Page 2 All persons using this new one from your Takeuchi dealer. machine should thoroughly familiarize When transferring ownership of this machine, themselves with the contents of this be sure to hand this manual to the next manual.
Page 3 SIGNAL WORDS IMPORTANT: The word IMPORTANT is used to alert operators and maintenance Safety messages appearing in this manual personnel about situations which could and on machine decals are identified by the result in damage to the machine and its words “DENGER”, “WARNING”...
Page 4: Introduction
If you have any questions about the machine, please contact a Takeuchi sales or service outlet. MANUAL STORAGE COMPARTMENT SERIAL NUMBERS A compartment for storing this manual is...
Page 5: Machine Description
MACHINE DESCRIPTION FRONT, REAR, LEFT AND RIGHT DESIGNATED OPERATIONS Use this machine primarily for the following operations: • Excavation • Digging ditches • Leveling • Loading FEATURES • Hydromounted cab minimizes vibration • Low engine noise and exhaust emissions • Electronic control of auxiliary hydraulic circuit •...
Page 6 NOTES ON READING THIS MANUAL Please note that the descriptions and diagrams included in this manual may not be applicable to your machine. The numbers used in the illustration are with circles around them. The same numbers appear between the parentheses in the text. (Example: (1)) Symbols used in this manual...
Page 7: Table Of Contents
CONTENTS Second /Fourth auxiliary hydraulic Introduction ........0-2 switch ..........2-44 Outrigger switches (If equipped) ..2-44 Machine description ......0-3 Third auxiliary hydraulic switch and button ..........2-44 Safety ..........1-1 Aux. 2/4 select button ....... 2-44 General precautions ........ 1-2 Light switch ........2-45 Precautions when preparing ....
Page 8 Service data ..........5-4 Operation .........3-1 Fuel and lubricant table ......5-4 Before starting operation ......3-2 Regularly replace the hydraulic oil ..5-8 Getting on or off the machine ....3-2 List of consumables ......5-9 Walk-around inspection ....... 3-2 List of tools (If equipped) ....
Page 9 Inspecting the slew motor gear oil ..5-41 Inspecting and maintenance the DPD or its related parts ...... 5-69 Cleaning the cooler fins ...... 5-42 Cleaning the air cleaner ..... 5-43 Inspecting the engine controller Cleaning the air filters (AC) ....5-45 (ECM) ..........
Page 10 Precautions when operating attachments ........8-3 Hydraulic breaker ........8-4 Cautions on operating ......8-4 Replacing the hydraulic oil regularly ..8-5 Biodegradable oil ........8-6 Replacing the hydraulic oil with biodegradable oil ......... 8-6 Operating lever switch kit 1 ...... 8-8 Horn button .........
Page 11: Safety
SAFETY...
Page 12: General Precautions
SAFETY GENERAL PRECAUTIONS GENERAL PRECAUTIONS When a problem is found on the machine It is your responsibility to observe all If any problem (noise, vibration, smell, disorder of instrument, smoke, oil leak or pertinent laws and regulations and to follow the manufacture s instructions on wrong indication of alarm and panel, etc.) is machine operation, inspection and detected during the operation or inspection...
Page 13 SAFETY GENERAL PRECAUTIONS Wear appropriate clothing and protective Install a fire extinguisher and first aid kit equipment AG7A005 Be prepared for fire and accidents AG7A004 • Do not wear loose clothing or any • Install an extinguisher and a first aid kit, accessory that can catch on controls or in and learn how to use them.
Page 14 SAFETY GENERAL PRECAUTIONS Use a signal person and a flag person Precautions when standing up from or leaving the operator’s seat AG7A007 Learn how to use the hand signals required AG7A009 for particular jobs and make sure who has • Before standing up from the operator’s the responsibility for signaling.
Page 15 SAFETY GENERAL PRECAUTIONS Avoid fire and explosion hazards • When handling the fuel, washing oil or paint, open the door and windows to ventilate thoroughly. • Store all flammable fluids and materials in a safe and well-ventilated place. • The short circuit of the electric system may cause the fire.
Page 16 SAFETY GENERAL PRECAUTIONS Exhaust fumes from the engine is Be careful not to get crushed or cut poisonous AG7A013 Never put your hands, feet or other parts of AG7A011 your body between the upperstructure and • Do not operate the engine in an enclosed area without adequate ventilation.
Page 17 Takeuchi. Doing so may compromise safety or adversely affect the machine’s operation or service life. • Takeuchi will not be held responsible for any injuries, accidents or damage to its products caused by the use by a non-...
Page 18: Precautions When Preparing
SAFETY PRECAUTIONS WHEN PREPARING PRECAUTIONS WHEN PREPARING Know the work area Before starting operation, know the working area condition to ensure a safety operation. • Inspect the topography and ground condition of the working area, or the structure of the building when working indoors, and take the safety precautions as •...
Page 19 SAFETY PRECAUTIONS WHEN PREPARING Check the strength of the bridge Always keep the machine clean When traveling over a bridge or a structure, check the permissible load. If the strength is insufficient, reinforce the bridge or the structure. AG7A019 • Clean windows, mirrors and lights to ensure good visibility.
Page 20 SAFETY PRECAUTIONS WHEN PREPARING Perform inspection and maintenance Cautions in the operator’s compartment every day • Remove mud and grease from shoe soles before entering the operator’s compartment. Pedaling the machine with the shoes with mud and grease will cause a slip accident. •...
Page 21 SAFETY PRECAUTIONS WHEN PREPARING Emergency exit Rear window If you should become trapped inside the cab, remove the rear window to get out. 1. Pull off the ring (A) and remove the tip of the rubber wedge. 2. Grasp and pull the tip of the rubber wedge to remove the entire rubber wedge.
Page 22: Precautions When Starting
SAFETY PRECAUTIONS WHEN STARTING PRECAUTIONS WHEN STARTING Support your weight in a three point secure stance when getting on/off the machine • Do not jump on or down from the machine. Never attempt to get on or off the moving machine.
Page 23 SAFETY PRECAUTIONS WHEN STARTING Starting with jumper cables In cold climates AG7A027 AG7A025 Use jumper cables only in the recommended • Be careful of slippery conditions on freezing manner. Improper use of jumper cables can ground, steps and hand holds. result in battery explosion or unexpected •...
Page 24: Precautions When Operating
SAFETY PRECAUTIONS WHEN OPERATING PRECAUTIONS WHEN Check if the work area is safe and secure before operation OPERATING Ensure good visibility • When working in dark places, turn on the machine’s working lights and headlights and additional lighting equipment installed, as necessary.
Page 25 SAFETY PRECAUTIONS WHEN OPERATING Check the position of the undercarriage Travel safely (steering device) before start traveling • Before traveling, set the machine to the “travel posture”. Equipped with outrigger Refer to “Preparing for travel” for further details. • When traveling on a road, be sure to lock the working equipment.
Page 26 SAFETY PRECAUTIONS WHEN OPERATING • Before traveling on a road, tilt the reflector. • Avoid crossing over obstacles whenever When operating at a job site, raise the possible. If you must do so, keep the hoe reflector to prevent it from being damaged. attachment close to the ground level and travel slowly.
Page 27 SAFETY PRECAUTIONS WHEN OPERATING Precautions when traveling on slopes • When traveling on slopes or grades, travel slowly in low gear. When descending a When traveling on slopes or grades, be slope, slow down the engine speed. careful that the machine does not tip (roll) •...
Page 28 SAFETY PRECAUTIONS WHEN OPERATING Operate the machine on snow or ice with Do not move the bucket over the heads of extra care people. • When traveling on snow or on frozen surfaces, drive at a low speed and avoid starting, stopping or changing directions abruptly.
Page 29 SAFETY PRECAUTIONS WHEN OPERATING Keep a safe distance from the overhead high-voltage cables • Pay also careful attention to the high- voltage electric cables buried underground. Never bring any part of the machine or loaded material to near to the high voltage cables unless all safety precautions required by the local and national authorities have been installed.
Page 30 SAFETY PRECAUTIONS WHEN OPERATING Watch out for hazardous working conditions • Do not enter areas where there is soft ground. Doing so could cause the machine to tilt under its own weight, resulting in a • Never undercut a high bank. Doing so is machine tipping over or sinking into the dangerous as it may cause ground ground.
Page 31 SAFETY PRECAUTIONS WHEN OPERATING • Do not perform demolition work under the • Do not use the impact force of the hoe machine. There is a hazard that the attachment for breaking work. There is a machine may fall down, because the hazard of serious injury being caused by ground becomes unstable.
Page 32 SAFETY PRECAUTIONS WHEN OPERATING Operating on slopes is dangerous Never slew sideways with a heavy load When operating on slopes or grades, slewing or operation of working equipment may cause the machine to lose stability and tip over. Avoid operating on slopes whenever possible.
Page 33 SAFETY PRECAUTIONS WHEN OPERATING Excavators are not designed for lifting Be careful with flying objects loads This machine is not equipped with protective equipment to protect the operator from flying objects. Do not use this machine in places where there are risks of the operator being hit by flying objects.
Page 34 SAFETY PRECAUTIONS WHEN OPERATING Cautions when towing When towing, serious injury or death could result, if performed incorrectly or the wire rope being used is inappropriate or not properly inspected. • It becomes dangerous if the wire rope breaks or becomes disengaged. Use a wire rope appropriate for the required tractive force.
Page 35: Precautions When Stopping
SAFETY PRECAUTIONS WHEN STOPPING PRECAUTIONS WHEN Parking procedures STOPPING 1. Slowly step on the brake pedal to stop the machine, and then further depress the Park safely pedal down to lock it. 2. Press the deceleration button to idle the engine at low speed.
Page 36: Precautions When Transporting
SAFETY PRECAUTIONS WHEN TRANSPORTING PRECAUTIONS WHEN • Lock the cab door after being loaded, if applicable. Otherwise, the door may open TRANSPORTING during transport. • Lock the slewing after loading. Load /unload the machine safely • Chock the wheels and secure the machine to the truck bed with wire rope or chain.
