SAFETY ALERT SYMBOL

This symbol represents the safety alert. Improper operation, inspection and
The message that follows the symbol maintenance of this machine can cause
contains important information about injury or death.
safety. Read and understand this manual before
Read and understand the message to performing any operation, inspection or
avoid personal injury or death. maintenance on this machine.

It is the owner or employer’s responsibility Always store this manual near at hand
to fully instruct each operator in the preferably on the machine itself. If it should
proper and safe operation of all be lost or damaged, immediately order a
equipment. All persons using this new one from your Takeuchi dealer.
machine should thoroughly familiarize When transferring ownership of this machine,
themselves with the contents of this be sure to hand this manual to the next
manual. owner.

All operators must be instructed on the Takeuchi supplies machines complying with
proper functions of the excavator before the local regulations and standards of the
running the machine. country of export. If your machine has been
purchased in another country or from a
Learn and practice correct use of the person or company of another country, it
machine controls in a safe, clear area may not have the safety devices or safety
before operating this machine on a job standards required for use in your country.
site. Should you have any question about whether
your machine complies with the regulations
and standards of your country, contact a
Takeuchi dealer.
SIGNAL WORDS IMPORTANT: The word IMPORTANT is
used to alert operators and maintenance
Safety messages appearing in this manual personnel about situations which could
and on machine decals are identified by the result in damage to the machine and its
words “DANGER”, “WARNING” and components.
“CAUTION”. These signal words mean the
following: 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
DANGER indicates a hazard with a high contingencies. You must exercise all due
level of risk which, if not avoided, will care and follow normal safety procedures
result in death or serious injury. when operating the machine so as to ensure
that no damage occurs to the machine, its
operators or other persons.

WARNING indicates a hazard with a

medium level of risk which, if not avoided,
could result in death or serious injury.

CAUTION indicates a hazard with a low

level of risk which, if not avoided, could
result in minor moderate injury.

0-1
INTRODUCTION
FOREWORD
This manual describes operation, inspection
and maintenance of the machine, as well as
safety instructions to be heeded during these
operations.
If you have any questions about the
machine, please contact a Takeuchi sales or
service outlet.

MANUAL STORAGE COMPARTMENT SERIAL NUMBERS

A compartment for storing this manual is IMPORTANT: Do not remove the machine
provided at the position shown on the name plate with the serial number.
diagram below. Check the serial numbers of the machine
and engine and write them down in the
Cabine spaces below.

Machine number:

Canopy

Engine number:

1. Insert the ignition key and turn it

counterclockwise to open the cover (1).
2. After using the manual, place it in the
plastic pouch and store it back in the
manual storage compartment.

0-2
MACHINE DESCRIPTION
FRONT, REAR, LEFT AND RIGHT BREAK-IN PERIOD
When the machine is new, operate the
machine for the first 100 hours (as indicated
on the hour meter) by following the
instructions below.
Using a new machine without a break-in
period will lead to quicker deterioration of
machine performance and may shorten the
machine’s service life.
• Sufficiently warm up the engine and
hydraulic oil.
• Avoid heavy loads and rapid operations.
Operate with a load of about 80% the
maximum load.
• Do not abruptly start up, accelerate,
change directions, or stop unless
necessary.

This manual refers the front, rear, left and

right of the machine as seen when sitting in
the operator’s seat with the dozer blade
visible to the front.

DESIGNATED OPERATIONS
Use this machine primarily for the following
operations:
• Excavation
• Digging ditches
• Digging side ditches
• Leveling
• Loading

0-3
NOTES ON READING THIS
MANUAL
Please note that the descriptions and
diagrams included in this manual may not be
applicable to your machine.
The numbers used in the illustration are with
circles around them. The same numbers
appear between the parentheses in the text.
(Example: (1))

Symbols used in this manual

The symbols used in this manual have the
following meanings.
...... Prohibition
............. Lock
............. Unlock

0-4
 CONTENTS
Starter switch..................................... 2-48
Introduction......................................0-2 Engine shutdown switch .................... 2-48
Throttle controller................................ 2-48
Machine description.........................0-3 Horn button........................................ 2-49
Deceleration button............................ 2-49
Safety...............................................1-1 Travel speed button............................ 2-49
General precautions................................. 1-2 Auxiliary 1st switches.......................... 2-50
Precautions when preparing..................... 1-8 Auxiliary 2nd/4th switch (If equipped).. 2-51
Precautions when starting...................... 1-12 Third auxiliary hydraulic switch and
Precautions when operating................... 1-14 button (If equipped)............................. 2-51
Precautions when stopping.................... 1-23 Auxiliary 2/4 select button
Precautions when transporting............... 1-24 (If equipped)........................................ 2-51
Precautions on maintenance.................. 1-26 Light switch........................................ 2-52
Safety signs (decals)............................... 1-35 Wiper switch....................................... 2-52
Washer switch.................................... 2-52
Controls............................................2-1 Automatic deceleration switch............ 2-53
Names of components (Canopy).............. 2-2 Power/Highland mode switch............. 2-53
Names of components (Cab).................... 2-4 Detent mode switch
Covers...................................................... 2-6 (Auxiliary 1st) (If equipped).................. 2-54
Starter key............................................ 2-6 Auxiliary 1st auto tank switch
Right side cover.................................... 2-6 (If equipped)........................................ 2-54
Engine hood......................................... 2-7 Lift overload warning switch
Left side cover...................................... 2-7 (If equipped)........................................ 2-55
Fuel lid.................................................. 2-8 Beacon lamp switch (If equipped)....... 2-55
Fuel filler port........................................ 2-8 Levers and Pedals.................................. 2-56
Fuse box cover..................................... 2-9 Safety lock lever................................. 2-56
Cab........................................................ 2-10 Operating levers................................. 2-56
Cab door............................................ 2-10 Blade lever.......................................... 2-57
Emergency exit................................... 2-10 Travel levers/pedals............................ 2-58
Front window...................................... 2-11 Boom swing pedal.............................. 2-58
Lower front window............................ 2-12 Accessories............................................ 2-60
Side window....................................... 2-12 Heater................................................ 2-60
Sun shade.......................................... 2-13 Cup holder......................................... 2-61
Emergency hammer (optional)............ 2-13 Ashtray............................................... 2-62
Seat and seat belt.................................. 2-14 Power supply socket.......................... 2-62
Seat ................................................... 2-14 Interior light......................................... 2-63
Seat belt............................................. 2-15 Mirrors................................................ 2-63
Multi-information display......................... 2-16 External power sockets ..................... 2-64
Main Menu screen.............................. 2-16 Radio (for cab).................................... 2-66
Warning lamps.................................... 2-17 Auxiliary hydraulic lines (If equipped)... 2-70
Indicators........................................... 2-18 Operating the machine with an
Screen control key.............................. 2-21 accumulator....................................... 2-75
Screen navigation............................... 2-22 Load safety device (If equipped).......... 2-76
Switching images............................... 2-27
Instrument cluster................................... 2-28 Operation..........................................3-1
Warning lamps.................................... 2-28 Before starting operation.......................... 3-2
Indicators........................................... 2-29 Getting on or off the machine................ 3-2
Meters................................................ 2-29 Walk-around inspection........................ 3-2
Multi-data display............................... 2-30 Daily inspection..................................... 3-2
Switches................................................ 2-48 Starting and stopping the engine.............. 3-3
0-5
 Before starting the engine..................... 3-3 Walk-around inspection.......................... 5-16
Starting the Engine............................... 3-4 Inspecting by opening the engine
Warming up the engine......................... 3-5 hood and covers................................ 5-16
Stopping the engine............................. 3-5 Inspecting by walking around the
Operating the machine............................. 3-6 machine............................................. 5-17
Lever pattern (ISO pattern).................... 3-6 Inspecting while sitting in the
Lever pattern (G pattern) (If equipped)... 3-7 operator’s seat.................................... 5-17
Warming up the machine (hydraulic oil).3-8 Daily inspection (every 10 hours)............. 5-18
Inspection after warm-up...................... 3-9 Inspecting and replenishing the
Operating the travel levers/pedals....... 3-10 coolant............................................... 5-18
Stopping travel................................... 3-13 Inspecting and replenishing the
Operating the working equipment....... 3-14 engine oil............................................ 5-19
Operating procedures............................. 3-16 Inspecting the water separator ........... 5-20
Prohibited operations.......................... 3-16 Inspecting the fuel level....................... 5-21
Cautions on operating........................ 3-19 Inspecting the hydraulic oil tank level
Cautions on traveling on slopes ......... 3-20 and replenishing................................. 5-22
Getting out of mud............................. 3-22 Lubricating the working equipment..... 5-23
Operations possible with this After the initial 50 hours
machine............................................. 3-22 (only for new machines).......................... 5-24
Parking the machine............................... 3-24 Replacing the engine oil and the oil
Parking............................................... 3-24 filter.................................................... 5-24
Inspection and checks after stopping Inspecting and adjusting the fan belt... 5-26
the engine.......................................... 3-24 Every 50 hours....................................... 5-28
Handling in cold climates........................ 3-25 Inspecting and adjusting the crawler
Preparing for cold climates................. 3-25 tension............................................... 5-28
Cautions after operations.................... 3-25 Lubricating the slew bearing............... 5-30
After the cold climate.......................... 3-25 Draining the water from the fuel tank... 5-31
Handling rubber crawlers........................ 3-26 Inspecting the battery......................... 5-32
Prohibitions......................................... 3-26 Every 100 hours..................................... 5-34
Cautions............................................. 3-27 Cleaning the water separator ............. 5-34
Preventing the rubber crawlers from After the initial 250 hours
coming off.......................................... 3-27 (only for new machines).......................... 5-35
Replacing the hydraulic oil return filter.5-35
Transport..........................................4-1 Replacing the pilot line filter................. 5-36
Loading and unloading............................. 4-2 Replacing the travel motor gear oil...... 5-37
Hoisting the machine................................ 4-4 Every 250 hours..................................... 5-38
Securing the machine............................... 4-6 Replacing the engine oil and the oil
filter.................................................... 5-38
Maintenance.....................................5-1 Inspecting and adjusting the fan belt... 5-38
General..................................................... 5-2 Cleaning the air cleaner...................... 5-38
Maintenance overview.......................... 5-2 Cleaning the radiator fins and the oil
Cautions on maintenance..................... 5-2 cooler fins........................................... 5-40
Service data............................................. 5-4 Cleaning the air filter (CAB)................. 5-41
Fuel and lubricant table......................... 5-4 Every 500 hours..................................... 5-42
Regularly replace the hydraulic oil......... 5-8 Replacing the fuel filter........................ 5-42
List of consumables.............................. 5-9 Every 1000 hours................................... 5-43
List of tools (If equipped)..................... 5-10 Replacing the hydraulic oil return filter.5-43
List of tightening torques.................... 5-11 Replacing the pilot line filter................. 5-43
Safety-critical parts................................. 5-12 Replacing the travel motor gear oil...... 5-43
Maintenance list...................................... 5-14 Cleaning the engine cooling system.... 5-43
0-6
 Replacing the air cleaner element....... 5-45
Replacing the air breather filter ........... 5-46 Specifications...................................7-1
Inspecting and adjusting the engine Basic Specifications.................................. 7-2
valve clearance................................... 5-46 Machine dimensions................................. 7-4
Every 1500 hours................................... 5-47 Operating ranges...................................... 7-6
Inspecting, cleaning and checking Lifting Capacities...................................... 7-9
operation of the engine fuel injectors... 5-47
Inspecting the crankcase breather Options.............................................8-1
system................................................ 5-47 General precautions................................. 8-2
Every 2000 hours................................... 5-48 Safety precautions................................ 8-2
Lapping the engine valve seats Cautions when installing attachments... 8-2
(If necessary)...................................... 5-48 Cautions when operating attachments.. 8-3
Every 3000 hours................................... 5-49 Attachment combination table.................. 8-4
Inspecting, cleaning and checking Selecting a lever pattern........................... 8-5
operation of the EGR valve ................ 5-49 Switching the lever pattern................... 8-5
Every 4000 hours................................... 5-50 Hydraulic breaker..................................... 8-6
Replacing the hydraulic oil and Cautions on operating.......................... 8-6
cleaning the suction strainer............... 5-50 Replacing the hydraulic oil regularly...... 8-7
When required........................................ 5-53 Travel alarm.............................................. 8-8
Replacing the bucket teeth and the Optional equipment mass ...................... 8-10
side cutters......................................... 5-53 Biodegradable oil.................................... 8-11
Replacing the bucket.......................... 5-56 Replacing the hydraulic oil with
Adjusting the gap between the bucket biodegradable oil................................ 8-11
and arm (If equipped).......................... 5-58 Cab options............................................ 8-12
Inspecting and replenishing the Angle dozer blade .................................. 8-13
windshield washer fluid....................... 5-59 Specifications..................................... 8-14
Lubricating the levers and pedals........ 5-60
Inspecting the rubber crawlers............ 5-61
Replacing the rubber crawlers............ 5-62
Maintenance during extended storage
period..................................................... 5-64
Troubleshooting................................6-1
Symptoms that are not malfunctions........ 6-2
If the engine overheats.............................. 6-3
If the battery goes dead............................ 6-4
If a fuse blows.......................................... 6-6
Inspecting and replacing the fuse.......... 6-6
Inspecting the fusible link...................... 6-8
Restarting after adding fuel....................... 6-9
Bleeding air from the fuel system.......... 6-9
If a warning lamp flashes........................ 6-10
Vehicle error code list.............................. 6-12
Engine error code list.............................. 6-14
Other symptoms..................................... 6-16
Lowering the boom to the ground.......... 6-19
Towing.................................................... 6-20
If the cab or canopy is damaged............ 6-21

0-7
0-8
 SAFETY

1-1
 SAFETY
GENERAL PRECAUTIONS

GENERAL PRECAUTIONS When a problem is found on the machine

It is your responsibility to observe all If any problem (noise, vibration, smell,

pertinent laws and regulations and to disorder of instrument, smoke, oil leak,
follow the manufacture’s instructions on wrong indication of alarm or unusual
machine operation, inspection and indication in the instrument cluster, etc.) is
maintenance. detected during the operation or inspection
and maintenance of the machine,
Virtually all accidents occur as the result of a immediately inform your sales or service
failure to observe basic safety rules and dealer and take proper actions. Do not
precautions. operate the machine until the trouble is
Most accidents can be prevented by cleared.
identifying the potentially hazardous
situations beforehand.
Read and understand all safety messages Operating temperature range
which describe how to prevent accidents.
Do not operate the machine until you are To maintain the performance of machine and
sure that you have gained a proper to prevent it from early wear, observe the
understanding of its operation, inspection following operating conditions.
and maintenance. • Do not operate the machine if the ambient
temperature is higher than +45°C (+113°F)
or lower than –15°C (+5°F).
Observe all safety rules · If operated at an ambient temperature of
higher than +45°C (+113°F), the engine
• Operation, inspection and maintenance of may overheat and cause the engine oil to
this machine must be performed only by a degrade. Also, the hydraulic oil may
trained and qualified person. become very hot, causing damage to the
• All rules, regulations, precautions and hydraulic equipment.
safety procedures must be understood and · If operated at an ambient temperature of
followed when performing operation, lower than –15°C (+5°F), the parts made
inspection and maintenance of this of rubber such as gaskets may get
machine. hardened to cause an early wear or
• Do not perform any operation, inspection damage to the machine.
and maintenance of this machine when · If the machine is to be used outside the
under the adverse influence of alcohol, ambient temperature range described
drugs, medication, fatigue, or insufficient above, consult your sales or a service
sleep. dealer.

1-2
 SAFETY
GENERAL PRECAUTIONS

Wear appropriate clothing and protective Install a fire extinguisher and first aid kit
equipment

Be prepared for fire and accidents

• Do not wear loose clothing or any • Install an extinguisher and a first aid kit,
accessory that can catch on controls or in and learn how to use them.
moving parts. • Lean how to fight a fire and how to deal
• Do not wear oily or fuel stained clothing with accidents.
that can easily catch fire. • Know how to contact emergency
• Wear a hard hat, safety shoes, safety assistance and make a list of emergency
glasses, filter mask, heavy gloves, ear contacts.
protection and other protective equipment
as required by job conditions. Wear
required appropriate equipment such as Never remove safety equipment
safety glasses and filter mask when using
grinders, hammers or compressed air, as
metal fragments or other objects can fly
and cause serious injury.
• Use hearing protection when operating the
machine. Loud prolonged noise can cause
hearing impairments, even the total loss of
hearing.

• Make sure all protective guards, covers

and doors are in place and secured. Repair
or replace damaged parts before operating
the machine.
• Know how to use the safety lock lever, seat
belt and other safety equipment and use
them properly.
• Never remove any safety equipment except
for servicing. Keep all safety equipment in
good operating condition.

1-3
 SAFETY
GENERAL PRECAUTIONS

Use a signal person and a flag person Cautions when standing up from or
leaving the operator’s seat

Learn how to use the hand signals required

for particular jobs and make sure who has • Before standing up from the operator’s
the responsibility for signaling. seat to open/close the window or remove/
• All personnel must fully understand all the install the lower window, lower the working
signals. equipment to the ground, raise the safety
• The operator must respond to signals only lock levers to engage the lock and stop the
from the appointed signal person, but must engine. If any controls should be
obey a stop signal at any time from accidentally touched when the safety lock
anyone. levers is lowered (unlocked), the machine
• The signal person must stand in a clearly will suddenly move and cause serious
visible location when giving signals. injury or death.
• Be careful not to touch the operating levers
when raising or lowering the safety lock
levers.
• Before leaving the operator’s seat, lower
the working equipment to the ground, raise
the safety lock levers to engage the lock
and stop the engine. Also, be sure to
remove the key, lock the door and covers,
take it with you and store it in a specified
place.

1-4
 SAFETY
GENERAL PRECAUTIONS

Avoid fire and explosion hazards • When handling the fuel, washing oil or
paint, open the door and windows to
ventilate thoroughly.
• Store all flammable fluids and materials in a
safe and well-ventilated place.
• The short circuit of the electric system may
cause the fire. Check for any loosened
connections or damage to the wires every
day. Retighten the loosened connector and
wire clamp. Fix or change the damaged
wire.
• Fire from the pipes:
Make sure that the clamps, guards and
Keep flames away from fuel, oil, grease and cushions of the hoses and tubes are
antifreeze. Fuel is particularly flammable and securely fixed. If not, hoses or tubes may
dangerous. be damaged due to vibration or contact
• When handling these combustible with other parts during operation. This can
materials, keep lit cigarettes, matches, cause the high-pressure oil to spurt out,
lighters and other flames or sources of resulting in the fire or injury.
flames away.
• Do not smoke or permit open flames while
handling fuel or working on the fuel system.
• Do not leave the location while refilling with
fuel or oil.
• Never remove the fuel cap or add fuel
when the engine is running or still hot. Also,
do not spill the fuel on the hot surface of
the machine or the component of the
electric system.
• Clean up spilled fuel or oil immediately.
• Check for fuel, oil leak. Stop all leaks and
clean the machine before operating.
• When operating with grinder or welding,
move inflammables to a safe place.
• Do not cut or weld on pipes or tubes that
contain flammable fluids. Clean thoroughly
with nonflammable solvent before cutting
or welding.
• Remove all trash or debris from the
machine. Make sure that oily rags or other
flammable material are not stored on the
machine.
• Handle all solvents and dry chemicals
(foam type fire extinguisher) according to
procedures identified on manufacturer’s
containers. Work in a well-ventilated area.
• Never use fuel for cleaning purposes.
Always use a nonflammable solvent.

1-5
 SAFETY
GENERAL PRECAUTIONS

Exhaust fumes from the engine is Be careful not to get crushed or cut
poisonous

Never put your hands, feet or other parts of

• Do not operate the engine in an enclosed your body between the upperstructure and
area without adequate ventilation. the undercarriage or tracks, between the
• If natural ventilation is not possible, install machine body and working equipment, or
ventilators, fans, exhaust extension pipes between a cylinder and moving part. The
or other venting devices. sizes of these gaps change when the
machine moves, and a person can suffer
severe injury or death.

Handling asbestos dust

Inhaling asbestos dust can cause lung

cancer. When handling the materials which
may contain asbestos, take the following
precautions:
• Never use compressed air for cleaning.
• Avoid brushing or grinding parts containing
asbestos.
• For clean up, use a vacuum equipped with
a high efficiency particulate air filter (HEPA).
• Wear the stipulated respirator if there is no
other way to control the dust. When
working indoors, install a ventilation system
with a macromolecular filter.
• Do not allow unauthorized personnel in the
work area while working.
• Follow the rules and environmental
standard applicable to the work area.

1-6
 SAFETY
GENERAL PRECAUTIONS

Using optional products Never modify the machine

• Consult with Takeuchi before installing Unauthorized modifications to this machine

optional attachments. Depending on the can cause injury or death. Never make
type of attachments or the combination of unauthorized modifications to any part of this
them, the attachment may come into machine.
contact with the operator’s compartment
or the other parts of the machine. Make
sure that the optional attachment installed
is not contacted with other parts before
use.
• Do not use attachments that have not
been approved by Takeuchi. Doing so may
compromise safety or adversely affect the
machine’s operation or service life.
• Takeuchi will not be held responsible for
any injuries, accidents or damage to its
products caused by the use by a non-
approved attachment.

1-7
 SAFETY
PRECAUTIONS WHEN PREPARING

PRECAUTIONS WHEN
PREPARING
Know the work area

Before starting operation, know the working

area condition to ensure a safety operation.
• Inspect the topography and ground
condition of the working area, or the
structure of the building when working
indoors, and take the safety precautions as
necessary.
• Be sure to avoid all hazards and
obstructions such as ditches, underground
lines, trees, cliffs, overhead electrical wires,
or places where there is a danger of falling
rocks or slides.

• Check with the administrator for the

locations of buried gas pipes, water pipes
and power cables. If necessary, determine
what specific precautions must be taken to
insure safety by consulting with the
administrator.
• When working on roads, be sure to
consider the safety of pedestrians and
vehicles.
· Use a flag person and/or a signal.
· Fence off the working area and keep off
unauthorized persons.
• When working in water or crossing shallow
streams or creeks, check the depth of the
water, the solidity of the ground and the
water flow speed beforehand.
Refer to “Cautions on operating” for further
instructions.

1-8
 SAFETY
PRECAUTIONS WHEN PREPARING

Check the strength of the bridge Always keep the machine clean

When traveling over a bridge or a structure,

check the permissible load. If the strength is
insufficient, reinforce the bridge or the
structure.

• Clean windows, mirrors and lights to

ensure good visibility.
Adjust the mirror to the best position for
the operator to see the rear view (blind
spot) from the operator’s seat.
• Wipe off any oil, grease, mud, snow or ice,
to prevent accidents due to slipping.
• Remove all loose objects and unnecessary
devices from the machine.
• Remove any dirt, oil or grease from the
engine area to prevent fires.
• Clean around the operator’s seat and
remove any unnecessary object from the
machine.

1-9
 SAFETY
PRECAUTIONS WHEN PREPARING

Perform inspection and maintenance Cautions in the operator’s compartment

every day
• Remove mud and grease from shoe soles
before entering the operator’s
compartment. Pedaling the machine with
the shoes with mud and grease will cause
a slip accident.
• Do not leave the parts or tools around the
operator’s seat.
• Do not leave any plastic bottles in the
operator’s compartment or attach any
suction cups on the window glass. The
plastic bottle or suction cup act as a lens
and can cause fire.
Failure to identify or repair the irregularities or • Do not use the mobile phone during
damage on machine can lead to accidents. traveling or working.
• Before operating, perform the specified • Do not bring combustibles or explosives
inspection and make prompt repairs where into the operator’s compartment.
necessary. • After smoking, be sure to tightly close the
• If a failure occurs and the operation lid of the ashtray to put out the match or
becomes impossible or the engine fails, cigarette.
immediately stop the machine by following • Do not leave the cigarette lighter in the
the shutdown procedure, and keep operator’s compartment. When the room
machine securely parked until the temperature rises, the lighter may explore.
malfunction is corrected.

1-10
 SAFETY
PRECAUTIONS WHEN PREPARING

Emergency exit Emergency hammer (optional)

Front window (excluding machines with a

front guard)

An emergency hammer is installed to be

used to escape from the cab in an
emergency. When escaping, break the
If you should become trapped inside the windows with the hammer.
cab, open the front window to get out. • When breaking the window pane with a
hammer, take great care not to injure
yourself with the broken glass pieces.
• Remove the glass pieces from the window
sill so as not to cut yourself when
evacuating. Broken glass will fall from the
window, so be careful of your footing and
do not slip on the glass.

1-11
 SAFETY
PRECAUTIONS WHEN STARTING

PRECAUTIONS WHEN
STARTING
Support your weight in a three point
secure stance when getting on/off the
machine

• Do not jump on or down from the machine.

Never attempt to get on or off the moving
machine.
• When getting on or off the cab, first fully • Check if there is a “DO NOT OPERATE”
open the door to the locked position and alert sign or similar sign is on the cab door,
check that it does not move (for machines controls or starter switch. If there is one, do
with cab). not start the engine or touch any levers.
• Sound the horn to warn people around the
machine.

Sit in the operator’s seat and start the

engine

• Adjust the seat to securely latch it.

• Climb up/down the steps facing the

machine and holding the handrail to
support your weight in a three point secure
stance (hand and feet).
• Never use the safety lock lever or control
levers as hand holds.

Before starting the machine, ask any • Fasten the seat belt.
unauthorized personnel to leave the area • Check if the parking brake is on and all
control levers and pedals are in the neutral
Do not start the engine until you are sure it is position.
safe to start the machine by checking the • Check if the safety lock lever is in the lock
following items. position.
• Walk around the machine and warn the • Make sure that no one is near the machine.
person who is servicing the machine or is • Start and operate the machine only from
walking near the machine. Do not start the the operator’s seat.
machine until you are certain that no one is • Never attempt to start the engine by
around the machine. shorting across the starter terminals.

1-12
 SAFETY
PRECAUTIONS WHEN STARTING

Starting with jumper cables In cold climates

Use jumper cables only in the recommended • Be careful of slippery conditions on freezing
manner. Improper use of jumper cables can ground, steps and hand holds.
result in battery explosion or unexpected • In severe cold climates, do not touch any
machine motion. metal parts of the machine with bare
Refer to “If the battery goes dead” for further hands. The skin will freeze to the metal,
instructions. resulting in severe injury.
• Do not use ether or starting fluid on this
engine. The starting fluids can cause
After starting the engine explosion and serious injury or death.
• Warm up the engine and hydraulic oil. If the
After starting the engine, perform the levers are operated without warming, the
operations and checks described below in a machine will not react or move promptly or
safe place with no persons or obstacles in properly, resulting in accident.
the area. If any malfunction is found, follow
the shutdown procedure and report the
malfunction.
• Warm up the engine and hydraulic oil.
• Check if all gauges and warning devices
are properly working.
• Check for any noises.
• Test the engine speed control.
• Operate each control to ensure they are
properly working.

1-13
 SAFETY
PRECAUTIONS WHEN OPERATING

PRECAUTIONS WHEN Check if the work area is safe and secure

before operation
OPERATING
Ensure good visibility

• When working in dark places, turn on the

machine’s working lights and headlights
and additional lighting equipment installed,
as necessary.
• When visibility is poor due to bad weather
(fog, snow, rain or a cloud of dust), stop
operating the machine and wait until
visibility improves.
• Confirm the performance limits of the
machine.
Do not permit riders on the machine • Use a signal person at road shoulders,
narrow places or where your vision is
obstructed.
• Never allow anyone to enter the machine’s
slewing radius and path.
• Signal your intention to move by sounding
the horn.
• There is a blind spot in the rear of the
machine. Before traveling in reverse, check
that the area is safe and clear.

Do not allow anyone to ride on any part of

the machine at any time while traveling or
operating.

1-14
 SAFETY
PRECAUTIONS WHEN OPERATING

Check the position of the undercarriage noted that the travel speed changes
(tracks) before traveling depending on the load condition (for
machines with the automatic travel shift-
down system).
• When traveling on the uneven road or
sharp slope, turn off the deceleration
switch and the auto-deceleration switch. If
the machine is operated on such roads
with these switches turned on, the engine
speed may increase, causing the machine
to travel unexpectedly rapidly (for machines
with the deceleration and auto-deceleration
switches).

Before operating the travel levers/pedals,

make sure that the dozer blade is to the front
of the operator’s seat. Remember that when
the dozer blade is to the rear of the
operator’s seat, the travel levers/pedals must
be operated in the reverse direction from
when it is to the front.

Travel safely

• Avoid crossing over obstacles whenever

possible. If you must do so, keep the hoe
attachment close to the ground level and
travel slowly. Never cross obstacles which
will tilt the machine to an angle of 10° or
greater.
• On uneven ground, maintain the low speed
and avoid starting, stopping or changing
directions abruptly. Otherwise, the working
equipment may come in contact with the
ground, causing the machine to lose its
• Travel with the dozer blade raised, the hoe balance and get damaged or to damage
attachment folded as shown on the figure the structures in the surrounding area.
above, and the bucket raised 30 to 40 cm
(12 to 16 in.) above the ground.
• Do not slew while traveling. If you must
operate the hoe attachment while traveling,
operate at speeds slow enough so you
have complete control at all times.
• When a load greater than a set value is
applied during traveling in 2nd (high)
speed, the speed will automatically slow
down to 1st (low) speed. When the load
becomes lighter, the speed will increase
and return to 2nd (high) speed. It should be
1-15
 SAFETY
PRECAUTIONS WHEN OPERATING

Cautions on traveling on slopes • When traveling on slopes or grades, drive

slowly in 1st (low) speed. When
When traveling on slopes or grades, be descending a slope, slow down the engine
careful that the machine does not tip (roll) speed.
over or slide. • Do not descend slopes in reverse.
• Never travel on slopes that are too steep
for the machine to maintain its stability
(maximum gradeability: 30°, lateral tipping
angle: 15°). Note that in reality, the
machine’s stability becomes lower than the
above values depending on the working
condition.

• Do not change directions on slopes or

traverse slopes. First return to a flat
surface, and then take an alternative path.
• The machine may slip sideways even on a
slight slope if the ground is covered with
grass or dead leaves, or when traveling on
a wet metal plate or frozen surfaces. Make
sure the machine is never positioned
sideways on slopes.
• If the machine is stalled on the slope,
return each operating lever to the neutral
position before restarting the engine.

• When climbing a hill, keep the operator’s

seat facing the hillside. When descending a
hill, keep the operator’s seat facing the
downhill direction. In either case, travel
must be done while paying attention to the
ground in front of the machine.
• When traveling on slopes, lower the bucket
to a height of 20 to 30 cm (8 to 12 in.)
above the ground. When climbing a steep
slope, extend the hoe attachment to the
front. In emergencies, lower the bucket to
the ground and stop the machine.

1-16
 SAFETY
PRECAUTIONS WHEN OPERATING

Operate the machine on snow or ice with Ensure driver’s safety when loading
extra care

• When traveling on snow or on frozen

surfaces, drive at a low speed and avoid
starting, stopping or changing directions
abruptly.
• In the snowy area, the road shoulder and
objects placed beside the road are buried
in the snow and cannot be seen. There is a
hazard of the machine tipping over or
hitting covered objects, so always carry out
operations carefully.
• If the machine enters deep snow, there is a Do not load a truck unless the truck driver is
hazard that it may tip over or become in a safe place.
buried in the snow. • Never swing or position the bucket over a
Be careful not to drive beyond the road person or the cab room.
shoulder or to get trapped in a snow drift. • Load the truck from the rear.
• With frozen ground surfaces, the ground
becomes soft when the temperature rises,
and this may cause the machine to tip
over, resulting in an operator trapped inside
the machine.
• When parking the machine on an unstable
ground, lower the dozer blade.

Do not move the bucket over the heads of

people

Moving the bucket over the heads of people

entails the danger of the load spilling or the
sudden dropping of the bucket.

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 SAFETY
PRECAUTIONS WHEN OPERATING

Keep a safe distance from the overhead

high-voltage cables

• Pay also careful attention to the high-

voltage electric cables buried underground.

Never bring any part of the machine or

loaded material to near to the high voltage
cables unless all safety precautions required
by the local and national authorities have
been installed. If a person comes near to the
machine that is discharging sparks or
located near to or in contact with the power
source, there is a hazard of electric shock
and death.
• Always maintain a safe distance between
the machine and the high-voltage electric
cable.
• Check with the local power company
about safe operating procedure before
starting operations.
• Consider all cables to be high-voltage
cables and treat all cables as energized
even though it is known or believed that
the power is shut off and the cables are
visibly grounded.
• Use a signal person to give warning if the
machine approaches too close to the
high-voltage electric cables.
• Caution all personnel in the work area not
to come close to the machine or the
loaded material.

1-18
 SAFETY
PRECAUTIONS WHEN OPERATING

Watch out for hazardous working

conditions

• Do not enter areas where there is soft

ground. Doing so could cause the machine
to tilt under its own weight, resulting in a
• Never undercut a high bank. Doing so is machine tipping over or sinking into the
dangerous as it may cause ground ground.
collapse.
• Do not operate in places where there is a
danger of falling rocks.

