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Takeuchi Compact Excavator TB014 (11410001~), TB016 (11610001~). Operators Manual - page 3

OPERATION

Operating Procedures

Cautions on Use in Water

Cautions on Traveling on Slopes

WARNING

¡ Never exceed the machine’s stability

capabilities (maximum gradeability -

25°, lateral tipping angle - 10°). Also

note that when actual working area

E4D038

conditions are poor the machine’s

stability capabilities may be lower.

If you leave water at a sharp angle, the rear

¡ When traveling on slopes or grades,

of the machine may be submerged, exposing

lower the bucket to a height of 20 to 30

the radiator fan to water and damaging them.

cm (8 to 12 in.) off the ground. In

Do not let the rear of the machine get

emergencies, lower the bucket to the

submerged.

ground and stop the machine.

¡ When traveling on slopes or grades,

move slowly in first gear (low speed).

1

¡ Do not travel down slopes in reverse.

C4D014

¡ Allowable water depth

In water, only use the machine up to a

depth at which the water comes up to the

¡Do not change directions or cross

middle of the shoe slide (1).

slopes sideways. First return to a flat

¡ When greasing places used under water

surface then redirect the machine.

for long periods of time, apply enough

¡ On grass, dead leaves, wet metal or

grease so that the old grease is expelled.

frozen surfaces, the machine may slide

¡ Never submerge the slew bearing or main

sideways even on very gentle slopes.

body in water or sand. If the slew bearing

Make sure the machine never faces

or main body should get submerged,

sideways with respect to the slope.

contact a Takeuchi sales or service outlet

for inspection.

80

OPERATION

Operating Procedures

Traveling Posture

Braking when traveling down slopes

Traveling up slopes

Braking

E4D045E

When traveling down slopes, the brakes are

When traveling up slopes at an angle of 15°

applied automatically when the travel levers

or greater, travel in the posture shown in the

are returned to the neutral position.

diagram above.

If the crawlers slip

Traveling down slopes

Climbing

E4D046

If the crawlers slip while traveling up a slope,

When traveling down slopes at an angle of

use the pulling force of the arm to climb the

15° or greater, lower the engine speed and

slope.

travel in the posture shown in the diagram

above.

If the engine stops

Descending

E4D047E

If the engine stops when traveling down a

slope, set the travel levers to the neutral

position, stop the machine, then start the

engine.

81

OPERATION

Operating Procedures

Do not open the door while traveling on

Getting Out of Mud

slopes

If the machine gets stuck in mud, use the

procedure below to get it out.

If one crawler is stuck

E4D048

Opening the door while traveling on slopes

is dangerous, as the force required to open

and close the door changes abruptly. Always

keep the door closed when traveling on

slopes.

1. Slew the bucket to the side which is stuck.

2. Set the arm and boom to an angle of 90

to 110°.

3. Press the bottom of the bucket (not the

teeth) against the ground.

4. Place a plank, etc., under the lifted crawler.

5. Lift the bucket and slowly move out of the

mud.

If both crawlers are stuck

1. Perform steps 1 to 4 above for both

crawlers.

2. Dig the bucket into the ground in front of

the machine.

3. Pull with the arm and travel forward

simultaneously to slowly move out of the

mud.

82

OPERATION

Operating Procedures

Digging Side Ditches

Operations Possible with this

Machine

Excavating

80 ~120

C4D015

Use the offset function to dig side ditches as

shown in the diagram.

E4D0501

1. Set the dozer blade on the side opposite

the side you want to dig on.

Loading

2. Use the arm and bucket and dig with

shallow, long strokes. The digging force

is strongest when the boom and arm angle

is 80 to 120°. Use this angle for effective

digging.

Digging Ditches

When loading dirt in a truck, starting from

the back of the truck’s bed makes for easier

loading and increases the amount of dirt that

can be loaded.

Also, use a small slewing angle for greater

efficiency.

E4D051

Mount a bucket suited for digging ditches and

set the crawlers parallel to the ditch to be

dug for greater efficiency.

When digging wide ditches, dig the sides first,

the center later.

83

OPERATION

Operating Procedures

Leveling

E4D053

1. Bring the hoe attachment close to the

body.

2. Gradually remove the dirt from the side of

the mound.

3. Once the mound is low, remove the dirt

from the top. If the load on the body is too

heavy, adjust by raising or lowering the

dozer blade.

84

OPERATION

Parking the Machine

Parking

Inspection and Checks After

Stopping the Engine

WARNING

1. Check for oil and water leakage and

inspect the working equipment, covers

and lower body. If any irregularities are

found, repair.

2. Fill the fuel tank.

Refer to page 109 “Checking the Fuel

Level”.

3. Remove any paper scraps or dirt from the

engine room.

E3A4901

4. Remove any mud from the lower body.

¡ Park the machine on firm, level ground

Locking

and apply the parking device.

Be sure to lock the following places:

¡ Before leaving the operator’s seat, set

the safety lock lever securely to the

lock position and stop the engine. If any

controls should be touched

accidentally when the safety lock lever

is lowered, the machine will move

suddenly, and cause serious injury or

death.

1. Set the left and right travel levers to the

¡ Cab door

neutral position.

¡ Fuel filler cap

2. Return the throttle lever and idle the

¡ Engine hood

engine at low speed.

