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

Maintenance

Every 100 hours

Cleaning the fuel filter

Every 100 hours

Cleaning the water separator

• Do not smoke or permit open flames

while handling fuel or working on the

• Do not smoke or permit open flames

fuel system.

while handling fuel or working on the

• Stop the engine in a well-ventilated

fuel system.

place and allow it to cool down before

• Stop the engine in a well-ventilated

performing maintenance.

place and allow it to cool down before

• Clean up spilled fuel immediately.

performing maintenance.

• Clean up spilled fuel immediately.

1. Open the engine hood.

2. Close the valve (2).

1. Open the side cover.

3. Loosen the ring (3), remove and clean the

2. Close the valve (2).

case (4) and the element (5).

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

4. Inspect the O-ring and the element (5). If

clean the case (4), element (5) indicator

there are any scratches or other

ring (6) and spring (7).

irregularities, replace them.

4. Inspect the O-ring and the element (5). If

5. Install the element (5) and the case (4) and

there are any scratches or other

tighten them with the ring (3).

irregularities, replace them.

6. Open the valve (2) to bleed air.

5. Install the indicator ring (6), spring (7),

Refer to “Bleeding air from the fuel

element (5) and case (4), and then tighten

system” on page 6-8.

the ring (3).

6. Open the valve (2) to bleed air.

Refer to “Bleeding air from the fuel

system” on page 6-8.

5-34

Maintenance

After the initial 250 hours (only for new machines)

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

After the initial 250

the very bottom.

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

hours

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

oil.

(only for new machines)

4. Rewrap the plugs with new sealing tape.

Replacing the travel motor gear

5. Tighten the plug (1).

oil

6. Add oil through the hole of the plug (2)

until oil flows out of the hole of the plug

(2).

7. Tighten the plug (2).

• Stop the engine and allow the machine

to cool down before performing

maintenance.

· The travel motor is hot immediately

after the engine is stopped. Touching

it will cause burns.

· The gear oil is also hot and under high

pressure immediately after the engine

is stopped.

Be careful when loosening the plugs.

Working on the machine under these

conditions could result in burns or

injuries.

• The pressure in the reduction gear case

of travel motor may cause oil or the plug

to fly out. Loosen the plug slowly to

release the pressure.

IMPORTANT: If the percentage of the

traveling time within the total operating

time is high, replace the gear oil earlier

than the specified time.

AD6G022

5-35

Maintenance

Every 250 hours

1. Open the engine hood.

Every 250 hours

Replacing the engine oil and the

oil filter

Refer to “Replacing the engine oil and the oil

filter” on page 5-24.

Inspecting and adjusting the fan

belt

Refer to “Inspecting and adjusting the fan

belt” on page 5-25.

2. Loosen the clamps (1) and remove the

dust cup (2).

Cleaning the air cleaner

• Stop the engine and allow the machine

to cool down before performing

maintenance.

· The engine, muffler, radiator and many

other parts of the machine are hot

immediately after the engine is

stopped. Touching it will cause burns.

• Wear required appropriate equipment

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

such as protective goggle and filter

4. Remove the primary element (3).

mask when using compressed air, as

5. Cover the intake hole at the back of the

metal fragments or other objects can fly

body (4) with cloth or tape to prevent dirt

and cause serious injury.

from getting in.

IMPORTANT: Be careful not to scratch the

To prevent dirt from getting inside the

element. Do not use an element if it is

engine, do not remove the secondary

damaged.

element (5).

IMPORTANT: When operating the

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

machine in very dusty places, perform

inspection and maintenance operations

every day.

IMPORTANT: Be sure to install the

element and dust cap securely. If not,

dust could be drawn into the cylinder,

damaging the engine.

5-36

Maintenance

Every 250 hours

7. Clean the primary element (3) with dried

compressed air (294 to 490 kPa or 43 to

71 psi).

First blow the air from the inside of the

element along the pleats. Then blow the

air from the outside and finally from the

inside again.

8. Light up the inside of the primary element

(3) with a light 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 primary element (3).

11. Install the dust cup (2) with its

“ TOP

” mark facing up, and then

fasten it with the clamps (1).

12. Push the button (3) on the dust indicator

to reset the red piston (2).

5-37

Maintenance

Every 250 hours

Cleaning the radiator fins and oil

cooler fins

Wear required appropriate equipment

such as protective goggle and filter mask

when using compressed air, as metal

fragments or other objects can fly and

cause serious injury.

IMPORTANT: Be careful not to damage

the fins when cleaning.

• When using compressed air or

pressurized water, make sure the

pressure is no higher than 200 kPa (28

psi) and hold the nozzle sufficiently

away from the fins.

IMPORTANT: When using water, cover the

electrical system to prevent water from

getting in.

IMPORTANT: When operating the

machine in very dusty places, perform

inspection and maintenance operations

every day.

