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  5. Operator's manual

Takeuchi TB215R Operator's manual

Manual is about: 215000003 MINI EXCAVATOR

Summary of TB215R

  • Page 1

    Tb215r tb 21 9 opera tor's manual e mini excavator warning read and understand these instructions. Failure to do so can cause injury or death. Tb 21 5r book no. Ac8e000 serial no. 215000003~ oetb215r-aa original instructions.

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    Safety alert symbol this symbol represents the safety alert. The message that follows the symbol contains important information about safety. Read and understand the message to avoid personal injury or death. It is the owner or employer’s responsibility to fully instruct each operator in the proper ...

  • Page 3

    0-1 signal words safety messages appearing in this manual and on machine decals are identified by the words “denger”, “warning” and “caution”. These signal words mean the following: danger indicates a hazard with a high level of risk which, if not avoided, will result in death or serious injury. Warn...

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    0-2 foreword this manual describes operation, inspection and maintenance of the machine, as well as safety instructions to be heeded during these operations. If you have any questions about the machine, please contact a takeuchi sales or service outlet. Introduction manual storage compartment a comp...

  • Page 5

    0-3 front, rear, left and right machine description ag7o012pe front left right rear this manual refers the front, rear, left and right of the machine as seen when sitting in the operator’s seat with the dozer blade visible to the front. Designated operations use this machine primarily for the follow...

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    0-4 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 i...

  • Page 7

    0-5 contents introduction .....................................0-2 machine description ........................0-3 safety ..............................................1-1 general precautions ................................ 1-2 precautions when preparing .................... 1-8 precautions when st...

  • Page 8

    0-6 cautions on maintenance .................... 5-2 service data ............................................ 5-4 fuel and lubricant table ........................ 5-4 regularly replace the hydraulic oil ........ 5-6 list of consumables ............................. 5-7 list of tools .................

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    0-7 specifications ..................................7-1 basic specifications ................................. 7-2 machine dimensions ................................ 7-4 lifting capacities ..................................... 7-9 options ............................................8-1 general preca...

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    0-8.

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    1-1 safety safety.

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    1-2 safety general precautions it is your responsibility to observe all pertinent laws and regulations and to follow the manufacture’s instructions on machine operation, inspection and maintenance. Virtually all accidents occur as the result of a failure to observe basic safety rules and precautions...

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    1-3 safety wear appropriate clothing and protective equipment ag7a004 • do not wear loose clothing or any accessory that can catch on controls or in moving parts. • do not wear oily or fuel stained clothing that can easily catch fire. • wear a hard hat, safety shoes, safety glasses, filter mask, heavy...

  • Page 14

    1-4 safety use a signal person and a flag person general precautions ag7a007 learn how to use the hand signals required for particular jobs and make sure who has the responsibility for signaling. • all personnel must fully understand all the signals. • the operator must respond to signals only from t...

  • Page 15

    1-5 safety avoid fire and explosion hazards general precautions keep flames away from fuel, oil, grease and antifreeze. Fuel is particularly flammable and dangerous. • when handling these combustible materials, keep lit cigarettes, matches, lighters and other flames or sources of flames away. • do not sm...

  • Page 16

    1-6 safety exhaust fumes from the engine is poisonous general precautions ag7a011 • do not operate the engine in an enclosed area without adequate ventilation. • if natural ventilation is not possible, install ventilators, fans, exhaust extension pipes or other venting devices. Handling asbestos dus...

  • Page 17

    1-7 safety using optional products • consult with takeuchi before installing optional attachments. Depending on the type of attachments or the combination of them, the attachment may come into contact with the operator’s compartment or the other parts of the machine. Make sure that the optional atta...

  • Page 18

    1-8 safety 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 ...

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    1-9 safety perform inspection and maintenance every day ag7a020 failure to identify or repair the irregularities or damage on machine can lead to accidents. • before operating, perform the specified inspection and make prompt repairs where necessary. • if a failure occurs and the operation becomes im...

  • Page 20

    1-10 safety 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. Precautions when starting ag7a022 • climb up/down the steps facing the machine and ho...

  • Page 21

    1-11 safety starting with jumper cables precautions when starting ag7a025 use jumper cables only in the recommended manner. Improper use of jumper cables can result in battery explosion or unexpected machine motion. Refer to “if the battery goes dead” for further instructions. After starting the eng...

  • Page 22

    1-12 safety 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 unti...

  • Page 23

    1-13 safety check the position of the undercarriage (tracks) before traveling precautions when operating ag7a032pe dozer blade 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 op...

  • Page 24

    1-14 safety cautions on traveling on slopes when traveling on slopes or grades, be careful that the machine does not tip (roll) over or slide. • never travel on slopes that are too steep for the machine to maintain its stability (maximum gradeability: 30°, lateral tipping angle: 10°). Note that in r...

  • Page 25

    1-15 safety operate the machine on snow or ice with 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 canno...

  • Page 26

    1-16 safety keep a safe distance from the overhead high-voltage cables precautions when operating ag7a041 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 p...

