Takeuchi Hydraulic Excavator TB175W (No. 175400095~). Operator's Manual

MAINTENANCE

Daily Inspection (Every 10 Hours)

Inspecting and Inflating the Tires

WARNING

W2G006

During your pressure checks, also inspect

for:

Objects wedged between duals or

W2A024

embedded in tires.

Mismatched duals. Diameters should be

Explosive separation of a tire and/or rim

equal as well as amount of tread wear.

parts can cause serious injury or death.

Missing valve caps and wheel lugs.

Always follow the service outlet or see

Cuts, tears, and breaks that may need

your tire supplier.

rapair.

Do not inflate tires with flammable

Abnormal or uneven wear.

gases or from systems utilizing an

Damaged or poor fitting rim or irm

alcohol injector.

flanges.

Never cut or weld on a wheel with an

Projecting body hardware, loose fender

inflated tire mounted on it. This could

bolts, spring clips - anything that could

cause explosive decompression.

contact a tire.

Always use a safety cage or cable

restraints when reinflating a repaired

tire.

A rise in tire pressure during operation is

normal, and should NOT be reduced.

Always maintain the correct tire

pressure. Do not inflate the tires above

the recommended pressure.

Recommended air pressure must be

maintaind in every tire. Dairy checks assure

that inflation is correct. If your periodic check

discloses a tire that is continuously losing air,

a leak is indicated and must be repaired.

121

MAINTENANCE

Daily Inspection (Every 10 Hours)

Inflating the tires

Checking the wheel nut torques

These instructions are for adding air to a

tire which is already inflated. If the tire has

WARNING

lost all its air pressure, call in a qualified tire

If, for whatever reason, wheel nut is

mechanic. The tire mechanic should use a

renewed, all the nuts for that wheel must

tire inflation cage and the correct equipment

be changed as a set, since the remaining

to do the job.

nuts may have been damaged.

1. Prepare the wheel.

On new machines, and whenever a wheel has

Before you add air to the tire, make sure it is

been removed, check the wheel nut torques

correctly fitted on the machine or installed

every two hours until they stay correct.

in a tire inflation cage.

Every day, before starting work, check that

2. Prepare the equipment.

the wheel nuts are tight.

Use only an air supply system which

• Tightening torque:

includes a pressure regulator.

400 to 500 N·m (295 to 369 ft-lb.)

Set the regulator no higher than above the

recommended tire pressure. (See below).

Use

an air hose fitted with a self locking air

chuck and remote shut-off valve.

W2A031

3. Add the air.

Make sure that the air hose is correctly

connected to the tire valve.

Clear other people from the area.

Stand behind the tread of the tire while

adding the air.

Inflate the tire to the recommended

pressure. Do not over-inflate.

• 8.25 - 20 Twin tires

• Tire pressure: 600kPa(87 psi)

122

MAINTENANCE

After First 50 Hours (New Machines Only)

Replacing the Hydraulic Oil

Return Filter

WARNING

Stop the engine and allow the machine

to cool down before performing

maintenance.

• The engine, hydraulic lines and many

other parts of the machine are hot

directly after the engine is stopped.

Touching these parts will cause

burns.

• The hydraulic fluid is also hot and

under high pressure.

Be careful when loosening caps and

L7G020

plugs. Working on the machine under

1. Press button (1) and bleed the air from the

these conditions could result in burns

tank.

or injuries due to the hot oil spurting

2. Loosen the bolts, and remove the flange

out.

(4).

Never jump off the machine. Use the

3. Remove the return filter (5).

steps and handrails when climbing on

4. Install the new return filter.

and off the machine, and always support

5. Install the flange (4).

your body at three points with your

6. Inspect the level with the sight gauge (6),

hands and feet.

and replenish if the level is low.

Oil may spurt out if caps or filters are

Refer to page 118 “Inspecting the Hydraulic

removed or pipes disconnected before

Oil Level and Replenishing”.

releasing the pressure in the hydraulic

system.

• Gradually press the air breather button

to relieve tank pressure.

• When removing plugs or screws or

disconnecting hoses, stand to the

side and loosen slowly to gradually

release the internal pressure before

removing.

123

MAINTENANCE

After First 50 Hours (New Machines Only)

2. Loosen the bolts and remove the under

Replacing the Engine Oil and Oil

cover.

Filter

3. Place a pan for catching the spent oil under

the drain plug (3).

WARNING

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

Stop the engine and allow the machine

drain the oil. (The oil comes out when the

to cool down before performing

screw is tightened.)

maintenance.

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

• The engine, muffler, radiator and

many other parts of the machine

IMPORTANT: Check the spent oil. If it

are hot directly after the engine is

contains large amounts of metal powder,

stopped. Touching these parts will

consult a Takeuchi sales or service

cause burns.

outlet.

• The engine oil is also hot.

6. Install the under cover.

Be careful when loosening caps

and plugs. Working on the machine

under these conditions could result

in burns.

Never jump off the machine. Use the

steps and handrails when climbing on

and off the machine, and always support

your body at three points with your

hands and feet.

L3G030

7. Open the maintenance cover.

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

counterclockwise and remove it.

9. Clean the surface of installation of the filter

stand.

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

the new filter.

11. Install the new filter by hand.

1. Open the engine hood and remove the oil

12. Tighten 3/4 more turn with the filter

supply cap (2).

wrench after the filter packing comes in

contact with the surface of installation.

