.2

10 hrs.

* : If the ratio of traveling time to total operating time is high, replace the gear oil earlier than

the specified time.

** : For water, use tap water (soft). Do not use well or river water. When the ambient

temperature drops below 0°C (32°F), add coolant (antifreeze). Follow the coolant

manufacturer’s instructions to determine the mixture ratio.

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

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

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

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

be replaced every 2000 hours.

API standard: American Petroleum Institute

ACEA standard: Association des Constructeurs Européens d’Automobiles

JASO standard: Japanese Automobile Standards Organization

SAE standard: Society of Automotive Engineers

5-6

MAINTENANCE

SERVICE DATA

Volume

Engine cooling

Hydraulic oil

Travel reduction

Engine oil pan

Fuel tank

system

tank

gear

Upper limit

4 L (4.2 US qt.)

System

Level capacity

0.5 L X 2

4.7 L (5 US qt.)

56 L (14.8 US gal.)

46 L (12.2 US gal.)

(0.53 US qt.) X 2

Lower limit

Tank

2.9 L (3.1 US qt.)

35 L (9.2 US gal.)

5-7

MAINTENANCE

SERVICE DATA

REGULARLY REPLACE THE HYDRAULIC

OIL

When a hydraulic breaker is used, the oil

deteriorates more quickly than that used for

a usual excavation operation. Be sure to

replace the hydraulic oil and the return filter

elements.

• Failure to replace these in time can lead to

damage to the machine and the breaker

hydraulic system. To prolong the service life

of the hydraulic devices, properly replace

the hydraulic oil and the return filter

elements according to the table below.

• When replacing the hydraulic oil, clean the

suction strainer.

Replacement interval (hours)

( ):

When a conventional antiwear hydraulic

oil is used.

Item

Hydraulic oil

Filter element

1st time

—

25

2nd time

—

100

Periodically

1200 (600)

200

When the breaker operating ratio is 100%.

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

5-8

MAINTENANCE

SERVICE DATA

LIST OF CONSUMABLES

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

System

Item

Part name

Part No.

When to replace

Hydraulic oil

15511-03900

Every 1000 hrs

return filter

after the initial 250

Hydraulic system

Element

hrs.

Pilot line filter

15512-00703

Air breather filter

15520-02715

Every 1000 hrs.

Engine lubrication

Every 250 hrs after

Engine oil filter

Cartridge

Y129150-35153

system

the initial 50 hrs.

Fuel system

Fuel filter

Cartridge

Y129A00-55800

Every 500 hrs.

Every 1000 hrs. or

Primary (Outer)

after 6 cleanings

Y129004-12520

element

(whichever comes

Air cleaner system

Air cleaner

first)

When the primary

Secondary

19111-02772

elements are

(Inner) element

replaced.

Once a year or if

Heater system

Filter

Element

19115-13680

clogging remains

after cleaning

5-9

MAINTENANCE

SERVICE DATA

LIST OF TOOLS (IF EQUIPPED)

Code

Part name

Part No.

Remarks

1

Spanner

Y28110-100120

10 - 12

2

Spanner

Y28110-140170

14 - 17

3

Screwdriver

Y104200-92350

(+) (-) replaceable shank

4

Filter wrench

Y119640-92750

ø80

5

Filter wrench

Y171301-92750

ø90

6

Filter wrench

Y171340-92760

7

Hammer

16903-00330

3/4

8

Monkey wrench

16904-00250

250 mm

9

Pliers

16905-00200

200 mm

10

Spanner

16900-01922

19-22

11

Spanner

16900-02427

24-27

12

Single-ended wrench

16901-00013

13

13

Single-ended wrench

16901-00041

41

14

Combination wrench

16909-00019

19

15

Hex. wrench

16906-00400

4 mm

16

Hex. wrench

16906-00500

5 mm

17

Hex. wrench

16906-00600

6 mm

18

Hex. wrench

16906-00800

8 mm

19

Hex. wrench

16906-01000

10 mm

20

Hex. wrench

16906-01400

14 mm

21

Tool case

16914-00005

22

Case

16919-00001

23

Grease gun

16910-60610

600 cc

24

Drain connector

15545-12601

5-10

MAINTENANCE

SERVICE DATA

LIST OF TIGHTENING TORQUES

Nuts and Bolts (for ISO strength category 10.9)

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

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

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

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

standards.

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

are evenly tightened.

Tightening torque

Head width (b)

Size (a) x pitch

Classification

General connection points

mm

mm

N·m

ft-lb.

