Takeuchi TB216, 216000002, 216100002 Operator's Manual

SAFETY ALERT SYMBOL

This symbol represents the safety alert. The message that follows the symbol contains important information about safety. Read and understand the message to avoid personal injury or death.

It is the owner or employer’s responsibility to fully instruct each operator in the proper and safe operation of all equipment. All persons using this machine should thoroughly familiarize themselves with the contents of this manual.

All operators must be instructed on the proper functions of the excavator before running the machine.

Learn and practice correct use of the machine controls in a safe, clear area before operating this machine on a job site.

Improper operation, inspection and maintenance of this machine can cause injury or death. Read and understand this manual before performing any operation, inspection or maintenance on this machine.

Always store this manual near at hand preferably on the machine itself. If it should be lost or damaged, immediately order a new one from your Takeuchi dealer. When transferring ownership of this machine, be sure to hand this manual to the next owner.

Takeuchi supplies machines complying with the local regulations and standards of the country of export. If your machine has been purchased in another country or from a person or company of another country, it may not have the safety devices or safety standards required for use in your country. Should you have any question about whether your machine complies with the regulations and standards of your country, contact a Takeuchi dealer.

SIGNAL WORDS

Safety messages appearing in this manual and on machine decals are identiﬁed by the words “DANGER”, “WARNING” and “CAUTION”. These signal words mean the following:

DANGER indicates a hazard with a high level of risk which, if not avoided, will result in death or serious injury.

WARNING indicates a hazard with a medium level of risk which, if not avoided, could result in death or serious injury.

CAUTION indicates a hazard with a low level of risk which, if not avoided, could result in minor moderate injury.

IMPORTANT: The word IMPORTANT is used to alert operators and maintenance personnel about situations which could result in damage to the machine and its components.

It is impossible to foresee every possible circumstance that might involve a potential hazard. The warnings in this manual or on the machine can not cover all possible contingencies. You must exercise all due care and follow normal safety procedures when operating the machine so as to ensure that no damage occurs to the machine, its operators or other persons.

0-1

INTRODUCTION

FOREWORD

This manual describes operation, inspection and maintenance of the machine, as well as safety instructions to be heeded during these operations. If you have any questions about the machine, please contact a Takeuchi sales or service outlet.

MANUAL STORAGE COMPARTMENT

A compartment for storing this manual is provided at the position shown on the diagram below.

1. Insert the starter key and turn it counterclockwise to open the cover under the seat.

2. After using the manual, place it in the plastic pouch and store it back in the manual storage compartment.

SERIAL NUMBERS

IMPORTANT: Do not remove the machine name plate with the serial number. Check the serial numbers of the machine and engine and write them down in the spaces below.

Machine number:

Engine number:

0-2

AD6O003

MACHINE DESCRIPTION

FRONT, REAR, LEFT AND RIGHT

This manual refers the front, rear, left and right of the machine as seen when sitting in the operator’s seat with the dozer blade visible to the front.

DESIGNATED OPERATIONS

FEATURES

• “Flexible machine width mechanism” for crawler width

• Low engine noise and exhaust emissions

BREAK-IN PERIOD

When the machine is new, operate the machine for the ﬁrst 100 hours (as indicated on the hour meter) by following the instructions below. Using a new machine without a break-in period will lead to quicker deterioration of machine performance and may shorten the machine’s service life.

• Sufﬁciently warm up the engine and hydraulic oil.

• Avoid heavy loads and rapid operations. Operate with a load of about 80% the maximum load.

• Do not abruptly start up, accelerate, change directions, or stop unless necessary.

Use this machine primarily for the following operations:

• Excavation

• Digging ditches

• Digging side ditches

• Leveling

• Loading

0-3

NOTES ON READING THIS MANUAL

Please note that the descriptions and diagrams included in this manual may not be applicable to your machine. The numbers used in the illustration are with circles around them. The same numbers appear between the parentheses in the text. (Example:

Symbols used in this manual The symbols used in this manual have the following meanings.

...... Prohibition

............. Lock

............. Unlock

(1))

0-4

Contents

Introduction .....................................0-2

Machine description ........................0-3

Safety ..............................................1-1

General precautions ................................1-2

Precautions when preparing ....................1-8

Precautions when starting .....................1-12

Precautions when operating ..................1-14

Precautions when stopping ...................1-23

Precautions when transporting ..............1-24

Precautions on maintenance .................1-26

Safety signs (decals) .............................. 1-35

Controls ...........................................2-1

Names of components (Cab) ................... 2-2

Names of components (Canopy) ............. 2-4

Covers ..................................................... 2-6

Starter key ........................................... 2-6

Maintenance cover .............................. 2-6

Fuse box ............................................. 2-7

Tool case ............................................. 2-7

Grease gun holder ............................... 2-7

Fuel lid ................................................. 2-8

Fuel ﬁller port ....................................... 2-8

Side cover ........................................... 2-9

Engine hood ........................................ 2-9

Cab ....................................................... 2-10

Cab door ........................................... 2-10

Emergency exit .................................. 2-10

Front window .....................................2-11

Lower front window ........................... 2-12

Side window ...................................... 2-12

Emergency hammer (optional) ........... 2-13

Seat and seat belt ................................. 2-14

Seat (If equipped) .............................. 2-14

High-back seat (If equipped) .............. 2-15

Seat belt ............................................ 2-16

Instrument cluster .................................. 2-18

Warning lamps ...................................2-18

Indicators........................................... 2-19

Meters ............................................... 2-19

Multi-data display .............................. 2-20

Switches ............................................... 2-26

Starter switch .................................... 2-26

Horn button ....................................... 2-26

Travel speed switch ........................... 2-26

Wiper switch ...................................... 2-27

Second auxiliary hydraulic switch ....... 2-27

Third auxiliary hydraulic switch and button

................................................ 2-27

Overload warning switch (If equipped)

Levers and Pedals ................................. 2-29

Safety lock lever ................................ 2-29

Throttle lever ...................................... 2-29

Operating levers ................................ 2-30

Blade lever ......................................... 2-30

Travel levers/pedals ........................... 2-31

Boom swing pedal ............................. 2-31

Auxiliary hydraulic pedal ..................... 2-32

Selector lever .................................... 2-32

Accessories ........................................... 2-34

Heater ............................................... 2-34

Cup holder ........................................ 2-36

Interior light ........................................ 2-36

Inside rear view mirror (cab) ...............2-36

Power sockets .................................. 2-37

Armrest..............................................2-37

Radio (for cab) ................................... 2-38

Auxiliary hydraulic lines ...................... 2-42

Accumulator (If equipped) .................. 2-46

....................................... 2-28

Operation .........................................3-1

Before starting operation .........................3-2

Getting on or off the machine ...............3-2

Walk-around inspection .......................3-2

Daily inspection .................................... 3-2

Starting and stopping the engine ............. 3-3

Before starting the engine .................... 3-3

Starting the Engine .............................. 3-4

Warming up the engine ........................ 3-5

Stopping the engine ............................ 3-5

Operating the machine ............................ 3-6

Lever pattern (ISO pattern) ................... 3-6

Lever pattern (G pattern) If equipped ... 3-7 Warming up the machine (hydraulic oil) 3-8

Inspection after warm-up ..................... 3-9

Crawler width switching ..................... 3-10

Switching the blade width .................. 3-11

Operating the travel levers ................. 3-12

Stopping travel .................................. 3-15

Operating the working equipment ...... 3-16

Operating procedures ............................ 3-18

Prohibited operations .........................3-18

Cautions on operating ........................... 3-21

Cautions on traveling ......................... 3-21

Cautions on traveling on slopes ........ 3-22

Getting out of mud ............................ 3-24

0-5

Operations possible with this

machine............................................. 3-24

Parking the machine

Parking .............................................. 3-26

Inspection and checks after stopping

the engine.......................................... 3-26

Handling in cold climates

Preparing for cold climates ................3-27

Cautions after operations ................... 3-27

After the cold climate ......................... 3-27

Handling rubber crawlers ....................... 3-28

Prohibitions ........................................3-28

Cautions ............................................ 3-29

Preventing the rubber crawlers from

coming off .........................................3-29

.............................. 3-26

....................... 3-27

Transport .........................................4-1

Loading and unloading ............................ 4-2

Hoisting the machine ............................... 4-4

Securing the machine .............................. 4-6

Maintenance ....................................5-1

General .................................................... 5-2

Maintenance overview ......................... 5-2

Cautions on maintenance .................... 5-2

Service data ............................................ 5-4

Fuel and lubricant table ........................ 5-4

Regularly replace the hydraulic oil ........ 5-8

List of consumables ............................. 5-9

List of tools ........................................ 5-10

List of tightening torques ...................5-11

Safety-critical parts ................................ 5-12

Maintenance list ..................................... 5-14

Walk-around inspection .........................5-16

Inspecting by opening the engine hood

and covers......................................... 5-16

Inspecting by walking around the

machine............................................. 5-17

Inspecting while sitting in the

operator’s seat

Daily inspection (every 10 hours) ............ 5-18

Inspecting and replenishing the

coolant

Inspecting and replenishing the

engine oil

Inspecting the dust indicator .............. 5-19

Inspecting the water separator ........... 5-20

Inspecting the fuel level ...................... 5-20

Inspecting the hydraulic oil tank level

and replenishing

................................... 5-17

.............................................. 5-18

........................................... 5-19

................................ 5-21

Lubricating the working equipment .... 5-23

After the initial 50 hours (only for new machines)

