Takeuchi TB108 Operator Manual

Download

TB10 8

Compact Excavator

Serial No. 10820001~ Book No. AB5E009

OPERA TOR’S MANUAL

W ARNING

Read and understand these instructions. Failure to do so can cause injury or death.

SAFETY ALERT SYMBOL

This symbol means Attention! Be Alert! Your Safety Is Involved. 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 following sections.

■ 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.

CAUTION

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 provide this manual to the next owner.

■ Takeuchi supplies machines complying to 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.

■ Please note that the contents and diagrams included in this manual may not match your machine exactly.

It is your responsibility to observe all pertinent laws and regulations and to follow the manufacturer’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. An accident can often be avoided by recognizing potentially hazardous situations beforehand. Read and understand all of the safety messages which explain how to prevent these accidents from occurring. Do not operate the machine until you are sure that you have gained a proper understanding of its operation, inspection and maintenance.

■ SlGNAL 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 WARNING CAUTION

The word “DANGER” indicates an imminently hazardous situation which, if not avoided, can result in serious injury or death.

IMPORT ANT: The word “IMPORTANT” is used to alert against operators and maintenance personnel about situations which can result in possible damage to the machine and its components.

The word “WARNING” indicates a potentially hazardous situation which, if not avoided, could result in serious injury or death.

The word “CAUTlON” indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

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. Y ou 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.

■ EXPLANA TION OF GRAPHICAL SYMBOLS

Following is an explanation of symbols used in this manual.

/ X......... prohibition

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

......... Unlock

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

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

B5A001

■ Serial numbers

Check the serial numbers of the machine and the engine and write them in the spaces provided below.

Machine number :

B5A002

Engine number :

MACHINE DESCRIPTlON

■ Front, rear, Ieft 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

Use this machine primarily for the following operations:

¡ Excavating ¡ Digging ditches ¡ Digging side ditches ¡ Leveling ¡ Loading

■ Features

¡ Short pitch rubber crawler ¡ Low engine noise and exhaust emissions ¡ Fast working speed and low-shock working equipment ¡ Excellent stability thanks to a low center of gravity

■ Break-in period

When is new, heed the instructions below when operating the machine for the first 100 hours (as indicated on the hour meter). Using a new machine roughly without breaking it in will lead to quicker deterioration of machine performance and may shorten the machine’s service life.

¡ Warm up the engine and hydraulic oil sufficiently. ¡ Avoid heavy loads and rapid operations. Operate with a load of about 80% the maximum

load.

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

Introduction .................................... 2

Machine Description ...................... 3

Safety.............................................. 7

Controls .........................................35

Operation.......................................51

Transport .......................................81

Maintenance ..................................85

Troubleshooting ..........................125

Specifications..............................135

Options ........................................149

Index ............................................161

SAFETY

General precautions ....................................8

Preparing precautions ...............................12

Starting precautions .................................. 14

Operating precautions...............................16

Stopping precautions ................................ 23

Transporting precautions .......................... 24

Maintenance precautions ..........................25

Safety signs (decals) ................................. 32

SAFETY

General Precautions

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.

Wear appropriate clothing and personal protective equipment

¡ Do not wear loose clothing or any

accessory that can catch on controls or in moving parts.

¡ Do not wear oily or fuel stained clothing

that can 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.

SAFETY

General Precautions

Provide a fire extinguisher and first aid kit

¡ Know where a fire extinguisher and first

aid kit are located and understand how to use them.

¡ Know how to contact emergency

assistance and first aid help.

Never remove safety equipment

¡ Make sure all protective guards, canopies,

doors, etc., are in place and secure. Repair or replace damaged components before operating the machine.

Use a signal person and flagman

Know and 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 shall respond to signals only

from the appointed signal person, but shall obey a stop signal at any time from anyone.

¡ The signal person must stand in a clearly

visible location when giving signals.

¡ 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 service. Keep all safety equipment in good operating condition.

SAFETY

General Precautions

Be sure to lock the safety lock lever before leaving the operator’s seat

¡ Before leaving the operator’s seat, raise

the safety lock lever to engage the lock and stop the engine. If any controls should be touched accidentally when the safety lock lever is lowered, the machine will move suddenly, and cause serious injury or death.

¡ Note that the dozer blade, boom swing

and auxiliary hydraulics controls are not locked, even when the safety lock lever is set to the lock position. Do not touch these controls accidentally.

¡ Before leaving the operator’s seat, lower

the working equipment, raise the safety lock lever, and stop the engine. Also, be sure to remove the key and take it with you.

Avoid fire and explosion hazards

Keep flames away from fuel, hydraulic fluid, 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

fueling or near fueling operations.

¡ Never remove the fuel cap or refuel with

the engine running or hot. Never allow fuel to spill on hot machine components.

¡ Clean up spilled fuel, oil or other

flammable fluids immediately.

¡ Check for fuel, oil or hydraulic fluid leaks.

Stop all leaks and clean the machine before operating.

¡ 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

according to procedures identified on manufacturers’ containers. Work in a wellventilated area.

¡ Never use fuel for cleaning purposes.

Always use a nonflammable solvent.

¡ Store all flammable fluids and materials

in a safe and well-ventilated place.

SAFETY

General Precautions

Exhaust fumes from the engine can kill

¡ Do not operate the engine in an enclosed

area without adequate ventilation.

¡ If natural ventilation is poor, install

ventilators, fans, exhaust extension pipes or other artificial venting devices.

Handling asbestos dust

Inhaling asbestos dust has been linked to lung cancer. When handling materials which may contain asbestos, take the following precautions:

¡ Never use compressed air for cleaning. ¡ Avoid brushing or grinding of the materials. ¡ For clean up, use wet methods or a

vacuum equipped with a high efficiency particulate air (HEP A) filter.

¡ Wear an approved respirator if there is no

other way to control the dust. When working indoors, install a ventilation system with a macro molecular filter.

Be careful not to get crushed or cut

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

Using optional products

¡ Consult with a Takeuchi dealer before

installing optional attachments.

¡ Do not use attachments that have not

been approved by T akeuchi or a Takeuchi dealer. 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 of 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.

SAFETY

Preparing Precautions

Know the working area

Before starting operation, know the working area to ensure safety. ¡ Check the topography and ground

condition of the working area, or the structure of the building when working indoors, and take the necessary safety measures in dangerous spots.

¡ Note and avoid all hazards and

obstructions such as ditches, underground lines, trees, cliffs, overhead electrical wires or areas where there is danger of a slide.

¡ Check with the local utilities for the

locations of buried gas and water pipes and buried power cables. Determine jointly what specific precautions must be taken to insure safety.

¡ When working on roads, be sure to take

into account the safety of pedestrians and vehicles.

• Use a flagman and/or signals.

• Fence off the working area and prohibit

entry to 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 speed of the current beforehand. Make sure the water is not deeper than the allowable depth.

Refer to the section titled “Cautions on Operating” for further instructions.

Alway keep the machine clean

¡ Clean windows, mirrors and lights to

ensure good visibility .

¡ Wipe off any oil, grease, mud, snow or

ice, to prevent accidents due to slipping.

¡ Remove all loose objects stored in the

machine and all objects which do not belong in or on the machine and its equipment.

¡ Remove any dirt, oil or grease from the

engine area, to prevent fires.

¡ Clean the area around the operator’s seat,

removing any potential obstacles.

SAFETY

Preparing Precautions

Perform inspection and maintenance daily

Failure to notice or repair machine irregularities or damage can lead to accidents. ¡ Before operating, perform the prescribed

inspections and make repairs immediately should any irregularities be found.

¡ If a failure that causes loss of control such

as steering, service brakes or engine occurs, stop the machine motion as quickly as possible, follow the shutdown procedure, and keep machine securely parked until the malfunction is corrected.

SAFETY

Starting Precautions

Maintain three point contact when mounting and dismounting

¡ Do not jump on or off the machine. Never

attempt to mount or dismount a moving machine.

¡ When mounting and dismounting the cab,

first open the door fully to the locked position and check that it does not move. (For machines with cabs)

¡ Always face the access system and

maintain a three point contact with the recommended handrails and steps while getting on and off the machine. Keep steps and platform clean.

¡ Never use the safety lock lever or control

levers as hand holds.

Clear the area of other persons before starting the machine

Do not start the engine until you are sure it is safe. Before starting, check or perform the following. ¡ Walk around the machine and warn all

personnel who may be servicing the machine or are in the machine path. Do not start until all personnel are clearly away from the machine.

¡ Check for any “DO NOT OPERATE” tags

or similar warning notices on the cab door, controls or starter switch.

¡ Sound horn to alert everyone around the

machine.

Start the engine from the operator’s seat

¡ Adjust, secure and latch the operator’s

seat.

¡ Fasten the seat belt. ¡ Check that the parking device is applied

and place all controls in the neutral position.

¡ Check that the safety lock lever is in the

lock position.

¡ Clear the area of all persons. ¡ Start and operate the engine from the

operator’s seat only.

¡ Never attempt to start the engine by

shorting across the starter terminals.

SAFETY

Starting Precautions

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 the section titled “If the Battery Goes Dead” for proper instructions.

After starting the engine

In cold weather

¡ Be careful of slippery conditions on

freezing ground, steps and hand holds.

¡ In severe cold weather, do not touch any

metal parts of the machine with exposed flesh, as flesh can freeze to the metal and Cause injury.

¡ Do not use ether or starting fluids on this

engine. These starting aids can cause explosion and serious injury or death.

¡ Warm up the engine and hydraulic fluid

before operating.

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

¡ Warm up the engine and hydraulic fluid. ¡ Observe all gauges or warning

instruments for proper operation.

¡ Listen for unusual noises. ¡ Test engine speed control. ¡ Operate each control to insure proper

operation.

SAFETY

Operating Precautions

Ensure good visibility

¡ When working in dark places, turn on the

machine’s working lights and headlights and/or provide extra stationary lighting if necessary.

¡ When visibility is poor due to severe

weather (fog, snow or rain), stop operating the machine and wait until conditions improves.

Do not permit riders on the machine

Check for safety in the surrounding area before starting

¡ Understand the machine limitations. ¡ Use a signal person where clearances are

close or your vision is obstructed.

¡ Never allow anyone to enter the slewing

(swing) radius and machine path.

¡ Signal your intention to move by sounding

the horn.

¡ There are blind spots to the rear of the

machine. If necessary, swing the cab around before backing up to check that the area is safe and clear.

¡ Do not allow anyone to ride on any part of

the machine at any time while traveling.

¡ Do not allow anyone to be on any part of

the machine while operating.

SAFETY

Operating Precautions

Check the position of the undercarriage (tracks) before traveling

Before operating the travel levers, check to make sure that the dozer blade is to the front of the operator’s seat. BE A WARE that when the dozer blade is to the rear of the operator’s seat, the travel levers operate in the opposite direction to when the dozer blade is in the front.

Fully extend the crawler width when operating

Travel safety

(12 to 16 in.)

