Takeuchi 216000002 Operator'S Manual Download Page 197

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6-7

TroubleshooTing

inSpecting the fuSible link

if a fuSe blowS

If the machine is not turned on after turning

the starter switch to the ON position, the

cartridge type fusible link (1) is likely blown.

Open the maintenance cover and inspect. If

the fusible link is blown, please contact your

sales or service dealer.

Note:

Fusible links are large type fuses used

in high current applications. Like a regular

fuse, they act as fuses by protecting the

electric components and wirings from

damage caused by excessive current draw.

Summary of Contents for 216000002

Page 1: ......

Page 2: ...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 t...

Page 3: ...es 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...

Page 4: ...partment 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...

Page 5: ...hanism 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 inst...

Page 6: ...s 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 t...

Page 7: ...ch and button 2 27 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 swin...

Page 8: ...ing 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...

Page 9: ...ystem 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 di...

Page 10: ...0 8...

Page 11: ...1 1 Safety...

Page 12: ...ol 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...

Page 13: ...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 acci...

Page 14: ...dow 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...

Page 15: ...ly 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 solvent...

Page 16: ...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...

Page 17: ...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 Tak...

Page 18: ...nger 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 precauti...

Page 19: ...ure good visibility Adjust the mirror to the best position for the operator to see the rear view blind spot from the operator s seat Wipe off any oil grease mud snow or ice to prevent accidents due to...

Page 20: ...ns in the operator s compartment Remove mud and grease from shoe soles before entering the operator s compartment Pedaling the machine with the shoes with mud and grease will cause a slip accident Do...

Page 21: ...ncy hammer is installed to be used to escape from the cab in an emergency When escaping break the windows with the hammer When breaking the windowpane with a hammer take great care not to injure yours...

Page 22: ...s safe to start the machine by checking the following items Walk around the machine and warn the person who is servicing the machine or is walking near the machine Do not start the machine until you a...

Page 23: ...up the engine and hydraulic oil Check if all gauges and warning devices are properly working Check for any noises Test the engine speed control Operate each control to ensure they are properly workin...

Page 24: ...laces or where your vision is obstructed Never allow anyone to enter the machine s slewing radius and path Signal your intention to move by sounding the horn There is a blind spot in the rear of the m...

Page 25: ...ucket raised 30 to 40 cm 12 to 16 in above the ground Do not slew while traveling If you must operate the hoe attachment while traveling operate at speeds slow enough so you have complete control at a...

Page 26: ...achine When traveling on slopes lower the bucket to a height of 20 to 30 cm 8 to 12 in above the ground When climbing a steep slope extend the hoe attachment to the front In emergencies lower the buck...

Page 27: ...Be careful not to drive beyond the road shoulder or to get trapped in a snow drift With frozen ground surfaces the ground becomes soft when the temperature rises and this may cause the machine to tip...

Page 28: ...th Always maintain a safe distance between the machine and the high voltage electric cable Check with the local power company about safe operating procedure before starting operations Consider all cab...

Page 29: ...set the crawlers at right angles to the cliff or road shoulder and the dozer blade to the front when carrying out operations Do not enter areas where there is soft ground Doing so could cause the mac...

Page 30: ...ons If a building or structure collapses serious injury or damage will result When doing demolition work do not perform demolition above your head There is a hazard of broken parts falling or of the b...

Page 31: ...hine can tip over more easily in the lateral direction than in the longitudinal direction Do not slew swing sideways with a heavy load at the tip of the hoe attachment In particular do not slew swing...

Page 32: ...ly attached resulting in serious injury or death Do not attempt to pull stumps out of the ground when using the machine as a crane The loads imposed on the machine under this use are completely unknow...

Page 33: ...movement of the machine When parking on a street use barriers caution signs lights etc so that the machine can easily be seen even at night to avoid collision with other vehicles Before leaving the ma...

Page 34: ...oing so may result in tipping over or falling down of the machine Keep the truck bed and loading ramps clean of oil soil ice snow and other materials to prevent the machine from sliding sideways Clean...

Page 35: ...Do not hoist the machine with an operator on it When hoisting hoist slowly so that the machine does not tip Keep everyone out of the area when hoisting Do not move the machine over the heads of the p...

Page 36: ...correct tools Do not use damaged or weakened tools or tools designed for other purposes Use tools appropriate for the work involved Replace safety critical parts periodically Replace fuel hoses period...

Page 37: ...enter Water on electrical parts could cause short circuits or malfunctions Do not use water or steam to wash the battery electronic control components sensors connectors or the operator s compartment...

Page 38: ...use wood blocks jack stands or other rigid and stable supports Never get under the machine or working equipment if they are not sufficiently supported This procedure is especially important when work...

Page 39: ...Use the correct grade of fuel for the operating season Handling of hoses Oil leak or fuel leak can cause a fire Do not twist bend or hit the hoses Never use twisted bent or cracked pipes tubes or hose...

Page 40: ...enetrates the skin it must be surgically removed within a few hours by a doctor familiar with this type of injury Release pressure before working on the hydraulic system Oil may spurt out if caps or f...

