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Takeuchi tb216 mini excavator operator manual (serial no. 216100002 and up)

This document provides safety instructions for operating an excavator. It states that only trained operators should operate the excavator. Any problems detected with the machine such as strange noises or smells should immediately be reported to the dealer. The machine should not be operated in temperatures outside of -15°C to 45°C. Safety rules and regulations must always be followed when operating and maintaining the excavator.

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SAFETY ALERT SYMBOL This symbol represents the safety alert. The message that follows the symbol contains important information about safety. Read and understand the message to avoid personal injury or death. It is the owner or employer’s responsibility to fully instruct each operator in the proper and safe operation of all equipment. All persons using this machine should thoroughly familiarize themselves with the contents of this manual. All operators must be instructed on the proper functions of the excavator before running the machine. Learn and practice correct use of the machine controls in a safe, clear area before operating this machine on a job site. Improper operation, inspection and maintenance of this machine can cause injury or death. Read and understand this manual before performing any operation, inspection or maintenance on this machine. Always store this manual near at hand preferably on the machine itself. If it should be lost or damaged, immediately order a new one from your Takeuchi dealer. When transferring ownership of this machine, be sure to hand this manual to the next owner. Takeuchi supplies machines complying with the local regulations and standards of the country of export. If your machine has been purchased in another country or from a person or company of another country, it may not have the safety devices or safety standards required for use in your country. Should you have any question about whether your machine complies with the regulations and standards of your country, contact a Takeuchi dealer.
0-1 SIGNAL WORDS Safety messages appearing in this manual and on machine decals are identified by the words “DANGER”, “WARNING” and “CAUTION”. These signal words mean the following: DANGER indicates a hazard with a high level of risk which, if not avoided, will result in death or serious injury. WARNING indicates a hazard with a medium level of risk which, if not avoided, could result in death or serious injury. CAUTION indicates a hazard with a low level of risk which, if not avoided, could result in minor moderate injury. IMPORTANT: The word IMPORTANT is used to alert operators and maintenance personnel about situations which could result in damage to the machine and its components. It is impossible to foresee every possible circumstance that might involve a potential hazard. The warnings in this manual or on the machine can not cover all possible contingencies. You must exercise all due care and follow normal safety procedures when operating the machine so as to ensure that no damage occurs to the machine, its operators or other persons.
0-2 FOREWORD This manual describes operation, inspection and maintenance of the machine, as well as safety instructions to be heeded during these operations. If you have any questions about the machine, please contact a Takeuchi sales or service outlet. INTRODUCTION MANUAL STORAGE COMPARTMENT A compartment for storing this manual is provided at the position shown on the diagram below. 1. Insert the starter key and turn it counterclockwise to open the cover under the seat. 2. After using the manual, place it in the plastic pouch and store it back in the manual storage compartment. SERIAL NUMBERS IMPORTANT: Do not remove the machine name plate with the serial number. Check the serial numbers of the machine and engine and write them down in the spaces below. Machine number: Engine number: AD6O003
0-3 FRONT, REAR, LEFT AND RIGHT MACHINE DESCRIPTION This manual refers the front, rear, left and right of the machine as seen when sitting in the operator’s seat with the dozer blade visible to the front. DESIGNATED OPERATIONS Use this machine primarily for the following operations: • Excavation • Digging ditches • Digging side ditches • Leveling • Loading FEATURES • “Flexible machine width mechanism” for crawler width • Low engine noise and exhaust emissions BREAK-IN PERIOD When the machine is new, operate the machine for the first 100 hours (as indicated on the hour meter) by following the instructions below. Using a new machine without a break-in period will lead to quicker deterioration of machine performance and may shorten the machine’s service life. • Sufficiently warm up the engine and hydraulic oil. • Avoid heavy loads and rapid operations. Operate with a load of about 80% the maximum load. • Do not abruptly start up, accelerate, change directions, or stop unless necessary.
