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SIGNAL WORDS

Safety messages appearing in this manual 

and on machine decals are identified by the 

words “DENGER”, “WARNING” and 

“CAUTION”. These signal words mean the 

following:

DANGER indicates a hazard with a high 

level of risk which, if not avoided, will 

result in death or serious injury.

WARNING indicates a hazard with a 

medium level of risk which, if not avoided, 

could result in death or serious injury.

CAUTION indicates a hazard with a low 

level of risk which, if not avoided, could 

result in minor moderate injury.

IMPORTANT: The word IMPORTANT is 

used to alert operators and maintenance 

personnel about situations which could 

result in damage to the machine and its 

components.

It is impossible to foresee every possible 

circumstance that might involve a potential 

hazard. The warnings in this manual or on 

the machine can not cover all possible 

contingencies. You must exercise all due 

care and follow normal safety procedures 

when operating the machine so as to ensure 

that no damage occurs to the machine, its 

operators or other persons.

Summary of Contents for TB215R

Page 1: ... TB219 OPERATOR S MANUAL E MINI EXCAVATOR WARNING Read and understand these instructions Failure to do so can cause injury or death TB215R Book No AC8E000 Serial No 215000003 OETB215R AA Original instructions ...

Page 2: ...roper operation inspection and maintenance of this machine can cause injury or death Read and understand this manual before performing any operation inspection or maintenance on this machine Always store this manual near at hand preferably on the machine itself If it should be lost or damaged immediately order a new one from your Takeuchi dealer When transferring ownership of this machine be sure ...

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 could result in damage to the machine and its components It is impossible to foresee every possible circumstance that might involve a potential hazard The warnings in this manual or on the machine ca...

Page 4: ...mpartment for storing this manual is provided at the position shown on the diagram below 1 Insert the starter key and turn it counterclockwise to open the cover under the seat 2 After using the manual place it in the plastic pouch and store it back in the manual storage compartment SERIAL NUMBERS IMPORTANT Do not remove the machine name plate with the serial number Check the serial numbers of the ...

Page 5: ...awler width Low engine noise and exhaust emissions Smaller rear slew radius smaller turns stability is retained BREAK IN PERIOD When the machine is new operate the machine for the first 100 hours as indicated on the hour meter by following the instructions below Using a new machine without a break in period will lead to quicker deterioration of machine performance and may shorten the machine s serv...

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 this manual The symbols used in this manual have the following meanings X Prohibition Lock Unlock ...

Page 7: ...on 3 1 Before starting operation 3 2 Getting on or off the machine 3 2 Walk around inspection 3 2 Daily inspection 3 2 Starting and stopping the engine 3 3 Before starting the engine 3 3 Starting the Engine 3 4 Warming up the engine 3 5 Stopping the engine 3 5 Operating the machine 3 6 Lever pattern ISO pattern 3 6 Lever pattern G pattern If equipped 3 7 Warming up the machine hydraulic oil 3 8 In...

Page 8: ...3 Replacing the travel motor gear oil 5 33 Every 250 hours 5 34 Replacing the engine oil and the oil filter 5 34 Inspecting and adjusting the fan belt 5 34 Cleaning the air cleaner 5 34 Cleaning the radiator fins and oil cooler fins 5 36 Every 500 hours 5 38 Replacing the hydraulic oil return filter 5 38 Replacing the water separator filter 5 38 Replacing the fuel filter 5 39 Every 1000 hours 5 40 Repla...

Page 9: ...y precautions 8 2 Cautions when installing attachments 8 2 Cautions when operating attachments 8 3 Attachment combination table 8 4 Selecting a lever pattern 8 5 Switching the lever pattern 8 5 Hydraulic breaker 8 6 Replacing the hydraulic oil regularly 8 7 Biodegradable oil 8 8 Replacing the hydraulic oil with biodegradable oil 8 8 ...

Page 10: ...0 8 ...

Page 11: ...1 1 SAFETY SAFETY ...

Page 12: ... adverse influence of alcohol drugs medication fatigue or insufficient sleep GENERAL PRECAUTIONS When a problem is found on the machine If any problem noise vibration smell disorder of instrument smoke oil leak or wrong indication of alarm and panel etc is detected during the operation or inspection and maintenance of the machine please inform the administrator and take proper actions Do not operate...

Page 13: ...en 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 AG7A005 Be prepared for fire and accidents Install an extinguisher and a first aid kit and learn how to use them Lean how to fight a fire and how to deal with accidents Know how to contact emergency assistance and make a list of emer...

Page 14: ...or s seat lower the working equipment to the ground raise the safety lock lever to the lock position and then stop the engine If any control is accidentally touched when the safety lock lever is lowered unlocked the machine will suddenly move and cause serious injury or death Note that the dozer blade boom swing and auxiliary hydraulic controls cannot be locked even when the safety lock lever is s...

Page 15: ...hly with nonflammable solvent before cutting or welding Remove all trash or debris from the machine Make sure that oily rags or other flammable material are not stored on the machine Handle all solvents and dry chemicals foam type fire extinguisher according to procedures identified on manufacturer s containers Work in a well ventilated area Never use fuel for cleaning purposes Always use a nonflammabl...

Page 16: ...r clean up use a vacuum equipped with a high efficiency particulate air filter HEPA Wear the stipulated respirator if there is no other way to control the dust When working indoors install a ventilation system with a macromolecular filter Do not allow unauthorized personnel in the work area while working Follow the rules and environmental standard applicable to the work area Be careful not to get cru...

Page 17: ...is not contacted with other parts before use Do not use attachments that have not been approved by Takeuchi Doing so may compromise safety or adversely affect the machine s operation or service life Takeuchi will not be held responsible for any injuries accidents or damage to its products caused by the use by a non approved attachment GENERAL PRECAUTIONS Never modify the machine Unauthorized modifi...

