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Takeuchi Hydraulic excavator TB1160W (Serial No. 514500002~). Operator's Manual (2016) - page 1

INTRODUCTION

FOREWORD

This manual describes operation, inspection

and maintenance of the machine, as well as

safety instructions to be heeded during these

operations.

If you have any questions about the

machine, please contact a Takeuchi sales or

service outlet.

MANUAL STORAGE COMPARTMENT

SERIAL NUMBERS

A compartment for storing this manual is

IMPORTANT: Do not remove the machine

provided at the position shown on the

name plate with the serial number.

diagram below.

Check the serial numbers of the machine

and engine and write them down in the

spaces below.

Machine number:

1. Open the cover behind the seat.

2. After using the manual, place it in the

plastic pouch and store it back in the

manual storage compartment.

Engine number:

0-2

MACHINE DESCRIPTION

FRONT, REAR, LEFT AND RIGHT

DESIGNATED OPERATIONS

Use this machine primarily for the following

operations:

• Excavation

• Digging ditches

• Leveling

• Loading

FEATURES

• Hydromounted cab minimizes vibration

• Low engine noise and exhaust emissions

• Electronic control of auxiliary hydraulic

circuit

• Automatic and manual operation for engine

deceleration

• Engine emergency stop system

Equipped with outrigger

BREAK-IN PERIOD

When the machine is new, operate the

machine for the first 100 hours (as indicated

on the hour meter) by following the

instructions below.

Using a new machine without a break-in

period will lead to quicker deterioration of

machine performance and may shorten the

machine’s service life.

• Sufficiently warm up the engine and

hydraulic oil.

• Avoid heavy loads and rapid operations.

Operate with a load of about 80% the

maximum load.

• Do not abruptly start up, accelerate,

change directions, or stop unless

necessary.

This manual refers the front, rear, left and

right of the machine as seen when sitting in

the operator’s seat with the steering device

visible to the front.

0-3

SAFETY

GENERAL PRECAUTIONS

Wear appropriate clothing and protective

Install a fire extinguisher and first aid kit

equipment

AG7A005

AG7A004

Be prepared for fire and accidents

• Do not wear loose clothing or any

• Install an extinguisher and a first aid kit,

accessory that can catch on controls or in

and learn how to use them.

moving parts.

• Lean how to fight a fire and how to deal

• Do not wear oily or fuel stained clothing

with accidents.

that can easily catch fire.

• Know how to contact emergency

• Wear a hard hat, safety shoes, safety

assistance and make a list of emergency

glasses, filter mask, heavy gloves, ear

contacts.

protection and other protective equipment

as required by job conditions. Wear

required appropriate equipment such as

Never remove safety equipment

safety glasses and filter mask when using

grinders, hammers or compressed air, as

metal fragments or other objects can fly

and cause serious injury.

• Use hearing protection when operating the

machine. Loud prolonged noise can cause

hearing impairments, even the total loss of

hearing.

• Make sure all protective guards, canopies

and doors are in place and secured. Repair

or replace damaged parts before operating

the machine.

• Know how to use the safety lock lever, seat

belt and other safety equipment and use

them properly.

• Never remove any safety equipment except

for servicing. Keep all safety equipment in

good operating condition.

1-3

SAFETY

GENERAL PRECAUTIONS

Use a signal person and a flag person

Precautions when standing up from or

leaving the operator’s seat

AG7A007

Learn how to use the hand signals required

AG7A009

for particular jobs and make sure who has

• Before standing up from the operator’s

the responsibility for signaling.

seat to open/close the window or remove/

• All personnel must fully understand all the

install the lower window, lower the working

signals.

equipment to the ground, raise the safety

• The operator must respond to signals only

lock lever to engage the lock and stop the

from the appointed signal person, but must

engine. If any control is accidentally

obey a stop signal at any time from

touched when the safety lock levers is

anyone.

lowered (unlocked), the machine will

• The signal person must stand in a clearly

suddenly move and cause serious injury or

visible location when giving signals.

death.

• Be careful not to touch the operating levers

when raising or lowering the safety lock

lever.