• Do not come close to unstable grounds

(cliffs, road shoulders, deep ditches). If the
ground should collapse under the weight
• Maintain a safe distance between the or vibration of the machine, there is a
machine and the edge of the digging site. hazard that the machine may fall or tip
Do not dig the ground under the front of over.
the machine. · Remember that the soil after heavy rain
• When working close to the cliffs or road or blasting is weak.
shoulders, to make it easier to escape if · The ground of top of the embankment
there is any problem, set the crawlers at and of the circumferences of the
right angles to the cliff or road shoulder and excavated ditches are also weak.
the dozer blade to the front when carrying
out operations.

1-19
 SAFETY
PRECAUTIONS WHEN OPERATING

• Do not use the impact force of the hoe

attachment for breaking work. There is a
hazard of serious injury being caused by
flying pieces of broken materials and by the
damaged hoe attachment.

Be careful with flying objects

This machine is not equipped with protective

equipment to protect the operator from flying
• Do not perform demolition work under the objects. Do not use this machine in places
machine. There is a hazard that the where there are risks of the operator being
machine may fall down, because the hit by flying objects.
ground becomes unstable.
• When working on or from the top of
buildings or other structures, check the
strength and the structure before starting
operations. If a building or structure
collapses, serious injury or damage will
result.

• When doing demolition work, do not

perform demolition above your head. There
is a hazard of broken parts falling or of the
building collapsing and causing serious
injury or damage.

1-20
 SAFETY
PRECAUTIONS WHEN OPERATING

Operating on slopes is dangerous Never slew (swing) sideways with a heavy

load
When operating on slopes or grades, slewing
or operation of working equipment may
cause the machine to lose stability and tip
over. Avoid operating on slopes whenever
possible.

The machine can tip over more easily in the

lateral direction than in the longitudinal
direction.
• Do not slew (swing) sideways with a heavy
load at the tip of the hoe attachment. In
• Level off the work area. particular, do not slew (swing) sideways on
slopes.
• The tip of the attachment is heavier for
machines equipped with breakers,
crushers or long arms than for machines
equipped with the standard bucket. For
such machines with heavier tips, do not
perform excavation with the digging arm
(boom) facing the downhill direction or
operate toward sideways.

Be careful with the overhead objects

• Avoid slewing to the downhill direction with
the bucket full of loaded material. This will
reduce the stability of the machine and
may result in tipping over.

When operating under bridges, in tunnels,

near electric cables or indoors, be careful not
to let the boom or arm hit overhead objects.

1-21
 SAFETY
PRECAUTIONS WHEN OPERATING

Excavators are not designed for lifting Cautions when towing

loads

AG8A001

When towing, serious injury or death could

This machine is specifically designed for result, if performed incorrectly or the wire
excavation work. Therefore, it has no safety rope being used is inappropriate or not
equipment for crane operation. Extreme properly inspected.
caution should be paid if the excavator is • Do not tow using only a towing hole on one
used for lifting. side.
• Never lift loads in excess of capacity. • It becomes dangerous if the wire rope
Overload will cause the machine to roll and breaks or becomes disengaged. Use a
can result in serious injury or death. wire rope appropriate for the required
• All rated lift capacities are determined by tractive force.
using a machine placed on a stable and flat • Do not use a wire rope that is kinked,
ground. For a safe lifting work, the user is twisted or otherwise damaged.
expected to make due allowance for the • Do not apply heavy loads abruptly to the
particular job conditions. They include, soft wire rope.
or uneven ground, non-level condition, side • Wear safety gloves when handling the wire
loads, dynamic or jerked loads, hazardous rope.
conditions, and experience of personnel. • Make sure there is an operator on the
The operator and other personnel should machine being towed as well as on the
fully acquaint themselves with the machine that is towing.
operator’s manual before operating this • Never tow on slopes.
machine, and rules for safe operation of • Do not let anyone come near to the wire
equipment shall be adhered to at all times. rope while towing.
• The bucket linkage or lifting device may fail Refer to “Towing” for further instructions.
if chains or lifting device are incorrectly
attached, resulting in serious injury or
death.
• Do not attempt to pull stumps out of the
ground when using the machine as a
crane. The loads imposed on the machine
under this use are completely unknown.
• Do not allow anyone to stand on or under
the lifted loads or come close to the work
area.

1-22
 SAFETY
PRECAUTIONS WHEN STOPPING

PRECAUTIONS WHEN • Before leaving the machine, do the

followings:
STOPPING 1. Lower the bucket and the dozer blade to
the ground.
Park safely 2. Raise the safety lock lever to the locked
position.
3. Stop the engine and remove the starter
key.
4. Lock the cab and covers and take the
key with you.

• Park the machine on a flat, rigid and safe

ground. Set the parking brake.

If you must park on a slope or incline, park

the machine securely and block the
movement of the machine.
• When parking on a street, use barriers,
caution signs, lights, etc., so that the
machine can easily be seen even at night
to avoid collision with other vehicles.

1-23
 SAFETY
PRECAUTIONS WHEN TRANSPORTING

PRECAUTIONS WHEN • Lock the cab door after being loaded, if

applicable. Otherwise, the door may open
TRANSPORTING during transport.
• Chock the tracks and secure the machine
Load/unload the machine safely to the truck bed with wire rope or chain.

The machine may roll or tip over or fall while

being loaded or unloaded. Take the following
precautions:
• Select a firm, level surface and keep
sufficient distance from road shoulders.
• Secure the ramps of adequate strength
and size to the truck bed. The slope of the
ramps must not exceed 15°. If the rumps
are bowed down too low, support them
with poles or blocks.
• Never use the working equipment to load
or unload the machine. Doing so may
result in tipping over or falling down of the
machine.
• Keep the truck bed and loading ramps
clean of oil, soil, ice, snow, and other
materials to prevent the machine from
sliding sideways. Clean the crawlers.
• Chock the transporter wheels to prevent
movement.
• Turn off the deceleration switch and auto-
deceleration switch. Otherwise, the engine
speed may suddenly increase to cause
troubles.
• When being loaded or unloaded, travel
slowly in 1st (low) gear by following the
signal from the signal person.
• Never change courses on the ramps.
• Do not slew/swing on the ramps. The
machine may tip over.
• When slewing/swinging on the truck bed,
do it slowly as the footing should be
unstable.
1-24
 SAFETY
PRECAUTIONS WHEN TRANSPORTING

Hoist the machine safely Transport the machine safely

• Know and use correct crane signals. • Know and follow the applicable safety
• Check the hoisting equipment for damaged rules, vehicle code and traffic laws when
or missing parts on a daily basis and transporting the machine.
replace as necessary. • Select the best transport route by
• When hoisting, use a wire rope capable of considering the length, width, height and
lifting the machine mass. weight of the truck with the machine
• Hoist the machine in such a manner loaded on it.
described in the procedure below. Do not • Never abruptly start or stop or run at a high
do it in any other manner, as it may result in speed at the sharp curves during transport.
the machine losing its balance. Doing so will move or lose the balance of
Refer to “Hoisting the machine” for further the loaded machine.
instructions.
• Do not hoist the machine with an operator
on it.
• When hoisting, hoist slowly so that the
machine does not tip.
• Keep everyone out of the area when
hoisting. Do not move the machine over
the heads of the persons.

1-25
 SAFETY
PRECAUTIONS ON MAINTENANCE

PRECAUTIONS ON Replace safety-critical parts periodically

MAINTENANCE • Replace fuel hoses periodically. Fuel hoses

wear out over time, even if they do not
Display a “DO NOT OPERATE” alert sign show any symptom of wear.
• Regardless of the replacement schedule,
Severe injury could result if an unauthorized replace immediately if a symptom of wear
person should start the engine or touch is found.
controls during inspection or maintenance. Refer to “List of safety-critical parts” for
• Before performing maintenance, stop the further details.
engine, remove the key and take it with
you.
Explosionproof lighting

• Display a “DO NOT OPERATE” alert sign

on easy-to-see locations such as on the To prevent an ignition or explosion, use
starter switch or on control levers. explosion-proof lights when inspecting fuel,
oil, coolant or battery fluid. Otherwise,
explosion could result causing serious injury
Use the correct tools or death.

Do not use damaged or weakened tools or

tools designed for other purposes. Use tools
appropriate for the work involved.

1-26
 SAFETY
PRECAUTIONS ON MAINTENANCE

Prohibit access by unauthorized persons Always keep the machine clean

Do not allow unauthorized personnel in the • Clean the machine before performing
work area while working. Be careful when maintenance.
grinding, welding or using a hammer. You • Stop the engine before washing the
could be injured by flying debris from the machine. Cover the electrical parts so that
machine. water cannot enter. Water on electrical
parts could cause short-circuits or
malfunctions. Do not use water or steam to
Prepare work area wash the battery, electronic control
components, sensors, connectors or the
• Select a firm, level work area. Make sure operator’s compartment.
there is adequate light and, if indoors,
ventilation.
• Clear obstacles and dangerous objects. Stop the engine before performing
Eliminate slippery areas. maintenance

• Avoid lubrication or mechanical

adjustments while the machine is moving
or while the engine is running when the
machine is not moving.
• If maintenance must be performed with the
engine running, always work as a two
person team communicating each other.
· One person must sit in the operator’s
seat so that he/she can immediately stop
the engine when necessary. He/she must
take care not to touch the lever or pedal
unless necessary.
· The one who performs maintenance
must make sure to keep his/her body or
clothing away from the moving part of the
machine.

1-27
 SAFETY
PRECAUTIONS ON MAINTENANCE

Stay clear of the moving parts Secure the working equipment

To prevent unexpected movement, firmly

secure the working equipment when
repairing or replacing the bucket teeth or
side cutter.

Secure the engine hood or cover when

opened

Be sure to secure the engine hood or cover

before working the inside. Do not keep the
• Stay clear of all rotating and moving parts. hood or cover open on a windy day or if the
If a hand or tool becomes trapped in the machine is parked on a slope.
rotating or moving part, serious injury or
death could result.
• If a tool or other objects is dropped or Place heavy objects in a stable position
inserted in the fan or fan belt, it will be
flown or cut in pieces. Do not drop or insert
anything in the fan or fan belt.

Firmly secure the machine or any

component that may fall

When it is necessary to temporally place a

heavy object or an attachment on the ground
during removal or installation, be sure to
place it in a stable position. Keep off
unauthorized persons from the storage place
for such object.

• Before performing maintenance or repairs

under the machine, lower all moveable
working equipment to the ground or in the
lowermost position.
• Chock 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 working equipment if they are
not sufficiently supported. This procedure
is especially important when working on
hydraulic cylinders.
1-28
 SAFETY
PRECAUTIONS ON MAINTENANCE

Cautions when refueling Be careful with hot and pressurized

components

• Do not smoke or permit open flames while

fueling or near fueling operations. Stop the engine and allow the machine to
• Never remove the fuel cap or add fuel cool down before performing maintenance.
when the engine is running or still hot. Do • The engine, muffler, radiator, hydraulic
not spill fuel on the hot surface of the lines, sliding parts and many other parts of
machine. the machine are hot immediately after the
• Fill the fuel tank in a well ventilated place. engine is stopped. Touching these parts
• Do not fill the fuel tank to capacity. Allow will cause burns.
room for oil expansion. • The engine coolant, hydraulic oil and other
• Clean up spilled fuel immediately. oils are also hot and under high pressure.
• Securely tighten the fuel filler cap. If the fuel Be careful not to touch the hydraulic oil
cap is lost, replace it only with the genuine when loosening the cap or plug. Working
cap. Use of a non-approved cap without on the machine under these conditions
proper venting may result in pressurization could result in burns or injuries due to the
of the tank. hot oil spurting out.
• Never use fuel for cleaning. • The DPF and the exhaust gas emitted from
• Use the correct grade of fuel for the the exhaust line can be very hot while the
operating season. engine is running or the regeneration is
under way, as well as immediately after the
engine is stopped. Be careful not to
Handling of hoses accidentally touch them; doing so could
cause burns.
Oil leak or fuel leak can cause a fire.
• Do not twist, bend or hit the hoses.
• Never use twisted, bent or cracked pipes,
tubes or hoses; otherwise, they may burst.
• Retighten loose connection.

1-29
 SAFETY
PRECAUTIONS ON MAINTENANCE

Be careful with hot cooling systems Release pressure before working on the
hydraulic system

Oil may spurt out if caps or filters are

removed or pipes are disconnected before
releasing the pressure in the hydraulic
system.
• Immediately after the engine is stopped,
and while the safety lock lever is still in the
unlock position, turn the starter switch to
ON and move all the control levers and
pedals several times all the way in each
direction to release the pressure from the
Do not remove the radiator cap or the drain working equipment circuitry.
plug when the cooling water is hot. Stop the • Press the air breather button to relieve the
engine and wait until the engine and the internal pressure from the tank.
cooling water cool. Then, slowly loosen the • When removing plugs or screws, or when
radiator cap to release the internal pressure disconnecting hoses, stand to the side and
and remove it. loosen them slowly to gradually release the
internal pressure before removing.
Be careful with oil internal pressure • Oil or plug may spurt out according to the
pressure in the travel motor case. Loosen
Pressure is maintained in the hydraulic circuit the plug slowly and release the internal
long after the engine has been shut down. pressure.
• Completely relieve the internal pressure
before performing maintenance work.
Be careful with debris when the hammer
is being used

When using a hammer, pins may fly out or

metal particles may be scattered. This may
lead to serious injury.
• If hard metal parts such as pins, bucket
teeth, side cutter or bearings are hit with a
hammer, wear protective gear such as
safety goggles and gloves.
• When hitting pins or bucket teeth, always
check that there is no one in the
• The hydraulic oil is high enough pressure to surrounding area.
penetrate the skin or eyes and cause
serious injury, blindness or death.
Remember that the hydraulic oil escaping
from a small hole is almost invisible. When
checking for leaks, wear protective goggle
and thick gloves, and use a paperboard or
plywood to keep your skin from oil
spurting.
If oil penetrates the skin, it must be
surgically removed within a few hours by a
doctor familiar with this type of injury.
1-30
 SAFETY
PRECAUTIONS ON MAINTENANCE

Be careful with the high-pressure grease Cautions when servicing the air
conditioner

If the refrigerant comes in contact with eyes,

it damages your eyesight. If the refrigerant
comes in contact with skin, it may cause
frostbite. Never touch the refrigerant.

Handling of the accumulator

AG7A086

In the track adjuster, the grease has been

injected under high pressure. If the tension is
adjusted without following the prescribed
procedure, the grease discharge valve may
fly off, resulting in injury.
• Never loosen the grease fitting.
• Loosen the grease discharge valve slowly.
Do not turn it more than one turn.
• Do not put your face, arms, legs or body in
front of the grease discharge valve. Be sure to handle the high-pressure nitrogen
• If grease does not come out when the gas enclosed in the accumulator with care. If
grease discharge valve is loosened, the handled incorrectly, it could explode and
valve is faulty. Ask a Takeuchi service agent cause serious injury. Strictly observe the
for repair. following precautions:
• Do not disassemble.
• Do not allow flame near or throw it into a
Never disassemble the track adjuster fire.
• Do not drill, weld or fuse.
• Do not subject it to physical shock such as
hitting, rolling or dropping.
• Before disposing of the unit, the sealed gas
must be drained. Contact a Takeuchi
service agent for help.

There is a very strong spring contained in the

track adjuster. If the track adjuster is
accidentally disassembled, the spring can
pop out, resulting in serious injury Never
disassemble the track adjuster.

1-31
 SAFETY
PRECAUTIONS ON MAINTENANCE

Disconnect the battery wiring • Do not charge a battery or jump-start the

engine if the battery is frozen; otherwise it
may explode. Warm the frozen battery to
15°C (60°F) before use.
• Do not use or charge the battery when the
battery indicator is white. The battery is at
its end of life. Immediately replace the
battery.
• Do not tilt the battery. Doing so could
cause the battery fluid to leak out of the
exhaust hole. If contacted, it may cause
skin irritation or the machine part corrosion.
• Use a dampened cloth to clean the battery
Disconnect the battery wiring before working indicator and check the fluid level. Do not
on the electrical system or doing electric clean with a dry cloth; it can cause static
welding. Disconnect the negative (–) battery electricity to build up, resulting in ignition or
cable first. When reconnecting, connect the explosion.
negative (–) battery cable last.

Use caution when handling batteries

• Batteries contain sulfuric acid which will

damage the eyes or skin in case of
contact.
· If eye contact occurs, flush immediately
with clean water and get prompt medical
attention.
· If accidentally swallowed, drink large
quantities of water or milk and call a
physician immediately.
· If acid contacts skin or clothing, wash off
immediately with a lot of water.
• Wear protective goggle and gloves when
working with batteries.
• Batteries generate flammable hydrogen
gas which may explode. Keep away from
flame, sparks, fire or lighted cigarettes.
• When checking the level of the battery
fluid, use a flashlight.
• Be sure to stop the engine by turning off
the starter switch before inspecting or
handling the battery.
• Be careful not to let metal tools or any
metal objects come into contact with the
battery terminals and cause a short circuit.
• Loose battery terminals may result in
sparks. Be sure to fasten terminals tightly.
• Make sure the battery caps are tightened
securely.
1-32
 SAFETY
PRECAUTIONS ON MAINTENANCE

Periodically replace the safety-critical Jump starting with booster cables

parts
• When starting the engine using the booster
• To use the machine safely for a longer cables, be sure to connect the cables in
period, periodically add oil and perform the proper order described below. Wrongly
inspection and maintenance. To improving connected cables can result in sparking
the safely, replace the safety-critical parts and battery explosion.
like hoses and seat belts periodically. Refer · Do not allow the “machine in trouble” and
to “Safety-critical parts to be replaced “rescue machine” to touch each other.
periodically” for further details. · Do not allow the positive (+) and negative
• The “Safety-critical parts to be replaced (–) clips of the booster cables to touch
periodically” are the parts which each other or to come in contact with the
deteriorate, wear and fatigue after repeated machine.
use and whose properties change over · When connecting, attach the positive
time. While these characters of these parts booster cable to the positive (+) terminals
could cause serious physical or personal first. When disconnecting, remove the
damage, judging the remaining life of these negative cable from the negative (–)
part are difficult from external inspection or terminal (ground) first.
the feeling when operating. · Be sure to connect the clips securely.
• Replace the “Safety-critical parts to be · Connect the last clip of the booster cable
replaced periodically” if any defect is found to a point as far away from the battery as
from external inspection, even when they possible.
have not reached the time specified • Always wear the protective goggle and
interval. gloves when starting the engine by using
the booster cables.
• Use the booster cables and clips of a size
suited to the capacity of battery. Do not
use damaged or corroded booster cables
and clips.
• Be sure that the battery of the “rescue
machine” has the same capacity as the
battery of the “machine in trouble”.

1-33
 SAFETY
PRECAUTIONS ON MAINTENANCE

Have a Takeuchi service agent repair Disposing of wastes

welding

If welding must be performed, make sure

that it is done by a qualified person in a
properly equipped workplace. To prevent any
part from breaking down or being damaged
due to overcurrent or sparks, observe the
following.
• 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. • Always collect oil that is drained from the
Do not connect the earth ground near to machine in containers. Improperly
an electronically controlled device/ disposed waste oil can cause
instrument or connectors. environmental harm.
• Make sure that there are no seals or • Follow appropriate laws and regulations
bearings between the welding section and when disposing of harmful objects such as
the earth ground. oil, fuel, coolant, solvent, filters and
• Do not connect the earth ground around batteries.
the pins for the working equipment or
hydraulic cylinders.
• When welding is to be done on the Handling of poisonous chemicals
machine body, disconnect the connectors
for the electronically controlled devices Poisonous chemicals will cause serious injury
before working. if directly contacted.
Poisonous chemistry used in this machine
includes grease, battery solution, coolant,
Vibrations operators are subject to paint and adhesive agent.
Handle the poisonous chemicals properly
According to the results of the tests with care.
conducted to determine the vibrations
transmitted to the operator by the machine,
the upper limbs are subjected to vibrations
lower than 2.5 m/s2 (8.2 ft/s2) while the
seated part of the body is subjected to
vibrations lower than 0.5 m/s2 (1.64 ft/s2).

Checks 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 the
serviced parts.
• Operate each control lever and check that
the machine is operating properly.

1-34
 SAFETY
SAFETY SIGNS (DECALS)

SAFETY SIGNS (DECALS)

For the safety of the operator and the personnel working around the site, safety signs (decals)
are placed at certain locations on the machine as shown below. Walk around the machine with
this manual, and check 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 clean and legible. If any of the safety labels is peeling or damaged and
becomes difficult to read, replenish it with a new one. Please include your product serial
number when ordering a new sign from the Takeuchi service agent.
• When a part/unit to which a safety sign is attached is replenished, a new sign must be
attached to the new part/unit.

1-35
SAFETY
SAFETY SIGNS (DECALS)

1-36
SAFETY
SAFETY SIGNS (DECALS)

1-37
SAFETY
SAFETY SIGNS (DECALS)

1-38
SAFETY
SAFETY SIGNS (DECALS)

1-39
1-40
 CONTROLS

2-1
 CONTROLS
NAMES OF COMPONENTS

NAMES OF COMPONENTS (CANOPY)

Upperstructure Undercarriage Working equipment

1. Canopy 6. Crawler belt 11. Bucket
2. Seat 7. Idler 12. Bucket cylinder
3. Engine hood 8. Track roller 13. Arm
4. Fuel tank 9. Carrier roller 14. Arm cylinder
5. Hydraulic oil tank 10. Travel motor 15. Boom
16. Boom cylinder
17. Boom bracket
18. Swing cylinder
19. Auxiliary hydraulic lines
20. Dozer blade
21. Blade cylinder

2-2
 CONTROLS
NAMES OF COMPONENTS

1. Instrument cluster 14. Light switch

2. Starter switch 15. Automatic deceleration switch
3. Blade lever 16. Power/Highland mode switch
4. Throttle controller 17. Detent mode switch
5. Right operating lever* 18. Auxiliary 1st auto tank switch*
6. Horn button 19. Lift overload warning switch*
7. Deceleration button 20. Beacon lamp switch*
8. Boom swing pedal 21. Engine shutdown switch*
9. Travel levers/pedals 22. Auxiliary 2nd/4th switch*
10. Travel speed button 23. Auxiliary 2/4 select button*
11. Left operating lever 24. Third auxiliary hydraulic button*
12. Auxiliary 1st switches 25. Third auxiliary hydraulic switch*
13. Safety lock lever

*: Subject to the specifications or optional products selected

2-3
 CONTROLS
NAMES OF COMPONENTS

NAMES OF COMPONENTS (CAB)

Upperstructure Undercarriage Working equipment

1. Cab 6. Crawler belt 11. Bucket
2. Seat 7. Idler 12. Bucket cylinder
3. Engine hood 8. Track roller 13. Arm
4. Fuel tank 9. Carrier roller 14. Arm cylinder
5. Hydraulic oil tank 10. Travel motor 15. Boom
16. Boom cylinder
17. Boom bracket
18. Swing cylinder
19. Auxiliary hydraulic lines
20. Dozer blade
21. Blade cylinder

2-4
 CONTROLS
NAMES OF COMPONENTS

1. Multi-information display 17. Washer switch

2. Starter switch 18. Heater switch
3. Blade lever 19. Automatic deceleration switch
4. Throttle controller 20. Power/Highland mode switch
5. Right operating lever* 21. Detent mode switch
6. Horn button 22. Auxiliary 1st auto tank switch*
7. Deceleration button 23. Lift overload warning switch*
8. Boom swing pedal 24. Beacon lamp switch*
9. Ashtray 25. Engine shutdown switch*
10. Travel levers/pedals 26. Auxiliary 2nd/4th switch*
11. Travel speed button 27. Auxiliary 2/4 select button*
12. Left operating lever 28. Third auxiliary hydraulic button*
13. Auxiliary 1st switches 29. Third auxiliary hydraulic switch*
14. Safety lock lever 30. Power supply socket*
15. Light switch 31. Radio*
16. Wiper switch

*: Subject to the specifications or optional products selected

2-5
 CONTROLS
COVERS

COVERS Opening

STARTER KEY

1. Insert the starter key and turn it

counterclockwise to unlock the right side
The starter key is used to start and stop the cover (1).
engine, as well as to lock and unlock the 2. Push in the key hole with your thumb and
following components: open the right side cover (1) all the way.
• Cab door
• Engine hood Closing
• Covers 1. Close the right side cover (1) and press it
down until a click is heard.
2. Insert the starter key and turn it clockwise
RIGHT SIDE COVER to lock the right side cover (1).

• Stop the engine and allow the machine

to cool down before performing
maintenance.
• Do not keep the right side cover open
on a windy day or if the machine is
parked on a slope.
• When opening and closing the right side
cover, be careful not to get your hands
or other parts of your body caught by
the cover.

For inspection and maintenance of the

hydraulic oil system, electrical system or
window washer, open this cover. The
selector valve switching in the auxiliary 1st
and the lever pattern (optional) switching are
also performed.
The grease gun and the tools are stored
under the cover.

2-6
 CONTROLS
COVERS

ENGINE HOOD LEFT SIDE COVER

• Before opening the engine hood, be Be sure to close the cab door before
sure to stop the engine. If a hand or tool opening the left side cover and work
becomes trapped in the rotating or inside. If not, the wind-blown door could
moving part, serious injury could result. cause injury by striking you in the head or
• When opening or closing the engine body.
hood, be careful not to get your hands
or other parts of your body caught by it.
Opening

Opening

1. Insert the starter key and turn it

counterclockwise to unlock the left side
1. Insert the starter key and turn it cover (1).
counterclockwise to unlock the engine 2. Open the left side cover (1).
hood (1).
2. Push in the key hole with your thumb and Closing
open the engine hood (1). 1. Close the left side cover (1) and turn the
key clockwise to lock it.
Closing
1. Close the engine hood (1) and press down
the edge of it until a click is heard.
2. Insert the starter key and turn it clockwise
to lock the engine hood (1).

2-7
 CONTROLS
COVERS

FUEL LID FUEL FILLER PORT

Be sure to close the cab door before • Do not smoke and keep away from heat
opening the fuel lid for fueling. If not, the or flame while filling the fuel tank.
wind-blown door could cause injury by • Fill the fuel tank in a well ventilated
striking you in the head or body. place, with the engine turned off.
• Clean up spilled fuel immediately.
For adding fuel or checking its level, open • Do not fill the fuel tank to capacity.
this cover. Allow room for oil expansion.
• Securely tighten the fuel filler cap.
Opening

Opening

1. Insert the starter key and turn it

counterclockwise to unlock the fuel lid (1).
2. Open the fuel lid (1). 1. Open the fuel lid.
2. Turn the fuel cap (1) counterclockwise and
Closing remove it.
1. Close the fuel lid (1).
2. Insert the starter key and turn it clockwise Closing
to lock the fuel lid (1). 1. Turn the fuel cap (1) it clockwise and close
it.
2. Close the fuel lid and lock it.

2-8
 CONTROLS
COVERS

FUSE BOX COVER

For inspection and maintenance of the fuse,
open this cover.

Opening

1. Insert the starter key and turn it

counterclockwise to unlock the fuse box
cover (1).
2. Tilt the fuse box cover (1) forward.

Closing
1. Close the fuse box cover (1) and turn the
key clockwise to lock it.

2-9
 CONTROLS
CAB

CAB 2. Open the door fully and press it against

the cab to secure it in place.
CAB DOOR
Closing

When getting on or off the cab, first open

the door all the way until it is secured in
the catch and check that it does not
move.

Open the door fully and press it against the

catch at the back of the door to secure it in
place.
The door must be locked when getting on or
off the machine and while in operation.
1. Push the release lever (3) to the lower.
Locking and unlocking 2. Close the released door.

EMERGENCY EXIT
Front window (excluding machines with a
front guard)

Insert the starter key and turn it.

Opening

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

the door.
If you should become trapped inside the
cab, open the front window to get out.

To open the door from inside the cab,

push the lever (2) to the lower.
2-10
 CONTROLS
CAB

FRONT WINDOW 5. Release your thumb from the knobs (2)

and then lift the front window (3) fully and
lock the front window with lock pin (4).

• Grasp the handles firmly with both Closing

hands when opening and closing the
front window. Your head or hands may
get caught if it slips from your hands. When closing the front window slowly so
• When the front window is opened or as not to hit your head. Lowering the
closed, it will come close to the head. window abruptly may result injury or
Be careful that the window does not damage the front window.
strike the head.
• When 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. Grasp the left and right handles (1) and

press the knobs (2) with your thumb to
release the lock.
2. Pull down the front window (3) and while
doing so, slide it to the front and slowly
lower it.

1. Park on a level surface and stop the engine.

2. Set the safety lock lever to the locked
position.
3. Grasp the left and right handles (1) and
press the knobs (2) with your thumb to
release the lock.
4. Pull the front window (3) toward you and
lift while doing so.

3. Release your thumb from the knobs (2)

and then press the front window toward
front and lock the front window with lock
pin (4).

2-11
 CONTROLS
CAB

LOWER FRONT WINDOW SIDE WINDOW

Removing

1. Grasp the catch (7), unlock it and open

the side window.
1. Open the front window and stow it in the 2. To close the side window, close it until a
ceiling. click is heard.
2. Slowly lift the lower front window (4).

3. Hold the window in a vertical position (the

bottom of the window should be in front of
you), place it through the guide (5) on the
left side of the cab, and then secure it with
the support (6).

2-12
 CONTROLS
CAB

SUN SHADE EMERGENCY HAMMER (OPTIONAL)

1. Pull out the sun shade forward. An emergency hammer is installed to be

2. Hook the sun shade to the two catches (1) used to escape from the cab in an
emergency. When escaping, break the
windows with the hammer.
• When breaking the window pane with a
hammer, take great care not to injure
yourself with the broken glass pieces.
• Remove the glass pieces from the window
sill so as not to cut yourself when
evacuating. Broken glass will fall from the
window, so be careful of your footing and
do not slip on the glass.

2-13
 CONTROLS
SEAT AND SEAT BELT

SEAT AND SEAT BELT (B) Fore-and-aft adjustment

1. Pull up the lever (2) and slide the seat
SEAT backward or forward to the desired
position for operation of machine.
2. Release the lever (2) at the desired
position to secure the seat.
• Adjust and secure the seat. Adjustment range: 15 positions, in 150
• Do not make any adjustments while mm (5.9 in.)
operating the machine.
• Do not set the backrest to its maximum
reclining position and slide the seat
backwards at the same time. Doing so
may damage the rear window or cause
injury.
• Remember that the backrest returns to
the forward position abruptly due to the
spring force.

A E

B (C) Adjusting according to operator’s

weight
1. Turn the handle (3) until the scale (4)
indicates the weight of operator.
3 Adjustment range: 50 to 130 kg (110 to
1 287 lbs)
4 2
AG7B021 (D) Adjusting the height of the seat
Upward
(A) Adjusting the backrest angle 1. Lift the seat to first or second position
1. Sit up and sit back in the chair. click-stop.
2. Pull up the lever (1), recline the backrest Adjustment ranges: 2positions, in 60mm
by using the spring force. Release the (2.36 in.)
lever (1) at the desired angle to secure the Downward
backrest. 1. First lift the seat to highest position, then
the seat can be lowered to lowest
position.

2-14
 CONTROLS
SEAT AND SEAT BELT

(E) Adjusting the headrest (Option) SEAT BELT

The headrest (E) can be moved upward or
downward.
1. Grab the headrest (E) with both hands,
and move upward or downward to the Be sure to fasten the seat belt securely
desired position. before starting the engine.

Fastening the seat belt

1. Adjust the seat to the desired position for
operation, sit up and sit back in the chair.
2. 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.
4. Check if the belt is securely locked by
pulling it, and arrange the belt around your
waist.

Releasing the seat belt

1. Grasp the tongue plate (A) and press the

button (C) on the buckle (B).
The seat belt retracts back into its original
position.

2-15
 CONTROLS
MULTI-INFORMATION DISPLAY

MULTI-INFORMATION DISPLAY
MAIN MENU SCREEN

For explanation purposes, all lamps on this page are in the lit condition. This screen image is
quite different from that of the real operation. In the actual operation, if a warning is given or
any function is selected, the corresponding symbol appears enlarged at the center of the
display for approx. one second.
When the starter switch is set to ON, the battery charge warning lamp and the engine oil
pressure warning lamp first appear enlarged, and then turn on with an alarm at their original
locations. The machine system is normal if the lamps turn off after the engine is started.

2-16
 CONTROLS
MULTI-INFORMATION DISPLAY

WARNING LAMPS 4. Coolant temperature warning lamp

This lamp flashes and an alarm is sounded
IMPORTANT: If a warning lamp flashes if the engine coolant temperature
and an alarm is sounded, immediately becomes abnormally high while the engine
stop all operations and check the is running.
corresponding component.
Refer to “If a warning lamp flashes” on 5. Air cleaner warning lamp
pages 6-10 and 6-11. This lamp flashes and an alarm is sounded
if the air cleaner filter is clogged while the
1. ECM error warning lamp engine is running.
This warning lamp flashes if the Electronic
Control Module (ECM) detects an engine 6. Fuel filter warning lamp
problem while the starter switch is in the This lamp flashes and an alarm is sounded
ON position. The problem detected is if the fuel filter is clogged while the engine
recorded as an ECM error. is running.
Refer to “Engine error code list” on pages
6-14 to 6-15. 7. Fuel level warning lamp
This lamp flashes when the fuel level is low
1-1. Vehicle and engine emergency lamp while the starter switch is in the ON
This lamp is displayed enlarged for one position.
second, and then flashes and an alarm
sounds if there is a problem with the 8. Third auxiliary hydraulic warning lamp
machine. Go to the (7) Error code This lamp starts flashing and an alarm
display from the Menu screen, get the sounds if the fixed side (left “e”) pressure
vehicle or engine error code number, of the auxiliary 3rd drops abnormally while
and consult your sales or service dealer the engine is running, or while the quick-
referring to the “Vehicle error code list” hitch is being removed or installed.
or “Engine error code list” in this
manual.
Refer to “Menu screen” on page 2-22.
Refer to “(7) Error code display” on
page 2-25.
Refer to “Vehicle error code list” on
pages 6-12 and 6-13.
Refer to “Engine error code list” on
pages 6-14 to 6-15.

