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 SERIAL NUMBERS
This manual describes operation, inspection IMPORTANT: Do not remove the machine
and maintenance of the machine, as well as name plate with the serial number.
safety instructions to be heeded during these Check the serial numbers of the machine
operations. and engine and write them down in the
If you have any questions about the spaces below.
machine, please contact a Takeuchi sales or
service outlet. Machine number:

MANUAL STORAGE COMPARTMENT

A compartment for storing this manual is
provided at the position shown on the
diagram below.

Engine number:

1. The storage place is located at the back of

the seat.
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 FEATURES
• A unique adjustable offset boom system
• Short tail swing radius
• Tilting up the operator seat floor for easier
maintenance
• Automatic travel shift-down system
• Short pitch rubber crawler
• Low engine noise and exhaust emissions
• Electronic control of auxiliary hydraulic
circuit
• Automatic and manual operation for engine
deceleration
• Slew motors are equipped with shockless
valves
• Engine emergency stop system

BREAK-IN PERIOD
This manual refers the front, rear, left and When the machine is new, operate the
right of the machine as seen when sitting in machine for the first 100 hours (as indicated
the operator’s seat with the dozer blade on the hour meter) by following the
visible to the front. instructions below.
Using a new machine without a break-in
period will lead to quicker deterioration of
DESIGNATED OPERATIONS machine performance and may shorten the
machine’s service life.
Use this machine primarily for the following • Sufficiently warm up the engine and
operations: hydraulic oil.
• Excavation • Avoid heavy loads and rapid operations.
• Digging ditches Operate with a load of about 80% the
• Digging side ditches maximum load.
• Leveling • Do not abruptly start up, accelerate,
• Loading change directions, or stop unless
necessary.

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
Auxiliary 1st switch............................. 2-28
Introduction......................................0-2 Auxiliary 2nd/4th switch...................... 2-28
Third auxiliary hydraulic switch and
Machine description.........................0-3 button (If equipped)............................. 2-29
Auxiliary 2/4 select button
Safety...............................................1-1 (If equipped)........................................ 2-29
General precautions................................. 1-2 DPF manual regeneration/inhibit select
Precautions when preparing..................... 1-8 switch................................................. 2-30
Precautions when starting...................... 1-12 Light switch........................................ 2-32
Precautions when operating................... 1-14 Wiper switch....................................... 2-32
Precautions when stopping.................... 1-23 Washer switch.................................... 2-32
Precautions when transporting............... 1-24 Attachment interference prevention
Precautions on maintenance.................. 1-26 switch................................................. 2-33
Safety signs (decals)............................... 1-35 Automatic deceleration switch............ 2-34
Power/Highland mode switch............. 2-34
Controls............................................2-1 Detent mode switch (Auxiliary 1st)...... 2-35
Names of components............................. 2-2 Auxiliary 1st auto tank switch
Covers...................................................... 2-4 (If equipped)........................................ 2-35
Starter key............................................ 2-4 Lift overload warning switch................ 2-36
Side cover............................................ 2-4 Beacon lamp switch........................... 2-36
Engine hood......................................... 2-5 Levers and Pedals.................................. 2-37
Tool case.............................................. 2-5 Safety lock lever................................. 2-37
Fuel lid.................................................. 2-6 Operating levers................................. 2-37
Fuel filler port........................................ 2-6 Blade lever.......................................... 2-38
Fuse box cover..................................... 2-7 Travel levers/pedals............................ 2-39
Cab.......................................................... 2-8 Boom offset pedal.............................. 2-39
Cab door.............................................. 2-8 Accessories............................................ 2-40
Emergency exit..................................... 2-8 Air conditioner (If equipped)................ 2-40
Front window........................................ 2-9 Ashtray............................................... 2-46
Lower front window............................ 2-10 Power supply socket.......................... 2-46
Side window....................................... 2-10 Interior light......................................... 2-47
Sun shade (If equipped)...................... 2-11 Mirrors................................................ 2-47
Emergency hammer (optional)............ 2-11 External power sockets ..................... 2-48
Seat and seat belt.................................. 2-12 Radio (for cab).................................... 2-50
Seat ................................................... 2-12 Auxiliary hydraulic lines (If equipped)... 2-54
Seat belt............................................. 2-13 Operating the machine with an
Multi-information display......................... 2-14 accumulator....................................... 2-59
Main Menu screen.............................. 2-14 Load safety device (If equipped).......... 2-60
Warning lamps.................................... 2-15 Fuel supply pump (If equipped)........... 2-62
Indicators........................................... 2-16
Screen control key.............................. 2-19 Operation..........................................3-1
Screen navigation............................... 2-20 Before starting operation.......................... 3-2
Switching images............................... 2-25 Getting on or off the machine................ 3-2
Switches................................................ 2-26 Walk-around inspection........................ 3-2
Starter switch..................................... 2-26 Daily inspection..................................... 3-2
Engine shutdown switch..................... 2-26 Starting and stopping the engine.............. 3-3
Throttle controller................................ 2-26 Before starting the engine..................... 3-3
Horn button........................................ 2-27 Starting the Engine............................... 3-4
Deceleration button............................ 2-27 Warming up the engine......................... 3-5
Travel speed button............................ 2-27 Stopping the engine............................. 3-5
0-5
Operating the machine............................. 3-6 Maintenance list...................................... 5-14
Lever pattern (ISO pattern).................... 3-6 Walk-around inspection.......................... 5-16
Lever pattern (G pattern) If equipped.... 3-7 Inspecting by opening the engine hood
Warming up the machine and covers......................................... 5-16
(hydraulic oil)......................................... 3-8 Inspecting by walking around the
Inspection after warm-up...................... 3-9 machine............................................. 5-17
Inspecting the attachment interference Inspecting while sitting in the operator’s
prevention system.............................. 3-10 seat.................................................... 5-17
Operating the travel levers.................. 3-11 Daily inspection (every 10 hours)............. 5-18
Stopping travel................................... 3-14 Inspecting and replenishing the
Attachment interference prevention coolant............................................... 5-18
device................................................. 3-14 Inspecting and replenishing the
Operating the working equipment....... 3-16 engine oil............................................ 5-19
Operating procedures............................. 3-18 Inspecting the water separator............ 5-20
Prohibited operations.......................... 3-18 Inspecting the fuel level....................... 5-20
Cautions on operating........................ 3-21 Inspecting the hydraulic oil tank level
Cautions on traveling on slopes.......... 3-22 and replenishing................................. 5-21
Getting out of mud............................. 3-24 Lubricating the working equipment..... 5-23
Operations possible with this After the initial 50 hours
machine............................................. 3-24 (only for new machines).......................... 5-24
Parking the machine............................... 3-26 Replacing the engine oil and the
Parking............................................... 3-26 oil filter................................................ 5-24
Inspection and checks after stopping Inspecting and adjusting the fan belt... 5-26
the engine.......................................... 3-26 Inspecting and adjusting the
Handling in cold climates........................ 3-27 compressor belt (AC).......................... 5-28
Preparing for cold climates................. 3-27 Every 50 hours....................................... 5-30
Cautions after operations.................... 3-27 Inspecting the crawler belt tension...... 5-30
After the cold climate.......................... 3-27 Lubricating the slew bearing............... 5-30
Handling rubber crawlers........................ 3-28 Draining the water from the fuel tank... 5-31
Prohibitions......................................... 3-28 Inspecting the battery fluid level and
Cautions............................................. 3-29 replenishing........................................ 5-32
Preventing the rubber crawlers from After the initial 250 hours
coming off.......................................... 3-29 (only for new machines).......................... 5-34
Replacing the hydraulic oil return
Transport..........................................4-1 filter.................................................... 5-34
Loading and unloading............................. 4-2 Replacing the pilot line filter................. 5-35
Hoisting the machine................................ 4-4 Replacing the travel motor gear oil...... 5-36
Securing the machine............................... 4-6 Every 250 hours..................................... 5-37
Replacing the engine oil and the oil
Maintenance.....................................5-1 filter.................................................... 5-37
General..................................................... 5-2 Inspecting and adjusting the fan belt... 5-37
Maintenance overview.......................... 5-2 Inspecting and adjusting the
Cautions on maintenance..................... 5-2 compressor belt (AC).......................... 5-37
Service data............................................. 5-4 Cleaning the air cleaner...................... 5-38
Fuel and lubricant table......................... 5-4 Cleaning the radiator fins and the oil
Regularly replace the hydraulic oil......... 5-8 cooler fins........................................... 5-39
List of consumables.............................. 5-9 Cleaning the air filters (AC).................. 5-40
List of tools (If equipped)..................... 5-10 Cleaning the condenser (AC).............. 5-41
List of tightening torques.................... 5-11 Inspecting the refrigerant (gas) level
Safety-critical parts................................. 5-12 (AC).................................................... 5-42
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Every 500 hours..................................... 5-44 Replacing the rubber crawlers............ 5-67
Replacing the fuel filter........................ 5-44 Every 2 years.......................................... 5-70
Replacing the water separator filter..... 5-45 Replacing the receiver dryer................ 5-70
Every 1000 hours................................... 5-46 Maintenance during extended storage
Replacing the hydraulic oil return period..................................................... 5-71
filter.................................................... 5-46
Replacing the pilot line filter................. 5-46 Troubleshooting................................6-1
Replacing the travel motor gear oil...... 5-46 Symptoms that are not malfunctions........ 6-2
Cleaning the engine cooling system.... 5-46 If the engine overheats.............................. 6-3
Replacing the air cleaner element....... 5-48 If the battery goes dead............................ 6-4
Replacing the air breather filter............ 5-49 If a fuse blows.......................................... 6-6
Inspecting and adjusting the engine Inspecting and replacing the fuse.......... 6-6
valve clearance................................... 5-49 Inspecting the fusible link...................... 6-7
Every 1500 hours................................... 5-50 Restarting after adding fuel....................... 6-8
Inspecting the crankcase breather Bleeding air from the fuel system.......... 6-8
system................................................ 5-50 If a warning lamp flashes........................ 6-10
Cleaning the EGR cooler Vehicle error code list.............................. 6-12
(cleaning the water side and exhaust Engine error code list.............................. 6-14
air passage blower)............................. 5-50 Other symptoms..................................... 6-22
Every 2000 hours................................... 5-51 Lowering the boom to the ground.......... 6-25
Lapping the engine valve seats Towing.................................................... 6-26
(If necessary)...................................... 5-51 If the cab is damaged............................. 6-27
Every 3000 hours................................... 5-52
Inspecting the turbocharger Specifications...................................7-1
(blow wash as necessary)................... 5-52 Basic Specifications.................................. 7-2
Inspecting, cleaning and checking Machine dimensions................................. 7-4
operation of the EGR valve................. 5-52 Operating ranges...................................... 7-6
Cleaning the EGR lead valve............... 5-52 Lifting Capacities...................................... 7-9
Inspecting and cleaning the DPF soot
filter.................................................... 5-52 Options.............................................8-1
Inspecting the operation of the air General precautions................................. 8-2
intake throttle valve............................. 5-52 Safety precautions................................ 8-2
Inspecting and cleaning the fuel Cautions when installing attachments... 8-2
injector............................................... 5-52 Cautions when operating attachments.. 8-3
Every 4000 hours................................... 5-53 Attachment combination table.................. 8-4
Replacing the hydraulic oil and Selecting a lever pattern........................... 8-5
cleaning the suction strainer............... 5-53 Switching the lever pattern................... 8-5
When required........................................ 5-56 Hydraulic breaker..................................... 8-6
Replacing the bucket teeth and the Cautions on operating.......................... 8-6
side cutters (If equipped)..................... 5-56 Replacing the hydraulic oil regularly...... 8-7
Replacing the bucket.......................... 5-58 Travel alarm.............................................. 8-8
Adjusting the gap between the bucket Optional equipment mass ........................ 8-9
and arm (If equipped).......................... 5-60 Biodegradable oil.................................... 8-10
Inspecting and replenishing the Replacing the hydraulic oil with
windshield washer fluid....................... 5-61 biodegradable oil................................ 8-10
Draining the water from the water Cab options............................................ 8-11
separator............................................ 5-62
Lubricating the levers and pedals........ 5-63
Tilting up the platform......................... 5-64
Inspecting the rubber crawlers............ 5-66
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 perform the DPF regeneration if the
• Do not smoke or permit open flames while machine is surrounded by flammable items
handling fuel or working on the fuel system. such as plants, trees, dry grass,
• Do not leave the location while refilling with wastepaper, oil and waste tires. There is a
fuel or oil. risk of fire due to the high-temperature
• Never remove the fuel cap or add fuel exhaust gas emitted from the DPF.
when the engine is running or still hot. Also, DPF: Diesel Particulate Filter
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
• Do not perform the DPF regeneration in machine moves, and a person can suffer
poorly-ventilated indoor spaces, as smoke severe injury or death.
may be generated during the regeneration.

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 • Do not perform the DPF regeneration if the
necessary. machine is surrounded by flammable items
• Be sure to avoid all hazards and such as plants, trees, dry grass,
obstructions such as ditches, underground wastepaper, oil and waste tires. There is a
lines, trees, cliffs, overhead electrical wires, risk of fire due to the high-temperature
or places where there is a danger of falling exhaust gas emitted from the DPF.
rocks or slides. DPF: Diesel Particulate Filter
• The DPF may automatically perform the
regeneration while the engine is left
running. Make sure that there are no
flammable items around the DPF and the
exhaust line, and also that the engine hood
is closed to prevent fire. Be careful not to
burn yourself on the high-temperature
exhaust gas.
• Do not perform the DPF regeneration in
poorly-ventilated indoor spaces, as smoke
may be generated during the regeneration.

• 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 windowpane 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.

Safety precautions when performing the

Do not allow anyone to ride on any part of DPF regeneration
the machine at any time while traveling or
operating. The DPF may automatically perform the
regeneration while the engine is left running.
Make sure that there are no flammable items
around the DPF and the exhaust line, and
also that the engine hood is closed to
prevent fire. Be careful not to burn yourself
on the high-temperature exhaust gas.
DPF: Diesel Particulate Filter

1-14
 SAFETY
PRECAUTIONS WHEN OPERATING

Check the position of the undercarriage that the travel speed changes depending
(tracks) before traveling 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
balance and get damaged or to damage
• Travel with the dozer blade raised, the hoe the structures in the surrounding area.
attachment folded as shown on the figure
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. Remember
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 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 sideways with a heavy load at
the tip of the hoe attachment. In particular,
do not slew sideways on slopes.
• Level off the work area. • 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

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 try to tow only one side.
used for lifting. • It becomes dangerous if the wire rope
• Never lift loads in excess of capacity. breaks or becomes disengaged. Use a
Overload will cause the machine to roll and wire rope appropriate for the required
can result in serious injury or death. tractive force.
• All rated lift capacities are determined by • Do not use a wire rope that is kinked,
using a machine placed on a stable and flat twisted or otherwise damaged.
ground. For a safe lifting work, the user is • Do not apply heavy loads abruptly to the
expected to make due allowance for the wire rope.
particular job conditions. They include, soft • Wear safety gloves when handling the wire
or uneven ground, non-level condition, side rope.
loads, dynamic or jerked loads, hazardous • Make sure there is an operator on the
conditions, and experience of personnel. machine being towed as well as on the
The operator and other personnel should machine that is towing.
fully acquaint themselves with the • Never tow on slopes.
operator’s manual before operating this • Do not let anyone come near to the wire
machine, and rules for safe operation of rope while towing.
equipment shall be adhered to at all times. Refer to “Towing” for further instructions.
• The bucket linkage or lifting device may fail
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.

Ramp
Stopper

Distance between ramps

15º or less
AG7F001PE

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 Stop the engine before performing

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
Do not allow unauthorized personnel in the take care not to touch the lever or pedal
work area while working. Be careful when unless necessary.
grinding, welding or using a hammer. You · The one who performs maintenance
could be injured by flying debris from the must make sure to keep his/her body or
machine. clothing away from the moving part of the
machine.
Prepare work area

• Select a firm, level work area. Make sure Stay clear of the moving parts
there is adequate light and, if indoors,
ventilation.
• Clear obstacles and dangerous objects.
Eliminate slippery areas.

Always keep the machine clean

• Stay clear of all rotating and moving parts.