¡ Travel with the dozer blade up, the hoe

attachment folded as shown on the diagram, and the bucket raised 30 to 40 cm (12 to 16 in.) from the ground.

¡ Do not slew (swing) while traveling. If you

must operate the hoe attachment while traveling, operate at speeds slow enough so you have complete control at all times.

Always operate the machine with the crawler width at the maximum to increase machine stability. The smaller the crawler width, the greater the possibility the machine can tip over. If it is absolutely necessary to operate the machine with a narrow crawler width, do so with great care.

E4A040

¡ Avoid crossing over obstacles whenever

possible. If you must do so, keep the hoe attachment close to the ground and travel slowly. Never cross obstacles if they will seriously tilt the machine (to an angle of 10° or greater).

¡ On uneven ground, travel at low speed

and avoid accelerating, stopping or changing directions abruptly.

¡ When roading a machine, know and use

the signaling devices required on the machine. Provide an escort for road travel when required.

SAFETY

Operating Precautions

Cautions on traveling on slopes

When traveling on slopes or grades, be careful that the machine does not tip (roll) over or slide. ¡ Never exceed the machine’s stability

capabilities (maximum gradeability - 25°, lateral tipping angle - 10°). Also note that when actual working area conditions are poor the machine’s stability capabilities may be lower.

¡ Do not change directions or cross slopes

sideways. First return to a flat surface then redirect the machine.

¡ When traveling on slopes or grades, lower

the bucket to a height of 20 to 30 cm (8 to 12 in.) off the ground. In emergencies, lower the bucket to the ground and stop the machine.

¡ When traveling on slopes or grades, move

slowly in first gear (low speed).

¡ Do not travel down slopes in reverse. ¡ On grass, dead leaves, wet metal or

frozen surfaces, the machine may slide sideways even on very gentle slopes. Make sure the machine never faces sideways with respect to the slope.

Operate on snow or ice with extra care

¡ When traveling on snow or frozen

surfaces, keep the machine travel speed down and avoid accelerating, stopping or changing directions abruptly .

¡ Remember that the road shoulder , fences,

etc., may be buried in the snow and not visible.

¡ Lower the dozer blade when parked on

unsure ground conditions.

SAFETY

Operating Precautions

Insure driver safety before loading trucks

Do not load a truck unless the driver is in a safe place. ¡ Never swing or position the bucket over

personnel or truck cabs.

¡ Load the truck from the rear.

Keep a safe distance from electrical power lines

¡ Maintain the maximum possible distance

from power lines and never violate the minimum clearance.

¡ Always contact the nearest electric utility

and determine jointly what specific precautions must be taken to insure safety.

¡ Consider all lines to be power lines and

treat all power lines as energized even though it is known or believed that the power is shut off and the line is visibly grounded.

¡ Use a signal person to observe the

approach of any part of the machine or load to the power line.

¡ Caution all ground personnel to stand

clear of the machine and the load at all times.

¡ If the machine should come in contact with

a live electrical source, do not leave the operator’s seat. Do not allow anyone to approach or touch the machine.

Never approach power lines with any part of the machine and its load unless all local and national required safety precautions have been taken. Electrocution and death can result from arcing, touching or even being close to a machine that is in contact with or near an electrical source.

¡ Be especially careful of buried high voltage

power lines.

SAFETY

Operating Precautions

Watch out for hazardous working conditions

¡ Never undercut a high bank. Be

particularly alert for the possibility of a cave-in.

¡ Do not operate in places where there is a

danger of falling rocks.

¡ Keep machine well back from the edge of

an excavation. Avoid undercutting the machine.

• The ground is weak after rain or explosions.

• The ground is also unstable on banks and near dugout trenches.

Operating on slopes is dangerous

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

Fill

¡ Do not approach unstable surfaces (cliffs,

road shoulders, deep trenches, etc.). The ground may give way under the machine’s weight or vibrations, causing the machine to tip over.

¡ Level off the work area.

¡ Avoid swinging the loaded bucket in a

downhill direction. This will reduce the stability of the machine.

SAFETY

Operating Precautions

Never slew (swing) sideways with excessive weights

The machine can tip over more easily in the lateral direction than in the longitudinal direction. ¡ Do not slew (swing) sideways with

excessive weight at the front. In particular do not slew sideways on slopes.

¡ The front is heavier for machines equipped

with breakers, crushers or telescopic arms than for machines equipped with the standard bucket. Do not operate such machines sideways especially with the digging arm (boom) downhill.

Watch boom clearance

When operating under bridges, in tunnels, near power lines or indoors, be careful not to hit the boom or arm against overhead objects.

Excavators are not designed for lifting loads

The machine is specifically designed for excavation work and has no safety devices for crane operation. Extreme caution should be used 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 based on the

machine being level and on a firm supporting surface. For safe working loads, the user is expected to make due allowance for the particular job conditions such as soft or uneven ground, non-level condition, side loads, dynamic or jerked loads, hazardous conditions, experience of personnel, etc. 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.

¡ Failure of the bucket linkage or slings

could result if chains or slings are incorrectly attached, resulting in serious injury or death.

¡ Do not attempt to pull stumps out of the

ground while using the machine as a crane. The loads imposed on the machine under this use are completely unknown.

¡ Never allow any personnel to stand on or

under lifted loads or even within the maneuvering area.

SAFETY

Operating Precautions

Danger of flying objects

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

Cautions on T owing

N0A006

When towing, selecting the wrong wire rope, inspecting improperly, or towing in the wrong way could lead to accidents resulting in serious injury or death. ¡ The wire rope breaking or coming

detached could be extremely dangerous. Use a wire rope suited for the required towing force.

¡ Do not use a wire rope that is kinked,

twisted or otherwise damaged.

¡ Do not apply strong loads abruptly to the

wire rope.

¡ Use 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 near the wire rope while

towing.

SAFETY

Stopping Precautions

Park safely

E3A4901

¡ Park the machine on firm, level ground and

apply the parking device.

¡ When parking on streets, use barriers,

caution signs, lights, etc., so that the machine can easily be seen even at night to avoid collision with other vehicles.

¡ Before leaving the machine, do the

following:

1. Set the slew lock lever to the locked position.

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

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

4. Stop the engine and remove the key.

5. Lock the engine hood and the tool box (option).

SAFETY

Transporting Precautions

Load and unload the machine safely

Fasten to the suspension fitting

Ramp

Stopper

Distance between ramps

The machine may roll or tip over or fall while loading or unloading it. Take the following precautions: ¡ Select a firm, level surface and keep

sufficient distance from road shoulders.

¡ Use loading ramps of adequate strength

and size. Maintain the slope of loading ramps within 15 degrees.

¡ Secure the ramps to the truck bed. ¡ Keep the truck bed and loading ramps

clean of oil, clay, ice, snow, and other materials which can become slippery. Clean the tracks.

¡ Block the transport vehicle so it can not

move.

¡ Use a signal person when loading and

unloading the machine, and travel slowly in first gear (low speed).

¡ Never change course on the ramp. ¡ Do not slew (swing) on ramps. The

machine may tip over.

¡ When slewing (swinging) on the truck bed,

do so slowly as the footing can be unstable.

¡ Engage the slew (swing) lock after loading. ¡ Block both tracks and secure the machine

to the truck bed with load binders.

15° or less

E4F001

Lifting the machine safely

¡ Know and use correct crane signals. ¡ Inspect the lifting equipment daily for

damaged or missing parts.

¡ Keep all other persons out of the area

when lifting. Do not move the machine over the heads of ther persons.

¡ Do not lift the machine with an operator(s)

on it.

¡ When lifting, use a wire rope with sufficient

strength with respect to the machine’s weight.

¡ Do not lift with the machine in a posture

other than the one described in the procedure below. Doing so is dangerous as it may result in the machine losing its balance. Refer to page 152 “Lifting the Machine”.

Transport the machine safely

¡ Know and follow the safety rules, vehicle

code and traffic laws when transporting the machine.

¡ Consider the length, width, height and

weight of the truck with the machine loaded on it when determining the best route.

SAFETY

Maintenance Precautions

Attach a “DO NOT OPERA TE” tag

Severe injury could result if an unauthorized person should start the engine or touch controls during inspection or maintenance. ¡ Stop the engine and remove the key

before performing maintenance.

¡ Attach a “DO NOT OPERATE” tag to the

starter switch or control lever.

Use the correct tools

Do not use damaged or weakened tools or tools designed for other purposes. Use tools suited for the operation at hand.

Anti-explosive lighting

Use anti-explosive electrical fixtures and lights when inspecting fuel, oil, coolant, battery fluid, etc. If lighting that is not antiexplosive should break, the substance could ignite, resulting in serious injury or death.

Do not allow unauthorized personnel in the work area

Replace important safety parts periodically

¡ Replace fuel hoses periodically. Fuel

hoses become weaker over time, even if they appear to be in good shape.

¡ Replace important safety parts whenever

an irregularity is found, even if it is before the normal time for replacement. Refer to the section titled “Important Parts” for further details.

Do not allow unauthorized personnel in the work area. Chips or other debris can fly off machine parts when grinding, welding or using a hammer.

SAFETY

Maintenance Precautions

Prepare the 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 clean the machine

Stop the engine before performing maintenance

¡ Avoid lubrication or mechanical

adjustments with the machine in motion or with the engine running while stationary.

¡ If maintenance must be performed with

the engine running, always work as a twoperson team with one person ready to shut off the engine immediately while the other works on the machine.

• When performing maintenance, be sure to keep your body and clothing away from moving parts.

Stay clear of moving parts

¡ Clean the machine before performing

maintenance.

¡ Stop the engine and cover electrical parts

when washing the machine. Water on electrical parts could cause short-circuits or malfunctions. Do not use water or steam to wash the battery, sensors, connectors or the operator’s seat area.

¡ Stay clear of all rotating and moving parts.

Wrapping or entanglement may result in serious injury or death.

¡ Keep hands, clothing and tools away from

the rotating fan and running fan belts.

SAFETY

Maintenance Precautions

Securely block the machine or any component that may fall

¡ Before performing maintenance or repairs

under the machine, set all working equipment against the ground or in the lowermost position.

¡ Securely block 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.

Cautions on opening the engine hood

¡ Opening the engine hood while the engine

is running may cause serious injury or death. Stop the engine before opening the engine hood.

¡ Be sure to secure the engine hood when

opening it. Do not open the engine hood on slopes or in strong wind.

Place heavy objects in a stable position

Securely block the working equipment

To prevent unexpected movement, securely block the working equipment when repairing or replacing the cutting edges or bucket teeth.

When removing or installing the hoe attachment, place it in a stable position so that it does not tip over.

SAFETY

Maintenance Precautions

Use caution when fueling

¡ Do not smoke or permit open flames while

fueling or near fueling operations.

¡ Never remove the fuel cap or refuel with

the engine running or hot. Never allow fuel to spill on hot machine components.

¡ Maintain control of the fuel filler nozzle

when filling the tank.