Page 41: ...Do not drill weld or fuse Do not subject it to physical shock such as hitting rolling or dropping Before disposing of the unit the sealed gas must be drained Contact a Takeuchi service agent for help...

Page 42: ...the engine by turning off the starter switch before inspecting or handling the battery Be careful not to let metal tools or any metal objects come into contact with the battery terminals and cause a s...

Page 43: ...on maintenance Jump starting with booster cables When starting the engine using the booster cables be sure to connect the cables in the proper order described below Wrongly connected cables can resul...

Page 44: ...tenance Vibrations operators are subject to According to the results of the tests conducted to determine the vibrations transmitted to the operator by the machine the upper limbs are subjected to vibr...

Page 45: ...y signs Review these signs and the operating instructions in this manual with your machine operators Keep the signs clean and legible If any of the safety labels is peeling or damaged and becomes diff...

Page 46: ...1 36 Safety Safety signs decals...

Page 47: ...1 37 Safety Safety signs decals...

Page 48: ...1 38 Safety Safety signs decals...

Page 49: ...1 39 Safety Safety signs decals...

Page 50: ...1 40...

Page 51: ...2 1 Controls...

Page 52: ...4 Fuel tank 5 Hydraulic tank Undercarriage 6 Crawler belt 7 Idler 8 Track roller 9 Shoe slide 10 Travel motor Working equipment 11 Bucket 12 Bucket cylinder 13 Arm 14 Arm cylinder 15 Boom 16 Boom cyl...

Page 53: ...lever 9 Boom swing pedal 10 Travel lever Pedal 11 Travel speed switch 12 Auxiliary hydraulic pedal 13 Left operating lever 14 Third auxiliary hydraulic button 15 Third auxiliary hydraulic switch 16 Au...

Page 54: ...hood 4 Fuel tank 5 Hydraulic tank Undercarriage 6 Crawler belt 7 Idler 8 Track roller 9 Shoe slide 10 Travel motor Working equipment 11 Bucket 12 Bucket cylinder 13 Arm 14 Arm cylinder 15 Boom 16 Boo...

Page 55: ...ever 9 Boom swing pedal Names of components Canopy 10 Travel lever Pedal 11 Travel speed switch 12 Auxiliary hydraulic pedal 13 Left operating lever 14 Third auxiliary hydraulic botton 15 Third auxili...

Page 56: ...ening the maintenance cover make sure that the safety lock lever is in the lock position and the engine is stopped Open this cover to perform a maintenance operation of the engine or to switch the sel...

Page 57: ...fuse box cover 1 while pushing the tab beside it Closing 1 Push in the fuse box cover 1 until the tab clicks into place Tool case Opening 1 To unlock this case insert the starter key and turn it count...

Page 58: ...se to lock the fuel lid 1 Fuel filler port Do not smoke and keep away from heat or flame while filling the fuel tank Fill the fuel tank in a well ventilated place with the engine turned off Clean up s...

Page 59: ...key hole 2 with your thumb and open the engine hood 1 Closing 1 Close the engine hood 1 and press down the edge of it until a click is heard Covers Side cover When opening and closing the side cover...

Page 60: ...ff the machine and while in operation Locking and unlocking Insert the starter key and turn it Opening 1 Pull the knob 1 towards you and open the door To open the door from inside the cab hold the doo...

Page 61: ...rface and stop the engine 2 Set the safety lock lever to the locked position 3 Grasp the left and right handles 1 and press the knobs 2 with your thumb to release the lock 4 Pull the front window 3 to...

Page 62: ...ough the guides 5 at the rear and then set it on the supports 6 to fasten it in place Side window Opening 1 Release the lock by turning the locking screw 7 counterclockwise 2 Hold the catch 8 to disen...

Page 63: ...aping break the windows with the hammer When breaking the windowpane with a hammer take great care not to injure yourself with the broken glass pieces Remove the glass pieces from the window sill so a...

Page 64: ...Pull up the lever 2 and slide the seat backward or forward to the desired position for operation of machine 2 Release the lever 2 at the desired position to secure the seat Adjustment range 10 positi...

Page 65: ...ide the seat backward or forward to the desired position for operation of machine 2 Release the lever 2 at the desired position to secure the seat Adjustment range 10 positions in 150mm 5 9in C Adjust...

Page 66: ...seat belt to the desired length 3 Make sure that the belt is not twisted and then insert the tongue plate A into the buckle B of the seat belt until you hear a clicking sound as it locks in place 4 C...

Page 67: ...2 17 Memo...

Page 68: ...m is sounded immediately stop all operations and check the corresponding component Refer to If a warning lamp flashes on page 6 9 1 Engine emergency lamp This lamp flashes and an alarm sounds if there...

Page 69: ...ure gauge Indicates the temperature of the engine coolant water The LED should be within the green range during machine operation The red range indicates overheating 9 Fuel Gauge Indicates the amount...

