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Takeuchi Hydraulic Excavator TB285 (No.185000001~), TB290 (No.190000001~). Operator's Manual - page 5

Maintenance

After the initial 50 hours (only for new machines)

Adjustment

<TB285>

<TB290>

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).

Tightening torque:

<TB290>

· Locking nut (4) 25 N·m (18.1 ft-lb.)

· Bolt (5) 51N·m (37.6 ft-lb.)

Note: When replacing with a new belt, run

the engine at low idle speed for about 3 to 5

minutes to break in the new belt, before

adjusting the tension.

5-25

Maintenance

After the initial 50 hours (only for new machines)

Inspecting and adjusting the

<TB290>

compressor belt (AC)

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.

• The high-pressure pipes of the air

Inspection

conditioner can be very hot (80 to 120°C

<TB285>

or 176 to 248°F). Be careful not to burn

yourself.

IMPORTANT: Do not let any oil or grease

get on the belt. It will cause the belt to

slip, decrease the cooling capacity or

shorten the service life of the air

conditioner.

If the belt is too slack, it will slip and vibrate,

resulting in decreased cooling capacity. The

service life of the air conditioner also will be

shortened. Adjust the belt tension to the

1. Loosen the bolts and remove the under

standard value.

cover (4). <TB285>

For TB285, 294 to 392 N or 66 to 88 lbf.

1. Open the engine hood. <TB290>

For TB290, 432.2 to 449.8 N or 97.2 to

2. Measure the belt (1) tension using the belt

101.1 lbf

tension gauge. The belt tension is normal

if the belt tension gauge indicates the

<TB285>

following values.

For TB285, 294 to 392 N or 66 to 88 lbf.

For TB290, 432.2 to 449.8 N or 97.2 to

101.1 lbf

5-26

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

Warning

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

Bleeding air from the fuel system

tank

Refer to “Bleeding air from the fuel system”

on page 6-8.

Warning

Note: Air in the fuel system causes the

• Do not smoke or permit open flames

engine to fail to start or to have problems.

while handling fuel or working on the

Bleed air when the fuel tank is emptied,

fuel system.

using the same procedure above.

• 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.

• Do not fill the fuel tank to capacity.

Allow room for oil expansion.

• Clean up spilled fuel immediately.

• Securely tighten the fuel filler cap.

• Use the correct grade of fuel for the

operating season.

Do the draining operation before starting the

machine.

1. Open the side cover.

2. Remove the fuel filler cap (2).

3. Place a pan under the drain valve (3).

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

(B), and then drain the water and sediment

buildup in the bottom of the tank (the

water comes out when the screw is

tightened).

5. Remove the connector (B) and install the

cap (A).

6. Add fuel while watching the sight gauge

(1).

7. Tighten the fuel filler cap (2).

8. Close the side cover and lock it with the

key.

9. Bleed air.

5-31

Maintenance

Every 50 hours

Inspecting the battery fluid level

Inspection

and replenishing

IMPORTANT: Check the fluid level of all

cells following the steps below, even

Danger

when the fluid level can be checked using

• Do not use the battery when the fluid

the indicator.

level is below the lower level limit. Doing

so will hasten the deterioration of the

1. Open the engine hood.

internal portions of the battery and

shorten the battery life. It also can

cause rupturing (explosion).

• Batteries generate flammable hydrogen

gas which may explode. Keep away

from flame, sparks, fire or lighted

cigarettes.

• Use a dampened cloth to clean above

the fluid level line and check the fluid

level. Do not clean with a dry cloth;

otherwise it can cause static electricity

to build up, resulting in ignition or

explosion.

2. Inspect the indicator (1).

· Blue: Good

· White: Charging needed

Warning

· Red: Insufficient battery fluid

• Wear protective goggle and clothing

3. Inspect the fluid level.

when working with batteries.

The fluid level must be between the upper

• Do not add the distilled water above the

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

upper level limit. Doing so could cause

add distilled water up to the line (H).

the fluid to leak. This fluid can cause

skin damage if contacted, or can cause

the machine components to corrode.

