Takeuchi Hydraulic Excavator TB285 (No.185000001~), TB290 (No.190000001~). Operator's Manual

Operation

Cautions on operating

Cautions on using machine in water

Cautions on operating

Cautions on traveling

If the rear of the machine is submerged in

water as shown in the figure above, it causes

Traveling over obstacles (rocks, stumps, etc.)

the radiator fan to turn in water, resulting in

may put a great load on the machine body

damage to the fan. The rear of the machine

and may cause damage to it. Avoid crossing

must not be submerged.

over obstacles whenever possible. If you

must do so, keep the hoe attachment near

the ground, travel at a low speed, and go

over the obstacle at the center of the crawler.

Cautions on traveling in 2nd (High) speed

• Allowable water depth

Use the machine in water only when the

water is up to the bottom of the carrier

roller (1).

• For those parts used in water for a long

time, apply enough grease until the old

• On uneven ground, maintain the low speed

grease is expelled.

and avoid starting, stopping or changing

• Never submerge the slew bearing or main

directions abruptly.

body in water or sand. If submerged,

• When a load greater than a set value is

contact a Takeuchi service agent for

applied during traveling in 2nd (high)

inspection.

speed, the speed will automatically slow

down to 1st (low) speed. When the load

becomes lighter, the speed will increase

and return to 2nd (high) speed. It should be

noted that the travel speed changes

depending on the load condition.

• When traveling in 2nd speed, do so with

the dozer blade at the front.

3-19

Operation

Cautions on operating

Cautions on traveling on slopes

• The machine may slip sideways even on

a slight slope if they are covered with

grass or dead leaves, or when traveling

Warning

on a wet metal plate or frozen surfaces.

• Never travel on slopes that are too

Do not allow the machine to position

steep for the machine to maintain its

sideways to slopes.

stability. (maximum gradeability: 35°,

lateral tipping angle: 15°) Note that in

reality, the machine’s stability becomes

Traveling posture on slopes

lower than the above values depending

Climbing slopes

on the working condition.

• When traveling on slopes, lower the

bucket to a height of 20 to 30 cm (8 to

12 in.) above the ground. When climbing

a steep slope, extend the hoe

attachment to the front. In emergencies,

lower the bucket to the ground and stop

the machine.

• When traveling on slopes or grades,

drive slowly in 1st (low) speed.

• When climbing a hill, keep the

operator’s seat facing the hillside. When

descending a hill, keep the operator’s

When climbing slopes of 15° or more,

seat facing the downhill direction. In

maintain the machine posture as shown in

either case, travel must be done while

the figure above.

paying attention to the ground in front

of the machine.

Descending slopes

• Do not descend slopes in reverse.

When descending slopes of 15° or more,

• Do not change directions on slopes or

slow down the engine speed and maintain

traverse slopes. First return to a flat

the machine posture as shown in the figure

surface, and then take an alternative

above.

path.

3-20

Operation

Cautions on operating

Braking when descending slopes

If the engine stops

When descending slopes, the brakes are

If the engine stops when descending a

applied automatically once the travel levers

slope, set the travel levers to the neutral

are returned to the neutral position.

position, stop the machine, then start the

engine.

If the crawler slips

Do not open the door while traveling on

slopes

If the crawler slips while climbing a slope and

impossible to travel, use the pulling force of

the arm to climb the slope.

Opening the door while traveling on slopes is

dangerous, as the force required to open

and close the door changes abruptly. Always

keep the door closed when traveling on

slopes.

3-21

Operation

Cautions on operating

Getting out of mud

Operations possible with this

machine

If the machine gets stuck in mud, use the

procedure below to get it out.

Excavating

If one crawler is stuck

1. Set the dozer blade on the side opposite

to the side you want to dig on.

1. Swing the bucket to the side of the

2. Use the arm and bucket and dig with

crawler being stuck.

shallow, long strokes. The maximum

2. Set the arm and boom to an angle of 90

digging force can be obtained when the

to 110°.

boom and arm angle is 80 to 120°. Use

3. Press the bottom of the bucket (not the

this angle for effective digging.

teeth) against the ground.

4. Place a plank or the like under the lifted

Digging ditches

crawler.

5. Lift the bucket and slowly move the

machine out of the mud.

If both crawlers are stuck

Install a bucket suited for digging ditches

and set the crawlers parallel to the ditch to

be dug for greater efficiency.

When digging wide ditches, dig the sides

first, and then dig the center.