13. Supply oil up to the upper limit (H) of the

dipstick (1). Problems could arise if the

oil level is either too low or too high.

14. Tighten the oil supply cap (2).

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

3 minutes, then stop it.

16. After about 10 minutes, inspect the oil

level.

L3G025

124

MAINTENANCE

After First 50 Hours (New Machines Only)

Adjustment

Inspecting and Adjusting the Fan

Belt

WARNING

Stop the engine and allow the machine to

cool down before performing inspection

and maintenance.

The engine, muffler, radiator, hydraulic

W3G030

lines, sliding parts and many other parts

of the machine are hot directly after the

1. Loosen the locking nut (6).

engine is stopped. Touching these parts

2. Turn the adjustment bolt (5) and adjust the

will cause burns.

fan belt (4).

• Tighten: Clockwise

Inspection

• Loosen: Counterclockwise

1. Open the engine hood.

3. Tighten the locking nut (6).

2. Press at the center of the fan pulley (2) and

alternator pulley (3) and check the tension

(about 98 N or 22 lbf.).

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

(0.28 to 0.4 in).

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

• there are cuts or cracks.

• the belt is worn and touches the bottom

of the V groove in the pulley.

• the belt stretches and cannot be

adjusted.

125

MAINTENANCE

After First 50 Hours (New Machines Only)

7. Inspect the level with the sight gauge, and

Replacing the Pilot Line Filter

replenish if the level is low.

Refer to page 118 “Inspecting the Hydraulic

WARNING

Oil Level and Replenishing”.

Stop the engine and allow the machine

to cool down before performing

maintenance.

• The engine, hydraulic lines and many

other parts of the machine are hot

directly after the engine is stopped.

Touching these parts will cause

burns.

• The hydraulic fluid is also hot and

under high pressure.

Be careful when loosening caps and

plugs. Working on the machine under

these conditions could result in burns

or injuries due to the hot oil spurting

out.

Oil may spurt out if caps or filters are

removed or pipes disconnected before

releasing the pressure in the hydraulic

system.

• Gradually press the air breather button

to relieve tank pressure.

W2G009

1. Open the right side cover.

2. Turn the case (1) counterclockwise and

remove it.

3. Remove the element (2) and O-ring (3).

4. Clean the inside of the case (1).

5. Install the new element in the case (1).

6. Set the new O-ring, then tighten the case

(1).

126

MAINTENANCE

Every 50 Hours

5. Repeat steps 2 to 4 above three times.

Lubricating the Slew Bearing

6. Wipe off the grease expelled from the slew

bearing and grease nipple.

WARNING

Do not slew while lubricating. Doing so

is dangerous, as you may get caught in

the machine.

W2G010

1. Stop the engine with the machine in the

posture shown on the diagram above.

W2G011

2. Use the grease gun to supply grease to the

grease nipple (1).

W2G012

3. Start the engine, lift the bucket and slew

clockwise 90°.

4. Ground the bucket and stop the engine.

127

MAINTENANCE

Every 50 Hours

Inspecting the Battery Fluid Level

and Replenishing

DANGER

Do not use the battery when the fluid

level is below the lower level. Doing

so will hasten the deterioration of the

W3G040

internal portions of the battery and

2. Inspect the indicator (1).

shorten the battery life, and can also

• Blue: Good

cause rupturing (or an explosion).

• White: Charging needed

Batteries generate flammable and

• Red: Insufficient battery fluid

explosive gases. Keep arcs, sparks,

3. Inspect the fluid level.

flames and lighted tobacco away.

The fluid level should be between the lines

Use a dampened cloth to clean the area

indicating the upper level (H) and lower

of the fluid level lines and check the fluid

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

level. Note that if this area is cleaned

line (H).

with a dry cloth, static electricity could

If the fluid level can not be checked by fluid

cause ignition or explosion.

level lines.

WARNING

Do not fill the battery above the upper

level. Doing so could cause the fluid to

leak, contact and damage the skin, or

cause parts to corrode.

Batteries contain sulfuric acid which will

damage eyes or skin on contact.

• If acid contacts eyes, flush immediately

with clean water and get prompt

Remove the caps (2) and look into the fluid

medical attention.

supply holes to check the fluid level. If the

• If acid is accidentally swallowed, drink

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

large quantities of water or milk and

distilled water up to the bottom edge of the

call a physician immediately.

sleeve (3).

• If acid contacts skin or clothing, wash

Proper amount

(A)

off immediately with clean water.

The fluid reaches up to the bottom edge

of the sleeve (3), so the surface tension

Inspection

causes the fluid to swell and the plate

IMPORTANT: Check the fluid level of all

appears distorted.

cells, even when the fluid level can be

Level too low

(B)

checked by indicator.

The fluid does not reach up to the bottom

edge of the sleeve (3), so the plate appears

1. Open the left side cover.

laminar, not distorted.

4. Also check the terminals for looseness and

dirt.

128

MAINTENANCE

Every 50 Hours

Replenishing

Draining the Fuel Tank

When adding distilled water, do so before

starting operations in order to prevent

WARNING

freezing.

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

Never jump off the machine. Use the

water until the upper level (H).

steps and handrails when climbing on

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

and off the machine, and always support

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

your body at three points with your

the caps (2) securely.

hands and feet.

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.

Do this before operating the machine.

1. Remove the fuel filler cap (2).

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

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

and sediment from the bottom of the tank.

