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Takeuchi compact excavator TB210R (Serial No. 211000004~). Operators Manual (2019) - page 4

MAINTENANCE

DAILY INSPECTION (EVERY 10 HOURS)

INSPECTING AND REPLENISHING THE

Replenishing

ENGINE OIL

Stop the engine and allow the machine to

cool down before performing

maintenance.

Inspection

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.

1. Open the engine hood and the

maintenance cover.

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

off with a rag.

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

it back out.

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

The level should be between the upper

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

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

5-17

MAINTENANCE

DAILY INSPECTION (EVERY 10 HOURS)

INSPECTING THE FUEL FILTER

INSPECTING THE FUEL LEVEL

(WATER SEPARATOR)

• 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.

• Never remove the fuel cap or add fuel

• Stop the engine in a well-ventilated

when the engine is running or still hot.

place and allow it to cool down before

Do not spill fuel on the hot surface of

performing maintenance.

the machine.

• Clean up spilled fuel immediately.

• 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 fuel lid.

2. Inspect the fuel filter (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 fuel filter” on page

1. Check the fuel level using the sight gauge

5-32.

(1).

Refer to “Bleeding air from the fuel

F: Tank is full.

system” on page 6-8.

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 (1).

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.

• Gradually loosen the vent plug to relieve

tank pressure.

Inspection

The oil level changes with the oil

IMPORTANT: Do not fill up to the level

temperature. Inspect the oil by maintaining

higher than the middle level of the sight

the machine at posture shown in the figure at

gauge (1). Doing so will damage the

the next.

hydraulic circuits or result in oil spurting.

• Machine posture for inspecting the

If filled over the middle level, stop the

hydraulic oil level

engine, wait for the hydraulic oil to cool

and then let the excessive oil drain from

the drain plug.

IMPORTANT: Do not forget to apply

pressure to the hydraulic oil tank to avoid

damage to the pump caused by air

sucking. (If not equipped with the air

breather)

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

relieve the internal pressure, and then

remove it.

2. Add hydraulic oil up to the midpoint of the

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

sight gauge (1).

2. Fully extend the crawler width.

3. Pressurize the hydraulic oil tank as follows.

3. Fully retract the cylinders (arm and

bucket), and lower the bucket to the

Note: For a machine equipped with the air

ground.

breather, no pressurization is necessary.

4. Lower the dozer blade, and then stop the

engine.

5. Open the engine hood.

6. Inspect the oil level using the sight gauge

(1).

· When the oil temperature is about 20°C

(68°F):

The proper oil level should be in the

middle of the sight gauge (1).

If the level is lower, replenish.

5-19

MAINTENANCE

DAILY INSPECTION (EVERY 10 HOURS)

Pressurizing the hydraulic oil tank

(If not equipped with the air breather)

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 oil tank pressurization posture

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

and span cylinders.

4. Stop the engine and raise the left safety

lock lever to engage the lock.

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

pressurize by retracting the cylinders.

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)

1. Open the engine hood and the

AFTER THE INITIAL 50

maintenance cover.

2. Remove the oil filler cap (2).

HOURS (ONLY FOR NEW

MACHINES)

REPLACING THE ENGINE OIL AND THE

OIL FILTER

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

3. Loosen the bolt and remove the under

of the machine are hot immediately after

cover (3).

the engine is stopped. Touching these

4. Place a pan for catching the waste oil

parts will cause burns.

under the drain plug (4).

• The engine oil is also hot.

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

Be careful not to touch the hydraulic oil

and drain the oil. (The oil comes out when

when loosening the cap or plug.

the screw is tightened.)

Working on the machine under these

6. Remove the connector (B) and install the

conditions could result in burns or

cap (A).

injuries.

IMPORTANT: Check the waste oil for

metal powder. If it contains large amounts

of metal powder, consult your sales or

service dealer.

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 adjusting bolt (4) and the

IMPORTANT: The loose belts could result

locking bolt (5).

in bad battery charge, overheat of engine

2. Move the alternator by using leverage to

or early wear of belt. Too tight belts could

adjust the slack.

damage the water pump or bearing and

3. Tighten the adjusting bolt (4) and the

belt used to drive the alternator.

locking bolt (5).

