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Takeuchi Hydraulic excavator TB1160W (Serial No. 514500002~). Operator's Manual (2016) - page 6

MAINTENANCE

EVERY 50 HOURS

1. Remove the fuel filler cap (2).

EVERY 50 HOURS

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

DRAINING THE WATER FROM THE FUEL

3. Open the drain valve (3) and drain the

TANK

water and sediment buildup in the bottom

of the tank.

4. Close the drain valve (3).

5. Add fuel while watching the fuel gauge (1).

• Before performing maintenance on the

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

top of the machine, clean the place you

7. Bleed air.

will work on and observe the following

to prevent falling.

Bleeding air from the fuel system

· Do not spill oil or grease.

Refer to “Bleeding air from the fuel system”

· Do not leave tools scattered around.

on page 6-10.

· Watch your step when walking.

• Never jump down from the machine.

Note: Air in the fuel system causes the

Use the steps and handrails when

engine to fail to start or to have problems.

climbing up and down the machine, and

Bleed air when the fuel tank is emptied,

always support your body at three

using the same procedure above.

points with your hands and feet.

• Do not smoke or permit open flames

while handling fuel or working on the

fuel system.

• 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.

5-35

MAINTENANCE

EVERY 50 HOURS

INSPECTING THE BATTERY FLUID LEVEL

the machine or work bench, use the

AND REPLENISHING

steps, handrails or work bench to

support your body. Your weight should

be evenly distributed among the three

contact points (one hand and two feet

• Do not use the battery when the fluid

or two hands and one foot).

level is below the lower level limit. Doing

• Do not stand on the dozer blade and

so will hasten the deterioration of the

perform maintenance work. Doing so is

internal portions of the battery and

dangerous because of the unsteady

shorten the battery life. It also can

foothold. Use the work bench.

cause rupturing (explosion).

• Batteries generate flammable hydrogen

Inspection

gas which may explode. Keep away

IMPORTANT: Check the fluid level of all

from flame, sparks, fire or lighted

cells following the steps below, even

cigarettes.

when the fluid level can be checked using

• Use a dampened cloth to clean above

the indicator.

the fluid level line and check the fluid

level. Do not clean with a dry cloth;

1. Open the left side cover.

otherwise it can cause static electricity

to build up, resulting in ignition or

explosion.

• 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.

2. Inspect the indicator (1).

• Batteries contain sulfuric acid which will

· Blue: Charging complete

damage eyes or skin if contacted.

· White: OK

· If eye contact occurs, flush

· Red/center White: Insufficient battery

immediately with clean water and get

fluid

prompt medical attention.

· Red/center Red: Charging needed

· If accidentally swallowed, drink large

3. Inspect the fluid level.

quantities of water or milk and call a

The fluid level must be between the upper

physician immediately.

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

· If acid contacts skin or clothing, wash

add distilled water up to the line (H).

off immediately with a lot of water.

• Before performing maintenance on top

of the work bench, clean the footing and

observe the following precautions to

prevent falling.

· Do not spill oil or grease.

· Do not leave tools scattered around.

· Watch your step when walking.

• Never jump down from the machine or

the work bench. When getting on or off

5-36

MAINTENANCE

EVERY 50 HOURS

• If the fluid level cannot be checked by

Replenishing

fluid level lines:

When adding distilled water, do so before

starting operations in order to prevent

freezing.

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

water until the upper level (H).

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

3. Clean the exhaust hole on the cap, then

tighten the caps (2) securely.

Remove the caps (2) and look into the fluid

filler holes to check the fluid level. If the

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

distilled water up to the bottom edge of the

sleeve (3).

Proper level (A)

If the fluid reaches up to the bottom edge

of the sleeve (3), the surface tension

causes the fluid to swell and the plate

appears as if it is distorted.

Level too low (B)

If fluid does not reach up to the bottom

edge of the sleeve (3), the plate looks

laminar, not distorted.

4. Check the terminals for looseness and

dirt.

5-37

MAINTENANCE

AFTER THE INITIAL 250 HOURS (ONLY FOR NEW MACHINES)

AFTER THE INITIAL 250

HOURS (ONLY FOR NEW

MACHINES)

REPLACING THE SLEW MOTOR GEAR OIL

• Stop the engine and allow each part of

the machine to cool down before

performing maintenance.

· The slew 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 not to touch the oil when

loosening the plug. Working on the

machine under these conditions could

result in burns or injuries.

1. Remove the cap (2).

• When performing maintenance on the

2. Place a pan under the hose (3) to catch

machine, clean up the foot area and

the waste oil.

strictly observe the following so as not

3. Loosen the drain valve (4) and drain the

to fall:

oil.

· Do not spill oil or grease.

4. Tighten the drain valve (4).

· Do not leave tools scattered around.

5. Add oil up to the upper limit (H) of the level

· Watch your step when walking.

gauge (1).

• Never jump down from the machine.

Problems could arise if the oil level is either

Use the steps and handrails when

too low to too high.

climbing up and down the machine, and

6. Tighten the cap (2).

always support your body at three

points with your hands and feet.