1. Perform the steps 1 to 4 above for both

crawlers.

2. Dig the bucket into the ground in front of

the machine.

3. Pull with the arm while traveling forward to

slowly move the machine out.

3-22

Operation

Cautions on operating

Digging side drains

Leveling

Use the boom swing function to dig side

1. Bring the hoe attachment close to the

ditches as shown in the figure.

body.

2. Gradually remove the dirt from the side of

the mound.

3. Once the mound is low, remove the dirt

from the top. If the load becomes too

heavy for the machine body, adjust by

raising or lowering the dozer blade.

When loading dirt onto a truck bed, load

from the back of the truck, as it is easier and

able to load more load than doing it from the

front.

Also, use a small slewing angle for greater

efficiency.

3-23

Operation

Parking the machine

3. Lower the bucket and the dozer blade to

Parking the machine

the ground.

Parking

4. Raise the safety lock lever to the locked

position.

5. Stop the engine and remove the key.

Warning

Refer to “Stopping the engine” on page

3-5.

For machines equipped with accumulator:

Refer to “Operating the machine with an

accumulator” on page 2-51.

Inspection and checks after

stopping the engine

1. Check for oil or water leak and inspect the

working equipment, covers and

• Park the machine on a flat, rigid and

undercarriage. If any irregularities are

safe ground. Set the parking brake.

found, repair.

2. Fill up the fuel tank.

Refer to “Inspecting the fuel level” on page

5-19.

3. Remove any paper scraps or dirt from the

engine room.

4. Remove any mud from the undercarriage.

Locking

Be sure to lock the following places:

If you must park on a slope or incline,

park the machine securely and block

the movement of the machine.

• When parking on a street, use barriers,

caution signs, lights, etc., so that the

machine can easily be seen even at

night to avoid collision with other

vehicles.

• Before leaving the operator’s seat, raise

the safety lock lever to engage the lock

• Cab door

and stop the engine. Also, be sure to

• Engine hood

remove the key, lock the door and

• Covers

covers, take it with you and store it in a

specified place.

1. Set the left and right travel levers to the

neutral position.

2. Return the throttle controller to set the

engine to low idling.

3-24

Operation

Handling in cold climates

Cautions after operations

Handling in cold

Observe the following cautions to prevent

climates

mud, water, or the undercarriage from

Preparing for cold climates

freezing and making it impossible for the

machine to move.

Starting engine in cold climates is not easy,

• Remove all mud and water from the

and it becomes more difficult if the coolant

machine body. In particular, wipe the

freezes. Prepare for cold-climate problems

hydraulic cylinder rod clean to prevent

as follows.

damage to the seal caused by mud or dirt

on the rod surface getting inside the seal

Replacing the fuel and lubricant

together with drops of water.

Replace the hydraulic oil, engine oil and fuel

• Park the machine on hard and dry ground.

with those intended for cold climates.

If this is impossible, park the machine on a

Refer to “Fuel and lubricant table” on page

wooden board placed on ground.

5-4.

• Drain any water in the fuel tank to prevent it

from freezing.

Engine coolant

Refer to “Draining the water from the fuel

tank” on page 5-31.

Warning

• As the battery capacity drops markedly in

The engine coolant is combustible. Keep

low temperatures, cover the battery or

away from flame.

remove it from the machine and keep it in a

Use long-life coolant (antifreeze) and tap

warm place.

water for the engine coolant.

If the electrolyte level is low, add distilled

water in the morning before beginning

Note: New machines are delivered with JIS

work. To prevent the battery electrolyte

Type 2 long-life coolant (antifreeze) at a

from freezing in the night, do not add water

concentration of 50%.

after the day’s work.

Refer to “Fuel and lubricant table” on page

5-4.

After the cold climate

Battery

As the temperature drops, the battery

When the climate becomes warmer, do as

performance decreases.

follows:

Inspect the battery. If it is discharging,

• Replace the fuel and oil for all parts with

contact a Takeuchi service agent to have the

those specified in the “Fuel and lubricant

battery recharged.

table”.

Refer to “Inspecting the battery fluid level

Refer to “Fuel and lubricant table” on page

and replenishing” on page 5-32.

5-4.

• If a coolant of “one season type” is used,

drain the cooling system completely, clean

out the inside of the cooling system

thoroughly, and fill with tap water.

Refer to “Cleaning the engine cooling

system” on page 5-48.

