Takeuchi TCR50 Operator's Manual

Operator's Manual for Takeuchi TCR50 Construction Equipment, Excavators (166 pages)

Specifications:

999/999797-tcr50.pdf file (26 Jan 2024)
  • Manufacturer: Takeuchi
  • Category of Device: Construction Equipment, Excavators
  • Document: TCR50, File Type: PDF Operator's Manual
  • Updated: 26-01-2024
  • Count of Pages: 166
Download TCR50 Manual (166 pages)

Takeuchi TCR50: Read PDF Manual Online

Data: UPD 26th January 2024

Takeuchi TCR50 Construction Equipment, Excavators PDF Operator's Manual (Updated: Friday 26th of January 2024 06:33:05 PM)

Rating: 4.2 (rated by 14 users)

Compatible devices: TB36, TB215R, TB260, TB175W, TB240, TB015, TB295W, TB210R.

Recommended Documentation:

Takeuchi TCR50: Text of Operator's Manual

(Ocr-Read Version Summary of Contents, UPD: 26 January 2024)
  • C-1

    Dump Carrier

    TCR50

    TCR50

    OPERA TOR’S MANUAL

    Read and understand these instructions.

    Failure to do so can cause injury or death.

    OPERATOR’S MANUAL

    E

    Book No. AS5E000

    Serial No. 30530002~

    WARNING

    Code No.

    OE-TCR50-C

    305200001~

  • C-2

    SAFETY ALERT SYMBOL

    This symbol means Attention! Be Alert! Your Safety Is Involved.

    The message that follows the symbol contains important information

    about safety.

    Read and understand the message to avoid personal injury or death.

    It is the owner or employer’s responsibility to fully instruct each operator in the proper

    and safe operation of all equipment. All persons using this machine should thoroughly

    familiarize themselves with the following sections.

     A

    ll operators must be instructed on the proper functions of the dump carrier before

    running the machine.

     L

    earn and practice correct use of the machine controls in a safe, clear area before

    operating this machine on a job site.

    Improper operation, inspection and maintenance of this ma-

    chine can cause injury or death.

    Read

    and understand this manual before performing any op-

    eration, inspection or maintenance on this machine.

     Always store this manual near at hand preferably on the machine itself. If it should be lost or

    damaged, immediately order a new one from your Takeuchi dealer.

    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. Should you have any question about whether your machine

    complies with the regulations and standards of your country, contact a Takeuchi dealer.

    Please note that the contents and diagrams included in this manual may not match your

    machine exactly.

    CAUTION

  • 1

    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. Read and understand all of the safety messages which explain how to prevent

    these accidents from occurring. Do not operate the machine until you are sure that you have

    gained a proper understanding of its operation, inspection and maintenance.

     SlGNAL WORDS

    Safety messages appearing in this manual and on machine decals are identified by the words

    “DANGER”, “WARNING” and “CAUTION”. These signal words mean the following:

    IMPORTANT: The word “IMPORTANT” is used to alert against operators and

    maintenance personnel about situations which can result in possible damage to the

    machine and its components.

    It is impossible to foresee every possible circumstance that might involve a potential hazard.

    The warnings in this manual or on the machine can not cover all possible contingencies. You

    must exercise all due care and follow normal safety procedures when operating the machine

    so as to ensure that no damage occurs to the machine, its operators or other persons.

     EXPLANATION OF GRAPHICAL SYMBOLS

    Following is an explanation of symbols used in this manual.

    , X ............prohibition

    / ..........Lock

    / .........Unlock

    The word “DANGER”

    indicates an imminently

    hazardous situation

    which, if not avoided,

    can result in serious

    injury or death.

    The word “WARNING”

    indicates a potentially

    hazardous situation

    which, if not avoided,

    could result in serious

    injury or death.

    The word “CAUTlON”

    indicates a potentially

    hazardous situation

    which, if not avoided,

    may result in minor or

    moderate injury.

    DANGER WARNING CAUTION

  • 2

    Foreword

    This manual describes operation, inspection

    and maintenance of the machine, as well

    as safety instructions to be heeded during

    these operations.

    If you have any questions about the machine,

    please contact a Takeuchi sales or service

    outlet.

     Manual storage

    A compartment for storing this manual

    is provided at the position shown on the

    diagram below.

    1. To open the lid, push the button.

    2. Always store the manual here after using.

    INTRODUCTION

     Serial numbers

    Check the serial numbers of the machine

    and the engine and write them in the spaces

    provided below.

    Machine number :

    Engine number :

    S2A001

    S2A002

  • 3

     Front, rear, Ieft and right

    This manual refers the front, rear, left and

    right of the machine as seen when sitting in

    the operator’s seat.

     Designated operations

    Use this machine primarily for the following

    operation :

    Operation on rough terrain.

    MACHINE DESCRIPTlON

     Features

     Dump body can be hydraulically rotated through 90°.

    Hydrostatic drive system.

    ROPS / FOPS cabine.

    Low engine noise and exhaust emissions.

    Isolation mounted cab minimizes vibration.

    Pilot operated joystick controls.

    Engine emergency stop system.

     Break-in period

    When the machine is new, heed the instructions below when operating the machine for the

    first 100 hours (as indicated on the hour meter).

    Using a new machine roughly without breaking it in will lead to quicker deterioration of machine

    performance and may shorten the machine’s service life.

    Warm up the engine and hydraulic oil sufficiently.

    Avoid heavy loads and rapid operations. Operate with a load of about 80% the maximum

    load.

    Do not start up, accelerate, change directions, or stop abruptly unless necessary.

    RIGHTLEFT

    REAR

    FRONT

    S2A003E

  • 4

  • 5

    Introduction ..........................................2

    Machine Description ..........................3

    S

    afety ....................................................7

    C

    ontrols ............................................. 35

    Operation ........................................... 63

    Transport ........................................... 83

    Maintenance ..................................... 87

    Troubleshooting .............................. 131

    Specifications ................................. 145

    Options ............................................ 153

    Index ................................................. 157

    CONTENTS

  • 6

  • 7

    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

    SAFETY

  • 8

    SAFETY

    Observe all safety rules

     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.

    Do not perform any operation, inspection

    and maintenance of this machine when

    under the adverse influence of alcohol,

    drugs, medication, fatigue, or insufficient

    sleep.

    General Precautions

    Wear appropriate clothing and

    personal protective equipment

     Do not wear loose clothing or any

    accessory that can catch on controls or in

    moving parts.

    Do not wear oily or fuel stained clothing

    that can catch fire.

    Wear a hard hat, safety shoes, safety

    glasses, filter mask, heavy gloves, ear

    protection and other protective equipment

    as required by job conditions. Wear

    required appropriate equipment such as

    safety glasses and filter mask when using

    grinders, hammers or compressed air, as

    metal fragments or other objects can fly

    and cause serious injury.

    Use hearing protection when operating

    the machine. Loud prolonged noise can

    cause hearing impairments, even the total

    loss of hearing.

  • 9

    SAFETY

    General Precautions

    Provide a fire extinguisher and

    first aid kit

     Know where a fire extinguisher and first

    aid kit are located and understand how to

    use them.

    Know how to contact emergency

    assistance and first aid help.

    Never remove safety equipment

     Make sure all protective guards, covers,

    doors, etc., are in place and secure.

    Repair or replace damaged components

    before operating the machine.

    Know how to use the safety lock lever,

    seat belt, raised body prop and other

    safety equipment and use them properly.

    Never remove any safety equipment

    except for service. Keep all safety

    equipment in good operating condition.

    Use a signal person and flagman

    Know and use the hand signals required for

    particular jobs and make sure who has the

    responsibility for signaling.

    All personnel must fully understand all the

    signals.

    The operator shall respond to signals only

    from the appointed signal person, but

    shall obey a stop signal at any time from

    anyone.

    The signal person must stand in a clearly

    visible location when giving signals.

  • 10

    SAFETY

    Be sure to lock the safety lock

    lever before leaving the operator’s

    seat

     Before leaving the operator’s seat, set

    the safety lock lever securely to the

    lock position and stop the engine. If any

    controls should be touched accidentally

    when the safety lock lever has not be

    locked, the machine will move suddenly,

    and cause serious injury or death.

    Before leaving the operator’s seat, lower

    the dump body, lock the safety lock lever,

    and stop the engine. Also, be sure to

    remove the key and take it with you.

    General Precautions

    Avoid fire and explosion hazards

    Keep flames away from fuel, hydraulic fluid,

    oil, grease and antifreeze. Fuel is particularly

    flammable and dangerous.

    When handling these combustible

    materials, keep lit cigarettes, matches,

    lighters and other flames or sources of

    flames away.

    Do not smoke or permit open flames while

    fueling or near fueling operations.

    Never remove the fuel cap or refuel with

    the engine running or hot. Never allow fuel

    to spill on hot machine components.

    Clean up spilled fuel, oil or other flammable

    fluids immediately.

    Check for fuel, oil or hydraulic fluid leaks.

    Stop all leaks and clean the machine

    before operating.

    Do not cut or weld on pipes or tubes that

    contain flammable fluids. Clean thoroughly

    with nonflammable solvent before cutting

    or welding.

    Remove all trash or debris from the

    machine. Make sure that oily rags or other

    flammable material are not stored on the

    machine.

    Handle all solvents and dry chemicals

    according to procedures identified on

    manufacturers’ containers. Work in a well-

    ventilated area.

    Never use fuel for cleaning purposes.

    Always use a nonflammable solvent.

    Store all flammable fluids and materials in

    a safe and well-ventilated place.

  • 11

    SAFETY

    General Precautions

    Exhaust fumes from the engine

    can kill

     Do not operate the engine in an enclosed

    area without adequate ventilation.

    If natural ventilation is poor, install

    ventilators, fans, exhaust extension pipes

    or other artificial venting devices.

    Handling asbestos dust

    Inhaling asbestos dust has been linked to

    lung cancer. When handling materials which

    may contain asbestos, take the following

    precautions :

    Never use compressed air for cleaning.

    Avoid brushing or grinding of the

    materials.

    For clean up, use wet methods or a

    vacuum equipped with a high efficiency

    particulate air (HEPA) filter.

    Wear an approved respirator if there is

    no other way to control the dust. When

    working indoors, install a ventilation

    system with a macro molecular filter.

    Be careful not to get crushed or

    cut

    Your body, hands, feet, or other body parts

    must not be inserted between the dump

    body and the main frame, or between the

    cylinder and the dump body, or other moving

    parts. Operation of the dump body under

    such circumstances may lead to you getting

    caught between the moving parts and can

    cause death or serious injury.

    Using optional products

     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.

    Takeuchi will not be held responsible for

    any injuries, accidents or damage to its

    products caused by the use of a non-

    approved attachment.

    Never modify the machine

    Unauthorized modifications to this machine

    can cause injury or death. Never make

    unauthorized modifications to any part of

    this machine.

    S2A004

  • 12

    SAFETY

    Preparing Precautions

    Know the working area

    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.

    Note and avoid all hazards and

    obstructions such as ditches, holes, trees,

    cliffs, overhead electrical wires or areas

    where there is danger of a slide.

    When working on roads, be sure to take

    into account the safety of pedestrians and

    vehicles.

    • Use a flagman and / or signals.

    • Fence off the working area and prohibit

    entry to unauthorized persons.

    When working in water or crossing shallow

    streams or creeks, check the depth of the

    water, the solidity of the ground, and the

    speed of the current beforehand. Make

    sure the water is not deeper than the

    allowable depth.

    Refer to the section titled “Cautions on

    Use in Water” for further instructions.

    Check the strength of the bridge

    When traveling over a bridge or other

    structure, check the permissible load.

    If the strength is insufficient, reinforce it.

    Always keep the machine clean

     Clean windows, mirrors and lights to

    ensure good visibility.

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

    to prevent accidents due to slipping.

    Remove all loose objects stored in the

    machine and all objects which do not

    belong in or on the machine and its

    equipment.

    Remove any dirt, oil or grease from the

    engine area, to prevent fires.

    Clean the area around the operator’s seat,

    removing any potential obstacles.

    S2A005

    S2A006

    S2A007

  • 13

    SAFETY

    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

    procedure, and keep machine securely

    parked until the malfunction is corrected.

    Preparing Precautions

  • 14

    SAFETY

    Starting Precautions

    Maintain three point contact when

    mounting and dismounting

     Do not jump on or off the machine. Never

    attempt to mount or dismount a moving

    machine.

    When mounting and dismounting the

    cab, first open the door fully to the locked

    position and check that it does not move.

    (For machines with cabs)

    Always face the access system and

    maintain a three point contact with the

    recommended handrails and steps while

    getting on and off the machine. Keep

    steps and platform clean.

    Never use the safety lock lever or control

    levers as hand holds.

    Clear the area of other persons

    before starting the machine

    Do not start the engine until you are sure it

    is safe. Before starting, check or perform the

    following.

    Walk around the machine and warn all

    personnel who may be servicing the

    machine or are in the machine path. Do

    not start until all personnel are clearly

    away from the machine.

    Check for any “DO NOT OPERATE” tags

    or similar warning notices on the cab door,

    controls or starter switch.

    Sound horn to alert everyone around the

    machine.

    Start the engine from the

    operator’s seat

     Adjust, secure and latch the operator’s

    seat.

    Fasten the seat belt.

    Check that the parking device is applied

    and place all controls in the neutral

    position.

    Check that the safety lock lever is in the

    lock position.

    Clear the area of all persons.

    Start and operate the engine from the

    operator’s seat only.

    Never attempt to start the engine by

    shorting across the starter terminals.

  • 15

    SAFETY

    Starting with jumper cables

    Use jumper cables only in the recommended

    manner. Improper use of jumper cables can

    result in battery explosion or unexpected

    machine motion.

    Refer to the section titled “If the Battery

    Goes Dead” for proper instructions.

    After starting the engine

    After starting the engine, perform the

    following operations and checks in a safe

    place with no persons or obstacles in the

    area. If any malfunctions are found, follow

    the shutdown procedure and report the

    malfunction.

    Warm up the engine and hydraulic fluid.

    Observe all gauges or warning instruments

    for proper operation.

    Listen for unusual noises.

    Test engine speed control.

    Operate each control to insure proper

    operation.

    In cold weather

     Be careful of slippery conditions on

    freezing ground, steps and hand holds.

    In severe cold weather, do not touch any

    metal parts of the machine with exposed

    flesh, as flesh can freeze to the metal and

    Cause injury.

    Do not use ether or starting fluids on this

    engine. These starting aids can cause

    explosion and serious injury or death.

    Warm up the engine and hydraulic fluid

    before operating.

    Starting Precautions

  • 16

    SAFETY

    Operating Precautions

    Check for safety in the

    surrounding area before starting

     Understand the machine limitations.

    Never allow anyone to enter the machine

    working range and machine path.

    Signal your intention to move by sounding

    the horn.

    There are blind spots to the rear of the

    machine. Check that the area is safe and

    clear.

    Use a signal person where clearances are

    close or your vision is obstructed.

    Ensure good visibility

     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.

    Do not permit riders on the

    machine

     Do not allow anyone to ride on any part of

    the machine at any time while traveling.

    Do not allow anyone to be on any part of

    the machine while operating.

    S2A008

  • 17

    SAFETY

    Travel safety

     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.

    When traveling over rough or slippery

    terrain, slow down to prevent losing

    control.

    Avoid crossing over obstacles whenever

    possible. If obstacles are unavoidable,

    travel slowly and cross at an angle. Never

    cross obstacles if they will seriously tilt the

    machine (to an angle of 10° or greater).

    When roading a machine, know and use

    the signaling devices required on the

    machine. Provide an escort for road travel

    when required.

    Operating Precautions

    S2A009

    S2A010

  • 18

    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

    actual working area conditions are poor

    the machine’s stability may be lower.

    When going up or down slopes having a

    gradient of 15 degrees or more, travel up

    and down the slope with the heavy end of

    the dump carrier pointed uphill.

    Travel at slow speed on slopes. Especially

    when going down slopes, reduce the

    engine (r.p.m.) speed and set the stroke of

    the travel lever to half or less before going

    down. Going down a slope too fast will

    lead to loss of control.

    Sudden stopping on slopes may lead to

    loss of balance of the vehicle and it could

    tip over.

    Traveling across an inclined surface at

    an angle or traveling straight across an

    inclined surface could result in slipping

    sideways or tipping over. Travel straight

    up and down the slope.

    Do not change directions or cross slopes

    sideways. First return to a flat surface then

    redirect the machine.

    On grass, dead leaves, wet metal or frozen

    surfaces, the machine may slide sideways

    even on very gentle slopes. Make sure

    the machine never faces sideways with

    respect to the slope.

    Travel in narrow or congested

    places

    To avoid contact accidents, pay attention to

    the surroundings at narrow sites, indoors,

    and congested places and operate at a

    speed at which the machine can be safely

    operated.

    S2A011

    S2A012E

    S2A013

  • 19

    SAFETY

    Precautions when passing

    through tunnels or under bridges

    Careless entry into tunnels or under bridges

    can lead to serious accidents such as

    contact accidents, etc. Check height and

    width limits in advance and verify that the

    machine is within the limits.

    Operate on snow or ice with extra

    care

     When traveling on snow or frozen surfaces,

    keep the machine travel speed down and

    avoid accelerating, stopping or changing

    directions abruptly.

    Remember that the road shoulder, fences,

    etc., may be buried in the snow and not

    visible.

    Precautions When Loading the

    Dump Body

    Do not allow loading the dump body unless

    the driver and personnel are in a safe place.

    Load on a firm location, do not load on a

    slope. Improper loading can be the cause of

    the machine tipping over or the load giving

    way.

    Do not exceed the maximum weight when

    loading.

    Do not load unevenly, load so as to

    distribute the load evenly on the dump

    body.

    A load with poor stability should be

    securely fixed to the dump body.

    Operating Precautions

    S2A014

    S2A015

  • 20

    SAFETY

    Operating Precautions

    Precautions When Dumping

    Do not dump in any of the following manners.

    The center of balance will shift and the

    machine could tip over.

    Dumping on a slope or bumpy location.

    Dumping while swinging the dump body.

    Dumping while traveling.

    Keep a safe distance from

    electrical power lines

    Never approach power lines with any part of

    the machine and its load unless all local and

    national required safety precautions have

    been taken. Electrocution and death can

    result from arcing, touching or even being

    close to a machine that is in contact with or

    near an electrical source.

    Maintain the maximum possible distance

    from power lines and never violate the

    minimum clearance.

    Always contact the nearest electric

    utility and determine jointly what specific

    precautions must be taken to insure

    safety.

    Consider all lines to be power lines and

    treat all power lines as energized even

    though it is known or believed that the

    power is shut off and the line is visibly

    grounded.

    Use a signal person to observe the

    approach of any part of the machine or

    load to the power line.

    Caution all ground personnel to stand

    clear of the machine and the load at all

    times.

    If the machine should come in contact

    with a live electrical source, do not leave

    the operator’s seat. Do not allow anyone

    to approach or touch the machine.

    S2A016

    S2A017

  • 21

    SAFETY

    Do not enter soft ground

    Entry onto soft ground can result in the

    machine tilting on its own weight, tipping

    over, or falling in.

    Do not enter weak ground such as that

    following back-filling.

    Unstable ground is dangerous

    and increases the likelihood of the

    machine tipping over

     The ground is weak in the vicinity of a cliff,

    road shoulder, or ditch; therefore, do not

    come close to such places.

    Be cautions when working on a bank,

    since the bank could give way due to the

    mass and vibration of the machine and

    the machine could tilt suddenly.

    The ground becomes loose after rain,

    earthquakes, and dynamite blasting.

    Operating Precautions

    S2A018

    S2A019

  • 22

    SAFETY

    Operating Precautions

    Danger of flying objects

    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.

