Takeuchi Hydraulic Excavator TB153FR (No.15820004~), TB180FR (17830004~). Operator's Manual

MAINTENANCE

Daily Inspection (Every 10 Hours)

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

WARNING

¡ Before operating, perform the Daily inspections and make repairs immediately should

any irregularities be found.

¡ Be sure to secure the engine hood or cover when opening it. Do not open the engine

hood or cover on slopes or in strong wind.

2. Inspect the quantity of coolant in the

Inspecting and Replenishing the

reserve tank (1).

Coolant

The level should be between the upper

limit (H) and lower limit (L).

WARNING

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

Do not remove the radiator cap or drain

plugs when the coolant is hot. Stop the

Replenishing

engine, let the engine and radiator cool

1. Remove the reserve tank’s cap (2).

and loosen the radiator cap or drain plugs

2. Add coolant up to the upper limit (H) of

slowly.

the reserve tank (1).

If the reserve tank is empty, inspect for

Inspection

fluid leakage, then inspect the radiator

< TB153FR >

coolant level. If it is low, add water to the

radiator first, then to the reserve tank.

3. Install the cap (2).

< TB180FR >

1. Open the engine hood.

120

MAINTENANCE

Daily Inspection (Every 10 Hours)

Inspecting and Replenishing the

Inspecting the Water Separator

Engine Oil

WARNING

Stop the engine and allow the machine

Stop the engine and allow the machine to cool down before performing

to cool down before performing

inspection and maintenance.

Inspection

L H

S : Closed

L4G019

1. Open the rear cover.

1. Open the engine hood.

2. Inspect the water separator (1).

2. Pull out the dipstick (1) and wipe off the

If the red indicator ring (6) is sunk to the

oil with a rag.

bottom of the case (4), no water is mixed

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

in.

back out.

If the red indicator ring (6) is floating, there

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

is water up to the bottom of the ring. Drain

The level should be between the upper

the water and clean.

limit (H) and lower limit (L).

3. Place a pan under the drain valve (7).

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

4. Open the drain valve (7) and drain the

water.

Replenishing

If the water does not drain easily, loosen

1. Remove the oil supply cap (2).

the plug (8).

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

5. Close the drain valve (7) and plug (8).

dipstick (1).

Refer to page 145 “Cleaning the Water

Problems could arise if the oil level is either

Separator”.

too low or too high.

3. Tighten the oil supply cap (2).

Bleeding the air from the fuel system

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

Refer to page 168 “Bleeding the Air from the

3 minutes, then stop it.

Fuel System”.

5. After about 10 minutes, inspect the oil

Supplement: Air in the fuel system can

level.

make it difficult to start the engine and cause

engine problems. Also bleed the air when

the fuel tank is emptied.

121

MAINTENANCE

Daily Inspection (Every 10 Hours)

Inspecting the Fuel Level

Inspecting the Hydraulic Oil Level

and Replenishing

WARNING

¡ Do not smoke or permit open flames

while fueling or near fueling

Oil may spurt out if caps or filters are

operations.

removed or pipes disconnected before

¡Stop the engine in a well-ventilated

releasing the pressure in the hydraulic

place when adding fuel.

system.

¡ Clean up spilled fuel immediately.

¡ Gradually press the air breather button

¡ Do not fill the fuel tank to capacity.

to relieve tank pressure.

Allow room for expansion.

¡ Tighten the fuel filler cap securely.

Inspection

The oil level changes according to the oil

temperature. Inspect the oil level in the

hydraulic oil level inspection posture shown

in the diagram.

¡ Hydraulic oil level inspection posture

1. Check the fuel level at the sight gauge (1).

2. If the level is low, add fuel from the fuel

port (2) while watching the sight gauge (1).

L4G004

Refer to page 42 “Fuel Filler Cap”.

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

2. Fully offset the boom to the left.

3. Fully retract the arm and bucket cylinders

and ground the bucket.

4. Ground the dozer blade, then stop the

engine.

5. Inspect the oil level at the sight gauge (7).

When the oil temperature is about 20°C

(68°F) :

• The level should be halfway between the

upper limit (H) and 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 near the upper limit

(H).

122

MAINTENANCE

After First 50 Hours (New Machines Only)

Replacing the Hydraulic Oil

Return Filter

WARNING

¡ Stop the engine and allow the machine

to cool down before performing

maintenance.

• The engine, hydraulic lines and many

1. Remove cap nut (3) on the air breather

other parts of the machine are hot

(2).

directly after the engine is stopped.

2. Press button (4) and bleed the air from

Touching these parts will cause

the tank.

burns.

3. Tighten securely by hand with cap nut (3).

• The hydraulic fluid is also hot and

4. Loosen the bolts, and remove the flange

under high pressure.

(5).

Be careful when loosening caps and

5. Remove the return filter (6).

plugs. Working on the machine under

6. Install the new return filter.

these conditions could result in

7. Install the flange (5).

burns or injuries due to the hot oil

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

spurting out.

and replenish if the level is low.

¡ Oil may spurt out if caps or filters are

Refer to page 122 “Inspecting the

removed or pipes disconnected before

Hydraulic Oil Level and Replenishing”.

releasing the pressure in the hydraulic

system.