3-25

Operation

Handling rubber crawlers

Handling rubber

crawlers

Rubber crawlers have an inherent weakness,

lack of strength, due to their use of rubber.

Be sure to observe the prohibitions and

cautions below to prevent the crawlers from

being damaged or coming off.

Prohibitions

• Do not let fuel, oil, salt or chemical solvents

Do not travel or operate the machine in the

get on the crawlers. These substances

following places:

may corrode the bonding of the steel cores

on the crawlers, resulting in rust or peeling.

If any of these substances gets on the

crawler, immediately clean it off with water.

• Traveling and slewing on crushed rock,

extremely rough hard rock, steel beams,

scrap iron, or near the edges of steel plates

will cause damage to the rubber crawlers.

• It will cause an irregular wear or damage to

the lugs, if the machine travels on irregular

surfaces such as recently paved with

asphalt, exposed to a bonfire or of hot iron

sheets under the blazing sun.

• Do not move earth in places where the

rubber crawlers may slip. Doing so may

speed up lug wear.

• Traveling on riverbeds or places where

there are large numbers of boulders may

cause the stones to get caught and

damage the crawler or make the crawler

come off.

• Do not use the machine on the seashore.

The salt may corrode the steel core.

3-26

Operation

Handling rubber crawlers

Cautions

Observe the following cautions when

operating the machine:

• Rubber crawler belts are not as stable as

steel crawler belts since the entire lugs are

made of rubber. Be very careful when

slewing and swinging sideways.

• Do not turn the undercarriage with the front

of the machine body lifted using the hoe

Preventing the rubber crawlers

attachment (the upperstructure is not

from coming off

turned). Doing so will twist the crawlers

with the load concentrated on a single

Observe the following cautions to prevent

point on the crawler belt, causing rapid

the crawler from coming off.

damage to the crawlers.

• Always keep the crawlers at the proper

• Avoid changing course abruptly or spin-

tension.

turning on concrete surfaces whenever

possible. Doing so may wear or damage

the rubber crawlers.

• Avoid drops that may expose the rubber

crawlers to strong shocks.

• Salt, potassium chloride, ammonium

sulfate, potassium sulfate, and triple

superphosphate of lime can damage the

crawler belts. If any of these substances

gets on the crawler belts, wash if off

thoroughly with water.

• Do not let the sides of the rubber crawlers

rub against concrete or walls.

• When traveling over a large step such as a

• Do not damage the rubber crawlers by

cobblestone or rock (20 cm (8 in.) or

hitting the bucket against them.

deeper), climb up the step at the right

• Be especially careful on snowy or frozen

angle and do not change courses on top of

surfaces in winter, as the crawler belts tend

the step.

to slip in such conditions.

• Use rubber crawler belts at temperatures

between -25°C to +55°C (-14°F to 131°F).

• When storing the rubber crawlers for long

periods of time (three months or more), do

so indoors in a place not exposed to direct

sunlight or rain.

3-27

Operation

Handling rubber crawlers

• When climbing in reverse, do not change

• Do not change directions when the crawler

directions at the point where the slope

belts are slack as shown in the figure.

starts.

• The rubber crawler belts will come off if the

• Avoid traveling by setting one crawler on a

machine travels backward in this condition.

slope or projecting portion and the other

crawler on a flat surface (with the machine

at a tilt of 10° or more). Travel with both

crawlers set on flat surfaces.

• The rubber crawler belts will come off if the

machine turns in this condition.

3-28

Transport

Loading and unloading

Warning

The machine may roll or tip over or fall

while being loaded or unloaded. Take the

following precautions:

• Select a firm, level surface and keep

sufficient distance from road shoulders.

• Secure the ramps of adequate strength

and size to the truck bed. The slope of

the ramps must not exceed 15°. If the

1. Set the parking brake on the transporter

rumps are bowed down too low,

and chock the wheels.

support them with poles or blocks.

2. Fix the ramps securely to the truck bed.

• Never use the working equipment to

The slope of the ramps must not exceed

load or unload the machine. Doing so

15°.

may result in tipping over or falling

3. Align the center of the truck bed with the

down of the machine.

center of the machine, and of the ramp

• Keep the truck bed and loading ramps

with the center of the crawler.

clean of oil, soil, ice, snow, and other

4. Make sure the dozer blade does not hit

materials to prevent the machine from

the ramps.

sliding sideways. Clean the crawlers.