• The pressure in the reduction gear case

of slew motor may cause oil or the cap

to fly out. Loosen the cap slowly to

release the pressure.

5-38

MAINTENANCE

EVERY 250 HOURS

LUBRICATING THE UNDERCARRIAGE

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.

5-40

MAINTENANCE

EVERY 250 HOURS

INSPECTING THE SLEW MOTOR GEAR

1. Take out the level gauge (1) and wipe off

OIL

the oil with a rag.

2. Fully insert the level gauge (1) again, and

then pull it out.

3. Check the oil left on the level gauge (1).

• Stop the engine and allow each part of

The level should be between the upper

the machine to cool down before

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

performing maintenance.

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

· The slew motor is hot immediately

after the engine is stopped. Touching

Replenishing

it will cause burns.

· The gear oil is also hot and under high

pressure immediately after the engine

is stopped.

Be careful not to touch the oil when

loosening the plugs. Working on the

machine under these conditions could

result in burns or injuries.

• When performing maintenance on the

machine, clean up the foot area and

strictly observe the following so as not

to fall:

· Do not spill oil or grease.

1. Remove the oil filler cap (2).

· Do not leave tools scattered around.

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

· Watch your step when walking.

and the lower limit (L) of the level gauge

• Never jump down from the machine.

(1).

Use the steps and handrails when

Problems could arise if the oil level is either

climbing up and down the machine, and

too low or too high.

always support your body at three

3. Tighten the oil filler cap (2).

points with your hands and feet.

• The pressure in the reduction gear case

of slew motor may cause oil or the plug

to fly out. Loosen the plug slowly to

release the pressure.

Inspection

5-41

MAINTENANCE

EVERY 250 HOURS

CLEANING THE COOLER FINS

• Wear required appropriate equipment

such as protective goggle and filter

mask when using compressed air, as

metal fragments or other objects can fly

and cause serious injury.

• Before performing maintenance on top

of the work bench, clean the footing and

observe the following precautions to

1. Open the left side cover and the engine

prevent falling.

hood.

· Do not spill oil or grease.

2. Blow compressed air on the fins to

· Do not leave tools scattered around.

remove mud and dirt stuck on them.

· Watch your step when walking.

• Never jump down from the machine or

the work bench. When getting on or off

the machine or work bench, use the

steps, handrails or work bench to

support your body. Your weight should

be evenly distributed among the three

contact points (one hand and two feet

or two hands and one foot).

• Do not stand on the dozer blade and

perform maintenance work. Doing so is

dangerous because of the unsteady

foothold. Use the work bench.

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.

5-42

MAINTENANCE

EVERY 250 HOURS

CLEANING THE AIR CLEANER

1. Open the left side cover.

• Stop the engine and allow the machine

to cool down before performing

maintenance.

· The engine, muffler, radiator and many

other parts of the machine are hot

immediately after the engine is

stopped. Touching it will cause burns.

• Wear required appropriate equipment

such as protective goggle and filter

mask when using compressed air, as

2. Loosen the clamps (1) and remove the

metal fragments or other objects can fly

dust cup (2).

and cause serious injury.

• Before performing maintenance on top

of the work bench, clean the footing and

observe the following precautions to

prevent falling.

· Do not spill oil or grease.

· Do not leave tools scattered around.

· Watch your step when walking.

• Never jump down from the machine or

the work bench. When getting on or off

the machine or work bench, use the

steps, handrails or work bench to

support your body. Your weight should

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

be evenly distributed among the three

4. Remove the primary element (3).

contact points (one hand and two feet

To prevent dirt from getting inside the

or two hands and one foot).

engine, do not remove the secondary

• Do not stand on the dozer blade and

element (5).

perform maintenance work. Doing so is

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

dangerous because of the unsteady

foothold. Use the work bench.

IMPORTANT: Be careful not to scratch the

element. Do not use an element if it is

damaged.

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.

5-43

MAINTENANCE

EVERY 250 HOURS

6. 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.

7. 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.

8. Install the primary element (3).

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

”

mark facing up or by aligning the arrows

“

/

”, and then fasten it with the clamps

(1).

5-44

MAINTENANCE

EVERY 250 HOURS

CLEANING THE AIR FILTERS (AC)

6. Remove the filter (4).

Ventilation filter (4): parts No. 05746-

00334

7. Use compressed air or water to clean the

Wear required appropriate equipment

filters, depending on how dirty they are.

such as protective goggle and filter mask

when using compressed air, as metal

Cleaning

fragments or other objects can fly and

1. Blow dry, compressed air (138 kPa or 20

cause serious injury.

psi or less) directly on the filters from the

inside, moving up and down along the

Clean the filters immediately after operating

pleats.

in dusty places.

Be sure to keep the nozzle at an adequate

If the filters are clogged, the air flow is

distance from the filters.

reduced and a booming sound is heard from

2. Wash the filter with neutral detergent if it is

the air conditioner unit.

very dirty. Dry the filter completely after

washing it.

Removing the filters

1. Move the seat all the way forward, and

then fold down the backrest toward the

front.

