Takeuchi Mini Excavator TB216 (No.216000002~, No.216100002~). Operator's Manual

Safety alert symbol

This symbol represents the safety alert.

Improper operation, inspection and

The message that follows the symbol

maintenance of this machine can cause

contains important information about

injury or death.

safety.

Read and understand this manual before

Read and understand the message to

performing any operation, inspection or

avoid personal injury or death.

maintenance on this machine.

It is the owner or employer’s responsibility

Always store this manual near at hand

to fully instruct each operator in the

preferably on the machine itself. If it should

proper and safe operation of all

be lost or damaged, immediately order a

equipment. All persons using this

new one from your Takeuchi dealer.

machine should thoroughly familiarize

When transferring ownership of this machine,

themselves with the contents of this

be sure to hand this manual to the next

manual.

owner.

All operators must be instructed on the

Takeuchi supplies machines complying with

proper functions of the excavator before

the local regulations and standards of the

running the machine.

country of export. If your machine has been

purchased in another country or from a

Learn and practice correct use of the

person or company of another country, it

machine controls in a safe, clear area

may not have the safety devices or safety

before operating this machine on a job

standards required for use in your country.

site.

Should you have any question about whether

your machine complies with the regulations

and standards of your country, contact a

Takeuchi dealer.

Signal words

IMPORTANT: The word IMPORTANT is

used to alert operators and maintenance

Safety messages appearing in this manual

personnel about situations which could

and on machine decals are identified by the

result in damage to the machine and its

words “DANGER”, “WARNING” and

components.

“CAUTION”. These signal words mean the

following:

It is impossible to foresee every possible

circumstance that might involve a potential

hazard. The warnings in this manual or on

the machine can not cover all possible

DANGER indicates a hazard with a high

contingencies. You must exercise all due

level of risk which, if not avoided, will

care and follow normal safety procedures

result in death or serious injury.

when operating the machine so as to ensure

that no damage occurs to the machine, its

operators or other persons.

WARNING indicates a hazard with a

medium level of risk which, if not avoided,

could result in death or serious injury.

CAUTION indicates a hazard with a low

level of risk which, if not avoided, could

result in minor moderate injury.

0-1

Introduction

Foreword

This manual describes operation, inspection

and maintenance of the machine, as well as

safety instructions to be heeded during these

operations.

If you have any questions about the

machine, please contact a Takeuchi sales or

service outlet.

Manual storage compartment

Serial numbers

A compartment for storing this manual is

IMPORTANT: Do not remove the machine

provided at the position shown on the

name plate with the serial number.

diagram below.

Check the serial numbers of the machine

and engine and write them down in the

spaces below.

Machine number:

1. Insert the starter key and turn it

counterclockwise to open the cover under

the seat.

2. After using the manual, place it in the

plastic pouch and store it back in the

manual storage compartment.

Engine number:

AD6O003

0-2

Machine description

Front, rear, left and right

Features

• “Flexible machine width mechanism” for

crawler width

• Low engine noise and exhaust emissions

Break-in period

When the machine is new, operate the

machine for the first 100 hours (as indicated

on the hour meter) by following the

instructions below.

Using a new machine without a break-in

period will lead to quicker deterioration of

machine performance and may shorten the

machine’s service life.

• Sufficiently warm up the engine and

hydraulic oil.

• Avoid heavy loads and rapid operations.

This manual refers the front, rear, left and

Operate with a load of about 80% the

right of the machine as seen when sitting in

maximum load.

the operator’s seat with the dozer blade

• Do not abruptly start up, accelerate,

visible to the front.

change directions, or stop unless

necessary.

Designated operations

Use this machine primarily for the following

operations:

• Excavation

• Digging ditches

• Digging side ditches

• Leveling

• Loading

0-3

Contents

Third auxiliary hydraulic switch and

Introduction

0-2

button

2-27

Overload warning switch

Machine description

0-3

(If equipped)

2-28

Levers and Pedals

2-29

Safety

1-1

Safety lock lever

2-29

General precautions

1-2

Throttle lever

2-29

Precautions when preparing

1-8

Operating levers

2-30

Precautions when starting

1-12

Blade lever

2-30

Precautions when operating

1-14

Travel levers/pedals

2-31

Precautions when stopping

1-23

Boom swing pedal

2-31

Precautions when transporting

1-24

Auxiliary hydraulic pedal

2-32

Precautions on maintenance

1-26

Selector lever

2-32

Safety signs (decals)

1-35

Accessories

2-34

Heater

2-34

Controls

2-1

Cup holder

2-36

Names of components (Cab)

2-2

Interior light

2-36

Names of components (Canopy)

2-4

Inside rear view mirror (cab)

2-36

Covers

2-6

Power sockets

2-37

Starter key

2-6

Armrest

2-37

Maintenance cover

2-6

Radio (for cab)

2-38

Fuse box

2-7

Auxiliary hydraulic lines

2-42

Tool case

2-7

Accumulator (If equipped)

2-46

Grease gun holder

2-7

Operation

3-1

Fuel lid

2-8

Fuel filler port

2-8

Before starting operation

3-2

Side cover

2-9

Getting on or off the machine

3-2

Engine hood

2-9

Walk-around inspection

3-2

Cab

2-10

Daily inspection

3-2

Cab door

2-10

Starting and stopping the engine

3-3

Emergency exit

2-10

Before starting the engine

3-3

Front window

2-11

Starting the Engine

3-4

Lower front window

2-12

Warming up the engine

3-5

Side window

2-12

Stopping the engine

3-5

Emergency hammer (optional)

2-13

Operating the machine

3-6

Seat and seat belt

2-14

Lever pattern (ISO pattern)

3-6

Seat (If equipped)

2-14

Lever pattern (G pattern) If equipped

3-7

High-back seat (If equipped)