• Gradually press the air breather

button to relieve tank pressure.

• When removing plugs or screws or

disconnecting hoses, stand to the

side and loosen slowly to gradually

release the internal pressure before

removing.

125

MAINTENANCE

After First 50 Hours (New Machines Only)

< TB180FR >

Replacing the Engine Oil and Oil

Filter

WARNING

Stop the engine and allow the machine

to cool down before performing

maintenance.

¡ The engine, muffler, radiator and many

L4G009

other parts of the machine are hot

2. Place a pan for catching the spent oil

directly after the engine is stopped.

under the drain plug (3).

Touching these parts will cause burns.

3. Remove cap (A), install connector (B) and

¡ The engine oil is also hot.

drain the oil. (The oil comes out when the

Be careful when loosening caps and

screw is tightened.)

plugs. Working on the machine under

4. Remove connector (B) and install cap (A).

these conditions could result in burns.

5. Using a filter wrench, turn the filter (4)

counterclockwise and remove it.

IMPORTANT: Check the spent oil. If it

6. Clean the filter installation surface on the

contains large amounts of metal powder,

filter stand.

consult a Takeuchi sales or service outlet.

7. Apply a thin layer of oil to the packing of

the new filter.

L H

8. Install the new filter by hand.

9. Tighten 3/4 more turns with the filter

wrench after the filter packing comes in

contact with the surface of installation.

• Tightening torque : 20 to 24 N·m

(14.5 to 17.4 ft-lb)

10. Remove the oil supply cap (2).

L4G019

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

dipstick (1). Problems could arise if the

1. Open the engine hood and remove the oil

oil level is either too low or too high.

supply cap (2).

12. Tighten the oil supply cap (2).

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

< TB153FR >

3 minutes, then stop it.

14. After about 10 minutes, inspect the oil

level.

B A

J1G011

126

MAINTENANCE

After First 50 Hours (New Machines Only)

Adjustment

Inspecting and Adjusting the Fan

Belt

WARNING

Stop the engine and allow the machine

to cool down before performing

inspection and maintenance.

¡ The engine, muffler, radiator, hydraulic

lines, sliding parts and many other

1. Tilt up the platform.

parts of the machine are hot directly

Refer to page 154 “Tilting Up the Platform”.

after the engine is stopped. Touching

2. Loosen the adjusting bolt (5) and locking

these parts will cause burns.

nut (6).

3. Using a lever (7), move the alternator (8)

Inspection

and adjust the slack.

1. Open the engine hood.

4. Tighten the adjusting bolt (5) and locking

nut (6).

2. Press the fan belt at midway between the

fan pulley (2) and alternator pulley (3) and

check the tension (about 98 N or 22 lbs.).

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

(0.28 to 0.4 in.).

3. Inspect the fan belt (4) and replace it if:

• there are cuts or cracks.

• the belt is worn and touches the bottom

of the V groove in the pulley.

• the belt stretches and cannot be

adjusted.

127

MAINTENANCE

Every 50 Hours

Inspection

Inspecting and Adjusting the

Crawler Tension

WARNING

¡ If you must work beneath the raised

machine or equipment, always use

wood blocks, jack-stands or other rigid

and stable supports. Never get under

E4G0192

the machine or working equipment if

1. For rubber crawlers, move the machine

they are not sufficiently supported.

so that the “M” or “∞” mark at the coupling

This procedure is especially important

is at the top center of the crawler frame.

when working on hydraulic cylinders.

¡ < TB153FR > : The track adjuster contains

highly pressurized grease. If the

A B

tension is adjusted without following

the prescribed procedure, the grease

discharge valve may fly off, resulting

in injury.

• Do not loosen the grease nipple.

• Loosen the grease discharge valve

slowly.

E4G0201

• Do not put your face, arms, legs or

2. Use the operating devices to lift the body.

body in front of the grease discharge

Operate the levers slowly.

valve.

• If no grease is expelled when grease

< TB153FR >

discharge valve is loosened, there is

a problem. Contact your nearest

service outlet for repairs. DO NOT

disassemble, as this is very

dangerous.

K3G001

128

MAINTENANCE

Every 50 Hours

< TB180FR >

Adjustment < TB153FR >

Increasing the tension

E4G0211

D5G025

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

bottom surface of the frame at the center

1. Remove the cover (1).

of the crawler frame and the top surface

2. Using the grease gun, insert grease

of the crawler.

through the grease nipple (3) in the grease

The gap (A or B) should be within the

discharge valve (2).

following range :

3. Inspect the crawler tension.

< TB153FR >

Decreasing the tension

(A) Rubber crawler :

108 to 118 mm (4.3 to 4.7 in.)

(B) Steel crawler :

172 to 192 mm (6.8 to 7.6 in.)

< TB180FR >

(A) Rubber crawler :

160 to 180 mm (6.3 to 7.1 in.)

D5G026

(B) Steel crawler :

260 to 280 mm (10.2 to 11.0 in.)

1. Remove the cover (1).

2. Using the Spanner, slowly loosen the

Adjustment < TB180FR >

grease discharge valve (2) and drain the

TB180FR uses a hydraulic cylinder to adjust

grease.

the tension of the crawler belts. Note that it

If the grease does not drain easily, move

is not necessary to regularly perform

the machine forward or backward.

adjustments of the tension of the belt itself.