IMPORTANT: Do not let any oil or grease

get on the belt.

Note: When replacing with a new belt, run

the engine at low idle speed for about 3 to 5

Inspection

minutes to break in the new belt, before

1. Open the maintenance cover.

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 9 mm (0.28 to

0.35 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.

5-24

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

3. Loosen the five bolts and remove the left

cause burns.

side cover (4).

· The hydraulic oil is also hot and under

4. Open the fuel lid.

high pressure.

5. Turn the filter (3) counterclockwise with the

Be careful not to touch the hydraulic

filter wrench and remove it.

oil when loosening the cap or plug.

6. Clean the surface of installation of the filter

Working on the machine under these

stand.

conditions could result in burns or

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

injuries due to the hot oil spurting out.

the new filter.

• Oil may spurt out if caps or filters are

8. Install the new filter.

removed or pipes are disconnected

· Tightening torque: 13.7 ± 2 N·m (10.1 ±

before releasing the pressure in the

1.5 ft-lb.)

hydraulic system.

9. Install the left side cover (4).

· Gradually loosen the vent plug to

10. Inspect the level with the sight gauge (1),

relieve tank pressure.

and replenish if the level is too low.

· When removing plugs or screws, or

Refer to “Inspecting the hydraulic oil tank

when disconnecting hoses, stand to

level and replenishing” on page 5-19.

the side and loosen them slowly to

11. Pressurize the hydraulic oil tank.

gradually release the internal pressure

(If not equipped with the air breather)

before removing.

Refer to “Pressurizing the hydraulic oil

tank” on page 5-20.

Note: For a machine equipped with the air

breather, no pressurization is necessary.

1. Open the engine hood.

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

relieve the internal pressure, and then

remove the plug.

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

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

cylinders.

is at 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:

(A) Rubber crawler

53 to 58 mm (2.1 to 2.3 in.)

5-26

MAINTENANCE

EVERY 50 HOURS

Adjustment

Decreasing the tension

Increasing the tension

1. Remove the cover (1).

2. Slowly loosen (one turn) the grease

1. Remove the cover (1).

discharge valve (2) with a spanner to

2. Inject grease through the grease fitting (3)

discharge grease. If grease does not

of the grease discharge valve (2) with a

come out well, move the machine back-

grease gun.

and-forth.

3. Inspect the crawler tension.

3. Tighten the grease discharge valve (2).

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

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. Stop the engine with the machine in the

posture shown on the figure above.

2. Use the grease gun to lubricate the grease

fitting (2).

3. 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 the

fuel lid.

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

Note: Under normal operating conditions,

internal portions of the battery and

the maintenance-free battery does not

shorten the battery life. It also can

require addition of water because of the

cause rupturing (explosion).

special plate designed to minimize fluid loss.

• Batteries generate flammable hydrogen

However, for those machines that are heavily

gas which may explode. Keep away

used or operated under severe conditions

from flame, sparks, fire or lighted

(for example, in high ambient temperature),

cigarettes.

the fluid level often becomes low. If that is

• Use a dampened cloth to clean above

the case, check the fluid level of the

the fluid level line and check the fluid

maintenance-free battery and add water as

level. Do not clean with a dry cloth;

needed.

otherwise it can cause static electricity

Note: The warranty will be void if the label on

to build up, resulting in ignition or

the battery is removed during the warranty

explosion.

period. If the indicator displays “Insufficient

• Do not use the cable if it’s connecting

battery fluid” during the warranty period,

terminal is loose or corroded. If used,

contact your sales or service dealer without

ignition or explosion may occur.

doing anything to the battery.

• Do not block the exhaust hole of the

battery. An explosion could result, if

1. Open the engine hood.

blocked.

• Wear protective goggle and clothing

when working with batteries.

• Do not add the distilled water above the

upper level limit. Doing so could cause

the fluid to leak. This fluid can cause

skin damage if contacted, or can cause

the machine components to corrode.