• Before leaving the operator’s seat, lower

the working equipment to the ground, set

the locking devices securely to the lock

position and stop the engine. Also, be sure

to remove the key, lock the cab, fuel filler

cap and covers, take the key with you and

store it in a specified place.

1-4

SAFETY

GENERAL PRECAUTIONS

Avoid fire and explosion hazards

• When handling the fuel, washing oil or

paint, open the door and windows to

ventilate thoroughly.

• Store all flammable fluids and materials in a

safe and well-ventilated place.

• The short circuit of the electric system may

cause the fire. Check for any loosened

connections or damage to the wires every

day. Retighten the loosened connector and

wire clamp. Fix or change the damaged

wire.

• Fire from the pipes:

Make sure that the clamps, guards and

Keep flames away from fuel, oil, grease and

cushions of the hoses and tubes are

antifreeze. Fuel is particularly flammable and

securely fixed. If not, hoses or tubes may

dangerous.

be damaged due to vibration or contact

• When handling these combustible

with other parts during operation. This can

materials, keep lit cigarettes, matches,

cause the high-pressure oil to spurt out,

lighters and other flames or sources of

resulting in the fire or injury.

flames away.

• Do not perform the DPD regeneration if the

• Do not smoke or permit open flames while

machine is surrounded by flammable items

handling fuel or working on the fuel system.

such as plants, trees, dry grass,

• Do not leave the location while refilling with

wastepaper, oil and waste tires. There is a

fuel or oil.

risk of fire due to the high-temperature

• Never remove the fuel cap or add fuel

exhaust gas emitted from the DPD.

when the engine is running or still hot. Also,

DPD: Diesel Particulate Diffuser

do not spill the fuel on the hot surface of

the machine or the component of the

electric system.

• Clean up spilled fuel or oil immediately.

• Check for fuel, oil leak. Stop all leaks and

clean the machine before operating.

• When operating with grinder or welding,

move inflammables to a safe place.

• Do not cut or weld on pipes or tubes that

contain flammable fluids. Clean thoroughly

with nonflammable solvent before cutting

or welding.

• Remove all trash or debris from the

machine. Make sure that oily rags or other

flammable material are not stored on the

machine.

• Handle all solvents and dry chemicals

(foam type fire extinguisher) according to

procedures identified on manufacturer’s

containers. Work in a well-ventilated area.

• Never use fuel for cleaning purposes.

Always use a nonflammable solvent.

1-5

SAFETY

GENERAL PRECAUTIONS

Exhaust fumes from the engine is

Be careful not to get crushed or cut

poisonous

AG7A013

AG7A011

Never put your hands, feet or other parts of

• Do not operate the engine in an enclosed

your body between the upperstructure and

area without adequate ventilation.

the undercarriage or tires, between the

• If natural ventilation is not possible, install

machine body and working equipment, or

ventilators, fans, exhaust extension pipes

between a cylinder and a moving part on the

or other venting devices.

working equipment. The sizes of these gaps

• Do not perform the DPD regeneration in

change when the machine moves, and a

poorly-ventilated indoor spaces, as smoke

person can suffer severe injury or death.

may be generated during the regeneration.

Handling asbestos dust

Inhaling asbestos dust can cause lung

cancer. When handling the materials which

may contain asbestos, take the following

precautions:

• Never use compressed air for cleaning.

• Avoid brushing or grinding parts containing

asbestos.

• For clean up, use a vacuum equipped with

a high efficiency particulate air filter (HEPA).

• Wear the stipulated respirator if there is no

other way to control the dust. When

working indoors, install a ventilation system

with a macromolecular filter.

• Do not allow unauthorized personnel in the

work area while working.

• Follow the rules and environmental

standard applicable to the work area.

1-6

SAFETY

PRECAUTIONS WHEN PREPARING

PRECAUTIONS WHEN

PREPARING

Know the work area

Before starting operation, know the working

area condition to ensure a safety operation.

• Inspect the topography and ground

condition of the working area, or the

structure of the building when working

indoors, and take the safety precautions as

• Do not perform the DPD regeneration if the

necessary.

machine is surrounded by flammable items

• Be sure to avoid all hazards and

such as plants, trees, dry grass,

obstructions such as ditches, underground

wastepaper, oil and waste tires. There is a

lines, trees, cliffs, overhead electrical wires,

risk of fire due to the high-temperature

or places where there is a danger of falling

exhaust gas emitted from the DPD.

rocks or slides.