  • Page 27

    1-17 safety watch out for hazardous working conditions precautions when operating • never undercut a high bank. Doing so is dangerous as it may cause ground collapse. • do not operate in places where there is a danger of falling rocks. • maintain a safe distance between the machine and the edge of t...

  • Page 28

    1-18 safety • do not perform demolition work under the machine. There is a hazard that the machine may fall down, because the 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...

  • Page 29

    1-19 safety precautions when operating never slew (swing) sideways with a heavy load the machine can tip over more easily in the lateral direction than in the longitudinal direction. • do not slew (swing) sideways with a heavy load at the tip of the hoe attachment. In particular, do not slew (swing)...

  • Page 30

    1-20 safety precautions when operating cautions when towing when towing, serious injury or death could result, if performed incorrectly or the wire rope being used is inappropriate or not properly inspected. • it becomes dangerous if the wire rope breaks or becomes disengaged. Use a wire rope approp...

  • Page 31

    1-21 safety precautions when stopping park safely precautions when stopping ag7a058 • 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 barr...

  • Page 32

    1-22 safety precautions when transporting load/unload the machine safely precautions when transporting ag7f001pe ramp distance between ramps 15º or less stopper the machine may roll or tip over or fall while being loaded or unloaded. Take the following precautions: • select a firm, level surface and ...

  • Page 33

    1-23 safety hoist the machine safely • know and use correct crane signals. • check the hoisting equipment for damaged or missing parts on a daily basis and replace as necessary. • when hoisting, use a wire rope capable of lifting the machine mass. • hoist the machine in such a manner described in th...

  • Page 34

    1-24 safety precautions on maintenance display a “do not operate” alert sign severe injury could result if an unauthorized person should start the engine or touch controls during inspection or maintenance. • before performing maintenance, stop the engine, remove the key and take it with you. Precaut...

  • Page 35

    1-25 safety prohibit access by unauthorized persons ag7a068 do not allow unauthorized personnel in the work area while working. Be careful when grinding, welding or using a hammer. You could be injured by flying debris from the machine. Precautions on maintenance prepare work area • select a firm, lev...

  • Page 36

    1-26 safety stay clear of the moving parts ag7a072 • 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 flown or cut...

  • Page 37

    1-27 safety cautions when refueling precautions on maintenance • do not smoke or permit open flames while fueling or near fueling operations. • 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...

  • Page 38

    1-28 safety be careful with hot cooling systems precautions on maintenance ag7a082 do not remove the radiator cap or the drain plug when the cooling water is hot. Stop the engine and wait until the engine and the cooling water cool. Then, slowly loosen the radiator cap to release the internal pressu...

  • Page 39

    1-29 safety never disassemble the track adjuster precautions on maintenance ag7a087 there is a very strong spring contained in the track adjuster. If the track adjuster is accidentally disassembled, the spring can pop out, resulting in serious injury never disassemble the track adjuster. Be careful ...

  • Page 40

    1-30 safety disconnect the battery wiring ag7a090 precautions on maintenance disconnect the battery wiring before working on the electrical system or doing electric welding. Disconnect the negative (–) battery cable first. When reconnecting, connect the negative (–) battery cable last. Use caution wh...

  • Page 41

    1-31 safety periodically replace the safety-critical parts • to use the machine safely for a longer period, periodically add oil and perform inspection and maintenance. To improving the safely, replace the safety-critical parts like hoses and seat belts periodically. Refer to “safety-critical parts ...

  • Page 42

    1-32 safety have a takeuchi service agent repair 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...

  • Page 43

    1-33 safety 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 ...

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    1-34 safety safety signs (decals).

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    1-35 safety safety signs (decals) no.00085-01011.

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    1-36 safety safety signs (decals).

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    1-37 safety safety signs (decals).

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    1-38.

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    2-1 controls.

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    2-2 controls names of components names of components upperstructure 1. Canopy 2. Seat 3. Engine hood 4. Fuel tank 5. Hydraulic tank undercarriage 6. Crawler belt 7. Idler 8. Track roller 9. Shoe slide 10. Travel motor working equipment 11. Bucket 12. Bucket cylinder 13. Arm 14. Arm cylinder 15. Boom...

  • Page 51

    2-3 controls 1. Instrument cluster 2. Starter switch 3. Blade lever 4. Throttle lever 5. Safety lock lever 6. Right operating lever 7. Horn button 8. Selector lever 9. Boom swing pedal names of components 10. Travel lever/pedal 11. Travel speed switch 12. Auxiliary hydraulic pedal 13. Left operating...

  • Page 52

    2-4 controls covers starter key covers the starter key is used to start and stop the engine, as well as to lock and unlock the following components: • fuel lid • manual storage compartment • engine hood • covers maintenance cover a opening open this cover to perform a maintenance operation of the en...

  • Page 53

    2-5 controls fuel lid when opening and closing the fuel lid, be careful not to get your hands caught by the lid. For adding fuel, open this cover. Opening 1. Insert the starter key and turn it counterclockwise to unlock the fuel lid (1). Closing 1. Close the fuel lid (1). 2. Insert the starter key a...

  • Page 54

    2-6 controls engine hood • 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. ...