4. Close the drain cock (3).

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

fuel.

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

the key.

7. Bleed the air.

Bleeding the air from the fuel system

Refer to page 157 “Bleeding the Air from the

Fuel System”.

Supplement: Air in the fuel system can make

it difficult to start the engine and cause engine

problems. Also bleed the air when the fuel

tank is emptied.

129

MAINTENANCE

Every 250 Hours

Cleaning the Air Cleaner

WARNING

Stop the engine and allow the machine

to cool down before performing

maintenance.

• The engine, muffler, radiator and many

E4G033

other parts of the machine are hot

6. Clean the outer element (3) with dried

directly after the engine is stopped.

compressed air {294 to 490 kPa (43 to 71

Touching these parts will cause

psi)}.

burns.

First blow the air from the inside of the

Wear required appropriate equipment

element along the flutes, then blow the air

such as safety glasses and filter mask

from the outside, and finally from the inside

when using compressed air, as metal

again.

fragments or other objects can fly and

cause serious personal injury.

IMPORTANT: Be careful not to scratch

the element. Do not use an element if it is

damaged.

IMPORTANT: When operating the machine

in very dusty places, inspection and

maintenance should be performed every

day.

E4G034

7. Light up the inside of the outer element (3)

1. Open the left side cover.

with a bulb, inspect it, and replace it if there

are small holes or thin spots.

8. Install the outer element (3).

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

at the top, then fasten it with the clamps

(1).

W3G050

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

cup (2).

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

4. Remove the outer element (3).

Do not remove and clean the inner element

(5).

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

131

MAINTENANCE

Every 250 Hours

Cleaning the Radiator Fins and Oil

Replacing the Engine Oil and Oil

Cooler Fins

Filter

Refer to page 124 “Replacing the Engine Oil

WARNING

and Oil Filter”.

Wear required appropriate equipment

such as safety glasses and filter mask

when using compressed air, as metal

fragments or other objects can fly and

Inspecting and Adjusting the Fan

cause serious personal injury.

Belt

Refer to page 125 “Inspecting and Adjusting

IMPORTANT: Be careful not to damage

the Fan Belt”.

the radiator fins and oil cooler fins when

cleaning them.

When using compressed air or pressurized

water, make sure the pressure is no higher

than 200 kPa (28 psi) and hold the nozzle

sufficiently away from the fins.

IMPORTANT: When using water, cover the

electrical system to prevent water from

getting in.

IMPORTANT: When operating the machine

in very dusty places, inspection and

maintenance should be performed every

day.

W3G060

1. Open the left side cover and the engine

hood.

2. Blow compressed air on the radiator fins

and oil cooler fins to remove mud and dirt

stuck on them.

132

MAINTENANCE

Every 400 Hours

Inspecting the Transmission Gear

Inspecting the Differential Gear

Oil

WARNING

Stop the engine and allow the machine

to cool down before performing

maintenance.

• The transmission are hot directly after

• The differential are hot directly after

the engine is stopped. Touching them

will cause burns.

• The gear oil is also hot and under high

pressure.

Be careful when loosening plugs.

Working on the machine under these

conditions could result in burns or

injuries.

The pressure in the transmission

The pressure in the differential gears

reduction gears case may cause oil

case may cause oil or the plug to fly

or the plug to fly out. Loosen the plug

out. Loosen the plug slowly to release

slowly to release the pressure.

the pressure.

1. Park the machine on a level surface. Stop

the engine.

Oil level

Ölstand

W2G0161

W2G017

2. Remove the plug (1) from the transmission

2. Remove the plug (1) from the differential

housing.

3. If oil can be reached with the tip of the

your finger through the hole, the oil level

is correct.

4. If the level is low, add oil through the check

4. If the level is low, add oil through the add

plug hole until the oil flows from the hole.

plug hole (2) until the oil flows from the

5. Install and tighten the plug.

hole.

5. Install and tighten the plug.

133

MAINTENANCE

Every 400 Hours

Inspecting the Hub Gear Oil

WARNING

Stop the engine and allow the machine

to cool down before performing

maintenance.

• The hubs are hot directly after the

engine is stopped. Touching them will

cause burns.

• The gear oil is also hot and under high

pressure.

Be careful when loosening plugs.

Working on the machine under these

conditions could result in burns or

injuries.

The pressure in the hubs reduction

gears case may cause oil or the plug

to fly out. Loosen the plug slowly to

release the pressure.

1. Park the machine on a level surface. Stop

the engine.

2. Set the hub so that the plug (1) is at the

level.

W2G018

3. Remove the plug (1) from the hub

housing.

4. If oil can be reached with the tip of the

your finger through the hole, the oil level

is correct.

5. If the level is low, add oil through the check

plug hole until the oil flows from the hole.

6. Install and tighten the plug.

134

MAINTENANCE

Every 500 Hours

Replacing the Fuel Filter

Replacing the Water Separator

Filter

WARNING

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.

L7G030

L3G032

1. Open the right side cover.

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

1. Open the right side cover.

counterclockwise and remove it.

2. Place a pan under the drain hose.

3. Clean the surface of installation of the filter

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

stand.

fuel.

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

4. Remove the sensor (2).

the new filter.

5. Remove and discard the filter (3).

5. Install the new filter by hand.

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

6. Tighten 2/3 more turn with the filter wrench

7. Clean the surface of installation of the filter

after the filter packing comes in contact

stand.

with the surface of installation.