• Batteries contain sulfuric acid which will

2. Inspect the indicator (1).

damage eyes or skin if contacted.

· Blue: Good

· If eye contact occurs, flush

· White: Charging needed

immediately with clean water and get

· Red: Insufficient battery fluid

prompt medical attention.

3. Inspect the fluid level.

· If accidentally swallowed, drink large

The fluid level must be between the upper

quantities of water or milk and call a

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

physician immediately.

add distilled water up to the line (H).

· If acid contacts skin or clothing, wash

4. Check the battery terminal for looseness,

off immediately with a lot of water.

dirt and corrosion.

5. Check the exhaust holes (2) for dirt.

5-30

MAINTENANCE

EVERY 100 HOURS

EVERY 100 HOURS

CLEANING THE FUEL FILTER

• Do not smoke or permit open flames

while handling fuel or working on the

fuel system.

• Stop the engine in a well-ventilated

place and allow it to cool down before

performing maintenance.

• Clean up spilled fuel immediately.

1. Open the fuel lid.

2. Close the valve (2).

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

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

ring (6) and spring (7).

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

there are any scratches or other

irregularities, replace them.

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

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

the ring (3).

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

Refer to “Bleeding air from the fuel

system” on page 6-8.

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

1. Open the fuel lid.

Refer to “Inspecting and adjusting the fan

2. Loosen the clamps (1) and remove the

belt” on page 5-24.

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.

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

• Wear required appropriate equipment

4. Remove the primary element (3).

such as protective goggle and filter

5. Cover the intake hole at the back of the

mask when using compressed air, as

body (4) with cloth or tape to prevent dirt

metal fragments or other objects can fly

from getting in.

and cause serious injury.

<If equipped with the secondary element>

To prevent dirt from getting inside the

IMPORTANT: Be careful not to scratch the

engine, do not remove the secondary

element. Do not use an element if it is

element (5).

damaged.

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

IMPORTANT: When operating the

machine in very dusty places, perform

inspection and maintenance operations

every day.

IMPORTANT: Be sure to install the

element and dust cap securely. If not,

dust could be drawn into the cylinder,

damaging the engine.

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).

5-35

MAINTENANCE

EVERY 250 HOURS

CLEANING THE RADIATOR 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. Blow compressed air on the fins to

remove mud and dirt stuck on them.

5-36

MAINTENANCE

EVERY 500 HOURS

Pre-fuel filter (If equipped)

EVERY 500 HOURS

REPLACING THE HYDRAULIC OIL

RETURN FILTER

Refer to “Replacing the hydraulic oil return

filter” on page 5-25.

REPLACING THE FUEL FILTERS

• Do not smoke or permit open flames

1. Open the fuel lid.

while handling fuel or working on the

2. Remove the clamps (8) and (9).

fuel system.

3. Remove the hoses (10) and (11).

• Stop the engine in a well-ventilated

4. Replace the filter (12) with a new one.

place and allow it to cool down before

5. Install the hoses (10) and (11).

performing maintenance.

6. Install the clamps (8) and (9).

• Clean up spilled fuel immediately.

7. Bleed air.

Refer to “Bleeding air from the fuel

Fuel filter

system” on page 6-8.

1. Open the fuel lid.

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.

5-37

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. Loosen the bolt and remove the under

or clothing away from the moving part

cover (5).

of the machine.

4. Place a pan for catching the waste coolant

• Standing at the back of the machine

under the drain plug (4), and then loosen

while the engine is running is extremely

the drain plug (4) to drain the coolant.

dangerous, as the machine could move

5. Tighten the drain plug (4).

suddenly. Never stand at the back of the

6. Add tap water to the radiator through the

machine while the engine is running.

coolant fill port up to the top of the port.

Take time and slowly add water, so that no

air enters the radiator.

5-38

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 fuel lid.

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).

5-40

MAINTENANCE

EVERY 1000 HOURS

REPLACING THE AIR BREATHER (IF

INSPECTING AND ADJUSTING THE

EQUIPPED)

ENGINE VALVE CLEARANCE

This operation requires experience. Ask your

service dealer for it.