3. Tighten the grease discharge valve (2).

• Tightening torque : 177 N·m (130 ft.lb.)

129

MAINTENANCE

Every 50 Hours

5. Repeat steps 2 to 4 above three times.

Lubricating the Slew Bearing

6. Wipe off the grease expelled from the slew

bearing and grease nipple.

WARNING

Do not slew while lubricating. Doing so

is dangerous, as you may get caught in

the machine.

L4G010

1. Stop the engine with the machine in the

posture shown on the diagram above.

J1G016

2. Use the grease gun to supply grease to

the grease nipple (1).

E4G026

3. Start the engine, lift the bucket and slew

clockwise 90°.

4. Ground the bucket and stop the engine.

130

MAINTENANCE

Every 50 Hours

Inspecting the Battery Fluid Level

and Replenishing

DANGER

¡ Do not use the battery when the fluid

level is below the lower level. Doing so

will hasten the deterioration of the

internal portions of the battery and

2. Inspect the indicator (1).

shorten the battery life, and can also

• Blue : Good

cause rupturing (or an explosion).

• White : Charging needed

¡Batteries generate flammable and

• Red : Insufficient battery fluid

explosive gases. Keep arcs, sparks,

3. Inspect the fluid level.

flames and lighted tobacco away.

The fluid level should be between the lines

¡ Use a dampened cloth to clean the area

indicating the upper level (H) and lower

of the fluid level lines and check the

level (L). If not, add distilled water up to

fluid level. Note that if this area is

line (H).

cleaned with a dry cloth, static

¡ If the fluid level can not be checked by

electricity could cause ignition or

fluid level lines.

explosion.

WARNING

¡ Do not fill the battery above the upper

level. Doing so could cause the fluid

to leak, contact and damage the skin,

or cause parts to corrode.

¡ Batteries contain sulfuric acid which

will damage eyes or skin on contact.

• If acid contacts eyes, flush

Remove the caps (2) and look into the fluid

immediately with clean water and get

supply holes to check the fluid level. If the

prompt medical attention.

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

• If acid is accidentally swallowed,

distilled water up to the bottom edge of the

drink large quantities of water or milk

sleeve (3).

and call a physician immediately.

Proper amount

(A)

• If acid contacts skin or clothing, wash

The fluid reaches up to the bottom edge

off immediately with clean water.

of the sleeve (3), so the surface tension

causes the fluid to swell and the plate

Inspection

appears distorted.

IMPORTANT: Check the fluid level of all

Level too low

(B)

cells, even when the fluid level can be

The fluid does not reach up to the bottom

checked by indicator.

edge of the sleeve (3), so the plate

appears laminar, not distorted.

1. Open the rear cover.

4. Also check the terminals for looseness and

dirt.

131

MAINTENANCE

Every 50 Hours

Replenishing

Draining the Fuel Tank

When adding distilled water, do so before

starting operations in order to prevent

WARNING

freezing.

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

¡ Do not smoke or permit open flames

water until the upper level (H).

while handling fuel or working on the

2. Inspect the indicator (1) then it turns blue.

fuel system.

3. Clean the cap’s exhaust hole, then tighten

¡Stop the engine in a well-ventilated

the caps (2) securely.

place and allow it to cool down before

performing maintenance.

¡ Clean up spilled fuel immediately.

Do this before operating the machine.

1. Remove the fuel filler cap (2).

2. Place a pan under the drain plug (3).

3. Open the drain plug (3) and drain the water

and sediment from the bottom of the tank.

4. Close the drain plug (3).

5. While watching the sight gauge (1), add

fuel.

6. Tighten the fuel filler cap (2) and lock it

with the key.

7. Bleed the air.

Bleeding the air from the fuel system

Refer to page 168 “Bleeding the Air from the

Fuel System”.

Supplement: Air in the fuel system can

make it difficult to start the engine and cause

engine problems. Also bleed the air when

the fuel tank is emptied.

132

MAINTENANCE

After First 250 Hours (New Machines Only)

< TB180FR >

Replacing the Travel Motor Gear

Oil

WARNING

¡ Stop the engine and allow the machine

to cool down before performing

maintenance.

• The travel motors are hot directly

after the engine is stopped. Touching

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

them will cause burns.

the very bottom.

• The gear oil is also hot and under

2. Place a pan for catching the spent oil

high pressure.

under plug (1).

Be careful when loosening plugs.

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

Working on the machine under these

the oil.

conditions could result in burns or

4. Wrap new sealing tape around the plugs.

injuries.

5. Tighten plug (1).

¡The pressure in the travel motor

6. Add oil through the hole for plug (3) until

reduction gears case may cause oil or

oil flows out of the hole of plug (2).

the plug to fly out. Loosen the plug

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

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.

< TB153FR >

133

MAINTENANCE

Every 250 Hours

1. Open the engine hood.

Replacing the Engine Oil and Oil

Filter

< TB153FR >

Refer to page 126 “Replacing the Engine Oil

and Oil Filter”.

