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Takeuchi compact excavator TB108 (Serial No. 10820001~). Operators Manual - page 3

TRANSPORT

Loading and Unloading

1. Apply the truck’s parking brake and place

WARNING

stoppers against its tires.

2. Fasten the ramps securely to the truck bed

The machine may roll or tip over or fall

so that they will not come off. Set the

while loading or unloading it. Take the

ramps to an angle of 15° or less.

following precautions:

3. Line up the center of the truck bed with

¡ Select a firm, level surface and keep

the center of the machine and the center

sufficient distance from road

of the ramps with the center of the

shoulders.

crawlers.

¡Use loading ramps of adequate

4. Make sure the dozer blade does not hit

strength and size. Maintain the slope

the ramps.

of loading ramps within 15 degrees.

5. Lower the hoe attachment as much as

¡ Keep the truck bed and loading ramps

possible, making sure it will not hit the

clean of oil, clay, ice, snow, and other

truck.

materials which can become slippery.

6. Lower the engine speed with the throttle

Clean the tracks.

lever.

¡ 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.

Fasten to the suspension fitting

Ramp

Stopper

15° or less

Distance between ramps

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”.

82

TRANSPORT

Securing the Machine

After loading the machine in the designated

position, secure it as described below.

Transporting Posture

Padding

Wire rope

E4F002

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.

IMPORTANT: Place a wooden block

under the bucket so that it is not damaged

by hitting the floor.

83

MAINTENANCE

General

Do not clean parts with fuel.

Disposing of wastes

Do not use fuel to clean parts. Use a non-

¡ Collect spent fluids from the machine in

combustible cleaning agent.

containers. Disposing of wastes

irresponsibly damages the environment.

Keep dirt out.

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

When mounting and removing parts, do so

filters, batteries and other harmful

in a place where there is no dust, clean the

substances as prescribed by law.

working area and the part, and keep dirt out.

Check after maintenance

Clean mounting surfaces.

¡ Gradually increase the engine speed from

When mounting and removing parts, be sure

a low idle to maximum speed and check

that the surfaces of contact of the parts are

that there is no oil or water leaking from

clean. If the sealing grooves of the surface

serviced parts.

of contact are damaged, consult a Takeuchi

¡ Operate all the operating levers and check

sales or service outlet.

that the machine is operating properly.

Seals and split pins

Cautions on handling of battery cables

¡ Replace removed seals and split pins with

¡ Disconnect the battery cables (+,-) before

new ones.

working on the electrical system or doing

¡ When mounting, be careful not to damage

any welding.

or twist the seal.

Remove the negative (-) battery cable first.

When reconnecting the battery, connect

Sealing tape

the negative (-) battery cable last.

¡ Do not disconnect the battery cables while

Sealing tape

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.

87

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.

Type by temperature

Replacement

Capacity

Part

Type

-22

-4

14 32 50 68 86 104°F

interval

R(US. qt.)

-30 -20 -10

0

10 20 30 40 °C

Upper limit:

Diesel

SAE 5W-20

After first 50

Engine oil

1.7

(1.8)

engine oil

SAE 10W-30

hrs.

pan

Lower limit:

API - CD

SAE 15W-40

Every 250 hrs.

1.0

(1.1)

System: 14

ISO VG32

Hydraulic

Antiwear

(3.7 U.S.gal)

ISO VG46

Every 2000 hrs.

tank

hydraulic oil

Tank: 7.3

ISO VG68

(1.9 U.S.gal)

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

Tank: 8

Fuel tank

Diesel fuel

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

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

(2.1 U.S.gal)

require the use of fuel with a higher cetane number.

Engine

Coolant

50% coolant mixture

cooling

(water * +

Every 1000 hrs.

2.8

(3.0)

30% coolant mixture

system

coolant **)

Travel

After first 250

Gear oil

0.33

(0.35)

reduction

SAE 90

hrs.

API-GL-4

each

gear

Every 1000 hrs.