¡ Do not fill the fuel tank to capacity. Allow

room for expansion.

¡ Clean up spilled fuel immediately. ¡ Tighten the fuel tank cap securely. Should

the fuel cap be lost, replace it only with the original manufacturer’s approved cap. Use of a non-approved cap without proper venting may result in pressurization of the tank.

¡ Never use fuel for cleaning purposes. ¡ Use the correct fuel grade for the operating

season.

Be careful with hot and pressurized components

Stop the engine and allow the machine to cool down before performing inspection and maintenance. ¡ The engine, muffler, radiator, hydraulic

lines, sliding parts and many other parts of the machine are hot directly after the engine is stopped. Touching these parts will cause burns.

¡ The engine coolant, oil and hydraulic fluid

are also hot and under high pressure. Be careful when loosening caps and plugs. Working on the machine under these conditions could result in burns or injuries due to the hot oil spurting out.

Be careful with hot cooling systems

Handling of hoses

Fuel, oil or hydraulic fluid leaks can cause a fire.

¡ Do not twist, bend or hit the hoses. ¡ Never use twisted, bent or cracked hoses,

tubes and pipes. They may burst.

¡ Retighten loose connections.

Do not remove the radiator cap or drain plugs when the coolant is hot. Stop the engine, let the engine and radiator cool and loosen the radiator cap or drain plugs slowly.

SAFETY

Maintenance Precautions

Be careful with fluids under pressure

Pressure can be maintained in the hydraulic circuit long after the engine has been shut down. ¡ Release all pressure before working on

the hydraulic system.

¡ Hydraulic fluid under pressure can

penetrate the skin or eyes and cause injury , blindness or death. Fluid escaping from a small hole can be almost invisible. Wear a safety goggles and heavy gloves and use a piece of cardboard or wood to search for suspected leaks. If fluid is injected into the skin, it must be removed within a few hours by a doctor familiar with this type of injury .

Release all pressure before working on the hydraulic system

Oil may spurt out if caps or filters are removed or pipes disconnected before releasing the pressure in the hydraulic system. ¡ Gradually loosen the vent plug to relieve

tank pressure.

¡ Move all the control levers and pedals

several times in all directions to release the pressure from the working equipment circuitry. (For link type controls)

¡ When removing plugs or screws or

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

Be careful with grease under pressure

E3A6201

The track adjuster contains highly pressurized grease. If the tension is adjusted without following the prescribed procedure, the grease discharge valve may fly off, resulting in injury.

¡ Do not loosen the grease nipple. ¡ Loosen the grease discharge valve slowly . ¡ Do not put your face, arms, legs or body

in front of the grease discharge valve.

¡ If no grease is expelled when grease

discharge valve is loosened, there is a problem. Contact your nearest service outlet for repairs. DO NOT disassemble, as this is very dangerous.

SAFETY

Maintenance Precautions

Disconnect the battery

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

Avoid battery hazards

¡ Batteries contain sulfuric acid which will

damage eyes or skin on contact.

• If acid contacts eyes, flush immediately with clean water and get prompt medical attention.

• If acid is accidentally swallowed, drink large quantities of water or milk and call a physician immediately .

• If acid contacts skin or clothing, wash off immediately with clean water .

¡ Wear safety glasses and gloves when

working with batteries.

¡ Batteries generate flammable and

explosive gases. Keep arcs, sparks, flames and lighted tobacco away.

¡ Use a flashlight to check battery electrolyte

level.

¡ Stop the engine and shut off electrical

equipment while inspecting or handling the battery .

¡ Do not short circuit the battery posts with

metal items.

¡ Always unfasten the negative (–) battery

cable first when disconnecting the battery cable. Always connect the negative (–) battery cable last when fastening the battery cable.

¡ Loose battery terminals may result in

sparks. Be sure to fasten terminals tightly.

¡ Make sure the vent caps are tightened

securely.

¡ Do not charge a battery or jump-start the

engine if the battery is frozen. Warm to 15°C (60°F) or the battery may explode.

¡ Do not use the battery when the fluid level

is below the lower level. Doing so will hasten the deterioration of the internal portions of the battery and shorten the battery life, and can also cause rupturing (or an explosion).

¡ Do not fill the battery above the upper

level. Doing so could cause the fluid to leak, contact and damage the skin, or cause parts to corrode.

SAFETY

Maintenance Precautions

Have a T akeuchi service agent repair welding cracks or other damage

Ask a Takeuchi service agent to repair any welding problems which are detected. If not feasible, make sure the welding is done by a qualified person in a properly equipped workplace.

Checks after maintenance

¡ Gradually raise the engine speed from a

low idle to maximum speed and check that no oil or water is leaking from serviced parts.

¡ Move the controls and check that the

machine is operating properly.

Disposing of wastes

¡ Funnel spent fluids from the machine into

containers. Disposing of fluids improperly destroys the environment.

¡ Follow the prescribed regulations when

disposing of oil, fuel, engine coolant, refrigerant, solvents, filters, batteries or other harmful substances.

SAFETY

Safety Signs (decals)

The following safety signs (decals) have been placed on your machine in the areas indicated. They are intended for the personal safety of you, and those working with you. Please take this manual, walk around your machine and note the content and location of these safety signs. Review these signs and the operating instructions in this manual with your machine operators.

¡ Keep the signs legible. If they are not, obtain replacements from your Service outlet.

SAFETY

03593-32300

Check what type of lever control arrangement you are operating with before beginning operations.

WARNING

05693-21980

Engine may be HOT

WARNING

03593-47010

THIS EXCAVATOR

MUST NOT BE USED

AS A CRANE

WARNING

03593-47020

WHEN BUCKETS WIDER THAN STANDARD ARE FITTED TO THIS MACHINE, CAB(CANOPY)DAMAGE MAY OCCUR WHEN FULL LEFT HAND BOOM OFFSET IS USED.

Safety Signs (decals)

1. No.03593-06500

WARNING

DO NOT

enter into

swinging area

2. No.03393-79820

3. No.03593-13700

WARNING

1 -

This machine,if improperly operated or maintained can cause bodily harm,or even DEATH. Read and understand the owners manual

2 -

supplied with this machine before operating. Keep all safety devices in place and

3 -

functional. Do not operate the machine unless the seat

4 -

belt is properly fastened around you.

Follow the instructions in the Operator’s

5 -

Manual when hoisting the machine or fastening it to the transport vehicle.

5. No.03593-32300

6. No.03993-00500 Position of Hoisting

7. No.05693-21980

8. No.03593-47010

03593-13700

4. No.03593-07400

CAUTION

STOP ENGINE

BEFORE OPENING

9. No.03593-47020

03593-07400

SAFETY

Safety Signs (decals)

10. No.03393-68100

WARNING

WHEN BUCKETS WIDER THAN STANDARD ARE FITTED TO THIS MACHINE, CAB(CANOPY)DAMAGE MAY OCCUR WHEN FULL RIGHT HAND BOOM OFFSET IS USED.

11. No.03393-75040

CAUTION

DO NOT USE ETHER

USAGE OF ETHER FOR STARTING PURPOSES MAY CAUSE INTERNAL ENGINE DAMAGE.

12. No.03393-75050

CAUTION

HYDRAULIC TANK MUST REMAIN PRESSURIZED TO AVOID DAMAGE TO PUMPS.

03393-68100

03393-75040

03393-75050

13. No.03593-06600 Diesel Fuel

Diesel Fuel Only

14. No.03593-06700 Hydraulic oil

15. No.03293-64601 Noise Outside the Cab This value indicates the noise level outside the machine and refers to the noise perceived by the persons who are in the vicinity of the work area.

03593-06600

CONTROLS

Names of Components ..............................36

Doors and Covers ......................................38

Seat and Seat Belt......................................40

Instruments ................................................41

Switches .....................................................42

Levers and Pedals ..................................... 43

Accessories ...............................................47

CONTROLS

Names of Components

Upperstructure

1. Canopy

2. Seat

3. Engine hood

4. Fuel tank

5. Hydraulic tank

1514

16 18

20 21

Undercarriage

6. Crawler belt

7. Idler

8. Track roller

9. Shoe slide

10. Travel motor

Working equipment

11. Bucket

12. Bucket cylinder

13. Arm

14. Arm cylinder

15. Boom

16. Boom cylinder

17. Boom bracket

18. Swing cylinder

19. Auxiliary hydraulic line

20. Dozer blade

21. Blade cylinder

B5B001

CONTROLS

Names of Components

1. Instruments

2. Starter switch

3. Horn switch

4. Travel speed lever

5. Selector lever

6. Slew lock lever

7. Safety lock lever

8. Throttle lever

9. Left operating lever

10. Right operating lever

11. Boom swing pedal

12. Travel lever

13. Auxiliary pedal

14. Blade lever

B5B002E

CONTROLS

Doors and Covers

Starter Key

E4B003

The starter key is used not only to start and stop the engine, but also to lock and unlock the following places: ¡ Engine hood

Engine Hood

WARNING

¡¡

¡ Before opening the engine hood, be

¡¡

sure to stop the engine. If your hands or tools should get caught in the fan or fan belt while the engine is running they may be severed.

¡¡

¡ When leaving the engine hood open,

¡¡

be sure to lock it in place. Do not leave the engine hood open when there is a strong wind or when on slopes.

¡¡

¡ When opening and closing the engine

¡¡

hood, be careful not to get your hands or other parts of your body caught.

Opening

B5B020

1. Insert the starter key and turn it counterclockwise to unlock the engine hood.

1 2

B5B004

2. Lift the engine hood (1) fully.

3. Check that the engine hood is securely locked in place.

Closing

1. Support the engine hood by hand and pull the stay (2) to the front to unlock it.

2. Close the engine hood (1) and press it down until a click is heard at the front.

CONTROLS

Doors and Covers

Fuel Filler Cap

WARNING

¡¡

¡ Do not smoke or permit open flames

¡¡

while fueling or near fueling operations.

¡¡

¡ Supply fuel in a well ventilated place

¡¡

and with the engine stopped.

¡¡

¡ Clean up spilled fuel immediately.

¡¡ ¡¡

¡ Do not fill the fuel tank to capacity.

¡¡

Allow room for expansion.

¡¡

¡ Tighten the fuel filler cap securely.

¡¡

Opening and closing

1. Open the engine hood.

O : Open S : Closed

2. Turn the fuel filler cap (1).

B5B021

Manual Case (option)

B5A001

CONTROLS

Seat and Seat Belt

Seat

WARNING

Adjust, secure and latch the operator’s seat.

Fore-and-aft adjustment

B5B005

1. Pull on lever and slide the seat backward or forward to bring it to the optimum position for operating the machine.

2. Release the lever at the desired position and the seat will remain fixed there.

Seat Belt

CAUTION

Always fasten the seat belt securely before starting the engine.

Fastening the seat belt

1. Adjust the seat to the optimum position for operating, raise your torso, and sit back firmly into the seat.

2. Pull the seat belt to the desired length.

3. Make sure that the belt is not twisted and then insert the tongue plate (A) into the buckle (B) of the seat belt until you hear a clicking sound as it locks in place.