Inspecting and Adjusting the Fan

Belt

Refer to page 127 “Inspecting and Adjusting

the Fan Belt”.

< TB180FR >

Cleaning the Air Cleaner

WARNING

¡ Stop the engine and allow the machine

to cool down before performing

maintenance.

• The engine, muffler, radiator and

2. Loosen the clamp (1) and remove the dust

many other parts of the machine are

cup (2).

hot directly after the engine is

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

stopped. Touching these parts will

4. Remove the element (3).

cause burns.

5. Cover the intake hole at the back of the

¡ Wear required appropriate equipment

body (4) with cloth or tape to prevent dirt

such as safety glasses and filter mask

from getting in.

when using compressed air, as metal

< If equipped with the inner element >

fragments or other objects can fly and

To prevent dirt from getting inside the

cause serious personal injury.

engine, do not remove the inner element

(5).

IMPORTANT: Be careful not to scratch

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

the element. Do not use an element if it is

damaged.

IMPORTANT: When operating the

machine in very dusty places, inspection

and maintenance should be performed

every day.

Supplement: Do not remove and clean the

inner element (option). Replace the inner

element every 1000 hrs. or after every 3

E4G033

cleaning of the outer element.

(whichever comes first)

134

MAINTENANCE

Every 250 Hours

7. Clean the element

(3) with dried

compressed air {294 to 490 kPa (43 to 71

psi)}.

First blow the air from the inside of the

element along the flutes, then blow the air

from the outside, and finally from the inside

again.

E4G034

8. Light up the inside of the element (3) with

a bulb, inspect it, and replace it if there

are small holes or thin spots.

9. Remove the cloth or tape applied in step

10. Install the element (3).

11. Install the dust cup (2) with the “TOP”

mark at the top, then fasten it with the

clamp (1).

135

MAINTENANCE

Every 250 Hours

Cleaning the Radiator Fins and

Oil Cooler Fins

WARNING

Wear required appropriate equipment

such as safety glasses and filter mask

when using compressed air, as metal

fragments or other objects can fly and

cause serious personal injury.

IMPORTANT: Be careful not to damage

the radiator fins and oil cooler fins when

cleaning them.

¡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, inspection

and maintenance should be performed

every day.

1. Open the rear cover.

2. Blow compressed air on the radiator fins

and oil cooler fins to remove mud and dirt

stuck on them.

136

MAINTENANCE

Every 500 Hours

Replacing the Hydraulic Oil

Replacing the Fuel Filter

Return Filter

WARNING

Refer to page 125 “Replacing the Hydraulic

Oil Return Filter”.

¡ Do not smoke or permit open flames

while handling fuel or working on the

fuel system.

¡Stop the engine in a well-ventilated

place and allow it to cool down before

performing maintenance.

¡ Clean up spilled fuel immediately.

K3G003

1. Open the engine hood.

2. Using a filter wrench, turn the filter (1)

counterclockwise and remove it.

3. Clean the filter installation surface on the

filter stand.

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

the new filter.

5. Install the new filter by hand.

6. Tighten 2/3 more turns with the filter

wrench after the filter packing comes in

contact with the surface of installation.

• Tightening torque : 20 to 24 N·m

(14.5 to 17.4 ft-lb)

7. Bleed the air.

Refer to page 168 “Bleeding the Air from

the Fuel System”.

137

MAINTENANCE

Every 1000 Hours

1. Open the engine hood.

Cleaning the Engine Cooling

System

< TB153FR >

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 directly after the engine is

stopped. Touching these parts will

< TB180FR >

cause burns.

• The engine coolant is also hot and

under high pressure. Be careful when

loosening caps and 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

2. Gradually loosen the radiator cap (3) to

two person team with one person

release the internal pressure, then

sitting in the operator’s seat while the

remove.

other works on the machine.

• When performing maintenance, be

< TB153FR >

sure to keep your body and clothing

away from moving parts.

¡ Standing at the back of the machine

while the engine is running is extremely

dangerous, as the machine could move

suddenly. Never stand at the back of

the machine while the engine is

running.

¡ Do not remove the radiator cap or drain

J1G012

plugs when the coolant is hot. Stop the

engine, let the engine and radiator cool

and loosen the radiator cap or drain

plugs slowly.

138

MAINTENANCE

Every 1000 Hours

< TB180FR >

L4G014

3. Place a pan for catching the spent coolant

under the drain plug (4), then loosen the

drain plug (4) and drain the coolant.

4. Tighten the drain plug (4), then add a little

cleaning agent and tap water to the

radiator until it is full. Take your time doing

this.

Follow the manufacturer’s instructions

when using the cleaning agent.

5. Run the engine at a low idle for about 30

minutes. For the first 5 minutes after

starting it, pay attention to the level of the

cleaning fluid, and add tap water if the level

drops.

6. Stop the engine and drain the cleaning

fluid.

7. Tighten the drain plug (4), add tap water,

run the engine at a low idle for about 10

minutes, then stop the engine and drain

the water.

Clean repeatedly until the drained water

is clear.

8. After cleaning is completed, tighten the

drain plug (4) and add new coolant up to

the specified level.

9. Run the engine at a low idle, bleed the air,

then stop the engine once the coolant level

stabilizes at the specified level.