Slew motor

Every 50 hrs.

pinion

Lithium

Slew

based

Every 50 hrs.

bearing

As

grease

Working

Daily or every

required

EP-2

equipment

10 hrs.

NLGI No. 2

Levers

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.

88

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

Hydraulic Oil

Filter Element

1st time

25

2nd time

100

Periodically

600

200

When the breaker operating ratio is 100%

Refer to page 154 “Hydraulic Breaker”.

Expendables

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

Item

Part name

Part No.

Replacement interval

Return filter

Cartridge

15510-20310

After first 50 hrs.

Every 500 hrs.

Fuel filter

Element

119810-55650

Every 500 hrs.

Engine oil filter

Cartridge

119305-35151

After first 50 hrs.

Every 250 hrs.

Air cleaner

Element

119655-12560

Every 1000 hrs. or

(outer)

after

6 cleanings

(whichever comes

first)

Inner Element

19111-01342

Every 1000 hrs. or

(option)

after 3 cleanings of

the outer element

(whichever comes

first)

89

MAINTENANCE

Service Data

Tools

No.

Part name

Part No.

Remarks

1

Grease gun

16910-60600

600cc

2

Drain connector

15545-12201

3

Case

16919-00001

90

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.

1

3

6

5

4

2

E4G003

Head width

Torque

Size (a) X Pitch

Thread

(b)

General Connection Points

mm

mm

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

Coarse

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

Fine

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

91

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

Replacement Interval

Fuel hoses

Fuel system

Packing in fuel filler cap

Hydraulic hoses ( Pump - delivery )

Hydraulic hoses ( Pump - suction )

Main

body

Hydraulic hoses ( Slew motor )

Hydraulic hoses ( Travel motor )

Hydraulic hoses ( Boom cylinder lines )

Hydraulic

Every 2 years

system

Hydraulic hoses ( Arm cylinder lines)

Hydraulic hoses ( Bucket cylinder lines )

Working

Hydraulic hoses ( Swing cylinder )

equipment

Hydraulic hoses ( Blade cylinder )

Hydraulic hoses ( Spanner cylinder )

Hydraulic hoses ( Auxiliary lines )

Seat belt

Every 3 years

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. To

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”.

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.

92

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

110

93

MAINTENANCE

Maintenance Chart

Maintenance Items

See page

Every 250 Hours

Cleaning the air cleaner

111

Cleaning the radiator fins

112

Replacing the engine oil and oil filter

112

Inspecting and adjusting the fan belt

112

Every 500 Hours

Replacing the fuel filter

113

Replacing the hydraulic oil return filter

113

Every 1000 Hours

Cleaning the engine cooling system

114

Replacing the air cleaner element

115

Replacing the travel motor gear oil

116

Inspecting and adjusting the engine valve clearance

116

Retightening the engine cylinder head bolts

116

Inspecting the engine fuel injection pressure and spray condition

116

Every 2000 Hours

Replacing the hydraulic oil and cleaning the suction strainer

117

Inspecting the engine fuel injection timing

118

Inspecting the engine fuel injection valve

118

When Required

Replacing the bucket

119

Inspecting the rubber crawlers

121

Replacing the rubber crawlers

122

94

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.

5

4

14

11

8

1

2

13

12

3

6

7

10

9

B5G003E

Inspecting by Opening the

Engine Hood

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

3. Check for oil leakage from the hydraulic

combustible materials around the engine

tank, hydraulic devices, hoses and

and battery.

connections.

2. Check for oil or engine coolant water

leakage around the engine.

95

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.

Replenishing

Inspecting and Replenishing the

1. Add coolant to a level of 30 mm (1.2 in.)

Coolant

above the top surface of the radiator core.

2. Install the radiator cap (1).

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.

97

MAINTENANCE

Daily Inspection (Every 10 Hours)

3. Tighten the oil supply cap (2).

Inspecting and Replenishing the

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

Engine Oil

3 minutes, then stop it.

5. After about 10 minutes, inspect the oil

WARNING

level.

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.

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.