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

7. Bleed the air.

the new filter.

Refer to page 157 “Bleeding the Air from

9. Install the new filter by hand.

the Fuel System”.

10. Tighten 2/3 more turn with the filter

wrench after the filter packing comes in

contact with the surface of installation.

11. Bleed the air.

Refer to page 157 “Bleeding the Air from

the Fuel System”.

135

MAINTENANCE

Every 1000 Hours

1. Open the left side cover and the engine

Cleaning the Engine Cooling

hood.

System

WARNING

Stop the engine and allow the machine

FULL

to cool down before performing

maintenance.

LOW

• The engine, muffler, radiator and many

other parts of the machine are hot

directly after the engine is stopped.

W3G010

Touching these parts will cause

burns.

2. Gradually loosen the radiator cap (3)

• The engine coolant is also hot and

to release the internal pressure, then

under high pressure. Be careful when

remove.

loosening caps and plugs. Working on

the machine under these conditions

could result in burns or injuries due

to the hot coolant spurting out.

If maintenance must be performed with

the engine running, always work as a

two person team with one person sitting

in the operator’s seat while the other

works on the machine.

L3G020

• When performing maintenance, be

sure to keep your body and clothing

3. Place a pan for catching the spent coolant

away from moving parts.

under the drain plug (4), then loosen the

Standing at the back of the machine

drain plug (4) and drain the coolant.

while the engine is running is extremely

4. Tighten the drain plug (4).

dangerous, as the machine could move

5. Add tap water through the radiator’s

suddenly. Never stand at the back of the

coolant supply port up to the top of the

machine while the engine is running.

port. Take your time doing this, adding the

Do not remove the radiator cap or drain

water slowly to avoid any air from entering

plugs when the coolant is hot. Stop the

the radiator.

engine, let the engine and radiator cool

6. Close the radiator cap (3).

and loosen the radiator cap or drain

7. Start the engine and run it at a speed

plugs slowly.

slightly above low idling. Raise the water

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

When cleaning, if the temperature of the

run the engine for about 10 minutes with

coolant is low, the thermostat will be closed

the thermostat open.

and the coolant will not circulate in the

8. Stop the engine, let the water’s temperature

radiator. Heat the coolant water to at least

lower, then loosen the drain plug (4) and

90°C (194°F) before cleaning.

drain the water.

137

MAINTENANCE

Every 1000 Hours

9. After draining the water, clean using

Replacing the Air Cleaner

cleaning agent. Clean following the

Elements

instructions included with the cleaning

agent you are using.

WARNING

10. Repeat steps 4 to 8 to rinse the cooling

system.

Stop the engine and allow the machine

11. Tighten the drain plug (4).

to cool down before performing

12. Slowly add the new coolant (mixture of

maintenance.

antifreeze and tap water) through the

The engine, muffler, radiator and many

radiator’s coolant supply port up to the

other parts of the machine are hot

top of the port. Take your time doing

directly after the engine is stopped.

this.

Touching these parts will cause burns.

13. Close the radiator cap (3).

14. Warm up the engine. Use the meters to

IMPORTANT: Do not use an element if its

check that there are no irregularities in the

flutes, gaskets or seals are damaged.

cooling system at this time.

15. Raise the water temperature to at least

1. Open the left side cover.

90°C (194°F), then run the engine as such

for about 10 minutes.

16. Stop the engine, let the water’s temperature

lower, then check the level of coolant in

the radiator, and replenish up to the top

of the coolant supply port.

17. Close the radiator cap (3).

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

then add coolant to the upper limit (H).

W3G050

19. After replacing the coolant, inspect the

coolant level once again after operating

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

the machine.

cup (2).

The coolant permeates the entire system

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

during operation, so the level decreases.

4. Remove the outer element (3).

Replenish by the amount the level has

Do not yet remove inner element (5).

decreased.

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

6. Remove the inner element (5).

7. Install the new elements.

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

at the top, then fasten it with the clamps

(1).

138

MAINTENANCE

Every 1000 Hours

Replacing the Air Breather Filter

Inspecting and Adjusting the

Engine Valve Clearance

WARNING

This operation requires experience. Have

Never jump off the machine. Use the

it performed by a Takeuchi sales or service

steps and handrails when climbing on

outlet.

and off the machine, and always support

your body at three points with your

hands and feet.

Oil may spurt out if caps or filters are

Retightening the Engine Cylinder

removed or pipes disconnected before

Head Bolts

releasing the pressure in the hydraulic

This operation requires experience. Have

system.

it performed by a Takeuchi sales or service

• Gradually press the air breather button

outlet.

to relieve tank pressure.

J3G003

1. Press the button (N) and bleed the air from

the tank.

2. Remove the button (N) on the air

breather.

3. Remove cover (H).

4. Replace filter (A).

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

6. Install the button (N).

139

MAINTENANCE

Every 1500 Hours

Replacing the Transmission Gear

Replacing the Differential Gear

Oil

WARNING

Stop the engine and allow the machine

to cool down before performing

maintenance.

• The transmission are hot directly after

• The differential are hot directly after

the engine is stopped. Touching them

will cause burns.

• The gear oil is also hot and under high

pressure.

Be careful when loosening plugs.

Working on the machine under these

conditions could result in burns or

injuries.

The pressure in the transmission

The pressure in the differential gears

reduction gears case may cause oil

case may cause oil or the plug to fly

or the plug to fly out. Loosen the plug

out. Loosen the plug slowly to release

slowly to release the pressure.

the pressure.