10. Check the coolant level, then tighten the

radiator cap (3).

11. Clean the inside of the reserve tank (1),

then add coolant up to the upper limit (H).

139

MAINTENANCE

Every 1000 Hours

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

Replacing the Air Cleaner

4. Remove the element (3).

Element

5. Cover the intake hole at the back of the

body (4) with cloth or tape to prevent dirt

WARNING

from getting in.

< If equipped with the inner element >

Stop the engine and allow the machine to

Do not yet remove the inner element (5).

cool down before performing maintenance.

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

¡ The engine, muffler, radiator and many

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

other parts of the machine are hot

< If equipped with the inner element >

directly after the engine is stopped.

Remove the inner element (5).

Touching these parts will cause burns.

8. Install the new elements.

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

IMPORTANT: Do not use an element if its

at the top, then fasten it with the clamp (1).

flutes, gaskets or seals are damaged.

Supplement: Do not remove and clean the

inner element (option). Replace the inner

element every 1000 hrs. or after every 3

cleaning of the outer element.

(whichever comes first)

< TB153FR >

< TB180FR >

1. Open the engine hood.

2. Loosen the clamp (1) and remove the dust

cup (2).

140

MAINTENANCE

Every 1000 Hours

Replacing the Air Breather Filter

Replacing the Travel Motor Gear

Oil

WARNING

Refer to page 133 “Replacing the Travel

Motor Gear Oil”.

Oil may spurt out if caps or filters are

removed or pipes disconnected before

releasing the pressure in the hydraulic

Inspecting and Adjusting the

system.

¡ Gradually press the air breather button

Engine Valve Clearance

to relieve tank pressure.

This operation requires experience. Have it

performed by a Takeuchi sales or service

outlet.

Retightening the Engine Cylinder

Head Bolts

This operation requires experience. Have it

performed by a Takeuchi sales or service

L2G023

outlet.

1. Remove cap nut (N) on the air breather.

2. Press botton (T) and bleed the air from

the tank.

Inspecting the Engine Fuel

3. Remove seal washers (W) and nut (G).

Injection Pressure and Spray

4. Remove cover (H).

Condition

5. Replace filter (A), making sure it is in the

proper direction.

This operation requires experience. Have it

6. Line up the cut section of body (B) and

performed by a Takeuchi sales or service

cover (H) and install.

outlet.

7. Install seal washers (W) and nut (G).

8. Tighten securely by hand with cap nut (N).

141

MAINTENANCE

Every 2000 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, hydraulic lines and many

other parts of the machine are hot

directly after the engine is stopped.

Touching these parts will cause

burns.

• The hydraulic fluid is also hot and

2. Remove cap nut (3) on the air breather (2).

under high pressure.

3. Press button (4) and bleed the air from

Be careful when loosening caps and

the tank.

plugs. Working on the machine under

4. Replace the air breather filter.

these conditions could result in

Refer to page 141 “Replacing the Air

burns or injuries due to the hot oil

Breather filter”.

spurting out.

5. Remove the plug (1).

¡ Oil may spurt out if caps or filters are

6. Loosen the bolts, and remove the flange (5).

removed or pipes disconnected before

7. Remove the return filter (6).

releasing the pressure in the hydraulic

8. Place a pan for catching the spent oil

system.

under the drain plug (8).

• Gradually press the air breather

9. Loosen the drain plug (8) and drain the

button to relieve tank pressure.

hydraulic oil.

• When removing plugs or screws or

10. Loosen the bolts, and remove the cover

disconnecting hoses, stand to the

(9).

side and loosen slowly to gradually

11. Loosen the bolts, and remove the flange

release the internal pressure before

(10).

removing.

12. Shift the flange (10) to the right.

13. Remove the flange (11) and suction

1. Slew 45° clockwise and set the machine

strainer (12) and clean them.

to the hydraulic oil level inspection posture.

14. Clean the inside of the hydraulic tank.

Refer to page 122 “Inspecting the

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

Hydraulic Oil Level and Replenishing”.

16. Install the suction strainer (12) to the

flange (11).

17. Install the flange (11) and (10).

18. Tighten the drain plug (8).

19. Add hydraulic oil up to the middle of the

sight gauge (7).

142

MAINTENANCE

Every 2000 Hours

20. Tighten the plug (1).

< TB180FR >

21. Follow the procedure next “Bleeding the

air” to bleed the air from the hydraulic oil

circuit.

22. Set the machine to the hydraulic oil level

inspection posture and inspect the level

once the temperature of the oil has

dropped.

Refer to page 122 “Inspecting the

Hydraulic Oil Level and Replenishing”.

2. Disconnect the drain hose (1) from the

Bleeding the air

hydraulic pump.

3. Once hydraulic oil overflows from the

IMPORTANT: After replacing the

elbow (2), connect the drain hose (1).

hydraulic oil, bleed the air from the

hydraulic oil circuit and hydraulic

¡ Slew motor

devices. Failure to do so may damage the

< TB153FR >

hydraulic devices.

¡ Hydraulic pump

1. Tilt up the platform.

Refer to page 154 “Tilting Up the Platform”.

< TB153FR >

< TB180FR >

2. Loosen the hydraulic pump’s air bleeding

plug (1).