98

MAINTENANCE

Daily Inspection (Every 10 Hours)

Inspecting the Water Separator

Checking the Fuel Level

WARNING

WARNING

Stop the engine and allow the machine

¡ Do not smoke or permit open flames

to cool down before performing

while fueling or near fueling operations.

inspection and maintenance.

¡Stop the engine in a well-ventilated

place when adding fuel.

¡ Clean up spilled fuel immediately.

¡ Do not fill the fuel

tank to capacity.

Allow room for expansion.

¡ Tighten the fuel filler cap securely.

1

3

1. Open the engine hood.

2

2. Inspect the water separator (1).

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

bottom of the case (4), no water is mixed

B5G008

in.

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

1. Check the fuel level

using the sight gauge

is water up to the bottom of the ring. Drain

(3).

the water and clean.

2. If the level is low, add fuel from the fuel

Refer to page 109 “Cleaning the Water

port (1) while watching the sight gauge (3).

Separator”.

Refer to page 39 “Fuel Filler Cap”.

99

MAINTENANCE

Daily Inspection (Every 10 Hours)

Replenishing

Inspecting the Hydraulic Oil Level

and Replenishing

3

1

WARNING

Oil may spurt out if caps or filters are

2

removed or pipes disconnected before

releasing the pressure in the hydraulic

system.

B5G010

¡Gradually loosen the vent plug to

1. Slowly turn the vent plug (1) to release

relieve tank pressure.

the internal pressure, then remove.

2. Add hydraulic oil up to the middle of the

Inspection

sight gauge (2).

The oil level changes according to the oil

3. Pressurize the hydraulic tank using the

temperature. Inspect the oil level in the

procedure next.

hydraulic oil level inspection posture shown

in the diagram.

Pressurizing the hydraulic tank

¡ Hydraulic oil level inspection posture

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

2. With the vent plug (1) removed, set the

safety lock lever to the released position.

¡ Hydraulic tank pressurization posture

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

2. Fully retract the arm and bucket cylinders

and ground the bucket.

3. Ground the dozer blade, then stop the

engine.

4. Open the engine hood.

5. Inspect the oil level using the sight gauge

(2).

¡ When the oil temperature is about 20°C

(68°F):

3. Fully extend the bucket, arm, boom and

The level should be at the middle of the

swing cylinders.

sight gauge.

4. Stop the engine and set the safety lock

If it is below the middle, replenish.

lever to the locked position.

5. Tighten the vent plug (1).

100

MAINTENANCE

Daily Inspection (Every 10 Hours)

Lubricating the Working Equipment

B5G0112

1. Set the machine to the lubrication posture shown in the diagram above, ground the working

equipment, then stop the engine.

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

3. Wipe off the expelled grease.

101

MAINTENANCE

After First 50 Hours (New Machines Only)

3. Using a filter wrench, turn the filter (3)

Replacing the Hydraulic Oil

counterclockwise and remove it.

Return Filter

4. Clean the surface of installation of the filter

stand.

WARNING

5. Apply a thin layer of oil to the packing of

the new filter.

¡ Stop the engine and allow the machine

6. Install the new filter by hand.

to cool down before performing

7. Tighten 3/4 more turns with the filter

maintenance.

wrench after the filter packing comes in

• The engine, hydraulic lines and many

contact with the surface of installation.

other parts of the machine are hot

8. Inspect the level with the sight gauge (2),

directly after the engine is stopped.

and replenish if the level is low.

Touching these parts will cause

Refer to page 100 “Inspecting the

burns.

Hydraulic Oil Level and Replenishing”.

• The hydraulic fluid is also hot and

9. Pressurize the hydraulic tank.

under high pressure.

Refer to page 100 “Pressurizing the

Be careful when loosening caps and

Hydraulic Tank”.

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 disconnected before

releasing the pressure in the hydraulic

system.

• Gradually loosen the vent plug to

relieve tank pressure.

• When removing plugs or screws or

disconnecting hoses, stand to the

side and loosen slowly to gradually

release the internal pressure before

removing.