1. Park the machine on a level surface. Stop

the engine.

Oil level

Ölstand

W2G0191

W2G020

2. Place a pan for catching the spent oil under

plug (2).

plugs (3).

3. Remove plug (2) and drain the oil.

3. Remove plugs (3) and drain the oil.

4. Tighten plug (2).

4. Tighten plugs (3).

5. Supply oil through the hole for plug (1) until

5. Supply oil through the hole for plug (2) until

oil flows out of the hole.

oil flows out of the hole (1).

6. Tighten plug (1).

6. Tighten plugs (1), (2).

140

MAINTENANCE

Every 1500 Hours

Replacing the Hub Gear Oil

WARNING

Stop the engine and allow the machine

to cool down before performing

maintenance.

• The hubs are hot directly after the

W2G018

engine is stopped. Touching them will

6. Supply oil through the hole for plug (1) until

cause burns.

oil flows out of the hole of plug (1).

• The gear oil is also hot and under high

7. Tighten plug (1).

pressure.

Be careful when loosening plugs.

Working on the machine under these

conditions could result in burns or

Inspecting and Cleaning the

injuries.

Engine Fuel Injectors

The pressure in the hubs reduction

gears case may cause oil or the plug

This operation requires experience. Have

to fly out. Loosen the plug slowly to

it performed by a Takeuchi sales or service

release the pressure.

outlet.

1. Set the hub so that the plug (1) is at the

very bottom.

Inspecting the Turbocharger

2. Park the machine on a level surface. Stop

(Blower wash as necessary)

the engine.

This operation requires experience. Have

it performed by a Takeuchi sales or service

outlet.

Inspecting and Cleaning the EGR

Valve, Lead Valve and Cooler

This operation requires experience. Have

W2G0211

it performed by a Takeuchi sales or service

outlet.

3. Place a pan for catching the spent oil under

plug (1).

4. Remove plug (1) and drain the oil.

Inspecting the Crankcase

5. Set the hub so that plug (1) is at the level.

Breather System

This operation requires experience. Have

it performed by a Takeuchi sales or service

outlet.

141

MAINTENANCE

Every 2000 Hours

Replacing the Hydraulic Oil and

Cleaning the Suction Strainer

WARNING

Stop the engine and allow the machine

to cool down before performing

maintenance.

• The engine, hydraulic lines and many

other parts of the machine are hot

directly after the engine is stopped.

Touching these parts will cause

burns.

• The hydraulic fluid is also hot and

under high pressure.

Be careful when loosening caps and

L7G020

plugs. Working on the machine under

2. Press button (1) and release the pressure

these conditions could result in burns

in the tank.

or injuries due to the hot oil spurting

3. Replace the air breather filter (A).

out.

Refer to page 139 “Replacing the Air

Never jump off the machine. Use the

Breather filter”.

steps and handrails when climbing on

4. Remove the plug (10).

and off the machine, and always support

5. Loosen the bolts, and remove the flange

your body at three points with your

(4).

hands and feet.

6. Remove the return filter (5).

Oil may spurt out if caps or filters are

7. Place a pan for catching the spent oil under

removed or pipes disconnected before

the drain plug (7).

releasing the pressure in the hydraulic

8. Loosen the drain plug (7) and drain the

system.

hydraulic oil.

• Gradually press the air breather button

9. Loosen the bolts, and remove the flange

to relieve tank pressure.

(8).

• When removing plugs or screws or

10. Remove the suction strainer (9) and clean

disconnecting hoses, stand to the

it.

side and loosen slowly to gradually

11. Clean the inside of the hydraulic tank.

release the internal pressure before

12. Install the new return filter and suction

removing.

strainer (9).

13. Install the flanges (4) and (8).

1. Slew 45° clockwise and set the machine to

14. Tighten the drain plug (7).

the hydraulic oil level inspection posture.

15. Supply hydraulic oil up to the middle of

Refer to page 118 “Inspecting the Hydraulic

the sight gauge (6) from the hole of plug

Oil Level and Replenishing”.

(10).

16. Tighten the plug (10).

143

MAINTENANCE

Every 2000 Hours

17. Follow the procedure next “Bleeding the

Slew motor

air” to bleed the air from the hydraulic oil

circuit.

18. Set the machine to the hydraulic oil

level inspection posture and inspect the

level once the temperature of the oil has

dropped.

Refer to page 118 “Inspecting the

Hydraulic Oil Level and Replenishing”.

Bleeding the air

IMPORTANT: After replacing the hydraulic

oil, bleed the air from the hydraulic circuit

and hydraulic devices. Failure to do so

may damage the hydraulic devices.

W2G022

Hydraulic pump

1. Loosen the bolts and remove the center

cover (1).

2. Remove the plug (2).

3. Once hydraulic oil overflows from the plug

hole, tighten the plug (2).

4. Install the center cover (1).

Cylinders

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

10 minutes.

1. Open the engine hood.

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

2. Disconnect the drain hose (1) from the

and contract all the cylinders 4 or 5 times,

hydraulic pump.

without going to the stroke end.

3. Once hydraulic oil overflows from the

3. Run the engine at high speed, then extend

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

and contract all the cylinders 4 or 5 times,

without going to 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.