Page 70: ...page 2 24 Instrument cluster 4 Alarm indicator lamp The clock symbol appears when the alarm function is turned on Refer to Alarm setting on page 2 24 5 Auxiliary 3rd hydraulic pressure warning lamp I...

Page 71: ...key turns on or off the work light Pressing and holding the B key for two seconds or more each time the display changes as follows 1 Hour meter 2 Trip meter 1 3 Trip meter 2 4 Trip meter 3 Instrument...

Page 72: ...Press the C key to return to the Home screen DATA Shows the coolant temperature and the trip meter for inspection and maintenance Unlike the trip meter displayed on the Home screen data items on the e...

Page 73: ...IP METER for maintenance The trip meters for the engine oil hydraulic oil or coolant are displayed Press and hold the A key for at least five seconds resets the selected trip meter to 0 Press the B ke...

Page 74: ...reen d Press the B key to move the selection bar e Press and hold the B key for at least three seconds to enter the alarm time setting mode f Press the C key to cancel editing and to return to the Set...

Page 75: ...the Setting Selection screen f Press the C key to cancel editing and to return to the Setting Selection screen Contrast setting CONTRAST Adjust the LCD contrast a When the selection bar is at CONTRAST...

Page 76: ...ine is running At this position all the electrical equipment is functional When the coolant temperature is too low the engine is automatically preheated START Position for starting the engine When the...

Page 77: ...her fluid when operating the wiper IMPORTANT In cold climates the wiper blade may freeze to the glass Operating the wiper forcibly may damage the wiper motor O Off I Wiper operates PUSH Sprays washer...

Page 78: ...rning horn is sounded the machine may tip over If the horn starts sounding stop operating the machine and lighten the load If a weight greater than the lifting capacity is applied or lifted the overlo...

Page 79: ...ked 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 lever Bef...

Page 80: ...pattern in this manual Use these levers to operate the boom arm bucket and upperstructure Refer to Lever pattern on pages 3 6 and 3 7 Refer to Operating the working equipment on pages 3 16 and 3 17 B...

Page 81: ...e may suddenly move and cause serious injury or death Use these levers pedals to move forward or backward and to change directions Fold the pedals when not being used Refer to Operating the travel lev...

Page 82: ...oil flows to left auxiliary hose B Hydraulic oil flows to right auxiliary hose Refer to Auxiliary hydraulic lines on page 2 42 Pedal lock Set the pedal cover over the pedal to lock it Open the pedal...

Page 83: ...2 33 Memo...

Page 84: ...an switch Low Neutral OFF High Ventilation Circulation lever Use this lever to switch between Ventilation and Circulation Full ventilation For heating with ventilation Intake of external air Defrostin...

Page 85: ...or fully closed Cooling water could leak when the valve is partly opened 1 Park the machine on a level surface and stop the engine 2 Open the engine hood 3 Turn the valve 1 clockwise until it stops t...

Page 86: ...r electric parts may be damaged if drinks are spilled on them Pull out the cup holder towards you to use it Push in the holder for storage after use Interior light IMPORTANT The battery capacity decre...

Page 87: ...Set the armrest to your desired position and turn the bolts 1 clockwise to lock the armrest Power sockets Use only those electric products which comply with the specifications of these sockets For bea...

Page 88: ...d the operation mode 3 Display button DISP Pressing this button while the frequency is displayed on the LCD changes the display to the clock Pressing the button again returns to the frequency If the b...

Page 89: ...1 Auxiliary input jack AUX IN Use this jack to connect an external audio source such as a portable music player Pull off the rubber cap and connect the output terminal headphone jack of the portable p...

Page 90: ...vious stations stored will be cleared cancelled by the auto storing If the station stored in the preset button is not desirable try to preset the station manually Auxiliary input AUX Connect a portabl...

Page 91: ...4 V Maximum output power 16 W 16 W 4 at 28 8 VDC input 5W 5W 4 at 14 4 VDC input Rated output power 12 W 12 W 10 distortion 4 at 28 8 VDC input 3 5 W 3 5 W 10 distortion 4 at 14 4 VDC input Dimensions...

Page 92: ...e releasing the pressure in the hydraulic system Immediately after the engine is stopped press each auxiliary hydraulic pedal and second auxiliary switch several times to release the pressure from the...

Page 93: ...a Start the engine and run it at a low idle speed with no load for 10 minutes b With the engine running in low idle operate the auxiliary hydraulic switches repeatedly approx 10 times to purge air fr...

Page 94: ...iliary line d Releasing the residual pressure Refer to Accumulator on page 2 46 Third auxiliary hydraulic switch and button The third auxiliary hydraulic lines are normally used to control the quick a...

Page 95: ...pressed When using a hydraulic breaker 1 way flow 1 Make sure that the auxiliary hydraulic pedal is in the neutral position 2 Loosen the lock nut 1 3 Loosen the adjustment bolt 2 until it touches the...

Page 96: ...Strictly observe the following precautions Do not disassemble Do not allow flame near or throw it into a fire Do not drill weld or fuse Do not subject it to physical shock such as hitting rolling or d...

Page 97: ...3 1 Operation...

