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Takeuchi Mini excavator TB230 (No.130000003~). Operator's Manual (2014) - page 6

MAINTENANCE

EVERY 500 HOURS

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: 19.6 to 23.5 N·m or 14

to 17ft-lb.)

7. Bleed the air.

Refer to “Bleeding air from the fuel

system” on page 6-9.

5-42

MAINTENANCE

EVERY 1000 HOURS

1. Open the engine hood and the side cover.

10. Repeat the steps 4 to 8 to rinse the

cooling system.

11. Tighten the drain plug (4).

12. Take time and slowly add the new

coolant (mixture of antifreeze and tap

water) to the radiator through the fill port

until it is full.

13. Close the radiator cap (3).

14. Warm up the engine. Use the meters to

check that there are no irregularities in

the cooling system at this time.

15. Increase the water temperature to at

least 90°C (194°F). Then, run the engine

2. Gradually loosen the radiator cap (3) to

for about 10 minutes with the thermostat

release the internal pressure, and then

kept open.

remove the cap.

16. Stop the engine, wait until the cooling

water temperature becomes lower, and

then check the level of coolant in the

radiator.

If necessary, add cooling water until the

radiator is full.

17. Close the radiator cap (3).

18. Clean the interior of the reserve tank (1),

and then add coolant to the upper limit

(H).

19. When the coolant has been replaced,

inspect the coolant level once again after

operating the machine.

3. Place a pan for catching the waste coolant

Once the machine is operated, the

under the drain plug (4), and then loosen

coolant is distributed throughout the

the drain plug (4) to drain the coolant.

entire system, resulting in the lower

4. Tighten the drain plug (4).

coolant level.

5. Add tap water to the radiator through the

Replenish the cooling water that has

coolant fill port up to the top of the port.

been used.

Take time and slowly add water, so that no

air enters the radiator.

6. Close the radiator cap (3).

7. Start the engine and run it at a speed

slightly above low idling. Raise the water

temperature to at least 90°C (194°F), and

then run the engine for about 10 minutes

with the thermostat open.

8. Stop the engine, wait until the cooling

water temperature becomes lower, and

then remove the drain plug (4) to drain the

water.

9. After draining, clean the cooling system

using a cleaning agent. When using the

cleaning agent, follow the instructions

included with the agent.

5-44

MAINTENANCE

EVERY 1000 HOURS

REPLACING THE AIR CLEANER ELEMENT

5. Cover the intake hole at the back of the

body (4) with cloth or tape to prevent dirt

from getting in.

<If equipped with the secondary element>

Stop the engine and allow the machine to

Do not yet remove the secondary element

cool down before performing

(5).

maintenance.

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

• The engine, muffler, radiator and many

7. Remove the cloth or tape applied in step

other parts of the machine are hot

5.

immediately after the engine is stopped.

<If equipped with the secondary element>

Touching these parts will cause burns.

Remove the secondary element (5).

8. Install the new elements.

IMPORTANT: Do not use an element if its

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

”

pleats, gaskets or seals are damaged.

mark facing up, and then fasten it with the

IMPORTANT: Be sure to install the

clamps (1).

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).

5-45

MAINTENANCE

EVERY 1000 HOURS

REPLACING THE AIR BREATHER FILTER

INSPECTING AND ADJUSTING THE

ENGINE VALVE CLEARANCE

This operation requires experience. Ask your

Oil may spurt out if caps or filters are

sales or service dealer for it.

removed or pipes are disconnected

before releasing the pressure in the

hydraulic system.

• Press the air breather button to relieve

the tank pressure.

1. Open the right side cover.

2. Press the button (K) to relieve the internal

pressure from the tank.

3. Remove the nut (N) on the air breather.

4. Remove the cover (H).

5. Replace the filter (A).

6. Install the cover (H) on the body (B).

7. Install the nut (N).

5-46

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

are hot immediately after the engine is

stopped. Touching these parts will

cause burns.

· 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

3. Press the button (2) to relieve the internal

hydraulic system.

pressure from the tank.

· Press the air breather button to relieve

4. Replace the air breather filter (A).

the internal pressure from the tank.