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.

1. Open the engine hood.

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

relieve the internal pressure, and then

remove the plug.

3. Turn the air breather (5) counterclockwise

by hand or with the wrench and remove it.

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

the new air breather

5. Install the new air breather by hand.

· Tightening torque: Max. 5 N·m

Note: For a machine equipped with the air

breather, no pressurization is necessary.

5-41

MAINTENANCE

EVERY 2000 HOURS

EVERY 2000 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

stopped. Touching these parts will

cause burns.

· 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

4. Remove the battery (C).

before releasing the pressure in the

a. Remove the key from the starter switch.

hydraulic system.

b. First, remove the cable from the

· Gradually loosen the vent plug to

negative (-) side.

relieve tank pressure.

c. Next, remove the cable from the

· When removing plugs or screws, or

positive (+) side.

when disconnecting hoses, stand to

d. Then, loosen the double nut (A) and

the side and loosen them slowly to

remove the fitting (B).

gradually release the internal pressure

e. Remove the battery (C).

before removing.

Note: Depending on the specifications of the

1. Set the machine to the hydraulic oil level

machine, the positions of the negative (-)

inspection posture.

and positive (+) terminals are reversed.

Refer to “Inspecting the hydraulic oil tank

Check the markings on the battery, and then

level and replenishing” on page 5-19.

disconnect the terminal from the earth (-)

2. Raise the safety lock lever to the locked

side first.

position.

5. Lift the reserve tank (D) and remove it.

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

relieve the internal pressure, and then

remove the plug.

5-43

MAINTENANCE

EVERY 2000 HOURS

14. Install the suction strainer (8).

15. Install the flange (7).

16. Tighten the drain plug (6).

17. Add hydraulic oil from the hole of plug (2)

up to the midpoint of the sight gauge (1).

18. Tighten the plug (2).

19. Bleed air from the hydraulic oil circuit

following “Bleeding air” below.

20. 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.

21. Pressurize the hydraulic oil tank.

(If not equipped with the air breather)

Refer to “Pressurizing the hydraulic oil

tank” on page 5-20.

Note: For a machine equipped with the air

breather, no pressurization is necessary.

Bleeding air

IMPORTANT: After replacing the hydraulic

oil or hydraulic devices, or after

performing maintenance of the hydraulic

devices, 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

7. Place a pan for catching the waste oil

end.

under the drain plug (6).

3. Run the engine at high speed, then extend

8. Loosen the drain plug (6) and drain the

and retract each cylinder 4 or 5 times,

hydraulic oil.

without let them reach the stroke end.

9. Loosen the bolts and remove the flange (7).

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

10. Remove the suction strainer (8) and

extend and contract all the cylinders 4 or 5

clean it.

times to the stroke ends.

11. Clean the inside of the hydraulic oil tank.

12. Replace the return filter (3).

Refer to “Replacing the hydraulic oil

return filter” on page 5-25.

13. Replace the air breather (5) (if equipped).

Refer to “Replacing the air breather (If

equipped)” on page 5-41

5-44

MAINTENANCE

WHEN REQUIRED

Removing

WHEN REQUIRED

REPLACING THE BUCKET

• Before performing maintenance or

repairs under the machine, lower all

working equipment to the ground or in

the lowermost position.

• If maintenance must be performed with

the engine running, always work as a

two person team communicating each

other.

1. Lower the bucket to the ground as shown

· One person must sit in the operator’s

on the figure above in a stable position.

seat so that he/she can immediately

stop the engine when necessary. He/

Note: When removing pins, set the bucket

she must take care not to touch the

so that it is barely touching the ground. If the

lever or pedal unless necessary.

bucket is firmly touching the ground, the

· The one who performs maintenance

resistance will be great and it will be difficult

must make sure to keep his/her body

to remove the pin.

or clothing away from the moving part

of the machine.

2. Set the safety lock lever to the locked

• When using a hammer, pins may fly out

position and stop the engine.

or metal particles may be scattered.

This may lead to serious injury.