Page 98: ...steps holding the handrail to support your weight in a three point secure stance hand and feet Never use the safety lock lever or control levers as hand holds Walk around inspection Perform the walk...

Page 99: ...ition then perform the following inspections All warning lamps flash for one second and an alarm is sounded for ten seconds The meters also start functioning After two seconds only the battery charge...

Page 100: ...rn the starter key to the ON position and confirm that the glow lamp is on The glow lamp stays lit for up to three seconds when the coolant temperature is 5 C 41 F 3 After the glow lamp goes out turn...

Page 101: ...n the engine at a low idle speed with no load for 5 minutes Starting and stopping the engine Stopping the engine IMPORTANT Do not stop the engine suddenly when operating with heavy loads or at the max...

Page 102: ...is described using the ISO pattern in this manual Operating the machine Left crawler forward Right crawler forward Left crawler reverse Right crawler reverse Arm out Boom lower Arm in Boom raise Uppe...

Page 103: ...O pattern in this manual Operating the machine Left crawler forward Right crawler forward Left crawler reverse Right crawler reverse Boom lower Arm out Boom raise Arm in Upperstructure slew left Bucke...

Page 104: ...temperature is below 20 C 68 F The proper hydraulic oil temperature during operation is 50 to 80 C 122 to 176 F If operations must be performed at lower temperatures heat up the hydraulic oil to at l...

Page 105: ...becomes normal Inspection after warm up After warming up the engine and machine hydraulic oil perform the checks and inspections described below and repair if necessary 1 Check that the warning lamps...

Page 106: ...th Normally it is best to operate with the crawler width extended for machine s stability Switching the crawler width Perform the operation on a flat and rigid ground where no obstacles around 1 Raise...

Page 107: ...eration Operating the machine Switching the blade width 1 Loosen bolts 1 and remove plate 2 2 Attach the right plate 2 to the left the left plate 2 to the right 3 Tighten the plate 2 with bolts 1 AC8D...

Page 108: ...sure that the dozer blade is to the front of the operator s seat Remember that when the dozer blade is to the rear of the operator s seat the travel levers pedals must be operated in the reverse direc...

Page 109: ...the levers backward Operating the machine When the dozer blade is behind the operator s seat To move forward Tilt the levers backward To move backward Tilt the levers forward Traveling in 2nd High spe...

Page 110: ...t lever Turning to the left while traveling To turn left while traveling forward Set the left lever to neutral To turn left while traveling backward Set the left lever to neutral To turn to the right...

Page 111: ...e machine may 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 locke...

Page 112: ...d slewing Return the operating levers to the neutral position to stop the hoe attachments 1 Lower the safety lock lever to the unlocked position 2 Set the pedal cover to the unlocked position Upperstr...

Page 113: ...he bucket Bucket load Tilt the right operating lever to the left Bucket dump Tilt the right operating lever to the right Boom swing left Step on the left side of the pedal Boom swing right Step on the...

Page 114: ...ground using slew force Also do not dig the bucket teeth into the ground during slewing Doing so will damage the hoe attachment Do not dig while traveling Do not dig the bucket into the ground and us...

Page 115: ...essive strain on the machine will shorten its service life When digging use the hydraulic force of the cylinders and the shallow and long strokes Digging bedrock For hard base rock break the rock up i...

Page 116: ...tion to the dozer blade when digging When digging deeply with the dozer blade positioned at the front be careful that the boom and bucket do not hit the dozer blade Operate with the dozer blade at the...

Page 117: ...ing or changing directions abruptly When traveling in 2nd speed do so with the dozer blade at the front Cautions on using machine in water If the rear of the machine is submerged in water as shown in...

Page 118: ...illside When descending a hill keep the operator s seat facing the downhill direction In either case travel must be done while paying attention to the ground in front of the machine Do not descend slo...

Page 119: ...ravel use the pulling force of the arm to climb the slope Cautions on operating If the engine stops when descending a slope set the travel levers to the neutral position stop the machine then start th...

Page 120: ...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 while traveling forward to slowly move the machine out Operations possible with this...

Page 121: ...he truck as it is easier and able to load more load than doing it from the front Also use a small slewing angle for greater efficiency Leveling 1 Bring the hoe attachment close to the body 2 Gradually...

Page 122: ...in a specified place 1 Set the left and right travel levers to the neutral position 2 Return the throttle lever to idle the engine at low speed 3 Lower the bucket and the dozer blade to the ground 4 R...

Page 123: ...nd making it impossible for the machine to move Remove all mud and water from the machine body In particular wipe the hydraulic cylinder rod clean to prevent damage to the seal caused by mud or dirt o...

Page 124: ...e are large numbers of boulders may cause the stones to get caught and damage the crawler or make the crawler come off Do not use the machine on the seashore The salt may corrode the steel core Do not...

Page 125: ...with water Do not let the sides of the rubber crawlers rub against concrete or walls Do not damage the rubber crawlers by hitting the bucket against them Be especially careful on snowy or frozen surfa...