2. Battery charge warning lamp

This lamp flashes and an alarm is sounded
if a problem rises in the charging system
while the engine is running.

3. Engine oil pressure warning lamp

This lamp flashes and an alarm is sounded
if the lubricant oil pressure abnormally low
while the engine is running.

2-17
 CONTROLS
MULTI-INFORMATION DISPLAY

INDICATORS 12. Travel speed indicator lamp

9. Deceleration indicator lamp

�������� High-speed travel

�������� Automatic deceleration
indicator
�������� Low-speed travel

�������� Deceleration indicator

This lamp turns on when the travel speed

button is set to the 2nd (high) speed.
Automatic deceleration indicator
It flashes when the automatic 13. Power mode indicator lamp
deceleration switch is pressed and This lamp lights up when the power
remains lit while in the deceleration mode side of the Power/Highland mode
mode. select switch is pressed. The maximum
Refer to “Deceleration button” on page engine output is maintained for as long
2-49. as this lamp is lit.
Refer to “Automatic deceleration switch”
on page 2-53. 14. Lift overload warning indicator lamp
This lamp turns on when the lift overload
Deceleration indicator lamp warning switch is turned on.
This lamp turns on when the deceleration
button is pressed. The lamp lights up to 15. Auxiliary 2nd/4th select indicator lamp
indicate that the engine is in the
deceleration mode at low idling speed
(1100 rpm).
�������� Auxiliary 2nd is selected.
10. Glow indicator lamp
This indicator lamp turns off when the
engine preheating is completed. �������� Auxiliary 4th is selected.

11. Highland mode indicator lamp

Highland mode is selected.
Refer to “Power/Highland mode switch” 16. Auxiliary 1st one-way (one-way
on page 2-53. circuit) indicator lamp

�������� Auxiliary 1st auto tank is

selected.

�������� Auxiliary 1st one-way is

selected.

No display: ����Two-way (two-way circuit) is

selected.
2-18
 CONTROLS
MULTI-INFORMATION DISPLAY

17. Dozer blade float indicator lamp 20. Throttle opening position indicator
(If equipped)

�������� This lamp lights up when

the float switch on the
blade lever is pressed.

18. Water temperature gauge

Indicates the temperature of the engine
coolant water. The indicator level must
be within the green range during
machine operation. The red range
indicates overheating.

19. Fuel gauge

IMPORTANT: If the fuel gauge

changes the color from green
to orange while traveling on a
flat ground, do not go to a
sloping land. Engine stalling
may occur on the sloping
land. Before operating on the
sloping land, be sure to add The red range increases as the engine
enough fuel. load increases, indicating higher fuel
consumption. When the button (C) (Bar
Indicates the amount of fuel in the tank. meter key) is pressed in a normal screen,
Be sure to fill up the tank before running the display is changed from the throttle
out of fuel. opening position to the lift load factor
and the PM accumulation amount, in this
order.
• The lift load factor is displayed if there
is no change in the throttle opening
position for five seconds after the lift
alarm switch is turned on.
• The throttle opening position is
displayed if the highland mode switch
is turned on or there is a change in the
throttle opening position.

2-19
 CONTROLS
MULTI-INFORMATION DISPLAY

21. Auxiliary 1st flow rate indicator lamp 24. Hour meter/Trip meter
This lamp lights up to indicate which flow • Hour meter
rate setting is selected in the auxiliary 1st.
Displays the total
engine running time in
�������� a Flow rate setting 1 hours.
The rightmost digit
�������� b Flow rate setting 2 indicates tenths of
hours (6 minutes).
Set the inspection and maintenance
�������� c Flow rate setting 3 intervals according to the time displayed on
the hour meter.
�������� d Flow rate setting 4 • Trip meter
Three patterns of desired operating hours
can be displayed.
�������� e Flow rate setting 5
Refer to “Trip meter setting” on page 2-23.

�������� f Flow rate setting 6

�������� 1 Flow rate setting 7

�������� 2 Flow rate setting 8

�������� 3 Flow rate setting 9

Refer to “Auxiliary 1st flow rate setting”

on page 2-23.

22. Working light indicator

Lights up when the working light is
turned on.

23. Date and time indicator

Displays the date and

time set.
Refer to “Date and
time setting” on page
2-25.

2-20
 CONTROLS
MULTI-INFORMATION DISPLAY

SCREEN CONTROL KEY Up ( ) key

Use this key to move the cursor upward
and to increase the value in each setting.
Press and hold this key for one second to
rapidly increase the value.

D. Auxiliary 1st key

The auxiliary 1st symbol is displayed in the
initial screen. Pressing this key changes
the symbol display in the following order.
Auxiliary 1st setting 1, Auxiliary 1st setting
2, Auxiliary 1st setting 3.

Note: Do not press the symbol keys on the Enter key

display. The LCD could be damaged if the Use this key to confirm or execute the
symbol keys are pressed hard. For actual setting made by each key.
operation, press the push button keys To clear the trip meter being displayed,
located at the bottom of the screen. press and hold this key for three seconds.

A. Menu key E. —
Use this key to switch between the Home
screen and the Menu screen. This key is
also used to cancel changes made in
each setting. The screen returns to the
Home screen if this key is pressed in the
information screen.

B. Hour meter key

This hour meter symbol is displayed in the
initial screen. Pressing this key changes
the meter display in the following order.
Trip meter 1, Trip meter 2, Trip meter 3,
Hour meter.

Down ( ) key
Use this key to move the cursor
downward and to decrease the value in
each setting. Press and hold this key for
one second to rapidly decrease the value.

C. Bar meter key

This hour meter symbol is displayed in the
initial screen. Pressing this key changes
the meter display in the following order.
Throttle opening position, Lift load factor,
PM accumulation amount

2-21
 CONTROLS
MULTI-INFORMATION DISPLAY

SCREEN NAVIGATION
• Menu screen

Press the Menu key to go the Menu screen while in the Home screen.

(1) Trip meter setting

(2) Auxiliary line flow rate display
(3) Auxiliary 1st flow rate setting
(4) Auxiliary 2nd/4th flow rate setting
(5) Date and time setting
(6) Data display
(7) Error code display
(8) LCD setting
Move the cursor with the Up ( ) or Down ( ) key to go to the desired item to be set, and
then press the Enter key to confirm. To return to the Menu screen, press the Menu key.
The wrench symbol indicates the “setting is possible state” and the ( i ) mark indicates
information only.

2-22
 CONTROLS
MULTI-INFORMATION DISPLAY

(1) TRIP METER SETTING (3) AUXILIARY 1ST FLOW RATE SETTING

Six patterns of desired operating hours can Three flow rate patterns can be set in the
be set. auxiliary 1st.
To start setting, press the Enter key. The Refer to the trip meter setting for the key
value flashes while being set. operation. To move the cursor in the
Up ( ) key: Increases the value or moves the direction of the arrow, use the Down ( ) key.
cursor upward. Rapidly increases the To move the cursor in the opposite
value when pressed and held for one direction of the arrow, use the Up ( ) key.
second.
Down ( ) key: Decreases the value or moves Initial A/B common, Variable
the cursor downward. Rapidly decreases condition standard flow range
the value when pressed and held for one
second. 100%
Enter key: Confirms setting Auxiliary 1st-1 = 54 L/min 10 to 100%
Menu key: Cancels setting or returns to the ( 14.3 US gpm)
Menu screen. 75%
Pressing and holding the Enter key for three Auxiliary 1st-2 = 40.5 L/min 10 to 100%
seconds clears the trip meter pointed by the ( 10.7 US gpm)
cursor. 50%
Auxiliary 1st-3 = 27 L/min 10 to 100%
( 7.1 US gpm)
(2) AUXILIARY LINE FLOW RATE DISPLAY
The table shows the 1-way flow rate when
there is no load.

Displays the flow rate of the Auxiliary 1st,

2nd and 4th.
The flow rate cannot be changed.

2-23
 CONTROLS
MULTI-INFORMATION DISPLAY

(4) AUXILIARY 2ND/4TH FLOW RATE

SETTING

Pressing the Enter key while the cursor is

at “Select ATT” goes to the attachment
select screen.
Pressing the Down ( ) key will move the One pattern of the auxiliary 2nd/4th flow rate
blue flashing light in the direction of the can be set.
arrow.
Pressing the UP ( ) key will move the blue Initial Variable
flashing light in the opposite direction of the Standard flow
condition range
arrow.
Move the blue flashing light to the desired C/D 100%
symbol or the number, and then press the Auxiliary 2nd =21.6 L/min 10 to 100%
Enter key to confirm. ( 5.7 US gpm)
The selected symbol will appear at the lower G/H 100%
left of the Home screen. Auxiliary 4th =21.6 L/min 10 to 100%
( 5.7 US gpm)

The table shows the 1-way flow rate when

there is no load.

Refer to the trip meter setting for the key

operation. To move the cursor in the
direction of the arrow, use the Down ( ) key.
To move the cursor in the opposite
direction of the arrow, use the Up ( ) key.

2-24
 CONTROLS
MULTI-INFORMATION DISPLAY

(5) DATE AND TIME SETTING Display items

• Engine RPM
• Coolant temperature
•—
• Battery voltage
• PM accumulation amount

(7) ERROR CODE DISPLAY

The year, month, date, hour and minute can

be set. (Effective year range: 2010 to 2099)
• Move the cursor to the clock symbol,
and then press the Enter key. The cursor
will be shifted to the place for setting the
year.
Press the Enter key again, and then enter
the year. (The year display keeps flashing
during editing.) ........Vehicle error code
Press the Enter key to confirm. The month, Displays four error codes, with the latest
date, hour and minute can be set using the code in the upper left.
same procedure for the year. Refer to “Vehicle error code list” on pages
• Move the cursor to the calendar symbol, 6-12 and 6-13.
and then press the Enter key to change the
format of “Year-Month-Date” to “Date- .........ECM error code
Month-Year” or “Month-Date-Year”. Engine ECM (Engine Control Module) error
Refer to the trip meter setting for the key code
operation. Displays three error codes, with the latest
code at the top.
Refer to “Engine error code list” on pages
(6) DATA DISPLAY 6-14 to 6-15.

IMPORTANT: If an error code appears,

immediately stop the operation and
contact a Takeuchi sales or service outlet
for help.

Displays various data. The setting cannot be

changed.

2-25
 CONTROLS
MULTI-INFORMATION DISPLAY

(8) LCD SETTING • Unit setting

Switch between SI unit and US units.
• Background color setting Move the blue flashing light to the desired
unit position, and then press the Enter key
to confirm.

Menu key: returns to the Menu screen.

Pressing the Menu key again returns to the
Home screen.

Move the cursor to the background

color symbol, and then press the Enter
key. The blue flashing light moves from
blue gray to gray, blue and black, in this
order. Move the blue flashing light to the
desired color position, and then press the
Enter key to confirm.
The background color can be changed in
this screen, regardless of mode (day or
night).

• The brightness of the LCD is set to

between 0 and 100%. The brightness
changes each time the adjustment is
made.
Day mode: initial setting value is 50%
Night mode: initial setting value is 50%
While in the day (night) mode, adjustment
is possible only for the brightness set to the
night (day) mode.
Refer to the trip meter setting for the key
operation.

2-26
 CONTROLS
MULTI-INFORMATION DISPLAY

SWITCHING IMAGES

• Changing the background color (day/

night)

Turn on the light switch on any screen to

decrease the display brightness and to enter
the “evening mode”.

2-27
 CONTROLS
INSTRUMENT CLUSTER

INSTRUMENT CLUSTER

For explanation purposes, all lamps on this WARNING LAMPS

page are in the lit condition. This screen
image is quite different from that of the real IMPORTANT: If a warning lamp flashes
operation. and an alarm is sounded, immediately
Once the starter switch is turned to ON, all stop all operations and check the
lamps on the instrument cluster light up and corresponding component.
the alarm sounds. Refer to “If a warning lamp flashes” on
Then, the battery charge warning lamp (3) pages 6-10 and 6-11.
and the engine oil pressure warning lamp (2)
start flashing and an alarm sounds. The
machine system is normal if the lamps turn
off after the engine is started.
If any lamp is not lit when the starter switch
is turned to ON, there is something wrong in
the machine. Consult your sales or service
dealer.

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1. Vehicle and engine emergency lamp INDICATORS

This lamp flashes and an alarm sounds if
there is a problem with the machine. Go to 7. Glow lamp
the “Failure Record (FAILURE RECORD)” This lamp goes out when the engine
from the side menu screen, get the vehicle preheating is completed.
or engine error code number, and then
consult your sales or service dealer 8. Travel speed lamp
referring to the “Vehicle error code list” or This lamp turns on when the travel speed
“Engine error code list” in this manual. button is set to the 2nd (high) speed.
Refer to “Side menu screen” on page
2-39. 9. Deceleration lamp
Refer to “Failure Record (FAILURE This lamp turns on when the deceleration
RECORD)” on page 2-46. button is pressed. The lamp lights up to
Refer to “Vehicle error code list” on pages indicate that the engine is in the
6-12 and 6-13. deceleration mode at low idling speed
Refer to “Engine error code list” on pages (1200 rpm).
6-14 to 6-15. It flashes When the automatic deceleration
switch is pressed to indicate that the
2. Engine oil pressure warning lamp machine is in the automatic deceleration
This lamp flashes and an alarm is sounded mode.
if the lubricant oil pressure abnormally low Refer to “Deceleration button” on page
while the engine is running. 2-49.
Refer to “Automatic deceleration switch”
3. Battery charge warning lamp on page 2-53.
This lamp flashes and an alarm is sounded
if a problem rises in the charging system
while the engine is running. METERS
4. Coolant temperature warning lamp 10. Water temperature gauge
This lamp flashes and an alarm is sounded Indicates the temperature of the engine
if the engine coolant temperature coolant water.
becomes abnormally high while the engine The LED should be within the green
is running. range during machine operation.
The red range indicates overheating.
5. Fuel level warning lamp
This lamp turns on if the fuel level 11. Fuel gauge
becomes low while the starter switch is in Indicates the amount of fuel in the tank.
the ON position. Be sure to top off the tank before running
out of fuel.
6. Air cleaner warning lamp
This lamp flashes and an alarm is sounded
if the air cleaner filter is clogged while the
engine is running.

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MULTI-DATA DISPLAY 3. Time display

Displays the time set.
12. LCD (Liquid Crystal Display) Refer to “Time setting” on page 2-37.
It displays various functions and data on
hour meter, trip meter, clock, tachometer 4. Tachometer
and the machine.

Home screen

Displays the engine RPM in 10 levels.

Pressing the (B) key while the tachometer is
displayed changes to the display of the PM
accumulation rate and lift load factor, in this
1. Key function display order.
The key function display changes • The throttle opening position is displayed if
depending on the screens (Home, Menu the lift alarm switch is turned on and there
and each setting) is no change in the throttle opening
For actual operation, use the buttons, “A”, position.
“B” and “C”, located beneath each • The tachometer is displayed if the highland
symbol. mode switch is turned on or there is a
Refer to “Function of each key” on pages change in the throttle opening position.
2-34 to 2-47. • For TB230, the PM accumulation rate does
not change.
2. Hour meter/Trip meter
• Hour meter 5. Functions (Page 1)
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.

• Trip meter
Three patterns of desired operating hours
can be displayed.
Refer to “Trip meter display” on page
2-34.

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A. Auxiliary 2nd/4th selection D. Highland Mode (If equipped)

This mode is used to reduce

the engine load due to the
�������� Auxiliary 2nd is selected.
hydraulic pump. When the
machine is operated at a high-
altitude site, the engine output
�������� Auxiliary 4th is selected. is decreased due to thin air. In such cases,
the hydraulic horse power is automatically
adjusted to prevent the engine from
stalling.
B. Auxiliary 1st One-way (one-way circuit) Refer to “Power/Highland mode switch”
on page 2-53.

�������� Auxiliary 1st auto tank is

selected.

�������� Auxiliary 1st one-way is

selected.

No display: ����� Two-way (two-way circuit)

is selected.

C. Lift overload warning/power mode

�������� Displays when the power

mode select switch is
pressed. It indicates the
maximum engine output is
selected.
�������� Display the symbol when
the lift overload warning
switch is turned on.

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E. Alarm I. Dozer blade float indicator

Displays the symbol of the dozer blade
Displays the clock symbol when float when the float button is pressed.
the alarm function is turned on.
Refer to “Alarm setting” on 7. Warning indicators (Page 3)
page 2-37. When the (A) key is pressed, the display
changes as the following. If there is no warning,
the screen returns to the “Functions” on Page 1.
6. Function indicators (Page 2)
When the (A) key is pressed, the display
changes as the following.

Warning display is first flashed and enlarged

for three seconds and then stays displayed,
if there is a problem with the machine. If
multiple warnings are to be displayed, the
F. Auxiliary 1st indicator highest priority warning is displayed. Priority
from the highest to the lowest: ECM error
G. Auxiliary 1st flow rate selection warning, Auxiliary 3rd hydraulic pressure
indicator warning, water separator warning and fuel
Press the (B) key to move the and select filter warning.
the desired flow rate. No enlarged display for the maintenance
Refer to “Auxiliary 1st Flow Rate Setting” warning.
on page 2-40. Go to the “MAINTENANCE/FAILURE
RECORD/Error cord display” from the Side
H. Attachment symbol indicator menu screen, get the vehicle or engine error
code number, and consult your sales or
service dealer referring to the “Vehicle error
code list” or “Engine error code list” in this
manual.

Displays the symbol of the attachment

selected in the “Auxiliary 1st Flow Rate
Setting” section.

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J. ECM error warning indicator M.Maintenance warning indicator

This warning lamp flashes if the Electronic When the time for maintenance set by the
Control Module (ECM) detects an engine trip meter is reached, this warning lamp
problem while the starter switch is in the flashes and an alarm sounds.
ON position. The problem detected is
recorded as an ECM error.
Refer to “Engine error code list” on pages
6-14 to 6-15.

K.Fuel filter warning indicator

This lamp flashes and an alarm is sounded
if the fuel filter is clogged while the engine
is running.

L. Auxiliary 3rd hydraulic pressure

warning indicator (If equipped)
This warning lamp starts flashing and an When the time for maintenance set by the
alarm sounds if the pressure in the fixed trip meter is reached, the screen is
side (left “e”) of the Auxiliary 3rd drops changed from the Main to the Trip Meter
abnormally while the engine is running, or for Maintenance on the DATA screen.
while the quick-hitch is being used for Each value remains flashing until its
changing the bucket. corresponding key is pressed. At this
stage, the trip meter values cannot be
reset. Pressing any key returns to the
Warning (Page 3) of Main screen in which
the maintenance warning lamp is flashing
and the alarm is sounding. Promptly
inspect and service the relevant item.
Refer to “Menu/Trip meter reset” on page
2-35.
Refer to “Maintenance” on page 5-1.

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FUNCTION OF EACH KEY 1. Hour meter

2. Trip meter 1

The functions are as below in the Home

screen. The different functions appear in the
other screens.
3. Trip meter 2
A. Stopping the alarm or switching the
display between Functions and
Warnings
· Pressing the (A) key while the alarm is
sounding stops the alarm.
· Pressing the (A) key to switch the
display; Functions (Page 1), Functions
(Page 2), and Warnings (Page 3). 4. Trip meter 3

B. Meter switching
Pressing and holding the (B) key for two
seconds or more each time the display
changes as follows:

5. Returns to the hour meter

· When the (B) key is pressed, the display

changes in the following order.

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 CONTROLS
INSTRUMENT CLUSTER

1. Tachometer MENU SCREEN

2. PM accumulation rate

3. Lift load factor

Press the (A) key to proceed to the screen
selected by the bar.
Press the (B) key to move the selection bar.
Press the (C) key to return to the Home
screen.
4. Return to the engine RPM.
• DATA
C. Menu/trip meter reset The trip meter for maintenance, battery
· Pressing the (C) key switches to the and auxiliary circuits can be checked.
Menu screen. Unlike the trip meter displayed on the Main
· Pressing and holding the (C) key for screen, data items on the engine oil filter,
three seconds or more while the trip hydraulic oil filter and fuel filter are included
meter is displayed returns the trip meter so that you can use them as a guideline for
to “0”. replacement.

• SETTING
Time, alarm and contrast can be set.

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INSTRUMENT CLUSTER

DATA SCREEN (DATA) • Battery (BATTERY)

Displays the battery voltage.

Press the (A) key to proceed to the screen

selected by the bar. Press the (C) key to return to the DATA
Press the (B) key to move the selection bar. screen.
Press the (C) key to return to the Menu
screen. • Auxiliary circuit (AUXILIARY)
Displays the flow rate in the auxiliary
• Trip meter (TRIP METER) for circuits of the 1st, 2nd or 3rd.
maintenance
The trip meters for the engine oil filter,
hydraulic oil filter or fuel filter are displayed.

Each time the (B) key is pressed, the

auxiliary circuit is displayed in this order:
Auxiliary 1st, Auxiliary 2nd and Auxiliary
Press and hold the (A) key for at least five 4th.
seconds resets the selected trip meter to Press the (C) key to return to the Data
“0”. screen.
Press the (B) key to move the selection bar.
Press the (C) key to return to the DATA
screen.

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SETTING SELECTION SCREEN (SETTING) e. Press the (C) key cancels editing and to
return to the Setting Selection screen.

• Alarm setting (ALARM)

Five patterns of alarm setting are
available.
Alarm function can be set to on or off
within the five patterns.

Press the (A) key to proceed to the screen

selected by the bar.
Press the (B) key to move the selection bar.
Press the (C) key to return to the Menu
screen.

• Time setting (CLOCK)

The time to be displayed on the Home a. When the selection bar is at ALARM,
screen can be set here. press the (A) key to proceed to the alarm
setting screen (ALARM SET).
b. Press the (A) key in this screen to place
a checkmark in the box at the left of the
setting bar. Press the (A) key again to
remove the checkmark.
The alarm setting cannot be changed
only by placing or removing a
checkmark.
c. Press and hold the (A) key for at least
two seconds to complete the setting
and to return to the Setting Selection
screen.
a. When the selection bar is at CLOCK, Be sure to perform the above operation
press the (A) key to proceed to the time when you wish to set the alarm.
setting screen (CLOCK SET). A clock symbol is displayed on the
b. Pressing the (A) key in this screen moves Home screen.
the selection bar and flashes the figures d. Press the (B) key to move the selection
on the bar. bar.
Setting range: hours, 1 to 24; minutes, e. Press and hold the (B) key for at least
00 to 59 three seconds to enter the alarm time
c. Press the (B) key to increase the number setting mode.
value selected. f. Press the (C) key to cancel editing and
Press and hold the (B) key to rapidly to return to the Setting Selection screen.
increase the number value selected. Checked.............On
d. Press and hold the (A) key for at least Unchecked.........Off
two seconds to complete the setting
and to return to the Setting Selection
screen.
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 CONTROLS
INSTRUMENT CLUSTER

• Alarm time setting mode • Contrast setting (CONTRAST)

Sets the time for alarm. Adjust the LCD contrast.

a. Select the item to be set in the alarm a. When the selection bar is at CONTRAST,
setting screen (ALARM SET). press the (A) key to proceed to the
b. Press and hold the (B) key for at least contrast setting screen (CONTRAST).
three seconds to enter the alarm time b. To increase contrast, press the (B) key.
setting mode. The bar advances to the right.
c. Press the (A) key in this screen to move Press and hold the (B) key to rapidly
the selection bar and to flash the figures advance the bar.
on the bar. Once the bar reaches the right end
Setting range: hours, 1 to 24; minutes, (highest contrast), it returns to the left
00 to 59 end (lowest contrast).
d. Press the (B) key to increase the number c. Press and hold the (A) key for at least
value selected. three seconds to complete the setting
Press and hold the (B) key to rapidly and to return to the Setting Selection
increase the number value selected. screen.
e. Press and hold the (A) key for at least d. Press the (C) key to cancel editing and
two seconds to complete the setting to return to the Setting Selection screen.
and to return to the Setting Selection The changes made to the setting are
screen. reflected, but they will be removed when
f. Press the (C) key to cancel editing and the starter switch is turned off.
to return to the Setting Selection screen.

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SIDE MENU SCREEN

To display the side menu, turn the starter

switch from the OFF to the ON position while
pressing the (C) key.
Press the (A) key to proceed to the screen
selected by the bar.
Press the (B) key to move the selection bar.

• SETTING
The flow rate ratio of the auxiliary circuits
(Auxiliary 1st, Auxiliary 2nd and Auxiliary
4th) can be set.

• MAINTENANCE
Diagnosis and failure record can be
checked.

2-39
 CONTROLS
INSTRUMENT CLUSTER

SETTING SELECTION SCREEN (SETTING) Initial A/B common, Variable

condition standard flow range
100%
Auxiliary 1st
= 54 L/min 10 to 100%
No. 1
( 14.3 US gpm)
75%
Auxiliary 1st
= 40.5 L/min 10 to 100%
No. 2
( 10.7 US gpm)
50%
Auxiliary 1st
= 27 L/min 10 to 100%
No. 3
( 7.1 US gpm)
Press the (A) key to proceed to the screen The table shows the 1-way flow rate when
selected by the bar. there is no load.
Press the (B) key to move the selection bar.
Press the (C) key to return to the side menu
screen.

• Auxiliary 1st flow rate setting

(1st AUX SET)
Set the flow rate ratio for the No. 1, No. 2
and No. 3rd in the Auxiliary 1 circuit. c. When the selection bar is at a symbol of
attachment, press the (B) key to change it
to the desired symbol.
Select the symbol representing the
attachment to be used.
d. The setting for Auxiliary 1 No. 2 and
Auxiliary 1 No. 3 can be done using the
same procedure as above.
e. Press and hold the (A) key for three
seconds or more to complete the setting
and return to the setting selection screen.
f. Press the (C) key to cancel editing and to
return to the setting selection screen.
a. Pressing the (A) key in this screen moves
the selection bar and flashes the figures
on the bar.
b. Press the (B) key to increase the number
value selected.
Press and hold the (B) key for at least one
second to rapidly increase the number
value selected.

2-40
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• Auxiliary 2nd flow rate setting • Auxiliary 4th flow rate setting
(2nd AUX SET) (4th AUX SET)
Set the flow rate ratio for the Auxiliary 2nd Set the flow rate ratio for the Auxiliary 4th
circuit. circuit.

a. For the key operation, refer to the Auxiliary a. For the key operation, refer to the Auxiliary
1st flow rate setting section. 1st flow rate setting section.

Initial Variable Initial Variable

Standard flow Standard flow
condition range condition range

C/D 100% G/H 100%

Auxiliary 2nd = 21.6 L/min 10 to 100% Auxiliary 4th = 21.6 L/min 10 to 100%
( 5.7 US gpm) ( 5.7 US gpm)

2-41
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MAINTENANCE · Inputs/outputs (INPUTS/OUTPUTS)

Diagnosis and failure record can be checked. The 9-page diagnosis data can be
Press the (A) key to proceed to the screen displayed.
selected by the bar. Press the (B) key to display a different
Press the (B) key to move the selection bar. page.
Press the (C) key to return to the side menu Press the (C) key to return to the
screen. Diagnosis screen.

• Diagnosis (DIAGNOSIS)
Input/Output, Analog Input, PWM Output,
Engine Control Module (ECM) can be
checked.

Press the (A) key to proceed to the screen

selected by the bar.
Press the (B) key to move the selection bar.
Press the (C) key to return to the
Maintenance screen.

2-42
 CONTROLS
INSTRUMENT CLUSTER

IN 1 page OUT
OFF/ON Load dump relay OFF/ON
OFF/I
Wiper relay OFF/ON
OFF/C
OFF/ON Overload warning relay OFF/ON

IN 2 page OUT
OFF/ON Blade float relay OFF/ON
OFF/ON Safety lock SOL. OFF/ON
OFF/ON Buzzer OFF/ON
OFF/ON AUX auto depress SOL. OFF/ON

IN 3 page OUT
OFF/G
Travel speed SOL. OFF/ON
OFF/L
OFF/G
AUX3 SOL. OFF/ON
OFF/F
OFF/2 AUX2/4 SOL. OFF/ON
OFF/S Swing/Adjust SOL. OFF/ON

IN 4 page OUT
OFF/ON Blade right angle SOL. OFF/ON
OFF/ON Blade left angle SOL. OFF/ON
OFF/ON 1 Way SOL. OFF/ON

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 CONTROLS
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IN 5 page OUT
OFF/ON Option AUX4 OFF/ON
OFF/ON Deceleration button OFF/ON
OFF/ON AUX2/4 SW OFF/ON
OFF/ON PWR mode SW OFF/ON
OFF/ON Highland mode SW OFF/ON

IN 6 page OUT
OFF/ON Engine discriminate (Yanmar) OFF/ON
OFF/ON Automatic deceleration SW OFF/ON

IN 7 page OUT
OFF/ON AUX1 flow rate select SW OFF/ON
OFF/ON Option 2 piece boom OFF/ON
OFF/ON Selector button (2 piece boom) OFF/ON

IN 8 page OUT
OFF/ON AUX3 pressure SW OFF/ON
OFF/ON Pressure SW(auto decel) OFF/ON
OFF/ON Air cleaner filter clogging OFF/ON

IN 9 page OUT
OFF/ON Water separator warning SW OFF/ON
OFF/ON Glow OFF/ON
OFF/ON AC compressor OFF/ON
OFF/ON BAT charge OFF/ON

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· Analog inputs (ANALOG INPUTS) · Engine Control Module (ECM)

Displays the analog input information in Displays the engine output information in
one page. three pages.
Accel 0.00 V
Fuel 0.0 Ohm Page 1
Lift pressure 0.00 V Pedal Position 000 %
0.0 Mpa Torque 0000 %
Engine Speed 0000 rpm
· PWM outputs (PWM OUTPUTS) Operating Speed 0000 rpm
Glow 0

Page 2
Coolant Temp. 000 °C
Fuel Temp. 000 °C
Oil Pressure 0000 kPa
Fuel Rate 0000 L/h
Barometric Pressure 000 kPa

Page 3
Air Inlet Temp. 000 °C
Boost Pressure 000 kPa
Displays the output information on the Boost Temp. 000 °C
pump and the auxiliary circuits in two Battery Voltage 0000 V
pages.

Page 1
Hydraulic pump 00000 mA
1st AUX Hydraulic A 00000 mA
1st AUX Hydraulic B 00000 mA

Page 2
2/4 AUX
Hydraulic C/G 00000 mA
2/4 AUX
Hydraulic D/H 00000 mA

2-45
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• Failure Record (FAILURE RECORD) ........ Engine error code

The Active Failure Record data and the
Past Failure Record data can be checked.

Pressing the (A) key while the Vehicle

Error Code List is displayed changes the
Press the (A) key to proceed to the screen screen to the Engine Error Code List. The
selected by the bar. three latest code SPNs and the FMIs are
Press the (B) key to move the selection bar. displayed.
Press the (C) key to return to the Press the (B) key to display a different
Maintenance screen. page.
Pressing the (C) key returns to the Failure
· Active Failure Record (ACTIVE) Record screen.

· Past Fault History (PAST)

........ Vehicle error code list

Pressing the (A) key while the Engine
Error Code List is displayed changes the ........ Vehicle Error Code 1 to 12
screen to the Vehicle Error Code List. When the (A) key is pressed while the
Four latest codes are displayed. past engine error codes are displayed,
the display changes to the past vehicle
error code screen. The fault history data
is displayed with the latest one at the top,
as well as with the serial numbers (1 to
12) attached. The most recent time of
fault occurrence recorded by the hour
meter is also displayed.

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 CONTROLS
INSTRUMENT CLUSTER

........ Engine error code 1 to 12

Pressing the (A) key while the past vehicle

error codes are displayed changes to the
past engine error code screen. The fault
history data is displayed with the latest
code SPNs and FMIs as well as the serial
numbers of 1 to 12.
Press the (B) key to display a different
page.
Pressing the (C) key returns to the Failure
Record screen.

2-47
 CONTROLS
SWITCHES

SWITCHES ENGINE SHUTDOWN SWITCH

STARTER SWITCH

This switch is used to shutdown the engine if

it fails to stop, due to machine failure or
IMPORTANT: Do not repeatedly switch breakage, when the starter switch is set to
the key from OFF to ON and ON to OFF the OFF position.
over a short period. Doing so will cause 1. Press the switch (1).
engine breakdown. 2. After use, reset the switch (1).