Replacing the engine oil and the

............................................... 5-24

oil ﬁlter

Inspecting and adjusting the fan belt .. 5-25

Replacing the hydraulic oil return ﬁlter 5-26

Every 50 hours ...................................... 5-28

Inspecting and adjusting the crawler

tension .............................................. 5-28

Lubricating the slew bearing .............. 5-30

Lubricating the slew motor pinion ...... 5-30

Draining the water from the fuel tank ..5-31

Inspecting the battery ﬂuid level and

replenishing .......................................5-32

Every 100 hours .................................... 5-34

Cleaning the water separator ............. 5-34

Cleaning the fuel ﬁlter ......................... 5-34

After the initial 250 hours (only for new machines)

Replacing the travel motor gear oil ..... 5-35

Every 250 hours .................................... 5-36

Replacing the engine oil and the oil

ﬁlter

................................................... 5-36

Inspecting and adjusting the fan belt .. 5-36

Cleaning the air cleaner ..................... 5-36

Cleaning the radiator ﬁns and oil cooler ﬁns

Cleaning the air ﬁlters ......................... 5-39

Every 500 hours .................................... 5-40

Replacing the hydraulic oil return ﬁlter 5-40

Replacing the water separator ﬁlter .... 5-40

Replacing the fuel ﬁlter ....................... 5-41

Every 1000 hours .................................. 5-42

Replacing the travel motor gear oil ..... 5-42

Cleaning the engine cooling system ... 5-42

Replacing the air cleaner element ...... 5-44

Inspecting and adjusting the engine valve clearance Retightening the engine cylinder head bolt

Every 1500 hours .................................. 5-46

Inspecting and cleaning the engine fuel injectors Inspecting the crankcase breather system

Every 2000 hours .................................. 5-47

Lapping the engine valve seats .......... 5-47

Every 4000 hours .................................. 5-48

0-6

.......................................... 5-38

........................................... 5-45

...................................... 5-46

............................................... 5-46

......................... 5-24

......................... 5-35

.................................. 5-45

Replacing the hydraulic oil and cleaning the suction strainer

When required ....................................... 5-50

Replacing the bucket teeth ............... 5-50

Replacing the bucket ......................... 5-52

Lubricating the levers ......................... 5-54

Inspecting the rubber crawlers ........... 5-55

Replacing the rubber crawlers ........... 5-56

Maintenance during extended storage period

.................................................... 5-58

.............. 5-48

Troubleshooting ...............................6-1

Symptoms that are not malfunctions .......6-2

If the engine overheats ............................. 6-3

If the battery goes dead ........................... 6-4

If a fuse blows ......................................... 6-6

Inspecting and replacing the fuse .........6-6

Inspecting the fusible link ..................... 6-7

Restarting after adding fuel ...................... 6-8

Bleeding air from the fuel system ......... 6-8

If a warning lamp ﬂashes ......................... 6-9

Other symptoms .................................... 6-10

Lowering the boom to the ground .........6-12

Towing ...................................................6-13

If the cab or canopy is damaged ........... 6-14

Speciﬁcations ..................................7-1

Basic Speciﬁcations ................................. 7-2

Machine dimensions ................................ 7-4

Operating ranges ..................................... 7-8

Lifting Capacities ................................... 7-11

Options ............................................8-1

General precautions ................................8-2

Safety precautions ............................... 8-2

Cautions when installing attachments .. 8-2

Cautions when operating attachments . 8-3

Attachment combination table ................. 8-4

Selecting a lever pattern .......................... 8-5

Switching the lever pattern .................. 8-5

Hydraulic breaker ....................................8-6

Replacing the hydraulic oil regularly .....8-7

Load safety device ................................... 8-8

Emergency shut-off valve .....................8-8

Overload warning device ..................... 8-9

Travel alarm ........................................... 8-10

Optional equipment mass ..................... 8-11

Biodegradable oil ................................... 8-12

Replacing the hydraulic oil with

biodegradable oil ............................... 8-12

0-7

0-8

SAFETY

1-1

Safety

GENERAL PRECAUTIONS

It is your responsibility to observe all pertinent laws and regulations and to follow the manufacture’s instructions on machine operation, inspection and maintenance.

Virtually all accidents occur as the result of a failure to observe basic safety rules and precautions. Most accidents can be prevented by identifying the potentially hazardous situations beforehand. Read and understand all safety messages which describe how to prevent accidents. Do not operate the machine until you are sure that you have gained a proper understanding of its operation, inspection and maintenance.

Observe all safety rules

• Operation, inspection and maintenance of this machine must be performed only by a trained and qualiﬁed person.

• All rules, regulations, precautions and safety procedures must be understood and followed when performing operation, inspection and maintenance of this machine.

• Do not perform any operation, inspection and maintenance of this machine when under the adverse inﬂuence of alcohol, drugs, medication, fatigue, or insufﬁcient sleep.

When a problem is found on the machine

If any problem (noise, vibration, smell, disorder of instrument, smoke, oil leak, wrong indication of alarm or unusual indication in the instrument cluster, etc.) is detected during the operation or inspection and maintenance of the machine, immediately inform your sales or service dealer and take proper actions. Do not operate the machine until the trouble is cleared.

Operating temperature range

To maintain the performance of machine and to prevent it from early wear, observe the following operating conditions.

• Do not operate the machine if the ambient temperature is higher than +45°C (+113°F) or lower than –15°C (+5°F).

· If operated at an ambient temperature of

higher than +45°C (+113°F), the engine may overheat and cause the engine oil to degrade. Also, the hydraulic oil may become very hot, causing damage to the hydraulic equipment.

· If operated at an ambient temperature of

lower than –15°C (+5°F), the parts made of rubber such as gaskets may get hardened to cause an early wear or damage to the machine.

· If the machine is to be used outside the

ambient temperature range described above, consult your sales or a service dealer.

1-2

Safety

GENERAL PRECAUTIONS

Wear appropriate clothing and protective equipment

• Do not wear loose clothing or any accessory that can catch on controls or in moving parts.

• Do not wear oily or fuel stained clothing that can easily catch ﬁre.

• Wear a hard hat, safety shoes, safety glasses, ﬁlter mask, heavy gloves, ear protection and other protective equipment as required by job conditions. Wear required appropriate equipment such as safety glasses and ﬁlter mask when using grinders, hammers or compressed air, as metal fragments or other objects can ﬂy and cause serious injury.

• Use hearing protection when operating the machine. Loud prolonged noise can cause hearing impairments, even the total loss of hearing.

Install a ﬁre extinguisher and ﬁrst aid kit

Be prepared for ﬁre and accidents

• Install an extinguisher and a ﬁrst aid kit, and learn how to use them.

• Lean how to ﬁght a ﬁre and how to deal with accidents.

• Know how to contact emergency assistance and make a list of emergency contacts.

Never remove safety equipment

• Make sure all protective guards, canopies and doors are in place and secured. Repair or replace damaged parts before operating the machine.

• Know how to use the safety lock lever, seat belt and other safety equipment and use them properly.

• Never remove any safety equipment except for servicing. Keep all safety equipment in good operating condition.

1-3

Safety

GENERAL PRECAUTIONS

Use a signal person and a ﬂag person

Learn how to use the hand signals required for particular jobs and make sure who has the responsibility for signaling.

• All personnel must fully understand all the signals.

• The operator must respond to signals only from the appointed signal person, but must obey a stop signal at any time from anyone.

• The signal person must stand in a clearly visible location when giving signals.

Cautions when standing up from or leaving the operator’s seat

• Before standing up from the operator’s seat to open/close the window or remove/ install the lower window, lower the working equipment to the ground, raise the safety lock levers to engage the lock and stop the engine. If any controls should be accidentally touched when the safety lock levers is lowered (unlocked), the machine will suddenly move and cause serious injury or death.

• Note that the dozer blade, boom swing and auxiliary hydraulic controls cannot be locked, even when the safety lock lever is set to the locked position.

Do not carelessly touch these controls.

• Be careful not to touch the operating levers when raising or lowering the safety lock levers.

• Before leaving the operator’s seat, lower the working equipment to the ground, raise the safety lock levers to engage the lock and stop the engine. Also, be sure to remove the key, lock the door and covers, take it with you and store it in a speciﬁed place.

1-4

Safety

GENERAL PRECAUTIONS

Avoid ﬁre and explosion hazards

Keep ﬂames away from fuel, oil, grease and antifreeze. Fuel is particularly ﬂammable and dangerous.

• When handling these combustible materials, keep lit cigarettes, matches, lighters and other ﬂames or sources of ﬂames away.

• Do not smoke or permit open ﬂames while handling fuel or working on the fuel system.

• Do not leave the location while reﬁlling with fuel or oil.

• Never remove the fuel cap or add fuel when the engine is running or still hot. Also, do not spill the fuel on the hot surface of the machine or the component of the electric system.

• Clean up spilled fuel or oil immediately.