DPD: Diesel Particulate Diffuser

• The DPD may automatically perform the

regeneration while the engine is left

running. Make sure that there are no

flammable items around the DPD and the

exhaust line, and also that the engine hood

is closed to prevent fire. Be careful not to

burn yourself on the high-temperature

exhaust gas.

• Do not perform the DPD regeneration in

poorly-ventilated indoor spaces, as smoke

may be generated during the regeneration.

AG7A017

• Check with the administrator for the

locations of buried gas pipes, water pipes

and power cables. If necessary, determine

what specific precautions must be taken to

insure safety by consulting with the

administrator.

• When working on roads, be sure to

consider the safety of pedestrians and

vehicles.

· Use a flag person and/or a signal.

· Fence off the working area and keep off

unauthorized persons.

• When working in water or crossing shallow

streams or creeks, check the depth of the

water, the solidity of the ground and the

water flow speed beforehand.

Refer to “Precautions for operation” for

further instructions.

1-8

SAFETY

PRECAUTIONS WHEN PREPARING

Check the strength of the bridge

Always keep the machine clean

When traveling over a bridge or a structure,

check the permissible load. If the strength is

insufficient, reinforce the bridge or the

structure.

AG7A019

• Clean windows, mirrors and lights to

ensure good visibility.

Adjust the mirror to the best position for

the operator to see the rear view (blind

spot) from the operator’s seat.

• Wipe off any oil, grease, mud, snow or ice,

to prevent accidents due to slipping.

• Remove all loose objects and unnecessary

devices from the machine.

• Remove any dirt, oil or grease from the

engine area to prevent fires.

• Clean around the operator’s seat and

remove any unnecessary object from the

machine.

1-9

SAFETY

PRECAUTIONS WHEN PREPARING

Perform inspection and maintenance

Cautions in the operator’s compartment

every day

• Remove mud and grease from shoe soles

before entering the operator’s compartment.

Pedaling the machine with the shoes with

mud and grease will cause a slip accident.

• Do not leave the parts or tools around the

operator’s seat.

• Do not leave any plastic bottles in the

operator’s compartment or attach any

suction cups on the window glass. The

plastic bottle or suction cup act as a lens

and can cause fire.

AG7A020

• Do not use the mobile phone during

Failure to identify or repair the irregularities or

traveling or working.

damage on machine can lead to accidents.

• Do not bring combustibles or explosives

• Before operating, perform the specified

into the operator’s compartment.

inspection and make prompt repairs where

• After smoking, be sure to tightly close the lid

necessary.

of the ashtray to put out the match or

• If a failure occurs and the operation

cigarette.

becomes impossible or the engine fails,

• Do not leave the cigarette lighter in the

immediately stop the machine by following

operator’s compartment. When the room

the shutdown procedure, and keep

temperature rises, the lighter may explore.

machine securely parked until the

malfunction is corrected.

1-10

SAFETY

PRECAUTIONS WHEN PREPARING

Emergency exit

Rear window

If you should become trapped inside the

cab, remove the rear window to get out.

1. Pull off the ring (A) and remove the tip of

the rubber wedge.

2. Grasp and pull the tip of the rubber wedge

to remove the entire rubber wedge.

3. Kick out the rear window. Note that the

glass may break. Be careful not to get

injured.

1-11

SAFETY

PRECAUTIONS WHEN STARTING

PRECAUTIONS WHEN

STARTING

Support your weight in a three point

secure stance when getting on/off the

machine

• Do not jump on or down from the machine.

Never attempt to get on or off the moving

machine.

• When getting on or off the cab, first fully

• Check if there is a “DO NOT OPERATE”

open the door to the locked position and

alert sign or similar sign is on the cab door,

check that it does not move (for machines

controls or starter switch. If there is one, do

with cab).

not start the engine or touch any levers.

• Sound the horn to warn people around the

machine.

Sit in the operator’s seat and start the

engine

• Adjust the seat to securely latch it.

AG7A022

• Climb up/down the steps facing the

machine and holding the handrail to

support your weight in a three point secure

stance (hand and feet).