OFF ��������� Position for stopping the engine

and inserting or removing the key. THROTTLE CONTROLLER
ON ���������� Position in which the engine is
running. At this position, all the
electrical equipment is functional.
When the coolant temperature is
too low, the engine is
automatically preheated.
START ����� Position for starting the engine.
When the key is released, the
switch automatically returns to the
ON position.

This controls the engine speed.

(A)........Low idling
(B).......Medium speed
(C).......Maximum speed

2-48
 CONTROLS
SWITCHES

HORN BUTTON Note: This deceleration button is capable of

decreasing the engine speed and reducing
the fuel consumption, with a simple
operation, in a situation such as when little
engine output is required and thus the
operating or the travel levers are in neutral.

TRAVEL SPEED BUTTON

When a load greater than a set value is

Press the button situated on the right applied during traveling in 2nd (high)
operating lever to blow the horn. speed, the speed will automatically slow
down to 1st (low) speed. When the load
becomes lighter, the speed will increase
DECELERATION BUTTON and return to 2nd (high) speed. It should
be noted that the travel speed changes
depending on the load condition (for
machines with the automatic travel shift-
Before operating the deceleration button, down system).
set the operating lever to the neutral
position and take your foot off the pedals.
If the deceleration button is pressed while
driving, the machine’s operating speed
will abruptly change to result in a
dangerous situation.

Press this switch to set the travel speed to

2nd (high) speed. Press it again to return to
1st (low) speed.

Press this button on the right operating lever

to lower the engine speed to low idling.
Press the button again to return to the
engine speed set with the throttle controller.
For safety reasons, it is designed that the
deceleration function is activated to set the
engine revolutions to low idling whenever the
engine is started.
Cancel the deceleration mode by pressing
the deceleration button as necessary.
2-49
 CONTROLS
SWITCHES

AUXILIARY 1ST SWITCHES Refer to “Auxiliary hydraulic lines (If

equipped)” on pages 2-70 to 2-74.
Auxiliary hydraulic buttons

Press those buttons to control the flow of the

oil in the first auxiliary hydraulic lines.
• Proportional control of the auxiliary
hydraulic circuit is not possible.
(A) �������Hydraulic oil flows to the left auxiliary
line (a).
(B) ������Hydraulic oil flows to the right auxiliary
line (b).

Slider switch
(Proportional control)
Proportional control allows for slow-to-fast/
fast-to-slow movement of attachment.
Example: If you move the slider switch half
way, the attachment will move at
approximately one-half the speed.

Move this switch to control the flow of the oil

in the first auxiliary hydraulic lines.
(A) �������Hydraulic oil flows to the left auxiliary
line (a).
(B) ������Hydraulic oil flows to the right auxiliary
line (b).

2-50
 CONTROLS
SWITCHES

AUXILIARY 2ND/4TH SWITCH THIRD AUXILIARY HYDRAULIC SWITCH

(IF EQUIPPED) AND BUTTON (IF EQUIPPED)
Slider switch Refer to “Third auxiliary hydraulic switch and
(Proportional control) button (If equipped)” on page 2-73.
Proportional control allows for slow-to-fast/
fast-to-slow movement of attachment.
Example: If you move the slider switch half AUXILIARY 2/4 SELECT BUTTON
way, the attachment will move at (IF EQUIPPED)
approximately one-half the speed.
Refer to “Auxiliary 2/4 select button (If
equipped)” on page 2-74.

Move this switch to control the flow of the oil

in the second auxiliary hydraulic lines.
(C): �����Hydraulic oil flows to the left auxiliary
line (c).
(D): �����Hydraulic oil flows to the right auxiliary
line (d).

To use the auxiliary 4th hydraulic line, press

the auxiliary 2/4 select button to change to
the operation of the auxiliary 4th.
Refer to “Auxiliary hydraulic lines (If
equipped)” on page 2-70 to 2-74.

2-51
 CONTROLS
SWITCHES

LIGHT SWITCH 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. Use water or washer fluid when
operating the wiper.
IMPORTANT: In cold climates, the wiper
blade may freeze to the glass. Operating
the wiper forcibly may damage the wiper
motor.
When this switch is turned while the starter
switch is at ON, the lights turn on as follows:

OFF ����Off
ON �����Switch lamps, front light, boom light,
side lights and tail lamps will be lit.
(switch lamp is lit)

OFF ����Off
INT �����Intermittence operation
ON �����Continuous operation

WASHER SWITCH

ON �����Pressing the ON side of the switch

causes the washer to spray washer
fluid. To stop spraying, release the
switch.

2-52
 CONTROLS
SWITCHES

AUTOMATIC DECELERATION SWITCH POWER/HIGHLAND MODE SWITCH

When the ON side of the switch is pressed,

the deceleration lamp in the instrument • Power mode
cluster flashes. This flashing stops when the · Pressing the PWR symbol side of the
deceleration function starts working, and the switch turns on the Power mode
lamp remains lit while in the deceleration indicator lamp on the instrument cluster.
mode. The engine speed automatically drops The maximum engine output is obtained.
to low idle (deceleration mode) four seconds · STD mode: Pressing the PWR symbol
after the control levers are set to neutral, to side of the switch again turns off the
reduce fuel consumption. Moving the control power mode indicator lamp.
levers will cause the speed to return to the
original engine speed. • Highland mode
Switching from the deceleration button to the This switch is used to reduce the engine
auto-deceleration switch will first return to load due to the hydraulic pump. When the
the engine speed set with the throttle machine is operated at a high-altitude site,
controller. Then, the engine will automatically the engine output is decreased due to thin
enter the deceleration mode (low idling) if the air. In such cases, the hydraulic horse
control levers are not operated within four power is automatically adjusted to prevent
seconds. the engine from stalling. Use this switch
when the machine is operated at a high-
altitude site.
· Pressing the PWR symbol side of the
switch turns on the Power mode
indicator lamp on the instrument cluster.
· To cancel the highland mode, press the
PWR symbol side halfway to set to the
neutral position. The highland mode
indicator lamp goes out and enters the
lowland mode.
Refer to “Multi-information display” on
page 2-16.
Refer to “Instrument cluster” on page
2-28.

2-53
 CONTROLS
SWITCHES

DETENT MODE SWITCH AUXILIARY 1ST AUTO TANK SWITCH

(AUXILIARY 1ST) (IF EQUIPPED) (IF EQUIPPED)
IMPORTANT: Do not operate the machine
in the detent mode for a long time. Doing
so will increase the hydraulic oil
temperature and shorten the service life
of the hydraulic units.

Use this switch to change the direction of

hydraulic oil flow in the Aux. 1st line.
(1) When using a hydraulic breaker (1-way
flow)
(2) When using a reversible attachment
(2-way flow)
This switch is used to change the operation (3) The one-way flow can be set only when
mode of the auxiliary 1st button (A). Pressing the button “A” of the Aux. 1 is pressed.
the ON side of the switch causes the (The tank circuit is automatically opened.)
auxiliary button (A) to enter the detent mode.
Pressing the OFF side changes to the
momentary mode.

2-54
 CONTROLS
SWITCHES

LIFT OVERLOAD WARNING SWITCH BEACON LAMP SWITCH (IF EQUIPPED)

(IF EQUIPPED)

If the overload is not removed after the

overload warning horn is sounded, the
machine may tip over. If the horn starts
sounding, stop operating the machine
and lighten the load.

When this switch is turned on while the

starter switch is at ON, the lamp turns on as
follows:
OFF.....Off
ON......Beacon lamp is lit

If a weight greater than the lifting capacity is

applied or lifted, the overload warning device
is activated and the horn sounds. (When the
lift overload warning switch is turned on.)
OFF.....Off
ON......On

2-55
 CONTROLS
LEVERS AND PEDALS

LEVERS AND PEDALS OPERATING LEVERS

SAFETY LOCK LEVER
• Before starting operation, carefully
check which lever pattern you are going
• Before standing up from the operator’s to use.
seat to open/close the window or • It is described using the ISO pattern in
remove/install the lower window, lower this manual.
the working equipment to the ground,
raise the safety lock levers to engage
the lock and stop the engine. If any
controls should be accidentally touched
when the safety lock levers is lowered
(unlocked), the machine will suddenly
move and cause serious injury or death.
• Be careful not to touch the operating
levers when raising or lowering the
safety lock lever.
• Before leaving the operator’s seat, lower
the working equipment to the ground,
raise the safety lock levers to engage Use these levers to operate the boom, arm,
the lock and stop the engine. Also, be bucket and upperstructure.
sure to remove the key, lock the door Refer to “Lever pattern” on pages 3-6 and
and covers, take it with you and store it 3-7.
in a specified place. Refer to “Operating the working equipment”
on pages 3-14 and 3-15.

This device is for locking the operations of

hoe attachment, slewing, auxiliary, dozer
blade and traveling.
When the lever is raised, the lever stand
springs up to lock the lever.

2-56
 CONTROLS
LEVERS AND PEDALS

BLADE LEVER Float operation

Use this lever to operate the dozer blade. Button (C) ������Float mode
(A)........Blade up Press the float button (C) to
(B).......Blade down set the dozer blade to the float
Refer to “Operating the dozer blade” on mode.
page 3-15. To cancel the float mode,
press the float button (C)
Float button (if equipped) again. The float mode is
temporally cancelled when the
blade lever is tilted backward.
• Do not press the float button while the To return to the float mode, tilt
machine is raised by the blade. Doing the blade lever back to the
so will cause the machine to fall. If you neutral position. Take caution
must work beneath the raised machine, when returning to the float
always use a secure support to keep the mode.
machine raised.
• Do not press the float button while the
blade is raised. Doing so will cause the
blade to fall. Lower the blade to the
ground before pressing the float button.
• Do not travel forward while the blade is
in the float mode.

2-57
 CONTROLS
LEVERS AND PEDALS

TRAVEL LEVERS/PEDALS BOOM SWING PEDAL

• Before operating the travel levers/ Keep the pedal cover to the locked
pedals, make sure that the dozer blade position when not using the pedal.
is to the front of the operator’s seat. Stepping on a pedal accidentally when it
Remember that when the dozer blade is is not locked may cause accidents.
to the rear of the operator’s seat, the
travel levers/pedals must be operated in
the reverse direction from when it is to
the front.
• Do not rest your foot on the pedal
unless operating it for traveling. If the
pedal is accidentally stepped while
working, the machine may suddenly
move and cause serious injury or death.

Use this pedal to operate the boom swing.

(A) �������Boom swing right
(B) ������Boom swing left
Refer to “Operating the boom swing” on
page 3-15.

Pedal lock

Use these levers/pedals to move forward or

backward and to change directions.
Refer to “Operating the travel levers/pedals”
on page 3-10.

Set the pedal cover over the pedal to lock it.

Open the pedal cover from the pedal to
unlock it.

2-58
MEMO

2-59
 CONTROLS
ACCESSORIES

ACCESSORIES Outlets

HEATER

• Always be sure to allow sufficient

ventilation.
• Do not place combustible or explosive
objects near the air outlets.

Heater fan switch

Move the louver up and down or left and
right to adjust the air flow direction and
amount.

............. Low
Neutral..... OFF
............. High

Ventilation/Circulation lever

Use this lever to switch between Ventilation

and Circulation.
���Full ventilation: For heating with
ventilation. Intake of
external air. Defrosting
the windows.
�������� Circulation: Quick heating or when
external air is dirty.
2-60
 CONTROLS
ACCESSORIES

Heater valve CUP HOLDER

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. • Drinks may be spilled due to vibration
when the machine is operating or
IMPORTANT: Use the valve (1) either fully traveling. Be particularly careful not to
open or fully closed. burn yourself with hot drinks.
Cooling water could leak when the valve • Note that the power supply socket or
is partly opened. other electric parts may be damaged if
drinks are spilled on them. Be careful
not to spill fluid on them.

1. Park the machine on a level surface and

stop the engine.
2. Open the engine hood. Use to hold cups or bottles.
3. Turn the valve (1) clockwise until it stops to
close it.

Filters
Clean the filters immediately after operating
in dusty places.
If the filters are clogged, the air flow is
reduced and a booming sound is heard from
the heater unit.
Refer to “Cleaning the air filter (CAB)” on
page 5-41.

2-61
 CONTROLS
ACCESSORIES

ASHTRAY POWER SUPPLY SOCKET

• Be sure to extinguish cigarettes and Use only those electric products which
matches completely before putting comply with the specifications of these
them in the ashtray, and close the sockets.
ashtray after each use.
• Do not overfill the ashtray with cigarette <Canopy>
butts or put in paper or other easily
burnable objects. Doing so could cause
fire.

<Cab>

Pull the ashtray out towards you to use it. To

clean, press the ash discharge button (1) and
pull out the ashtray.

This socket is used to supply power to the

interior electrical components. When using,
be careful not to exceed 12V/5A.
To use, open the cap (1).

2-62
 CONTROLS
ACCESSORIES

INTERIOR LIGHT MIRRORS

IMPORTANT: The battery capacity
decreases if the interior light is left on for
a long time when the engine is stopped.

OFF ��������� Remains off all the time.

Neutral position
��������������� Lights up for 30 seconds when
the starter switch is turned to OFF
from ON.
ON ���������� Lights up all the time.

Adjust the rear view mirrors and side view

mirrors so that you have a better view.
1. Check the left side rear view
2. Check the rear view.

2-63
 CONTROLS
ACCESSORIES

EXTERNAL POWER SOCKETS

Use only those electric products which

comply with the specifications of these
sockets.

For beacon

Use these sockets to connect the external

power supply. When using, be careful not to
exceed 12V/5A.
To use, open the cap (1).

2-64
MEMO

2-65
 CONTROLS
ACCESSORIES

RADIO (FOR CAB)

CAUTIONS ON USE
• To ensure safe operation of the machine, always be sure to keep the volume of the
radio down to a level where you can easily hear sounds from outside the machine.
• Do not use the radio for a long time when the engine is stopped. Doing so will drain
the battery 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.
Otherwise, it may result in malfunction.

NAMES OF COMPONENTS

(1) POWER button (4) Auto store/Auto seek station (AST)

Use this button to turn on or off the Press this button to automatically assign
radio. receivable radio stations to preset
buttons (1 to 6).
(2) LCD
Displays the time/the receiving frequency (5) Tuning button (TUNE )
and the operation mode. Press and hold this button ( or ) for
one second or more to start seeking the
(3) Display button (DISP) receivable stations. The seeking stops
Pressing this button while the frequency when a station is found. To cancel tuning
is displayed on the LCD changes the halfway, press the button again.
display to the clock. Pressing the button Pressing the TUNE button starts
again returns to the frequency. If the seeking stations with higher frequency.
button is not pressed for five seconds, Pressing the TUNE button starts
the display returns to the frequency. seeking stations with lower frequency.
The frequency changes as either button
is pressed in one second intervals.

2-66
 CONTROLS
ACCESSORIES

(6) Preset buttons (1 to 6) (PRESET (11)Auxiliary input jack (AUX-IN)

STATION) Use this jack to connect an external
Each button can store three FM stations audio source such as a portable music
(FM1, FM2, FM3) and one MW (AM) player. Pull off the rubber cap and
station. For how to set these buttons, connect the output terminal (headphone
refer to “Presetting stations”. jack) of the portable player to the AUX-IN
with the stereo mini-plug (3.5 mm) cord.
(7) Band button (BAND) Be sure that jack is closed with the
Pressing this button changes the band rubber cap when not in use.
from FM1 to FM2, FM3 and MW (AM) in
this order. The received band and its Playing the radio
frequency appear on the display. 1. Turn the ignition key to the ACC or ON
position, and then press the power button
(8) VOL buttons (1) to turn on the radio.
Use these buttons to control the sound 2. Select the band, FM or MW (AM) by
volume. Press the button to increase pressing the BAND button.
the volume and the button to 3. Select the station with the preset button or
decrease the sound volume. Press and the tuning button, and adjust the volume
hold each button to continuously with the volume button.
increase/decrease the volume. 4. To turn off the radio, press the power
button.
(9) Clock zero set button (ZERO)
Use this button to set the minute to “00” Selecting a station-auto select
when it is between “55” to “59” or “01” Press and hold the TUNE button for one
to “05”. second or more to start seeking stations in
The LCD returns to the frequency display the higher frequencies direction. Press and
if no more operation is performed for five hold the TUNE button for one second or
seconds. more to start seeking stations in the lower
frequencies direction. The radio will stop
(10)Auxiliary input select button (AUX) seeking when it finds an receivable station
Pressing this button changes the input and start playing.
source to the external device connected
to the AUX-IN (11) jack. The display of Selecting a station-manual select
“AUX” appears on the LCD. Pressing the The selection can be done manually. Press
button again returns to the radio. the tune button to seek stations with
higher frequencies. Press the tune button
to seek stations with lower frequencies.

2-67
 CONTROLS
ACCESSORIES

Presetting stations Auxiliary input (AUX)

1. Press the BAND button to select a band • Connect a portable audio player and listen
(MW (AM) or FM), and then select the to your favorite music.
station by pressing the TUNE button for • Plug a patch cord (without resistor) into the
seeking. headphone jack of the audio player.
2. To assign the selected station to a preset • Plug a stereo mini plug (3.5 mm) into the
button, press and hold the button to be AUX-IN jack on the radio.
assigned for one second or more. The • To listen to an external portable audio
number of the preset button appears on player, press the AUX button. (The “AUX”
the LCD. display appears on the LCD and the
3. For more stations to preset, repeat the frequency display is changed to the clock
steps 1 and 2 above. display.)
• If the preset button on which a station • To return to the radio, press the AUX
has been assigned is pressed and held button again.
for one second or more, the preset • When connecting, adjust the sound volume
information will be modified. level of the audio player so that it is same
• If the stored information is erased during as that of the radio.
battery replacement on the vehicle, • Adjust the sound volume of the audio
assign the stations again to the preset player by using the volume control buttons
buttons. on the radio.
• Each preset button (1 to 6) can store • Do not connect a device with a larger
three FM stations (one from each FM1, output compared with a portable audio
FM2, FM3) and one AM station. player.

Auto storing (AST) Setting the clock

Press the AST button while playing the radio.
The radio automatically starts seeking the
receivable stations within the band currently
selected and assign each preset button (1 to
6) a station.
Note: The previous stations stored will be
cleared (cancelled) by the auto storing. If the
station stored in the preset button is not
desirable, try to preset the station manually.

• If a frequency is displayed on the LCD,

press the AUX button (auxiliary input) to
display the clock.
• 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.

2-68
 CONTROLS
ACCESSORIES

Resetting SPECIFICATIONS
If there are any problems, such as the Power source: ���� 12/24 VDC (negative
abnormal display of frequency or failure of ground)
selection, reset the radio by pressing the “4” Maximum power consumption:
button while pressing the AST button and �������������������������� 3A or less (at max. volume,
the AUX button together. Then, “JP” and the 24 V)
clock display appear on the LCD, indicating Maximum output power:
that the radio is turned off. Note that the �������������������������� 16 W + 16 W (4Ω) (at 28.8
memory stored in the preset button is VDC input)
cleared. 5W+5W (4Ω) (at 14.4 VDC
input)
Switching the volume mode when the Rated output power:
radio is on �������������������������� 12 W + 12 W (10%
Switch the modes between SU and FI by distortion, 4Ω) (at 28.8
pressing the (1) button while pressing the VDC input)
AST and AUX buttons together, when the 3.5 W + 3.5 W (10%
radio is on. distortion, 4Ω) (at 14.4
The SU or FI display appears on the LCD, VDC input)
followed by the radio turning off by itself. Dimensions: �������� 178 (W) x 50 (H) x 65 (D)
SU mode: �����The volume at power-off is mm (excluding protrusions)
retained. Receiving frequency:
FI mode: �������The volume at power-off is �������������������������� MW (AM) 531 to 1602 kHz
reset. (Europe, Asia), 530 to
1710 kHz (North, Central
and South America)
FM 87.5 to 108 MHz
(Europe, Asia), 87.9 to 108
MHz (North, Central and
South America)
Practical sensitivity:
�������������������������� MW (AM) 32 dB or less
(S/N 20 dB)
FM 12 dB or less (S/N 30
dB)
S/N ratio: ������������ MW (AM) 40 dB or more
FM 50 dB or more
AUX-IN: �������������� Stereo mini jack (3.5 mm);
rated input, 90 mV; 20 kΩ
impedance

Note: Specifications and dimensions may be

changed without notice.

2-69
 CONTROLS
ACCESSORIES

AUXILIARY HYDRAULIC LINES (IF EQUIPPED)

These lines deliver the hydraulic oil necessary

for operating a hydraulic breaker, crusher or
Oil may spurt out if pipes disconnected other attachments.
before releasing the pressure in the
hydraulic system. (1)........First auxiliary hydraulic lines
• Immediately after the engine is stopped (2)........Second auxiliary hydraulic lines
and while the safety lock lever is still in (3)........Third auxiliary hydraulic lines
the unlock position, turn the starter (4)........Fourth auxiliary hydraulic lines
switch to ON and press each auxiliary
hydraulic switch several times to Stop valve
release the pressure from the auxiliary (S) : Closed
hydraulic circuit. (O) : Open
• Press the air breather button to relieve
the tank pressure.
• When disconnecting hoses, stand to the
side and loosen them slowly to
gradually release the internal pressure
before removing.

2-70
 CONTROLS
ACCESSORIES

Connecting the hydraulic circuits Disconnecting the hydraulic circuits

To connect the attachment hydraulic lines, 1. Release the pressure remaining in the
observe the following procedures: lines, and then close the stop valve.
1. Release the pressure remaining in the Refer to “Releasing the residual pressure”
lines, and then close the stop valve. on page 2-72.
Refer to “Releasing the residual pressure” 2. Disconnect the lines from the ports (a/c)
on page 2-72. and (b/d).
2. Remove the plugs. 3. Install the plugs.
3. Connect the attachment hydraulic lines to
ports (a/c) and (b/d). When installing a
hydraulic breaker, connect the supply
circuit to the port (a) and the return circuit
to port (b).
4. Open the stop valves. When installing a
hydraulic breaker, open the selector valve
(1).
Refer to “Selector valve” on page 2-73.
5. When connecting is complete, purge air
from the hydraulic lines.
a. Start the engine and run it at a low idle
speed with no load for 10 minutes.
b. With the engine running in low idle,
operate the auxiliary hydraulic switches
repeatedly (approx. 10 times) to purge
air from the hydraulic lines.
c. Stop the engine and wait for at least 5
minutes until bubbles escape from the
hydraulic oil in the tank.

IMPORTANT: Follow the procedures for

purging air as instructed by the
attachment manufacturer, if applicable.

6. Check for oil leaks.

2-71
 CONTROLS
ACCESSORIES

Operating Releasing the residual pressure

Press those buttons to control the flow of the After the auxiliary hydraulic circuits have
oil in the first/second auxiliary hydraulic lines. been used, pressure remains in the circuits.
(A) �������Hydraulic oil flows to left auxiliary line This is called the residual pressure. Release
(a). this residual pressure before disconnecting
(B) ������Hydraulic oil flows to right auxiliary line the lines.
(b). Perform the residual pressure releasing
(C) ������Hydraulic oil flows to left auxiliary line within 10 minutes after the engine stopping.
(c). 1. Park the machine on a flat, rigid and safe
(D) ������Hydraulic oil flows to right auxiliary line ground.
(d). 2. Stop the engine.
3. Lower the safety lock lever to the
unlocked position.
4. Turn the starter switch to the ON position.
5. Press the auxiliary hydraulic switches
several times to release the residual
pressure in the auxiliary hydraulic circuitry.

2-72
 CONTROLS
ACCESSORIES

Selector valve Third auxiliary hydraulic switch and

button (If equipped)

Open ������� When using a hydraulic breaker

(1-way flow) The auxiliary 3rd is mainly used for the
Closed ����� When using a reversible attachment that can quickly connect/
attachment (2-way flow) disconnect the bucket. After the engine is
Change the direction of the hydraulic oil flow started, hydraulic oil constantly flows into the
by opening or closing the selector valve (1) pipe (e). This allows the pressure in the (e)
inside the right side cover. side to increase, preventing the pin inserted
For the machine with the auxiliary 1st auto on the bucket from coming out. If the
tank switch, use the switch to select the pressure in the (e) side drops, the warning
flow. lamp starts flashing to warn that the bucket
Refer to “Auxiliary 1st auto tank switch (If may come out. For a safety reason, the
equipped)” on page 2-54. bucket can be disconnected only when the
button (1) and the switch (2) are pressed at
the same time. When they are pressed, the
hydraulic oil flows into the line (f) to increase
the pressure there. As the result, the pin on
the bucket comes out and the bucket is
removed from the machine.

• Bleeder unit for simultaneous use with

the auxiliary 1st and 2nd (if equipped)
Pressing both the auxiliary 3rd button (1)
and the switch (2) makes it possible to
release internal pressure from the auxiliary
3rd (e side), auxiliary 1st and auxiliary 2nd
at the same time. (The pressure is kept
drawn for six seconds after the button and
the switch are released.) This enables
faster attachment change.

2-73
 CONTROLS
ACCESSORIES

Third auxiliary hydraulic warning lamp Auxiliary 2/4 select button (If equipped)

<Canopy>

This button is used to change from the

second auxiliary operation to the fourth
auxiliary operation.
<Cab> Pressing this button displays the second
auxiliary on the LCD to indicate that the
second auxiliary operation is enabled.
Pressing this button again displays the
auxiliary 4th on the LCD to indicate that the
auxiliary 4th operation is enabled.
The actual operation is performed with the
auxiliary 2nd/4th switch (slider switch).
Refer to “Auxiliary 2nd/4th switch (If
equipped)” on page 2-51.

This lamp illuminates and an alarm sounds if

the auxiliary 3rd hydraulic pressure drops
abnormally while the engine is running.

2-74
 CONTROLS
ACCESSORIES

OPERATING THE MACHINE WITH AN

ACCUMULATOR

Be sure to handle the high-pressure

nitrogen gas enclosed in the accumulator
with care. If handled incorrectly, it could
explode and cause serious injury. Strictly
observe the following precautions:
• Do not disassemble.
• Do not allow flame near or throw it into 6. Move or press the auxiliary hydraulic
a fire. switches several times to release the
• Do not drill, weld or fuse. residual pressure in the circuitry.
• Do not subject it to physical shock such 7. Move all the control levers and pedals
as hitting, rolling or dropping. several times in all directions to release the
• Before disposing of the unit, the sealed pressure from the working equipment
gas must be drained. Contact a circuitry.
Takeuchi service agent for help. 8. Raise the safety lock lever to engage the
lock.
For a machine with an accumulator, the
residual pressure in the auxiliary hydraulic Lowering the boom when the engine has
circuit or the working equipment circuit can stopped
be released even after the engine is stopped. Perform this operation within 10 minutes
after the engine stopping.
Releasing residual pressure 1. Sit at the operator’s seat.
Residual pressure refers to the pressure that 2. Turn the starter switch to the ON position.
remains in the hydraulic circuit after the 3. Lower the safety lock lever to the unlock
operation. Release the residual pressure as position
necessary by using the following steps. 4. Slowly push the operating lever forward to
Perform the residual pressure releasing lower the boom.
within 10 minutes after the engine stopping.
1. Return the throttle controller to idle the
engine at low speed.
2. Lower the bucket and dozer blade to the
ground.
3. Check that the safety lock lever is in the
released position.
4. Stop the engine.
5. Turn the starter switch to the ON position.

2-75
 CONTROLS
ACCESSORIES

LOAD SAFETY DEVICE (IF EQUIPPED) Arm (option)

The load safety devices include an

emergency shut-off valve and an overload
warning device.

Emergency shut-off valve

If the boom or arm stops due to the

breakage of hose, immediately move
away from the load being lifted and go to
a safe location.
If the hose breaks and the emergency shut-
The emergency shut-off valve (1) prevents off valve (1) is activated to stop the operation
the boom or arm from falling rapidly in case of boom or arm, lower the boom or arm by
the hydraulic hose is broken. slowly operating the lever while ensuring
safety. Ask your sales or service dealer for
Boom repair.

2-76
 CONTROLS
ACCESSORIES

Overload warning device

If the overload is not removed after the

overload warning horn is sounded, the
machine may tip over. If the horn starts
sounding, stop operating the machine
and lighten the load.

If a weight greater than the lifting capacity is

applied or lifted, the overload warning device
is activated and the horn sounds. (When the
lift overload warning switch is turned on.)

Lift overload warning switch

OFF.....Off
ON......On

2-77
2-78
 OPERATION

3-1
 OPERATION
BEFORE STARTING OPERATION

BEFORE STARTING WALK-AROUND INSPECTION

OPERATION Perform the walk-around inspections once a

day before starting the engine for the first
GETTING ON OR OFF THE MACHINE time that day.
Refer to “MAINTENANCE, Walk-around
inspection”, on pages 5-16 and 5-17.

• Do not jump on or down from the

machine. Never attempt to get on or off DAILY INSPECTION
the moving machine.
• When getting on or off the cab, first fully Perform the daily inspections once a day
open the door to the locked position before starting the engine for the first time.
and check that it does not move. Refer to “MAINTENANCE, Daily inspection”,
on pages 5-18 to 5-23.

• Climb up/down the steps holding the

handrail to support your weight in a
three point secure stance (hand and
feet).
• Never use the safety lock lever or
control levers as hand holds.

3-2
 OPERATION
STARTING AND STOPPING THE ENGINE

STARTING AND STOPPING 5. Insert the key into the starter switch, turn it
to the ON position, then perform the
THE ENGINE following inspections:

BEFORE STARTING THE ENGINE <Canopy>

1. Adjust the seat for a comfortable operating

position.
2. Fasten the seat belt.

<Cab>

3. Check that the safety lock lever is in the

locked position.

· All warning lamps flash and an alarm is

sounded for two seconds. The meters
also start functioning. After two seconds,
the deceleration lamp (3) stops flashing
4. Check that all levers and pedals are in the and remains lit, while the battery charge
neutral position. warning lamp (1) and engine oil pressure
warning lamp (2) remain flashing. (If the
auxiliary 3rd is selected, it is also
flashing.) The other lamps go out.
· Turn on the light switch to check that the
boom light, front light and tail lamps turn
on.
· Check the fuel level.

If a lamp does not light or the alarm is not

sounded, the display or a wire may be
damaged. Ask your sales or service dealer
for repair.

3-3
 OPERATION
STARTING AND STOPPING THE ENGINE

STARTING THE ENGINE press the deceleration button to cancel

the deceleration mode.

Starting in cold climates

• Clear all personnel from the work area.
• Sound the horn to warn people around
the machine. Never use starting fluid on this engine, as
the starting fluid could cause an
IMPORTANT: Do not run the starter motor explosion.
for more than 15 consecutive seconds. If
the engine fails to start, wait for 30
seconds, and then try again to start the
engine.
IMPORTANT: If the engine stalls due to
fuel shortage, add fuel, turn the key to the
ON position for 60 seconds, and then turn
it to the START position. Running the
starter for a long time before there is
enough fuel is going through can cause
the starter to fail.

Normal starting 1. Turn the throttle controller to the middle

position.

1. Turn the starter key to the START position 2. Turn the starter key to the ON position,
and start the engine. and confirm that the glow lamp is on. (The
2. Once the engine starts, release the key. glow lamp stays lit for 15 seconds when
The key automatically returns to the ON the coolant temperature is –10°C (14°F).)
position. 3. After the glow lamp goes out, press the
3. Check that the warning lamps are off. deceleration button (to cancel the
For safety reasons, it is designed that the deceleration mode), and then turn the key
deceleration function is activated to set to the START position to start the engine.
the engine revolutions to low idling 4. Once the engine starts, release the key.
whenever the engine is started. The key automatically returns to the ON
Cancel the deceleration mode by pressing position.
the deceleration button as necessary. 5. Check that the warning lamps are off.
4. Warm up the engine. 6. Return the throttle controller to the original
Refer to “Warming up the engine” on page position and warm up the engine.
3-5. Refer to “Warming up the engine” on page
5. After the completion of the warming up, 3-5.
3-4
 OPERATION
STARTING AND STOPPING THE ENGINE

WARMING UP THE ENGINE STOPPING THE ENGINE

IMPORTANT: Avoid racing the engine until IMPORTANT: Do not stop the engine
it has warmed up. suddenly when operating with heavy
Do not warm up the engine for a long time loads or at the maximum speed. Doing so
(20 minutes or more). When idling is may cause the engine to overheat or
required, occasionally place a load or run seize. Never stop running the engine
the engine at medium speed. suddenly except in emergency.

1. Return the throttle controller, and then run 1. Return the throttle controller.
at a low idle with no load for 5 minutes. 2. Idle the engine for about 5 minutes to
gradually let it cool.

3. Turn the starter key to the OFF position to

stop the engine.

3-5
 OPERATION
OPERATING THE MACHINE

OPERATING THE MACHINE

LEVER PATTERN (ISO PATTERN)

• Before starting operation, carefully check which lever pattern you are going to use.
• It is described using the ISO pattern in this manual.

Left crawler forward Right crawler forward

Left crawler reverse Right crawler reverse

Arm out Boom lower

Arm in Boom raise

Upperstructure slew left Bucket load

Upperstructure slew right Bucket dump

Boom swing left Dozer blade lower

Boom swing right Dozer blade raise

3-6
 OPERATION
OPERATING THE MACHINE

LEVER PATTERN (G PATTERN) (IF EQUIPPED)

• Before starting operation, carefully check which lever pattern you are going to use.
• It is described using the ISO pattern in this manual.