Page 37 SAFETY PRECAUTIONS WHEN TRANSPORTING Hoist the machine safely Transport the machine safely • Know and use correct crane signals. • Know and follow the applicable safety • Check the hoisting equipment for damaged rules, vehicle code and traffic laws when or missing parts on a daily basis and transporting the machine.
Page 38: Precautions On Maintenance
SAFETY PRECAUTIONS ON MAINTENANCE PRECAUTIONS ON Replace safety-critical parts periodically MAINTENANCE • Replace fuel hoses periodically. Fuel hoses wear out over time, even if they do not Display a “DO NOT OPERATE” alert sign show any symptom of wear. • Regardless of the replacement schedule, Severe injury could result if an unauthorized replace immediately if a symptom of wear person should start the engine or touch...
Page 39 SAFETY PRECAUTIONS ON MAINTENANCE Prohibit access by unauthorized persons • Never jump down from the machine. Use the steps and handrails when climbing up and down the machine, and always support your body at three points with your hands and feet. •...
Page 40 SAFETY PRECAUTIONS ON MAINTENANCE Stop the engine before performing Firmly secure the machine or any maintenance component that may fall • Avoid lubrication or mechanical adjustments while the machine is moving or while the engine is running when the machine is not moving. •...
Page 41 SAFETY PRECAUTIONS ON MAINTENANCE Secure the working equipment Cautions when refueling To prevent unexpected movement, firmly secure the working equipment when repairing or replacing the bucket teeth or side cutter. Secure the engine hood or cover when opened Be sure to secure the engine hood or cover before working the inside.
Page 42 SAFETY PRECAUTIONS ON MAINTENANCE Be careful with hot and pressurized Be careful with hot cooling systems components AG7A082 Do not remove the radiator cap or the drain AG7A081 Stop the engine and allow the machine to plug when the cooling water is hot. Stop the cool down before performing maintenance.
Page 43 SAFETY PRECAUTIONS ON MAINTENANCE Be careful with oil internal pressure Release pressure before working on the hydraulic system Pressure is maintained in the hydraulic circuit long after the engine has been shut down. Oil may spurt out if caps or filters are •...
Page 44 SAFETY PRECAUTIONS ON MAINTENANCE Tire maintenance • Never cut or weld on a wheel with an inflated tire mounted on it. This could cause an explosive decompression. • Tires should be replaced only by an authorized person using the proper procedures and safety equipment.
Page 45 • Do not drill, weld or fuse. • Do not subject it to physical shock such as hitting, rolling or dropping. • Before disposing of the unit, the sealed gas must be drained. Contact a Takeuchi service agent for help. 1-35...
Page 46 SAFETY PRECAUTIONS ON MAINTENANCE Disconnect the battery wiring • Do not charge a battery or jump-start the engine if the battery is frozen; otherwise it may explode. Warm the frozen battery to 15°C (60°F) before use. • Do not use the battery when the fluid level is below the lower level limit.
Page 47 SAFETY PRECAUTIONS ON MAINTENANCE Periodically replace the safety-critical Jump starting with booster cables parts • When starting the engine using the booster • To use the machine safely for a longer cables, be sure to connect the cables in period, periodically add oil and perform the proper order described below.
Page 48 SAFETY PRECAUTIONS ON MAINTENANCE Have a Takeuchi service agent repair Disposing of wastes welding If welding must be performed, make sure that it is done by a qualified person in a properly equipped workplace. To prevent any part from breaking down or being damaged due to overcurrent or sparks, observe the following.
Page 49: Safety Signs (Decals)
Please include your product serial number when ordering a new sign from the Takeuchi service agent. • When a part/unit to which a safety sign is attached is replenished, a new sign must be attached to the new part/unit.
Page 50 SAFETY SAFETY SIGNS (DECALS) 1-40...
Page 51 SAFETY SAFETY SIGNS (DECALS) 1-41...
Page 52 SAFETY SAFETY SIGNS (DECALS) 1-42...
Page 53: Controls
CONTROLS...
Page 54: Names Of Components
CONTROLS NAMES OF COMPONENTS NAMES OF COMPONENTS Undercarriage Working equipment Upperstructure 1. Cab 6. Tire 11. Dozer blade 12. Blade cylinder 2. Seat 7. Ram lock cylinder 8. Steering device 13. Bucket 3. Engine hood 4. Fuel tank 9. Hub 14.
Page 55 CONTROLS NAMES OF COMPONENTS 1. Multi-information display 16. Turn signal lever 2. Starter switch 17. Travel pedal 3. Working light switch 18. Brake pedal 4. Deceleration button 19. Tilt steering lever 5. Control console 20. Second boom pedal* 6. Safety lock lever 21.
Page 56: Covers
CONTROLS COVERS COVERS FRONT COVER (TOOL BOX) STARTER KEY • 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. •...
Page 57: Tool Box
CONTROLS COVERS TOOL BOX FUEL FILLER PORT Opening • 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. •...
Page 58: Right Side Cover
CONTROLS COVERS RIGHT SIDE COVER LEFT SIDE COVER • Before opening the side cover, be sure • Before opening the side cover, be sure to stop the engine. to stop the engine. • Do not keep the side cover open on a •...
Page 59: Engine Hood
CONTROLS COVERS ENGINE HOOD • Before performing maintenance on the top of the machine, clean the place you will work on and observe the following to prevent falling. Before opening the engine hood, be sure · Do not spill oil or grease. to stop the engine.
Page 60: Cab
CONTROLS CAB DOOR When getting on or off the cab, first open the door all the way until it is secured in the catch and check that it does not move. Open the door fully and press it against the To open the door from inside the cab, pull catch at the back of the door to secure it in the lever (2).
Page 61: Front Window
CONTROLS FRONT WINDOW • Grasp the handles firmly with both hands when opening and closing the front window. Your head or hands may get caught if it slips from your hands. • when the front window is opened or closed, it will come close to the head. Be careful that the window does not AG7B015 strike the head.
Page 62: Lower Front Window
CONTROLS LOWER FRONT WINDOW Removing AG7B017 3. Release your thumb from the knobs (2) and then press the front window toward front and lock the front window with lock pin (4). 1. Open the front window and stow it in the ceiling.
Page 63: Side Window
CONTROLS SIDE WINDOW EMERGENCY EXIT Rear window If you should become trapped inside the cab, remove the rear window to get out. 1. Grasp the catch (7), unlock it and open the side window. 2. To close the side window, close it until a click is heard.
Page 64: Seat And Seat Belt
CONTROLS SEAT AND SEAT BELT SEAT AND SEAT BELT (A) Adjusting the lumber support 1. Turning the knob (1) in the direction of the AIR SUSPENSION SEAT arrow causes the lumber of the backrest to curve outwards. 2. Turning the knob (1) further removes the curve and returns the seat to its original •...
Page 65 CONTROLS SEAT AND SEAT BELT (D) The fore /aft isolator (F) Adjusting the seat height It is activated under certain conditions such as crashing. Impacts of crash applied in the IMPORTANT: Be sure to set the absorber operating direction can be well absorbed by to the soft position (1) when performing the operator’s seat.
Page 66 CONTROLS SEAT AND SEAT BELT (H) Adjusting the seat depth (K) Adjusting the operating lever stand The depth of the seat pan can be individually 1. Pull up the lever (9) and slide the lever adjusted. stand (seat). To adjust, lift the right side handle (7). Move 2.
Page 67: Seat Belt
CONTROLS SEAT AND SEAT BELT SEAT BELT Be sure to fasten the seat belt securely before starting the engine. Fastening the seat belt 1. Adjust the seat to the desired position for operation, sit up and sit back in the chair. 2.
Page 68: Multi-Information Display
CONTROLS MULTI-INFORMATION DISPLAY MULTI-INFORMATION DISPLAY MAIN MENU SCREEN For explanation purposes, all items on this page are in the lit condition. This screen image is quite different from that of the real operation. In the actual operation, if a warning is given or any function is selected, the corresponding symbol appears.
Page 69 CONTROLS MULTI-INFORMATION DISPLAY 1. Menu key 6. Fuel gauge /Fuel level warning lamp Use this key to switch between the Main · Fuel gauge Menu screen and the Setting Menu Indicates the amount of fuel in the tank. screen. This key is also used to cancel Be sure to fill up the tank before running changes made in each setting.
Page 70 CONTROLS MULTI-INFORMATION DISPLAY 10. Engine load factor indicator 11. Hour meter /Trip meter • Hour meter Displays the total engine running time in hours. The rightmost digit indicates tenths of hours (6 minutes). Set the inspection and maintenance intervals according to the time displayed on the hour meter.
Page 71 CONTROLS MULTI-INFORMATION DISPLAY 12. Digging mode display C. Travel gear position /PB indicator lamp ..Travel Forward ..Neutral ..Travel in Reverse ..Parking brake is on. A. Digging mode symbol This symbol indicates that the machine is in the digging mode, and the icon suitable for the digging work is displayed.
Page 72 CONTROLS MULTI-INFORMATION DISPLAY E. Glow & DPD auto regeneration /inhibit D. Deceleration indicator lamp indicator lamp ..Automatic deceleration mode ..Engine being preheated ..Deceleration mode ..DPD auto regeneration under way ..Travel pedal mode ..DPD auto regeneration inhibit •...
Page 73 CONTROLS MULTI-INFORMATION DISPLAY F. DPD manual regeneration under way J. Ram lock indicator lamps /regeneration promoting indicator The indicator starts flashing and ..Lock: Digging an alarm starts sounding, if the accumulated PM exceeds the limited amount on the DPD..
Page 74 CONTROLS MULTI-INFORMATION DISPLAY L. Auxiliary 1st one-way (one-way circuit) N. Auxiliary 1st flow rate indicator lamp indicator lamp This lamp lights up to indicate which flow rate setting is selected in the auxiliary 1st..Auxiliary 1st auto tank is selected.