5. Lower the hoe attachment as far as

• Chock the transporter wheels to prevent

possible without letting it touch the

movement.

transporter.

• Turn off the deceleration switch and

6. Decrease the engine speed.

auto-deceleration switch. Otherwise,

the engine speed may suddenly

increase to cause troubles.

• When being loaded or unloaded, travel

slowly in 1st (low) gear by following the

signal from the signal person.

• Never change courses on the ramps.

• Do not slew/swing on the ramps. The

machine may tip over.

• When slewing/swinging on the truck

bed, do it slowly as the footing should

be unstable.

• Lock the cab door after being loaded, if

applicable. Otherwise, the door may

open during transport.

• Chock the tracks and secure the

machine to the truck bed with wire rope

or chain.

When loading or unloading the machine, be

sure to use ramps or a platform and follow

the procedure below.

4-2

Transport

Hoisting the machine

Hoisting

Hoisting the machine

1. Slew the upperstructure so that the dozer

blade is at the rear of the machine (set the

Warning

upperstructure parallel to the track frame).

• Know and use the correct crane signals.

2. Raise the dozer blade fully.

• Check the hoisting equipment for

3. Extend the bucket cylinder and arm

damaged or missing parts on a daily

cylinder fully to raise the boom to its

basis and replace as necessary.

uppermost position.

• When hoisting, use a wire rope capable

4. If the boom is swung to either the left or

of lifting the machine mass.

right side, set it in the neutral position.

• Hoist the machine in such a manner

5. Raise the safety lock lever to the locked

described in the procedure below. Do

position.

not do it in any other manner. Doing so

6. Stop the engine, remove the starter key

is dangerous as it may result in the

and get off the machine.

machine losing its balance.

7. Install the wire ropes as shown on the

• Do not hoist the machine with an

figure below. Install the wire ropes and

operator on it.

hoisting attachment without letting them

• When hoisting, hoist slowly so that the

touch the machine body.

machine does not tip.

8. Hoist the machine slowly until it leaves the

• Keep everyone out of the area when

ground.

hoisting. Do not move the machine over

9. Stop hoisting until the machine becomes

the heads of the persons.

stable, and then start hoisting the machine

slowly again.

IMPORTANT: This hoisting method

applies to machines with standard

specifications. The center of gravity

differs according to the attachments and

optional equipment installed.

Contact your Takeuchi service agent for

details.

4-4

Transport

Securing the machine

After loading the machine at the specified position, secure it as described below.

Transporting posture

1. Lower the dozer blade.

Precautions to be taken during

2. Extend the bucket cylinder and arm

transportation

cylinder fully, and then lower the boom.

Warning

3. Raise the safety lock lever to the locked

position.

• Know and follow the applicable safety

4. Stop the engine, remove the starter key

rules, vehicle code and traffic laws

and lock all locks.

when transporting the machine.

5. Place the stoppers (chocks) in front and

• Select the best transport route by

behind the crawlers.

considering the length, width, height

6. Install a chain or wire rope over the lower

and weight of the truck with the

frame of the machine and fasten it

machine loaded on it.

securely to prevent the machine from

• Never abruptly start or stop or run at a

slipping sideways.

high speed at the sharp curves during

7. Secure the bucket with a chain or wire

transport. Doing so will move or lose the

rope.

balance of the loaded machine.

IMPORTANT: Place a wooden block under

the bucket to protect the floor from

damage caused by the bucket.

4-6

Maintenance

General

Cautions on maintenance

General

Maintenance overview

Do not perform any other inspection and

maintenance works than those listed in this

To keep the machine in good condition and

manual.

use if for a long period, perform the

For works not listed in this manual, ask your

inspection and maintenance properly and

sales or a service dealer for help.

safely following the procedures

recommended by this manual.

Keep the machine clean

• Clean the machine before performing

The inspection and maintenance items are

inspection and maintenance and try to

divided into groups according to the

keep it clean.

machine’s total operating time: every 10

• Stop the engine before washing the

hours (walk-around and daily inspection),

machine. Cover the electrical parts so that

every 50 hours, every 250 hours, etc. Refer

water cannot enter. Water on electrical

to the hour meter readings to determine

parts could cause short-circuits or

when to schedule an inspection and

malfunctions. Do not use water or steam to

maintenance. Items for which it is not

wash the battery, electronic control

possible to determine the inspection and

components, sensors, connectors or the

maintenance interval are included under

operator’s compartment.

“When Required”.