Left crawler forward Right crawler forward

Left crawler reverse Right crawler reverse

Boom lower Arm out

Boom raise Arm in

Upperstructure slew left Bucket load

Upperstructure slew right Bucket dump

Boom swing left Dozer blade lower

Boom swing right Dozer blade raise

Refer to “Selecting a lever pattern” on page 8-5.

3-7
 OPERATION
OPERATING THE MACHINE

WARMING UP THE MACHINE 2. Fully lower the safety lock lever to

(HYDRAULIC OIL) disengage the lock and lift the bucket from
the ground.

Operating the working equipment without

warming up the machine (hydraulic oil) is
dangerous, as the working equipment
cannot response to controls quickly or may
move in unexpected ways, and the safety
devices may not operate properly. Be
sure to sufficiently warm up the machine.

IMPORTANT: Do not operate the levers

too quickly when the hydraulic oil
temperature is below 20°C (68°F). The 3. Extend and retract each of the cylinders
proper hydraulic oil temperature during slowly several times with no load.
operation is 50 to 80°C (122 to 176°F). If
operations must be performed at lower
temperatures, heat up the hydraulic oil to
at least 20°C (68°F).

Normal warm-up

4. Slew slowly to the left and the right several

times.

1. Turn the throttle controller to the middle

position, and then run the engine at medium
speed for about five minutes with no load.

5. Travel slowly forward and in reverse

several times.

3-8
 OPERATION
OPERATING THE MACHINE

Warm-up in cold climates <Cab>

1. Perform the normal warm-up procedure.

1. Check that the warning lamps and meters

2. Set the bucket cylinder at the stroke end are as follows:
and keep it there. · Are all warning lamps off?
Do not keep this condition for more than · Is the water temperature level within the
30 seconds. green range?
3. Repeat Step 2 until the bucket operating 2. Check that there are no irregularities in the
speed becomes normal. exhaust color, sound and vibrations.

INSPECTION AFTER WARM-UP

After warming up the engine and machine
(hydraulic oil), perform the checks and
inspections described below, and repair if
necessary.

<Canopy>

3. Raise the safety lock lever to the locked

position, and then check that the
operating and travel levers are locked.

3-9
 OPERATION
OPERATING THE MACHINE

OPERATING THE TRAVEL LEVERS/ Moving the machine forward and

PEDALS backward

• Never allow anyone to enter the

machine’s slewing radius and path.
• Signal your intention to move by
sounding the horn.
• There is a blind spot in the rear of the
machine. Before traveling in reverse, as
necessary, swing the cab around in
reverse to check that the area is safe
and clear.
1. Turn the throttle controller and increase
the engine speed.

• Before operating the travel levers/

pedals, make sure that the dozer blade
is to the front of the operator’s seat. 2. Fully lower the safety lock lever to
Remember that when the dozer blade is disengage the lock.
to the rear of the operator’s seat, the
travel levers/pedals must be operated in
the reverse direction from when it is to
the front.
• Clear all obstacles from the path of the
machine.

3. Fold the hoe attachment and lower it 30 to

40 cm (12 to 16 in.) above the ground.
4. Lift the dozer blade.
5. Operate the left and right travel levers as
below.

3-10
 OPERATION
OPERATING THE MACHINE

Traveling in 2nd (High) speed

When a load greater than a set value is

applied during traveling in 2nd (high)
speed, the speed will automatically slow
down to 1st (low) speed. When the load
becomes lighter, the speed will increase
and return to 2nd (high) speed. It should
be noted that the travel speed changes
depending on the load condition (for
When the dozer blade is in front of the machines with the automatic travel shift-
operator’s seat: down system).
To move forward:
Tilt the levers forward.
To move backward:
Tilt the levers backward.

Press the travel speed switch to set to the

2nd (high) speed, and press it again to return
to the 1st (low) speed.

When the dozer blade is behind the

operator’s seat:
To move forward:
Tilt the levers backward.
To move backward:
Tilt the levers forward.

3-11
 OPERATION
OPERATING THE MACHINE

Pivot turn Spin turn

Turning to the left when stopped: To spin left:

To turn forward to the left: Tilt the left lever backward and the right
Tilt the right lever forward. lever forward.
To turn backward to the left: To spin right:
Tilt the right lever backward. Tilt the right lever backward and the left
To turn to the right, operate the left lever in lever forward.
the same way as for the right lever.

Turning to the left while traveling:

To turn left while traveling forward:
Set the left lever to neutral.
To turn left while traveling backward:
Set the left lever to neutral.
To turn to the right while traveling, operate
the right lever in the same way as for the left
lever.

3-12
 OPERATION
OPERATING THE MACHINE

STOPPING TRAVEL

• Park the machine on a flat, rigid and

safe ground. Set the parking brake. If
you must park on a slope, chock the
tracks to block the machine.
• If any control is accidentally touched
when the safety lock lever is not locked,
the machine may suddenly move and
cause serious injury or death.

Never stop running the machine suddenly

except in emergency. Stop in good time,
if possible.

1. Set the left and right travel levers slowly to

the neutral position. The machine stops.

3-13
 OPERATION
OPERATING THE MACHINE

OPERATING THE WORKING EQUIPMENT Slewing

Check the surrounding area for safety

• Before starting operation, carefully before slewing.
check which lever pattern you are going
to use.
• It is described using the ISO pattern in
this manual.

Upperstructure slew left:

Tilt the left operating lever to the left.
Upperstructure slew right:
Tilt the left operating lever to the right.
Use the right operating lever to operate the
boom and bucket. Operating the boom
Use the left operating lever to operate the
arm and slewing.
Return the operating levers to the neutral
position to stop the hoe attachments.
1. Lower the safety lock lever to the
unlocked position.
2. Set the pedal cover to the unlocked
position.

Boom lower:
Tilt the right operating lever forward.
Boom raise:
Tilt the right operating lever backward.

3-14
 OPERATION
OPERATING THE MACHINE

Operating the arm Operating the boom swing

Arm in: Boom swing left:

Tilt the left operating lever backward. Step on the left side of the pedal.
Arm out: Boom swing right:
Tilt the left operating lever forward. Step on the right side of the pedal.

Operating the bucket Operating the dozer blade

Bucket load: Dozer blade lower:

Tilt the right operating lever to the left. Tilt the lever forward.
Bucket dump: Dozer blade raise:
Tilt the right operating lever to the right. Tilt the lever backward.

3-15
 OPERATION
OPERATING PROCEDURES

OPERATING PROCEDURES Be gentle when using the hydraulic

cylinder
PROHIBITED OPERATIONS

• Do not operate on bedrock (hard or

soft).
• Do not slew /swing while traveling. If
you must operate the hoe attachment
while traveling, operate at speeds slow
enough so you have complete control at
all times.

Do not perform demolition or leveling Do not extend the hydraulic cylinders to the
using slew force stroke ends. Operate them with leeway.

Do not demolish walls or level ground using Do not support the machine body with the
slew force. Also, do not dig the bucket teeth hoe attachment when the body is lowering
into the ground during slewing. Doing so will with the arm cylinder fully extended. Doing
damage the hoe attachment. so concentrates the load on the arm cylinder
and could damage the arm cylinder.
Do not dig while traveling

Do not dig the bucket into the ground and

use the traveling force to dig.

3-16
 OPERATION
OPERATING PROCEDURES

Do not drive piles with the bucket or dig Digging bedrock

by banging the bucket

For hard base rock, break the rock up into

Doing so will shorten the service life of the small pieces with a breaker, etc., before
hoe attachment. Use the hydraulic force to digging. This prevents damage to the
dig. machine and is thus more economical in the
end.
Do not perform operations using the
machine’s dropping force Caution on exposing the dozer blade to
shocks

Hitting the dozer blade against rocks, etc.,

could damage the dozer blade or the blade
cylinder.

Putting excessive strain on the machine will

shorten its service life. When digging, use the
hydraulic force of the cylinders and the
shallow and long strokes.

3-17
 OPERATION
OPERATING PROCEDURES

Caution on folding the hoe attachment Pay attention to the dozer blade when
digging

Be careful not to let the bucket to hit the

dozer blade when the hoe attachment is When digging deeply with the dozer blade
being folded. positioned at the front, be careful that the
boom cylinder and bucket do not hit the
Do not use the dozer blade as an dozer blade.
outrigger Operate with the dozer blade at the rear
whenever possible.

Caution on digging down with the dozer

blade

This dozer blade is designed for simple earth

pushing. Do not dig down deeply with the
dozer blade. Doing so could damage the
dozer blade and undercarriage.

3-18
 OPERATION
OPERATING PROCEDURES

CAUTIONS ON OPERATING • When traveling in 2nd speed, do so with

the dozer blade at the front.
Cautions on traveling
Cautions on using machine in water

Traveling over obstacles (rocks, stumps, etc.)

may put a great load on the machine body If the rear of the machine is submerged in
and may cause damage to it. Avoid crossing water as shown in the figure above, it causes
over obstacles whenever possible. If you the radiator fan to turn in water, resulting in
must do so, keep the hoe attachment near damage to the fan. The rear of the machine
the ground, travel at a low speed, and go must not be submerged.
over the obstacle at the center of the crawler.

Cautions on traveling in 2nd (High) speed

• Allowable water depth

Use the machine in water only when the
water is up to the bottom of the carrier
• On uneven ground, maintain the low speed roller (1).
and avoid starting, stopping or changing • For those parts used in water for a long
directions abruptly. time, apply enough grease until the old
• When a load greater than a set value is grease is expelled.
applied during traveling in 2nd (high) • Never submerge the slew bearing or main
speed, the speed will automatically slow body in water or sand. If submerged,
down to 1st (low) speed. When the load contact a Takeuchi service agent for
becomes lighter, the speed will increase inspection.
and return to 2nd (high) speed. It should be
noted that the travel speed changes
depending on the load condition. (for
machines with the automatic travel shift-
down system)

3-19
 OPERATION
OPERATING PROCEDURES

CAUTIONS ON TRAVELING ON SLOPES • The machine may slip sideways even on

a slight slope if they are covered with
grass or dead leaves, or when traveling
on a wet metal plate or frozen surfaces.
• Never travel on slopes that are too Do not allow the machine to position
steep for the machine to maintain its sideways to slopes.
stability. (maximum gradeability: 30°,
lateral tipping angle: 15°) Note that in
reality, the machine’s stability becomes Traveling posture on slopes
lower than the above values depending Climbing slopes
on the working condition.
• When traveling on slopes, lower the
bucket to a height of 20 to 30 cm (8 to
12 in.) above the ground. When climbing
a steep slope, extend the hoe
attachment to the front. In emergencies,
lower the bucket to the ground and stop
the machine.
• When traveling on slopes or grades,
drive slowly in 1st (low) speed.
• When climbing a hill, keep the
operator’s seat facing the hillside. When
descending a hill, keep the operator’s When climbing slopes of 15° or more,
seat facing the downhill direction. In maintain the machine posture as shown in
either case, travel must be done while the figure above.
paying attention to the ground in front
of the machine. Descending slopes
• Do not descend slopes in reverse.

When descending slopes of 15° or more,

• Do not change directions on slopes or slow down the engine speed and maintain
traverse slopes. First return to a flat the machine posture as shown in the figure
surface, and then take an alternative above.
path.

3-20
 OPERATION
OPERATING PROCEDURES

Braking when descending slopes If the engine stops

When descending slopes, the brakes are If the engine stops when descending a
applied automatically once the travel levers slope, set the travel levers to the neutral
are returned to the neutral position. position, stop the machine, then start the
engine.
If the crawler slips
Do not open the door while traveling on
slopes

If the crawler slips while climbing a slope and

impossible to travel, use the pulling force of
the arm to climb the slope. Opening the door while traveling on slopes is
dangerous, as the force required to open
and close the door changes abruptly. Always
keep the door closed when traveling on
slopes.

3-21
 OPERATION
OPERATING PROCEDURES

GETTING OUT OF MUD OPERATIONS POSSIBLE WITH THIS

MACHINE
If the machine gets stuck in mud, use the
procedure below to get it out. Excavating

If one crawler is stuck

1. Set the dozer blade on the side opposite

to the side you want to dig on.
1. Swing the bucket to the side of the 2. Use the arm and bucket and dig with
crawler being stuck. shallow, long strokes. The maximum
2. Set the arm and boom to an angle of 90 digging force can be obtained when the
to 110°. boom and arm angle is 80 to 120°. Use
3. Press the bottom of the bucket (not the this angle for effective digging.
teeth) against the ground.
4. Place a plank or the like under the lifted Digging ditches
crawler.
5. Lift the bucket and slowly move the
machine out of the mud.

If both crawlers are stuck

Install a bucket suited for digging ditches

and set the crawlers parallel to the ditch to
be dug for greater efficiency.
When digging wide ditches, dig the sides
first, and then dig the center.
1. Perform the steps 1 to 4 above for both
crawlers.
2. Dig the bucket into the ground in front of
the machine.
3. Pull with the arm while traveling forward to
slowly move the machine out.

3-22
 OPERATION
OPERATING PROCEDURES

Digging side drains Leveling

Use the boom swing function to dig side 1. Bring the hoe attachment close to the
ditches as shown in the figure. body.
2. Gradually remove the dirt from the side of
Loading the mound.
3. Once the mound is low, remove the dirt
from the top. If the load becomes too
heavy for the machine body, adjust by
raising or lowering the dozer blade.

When loading dirt onto a truck bed, load

from the back of the truck, as it is easier and
able to load more load than doing it from the
front.
Also, use a small slewing angle for greater
efficiency.

3-23
 OPERATION
PARKING THE MACHINE

PARKING THE MACHINE 3. Lower the bucket and the dozer blade to
the ground.
PARKING 4. Raise the safety lock lever to the locked
position.
5. Stop the engine and remove the key.
Refer to “Stopping the engine” on page
3-5.
For machines equipped with accumulator:
Refer to “Operating the machine with an
accumulator” on page 2-75.

INSPECTION AND CHECKS AFTER

STOPPING THE ENGINE
1. Check for oil or water leak and inspect the
working equipment, covers and
• Park the machine on a flat, rigid and undercarriage. If any irregularities are
safe ground. Set the parking brake. found, repair.
2. Fill up the fuel tank.
Refer to “Inspecting the fuel level” on page
5-21.
3. Remove any paper scraps or dirt from the
engine room.
4. Remove any mud from the undercarriage.

Locking
Be sure to lock the following places:

If you must park on a slope or incline,

park the machine securely and block
the movement of the machine.
• When parking on a street, 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 operator’s seat, raise
the safety lock lever to engage the lock • Cab door
and stop the engine. Also, be sure to • Engine hood
remove the key, lock the door and • Covers
covers, take it with you and store it in a
specified place.

1. Set the left and right travel levers to the

neutral position.
2. Return the throttle controller to set the
engine to low idling.
3-24
 OPERATION
HANDLING IN COLD CLIMATES

HANDLING IN COLD CAUTIONS AFTER OPERATIONS

CLIMATES Observe the following cautions to prevent

mud, water, or the undercarriage from
PREPARING FOR COLD CLIMATES freezing and making it impossible for the
machine to move.
Starting engine in cold climates is not easy, • Remove all mud and water from the
and it becomes more difficult if the coolant machine body. In particular, wipe the
freezes. Prepare for cold-climate problems hydraulic cylinder rod clean to prevent
as follows. damage to the seal caused by mud or dirt
on the rod surface getting inside the seal
Replacing the fuel and lubricant together with drops of water.
Replace the hydraulic oil, engine oil and fuel • Park the machine on hard and dry ground.
with those intended for cold climates. If this is impossible, park the machine on a
Refer to “Fuel and lubricant table” on page wooden board placed on ground.
5-4. • Drain any water in the fuel tank to prevent it
from freezing.
Engine coolant Refer to “Draining the water from the fuel
tank” on page 5-31.
• As the battery capacity drops markedly in
The engine coolant is combustible. Keep low temperatures, cover the battery or
away from flame. remove it from the machine and keep it in a
Use long-life coolant (antifreeze) and tap warm place.
water for the engine coolant. If the electrolyte level is low, add distilled
water in the morning before beginning
Note: New machines are delivered with JIS work. To prevent the battery electrolyte
Type 2 long-life coolant (antifreeze) at a from freezing in the night, do not add water
concentration of 50%. after the day’s work.
Refer to “Fuel and lubricant table” on page
5-4.
AFTER THE COLD CLIMATE
Battery
As the temperature drops, the battery When the climate becomes warmer, do as
performance decreases. follows:
Inspect the battery. If it is discharging, • Replace the fuel and oil for all parts with
contact a Takeuchi service agent to have the those specified in the “Fuel and lubricant
battery recharged. table”.
Refer to “Inspecting the battery” on page Refer to “Fuel and lubricant table” on page
5-32. 5-4.
• If a coolant of “one season type” is used,
drain the cooling system completely, clean
out the inside of the cooling system
thoroughly, and fill with tap water.
Refer to “Cleaning the engine cooling
system” on page 5-43.

3-25
 OPERATION
HANDLING RUBBER CRAWLERS

HANDLING RUBBER
CRAWLERS
Rubber crawlers have an inherent weakness,
lack of strength, due to their use of rubber.
Be sure to observe the prohibitions and
cautions below to prevent the crawlers from
being damaged or coming off.

PROHIBITIONS
• Do not let fuel, oil, salt or chemical solvents
Do not travel or operate the machine in the get on the crawlers. These substances
following places: may corrode the bonding of the steel cores
on the crawlers, resulting in rust or peeling.
If any of these substances gets on the
crawler, immediately clean it off with water.

• Traveling and slewing on crushed rock,

extremely rough hard rock, steel beams,
scrap iron, or near the edges of steel plates
will cause damage to the rubber crawlers. • It will cause an irregular wear or damage to
the lugs, if the machine travels on irregular
surfaces such as recently paved with
asphalt, exposed to a bonfire or of hot iron
sheets under the blazing sun.
• Do not move earth in places where the
rubber crawlers may slip. Doing so may
speed up lug wear.

• Traveling on riverbeds or places where

there are large numbers of boulders may
cause the stones to get caught and
damage the crawler or make the crawler
come off.
• Do not use the machine on the seashore.
The salt may corrode the steel core.

3-26
 OPERATION
HANDLING RUBBER CRAWLERS

CAUTIONS
Observe the following cautions when
operating the machine:

• Rubber crawler belts are not as stable as

steel crawler belts since the entire lugs are
made of rubber. Be very careful when
slewing and swinging sideways.

• Do not turn the undercarriage with the front

of the machine body lifted using the hoe PREVENTING THE RUBBER CRAWLERS
attachment (the upperstructure is not FROM COMING OFF
turned). Doing so will twist the crawlers
with the load concentrated on a single Observe the following cautions to prevent
point on the crawler belt, causing rapid the crawler from coming off:
damage to the crawlers. • Always keep the crawlers at the proper
• Avoid changing course abruptly or spin- tension.
turning 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
gets on the crawler belts, wash if off
thoroughly with water.
• Do not let the sides of the rubber crawlers
rub against concrete or walls. • When traveling over a large step such as a
• Do not damage the rubber crawlers by cobblestone or rock (20 cm (8 in.) or
hitting the bucket against them. deeper), climb up the step at the right
• Be especially careful on snowy or frozen angle and do not change courses on top of
surfaces in winter, as the crawler belts tend the step.
to slip in such conditions.
• 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 (three months or more), do
so indoors in a place not exposed to direct
sunlight or rain.

3-27
 OPERATION
HANDLING RUBBER CRAWLERS

• When climbing in reverse, do not change • Do not change directions when the crawler
directions at the point where the slope belts are slack as shown in the figure.
starts.

• The rubber crawler belts will come off if the

• Avoid traveling by setting one crawler on a machine travels backward in this condition.
slope or projecting portion and the other
crawler on a flat surface (with the machine
at a tilt of 10° or more). Travel with both
crawlers set on flat surfaces.

• The rubber crawler belts will come off if the

machine turns in this condition.

3-28
 TRANSPORT

4-1
 TRANSPORT
LOADING AND UNLOADING

LOADING AND UNLOADING

The machine may roll or tip over or fall

while being loaded or unloaded. Take the
following precautions:
• Select a firm, level surface and keep
sufficient distance from road shoulders.
• Secure the ramps of adequate strength
and size to the truck bed. The slope of
the ramps must not exceed 15°. If the 1. Set the parking brake on the transporter
rumps are bowed down too low, and chock the wheels.
support them with poles or blocks. 2. Fix the ramps securely to the truck bed.
• Never use the working equipment to The slope of the ramps must not exceed
load or unload the machine. Doing so 15°.
may result in tipping over or falling 3. Align the center of the truck bed with the
down of the machine. center of the machine, and of the ramp
• Keep the truck bed and loading ramps with the center of the crawler.
clean of oil, soil, ice, snow, and other 4. Make sure the dozer blade does not hit
materials to prevent the machine from the ramps.
sliding sideways. Clean the crawlers. 5. Lower the hoe attachment as far as
• Chock the transporter wheels to prevent possible without letting it touch the
movement. transporter.
• Turn off the deceleration switch and 6. Decrease the engine speed.
auto-deceleration switch. Otherwise,
the engine speed may suddenly
increase to cause troubles.
• When being loaded or unloaded, travel
slowly in 1st (low) gear by following the
signal from the signal person.
• Never change courses on the ramps.
• Do not slew/swing on the ramps. The
machine may tip over.
• When slewing/swinging on the truck
bed, do it slowly as the footing should
be unstable.
• Lock the cab door after being loaded, if
applicable. Otherwise, the door may
open during transport.
• Chock the tracks and secure the
machine to the truck bed with wire rope
or chain.

When loading or unloading the machine, be

sure to use ramps or a platform and follow
the procedure below.

4-2
 TRANSPORT
LOADING AND UNLOADING

7. Drive the machine straight toward the

ramps and travel up or down the ramps at
1st (low) speed, by following the signal
from the signal person.
8. Load the machine at the specified position
on the transporter.
Refer to “Transporting posture” on page
4-6.

4-3
 TRANSPORT
HOISTING THE MACHINE

HOISTING THE MACHINE Hoisting

1. Slew the upperstructure so that the dozer
blade is at the rear of the machine (set the
upperstructure parallel to the track frame).
• Know and use the correct crane signals. 2. Raise the dozer blade fully.
• Check the hoisting equipment for 3. Extend the bucket cylinder and arm
damaged or missing parts on a daily cylinder fully to raise the boom to its
basis and replace as necessary. uppermost position.
• When hoisting, use a wire rope capable 4. If the boom is swung to either the left or
of lifting the machine mass. right side, set it in the neutral position.
• Hoist the machine in such a manner 5. Raise the safety lock lever to the locked
described in the procedure below. Do position.
not do it in any other manner. Doing so 6. Stop the engine, remove the starter key
is dangerous as it may result in the and get off the machine.
machine losing its balance. 7. Install the wire ropes as shown on the
• Do not hoist the machine with an figure below. Install the wire ropes and
operator on it. hoisting attachment without letting them
• When hoisting, hoist slowly so that the touch the machine body.
machine does not tip. 8. Hoist the machine slowly until it leaves the
• Keep everyone out of the area when ground.
hoisting. Do not move the machine over 9. Stop hoisting until the machine becomes
the heads of the persons. stable, and then start hoisting the machine
slowly again.
IMPORTANT: This hoisting method
applies to machines with standard
specifications. The center of gravity
differs according to the attachments and
optional equipment installed.
Contact your Takeuchi service agent for
details.

4-4
TRANSPORT
HOISTING THE MACHINE

4-5
 TRANSPORT
SECURING THE MACHINE

SECURING THE MACHINE

After loading the machine at the specified position, secure it as described below.

Transporting posture

1. Lower the dozer blade. Precautions to be taken during

2. Extend the bucket cylinder and arm transportation
cylinder fully, and then lower the boom.
3. Raise the safety lock lever to the locked
position. • Know and follow the applicable safety
4. Stop the engine, remove the starter key rules, vehicle code and traffic laws
and lock all locks. when transporting the machine.
5. Place the stoppers (chocks) in front and • Select the best transport route by
behind the crawlers. considering the length, width, height
6. Install a chain or wire rope over the lower and weight of the truck with the
frame of the machine and fasten it machine loaded on it.
securely to prevent the machine from • Never abruptly start or stop or run at a
slipping sideways. high speed at the sharp curves during
7. Secure the bucket with a chain or wire transport. Doing so will move or lose the
rope. balance of the loaded machine.

IMPORTANT: Place a wooden block under

the bucket to protect the floor from
damage caused by the bucket.

4-6
MAINTENANCE

5-1
 MAINTENANCE
GENERAL

GENERAL CAUTIONS ON MAINTENANCE

MAINTENANCE OVERVIEW Do not perform any other inspection and
maintenance works than those listed in this
To keep the machine in good condition and manual.
use if for a long period, perform the For works not listed in this manual, ask your
inspection and maintenance properly and sales or a service dealer for help.
safely following the procedures
recommended by this manual. Keep the machine clean
• Clean the machine before performing
The inspection and maintenance items are inspection and maintenance and try to
divided into groups according to the keep it clean.
machine’s total operating time: every 10 • Stop the engine before washing the
hours (walk-around and daily inspection), machine. Cover the electrical parts so that
every 50 hours, every 250 hours, etc. Refer water cannot enter. Water on electrical
to the hour meter readings to determine parts could cause short-circuits or
when to schedule an inspection and malfunctions. Do not use water or steam to
maintenance. Items for which it is not wash the battery, electronic control
possible to determine the inspection and components, sensors, connectors or the
maintenance interval are included under operator’s compartment.
“When Required”.
Fuel, lubricant and grease
When operating the machine in extremely • Choose fuel, lubricant and grease by
harsh environments (with high dust levels or following to the “Fuel and lubricant table”.
high temperatures), inspection and • Use fuels, lubricants and greases which do
maintenance should be performed earlier not contain water, and be careful to keep
than the times specified on the Maintenance dirt out when changing or replenishing fuel,
List. 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 refueling
• If the port includes a strainer, do not
remove the strainer when fueling.
• After fueling, be sure to securely tighten the
fuel filler cap.
• Do not add more than the specified
amount of fuel.

Do not use fuel to clean parts

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.

5-2
 MAINTENANCE
GENERAL

Clean the installation surfaces Cautions on handling of battery wiring

When installing and removing parts, be sure • Disconnect the wiring from the both
that the surfaces of contact of the parts are terminals (+ and –) on the battery before
clean. If the sealing grooves of the surface of working on the electrical system or doing
contact are damaged, consult your sales or electric welding.
service dealer for repair or release. Always disconnect it from the earth side
(–). When connecting, connect the earth
Seals and split pins side last.
• Be sure to replace all seals and cotter pins • Do not disconnect the battery wiring while
with new ones. the engine is moving. Otherwise, the
• When installing, be careful not to damage electric circuits of the rotary converter or
or twist the seal. others may be damaged.

Sealing tape

• When wrapping the plug with sealing tape,

remove any old sealing tape from the
threads and clean the threads.
• Wrap the thread tight with seal tape
starting 1 or 2 threads away from the
thread end.

Disposing of wastes
• Always collect oil that is drained from the
machine in containers. Improperly
disposed waste oil can cause
environmental harm.
• Follow appropriate laws and regulations
when disposing of harmful objects such as
oil, fuel, cooling water, coolant, filters and
batteries.

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 each control lever and check that
the machine is operating properly.
5-3
 MAINTENANCE
SERVICE DATA

SERVICE DATA
FUEL AND LUBRICANT TABLE
Select the appropriate fuel, lubricant and grease according to the temperature by referring to
the table below.
• Regardless of the specified time, change the oil if it becomes too dirty or degraded.
• When refilling, never mix oils of different brands. If a brand is to be changed, replace the
whole fuel/oil.

Fuel
Diesel fuel specifications
Diesel fuel should comply with the following specifications. The table lists several worldwide
specifications for diesel fuels.

Diesel fuel specification Location Diesel fuel specification Location

ASTM D975
No.1-D S15
No.2-D S15 USA
ISO 8217DMX International
Bio-diesel fuel Canada
Biodiesel blends up to B5
ASTM D6751, D7467
EN590: 2009
Bio-diesel fuel European union BS2869-A1 or A2 United kingdom
Biodiesel blends up to B5
EN14214, EN590

5-4
 MAINTENANCE
SERVICE DATA

To maintain the performance and service life of the engine,

always use clean and high-quality fuel.
• To avoid freezing in cold climates, use a diesel fuel that still
functions when the temperature is at least 12°C (53.6°F) below
the lowest expected ambient temperature.
• Use a diesel fuel that has a cetane number of 45 or higher.
When operating at a very low temperature or at a high altitude,
a higher cetane number fuel will be required.
• Use fuel with sulfur content of less than 0.5% by volume.
Especially in the U.S.A. and Canada, ultra-low sulfur fuel
should be used.
A higher sulfur content fuel may cause sulfuric acid corrosion
in the cylinders of the engines.
Fuel tank Diesel fuel • Never mix kerosene, used engine oil, or residual fuel with the
diesel fuel. Use of kerosene is prohibited.
• 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.
• The content of metal, such as zinc, sodium, magnesium,
silicon and aluminum, must be 1 mass ppm or less. (JPI-
5S-44-95 test analysis method)
Precautions when using bio-diesel fuel
The warranty of the engine manufacturer may be voided by
using a bio-diesel fuel that does not meet the standard or that is
deteriorated.

5-5
 MAINTENANCE
SERVICE DATA

Lubricant

Type by air temperature

Location Type -4 14 32 50 68 86 104°F When to replace
-20 -10 0 10 20 30 40°C
API: CF class or higher SAE 10W-30 Every 250 hrs
Engine oil pan ACEA: E6 class after the initial
JASO: DH2 class SAE 15W-40 50 hrs.

Takeuchi genuine Every 4000

ISO VG46
hydraulic oil 46 hrs.***
Hydraulic oil
ISO VG32
tank Every 2000
Anti-wear hydraulic oil ISO VG46
hrs.***
ISOVG68

Cooling water Mixture of 50% coolant

Engine cooling
(water + coolant)** Every 1000 hrs.
system Mixture of 30% coolant
SAE: J814C or J1034
Every 1000 hrs
Travel reduction Gear oil
SAE 90 after the initial
gear API: GL-4
250 hrs*.
Slew bearing Lithium based grease Every 50 hrs.
Working EP-2 — Daily or every
equipment NLGI No.2 10 hrs.
* : If the ratio of traveling time to 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 (32°F), add coolant (antifreeze). Follow the coolant
manufacturer’s instructions to determine the mixture ratio.
*** : The hydraulic oil replacement interval depends on the type of hydraulic oil being used. New
machine are delivered with Takeuchi genuine hydraulic oil 46, and the hydraulic oil
replacement intervals indicated in this manual assume that Takeuchi genuine hydraulic oil
46 is being used. When using conventional antiwear hydraulic oil, the hydraulic oil should
be replaced every 2000 hours.

API standard: American Petroleum Institute

ACEA standard: Association des Constructeurs Européens d’Automobiles
JASO standard: Japanese Automobile Standards Organization
SAE standard: Society of Automotive Engineers

5-6
 MAINTENANCE
SERVICE DATA

Volume

Engine cooling Hydraulic oil Travel reduction

Engine oil pan Fuel tank
system tank gear
Upper limit 4 L (4.2 US qt.) System Level capacity 0.5 L X 2
4.7 L (5 US qt.) 56 L (14.8 US gal.) 46 L (12.2 US gal.) (0.53 US qt.) X 2
Lower limit Tank
2.9 L (3.1 US qt.) 35 L (9.2 US gal.)

5-7
 MAINTENANCE
SERVICE DATA

REGULARLY REPLACE THE HYDRAULIC

OIL
When a hydraulic breaker is used, the oil
deteriorates more quickly than that used for
a usual excavation operation. Be sure to
replace the hydraulic oil and the return filter
elements.
• Failure to replace these in time can lead to
damage to the machine and the breaker
hydraulic system. To prolong the service life
of the hydraulic devices, properly replace
the hydraulic oil and the return filter
elements according to the table below.
• When replacing the hydraulic oil, clean the
suction strainer.

Replacement interval (hours)

( ): When a conventional antiwear hydraulic
oil is used.
Item Hydraulic oil Filter element
1st time — 25
2nd time — 100
Periodically 1200 (600) 200
When the breaker operating ratio is 100%.
Refer to “Hydraulic breaker” on page 8-6.

5-8
 MAINTENANCE
SERVICE DATA

LIST OF CONSUMABLES
Periodically replace consumables such as filters and elements according to the table below.

System Item Part name Part No. When to replace

Hydraulic oil Every 1000 hrs
15511-03900
return filter after the initial 250
Hydraulic system Pilot line filter Element 15512-00703 hrs.

Air breather filter 15520-02715 Every 1000 hrs.

