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Takeuchi Mini excavator TB215R (Serial No.215000003~). Operators Manual (2013) - page 4

MAINTENANCE

SAFETY-CRITICAL PARTS

The material of the safety-critical part listed above tends to change over time and cause wear

or deterioration. It is difficult to determine the degree of deterioration at the periodic inspection,

and thus they need to be replaced with new ones after a certain time to maintain their proper

performance even if they appear in good condition. Note that regardless of the replacement

schedule, replacement must be performed immediately if a symptom of wear is found. If a

hose clamp is deformed or cracked, replace it together with the hose immediately. When

replacing the safety-critical parts, ask your sales or service dealer.

In addition to the safety-critical parts, inspect the hydraulic hoses and retighten or replace as

necessary. When replacing the hydraulic hoses, replace the O-rings and seals at the same

time.

Check the fuel and hydraulic hoses according to the periodic schedule described below.

Refer to “Maintenance”.

Type of inspection

Inspection item

Leakage from the connecting parts of hydraulic or fuel hoses

Daily inspection

Damage to cab or canopy - replace*

Leakage from the connecting parts of hydraulic or fuel hoses

Monthly inspection

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

Leakage from the connecting parts of hydraulic or fuel hoses

Annual inspection

Deteriorated, twisted, damaged hydraulic or fuel hoses (cracks, wear

and tear) or hoses in contact with other parts of the machine

*: Canopy parts No.(1) 03384-00031

*: Canopy parts No.(2) 03384-00039

5-11

MAINTENANCE

MAINTENANCE LIST

MAINTENANCE LIST

Inspection and maintenance item

Page

Walk-around inspection

Inspecting by opening the engine hood and covers

5-14

Inspecting by walking around the machine

5-15

Inspecting while sitting in the operator’s seat

5-15

Daily inspection (every 10 Hours)

Inspecting and replenishing the coolant

5-16

Inspecting and replenishing the engine oil

5-17

Inspecting the dust indicator

5-17

Inspecting the water separator

5-18

Inspecting the fuel level

5-18

Inspecting the hydraulic oil tank level and replenishing

5-19

Lubricating the working equipment

5-21

After the initial 50 hours (only for new machines)

Replacing the engine oil and the oil filter

5-22

Inspecting and adjusting the fan belt

5-23

Replacing the hydraulic oil return filter

5-24

Every 50 hours

Inspecting and adjusting the crawler tension

5-26

Lubricating the slew bearing

5-28

Lubricating the slew motor pinion

5-28

Draining the water from the fuel tank

5-29

Inspecting the battery fluid level and replenishing

5-30

Every 100 hours

Cleaning the water separator

5-32

Cleaning the fuel filter

5-32

After the initial 250 hours (only for new machines)

Replacing the travel motor gear oil*

5-33

Every 250 hours

Replacing the engine oil and the oil filter

5-34

Inspecting and adjusting the fan belt

5-34

Cleaning the air cleaner

5-34

Cleaning the radiator fins and oil cooler fins

5-36

*: If the percentage of the traveling time within the total operating time is high, replace the gear

oil earlier than the specified time.

5-12

MAINTENANCE

MAINTENANCE LIST

Inspection and maintenance item

Page

Every 500 hours

Replacing the hydraulic oil return filter

5-38

Replacing the water separator filter

5-38

Replacing the fuel filter

5-39

Every 1000 hours

Replacing the travel motor gear oil *

5-40

Cleaning the engine cooling system

5-40

Replacing the air cleaner element

5-42

Inspecting and adjusting the engine valve clearance

5-43

Retightening the engine cylinder head bolt

5-43

Every 1500 hours

Inspecting and cleaning the engine fuel injectors

5-44

Inspecting the crankcase breather system

5-44

Every 2000 hours

Lapping the engine valve seats

5-45

Every 4000 hours

Replacing the hydraulic oil and cleaning the suction strainer

5-46

When Required

Replacing the bucket teeth

5-48

Replacing the bucket

5-50

Lubricating the levers

5-52

Inspecting the rubber crawlers

5-53

Replacing the rubber crawlers

5-54

*: If the percentage of the traveling time within the total operating time is high, replace the gear

oil earlier than the specified time.

5-13

MAINTENANCE

WALK-AROUND INSPECTION

WALK-AROUND INSPECTION

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

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

where necessary.

• Be sure to secure the engine hood or cover before working the inside. Do not keep the

hood or cover open on a windy day or if the machine is parked on a slope.

Before starting the engine, look around the machine and clean any combustibles from the

surroundings of the engine. Also, inspect if oil or water is leaking and any nuts or bolts are

loosened.

INSPECTING BY OPENING THE ENGINE

HOOD AND COVERS

1. Check for any twigs, leaves, oil or other

combustible materials around the engine

and battery.

2. Check for oil or engine coolant water

leakage around the engine.

3. Check for oil leakage from the hydraulic

tank, hydraulic devices, hoses or

connections.

5-14

MAINTENANCE

DAILY INSPECTION (EVERY 10 HOURS)

Inspection

DAILY INSPECTION (EVERY

10 HOURS)

Perform the following inspections every day

before starting the engine for the first time.