· If hard metal parts such as pins,

bucket teeth, side cutter or bearings

are hit with a hammer, wear protective

gear such as safety goggles and

gloves.

· When hitting pins or bucket teeth,

always check that there is no one in

the surrounding area.

• When aligning the pin holes, always do

so by checking them visually. Do not

insert your finger in the pin hole, or you

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

could lose your finger.

remove the lock pin (1).

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

5. Remove the bucket.

5-46

MAINTENANCE

WHEN REQUIRED

Installation

1. Align the pin hole (A) on the bucket with

the pin hole on the arm (5), and install the

pin (2).

2. Operate the cylinder, align the pin hole (B)

on the bucket with the pin hole on the link

arm (6), and install the pin (2).

1

AD6G034

3. Align the turn prevention holes, install the

lock pin (1), and then engage the ring

inside.

5-47

MAINTENANCE

WHEN REQUIRED

LUBRICATING THE LEVERS

Set the machine to the parking posture,

stop the engine, remove the starter key

and store it. Failure to do so may result in

the machine moving abruptly, leading to

serious injury or death.

If the levers or pedals no longer move

smoothly, grease them.

Operating levers

1. Remove the lower mount section of the

boot (1) and turn it upward.

2. Wipe off the old grease.

3. Apply grease to points (A) and (B).

4. Set the boot (1) back as it was.

5-48

MAINTENANCE

WHEN REQUIRED

INSPECTING THE RUBBER CRAWLERS

(3) Metal core

Repair or replace the rubber crawlers if their

condition becomes as described below.

Consult your sales or service dealer for repair

or replacement.

Rubber crawler

Replace the crawler if the entire crawler is

stretched and cannot be adjusted.

(1) Lug

Replace if even one metal core is off.

(4) Rubber

Replace if the height of (A) is 5 mm (0.2 in.)

or below.

(2) Steel cord

Repair if there are cracks of 60 mm (2.4 in.)

or greater in length.

If the steel cord is visible, repair as soon as

possible, regardless of the length of the

crack.

Replace if the steel cord is exposed for two

links or more.

Replace if the half or more of the steel cords

on one side are cut.

5-49

MAINTENANCE

WHEN REQUIRED

REPLACING THE RUBBER CRAWLERS

Removal

1. Fully release the tension of the rubber

crawler.

Refer to “Inspecting and adjusting the

• If you must work beneath the raised

crawler tension” on page 5-26.

machine or working 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.

• 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/

2. Use the working equipment to lift the

she must take care not to touch the

body.

lever or pedal unless necessary.

· The one who performs maintenance

must make sure to keep his/her body

or clothing away from the moving part

of the machine.

3. Set an iron pipe (1) in the rubber crawler

and turn the sprocket slowly in the reverse

direction.

4. Turn until the iron pipe (1) is directly next to

the idler and the rubber crawler lifts away

from the idler, then stop turning the

sprocket.

5. Slide the rubber crawler sideways and

remove it from the crawler frame.

Remove the other rubber crawler using

the same procedure.

5-50

MAINTENANCE

WHEN REQUIRED

Installation

1. Use the working equipment to lift the

body.

2. Set the rubber crawler on the sprocket.

3. Set an iron pipe (1) in the rubber crawler

and turn the sprocket slowly in the reverse

direction.

4. Turn until the iron pipe (1) is directly next to

the idler and the rubber crawler lifts away

from the idler, then stop turning the

sprocket.

5. Slide the rubber crawler inward, engage it

on the idler, then pull out the iron pipe.

6. Check that the rubber crawler is securely

engaged on the sprocket and idler.

7. Tighten the rubber crawler to the standard

tension.

Refer to “Inspecting and adjusting the

crawler tension” on page 5-26.

8. Install the other rubber crawler using the

same procedure.

5-51

TROUBLESHOOTING

SYMPTOMS THAT ARE NOT MALFUNCTIONS

• It becomes less easy to operate the

SYMPTOMS THAT ARE NOT

machine when an attachment weighing

more than a standard arm or bucket is

MALFUNCTIONS

installed.

