Page 1 TCR50 Dump Carrier Serial No. 30530002~ 305200001~ Book No. AS5E000 Code No. OE-TCR50-C OPERA TOR’S MANUAL WARNING Read and understand these instructions. Failure to do so can cause injury or death.
Page 2 When transferring ownership of this machine, be sure to provide this manual to the next owner. � Takeuchi supplies machines complying to the local regulations and standards of the country of export. If your machine has been purchased in another country or from a person or company of another country, it may not have the safety devices or safety standards required for use in your country.
Page 3 It is your responsibility to observe all pertinent laws and regulations and to follow the manufacturer’s instructions on machine operation, inspection and maintenance. Virtually all accidents occur as the result of a failure to observe basic safety rules and precautions. An accident can often be avoided by recognizing potentially hazardous situations beforehand.
Page 4: Introduction
If you have any questions about the machine, please contact a Takeuchi sales or service outlet. � Manual storage � Serial numbers A compartment for storing this manual...
Page 5: Machine Description
MACHINE DESCRIPTlON � Front, rear, Ieft and right FRONT This manual refers the front, rear, left and right of the machine as seen when sitting in the operator’s seat. LEFT RIGHT � Designated operations Use this machine primarily for the following operation : �...
Page 7: Table Of Contents
CONTENTS Introduction ..........2 Machine Description ......3 Safety ............7 Controls ..........35 Operation ........... 63 Transport ........... 83 Maintenance ........87 Troubleshooting ......131 Speciﬁcations ......... 145 Options ..........153 Index ..........157...
Page 9: Safety
SAFETY General precautions ......... 8 Preparing precautions ........12 Starting precautions ........14 Operating precautions ........16 Stopping precautions ........23 Transporting precautions ......24 Maintenance precautions ......25 Safety signs (Decals) ........32...
Page 10: Safety
SAFETY General Precautions Observe all safety rules Wear appropriate clothing and personal protective equipment � Operation, inspection and maintenance of this machine must be performed only by a trained and qualiﬁed person. � All rules, regulations, precautions and safety procedures must be understood and followed when performing operation, inspection and maintenance of this machine.
Page 11: General Precautions
SAFETY General Precautions Provide a ﬁre extinguisher and Use a signal person and ﬂagman ﬁrst aid kit Know and use the hand signals required for particular jobs and make sure who has the � Know where a ﬁre extinguisher and ﬁrst responsibility for signaling.
Page 12 SAFETY General Precautions Avoid ﬁre and explosion hazards Be sure to lock the safety lock lever before leaving the operator’s seat Keep ﬂames away from fuel, hydraulic ﬂuid, oil, grease and antifreeze. Fuel is particularly ﬂammable and dangerous. � Before leaving the operator’s seat, set �...
Page 13 � For clean up, use wet methods or a � Takeuchi will not be held responsible for vacuum equipped with a high efﬁciency any injuries, accidents or damage to its particulate air (HEPA) ﬁlter.
Page 14 SAFETY Preparing Precautions Know the working area Check the strength of the bridge Before starting operation, know the working area to ensure safety. � Check the topography and ground condition of the working area, or the structure of the building when working indoors, and take the necessary safety measures in dangerous spots.
Page 15: Preparing Precautions
SAFETY Preparing Precautions Perform inspection and maintenance daily Failure to notice or repair machine irregularities or damage can lead to accidents. � Before operating, perform the prescribed inspections and make repairs immediately should any irregularities be found. � If a failure that causes loss of control such as steering, service brakes or engine occurs, stop the machine motion as quickly as possible, follow the shutdown...
Page 16 SAFETY Starting Precautions Maintain three point contact when Clear the area of other persons mounting and dismounting before starting the machine � Do not jump on or off the machine. Never Do not start the engine until you are sure it attempt to mount or dismount a moving is safe.
Page 17: Starting Precautions
SAFETY Starting Precautions Starting with jumper cables In cold weather Use jumper cables only in the recommended � Be careful of slippery conditions on manner. Improper use of jumper cables can freezing ground, steps and hand holds. result in battery explosion or unexpected �...
Page 18 SAFETY Operating Precautions Ensure good visibility Check for safety in the surrounding area before starting � When working in dark places, turn on the machine’s working lights and headlights and / or provide extra stationary lighting if necessary. � When visibility is poor due to severe weather (fog, snow or rain), stop operating the machine and wait until conditions improves.
Page 19: Operating Precautions
SAFETY Operating Precautions Travel safety S2A009 � Raising or swinging the dump body while traveling will cause the machine to become unstable and is dangerous. Lower the dump body and make it parallel with the main frame. � Avoid sudden stops, starts or turns. �...
Page 20 SAFETY Operating Precautions Cautions on traveling on slopes When traveling on slopes or grades, be careful that the machine does not tip (roll) over or slide. � Never exceed the machine’s stability (maximum gradeability – 30°, lateral tipping angle – 10°). Also note that when S2A012E actual working area conditions are poor the machine’s stability may be lower.
Page 21 SAFETY Operating Precautions Precautions when passing Precautions When Loading the through tunnels or under bridges Dump Body S2A015 S2A014 Careless entry into tunnels or under bridges Do not allow loading the dump body unless can lead to serious accidents such as the driver and personnel are in a safe place.
Page 22 SAFETY Operating Precautions Precautions When Dumping Keep a safe distance from electrical power lines S2A016 Do not dump in any of the following manners. S2A017 The center of balance will shift and the Never approach power lines with any part of machine could tip over.