¡ Manual storage compartment

3. Lower the bucket and dozer blade to the

¡ Storage box

ground.

¡ Tool box

4. Place the safety lock lever in the lock

position.

5. Stop the engine and remove the key.

Refer to page 65 “Stopping the Engine” .

85

OPERATION

Handling Rubber Crawlers

Rubber crawlers have an inherent weakness

due to their use of rubber. Be sure to heed

the prohibitions and cautions below so as to

prevent damage to the crawlers and crawler

slippage.

Prohibited Actions

E4D057

Do not travel or operate the machine in the

¡ Do not let fuel, oil, salt or chemical solvents

following places:

get on the crawlers. These substances

may corrode the couplings of the crawlers’

metal cores, resulting in rust or peeling. If

these substances should get on the

crawlers, wipe them off immediately using

water.

E4D056

¡ Traveling or slewing on broken stone,

jagged base rock, iron rods, iron scraps

or the edges of iron sheets may damage

or cut the crawlers.

E4D058

¡ Traveling on roads directly after asphalting

or on hot surfaces such as over fires or

on iron sheets under strong sunlight may

result in irregular wear or damage of the

lugs.

¡ Do not move earth in places where the

rubber crawlers may slip. Doing so may

E4D055

speed up lug wear.

¡ Traveling on riverbeds or places with many

soft rocks may cause the crawlers to slip

off or be damaged due to rocks getting

stuck in them.

¡ Do not use on the seashore. The salt may

corrode the metal cores.

87

OPERATION

Handling Rubber Crawlers

¡ When storing the rubber crawlers for long

Cautions

periods of time (3 months or more), do so

indoors in a place not exposed to direct

Heed the following cautions when operating

sunlight or rain.

the machine:

L4D013

¡ Rubber crawler belts are not as stable as

¡ Do not turn the undercarriage with the front

steel crawler belts since the entire lug is

of the machine body lifted using the hoe

rubber. Be very careful when slewing and

attachment and the upperstructure left in

swinging sideways.

this posture. Doing so will twist the crawler

with the load concentrated on a single

Preventing the Rubber Crawlers from

point on the crawler belt, rapidly leading

Slipping Off

to damage.

Heed the following in order to prevent the

¡Avoid changing course abruptly and

rubber crawlers from slipping off:

spinning on concrete surfaces whenever

¡ Always keep the crawlers at the proper

possible.

tension.

Doing so may wear or damage the rubber

crawlers.

¡ Avoid drops that may expose the rubber

crawlers to strong shocks.

¡Salt, potassium chloride, ammonium

sulfate, potassium sulfate, and triple

superphosphate of lime can damage the

crawler belts. If any of these substances

should get on the crawler belts, wash them

off thoroughly with water.

¡ Do not let the sides of the rubber crawlers

¡ When traveling up large cobblestone or

rub against concrete or walls.

rock steps (20 cm (8 in.) or greater), climb

¡ Do not damage the rubber crawlers by

up the step at a direct angle and do not

hitting the bucket against them.

change course on top of the step.

¡Be especially careful in the winter on

snowy or frozen surfaces as the crawler

belts tend to slip.

¡ Use rubber crawler belts at temperatures

between -25°C to +55°C (-14°F to 131°F).

88

OPERATION

Handling Rubber Crawlers

¡ When climbing in reverse, do not change

course at the point where the slope starts.

¡ Do not change directions when the crawler

belts are slack as shown in the diagram.

¡ Avoid traveling with one crawler on a slope

or projecting object and the other crawler

on a flat surface (with the machine at a tilt

of 10° or greater). Travel with both

crawlers on flat surfaces.

89

TRANSPORT

Loading and Unloading

1. Apply the truck’s parking brake and place

WARNING

stoppers against its tires.

2. Fasten the ramps securely to the truck bed

The machine may roll or tip over or fall

so that they will not come off. Set the

while loading or unloading it. Take the

ramps to an angle of 15° or less.

following precautions:

3. Line up the center of the truck bed with

¡ Select a firm, level surface and keep

the center of the machine and the center

sufficient distance from road

of the ramps with the center of the

shoulders.

crawlers.

¡Use loading ramps of adequate

4. Make sure the dozer blade does not hit

strength and size. Maintain the slope

the ramps.

of loading ramps within 15 degrees.

5. Lower the hoe attachment as much as

¡ Keep the truck bed and loading ramps

possible, making sure it will not hit the

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

truck.

materials which can become slippery.

6. Lower the engine speed with the throttle

Clean the tracks.

lever.

¡ Never change course on the ramp.

¡Do not slew (swing) on ramps. The

machine may tip over.

¡ When slewing (swinging) on the truck

bed, do so slowly as the footing can

be unstable.

When loading or unloading the machine, be

sure to use ramps and following the

procedure below.

Fasten to the suspension fitting

Ramp

Stopper

15° or less

Distance between ramps

E4F001

7. Determine the direction on the ramps, then

slowly travel up or down the ramps in 1st

speed (low speed), following the signals

of a flagman.

8. Load the machine properly at the

prescribed position on the bed.

Refer to page 94 “Transporting Posture”.

92

TRANSPORT

Hoisting the Machine

Hoisting posture

WARNING

Lift Eye

¡ Know and use correct crane signals.

¡ Inspect the hoisting equipment daily

for damaged or missing parts.

