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Takeuchi TB153FR, Operator'S Manual

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168

TROUBLESHOOTING

After the Fuel Runs Out

Bleeding the Air from the Fuel
System

1. Add fuel.

2. Turn the starter key to the ON position and

hold it there for about 20 seconds.
The automatic air bleeder bleeds the air
from the fuel system.

Supplement: Air in the fuel system can
make it difficult to start the engine and cause
engine problems. Also bleed the air when
the fuel tank is emptied or air in the fuel
system.

PREHEAT

OFF

ON

START

E4D002

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Summary of Contents for TB153FR

Page 1: ...RATOR S MANUAL Read and understand these instructions Failure to do so can cause injury or death WARNING TB153 TB180 FR Book No AL5E001 TB153FR 15820004 TB180FR 17830004 Serial No FR Hydraulic Excavat...

Page 2: ...achine 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 machi...

Page 3: ...sed to alert against operators and maintenance personnel about situations which can result in possible damage to the machine and its components It is impossible to foresee every possible circumstance...

Page 4: ...A compartment for storing this manual is provided at the position shown on the diagram below 1 After using the manual place it in the plastic pouch and store it back in the manual storage compartment...

Page 5: ...button Slew cushioning system for easy bucket positioning Engine emergency stop idle system Tilt up operators platform for easy access to major compartment Break in period When the machine is new heed...

Page 6: ...4...

Page 7: ...5 Introduction 2 Machine Description 3 Safety 7 Controls 35 Operation 67 Transport 101 Maintenance 107 Troubleshooting 161 Specifications 175 Options 193 Index 229 CONTENTS...

Page 8: ...6...

Page 9: ...eneral Precautions 8 Preparing Precautions 12 Starting Precautions 14 Operating Precautions 16 Stopping Precautions 23 Transporting Precautions 24 Maintenance Precautions 25 Safety Signs Decals 32 SAF...

Page 10: ...ep Wear appropriate clothing and personal 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...

Page 11: ...ow to use the safety lock lever seat belt and other safety equipment and use them properly Never remove any safety equipment except for service Keep all safety equipment in good operating condition Us...

Page 12: ...angerous 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 fueling or near fueling oper...

Page 13: ...cro molecular filter 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...

Page 14: ...nto account the safety of pedestrians and vehicles Use a flagman an or signals Fence off the working area and prohibit entry to unauthorized persons When working in water or crossing shallow streams o...

Page 15: ...ts Before operating perform the prescribed inspections and make repairs immediately should any irregularities be found If a failure that causes loss of control such as steering service brakes or engin...

Page 16: ...he engine until you are sure it is safe Before starting check or perform the following Walk around the machine and warn all personnel who may be servicing the machine or are in the machine path Do not...

Page 17: ...Use jumper cables only in the recommended manner Improper use of jumper cables can result in battery explosion or unexpected machine motion Refer to the section titled If the Battery Goes Dead for pr...

Page 18: ...ine If necessary swing the cab around before backing up to check that the area is safe and clear Ensure good visibility When working in dark places turn on the machine s working lights and headlights...

Page 19: ...s slow enough so you have complete control at all times When a load greater than a set value is applied during 2nd speed high speed travel the speed will automatically slow down by switching to 1st sp...

Page 20: ...he machine When traveling on slopes or grades move slowly in first gear low speed Do not travel down slopes in reverse On grass dead leaves wet metal or frozen surfaces the machine may slide sideways...

Page 21: ...maximum possible distance from power lines and never violate the minimum clearance Always contact the nearest electric utility and determine jointly what specific precautions must be taken to insure...

Page 22: ...eep trenches etc The ground may give way under the machine s weight or vibrations causing the machine to tip over The ground is weak after rain or explosions The ground is also unstable on banks and n...

Page 23: ...is used for lifting Never lift loads in excess of capacity Overload will cause the machine to roll and can result in serious injury or death All rated lift capacities are based on the machine being l...

Page 24: ...in the wrong way could lead to accidents resulting in serious injury or death The wire rope breaking or coming detached could be extremely dangerous Use a wire rope suited for the required towing for...

Page 25: ...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 machine do the following 1 Lower the bucket and dozer b...

Page 26: ...both tracks and secure the machine to the truck bed with load binders Fasten to the suspension fitting Ramp 15 or less Distance between ramps Stopper E4F001 Hoist the machine safely Know and use corre...

Page 27: ...uel hoses periodically Fuel hoses become weaker over time even if they appear to be in good shape Replace important safety parts whenever an irregularity is found even if it is before the normal time...

Page 28: ...onnectors or the operator s seat area Stop the engine before performing maintenance Avoid lubrication or mechanical adjustments with the machine in motion or with the engine running while stationary I...

Page 29: ...unexpected movement securely block the working equipment when repairing or replacing the cutting edges or bucket teeth Secure the engine hood or cover when opened Be sure to secure the engine hood or...

Page 30: ...el oil or hydraulic fluid leaks can cause a fire Do not twist bend or hit the hoses Never use twisted bent or cracked hoses tubes and pipes They may burst Retighten loose connections Be careful with h...

Page 31: ...ted before releasing the pressure in the hydraulic system Gradually press the air breather button to relieve tank pressure Move all the control levers and pedals several times in all directions to rel...

Page 32: ...ater or milk and call a physician immediately If acid contacts skin or clothing wash off immediately with clean water Wear safety glasses and gloves when working with batteries Batteries generate flam...

Page 33: ...pper limbs are subjected to vibrations lower than 2 5 m 8 2 ft sq sec while the seated part of the body is subjected to vibrations lower than 0 5 m 1 64ft sq sec Checks after maintenance Gradually rai...

Page 34: ...or the personal safety of you and those working with you Please take this manual walk around your machine and note the content and location of these safety signs Review these signs and the operating i...

Page 35: ...d on the boom and main body In addition do not install attachments other than those designated by Takeuchi The interference prevention system may not function properly if other attachments are install...