    Cautions on towing

    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 be extremely dangerous.

    Use a wire rope suited for the required

    towing force.

    Do not use a wire rope that is kinked,

    twisted or otherwise damaged.

    Do not apply strong loads abruptly to the

    wire rope.

    Use safety gloves when handling the wire

    rope.

    Make sure there is an operator on the

    machine being towed as well as on the

    machine that is towing.

    Never tow on slopes.

    Do not let anyone near the wire rope while

    towing.

  • 23

    SAFETY

    Stopping Precautions

    Park safely

     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.

    Before leaving the machine, do the

    following :

    1. Fully lower the dump body.

    2. Place the safety lock lever in the lock

    position.

    3. Stop the engine and remove the key.

    4. Lock the cab and covers.

    S2A020

  • 24

    SAFETY

    Transporting Precautions

    Load and unload the machine

    safely

    The machine may roll or tip over or fall while

    loading or unloading it. Take the following

    precautions :

    Select a firm, level surface and keep

    sufficient distance from road shoulders.

    Use loading ramps of adequate strength

    and size. Maintain the slope of loading

    ramps within 15 degrees.

    Secure the ramps to the truck bed.

    Keep the truck bed and loading ramps

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

    materials which can become slippery.

    Clean the tracks.

    Block the transport vehicle so it can not

    move.

    Use a signal person when loading and

    unloading the machine, and travel slowly

    in first gear (low speed).

    Never change course on the ramp.

    Do not raise and / or swing the dump body

    on the ramps and truck bed. The machine

    may tip over.

    Block both tracks and secure the machine

    to the truck bed.

    Transport the machine safely

     Know and follow the safety rules, vehicle

    code and traffic laws when transporting

    the machine.

    Consider the length, width, height and

    weight of the transport vehicle with the

    machine loaded on it when determining

    the best route.

    Do not hoist this machine

    The machine is NOT equipped with any

    hooking points for hoisting.

    Never hoist the machine with any device

    such as crane, etc.

    Fasten to the suspension fitting

    Ramp

    15° or less

    Distance between ramps

    Stopper

    E4F001

  • 25

    SAFETY

    Maintenance Precautions

    Attach a “DO NOT OPERATE” tag

    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.

    Attach a “DO NOT OPERATE” tag to the

    starter switch or control lever.

    Use the correct tools

    Do not use damaged or weakened tools or

    tools designed for other purposes. Use tools

    suited for the operation at hand.

    Replace important safety parts

    periodically

     Replace fuel hoses periodically. Fuel

    hoses become weaker over time, even if

    they appear to be in good shape.

    Replace important safety parts whenever

    an irregularity is found, even if it is before

    the normal time for replacement.

    Refer to the section titled “Important

    Parts” for further details.

    Anti-explosive lighting

    Use anti-explosive electrical fixtures and

    lights when inspecting fuel, oil, coolant,

    battery fluid, etc. If lighting that is not anti-

    explosive should break, the substance could

    ignite, resulting in serious injury or death.

    Do not allow unauthorized

    personnel in the work area

    Do not allow unauthorized personnel in the

    work area. Chips or other debris can fly off

    machine parts when grinding, welding or

    using a hammer.

  • 26

    SAFETY

    Maintenance Precautions

    Prepare the work area

     Select a firm, level work area. Make sure

    there is adequate light and, if indoors,

    ventilation.

    Clear obstacles and dangerous objects.

    Eliminate slippery areas.

    Stop the engine before performing

    maintenance

     Avoid lubrication or mechanical

    adjustments with the machine in motion or

    with the engine running while stationary.

    If maintenance must be performed with

    the engine running, always work as a two-

    person team with one person sitting in the

    operator’s seat while the other works on

    the machine.

    • When performing maintenance, be sure

    to keep your body and clothing away

    from moving parts.

    Stay clear of moving parts

     Stay clear of all rotating and moving parts.

    Wrapping or entanglement may result in

    serious injury or death.

    Keep hands, clothing and tools away from

    the rotating fan and running fan belts.

    Always clean the machine

     Clean the machine before performing

    maintenance.

    Stop the engine and cover electrical parts

    when washing the machine. Water on

    electrical parts could cause short-circuits

    or malfunctions.

    Do not use water or steam to wash the

    battery, sensors, connectors or the

    operator’s seat area.

  • 27

    SAFETY

    Securely block the machine or any

    component that may fall

     Before performing maintenance or

    repairs under the machine, set all working

    equipment against the ground or in the

    lowermost position.

    Securely block the tracks.

    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 the

    machine or raised dump body if they are

    not sufficiently supported. This procedure

    is especially important when working on

    hydraulic cylinders.

    Securely block the raised dump

    body

    If you must work beneath the raised dump

    body, securely engage the raised body prop.

    Never get under the dump body if it is not

    sufficiently supported.

    Secure the engine hood or cover

    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

     When performing maintenance on the

    machine, clean up the foot area and

    strictly observe the following so as not to

    fall :

    • Do not spill oil or grease.

    • Do not leave tools laying around.

    • When walking, watch your step.

    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.

    Use protective equipment as required by

    job conditions.

    Maintenance Precautions

    S2A004

  • 28

    SAFETY

    Maintenance Precautions

    Use caution when fueling

     Do not smoke or permit open flames while

    fueling or near fueling operations.

    Never remove the fuel cap or refuel with

    the engine running or hot. Never allow fuel

    to spill on hot machine components.

    Maintain control of the fuel filler nozzle

    when filling the tank.

    Do not fill the fuel tank to capacity. Allow

    room for expansion.

    Clean up spilled fuel immediately.

    Tighten the fuel tank cap securely. Should

    the fuel cap be lost, replace it only with

    the original manufacturer's approved cap.

    Use of a non-approved cap without proper

    venting may result in pressurization of the

    tank.

    Never use fuel for cleaning purposes.

    Use the correct fuel grade for the operating

    season.

    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.

    Retighten loose connections.

    Be careful with hot and

    pressurized components

    Stop the engine and allow the machine to

    cool down before performing inspection and

    maintenance.

    The engine, muffler, radiator, hydraulic

    lines, sliding parts and many other parts

    of the machine are hot directly after the

    engine is stopped. Touching these parts

    will cause burns.

    The engine coolant, oil and hydraulic fluid

    are also hot and under high pressure.

    Be careful when loosening caps and

    plugs. Working on the machine under

    these conditions could result in burns or

    injuries due to the hot oil spurting out.

  • 29

    SAFETY

    Maintenance Precautions

    Be careful with hot cooling

    systems

    Do not remove the radiator cap or drain plugs

    when the coolant is hot. Stop the engine, let

    the engine and radiator cool and loosen the

    radiator cap or drain plugs slowly.

    Be careful with fluids under

    pressure

    Pressure can be maintained in the hydraulic

    circuit long after the engine has been shut

    down.

    Release all pressure before working on

    the hydraulic system.

    Hydraulic fluid under pressure can

    penetrate the skin or eyes and cause

    injury, blindness or death. Fluid escaping

    from a small hole can be almost invisible.

    Wear a safety goggles and heavy gloves

    and use a piece of cardboard or wood to

    search for suspected leaks.

    If fluid is injected into the skin, it must be

    removed within a few hours by a doctor

    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.

    Gradually loosen the vent plug to relieve

    tank pressure.

    Move all the control levers and pedals

    several times in all directions to release

    the pressure from the working equipment

    circuitry. (For link type controls)

    When removing plugs or screws or

    disconnecting hoses, stand to the side

    and loosen slowly to gradually release the

    internal pressure before removing.

  • 30

    SAFETY

    Disconnect the battery

    Disconnect the battery before working on

    the electrical system or doing any welding.

    Remove the negative (–) battery cable first.

    When reconnecting the battery, connect the

    negative (–) battery cable last.

    Avoid battery hazards

     Batteries contain sulfuric acid which will

    damage eyes or skin on contact.

    • If acid contacts eyes, flush immediately

    with clean water and get prompt medical

    attention.

    • If acid is accidentally swallowed, drink

    large quantities of water or milk and call

    a physician immediately.

    • If acid contacts skin or clothing, wash

    off immediately with clean water.

    Wear safety glasses and gloves when

    working with batteries.

    Batteries generate flammable and

    explosive gases. Keep arcs, sparks,

    flames and lighted tobacco away.

    Use a flashlight to check battery electrolyte

    level.

    Stop the engine and shut off electrical

    equipment while inspecting or handling

    the battery.

    Do not short circuit the battery posts with

    metal items.

    Maintenance Precautions

     Always unfasten the negative (–) 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. Be sure to fasten terminals

    tightly.

    Make sure the vent caps are tightened

    securely.

    Do not charge a battery or jump-start the

    engine if the battery is frozen. Warm to

    15°C (60°F) or the battery may explode.

    Do not use the battery when the fluid

    level is below the lower level. Doing so

    will hasten the deterioration of the internal

    portions of the battery and shorten the

    battery life, and can also cause rupturing

    (or an explosion).

    Do not fill the battery above the upper

    level. Doing so could cause the fluid to

    leak, contact and damage the skin, or

    cause parts to corrode.

  • 31

    SAFETY

    Have a Takeuchi service agent

    repair welding cracks or other

    damage

    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.

    Disconnect the wiring from the battery

    before doing electric welding.

    Do not continuously apply 200 V or

    more.

    The earth ground must be connected

    within one meter from the welding

    section. Do not connect the earth ground

    near to an electronically controlled device/

    instrument or connectors.

    Make sure that there are no seals or

    bearings between the welding section

    and the earth ground.

    Do not connect the earth ground around

    the pins for the working equipment or

    hydraulic cylinders.

    When welding is to be done on the

    machine body, disconnect the connectors

    for the electronically controlled devices

    before working.

    Maintenance Precautions

    Disposing of wastes

     Funnel spent fluids from the machine into

    containers. Disposing of fluids improperly

    destroys the environment.

    Follow the prescribed regulations when

    disposing of oil, fuel, engine coolant,

    refrigerant, solvents, filters, batteries or

    other harmful substances.

    Checks after maintenance

     Gradually raise the engine speed from a

    low idle to maximum speed and check

    that no oil or water is leaking from serviced

    parts.

    Move the controls and check that the

    machine is operating properly.

    Vibrations operators are subject

    to

    According to the results of the tests

    conducted to determine the vibrations

    transmitted to the operator by the machine,

    the upper limbs are subjected to vibrations

    lower than 2.5 m/s

    2

    (8.2 ft/s

    2

    ) while the seated

    part of the body is subjected to vibrations

    lower than 0.5 m/s

    2

    (1.64 ft/s

    2

    ).

  • 32

    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. Review these signs and the operating instructions in this manual with your machine

    operators.

    Keep the signs legible. If they are not, obtain replacements from your Service outlet.

  • 33

    SAFETY

    Safety Signs (Decals)

  • 34

    SAFETY

    Safety Signs (Decals)

  • 35

    Names of Components ..................................36

    Doors and Covers ...........................................38

    Seat and Seat Belt ..........................................43

    Instrument Cluster ..........................................46

    Switches ...........................................................51

    Levers ...............................................................54

    Accessories .....................................................55

    CONTROLS

  • 36

    CONTROLS

    Names of Components

    1. Cab

    2. Seat

    3. Engine hood

    4. Bumper

    5. Front light

    6. Turn light

    7. Rear light

    8. Outside mirror

    9. Fuel tank

    10. Hydraulic tank

    11. Dump body

    12. Dump cylinder

    13. Swing motor

    14. Crawler belt

    15. Idler

    16. Track roller

    17. Carrier roller

    18. Travel motor

  • 37

    CONTROLS

    1. Instrument cluster

    2. Starter switch

    3. Light switch

    4. Horn switch

    5. Travel speed switch

    6. Wiper switch

    7. Safety lock lever

    8. Turn switch

    9. Throttle controller

    10. Left control lever

    11. Right control lever

    12. Fuse box

    13. Fan switch (Heater)

    14. Heater / Defroster lever

    15. Rec / fresh lever

    16. Parking brake button

    17. Engine shutdown switch

    18. Dump body alignment indicator

    19. Dump body raising indicator

    20. Display selection buttons

    21. Hour meter

    Names of Components

  • 38

    CONTROLS

    Doors and Covers

    Starter Key

    The starter key is used not only to start and

    stop the engine, but also to lock and unlock

    the following places :

    Fuel filler cap  Engine hood

    Cab door  Battery cover

    Side cover

    Cab Door

    WARNING

    When mounting and dismounting the

    cab, first open the door fully to the locked

    position and check that it does not

    move.

    Open the door fully and press it against the

    catch at the back of the door to lock it in

    place. Always lock the door when mounting

    and dismounting and when operating the

    machine.

    Lock and unlock

    1. Insert and turn the starter key.

    Opening

    1. Pull the knob (1) towards you and open

    the door.

    To open the door from inside the cab,

    push the lever (2) to the front.

    2. Open the door fully and press it against

    the cab to lock it in place.

    Closing

    1. Either push release lever (3) to the front or

    lower release lever (4).

    2. Close the released door.

    E4B003

    S2B003

    2

    1

    S2B004

    4

    3

  • 39

    CONTROLS

    Doors and Covers

    Front Window

    WARNING

     Grasp the handles firmly with both

    hands when opening and closing the

    front window. Your head or hands may

    get caught if they slip.

    If you open the front window, be sure to

    lock it in place with the lock pins on the

    left and right sides. The window may

    fall if it is not locked in place.

    Opening

    1. Park the machine on a level surface and

    stop the engine.

    2. Set the safety lock lever to the locked

    position.

    3. Pull the left and right lock pins (1) to

    the inside then turn them to the locked

    position to unlock the front window. If the

    lock pins (1) are partially sticking out they

    may cause damage.

    4. Grasp the lower handle (2) with the left

    hand, the upper handle (3) with the right

    hand, then lift and slide to the rear.

    5. Once the window frame is against the

    stopper, move the lock pins (1) to the

    outside to lock front window.

    Closing

    WARNING

    When closing the front window, lower the

    window slowly so as not to hit your head.

    Lowering the window abruptly may result

    in injury or damage the front window.

    1. Pull the left and right lock pins (1) to

    the inside and turn them to the locked

    position to unlock the front window. If the

    lock pins (1) are partially sticking out they

    may cause damage.

    2. Grasp the front (lower) handle (2) with the

    left hand, the rear (upper) handle (3) with

    the right hand, then slowly lower the front

    window.

    3. Move the lock pins (1) to the outside to

    lock the front window.

    1

    1

    1

    1

    3

    C4C003

    Released

    Locked

    1

    1

    2

    3

    C4C004

  • 40

    CONTROLS

    Lower Front Window

    Removing

    1. Open the front window and stow it in the

    ceiling.

    2. Grasp the protruding parts (4) on the left

    and right with your fingers and slowly lift

    the lower front window off.

    3. Hold the glass firmly, place the lower front

    window through the guides (5) at the rear,

    then set it on the supports (6) and fasten it

    in place.

    Doors and Covers

    Side Window

    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.

    Side Cover (Tool Box)

    The grease gun and tools are stored behind

    the cover.

    Lock and unlock

    1. Insert and turn the starter key

    counterclockwise (clockwise) to unlock

    (lock).

    2. Tilt the cover (1) until it stops.

    Closing

    1. Support the cover (1) by hand and release

    the stay.

    2. Close the front cover (1).

    3. Insert the starter key and turn it clockwise

    to lock the cover (1).

    S2B005

    4

    4

    4

    5

    6

    6

    4

    5

    C4C006

    7

    N0B023

  • 41

    CONTROLS

    Doors and Covers

    Battery Cover

    Lock and unlock

    1. Insert and turn the starter key

    counterclockwise (clockwise) to unlock

    (lock).

    2. Tilt the cover (1) until it stops.

    Closing

    1. Support the cover (1) by hand and release

    the stay.

    2. Close the front cover (1).

    3. Insert the starter key and turn it clockwise

    to lock the cover (1).

    Engine Hood

    WARNING

     Before opening the engine hood, be

    sure to stop the engine. If your hands

    or tools should get caught in the fan or

    fan belt while the engine is running they

    may be severed.

    Be sure to secure the engine hood

    when opening it. Do not open the

    engine hood on slopes or in strong

    wind.

    When opening and closing the engine

    hood, be careful not to get your hands

    or other parts of your body caught.

    Opening

    1. Insert and turn the starter key clockwise

    to unlock.

    2. Turn the handle and lift the engine hood

    fully.

    3. Raise the stay (1), then insert and fix it into

    the stay hole.

    Closing

    1. Support the engine hood by hand, remove

    stay (1), and fix it to the original position.

    2. Close the engine hood and press it down

    until a click is heard at the front.

  • 42

    CONTROLS

    Fuel Filler Cap

    WARNING

     Do not smoke or permit open

    flames while fueling or near fueling

    operations.

    Supply fuel in a well ventilated place

    and with the engine stopped.

    Clean up spilled fuel immediately.

    Do not fill the fuel tank to capacity.

    Allow room for expansion.

    Tighten the fuel filler cap securely.

    Opening

    1. Open the keyhole cover, insert the key

    and turn it counterclockwise to unlock the

    fuel cap.

    2. Turn the fuel cap counterclockwise and

    remove it.

    Closing

    1. Set the fuel cap in place and turn it

    clockwise.

    2. Turn the key clockwise to lock the fuel

    cap, then remove the key.

    Raised Body Prop

    WARNING

    If you must work beneath the raised dump

    body, securely engage the raised body

    prop. Never get under the dump body if it

    is not sufficiently supported.

    Engaging the raised body prop

    1. Fully raise the dump body.

    2. Set the safety lock lever to the lock

    position and stop the engine.

    3. Pull up the ring and remove the lock pin

    (1), then remove the pin (2).

    4. Put the disconnected end of the prop (3)

    between the lock holes and insert the pin

    (2).

    5. Install the lock pin (1) and push down the

    ring.

    Disengaging the raised body prop

    1. Move the right control lever to raise the

    dump body.

    2. Disengage the prop (3) and put it back in

    place.

    Doors and Covers

    1

    3

    2

    S2B0221

  • 43

    CONTROLS

    Seat

    WARNING

    Adjust, secure and latch the operator’s

    seat.

    (A) Lumber adjustment

    1. Turning knob (1) in the direction of the

    arrow causes the lumber of the backrest to

    curve outwards for greater back support.

    2. Turning the knob (1) further then removes

    the curve and returns the seat to its original

    position.

    The knob (1) cannot be turned counter to

    the direction of the arrow.

    (B) Seat cushion angle and height

    adjustment

    Lift lever (2) to adjust the rear angle of the

    seat cushion.

    1. To raise the rear angle of the seat cushion,

    raise yourself slightly off the seat while

    lifting the lever.

    2. To lower the rear angle of the seat cushion,

    apply your weight to the rear of the seat

    cushion while lifting the lever.

    Lower lever (2) to adjust the front angle of

    the seat cushion.

    1. To raise the front angle of the seat cushion,

    apply your weight to the backrest while

    holding the lever down.

    2. To lower the front angle of the seat

    cushion, apply your weight to the front of

    the seat cushion while holding the lever

    down.

    To adjust the height of the seat, adjust the

    front and rear angles of the seat cushion

    alternately.

    (5 steps, 60 mm (2.36 in.) adjustment

    range)

    Example: First raise the front angle of the

    seat cushion, then raise the rear

    angle of the seat cushion by the

    same amount. This raises the

    height of the seat.

    After adjusting to the desired position,

    release the lever to lock it.

    (C) Back angle adjustment

    WARNING

     Do not set the seat back to its maximum

    reclining position and slide the seat

    backwards at the same time. Doing

    so may break the rear window glass,

    resulting in injury.

    Be careful not to allow the force of the

    spring to bring the seat back sharply

    forward.