E4B023

Releasing the seat belt

1. T o remove the seat belt, simply press the button (C) located on the buckle. The seat belt is automatically stowed away.

E4B024

CONTROLS

Instruments

Warning Lamps

IMPORTANT: If a warning lamp lights, stop all operations immediately and inspect and maintain the appropriate part.

Refer to page 131 “Troubleshooting”.

1. Battery Charge Warning Lamp

This lamp lights if a problem arises in the charging system while the engine is

C4B030

running.

2. Engine Oil Pressure Warning Lamp

This lamp lights if the lubricant oil pressure drops abnormally while the engine

C4B031

is running.

HOURS

1/10

°C

B5B0061

Meters

3. Hour Meter

This displays the total engine running time in hours.

C4B016

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. Water Temperature Gauge

This indicates the

°C

the green range during machine operation. The red range indicates overheating.

temperature of the engine coolant.

B5B007

The needle should be within

CONTROLS

Switches

Starter Switch

PREHEAT

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.

PREHEA T.....Position for preheating the

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

ON................ Position in which the engine

START ..........Position for starting the

OFF

START

E4B010

engine. engine and inserting or

removing the key. is running. At this position, all

the electrical equipment is functional.

engine. When the key is released, the switch automatically returns to the ON position.

Horn Switch

B5B008

Press the switch on the right operating lever to blow the horn.

Boom Light

When the switch is depressed while the starter switch is at ON, the light turns on or off as follows:

O ...... Off

I ....... On

B5B009

CONTROLS

Levers and Pedals

Safety Lock Lever

WARNING

¡¡

¡ Before leaving the operator’s seat,

¡¡

raise the safety lock lever to engage the lock and stop the engine. If any controls should be touched accidentally when the safety lock lever is lowered, the machine will move suddenly, and cause serious injury or death.

¡¡

¡ Note that the dozer blade, boom swing

¡¡

and auxiliary hydraulics controls are not locked, even when the safety lock lever is set to the lock position. Do not touch these controls accidentally.

¡¡

¡ Be careful not to touch the operating

¡¡

levers when raising and lowering the safety lock lever.

B5B022

This device is for locking the hoe attachment, slewing and traveling. When the safty lock lever is raised, the operating and travel levers are locked.

Slew Lock Lever

WARNING

Engage the slew lock when traveling, parking or transporting the machine.

IMPORTANT: Do not try to slew when the slew lock lever is set to the locked position.

B5B010

Use this lever to lock the upperstructure so that it cannot slew.

¡ Turn the lever forward to unlock. ¡ When setting to the locked position,

always line up the upperstructure and undercarriage and turn the lever backward to lock.

¡ If the upperstructure and undercarriage

are not lined up, slewing will not be locked even if the lever is set to the locked position.

CONTROLS

Levers and Pedals

Throttle Lever

B5B011

This controls the engine speed.

(A) .... Low idling

(B) .... Maximum speed

Operating Levers

WARNING

¡¡

¡ Be careful to check which pattern of

¡¡

lever control arrangement you are operating with before beginning operations.

¡¡

¡ The explanations in this manual are for

¡¡

the ISO pattern.

Blade Lever

B5B013

Use this lever to operate the dozer blade and switch the crawler width.

(A) .... Blade up/narrow crawler width

(B) .... Blade down/wide crawler width

To change the crawler width, press the selector lever in before operating it. Refer to page 60 “Changing the Crawler Width”.

Travel Levers

WARNING

Before operating the travel levers, check to make sure that the dozer blade is to the front of the operator’s seat. BE AWARE that when the dozer blade is to the rear of the operator’s seat, the travel levers operate in the opposite direction to when the dozer blade is in the front.

B5B012

Use these levers to operate the boom, arm, bucket and upperstructure (slew). Refer to pages 56, 57 “Lever Pattern”. Refer to page 64 “Operating the Working Equipment”.

B5B015

Use these levers to move forward and backward and to change directions. Refer to page 61 “Operating the Travel Levers”.

CONTROLS

Levers and Pedals

Travel Speed Lever

CAUTION

It is not possible to change directions when traveling in 2nd (high) speed. To change directions, first release the travel speed lever to uncouple the travel levers.

B5B0161

The travel speed lever switches the machine travel speed.

(1)..... 1st (low) speed

(2)..... 2nd (high) speed

In 2nd speed, the left and right travel levers are coupled so only straight travel is possible.

Boom Swing Pedal

B5B017

Use this pedal to operate the boom swing.

(A) .... Boom swing right

(B) .... Boom swing left

Auxiliary Pedal

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

B5B018

CONTROLS

Levers and Pedals

Pedal Stopper

This is a device for fixing the auxiliary pedal to the operating status so that when using with a hand breaker, etc., connected to the auxiliary ports, the hand breaker can be turned on and off using it’s own switch.

1. Lift the pedal and press on the heel side (A).

2. Put the bolt (1) through the hole in the pedal to lock it.

B5B019

Selector Lever

Use this lever when changing the crawler width. This lever switches the operation of the blade and span cylinder.

1. To change the crawler width, move this lever to the right (S).

2. Move the blade lever and change the crawler width.

B5B0231

CONTROLS

Accessories

Auxiliary Hydraulic Lines

WARNING

Oil may spurt out if caps or filters are removed or pipes disconnected before releasing the pressure in the hydraulic system.

¡¡

¡ When removing plugs or

¡¡

disconnecting hoses, release the internal pressure before removing.

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

B5D023

S O

Connecting the Hydraulic Circuits

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

1. Move the auxiliary pedal several times to relieve pressure on the lines.

2. Make sure the stop valves are closed.

3. Remove the plugs.

4. Connect the attachment hydraulic lines to ports (a) and (b).

5. Open the stop valves.

6. When connecting is complete, purge air from the hydraulic lines. a. Start and run the engine at low idle with

no load for 10 minutes.

b. With the engine running at low idle

operate the auxiliary pedal repeatedly (approx. 10 times) to purge air from the hydraulic lines.

c. Stop the engine and wait for more than

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 specified to do so.

7. Check for leaks.

Stop valve..... S : Closed O : Open

Before dismantling the attachment, move the auxiliary pedal several times to relieve pressure on the lines and be sure to close the stop valves.

B5C004

CONTROLS

Accessories

External Power Socket (for EU)

WARNING

Only use applicable electric products with this socket.

B5C007

Use this socket as an external power supply. To use, raise the cap (1).

CONTROLS

Accessories

The operating pattern of the left and right operating levers can be changed.

WARNING

Be careful to check which pattern of lever control arrangement you are operating with before beginning operations.

ISO

JCB

Switching the Lever Pattern

(A) : ISO pattern (G): JCB pattern

1. Remove the lower mount section of the boots and turn them upwards.

2. Loosen the bolts and remove the cover.

C4L004

3. Switch rod (2) to plate (3).

4. Switch rod (4) to plate (5).

5. Set the boots and cover back as they were.

6. Check the lever pattern.

OPERATION

Before Starting Operation ......................... 52

Starting and Stopping the Engine............. 53

Machine Operation.....................................56

Operating Procedures ...............................67

Parking the Machine ..................................75

Handling in Cold Weather..........................76

Handling Rubber Crawlers ........................ 77

OPERATION

Before Starting Operation

Mounting and Dismounting

WARNING

¡¡

¡Do not jump on or off the machine.

¡¡

Never attempt to mount or dismount a moving machine.

¡¡

¡When mounting and dismounting the

¡¡

cab, first open the door fully to the locked position and check that it does not move. (For machines with cabs)

B5D0011

¡¡

¡Always face the access system and

¡¡

maintain a three point contact with the recommended handrails and steps while getting on and off the machine. Keep steps and platform clean.

¡¡

¡Never use the safety lock lever or

¡¡

control levers as hand holds.

Walk-Around Inspection

Perform the walk-around inspections before starting the engine the first time that day . Perform the inspections as described under “Maintenance - Walk-Around Inspection” (pages 95 and 96).

Daily Inspection

Perform the daily inspections once a day before starting the engine the first time that day. Perform the inspections as described under “Maintenance - Daily Inspection” (pages 97 to 101).

OPERATION

Starting and Stopping the Engine

Before Starting the Engine

1. Adjust the seat for a comfortable operating position.

2. Fasten your seatbelt.

B5B003

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

B5D002

HOURS

1/10

°C

B5D0032

¡The battery charge warning lamp (1)

and engine oil pressure warning lamp (2) light, and the meters also start functioning.

If a lamp does not light, the bulb may be burnt out or a wire may be damaged. Contact a Takeuchi sales or service outlet for repairs.

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

OFF

PREHEAT

START

E4D002

5. Insert the key into the starter switch, turn it to the ON position, then perform the following inspection:

OPERATION

Starting and Stopping the Engine

Starting the Engine

WARNING

¡¡

¡Clear the area of all persons.

¡¡ ¡¡

¡Sound horn to alert everyone around

¡¡

the machine.

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

Normal Starting

B5D004

1. Pull the throttle lever to the middle position.

OFF

PREHEAT

START

E4D005

Starting in Cold Weather

B5D004

1. Pull the throttle lever to the middle speed position.

OFF

PREHEAT

START

E4D060

2. Turn the key to the PREHEA T position and hold it there about 3 seconds.

3. Turn the key to the START position and start the engine.

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

5. Return the throttle lever.

6. Check that the warning lamps are off.

7. Warm up the engine. Refer to page 55 “Warming Up the Engine”.

2. Turn the 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. Return the throttle lever.

5. Check that the warning lamps are off.

6. Warm up the engine. Refer to page 55 “Warming Up the Engine”.

OPERATION

Starting and Stopping the Engine

Warming Up the Engine

IMPORT ANT: Avoid racing the engine until it is warmed up. Do not warm up the engine for long periods of time (20 minutes or more).

B5D006

1. Return the throttle lever, then idle the engine and run it for about 5 minutes with no load.

Stopping the Engine

IMPORTANT: Do not stop the engine suddenly when operating with heavy loads or at maximum speed. Doing so may cause the engine to overheat or seize. Never bring the engine to a sudden stop except in the case of a true emergency.

B5D007

1. Idle the engine for about 5 minutes to gradually let it cool.

OFF

PREHEAT

START

2. Turn the key to the OFF position to stop the engine.

E4D007

OPERATION

Machine Operation

Lever Pattern (ISO Pattern)

WARNING

¡¡

¡Be careful to check which pattern of lever control arrangement you are operating

¡¡

with before beginning operations.

¡¡

¡The explanations in this manual are for the ISO pattern.