Engine lubrication Every 250 hrs after
Engine oil filter Cartridge Y129150-35153
system the initial 50 hrs.
Fuel system Fuel filter Cartridge Y129A00-55800 Every 500 hrs.
Every 1000 hrs. or
Primary (Outer) after 6 cleanings
Y129004-12520
element (whichever comes
Air cleaner system Air cleaner first)
When the primary
Secondary
19111-02772 elements are
(Inner) element
replaced.
Once a year or if
Heater system Filter Element 19115-13680 clogging remains
after cleaning

5-9
 MAINTENANCE
SERVICE DATA

LIST OF TOOLS (IF EQUIPPED)

Code Part name Part No. Remarks

1 Spanner Y28110-100120 10 - 12
2 Spanner Y28110-140170 14 - 17
3 Screwdriver Y104200-92350 (+) (–) replaceable shank
4 Filter wrench Y119640-92750 ø80
5 Filter wrench Y171301-92750 ø90
6 Filter wrench Y171340-92760
7 Hammer 16903-00330 3/4
8 Monkey wrench 16904-00250 250 mm
9 Pliers 16905-00200 200 mm
10 Spanner 16900-01922 19-22
11 Spanner 16900-02427 24-27
12 Single-ended wrench 16901-00013 13
13 Single-ended wrench 16901-00041 41
14 Combination wrench 16909-00019 19
15 Hex. wrench 16906-00400 4 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 16906-01400 14 mm
21 Tool case 16914-00005
22 Case 16919-00001
23 Grease gun 16910-60610 600 cc
24 Drain connector 15545-12601

5-10
 MAINTENANCE
SERVICE DATA

LIST OF TIGHTENING TORQUES

Nuts and Bolts (for ISO strength category 10.9)
Tighten nuts and bolts at the torques shown on the table below, unless otherwise specified.
• The tightening torques used for the mounted plastic covers are not listed in the table below.
Consult your sales or service dealer for details. They will be damaged if over tightened.
• 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 evenly tightened.

Tightening torque
Head width (b) Size (a) x pitch
Classification General connection points
mm mm N·m ft-lb.
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
Coarse 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
Fine
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

5-11
 MAINTENANCE
SAFETY-CRITICAL PARTS

SAFETY-CRITICAL PARTS
To use the machine safely, periodically perform inspection and maintenance. The safety-critical
parts listed below must be periodically replaced for an increased safety.
Serious injury or a fire could result if they are worn or damaged.

List of safety-critical parts

Unit Safety-critical parts to be replaced periodically When to replace

Fuel hoses
Fuel system
Packing on fuel filler cap

Heater Heater hoses

Hydraulic hoses (pump - delivery)

Hydraulic hoses (pump - suction)

Main body
Hydraulic hoses (slew motor)

Hydraulic hoses (travel motor)

Hydraulic hoses (boom cylinder piping) Every 2 years

Hydraulic Hydraulic hoses (arm cylinder piping)

system
Hydraulic hoses (bucket cylinder piping)

Working Hydraulic hoses (swing cylinder)

equipment Hydraulic hoses (blade cylinder)

Hydraulic hoses (angle blade cylinder)

Hydraulic hoses (pilot valve)

Hydraulic hoses (auxiliary piping)

Seat belt Every 3 years

5-12
 MAINTENANCE
SAFETY-CRITICAL PARTS

The material of the safety-critical part listed above tends to change over time and cause wear
or deterioration. It is difficult to determine the degree of deterioration at the periodic inspection,
and thus they need to be replaced with new ones after a certain time to maintain their proper
performance even if they appear in good condition. Note that regardless of the replacement
schedule, replacement must be performed immediately if a symptom of wear is found. If a
hose clamp is deformed or cracked, replace it together with the hose immediately. When
replacing the safety-critical parts, ask your sales or service dealer.
In addition to the safety-critical parts, inspect the hydraulic hoses and retighten or replace as
necessary. 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”.

Type of inspection Inspection item

Leakage from the connecting parts of hydraulic or fuel hoses
Daily inspection
Damage to cab or canopy - replace*
Leakage from the connecting parts of hydraulic or fuel hoses
Monthly inspection
Damaged hydraulic or fuel hoses (cracks, wear and tear)
Leakage from the connecting parts of hydraulic or fuel hoses
Annual inspection Deteriorated, twisted, damaged hydraulic or fuel hoses (cracks, wear
and tear) or hoses in contact with other parts of the machine
*: Canopy parts No. 05584-00085
*: Cab parts No. 03586-00070

5-13
 MAINTENANCE
MAINTENANCE LIST

MAINTENANCE LIST
Inspection and maintenance item Page
Walk-around inspection
Inspecting by opening the engine hood and covers 5-16
Inspecting by walking around the machine 5-17
Inspecting while sitting in the operator’s seat 5-17
Daily inspection (every 10 hours)
Inspecting and replenishing the coolant 5-18
Inspecting and replenishing the engine oil 5-19
Inspecting the water separator 5-20
Inspecting the fuel level 5-21
Inspecting the hydraulic oil tank level and replenishing 5-22
Lubricating the working equipment 5-23
After the initial 50 hours (only for new machines)
Replacing the engine oil and the oil filter 5-24
Inspecting and adjusting the fan belt 5-26
Every 50 hours
Inspecting and adjusting the crawler tension 5-28
Lubricating the slew bearing 5-30
Draining the water from the fuel tank 5-31
Inspecting the battery 5-32
Every 100 hours
Cleaning the water separator 5-34
After the initial 250 hours (only for new machines)
Replacing the hydraulic oil return filter 5-35
Replacing the pilot line filter 5-36
Replacing the travel motor gear oil* 5-37
Every 250 hours
Replacing the engine oil and the oil filter 5-38
Inspecting and adjusting the fan belt 5-38
Cleaning the air cleaner 5-38
Cleaning the radiator fins and the oil cooler fins 5-40
Cleaning the air filter (CAB) 5-41
Every 500 hours
Replacing the fuel filter 5-42
*: If the percentage of the traveling time within the total operating time is high, replace the gear
oil earlier than the specified time.

5-14
 MAINTENANCE
MAINTENANCE LIST

Inspection and maintenance item Page

Every 1000 hours
Replacing the hydraulic oil return filter 5-43
Replacing the pilot line filter 5-43
Replacing the travel motor gear oil * 5-43
Cleaning the engine cooling system 5-43
Replacing the air cleaner element 5-45
Replacing the air breather filter 5-46
Inspecting and adjusting the engine valve clearance 5-46
Every 1500 hours
Inspecting, cleaning and checking operation of the engine fuel injectors 5-47
Inspecting the crankcase breather system 5-47
Every 2000 hours
Lapping the engine valve seats (If necessary) 5-48
Every 3000 hours
Inspecting, cleaning and checking operation of the EGR valve 5-49
Every 4000 hours
Replacing the hydraulic oil and cleaning the suction strainer 5-50
When required
Replacing the bucket teeth and the side cutters 5-53
Replacing the bucket 5-56
Adjusting the gap between the bucket and arm (If equipped) 5-58
Inspecting and replenishing the windshield washer fluid 5-59
Lubricating the levers and pedals 5-60
Inspecting the rubber crawlers 5-61
Replacing the rubber crawlers 5-62
*: If the percentage of the traveling time within the total operating time is high, replace the gear
oil earlier than the specified time.

5-15
 MAINTENANCE
WALK-AROUND INSPECTION

WALK-AROUND INSPECTION
Perform the following inspections every day before starting the engine for the first time.

• Before operating, perform the walk-around inspections and make repairs immediately
where necessary.
• Be sure to secure the engine hood or cover before working the inside. Do not keep the
hood or cover open on a windy day or if the machine is parked on a slope.

Before starting the engine, look around the machine and clean any combustibles from the
surroundings of the engine. Also, inspect if oil or water is leaking and any nuts or bolts are
loosened.

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.
3. Check for oil leakage from the hydraulic oil
tank, hydraulic devices, hoses or
connections.
5-16
 MAINTENANCE
WALK-AROUND INSPECTION

INSPECTING BY WALKING AROUND THE INSPECTING WHILE SITTING IN THE

MACHINE OPERATOR’S SEAT
4. Check lights for dirt, damage and burnt 14. Check the windshield for dirt or damage.
out bulbs. 15. Check the seat and seat belt for dirt or
5. Check attachments and hoses for damage.
damage. Check the operator’s seat for dirt, oil or
6. Check the bucket, bucket teeth and side other combustible materials.
cutter for wear, damage and looseness. 16. Check the monitor, instruments and
7. Check the hook, slip stopper and hook switches for dirt or damage.
mount of buckets with hooks for damage.
(Option)
8. Check the handrail, the steps and the
slip-resistant surfaces for damage and
loose bolts.
9. Check the crawlers, carrier rollers, track
rollers, idlers and sprockets for damage,
wear and loose bolts.
10. Check for oil leakage from the travel
motor, carrier rollers, track rollers and
idlers.
11. Check the cab and guard for damage
and loose nuts and bolts.
12. Check the mirrors for dirt or damage,
and adjust them.
13. Check the labels for dirt and damage.

5-17
 MAINTENANCE
DAILY INSPECTION (EVERY 10 HOURS)

DAILY INSPECTION Inspection

(EVERY 10 HOURS)
Perform the following inspections every day
before starting the engine for the first time.

• Before operating, perform the daily

inspections and make repairs
immediately where necessary.
• Be sure to secure the engine hood or
cover before working the inside. Do not
keep the hood or cover open on a windy 1. Open the engine hood.
day or if the machine is parked on a 2. Inspect the cooling water level in the
slope. reserve tank (1).
The level should be between the upper
limit (H) and the lower limit (L).
If it is below the lower limit (L), replenish.
INSPECTING AND REPLENISHING THE
COOLANT Replenishing
1. Remove the cap (2) of the reserve tank (1).
2. Add cooling water up to the upper limit (H)
of the reserve tank (1).
• Do not remove the radiator cap or the If the reserve tank (1) is found empty at the
drain plug when the cooling water is inspection, check for water leakage and
hot. Stop the engine and wait until the then the water level in the radiator (3). Add
engine and the radiator cool before water to the radiator (3) as required, and
slowly loosening the radiator cap and then to the reserve tank (1).
the drain plug to remove them. 3. Install the cap (2).
• Always wear the protective goggle and
gloves when handling coolant Note: Use only clean water (soft water), such
(antifreeze). If any coolant (antifreeze) as tap water, to replenish the coolant loss
comes in contact with eyes or skin, due to evaporation. If the coolant loss is due
wash it off with clean water. Otherwise, to leakage, replenish the mixture of antifreeze
it could result in injures. and clean water (soft water) prepared using
the same mixing ratio used for the current
coolant.

5-18
 MAINTENANCE
DAILY INSPECTION (EVERY 10 HOURS)

INSPECTING AND REPLENISHING THE Replenishing

ENGINE OIL 1. Remove the oil filler cap (2).
2. Add oil up to between the upper limit (H)
and the lower limit (L) of the dipstick (1).
Problems could arise if the oil level is either
Stop the engine and allow the machine to too low or too high.
cool down before performing 3. Tighten the oil filler cap (2).
maintenance. 4. Start the engine, run it at low idle for about
5 minutes, then stop it.
5. After about 10 to 20 minutes, inspect the
Inspection oil level.

1. Open the engine hood.

2. Take out the dipstick (1) and wipe the oil
off with a rag.
3. Fully reinsert the dipstick (1), and then pull
it back out.
4. Check the oil on the dipstick (1).
The level should be between the upper
limit (H) and the lower limit (L).
If it is below the lower limit (L), replenish.

5-19
 MAINTENANCE
DAILY INSPECTION (EVERY 10 HOURS)

INSPECTING THE WATER SEPARATOR

• 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. Open the engine hood.

2. Check if there is water in the water
separator (1).
If water collects in the separator, the float
(red ring) (6) goes up. Be sure to drain
water before the float goes up to the
element (5),
3. Loose the vent plug (8) and then the drain
plug (7) to discharge water collected
inside.
4. After drainage of water, tighten each plug
and bleed air from the fuel system.
Refer to “Bleeding air from the fuel
system” on page 6-9.

5-20
 MAINTENANCE
DAILY INSPECTION (EVERY 10 HOURS)

INSPECTING THE FUEL LEVEL

• Do not smoke or permit open flames

while handling fuel or working on the
fuel system.
• Never remove the fuel cap or add fuel
when the engine is running or still hot.
Do not spill fuel on the hot surface of
the machine.
• Fill the fuel tank in a well ventilated
place.
• Clean up spilled fuel immediately.
• Do not fill the fuel tank to capacity.
Allow room for oil expansion.
• Securely tighten the fuel filler cap.
• Use the correct grade of fuel for the
operating season.

1. Check the fuel level using the fuel gauge

(1).
F: Tank is full.
E: Tank is empty.
2. If the fuel level is low, open the fuel lid.
3. Add fuel from the fuel filler port (2) while
watching the sight gauge (3).
Refer to “Fuel filler port” on page 2-8.

5-21
 MAINTENANCE
DAILY INSPECTION (EVERY 10 HOURS)

INSPECTING THE HYDRAULIC OIL TANK Replenishing

LEVEL AND REPLENISHING

Oil may spurt out if caps or filters are

removed or pipes are disconnected
before releasing the pressure in the
hydraulic system.
• Press the air breather button to relieve
the internal pressure from the tank.

Inspection
The oil level changes with the oil IMPORTANT: Do not fill up to the level
temperature. Inspect the oil by maintaining higher than the upper limit (H). It will
the machine at posture shown in the figure at damage the hydraulic circuits or result in
the next. oil spurting. If accidentally done, stop the
• Machine posture for inspecting the engine and wait the hydraulic oil to cool,
hydraulic oil level and then let the excessive oil to drain
from the drain plug.

1. Open the right side cover.

2. Press the air breather button (2) to relieve
the internal pressure from the tank.
3. Remove the plug (3).
4. Add the hydraulic oil up to the middle
point of the sight gauge (1).
5. Tighten the plug (3).

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

2. Fully retract the cylinders (arm and
bucket), and lower the bucket to the
ground.
3. Lower the dozer blade, and then stop the
engine.
4. Open the right side cover.
5. Inspect the oil level using the sight gauge
(1).
· When the oil temperature is about 20°C
(68°F):
The level should be between the upper
limit (H) and the lower limit (L).
If it is below the lower limit (L), replenish.
· When the oil temperature is about 50 to
80°C (122 to 176°F):
The level should be slightly below the
upper limit (H).
5-22
 MAINTENANCE
DAILY INSPECTION (EVERY 10 HOURS)

LUBRICATING THE WORKING EQUIPMENT

1. Keep the machine configuration as shown in the diagram above, lower the working
equipment to the ground, and then stop the engine.
2. Use the grease gun to lubricate the grease fittings.
3. Wipe off the excess grease.

5-23
 MAINTENANCE
AFTER THE INITIAL 50 HOURS (ONLY FOR NEW MACHINES)

AFTER THE INITIAL 50 Engine oil

HOURS (ONLY FOR NEW

MACHINES)
REPLACING THE ENGINE OIL AND THE
OIL FILTER

Stop the engine and allow the machine to

cool down before performing
maintenance. 1. Open the engine hood and remove the oil
• The engine, muffler, radiator, hydraulic filler cap (2).
lines, sliding parts and many other parts
of the machine are hot immediately after
the engine is stopped. Touching these
parts will cause burns.
• The engine oil is also hot.
Be careful not to touch the hydraulic oil
when loosening the cap or plug.
Working on the machine under these
conditions could result in burns or
injuries.

2. Place a pan for catching the waste oil

under the drain plug (3).
3. Remove the drain plug (3) and drain the
oil.
<Equipped with drain valve>
a. Remove the cap (A), install connector
(B) and drain the oil. (The oil comes out
when the screw is tightened.)
b. Remove the connector (B) and install
the cap (A).
4. Tighten the drain plug (3).

IMPORTANT: Check the waste oil for

metal powder. If it contains large amounts
of metal powder, consult your sales or
service dealer.

5-24
 MAINTENANCE
AFTER THE INITIAL 50 HOURS (ONLY FOR NEW MACHINES)

Engine oil filter

5. Turn the filter (4) counterclockwise with the
filter wrench and remove it.
6. Clean the surface of installation of the filter
stand.
7. Apply a thin layer of oil on the packing of
the new filter.
8. Install the new filter by hand.
9. Tighten one more turn (with the filter
wrench) after the filter packing comes in
contact with the surface of installation.
(Torque when tightening with filter wrench:
19.6 to 23.5 N·m or14 to 17 ft-lb.)
10. Add oil up to between the upper limit (H)
and the lower limit (L) of the dipstick (1).
Problems could arise if the oil level is
either too low or too high. It takes around
10 to 20 minutes for all of the added oil
to go down to the oil pan.
11. Tighten the oil filler cap (2).
12. Start the engine, run it at low idle for
about 5 minutes, then stop it.
13. After about 10 minutes, inspect the oil
level.

5-25
 MAINTENANCE
AFTER THE INITIAL 50 HOURS (ONLY FOR NEW MACHINES)

INSPECTING AND ADJUSTING THE FAN 3. Press the fan belt (1) at the midpoint
BELT between the fan pulley (2) and alternator
pulley (3) to check the tension (approx. 98
N or 22 lbf).
The slack (A) should be 7 to 10 mm (0.28
Stop the engine and allow the machine to to 0.4 in).
cool down before performing 4. Inspect the fan belt (1) and replace if it is
maintenance. as follows.
• The engine, muffler, radiator, hydraulic · There are cuts or cracks.
lines, sliding parts and many other parts · The belt is worn and touches the bottom
of the machine are hot immediately after of the V groove in the pulley.
the engine is stopped. Touching these · The belt stretched too loose to be
parts will cause burns. adjusted.

IMPORTANT: The loose belts could result Adjustment

in bad battery charge, overheat of engine
or early wear of belt. Too tight belts could
damage the water pump or bearing and
belt used to drive the alternator.
IMPORTANT: Do not let any oil or grease
get on the belt.

Inspection

1. Loosen the bolt (5) and locking nut (4).

2. Turn the adjustment bolt (6) to move the
alternator (7) and to adjust the tension of
the fan belt (1).
· Tighten: Clockwise
· Loosen: Counterclockwise
3. Tighten the bolt (5) and locking nut (4).
Note: When replacing with a new belt, run
1. Move the sheet all the way forward. the engine at low idle speed for about 3 to 5
2. Loosen the bolts and remove the cover minutes to break in the new belt, before
(A). adjusting the tension.

5-26
MEMO

5-27
 MAINTENANCE
EVERY 50 HOURS

EVERY 50 HOURS 1. For rubber crawlers, move the machine so

that the “M”, “J” or “∞” mark at the joint is
INSPECTING AND ADJUSTING THE at the top center of the crawler frame.
CRAWLER TENSION

• If you must work beneath the raised

machine or working equipment, always
use wood blocks, jack-stands or other
rigid and stable supports. Never get
under the machine or working
equipment if they are not sufficiently
supported. This procedure is especially
important when working on hydraulic
cylinders. 2. Use the working equipment to lift the
• Be careful with the high-pressure grease machine body. Operate the levers slowly.
In the track adjuster, the grease has
been injected under high pressure. If the
tension is adjusted without following the
prescribed procedure, the grease
discharge valve may fly off, resulting in
injury.
· Never loosen the grease fitting.
· Loosen the grease discharge valve
slowly. Do not turn it more than one
turn.
· Do not put your face, arms, legs or
body in front of the grease discharge
valve. 3. Inspect the gap (A or B) between the
· If grease does not come out when the bottom surface of the frame at the center
grease discharge valve is loosened, of the crawler frame and the top surface of
the valve is faulty. Ask a Takeuchi the crawler.
service agent for repair. The gap (A or B) must be within the
following range:

Inspection (A) Rubber crawler

77 to 87 mm (3.0 to 3.4 in.)
(B) Steel crawler
144 to 154 mm (5.7 to 6.1 in.)
(B) Rubber pads
144 to 154 mm (5.7 to 6.1 in.)

5-28
 MAINTENANCE
EVERY 50 HOURS

Adjustment
Increasing the tension

1. Remove the cover (1).

2. Using the grease gun, insert grease
through the grease fitting (3) in the grease
discharge valve (2).
3. Inspect the crawler tension.

Decreasing the tension

1. Remove the cover (1).

2. Using the spanner, slowly loosen the
grease discharge valve (2) (one turn) and
drain the grease.
If the grease does not drain easily, move
the machine forward or backward.
3. Tighten the grease discharge valve (2).
· Tightening torque: 59 to 88 N·m (43.4 to
65.1 ft-lb.)

5-29
 MAINTENANCE
EVERY 50 HOURS

LUBRICATING THE SLEW BEARING 4. Lower the bucket to the ground, and then
stop the engine.
5. Repeat the steps 2 to 4 above three
times.
Do not slew while lubricating. Doing so is 6. Wipe off the grease expelled from the slew
dangerous, as you may get caught in the bearing and grease fitting.
machine.

1. Stop the engine with the machine in the

posture shown on the figure above.

2. Use the grease gun to grease the grease

fitting (1).

3. Start the engine, lift the bucket and slew

clockwise 90°.

5-30
 MAINTENANCE
EVERY 50 HOURS

DRAINING THE WATER FROM THE FUEL 1. Open the fuel lid.
TANK 2. Remove the fuel filler cap (2).
3. Loosen the bolts and remove the under
cover (3).
4. Place a pan under the drain plug (4).
• Do not smoke or permit open flames 5. Remove the drain plug (4), and then drain
while handling fuel or working on the the water and sediment buildup in the
fuel system. bottom of the tank.
• Never remove the fuel cap or add fuel 6. Tighten the drain plug (4).
when the engine is running or still hot. 7. Install the under cover (3).
Do not spill fuel on the hot surface of 8. Add fuel while watching the sight gauge
the machine. (1).
• Fill the fuel tank in a well ventilated 9. Tighten the fuel filler cap (2).
place. 10. Close the fuel lid and lock it with the key.
• Do not fill the fuel tank to capacity. 11. Bleed air.
Allow room for oil expansion.
• Clean up spilled fuel immediately. Bleeding air from the fuel system
• Securely tighten the fuel filler cap. Refer to “Bleeding air from the fuel system”
• Use the correct grade of fuel for the on page 6-9.
operating season.
Note: Air in the fuel system causes the
Do the draining operation before starting the engine to fail to start or to have problems.
machine. Bleed air when the fuel tank is emptied,
using the same procedure above.

AG8G005

5-31
 MAINTENANCE
EVERY 50 HOURS

INSPECTING THE BATTERY Inspection

Turn the starter switch to ON and check the
battery voltage on the display. The battery is
normal if the voltage is 12 V or more.
• Do not use or charge the battery when Refer to “(6) Data display” on page 2-25 and
the battery indicator is white. The “Data screen (DATA)” on page 2-36.
battery is at its end of life. Immediately
replace the battery. Note: Under normal operating conditions,
• Batteries generate flammable hydrogen the maintenance-free battery does not
gas which may explode. Keep away require addition of water because of the
from flame, sparks, fire or lighted special plate designed to minimize fluid loss.
cigarettes.
• Use a dampened cloth to clean the 1. Open the right side cover.
battery indicator and check the fluid
level. Do not clean with a dry cloth; it
can cause static electricity to build up,
resulting in ignition or explosion.
• Do not use the cable if it’s connecting
terminal is loose or corroded. If used,
ignition or explosion may occur.

• Wear protective goggle and clothing

when working with batteries. 2. Inspect the indicator (1).
• Do not tilt the battery. Doing so could · Green: Good
cause the battery fluid to leak out of the · Black: Charging needed
exhaust hole. If contacted, it may cause · White: Replace the battery
skin irritation or the machine part 3. Check the battery terminal for looseness,
corrosion. dirt and corrosion.
• Batteries contain sulfuric acid which will 4. Check the exhaust holes (2) for dirt.
damage eyes or skin if contacted. 5. Check the battery voltage. Confirm it is 12
· If eye contact occurs, flush V or more.
immediately with clean water and get Refer to “(6) Data display” on page 2-25
prompt medical attention. and “Data screen (DATA)” on page 2-36.
· If accidentally swallowed, drink large
quantities of water or milk and call a
physician immediately.
· If acid contacts skin or clothing, wash
off immediately with a lot of water.

5-32
MEMO

5-33
 MAINTENANCE
EVERY 100 HOURS

EVERY 100 HOURS

CLEANING THE WATER SEPARATOR

• 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.

(S): Close
1. Open the engine hood.
2. Close the valve (2).
3. Loosen the case (3), then remove the
stand (4), element (5) and indicator ring (6)
and clean them.
4. Inspect the O-ring and the element (5). If
there are any scratches or other
irregularities, replace them.
5. Assemble the indicator ring (6), stand (4)
and element (5) and tighten the case (3).
6. Open the valve (2).
7. Loosen the vent plug (8) and bleed the air.
8. Tighten the vent plug (8).
Refer to “Bleeding air from the fuel
system” on page 6-9.

5-34
 MAINTENANCE
AFTER THE INITIAL 250 HOURS (ONLY FOR NEW MACHINES)

AFTER THE INITIAL 250

HOURS (ONLY FOR NEW
MACHINES)
REPLACING THE HYDRAULIC OIL
RETURN FILTER

• Stop the engine and allow the machine

to cool down before performing
maintenance.
· The engine and the hydraulic system
and many other parts of the machine
are hot immediately after the engine is
stopped. Touching these parts will
cause burns.
· The hydraulic oil is also hot and under
high pressure.
Be careful not to touch the hydraulic
oil when loosening the cap or plug.
Working on the machine under these 1. Open the right side cover.
conditions could result in burns or 2. Press the air breather button (2) to relieve
injuries due to the hot oil spurting out. the internal pressure from the tank.
• Oil may spurt out if caps or filters are 3. Loosen the bolts and remove the flange
removed or pipes are disconnected (4).
before releasing the pressure in the 4. Remove the return filter (5).
hydraulic system. 5. Install a new return filter.
· Press the air breather button to relieve 6. Install the flange (4) on its original position.
the internal pressure from the tank. 7. Inspect the level with the sight gauge (1),
· When removing plugs or screws, or and replenish if the level is too low.
when disconnecting hoses, stand to Refer to “Inspecting the hydraulic oil tank
the side and loosen them slowly to level and replenishing” on page 5-22.
gradually release the internal pressure
before removing.

5-35
 MAINTENANCE
AFTER THE INITIAL 250 HOURS (ONLY FOR NEW MACHINES)

REPLACING THE PILOT LINE FILTER

• Stop the engine and allow each part of

the machine to cool down before
performing maintenance.
· The engine, the hydraulic system and
many other parts of the machine are
hot immediately after the engine is
stopped. Touching these parts will
cause burns. 3. Open the engine hood.
· The hydraulic oil is also hot and under 4. Turn the case (4) counterclockwise and
high pressure immediately after the remove it.
engine is stopped. 5. Remove the element (5) and O-ring (6).
Be careful not to touch the oil when 6. Clean the inside of the case (4).
loosening the cap or plug. Working on 7. Apply a thin layer of oil on the O-ring of the
the machine under these conditions new filter.
could result in burns or injuries due to 8. Install the new element on the filter stand
the hot oil spurting out. (7).
• Oil may spurt out if caps or filters are 9. Apply a thin layer of oil on the new O-ring
removed or pipes are disconnected (6).
before releasing the pressure in the 10. Install the new O-ring (6) and the case (4)
hydraulic system. on the filter stand (7).
· Press the air breather button to relieve 11. Inspect the level with the sight gauge (1)
the internal pressure from the tank. and replenish if the level is too low.
· When removing plugs or screws, or Refer to “Inspecting the hydraulic oil tank
when disconnecting hoses, stand to level and replenishing” on page 5-22.
the side and loosen them slowly to
gradually release the internal pressure
before removing.

1. Open the right side cover.

2. Press the air breather button (2) to relieve
the internal pressure from the tank.

5-36
 MAINTENANCE
AFTER THE INITIAL 250 HOURS (ONLY FOR NEW MACHINES)

REPLACING THE TRAVEL MOTOR GEAR

OIL

• Stop the engine and allow the machine

to cool down before performing
maintenance.
· The travel motor is hot immediately
after the engine is stopped. Touching
it will cause burns.
· The gear oil is also hot and under high
pressure immediately after the engine
is stopped.
Be careful when loosening the plugs.
Working on the machine under these
conditions could result in burns or
injuries.
• The pressure in the reduction gear case
of travel motor may cause oil or the plug
to fly out. Loosen the plug slowly to
release the pressure.

IMPORTANT: If the percentage of the

traveling time within the total operating
time is high, replace the gear oil earlier
than the specified time.

AE7G002

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

the very bottom.
2. Place a pan under the plug (1).
3. Remove the plugs (1) and (2) and drain the
oil.
4. Rewrap the plugs with new sealing tape.
5. Tighten the plug (1).
6. Add oil through the hole of the plug (2)
until oil flows out of the hole of the plug
(2).
7. Tighten the plugs (2).
5-37
 MAINTENANCE
EVERY 250 HOURS

EVERY 250 HOURS

REPLACING THE ENGINE OIL AND THE
OIL FILTER
Refer to “Replacing the engine oil and the oil
filter” on page 5-24.

INSPECTING AND ADJUSTING THE FAN

BELT
1. Open the engine hood.
Refer to “Inspecting and adjusting the fan
belt” on page 5-26.

CLEANING THE AIR CLEANER

• 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 2. Loosen the clamps (1) and remove the
immediately after the engine is dust cup (2).
stopped. Touching it will cause burns. 3. Clean the inside of the dust cup (2).
• Wear required appropriate equipment 4. Remove the primary element (3).
such as protective goggle and filter 5. Cover the intake hole at the back of the
mask when using compressed air, as body (4) with cloth or tape to prevent dirt
metal fragments or other objects can fly from getting in.
and cause serious injury. <If equipped with the secondary element>
To prevent dirt from getting inside the
IMPORTANT: Be careful not to scratch the engine, do not remove the secondary
element. Do not use an element if it is element (5).
damaged. 6. Clean the inside of the body (4).
IMPORTANT: When operating the
machine in very dusty places, perform
inspection and maintenance operations
every day.
IMPORTANT: Be sure to install the
element and dust cap securely. If not,
dust could be drawn into the cylinder,
damaging the engine.

5-38
 MAINTENANCE
EVERY 250 HOURS

7. Clean the primary element (3) with dried

compressed air (294 to 490 kPa or 43 to
71 psi).
First blow the air from the inside of the
element along the pleats. Then blow the
air from the outside and finally from the
inside again.
8. Light up the inside of the primary element
(3) with a light bulb, inspect it, and replace
it if there are small holes or thin spots.
9. Remove the cloth or tape applied in step 5.
10. Install the primary element (3).
11. Install the dust cup (2) with its
“ TOP ” mark facing, and then
fasten it with the clamps (1).

5-39
 MAINTENANCE
EVERY 250 HOURS

CLEANING THE RADIATOR FINS AND

THE OIL COOLER FINS

Wear required appropriate equipment

such as protective goggle and filter mask
when using compressed air, as metal
fragments or other objects can fly and
cause serious injury.

IMPORTANT: Be careful not to damage

the fins when cleaning.
• When using compressed air or
pressurized water, make sure the
pressure is no higher than 200 kPa (28
psi) and hold the nozzle sufficiently
away from the fins.
IMPORTANT: When using water, cover the
electrical system to prevent water from
getting in.
IMPORTANT: When operating the
machine in very dusty places, perform
inspection and maintenance operations
every day.

1. Open the engine hood and right side

cover.
2. Blow compressed air on the fins to
remove mud and dirt stuck on them.

5-40
 MAINTENANCE
EVERY 250 HOURS

CLEANING THE AIR FILTER (CAB) Replacing

Replace the filter with a new one once a year
or if it is still clogged after blow-drying with
compressed air and washing.
Wear required appropriate equipment
such as protective goggle and filter mask
when using compressed air, as metal
fragments or other objects can fly and
cause serious injury.

Clean the filter immediately after operating in

dusty places.
If the filter is clogged, the air flow is reduced
and a booming sound is heard from the air
conditioner unit.

Removing the filter

1. Open the fuel lid.

2. Loosen the screw and remove the cover
(4).
3. Remove the circulation filter (5).
4. Use compressed air or water to clean the
filter, depending on how dirty it is.
Circulation filter (2) Part No. 19115-13680

Cleaning
1. Blow dry, compressed air (138 kPa or 20
psi or less) directly on the filter from the
inside, moving up and down along the
pleats.
Be sure to keep the nozzle at an adequate
distance from the filter.
2. Wash the filter with neutral detergent if it is
very dirty. Dry the filter completely after
washing it.

5-41
 MAINTENANCE
EVERY 500 HOURS

EVERY 500 HOURS

REPLACING THE FUEL FILTER

• Do not smoke or permit open flames

while handling fuel or working on the
fuel system.
• Stop the engine in a well-ventilated
place and allow it to cool down before
performing maintenance.
• Clean up spilled fuel immediately.

1. Open the engine hood.

2. Turn the filter (1) counterclockwise with the
filter wrench and remove it.
3. Clean the surface of installation of the filter
stand.
4. Apply a thin layer of oil on the packing of
the new filter.
5. Install the new filter by hand.
6. Tighten one more turn after the filter
packing comes in contact with the surface
of installation. (Torque when tightening
with filter wrench: 19.6 to 23.5 N·m or 14
to 17ft-lb.)
7. Bleed the air.
Refer to “Bleeding air from the fuel
system” on page 6-9.