2. Loosen the bolts and open the cover (1).

3. Loosen the knob and remove the filter (2).

Circulation filter (2) Part No. 19115-06736

4. Open the left side cover.

5. Loosen the knobs and remove the cover

(3).

5-45

MAINTENANCE

EVERY 250 HOURS

CLEANING THE CONDENSER (AC)

• 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.

• Before performing maintenance on top

of the work bench, clean the footing and

observe the following precautions to

1. Open the left side cover.

prevent falling.

2. Clean the condenser (1).

· Do not spill oil or grease.

· Do not leave tools scattered around.

· Watch your step when walking.

• Never jump down from the machine or

the work bench. When getting on or off

the machine or work bench, use the

steps, handrails or work bench to

support your body. Your weight should

be evenly distributed among the three

contact points (one hand and two feet

or two hands and one foot).

• Do not stand on the dozer blade and

perform maintenance work. Doing so is

dangerous because of the unsteady

foothold. Use the work bench.

IMPORTANT: Be careful not to damage

the fins when cleaning.

• When compressed air or pressurized

water is to be used, make sure the

pressure is no higher than 200 kPa (28

psi) and hold the nozzle sufficiently

away from the fins.

If the condenser is dirty, heat will not

discharge properly. Wash dirt off the

condenser with water.

5-46

MAINTENANCE

EVERY 250 HOURS

INSPECTING THE REFRIGERANT (GAS)

LEVEL (AC)

The cooling capacity decreases if the

amount of refrigerant is insufficient.

Inspect the refrigerant level using the sight

glass (2) on the top of the receiver dryer .

5. Check the temperature of the

compressor’s high pressure pipe (1) and

low pressure pipe (2).

Refer to “Check list for refrigerant volume”

on page 5-48.

1. Open the left side cover.

2. Inspect the places for the conditions

below.

Places for inspection

Conditions

Cab door

Fully open

Temperature control

Set fully to the COOL

dial

side

Fan speed

High

Ventilation/circulation

Circulation

Engine speed

Maximum speed

Air conditioner

ON

switch

3. Inspect the refrigerant by watching the flow

of air bubbles through the sight glass (2).

Refer to “Check list for refrigerant volume”

on page 5-48.

4. Open the engine food.

5-47

MAINTENANCE

EVERY 250 HOURS

Check list for refrigerant volume

Air conditioner

Normal

Abnormal

High/low

High pressure

High pressure

Little difference in

High pressure

pressure pipe

pipe is hot (80 to

pipe is warm, low

temperature

pipe is hot, low

temperature

120°C or 176 to

pressure pipe is

between the

pressure pipe is

248°F), low

slightly cool. No

high-pressure

slightly cool. A

pressure pipe is

significant

pipe and the low-

significant

cold (8 to 15°C

difference in

pressure pipe.

difference in

or 46 to 59°F).

temperature

temperature

Clear difference

between the

between the

in temperature

pipes.

pipes.

between the

pipes.

Pipe connection

Normal

Some places are

Some places are

Normal

dirty with oil.

extremely dirty

with oil.

Sight glass

AG7G064

AG7G065

AG7G066

AG7G067

Almost

Flow of bubbles

Mist-like flow is

No bubbles is

transparent with

can be seen

faintly visible.

visible, even

some bubbles.

constantly.

when the fan is

Fully transparent

Sometimes

set to High and

when the engine

transparent or

the engine is

speed is

white with

idling.

increased or

bubbles.

decreased.

Refrigerant level

Proper level

Refrigerant may

Refrigerant has

Refrigerant level

be leaking.

leaked; little is

too high

left.

If the air conditioner is not working

If the air conditioner does not work well, set the fan switch to OFF and contact your sales or

service dealer for inspection and/or repairs.

IMPORTANT: Continued use of the air conditioner when it is not working properly will

damage its various parts.

IMPORTANT: Using the air conditioner when there is no refrigerant will damage the

compressor.

IMPORTANT: Always consult your sales or service dealer for replacing the refrigerant.

Be sure to use R134a refrigerant (1900 g or 4.19 lb).

5-48

MAINTENANCE

EVERY 500 HOURS

INSPECTING THE TRANSMISSION GEAR

EVERY 500 HOURS

OIL

REPLACING THE ENGINE OIL AND THE

OIL FILTER

Refer to “Replacing the engine oil and the oil

• Stop the engine and allow each part of

filter” on page 5-28.

the machine to cool down before

performing maintenance.

· The transmission 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 not to touch the oil 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 transmission may cause oil or the

plug to fly out. Loosen the plug slowly

to release the pressure.

1. Park the machine on a level surface and

stop the engine.

2. Remove the plug (1).

3. If oil is left on your finger when it is inserted

through the hole, the oil level is proper.

4. If the level is too low, add oil through the

hole of the plug (1) until the oil flows from

the hole.

5. Install the plug (1) and tighten it.

· Tightening torque: 80 N·m (59.3 ft-lb.)