1. Open the side cover.

2. Blow compressed air on the fins to

remove mud and dirt stuck on them.

5-38

Maintenance

Every 250 hours

Cleaning the air filters

Cleaning

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

psi or less) directly on the filters from the

inside, moving up and down along the

Wear required appropriate equipment

pleats.

such as protective goggle and filter mask

Be sure to keep the nozzle at an adequate

when using compressed air, as metal

distance from the filters.

fragments or other objects can fly and

2. Wash the filter with neutral detergent if it is

cause serious injury.

very dirty. Dry the filter completely after

washing it.

Clean the filters immediately after operating

in dusty places.

Replacing

If the filters are clogged, the air flow is

Replace the filter with a new one once a year

reduced and a booming sound is heard from

or if it is still clogged after blow-drying with

the air conditioner unit.

compressed air and washing.

Removing the filters

1. Move the sheet all the way forward.

2. Take out two screws and open the cover

(1).

3. Remove the air filter (2).

Air filter (2): Part No. 03345-00024

4. Use compressed air or water to clean

each filter, depending on how dirty it is.

5-39

Maintenance

Every 500 hours

Replacing the hydraulic oil

return filter

Refer to “Replacing the hydraulic oil return

filter” on page 5-26.

Replacing the water separator

filter

• Do not smoke or permit open flames

while handling fuel or working on the

fuel system.

• Stop the engine in a well-ventilated

place and allow it to cool down before

performing maintenance.

• Clean up spilled fuel immediately.

1. Open the side cover.

2. Close the valve (2).

3. Loosen the ring (3) and remove the case

(4).

4. Remove the spring (7) and the indicator

ring (6) from the case (4).

5. Clean the case (4).

6. Inspect the O-ring. If there are any

scratches or other irregularities, replace it.

7. Replace the element (5) with a new one.

8. Install the indicator ring (6) and the spring

(7) in the case (4).

9. Install the case (4) to the bracket and

tighten the ring (3) by hand.

10 Open the valve (2) to bleed air.

Refer to “Bleeding air from the fuel

system” on page 6-8.

5-40

Maintenance

Every 500 hours

Replacing the fuel filter

• Do not smoke or permit open flames

while handling fuel or working on the

fuel system.

• Stop the engine in a well-ventilated

place and allow it to cool down before

performing maintenance.

• Clean up spilled fuel immediately.

1. Open the engine hood.

2. Close the valve (2).

3. Loosen the ring (3) and remove the case

(4).

4. Clean the case (4).

5. Inspect the O-ring. If there are any

scratches or other irregularities, replace it.

6. Replace the element (5) with a new one.

7. Install the case (4) to the bracket and

tighten the ring (3) by hand.

8. Open the valve (2) to bleed air.

Refer to “Bleeding air from the fuel

system” on page 6-8.

5-41

Maintenance

Every 1000 hours

• Do not remove the radiator cap or the

Every 1000 hours

drain plug when the cooling water is

Replacing the travel motor gear

hot. Stop the engine and wait until the

oil

engine and the cooling water cool.

Then, slowly loosen the radiator cap

Refer to “Replacing the travel motor gear oil”

and the drain plug to remove them.

on page 5-35.

When cleaning, if the temperature of the

coolant is low, the thermostat will be closed

Cleaning the engine cooling

and the coolant will not circulate in the

system

radiator. Heat the coolant water to at least

90°C (194°F) before cleaning.

1. Open the engine hood.

• Stop the engine and allow the machine

to cool down before performing

maintenance.

· The engine, muffler, radiator and many

other parts of the machine are hot

immediately after the engine is

stopped. Touching these parts will

cause burns.

· The engine coolant is also hot and

under high pressure immediately after

the engine is stopped. Be careful

when loosening the caps or plugs.

2. Gradually loosen the radiator cap (3) to

Working on the machine under these

release the internal pressure, and then

conditions could result in burns or

remove the cap.

injuries due to the hot coolant spurting

out.

• If maintenance must be performed with

the engine running, always work as a

two person team communicating each

other.

· One person must sit in the operator’s

seat so that he/she can immediately

stop the engine when necessary. He/

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

3. Place a pan for catching the waste coolant

or clothing away from the moving part

under the drain plug (4), and then loosen

of the machine.

the drain plug (4) to drain the coolant.

• Standing at the back of the machine

4. Tighten the drain plug (4).

while the engine is running is extremely

5. Add tap water to the radiator through the

dangerous, as the machine could move

coolant fill port up to the top of the port.

suddenly. Never stand at the back of the

Take time and slowly add water, so that no

machine while the engine is running.

air enters the radiator.

6. Close the radiator cap (3).

5-42

Maintenance

Every 1000 hours

7. Start the engine and run it at a speed

slightly above low idling. Raise the water

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

then run the engine for about 10 minutes

with the thermostat open.