2-15

Warming up the machine (hydraulic oil).3-8

Seat belt

2-16

Inspection after warm-up

3-9

Instrument cluster

2-18

Crawler width switching

3-10

Warning lamps

2-18

Switching the blade width

3-11

Indicators

2-19

Operating the travel levers

3-12

Meters

2-19

Stopping travel

3-15

Multi-data display

2-20

Operating the working equipment

3-16

Switches

2-26

Operating procedures

3-18

Starter switch

2-26

Prohibited operations

3-18

Horn button

2-26

Cautions on operating

3-21

Travel speed switch

2-26

Cautions on traveling

3-21

Wiper switch

2-27

Cautions on traveling on slopes

3-22

Second auxiliary hydraulic switch

2-27

Getting out of mud

3-24

0-5

Operations possible with this

Lubricating the working equipment

5-23

machine

3-24

After the initial 50 hours

Parking the machine

3-26

(only for new machines)

5-24

Parking

3-26

Replacing the engine oil and the

Inspection and checks after stopping

oil filter

5-24

the engine

3-26

Inspecting and adjusting the fan belt.. 5-25

Handling in cold climates

3-27

Replacing the hydraulic oil return filter.5-26

Preparing for cold climates

3-27

Every 50 hours

5-28

Cautions after operations

3-27

Inspecting and adjusting the crawler

After the cold climate

3-27

tension

5-28

Handling rubber crawlers

3-28

Lubricating the slew bearing

5-30

Prohibitions

3-28

Lubricating the slew motor pinion

5-30

Cautions

3-29

Draining the water from the fuel tank.. 5-31

Preventing the rubber crawlers from

Inspecting the battery fluid level and

coming off

3-29

replenishing

5-32

Every 100 hours

5-34

Transport

4-1

Cleaning the water separator

5-34

Loading and unloading

4-2

Cleaning the fuel filter

5-34

Hoisting the machine

4-4

After the initial 250 hours

Securing the machine

4-6

(only for new machines)

5-35

Replacing the travel motor gear oil

5-35

Maintenance

5-1

Every 250 hours

5-36

General

5-2

Replacing the engine oil and the oil

Maintenance overview

5-2

filter

5-36

Cautions on maintenance

5-2

Inspecting and adjusting the fan belt.. 5-36

Service data

5-4

Cleaning the air cleaner

5-36

Fuel and lubricant table

5-4

Cleaning the radiator fins and oil

Regularly replace the hydraulic oil

5-8

cooler fins

5-38

List of consumables

5-9

Cleaning the air filters

5-39

List of tools

5-10

Every 500 hours

5-40

List of tightening torques

5-11

Replacing the hydraulic oil return filter.5-40

Safety-critical parts

5-12

Replacing the water separator filter

5-40

Maintenance list

5-14

Replacing the fuel filter

5-41

Walk-around inspection

5-16

Every 1000 hours

5-42

Inspecting by opening the engine hood

Replacing the travel motor gear oil

5-42

and covers

5-16

Cleaning the engine cooling system

5-42

Inspecting by walking around the

Replacing the air cleaner element

5-44

machine

5-17

Inspecting and adjusting the engine

Inspecting while sitting in the

valve clearance

5-45

operator’s seat

5-17

Retightening the engine cylinder

Daily inspection (every 10 hours)

5-18

head bolt

5-45

Inspecting and replenishing the

Every 1500 hours

5-46

coolant

5-18

Inspecting and cleaning the engine

Inspecting and replenishing the

fuel injectors

5-46

engine oil

5-19

Inspecting the crankcase breather

Inspecting the dust indicator

5-19

system

5-46

Inspecting the water separator

5-20

Every 2000 hours

5-47

Inspecting the fuel level

5-20

Lapping the engine valve seats

5-47

Inspecting the hydraulic oil tank level

Every 4000 hours

5-48

and replenishing

5-21

0-6

Replacing the hydraulic oil and

cleaning the suction strainer

5-48

When required

5-50

Replacing the bucket teeth

5-50

Replacing the bucket

5-52

Lubricating the levers

5-54

Inspecting the rubber crawlers

5-55

Replacing the rubber crawlers

5-56

Maintenance during extended storage

period

5-58

Troubleshooting

6-1

Symptoms that are not malfunctions

6-2

If the engine overheats

6-3

If the battery goes dead

6-4

If a fuse blows

6-6

Inspecting and replacing the fuse

6-6

Inspecting the fusible link

6-7

Restarting after adding fuel

6-8

Bleeding air from the fuel system

6-8

If a warning lamp flashes

6-9

Other symptoms

6-10

Lowering the boom to the ground

6-12

Towing

6-13

If the cab or canopy is damaged

6-14

Specifications

7-1

Basic Specifications

7-2

Machine dimensions

7-4

Operating ranges

7-8

Lifting Capacities

7-11

Options

8-1

General precautions

8-2

Safety precautions

8-2

Cautions when installing attachments... 8-2

Cautions when operating attachments. 8-3

Attachment combination table

8-4

Selecting a lever pattern

8-5

Switching the lever pattern

8-5

Hydraulic breaker

8-6

Replacing the hydraulic oil regularly

8-7

Load safety device

8-8

Emergency shut-off valve

8-8

Overload warning device

8-9

Travel alarm

8-10

Optional equipment mass

8-11

Biodegradable oil

8-12

Replacing the hydraulic oil with

biodegradable oil

8-12

0-7

Safety

General precautions

When a problem is found on the machine

General precautions

It is your responsibility to observe all

If any problem (noise, vibration, smell,

pertinent laws and regulations and to

disorder of instrument, smoke, oil leak,

follow the manufacture’s instructions on

wrong indication of alarm or unusual

machine operation, inspection and

indication in the instrument cluster, etc.) is

maintenance.

detected during the operation or inspection

and maintenance of the machine,

Virtually all accidents occur as the result of a

immediately inform your sales or service

failure to observe basic safety rules and

dealer and take proper actions. Do not

precautions.

operate the machine until the trouble is

Most accidents can be prevented by

cleared.

identifying the potentially hazardous

situations beforehand.