3

1

2

B5G010

1. Open the engine hood.

2. Slowly turn the vent plug (1) to relieve tank

pressure, then remove.

102

MAINTENANCE

After First 50 Hours (New Machines Only)

4. Remove cap (A), install connector (B) and

Replacing the Engine Oil and Oil

drain the oil. (The oil comes out when the

Filter

screw is tightened.)

5. Remove connector (B) and install cap (A).

WARNING

IMPORTANT: Check the spent oil. If it

Stop the engine and allow the machine

contains large amounts of metal powder,

to cool down before performing

consult a Takeuchi sales or service outlet.

maintenance.

¡ The engine, muffler, radiator and many

other parts of the machine are hot

directly after the engine is stopped.

Touching these parts will cause burns.

¡ The engine oil is also hot.

Be careful when loosening caps and

plugs. Working on the machine under

these conditions could result in burns.

6. Using a filter wrench, turn the filter (4)

counterclockwise and remove it.

7. Clean the surface of installation of the filter

stand.

8. Apply a thin layer of oil to the packing of

the new filter.

9. Install the new filter by hand.

10. Tighten 3/4 more turns with the filter

wrench after the filter packing comes in

1. Open the engine hood.

contact with the surface of installation.

2. Remove the oil supply cap (2).

11. 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.

12. Tighten the oil supply cap (2).

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

3 minutes, then stop it.

14. After about 10 minutes, inspect the oil

3

level.

B

A

B5G013

3. Place a pan for catching the spent oil

under the drain plug (3).

103

MAINTENANCE

After First 50 Hours (New Machines Only)

Adjustment

Inspecting and Adjusting the Fan

Belt

WARNING

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

1. Loosen the adjustment bolt (5) and locking

parts of the machine are hot directly

nut (6).

after the engine is stopped. Touching

2. Using a lever (7), move the alternator (8)

these parts will cause burns.

and adjust the slack.

3. Tighten the adjustment bolt (5) and locking

Inspection

nut (6).

1. Open the engine hood.

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

and alternator pulley (3) and check the

tension (about 98N or 22 lbs.).

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

(0.28 to 0.4 in.).

3. Inspect the fan belt (4) and replace it if:

¡ there are cuts or cracks.

¡ the belt is worn and touches the bottom

of the V groove in the pulley.

¡the belt stretches and cannot be

adjusted.

104

MAINTENANCE

Every 50 Hours

Inspecting and Adjusting the

A

Crawler Tension

WARNING

¡ If you must work beneath the raised

machine or equipment, always use

wood blocks, jack-stands or other rigid

B5G024

and stable supports. Never get under

2. Use the operating devices to lift the body.

the machine or working equipment if

Operate the levers slowly.

they are not sufficiently supported.

This procedure is especially important

when working on hydraulic cylinders.

¡The track adjuster contains highly

pressurized grease. If the tension is

adjusted without following the

prescribed procedure, the grease

A

discharge valve may fly off, resulting

in injury.

B5G023

• Do not loosen the grease nipple.

3. Inspect the gap (A) between the bottom

• Loosen the grease discharge valve

surface of the frame at the center of the

slowly.

crawler frame and the top surface of the

• Do not put your face, arms, legs or

crawler.

body in front of the grease discharge

The gap (A) should be within the following

valve.

range:

• If no grease is expelled when grease

(A) Rubber crawler :

discharge valve is loosened, there is a

53 to 58 mm (2.1 to 2.3 in.)

problem. Contact your nearest service

outlet for repairs. DO NOT disassemble,

Adjustment

as this is very dangerous.

Increasing the tension

Inspection

2

1

3

D5G025

C4G0182

1. Remove the cover (1).

2. Using the grease gun, insert grease

1. For rubber crawlers, move the machine

through the grease nipple (3) in the grease

so that the “M” or “∞” mark at the coupling

discharge valve (2).

is at the top center of the crawler frame.

3. Inspect the crawler tension.

105

MAINTENANCE

Every 50 Hours

Decreasing the tension

Lubricating the Slew Bearing

WARNING

2

1

Do not slew while lubricating. Doing so

is dangerous, as you may get caught in

3

the machine.