3. Once hydraulic oil overflows from the hole

in the air bleeding plug (1), tighten the plug.

4. Loosen the air bleeding plug (1).

5. Once hydraulic oil overflows from the hole

in the air bleeding plug (1), tighten the plug.

6. Lower the platform.

143

MAINTENANCE

Every 2000 Hours

¡ Cylinders

Inspecting the Engine Fuel

7. Start the engine and run it at low idle for

Injection Timing

10 minutes.

8. Set the engine to a low idle, then extend

This operation requires experience. Have it

and contract all the cylinders 4 or 5 times,

performed by a Takeuchi sales or service

without going to the stroke end.

outlet.

9. Run the engine at high speed, then extend

and contract all the cylinders 4 or 5 times,

without going to the stroke end.

Inspecting the Engine Fuel

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

Injection Valve

extend and contract all the cylinders 4 or

5 times to the stroke ends.

This operation requires experience. Have it

performed by a Takeuchi sales or service

outlet.

144

MAINTENANCE

When Required

Inspecting and Replenishing the

Cleaning the Water Separator

Windshield Washer Fluid

WARNING

Use a windshield washer fluid designed

specifically for motor vehicles. Follow the

¡ Do not smoke or permit open flames

instructions including with the washer fluid.

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.

G4G030

Inspection

1. Open the cab door.

2. Inspect the washer tank (1) and add

washer fluid if the level is low.

Replenishment

S : Closed

1. Mix the washer fluid to the prescribed

1. Open the rear cover.

concentration.

2. Close the lever (2).

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

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

3. Reinstall the cap (2).

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

clean them.

4. Inspect the O-ring, and if there are any

scratches or other irregularities, replace

it.

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

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

6. Open the lever (2) and bleed the air.

Bleeding the air from the fuel system

Refer to page 168 “Bleeding the Air from the

Fuel System”.

145

MAINTENANCE

When Required

Offset pedal

Lubricating the Levers

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.

1. Remove the lower mount section of the

If the levers or pedals no longer move

boot (1) and turn it upwards.

smoothly, supply grease.

2. Wipe off the old grease.

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

Operating levers

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

Blade lever < TB180FR >

E4G058

1. Remove the lower mount section of the

boot (1) and turn it upwards.

2. Wipe off the old grease.

1. Remove the lower mount section of the

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

boot (1) and turn it upwards.

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

2. Wipe off the old grease.

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

Travel levers

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

A B

L3G0221

1. Remove the lower mount section of the

boots (1) and turn it upwards.

2. Wipe off the old grease.

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

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

146

MAINTENANCE

When Required

Adjusting the Gap Between the

Bucket and Arm < TB180FR >

WARNING

¡Before performing maintenance or

repairs under the machine, set all

working equipment against the ground

E4G050

or in the lowermost position.

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

¡ To prevent unexpected movement,

(3) and flange (4).

securely block the working equipment

when adjusting.

E4G051

E4G048

5. Extract adjustment shim (5) from between

flange (4) and the bucket body according

1. Ground the bucket as shown on the

to gap (A).

diagram above in a stable position.

Adjustment shim thickness : 0.5 mm (0.02 in.)

2. Check that the bucket dose not move, then

Be careful that the gap is no less than 0.5

set the safety lock lever to the locked

mm (0.02 in.) after adjustment.

position and stop the engine.

Supplement

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

2 mm (X) - 0.5 mm (standard value)

= 1.5 mm (0.06 in)

In the above example, three shims (5) should

be removed.

6. Insert adjustment shim (5) removed in step

E4G049

5 above between end plate (3) and flange

(4) and fasten it in place with the three

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

bolts (2).

into view and measure the width of the

• Tightening torque for bolts (2)

gap (A).

54.9 N·m (40.5 ft-lb.)

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

Swing the buckte slightly to the left and

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

lightly press the arm point to the left side

position.

of the bucket (the side without an adjuster).

147

MAINTENANCE

When Required

2. Set the safety lock lever to the locked

Replacing the Bucket

position and stop the engine.

3. Remove the bolt (1).

WARNING

¡Before performing maintenance or

repairs under the machine, set all

working equipment against the ground

or in the lowermost position.

¡ If maintenance must be performed with

the engine running, always work as a

two person team with one person

sitting in the operator’s seat while the

E4G052

other works on the machine.

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

• When performing maintenance, be

5. Remove the bucket.

sure to keep your body and clothing

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

away from moving parts.

is deformed or damaged. (See next page.)

¡ Wear required appropriate equipment

such as safety glasses and filter mask

Installation

when using hammers, as metal

fragments or other objects can fly and

cause serious personal injury.

¡ When lining up the pin holes, always

do so by sight. Your finger may be cut

off if you stick it into the hole.

Removal

E4G053

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

the diagram.

E4G048

1. Ground the bucket as shown on the

diagram above in a stable position.

Supplement: When removing pins, set the

bucket so that it is just gently against the

E4G054

ground. If it is strongly against the ground,

2. Line up pin hole (A) in the bucket with the

the resistance will be great and it will be

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

difficult to remove the pin.

(2).

