Takeuchi TB216 User Manual Download

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Summary of Contents for TB216

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

Page 3: ...tes 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 c...

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: ...chanism for crawler width Low engine noise and exhaust emissions Break in period When the machine is new operate the machine for the first 100 hours as indicated on the hour meter by following the instructions below Using a new machine without a break in period will lead to quicker deterioration of machine performance and may shorten the machine s service life Sufficiently warm up the engine and h...

Page 6: ...is manual may not be applicable to your machine The numbers used in the illustration are with circles around them The same numbers appear between the parentheses in the text Example 1 Symbols used in this manual The symbols used in this manual have the following meanings Prohibition Lock Unlock ...

Page 7: ...tch and button 2 27 Overload warning switch If equipped 2 28 Levers and Pedals 2 29 Safety lock lever 2 29 Throttle lever 2 29 Operating levers 2 30 Blade lever 2 30 Travel levers pedals 2 31 Boom swing pedal 2 31 Auxiliary hydraulic pedal 2 32 Selector lever 2 32 Accessories 2 34 Heater 2 34 Cup holder 2 36 Interior light 2 36 Inside rear view mirror cab 2 36 Power sockets 2 37 Armrest 2 37 Radio...

Page 8: ...king equipment 5 23 After the initial 50 hours only for new machines 5 24 Replacing the engine oil and the oil filter 5 24 Inspecting and adjusting the fan belt 5 25 Replacing the hydraulic oil return filter 5 26 Every 50 hours 5 28 Inspecting and adjusting the crawler tension 5 28 Lubricating the slew bearing 5 30 Lubricating the slew motor pinion 5 30 Draining the water from the fuel tank 5 31 I...

Page 9: ...system 6 8 If a warning lamp flashes 6 9 Other symptoms 6 10 Lowering the boom to the ground 6 12 Towing 6 13 If the cab or canopy is damaged 6 14 Specifications 7 1 Basic Specifications 7 2 Machine dimensions 7 4 Operating ranges 7 8 Lifting Capacities 7 11 Options 8 1 General precautions 8 2 Safety precautions 8 2 Cautions when installing attachments 8 2 Cautions when operating attachments 8 3 A...

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

Page 12: ...hol drugs medication fatigue or insufficient sleep General precautions When a problem is found on the machine If any problem noise vibration smell disorder of instrument smoke oil leak wrong indication of alarm or unusual indication in the instrument cluster etc is detected during the operation or inspection and maintenance of the machine immediately inform your sales or service dealer and take pr...

Page 13: ...n operating the machine Loud prolonged noise can cause hearing impairments even the total loss of hearing General precautions Install a fire extinguisher and first aid kit Be prepared for fire and accidents Install an extinguisher and a first aid kit and learn how to use them Lean how to fight a fire and how to deal with accidents Know how to contact emergency assistance and make a list of emergen...

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

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 nonfla...

Page 16: ... clean up use a vacuum equipped with a high efficiency particulate air filter HEPA Wear the stipulated respirator if there is no other way to control the dust When working indoors install a ventilation 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 c...

Page 17: ...s 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: ...anger of falling rocks or slides Precautions when preparing Check with the administrator for the locations of buried gas pipes water pipes and power cables If necessary determine what specific precautions must be taken to insure safety by consulting with the administrator When working on roads be sure to consider the safety of pedestrians and vehicles Use a flag person and or a signal Fence off th...

Page 19: ...sure good visibility Adjust the mirror to the best position for the operator to see the rear view blind spot from the operator s seat Wipe off any oil grease mud snow or ice to prevent accidents due to slipping Remove all loose objects and unnecessary devices from the machine Remove any dirt oil or grease from the engine area to prevent fires Clean around the operator s seat and remove any unneces...

Page 20: ...ons 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 cup...

Page 21: ...ency hammer is installed to be used to escape from the cab in an emergency When escaping break the windows with the hammer When breaking the windowpane with a hammer take great care not to injure yourself with the broken glass pieces Remove the glass pieces from the window sill so as not to cut yourself when evacuating Broken glass will fall from the window so be careful of your footing and do not...

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

Page 23: ...m 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 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 freeze t...

Page 24: ...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 AD6A001 Always operate the machine with the craw...