8. Stop the engine, wait until the cooling

water temperature becomes lower, and

then remove the drain plug (4) to drain the

water.

9. After draining, clean the cooling system

using a cleaning agent. When using the

cleaning agent, follow the instructions

included with the agent.

10. Repeat the steps 4 to 8 to rinse the

cooling system.

11. Tighten the drain plug (4).

12. Take time and slowly add the new

coolant (mixture of antifreeze and tap

water) to the radiator through the fill port

until it is full.

13. Close the radiator cap (3).

14. Warm up the engine. Use the meters to

check that there are no irregularities in

the cooling system at this time.

15. Increase the water temperature to at

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

for about 10 minutes with the thermostat

kept open.

16. Stop the engine, wait until the cooling

water temperature becomes lower, and

then check the level of coolant in the

radiator.

If necessary, add cooling water until the

radiator is full.

17. Close the radiator cap (3).

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

and then add coolant to the upper limit

(H).

19. When the coolant has been replaced,

inspect the coolant level once again after

operating the machine.

Once the machine is operated, the

coolant is distributed throughout the

entire system, resulting in the lower

coolant level.

Replenish the cooling water that has

been used.

5-43

Maintenance

Every 1000 hours

Replacing the air cleaner element

5. Cover the intake hole at the back of the

body (4) with cloth or tape to prevent dirt

from getting in.

Stop the engine and allow the machine to

Do not yet remove the secondary element

cool down before performing

(5).

maintenance.

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

• The engine, muffler, radiator and many

7. Remove the cloth or tape applied in step

other parts of the machine are hot

immediately after the engine is stopped.

Touching these parts will cause burns.

Remove the secondary element (5).

8. Install the new elements.

IMPORTANT: Do not use an element if its

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

”

pleats, gaskets or seals are damaged.

mark facing up, and then fasten it with the

IMPORTANT: Be sure to install the

clamps (1).

element and dust cap securely. If not,

dust could be drain into the cylinder,

damaging the engine.

1. Open the engine hood.

10. Push the button (3) on the dust indicator

to reset the red piston (2).

2. Loosen the clamps (1) and remove the

dust cup (2).

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

4. Remove the primary element (3).

5-44

Maintenance

Every 4000 hours

Replacing the hydraulic oil and

cleaning the suction strainer

• Stop the engine and allow the machine

to cool down before performing

maintenance.

· The engine and the hydraulic system

and many other parts of the machine

3. Open the engine hood.

are hot immediately after the engine is

4. Slowly loosen the air bleeding plug (1) to

stopped. Touching these parts will

relieve the internal pressure, and then

cause burns.

remove the plug.

· The hydraulic oil is also hot and under

high pressure immediately after the

engine is stopped.

Be careful when loosening the caps or

plugs. Working on the machine under

these conditions could result in burns

or injuries due to the hot oil spurting

out.

• Oil may spurt out if caps or filters are

removed or pipes are disconnected

before releasing the pressure in the

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.

1. Set the machine to the hydraulic oil level

inspection posture.

Refer to “Inspecting the hydraulic oil tank

level and replenishing” on page 5-21.

2. Raise the safety lock lever to the locked

position.

5. Loosen the hose bands and remove the

hose (2) from the flange (3).

6. Loosen the bolts to take out the flange (3).

7. Remove the return filter (4).

8. Place a pan for catching the waste oil

under the drain plug (6).

9. Loosen the drain plug (6) and drain the

hydraulic oil.

5-48

Maintenance

Every 4000 hours

10. Loosen the hose bands and remove the

Bleeding air

hose (7).

11. Loosen the bolts and remove the flange

IMPORTANT: After replacing the hydraulic

(8).

oil, bleed air from the hydraulic circuits

12. Remove the suction strainer (9) and

and hydraulic devices. Failure to do so

clean it.

may damage the hydraulic devices.

13. Clean the inside of the hydraulic tank.

14. Install the suction strainer (9) to the

• Hydraulic pump

flange (8).

1. Open the engine hood.

15. Reinstall the flange (8) and the hose (7)

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

to their original positions.

pump.

16. Install a new return filter to the flange (3).

3. Once hydraulic oil overflows from the vent

17. Reinstall the flange (3) to their original

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

positions.

18. Tighten the drain plug (6).

• Cylinders

19. Add hydraulic oil from the hole of plug (1)

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

up to the level between the upper limit

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

gauge (5).

20. Tighten the plug (1).

21. Bleed air from the hydraulic oil circuit

following “Bleeding air” below.

22. Set the machine to the hydraulic oil level

inspection posture and inspect the oil

level when the oil temperature drops.

Refer to “Inspecting the hydraulic oil tank

level and replenishing” on page 5-21.

speed for 10 minutes.