B5G0261

1. Remove the cover (1).

2. Using the Spanner, slowly loosen the

grease discharge valve (2) and drain the

grease.

If the grease does not drain easily, move

the machine forward or backward.

1

3. Tighten the grease discharge valve (2).

B5G014

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

1. Stop the engine with the machine in the

posture shown on the diagram above.

2. Use the grease gun to supply grease to

the grease nipple (1).

E4G026

3. Start the engine, lift the bucket and slew

clockwise 90°.

4. Ground the bucket and stop the engine.

5. Repeat steps 2 to 4 above three times.

6. Wipe off the grease expelled from the slew

bearing and grease nipple.

106

MAINTENANCE

Every 50 Hours

Lubricating the Slew Motor

Inspecting the Battery Fluid Level

Pinion

and Replenishing

DANGER

¡ 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

2

cause rupturing (or an explosion).

B5G016

¡Batteries generate flammable and

1. Stop the engine with the machine in the

explosive gases. Keep arcs, sparks,

posture shown on the diagram above.

flames and lighted tobacco away.

2. Use the grease gun to supply grease to

¡ Use a dampened cloth to clean the area

the grease nipple (2).

of the fluid level lines and check the

3. Wipe off the grease expelled from the

fluid level. Note that if this area is

grease nipple.

cleaned with a dry cloth, static

electricity could cause ignition or

explosion.

WARNING

¡ 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.

¡ 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.

107

MAINTENANCE

Every 50 Hours

Inspection

Draining the Fuel Tank

1. Open the engine hood.

WARNING

¡ 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.

2. Inspect the battery fluid level by sight.

Do

this before operating

the machine.

¡ The level should be between the upper

limit (H) and lower limit (L).

1

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

3. Also check the terminals for looseness and

dirt.

3

2

Replenishing

When adding distilled water, do so before

starting operations in order to prevent

B5G008

freezing.

1. Open the engine hood.

1. Remove the caps (4), and add distilled

2. Remove the fuel filler cap (1).

water until the upper limit (H).

3. Place a pan under the drain plug (2).

2. Clean the cap’s exhaust hole, then tighten

4. Remove the drain plug (2) and drain the

the caps securely.

water and sediment from the bottom of

the tank.

5. Tighten the drain plug (2).

6. While watching the sight gauge (3), add

fuel.

7. Tighten the fuel filler cap (1) and closing

the engine hood and lock it with the key.

8. Bleed the air.

Refer to page 129 “Bleeding the Air from

the Fuel System”.

Supplement: Air in the fuel system can

make it difficult to start the engine and cause

engine problems. Also bleed the air when

the fuel tank is emptied.

108

MAINTENANCE

Every 100 Hours

Cleaning the Fuel Filter

Cleaning the Water Separator

WARNING

WARNING

¡ 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

¡Stop the engine in a well-ventilated

place and allow it to cool down before

place and allow it to cool down before

performing maintenance.

performing maintenance.

¡ Clean up spilled fuel immediately.

¡ Clean up spilled fuel immediately.

1. Open the engine hood.

1. Open the engine hood.

2. Close the cock (2).

2. Close the cock (2).

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

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

(4) and element (5) and clean them.

(4), element (5) and indicator ring (6) and

4. Inspect the O-ring, and if there are any

clean them.

scratches or other irregularities, replace

4. Inspect the O-ring, and if there are any

it.

scratches or other irregularities, replace

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

it.

and tighten the ring (3).

5. Assemble the indicator ring (6), case (4)

6. Open the cock (2) and bleed the air.

and element (5) and tighten the ring (3).

Refer to page 129 “Bleeding the Air from

6. Open the cock (2) and bleed the air.

the Fuel System”.

Refer to page 129 “Bleeding the Air from

the Fuel System”.

109

MAINTENANCE

After First 250 Hours (New Machines Only)

Replacing the Travel Motor Gear

Oil

WARNING

¡ Stop the engine and allow the machine

to cool down before performing

maintenance.