• Before operating, perform the daily

inspections and make repairs

immediately where necessary.

• Be sure to secure the engine hood or

cover before working the inside. Do not

keep the hood or cover open on a windy

1. Open the engine hood.

day or if the machine is parked on a

2. Inspect the cooling water level in the

slope.

reserve tank (1).

The level should be between the upper

limit (H) and the lower limit (L).

If it is below the lower limit (L), replenish.

INSPECTING AND REPLENISHING THE

COOLANT

Replenishing

1. Remove the cap (2) of the reserve tank (1).

2. Add cooling water up to the upper limit (H)

of the reserve tank (1).

• Do not remove the radiator cap or the

If the reserve tank (1) is found empty at the

drain plug when the cooling water is

inspection, check for water leakage and

hot. Stop the engine and wait until the

then the water level in the radiator (3). Add

engine and the radiator cool before

water to the radiator (3) as required, and

slowly loosening the radiator cap and

then to the reserve tank (1).

the drain plug to remove them.

3. Install the cap (2).

• Always wear the protective goggle and

gloves when handling coolant

Note: Use only clean water (soft water) to

(antifreeze). If any coolant (antifreeze)

replenish the cooling water loss due to

comes in contact with eyes or skin,

evaporation. Use coolant (antifreeze) and

wash it off with clean water. Otherwise,

clean water (soft water) of the specified

it could result in injures.

mixing ratio to replenish the cooling water

loss due to leaking.

5-16

MAINTENANCE

DAILY INSPECTION (EVERY 10 HOURS)

INSPECTING AND REPLENISHING THE

INSPECTING THE DUST INDICATOR

ENGINE OIL

Stop the engine and allow the machine to

Stop the engine and allow the machine to

cool down before performing

cool down before performing

maintenance.

maintenance.

The dust indicator is the equipment to be

used to find out if there is clogging in the air

Inspection

cleaner.

L

H

1

2

4

AD6G003

1. Open the engine hood.

1. Open the maintenance cover A.

2. Take out the dipstick (1) and wipe the oil

2. Check that if the red piston (2) is shown in

off with a rag.

the dust indicator (1).

3. Fully reinsert the dipstick (1), and then pull

3. If the red piston (2) is visible, immediately

it back out.

clean or replace the element.

4. Check the oil on the dipstick (1).

Refer to “Cleaning the air cleaner” on page

The level should be between the upper

5-34.

limit (H) and the lower limit (L).

4. After cleaning/replacement, push the

If it is below the lower limit (L), replenish.

button (3) on the dust indicator to reset

the red piston (2).

Replenishing

1. Remove the oil filler cap (2).

2. Add oil up to between the upper limit (H)

and the lower limit (L) of the dipstick (1).

Problems could arise if the oil level is either

too low or too high.

3. Tighten the oil filler cap (2).

4. Start the engine, run it at low idle for about

5 minutes, then stop it.

5. After about 10 minutes, inspect the oil

level.

5-17

MAINTENANCE

DAILY INSPECTION (EVERY 10 HOURS)

INSPECTING THE WATER SEPARATOR

INSPECTING THE FUEL LEVEL

• Do not smoke or permit open flames

• Do not smoke or permit open flames

while handling fuel or working on the

while handling fuel or working on the

fuel system.

fuel system.

• Stop the engine in a well-ventilated

• Never remove the fuel cap or add fuel

place and allow it to cool down before

when the engine is running or still hot.

performing maintenance.

Do not spill fuel on the hot surface of

• Clean up spilled fuel immediately.

the machine.

• Fill the fuel tank in a well ventilated

place.

• Clean up spilled fuel immediately.

• Do not fill the fuel tank to capacity.

Allow room for oil expansion.

• Securely tighten the fuel filler cap.

• Use the correct grade of fuel for the

operating season.

1. Open the engine hood.

2. Inspect the water separator (1).

If the red indicator ring (6) is sunk to the

bottom of case (4), no water is mixed in.

If the red indicator ring (6) is floating, there

is water up to the ring. Drain the water

and clean.

Refer to “Cleaning the water separator” on

page 5-32.

1. Check the fuel level using the fuel gauge

Refer to “Bleeding air from the fuel

(1).

system” on page 6-8.

F: Tank is full.

E: Tank is empty.

2. If the fuel level is low, open the fuel lid.

3. Add fuel from the fuel filler port (2) while

watching the sight gauge (3).

Use this gauge (3) to check the full state

when adding fuel. For checking the

remaining amount, use the gauge in the

instrument cluster.

Refer to “Fuel filler port” on page 2-5.

5-18

MAINTENANCE

DAILY INSPECTION (EVERY 10 HOURS)

INSPECTING THE HYDRAULIC OIL TANK

Replenishing

LEVEL AND REPLENISHING

Oil may spurt out if caps or filters are

removed or pipes are disconnected

before releasing the pressure in the

hydraulic system.

• Press the air breather button to relieve

the internal pressure from the tank.

Inspection

IMPORTANT: Do not fill up to the level

The oil level changes with the oil

higher than the upper limit (H). It will

temperature. Inspect the oil by maintaining

damage the hydraulic circuits or result in

the machine at posture shown in the figure at

oil spurting. If accidentally done, stop the

the next.

engine and wait the hydraulic oil to cool,

• Machine posture for inspecting the

and then let the excessive oil to drain

hydraulic oil level

from the drain plug.