Page 18: ...edestrians and vehicles Use a flag person and or a signal Fence off the working area and keep off unauthorized persons When working in water or crossing shallow streams or creeks check the depth of the water the solidity of the ground and the water flow speed beforehand Refer to Cautions on operating for further instructions Check the strength of the bridge When traveling over a bridge or a structur...

Page 19: ...autions 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 not leave the parts or tools around the operator s seat Do not leave any plastic bottles in the operator s compartment or attach any suction cups on the window glass The plastic bottle or suction...

Page 20: ...round the machine and warn the person who is servicing the machine or is walking near the machine Do not start the machine until you are certain that no one is around the machine Check if there is a DO NOT OPERATE alert sign or similar sign is on the cab door controls or starter switch If there is one do not start the engine or touch any levers Sound the horn to warn people around the machine Sit ...

Page 21: ...rm 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 working In cold climates AG7A027 Be careful of slippery conditions on freezing ground steps and hand holds In severe cold climates do not touch any metal parts of the machine with bare hands The skin will...

Page 22: ...ow places 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 machine Before traveling in reverse check that the area is safe and clear PRECAUTIONS WHEN OPERATING Operate the machine with the maximum crawler width Always operate the machine with the crawler w...

Page 23: ...e and the bucket 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 all times Avoid crossing over obstacles whenever possible If you must do so keep the hoe attachment close to the ground level and travel slowly Never cross obstacles which will tilt the mach...

Page 24: ...while paying attention to the ground in front of the machine 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 bucket to the ground and stop the machine When traveling on slopes or grades drive slowly in 1st low speed When descending a slope slow down the engin...

Page 25: ... 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 over resulting in an operator trapped inside the machine When parking the machine on an unstable ground lower the dozer blade PRECAUTIONS WHEN OPERATING Do not move the bucket over the heads of people M...

Page 26: ...d death 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 cables to be high voltage cables and treat all cables as energized even though it is known or believed that the power is shut off and the cables are visibly grounded Use a signal person to give warn...

Page 27: ...m 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 machine to tilt under its own weight resulting in a machine tipping over or sinking into the ground Do not come close to unstable grounds cliffs road shoulders deep ditches If the ground should collapse...

Page 28: ...uilding collapsing and causing serious injury or damage PRECAUTIONS WHEN OPERATING Do not use the impact force of the hoe attachment for breaking work There is a hazard of serious injury being caused by flying pieces of broken materials and by the damaged hoe attachment Operating on slopes is dangerous When operating on slopes or grades slewing or operation of working equipment may cause the machin...

Page 29: ...ent for crane operation Extreme caution should be paid if the excavator 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 determined by using a machine placed on a stable and flat ground For a safe lifting work the user is expected to make due allowance for the particular job con...

Page 30: ... rope that is kinked twisted or otherwise damaged Do not apply heavy loads abruptly to the wire rope Wear safety gloves when handling the wire rope Make sure there is an operator on the machine being towed as well as on the machine that is towing Never tow on slopes Do not let anyone come near to the wire rope while towing Be careful with flying objects This machine is not equipped with protective ...

Page 31: ...the 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 AG7A060 Before leaving the machine do the followings 1 Lower the bucket and the dozer blade to the ground 2 Raise the safety lock lever to the locked position 3 Stop the engine and remove the starter key 4 Lock the co...

Page 32: ...les or blocks Never use the working equipment to load or unload the machine Doing 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 the crawlers Chock the transporter wheels to prevent movement When being loaded or unloaded travel slowly in 1st low gear ...

Page 33: ...s 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 persons PRECAUTIONS WHEN TRANSPORTING Transport the machine safely Know and follow the applicable safety rules vehicle code and traffic laws when transporting the machine Select the best transport rout...

Page 34: ...t tools AG7A065 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 periodically Fuel hoses wear out over time even if they do not show any symptom of wear Regardless of the replacement schedule replace immediately if a symptom of wear is found Refer to List of safety cri...

Page 35: ... cannot 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 Stop the engine before performing maintenance Avoid lubrication or mechanical adjustments while the machine is moving or while the engine is running when the machine is not moving If maintenan...

Page 36: ...lways 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 working on hydraulic cylinders Secure the working equipment To prevent unexpected movement firmly secure the working equipment when repairing or replacing the bucket teeth or side cutter Secure the eng...

Page 37: ... 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 hoses otherwise they may burst Retighten loose connection Be careful with hot and pressurized components AG7A081 Stop the engine and allow the machine to cool down before performing maintenance The engine muf...

Page 38: ...g If oil penetrates 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 filters are removed or pipes are disconnected before releasing the pressure in the hydraulic system Gradually loosen the vent plug to relieve tank pressure When removing plugs or screws or whe...

Page 39: ...rease discharge valve slowly Do not turn it more than one turns Do not put your face arms legs or body in front of the grease discharge valve If grease does not come out when the grease discharge valve is loosened the valve is faulty Ask a Takeuchi service agent for repair AG7A086 Handling of the accumulator Be sure to handle the high pressure nitrogen gas enclosed in the accumulator with care If ...

Page 40: ...top 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 short circuit Loose battery terminals may result in sparks Be sure to fasten terminals tightly Make sure the battery caps are tightened securely Do not charge a battery or jump start the engine if ...

Page 41: ...S 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 result in sparking and battery explosion Do not allow the machine in trouble and rescue machine to touch each other Do not allow the positive and negative clips of the booster cables to touch each other o...

Page 42: ...ANCE 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 vibrations lower than 2 5 m s2 8 2 ft s2 while the seated part of the body is subjected to vibrations lower than 0 5 m s2 1 64 ft s2 Checks after maintenance Gradually increase the engine speed from a low id...

Page 43: ...ety 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 difficult to read replenish it with a new one Please include your product serial number when ordering a new sign from the Takeuchi service agent When a part unit to which a safety sign is attached is rep...

Page 44: ...1 34 SAFETY SAFETY SIGNS DECALS ...