¡ Keep all other persons out of the area

when hoisting. Do not move the

machine over the heads of the persons.

¡Do not hoist the machine with an

operator(s) on it.

¡ When hoisting, use a wire rope with

sufficient strength with respect to the

machine’s weight.

¡Do not hoist with the machine in a

posture other than the one described

in the procedure below. Doing so is

C4F002E

dangerous as it may result in the

1. Park the machine on a level surface.

machine losing its balance.

2. Slew the upper structure so that the dozer

blade is positioned to the rear of the body

IMPORTANT: This hoisting method

(so that the crawler frame and upper

applies to machines with standard

structure are parallel).

specifications.

3. Fully extend the bucket, arm and boom

cylinders.

4. If the boom is swung to either the left or

right side, set it so that it is straight ahead.

5. Raise the dozer blade.

6. Set the safety lock lever securely to the

locked position.

7. Stop the engine and remove the starter

key and get off the machine.

8. Fix the sling to the lift eyes.

Hoisting

1. Hoist slowly until the machine just leaves

the ground.

2. Stop hoisting until the machine is stable.

3. Hoist slowly.

C4F001

When hoisting this machine with a crane, use

a two leg sling with a 60 degree sling angle.

Each leg of the sling must have a minimum

length of 810 mm (31.9 in.).

93

TRANSPORT

Securing the Machine

Cautions on Transporting

After loading the machine in the designated

position, secure it as described below.

Transporting Posture

Wire rope

Padding

E4F002

1. Lower the dozer blade.

Cautions on Transporting

2. Fully extend the bucket and arm cylinders,

then lower the boom.

WARNING

3. Stop the engine and remove the starter

key.

¡Know and follow the safety rules,

4. Set the safety lock lever securely to the

vehicle code and traffic laws when

locked position.

transporting the machine.

5. Set stoppers in front and behind the

¡ Consider the length, width, height and

crawlers.

weight of the truck with the machine

6. Put a chain or wire rope over the lower

loaded on it when determining the best

frame and fasten it securely to prevent

route.

sideways slippage.

7. Secure the bucket with a chain or wire

rope.

IMPORTANT: Place a wooden block

under the bucket so that it is not damaged

by hitting the floor.

94

MAINTENANCE

General

Do not clean parts with fuel.

Disposing of wastes

Do not use fuel to clean parts. Use a non-

¡ Collect spent fluids from the machine in

combustible cleaning agent.

containers. Disposing of wastes

irresponsibly damages the environment.

Keep dirt out.

¡ Dispose of oil, fuel, cooling water, coolant,

When mounting and removing parts, do so

filters, batteries and other harmful

in a place where there is no dust, clean the

substances as prescribed by law.

working area and the part, and keep dirt out.

Check after maintenance

Clean mounting surfaces.

¡ Gradually increase the engine speed from

When mounting and removing parts, be sure

a low idle to maximum speed and check

that the surfaces of contact of the parts are

that there is no oil or water leaking from

clean. If the sealing grooves of the surface

serviced parts.

of contact are damaged, consult a Takeuchi

¡ Operate all the operating levers and check

sales or service outlet.

that the machine is operating properly.

Seals and split pins

Cautions on handling of battery cables

¡ Replace removed seals and split pins with

¡ Disconnect the battery cables (+,-) before

new ones.

working on the electrical system or doing

¡ When mounting, be careful not to damage

any welding.

or twist the seal.

Remove the negative (-) battery cable first.

When reconnecting the battery, connect

Sealing tape

the negative (-) battery cable last.

¡ Do not disconnect the battery cables while

Sealing tape

the engine is running. Doing so could

damage the electronic circuitry of the

alternator and other parts.

Leave 1 or 2 threads free

E4G001

¡When wrapping sealing tape around

plugs, etc., remove any old sealing tape

from the threads and clean the threads.

¡ Wrap the sealing tape tight, leaving 1 or 2

threads at the tip free.

97

MAINTENANCE

Service Data

Fuel and Lubricant Chart

Use different fuels, lubricants and greases according to the temperature, referring to the

chart below.

¡ Change the lubricant earlier than as shown in the table if it is extremely dirty or its

performance has deteriorated severely.

¡ Whenever possible, use the same brand of lubricant as before. If changing with a different

brand, replace the entire quantity - do not mix different brands.

Type by temperature

Replacement

Capacity

Part

Type

-22

-4

14 32 50 68 86 104°F

interval

R(US. qt.)

-30 -20 -10

0

10 20 30 40 °C

Upper limit:

TB014: 3.0 (3.2)

Diesel

SAE 5W-20

After first 50

Engine

TB016: 2.8 (3.0)

engine oil

SAE 10W-30

hrs.

oil pan

Lower limit:

API - CD

SAE 15W-40

Every 250 hrs.

TB014: 1.7 (1.8)

TB016: 1.5 (1.6)

Antiwear

System:

hydraulic oil

ISO VG32

TB014: 33 (34.9)

Hydraulic

(Option:

ISO VG46

Every 2000 hrs.

TB016: 33.5 (35.4)

tank

Biodegradable

ISO VG68

Tank:

oil)

23 (24.3)

Use a clean, Quality fuel for good performance and optimum engine life.

¡ To prevent fuel flow problems in cold weather, use diesel fuel with a pour point of at

Tank:

Fuel tank

Diesel fuel

least -12°C (10°F) below the lowest expected ambient temperature.