Read and understand all safety messages

Operating temperature range

which describe how to prevent accidents.

Do not operate the machine until you are

To maintain the performance of machine and

sure that you have gained a proper

to prevent it from early wear, observe the

understanding of its operation, inspection

following operating conditions.

and maintenance.

• Do not operate the machine if the ambient

temperature is higher than +45°C (+113°F)

or lower than -15°C (+5°F).

Observe all safety rules

· If operated at an ambient temperature of

higher than +45°C (+113°F), the engine

• Operation, inspection and maintenance of

may overheat and cause the engine oil to

this machine must be performed only by a

degrade. Also, the hydraulic oil may

trained and qualified person.

become very hot, causing damage to the

• All rules, regulations, precautions and

hydraulic equipment.

safety procedures must be understood and

· If operated at an ambient temperature of

followed when performing operation,

lower than -15°C (+5°F), the parts made

inspection and maintenance of this

of rubber such as gaskets may get

machine.

hardened to cause an early wear or

• Do not perform any operation, inspection

damage to the machine.

and maintenance of this machine when

· If the machine is to be used outside the

under the adverse influence of alcohol,

ambient temperature range described

drugs, medication, fatigue, or insufficient

above, consult your sales or a service

sleep.

dealer.

1-2

Safety

General precautions

Wear appropriate clothing and protective

Install a fire extinguisher and first aid kit

equipment

Be prepared for fire and accidents

• Do not wear loose clothing or any

• Install an extinguisher and a first aid kit,

accessory that can catch on controls or in

and learn how to use them.

moving parts.

• Lean how to fight a fire and how to deal

• Do not wear oily or fuel stained clothing

with accidents.

that can easily catch fire.

• Know how to contact emergency

• Wear a hard hat, safety shoes, safety

assistance and make a list of emergency

glasses, filter mask, heavy gloves, ear

contacts.

protection and other protective equipment

as required by job conditions. Wear

required appropriate equipment such as

Never remove safety equipment

safety glasses and filter mask when using

grinders, hammers or compressed air, as

metal fragments or other objects can fly

and cause serious injury.

• Use hearing protection when operating the

machine. Loud prolonged noise can cause

hearing impairments, even the total loss of

hearing.

• Make sure all protective guards, canopies

and doors are in place and secured. Repair

or replace damaged parts before operating

the machine.

• Know how to use the safety lock lever, seat

belt and other safety equipment and use

them properly.

• Never remove any safety equipment except

for servicing. Keep all safety equipment in

good operating condition.

1-3

Safety

General precautions

Use a signal person and a flag person

Cautions when standing up from or

leaving the operator’s seat

Learn how to use the hand signals required

for particular jobs and make sure who has

• Before standing up from the operator’s

the responsibility for signaling.

seat to open/close the window or remove/

• All personnel must fully understand all the

install the lower window, lower the working

signals.

equipment to the ground, raise the safety

• The operator must respond to signals only

lock levers to engage the lock and stop the

from the appointed signal person, but must

engine. If any controls should be

obey a stop signal at any time from

accidentally touched when the safety lock

anyone.

levers is lowered (unlocked), the machine

• The signal person must stand in a clearly

will suddenly move and cause serious

visible location when giving signals.

injury or death.

• Note that the dozer blade, boom swing

and auxiliary hydraulic controls cannot be

locked, even when the safety lock lever is

set to the locked position.

Do not carelessly touch these controls.

• Be careful not to touch the operating levers

when raising or lowering the safety lock

levers.

• Before leaving the operator’s seat, lower

the working equipment to the ground, raise

the safety lock levers to engage the lock

and stop the engine. Also, be sure to

remove the key, lock the door and covers,

take it with you and store it in a specified

place.

1-4

Safety

General precautions

Avoid fire and explosion hazards

• When handling the fuel, washing oil or

paint, open the door and windows to

ventilate thoroughly.

• Store all flammable fluids and materials in a

safe and well-ventilated place.

• The short circuit of the electric system may

cause the fire. Check for any loosened

connections or damage to the wires every

day. Retighten the loosened connector and

wire clamp. Fix or change the damaged

wire.

• Fire from the pipes:

Make sure that the clamps, guards and

Keep flames away from fuel, oil, grease and

cushions of the hoses and tubes are

antifreeze. Fuel is particularly flammable and

securely fixed. If not, hoses or tubes may

dangerous.

be damaged due to vibration or contact

• When handling these combustible

with other parts during operation. This can

materials, keep lit cigarettes, matches,

cause the high-pressure oil to spurt out,

lighters and other flames or sources of

resulting in the fire or injury.

flames away.

• Do not smoke or permit open flames while

handling fuel or working on the fuel system.

• Do not leave the location while refilling with

fuel or oil.

• Never remove the fuel cap or add fuel

when the engine is running or still hot. Also,

do not spill the fuel on the hot surface of

the machine or the component of the

electric system.

• Clean up spilled fuel or oil immediately.

• Check for fuel, oil leak. Stop all leaks and

clean the machine before operating.

• When operating with grinder or welding,

move inflammables to a safe place.

• Do not cut or weld on pipes or tubes that

contain flammable fluids. Clean thoroughly

with nonflammable solvent before cutting

or welding.

• Remove all trash or debris from the

machine. Make sure that oily rags or other

flammable material are not stored on the

machine.