• Batteries contain sulfuric acid which will

damage eyes or skin if contacted.

· If eye contact occurs, flush

immediately with clean water and get

prompt medical attention.

· 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 50 hours

• If the fluid level cannot be checked by fluid

level lines:

Remove the caps (2) and look into the

fluid filler holes to check the fluid level. If

the fluid is below the sleeve (3), be sure to

add distilled water up to the bottom edge

of the sleeve (3).

Proper level (A)

If the fluid reaches up to the bottom edge

of the sleeve (3), the surface tension

causes the fluid to swell and the plate

appears as if it is distorted.

Level too low (B)

If fluid does not reach up to the bottom

edge of the sleeve (3), the plate looks

laminar, not distorted.

4. Check the terminals for looseness and

dirt.

Replenishing

When adding distilled water, do so before

starting operations in order to prevent

freezing.

1. Remove the caps (2), and add distilled

water until the upper level (H).

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

3. Clean the exhaust hole on the cap, then

tighten the caps (2) securely.

5-33

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

Warning

• 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.

1. Open the side cover.

· The hydraulic oil is also hot and under

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

high pressure.

the internal pressure from the tank.

Be careful not to touch the hydraulic

3. Loosen the bolts and remove the flange

oil when loosening the cap or plug.

(4).

Working on the machine under these

4. Remove the return filter (5).

conditions could result in burns or

5. Install a new return filter.

injuries due to the hot oil spurting out.

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

• Oil may spurt out if caps or filters are

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

removed or pipes are disconnected

and replenish if the level is too low.

before releasing the pressure in the

Refer to “Inspect the hydraulic oil tank

hydraulic system.

level and replenishing” on page 5-20.

· Press the air breather button to relieve

the internal pressure from the tank.

· When removing plugs or screws, or

when disconnecting hoses, stand to

the side and loosen them slowly to

gradually release the internal pressure

before removing.

5-34

Maintenance

After the initial 250 hours (only for new machines)

Replacing the pilot line filter

Warning

• 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 (3) counterclockwise and

high pressure immediately after the

remove it.

engine is stopped.

5. Remove the element (4) and O-ring (5).

Be careful not to touch the oil when

6. Clean the inside of the case (3).

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.

(6).

• 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

(5).

before releasing the pressure in the

10. Install the new O-ring (5) and the case (3)

hydraulic system.

on the filter stand (6).

· 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 5-20.

the side and loosen them slowly to

gradually release the internal pressure

before removing.

1. Open the side cover.

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

the internal pressure from the tank.

5-35

Maintenance

After the initial 250 hours (only for new machines)

Replacing the travel motor gear

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

oil

until oil flows out of the hole of the plug

(2).

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

Warning

·

Tightening torque: 58.8 ± 9.8 N·m (43.4

• Stop the engine and allow the machine

± 7.2 ft-lb.)

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.

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

the very bottom.

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

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

the oil.

4. Rewrap the plugs with new sealing tape.

5. Tighten the plug (1).

· Tightening torque: 58.8 ± 9.8 N·m (43.4

± 7.2 ft-lb.)

5-36

Maintenance

Every 250 hours

Cleaning the air cleaner

Warning

• Stop the engine and allow the machine

to cool down before performing

maintenance.

· The engine, muffler, radiator and many

other parts of the machine are hot

immediately after the engine is

stopped. Touching it will cause burns.

• Wear required appropriate equipment

2. Loosen the clamps (1) and remove the

such as protective goggle and filter

dust cup (2).

mask when using compressed air, as

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

metal fragments or other objects can fly

4. Remove the primary element (3).

and cause serious injury.

To prevent dirt from getting inside the

engine, do not remove the secondary

IMPORTANT: Be careful not to scratch the

element (5).

element. Do not use an element if it is

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

damaged.

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.

6. 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.