• Never use the safety lock lever or control

levers as hand holds.

AG7A024

Before starting the machine, ask any

• Fasten the seat belt.

unauthorized personnel to leave the area

• Check if the parking brake is on and all

control levers and pedals are in the neutral

Do not start the engine until you are sure it is

position.

safe to start the machine by checking the

• Check if the safety lock lever is in the lock

following items.

position.

• Walk around the machine and warn the

• Make sure that no one is near the machine.

person who is servicing the machine or is

• Start and operate the machine only from

walking near the machine. Do not start the

the operator’s seat.

machine until you are certain that no one is

• Never attempt to start the engine by

around the machine.

shorting across the starter terminals.

1-12

SAFETY

PRECAUTIONS WHEN STARTING

Starting with jumper cables

In cold climates

AG7A025

AG7A027

Use jumper cables only in the recommended

• Be careful of slippery conditions on freezing

manner. Improper use of jumper cables can

ground, steps and hand holds.

result in battery explosion or unexpected

• In severe cold climates, do not touch any

machine motion.

metal parts of the machine with bare

Refer to “If the battery goes dead” for further

hands. The skin will freeze to the metal,

instructions.

resulting in severe injury.

• Do not use ether or starting fluid on this

engine. The starting fluids can cause

After starting the engine

explosion and serious injury or death.

• Warm up the engine and hydraulic oil. If the

After starting the engine, perform the

levers are operated without warming, the

operations and checks described below in a

machine will not react or move promptly or

safe place with no persons or obstacles in

properly, resulting in accident.

the area. If any malfunction is found, follow

the shutdown procedure and report the

malfunction.

• Warm up the engine and hydraulic oil.

• Check if all gauges and warning devices

are properly working.

• Check for any noises.

• Test the engine speed control.

• Operate each control to ensure they are

properly working.

1-13

SAFETY

PRECAUTIONS WHEN OPERATING

Check if the work area is safe and secure

PRECAUTIONS WHEN

before operation

OPERATING

Ensure good visibility

• When working in dark places, turn on the

machine’s working lights and headlights

and additional lighting equipment installed,

as necessary.

• When visibility is poor due to bad weather

(fog, snow, rain or a cloud of dust), stop

operating the machine and wait until

AG7A031

visibility improves.

• Confirm the performance limits of the

machine.

Do not permit riders on the machine

• Use a signal person at road shoulders,

narrow places or where your vision is

obstructed.

• Never allow anyone to enter the machine’s

slewing radius and path.

• Signal your intention to move by sounding

the horn.

• There is a blind spot in the rear of the

machine. Check that the area is safe and

clear for yourself. When necessary, use the

real camera.

Do not allow anyone to ride on any part of

Safety precautions when performing the

the machine at any time while traveling or

DPD regeneration

operating.

The DPD may automatically perform the

regeneration while the engine is left running.

Make sure that there are no flammable items

around the DPD and the exhaust line, and

also that the engine hood is closed to

prevent fire. Be careful not to burn yourself

on the high-temperature exhaust gas.

DPD: Diesel Particulate Diffuser

1-14

SAFETY

PRECAUTIONS WHEN OPERATING

Check the position of the undercarriage

Travel safely

(steering device) before start traveling

• Before traveling, set the machine to the

“travel posture”.

Equipped with outrigger

Refer to “Preparing for travel” for further

details.

• When traveling on a road, be sure to lock

the working equipment. If any of the

controls is accidentally touched when it is

unlocked, the machine may suddenly move

and cause serious injury or death.

• Keep in mind that the steering wheel

operation is not possible when the engine

is stopped or if the steering pump

becomes faulty.

Before operating the travel pedal, make sure

that the steering device is to the front of the

operator’s seat. Remember that when the

steering device is to the rear of the operator’s

seat, the steering wheel must be operated in

the reverse direction from when it is to the

front.

• When traveling on a public road, be sure to

lock slewing with the slew lock pin. For

machines with outriggers, retract the

outriggers within the machine width and

install the turnbuckles.

· Make sure that the outrigger pads (the

sections to contact the ground) are within

the machine width. Failure to do so could

cause minor collisions.