• Handle all solvents and dry chemicals

(foam type fire extinguisher) according to

procedures identified on manufacturer’s

containers. Work in a well-ventilated area.

• Never use fuel for cleaning purposes.

Always use a nonflammable solvent.

1-5

Safety

General precautions

Exhaust fumes from the engine is

Be careful not to get crushed or cut

poisonous

Never put your hands, feet or other parts of

• Do not operate the engine in an enclosed

your body between the upperstructure and

area without adequate ventilation.

the undercarriage or tracks, between the

• If natural ventilation is not possible, install

machine body and working equipment, or

ventilators, fans, exhaust extension pipes

between a cylinder and moving part. The

or other venting devices.

sizes of these gaps change when the

machine moves, and a person can suffer

severe injury or death.

Handling asbestos dust

Inhaling asbestos dust can cause lung

cancer. When handling the materials which

may contain asbestos, take the following

precautions:

• Never use compressed air for cleaning.

• Avoid brushing or grinding parts containing

asbestos.

• For clean up, use a vacuum equipped with

a high efficiency particulate air filter (HEPA).

• Wear the stipulated respirator if there is no

other way to control the dust. When

working indoors, install a ventilation system

with a macromolecular filter.

• Do not allow unauthorized personnel in the

work area while working.

• Follow the rules and environmental

standard applicable to the work area.

1-6

Safety

General precautions

Using optional products

Never modify the machine

• Consult with Takeuchi before installing

Unauthorized modifications to this machine

optional attachments. Depending on the

can cause injury or death. Never make

type of attachments or the combination of

unauthorized modifications to any part of this

them, the attachment may come into

machine.

contact with the operator’s compartment

or the other parts of the machine. Make

sure that the optional attachment installed

is not contacted with other parts before

use.

• Do not use attachments that have not

been approved by Takeuchi. Doing so may

compromise safety or adversely affect the

machine’s operation or service life.

• Takeuchi will not be held responsible for

any injuries, accidents or damage to its

products caused by the use by a non-

approved attachment.

1-7

Safety

Precautions when preparing

Precautions when

preparing

Know the work area

Before starting operation, know the working

area condition to ensure a safety operation.

• Inspect the topography and ground

condition of the working area, or the

structure of the building when working

indoors, and take the safety precautions as

necessary.

• Be sure to avoid all hazards and

obstructions such as ditches, underground

lines, trees, cliffs, overhead electrical wires,

or places where there is a danger of falling

rocks or slides.

• Check with the administrator for the

locations of buried gas pipes, water pipes

and power cables. If necessary, determine

what specific precautions must be taken to

insure safety by consulting with the

administrator.

• When working on roads, be sure to

consider the safety of pedestrians and

vehicles.

· Use a flag person and/or a signal.

· Fence off the working area and keep off

unauthorized persons.

• When working in water or crossing shallow

streams or creeks, check the depth of the

water, the solidity of the ground and the

water flow speed beforehand.

Refer to “Cautions on operating” for further

instructions.

1-8

Safety

Precautions when preparing

Check the strength of the bridge

Always keep the machine clean

When traveling over a bridge or a structure,

check the permissible load. If the strength is

insufficient, reinforce the bridge or the

structure.

• Clean windows, mirrors and lights to

ensure good visibility.

Adjust the mirror to the best position for

the operator to see the rear view (blind

spot) from the operator’s seat.

• Wipe off any oil, grease, mud, snow or ice,

to prevent accidents due to slipping.

• Remove all loose objects and unnecessary

devices from the machine.

• Remove any dirt, oil or grease from the

engine area to prevent fires.

• Clean around the operator’s seat and

remove any unnecessary object from the

machine.

1-9

Safety

Precautions when preparing

Perform inspection and maintenance

Cautions in the operator’s compartment

every day

• Remove mud and grease from shoe soles

before entering the operator’s

compartment. Pedaling the machine with

the shoes with mud and grease will cause

a slip accident.

• Do not leave the parts or tools around the

operator’s seat.

• Do not leave any plastic bottles in the

operator’s compartment or attach any

suction cups on the window glass. The

plastic bottle or suction cup act as a lens

and can cause fire.

Failure to identify or repair the irregularities or

• Do not use the mobile phone during

damage on machine can lead to accidents.

traveling or working.

• Before operating, perform the specified

• Do not bring combustibles or explosives

inspection and make prompt repairs where

into the operator’s compartment.

necessary.

• Do not leave the cigarette lighter in the

• If a failure occurs and the operation

operator’s compartment. When the room

becomes impossible or the engine fails,

temperature rises, the lighter may explore.

immediately stop the machine by following

the shutdown procedure, and keep

machine securely parked until the

malfunction is corrected.

1-10

Safety

Precautions when preparing

Emergency exit

Emergency hammer (optional)

Front window (excluding machines with a

front guard)

An emergency hammer is installed to be

used to escape from the cab in an

emergency. When escaping, break the

If you should become trapped inside the

windows with the hammer.

cab, open the front window to get out.

• When breaking the windowpane with a

hammer, take great care not to injure

yourself with the broken glass pieces.

• Remove the glass pieces from the window

sill so as not to cut yourself when

evacuating. Broken glass will fall from the

window, so be careful of your footing and

do not slip on the glass.

1-11

Safety

Precautions when starting

Precautions when

starting

Support your weight in a three point

secure stance when getting on/off the

machine

• Do not jump on or down from the machine.

Never attempt to get on or off the moving

machine.

• When getting on or off the cab, first fully

• Check if there is a “DO NOT OPERATE”

open the door to the locked position and

alert sign or similar sign is on the cab door,

check that it does not move (for machines

controls or starter switch. If there is one, do

with cab).

not start the engine or touch any levers.

• Sound the horn to warn people around the

machine.

Sit in the operator’s seat and start the

engine

• Adjust the seat to securely latch it.