Refer to “Replacing the air breather filter”

· When removing plugs or screws, or

on page 5-46.

when disconnecting hoses, stand to

5. Remove the plug (3).

the side and loosen them slowly to

6. Loosen the bolts and remove the flange

gradually release the internal pressure

(4).

before removing.

7. Remove the return filter (5).

8. Place a pan under the plug (6) to catch the

1. Slew 60° clockwise and set the machine

waste oil.

to the hydraulic oil level inspection

9. Remove the drain plug (6), and then drain

posture.

the hydraulic oil.

Refer to “Inspecting the hydraulic oil tank

10. Loosen the bolts and remove the flange

level and replenishing” on page 5-22.

(7).

2. Open the right side cover.

11. Remove the suction strainer (8) and

clean it.

12. Clean the inside of the hydraulic oil tank.

13. Tighten the drain plug (6).

14. Install the suction strainer (8) on the tank

and then install the flange (7).

5-50

MAINTENANCE

EVERY 4000 HOURS

15. Install the new return filter (5) and the

• Cylinders

flange (4) on the tank.

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

16. Add hydraulic oil from the hole of plug (3)

speed for 10 minutes.

up to the level between the upper limit

2. Maintain the engine at low idle, and then

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

slowly extend and retract each cylinder 4

gauge (1).

or 5 times, without letting them reach the

17. Tighten the plug (3).

stroke end.

18. Bleed air from the hydraulic oil circuit

3. While running the engine at high speed,

following “Bleeding air” below.

slowly extend and retract each cylinder 4

19. Set the machine to the hydraulic oil level

or 5 times, without letting them reach the

inspection posture and inspect the oil

stroke end.

level after the oil cools.

4. Return the engine speed to low idle, and

Refer to “Inspecting the hydraulic oil tank

then slowly extend and retract each

level and replenishing” on page 5-22.

cylinder 4 or 5 times to the stroke end.

Bleeding air

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

1. Open the engine hood.

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

pump.

3. Once hydraulic oil overflows from the vent

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

5-51

MAINTENANCE

EVERY 4000 HOURS

• Emergency shut-off valve (If equipped)

Arm

This operation is dangerous and requires

experience. Ask your sales or service

dealer for help.

If air is not released, the working

equipment could become slow in reacting

to the operation of the operator and show

unexpected behavior.

When removing plugs or screws, or when

disconnecting hoses, stand to the side

and loosen them slowly to gradually

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

release the internal pressure before

wrench and slowly loosen the hose nut (2).

removing.

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

direction a little until there are no more air

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

bubbles coming from the hose nut (2)

catch the waste oil.

joint.

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

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

3. Fully lower the safety lock lever to the

wrench and tighten the hose nut (2).

unlock position.

Boom

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

wrench and slowly loosen the hose nut (1).

5. Slowly move the boom in the “Boom

lower” direction a little until there are no

more air bubbles coming from the hose

nut (1) joint.

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

wrench and tighten the hose nut (1).

5-52

MAINTENANCE

WHEN REQUIRED

2. Set the bottom surface of the bucket flat

WHEN REQUIRED

and lower it on a block so that the locking

REPLACING THE BUCKET TEETH AND

pin (1) can be knocked out.

THE SIDE CUTTERS

3. Remove the key, then check that the

bucket is stable.

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

when repairing or replacing the bucket

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

teeth or side cutter.

knock the locking pin out by hammering

• When using a hammer, pins may fly out

against the rod.

or metal particles may be scattered.

The rod should be round and thinner than

This may lead to serious injury.

the locking pin.

· 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.

• Bucket tooth <V13SY or V17S>

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

Removal

points (2) are of the type that are removed

1. Clean the bucket and park the machine in

by turning (twisting) them

a flat, safe place where the ground is hard.

counterclockwise.

The same procedure can be used to

remove the other tooth points.

5-53

MAINTENANCE

WHEN REQUIRED

Installation

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

until it is flush with the tip of the tooth

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

point (2) ear.

gravel or mud on the adapter nose, the

tooth point will not go in all the way and

the pin cannot be driven in.

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

(3).

Push in firmly until the tooth point (2)

touches the tip of the adapter nose(3).