10

M6 x 1.0

9.8±0.5

7.2±0.4

12, 13

M8 x 1.25

22.6±1.1

16.6±0.8

14, 17

M10 x 1.5

47.1±2.4

34.7±1.7

Coarse

17, 19

M12 x 1.75

83.4±4.1

61.5±3.0

19, 22

M14 x 2.0

134.4±6.7

99.1±4.9

22, 24

M16 x 2.0

207.9±10.4

153.3±7.7

27, 30

M20 x 2.5

410.9±20.5

303.1±15.1

12, 13

M8 x 1.0

24.5±1.2

18.1±0.9

14, 17

M10 x 1.25

50±2.5

36.9±1.8

17, 19

M12 x 1.5

87.3±4.3

64.4±3.2

Fine

19, 22

M14 x 1.5

135.3±6.8

99.8±5.0

22, 24

M16 x 1.5

220.6±11

162.7±8.1

27, 30

M20 x 1.5

452.1±22.6

333.4±16.6

5-11

MAINTENANCE

SAFETY-CRITICAL PARTS

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

Hydraulic hoses (pump - delivery)

Hydraulic hoses (pump - suction)

Main body

Hydraulic hoses (slew motor)

Hydraulic hoses (travel motor)

Hydraulic hoses (boom cylinder piping)

Every 2 years

Hydraulic hoses (arm cylinder piping)

Hydraulic

system

Hydraulic hoses (bucket cylinder piping)

Hydraulic hoses (swing cylinder)

Working

equipment

Hydraulic hoses (blade cylinder)

Hydraulic hoses (angle blade cylinder)

Hydraulic hoses (pilot valve)

Hydraulic hoses (auxiliary piping)

Seat belt

Every 3 years

5-12

MAINTENANCE

SAFETY-CRITICAL PARTS

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

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

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

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

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

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

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

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

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

time.

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

Refer to “Maintenance”.

Type of inspection

Inspection item

Leakage from the connecting parts of hydraulic or fuel hoses

Daily inspection

Damage to cab or canopy - replace*

Leakage from the connecting parts of hydraulic or fuel hoses

Monthly inspection

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

Leakage from the connecting parts of hydraulic or fuel hoses

Annual inspection

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

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

*: Canopy parts No. 05584-00085

*: Cab parts No. 03586-00070

5-13

MAINTENANCE

MAINTENANCE LIST

MAINTENANCE LIST

Inspection and maintenance item

Page

Walk-around inspection

Inspecting by opening the engine hood and covers

5-16

Inspecting by walking around the machine

5-17

Inspecting while sitting in the operator’s seat

5-17

Daily inspection (every 10 hours)

Inspecting and replenishing the coolant

5-18

Inspecting and replenishing the engine oil

5-19

Inspecting the water separator

5-20

Inspecting the fuel level

5-21

Inspecting the hydraulic oil tank level and replenishing

5-22

Lubricating the working equipment

5-23

After the initial 50 hours (only for new machines)

Replacing the engine oil and the oil filter

5-24

Inspecting and adjusting the fan belt

5-26

Every 50 hours

Inspecting and adjusting the crawler tension

5-28

Lubricating the slew bearing

5-30

Draining the water from the fuel tank

5-31

Inspecting the battery

5-32

Every 100 hours

Cleaning the water separator

5-34

After the initial 250 hours (only for new machines)

Replacing the hydraulic oil return filter

5-35

Replacing the pilot line filter

5-36

Replacing the travel motor gear oil*

5-37

Every 250 hours

Replacing the engine oil and the oil filter

5-38

Inspecting and adjusting the fan belt

5-38

Cleaning the air cleaner

5-38

Cleaning the radiator fins and the oil cooler fins

5-40

Cleaning the air filter (CAB)

5-41

Every 500 hours

Replacing the fuel filter

5-42

*: 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 1000 hours

Replacing the hydraulic oil return filter

5-43

Replacing the pilot line filter

5-43

Replacing the travel motor gear oil *

5-43

Cleaning the engine cooling system

5-43

Replacing the air cleaner element

5-45

Replacing the air breather filter

5-46

Inspecting and adjusting the engine valve clearance

5-46

Every 1500 hours

Inspecting, cleaning and checking operation of the engine fuel injectors

5-47

Inspecting the crankcase breather system

5-47

Every 2000 hours

Lapping the engine valve seats (If necessary)

5-48

Every 3000 hours

Inspecting, cleaning and checking operation of the EGR valve

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

Inspecting and replenishing the windshield washer fluid

5-59

Lubricating the levers and pedals

5-60

Inspecting the rubber crawlers

5-61

Replacing the rubber crawlers

5-62

*: 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

WALK-AROUND INSPECTION

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

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

where necessary.