  • Page 55

    2-7 controls seat and seat belt seat (if equipped) adjust and secure the seat. Seat and seat belt (a) adjusting the backrest angle 1. Sit up and sit back in the chair. 2. Set the backrest to the desired angle by turning the handle (1). (b) fore-and-aft adjustment 1. Pull up the lever (2) and slide t...

  • Page 56

    2-8 controls high-back seat (if equipped) adjust and secure the seat. (a) adjusting the backrest 1. Sit up and sit back in the chair. 2. Pull up the lever (1), recline the backrest by using the spring force. Release the lever (1) at the desired angle to secure the backrest. (b) fore-and-aft adjustme...

  • Page 57

    2-9 controls seat and seat belt seat belt be sure to fasten the seat belt securely before starting the engine. Fastening the seat belt 1. Adjust the seat to the desired position for operation, sit up and sit back in the chair. 2. Pull the seat belt to the desired length. Ag7b023 b a 3. Make sure tha...

  • Page 58

    2-10 controls instrument cluster instrument cluster once the starter switch is turned to on, all lamps on the instrument cluster light up and the alarm sounds. Then, the battery charge warning lamp (3) and the engine oil pressure warning lamp (2) start flashing and an alarm sounds. The machine system...

  • Page 59

    2-11 controls indicators 6. Glow lamp this lamp goes out when the engine preheating is completed. 7. Travel speed lamp this lamp turns on when the travel speed button is set to the 2nd (high) speed. Meters 8. Water temperature gauge indicates the temperature of the engine coolant water. The led shou...

  • Page 60

    2-12 controls multi-data display 10. Lcd (liquid crystal display) it displays various data on hour meter, trip meter and the machine. Home screen 1. Key function display the key function display changes depending on the screens (home, menu and each setting) for actual operation, use the buttons, “a”...

  • Page 61

    2-13 controls function of each key the functions are as below in the home screen. The different functions appear in the other screens. A. Stopping alarm pressing the (a) key stops alarm. B. Work light/meter switching · pressing the (b) key turns on or off the work light. · pressing and holding the (...

  • Page 62

    2-14 controls menu screen instrument cluster press the (a) key to proceed to the screen selected by the bar. Press the (b) key to move the selection bar. Press the (c) key to return to the home screen. • data shows the coolant temperature and the trip meter for inspection and maintenance. Unlike the...

  • Page 63

    2-15 controls instrument cluster data screen (data) press the (a) key to proceed to the screen selected by the bar. Press the (b) key to move the selection bar. Press the (c) key to return to the menu screen. • trip meter (trip meter) for maintenance the trip meters for the engine oil, hydraulic oil...

  • Page 64

    2-16 controls instrument cluster • alarm setting (alarm) five patterns of alarm setting are available. Alarm function can be set to on or off within the five patterns. A. When the selection bar is at alarm, press the (a) key to proceed to the alarm setting screen (alarm set). B. Press the (a) key in ...

  • Page 65

    2-17 controls instrument cluster • alarm time setting mode sets the time for alarm. A. Select the item to be set in the alarm setting screen (alarm set). B. Press and hold the (b) key for at least three seconds to enter the alarm time setting mode. C. Press the (a) key in this screen to move the sel...

  • Page 66

    2-18 controls switches starter switch switches important: do not repeatedly switch the key from off to on and on to off over a short period. Doing so will cause engine breakdown. Off ......... Position for stopping the engine and inserting or removing the key. On .......... Position in which the eng...

  • Page 67

    2-19 controls levers and pedals safety lock lever • before standing up from the operator’s seat to, for example, adjust the operator’s seat, lower the working equipment to the ground, raise the safety lock lever to the lock position and then stop the engine. If any control is accidentally touched wh...

  • Page 68

    2-20 controls operating levers • before starting operation, carefully check which lever pattern you are going to use. • it is described using the iso pattern in this manual. Use these levers to operate the boom, arm, bucket and upperstructure. Refer to “lever pattern” on pages 3-6 and 3-7. Refer to ...

  • Page 69

    2-21 controls travel levers/pedals • 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 wh...

  • Page 70

    2-22 controls levers and pedals auxiliary hydraulic pedal keep the pedal cover to the locked position when not using the pedal. Stepping on a pedal accidentally when it is not locked may cause accidents. This pedal controls the flow of the oil in the auxiliary hydraulic circuit. (a) ...... Hydraulic ...

  • Page 71

    2-23 controls accessories accessories power sockets use only those electric products which comply with the specifications of these sockets. Use these sockets to connect the power supply. When using, be careful not to exceed 12v/5a. To use, open the cap (1). Armrest adjusting the height 1. Loosen the ...

  • Page 72

    2-24 controls auxiliary hydraulic lines first / second auxiliary hydraulic lines (if equipped) accessories oil may spurt out if pipes disconnected before releasing the pressure in the hydraulic system. • immediately after the engine is stopped, press each auxiliary hydraulic pedal and second auxilia...

  • Page 73

    2-25 controls • when disconnecting hoses, stand to the side and loosen them slowly to gradually release the internal pressure before removing. These lines deliver the hydraulic oil necessary for operating a hydraulic breaker, crusher or other attachments. (1)........First auxiliary hydraulic lines (...