Page 75 CONTROLS MULTI-INFORMATION DISPLAY 13. Traveling mode display C. Travel gear position /PB indicator lamp ..Travel Forward ..Neutral ..Travel in Reverse ..Parking brake is on. Q. Traveling mode symbol This symbol indicates that the machine is in the traveling mode, and the icon suitable for the traveling is displayed.
Page 76 CONTROLS MULTI-INFORMATION DISPLAY D. Deceleration indicator lamp E. Glow & DPD auto regeneration /inhibit indicator lamp ..Automatic deceleration mode ..Engine being preheated ..Deceleration mode ..DPD auto regeneration under way ..Travel pedal mode ..DPD auto regeneration inhibit •...
Page 77 CONTROLS MULTI-INFORMATION DISPLAY F. DPD manual regeneration under way / R. Lamp /light indicator lamp regeneration promoting indicator The indicator starts flashing and ..Working light /high beam is an alarm starts sounding, if the accumulated PM exceeds the limited amount on the DPD..
Page 78 CONTROLS MULTI-INFORMATION DISPLAY S. Auto-cruise indicator lamp 14. Warning lamps (Traveling mode) IMPORTANT: If a warning lamp flashes and an alarm is sounded, immediately stop all operations and check the corresponding component..Auto-cruise is on. Refer to “If a warning lamp flashes” on pages 6-12 and 6-13.
Page 79 CONTROLS MULTI-INFORMATION DISPLAY c. Water separator warning lamp 15. Date and time indicator This lamp flashes if the water is detected within the water separator while the starter Displays the date and switch is in the ON position. time set. Refer to “Date and time d.
Page 80: Screen Navigation
CONTROLS MULTI-INFORMATION DISPLAY SCREEN NAVIGATION • Main Menu screen • Menu screen Press the Menu key to go the Menu screen (1) Trip meter setting while in the Home screen. (2) Auxiliary line flow rate display (3) Auxiliary line flow rate setting (4) LCD setting (5) Data /Error code display (6) Date and time setting...
Page 81 CONTROLS MULTI-INFORMATION DISPLAY (1) TRIP METER SETTING (2) AUXILIARY LINE FLOW RATE DISPLAY Displays the output information of the Auxiliary 1st, 2nd and 4th. The flow rate cannot be changed. Six patterns of desired operating hours can be set. To start setting, press the Enter key. The value flashes while being set.
Page 82 CONTROLS MULTI-INFORMATION DISPLAY (3) AUXILIARY LINE FLOW RATE SETTING Maximum A/B common, Variable flow rate high-flow range Auxiliary 200%=224L/min 100 to 1st-1, 2, 3 (59.2 US gpm) 200% Initial Variable Standard flow condition range C/D 100%=112L/ 10 to Auxiliary 2nd min (29.6 US gpm) 100% G/H 100%=112L/...
Page 83 CONTROLS MULTI-INFORMATION DISPLAY (4) LCD SETTING (5) DATA /ERROR CODE DISPLAY • The brightness of the LCD is set to between 0 and 100%. The brightness changes each time the adjustment is made. Day mode: initial setting value is 50% Night mode: initial setting value is 50% While in the day (night) mode, adjustment is possible only for the brightness set to the...
Page 84 • Move the cursor to the clock symbol, and then press the Enter key. The cursor immediately stop the operation and contact a Takeuchi sales or service outlet will be shifted to the place for setting the for help. year.
Page 85: Switching Images
CONTROLS MULTI-INFORMATION DISPLAY SWITCHING IMAGES • Background color (daytime) • Changing the background color (day / night) When one of the items (head light, signal light, working light, high beam switch) is turned on, the background will always be night mode in any screen even if the display brightness is lowered.
Page 86 CONTROLS MULTI-INFORMATION DISPLAY • CAMERA Do not look at the images produced by the camera while traveling in reverse. Move in reverse while looking at the direction of travel. 1. Press the ON (symbol) side of the image select switch (CAMERA) to show the camera image captured by the external camera at the top of the screen.
Page 87: Control Console
CONTROLS CONTROL CONSOLE CONTROL CONSOLE SWITCHES 2. Creeping travel switch Pressing this switch displays the digging mode. 1. Light switch When this switch is depressed, the lights are Depress the “Snail” symbol on this illuminated as follows. switch to change the travel speed to creeping travel.
Page 88 CONTROLS CONTROL CONSOLE 3. Low /high-speed travel switch 5. Ram Lock switch Low-speed travel Depress the “Turtle” symbol on this switch to change the travel gear from Do not lock the suspension while high-speed travel to low-speed travel. traveling. Doing so may create a It is possible to switch from the low-speed dangerous situation.
Page 89 Refer to the “Engine error code list” and dry grass, wastepaper, oil and waste contact a Takeuchi sales or service dealer tires. There is a risk of fire due to the for repair. high-temperature exhaust gas emitted from the DPD.
Page 90 CONTROLS CONTROL CONSOLE · Since the DPD regeneration is designed to work only when the accumulated particulate matter (PM) in the filter exceeds a certain amount, it will not start otherwise, even if you attempt to perform manual regeneration. • DPD regeneration inhibit (cancel) To cancel the DPD regeneration currently being processed (manual or auto), press the regeneration inhibit symbol side.
Page 91: Buttons
CONTROLS CONTROL CONSOLE BUTTONS 7. Automatic deceleration switch 8. Hazard button Press this button to turn on the hazard lamp. The turn signal indicator lamp also turns on. Note: This switch can be operated even when the power is turned off. 9.
Page 92 CONTROLS CONTROL CONSOLE 11. Auto-cruise button (cruise control) 12. Parking brake button Pressing this button will turn on the button lamp, indicating that the Do not use this button on the following parking brake is engaged. The roads. parking brake indicator lamp lights up on the •...
Page 93: Switches
CONTROLS SWITCHES SWITCHES ENGINE SHUTDOWN SWITCH STARTER SWITCH This switch is used to shutdown the engine if it fails to stop, due to machine failure or IMPORTANT: Do not repeatedly switch breakage, when the starter switch is set to the OFF position. the key from OFF to ON and ON to OFF over a short period.
Page 94: Horn Button
CONTROLS SWITCHES HORN BUTTON DECELERATION BUTTON Before operating the deceleration button, set the operating lever to the neutral position and take your foot off the pedals. If the deceleration button is pressed while driving, the machine’s operating speed will abruptly change to result in a dangerous situation.
Page 95: Travel Select Button
CONTROLS SWITCHES TRAVEL SELECT BUTTON Slider switch (Proportional control) Proportional control allows for slow-to-fast/ fast-to-slow movement of attachment. Example: If you move the slider switch half way, the attachment will move at approximately one-half the speed. Use this button to change the travel direction.
Page 96: Second /Fourth Auxiliary Hydraulic Switch
CONTROLS SWITCHES SECOND /FOURTH AUXILIARY OUTRIGGER SWITCHES (IF EQUIPPED) HYDRAULIC SWITCH Slider switch (Proportional control) Proportional control allows for slow-to-fast/ fast-to-slow movement of attachment. Example: If you move the slider switch half way, the attachment will move at approximately one-half the speed. J ..Dozer blade operation (both sides) K ..Outrigger operation (both sides) L ..Left outrigger operation...
Page 97: Light Switch
CONTROLS SWITCHES LIGHT SWITCH LIFT OVERLOAD WARNING SWITCH (IF EQUIPPED) If the overload is not removed after the overload warning horn is sounded, the machine may tip over. If the horn starts sounding, stop operating the machine and lighten the load. When this switch is turned while the starter switch is at ON, the lights turn on as follows: OFF ..
Page 98: Auxiliary 1St Flow Rate Select Switch
CONTROLS SWITCHES AUXILIARY 1ST FLOW RATE SELECT DETENT MODE SWITCH (AUXILIARY SWITCH 1ST) IMPORTANT: Do not operate the machine in the detent mode for a long time. Doing so will increase the hydraulic oil temperature and shorten the service life of the hydraulic units.
Page 99: Beacon Lamp Switch
CONTROLS SWITCHES BEACON LAMP SWITCH IMAGE SELECT SWITCH (CAMERA) When this switch is turned on while the Press the ON (symbol) side of this switch to starter switch is at ON, the lamp turns on as show the camera image captured by the follows: external camera at the top of the screen.
Page 100: Levers And Pedals
CONTROLS LEVERS AND PEDALS LEVERS AND PEDALS SLEW LOCK PIN SAFETY LOCK LEVER When transporting or traveling on a road, be sure to lock slewing with the slew lock pin. • Before standing up from the operator’s Otherwise, the upperstructure could slew seat to open/close the window or and cause a serious accident if a sudden remove/install the lower window, lower...
Page 101: Steering Wheel
CONTROLS LEVERS AND PEDALS STEERING WHEEL Adjusting the position of the steering wheel • Check the position of the undercarriage • Adjust the position of the steering wheel (steering device) before traveling. before driving the machine. Before operating the travel pedal, make If you adjust it while driving the sure that the steering device is to the machine, steering will become unstable,...
Page 102: Turn Signal Lever
CONTROLS LEVERS AND PEDALS TURN SIGNAL LEVER BRAKE PEDAL • When parking, depress the braking pedal all the way down to engage the pedal lock so that the machine cannot start while parked. • Release the brake pedal lock before start traveling.
Page 103: Travel Pedal
CONTROLS LEVERS AND PEDALS TRAVEL PEDAL Use the travel select button to change the travel direction (forward or reverse). Refer to “Travel select button” on page 2-43. • Check the position of the undercarriage SECOND BOOM PEDAL (2-PIECE BOOM) (steering device) before traveling. Before operating the travel pedal, make sure that the steering device is to the front of the operator’s seat.
Page 104: Operating Levers
CONTROLS LEVERS AND PEDALS OPERATING LEVERS BLADE LEVER • Before starting operation, carefully check which lever pattern you are going to use. • It is described using the ISO pattern in this manual. Use this lever to operate the dozer blade. (A) ..Blade up (B) ..Blade down Refer to “Operating the dozer blade”...