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

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

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

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

loosened.

INSPECTING BY OPENING THE ENGINE

HOOD AND COVERS

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

combustible materials around the engine

and battery.

2. Check for oil or engine coolant water

leakage around the engine.

3. Check for oil leakage from the hydraulic oil

tank, hydraulic devices, hoses or

connections.

5-16

MAINTENANCE

DAILY INSPECTION (EVERY 10 HOURS)

Inspection

DAILY INSPECTION

(EVERY 10 HOURS)

Perform the following inspections every day

before starting the engine for the first time.

• Before operating, perform the daily

inspections and make repairs

immediately where necessary.

• Be sure to secure the engine hood or

cover before working the inside. Do not

keep the hood or cover open on a windy

1. Open the engine hood.

day or if the machine is parked on a

2. Inspect the cooling water level in the

slope.

reserve tank (1).

The level should be between the upper

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

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

INSPECTING AND REPLENISHING THE

COOLANT

Replenishing

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

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

of the reserve tank (1).

• Do not remove the radiator cap or the

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

drain plug when the cooling water is

inspection, check for water leakage and

hot. Stop the engine and wait until the

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

engine and the radiator cool before

water to the radiator (3) as required, and

slowly loosening the radiator cap and

then to the reserve tank (1).

the drain plug to remove them.

3. Install the cap (2).

• Always wear the protective goggle and

gloves when handling coolant

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

(antifreeze). If any coolant (antifreeze)

as tap water, to replenish the coolant loss

comes in contact with eyes or skin,

due to evaporation. If the coolant loss is due

wash it off with clean water. Otherwise,

to leakage, replenish the mixture of antifreeze

it could result in injures.

and clean water (soft water) prepared using

the same mixing ratio used for the current

coolant.

5-18

MAINTENANCE

DAILY INSPECTION (EVERY 10 HOURS)

INSPECTING AND REPLENISHING THE

Replenishing

ENGINE OIL

1. Remove the oil filler cap (2).

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

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

Problems could arise if the oil level is either

Stop the engine and allow the machine to

too low or too high.

cool down before performing

3. Tighten the oil filler cap (2).

maintenance.

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

5 minutes, then stop it.

5. After about 10 to 20 minutes, inspect the

Inspection

oil level.

1. Open the engine hood.

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

off with a rag.

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

it back out.

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

The level should be between the upper

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

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

5-19

MAINTENANCE

DAILY INSPECTION (EVERY 10 HOURS)

INSPECTING THE WATER SEPARATOR

• 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. Check if there is water in the water

separator (1).

If water collects in the separator, the float

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

water before the float goes up to the

element (5),

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

plug (7) to discharge water collected

inside.

4. After drainage of water, tighten each plug

and bleed air from the fuel system.

Refer to “Bleeding air from the fuel

system” on page 6-9.

5-20

MAINTENANCE

DAILY INSPECTION (EVERY 10 HOURS)

INSPECTING THE FUEL LEVEL

• Do not smoke or permit open flames

while handling fuel or working on the

fuel system.

• Never remove the fuel cap or add fuel

when the engine is running or still hot.

Do not spill fuel on the hot surface of

the machine.

• Fill the fuel tank in a well ventilated

place.

• Clean up spilled fuel immediately.

• Do not fill the fuel tank to capacity.

Allow room for oil expansion.

• Securely tighten the fuel filler cap.

• Use the correct grade of fuel for the

operating season.

1. Check the fuel level using the fuel gauge

(1).

F: Tank is full.

E: Tank is empty.

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

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

watching the sight gauge (3).

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

5-21

MAINTENANCE

DAILY INSPECTION (EVERY 10 HOURS)

INSPECTING THE HYDRAULIC OIL TANK

Replenishing

LEVEL AND REPLENISHING

Oil may spurt out if caps or filters are

removed or pipes are disconnected

before releasing the pressure in the

hydraulic system.

• Press the air breather button to relieve

the internal pressure from the tank.

Inspection

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 right side cover.

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

the internal pressure from the tank.

3. Remove the plug (3).

4. Add the hydraulic oil up to the middle

point of the sight gauge (1).