5-49

MAINTENANCE

EVERY 500 HOURS

INSPECTING THE DIFFERENTIAL GEAR

<Rear>

OIL

• Stop the engine and allow each part of

the machine to cool down before

performing maintenance.

· The differentials are hot immediately

after the engine is stopped. Touching

them will cause burns.

· The gear oil is also hot and under high

pressure immediately after the engine

is stopped.

2. Remove the plug (1).

Be careful not to touch the oil when

3. If oil is left on your finger when it is inserted

loosening the plugs. Working on the

through the hole, the oil level is proper.

machine under these conditions could

4. If the level is too low, add oil through the

result in burns or injuries.

hole of the plug (1) until the oil flows from

• The pressure in the gear case of

the hole.

differentials may cause oil or the plug to

5. Install the plug (1) and tighten it.

fly out. Loosen the plug slowly to

· Tightening torque: 50 N·m (36.9 ft-lb.)

release the pressure.

1. Park the machine on a level surface and

stop the engine.

<Front>

5-50

MAINTENANCE

EVERY 500 HOURS

INSPECTING THE HUB GEAR OIL

• Stop the engine and allow each part of

the machine to cool down before

performing maintenance.

· The hubs are hot immediately after the

engine is stopped. Touching them will

cause burns.

· The gear oil is also hot and under high

pressure immediately after the engine

is stopped.

Be careful not to touch the oil 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 hubs may cause oil or the plug to fly

out. Loosen the plug slowly to release

the pressure.

1. Park the machine on a level surface and

stop the engine.

2. Set the hub so that the plug (1) is in a level

position.

3. Remove the plug (1).

4. If oil is left on your finger when it is inserted

through the hole, the oil level is proper.

5. If the level is too low, add oil through the

hole of the plug (1) until the oil flows from

the hole.

6. Install the plug (1) and tighten it.

· Tightening torque: 50 N·m (36.9 ft-lb.)

5-51

MAINTENANCE

EVERY 500 HOURS

LUBRICATING THE SLEW BEARING

4. Lower the bucket to the ground, and then

stop the engine.

5. Repeat the steps 2 to 4 above three

times.

Do not slew while lubricating. Doing so is

6. Wipe off the grease expelled from the slew

dangerous, as you may get caught in the

bearing and grease fitting.

machine.

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°.

5-52

MAINTENANCE

EVERY 500 HOURS

REPLACING THE FUEL FILTERS

Pre-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.

• Before performing maintenance on top

of the work bench, clean the footing and

observe the following precautions to

2. Place a pan under the pre-fuel filter (1) to

prevent falling.

catch fuel.

· Do not spill oil or grease.

3. Loosen the vent plug (5) and the drain

· Do not leave tools scattered around.

plug (6) to drain the fuel inside.

· Watch your step when walking.

4. Remove the case (7) by using a filter

• Never jump down from the machine or

wrench.

the work bench. When getting on or off

5. Replace the seals with new ones and

the machine or work bench, use the

lubricate the new seals with diesel fuel.

steps, handrails or work bench to

6. Put the new element (length of 150 mm /

support your body. Your weight should

5.9 in) (4) in the case (7) and install by

be evenly distributed among the three

hand until the seal makes contact with the

contact points (one hand and two feet

sealing surface.

or two hands and one foot).

7. Tighten the case (7) with the filter wrench.

• Do not stand on the dozer blade and

· Tightening torque: 30 N·m (22.1 ft-lb)

perform maintenance work. Doing so is

8. Bleed air.

dangerous because of the unsteady

Refer to “Bleeding air from the fuel

foothold. Use the work bench.

system” on page 6-10.

Main fuel filter

1. Open the right side cover.

2. Place a pan under the main fuel filter (2) to

catch fuel.

3. Loosen the vent plug (5) and the drain

plug (6) to drain the fuel inside.

5-53

MAINTENANCE

EVERY 500 HOURS

4. Remove the case (7) by using a filter

wrench.

5. Replace the seals with new ones and

lubricate the new seals with diesel fuel.

6. Put the new element (length of 131 mm /

5.2 in) (4) in the case (7) and install by

hand until the seal makes contact with the

sealing surface.

7. Tighten the case (7) with the filter wrench.

· Tightening torque: 29.4 N·m (21.7 ft-lb)

8. Bleed air.

Refer to “Bleeding air from the fuel

2. Place a pan under the feed pump (1) to

system” on page 6-10.

catch fuel.

3. Remove the cover (2).

4. Remove the element (3) and gaskets (4).

REPLACING THE FEED PUMP FILTER

5. Install the new element and gaskets.

6. Install the cover (2).

7. Bleed air.

Refer to “Bleeding air from the fuel

• Do not smoke or permit open flames

system” on page 6-10.

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.

• Before performing maintenance on top

of the work bench, clean the footing and

observe the following precautions to

prevent falling.

· Do not spill oil or grease.

· Do not leave tools scattered around.

· Watch your step when walking.

• Never jump down from the machine or

the work bench. When getting on or off

the machine or work bench, use the

steps, handrails or work bench to

support your body. Your weight should

be evenly distributed among the three

contact points (one hand and two feet

or two hands and one foot).