0-4 NOTES ON READING THIS MANUAL Please note that the descriptions and diagrams included in this manual may not be applicable to your machine. The numbers used in the illustration are with circles around them. The same numbers appear between the parentheses in the text. (Example: (1)) Symbols used in this manual The symbols used in this manual have the following meanings. ...... Prohibition ............. Lock ............. Unlock
0-5 CONTENTS Introduction......................................0-2 Machine description.........................0-3 Safety...............................................1-1 General precautions.................................1-2 Precautions when preparing.....................1-8 Precautions when starting......................1-12 Precautions when operating...................1-14 Precautions when stopping....................1-23 Precautions when transporting...............1-24 Precautions on maintenance..................1-26 Safety signs (decals)...............................1-35 Controls............................................2-1 Names of components (Cab)....................2-2 Names of components (Canopy)..............2-4 Covers......................................................2-6 Starter key............................................2-6 Maintenance cover...............................2-6 Fuse box..............................................2-7 Tool case..............................................2-7 Grease gun holder................................2-7 Fuel lid..................................................2-8 Fuel filler port........................................2-8 Side cover............................................2-9 Engine hood.........................................2-9 Cab........................................................2-10 Cab door............................................2-10 Emergency exit...................................2-10 Front window......................................2-11 Lower front window............................2-12 Side window.......................................2-12 Emergency hammer (optional)............2-13 Seat and seat belt..................................2-14 Seat (If equipped)................................2-14 High-back seat (If equipped)...............2-15 Seat belt.............................................2-16 Instrument cluster...................................2-18 Warning lamps....................................2-18 Indicators...........................................2-19 Meters................................................2-19 Multi-data display...............................2-20 Switches................................................2-26 Starter switch.....................................2-26 Horn button........................................2-26 Travel speed switch............................2-26 Wiper switch.......................................2-27 Second auxiliary hydraulic switch........2-27 Third auxiliary hydraulic switch and button.................................................2-27 Lift overload warning switch (If equipped)........................................2-28 Levers and Pedals..................................2-29 Safety lock lever.................................2-29 Throttle lever.......................................2-29 Operating levers.................................2-30 Blade lever..........................................2-30 Travel levers/pedals............................2-31 Boom swing pedal..............................2-31 Auxiliary hydraulic pedal......................2-32 Selector lever .....................................2-32 Accessories............................................2-34 Heater................................................2-34 Cup holder.........................................2-36 Interior light.........................................2-36 Inside rear view mirror (cab)................2-36 Power sockets ...................................2-37 Armrest..............................................2-37 Radio (for cab)....................................2-38 Auxiliary hydraulic lines.......................2-42 Accumulator (If equipped)...................2-46 Operation..........................................3-1 Before starting operation..........................3-2 Getting on or off the machine................3-2 Walk-around inspection........................3-2 Daily inspection.....................................3-2 Starting and stopping the engine..............3-3 Before starting the engine.....................3-3 Starting the Engine...............................3-4 Warming up the engine.........................3-5 Stopping the engine.............................3-5 Operating the machine.............................3-6 Lever pattern (ISO pattern)....................3-6 Lever pattern (G pattern) (If equipped)...3-7 Warming up the machine (hydraulic oil).3-8 Inspection after warm-up......................3-9 Crawler width switching......................3-10 Switching the blade width...................3-11 Operating the travel levers/pedals.......3-12 Stopping travel...................................3-15 Operating the working equipment.......3-16 Operating procedures.............................3-18 Prohibited operations..........................3-18 Cautions on operating............................3-21 Cautions on traveling..........................3-21 Cautions on traveling on slopes .........3-22 Getting out of mud.............................3-24
0-6 Operations possible with this machine.............................................3-24 Parking the machine...............................3-26 Parking...............................................3-26 Inspection and checks after stopping the engine..........................................3-26 Handling in cold climates........................3-27 Preparing for cold climates.................3-27 Cautions after operations....................3-27 After the cold climate..........................3-27 Handling rubber crawlers........................3-28 Prohibitions.........................................3-28 Cautions.............................................3-29 Preventing the rubber crawlers from coming off..........................................3-29 Transport..........................................4-1 Loading and unloading.............................4-2 Hoisting the machine................................4-4 Securing the machine...............................4-6 Maintenance.....................................5-1 General.....................................................5-2 Maintenance overview..........................5-2 Cautions on maintenance.....................5-2 Service data.............................................5-4 Fuel and lubricant table.........................5-4 Regularly replace the hydraulic oil.........5-8 List of consumables..............................5-9 List of tools.........................................5-10 List of tightening torques....................5-11 Safety-critical parts.................................5-12 Maintenance list......................................5-14 Walk-around inspection..........................5-16 Inspecting by opening the engine hood and covers.........................................5-16 Inspecting by walking around the machine.............................................5-17 Inspecting while sitting in the operator’s seat....................................5-17 Daily inspection (every 10 hours).............5-18 Inspecting and replenishing the coolant...............................................5-18 Inspecting and replenishing the engine oil............................................5-19 Inspecting the dust indicator...............5-19 Inspecting the water separator............5-20 Inspecting the fuel level.......................5-20 Inspecting the hydraulic oil tank level and replenishing.................................5-21 Lubricating the working equipment.....5-23 After the initial 50 hours (only for new machines)..........................5-24 Replacing the engine oil and the oil filter....................................................5-24 Inspecting and adjusting the fan belt...5-25 Replacing the hydraulic oil return filter.5-26 Every 50 hours.......................................5-28 Inspecting