    1. Raising your torso, sitting down firmly in

    the seat.

    2. Pulling lever (3) allows you to use the

    pressure of the springs in the seat pressing

    against your back to adjust the reclining

    angle of the seat back. Release the lever

    (3) at the desired angle and the seat back

    will be locked in that position.

    6

    1

    4

    3

    S2B024

    2

    5

    A

    D

    F

    C

    B

    E

    Seat and Seat Belt

  • 44

    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.

    Adjustment stroke: 17 steps,160 mm (5.9

    in.)

    (E) Weight adjustment

    1. Turn handle (5) and set it to indicate

    the weight of the person to operate the

    machine.

    May be set to any value from 50 to 120 kg

    (110 to 265 lbs.)

    (F) Lever stand adjustment

    1. Pull on lever (6) and slide the lever stand

    backward or forward to bring it to the

    optimum position for operating the

    machine.

    2. Release the lever at the desired position

    and the lever stand will remain fixed

    there.

    Adjustment stroke: 70mm (2.8 in.)

    6

    3

    L3B013

    2

    5

    4

    E

  • 45

    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. Pull the seat belt to the desired length.

    3. Make sure that the belt is not twisted and

    then insert the tongue plate (A) into the

    buckle (B) of the seat belt until you hear a

    clicking sound as it locks in place.

    Releasing the seat belt

    1. To remove the seat belt, simply press the

    button (C) located on the buckle.

    The seat belt is automatically stowed

    away.

    E4B023

    B

    A

    E4B024

    C

  • 46

    CONTROLS

    Instrument Cluster

    Warning Lamps

    IMPORTANT: If a warning lamp flashes

    and an alarm sounds, stop all operations

    immediately and inspect and maintain the

    appropriate part.

    Refer to pages 138 and 139 “If a Warning

    Lamp Flashes”.

    1. Engine Emergency Lamp

    This lamp flashes and an

    alarm sounds if the engine

    oil pressure drops or the

    coolant temperature rises

    abnormally while the engine is running.

    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.

    This lamp may flashes directly after the

    engine in started in cold weather. This is not

    a malfunction. The lamp will turn off as the

    engine warms up

    3. Battery Charge Warning Lamp

    This lamp flashes if a

    problem arises in the

    charging system while the

    engine is running.

    4. Engine Oil Pressure Warning Lamp

    This lamp flashes and

    an alarm sounds if the

    lubricant oil pressure drops

    abnormally while the engine

    is running.

    5. Coolant Temperature Warning Lamp

    This lamp flashes and an

    alarm sounds if the engine

    coolant temperature rises

    abnormally while the engine

    is running.

    6. Air Cleaner Warning Lamp

    This lamp flashes if the air

    cleaner filter is clogged

    while the engine is running.

    7. Water Separator Warning Lamp

    This lamp flashes if the water

    is detected within the water

    separator while the starter

    switch is in the ON position.

    G4B009

    C4B012

    C4B030

    G4B010

    L3B015

    C4B031

    T7B008

  • 47

    CONTROLS

    Indicators

    11. Travel Speed Lamp

    This lamp lights when the

    travel speed switch is set to

    2nd (high speed).

    12. Glow Lamp

    This lamp turns off when

    engine preheating is

    completed.

    13. Deceleration Lamp

    When the deceleration

    button is pressed or the

    engine speed is set to low

    idle, this lamp lights up to

    indicate.

    8. —

    9. Fuel Level Warning Lamp

    This lamp flashes when the

    fuel level is low while the

    starter switch is in the ON

    position.

    10. ECM Warning Lamp

    This lamp flashes and an

    alarm sounds if the ECM

    (Electronic Control Module)

    detects an engine problem

    when the starter switch is in the ON position.

    The LCD screen is interrupted with an ECM

    error code indicating the problem detected.

    L3B016

    C4B014

    C4B013

    Meters

    14. Water Temperature Gauge

    This gauge indicates the

    temperature of the engine

    coolant water.

    The lamps should be within

    the green range during machine operation.

    The red range indicates overheating.

    15. Fuel Gauge

    This gauge indicates the

    amount of fuel in the tank.

    Be sure to top off the tank

    before running out of fuel.

    Hour Meter

    This 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.

    G4B011

    Instrument Cluster

  • 48

    CONTROLS

    Instrument Cluster

    Multi-Data Display

    LCD

    Displays the Trip display on the hour meter

    or various data on the engine. If an error

    is detected, a corresponding error code is

    displayed interrupting the current process.

    IMPORTANT: If an error code appears,

    immediately stop the operation and

    contact a Takeuchi sales or service outlet

    for help.

    Display selection buttons

    The TRIP (1) button and the DATA button (2)

    are used to switch among displays.

    Displaying the user mode

    Used to display the operating time spent in

    each section.

    The display changes as the TRIP button (1)

    is pressed.

    1. TRIP-1

    2. TRIP-2

    3. TRIP-3

    4. Returns to the top screen.

    To reset the meter to “0”, display the way to

    be reset, and then press and hold the TRIP

    button.

    N2B008

    N2B009

    N2B010

  • 49

    CONTROLS

    Instrument Cluster

    Displaying the data mode

    The display changes as the DATA button (2)

    is pressed.

    1. Engine revolution

    2. Battery voltage

    3. Error code

    Displays five error codes, with the latest

    code in the left.

    Refer to page 140 “Error Code List”.

    4. Engine ECM error code

    Displays three error codes, with the latest

    code in the left.

    IMPORTANT: If an error code appears,

    immediately stop the operation and

    contact a Takeuchi sales or service outlet

    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.

    6. Engine model

    7. Engine serial number

    8. Engine controller part number

    9. Software version control number

    10. Returns to the top screen.

    N2B011

    N2B012

    N2B013

    N2B014

  • 50

    CONTROLS

    Instrument Cluster

    Dump Body Alignment Indicator

    This lamp lights when the orientation of the

    dump body is parallel with the main frame.

    The lamp is off when the dump body swings

    left or right.

    Dump Body Raising Indicator

    This lamp lights when the dump body is

    raised and moves out of the sensor’s range.

    It goes out when the dump body is lowered

    all the way down.

  • 51

    CONTROLS

    Switches

    Starter Switch

    IMPORTANT: Do not repeatedly switch

    the key from OFF to ON and ON to OFF

    over a short period. Doing so will cause

    engine breakdown.

    OFF ..........Position for stopping the engine

    and inserting or removing the

    key.

    ON ........... Position in which the engine

    is running. At this position,

    all the electrical equipment is

    functional.

    When the coolant temperature is

    low, the glow plugs are energized

    and automatic preheating is

    done.

    START ...... Position for starting the engine.

    When the key is released, the

    switch automatically returns to

    the ON position.

    Engine Shutdown Switch

    Use to shutdown the engine if it fails to stop

    when the starter switch is set to the OFF

    position due to machine failure or breakage.

    1. Lift the front part of the cover (1).

    2. Raise the lever (2) of the switch.

    3. After use, lower the front part of the cover

    (1) to return the lever (2) to the lower

    position.

    L3B043

    START

    ON

    OFF

    Throttle Controller

    This controls the engine speed.

    (A) .......Low idling

    (B) .......Middle speed

    (C) .......Maximum speed

  • 52

    CONTROLS

    Switches

    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.

    Pressing the button will cause the pilot lamp

    to light and there will be a forced application

    of the parking brake.

    ON (Lamp is lit)

    ..........Forced operation of the parking brake

    OFF (Lamp is not lit)

    .... Automatic operation of the parking brake

    Even when the button is OFF, it is normal for

    the parking brake to operate automatically

    when travel is stopped.

    S2B013

    A

    B

    S2B012

    S2B023

    Horn Switch

    Press the switch to activate the horn.

    Turn Switch

    Press the left button (A) on this switch to blink

    the left turn light and press the right button

    (B) to blink the right turn light.

    An alarm sounds while either button is

    pressed.

  • 53

    CONTROLS

    Travel Speed Switch

    Press this switch to set the travel speed

    to 2nd speed (high speed). Press again to

    return to 1st speed (low speed).

    Light Switch

    When this switch is turned while the starter

    switch is at ON, the lights turn on as follows :

    O .........Off

    I ..........Front lights, rear light and meter light

    turn on.

    Switches

    Wiper Switch

    IMPORTANT: If no washer fluid is

    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.

    IMPORTANT: In cold seasons, the wiper

    blade may freeze to the glass. Operating

    the wiper forcibly may damage the wiper

    motor.

    O .............. Off

    I ............... Wiper operates.

    PUSH ....... Washer fluid is squirted from the

    nozzle while pressed, and stops

    when released.

    S2B014

    L3B028

    L3B029

    PUSH

  • 54

    CONTROLS

    Levers

    Control Levers

    WARNING

    Be careful to check which pattern of lever

    control arrangement you are operating

    with before beginning operations.

    1. Right Control Lever

    Use the right control lever to operate the

    dump body.

    Refer to page 73 “Operating the Dump

    Body”.

    2. Left Control Lever

    Use the left control lever to travel the

    machine.

    Refer to page 70 “Traveling the

    Machine”.

    Safety Lock Lever

    WARNING

     Before leaving the operator’s seat, set

    the safety lock lever to the lock position

    and stop the engine. 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.

    Be careful not to touch the control

    levers when raising and lowering the

    safety lock lever.

    This device is for locking the dump body

    movement and machine travel.

    When the lever is lifted and the lever stand

    springs up, the control levers are locked.

    S2B015

    S2B017

    2

    1

  • 55

    CONTROLS

    Accessories

    Heater

    WARNING

     Always be sure to allow sufficient

    ventilation.

    Do not place combustible or explosive

    objects near the air outlets.

    Fan Switch

    O .............. Off

    I ............... Heater fan rotates at low speed.

    II ............... Heater fan rotates at high speed.

    Heater / Defroster Lever

    Rec / Fresh Lever

    Use this switch to heat the cab and to defrost

    the windshield.

    ............Heater

    .............Windshield defroster

    ........... Fresh

    ............Half ventilation

    .............Recirculate

    Air Outlets

    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. Coolant circulates in the

    heater even when the heater switch is turned

    off.

    When the heater is no longer needed, stop

    coolant circulation as follows :

    IMPORTANT: Use the valve (1) either fully

    open or fully closed.

    1. Park on a flat surface and stop the

    engine.

    2. Fold the seat backrest forward.

    3. Close the valve (1).

    T8B002

    L3B038

    1

    S2B018

  • 56

    CONTROLS

    Accessories

    External Power Socket (for EU)

    WARNING

    Only use applicable electric products with

    these sockets.

    for Beacon

    Use these sockets as an external power

    supply. When using these sockets, be

    careful not to exceed 24V/5A.

    To use, raise the cap (1).

    Interior Light

    IMPORTANT: The battery capacity will

    decrease if the interior light is left on for

    long periods of time the engine stopped.

    Turn the light off when leaving the

    machine.

    OFF ..........Lamp is turned off all the time,

    with no regard for the door being

    opened or closed.

    Neutral ..... Lamp is turned on when the door

    is opened, and it turned off when

    the door is closed.

    ON ............ Lamp is turned on all the time,

    with no regard for the door being

    opened or closed.

    1

    N0C008

  • 57

    CONTROLS

    Accessories

    Cigarette Lighter

    WARNING

     Do not leave the cigarette lighter’s

    knob pressed in. Doing so heats up the

    lighter, and could be dangerous.

    If the knob does not pop out after 30

    seconds, it may be broken. Pull it out

    by hand.

    Do not use other cigarette lighters, as

    they may get stuck.

    Only use applicable electric products

    with this socket.

    Do not touch metal parts of the lighter.

    Doing so could cause burns.

    This is the cigarette lighter and internal power

    supply socket.

    When using this socket, be careful not to

    exceed 24V/5A.

    1. Press the lighter in.

    2. Release the lighter and wait for it to pop

    out. The lighter pops out automatically

    when the heater becomes red.

    3. Once the lighter pops out, pull it out.

    Ashtray

    WARNING

     Be sure to extinguish cigarettes and

    matches completely before putting

    them in the ashtray, and always close

    the ashtray afterwards.

    Do not overfill the ashtray with cigarette

    butts or put in paper or other easily

    burnable objects. Doing so could lead

    to fire.

    Pull the ashtray out towards you to use it.

    To clean, press the ash discharge button (1)

    and pull out the ashtray.

    L3B041

  • 58

    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.

    Be careful not to allow water or other liquids to come into contact with the radio. Doing so

    may result in it being rendered inoperable.

    Names of the components

    (1) POWER button

    Use this button to turn on or off the radio.

    (2) TONE control button

    Use this button to select the tone. Press

    the button to select low tone. The TONE

    LOW display appears on the LCD. Press the

    button again to select high tone.

    (3) LCD

    Displays the time/the receiving frequency

    and the operation mode.

    (4) CLOCK button

    Use this button to switch between the clock

    display and the receiving frequency display

    on the LCD. If this button is not pressed for

    six seconds while the frequency is displayed,

    the LCD returns to the clock display.

    (5) AST button

    Use this button to automatically seek the

    station information, store it into memory and

    assign each preset button (1 to 6) a station.

    (6) PRESET STATION buttons (1 to 6)

    Use these buttons to store station information.

    Each button can store information on one FM

    station and one AM station. For how to use

    these buttons, refer to “Presetting stations”.

    AUOC001

  • 59

    CONTROLS

    Accessories

    (7) TUNE button

    Use this button to tune to a radio station.

    Press and hold this button (

    or ) for

    two seconds or more to start seeking the

    audible stations. The seeking stops when a

    station is found. To cancel tuning in progress,

    press the button again.

    Pressing the

    button will start seeking

    stations with higher frequencies. Pressing

    the

    button will start seeking stations

    with lower frequency. The frequency will

    continuously be increased/decreased if the

    or button is held pressed.

    (8) BAND button

    Use this button to select FM or AM. The

    selected band and the receiving frequency

    will be displayed on the LCD.

    (9) VOL buttons

    Use these buttons to control the sound

    volume. Press the button

    to increase

    the volume and the button

    to decrease

    the sound volume. Press and hold each

    button to continuously increase/decrease

    the volume.

    (10) MUTE button

    Use this button to temporarily turn off the

    sound output. If pressed, the “mute is on”

    mark

    appears on the LCD. Press this

    button again to cancel mute.

    (11) ZERO button

    Use this button to set the minute to “00”

    when it is between “55” and “59” or “01”

    and “05”.

    (12) AUX button

    Use this button to choose which to listen

    to, the radio or the external audio source

    connected to the AUX-IN. If the external

    source is chosen, the AUX display appears

    on the LCD.

    (13) AUX-IN jack

    Use this jack to connect an external audio

    source. Pull off the rubber cap and plug the

    stereo mini-plug of the external audio device

    into this jack. Be sure that the jack is closed

    with the rubber cap when not in use.

    Playing the radio

    1. Turn the ignition key to the ACC or ON

    position, and then press the power button

    (1) to turn on the radio.

    2. Select the band FM or AM with the band

    button.

    3. Select the station with the preset button or

    the tuning button, and adjust the volume

    with the volume button.

    4. To turn off the radio, press the power

    button.

    Selecting a station — auto select

    Press and hold the tune button

    for two

    seconds or more to start seeking stations

    in the higher frequencies direction. Press

    and hold the button

    for two seconds or

    more to start seeking stations in the lower

    frequencies direction. The radio will stop

    seeking when it finds an audible station and

    start playing.

    Selecting a station — manual select

    The selection can be done manually. Press

    the tune

    button to seek stations with

    higher frequencies. Press the tune

    button

    to seek stations with lower frequencies.

    Presetting stations

    1. Select the band (FM or AM) and the station

    you want to preset.

    2. To set the selected station to a preset

    button, choose the button to be set and

    then press and hold the button for three

    seconds or more. The number of the

    preset button chosen appears on the

    LCD.

  • 60

    CONTROLS

    Accessories

    3. For more stations, repeat the steps (1) and

    (2) above.

    If the preset button on which a station

    has been set to is pressed and held

    for two seconds or more, the preset

    information will be modified.

    If the stored information is erased

    during battery replacement on the

    vehicle, set the stations again to the

    preset buttons.

    Each preset button can store

    information on one FM station and one

    AM station.

    Auto storing

    Press the AST button for two seconds or

    more while playing the radio. The radio

    starts seeking the audible stations within the

    band selected, store the information on the

    stations obtained into memory, and assign

    each preset button (1 to 6) a station. Note:

    The previous station setting stored in memory

    will be overwritten. If the arrangement of the

    preset buttons to the corresponding stations

    is not desirable, try the “Presetting stations”

    described above.

    AUX audio connection

    Connect a favorite headphone stereo set

    to enjoy music on the radio, or connect

    a portable audio player and listen to your

    favorite music.

    Plug a patch cord (without resistor) into

    the headphone jack of the audio player.

    Plug a stereo mini plug (3.5 mm) into the

    AUX-IN jack on the radio.

    To listen to the audio player, press the AUX

    button. (The AUX display appears and the

    frequency display is changed to the clock

    display.)

    To return to the radio, press the AUX

    button again.

    When connecting, adjust the sound

    volume level of the audio player so that it

    is same as that of the radio.

    Adjust the sound volume of the audio

    player by using the volume control buttons

    on the radio.

    Do not connect a device with a larger

    output compared with a portable audio

    player.

    Setting the clock time

    Be sure that the time is displayed on

    the LCD. If not, press the AUX button to

    display the time.

    Use the tune button to set the minute.

    Use the tune

    button to set the hour.

    To set the minute digits to “00” when they

    are from “55” to “59” or from “01” to “05”,

    press the ZERO button.

    Resetting the radio

    If there are any problems, such as the

    abnormal display of frequency or failure of

    selection, reset the radio by pressing the

    power button and the ZERO button together.

    Note that the memory containing the clock

    setting and the channel setting is cleared

    after reset.

    AUOC002

  • 61

    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

    92 (D) mm (without

    projections)

    Receiving frequency : MW (AM) 522 to

    1629 kHz

    FM 76.1 to

    89.9 MHz

    Practical sensitivity : MW (AM) 20 µV

    (S/N 20 dB)

    FM 3 µV

    (S/N 30 dB)

    S/N ratio : FM 50 dB

    AUX IN : Stereo mini jack

    (3.5 mm); max.

    input, 1 V; rated

    input, 90 mV

    Note: Specifications and dimensions may

    be changed without notice.

  • 62

  • 63

    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

    OPERATION

  • 64

    OPERATION

    Before Starting Operation

    Walk-Around Inspection

    Perform the walk-around inspections once a

    day before starting the engine the first time

    that day.

    Perform the inspections as described under

    “Maintenance - Walk-Around Inspection”

    (pages 98 and 99).

    Daily Inspection

    Perform the daily inspections once a day

    before starting the engine the first time that

    day.

    Perform the inspections as described under

    “Maintenance - Daily Inspection” (pages 100

    to 104).

    Mounting and Dismounting

    WARNING

     Do not jump on or off the machine.

    Never attempt to mount or dismount a

    moving machine.

    When mounting and dismounting the

    cab, first open the door fully to the

    locked position and check that it does

    not move.

    Always face the access system and

    maintain a three point contact with

    the recommended handrails and steps

    while getting on and off the machine.

    Keep steps and platform clean.

    Never use the safety lock lever or

    control levers as hand holds.

    S2D001

  • 65

    OPERATION

    Before Starting Operation

    Before Starting the Engine

    1. Adjust the seat for a comfortable operating

    position.

    2. Fasten your seat belt.

    3. Check that the safety lock lever is in the

    locked position.

    4. Check that the control levers are in the

    neutral position.