7. Light up the inside of the primary element

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

1. Open the engine hood.

it if there are small holes or thin spots.

8. Install the primary element (3).

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

OBEN/TOP” mark facing up, and then

fasten it with the clamps (1).

5-38

Maintenance

Every 250 hours

Cleaning the radiator fins and oil

2. Remove the screws (1) and open the

cooler fins

condenser.

3. Blow compressed air on the fins to

remove mud and dirt stuck on them.

Warning

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.

5-39

Maintenance

Every 250 hours

Cleaning the air filters (air

Cleaning

conditioner)

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

psi or less) directly on the filters from the

inside, moving up and down along the

Warning

pleats.

Wear required appropriate equipment

Be sure to keep the nozzle at an adequate

such as protective goggle and filter mask

distance from the filters.

when using compressed air, as metal

2. Wash the filter with neutral detergent if it is

fragments or other objects can fly and

very dirty. Dry the filter completely after

cause serious injury.

washing it.

Clean the filters immediately after operating

in dusty places.

If the filters are clogged, the air flow is

reduced and a booming sound is heard from

the air conditioner unit.

Removing the filters

1. Open the cab door.

2. Pull out the filter case (1) upward and

remove the ventilation filter (2) from the

filter case (1).

3. Open the cover (3).

4. Remove the circulation filter (4).

5. Use compressed air or water to clean the

filters, depending on how dirty they are.

5-40

Maintenance

Every 250 hours

Cleaning the condenser (AC)

Warning

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 200kPa (28

psi) and hold the nozzle sufficiently

away from the fins.

1. Open the engine hood.

2. Clean the condenser (1).

5-41

Maintenance

Every 250 hours

Inspecting the refrigerant (gas)

3. Inspect the refrigerant by watching the

level (AC)

flow of air bubbles through the sight glass

(2).

Refer to “Check list for refrigerant volume”

Warning

on page 5-43.

• Exposure of the eyes or hands to the

cooler’s refrigerant could result in

<TB285>

blindness or frostbite.

Never touch the refrigerant or loosen

the parts of the cooling circuit.

• Keep flames away if the refrigerant gas

is leaking.

• The high-pressure pipes of the air

conditioner can be very hot (80 to 120°C

or 176 to 248°F). Be careful not to burn

yourself.

The cooling capacity decreases if the

amount of refrigerant is insufficient.

Inspect the refrigerant level using the sight

glass (2) on the top of the receiver drier (1).

<TB290>

1. Open the engine hood.

4. Check the temperature of the

2. Inspect the places for the conditions

compressor’s high pressure pipe (1) and

below.

low pressure pipe (2).

Refer to “Check list for refrigerant volume”

on page 5-43.

Places for inspection

Conditions

Cab door

Fully open

Temperature control

Set fully to the COOL

dial

side

Fan speed

High

Ventilation /

Circulation select

Circulation

switch

Engine speed

Maximum speed

Air conditioner

ON

switch

5-42

Maintenance

Every 250 hours

Check list for refrigerant volume

Air conditioner

Normal

Abnormal

High/low

High pressure

High pressure

Little difference in

High pressure

pressure pipe

pipe is hot (80 to

pipe is warm, low

temperature

pipe is hot, low

temperature

120°C or 176 to

pressure pipe is

between the

pressure pipe is

248°F), low

slightly cool. No

high-pressure

slightly cool. A

pressure pipe is

significant

pipe and the low-

significant

cold (8 to 15°C

difference in

pressure pipe.

difference in

or 46 to 59°F).

temperature

temperature

Clear difference

between the

between the

in temperature

pipes.

pipes.

between the

pipes.

Pipe connection

Normal

Some places are

Some places are

Normal

dirty with oil.

extremely dirty

with oil.

Sight glass

Almost

Flow of bubbles

Mist-like flow is

No bubbles is

transparent with

can be seen

faintly visible.

visible, even

some bubbles.

constantly.

when the fan is

Fully transparent

Sometimes

set to High and

when the engine

transparent or

the engine is

speed is

white with

idling.

increased or

bubbles.

decreased.