and adjusting the crawler tension...............................................5-28 Lubricating the slew bearing...............5-30 Lubricating the slew motor pinion.......5-30 Draining the water from the fuel tank...5-31 Inspecting the battery fluid level and replenishing........................................5-32 Every 100 hours.....................................5-34 Cleaning the water separator..............5-34 Cleaning the fuel filter..........................5-34 After the initial 250 hours (only for new machines)..........................5-35 Replacing the travel motor gear oil......5-35 Every 250 hours.....................................5-36 Replacing the engine oil and the oil filter....................................................5-36 Inspecting and adjusting the fan belt...5-36 Cleaning the air cleaner......................5-36 Cleaning the radiator fins and the oil cooler fins...........................................5-38 Replacing the fuel filter (cartridge type)....................................5-38 Cleaning the air filters..........................5-39 Every 500 hours.....................................5-40 Replacing the hydraulic oil return filter.5-40 Replacing the water separator filter.....5-40 Replacing the fuel filter (element type).5-41 Every 1000 hours...................................5-42 Replacing the travel motor gear oil......5-42 Cleaning the engine cooling system....5-42 Replacing the air cleaner element.......5-44 Inspecting and adjusting the engine valve clearance...................................5-45 Retightening the engine cylinder head bolt.....................................................5-45 Every 1500 hours...................................5-46 Inspecting and cleaning the engine fuel injectors..............................................5-46 Inspecting the crankcase breather system................................................5-46 Every 2000 hours...................................5-47 Lapping the engine valve seats...........5-47
0-7 Every 4000 hours...................................5-48 Replacing the hydraulic oil and cleaning the suction strainer.............................5-48 When required........................................5-50 Replacing the bucket teeth ................5-50 Replacing the bucket..........................5-52 Lubricating the levers..........................5-54 Inspecting the rubber crawlers............5-55 Replacing the rubber crawlers............5-56 Inspecting and replenishing the windshield washer fluid.......................5-57 Maintenance during extended storage period.....................................................5-58 Troubleshooting................................6-1 Symptoms that are not malfunctions........6-2 If the engine overheats..............................6-3 If the battery goes dead............................6-4 If a fuse blows..........................................6-6 Inspecting and replacing the fuse..........6-6 Inspecting the fusible link......................6-7 Restarting after adding fuel.......................6-8 Bleeding air from the fuel system..........6-8 If a warning lamp flashes..........................6-9 Other symptoms.....................................6-10 Lowering the boom to the ground..........6-12 Towing....................................................6-13 If the cab or canopy is damaged............6-14 Specifications...................................7-1 Basic Specifications..................................7-2 Machine dimensions.................................7-4 Operating ranges......................................7-8 Lifting Capacities....................................7-11 Options.............................................8-1 General precautions.................................8-2 Safety precautions................................8-2 Cautions when installing attachments...8-2 Cautions when operating attachments..8-3 Attachment combination table..................8-4 Selecting a lever pattern...........................8-5 Switching the lever pattern...................8-5 Hydraulic breaker.....................................8-6 Replacing the hydraulic oil regularly......8-7 Load safety device....................................8-8 Emergency shut-off valve......................8-8 Overload warning device......................8-9 Travel alarm............................................8-10 Optional equipment mass ......................8-11 Biodegradable oil....................................8-12 Replacing the hydraulic oil with biodegradable oil................................8-12
1-1 SAFETY
1-2 SAFETY GENERAL PRECAUTIONS It is your responsibility to observe all pertinent laws and regulations and to follow the manufacture’s instructions on machine operation, inspection and maintenance. Virtually all accidents occur as the result of a failure to observe basic safety rules and precautions. Most accidents can be prevented by identifying the potentially hazardous situations beforehand. Read and understand all safety messages which describe how to prevent accidents. Do not operate the machine until you are sure that you have gained a proper understanding of its operation, inspection and maintenance. Observe all safety rules • Operation, inspection and maintenance of this machine must be performed only by a trained and qualified person. • All rules, regulations, precautions and safety procedures must be understood and followed when performing operation, inspection and maintenance of this machine. • Do not perform any operation, inspection and maintenance of this machine when under the adverse influence of alcohol, drugs, medication, fatigue, or insufficient sleep. GENERAL PRECAUTIONS When a problem is found on the machine If any problem (noise, vibration, smell, disorder of instrument, smoke, oil leak, wrong indication of alarm or unusual indication in the instrument cluster, etc.) is detected during the operation or inspection and maintenance of the machine, immediately inform your sales or service dealer and take proper actions. Do not operate the machine until the trouble is cleared. Operating temperature range To maintain the performance of machine and to prevent it from early wear, observe the following operating conditions. • Do not operate the machine if the ambient temperature is higher than +45°C (+113°F) or lower than –15°C (+5°F). · If operated at an ambient temperature of higher than +45°C (+113°F), the engine may overheat and cause the engine oil to degrade. Also, the hydraulic oil may become very hot, causing damage to the hydraulic equipment. · If operated at an ambient temperature of lower than –15°C (+5°F), the parts made of rubber such as gaskets may get hardened to cause an early wear or damage to the machine. · If the machine is to be used outside the ambient temperature range described above, consult your sales or a service dealer.
1-3 SAFETY Wear appropriate clothing and protective equipment • Do not wear loose clothing or any accessory that can catch on controls or in moving parts. • Do not wear oily or fuel stained clothing that can easily catch fire. • Wear a hard hat, safety shoes, safety glasses, filter mask, heavy gloves, ear protection and other protective equipment as required by job conditions. Wear required appropriate equipment such as safety glasses and filter mask when using grinders, hammers or compressed air, as metal fragments or other objects can fly and cause serious injury. • Use hearing protection when operating the machine. Loud prolonged noise can cause hearing impairments, even the total loss of hearing. GENERAL PRECAUTIONS Install a fire extinguisher and first aid kit Be prepared for fire and accidents • Install an extinguisher and a first aid kit, and learn how to use them. • Lean how to fight a fire and how to deal with accidents. • Know how to contact emergency assistance and make a list of emergency contacts. Never remove safety equipment • Make sure all protective guards, canopies and doors are in place and secured. Repair or replace damaged parts before operating the machine. • Know how to use the safety lock lever, seat belt and other safety equipment and use them properly. • Never remove any safety equipment except for servicing. Keep all safety equipment in good operating condition.