    5. Insert the key into the starter switch, turn

    it to the ON position, then perform the

    following inspection :

    • All the warning lamps flash and an alarm

    sounds for 2 seconds. The meters also

    start functioning. After 2 seconds, only

    the battery charge warning lamp (3) and

    engine oil pressure warning lamp (4)

    flash, and the other lamps turn off.

    • Turn the light switch to check that the

    front lights, rear light and meter light turn

    on.

    • Operate the turn switch and check

    whether the turn lights flash and the

    alarm sounds.

    • Press the horn switch to check that the

    horn sounds.

    • Check the fuel level.

    If a lamp does not light or the alarm does not

    sound, the bulb may be burnt out or a wire

    may be damaged. Contact a Takeuchi sales

    or service outlet for repairs.

    S2B015

    S2D002

    OFF

    ON

    START

    L3D001

  • 66

    OPERATION

    Starting and Stopping the Engine

    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.

    If the engine fails to start, wait for 30

    seconds to protect the battery, and then

    try again to start the engine.

    Normal Starting

    1. Turn the throttle controller to the middle

    position.

    2. Turn the key to the START position and

    start the engine.

    3. Once the engine starts, release the key.

    The key automatically returns to the ON

    position.

    4. Check that the warning lamps are off.

    5. Return the throttle lever and warm up the

    engine.

    Refer to page 67 “Warming Up the

    Engine”.

    Starting in Cold Weather

    1. Make sure that the glow lamp (12) is lit.

    (The glow lamp lights for 8 seconds when

    coolant temperature is -10°C (14F°)

    2. Turn the throttle controller to the middle

    position.

    3. After the glow lamp (12) turns off, then

    turn it to the START position and start the

    engine.

    4. Once the engine starts, release the key.

    The key automatically returns to the ON

    position.

    5. Check that the warning lamps are off.

    6. Return the throttle lever and warm up the

    engine.

    Refer to page 67 “Warming Up the

    Engine”.

    OFF

    ON

    START

    L3D003

    OFF

    ON

    START

    L3D003

  • 67

    OPERATION

    Starting and Stopping the Engine

    Stopping the Engine

    IMPORTANT: Do not stop the engine

    suddenly when operating with heavy

    loads or at maximum speed. Doing so

    may cause the engine to overheat or seize.

    Never bring the engine to a sudden stop

    except in the case of a true emergency.

    1. Return the throttle controller.

    2. Low idle the engine for about 5 minutes to

    gradually let it cool.

    3. Turn the key to the OFF position to stop

    the engine.

    Warming Up the Engine

    IMPORTANT: Avoid racing the engine

    until it is warmed up.

    Do not warm up the engine for long

    periods of time (20 minutes or more).

    1. Return the throttle controller, then idle the

    engine and run it for about 5 minutes with

    no load.

    OFF

    ON

    START

    L3D007

  • 68

    OPERATION

    Machine Operation

    Lever Pattern

    Crawler Forward

    Crawler Reverse

    Left Spin T

    urn

    Right Spin Turn

    Left Pivot Turn

    Right Pivot Turn

    Right Pivot Turn Reverse

    Left Pivot Turn Reverse

    Dump body Lower

    Dump body Dump

    Dump body Swing Left

    Dump body Swing Right

  • 69

    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

    the equipment may move in unexpected

    ways. Be sure to sufficiently warm up the

    machine.

    IMPORTANT: Do not operate the

    levers suddenly when the hydraulic oil

    temperature is below 20°C (68°F). The

    proper hydraulic oil temperature during

    operation is 50 to 80°C (122 to 176°F), but

    if operations must be performed at lower

    temperatures, warm up the hydraulic oil

    to at least 20°C (68°F).

    Normal Warm-up

    1. Run the engine at medium speed for

    about 5 minutes with no load.

    2. Set the safety lock lever to the released

    position.

    3. Extend and retract the dump cylinders

    several times with no load.

    4. Slowly swing the dump body several

    times.

    5. Slowly travel forward and backward

    several times.

    Warming Up in Cold Weather

    1. Perform the normal warm-up procedure.

    2. Set the dump cylinders at the stroke end

    and keep them there.

    Do not do this for more than 30 seconds.

    3. Repeat step 2 until the dump body

    operating speed is normal.

    S2D007

    S2D008

    S2D009

    S2D010

  • 70

    OPERATION

    Traveling the Machine

    WARNING

     Never allow anyone to enter the

    machine working range and machine

    path.

    Signal your intention to move by

    sounding the horn.

    There are blind spots to the rear of the

    machine. Check that the area is safe

    and clear.

    Remove any obstacles in the machine’s

    path.

    1. Increase the engine speed.

    2. Set the safety lock lever to the released

    position.

    Machine Operation

    Inspection After Warm-up

    After warming up the engine and hydraulic

    oil, perform the checks and inspections

    described below, and repair if there is a

    problem.

    1. Check that the warning lamps and meters

    are as follows :

    • Are all the warning lamps off?

    • Is the water temperature gauge showing

    within the green range?

    2. Check that there are no irregularities in the

    exhaust color, sound and vibrations.

    3. Set the safety lock lever to the locked

    position and check that the control levers

    are locked.

    S2B015

    S2D007

  • 71

    OPERATION

    Machine Operation

    3. Make sure that the dump body is lowered

    and is parallel to the main frame.

    4. Operate the left control lever to control

    foward and reverse travel and turning of

    the machine.

    Foward and Reverse Travel

    To move forward :

    Push the left control lever forward.

    To move backward :

    Pull the left control lever backward.

    Left Turn

    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

    To turn right while traveling forward :

    Move the left control lever forward to the

    right.

    To turn right while traveling backward :

    Move the left control lever backward to

    the left.

    Spin Turn

    To spin left :

    Move the left control lever to the left.

    To spin right :

    Move the left control lever to the right.

    S2D011

    S2D012

    S2D013

    S2D014

    S2D015

  • 72

    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.

    CAUTION

    Never bring the machine to a sudden stop

    except in the case of a true emergency.

    Stop as gently as possible.

    1. Move the left control lever to the neutral

    position. The machine stops.

    S2D016

  • 73

    OPERATION

    Machine Operation

    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.

    Lower the dump body and make it

    parallel with the main frame.

    Use the right control lever to operate the

    dump body.

    Return the lever to the neutral position to

    stop the dump body.

    Swing

    To swing left :

    Move the right control lever to the right.

    To swing right :

    Move the right control lever to the left.

    Dump and Lower

    To lower the dump body :

    Push the right control lever forward.

    To dump the dump body :

    Pull the right control lever backward.

    S2D017

    S2D018

  • 74

    OPERATION

    Operating Procedures

    Cautions on Operating

    Cautions on Traveling

    Traveling over obstacles (rocks, stumps,

    etc.) may subject the body to strong shocks

    and result in damage. Avoid traveling over

    obstacles whenever possible. If you must

    do so, travel at low speed, and go over the

    obstacle at the center of the crawler.

    Cautions on Traveling in 2nd (High)

    Speed

    On uneven ground, travel at low speed and

    avoid accelerating, stopping or changing

    directions abruptly.

    Precautions When Loading the Dump

    Body

    Do not allow loading the dump body unless

    the driver and personnel are in a sage place.

    Load on a firm location, do not load on a

    slope. Improper loading can be the cause of

    the machine tipping over or the load giving

    way.

    Do not exceed the maximum weight when

    loading.

    Do not load unevenly, load so as to

    distribute the load evenly on the dump

    body.

    A load with poor stability should be

    securely fixed to the dump body.

    Precautions When Dumping

    Do not dump in any of the following manners.

    The center of balance will shift and the

    machine could tip over.

    Dumping on a slope or bumpy location.

    Dumping while swinging the dump body.

    Dumping while traveling.

    S2A010

    S2D019

    S2A015

    S2A016

  • 75

    OPERATION

    Operating Procedures

    Cautions on Use in Water

    If you enter water at a sharp angle, the front

    of the machine may be submerged, exposing

    the radiator fan to water and damaging

    them. Do not let the front of the machine get

    submerged.

    Allowable water depth

    In water, only use the machine up to a

    depth at which the water comes up to the

    center part of the travel reduction gear

    case.

    When greasing places used under water

    for long periods of time, apply enough

    grease so that the old grease is expelled.

    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.

    S2D020

    S5D009

  • 76

    OPERATION

    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

    are poor the machine’s stability may be

    lower.

    When going up or down slopes having

    a gradient of 15 degrees or more, travel

    up and down the slope with the heavy

    end of the dump carrier pointed uphill.

    Travel at slow speed on slopes.

    Especially when going down slopes,

    reduce the engine (r.p.m.) speed and

    set the stroke of the travel lever to

    half or less before going down. Going

    down a slope too fast will lead to loss

    of control.

    Sudden stopping on slopes may lead

    to loss of balance of the vehicle and it

    could tip over.

    Traveling across an inclined surface at

    an angle or traveling straight across an

    inclined surface could result in slipping

    sideways or tipping over. Travel straight

    up and down the slope.

    Operating Procedures

     Do not change directions or cross

    slopes sideways. First return to a flat

    surface then redirect the machine.

    On grass, dead leaves, wet metal or

    frozen surfaces, the machine may slide

    sideways even on very gentle slopes.

    Make sure the machine never faces

    sideways with respect to the slope.

    S2A011

    S2A012E

  • 77

    OPERATION

    Parking the Machine

    Inspection and Checks After

    Stopping the Engine

    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”.

    3. Remove any paper scraps or dirt from the

    engine room.

    4. Remove any mud from the machine.

    Locking

    Be sure to lock the following places :

    Cab door

    Fuel filler cap

    Engine hood

    Side cover

    Battery cover

    Parking

    WARNING

     Park the machine on firm, level ground.

    If you must park on a slope or incline,

    block the machine securely to prevent

    movement.

    Before leaving the operator’s seat, set

    the safety lock lever to the lock position

    and stop the engine. 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.

    1. Set the left control controller to the neutral

    position.

    2. Return the throttle controller and idle the

    engine at low speed.

    3. Place the safety lock lever to the lock

    position.

    4. Stop the engine and remove the key.

    Refer to page 67 “Stopping the Engine”.

    S2A020

  • 78

    OPERATION

    Handling in Cold Weather

    Cautions after Completing

    Operations

    Heed the following in order to prevent dirt,

    water, or other objects stuck on the machine

    as well as the lower frame from freezing :

    Remove any dirt or water from the body.

    In particular, water droplets on the

    hydraulic cylinder rod surfaces could

    freeze, and if dirt enters into the seals

    along with this, the seals could break.

    Park the machine on a dry, hard surface.

    If no appropriate place can be found, put

    boards down and park the machine on

    them.

    Drain any water from the fuel tank to

    prevent freezing.

    Refer to page 112 “Draining the Fuel

    Tank”.

    To prevent decreased battery performance,

    place a cover over the battery or remove

    it from the machine and store it in a warm

    place.

    Also add battery fluid before starting the

    next morning. If battery fluid is added

    after completing operations, the distilled

    water may not mix, resulting in freezing.

    After Cold Weather is Over

    Perform the following after cold weather is

    over :

    Change the fuel and the oils for the

    different devices with those specified on

    the Fuel and Lubricant Chart.

    Refer to page 90 “Lubricant and Fuel

    Chart”.

    When using one-season type antifreeze

    coolant, completely drain the antifreeze

    coolant, carefully clean the inside of the

    coolant system, then add tap water.

    Refer to page 120 “Cleaning the Engine

    Cooling System”.

    Preparing for Cold Weather

    In cold weather, it may be difficult to start the

    engine and the coolant may freeze. Make

    the preparations described below.

    Changing the Lubricant and Fuel

    Change the fuel, hydraulic oil and engine oil

    to types suited for cold conditions.

    Refer to page 90 “Lubricant and Fuel

    Chart”.

    Engine Coolant

    WARNING

    The coolant is combustible. Keep flames

    away.

    Use long-life coolant (antifreeze) and tap

    water for the engine coolant.

    Supplement: New machine are delivered

    with JIS Type 2 long-life coolant (antifreeze)

    at a concentration of 50%.

    Refer to page 90 “Lubricant and Fuel

    Chart”.

    Battery

    As the temperature drops, the battery

    performance decreases.

    Inspect the battery. If the charge is low,

    contact a Takeuchi sales or service outlet to

    have the battery charged.

    Refer to page 110 “Inspecting the Battery

    Fluid Level and Replenishing”.

  • 79

    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

    Do not travel or operate the machine in the

    following places :

    Traveling on broken stone, jagged base

    rock, iron rods, iron scraps or the edges

    of iron sheets may damage or cut the

    crawlers.

    Traveling on riverbeds or places with many

    soft rocks may cause the crawlers to slip

    off or be damaged due to rocks getting

    stuck in them.

    Do not use on the seashore. The salt may

    corrode the metal cores.

    Do not let fuel, oil, salt or chemical solvents

    get on the crawlers. These substances

    may corrode the couplings of the crawlers’

    metal cores, resulting in rust or peeling.

    If these substances should get on the

    crawlers, wipe them off immediately using

    water.

    Traveling on roads directly after asphalting

    or on hot surfaces such as over fires or

    on iron sheets under strong sunlight may

    result in irregular wear or damage of the

    lugs.

    Do not move earth in places where the

    rubber crawlers may slip. Doing so may

    speed up lug wear.

    S2D022

    S2D023

    S2D024

    S2D025

  • 80

    OPERATION

    Handling Rubber Crawlers

    Cautions

    Heed the following cautions when operating

    the machine :

    Avoid changing course abruptly and

    spinning on concrete surfaces whenever

    possible.

    Doing so may wear or damage the rubber

    crawlers.

    Avoid drops that may expose the rubber

    crawlers to strong shocks.

    Salt, potassium chloride, ammonium

    sulfate, potassium sulfate, and triple

    superphosphate of lime can damage the

    crawler belts. If any of these substances

    should get on the crawler belts, wash

    them off thoroughly with water.

    Do not let the sides of the rubber crawlers

    rub against concrete or walls.

    Be especially careful in the winter on

    snowy or frozen surfaces as the crawler

    belts tend to slip.

    Use rubber crawler belts at temperatures

    between – 25°C to + 55°C (– 14°F to

    131°F).

    When storing the rubber crawlers for long

    periods of time (3 months or more), do so

    indoors in a place not exposed to direct

    sunlight or rain.

    Rubber crawler belts are not as stable as

    steel crawler belts since the entire lug is

    rubber. Be very careful when swinging the

    dump body sideways.

    Preventing the Rubber Crawlers from

    Slipping Off

    Heed the following in order to prevent the

    rubber crawlers from slipping off :

    Always keep the crawlers at the proper

    tension.

    When traveling up large cobblestone or

    rock steps (20 cm (8 in.) or greater), climb

    up the step at a direct angle and do not

    change course on top of the step.

    When climbing in reverse, do not change

    course at the point where the slope

    starts.

    S2D026

    S2D027

    S2D028

  • 81

    OPERATION

    Handling Rubber Crawlers

     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.

    Do not change directions when the crawler

    belts are slack as shown in the diagram.

    S2D029

  • 82

  • 83

    TRANSPORT

    Loading and Unloading ..................................84

    Hoisting the Machine .....................................85

    Securing the Machine ....................................86

  • 84

    TRANSPORT

    Loading and Unloading

    1. Apply the truck’s parking brake and place

    stoppers against its tires.

    2. Fasten the ramps securely to the truck

    bed so that they will not come off. Set the

    ramps to an angle of 15° or less.

    3. Line up the center of the truck bed with

    the center of the machine and the center

    of the ramps with the center of the

    crawlers.

    4. Lower the engine speed.

    5. Determine the direction on the ramps,

    then slowly travel up or down the ramps

    in 1st speed (low speed), following the

    signals of a flagman.

    6. Load the machine properly at the

    prescribed position on the bed.

    Refer to page 81 “Transporting Posture”.

    WARNING

    The machine may roll or tip over or fall

    while loading or unloading it. Take the

    following precautions :

    Select a firm, level surface and

    keep sufficient distance from road

    shoulders.

    Use loading ramps of adequate

    strength and size. Maintain the slope

    of loading ramps within 15 degrees.

    Keep the truck bed and loading ramps

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

    materials which can become slippery.

    Clean the tracks.

    Never change course on the ramp.

    Do not raise and / or swing the dump

    body on the ramps and truck bed. The

    machine may tip over.

    When loading or unloading the machine,

    be sure to use ramps and following the

    procedure below.

    E4F001

    Fasten to the suspension fitting

    Ramp

    15° or less

    Distance between ramps

    Stopper

    S2F001

    86

  • 85

    TRANSPORT

    Hoisting the Machine

    WARNING

     Know and use correct crane signals.

    Inspect the hoisting equipment daily

    for damaged or missing parts.

    When hoisting, use a wire rope with

    sufficient strength with respect to the

    machine’s weight.

    Do not hoist with the machine in a

    posture other than the one described

    in the procedure below. Doing so

    is dangerous as it may result in the

    machine losing its balance.

    Do not hoist the machine with an

    operator (s) on it.

    When hoisting, hoist slowly so that the

    machine does not tip.

    Keep all other persons out of the

    area when hoisting. Do not move

    the machine over the heads of the

    persons.

    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

    Hoisting

    1. Lower the dump body all the way down.

    2. Align the crawler frame in parallel with the

    dump body.

    3. Raise the safety lock lever to engage the

    lock.

    4. Stop the engine and remove the starter

    key and get off the machine.

    5. Install the sling as shown on the diagram

    below.

    Suspend in such a way that the sling and

    Lifting tool do not touch the body.

    6. Set the sling angle to 33° and hoist slowly

    until the machine just leaves the ground.

    7. Stop hoisting until the machine is stable

    and hoist slowly.

  • 86

    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

    key.

    2. Set the safety lock lever securely to the

    locked position.

    3. Set stoppers in front and behind the

    crawlers.

    4. Put a chain or wire rope over the machine

    and fasten it securely to prevent sideways

    slippage.

    Cautions on Transporting

    WARNING

     Know and follow the safety rules,

    vehicle code and traffic laws when

    transporting the machine.

    Consider the length, width, height and

    weight of the truck with the machine

    loaded on it when determining the best

    route.

  • 87

    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

    When Required ..............................................125

    Long-term Storage .......................................130

  • 88

    MAINTENANCE

    General

    Cautions on Maintenance

    Do not perform inspection and maintenance

    procedures not prescribed in this manual.

    Have inspection and maintenance

    procedures not prescribed in this manual

    performed by a Takeuchi sales or service

    outlet.

    Always keep the machine clean.

    Always keep the machine clean, and

    wash it before performing inspection and

    maintenance.

    When washing the machine with water,

    stop the engine and cover the electrical

    system with plastic to protect it from

    water. Exposing the electrical system

    to water is dangerous and could result

    in short-circuits or malfunction. Do not

    wash the battery, sensors, connectors or

    the inside of the cab with water or steam.

    Fuel, lubricant and grease

    For fuels, lubricant and grease, follow the

    instructions on the “Fuel and Lubricant

    Chart”.

    Use pure fuels, lubricants and greases

    which do not contain water, and be

    careful to keep dirt out when changing or

    replenishing fuel, lubricant or grease.

    Store fuels, lubricants and greases in the

    prescribed places and in such a way that

    no water or dirt can get in them.

    Cautions on fueling

    If the port includes a strainer, do not

    remove the strainer when fueling.

    After fueling, be sure to securely tighten

    the cap, etc.

    Do not add more than the prescribed

    amount of fuel.

    Maintenance Description

    For long-term use of the machine under

    good conditions, perform the inspection and

    maintenance procedures properly and safely

    as recommended in this manual.

    The inspection and maintenance items are

    divided according to the machine’s total

    operating time (inspection and maintenance

    to be performed every 10 hours (walk-around

    and daily inspection), every 50 hours, every

    250 hours, etc.). Refer to the hour meter

    to determine when it is time to perform

    inspection and maintenance. Items for which

    it is not possible to determine the inspection

    and maintenance interval are included under

    “When Required”.