Page 105: Air Conditioner
CONTROLS AIR CONDITIONER AIR CONDITIONER Do not turn on the air conditioner until the engine is started CAUTIONS ON USE To avoid placing an excessive load on the compressor, wait until the engine is started Ventilate periodically and is running smoothly before turning on •...
Page 106: Names Of Components
CONTROLS AIR CONDITIONER NAMES OF COMPONENTS 1. Defroster 2. Condenser 3. Receiver dryer 4. Foot outlet 5. Back outlets 6. Control panel 7. Compressor 8. Air conditioner unit 9. External air duct 10. Filter 2-54...
Page 107: Control Panel Operation
CONTROLS AIR CONDITIONER CONTROL PANEL OPERATION (5) AUTO Places the system in a fully automatic temperature control mode including fan speed. A panel indicator light indicates when this mode is active. The system will adjust the blower fan speed to the lowest setting necessary to maintain the cab temperature at the displayed set point temperature.
Page 108: General System Operation
CONTROLS AIR CONDITIONER GENERAL SYSTEM OPERATION DEFROSTING OR DEFOGGING OPERATION Heater Operation The ATC automatically controls the Heater- Note: If the air conditioner is set to high A/C to maintain the cab air temperature when using the defroster, the difference close to the set point selected by the between the external and internal temperature control pushbuttons.
Page 109: Air Conditioner (A/C) Operation
CONTROLS AIR CONDITIONER AIR CONDITIONER (A/C) OPERATION VENTILATION (FRESH /RECIRC) The unit draws in a mix of outside and recirculated air when in fresh air mode. This • When the air conditioner is set to the allows the cab to maintain a positive cab air recirculation mode, the air in the cab pressure to prevent excessive dust from entering the cab.
Page 110: Accessories
• Do not use any other cigarette lighters are spilled on them. than Takeuchi’s. They could be stuck in the middle and not pop out. • Use only those electric products which comply with the specifications of these sockets.
Page 111: Ashtray
CONTROLS ACCESSORIES ASHTRAY OFF (O) ..Lamp is turned off all the time, with no regard for the door being opened or closed. Neutral (N) ..Lamp is turned on when the • Be sure to extinguish cigarettes and door is opened, and it turned matches completely before putting off when the door is closed.
Page 112: 12 V Power Socket
CONTROLS ACCESSORIES 12 V POWER SOCKET 24 V EXTERNAL POWER SOCKETS Use only those electric products which Use only those electric products which comply with the specifications of this comply with the specifications of these socket. sockets. Use this socket to connect the 12 V power For beacon supply.
Page 113: Radio (For Cab)
CONTROLS ACCESSORIES RADIO (FOR CAB) CAUTIONS ON USE • 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. •...
Page 114 CONTROLS ACCESSORIES (6) Preset buttons (1 to 6) (PRESET (11) Auxiliary input jack (AUX-IN) STATION) Use this jack to connect an external Each button can store three FM stations audio source such as a portable music (FM1, FM2, FM3) and one MW (AM) player.
Page 115 CONTROLS ACCESSORIES Presetting stations Auxiliary input (AUX) 1. Press the BAND button to select a band • Connect a portable audio player and listen (MW (AM) or FM), and then select the to your favorite music. station by pressing the TUNE button for •...
Page 116 CONTROLS ACCESSORIES Resetting (North, Central and South SPECIFICATIONS America) Power source: ..12/24 VDC (negative If there are any problems, such as the ground) abnormal display of frequency or failure of Maximum power consumption: selection, reset the radio by pressing the “3” ......
Page 117: Auxiliary Hydraulic Lines
CONTROLS ACCESSORIES AUXILIARY HYDRAULIC LINES These lines deliver the hydraulic oil necessary for operating a hydraulic breaker, crusher or other attachments. Oil may spurt out if pipes disconnected before releasing the pressure in the hydraulic system. (1) ..First auxiliary hydraulic lines •...
Page 118 CONTROLS ACCESSORIES Connecting the hydraulic circuits Disconnecting the hydraulic circuits To connect the attachment hydraulic lines, 1. Release the pressure remaining in the observe the following procedures: lines, and then close the stop valve. 1. Release the pressure remaining in the Refer to “Releasing the residual pressure”...
Page 119 CONTROLS ACCESSORIES Operating Releasing the residual pressure Press those buttons to control the flow of the After the auxiliary hydraulic circuits have oil in the first/second auxiliary hydraulic lines. been used, pressure remains in the circuits. (A) ..Hydraulic oil flows to left auxiliary line This is called the residual pressure.
Page 120 CONTROLS ACCESSORIES Selector valve when the button (1) and the switch (2) are pressed at the same time. When they are pressed, the hydraulic oil flows into the line (f) to increase the pressure there. As the result, the pin on the bucket comes out and the bucket is removed from the machine.
Page 121 CONTROLS ACCESSORIES Auxiliary 2/4 select button (If equipped) This button is used to switch the operation between the second auxiliary and the fourth auxiliary. Pressing this button while the second auxiliary symbol is displayed on the LCD will switch to the fourth auxiliary operation. Pressing this button one more time will display the second auxiliary symbol on the LCD to indicate that the second auxiliary...
Page 122: Operating The Machine With An Accumulator
• Before disposing of the unit, the sealed pressure from the working equipment gas must be drained. Contact a circuitry. Takeuchi service agent for help. 8. Raise the safety lock lever to engage the lock. For a machine with an accumulator, the...
Page 123: Load Safety Device
• Since the emergency shut-off valve (1), (2) or (3) is a safety device, you must not disassemble it and/or replace or adjust its internal part. Takeuchi shall not be held responsible for any injuries, accidents or product malfunction caused by disassembly.
Page 124 CONTROLS ACCESSORIES Overload warning switch Refer to “Overload warning switch” on page 2-45. If the hose breaks and the emergency shut- off valve (1), (2) or (3) is activated to stop the operation of boom or arm, lower the boom or arm by slowly operating the lever while ensuring safety.
Page 125: Outrigger
CONTROLS ACCESSORIES OUTRIGGER • Select a firm and uniform ground for outrigger pads (surfaces to contact the ground). • When traveling on a public road, secure the outriggers with the turnbuckles. When retracting the outriggers, make sure that the outrigger pads (the surfaces to contact the ground) are within the machine width.
Page 126: Fuel Supply Pump
CONTROLS ACCESSORIES FUEL SUPPLY PUMP This device automatically supplies fuel to the fuel tank and stops automatically when the fuel tank is full. Do not use the fuel supply pump for gasoline or hydraulic oil. Doing so could result in explosion or damage. Only use the fuel supply pump for diesel fuel.
Page 127: Operation
OPERATION...
Page 128: Before Starting Operation
OPERATION BEFORE STARTING OPERATION BEFORE STARTING WALK-AROUND INSPECTION OPERATION Perform the walk-around inspections once a day before starting the engine for the first GETTING ON OR OFF THE MACHINE time that day. Refer to “MAINTENANCE, Walk-around inspection”, on pages 5-18 and 5-19. •...
Page 129: Starting And Stopping The Engine
OPERATION STARTING AND STOPPING THE ENGINE STARTING AND STOPPING 5. Insert the key into the starter switch, turn it to the ON position, and then perform the THE ENGINE following inspections: BEFORE STARTING THE ENGINE 1. Adjust the seat for a comfortable operating position.
Page 130: Starting The Engine
OPERATION STARTING AND STOPPING THE ENGINE STARTING THE ENGINE press the deceleration button to cancel the deceleration mode. Starting in cold climates • Clear all personnel from the work area. • Sound the horn to warn people around the machine. Never use starting fluid on this engine, as the starting fluid could cause an IMPORTANT: Do not run the starter motor...
Page 131: Warming Up The Engine
OPERATION STARTING AND STOPPING THE ENGINE WARMING UP THE ENGINE STOPPING THE ENGINE IMPORTANT: Avoid racing the engine until IMPORTANT: Do not stop the engine it has warmed up. suddenly when operating with heavy Do not warm up the engine for a long time loads or at the maximum speed.
Page 132: Operating The Machine
OPERATION OPERATING THE MACHINE OPERATING THE MACHINE LEVER PATTERN (ISO PATTERN) • Before starting operation, carefully check which lever pattern you are going to use. • It is described using the ISO pattern in this manual. Brake Forward Travel Reverse Travel Arm Out Boom Lower Arm In...
Page 133 MEMO...
Page 134: Warming Up The Machine (Hydraulic Oil)
OPERATION OPERATING THE MACHINE WARMING UP THE MACHINE (HYDRAULIC OIL) Operating the working equipment without warming up the machine (hydraulic oil) is dangerous, as the working equipment cannot response to controls quickly or may move in unexpected ways, and the safety devices may not operate properly.
Page 135 OPERATION OPERATING THE MACHINE Warm-up in cold climates 1. Perform the normal warm-up procedure. 5. Disengage the locks of the brake pedal and the parking brake. 2. Set the bucket cylinder at the stroke end and keep it there. Do not keep this condition for more than 30 seconds.
Page 136: Inspection After Warm-Up
OPERATION OPERATING THE MACHINE INSPECTION AFTER WARM-UP After warming up the engine and machine (hydraulic oil), perform the checks and inspections described below, and repair if necessary. 3. Raise the safety lock lever to the locked position, and then check that the operating and travel levers are locked.
Page 137: Traveling The Machine
OPERATION OPERATING THE MACHINE TRAVELING THE MACHINE • Before traveling, set the machine to the “travel posture”. Refer to “Preparing for travel” for further details. • When traveling on a road, be sure to lock the working equipment. If any of the controls is accidentally touched when it is unlocked, the machine may •...
Page 138 OPERATION OPERATING THE MACHINE • Avoid crossing over obstacles whenever Equipped with outrigger possible. If you must do so, keep the hoe attachment close to the ground level and travel slowly. Never cross obstacles which will tilt the machine to an angle of 10°...