Refrigerant level

Proper level

Refrigerant may

Refrigerant has

Refrigerant level

be leaking.

leaked; little is

too high

left.

If the air conditioner is not working

If the air conditioner does not work well, set the fan switch to OFF and contact your sales or

service dealer for inspection and/or repairs.

IMPORTANT: Continued use of the air conditioner when it is not working properly will

damage its various parts.

IMPORTANT: Using the air conditioner when there is no refrigerant will damage the

compressor.

IIMPORTANT: Always consult your sales or service dealer for replacing the refrigerant.

Be sure to use R134a refrigerant (740 to 820 g or 1.72 to 1.81 lb.).

5-43

Maintenance

Every 500 hours

<TB290>

Every 500 hours

Replacing the fuel filter

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 side cover.

<TB285>

Pre-fuel filter

1. Open the engine hood.

2. Turn the filter (1) counterclockwise with the

2. Place a pan under the pre-fuel filter (1) to

filter wrench and remove it.

catch fuel.

3. Clean the surface of installation of the filter

3. Loosen the vent plug (5) and the drain

stand.

plug (6) to drain the fuel inside.

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

4. Remove the case (7) by using a filter

the new filter.

wrench.

5. Install the new filter by hand.

5. Replace the seals with new ones and

6. Tighten one more turn after the filter

lubricate the new seals with diesel fuel.

packing comes in contact with the surface

6. Put the new element (length of 150 mm /

of installation. (Torque when tightening

5.9 in.) (4) in the case (7) and install by

with filter wrench: 19.6 to 23.5 N·m or 14

hand until the seal makes contact with the

to 17ft-lb.)

sealing surface.

7. Bleed the air.

7. Tighten the case (7) with the filter wrench.

Refer to “Bleeding air from the fuel

Tightening torque: 30 N·m (22.1 ft-lb.)

system” on page 6-8.

5-44

Maintenance

Every 500 hours

Main fuel filter

8. Place a pan under the main fuel filter (2) to

catch fuel.

9. Loosen the vent plug (5) and the drain

plug (6) to drain the fuel inside.

10. Remove the case (7) by using a filter

wrench.

11. Replace the seals with new ones and

lubricate the new seals with diesel fuel.

12. Put the new element (length of 131 mm /

5.2 in.) (4) in the case (7) and install by

hand until the seal makes contact with

the sealing surface.

13. Tighten the case (7) with the filter

wrench.

Tightening torque: 29.4 N·m (21.7 ft-lb.)

14. Bleed air.

Refer to “Bleeding air from the fuel

system” on page 6-8.

5-45

Maintenance

Every 500 hours

Replacing the water separator

filter <TB285>

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 side cover.

2. Place a pan for catching the waste oil

under the drain hose.

3. Open the drain cock (1) and drain the fuel.

4. Remove the sensor (2).

5. Remove the filter (3).

6. Install the sensor (2) on the new filter.

7. Clean the surface to install 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 2/3 more turn after the filter

packing comes in contact with the

surface of installation.

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

11. Bleed air.

Refer to “Bleeding air from the fuel

system” on page 6-8.

5-46

Maintenance

Every 500 hours

Replacing the feed pump filter

<TB290>

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 side cover.

2. Place a pan under the feed pump (1) to

catch fuel.

3. Remove the cover (2).

4. Remove the element (3) and gaskets (4).

5. Install the new element and gaskets.

6. Install the cover (2).

7. Bleed air.

Refer to “Bleeding air from the fuel

system” on page 6-8.

5-47

Maintenance

Every 1000 hours

she must take care not to touch the

Every 1000 hours

lever or pedal unless necessary.

Replacing the hydraulic oil

· The one who performs maintenance

return filter

must make sure to keep his/her body

or clothing away from the moving part

Refer to “Replacing the hydraulic oil return

of the machine.

filter” on page 5-34.