Page 36: ...T HAND BOOM OFFSET IS USED CAUTION 03393 75040 DO NOT USE ETHER USAGE OF ETHER FOR STARTING PURPOSES MAY CAUSE INTERNAL ENGINE DAMAGE CAUTION 03393 75050 HYDRAULIC TANK MUST REMAIN PRESSURIZED TO AVOI...

Page 37: ...35 Names of Components 36 Doors and Covers 38 Seat and Seat Belt 44 Instrument Cluster 46 Switches 48 Levers and Pedals 53 Accessories 56 CONTROLS...

Page 38: ...ank Undercarriage 6 Crawler belt 7 Idler 8 Track roller 9 Carrier roller 10 Travel motor Working equipment 11 Bucket 12 Bucket cylinder 13 Arm 14 Arm cylinder 15 Boom 16 Boom cylinder 17 Boom bracket...

Page 39: ...raulic switches 14 Blade lever 15 Offset pedal 16 Decel button 17 Heater AC control panel 18 Automatic decel button TB180FR 19 Cigarette lighter 20 Overload warning switch Option 21 Selector button 2n...

Page 40: ...oes not move Open the door fully and press it against the catch at the back of the door to lock it in place Always lock the door when mounting and dismounting and when operating the machine Lock and u...

Page 41: ...right handles 1 and press the knobs 2 with your thumb to release the lock 2 Pull the front window toward you and lift while doing so 3 Lift the front window fully and then release your thumb from the...

Page 42: ...e glass firmly place the lower front window through the guides 5 at the rear then set it on the supports 6 and fasten it in place 4 5 6 6 4 5 C4C006 Doors and Covers Side Window Cab 1 Grasp the catch...

Page 43: ...e front Rear Cover CAUTION When opening the rear cover open it firmly to the locked position When opening and closing the rear cover be careful not to get your hands or other parts of your body caught...

Page 44: ...an up spilled fuel immediately Do not fill the fuel tank to capacity Allow room for expansion Tighten the fuel filler cap securely Opening 1 Open the key cover insert and turn the key counterclockwise...

Page 45: ...43 MEMO...

Page 46: ...ever 2 andslidetheseatbackward or forward to bring it to the optimum position for operating the machine 2 Release the lever 2 at the desired position and the seat will be locked there Adjustmentstroke...

Page 47: ...rso and sit back firmly into the seat 2 Pull the 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 yo...

Page 48: ...ng automatically 2 Engine Oil Pressure Coolant Level Warning Lamp This lamp flashes and an alarm is sounded if the lubricant oil pressure or coolant level in the radiator drops abnormally while the en...

Page 49: ...s the total engine running time in hours The rightmost digit indicates tenths of hours 6 minutes Set the inspection and maintenance intervals according to the time displayed on the hour meter 10 Water...

Page 50: ...the ON position Battery Switch IMPORTANT Never set this switch to the OFF O position while the engine is running Doing so might cause damage to the electrical system 1 Open the rear cover OFF O Switc...

Page 51: ...ling B Middle speed C Maximum speed Switches Horn Button Press the button on the right operating lever to blow the horn Decel Button WARNING Set the operating and travel levers to neutral before opera...

Page 52: ...AIS to the M position then select the appropriate attachment width S L or M TB153FR TB180FR Switches M S J1B017 L Modes of Operation TB153FR S Standard bucket attachment less than 635mm 24 inches wide...

Page 53: ...auxiliary hydraulic lines Proportional control of the auxiliary hydraulic circuit is not possible A Hydraulic oil flows to left auxiliary line a B Hydraulic oil flows to right auxiliary line b Travel...

Page 54: ...id is discharged do not operate the washer Doing so may damage the pump IMPORTANT Operating the wiper with no moisture on the windshield will scratch the glass Apply water or washer fluid when operati...

Page 55: ...accidentally when the safety lock lever is lowered the machine will move suddenly and cause serious injury or death TB153FR Note that the dozer blade control is not locked even when the safety lock l...

Page 56: ...vel levers operate in the opposite direction to when the dozer blade is in the front Use these to move forward and backward and to change directions Refer to page 79 Operating the Travel Levers Levers...

Page 57: ...page 85 Operating the Boom Offset Pedal Lock WARNING When not using the pedal set the pedal lock to the locked position Stepping on a pedal accidentally when it is not locked may lead to unexpected ac...

Page 58: ...l dial 3 Use this dial to select recirculation or fresh air intake Recirculation To cool or heat the cab quickly When external air is dirty CENTER 50 fresh air intake To ventilate while heating the ca...

Page 59: ...terior light is left on for long periods of time the engine stopped Turn the lamp off when leaving the machine O Off I Lit Accessories O I C4C024 TB153FR TB180FR 1 Park on a flat surface and stop the...

Page 60: ...socket When using the wiper and this socket simultaneously be careful not to exceed 12V 10A 1 Press the lighter in 2 Release the lighter and wait for it to pop out The lighter pops out automatically...

Page 61: ...use applicable electric products with these sockets for Beacon Use these sockets as an external power supply When using these sockets be careful not to exceed 12V 10A To use raise the cap 1 Applicabl...

Page 62: ...erable Be careful not to insert cassette tapes backward Doing so may damage the cassette player Insert tapes with the head of the tape facing to the right Always remove the cassette from the player wh...

Page 63: ...radio 7 Cassette door Insert the cassette tape with the exposed magnetic tape side facing to the right Simply insert a tape to change over to the cassette tape mode while listening to the radio 8 Fas...

Page 64: ...ND button changes over between FM1 FM2 and AM MW bands The display indicates the receiving band name and frequency 13 Metal switch Press the MTL 5 button before playing a metal or CrO2 tape The MTL in...

Page 65: ...d press the this button again If you will auto memory push this button over 5 sec so initiates a scan of the band Station frequencies are either stored in order of low of frequency for FM or in sequen...