IMPORTANT: Do not forget to apply

pressure to the hydraulic tank to avoid

damage to the pump caused by air

sucking.

1. Open the engine hood.

2. Slowly loosen the air bleeding plug (2) to

relieve the internal pressure, and then

remove it.

3. Add the hydraulic oil up to the middle of

the sight gauge (1).

4. Pressurize the hydraulic oil tank as follows.

1. Start the engine and run it at low speed.

2. Fully retract the cylinders (arm and

bucket), and lower the bucket to the

ground.

3. Lower the dozer blade, and then stop the

engine.

4. Inspect the oil level using the sight gauge

(1).

· When the oil temperature is about 20°C

(68°F):

The level should be between the upper

limit (H) and the lower limit (L).

If it is below the lower limit (L), replenish.

· When the oil temperature is about 50 to

80°C (122 to 176°F):

The level should be slightly below the

upper limit (H).

5-19

MAINTENANCE

DAILY INSPECTION (EVERY 10 HOURS)

Pressurizing the hydraulic tank

1. Start the engine and run it at low speed.

2. With the vent plug (2) removed, set the

safety lock levers to the released position.

· Hydraulic tank pressurization posture

AD6G009

3. Fully extend the bucket, arm, boom, swing

and span cylinders.

4. Stop the engine and raise the left safety

lock lever to engage the lock.

5. Tighten the vent plug (2), and then

pressurize by retracting the cylinders.

5-20

MAINTENANCE

DAILY INSPECTION (EVERY 10 HOURS)

LUBRICATING THE WORKING EQUIPMENT

1. Keep the machine configuration as shown in the diagram above, lower the working

equipment to the ground, and then stop the engine.

2. Use the grease gun to lubricate the grease fittings.

3. Wipe off the excess grease.

Note: It is not necessary to lubricate the dozer blade, as it is using a “self-lubrication bush”.

5-21

MAINTENANCE

AFTER THE INITIAL 50 HOURS (ONLY FOR NEW MACHINES)

2. Place a pan for catching the waste oil

AFTER THE INITIAL 50

under the drain plug (3).

3. Remove the cap (A), install connector (B)

HOURS (ONLY FOR NEW

and drain the oil. (The oil comes out when

the screw is tightened.)

MACHINES)

4. Remove the connector (B) and install the

REPLACING THE ENGINE OIL AND THE

cap (A).

OIL FILTER

IMPORTANT: Check the waste oil for

metal powder. If it contains large amounts

of metal powder, consult your sales or

Stop the engine and allow the machine to

service dealer.

cool down before performing

maintenance.

5. Turn the filter (4) counterclockwise with the

• The engine, muffler, radiator, hydraulic

filter wrench and remove it.

lines, sliding parts and many other parts

6. Clean the surface of installation of the filter

of the machine are hot immediately after

stand.

the engine is stopped. Touching these

7. Apply a thin layer of oil on the packing of

parts will cause burns.

the new filter.

• The engine oil is also hot.

8. Install the new filter by hand.

Be careful not to touch the hydraulic oil

9. Tighten one more turn (with the filter

when loosening the cap or plug.

wrench) after the filter packing comes in

Working on the machine under these

contact with the surface of installation.

conditions could result in burns or

(Torque when tightening with filter wrench:

injuries.

19.6 to 23.5 N·m or14 to 17 ft-lb)

10. Add oil up to between the upper limit (H)

and the lower limit (L) of the dipstick (1).

Problems could arise if the oil level is

L

H

1

either too low or too high.

2

11. Tighten the oil filler cap (2).

12. Start the engine, run it at low idle for

about 5 minutes, then stop it.

13. After about 10 minutes, inspect the oil

level.

4

AD6G003

1. Open the engine hood and remove the oil

filler cap (2).

5-22

MAINTENANCE

AFTER THE INITIAL 50 HOURS (ONLY FOR NEW MACHINES)

INSPECTING AND ADJUSTING THE FAN

Adjustment

BELT

Stop the engine and allow the machine to

cool down before performing

maintenance.

• The engine, muffler, radiator, hydraulic

lines, sliding parts and many other parts

of the machine are hot immediately after

the engine is stopped. Touching these

parts will cause burns.

1. Loosen the bolt (5) and locking nut (4).

IMPORTANT: The loose belts could result

2. Turn the adjustment bolt (6) to move the

in bad battery charge, overheat of engine

alternator (7) and to adjust the tension of

or early wear of belt. Too tight belts could

the fan belt (1).

damage the water pump or bearing and

· Tighten: Clockwise

belt used to drive the alternator.

· Loosen: Counterclockwise

IMPORTANT: Do not let any oil or grease

3. Tighten the bolt (5) and locking nut (4).

get on the belt.

Note: When replacing with a new belt, run

Inspection

the engine at low idle speed for about 3 to 5

minutes to break in the new belt, before

1. Open the maintenance cover A.

adjusting the tension.

2. Press at the center of the fan pulley (1)

and alternator pulley (2) to check the

tension (approx. 98 N or 22 lbf).