    When operating the machine in extremely

    harsh environments (with high dust levels

    or high temperatures), inspection and

    maintenance should be performed earlier

    than the times indicated on the Maintenance

    Chart.

  • 89

    MAINTENANCE

    Disposing of wastes

    Collect spent fluids from the machine

    in containers. Disposing of wastes

    irresponsibly damages the environment.

    Dispose of oil, fuel, cooling water, coolant,

    filters, batteries and other harmful

    substances as prescribed by law.

    Check after maintenance

    Gradually increase the engine speed from

    a low idle to maximum speed and check

    that there is no oil or water leaking from

    serviced parts.

    Operate all the operating levers and check

    that the machine is operating properly.

    Cautions on handling of battery cables

    Disconnect the battery cables (+,–) before

    working on the electrical system or doing

    any welding.

    Remove the negative (–) battery cable

    first.

    When reconnecting the battery, connect

    the negative (–) battery cable last.

    Do not disconnect the battery cables

    while the engine is running. Doing so

    could damage the electronic circuitry of

    the alternator and other parts.

    Do not clean parts with fuel.

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

    combustible cleaning agent.

    Keep dirt out.

    When mounting and removing parts, do so

    in a place where there is no dust, clean the

    working area and the part, and keep dirt

    out.

    Clean mounting surfaces.

    When mounting and removing parts, be sure

    that the surfaces of contact of the parts are

    clean. If the sealing grooves of the surface

    of contact are damaged, consult a Takeuchi

    sales or service outlet.

    Seals and split pins

    Replace removed seals and split pins with

    new ones.

    When mounting, be careful not to damage

    or twist the seal.

    Sealing tape

    When wrapping sealing tape around

    plugs, etc., remove any old sealing tape

    from the threads and clean the threads.

    Wrap the sealing tape tight, leaving 1 or 2

    threads at the tip free.

    General

    E4G001

    Sealing tape

    Leave 1 or 2 threads free

  • 90

    MAINTENANCE

    * : If the percentage of the traveling time within the total operating time is high, replace the

    gear oil earlier than the specified time.

    ** : For water, use tap water (soft). Do not use well or river water.

    When the ambient temperature drops below 0°C, add coolant (antifreeze). Follow the

    coolant manufacturer’s instructions to determine the mixture ratio.

    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.

    Whenever possible, use the same brand of lubricant as before. If changing with a different

    brand, replace the entire quantity – do not mix different brands.

    Lubricants and greases

    Part Type

    Type by temperature

    -22 -4 14 32 50 68 86

    104

    °F

    -30 -20 -10 0 10 20 30 40

    °C

    Replacement

    interval

    Capacity

    L (US. qt.)

    E

    ngine

    oil pan

    Diesel engine

    oil

    API-CF-4

    After first 50 hrs.

    Every 250 hrs.

    Upper limit:

    15 (15.9)

    Lower limit:

    9 (9.5)

    System: 57

    (15.1 US.gal.)

    Tank: 36

    (9.5 US.gal.)

    Hydraulic

    tank

    Antiwear

    hydraulic oil

    (Option:

    Biodegradable

    oil)

    Every 1000 hrs.

    Engine

    cooling

    system

    Coolant

    (water +

    coolant) **

    Every 1000 hrs.

    15 (15.9)

    Travel

    reduction

    gear

    Gear oil

    API-GL-4

    SAE 90

    A

    fter first 250

    hrs.*

    Every 1000 hrs.

    Slew

    bearing

    Dump body,

    Track roller

    Levers

    Lithium

    based

    grease

    EP-2

    NLGI No. 2

    Every 50 hrs.

    Daily or every

    10 hrs.

    When required

    As required

    2.6 (2.75)

    SAE 5W-20

    SAE 10W-30

    SAE 15W-40

    ISO VG32

    ISO VG46

    ISO VG68

    50% coolant mixture

    30% coolant mixture

  • 91

    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

    D975-94

    USA ISO 8217 DMX International

    EN590:96 European

    Union

    BS 2869-A1 or A2 United

    Kingdom

    Part Type

    Capacity

    L (US. gal.)

    Fuel tank Diesel fuel

    Use a clean, Quality fuel for good performance and

    optimum engine life.

    To prevent fuel flow problems in cold weather, use

    diesel fuel with pour point of at least -12°C (10°F)

    below the lowest expected ambient temperature.

    Minimum cetane number is 45. Low temperature

    or high altitude operation may require the use of

    fuel with a higher cetane number.

    The sulfur content must not exceed 0.5% by

    volume. Less than 0.05% is preferred. For

    electronically controlled EGR engines, use fuel

    with sulfur content of less than 0.05%.

    A higher sulfur content fuel may cause sulfuric

    acid corrosion in the cylinders of the engines.

    NEVER mix kerosene, used engine oil, or residual

    fuels with the diesel fuel.

    Poor quality fuel can reduce engine performance

    and / or cause engine damage.

    Fuel additives are not recommended. Some fuel

    additives may cause poor engine performance.

    100 (26.4)

  • 92

    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 After first 50 hrs.

    Every 500 hrs.

    15511-02103

    Pre fuel filter

    Every 500 hrs.

    Element 15520-02502

    Hydraulic oil return

    filter

    Cartridge After first 50 hrs.

    Every 1000 hrs.

    15510-00320

    Main fuel filter Element 898008-8400

    After first 50 hrs.

    Every 250 hrs.

    898018-8580Engine oil filter Element

    Every 1000 hrs. or after

    6 cleanings (whichever

    comes first)

    Air cleaner Primary (outer)

    Element

    F-10806016-F

    Secondary (Inner)

    Element

    F-10806015-F When the primary

    element is replaced

    Feed pump filter Repair kit 898071-4010

    898143-0410

  • 93

    MAINTENANCE

    Tools

    Service Data

    No. Part name Part No. Remarks

    1 Spanner

    16900-01012

    10-12

    2 S

    panner

    16900-01417

    14-17

    3 S

    crewdriver

    16902-20205

    (+) (-)

    4 F

    ilter wrench

    16919-03560

    5

    Monkey wrench

    16904-00250

    250 mm

    6 S

    panner

    16900-01922

    19-22

    7 S

    panner

    16900-02427

    24-27

    8 S

    panner

    16900-02730

    27-30

    9 S

    panner

    16900-03236

    32-36

    10 Spanner

    16901-00013

    13

    11 Spanner

    16901-00041

    41

    12 Spanner

    16909-00019

    19

    No. Part name Part No. Remarks

    13 Pliers

    16905-00200

    200 mm

    14 Hammer

    16903-00330

    3/4

    15 Hex. wrench

    16906-00250

    2.5 mm

    16 Hex. wrench

    16906-00500

    5 mm

    17 Hex. wrench

    16906-00600

    6 mm

    18 Hex. wrench

    16906-00800

    8 mm

    19 Hex. wrench

    16906-01000

    10 mm

    20 Hex. wrench

    16906-01200

    12 mm

    21 Grease gun

    16910-60600

    600 cc

    22 Tool case

    16914-00001

    23 Case

    16919-00001

  • 94

    MAINTENANCE

    Tightening Torques

    Nuts and Bolts (for ISO strength category 10.9)

    Tighten nuts and bolts at the torques shown on the table below, unless otherwise specified

    in the text.

    Tightening torques when mounting plastic covers differ from the values on the table below.

    Consult a Takeuchi sales or service outlet. Tightening too strongly will break the cover.

    When replacing nuts and bolts, replace them with nuts and bolts of the same size and

    standards.

    Tighten nuts and bolts alternately (top, bottom, left then right) or in 2 or 3 times so that they

    are tightened uniformly.

    Service Data

    Thread

    Coarse

    Fine

    10 M6 X 1.0 9.8 ± 0.5 7.2 ± 0.4

    12, 13 M8 X 1.25 22.6 ± 1.1 16.6 ± 0.8

    14, 17 M10 X 1.5 47.1 ± 2.4 34.7 ± 1.7

    17, 19 M12 X 1.75 83.4 ± 4.1 61.5 ± 3.0

    19, 22 M14 X 2.0 134.4 ± 6.7 99.1 ± 4.9

    22, 24 M16 X 2.0 207.9 ± 10.4 153.3 ± 7.7

    27, 30 M20 X 2.5 410.9 ± 20.5 303.1 ± 15.1

    12, 13 M8 X 1.0 24.5 ± 1.2 18.1 ± 0.9

    14, 17 M10 X 1.25 50 ± 2.5 36.9 ± 1.8

    17, 19 M12 X 1.5 87.3 ± 4.3 64.4 ± 3.2

    19, 22 M14 X 1.5 135.3 ± 6.8 99.8 ± 5.0

    22, 24 M16 X 1.5 220.6 ± 11 162.7 ± 8.1

    27, 30 M20 X 1.5 452.1 ± 22.6 333.4 ± 16.6

    mm

    N·m ft-lb

    Head width

    (b)

    Size (a) X Pitch

    T

    orque

    General Connection Points

    mm

    E4G003

    1

    6

    4

    2

    5

    3

  • 95

    MAINTENANCE

    Important Parts

    For safe use, the machine must be serviced periodically. To increase safety, periodically replace

    the parts listed in the following table of important parts.

    Serious injury or a fire could result if they deteriorate or are damaged.

    Table of Important Parts

    Above important parts are vulnerable to aging and wear or deterioration and it is difficult to

    determine the degree to which they have deteriorated on the occasion of periodic service. To

    maintain their proper function at all times, therefore, replace them with new ones after using

    them for a specific period of time even if no abnormality is found with the parts. If you find

    abnormalities in these parts before their scheduled replacement time is reached, repair or

    replace them immediately. If a hose clamp is deformed or cracked, replace it immediately.

    When replacing the important parts, please contact a Takeuchi sales or service outlet .

    Also check the hydraulic hoses other than the above important parts. If any abnormality is

    found in them, retighten them or replace them immediately.

    When replacing the hydraulic hoses, replace the O-rings and seals at the same time.

    Check the fuel and hydraulic hoses according to the periodic schedule described below.

    Refer to “Maintenance”.

    Daily inspection Leakages from joints, hydraulic or fuel hoses.

    Monthly inspection

    Leakages from joints, hydraulic or fuel hoses.

    Damaged hydraulic or fuel hoses (cracks, wear and tear).

    Annual inspection

    Leakages from joints, hydraulic or fuel hoses.

    Deteriorated, twisted, damaged hydraulic or fuel hoses (cracks,

    wear and tear) or hoses in contact with other parts of the machine.

    Type of inspection Inspection item

    Unit Important parts to be replaced periodically

    Replacement Interval

    Fuel hoses

    Packing in fuel filler cap

    Heater hoses

    Air conditioner hoses

    Hydraulic hoses ( Pump - delivery )

    Hydraulic hoses ( Pump - suction )

    Hydraulic hoses ( Swing motor )

    Hydraulic hoses ( T

    ravel motor )

    Hydraulic hoses ( Dump cylinder )

    Hydraulic hoses ( Tension cylinder )

    Hydraulic hoses ( Pilot valve )

    Seat belt

    Fuel system

    Heater & AC systems

    Every 2 years

    Every 3 years

    Hydraulic system

  • 96

    MAINTENANCE

    Maintenance Chart

    Maintenance Items See page

    Walk-Around Inspection

    Inspecting by opening the engine hood and covers 98

    Inspecting by walking around the machine 99

    Inspecting while sitting in the operator’s seat 99

    Daily Inspection (Every 10 Hours)

    Inspecting and replenishing the coolant 100

    Inspecting and replenishing the engine oil 101

    Inspecting the water separator and the fuel filters 102

    Inspecting the fuel level 102

    Inspecting the hydraulic oil level and replenishing 103

    Lubricating the dump body and track rollers 104

    After First 50 Hours (New Machines Only)

    Replacing the pilot line filter 105

    Replacing the hydraulic oil return filter 106

    Inspecting and adjusting the fan belt 107

    Replacing the engine oil and oil filter 108

    Every 50 Hours

    Inspecting the crawler tension 110

    Inspecting the battery fluid level and replenishing 110

    Draining the fuel tank 112

    After First 250 Hours (New Machines Only)

    Replacing the travel motor gear oil* 113

    Every 250 Hours

    Cleaning the air cleaner 114

    Lubricating the swing bearing 115

    Cleaning the radiator fins and oil cooler fins 116

    Inspecting and adjusting the fan belt 116

    *: If the percentage of the traveling time within the total operating time is high, replace the gear

    oil earlier than the specified time.

  • 97

    MAINTENANCE

    Maintenance Chart

    Maintenance Items See page

    Every 500 Hours

    Replacing the fuel filters 117

    Replacing the feed pump filter 118

    Replacing the pilot line filter 119

    Replacing the engine oil and oil filter 119

    Every 1000 Hours

    Cleaning the engine cooling system 120

    Replacing the air cleaner elements 121

    Replacing the hydraulic oil and cleaning the suction strainer 122

    Replacing the hydraulic oil return filter 124

    Replacing the travel motor gear oil* 124

    Inspecting and adjusting the engine valve clearance 124

    Inspecting the engine compression pressure 124

    Inspecting the starter and alternator 124

    IInspecting the radiator cap 124

    When Required

    Inspecting and replenishing the windshield washer fluid 125

    Lubricating the levers 126

    Inspecting the rubber crawlers 127

    Replacing the rubber crawlers 128

    *: If the percentage of the traveling time within the total operating time is high, replace the gear

    oil earlier than the specified time.

  • 98

    MAINTENANCE

    Walk-Around Inspection

    Inspecting by Opening the Engine

    Hood and Covers

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

    combustible materials around the engine

    and battery.

    2. Check for oil or engine coolant water

    leakage around the engine.

    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.

    Before starting the engine, look around the machine and lower body, clean any combustible

    materials off high temperature parts of the engine, and inspect for such irregularities as oil

    leakage, water leakage and looseness of nuts and bolts.

  • 99

    MAINTENANCE

    Walk-Around Inspection

    Inspecting While Sitting in the

    Operator’s Seat

    12. Check the windshield for dirt or

    damage.

    13. Check the seat and seat belt for dirt or

    damage.

    Check the operator’s seat for dirt, oil or

    other combustible materials.

    14. Check the monitor, instruments and

    switches for dirt or damage.

    Inspecting by Walking Around the

    Machine

    3. Check for oil leakage from the hydraulic

    tank, hydraulic devices, hoses and

    connections.

    4. Check lights for dirt, damage and burnt

    out bulbs.

    5. Check the rear view mirror and room mirror

    for dirt, damage, and angle adjustment.

    6. Check the dump body, cylinders and pins

    for wear, damage and looseness.

    7. Check the handrail and step for damage

    and loose bolts.

    8. Check the crawler, carrier roller, track

    roller, idler and sprocket for damage, wear

    and loose bolts.

    9. Check for oil leakage from the travel

    motors, track rollers and idlers.

    10. Check the canopy, cab and guard for

    damage and loose nuts and bolts.

    11. Check the labels for dirt and damage.

  • 100

    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.

    Replenishing

    1. Remove the cap (2).

    2. Add coolant up to the upper limit (H) of the

    reserve tank (1).

    If the reserve tank is empty, inspect for

    fluid leakage, then inspect the radiator (3)

    coolant level. If it is low, add water to the

    radiator (3) first, then to the reserve tank.

    3. Install the cap (2).

    Inspecting and Replenishing the

    Coolant

    WARNING

     Do not remove the radiator cap or drain

    plugs when the coolant is hot. Stop the

    engine, let the engine and radiator cool

    and loosen the radiator cap or drain

    plugs slowly.

    Never jump off the machinne. 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.

    Inspection

    1. Open the engine hood.

    2. Inspect the coolant level in the reserve

    tank (1).

    The level should be between the upper

    limit (H) and lower limit (L).

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

  • 101

    MAINTENANCE

    Daily Inspection (Every 10 Hours)

    Inspecting and Replenishing the

    Engine Oil

    WARNING

     Stop the engine and allow the machine

    to cool down before performing

    inspection and maintenance.

    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.

    Inspection

    1. Open the engine hood.

    2. Pull out the dipstick (1) and wipe off the oil

    with a rag.

    3. Fully reinsert the dipstick (1), then pull it

    back out.

    4. Check the oil on the dipstick (1).

    The level should be between the upper

    limit (H) and lower limit (L).

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

    Replenishing

    1. Remove the oil supply cap (2).

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

    dipstick (1).

    Problems could arise if the oil level is

    either too low or too high.

    3. Tighten the oil supply cap (2).

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

    3 minutes, then stop it.

    5. After about 10 minutes, inspect the oil

    level.

  • 102

    MAINTENANCE

    Daily Inspection (Every 10 Hours)

    Inspecting the Fuel Level

    WARNING

     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.

    Do not smoke or permit open

    flames while fueling or near fueling

    operations.

    Stop the engine in a well-ventilated

    place when supplying fuel.

    Clean up spilled fuel immediately.

    Do not fill the fuel tank to capacity.

    Allow room for expansion.

    Tighten the fuel filler cap securely.

    1. Check the fuel level using the fuel gauge

    (1).

    F: full

    E: empty

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

    port (3) while watching the fuel gauge (2).

    Refer to page 42 “Fuel Filler Cap”.

    Inspecting the Water Separator

    and the Fuel Filters

    Water Separator

    1. Turn the starter switch to the ON

    position.

    2. Inspect the water separator warning lamp

    (7).

    3. If the warning lamp starts flashing, drain

    the water.

    Pre Fuel Filter, Main Fuel Filter

    1. Open the side cover.

    2. Check for water in the pre-fuel filter and

    the main fuel filter.

    If there is water, the float (red ring) goes

    up. Be sure to drain water before the float

    goes up to the element.

    3. Loose the vent plug (6) and then the drain

    plug (5) to discharge water accumulated

    inside.

    4. After drainage of water, tighten each plug

    and bleed air from the fuel system.

    Refer to page 135 “Bleeding the Air from

    the Fuel System”.

  • 103

    MAINTENANCE

    Daily Inspection (Every 10 Hours)

    Inspecting the Hydraulic Oil Level

    and Replenishing

    WARNING

     Oil may spurt out if caps or filters are

    removed or pipes disconnected before

    releasing the pressure in the hydraulic

    system.

    If you must work beneath the raised

    dump body, securely engage the raised

    body prop. Never get under the dump

    body if it is not sufficiently supported.

    Inspection

    The oil level changes according to the oil

    temperature. Inspect the oil level in the

    hydraulic oil level inspection posture shown

    in the diagram.

    Hydraulic oil level inspection posture

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

    2. Fully raise the dump body.

    3. Set the safety lock lever to the lock

    position, and stop the engine.

    4. Securely engage the raised body prop.

    5. Inspect the oil level at the sight gauge (1).

    • When the oil temperature is about 20°C

    (68°F):

    The level should be halfway between

    the middle (M) and lower limit (L).

    (When the dump body is lowerd, the oil

    level rises to the “M” position.)

    If it is below the lower limit (L),

    replenish.

    S2G008

    1

    • When the oil temperature is about 50 to

    80°C (122 to 176°F) :

    The level should be near the middle

    (M).

    (When the dump body is lowerd, the oil

    level rises to the middle point between

    the “M” and “H” positions.)

    Replenishing

    IMPORTANT: Do not add oil above the

    middle point between the sight gauge’s

    “M” and “L” positions. Doing so may

    cause the oil to spurt out.

    1. Remove the cover (4).

    2. Remove the air breather (2).

    3. Add hydraulic oil up to the middle point

    between the “M” and “L” positions of the

    sight gauge (1) through the hole in the air

    breather (2).