Page 66: ...fitted with a hydraulic breaker open the selector valve 1 Refer to pege 65 Selector valve 5 When connecting is complete purge air from the hydraulic lines a Start and run the engine at low idle with...

Page 67: ...he selector valve 1 on the machine body The residual pressure is released from the b port line When equipped with accumulator option Refer to page 204 Releasing the residual pressure Selector valve O...

Page 68: ...66...

Page 69: ...n 68 Starting and Stopping the Engine TB153FR 70 Starting and Stopping the Engine TB180FR 72 Machine Operation 74 Operating Procedures 88 Parking the Machine 96 Handling in Cold Weather 97 Handling Ru...

Page 70: ...inspections as described under Maintenance Daily Inspection pages 120 to 124 Mounting and Dismounting WARNING Do not jump on or off the machine Never attempt to mount or dismount a moving machine Whe...

Page 71: ...the warning lamps flash and an alarm is sounded for 2 seconds The meters also start functioning After 2 seconds only the battery charge warning lamp 4 and engine oil pressure coolant level warning la...

Page 72: ...Up the Engine Starting the Engine WARNING Clear the area of all persons Sound horn to alert everyone around the machine IMPORTANT Do not run the starter motor for more than 15 consecutive seconds If t...

Page 73: ...of a true emergency 1 Press the decel button or return the throttle lever 2 Idle the engine for about 5 minutes to gradually let it cool 3 Turn the key to the OFF position to stop the engine Warming...

Page 74: ...ne starts release the key The key automatically returns to the ON position 3 Check that the warning lamps are off 4 Warm up the engine Refer to page 73 Warming Up the Engine Starting in Cold Weather 1...

Page 75: ...Press the decel button or return the throttle controller 2 Idle the engine for about 5 minutes to gradually let it cool 3 Turn the key to the OFF position to stop the engine Warming Up the Engine IMPO...

Page 76: ...efore beginning operations The explanations in this manual are for the ISO pattern Left Crawler Forward Left Crawler Reverse Arm Out Arm In Upperstructure Left Slew Upperstructure Right Slew Boom Offs...

Page 77: ...efore beginning operations The explanations in this manual are for the ISO pattern Left Crawler Forward Left Crawler Reverse Boom Lower Boom Raise Upperstructure Left Slew Upperstructure Right Slew Bo...

Page 78: ...ng operation is 50 to 80 C 122 to 176 F but if operations must be performed at lower temperatures heat up the hydraulic oil to at least 20 C 68 F Normal Warm up TB153FR 1 Pull the throttle lever to th...

Page 79: ...and check that the operating offset dozer blade and travel levers are locked TB153FR Note that the dozer blade control is not locked even when the safety lock lever is set to the lock position 4 Perf...

Page 80: ...mum rear inclination 3 Offset to the left in the posture in 2 above Operation when the boom has stopped automatically 1 If the boom has stopped while rising Operate the boom downward 2 If the boom has...

Page 81: ...sure that the dozer blade is to the front of the operator s seat BE AWARE that when the dozer blade is to the rear of the operator s seat the travel levers operate in the opposite direction to when th...

Page 82: ...omatically slow down by switching to 1st speed low speed Thereafter when the load becomes lighter the speed will increase by returning to 2nd speed high speed Exercise due caution since the travel spe...

Page 83: ...this control accidentally CAUTION Never bring the machine to a sudden stop except in the case of a true emergency Stop as gently as possible 1 Slowly set the left and right travel levers to the neutr...

Page 84: ...a problem contact a Takeuchi sales or service outlet for inspection or repair The interference prevention system may not function properly if attachments other than Takeuchi approved attachments are i...

Page 85: ...ucket attachment more than 800mm 31 inches wide or any other approved attachment TB180FR S Standard bucket attachment less than 750mm 30 inches wide L Bucket attachment more than 750mm 30 inches and l...

Page 86: ...ition to stop the hoe attachments 1 Fully lower the safety lock lever to disengage the lock 2 Raise the pedal lock to disengage the lock Slewing WARNING Check the surrounding area for safety before sl...

Page 87: ...lt the right operating lever to the right Operating the Boom Offset aTo offset left Press the left side of the pedal eTo offset right Press the right side of the pedal Operating the Dozer Blade aTo lo...

Page 88: ...ns and operation with the slider switch proportional control TB153FR TB180FR Operating With the Slider Switch Proportional Control aTo deliver hydraulic oil to port a Move the switch to the left A eTo...

Page 89: ...87 MEMO...

Page 90: ...rvice life of the hoe attachment Use hydraulic force to dig Prohibited Operations WARNING Do not operate on base rock hard or soft Do not slew swing while traveling If you must operate the hoe attachm...

Page 91: ...up into small pieces with a breaker etc before digging This prevents damage to the machine and is thus more economical in the end Caution on Exposing the Dozer Blade to Shocks Hitting the dozer blade...

Page 92: ...t be careful that the boom cylinder and bucket do not hit the dozer blade Operate with the dozer blade at the rear whenever possible Caution on Digging Down with the Dozer Blade This dozer blade is de...

Page 93: ...ing or main body in water or sand If the slew bearing or main body should get submerged contact a Takeuchi sales or service outlet for inspection Cautions on Operating Cautions on Traveling Traveling...

Page 94: ...bility capabilities maximumgradeability 30 lateral tipping angle 15 Also note that when actual working area conditions are poor the machine s stability capabilities may be lower When traveling on slop...

Page 95: ...ne stops when traveling down a slope set the travel levers to the neutral position stop the machine then start the engine Do not open the door while traveling on slopes Opening the door while travelin...

Page 96: ...digging wide ditches dig the sides first the center later E4D0501 80 120 E4D051 Getting Out of Mud If the machine gets stuck in mud use the procedure below to get it out If one crawler is stuck 1 Slew...

Page 97: ...om swing function to dig side ditches as shown in the diagram Loading When loading dirt in a truck starting from the back of the truck s bed makes for easier loading and increases the amount of dirt t...