Page 45: ...1 35 SAFETY SAFETY SIGNS DECALS No 00085 01011 ...

Page 46: ...1 36 SAFETY SAFETY SIGNS DECALS ...

Page 47: ...1 37 SAFETY SAFETY SIGNS DECALS ...

Page 48: ...1 38 ...

Page 49: ...2 1 CONTROLS ...

Page 50: ...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 cylinder 17 Boom bracket 18 Swing cylinder 19 Auxiliary hydraulic lines 20 Dozer blade 21 Blade cylinder ...

Page 51: ...er 7 Horn button 8 Selector lever 9 Boom swing pedal NAMES OF COMPONENTS 10 Travel lever Pedal 11 Travel speed switch 12 Auxiliary hydraulic pedal 13 Left operating lever 14 Third auxiliary hydraulic botton 15 Third auxiliary hydraulic switch 16 Auxiliary 2nd switch Subject to the specifications or optional products selected ...

Page 52: ...e compartment Engine hood Covers MAINTENANCE COVER A Opening Open this cover to perform a maintenance operation of the engine or to switch the selector valve 1 Insert the starter key and turn it counterclockwise to unlock the maintenance cover A 1 Closing 1 Close the maintenance cover A 1 2 Insert the starter key and turn it clockwise to lock the maintenance cover A 1 ...

Page 53: ...kwise 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 spilled fuel immediately Do not fill the fuel tank to capacity Allow room for oil expansion Securely tighten the fuel filler cap Opening 1 Open the fuel lid 2 Turn the fuel cap 1 counterclockwise and re...

Page 54: ...1 2 Push in the key hole 2 with your thumb and open the engine hood 1 3 Open the engine hood 1 all the way until it is fastened It is fastened automatically Closing 1 Support the engine hood 1 by hand them pull up the stay 3 to release the engine hood 1 2 Close the engine hood 1 3 Insert the starter key and turn it clockwise to lock the engine hood 1 COVERS MAINTENANCE COVER B For inspection and m...

Page 55: ...1 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 positions in 150 mm 5 9 in C Adjusting according to operator s weight 1 Move the lever 3 to set it according to the weight of operator Position of the lever 3 Upper Light weight operator Middle Medium weig...

Page 56: ...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 positions in 150mm 5 9in C Adjusting according to operator s weight 1 Turn the handle 3 until the display indicates the weight of operator Adjustment range 50 to 130 kg 110 to 287 lbs 2 When adjusting for a weight lower than the cu...

Page 57: ...o the desired length AG7B023 B A 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 Check if the belt is securely locked by pulling it and arrange the belt around your waist AG7B024 A C B Releasing the seat belt 1 Grasp the tongue plate A and press the button C on the buckle B The sea...

Page 58: ...ning lamp flashes and an alarm 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 is a problem with the engine or charging system 2 Engine oil pressure warning lamp This lamp flashes and an alarm is sounded if the lubricant oil pressure abnormally low whil...

Page 59: ...ture 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 of fuel in the tank Be sure to top off the tank before running out of fuel INSTRUMENT CLUSTER 5 Fuel level warning lamp This lamp turns on if the fuel level becomes low while the starter switch is in...

Page 60: ...ths of hours 6 minutes Set the inspection and maintenance intervals according to the time displayed on the hour meter Trip meter Three patterns of desired operating hours can be displayed Refer to Trip meter display on page 2 13 3 Time display Displays the time set Refer to Time setting on page 2 16 INSTRUMENT CLUSTER 4 Alarm indicator lamp The clock symbol appears when the alarm function is turne...

Page 61: ... 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 CLUSTER C Menu trip meter reset Pressing the C key switches to the Menu screen Pressing and holding the C key for three seconds or more while the trip meter is displayed returns the trip meter to 0 5...

Page 62: ... 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 engine oil hydraulic oil and coolant are included so that you can use them as a guideline for replacement SETTING Time alarm and contrast can be set ...

Page 63: ...TRIP 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 key to move the selection bar Press the C key to return to the DATA screen Coolant temperature WATER TEMP Displays the coolant temperature in Celsius C or Fahrenheit F Press the C key to return to the ...

Page 64: ... at least three seconds to enter the alarm time setting mode f Press the C key to cancel editing and to return to the Setting Selection screen Checked On Unchecked Off SETTING SELECTION SCREEN SETTING Press the A key to proceed to the screen selected by the bar Press the key B to move the selection bar Press the C key to return to the Menu screen Time setting CLOCK The time to be displayed on the ...

Page 65: ...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 press the A key to proceed to the contrast setting screen CONTRAST b To increase contrast press the B key The bar advances to the right Press and hold the B key to rapidly advance the bar Once the ba...

Page 66: ...ture is too low the engine is automatically preheated START Position for starting the engine When the key is released the switch automatically returns to the ON position HORN BUTTON Press the button situated on the right operating lever to blow the horn TRAVEL SPEED SWITCH Press this switch to set the travel speed to 2nd high speed Press it again to return to 1st low speed SECOND AUXILIARY HYDRAUL...

Page 67: ...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 Before leaving the operator s seat lower the working equipment to the ground raise the safety lock levers to engage the lock and stop the engine Also be sure to remove the key lock the door and covers ta...

Page 68: ...O 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 BLADE LEVER LEVERS AND PEDALS Use this lever to operate the dozer blade A Blade up B Blade down Refer to Operating the dozer blade on page 3 17 ...

Page 69: ...ne 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 levers on page 3 12 LEVERS AND PEDALS BOOM SWING PEDAL Keep the pedal cover to the locked position when not using the pedal Stepping on a pedal accidentally when it is not locked may cause accidents Use...

Page 70: ...c oil flows to left auxiliary hose B Hydraulic oil flows to right auxiliary hose Refer to Auxiliary hydraulic lines on page 2 24 Pedal lock Set the pedal cover over the pedal to lock it Open the pedal cover from the pedal to unlock it SELECTOR LEVER This lever is used to change the crawler width The operation of the dozer blade cylinder and the span cylinder is switched with this lever 1 Change the ...