148

MAINTENANCE

When Required

3. Operate the cylinder, line up pin hole (B)

2. Use a mallet to slowly press the pin seal

in the bucket with the pin hole in the link

in. Be careful not to damage the seal.

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

0.5~1mm

E4G055

4. Line up the turn prevention holes, install

the bolt (1), and the nuts.

Be sure to leave a gap of about 0.5 ~ 1 mm

(0.02 ~ 0.04 in.) between the nut and bucket

bush, or the nut will come loose.

E4G056

5. Adjust the gap between the bucket and

the arm. Refer to page 134.

6. Slide the O-ring (4).

Replacing the pin seal

E4G057

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

on the diagram above.

149

MAINTENANCE

When Required

3. Remove the key, then check that the

Replacing the Bucket Teeth and

bucket is stable.

the Side Cutters < TB153FR >

Replace the bucket teeth and the side cutters

when the tooth points or the side cutters are

worn, before the adapter or the bucket is

damaged.

WARNING

¡Before performing maintenance or

OL1L200

repairs under the machine, set all

working equipment against the ground

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

or in the lowermost position.

knock the locking pin out by hammering

¡ To prevent unexpected movement,

against the rod.

securely block the working elements

The rod should be round and thinner than

when repairing or replacing the bucket

the locking pin.

teeth and the side cutters.

¡ Wear required appropriate equipment

such as safety glasses when using

hammers, as metal fragments or other

objects can fly and cause serious

personal injury.

¡ Do not allow unauthorized personnel

in the work area.

OL1L210

¡ Bucket tooth

5. Remove the tooth point (2).

Removal

Some tooth points (2) are of the type that

1. Clean the bucket and park the machine in

are removed by turning (twisting) them

a flat, safe place where the ground is hard.

counterclockwise.

The same procedure can be used to

remove the other tooth points.

2. Set the bottom surface of the bucket flat

and lower it on a block so that the locking

pin (1) can be knocked out.

150

MAINTENANCE

When Required

Installation

OL1L250

OL1L220

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

1. Clean the adapter nose (3).

until it is flush with the tip of the tooth point

If there is gravel or mud on the adapter

(2) ear.

nose, the tooth point will not go in all the

way and the pin cannot be driven in.

OL1L260

OL1L230

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

(3).

Push in firmly until the tooth point (2)

touches the tip of the adapter nose (3).

Some tooth points (2) are of the type that

are installed by turning (twisting) them

OL1L270

clockwise.

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

The same procedure can be used to install

the other tooth points.

¡ Side cutter

Refer to page 153 “Side cutter”.

OL1L240

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

in the right direction.

151

MAINTENANCE

When Required

3. Remove the key, then check that the

Replacing the Bucket Teeth and

bucket is stable.

the Side Cutters < TB180FR >

Replace the bucket teeth and the side cutters

when the tooth points or the side cutters are

worn, before the adapter or the bucket is

damaged.

WARNING

¡Before performing maintenance or

E4G043

repairs under the machine, set all

working equipment against the ground

4. Remove locking pin (1) and remove point

or in the lowermost position.

(2).

¡ To prevent unexpected movement,

5. Take out rubber pin lock (3) and check

securely block the working elements

whether it is still usable.

when repairing or replacing the bucket

teeth and the side cutters.

¡ Wear required appropriate equipment

such as safety glasses when using

hammers, as metal fragments or other

objects can fly and cause serious

personal injury.

¡ Do not allow unauthorized personnel

in the work area.

E4G044

¡ Bucket tooth

When these are cracks in the rubber

Removal

and it seems like the roller is about

1. Clean the bucket and park the machine in

to come off.

a flat, safe place where the ground is hard.

When the roller becomes dented

when pressed with a finger.

Installation

E4G042

2. Set the bottom surface of the bucket flat

E4G045

and lower it on a block so that the locking

pin can be knocked out.

1. Push rubber pin lock (3) into welding

adaptor (4).

152

MAINTENANCE

When Required

Do not let the rubber pin lock stick out past

¡ Side cutter

the welding adapter surface.

Installation

G4G026

1. Insert the bolts from the inner of the bucket

2. Install point (2) onto welding adaptor (4).

and tighten the nuts.

• Insert the point so that the surface

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

behind the point’s pin hole is flush or

2. Caulk the bolts with a punch at three spots

deeper than the surface behind the

along the periphery of the screw to prevent

welding adapter’s pin hole.

the nuts from coming loose.

E4G047

3. Drive in locking pin (1).

After driving in the locking pin, use a pin with

the same surface as the point surface. Do

not use worn locking pins.

153

MAINTENANCE

When Required

4. Remove the lock bolts (A) and (B).

Tilting Up the Platform

5. Slowly raise the platform. (Tilt up : 30°)

6. Lift stopper (D) and insert it into the

For inspection and maintenance, the platform

platform’s holder.

is designed so that it can be tilted up.

If you need to run the engine while the

WARNING

platform is raised follow these steps.

7. Make sure that all levers and pedal are in

¡ Raising or lowering the platform while

neutral positions.

the engine is running may cause the

8. Turn the throttle controller to the low idling

machine to move, and cause serious

position.

injury or death. Lower the working

9. Start the engine.

equipment to the ground and stop the

10. Be sure to stop the engine after

engine before raising or lowering the

inspection and maintenance.

platform.