• Standing at the back of the machine

while the engine is running is extremely

dangerous, as the machine could move

Replacing the pilot line filter

suddenly. Never stand at the back of the

machine while the engine is running.

Refer to “Replacing the pilot line filter” on

• Do not remove the radiator cap or the

page 5-35.

drain plug when the cooling water is

hot. Stop the engine and wait until the

engine and the cooling water cool.

Replacing the travel motor gear

Then, slowly loosen the radiator cap

oil

and the drain plug to remove them.

Refer to “Replacing the travel motor gear oil”

When cleaning, if the temperature of the

on page 5-36.

coolant is low, the thermostat will be closed

and the coolant will not circulate in the

radiator. Heat the coolant water to at least

Cleaning the engine cooling

90°C (194°F) before cleaning.

system

1. Open the engine hood and the side cover.

<TB285>

Warning

• Stop the engine and allow the machine

to cool down before performing

maintenance.

· The engine, muffler, radiator and many

other parts of the machine are hot

immediately after the engine is

stopped. Touching these parts will

cause burns.

· The engine coolant is also hot and

under high pressure immediately after

the engine is stopped. Be careful

<TB290>

when loosening the caps or plugs.

Working on the machine under these

conditions could result in burns or

injuries due to the hot coolant spurting

out.

• If maintenance must be performed with

the engine running, always work as a

two person team communicating each

other.

· One person must sit in the operator’s

seat so that he/she can immediately

stop the engine when necessary. He/

5-48

Maintenance

Every 1000 hours

2. Gradually loosen the radiator cap (3) to

15. Increase the water temperature to at

release the internal pressure, and then

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

remove the cap.

for about 10 minutes with the thermostat

kept open.

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,

3. Place a pan for catching the waste coolant

inspect the coolant level once again after

under the drain plug (4), and then loosen

operating the machine.

the drain plug (4) to drain the coolant.

Once the machine is operated, the

4. Tighten the drain plug (4).

coolant is distributed throughout the

5. Add tap water to the radiator through the

entire system, resulting in the lower

coolant fill port up to the top of the port.

coolant level.

Take time and slowly add water, so that no

Replenish the cooling water that has

air enters the radiator.

been used.

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.

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.

5-49

Maintenance

Every 1000 hours

Replacing the air cleaner element

7. Install the new elements. Press them firmly

into the body (4).

8. Install the dust cup (2) with its “

Warning

OBEN/TOP” mark facing up, and then

Stop the engine and allow the machine to

fasten it with the clamps (1).

cool down before performing

maintenance.

• The engine, muffler, radiator and many

other parts of the machine are hot

immediately after the engine is stopped.

Touching these parts will cause burns.

IMPORTANT: Do not use an element if its

pleats, gaskets or seals are damaged.

IMPORTANT: Be sure to install the

element and dust cap securely. If not,

dust could be drain into the cylinder,

damaging the engine.

1. Open the engine hood.

2. Loosen the clamps (1) and remove the

dust cup (2).

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

4. Remove the primary element (3).

Do not remove the secondary element yet.

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

6. Remove the secondary element (5).

5-50

Maintenance

Every 1000 hours

Replacing the air breather filter

Inspecting and adjusting the

engine valve clearance

Warning

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.

Retightening the engine cylinder

• Press the air breather button to relieve

head bolt <TB285>

the tank pressure.

This operation requires experience. Ask your

sales or service dealer for it.

Inspecting the engine

compression pressure <TB290>

This operation requires experience. Ask your

sales or service dealer for it.

Inspecting and cleaning the

1. Open the side cover.

engine starter and the alternator

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

<TB290>

pressure from the tank.

3. Loosen the nut and remove the button (N)

This operation requires experience. Ask your

on the air breather.

sales or service dealer for it.

4. Remove the cover (H).

5. Replace the filter (A).

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

7. Install the button (N).

5-51

Maintenance

Every 4000 hours

Every 4000 hours

Replacing the hydraulic oil and

cleaning the suction strainer

Warning

• 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 5-51.