Page 23 SAFETY Operating Precautions Do not enter soft ground Unstable ground is dangerous and increases the likelihood of the machine tipping over S2A018 Entry onto soft ground can result in the machine tilting on its own weight, tipping S2A019 over, or falling in. �...
Page 24 SAFETY Operating Precautions Danger of ﬂying objects Cautions on towing This machine is not equipped with protective guards to protect the operator from ﬂying objects. Do not use the machine in places where there are risks of the operator being hit by ﬂying objects.
Page 25: Stopping Precautions
SAFETY Stopping Precautions Park safely S2A020 � Park the machine on ﬁrm, level ground. If you must park on a slope or incline, block the machine securely to prevent movement. � When parking on streets, use barriers, caution signs, lights, etc., so that the machine can easily be seen even at night to avoid collision with other vehicles.
Page 26: Transporting Precautions
SAFETY Transporting Precautions Load and unload the machine Transport the machine safely safely � Know and follow the safety rules, vehicle code and trafﬁc laws when transporting the machine. � Consider the length, width, height and Fasten to the suspension ﬁtting weight of the transport vehicle with the machine loaded on it when determining Ramp...
Page 27 SAFETY Maintenance Precautions Attach a “DO NOT OPERATE” tag Anti-explosive lighting Severe injury could result if an unauthorized person should start the engine or touch controls during inspection or maintenance. � Stop the engine and remove the key before performing maintenance. �...
Page 28: Maintenance Precautions
SAFETY Maintenance Precautions Prepare the work area Stop the engine before performing maintenance � Select a ﬁrm, level work area. Make sure there is adequate light and, if indoors, � Avoid lubrication mechanical ventilation. adjustments with the machine in motion or �...
Page 29 SAFETY Maintenance Precautions Securely block the machine or any Secure the engine hood or cover component that may fall when opened Be sure to secure the engine hood or cover when opening it. Do not open the engine hood or cover on slopes or in strong wind. Cautions on working on the machine �...
Page 30 SAFETY Maintenance Precautions Use caution when fueling Handling of hoses Fuel, oil or hydraulic ﬂuid leaks can cause a ﬁre. � Do not twist, bend or hit the hoses. � Never use twisted, bent or cracked hoses, tubes and pipes. They may burst. �...
Page 31 SAFETY Maintenance Precautions If ﬂuid is injected into the skin, it must be Be careful with hot cooling removed within a few hours by a doctor systems familiar with this type of injury. Release all pressure before working on the hydraulic system Oil may spurt out if caps or ﬁlters are removed or pipes disconnected before releasing the pressure in the hydraulic system.
Page 32 SAFETY Maintenance Precautions � Always unfasten the negative (–) battery Disconnect the battery cable ﬁrst when disconnecting the battery cable. Always connect the negative (–) battery cable last when fastening the battery cable. � Loose battery terminals may result in sparks.
Page 33 SAFETY Maintenance Precautions Have a Takeuchi service agent Checks after maintenance repair welding cracks or other � Gradually raise the engine speed from a damage low idle to maximum speed and check that no oil or water is leaking from serviced If welding must be performed, make sure that parts.
Page 34 SAFETY Safety Signs (Decals) The following safety signs (decals) have been placed on your machine in the areas indicated. They are intended for the personal safety of you, and those working with you. Please take this manual, walk around your machine and note the content and location of these safety signs.
Page 35: Safety Signs (Decals)
SAFETY Safety Signs (Decals)
Page 36 SAFETY Safety Signs (Decals)
Page 37: Controls
CONTROLS Names of Components ........36 Doors and Covers ...........38 Seat and Seat Belt ..........43 Instrument Cluster ..........46 Switches ............51 Levers ...............54 Accessories .............55...
Page 38: Names Of Components
CONTROLS Names of Components 1. Cab 10. Hydraulic tank 2. Seat 11. Dump body 3. Engine hood 12. Dump cylinder 4. Bumper 13. Swing motor 5. Front light 14. Crawler belt 6. Turn light 15. Idler 7. Rear light 16. Track roller 8.
Page 39 CONTROLS Names of Components 1. Instrument cluster 11. Right control lever 2. Starter switch 12. Fuse box 3. Light switch 13. Fan switch (Heater) 4. Horn switch 14. Heater / Defroster lever 5. Travel speed switch 15. Rec / fresh lever 6.
Page 40: Doors And Covers
CONTROLS Doors and Covers Lock and unlock Starter Key S2B003 E4B003 1. Insert and turn the starter key. The starter key is used not only to start and stop the engine, but also to lock and unlock Opening the following places : 1.
Page 41 CONTROLS Doors and Covers 5. Once the window frame is against the Front Window stopper, move the lock pins (1) to the outside to lock front window. WARNING Closing � Grasp the handles ﬁrmly with both hands when opening and closing the front window.
Page 42 CONTROLS Doors and Covers Lower Front Window Side Window Removing N0B023 1. Grasp the catch (7), unlock it and open the S2B005 1. Open the front window and stow it in the side window. ceiling. 2. To close the side window, close it until a 2.
Page 43 CONTROLS Doors and Covers Opening Battery Cover 1. Insert and turn the starter key clockwise Lock and unlock to unlock. 1. Insert turn starter 2. Turn the handle and lift the engine hood counterclockwise (clockwise) to unlock fully. (lock). 2. Tilt the cover (1) until it stops. Closing 1.