5. Tighten the plug (3).

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

2. Fully retract the cylinders (arm and

bucket), and lower the bucket to the

ground.

3. Lower the dozer blade, and then stop the

engine.

4. Open the right side cover.

5. Inspect the oil level using the sight gauge

(1).

· When the oil temperature is about 20°C

(68°F):

The level should be between the upper

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

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

· When the oil temperature is about 50 to

80°C (122 to 176°F):

The level should be slightly below the

upper limit (H).

5-22

MAINTENANCE

DAILY INSPECTION (EVERY 10 HOURS)

LUBRICATING THE WORKING EQUIPMENT

1. Keep the machine configuration as shown in the diagram above, lower the working

equipment to the ground, and then stop the engine.

2. Use the grease gun to lubricate the grease fittings.

3. Wipe off the excess grease.

5-23

MAINTENANCE

AFTER THE INITIAL 50 HOURS (ONLY FOR NEW MACHINES)

Engine oil

AFTER THE INITIAL 50

HOURS (ONLY FOR NEW

MACHINES)

REPLACING THE ENGINE OIL AND THE

OIL FILTER

Stop the engine and allow the machine to

cool down before performing

maintenance.

1. Open the engine hood and remove the oil

• The engine, muffler, radiator, hydraulic

filler cap (2).

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.

2. Place a pan for catching the waste oil

under the drain plug (3).

3. Remove the drain plug (3) and drain the

oil.

<Equipped with drain valve>

a. Remove the cap (A), install connector

(B) and drain the oil. (The oil comes out

when the screw is tightened.)

b. Remove the connector (B) and install

the cap (A).

4. Tighten the drain plug (3).

IMPORTANT: Check the waste oil for

metal powder. If it contains large amounts

of metal powder, consult your sales or

service dealer.

5-24

MAINTENANCE

AFTER THE INITIAL 50 HOURS (ONLY FOR NEW MACHINES)

INSPECTING AND ADJUSTING THE FAN

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

BELT

between the fan pulley (2) and alternator

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

N or 22 lbf).

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

Stop the engine and allow the machine to

to 0.4 in).

cool down before performing

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

maintenance.

as follows.

• The engine, muffler, radiator, hydraulic

· There are cuts or cracks.

lines, sliding parts and many other parts

· The belt is worn and touches the bottom

of the machine are hot immediately after

of the V groove in the pulley.

the engine is stopped. Touching these

· The belt stretched too loose to be

parts will cause burns.

adjusted.

IMPORTANT: The loose belts could result

Adjustment

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.

Inspection

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

1. Move the sheet all the way forward.

the engine at low idle speed for about 3 to 5

2. Loosen the bolts and remove the cover

minutes to break in the new belt, before

(A).

adjusting the tension.

5-26

MAINTENANCE

EVERY 50 HOURS

1. For rubber crawlers, move the machine so

EVERY 50 HOURS

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

INSPECTING AND ADJUSTING THE

at the top center of the crawler frame.

CRAWLER TENSION

• If you must work beneath the raised

machine or working equipment, always

use wood blocks, jack-stands or other

rigid and stable supports. Never get

under the machine or working

equipment if they are not sufficiently

supported. This procedure is especially

important when working on hydraulic

cylinders.

2. Use the working equipment to lift the

• Be careful with the high-pressure grease

machine body. Operate the levers slowly.

In the track adjuster, the grease has

been injected under high pressure. If the

tension is adjusted without following the

prescribed procedure, the grease

discharge valve may fly off, resulting in

injury.

· Never loosen the grease fitting.

· Loosen the grease discharge valve

slowly. Do not turn it more than one

turn.

· Do not put your face, arms, legs or

body in front of the grease discharge

valve.

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

· If grease does not come out when the

bottom surface of the frame at the center

grease discharge valve is loosened,

of the crawler frame and the top surface of

the valve is faulty. Ask a Takeuchi

the crawler.

service agent for repair.

The gap (A or B) must be within the

following range:

Inspection

(A) Rubber crawler

77 to 87 mm (3.0 to 3.4 in.)

(B) Steel crawler

144 to 154 mm (5.7 to 6.1 in.)

(B) Rubber pads

144 to 154 mm (5.7 to 6.1 in.)

5-28

MAINTENANCE

EVERY 50 HOURS

Adjustment

Increasing the tension

1. Remove the cover (1).

2. Using the grease gun, insert grease

through the grease fitting (3) in the grease

discharge valve (2).