    4. Tighten the air breather (2).

    S2G033

    H

    M

    L

    1

    4

    2

  • 104

    MAINTENANCE

    Daily Inspection (Every 10 Hours)

    Lubricating the Dump body and Track Rollers

    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. Wipe off the expelled grease.

    S2G010

  • 105

    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

    other parts of the machine are hot

    directly after the engine is stopped.

    Touching these parts will cause

    burns.

    • The hydraulic fluid is also hot and

    under high pressure.

    Be careful when loosening caps and

    plugs. Working on the machine under

    these conditions could result in burns

    or injuries due to the hot oil spurting

    out.

    Oil may spurt out if caps or filters are

    removed or pipes disconnected before

    releasing the pressure in the hydraulic

    system.

    • When removing plugs or screws or

    disconnecting hoses, stand to the

    side and loosen slowly to gradually

    release the internal pressure before

    removing.

    If you must work beneath the raised

    dump body, securely engage the raised

    body prop. Never get under the dump

    body if it is not sufficiently supported.

    1. Start and run the engine at low speed.

    2. Fully raise the dump body.

    3. Set the safety lock lever to the lock

    position, and stop the engine.

    4. Securely engage the raised body prop.

    5. Remove the cover (4).

    6. Turn the case (1) counterclockwise and

    remove it.

    7. Remove the element (2) and O-ring (3).

    8. Clean the inside of the case (1).

    9. Install the new element in the case (1).

    10. Set the new O-ring, then tighten the case

    (1).

    11. Inspect the level with the sight gauge,

    and replenish if the level is low.

    Refer to page 103 “Inspecting the

    Hydraulic Oil Level and Replenishing”.

    1

    2

    3

    4

    S2G034

  • 106

    MAINTENANCE

    Replacing the Hydraulic Oil

    Return Filter

    WARNING

     Stop the engine and allow the machine

    to cool down before performing

    maintenance.

    • The engine, hydraulic lines and many

    other parts of the machine are hot

    directly after the engine is stopped.

    Touching these parts will cause

    burns.

    • The hydraulic fluid is also hot and

    under high pressure.

    Be careful when loosening caps and

    plugs. Working on the machine under

    these conditions could result in burns

    or injuries due to the hot oil spurting

    out.

    Oil may spurt out if caps or filters are

    removed or pipes disconnected before

    releasing the pressure in the hydraulic

    system.

    • When removing plugs or screws or

    disconnecting hoses, stand to the

    side and loosen slowly to gradually

    release the internal pressure before

    removing.

    If you must work beneath the raised

    dump body, securely engage the raised

    body prop. Never get under the dump

    body if it is not sufficiently supported.

    1. Start and run the engine at low speed.

    2. Fully raise the dump body.

    3. Set the safety lock lever to the lock

    position, and stop the engine.

    4. Securely engage the raised body prop.

    After First 50 Hours (New Machines Only)

    5. Remove the cover (4).

    6. Remove the air breather (2).

    7. Using a filter wrench, turn the return filter

    (8) counterclockwise and remove it.

    8. Clean the filter installation surface on the

    filter stand.

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

    the new filter.

    10. Install the new return filter by hand.

    11. Tighten 3/4 more turn with the filter

    wrench after the filter packing comes in

    contact with the surface of installation.

    12. Inspect the level with the sight gauge (1),

    and replenish if the level is low.

    Refer to page 103 “Inspecting the

    Hydraulic Oil Level and Replenishing”.

    13. Tighten the air breather (2).

    S2G033

    H

    M

    L

    1

    4

    2

    S2G041

    8

  • 107

    MAINTENANCE

    After First 50 Hours (New Machines Only)

    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. Touching

    these parts will cause burns.

    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.

    Inspection

    1. Open the engine hood.

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

    alternator pulley (3) and check the tension

    (about 98 N or 22 lbs.).

    The slack (A) should be about 7 to 8 mm

    (0.27 to 0.31 in.).

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

    • There are cuts or cracks.

    • The belt is worn and touches the botton

    of the V groove in the pulley.

    • The belt stretches and cannot be

    adjusted.

    Adjustment

    1. Loosen the locking nut (6) and the bolt

    (7).

    2. Turn the adjustment bolt (5) and adjust the

    fan belt (4).

    • Tighten: Clockwise

    • Loosen: Counterclockwise

    3. Tighten the locking nut (6) and the bolt

    (7).

    Tightening torque:

    • Locking nut (6) 25 N·m (18.1 ft-lb)

    • Bolt (7) 51 N·m (37.6 ft-lb)

  • 108

    MAINTENANCE

    2. Loosen the bolts and remove the under

    cover (4).

    3. Place a pan for catching the spent oil

    under the drain plug (3).

    4. Remove the drain plug (3) and drain the

    oil.

    When a drain valve is included

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

    drain the oil. (The oil comes out when the

    screw is tightened.)

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

    IMPORTANT: Check the spent oil. If it

    contains large amounts of metal powder,

    consult a Takeuchi sales or service

    outlet.

    5. Tighten the drain plug (3).

    6. Install the under cover (4).

    After First 50 Hours (New Machines Only)

    Replacing the Engine Oil and Oil

    Filter

    WARNING

     Stop the engine and allow the machine

    to cool down before performing

    maintenance.

    • The engine, muffler, radiator and

    many other parts of the machine

    are hot directly after the engine is

    stopped. Touching these parts will

    cause burns.

    • The engine oil is also hot.

    Be careful when loosening caps

    and plugs. Working on the machine

    under these conditions could result

    in burns.

    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.

    Supplement: The machine should be taken

    into a workshop for replacing the oil filter.

    This workshop should have a underground

    working facility.

    Engine oil

    1. Open the engine hood and remove the oil

    supply cap (2).

    S5G018

    A

    3

    B

    4

  • 109

    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).

    3. Loosen the bolt (5) and remove the filter

    case (6).

    4. Clean the inside of the filter case (6) and

    install a new element (7).

    5. Clean the filter stand and apply engine oil

    to the O-rings.

    6. Install the case (6) and tighten it with the

    bolt (5), and then install the drain plug (4).

    • Bolt (5) tightening torque: 44.1 N·m (32.5

    ft-lb)

    • Drain plug (4) tightening torque: 24.5

    N·m (18.1 ft-lb)

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

    dipstick (1). Problems could arise if the oil

    level is either too low or too high.

    8. Tighten the oil supply cap (2).

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

    3 minutes, then stop it.

    10. After about 10 minutes, inspect the oil

    level.

  • 110

    MAINTENANCE

    Inspecting the Battery Fluid Level

    and Replenishing

    DANGER

     Do not use the battery when the fluid

    level is below the lower level. Doing

    so will hasten the deterioration of the

    internal portions of the battery and

    shorten the battery life, and can also

    cause rupturing (or an explosion).

    Batteries generate flammable and

    explosive gases. Keep arcs, sparks,

    flames and lighted tobacco away.

    Use a dampened cloth to clean the area

    of the fluid level lines and check the fluid

    level. Note that if this area is cleaned

    with a dry cloth, static electricity could

    cause ignition or explosion.

    WARNING

     Do not fill the battery above the upper

    level. Doing so could cause the fluid to

    leak, contact and damage the skin, or

    cause parts to corrode.

    Batteries contain sulfuric acid which

    will damage eyes or skin on contact.

    • If acid contacts eyes, flush

    immediately with clean water and get

    prompt medical attention.

    • If acid is accidentally swallowed,

    drink large quantities of water or milk

    and call a physician immediately.

    • If acid contacts skin or clothing, wash

    off immediately with clean water.

    Inspection

    IMPORTANT: Check the fluid level of all

    cells, even when the fluid level can be

    checked by indicator.

    Every 50 Hours

    Inspecting the Crawler Tension

    This machine uses a hydraulic cylinder to

    adjust the tension of the crawler belts. Note

    that it is not necessary to regularly perform

    adjustments of the tension of the belt itself.

    Inspection

    1. On level ground, move the machine

    forward and backward two or three times

    then travel in reverse so that the slack in

    the crawler is on the upper side.

    2. Place straight bars on the sprocket and

    idler sides with the carrier roller at the

    center. The standard slack of (A) and (B)

    is 5 to 15 mm (0.2 to 0.6 in.).

    If the amount of slack is large, contact a

    Takeuchi sales or service outlet for repairs.

    A

    B

    S2G014

  • 111

    MAINTENANCE

    Every 50 Hours

    1. Open the battery cover.

    2. Inspect the indicator (1).

    Blue : Good

    White : Charging needed

    Red : Insufficient battery fluid

    3. Inspect the fluid level.

    The fluid level should be between the lines

    indicating the upper level (H) and lower

    level (L). If not, add distilled water up to

    line (H).

    If the fluid level can not be checked by

    fluid level lines.

    Remove the caps (2) and look into the fluid

    supply holes to check the fluid level. If the fluid

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

    water up to the bottom edge of the sleeve (3).

    Proper amount ...... (A)

    The fluid reaches up to the bottom edge

    of the sleeve (3), so the surface tension

    causes the fluid to swell and the plate

    appears distorted.

    Level too low ......... (B)

    The fluid does not reach up to the bottom

    edge of the sleeve (3), so the plate appears

    laminar, not distorted.

    4. Also check the terminals for looseness

    and dirt.

    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. Clean the cap’s exhaust hole, then tighten

    the caps (2) securely.

  • 112

    MAINTENANCE

    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.

    Clean up spilled fuel immediately.

    Do this before operating the machine.

    1. Remove the fuel filler cap (2).

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

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

    water and sediment from the bottom of

    the tank.

    4. Close the drain valve (3).

    5. While watching the fuel gauge (1), add

    fuel.

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

    with the key.

    7. Bleed the air.

    Refer to page 135 “Bleeding the Air from

    the Fuel System”.

    Every 50 Hours

  • 113

    MAINTENANCE

    After First 250 Hours (New Machines Only)

    Replacing the Travel Motor Gear

    Oil

    WARNING

     Stop the engine and allow the machine

    to cool down before performing

    maintenance.

    • The travel motors are hot directly

    after the engine is stopped. Touching

    them will cause burns.

    • The gear oil is also hot and under

    high pressure.

    Be careful when loosening plugs.

    Working on the machine under these

    conditions could result in burns or

    injuries.

    The pressure in the travel motor

    reduction gears case may cause oil

    or the plug to fly out. Loosen the plug

    slowly to release the pressure.

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

    the very bottom.

    2. Place a pan for catching the spent oil

    under plug (1).

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

    oil.

    4. Wrap new sealing tape around the plugs.

    5. Tighten plug (1).

    6. Add oil through the hole for plug (3) until

    oil flows out of the hole of plug (2).

    7. Tighten plugs (2) and (3).

    3

    2

    1

    S2G037

    FILL

    LEVEL

    DRAIN

  • 114

    MAINTENANCE

    Cleaning the Air Cleaner

    WARNING

     Stop the engine and allow the machine

    to cool down before performing

    maintenance.

    • The engine, muffler, radiator and

    many other parts of the machine

    are hot directly after the engine is

    stopped. Touching these parts will

    cause burns.

    Wear required appropriate equipment

    such as safety glasses and filter mask

    when using compressed air, as metal

    fragments or other objects can fly and

    cause serious personal injury.

    IMPORTANT: Be careful not to scratch

    the element. Do not use an element if it is

    damaged.

    IMPORTANT: When operating the

    machine in very dusty places, inspection

    and maintenance should be performed

    every day.

    1. Open the side cover.

    Every 250 Hours

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

    cup (2).

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

    4. Remove the primary element (3).

    Do not remove and clean the secondary

    element (5).

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

    6. Clean the primary element (3) with dried

    compressed air {294 to 490 kPa (43 to 71

    psi)}.

    First blow the air from the inside of the

    element along the flutes, then blow the

    air from the outside, and finally from the

    inside again.

    7. Light up the inside of the primary element

    (3) with a bulb, inspect it, and replace it if

    there are small holes or thin spots.

    8. Install the primary element (3).

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

    mark at the top, then fasten it with the

    clamp (1).

  • 115

    MAINTENANCE

    Every 250 Hours

    Lubricating the Swing Bearing

    WARNING

    Do not swing while lubricating. Doing so

    is dangerous, as you may get caught in

    the machine.

    1. Stop the engine with the machine in the

    posture shown on the diagram above.

    2. Use the grease gun to supply grease to

    the grease nipple (1).

    3. Start the engine and swing the dump

    body clockwise 90°.

    4. Stop the engine.

    5. Repeat step 2.

    6. Start the engine and swing the dump

    body counterclockwise 180°.

    7. Repeat step 2.

    8. Wipe off the grease expelled from the

    swing bearing and grease nipple.

    S2D011

    S2G0171

    1

    S2G018

  • 116

    MAINTENANCE

    Cleaning the Radiator Fins and Oil

    Cooler Fins

    WARNING

    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.

    IMPORTANT: Be careful not to damage

    the radiator fins and oil cooler fins when

    cleaning them.

    When using compressed air or

    pressurized water, make sure the

    pressure is no higher than 200 kPa (28

    psi) and hold the nozzle sufficiently

    away from the fins.

    IMPORTANT: When using water, cover

    the electrical system to prevent water

    from getting in.

    IMPORTANT: When operating the

    machine in very dusty places, inspection

    and maintenance should be performed

    every day.

    1. Blow compressed air on the radiator fins

    and oil cooler fins to remove mud and dirt

    stuck on them.

    Every 250 Hours

    Inspecting and Adjusting the Fan

    Belt

    Refer to page 107 “Inspecting and Adjusting

    the Fan Belt”.

  • 117

    MAINTENANCE

    Every 500 Hours

    Replacing the Fuel Filters

    WARNING

     Do not smoke or permit open flames

    while handling fuel or working on the

    fuel system.

    Stop the engine in a well-ventilated

    place and allow it to cool down before

    performing maintenance.

    Clean up spilled fuel immediately.

    Pre Fuel Filter

    1. Open the side cover

    2. Place a receptacle under the pre fuel filter

    (1) to catch any fuel.

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

    plug (6) to drain the filter.

    4. Use the filter wrench and remove the case

    (4).

    5. Replace the seals with new ones and

    lubricate the new seals with correct fuel

    oil.

    6. Put the new element (green) in the case (4)

    and install by hand untill the seal makes

    contact with the sealing surface.

    7. Use the filter wrench and tighten the

    case.

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

    8. Purge the air.

    Refer to page 135 “Bleeding the Air from

    the Fuel System”.

    Main Fuel Filter

    1. Open the side cover.

    2. Place a receptacle under the main fuel

    filter (2) to catch any fuel.

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

    plug (6) to drain the filter.

    4. Use the filter wrench and remove the case

    (4).

    5. Replace the seals with new ones and

    lubricate the new seals with correct fuel

    oil.

    6. Put the new element (yellow) in the case

    (4) and install by hand until the seal makes

    contact with the sealing surface.

    7. Use the filter wrench and tighten the

    case.

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

    8. Purge the air

    Refer to page 135 “Bleeding the Air from

    the Fuel System”.

    150mm

    131mm

    (

    )

    (

    )

  • 118

    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.

    Clean up spilled fuel immediately.

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

    2. Remove the cover (2).

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

    4. Install the new element and gaskets.

    5. Tighten the cover (2).

    6. Bleed the air.

    Refer to page 135 “Bleeding the Air from

    the Fuel System”.

  • 119

    MAINTENANCE

    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”.

    Every 500 Hours

  • 120

    MAINTENANCE

    Every 1000 Hours

    Cleaning the Engine Cooling

    System

    WARNING

     Stop the engine and allow the machine

    to cool down before performing

    maintenance.

    • The engine, muffler, radiator and

    many other parts of the machine

    are hot directly after the engine is

    stopped. Touching these parts will

    cause burns.

    • The engine coolant is also hot and

    under high pressure. Be careful

    when loosening caps and valves.

    Working on the machine under these

    conditions could result in burns

    or injuries due to the hot coolant

    spurting out.

    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.

    If maintenance must be performed

    with the engine running, always work

    as a two person team with one person

    sitting in the operator’s seat while the

    other works on the machine.

    • When performing maintenance, be

    sure to keep your body and clothing

    away from moving parts.

    Standing at the back of the machine

    while the engine is running is extremely

    dangerous, as the machine could move

    suddenly. Never stand at the back of the

    machine while the engine is running.

    Do not open the radiator cap or drain

    valves when the coolant is hot. Stop

    the engine, let the engine and radiator

    cool and loosen the radiator cap or

    drain valve slowly.

    When cleaning, if the temperature of the

    coolant is low, the thermostat will be closed

    and the coolant will not circulate in the

    radiator. Heat the coolant water to at least

    90°C before cleaning.

    1. Open the engine hood.

    2. Gradually loosen the radiator cap (3) to

    release the internal pressure, then remove

    the cap.

    3. Place a pan for catching the spent coolant

    under the drain valve (4), then loosen the

    drain valve (4) and drain the coolant.

    4. Tighten the drain valve (4).

    5. Add tap water through the radiator’s

    coolant supply port up to the top of the

    port. Take your time doing this, adding the

    water slowly to avoid any air from entering

    the radiator.

    6. Close the radiator cap (3).

    7. Start the engine and run it at a speed

    slightly above low idling. Raise the water

    temperature to at least 90°C, then run

    the engine for about 10 minutes with the

    thermostat open.

  • 121

    MAINTENANCE

    Every 1000 Hours

    8. Stop the engine, let the water’s temperature

    lower, then loosen the drain valve (4) and

    drain the water.

    9. After draining the water, clean using

    cleaning agent. Clean following the

    instructions included with the cleaning

    agent you are using.

    10. Repeat steps 4 to 8 to rinse the cooling

    system.

    11. Tighten the drain valve (4).

    12. Slowly add the new coolant (mixture of

    antifreeze and tap water) through the

    radiator’s coolant supply port up to the

    top of the port. Take your time doing

    this.

    13. Close the radiator cap (3).

    14. Warm up the engine. Use the meters to

    check that these are no irregularities in

    the cooling system at this time.

    15. Raise the water temperature to at least

    90°C, then run the engine as such for

    about 10 minutes.

    16. Stop the engine, let the water’s

    temperature lower, then check the level

    of coolant in the radiator, and replenish

    up to the top of the coolant supply port.

    17. Close the radiator cap (3).

    18. Clean the interior of the reserve tank (1),

    then add coolant to the upper limit (H).

    19. After replacing the coolant, inspect the

    coolant level once again after operating

    the machine.

    The coolant permeates the entire system

    during operation, so the level decreases.

    Replenish by the amount tyhe level has

    decreased.

    Replacing the Air Cleaner

    Elements

    WARNING

    Stop the engine and allow the machine

    to cool down before performing

    maintenance.

    The engine, muffler, radiator and many

    other parts of the machine are hot

    directly after the engine is stopped.

    Touching these parts will cause burns.

    IMPORTANT: Do not use an element if its

    flutes, gaskets or seals are damaged.

    1. Open the side cover.

    2. Loosen the clamps (1) and remove the

    dust cup (2).

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

    4. Remove the primary element (3).

    Do not yet remove secondary element (5).

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

    6. Remove the secondary element (5).

    7. Install the new elements.

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

    at the top, then fasten it with the clamp

    (1).

  • 122

    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.

    • The engine, hydraulic lines and many

    other parts of the machine are hot

    directly after the engine is stopped.

    Touching these parts will cause

    burns.

    • The hydraulic fluid is also hot and

    under high pressure.

    Be careful when loosening caps and

    plugs. Working on the machine under

    these conditions could result in burns

    or injuries due to the hot oil spurting

    out.

    Oil may spurt out if caps or filters are

    removed or pipes disconnected before

    releasing the pressure in the hydraulic

    system.