Page 44 CONTROLS Doors and Covers Fuel Filler Cap Raised Body Prop WARNING WARNING � Do smoke permit open If you must work beneath the raised dump ﬂames while fueling or near fueling body, securely engage the raised body operations. prop. Never get under the dump body if it �...
Page 45: Seat And Seat Belt
CONTROLS Seat and Seat Belt � Lower lever (2) to adjust the front angle of Seat the seat cushion. 1. To raise the front angle of the seat cushion, WARNING apply your weight to the backrest while holding the lever down. Adjust, secure and latch the operator’s seat.
Page 46 CONTROLS Seat and Seat Belt (D) Fore-and-aft adjustment 1. Pull on lever (4) and slide the seat backward or forward to bring it to the optimum position for operating the machine. 2. Release the lever (4) at the desired position and the seat will remain ﬁxed there.
Page 47 CONTROLS Seat and Seat Belt Seat Belt CAUTION Always fasten the seat belt securely before starting the engine. Fastening the seat belt 1. Adjust the seat to the optimum position for operating, raise your torso, and sit back ﬁrmly into the seat. 2.
Page 48: Instrument Cluster
CONTROLS Instrument Cluster 2. Pilot Line Filter Warning Lamp This lamp ﬂashes and an alarm sounds if the pilot line ﬁlter is clogged while the engine is running. T7B008 This lamp may ﬂashes directly after the engine in started in cold weather. This is not a malfunction.
Page 49 CONTROLS Instrument Cluster 8. — Meters 14. Water Temperature Gauge This gauge indicates the temperature of the engine coolant water. The lamps should be within 9. Fuel Level Warning Lamp the green range during machine operation. This lamp ﬂashes when the The red range indicates overheating.
Page 50 N2B008 displayed interrupting the current process. IMPORTANT: If an error code appears, 2. TRIP-2 immediately stop the operation and contact a Takeuchi sales or service outlet for help. Display selection buttons N2B009 3. TRIP-3 The TRIP (1) button and the DATA button (2) are used to switch among displays.
Page 51 IMPORTANT: If an error code appears, N2B011 immediately stop the operation and contact a Takeuchi sales or service outlet 2. Battery voltage for help. 5. Press the button to return to the top screen or press and hold the button for three seconds or more to display the next data.
Page 52 CONTROLS Instrument Cluster Dump Body Alignment Indicator Dump Body Raising Indicator This lamp lights when the orientation of the This lamp lights when the dump body is dump body is parallel with the main frame. raised and moves out of the sensor’s range. The lamp is off when the dump body swings It goes out when the dump body is lowered left or right.
Page 53: Switches
CONTROLS Switches Starter Switch Engine Shutdown Switch START L3B043 IMPORTANT: Do not repeatedly switch Use to shutdown the engine if it fails to stop the key from OFF to ON and ON to OFF when the starter switch is set to the OFF over a short period.
Page 54 CONTROLS Switches Horn Switch Parking Brake Button WARNING Pressing this button while traveling will cause the brake to be applied abruptly and is dangerous. It may also damage the travel motors. Do not press this button while traveling. S2B012 Press the switch to activate the horn. Turn Switch S2B023 Pressing the button will cause the pilot lamp...
Page 55 CONTROLS Switches Travel Speed Switch Wiper Switch IMPORTANT: If washer ﬂuid discharged, do not operate the washer. Doing so may damage the pump. IMPORTANT: Operating the wiper with no moisture on the windshield will scratch the glass. Apply water or washer ﬂuid when operating the wiper.
Page 56: Levers
CONTROLS Levers Safety Lock Lever Control Levers WARNING WARNING � Before leaving the operator’s seat, set Be careful to check which pattern of lever the safety lock lever to the lock position control arrangement you are operating and stop the engine. If any controls with before beginning operations.
Page 57: Accessories
CONTROLS Accessories Air Outlets Heater WARNING � Always be sure to allow sufﬁcient ventilation. � Do not place combustible or explosive objects near the air outlets. S2B018 Fan Switch Move knob (1) up and down or left and right to adjust the direction of the air. Supplement: Use the heater with care in warm seasons.
Page 58 CONTROLS Accessories External Power Socket (for EU) Interior Light IMPORTANT: The battery capacity will WARNING decrease if the interior light is left on for long periods of time the engine stopped. Only use applicable electric products with Turn the light off when leaving the these sockets.
Page 59 CONTROLS Accessories Cigarette Lighter Ashtray WARNING WARNING � Do not leave the cigarette lighter’s � Be sure to extinguish cigarettes and knob pressed in. Doing so heats up the matches completely before putting lighter, and could be dangerous. them in the ashtray, and always close �...
Page 60 CONTROLS Accessories Radio (Cab Type) Operating precautions � To ensure safe operation of the machine, always be sure to keep the volume of the radio down to a level where you can easily hear sounds from outside the machine. � Do not keep the radio playing for long periods of time with the engine stopped. Doing so will drain the battery of its charge and make it difﬁcult or impossible to restart the engine.
Page 61 CONTROLS Accessories (7) TUNE button (13) AUX-IN jack Use this button to tune to a radio station. Use this jack to connect an external audio Press and hold this button ( ) for source. Pull off the rubber cap and plug the two seconds or more to start seeking the stereo mini-plug of the external audio device audible stations.
Page 62 CONTROLS Accessories 3. For more stations, repeat the steps (1) and � Adjust the sound volume of the audio (2) above. player by using the volume control buttons � If the preset button on which a station on the radio. has been set to is pressed and held �...