Page 139 OPERATION OPERATING THE MACHINE Preparing for travel Moving forward and in reverse 1. Set the steering device facing forward and to the front of the operator’s seat. 2. Fully raise the boom, fully lower the second boom, and then set the arm vertically to rollback the bucket.
Page 140 OPERATION OPERATING THE MACHINE 4. Press the travel pedal button (1) while the When the steering device is in front of the brake pedal is depressed. operator’s seat: (When entering the foot accelerator mode) To move forward: 5. Press the attachment lock button (2) to Press the travel select button (F) and lock the working equipment.
Page 141: Stopping Travel
OPERATION OPERATING THE MACHINE STOPPING TRAVEL Turning • Park the machine on a flat, rigid and safe ground. Set the parking brake. If you must park on a slope, chock the tracks to block the machine. • If any of the controls is accidentally touched when it is unlocked, the machine may suddenly move and cause serious injury or death.
Page 142: Operating The Working Equipment
OPERATION OPERATING THE MACHINE OPERATING THE WORKING EQUIPMENT Slewing Check the surrounding area for safety • Before starting operation, carefully before slewing. check which lever pattern you are going to use. • It is described using the ISO pattern in this manual.
Page 143 OPERATION OPERATING THE MACHINE Operating the arm Operating the second boom Arm in: Second boom raise: Tilt the left operating lever backward. Step on the toe side of the pedal. Arm out: Second boom lower: Tilt the left operating lever forward. Step on the heel side of the pedal.
Page 144 OPERATION OPERATING THE MACHINE Operating the Outrigger (If equipped) Select the outrigger operation with the outrigger switch. Outrigger lower: Tilt the blade lever forward. Outrigger raise: Tilt the blade lever backward. · Outrigger switch L: Operating only the left side outrigger ·...
Page 145: Operating Procedures
OPERATION OPERATING PROCEDURES OPERATING PROCEDURES Be gentle when using the hydraulic cylinder PROHIBITED OPERATIONS • Do not operate on bedrock (hard or soft). • Do not slew while traveling. If you must operate the hoe attachment while traveling, operate at speeds slow enough so you have complete control at all times.
Page 146 OPERATION OPERATING PROCEDURES Do not drive piles with the bucket or dig Digging bedrock by banging the bucket For hard base rock, break the rock up into Doing so will shorten the service life of the small pieces with a breaker, etc., before hoe attachment.
Page 147 OPERATION OPERATING PROCEDURES Caution on folding the hoe attachment When using the dozer blade to stabilize or raise the machine, lower the both ends of the blade to the ground. Pay attention to the dozer blade when digging Be careful not to let the bucket hit the dozer blade when the hoe attachment is being folded.
Page 148: Precautions For Operation
OPERATION OPERATING PROCEDURES PRECAUTIONS FOR OPERATION Precautions on traveling Traveling over obstacles (rocks, stumps, etc.) may put a great load on the machine body and may cause damage to it. Avoid crossing over obstacles whenever possible. If you must do so, keep the hoe attachment near the ground, travel at a low speed, and go over the obstacle at the center of the tires.
Page 149: Precautions When Traveling On Slopes
OPERATION OPERATING PROCEDURES PRECAUTIONS WHEN TRAVELING ON surface, and then take an alternative SLOPES path. • The machine may slip sideways even on a slight slope if it is covered with grass or fallen leaves, or when traveling on • Never travel on slopes that are too wet meta plates or frozen surfaces.
Page 150 OPERATION OPERATING PROCEDURES Braking when descending slopes If the engine stops When descending slopes, apply the brake If the engine stops when descending a earlier than usual. slope, depress the brake pedal to stop the machine, use the bucket to anchor the machine to the ground, and then start the If the tire slips engine.
Page 151: Getting Out Of Mud
OPERATION OPERATING PROCEDURES GETTING OUT OF MUD If tires on both sides are stuck If the machine gets stuck in mud, use the procedure below to get it out. If tires on one side are stuck 1. Perform the steps 1 to 4 above for both tires.
Page 152: Operations Possible With This Machine
OPERATION OPERATING PROCEDURES OPERATIONS POSSIBLE WITH THIS Loading MACHINE Excavating When loading dirt onto a truck bed, load from the back of the truck, as it is easier and able to load more load than doing it from the 1. Set the dozer blade on the side opposite front.
Page 153: Parking The Machine
OPERATION PARKING THE MACHINE PARKING THE MACHINE Parking procedures 1. Slowly step on the brake pedal to stop the PARKING machine, and then further depress the pedal down to lock it. 2. Press the deceleration button to idle the engine at low speed. 3.
Page 154: Inspection And Checks After Stopping The Engine
OPERATION PARKING THE MACHINE INSPECTION AND CHECKS AFTER STOPPING THE ENGINE 1. Check for oil or water leak and inspect the working equipment, covers and undercarriage. If any irregularities are found, repair. 2. Fill up the fuel tank. Refer to “Inspecting the fuel level” on page 5-23.
Page 155: Handling In Cold Climates
• Replace the fuel and oil for all parts with Inspect the battery. If it is discharging, those specified in the “Fuel and lubricant contact a Takeuchi service agent to have the table”. battery recharged. Refer to “Fuel and lubricant table” on page Refer to “Inspecting the battery fluid level...
Page 156: Handling Tires
OPERATION HANDLING TIRES HANDLING TIRES Tires are weak in strength due to the material they are made of. Be sure to observe the prohibitions and precautions below to prevent the tires from being damaged or coming off. PROHIBITIONS Do not travel or operate the machine in the following places: •...
Page 157: Precautions
OPERATION HANDLING TIRES PRECAUTIONS Observe the following precautions when operating the machine: • Tires are not very stable. Be very careful when slewing sideways. • Do not turn the undercarriage with the front of the machine body lifted using the hoe attachment (the upperstructure is not turned).
Page 158 3-32...
Page 159: Transport
TRANSPORT...
Page 160: Loading And Unloading
TRANSPORT LOADING AND UNLOADING LOADING AND UNLOADING The machine may roll or tip over or fall while being loaded or unloaded. Take the following precautions: • Select a firm, level surface and keep sufficient distance from road shoulders. • Secure ramps of adequate strength and size to the truck bed.
Page 161 TRANSPORT LOADING AND UNLOADING 7. Drive the machine straight toward the ramps and go up or down the ramps slowly in low gear, by following the signal from the signal person. 8. Load the machine at the specified position on the transporter. Refer to “Transporting posture”...
Page 162: Hoisting The Machine
Do not move the machine over the heads of the persons. IMPORTANT: This hoisting method applies to machines with standard specifications. The center of gravity differs according to the attachments and optional equipment installed. Contact your Takeuchi service agent for details.
Page 163 TRANSPORT HOISTING THE MACHINE <Hoisting posture>...
Page 164: Securing The Machine
TRANSPORT SECURING THE MACHINE SECURING THE MACHINE After loading the machine at the specified position, secure it as described below. TRANSPORTING POSTURE 1. Lower the dozer blade. 2. Set the hoe attachment posture as above. 3. Raise the safety lock lever to the lock position, and engage the brake pedal lock and parking brake lock.
Page 165: Precautions To Be Taken During Transportation
TRANSPORT PRECAUTIONS TO BE TAKEN DURING TRANSPORTATION PRECAUTIONS TO BE TAKEN Road travel posture DURING TRANSPORTATION • Know and follow the applicable safety rules, vehicle code and traffic laws when transporting the machine. • Select the best transport route by considering the length, width, height and weight of the truck with the machine loaded on it.
Page 167: Maintenance
MAINTENANCE...
Page 168: General
MAINTENANCE GENERAL GENERAL CAUTIONS ON MAINTENANCE MAINTENANCE OVERVIEW Do not perform any other inspection and maintenance works than those listed in this To keep the machine in good condition and manual. use if for a long period, perform the For works not listed in this manual, ask your inspection and maintenance properly and sales or a service dealer for help.
Page 169 MAINTENANCE GENERAL Do not use fuel to clean parts Disposing of wastes Do not use fuel to clean parts. Use a non- • Always collect oil that is drained from the combustible cleaning agent. machine in containers. Improperly disposed waste oil can cause Keep dirt out environmental harm.
Page 170: Service Data
MAINTENANCE SERVICE DATA SERVICE DATA FUEL AND LUBRICANT TABLE Select the appropriate fuel, lubricant and grease according to the temperature by referring to the table below. • Regardless of the specified time, change the oil if it becomes too dirty or degraded. •...
Page 171 MAINTENANCE SERVICE DATA To maintain the performance and service life of the engine, always use clean and high-quality fuel. • To avoid freezing in cold climates, use a diesel fuel that still functions when the temperature is at least 12°C (53.6°F) below the lowest expected ambient temperature.
Page 172 Diesel engine oil Every 500 hrs. SAE 10W-30 Engine oil pan API: CJ-4 class after the initial SAE 15W-40 ACEA: E6 class 50 hrs. Takeuchi genuine Every 4000 ISO VG46 hydraulic oil 46 hrs.*** Hydraulic oil ISO VG32 tank Every 2000...
Page 173 *** : The hydraulic oil replacement interval depends on the type of hydraulic oil being used. New machine are delivered with Takeuchi genuine hydraulic oil 46, and the hydraulic oil replacement intervals indicated in this manual assume that Takeuchi genuine hydraulic oil 46 is being used.
Page 174: Regularly Replace The Hydraulic Oil
MAINTENANCE SERVICE DATA REGULARLY REPLACE THE HYDRAULIC Replacement interval (hours) Item Hydraulic oil Filter element When a hydraulic breaker is used, the oil deteriorates more quickly than that used for 1st time — a usual excavation operation. Be sure to 2nd time —...
Page 175: List Of Consumables
MAINTENANCE SERVICE DATA LIST OF CONSUMABLES Periodically replace consumables such as filters and elements according to the table below. System Item Part name Part No. When to replace Hydraulic oil 15511-03400 Every 1000 hrs after return filter the initial 50 hrs. Hydraulic system Pilot line filter Element...