Fuel, lubricant and grease

When operating the machine in extremely

• Choose fuel, lubricant and grease by

harsh environments (with high dust levels or

following to the “Fuel and lubricant table”.

high temperatures), inspection and

• Use fuels, lubricants and greases which do

maintenance should be performed earlier

not contain water, and be careful to keep

than the times specified on the Maintenance

dirt out when changing or replenishing fuel,

List.

lubricant or grease.

• Store fuels, lubricants and greases in the

prescribed places and in such a way that

no water or dirt can get in them.

Cautions on refueling

• If the port includes a strainer, do not

remove the strainer when fueling.

• After fueling, be sure to securely tighten the

fuel filler cap.

• Do not add more than the specified

amount of fuel.

Do not use fuel to clean parts

Do not use fuel to clean parts. Use a non-

combustible cleaning agent.

Keep dirt out

When mounting and removing parts, do so in

a place where there is no dust, clean the

working area and the part, and keep dirt out.

5-2

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 side

Seals and split pins

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

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, S500

USA

ISO 8217DMX

International

No.2-D S15, S500

EN590: 96

European union BS2869-A1 or A2

United kingdom

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 0.05 to 0.0015% by

volume.

Fuel tank

Diesel fuel

<TB285> 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.

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

diesel fuel.

• 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.

5-4

Maintenance

Service data

Lubricant

Type by air temperature

Location

Type

-4

86 104°F

When to replace

-20 -10

30 40°C

Diesel engine oil

<TB285>

Every 250 hrs

API: CF class or higher

SAE 10W-30

Engine oil pan

after the initial

<TB290>

SAE 15W-40

50 hrs.

API: CF-4 class or

higher

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 (water +

coolant)**

Mixture of 50% coolant

Engine cooling

SAE: J814C, J1941,

Every 1000 hrs.

system

J1034 or J2036

Mixture of 30% coolant

ASTM: D6210 or

D4985(USA)

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.

EP-2

—

Working

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.

5-5

Maintenance

Service data

Volume

<TB285>

Engine cooling

Hydraulic oil

Travel reduction

Engine oil pan

Fuel tank

system

tank

gear

Upper limit

14 L (14.8 US qt.)

System

128 L (33.8 US gal.)

1.1L X 2

10.2 L (10.8 US qt.)

140 L (37 US gal.)

(1.16 US qt.) X 2

Lower limit

Tank

5.7 L (6 US qt.)

73 L (19.3 US gal.)

<TB290>

Engine cooling

Hydraulic oil

Travel reduction

Engine oil pan

Fuel tank

system

tank

gear

Upper limit

16 L (16.9 US qt.)

System

128 L (33.8 US gal.)

1.1L X 2

15 L (15.9 US qt.)

140 L (37 US gal.)

(1.16 US qt.) X 2

Lower limit

Tank

11 L (11.6 US qt.)

73 L (19.3 US gal.)

Regularly replace the hydraulic

oil

When a hydraulic breaker is used, the oil

deteriorates more quickly than that used for

a usual excavation operation. Be sure to

replace the hydraulic oil and the return filter

elements.

• Failure to replace these in time can lead to

damage to the machine and the breaker

hydraulic system. To prolong the service life

of the hydraulic devices, properly replace

the hydraulic oil and the return filter

elements according to the table below.

• When replacing the hydraulic oil, clean the

suction strainer.

Replacement interval (hours)

( ):

When a conventional antiwear hydraulic

oil is used.

Item

Hydraulic oil

Filter element

1st time

—

2nd time

—

100

Periodically

1200 (600)

200

When the breaker operating ratio is 100%.

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

5-6

Maintenance

Service data

List of consumables

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

<TB285>

System

Item

Part name

Part No.

When to replace

Hydraulic oil

Every 1000 hrs

1551103900

return filter

after the initial 250

Hydraulic system

Element

Pilot line filter

1551200601

hrs.

Air breather filter

1552002715

Every 1000 hrs.

Engine lubrication

Every 250 hrs after

Engine oil filter

Cartridge

Y129150-35153

system

the initial 50 hrs.

Fuel filter

Cartridge

Y129907-55801

Fuel system

Every 500 hrs.

Water separator

Cartridge

Y129917-55850

filter

Every 1000 hrs. or

Primary (Outer)

after 6 cleanings

1911113001

element

(whichever comes

Air cleaner system

Air cleaner

first)

When the primary

Secondary

1911113002

elements are

(Inner) element

replaced.