Page 63 CONTROLS Accessories SPECIFICATIONS Power source : 12 V to 24 VDC (negative ground) Power consumption : 5A Rated output power : 20 W + 20 W (4 Ω) (at 28 VDC input) 16 W + 16 W (10% distortion, 4 Ω) (at 24 VDC input) Dimension : 178 (W) x 50 (H) X...
Page 65: Operation
OPERATION Before Starting Operation ......64 Starting and Stopping the Engine ....66 Machine Operation .........68 Operating Procedures ........74 Parking the Machine ........77 Handling in Cold Weather ......78 Handling Rubber Crawlers ......79...
Page 66: Before Starting Operation
OPERATION Before Starting Operation Mounting and Dismounting Walk-Around Inspection Perform the walk-around inspections once a WARNING day before starting the engine the ﬁrst time that day. � Do not jump on or off the machine. Perform the inspections as described under Never attempt to mount or dismount a “Maintenance - Walk-Around Inspection”...
Page 67 If a lamp does not light or the alarm does not sound, the bulb may be burnt out or a wire S2D002 may be damaged. Contact a Takeuchi sales 4. Check that the control levers are in the or service outlet for repairs.
Page 68: Starting And Stopping The Engine
OPERATION Starting and Stopping the Engine Starting in Cold Weather Starting the Engine WARNING � Clear the area of all persons. � Sound horn to alert everyone around the machine. IMPORTANT: Do not run the starter motor for more than 15 consecutive seconds. 1.
Page 69 OPERATION Starting and Stopping the Engine Warming Up the Engine Stopping the Engine IMPORTANT: Avoid racing the engine IMPORTANT: Do not stop the engine until it is warmed up. suddenly when operating with heavy Do not warm up the engine for long loads or at maximum speed.
Page 70: Machine Operation
OPERATION Machine Operation Lever Pattern Crawler Forward Dump body Lower Crawler Reverse Dump body Dump Dump body Swing Left Left Spin Turn Right Spin Turn Dump body Swing Right Left Pivot Turn Right Pivot Turn Right Pivot Turn Reverse Left Pivot Turn Reverse...
Page 71 OPERATION Machine Operation Warming Up the Machine (Hydraulic Oil) WARNING Operating the working equipment without warming up the machine (hydraulic oil) is dangerous, as response will be slow and S2D008 the equipment may move in unexpected 3. Extend and retract the dump cylinders ways.
Page 72 OPERATION Machine Operation Inspection After Warm-up Traveling the Machine After warming up the engine and hydraulic WARNING oil, perform the checks and inspections described below, and repair if there is a � Never allow anyone to enter the problem. machine working range and machine path.
Page 73 OPERATION Machine Operation To turn left while traveling forward : Move the left control lever forward to the left. To turn left while traveling backward : Move the left control lever backward to the right. Right Turn S2D011 3. Make sure that the dump body is lowered and is parallel to the main frame.
Page 74 OPERATION Machine Operation Stopping Travel WARNING � Park the machine on ﬁrm, level ground. If you must park on a slope or incline, block the machine securely to prevent movement. � If any controls should be touched accidentally when the safety lock lever is lowered, the machine will move suddenly, and cause serious injury or death.
Page 75 OPERATION Machine Operation Dump and Lower Operating the Dump Body WARNING � Check the surrounding area for safety before operating the dump body. � Raising or swinging the dump body while traveling will cause the machine to become unstable and is dangerous. S2D018 Lower the dump body and make it To lower the dump body :...
Page 76: Operating Procedures
OPERATION Operating Procedures Precautions When Loading the Dump Cautions on Operating Body Cautions on Traveling S2A015 Do not allow loading the dump body unless S2A010 Traveling over obstacles (rocks, stumps, the driver and personnel are in a sage place. etc.) may subject the body to strong shocks Load on a ﬁrm location, do not load on a and result in damage.
Page 77 � Never submerge the swing bearing or main body in water or sand. If the slew bearing or main body should get submerged, contact a Takeuchi sales or service outlet for inspection.
Page 78 OPERATION Operating Procedures Cautions on Traveling on Slopes WARNING � Never exceed the machine’s stability (maximum gradeability – 30°, lateral tipping angle – 10°). Also note that when actual working area conditions S2A012E are poor the machine’s stability may be �...
Page 79: Parking The Machine
OPERATION Parking the Machine Parking Inspection and Checks After Stopping the Engine WARNING 1. Check for oil and water leakage and inspect the dump body, covers and main frame. If any irregularities are found, repair. 2. Fill the fuel tank. Refer to page 102 “Inspecting the Fuel Level”.
Page 80: Handling In Cold Weather
After Cold Weather is Over Inspect the battery. If the charge is low, Perform the following after cold weather is contact a Takeuchi sales or service outlet to over : have the battery charged. � Change the fuel and the oils for the Refer to page 110 “Inspecting the Battery...
Page 81: Handling Rubber Crawlers
OPERATION Handling Rubber Crawlers Rubber crawlers have an inherent weakness due to their use of rubber. Be sure to heed the prohibitions and cautions below so as to prevent damage to the crawlers and crawler slippage. Prohibited Actions S2D024 Do not travel or operate the machine in the �...
Page 82 OPERATION Handling Rubber Crawlers Preventing the Rubber Crawlers from Cautions Slipping Off Heed the following cautions when operating Heed the following in order to prevent the the machine : rubber crawlers from slipping off : � Avoid changing course abruptly and �...