• The travel motors are hot directly

after the engine is stopped. Touching

them will cause burns.

• The gear oil is also hot and under

high pressure.

Be careful when loosening plugs.

Working on the machine under these

conditions could result in burns or

injuries.

¡The pressure in the travel motor

reduction gears case may cause oil or

the plug to fly out. Loosen the plug

slowly to release the pressure.

1. Set the travel motor so that plug (2) is at

the very bottom.

2. Place a pan for catching the spent oil

under plug (2).

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

oil.

4. Wrap new sealing tape around the plugs.

5. Tighten plug (2).

6. Add oil through the hole for plug (1) until

oil flows out of the hole.

7. Tighten plug (1).

110

MAINTENANCE

Every 250 Hours

3. Loosen the clamp (1) and remove the dust

Cleaning the Air Cleaner

cup (2).

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

WARNING

5. Remove the element (3).

6. Cover the intake hole at the back of the

¡ Stop the engine and allow the machine

body (4) with cloth or tape to prevent dirt

to cool down before performing

from getting in.

maintenance.

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

• The engine, muffler, radiator and

many other parts of the machine are

hot directly after the engine is

stopped. Touching these parts will

cause burns.

¡ Wear required appropriate equipment

such as safety glasses and filter mask

when using compressed air, as metal

fragments or other objects can fly and

cause serious personal injury.

E4G033

8. Clean the element

(3) with dried

IMPORTANT: Be careful not to scratch

compressed air {294 to 490 kPa (43 to 71

the element. Do not use an element if it

psi)}.

is damaged.

First blow the air from the inside of the

IMPORTANT: When operating the

element along the flutes, then blow the air

machine in very dusty places, inspection

from the outside, and finally from the inside

and maintenance should be performed

again.

every day.

Supplement: Do not remove and clean the

inner element (option). Replace the inner

element every 1000 hrs. or after every 3

cleaning of the outer element.

(whichever comes first)

1. Open the engine hood.

2. Remove the hook of the rubber band (5)

and free the body (4).

E4G034

9. Light up the inside of the element with a

5

bulb, inspect it, and replace it if there are

2

4

small holes or thin spots.

10. Remove the cloth or tape applied in step 6.

11. Install the element (3).

12. Install the dust cup (2), then fasten it with

1

the clamp (1).

3

13. Fasten the body (4) with the rubber band

B5G019

(5).

111

MAINTENANCE

Every 250 Hours

Cleaning the Radiator Fins

Replacing the Engine Oil and Oil

Filter

WARNING

Refer to page 103 “Replacing the Engine Oil

and Oil Filter”.

Wear required appropriate equipment

such as safety glasses and filter mask

when using compressed air, as metal

fragments or other objects can fly and

Inspecting and Adjusting the Fan

cause serious personal injury.

Belt

IMPORTANT: Be careful not to damage

Refer to page 104 “Inspecting and Adjusting

the radiator fins when cleaning them.

the Fan Belt”.

¡When using compressed air or

pressurized water, make sure the

pressure is no higher than 200kPa (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, inspection

and maintenance should be performed

every day.

1. Blow compressed air on the radiator fins

to remove mud and dirt stuck on them.

112

MAINTENANCE

Every 500 Hours

Replacing the Fuel Filter

Replacing the Hydraulic Oil

Return Filter

WARNING

Refer to page 102 “Replacing the Hydraulic

Oil Return 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 cock (2).

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

(4) and element (5).

4. Clean the case (4).

5. Assemble the new element in the case

(4), then tighten the ring (3).

6. Open the cock (2) and bleed the air.

Refer to page 129 “Bleeding the air from

the fuel system”.

113

MAINTENANCE

Every 1000 Hours

1. Open the engine hood.

Cleaning the Engine Cooling

System

WARNING

¡ 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 directly after the engine is

2. Place a cloth over the radiator cap (1) and

stopped. Touching these parts will

loosen it gradually to release the internal

cause burns.

pressure before removing it.