2. Maintain the engine at low idle, then

extend and retract each cylinder 4 or 5

times, without let them reach the stroke

end.

3. Run the engine at high speed, then extend

and retract each cylinder 4 or 5 times,

without let them reach the stroke end.

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

extend and contract all the cylinders 4 or 5

times to the stroke ends.

5-49

Maintenance

When required

Removal

When required

1. Clean the bucket and park the machine in

Replacing the bucket teeth

a flat, safe place where the ground is hard.

2. Set the bottom surface of the bucket flat

Replace the bucket teeth if the tooth points

and lower it on a block so that the bolt (1)

are worn. Do not wait until the bucket is

can be taken out.

damaged.

3. Remove the starter key, and then check

that the bucket is stable.

• Before performing maintenance or

repairs under the machine, lower all

moveable working equipment to the

ground or in the lowermost position.

• To prevent unexpected movement,

firmly secure the working equipment

when repairing or replacing the bucket

teeth or side cutter.

• When using a hammer, pins may fly out

or metal particles may be scattered.

This may lead to serious injury.

AD6G028

· If hard metal parts such as pins,

4. Remove the bolt (1).

bucket teeth, side cutter or bearings

5. Remove the teeth (2) and the shim (3).

are hit with a hammer, wear protective

gear such as safety goggles and

gloves.

· When hitting pins or bucket teeth,

always check that there is no one in

the surrounding area.

• Do not allow unauthorized personnel in

the work area while working.

Replace the teeth if they are worn to 140

mm (5.5 in.).

5-50

Maintenance

When required

Installation

1. Clean the section where the teeth are to

be installed. If there is gravel or mud on

the section, the tooth point may not go in

all the way.

2. Put the teeth into the bucket.

3. If the teeth are not secured, insert a shim

to reduce the clearance.

4. Insert the bolt from the outside of the

bucket and tighten it with the nut.

· Tightening torque: 102 N·m (75.2 ft-lb)

AD6G029

5. Caulk the bolt with a punch or weld it at

three spots on the threaded portion (nut

side).

5-51

Maintenance

When required

Replacing the bucket

1. Lower the bucket to the ground as shown

on the figure above in a stable position.

Note: When removing pins, set the bucket

• Before performing maintenance or

so that it is barely touching the ground If the

repairs under the machine, lower all

bucket is firmly touching the ground, the

working equipment to the ground or in

resistance will be great and it will be difficult

the lowermost position.

to remove the pin.

• If maintenance must be performed with

the engine running, always work as a

2. Set the safety lock lever to the locked

two person team communicating each

position and stop the engine.

other.

· One person must sit in the operator’s

seat so that he/she can immediately

stop the engine when necessary. He/

she must take care not to touch the

lever or pedal unless necessary.

· The one who performs maintenance

must make sure to keep his/her body

or clothing away from the moving part

of the machine.

• When using a hammer, pins may fly out

or metal particles may be scattered.

AD6G033

This may lead to serious injury.

3. Disengage the ring of the lock pin (1) and

· If hard metal parts such as pins,

remove the lock pin (1).

bucket teeth, side cutter or bearings

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

are hit with a hammer, wear protective

5. Remove the bucket.

gear such as safety goggles and

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

gloves.

deformed or damaged. (See next page.)

· When hitting pins or bucket teeth,

always check that there is no one in

the surrounding area.

• When aligning the pin holes, always do

so by checking them visually. Do not

insert your finger in the pin hole, or you

could lose your finger.

Removing

5-52

Maintenance

When required

Installation

5. Slide the O-ring (4).

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

Replacing the pin seal

on the figure above.

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

2. Align the pin hole (A) on the bucket with

on the figure above.

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

2. Use a mallet to slowly press the pin seal

pin (2).

in. Be careful not to damage the seal.

3. Operate the cylinder, align the pin hole (B)

on the bucket with the pin hole on the link

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

AD6G034

4. Align the turn prevention holes, install the

lock pin (1), and then engage the ring

inside.

5-53

Maintenance

When required

Lubricating the levers

Travel levers, dozer blade lever, pedals

Set the machine to the parking posture,

stop the engine, remove the starter key

and store it. Failure to do so may result in

the machine moving abruptly, leading to

serious injury or death.

If the levers or pedals no longer move

smoothly, grease them.

Operating levers

1. Remove the floor mat (1).

2. Loosen the bolts and remove the cover

(2).

3. Remove the lower mount section of the

boot (3) and turn it upward.

1. Remove the lower mount section of the

boot (1) and turn it upward.

2. Wipe off the old grease.

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

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

4. Use the grease gun to lubricate the grease

fitting (4).

5. Wipe off the excess grease.

6. For installation, follow the same procedure

as for removal in the reverse order.

5-54

Maintenance

When required

Inspecting the rubber crawlers

(3) Metal core

Repair or replace the rubber crawlers if their

condition becomes as described below.