• Climb up/down the steps facing the

machine and holding the handrail to

support your weight in a three point secure

stance (hand and feet).

• Never use the safety lock lever or control

levers as hand holds.

Before starting the machine, ask any

• Fasten the seat belt.

unauthorized personnel to leave the area

• Check if the parking brake is on and all

control levers and pedals are in the neutral

Do not start the engine until you are sure it is

position.

safe to start the machine by checking the

• Check if the safety lock lever is in the lock

following items.

position.

• Walk around the machine and warn the

• Make sure that no one is near the machine.

person who is servicing the machine or is

• Start and operate the machine only from

walking near the machine. Do not start the

the operator’s seat.

machine until you are certain that no one is

• Never attempt to start the engine by

around the machine.

shorting across the starter terminals.

1-12

Safety

Precautions when starting

Starting with jumper cables

In cold climates

Use jumper cables only in the recommended

• Be careful of slippery conditions on freezing

manner. Improper use of jumper cables can

ground, steps and hand holds.

result in battery explosion or unexpected

• In severe cold climates, do not touch any

machine motion.

metal parts of the machine with bare

Refer to “If the battery goes dead” for further

hands. The skin will freeze to the metal,

instructions.

resulting in severe injury.

• Do not use ether or starting fluid on this

engine. The starting fluids can cause

After starting the engine

explosion and serious injury or death.

• Warm up the engine and hydraulic oil. If the

After starting the engine, perform the

levers are operated without warming, the

operations and checks described below in a

machine will not react or move promptly or

safe place with no persons or obstacles in

properly, resulting in accident.

the area. If any malfunction is found, follow

the shutdown procedure and report the

malfunction.

• Warm up the engine and hydraulic oil.

• Check if all gauges and warning devices

are properly working.

• Check for any noises.

• Test the engine speed control.

• Operate each control to ensure they are

properly working.

1-13

Safety

Precautions when operating

Do not permit riders on the machine

Precautions when

operating

Operate the machine with the maximum

crawler width

Do not allow anyone to ride on any part of

the machine at any time while traveling or

operating.

AD6A001

• Always operate the machine with the

Check if the work area is safe and secure

crawler width extended to 1300 mm (51.2

before operation

in.) to maximize the machine stability. If the

machine is operated with the crawler width

narrowed (980 mm, 38.6 in.), the machine

may tip over due to its poor stability.

• If the machine must be operated with the

narrowed crawler width (980 mm, 38.6 in.),

traveling should be done after folding the

hoe attachment, lowering the boom to

lower the center of gravity and keeping the

machine facing forward.

Ensure good visibility

• Confirm the performance limits of the

machine.

• When working in dark places, turn on the

• Use a signal person at road shoulders,

machine’s working lights and headlights

narrow places or where your vision is

and additional lighting equipment installed,

obstructed.

as necessary.

• Never allow anyone to enter the machine’s

• When visibility is poor due to bad weather

slewing radius and path.

(fog, snow, rain or a cloud of dust), stop

• Signal your intention to move by sounding

operating the machine and wait until

the horn.

visibility improves.

• There is a blind spot in the rear of the

machine. Before traveling in reverse, check

that the area is safe and clear.

1-14

Safety

Precautions when operating

Check the position of the undercarriage

Travel safely

(tracks) before traveling

• Travel with the dozer blade raised, the hoe

Before operating the travel levers/pedals,

attachment folded as shown on the figure

make sure that the dozer blade is to the front

above, and the bucket raised 30 to 40 cm

of the operator’s seat. Remember that when

(12 to 16 in.) above the ground.

the dozer blade is to the rear of the

• Do not slew while traveling. If you must

operator’s seat, the travel levers/pedals must

operate the hoe attachment while traveling,

be operated in the reverse direction from

operate at speeds slow enough so you

when it is to the front.

have complete control at all times.

• Avoid crossing over obstacles whenever

possible. If you must do so, keep the hoe

attachment close to the ground level and

travel slowly. Never cross obstacles which

will tilt the machine to an angle of 10° or

greater.

• On uneven ground, maintain the low speed

and avoid starting, stopping or changing

directions abruptly. Otherwise, the working

equipment may come in contact with the

ground, causing the machine to lose its

balance and get damaged or to damage

the structures in the surrounding area.

1-15

Safety

Precautions when operating

Cautions on traveling on slopes

• When traveling on slopes or grades, drive

slowly in 1st (low) speed. When

When traveling on slopes or grades, be

descending a slope, slow down the engine

careful that the machine does not tip (roll)

speed.

over or slide.

• Do not descend slopes in reverse.

• Never travel on slopes that are too steep

for the machine to maintain its stability

(maximum gradeability: 30°, lateral tipping

angle: 10°). Note that in reality, the

machine’s stability becomes lower than the

above values depending on the working

condition.

• Do not change directions on slopes or

traverse slopes. First return to a flat

surface, and then take an alternative path.

• The machine may slip sideways even on a

slight slope if the ground is covered with

grass or dead leaves, or when traveling on

a wet metal plate or frozen surfaces. Make

sure the machine is never positioned

sideways on slopes.

• If the machine is stalled on the slope,

return each operating lever to the neutral

position before restarting the engine.

• When climbing a hill, keep the operator’s

seat facing the hillside. When descending a

hill, keep the operator’s seat facing the

downhill direction. In either case, travel

must be done while paying attention to the

ground in front of the machine.

• 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.

1-16

Safety

Precautions when operating

Operate the machine on snow or ice with

Ensure driver’s safety when loading

extra care

• When traveling on snow or on frozen

surfaces, drive at a low speed and avoid

starting, stopping or changing directions

abruptly.