  • Page 74

    2-26 controls selector valve (option) open ....... When using a hydraulic breaker (1-way flow) closed ..... When using a reversible attachment (2-way flow) change the direction of the hydraulic oil flow by opening or closing the selector valve (1) on the machine body. Second auxiliary hydraulic switch ...

  • Page 75

    2-27 controls accessories adjusting the stroke of auxiliary hydraulic pedal when a breaker is used, the pedal stroke must be adjusted so as not to activate the right auxiliary hydraulic line even if the b side of the pedal is accidentally depressed. When a general attachment is used, the pedal strok...

  • Page 76

    2-28 controls 6. Move the auxiliary 2nd switch several times to release the residual pressure in the circuitry. (if equipped) 7. Move all the control levers and pedals several times in all directions to release the pressure from the working equipment circuitry. 8. Raise the safety lock lever to enga...

  • Page 77

    3-1 operation.

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    3-2 operation before starting operation getting on or off the machine • do not jump on or down from the machine. Never attempt to get on or off the moving machine. Before starting operation • climb up/down the steps holding the handrail to support your weight in a three point secure stance (hand and...

  • Page 79

    3-3 operation starting and stopping the engine before starting the engine 1. Adjust the seat for a comfortable operating position. 2. Fasten the seat belt. Starting and stopping the engine 3. Check that the safety lock lever is in the locked position. 4. Check that all levers and pedals are in the n...

  • Page 80

    3-4 operation starting the engine • clear all personnel from the work area. • sound the horn to warn people around the machine. Important: do not run the starter motor for more than 15 consecutive seconds. If the engine fails to start, wait for 30 seconds, and then try again to start the engine. Nor...

  • Page 81

    3-5 operation 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 required, occasionally place a load or run the engine at medium speed. 1. Return the throttle lever, then run the engine at a ...

  • Page 82

    3-6 operation 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. Operating the machine left crawler forward right crawler forward left crawler reverse right c...

  • Page 83

    3-7 operation 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. Operating the machine left crawler forward right crawler forward left crawler reverse right crawler rever...

  • Page 84

    3-8 operation 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 s...

  • Page 85

    3-9 operation 5. Travel slowly forward and in reverse several times. Warm-up in cold climates 1. Perform the normal warm-up procedure. Operating the machine 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...

  • Page 86

    3-10 operation crawler width switching operate the machine with the maximum crawler width • always operate the machine with the crawler width extended to 1300 mm (51.2 in.) to maximize the machine stability. If the machine is operated with the crawler width narrowed (980 mm, 38.6 in.), the machine m...

  • Page 87

    3-11 operation operating the machine switching the blade width 1. Loosen bolts (1) and remove plate (2). 2. Attach the right plate (2) to the left, the left plate (2) to the right. 3. Tighten the plate (2) with bolts (1). Ac8d015 2 1.

  • Page 88

    3-12 operation operating the travel levers • 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 chec...

  • Page 89

    3-13 operation when the dozer blade is in front of the operator’s seat: to move forward: tilt the levers forward. To move backward: tilt the levers backward. Operating the machine when the dozer blade is behind the operator’s seat: to move forward: tilt the levers backward. To move backward: tilt th...

  • Page 90

    3-14 operation pivot turn turning to the left when stopped: to turn forward to the left: tilt the right lever forward. To turn backward to the left: tilt the right lever backward. To turn to the right, operate the left lever in the same way as for the right lever. Turning to the left while traveling...

  • Page 91

    3-15 operation stopping travel • park the machine on a flat, rigid and safe ground. Set the parking brake. If you must park on a slope, chock the tracks to block the machine. • if any control is accidentally touched when the safety lock lever is not locked, the machine may suddenly move and cause ser...

  • Page 92

    3-16 operation operating the working equipment • before starting operation, carefully check which lever pattern you are going to use. • it is described using the iso pattern in this manual. Operating the machine use the right operating lever to operate the boom and bucket. Use the left operating lev...

  • Page 93

    3-17 operation operating the arm operating the machine arm in: tilt the left operating lever backward. Arm out: tilt the left operating lever forward. Operating the bucket bucket load: tilt the right operating lever to the left. Bucket dump: tilt the right operating lever to the right. Boom swing le...

  • Page 94

    3-18 operation operating procedures prohibited operations • do not operate on bedrock (hard or soft). • do not slew while traveling. If you must operate the hoe attachment while traveling, operate at speeds slow enough so you have complete control at all times. Do not perform demolition or leveling ...

  • Page 95

    3-19 operation do not drive piles with the bucket or dig by banging the bucket operating procedures doing so will shorten the service life of the hoe attachment. Use the hydraulic force to dig. Do not perform operations using the machine’s dropping force putting excessive strain on the machine will ...

  • Page 96

    3-20 operation caution on folding the hoe attachment operating procedures be careful not to let the bucket to hit the dozer blade when the hoe attachment is being folded. Do not use the dozer blade as an outrigger pay attention to the dozer blade when digging when digging deeply with the dozer blade...