¡¡

〈〈

〉〉

〈ISO

〉

〈〈

〉〉

Left Crawler Forward

Left Crawler Reverse

Arm Out

Arm In

Upperstructure Slew Left

Upperstructure Slew Right

Boom Swing Left

Boom Swing Right

B5D008

Right Crawler Forward

Right Crawler Reverse

Boom Lower

Boom Raise

Bucket Load

Bucket Dump

Dozer Blade Lower

Dozer Blade Raise

OPERATION

Machine Operation

Lever Pattern (JCB Pattern)

WARNING

¡¡

¡Be careful to check which pattern of lever control arrangement you are operating

¡¡

with before beginning operations.

¡¡

¡The explanations in this manual are for the ISO pattern.

¡¡

〈〈

〉〉

〈JCB

〉

〈〈

〉〉

Left Crawler Forward

Left Crawler Reverse

Boom Lower

Boom Raise

Upperstructure Slew Left

Upperstructure Slew Right

Boom Swing Left

Boom Swing Right

B5D016

Right Crawler Forward

Right Crawler Reverse

Arm Out

Arm In

Bucket Load

Bucket Dump

Dozer Blade Lower

Dozer Blade Raise

OPERATION

Machine Operation

Warming Up the Machine (Hydraulic Oil)

WARNING

Operating the working equipment without warming up the machine (hydraulic oil) is dangerous, as response will be slow and the equipment may move in unexpected ways. Be sure to sufficiently warm up the machine.

IMPORTANT: Do not operate the levers suddenly when the hydraulic oil temperature is below 20 proper hydraulic oil temperature during operation is 50 to 80 if operations must be performed at lower temperatures, heat up the hydraulic oil to at least 20

°C (68°F).

Normal Warm-up

°C (68°F). The

°C (122 to 176°F), but

B5D009

2. Fully lower the safety lock lever to disengage the lock and lift the bucket from the ground.

G4D005

3. Extend and retract each of the cylinders several times with no load.

B5D004

1. Pull the throttle lever to the middle position, then run the engine at medium speed for about 5 minutes with no load.

B5B024

4. Set the slew lock lever to the released position before starting to slew.

OPERATION

Machine Operation

5. Slew slowly left and right several times.

6. Travel slowly forward and backward several times.

Warming Up in Cold Weather

1. Perform the normal warm-up procedure. Refer to the previous page.

Inspection After Warm-up

After warming up the engine and hydraulic oil, perform the checks and inspections described below, and repair if there is a problem.

HOURS

1/10

°C

B5D0101

1. Check that the warning lamps and meters are as follows:

¡Are all the warning lamps off? ¡Is the water temperature gauge’s

needle within the green range?

2. Check that there are no irregularities in the exhaust color, sound and vibrations.

E4D011

2. Set the bucket cylinder at the stroke end and keep it there. Do not do this for more than 30 seconds.

3. Repeat step 2 until the bucket operating speed is normal.

B5B003

3. Raise the safety lock lever to engage the lock and check that the operating and travel levers are locked.

OPERATION

Machine Operation

Changing the Crawler Width

WARNING

Perform these operations on a flat, solid surface with no obstacles in the way.

C4D016

1. Lift the machine body using the hoe attachment and dozer blade.

B5D011

3. Push the blade lever forward to extend crawler width. ¡a900mm (35.4 in.) If necessary, also replace the blade’s plates and use the dozer blade with the extended width.

B5D012

4. Pull the blade lever backward to retract crawler width. ¡a680mm (26.8 in.)

IMPORTANT: Always lift the body before changing the crawler width. Failure to do so can result in damage to the track frames and spanner cylinder.

B5B014

2. Move the selector lever to the right (S).

OPERATION

Machine Operation

Changing the Dozer blade width

B5D013

1. Pull out the lock pins (1).

B5D014

2.Turn the plate (2).

3.Secure the plate (2) with the lock pins (1).

Operating the Travel Levers

¡¡

¡Before operating the travel levers, check

¡¡

to make sure that the dozer blade is to the front of the operator’s seat. BE AWARE that when the dozer blade is to the rear of the operator’s seat, the travel levers operate in the opposite direction to when the dozer blade is in the front.

¡¡

¡Remove any obstacles in the

¡¡

machine’s path.

Traveling Forward and Backward

B5D005

1. Pull the throttle lever and increase the engine speed.

WARNING

¡¡

¡Never allow anyone to enter the

¡¡

slewing (swing) radius and machine path.

¡¡

¡Signal your intention to move by

¡¡

sounding the horn.

¡¡

¡There are blind spots to the rear of the

¡¡

machine. If necessary, slew the cab around before backing up to check that the area is safe and clear.

B5D009

2. Lower the safety lock lever to the released position.

OPERATION

Machine Operation

30~40cm

E4D014

3. Fold the hoe attachment and lower it to 30 to 40 cm(12 to 16 in.) above the ground.

4. Lift the dozer blade.

5. Operate the left and right travel levers as described below.

Traveling in 2nd (High) Speed

CAUTION

It is not possible to change directions when traveling in 2nd (high) speed. To change directions, first release the travel speed lever to uncouple the travel levers.

Neutral

E4D015

When the dozer blade is in front of the operator’s seat: aTo move forward:

Tilt the levers forward.

eTo move backward:

Tilt the levers backward.

Neutral

E4D016

When the dozer blade is behind the operator’s seat: aTo move forward:

Tilt the levers backward.

eTo move backward:

Tilt the levers forward.

B5D0241

1. Tilt the travel speed lever fully to the left and grasp the right travel lever with the same hand.

2. Tilt the levers forward or backward to travel straight in 2nd speed.

3. Release the travel speed lever to return to 1st (low) speed.

Pivot Turn

Neutral

E4D017

Turning to the left when stopped: aTo turn forward to the left:

Tilt the right lever forward.

eTo turn backward to the left:

Tilt the right lever backward.

To turn to the right, operate the left lever in the same way.

OPERATION

Machine Operation

Stopping Travel

Neutral

E4D018

Turning to the left while traveling: aTo turn left while traveling forward:

Set the left lever to neutral.

eTo turn left while traveling backward:

Set the left lever to neutral. To turn to the right while traveling, operate the right lever in the same way .

Spin T urn

Neutral

E4D019

aTo spin left:

Tilt the left lever backward and the right

lever forward. eTo spin right:

Tilt the right lever backward and the left

lever forward.

WARNING

¡¡

¡Park the machine on firm, level ground

¡¡

and apply the parking device. If you must park on a slope or incline, block the machine securely to prevent movement.

¡¡

¡If any controls should be touched

¡¡

accidentally when the safety lock lever is lowered, the machine will move suddenly, and cause serious injury or death.

¡¡

¡Note that the dozer blade, boom swing

¡¡

and auxiliary hydraulics controls are not locked, even when the safety lock lever is set to the lock position. Do not touch these controls accidentally.

CAUTION

Never bring the machine to a sudden stop except in the case of a true emergency. Stop as gently as possible.

NeutralNeutral

E4D020

1. Slowly set the left and right travel levers to the neutral position. The machine stops.

OPERATION

Machine Operation

Operating the Working Equipment

WARNING

¡¡

¡Be careful to check which pattern of

¡¡

lever control arrangement you are operating with before beginning operations.

¡¡

¡The explanations in this manual are for

¡¡

the ISO pattern.

B5D002

Use the right operating lever to operate the boom and bucket. Use the left operating lever to operate the arm and for slewing. Return the operating levers to the neutral position to stop the hoe attachments.

Slewing

WARNING

Check the surrounding area for safety before slewing.

B5D017

aTo slew left:

Tilt the left operating lever to the left.

eTo slew right:

Tilt the left operating lever to the right.

Operating the Boom

1. Set the safety lock lever to the released position.

2. Set the slew lock lever to the released position.

3. Set the pedals to the level position.

B5D018

aTo lower the boom:

Tilt the right operating lever forward.

eTo raise the boom:

Tilt the right operating lever backward.

OPERATION

Machine Operation

Operating the Arm

aTo contract the arm:

Tilt the left operating lever backward.

eTo extend the arm:

Tilt the left operating lever forward.

Operating the Bucket

aTo dig:

Tilt the right operating lever to the left.

eTo dump:

Tilt the right operating lever to the right.

B5D019

B5D020

Operating the Boom Swing

B5D015

aTo swing left:

Press the toe side of the pedal.

eTo swing right:

Press the heel side of the pedal.

Operating the Dozer Blade

B5D021

aTo lower the dozer blade:

Tilt the lever forward.

eTo raise the dozer blade:

Tilt the lever backward.

OPERATION

Machine Operation

Operating the Auxiliary Hydraulics

Use this to operate a breaker, crusher or other attachment.

B5D023

S O

B5C004

When the pedal is pressed, hydraulic oil is delivered to the auxiliary hose’s ports (a) and (b). aTo deliver hydraulic oil to port (a):

Press the heel side (A) of the pedal.

eTo deliver hydraulic oil to port (b):

Press the toe side (B) of the pedal.

Refer to page 47 “Auxiliary Hydraulic Lines”.

OPERATION

Operating Procedures

Prohibited Operations

WARNING

¡¡

¡Do not operate on base rock (hard or

¡¡

soft).

¡¡

¡Do not slew (swing) while traveling. If

¡¡

you must operate the hoe attachment while traveling, operate at speeds slow enough so you have complete control at all times.

Do not perform breaking or leveling operations using slew force

E4D029

Do not break down walls or level ground using slew force. Also, do not dig the bucket teeth into the ground during slewing. Doing so will damage the hoe attachment.

Be Gentle on the Hydraulic Cylinders

E4D031

Do not extend the hydraulic cylinders to the stroke ends. Operate them with leeway.

Do not support the machine body with the hoe attachment as it is lowering with the arm cylinder fully extended. Doing so concentrates the load on the arm cylinder and could damage the arm cylinder.

Do not Dig while Traveling

E4D030

Do not dig the bucket into the ground and use the traveling force to dig.

Do not Drive Piles with the Bucket or Dig with it Using Shock Force

E4D032

Doing so will shorten the service life of the hoe attachment. Use hydraulic force to dig.

OPERATION

Operating Procedures

Do not Perform Operations Using the Machine’s Dropping Force

E4D033

Putting excessive strain on the machine will shorten its service life. Use the hydraulic force of the cylinders and always dig with shallow, long strokes.

Digging Base Rock

Caution on Exposing the Dozer Blade to Shocks

E4D040

Hitting the dozer blade against rocks, etc., could damage the dozer blade or the blade cylinder.

Caution on Folding the Hoe Attachment

E4D041

Be careful not to hit the bucket or dozer blade when folding the hoe attachment.

E4D034

For hard base rock, break the rock up into small pieces with a breaker, etc., before digging. This prevents damage to the machine and is thus more economical in the end.

Do not use the Dozer Blade as an Outrigger

N0D009

OPERATION

Operating Procedures

Pay Attention to the Dozer Blade when Digging

E4D0431

When digging deeply with the dozer blade positioned at the front, be careful that the boom cylinder and bucket do not hit the dozer blade. Operate with the dozer blade at the rear whenever possible.