The slack (A) should be 7 to 10 mm (0.28

to 0.4 in).

3. Inspect the fan belt (3) and replace if it is

as follows.

· There are cuts or cracks.

· The belt is worn and touches the bottom

of the V groove in the pulley.

· The belt stretched too loose to be

adjusted.

5-23

MAINTENANCE

AFTER THE INITIAL 50 HOURS (ONLY FOR NEW MACHINES)

REPLACING THE HYDRAULIC OIL

RETURN FILTER

• Stop the engine and allow the machine

to cool down before performing

maintenance.

· The engine and the hydraulic system

and many other parts of the machine

are hot immediately after the engine is

stopped. Touching these parts will

1. Open the engine hood.

cause burns.

2. Slowly loosen the air bleeding plug (1) to

· The hydraulic oil is also hot and under

relieve the internal pressure, and then

high pressure.

remove the plug.

Be careful not to touch the hydraulic

oil when loosening the cap or plug.

Working on the machine under these

conditions could result in burns or

injuries due to the hot oil spurting out.

• Oil may spurt out if caps or filters are

removed or pipes are disconnected

before releasing the pressure in the

hydraulic system.

· Gradually loosen the vent plug to

relieve tank pressure.

· When removing plugs or screws, or

when disconnecting hoses, stand to

3. Loosen the bolts (2) and remove the cover

the side and loosen them slowly to

(3).

gradually release the internal pressure

before removing.

5-24

MAINTENANCE

AFTER THE INITIAL 50 HOURS (ONLY FOR NEW MACHINES)

4. Loosen the hose bands and remove the

hose (5) from the flange (6).

5. Loosen the bolts to take out the flange (6).

6. Remove the return filter (7).

7. Install a new return filter.

8. Reassemble the flange (6) and the hose

(5).

9. Inspect the level with the sight gauge (8),

and replenish if the level is too low.

Refer to “Inspecting the hydraulic oil tank

level and replenishing” on page 5-19.

5-25

MAINTENANCE

EVERY 50 HOURS

Inspection

EVERY 50 HOURS

INSPECTING AND ADJUSTING THE

CRAWLER TENSION

• If you must work beneath the raised

machine or working equipment, always

use wood blocks, jack-stands or other

rigid and stable supports. Never get

under the machine or working

AD6G013

equipment if they are not sufficiently

supported. This procedure is especially

1. For rubber crawlers, move the machine so

important when working on hydraulic

that the “M” or “∞” mark at the joint is at

cylinders.

the top center of the crawler frame.

• Be careful with the high-pressure grease

In the track adjuster, the grease has

been injected under high pressure. If the

tension is adjusted without following the

prescribed procedure, the grease

discharge valve may fly off, resulting in

injury.

· Never loosen the grease fitting.

· Loosen the grease discharge valve

slowly. Do not turn it more than one

turns.

· Do not put your face, arms, legs or

body in front of the grease discharge

2. Use the working equipment to lift the

valve.

machine body. Operate the levers slowly.

· If grease does not come out when the

grease discharge valve is loosened,

the valve is faulty. Ask a Takeuchi

service agent for repair.

3. Inspect the gap between the bottom

surface of the frame at the center of the

crawler frame and the top surface of the

crawler.

The gap must be within the following

range:

5-26

MAINTENANCE

EVERY 50 HOURS

(A) Rubber crawler

Decreasing the tension

59 to 64 mm (2.3 to 2.5 in.)

Adjustment

Increasing the tension

1. Remove the cover (1).

2. Slowly loosen (one turn) the grease

discharge valve (2) with a spanner to

discharge grease. If grease does not

come out well, move the machine back-

1. Remove the cover (1).

and-forth.

2. Inject grease through the grease fitting (3)

3. Tighten the grease discharge valve (2).

of the grease discharge valve (2) with a

· Tightening torque: 177 N·m (130 ft-lb.)

grease gun.

3. Inspect the crawler tension.

5-27

MAINTENANCE

EVERY 50 HOURS

LUBRICATING THE SLEW BEARING

LUBRICATING THE SLEW MOTOR PINION

Do not slew while lubricating. Doing so is

dangerous, as you may get caught in the

machine.

1. Use the grease gun to lubricate the grease

fitting (2).

2. Wipe off the excess grease.

1. Stop the engine with the machine in the

posture shown on the figure above.

2. Use the grease gun to grease the grease

fitting (1).

3. Start the engine, lift the bucket and slew

clockwise 90°.

4. Lower the bucket to the ground, and then

stop the engine.

5. Repeat the steps 2 to 4 above three

times.

6. Wipe off the grease expelled from the slew

bearing and grease fitting.

5-28

MAINTENANCE

EVERY 50 HOURS

DRAINING THE WATER FROM THE FUEL

Bleeding air from the fuel system

TANK

Refer to “Bleeding air from the fuel system”

on page 6-8.

Note: Air in the fuel system causes the

• Do not smoke or permit open flames

engine to fail to start or to have problems.

while handling fuel or working on the

Bleed air when the fuel tank is emptied,

fuel system.

using the same procedure above.

• Never remove the fuel cap or add fuel

when the engine is running or still hot.