• Do not stand on the dozer blade and

perform maintenance work. Doing so is

dangerous because of the unsteady

foothold. Use the work bench.

1. Open the right side cover.

5-54

MAINTENANCE

EVERY 500 HOURS

INSPECTING AND CLEANING THE

When cleaning, do not remove the strainer

SUPPLY PUMP STRAINER

(2) from the joint bolt. (Disassembly

prohibited)

If the dirt is persistent or the joint bolt is

clogged, replace the joint bolt with the

• Do not smoke or permit open flames

strainer in it.

while handling fuel or working on the

5. Arrange the joint bolt (1), hose and the

fuel system.

new packing (3) together, and then install

• Stop the engine in a well-ventilated

them on their original positions.

place and allow it to cool down before

· Joint bolt (1) tightening torque: 14.6 to

performing maintenance.

24.6 N·m (11 to 18 ft-lb)

• Clean up spilled fuel immediately.

6. Bleed air.

• Before performing maintenance on top

Refer to “Bleeding air from the fuel

of the work bench, clean the footing and

system” on page 6-10.

observe the following precautions to

Note: Replace the supply pump strainer

prevent falling.

(integrated with the joint bolt), if the “lowered

· Do not spill oil or grease.

output” or “engine stopping” cannot be

· Do not leave tools scattered around.

corrected after replacing the fuel filter

· Watch your step when walking.

element. When replacing the strainer, replace

• Never jump down from the machine or

the packing on both sides of the hose with

the work bench. When getting on or off

the new one at the same time.

the machine or work bench, use the

steps, handrails or work bench to

support your body. Your weight should

be evenly distributed among the three

contact points (one hand and two feet

or two hands and one foot).

• Do not stand on the dozer blade and

perform maintenance work. Doing so is

dangerous because of the unsteady

foothold. Use the work bench.

1. Open the engine hood.

2. Place a pan under the joint bolt (1) to

catch fuel.

3. Loosen the joint bolt (1) and remove it.

4. Check the strainer (2) inside the joint bolt

(1), and clean it if it is dirty.

5-55

MAINTENANCE

EVERY 1000 HOURS

CLEANING THE ENGINE COOLING

· Do not spill oil or grease.

SYSTEM

· Do not leave tools scattered around.

· Watch your step when walking.

• Never jump down from the machine or

the work bench. When getting on or off

• Stop the engine and allow the machine

the machine or work bench, use the

to cool down before performing

steps, handrails or work bench to

maintenance.

support your body. Your weight should

· The engine, muffler, radiator and many

be evenly distributed among the three

other parts of the machine are hot

contact points (one hand and two feet

immediately after the engine is

or two hands and one foot).

stopped. Touching these parts will

• Do not stand on the dozer blade and

cause burns.

perform maintenance work. Doing so is

· The engine coolant is also hot and

dangerous because of the unsteady

under high pressure immediately after

foothold. Use the work bench.

the engine is stopped. Be careful

when loosening the caps or plugs.

When cleaning, if the temperature of the

Working on the machine under these

coolant is low, the thermostat will be closed

conditions could result in burns or

and the coolant will not circulate in the

injuries due to the hot coolant spurting

radiator. Heat the coolant water to at least

out.

90°C (194°F) before cleaning.

• If maintenance must be performed with

1. Open the engine hood.

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

or clothing away from the moving part

of the machine.

• Standing at the back of the machine

2. Gradually loosen the radiator cap (3) to

while the engine is running is extremely

release the internal pressure, and then

dangerous, as the machine could move

remove the cap.

suddenly. Never stand at the back of the

machine while the engine is running.

• Do not remove the radiator cap or the

drain plug when the cooling water is

hot. Stop the engine and wait until the

engine and the cooling water cool.

Then, slowly loosen the radiator cap

and the drain plug to remove them.

• Before performing maintenance on top

of the work bench, clean the footing and

observe the following precautions to

prevent falling.

3. Loosen the bolts and open the cover (5).

5-57

MAINTENANCE

EVERY 1000 HOURS

REPLACING THE AIR CLEANER ELEMENT

1. Open the left side cover.

• 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.

• Before performing maintenance on top

of the work bench, clean the footing and

observe the following precautions to

prevent falling.

· Do not spill oil or grease.

· Do not leave tools scattered around.

· Watch your step when walking.

• Never jump down from the machine or

the work bench. When getting on or off

the machine or work bench, use the

steps, handrails or work bench to

support your body. Your weight should

be evenly distributed among the three

2. Loosen the clamps (1) and remove the

contact points (one hand and two feet

dust cup (2).

or two hands and one foot).

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

• Do not stand on the dozer blade and

4. Remove the primary element (3).

perform maintenance work. Doing so is

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

dangerous because of the unsteady

6. Remove the secondary element (5).

foothold. Use the work bench.

7. Install the new elements.

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

”

IMPORTANT: Do not use an element if its

mark facing up or by aligning the arrows

pleats, gaskets or seals are damaged.