Page 25: ...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 machine to an ...

Page 26: ...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 engine speed Do not descend slopes in reverse Do not chang...

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

Page 28: ...ath 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 warning ...

Page 29: ...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 30: ...ions If a building or structure collapses serious injury or damage will result When doing demolition work do not perform demolition above your head There is a hazard of broken parts falling or of the building 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...

Page 31: ...chine can tip over more easily in the lateral direction than in the longitudinal direction Do not slew swing sideways with a heavy load at the tip of the hoe attachment In particular do not slew swing sideways on slopes The tip of the attachment is heavier for machines equipped with breakers crushers or long arms than for machines equipped with the standard bucket For such machines with heavier ti...

Page 32: ...tly attached resulting in serious injury or death Do not attempt to pull stumps out of the ground when using the machine as a crane The loads imposed on the machine under this use are completely unknown Do not allow anyone to stand on or under the lifted loads or come close to the work area Precautions when operating Cautions when towing When towing serious injury or death could result if performe...

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

Page 34: ...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 by following the signal from the signal person Never change courses on the r...

Page 35: ...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 rou...

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

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

Page 38: ...s 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 engin...

Page 39: ... Use the correct grade of fuel for the operating season Handling of hoses Oil leak or fuel leak can cause a fire Do not twist bend or hit the hoses Never use twisted bent or cracked pipes tubes or hoses otherwise they may burst Retighten loose connection Be careful with hot and pressurized components Stop the engine and allow the machine to cool down before performing maintenance The engine muffle...

Page 40: ...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 when discon...

Page 41: ...e 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 Be careful with the high pressure grease AG7A086 In the track adjuster the grease has been injected under high pressure If the tension is adjusted without following the prescribed procedure the grea...

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

Page 43: ...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 44: ...ntenance 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 lo...

Page 45: ...ty 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 46: ...1 36 Safety Safety signs decals ...

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

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

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

Page 50: ...1 40 ...

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

Page 52: ...d 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 53: ... lever 9 Boom swing pedal 10 Travel lever Pedal 11 Travel speed switch 12 Auxiliary hydraulic pedal 13 Left operating lever 14 Third auxiliary hydraulic button 15 Third auxiliary hydraulic switch 16 Auxiliary 2nd switch 17 Radio 18 Heater fan switch 19 Wiper switch 20 Lift overload warning switch 21 Light switch Subject to the specifications or optional products selected 21 ...

Page 54: ...e hood 4 Fuel tank 5 Hydraulic tank Undercarriage 6 Crawler belt 7 Idler 8 Track roller 9 Shoe slide 10 Travel motor Working equipment 11 Bucket 12 Bucket cylinder 13 Arm 14 Arm cylinder 15 Boom 16 Boom cylinder 17 Boom bracket 18 Swing cylinder 19 Auxiliary hydraulic lines 20 Dozer blade 21 Blade cylinder ...

Page 55: ...lever 9 Boom swing pedal Names of components Canopy 10 Travel lever Pedal 11 Travel speed switch 12 Auxiliary hydraulic pedal 13 Left operating lever 14 Third auxiliary hydraulic botton 15 Third auxiliary hydraulic switch 16 Auxiliary 2nd switch 17 Light switch 18 Lift overload warning switch Subject to the specifications or optional products selected ...

Page 56: ...pening the maintenance cover make sure that the safety lock lever is in the lock position and the engine is stopped Open this cover to perform a maintenance operation of the engine or to switch the selector valve Opening 1 Insert the starter key and turn it counterclockwise to unlock the maintenance cover 1 Closing 1 Close the maintenance cover 1 2 Insert the starter key and turn it clockwise to l...

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

Page 58: ...ise 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 ...

Page 59: ...e key hole 2 with your thumb and open the engine hood 1 Closing 1 Close the engine hood 1 and press down the edge of it until a click is heard Covers Side cover When opening and closing the side cover be careful not to get your hands or other parts of your body caught by the cover Opening 1 Insert the starter key and turn it counterclockwise to unlock the side cover 1 2 Fully open the side cover 1...