Page 176: List Of Tools (If Equipped)
MAINTENANCE SERVICE DATA LIST OF TOOLS (IF EQUIPPED) Code Part name Part No. Remarks Spanner 16900-01012 10-12 Spanner 16900-01417 14-17 Screwdriver 16902-20205 (+) (–) replaceable shank Filter wrench 16919-03560 Hammer 16903-00330 Adjustable wrench 16904-00250 250 mm Pliers 16905-00200 200 mm Spanner 16900-01013 10-13...
Page 177: List Of Tightening Torques
MAINTENANCE SERVICE DATA LIST OF TIGHTENING TORQUES Nuts and Bolts (for ISO strength category 10.9) Tighten nuts and bolts at the torques shown on the table below, unless otherwise specified. • The tightening torques used for the mounted plastic covers are not listed in the table below. Consult your sales or service dealer for details.
Page 178: Safety-Critical Parts
MAINTENANCE SAFETY-CRITICAL PARTS SAFETY-CRITICAL PARTS To use the machine safely, periodically perform inspection and maintenance. The safety-critical parts listed below must be periodically replaced for an increased safety. Serious injury or a fire could result if they are worn or damaged. List of safety-critical parts Unit Safety-critical parts to be replaced periodically When to replace...
Page 179 MAINTENANCE SAFETY-CRITICAL PARTS The material of the safety-critical part listed on the left tends to change over time and cause wear or deterioration. It is difficult to determine the degree of deterioration at the periodic inspection, and thus they need to be replaced with new ones after a certain time to maintain their proper performance even if they appear in good condition.
Page 180: Maintenance List
MAINTENANCE MAINTENANCE LIST MAINTENANCE LIST Inspection and maintenance item Page Walk-around inspection Inspecting by opening the engine hood and covers 5-18 Inspecting by walking around the machine 5-19 Inspecting while sitting in the operator’s seat 5-19 Daily inspection (every 10 Hours) Inspecting and replenishing the coolant 5-20 Inspecting and replenishing the engine oil...
Page 181 MAINTENANCE MAINTENANCE LIST Inspection and maintenance item Page After the initial 250 hours (only for new machines) Replacing the slew motor gear oil 5-38 Every 250 hours Inspecting and adjusting the V-belt 5-39 Inspecting and adjusting the compressor belt (AC) 5-39 Lubricating the undercarriage 5-40...
Page 182 MAINTENANCE MAINTENANCE LIST Inspection and maintenance item Page Every 500 hours Replacing the engine oil and the oil filter 5-49 Inspecting the transmission gear oil 5-49 Inspecting the differential gear oil 5-50 Inspecting the hub gear oil 5-51 Lubricating the slew bearing 5-52 Replacing the fuel filters 5-53...
Page 183 MAINTENANCE MAINTENANCE LIST Inspection and maintenance item Page Every 2000 hours Replacing the transmission gear oil 5-63 Replacing the differential gear oil 5-64 Replacing the hub gear oil 5-65 Every 4000 hours Replacing the hydraulic oil and cleaning the suction strainer 5-66 Every 4500 hours Inspecting the turbocharger (blow wash as necessary)
Page 184: Walk-Around Inspection
MAINTENANCE WALK-AROUND INSPECTION WALK-AROUND INSPECTION Perform the following inspections every day before starting the engine for the first time. • Before operating, perform the walk-around inspections and make repairs immediately where necessary. • Be sure to secure the engine hood or cover before working the inside. Do not keep the hood or cover open on a windy day or if the machine is parked on a slope.
Page 185: Inspecting By Walking Around The Machine
MAINTENANCE WALK-AROUND INSPECTION INSPECTING BY WALKING AROUND THE INSPECTING WHILE SITTING IN THE MACHINE OPERATOR’S SEAT 4. Check lights for dirt, damage and burnt 14. Check the windshield for dirt or damage. out bulbs. 15. Check the seat and seat belt for dirt or 5.
Page 186: Daily Inspection (Every 10 Hours)
MAINTENANCE DAILY INSPECTION (EVERY 10 HOURS) DAILY INSPECTION (EVERY • Do not stand on the dozer blade and perform maintenance work. Doing so is 10 HOURS) dangerous because of the unsteady foothold. Use the work bench. Perform the following inspections every day before starting the engine for the first time.
Page 187: Inspecting And Replenishing The Engine Oil
MAINTENANCE DAILY INSPECTION (EVERY 10 HOURS) INSPECTING AND REPLENISHING THE 3. Fully insert the dipstick (1) again, and then ENGINE OIL pull it out. 4. Check the oil left on the dipstick (1). The level should be between the upper limit (H) and the lower limit (L).
Page 188: Cleaning The Dust Screen
MAINTENANCE DAILY INSPECTION (EVERY 10 HOURS) CLEANING THE DUST SCREEN 1. Turn the starter switch to the ON position. 2. Inspect the water separator warning lamp. 3. If the warning lamp is flashing, drain the water. Stop the engine and allow each part of Refer to “Draining the water from the the machine to cool down before water separator”...
Page 189: Inspecting The Fuel Level
MAINTENANCE DAILY INSPECTION (EVERY 10 HOURS) INSPECTING THE FUEL LEVEL • 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. •...
Page 190: Inspecting The Hydraulic Oil Tank Level And Replenishing
MAINTENANCE DAILY INSPECTION (EVERY 10 HOURS) INSPECTING THE HYDRAULIC OIL TANK 5. Inspect the oil level using the sight gauge LEVEL AND REPLENISHING (1). · When the oil temperature is about 20°C (68°F): The level should be between the upper •...
Page 191: Lubricating The Working Equipment
MAINTENANCE DAILY INSPECTION (EVERY 10 HOURS) LUBRICATING THE WORKING EQUIPMENT • 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. ·...
Page 192: Inspecting And Inflating The Tires
MAINTENANCE DAILY INSPECTION (EVERY 10 HOURS) INSPECTING AND INFLATING THE TIRES • Do not inflate tires with flammable gases or from systems using an alcohol injector. • Never cut or weld on a wheel with an inflated tire mounted on it. This could cause an explosive decompression.
Page 193: Checking The Wheel Nut Torques
MAINTENANCE DAILY INSPECTION (EVERY 10 HOURS) CHECKING THE WHEEL NUT TORQUES Inflating the tires These instructions are for adding air to a tire which is already inflated. If the tire has lost all its air pressure, call in a qualified tire mechanic.
Page 194: After The Initial 50 Hours (Only For New Machines)
MAINTENANCE AFTER THE INITIAL 50 HOURS (ONLY FOR NEW MACHINES) AFTER THE INITIAL 50 1. Open the maintenance cover and remove the oil filler cap (2). HOURS (ONLY FOR NEW MACHINES) REPLACING THE ENGINE OIL AND THE OIL FILTER • Stop the engine and allow the machine to cool down before performing maintenance.
Page 195 MAINTENANCE AFTER THE INITIAL 50 HOURS (ONLY FOR NEW MACHINES) 11. Install the new filter by hand. 12. Tighten one more turn after the filter packing comes in contact with the surface of installation. 13. Add oil up to between the upper limit (H) and the lower limit (L) of the dipstick (1).
Page 196: Inspecting And Adjusting The V-Belt
MAINTENANCE AFTER THE INITIAL 50 HOURS (ONLY FOR NEW MACHINES) INSPECTING AND ADJUSTING THE 2. Press the midpoint of the V-belt between V-BELT the pulley (2) and alternator pulley (3) to check the tension. (approx. 98 N or 22 lbs.). The slack (A) should be 6.6 to 7.4 mm Stop the engine and allow the machine to (0.26 to 0.29 in).
Page 197 MAINTENANCE AFTER THE INITIAL 50 HOURS (ONLY FOR NEW MACHINES) Adjustment 1. Loosen the bolt (7) and locking nut (6). 2. Turn the adjustment bolt (5) to adjust the V-belt (4). · Tighten: Clockwise · Loosen: Counterclockwise 3. Tighten the bolt (7) and locking nut (6). Tightening torque: ·...
Page 198: Inspecting And Adjusting The Compressor Belt (Ac)
MAINTENANCE AFTER THE INITIAL 50 HOURS (ONLY FOR NEW MACHINES) INSPECTING AND ADJUSTING THE COMPRESSOR BELT (AC) • 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.
Page 199: Replacing The Hydraulic Oil Return Filter
MAINTENANCE AFTER THE INITIAL 50 HOURS (ONLY FOR NEW MACHINES) REPLACING THE HYDRAULIC OIL RETURN 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.
Page 200: Replacing The Pilot Line Filter
MAINTENANCE AFTER THE INITIAL 50 HOURS (ONLY FOR NEW MACHINES) REPLACING THE PILOT LINE 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.
Page 201: Every 50 Hours
MAINTENANCE EVERY 50 HOURS EVERY 50 HOURS 1. Remove the fuel filler cap (2). 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.
Page 202: Inspecting The Battery Fluid Level And Replenishing
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 •...
Page 203 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.
Page 204: After The Initial 250 Hours (Only For New Machines)
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.
Page 205: Every 250 Hours
MAINTENANCE EVERY 250 HOURS EVERY 250 HOURS INSPECTING AND ADJUSTING THE V-BELT Refer to “Inspecting and adjusting the V-belt” on page 5-30. INSPECTING AND ADJUSTING THE COMPRESSOR BELT (AC) Refer to “Inspecting and adjusting the compressor belt (AC)” on page 5-32. 5-39...
Page 206: Lubricating The Undercarriage
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.
Page 207: Inspecting The Slew Motor Gear Oil
MAINTENANCE EVERY 250 HOURS INSPECTING THE SLEW MOTOR GEAR 1. Take out the level gauge (1) and wipe off 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). •...
Page 208: Cleaning The Cooler Fins
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.
Page 209: Cleaning The Air Cleaner
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.
Page 210 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.
Page 211: Cleaning The Air Filters (Ac)
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...