1-15

SAFETY

PRECAUTIONS WHEN OPERATING

• Before traveling on a road, tilt the reflector.

• Avoid crossing over obstacles whenever

When operating at a job site, raise the

possible. If you must do so, keep the hoe

reflector to prevent it from being damaged.

attachment close to the ground level and

travel slowly. Never cross obstacles which

<For Germany>

will tilt the machine to an angle of 10° or

greater.

• Avoid starting, stopping or changing

directions abruptly and maintain a proper

speed. Otherwise, the working equipment

may come in contact with the ground,

causing the machine to lose its balance

and get damaged or to damage the

structures in the surrounding area.

• When traveling on the uneven road or

sharp slope, turn off the deceleration

switch and the auto-deceleration switch. If

the machine is operated on such roads

• When traveling during nighttime hours, be

with these switches turned on, the engine

sure to install the position lights.

speed may increase, causing the machine

To prevent damage, remove the position

to travel unexpectedly rapidly (for machines

lights (including the brackets and harness)

with the deceleration and auto-deceleration

before working at the site.

switches).

• When traveling on a road, know and use

• Do not slew while traveling. If slewed, the

the signaling devices required on the

upperstructure position warning lamp lights

machine. Use an escort vehicle for road

up to alert the operator to the danger. If you

travel when required.

must operate the hoe attachment while

traveling, operate at speeds slow enough

so you have complete control at all times.

• Do not raise the safety lock lever or turn

the starter switch to the OFF position while

traveling. Doing so is dangerous because it

activates the parking brake and causes the

machine to stop suddenly.

1-16

SAFETY

PRECAUTIONS WHEN OPERATING

Precautions when traveling on slopes

• When traveling on slopes or grades, travel

slowly in low gear. When descending a

When traveling on slopes or grades, be

slope, slow down the engine speed.

careful that the machine does not tip (roll)

• Do not travel at speeds of over 20 km/h

over or slide.

(12.4 mph) on long down slopes. Release

• Never travel on slopes that are too steep

the travel pedal from time to time to protect

for the machine to maintain its stability

the travel motor and ensure travel stability.

(maximum gradeability: 35°, lateral tipping

• Do not travel downhill in reverse.

angle: 15°). Note that in reality, the

machine’s stability becomes lower than the

above values depending on the working

condition.

• Do not turn on slopes or travel across

slopes. Go down to a flat surface, and then

take an alternative path.

• The machine may slip sideways even on a

slight slope if it is covered with grass or

fallen leaves, or when traveling on wet

meta plates or frozen surfaces. Do not

allow the machine to position sideways to

a slope.

• If the machine is stalled on the slope,

return each operating lever to the neutral

position before restarting the engine.

• When climbing a hill, keep the operator’s

seat facing the hillside. When descending a

hill, keep the operator’s seat facing

downhill. In either case, travel must be

done while paying attention to the ground

in front of the machine.

• When traveling on slopes, lower the bucket

to a height of 20 to 30 cm (8 to 12 in.)

above the ground. When climbing a steep

slope, extend the hoe attachment to the

front. In emergencies, lower the bucket to

the ground and stop the machine.

1-17

SAFETY

PRECAUTIONS WHEN OPERATING

Operate the machine on snow or ice with

Do not move the bucket over the heads of

extra care

people.

• When traveling on snow or on frozen

surfaces, drive at a low speed and avoid

starting, stopping or changing directions

abruptly.

• In the snowy area, the road shoulder and

objects placed beside the road are buried

in the snow and cannot be seen. There is a

hazard of the machine tipping over or

hitting covered objects, so always carry out

operations carefully.

• If the machine enters deep snow, there is a

hazard that it may tip over or become

Moving the bucket over the heads of people

buried in the snow.

entails the danger of the load spilling or the

Be careful not to drive beyond the road

sudden dropping of the bucket.

shoulder or to get trapped in a snow drift.

• With frozen ground surfaces, the ground

becomes soft when the temperature rises,

Ensure driver’s safety when loading

and this may cause the machine to tip

over, resulting in an operator trapped inside

the machine.

• When parking the machine on an unstable

ground, lower the dozer blade.

Do not load a truck unless the truck driver is

in a safe place.

• Never swing or position the bucket over a

person or the cab room.