21 (22.2)

¡ Minimum cetane number is 45. Low temperature or high altitude operation may

require the use of fuel with a higher cetane number.

Engine

Coolant (water*

50% coolant mixture

cooling

Every 1000 hrs.

3.4

(3.6)

+ coolant**)

30% coolant mixture

system

Travel

Gear oil

After first 250 hrs.

0.33

reduction

SAE 90

API-GL-4

Every 1000 hrs.

(0.35)each

gear

Slew motor

Every 50 hrs.

pinion

Lithium

Slew

based

Every 50 hrs.

bearing

As

grease

Working

EP-2

Daily or every

required

equipment

10 hrs.

NLGI No. 2

When

Levers

required

* For water, use tap water (soft). Do not use well or river water.

** When the ambient temperature drops below 0°C, add coolant (antifreeze). Follow the

coolant manufacturer’s instructions to determine the mixture ratio.

98

MAINTENANCE

Service Data

Replace the hydraulic oil regularly!

¡ When using a hydraulic breaker, the oil

Replacement Interval (Hours)

deteriorates quicker than during normal

Item

Hydraulic Oil

Filter Element

digging. Be sure to replace the hydraulic

oil and return filter element.

1st time

25

• Failure to replace these in time can lead

2nd time

100

to damage to the machine and breaker’s

Periodically

600

200

hydraulic systems. In order to improve

the service life of the hydraulic systems,

When the breaker operating ratio is 100%

be sure to replace the hydraulic oil and

Refer to page 192 “Hydraulic Breaker”.

return filter element according to the

following chart of the replacement

interval.

• Clean the suction strainer when

changing the return filter element.

Expendables

Replace expendables such as filters and elements periodically, referring to the table below.

Item

Part name

Part No.

Replacement interval

Hydraulic oil return

Element

15511-01300

After first 50 hrs.

filter

Every 500 hrs.

Fuel filter

Element

<

TB014 >

Every 500 hrs.

RA211-51281

< TB016 >

119810-55650

Engine oil filter

Cartridge

< TB014 >

After first 50 hrs.

15852-32431

Every 250 hrs.

< TB016 >

129150-35151

Air cleaner

Element

< TB014 >

Every 1000 hrs. or

(outer)

1G659-11221

after 6 cleanings

< TB016 >

(whichever comes

119515-12520

first)

Inner Element

19111-01342

Every 1000 hrs. or

(option)

after 3 cleanings of

the outer element

(whichever comes

first)

99

MAINTENANCE

Service Data

Tools

No.

Part name

Part No.

Remarks

No.

Part name

Part No.

Remarks

1

Spanner

19102-12081

10-12 <TB014>

7

Filter wrench

19100-96081

< TB016 >

1

Spanner

19100-47081

10-12 <TB016>

8

Monkey wrench

16904-00250

250mm

2

Spanner

19102-12082

12-14 <TB014>

9

Spanner

16901-00013

13

3

Spanner

19102-12083

13-17 <TB014>

10

Spanner

16900-01922

19-22

3

Spanner

19100-47082

14-17 <TB016>

11

Spanner

16909-00026

26

4

Socket wrench

19102-12084

19-22 <TB014>

12

Pliers

16905-00200

200mm

5

Screwdriver

19102-12085

(+) (-) <TB014>

13

Grease gun

16910-60600

600cc

5

Screwdriver

19100-06112

(+) (-) <TB016>

14

Tool case

16914-00001

6

Filter wrench

03392-22610

< TB014 >

15

Drain connector

15545-12201

for EU

100

MAINTENANCE

Service Data

Tightening Torques

Nuts and Bolts (for ISO strength category 10.9)

Tighten nuts and bolts at the torques shown on the table below, unless otherwise specified in

the text.

¡ Tightening torques when mounting plastic covers differ from the values on the table below.

Consult a Takeuchi sales or service outlet. Tightening too strongly will break the cover.

¡ When replacing nuts and bolts, replace them with nuts and bolts of the same size and

standards.

¡ Tighten nuts and bolts alternately (top, bottom, left then right) or in 2 or 3 times so that they

are tightened uniformly.

1

3

6

5

4

2

E4G003

Head width

Torque

Size (a) X Pitch

Thread

(b)

General Connection Points

mm

mm

N·m

ft-lb

10

M6 X 1.0

9.8 ± 0.5

7.2 ± 0.4

12, 13

M8 X 1.25

22.6 ± 1.1

16.6 ± 0.8

14, 17

M10 X 1.5

47.1 ± 2.4

34.7 ± 1.7

Coarse

17, 19

M12 X 1.75

83.4 ± 4.1

61.5 ± 3.0

19, 22

M14 X 2.0

134.4 ± 6.7

99.1 ± 4.9

22, 24

M16 X 2.0

207.9 ± 10.4

153.3 ± 7.7

27, 30

M20 X 2.5

410.9 ± 20.5

303.1 ± 15.1

12, 13

M8 X 1.0

24.5 ± 1.2

18.1 ± 0.9

14, 17

M10 X 1.25

50 ± 2.5

36.9 ± 1.8

17, 19

M12 X 1.5

87.3 ± 4.3

64.4 ± 3.2

Fine

19, 22

M14 X 1.5

135.3 ± 6.8

99.8 ± 5.0

22, 24

M16 X 1.5

220.6 ± 11

162.7 ± 8.1

27, 30

M20 X 1.5

452.1 ± 22.6

333.4 ± 16.6

101

MAINTENANCE

Important Parts

For safe use, the machine must be serviced periodically. To increase safety, periodically

replace the parts listed in the following table of important parts.