Page 98: ...partment Canopy Parking WARNING Park the machine on firm level ground and apply the parking device Before leaving the operator s seat raise the safety lock lever to engage the lock and stop the engine...

Page 99: ...he fuel and the oils for the different devices with those specified on the Lubricant and Fuel Chart Refer to page 110 Lubricant and Fuel Chart When using one season type antifreeze coolant completely...

Page 100: ...cause the crawlers to slip off or be damaged due to rocks getting stuck in them Do not use on the seashore The salt may corrode the metal cores Do not let fuel oil salt or chemical solvents get on th...

Page 101: ...o 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 in the winter on snowy or frozen sur...

Page 102: ...where the slope starts Avoid traveling with one crawler on a slope or projecting object and the other crawler on a flat surface with the machine at a tilt of 10 or greater Travel with both crawlers o...

Page 103: ...101 TRANSPORT Loading and Unloading 102 Hoisting the Machine TB153FR 103 Hoisting the Machine TB180FR 104 Securing the Machine 105 Cautions on Transporting 105...

Page 104: ...sure to use ramps and following the procedure below 1 Apply the truck s parking brake and place stoppers against its tires 2 Fasten the ramps securely to the truck bed so that they will not come off...

Page 105: ...h standard specifications The center of gravity differs according to the attachments and options that are mounted Consult a Takeuchi sales or service outlet Hoisting posture Hoisting 1 Slew the upper...

Page 106: ...h standard specifications The center of gravity differs according to the attachments and options that are mounted Consult a Takeuchi sales or service outlet Hoisting posture Hoisting 1 Slew the upper...

Page 107: ...to engage the lock 5 Set stoppers in front and behind the crawlers 6 Put a chain or wire rope over the lower frame and fasten it securely to prevent sideways slippage 7 Secure the bucket with a chain...

Page 108: ...106...

Page 109: ...lk Around Inspection 118 Daily Inspection Every 10 Hours 120 After First 50 Hours New Machines Only 125 Every 50 Hours 128 After First 250 Hours New Machines Only 133 Every 250 Hours 134 Every 500 Hou...

Page 110: ...grease Store fuels lubricants and greases in the prescribed places and in such a way that no water or dirt can get in them Cautions on fueling If the port includes a strainer do not remove the straine...

Page 111: ...e battery cables while the engine is running Doing so could damage the electronic circuitry of the alternator and other parts Do not clean parts with fuel Do not use fuel to clean parts Use a non comb...

Page 112: ...he coolant manufacturer s instructions to determine the mixture ratio Part Type Type by temperature 22 4 14 32 50 68 86 104 F 30 20 10 0 10 20 30 40 C Replacement interval Capacity R R R R R US qt Eng...

Page 113: ...mal digging Be sure to replace the hydraulic oil and return filter element Failure to replace these in time can lead to damage to the machine and breaker s hydraulic systems In order to improve the se...

Page 114: ...ry 500 hrs Cartridge 119802 55800 After first 50 hrs Every 250 hrs TB153FR 129150 35152 TB180FR 129150 35151 Engine oil filter Cartridge Every 1000 hrs or after 6 cleanings whichever comes first Air c...

Page 115: ...11 Spanner 16909 00026 26 12 Pliers 16905 00200 200mm 13 Hammer 16903 00330 3 4 14 Hex wrench 16906 00400 4mm 15 Hex wrench 16906 00500 5mm 16 Hex wrench 16906 00600 6mm 17 Hex wrench 16906 00800 8mm...

Page 116: ...nuts and bolts alternately top bottom left then right or in 2 or 3 times so that they are tightened uniformly Thread Coarse Fine 10 M6 X 1 0 9 8 0 5 7 2 0 4 12 13 M8 X 1 25 22 6 1 1 16 6 0 8 14 17 M1...

Page 117: ...m immediately When replacing the hydraulic hoses replace the O rings and seals at the same time Check the fuel and hydraulic hoses according to the periodic schedule described below Refer to Maintenan...

Page 118: ...ting the fuel level 122 Inspecting the hydraulic oil level and replenishing 122 Lubricating the working equipment 124 After First 50 Hours New Machines Only Replacing the hydraulic oil return filter 1...

Page 119: ...pray condition 141 Every 2000 Hours Replacing the hydraulic oil and cleaning the suction strainer 142 Inspecting the engine fuel injection timing 144 Inspecting the engine fuel injection valve 144 Whe...

Page 120: ...g inspections once every day before starting the engine the first time WARNING Before operating perform the walk around inspections and make repairs immediately should any irregularities be found Be s...

Page 121: ...bulbs 5 Check attachments and hoses for damage 6 Check the bucket bucket teeth and side cutter for wear damage and looseness 7 Check the hook slip stopper and hook mount of buckets with hooks for dama...

Page 122: ...ator cap or drain plugs when the coolant is hot Stop the engine let the engine and radiator cool and loosen the radiator cap or drain plugs slowly Inspection TB153FR TB180FR 1 Open the engine hood 2 I...

Page 123: ...rom the Fuel System Supplement Air in the fuel system can make it difficult to start the engine and cause engine problems Also bleed the air when the fuel tank is emptied Inspecting and Replenishing t...

Page 124: ...ressure in the hydraulic system Gradually press the air breather button to relieve tank pressure Inspection The oil level changes according to the oil temperature Inspect the oil level in the hydrauli...

Page 125: ...s Replenishing 1 Remove cap nut 3 on the air breather 2 2 Press button 4 and bleed the air from the tank 3 Tighten securely by hand with cap nut 3 4 Remove the plug 1 5 Add hydraulic oil up to the mid...

Page 126: ...urs Lubricating the Working Equipment 1 Set the machine to the lubrication posture shown in the diagram above ground the working equipment then stop the engine 2 Use the grease gun to lubricate the gr...