Consult your sales or service dealer for repair

or replacement.

Rubber crawler

Replace the crawler if the entire crawler is

stretched and cannot be adjusted.

(1) Lug

Replace if even one metal core is off.

(4) Rubber

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

or below.

(2) Steel cord

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

or greater in length.

If the steel cord is visible, repair as soon as

possible, regardless of the length of the

crack.

Replace if the steel cord is exposed for two

links or more.

Replace if the half or more of the steel cords

on one side are cut.

5-55

Maintenance

When required

Replacing the rubber crawlers

Removal

1. Fully release the tension of the rubber

crawler.

Refer to “Inspecting and adjusting the

• If you must work beneath the raised

crawler tension” on page 5-28.

machine or working equipment, always

use wood blocks, jack-stands or other

rigid and stable supports. Never get

under the machine or working

equipment if they are not sufficiently

supported.

• If maintenance must be performed with

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/

2. Use the working equipment to lift the

she must take care not to touch the

body.

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.

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

and turn the sprocket slowly in the reverse

direction.

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

the idler and the rubber crawler lifts away

from the idler, then stop turning the

sprocket.

5. Slide the rubber crawler sideways and

remove it from the crawler frame.

Remove the other rubber crawler using

the same procedure.

5-56

Maintenance

When required

Installation

1. Use the working equipment to lift the

body.

2. Set the rubber crawler on the sprocket.

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

and turn the sprocket slowly in the reverse

direction.

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

the idler and the rubber crawler lifts away

from the idler, then stop turning the

sprocket.

5. Slide the rubber crawler inward, engage it

on the idler, then pull out the iron pipe.

6. Check that the rubber crawler is securely

engaged on the sprocket and idler.

7. Tighten the rubber crawler to the standard

tension.

Refer to “Inspecting and adjusting the

crawler tension” on page 5-28.

8. Install the other rubber crawler using the

same procedure.

5-57

Maintenance

Maintenance during extended storage period

Starting the machine after storage

Maintenance during

IMPORTANT: If the above “Storage

extended storage period

procedures” have not been followed

Storage procedures

during the extended storage periods,

If the machine is to be stored for 30 days or

consult your sales or service dealer

more, store it indoors. If it must be stored

before starting the machine again.

outdoors, park the machine on a surface laid

with lumber on a flat ground, and place a

1. Wipe off the rust-inhibiting oil that was

waterproof cover over it so that it stays dry.

applied on the piston rods of the hydraulic

1. Clean the machine.

oil cylinders.

2. Inspect for oil leakage, water leakage,

2. Add oil or grease as necessary.

cracks and loose nuts and bolts.

3. Add fuel and replace the hydraulic oil and

Returning the engine to service

oil.

1. Perform the daily checks.

4. To prevent rusting and freezing, replace

2. The engine should be pre-oiled before

the engine coolant with long-life coolant

startup.

(LLC).

a. Crank the engine, leaving the fuel

Refer to “Cleaning the engine cooling

system shut off so the engine will not

system” on page 5-42.

start, for 15 seconds.

5. Use the grease gun to lubricate the grease

b. Then pause for 30 seconds.

fittings.

c. Repeat the procedure until you have

6. Fully retract the bucket and arm cylinders

cranked the engine for a total of one

and lower the bucket and dozer blade to

minute. This will circulate the oil in the

the ground.

engine’s lubrication system.

7. Apply rust-inhibiting oil to the hydraulic

3. Prime the fuel system.

cylinder rods.

4. Start the engine. Allow the engine to idle

8. Disconnect the negative cable from the

for approximately 15 minutes while you

battery and cover the battery to prevent

check for:

freezing.

· Proper oil pressure

· Fuel, engine oil or coolant leaks

During storage

· Proper operation of the indicators and/or

gauges

5. Avoid prolonged operation at minimum or

• Do not operate the machine in an

maximum engine speeds and loads for the

enclosed area without adequate

remainder of the first hour of operation.

ventilation.

• If natural ventilation is not possible,

install ventilators, fans, exhaust

extension pipes or other venting

devices.

1. To prevent rusting, operate the machine

once a month so that the oil can be

circulated throughout the system.

2. Inspect the battery and recharge it as

necessary.

Ask your sales or service dealer for

recharging.

5-58

Troubleshooting

Symptoms that are not malfunctions

• It becomes less easy to operate the

Symptoms that are not

machine when an attachment weighing

more than a standard arm or bucket is

malfunctions

installed.

The symptoms listed below are not

malfunctions.

• The arm retracting speed momentarily

slows down when it reaches an almost

vertical position while the engine is running

at low speed.

• The bucket teeth moving speed

momentarily slows down when it reaches

an almost horizontal position while the

engine is running at low speed.

• The slew motor produces noise at the

beginning and end of the slewing.