Serious injury or a fire could result if they deteriorate or are damaged.

Table of Important Parts

Unit

Important parts to be replaced periodically

Replacement Interval

Fuel hoses

Fuel system

Packing in fuel filler cap

Heater hoses

Heater & AC systems

Air conditioner hoses

Hydraulic hoses ( Pump - delivery )

Machine

Hydraulic hoses ( Pump - suction )

body

Hydraulic hoses ( Slew motor )

Hydraulic hoses ( Travel motor )

Hydraulic hoses ( Boom cylinder lines )

Every 2 years

Hydraulic

Hydraulic hoses ( Arm cylinder lines)

system

Hydraulic hoses ( Bucket cylinder lines )

Working

Hydraulic hoses ( Swing cylinder )

equipment

Hydraulic hoses ( Blade cylinder )

Hydraulic hoses ( Span cylinder )

Hydraulic hoses ( Pilot valve )

Hydraulic hoses ( Auxiliary lines )

Seat belt

Every 3 years

Above important parts are vulnerable to aging and wear or deterioration and it is difficult to

determine the degree to which they have deteriorated on the occasion of periodic service. To

maintain their proper function at all times, therefore, replace them with new ones after using

them for a specific period of time even if no abnormality is found with the parts. If you find

abnormalities in these parts before their scheduled replacement time is reached, repair or

replace them immediately. If a hose clamp is deformed or cracked, replace it immediately.

When replacing the important parts, please contact a Takeuchi sales or service outlet .

Also check the hydraulic hoses other than the above important parts. If any abnormality is

found in them, retighten them or replace them immediately.

When replacing the hydraulic hoses, replace the O-rings and seals at the same time.

Check the fuel and hydraulic hoses according to the periodic schedule described below.

Refer to “Maintenance”.

Type of inspection

Inspection item

Daily inspection

Leakages from joints, hydraulic or fuel hoses.

Monthly inspection

Leakages from joints, hydraulic or fuel hoses.

Damaged hydraulic or fuel hoses (cracks, wear and tear).

Annual inspection

Leakages from joints, hydraulic or fuel hoses.

Deteriorated, twisted, damaged hydraulic or fuel hoses (cracks, wear

and tear) or hoses in contact with other parts of the machine.

102

MAINTENANCE

Maintenance Chart

Maintenance Items

See page

Walk-Around Inspection

Inspecting by opening the engine hood and covers

105

Inspecting by walking around the machine

106

Inspecting while sitting in the operator’s seat

106

Daily Inspection (Every 10 Hours)

Inspecting and replenishing the coolant

107

Inspecting and replenishing the engine oil

108

Inspecting the dust indicator

108

Inspecting the water separator

109

Checking the fuel level

109

Inspecting the hydraulic oil level and replenishing

110

Lubricating the working equipment

111

After First 50 Hours (New Machines Only)

Replacing the hydraulic oil return filter

112

Replacing the engine oil and oil filter

113

Inspecting and adjusting the fan belt

114

Every 50 Hours

Inspecting and adjusting the crawler tension

115

Lubricating the slew bearing

116

Lubricating the slew motor pinion

117

Inspecting the battery fluid level and replenishing

117

Draining the fuel tank

118

Every 100 Hours

Cleaning the fuel filter

119

Cleaning the water separator

119

After First 250 Hours (New Machines Only)

Replacing the travel motor gear oil

120

103

MAINTENANCE

Maintenance Chart

Maintenance Items

See page

Every 250 Hours

Inspecting and adjusting the fan belt

121

Replacing the engine oil and oil filter

121

Cleaning the air cleaner

121

Cleaning the radiator fins and oil cooler fins

122

Every 500 Hours

Replacing the hydraulic oil return filter

123

Replacing the fuel filter

123

Every 1000 Hours

Cleaning the engine cooling system

124

Replacing the air cleaner element

125

Replacing the travel motor gear oil

126

Inspecting and adjusting the engine valve clearance

126

Retightening the engine cylinder head bolts

126

Inspecting the engine fuel injection pressure and spray condition

126

Every 2000 Hours

Replacing the hydraulic oil and cleaning the suction strainer

127

Inspecting the engine fuel injection timing

128

Inspecting the engine fuel injection valve

128

When Required

Replacing the bucket teeth

129

Replacing the bucket

130

Lubricating the levers

131

Inspecting and replenishing the windshield washer fluid

132

Inspecting the rubber crawlers

133

Replacing the rubber crawlers

134

104

MAINTENANCE

Walk-Around Inspection

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

WARNING

¡ Before operating, perform the walk-around inspections and make repairs immediately

should any irregularities be found.

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

hood or cover on slopes or in strong wind.

Before starting the engine, look around the machine and lower body, clean any combustible

materials off high temperature parts of the engine, and inspect for such irregularities as oil

leakage, water leakage and looseness of nuts and bolts.