Page 60: ...off the machine and while in operation Locking and unlocking Insert the starter key and turn it Opening 1 Pull the knob 1 towards you and open the door To open the door from inside the cab hold the door opener 2 2 Open the door fully and press it against the cab to secure it in place Closing 1 Push the release lever 3 to the lower 2 Close the released door Emergency exit Front window excluding mac...

Page 61: ...urface and stop the engine 2 Set the safety lock lever to the locked position 3 Grasp the left and right handles 1 and press the knobs 2 with your thumb to release the lock 4 Pull the front window 3 toward you and lift while doing so 5 Release your thumb from the knobs 2 and then lift the front window 3 fully and lock the front window with lock pin 4 Closing When closing the front window slowly so...

Page 62: ...rough the guides 5 at the rear and then set it on the supports 6 to fasten it in place Side window Opening 1 Release the lock by turning the locking screw 7 counterclockwise 2 Hold the catch 8 to disengage it and open the side window 3 Secure the side window by turning the locking screw 7 clockwise Closing 1 Release the lock by turning the locking screw 7 counterclockwise 2 Close the window until ...

Page 63: ...caping break the windows with the hammer When breaking the windowpane with a hammer take great care not to injure yourself with the broken glass pieces Remove the glass pieces from the window sill so as not to cut yourself when evacuating Broken glass will fall from the window so be careful of your footing and do not slip on the glass ...

Page 64: ...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 65: ...lide 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 cur...

Page 66: ...e seat belt to the desired length 3 Make sure that the belt is not twisted and then insert the tongue plate A into the buckle B of the seat belt until you hear a clicking sound as it locks in place 4 Check if the belt is securely locked by pulling it and arrange the belt around your waist Releasing the seat belt 1 Grasp the tongue plate A and press the button C on the buckle B The seat belt retrac...

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

Page 68: ...rm 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 while the engine is running ...

Page 69: ...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 70: ...n page 2 24 Instrument cluster 4 Alarm indicator lamp The clock symbol appears when the alarm function is turned on Refer to Alarm setting on page 2 24 5 Auxiliary 3rd hydraulic pressure warning lamp If equipped This lamp lights up and an alarm sounds if the fixed side left e pressure of the auxiliary 3rd drops abnormally while the engine is running or if the quick hitch is being removed or instal...

Page 71: ... key turns on or off the work light Pressing and holding the B key for two seconds or more each time the display changes as follows 1 Hour meter 2 Trip meter 1 3 Trip meter 2 4 Trip meter 3 Instrument 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 72: ... Press the C key to return to the Home screen DATA Shows the coolant temperature and the trip meter for inspection and maintenance Unlike the trip meter displayed on the Home screen data items on the 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 73: ...RIP 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 74: ...creen d Press the B key to move the selection bar e Press and hold the B key for at least three seconds to enter the alarm time setting mode f Press the C key to cancel editing and to return to the 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 ...

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

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

Page 77: ...sher fluid when operating the wiper IMPORTANT In cold climates the wiper blade may freeze to the glass Operating the wiper forcibly may damage the wiper motor O Off I Wiper operates PUSH Sprays washer fluid when pressed Stops when released Second auxiliary hydraulic switch Refer to Second auxiliary hydraulic switch on page 2 44 Third auxiliary hydraulic switch and button Refer to Third auxiliary h...

Page 78: ...arning horn is sounded the machine may tip over If the horn starts sounding stop operating the machine and lighten the load If a weight greater than the lifting capacity is applied or lifted the overload warning device is activated and the horn sounds When the overload warning switch is turned on OFF Off ON On ...

Page 79: ...cked 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 t...

Page 80: ...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 81: ...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 82: ...c oil flows to left auxiliary hose B Hydraulic oil flows to right auxiliary hose Refer to Auxiliary hydraulic lines on page 2 42 Pedal lock Set the pedal cover over the pedal to lock it Open the pedal 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 th...

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

Page 84: ...fan switch Low Neutral OFF High Ventilation Circulation lever Use this lever to switch between Ventilation and Circulation Full ventilation For heating with ventilation Intake of external air Defrosting the windows Circulation Quick heating or when external air is dirty Outlets Move the louver up and down or left and right to adjust the air flow direction and amount ...