• The travel motor produces noise when

stopped suddenly from its high speed

traveling.

• The control valve produces noise if

excessive force is applied to the working

equipment or when it moved to the stroke

end.

6-2

Troubleshooting

If the engine overheats

Remedy procedure

If the engine overheats

1. Park the machine in a safe place.

2. Check if steam is coming out of the closed

engine hood and covers.

• Do not open the engine hood and

3. If there is steam, stop the engine

covers when steam is coming from it.

immediately and contact your sales or

The steam or hot water may spurt out

service dealer for repair. If steam, is not

and cause burns.

coming out run the engine at low idle and

• Do not try to remove the radiator cap or

let the water temperature cool down.

the drain plug when the cooling water is

4. When the water temperature gauge LED

hot. Stop the engine, wait until the

drops in the green zone, stop the engine.

engine and the radiator cool, and then

5. Perform the inspections and the remedies

slowly loosen the radiator cap to release

listed below once the engine cools down.

the internal pressure.

· Fan belt slack

Adjust

• Before performing maintenance, stop

Refer to page 5-25.

the engine and allow the machine to

· Coolant level

Add

cool down.

Refer to page 5-18.

· Water leakage

Repair

The symptoms listed below indicate

· Radiator fins

Clean

overheating.

Refer to page 5-38.

· Sediment in cooling system

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

Refer to page 5-42.

If the problem persists after the above

remedies, contact your sales or service

dealer for repair.

• An alarm is sounded and the engine

emergency lamp and the coolant

temperature warning lamp start flashing.

• The water temperature gauge LED is in the

red zone.

• The engine slows down and the engine

power decreases.

• Steam comes from the engine room.

6-3

Troubleshooting

If the battery goes dead

Connecting the jumper cables

If the battery goes dead

The symptoms below indicate that the

IMPORTANT: Set the starter keys of the

battery is dead.

booster vehicle and the dead machine to

• The starter motor does not turn or fails to

the OFF position.

start the engine.

• The horn is too weak.

Remedy procedure

Start the engine using the booster battery on

the other vehicle (booster vehicle) and the

jumper cables.

• When starting the engine using the

jumper cables, be sure to connect the

cables by following the proper steps.

Improper use of jumper cables can

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

result in battery explosion or

positive (+) battery terminal of the dead

unexpected machine motion.

machine.

· Do not allow the booster vehicle and

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

the machine with a dead battery (dead

to the positive (+) battery terminal of the

machine) to touch each other.

booster vehicle.

· Do not allow the positive (+) and the

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

negative (-) clips of the jumper cables

negative (-) battery terminal of the booster

to touch each other.

vehicle.

· When connecting, attach the jumper

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

cable to the positive (+) terminals first.

to the engine block of the dead machine.

When disconnecting, remove the

Connect the clip to a place as far from the

cable from the negative (-) terminal

battery as possible.

(ground) first.

· Connect the last clip of the jumper

Starting the engine

cable to a point as far away from the

1. Check that the clips are securely

battery as possible.

connected to the terminals.

• Always wear the protective goggle when

2. Start the engine of the booster vehicle and

jump starting the engine by using the

run it at high speed.

jumper cables.

3. Start the engine of the dead machine.

IMPORTANT: Use the jumper cables and

clips of a size suited to the capacity of

battery. Do not use damaged or corroded

jumper cables and clips.

IMPORTANT: Be sure that the battery of

the booster vehicle has the same

capacity as the battery of the dead

machine.

IMPORTANT: Be sure to connect the clips

securely.

6-4

Troubleshooting

If the battery goes dead

Disconnecting the jumper cables

Once the dead machine is successfully

running, remove the jumper cables by

following the same steps as for connection in

the reverse order.

1. Disconnect the clip of jumper cable (B)

from the engine block of the dead

machine.

2. Disconnect the other clip of jumper cable

(B) from the negative (-) battery terminal of

the booster vehicle.

3. Disconnect the clip of jumper cable (R)

from the positive (+) battery terminal of the

booster vehicle.

4. Disconnect the clip of jumper cable (R)

from the positive (+) battery terminal of the

dead machine.

Recharging

Ask your sales or service dealer for

recharging the dead battery.

6-5

Troubleshooting

If a fuse blows

Fuse layout and circuits protected

If a fuse blows

If a light does not come on or the electrical

<Applicable machine models 216000002 or

system does not work, a fuse may be blown.

later>

Inspect the fuses.

Protected

Capacity

circuit

Inspecting and replacing the fuse

10A

Cluster

20A

Light

10A

Horn

Lever lock

Cab interior

If the fuse blows again soon after

Third auxiliary

25A

power supply

10A

hydraulic

replacement, then the electric system is

(Cab)

likely faulty. It may pose a fire hazard if

15A

Feed pump

15A

Option (1)

not properly repaired. Contact your sales

or service dealer for advice.