11

13

15

14

8

4

5

1

2

12

3

10

9

6

7

C4G003

Inspecting by Opening the

Engine Hood and Covers

1. Check for any twigs, leaves, oil or other

3. Check for oil leakage from the hydraulic

combustible materials around the engine

tank, hydraulic devices, hoses and

and battery.

connections.

2. Check for oil or engine coolant water

leakage around the engine.

105

MAINTENANCE

Daily Inspection (Every 10 Hours)

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

WARNING

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

any irregularities be found.

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

hood or cover on slopes or in strong wind.

2. Inspect the quantity of coolant in the

Inspecting and Replenishing the

reserve tank (1).

Coolant

The level should be between the upper

limit (H) and lower limit (L).

WARNING

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

Do not remove the radiator cap or drain

Replenishing

plugs when the coolant is hot. Stop the

1. Remove the reserve tank’s cap (2).

engine, let the engine and radiator cool

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

and loosen the radiator cap or drain plugs

the reserve tank (1).

slowly.

If the reserve tank is empty, inspect for

fluid leakage, then inspect the radiator

Inspection

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

< TB014 >

radiator first, then to the reserve tank.

3. Install the cap (2).

2

H

3

1

L

< TB016 >

2

1

3

H

L

1. Open the engine hood.

107

MAINTENANCE

Daily Inspection (Every 10 Hours)

Replenishing

Inspecting and Replenishing the

1. Remove the oil supply cap (2).

Engine Oil

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

dipstick (1).

WARNING

Problems could arise if the oil level is either

too low or too high.

Stop the engine and allow the machine

3. Tighten the oil supply cap (2).

to cool down before performing

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

inspection and maintenance.

3 minutes, then stop it.

5. After about 10 minutes, inspect the oil

Inspection

level.

< TB014 >

L

H

1

2

Inspecting the Dust Indicator

4

WARNING

Stop the engine and allow the machine

to cool down before performing

< TB016 >

inspection and maintenance.

L

H

1

The dust indicator indicates clogging of the

air cleaner.

2

3

1

4

D5G003

2

1. Open the engine hood.

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

C4G006

oil with a rag.

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

1. Open the engine hood.

back out.

2. Check that the red piston (2) is not sticking

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

out of the dust indicator (1).

The level should be between the upper

3. If the red piston (2) is sticking out, clean

limit (H) and lower limit (L).

or replace the element immediately.

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

Refer to page 121 “Cleaning the Air

Cleaner”.

4. After the operation is completed, press the

button (3) on the dust indicator (1) to push

the red piston (2) back in.

108

MAINTENANCE

Daily Inspection (Every 10 Hours)

Inspecting the Water Separator

Checking the Fuel Level

WARNING

WARNING

Stop the engine and allow the machine

¡ Do not smoke or permit open flames

to cool down before performing

while fueling or near fueling

inspection and maintenance.

operations.

¡Stop the engine in a well-ventilated

< TB014 >

place when adding fuel.

¡ Clean up spilled fuel immediately.

¡ Do not fill the fuel tank to capacity.

Allow room for expansion.

¡ Tighten the fuel tank cap securely.

2

1

< TB016 >

Closed

1

C4G009

2

1. Check the fuel level using the sight gauge

3

(1).

4

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

5

6

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

Refer to page 42 “Fuel Filler Cap”.

1. Open the engine hood.

2. Inspect the water separator (1).

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

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

in.

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

is water up to the bottom of the ring. Drain

the water and clean.

Refer to page 119 “Cleaning the Water

Separator”.

109

MAINTENANCE

Daily Inspection (Every 10 Hours)

Replenishing

Inspecting the Hydraulic Oil Level

and Replenishing

8

WARNING

1

Oil may spurt out if caps or filters are

removed or pipes disconnected before

releasing the pressure in the hydraulic

4

system.

C4G011

¡Gradually loosen the vent plug to

1. Set the left safety lock lever to the locked

relieve tank pressure.

position.

2. Loosen the bolt and remove the cover (8).

Inspection

(For cab models)

The oil level changes according to the oil

3. Slowly turn the vent plug (1) to release

temperature. Inspect the oil level in the

the internal pressure, then remove.

hydraulic oil level inspection posture shown

4. Add hydraulic oil up to the middle of the

in the diagram.

sight gauge (4).

¡ Hydraulic oil level inspection posture

5. Pressurize the hydraulic tank using the

procedure next.

Pressurizing the hydraulic tank

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

2. With the vent plug (1) removed, set the

safety lock lever to the released position.

¡ Hydraulic tank pressurization posture

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

2. Fully retract the arm and bucket cylinders

and ground the bucket.

3. Ground the dozer blade, then stop the

engine.

4. Inspect the oil level using the sight gauge

(4).

• When the oil temperature is about 20°C

(68°F):

3. Fully extend the bucket, arm, boom and

The level should be halfway between the

swing cylinders.

upper limit (H) and lower limit (L).

4. Stop the engine and set the left safety lock

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

lever to the locked position.

• When the oil temperature is about 50 to

5. Tighten the vent plug (1), then pressurize.

80°C (122 to 176°F):

The level should be near the upper limit

(H).

110

MAINTENANCE

Daily Inspection (Every 10 Hours)

Lubricating the Working Equipment

C4G0132

1. Set the machine to the lubrication posture shown in the diagram above, ground the

working equipment, then stop the engine.