If a hand or tool becomes trapped in the
rotating or moving part, serious injury or
death could result.
• If a tool or other objects is dropped or
inserted in the fan or fan belt, it will be
• Clean the machine before performing flown or cut in pieces. Do not drop or insert
maintenance. anything in the fan or fan belt.
• Stop the engine before washing the
machine. Cover the electrical parts so that
water cannot enter. Water on electrical
parts could cause short-circuits or
malfunctions. Do not use water or steam to
wash the battery, electronic control
components, sensors, connectors or the
operator’s compartment.
1-27
 SAFETY
PRECAUTIONS ON MAINTENANCE

Firmly secure the machine or any Cautions on tilting up the platform

component that may fall

• Raising or lowering the platform while the

• Before performing maintenance or repairs engine is running may cause the machine
under the machine, lower all moveable to move, resulting in serious injury or death.
working equipment to the ground or in the Stop the engine before raising or lowering
lowermost position. the platform.
• Chock the tracks. • When the platform is tilted up, support it
• If you must work beneath the raised firmly with the stopper (D) to prevent it from
machine or equipment, always use wood falling.
blocks, jack-stands or other rigid and
stable supports. Never get under the
machine or working equipment if they are Place heavy objects in a stable position
not sufficiently supported. This procedure
is especially important when working on
hydraulic cylinders.

Secure the working equipment

To prevent unexpected movement, firmly

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

When it is necessary to temporally place a

Secure the engine hood or cover when heavy object or an attachment on the ground
opened during removal or installation, be sure to
place it in a stable position. Keep off
Be sure to secure the engine hood or cover unauthorized persons from the storage place
before working the inside. Do not keep the for such object.
hood or cover open on a windy day or if the
machine is parked on a slope.

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

Never disassemble the track adjuster Handling of the accumulator

There is a very strong spring contained in the Be sure to handle the high-pressure nitrogen
track adjuster. If the track adjuster is gas enclosed in the accumulator with care. If
accidentally disassembled, the spring can handled incorrectly, it could explode and
pop out, resulting in serious injury Never cause serious injury. Strictly observe the
disassemble the track adjuster. following precautions:
• Do not disassemble.
• Do not allow flame near or throw it into a
Cautions when servicing the air fire.
conditioner • Do not drill, weld or fuse.
• Do not subject it to physical shock such as
If the refrigerant comes in contact with eyes, hitting, rolling or dropping.
it damages your eyesight. If the refrigerant • Before disposing of the unit, the sealed gas
comes in contact with skin, it may cause must be drained. Contact a Takeuchi
frostbite. Never touch the refrigerant. service agent for help.

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 the battery when the fluid level
is below the lower level limit. Doing so will
hasten the deterioration of the internal
portions of the battery and shorten the
battery life. It also can cause rupturing
(explosion).
• Do not add the distilled water above the
upper level limit. Doing so could cause the
fluid to leak. This fluid can cause skin
Disconnect the battery wiring before working damage if contacted, or can cause the
on the electrical system or doing electric machine components to corrode.
welding. Disconnect the negative (–) battery • Use a dampened cloth to clean around the
cable first. When reconnecting, connect the fluid level line and check the fluid level. Do
negative (–) battery cable last. not clean with a dry cloth; otherwise it
could cause static electricity to build up,
resulting in ignition or explosion.
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
SAFETY
SAFETY SIGNS (DECALS)

1-40
 CONTROLS

2-1
 CONTROLS
NAMES OF COMPONENTS

NAMES OF COMPONENTS

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 tank 10. Travel motor 15. Boom
16. Boom cylinder
17. Boom bracket
18. Offset cylinder
19. Link arm (R. H)
20. Auxiliary hydraulic lines
21. Dozer blade
22. Blade cylinder

2-2
 CONTROLS
NAMES OF COMPONENTS

1. Multi-information display 18. Light switch

2. Starter switch 19. Wiper switch
3. Blade lever 20. Washer switch
4. Throttle controller 21. Attachment interference prevention
5. Right operating lever switch
6. Horn button 22. Automatic deceleration switch
7. Deceleration button 23. Power/Highland mode switch
8. Offset pedal 24. Detent mode switch
9. Ashtray 25. Auxiliary 1st auto tank switch*
10. Travel lever/pedal 26. Lift overload warning switch*
11. Travel speed button 27. Beacon lamp switch*
12. Left operating lever 28. Auxiliary 2/4 select button*
13. Auxiliary 1st switch 29. Third auxiliary hydraulic button*
14. Safety lock lever 30. Third auxiliary hydraulic switch*
15. Engine shutdown switch 31. Power supply socket*
16. Auxiliary 2nd/4th switch* 32. Radio
17. DPF manual regeneration/inhibit select 33. AC Control panel
switch

*: Subject to the specifications or optional products selected

2-3
 CONTROLS
COVERS

COVERS Opening

STARTER KEY

1. Insert the starter key into the key hole and

turn it clockwise to unlock the side cover
The starter key is used to start and stop the (1).
engine, as well as to lock and unlock the 2. Open the side cover (1) all the way until it
following components: is no longer possible (automatically
• Cab door locked).
• Engine hood
• Covers Closing
1. Support the side cover (1) by hand and lift
the stay (2) to release it.
SIDE COVER 2. Close the side cover (1) and press it down
until a click is heard.
3. Insert the starter key into the key hole and
turn it counterclockwise to lock the side
• Stop the engine and allow the machine cover (1).
to cool down before performing
maintenance.
• Do not keep the side cover open on a
windy day or if the machine is parked
on a slope.
• When opening and closing the 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 fuel

system, electrical system, coolant system, air
conditioner system, air cleaner or window
washer, open this cover.

2-4
 CONTROLS
COVERS

ENGINE HOOD TOOL CASE

Opening

• Before opening the engine hood, be

sure to stop the engine. If a hand or tool
becomes trapped in the rotating or
moving part, serious injury could result.
• When opening or closing the engine
hood, be careful not to get your hands
or other parts of your body caught by it.

Opening

1. To unlock this case, insert the starter key

and turn it counterclockwise.

1. Insert the starter key into the key hole and

turn it counterclockwise to unlock the
engine hood (1).
2. Push in the key hole with your thumb and
open the engine hood (1).

Closing
1. Close the engine hood (1) and press down
the edge of it until a click is heard.
2. Insert the starter key into the key hole and
turn it clockwise to lock the engine hood
(1).

2-5
 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 • Be sure to retract the fuel filler port
before tilting up the platform. Otherwise,
the filler port will come in contact with
the platform and be damaged when the
platform is tilted up.

Opening

1. Insert the starter key and turn it

counterclockwise to unlock the fuel lid (1).
2. Open the fuel lid (1).

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

Closing
1. Turn the fuel cap (1) it clockwise and close
it.
2. Close the fuel lid and lock it.

2-6
 CONTROLS
COVERS

FUSE BOX COVER

Open this cover to perform a maintenance
operation on the fuse or to switch the lever
pattern selector valve.
The port for connecting to a computer is
inside the box.

Opening

1. Hold the knob (1) and open the fuse box

cover (2).

Closing
1. Close the fuse box cover (2).

2-7
 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 3 3

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. AG7B013

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

2 cab, open the front window to get out.

AG7B012

To open the door from inside the cab,

push the lever (2) to the lower.

2-8
 CONTROLS
CAB

FRONT WINDOW
4

• Grasp the handles firmly with both

2
2
hands when opening and closing the
front window. Your head or hands may
get caught if it slips from your hands.
• When the front window is opened or
closed, it will come close to the head. 3
Be careful that the window does not AG7B015

strike the head. 5. Release your thumb from the knobs (2)
• When you open the front window, be and then lift the front window (3) fully and
sure to lock it in place with the lock pins lock the front window with lock pin (4).
on the left and right sides. The window
may fall if it is not locked in place. Closing

Opening When closing the front window slowly so

as not to hit your head. Lowering the
window abruptly may result injury or
damage the front window.
3

2 2
2 2
1 1
1 1

AG7B014

1. Park on a level surface and stop the

engine. 3
2. Set the safety lock lever to the locked AG7B016

position. 1. Grasp the left and right handles (1) and

3. Grasp the left and right handles (1) and press the knobs (2) with your thumb to
press the knobs (2) with your thumb to release the lock.
release the lock. 2. Pull down the front window (3) and while
4. Pull the front window (3) toward you and doing so, slide it to the front and slowly
lift while doing so. lower it.

2-9
 CONTROLS
CAB

SIDE WINDOW
3

2 2

4
AG7B017

3. Release your thumb from the knobs (2)

and then press the front window toward
front and lock the front window with lock 1. Grasp the catch (7), unlock it and open
pin (4). the side window.
2. To close the side window, close it until a
click is heard.
LOWER FRONT WINDOW
Removing

1. Open the front window and stow it in the

ceiling.
2. Slowly lift the lower front window (4).

3. Place the bottom of the front window

through the guides (5), and then secure
the window with the support (6).
2-10
 CONTROLS
CAB

SUN SHADE (IF EQUIPPED) 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 windowpane 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.

2-11
 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 seat. 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.

2-12
 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.

2-13
 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.

2-14
 CONTROLS
MULTI-INFORMATION DISPLAY

WARNING LAMPS 4. Water separator warning lamp

This lamp flashes if the water is detected
IMPORTANT: If a warning lamp flashes within the water separator while the starter
and an alarm is sounded, immediately switch is in the ON position.
stop all operations and check the
corresponding component. 5. Coolant temperature warning lamp
Refer to “If a warning lamp flashes” on This lamp flashes and an alarm is sounded
pages 6-10 and 6-11. if the engine coolant temperature
becomes abnormally high while the engine
1. ECM warning lamp is running.
This warning lamp flashes if the Electronic
Control Module (ECM) detects an engine 6. Air cleaner 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 air cleaner filter is clogged while the
recorded as an ECM error. engine is running.
Refer to “Engine error code list” on pages
6-14 to 6-21. 7. Fuel filter warning lamp
This lamp flashes and an alarm is sounded
1-1. Vehicle and engine emergency lamp if the fuel filter is clogged while the engine
This lamp is displayed enlarged for one is running.
second, and then flashes and an alarm
sounds if there is a problem with the 8. Fuel level warning lamp
machine. Go to the (7) Data/Error code This lamp flashes when the fuel level is low
display from the Menu screen, get the while the starter switch is in the ON
vehicle or engine error code number, position.
and consult your sales or service dealer
referring to the “Vehicle error code list” 9. Third auxiliary hydraulic warning lamp
or “Engine error code list” in this This lamp starts flashing and an alarm
manual. sounds if the fixed side (left “e”) pressure
Refer to “Menu screen” on page 2-20. of the auxiliary 3rd drops abnormally while
Refer to “Error code display” on page the engine is running, or while the quick-
2-23. hitch is being removed or installed.
Refer to “Vehicle error code list” on
page 6-12 to 6-13.
Refer to “Engine error code list” on
pages 6-14 to 6-21.

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.

2-15
 CONTROLS
MULTI-INFORMATION DISPLAY

INDICATORS 13. DPF auto regeneration/inhibit

indicator lamp
10. Deceleration indicator lamp

�������� DPF auto regeneration

�������� Automatic deceleration under way
indicator
�������� DPF auto regeneration
inhibit
�������� Deceleration indicator

DPF auto regeneration under way

The DPF regeneration is automatically
Automatic deceleration indicator performed by the engine, when certain
It flashes when the automatic criteria are met. The operator only has to
deceleration switch is pressed and check the display.
remains lit while in the deceleration
mode. DPF auto regeneration inhibit
Refer to “Deceleration button” on page The DPF manual regeneration inhibit
2-27. symbol appears on the display when the
Refer to “Automatic deceleration switch” DPF manual regeneration under way or
on page 2-34. the DPF auto regeneration under way is
cancelled.
Deceleration indicator lamp Refer to “DPF manual regeneration/
This lamp turns on when the deceleration inhibit select switch” on page 2-30.
button is pressed. The lamp lights up to
indicate that the engine is in the 14. DPF manual regeneration under way/
deceleration mode at low idling speed regeneration promoting indicator
(1100 rpm). The indicator starts flashing and an alarm
starts sounding, if the accumulated PM
11. Exhaust temperature warning exceeds the limited amount on the DPF.
indicator Immediately perform the manual DPF
This indicator lights up to warn if the regeneration.
exhaust temperature is abnormally Refer to “DPF manual regeneration/
increased. Check for any flammable inhibit select switch” on page 2-30.
items around the exhaust piping.
15. Highland mode indicator lamp
12. Glow indicator lamp Highland mode is selected.
This indicator lamp turns off when the Refer to “Power/Highland mode switch”
engine preheating is completed. on page 2-34.

2-16
 CONTROLS
MULTI-INFORMATION DISPLAY

16. Travel speed indicator lamp 21. High-flow indicator lamp

This lamp flashes and then stays lit when
the auxiliary 1st flow rate is set to high-
flow.
�������� High-speed travel It also flashes when the high-flow setting
is changed.

�������� Low-speed travel 22. Dozer blade float indicator lamp (If
equipped)

�������� This lamp lights up when

This lamp turns on when the travel speed the float switch on the
button is set to the 2nd (high) speed. blade lever is pressed.
17. Power mode indicator lamp
This lamp lights up when the power 23. Water temperature gauge
mode side of the Power/Highland mode Indicates the temperature of the engine
select switch is pressed. The maximum coolant water. The indicator level must
engine output is maintained for as long be within the green range during
as this lamp is lit. machine operation. The red range
indicates overheating.
18. Lift overload warning indicator lamp
This lamp turns on when the lift overload 24. Fuel gauge
warning switch is turned on.
IMPORTANT: If the fuel gauge
19. Auxiliary 2nd/4th select indicator lamp changes the color from green
to orange while traveling on a
flat ground, do not go to a
sloping land. Engine stalling
�������� Auxiliary 2nd is selected. may occur on the sloping
land. Before operating on the
sloping land, be sure to add
�������� Auxiliary 4th is selected. enough fuel.

Indicates the amount of fuel in the tank.

Be sure to fill up the tank before running
20. Auxiliary 1st one-way (one-way out of fuel.
circuit) indicator lamp

�������� Auxiliary 1st auto tank is

selected.

�������� Auxiliary 1st one-way is

selected.

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

is selected.
2-17
 CONTROLS
MULTI-INFORMATION DISPLAY

25. Throttle opening position indicator 26. Auxiliary 1st flow rate indicator lamp
This lamp lights up to indicate which flow
rate setting is selected in the auxiliary
1st.

�������� a Flow rate setting 1

�������� b Flow rate setting 2

�������� c Flow rate setting 3

�������� d Flow rate setting 4

�������� e Flow rate setting 5

�������� f Flow rate setting 6

�������� 1 Flow rate setting 7

The red range increases as the engine �������� 2 Flow rate setting 8
load increases, indicating higher fuel
consumption. When the button (C) (Bar
meter key) is pressed in a normal screen, �������� 3 Flow rate setting 9
the display is changed from the throttle
opening position to the lift load factor
and the PM accumulation amount, in this Refer to “Auxiliary 1st flow rate setting” on
order. page 2-21.
• The lift load factor is displayed if there
is no change in the throttle opening 27. Air conditioner indicator lamp
position for five seconds after the lift Lights up while the air conditioner is
alarm switch is turned on. operating.
• The throttle opening position is
displayed if the highland mode switch 28. Working light indicator
is turned on or there is a change in the Lights up when the working light is
throttle opening position. turned on.

29. Date and time indicator

Displays the date and

time set.
Refer to “Date and
time setting” on page
2-23.

2-18
 CONTROLS
MULTI-INFORMATION DISPLAY

30. Hour meter/Trip meter Trip meter 1, Trip meter 2, Trip meter 3,
• Hour meter Hour meter.

Displays the total Down ( ) key

engine running time in Use this key to move the cursor
hours. downward and to decrease the value in
The rightmost digit each setting. Press and hold this key for
indicates tenths of one second to rapidly decrease the value.
hours (6 minutes).
Set the inspection and maintenance C. Bar meter key
intervals according to the time displayed on This hour meter symbol is displayed in the
the hour meter. initial screen. Pressing this key changes
the meter display in the following order.
• Trip meter Throttle opening position, Lift load factor,
Three patterns of desired operating hours PM accumulation amount
can be displayed.
Refer to “Trip meter setting” on page 2-21. Up ( ) key
Use this key to move the cursor upward
and to increase the value in each setting.
SCREEN CONTROL KEY 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.

Enter key
Use this key to confirm or execute the
setting made by each key.
Note: Do not press the symbol keys on the To clear the trip meter being displayed,
display. The LCD could be damaged if the press and hold this key for three seconds.
symbol keys are pressed hard. For actual
operation, press the push button keys E. —
located at the bottom of the screen.

A. Menu key
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.
2-19
 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 indicator
(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.

2-20
 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 direction
value when pressed and held for one 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%=74L/min
Auxiliary 1st-1 10 to 100%
Enter key: Confirms setting (19.6 US gpm)
Menu key: Cancels setting or returns to the 75%=55L/min
Auxiliary 1st-2 10 to 100%
Menu screen. (14.7 US gpm)
Pressing and holding the Enter key for three 50%=37L/min
seconds clears the trip meter pointed by the Auxiliary 1st-3 10 to 100%
(9.8 US gpm)
cursor.
Maximum A/B common, Variable
flow rate high-flow range
(2) AUXILIARY LINE FLOW RATE
Auxiliary 200%=148L/min 101 to
1st-1, 2, 3 (39.1 US gpm) 200%
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.