Engine power

15A

Heater (Cab)

25A

source

1. Turn the starter key to the OFF position to

stop the engine.

<Applicable machine models 216100002 or

2. Open the maintenance cover.

later>

Protected

Capacity

circuit

25A

Controller

10A

Cluster

20A

Light

10A

Horn

Lever lock

Third auxiliary

10A

hydraulic

15A

Feed pump

15A

Option (1)

Highland

Engine power

25A

mode

source

3. Open the fuse box cover (1).

4. Check for any blown fuses.

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

fuse of the same capacity.

6-6

Troubleshooting

If a fuse blows

Inspecting the fusible link

If the machine is not turned on after turning

the starter switch to the ON position, the

cartridge type fusible link (1) is likely blown.

Open the maintenance cover and inspect. If

the fusible link is blown, please contact your

sales or service dealer.

Note: Fusible links are large type fuses used

in high current applications. Like a regular

fuse, they act as fuses by protecting the

electric components and wirings from

damage caused by excessive current draw.

6-7

Troubleshooting

Restarting after adding fuel

Restarting after adding

fuel

Bleeding air from the fuel system

IMPORTANT: NEVER use the starter

motor to crank the engine in order to

prime the fuel system. This may cause the

starter motor to overheat and damage the

coils, pinion gear and/or ring gear.

3. Turn the starter key to the ON position and

hold it for about 60 seconds.

The automatic air bleeder bleeds air from

the fuel system.

Note: Air in the fuel system causes the

engine to fail to start or to have other

problems. Always bleed air when the fuel

tank is emptied or when there is air in the

fuel system.

1. Add fuel.

2. Open the valve (2) of the water separator

and the fuel filter.

6-8

Troubleshooting

If a warning lamp flashes

If an alarm is sounded or a warning lamp starts flashing during operation, park the machine in

a safe place and perform the remedy procedures described below.

Warning lamp

Lamp name

Causes and remedies

Engine

There is a problem in the engine.

emergency

lamp

Refer to the respective warning lamp below.

Battery charge

There is a problem with the fan belt or charger.

warning lamp

Check the fan belt for slack or breakage and adjust as

necessary.

If the lamp continues flashing after maintenance, there is

likely a problem with the charger. Consult your sales or

service dealer for help.

Refer to “Inspecting and adjusting the fan belt” on page

5-25.

Engine oil

A problem has occurred in the engine lubrication system.

pressure

Inspect the engine oil level.

warning lamp

If the lamp is flashing when the oil is normal or if it

continues flashing after replenishment of oil, consult your

sales or service dealer.

Refer to “Inspecting and replenishing the engine oil” on

page 5-19.

Coolant

The coolant temperature is too high and the engine is

temperature

overheating.

warning lamp

Refer to “If the engine overheats” on page 6-3.

Fuel level

The fuel level is too low. Add fuel.

warning lamp

Refer to “Inspecting the fuel level” on page 5-20.

6-9

Troubleshooting

Other symptoms

For symptoms not included in the table below or if the problem persists after the proper

remedies have been taken, consult your sales or service dealer.

Symptoms

Major causes

Remedies

Left and right operating levers

• Insufficient grease on the

• Grease the levers.

do not move smoothly

left and right operating

Refer to page 5-54.

levers

Blade lever and throttle lever

• Wire is stretched too lose

• Adjust or replace (ask your

do not move smoothly

sales or service dealer).

Hoe attachment, slewing or

• Safety lock lever is raised

• Lower (release) the safety

traveling operation not

(locked)

lock lever.

possible

Refer to page 2-29.

• Fuse is blown

• Replace the fuse.

Refer to page 6-6.

• Adjustment of travel lock is

• Adjust the travel lock (ask

faulty

your sales or service dealer).

Digging force is insufficient

• Hydraulic oil level too low

• Add to the specified level.

Refer to page 5-21.

• Hydraulic oil is not warm

• Perform the warm-up.

enough

Refer to page 3-8.

• Air cleaner is clogged

• Clean the air cleaner.

Refer to page 5-36.

• Hydraulic oil is not of

• Replace the hydraulic oil.

suitable type

Refer to page 5-48.

Traveling is not possible or

• Stones or foreign objects

• Remove the foreign object.

not smooth

are stuck

Machine veers to the right/left

• Stones or foreign objects

• Remove the foreign object.

are stuck

• Faulty crawler tension

• Adjust the crawler to the

adjustment

prescribed tension.

Refer to page 5-28.

Travel speed cannot be

• Fuse is blown

• Replace the fuse.

changed

Refer to page 6-6.

6-10

Troubleshooting

Other symptoms

Symptoms

Major causes

Remedies

Slewing is not possible or not

• Insufficient grease on slew

• Grease the bearing.

smooth

bearing

Refer to page 5-30.