Page 127: ...il may spurt out if caps or filters are removed or pipes disconnected before releasing the pressure in the hydraulic system Gradually press the air breather button to relieve tank pressure When removi...

Page 128: ...the drain plug 3 3 Remove cap A install connector B and drain the oil The oil comes out when the screw is tightened 4 Remove connector B and install cap A 5 Using a filter wrench turn the filter 4 co...

Page 129: ...ming inspection and maintenance The engine muffler radiator hydraulic lines sliding parts and many other parts of the machine are hot directly after the engine is stopped Touching these parts will cau...

Page 130: ...ut following the prescribed procedure the grease discharge valve may fly off resulting in injury Do not loosen the grease nipple Loosen the grease discharge valve slowly Do not put your face arms legs...

Page 131: ...raulic cylinder to adjust the tension of the crawler belts Note that it is not necessary to regularly perform adjustments of the tension of the belt itself Adjustment TB153FR Increasing the tension 1...

Page 132: ...the engine with the machine in the posture shown on the diagram above 2 Use the grease gun to supply grease to the grease nipple 1 3 Start the engine lift the bucket and slew clockwise 90 4 Ground th...

Page 133: ...id is accidentally swallowed drink large quantities of water or milk and call a physician immediately If acid contacts skin or clothing wash off immediately with clean water Inspection IMPORTANT Check...

Page 134: ...k 4 Close the drain plug 3 5 While watching the sight gauge 1 add fuel 6 Tighten the fuel filler cap 2 and lock it with the key 7 Bleed the air Bleeding the air from the fuel system Refer to page 168...

Page 135: ...injuries The pressure in the travel motor reduction gears case may cause oil or the plug to fly out Loosen the plug slowly to release the pressure IMPORTANT If the percentage of the traveling time wi...

Page 136: ...use serious personal injury IMPORTANT Be careful not to scratch the element Do not use an element if it is damaged IMPORTANT When operating the machine in very dusty places inspection and maintenance...

Page 137: ...g the flutes then blow the air from the outside and finally from the inside again 8 Light up the inside of the element 3 with a bulb inspect it and replace it if there are small holes or thin spots 9...

Page 138: ...and oil cooler fins when cleaning them When using compressed air or pressurized water make sure the pressure is no higher than 200 kPa 28 psi and hold the nozzle sufficiently away from the fins IMPORT...

Page 139: ...r 1 counterclockwise and remove it 3 Clean the filter installation surface on the filter stand 4 Apply a thin layer of oil to the packing of the new filter 5 Install the new filter by hand 6 Tighten 2...

Page 140: ...performed with the engine running always work as a two person team with one person sitting in the operator s seat while the other works on the machine When performing maintenance be sure to keep your...

Page 141: ...the level of the cleaning fluid and add tap water if the level drops 6 Stop the engine and drain the cleaning fluid 7 Tighten the drain plug 4 add tap water run the engine at a low idle for about 10 m...

Page 142: ...or after every 3 cleaning of the outer element whichever comes first TB153FR TB180FR 1 Open the engine hood 2 Loosen the clamp 1 and remove the dust cup 2 3 Clean the inside of the dust cup 2 4 Remove...

Page 143: ...the cut section of body B and cover H and install 7 Install seal washers W and nut G 8 Tighten securely by hand with cap nut N Replacing the Travel Motor Gear Oil Refer to page 133 Replacing the Trave...

Page 144: ...release the internal pressure before removing 1 Slew 45 clockwise and set the machine to the hydraulic oil level inspection posture Refer to page 122 Inspecting the Hydraulic Oil Level and Replenishi...

Page 145: ...the hydraulic oil circuit and hydraulic devices Failure to do so may damage the hydraulic devices Hydraulic pump 1 Tilt up the platform Refer to page 154 Tilting Up the Platform TB153FR 2 Loosen the h...

Page 146: ...ll the cylinders 4 or 5 times without going to the stroke end 10 Set the engine back to a low idle then extend and contract all the cylinders 4 or 5 times to the stroke ends Every 2000 Hours Inspectin...

Page 147: ...irregularities replace it 5 Assemble the indicator ring 6 case 4 and element 5 and tighten the ring 3 6 Open the lever 2 and bleed the air Bleeding the air from the fuel system Refer to page 168 Blee...

Page 148: ...Supply grease to points A and B 4 Set the boot 1 back as it was Travel levers 1 Remove the lower mount section of the boots 1 and turn it upwards 2 Wipe off the old grease 3 Supply grease to points A...

Page 149: ...Swing the buckte slightly to the left and lightly press the arm point to the left side of the bucket the side without an adjuster 4 Remove the three bolts 2 the end plate 3 and flange 4 5 Extract adju...

Page 150: ...injury When lining up the pin holes always do so by sight Your finger may be cut off if you stick it into the hole Removal 1 Ground the bucket as shown on the diagram above in a stable position Suppl...

Page 151: ...uts Be sure to leave a gap of about 0 5 1 mm 0 02 0 04 in between the nut and bucket bush or the nut will come loose 5 Adjust the gap between the bucket and the arm Refer to page 134 6 Slide the O rin...

Page 152: ...mmers as metal fragments or other objects can fly and cause serious personal injury Do not allow unauthorized personnel in the work area Bucket tooth Removal 1 Clean the bucket and park the machine in...

Page 153: ...tip of the adapter nose 3 Some tooth points 2 are of the type that are installed by turning twisting them clockwise 3 Insert the locking pin 1 making sure it is in the right direction 4 Drive in the l...

Page 154: ...hammers as metal fragments or other objects can fly and cause serious personal injury Do not allow unauthorized personnel in the work area Bucket tooth Removal 1 Clean the bucket and park the machine...

Page 155: ...welding adapter s pin hole 3 Drive in locking pin 1 After driving in the locking pin use a pin with the same surface as the point surface Do not use worn locking pins When Required E4G047 1 Side cutte...