3. Inspect the crawler tension.

Decreasing the tension

1. Remove the cover (1).

2. Using the spanner, slowly loosen the

grease discharge valve (2) (one turn) and

drain the grease.

If the grease does not drain easily, move

the machine forward or backward.

3. Tighten the grease discharge valve (2).

· Tightening torque: 59 to 88 N·m (43.4 to

65.1 ft-lb.)

5-29

MAINTENANCE

EVERY 50 HOURS

LUBRICATING THE SLEW BEARING

4. Lower the bucket to the ground, and then

stop the engine.

5. Repeat the steps 2 to 4 above three

times.

Do not slew while lubricating. Doing so is

6. Wipe off the grease expelled from the slew

dangerous, as you may get caught in the

bearing and grease fitting.

machine.

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°.

5-30

MAINTENANCE

EVERY 50 HOURS

DRAINING THE WATER FROM THE FUEL

1. Open the fuel lid.

TANK

2. Remove the fuel filler cap (2).

3. Loosen the bolts and remove the under

cover (3).

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

• Do not smoke or permit open flames

5. Remove the drain plug (4), and then drain

while handling fuel or working on the

the water and sediment buildup in the

fuel system.

bottom of the tank.

• Never remove the fuel cap or add fuel

6. Tighten the drain plug (4).

when the engine is running or still hot.

7. Install the under cover (3).

Do not spill fuel on the hot surface of

8. Add fuel while watching the sight gauge

the machine.

(1).

• Fill the fuel tank in a well ventilated

9. Tighten the fuel filler cap (2).

place.

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

• Do not fill the fuel tank to capacity.

11. Bleed air.

Allow room for oil expansion.

• Clean up spilled fuel immediately.

Bleeding air from the fuel system

• Securely tighten the fuel filler cap.

Refer to “Bleeding air from the fuel system”

• Use the correct grade of fuel for the

on page 6-9.

operating season.

Note: Air in the fuel system causes the

Do the draining operation before starting the

engine to fail to start or to have problems.

machine.

Bleed air when the fuel tank is emptied,

using the same procedure above.

AG8G005

5-31

MAINTENANCE

EVERY 50 HOURS

INSPECTING THE BATTERY

Inspection

Turn the starter switch to ON and check the

battery voltage on the display. The battery is

normal if the voltage is 12 V or more.

• Do not use or charge the battery when

Refer to “(6) Data display” on page 2-25 and

the battery indicator is white. The

“Data screen (DATA)” on page 2-36.

battery is at its end of life. Immediately

replace the battery.

Note: Under normal operating conditions,

• Batteries generate flammable hydrogen

the maintenance-free battery does not

gas which may explode. Keep away

require addition of water because of the

from flame, sparks, fire or lighted

special plate designed to minimize fluid loss.

cigarettes.

• Use a dampened cloth to clean the

1. Open the right side cover.

battery indicator and check the fluid

level. Do not clean with a dry cloth; it

can cause static electricity to build up,

resulting in ignition or explosion.

• Do not use the cable if it’s connecting

terminal is loose or corroded. If used,

ignition or explosion may occur.

• Wear protective goggle and clothing

when working with batteries.

2. Inspect the indicator (1).

• Do not tilt the battery. Doing so could

· Green: Good

cause the battery fluid to leak out of the

· Black: Charging needed

exhaust hole. If contacted, it may cause

· White: Replace the battery

skin irritation or the machine part

3. Check the battery terminal for looseness,

corrosion.

dirt and corrosion.

• Batteries contain sulfuric acid which will

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

damage eyes or skin if contacted.

5. Check the battery voltage. Confirm it is 12

· If eye contact occurs, flush

V or more.

immediately with clean water and get

Refer to “(6) Data display” on page 2-25

prompt medical attention.

and “Data screen (DATA)” on page 2-36.

· If accidentally swallowed, drink large

quantities of water or milk and call a

physician immediately.

· If acid contacts skin or clothing, wash

off immediately with a lot of water.

5-32

MAINTENANCE

EVERY 100 HOURS

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.

(S): Close

1. Open the engine hood.

2. Close the valve (2).

3. Loosen the case (3), then remove the

stand (4), element (5) and indicator ring (6)

and clean them.

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

there are any scratches or other

irregularities, replace them.

5. Assemble the indicator ring (6), stand (4)

and element (5) and tighten the case (3).