2. Use the grease gun to lubricate the grease nipples.

3. Wipe off the expelled grease.

Supplement: The dozer blade uses greaseless bushes, so there is no need to lubricate it.

111

MAINTENANCE

After First 50 Hours (New Machines Only)

2. Loosen the bolt and remove the cover (8).

Replacing the Hydraulic Oil

(For cab models)

Return Filter

WARNING

1

¡ Stop the engine and allow the machine

9

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.

2

C4G014

Touching these parts will cause

3. Slowly turn the vent plug (1) to relieve tank

burns.

pressure, then remove.

• The hydraulic fluid is also hot and

4. Open the maintenance cover.

under high pressure.

5. Remove the four bolts from the cover (2).

Be careful when loosening caps and

6. Remove the adapter (9), then remove the

plugs. Working on the machine under

cover (2).

these conditions could result in

burns or injuries due to the hot oil

spurting out.

2

1

9

2

8

¡ Oil may spurt out if caps or filters are

removed or pipes disconnected before

4

releasing the pressure in the hydraulic

3

system.

7

• Gradually loosen the vent plug to

3

relieve tank pressure.

5

6

• When removing plugs or screws or

6

10

C4G036

disconnecting hoses, stand to the

7. Remove the return filter (3).

side and loosen slowly to gradually

8. Install the new return filter.

release the internal pressure before

9. Install the adapter (9) and cover (2).

removing.

10. Inspect the level with the sight gauge (4),

and replenish if the level is low.

8

Refer to page 110 “Inspecting the

Hydraulic Oil Level and Replenishing”.

1

11. Pressurize the hydraulic tank.

Refer to page 110 “Pressurizing the

hydraulic tank”.

4

C4G011

1. Set the left safety lock lever to the locked

position.

112

MAINTENANCE

After First 50 Hours (New Machines Only)

IMPORTANT: Check the spent oil. If it

Replacing the Engine Oil and Oil

contains large amounts of metal powder,

Filter

consult a Takeuchi sales or service outlet.

WARNING

< TB014 >

Stop the engine and allow the machine

to cool down before performing

L

H

1

2

maintenance.

¡ The engine, muffler, radiator and many

4

other parts of the machine are hot

directly after the engine is stopped.

Touching these parts will cause burns.

¡ The engine oil is also hot.

Be careful when loosening caps and

< TB016 >

plugs. Working on the machine under

these conditions could result in burns.

L

H

1

< TB014 >

2

4

D5G003

B

A

3

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

counterclockwise and remove it.

5. Clean the surface of installation of the filter

stand.

< TB016 >

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

the new filter.

7. Install the new filter by hand.

8. Tighten 3/4 more turn after the filter

packing comes in contact with the surface

3

of installation.

B

A

9. Remove the oil supply cap (2).

10. 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.

1. Place a pan for catching the spent oil

11. Tighten the oil supply cap (2).

under the drain plug (3).

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

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

3 minutes, then stop it.

drain the oil. (The oil comes out when the

13. After about 10 minutes, inspect the oil

screw is tightened.)

level.

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

113

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.

1

¡ The engine, muffler, radiator, hydraulic

C4G017

lines, sliding parts and many other

1. Open the maintenance cover.

parts of the machine are hot directly

2. Remove the four bolts, then remove the

after the engine is stopped. Touching

cover (1).

these parts will cause burns.

Inspection

1. Open the engine hood.

3. Loosen the adjustment bolt (5) and locking

nut (6).

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

and adjust the slack.

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

5. Tighten the adjustment bolt (5) and locking

and alternator pulley (3) and check the

nut (6).

tension (about 98 N or 22 lbs.).

6. Install the cover (1).

Proper slack (A) :

< TB014 >

5 to 7 mm (0.2 to 0.28 in.)

< TB016 >

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.

114

MAINTENANCE

Every 50 Hours

Inspecting and Adjusting the

A B

Crawler Tension

WARNING

¡ If you must work beneath the raised

machine or equipment, always use

wood blocks, jack-stands or other rigid

E4G0201

and stable supports. Never get under

2. Use the operating devices to lift the body.

the machine or working equipment if

Operate the levers slowly.

they are not sufficiently supported.

This procedure is especially important

when working on hydraulic cylinders.

¡The track adjuster contains highly

pressurized grease. If the tension is

adjusted without following the

prescribed procedure, the grease

A

B

discharge valve may fly off, resulting

in injury.

• Do not loosen the grease nipple.

C5G024

• Loosen the grease discharge valve

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

slowly.

bottom surface of the frame at the center

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

of the crawler frame and the top surface

in front of the grease discharge valve.

of the crawler.

• If no grease is expelled when grease

The gap (A or B) should be within the

discharge valve is loosened, there is

following range:

a problem. Contact your nearest

(A) Rubber crawler:

service outlet for repairs. DO NOT

65 to 70 mm (2.6 to 2.8 in.)

disassemble, as this is very

(B) Steel crawler:

dangerous.

100 to 115 mm (3.9 to 4.5 in.)

Inspection

C4G0182

1. For rubber crawlers, move the machine

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

is at the top center of the crawler frame.

115

MAINTENANCE

Every 50 Hours

Adjustment

Lubricating the Slew Bearing

Increasing the tension

WARNING

1

2

Do not slew while lubricating. Doing so

is dangerous, as you may get caught in

the machine.