1-4 SAFETY Use a signal person and a flag person GENERAL PRECAUTIONS Learn how to use the hand signals required for particular jobs and make sure who has the responsibility for signaling. • All personnel must fully understand all the signals. • The operator must respond to signals only from the appointed signal person, but must obey a stop signal at any time from anyone. • The signal person must stand in a clearly visible location when giving signals. Cautions when standing up from or leaving the operator’s seat • Before standing up from the operator’s seat to open/close the window or remove/ install the lower window, lower the working equipment to the ground, raise the safety lock levers to engage the lock and stop the engine. If any controls should be accidentally touched when the safety lock levers is lowered (unlocked), the machine will suddenly move and cause serious injury or death. • Note that the dozer blade, boom swing and auxiliary hydraulic controls cannot be locked, even when the safety lock lever is set to the locked position. Do not carelessly touch these controls. • Be careful not to touch the operating levers when raising or lowering the safety lock levers. • Before leaving the operator’s seat, lower the working equipment to the ground, raise the safety lock levers to engage the lock and stop the engine. Also, be sure to remove the key, lock the door and covers, take it with you and store it in a specified place.
1-5 SAFETY Avoid fire and explosion hazards GENERAL PRECAUTIONS Keep flames away from fuel, oil, grease and antifreeze. Fuel is particularly flammable and dangerous. • When handling these combustible materials, keep lit cigarettes, matches, lighters and other flames or sources of flames away. • Do not smoke or permit open flames while handling fuel or working on the fuel system. • Do not leave the location while refilling with fuel or oil. • Never remove the fuel cap or add fuel when the engine is running or still hot. Also, do not spill the fuel on the hot surface of the machine or the component of the electric system. • Clean up spilled fuel or oil immediately. • Check for fuel, oil leak. Stop all leaks and clean the machine before operating. • When operating with grinder or welding, move inflammables to a safe place. • Do not cut or weld on pipes or tubes that contain flammable fluids. Clean thoroughly with nonflammable solvent before cutting or welding. • Remove all trash or debris from the machine. Make sure that oily rags or other flammable material are not stored on the machine. • Handle all solvents and dry chemicals (foam type fire extinguisher) according to procedures identified on manufacturer’s containers. Work in a well-ventilated area. • Never use fuel for cleaning purposes. Always use a nonflammable solvent. • When handling the fuel, washing oil or paint, open the door and windows to ventilate thoroughly. • Store all flammable fluids and materials in a safe and well-ventilated place. • The short circuit of the electric system may cause the fire. Check for any loosened connections or damage to the wires every day. Retighten the loosened connector and wire clamp. Fix or change the damaged wire. • Fire from the pipes: Make sure that the clamps, guards and cushions of the hoses and tubes are securely fixed. If not, hoses or tubes may be damaged due to vibration or contact with other parts during operation. This can cause the high-pressure oil to spurt out, resulting in the fire or injury.
1-6 SAFETY Exhaust fumes from the engine is poisonous GENERAL PRECAUTIONS • Do not operate the engine in an enclosed area without adequate ventilation. • If natural ventilation is not possible, install ventilators, fans, exhaust extension pipes or other venting devices. Handling asbestos dust Inhaling asbestos dust can cause lung cancer. When handling the materials which may contain asbestos, take the following precautions: • Never use compressed air for cleaning. • Avoid brushing or grinding parts containing asbestos. • For clean up, use a vacuum equipped with a high efficiency particulate air filter (HEPA). • Wear the stipulated respirator if there is no other way to control the dust. When working indoors, install a ventilation system with a macromolecular filter. • Do not allow unauthorized personnel in the work area while working. • Follow the rules and environmental standard applicable to the work area. Be careful not to get crushed or cut Never put your hands, feet or other parts of your body between the upperstructure and the undercarriage or tracks, between the machine body and working equipment, or between a cylinder and moving part. The sizes of these gaps change when the machine moves, and a person can suffer severe injury or death.
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1-7 SAFETY Using optional products • Consult with Takeuchi before installing optional attachments. Depending on the type of attachments or the combination of them, the attachment may come into contact with the operator’s compartment or the other parts of the machine. Make sure that the optional attachment installed is not contacted with other parts before use. • Do not use attachments that have not been approved by Takeuchi. Doing so may compromise safety or adversely affect the machine’s operation or service life. • Takeuchi will not be held responsible for any injuries, accidents or damage to its products caused by the use by a non- approved attachment. GENERAL PRECAUTIONS Never modify the machine Unauthorized modifications to this machine can cause injury or death. Never make unauthorized modifications to any part of this machine.
1-8 SAFETY PRECAUTIONS WHEN PREPARING Know the work area Before starting operation, know the working area condition to ensure a safety operation. • Inspect the topography and ground condition of the working area, or the structure of the building when working indoors, and take the safety precautions as necessary. • Be sure to avoid all hazards and obstructions such as ditches, underground lines, trees, cliffs, overhead electrical wires, or places where there is a danger of falling rocks or slides. PRECAUTIONS WHEN PREPARING • Check with the administrator for the locations of buried gas pipes, water pipes and power cables. If necessary, determine what specific precautions must be taken to insure safety by consulting with the administrator. • When working on roads, be sure to consider the safety of pedestrians and vehicles. · Use a flag person and/or a signal. · Fence off the working area and keep off unauthorized persons. • When working in water or crossing shallow streams or creeks, check the depth of the water, the solidity of the ground and the water flow speed beforehand. Refer to “Cautions on operating” for further instructions.

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Takeuchi tb216 mini excavator operator manual (serial no. 216100002 and up)

  • 2.