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 45° clockwise and set the machine

waste oil.

to the hydraulic oil level inspection

9. Remove the cap (B), install connector (C)

posture.

and drain the oil. (The oil comes out when

Refer to “Inspecting the hydraulic oil tank

the screw is tightened.)

level and replenishing” on page 5-20.

2. Open the side cover.

5-54

Maintenance

Every 4000 hours

10. Remove the relay and fuse panel (9).

3. Tighten the drain hose (1) once there are

11. Loosen the bolts and remove the flange

no more air bubbles coming from the

(7).

elbow (2) joint.

12. Remove the suction strainer (8) and

clean it.

• Slew motor

13. Clean the inside of the hydraulic tank.

14. Remove the connector (C) and install the

cap (B).

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

and then install the flange (7).

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

flange (4) on the tank.

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

up to the level between the upper limit

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

gauge (1).

18. Tighten the plug (3).

19. Install the relay and fuse panel (9).

1. Loosen the air-bleeding plug (1).

20. Bleed air from the hydraulic oil circuit

2. Tighten the plug (1) once the hydraulic oil

following “Bleeding air” below.

overflows from the air-bleeding plug hole

21. Set the machine to the hydraulic oil level

(1).

inspection posture and inspect the oil

level after the oil cools.

• Cylinders

Refer to “Inspect the hydraulic oil tank

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

level and replenishing” on page 5-20.

speed for 10 minutes.

2. Maintain the engine at low idle, and then

Bleeding air

slowly extend and retract each cylinder 4

or 5 times, without letting them reach the

IMPORTANT: After replacing the hydraulic

stroke end.

oil, bleed air from the hydraulic circuits

3. While running the engine at high speed,

and hydraulic devices. Failure to do so

slowly extend and retract each cylinder 4

may damage the hydraulic devices.

or 5 times, without letting them reach the

stroke end.

• Hydraulic pump

4. Return the engine speed to low idle, and

then slowly extend and retract each

cylinder 4 or 5 times to the stroke end.

1. Open the engine hood.

2. Loosen the drain hose (1) of the hydraulic

pump.

5-55

Maintenance

Every 4000 hours

This operation is dangerous and requires

5. Slowly move the boom in the “Boom

experience. Ask your sales or service dealer

lower” direction a little until there are no

for help.

more air bubbles coming from the hose

If air is not released, the working equipment

nut (1) joint.

could become slow in reacting to the

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

operation of the operator and show

wrench and tighten the hose nut (1).

unexpected behavior.

Second boom

Warning

When removing plugs or screws, or when

disconnecting hoses, stand to the side

and loosen them slowly to gradually

release the internal pressure before

removing.

• Emergency shut-off valve

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

catch the waste oil.

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

3. Fully lower the safety lock lever to the

unlock position.

Arm

Boom

4. Loosen the hose (B) slowly.

2-Piece boom

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

direction a little until there are no more air

bubbles coming from the hose (B) joint.

6. Tighten the hose (B).

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

wrench and slowly loosen the hose nut (1).

5-56

Maintenance

When required

3. Remove the key, and then check that the

When required

bucket is stable.

Replacing the bucket teeth and

the side cutters

Replace the bucket teeth if the tooth points

are worn. Do not wait until the bucket is

damaged.

Warning

• 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,

4. Knock out the locking pin (1) and remove

firmly secure the working equipment

the point (2).

when repairing or replacing the bucket

teeth or side cutter.

Note: If the drift is set against rubber pin lock

• When using a hammer, pins may fly out

(3) when it is hit, the rubber pin lock may

or metal particles may be scattered.

break. Set it against the back of the locking

This may lead to serious injury.

pin.

· If hard metal parts such as pins,

bucket teeth, side cutter or bearings

5. Remove the rubber pin lock (3). Check if

are hit with a hammer, wear protective

the rubber pin lock is still usable. Replace

gear such as safety goggles and

it if it is as follows.