  • Page 97

    3-21 operation cautions on operating cautions on traveling cautions on operating traveling over obstacles (rocks, stumps, etc.) may put a great load on the machine body and may cause damage to it. Avoid crossing over obstacles whenever possible. If you must do so, keep the hoe attachment near the gr...

  • Page 98

    3-22 operation cautions on traveling on slopes • never travel on slopes that are too steep for the machine to maintain its stability. (maximum gradeability: 30°, lateral tipping angle: 10°) note that in reality, the machine’s stability becomes lower than the above values depending on the working con...

  • Page 99

    3-23 operation braking when descending slopes when descending slopes, the brakes are applied automatically once the travel levers are returned to the neutral position. If the crawler slips if the crawler slips while climbing a slope and impossible to travel, use the pulling force of the arm to climb...

  • Page 100

    3-24 operation getting out of mud if the machine gets stuck in mud, use the procedure below to get it out. If one crawler is stuck cautions on operating 1. Swing the bucket to the side of the crawler being stuck. 2. Set the arm and boom to an angle of 90 to 110°. 3. Press the bottom of the bucket (n...

  • Page 101

    3-25 operation digging side drains cautions on operating use the boom swing function to dig side ditches as shown in the figure. Loading ag7a040 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 sm...

  • Page 102

    3-26 operation parking the machine parking parking the machine ag7a058 • 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...

  • Page 103

    3-27 operation handling in cold climates preparing for cold climates starting engine in cold climates is not easy, and it becomes more difficult if the coolant freezes. Prepare for cold-climate problems as follows. Replacing the fuel and lubricant replace the hydraulic oil, engine oil and fuel with t...

  • Page 104

    3-28 operation 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 travel or operate the machine in the f...

  • Page 105

    3-29 operation cautions observe the following cautions when operating the machine: handling rubber crawlers • do not turn the undercarriage with the front of the machine body lifted using the hoe attachment (the upperstructure is not turned). Doing so will twist the crawlers with the load concentrat...

  • Page 106

    3-30 operation • when climbing in reverse, do not change directions at the point where the slope starts. • avoid traveling by setting one crawler on a 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 ...

  • Page 107

    4-1 transport.

  • Page 108

    4-2 transport loading and unloading the machine may roll or tip over or fall while being loaded or unloaded. Take the following precautions: • select a firm, level surface and keep sufficient distance from road shoulders. • secure the ramps of adequate strength and size to the truck bed. The slope of ...

  • Page 109

    4-3 transport ag7f003 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 4-5. Loading and unloading.

  • Page 110

    4-4 transport hoisting the machine • know and use the correct crane signals. • check the hoisting equipment for damaged or missing parts on a daily basis and replace as necessary. • when hoisting, use a wire rope capable of lifting the machine mass. • hoist the machine in such a manner described in ...

  • Page 111

    4-5 transport securing the machine after loading the machine at the specified position, secure it as described below. Transporting posture securing the machine 1. Lower the dozer blade. 2. Extend the bucket cylinder and arm cylinder fully, and then lower the boom. 3. Raise the safety lock lever to th...

  • Page 112

    4-6.

  • Page 113

    5-1 maintenance.

  • Page 114

    5-2 maintenance general maintenance overview to keep the machine in good condition and use if for a long period, perform the inspection and maintenance properly and safely following the procedures recommended by this manual. The inspection and maintenance items are divided into groups according to t...

  • Page 115

    5-3 maintenance general clean the installation surfaces when installing and removing parts, be sure that the surfaces of contact of the parts are clean. If the sealing grooves of the surface of contact are damaged, consult your sales or service dealer for repair or release. Seals and split pins • be...

  • Page 116

    5-4 maintenance 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 br...

  • Page 117

    5-5 maintenance service data * : 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). F...

  • Page 118

    5-6 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 dam...

  • Page 119

    5-7 maintenance 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 system hydraulic oil return filter element 15511-01300 every 500 hrs after the initial 50 hrs. Engine lubrication sys...

  • Page 120

    5-8 maintenance service data list of tools code part name part no. Remarks 1 spanner 19100-47081 10 - 12 2 spanner 19100-47082 14 - 17 3 screwdriver 19100-06112 (+) (–) replaceable shank 4 filter wrench 19100-96081 5 monkey wrench 16904-00250 250 mm 6 pliers 16905-00200 200 mm 7 spanner 16901-00013 ...

  • Page 121

    5-9 maintenance 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 ...

  • Page 122

    5-10 maintenance 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 p...

  • Page 123

    5-11 maintenance 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...

  • Page 124

    5-12 maintenance maintenance list maintenance list inspection and maintenance item page walk-around inspection inspecting by opening the engine hood and covers 5-14 inspecting by walking around the machine 5-15 inspecting while sitting in the operator’s seat 5-15 daily inspection (every 10 hours) in...

  • Page 125

    5-13 maintenance maintenance list inspection and maintenance item page every 500 hours replacing the hydraulic oil return filter 5-38 replacing the water separator filter 5-38 replacing the fuel filter 5-39 every 1000 hours replacing the travel motor gear oil * 5-40 cleaning the engine cooling system 5...