Page 126: ...crawler on a flat surface with the machine at a tilt of 10 or more Travel with both crawlers set on flat surfaces Do not change directions when the crawler belts are slack as shown in the figure The r...

Page 127: ...4 1 Transport...

Page 128: ...1st low gear by following the signal from the signal person Never change courses on the ramp Do not slew swing on the ramp The machine may tip over When slewing swinging on the truck bed do it slowly...

Page 129: ...toward the ramps and travel up or down the ramps at 1st low speed by following the signal from the signal person 8 Load the machine at the specified position on the transporter Refer to Transporting...

Page 130: ...gravity differs according to the attachments and optional equipment installed Contact your Takeuchi service agent for details Hoisting the machine Hoisting 1 Slew the upperstructure so that the dozer...

Page 131: ...4 5 Transport Hoisting the machine Cab Canopy...

Page 132: ...e lower frame of the machine and fasten it securely to prevent the machine from slipping sideways 7 Secure the bucket with a chain or wire rope IMPORTANT Place a wooden block under the bucket to prote...

Page 133: ...5 1 Maintenance...

Page 134: ...er for help Keep the machine clean Clean the machine before performing inspection and maintenance and try to keep it clean Stop the engine before washing the machine Cover the electrical parts so that...

Page 135: ...ined from the machine in containers Improperly disposed waste oil can cause environmental harm Follow appropriate laws and regulations when disposing of harmful objects such as oil fuel cooling water...

Page 136: ...e changed replace the whole fuel oil Fuel Diesel fuel specifications Diesel fuel should comply with the following specifications The table lists several worldwide specifications for diesel fuels Diese...

Page 137: ...in the U S A and Canada ultra low sulfur fuel should be used A higher sulfur content fuel may cause sulfuric acid corrosion in the cylinders of the engines Never mix kerosene used engine oil or resid...

Page 138: ...sing conventional antiwear hydraulic oil the hydraulic oil should be replaced every 2000 hours Lubricant Location Type Type by air temperature When to replace 4 14 32 50 68 86 104 F 20 10 0 10 20 30 4...

Page 139: ...oil pan Engine cooling system Hydraulic oil tank Fuel tank Travel reduction gear Upper limit 4 3 L 4 5 US qt Lower limit 1 5 L 1 6 US qt 3 8 L 4 0 US qt System 24 5 L 6 5 US gal Tank 16 0 L 4 2 US ga...

Page 140: ...to the machine and the breaker hydraulic system To prolong the service life of the hydraulic devices properly replace the hydraulic oil and the return filter elements according to the table below Whe...

Page 141: ...hrs after the initial 50 hrs Engine lubrication system Engine oil filter Cartridge Y119305 35160 Every 250 hrs after the initial 50 hrs Fuel system Water separator filter Element Y171081 55910 Every...

Page 142: ...00 47082 14 17 3 Screwdriver 19100 06112 replaceable shank 4 Filter wrench 19100 96081 5 Monkey wrench 16904 00250 250 mm 6 Pliers 16905 00200 200 mm 7 Spanner 16901 00013 13 8 Spanner 16900 01922 19...

Page 143: ...olts alternately top bottom left then right or in 2 or 3 times so that they are evenly tightened Service data Classification Head width b Size a x pitch Tightening torque General connection points mm...

Page 144: ...ly When to replace Fuel system Fuel hoses Every 2 years Packing on fuel filler cap Hydraulic system Main body Hydraulic hoses pump delivery Hydraulic hoses pump suction Hydraulic hoses slew motor Hydr...

Page 145: ...cessary 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 Typ...

Page 146: ...he oil filter 5 24 Inspecting and adjusting the fan belt 5 25 Replacing the hydraulic oil return filter 5 26 Every 50 hours Inspecting and adjusting the crawler tension 5 28 Lubricating the slew beari...

Page 147: ...ightening the engine cylinder head bolt 5 45 Every 1500 hours Inspecting and cleaning the engine fuel injectors 5 46 Inspecting the crankcase breather system 5 46 Every 2000 hours Lapping the engine v...

Page 148: ...or if the machine is parked on a slope Before starting the engine look around the machine and clean any combustibles from the surroundings of the engine Also inspect if oil or water is leaking and any...

Page 149: ...and sprockets for damage wear and loose bolts 10 Check for oil leakage from the travel motor 11 Check the canopy cab and guard for damage and the nuts and bolts for looseness 12 Check the rearview mir...

Page 150: ...eeze If any coolant antifreeze comes in contact with eyes or skin wash it off with clean water Otherwise it could result in injures Daily inspection every 10 hours Inspection 1 Open the engine hood 2...

Page 151: ...limit L of the dipstick 1 Problems could arise if the oil level is either too low or too high 3 Tighten the oil filler cap 2 4 Start the engine run it at low idle for about 5 minutes then stop it 5 A...

Page 152: ...ecting the fuel level Do not smoke or permit open flames while handling fuel or working on the fuel system Never remove the fuel cap or add fuel when the engine is running or still hot Do not spill fu...