Some tooth points (2) are of the type that

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

are installed by turning (twisting) them

The same procedure can be used to install

clockwise.

the other tooth points.

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

in the right direction.

5-54

MAINTENANCE

WHEN REQUIRED

• Side cutter

Installation

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.

5-55

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.

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

(3) and flange (4).

1. Lower the bucket to the ground as shown

on the figure above in a stable position.

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

2. Check that the bucket dose not move,

corresponding to the gap (A) from

and then set the safety lock lever to the

between the flange (4) and the bucket

locked position and stop the engine.

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.

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

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

into view and measure the width of the

in step 5 above between the end plate (3)

gap (A).

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

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

place with the three bolts (2).

Swing the upperstructure slightly to the left

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

and lightly press the arm point to the left

(61.5 ft-lb.)

side of the bucket (the side without an

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

adjuster).

position.

5-58

MAINTENANCE

WHEN REQUIRED

INSPECTING AND REPLENISHING THE

WINDSHIELD WASHER FLUID

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.

Inspection

1. Open the right side cover.

2. Inspect the washer tank (1) and add

washer fluid if the level is low.

Replenishing

1. Mix the washer fluid to the prescribed

concentration.

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

Keep the dust away while replenishing the

washer fluid.

3. Install the cap (2).

5-59

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

Dozer blade lever

Travel 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.

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

• 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.

• If maintenance must be performed with

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

the engine running, always work as a

and turn the sprocket slowly in the reverse

two person team communicating each

direction.

other.

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

· One person must sit in the operator’s

the idler and the rubber crawler lifts away

seat so that he/she can immediately

from the idler, then stop turning the

stop the engine when necessary. He/

sprocket.

she must take care not to touch the

5. Slide the rubber crawler sideways and

lever or pedal unless necessary.

remove it from the crawler frame.

· The one who performs maintenance

Remove the other rubber crawler using

must make sure to keep his/her body

the same procedure.

or clothing away from the moving part

of the machine.

Removal

1. Fully release the tension of the rubber

crawler.

Refer to “Inspecting and adjusting the

crawler tension” on page 5-28.

2. Use the working equipment to lift the

body.

5-62

MAINTENANCE

WHEN REQUIRED

Installation

1. Use the working equipment to lift the

body.

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

engaged on the sprocket and idler.

7. Tighten the rubber crawler to the standard

tension.

Refer to “Inspecting and adjusting the

crawler tension” on page 5-28.

8. Install the other rubber crawler using the

same procedure.

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

• The water temperature gauge level is in the

IF THE ENGINE OVERHEATS

red zone.

• The engine slows down and the engine

power decreases.

• Do not open the engine hood when steam

• Steam comes from the engine room.

is coming from it. The steam or hot water

may spurt out and cause burns.

• Do not try to remove the radiator cap or

Remedy procedure

the drain plug when the cooling water is

1. Park the machine in a safe place.

hot. Stop the engine, wait until the

2. Check if steam is coming out of the closed

engine and the radiator cool, and then

engine hood.

slowly loosen the radiator cap to release

3. If there is steam, stop the engine

the internal pressure.

immediately and contact your sales or

• Before performing maintenance, stop the

service dealer for repair. If steam, is not

engine and allow the machine to cool down.

coming out run the engine at low idle and

let the water temperature cool down.

The symptoms listed below indicate

4. When the water temperature gauge level

overheating.

drops in the green zone, stop the engine.

5. Perform the inspections and the remedies

< Canopy >

listed below once the engine cools down.

· Fan belt slack

Adjust

Refer to page 5-26.

· Coolant level

Add

Refer to page 5-18.

· Water leakage

Repair

· Radiator fins

Clean

Refer to page 5-40.

· Sediment in cooling system

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

Refer to page 5-43.

If the problem persists after the above

remedies, contact your sales or service

dealer for repair.

< Cab >

• An alarm is sounded and the engine

emergency lamp and the coolant

temperature warning lamp start flashing.

6-3

TROUBLESHOOTING

IF THE BATTERY GOES DEAD

IMPORTANT: Be sure that the battery of

IF THE BATTERY GOES DEAD

the booster vehicle has the same

The symptoms below indicate that the

capacity as the battery of the dead

battery is dead.

machine.