Page 83 OPERATION Handling Rubber Crawlers S2D029 � Avoid traveling with one crawler on a slope or projecting object and the other crawler on a ﬂat surface (with the machine at a tilt of 10° or greater). Travel with both crawlers on ﬂat surfaces. �...
Page 85: Transport
TRANSPORT Loading and Unloading ........84 Hoisting the Machine ........85 Securing the Machine ........86...
Page 86 TRANSPORT Loading and Unloading 1. Apply the truck’s parking brake and place WARNING stoppers against its tires. The machine may roll or tip over or fall 2. Fasten the ramps securely to the truck while loading or unloading it. Take the bed so that they will not come off.
Page 87 IMPORTANT: This hoisting method applles to machines with standard speciﬁcations. The center of gravity differs according to the attachments and options that are mounted. Consult a Takeuchi sales or service outlet. Hoisting posture...
Page 88 TRANSPORT Securing the Machine After loading the machine in the designated position, secure it as described below. Transporting Posture 1. Stop the engine and remove the starter Cautions on Transporting key. 2. Set the safety lock lever securely to the WARNING locked position.
Page 89: Maintenance
MAINTENANCE General .............88 Service Data .............90 Important Parts ..........95 Maintenance Chart .........96 Walk-Around Inspection ........98 Daily Inspection (Every 10 Hours) ....100 After First 50 Hours (New Machines Only) ......105 Every 50 Hours ..........110 After First 250 Hours (New Machines Only) ......113 Every 250 Hours ..........114 Every 500 Hours ..........117 Every 1000 Hours ..........120...
Page 90: General
Have inspection maintenance as recommended in this manual. procedures not prescribed in this manual performed by a Takeuchi sales or service The inspection and maintenance items are outlet. divided according to the machine’s total operating time (inspection and maintenance Always keep the machine clean.
Page 91 If the sealing grooves of the surface � Operate all the operating levers and check of contact are damaged, consult a Takeuchi that the machine is operating properly. sales or service outlet. Cautions on handling of battery cables Seals and split pins �...
Page 92: Service Data
MAINTENANCE Service Data Lubricant and Fuel Chart Use different lubricants, greases and fuels 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.
Page 93 MAINTENANCE Service Data Fuel Diesel Fuel Speciﬁcathions Diesel fuel should comply with the following speciﬁcations. This table lists several worldwide speciﬁcations for diesel fuels. Diesel Fuel Speciﬁcation Location Diesel Fuel Speciﬁcation Location No.2-D, No.1-D, ASTM ISO 8217 DMX International D975-94 EN590:96 European BS 2869-A1 or A2...
Page 94 MAINTENANCE Service Data Expendables Replace expendables such as ﬁlters and elements periodically, referring to the table below. Item Part name Part No. Replacement interval Pilot line ﬁlter Element 15511-02103 After ﬁrst 50 hrs. Every 500 hrs. Hydraulic oil return Cartridge 15510-00320 After ﬁrst 50 hrs.
Page 95 MAINTENANCE Service Data Tools Part name Part No. Remarks Part name Part No. Remarks 13 Pliers Spanner 16900-01012 10-12 16905-00200 200 mm 14 Hammer Spanner 16900-01417 14-17 16903-00330 15 Hex. wrench Screwdriver 16902-20205 (+) (-) 16906-00250 2.5 mm 16 Hex. wrench Filter wrench 16919-03560 16906-00500...
Page 96 � 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.
Page 97: Important Parts
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.
Page 98: Maintenance Chart
MAINTENANCE Maintenance Chart Maintenance Items See page Walk-Around Inspection Inspecting by opening the engine hood and covers Inspecting by walking around the machine Inspecting while sitting in the operator’s seat Daily Inspection (Every 10 Hours) Inspecting and replenishing the coolant Inspecting and replenishing the engine oil Inspecting the water separator and the fuel ﬁlters Inspecting the fuel level...
Page 99 MAINTENANCE Maintenance Chart Maintenance Items See page Every 500 Hours Replacing the fuel ﬁlters Replacing the feed pump ﬁlter Replacing the pilot line ﬁlter Replacing the engine oil and oil ﬁlter Every 1000 Hours Cleaning the engine cooling system Replacing the air cleaner elements Replacing the hydraulic oil and cleaning the suction strainer Replacing the hydraulic oil return ﬁlter Replacing the travel motor gear oil*...
Page 100: Walk-Around Inspection
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 or cover when opening it. Do not open the engine hood or cover on slopes or in strong wind.
Page 101 MAINTENANCE Walk-Around Inspection Inspecting by Walking Around the Inspecting While Sitting in the Machine Operator’s Seat 3. Check for oil leakage from the hydraulic 12. Check the windshield for dirt or tank, hydraulic devices, hoses and damage. connections. 13. Check the seat and seat belt for dirt or 4.
Page 102: Daily Inspection (Every 10 Hours)
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 or cover when opening it. Do not open the engine hood or cover on slopes or in strong wind.
Page 103 MAINTENANCE Daily Inspection (Every 10 Hours) Replenishing Inspecting and Replenishing the 1. Remove the oil supply cap (2). Engine Oil 2. Add oil up to the upper limit (H) of the dipstick (1). WARNING Problems could arise if the oil level is either too low or too high.