• Check for fuel, oil leak. Stop all leaks and clean the machine before operating.

• When operating with grinder or welding, move inﬂammables to a safe place.

• Do not cut or weld on pipes or tubes that contain ﬂammable ﬂuids. Clean thoroughly with nonﬂammable solvent before cutting or welding.

• Remove all trash or debris from the machine. Make sure that oily rags or other ﬂammable material are not stored on the machine.

• Handle all solvents and dry chemicals (foam type ﬁre extinguisher) according to procedures identiﬁed on manufacturer’s containers. Work in a well-ventilated area.

• Never use fuel for cleaning purposes. Always use a nonﬂammable solvent.

• When handling the fuel, washing oil or paint, open the door and windows to ventilate thoroughly.

• Store all ﬂammable ﬂuids and materials in a safe and well-ventilated place.

• The short circuit of the electric system may cause the ﬁre. Check for any loosened connections or damage to the wires every day. Retighten the loosened connector and wire clamp. Fix or change the damaged wire.

• Fire from the pipes:

Make sure that the clamps, guards and

cushions of the hoses and tubes are securely ﬁxed. If not, hoses or tubes may be damaged due to vibration or contact with other parts during operation. This can cause the high-pressure oil to spurt out, resulting in the ﬁre or injury.

1-5

Safety

GENERAL PRECAUTIONS

Exhaust fumes from the engine is poisonous

• Do not operate the engine in an enclosed area without adequate ventilation.

• If natural ventilation is not possible, install ventilators, fans, exhaust extension pipes or other venting devices.

Handling asbestos dust

Inhaling asbestos dust can cause lung cancer. When handling the materials which may contain asbestos, take the following precautions:

• Never use compressed air for cleaning.

• Avoid brushing or grinding parts containing asbestos.

• For clean up, use a vacuum equipped with a high efﬁciency particulate air ﬁlter (HEPA).

• Wear the stipulated respirator if there is no other way to control the dust. When working indoors, install a ventilation system with a macromolecular ﬁlter.

• Do not allow unauthorized personnel in the work area while working.

• Follow the rules and environmental standard applicable to the work area.

Be careful not to get crushed or cut

Never put your hands, feet or other parts of your body between the upperstructure and the undercarriage or tracks, between the machine body and working equipment, or between a cylinder and moving part. The sizes of these gaps change when the machine moves, and a person can suffer severe injury or death.

1-6

Safety

GENERAL PRECAUTIONS

Using optional products

• Consult with Takeuchi before installing optional attachments. Depending on the type of attachments or the combination of them, the attachment may come into contact with the operator’s compartment or the other parts of the machine. Make sure that the optional attachment installed is not contacted with other parts before use.

• Do not use attachments that have not been approved by Takeuchi. Doing so may compromise safety or adversely affect the machine’s operation or service life.

• Takeuchi will not be held responsible for any injuries, accidents or damage to its products caused by the use by a nonapproved attachment.

Never modify the machine

Unauthorized modiﬁcations to this machine can cause injury or death. Never make unauthorized modiﬁcations to any part of this machine.

1-7

Safety

PRECAUTIONS WHEN PREPARING

Know the work area

Before starting operation, know the working area condition to ensure a safety operation.

• Inspect the topography and ground condition of the working area, or the structure of the building when working indoors, and take the safety precautions as necessary.

• Be sure to avoid all hazards and obstructions such as ditches, underground lines, trees, cliffs, overhead electrical wires, or places where there is a danger of falling rocks or slides.

• Check with the administrator for the locations of buried gas pipes, water pipes and power cables. If necessary, determine what speciﬁc precautions must be taken to insure safety by consulting with the administrator.

• When working on roads, be sure to consider the safety of pedestrians and vehicles.

· Use a ﬂag person and/or a signal.

· Fence off the working area and keep off

unauthorized persons.

• When working in water or crossing shallow streams or creeks, check the depth of the water, the solidity of the ground and the water ﬂow speed beforehand.

Refer to “Cautions on operating” for further

instructions.

1-8

Safety

PRECAUTIONS WHEN PREPARING

Check the strength of the bridge

When traveling over a bridge or a structure, check the permissible load. If the strength is insufﬁcient, reinforce the bridge or the structure.

Always keep the machine clean

• Clean windows, mirrors and lights to ensure 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 unnecessary object from the machine.

1-9

Safety

PRECAUTIONS WHEN PREPARING

Perform inspection and maintenance every day

Failure to identify or repair the irregularities or damage on machine can lead to accidents.

• Before operating, perform the speciﬁed inspection and make prompt repairs where necessary.

• If a failure occurs and the operation becomes impossible or the engine fails, immediately stop the machine by following the shutdown procedure, and keep machine securely parked until the malfunction is corrected.

Cautions 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 act as a lens and can cause ﬁre.

• Do not use the mobile phone during traveling or working.

• Do not bring combustibles or explosives into the operator’s compartment.

• Do not leave the cigarette lighter in the operator’s compartment. When the room temperature rises, the lighter may explore.

1-10

Safety

PRECAUTIONS WHEN PREPARING

Emergency exit

Front window (excluding machines with a front guard)

If you should become trapped inside the cab, open the front window to get out.

Emergency hammer (optional)

An emergency 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 slip on the glass.

1-11

Safety

PRECAUTIONS WHEN STARTING

Support your weight in a three point secure stance when getting on/off the machine

• Do not jump on or down from the machine. Never attempt to get on or off the moving machine.

• When getting on or off the cab, ﬁrst fully open the door to the locked position and check that it does not move (for machines with cab).

• 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 in the operator’s seat and start the engine

• Adjust the seat to securely latch it.

• Climb up/down the steps facing the machine and 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.

Before starting the machine, ask any unauthorized personnel to leave the area

Do not start the engine until you are sure it 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.

• Fasten the seat belt.

• Check if the parking brake is on and all control levers and pedals are in the neutral position.

• Check if the safety lock lever is in the lock position.

• Make sure that no one is near the machine.

• Start and operate the machine only from the operator’s seat.

• Never attempt to start the engine by shorting across the starter terminals.

1-12

Safety

PRECAUTIONS WHEN STARTING

Starting with jumper cables

Use jumper cables only in the recommended manner. Improper use of jumper cables can result in battery explosion or unexpected machine motion. Refer to “If the battery goes dead” for further instructions.

After starting the engine

After starting the engine, perform the operations and checks described below in a safe place with no persons or obstacles in the area. If any malfunction is found, follow the shutdown procedure and report the malfunction.

• Warm 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 to the metal, resulting in severe injury.

• Do not use ether or starting ﬂuid on this engine. The starting ﬂuids can cause explosion and serious injury or death.

• Warm up the engine and hydraulic oil. If the levers are operated without warming, the machine will not react or move promptly or properly, resulting in accident.

1-13

Safety

AD6A001

PRECAUTIONS WHEN OPERATING

Operate the machine with the maximum crawler width

• Always operate the machine with the crawler width extended to 1300 mm (51.2 in.) to maximize the machine stability. If the machine is operated with the crawler width narrowed (980 mm, 38.6 in.), the machine may tip over due to its poor stability.

• If the machine must be operated with the narrowed crawler width (980 mm, 38.6 in.), traveling should be done after folding the hoe attachment, lowering the boom to lower the center of gravity and keeping the machine facing forward.

Do not permit riders on the machine

Do not allow anyone to ride on any part of the machine at any time while traveling or operating.

Check if the work area is safe and secure before operation

Ensure good visibility

• When working in dark places, turn on the machine’s working lights and headlights and additional lighting equipment installed, as necessary.

• When visibility is poor due to bad weather (fog, snow, rain or a cloud of dust), stop operating the machine and wait until visibility improves.

• Conﬁrm the performance limits of the machine.

• Use a signal person at road shoulders, narrow 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.

1-14

Safety

PRECAUTIONS WHEN OPERATING

Check the position of the undercarriage (tracks) before traveling

Before operating the travel levers/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.

Travel safely

• Travel with the dozer blade raised, the hoe attachment folded as shown on the ﬁgure above, 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 machine to an angle of 10° or greater.

• On uneven ground, maintain the low speed and avoid starting, stopping or changing directions abruptly. Otherwise, the working equipment may come in contact with the ground, causing the machine to lose its balance and get damaged or to damage the structures in the surrounding area.

1-15

Safety

PRECAUTIONS WHEN OPERATING

Cautions on traveling on slopes

When traveling on slopes or grades, be careful that the machine does not tip (roll) over or slide.

• Never travel on slopes that are too steep for the machine to maintain its stability (maximum gradeability: 30°, lateral tipping angle: 10°). Note that in reality, the machine’s stability becomes lower than the above values depending on the working condition.

• 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 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 the ground is covered with grass or dead leaves, or when traveling on a wet metal plate or frozen surfaces. Make sure the machine is never positioned sideways on slopes.

• If the machine is stalled on the slope, return each operating lever to the neutral position before restarting the engine.

• When climbing a hill, keep the operator’s seat facing the 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.

• 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.

1-16

Safety

PRECAUTIONS WHEN OPERATING

Operate the machine on snow or ice with extra care

• When traveling on snow or on frozen surfaces, drive at a low speed and avoid starting, stopping or changing directions abruptly.