2-21
 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
symbol or the number, and then press the Auxiliary 2nd100%=59 L/min 10 to 100%
Enter key to confirm. (15.6 US gpm)
The selected symbol will appear at the lower G/H
left of the Home screen. Auxiliary 4th 100%=59 L/min 10 to 100%
(15.6 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.

2-22
 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 page
• Move the cursor to the calendar symbol, 6-12 to 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 6-21.

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.

2-23
 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.

2-24
 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”.

2-25
 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

2-26
 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 while 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.
Remember that the travel speed changes
depending on the load condition.

Before operating the deceleration button,

set the operating lever to the neutral
position and take your foot off the pedals.
If the deceleration button is pressed while
driving, the machine’s operating speed
will abruptly change to result in a
dangerous situation.

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.
2-27
 CONTROLS
SWITCHES

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

equipped)” on page 2-54 to 2-58.
Auxiliary hydraulic buttons

AUXILIARY 2ND/4TH SWITCH

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

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) Move this switch to control the flow of the oil
Proportional control allows for slow-to-fast/ in the second auxiliary hydraulic lines.
fast-to-slow movement of attachment. (C): �����Hydraulic oil flows to the left auxiliary
Example: If you move the slider switch half line (c).
way, the attachment will move at (D): �����Hydraulic oil flows to the right auxiliary
approximately one-half the speed. line (d).

Move this switch to control the flow of the oil To use the auxiliary 4th hydraulic line, press
in the first auxiliary hydraulic lines. the auxiliary 2/4 select button to change to
(A) �������Hydraulic oil flows to the left auxiliary the operation of the auxiliary 4th.
line (a). Refer to “Auxiliary hydraulic lines (If
(B) ������Hydraulic oil flows to the right auxiliary equipped)” on page 2-54 to 2-58.
line (b).

2-28
 CONTROLS
SWITCHES

THIRD AUXILIARY HYDRAULIC SWITCH

AND BUTTON (IF EQUIPPED)
Refer to “Third auxiliary hydraulic switch and
button (If equipped)” on page 2-57.

AUXILIARY 2/4 SELECT BUTTON

(IF EQUIPPED)
Refer to “Auxiliary 2/4 select button
(If equipped)” on 2-58.

2-29
 CONTROLS
SWITCHES

DPF MANUAL REGENERATION/INHIBIT IMPORTANT: Press the manual

SELECT SWITCH regeneration side on the DPF manual
regeneration/inhibit regeneration select
switch to burn the particulate matter
(PM), when the DPF manual regeneration
lamp flashes and an alarm sounds. If the
machine continues to be operated
without performing the manual
regeneration, the engine power will
decrease and eventually the engine will
stop running. The ECM warning display
will also flash if the DPF needs to be
repaired. A number appears on the engine
error code screen. Refer to the “Engine
error code list” and contact a Takeuchi
sales or service dealer for repair.
• The DPF and the exhaust gas emitted
from the exhaust line can be very hot • DPF manual regeneration
while the engine is running or the When the DPF manual regeneration symbol
regeneration is under way, as well as on the display starts flashing and an alarm
immediately after the engine is stopped. starts sounding, perform the DPF manual
Be careful not to accidentally touch regeneration by following the procedure
them; doing so could cause burns. below.
• Do not perform the DPF regeneration if 1. Park the machine in a safe place where
the machine is surrounded by there is no fire hazard.
flammable items such as plants, trees, 2. Raise the safety lock lever to the lock
dry grass, wastepaper, oil and waste position.
tires. There is a risk of fire due to the · Do not lower the safety lock lever and
high-temperature exhaust gas emitted move the control levers during
from the DPF. regeneration. Doing so interrupts the
• Do not perform the DPF regeneration in regeneration.
poorly-ventilated indoor spaces, as 3. Decrease the engine speed to low idling.
smoke may be generated during the 4. Press and hold the manual regeneration
regeneration. side on the DPF manual regeneration/
• Do not perform regeneration when the inhibit regeneration select switch.
engine hood is open. There is a risk of
fire due to the high-temperature exhaust
gas emitted from the DPF.

2-30
 CONTROLS
SWITCHES

5. The manual regeneration symbol stops • DPF regeneration inhibit (cancel)

flashing and remains lit to indicate that To cancel the DPF regeneration currently
the engine RPM is automatically being processed (manual or auto), press
increased and the DPF (1) regeneration the regeneration inhibit symbol side.
(PM burning) has started. The DPF regeneration inhibit symbol
6. Release the switch. Do not leave the appears on the display, and the
machine during regeneration. regeneration operation must be performed
It takes approximately 25 to 30 minutes, again. Start the manual regeneration
depending on the ambient temperature, procedure from Step (1) above, as soon as
to complete the regeneration operation. possible. Do not press the DPF
7. The manual regeneration symbol goes regeneration inhibit switch unless there is a
off to indicate the end of manual risk of fire.
regeneration. To cancel, press the switch again. Turning
the starter switch to OFF will also cancel
Note: the operation.
· Since the exhaust gas is cleaned through Refer to “DPF manual regeneration/
the catalyst fitted inside the DPF, it has a regeneration inhibit/auto regeneration
smell different from that of the conventional display” on page 2-16.
diesel engine.
· In some cases smoke may be emitted from
the tail pipe while the DPF regeneration is
being performed. This is not a failure; it is
due to burning of the particulate matter
(PM).
· It is normal that a sound is produced when
the DPF regeneration is started or
completed; This is to adjust the air-intake
throttle and EGR opening position.
· In some cases the noise associated with
the DPF regeneration operation or cancel
operation may change; this is not a failure.
· The DPF manual regeneration can be
completed faster while the machine engine
is warm rather than cold. Note that the
manual regeneration does not start unless
the coolant temperature is higher than a
set value. The coolant temperature may
increase while manual regeneration is being
performed.
· Since the DPF regeneration is designed to
work only when the accumulated
particulate matter (PM) in the filter exceeds
a certain amount, it will not start otherwise,
even if you attempt to perform manual
regeneration.

2-31
 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
and tail lamps will be 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.

2-32
 CONTROLS
SWITCHES

ATTACHMENT INTERFERENCE
PREVENTION SWITCH

• Failure to properly set the Attachment

Interference Prevention Switch can
result in equipment damage, serious
injury or death.
• Ensure that all buckets used in the S
mode are standard buckets or those
with shorter width than standard S ��������Standard bucket attachments or
buckets when measured from the pin to those having the width of 750 mm (30
the tooth. in.) or less
L ���������Bucket attachment whose width is
The Attachment Interference Prevention between 750 mm (30 in.) and 1000
Switch (AIPS) is automatically set to the M mm (40 in.)
mode by the Interference Prevention System M ��������Bucket attachments having a width of
(IPS) when the engine is started. more than 1000 mm (40 in.), or any
To use the minimal front radius feature, reset other approved attachments
the AIPS to the M position then select the Refer to “Attachment interference prevention
appropriate attachment width (S or M). device” on page 3-14.

Modes of operation

2-33
 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
It is not possible to use the deceleration This switch is used to reduce the engine
button at the same time. Switching from the load due to the hydraulic pump. When the
deceleration button to the auto-deceleration machine is operated at a high-altitude site,
switch will first return to the engine speed set the engine output is decreased due to thin
with the throttle controller. Then, the engine air. In such cases, the hydraulic horse
will automatically enter the deceleration power is automatically adjusted to prevent
mode (low idling) if the control levers are not the engine from stalling. Use this switch
operated within four seconds. 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 2-14.

2-34
 CONTROLS
SWITCHES

DETENT MODE SWITCH AUXILIARY 1ST AUTO TANK SWITCH

(AUXILIARY 1ST) (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.

2-35
 CONTROLS
SWITCHES

LIFT OVERLOAD WARNING SWITCH BEACON LAMP SWITCH

If the overload is not removed after the

overload warning horn is sounded, the
machine may tip over or the emergency
shut-off valve may be activated. 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

2-36
 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 3-16 and 3-17.

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.

2-37
 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 to set the
(B).......Blade down dozer blade to the float mode.
Refer to “Operating the dozer blade” on To cancel the float mode, press
page 3-17. the button again. The float mode
is temporally cancelled when the
Float button (if equipped) blade lever is tilted backward. To
return to the float mode, tilt the
blade lever back to the neutral
• Do not press the float button while the position. Take caution when
machine is raised by the blade. Doing returning to the float mode.
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
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.

2-38
 CONTROLS
LEVERS AND PEDALS

TRAVEL LEVERS/PEDALS BOOM OFFSET 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 offset.

(A)........Boom offset right
(B).......Boom offset left
Refer to “Operating the boom offset” on
page 3-17.

Pedal lock

Use these levers/pedals to move forward or

backward and to change directions.
Refer to “Operating the travel levers” on
page 3-11.

Set the pedal cover over the pedal to lock it.

Open the pedal cover from the pedal to
unlock it.

2-39
 CONTROLS
ACCESSORIES

ACCESSORIES Do not overcool

For health reasons, the air inside the cab
AIR CONDITIONER (IF EQUIPPED) should be kept at a temperature at which
you feel a little cool when entering the cab
CAUTIONS ON USE from outside (a difference of 5 to 6°C (41 to
43°F)). Remember to adjust the temperature
Ventilate periodically properly.
• When using the air conditioner over an
extended period of time, open the Do not turn on the air conditioner until the
windows about once each hour to let in engine is started
fresh air. To avoid placing an excessive load on the
• Your eyes may become irritated if you compressor, wait until the engine is started
smoke while using the air conditioner. If this and is running smoothly before turning on
happens, open the windows to let in fresh the air conditioner.
air. Smoking particularly irritates the eyes
when the air conditioner is being used. Let hot air out first
Since the humidity in the cab drops, the If the machine has been parked in the sun,
cornea becomes dry. open the windows and door to let the hot air
• If the outside air is dirty, set the air out of the cab before using the air
conditioner to the circulation mode. conditioner.

Always maintain good visibility Caution on refrigerant (gas)

Working with the dirty windows or fogged If the refrigerant comes in contact with skin
windows restricts visibility and is dangerous. or eyes, it may cause frostbite or eye
Always clean dirt and moisture off the damage. Never touch the refrigerant or
windows before working. loosen the parts on the cooling circuit.
• The windows tend to get foggy when the If the refrigerant gas leaks, keep flames
humidity is high. If this happens, turn on away.
the air conditioner to use outside air and
the defroster to get rid of the fog. Off-season inspection
• If the air conditioner is set to high when Even off season, run the air conditioner for 3
using the defroster, the difference between to 5 minutes at least once a week to
the external and internal temperatures maintain oil in the various parts of the
increases, resulting in frost on the outside compressor.
of the windows. If this happens, either turn
the air conditioner off or turn the
temperature control dial clockwise to
increase the internal temperature.
• Mist may blow out of the air outlets. This is
not a malfunction. When moist air passes
through the evaporator on the air
conditioner unit, water particles in the air
freeze and are emitted as mist.

2-40
 CONTROLS
ACCESSORIES

NAMES OF COMPONENTS

1. Defroster
2. Condenser
3. Receiver dryer
4. Outlets
5. Compressor
6. Air conditioner unit
7. Circulation filter
8. Ventilation filter
9. Ventilation/Circulation select lever
10. —

Control panel
11. Air conditioner switch
12. Temperature control dial
13. Fan dial

2-41
 CONTROLS
ACCESSORIES

Air conditioner switch Fan dial

IMPORTANT: To avoid placing an

excessive load on the compressor, wait
until the engine is started and is running
smoothly before turning on the air
conditioner.

Use this dial to select the fan speed from the

three levels. Turning this dial to the OFF
position turns off the air conditioner.
OFF ����Turning off the fan and the air
conditioner.
���������Low
Use this switch to turn on or off the cooling/ ��������Medium
dehumidifying function. When this switch is �������High
pressed while the engine is running with the
fan dial set to ON, the lamp lights up and the Temperature control dial
cooling/dehumidifying function is turned on.
Press this switch again or turn the fan dial to
OFF to turn off the cooling/dehumidifying
function.
Lamp is off.....OFF
Lamp is on.....ON
Note: To prevent leakage of refrigerant gas
from the compressor’s seal, operate the air
conditioner at least once a week, regardless
of the season.
Note: The air conditioner will not function if
the temperature in the cab is low (3°C (38°F) AU5C0051

or lower). Use this dial to adjust the air temperature.

COOL....... Decreases the temperature
HOT......... Increases the temperature
Note: No warm air is emitted if the
temperature of the engine coolant is low.

2-42
 CONTROLS
ACCESSORIES

Outlets Operation
Dehumidifying and Heating (in cold climates
or when the humidity is high)

Move the louvers up or down or left or right

to adjust the air flow direction and volume.
Arrange the foot outlets and the defroster so
Ventilation/Circulation select lever that they are directed to the front window.
Let the dehumidified warm air blow on the
front window, to prevent frosting.

Use this lever to select between Ventilation

and Circulation.
(C).......Circulation 1. Set the desired temperature by turning the
• Cool or heat the cab quickly temperature control dial to between the
• When external air is dirty center and the right end (HOT).
(D).......Ventilation 2. Set the fan dial to the desired position.
• Lets in fresh air
• Removes frosting from the windows
• Ventilates while cooling or heating

2-43
 CONTROLS
ACCESSORIES

Cooling Quick cooling

• When the air conditioner is set to the

circulation mode, the air in the cab
gradually becomes dirty. Switch to the
“ventilation” to ventilate once a
comfortable temperature is obtained.
• Excessive cooling can be harmful to
your health. It is best to keep the air
inside the cab only about 5 to 6°C (41 to
43°F) cooler than the outside air.

Note: If the machine has been parked in the 1. Set the fan outlet to the desired position.
sun, open the windows and door to let the 2. Set the desired temperature by turning the
hot air out of the cab before using the air temperature control dial to between the
conditioner. center and the left end (COOL).
3. Turn the fan dial to “High”.
4. Move the Ventilation/Circulation select
lever to the right to select “Circulation”.

Heating

1. Set the fan outlet to the desired position.

2. Set the desired temperature by turning the
temperature control dial to between the
center and the left end (COOL).
3. Set the fan dial to the desired position.
1. Arrange the outlet louvers so that air can
be directed to the feet.
2. Set the fan dial to the desired position.
3. Set the desired temperature by turning the
temperature control dial to between the
center and the right end (HOT).
For the highest temperature, turn the dial
all the way to the right.
4. Turn the fan dial to the OFF position to
turn off heating.

2-44
 CONTROLS
ACCESSORIES

Defrosting or defogging the windows

Note: If the air conditioner fan is set to High
when using the defroster, the difference
between the external and internal
temperatures increases, resulting in frost on
the outside of the windows. If this happens,
either turn off the air conditioner or turn the
temperature control dial clockwise to
increase the internal temperature.

1. Set the desired temperature by turning the

temperature control dial to between the
center and the right end (HOT).
2. Set the fan dial to the desired position.
3. Move the Ventilation/Circulation select
lever to the left to select “Ventilation”.
4. Arrange the foot and defroster outlets so
that they are directed to the front window.

2-45
 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
butts or put in paper or other easily
burnable objects. Doing so could cause
fire.

This socket is used to supply power to the

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

Pull the ashtray out towards you to use it. To

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

2-46
 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.

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 right side rear view
2. —
3. Check the rear view.

2-47
 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).

2-48
MEMO

2-49
 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.

2-50
 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.

2-51
 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 can store three FM • Do not connect a device with a larger
stations (one from each FM1, FM2, FM3) output compared with a portable audio
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.

2-52
 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.

2-53
 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 (1)........First auxiliary hydraulic lines
hydraulic system. (2)........Second auxiliary hydraulic lines
• Immediately after the engine is stopped (3)........Third auxiliary hydraulic lines
and while the safety lock lever is still in (4)........Fourth auxiliary hydraulic lines
the unlock position, turn the starter
switch to ON and press each auxiliary Stop valve
hydraulic switch several times to (S) : Closed
release the pressure from the auxiliary (O) : Open
hydraulic circuit.
• 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.

2-54
 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 2-56.
Refer to “Releasing the residual pressure” 2. Disconnect the lines from the ports (a/c)
on page 2-56. 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 2-57.
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.

2-55
 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.