    SAFETY ALERT SYMBOL Thissymbol represents the safety alert. The message that follows the symbol contains important information about safety. Read and understand the message to avoid personal injury or death. It is the owner or employer’s responsibility to fully instruct each operator in the proper and safe operation of all equipment. All persons using this machine should thoroughly familiarize themselves with the contents of this manual. All operators must be instructed on the proper functions of the excavator before running the machine. Learn and practice correct use of the machine controls in a safe, clear area before operating this machine on a job site. Improper operation, inspection and maintenance of this machine can cause injury or death. Read and understand this manual before performing any operation, inspection or maintenance on this machine. Always store this manual near at hand preferably on the machine itself. If it should be lost or damaged, immediately order a new one from your Takeuchi dealer. When transferring ownership of this machine, be sure to hand this manual to the next owner. Takeuchi supplies machines complying with the local regulations and standards of the country of export. If your machine has been purchased in another country or from a person or company of another country, it may not have the safety devices or safety standards required for use in your country. Should you have any question about whether your machine complies with the regulations and standards of your country, contact a Takeuchi dealer.
  • 3.
    0-1 SIGNAL WORDS Safety messagesappearing in this manual and on machine decals are identified by the words “DANGER”, “WARNING” and “CAUTION”. These signal words mean the following: DANGER indicates a hazard with a high level of risk which, if not avoided, will result in death or serious injury. WARNING indicates a hazard with a medium level of risk which, if not avoided, could result in death or serious injury. CAUTION indicates a hazard with a low level of risk which, if not avoided, could result in minor moderate injury. IMPORTANT: The word IMPORTANT is used to alert operators and maintenance personnel about situations which could result in damage to the machine and its components. It is impossible to foresee every possible circumstance that might involve a potential hazard. The warnings in this manual or on the machine can not cover all possible contingencies. You must exercise all due care and follow normal safety procedures when operating the machine so as to ensure that no damage occurs to the machine, its operators or other persons.
  • 4.
    0-2 FOREWORD This manual describesoperation, inspection and maintenance of the machine, as well as safety instructions to be heeded during these operations. If you have any questions about the machine, please contact a Takeuchi sales or service outlet. INTRODUCTION MANUAL STORAGE COMPARTMENT A compartment for storing this manual is provided at the position shown on the diagram below. 1. Insert the starter key and turn it counterclockwise to open the cover under the seat. 2. After using the manual, place it in the plastic pouch and store it back in the manual storage compartment. SERIAL NUMBERS IMPORTANT: Do not remove the machine name plate with the serial number. Check the serial numbers of the machine and engine and write them down in the spaces below. Machine number: Engine number: AD6O003
  • 5.
    0-3 FRONT, REAR, LEFTAND RIGHT MACHINE DESCRIPTION This manual refers the front, rear, left and right of the machine as seen when sitting in the operator’s seat with the dozer blade visible to the front. DESIGNATED OPERATIONS Use this machine primarily for the following operations: • Excavation • Digging ditches • Digging side ditches • Leveling • Loading FEATURES • “Flexible machine width mechanism” for crawler width • Low engine noise and exhaust emissions BREAK-IN PERIOD When the machine is new, operate the machine for the first 100 hours (as indicated on the hour meter) by following the instructions below. Using a new machine without a break-in period will lead to quicker deterioration of machine performance and may shorten the machine’s service life. • Sufficiently warm up the engine and hydraulic oil. • Avoid heavy loads and rapid operations. Operate with a load of about 80% the maximum load. • Do not abruptly start up, accelerate, change directions, or stop unless necessary.
  • 6.
    0-4 NOTES ON READINGTHIS MANUAL Please note that the descriptions and diagrams included in this manual may not be applicable to your machine. The numbers used in the illustration are with circles around them. The same numbers appear between the parentheses in the text. (Example: (1)) Symbols used in this manual The symbols used in this manual have the following meanings. ...... Prohibition ............. Lock ............. Unlock
  • 7.