• Load the truck from the rear.

1-18

SAFETY

PRECAUTIONS WHEN OPERATING

Keep a safe distance from the overhead

high-voltage cables

• Pay also careful attention to the high-

voltage electric cables buried underground.

Never bring any part of the machine or

loaded material to near to the high voltage

cables unless all safety precautions required

by the local and national authorities have

been installed. If a person comes near to the

machine that is discharging sparks or

located near to or in contact with the power

source, there is a hazard of electric shock

and death.

• Always maintain a safe distance between

the machine and the high-voltage electric

cable.

• Check with the local power company

about safe operating procedure before

starting operations.

• Consider all cables to be high-voltage

cables and treat all cables as energized

even though it is known or believed that

the power is shut off and the cables are

visibly grounded.

• Use a signal person to give warning if the

machine approaches too close to the

high-voltage electric cables.

• Caution all personnel in the work area not

to come close to the machine or the

loaded material.

1-19

SAFETY

PRECAUTIONS WHEN OPERATING

Watch out for hazardous working

conditions

• Do not enter areas where there is soft

ground. Doing so could cause the machine

to tilt under its own weight, resulting in a

• Never undercut a high bank. Doing so is

machine tipping over or sinking into the

dangerous as it may cause ground

ground.

collapse.

• Do not operate in places where there is a

danger of falling rocks.

• Do not come close to unstable grounds

(cliffs, road shoulders, deep ditches). If the

ground should collapse under the weight or

• Maintain a safe distance between the

vibration of the machine, there is a hazard

machine and the edge of the digging site.

that the machine may fall or tip over.

Do not dig the ground under the front of

· Remember that the soil after heavy rain

the machine.

or blasting is weak.

• When working close to the cliffs or road

· The ground of top of the embankment

shoulders, set the tires at right angles to

and of the circumferences of the

the cliff or road shoulder and the dozer

excavated ditches are also weak.

blade to the front so that it is easier to

escape in case of an emergency.

1-20

SAFETY

PRECAUTIONS WHEN OPERATING

• Do not perform demolition work under the

• Do not use the impact force of the hoe

machine. There is a hazard that the

attachment for breaking work. There is a

machine may fall down, because the

hazard of serious injury being caused by

ground becomes unstable.

flying pieces of broken materials and by the

• When working on or from the top of

damaged hoe attachment.

buildings or other structures, check the

strength and the structure before starting

operations. If a building or structure

collapses, serious injury or damage will

result.

• When doing demolition work, do not

perform demolition above your head. There

is a hazard of broken parts falling or of the

building collapsing and causing serious

injury or damage.

1-21

SAFETY

PRECAUTIONS WHEN OPERATING

Operating on slopes is dangerous

Never slew sideways with a heavy load

When operating on slopes or grades, slewing

or operation of working equipment may

cause the machine to lose stability and tip

over. Avoid operating on slopes whenever

possible.

The machine can tip over more easily in the

lateral direction than in the longitudinal

direction.

• Do not slew sideways with a heavy load at

the tip of the hoe attachment. In particular,

do not slew sideways on slopes.

• Level off the work area.

• The tip of the attachment is heavier for

machines equipped with breakers,

crushers or long arms than for machines

equipped with the standard bucket. For

such machines with heavier tips, do not

perform excavation with the digging arm

(boom) facing the downhill direction or

operate toward sideways.

Be careful with the overhead objects

• Avoid slewing to the downhill direction with

the bucket full of loaded material. This will

reduce the stability of the machine and

may result in tipping over.

When operating under bridges, in tunnels,

near electric cables or indoors, be careful not

to let the boom or arm hit overhead objects.

1-22

SAFETY

PRECAUTIONS WHEN OPERATING

Excavators are not designed for lifting

Be careful with flying objects

loads

This machine is not equipped with protective

equipment to protect the operator from flying

objects. Do not use this machine in places

where there are risks of the operator being

hit by flying objects.

This machine is specifically designed for

excavation work. Therefore, it has no safety

equipment for crane operation. Extreme

caution should be paid if the excavator is

used for lifting.

• Never lift loads in excess of capacity.

Overload will cause the machine to roll and

can result in serious injury or death.