2-56
 CONTROLS
ACCESSORIES

Selector valve Third auxiliary hydraulic switch and

button (If equipped)

(O): Open �������When using a hydraulic

breaker (1-way flow) The auxiliary 3rd is mainly used for the
(S): Closed �����When using a reversible attachment that can quickly connect/
attachment (2-way flow) disconnect the bucket. After the engine is
1. Remove the cover (2). started, hydraulic oil constantly flows into the
2. Change the direction of the hydraulic oil pipe (e). This allows the pressure in the (e)
flow by opening or closing the selector side to increase, preventing the pin inserted
valve (1) inside the right side cover. on the bucket from coming out. If the
· For the machine with the auxiliary 1st pressure in the (e) side drops, the warning
auto tank switch, use the switch to lamp starts flashing to warn that the bucket
select the flow. may come out. For a safety reason, the
Refer to “Auxiliary 1st auto tank switch (If bucket can be disconnected only when the
equipped)” on page 2-35. 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.

2-57
 CONTROLS
ACCESSORIES

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

This lamp illuminates and an alarm sounds if This button is used to change from the
the auxiliary 3rd hydraulic pressure drops second auxiliary operation to the fourth
abnormally while the engine is running. auxiliary operation.
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” on page
2-28.

2-58
 CONTROLS
ACCESSORIES

OPERATING THE MACHINE WITH AN First auxiliary hydraulics Second auxiliary hydraulics
ACCUMULATOR
A D
B C
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. AG7B034PE

• 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.

2-59
 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.

2-60
 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

2-61
 CONTROLS
ACCESSORIES

FUEL SUPPLY PUMP (IF EQUIPPED)

Do not use the fuel supply pump for

gasoline or hydraulic oil. Doing so could
result in explosion or damage.
Only use the fuel supply pump for diesel
fuel.

This device automatically supplies fuel to the

fuel tank and stops automatically when the
fuel tank is full.

1. Open the engine hood.

2. Insert the pump’s nozzle (1) in the fuel
supply tank.
3. Open the cab door and the fuse box
cover.

4. Press the switch (2) under the fuse box.

The pump automatically stops once the
fuel tank becomes full.
5. Turn off the switch.
6. Store the nozzle.

2-62
 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

1. Adjust the seat for a comfortable operating
position.
2. Fasten the seat belt.

· 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
and remains lit, while the battery charge
warning lamp (1) and engine oil pressure
3. Check that the safety lock lever is in the warning lamp (2) remain flashing. (If the
locked position. auxiliary 3rd is selected, it is also
flashing.) The other lamps go out.
· Turn on the light switch to check that the
boom light and each switch lamp 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.

4. Check that all levers and pedals are in the

neutral position.

3-3
 OPERATION
STARTING AND STOPPING THE ENGINE

STARTING THE ENGINE 5. After the completion of the warming up,

press the deceleration button to cancel
the deceleration mode.

• Clear all personnel from the work area. Starting in cold climates
• Sound the horn to warn people around
the machine.
Never use starting fluid on this engine, as
IMPORTANT: Do not run the starter motor the starting fluid could cause an
for more than 15 consecutive seconds. If explosion.
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

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

3-4
 OPERATION
STARTING AND STOPPING THE ENGINE

4. Once the engine starts, release the key. STOPPING THE ENGINE
The key automatically returns to the ON
position. IMPORTANT: Do not stop the engine
5. Check that the warning lamps are off. suddenly when operating with heavy
6. Return the throttle controller to the original loads or at the maximum speed. Doing so
position and warm up the engine. may cause the engine to overheat or
Refer to “Warming up the engine”. seize. Never stop running the engine
Note: If the engine is started at −15°C (5°F), suddenly except in emergency.
the revolution speed is controlled to 1500
min-1 (rpm). After 10 seconds, the throttle
controller operation becomes available.
Note: The glow lamp turns on if the coolant
temperature is low after the engine is started.

WARMING UP THE ENGINE

IMPORTANT: Avoid racing the engine until
it has warmed up.
Do not warm up the engine for a long time
(20 minutes or more). When idling is 1. Return the throttle controller.
required, occasionally place a load or run 2. Idle the engine for about 5 minutes to
the engine at medium speed. gradually let it cool.

1. Return the throttle controller, and then run 3. Turn the starter key to the OFF position to
at a low idle with no load for 10 minutes. 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 offset left Dozer blade lower

Boom offset 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 offset left Dozer blade lower

Boom offset right Dozer blade raise

3-7
 OPERATION
OPERATING THE MACHINE

WARMING UP THE MACHINE

(HYDRAULIC OIL)

Operating the working equipment without

warming up the machine (hydraulic oil) is
dangerous, as the working equipment
cannot response to controls quickly or
may move in unexpected ways, and the
safety devices may not operate properly.
Be sure to sufficiently warm up the 2. Fully lower the safety lock lever to the
machine. unlock position, and then unlock the offset
pedal.
IMPORTANT: Do not operate the levers 3. Lift the bucket from the ground.
too quickly when the hydraulic oil
temperature is below 20°C (68°F). The
proper hydraulic oil temperature during
operation is 50 to 80°C (122 to 176°F). If
operations must be performed at lower
temperatures, heat up the hydraulic oil to
at least 20°C (68°F).

Normal warm-up

4. Extend and retract each of the cylinders

slowly several times with no load.

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. Slew slowly to the left and the right several

times.

3-8
 OPERATION
OPERATING THE MACHINE

INSPECTION AFTER WARM-UP

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

6. Travel slowly forward and in reverse

several times.

Warm-up in cold climates

1. Perform the normal warm-up procedure.

1. Check that the warning lamps and meters

are as follows:
· Are all warning lamps off?
· Is the water temperature level within the
green range?
2. Check that there are no irregularities in the
exhaust color, sound and vibrations.

2. Set the bucket cylinder at the stroke end

and keep it there.
Do not keep this condition for more than
30 seconds.
3. Repeat Step 2 until the bucket operating
speed becomes normal.

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

INSPECTING THE ATTACHMENT What to do if the boom automatically

INTERFERENCE PREVENTION SYSTEM stops
1. If the boom stops while it is being raised:
Perform an inspection below to confirm that Operate the boom downward.
the bucket, arm and boom do not touch the 2. If the boom has stopped while offsetting
cab if the boom or bucket is stopped by to the left:
itself after moved very close to the cab. a. Operate the boom downward to move
the boom out of the auto-stop range.
b. Offset the boom to the left.
Offsetting to the right is possible
regardless of the boom’s posture.

1. Offset the boom to the front of the

operator’s seat and move the boom
closed to the cab.
Offset the boom to the right and move the
bucket close to the cab

2. Offset the boom fully to the right and

check if it can be set to the maximum rear
inclination.
3. Offset to the left by maintaining the
posture shown in the figure 2 above.

3-10
 OPERATION
OPERATING THE MACHINE

OPERATING THE TRAVEL LEVERS Moving the machine forward and

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.
Remember that when the dozer blade is 2. Fully lower the safety lock lever to
to the rear of the operator’s seat, the disengage the lock.
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.

3-11
 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.

3-12
 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.

3-13
 OPERATION
OPERATING THE MACHINE

STOPPING TRAVEL ATTACHMENT INTERFERENCE

PREVENTION DEVICE

• Park the machine on a flat, rigid and

safe ground. Set the parking brake. If • All attachments other than a bucket
you must park on a slope, chock the should be used with the AIPS set to the
tracks to block the machine. M mode.
• If any control is accidentally touched • Failure to properly set the Attachment
when the safety lock lever is not locked, Interference Prevention Switch can
the machine may suddenly move and result in equipment damage, serious
cause serious injury or death. injury or death.
• Ensure that all buckets used in the S
mode are standard buckets or those
with shorter width than standard
Never stop running the machine suddenly buckets when measured from the pin to
except in emergency. Stop in good time, the tooth.
if possible.

• Do not disassemble or damage the

1. Set the left and right travel levers slowly to sensors installed on the boom and main
the neutral position. The machine stops. body. Doing so may cause the
Interference Prevention System to
malfunction. If there is a problem,
contact a Takeuchi sales or service
outlet for inspection or repair.
• The interference prevention system may
not function properly if attachments
other than Takeuchi-approved
attachments are installed.
Do not install attachments not approved
by Takeuchi.

3-14
 OPERATION
OPERATING THE MACHINE

The Attachment Interference Prevention Operate excavator

Switch (AIPS) allows the operator to select The minimal front radius feature is only
the attachment size used on the excavator. available for the standard bucket attachment
The Interference Prevention System uses the 750 mm (30 in.) or smaller.
operator’s AIPS selection to limit the
movement of the boom (raising, lowering,
and offsetting) to prevent the cab from being
struck by the boom, attachment, or the
material being handled.
The Interference Prevention System (IPS) is
automatically set to the M mode when the
engine is started to provide the maximum
operator protection.

Modes of operation

To properly set the AIPS:

Select the appropriate attachment width.
S ��������Standard bucket attachments or
those having the width of 750 mm (30
in.) or less
L ���������Bucket attachment whose width is
between 750 mm (30 in.) and 1000
mm (40 in.)
M ��������Bucket attachments having a width of
more than 1000 mm (40 in.), or any
other approved attachments

3-15
 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.

3-16
 OPERATION
OPERATING THE MACHINE

Operating the arm Operating the boom offset

Arm in: Boom offset left:

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

3-17
 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.

3-18
 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.

3-19
 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.

3-20
 OPERATION
OPERATING PROCEDURES

CAUTIONS ON OPERATING Cautions on using machine in water

Cautions on traveling

If the rear of the machine is submerged in

water as shown in the figure above, it causes
Traveling over obstacles (rocks, stumps, etc.) the radiator fan to turn in water, resulting in
may put a great load on the machine body damage to the fan. The rear of the machine
and may cause damage to it. Avoid crossing must not be submerged.
over obstacles whenever possible. If you
must do so, keep the hoe attachment near
the ground, travel at a low speed, and go
over the obstacle at the center of the 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
roller (1).
• For those parts used in water for a long
time, apply enough grease until the old
• On uneven ground, maintain the low speed grease is expelled.
and avoid starting, stopping or changing • Never submerge the slew bearing or main
directions abruptly. body in water or sand. If submerged,
• When a load greater than a set value is contact a Takeuchi service agent for
applied during traveling in 2nd (high) inspection.
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.
• When traveling in 2nd speed, do so with
the dozer blade at the front.

3-21
 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.

3-22
 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.

3-23
 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.

3-24
 OPERATION
OPERATING PROCEDURES

Digging side drains Leveling

Use the boom offset 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.

3-25
 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 2-59.

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
5-20.
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.
3-26
 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 fluid level Refer to “Fuel and lubricant table” on page
and replenishing” 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 5-46.

3-27
 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.

3-28
 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.

3-29
 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.

3-30
 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
Ramp
following precautions:
• Select a firm, level surface and keep Stopper
sufficient distance from road shoulders.
• Secure the ramps of adequate strength Distance between ramps
15º or less
and size to the truck bed. The slope of AG7F001PE

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. AG7F002

• 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.
AG7F003

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 offseted to either the left or
of lifting the machine mass. right side, set it to 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: 96
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 0.05 to 0.0015% by
volume.
It is essential to use ultra-low sulfur fuel.
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
Diesel engine oil
SAE 10W-30 Every 250 hrs
API: CJ-4 class or
Engine oil pan after the initial 50
higher SAE 15W-40 hrs.
ACEA: E6 class
Takeuchi genuine
ISO VG46 Every 4000 hrs.***
hydraulic oil 46

Hydraulic oil tank ISO VG32

Anti-wear
ISO VG46 Every 2000 hrs.***
hydraulic oil
ISO VG68

Cooling water
Engine cooling (water + coolant)** Mixture of 50% coolant
Every 1000 hrs.
system SAE: J814C or Mixture of 30% coolant
J1034
Every 1000 hrs
Travel reduction Gear oil
SAE 90 after the initial 250
gear API: GL-4
hrs*.
Slew bearing Lithium based Every 50 hrs.
Working grease EP-2 — Daily or every 10
equipment NLGI No.2 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
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 14 L (14.8 US qt.) System 100 L (26.3 US gal.) 1.1 L X 2
9.4 L (9.9 US qt.) 120 L (31.7 US gal.) 92 L (25.7 US gal.)* (1.16 US qt.) X 2
Lower limit Tank
5.0 L (5.3 US qt.) 71 L (18.7 US gal.)
*: When the fuel supply pump (if equipped) is automatically stopped

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
Hydraulic system Pilot line filter Element 15512-00601 250 hrs.

Air breather filter 15520-02715 Every 1000 hrs.

Every 250 hrs
Engine lubrication
Engine oil filter Cartridge Y129150-35153 after the initial 50
system
hrs.
Fuel filter Cartridge Y129A00-55800
Fuel system Water separator Every 500 hrs.
Cartridge Y129A00-55730
filter
Every 1000 hrs.
or after 6
Primary (Outer)
19111-13001 cleanings
element
Air cleaner (whichever comes
Air cleaner first)
system
When the primary
Secondary (Inner)
19111-13002 elements are
element
replaced.
Receiver dryer 19115-05511 Every 2 years
AC system Once a year or if
Ventilation filter Element 19115-15570 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
5 Hammer 16903-00330 3/4
6 Monkey wrench 16904-00250 250 mm
7 Pliers 16905-00200 200 mm
8 Spanner 16900-01922 19-22
9 Spanner 16900-02427 24-27
10 Single-ended wrench 16901-00013 13
11 Single-ended wrench 16901-00041 41
12 Combination wrench 16909-00026 26
13 Hex. wrench 16906-00400 4 mm
14 Hex. wrench 16906-00500 5 mm
15 Hex. wrench 16906-00600 6 mm
16 Hex. wrench 16906-00800 8 mm
17 Hex. wrench 16906-01000 10 mm
18 Hex. wrench 16906-01400 14 mm
19 Tool case 16914-00005
20 Case 16919-00001
21 Grease gun 16910-60600 600 cc
22 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.

AG7G009

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 hoses
Heater & AC systems
Air conditioner hoses

Hydraulic hoses (pump - delivery)

Hydraulic hoses (pump - suction)

Main body
Hydraulic hoses (slew motor)

Hydraulic hoses (travel motor)

Every 2 years
Hydraulic hoses (boom cylinder piping)

Hydraulic Hydraulic hoses (arm cylinder piping)

system
Hydraulic hoses (bucket cylinder piping)

Working Hydraulic hoses (offset cylinder)

equipment Hydraulic hoses (blade cylinder)

Hydraulic hoses (tension 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 - 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
*: Cab parts No. 03986-00007

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 5-20
Inspecting the hydraulic oil tank level and replenishing 5-21
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
Inspecting and adjusting the compressor belt (AC) 5-28
Every 50 hours
Inspecting the crawler belt tension 5-30
Lubricating the slew bearing 5-30
Draining the water from the fuel tank 5-31
Inspecting the battery fluid level and replenishing 5-32
After the initial 250 hours (only for new machines)
Replacing the hydraulic oil return filter 5-34
Replacing the pilot line filter 5-35
Replacing the travel motor gear oil* 5-36
Every 250 hours
Replacing the engine oil and the oil filter 5-37
Inspecting and adjusting the fan belt 5-37
Inspecting and adjusting the compressor belt (AC) 5-37
Cleaning the air cleaner 5-38
Cleaning the radiator fins and the oil cooler fins 5-39
Cleaning the air filters (AC) 5-40
Cleaning the condenser (AC) 5-41
Inspecting the refrigerant (gas) level (AC) 5-42
Every 500 hours
Replacing the fuel filter 5-44
Replacing the water separator filter 5-45
*: 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 5-46
Replacing the pilot line filter 5-46
Replacing the travel motor gear oil* 5-46
Cleaning the engine cooling system 5-46
Replacing the air cleaner element 5-48
Replacing the air breather filter 5-49
Inspecting and adjusting the engine valve clearance 5-49
Every 1500 hours
Inspecting the crankcase breather system 5-50
Cleaning the EGR cooler
5-50
(cleaning the water side and exhaust air passage blower)
Every 2000 hours
Lapping the engine valve seats (If necessary) 5-51
Every 3000 hours
Inspecting the turbocharger (blow wash as necessary) 5-52
Inspecting, cleaning and checking operation of the EGR valve 5-52
Cleaning the EGR lead valve 5-52
Inspecting and cleaning the DPF soot filter 5-52
Inspecting the operation of the air intake throttle valve 5-52
Inspecting and cleaning the fuel injector 5-52
Every 4000 hours
Replacing the hydraulic oil and cleaning the suction strainer 5-53
When required
Replacing the bucket teeth and the side cutters (If equipped) 5-56
Replacing the bucket 5-58
Adjusting the gap between the bucket and arm (If equipped) 5-60
Inspecting and replenishing the windshield washer fluid 5-61
Draining the water from the water separator 5-62
Lubricating the levers and pedals 5-63
Tilting up the platform 5-64
Inspecting the rubber crawlers 5-66
Replacing the rubber crawlers 5-67
Every 2 years
Replacing the receiver dryer 5-70
*: 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 3. Check for oil leakage from the hydraulic
HOOD AND COVERS tank, hydraulic devices, hoses or
connections.
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.