<TB290>

System

Item

Part name

Part No.

When to replace

Hydraulic oil

1551103900

Every 1000 hrs

return filter

after the initial 250

Hydraulic system

Element

Pilot line filter

1551200601

hrs.

Air breather filter

1552002715

Every 1000 hrs.

Engine lubrication

Every 250 hrs after

Engine oil filter

Element

I8-98018-8580

system

the initial 50 hrs.

Pre-fuel filter

1552002502

Element

Fuel system

Main fuel filter

I8-98143-0410

Every 500 hrs.

Feed pump filter

Repair kit

I8-98071-4010

Every 1000 hrs. or

Primary (Outer)

after 6 cleanings

1911113001

element

(whichever comes

Air cleaner system

Air cleaner

first)

When the primary

Secondary

1911113002

elements are

(Inner) element

replaced.

5-7

Maintenance

Service data

List of tools

Code

Part name

Part No.

Remarks

Spanner

Y28110-100120

10 - 12

Spanner

Y28110-140170

14 - 17

Screwdriver

Y104200-92350

(+) (-) replaceable shank

Y119640-92750

<TB285>

Filter wrench

1691903560

<TB290>

Hammer

1690300330

3/4

Monkey wrench

1690400250

250 mm

Pliers

1690500200

200 mm

Spanner

1690001013

10-13

Spanner

1690001922

19-22

Spanner

1690002427

24-27

Spanner

1690002730

27-30

Spanner

1690003236

32-36

Spanner

1690100041

Hex. wrench

1690600500

5 mm

Hex. wrench

1690600600

6 mm

Hex. wrench

1690600800

8 mm

Hex. wrench

1690601000

10 mm

Hex. wrench

1690601200

12 mm

Tool case

1691400001

Case

1691900001

Grease gun

1691060610

600 cc

Drain connector

1554512601

5-8

Maintenance

Service data

List of tightening torques

Nuts and Bolts (for ISO strength category 10.9)

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

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

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

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

standards.

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

are evenly tightened.

Tightening torque

Head width (b)

Size (a) x pitch

Classification

General connection points

N·m

ft-lb.

M6 x 1.0

9.8±0.5

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

5-9

Maintenance

Safety-critical parts

To use the machine safely, periodically perform inspection and maintenance. The safety-critical

parts listed below must be periodically replaced for an increased safety.

Serious injury or a fire could result if they are worn or damaged.

List of safety-critical parts

Unit

Safety-critical parts to be replaced periodically

When to replace

Fuel hoses

Fuel system

Packing on fuel filler cap

Heater hoses

Heater & AC systems

Air conditioner 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 (second boom cylinder piping)

Hydraulic

Hydraulic hoses (arm cylinder piping)

system

Hydraulic hoses (bucket cylinder piping)

Working

Hydraulic hoses (swing cylinder)

equipment

Hydraulic hoses (blade cylinder)

Hydraulic hoses (angle blade cylinder)

Hydraulic hoses (pilot valve)

Hydraulic hoses (auxiliary piping)

Seat belt

Every 3 years

5-10

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

Daily inspection

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

5-11

Maintenance

Maintenance list

Inspection and maintenance item

Page

Walk-around inspection

Inspecting by opening the engine hood and covers

5-14

Inspecting by walking around the machine

5-15

Inspecting while sitting in the operator’s seat

5-15

Daily inspection (every 10 hours)

Inspecting and replenishing the coolant

5-16

Inspecting and replenishing the engine oil

5-17

Inspecting the water separator and the fuel filters

5-18

Inspecting the fuel level

5-19

Inspecting the hydraulic oil tank level and replenishing

5-20

Lubricating the working equipment

5-21

After the initial 50 hours (only for new machines)

Replacing the engine oil and the oil filter

5-22

Inspecting and adjusting the fan belt

5-24

Inspecting and adjusting the compressor belt (AC)

5-26

Every 50 hours

Inspecting the crawler belt tension

5-28

Lubricating the slew bearing

5-30

Draining the water from the fuel tank

5-31

Inspecting the battery fluid level and replenishing

5-32

After the initial 250 hours (only for new machines)

Replacing the hydraulic oil return filter

5-34

Replacing the pilot line filter

5-35

Replacing the travel motor gear oil*

5-36

Every 250 hours

Replacing the engine oil and the oil filter

5-37

Inspecting and adjusting the fan belt

5-37

Inspecting and adjusting the compressor belt (AC)

5-37

Cleaning the air cleaner

5-38

Cleaning the radiator fins and oil cooler fins

5-39

Cleaning the air filters (AC)

5-40

Cleaning the condenser (AC)

5-41

Inspecting the refrigerant (gas) level (AC)

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.