Page 156: ...m touching the cab Raising Tilt up 1 Select a firm level surface lower the working equipment to the ground and stop the engine 2 Raise the safety lock lever to engage the lock 3 Loosen the bolts and r...

Page 157: ...cannot be adjusted 1 Lug Replace if the height of A is 5 mm 0 2 in or below 2 Steel cord Replace if the steel cord is exposed over 2 or more links Replace if half or more of the steel cords on one si...

Page 158: ...ler Tension 2 Use the working equipment to lift the body 3 Set an iron pipe 1 in the rubber crawler and turn the sprocket slowly in the reverse direction 4 Turn until the iron pipe 1 is directly next...

Page 159: ...awler is securely engaged on the sprocket and idler 7 Tighten the rubber crawler to the standard tension Refer to page 128 Inspecting and Adjusting the Crawler Tension 8 Install the other rubber crawl...

Page 160: ...RTANT During the replacement procedure only start the engine when raising and lowering the machine body Otherwise always keep the engine off IMPORTANT When the travel speed switch is set to the 2nd sp...

Page 161: ...ockets then remove the crawlers from the crawler frames Installation 1 Engage the crawlers with the left and right sprockets 2 Set the left and right crawlers on the idlers 3 Start the engine 4 Press...

Page 162: ...ention oil that was applied to the hydraulic oil cylinders piston rods 2 Add fuel oil and grease to all parts Procedures for storage If the machine is to be stored for 30 days or more store it indoors...

Page 163: ...ot Malfunctions 162 If the Engine Overheats 163 If the Battery Goes Dead 164 If a Fuse Blows 166 After the Fuel Runs Out 168 If a Warning Lamp Flashes 169 Other Symptoms 170 To Lower the Boom 172 Towi...

Page 164: ...osition while the engine is running at low speed the speed of bucket movement slows down momentarily The slew motor produces noise at the beginning and end of the slewing operation The travel motor pr...

Page 165: ...ine slows down and the force decreases Steam comes from the engine room Procedure 1 Park the machine in a safe place 2 Inspect whether the engine oil pressure coolant level warning lamp is flashing or...

Page 166: ...eakly and the engine does not start The horn is weak Procedure Use jumper cables and start the engine using the rescue vehicle s battery WARNING Use jumper cables only in the recommended manner Improp...

Page 167: ...2 Disconnect the other clip of jumper cable B from the rescue vehicle s terminal 3 Disconnect the clip of jumper cable R from the rescue vehicle s terminal 4 Disconnect the other clip of jumper cable...

Page 168: ...a spare fuse of the same capacity If a Fuse Blows Fuse Layout and Circuits Protected E4J007 Normal Blown TB153FR 20A Horn 10A Radio Interior light 10A Lever lock 5A Lights 30A Wiper Cigarette lighter...

Page 169: ...the cover located at below of the left operating lever and inspect If the fusible link is blown please contact your dealer Supplement A fusible link is a large piece of fuse wiring which is mounted i...

Page 170: ...he ON position and hold it there for about 20 seconds The automatic air bleeder bleeds the air from the fuel system Supplement Air in the fuel system can make it difficult to start the engine and caus...

Page 171: ...multaneously For the procedures refer to the respective warning lamps below Battery charge warning lamp There is a problem with the fan belt or charger Inspect the fan belt for slack or breakage and a...

Page 172: ...Hydraulic oil is not heated Air cleaner is clogged Hydraulic oil is not of suitable type Replenish to the prescribed level Refer to page 122 Perform the warm up procedure Refer to page 76 Clean the a...

Page 173: ...haust is white or bluish Excessive engine oil Insufficient fuel Adjust to the prescribed level Refer to page 121 Replace the fuel Engine exhaust is occasionally black Air cleaner is clogged Clean the...

Page 174: ...hment as it drops Turn the port relief valve s set screw slowly so that the boom lowers slowly Do not turn the screw more than the specified amount 1 Loosen the bolts and remove the cover 1 TB153FR TB...

Page 175: ...G To Lower the Boom 7 Gripping the set screw 3 with a hexagonal wrench so that it does not turn together with the lock nut 4 tighten the lock nut 4 Tightening torque 27 to 31 N m 20 to 23 ft lb 8 Rein...

Page 176: ...hould get stuck in the mud and not be able to get out on its own 1 Fasten the wire rope to the frame 2 Place splints or other objects between the wire rope and frame to prevent the machine and wire ro...

Page 177: ...175 SPECIFICATIONS Main Specifications 176 Machine Dimensions 178 Operating Range 180 Lifting Capacities 183...

Page 178: ...Rubber crawlers 5505 12135 5615 12375 5540 12215 5645 12445 PERFORMANCE Bucket capacity m3 cu ft standard bucket Heaped 0 141 4 98 Struck 0 102 3 60 Slew speed min 1 rpm 9 8 9 8 Ground pressure kPa ps...

Page 179: ...ng operator Rubber crawlers 8325 18355 8350 18410 Steel crawlers 8530 18810 8555 18865 PERFORMANCE Bucket capacity m3 cu ft standard bucket Heaped 0 245 8 65 Struck 0 165 5 83 Slew speed min 1 rpm 9 9...

Page 180: ...178 SPECIFICATIONS Machine Dimensions...

Page 181: ...1860 73 2 2140 84 3 C 2570 101 3 2585 101 7 2765 108 9 D 1110 43 7 1255 49 4 E 615 24 2 720 28 3 F 1985 78 1 2210 87 G 2500 98 5 2855 112 4 H 2000 78 7 2300 90 6 J 400 15 7 450 17 7 K 300 11 8 345 13...

Page 182: ...180 SPECIFICATIONS Operating Range J1K0021 D J H K C F G A E B...

Page 183: ...Max vertical digging radius 3885 153 0 4075 160 4 J Max raising height 320 12 6 K Max lowering depth 325 12 8 TB153FR Units mm inches Item Standard Arm Long Arm Rubber Crawlers A Max digging radius 6...

Page 184: ...182 MEMO...