Page 71: ...ations of these sockets Use these sockets to connect the power supply When using be careful not to exceed 12V 5A To use open the cap 1 ARMREST Adjusting the height 1 Loosen the lock by turning the bolts 1 counterclockwise 2 Set the armrest to your desired position and turn the bolts 1 clockwise to lock the armrest ...

Page 72: ...ng 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 auxiliary hydraulic circuit Slowly loosen the air bleeding plug to relieve the internal pressure of the hydraulic oil tank Third auxiliary hydraulic lines If equipped ...

Page 73: ...e 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 from the hydraulic lines c Stop the engine and wait for at least 5 minutes until bubbles escape from the hydraulic oil in the tank IMPORTANT Follow the procedures for purging air as instructed by the attachment ma...

Page 74: ...liary line d Releasing the residual pressure Refer to Accumulator on page 2 28 Third auxiliary hydraulic switch and button The third auxiliary hydraulic lines are normally used to control the quick attachment installed to connect disconnect the bucket When the safety lock lever is released after the engine is started hydraulic oil flows into the pipe e This allows the pressure in the e side to incr...

Page 75: ...depressed 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 pedal 4 Fasten the lock nut 1 to secure the adjustment bolt 2 When using a reversible attachment 2 way flow 1 Loosen the lock nut 1 and screw in the adjustment bolt 2 to the end 2 Depress the B side o...

Page 76: ...ctly 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 dropping Before disposing of the unit the sealed gas must be drained Contact a Takeuchi service agent for help For a machine with an accumulator the residual pressure in the auxiliary hydraulic circuit or th...

Page 77: ...3 1 OPERATION ...

Page 78: ...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 around inspections once a day before starting the engine for the first time that day Refer to MAINTENANCE Walk around inspection on pages 5 14 and 5 15 DAILY INSPECTION Perform the daily inspections once a day before starting the engine for the first time ...

Page 79: ...osition 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 warning lamp 3 the engine oil pressure warning lamp 2 and the engine emergency lamp 1 start flashing and the other lamps turn off Press the light switch to check that the boom light front light and me...

Page 80: ...urn 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 the key to the START position to start the engine 4 Once the engine starts release the key The key automatically returns to the ON position 5 Check that the warning lamps are off 6 Return the throttle...

Page 81: ...un 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 maximum speed Doing so may cause the engine to overheat or seize Never stop running the engine suddenly except in emergency 1 Return the throttle lever 2 Idle the engine for about 5 minutes to gradually...

Page 82: ...t 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 Upperstructure slew left Bucket load Upperstructure slew right Bucket dump Boom swing left Dozer blade lower Boom swing right Dozer blade raise AD6D008 ...

Page 83: ...SO 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 Bucket load Upperstructure slew right Bucket dump Boom swing left Dozer blade lower Boom swing right Dozer blade raise Refer to Selecting a lever pattern on page 8 5 ...

Page 84: ...l 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 least 20 C 68 F Normal warm up OPERATING THE MACHINE 1 Pull the throttle lever to the middle position then run the engine at medium speed for about 5 minutes with no load 2 Fully lower the safety lock...

Page 85: ... 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 and meters are as follows Are all warning lamps off Is the LED on water temperature gauge seen within the green range 2 Check that there are no irregularities in the exhaust color sound and vibration...

Page 86: ...idth 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 the machine body by using the hoe attachment and the dozer blade IMPORTANT Be sure to raise the machine body before switching the crawler width If the operation is attempted when the crawler is rest...

Page 87: ...PERATION 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 AC8D015 2 1 ...

Page 88: ...pedals make 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 direction from when it is to the front Clear all obstacles from the path of the machine 1 Pull the throttle lever and increase the engine speed 2 Fully lower the safety lock lever to disengage ...

Page 89: ... 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 speed Press the travel speed switch on the right travel lever to switch to 2nd high speed and press it again to return to 1st low speed ...

Page 90: ...ht 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 while traveling operate the right lever in the same way as for the left lever Spin turn OPERATING THE MACHINE To spin left Tilt the left lever backward and the right lever forward To spin right Tilt ...

Page 91: ...he 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 locked position Do not carelessly touch these controls Never stop running the machine suddenly except in emergency Stop in good time if possible 1 Set the left and right travel levers slowly to the neutra...

Page 92: ...nd 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 Upperstructure slew left Tilt the left operating lever to the left Upperstructure slew right Tilt the left operating lever to the right Operating the boom Slewing Check the surrounding area for safety before...

Page 93: ...the 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 right side of the pedal Operating the dozer blade Operating the boom swing Dozer blade lower Tilt the lever forward Dozer blade raise Tilt the lever backward ...

Page 94: ...l 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 use the traveling force to dig Be gentle when using the hydraulic cylinder Do not extend the hydraulic cylinders to the stroke ends Operate them with leeway Do not support the machine body with the hoe...

Page 95: ...cessive 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 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 aga...

Page 96: ... to the dozer blade when digging When digging deeply with the dozer blade positioned at the front 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 designed for simple earth pushing Do not dig down deeply with the dozer blade Doing so could damage the do...

Page 97: ...pping 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 the figure above it causes the radiator fan to turn in water resulting in damage to the fan The rear of the machine must not be submerged Allowable water depth Use the machine in water only when the ...

Page 98: ... 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 slopes in reverse CAUTIONS ON OPERATING Do not change directions on slopes or traverse slopes First return to a flat surface and then take an alternative path The machine may slip sideways even on a slight slope if they are covered with grass or dead lea...

Page 99: ...ned to the neutral position If the crawler slips If the crawler slips while climbing a slope and impossible to travel 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 the engine If the engine stops ...