• In the snowy area, the road shoulder and objects placed beside the road are buried in the snow and cannot be seen. There is a hazard of the machine tipping over or hitting covered objects, so always carry out operations carefully.

• If the machine enters deep snow, there is a hazard that it may tip over or become buried in the snow.

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.

Do not move the bucket over the heads of people

Ensure driver’s safety when loading

Do not load a truck unless the truck driver is in a safe place.

• Never swing or position the bucket over a person or the cab room.

• Load the truck from the rear.

Moving the bucket over the heads of people entails the danger of the load spilling or the sudden dropping of the bucket.

1-17

Safety

PRECAUTIONS WHEN OPERATING

Keep a safe distance from the overhead high-voltage cables

Never bring any part of the machine or loaded material to near to the high voltage cables unless all safety precautions required by the local and national authorities have been installed. If a person comes near to the machine that is discharging sparks or located near to or in contact with the power source, there is a hazard of electric shock and 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 warning if the machine approaches too close to the high-voltage electric cables.

• Caution all personnel in the work area not to come close to the machine or the loaded material.

• Pay also careful attention to the highvoltage electric cables buried underground.

1-18

Safety

PRECAUTIONS WHEN OPERATING

Watch out for hazardous working conditions

• Never undercut a high bank. Doing so is dangerous as it may cause ground collapse.

• Do not operate in places where there is a danger of falling rocks.

• 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.

• Maintain a safe distance between the machine and the edge of the digging site. Do not dig the ground under the front of the machine.

• When working close to the cliffs or road shoulders, to make it easier to escape if there is any problem, 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 come close to unstable grounds (cliffs, road shoulders, deep ditches). If the ground should collapse under the weight or vibration of the machine, there is a hazard that the machine may fall or tip over.

· Remember that the soil after heavy rain

or blasting is weak.

· The ground of top of the embankment

and of the circumferences of the excavated ditches are also weak.

1-19

Safety

PRECAUTIONS WHEN OPERATING

• Do not perform demolition work under the machine. There is a hazard that the machine may fall down, because the ground becomes unstable.

• When working on or from the top of buildings or other structures, check the strength and the structure before starting operations. If a building or structure collapses, serious injury or damage will result.

• 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.

• 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.

1-20

Safety

PRECAUTIONS WHEN OPERATING

Operating on slopes is dangerous

When operating on slopes or grades, slewing or operation of working equipment may cause the machine to lose stability and tip over. Avoid operating on slopes whenever possible.

• Level off the work area.

Never slew (swing) sideways with a heavy load

The machine 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 tips, do not perform excavation with the digging arm (boom) facing the downhill direction or operate toward sideways.

• Avoid slewing to the downhill direction with the bucket full of loaded material. This will reduce the stability of the machine and may result in tipping over.

Be careful with the overhead objects

When operating under bridges, in tunnels, near electric cables or indoors, be careful not to let the boom or arm hit overhead objects.

1-21

Safety

PRECAUTIONS WHEN OPERATING

Excavators are not designed for lifting loads

This machine is speciﬁcally designed for excavation work. Therefore, it has no safety equipment 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 conditions. They include, soft or uneven ground, non-level condition, side loads, dynamic or jerked loads, hazardous conditions, and experience of personnel. The operator and other personnel should fully acquaint themselves with the operator’s manual before operating this machine, and rules for safe operation of equipment shall be adhered to at all times.

• The bucket linkage or lifting device may fail if chains or lifting device are incorrectly 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.

Be careful with ﬂying objects

This machine is not equipped with protective equipment to protect the operator from ﬂying objects. Do not use this machine in places where there are risks of the operator being hit by ﬂying objects.

Cautions when towing

When towing, serious injury or death could result, if performed incorrectly or the wire rope being used is inappropriate or not properly inspected.

• It becomes dangerous if the wire rope breaks or becomes disengaged. Use a wire rope appropriate for the required tractive force.

• Do not use a wire 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.

1-22

Safety

PRECAUTIONS WHEN STOPPING

Park safely

• Park the machine on a ﬂat, rigid and safe ground. Set the parking brake.

• 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 covers and take the

key with you.

If you must park on a slope or incline, park

the machine securely and block 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.

1-23

Safety

PRECAUTIONS WHEN TRANSPORTING

Load/unload the machine safely

The machine may roll or tip over or fall while being loaded or unloaded. Take the following precautions:

• Select a ﬁrm, level surface and keep sufﬁcient distance from road shoulders.

• Secure the ramps of adequate strength and size to the truck bed. The slope of the ramps must not exceed 15°. If the rumps are bowed down too low, support them with poles 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 by following the signal from the signal person.

• Never change courses on the ramps.

• Do not slew/swing on the ramps. 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 rope or chain.

1-24

Safety

PRECAUTIONS WHEN TRANSPORTING

Hoist the machine safely

• Know and use correct crane signals.

• Check the hoisting equipment for damaged or missing parts on a daily basis and replace as necessary.

• When hoisting, use a wire rope capable of lifting the machine mass.

• Hoist the machine in such a manner described in the procedure below. Do not do it in any other manner, as it may result in the machine losing its balance.

Refer to “Hoisting the machine” for further

instructions.

• 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.

Transport the machine safely

• Know and follow the applicable safety rules, vehicle code and trafﬁc laws when transporting the machine.

• Select the best transport route by considering the length, width, height and weight of the truck with the machine loaded on it.

• Never abruptly start or stop or run at a high speed at the sharp curves during transport. Doing so will move or lose the balance of the loaded machine.

1-25

Safety

PRECAUTIONS ON MAINTENANCE

Display a “DO NOT OPERATE” alert sign

Severe injury could result if an unauthorized person should start the engine or touch controls during inspection or maintenance.

• Before performing maintenance, stop the engine, remove the key and take it with you.

• Display a “DO NOT OPERATE” alert sign on easy-to-see locations such as on the starter switch or on control levers.

Use the correct tools

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-critical parts” for

further details.

Explosionproof lighting

To prevent an ignition or explosion, use explosion-proof lights when inspecting fuel, oil, coolant or battery ﬂuid. Otherwise, explosion could result causing serious injury or death.

Do not use damaged or weakened tools or tools designed for other purposes. Use tools appropriate for the work involved.

1-26

Safety

PRECAUTIONS ON MAINTENANCE

Prohibit access by unauthorized persons

Do not allow unauthorized personnel in the work area while working. Be careful when grinding, welding or using a hammer. You could be injured by ﬂying debris from the machine.

Prepare work area

• Select a ﬁrm, level work area. Make sure there is adequate light and, if indoors, ventilation.

• Clear obstacles and dangerous objects. Eliminate slippery areas.

Always keep the machine clean

• Clean the machine before performing maintenance.

• 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’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 be performed with the engine running, always work as a two person team communicating each other.

· One person must sit in the operator’s

seat so that he/she can immediately stop the engine when necessary. He/she must take care not 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.

1-27

Safety

PRECAUTIONS ON MAINTENANCE

Stay clear of the moving parts

• Stay clear of all rotating and moving parts. If a hand or tool becomes trapped in the rotating or moving part, serious injury or death could result.

• If a tool or other objects is dropped or inserted in the fan or fan belt, it will be ﬂown or cut in pieces. Do not drop or insert anything in the fan or fan belt.

Firmly secure the machine or any component that may fall

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 engine hood or cover when opened

Be sure to secure the engine hood or cover before working the inside. Do not keep the hood or cover open on a windy day or if the machine is parked on a slope.

Place heavy objects in a stable position

• Before performing maintenance or repairs under the machine, lower all moveable working equipment to the ground or in the lowermost position.

• Chock the tracks.

• If you must work beneath the raised machine or equipment, always 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.

When it is necessary 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 off unauthorized persons from the storage place for such object.

1-28

Safety

PRECAUTIONS ON MAINTENANCE

Cautions when refueling

• Do not smoke or permit open ﬂames while fueling or near fueling operations.

• 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.

• Do not ﬁll the fuel tank to capacity. Allow room for oil expansion.

• Clean up spilled fuel immediately.

• Securely tighten the fuel ﬁller cap. If the fuel cap is lost, replace it only with the genuine cap. Use of a non-approved cap without proper venting may result in pressurization of the tank.

• Never use fuel for cleaning.

• Use the correct grade of fuel for the operating season.

Be careful with hot and pressurized components

Stop the engine and allow the machine to cool down before performing maintenance.

• The engine, mufﬂer, radiator, hydraulic lines, sliding parts and many other parts of the machine are hot immediately after the engine is stopped. Touching these parts will cause burns.

• The engine coolant, hydraulic oil and other oils are also hot and under high pressure.

Be careful not to touch 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.

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.

1-29

Safety

PRECAUTIONS ON MAINTENANCE

Be careful with hot cooling systems

Do not remove the radiator cap or the drain plug when the cooling water is hot. Stop the engine and wait until the engine and the cooling water cool. Then, slowly loosen the radiator cap to release the internal pressure and remove it.

Be careful with oil internal pressure

Pressure is maintained in the hydraulic circuit long after the engine has been shut down.

• Completely relieve the internal pressure before performing maintenance work.

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 disconnecting hoses, stand to the side and loosen them slowly to gradually release the internal pressure before removing.