Page 85: ...n or fully closed Cooling water could leak when the valve is partly opened 1 Park the machine on a level surface and stop the engine 2 Open the engine hood 3 Turn the valve 1 clockwise until it stops to close it Filters Clean the filters immediately after operating in dusty places If the filters are clogged the air flow is reduced and a booming sound is heard from the heater unit Refer to Cleaning...

Page 86: ...er electric parts may be damaged if drinks are spilled on them Pull out the cup holder towards you to use it Push in the holder for storage after use Interior light IMPORTANT The battery capacity decreases if the interior light is left on for a long time when the engine is stopped OFF Remains off all the time ON Lights up all the time Inside rear view mirror cab Adjust the rear view mirror to have...

Page 87: ... Set the armrest to your desired position and turn the bolts 1 clockwise to lock the armrest Power sockets Use only those electric products which comply with the specifications of these sockets For beacon Use these sockets to connect the power supply When using be careful not to exceed 12V 5A To use open the cap 1 ...

Page 88: ...nd the operation mode 3 Display button DISP Pressing this button while the frequency is displayed on the LCD changes the display to the clock Pressing the button again returns to the frequency If the button is not pressed for five seconds the display returns to the frequency 4 Auto store Auto seek station AST Press this button to automatically assign receivable radio stations to preset buttons 1 t...

Page 89: ...11 Auxiliary input jack AUX IN Use this jack to connect an external audio source such as a portable music player Pull off the rubber cap and connect the output terminal headphone jack of the portable player to the AUX IN with the stereo mini plug 35 mm cord Be sure that jack is closed with the rubber cap when not in use Playing the radio 1 Turn the ignition key to the ACC or ON position and then p...

Page 90: ...evious stations stored will be cleared cancelled by the auto storing If the station stored in the preset button is not desirable try to preset the station manually Auxiliary input AUX Connect a portable audio player and listen to your favorite music Plug a patch cord without resistor into the headphone jack of the audio player Plug a stereo mini plug 3 5 mm into the AUX IN jack on the radio To lis...

Page 91: ...V Maximum output power 16 W 16 W 4Ω at 28 8 VDC input 5W 5W 4Ω at 14 4 VDC input Rated output power 12 W 12 W 10 distortion 4Ω at 28 8 VDC input 3 5 W 3 5 W 10 distortion 4Ω at 14 4 VDC input Dimensions 178 W x 50 H x 65 D mm excluding protrusions Receiving frequency MW AM 531 to 1602 kHz Europe Asia 530 to 1710 kHz North Central and South America FM 87 5 to 108 MHz Europe Asia 87 9 to 108 MHz Nor...

Page 92: ...re releasing the pressure in the hydraulic system Immediately after the engine is stopped press each auxiliary hydraulic pedal and second auxiliary switch several times to release the pressure from the auxiliary hydraulic circuit Slowly loosen the air bleeding plug to relieve the internal pressure of the Third auxiliary hydraulic lines If equipped ...

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

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

Page 95: ...epressed 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 ...

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

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

Page 98: ...e steps holding the handrail to support your weight in a three point secure stance hand and feet Never use the safety lock lever or control levers as hand holds Walk around inspection Perform the walk around inspections once a day before starting the engine for the first time that day Refer to MAINTENANCE Walk around inspection on pages 5 16 and 5 17 Daily inspection Perform the daily inspections ...

Page 99: ...sition 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 m...

Page 100: ...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 throttl...

Page 101: ...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 102: ...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 103: ...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 104: ...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 105: ... becomes normal Inspection after warm up After warming up the engine and machine hydraulic oil perform the checks and inspections described below and repair if necessary 1 Check that the warning lamps 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 106: ...dth 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 107: ...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 108: ... sure that the dozer blade is to the front of the operator s seat Remember that when the dozer blade is to the rear of the operator s seat the travel levers pedals must be operated in the reverse 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 the lock 3 ...

Page 109: ... the levers backward Operating the machine When the dozer blade is behind the operator s seat To move forward Tilt the levers backward To move backward Tilt the levers forward Traveling in 2nd High 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 110: ...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 111: ...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 112: ...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 113: ...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 114: ...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 115: ...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 116: ...ntion to the dozer blade when digging When digging deeply with the dozer blade positioned at the front be careful that the boom and bucket do not hit the dozer blade Operate with the dozer blade at the 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 dozer ...