• In the snowy area, the road shoulder and

objects placed beside the road are buried

in the snow and cannot be seen. There is a

hazard of the machine tipping over or

hitting covered objects, so always carry out

operations carefully.

• If the machine enters deep snow, there is a

Do not load a truck unless the truck driver is

hazard that it may tip over or become

in a safe place.

buried in the snow.

• Never swing or position the bucket over a

Be careful not to drive beyond the road

person or the cab room.

shoulder or to get trapped in a snow drift.

• Load the truck from the rear.

• With frozen ground surfaces, the ground

becomes soft when the temperature rises,

and this may cause the machine to tip

over, resulting in an operator trapped inside

the machine.

• When parking the machine on an unstable

ground, lower the dozer blade.

Do not move the bucket over the heads of

people

Moving the bucket over the heads of people

entails the danger of the load spilling or the

sudden dropping of the bucket.

1-17

Safety

Precautions when operating

Keep a safe distance from the overhead

high-voltage cables

• Pay also careful attention to the high-

voltage electric cables buried underground.

Never bring any part of the machine or

loaded material to near to the high voltage

cables unless all safety precautions required

by the local and national authorities have

been installed. If a person comes near to the

machine that is discharging sparks or

located near to or in contact with the power

source, there is a hazard of electric shock

and death.

• Always maintain a safe distance between

the machine and the high-voltage electric

cable.

• Check with the local power company

about safe operating procedure before

starting operations.

• Consider all cables to be high-voltage

cables and treat all cables as energized

even though it is known or believed that

the power is shut off and the cables are

visibly grounded.

• Use a signal person to give warning if the

machine approaches too close to the

high-voltage electric cables.

• Caution all personnel in the work area not

to come close to the machine or the

loaded material.

1-18

Safety

Precautions when operating

Watch out for hazardous working

conditions

• Do not enter areas where there is soft

ground. Doing so could cause the machine

to tilt under its own weight, resulting in a

• Never undercut a high bank. Doing so is

machine tipping over or sinking into the

dangerous as it may cause ground

ground.

collapse.

• Do not operate in places where there is a

danger of falling rocks.

• Do not come close to unstable grounds

(cliffs, road shoulders, deep ditches). If the

ground should collapse under the weight

• Maintain a safe distance between the

or vibration of the machine, there is a

machine and the edge of the digging site.

hazard that the machine may fall or tip

Do not dig the ground under the front of

over.

the machine.

· Remember that the soil after heavy rain

• When working close to the cliffs or road

or blasting is weak.

shoulders, to make it easier to escape if

· The ground of top of the embankment

there is any problem, set the crawlers at

and of the circumferences of the

right angles to the cliff or road shoulder and

excavated ditches are also weak.

the dozer blade to the front when carrying

out operations.

1-19

Safety

Precautions when operating

• Do not use the impact force of the hoe

attachment for breaking work. There is a

hazard of serious injury being caused by

flying pieces of broken materials and by the

damaged hoe attachment.

• Do not perform demolition work under the

machine. There is a hazard that the

machine may fall down, because the

ground becomes unstable.

• When working on or from the top of

buildings or other structures, check the

strength and the structure before starting

operations. If a building or structure

collapses, serious injury or damage will

result.

• When doing demolition work, do not

perform demolition above your head. There

is a hazard of broken parts falling or of the

building collapsing and causing serious

injury or damage.

1-20

Safety

Precautions when operating

Operating on slopes is dangerous

Never slew (swing) sideways with a heavy

load

When operating on slopes or grades, slewing

or operation of working equipment may

cause the machine to lose stability and tip

over. Avoid operating on slopes whenever

possible.

The machine can tip over more easily in the

lateral direction than in the longitudinal

direction.

• Do not slew (swing) sideways with a heavy

load at the tip of the hoe attachment. In

• Level off the work area.

particular, do not slew (swing) sideways on

slopes.

• The tip of the attachment is heavier for

machines equipped with breakers,

crushers or long arms than for machines

equipped with the standard bucket. For

such machines with heavier tips, do not

perform excavation with the digging arm

(boom) facing the downhill direction or

operate toward sideways.

Be careful with the overhead objects

• Avoid slewing to the downhill direction with

the bucket full of loaded material. This will

reduce the stability of the machine and

may result in tipping over.

When operating under bridges, in tunnels,

near electric cables or indoors, be careful not

to let the boom or arm hit overhead objects.

1-21

Safety

Precautions when operating

Excavators are not designed for lifting

Be careful with flying objects

loads

This machine is not equipped with protective

equipment to protect the operator from flying

objects. Do not use this machine in places

where there are risks of the operator being

hit by flying objects.

Cautions when towing

This machine is specifically designed for

excavation work. Therefore, it has no safety

equipment for crane operation. Extreme

caution should be paid if the excavator is

used for lifting.

• Never lift loads in excess of capacity.

Overload will cause the machine to roll and

can result in serious injury or death.

• All rated lift capacities are determined by

When towing, serious injury or death could

using a machine placed on a stable and flat

result, if performed incorrectly or the wire

ground. For a safe lifting work, the user is

rope being used is inappropriate or not

expected to make due allowance for the

properly inspected.

particular job conditions. They include, soft

• It becomes dangerous if the wire rope

or uneven ground, non-level condition, side

breaks or becomes disengaged. Use a

loads, dynamic or jerked loads, hazardous

wire rope appropriate for the required

conditions, and experience of personnel.

tractive force.

The operator and other personnel should

• Do not use a wire rope that is kinked,

fully acquaint themselves with the

twisted or otherwise damaged.

operator’s manual before operating this

• Do not apply heavy loads abruptly to the

machine, and rules for safe operation of

wire rope.

equipment shall be adhered to at all times.