Do not spill fuel on the hot surface of

the machine.

• Fill the fuel tank in a well ventilated

place.

• Do not fill the fuel tank to capacity.

Allow room for oil expansion.

• Clean up spilled fuel immediately.

• Securely tighten the fuel filler cap.

• Use the correct grade of fuel for the

operating season.

Do the draining operation before starting the

machine.

1. Slew the upperstructure to the position for

easy draining.

2. Remove the fuel filler cap (2).

3. Place a pan under the drain plug (3).

4. Loosen the drain plug (3) to drain water

and sediment buildup in the bottom of the

tank.

5. Tighten the drain plug (3).

6. Add fuel while watching the sight gauge

(1).

7. Tighten the fuel filler cap (2) and lock it.

8. Bleed air.

5-29

MAINTENANCE

EVERY 50 HOURS

INSPECTING THE BATTERY FLUID LEVEL

Inspection

AND REPLENISHING

IMPORTANT: Check the fluid level of all

cells following the steps below, even

when the fluid level can be checked using

• Do not use the battery when the fluid

the indicator.

level is below the lower level limit. Doing

so will hasten the deterioration of the

1. Open the engine hood.

internal portions of the battery and

shorten the battery life. It also can

cause rupturing (explosion).

• Batteries generate flammable hydrogen

gas which may explode. Keep away

from flame, sparks, fire or lighted

cigarettes.

• Use a dampened cloth to clean above

the fluid level line and check the fluid

level. Do not clean with a dry cloth;

otherwise it can cause static electricity

to build up, resulting in ignition or

explosion.

2. Inspect the indicator (1).

· Blue: Good

· White: Charging needed

· Red: Insufficient battery fluid

• Wear protective goggle and clothing

3. Inspect the fluid level.

when working with batteries.

The fluid level must be between the upper

• Do not add the distilled water above the

level line (H) and lower level line (L). If not,

upper level limit. Doing so could cause

add distilled water up to the line (H).

the fluid to leak. This fluid can cause

skin damage if contacted, or can cause

the machine components to corrode.

• Batteries contain sulfuric acid which will

damage eyes or skin if contacted.

· If eye contact occurs, flush

immediately with clean water and get

prompt medical attention.

· If accidentally swallowed, drink large

quantities of water or milk and call a

physician immediately.

· If acid contacts skin or clothing, wash

off immediately with a lot of water.

5-30

MAINTENANCE

EVERY 50 HOURS

• If the fluid level cannot be checked by fluid

level lines:

Remove the caps (2) and look into the

fluid filler holes to check the fluid level. If

the fluid is below the sleeve (3), be sure to

add distilled water up to the bottom edge

of the sleeve (3).

Proper level (A)

If the fluid reaches up to the bottom edge

of the sleeve (3), the surface tension

causes the fluid to swell and the plate

appears as if it is distorted.

Level too low (B)

If fluid does not reach up to the bottom

edge of the sleeve (3), the plate looks

laminar, not distorted.

4. Check the terminals for looseness and

dirt.

Replenishing

When adding distilled water, do so before

starting operations in order to prevent

freezing.

1. Remove the caps (2), and add distilled

water until the upper level (H).

2. Check that the indicator (1) turns blue.

3. Clean the exhaust hole on the cap, then

tighten the caps (2) securely.

5-31

MAINTENANCE

EVERY 100 HOURS

CLEANING THE FUEL FILTER

EVERY 100 HOURS

CLEANING THE WATER SEPARATOR

• Do not smoke or permit open flames

while handling fuel or working on the

• Do not smoke or permit open flames

fuel system.

while handling fuel or working on the

• Stop the engine in a well-ventilated

fuel system.

place and allow it to cool down before

• Stop the engine in a well-ventilated

performing maintenance.

place and allow it to cool down before

• Clean up spilled fuel immediately.

performing maintenance.

• Clean up spilled fuel immediately.

1. Open the engine hood.

2. Close the valve (2).

1. Open the engine hood.

3. Loosen the ring (3), remove and clean the

2. Close the valve (2).

case (4) and the element (5).

3. Loosen the ring (3), and then remove and

4. Inspect the O-ring and the element (5). If

clean the case (4), element (5) indicator

there are any scratches or other

ring (6) and spring (7).

irregularities, replace them.

4. Inspect the O-ring and the element (5). If

5. Install the element (5) and the case (4) and

there are any scratches or other

tighten them with the ring (3).

irregularities, replace them.

6. Open the valve (2) to bleed air.

5. Install the indicator ring (6), spring (7),

Refer to “Bleeding air from the fuel

element (5) and case (4), and then tighten

system” on page 6-8.

the ring (3).

6. Open the valve (2) to bleed air.

Refer to “Bleeding air from the fuel

system” on page 6-8.

5-32

MAINTENANCE

AFTER THE INITIAL 250 HOURS (ONLY FOR NEW MACHINES)

1. Set the travel motor so that plug (1) is at

AFTER THE INITIAL 250

the very bottom.

2. Place a pan under the plug (1).

HOURS (ONLY FOR NEW

3. Remove the plugs (1) and (2) and drain the

oil.