144

MAINTENANCE

When Required

3. Remove the key, then check that the

Replacing the Bucket Teeth and

bucket is stable.

the Side Cutters

Replace the bucket teeth and the side cutters

when the tooth points or the side cutters are

worn, before the adapter or the bucket is

damaged.

WARNING

Before performing maintenance or

E4G043

repairs under the machine, set all

working equipment against the ground

4. Remove locking pin (1) and remove point

or in the lowermost position.

(2).

To prevent unexpected movement,

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

securely block the working elements

whether it is still usable.

when repairing or replacing the bucket

teeth and the side cutters.

Wear required appropriate equipment

such as safety glasses when using

hammers, as metal fragments or other

objects can fly and cause serious

personal injury.

Do not allow unauthorized personnel in

the work area.

E4G044

When these are cracks in the rubber

Bucket tooth

and it seems like the roller is about to

Removal

come off.

1. Clean the bucket and park the machine in a

When the roller becomes dented

flat, safe place where the ground is hard.

when pressed with a finger.

E4G042

2. Set the bottom surface of the bucket flat

and lower it on a block so that the locking

pin can be knocked out.

145

MAINTENANCE

When Required

Installation

Side cutter

Installation

E4G045

G4G026

1. Push rubber pin lock (3) into welding

adaptor (4).

1. Insert the bolts from the inner of the bucket

and tighten the nuts.

Do not let the rubber pin lock stick out past

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

the welding adapter surface.

2. Caulk the bolts with a punch at three spots

along the periphery of the screw to prevent

the nuts from coming loose.

Improper

Proper

E4G046

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

Insert the point so that the surface behind

the point’s pin hole is flush or deeper than

the surface behind the welding adapter’s

pin hole.

E4G047

3. Drive in locking pin (1).

After driving in the locking pin, use a pin with

the same surface as the point surface. Do not

use worn locking pins.

146

MAINTENANCE

When Required

Adjusting the gap between the

bucket and arm

WARNING

Before performing maintenance or

repairs under the machine, set all

working equipment against the ground

E4G050

or in the lowermost position.

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

To prevent unexpected movement,

(3) and flange (4).

securely block the working equipment

when adjusting.

E4G051

E4G048

5. Extract adjustment shim (5) from between

flange (4) and the bucket body according

1. Ground the bucket as shown on the

to gap (A).

diagram above in a stable position.

Adjustment shim thickness : 0.5 mm (0.02

2. Check that the bucket dose not move,

in.)

then set the safety lock lever to the locked

Be careful that the gap is no less than 0.5

position and stop the engine.

mm (0.02 in.) after adjustment.

Note: Example (for a gap of 2 mm or 0.08

in.)

2 mm - 0.5 mm (standard value)

= 1.5 mm (0.06 in)

In the above example, three shims (5) should

be removed.

6. Insert adjustment shim (5) removed in

E4G049

step 5 above between end plate (3) and

flange (4) and fasten it in place with the

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

three bolts (2).

view and measure the width of the gap

• Tightening torque for bolts (2)

(A).

83.4 N·m (61.5 ft-lb.)

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

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

Swing the bucket slightly to the left and

position.

lightly press the arm point to the left side of

the bucket (the side without an adjuster).

147

MAINTENANCE

When Required

Inspecting and Replenishing the

Draining the Water Separator

Windshield Washer Fluid

WARNING

Use a windshield washer fluid designed

specifically for motor vehicles. Follow the

Do not smoke or permit open flames

instructions including with the washer fluid.

while handling fuel or working on the

fuel system.

Stop the engine in a well-ventilated

place and allow it to cool down before

performing maintenance.

Clean up spilled fuel immediately.

G4G030

Inspection

1. Open the cab door.

2. Inspect the washer tank (1) and add washer

fluid if the level is low.

L3G032

Replenishment

1. Open the right side cover.

1. Mix the washer fluid to the prescribed

2. Place a pan under the drain hose.

concentration.

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

2. Remove the cap (2) and add washer

water.

fluid.

4. Close the drain cock (1).

3. Reinstall the cap (2).

Bleeding the air from the fuel system

Refer to page 157 “Bleeding the Air from the

Fuel System”.

Supplement: Air in the fuel system can make

it difficult to start the engine and cause engine

problems. Also bleed the air when the fuel

tank is emptied.

148

MAINTENANCE

When Required

3. Remove the bolt (1).

Replacing the Bucket

WARNING

Before performing maintenance or

repairs under the machine, set all

working equipment against the ground

or in the lowermost position.

If maintenance must be performed with

the engine running, always work as a

E4G052

two person team with one person sitting

in the operator’s seat while the other

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

works on the machine.

5. Remove the bucket.

• When performing maintenance, be

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

sure to keep your body and clothing

deformed or damaged. (See next page.)

away from moving parts.

Wear required appropriate equipment

Installation

such as safety glasses and filter

mask when using hammers, as metal

fragments or other objects can fly and

cause serious personal injury.

When lining up the pin holes, always do

so by sight. Your finger may be cut off

if you stick it into the hole.

E4G053

Removal

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

diagram.

E4G048

1. Ground the bucket as shown on the

diagram above in a stable position.

E4G054

Supplement: When removing pins, set the

bucket so that it is just gently against the

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

ground. If it is strongly against the ground, the

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

resistance will be great and it will be difficult

(2).

to remove the pin.

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

2. Set the safety lock lever to the locked

the bucket with the pin hole in the link arm

position and stop the engine.