Page 100: ...he 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 MACHINE Excavating 1 Set the dozer blade on the side opposite to the side you want to dig on 2 Use the arm and bucket and dig with shallow long strokes The maximum digging force can be obtained when...

Page 101: ... of the 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 remove the dirt from the side of the mound 3 Once the mound is low remove the dirt from the top If the load becomes too heavy for the machine body adjust by raising or lowering the dozer blade ...

Page 102: ...re it 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 Raise the safety lock lever to the locked position 5 Stop the engine and remove the key Refer to Stopping the engine on page 3 5 INSPECTION AND CHECKS AFTER STOPPING THE ENGINE 1 Check for oil or ...

Page 103: ...and 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 on the rod surface getting inside the seal together with drops of water Park the machine on hard and dry ground If this is impossible park the machine on a wooden board placed on ground Drain any wate...

Page 104: ...ere 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 let fuel oil salt or chemical solvents get on the crawlers These substances may corrode the bonding of the steel cores on the crawlers resulting in rust or peeling If any of these substances gets o...

Page 105: ... 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 surfaces in winter as the crawler belts tend to slip in such conditions Use rubber crawler belts at temperatures between 25 C to 55 C 14 F to 131 F When storing the rubber crawlers for long periods of tim...

Page 106: ...er 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 rubber crawler belts will come off if the machine travels backward in this condition The rubber crawler belts will come off if the machine turns in this condition HANDLING RUBBER CRAWLERS ...

Page 107: ...4 1 TRANSPORT ...

Page 108: ...avel slowly in 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 as the footing should be unstable Chock the tracks and secure the machine to the truck bed with wire rope or chain LOADING AND UNLOADING AG7F001PE Ramp Distance between ramps 15º or les...

Page 109: ...raight 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 posture on page 4 5 LOADING AND UNLOADING ...

Page 110: ...The center of 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 blade is at the rear of the machine set the upperstructure parallel to the track frame 2 Raise the dozer blade fully 3 Extend the bucket cylinder and arm cylinder fully to raise the boom...

Page 111: ...he 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 protect the floor from damage caused by the bucket Precautions to be taken during transportation Know and follow the applicable safety rules vehicle code and traffic laws when transporting the machine Selec...

Page 112: ...4 6 ...

Page 113: ...5 1 MAINTENANCE ...

Page 114: ...ler 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 water cannot 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...

Page 115: ...rained 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 coolant filters and batteries Check after maintenance Gradually increase the engine speed from a low idle to maximum speed and check that there is no oil or water leaking from serviced parts Operate ...

Page 116: ...l To avoid freezing in cold climates use a diesel fuel that still functions when the temperature is at least 12 C 53 6 F below the lowest expected ambient temperature Use a diesel fuel that has a cetane number of 45 or higher When operating at a very low temperature or at a high altitude a higher cetane number fuel will be required Use fuel with sulfur content of less than 0 05 to 0 0015 by volume...

Page 117: ...using 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 40 C Engine oil pan Diesel engine oil API CD class ACEA E 3 E 4 or E 5 Every 250 hrs after the initial 50 hrs Hydraulic oil tank Takeuchi genuine hydraulic oil 46 Every 4000 hrs Anti wear hydraulic oi...

Page 118: ...raulic oil and the return filter elements according to the table below When replacing the hydraulic oil clean the suction strainer Replacement interval hours Item Hydraulic oil Filter element 1st time 25 2nd time 100 Periodically 1200 600 200 When a conventional antiwear hydraulic oil is used When the breaker operating ratio is 100 Refer to Hydraulic breaker on page 8 6 Volume Engine oil pan Engine...

Page 119: ...00 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 500 hrs Fuel filter Y119810 55650 Air cleaner system Air cleaner Primary Outer element Y119515 12520 Every 1000 hrs or after 6 cleanings whichever comes first Secondary Inner element 19111 01342 When th...

Page 120: ...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 22 9 Spanner 16909 00026 26 10 Tool case 16914 00005 11 Grease gun 16910 60600 600 cc 12 Drain connector 15545 12201 ...

Page 121: ... alternately top bottom left then right or in 2 or 3 times so that they are evenly tightened SERVICE DATA AG7G009 Classification Head width b Size a x pitch Tightening torque General connection points mm mm N m ft lb Coarse 10 M6 x 1 0 9 8 0 5 7 2 0 4 12 13 M8 x 1 25 22 6 1 1 16 6 0 8 14 17 M10 x 1 5 47 1 2 4 34 7 1 7 17 19 M12 x 1 75 83 4 4 1 61 5 3 0 19 22 M14 x 2 0 134 4 6 7 99 1 4 9 22 24 M16 x...

Page 122: ...lly 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 Hydraulic hoses travel motor Working equipment Hydraulic hoses boom cylinder piping Hydraulic hoses arm cylinder piping Hydraulic hoses bucket cylinder piping Hydraulic hoses swing cylinder Hydraulic hose...

Page 123: ... to the safety critical parts inspect the hydraulic hoses and retighten or replace as necessary When replacing the hydraulic hoses replace the O rings and seals at the same time Check the fuel and hydraulic hoses according to the periodic schedule described below Refer to Maintenance Type of inspection Inspection item Daily inspection Leakage from the connecting parts of hydraulic or fuel hoses Da...

Page 124: ...the engine oil and the oil filter 5 22 Inspecting and adjusting the fan belt 5 23 Replacing the hydraulic oil return filter 5 24 Every 50 hours Inspecting and adjusting the crawler tension 5 26 Lubricating the slew bearing 5 28 Lubricating the slew motor pinion 5 28 Draining the water from the fuel tank 5 29 Inspecting the battery fluid level and replenishing 5 30 Every 100 hours Cleaning the water s...