“

/

”, and then fasten it with the clamps

IMPORTANT: Be sure to install the

(1).

element and dust cap securely. If not,

dust could be drain into the cylinder,

damaging the engine.

5-59

MAINTENANCE

EVERY 1000 HOURS

REPLACING THE AIR BREATHER FILTER

• Stop the engine and allow each part of

the machine to cool down before

performing maintenance.

· The engine, the hydraulic system and

many other parts of the machine are

hot immediately after the engine is

stopped. Touching these parts will

cause burns.

1. Remove the cap nut (N).

· The hydraulic oil is also hot and under

2 Press the button (2) to relieve the internal

high pressure.

pressure from the tank.

Be careful not to touch the hydraulic

3. Remove the seal washer (W) and the nut

oil when loosening the cap or plug.

(G).

Working on the machine under these

4. Remove the cover (H).

conditions could result in burns or

5. Install the filter (A) paying attention to the

injuries due to the hot oil spurting out.

sides (top and bottom).

• Before performing maintenance on the

6. Install the body (B) and the cover (H) by

top of the machine, clean the place you

aligning their notches.

will work on and observe the following

7. Install the seal washer (W) and the nut (G).

to prevent falling.

8. Securely tighten the cap nut (N) by hand.

· Do not spill oil or grease.

· Do not leave tools scattered around.

· Watch your step when walking.

• 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.

• Oil may spurt out if caps or filters are

removed or pipes are disconnected

before releasing the pressure in the

hydraulic system.

· Press the air breather button to relieve

the internal pressure from the tank.

5-60

MAINTENANCE

EVERY 2000 HOURS

EVERY 2000 HOURS

REPLACING THE TRANSMISSION GEAR

OIL

• Stop the engine and allow each part of

the machine to cool down before

performing maintenance.

· The transmission 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 not to touch the oil 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 transmission may cause oil or the

plug to fly out. Loosen the plug slowly

to release the pressure.

1. Park the machine on a level surface and

stop the engine.

2. Place a pan under the plug (2) to catch the

waste oil.

3. Remove the plug (2) and drain the oil.

4. Tighten the plug (2).

· Tightening torque: 80 N·m (59.3 ft-lb.)

5. Add oil through the hole of the plug (1)

until the oil flows from the hole.

6. Tighten the plug (1).

· Tightening torque: 80 N·m (59.3 ft-lb.)

5-63

MAINTENANCE

EVERY 2000 HOURS

REPLACING THE DIFFERENTIAL GEAR

<Rear>

OIL

• Stop the engine and allow each part of

the machine to cool down before

performing maintenance.

· The differentials are hot immediately

after the engine is stopped. Touching

them will cause burns.

· The gear oil is also hot and under high

pressure immediately after the engine

is stopped.

2. Place a pan under the plug (2) to catch the

Be careful not to touch the oil when

waste oil.

loosening the plugs. Working on the

3. Remove the plug (2) and drain the oil.

machine under these conditions could

4. Tighten the plug (2).

result in burns or injuries.

· Tightening torque: 50 N·m (36.9 ft-lb.)

• The pressure in the gear case of

5. Add oil through the hole of the plug (1)

differentials may cause oil or the plug to

until the oil flows from the hole.

fly out. Loosen the plug slowly to

6. Tighten the plug (1).

release the pressure.

· Tightening torque: 50 N·m (36.9 ft-lb.)

1. Park the machine on a level surface and

stop the engine.

<Front>

5-64

MAINTENANCE

EVERY 2000 HOURS

REPLACING THE HUB GEAR OIL

• Stop the engine and allow each part of

the machine to cool down before

performing maintenance.

· The hubs are hot immediately after the

engine is stopped. Touching them will

cause burns.

· The gear oil is also hot and under high

pressure immediately after the engine

5. Set the hub so that the plug (1) is in a level

is stopped.

position.

Be careful not to touch the oil when

6. Add oil through the hole of the plug (1)

loosening the plugs. Working on the

until the oil flows from the hole.

machine under these conditions could

7. Tighten the plug (1).

result in burns or injuries.

· Tightening torque: 50 N·m (36.9 ft-lb.)

• The pressure in the reduction gear case

of hubs may cause oil or the plug to fly

out. Loosen the plug slowly to release

the pressure.

1. Set the hub so that the plug (1) is directly

below the hub.

2. Park the machine on a level surface and

stop the engine.

3. Place a pan under the plug (1) to catch the

waste oil.

4. Remove the plug (1) and drain the oil.

5-65

MAINTENANCE

EVERY 4000 HOURS

1. Slew 45° clockwise and set the machine

EVERY 4000 HOURS

to the hydraulic oil level inspection

REPLACING THE HYDRAULIC OIL AND

posture.

CLEANING THE SUCTION STRAINER

Refer to “Inspecting the hydraulic oil tank

level and replenishing” on page 5-24.

• Stop the engine and allow each part of

the machine to cool down before

performing maintenance.

· The engine, the hydraulic system and

many other parts of the machine are

hot immediately after the engine is

stopped. Touching these parts will

cause burns.

· The hydraulic oil is also hot and under

high pressure.