Page 117: ...ping 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 118: ...hillside When descending a hill keep the operator s seat facing the downhill direction In either case travel must be done while paying attention to the ground in front of the machine Do not descend 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 sli...

Page 119: ...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 Do not open the door while traveling on slopes If the engine stops Opening the door while traveling on slopes is dangerous as the force required to open and close the door changes abruptly A...

Page 120: ...e 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 121: ...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 122: ... in a specified place 1 Set the left and right travel levers to the neutral position 2 Return the throttle lever to idle the engine at low speed 3 Lower the bucket and the dozer blade to the ground 4 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 wate...

Page 123: ...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 124: ...re 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 on...

Page 125: ... with water Do not let the sides of the rubber crawlers rub against concrete or walls Do not damage the rubber crawlers by hitting the bucket against them Be especially careful on snowy or frozen 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 126: ... crawler on a flat surface with the machine at a tilt of 10 or more Travel with both crawlers set on flat surfaces Do not change directions when the crawler belts are slack as shown in the figure The 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 127: ...4 1 Transport ...

Page 128: ... 1st low gear by following the signal from the signal person Never change courses on the ramp Do not slew swing on the ramp The machine may tip over When slewing swinging on the truck bed do it slowly as the footing should be unstable Lock the cab door after being loaded if applicable Otherwise the door may open during transport Chock the tracks and secure the machine to the truck bed with wire ro...

Page 129: ...t 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 6 Loading and unloading ...

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

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

Page 132: ...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 Sel...

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

Page 134: ...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 135: ...ained 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 136: ...be changed replace the whole fuel oil Fuel Diesel fuel specifications Diesel fuel should comply with the following specifications The table lists several worldwide specifications for diesel fuels Diesel fuel specification Location Diesel fuel specification Location ASTM D975 No 1 D S15 No 2 D S15 USA Canada ISO 8217DMX International Bio diesel fuel Biodiesel blends up to B5 ASTM D6751 D7467 EN590 ...

Page 137: ...y in the U S A and Canada ultra low sulfur fuel should be used A higher sulfur content fuel may cause sulfuric acid corrosion in the cylinders of the engines Never mix kerosene used engine oil or residual fuel with the diesel fuel Use of kerosene is prohibited Poor quality fuel can reduce engine performance and or cause engine damage Fuel additives are not recommended Some fuel additives may cause...

Page 138: ...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 139: ...e oil pan Engine cooling system Hydraulic oil tank Fuel tank Travel reduction gear Upper limit 4 3 L 4 5 US qt Lower limit 1 5 L 1 6 US qt 3 8 L 4 0 US qt System 24 5 L 6 5 US gal Tank 16 0 L 4 2 US gal 22 L 5 8 US gal 0 33L X 2 0 35 US qt X 2 ...

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

Page 141: ...0 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...

Page 142: ...100 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 143: ...bolts alternately top bottom left then right or in 2 or 3 times so that they are evenly tightened Service data Classification Head width b Size a x pitch Tightening torque General connection points mm 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 2...

Page 144: ...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 hos...

Page 145: ...ecessary 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 Damage to cab or canopy replace Monthly inspection Leakage from the connecting parts of h...

Page 146: ...the oil filter 5 24 Inspecting and adjusting the fan belt 5 25 Replacing the hydraulic oil return filter 5 26 Every 50 hours Inspecting and adjusting the crawler tension 5 28 Lubricating the slew bearing 5 30 Lubricating the slew motor pinion 5 30 Draining the water from the fuel tank 5 31 Inspecting the battery fluid level and replenishing 5 32 Every 100 hours Cleaning the water separator 5 34 Cl...

Page 147: ...tightening the engine cylinder head bolt 5 45 Every 1500 hours Inspecting and cleaning the engine fuel injectors 5 46 Inspecting the crankcase breather system 5 46 Every 2000 hours Lapping the engine valve seats 5 47 Every 4000 hours Replacing the hydraulic oil and cleaning the suction strainer 5 48 When required Replacing the bucket teeth 5 50 Replacing the bucket 5 52 Lubricating the levers 5 54...