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 Note: Use only clean water (soft water), such
gloves when handling coolant as tap water, to replenish the coolant loss
(antifreeze). If any coolant (antifreeze) due to evaporation. If the coolant loss is due
comes in contact with eyes or skin, to leakage, replenish the mixture of antifreeze
wash it off with clean water. Otherwise, and clean water (soft water) prepared using
it could result in injures. 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 15 minutes, inspect the oil
Inspection 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 INSPECTING THE FUEL LEVEL

• Do not smoke or permit open flames • Do not smoke or permit open flames
while handling fuel or working on the while handling fuel or working on the
fuel system. fuel system.
• Stop the engine in a well-ventilated • Never remove the fuel cap or add fuel
place and allow it to cool down before when the engine is running or still hot.
performing maintenance. Do not spill fuel on the hot surface of
• Clean up spilled fuel immediately. the machine.
• Fill the fuel tank in a well ventilated
place.
Water separator • 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. Turn the starter switch to the ON position.

2. Inspect the water separator warning lamp.
3. If the warning lamp is flashing, drain the
water.
Refer to “Draining the water from the
water separator” on page 5-62. 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 2-6.

5-20
 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. Press the air breather button (2) to relieve

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

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

2. Fully offset the boom to the left.
3. Fully retract the cylinders (arm and
bucket), and lower the bucket to the
ground.
4. Lower the dozer blade, and then stop the
engine.
5. Open the side cover.
6. 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).
5-21
 MAINTENANCE
DAILY INSPECTION (EVERY 10 HOURS)

Pressurizing the hydraulic tank

1. Start the engine and run it at low speed.
2. With the vent plug (3) removed, set the
safety lock levers to the released position.
· Hydraulic tank pressurization posture

3. Fully extend the bucket, arm, boom and

offset cylinders. (Tank pressurizing
posture)
4. Stop the engine and raise the left safety
lock lever to engage the lock.
5. Tighten the vent plug (3), and then
pressurize by retracting the cylinders.

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

HOURS (ONLY FOR NEW
MACHINES)
REPLACING THE ENGINE OIL AND THE
OIL FILTER

Stop the engine and allow the machine to 2. Loosen the bolts and remove the under
cool down before performing cover (3).
maintenance. 3. Place a pan for catching the waste oil
• The engine, muffler, radiator, hydraulic under the drain plug (4).
lines, sliding parts and many other parts 4. Remove the drain plug (4) and drain the
of the machine are hot immediately after oil.
the engine is stopped. Touching these 4. Machines equipped with the optional drain
parts will cause burns. plug:
• The engine oil is also hot. Remove the cap (A), install connector (B),
Be careful not to touch the hydraulic oil and then drain the oil. (The oil comes out
when loosening the cap or plug. when the screw is tightened.)
Working on the machine under these 5. Tighten the drain plug (4).
conditions could result in burns or 5. Machines equipped with the optional drain
injuries. plug:
Remove the connector (B) and install the
cap (A).
Engine oil
IMPORTANT: Check the waste oil for
metal powder. If it contains large amounts
of metal powder, consult your sales or
service dealer.

1. Open the engine hood and remove the oil

filler cap (2).

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

Engine oil filter

6. Turn the filter (5) counterclockwise with the
filter wrench and remove it.
7. Clean the surface of installation of the filter
stand.
8. Apply a thin layer of oil on the packing of
the new filter.
9. Install the new filter by hand.
10. 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.)
11. 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.
12. Tighten the oil filler cap (2).
13. Start the engine, run it at low idle for
about 5 minutes, then stop it.
14. After about 15 minutes, inspect the oil
level.

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

INSPECTING AND ADJUSTING THE FAN

BELT

Stop the engine and allow the machine to

cool down before performing
maintenance.
• The engine, muffler, radiator, hydraulic
lines, sliding parts and many other parts
of the machine are hot immediately after
the engine is stopped. Touching these 3. Press the fan belt (1) at the midpoint
parts will cause burns. between the fan pulley (2) and alternator
pulley (3) to check the tension (approx. 98
IMPORTANT: The loose belts could result N or 22 lbf).
in bad battery charge, overheat of engine The slack (A) should be 7 to 10 mm (0.28
or early wear of belt. Too tight belts could to 0.4 in).
damage the water pump or bearing and 4. Inspect the fan belt (1) and replace if it is
belt used to drive the alternator. as follows.
IMPORTANT: Do not let any oil or grease · There are cuts or cracks.
get on the belt. · The belt is worn and touches the bottom
of the V groove in the pulley.
Inspection · The belt stretched too loose to be
adjusted.

1. Loosen the bolts and remove the

maintenance cover (8).
2. Tilt up the platform.
Refer to “Tilting up the platform” on page
5-64.

5-26
 MAINTENANCE
AFTER THE INITIAL 50 HOURS (ONLY FOR NEW MACHINES)

Adjustment

1. Loosen the bolts (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 bolts (5) and locking nut (4).
4. Reinstall the maintenance cover (8) on its
original position.

Note: When replacing with a new belt, run

the engine at low idle speed for about 3 to 5
minutes to break in the new belt, before
adjusting the tension.

5-27
 MAINTENANCE
AFTER THE INITIAL 50 HOURS (ONLY FOR NEW MACHINES)

INSPECTING AND ADJUSTING THE Inspection

COMPRESSOR BELT (AC)

• Stop the engine and allow the machine

to cool down before performing
maintenance.
· The engine, muffler, radiator, hydraulic
lines, sliding parts and many other
parts of the machine are hot
immediately after the engine is
stopped. Touching these parts will
cause burns. 1. Loosen the bolts and remove the
• The high-pressure pipes of the air maintenance cover (8).
conditioner can be very hot (80 to 120°C 2. Tilt up the platform.
or 176 to 248°F). Be careful not to burn Refer to “Tilting up the platform” on page
yourself. 5-64.

IMPORTANT: Do not let any oil or grease

get on the belt. It will cause the belt to
slip, decrease the cooling capacity or
shorten the service life of the air
conditioner.

If the belt is too slack, it will slip and vibrate,

resulting in decreased cooling capacity. The
service life of the air conditioner also will be
shortened. Adjust the belt tension to the
standard value.
3. Measure the belt (1) tension using the belt
tension gauge. The belt tension is normal
if the belt tension gauge indicates the
following values.
294 to 392 N or 66 to 88 lbf.

5-28
 MAINTENANCE
AFTER THE INITIAL 50 HOURS (ONLY FOR NEW MACHINES)

Adjustment
If the belt tension is not normal, adjust it with
the adjuster bolt (2).
1. Loosen the locking nut (3).
2. Turn the adjuster bolt (2) as follows.
· Tighten: Clockwise
· Loosen: Counterclockwise
3. Tighten the locking nut (3) after
adjustment.
Tightening torque:
· Locking nut (4) 31.4 to 45.1 N·m (23.2
to 33.3 ft-lb.)
4. Reinstall the maintenance cover (8) on its
original position.

Note: When replacing with a new belt, run

the engine at low idle speed for about 3 to 5
minutes to break in the new belt, before
adjusting the tension again.

Replacing
Replace the belt in the following cases:
· There are cuts or cracks.
· The belt is worn and touches the bottom of
the V groove in the pulley.
· The belt stretched too loose to be
adjusted.

5-29
 MAINTENANCE
EVERY 50 HOURS

EVERY 50 HOURS 2. Use the grease gun to grease the grease

fitting (1).
INSPECTING THE CRAWLER BELT
TENSION
Note: This machine uses a hydraulic cylinder
to adjust the tension of the crawler belts. It is
not necessary to regularly perform
adjustments of the crawler belt tension.

If the tension is too loose and the track

comes off, the hydraulic cylinder is likely
faulty. Ask your sales or service dealer for
repairs.
3. Start the engine, lift the bucket and slew
clockwise 90°.
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.

5-30
 MAINTENANCE
EVERY 50 HOURS

DRAINING THE WATER FROM THE FUEL Bleeding air from the fuel system
TANK Refer to “Bleeding air from the fuel system”
on page 6-8.

Note: Air in the fuel system causes the

• Do not smoke or permit open flames engine to fail to start or to have problems.
while handling fuel or working on the Bleed air when the fuel tank is emptied,
fuel system. using the same procedure above.
• Never remove the fuel cap or add fuel
when the engine is running or still hot.
Do not spill fuel on the hot surface of
the machine.
• Fill the fuel tank in a well ventilated
place.
• Do not fill the fuel tank to capacity.
Allow room for oil expansion.
• Clean up spilled fuel immediately.
• Securely tighten the fuel filler cap.
• Use the correct grade of fuel for the
operating season.

Do the draining operation before starting the

machine.

1. Open the fuel lid.

2. Remove the fuel filler cap (2).
3. Place a pan under the drain plug (3).
4. Remove the drain plug (3) and drain the
water and sediment built up in the bottom
of the tank.
5. Tighten the drain plug (3).
6. Add fuel while watching the sight gauge
(1).
7. Tighten the fuel filler cap (2).
8. Close the fuel lid and lock it with the key.
9. Bleed air.

5-31
 MAINTENANCE
EVERY 50 HOURS

INSPECTING THE BATTERY FLUID LEVEL Inspection

AND REPLENISHING
IMPORTANT: Check the fluid level of all
cells following the steps below, even
when the fluid level can be checked using
• Do not use the battery when the fluid the indicator.
level is below the lower level limit. Doing
so will hasten the deterioration of the 1. Open the side cover.
internal portions of the battery and
shorten the battery life. It also can
cause rupturing (explosion).
• Batteries generate flammable hydrogen
gas which may explode. Keep away
from flame, sparks, fire or lighted
cigarettes.
• Use a dampened cloth to clean above
the fluid level line and check the fluid
level. Do not clean with a dry cloth;
otherwise it can cause static electricity
to build up, resulting in ignition or
explosion. 2. Inspect the indicator (1).
· Blue: Good
· White: Charging needed
· Red: Insufficient battery fluid
• Wear protective goggle and clothing 3. Inspect the fluid level.
when working with batteries. The fluid level must be between the upper
• Do not add the distilled water above the level line (H) and lower level line (L). If not,
upper level limit. Doing so could cause add distilled water up to the line (H).
the fluid to leak. This fluid can cause
skin damage if contacted, or can cause
the machine components to corrode.
• Batteries contain sulfuric acid which will
damage eyes or skin if contacted.
· 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.

5-32
 MAINTENANCE
EVERY 50 HOURS

• If the fluid level cannot be checked by fluid

level lines:

Remove the caps (2) and look into the

fluid filler holes to check the fluid level. If
the fluid is below the sleeve (3), be sure to
add distilled water up to the bottom edge
of the sleeve (3).

Proper level (A)

If the fluid reaches up to the bottom edge
of the sleeve (3), the surface tension
causes the fluid to swell and the plate
appears as if it is distorted.

Level too low (B)

If fluid does not reach up to the bottom
edge of the sleeve (3), the plate looks
laminar, not distorted.

4. Check the terminals for looseness and

dirt.

Replenishing
When adding distilled water, do so before
starting operations in order to prevent
freezing.
1. Remove the caps (2), and add distilled
water until the upper level (H).
2. Check that the indicator (1) turns blue.
3. Clean the exhaust hole on the cap, then
tighten the caps (2) securely.

5-33
 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. 1. Press the air breather button (2) to relieve
· The hydraulic oil is also hot and under the internal pressure from the tank.
high pressure. 2. Loosen the bolts and remove the flange
Be careful not to touch the hydraulic (4).
oil when loosening the cap or plug. 3. Remove the return filter (5).
Working on the machine under these 4. Install a new return filter.
conditions could result in burns or 5. Install the flange (4) on its original position.
injuries due to the hot oil spurting out. 6. Open the side cover.
• Oil may spurt out if caps or filters are 7. Inspect the level with the sight gauge (1),
removed or pipes are disconnected and replenish if the level is too low.
before releasing the pressure in the Refer to “Inspecting the hydraulic oil tank
hydraulic system. level and replenishing” on page 5-21.
· Press the air breather button to relieve
the internal pressure from the tank.
· When removing plugs or screws, or
when disconnecting hoses, stand to
the side and loosen them slowly to
gradually release the internal pressure
before removing.

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

REPLACING THE PILOT LINE FILTER 6. Apply a thin layer of oil on the O-ring of the
new filter.
7. Install the new element on the filter stand
(7).
• Stop the engine and allow each part of 8. Apply a thin layer of oil on the new O-ring
the machine to cool down before (6).
performing maintenance. 9. Install the new O-ring (6) and the case (4)
· The engine, the hydraulic system and on the filter stand (7).
many other parts of the machine are 10. Open the side cover.
hot immediately after the engine is 11. Inspect the level with the sight gauge (1)
stopped. Touching these parts will and replenish if the level is too low.
cause burns. Refer to “Inspecting the hydraulic oil tank
· The hydraulic oil is also hot and under level and replenishing” on page 5-21.
high pressure immediately after the
engine is stopped.
Be careful not to touch the oil when
loosening the cap or plug. Working on
the machine under these conditions
could result in burns or injuries due to
the hot oil spurting out.
• 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.
· When removing plugs or screws, or
when disconnecting hoses, stand to
the side and loosen them slowly to
gradually release the internal pressure
before removing.

1. Press the air breather button (2) to relieve

the internal pressure from the tank.
2. Open the engine hood.
3. Turn the case (4) counterclockwise and
remove it.
4. Remove the element (5) and O-ring (6).
5. Clean the inside of the case (4).
5-35
 MAINTENANCE
AFTER THE INITIAL 250 HOURS (ONLY FOR NEW MACHINES)

REPLACING THE TRAVEL MOTOR GEAR 6. Add oil through the hole of the plug (3)
OIL until oil flows out of the hole of the plug
(2).
7. Tighten the plugs (2) and (3).
· Tightening torque: 58.8 ± 9.8 N·m (43.4
• Stop the engine and allow the machine ± 7.2 ft-lb.)
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.

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), (2) and (3) and drain
the oil.
4. Rewrap the plugs with new sealing tape.
5. Tighten the plug (1).
· Tightening torque: 58.8 ± 9.8 N·m (43.4
± 7.2 ft-lb.)

5-36
 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
Refer to “Inspecting and adjusting the fan
belt” on page 5-26.

INSPECTING AND ADJUSTING THE

COMPRESSOR BELT (AC)
Refer to “Inspecting and adjusting the
compressor belt (AC)” on page 5-28.

5-37
 MAINTENANCE
EVERY 250 HOURS

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

6. Clean the primary element (3) with dried

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

5-38
 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 3. Blow compressed air on the fins to

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

1. Open the side cover.

2. Remove the screws (1) and open the

condenser.

5-39
 MAINTENANCE
EVERY 250 HOURS

CLEANING THE AIR FILTERS (AC) Cleaning

1. Blow dry, compressed air (138 kPa or 20
psi or less) directly on the filters from the
inside, moving up and down along the
Wear required appropriate equipment pleats.
such as protective goggle and filter mask Be sure to keep the nozzle at an adequate
when using compressed air, as metal distance from the filters.
fragments or other objects can fly and 2. Wash the filter with neutral detergent if it is
cause serious injury. very dirty. Dry the filter completely after
washing it.
Clean the filters immediately after operating
in dusty places. Replacing
If the filters are clogged, the air flow is Replace the filter with a new one once a year
reduced and a booming sound is heard from or if it is still clogged after blow-drying with
the air conditioner unit. compressed air and washing.

Removing the filters

Ventilation filter

1. Loosen the bolts and remove the cover

(1).
2. Remove the filter (2).
Ventilation filter (2):
Part number 19115-15570

Circulation filter
1. Open the cab door.
2. Release the fixing knob (3) by pulling it
toward you.
3. Lift the filter (4) and remove it.
4. Use compressed air or water to clean
each filter, depending on how dirty it is.

5-40
 MAINTENANCE
EVERY 250 HOURS

CLEANING THE CONDENSER (AC)

Wear required appropriate equipment

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

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 200kPa (28
psi) and hold the nozzle sufficiently
away from the fins.

1. Open the side cover.

2. Clean the condenser (1).

5-41
 MAINTENANCE
EVERY 250 HOURS

INSPECTING THE REFRIGERANT (GAS) 3. Inspect the refrigerant by watching the

LEVEL (AC) flow of air bubbles through the sight glass
(2).
Refer to “Check list for refrigerant volume”
on page 5-43.
• Exposure of the eyes or hands to the 4. Remove the maintenance cover.
cooler’s refrigerant could result in Refer to “Inspecting and adjusting the
blindness or frostbite. compressor belt (AC)” on page 5-28.
Never touch the refrigerant or loosen 5. Tilt up the platform.
the parts of the cooling circuit. Refer to “Tilting up the platform” on page
• Keep flames away if the refrigerant gas 5-64.
is leaking.
• The high-pressure pipes of the air
conditioner can be very hot (80 to 120°C
or 176 to 248°F). Be careful not to burn
yourself.