Hydraulic oil temperature is

• Hydraulic oil level too low

• Add up to the specified

too high

level.

Refer to page 5-21.

Starter motor turns but

• Insufficient fuel

• Add fuel.

engine does not start

Refer to page 5-20.

• Air in fuel system

• Bleed air.

Refer to page 6-8.

• Water in fuel system

• Drain water.

Refer to page 5-31.

Crawlers come off

• Crawlers too loose

• Increase the tension.

Refer to page 5-28.

Engine exhaust is white or

• Excessive engine oil

• Adjust to the specified level.

bluish

Refer to page 5-19.

• Poor fuel

• Replace the fuel.

Engine exhaust is

• Air cleaner is clogged

• Clean the air cleaner.

occasionally black

Refer to page 5-36.

Irregular noise is produced

• Low quality fuel is being

• Replace the fuel.

from the engine

used

(combustion or mechanical

• Engine is overheating

• Refer to “If the engine

noise)

overheats” on page 6-3.

• Damage inside the muffler

• Replace the muffler.

For replacement, ask your

sales or service dealer.

6-11

Troubleshooting

Lowering the boom to the ground

3. Loosen the lock nut (3) while holding the

Lowering the boom to

adjust screw (4) in place with a hexagonal

wrench so that the adjust screw (4) will not

the ground

be loosened together with the lock nut (3).

If the hoe attachment must be lowered to the

4. Turn the adjust screw (4) slowly 1/4 turn to

ground while the engine is stopped, use the

lower the boom.

following procedure.

5. Check for safety and stability of the

This operation is dangerous and requires

machine.

experience. Ask your sales or service dealer

6. Return the adjust screw (4) to the original

for it.

position.

7. Tighten the lock nut (3) while holding the

Procedure

adjust screw (4) in place with a hexagonal

wrench so that the adjust screw (4) will not

be loosened together with the lock nut (3).

• Keep away from the working area when

· Lock nut (3) tightening torque: 12.4 to

the hoe attachment is lowered. You may

13.6 N·m (9.1 to 10 ft-lb.)

be hit by dirt falling out of the bucket or

· Adjust screw (4) tightening torque: 6.3 to

the hoe attachment as it drops.

7.5 N·m (4.6 to 5.5 ft-lb.)

• Gradually lower the boom slowly by

8. Reinstall the side cover (1) and the lever

slowly turning the set screw on the

(2).

shut-off valve. Do not turn the screw

more than the specified amount.

1. Remove the cover (1).

2. Take out the bolt and remove the cover

(2).

6-12

Troubleshooting

Towing

Towing the machine

Towing

Use the procedure described below to tow

heavy objects or the machine itself if it

should get stuck in the mud and not be able

When towing, serious injury or death

to get out on its own.

could result, if performed incorrectly or

the wire rope being used is inappropriate

or not properly inspected.

• It becomes dangerous if the wire rope

breaks or becomes disengaged. Use a

wire rope appropriate for the required

tractive force.

• Do not use a wire rope that is kinked,

twisted or otherwise damaged.

• Do not apply heavy loads abruptly to

the wire rope.

• Wear safety gloves when handling the

wire rope.

• Permissible force: 28.2 KN (6339 lbf)

• Make sure there is an operator on the

machine being towed as well as on the

1. Attach the wire rope to the shackle (1).

machine that is towing.

2. Fasten the shackle (1) to the towing holes

• Never tow on slopes.

(2).

• Do not let anyone come near to the wire

3. Make sure that the wire rope is at a cone

rope while towing.

angle of 20° or less to the travel frame.

4. Move the machine to tension the wire

IMPORTANT: Do not tow a machine if its

rope.

engine does not start or if the machine

5. Operate the machine slowly and tow.

does not run. Doing so could damage the

machine being towed.

IMPORTANT: Be sure to follow the steps

below closely when using the towing hole

to tow. Failure to heed even one of the

steps may cause damage to the towing

hole or other parts of the frame.

6-13

Troubleshooting

If the cab or canopy is damaged

If the cab or canopy is

damaged

Immediately replace the damaged cab or

canopy. Serious injury or death may occur

if the machine is operated with damaged

cab/canopy.

Do not operate the machine until the

replacement is complete. Do not try to

repair the damaged cab or canopy by

welding. Doing so could endanger the

safety of the cab/canopy.

<Applicable machine models 216000002

or later>

· Cab parts No. 03386-00101

· Canopy parts No.(1) 03384-00135

· Canopy parts No.(2) 03684-16300

<Applicable machine models 216100002

or later>

· Canopy parts No.(1) 03384-00120

· Canopy parts No.(2) 03384-00128

6-14

Takeuchi Mini Excavator TB216 (No.216000002~, No.216100002~). Operator's Manual - page 5