Caution on Digging Down with the Dozer Blade

Cautions on Operating

Cautions on Traveling

E4A040

Traveling over obstacles (rocks, stumps, etc.) may subject the body to strong shocks and result in damage. Avoid traveling over obstacles whenever possible. If you must do so, keep the hoe attachment near the ground, travel at low speed, and go over the obstacle at the center of the crawler.

Cautions on Traveling in 2nd (High) Speed

E4D044

This dozer blade is designed for simple earth pushing. Do not dig down deeply with the dozer blade. Doing so could damage the dozer blade and lower body .

E4D037

On uneven ground, travel at low speed and avoid accelerating, stopping or changing directions abruptly. Also, when traveling in 2nd speed, do so with the dozer blade at the front.

OPERATION

Operating Procedures

Cautions on Use in Water

E4D038

If you leave water at a sharp angle, the rear of the machine may be submerged, exposing the radiator fan to water and damaging them. Do not let the rear of the machine get submerged.

C4D014

¡Allowable water depth

In water, only use the machine up to a depth at which the water comes up to the middle of the shoe slide (1).

¡When greasing places used under water

for long periods of time, apply enough grease so that the old grease is expelled.

¡Never submerge the slew bearing or main

body in water or sand. If the slew bearing or main body should get submerged, contact a Takeuchi sales or service outlet for inspection.

Cautions on Traveling on Slopes

WARNING

¡¡

¡Never exceed the machine’s stability

¡¡

capabilities (maximum gradeability 25°, lateral tipping angle - 10°). Also note that when actual working area conditions are poor the machine’s stability capabilities may be lower.

¡¡

¡When traveling on slopes or grades,

¡¡

lower the bucket to a height of 20 to 30 cm (8 to 12 in.) off the ground. In emergencies, lower the bucket to the ground and stop the machine.

¡¡

¡When traveling on slopes or grades,

¡¡

move slowly in first gear (low speed).

¡¡

¡Do not travel down slopes in reverse.

¡¡

¡Do not change directions or cross

¡¡

slopes sideways. First return to a flat surface then redirect the machine.

¡¡

¡On grass, dead leaves, wet metal or

¡¡

frozen surfaces, the machine may slide sideways even on very gentle slopes. Make sure the machine never faces sideways with respect to the slope.

OPERATION

Operating Procedures

Traveling Posture Traveling up slopes

When traveling up slopes at an angle of 15° or greater, travel in the posture shown in the diagram above.

Traveling down slopes

When traveling down slopes at an angle of 15° or greater, lower the engine speed and travel in the posture shown in the diagram above.

Braking when traveling down slopes

Braking

E4D045E

When traveling down slopes, the brakes are applied automatically when the travel levers are returned to the neutral position.

If the crawlers slip

Climbing

E4D046

If the crawlers slip while traveling up a slope, use the pulling force of the arm to climb the slope.

If the engine stops

Descending

If the engine stops when traveling down a slope, set the travel levers to the neutral position, stop the machine, then start the engine.

E4D047E

OPERATION

Operating Procedures

Do not open the door while traveling on slopes

E4D048

Opening the door while traveling on slopes is dangerous, as the force required to open and close the door changes abruptly. Always keep the door closed when traveling on slopes.

Getting Out of Mud

If the machine gets stuck in mud, use the procedure below to get it out.

If one crawler is stuck

1. Slew the bucket to the side which is stuck.

2. Set the arm and boom to an angle of 90 to 110 °.

3. Press the bottom of the bucket (not the teeth) against the ground.

4. Place a plank, etc., under the lifted crawler.

5. Lift the bucket and slowly move out of the mud.

If both crawlers are stuck

1. Perform steps 1 to 4 above for both crawlers.

2. Dig the bucket into the ground in front of the machine.

3. Pull with the arm and travel forward simultaneously to slowly move out of the mud.

OPERATION

Operating Procedures

Operations Possible with this Machine

Excavating

80 ~120

E4D0501

1. Set the dozer blade on the side opposite the side you want to dig on.

2. Use the arm and bucket and dig with shallow, long strokes. The digging force is strongest when the boom and arm angle is 80 to 120°. Use this angle for effective digging.

Digging Ditches

E4D051

Mount a bucket suited for digging ditches and set the crawlers parallel to the ditch to be dug for greater efficiency. When digging wide ditches, dig the sides first, the center later.

Digging Side Ditches

B5D022

Use the offset function to dig side ditches as shown in the diagram.

When loading dirt in a truck, starting from the back of the truck’s bed makes for easier loading and increases the amount of dirt that can be loaded. Also, use a small slewing angle for greater efficiency.

OPERATION

Operating Procedures

Leveling

E4D053

1. Bring the hoe attachment close to the body.

2. Gradually remove the dirt from the side of the mound.

3. Once the mound is low, remove the dirt from the top. If the load on the body is too heavy, adjust by raising or lowering the dozer blade.

OPERATION

Parking the Machine

Parking

WARNING

E3A4901

¡¡

¡ Park the machine on firm, level ground

¡¡

and apply the parking device.

¡¡

¡ Before leaving the operator’s seat,

¡¡

1. Set the left and right travel levers to the neutral position.

2. Return the throttle lever and idle the engine at low speed.

3. Set the slew lock lever to the locked position.

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

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

6. Stop the engine and remove the key. Refer to page 55 “Stopping the Engine”.

Inspection and Checks After Stopping the Engine

1. Check for oil and water leakage and inspect the working equipment, covers and lower body. If any irregularities are found, repair.

2. Fill the fuel tank. Refer to page 99 “Checking the Fuel Level”.

3. Remove any paper scraps or dirt from the engine room.

4. Remove any mud from the lower body.

Locking

Be sure to lock the following places:

¡ Engine hood

OPERATION

Handling in Cold Weather

Preparing for Cold Weather

In cold weather, it may be difficult to start the engine and the coolant may freeze. Make the preparations described below.

Changing the Fuel and Lubricant

Change the fuel, hydraulic oil and engine oil to types suited for cold conditions. Refer to page 88 “Fuel and Lubricant Chart”.

Engine Coolant

WARNING

The coolant is combustible. Keep flames away.

Use long-life coolant (antifreeze) and tap water for the engine coolant. Supplement: New machines are delivered with JIS Type 2 long-life coolant (antifreeze) at a concentration of 50%. Refer to page 88 “Fuel and Lubricant Chart”.

Battery

As the temperature drops, the battery performance decreases. Inspect the battery. If the charge is low, contact a Takeuchi sales or service outlet to have the battery charged. Refer to page 107 “Inspecting the Battery Fluid Level and Replenishing”.

Cautions after Completing Operations

Heed the following in order to prevent dirt, water, or other objects stuck on the machine as well as the lower body from freezing: ¡ Remove any dirt or water from the body.

In particular, water droplets on the hydraulic cylinder rod surfaces could freeze, and if dirt enters into the seals along with this, the seals could break.

¡ Park the machine on a dry, hard surface.

If no appropriate place can be found, put boards down and park the machine on them.

¡ Drain any water from the fuel tank to

prevent freezing. Refer to page 108 “Draining the Fuel T ank”.

¡ To prevent decreased battery

performance, place a cover over the battery or remove it from the machine and store it in a warm place. Also add battery fluid before starting the next morning. If battery fluid is added after completing operations, the distilled water may not mix, resulting in freezing.

After Cold Weather is Over

Perform the following after cold weather is over: ¡ Change the fuel and the oils for the

different devices with those specified on the Fuel and Lubricant Chart. Refer to page 88 “Fuel and Lubricant Chart”.

¡ When using one-season type antifreeze

coolant, completely drain the antifreeze coolant, carefully clean the inside of the coolant system, then add tap water. Refer to page 114 “Cleaning the Engine Cooling System”.

OPERATION

Handling Rubber Crawlers

Rubber crawlers have an inherent weakness due to their use of rubber. Be sure to heed the prohibitions and cautions below so as to prevent damage to the crawlers and crawler slippage.

Prohibited Actions

Do not travel or operate the machine in the following places:

E4D056

¡ Traveling or slewing on broken stone,

jagged base rock, iron rods, iron scraps or the edges of iron sheets may damage or cut the crawlers.

E4D055

¡ Traveling on riverbeds or places with many

soft rocks may cause the crawlers to slip off or be damaged due to rocks getting stuck in them.

¡ Do not use on the seashore. The salt may

corrode the metal cores.

E4D057

¡ Do not let fuel, oil, salt or chemical solvents

get on the crawlers. These substances may corrode the couplings of the crawlers’ metal cores, resulting in rust or peeling. If these substances should get on the crawlers, wipe them off immediately using water.

E4D058

¡ Traveling on roads directly after asphalting

or on hot surfaces such as over fires or on iron sheets under strong sunlight may result in irregular wear or damage of the lugs.

¡ Do not move earth in places where the

rubber crawlers may slip. Doing so may speed up lug wear.

OPERATION

Handling Rubber Crawlers

Cautions

Heed the following cautions when operating the machine:

L4D013

¡ Do not turn the undercarriage with the front

of the machine body lifted using the hoe attachment and the upperstructure left in this posture. Doing so will twist the crawler with the load concentrated on a single point on the crawler belt, rapidly leading to damage.

¡ Avoid changing course abruptly and

spinning on concrete surfaces whenever possible. Doing so may wear or damage the rubber crawlers.

¡ Avoid drops that may expose the rubber

crawlers to strong shocks.

¡ Salt, potassium chloride, ammonium

sulfate, potassium sulfate, and triple superphosphate of lime can damage the crawler belts. If any of these substances should get on the crawler belts, wash them off thoroughly with water.

¡ Do not let the sides of the rubber crawlers

rub against concrete or walls.

¡ Do not damage the rubber crawlers by

hitting the bucket against them.

¡ Be especially careful in the winter on

snowy or frozen surfaces as the crawler belts tend to slip.

¡ Use rubber crawler belts at temperatures

between -25°C to +55°C (-14°F to 131°F).

¡ When storing the rubber crawlers for long

periods of time (3 months or more), do so indoors in a place not exposed to direct sunlight or rain.

¡ Rubber crawler belts are not as stable as

steel crawler belts since the entire lug is rubber. Be very careful when slewing and swinging sideways.

Preventing the Rubber Crawlers from Slipping Off

Heed the following in order to prevent the rubber crawlers from slipping off: ¡ Always keep the crawlers at the proper

tension.

¡ When traveling up large cobblestone or

rock steps (20 cm (8 in.) or greater), climb up the step at a direct angle and do not change course on top of the step.

OPERATION

Handling Rubber Crawlers

¡ When climbing in reverse, do not change

course at the point where the slope starts.

¡ Avoid traveling with one crawler on a slope

or projecting object and the other crawler on a flat surface (with the machine at a tilt of 10° or greater). Travel with both crawlers on flat surfaces.

¡ Do not change directions when the crawler

belts are slack as shown in the diagram.

TRANSPORT

Loading and Unloading .............................82

Securing the Machine ................................83

Cautions on Transporting..........................84

TRANSPORT

Loading and Unloading

WARNING

The machine may roll or tip over or fall while loading or unloading it. Take the following precautions:

¡¡

¡ Select a firm, level surface and keep

¡¡

sufficient distance from road shoulders.