• The engine coolant is 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 coolant

spurting out.

¡ If maintenance must be performed with

the engine running, always work as a

two-person 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.

¡ Standing at the back of the machine

while the engine is running is extremely

dangerous, as the machine could move

suddenly. Never stand at the back of

the machine while the engine is

running.

¡ Do not remove the radiator cap or drain

plugs when the coolant is hot. Stop the

engine, let the engine and radiator cool

3. Place a pan for catching the spent coolant

and loosen the radiator cap or drain

under the drain hose (2), plug (3), then

plugs slowly.

loosen the drain hose (2), plug (3) and

drain the coolant.

114

MAINTENANCE

Every 1000 Hours

4. Tighten the drain hose (2), plug (3), then

Replacing the Air Cleaner

add a little cleaning agent and tap water

Element

to the radiator until it is full. Take your time

doing this.

WARNING

Follow the manufacturer’s instructions

when using the cleaning agent.

Stop the engine and allow the machine

5. Run the engine at a low idle for about 30

to cool down before performing

minutes. For the first 5 minutes after

maintenance.

starting it, pay attention to the level of the

¡ The engine, muffler, radiator and many

cleaning fluid, and add tap water if the level

other parts of the machine are hot

drops.

directly after the engine is stopped.

6. Stop the engine and drain the cleaning

Touching these parts will cause burns.

fluid.

7. Tighten the drain hose (2), plug (3), add

IMPORTANT: Do not use an element if its

tap water, run the engine at a low idle for

flutes, gaskets or seals are damaged.

about 10 minutes, then stop the engine

Supplement: Do not remove and clean the

inner element (option). Replace the inner

and drain the water.

element every 1000 hrs. or after every 3

Clean repeatedly until the drained water

cleaning of the outer element.

is clear.

(whichever comes first)

8. After cleaning is completed, tighten the

1. Open the engine hood.

drain hose (2), plug (3) and add new

coolant up to the specified level.

9. Run the engine at a low idle, bleed the air,

5

2

then stop the engine once the coolant level

4

stabilizes at the specified level.

10. Check the coolant level, then tighten the

radiator cap (1).

1

3

B5G019

2. Remove the hook of the rubber band (5).

3. Loosen the clamp (1) and remove the dust

cup (2).

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

5. Remove the element (3).

6. Cover the intake hole at the back of the

body (4) with cloth or tape to prevent dirt

from getting in.

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

8. Remove the cloth or tape applied in step 6.

9. Install the new element.

10. Install the dust cup (2), then fasten it with

the clamp (1).

11. Fasten the body (4) with the rubber band

(5).

115

MAINTENANCE

Every 2000 Hours

Replacing the Hydraulic Oil and

4

1

Cleaning the Suction Strainer

WARNING

¡ Stop the engine and allow the machine

to cool down before performing

7

maintenance.

4

2

• The engine, hydraulic lines and many

other parts of the machine are hot

3

directly after the engine is stopped.

4

Touching these parts will cause

6

burns.

5

• The hydraulic fluid is also hot and

9

under high pressure.

7

8

B5G0182

Be careful when loosening caps and

plugs. Working on the machine under

3. Loosen the bolts (4) and remove the cover

these conditions could result in

(5).

burns or injuries due to the hot oil

4. Slowly turn the vent plug (1) to relieve tank

spurting out.

pressure, then remove.

¡ Oil may spurt out if caps or filters are

5. Using a filter wrench, turn the filter (3)

removed or pipes disconnected before

counterclockwise and remove it.

releasing the pressure in the hydraulic

6. Clean the surface of installation of the filter

system.

stand.

• Gradually loosen the vent plug to

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

relieve tank pressure.

the new filter.

• When removing plugs or screws or

8. Install the new filter by hand.

disconnecting hoses, stand to the

9. Tighten 3/4 more turns with the filter

side and loosen slowly to gradually

wrench after the filter packing comes in

release the internal pressure before

contact with the surface of installation.

removing.