• Oil or plug may spurt out according to the pressure in the travel motor case. Loosen the plug slowly and release the internal pressure.

Be careful with debris when the hammer is being used

When using a hammer, pins may ﬂy out or metal particles may be scattered. This may lead to serious 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.

• The hydraulic oil is high enough pressure to penetrate the skin or eyes and cause serious injury, blindness or death. Remember that the hydraulic oil escaping from a small hole is almost invisible. When checking for leaks, wear protective goggle and thick gloves, and use a paperboard or plywood to keep your skin from oil spurting.

If oil penetrates the skin, it must be

surgically removed within a few hours by a doctor familiar with this type of injury.

1-30

Safety

AG7A086

PRECAUTIONS ON MAINTENANCE

Be careful with the high-pressure grease

In the track adjuster, the grease has been injected 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 turn.

• 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.

Handling of the accumulator

Be sure to handle the high-pressure nitrogen gas enclosed in the accumulator with care. If handled incorrectly, it could explode and cause serious injury. 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.

Never disassemble the track adjuster

There is a very strong spring contained in the track adjuster. If the track adjuster is accidentally disassembled, the spring can pop out, resulting in serious injury Never disassemble the track adjuster.

1-31

Safety

PRECAUTIONS ON MAINTENANCE

Disconnect the battery wiring

Disconnect the battery wiring before working on the electrical system or doing electric welding. Disconnect the negative (–) battery cable ﬁrst. When reconnecting, connect the negative (–) battery cable last.

Use caution when handling batteries

• Batteries contain sulfuric acid which will damage the eyes or skin in case of contact.

· 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 skin or clothing, wash off

immediately with a lot of water.

• Wear protective goggle and gloves when working with batteries.

• Batteries generate ﬂammable hydrogen gas which may explode. Keep away from ﬂame, sparks, ﬁre or lighted cigarettes.

• When checking the level of the battery ﬂuid, use a ﬂashlight.

• Be sure to stop 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 battery is frozen; otherwise it may explode. Warm the frozen battery to 15°C (60°F) before use.

• Do not use the battery when the ﬂuid level is below the lower level limit. Doing so will hasten the deterioration of the internal portions of the battery and shorten the battery life. It also can cause rupturing (explosion).

• Do not add the distilled water above 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.

• Use a dampened cloth to clean around the ﬂuid level line and check the ﬂuid level. Do not clean with a dry cloth; otherwise it could cause static electricity to build up, resulting in ignition or explosion.

1-32

Safety

PRECAUTIONS ON MAINTENANCE

Periodically replace the safety-critical parts

• To use the machine safely for a longer period, periodically add oil and perform inspection and maintenance. To improving the safely, replace the safety-critical parts like hoses and seat belts periodically. Refer to “Safety-critical parts to be replaced periodically” for further details.

• The “Safety-critical parts to be replaced periodically” are the parts which deteriorate, wear and fatigue after repeated use and whose properties change over time. While these characters of these parts could cause serious physical or personal damage, judging the remaining life of these part are difﬁcult from external inspection or the feeling when operating.

• Replace the “Safety-critical parts to be replaced periodically” if any defect is found from external inspection, even when they have not reached the time speciﬁed interval.

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 or to come in contact with the machine.

· When connecting, attach the positive

booster cable to the positive (+) terminals ﬁrst. When disconnecting, remove the negative cable from the negative (–) terminal (ground) ﬁrst.

· Be sure to connect the clips securely.

· Connect the last clip of the booster cable

to a point as far away from the battery as possible.

• Always wear the protective goggle and gloves when starting the engine by using the booster cables.

• Use the booster cables and clips of a size suited to the capacity of battery. Do not use damaged or corroded booster cables and clips.

• Be sure that the battery of the “rescue machine” has the same capacity as the battery of the “machine in trouble”.

1-33

Safety

PRECAUTIONS ON MAINTENANCE

Have a Takeuchi service agent repair welding

If welding must be performed, make sure that it is done by a qualiﬁed person in a properly equipped workplace. To prevent any part from breaking down or being damaged due to overcurrent or sparks, observe the following.

• Disconnect the wiring from the battery before doing electric welding.

• Do not continuously apply 200 V or more.

• The earth ground must be connected within one meter from the welding section. Do not connect the earth ground near to an electronically controlled device/ instrument or connectors.

• Make sure that there are no seals or bearings between the welding section and the earth ground.

• Do not connect the earth ground around the pins for the working equipment or hydraulic cylinders.

• When welding is to be done on the machine body, disconnect the connectors for the electronically controlled devices before working.

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/s seated part of the body is subjected to vibrations lower than 0.5 m/s

(8.2 ft/s2) while the

(1.64 ft/s2).

Disposing of wastes

• Always collect oil that is drained 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, coolant, solvent, ﬁlters and batteries.

Handling of poisonous chemicals

Poisonous chemicals will cause serious injury if directly contacted. Poisonous chemistry used in this machine includes grease, battery solution, coolant, paint and adhesive agent. Handle the poisonous chemicals properly with care.

Checks 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 the serviced parts.

• Operate each control lever and check that the machine is operating properly.

1-34

Safety

SAFETY SIGNS (DECALS)

For the safety of the operator and the personnel working around the site, safety signs (decals) are placed at certain locations on the machine as shown below. Walk around the machine with this manual, and check the content and location of these safety 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 replenished, a new sign must be attached to the new part/unit.

1-35

Safety

SAFETY SIGNS (DECALS)

1-36

Safety

SAFETY SIGNS (DECALS)

1-37

Safety

SAFETY SIGNS (DECALS)

1-38

Safety

SAFETY SIGNS (DECALS)

1-39

1-40

CONTROLS

2-1

Controls

NAMES OF COMPONENTS (CAB)

Upperstructure

1. Cab

2. Seat

3. Engine hood

4. Fuel tank

5. Hydraulic tank

Undercarriage

6. Crawler belt

7. Idler

8. Track roller

9. Shoe slide

10. Travel motor

2-2

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

Controls

NAMES OF COMPONENTS (CAB)

1. Instrument cluster

2. Starter switch

3. Blade lever

4. Throttle lever

5. Safety lock lever

6. Right operating lever

7. Horn button

8. Selector lever

9. Boom swing pedal

10. Travel lever/Pedal

*: Subject to the speciﬁcations or optional products selected

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

2-3

Controls

NAMES OF COMPONENTS (CANOPY)

Upperstructure

1. Canopy

2. Seat

3. Engine hood

4. Fuel tank

5. Hydraulic tank

Undercarriage

6. Crawler belt

7. Idler

8. Track roller

9. Shoe slide

10. Travel motor

2-4

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

Controls

NAMES OF COMPONENTS (CANOPY)

1. Instrument cluster

2. Starter switch

3. Blade lever

4. Throttle lever

5. Safety lock lever

6. Right operating lever

7. Horn button

8. Selector lever

9. Boom swing pedal

*: Subject to the speciﬁcations or optional products selected

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*

2-5

Controls

COVERS

STARTER KEY

The starter key is used to start and stop the engine, as well as to lock and unlock the following components:

• Fuel lid

• Manual storage compartment

• Engine hood

• Covers

MAINTENANCE COVER

When opening 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 lock the maintenance cover (1).

2-6

Controls

COVERS

FUSE BOX

This box is used to protect the electric system from overcurrent.

Opening

1. Pull the 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.

2-7

Controls

COVERS

FUEL LID

When opening and closing the fuel lid, be careful not to get your hands caught by the lid.

For adding fuel, open this cover.

Opening

1. Insert the starter key and turn it counterclockwise to unlock the fuel lid (1).

Closing

1. Close the fuel lid (1).

2. Insert the starter key and turn it clockwise 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

remove it.

Closing

1. Turn the fuel cap (1) it clockwise and close

it.

2. Close the fuel lid and lock it.

2-8

Controls

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).

ENGINE HOOD

• Before opening the engine hood, be sure to stop the engine. If a hand or tool becomes trapped in the rotating or moving part, serious injury could result.

• When opening or closing the engine hood, be careful not to get your hands or other parts of your body caught by it.

Opening

1. Insert the starter key and turn it

counterclockwise to unlock the engine hood (1).

2. Push in the key hole (2) with your thumb

and open the engine hood (1).

2. Fully open the side cover (1) and secure it with the stay (2)

Closing

1. Support the side cover (1) by hand and release the stay (2).

2. Close the side cover (1).

3. Insert the starter key and turn it clockwise to lock the side cover (1).

Closing

1. Close the engine hood (1) and press down the edge of it until a click is heard.

2-9

Controls

CAB

CAB DOOR

When getting on or off the cab, ﬁrst open the door all the way until it is secured in the catch and check that it does not move.

Open the door fully and press it against the catch at the back of the door to secure it in place. The door must be locked when getting on or off the machine and while in operation.

Locking and unlocking

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 machines with a front guard)

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).

If you should become trapped inside the cab, open the front window to get out.

2-10

Controls

CAB

FRONT WINDOW

• Grasp the handles ﬁrmly with both hands when opening and closing the front window. Your head or hands may get caught if it slips from your hands.

• When the front window is opened or closed, it will come close to the head. Be careful that the window does not strike the head.