Page 104 MAINTENANCE Daily Inspection (Every 10 Hours) Inspecting the Water Separator Inspecting the Fuel Level and the Fuel Filters WARNING Water Separator � Never jump off the machine. Use the steps and handrails when climbing on and off the machine, and always support your body at three points with your hands and feet.
Page 105 MAINTENANCE Daily Inspection (Every 10 Hours) • When the oil temperature is about 50 to Inspecting the Hydraulic Oil Level 80°C (122 to 176°F) : and Replenishing The level should be near the middle (M). WARNING (When the dump body is lowerd, the oil level rises to the middle point between �...
Page 106 MAINTENANCE Daily Inspection (Every 10 Hours) Lubricating the Dump body and Track Rollers S2G010 1. Set the machine to the lubrication posture shown in the diagram above, lower the dump body, then stop the engine. 2. Use the grease gun to lubricate the grease nipples. 3.
Page 107: After First 50 Hours
MAINTENANCE After First 50 Hours (New Machines Only) Replacing the Pilot Line Filter WARNING � Stop the engine and allow the machine to cool down before performing maintenance. • The engine, hydraulic lines and many S2G034 other parts of the machine are hot 5.
Page 108 MAINTENANCE After First 50 Hours (New Machines Only) Replacing the Hydraulic Oil Return Filter WARNING � Stop the engine and allow the machine to cool down before performing maintenance. S2G033 • The engine, hydraulic lines and many 5. Remove the cover (4). other parts of the machine are hot 6.
Page 109 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 may other parts of the machine are hot directly after the engine is stopped.
Page 110 IMPORTANT: Check the spent oil. If it your hands and feet. contains large amounts of metal powder, consult a Takeuchi sales or service Supplement: The machine should be taken outlet. into a workshop for replacing the oil ﬁlter.
Page 111 MAINTENANCE After First 50 Hours (New Machines Only) Engine oil ﬁlter The engine oil ﬁlter is located under the turbocharger. 1. Place a pan under the engine oil ﬁlter to catch the waste oil. 2. Remove the ﬁlter drain plug (4) and drain the oil from the ﬁlter case (6).
Page 112: Every 50 Hours
If the amount of slack is large, contact a � Batteries contain sulfuric acid which Takeuchi sales or service outlet for repairs. will damage eyes or skin on contact. • If acid...
Page 113 MAINTENANCE Every 50 Hours Replenishing When adding distilled water, do so before starting operations in order to prevent freezing. 1. Remove the caps (2), and add distilled water until the upper level (H). 2. Inspect the indicator (1) then it turns blue. 3.
Page 114 MAINTENANCE Every 50 Hours Draining the Fuel Tank 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.
Page 115: After First 250 Hours
MAINTENANCE After First 250 Hours (New Machines Only) Replacing the Travel Motor Gear 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.
Page 116: Every 250 Hours
MAINTENANCE Every 250 Hours 2. Loosen the clamp (1) and remove the dust Cleaning the Air Cleaner cup (2). 3. Clean the inside of the dust cup (2). WARNING 4. Remove the primary element (3). Do not remove and clean the secondary �...
Page 117 MAINTENANCE Every 250 Hours 5. Repeat step 2. Lubricating the Swing Bearing 6. Start the engine and swing the dump body counterclockwise 180°. WARNING 7. Repeat step 2. 8. Wipe off the grease expelled from the Do not swing while lubricating. Doing so swing bearing and grease nipple.
Page 118 MAINTENANCE Every 250 Hours Cleaning the Radiator Fins and Oil Inspecting and Adjusting the Fan Cooler Fins Belt Refer to page 107 “Inspecting and Adjusting WARNING the Fan Belt”. 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.
Page 119: Every 500 Hours
MAINTENANCE Every 500 Hours 7. Use the ﬁlter wrench and tighten the Replacing the Fuel Filters case. Tightening torque: 30 N·m (22.1 ft-lb) WARNING 8. Purge the air. � Do not smoke or permit open ﬂames Refer to page 135 “Bleeding the Air from while handling fuel or working on the the Fuel System”.
Page 120 MAINTENANCE Every 500 Hours Replacing the Feed Pump Filter 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.
Page 121 MAINTENANCE Every 500 Hours Replacing the Pilot Line Filter Refer to page 105 “Replacing the Pilot Line Filter”. Replacing the Engine Oil and Oil Filter Refer to page 108 “Replacing the Engine Oil and Oil Filter”.
Page 122: Every 1000 Hours
MAINTENANCE Every 1000 Hours When cleaning, if the temperature of the Cleaning the Engine Cooling coolant is low, the thermostat will be closed System and the coolant will not circulate in the radiator. Heat the coolant water to at least WARNING 90°C before cleaning.
Page 123 MAINTENANCE Every 1000 Hours 8. Stop the engine, let the water’s temperature Replacing the Air Cleaner lower, then loosen the drain valve (4) and Elements drain the water. 9. After draining the water, clean using WARNING cleaning agent. Clean following the instructions included with the cleaning Stop the engine and allow the machine agent you are using.
Page 124 MAINTENANCE Every 1000 Hours Replacing the Hydraulic Oil and Cleaning the Suction Strainer WARNING � Stop the engine and allow the machine to cool down before performing maintenance. S2G033 • The engine, hydraulic lines and many 5. Remove the cover (4). other parts of the machine are hot 6.