10. Place a pan for catching the spent oil

under the drain plug (6).

1. Slew 45° clockwise and set the machine

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

to the hydraulic oil level inspection posture.

hydraulic oil.

Refer to page 100 “Inspecting the

12. Loosen the hose clip, then remove the

Hydraulic Oil Level and Replenishing”.

hoses (7).

2. Open the engine hood.

13. Remove the bolts, then remove the

flange (8).

14. Remove the suction strainer (9) and

clean it.

15. Clean the inside of the hydraulic tank.

16. Install the suction strainer (9) to the flange

(8).

117

MAINTENANCE

When Required

2. Set the safety lock lever to the locked

Replacing the Bucket

position and stop the engine.

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

WARNING

remove the lock pin.

¡Before performing maintenance or

repairs under the machine, set all

working equipment against the ground

2

1

or in the lowermost position.

¡ If maintenance must be performed with

the engine running, always work as a

2

two-person team with one person

sitting in the operator’s seat while the

other works on the machine.

B5G027

• When performing maintenance, be

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

sure to keep your body and clothing

5. Remove the bucket.

away from moving parts.

¡ Wear required appropriate equipment

Installation

such as safety glasses and filter mask

when using hammers, as metal

fragments or other objects can fly and

5

cause serious personal injury.

¡ When lining up the pin holes, always

6

do so by sight. Your finger may be cut

A

B

off if you stick it into the hole.

Removal

E4G054

1. Line up pin hole (A) in the bucket with the

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

(2).

2. Operate the cylinder, line up pin hole (B)

in the bucket with the pin hole in the link

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

E4G048

1. Ground the bucket as shown on the

diagram above in a stable position.

Supplement: When removing pins, set the

bucket so that it is just gently against the

ground. If it is strongly against the ground,

the resistance will be great and it will be

difficult to remove the pin.

119

MAINTENANCE

When Required

1

C4G032

3. Line up the turn prevention holes, install

lock pin (1), and set the ring on the inner

side.

120

MAINTENANCE

When Required

(3) Metal core

Inspecting the Rubber Crawlers

Repair or replace the rubber crawlers if their

conditions are as described below. Consult

a Takeuchi sales or service outlet about

repairs or replacement.

Rubber crawler

Replace the crawler if the entire crawler is

3

E4G064

stretched and cannot be adjusted.

Replace if even one metal core is off.

(1) Lug

(4) Rubber

60 mm or greater

4

3

A

1

2

E4G062

E4G065

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

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

or below.

or greater in length.

If the steel cord is visible, repair as soon as

(2) Steel cord

possible, regardless of the length of the

crack.

2

E4G063

Replace if the steel cord is exposed over 2

or more links.

Replace if half or more of the steel cords on

one side are cut.

121

MAINTENANCE

When Required

Replacing the Rubber Crawlers

Direction of rotation

WARNING

¡ If you must work beneath the raised

machine or equipment, always use

wood blocks, jack-stands or other rigid

1

E4G067

and stable supports. Never get under

the machine or working equipment if

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

they are not sufficiently supported.

and turn the sprocket slowly in the reverse

This procedure is especially important

direction.

when working on hydraulic cylinders.

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

¡ If maintenance must be performed with

to the idler and the rubber crawler lifts

the engine running, always work as a

away from the idler, then stop turning the

two-person team with one person

sprocket.

sitting in the operator’s seat while the

5. Slide the rubber crawler sideways and

other works on the machine.

remove it from the crawler frame.

• When performing maintenance, be

Remove the other rubber crawler using

sure to keep your body and clothing

the same procedure.

away from moving parts.

Installation

Removal

1. Use the working equipment to lift the body.

1. Fully release the tension of the rubber

crawler.

Refer to page 105 “Inspecting and

Direction of rotation

Adjusting the Crawler Tension”.

1

E4G068

2. Set the rubber crawler on the sprocket.

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

E4G070

and turn the sprocket slowly in the reverse

direction.

2. Use the working equipment to lift the body.

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.

122

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