• When you open the front window, be sure to lock it in place with the lock pins on the left and right sides. The window may fall if it is not locked in place.

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

Opening

1. Park on a level surface 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.

When closing the front window slowly so as not to hit your head. Lowering the window abruptly may result injury or damage the front window.

1. Grasp the left and right handles (1) and press the knobs (2) with your thumb to release the lock.

2. Pull down the front window (3) and while doing so, slide it to the front and slowly lower it.

2-11

Controls

AG7B019

CAB

3. Release your thumb from the knobs (2) and then press the front window toward front and lock the front window with lock pin (4).

LOWER FRONT WINDOW

Removing

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 a click is heard, and then secure the window by turning the lock screw (7) clockwise.

1. Open the front window and stow it in the ceiling.

2. Slowly lift the lower front window (4).

3. Hold the glass ﬁrmly, place it through the guides (5) at the rear, and then set it on the supports (6) to fasten it in place.

2-12

Controls

CAB

EMERGENCY HAMMER (OPTIONAL)

An emergency 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 slip on the glass.

2-13

Controls

SEAT AND SEAT BELT

SEAT (IF EQUIPPED)

Adjust and secure the seat.

AD6B017

(A) Adjusting the backrest angle

1. Sit up and sit back in the seat.

2. Set the backrest to the desired angle by turning the handle (1).

(B) Fore-and-aft adjustment

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.)

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 weight operator

Lower ...... Heavy weight operator

2-14

Controls

SEAT AND SEAT BELT

HIGH-BACK SEAT (IF EQUIPPED)

Adjust and secure the seat.

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 currently set weight, ﬁrst turn the handle (3) as far as it goes to cancel the setting, then readjust.

(A) Adjusting the backrest

1. Sit up and sit back in the seat.

2. Pull up the lever (1), recline the backrest by using the spring force. Release the lever (1) at the desired angle to secure the backrest.

(B) Fore-and-aft adjustment

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 150mm

(5.9in.)

2-15

Controls

SEAT AND SEAT BELT

SEAT BELT

Be sure to fasten the seat belt securely before starting the engine.

Fastening the seat belt

1. Adjust the seat to the desired position for operation, sit up and sit back in the seat.

2. Pull the seat belt to the desired length.

3. Make sure that the belt is not twisted and then insert the tongue plate (A) into the buckle (B) of the seat belt until 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 retracts back into its original

position.

2-16

MEMO

2-17

Controls

INSTRUMENT CLUSTER

Once the starter switch is turned to ON, all lamps on the instrument cluster light up. Then, the battery charge warning lamp (3) and the engine emergency lamp (1) start ﬂashing. The machine system is normal if the lamps turn off after the engine is started. If any lamp is not lit when the starter switch is turned to ON, there is something wrong in the machine. Consult your sales or service dealer.

WARNING LAMPS

IMPORTANT: If a warning 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 while the engine is running.

3. Battery charge warning lamp

This lamp ﬂashes and an alarm is sounded

if a problem rises in the charging system while the engine is running.

4. Coolant temperature warning lamp

This lamp ﬂashes and an alarm is sounded

if the engine coolant temperature becomes abnormally high while the engine is running.

2-18

Controls

INSTRUMENT CLUSTER

5. Fuel level warning lamp

This lamp turns on if the fuel level

becomes low while the starter switch is in the ON position.

INDICATORS

6. Glow lamp

This lamp goes out when the engine

preheating is completed.

7. Travel speed lamp

This lamp turns on when the travel speed

button is set to the 2nd (high) speed.

METERS

8. Water temperature 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.

2-19

Controls

INSTRUMENT CLUSTER

MULTI-DATA DISPLAY

10. LCD (liquid crystal display)

It displays various data on hour meter,

trip meter and the machine.

Home screen

1. Key function display

The key function display changes

depending on the screens (Home, Menu and each setting)

For actual operation, use the buttons,

“A”, “B” and “C”, located beneath each symbol. Refer to “Operating each key” on pages 2-20 to 2-25.

2. Hour meter/Trip meter

• Hour meter

Displays the total engine running time

in hours.

The rightmost digit indicates tenths of

hours (6 minutes).

Set the inspection and maintenance

intervals according to the time displayed on the hour meter.

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 installed.

6. Highland mode indicator lamp (If equipped)

When the highland mode is selected This mode is used to reduce the

engine load due to the hydraulic pump. When the machine is operated at a high-altitude site, the engine output is decreased due to thin air. In such cases, the hydraulic horse power is automatically adjusted to prevent the engine from stalling. The machine automatically enters this mode if the altitude detected by the bolometric sensor is 800 m (2622 ft) or more.

7. Lift overload warning indicator lamp

This lamp turns on when the lift

overload warning switch is turned on.

• Trip meter Three patterns of desired operating

hours can be displayed.

Refer to “Trip meter display” on page

2-21.

3. Time display

Displays the time set. Refer to “Time setting” on page 2-24.

2-20

Controls

INSTRUMENT CLUSTER

FUNCTION OF EACH KEY

The functions are as below in the Home screen. The different functions appear in the other screens.

A. Stopping alarm

Pressing the (A) key stops alarm.

B. Work light/meter switching

· Pressing the (B) 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

4. Trip meter 3

5. Returns to the hour meter

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”.

3. Trip meter 2

2-21

Controls

INSTRUMENT CLUSTER

MENU SCREEN

Press the (A) key to proceed to the screen selected by the bar. Press the (B) key to move the selection bar. 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.

2-22

Controls

INSTRUMENT CLUSTER

DATA SCREEN (DATA)

Press the (A) key to proceed to the screen selected by the bar. Press the (B) key to move the selection bar. Press the (C) key to return to the Menu screen.

• Trip meter (TRIP METER) for maintenance

The trip meters for the engine oil,

hydraulic oil or coolant are displayed.

• Coolant temperature (WATER TEMP)

Displays the coolant temperature in

Celsius °C or Fahrenheit °F.

Press the (C) key to return to the Data

screen.

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.

2-23

Controls

INSTRUMENT CLUSTER

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 Home

screen can be set here.

a. When the selection bar is at CLOCK,

press the (A) key to proceed to the time setting screen (CLOCK SET).

b. Pressing the (A) key in this screen moves

the selection bar and ﬂashes the ﬁgures on the bar.

Setting range: hours, 1 to 24; minutes,

00 to 59

c. Press the (B) key to increase the number

value selected.

Press and hold the (B) key to rapidly

increase the number value selected.

d. Press and hold the (A) key for at least

two seconds to complete the setting and to return to the Setting Selection screen.

e. Press the (C) key cancels editing and to

return to the Setting Selection screen.

• Alarm setting (ALARM)

Five patterns of alarm setting are

available.

Alarm function can be set to on or off

within the ﬁve patterns.

a. When the selection bar is at ALARM,

press the (A) key to proceed to the alarm setting screen (ALARM SET).

b. Press the (A) key in this screen to place

a checkmark in the box at the left of the setting bar. Press the (A) key again to remove the checkmark.

The alarm setting cannot be changed

only by placing or removing a checkmark.

c. Press and hold the (A) key for at least

two seconds to complete the setting and to return to the Setting Selection screen.

Be sure to perform the above operation

when you wish to set the alarm.

A clock symbol is displayed on the

Home screen.

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

2-24

Controls

INSTRUMENT CLUSTER

• Alarm time setting mode

Sets the time for alarm.

a. Select the item to be set in the alarm

setting screen (ALARM SET).

b. Press and hold the (B) key for at least

three seconds to enter the alarm time setting mode.

c. Press the (A) key in this screen to move

the selection bar and to ﬂash the ﬁgures on the bar.

Setting range: hours, 1 to 24; minutes,

00 to 59

d. Press the (B) key to increase the number

value selected.

Press and hold the (B) key to rapidly

increase the number value selected.

e. Press and hold the (A) key for at least

two seconds to complete the setting and to return to 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 bar reaches the right end

(highest contrast), it returns to the left end (lowest contrast).

c. Press and hold the (A) key for at least

three seconds to complete the setting and to return to the Setting Selection screen.

d. Press the (C) key to cancel editing and

to return to the Setting Selection screen.

The changes made to the setting are

reﬂected, but they will be removed when the starter switch is turned off.

2-25

Controls

SWITCHES

STARTER SWITCH

IMPORTANT: Do not repeatedly switch the key from OFF to ON and ON to OFF over a short period. Doing so will cause engine breakdown.

OFF ......... Position for stopping the engine

and inserting or removing the key.

ON .......... Position in which the engine 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 the travel speed to 2nd (high) speed. Press it again to return to 1st (low) speed.

2-26

Controls

SWITCHES

WIPER SWITCH

IMPORTANT: If no washer ﬂuid is discharged, do not operate the washer. Doing so may damage the pump. IMPORTANT: Operating the wiper with no moisture on the windshield will scratch the glass. Use water or washer 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 hydraulic switch and button” on page 2-44.

2-27

Controls

SWITCHES

OVERLOAD WARNING SWITCH (IF EQUIPPED)

If the overload is not removed after the overload warning 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

2-28

Controls

LEVERS AND PEDALS

SAFETY LOCK LEVER

• Before standing up from the operator’s seat to, for example, adjust the operator’s seat, lower the working equipment to the ground, raise the safety lock levers to engage the lock and stop the engine. If any controls should be accidentally touched when the safety lock levers is lowered (unlocked), the machine will suddenly move and cause serious injury or death.