The cooling capacity decreases if the

amount of refrigerant is insufficient.
Inspect the refrigerant level using the sight
glass (2) on the top of the receiver dryer (1).

6. Check the temperature of the

compressor’s high pressure pipe (3) and
low pressure pipe (4).
Refer to “Check list for refrigerant volume”
on page 5-43.

1. Open the side cover.

2. Inspect the places for the conditions
below.

Places for inspection Conditions

Cab door Fully open
Temperature control Set fully to the COOL
dial side
Fan speed High
Ventilation /
Circulation select Circulation
switch
Engine speed Maximum speed
Air conditioner
ON
switch
5-42
 MAINTENANCE
EVERY 250 HOURS

Check list for refrigerant volume

Air conditioner Normal Abnormal

High/low High pressure High pressure Little difference in High pressure
pressure pipe pipe is hot (80 to pipe is warm, low temperature pipe is hot, low
temperature 120°C or 176 to pressure pipe is between the pressure pipe is
248°F), low slightly cool. No high-pressure slightly cool. A
pressure pipe is significant pipe and the low- significant
cold (8 to 15°C difference in pressure pipe. difference in
or 46 to 59°F). temperature temperature
Clear difference between the between the
in temperature pipes. pipes.
between the
pipes.
Pipe connection Normal Some places are Some places are Normal
dirty with oil. extremely dirty
with oil.
Sight glass

AG7G064 AG7G065 AG7G066 AG7G067

Almost Flow of bubbles Mist-like flow is No bubbles is

transparent with can be seen faintly visible. visible, even
some bubbles. constantly. when the fan is
Fully transparent Sometimes set to High and
when the engine transparent or the engine is
speed is white with idling.
increased or bubbles.
decreased.
Refrigerant level Proper level Refrigerant may Refrigerant has Refrigerant level
be leaking. leaked; little is too high
left.

If the air conditioner is not working

If the air conditioner does not work well, set the fan switch to OFF and contact your sales or
service dealer for inspection and/or repairs.

IMPORTANT: Continued use of the air conditioner when it is not working properly will
damage its various parts.
IMPORTANT: Using the air conditioner when there is no refrigerant will damage the
compressor.
IMPORTANT: Always consult your sales or service dealer for replacing the refrigerant.
Be sure to use R134a refrigerant (1475 g or 3.25 lb.).

5-43
 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 6-8.

5-44
 MAINTENANCE
EVERY 500 HOURS

REPLACING THE WATER SEPARATOR

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.

(S): Close
1. Open the engine hood.
2. Close the valve (2) of the water separator (1).
3. Place a pan for catching fuel under the
drain hose.
4. Loose the air-bleeding plug (8) and the
drain plug (7) to discharge fuel from inside.
5. Remove the sensor wiring coupler (3).
6. Remove the case (4) with the filter wrench.
7. Remove the element (5), and then clean
the case. When doing the above, be
careful not to damage the sensor.
8. Replace the packing with a new one and
lubricate it with diesel fuel.
9. Install the new element (5) on the filter stand.
10. Tighten the case (4) by hand. Be sure to
do it by hand.
Tightening torque: 27 to 33 N·m (20 to
24.6 ft-lb)
11. Install the sensor wiring coupler (3).
12. Tighten the drain plug (7).
13. Bleed air.
Refer to “Bleeding air from the fuel
system” on page 6-8.

5-45
 MAINTENANCE
EVERY 1000 HOURS

EVERY 1000 HOURS · One person must sit in the operator’s

seat so that he/she can immediately
REPLACING THE HYDRAULIC OIL stop the engine when necessary. He/
RETURN FILTER she must take care not to touch the
lever or pedal unless necessary.
Refer to “Replacing the hydraulic oil return · The one who performs maintenance
filter” on page 5-34. must make sure to keep his/her body
or clothing away from the moving part
of the machine.
REPLACING THE PILOT LINE FILTER • Standing at the back of the machine
while the engine is running is extremely
Refer to “Replacing the pilot line filter” on dangerous, as the machine could move
page 5-35. suddenly. Never stand at the back of the
machine while the engine is running.
• Do not remove the radiator cap or the
REPLACING THE TRAVEL MOTOR GEAR drain plug when the cooling water is
OIL hot. Stop the engine and wait until the
engine and the cooling water cool.
Refer to “Replacing the travel motor gear oil” Then, slowly loosen the radiator cap
on page 5-36. and the drain plug to remove them.

When cleaning, if the temperature of the

CLEANING THE ENGINE COOLING coolant is low, the thermostat will be closed
SYSTEM and the coolant will not circulate in the
radiator. Heat the coolant water to at least
90°C (194°F) before cleaning.

• Stop the engine and allow the machine 1. Open the engine hood.
to cool down before performing
maintenance.
· The engine, muffler, radiator and many
other parts of the machine are hot
immediately after the engine is
stopped. Touching these parts will
cause burns.
· The engine coolant 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 coolant spurting
out.
• If maintenance must be performed with
the engine running, always work as a
two person team communicating each
other.

5-46
 MAINTENANCE
EVERY 1000 HOURS

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.
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
5-47
 MAINTENANCE
EVERY 1000 HOURS

REPLACING THE AIR CLEANER ELEMENT 7. Install the new elements. Press them firmly
into the body (4).
8. Install the dust cup (2) with its “
OBEN/TOP” mark facing up, and then
Stop the engine and allow the machine to fasten it with the clamps (1).
cool down before performing
maintenance.
• The engine, muffler, radiator and many
other parts of the machine are hot
immediately after the engine is stopped.
Touching these parts will cause burns.

IMPORTANT: Do not use an element if its

pleats, gaskets or seals are damaged.
IMPORTANT: Be sure to install the
element and dust cap securely. If not,
dust could be drain into the cylinder,
damaging the engine.

1. Open the side cover.

2. Loosen the clamps (1) and remove the

dust cup (2).
3. Clean the inside of the dust cup (2).
4. Remove the primary element (3).
Do not remove the secondary element yet.
5. Clean the inside of the body (4).
6. Remove the secondary element (5).
5-48
 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 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).

5-49
 MAINTENANCE
EVERY 1500 HOURS

EVERY 1500 HOURS

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

CLEANING THE EGR COOLER

(CLEANING THE WATER SIDE AND
EXHAUST AIR PASSAGE BLOWER)
This operation requires experience. Ask your
sales or service dealer for it.

5-50
 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.

5-51
 MAINTENANCE
EVERY 3000 HOURS

EVERY 3000 HOURS INSPECTING THE OPERATION OF THE

AIR INTAKE THROTTLE VALVE
INSPECTING THE TURBOCHARGER
(BLOW WASH AS NECESSARY) This operation requires experience. Ask your
sales or service dealer for it.
This operation requires experience. Ask your
sales or service dealer for it.
INSPECTING AND CLEANING THE FUEL
INJECTOR
INSPECTING, CLEANING AND CHECKING
OPERATION OF THE EGR VALVE This operation requires experience. Ask your
sales or service dealer for it.
This operation requires experience. Ask your
sales or service dealer for it.

CLEANING THE EGR LEAD VALVE

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

INSPECTING AND CLEANING THE DPF

SOOT FILTER
This operation requires experience. Ask your
sales or service dealer for it.
• Do not modify the DPF without permission.
If modified, it may be damaged or
malfunction may occur. As a result, an
expensive repair work may be required.
• Do not reuse the DPF that has been
dropped to the ground. There is catalyst
fitted inside the DPF. It can be damaged if
strong shocks are applied to it.

5-52
 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 2. Press the button (2) to relieve the internal
hydraulic system. pressure from the tank.
· Press the air breather button to relieve 3. 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 5-49.
when disconnecting hoses, stand to 4. Remove the plug (3).
the side and loosen them slowly to 5. Loosen the bolts and remove the flange
gradually release the internal pressure (4).
before removing. 6. Remove the return filter (5).
7. Place a pan under the plug (6) to catch the
1. Slew 45° clockwise and set the machine waste oil.
to the hydraulic oil level inspection 8. Loosen the drain plug (6) and drain the
posture. hydraulic oil.
Refer to “Inspecting the hydraulic oil tank 9. Loosen the three bolts and remove the
level and replenishing” on page 5-21. panel (7).
10. Loosen the hose clip (8).
11. Loosen the bolts and remove the flange
(9).
12. Remove the flange (10) and the suction
strainer (11), and then clean them.
13. Clean the inside of the hydraulic tank.
14. Install the suction strainer (11) on the
flange (10).
15. Install the flanges (10) and (9) on the
tank, and then reconnect the hoses as
5-53
 MAINTENANCE
EVERY 4000 HOURS

before. Bleeding air

16. Tighten the drain plug (6).
17. Install the new return filter (5) and the IMPORTANT: After replacing the hydraulic
flange (4) on the tank. oil or hydraulic devices, or after
18. Open the side cover. performing maintenance of the hydraulic
19. Add hydraulic oil from the hole of plug (3) devices, bleed air from the hydraulic
up to the level between the upper limit circuits and hydraulic devices. Failure to
(H) and the lower limit (L) in the sight do so may damage the hydraulic devices.
gauge (1).
20. Tighten the plug (3). • Hydraulic pump
21. Install the panel (7). 1. Tilt up the platform.
22. Bleed air from the hydraulic oil circuit Refer to “Tilting up the platform” on page
following “Bleeding air” below. 5-64.
23. Set the machine to the hydraulic oil level
inspection posture and inspect the oil
level after the oil cools.
Refer to “Inspecting the hydraulic oil tank
level and replenishing” on page 5-21.

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).

• Slew motor

1. Loosen the air-bleeding plug (1).

2. Tighten the plug (1) once the hydraulic oil
overflows from the air-bleeding plug hole
(1).

5-54
 MAINTENANCE
EVERY 4000 HOURS

• Cylinders Boom
1. Start the engine, let it run at a low-idling
speed for 10 minutes.
2. Maintain the engine at low idle, and then
slowly extend and retract each cylinder 4
or 5 times, without letting them reach the
stroke end.
3. While running the engine at high speed,
slowly extend and retract each cylinder 4
or 5 times, without letting them reach the
stroke end.
4. Return the engine speed to low idle, and
then slowly extend and retract each
cylinder 4 or 5 times to the stroke end. 4. Hold the hose fitting (A) in place with a
wrench and slowly loosen the hose nut (1).
• Emergency shut-off valve 5. Slowly move the boom in the “Boom
This operation is dangerous and requires lower” direction a little until there are no
experience. Ask your sales or service dealer more air bubbles coming from the hose
for help. nut (1) joint.
If air is not released, the working equipment 6. Hold the hose fitting (A) in place with a
could become slow in reacting to the wrench and tighten the hose nut (1).
operation of the operator and show
unexpected behavior. Arm

When removing plugs or screws, or when

disconnecting hoses, stand to the side
and loosen them slowly to gradually
release the internal pressure before
removing.

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

catch the waste oil.
2. Start the engine and run it at low idle.
3. Fully lower the safety lock lever to the 4. Hold the hose fitting (B) in place with a
unlock position. wrench and slowly loosen the hose nut (1).
5. Slowly move the arm in the “Arm lower”
direction slightly, until there are no more air
bubbles coming from the hose nut (1)
joint.
6. Hold the hose fitting (B) in place with a
wrench and tighten the hose nut (1).

5-55
 MAINTENANCE
WHEN REQUIRED

WHEN REQUIRED 3. Remove the key, and then check that the
bucket is stable.
REPLACING THE BUCKET TEETH AND
THE SIDE CUTTERS (IF EQUIPPED)
Replace the bucket teeth if the tooth points
are worn. Do not wait until the bucket is
damaged.

• Before performing maintenance or

repairs under the machine, lower all
moveable working equipment to the
ground or in the lowermost position.
• To prevent unexpected movement, 4. Knock out the locking pin (1) and remove
firmly secure the working equipment the point (2).
when repairing or replacing the bucket
teeth or side cutter. Note: If the drift is set against rubber pin lock
• When using a hammer, pins may fly out (3) when it is hit, the rubber pin lock may
or metal particles may be scattered. break. Set it against the back of the locking
This may lead to serious injury. pin.
· If hard metal parts such as pins,
bucket teeth, side cutter or bearings 5. Remove the rubber pin lock (3). Check if
are hit with a hammer, wear protective the rubber pin lock is still usable. Replace
gear such as safety goggles and it if it is as follows.
gloves.
· When hitting pins or bucket teeth,
always check that there is no one in
the surrounding area.
• Do not allow unauthorized personnel in
the work area while working.

Removing
1. Clean the bucket and park the machine on
a flat and rigid ground.

A ��������There are cracks in the rubber and

the roller is coming off.
B ��������The roller is dented when pressed
with a finger.

2. Place the bucket with its bottom flat on

the blocks so that the locking pin can be
knocked out.
5-56
 MAINTENANCE
WHEN REQUIRED

Installation 4. Knock out the locking pin (1).

Check that the end surfaces of the locking
pin just knocked out are aligned with the
upper and lower surface of the point. Do
not use the worn locking pin.
The life of the teeth can be lengthened
and the frequency of its replacement can
be reduced by turning it upside down so
that it will wear evenly.
Replace the rubber pin lock and locking
pin at the same time as replacing the
teeth. This makes it possible to prevent
the teeth from falling out
1. Remove the dirt on the surface of adaptor
and the inner part of tooth, make the • Side cutter
better contact on the mating part. Installation
2. Push rubber pin lock (3) into the welding
adaptor (4).
Do not let the rubber pin lock stick out
from the welding adaptor surface.

1. Insert the bolts from the inner of the

bucket and tighten the side cutter with
nuts.
Tightening torque: 475 N·m (350 ft-lb.)
3. Install the point (2) onto the welding 2. Caulk the bolts with a punch at three
adaptor (4). spots along the periphery of the screw to
Insert the point so that the surface behind prevent the nuts from coming loose.
the point’s pin hole is aligned with the
surface behind the welding adapter’s pin
hole.

5-57
 MAINTENANCE
WHEN REQUIRED

REPLACING THE BUCKET 1. Lower the bucket to the ground as shown

on the figure above in a stable position.

Note: When removing pins, set the bucket

• Before performing maintenance or so that it is barely touching the ground If the
repairs under the machine, lower all bucket is firmly touching the ground, the
working equipment to the ground or in resistance will be great and it will be difficult
the lowermost position. to remove the pin.
• If maintenance must be performed with
the engine running, always work as a 2. Set the safety lock lever to the locked
two person team communicating each position and stop the engine.
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.
• When using a hammer, pins may fly out
or metal particles may be scattered.
This may lead to serious injury. 3. Remove the bolt (1).
· If hard metal parts such as pins, 4. Hammer the pin (2) out of the bucket.
bucket teeth, side cutter or bearings 5. Remove the bucket.
are hit with a hammer, wear protective Inspect the pin seal (3) and replace it if it is
gear such as safety goggles and deformed or damaged. (See next page.)
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.

Removing

5-58
 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
5-60.
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.
5-59
 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.

5-60
 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 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).

5-61
 MAINTENANCE
WHEN REQUIRED

DRAINING THE WATER FROM 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. Place a pan under the drain valve (7) to
catch fuel.
3. Open the drain valve (7) and drain the
water.
If the water does not drain easily, loosen
the plug (8).
4. Close the drain valve (7) and tighten the
plug (8).
Refer to “Bleeding air from the fuel
system” on page 6-8.

5-62
 MAINTENANCE
WHEN REQUIRED

LUBRICATING THE LEVERS AND PEDALS Offset 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.

5-63
 MAINTENANCE
WHEN REQUIRED

TILTING UP THE PLATFORM 2. Raise the safety lock lever to the lock
position, and then close the cab door.
For inspection and maintenance, the
platform is designed so that it can be tilted
up.

• Raising or lowering the platform while

the engine is running may cause the
machine to move, resulting in serious
injury or death. Stop the engine before
raising or lowering the platform.
• When the platform is tilted up, be sure
to firmly secure the platform with the 3. Open the fuel lid.
stopper (D) to prevent it from falling. 4. Raise the filler port (2) upright to secure it
When the stopper is removed to lower in the retraction position while pulling the
the platform, be careful not to be caught lever (1) toward you to release the lock.
between the platform and the main · The cover (3) is locked when the lever (1)
body. is toward you. The cover (3) is released
when the filler port (2) is pushed to move
IMPORTANT: Before the platform is tilted the lever (1) away from you (the lever (1)
up, to avoid the interference between the cannot be pushed by hand).
cab and the boom, fully offset the boom 5. Close the fuel lid.
to the right, fully extend the arm and the
bucket cylinders and lower the hoe
attachment to the ground.
IMPORTANT: When raising or lowering the
platform, be sure to raise the filler port (2)
upright and secure it in the retraction
position so that the filler port (2) does not
interfere with the cab.