MACHINES)

4. Rewrap the plugs with new sealing tape.

REPLACING THE TRAVEL MOTOR GEAR

5. Tighten the plug (1).

OIL

6. Add oil through the hole of the plug (2)

until oil flows out of the hole of the plug

(2).

7. Tighten the plug (2).

• Stop the engine and allow the machine

to cool down before performing

maintenance.

· The travel motor is hot immediately

after the engine is stopped. Touching

it will cause burns.

· The gear oil is also hot and under high

pressure immediately after the engine

is stopped.

Be careful when loosening the plugs.

Working on the machine under these

conditions could result in burns or

injuries.

• The pressure in the reduction gear case

of travel motor may cause oil or the plug

to fly out. Loosen the plug slowly to

release the pressure.

IMPORTANT: If the percentage of the

traveling time within the total operating

time is high, replace the gear oil earlier

than the specified time.

2

1

AD6G022

5-33

MAINTENANCE

EVERY 250 HOURS

EVERY 250 HOURS

REPLACING THE ENGINE OIL AND THE

OIL FILTER

Refer to “Replacing the engine oil and the oil

filter” on page 5-22.

INSPECTING AND ADJUSTING THE FAN

BELT

Refer to “Inspecting and adjusting the fan

1. Open the maintenance cover A.

belt” on page 5-23.

2. Loosen the clamps (1) and remove the

dust cup (2).

CLEANING THE AIR CLEANER

• Stop the engine and allow the machine

to cool down before performing

maintenance.

· The engine, muffler, radiator and many

other parts of the machine are hot

immediately after the engine is

stopped. Touching it will cause burns.

• Wear required appropriate equipment

3. Clean the inside of the dust cup (2).

such as protective goggle and filter

4. Remove the primary element (3).

mask when using compressed air, as

5. Cover the intake hole at the back of the

metal fragments or other objects can fly

body (4) with cloth or tape to prevent dirt

and cause serious injury.

from getting in.

<If equipped with the secondary element>

IMPORTANT: Be careful not to scratch the

To prevent dirt from getting inside the

element. Do not use an element if it is

engine, do not remove the secondary

damaged.

element (5).

IMPORTANT: When operating the

6. Clean the inside of the body (4).

machine in very dusty places, perform

inspection and maintenance operations

every day.

IMPORTANT: Be sure to install the

element and dust cap securely. If not,

dust could be drawn into the cylinder,

damaging the engine.

5-34

MAINTENANCE

EVERY 250 HOURS

7. Clean the primary element (3) with dried

compressed air (294 to 490 kPa or 43 to

71 psi).

First blow the air from the inside of the

element along the pleats. Then blow the

air from the outside and finally from the

inside again.

8. Light up the inside of the primary element

(3) with a light bulb, inspect it, and replace

it if there are small holes or thin spots.

9. Remove the cloth or tape applied in step

5.

10. Install the primary element (3).

11. Install the dust cup (2) with its

“ TOP

” mark facing up, and then

fasten it with the clamps (1).

12. Push the button (3) on the dust indicator

to reset the red piston (2).

5-35

MAINTENANCE

EVERY 250 HOURS

CLEANING THE RADIATOR FINS AND OIL

COOLER FINS

Wear required appropriate equipment

such as protective goggle and filter mask

when using compressed air, as metal

fragments or other objects can fly and

cause serious injury.

IMPORTANT: Be careful not to damage

the fins when cleaning.

• When using compressed air or

pressurized water, make sure the

pressure is no higher than 200 kPa (28

psi) and hold the nozzle sufficiently

away from the fins.

IMPORTANT: When using water, cover the

electrical system to prevent water from

getting in.

IMPORTANT: When operating the

machine in very dusty places, perform

inspection and maintenance operations

every day.

1. Open the engine hood.

2. Blow compressed air on the fins to

remove mud and dirt stuck on them.

5-36

MAINTENANCE

EVERY 500 HOURS

EVERY 500 HOURS

REPLACING THE HYDRAULIC OIL

RETURN FILTER

Refer to “Replacing the hydraulic oil return

filter” on page 5-24.

REPLACING THE WATER SEPARATOR

FILTER

• Do not smoke or permit open flames

while handling fuel or working on the

fuel system.

• Stop the engine in a well-ventilated

place and allow it to cool down before

performing maintenance.

• Clean up spilled fuel immediately.

1. Open the engine hood.

2. Close the valve (2).

3. Loosen the ring (3) and remove the case

(4).

4. Remove the spring (7) and the indicator

ring (6) from the case (4).

5. Clean the case (4).

6. Inspect the O-ring. If there are any

scratches or other irregularities, replace it.

7. Replace the element (5) with a new one.

8. Install the indicator ring (6) and the spring

(7) in the case (4).

9. Install the case (4) to the bracket and

tighten the ring (3) by hand.

10 Open the valve (2) to bleed air.

Refer to “Bleeding air from the fuel

system” on page 6-8.

5-38

MAINTENANCE

EVERY 500 HOURS

REPLACING THE FUEL FILTER

• Do not smoke or permit open flames

while handling fuel or working on the

fuel system.

• Stop the engine in a well-ventilated

place and allow it to cool down before

performing maintenance.

• Clean up spilled fuel immediately.