    0-5 CONTENTS Introduction......................................0-2 Machine description.........................0-3 Safety...............................................1-1 General precautions.................................1-2 Precautionswhen preparing.....................1-8 Precautions when starting......................1-12 Precautions when operating...................1-14 Precautions when stopping....................1-23 Precautions when transporting...............1-24 Precautions on maintenance..................1-26 Safety signs (decals)...............................1-35 Controls............................................2-1 Names of components (Cab)....................2-2 Names of components (Canopy)..............2-4 Covers......................................................2-6 Starter key............................................2-6 Maintenance cover...............................2-6 Fuse box..............................................2-7 Tool case..............................................2-7 Grease gun holder................................2-7 Fuel lid..................................................2-8 Fuel filler port........................................2-8 Side cover............................................2-9 Engine hood.........................................2-9 Cab........................................................2-10 Cab door............................................2-10 Emergency exit...................................2-10 Front window......................................2-11 Lower front window............................2-12 Side window.......................................2-12 Emergency hammer (optional)............2-13 Seat and seat belt..................................2-14 Seat (If equipped)................................2-14 High-back seat (If equipped)...............2-15 Seat belt.............................................2-16 Instrument cluster...................................2-18 Warning lamps....................................2-18 Indicators...........................................2-19 Meters................................................2-19 Multi-data display...............................2-20 Switches................................................2-26 Starter switch.....................................2-26 Horn button........................................2-26 Travel speed switch............................2-26 Wiper switch.......................................2-27 Second auxiliary hydraulic switch........2-27 Third auxiliary hydraulic switch and button.................................................2-27 Lift overload warning switch (If equipped)........................................2-28 Levers and Pedals..................................2-29 Safety lock lever.................................2-29 Throttle lever.......................................2-29 Operating levers.................................2-30 Blade lever..........................................2-30 Travel levers/pedals............................2-31 Boom swing pedal..............................2-31 Auxiliary hydraulic pedal......................2-32 Selector lever .....................................2-32 Accessories............................................2-34 Heater................................................2-34 Cup holder.........................................2-36 Interior light.........................................2-36 Inside rear view mirror (cab)................2-36 Power sockets ...................................2-37 Armrest..............................................2-37 Radio (for cab)....................................2-38 Auxiliary hydraulic lines.......................2-42 Accumulator (If equipped)...................2-46 Operation..........................................3-1 Before starting operation..........................3-2 Getting on or off the machine................3-2 Walk-around inspection........................3-2 Daily inspection.....................................3-2 Starting and stopping the engine..............3-3 Before starting the engine.....................3-3 Starting the Engine...............................3-4 Warming up the engine.........................3-5 Stopping the engine.............................3-5 Operating the machine.............................3-6 Lever pattern (ISO pattern)....................3-6 Lever pattern (G pattern) (If equipped)...3-7 Warming up the machine (hydraulic oil).3-8 Inspection after warm-up......................3-9 Crawler width switching......................3-10 Switching the blade width...................3-11 Operating the travel levers/pedals.......3-12 Stopping travel...................................3-15 Operating the working equipment.......3-16 Operating procedures.............................3-18 Prohibited operations..........................3-18 Cautions on operating............................3-21 Cautions on traveling..........................3-21 Cautions on traveling on slopes .........3-22 Getting out of mud.............................3-24
  • 8.
    0-6 Operations possible withthis machine.............................................3-24 Parking the machine...............................3-26 Parking...............................................3-26 Inspection and checks after stopping the engine..........................................3-26 Handling in cold climates........................3-27 Preparing for cold climates.................3-27 Cautions after operations....................3-27 After the cold climate..........................3-27 Handling rubber crawlers........................3-28 Prohibitions.........................................3-28 Cautions.............................................3-29 Preventing the rubber crawlers from coming off..........................................3-29 Transport..........................................4-1 Loading and unloading.............................4-2 Hoisting the machine................................4-4 Securing the machine...............................4-6 Maintenance.....................................5-1 General.....................................................5-2 Maintenance overview..........................5-2 Cautions on maintenance.....................5-2 Service data.............................................5-4 Fuel and lubricant table.........................5-4 Regularly replace the hydraulic oil.........5-8 List of consumables..............................5-9 List of tools.........................................5-10 List of tightening torques....................5-11 Safety-critical parts.................................5-12 Maintenance list......................................5-14 Walk-around inspection..........................5-16 Inspecting by opening the engine hood and covers.........................................5-16 Inspecting by walking around the machine.............................................5-17 Inspecting while sitting in the operator’s seat....................................5-17 Daily inspection (every 10 hours).............5-18 Inspecting and replenishing the coolant...............................................5-18 Inspecting and replenishing the engine oil............................................5-19 Inspecting the dust indicator...............5-19 Inspecting the water separator............5-20 Inspecting the fuel level.......................5-20 Inspecting the hydraulic oil tank level and replenishing.................................5-21 Lubricating the working equipment.....5-23 After the initial 50 hours (only for new machines)..........................5-24 Replacing the engine oil and the oil filter....................................................5-24 Inspecting and adjusting the fan belt...5-25 Replacing the hydraulic oil return filter.5-26 Every 50 hours.......................................5-28 Inspecting and adjusting the crawler tension...............................................5-28 Lubricating the slew bearing...............5-30 Lubricating the slew motor pinion.......5-30 Draining the water from the fuel tank...5-31 Inspecting the battery fluid level and replenishing........................................5-32 Every 100 hours.....................................5-34 Cleaning the water separator..............5-34 Cleaning the fuel filter..........................5-34 After the initial 250 hours (only for new machines)..........................5-35 Replacing the travel motor gear oil......5-35 Every 250 hours.....................................5-36 Replacing the engine oil and the oil filter....................................................5-36 Inspecting and adjusting the fan belt...5-36 Cleaning the air cleaner......................5-36 Cleaning the radiator fins and the oil cooler fins...........................................5-38 Replacing the fuel filter (cartridge type)....................................5-38 Cleaning the air filters..........................5-39 Every 500 hours.....................................5-40 Replacing the hydraulic oil return filter.5-40 Replacing the water separator filter.....5-40 Replacing the fuel filter (element type).5-41 Every 1000 hours...................................5-42 Replacing the travel motor gear oil......5-42 Cleaning the engine cooling system....5-42 Replacing the air cleaner element.......5-44 Inspecting and adjusting the engine valve clearance...................................5-45 Retightening the engine cylinder head bolt.....................................................5-45 Every 1500 hours...................................5-46 Inspecting and cleaning the engine fuel injectors..............................................5-46 Inspecting the crankcase breather system................................................5-46 Every 2000 hours...................................5-47 Lapping the engine valve seats...........5-47
  • 9.