Page 125 MAINTENANCE Every 1000 Hours Bleeding the air 14. Replace the line ﬁlter. Refer to page 105 “Replacing the Pilot IMPORTANT: After replacing the hydraulic Line Filter”. 15. Replace the return ﬁlter. oil, bleed the air from the hydraulic oil circuit and hydraulic devices. Failure to do Refer to page 106 “Replacing the Hydraulic Oil Return Filter”.
Page 126 Refer to page 113 “Replacing the Travel Motor Gear Oil”. Inspecting and Adjusting the Engine Valve Clearance This operation requires experience. Have it performed by a Takeuchi sales or service outlet. Inspecting the Engine Compression Pressure This operation requires experience. Have it performed by a Takeuchi sales or service outlet.
Page 127: When Required
MAINTENANCE When Required Inspecting and Replenishing the Windshield Washer Fluid Use a windshield washer ﬂuid designed speciﬁcally for motor vehicles. Follow the instructions including with the washer ﬂuid. G4G030 Inspection 1. Open the cab door. 2. Inspect the washer tank (1) and add washer ﬂuid if the level is low.
Page 128 MAINTENANCE When Required Lubricating the Levers WARNING Set the machine to the parking posture, stop the engine, remove the starter key and store it. Failure to do so may result in the machine moving abruptly, leading to serious injury or death. If the levers no longer move smoothly, supply grease.
Page 129 (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 stretched and cannot be adjusted.
Page 130 MAINTENANCE When Required Replacing the Rubber Crawlers WARNING � If you must work beneath the raised machine or equipment, always use wood blocks, jack-stands or other rigid and stable supports. Never get under S2G043 the machine or raised dump body if 1.
Page 131 MAINTENANCE When Required 5. Remove the rubber crawler from the idler ﬁrst, and then from the sprocket. Take great care in handling rubber crawlers, because they are very heavy. Installation 1. Engage the rubber crawler with the sprocket, and place the rubber crawler on the idler.
Page 132: Long-Term Storage
2. Inspect the battery and recharge it if Refer to page 120 “Cleaning the Engine necessary. Cooling System”. Have the battery charged by a Takeuchi 5. Use the grease gun to supply grease to sales or service outlet. the grease nipples.
Page 133: Troubleshooting
TROUBLESHOOTING Symptoms that are not Malfunctions ..132 If the Engine Overheats ........133 If the Battery Goes Dead ......134 After the Fuel Runs Out ........135 If a Fuse Blows ..........136 If a Warning Lamp Flashes ......138 Other Symptoms ...........142 Towing .............144...
Page 134: Symptoms That Are Not Malfunctions
TROUBLESHOOTING Symptoms that are not Malfunctions The following symptoms are not malfunctions : � The swing motor produces noise at the beginning and end of the swing operation. � The travel motor produces noise when stopped suddenly during high speed travel.
Page 135: If The Engine Overheats
3. If there is steam, stop the engine � Do not remove the radiator cap or drain immediately and contact a Takeuchi sales plugs when the coolant is hot. Stop the or service outlet for repairs.
Page 136: If The Battery Goes Dead
TROUBLESHOOTING If the Battery Goes Dead Connecting the jumper cables The following symptoms indicate that the battery is dead : IMPORTANT: Set the starter keys of both � The starter motor does not turn or turns weakly, and the engine does not start. the rescue vehicle and problem vehicle to the OFF position.
Page 137: After The Fuel Runs Out
(R) from the problem vehicle’s “+” terminal. Recharging L3D001 Have a Takeuchi sales or service outlet 3. Turn the starter key to the ON position and recharge batteries that have gone dead. wait for the air to bleed around the vent plug (6).
Page 138: If A Fuse Blows
Interior light, 10A Turn signal Continued use may lead to ﬁre. Consult a Radio backup Instrument Takeuchi sales or service outlet. 10A Starter circuit cluster, Lamp 1. Turn the starter key to the OFF position and stop the engine. L3J002 2.
Page 139 TROUBLESHOOTING If a Fuse Blows Inspecting the Fusible Link S2J002 If the power is not switched on after turning the starter switch to the ON position, the cartridge type fusible links (1) might be blown open. Open the battery cover and inspect. If the fusible link is blown, please contact your dealer.
Page 140: If A Warning Lamp Flashes
Inspect the engine oil level. If the lamp is ﬂashing even Engine oil though the level is normal or if it continues ﬂashing after pressure oil is added, consult a Takeuchi sales or service outlet. warning lamp Refer to page 101 “Inspecting and Replenishing the Engine Oil”.
Page 141 ECM warning An error code indicating the type of error appears in the lamp multi-data display. Inform a Takeuchi sales or service outlet of such error code and consult how to remedy. Refer to page 48 “Multi-Data Display”. Refer to page 140 “Error Code List”.
Page 142 If a Warning Lamp Flashes Error Code List The ﬁve error codes are displayed (the leftmost code is the most recent error). If an error code is display on the multidata display, consult a Takeuchi sales or service outlet. Error Code No. Error details Short-time operations (0.5 seconds or less) of the key switch are...
Page 143 TROUBLESHOOTING If a Warning Lamp Flashes Error details Error Code No. When the key switch is turned ON, the engine oil pressure sensor malfunctions. When the key switch is turned ON, the charger outputs an ON (24V) signal. The status change (Low to High) of an open-circuit interlock signal is recorded.
Page 144: Other Symptoms
TROUBLESHOOTING Other Symptoms For symptoms not included on the table below or if the problem persists after the proper procedures have been taken, consult a Takeuchi sales or service outlet. Symptom Main cause Procedure Control levers do not � Insufﬁcient grease on left and �...