  • Page 126

    5-14 maintenance 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 insi...

  • Page 127

    5-15 maintenance inspecting by walking around the machine 4. Check lights for dirt, damage and burnt out bulbs. 5. Check attachments and hoses for damage. 6. Check the bucket, bucket teeth and side cutter for wear, damage and looseness. 7. Check the hook, slip stopper and hook mount of buckets with ...

  • Page 128

    5-16 maintenance daily 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...

  • Page 129

    5-17 maintenance inspecting and replenishing the engine oil stop the engine and allow the machine to cool down before performing maintenance. Inspection daily inspection (every 10 hours) 1. Open the engine hood. 2. Take out the dipstick (1) and wipe the oil off with a rag. 3. Fully reinsert the dips...

  • Page 130

    5-18 maintenance inspecting the water separator • do not smoke or permit open flames while handling fuel or working on the fuel system. • stop the engine in a well-ventilated place and allow it to cool down before performing maintenance. • clean up spilled fuel immediately. Daily inspection (every 10...

  • Page 131

    5-19 maintenance inspecting the hydraulic oil tank 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 oi...

  • Page 132

    5-20 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 (2) removed, set the safety lock levers to the released position. · hydraulic tank pressurization posture 3. Fully extend the bucket, arm, boom, swing...

  • Page 133

    5-21 maintenance 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. Note: it is not necessary to l...

  • Page 134

    5-22 maintenance 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 cool down before performing maintenance. • the engine, muffler, radiator, hydraulic lines, sliding parts and many other parts of the machine are hot...

  • Page 135

    5-23 maintenance 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 ...

  • Page 136

    5-24 maintenance after the initial 50 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 en...

  • Page 137

    5-25 maintenance after the initial 50 hours (only for new machines) 4. Loosen the hose bands and remove the hose (5) from the flange (6). 5. Loosen the bolts to take out the flange (6). 6. Remove the return filter (7). 7. Install a new return filter. 8. Reassemble the flange (6) and the hose (5). 9. Insp...

  • Page 138

    5-26 maintenance every 50 hours every 50 hours inspecting and adjusting the crawler tension • if you must work beneath the raised machine or working equipment, always use wood blocks, jack-stands or other rigid and stable supports. Never get under the machine or working equipment if they are not suf...

  • Page 139

    5-27 maintenance every 50 hours (a) rubber crawler 59 to 64 mm (2.3 to 2.5 in.) adjustment increasing the tension 1. Remove the cover (1). 2. Inject grease through the grease fitting (3) of the grease discharge valve (2) with a grease gun. 3. Inspect the crawler tension. Decreasing the tension 1. Rem...

  • Page 140

    5-28 maintenance lubricating the slew bearing do not slew while lubricating. Doing so is dangerous, as you may get caught in the machine. 1. Stop the engine with the machine in the posture shown on the figure above. 2. Use the grease gun to grease the grease fitting (1). Every 50 hours 3. Start the en...

  • Page 141

    5-29 maintenance draining the water from the fuel tank • do not smoke or permit open flames while handling fuel or working on the fuel system. • never remove the fuel cap or add fuel when the engine is running or still hot. Do not spill fuel on the hot surface of the machine. • fill the fuel tank in ...

  • Page 142

    5-30 maintenance inspecting the battery fluid level and replenishing • 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). • ba...

  • Page 143

    5-31 maintenance • if the fluid level cannot be checked by fluid level lines: every 50 hours 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 ...

  • Page 144

    5-32 maintenance every 100 hours cleaning the water separator • do not smoke or permit open flames while handling fuel or working on the fuel system. • stop the engine in a well-ventilated place and allow it to cool down before performing maintenance. • clean up spilled fuel immediately. 1. Open the ...

  • Page 145

    5-33 maintenance after the initial 250 hours (only for new machines) replacing the travel motor gear oil • stop the engine and allow the machine to cool down before performing maintenance. · the travel motor is hot immediately after the engine is stopped. Touching it will cause burns. · the gear oil...

  • Page 146

    5-34 maintenance every 250 hours replacing the engine oil and the oil filter refer to “replacing the engine oil and the oil filter” on page 5-22. Every 250 hours inspecting and adjusting the fan belt refer to “inspecting and adjusting the fan belt” on page 5-23. Cleaning the air cleaner • stop the en...

  • Page 147

    5-35 maintenance every 250 hours 7. Clean the primary element (3) with dried compressed air (294 to 490 kpa or 43 to 71 psi). First blow the air from the inside of the element along the pleats. Then blow the air from the outside and finally from the inside again. 8. Light up the inside of the primary...

  • Page 148

    5-36 maintenance cleaning the radiator fins and oil cooler fins wear required appropriate equipment such as protective goggle and filter mask when using compressed air, as metal fragments or other objects can fly and cause serious injury. Important: be careful not to damage the fins when cleaning. • wh...

  • Page 149

    5-37 memo.