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.

Removing

1. Clean the bucket and park the machine on

a flat and rigid ground.

A

There are cracks in the rubber and

the roller is coming off.

B

The roller is dented when pressed

with a finger.

2. Place the bucket with its bottom flat on

the blocks so that the locking pin can be

knocked out.

5-58

Maintenance

When required

Installation

4. Knock out the locking pin (1).

Check that the end surfaces of the locking

pin just knocked out are aligned with the

upper and lower surface of the point. Do

not use the worn locking pin.

The life of the teeth can be lengthened

and the frequency of its replacement can

be reduced by turning it upside down so

that it will wear evenly.

Replace the rubber pin lock and locking

pin at the same time as replacing the

teeth. This makes it possible to prevent

the teeth from falling out

1. Remove the dirt on the surface of adaptor

and the inner part of tooth, make the

• Side cutter

better contact on the mating part.

Installation

2. Push rubber pin lock (3) into the welding

adaptor (4).

Do not let the rubber pin lock stick out

from the welding adaptor surface.

1. Insert the bolts from the inner of the

bucket and tighten the side cutter with

nuts.

Tightening torque: 475 N·m (350 ft-lb.)

3. Install the point (2) onto the welding

2. Caulk the bolts with a punch at three

adaptor (4).

spots along the periphery of the screw to

Insert the point so that the surface behind

prevent the nuts from coming loose.

the point’s pin hole is aligned with the

surface behind the welding adapter’s pin

hole.

5-59

Maintenance

When required

Replacing the bucket

1. Lower the bucket to the ground as shown

on the figure above in a stable position.

Warning

Note: When removing pins, set the bucket

• Before performing maintenance or

so that it is barely touching the ground If the

repairs under the machine, lower all

bucket is firmly touching the ground, the

working equipment to the ground or in

resistance will be great and it will be difficult

the lowermost position.

to remove the pin.

• If maintenance must be performed with

the engine running, always work as a

2. Set the safety lock lever to the locked

two person team communicating each

position and stop the engine.

other.

· One person must sit in the operator’s

seat so that he/she can immediately

stop the engine when necessary. He/

she must take care not to touch the

lever or pedal unless necessary.

· The one who performs maintenance

must make sure to keep his/her body

or clothing away from the moving part

of the machine.

• When using a hammer, pins may fly out

or metal particles may be scattered.

This may lead to serious injury.

3. Remove the bolt (1).

· If hard metal parts such as pins,

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

bucket teeth, side cutter or bearings

5. Remove the bucket.

are hit with a hammer, wear protective

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

gear such as safety goggles and

deformed or damaged. (See next page.)

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.

Removing

5-60

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

5-62.

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.

5-61

Maintenance

When required

Adjusting the gap between the

bucket and arm (If equipped)

Warning

• 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.

5-62

Maintenance

When required

Inspecting and replenishing the

Draining the water from the

windshield washer fluid

water separator

Warning

Warning

Choose ethyl alcohol as washer solution.

• Do not smoke or permit open flames

Do not use methyl alcohol as washer

while handling fuel or working on the

solution. It could damage the eyes.

fuel system.

• Stop the engine in a well-ventilated

Use a windshield washer fluid designed

place and allow it to cool down before

specifically for motor vehicles. Follow the

performing maintenance.

instructions included with the washer fluid.

• Clean up spilled fuel immediately.

<TB285>

Inspection

1. Open the side cover.

<TB290>

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).

1. Open the side cover.

2. Place a pan under the drain valve (1) to

catch fuel.

3. Open the drain valve (1) and drain the

water.

If the water does not drain easily, loosen

the plug (2). <TB290>

4. Close the drain valve (1) and tighten the

plug (2) <TB290>.

Refer to “Bleeding air from the fuel system”

on page 6-8.

5-63

Maintenance

When required

Lubricating the levers and pedals

Boom swing pedal

Warning

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.

5-64

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.

5-65

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