• Wear safety gloves when handling the wire

• The bucket linkage or lifting device may fail

rope.

if chains or lifting device are incorrectly

• Make sure there is an operator on the

attached, resulting in serious injury or

machine being towed as well as on the

death.

machine that is towing.

• Do not attempt to pull stumps out of the

• Never tow on slopes.

ground when using the machine as a

• Do not let anyone come near to the wire

crane. The loads imposed on the machine

rope while towing.

under this use are completely unknown.

• Do not allow anyone to stand on or under

the lifted loads or come close to the work

area.

1-22

Safety

Precautions when stopping

• Before leaving the machine, do the

Precautions when

followings:

1. Lower the bucket and the dozer blade to

stopping

the ground.

Park safely

2. Raise the safety lock lever to the locked

position.

3. Stop the engine and remove the starter

key.

4. Lock the cab and covers and take the

key with you.

• Park the machine on a flat, rigid and safe

ground. Set the parking brake.

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.

1-23

Safety

Precautions when transporting

• Chock the tracks and secure the machine

Precautions when

to the truck bed with wire rope or chain.

transporting

Load/unload the machine safely

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 rumps

are bowed down too low, support them

with poles or blocks.

• Never use the working equipment to load

or unload the machine. Doing so may

result in tipping over or falling down of the

machine.

• Keep the truck bed and loading ramps

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

materials to prevent the machine from

sliding sideways. Clean the crawlers.

• Chock the transporter wheels to prevent

movement.

• 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.

1-24

Safety

Precautions when transporting

Hoist the machine safely

Transport the machine safely

• Know and use correct crane signals.

• Know and follow the applicable safety

• Check the hoisting equipment for damaged

rules, vehicle code and traffic laws when

or missing parts on a daily basis and

transporting the machine.

replace as necessary.

• Select the best transport route by

• When hoisting, use a wire rope capable of

considering the length, width, height and

lifting the machine mass.

weight of the truck with the machine

• Hoist the machine in such a manner

loaded on it.

described in the procedure below. Do not

• Never abruptly start or stop or run at a high

do it in any other manner, as it may result in

speed at the sharp curves during transport.

the machine losing its balance.

Doing so will move or lose the balance of

Refer to “Hoisting the machine” for further

the loaded machine.

instructions.

• Do not hoist the machine with an operator

on it.

• When hoisting, hoist slowly so that the

machine does not tip.

• Keep everyone out of the area when

hoisting. Do not move the machine over

the heads of the persons.

1-25

Safety

Precautions on maintenance

Replace safety-critical parts periodically

Precautions on

• Replace fuel hoses periodically. Fuel hoses

maintenance

wear out over time, even if they do not

Display a “DO NOT OPERATE” alert sign

show any symptom of wear.

• Regardless of the replacement schedule,

Severe injury could result if an unauthorized

replace immediately if a symptom of wear

person should start the engine or touch

is found.

controls during inspection or maintenance.

Refer to “List of safety-critical parts” for

• Before performing maintenance, stop the

further details.

engine, remove the key and take it with

you.

Explosionproof lighting

• Display a “DO NOT OPERATE” alert sign

on easy-to-see locations such as on the

To prevent an ignition or explosion, use

starter switch or on control levers.

explosion-proof lights when inspecting fuel,

oil, coolant or battery fluid. Otherwise,

explosion could result causing serious injury

Use the correct tools

or death.

Do not use damaged or weakened tools or

tools designed for other purposes. Use tools

appropriate for the work involved.

1-26

Safety

Precautions on maintenance

Prohibit access by unauthorized persons

Always keep the machine clean

Do not allow unauthorized personnel in the

• Clean the machine before performing

work area while working. Be careful when

maintenance.

grinding, welding or using a hammer. You

• Stop the engine before washing the

could be injured by flying debris from the

machine. Cover the electrical parts so that

machine.

water cannot enter. Water on electrical

parts could cause short-circuits or

malfunctions. Do not use water or steam to

Prepare work area

wash the battery, electronic control

components, sensors, connectors or the

• Select a firm, level work area. Make sure

operator’s compartment.

there is adequate light and, if indoors,

ventilation.

• Clear obstacles and dangerous objects.

Stop the engine before performing

Eliminate slippery areas.

maintenance

• Avoid lubrication or mechanical

adjustments while the machine is moving

or while the engine is running when the

machine is not moving.

• 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/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.

1-27

Safety

Precautions on maintenance

Stay clear of the moving parts

Secure the working equipment

To prevent unexpected movement, firmly

secure the working equipment when

repairing or replacing the bucket teeth or

side cutter.

Secure the engine hood or cover when

opened

Be sure to secure the engine hood or cover

before working the inside. Do not keep the

• Stay clear of all rotating and moving parts.

hood or cover open on a windy day or if the

If a hand or tool becomes trapped in the

machine is parked on a slope.

rotating or moving part, serious injury or

death could result.

• If a tool or other objects is dropped or

Place heavy objects in a stable position

inserted in the fan or fan belt, it will be

flown or cut in pieces. Do not drop or insert

anything in the fan or fan belt.

Firmly secure the machine or any

component that may fall

When it is necessary to temporally place a

heavy object or an attachment on the ground

during removal or installation, be sure to

place it in a stable position. Keep off

unauthorized persons from the storage place

for such object.

• Before performing maintenance or repairs

under the machine, lower all moveable

working equipment to the ground or in the

lowermost position.

• Chock the tracks.

• 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 the

machine or working equipment if they are

not sufficiently supported. This procedure

is especially important when working on

hydraulic cylinders.

1-28

Safety

Precautions on maintenance

Cautions when refueling

Be careful with hot and pressurized

components

• Do not smoke or permit open flames while

fueling or near fueling operations.