  • Page 150

    5-38 maintenance every 500 hours every 500 hours replacing the hydraulic oil return filter refer to “replacing the hydraulic oil return filter” on page 5-24. Replacing the water separator filter • do not smoke or permit open flames while handling fuel or working on the fuel system. • stop the engine i...

  • Page 151

    5-39 maintenance 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. Every 500 hours 1. Open the eng...

  • Page 152

    5-40 maintenance every 1000 hours replacing the travel motor gear oil refer to “replacing the travel motor gear oil” on page 5-33. Every 1000 hours cleaning the engine cooling system • stop the engine and allow the machine to cool down before performing maintenance. · the engine, muffler, radiator an...

  • Page 153

    5-41 maintenance every 1000 hours 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 low...

  • Page 154

    5-42 maintenance replacing the air cleaner element 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 these parts will cause burns. Important: d...

  • Page 155

    5-43 maintenance every 1000 hours inspecting and adjusting the engine valve clearance this operation requires experience. Ask your sales or service dealer for it. Retightening the engine cylinder head bolt this operation requires experience. Ask your sales or service dealer for it..

  • Page 156

    5-44 maintenance every 1500 hours inspecting and cleaning the engine fuel injectors this operation requires experience. Ask your sales or service dealer for it. Every 1500 hours inspecting the crankcase breather system this operation requires experience. Ask your sales or service dealer for it..

  • Page 157

    5-45 maintenance every 2000 hours lapping the engine valve seats this operation requires experience. Ask your sales or service dealer for it. Every 2000 hours.

  • Page 158

    5-46 maintenance 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 stoppe...

  • Page 159

    5-47 maintenance 8. Remove the return filter (7). 9. Place a pan for catching the waste oil under the drain plug (9). 10. Loosen the drain plug (9) and drain the hydraulic oil. 11. Loosen the hose bands and remove the hose (4). 12. Loosen the bolts and remove the flange (10). 13. Remove the suction st...

  • Page 160

    5-48 maintenance when required replacing the bucket teeth 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. • t...

  • Page 161

    5-49 maintenance installation 1. Clean the section where the teeth are to be installed. If there is gravel or mud on the section, the tooth point may not go in all the way. 2. Put the teeth into the bucket. 3. If the teeth are not secured, insert a shim to reduce the clearance. 4. Insert the bolt fr...

  • Page 162

    5-50 maintenance replacing the bucket • before performing maintenance or repairs under the machine, lower all working equipment to the ground or in the lowermost position. • if maintenance must be performed with the engine running, always work as a two person team communicating each other. · one per...

  • Page 163

    5-51 maintenance installation when required 1. Set the o-ring (4) on the bucket as shown on the figure above. 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 ...

  • Page 164

    5-52 maintenance lubricating the levers 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. Operatin...

  • Page 165

    5-53 maintenance inspecting the rubber crawlers 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 w...

  • Page 166

    5-54 maintenance replacing the rubber crawlers • if you must work beneath the raised machine or working equipment, always use wood blocks, jack-stands or other rigid and stable supports. Never get under the machine or working equipment if they are not sufficiently supported. • if maintenance must be ...

  • Page 167

    5-55 maintenance installation 1. Use the working equipment to lift the body. When required 2. Set the rubber crawler on the sprocket. 3. Set an iron pipe (1) in the rubber crawler and turn the sprocket slowly in the reverse direction. 4. Turn until the iron pipe (1) is directly next to the idler and...

  • Page 168

    5-56 maintenance maintenance during extended storage period storage procedures if the machine is to be stored for 30 days or more, store it indoors. If it must be stored outdoors, park the machine on a surface laid with lumber on a flat ground, and place a waterproof cover over it so that it stays dr...

  • Page 169

    6-1 troubleshooting.

  • Page 170

    6-2 troubleshooting symptoms that are not malfunctions the symptoms listed below are not malfunctions. Symptoms that are not malfunctions ag7j002 • the arm retracting speed momentarily slows down when it reaches an almost vertical position while the engine is running at low speed. Ag7j003 • the buck...

  • Page 171

    6-3 troubleshooting if the engine overheats • do not open the engine hood and covers when steam is coming from it. The steam or hot water may spurt out and cause burns. • do not try to remove the radiator cap or the drain plug when the cooling water is hot. Stop the engine, wait until the engine and...

  • Page 172

    6-4 troubleshooting if the battery goes dead the symptoms below indicate that the battery is dead. • the starter motor does not turn or fails to 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...

  • Page 173

    6-5 troubleshooting 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 othe...

  • Page 174

    6-6 troubleshooting if a fuse blows if a light does not come on or the electrical system does not work, a fuse may be blown. Inspect the fuses. Inspecting and replacing the fuse if the fuse blows again soon after replacement, then the electric system is likely faulty. It may pose a fire hazard if not...

  • Page 175

    6-7 troubleshooting inspecting the fusible link if a fuse blows if the machine is not turned on after turning the starter switch to the on position, the cartridge type fusible link (1) is likely blown. Open the maintenance cover and inspect. If the fusible link is blown, please contact your sales or...