    0-7 Every 4000 hours...................................5-48 Replacingthe hydraulic oil and cleaning the suction strainer.............................5-48 When required........................................5-50 Replacing the bucket teeth ................5-50 Replacing the bucket..........................5-52 Lubricating the levers..........................5-54 Inspecting the rubber crawlers............5-55 Replacing the rubber crawlers............5-56 Inspecting and replenishing the windshield washer fluid.......................5-57 Maintenance during extended storage period.....................................................5-58 Troubleshooting................................6-1 Symptoms that are not malfunctions........6-2 If the engine overheats..............................6-3 If the battery goes dead............................6-4 If a fuse blows..........................................6-6 Inspecting and replacing the fuse..........6-6 Inspecting the fusible link......................6-7 Restarting after adding fuel.......................6-8 Bleeding air from the fuel system..........6-8 If a warning lamp flashes..........................6-9 Other symptoms.....................................6-10 Lowering the boom to the ground..........6-12 Towing....................................................6-13 If the cab or canopy is damaged............6-14 Specifications...................................7-1 Basic Specifications..................................7-2 Machine dimensions.................................7-4 Operating ranges......................................7-8 Lifting Capacities....................................7-11 Options.............................................8-1 General precautions.................................8-2 Safety precautions................................8-2 Cautions when installing attachments...8-2 Cautions when operating attachments..8-3 Attachment combination table..................8-4 Selecting a lever pattern...........................8-5 Switching the lever pattern...................8-5 Hydraulic breaker.....................................8-6 Replacing the hydraulic oil regularly......8-7 Load safety device....................................8-8 Emergency shut-off valve......................8-8 Overload warning device......................8-9 Travel alarm............................................8-10 Optional equipment mass ......................8-11 Biodegradable oil....................................8-12 Replacing the hydraulic oil with biodegradable oil................................8-12
  • 10.
  • 11.
    1-2 SAFETY GENERAL PRECAUTIONS It isyour responsibility to observe all pertinent laws and regulations and to follow the manufacture’s instructions on machine operation, inspection and maintenance. Virtually all accidents occur as the result of a failure to observe basic safety rules and precautions. Most accidents can be prevented by identifying the potentially hazardous situations beforehand. Read and understand all safety messages which describe how to prevent accidents. Do not operate the machine until you are sure that you have gained a proper understanding of its operation, inspection and maintenance. Observe all safety rules • Operation, inspection and maintenance of this machine must be performed only by a trained and qualified person. • All rules, regulations, precautions and safety procedures must be understood and followed when performing operation, inspection and maintenance of this machine. • Do not perform any operation, inspection and maintenance of this machine when under the adverse influence of alcohol, drugs, medication, fatigue, or insufficient sleep. GENERAL PRECAUTIONS When a problem is found on the machine If any problem (noise, vibration, smell, disorder of instrument, smoke, oil leak, wrong indication of alarm or unusual indication in the instrument cluster, etc.) is detected during the operation or inspection and maintenance of the machine, immediately inform your sales or service dealer and take proper actions. Do not operate the machine until the trouble is cleared. Operating temperature range To maintain the performance of machine and to prevent it from early wear, observe the following operating conditions. • Do not operate the machine if the ambient temperature is higher than +45°C (+113°F) or lower than –15°C (+5°F). · If operated at an ambient temperature of higher than +45°C (+113°F), the engine may overheat and cause the engine oil to degrade. Also, the hydraulic oil may become very hot, causing damage to the hydraulic equipment. · If operated at an ambient temperature of lower than –15°C (+5°F), the parts made of rubber such as gaskets may get hardened to cause an early wear or damage to the machine. · If the machine is to be used outside the ambient temperature range described above, consult your sales or a service dealer.
  • 12.
    1-3 SAFETY Wear appropriate clothingand protective equipment • Do not wear loose clothing or any accessory that can catch on controls or in moving parts. • Do not wear oily or fuel stained clothing that can easily catch fire. • Wear a hard hat, safety shoes, safety glasses, filter mask, heavy gloves, ear protection and other protective equipment as required by job conditions. Wear required appropriate equipment such as safety glasses and filter mask when using grinders, hammers or compressed air, as metal fragments or other objects can fly and cause serious injury. • Use hearing protection when operating the machine. Loud prolonged noise can cause hearing impairments, even the total loss of hearing. GENERAL PRECAUTIONS Install a fire extinguisher and first aid kit Be prepared for fire and accidents • Install an extinguisher and a first aid kit, and learn how to use them. • Lean how to fight a fire and how to deal with accidents. • Know how to contact emergency assistance and make a list of emergency contacts. Never remove safety equipment • Make sure all protective guards, canopies and doors are in place and secured. Repair or replace damaged parts before operating the machine. • Know how to use the safety lock lever, seat belt and other safety equipment and use them properly. • Never remove any safety equipment except for servicing. Keep all safety equipment in good operating condition.
  • 13.