Page 125: ...ightening the engine cylinder head bolt 5 43 Every 1500 hours Inspecting and cleaning the engine fuel injectors 5 44 Inspecting the crankcase breather system 5 44 Every 2000 hours Lapping the engine valve seats 5 45 Every 4000 hours Replacing the hydraulic oil and cleaning the suction strainer 5 46 When Required Replacing the bucket teeth 5 48 Replacing the bucket 5 50 Lubricating the levers 5 52 ...

Page 126: ... 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 nuts or bolts are loosened WALK AROUND INSPECTION INSPECTING BY OPENING THE ENGINE HOOD AND COVERS 1 Check for any twigs leaves oil or other combustible materials around the engine and battery 2 Che...

Page 127: ...teps for damage and loose bolts 9 Check the crawlers shoe slides track rollers idlers and sprockets for damage wear and loose bolts 10 Check for oil leakage from the travel motor 11 Check the canopy and guard for damage and loose nuts and bolts 12 Check the labels for dirt and damage WALK AROUND INSPECTION INSPECTING WHILE SITTING IN THE OPERATOR S SEAT 13 Check the seat and seat belt for dirt or ...

Page 128: ...reeze 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 Inspect the cooling water level in the reserve tank 1 The level should be between the upper limit H and the lower limit L If it is below the lower limit L replenish Replenishing 1 Remove the cap 2 of...

Page 129: ... 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 After about 10 minutes inspect the oil level INSPECTING THE DUST INDICATOR Stop the engine and allow the machine to cool down before performing maintenance The dust indicator is the equipment to be used to find ...

Page 130: ...NSPECTING 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 fuel on the hot surface of the machine Fill the fuel tank in a well ventilated place Clean up spilled fuel immediately Do not fill the fuel tank to capacity Allow room for oil expansion Securely tighte...

Page 131: ...l 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 temperature is about 50 to 80 C 122 to 176 F The level should be slightly below the upper limit H Replenishing IMPORTANT Do not fill up to the level higher than the upper limit H It will damage the hydraulic...

Page 132: ...h 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 raise the left safety lock lever to engage the lock 5 Tighten the vent plug 2 and then pressurize by retracting the cylinders AD6G009 ...

Page 133: ...in 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 lubricate the dozer blade as it is using a self lubrication bush DAILY INSPECTION EVERY 10 HOURS ...

Page 134: ...n 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 consult your sales or service dealer 5 Turn the filter 4 counterclockwise with the filter wrench and remove it 6 Clean the surface of installation of the filter stand 7 Apply a thin layer of oil on the packin...

Page 135: ...tenance cover A AFTER THE INITIAL 50 HOURS ONLY FOR NEW MACHINES 2 Press at the center of the fan pulley 1 and alternator pulley 2 to check the tension approx 98 N or 22 lbf The slack A should be 7 to 10 mm 0 28 to 0 4 in 3 Inspect the fan belt 3 and replace if it is as follows There are cuts or cracks The belt is worn and touches the bottom of the V groove in the pulley The belt stretched too loo...

Page 136: ...en 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 are removed or pipes are disconnected 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...

Page 137: ...rom the flange 6 5 Loosen the bolts to take out the flange 6 6 Remove the return filter 7 7 Install a new return filter 8 Reassemble the flange 6 and the hose 5 9 Inspect the level with the sight gauge 8 and replenish if the level is too low Refer to Inspecting the hydraulic oil tank level and replenishing on page 5 19 ...

Page 138: ...cedure the grease discharge valve may fly off resulting in injury Never loosen the grease fitting Loosen the grease discharge valve slowly Do not turn it more than one turns Do not put your face arms legs or body in front of the grease discharge valve If grease does not come out when the grease discharge valve is loosened the valve is faulty Ask a Takeuchi service agent for repair 2 Use the working ...

Page 139: ...se fitting 3 of the grease discharge valve 2 with a grease gun 3 Inspect the crawler tension Decreasing the tension 1 Remove the cover 1 2 Slowly loosen one turn the grease discharge valve 2 with a spanner to discharge grease If grease does not come out well move the machine back and forth 3 Tighten the grease discharge valve 2 Tightening torque 177 N m 130 ft lb ...

Page 140: ...2 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 to 4 above three times 6 Wipe off the grease expelled from the slew bearing and grease fitting LUBRICATING THE SLEW MOTOR PINION 1 Use the grease gun to lubricate the grease fitting 2 2 Wipe off the e...

Page 141: ...el 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 under the drain plug 3 4 Loosen the drain plug 3 to drain water and sediment buildup in the bottom of the tank 5 Tighten the drain plug 3 6 Add fuel while watching the sight gauge 1 7 Tighten the fue...

Page 142: ... the upper level limit Doing so could 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 contact occurs flush immediately with clean water and get prompt medical attention If accidentally swallowed drink large quantities of water or milk and call a physi...

Page 143: ...eeve 3 the surface tension causes the fluid to swell and the plate appears as if it is distorted Level too low B If fluid does not reach up to the bottom edge of the sleeve 3 the plate looks laminar not distorted 4 Check the terminals for looseness and dirt Replenishing When adding distilled water do so before starting operations in order to prevent freezing 1 Remove the caps 2 and add distilled wat...

Page 144: ...element 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 open flames while handling fuel or working on the fuel system Stop the engine in a well ventilated place and allow it to cool down before performing maintenance Clean up spilled fuel immediately 1 Open...

Page 145: ...burns 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 time within the total operating time is high replace the gear oil earlier than the specified time AFTER THE INITIAL 250 HOURS ONLY FOR NEW MACHINES 1 Set the travel motor so that plug 1 is at the ver...

Page 146: ...ir 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 in very dusty places perform inspection and maintenance operations every day IMPORTANT Be sure to install the element and dust cap securely If not dust could be drawn into the cylinder damaging the engine ...

Page 147: ...the 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 applied in step 5 10 Install the primary element 3 11 Install the dust cup 2 with its TOP mark facing up and then fasten it with the clamps 1 12 Push the button 3 on the dust indicator to reset the ...