5-12

Maintenance

Maintenance list

Inspection and maintenance item

Page

Every 500 hours

Replacing the fuel filter

5-44

Replacing the water separator filter <TB285>

5-46

Replacing the feed pump filter <TB290>

5-47

Every 1000 hours

Replacing the hydraulic oil return filter

5-48

Replacing the pilot line filter

5-48

Replacing the travel motor gear oil *

5-48

Cleaning the engine cooling system

5-48

Replacing the air cleaner element

5-50

Replacing the air breather filter

5-51

Inspecting and adjusting the engine valve clearance

5-51

Retightening the engine cylinder head bolt <TB285>

5-51

Inspecting the engine compression pressure <TB290>

5-51

Inspecting and cleaning the engine starter and the alternator <TB290>

5-51

Every 1500 hours

Inspecting and cleaning the engine fuel injectors <TB285>

5-52

Inspecting the crankcase breather system <TB285>

5-52

Every 2000 hours

Lapping the engine valve seats <TB285>

5-53

Every 4000 hours

Replacing the hydraulic oil and cleaning the suction strainer

5-54

When Required

Replacing the bucket teeth and the side cutters

5-58

Replacing the bucket

5-60

Adjusting the gap between the bucket and arm

5-62

Inspecting and replenishing the windshield washer fluid

5-63

Draining the water from the water separator

5-63

Lubricating the levers and pedals

5-64

Inspecting the rubber crawlers

5-65

Replacing the rubber crawlers

5-66

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

oil earlier than the specified time.

5-13

Maintenance

Walk-around inspection

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

Warning

• 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

tank, hydraulic devices, hoses or

connections.

5-14

Maintenance

Walk-around inspection

Inspecting by walking around the

Inspecting while sitting in the

machine

operator’s seat

4. Check lights for dirt, damage and burnt

14. Check the windshield for dirt or damage.

out bulbs.

15. Check the seat and seat belt for dirt or

5. Check attachments and hoses for

damage.

Check the operator’s seat for dirt, oil or

6. Check the bucket, bucket teeth and side

other combustible materials.

cutter for wear, damage and looseness.

16. Check the monitor, instruments and

7. Check the hook, slip stopper and hook

switches for dirt or damage.

mount of buckets with hooks for damage.

(Option)

8. Check the handrail and steps for damage

and loose bolts.

9. Check the crawlers, carrier rollers, track

rollers, idlers and sprockets for damage,

wear and loose bolts.

10. Check for oil leakage from the travel

motor, carrier rollers, track rollers and

idlers.

11. Check the cab and guard for damage

and loose nuts and bolts.

12. Check the mirrors for dirt or damage,

and adjust them.

13. Check the labels for dirt and damage.

5-15

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.

Warning

• 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 fuel lid.

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. Open the side cover.

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

Warning

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

• Do not remove the radiator cap or the

of the reserve tank (1).

drain plug when the cooling water is

hot. Stop the engine and wait until the

engine and the radiator cool before

slowly loosening the radiator cap and

the drain plug to remove them.

• Always wear the protective goggle and

gloves when handling coolant

(antifreeze). If any coolant (antifreeze)

comes in contact with eyes or skin,

wash it off with clean water. Otherwise,

it could result in injures.

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

inspection, check for water leakage and

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

water to the radiator (3) as required, and

then to the reserve tank (1).

4. Install the cap (2).

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

as tap water, to replenish the coolant loss

due to evaporation. If the coolant loss is due

to leakage, replenish the mixture of antifreeze

and clean water (soft water) prepared using

the same mixing ratio used for the current

coolant.

5-16

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).

Warning

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 minutes, inspect the oil

Inspection

level.

<TB285>

<TB290>

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.

5-17

Maintenance

Daily inspection (every 10 hours)

Inspecting the water separator

Fuel filters <TB290>

and the fuel filters

Warning

• 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 fuel lid or the side cover.

Water separator

2. Check if there is water in the pre-fuel filter

(1) and the main fuel filter (2).

If water collects in the filter, the float (red

ring) (3) goes up. Be sure to drain water

before the float (3) goes up to the element

(4).