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

149

MAINTENANCE

When Required

0.5~1mm

E4G055

4. Line up the turn prevention holes, install

the bolt (1), and the nuts.

Be sure to leave a gap of about 0.5 ~ 1

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

bucket bush, or the nut will come loose.

E4G056

5. Adjust the gap between the bucket and

the arm. Refer to page 145.

6. Slide the O-ring (4).

Replacing the pin seal

E4G057

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

on the diagram above.

2. Use a mallet to slowly press the pin seal

in. Be careful not to damage the seal.

150

MAINTENANCE

When Required

Boom swing pedal

Lubricating the Levers

WARNING

Set the machine to the parking posture,

stop the engine, remove the starter key

and store it. Failure to do so may result in

the machine moving abruptly, leading to

serious injury or death.

If the levers or pedals no longer move

1. Remove the lower mount section of the

smoothly, supply grease.

boot (1) and turn it upwards.

2. Wipe off the old grease.

Operating levers

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

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

E4G058

1. Remove the lower mount section of the

boot (1) and turn it upwards.

2. Wipe off the old grease.

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

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

151

MAINTENANCE

Long-term Storage

Procedures for storage

During storage

If the machine is to be stored for 30 days or

more, store it indoors. If it must be stored

WARNING

outdoors, stop it on wood laid out on a flat

surface and place a waterproof cover over it

Do not operate the engine in an enclosed

so that it stays dry.

area without adequate ventilation.

1. Clean the machine.

If natural ventilation is poor, install

2. Inspect for oil leakage, water leakage and

ventilators, fans, exhaust extension

loose nuts and bolts.

pipes or other artificial venting

3. Add fuel and replace the hydraulic oil and

devices.

oil.

4. To prevent rusting and freezing, replace

1. To prevent rusting, operate the machine

the engine coolant with long-life coolant

once a month so that the oil is fully

(LLC).

circulated.

Refer to page 137 “Cleaning the Engine

2. Inspect the battery and recharge it if

Cooling System”.

necessary.

5. Use the grease gun to supply grease to the

Have the battery charged by a Takeuchi

grease nipples.

sales or service outlet.

6. Fully contract the bucket and arm cylinders

and ground the bucket and dozer blade.

Starting the machine after storage

7. Apply rust-prevention oil to the hydraulic

cylinder rods.

IMPORTANT: If the “Procedures for

8. Disconnect the cable from the battery’s

storage” have not been performed and the

“-” terminal and cover the battery to

machine has been stored for a long period

prevent freezing.

of time, consult a Takeuchi sales or service

outlet before reusing the machine.

1. Wipe off the rust-prevention oil that was

applied to the hydraulic oil cylinders’ piston

rods.

2. Add fuel, oil and grease to all parts.

152

TROUBLESHOOTING

Symptoms that are not Malfunctions

The following symptoms are not

Performance decreases when an

malfunctions:

attachment weighing more than a standard

arm or bucket is mounted.

E4J001

When the arm reaches the vertical position

while contracting it while the engine is

running at low speed, the contracting

speed slows down momentarily.

E4J002

When the bucket teeth reach the horizontal

position while the engine is running at low

speed, the speed of bucket movement

slows down momentarily.

The slew motor produces noise at

the beginning and end of the slewing

operation.

The travel motor produces noise when

stopped suddenly during high speed

travel.

The control valve produces noise if

excessive force is applied to the working

equipment and when the stroke end is

reached.

154

TROUBLESHOOTING

If the Engine Overheats

Procedure

WARNING

1. Park the machine in a safe place.

Do not open the engine hood when there

2. Inspect whether the coolant temperature

is steam coming from the engine room.

warning lamp is flashing or if there is

The steam or hot water may spurt out,

steam coming out when the engine hood

resulting in burns.

is closed.

Do not remove the radiator cap or drain

3. If there is steam, stop the engine

plugs when the coolant is hot. Stop the

immediately and contact a Takeuchi sales

engine, let the engine and radiator cool

or service outlet for repairs.

and loosen the radiator cap or drain

If the coolant temperature warning lamp

plugs slowly.

is off, run the engine at low idle and let the

Stop the engine and allow the machine to

water temperature decrease.

cool down before performing inspection

4. Once the water temperature gauge drops

and maintenance.

to the green zone, stop the engine.

5. Once the engine is cool, perform the

The following symptoms indicate

following inspections and procedures:

overheating:

• Fan belt slack

Adjust.

Refer to page 125.

• Coolant level

Add.

Refer to page 116.

• Water leakage

Repair.

• Radiator fins

Clean.

Refer to page 132.

• Sediment in cooling system

Clean.

Refer to page 137.

If the problem persists after the above

L7J0101

procedures are taken, contact a Takeuchi

An alarm is sounded and the coolant

sales or service outlet for repairs.

temperature warning lamp flashes.

The water temperature gauge is in the red

zone.

The engine slows down and the force

decreases.

Steam comes from the engine room.

155

TROUBLESHOOTING

If the Battery Goes Dead

The following symptoms indicate that the

Connecting the jumper cables

battery is dead:

The starter motor does not turn or turns

IMPORTANT: Set the starter keys of both

weakly, and the engine does not start.

the rescue vehicle and problem vehicle to

The horn is weak.

the OFF position.

Procedure

Rescue vehicle battery

Problem vehicle battery

Use jumper cables and start the engine using

the rescue vehicle’s battery.