Raising (Tilt up)

6. Loosen the bolts and remove the cover

(3). The cover (3) cannot be removed
without raising the filler port (2) upright in
the retraction position.

1. Select a firm, level surface, set the

machine to the posture shown in the
diagram above, ground the working
equipment, then stop the engine.
5-64
 MAINTENANCE
WHEN REQUIRED

Lowering

IMPORTANT: Before lowering the

platform, make sure that the filler port (2)
is in the retraction position.

1. Remove the stopper (D), and set it back to

the original position.
2. Push the upper part of the handrail (C) in
the rear direction of the vehicle and lower
the platform.
3. Tighten the lock bolts (A) and (B).
· Tightening torque: 135 N·m (99.6 ft-lb)
4. Install the cover (3).
5. Open the fuel lid.
6. Fold the filler port (2) toward you to secure
it in the fill position.
7. Close the fuel lid and lock it.
7. Remove the lock bolts (A) and (B).
8. Pull the upper part of the handrail (C) in
the forward direction of the vehicle and
slowly raise the platform.
(Tilt up: approx. 30°)
9. Lift the stopper (D) and insert it into the
platform’s holder to support the platform.
If you need to run the engine while the
platform is raised follow these steps.
10. Make sure that all levers and pedal are in
neutral positions.
11. Push the throttle controller to the low
idling position.
12. Start the engine.
13. Be sure to stop the engine after
inspection and maintenance.

5-65
 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.

5-66
 MAINTENANCE
WHEN REQUIRED

REPLACING THE RUBBER CRAWLERS Removal

• 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
the engine running, always work as a
two person team communicating each 1. Start the engine and raise the machine
other. body with the hoe attachment and the
· One person must sit in the operator’s dozer blade.
seat so that he/she can immediately 2. Stop the engine.
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.

IMPORTANT: When replacing the crawler

belts, replace the right and left belts at
the same time.
IMPORTANT: When the travel speed
button is set to the 2nd speed side while 3. Remove the valve cover (1) at the center
the engine is running, the tensioning of one of the crawler frames.
cylinder rods extend and the crawler belt 4. Turn the plug (2) counterclockwise and
tension is increased. Keep the engine at remove it.
the 1st speed when replacing. Do not set 5. Turn the stem (3) counterclockwise with a
to the 2nd unless for increasing tension. hex wrench to completely loosen the
tension of the crawler.
Note: This machine uses a hydraulic cylinder 6. Once the crawler belt is completely loose,
to adjust the tension of the crawler belts. It is tighten the stem (3) until it is firm.
not necessary to regularly perform · Tightening torque: 18.6 to 21.6 N·m
adjustments of the crawler belt tension. (13.7 to 15.9 ft-lb.)
7. Tighten the plug (2).
· Tightening torque: 18.6 to 21.6 N·m
(13.7 to 15.9 ft-lb.)
8. Do the same for the other side.

5-67
 MAINTENANCE
WHEN REQUIRED

Installation
1. Engage the crawlers around the left and
right sprockets.
2. Set the left and right crawlers on the
idlers.
3. Start the engine.
4. Press the travel speed button once to set
it to the 2nd speed side. The left and right
crawler belts are tightened simultaneously.

9. Slowly lower the dozer blade side of the

machine body. (Do not start the engine.)
10. Lower the machine body until the
crawlers contact the ground with the
maximum slack.
11. When the crawlers are disengaged from
the idlers, slide the crawlers to the
outside and remove them.
12. Remove the crawlers from the sprockets,
and then remove the crawlers from the
crawler frames. 5. Check that the crawler belts are properly
tightened.

6. For rubber crawlers, move the machine so

that the “M”, “J” or “∞” mark at the joint is
at the top center of the crawler frame.

5-68
 MAINTENANCE
WHEN REQUIRED

AK7G0361

7. Inspect the gap (A or B) between the

bottom surface of the frame at the center
of the crawler frame and the top surface of
the crawler.
The gap (A or B) must be within the
following range:

(A)........Rubber crawler
160 to 180 mm (6.3 to 7.1 in.)
(B).......Steel crawler
270 to 290 mm (10.6 to 11.4 in.)
(B).......Segmental rubber crawler
257 to 277 mm (10.1 to 10.9 in.)

Note: When the self-adjusting shoe tension

system is properly working, the shoe should
have the gap (A or B) as described above, at
the time of installation.
When the machine is lowered and driven in
2nd speed, the crawler belts will be
stretched to the correct tension. The values
of shoe tension (gap values) after the 2nd
speed travel are different from those
described above.

5-69
 MAINTENANCE
EVERY 2 YEARS

EVERY 2 YEARS
REPLACING THE RECEIVER DRYER
This operation requires experience. Ask your
sales or service dealer for it.

5-70
 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 5-46. 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.

5-71
5-72
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 Remedy procedure

1. Park the machine in a safe place.
2. Check if steam is coming out of the closed
engine hood.
• Do not open the engine hood when 3. If there is steam, stop the engine
steam is coming from it. The steam or immediately and contact your sales or
hot water may spurt out and cause service dealer for repair. If steam, is not
burns. coming out run the engine at low idle and
• Do not try to remove the radiator cap or let the water temperature cool down.
the drain plug when the cooling water is 4. When the water temperature gauge level
hot. Stop the engine, wait until the drops in the green zone, stop the engine.
engine and the radiator cool, and then 5. Perform the inspections and the remedies
slowly loosen the radiator cap to release listed below once the engine cools down.
the internal pressure. · Fan belt slack........... Adjust
• Before performing maintenance, stop Refer to page 5-26.
the engine and allow the machine to · Coolant level............ Add
cool down. Refer to page 5-18.
· Water leakage.......... Repair
The symptoms listed below indicate · Radiator fins............. Clean
overheating. Refer to page 5-39.
· Sediment in cooling system
................................ Clean
Refer to page 5-46.
If the problem persists after the above
remedies, contact your sales or service
dealer for repair.

• An alarm is sounded and the engine

emergency lamp and the coolant
temperature warning lamp start flashing.
• The water temperature gauge level is in the
red zone.
• The engine slows down and the engine
power decreases.
• Steam comes from the engine room.

6-3
 TROUBLESHOOTING
IF THE BATTERY GOES DEAD

IF THE BATTERY GOES DEAD Connecting the jumper cables

The symptoms below indicate that the IMPORTANT: Set the starter keys of the
battery is dead. booster vehicle and the dead machine to
• The starter motor does not turn or fails to the OFF position.
start the engine.
• The horn is too weak.

Remedy procedure
Start the engine using the booster battery on
the other vehicle (booster vehicle) and the
jumper cables.

• 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 1. Connect the clip of jumper cable (R) to the
result in battery explosion or positive (+) battery terminal of the dead
unexpected machine motion. machine.
· Do not allow the booster vehicle and 2. Connect the other clip of jumper cable (R)
the machine with a dead battery (dead to the positive (+) battery terminal of the
machine) to touch each other. booster vehicle.
· Do not allow the positive (+) and the 3. Connect the clip of jumper cable (B) to the
negative (–) clips of the jumper cables negative (–) battery terminal of the booster
to touch each other. vehicle.
· When connecting, attach the jumper 4. Connect the other clip of jumper cable (B)
cable to the positive (+) terminals first. to the engine block of the dead machine.
When disconnecting, remove the Connect the clip to a place as far from the
cable from the negative (–) terminal battery as possible.
(ground) first.
· Connect the last clip of the jumper Starting the engine
cable to a point as far away from the 1. Check that the clips are securely
battery as possible. connected to the terminals.
• Always wear the protective goggle when 2. Start the engine of the booster vehicle and
jump starting the engine by using the run it at high speed.
jumper cables. 3. Start the engine of the dead machine.

IMPORTANT: Use the jumper cables and

clips of a size suited to the capacity of
battery. Do not use damaged or corroded
jumper cables and clips.
IMPORTANT: Be sure that the battery of
the booster vehicle has the same
capacity as the battery of the dead
machine.
IMPORTANT: Be sure to connect the clips
securely.

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

If a light does not come on or the electrical Protected

system does not work, a fuse may be blown. Capacity Symbol
circuit
Inspect the fuses.
20A Light
10A Wiper
INSPECTING AND REPLACING THE FUSE
20A Lever lock
Controller
15A
power supply
If the fuse blows again soon after
replacement, then the electric system is OX controller
20A
likely faulty. It may pose a fire hazard if power supply
not properly repaired. Contact your sales Cab interior
25A
or service dealer for advice. power supply
25A Option (1)
1. Turn the starter key to the OFF position to
stop the engine. 25A AC motor
10A Immobilizer
Air conditioner
15A
compressor
20A Cab light

5A Switch lighting

Protected
Capacity Symbol
circuit
2. Open the fuse box cover (1). 10A Horn
3. Check for any blown fuses (2). 15A Starter switch
10A Feed pump
Fuel supply
25A
pump

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

fuse of the same capacity.

6-6
 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, there is
likely a break in the cartridge type fusible link
(2). Inspect the link by following the steps
below. If there is a break, please contact
your sales or service dealer.

1. Open the side cover.

2. Loosen the bolts and remove the cover
(1).
3. Inspect the fusible link (2).
(a): 75 A
(b): 75 A
(c): 45 A

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.

6-7
 TROUBLESHOOTING
RESTARTING AFTER ADDING FUEL

RESTARTING AFTER ADDING

FUEL
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.
4. Turn the ignition key to the ON position
and hold it for about 60 seconds.
The automatic air bleeder bleeds air from
the fuel system.
5. Start the engine and check for fuel
leakage.

Note: Air in the fuel system causes the

engine to fail to start or to have other
problems. Always bleed air when the fuel
tank is emptied or when there is air in the
fuel system.
1. Add fuel.

(S): Close
2. Open the engine hood.
3. Open the valve (2) of the water separator.

6-8
MEMO

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 and consult your sales or
service dealer referring to the “Vehicle error code list” or
“Engine error code list”.
Refer to “Vehicle error code list” on page 6-12 to 6-13.
Refer to “Engine error code list” on page 6-14 to 6-21.
ECM error There is a problem in the engine.
warning lamp If an error code is displayed on the multi-information
display, inform your sales or service dealer of the code
and ask for help.
Refer to “Multi-information display” on 2-14.
Refer to “Engine error code list” on page 6-14 to 6-21.
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.
Water Water is in the water separator. Drain water.
separator Refer to “Draining the water from the water separator” on
warning lamp page 5-62.

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 5-44.

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

warning lamp Refer to “Inspecting the fuel level” on page 5-20.

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” on page 2-36.

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
402 CAN 0 communication error
502 CAN communication error (EECU)
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
3700 Water separator alarm
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)
5613 Boom angle sensor error (high pressure)
5614 Boom angle sensor error (low pressure)
5623 Offset arm angle sensor error (high pressure)
5624 Offset arm angle sensor error (low pressure)

6-12
 TROUBLESHOOTING
VEHICLE ERROR CODE LIST

Error code Error details

6503 AUX1 slide switch voltage value error (too high)
6504 AUX1 slide switch voltage value error (too low)
6509 AUX1 slide switch neutral error
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 switch 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 changed
9991 Unknown model
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-information 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.

Error code
Error details DTC
SPN FMI
2 Crank speed sensor (Crank signal malfunction) P0336
522400
5 Crank speed sensor (No crank signal) P0337
2 Cam speed sensor (Cam signal malfunction) P0341
522401 5 Cam speed sensor (No cam signal) P0342
7 Cam speed sensor (Angle offset failure) P1341
523249 5 No signal on both crank and cam speed sensor P0008
3 Accelerator sensor 1 (Excessive sensor output) P0123
91
4 Accelerator sensor 1 (Insufficient sensor output) P0122
3 Accelerator sensor 2 (Excessive sensor output) P0223
28
4 Accelerator sensor 2 (Insufficient sensor output) P0222
522624 7 Dual accelerator sensor (closed position) failure P1646
522623 7 Dual accelerator sensor (open position) failure P1647
3 Accelerator sensor 3 (Excessive sensor output) P0228
29 4 Accelerator sensor 3 (Insufficient sensor output) P0227
8 Pulse sensor failure (Pulse communication) P1227
0 Accelerator sensor 3 failure (Foot pedal in open positon) P1126
28
1 Accelerator sensor 3 failure (Foot pedal in closed positon) P1125
3 Intake throttle opening sensor fault (High voltage) P02E9
51
4 Intake throttle opening sensor fault (Low voltage) P02E8

6-14
 TROUBLESHOOTING
ENGINE ERROR CODE LIST

Error code
Error details DTC
SPN FMI
3 EGR low pressure side sensor fault (High voltage) P0238
102 4 EGR low pressure side sensor fault (Low voltage) P0237
13 EGR low pressure side sensor fault (Abnormal learning value) P0236
3 EGR high pressure side sensor fault (High voltage) P0473
1209 4 EGR high pressure side sensor fault (Low voltage) P0472
13 EGR high pressure side sensor (Abnormal learning value) P0471
3 Cooling water temperature sensor fault (High voltage) P0118
4 Cooling water temperature sensor fault (Low voltage) P0117
110
Cooling water temperature sensor temperature abnormal
0 P0217
high (Overheat)
3 New air temperature sensor fault (High voltage) P0113
172
4 New air temperature sensor fault (Low voltage) P0112
3 Fuel temperature sensor fault (High voltage) P0183
174 4 Fuel temperature sensor fault (Low voltage) P0182
0 Fuel temperature sensor temperature abnormal high P0168
3 Rail pressure sensor fault (High voltage) P0193
157
4 Rail pressure sensor fault (Low voltage) P0192
3 DPF differential pressure sensor fault (High voltage) P2455
4 DPF differential pressure sensor fault (Low voltage) P2454
3251 DPF differential pressure sensor differential pressure
0 P2452
abnormal high
13 DPF differential pressure sensor (Abnormal learning value) P2453
3 DPF high pressure side sensor fault (High voltage) P1455
3609
4 DPF high pressure side sensor fault (Low voltage) P1454
3 DPF inlet temperature sensor fault (High voltage) P1428
3242 4 DPF inlet temperature sensor fault (Low voltage) P1427
0 DPF inlet temperature sensor temperature abnormal high P1436

6-15
 TROUBLESHOOTING
ENGINE ERROR CODE LIST

Error code
Error details DTC
SPN FMI
3 DPF intermediate temperature sensor fault (High voltage) P1434
4 DPF intermediate temperature sensor fault (Low voltage) P1435
3250 DPF intermediate temperature sensor temperature abnormal
1 P0420
low temperature
DPF intermediate temperature sensor temperature abnormal
0 P1426
high (Post-injection failure)
3 Atmospheric pressure sensor fault (High voltage) P2229
108 4 Atmospheric pressure sensor fault (Low voltage) P2228
10 Atmospheric pressure sensor characteristic fault P1231
3 EGR gas temperature sensor fault (High voltage) P041D
412
4 EGR gas temperature sensor fault (Low voltage) P041C
3 Intake manifold temperature sensor fault (High voltage) P040D
105
4 Intake manifold temperature sensor fault (Low voltage) P040C
3 Exhaust manifold temperature sensor fault (High voltage) P0546
173
4 Exhaust manifold temperature sensor fault (Low voltage) P0545
7 Main relay contact stuck P068B
1485
2 Main relay early opening P068A
5 Startup assist relay interrupted P0543
522243
6 Startup assist relay GND interrupted P0541
P0204
(4TNV),
5 Injector 1 open circuit (Inherent location of the injector)
P0203
(3TNV)
651 P0271
(4TNV), (4TNV),
6 Injector 1 coil short circuit
652 P0268
(3TNV) (3TNV)
P1271
(4TNV),
3 Injector 1 short circuit
P1262
(3TNV)

6-16
 TROUBLESHOOTING
ENGINE ERROR CODE LIST

Error code
Error details DTC
SPN FMI
5 Injector 2 open circuit (Inherent location of the injector) P0202
653 6 Injector 2 coil short circuit P0265
3 Injector 2 short circuit P1265
5 Injector 3 open circuit (Inherent location of the injector) P0201
654 6 Injector 3 coil short circuit P0262
3 Injector 3 short circuit P1262
5 Injector 4 open circuit (Inherent location of the injector) P0203
652 6 Injector 4 coil short circuit P0268
3 Injector 4 short circuit P1268
4257 12 Injector drive IC error P0611
Injector drive circuit (Bank 1) short circuit
2797 6 P1146
(4TN: Common circuit for No.1, No.4 and all 3TN cylinders)
Injector drive circuit (Bank 2) short circuit
2798 6 P1149
(4TN: Circuit for No.2 and No.3 cylinders)
523462 13 IQA corrected injection amount for injector 1 error P1648
523463 13 IQA corrected injection amount for injector 2 error P1649
523464 13 IQA corrected injection amount for injector 3 error P1650
523465 13 IQA corrected injection amount for injector 4 error P1651
3 High-pressure pump drive circuit (Low side VB short-circuit) P1641
522571 High-pressure pump drive circuit (Low side GND short-
6 P1643
circuit)
3 High-pressure pump drive circuit (High side VB short-circuit) P0629
High-pressure pump drive circuit (High side GND short-
633 6 P1642
circuit)
5 High-pressure pump drive circuit (Open circuit) P0627
6 High-pressure pump drive circuit (Drive current (high level)) P062A
522572
11 High-pressure pump drive circuit (Pump overload error) P1645