Page 153: ...using the sight gauge 1 When the oil temperature is about 20 C 68 F The level should be between the upper limit H and the lower limit L If it is below the lower limit L replenish When the oil tempera...

Page 154: ...With the vent plug 2 removed set the safety lock levers to the released position Hydraulic tank pressurization posture 3 Fully extend the bucket arm boom swing and span cylinders 4 Stop the engine and...

Page 155: ...n the diagram above lower the working equipment to the ground and then stop the engine 2 Use the grease gun to lubricate the grease fittings 3 Wipe off the excess grease Note It is not necessary to lu...

Page 156: ...drain the oil The oil comes out when the screw is tightened 4 Remove the connector B and install the cap A IMPORTANT Check the waste oil for metal powder If it contains large amounts of metal powder...

Page 157: ...chines 1 Move the sheet all the way forward 2 Take out three bolts and remove the cover 1 1 Loosen the bolt 5 and locking nut 4 2 Turn the adjustment bolt 6 to move the alternator 7 and to adjust the...

Page 158: ...the hydraulic oil when loosening the cap or plug Working on the machine under these conditions could result in burns or injuries due to the hot oil spurting out Oil may spurt out if caps or filters ar...

Page 159: ...the flange 3 4 Loosen the bolts to take out the flange 3 5 Remove the return filter 4 6 Install a new return filter 7 Reinstall the flange 3 and the hose 2 8 Inspect the level with the sight gauge 5...

Page 160: ...under high pressure If the tension is adjusted without following the prescribed procedure the grease discharge valve may fly off resulting in injury Never loosen the grease fitting Loosen the grease...

Page 161: ...9 mm 3 3 to 3 5 in Adjustment Increasing the tension 1 Remove the cover 1 2 Inject grease through the grease fitting 3 of the grease discharge valve 2 with a grease gun 3 Inspect the crawler tension D...

Page 162: ...Use the grease gun to grease the grease fitting 1 Every 50 hours 3 Start the engine lift the bucket and slew clockwise 90 4 Lower the bucket to the ground and then stop the engine 5 Repeat the steps 2...

Page 163: ...l for the operating season Do the draining operation before starting the machine Every 50 hours 1 Slew the upperstructure to the position for easy draining 2 Remove the fuel filler cap 2 3 Place a pan...

Page 164: ...cause the fluid to leak This fluid can cause skin damage if contacted or can cause the machine components to corrode Batteries contain sulfuric acid which will damage eyes or skin if contacted If eye...

Page 165: ...5 33 Memo...

Page 166: ...ement 5 and case 4 and then tighten the ring 3 6 Open the valve 2 to bleed air Refer to Bleeding air from the fuel system on page 6 8 Every 100 hours Cleaning the fuel filter Do not smoke or permit op...

Page 167: ...rns or injuries The pressure in the reduction gear case of travel motor may cause oil or the plug to fly out Loosen the plug slowly to release the pressure IMPORTANT If the percentage of the traveling...

Page 168: ...ed air as metal fragments or other objects can fly and cause serious injury IMPORTANT Be careful not to scratch the element Do not use an element if it is damaged IMPORTANT When operating the machine...

Page 169: ...e outside and finally from the inside again 8 Light up the inside of the primary element 3 with a light bulb inspect it and replace it if there are small holes or thin spots 9 Remove the cloth or tape...

Page 170: ...when cleaning When using compressed air or pressurized water make sure the pressure is no higher than 200 kPa 28 psi and hold the nozzle sufficiently away from the fins IMPORTANT When using water cov...

Page 171: ...ll the way forward 2 Take out two screws and open the cover 1 3 Remove the air filter 2 Air filter 2 Part No 03345 00024 4 Use compressed air or water to clean each filter depending on how dirty it is...

Page 172: ...orming maintenance Clean up spilled fuel immediately 1 Open the side cover 2 Close the valve 2 3 Loosen the ring 3 and remove the case 4 4 Remove the spring 7 and the indicator ring 6 from the case 4...

Page 173: ...lean up spilled fuel immediately Every 500 hours 1 Open the engine hood 2 Close the valve 2 3 Loosen the ring 3 and remove the case 4 4 Clean the case 4 5 Inspect the O ring If there are any scratches...

Page 174: ...ho performs maintenance must make sure to keep his her body or clothing away from the moving part of the machine Standing at the back of the machine while the engine is running is extremely dangerous...

Page 175: ...gh the fill port until it is full 13 Close the radiator cap 3 14 Warm up the engine Use the meters to check that there are no irregularities in the cooling system at this time 15 Increase the water te...

Page 176: ...engine 1 Open the engine hood 2 Loosen the clamps 1 and remove the dust cup 2 3 Clean the inside of the dust cup 2 5 Cover the intake hole at the back of the body 4 with cloth or tape to prevent dirt...

Page 177: ...cting and adjusting the engine valve clearance This operation requires experience Ask your sales or service dealer for it Retightening the engine cylinder head bolt This operation requires experience...

Page 178: ...nd cleaning the engine fuel injectors This operation requires experience Ask your sales or service dealer for it Every 1500 hours Inspecting the crankcase breather system This operation requires exper...