1. Open the engine hood.

2. Close the valve (2).

3. Loosen the ring (3) and remove the case

(4).

4. Clean the case (4).

5. Inspect the O-ring. If there are any

scratches or other irregularities, replace it.

6. Replace the element (5) with a new one.

7. Install the case (4) to the bracket and

tighten the ring (3) by hand.

8. Open the valve (2) to bleed air.

Refer to “Bleeding air from the fuel

system” on page 6-8.

5-39

MAINTENANCE

EVERY 1000 HOURS

• Do not remove the radiator cap or the

EVERY 1000 HOURS

drain plug when the cooling water is

REPLACING THE TRAVEL MOTOR GEAR

hot. Stop the engine and wait until the

OIL

engine and the cooling water cool.

Then, slowly loosen the radiator cap

Refer to “Replacing the travel motor gear oil”

and the drain plug to remove them.

on page 5-33.

When cleaning, if the temperature of the

coolant is low, the thermostat will be closed

CLEANING THE ENGINE COOLING

and the coolant will not circulate in the

SYSTEM

radiator. Heat the coolant water to at least

90°C (194°F) before cleaning.

1. Open the engine hood.

• Stop the engine and allow the machine

to cool down before performing

maintenance.

· The engine, muffler, radiator and many

other parts of the machine are hot

immediately after the engine is

stopped. Touching these parts will

cause burns.

· The engine coolant is also hot and

under high pressure immediately after

the engine is stopped. Be careful

when loosening the caps or plugs.

2. Gradually loosen the radiator cap (3) to

Working on the machine under these

release the internal pressure, and then

conditions could result in burns or

remove the cap.

injuries due to the hot coolant spurting

out.

• If maintenance must be performed with

the engine running, always work as a

two person team communicating each

other.

· One person must sit in the operator’s

seat so that he/she can immediately

stop the engine when necessary. He/

she must take care not to touch the

lever or pedal unless necessary.

· The one who performs maintenance

must make sure to keep his/her body

3. Place a pan for catching the waste coolant

or clothing away from the moving part

under the drain plug (4), and then loosen

of the machine.

the drain plug (4) to drain the coolant.

• Standing at the back of the machine

4. Tighten the drain plug (4).

while the engine is running is extremely

5. Add tap water to the radiator through the

dangerous, as the machine could move

coolant fill port up to the top of the port.

suddenly. Never stand at the back of the

Take time and slowly add water, so that no

machine while the engine is running.

air enters the radiator.

6. Close the radiator cap (3).

5-40

MAINTENANCE

EVERY 1000 HOURS

REPLACING THE AIR CLEANER ELEMENT

5. Cover the intake hole at the back of the

body (4) with cloth or tape to prevent dirt

from getting in.

<If equipped with the secondary element>

Stop the engine and allow the machine to

Do not yet remove the secondary element

cool down before performing

(5).

maintenance.

6. Clean the inside of the body (4).

• The engine, muffler, radiator and many

7. Remove the cloth or tape applied in step

other parts of the machine are hot

5.

immediately after the engine is stopped.

<If equipped with the secondary element>

Touching these parts will cause burns.

Remove the secondary element (5).

8. Install the new elements.

IMPORTANT: Do not use an element if its

9. Install the dust cup (2) with its “ TOP

”

pleats, gaskets or seals are damaged.

mark facing up, and then fasten it with the

IMPORTANT: Be sure to install the

clamps (1).

element and dust cap securely. If not,

dust could be drain into the cylinder,

damaging the engine.

1. Open the maintenance cover A.

10. Push the button (3) on the dust indicator

to reset the red piston (2).

2. Loosen the clamps (1) and remove the

dust cup (2).

3. Clean the inside of the dust cup (2).

4. Remove the primary element (3).

5-42

MAINTENANCE

EVERY 4000 HOURS

EVERY 4000 HOURS

REPLACING THE HYDRAULIC OIL AND

CLEANING THE SUCTION STRAINER

• Stop the engine and allow the machine

to cool down before performing

maintenance.

· The engine and the hydraulic system

and many other parts of the machine

3. Open the engine hood.

are hot immediately after the engine is

4. Slowly loosen the air bleeding plug (1) to

stopped. Touching these parts will

relieve the internal pressure, and then

cause burns.

remove the plug.

· The hydraulic oil is also hot and under

high pressure immediately after the

engine is stopped.

Be careful when loosening the caps or

plugs. Working on the machine under

these conditions could result in burns

or injuries due to the hot oil spurting

out.

• Oil may spurt out if caps or filters are

removed or pipes are disconnected

before releasing the pressure in the

hydraulic system.

· Gradually loosen the vent plug to

5. Loosen the bolts (2) and remove the cover

relieve tank pressure.

(3).

· When removing plugs or screws, or

6. Loosen the hose bands and remove the

when disconnecting hoses, stand to

hose (5) from the flange (6).

the side and loosen them slowly to

7. Loosen the bolts to take out the flange (6).

gradually release the internal pressure

before removing.

1. Set the machine to the hydraulic oil level

inspection posture.

Refer to “Inspecting the hydraulic oil tank

level and replenishing” on page 5-19.

2. Raise the safety lock lever to the locked

position.