The symptoms listed below are not

malfunctions.

AG7J002

• The arm retracting speed momentarily

slows down when it reaches an almost

vertical position while the engine is running

at low speed.

AG7J003

• The bucket teeth moving speed

momentarily slows down when it reaches

an almost horizontal position while the

engine is running at low speed.

• The slew motor produces noise at the

beginning and end of the slewing.

• The travel motor produces noise when

stopped suddenly from its high speed

traveling.

• The control valve produces noise if

excessive force is applied to the working

equipment or when it moved to the stroke

end.

6-2

TROUBLESHOOTING

IF THE ENGINE OVERHEATS

Remedy procedure

IF THE ENGINE OVERHEATS

1. Park the machine in a safe place.

2. Check if steam is coming out of the closed

engine hood and covers.

• Do not open the engine hood and

3. If there is steam, stop the engine

covers when steam is coming from it.

immediately and contact your sales or

The steam or hot water may spurt out

service dealer for repair. If steam, is not

and cause burns.

coming out run the engine at low idle and

• Do not try to remove the radiator cap or

let the water temperature cool down.

the drain plug when the cooling water is

4. Stop the engine when the coolant

hot. Stop the engine, wait until the

temperature warning lamp goes out.

engine and the radiator cool, and then

5. Perform the inspections and the remedies

slowly loosen the radiator cap to release

listed below once the engine cools down.

the internal pressure.

· Fan belt slack

Adjust

• Before performing maintenance, stop

Refer to page 5-24.

the engine and allow the machine to

· Coolant level

Add

cool down.

Refer to page 5-16.

· Water leakage

Repair

The symptoms listed below indicate

· Radiator fins

Clean

overheating.

Refer to page 5-36.

· Sediment in cooling system

............................... Clean

Refer to page 5-38.

If the problem persists after the above

remedies, contact your sales or service

dealer for repair.

• The coolant temperature warning lamp

lights up.

• Steam comes from the engine room.

6-3

TROUBLESHOOTING

IF THE BATTERY GOES DEAD

Connecting the jumper cables

IF THE BATTERY GOES DEAD

The symptoms below indicate that the

IMPORTANT: Set the starter keys of the

battery is dead.

booster vehicle and the dead machine to

• The starter motor does not turn or fails to

the OFF position.

start the engine.

• The horn is too weak.

Remedy procedure

Start the engine using the booster battery on

the other vehicle (booster vehicle) and the

jumper cables.

• When starting the engine using the

jumper cables, be sure to connect the

cables by following the proper steps.

Improper use of jumper cables can

1. Connect the clip of jumper cable (R) to the

result in battery explosion or

positive (+) battery terminal of the dead

unexpected machine motion.

machine.

· Do not allow the booster vehicle and

2. Connect the other clip of jumper cable (R)

the machine with a dead battery (dead

to the positive (+) battery terminal of the

machine) to touch each other.

booster vehicle.

· Do not allow the positive (+) and the

3. Connect the clip of jumper cable (B) to the

negative (-) clips of the jumper cables

negative (-) battery terminal of the booster

to touch each other.

vehicle.

· When connecting, attach the jumper

4. Connect the other clip of jumper cable (B)

cable to the positive (+) terminals first.

to the engine block of the dead machine.

When disconnecting, remove the

Connect the clip to a place as far from the

cable from the negative (-) terminal

battery as possible.

(ground) first.

· Connect the last clip of the jumper

Starting the engine

cable to a point as far away from the

1. Check that the clips are securely

battery as possible.

connected to the terminals.

• Always wear the protective goggle when

2. Start the engine of the booster vehicle and

jump starting the engine by using the

run it at high speed.

jumper cables.

3. Start the engine of the dead machine.

IMPORTANT: Use the jumper cables and

clips of a size suited to the capacity of

battery. Do not use damaged or corroded

jumper cables and clips.

IMPORTANT: Be sure that the battery of

the booster vehicle has the same

capacity as the battery of the dead

machine.

IMPORTANT: Be sure to connect the clips

securely.

6-4

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