• The starter motor does not turn or fails to

IMPORTANT: Be sure to connect the clips

start the engine.

securely.

• The horn is too weak.

Connecting the jumper cables

Remedy procedure

Start the engine using the booster battery on

IMPORTANT: Set the starter keys of the

the other vehicle (booster vehicle) and the

booster vehicle and the dead machine to

jumper cables.

the OFF position.

• 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

result in battery explosion or

unexpected machine motion.

· Do not allow the booster vehicle and

the machine with a dead battery (dead

machine) to touch each other.

· Do not allow the positive (+) and the

negative (-) clips of the jumper cables

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

to touch each other.

positive (+) battery terminal of the dead

· When connecting, attach the jumper

machine.

cable to the positive (+) terminals first.

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

When disconnecting, remove the

to the positive (+) battery terminal of the

cable from the negative (-) terminal

booster vehicle.

(ground) first.

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

· Connect the last clip of the jumper

negative (-) battery terminal of the booster

cable to a point as far away from the

vehicle.

battery as possible.

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

• Always wear the protective goggle when

to the engine block of the dead machine.

jump starting the engine by using the

Connect the clip to a place as far from the

jumper cables.

battery as possible.

• Set the battery charging current to at or

below one tenth of the rated capacity.

Starting the engine

Too high charging current could cause

1. Check that the clips are securely

the battery to leak or be depleted,

connected to the terminals.

resulting in explosion if ignited.

2. Start the engine of the booster vehicle and

run it at high speed.

IMPORTANT: Use the jumper cables and

3. Start the engine of the dead machine.

clips of a size suited to the capacity of

battery. Do not use damaged or corroded

jumper cables and clips.

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 (1)

IF A FUSE BLOWS

If a light does not come on or the electrical

<Cab>

system does not work, a fuse may be blown.

Inspect the fuses.

Protected

Capacity

Symbol

circuit

INSPECTING AND REPLACING THE FUSE

5A

Switch lighting

10A

Horn

If the fuse blows again soon after

5A

Starter switch

replacement, then the electric system is

likely faulty. It may pose a fire hazard if

10A

Immobilizer

not properly repaired. Contact your sales

or service dealer for advice.

20A

Light

1. Turn the starter key to the OFF position to

stop the engine.

10A

Wiper

20A

Lever lock

Controller power

10A

supply (2)

10A

Solenoid

Cab interior

20A

power supply

25A

OPT

Option

10A

Heater

10A

Feed pump

2. Open the fuse box cover (1).

3. Check for any blown fuses (2).

30A

Blower motor

20A

Cab light

Controller power

20A

supply (1)

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

fuse of the same capacity.

6-6

TROUBLESHOOTING

IF A FUSE BLOWS

<Canopy>

7. Open the fuse box.

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

fuse of the same capacity.

Protected

Capacity

Symbol

circuit

Fuse layout and circuits protected (2)

5A

Switch lighting

Capacity

Protected circuit

10A

Horn

10A

ECU

5A

Starter switch

25A

Fuel pump

10A

Immobilizer

20A

Light (1)

20A

Lever lock

Controller power

15A

supply

25A

Solenoid

20A

OPT (1)

Option (1)

25A

OPT (2)

Option (2)

10A

Feed pump

15A

Light (2)

5. Open the right side cover and engine

hood.

6. Loosen the bolts and remove the cover

(3).

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 (2) is likely blown.

Open the right side cover and inspect it. If

the fusible link is blown, contact your sales

or service dealer.

1. Open the right side cover.

2. Loosen the bolts and remove the cover

(1).

3. Inspect the fusible link (2).

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

problems. Always bleed air when the fuel

RESTARTING AFTER ADDING

tank is emptied or when there is air in the

fuel system.

FUEL

BLEEDING AIR FROM THE 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.

Note: Air in the fuel system causes the

engine to fail to start or to have other

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 or engine error code number from the

lamp

multi-information display or the instrument cluster, and

then consult your sales or service dealer referring to the

“Vehicle error code list” or “Engine error code list”.