Page 179: ...5 47 Maintenance Every 2000 hours Lapping the engine valve seats This operation requires experience Ask your sales or service dealer for it Every 2000 hours...

Page 180: ...d before releasing the pressure in the hydraulic system Gradually loosen the vent plug to relieve tank pressure When removing plugs or screws or when disconnecting hoses stand to the side and loosen t...

Page 181: ...posture and inspect the oil level when the oil temperature drops Refer to Inspecting the hydraulic oil tank level and replenishing on page 5 21 Every 4000 hours Bleeding air IMPORTANT After replacing...

Page 182: ...injury If hard metal parts such as pins bucket teeth side cutter or bearings are hit with a hammer wear protective gear such as safety goggles and gloves When hitting pins or bucket teeth always chec...

Page 183: ...not go in all the way 2 Put the teeth into the bucket 3 If the teeth are not secured insert a shim to reduce the clearance 4 Insert the bolt from the outside of the bucket and tighten it with the nut...

Page 184: ...th side cutter or bearings are hit with a hammer wear protective gear such as safety goggles and gloves When hitting pins or bucket teeth always check that there is no one in the surrounding area When...

Page 185: ...erate the cylinder align the pin hole B on the bucket with the pin hole on the link arm 6 and install the pin 2 4 Align the turn prevention holes install the lock pin 1 and then engage the ring inside...

Page 186: ...n required 1 Remove the lower mount section of the boot 1 and turn it upward 2 Wipe off the old grease 3 Apply grease to points A and B 4 Set the boot 1 back as it was Travel levers dozer blade lever...

Page 187: ...etched and cannot be adjusted 1 Lug When required Replace if the height of A is 5 mm 0 2 in or below 2 Steel cord Replace if the steel cord is exposed for two links or more Replace if the half or more...

Page 188: ...to touch the lever or pedal unless necessary The one who performs maintenance must make sure to keep his her body or clothing away from the moving part of the machine Removal 1 Fully release the tensi...

Page 189: ...1 is directly next to the idler and the rubber crawler lifts away from the idler then stop turning the sprocket 5 Slide the rubber crawler inward engage it on the idler then pull out the iron pipe 6 C...

Page 190: ...rusting operate the machine once a month so that the oil can be circulated throughout the system 2 Inspect the battery and recharge it as necessary Ask your sales or service dealer for recharging Sta...

Page 191: ...6 1 Troubleshooting...

Page 192: ...entarily slows down when it reaches an almost horizontal position while the engine is running at low speed The slew motor produces noise at the beginning and end of the slewing The travel motor produc...

Page 193: ...ED is in the red zone The engine slows down and the engine power decreases Steam comes from the engine room Remedy procedure 1 Park the machine in a safe place 2 Check if steam is coming out of the cl...

Page 194: ...e protective goggle when jump starting the engine by using the jumper cables IMPORTANT Use the jumper cables and clips of a size suited to the capacity of battery Do not use damaged or corroded jumper...

Page 195: ...the engine block of the dead machine 2 Disconnect the other clip of jumper cable B from the negative battery terminal of the booster vehicle 3 Disconnect the clip of jumper cable R from the positive b...

Page 196: ...use box cover 1 4 Check for any blown fuses 5 If a fuse is blown replace it with a spare fuse of the same capacity Fuse layout and circuits protected Applicable machine models 216000002 or later Capac...

Page 197: ...dge type fusible link 1 is likely blown Open the maintenance cover and inspect If the fusible link is blown please contact your sales or service dealer Note Fusible links are large type fuses used in...

Page 198: ...pinion gear and or ring gear Restarting after adding fuel 1 Add fuel 2 Open the valve 2 of the water separator and the fuel filter 3 Turn the starter key to the ON position and hold it for about 60 s...

Page 199: ...s likely a problem with the charger Consult your sales or service dealer for help Refer to Inspecting and adjusting the fan belt on page 5 25 Engine oil pressure warning lamp A problem has occurred in...

Page 200: ...o page 2 29 Fuse is blown Replace the fuse Refer to page 6 6 Adjustment of travel lock is faulty Adjust the travel lock ask your sales or service dealer Digging force is insufficient Hydraulic oil lev...

Page 201: ...in fuel system Drain water Refer to page 5 31 Crawlers come off Crawlers too loose Increase the tension Refer to page 5 28 Engine exhaust is white or bluish Excessive engine oil Adjust to the specifie...

Page 202: ...ng the boom to the ground 3 Loosen the lock nut 3 while holding the adjust screw 4 in place with a hexagonal wrench so that the adjust screw 4 will not be loosened together with the lock nut 3 4 Turn...

Page 203: ...o the wire rope while towing IMPORTANT Do not tow a machine if its engine does not start or if the machine does not run Doing so could damage the machine being towed IMPORTANT Be sure to follow the st...

Page 204: ...until the replacement is complete Do not try to repair the damaged cab or canopy by welding Doing so could endanger the safety of the cab canopy Applicable machine models 216000002 or later Cab parts...