Page 148: ... or if the machine is parked on a slope Before starting the engine look around the machine and clean any combustibles from the surroundings of the engine Also inspect if oil or water is leaking and any 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 149: ... and sprockets for damage wear and loose bolts 10 Check for oil leakage from the travel motor 11 Check the canopy cab and guard for damage and the nuts and bolts for looseness 12 Check the rearview mirror and the interior rearview mirror for dirt or damage and adjust them if necessary 13 Check the labels for dirt and damage Walk around inspection Inspecting while sitting in the operator s seat 14 ...

Page 150: ...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 151: ...r limit L of the dipstick 1 Problems could arise if the oil level is either too low or too high 3 Tighten the oil filler cap 2 4 Start the engine run it at low idle for about 5 minutes then stop it 5 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 us...

Page 152: ...pecting 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 153: ...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 hydrauli...

Page 154: ... With the vent plug 2 removed set the safety lock levers to the released position Hydraulic tank pressurization posture 3 Fully extend the bucket arm boom swing and span cylinders 4 Stop the engine and raise the left safety lock lever to engage the lock 5 Tighten the vent plug 2 and then pressurize by retracting the cylinders ...

Page 155: ...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 156: ...d drain the oil The oil comes out when the screw is tightened 4 Remove the connector B and install the cap A IMPORTANT Check the waste oil for metal powder If it contains large amounts of metal powder 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 t...

Page 157: ...achines 1 Move the sheet all the way forward 2 Take out three bolts and remove the cover 1 1 Loosen the bolt 5 and locking nut 4 2 Turn the adjustment bolt 6 to move the alternator 7 and to adjust the tension of the fan belt 1 Tighten Clockwise Loosen Counterclockwise 3 Tighten the bolt 5 and locking nut 4 Note When replacing with a new belt run the engine at low idle speed for about 3 to 5 minute...

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

Page 159: ...m the flange 3 4 Loosen the bolts to take out the flange 3 5 Remove the return filter 4 6 Install a new return filter 7 Reinstall the flange 3 and the hose 2 8 Inspect the level with the sight gauge 5 and replenish if the level is too low Refer to Inspecting the hydraulic oil tank level and replenishing on page 5 21 ...

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

Page 161: ...89 mm 3 3 to 3 5 in Adjustment Increasing the tension 1 Remove the cover 1 2 Inject grease through the grease fitting 3 of the grease discharge valve 2 with a grease gun 3 Inspect the crawler tension 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 ...

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

Page 163: ...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 fu...

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

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

Page 166: ...lement 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 167: ...urns 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 ve...

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

Page 169: ...he 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 170: ...s 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 ...

Page 171: ...all the way forward 2 Take out two screws and open the cover 1 3 Remove the air filter 2 Air filter 2 Part No 03345 00024 4 Use compressed air or water to clean each filter depending on how dirty it is Cleaning 1 Blow dry compressed air 138 kPa or 20 psi or less directly on the filters from the inside moving up and down along the pleats Be sure to keep the nozzle at an adequate distance from the f...

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

Page 173: ...Clean 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 fro...

Page 174: ...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 175: ...ugh 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 176: ... engine 1 Open the engine hood 2 Loosen the clamps 1 and remove the dust cup 2 3 Clean the inside of the dust cup 2 5 Cover the intake hole at the back of the body 4 with cloth or tape to prevent dirt 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 sec...

Page 177: ...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 178: ...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 179: ...5 47 Maintenance Every 2000 hours Lapping the engine valve seats This operation requires experience Ask your sales or service dealer for it Every 2000 hours ...

Page 180: ...ed 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 1 Set the machine to the hydraulic oil level inspection posture Refer to Inspecting the hydraulic oil tank level and replenishing...

Page 181: ...n posture and inspect the oil level when the oil temperature drops Refer to Inspecting the hydraulic oil tank level and replenishing on page 5 21 Every 4000 hours Bleeding air IMPORTANT After replacing the hydraulic oil bleed air from the hydraulic circuits and hydraulic devices Failure to do so may damage the hydraulic devices Hydraulic pump 1 Open the engine hood 2 Loosen the vent plug 1 on the ...