• All rated lift capacities are determined by

using a machine placed on a stable and flat

ground. For a safe lifting work, the user is

expected to make due allowance for the

particular job conditions. They include, soft

or uneven ground, non-level condition, side

loads, dynamic or jerked loads, hazardous

conditions, and experience of personnel.

The operator and other personnel should

fully acquaint themselves with the

operator’s manual before operating this

machine, and rules for safe operation of

equipment shall be adhered to at all times.

• The bucket linkage or lifting device may fail

if chains or lifting device are incorrectly

attached, resulting in serious injury or

death.

• Do not attempt to pull stumps out of the

ground when using the machine as a

crane. The loads imposed on the machine

under this use are completely unknown.

• Do not allow anyone to stand on or under

the lifted loads or come close to the work

area.

1-23

SAFETY

PRECAUTIONS WHEN OPERATING

Cautions when towing

When towing, serious injury or death could

result, if performed incorrectly or the wire

rope being used is inappropriate or not

properly inspected.

• It becomes dangerous if the wire rope

breaks or becomes disengaged. Use a

wire rope appropriate for the required

tractive force.

• Do not use a wire rope that is kinked,

twisted or otherwise damaged.

• Do not apply heavy loads abruptly to the

wire rope.

• Wear safety gloves when handling the wire

rope.

• Make sure there is an operator on the

machine being towed as well as on the

machine that is towing.

• Never tow on slopes.

• Do not let anyone come near to the wire

rope while towing.

• The machine should be towed only when it

gets stuck in mud.

• Be sure to use a towing truck with

sufficient braking power.

Refer to “Towing” for further instructions.

1-24

SAFETY

PRECAUTIONS WHEN STOPPING

Parking procedures

PRECAUTIONS WHEN

1. Slowly step on the brake pedal to stop the

STOPPING

machine, and then further depress the

Park safely

pedal down to lock it.

2. Press the deceleration button to idle the

engine at low speed.

3. Lower the bucket and the dozer blade to

the ground.

When replacing the attachment or

performing the inspection and

maintenance on it, follow the procedure

“Releasing the residual pressure from the

working equipment circuit” described

below, as necessary.

4. Raise the safety lock lever to the lock

position.

• Park the machine on a flat, rigid and safe

5. Stop the engine and remove the starter

ground. Set the parking brake, brake pedal

key.

lock and wheel stoppers.

Refer to “Stopping the engine” on page

3-5.

6. Lock the cab, fuel filler cap and covers,

take the key with you and store it in a

specified place.

Releasing the residual pressure from the

working equipment circuit

Perform the operation of releasing the

residual pressure within 30 minutes after the

engine comes to a complete stop.

1. Stop the engine.

If you must park on a slope, chock the

2. Turn the starter switch to the ON position.

wheels to block the machine.

3. Lower the safety lock lever to the unlock

• When parking on a street, use barriers,

position.

caution signs, lights, etc., so that the

4. Release the lock of the attachment lock

machine can easily be seen even at night

button.

to avoid collision with other vehicles.

5. Move all the control levers, pedals and

• Before leaving the operator’s seat, safely

auxiliary hydraulic switches several times

park the machine by referring to “Parking

in all directions to release the residual

procedures” below.

pressure in the working equipment circuit.

1-25

SAFETY

PRECAUTIONS WHEN TRANSPORTING

• Lock the cab door after being loaded, if

PRECAUTIONS WHEN

applicable. Otherwise, the door may open

during transport.

TRANSPORTING

• Lock the slewing after loading.

Load /unload the machine safely

• Chock the wheels and secure the machine

to the truck bed with wire rope or chain.

The machine may roll or tip over or fall while

being loaded or unloaded. Take the following

precautions:

• Select a firm, level surface and keep

sufficient distance from road shoulders.

• Secure ramps of adequate strength and

size to the truck bed. The slope of the

ramps must not exceed 15°. If the rumps

are bowed down too low, support them

with poles or blocks.

• Never use the working equipment to load

or unload the machine. Doing so may

result in tipping over or falling down of the

machine.

• Keep the truck bed and loading ramps

clean of oil, soil, ice, snow and other

materials to prevent the machine from

sliding sideways. Clean the tires too.