5-42
 MAINTENANCE
EVERY 1000 HOURS

EVERY 1000 HOURS CLEANING THE ENGINE COOLING

SYSTEM
REPLACING THE HYDRAULIC OIL
RETURN FILTER
Refer to “Replacing the hydraulic oil return • Stop the engine and allow the machine
filter” on page 5-35. to cool down before performing
maintenance.
· The engine, muffler, radiator and many
REPLACING THE PILOT LINE FILTER other parts of the machine are hot
immediately after the engine is
Refer to “Replacing the pilot line filter” on stopped. Touching these parts will
page 5-36. cause burns.
· The engine coolant is also hot and
under high pressure immediately after
REPLACING THE TRAVEL MOTOR GEAR the engine is stopped. Be careful
OIL when loosening the caps or plugs.
Working on the machine under these
Refer to “Replacing the travel motor gear oil” conditions could result in burns or injuries
on page 5-37. due to the hot coolant spurting out.
• If maintenance must be performed with
the engine running, always work as a two
person team communicating each other.
· One person must sit in the operator’s
seat so that he/she can immediately
stop the engine when necessary. He/
she must take care not to touch the
lever or pedal unless necessary.
· The one who performs maintenance
must make sure to keep his/her body
or clothing away from the moving part
of the machine.
• Standing at the back of the machine
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 remove the radiator cap or the
drain plug when the cooling water is
hot. Stop the engine and wait until the
engine and the cooling water cool.
Then, slowly loosen the radiator cap
and the drain plug to remove them.

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 (194°F) before cleaning.

5-43
 MAINTENANCE
EVERY 1000 HOURS

1. Open the engine hood and the side cover. 10. Repeat the steps 4 to 8 to rinse the
cooling system.
11. Tighten the drain plug (4).
12. Take time and slowly add the new
coolant (mixture of antifreeze and tap
water) to the radiator through the fill port
until it is full.
13. Close the radiator cap (3).
14. Warm up the engine. Use the meters to
check that there are no irregularities in
the cooling system at this time.
15. Increase the water temperature to at
least 90°C (194°F). Then, run the engine
2. Gradually loosen the radiator cap (3) to for about 10 minutes with the thermostat
release the internal pressure, and then kept open.
remove the cap. 16. Stop the engine, wait until the cooling
water temperature becomes lower, and
then check the level of coolant in the
radiator.
If necessary, add cooling water until the
radiator is full.
17. Close the radiator cap (3).
18. Clean the interior of the reserve tank (1),
and then add coolant to the upper limit
(H).
19. When the coolant has been replaced,
inspect the coolant level once again after
operating the machine.
3. Place a pan for catching the waste coolant Once the machine is operated, the
under the drain plug (4), and then loosen coolant is distributed throughout the
the drain plug (4) to drain the coolant. entire system, resulting in the lower
4. Tighten the drain plug (4). coolant level.
5. Add tap water to the radiator through the Replenish the cooling water that has
coolant fill port up to the top of the port. been used.
Take time and slowly add water, so that no
air enters 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 (194°F), and
then run the engine for about 10 minutes
with the thermostat open.
8. Stop the engine, wait until the cooling
water temperature becomes lower, and
then remove the drain plug (4) to drain the
water.
9. After draining, clean the cooling system
using a cleaning agent. When using the
cleaning agent, follow the instructions
included with the agent.
5-44
 MAINTENANCE
EVERY 1000 HOURS

REPLACING THE AIR CLEANER ELEMENT 5. Cover the intake hole at the back of the
body (4) with cloth or tape to prevent dirt
from getting in.
<If equipped with the secondary element>
Stop the engine and allow the machine to Do not yet remove the secondary element
cool down before performing (5).
maintenance. 6. Clean the inside of the body (4).
• The engine, muffler, radiator and many 7. Remove the cloth or tape applied in step
other parts of the machine are hot 5.
immediately after the engine is stopped. <If equipped with the secondary element>
Touching these parts will cause burns. Remove the secondary element (5).
8. Install the new elements.
IMPORTANT: Do not use an element if its 9. Install the dust cup (2) with its “ TOP ”
pleats, gaskets or seals are damaged. mark facing up, and then fasten it with the
IMPORTANT: Be sure to install the clamps (1).
element and dust cap securely. If not,
dust could be drain into the cylinder,
damaging the engine.

1. Open the engine hood.

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).

5-45
 MAINTENANCE
EVERY 1000 HOURS

REPLACING THE AIR BREATHER FILTER INSPECTING AND ADJUSTING THE

ENGINE VALVE CLEARANCE
This operation requires experience. Ask your
Oil may spurt out if caps or filters are sales or service dealer for it.
removed or pipes are disconnected
before releasing the pressure in the
hydraulic system.
• Press the air breather button to relieve
the tank pressure.

1. Open the right side cover.

2. Press the button (K) to relieve the internal
pressure from the tank.
3. Remove the nut (N) on the air breather.
4. Remove the cover (H).
5. Replace the filter (A).
6. Install the cover (H) on the body (B).
7. Install the nut (N).

5-46
 MAINTENANCE
EVERY 1500 HOURS

EVERY 1500 HOURS

INSPECTING, CLEANING AND CHECKING
OPERATION OF THE ENGINE FUEL
INJECTORS
This operation requires experience. Ask your
sales or service dealer for it.

INSPECTING THE CRANKCASE

BREATHER SYSTEM
This operation requires experience. Ask your
sales or service dealer for it.

5-47
 MAINTENANCE
EVERY 2000 HOURS

EVERY 2000 HOURS

LAPPING THE ENGINE VALVE SEATS (IF
NECESSARY)
This operation requires experience. Ask your
sales or service dealer for it.

5-48
 MAINTENANCE
EVERY 3000 HOURS

EVERY 3000 HOURS

INSPECTING, CLEANING AND CHECKING
OPERATION OF THE EGR VALVE
This operation requires experience. Ask your
sales or service dealer for it.

5-49
 MAINTENANCE
EVERY 4000 HOURS

EVERY 4000 HOURS

REPLACING THE HYDRAULIC OIL AND
CLEANING THE SUCTION STRAINER

• Stop the engine and allow the machine

to cool down before performing
maintenance.
· The engine and the hydraulic system
and many other parts of the machine
are hot immediately after the engine is
stopped. Touching these parts will
cause burns.
· The hydraulic oil is also hot and under
high pressure immediately after the
engine is stopped.
Be careful when loosening the caps or
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 are disconnected
before releasing the pressure in the 3. Press the button (2) to relieve the internal
hydraulic system. pressure from the tank.
· Press the air breather button to relieve 4. Replace the air breather filter (A).
the internal pressure from the tank. Refer to “Replacing the air breather filter”
· When removing plugs or screws, or on page 5-46.
when disconnecting hoses, stand to 5. Remove the plug (3).
the side and loosen them slowly to 6. Loosen the bolts and remove the flange
gradually release the internal pressure (4).
before removing. 7. Remove the return filter (5).
8. Place a pan under the plug (6) to catch the
1. Slew 60° clockwise and set the machine waste oil.
to the hydraulic oil level inspection 9. Remove the drain plug (6), and then drain
posture. the hydraulic oil.
Refer to “Inspecting the hydraulic oil tank 10. Loosen the bolts and remove the flange
level and replenishing” on page 5-22. (7).
2. Open the right side cover. 11. Remove the suction strainer (8) and
clean it.
12. Clean the inside of the hydraulic oil tank.
13. Tighten the drain plug (6).
14. Install the suction strainer (8) on the tank
and then install the flange (7).

5-50
 MAINTENANCE
EVERY 4000 HOURS

15. Install the new return filter (5) and the • Cylinders
flange (4) on the tank. 1. Start the engine, let it run at a low-idling
16. Add hydraulic oil from the hole of plug (3) speed for 10 minutes.
up to the level between the upper limit 2. Maintain the engine at low idle, and then
(H) and the lower limit (L) in the sight slowly extend and retract each cylinder 4
gauge (1). or 5 times, without letting them reach the
17. Tighten the plug (3). stroke end.
18. Bleed air from the hydraulic oil circuit 3. While running the engine at high speed,
following “Bleeding air” below. slowly extend and retract each cylinder 4
19. Set the machine to the hydraulic oil level or 5 times, without letting them reach the
inspection posture and inspect the oil stroke end.
level after the oil cools. 4. Return the engine speed to low idle, and
Refer to “Inspecting the hydraulic oil tank then slowly extend and retract each
level and replenishing” on page 5-22. cylinder 4 or 5 times to the stroke end.

Bleeding air

IMPORTANT: After replacing the hydraulic

oil or hydraulic devices, or after
performing maintenance of the hydraulic
devices, bleed air from the hydraulic
circuits and hydraulic devices. Failure to
do so may damage the hydraulic devices.

• Hydraulic pump

1. Open the engine hood.

2. Loosen the vent plug (1) on the hydraulic
pump.
3. Once hydraulic oil overflows from the vent
plug hole (1), tighten the vent plug (1).

5-51
 MAINTENANCE
EVERY 4000 HOURS

• Emergency shut-off valve (If equipped) Arm

This operation is dangerous and requires
experience. Ask your sales or service
dealer for help.
If air is not released, the working
equipment could become slow in reacting
to the operation of the operator and show
unexpected behavior.

When removing plugs or screws, or when

disconnecting hoses, stand to the side
and loosen them slowly to gradually 4. Hold the hose fitting (B) in place with a
release the internal pressure before wrench and slowly loosen the hose nut (2).
removing. 5. Slowly move the arm in the “Arm lower”
direction a little until there are no more air
1. Place a pan under the hose (A) or (B) to bubbles coming from the hose nut (2)
catch the waste oil. joint.
2. Start the engine and run it at low idle. 6. Hold the hose fitting (B) in place with a
3. Fully lower the safety lock lever to the wrench and tighten the hose nut (2).
unlock position.

Boom

4. Hold the hose fitting (A) in place with a

wrench and slowly loosen the hose nut (1).
5. Slowly move the boom in the “Boom
lower” direction a little until there are no
more air bubbles coming from the hose
nut (1) joint.
6. Hold the hose fitting (A) in place with a
wrench and tighten the hose nut (1).

5-52
 MAINTENANCE
WHEN REQUIRED

WHEN REQUIRED 2. Set the bottom surface of the bucket flat

and lower it on a block so that the locking
REPLACING THE BUCKET TEETH AND pin (1) can be knocked out.
THE SIDE CUTTERS 3. Remove the key, then check that the
bucket is stable.
Replace the bucket teeth and the side
cutters when the tooth points or the side
cutters are worn. Do not wait until the
adapter or bucket is damaged.

• Before performing maintenance or

repairs under the machine, lower all
moveable working equipment to the
ground or in the lowermost position.
• To prevent unexpected movement,
firmly secure the working equipment
when repairing or replacing the bucket 4. Place a rod against the locking pin (1) and
teeth or side cutter. knock the locking pin out by hammering
• When using a hammer, pins may fly out against the rod.
or metal particles may be scattered. The rod should be round and thinner than
This may lead to serious injury. the locking pin.
· If hard metal parts such as pins,
bucket teeth, side cutter or bearings
are hit with a hammer, wear protective
gear such as safety goggles and
gloves.
· When hitting pins or bucket teeth,
always check that there is no one in
the surrounding area.
• Do not allow unauthorized personnel in
the work area while working.

• Bucket tooth <V13SY or V17S> 5. Remove the tooth point (2). Some tooth
Removal points (2) are of the type that are removed
1. Clean the bucket and park the machine in by turning (twisting) them
a flat, safe place where the ground is hard. counterclockwise.
The same procedure can be used to
remove the other tooth points.

5-53
 MAINTENANCE
WHEN REQUIRED

Installation

4. Drive in the locking pin (1) with a hammer

until it is flush with the tip of the tooth
1. Clean the adapter nose (3). If there is point (2) ear.
gravel or mud on the adapter nose, the
tooth point will not go in all the way and
the pin cannot be driven in.

2. Put the tooth point (2) in the adapter nose

(3).
Push in firmly until the tooth point (2)
touches the tip of the adapter nose(3).
Some tooth points (2) are of the type that 5. The locking pin (1) is now driven in.
are installed by turning (twisting) them The same procedure can be used to install
clockwise. the other tooth points.

3. Insert the locking pin (1), making sure it is

in the right direction.
5-54
 MAINTENANCE
WHEN REQUIRED

• Side cutter
Installation

1. Insert the bolts from the inner of the

bucket and tighten the side cutterwith
nuts.
Tightening torque: 241 N·m (178 ft-lb)
2. Caulk the bolts with a punch at three
spots along the periphery of the screw to
prevent the nuts from coming loose.

5-55
 MAINTENANCE
WHEN REQUIRED

REPLACING THE BUCKET Removing

• Before performing maintenance or

repairs under the machine, lower all
working equipment to the ground or in
the lowermost position.
• If maintenance must be performed with
the engine running, always work as a
two person team communicating each
other.
· One person must sit in the operator’s
seat so that he/she can immediately 1. Lower the bucket to the ground as shown
stop the engine when necessary. He/ on the figure above in a stable position.
she must take care not to touch the
lever or pedal unless necessary. Note: When removing pins, set the bucket
· The one who performs maintenance so that it is barely touching the ground If the
must make sure to keep his/her body bucket is firmly touching the ground, the
or clothing away from the moving part resistance will be great and it will be difficult
of the machine. to remove the pin.
• When using a hammer, pins may fly out
or metal particles may be scattered. 2. Set the safety lock lever to the locked
This may lead to serious injury. position and stop the engine.
· If hard metal parts such as pins,
bucket teeth, side cutter or bearings
are hit with a hammer, wear protective
gear such as safety goggles and
gloves.
· When hitting pins or bucket teeth,
always check that there is no one in
the surrounding area.
• When aligning the pin holes, always do
so by checking them visually. Do not
insert your finger in the pin hole, or you
could lose your finger.
3. Remove the bolt (1).
4. Hammer the pin (2) out of the bucket.
5. Remove the bucket.
Inspect the pin seal (3) and replace it if it is
deformed or damaged. (See next page.)

5-56
 MAINTENANCE
WHEN REQUIRED

Installation

5. Adjust the gap between the bucket and

the arm.
1. Set the O-ring (4) on the bucket as shown Refer to “Adjusting the gap between the
on the figure above. bucket and arm (If equipped)” on page
5-58.
6. Slide the O-ring (4).

Replacing the pin seal

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

the pin hole on the arm (5), and install the
pin (2).
3. Operate the cylinder, align the pin hole (B)
on the bucket with the pin hole on the link 1. Set the pin seal (3) in the direction shown
arm (6), and install the pin (2). on the figure above.
2. Use a mallet to slowly press the pin seal
in. Be careful not to damage the seal.

4. Align the turn prevention holes, and then

install the bolt (1) and the nut. Be sure to
leave a gap of about 0.5 to 1 mm (0.02 to
0.04 in.) between the nut and bucket
bush, or the nut will come loose.
5-57
 MAINTENANCE
WHEN REQUIRED

ADJUSTING THE GAP BETWEEN THE

BUCKET AND ARM (IF EQUIPPED)

• Before performing maintenance or

repairs under the machine, lower all
working equipment to the ground or in
the lowermost position.
• To prevent unexpected movement,
securely block the working equipment
when adjusting the gap. 4. Remove the three bolts (2), the end plate
(3) and flange (4).

1. Lower the bucket to the ground as shown

on the figure above in a stable position. 5. Pull out the adjustment shim(s) (5)
2. Check that the bucket dose not move, corresponding to the gap (A) from
and then set the safety lock lever to the between the flange (4) and the bucket
locked position and stop the engine. body.
Adjustment shim thickness : 0.5 mm (0.02
in.)
Be careful that the gap is no less than 0.5
mm (0.02 in.) after adjustment.

Note:
Example (for a gap of 2 mm or 0.08 in.):
2 mm - 0.5 mm (standard value)= 1.5 mm
(0.06 in.)
In the above example, three shims (5) should
be removed.

3. Move the O-ring (1) to bring the gap (A) 6. Insert the adjustment shim(s) (5) removed
into view and measure the width of the in step 5 above between the end plate (3)
gap (A). and the flange (4), and then fasten it in
The gap (A) should be 0.5 mm (0.02 in.). place with the three bolts (2).
Swing the upperstructure slightly to the left · Tightening torque for bolts (2): 83 N·m
and lightly press the arm point to the left (61.5 ft-lb.)
side of the bucket (the side without an 7. Return the O-ring (1) to the original
adjuster). position.

5-58
 MAINTENANCE
WHEN REQUIRED

INSPECTING AND REPLENISHING THE

WINDSHIELD WASHER FLUID

Choose ethyl alcohol as washer solution.

Do not use methyl alcohol as washer
solution. It could damage the eyes.

Use a windshield washer fluid designed

specifically for motor vehicles. Follow the
instructions included with the washer fluid.

Inspection
1. Open the right side cover.
2. Inspect the washer tank (1) and add
washer fluid if the level is low.

Replenishing
1. Mix the washer fluid to the prescribed
concentration.
2. Remove the cap (2) and add washer fluid.
Keep the dust away while replenishing the
washer fluid.
3. Install the cap (2).

5-59
 MAINTENANCE
WHEN REQUIRED

LUBRICATING THE LEVERS AND PEDALS Boom swing pedal

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 or pedals no longer move

smoothly, grease them.

Operating levers
Dozer blade lever

Travel levers 1. Remove the lower mount section of the

boot (1) and turn it upward.
2. Wipe off the old grease.
3. Apply grease to points (A) and (B).
4. Set the boot (1) back as it was.

5-60
 MAINTENANCE
WHEN REQUIRED

INSPECTING THE RUBBER CRAWLERS (3) Metal core

Repair or replace the rubber crawlers if their

condition becomes as described below.
Consult your sales or service dealer for repair
or replacement.

Rubber crawler
Replace the crawler if the entire crawler is
stretched and cannot be adjusted.

(1) Lug

Replace if even one metal core is off.

(4) Rubber

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

or below.

(2) Steel cord

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.

Replace if the steel cord is exposed for two

links or more.
Replace if the half or more of the steel cords
on one side are cut.

5-61
 MAINTENANCE
WHEN REQUIRED

REPLACING THE RUBBER CRAWLERS

• If you must work beneath the raised

machine or working equipment, always
use wood blocks, jack-stands or other
rigid and stable supports. Never get
under the machine or working
equipment if they are not sufficiently
supported.
• If maintenance must be performed with 3. Set an iron pipe (1) in the rubber crawler
the engine running, always work as a and turn the sprocket slowly in the reverse
two person team communicating each direction.
other. 4. Turn until the iron pipe (1) is directly next to
· One person must sit in the operator’s the idler and the rubber crawler lifts away
seat so that he/she can immediately from the idler, then stop turning the
stop the engine when necessary. He/ sprocket.
she must take care not to touch the 5. Slide the rubber crawler sideways and
lever or pedal unless necessary. remove it from the crawler frame.
· The one who performs maintenance Remove the other rubber crawler using
must make sure to keep his/her body the same procedure.
or clothing away from the moving part
of the machine.

Removal
1. Fully release the tension of the rubber
crawler.
Refer to “Inspecting and adjusting the
crawler tension” on page 5-28.

2. Use the working equipment to lift the

body.

5-62
 MAINTENANCE
WHEN REQUIRED

Installation
1. Use the working equipment to lift the
body.

2. Set the rubber crawler on the sprocket.

3. Set an iron pipe (1) in the rubber crawler
and turn the sprocket slowly in the reverse
direction.
4. Turn until the iron pipe (1) is directly next to
the idler and the rubber crawler lifts away
from the idler, then stop turning the
sprocket.
5. Slide the rubber crawler inward, engage it
on the idler, then pull out the iron pipe.
6. Check that the rubber crawler is securely
engaged on the sprocket and idler.
7. Tighten the rubber crawler to the standard
tension.
Refer to “Inspecting and adjusting the
crawler tension” on page 5-28.
8. Install the other rubber crawler using the
same procedure.

5-63
 MAINTENANCE
MAINTENANCE DURING EXTENDED STORAGE PERIOD

MAINTENANCE DURING Starting the machine after storage

EXTENDED STORAGE PERIOD IMPORTANT: If the above “Storage

procedures” have not been followed
Storage procedures during the extended storage periods,
If the machine is to be stored for 30 days or consult your sales or service dealer
more, store it indoors. If it must be stored before starting the machine again.
outdoors, park the machine on a surface laid
with lumber on a flat ground, and place a 1. Wipe off the rust-inhibiting oil that was
waterproof cover over it so that it stays dry. applied on the piston rods of the hydraulic
1. Clean the machine. oil cylinders.
2. Inspect for oil leakage, water leakage, 2. Add oil or grease as necessary.
cracks and loose nuts and bolts.
3. Add fuel and replace the hydraulic oil and Returning the engine to service
oil. 1. Perform the daily checks.
4. To prevent rusting and freezing, replace 2. The engine should be pre-oiled before
the engine coolant with long-life coolant startup.
(LLC). a. Crank the engine, leaving the fuel
Refer to “Cleaning the engine cooling system shut off so the engine will not
system” on page 5-43. start, for 15 seconds.
5. Use the grease gun to lubricate the grease b. Then pause for 30 seconds.
fittings. c. Repeat the procedure until you have
6. Fully retract the bucket and arm cylinders cranked the engine for a total of one
and lower the bucket and dozer blade to minute. This will circulate the oil in the
the ground. engine’s lubrication system.
7. Apply rust-inhibiting oil to the hydraulic 3. Prime the fuel system.
cylinder rods. 4. Start the engine. Allow the engine to idle
8. Disconnect the negative cable from the for approximately 15 minutes while you
battery and cover the battery to prevent check for:
freezing. · Proper oil pressure
· Fuel, engine oil or coolant leaks
During storage · Proper operation of the indicators and/or
gauges
5. Avoid prolonged operation at minimum or
• Do not operate the machine in an maximum engine speeds and loads for the
enclosed area without adequate remainder of the first hour of operation.
ventilation.
• If natural ventilation is not possible,
install ventilators, fans, exhaust
extension pipes or other venting
devices.

1. To prevent rusting, operate the machine

once a month so that the oil can be
circulated throughout the system.
2. Inspect the battery and recharge it as
necessary.
Ask your sales or service dealer for
recharging.

5-64
TROUBLESHOOTING

6-1
 TROUBLESHOOTING
SYMPTOMS THAT ARE NOT MALFUNCTIONS

SYMPTOMS THAT ARE NOT • It becomes less easy to operate the

machine when an attachment weighing
MALFUNCTIONS more than a standard arm or bucket is
installed.
The symptoms listed below are not
malfunctions.

• The arm retracting speed momentarily

slows down when it reaches an almost
vertical position while the engine is running
at low speed.

• The bucket teeth moving speed

momentarily slows down when it reaches
an almost horizontal position while the
engine is running at low speed.
• The slew motor produces noise at the
beginning and end of the slewing.
• The travel motor produces noise when
stopped suddenly from its high speed
traveling.
• The control valve produces noise if
excessive force is applied to the working
equipment or when it moved to the stroke
end.

6-2
 TROUBLESHOOTING
IF THE ENGINE OVERHEATS

IF THE ENGINE OVERHEATS • The water temperature gauge level is in the

red zone.
• The engine slows down and the engine
power decreases.
• Do not open the engine hood when steam • Steam comes from the engine room.
is coming from it. The steam or hot water
may spurt out and cause burns.
• Do not try to remove the radiator cap or Remedy procedure
the drain plug when the cooling water is 1. Park the machine in a safe place.
hot. Stop the engine, wait until the 2. Check if steam is coming out of the closed
engine and the radiator cool, and then engine hood.
slowly loosen the radiator cap to release 3. If there is steam, stop the engine
the internal pressure. immediately and contact your sales or
• Before performing maintenance, stop the service dealer for repair. If steam, is not
engine and allow the machine to cool down. coming out run the engine at low idle and
let the water temperature cool down.
The symptoms listed below indicate 4. When the water temperature gauge level
overheating. drops in the green zone, stop the engine.
5. Perform the inspections and the remedies
< Canopy > listed below once the engine cools down.
· Fan belt slack........... Adjust
Refer to page 5-26.
· Coolant level............ Add
Refer to page 5-18.
· Water leakage.......... Repair
· Radiator fins............. Clean
Refer to page 5-40.
· Sediment in cooling system
................................ Clean
Refer to page 5-43.
If the problem persists after the above
remedies, contact your sales or service
dealer for repair.
< Cab >

• An alarm is sounded and the engine

emergency lamp and the coolant
temperature warning lamp start flashing.

6-3
 TROUBLESHOOTING
IF THE BATTERY GOES DEAD

IF THE BATTERY GOES DEAD IMPORTANT: Be sure that the battery of

the booster vehicle has the same
The symptoms below indicate that the capacity as the battery of the dead
battery is dead. machine.
• The starter motor does not turn or fails to IMPORTANT: Be sure to connect the clips
start the engine. securely.
• The horn is too weak.
Connecting the jumper cables
Remedy procedure
Start the engine using the booster battery on IMPORTANT: Set the starter keys of the
the other vehicle (booster vehicle) and the booster vehicle and the dead machine to
jumper cables. the OFF position.

• When starting the engine using the

jumper cables, be sure to connect the
cables by following the proper steps.
Improper use of jumper cables can
result in battery explosion or
unexpected machine motion.
· Do not allow the booster vehicle and
the machine with a dead battery (dead
machine) to touch each other.
· Do not allow the positive (+) and the
negative (–) clips of the jumper cables 1. Connect the clip of jumper cable (R) to the
to touch each other. positive (+) battery terminal of the dead
· When connecting, attach the jumper machine.
cable to the positive (+) terminals first. 2. Connect the other clip of jumper cable (R)
When disconnecting, remove the to the positive (+) battery terminal of the
cable from the negative (–) terminal booster vehicle.
(ground) first. 3. Connect the clip of jumper cable (B) to the
· Connect the last clip of the jumper negative (–) battery terminal of the booster
cable to a point as far away from the vehicle.
battery as possible. 4. Connect the other clip of jumper cable (B)
• Always wear the protective goggle when to the engine block of the dead machine.
jump starting the engine by using the Connect the clip to a place as far from the
jumper cables. battery as possible.
• Set the battery charging current to at or
below one tenth of the rated capacity. Starting the engine
Too high charging current could cause 1. Check that the clips are securely
the battery to leak or be depleted, connected to the terminals.
resulting in explosion if ignited. 2. Start the engine of the booster vehicle and
run it at high speed.
IMPORTANT: Use the jumper cables and 3. Start the engine of the dead machine.
clips of a size suited to the capacity of
battery. Do not use damaged or corroded
jumper cables and clips.

6-4
 TROUBLESHOOTING
IF THE BATTERY GOES DEAD

Disconnecting the jumper cables

Once the dead machine is successfully

running, remove the jumper cables by
following the same steps as for connection in
the reverse order.

1. Disconnect the clip of jumper cable (B)

from the engine block of the dead
machine.
2. Disconnect the other clip of jumper cable
(B) from the negative (–) battery terminal of
the booster vehicle.
3. Disconnect the clip of jumper cable (R)
from the positive (+) battery terminal of the
booster vehicle.
4. Disconnect the clip of jumper cable (R)
from the positive (+) battery terminal of the
dead machine.

Recharging
Ask your sales or service dealer for
recharging the dead battery.

6-5
 TROUBLESHOOTING
IF A FUSE BLOWS

IF A FUSE BLOWS Fuse layout and circuits protected (1)

If a light does not come on or the electrical <Cab>

system does not work, a fuse may be blown.
Inspect the fuses. Protected
Capacity Symbol
circuit
INSPECTING AND REPLACING THE FUSE
5A Switch lighting

10A Horn
If the fuse blows again soon after
replacement, then the electric system is 5A Starter switch
likely faulty. It may pose a fire hazard if 10A Immobilizer
not properly repaired. Contact your sales
or service dealer for advice.
20A Light
1. Turn the starter key to the OFF position to
stop the engine. 10A Wiper
20A Lever lock
Controller power
10A
supply (2)
10A Solenoid
Cab interior
20A
power supply
25A OPT Option
10A Heater
10A Feed pump
2. Open the fuse box cover (1).
3. Check for any blown fuses (2). 30A Blower motor
20A Cab light
Controller power
20A
supply (1)

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

fuse of the same capacity.

6-6
 TROUBLESHOOTING
IF A FUSE BLOWS

<Canopy> 7. Open the fuse box.

8. If a fuse is blown, replace it with a spare
Protected fuse of the same capacity.
Capacity Symbol
circuit
Fuse layout and circuits protected (2)
5A Switch lighting
Capacity Protected circuit
10A Horn
5A Starter switch 10A ECU

10A Immobilizer 25A Fuel pump

20A Light (1)

20A Lever lock

Controller power
15A
supply
25A Solenoid
20A OPT (1) Option (1)
25A OPT (2) Option (2)

10A Feed pump

15A Light (2)

5. Open the right side cover and engine

hood.
6. Loosen the bolts and remove the cover
(3).

6-7
 TROUBLESHOOTING
IF A FUSE BLOWS

INSPECTING THE FUSIBLE LINK

If the machine is not turned on after turning

the starter switch to the ON position, the
cartridge type fusible link (2) is likely blown.
Open the right side cover and inspect it. If
the fusible link is blown, contact your sales
or service dealer.

1. Open the right side cover.

2. Loosen the bolts and remove the cover
(1).
3. Inspect the fusible link (2).

Note: Fusible links are large type fuses used

in high current applications. Like a regular
fuse, they act as fuses by protecting the
electric components and wirings from
damage caused by excessive current draw.

6-8
 TROUBLESHOOTING
RESTARTING AFTER ADDING FUEL

RESTARTING AFTER ADDING problems. Always bleed air when the fuel
tank is emptied or when there is air in the
FUEL fuel system.

BLEEDING AIR FROM THE FUEL SYSTEM

IMPORTANT: NEVER use the starter
motor to crank the engine in order to
prime the fuel system. This may cause the
starter motor to overheat and damage the
coils, pinion gear and/or ring gear.
IMPORTANT: If the engine stalls due to
fuel shortage, add fuel, turn the key to the
ON position for 60 seconds, and then turn
it to the START position. Running the
starter for a long time before there is
enough fuel is going through can cause
the starter to fail.

1. Add fuel.

2. Turn the starter key to the ON position and

hold it for about 60 seconds.
The automatic air bleeder bleeds air from
the fuel system.

Note: Air in the fuel system causes the

engine to fail to start or to have other
6-9
 TROUBLESHOOTING
IF A WARNING LAMP FLASHES

IF A WARNING LAMP FLASHES

If an alarm is sounded or a warning lamp starts flashing during operation, park the machine in
a safe place and perform the remedy procedures described below.

Warning lamp Lamp name Causes and remedies

Vehicle and There is a problem in the machine.
engine Refer to the respective warning lamp below.
emergency Get the vehicle or engine error code number from the
lamp multi-information display or the instrument cluster, and
then consult your sales or service dealer referring to the
“Vehicle error code list” or “Engine error code list”.
Refer to “Multi-information display” on page 2-16 or
“Instrument cluster” on page 2-28.
Refer to “Vehicle error code list” on pages 6-12 and
6-13.
Refer to “Engine error code list” on pages 6-14 to 6-15.
ECM error An engine problem is detected.
warning lamp If an error code is displayed on the multi-information
display or the instrument cluster, inform your sales or
service dealer of the code and ask for help.
Refer to “Multi-information display” on page 2-16 or
“Instrument cluster” on page 2-28.
Refer to “Engine error code list” on pages 6-14 to 6-15.
Battery charge There is a problem with the fan belt or charger.
warning lamp
Check the fan belt for slack or breakage and adjust as
necessary.
If the lamp continues flashing after maintenance, there is
likely a problem with the charger. Consult your sales or
service dealer for help.
Refer to “Inspecting and adjusting the fan belt” on page
5-26.
Engine oil There is a problem in the engine lubrication system.
pressure
warning lamp Check the engine oil level. If the lamp is flashing when
the level is normal or even after replenishment of oil or
coolant, consult your sales or service dealer.
Refer to “Inspecting and replenishing the engine oil” on
page 5-19.

6-10
 TROUBLESHOOTING
IF A WARNING LAMP FLASHES

Warning lamp Lamp name Causes and remedies

Coolant The coolant temperature is too high and the engine is
temperature overheating.
warning lamp Refer to “If the engine overheats” on page 6-3.

Air cleaner The air cleaner is clogged. Clean it.

warning lamp Refer to “Cleaning the air cleaner” on page 5-38.

Fuel filter The fuel filter is clogged. Replace the fuel filter.
warning lamp Refer to “Replacing the fuel filter” on page 5-42.

Fuel level The fuel level is too low. Add fuel.

warning lamp Refer to “Inspecting the fuel level” on page 5-21.

Third auxiliary Pressure in the third auxiliary hydraulic line is too low
hydraulic
warning lamp Consult your sales or service dealer for help.

Lift overload This lamp starts flashing if the overload warning device is
warning activated. If it occurs, reduce the load to be lifted.
indicator lamp Refer to “Lift overload warning switch (If equipped)” on
page 2-55.

6-11
 TROUBLESHOOTING
VEHICLE ERROR CODE LIST

VEHICLE ERROR CODE LIST

When the multi-information display is set to the data mode, the number that is corresponding
to the error, if applicable, appears in the error code field. Up to four types of error codes are
displayed (the leftmost code is the most recent error). If this occurs, consult your sales or
service dealer.