Page 185: ...n the load is applied 2 A system in which there is no risk of the lifted load falling from the hooking device for example one equipped with a hook slippage prevention device 3 A system in which there...

Page 186: ...5 0 16 4 4 0 13 1 7 0 3 0 9 8 0 1 0 3 3 1 0 3 3 2 0 6 6 4 0 13 1 6 0 19 7 3 0 9 8 23 0 m 7 0 ft 23 0 m 7 0 Over Front Dozer Blade Down Over Front Dozer Blade Up ft m ft m 1876 4216 1992 4478 701 1577...

Page 187: ...3 3 19 7 2 0 6 6 5 0 16 4 4 0 13 1 7 0 3 0 9 8 0 1 0 3 3 1 0 3 3 2 0 6 6 4 0 13 1 6 0 19 7 3 0 9 8 23 0 m 7 0 ft 23 0 m 7 0 Over Rear Over Side ft m ft m 789 1773 1133 2546 2461 5531 1534 3449 1690 3...

Page 188: ...7 3 0 9 8 23 0 m 7 0 ft 23 0 m 7 0 Over Front Dozer Blade Down Over Front Dozer Blade Up ft m ft m 913 2052 3857 8671 2794 6280 2566 5768 2779 6248 1899 4269 2512 5647 2515 5654 2554 5742 1847 4151 17...

Page 189: ...0 1 0 3 3 1 0 3 3 2 0 6 6 4 0 13 1 6 0 19 7 3 0 9 8 23 0 ft m Over Rear Over Side 1569 3527 913 2052 1650 3708 3076 6916 1177 2647 3516 7905 3363 7559 913 2052 785 1765 2325 5225 1177 2647 3363 7559 2...

Page 190: ...3 2 0 6 6 4 0 13 1 6 0 19 7 3 0 9 8 23 0 m 7 0 ft 23 0 m 7 0 Over Front Dozer Blade Down Over Front Dozer Blade Up ft m ft m 1154 2595 743 1669 311 698 930 2091 888 1996 1786 4015 1949 4380 1073 2412...

Page 191: ...8 0 1 0 3 3 1 0 3 3 2 0 6 6 4 0 13 1 6 0 19 7 3 0 9 8 23 0 m 7 0 ft 23 0 m 7 0 Over Rear Over Side ft m ft m 880 1978 511 1149 905 2034 2300 5170 1972 4433 1190 2675 1170 2629 1191 2677 922 2072 825...

Page 192: ...0 Over Front Dozer Blade Down Over Front Dozer Blade Up ft m ft m 1325 2979 1484 3336 2255 5069 3681 8275 3871 8701 868 1951 890 2001 830 1866 4551 10231 2532 5692 2510 5643 2532 5693 2909 6540 2636...

Page 193: ...0 m 7 0 ft 23 0 m 7 0 Over Rear Over Side ft m ft m 2255 5069 3672 8255 1714 3853 1051 2363 2417 5434 758 1704 779 1752 725 1630 2255 5069 2909 6540 4280 9621 2101 4724 2082 4679 2102 4725 1051 2363 2...

Page 194: ...192...

Page 195: ...e Bucket TB180FR 199 Hydraulic Breaker 200 Load Safety Device 202 Accumulator 204 Pre Cleaner TB180FR 205 Second Auxiliary Hydraulics 206 Third Auxiliary Hydraulics 208 Fourth Auxiliary Hydraulics TB1...

Page 196: ...Follow the leader s instructions on operating methods and procedures Determine a signal leader and heed this person s signals When removing or installing the hoe attachment place it in a stable positi...

Page 197: ...nt under its own weight when it is stopped in midair also increases when heavy attachments are installed The machine can tip over more easily in the lateral direction than in the longitudinal directio...

Page 198: ...Signs Decals Keep all safety signs clean and legible Replace all missing illegible or damaged safety and warning signs There are other safety signs in addition to the ones listed here Treat them in t...

Page 199: ...97 OPTIONS 1 No 03593 32200 2 No 03593 32300 Safety Signs Decals G A ISO 03593 32200 03593 32300 Check what type of lever control arrangement you are operating with before beginning operations WARNING...

Page 200: ...or Switching the Lever Pattern A ISO pattern G JCB pattern Switching the Lever Pattern ISO A JCB G C4L004 1 Park the machine in a safe place and turn off the engine 2 Fully open the cab door and fix i...

Page 201: ...arm installation position is switched from A to B However this shortens the bucket stroke Struck capacity SAE 0 210 m3 0 275 cu yd Rated capacity SAE 0 261 m3 0 341 cu yd Changing the Link Arm Install...

Page 202: ...the engine with 75 the maximum speed Pound with the chisel perpendicular to the surface you are pounding When pounding press the chisel properly against the object to be broken so as to avoid poundin...

Page 203: ...e sure to replace the hydraulic oil and return filter element Failure to replace these in time can lead to damage to the machine and breaker s hydraulic systems In order to improve the service life of...

Page 204: ...suspended object Boom Arm TB153FR TB180FR If the emergency shut off valves 1 or 2 are activated immediately set the operating lever to the neutral position Do not move the operating lever to the boom...

Page 205: ...ING Continuing to apply the load after the overload warning horn sounds could result in the machine tipping over or the emergency shut off valve being activated If the horn sounds stop operating the m...

Page 206: ...e ON position First auxiliary hydraulics 6 Press both the auxiliary hydraulic buttons A and B several times to release the residual pressure in the circuitry Second and fourth auxiliary hydraulics 6 M...

Page 207: ...ents or other objects can fly and cause serious personal injury IMPORTANT When operating the machine in very dusty places inspection and maintenance should be performed every day IMPORTANT If the air...

Page 208: ...then close the stop valve When equipped with accumulator Refer to page 204 Releasing the residual pressure 2 Remove the plugs 3 Connect the attachment hydraulic lines to ports c and d 4 Open the stop...