Page 145 � Water in fuel system � Drain the water. Refer to page 112. Crawlers slip off � Crawlers are too loose � Consult a Takeuchi sales or service outlet. Engine exhaust is white � Excessive engine oil � Adjust to the prescribed or bluish level.
Page 146: Towing
TROUBLESHOOTING Towing <Rear> WARNING When towing, selecting the wrong wire rope, inspecting improperly, or towing in the wrong way could lead to accidents resulting in serious injury or death. � The wire rope breaking or coming detached could extremely dangerous. Use a wire rope suited for the required towing force.
Page 147: Speciﬁcations
SPECIFICATIONS Main Speciﬁcations ........146 Machine Dimensions ........148 Operating Range ...........150...
Page 148 SPECIFICATIONS Main Speciﬁcations TYPE MASS Operating mass kg (lb.) 6025 (13285) PERFORMANCE Dump body capacity m (cu.ft.) Heaped 2.055 (72.57) (standard dump body) Struck 1.15 (40.61) Maximum loading mass kg (lb.) 3700 (8155) –1 Swing speed min (rph) 180° 6.6 (6.6) Travel speed km / h (mph) 0~9.2 (5.72) Gradeability (degrees)
Page 149 MEMO...
Page 150 SPECIFICATIONS Machine Dimensions...
Page 151 SPECIFICATIONS Machine Dimensions Units: mm (inches) Standard Dump Body Short Dump Body 2725 (107.3) 1040 (41.0) 4745 (186.8) 4830 (190.3) 2500 (98.4) 3190 (125.6) 1305 (51.4) 1310 (51.6) 1760 (69.3) — 1695 (66.7) 2000 (78.7) 450 (17.7) 435 (17.1) 990 (39.0) 980 (38.6) 2605 (102.6) 2420 (95.2)
Page 152 SPECIFICATIONS Operating Range...
Page 153 SPECIFICATIONS Operating Range Units: mm (inches) Standard Dump Body Short Dump Body 4630 (182.3) 4825 (190) 880 (34.6) 725 (28.5) 3600 (141.7) 3220 (126.8) 3590 (141.3) 1000 (39.4) 1730 (68.1) 1965 (77.4) 2745 (108.1) 2535 (99.8) 90° 90° 65°...
Page 155: Options
OPTIONS General Precautions ........154 Optional Equipment Mass ......156...
Page 156 Heed the following when removing or installing an attachment or option : � Consult with a Takeuchi dealer before installing optional attachments. � Do not use attachments that have not been approved by Takeuchi or a Takeuchi dealer. Doing so may compromise safety or adversely affect the machine’s operation or service life.
Page 157 OPTIONS General Precautions Precautions on Operating Attachments WARNING Long or big attachments reduce machine stability. When traveling down steep slopes or turning on slopes, the machine may loose its balance and tip over. The following operations are particularly dangerous. Do not perform them. �...
Page 158 OPTIONS Optional Equipment Mass Standard machine mass (rubber crawlers, not including operator) 5950 (13120) OPTION Short dump body (Short vessel) -65 (-143) Air conditioner 15 (33) Units: kg (lb) *: Mass of optional equipment is added to the standard machine mass. *: This table only contains the optional equipment of 10kg (20lb) or more in mass.
Page 159: Index
INDEX...
Page 160 INDEX A ~ D Cautions on towing ............22 Cautions on Transporting ..........86 Accessories ................ 55 Cautions on traveling on slopes ........18 After Cold Weather is Over ..........78 Cautions on Traveling on Slopes ........76 After First 250 Hours (New Machines Only) ....113 Cautions on working on the machine .......
Page 161 Inspecting the water separator and the fuel ﬁlters ..102 Handling Rubber Crawlers ..........79 Inspecting while sitting in the operator’s seat ....99 Have a Takeuchi service agent repair welding cracks or Inspection After Warm-up ..........70 other damage ..............31 Inspection and Checks After Stopping the Engine ..
Page 162 INDEX K ~ P Keep a safe distance from electrical power lines ..... 20 Names of Components ............. 36 Know the working area ............12 Never modify the machine ..........11 Never remove safety equipment ......... 9 Lever Pattern ..............68 Levers .................
Page 163 INDEX R ~ U Speciﬁcations ..............145 Start the engine from the operator’s seat ......14 Radio (Cab type) ..............58 Starter Key ................38 Raised Body Prop .............. 42 Starter Switch ..............51 Release all pressure before working on the hydraulic Starting and Stopping the Engine ........
Page 164 INDEX U ~ W Use the correct tools ............25 Using optional products ............ 11 Vibrations operators are subject to ........31 Walk-Around Inspection ............ 64 Walk-Around Inspection ............ 98 Warming Up the Engine ............. 67 Warming Up the Machine (Hydraulic Oil) ......69 Warning Lamps ..............
Page 165 First Published July 2009 No.31768 OPERATOR’S MANUAL TCR50 Dump Carrier Edited and issued by TAKEUCHI MFG. CO., LTD. Printed in Japan by STATION M Co., Ltd.
Page 166 CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

Takeuchi TCR50 Operator's Manual

Table of Contents

Controls

Operation

Maintenance

Troubleshooting

Quick Links

Chapters

Related Manuals for Takeuchi TCR50

Summary of Contents for Takeuchi TCR50

Table of Contents