¡ When the platform is tilted up, support

Lowering

it firmly with the stopper to prevent it

1. Remove the stopper (D), and set back to

from falling.

the original position.

2. Lower the platform.

IMPORTANT: Lower the working

3. Tighten the lock bolts (A) and (B).

equipment to the ground before raising

4. Install the cover (1).

the platform. If not avoided, could result

in the boom from touching the cab.

Raising (Tilt up)

1. Select a firm, level surface, lower the

working equipment to the ground, and stop

the engine.

2. Raise the safety lock lever to engage the

lock.

L4G0171

3. Loosen the bolts, and remove the cover (1).

154

MAINTENANCE

When Required

(3) Metal core

Inspecting the Rubber Crawlers

Repair or replace the rubber crawlers if their

conditions are as described below. Consult

a Takeuchi sales or service outlet about

repairs or replacement.

Rubber crawler

Replace the crawler if the entire crawler is

E4G064

stretched and cannot be adjusted.

Replace if even one metal core is off.

(1) Lug

(4) Rubber

60 mm or greater

E4G062

E4G065

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

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

or below.

or greater in length.

If the steel cord is visible, repair as soon as

(2) Steel cord

possible, regardless of the length of the

crack.

E4G063

Replace if the steel cord is exposed over 2

or more links.

Replace if half or more of the steel cords on

one side are cut.

155

MAINTENANCE

When Required

Replacing the Rubber Crawlers

Direction of rotation

< TB153FR >

WARNING

¡ If you must work beneath the raised

machine or equipment, always use

wood blocks, jack-stands or other rigid

E4G067

and stable supports. Never get under

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

the machine or working equipment if

and turn the sprocket slowly in the reverse

they are not sufficiently supported.

direction.

This procedure is especially important

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

when working on hydraulic cylinders.

to the idler and the rubber crawler lifts

¡ If maintenance must be performed with

away from the idler, then stop turning the

the engine running, always work as a

sprocket.

two-person team with one person

5. Slide the rubber crawler sideways and

sitting in the operator’s seat while the

remove it from the crawler frame.

other works on the machine.

Remove the other rubber crawler using

• When performing maintenance, be

the same procedure.

sure to keep your body and clothing

away from moving parts.

Installation

1. Use the working equipment to lift the body.

Removal

1. Fully release the tension of the rubber

crawler.

Direction of rotation

Refer to page 128 “Inspecting and

Adjusting the Crawler Tension”.

E4G068

2. Set the rubber crawler on the sprocket.

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

and turn the sprocket slowly in the reverse

E4G070

direction.

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

2. Use the working equipment to lift the body.

to the idler and the rubber crawler lifts

away from the idler, then stop turning the

sprocket.

5. Slide the rubber crawler inward, engage

it on the idler, then pull out the iron pipe.

156

MAINTENANCE

When Required

2. Stop the engine.

Replacing the Rubber Crawlers

< TB180FR >

WARNING

¡ Replacements should always be done

by two persons, with one person acting

as operator and following instructions

from the other.

¡ The machine must be elevated before

replacing the rubber crawler belts. Be

3. Remove the valve covers (1) at the center

careful not to allow the machine to fall

of the left and right crawler frames.

when replacing crawler belts, since this

could be extremely dangerous. Slowly

lower the machine on the side of the

idler and remove the crawler belts.

This machine uses a hydraulic cylinder to

adjust the tension of the crawler belts. Note

that it is not necessary to regularly perform

adjustments of the tension of the belt itself.

IMPORTANT: During the replacement

4. Loosen the lock plate (2) counterclockwise.

procedure, only start the engine when

5. Turn the valve handle (3) counterclockwise

raising and lowering the machine body.

to loosen the tension of the crawler.

Otherwise, always keep the engine off.

6. Once the crawler is completely loose,

IMPORTANT: When the travel speed

tighten the valve handle (3).

switch is set to the 2nd speed side while

7. Tighten the lock plate (2).

the engine is running, the tensioning

8. Do the same for the other side.

cylinder rods extend and the crawlers are

tightened.

Removal

9. Slowly lower the dozer blade side of the

machine body, by the dozer blade lever.

(Do not start the engine.)

1. Start the engine and raise the machine

body with the hoe attachment and dozer

blade.

158

MAINTENANCE

When Required

10. Ground the crawlers and lower the

machine body so that the crawler slack

is maximum.

11. When the crawlers come away from the

idlers, slide the crawlers to the outside

and remove them.

12. Disengage the crawlers and sprockets,

then remove the crawlers from the

crawler frames.

Installation

1. Engage the crawlers with the left and right

sprockets.

2. Set the left and right crawlers on the idlers.

3. Start the engine.

4. Press the travel speed switch once and

set it to the 2nd speed side. The left and

right

crawlers

are

tightened

simultaneously.

5. Check that the crawlers are properly

tightened. Standard value (A).

Refer to page 128 “Inspecting and

adjusting the Crawler Tension”.

159

Takeuchi Hydraulic Excavator TB153FR (No.15820004~), TB180FR (17830004~). Operator's Manual - page 4