Page 148: ... 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 cover the electrical system to prevent water from getting in IMPORTANT When operating the machine in very dusty places perform inspection and maintenance operations every day EVERY 250 HOURS 1 Open the eng...

Page 149: ...5 37 MEMO ...

Page 150: ...rming maintenance Clean up spilled fuel immediately 1 Open the engine hood 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 5 Clean the case 4 6 Inspect the O ring If there are any scratches or other irregularities replace it 7 Replace the element 5 with a new one 8 Install the indicator ring 6 and the spring 7 in the case...

Page 151: ...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 or other irregularities replace it 6 Replace the element 5 with a new one 7 Install the case 4 to the bracket and tighten the ring 3 by hand 8 Open the valve 2 to bleed air Refer to Bleeding air from...

Page 152: ...who 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 as the machine could move suddenly Never stand at the back of the machine while the engine is running Do not remove the radiator cap or the drain plug when the cooling water is hot Stop the engine an...

Page 153: ...ough 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 temperature to at least 90 C 194 F Then run the engine for about 10 minutes with the thermostat kept open 16 Stop the engine wait until the cooling water temperature becomes lower and then check the le...

Page 154: ...ne 1 Open the maintenance cover A 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 from getting in If equipped with the secondary element Do not yet remove the secondary element 5 6 Clean the inside of the body 4 7 Remove the cloth or tape applied in step 5 If equipped with the ...

Page 155: ...ECTING 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 Ask your sales or service dealer for it ...

Page 156: ...AND 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 experience Ask your sales or service dealer for it ...

Page 157: ...5 45 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 158: ...f caps or filters are removed or pipes are disconnected 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 them slowly to gradually release the internal pressure before removing EVERY 4000 HOURS 3 Open the engine hood 4 Slowly loosen the air bleeding plug...

Page 159: ...uge 8 EVERY 4000 HOURS 21 Tighten the plug 1 22 Bleed air from the hydraulic oil circuit following Bleeding air below 23 Set the machine to the hydraulic oil level inspection posture and inspect the oil level when the oil temperature drops Refer to Inspecting the hydraulic oil tank level and replenishing on page 5 19 Bleeding air IMPORTANT After replacing the hydraulic oil bleed air from the hydra...

Page 160: ...s 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 check that there is no one in the surrounding area Do not allow unauthorized personnel in the work area while working WHEN REQUIRED Replace the teeth if they are worn to 140 mm 5 5 in Removal 1 Clean the...

Page 161: ... 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 Tightening torque 102 N m 75 2 ft lb 5 Caulk the bolt with a punch or weld it at three spots on the threaded portion nut side WHEN REQUIRED AD6G029 ...

Page 162: ...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 check that there is no one in the surrounding area When aligning the pin holes always do so by checking them visually Do not insert your finger in the pin hole or you could lose your finger Removing WHEN REQUIRED 1 Lower the bucket to the ground as shown...

Page 163: ...perate 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 5 Slide the O ring 4 Replacing the pin seal 1 Set the pin seal 3 in the direction shown on the figure above 2 Use a mallet to slowly press the pin seal in Be careful not to damage the seal AD6G034 1 ...

Page 164: ...ure to do so may result in the machine moving abruptly leading to serious injury or death If the levers or pedals no longer move smoothly grease them Operating levers WHEN 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 ...

Page 165: ...retched 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 of the steel cords on one side are cut 3 Metal core Replace if even one metal core is off 4 Rubber Repair if there are cracks of 60 mm 2 4 in or greater in length If the steel cord is visible repair...

Page 166: ...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 tension of the rubber crawler Refer to Inspecting and adjusting the crawler tension on page 5 26 WHEN REQUIRED 2 Use the working equipment to lift the body 3 Set an iron pipe 1 in the rubber crawler and tu...

Page 167: ... 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 Check that the rubber crawler is securely engaged on the sprocket and idler 7 Tighten the rubber crawler to the standard tension Refer to Inspecting and adjusting the crawler tension on page 5 26 8 In...

Page 168: ...t 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 Starting the machine after storage IMPORTANT If the above Storage procedures have not been followed during the extended storage periods consult your sales or service dealer before starting the machine a...

Page 169: ...6 1 TROUBLESHOOTING ...

Page 170: ...speed momentarily 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 produces noise when stopped suddenly from its high speed traveling The control valve produces noise if excessive force is applied to the working equipment or when it moved to the stroke end It beco...

Page 171: ...LED 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 closed engine hood and covers 3 If there is steam stop the engine immediately and contact your sales or service dealer for repair If steam is not coming out run the engine at low idle and let the water...

Page 172: ...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 cables and clips IMPORTANT Be sure that the battery of the booster vehicle has the same capacity as the battery of the dead machine IMPORTANT Be sure to connect the clips securely IF THE BATTERY GOES...

Page 173: ... 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 battery terminal of the booster vehicle 4 Disconnect the clip of jumper cable R from the positive battery terminal of the dead machine Recharging Ask your sales or service dealer for recharging the de...

Page 174: ...epaired Contact your sales or service dealer for advice 1 Turn the starter key to the OFF position to stop the engine 2 Open the maintenance cover B IF A FUSE BLOWS 3 Open the fuse 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 Capacity Symbol Protected circuit 25A Starter switch 10A AUX3 Third auxil...

Page 175: ...act 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 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 engine hood and i...

Page 176: ... Turn the starter key to the ON position and hold it for about 10 to 15 seconds The automatic air bleeder bleeds air from the fuel system Note Air in the fuel system causes the engine to fail to start or to have other problems Always bleed air when the fuel tank is emptied or when there is air in the fuel system Turn the starter key to the ON position and hold it for about 60 seconds ...

Page 177: ...is 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 23 Engine oil pressure warning lamp A problem has occurred in the engine lubrication system Inspect the engine oil level If the lamp is flashing when the oil is normal or if it continues flashing after replenishment of oil consult your sales or service dealer Re...