6. Open the valve (2).

7. Loosen the vent plug (8) and bleed the air.

8. Tighten the vent plug (8).

Refer to “Bleeding air from the fuel

system” on page 6-9.

5-34

MAINTENANCE

AFTER THE INITIAL 250 HOURS (ONLY FOR NEW MACHINES)

AFTER THE INITIAL 250

HOURS (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

1. Open the right side cover.

conditions could result in burns or

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

injuries due to the hot oil spurting out.

the internal pressure from the tank.

• Oil may spurt out if caps or filters are

3. Loosen the bolts and remove the flange

removed or pipes are disconnected

(4).

before releasing the pressure in the

4. Remove the return filter (5).

hydraulic system.

5. Install a new return filter.

· Press the air breather button to relieve

6. Install the flange (4) on its original position.

the internal pressure from the tank.

7. Inspect the level with the sight gauge (1),

· When removing plugs or screws, or

and replenish if the level is too low.

when disconnecting hoses, stand to

Refer to “Inspecting the hydraulic oil tank

the side and loosen them slowly to

level and replenishing” on page 5-22.

gradually release the internal pressure

before removing.

5-35

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).

· Press the air breather button to relieve

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

the internal pressure from the tank.

and replenish if the level is too low.

· When removing plugs or screws, or

Refer to “Inspecting the hydraulic oil tank

when disconnecting hoses, stand to

level and replenishing” on page 5-22.

the side and loosen them slowly to

gradually release the internal pressure

before removing.

1. Open the right side cover.

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

the internal pressure from the tank.

5-36

MAINTENANCE

AFTER THE INITIAL 250 HOURS (ONLY FOR NEW MACHINES)

REPLACING THE TRAVEL MOTOR GEAR

OIL

• Stop the engine and allow the machine

to cool down before performing

maintenance.

· 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.

2

1

AE7G002

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) and (2) and drain the

oil.

4. Rewrap the plugs with new sealing tape.

5. Tighten the plug (1).

6. Add oil through the hole of the plug (2)

until oil flows out of the hole of the plug

(2).

7. Tighten the plugs (2).

5-37

MAINTENANCE

EVERY 250 HOURS

EVERY 250 HOURS

REPLACING THE ENGINE OIL AND THE

OIL FILTER

Refer to “Replacing the engine oil and the oil

filter” on page 5-24.

INSPECTING AND ADJUSTING THE FAN

BELT

1. Open the engine hood.

Refer to “Inspecting and adjusting the fan

belt” on page 5-26.

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

2. Loosen the clamps (1) and remove the

immediately after the engine is

dust cup (2).

stopped. Touching it will cause burns.

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

• Wear required appropriate equipment

4. Remove the primary element (3).

such as protective goggle and filter

5. Cover the intake hole at the back of the

mask when using compressed air, as

body (4) with cloth or tape to prevent dirt

metal fragments or other objects can fly

from getting in.

and cause serious injury.

<If equipped with the secondary element>

To prevent dirt from getting inside the

IMPORTANT: Be careful not to scratch the

engine, do not remove the secondary

element. Do not use an element if it is

element (5).

damaged.

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

IMPORTANT: When operating the

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.

5-38

MAINTENANCE

EVERY 250 HOURS

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

it if there are small holes or thin spots.

9. Remove the cloth or tape applied in step 5.

10. Install the primary element (3).

11. Install the dust cup (2) with its

“ TOP

” mark facing, and then

fasten it with the clamps (1).

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.

1. Open the engine hood and right side

cover.

2. Blow compressed air on the fins to

remove mud and dirt stuck on them.

5-40

MAINTENANCE

EVERY 250 HOURS

CLEANING THE AIR FILTER (CAB)

Replacing

Replace the filter with a new one once a year

or if it is still clogged after blow-drying with

compressed air and washing.

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.

Clean the filter immediately after operating in

dusty places.

If the filter is clogged, the air flow is reduced

and a booming sound is heard from the air

conditioner unit.

Removing the filter

1. Open the fuel lid.

2. Loosen the screw and remove the cover

(4).

3. Remove the circulation filter (5).

4. Use compressed air or water to clean the

filter, depending on how dirty it is.

Circulation filter (2) Part No. 19115-13680

Cleaning

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

psi or less) directly on the filter from the

inside, moving up and down along the

pleats.

Be sure to keep the nozzle at an adequate

distance from the filter.

2. Wash the filter with neutral detergent if it is

very dirty. Dry the filter completely after

washing it.

5-41

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