3. Loose the vent plug (5) and then the drain

plug (6) 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 6-8.

1. Turn the starter switch to the ON position.

2. Inspect the water separator warning lamp.

3. If the warning lamp is flashing, drain the

water.

Refer to “Draining the water from the

water separator” on page 5-63.

5-18

Maintenance

Daily inspection (every 10 hours)

Inspecting the fuel level

Warning

• 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 2-5.

5-19

Maintenance

Daily inspection (every 10 hours)

Inspecting the hydraulic oil tank

Replenishing

level and replenishing

Warning

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

IMPORTANT: Do not fill up to the level

The oil level changes with the oil

higher than the upper limit (H). It will

temperature. Inspect the oil by maintaining

damage the hydraulic circuits or result in

the machine at posture shown in the figure at

oil spurting. If accidentally done, stop the

the next.

engine and wait the hydraulic oil to cool,

• Machine posture for inspecting the

and then let the excessive oil to drain

hydraulic oil level

from the drain plug.

1. Open the 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 fuel lid.

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).

5-20

Maintenance

After the initial 50 hours (only for new machines)

<TB290>

After the initial 50

hours (only for new

machines)

Replacing the engine oil and the

oil filter

Warning

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.

Engine oil

2. Loosen the bolts and remove the under

cover (3).

<TB285>

3. Place a pan for catching the waste oil

under the drain plug (4).

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

and drain the oil. (The oil comes out when

the screw is tightened.)

5. Remove the connector (B) and install the

cap (A).

IMPORTANT: Check the waste oil for

metal powder. If it contains large amounts

of metal powder, consult your sales or

service dealer.

5-22

Maintenance

After the initial 50 hours (only for new machines)

Engine oil filter

<TB290>

<TB285>

6. Turn the filter (5) counterclockwise with the

filter wrench and remove it.

7. Clean the surface of installation of the filter

stand.

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

the new filter.

9. Install the new filter by hand.

10. Tighten one more turn (with the filter

wrench) after the filter packing comes in

contact with the surface of installation.

(Torque when tightening with filter

wrench: 19.6 to 23.5 N·m or 14 to 17 ft-

6. Place a pan for catching the waste oil

lb.)

under the engine oil filter.

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

7. Remove the drain plug (5) and drain the oil

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

from the filter case (7).

Problems could arise if the oil level is

8. Loosen the bolt (6) and remove the filter

either too low or too high. It takes around

case (7).

10 minutes for all of the added oil to go

9. Clean the inside of the filter case (7) and

down to the oil pan.

install a new element (8).

12. Tighten the oil filler cap (2).

10. Clean the surface to install the filter stand

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

and coat the new O-rings with thin oil.

about 5 minutes, then stop it.

11. Install the case (7) and secure it with the

14. After about 10 minutes, inspect the oil

bolt (6).

level.

· Tightening torque: 44.1 N·m (32.5 ft-lb.)

12. Install the drain plug (5).

· Tightening torque: 24.5 N·m (18.1 ft-lb.)

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

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

Problems could arise if the oil level is

either too low or too high. It takes around

15 minutes for all of the added oil to go

down to the oil pan.

14. Tighten the oil filler cap (2).

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

about 5 minutes, and then stop it.

16. After about 15 minutes, inspect the oil

level.

5-23

Maintenance

After the initial 50 hours (only for new machines)

Inspecting and adjusting the fan

<TB290>

belt

Warning

Stop the engine and allow the machine to

cool down before performing

maintenance.

• The engine, muffler, radiator, hydraulic

lines, sliding parts and many other parts

of the machine are hot immediately after

the engine is stopped. Touching these

parts will cause burns.

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

IMPORTANT: The loose belts could result

between the fan pulley (2) and alternator

in bad battery charge, overheat of engine

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

or early wear of belt. Too tight belts could

N or 22 lbf).

damage the water pump or bearing and

<TB285>

belt used to drive the alternator.

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

IMPORTANT: Do not let any oil or grease

to 0.4 in).

get on the belt.

<TB290>

The slack (A) should be 7 to 8 mm (0.27 to

Inspection

0.31 in).

1. Open the engine hood.

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

as follows.

<TB285>

· There are cuts or cracks.

· The belt is worn and touches the bottom

of the V groove in the pulley.

· The belt stretched too loose to be

adjusted.

5-24

Takeuchi Hydraulic Excavator TB285 (No.185000001~), TB290 (No.190000001~). Operator's Manual - page 4