Page 182: ...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 183: ... not go in all the way 2 Put the teeth into the bucket 3 If the teeth are not secured insert a shim to reduce the clearance 4 Insert the bolt from the outside of the bucket and tighten it with the nut 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 184: ...eth 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 185: ...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 186: ...en required 1 Remove the lower mount section of the boot 1 and turn it upward 2 Wipe off the old grease 3 Apply grease to points A and B 4 Set the boot 1 back as it was Travel levers dozer blade lever pedals 1 Remove the floor mat 1 2 Loosen the bolts and remove the cover 2 3 Remove the lower mount section of the boot 3 and turn it upward 4 Use the grease gun to lubricate the grease fitting 4 5 Wi...

Page 187: ...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 188: ... to touch the lever or pedal unless necessary The one who performs maintenance must make sure to keep his her body or clothing away from the moving part of the machine Removal 1 Fully release the tension of the rubber crawler Refer to Inspecting and adjusting the crawler tension on page 5 28 When required 2 Use the working equipment to lift the body 3 Set an iron pipe 1 in the rubber crawler and t...

Page 189: ... 1 is directly next to the idler and the rubber crawler lifts away from the idler then stop turning the sprocket 5 Slide the rubber crawler inward engage it on the idler then pull out the iron pipe 6 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 28 8 In...

Page 190: ...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 191: ...6 1 Troubleshooting ...

Page 192: ...mentarily 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 becomes less...

Page 193: ...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 194: ...he 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 goe...

Page 195: ... the engine block of the dead machine 2 Disconnect the other clip of jumper cable B from the negative battery terminal of the booster vehicle 3 Disconnect the clip of jumper cable R from the positive 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 196: ...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 Applicable machine models 216000002 or later Capacity Protected circuit Capacity Protected circuit 10A Cluster 20A Light 10A Horn 5A Lever lock 25A Cab interior power supply Cab 10A Third auxiliary hydraulic 15A Feed pump 15A Option 1 15A Heater Cab...

Page 197: ...idge type fusible link 1 is likely blown Open the maintenance cover and inspect If the fusible link is blown please contact your sales or service dealer Note Fusible links are large type fuses used in high current applications Like a regular fuse they act as fuses by protecting the electric components and wirings from damage caused by excessive current draw ...

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

Page 199: ...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 25 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 ...

Page 200: ...to page 2 29 Fuse is blown Replace the fuse Refer to page 6 6 Adjustment of travel lock is faulty Adjust the travel lock ask your sales or service dealer Digging force is insufficient Hydraulic oil level too low Add to the specified level Refer to page 5 21 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 36 Hydraul...

Page 201: ... in fuel system Drain water Refer to page 5 31 Crawlers come off Crawlers too loose Increase the tension Refer to page 5 28 Engine exhaust is white or bluish Excessive engine oil Adjust to the specified level Refer to page 5 19 Poor fuel Replace the fuel Engine exhaust is occasionally black Air cleaner is clogged Clean the air cleaner Refer to page 5 36 Irregular noise is produced from the engine ...

Page 202: ...ing the boom to the ground 3 Loosen the lock nut 3 while holding the adjust screw 4 in place with a hexagonal wrench so that the adjust screw 4 will not be loosened together with the lock nut 3 4 Turn the adjust screw 4 slowly 1 4 turn to lower the boom 5 Check for safety and stability of the machine 6 Return the adjust screw 4 to the original position 7 Tighten the lock nut 3 while holding the ad...

Page 203: ...to 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 d...

Page 204: ... until the replacement is complete Do not try to repair the damaged cab or canopy by welding Doing so could endanger the safety of the cab canopy Applicable machine models 216000002 or later Cab parts No 03386 00101 Canopy parts No 1 03384 00135 Canopy parts No 2 03684 16300 Applicable machine models 216100002 or later Canopy parts No 1 03384 00120 Canopy parts No 2 03384 00128 If the cab or canop...

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

Page 206: ...s 1st 2 2 1 37 2nd 4 2 2 61 Steel crawlers 1st 2 1 1 30 2nd 4 0 2 49 Gradeability degrees 30 Ground pressure kPa psi Rubber crawlers 31 0 4 50 29 4 4 26 Steel crawlers 34 5 5 00 32 8 4 76 Noise level dB A Sound power level LWA 93 Sound pressure level LpA 78 LpA Engine Manufacturer and model Yanmar 3TNV70 Rated output Net ISO 14396 kW min 1 hp rpm 11 5 2400 15 4 2400 Net ISO 9249 SAEJ1349 kW min 1 ...