Page 178: ... to page 2 19 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 level too low Add to the specified level Refer to page 5 19 Hydraulic oil is not warm enough Perform the warm up Refer to page 3 8 Air cleaner is clogged Clean the air cleaner Refer to page 5 34 Hydrauli...

Page 179: ... in fuel system Drain water Refer to page 5 29 Crawlers come off Crawlers too loose Increase the tension Refer to page 5 26 Engine exhaust is white or bluish Excessive engine oil Adjust to the specified level Refer to page 5 17 Poor fuel Replace the fuel Engine exhaust is occasionally black Air cleaner is clogged Clean the air cleaner Refer to page 5 34 Irregular noise is produced from the engine c...

Page 180: ...he cover 2 3 Remove the cover 4 Remove the harness of the auxiliary 3rd switch 3 together with the cover 4 4 Loosen the lock nut 5 while holding the adjust screw 6 in place with a hexagonal wrench so that the adjust screw 6 will not be loosened together with the lock nut 5 5 Turn the adjust screw 6 slowly 1 4 turn to lower the boom 6 Check for safety and stability of the machine 7 Return the adjus...

Page 181: ...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 steps below closely when using the towing hole to tow Failure to heed even one of the steps may cause damage to the towing hole or other parts of the frame TOWING Towing the machine Use the procedure de...

Page 182: ...may occur if the machine is operated with damaged cab canopy Do not operate the machine 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 Canopy parts No 1 03384 00031 Canopy parts No 2 03384 00039 IF THE CAB OR CANOPY IS DAMAGED ...

Page 183: ...7 1 SPECIFICATIONS ...

Page 184: ...1st 2 2 1 37 2nd 4 2 2 61 Gradeability degrees 30 Ground pressure kPa psi Rubber crawlers 26 2 3 8 Noise level dB A Sound power level LWA 93 Sound pressure level LpA 80 ENGINE Manufacturer and model Yanmar 3TNV70 PTB1R Rated output Net ISO 14396 kW min 1 hp rpm 11 5 2400 15 4 2400 Net ISO 9249 SAEJ 1349 kW min 1 hp rpm 10 9 2400 14 6 2400 Displacement ml cu in 854 52 1 Starter V kW 12 1 0 Alternat...

Page 185: ...7 3 MEMO ...

Page 186: ...7 4 SPECIFICATIONS MACHINE DIMENSIONS MACHINE DIMENSIONS ...

Page 187: ...h 230 9 1 K Ground clearance of undercarriage 205 8 0 L Minimum radius of equipment and attachment 1450 57 0 M Minimum radius of equipment at maximum front offset 1185 46 7 P Offset distance of bucket Left 395 15 6 Q Offset distance of bucket Right 555 21 9 R Dozer blade width narrow 980 38 6 R2 Dozer blade width wide 1300 51 2 S Dozer blade height 250 9 8 T Front distance to axis of rotation 2725...

Page 188: ...7 6 SPECIFICATIONS OPERATING RANGES ...

Page 189: ... Maximum digging depth 2190 86 2 D Maximum vertical digging depth 1780 70 1 E Reach at maximum vertical digging depth 2705 106 5 F Maximum height of cutting edge 3430 135 1 G Maximum dumping height 2400 94 6 H Minimum dumping height 835 32 9 J Dozer blade maximum lifting 215 8 4 K Dozer blade maximum lowering 210 8 3 OPERATING RANGES ...

Page 190: ...7 8 MEMO ...

Page 191: ...lifted load 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 Do not attempt to lift or hold any load that is greater than these rated values at their specified load radii and height The rated lift capacities are based on the machine being level and situa...

Page 192: ...7 10 SPECIFICATIONS LIFTING CAPACITIES ...

Page 193: ...7 11 SPECIFICATIONS LIFTING CAPACITIES ...

Page 194: ...7 12 ...

Page 195: ...8 1 OPTIONS ...

Page 196: ...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 hazard of objects falling or contacting with people in the area Use a crane to move heavy objects 25 kg 55 lb or greater Before removing a heavy object be sure to put a support to it When lifting with a c...

Page 197: ...pping operation is performed Carefully judge the distance so as not to bump into an object around 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 midair increases The machine can tip over more easily in the lateral direction than in the longitudinal direct...

Page 198: ... 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 bucket hitting the machine body Can be used Can be used only for light operations digging and loading of dry and loose soil or mud Cannot be used ATTACHMENT COMBINATION TABLE Bucket Rated capacity m3 cu...

Page 199: ... 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 cover A 3 Loosen the wing bolt 1 4 Turn the selector valve lever 2 to switch the pattern 5 Tighten the wing bolt 1 and fasten the lever 2 in place 6 Close the maintenance cover A 7 Confirm the lever pa...

Page 200: ...he center 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 in IMPORTANT When installing an attachment make sure that it is appropriate for the machine being used Contact your sales or service dealer for advice on selecting attachments Cautions on operatin...

Page 201: ...draulic 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 Filter element 1st time 25 2nd time 100 Periodically 1200 600 200 When the breaker operating ratio is 100 When using conventional antiwear hydraulic oil Do not pound with the arm placed perpendicular to t...

Page 202: ... oil 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 mineral oil from the hydraulic tank and clean the inside of the tank and suction strainer Refer to Replacing the hydraulic oil and cleaning the suction strainer on pege 5 46 2 Remove the cylinder ho...

Page 203: ...8 9 ...

Page 204: ...8 10 First Published March 2013 Printed in Japan by STATION M Co Ltd OPERATOR S MANUAL No 41075 Mini excavator TB215R Edited and issued by TAKEUCHI MFG CO LTD ...

Page 205: ... any alteration of the machine 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 Japan Model Engine type Engine power The machine is in accordance with the requirements of EC regulations 1 Machine directive 2006 42 EC and appendix 2 Electromagnetic compatib...

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