• Chock the transporter wheels to prevent

movement.

• Turn off the deceleration switch and auto-

deceleration switch. Otherwise, the engine

speed may suddenly increase to cause

troubles.

• When being loaded or unloaded, travel

slowly in low gear while following the signal

from the signal person.

• Never change courses on the ramp.

• Do not slew/swing on the ramp. The

machine may tip over.

• When slewing/swinging on the truck bed,

do it slowly as the footing should be

unstable.

1-26

SAFETY

PRECAUTIONS ON MAINTENANCE

Replace safety-critical parts periodically

PRECAUTIONS ON

• Replace fuel hoses periodically. Fuel hoses

MAINTENANCE

wear out over time, even if they do not

Display a “DO NOT OPERATE” alert sign

show any symptom of wear.

• Regardless of the replacement schedule,

Severe injury could result if an unauthorized

replace immediately if a symptom of wear

person should start the engine or touch

is found.

controls during inspection or maintenance.

Refer to “List of safety-critical parts” for

• Before performing maintenance, stop the

further details.

engine, remove the key and take it with

you.

Explosionproof lighting

AG7A067

• Display a “DO NOT OPERATE” alert sign

on easy-to-see locations such as on the

To prevent an ignition or explosion, use

starter switch or on control levers.

explosion-proof lights when inspecting fuel,

oil, coolant or battery fluid. Otherwise,

explosion could result causing serious injury

Use the correct tools

or death.

AG7A065

Do not use damaged or weakened tools or

tools designed for other purposes. Use tools

appropriate for the work involved.

1-28

SAFETY

PRECAUTIONS ON MAINTENANCE

Prohibit access by unauthorized persons

• Never jump down from the machine. Use

the steps and handrails when climbing up

and down the machine, and always

support your body at three points with your

hands and feet.

• Do not stand on the dozer blade and

perform maintenance work. Doing so is

dangerous because of the unsteady

foothold. Use the work bench.

Always keep the machine clean

AG7A068

Do not allow unauthorized personnel in the

work area while working. Be careful when

grinding, welding or using a hammer. You

could be injured by flying debris from the

machine.

Prepare work area

• Select a firm, level work area. Make sure

there is adequate light and, if indoors,

AG7A070

ventilation.

• Clean the machine before performing

• Clear obstacles and dangerous objects.

maintenance.

Eliminate slippery areas.

• Stop the engine before washing the

machine. Cover the electrical parts so that

water cannot enter. Water on electrical

Cautions on working on top of the

parts could cause short-circuits or

machine

malfunctions. Do not use water or steam to

wash the battery, electronic control

components, sensors, connectors or the

operator’s compartment.

• Before performing maintenance on the top

of the machine, clean the place you will

work on and observe the following to

prevent falling.

· Do not spill oil or grease.

· Do not leave tools scattered around.

· Watch your step when walking.

1-29

SAFETY

PRECAUTIONS ON MAINTENANCE

Stop the engine before performing

Firmly secure the machine or any

maintenance

component that may fall

• Avoid lubrication or mechanical

adjustments while the machine is moving

or while the engine is running when the

machine is not moving.

• If maintenance must be performed with the

engine running, always work as a two

person team communicating each other.

· One person must sit in the operator’s

seat so that he/she can immediately stop

the engine when necessary. He/she must

take care not to touch the lever or pedal

AG7A073

unless necessary.

• Before performing maintenance or repairs

· The one who performs maintenance

under the machine, lower all moveable

must make sure to keep his/her body or

working equipment to the ground or in the

clothing away from the moving part of the

lowermost position.

machine.

• Chock the tires.

• If you must work beneath the raised

machine or equipment, always use wood

Stay clear of the moving parts

blocks, jack-stands or other rigid and

stable supports. Never get under the

machine or working equipment if they are

not sufficiently supported. This procedure

is especially important when working on

hydraulic cylinders.

AG7A072

• Stay clear of all rotating and moving parts.

If a hand or tool becomes trapped in the

rotating or moving part, serious injury or

death could result.

• If a tool or other objects is dropped or

inserted in the fan or fan belt, it will be

flown or cut in pieces. Do not drop or insert

anything in the fan or fan belt.

1-30

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