Page 207: ... 1 37 2nd 4 2 2 61 Steel crawlers 1st 2 1 1 30 2nd 4 0 2 49 Gradeability degrees 30 Ground pressure kPa psi Rubber crawlers 29 4 4 26 Steel crawlers 32 8 4 76 Noise level dB A Sound power level LWA 93 Sound pressure level LpA Engine Manufacturer and model Yanmar 3TNV74 Rated output Net ISO 14396 kW min 1 hp rpm 11 2 2400 15 0 2400 Net ISO 9249 SAEJ1349 kW min 1 hp rpm 10 8 2400 14 5 2400 Displacem...

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

Page 209: ...ll width wide 1300 51 2 J Crawler shoe width 230 9 1 K Ground clearance of undercarriage 205 8 0 210 8 2 L Minimum radius of equipment and attachment 1480 58 2 M Minimum radius of equipment at maximum front offset 1155 45 4 P Offset distance of bucket right swing 400 15 7 Q Offset distance of bucket left swing 570 22 5 R Dozer blade width narrow 980 38 6 R2 Dozer blade width wide 1300 51 2 S Dozer...

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

Page 211: ...shoe width 230 9 1 K Ground clearance of undercarriage 205 8 0 210 8 2 L Minimum radius of equipment and attachment 1480 58 2 M Minimum radius of equipment at maximum front offset 1155 45 4 P Offset distance of bucket right swing 400 15 7 Q Offset distance of bucket left swing 570 22 5 R Dozer blade width narrow 980 38 6 R2 Dozer blade width wide 1300 51 2 S Dozer blade height 310 12 1 T Front dis...

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

Page 213: ...ht 755 29 8 760 30 0 J Dozer blade maximum lifting 360 14 2 365 14 4 K Dozer blade maximum lowering 365 14 3 360 14 1 Canopy Unit mm inch Item Long arm Rubber crawlers Steel crawlers A Maximum reach 4090 160 9 B Maximum reach at ground reference plane 4035 158 9 C Maximum digging depth 2390 94 0 2385 93 8 D Maximum vertical digging depth 2060 81 0 2055 80 8 E Reach at maximum vertical digging dept...

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

Page 215: ...oad 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 situated on ...

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

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

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

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

Page 220: ...7 16 ...

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

Page 222: ...ary 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 ...

Page 223: ...und 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 direction Do not slew sideways with a heavy load at the how attachment In particular do not slew sid...

Page 224: ... its products caused by the use by a non approved attachment The swing stopper must be mounted when a bucket wider than a 450W bucket is mounted Failure to mount the swing stopper may result in the 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 Bucket Rated capacity m3 cu yd Bucket cutting width mm i...

Page 225: ...d 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 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 7 Confirm the lever pat...

Page 226: ...enter 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 operating St...

Page 227: ...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 ...

Page 228: ...g lifted Boom Arm If the emergency shut off valve 1 or 2 is activated immediately set the operating levers to the neutral position Do not move the operating lever to the boom or arm lowering side Ask your sales or service dealer for repair If the engine can be started without problems the boom or arm can be lowered with the operating lever Slowly lower the boom or arm while ensuring safety If the ...

Page 229: ... overload warning device is activated and the horn sounds When the overload warning switch is turned on If the overload is not removed after the overload warning horn is sounded the machine may tip over or the emergency shut off valve may be activated If the horn starts sounding stop operating the machine and lighten the load ...

Page 230: ...Open the fuse box cover 1 4 Check for fuse 5 If a fuse is blown replace it with a spare fuse of the same capacity Fuse layout and circuits protected Applicable machine models 216000002 or later Capacity Protected circuit Capacity Protected circuit 10A Cluster 20A Light 10A Horn 5A Lever lock 25A Cab interior power supply Cab 10A Third auxiliary hydraulic 15A Feed pump 15A Option 1 Travel alarm 15A...

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

Page 232: ...il 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 page 5 48 2 Remove the cylinder hose...

Page 233: ...8 13 ...

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

Page 235: ...ine 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 compatibility regulation 2004 108 ...

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Takeuchi TB216, Operator'S Manual

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