Error code Error details

9 Impossible to sense ACC key
19 Parameter version mismatching
402 CAN 0 communication error
502 CAN communication error (engine ECU)
602 CAN communication error (cluster gauge)
612 CAN communication error (OX024)
1703 Main power supply voltage error (too high)
1704 Main power supply voltage error (too low)
1713 OX024 power supply voltage error (too high)
1714 OX024 power supply voltage error (too low)
2503 Sensor voltage error (too high) MMC
2504 Sensor voltage error (too low) MMC
3300 Alternator charge faulty
3401 Engine oil pressure error
3500 Overheat
3600 Air cleaner clogged
5303 Accelerator sensor error (too high)
5304 Accelerator sensor error (too low)
5505 Fuel gauge resistance value error (cable break)
5603 Lift alarm sensor error (too high)
5604 Lift alarm sensor error (too low)
6503 AUX1 slide switch voltage value error (too high)
6504 AUX1 slide switch voltage value error (too low)
6509 AUX1 slide switch neutral error

6-12
 TROUBLESHOOTING
VEHICLE ERROR CODE LIST

Error code Error details

6519 AUX1 (L) switch error
6529 AUX1 (R) switch error
6603 AUX2 slide switch voltage value error (too high)
6604 AUX2 slide switch voltage value error (too low)
6609 AUX2 slide switch neutral error
6709 AUX3 button error (Grip)
6719 AUX3 switch error (Foot)
8005 Pump PWM output voltage error (too low)
8006 Pump PWM output voltage error (too high)
8015 AUX1 (L) PWM output voltage error (too low)
8016 AUX1 (L) PWM output voltage error (too high)
8025 AUX1 (R) PWM output voltage error (too low)
8026 AUX1 (R) PWM output voltage error (too high)
8035 AUX2 (L) PWM output voltage error (too low)
8036 AUX2 (L) PWM output voltage error (too high)
8045 AUX2 (R) PWM output voltage error (too low)
8046 AUX2 (R) PWM output voltage error (too high)
9990 Model change
9991 Unknown models

PWM = Pulse width modulation

6-13
 TROUBLESHOOTING
ENGINE ERROR CODE LIST

ENGINE ERROR CODE LIST

When the engine error code is displayed on the multi-data display, the number that is
corresponding to the error, if applicable, appears in the error code field. Up to three types of
error codes are displayed, with the latest code at the top. If this occurs, consult your sales or
service dealer for help.

Error code
Error details
SPN FMI
4 Engine Fuel Rack Position Sensor: Shorted to low source
1210
3 Engine Fuel Rack Position Sensor: Shorted to high source
4 Barometric Pressure Sensor: Shorted to low source
108 3 Barometric Pressure Sensor: Shorted to high source
2 Barometric Pressure Sensor: Intermittent fault
4 E-ECU Internal Temperature Sensor: Shorted to low source
3 E-ECU Internal Temperature Sensor: Shorted to high source
1136
2 E-ECU Internal Temperature Sensor: Intermittent fault
0 E-ECU Internal Temperature: Too high
4 Engine Coolant Temperature Sensor: Shorted to low source
3 Engine Coolant Temperature Sensor: Shorted to high source
110
2 Engine Coolant Temperature Sensor: Intermittent fault
0 Engine Coolant Temperature: Too high
4 Sensor 5V: Shorted to low source
1079 3 Sensor 5V: Shorted to high source
2 Sensor 5V: Intermittent fault
1 System Voltage: Too low
158
0 System Voltage: Too high
1078 4 Engine Fuel Injection Pump Speed Sensor: Shorted to low source
522402 4 Auxiliary Speed Sensor: Shorted to low source
4 Engine Fuel Rack Actuator Relay: Circuit fault A
3 Engine Fuel Rack Actuator Relay: Circuit fault B
522241
7 (Reserved)
2 Engine Fuel Rack Actuator Relay: Intermittent fault
4 Air Heater Relay: Circuit fault A
522243 3 Air Heater Relay: Circuit fault B
2 Air Heater Relay: Intermittent fault
4 Cold Start Device: Circuit fault A
522242 3 Cold Start Device: Circuit fault B
2 Cold Start Device: Intermittent fault
4 EGR Stepping Motor “A”: Circuit fault A
522251
3 EGR Stepping Motor “A”: Circuit fault B

6-14
 TROUBLESHOOTING
ENGINE ERROR CODE LIST

Error code
Error details
SPN FMI
4 EGR Stepping Motor “B”: Circuit fault A
522252
3 EGR Stepping Motor “B”: Circuit fault B
4 EGR Stepping Motor “C”: Circuit fault A
522253
3 EGR Stepping Motor “C”: Circuit fault B
4 EGR Stepping Motor “D”: Circuit fault A
522254
3 EGR Stepping Motor “D”: Circuit fault B
4 Oil Pressure Switch: Shorted to low source
100
1 Oil Pressure: Too low
4 Battery Charge Switch: Shorted to low source
167
1 Charge warning
522314 0 Engine Coolant Temperature: Abnormal temperature
522323 0 Air Cleaner: Mechanical malfunction
522329 0 Oily Water Separator: Mechanical malfunction
190 0 Engine speed: Overspeed condition
4 Engine Fuel Rack Actuator: Shorted to low source
3 Engine Fuel Rack Actuator: Shorted to high source
638
7 Engine Fuel Rack Actuator: Mechanical malfunction
2 Engine: Malfunction
639 12 High-speed CAN Communication: Communication fault
2 E-ECU internal fault: EEPROM checksum error (Data Set 2)
630
12 E-ECU internal fault: EEPROM read/write fault
12 E-ECU internal fault: Flash ROM checksum error (Main software)
628 2 E-ECU internal fault: Flash ROM checksum error (Data Set 1)
2 E-ECU internal fault: Flash ROM checksum error (Data Set 2)
1485 4 E-ECU Main Relay: Shorted to low source
12 E-ECU internal fault: Sub-CPU error A
522727 12 E-ECU internal fault: Sub-CPU error B
12 E-ECU internal fault: Sub-CPU error C
522728 12 E-ECU internal fault: Engine Map Data Version Error
12 Immobilizer: CAN communication fault
522730
8 Immobilizer: Pulse communication fault
1202 2 Immobilizer: System fault

6-15
 TROUBLESHOOTING
OTHER SYMPTOMS

OTHER SYMPTOMS
For symptoms not included in the table below or if the problem persists after the proper
remedies have been taken, consult your sales or service dealer.

Symptoms Major causes Remedies

Left and right operating levers • Insufficient grease on the • Grease the levers.
do not move smoothly left and right operating Refer to page 5-60.
levers
Travel levers, blade lever and • Insufficient grease on travel • Grease the levers and
pedals do not move smoothly levers, blade lever and pedals.
pedals Refer to page 5-60.
Operation of hoe attachment, • Safety lock lever is raised • Lower (release) the safety
dozer blade, auxiliary (locked) lock lever.
hydraulics, slewing or Refer to page 2-57.
traveling is not possible. • Fuse is blown • Replace the fuse.
Refer to page 6-6.
Digging force is insufficient • Hydraulic oil level too low • Add to the specified level.
Refer to page 5-22.
• Hydraulic oil is not warm • Perform the warm-up.
enough Refer to pages 3-8 to 3-9.
• Air cleaner is clogged • Clean the air cleaner.
Refer to page 5-38.
• Hydraulic oil is not of • Replace the hydraulic oil.
suitable type Refer to page 5-50.
Traveling is not possible or • Stones or foreign objects • Remove the foreign object.
not smooth are stuck
Machine veers to the right/left • Stones or foreign objects • Remove the foreign object.
are stuck
• Crawler belt tension is • Check and adjust (ask your
faulty. sales or service dealer).
Refer to pages 5-28 to
5-29.
Travel speed cannot be • Fuse is blown • Replace the fuse.
changed Refer to page 6-6.
Slewing is not possible or not • Insufficient grease on slew • Grease the bearing.
smooth bearing Refer to page 5-30.
Hydraulic oil temperature is • Hydraulic oil level too low • Add up to the specified
too high level.
Refer to page 5-22.

6-16
 TROUBLESHOOTING
OTHER SYMPTOMS

Symptoms Major causes Remedies

Starter motor turns but • Insufficient fuel • Add fuel.
engine does not start Refer to page 5-21.
• Air in fuel system • Bleed air.
Refer to page 6-9.
• Water in fuel system • Drain water.
Refer to page 5-31.
• Fuel is frozen. • Warm the fuel pipe with hot
water or wait until the
ambient temperature
becomes high.
• Engine control system is • Adjust or repair (ask your
faulty. sales or service dealer).
• Fuel line is faulty. • Adjust or repair (ask your
sales or service dealer).
• Preheating device is faulty. • Adjust or repair (ask your
sales or service dealer).
Crawlers come off • Crawlers too loose • Check and adjust (ask your
sales or service dealer).
Refer to pages 5-28 to
5-29.
Engine exhaust is white or • Excessive engine oil • Adjust to the specified level.
bluish Refer to page 5-19.
• Insufficient machine warm- • Perform the warm-up
up. operation.
Refer to page 3-5.
• Engine control system is • Adjust or repair (ask your
faulty. sales or service dealer).
• Fuel line is faulty. • Adjust or repair (ask your
sales or service dealer).
• Prolonged idling (approx. • Increase the engine RPM
two hours or more) and check for smoke.
• Poor fuel • Replace the fuel.

6-17
 TROUBLESHOOTING
OTHER SYMPTOMS

Symptoms Major causes Remedies

Engine exhaust is • Air cleaner is clogged • Clean the air cleaner.
occasionally black Refer to page 5-38.
• Engine control system is • Adjust or repair (ask your
faulty. sales or service dealer).
• Fuel line is faulty. • Adjust or repair (ask your
sales or service dealer).
• Clogging in the exhaust line. • Adjust or repair (ask your
sales or service dealer).
• DPF is faulty. • Adjust or repair (ask your
sales or service dealer).
Irregular noise is produced • Low quality fuel is being • Replace the fuel.
from the engine used
(combustion or mechanical • Engine is overheating • Refer to “If the engine
noise) overheats” on page 6-3.
• Damage inside the muffler • Replace the muffler.
For replacement, ask your
sales or service dealer.

6-18
 TROUBLESHOOTING
LOWERING THE BOOM TO THE GROUND

LOWERING THE BOOM TO • Do not loosen or remove the hoses not

located in the specified places. Oil may
THE GROUND spurt out if wrongly handled.

If the hoe attachment must be lowered to the

ground while the engine is stopped, use the Equipped with emergency shut-off valve
following procedure.

Procedure 1 (machines with an

accumulator)
Perform this operation within 10 minutes
after the engine stopping.
1. Sit at the operator’s seat.
2. Turn the starter switch to the ON position.
3. Lower the safety lock lever to the unlock
position
4. Slowly push the operating lever forward to
lower the boom.
1. Place a pan under the hose to catch the
Procedure 2 (machines without an waste oil.
accumulator) 2. Hold the hose fitting (1) with a wrench and
This operation is dangerous and requires slowly loosen the hose nut (2) with another
experience. Ask your sales or service dealer wrench.
for it. 3. The oil in the boom cylinder is drained and
the hoe attachment is lowered.
4. After the hoe attachment is lowered to the
• Stop the engine and allow the machine ground, check the safety and stability of
to cool down before performing the machine.
maintenance. 5. Hold the hose fitting (1) with a wrench and
· The engine and the hydraulic system tighten the hose nut (2) with another
and many other parts of the machine wrench.
are hot immediately after the engine is · Tightening torque: 31.4 N·m (23.1 ft-lb.)
stopped. Touching these parts will
cause burns.
· The hydraulic oil is also hot and under
high pressure immediately after the
engine is stopped.
Be careful when loosening the caps or
plugs. Working on the machine under
these conditions could result in burns
or injuries due to the hot oil spurting
out.
• Keep away from the working area when
the hoe attachment is lowered. You may
be hit by dirt falling out of the bucket or
the hoe attachment as it drops.
• Slowly turn the hose nut and lower the
boom at a slow pace.

6-19
 TROUBLESHOOTING
TOWING

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
When towing, serious injury or death to get out on its own.
could result, if performed incorrectly or
the wire rope being used is inappropriate
or not properly inspected.
• It becomes dangerous if the wire rope
breaks or becomes disengaged. Use a
wire rope appropriate for the required
tractive force.
• Do not use a wire rope that is kinked,
twisted or otherwise damaged.
• Do not apply heavy loads abruptly to
the wire rope.
• Wear safety gloves when handling the AG8A001

wire rope. • Permissible forces: 47.0 kN (10566 lbf)

• Make sure there is an operator on the Do not tow using only a towing hole on one
machine being towed as well as on the side.
machine that is towing.
• Never tow on slopes. 1. Attach the wire rope to the shackle (1).
• Do not let anyone come near to the wire 2. Fasten the shackle (1) to the towing holes
rope while towing. (2).
3. Make sure that the wire rope is at a cone
IMPORTANT: Do not tow a machine if its angle of 20° or less to the travel frame.
engine does not start or if the machine 4. Move the machine to tension the wire
does not run. Doing so could damage the rope.
machine being towed. 5. Operate the machine slowly and tow.
IMPORTANT: Be sure to follow the steps
below closely when using the towing hole
to tow. Failure to heed even one of the
steps may cause damage to the towing
hole or other parts of the frame.

6-20
 TROUBLESHOOTING
IF THE CAB OR CANOPY IS DAMAGED

IF THE CAB OR CANOPY IS

DAMAGED

Immediately replace the damaged cab or

canopy. Serious injury or death may occur
if the machine is operated with damaged
cab/canopy.
Do not operate the machine until the
replacement is complete. Do not try to
repair the damaged cab or canopy by
welding. Doing so could endanger the
safety of the cab/canopy.

Canopy part number: 05584-00085

Cab part number: 03586-00070

6-21
6-22
SPECIFICATIONS

7-1
 SPECIFICATIONS
BASIC SPECIFICATIONS

BASIC SPECIFICATIONS
Type Canopy Cab
MASS
Operating mass kg (lb) Rubber crawlers 2885 (6360) 2950 (6505)
PERFORMANCE

Bucket capacity Heaped 0.068 (2.4)

m3 (cu. ft.)
(Standard bucket) Struck 0.051 (1.8)
Slew speed min (rpm)
-1
10.3 (10.3)
1st 2.9 (1.8)
Travel speed km/h (mph) Rubber crawlers
2nd 5.2 (3.23)
Gradeability (degrees) 30
Ground pressure kPa (psi) Rubber crawlers 30.1 (4.63) 31.6 (4.58)
Sound power level LWA 93
Noise level dB (A)
Sound pressure level LpA 78
ENGINE
Yanmar Yanmar
Manufacturer and model 3TNV88F- 3TNV88F-
EPTB1 EPTB
Net
kW/min-1 (hp/rpm) 18.2/2400 (24.4/2400)
(ISO 14396)
Rated output
Net (ISO 9249/
kW/min-1 (hp/rpm) 17.6/2400 (23.6/2400)
SAEJ1349)
Displacement ml (cu.in.) 1642 (100.2)
Starter V-kW 12-1.7
Alternator V-kW 12-0.66
Battery (IEC 60095-1) V-A·h 12-64

7-2
MEMO

7-3
 SPECIFICATIONS
MACHINE DIMENSIONS

MACHINE DIMENSIONS

7-4
 SPECIFICATIONS
MACHINE DIMENSIONS

Unit: mm (inch)
Long arm
Item
Rubber crawlers
A Overall length 4595 (180.9)
B Upperstructure overall width 1460 (57.5)
2540 (100)
C Overall height
2525 (99.3)**
D Slew radius 1330 (52.4)
E Clearance height under upperstructure 590 (23.2)
F Crawler base 1440 (56.7)
G Crawler overall length 1900 (74.9)
H Crawler overall width 1450 (57.1)
J Crawler shoe width 300 (11.8)
K Ground clearance of undercarriage 305 (11.9)
L Minimum radius of equipment and attachment 1895 (74.7)
M Minimum radius of equipment at maximum front offset 1505 (59.2)
P Offset distance of bucket (right swing) 490 (19.3)
Q Offset distance of bucket (left swing) 610 (23.9)
R Dozer blade width 1450 (57.1)
S Dozer blade height 355 (14.0)
T Front distance to axis of rotation 3265 (128.5)
1455 (57.3)
U Dozer blade distance to axis of rotation
1480 (58.3)*
V Boom swing angle (Left) 79°
W Boom swing angle (Right) 58°
4730 (186.3)
X Overall length (dozer blade at rear)
4755 (187.2)*
* : With an angle dozer blade
** : Cab

7-5
 SPECIFICATIONS
OPERATING RANGES

OPERATING RANGES

7-6
 SPECIFICATIONS
OPERATING RANGES

Unit: mm (inch)
Long arm
Item
Rubber crawlers
A Maximum reach 4850 (190.9)
B Maximum reach at ground reference plane 4710 (185.4)
C Maximum digging depth 2835 (111.6)
D Maximum vertical digging depth 2165 (85.2)
E Reach at maximum vertical digging depth 3310 (130.4)
F Maximum height of cutting edge 4490 (176.7)
G Maximum dumping height 3230 (127.2)
H Minimum dumping height 1020 (40.2)
380 (15.0)
J Dozer blade maximum lifting
370 (14.5)*
310 (12.2)
K Dozer blade maximum lowering
325 (12.9)*
*: With an angle dozer blade

7-7
MEMO

7-8
 SPECIFICATIONS
LIFTING CAPACITIES

LIFTING CAPACITIES
Rated lift capacity chart • Do not attempt to lift or hold any load
• The loads in the charts do not exceed 87% that is greater than these rated values at
of hydraulic lift capacity or 75% of tipping their specified load radii and height.
load. • The rated lift capacities are based on
• Figures marked with an asterisk (*) are the machine being level and situated on
hydraulically-limited capacities. a firm supporting surface. For safe
• The mass of slings and any other lifting lifting, the operator is expected to make
devices shall be deducted from the rated due allowance for the particular job
load to determine the net load that may be conditions such as soft or uneven
lifted. ground, non-level condition, load to the
• The load point is the bucket hinge pin, and machine sides, hazardous conditions,
the bucket posture is with the standard experience of personnel, etc. The
bucket completely retracted under the arm. operator and other personnel should
• Unit: daN (lbs) fully acquaint themselves with the
operator’s manual furnished by the
Load hooking system manufacturer before operating this
A load hooking system must be provided machine. When operating the machine,
with the following capabilities. the safety rules of the equipment must
1. A system which can withstand twice the also be followed.
rated lift capacity no matter at what • Do not travel while lifting a load; It is
position the load is applied. very dangerous.
2. A system that poses no risk of the lifted
load falling from the hooking device. For
example, equipped with a hook slippage
prevention device.
3. A system that poses no risk of the hooking
system slipping from the hoe attachment.

7-9
 SPECIFICATIONS
LIFTING CAPACITIES

<Cab> Long arm

7-10
 SPECIFICATIONS
LIFTING CAPACITIES

<Cab> Long arm

7-11
 SPECIFICATIONS
LIFTING CAPACITIES

<Canopy> Long arm

7-12
 SPECIFICATIONS
LIFTING CAPACITIES

<Canopy> Long arm

7-13
7-14
 OPTIONS

8-1
 OPTIONS
GENERAL PRECAUTIONS

GENERAL PRECAUTIONS • Use the proper procedure when

mounting a boom or arm; otherwise
SAFETY PRECAUTIONS serious damage could result. Consult
your sales or service dealer for help.

When removing or installing an

attachment or optional part, take the CAUTIONS WHEN INSTALLING
following precautions. ATTACHMENTS
• Consult with Takeuchi before installing
an optional attachment. Be sure to perform a test operation after an
• Do not use any attachments not optional or other special attachment has
approved by Takeuchi. Doing so may been replaced. Inspect the hydraulic oil level
cause safety problems. Or, it may and recharge it as necessary. Consult your
adversely affect the machine’s operation sales or service dealer for detailed
or service life. procedures on installing/removing
• We will not be held responsible for any attachments.
injuries, accidents or damage to its
products caused by the use by a non-
approved attachment.
• Select a firm, level work area. Also, be
sure to park in a well ventilated place.
• Clear obstacles and dangerous objects,
and clean up spilled fuel immediately.
• When hoisting, be sure to designate a
person to act as a signalman.
Follow the instructions of the signalman
regarding the procedure and measures.
• When it is necessary to temporally
place a heavy object or an attachment
on the ground during removal or
installation, be sure to place it in a
stable position.
• Keep everyone out of the area when
hoisting. There is a hazard of objects
falling or contacting with people in the
area.
• Use a crane to move heavy objects (25
kg (55 lb.) or greater).
• Before removing a heavy object, be sure
to put a support to it. When lifting with a
crane, pay attention to the center of
gravity of the load to keep the machine
in balance.
• Do not operate the machine while the
load is lifted by a crane stand.

8-2
 OPTIONS
GENERAL PRECAUTIONS

CAUTIONS WHEN OPERATING • Slewing on slopes

ATTACHMENTS • If there is a heavy attachment is
installed, the machine takes longer
distance than usual to come to a
complete stop when the stopping
Long attachments reduce stability of the operation is performed. Carefully judge
machine. The machine may tip over if it the distance so as not to bump into an
loses the balance when traveling or object around the machine. Keep a safe
slewing on slopes. distance from surrounding obstacles.
Never perform the operations listed below When a heavy attachment is installed,
as they are extremely dangerous. natural drop (the gradual dropping of
the attachment under its own weight
when it is stopped in midair) increases.
• The machine can tip over more easily in
the lateral direction than in the
longitudinal direction.
· Do not slew sideways with a heavy
load at the how attachment. In
particular, do not slew sideways on
slopes.
· The attachment is heavier for
machines equipped with breakers or
crushers than for machines equipped
• Traveling down the slopes with the with the standard bucket. Do not
attachment raised operate such machines sideways,
especially digging downhill.
• When a long arm is installed, the
operating range increases. Carefully
judge the distance so as not to bump
into an object around the machine.
Keep a safe distance from surrounding
obstacles.

• Traveling across slopes

8-3
 OPTIONS
ATTACHMENT COMBINATION TABLE

ATTACHMENT COMBINATION TABLE

The table below shows which bucket should be installed when the machine is using a
standard arm, middle arm or long arm. Select a proper bucket by following the table.

• Consult with Takeuchi before installing an optional attachment.

• Do not use any attachments not approved by Takeuchi. Doing so may cause safety
problems. Or, it may adversely affect the machine’s operation or service life.
• We will not be held responsible for any injuries, accidents or damage to its products
caused by the use by a non-approved attachment.
• The swing stopper must be installed when a bucket wider than a 640W (standard)
bucket is installed. Failure to do so may result in the bucket hitting the machine body.

√ :Can be used.
∆ :Can be used only for light operations (digging and loading of dry and loose soil or mud)
— :Cannot be used.
Total bucket mass = Bucket mass + Heaped bucket load (specific gravity: 1.8)

Bucket cutting Middle arm Long arm

Rated capacity
Bucket width 1290 mm 1445 mm
m3 (cu.yd.)
mm (inch) (50.8 in.) (56.9 in.)
460 W (S.T.D.) 0.068 (0.081) 460 (18.1) √ √
Total bucket weight= Within 178 kg
Within 460 (18.1) √ √
(392 lb.)

8-4
 OPTIONS
SELECTING A LEVER PATTERN

SELECTING A LEVER PATTERN

The operating pattern of the left and right operating levers can be changed.

Before starting the engine, check the selector to see which operating pattern the left
and right operating levers are set.

SWITCHING THE LEVER PATTERN 1. Park the machine on a flat and rigid
ground, and stop the engine.
2. Open the right side cover.
3. Loosen the wing bolt (1).
4. Turn the selector valve lever (2) to change
the pattern.
5. Tighten the wing bolt (1) and fasten the
lever (2) in place.
6. Close the right side cover.
7. Confirm the lever pattern.

(A) : ISO pattern

(G) : G pattern

8-5
 OPTIONS
HYDRAULIC BREAKER

HYDRAULIC BREAKER
For handling of the breaker, read the
hydraulic breaker’s manual, provided
separately.

IMPORTANT: When installing an

attachment, make sure that it is
appropriate for the machine being used.
Contact your sales or service dealer for
advice on selecting attachments.
• Do not pry with the chisel or do not pry
while pounding.
CAUTIONS ON OPERATING • Do not move the chisel while pounding.
• Do not pound continuously for over 30
seconds on the same surface.

• Start the engine and run it at 75% of the

maximum speed.
• Do not pound with the cylinder fully
extended or retracted (at the stroke end).
Leave a margin of at least 50mm(2 in).

• Pound with the chisel pressed

perpendicular to the surface to be
pounded.
• When pounding, press the chisel properly • Do not pound with the arm placed
against the object to be broken so as to perpendicular to the ground surface.
avoid pounding the air.

8-6
 OPTIONS
HYDRAULIC BREAKER

REPLACING THE HYDRAULIC OIL

REGULARLY
When a hydraulic breaker is used, the oil
deteriorates more quickly than that used for
a usual operation. Be sure to replace the
hydraulic oil and the return filter elements.
• Failure to replace these in time can lead to
damage to the machine and the breaker
hydraulic system. To improve the service
life of the hydraulic systems, be sure to
• Do not drop the breaker itself on the object replace the hydraulic oil and return filter
to be broken in order to break it. element after the number of hours shown
• Do not move objects to be broken or rocks on the diagram below.
with the breaker itself. • When replacing the hydraulic oil, clean the
• Slew the machine occasionally to cool the suction strainer.
engine.
• If a hydraulic hose is vibrating abnormally, Replacement interval (hours)
nitrogen gas may be leaking from the
accumulator. Ask for an inspection early.
Item Hydraulic oil Filter element
1st time — 25
2nd time — 100
Periodically 1200 (600) 200

When the breaker operating ratio is 100%.

( ): When using conventional antiwear

hydraulic oil.

8-7
 OPTIONS
TRAVEL ALARM

TRAVEL ALARM Fuse layout and circuits protected

The alarm sounds while the machine is <Cab>

traveling and stops when the machine stops
traveling. Protected
If the alarm does not sound when the Capacity Symbol
circuit
machine travels, the fuse may be blown.
Inspect the fuses. 5A Switch lighting

10A Horn
If the fuse blows again soon after
replacement, then the electric system is 5A Starter switch
likely faulty. It may pose a fire hazard if 10A Immobilizer
not properly repaired. Contact your sales
or service dealer for advice.
20A Light
1. Turn the starter key to the OFF position to
stop the engine. 10A Wiper
20A Lever lock
Controller power
10A supply (2),
Travel alarm
10A Solenoid
Cab interior
20A
power supply
25A OPT Option
10A Heater
2. Open the fuse box cover (1).
10A Feed pump
3. Check for any blown fuses (2).
30A Blower motor
20A Cab light
Controller power
20A
supply (1)

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

fuse of the same capacity.

8-8
 OPTIONS
TRAVEL ALARM

<Canopy>

Protected
Capacity Symbol
circuit

5A Switch lighting

10A Horn
5A Starter switch
10A Immobilizer

20A Light (1)

20A Lever lock

Controller power
15A supply,
Travel alarm
25A Solenoid
20A OPT (1) Option (1)
25A OPT (2) Option (2)

10A Feed pump

15A Light (2)

8-9
 OPTIONS
OPTIONAL EQUIPMENT MASS

OPTIONAL EQUIPMENT MASS

OPTION
Steel crawler (Including shoe guide) 83 (183)
Angle blade 89 (196)
Long arm 9 (20)
Roof guard (Level II: ISO 10262) 47 (104)
Front guard (Level II: ISO 10262) 42 (91)

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.

8-10
 OPTIONS
BIODEGRADABLE OIL

BIODEGRADABLE OIL 4. Bleed the air from the hydraulic oil system.
5. Operate the hydraulic devices for 30
Biodegradable oil is a new type of hydraulic minutes.
oil that is decomposed into carbon dioxide 6. Drain the biodegradable oil from the tank
and water by microorganisms in the soil and and cylinders.
water. It is highly safe for living organisms 7. Replace the hydraulic oil return filter with a
and offers advantages in term of new filter.
environmental protection. 8. Repeat steps 3 and 4.
• Recommended biodegradable oil: Mobile 9. Operate the hydraulic devices for 30
EAL Envirosyn 46H (an ester synthetic oil). minutes.
When replacing the hydraulic oil with 10. Drain the biodegradable oil from the tank
biodegradable oil, use the above or an and cylinders.
equivalent oil. 11. Repeat steps 3 and 4.
Note that other oils, even other brands of 12. Operate the hydraulic devices for 1 hour.
ester synthetic oils, may damage O-rings, 13. Drain the biodegradable oil from the tank
packings and seals. Takeuchi products and cylinders.
shipped with the optional biodegradable oil 14. Replace the return filter with a new filter.
are shipped with the above brand of oil. 15. Repeat steps 3 and 4.
• When switching from a mineral oil to a 16. Operate the hydraulic devices, then
biodegradable oil, the parking brake torque check for oil leakage.
decreases by about 30%. There is no need to flush the hydraulic oil
system when switching from biodegradable
to mineral hydraulic oil.
REPLACING THE HYDRAULIC OIL WITH
BIODEGRADABLE OIL
Mixing mineral oil with biodegradable oil will
result in a decrease of the hydraulic oil’s
performance as well as a decrease in
biodegradability and safety. The hydraulic oil
system must be flushed as described below
before supplying the biodegradable oil. This
operation is dangerous and requires
experience. Have it performed by a Takeuchi
sales or service outlet.

Flushing
To be performed by a Takeuchi sales or
service outlet
1. Drain the hydraulic oil (mineral oil) from the
hydraulic oil tank and clean the inside of
the tank and suction strainer.
Refer to “Replacing the hydraulic oil and
cleaning the suction strainer”.
2. Remove the cylinder hoses and drain the
hydraulic oil (mineral oil) from inside the
cylinders.
3. Supply new biodegradable oil to the
hydraulic oil tank.

8-11
 OPTIONS
CAB OPTIONS

CAB OPTIONS

1. Rain guard
2. Front light
3. Roof guard (Level II: ISO 10262)
4. Front guard (Level II: ISO 10262)
5. Rear light

8-12
 OPTIONS
ANGLE DOZER BLADE

ANGLE DOZER BLADE

• Do not press the float button while the

machine is raised by the dozer blade.
Doing so will cause the machine to fall.
If you must work beneath the raised
machine, always use a secure support
to keep the machine raised.
• Do not press the float button while the
dozer blade is raised. Doing so will Button (A) ������Left angle (0 to 25°)
cause the dozer blade to fall. Lower the Button (B) ������Right angle (0 to 25°)
dozer blade to the ground before The dozer blade angle is
pressing the float button. increased/decreased between
• Do not travel forward while the dozer 0 and 25° as long as the
blade is in the float mode. button is pressed.
To position the dozer blade at
IMPORTANT: Do not raise the machine by a right angle, align the
using the angled dozer blade. Or, the matching marks (D) as shown
dozer blade may be damaged due to the in the figure.
load concentrated onto a point on the
dozer blade. Float operation
This dozer blade can be angled (to 25° right Button (C) ������Float mode
or left). Also, it can be used in the float To cancel the float mode,
mode. press the button again.

Angle operation Daily inspection (every 10 hours)

Lubricating

1. Lower the working equipment to the

ground and stop the engine.
2. Use the grease gun to lubricate the grease
fitting.
3. Wipe off the excess grease.

8-13
 OPTIONS
ANGLE DOZER BLADE

SPECIFICATIONS

Item Rubber crawlers

A Dozer blade width 1450 (57.1)
B Dozer blade height 355 (14)
C Dozer blade distance to axis of rotation 1480 (58.3)
D Dozer blade maximum lifting 370 (14.5)
E Dozer blade maximum lowering 325 (12.9)
F Angle degree (Left/Right) 25°

Unit: mm (inch)

8-14
8-15
First Published August 2014 No.43521
Second Published December 2014

OPERATOR’S MANUAL

TB230 Mini excavator

Edited and issued by TAKEUCHI MFG. CO., LTD.

Printed in Japan by STATION M Co., Ltd.

8-16
 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.

EC-CONFORMITY CERTIFICATE
We herewith declare that following named machine, based on its conception and design
and in the form brought into service is in accordance with the relevant, basic safety and
health requirements of the following EC directives. In case of any alteration of the
machine not coordinated with us, this certificate loses its validity.
Designation of the machine Compact Excavator
Manufacturer TAKEUCHI MFG. CO., LTD
205 Uwadaira, Sakaki-machi, Hanishina-gun, Nagano
389-0605, Japan
Model TB230
Engine type 3TNV88F-EPTB
Engine power 18.2 kW @ 2400 rpm
The machine is in accordance with the requirements of EC regulations:
1) Machine directive 2006/42/EC and appendix
2) Electromagnetic compatibility-regulation 2004/108/EC and appendix
3) Noise directive 2000/14/EC (Evaluation procedure according to appendix VI),
2005/88/EC and appendices.
4) Regulations on engine emissions: 2004/26/EC and appendices.
Harmonized norms: EN474-1:2006+A1:2009, EN474-5:2006+A2:2012.
Complier of the technical files:
Adam Geiss
Oliver Scharschmidt
Wilhelm Schafer Gmbh
68307 Manheim-Sandhofen GERMANY
Issued in Sakaki, Japan
Akio Takeuchi, President