6-17
 TROUBLESHOOTING
ENGINE ERROR CODE LIST

Error code
Error details DTC
SPN FMI
0 Actual rail pressure rise error P0088
Rail pressure deviation error during the actual rail pressure
18 P0094
drop
157
Rail pressure deviation error during the actual rail pressure
15 P0093
rise
16 PLV open valve P000F
523469 0 Rail pressure fault (The times of PLV valve opening error) P1666
523470 0 Rail pressure fault (The time of PLV valve opening error) P1667
Rail pressure fault (The actual rail pressure is too high during
523489 0 P1668
PRV limp home)
Rail pressure fault (Controlled rail pressure error after PLV
523468 9 P1665
valve opening)
Rail pressure fault (Injector B/F temperature error during
523491 0 P1669
PLV4 limp home)
Rail pressure fault (Operation time error during RPS limp
523460 7 P1670
home)
190 16 Overspeed P0219
5 No-load of throttle valve drive H bridge circuit P0660
3 Power short circuit of throttle valve drive H bridge output 1 P1658
2950
4 GND short circuit of throttle valve drive H bridge output 1 P1659
6 Overload on the drive H bridge circuit of throttle valve P1660
VB Power short circuit of throttle valve drive H bridge output
3 P1661
2951 2
4 GND short circuit of throttle valve drive H bridge output 2 P1662
522596 9 TSC1 (CAN message) reception time out (SA1) U0292
522597 9 TSC1 (CAN message) reception time out (SA2) U1301
522599 9 Y_ECR1 (CAN message) reception time out U1292
522600 9 Y_EC (CAN message) reception time out U1293
522601 9 Y_RSS (CAN message) reception time out U1294
522603 9 VH (CAN message) reception time out U1296
522605 9 Y_ECM3 (CAN message) reception time out U1298

6-18
 TROUBLESHOOTING
ENGINE ERROR CODE LIST

Error code
Error details DTC
SPN FMI
31 VI (CAN message) reception time out U0168
237
13 VI (CAN message) reception data fault U3002
522609 9 Y_ETCP1 (CAN message) reception time out U1300
522618 9 EBC1 (CAN message) reception time out U1302
522619 9 Y_DPFIF (CAN message) reception time out U1303
522610 9 CAN1 (for EGR): Reception time out U010B
Exhaust throttle (CAN message from the exhaust throttle
522611 9 U1107
time out)
0 EGR over-voltage fault P0404
1 EGR under-voltage fault P1404
2791 7 EGR feedback malfunction P1409
9 EGR ECM data fault U0401
12 Open circuit between the EGR motor coils P0403
522579 12 Short circuit between the EGR motor coils P1405
522580 12 EGR position sensor malfunction P0488
522581 7 EGR stuck open valve malfunction P148A
522582 7 EGR initialization malfunction P049D
522183 1 EGR high temperature thermistor malfunction P1410
522184 1 EGR low temperature thermistor malfunction P1411
522617 12 EGR target value out of range U1401
522746 12 Exhaust throttle (Voltage fault) P1438
522747 12 Exhaust throttle (Motor fault) P1439
522748 12 Exhaust throttle (Sensor system fault) P1440
522749 12 Exhaust throttle (MPU fault) P1441
522750 12 Exhaust throttle (PCB fault) P1442
522751 19 Exhaust throttle (CAN fault) P1443
630 12 EEPROM memory deletion error P0601
522576 12 EEPROM memory read error P160E

6-19
 TROUBLESHOOTING
ENGINE ERROR CODE LIST

Error code
Error details DTC
SPN FMI
522578 12 EEPROM memory writing error P160F
522585 12 ECU internal fault (CY146 SPI communication fault) P1613
522588 12 ECU internal fault (Excessive voltage of supply 1) P1608
522589 12 ECU internal fault (Insufficient voltage of supply 1) P1617
522590 12 ECU internal fault (Sensor supply voltage error 1) P1609
522591 12 ECU internal fault (Sensor supply voltage error 2) P1618
522592 12 ECU internal fault (Sensor supply voltage error 3) P1619
522744 4 ECU internal fault (Actuator drive circuit 1 short to ground) P1626
522994 4 ECU internal fault (Actuator drive circuit 2 short to ground) P1633
523471 6 ECU internal fault (Actuator drive circuit 3 short to ground) P1467
523473 12 ECU internal fault (AD converter fault 1) P1469
523474 12 ECU internal fault (AD converter fault 2) P1470
523475 12 ECU internal fault (External monitoring IC and CPU fault 1) P1471
523476 12 ECU internal fault (External monitoring IC and CPU fault 2) P1472
523477 12 ECU internal fault (ROM fault) P1473
523478 12 ECU internal fault (Shutoff path fault 1) P1474
523479 12 ECU internal fault (Shutoff path fault 2) P1475
523480 12 ECU internal fault (Shutoff path fault 3) P1476
523481 12 ECU internal fault (Shutoff path fault 4) P1477
523482 12 ECU internal fault (Shutoff path fault 5) P1478
523483 12 ECU internal fault (Shutoff path fault 6) P1479
523484 12 ECU internal fault (Shutoff path fault 7) P1480
523485 12 ECU internal fault (Shutoff path fault 8) P1481
523486 12 ECU internal fault (Shutoff path fault 9) P1482
523487 12 ECU internal fault (Shutoff path fault 10) P1483
523488 0 ECU internal fault (Recognition error of engine speed) P1484
522323 0 Air cleaner clogged alarm P1101

6-20
 TROUBLESHOOTING
ENGINE ERROR CODE LIST

Error code
Error details DTC
SPN FMI
522329 0 Oil/water separator alarm P1151
5 Charge switch (Charge switch open circuit) P1562
167
1 Charge switch (Charge alarm) P1568
4 Oil pressure switch (Oil pressure switch open circuit) P1192
100
1 Oil pressure switch (Low oil pressure fault alarm) P1198
522573 0 DPF overaccumulation (Method C) P2463
522574 0 DPF overaccumulation (Method P) P1463
522575 7 DPF regeneration defect (Stationary regeneration failure) P2458
DPF regeneration defect (Stationary regeneration not-
522577 11 P2459
performed)
16 DPF OP interface (Ash cleaning request 1) P242F
3720
0 DPF OP interface (Ash cleaning request 2) P1420
16 DPF OP interface (Stationary regeneration standby) P1421
3719
0 DPF OP interface (Backup mode) P1424
3695 14 DPF OP interface (Reset regeneration prohibited) P1425
9 DPF OP interface (Recovery regeneration failure) P1445
3719
7 DPF OP interface (Recovery regeneration prohibition) P1446

6-21
 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 5-63.
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 5-63.
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 2-37.
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 5-21.
• 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 5-53.
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 5-30 and
5-67.
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 5-21.

6-22
 TROUBLESHOOTING
OTHER SYMPTOMS

Symptoms Major causes Remedies

Starter motor turns but • Insufficient fuel • Add fuel.
engine does not start Refer to page 5-20.
• Air in fuel system • Bleed air.
Refer to page 6-8.
• 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 5-30 and
5-67.
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 3-8.
• 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.

6-23
 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.

6-24
 TROUBLESHOOTING
LOWERING THE BOOM TO THE GROUND

LOWERING THE BOOM TO

THE GROUND
If the hoe attachment must be lowered to the
ground while the engine is stopped, use the
following procedure.

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.

6-25
 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
wire rope. • Permissible forces: 125.2 kN (28146 lbf)
• Make sure there is an operator on the Do not try to tow only one side.
machine being towed as well as on the
machine that is towing. 1. Attach the wire rope to the shackle (1).
• Never tow on slopes. 2. Fasten the shackle (1) to the towing holes
• Do not let anyone come near to the wire (2).
rope while towing. 3. Make sure that the wire rope is at a cone
angle of 20° or less to the travel frame.
IMPORTANT: Do not tow a machine if its 4. Move the machine to tension the wire
engine does not start or if the machine rope.
does not run. Doing so could damage the 5. Operate the machine slowly and tow.
machine being towed.
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.

6-26
 TROUBLESHOOTING
IF THE CAB IS DAMAGED

IF THE CAB IS DAMAGED

Immediately replace the damaged cab.

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

Cab part number: 03986-00007

6-27
6-28
SPECIFICATIONS

7-1
 SPECIFICATIONS
BASIC SPECIFICATIONS

BASIC SPECIFICATIONS
Standard Middle Long
Type
arm arm arm
MASS
8500 8520 8530
Rubber crawlers
(18735) (18780) (18810)
Operating mass kg (lb)
8695 8715 8730
Steel crawlers
(19170) (19210) (19240)
PERFORMANCE

Bucket capacity Heaped 0.245 (8.65)

m3 (cu. ft.)
(Standard bucket) Struck 0.185 (6.53)
Slew speed min-1 (rpm) 10 (10)

Rubber 1st 2.7 (1.68)

crawlers 2nd 5.2 (3.23)
Travel speed km/h (mph)
Steel 1st 2.6 (1.62)
crawlers 2nd 4.9 (3.04)
Gradeability (degrees) 30
37.9 38.1
Rubber crawlers 38 (5.51)
(5.50) (5.53)
Ground pressure kPa (psi)
39.3 39.4 39.5
Steel crawlers
(5.70) (5.71) (5.73)
Sound power level LWA 99
Noise level dB (A) Sound pressure
LpA 82
level
ENGINE
Manufacturer and model Yanmar 4TNV98CT-WTBZ
Net (ISO 14396) kW/min (hp/rpm)
-1
51.6/2000 (69.2/2000)
Rated output Net (ISO 9249/
kW/min-1 (hp/rpm) 49.6/2000 (66.5/2000)
SAEJ1349)
Displacement ml (cu.in.) 3318 (202.5)
Starter V-kW 12-3.0
Alternator V-kW 12-0.96
Battery (IEC 60095-1) V-A·h 12-90

7-2
MEMO

7-3
 SPECIFICATIONS
MACHINE DIMENSIONS

MACHINE DIMENSIONS

7-4
 SPECIFICATIONS
MACHINE DIMENSIONS

Unit: mm (inch)
Standard arm Middle arm Long arm
Item
Rubber crawlers
A Overall length 6160 (242.5) 6175 (243.1) 6285 (247.4)
B Upperstructure overall width 2170 (85.4)
2725 (107.4)
C Overall height
2735 (107.7)*
D Slew radius 1280 (50.3)
Clearance height under 715 (28.1)
E
upperstructure 720 (28.4)*
2210 (87)
F Crawler base
2180 (85.8)*
2855 (112.4)
G Crawler overall length
2830 (111.4)*
H Crawler overall width 2300 (90.6)
J Crawler shoe width 450 (17.7)
315 (12.3)
K Ground clearance of undercarriage
320 (12.6)*
Minimum radius of equipment and
L 2835 (111.6) 2880 (113.3)
attachment
Minimum radius of equipment at
M 1610 (63.5)
maximum front offset
P Offset distance of bucket (Left) 805 (31.6)
Q Offset distance of bucket (Right) 945 (37.1)
R Dozer blade width 2300 (90.6)
S Dozer blade height 500 (19.7)
T Front distance to axis of rotation 4755 (187.2) 4770 (187.7) 4795 (188.9)
Dozer blade distance to axis of
U 2055 (80.9)
rotation
V Boom offset angle (Left) 30°
W Boom offset angle (Right) 15°
X Overall length (dozer blade at rear) 6845 (269.5) 6860 (270) 6885 (271.1)

*: With steel crawlers

7-5
 SPECIFICATIONS
OPERATING RANGES

OPERATING RANGES

7-6
 SPECIFICATIONS
OPERATING RANGES

Unit: mm (inch)
Standard arm Middle arm Long arm
Item
Rubber crawlers
A Maximum reach 6870 (270.5) 7035 (277) 7195 (283.2)
Maximum reach at ground reference
B 6715 (264.3) 6885 (271) 7045 (277.4)
plane
4195 (165.1) 4375 (172.2) 4540 (178.8)
C Maximum digging depth
4185 (164.8)* 4365 (171.9)* 4535 (178.5)*
3160 (124.4) 3330 (131.1) 3495 (137.5)
D Maximum vertical digging depth
3150 (124.1)* 3320 (130.8)* 3485 (137.2)*
Reach at maximum vertical digging
E 4700 (185.1) 4750 (187) 4795 (188.7)
depth
6280 (247.3) 6375 (251) 6465 (254.5)
F Maximum height of cutting edge
6290 (247.6)* 6385 (251.3)* 6475 (254.8)*
4295 (169.1) 4390 (172.8) 4480 (176.4)
G Maximum dumping height
4305 (169.4)* 4400 (173.1)* 4490 (176.7)*
1765 (69.4) 1575 (62.1) 1405 (55.4)
H Minimum dumping height
1770 (69.7)* 1585 (62.4)* 1415 (55.7)*
J Dozer blade maximum lifting 525 (20.6)
K Dozer blade maximum lowering 490 (19.2)

*: With steel crawlers

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

Standard arm

AL9K007E

7-10
 SPECIFICATIONS
LIFTING CAPACITIES

Standard arm

7-11
 SPECIFICATIONS
LIFTING CAPACITIES

Middle arm

7-12
 SPECIFICATIONS
LIFTING CAPACITIES

Middle arm

7-13
 SPECIFICATIONS
LIFTING CAPACITIES

Long arm

7-14
 SPECIFICATIONS
LIFTING CAPACITIES

Long arm

7-15
7-16
 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.

√ :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)

Rated Bucket Standard arm Middle arm Long arm

Bucket capacity cutting width 1650 mm 1810 mm 2000 mm
m3 (cu.yd.) mm (inch) (65 in.) (71.3 in.) (78.7 in.)
750 W (S.T.D.) 0.245 (0.33) 750 (29.5) √ √ √
Total bucket mass: 600 kg (1318 lb.) or less

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. Fully open the cab door and fix it in place.
3. Open the fuse box cover (1).
4. Loosen the wing bolt (2).
5. Turn the selector valve lever (3) to change
the pattern.
6. Tighten the wing bolt (2) and fasten the
lever (3) in place.
7. Close the fuse box cover (1).
8. 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 Protected

traveling and stops when the machine stops Capacity Symbol
circuit
traveling.
If the alarm does not sound when the 20A Light
machine travels, the fuse may be blown. 10A Wiper
Inspect the fuses.
20A Lever lock
Controller
If the fuse blows again soon after 15A power supply,
replacement, then the electric system is travel alarm
likely faulty. It may pose a fire hazard if
not properly repaired. Contact your sales OX controller
20A
or service dealer for advice. power supply
Cab interior
25A
1. Turn the starter key to the OFF position to power supply
stop the engine. 25A Option (1)
25A AC motor
10A Immobilizer
Air conditioner
15A
compressor
20A Cab light

5A Switch lighting

Protected
2. Open the fuse box cover (1). Capacity Symbol
circuit
3. Check for any blown fuses (2).
10A Horn
15A Starter switch
10A Feed pump
Fuel supply
25A
pump

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

fuse of the same capacity.

8-8
 OPTIONS
OPTIONAL EQUIPMENT MASS

OPTIONAL EQUIPMENT MASS

Rubber crawlers
Machine mass kg (lb.)
(Not including operator) Standard arm Middle arm Long arm
8420 (18565) 8445 (18615) 8455 (18645)
OPTION
Steel crawlers 200 (440)
Segmental rubber crawler 266 (585)
Shoe guide 18 (40)
Center guide 21 (46)
Middle arm 20 (45)
Long arm 35 (75)
Auxiliary 3rd 30 (65)
Auxiliary hydraulic
lines Auxiliary 3rd +
50 (110)
Auxiliary 4th.
Roof guard (Level II: ISO 10262) 23 (50)
Front guard (Level II: ISO 10262) 42 (95)

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.

8-9
 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 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 tank.

8-10
 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

8-11
First Published June 2014 No.43192
Second Published September 2014

OPERATOR’S MANUAL

TB280FR Hydraulic excavator

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

Printed in Japan by STATION M Co., Ltd.

8-12
 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 Hydraulic Excavator
Manufacturer TAKEUCHI MFG. CO., LTD
205 Uwadaira, Sakaki-machi, Hanishina-gun, Nagano
389-0605, Japan
Model TB280FR
Engine type 4TNV98CT-WTBZ
Engine power 51.6 kW @ 2000 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