WARNING

Use jumper cables only in the

To engine block

recommended manner. Improper use

E4J005

of jumper cables can result in battery

explosion or unexpected machine

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

motion.

problem vehicle’s “+” terminal.

• Do not let the problem vehicle and

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

rescue vehicle touch each other.

to the rescue vehicle’s “+” terminal.

• Do not let the “+” and “-” clips of the

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

jumper cables touch each other.

rescue vehicle’s “-” terminal.

• Connect the jumper cables to the “+”

4. Connect the other clip of jumper cable

terminals first, and disconnect them

(B) to the problem vehicle’s engine block.

from the “-” terminals (ground) first.

Connect the clip as far from the battery as

• Connect the final clip of the jumper

possible.

cable to a point as far away from the

battery as possible.

Starting the engine

Use safety glasses when using jumper

1. Check that the clips are securely connected

cables to start the machine.

to the terminals.

2. Start the rescue vehicle’s engine and run

it at high speed.

IMPORTANT: Use jumper cables and clips

3. Start the problem vehicle’s engine.

of a size suited to the battery’s capacity.

Do not used damaged or corroded jumper

cables and clips.

IMPORTANT: The rescue vehicle’s battery

must have the same capacity as the

problem vehicle’s battery.

IMPORTANT: Connect the clips securely.

156

TROUBLESHOOTING

If the Battery Goes Dead

After the Fuel Runs Out

Disconnecting the jumper cables

Bleeding the Air from the Fuel

Once the engine starts, disconnect the jumper

System

cables following the connection procedure in

reverse order.

1. Add fuel.

Rescue vehicle battery

Problem vehicle battery

OFF

START

From engine block

E4J006

L3D001

1. Disconnect the clip of jumper cable (B)

2. Turn the starter key to the ON position and

from the problem vehicle’s engine block.

hold it there for about 20 seconds.

2. Disconnect the other clip of jumper cable

The automatic air bleeder bleeds the air

(B) from the rescue vehicle’s “-” terminal.

from the fuel system.

3. Disconnect the clip of jumper cable (R)

from the rescue vehicle’s “+” terminal.

Supplement: Air in the fuel system can make

4. Disconnect the other clip of jumper

it difficult to start the engine and cause engine

cable (R) from the problem vehicle’s “+”

problems. Also bleed the air when the fuel

terminal.

tank is emptied.

Recharging

Have a Takeuchi sales or service outlet

recharge batteries that have gone dead.

157

TROUBLESHOOTING

If a Fuse Blows

If a light does not turn on or the electric

system does not operate, a fuse may be

Blown

Normal

blown. Inspect the fuses.

Inspecting and Replacing the

Fuse

E4J007

WARNING

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

If the fuse blows as soon as it is replaced,

fuse of the same capacity.

there is a problem with the electric system.

Continued use may lead to fire. Consult a

Takeuchi sales or service outlet.

Fuse Layout and Circuits Protected (1)

1. Turn the starter key to the OFF position and

Capacity

Protected circuit

Capacity

Protected circuit

stop the engine.

Starter switch

10A

Turn signal

10A

Solenoid

10A

Lever lock

(Opt.)

10A

Wiper,

Instrument

Radio

cluster

30A

Air conditioner

10A

Solenoid

(Opt.)

10A

Option

10A

T-ECU

L3J002

30A

F. S. pump

10A

Sensor

Horn,

Feed Pump

Radio (B)

10A

T-ECU (B)

E-ECU (IG)

W2J0011

2. Open the fuse box cover (1) or (2).

3. Inspect for any blown fuses.

158

TROUBLESHOOTING

If a Fuse Blows

Fuse Layout and Circuits Protected (2)

Inspecting the Fusible Link

Capacity

Protected circuit

10A

Hazard, Turn signal

10A

Buzzer

Parking lights (R.H.)

Parking lights (L.H.)

10A

Head lights (R.H.)

10A

Head lights (L.H.)

W3J010

Reserve

If the power is not switched on after

turning the starter switch to the ON

10A

Reserve

position, the cartridge type fusible links

(1) might be blown open. Open the left

side cover and inspect. If the fusible link

is blown, please contact your dealer.

Supplement: A fusible link is a large piece

of fuse wiring which is mounted in a circuit

which carries a large electrical current. Link

a regular fuse, the fusible link protects the

electrical parts and wiring from damage due

to abnormally large currents.

159

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 procedures described below.

Warning lamp

Lamp name

Procedure

Battery charge

There is a problem with the fan belt or charger.

warning lamp

Inspect the fan belt for slack or breakage and adjust

as necessary. If the lamp continues flashing after

maintenance, there is a problem with the charger.

Consult a Takeuchi sales or service outlet.

OSOB080

Refer to page 125 “Inspecting and Adjusting the Fan

Belt”.

Engine oil

Inspect the engine oil level. If the lamp is flashing even

pressure

though the level is normal or if it continues flashing after

warning lamp

oil are added, consult a Takeuchi sales or service outlet.

Refer to page 117 “Inspecting and Replenishing the

Engine Oil”.

OS0B070

Coolant

The coolant temperature has risen irregularly and the

temperature

engine is overheating.

warning lamp

Refer to page 155 “If the Engine Overheats”.

C4BC12

Air cleaner

The air cleaner filter is clogged.

warning lamp

Refer to page 131 “Cleaning the Air Cleaner”.

G4B010

160

Takeuchi Hydraulic Excavator TB175W (No. 175400095~). Operator's Manual - page 4