    • When removing plugs or screws or

    disconnecting hoses, stand to the

    side and loosen slowly to gradually

    release the internal pressure before

    removing.

    If you must work beneath the raised

    dump body, securely engage the raised

    body prop. Never get under the dump

    body if it is not sufficiently supported.

    1. Start and run the engine at low speed.

    2. Fully raise the dump body.

    3. Set the safety lock lever to the lock

    position, and stop the engine.

    4. Securely engage the raised body prop.

    5. Remove the cover (4).

    6. Remove the air breather (2).

    7. Place a pan for catching the spent oil

    under the drain plug (5).

    8. Loosen the drain plug (5) and drain the

    hydraulic oil.

    9. Loosen the bolts, and remove the flange

    (6).

    10. Remove the suction strainer (7) and clean

    it.

    11. Clean the inside of the hydraulic tank.

    12. Install the suction strainer (7) and flange

    (6).

    13. Tighten the drain plug (5).

    S2G033

    H

    M

    L

    1

    4

    2

    5

    S2G038

    S2G039

    6

    7

    2

  • 123

    MAINTENANCE

    Every 1000 Hours

    Bleeding the air

    IMPORTANT: After replacing the hydraulic

    oil, bleed the air from the hydraulic oil

    circuit and hydraulic devices. Failure to do

    so may damage the hydraulic devices.

    Hydraulic pump

    1. Loosen the hydraulic oil pump’s air

    bleeding plug (9).

    2. Once hydraulic oil overflows from the hole

    in the air bleeding plug (9), tighten the

    plug.

    Cylinders

    1. Start the engine and run it at low idle for

    10 minutes.

    2. Set the engine to a low idle, then extend

    and retract all the cylinders 4 or 5 times,

    without going to the stroke end.

    3. Run the engine at high speed, then extend

    and retract all the cylinders 4 or 5 times,

    without going to the stroke end.

    4. Set the engine back to a low idle, then

    extend and retract all the cylinders 4 or 5

    times to the stroke ends.

    14. Replace the line filter.

    Refer to page 105 “Replacing the Pilot

    Line Filter”.

    15. Replace the return filter.

    Refer to page 106 “Replacing the

    Hydraulic Oil Return Filter”.

    16. Add hydraulic oil up to the middle point

    between the “M” and “L” positions of the

    sight gauge (1) through the hole in the air

    breather (2).

    17. Tighten the air breather (2) and cover

    (4).

    18. Follow the procedure next “Bleeding the

    air” to bleed the air from the hydraulic oil

    circuit.

    19. Set the machine to the hydraulic oil

    level inspection posture and inspect the

    level once the temperature of the oil has

    dropped.

    Refer to page 103 “Inspecting the

    Hydraulic Oil Level and Replenishing”.

  • 124

    MAINTENANCE

    Every 1000 Hours

    Replacing the Hydraulic oil Return

    Filter

    Refer to page 106 “Replacing the Hydraulic

    Oil Return Filter”.

    Replacing the Travel Motor Gear

    Oil

    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.

    Inspecting the Starter and

    Alternator

    This operation requires experience. Have it

    performed by a Takeuchi sales or service

    outlet.

    Inspecting the Radiator Cap

    This operation requires experience. Have it

    performed by a Takeuchi sales or service

    outlet.

  • 125

    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.

    Inspection

    1. Open the cab door.

    2. Inspect the washer tank (1) and add

    washer fluid if the level is low.

    Replenishment

    1. Mix the washer fluid to the prescribed

    concentration.

    2. Remove the cap (2) and add washer

    fluid.

    3. Reinstall the cap (2).

    2

    1

    G4G030

  • 126

    MAINTENANCE

    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.

    Control levers

    1. Remove the lower mount section of the

    boot (1) and turn it upwards.

    2. Wipe off the old grease.

    3. Supply grease to points (A) and (B).

    4. Set the boot (1) back as it was.

    E4G058

    1

    A

    B

    When Required

  • 127

    MAINTENANCE

    2

    S2G028

    1/2

    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.

    (1) Lug

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

    or below.

    (2) Steel cord

    Replace if the steel cord is exposed over 2

    or more links.

    Replace if half or more of the steel cords on

    one side are cut.

    When Required

    (3) Metal core

    Replace if even one metal core is off.

    (4) Rubber

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

    or greater in length.

    If the steel cord is visible, repair as soon

    as possible, regardless of the length of the

    crack.

    S2G027

    4

    3

    2

    1

    A

    3

    S2G029

    60mm or greater

    S2G030

  • 128

    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

    the machine or raised dump body if

    they are not sufficiently supported.

    If maintenance must be performed

    with the engine running, always work

    as a two-person team with one person

    sitting in the operator’s seat while the

    other works on the machine.

    • When performing maintenance, be

    sure to keep your body and clothing

    away from moving parts.

    Take great care in handling rubber

    crawlers, because they are very heavy.

    Stop the engine and allow the machine

    to cool down before performing

    maintenance.

    • When disconnecting hoses, stand to

    the side and loosen slowly to gradually

    release the internal pressure before

    removing.

    Removal

    If the tension of the rubber crawler cannot

    be loosened, ask your dealer to repair or

    replace the rubber crawler.

    IMPORTANT: Prepare two wrenches

    for removal and installation of hydraulic

    hoses. Use one of the wrenches for

    holding the hydraulic hose to prevent it

    from twisting.

    1. Set the machine to the hydraulic oil level

    inspection posture.

    Refer to page 103 “Inspecting the

    Hydraulic Oil Level and Replenishing”.

    2. Change the connecting locations of the

    hydraulic hoses connected to the auto-

    tension valve (1).

    Changing the connecting locations of

    the hydraulic hoses allows the tension

    cylinder to be retracted and extended.

    • Right rubber crawler :

    Change the connecting locations of

    the hydraulic hoses (2) and (3) for each

    other.

    • Left rubber crawler :

    Change the connecting locations of

    the hydraulic hoses (4) and (5) for each

    other.

    3. Start the engine and retract the tension

    cylinder fully. Then stop the engine.

    4. Jack up the machine so that a clearance

    can be created between the core metal

    protrusion of the rubber crawler and the

    track rollers, and put wood bases or the

    like between the crawler frame on its

    lower side and ground.

    S2G043

    3

    2

    4

    5

    S2G044

    1

  • 129

    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.

    2. Start the engine and turn the rubber

    crawler slowly to install the rubber crawler

    onto the idler securely, using a lever.

    3. Stop the engine and confirm that the

    rubber crawler is fully engaged with the

    sprocket, the rollers and idler.

    4. Referring to the step (2) on the previous

    page, change the connecting locations of

    the hydraulic hoses connected the auto-

    tension valve (1), to return those to the

    original state before the removal of the

    rubber crawler.

    5. Start the engine and check that the rubber

    crawler tension is sufficient. Then lower

    the machine to the ground.

    6. Check the hydraulic hoses for oil

    leakage.

  • 130

    MAINTENANCE

    Long-term Storage

    During storage

    WARNING

     Do not operate the engine in an enclosed

    area without adequate ventilation.

    If natural ventilation is poor, install

    ventilators, fans, exhaust extension

    pipes or other artificial venting

    devices.

    1. To prevent rusting, operate the machine

    once a month so that the oil is fully

    circulated.

    2. Inspect the battery and recharge it if

    necessary.

    Have the battery charged by a Takeuchi

    sales or service outlet.

    Starting the machine after storage

    IMPORTANT: If the “Procedures for

    storage” have not been performed and

    the machine has been stored for a long

    period of time, consult a Takeuchi sales

    or service outlet before reusing the

    machine.

    1. Wipe off the rust-prevention oil that was

    applied to the hydraulic oil cylinders’

    piston rods.

    2. Add fuel, oil and grease to all parts.

    Procedures for storage

    If the machine is to be stored for 30 days or

    more, store it indoors. If it must be stored

    outdoors, stop it on wood laid out on a flat

    surface and place a waterproof cover over it

    so that it stays dry.

    1. Clean the machine.

    2. Inspect for oil leakage, water leakage and

    loose nuts and bolts.

    3. Add fuel and replace the hydraulic oil and

    oil.

    4. To prevent rusting and freezing, replace

    the engine coolant with long-life coolant

    (LLC).

    Refer to page 120 “Cleaning the Engine

    Cooling System”.

    5. Use the grease gun to supply grease to

    the grease nipples.

    6. Fully lower the dump body.

    7. Apply rust-prevention oil to the hydraulic

    cylinder rods.

    8. Disconnect the cable from the battery’s

    “–” terminal and cover the battery to

    prevent freezing.

  • 131

    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

    TROUBLESHOOTING

  • 132

    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.

    The control valve produces noise if

    excessive force is applied to the dump

    body and when the stroke end is

    reached.

  • 133

    TROUBLESHOOTING

    If the Engine Overheats

    WARNING

     Do not open the engine hood when

    there is steam coming from the engine

    room. The steam or hot water may

    spurt out, resulting in burns.

    Do not remove the radiator cap or drain

    plugs when the coolant is hot. Stop the

    engine, let the engine and radiator cool

    and loosen the radiator cap or drain

    plugs slowly.

    Stop the engine and allow the machine

    to cool down before performing

    inspection and maintenance.

    The following symptoms indicate

    overheating:

    An alarm is sounded and the coolant

    temperature warning lamp and engine

    emergency lamp flash.

    The water temperature gauge is in the red

    zone.

    The engine slows down and the force

    decreases.

    Steam comes from the engine room.

    Procedure

    1. Park the machine in a safe place.

    2. With the engine hood closed, inspect

    whether steam is coming from the engine

    room.

    3. If there is steam, stop the engine

    immediately and contact a Takeuchi sales

    or service outlet for repairs.

    If there is no steam, run the engine at

    low idle and let the water temperature

    decrease.

    4. Once the water temperature gauge drops

    to the green zone, stop the engine.

    5. Once the engine is cool, perform the

    following inspections and procedures:

    • Fan belt slack .............................. Adjust.

    Refer to page 107.

    • Coolant level ...................................Add.

    Refer to page 100.

    • Water leakage ............................. Repair.

    • Radiator fins ................................ Clean.

    Refer to page 116.

    • Sediment in cooling system ........ Clean.

    Refer to page 120.

    If the problem persists after the above

    procedures are taken, contact a Takeuchi

    sales or service outlet for repairs.

  • 134

    TROUBLESHOOTING

    If the Battery Goes Dead

    Connecting the jumper cables

    IMPORTANT: Set the starter keys of both

    the rescue vehicle and problem vehicle to

    the OFF position.

    Refer to page 41 “Battery Cover”.

    1. Connect the clip of jumper cable (R) to the

    problem vehicle’s “+” terminal.

    2. Connect the other clip of jumper cable (R)

    to the rescue vehicle’s “+” terminal.

    3. Connect the clip of jumper cable (B) to the

    rescue vehicle’s “–” terminal.

    4. Connect the other clip of jumper cable

    (B) to the problem vehicle’s engine block.

    Connect the clip as far from the battery as

    possible.

    Starting the engine

    1. Check that the clips are securely

    connected to the terminals.

    2. Start the rescue vehicle’s engine and run

    it at high speed.

    3. Start the problem vehicle’s engine.

    The following symptoms indicate that the

    battery is dead :

    The starter motor does not turn or turns

    weakly, and the engine does not start.

    The horn is weak.

    Procedure

    Use jumper cables and start the engine using

    the rescue vehicle’s battery.

    WARNING

     Use jumper cables only in the

    recommended manner. Improper use

    of jumper cables can result in battery

    explosion or unexpected machine

    motion.

    • Do not let the problem vehicle and

    rescue vehicle touch each other.

    • Do not let the “+” and “–” clips of the

    jumper cables touch each other.

    • Connect the jumper cables to the “+”

    terminals first, and disconnect them

    from the “–” terminals (ground) first.

    • Connect the final clip of the jumper

    cable to a point as far away from the

    battery as possible.

    Use safety glasses when using jumper

    cables to start the machine.

    IMPORTANT: Use jumper cables and clips

    of a size suited to the battery’s capacity.

    Do not used damaged or corroded jumper

    cables and clips.

    IMPORTANT: The rescue vehicle’s

    battery must have the same capacity as

    the problem vehicle’s battery.

    IMPORTANT: Connect the clips securely.

    Rescue vehicle battery Problem vehicle battery

    To engine block

    E4J005

    1

    2

    3

    4

    R

    B

  • 135

    TROUBLESHOOTING TROUBLESHOOTING

    If the Battery Goes Dead After the Fuel Runs Out

    Bleeding the Air from the Fuel

    System

    1. Add fuel.

    2. Loosen the vent plug (6) on the main fuel

    filter (2).

    3. Turn the starter key to the ON position and

    wait for the air to bleed around the vent

    plug (6).

    4. When the air is bled and the fuel starts

    coming from the vent plug (6), retighten

    the vent plug (6).

    5. Turn and hold the starter key to the ON

    position for three minutes before turning it

    back to the OFF position.

    Supplement: Air in the fuel system can

    make it difficult to start the engine and cause

    engine problems. Also bleed the air when

    the fuel tank is emptied.

    Disconnecting the jumper cables

    Once the engine starts, disconnect the

    jumper cables following the connection

    procedure in reverse order.

    1. Disconnect the clip of jumper cable (B)

    from the problem vehicle’s engine block.

    2. Disconnect the other clip of jumper cable

    (B) from the rescue vehicle’s “–” terminal.

    3. Disconnect the clip of jumper cable (R)

    from the rescue vehicle’s “+” terminal.

    4. Disconnect the other clip of jumper

    cable (R) from the problem vehicle’s “+”

    terminal.

    Recharging

    Have a Takeuchi sales or service outlet

    recharge batteries that have gone dead.

    E4J006

    4

    1

    3

    2

    R

    B

    Rescue vehicle battery

    Problem vehicle battery

    From engine block

    OFF

    ON

    START

    L3D001

  • 136

    TROUBLESHOOTING

    If a light does not turn on or the electric

    system does not operate, a fuse may be

    blown. Inspect the fuses.

    Inspecting and Replacing the

    Fuse

    WARNING

    If the fuse blows as soon as it is replaced,

    there is a problem with the electric system.

    Continued use may lead to fire. Consult a

    Takeuchi sales or service outlet.

    1. Turn the starter key to the OFF position

    and stop the engine.

    2. Open the fuse box cover (1).

    3. Inspect for any blown fuses.

    4. If a fuse is blown, replace it with a spare

    fuse of the same capacity.

    If a Fuse Blows

    Fuse Layout and Circuits Protected

    E4J007

    NormalBlown

    10

    10

    10

    20

    20

    10

    20

    10

    5

    10

    5

    10

    20

    20

    20

    10

    1

    L3J002

    Capacity

    Protected circuit

    Capacity

    Protected circuit

    5A Fuel feed pump 20A Lights

    10A Control circuit 10A Wiper motor

    20A ECM 20A Air conditioner

    10A Controller 10A Solenoid valve

    5A Option 10A Option

    10A Horn 10A

    Cigarette lighter,

    Radio

    5A

    Interior light,

    Radio backup

    10A Turn signal

    10A Starter circuit 5A

    Instrument

    cluster, Lamp

  • 137

    TROUBLESHOOTING

    Inspecting the Fusible Link

    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.

    Supplement: A fusible link is a large piece

    of fuse wiring which is mounted in a circuit

    which carries a large electrical current. Link

    a regular fuse, the fusible link protects the

    electrical parts and wiring from damage due

    to abnormally large currents.

    If a Fuse Blows

    1

    S2J002

  • 138

    TROUBLESHOOTING

    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 procedures described below.

    Pilot line filter

    warning lamp

    Hydraulic oil pilot line filter is clogged.

    Stop the engine and replace the filter.

    Continuing to operate the machine while the lamp

    is lit could damage the pilot line filter and hydraulic

    equipment.

    Replace the filter immediately should the lamp flashes.

    Refer to page 105 “Replacing the Pilot Line Filter”.

    T7B008

    T7B008

    Warning lamp

    Lamp name

    Pr

    ocedure

    The coolant temperature has risen irregularly and the

    engine is overheating.

    Refer to page 133 “If the Engine Overheats”.

    Engine

    emergency

    lamp

    A problem has occurred in the engine lubrication

    system or cooling system.

    When there is a problem in the engine lubrication

    system, the engine oil pressure warning lamp flashes

    simultaneously.

    When the coolant temperature has risen irregularly,

    the coolant temperature warning lamp flashes

    simultaneously.

    For the procedures, refer to the respective warning

    lamps below.

    Battery charge

    warning lamp

    There is a problem with the fan belt or charger.

    Inspect the fan belt for slack or breakage and adjust

    as necessary. If the lamp continues flashing after

    maintenance, there is a problem with the charger.

    Consult a Takeuchi sales or service outlet.

    Refer to page 107 “Inspecting and Adjusting the Fan

    Belt”.

    Coolant

    temperature

    warning lamp

    OSOB080

    C4B012

    G4B009

    G4B009

    C4B012

    Engine oil

    pressure

    warning lamp

    Inspect the engine oil level. If the lamp is flashing even

    though the level is normal or if it continues flashing after

    oil is added, consult a Takeuchi sales or service outlet.

    Refer to page 101 “Inspecting and Replenishing the

    Engine Oil”.

    OSOB070

  • 139

    TROUBLESHOOTING

    Air cleaner

    warning lamp

    The air cleaner filter is clogged.

    Refer to page 114 “Cleaning the Air Cleaner”.

    G4B010

    G4B010

    Warning lamp

    Lamp name

    Pr

    ocedure

    Water

    separator

    warning lamp

    Water has accumulated in the water separator. Drain

    the water.

    Refer to page 102 “Inspecting the Water Separator and

    the Fuel Filters”.

    Fuel level

    warning lamp

    The fuel level is low. Supply fuel.

    Refer to page 42 “Fuel Filler Cap”.

    ECM warning

    lamp

    Engine problem detected.

    An error code indicating the type of error appears in the

    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”.

    If a Warning Lamp Flashes

  • 140

    TROUBLESHOOTING

    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 details

    Error Code No.

    01

    02

    03

    04

    05

    06

    07

    08

    09

    10

    11

    12

    13

    14

    15

    Short-time operations (0.5 seconds or less) of the key switch are

    repeatedly recorded.

    After the engine starts, the engine oil pressure drops below the specified

    level (oil shortage).

    After the engine starts, the charge alternator malfunctions.

    The engine overheats (water temperature exceeds 107 ºC).

    The air cleaner filter becomes clogged.

    Emergency release operation is recorded.

    Excess ignition time (15 seconds or more) of the glow plug is recorded.

    The battery voltage becomes too high (it exceeds 30 V for one second or

    more).

    The battery voltage becomes too low (it drops below 12 V for one second

    or more).

    The emergency release signal state changes from ON to OFF.

    A real-time lock error occurs. Reset operation is recorded. The battery

    voltage drops for too long, and the CPU time function is reset.

  • 141

    TROUBLESHOOTING

    “Open circuit” in items “19” and “20” means engine oil pressure reduction caused by an oil

    shortage.

    Error details

    Error Code No.

    16

    17

    1

    8

    1

    9

    2

    0

    2

    1

    22

    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. Even if an open circuit is detected, the engine does not stop (if

    the open-circuit interlock signal line is grounded). The “High” signal level

    detected when the engine is started is recorded.

    The status change (High to Low) of an open-circuit interlock signal is

    recorded. When an open circuit is detected, the engine stops (if the open-

    circuit interlock signal is in an OPEN state).

    An error occurs on a comparative amplifier. A shoot-through current or

    open circuit occurs.

    A CAN communication error occurs. A communication error with ECM

    occurs.

    If a Warning Lamp Flashes

  • 142

    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

    move smoothly

    Insufficient grease on left and

    right control levers

     Add grease.

    Refer to page 126.