Page 212: Cleaning The Condenser (Ac)
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.
Page 213: Inspecting The Refrigerant (Gas) Level (Ac)
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).
Page 214 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...
Page 215: Every 500 Hours
MAINTENANCE EVERY 500 HOURS EVERY 500 HOURS INSPECTING THE TRANSMISSION GEAR 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.
Page 216: Inspecting The Differential Gear Oil
MAINTENANCE EVERY 500 HOURS INSPECTING THE DIFFERENTIAL GEAR <Rear> • 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. ·...
Page 217: Inspecting The Hub Gear Oil
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.
Page 218: Lubricating The Slew Bearing
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.
Page 219: Replacing The Fuel Filters
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.
Page 220: Replacing The Feed Pump Filter
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.
Page 221: Inspecting And Cleaning The Supply Pump Strainer
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 •...
Page 222: Every 1000 Hours
MAINTENANCE EVERY 1000 HOURS EVERY 1000 HOURS REPLACING THE HYDRAULIC OIL RETURN FILTER Refer to “Replacing the hydraulic oil return filter” on page 5-33. REPLACING THE PILOT LINE FILTER Refer to “Replacing the pilot line filter” on page 5-34. REPLACING THE SLEW MOTOR GEAR OIL Refer to “Replacing the slew motor gear oil”...
Page 223: Cleaning The Engine Cooling System
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 •...
Page 224 MAINTENANCE EVERY 1000 HOURS 4. Place a pan for catching the waste coolant 20. When the coolant has been replaced, under the drain plug (4), and then loosen inspect the coolant level once again after the drain plug (4) to drain the coolant. operating the machine.
Page 225: Replacing The Air Cleaner Element
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.
Page 226: Replacing The Air Breather Filter
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.
Page 227: Inspecting And Adjusting The Engine Valve Clearance
MAINTENANCE EVERY 1000 HOURS INSPECTING AND ADJUSTING THE ENGINE VALVE CLEARANCE This operation requires experience. Ask your sales or service dealer for it. INSPECTING THE ENGINE COMPRESSION PRESSURE This operation requires experience. Ask your sales or service dealer for it. INSPECTING AND CLEANING THE ENGINE STARTER AND THE ALTERNATOR This operation requires experience.
Page 228: Every 1500 Hours
MAINTENANCE EVERY 1500 HOURS EVERY 1500 HOURS INSPECTING, CLEANING AND CHECKING OPERATION OF THE ENGINE FUEL INJECTORS This operation requires experience. Ask your sales or service dealer for it. INSPECTING AND REPLACING THE AIR FILTER CASE FOR CRACKING This operation requires experience. Ask your sales or service dealer for it.
Page 229: Every 2000 Hours
MAINTENANCE EVERY 2000 HOURS EVERY 2000 HOURS REPLACING THE TRANSMISSION GEAR • 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.
Page 230: Replacing The Differential Gear Oil
MAINTENANCE EVERY 2000 HOURS REPLACING THE DIFFERENTIAL GEAR <Rear> • 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. ·...
Page 231: Replacing The Hub Gear Oil
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.
Page 232: Every 4000 Hours
MAINTENANCE EVERY 4000 HOURS EVERY 4000 HOURS 1. Slew 45° clockwise and set the machine 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. •...
Page 233 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).
Page 234 MAINTENANCE EVERY 4000 HOURS • Emergency shut-off valve 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.
Page 235: Every 4500 Hours
MAINTENANCE EVERY 4500 HOURS EVERY 4500 HOURS INSPECTING AND MAINTENANCE THE DPD OR ITS RELATED PARTS INSPECTING THE TURBOCHARGER (BLOW WASH AS NECESSARY) • Do not modify the DPD without permission. If modified, it may be This operation requires experience. Ask your damaged or malfunction may occur.
Page 236: When Required
MAINTENANCE WHEN REQUIRED WHEN REQUIRED 3. Remove the key, and then check that the 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.
Page 237 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...
Page 238: Replacing The Bucket
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.
Page 239 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.
Page 240: Adjusting The Gap Between The Bucket And Arm (If Equipped)
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 •...
Page 241: Inspecting And Replenishing The Windshield Washer Fluid
MAINTENANCE WHEN REQUIRED INSPECTING AND REPLENISHING THE Inspection WINDSHIELD WASHER FLUID 1. Open the left side cover. 2. Inspect the washer tank (1) and add washer fluid if the level is low. • Choose ethyl alcohol as washer Replenishing 1. Mix the washer fluid to the prescribed solution.
Page 242: Draining The Water From The Water Separator
MAINTENANCE WHEN REQUIRED DRAINING THE WATER FROM THE If the water does not drain easily, loosen WATER SEPARATOR the plug (2). 4. Close the drain valve (1) and tighten the plug (2). Refer to “Bleeding air from the fuel • Do not smoke or permit open flames system”...
Page 243: Lubricating The Levers And Pedal
MAINTENANCE WHEN REQUIRED LUBRICATING THE LEVERS AND PEDAL Dozer blade lever 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.
Page 244: Every 2 Years
MAINTENANCE EVERY 2 YEARS EVERY 2 YEARS REPLACING THE RECEIVER DRYER This operation requires experience. Ask your sales or service dealer for it. 5-78...
Page 245: Maintenance During Extended Storage Period
MAINTENANCE MAINTENANCE DURING EXTENDED STORAGE PERIOD MAINTENANCE DURING Starting the machine after storage EXTENDED STORAGE PERIOD IMPORTANT: If the above “Storage procedures” have not been followed Storage procedures during the extended storage periods, If the machine is to be stored for 30 days or consult your sales or service dealer more, store it indoors.
Page 246 5-80...
Page 247: Troubleshooting
TROUBLESHOOTING...
Page 248: Symptoms That Are Not Malfunctions
TROUBLESHOOTING SYMPTOMS THAT ARE NOT MALFUNCTIONS SYMPTOMS THAT ARE NOT • It becomes less easy to operate the machine when an attachment weighing MALFUNCTIONS more than a standard arm or bucket is installed. The symptoms listed below are not • In some cases smoke may be emitted from malfunctions.
Page 249 MEMO...
Page 250: If The Engine Overheats
TROUBLESHOOTING IF THE ENGINE OVERHEATS IF THE ENGINE OVERHEATS The symptoms listed below indicate overheating. • Do not open the engine hood when steam is coming from it. The steam or hot water may spurt out and cause burns. • Do not remove the radiator cap or the drain plug when the coolant is hot.
Page 251 TROUBLESHOOTING IF THE ENGINE OVERHEATS Remedy procedure 1. Park the machine in a safe place. 2. Check if steam is coming out of the closed engine hood. 3. If there is steam, stop the engine immediately and contact your sales or service dealer for repair.
Page 252: If The Battery Goes Dead
TROUBLESHOOTING IF THE BATTERY GOES DEAD IF THE BATTERY GOES DEAD Connecting the jumper cables The symptoms below indicate that the IMPORTANT: Set the starter keys of the battery is dead. booster vehicle and the dead machine to • The starter motor does not turn or fails to the OFF position.
Page 253 TROUBLESHOOTING IF THE BATTERY GOES DEAD Disconnecting the jumper cables Once the dead machine is successfully running, remove the jumper cables by following the same steps as for connection in the reverse order. 1. Disconnect the clip of jumper cable (B) from the engine block of the dead machine.
Page 254: If A Fuse Blows
TROUBLESHOOTING IF A FUSE BLOWS IF A FUSE BLOWS Fuse layout and circuits protected If a light does not come on or the electrical Capacity Symbol Protected circuit system does not work, a fuse may be blown. Inspect the fuses. Head light low Beam (2) INSPECTING AND REPLACING THE FUSE Head light low Beam (1)
Page 255: Inspecting The Fusible Link
TROUBLESHOOTING IF A FUSE BLOWS INSPECTING THE FUSIBLE LINK Capacity Symbol Protected circuit ECM (2) power source Option Starter switch Immobilizer power source Multi-information If the machine is not turned on after turning display the starter switch to the ON position, the cartridge type fusible links (1) is likely blown.
Page 256: Restarting After Adding Fuel
TROUBLESHOOTING RESTARTING AFTER ADDING FUEL RESTARTING AFTER ADDING 4. Retighten the vent plug (5) when air bleeding is finished and fuel starts leaking FUEL out from around the vent plug (5). · Tightening torque: 8 to 12 N·m (6 to 9 BLEEDING AIR FROM THE FUEL SYSTEM ft-lb) 5.
Page 257 MEMO 6-11...
Page 258: If A Warning Lamp Flashes
TROUBLESHOOTING IF A WARNING LAMP FLASHES IF A WARNING LAMP FLASHES If an alarm is sounded or a warning lamp starts flashing during operation, park the machine in a safe place and perform the remedy procedures described below. Warning lamp Lamp name Causes and remedies Vehicle and...
Page 259 TROUBLESHOOTING IF A WARNING LAMP FLASHES Warning lamp Lamp name Causes and remedies Fuel filter The fuel filter is clogged. Replace the fuel filter. warning lamp Refer to “Replacing the fuel filter” on page 5-53. Third auxiliary Pressure in the third auxiliary hydraulic line is too low hydraulic warning lamp Consult your sales or service dealer for help.