5-46

MAINTENANCE

EVERY 4000 HOURS

21. Tighten the plug (1).

22. Bleed air from the hydraulic oil circuit

following “Bleeding air” below.

23. Set the machine to the hydraulic oil level

inspection posture and inspect the oil

level when the oil temperature drops.

Refer to “Inspecting the hydraulic oil tank

level and replenishing” on page 5-19.

Bleeding air

IMPORTANT: After replacing the hydraulic

oil, bleed air from the hydraulic circuits

and hydraulic devices. Failure to do so

may damage the hydraulic devices.

• Cylinders

1. Start the engine, let it run at a low-idling

speed for 10 minutes.

2. Maintain the engine at low idle, then

extend and retract each cylinder 4 or 5

times, without let them reach the stroke

end.

3. Run the engine at high speed, then extend

and retract each cylinder 4 or 5 times,

8. Remove the return filter (7).

without let them reach the stroke end.

9. Place a pan for catching the waste oil

4. Set the engine back to a low idle, then

under the drain plug (9).

extend and contract all the cylinders 4 or 5

10. Loosen the drain plug (9) and drain the

times to the stroke ends.

hydraulic oil.

11. Loosen the hose bands and remove the

hose (4).

12. Loosen the bolts and remove the flange

(10).

13. Remove the suction strainer (11) and

clean it.

14. Clean the inside of the hydraulic tank.

15. Install the suction strainer (11) to the

flange (10).

16. Reinstall the flange (10) and the hose (4)

to their original positions.

17. Install a new return filter to the flange (6).

18. Reinstall the flange (6) to their original

positions.

19. Tighten the drain plug (9).

20. Add hydraulic oil from the hole of plug (1)

up to the level between the upper limit

(H) and the lower limit (L) in the sight

gauge (8).

5-47

MAINTENANCE

WHEN REQUIRED

Removal

WHEN REQUIRED

1. Clean the bucket and park the machine in

REPLACING THE BUCKET TEETH

a flat, safe place where the ground is hard.

2. Set the bottom surface of the bucket flat

Replace the bucket teeth if the tooth points

and lower it on a block so that the bolt (1)

are worn. Do not wait until the bucket is

can be taken out.

damaged.

3. Remove the starter key, and then check

that the bucket is stable.

• Before performing maintenance or

repairs under the machine, lower all

moveable working equipment to the

ground or in the lowermost position.

• To prevent unexpected movement,

firmly secure the working equipment

when repairing or replacing the bucket

teeth or side cutter.

• When using a hammer, pins may fly out

2

1

4

3

or metal particles may be scattered.

This may lead to serious injury.

AD6G028

· If hard metal parts such as pins,

4. Remove the bolt (1).

bucket teeth, side cutter or bearings

5. Remove the teeth (2) and the shim (3).

are hit with a hammer, wear protective

gear such as safety goggles and

gloves.

· When hitting pins or bucket teeth,

always check that there is no one in

the surrounding area.

• Do not allow unauthorized personnel in

the work area while working.

Replace the teeth if they are worn to 140

mm (5.5 in.).

5-48

MAINTENANCE

WHEN REQUIRED

Installation

1. Clean the section where the teeth are to

be installed. If there is gravel or mud on

the section, the tooth point may not go in

all the way.

2. Put the teeth into the bucket.

3. If the teeth are not secured, insert a shim

to reduce the clearance.

4. Insert the bolt from the outside of the

bucket and tighten it with the nut.

· Tightening torque: 102 N·m (75.2 ft-lb)

AD6G029

5. Caulk the bolt with a punch or weld it at

three spots on the threaded portion (nut

side).

5-49

MAINTENANCE

WHEN REQUIRED

REPLACING THE BUCKET

1. Lower the bucket to the ground as shown

on the figure above in a stable position.

Note: When removing pins, set the bucket

• Before performing maintenance or

so that it is barely touching the ground If the

repairs under the machine, lower all

bucket is firmly touching the ground, the

working equipment to the ground or in

resistance will be great and it will be difficult

the lowermost position.

to remove the pin.

• If maintenance must be performed with

the engine running, always work as a

2. Set the safety lock lever to the locked

two person team communicating each

position and stop the engine.

other.

· One person must sit in the operator’s

seat so that he/she can immediately

2

stop the engine when necessary. He/

she must take care not to touch the

lever or pedal unless necessary.

2

· The one who performs maintenance

must make sure to keep his/her body

or clothing away from the moving part

of the machine.

• When using a hammer, pins may fly out

4

3

1

or metal particles may be scattered.

AD6G033

This may lead to serious injury.

3. Disengage the ring of the lock pin (1) and

· If hard metal parts such as pins,

remove the lock pin (1).

bucket teeth, side cutter or bearings

4. Hammer the pin (2) out of the bucket.

are hit with a hammer, wear protective

5. Remove the bucket.

gear such as safety goggles and

Inspect the pin seal (3) and replace it if it is

gloves.

deformed or damaged. (See next page.)

· When hitting pins or bucket teeth,

always check that there is no one in

the surrounding area.

• When aligning the pin holes, always do

so by checking them visually. Do not

insert your finger in the pin hole, or you

could lose your finger.

Removing

5-50

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