Stop the engine and allow the machine to

• Never remove the fuel cap or add fuel

cool down before performing maintenance.

when the engine is running or still hot. Do

• The engine, muffler, radiator, hydraulic

not spill fuel on the hot surface of the

lines, sliding parts and many other parts of

machine.

the machine are hot immediately after the

• Fill the fuel tank in a well ventilated place.

engine is stopped. Touching these parts

• Do not fill the fuel tank to capacity. Allow

will cause burns.

room for oil expansion.

• The engine coolant, hydraulic oil and other

• Clean up spilled fuel immediately.

oils are also hot and under high pressure.

• Securely tighten the fuel filler cap. If the fuel

Be careful not to touch the hydraulic oil

cap is lost, replace it only with the genuine

when loosening the cap or plug. Working

cap. Use of a non-approved cap without

on the machine under these conditions

proper venting may result in pressurization

could result in burns or injuries due to the

of the tank.

hot oil spurting out.

• Never use fuel for cleaning.

• Use the correct grade of fuel for the

operating season.

Handling of hoses

Oil leak or fuel leak can cause a fire.

• Do not twist, bend or hit the hoses.

• Never use twisted, bent or cracked pipes,

tubes or hoses; otherwise, they may burst.

• Retighten loose connection.

1-29

Safety

Precautions on maintenance

Be careful with hot cooling systems

Release pressure before working on the

hydraulic system

Oil may spurt out if caps or filters are

removed or pipes are disconnected before

releasing the pressure in the hydraulic

system.

• Gradually loosen the vent plug to relieve

tank pressure.

• 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.

Do not remove the radiator cap or the drain

• Oil or plug may spurt out according to the

plug when the cooling water is hot. Stop the

pressure in the travel motor case. Loosen

engine and wait until the engine and the

the plug slowly and release the internal

cooling water cool. Then, slowly loosen the

pressure.

radiator cap to release the internal pressure

and remove it.

Be careful with debris when the hammer

Be careful with oil internal pressure

is being used

Pressure is maintained in the hydraulic circuit

When using a hammer, pins may fly out or

long after the engine has been shut down.

metal particles may be scattered. This may

• Completely relieve the internal pressure

lead to serious injury.

before performing maintenance work.

• If hard metal parts such as pins, bucket

teeth, side cutter or bearings are hit with a

hammer, wear protective gear such as

safety goggles and gloves.

• When hitting pins or bucket teeth, always

check that there is no one in the

surrounding area.

• The hydraulic oil is high enough pressure to

penetrate the skin or eyes and cause

serious injury, blindness or death.

Remember that the hydraulic oil escaping

from a small hole is almost invisible. When

checking for leaks, wear protective goggle

and thick gloves, and use a paperboard or

plywood to keep your skin from oil

spurting.

If oil penetrates the skin, it must be

surgically removed within a few hours by a

doctor familiar with this type of injury.

1-30

Safety

Precautions on maintenance

Be careful with the high-pressure grease

Handling of the accumulator

AG7A086

In the track adjuster, the grease has been

Be sure to handle the high-pressure nitrogen

injected under high pressure. If the tension is

gas enclosed in the accumulator with care. If

adjusted without following the prescribed

handled incorrectly, it could explode and

procedure, the grease discharge valve may

cause serious injury. Strictly observe the

fly off, resulting in injury.

following precautions:

• Never loosen the grease fitting.

• Do not disassemble.

• Loosen the grease discharge valve slowly.

• Do not allow flame near or throw it into a

Do not turn it more than one turn.

fire.

• Do not put your face, arms, legs or body in

• Do not drill, weld or fuse.

front of the grease discharge valve.

• Do not subject it to physical shock such as

• If grease does not come out when the

hitting, rolling or dropping.

grease discharge valve is loosened, the

• Before disposing of the unit, the sealed gas

valve is faulty. Ask a Takeuchi service agent

must be drained. Contact a Takeuchi

for repair.

service agent for help.

Never disassemble the track adjuster

There is a very strong spring contained in the

track adjuster. If the track adjuster is

accidentally disassembled, the spring can

pop out, resulting in serious injury Never

disassemble the track adjuster.

1-31

Safety

Precautions on maintenance

Disconnect the battery wiring

• Do not charge a battery or jump-start the

engine if the battery is frozen; otherwise it

may explode. Warm the frozen battery to

15°C (60°F) before use.

• Do not use the battery when the fluid level

is below the lower level limit. Doing so will

hasten the deterioration of the internal

portions of the battery and shorten the

battery life. It also can cause rupturing

(explosion).

• Do not add the distilled water above the

upper level limit. Doing so could cause the

fluid to leak. This fluid can cause skin

Disconnect the battery wiring before working

damage if contacted, or can cause the

on the electrical system or doing electric

machine components to corrode.

welding. Disconnect the negative (-) battery

• Use a dampened cloth to clean around the

cable first. When reconnecting, connect the

fluid level line and check the fluid level. Do

negative (-) battery cable last.

not clean with a dry cloth; otherwise it

could cause static electricity to build up,

resulting in ignition or explosion.

Use caution when handling batteries

• Batteries contain sulfuric acid which will

damage the eyes or skin in case of

contact.

· 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.

• Wear protective goggle and gloves when

working with batteries.

• Batteries generate flammable hydrogen

gas which may explode. Keep away from

flame, sparks, fire or lighted cigarettes.

• When checking the level of the battery

fluid, use a flashlight.

• Be sure to stop the engine by turning off

the starter switch before inspecting or

handling the battery.

• Be careful not to let metal tools or any

metal objects come into contact with the

battery terminals and cause a short circuit.

• Loose battery terminals may result in

sparks. Be sure to fasten terminals tightly.

• Make sure the battery caps are tightened

securely.

1-32

Takeuchi Mini Excavator TB216 (No.216000002~, No.216100002~). Operator's Manual - page 1