Be careful not to touch the hydraulic

oil when loosening the cap or plug.

Working on the machine under these

conditions could result in burns or

injuries due to the hot oil spurting out.

• Before performing maintenance on the

top of the machine, clean the place you

will work on and observe the following

2.

Press the button (2) to relieve the internal

to prevent falling.

pressure from the tank.

· Do not spill oil or grease.

3.

Replace the air breather filter (A).

· Do not leave tools scattered around.

Refer to “Replacing the air breather filter”

· Watch your step when walking.

on page 5-60.

• Never jump down from the machine.

4.

Remove the plug (3).

Use the steps and handrails when

5.

Loosen the bolts and remove the flange

climbing up and down the machine, and

(4).

always support your body at three

6.

Remove the return filter (5).

points with your hands and feet.

7.

Loosen the bolts and remove the under

• Oil may spurt out if caps or filters are

cover (6).

removed or pipes are disconnected

8.

Place a pan under the plug (7) to catch

before releasing the pressure in the

the waste oil.

hydraulic system.

9.

Loosen the drain plug (7) and drain the

· Press the air breather button to relieve

hydraulic oil.

the internal pressure from the tank.

10. Loosen the bolts and remove the flange

· When removing plugs or screws, or

(8).

when disconnecting hoses, stand to

11. Remove the suction strainer (9) and

the side and loosen them slowly to

clean it.

gradually release the internal pressure

12. Clean the inside of the hydraulic oil tank.

before removing.

13. Install the suction strainer (9) on the tank

and then install the flange (8).

14. Install the new return filter (5) and the

flange (4) on the tank.

5-66

MAINTENANCE

EVERY 4000 HOURS

15. Tighten the drain plug (7).

Bleeding air

16. Add hydraulic oil from the hole of plug (3)

up to the level between the upper limit

IMPORTANT: After replacing the hydraulic

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

oil or hydraulic devices, or after

gauge (1).

performing maintenance of the hydraulic

17. Tighten the plug (3).

devices, bleed air from the hydraulic

18. Bleed air from the hydraulic oil circuit

circuits and hydraulic devices. Failure to

following “Bleeding air” below.

do so may damage the hydraulic devices.

19. Set the machine to the hydraulic oil level

inspection posture and inspect the oil

• Hydraulic pump

level after the oil cools.

Refer to “Inspecting the hydraulic oil tank

level and replenishing” on page 5-24.

20. Tighten the under cover (6).

1. Open the engine hood.

2. Loosen the vent plug (1) on the hydraulic

pump.

3. Once hydraulic oil overflows from the vent

plug hole (1), tighten the vent plug (1).

If the boom or arm does not move normally,

air may be present in the following locations.

This operation is dangerous and requires

experience. Ask your sales or service dealer

for help.

5-67

MAINTENANCE

EVERY 4000 HOURS

• Emergency shut-off valve

Arm

1. Place a pan under the plugs (A) or hose

(B) to catch the waste oil.

2. Start the engine and run it at low idle.

3. Fully lower the safety lock lever to the

unlock position.

Boom

4. Loosen the hose (B) slowly.

5. Slowly move the right operating lever fore

and aft a little until there are no more air

bubbles coming out of the hose (B)

connecting part.

6. Tighten the hose (B).

4. Loosen the plugs (A / PIL) slowly.

• Slew motor and cylinders

5. Slowly move the right operating lever fore

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

and aft a little until there are no more air

speed for 10 minutes.

bubbles coming out of the plug hole (A).

2. Maintain the engine at low idle, then

6. Tighten the plugs (A).

extend and retract each cylinder 4 or 5

times, without letting them reach the

Second boom

stroke end.

3. Slew slowly left and right several times.

4. Run the engine at high speed, then extend

and retract each cylinder 4 or 5 times,

without letting them reach the stroke end.

5. Slew left and right several times.

6. Return the engine speed to low idle, then

extend and retract each cylinder 4 or 5

times to the stroke end.

5-68

MAINTENANCE

WHEN REQUIRED

3. Remove the key, and then check that the

WHEN REQUIRED

bucket is stable.

REPLACING THE BUCKET TEETH AND

THE SIDE CUTTERS

Replace the bucket teeth if the tooth points

are worn. Do not wait until the bucket is

damaged.

• Before performing maintenance or

repairs under the machine, lower all

moveable working equipment to the

ground or in the lowermost position.

• To prevent unexpected movement,

4. Knock out the locking pin (1) and remove

firmly secure the working equipment

the point (2).

when repairing or replacing the bucket

teeth or side cutter.

Note: If the drift is set against rubber pin lock

• When using a hammer, pins may fly out

(3) when it is hit, the rubber pin lock may

or metal particles may be scattered.

break. Set it against the back of the locking

This may lead to serious injury.

pin.

· If hard metal parts such as pins,

bucket teeth, side cutter or bearings

5. Remove the rubber pin lock (3). Check if

are hit with a hammer, wear protective

the rubber pin lock is still usable. Replace

gear such as safety goggles and

it if it is as follows.

gloves.