  • Page 176

    6-8 troubleshooting restarting after adding fuel bleeding air from the fuel system restarting after adding fuel 1. Add fuel. 2. Open the valve (2) of the water separator and the fuel filter. 3. Turn the starter key to the on position and hold it for about 10 to 15 seconds. The automatic air bleeder b...

  • Page 177

    6-9 troubleshooting if a warning lamp flashes if an alarm is sounded or a warning lamp starts flashing during operation, park the machine in a safe place and perform the remedy procedures described below. Warning lamp lamp name causes and remedies engine emergency lamp there is a problem in the engin...

  • Page 178

    6-10 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 do not move smoothly • insufficien...

  • Page 179

    6-11 troubleshooting other symptoms symptoms major causes remedies slewing is not possible or not smooth • insufficient grease on slew bearing • grease the bearing. Refer to page 5-28. Hydraulic oil temperature is too high • hydraulic oil level too low • add up to the specified level. Refer to page 5-...

  • Page 180

    6-12 troubleshooting 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. This operation is dangerous and requires experience. Ask your sales or service dealer for it. Procedure • keep away from the working area...

  • Page 181

    6-13 troubleshooting towing when towing, serious injury or death could result, if performed incorrectly or the wire rope being used is inappropriate or not properly inspected. • it becomes dangerous if the wire rope breaks or becomes disengaged. Use a wire rope appropriate for the required tractive ...

  • Page 182

    6-14 troubleshooting if the cab or canopy is damaged immediately replace the damaged cab or canopy. Serious injury or death may occur if the machine is operated with damaged cab/canopy. Do not operate the machine until the replacement is complete. Do not try to repair the damaged cab or canopy by we...

  • Page 183

    7-1 specifications.

  • Page 184

    7-2 specifications basic specifications type canopy mass operating mass kg (lb) rubber crawlers 1575 (3470) performance bucker capacity (standard bucket) m 3 (cu. Ft.) heaped 0.038 (1.34) struck 0.028 (0.99) slew speed min -1 (rpm) 9.2 (9.2) travel speed km/h (mph) rubber crawlers 1st 2.2 (1.37) 2nd...

  • Page 185

    7-3 memo.

  • Page 186

    7-4 specifications machine dimensions machine dimensions.

  • Page 187

    7-5 specifications unit: mm (inch) item rubber crawlers a overall length 3445 (135.6) b upperstructure overall width 980 (38.5) c overall height 2345 (92.2) d slew radius 720 (28.3) e clearance height under upperstructure 460 (18.1) f crawler base 1155 (45.6) g crawler overall length 1520 (59.9) h c...

  • Page 188

    7-6 specifications operating ranges.

  • Page 189

    7-7 specifications unit: mm (inch) item rubber crawlers a maximum reach 3815 (150.2) b maximum reach at ground reference plane 3760 (148.0) c maximum digging depth 2190 (86.2) d maximum vertical digging depth 1780 (70.1) e reach at maximum vertical digging depth 2705 (106.5) f maximum height of cutt...

  • Page 190

    7-8 memo.

  • Page 191

    7-9 specifications lifting capacities rated lift capacity chart • the loads in the charts do not exceed 87% of hydraulic lift capacity or 75% of tipping load. • figures marked with an asterisk (*) are hydraulically-limited capacities. • the mass of slings and any other lifting devices shall be deduc...

  • Page 192

    7-10 specifications lifting capacities.

  • Page 193

    7-11 specifications lifting capacities.

  • Page 194

    7-12.

  • Page 195

    8-1 options.

  • Page 196

    8-2 options general precautions safety precautions when removing or installing an attachment or optional part, take the following precautions. • consult with takeuchi before installing an optional attachment. • do not use any attachments not approved by takeuchi. Doing so may cause safety problems. ...

  • Page 197

    8-3 options cautions when operating attachments long attachments reduce stability of the machine. The machine may tip over if it loses the balance when traveling or slewing on slopes. Never perform the operations listed below as they are extremely dangerous. General precautions • traveling down the ...

  • Page 198

    8-4 options attachment combination table the table below shows which bucket should be installed when the machine is using a standard 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 appr...

  • Page 199

    8-5 options 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. Selecting a lever pattern switching the lever pattern (a) : is...

  • Page 200

    8-6 options hydraulic breaker for handling of the breaker, read the hydraulic breaker’s manual, provided separately. Hydraulic breaker do not use the breaker when the crawler width is narrowed! • always operate the machine with the crawler width extended to 1300 mm (51.2 in.) to maximize the machine...

  • Page 201

    8-7 options • do not pound with the cylinder fully extended or retracted (at the stroke end). Leave a margin of at least 50mm(2 in). 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 su...

  • Page 202

    8-8 options biodegradable oil biodegradable oil is a new type of hydraulic oil that is decomposed into carbon dioxide and water by microorganisms in the soil and water. It is highly safe for living organisms and offers advantages in term of environmental protection. • recommended biodegradable oil: ...

  • Page 203

    8-9.

  • Page 204

    8-10 first published march 2013 printed in japan by station m co., ltd. Operator’s manual no.41075 mini excavator tb215r edited and issued by takeuchi mfg. Co., ltd..

  • Page 205

    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 cal...