Page 205: ...7 1 Specifications...

Page 206: ...1st 2 2 1 37 2nd 4 2 2 61 Steel crawlers 1st 2 1 1 30 2nd 4 0 2 49 Gradeability degrees 30 Ground pressure kPa psi Rubber crawlers 31 0 4 50 29 4 4 26 Steel crawlers 34 5 5 00 32 8 4 76 Noise level d...

Page 207: ...1 37 2nd 4 2 2 61 Steel crawlers 1st 2 1 1 30 2nd 4 0 2 49 Gradeability degrees 30 Ground pressure kPa psi Rubber crawlers 29 4 4 26 Steel crawlers 32 8 4 76 Noise level dB A Sound power level LWA 93...

Page 208: ...7 4 Specifications Machine dimensions Cab Machine dimensions...

Page 209: ...l width wide 1300 51 2 J Crawler shoe width 230 9 1 K Ground clearance of undercarriage 205 8 0 210 8 2 L Minimum radius of equipment and attachment 1480 58 2 M Minimum radius of equipment at maximum...

Page 210: ...7 6 Specifications Machine dimensions Canopy...

Page 211: ...hoe width 230 9 1 K Ground clearance of undercarriage 205 8 0 210 8 2 L Minimum radius of equipment and attachment 1480 58 2 M Minimum radius of equipment at maximum front offset 1155 45 4 P Offset di...

Page 212: ...7 8 Specifications Operating ranges Operating ranges...

Page 213: ...t 755 29 8 760 30 0 J Dozer blade maximum lifting 360 14 2 365 14 4 K Dozer blade maximum lowering 365 14 3 360 14 1 Canopy Unit mm inch Item Long arm Rubber crawlers Steel crawlers A Maximum reach 40...

Page 214: ...7 10 Memo...

Page 215: ...ad falling from the hooking device For example equipped with a hook slippage prevention device 3 A system that poses no risk of the hooking system slipping from the hoe attachment Lifting Capacities D...

Page 216: ...7 12 Specifications Long arm Cab Lifting Capacities...

Page 217: ...7 13 Specifications Long arm Cab Lifting Capacities...

Page 218: ...7 14 Specifications Long arm Canopy Lifting Capacities...

Page 219: ...7 15 Specifications Lifting Capacities Long arm Canopy...

Page 220: ...7 16...

Page 221: ...8 1 Options...

Page 222: ...ry to temporally place a heavy object or an attachment on the ground during removal or installation be sure to place it in a stable position Keep everyone out of the area when hoisting There is a haza...

Page 223: ...nd the machine Keep a safe distance from surrounding obstacles When a heavy attachment is installed natural drop the gradual dropping of the attachment under its own weight when it is stopped in midai...

Page 224: ...its products caused by the use by a non approved attachment The swing stopper must be mounted when a bucket wider than a 450W bucket is mounted Failure to mount the swing stopper may result in the buc...

Page 225: ...right operating levers are set Selecting a lever pattern Switching the lever pattern A ISO pattern G G pattern 1 Park the machine on a flat and rigid ground and stop the engine 2 Open the maintenance...

Page 226: ...nter of gravity and keeping the machine facing forward When an optional attachment such as a breaker tilted bucket or clamshell is operated be sure that the crawler width is extended to 1300 mm 51 2 i...

Page 227: ...raulic oil and return filter element after the number of hours shown on the diagram below When replacing the hydraulic oil clean the suction strainer Replacement interval hours Item Hydraulic oil Filt...

Page 228: ...lifted Boom Arm If the emergency shut off valve 1 or 2 is activated immediately set the operating levers to the neutral position Do not move the operating lever to the boom or arm lowering side Ask y...

Page 229: ...overload warning device is activated and the horn sounds When the overload warning switch is turned on If the overload is not removed after the overload warning horn is sounded the machine may tip ove...

Page 230: ...pen the fuse box cover 1 4 Check for fuse 5 If a fuse is blown replace it with a spare fuse of the same capacity Fuse layout and circuits protected Applicable machine models 216000002 or later Capacit...

Page 231: ...ass Option Steel crawlers 50 110 With hydraulic thumbs 120 265 Emergency shut off valve Boom Arm 10 20 Units kg lb Mass of optional equipment is added to the standard machine mass This table only cont...

Page 232: ...l This operation is dangerous and requires experience Have it performed by a Takeuchi sales or service outlet Flushing To be performed by a Takeuchi sales or service outlet 1 Drain the hydraulic oil m...

Page 233: ...8 13...

Page 234: ...8 14 First Published August 2013 Second Published September 2013 Printed in Japan by STATION M Co Ltd Operator s manual No 41765 Mini excavator TB216 Edited and issued by TAKEUCHI MFG CO LTD...

Page 235: ...ne not coordinated with us this certificate loses its validity Designation of the machine Compact Excavator Manufacturer TAKEUCHI MFG CO LTD 205 Uwadaira Sakaki machi Hanishina gun Nagano 389 0605 Jap...

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