• Note that the dozer blade, boom swing and auxiliary hydraulic controls cannot be locked, even when the safety lock lever is set to the locked position.

Do not carelessly touch these controls.

• Be careful not to touch the operating levers when raising or lowering the safety lock lever.

THROTTLE LEVER

This controls the engine speed.

(A) .......Low idling

(B) ......Maximum speed

This device is for locking the hoe attachment, slewing and traveling. When the lever is raised, the lever stand springs up and the controls are locked.

2-29

Controls

LEVERS AND PEDALS

OPERATING LEVERS

• Before starting operation, carefully check which lever pattern you are going to use.

• It is described using the ISO 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

Use this lever to operate the dozer blade.

(A) .......Blade up

(B) ......Blade down

Refer to “Operating the dozer blade” on page 3-17.

2-30

Controls

AD6B031

AD6B032

LEVERS AND PEDALS

TRAVEL LEVERS/PEDALS

• Before operating the travel levers/ 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.

• Do not rest your foot on the pedal unless operating it for traveling. If the pedal is accidentally stepped while working, the machine may suddenly move and cause serious injury or death.

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.

B A

Use this pedal to operate the boom swing.

(A) .......Boom swing right

(B) ......Boom swing left

Refer to “Operating the boom swing” on page 3-17.

Pedal lock

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.

Set the pedal cover over the pedal to lock it. Open the pedal cover from the pedal to unlock it.

2-31

Controls

AD6B033

AD6B032

LEVERS AND PEDALS

AUXILIARY HYDRAULIC 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.

This pedal controls the ﬂow of the oil in the auxiliary hydraulic circuit.

(A) .......Hydraulic oil ﬂows to left auxiliary

hose.

(B) ......Hydraulic oil ﬂows to right auxiliary

hose. Refer to “Auxiliary hydraulic lines” on page 2-42.

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 crawler width by moving the blade lever while depressing this lever.

Pedal lock

Set the pedal cover over the pedal to lock it. Open the pedal cover from the pedal to unlock it.

2-32

MEMO

2-33

Controls

ACCESSORIES

HEATER

• Always be sure to allow sufﬁcient ventilation.

• Do not place combustible or explosive objects near the air outlets.

Heater fan switch

............ Low

Neutral .... OFF

............ High

Outlets

Move the louver up and down or left and right to adjust the air ﬂow direction and amount.

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.

2-34

Controls

ACCESSORIES

Heater valve

Coolant circulates in the heater even when the heater switch is turned off. When the heater is no longer needed, stop coolant circulation as follows.

IMPORTANT: Use the valve (1) either fully open 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 the air ﬁlters” on page 5-39.

2-35

Controls

ACCESSORIES

CUP HOLDER

• Drinks may be spilled due to vibration when the machine is operating or traveling. Be particularly careful not to burn yourself with hot drinks.

• Note that the cigarette lighter or other 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 a better rear view.

2-36

Controls

ACCESSORIES

POWER SOCKETS

Use only those electric products which comply with the speciﬁcations of these sockets.

For beacon

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.

Use these sockets to connect the power supply. When using, be careful not to exceed 12V/5A. To use, open the cap (1).

2-37

Controls

ACCESSORIES

RADIO (FOR CAB)

CAUTIONS ON USE

• To ensure safe operation of the machine, always be sure to keep the volume of the radio down to a level where you can easily hear sounds from outside the machine.

• Do not use the radio for a long time when the engine is stopped. Doing so will drain the battery and make it difﬁcult or impossible to restart the engine.

• Be careful not to allow water or other liquids to come into contact with the radio. Otherwise, it may result in malfunction.

NAMES OF COMPONENTS

(1) POWER button

Use this button too turn on or off the

radio.

(2) LCD

Displays the time/the receiving frequency

and 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 to 6).

(5) Tuning button (TUNE

Press and hold this button (

one second or more to start seeking the receivable stations. The seeking stops when a station is found. To cancel tuning halfway, press the button again.

Pressing the TUNE button

seeking stations with higher frequency. Pressing the TUNE button seeking stations with lower frequency. The frequency changes as either button is pressed in one second intervals.

2-38

)

starts

or ) for

Controls

ACCESSORIES

(6) Preset buttons (1 to 6) (PRESET

STATION)

Each button can store three FM stations

(FM1, FM2, FM3) and one MW (AM) station. For how to set these buttons, refer to “Presetting stations”.

(7) Band button (BAND)

Pressing this button changes the band

from FM1 to FM2, FM3 and MW (AM) in this order. The received band and its frequency appear on the display.

(8) VOL buttons

Use these buttons to control the sound

volume. Press the button the volume and the button decrease the sound volume. Press and hold each button to continuously increase/decrease the volume.

(9) Clock zero set button (ZERO)

Use this button to set the minute to “00”

when it is between “55” to “59” or “01” to “05”.

The LCD returns to the frequency display

if no more operation is performed for ﬁve seconds.

(10) Auxiliary input select button (AUX)

Pressing this button changes the input

source to the external device connected to the AUX-IN (13) jack. The display of “AUX” appears on the LCD. Pressing the button again returns to the radio.

to increase

(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 press the power button (1) to turn on the radio.

2. Select the band, FM or MW (AM) by pressing the BAND button.

3. Select the station with the preset button or the tuning button, and adjust the volume with the volume button.

4. To turn off the radio, press the power button.

Selecting a station-auto select

Press and hold the TUNE button second or more to start seeking stations in the higher frequencies direction. Press and hold the TUNE button more to start seeking stations in the lower frequencies direction. The radio will stop seeking when it ﬁnds an receivable station and start playing.

Selecting a station-manual select

The selection can be done manually. Press the tune higher frequencies. Press the tune to seek stations with lower frequencies.

button to seek stations with

for one second or

for one

button

2-39

Controls

ACCESSORIES

Presetting stations

1. Press the BAND button to select a band (MW (AM) or FM), and then select the station by pressing the TUNE button for seeking.

2. To assign the selected station to a preset button, press and hold the button to be assigned for one second or more. The number of the preset button appears on the LCD.

3. For more stations to preset, repeat the steps (1) and (2) above.

• If the preset button on which a station

has been assigned is pressed and held for one second or more, the preset information will be modiﬁed.

• If the stored information is erased during

battery replacement on the vehicle, assign the stations again to the preset buttons.

• Each preset button can store three FM

stations (one from each FM1, FM2, FM3) and one AM station.

Auto storing (AST)

Press the AST button while playing the radio. The radio automatically starts seeking the receivable stations within the band currently selected and assign each preset button (1 to

6) a station.

Note: The previous 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 listen to an external portable audio player, press the AUX button. (The “AUX” display appears on the LCD and the frequency display is changed to the clock display.)

• To return to the radio, press the AUX button again.

• When connecting, adjust the sound volume level of the audio player so that it is same as that of the radio.

• Adjust the sound volume of the audio player by using the volume control buttons on the radio.

• Do not connect a device with a larger output compared with a portable audio player.

Setting the clock

• If a frequency is displayed on the LCD, press the AUX button (auxiliary input) to display the clock.

• Use the tune Use the tune

• To set the minute digits to “00” when they are from “55” to “59” or from “01” to “05”, press the ZERO button.

2-40

button to set the minute. button to set the hour.

Controls

ACCESSORIES

Resetting

If there are any problems, such as the abnormal display of frequency or failure of selection, reset the radio by pressing the “4” button while pressing the AST button and the AUX button together. Then, “JP” and the clock display appear on the LCD, indicating that the radio is turned off. Note that the memory stored in the preset button is cleared.

SPECIFICATIONS

Power source: .... 12/24 VDC (negative

ground) Maximum power consumption:

........................... 3A or less (at max. volume,

24 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 (North, Central and

South America) Practical sensitivity:

........................... MW (AM) 32 dB or less

(S/N 20 dB) FM 12 dB or less (S/N 30

dB)

S/N ratio: ............ MW (AM) 40 dB or more

FM 50 dB or more

AUX-IN: .............. Stereo mini jack (3.5 mm);

rated input, 90 mV; 20 kΩ

impedance

Note: Speciﬁcations and dimensions may be changed without notice.

2-41

Controls

ACCESSORIES

AUXILIARY HYDRAULIC LINES

First / second auxiliary hydraulic lines (If equipped)

Third auxiliary hydraulic lines (If equipped)

Oil may spurt out if pipes disconnected before 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

2-42

Controls

ACCESSORIES

hydraulic oil tank.

• When disconnecting hoses, stand to the side and loosen them slowly to gradually release the internal pressure before removing.

These lines deliver the hydraulic oil necessary for operating a hydraulic breaker, crusher or other attachments.

(1) .......First auxiliary hydraulic lines

(2) .......Second auxiliary hydraulic lines

(3) .......Third auxiliary hydraulic lines

Stop valve (S) : Closed (O) : Open

Connecting the hydraulic circuits

To connect the attachment hydraulic lines, observe the following procedures:

1. Release the pressure remaining in the

lines, and then close the stop valve.