· When hitting pins or bucket teeth,

always check that there is no one in

the surrounding area.

• Do not allow unauthorized personnel in

the work area while working.

Removing

1. Clean the bucket and park the machine on

a flat and rigid ground.

A

There are cracks in the rubber and

the roller is coming off.

B

The roller is dented when pressed

with a finger.

2. Place the bucket with its bottom flat on

the blocks so that the locking pin can be

knocked out.

5-70

MAINTENANCE

WHEN REQUIRED

Installation

4. Knock out the locking pin (1).

Check that the end surfaces of the locking

pin just knocked out are aligned with the

upper and lower surface of the point. Do

not use the worn locking pin.

The life of the teeth can be lengthened

and the frequency of its replacement can

be reduced by turning it upside down so

that it will wear evenly.

Replace the rubber pin lock and locking

pin at the same time as replacing the

teeth. This makes it possible to prevent

the teeth from falling out

1. Remove the dirt on the surface of adaptor

and the inner part of tooth, make the

• Side cutter

better contact on the mating part.

Installation

2. Push rubber pin lock (3) into the welding

adaptor (4).

Do not let the rubber pin lock stick out

from the welding adaptor surface.

1. Insert the bolts from the inner of the

bucket and tighten the side cutter with

nuts.

Tightening torque: 475 N·m (350 ft-lb)

3. Install the point (2) onto the welding

2. Caulk the bolts with a punch at three

adaptor (4).

spots along the periphery of the screw to

Insert the point so that the surface behind

prevent the nuts from coming loose.

the point’s pin hole is aligned with the

surface behind the welding adapter’s pin

hole.

5-71

MAINTENANCE

WHEN REQUIRED

REPLACING THE BUCKET

Removing

• 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.

· One person must sit in the operator’s

seat so that he/she can immediately

1. Lower the bucket to the ground as shown

stop the engine when necessary. He/

on the figure above in a stable position.

she must take care not to touch the

lever or pedal unless necessary.

Note: When removing pins, set the bucket

· The one who performs maintenance

so that it is barely touching the ground. If the

must make sure to keep his/her body

bucket is firmly touching the ground, the

or clothing away from the moving part

resistance will be great and it will be difficult

of the machine.

to remove the pin.

• When using a hammer, pins may fly out

or metal particles may be scattered.

2. Set the safety lock lever to the locked

This may lead to serious injury.

position and stop the engine.

· 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

could lose your finger.

3. Remove the bolt (1).

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

5. Remove the bucket.

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

deformed or damaged. (See next page.)

5-72

MAINTENANCE

WHEN REQUIRED

Installation

5. Adjust the gap between the bucket and

the arm.

1. Set the O-ring (4) on the bucket as shown

Refer to “Adjusting the gap between the

on the figure above.

bucket and arm (If equipped)” on page

5-74.

6. Slide the O-ring (4).

Replacing the pin seal

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

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

pin (2).

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

on the bucket with the pin hole on the link

1. Set the pin seal (3) in the direction shown

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

on the figure above.

2. Use a mallet to slowly press the pin seal

in. Be careful not to damage the seal.

4. Align the turn prevention holes, and then

install the bolt (1) and the nut. Be sure to

leave a gap of about 0.5 to 1 mm (0.02 to

0.04 in.) between the nut and bucket

bush, or the nut will come loose.

5-73

MAINTENANCE

WHEN REQUIRED

ADJUSTING THE GAP BETWEEN THE

4. Slightly loosen the 3 bolts (2) (using a 22

BUCKET AND ARM (IF EQUIPPED)

mm (0.87 in) wrench) and remove the

shims (4) from “gap c” between the blade

(3) and bucket. The shims (4) are in two

parts and can be removed easily when the

• Before performing maintenance or

bolts are slightly loosened by sticking a

repairs under the machine, lower all

screwdriver in the seam between the left

working equipment to the ground or in

and right shims.

the lowermost position.

5. Move the O-ring (5) to bring the gap (a)

• To prevent unexpected movement,

into view and measure the width of the

securely block the working equipment

gap (a).

when adjusting the gap.

6. Press the head of the bolts (2) with a finger

1. Lower the bucket to the ground in a stable

to eliminate gap (a). This increases gap (b).

position as shown in the figure above.

Insert the shims removed above into gap

2. Slew the upperstructure slightly to the left

(b), using as many shims as can be

and lightly press the arm to the left side of

inserted easily.

the bucket (the side without an adjuster).

7. Set the remaining shims back in gap (c),

3. Set the safety lock lever to the lock

then tighten the bolts.

position and stop the engine.

Tightening torque : 83 N·m (61.5 ft-lb).

This completes the adjustment.

Note: The proper total number of shims for

gaps (b) and (c) is 6 x 2 = 12. If you forget to

set the shims remaining in step 7 above

back in gap (c), the tip of bolts (2) will extend

past the boss (6). This may damage the boss

at the arm’s tip or cause the bolt to break. If

the end face of boss (6) wears and the width

of the groove (d) for the O-ring reaches 5

mm (0.2 in), replace boss (6) with a new one.

5-74

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