3

D5G025

1. Remove the cover (1).

2. Using the grease gun, insert grease

through the grease nipple (3) in the grease

discharge valve (2).

3. Inspect the crawler tension.

Decreasing the tension

1. Stop the engine with the machine in the

posture shown on the diagram above.

2. Use the grease gun to supply grease to

2

1

the grease nipple (1).

3

D5G026

1. Remove the cover (1).

2. Using the Spanner, slowly loosen the

grease discharge valve (2) and drain the

E4G026

grease.

If the grease does not drain easily, move

3. Start the engine, lift the bucket and slew

the machine forward or backward.

clockwise 90°.

3. Tighten the grease discharge valve (2).

4. Ground the bucket and stop the engine.

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

5. Repeat steps 2 to 4 above three times.

6. Wipe off the grease expelled from the slew

bearing and grease nipple.

116

MAINTENANCE

Every 50 Hours

Lubricating the Slew Motor

WARNING

Pinion

¡ 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 medical attention.

• If acid is accidentally swallowed,

1. Use the grease gun to supply grease to

drink large quantities of water or milk

the grease nipple (2).

and call a physician immediately.

2. Wipe off the grease expelled from the

• If acid contacts skin or clothing, wash

grease nipple.

off immediately with clean water.

Inspection

IMPORTANT: Check the fluid level of all

Inspecting the Battery Fluid Level

cells, even when the fluid level can be

checked by indicator.

and Replenishing

DANGER

¡ Do not use the battery when the fluid

level is below the lower level. Doing so

will hasten the deterioration of the

internal portions of the battery and

shorten the battery life, and can also

cause rupturing (or an explosion).

¡Batteries generate flammable and

explosive gases. Keep arcs, sparks,

1. Open the maintenance cover.

flames and lighted tobacco away.

2. Inspect the indicator (1).

¡ Use a dampened cloth to clean the area

• Blue: Good

of the fluid level lines and check the

• White: Charging needed

fluid level. Note that if this area is

• Red: Insufficient battery fluid

cleaned with a dry cloth, static

3. Inspect the fluid level.

electricity could cause ignition or

The fluid level should be between the lines

explosion.

indicating the upper level (H) and lower

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

line (H).

117

MAINTENANCE

Every 50 Hours

¡ If the fluid level can not be checked by

Draining the Fuel Tank

fluid level lines.

WARNING

¡ Do not smoke or permit open flames

while handling fuel or working on the

fuel system.

¡Stop the engine in a well-ventilated

place and allow it to cool down before

performing maintenance.

¡ Clean up spilled fuel immediately.

Remove the caps (2) and look into the fluid

supply holes to check the fluid level. If the

Do this before operating the machine.

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

distilled water up to the bottom edge of the

sleeve (3).

Proper amount

(A)

The fluid reaches up to the bottom edge

of the sleeve (3), so the surface tension

causes the fluid to swell and the plate

appears distorted.

Level too low

(B)

The fluid does not reach up to the bottom

1. Remove the fuel cap (2).

edge of the sleeve (3), so the plate

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

appears laminar, not distorted.

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

4. Also check the terminals for looseness and

water and sediment from the bottom of

dirt.

the tank.

4. Close the drain cock (3).

Replenishing

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

When adding distilled water, do so before

fuel.

starting operations in order to prevent

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

freezing.

the key.

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

Refer to page 141 “Bleeding the air from

water until the upper level (H).

the fuel system”.

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

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

the caps (2) securely.

118

MAINTENANCE

Every 100 Hours

Cleaning the Fuel Filter

Cleaning the Water Separator

WARNING

WARNING

¡ Do not smoke or permit open flames

¡ Do not smoke or permit open flames

while handling fuel or working on the

while handling fuel or working on the

fuel system.

fuel system.

¡Stop the engine in a well-ventilated

¡Stop the engine in a well-ventilated

place and allow it to cool down before

place and allow it to cool down before

performing maintenance.

performing maintenance.

¡ Clean up spilled fuel immediately.

¡ Clean up spilled fuel immediately.

< TB014 >

< TB014 >

Refer to “Cleaning the Water Separator”.

< TB016 >

< TB016 >

C4G023E

Closed

1

1. Open the engine hood.

2. Close the cock (2).

2

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

3

(4) and element (5) and clean them.

4

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

5

6

scratches or other irregularities, replace it.

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

and tighten the ring (3).

1. Open the engine hood.

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

2. Close the cock (2).

Refer to page 141 “Bleeding the air from

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

the fuel system”.

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

7. Start the engine and inspect for fuel

clean them.

leakage.

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

scratches or other irregularities, replace it.

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

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

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

Refer to page 141 “Bleeding the air from

the fuel system”.

119

MAINTENANCE

After First 250 Hours (New Machines Only)

Replacing the Travel Motor Gear

Oil

WARNING

¡ Stop the engine and allow the machine

to cool down before performing

maintenance.

• The travel motors are hot directly

after the engine is stopped. Touching

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 travel motor

reduction gears case may cause oil or

the plug to fly out. Loosen the plug

slowly to release the pressure.

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

the very bottom.

2. Place a pan for catching the spent oil

under plug (2).

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

oil.

4. Wrap new sealing tape around the plugs.

5. Tighten plug (2).

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

oil flows out of the hole.

7. Tighten plug (1).

120

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