Page 209: ...oil flows to right auxiliary line d When the safety lock lever is set to the lock position this control is locked Disconnecting the hydraulic circuits 1 Release the pressure remaining in the lines the...

Page 210: ...the pressure remaining in the lines Refer to Releasing the residual pressure 2 Remove the plugs 3 Connect the attachment hydraulic lines to ports e and f 4 When connecting is complete purge air from...

Page 211: ...ng the hydraulic circuits 1 Release the pressure remaining in the lines Refer to Releasing the residual pressure 2 Disconnect the lines from ports e and f 3 Install the plugs Releasing the residual pr...

Page 212: ...remaining in the lines When equipped with accumulator Refer to page 204 Releasing the residual pressure 2 Remove the plugs 3 Connect the attachment hydraulic lines to ports g and h 4 When connecting...

Page 213: ...Refer to page 204 Releasing the residual pressure 2 Disconnect the lines from ports g and h 3 Install the plugs Fourth Auxiliary Hydraulics TB180FR Selector Button 2nd or 4th Aux This button changes f...

Page 214: ...are fuse of the same capacity Travel Alarm E4J007 Normal Blown Fuse Layout and Circuits Protected TB153FR 20A Horn 10A Radio Interior light 10A Lever lock 5A Lights 30A Wiper Cigarette lighter 10A Opt...

Page 215: ...full DANGER Do not use the fuel supply pump for gasoline or hydraulic oil Doing so could result in explosion or damage Only use the fuel supply pump for diesel fuel 1 Open the engine hood 2 Insert th...

Page 216: ...windows If this happens either turn the air conditioner off or turn the temperature control dial clockwise to increase the internal temperature Mist may blow out of the air outlets This is not a malf...

Page 217: ...er 2 Condenser 3 Receiver drier 4 Foot outlets 5 Control panel 6 Compressor 7 Air conditioner unit 8 Inner filter 9 Outer filter 10 Air conditioner switch 11 Temperature control dial 12 Fan switch 13...

Page 218: ...pplement To prevent leakage of coolant gas from the compressor s seal operate the air conditioner at least once a week regardless of the season Supplement The air conditioner will not function if the...

Page 219: ...air conditioner ON and adjust the switches as shown in the diagram above The outflow slot of foot area and the outflow slots of the defroster can be directed at the front window Warm dehumidified air...

Page 220: ...am above Defogging the Windows CAUTION If the air conditioner is set to high when using the defroster the difference between the external and internal temperatures increases and fog may form on the ou...

Page 221: ...t to slip shorteningitsservicelifeandreducing the air conditioner s cooling capacity If the belt is slack it will slip and vibrate shortening its service life and reducing the air conditioner s coolin...

Page 222: ...ecomes weak and a muted booming sound is heard from the air conditioner unit Removing the filters 1 Loosen the bolts 1 and remove the cover 2 2 Remove the inner filter 3 3 Loosen the bolts 4 and remov...

Page 223: ...g the Refrigerant gas Level WARNING Exposure of the eyes or hands to the cooler s refrigerant could result in blindness or frostbite Never touch the refrigerant or loosen the parts of the cooling circ...

Page 224: ...t when the engine speed is increased or decreased High pressure pipe 1 hot 80 to 120 C 176 to 248 F low pressure pipe 2 cold 8 to 15 C 46 to 59 F Clear difference in temperature between the pipes No i...

Page 225: ...223 MEMO...

Page 226: ...ration key The keys are used for the immobilizer system theft prevention device Immobilizer key key grip black The immobilizer key is used not only to start and stop the engine but also to lock and un...

Page 227: ...ght near or into contact with the starter switch or key section the system may no longer be able to identify the keys ID codes in which case it is no longer possible to start the engine Do not place k...

Page 228: ...edure before starting If you stop in the middle you may have to start over from the beginning Do not turn the key to the START position while performing the steps 3 to 12 Registration Procedure 1 Prep...

Page 229: ...econds after registering the immobilizer keys insert the registration key into the starter switch and turn it from the OFF O position to the ON I position 11 Hold for about 10 seconds 12 Return to the...

Page 230: ...228...

Page 231: ...229 INDEX...

Page 232: ...omponents 28 Be careful with hot cooling systems 28 Be sure to lock the safety lock lever before leaving the operator s seat 10 Before Starting Operation 68 Before Starting the Engine 69 Blade Lever 5...

Page 233: ...l 11 Expendables 112 External Power Sockets for EU 59 F Fan Switch 216 First Auxiliary Hydraulic Lines 64 First Auxiliary Hydraulic Switches 51 Fourth Auxiliary Hydraulic Lines 210 Fourth Auxiliary Hy...

Page 234: ...sible Link 167 Inspecting the hydraulic oil level and replenishing 122 Inspecting the Refrigerant gas Level 221 Inspecting the rubber crawlers 155 Inspecting the water separator 121 Inspecting while s...

Page 235: ...aner TB180FR 205 Precautions on Installing Attachments 194 Precautions on Operating 200 Precautions on Operating Attachments 195 Precautions on Safety 194 Prepare the work area 26 Preparing for Cold W...

Page 236: ...perator s seat 14 Starter Key 38 Starter Switch 48 Starting and Stopping the Engine TB153FR 70 Starting and Stopping the Engine TB180FR 72 Starting Precautions 14 Starting the Engine 70 Starting the E...

Page 237: ...o which the operator is subjected 31 W Walk Around Inspection 68 Walk Around Inspection 118 Warming Up the Engine 71 Warming Up the Engine 73 Warming Up the Machine Hydraulic Oil 76 Warning Lamps 46 W...

Page 238: ...First Published April 2006 No 23190 OPERATOR S MANUAL TB153FR TB180FR Hydraulic Excavator Edited and issued by TAKEUCHI MFG CO LTD Printed in Japan by STATION M Co Ltd...

Page 239: ...he State of California to cause cancer birth defects and other reproductive harm Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of Califor...

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