Refer to “Releasing the residual pressure”

on page 2-43.

2. Remove the plugs.

3. Connect the attachment hydraulic lines to

ports (a/c) and (b/d). When installing a hydraulic breaker, connect the supply circuit to the port (a) and the return circuit to port (b).

4. Open the stop valves. When installing a

hydraulic breaker, open the selector valve (1). Refer to “Selector valve (Option)” on page 2-44.

5. When connecting is complete, purge air

from the hydraulic lines. 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 attachment manufacturer, if applicable.

6. Check for oil leaks.

Disconnecting the hydraulic circuits

1. Release the pressure remaining in the lines, and then close the stop valve.

Refer to “Releasing the residual pressure”

on page 2-43.

2. Disconnect the lines from the ports (a/c) and (b/d).

3. Install the plugs.

Operating

AD6B033

Press this pedal to control the ﬂow of the oil in the auxiliary hydraulic lines.

(A) .......Hydraulic oil ﬂows to left auxiliary line

(a).

(B) ......Hydraulic oil ﬂows to right auxiliary line

(b).

Releasing the residual pressure

After the auxiliary hydraulic circuits have been used, pressure remains in the circuits. This is called the residual pressure. Release this residual pressure before disconnecting the lines.

1. When the engine is stopped, depress the auxiliary hydraulic pedals from side to side several times.

2-43

Controls

ACCESSORIES

Selector valve (Option)

Open ....... When using a hydraulic breaker

(1-way ﬂow)

Closed ..... When using a reversible

attachment (2-way ﬂow) Change the direction of the hydraulic oil ﬂow by opening or closing the selector valve (1) on the machine body.

Second auxiliary hydraulic switch

Slider switch (Proportional control) Proportional control allows for slow-to-fast/ fast-to-slow movement of attachment. Example: If you move the slider switch half way, the attachment will move at approximately one-half the speed.

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 increase and to prevent the pin inserted on the bucket from coming out. If the pressure in the (e) side drops, the alert that the bucket may come out is indicated by the warning lamp and the alarm. For a safety reason, the bucket can be disconnected only when the button (1) and the switch (2) are pressed at the same time. When they are pressed, the hydraulic oil ﬂows into the line (f) to increase the pressure there. As the result, the pin on the bucket comes out and the bucket is removed from the machine.

Move this switch to control the ﬂow of the oil in the second auxiliary hydraulic lines.

(C): .... Hydraulic oil ﬂows to the left auxiliary line (c).

(D): .... Hydraulic oil ﬂows to the right auxiliary line (d).

Releasing the residual pressure

Refer to “Accumulator” on page 2-46.

2-44

Controls

AD6C013

AD6C014

ACCESSORIES

Adjusting the stroke of auxiliary hydraulic pedal

When a breaker is used, the pedal stroke must be adjusted so as not to activate the right auxiliary hydraulic line even if the B side of the pedal is accidentally depressed. When a general attachment is used, the pedal stroke must be readjusted. Adjust it so that the right auxiliary hydraulic line is activated when the B side of the pedal is depressed.

When using a hydraulic breaker (1-way ﬂow)

Make sure that the auxiliary hydraulic

1. 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 of the auxiliary hydraulic pedal to the stroke end and hold its position.

3. Loosen the adjustment bolt (2) until it touches the pedal.

4. Fasten the lock nut (1) to secure the adjustment bolt (2).

2-45

Controls

ACCESSORIES

ACCUMULATOR (IF EQUIPPED)

Operating the machine with an accumulator

Be sure to handle the high-pressure nitrogen gas enclosed in the accumulator with care. If handled incorrectly, it could explode and cause serious injury. 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.

6. Move the auxiliary 2nd switch several times to release the residual pressure in the circuitry. (If equipped)

7. Move all the control levers and pedals several times in all directions to release the pressure from the working equipment circuitry.

8. Raise the safety lock lever to engage the lock.

For a machine with an accumulator, the residual pressure in the auxiliary hydraulic circuit or the working equipment circuit can be released even after the engine is stopped.

Releasing residual pressure

Residual pressure refers to the pressure that remains in the hydraulic circuit after the operation. Release the residual pressure as necessary by using the following steps. Perform the residual pressure releasing within 10 minutes after the engine stopping.

1. Return the throttle lever to idle the engine at low speed.

2. Lower the bucket and dozer blade to the ground.

3. Check that the safety lock lever is in the released position.

4. Stop the engine.

5. Turn the starter switch to the ON position.

Lowering the boom when the engine has stopped

Perform this operation within 10 minutes after the engine stopping.

1. Check that the safety lock lever is in the released position.

2. Check that the starter switch is in the ON position.

3. Slowly push the operating lever forward to lower the boom.

2-46

OPERATION

3-1

OperatiOn

BEFORE STARTING OPERATION

GETTING ON OR OFF THE MACHINE

• Do not jump on or down from the machine. Never attempt to get on or off the moving machine.

• When getting on or off the cab, ﬁrst fully open the door to the locked position and check that it does not move.

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 once a day before starting the engine for the ﬁrst time. Refer to “MAINTENANCE, Daily inspection”, on pages 5-18 to 5-23.

• Climb up/down the 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.

3-2

OperatiOn

STARTING AND STOPPING THE ENGINE

BEFORE STARTING THE ENGINE

1. Adjust the seat for a comfortable operating position.

2. Fasten the seat belt.

3. Check that the safety lock lever is in the locked position.

5. Insert the key into the starter switch, turn it to the ON position, 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 meter lights turn on.

If a lamp does not light or the alarm is not sounded, the bulb may be burnt out or a wire may be damaged. Ask a Takeuchi service agent for repair.

AD6D003

4. Check that all levers and pedals are in the neutral position.

3-3

OperatiOn

STARTING AND STOPPING THE ENGINE

STARTING THE ENGINE

• Clear all personnel from the work area.

• Sound the horn to warn people around the machine.

IMPORTANT: Do not run the starter motor for more than 15 consecutive seconds. If the engine fails to start, wait for 30 seconds, and then try again to start the engine.

Normal starting

1. Pull the throttle lever to the middle

position.

Starting in cold climates

Never use starting ﬂuid on this engine, as the starting ﬂuid could cause an explosion.

1. Pull the throttle lever to the middle position.

2. Turn the starter key to the START position and start the engine.

3. Once the engine starts, release the key. The key automatically returns to the ON position.

4. Check that the warning lamps are off.

5. Return the throttle lever and warm up the engine.

Refer to “Warming up the engine” on page

3-5.

2. Turn 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 lever and warm up the engine.

Refer to “Warming up the engine”.

3-4

Takeuchi TB216, 216000002, 216100002 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

SAFETY ALERT SYMBOL

SIGNAL WORDS

INTRODUCTION

FOREWORD

MANUAL STORAGE COMPARTMENT

SERIAL NUMBERS

MACHINE DESCRIPTION

FRONT, REAR, LEFT AND RIGHT

DESIGNATED OPERATIONS

FEATURES

BREAK-IN PERIOD

NOTES ON READING THIS MANUAL

SAFETY

GENERAL PRECAUTIONS

PRECAUTIONS WHEN PREPARING

PRECAUTIONS WHEN STARTING

PRECAUTIONS WHEN OPERATING

PRECAUTIONS WHEN STOPPING

PRECAUTIONS WHEN TRANSPORTING

PRECAUTIONS ON MAINTENANCE

SAFETY SIGNS (DECALS)

CONTROLS

NAMES OF COMPONENTS (CAB)

NAMES OF COMPONENTS (CANOPY)

COVERS

STARTER KEY

MAINTENANCE COVER

FUSE BOX

TOOL CASE

GREASE GUN HOLDER

FUEL LID

FUEL FILLER PORT

SIDE COVER

ENGINE HOOD

CAB DOOR

EMERGENCY EXIT

FRONT WINDOW

LOWER FRONT WINDOW

SIDE WINDOW

EMERGENCY HAMMER (OPTIONAL)

SEAT AND SEAT BELT

SEAT (IF EQUIPPED)

HIGH-BACK SEAT (IF EQUIPPED)

SEAT BELT

INSTRUMENT CLUSTER

WARNING LAMPS

INDICATORS

METERS

MULTI-DATA DISPLAY

SWITCHES

STARTER SWITCH

HORN BUTTON

TRAVEL SPEED SWITCH

WIPER SWITCH

SECOND AUXILIARY HYDRAULIC SWITCH

THIRD AUXILIARY HYDRAULIC SWITCH AND BUTTON

OVERLOAD WARNING SWITCH (IF EQUIPPED)

LEVERS AND PEDALS

SAFETY LOCK LEVER

THROTTLE LEVER

OPERATING LEVERS

BLADE LEVER

TRAVEL LEVERS/PEDALS

BOOM SWING PEDAL

AUXILIARY HYDRAULIC PEDAL

SELECTOR LEVER

ACCESSORIES

HEATER

CUP HOLDER

INTERIOR LIGHT

INSIDE REAR VIEW MIRROR (CAB)

POWER SOCKETS

ARMREST

RADIO (FOR CAB)

AUXILIARY HYDRAULIC LINES

ACCUMULATOR (IF EQUIPPED)