    Safety lock lever is raised

    Fuse is blown

    Dumping, swinging or

    traveling operation not

    possible

    Lower the safety lock lever.

    Refer to page 54.

    Replace the fuse.

    Refer to page 136.

    Dumping or swinging

    force is insufficient

    Insufficient hydraulic oil level

    Hydraulic oil is not heated

    Air cleaner is clogged

    Hydraulic oil is not of suitable

    type

    Replenish to the prescribed

    level.

    Refer to page 103.

    Perform the warm-up

    procedure.

    Refer to page 69.

    Clean the air cleaner.

    Refer to page 114.

    Replace the hydraulic oil.

    Refer to page 122.

    Traveling is not possible

    or not smooth

    Stones or foreign objects are

    stuck

     Remove the foreign object.

    Machine does not travel

    straight forward

    Stones or foreign objects are

    stuck

     Remove the foreign object.

    Travel speed cannot be

    changed

    Fuse is blown  Replace the fuse.

    Refer to page 136.

    Swinging is not possible

    or not smooth

    Insufficient grease on swing

    bearing

     Add grease.

    Refer to page 115.

    Hydraulic oil

    temperature is too high

    Insufficient hydraulic oil  Replenish to the prescribed

    level.

    Refer to page 103.

  • 143

    TROUBLESHOOTING

    Other Symptoms

    Symptom Main cause Procedure

    Starter motor turns but

    engine does not start

    Insufficient fuel

    Air in fuel system

    Water in fuel system

    Add fuel.

    Refer to page 102.

    Bleed the air.

    Refer to page 135.

    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

    or bluish

    Excessive engine oil

    Insufficient fuel

    Adjust to the prescribed

    level.

    Refer to page 101.

    Replace the fuel.

    Engine exhaust is

    occasionally black

    Air cleaner is clogged  Clean the air cleaner.

    Refer to page 114.

    Irregular noise is

    produced from the

    engine (combustion or

    mechanical noise)

     Low quality fuel is being used

     Engine is overheating

    Damage in muffler

    Replace the fuel.

    If the Engine Overheats

    Refer to page 133.

    Replace the muffler.

    (Request at a sales or

    service outlet.)

  • 144

    TROUBLESHOOTING

    Towing

    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 be extremely

    dangerous. Use a wire rope suited for

    the required towing force.

    Do not use a wire rope that is kinked,

    twisted or otherwise damaged.

    Do not apply strong loads abruptly to

    the wire rope.

    Use safety gloves when handling the

    wire rope.

    Make sure there is an operator on the

    machine being towed as well as on the

    machine that is towing.

    Never tow on slopes.

    Do not let anyone near the wire rope

    while towing.

    Towing the Machine

    Use the procedure described below to tow

    heavy objects or the machine itself if it should

    get stuck in the mud and not be able to get

    out on its own.

    <Front>

    1. Fasten the wire rope to the hooks (1).

    2. Make the wire rope horizontal and line up

    straight with the travel frame.

    3. Move the machine to tauten the wire

    rope.

    4. Move the machine slowly and tow.

    <Rear>

    Maximum tractive force: 72.2 kN (16230 lbf)

    1. Fasten the wire rope to the frame.

    IMPORTANT: Be careful not to get the

    hydraulic hose entangled with the wire

    rope.

    2. Make the wire rope horizontal and line up

    straight with the travel frame.

    3. Move the machine to tauten the wire

    rope.

    4. Move the machine slowly and tow.

  • 145

    SPECIFICATIONS

    Main Specifications ......................................146

    Machine Dimensions ....................................148

    Operating Range ...........................................150

  • 146

    SPECIFICATIONS

    Main Specifications

    ENGINE

    Manufacturer and model ISUZU 4JJ1X

    Rated output kW / min

    –1

    (hp / rpm) 72 / 2200 (96.6 / 2200)

    Displacement mI (cu.in.) 2999 (183)

    Starter V – kW 24 – 4

    Alternator V – kW 24 – 1.2

    Battery V – A·h 12 – 54 x 2

    MASS

    Operating mass kg (lb.) 6025 (13285)

    PERFORMANCE

    TYPE CAB

    Dump body capacity m

    3

    (cu.ft.) Heaped 2.055 (72.57)

    (standard dump body) Struck 1.15 (40.61)

    Maximum loading mass kg (lb.) 3700 (8155)

    Swing speed min

    –1

    (rph) 180° 6.6 (6.6)

    Travel speed km / h (mph) 0~9.2 (5.72)

    Gradeability (degrees) 30

    Ground pressure

    with Dump body Full 33.3 (4.84)

    kPa (psi)

    with Dump body Empty 20.4 (2.96)

    Noise level dB (A)

    Sound-power level L

    WA

    103

    Sound-pressure level L

    pA

  • 147

    MEMO

  • 148

    SPECIFICATIONS

    Machine Dimensions

  • 149

    SPECIFICATIONS

    Machine Dimensions

    Units: mm (inches)

    Standard Dump Body Short Dump Body

    A 2

    725 (107.3)

    B 1040 (41.0)

    C 4745 (186.8) 4830 (190.3)

    D 2

    500 (98.4)

    E 3190 (125.6)

    F 1305 (51.4)

    G 1760 (69.3) —

    H 2

    000 (78.7)

    J 450 (17.7)

    K 435 (17.1)

    L 990 (39.0)

    M 2605 (102.6) 2420 (95.2)

    N 1

    795 (70.6) 1825 (71.9)

    P 3

    85 (15.2) —

    Q 7

    80 (30.7) 750 (29.5)

    1310 (51.6)

    1695 (66.7)

    980 (38.6)

    2615 (103)

  • 150

    SPECIFICATIONS

    Operating Range

  • 151

    SPECIFICATIONS

    Operating Range

    Units: mm (inches)

    Standard Dump Body Short Dump Body

    A 4

    630 (182.3) 4825 (190)

    B 8

    80 (34.6) 725 (28.5)

    C 3

    600 (141.7) 3220 (126.8)

    D 1

    000 (39.4)

    E 1730 (68.1) 1965 (77.4)

    F 2

    745 (108.1) 2535 (99.8)

    G 9

    H 90°

    J 65°

    3590 (141.3)

  • 152

  • 153

    OPTIONS

    General Precautions .....................................154

    Optional Equipment Mass ...........................156

  • 154

    OPTIONS

    General Precautions

    Precautions on Safety

    WARNING

    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.

    Takeuchi will not be held responsible for any injuries, accidents or damage to products

    caused by the use of a non-approved attachment.

    Choose a flat, hard surface to perform the operations. Also make sure there is enough

    light and good ventilation.

    Clean the area, remove any articles that may get in the way or be dangerous, and

    remove any spilt oil or grease.

    When removing or installing the attachment, place it in a stable position so that it

    does not tip over.

    Due to the risk of loads falling and/or hitting people, do not allow unauthorized

    personnel in the work area.

    Use the crane to carry heavy objects (25 kg (55 lb.) or greater).

    When removing heavy parts, be sure to prop them up before removing them. When

    lifting them with a crane, be careful to balance them properly.

    Operating with loads suspended with the crane is dangerous. Place loads on a stand

    and check for safety.

    When attaching the attachments, failure to follow proper procedures could result in

    serious damage. Consult with a Takeuchi dealer beforehand.

    Precautions on Installing Attachments

    After replacing optional attachments or other special attachments, test-run them, then inspect

    the hydraulic oil level and add oil if necessary.

    In addition, consult with a Takeuchi dealer for details of removal and installation procedures.

  • 155

    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.

    When heavy attachments are installed, the overswing (the distance from where the

    operation to stop swinging is performed until swinging stops completely) increases

    and mistakes in judgment may result in the attachment hitting surrounding objects.

    Allow for plenty of room between the attachment and obstacles.

    In addition, the natural drop (the gradual dropping of the attachment under its own

    weight when it is stopped in midair) also increases when heavy attachments are

    installed.

    The machine can tip over more easily in the lateral direction than in the longitudinal

    direction.

    • Do not swing sideways with excessive weight. In particular do not swing sideways

    on slopes.

     Traveling down slopes

    with the dump body lifted

     Traveling across slopes  Turning on slopes

    S2A016

    S2L001

    S2A012E

  • 156

    OPTIONS

    Standard machine mass

    (rubber crawlers, not including operator)

    Cab

    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.

    Optional Equipment Mass

  • 157

    INDEX

  • 158

    INDEX

    A ~ D

    A

    Accessories ........................................................................55

    After Cold Weather is Over ................................................ 78

    After First 250 Hours (New Machines Only) ....................113

    After First 50 Hours (New Machines Only) ......................105

    After starting the engine ..................................................... 15

    After the Fuel Runs Out ...................................................135

    Always clean the machine ................................................. 26

    Always keep the machine clean ........................................12

    Anti-explosive lighting ........................................................ 25

    Ashtray ................................................................................ 57

    Attach a “DO NOT OPERATE” tag ....................................25

    Avoid battery hazards ........................................................ 30

    Avoid fire and explosion hazards ...................................... 10

    B

    Battery Cover ..................................................................... 41

    Be careful not to get crushed or cut ................................. 11

    Be careful with fluids under pressure ................................29

    Be careful with hot and pressurized components ............ 28

    Be careful with hot cooling systems ................................. 29

    Be sure to lock the safety lock lever before leaving the

    operator’s seat ............................................................... 10

    Before Starting Operation .................................................. 64

    Before Starting the Engine ................................................. 65

    Bleeding the Air from the Fuel System ...........................135

    C

    Cab Door ............................................................................38

    Cautions .............................................................................. 80

    Cautions after Completing Operations ............................. 78

    Cautions on Maintenance .................................................. 88

    Cautions on Operating .......................................................74

    Cautions on towing ............................................................ 22

    Cautions on Transporting .................................................. 86

    Cautions on traveling on slopes ........................................ 18

    Cautions on Traveling on Slopes ....................................... 76

    Cautions on working on the machine ...............................27

    Check for safety in the surrounding area before

    starting ........................................................................... 16

    Check the strength of the bridge ......................................12

    Checks after maintenance ................................................. 31

    Cigarette Lighter ................................................................. 57

    Cleaning the air cleaner ...................................................114

    Cleaning the engine cooling system ...............................120

    Cleaning the radiator fins and oil cooler fins ..................116

    Clear the area of other persons before starting the

    machine ......................................................................... 14

    Control Levers ....................................................................54

    Controls ..............................................................................35

    D

    Daily Inspection .................................................................. 64

    Daily Inspection (Every 10 Hours) ...................................100

    Danger of flying objects .....................................................22

    Disconnect the battery ....................................................... 30

    Disposing of wastes ........................................................... 31

    Do not allow unauthorized personnel in the work area .... 25

    Do not enter soft ground .................................................... 21

    Do not hoist this machine .................................................. 24

    Do not permit riders on the machine ................................ 16

    Doors and Covers .............................................................. 38

    Draining the fuel tank ....................................................... 112

    Dump Body Alignment Indicator ....................................... 50

    Dump Body Raising Indicator ........................................... 50

  • 159

    INDEX

    E ~ I

    E

    Engine Hood .......................................................................41

    Engine shutdown switch ....................................................51

    Ensure good visibility ......................................................... 16

    Every 1000 Hours .............................................................120

    Every 250 Hours ...............................................................114

    Every 50 Hours .................................................................110

    Every 500 Hours ...............................................................117

    Exhaust fumes from the engine can kill ............................ 11

    Expendables .......................................................................92

    External Power Socket (for EU) ......................................... 56

    F

    Front Window ..................................................................... 39

    Fuel Filler Cap ..................................................................... 42

    G

    General ............................................................................... 88

    General precautions ............................................................. 8

    G

    eneral Precautions ......................................................... 154

    H

    Handling asbestos dust ..................................................... 11

    Handling in Cold Weather ..................................................78

    Handling of hoses ..............................................................28

    Handling Rubber Crawlers ................................................ 79

    Have a Takeuchi service agent repair welding cracks or

    other damage ................................................................ 31

    Heater ................................................................................. 55

    Hoisting the Machine ......................................................... 85

    Horn Switch ........................................................................ 52

    Hour Meter .......................................................................... 47

    I

    If a Fuse Blows .................................................................136

    If a Warning Lamp Flashes ..............................................138

    If the Battery Goes Dead .................................................134

    If the Engine Overheats .................................................... 133

    Important Parts ...................................................................95

    In cold weather ................................................................... 15

    Index .................................................................................157

    Indicators ............................................................................ 47

    Inspecting and adjusting the engine valve clearance ....124

    Inspecting and adjusting the fan belt ..............................107

    Inspecting and adjusting the fan belt ..............................116

    Inspecting and Replacing the Fuse .................................136

    Inspecting and replenishing the coolant .........................100

    Inspecting and replenishing the engine oil ..................... 101

    Inspecting and replenishing the windshield washer

    fluid ..............................................................................125

    Inspecting by opening the engine hood and covers ........98

    Inspecting by walking around the machine ...................... 99

    Inspecting the battery fluid level and replenishing .........110

    Inspecting the crawler tension ........................................110

    Inspecting the engine compression pressure ................. 124

    Inspecting the fuel level ...................................................102

    Inspecting the Fusible Link .............................................. 137

    Inspecting the hydraulic oil level and replenishing ......... 103

    Inspecting the Radiator cap ............................................124

    Inspecting the rubber crawlers ........................................127

    Inspecting the starter and alternator ...............................124

    Inspecting the water separator and the fuel filters .........102

    Inspecting while sitting in the operator’s seat ................... 99

    Inspection After Warm-up ................................................. 70

    Inspection and Checks After Stopping the Engine .......... 77

    Instrument Cluster .............................................................. 46

    Interior Light ........................................................................ 56

    Introduction .......................................................................... 2

  • 160

    INDEX

    K ~ P

    K

    Keep a safe distance from electrical power lines ............. 20

    Know the working area ......................................................12

    L

    Lever Pattern ......................................................................68

    Levers .................................................................................54

    Light Switch ........................................................................ 53

    Load and unload the machine safely ................................ 24

    Loading and Unloading ..................................................... 84

    Long-term Storage ........................................................... 130

    Lower Front Window .......................................................... 40

    Lubricant and Fuel Chart ................................................... 90

    Lubricating the dump body and track rollers ................. 104

    Lubricating the levers ....................................................... 126

    Lubricating the swing bearing ......................................... 115

    M

    Machine Description ............................................................ 3

    Machine Dimensions ....................................................... 148

    Machine Operation ............................................................. 68

    Main Specifications ..........................................................146

    Maintain three point contact when mounting and dis-

    m

    ounting ........................................................................14

    Maintenance ....................................................................... 87

    Maintenance Chart ............................................................. 96

    Maintenance Description ................................................... 88

    Maintenance precautions .................................................. 25

    Meters ................................................................................. 47

    Mounting and Dismounting ............................................... 64

    Multi-data display ............................................................... 48

    N

    Names of Components ..................................................... 36

    Never modify the machine ................................................. 11

    Never remove safety equipment ......................................... 9

    O

    Observe all safety rules ........................................................ 8

    Operate on snow or ice with extra care ............................ 19

    Operating precautions ....................................................... 16

    Operating Procedures ........................................................ 74

    Operating Range .............................................................. 150

    Operating the Dump Body ................................................ 73

    Operation ............................................................................ 63

    Optional Equipment Mass ...............................................156

    Options ............................................................................. 153

    Other Symptoms ..............................................................142

    P

    Park safely .......................................................................... 23

    Parking ................................................................................ 77

    Parking Brake Button ......................................................... 52

    Parking the Machine ..........................................................77

    Perform inspection and maintenance daily ...................... 13

    Precautions on Installing Attachments ........................... 154

    Precautions on Operating Attachments .........................155

    Precautions on Safety ......................................................154

    Precautions When Dumping .............................................. 20

    Precautions When Loading the Dump Body .................... 19

    Precautions when passing through tunnels or under

    bridges ........................................................................... 19

    Prepare the work area ........................................................ 26

    Preparing for Cold Weather ...............................................78

    Preparing precautions ........................................................ 12

    Prohibited Actions ..............................................................79

    Provide a fire extinguisher and first aid kit .......................... 9

  • 161

    INDEX

    R ~ U

    R

    Radio (Cab type) ................................................................. 58

    Raised Body Prop .............................................................. 42

    Release all pressure before working on the hydraulic

    system ........................................................................... 29

    Replace important safety parts periodically ..................... 25

    Replacing the air cleaner elements .................................121

    Replacing the engine oil and oil filter ..............................108

    Replacing the engine oil and oil filter ..............................119

    Replacing the feed pump filter ........................................118

    Replacing the fuel filter ....................................................117

    Replacing the hydraulic oil and cleaning the suction

    strainer .........................................................................122

    Replacing the hydraulic oil return filter ............................ 106

    Replacing the hydraulic oil return filter ............................ 124

    Replacing the pilot line filter .............................................105

    Replacing the pilot line filter .............................................119

    Replacing the rubber crawlers ........................................ 128

    Replacing the travel motor gear oil ................................. 113

    Replacing the travel motor gear oil ................................. 124

    S

    Safety .................................................................................... 7

    Safety Lock Lever ..............................................................54

    Safety signs (Decals) .......................................................... 32

    Seat ..................................................................................... 43

    Seat and Seat Belt ............................................................. 43

    Seat Belt ............................................................................. 45

    Secure the engine hood or cover when opened .............. 27

    Securely block the machine or any component that may

    fall ................................................................................... 27

    Securely block the raised dump body .............................. 27

    Securing the Machine ........................................................ 86

    Service Data ....................................................................... 90

    Side Cover (Tool Box) ......................................................... 40

    Side Window ...................................................................... 40

    Specifications ...................................................................145

    Start the engine from the operator’s seat ......................... 14

    Starter Key ..........................................................................38

    Starter Switch ..................................................................... 51

    Starting and Stopping the Engine ..................................... 66

    Starting precautions ........................................................... 14

    Starting the Engine ............................................................. 66

    Starting with jumper cables ............................................... 15

    Stay clear of moving parts .................................................26

    Stop the engine before performing maintenance ............ 26

    Stopping precautions ......................................................... 23

    Stopping the Engine .......................................................... 67

    Switches ............................................................................. 51

    Symptoms that are not Malfunctions ..............................132

    T

    Throttle Controller ............................................................... 51

    Tightening Torques .............................................................94

    Tools .................................................................................... 93

    Towing ...............................................................................144

    Transport ............................................................................. 83

    Transport the machine safely ............................................ 24

    Transporting precautions ................................................... 24

    Travel in narrow or congested places ...............................18

    Travel safety ........................................................................ 17

    Travel Speed Switch .......................................................... 53

    Traveling the Machine ........................................................ 70

    Troubleshooting ................................................................131

    Turn Switch ......................................................................... 52

    U

    Unstable ground is dangerous and increases the likelihood

    of the machine tipping over .......................................... 21

    Use a signal person and flagman ........................................ 9

    U

    se caution when fueling .................................................. 28

  • 162

    INDEX

    U ~ W

    Use the correct tools .......................................................... 25

    Using optional products .................................................... 11

    V

    Vibrations operators are subject to .................................. 31

    W

    Walk-Around Inspection .................................................... 64

    Walk-Around Inspection .................................................... 98

    Warming Up the Engine ..................................................... 67

    Warming Up the Machine (Hydraulic Oil) ..........................69

    Warning Lamps ..................................................................46

    Wear appropriate clothing and personal protective equip-

    m

    ent ................................................................................. 8

    W

    hen Required .................................................................125

    Wiper Switch ...................................................................... 53

  • 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.

  • C-3

    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. Wash hands after handling battery.

  • Takeuchi TCR50 User Manual
  • Takeuchi TCR50 User Guide
  • Takeuchi TCR50 PDF Manual
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