¡¡

¡ Use loading ramps of adequate

¡¡

strength and size. Maintain the slope of loading ramps within 15 degrees.

¡¡

¡ Keep the truck bed and loading ramps

¡¡

clean of oil, clay, ice, snow, and other materials which can become slippery. Clean the tracks.

¡¡

¡ Never change course on the ramp.

¡¡ ¡¡

¡ Do not slew (swing) on ramps. The

¡¡

machine may tip over.

¡¡

¡ When slewing (swinging) on the truck

¡¡

bed, do so slowly as the footing can be unstable.

When loading or unloading the machine, be sure to use ramps and following the procedure below.

1. Apply the truck’s parking brake and place stoppers against its tires.

2. Fasten the ramps securely to the truck bed so that they will not come off. Set the ramps to an angle of 15° or less.

3. Line up the center of the truck bed with the center of the machine and the center of the ramps with the center of the crawlers.

4. Make sure the dozer blade does not hit the ramps.

5. Lower the hoe attachment as much as possible, making sure it will not hit the truck.

6. Lower the engine speed with the throttle lever.

Fasten to the suspension fitting

Ramp

Distance between ramps

15° or less

Stopper

E4F001

7. Determine the direction on the ramps, then slowly travel up or down the ramps in 1st speed (low speed), following the signals of a flagman.

8. Load the machine properly at the prescribed position on the bed. Refer to page 83 “Transporting Posture”.

TRANSPORT

Securing the Machine

After loading the machine in the designated position, secure it as described below.

Transporting Posture

1. Lower the dozer blade.

2. Set the slew lock lever to the locked position.

3. Fully extend the bucket and arm cylinders, then lower the boom.

4. Stop the engine and remove the starter key .

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

6. Set stoppers in front and behind the crawlers.

7. Put a chain or wire rope over the lower frame and fasten it securely to prevent sideways slippage.

8. Secure the bucket with a chain or wire rope.

Wire rope

Padding

E4F002

IMPORT ANT: Place a wooden block under the bucket so that it is not damaged by hitting the floor.

TRANSPORT

Cautions on Transporting

WARNING

¡¡

¡ Know and follow the safety rules,

¡¡

vehicle code and traffic laws when transporting the machine.

¡¡

¡ Consider the length, width, height and

¡¡

weight of the truck with the machine loaded on it when determining the best route.

MAINTENANCE

General .......................................................86

Service Data ...............................................88

Important Parts ..........................................92

Maintenance Chart.....................................93

Walk-Around Inspection............................95

Daily Inspection (Every 10 Hours).............97

After First 50 Hours

(New Machines Only)...................... 102

Every 50 Hours.........................................105

Every 100 Hours.......................................109

After First 250 Hours

(New Machines Only)...................... 110

Every 250 Hours....................................... 111

Every 500 Hours....................................... 113

Every 1000 Hours..................................... 114

Every 2000 Hours..................................... 117

When Required ........................................ 119

Long-term Storage................................... 124

MAINTENANCE

General

Maintenance Description

For long-term use of the machine under good conditions, perform the inspection and maintenance procedures properly and safely as recommended in this manual.

The inspection and maintenance items are divided according to the machine’s total operating time (inspection and maintenance to be performed every 10 hours (walk-around and daily inspection), every 50 hours, every 250 hours, etc.). Refer to the hour meter to determine when it is time to perform inspection and maintenance. Items for which it is not possible to determine the inspection and maintenance interval are included under “When Required”.

When operating the machine in extremely harsh environments (with high dust levels or high temperatures), inspection and maintenance should be performed earlier than the times indicated on the Maintenance Chart.

Cautions on Maintenance

Do not perform inspection and maintenance procedures not prescribed in this manual. Have inspection and maintenance procedures not prescribed in this manual performed by a Takeuchi sales or service outlet.

Always keep the machine clean.

¡ Always keep the machine clean, and wash

it before performing inspection and maintenance.

¡ When washing the machine with water,

stop the engine and cover the electrical system with plastic to protect it from water. Exposing the electrical system to water is dangerous and could result in shortcircuits or malfunction. Do not wash the battery, sensors, connectors or the inside of the cab with water or steam.

Fuel, lubricant and grease

¡ For fuels, lubricant and grease, follow the

instructions on the “Fuel and Lubricant Chart”.

¡ Use pure fuels, lubricants and greases

which do not contain water, and be careful to keep dirt out when changing or replenishing fuel, lubricant or grease.

¡ Store fuels, lubricants and greases in the

prescribed places and in such a way that no water or dirt can get in them.

Cautions on fueling

¡ If the port includes a strainer, do not

remove the strainer when fueling.

¡ After fueling, be sure to securely tighten

the cap, etc.

¡ Do not add more than the prescribed

amount of fuel.

MAINTENANCE

General

Do not clean parts with fuel.

Do not use fuel to clean parts. Use a noncombustible cleaning agent.

Keep dirt out.

When mounting and removing parts, do so in a place where there is no dust, clean the working area and the part, and keep dirt out.

Clean mounting surfaces.

When mounting and removing parts, be sure that the surfaces of contact of the parts are clean. If the sealing grooves of the surface of contact are damaged, consult a Takeuchi sales or service outlet.

Seals and split pins

¡ Replace removed seals and split pins with

new ones.

¡ When mounting, be careful not to damage

or twist the seal.

Sealing tape

Disposing of wastes

¡ Collect spent fluids from the machine in

containers. Disposing of wastes irresponsibly damages the environment.

¡ Dispose of oil, fuel, cooling water , coolant,

filters, batteries and other harmful substances as prescribed by law.

Check after maintenance

¡ Gradually increase the engine speed from

a low idle to maximum speed and check that there is no oil or water leaking from serviced parts.

¡ Operate all the operating levers and check

that the machine is operating properly.

Cautions on handling of battery cables

¡ Disconnect the battery cables (+,-) before

working on the electrical system or doing any welding. Remove the negative (-) battery cable first. When reconnecting the battery, connect the negative (-) battery cable last.

¡ Do not disconnect the battery cables while

the engine is running. Doing so could damage the electronic circuitry of the alternator and other parts.

Leave 1 or 2 threads free

E4G001

¡ When wrapping sealing tape around

plugs, etc., remove any old sealing tape from the threads and clean the threads.

¡ Wrap the sealing tape tight, leaving 1 or 2

threads at the tip free.

MAINTENANCE

Service Data

Fuel and Lubricant Chart

Use different fuels, lubricants and greases according to the temperature, referring to the chart below. ¡ Change the lubricant earlier than as shown in the table if it is extremely dirty or its

performance has deteriorated severely.

¡ Whenever possible, use the same brand of lubricant as before. If changing with a different

brand, replace the entire quantity – do not mix different brands.

Part

Engine oil pan

Hydraulic tank

Fuel tank

Engine cooling system

Travel reduction gear

Slew motor pinion

Slew bearing

Working equipment

Levers

Type

Diesel engine oil API - CD

Antiwear hydraulic oil

Diesel fuel

Coolant (water * + coolant **)

Gear oil API-GL-4

Lithium based grease EP-2 NLGI No. 2

Type by temperature

-22 -4 14 32 50 68 86

-30 -20 -10 0 10 20 30 40 °C

SAE 5W-20 SAE 10W-30 SAE 15W-40

ISO VG32

ISO VG46

ISO VG68

Use a clean, Quality fuel for good performance and optimum engine life. ¡ To prevent fuel flow problems in cold weather, use diesel fuel with a pour point of

at least -12°C (10°F) below the lowest expected ambient temperature.

¡ Minimum cetane number is 45. Low temperature or high altitude operation may

require the use of fuel with a higher cetane number.

50% coolant mixture

30% coolant mixture

Replacement

104

°F

interval

After first 50 hrs. Every 250 hrs.

Every 2000 hrs.

Every 1000 hrs.

After first 250

SAE 90

hrs. Every 1000 hrs.

Capacity

R(US. qt.)

Upper limit:

1.7 (1.8) Lower limit:

1.0 (1.1) System: 14

(3.7 U.S.gal) Tank: 7.3

(1.9 U.S.gal)

Tank: 8 (2.1 U.S.gal)

2.8 (3.0)

0.33 (0.35) each

Every 50 hrs.

Every 50 hrs. Daily or every

As required

10 hrs. When required

* For water, use tap water (soft). Do not use well or river water. ** When the ambient temperature drops below 0°C, add coolant (antifreeze). Follow the

coolant manufacturer’s instructions to determine the mixture ratio.

MAINTENANCE

Service Data

Replace the hydraulic oil regularly!

¡ When using a hydraulic breaker, the oil deteriorates quicker than during normal digging.

Be sure to replace the hydraulic oil and return filter element.

• Failure to replace these in time can lead to damage to the machine and breaker’s hydraulic systems. In order to improve the service life of the hydraulic systems, be sure to replace the hydraulic oil and return filter element after the number of hours shown on the diagram below.

• Clean the suction strainer when changing the return filter element.

Replacement Interval (Hours)

Item

1st time 25

2nd time 100

Periodically 600 200

When the breaker operating ratio is 100% Refer to page 154 “Hydraulic Breaker”.

Hydraulic Oil Filter Element

Expendables

Replace expendables such as filters and elements periodically, referring to the table below.

Item Part name

Return filter Cartridge After first 50 hrs.

Fuel filter Every 500 hrs.Element 119810-55650

Air cleaner Element

(outer)

Inner Element (option)

Part No.

15510-20310

119305-35151Engine oil filter Cartridge

119655-12560

19111-01342

Replacement interval

Every 500 hrs.

After first 50 hrs. Every 250 hrs.

Every 1000 hrs. or after 6 cleanings (whichever comes first)

Every 1000 hrs. or after 3 cleanings of the outer element (whichever comes first)

MAINTENANCE

Service Data

Tools

Part nameNo. Part No. Remarks

1 Grease gun 2

Drain connector

3 Case

16910-60600 15545-12201 16919-00001

600cc

MAINTENANCE

Service Data

Tightening Torques

Nuts and Bolts (for ISO strength category 10.9)

Tighten nuts and bolts at the torques shown on the table below , unless otherwise specified in the text. ¡ Tightening torques when mounting plastic covers differ from the values on the table below.

Consult a Takeuchi sales or service outlet. Tightening too strongly will break the cover.

¡ When replacing nuts and bolts, replace them with nuts and bolts of the same size and

standards.

¡ Tighten nuts and bolts alternately (top, bottom, left then right) or in 2 or 3 times so that they

are tightened uniformly.