Refer to “Multi-information display” on page 2-16 or

“Instrument cluster” on page 2-28.

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

6-13.

Refer to “Engine error code list” on pages 6-14 to 6-15.

ECM error

An engine problem is detected.

warning lamp

If an error code is displayed on the multi-information

display or the instrument cluster, inform your sales or

service dealer of the code and ask for help.

Refer to “Multi-information display” on page 2-16 or

“Instrument cluster” on page 2-28.

Refer to “Engine error code list” on pages 6-14 to 6-15.

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

5-26.

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 filter

The fuel filter is clogged. Replace the fuel filter.

warning lamp

Refer to “Replacing the fuel filter” on page 5-42.

Fuel level

The fuel level is too low. Add fuel.

warning lamp

Refer to “Inspecting the fuel level” on page 5-21.

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 2-55.

6-11

TROUBLESHOOTING

VEHICLE ERROR CODE LIST

VEHICLE ERROR CODE LIST

When the multi-information display is set to the data mode, the number that is corresponding

to the error, if applicable, appears in the error code field. Up to four types of error codes are

displayed (the leftmost code is the most recent error). If this occurs, consult your sales or

service dealer.

Error code

Error details

9

Impossible to sense ACC key

19

Parameter version mismatching

402

CAN 0 communication error

502

CAN communication error (engine ECU)

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)

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 (Grip)

6719

AUX3 switch error (Foot)

8005

Pump PWM output voltage error (too low)

8006

Pump PWM output voltage error (too high)

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)

9990

Model change

9991

Unknown models

PWM = Pulse width modulation

6-13

TROUBLESHOOTING

ENGINE ERROR CODE LIST

ENGINE ERROR CODE LIST

When the engine error code is displayed on the multi-data display, the number that is

corresponding to the error, if applicable, appears in the error code field. Up to three types of

error codes are displayed, with the latest code at the top. If this occurs, consult your sales or

service dealer for help.

Error code

Error details

SPN

FMI

4

Engine Fuel Rack Position Sensor: Shorted to low source

1210

3

Engine Fuel Rack Position Sensor: Shorted to high source

4

Barometric Pressure Sensor: Shorted to low source

108

3

Barometric Pressure Sensor: Shorted to high source

2

Barometric Pressure Sensor: Intermittent fault

4

E-ECU Internal Temperature Sensor: Shorted to low source

3

E-ECU Internal Temperature Sensor: Shorted to high source

1136

2

E-ECU Internal Temperature Sensor: Intermittent fault

0

E-ECU Internal Temperature: Too high

4

Engine Coolant Temperature Sensor: Shorted to low source

3

Engine Coolant Temperature Sensor: Shorted to high source

110

2

Engine Coolant Temperature Sensor: Intermittent fault

0

Engine Coolant Temperature: Too high

4

Sensor 5V: Shorted to low source

1079

3

Sensor 5V: Shorted to high source

2

Sensor 5V: Intermittent fault

1

System Voltage: Too low

158

0

System Voltage: Too high

1078

4

Engine Fuel Injection Pump Speed Sensor: Shorted to low source

522402

4

Auxiliary Speed Sensor: Shorted to low source

4

Engine Fuel Rack Actuator Relay: Circuit fault A

3

Engine Fuel Rack Actuator Relay: Circuit fault B

522241

7

(Reserved)