    1-4 SAFETY Use a signalperson and a flag person GENERAL PRECAUTIONS Learn how to use the hand signals required for particular jobs and make sure who has the responsibility for signaling. • All personnel must fully understand all the signals. • The operator must respond to signals only from the appointed signal person, but must obey a stop signal at any time from anyone. • The signal person must stand in a clearly visible location when giving signals. Cautions when standing up from or leaving the operator’s seat • Before standing up from the operator’s seat to open/close the window or remove/ install the lower window, lower the working equipment to the ground, raise the safety lock levers to engage the lock and stop the engine. If any controls should be accidentally touched when the safety lock levers is lowered (unlocked), the machine will suddenly move and cause serious injury or death. • Note that the dozer blade, boom swing and auxiliary hydraulic controls cannot be locked, even when the safety lock lever is set to the locked position. Do not carelessly touch these controls. • Be careful not to touch the operating levers when raising or lowering the safety lock levers. • Before leaving the operator’s seat, lower the working equipment to the ground, raise the safety lock levers to engage the lock and stop the engine. Also, be sure to remove the key, lock the door and covers, take it with you and store it in a specified place.
  • 14.
    1-5 SAFETY Avoid fire andexplosion hazards GENERAL PRECAUTIONS Keep flames away from fuel, oil, grease and antifreeze. Fuel is particularly flammable and dangerous. • When handling these combustible materials, keep lit cigarettes, matches, lighters and other flames or sources of flames away. • Do not smoke or permit open flames while handling fuel or working on the fuel system. • Do not leave the location while refilling with fuel or oil. • Never remove the fuel cap or add fuel when the engine is running or still hot. Also, do not spill the fuel on the hot surface of the machine or the component of the electric system. • Clean up spilled fuel or oil immediately. • Check for fuel, oil leak. Stop all leaks and clean the machine before operating. • When operating with grinder or welding, move inflammables to a safe place. • Do not cut or weld on pipes or tubes that contain flammable fluids. Clean thoroughly with nonflammable solvent before cutting or welding. • Remove all trash or debris from the machine. Make sure that oily rags or other flammable material are not stored on the machine. • Handle all solvents and dry chemicals (foam type fire extinguisher) according to procedures identified on manufacturer’s containers. Work in a well-ventilated area. • Never use fuel for cleaning purposes. Always use a nonflammable solvent. • When handling the fuel, washing oil or paint, open the door and windows to ventilate thoroughly. • Store all flammable fluids and materials in a safe and well-ventilated place. • The short circuit of the electric system may cause the fire. Check for any loosened connections or damage to the wires every day. Retighten the loosened connector and wire clamp. Fix or change the damaged wire. • Fire from the pipes: Make sure that the clamps, guards and cushions of the hoses and tubes are securely fixed. If not, hoses or tubes may be damaged due to vibration or contact with other parts during operation. This can cause the high-pressure oil to spurt out, resulting in the fire or injury.
  • 15.
    1-6 SAFETY Exhaust fumes fromthe engine is poisonous GENERAL PRECAUTIONS • Do not operate the engine in an enclosed area without adequate ventilation. • If natural ventilation is not possible, install ventilators, fans, exhaust extension pipes or other venting devices. Handling asbestos dust Inhaling asbestos dust can cause lung cancer. When handling the materials which may contain asbestos, take the following precautions: • Never use compressed air for cleaning. • Avoid brushing or grinding parts containing asbestos. • For clean up, use a vacuum equipped with a high efficiency particulate air filter (HEPA). • Wear the stipulated respirator if there is no other way to control the dust. When working indoors, install a ventilation system with a macromolecular filter. • Do not allow unauthorized personnel in the work area while working. • Follow the rules and environmental standard applicable to the work area. Be careful not to get crushed or cut Never put your hands, feet or other parts of your body between the upperstructure and the undercarriage or tracks, between the machine body and working equipment, or between a cylinder and moving part. The sizes of these gaps change when the machine moves, and a person can suffer severe injury or death.
  • 16.
    Thank you verymuch for your reading. Please Click Here. Then Get COMPLETE MANUAL. NO WAITING NOTE: If there is no response to click on the link above, please download the PDF document first and then click on it.
  • 17.
    1-7 SAFETY Using optional products • Consultwith Takeuchi before installing optional attachments. Depending on the type of attachments or the combination of them, the attachment may come into contact with the operator’s compartment or the other parts of the machine. Make sure that the optional attachment installed is not contacted with other parts before use. • Do not use attachments that have not been approved by Takeuchi. Doing so may compromise safety or adversely affect the machine’s operation or service life. • Takeuchi will not be held responsible for any injuries, accidents or damage to its products caused by the use by a non- approved attachment. GENERAL PRECAUTIONS Never modify the machine Unauthorized modifications to this machine can cause injury or death. Never make unauthorized modifications to any part of this machine.
  • 18.
    1-8 SAFETY PRECAUTIONS WHEN PREPARING Know thework area Before starting operation, know the working area condition to ensure a safety operation. • Inspect the topography and ground condition of the working area, or the structure of the building when working indoors, and take the safety precautions as necessary. • Be sure to avoid all hazards and obstructions such as ditches, underground lines, trees, cliffs, overhead electrical wires, or places where there is a danger of falling rocks or slides. PRECAUTIONS WHEN PREPARING • Check with the administrator for the locations of buried gas pipes, water pipes and power cables. If necessary, determine what specific precautions must be taken to insure safety by consulting with the administrator. • When working on roads, be sure to consider the safety of pedestrians and vehicles. · Use a flag person and/or a signal. · Fence off the working area and keep off unauthorized persons. • When working in water or crossing shallow streams or creeks, check the depth of the water, the solidity of the ground and the water flow speed beforehand. Refer to “Cautions on operating” for further instructions.