Thread

Coarse

Fine

Head width

(b)

E4G003

Size (a) X Pitch

Torque

General Connection Points

N·m ft-lb

10 M6 X 1.0 9.8 ± 0.5 7.2 ± 0.4 12, 13 M8 X 1.25 22.6 ± 1.1 16.6 ± 0.8 14, 17 M10 X 1.5 47.1 ± 2.4 34.7 ± 1.7 17, 19 M12 X 1.75 83.4 ± 4.1 61.5 ± 3.0 19, 22 M14 X 2.0 134.4 ± 6.7 99.1 ± 4.9 22, 24 M16 X 2.0 207.9 ± 10.4 153.3 ± 7.7 27, 30 M20 X 2.5 410.9 ± 20.5 303.1 ± 15.1 12, 13 M8 X 1.0 24.5 ± 1.2 18.1 ± 0.9 14, 17 M10 X 1.25 50 ± 2.5 36.9 ± 1.8 17, 19 M12 X 1.5 87.3 ± 4.3 64.4 ± 3.2 19, 22 M14 X 1.5 135.3 ± 6.8 99.8 ± 5.0 22, 24 M16 X 1.5 220.6 ± 11 162.7 ± 8.1 27, 30 M20 X 1.5 452.1 ± 22.6 333.4 ± 16.6

MAINTENANCE

Important Parts

For safe use, the machine must be serviced periodically. To increase safety, periodically replace the parts listed in the following table of important parts. Serious injury or a fire could result if they deteriorate or are damaged.

Table of Important Parts

Unit Important parts to be replaced periodically

Fuel system

Main body

Hydraulic

system

Working equipment

Above important parts are vulnerable to aging and wear or deterioration and it is difficult to determine the degree to which they have deteriorated on the occasion of periodic service. T o maintain their proper function at all times, therefore, replace them with new ones after using them for a specific period of time even if no abnormality is found with the parts. If you find abnormalities in these parts before their scheduled replacement time is reached, repair or replace them immediately. If a hose clamp is deformed or cracked, replace it immediately. When replacing the important parts, please contact a Takeuchi sales or service outlet .

Also check the hydraulic hoses other than the above important parts. If any abnormality is found in them, retighten them or replace them immediately. When replacing the hydraulic hoses, replace the O-rings and seals at the same time.

Check the fuel and hydraulic hoses according to the periodic schedule described below. Refer to “Maintenance”.

Fuel hoses Packing in fuel filler cap Hydraulic hoses ( Pump - delivery ) Hydraulic hoses ( Pump - suction ) Hydraulic hoses ( Slew motor ) Hydraulic hoses ( Travel motor ) Hydraulic hoses ( Boom cylinder lines ) Hydraulic hoses ( Arm cylinder lines) Hydraulic hoses ( Bucket cylinder lines ) Hydraulic hoses ( Swing cylinder ) Hydraulic hoses ( Blade cylinder ) Hydraulic hoses ( Spanner cylinder ) Hydraulic hoses ( Auxiliary lines ) Seat belt

Replacement Interval

Every 2 years

Every 3 years

Type of inspection Inspection item Daily inspection Leakages from joints, hydraulic or fuel hoses. Monthly inspection Leakages from joints, hydraulic or fuel hoses.

Damaged hydraulic or fuel hoses(cracks, wear and tear).

Annual inspection Leakages from joints, hydraulic or fuel hoses.

Deteriorated, twisted, damaged hydraulic or fuel hoses (cracks, wear and tear) or hoses in contact with other parts of the machine.

MAINTENANCE

Maintenance Chart

Maintenance Items See page

Walk-Around Inspection

Inspecting by opening the engine hood 95 Inspecting by walking around the machine 96 Inspecting while sitting in the operator’s seat 96

Daily Inspection (Every 10 Hours)

Inspecting and replenishing the coolant 97 Inspecting and replenishing the engine oil 98 Inspecting the water separator 99 Checking the fuel level 99 Inspecting the hydraulic oil level and replenishing 100 Lubricating the working equipment 101

After First 50 Hours (New Machines Only)

Replacing the hydraulic oil return filter 102 Replacing the engine oil and oil filter 103 Inspecting and adjusting the fan belt 104

Every 50 Hours

Inspecting and adjusting the crawler tension 105 Lubricating the slew bearing 106 Lubricating the slew motor pinion 107 Inspecting the battery fluid level and replenishing 107 Draining the fuel tank 108

Every 100 Hours

Cleaning the fuel filter 109 Cleaning the water separator 109

After First 250 Hours (New Machines Only)

Replacing the travel motor gear oil 1 10

MAINTENANCE

Maintenance Chart

Maintenance Items

Every 250 Hours

Cleaning the air cleaner 1 11 Cleaning the radiator fins 1 12 Replacing the engine oil and oil filter 112 Inspecting and adjusting the fan belt 1 12

Every 500 Hours

Replacing the fuel filter 1 13 Replacing the hydraulic oil return filter 113

Every 1000 Hours

Cleaning the engine cooling system 1 14 Replacing the air cleaner element 1 15 Replacing the travel motor gear oil 1 16 Inspecting and adjusting the engine valve clearance 1 16 Retightening the engine cylinder head bolts 1 16 Inspecting the engine fuel injection pressure and spray condition 1 16

Every 2000 Hours

Replacing the hydraulic oil and cleaning the suction strainer 1 17 Inspecting the engine fuel injection timing 1 18 Inspecting the engine fuel injection valve 118

When Required

Replacing the bucket 1 19 Inspecting the rubber crawlers 121 Replacing the rubber crawlers 122

See page

MAINTENANCE

Walk-Around Inspection

Perform the following inspections once every day before starting the engine the first time.

WARNING

¡¡

¡ Before operating, perform the walk-around inspections and make repairs immediately

¡¡

should any irregularities be found.

¡¡

¡ Be sure to secure the engine hood when opening it. Do not open the engine hood

¡¡

on slopes or in strong wind.

Before starting the engine, look around the machine and lower body , clean any combustible materials off high temperature parts of the engine, and inspect for such irregularities as oil leakage, water leakage and looseness of nuts and bolts.

Inspecting by Opening the Engine Hood

1. Check for any twigs, leaves, oil or other combustible materials around the engine and battery .

2. Check for oil or engine coolant water leakage around the engine.

B5G003E

3. Check for oil leakage from the hydraulic tank, hydraulic devices, hoses and connections.

MAINTENANCE

Walk-Around Inspection

Inspecting by Walking Around the Machine

4. Check lights for dirt, damage and burnt out bulbs.

5. Check attachments and hoses for damage.

6. Check the bucket, bucket teeth and side cutter for wear, damage and looseness.

7. Check the hook, slip stopper and hook mount of buckets with hooks for damage. (Option)

8. Check the handrail and step for damage and loose bolts.

9. Check the crawler, shoe slide, track roller, idler and sprocket for damage, wear and loose bolts.

10. Check for oil leakage from the travel

motor.

11. Check the canopy, cab and guard for

damage and loose nuts and bolts.

12. Check the labels for dirt and damage.

Inspecting While Sitting in the Operator’s Seat

13. Check the operator’s seat for dirt, oil or other combustible materials.

14. Check the monitor, instruments and switches for dirt or damage.

MAINTENANCE

Daily Inspection (Every 10 Hours)

Perform the following inspections once every day before starting the engine the first time.

WARNING

¡¡

¡ Before operating, perform the Daily inspections and make repairs immediately should

¡¡

any irregularities be found.

¡¡

¡ Be sure to secure the engine hood when opening it. Do not open the engine hood

¡¡

on slopes or in strong wind.

Inspecting and Replenishing the Coolant

WARNING

Do not remove the radiator cap or drain plugs when the coolant is hot. Stop the engine, let the engine and radiator cool and loosen the radiator cap or drain plugs slowly .

Inspection

1. Open the engine hood.

2. Place a cloth over the radiator cap (1) and loosen it gradually to release the internal pressure before removing it.

3. Inspect the coolant level in the radiator.

• The coolant level must be 30 mm (1.2 in.)

above the top surface of the radiator core.

• If the coolant level is low, add coolant.

Replenishing

1. Add coolant to a level of 30 mm (1.2 in.) above the top surface of the radiator core.

2. Install the radiator cap (1).

MAINTENANCE

Daily Inspection (Every 10 Hours)

Inspecting and Replenishing the Engine Oil

WARNING

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

Inspection

1. Open the engine hood.

2. Pull out the dipstick (1) and wipe off the oil with a rag.

3. Fully reinsert the dipstick (1), then pull it back out.

4. Check the oil on the dipstick (1). The level must be between the upper limit (H) and lower limit (L). If it is below the lower limit (L), replenish.

3. Tighten the oil supply cap (2).

4. Start the engine, run it at low idle for about 3 minutes, then stop it.

5. After about 10 minutes, inspect the oil level.

Replenishing

1. Remove the oil supply cap (2).

2. Add oil up to the upper limit (H) of the dipstick (1). Problems could arise if the oil level is either too low or too high.

Takeuchi TB108 Operator Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

OPERA TOR’S MANUAL

SAFETY ALERT SYMBOL

■ SlGNAL WORDS

■ EXPLANA TION OF GRAPHICAL SYMBOLS

INTRODUCTION

MACHINE DESCRIPTlON

CONTENTS

SAFETY

General Precautions

Observe all safety rules

Provide a fire extinguisher and first aid kit

Never remove safety equipment

Use a signal person and flagman

Be sure to lock the safety lock lever before leaving the operator’s seat

Avoid fire and explosion hazards

Exhaust fumes from the engine can kill

Handling asbestos dust

Be careful not to get crushed or cut

Using optional products

Never modify the machine

Preparing Precautions

Know the working area

Alway keep the machine clean

Perform inspection and maintenance daily

Starting Precautions

Maintain three point contact when mounting and dismounting

Clear the area of other persons before starting the machine

Start the engine from the operator’s seat

Starting with jumper cables

After starting the engine

In cold weather

Operating Precautions

Ensure good visibility

Do not permit riders on the machine

Check for safety in the surrounding area before starting

Fully extend the crawler width when operating

Travel safety

Cautions on traveling on slopes

Operate on snow or ice with extra care

Insure driver safety before loading trucks

Keep a safe distance from electrical power lines

Watch out for hazardous working conditions

Operating on slopes is dangerous

Never slew (swing) sideways with excessive weights

Excavators are not designed for lifting loads

Danger of flying objects

Cautions on T owing

Stopping Precautions

Park safely

Transporting Precautions

Load and unload the machine safely

Lifting the machine safely

Transport the machine safely

Maintenance Precautions

Attach a “DO NOT OPERA TE” tag

Use the correct tools

Anti-explosive lighting

Do not allow unauthorized personnel in the work area

Replace important safety parts periodically

Prepare the work area

Always clean the machine

Stop the engine before performing maintenance

Stay clear of moving parts

Securely block the machine or any component that may fall

Cautions on opening the engine hood

Place heavy objects in a stable position

Securely block the working equipment

Use caution when fueling

Be careful with hot and pressurized components

Be careful with hot cooling systems

Handling of hoses

Be careful with fluids under pressure

Release all pressure before working on the hydraulic system

Be careful with grease under pressure

Disconnect the battery

Avoid battery hazards