2

Engine Fuel Rack Actuator Relay: Intermittent fault

4

Air Heater Relay: Circuit fault A

522243

3

Air Heater Relay: Circuit fault B

2

Air Heater Relay: Intermittent fault

4

Cold Start Device: Circuit fault A

522242

3

Cold Start Device: Circuit fault B

2

Cold Start Device: Intermittent fault

4

EGR Stepping Motor “A”: Circuit fault A

522251

3

EGR Stepping Motor “A”: Circuit fault B

6-14

TROUBLESHOOTING

ENGINE ERROR CODE LIST

Error code

Error details

SPN

FMI

4

EGR Stepping Motor “B”: Circuit fault A

522252

3

EGR Stepping Motor “B”: Circuit fault B

4

EGR Stepping Motor “C”: Circuit fault A

522253

3

EGR Stepping Motor “C”: Circuit fault B

4

EGR Stepping Motor “D”: Circuit fault A

522254

3

EGR Stepping Motor “D”: Circuit fault B

4

Oil Pressure Switch: Shorted to low source

100

1

Oil Pressure: Too low

4

Battery Charge Switch: Shorted to low source

167

1

Charge warning

522314

0

Engine Coolant Temperature: Abnormal temperature

522323

0

Air Cleaner: Mechanical malfunction

522329

0

Oily Water Separator: Mechanical malfunction

190

0

Engine speed: Overspeed condition

4

Engine Fuel Rack Actuator: Shorted to low source

3

Engine Fuel Rack Actuator: Shorted to high source

638

7

Engine Fuel Rack Actuator: Mechanical malfunction

2

Engine: Malfunction

639

12

High-speed CAN Communication: Communication fault

2

E-ECU internal fault: EEPROM checksum error (Data Set 2)

630

12

E-ECU internal fault: EEPROM read/write fault

12

E-ECU internal fault: Flash ROM checksum error (Main software)

628

2

E-ECU internal fault: Flash ROM checksum error (Data Set 1)

2

E-ECU internal fault: Flash ROM checksum error (Data Set 2)

1485

4

E-ECU Main Relay: Shorted to low source

12

E-ECU internal fault: Sub-CPU error A

522727

12

E-ECU internal fault: Sub-CPU error B

12

E-ECU internal fault: Sub-CPU error C

522728

12

E-ECU internal fault: Engine Map Data Version Error

12

Immobilizer: CAN communication fault

522730

8

Immobilizer: Pulse communication fault

1202

2

Immobilizer: System fault

6-15

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

Travel levers, blade lever and

• Insufficient grease on travel

• Grease the levers and

pedals do not move smoothly

levers, blade lever and

pedals.

pedals

Refer to page 5-60.

Operation of hoe attachment,

• Safety lock lever is raised

• Lower (release) the safety

dozer blade, auxiliary

(locked)

lock lever.

hydraulics, slewing or

Refer to page 2-57.

traveling is not possible.

• 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 5-22.

• Hydraulic oil is not warm

• Perform the warm-up.

enough

Refer to pages 3-8 to 3-9.

• 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

• Crawler belt tension is

• Check and adjust (ask your

faulty.

sales or service dealer).

Refer to pages 5-28 to

5-29.

Travel speed cannot be

• Fuse is blown

• Replace the fuse.

changed

Refer to page 6-6.

Slewing is not possible or not

• Insufficient grease on slew

• Grease the bearing.

smooth

bearing

Refer to page 5-30.

Hydraulic oil temperature is

• Hydraulic oil level too low

• Add up to the specified

too high

level.

Refer to page 5-22.

6-16

TROUBLESHOOTING

OTHER SYMPTOMS

Symptoms

Major causes

Remedies

Starter motor turns but

• Insufficient fuel

• Add fuel.

engine does not start

Refer to page 5-21.

• Air in fuel system

• Bleed air.

Refer to page 6-9.

• Water in fuel system

• Drain water.

Refer to page 5-31.

• Fuel is frozen.

• Warm the fuel pipe with hot

water or wait until the

ambient temperature

becomes high.

• Engine control system is

• Adjust or repair (ask your

faulty.

sales or service dealer).

• Fuel line is faulty.

• Adjust or repair (ask your

sales or service dealer).

• Preheating device is faulty.

• Adjust or repair (ask your

sales or service dealer).

Crawlers come off

• Crawlers too loose

• Check and adjust (ask your

sales or service dealer).

Refer to pages 5-28 to

5-29.

Engine exhaust is white or

• Excessive engine oil

• Adjust to the specified level.

bluish

Refer to page 5-19.

• Insufficient machine warm-

• Perform the warm-up

up.

operation.

Refer to page 3-5.

• Engine control system is

• Adjust or repair (ask your

faulty.

sales or service dealer).

• Fuel line is faulty.

• Adjust or repair (ask your

sales or service dealer).

• Prolonged idling (approx.

• Increase the engine RPM

two hours or more)

and check for smoke.

• Poor fuel

• Replace the fuel.

6-17

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