Page 260: Vehicle Error Code List
TROUBLESHOOTING ERROR CODE LIST VEHICLE ERROR CODE LIST If an error code appears on the display, consult your sales or service dealer. Error code Error details Impossible to sense ACC key Parameter version mismatching CAN 0 communication error CAN communication error (ECM) CAN communication error (cluster gauge) CAN communication error (MOX024) CAN communication error (MIX024)
Page 261 TROUBLESHOOTING ERROR CODE LIST Error code Error details 3825 Wire break in hydraulic oil temp. sensor Fuel filter clogged (phase 1) 3350 3359 Fuel filter clogged (phase 2) DPD over trapping 3360 5303 Accelerator sensor error (too high) Accelerator sensor error (too low) 5304 5313 Foot accelerator sensor error (high pressure)
Page 262: Engine Error Code List
TROUBLESHOOTING ENGINE ERROR CODE LIST ENGINE ERROR CODE LIST If an error code appears on the display, consult your sales or service dealer. Error code Error details DPD differential pressure high P2453 DPD differential pressure low P2452 Zero-point learning error in the DPD differential pressure P2456 sensor DPD differential pressure sensor error (high-voltage error)
Page 263 TROUBLESHOOTING ENGINE ERROR CODE LIST Error code Error details Air flow sensor error P0101 Air flow sensor error (high-voltage error) P0103 Air flow sensor error (low-voltage error) P0102 Common rail pressure sensor error (high-voltage error) P0193 Common rail pressure sensor error (low-voltage error) P0192 Common rail pressure rise (2nd stage) P0088...
Page 264 TROUBLESHOOTING ENGINE ERROR CODE LIST Error code Error details Crank sensor error (no signal) P0335 Crank sensor error (abnormal signal) P0336 Idle up/down switch failure P256A Check engine lamp error P0650 1077 CPU error P0606 1079 5V power system 1 error P0641 1080 5V power system 2 error...
Page 265 TROUBLESHOOTING ENGINE ERROR CODE LIST Error code Error details Intake throttle control error P0638 10022 Intake throttle position sensor error (high-voltage error) P0123 Intake throttle position sensor error (low-voltage error) P0122 EVRV vacuum sensor error (high-voltage error) P2528 10023 EVRV vacuum sensor error (low-voltage error) P2527 Turbo EVRV error P0045...
Page 266: Other Symptoms
TROUBLESHOOTING OTHER SYMPTOMS OTHER SYMPTOMS For symptoms not included in the table below or if the problem persists after the proper remedies have been taken, consult your sales or service dealer. Symptoms Major causes Action Operating levers or pedals do •...
Page 267 TROUBLESHOOTING OTHER SYMPTOMS Symptoms Major causes Action Travel speed cannot be • Fuse is blown • Replace the fuse. changed Refer to page 6-8. Slewing is not possible or not • Insufficient grease on slew • Add grease. smooth. bearing Refer to page 5-52.
Page 268 TROUBLESHOOTING OTHER SYMPTOMS Symptoms Major causes Action Engine exhaust is • Air cleaner is clogged • Clean the air cleaner occasionally black Refer to page 5-43. • Engine control system is • Adjust or repair (ask your faulty. sales or service dealer). •...
Page 269: Lowering The Boom To The Ground
TROUBLESHOOTING LOWERING THE BOOM TO THE GROUND LOWERING THE BOOM TO 1. Check that the load being lifted and the machine are secure and the work area is THE GROUND safe. 2. Place a pan under the plug (E) to catch If the hoe attachment must be lowered to the the used oil.
Page 270: Towing
TROUBLESHOOTING TOWING TOWING IMPORTANT: The transmission could be damaged during operation if the emergency actuator is wrongly released. Be sure to follow the steps below to When towing, serious injury or death correctly release the parking brake. could result, if performed incorrectly or In case of hydraulic oil pressure failure or the wire rope being used is inappropriate or not properly inspected.
Page 271 TROUBLESHOOTING TOWING Towing the machine 7. Depress the “Hare” symbol on low/high- speed travel switch to change to the 1. Attach the wire rope to the shackle (1). high-speed travel gear. 2. Make sure that the wire rope is horizontal (Creeping travel switch: OFF) and is lined up straight with the travel 8.
Page 272: If The Cab Is Damaged
TROUBLESHOOTING IF THE CAB IS DAMAGED IF THE CAB IS DAMAGED Immediately replace the damaged cab. Serious injury or death may occur if the machine is operated with damaged cab. Do not operate the machine until the replacement is complete. Do not try to repair the damaged cab by welding.
Page 273: Specifications
SPECIFICATIONS...
Page 274: Basic Specifications
SPECIFICATIONS BASIC SPECIFICATIONS BASIC SPECIFICATIONS Type 2-Piece boom MASS Machine with an Outriggers 15070 (33225) Operating mass*** kg (lb) Equipped with a rear blade 14570 (32120) Maximum Operating mass** kg (lb) 16000 (35274) PERFORMANCE Heaped 0.505 (17.83) Bucket capacity (cu. ft.) (Standard bucket) Struck 0.369 (13.02)
Page 275 MEMO...
Page 276: Machine Dimensions
SPECIFICATIONS MACHINE DIMENSIONS MACHINE DIMENSIONS...
Page 277 SPECIFICATIONS MACHINE DIMENSIONS Unit: mm (inch) Item 2-Piece boom Overall length 6030 (237.5)*/ 6085 (239.5) B Overall width 2525 (99.4) C Overall height 3985 (156.9) D Slew radius 2065 (81.4) Clearance height under upperstructure 1245 (49.0) Wheel base 2565 (101) G Tread 1945 (76.5) H Overall length of undercarriage...
Page 278: Operating Ranges
SPECIFICATIONS OPERATING RANGES OPERATING RANGES 2-Piece boom...
Page 279 SPECIFICATIONS OPERATING RANGES 2-Piece boom Unit: mm (inch) Item 2570 mm (101.2 in) arm Maximum reach 8885 (349.8) B Maximum reach at ground reference plane 8705 (342.8) C Maximum digging depth 5555 (218.7) D Maximum vertical digging depth 4965 (195.5) Reach at maximum vertical digging depth 4480 (176.4) Maximum height of cutting edge...
Page 280 MEMO...
Page 281: Lifting Capacities
SPECIFICATIONS LIFTING CAPACITIES LIFTING CAPACITIES Rated lift capacity chart • Do not attempt to lift or hold any load • The loads in the charts do not exceed 87% that is greater than these rated values at of hydraulic lift capacity or 75% of tipping their specified load radii and height.
Page 282 SPECIFICATIONS LIFTING CAPACITIES 2-Piece boom, 2570 mm (101.2 in.) arm 7-10...
Page 283 SPECIFICATIONS LIFTING CAPACITIES 2-Piece boom, 2570 mm (101.2 in.) arm 7-11...
Page 284 7-12...
Page 285: Options
OPTIONS...
Page 286: General Precautions
• Do not use any attachments not been replaced. Inspect the hydraulic oil level and recharge it as necessary. Consult your approved by Takeuchi. Doing so may cause safety problems. Or, it may sales or service dealer for detailed adversely affect the machine’s operation procedures on installing/removing or service live.
Page 287: Precautions When Operating Attachments
OPTIONS GENERAL PRECAUTIONS PRECAUTIONS WHEN OPERATING • Slewing on slopes ATTACHMENTS • If there is a heavy attachment is installed, the machine takes longer distance than usual to come to a complete stop when the stopping Long attachments reduce stability of the operation is performed.
Page 288: Hydraulic Breaker
OPTIONS HYDRAULIC BREAKER HYDRAULIC BREAKER For handling of the breaker, read the hydraulic breaker’s manual, provided separately. IMPORTANT: When installing an attachment, make sure that it is appropriate for the machine being used. Contact your sales or service dealer for advice on selecting attachments.
Page 289: Replacing The Hydraulic Oil Regularly
OPTIONS HYDRAULIC BREAKER REPLACING THE HYDRAULIC OIL REGULARLY When a hydraulic breaker is used, the oil deteriorates more quickly than that used for a usual operation. Be sure to replace the hydraulic oil and the return filter elements. • Failure to replace these in time can lead to damage to the machine and the breaker hydraulic system.
Page 290: Biodegradable Oil
Have it performed by a Takeuchi sales or service outlet. Flushing To be performed by a Takeuchi sales or service outlet 1. Drain the hydraulic oil (mineral oil) from the hydraulic tank and clean the inside of the tank and suction strainer.
Page 291 MEMO...
Page 292: Operating Lever Switch Kit 1
OPTIONS OPERATING LEVER SWITCH KIT 1 OPERATING LEVER SWITCH engine revolutions to low idling whenever the engine is started. KIT 1 Cancel the deceleration mode by pressing the deceleration button as necessary. HORN BUTTON Note: This deceleration button is capable of decreasing the engine speed and reducing the fuel consumption, with a simple operation, in a situation such as when little...
Page 293: Auxiliary 1St Switches
OPTIONS OPERATING LEVER SWITCH KIT 1 AUXILIARY 1ST SWITCHES Refer to “Auxiliary hydraulic lines” on pages 2-65 to 2-69. Auxiliary hydraulic buttons AUXILIARY 2ND/4TH SWITCH Slider switch (Proportional control) Proportional control allows for slow-to-fast/ fast-to-slow movement of attachment. Example: If you move the slider switch half way, the attachment will move at approximately one-half the speed.
Page 294: Auxiliary 2/4 Select Button
OPTIONS OPERATING LEVER SWITCH KIT 1 AUXILIARY 2/4 SELECT BUTTON This switch is used to change from the second auxiliary operation to the fourth auxiliary operation. Pressing this button displays the second auxiliary on the Multi-information display to indicate that the second auxiliary operation is enabled.
Page 295 OPTIONS OPERATING LEVER SWITCH KIT 1 Operating Releasing the residual pressure Press those buttons to control the flow of the After the auxiliary hydraulic circuits have oil in the first/second auxiliary hydraulic lines. been used, pressure remains in the circuits. (A) ..Hydraulic oil flows to left auxiliary line This is called the residual pressure.
Page 296 First Published October 2013 No.41911 Third Published January 2016 OPERATOR’S MANUAL TB1160W Hydraulic excavator Edited and issued by TAKEUCHI MFG. CO., LTD. Printed in Japan by STATION M Co., Ltd. 8-12...
Page 297 EU directives. In case of any alteration of the machine not coordinated with us, this certificate loses its validity. Designation of the machine Hydraulic Excavator Manufacturer TAKEUCHI MFG. CO., LTD 205 Uwadaira, Sakaki-machi, Hanishina-gun, Nagano 389-0605, Japan Model TB1160W...

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