Summary of TL230

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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 ...

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    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 danger indicates a hazard with a high level of risk which, if not avoided, will result in death or serious injur...

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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...

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    0-3 front, rear, left and right machine description this manual refers the front, rear, left and right of the machine as seen when sitting in the operator’s seat with the bucket visible to the front. Designated operations use this machine primarily for the following operations: • hauling • leveling ...

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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...

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    0-5 contents introduction .....................................0-2 machine description ........................0-3 safety ..............................................1-1 general precautions ................................ 1-2 precautions when preparing .................. 1-11 precautions when sta...

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    0-6 transport .........................................4-1 loading and unloading ............................ 4-2 hoisting the machine ............................... 4-3 securing the machine .............................. 4-4 maintenance ....................................5-1 general ................

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    0-7 bleeding air from the fuel system ......... 6-8 error code list .......................................... 6-9 if a warning lamp flashes ....................... 6-10 other symptoms .................................... 6-12 lowering the lift arms to the ground ...... 6-14 towing .....................

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    0-8.

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    1-1 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 general precautions 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 glasse...

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    1-4 safety general precautions use a signal person and a flag person 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...

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    1-5 safety general precautions avoid fire and explosion hazards ag7a010 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. • d...

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    1-6 safety general precautions fire prevention when working in a certain environment, it is impossible to prevent combustible debris from collecting in the machine. This debris, in itself, may cause a fire; however, when mixed with fuel, oil or grease in a hot or confined place, the danger of fire is g...

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    1-7 safety 10. During daily operation of the machine, the occurrence of exhaust leaks are usually accompanied by a change or increase in engine exhaust noise levels. These audible warnings cannot be ignored. Should any exhaust leaks occur during operation, the machine must be shut down immediately a...

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    1-8 safety • to use a fire extinguisher in the most effectively way, follow the instructions below. · pull the pin at the top of the extinguisher that keeps the handle from being pressed. Break the plastic seal as the pin is pulled. · aim the nozzle at the base of the fire. Do not aim the nozzle at th...

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    1-9 safety general precautions exhaust fumes from the engine is poisonous 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...

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    1-10 safety general precautions be careful not to get crushed or cut • never put your hands, feet or other parts of your body between the machine body or bucket and lift arms, or between a cylinder and moving part on the working equipment. The sizes of these gaps change when the machine moves, and a...

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    1-11 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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    1-12 safety precautions when preparing always keep the machine clean • 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 pre...

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    1-13 safety precautions when preparing cautions in the operator’s compartment • 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’...

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    1-14 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. • when getting on or off the cab, first fully open the door to the locked position and...

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    1-15 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...

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    1-16 safety precautions when 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 operatin...

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    1-17 safety precautions when operating precautions on traveling and turning • traveling and turning should be performed with the bucket cylinder fully retracted and the bucket at a height of approximately 30 cm (12 in.) from the ground. • avoid sudden stops, starts and turns. Otherwise, the working ...

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    1-18 safety precautions when operating cautions on traveling on slopes do not perform any operation on a slope. The machine may lose its balance and tip over if the working equipment is operated on a slope. When traveling on slopes of 15 degrees or more, position the heavier end of the machine (fron...

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    1-19 safety precautions when the lift arms are in the float mode precautions when operating • it is very dangerous to set the lift arms to the float mode while the bucket is raised too high, as the bucket is likely to fall. Lower the bucket to a height of 30 cm (12 in.) or less above the ground before...

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    1-20 safety take care when handling unstable loads precautions when operating unstable loads such as round items, cylindrical items, and stacked plates may fall from the bucket. When handling unstable load, do not raise the bucket too high or tilt it backward too far. Do not suddenly stop or lower t...

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    1-21 safety keep a safe distance from the overhead high-voltage cables precautions when operating 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 co...

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    1-22 safety travel in narrow or crowded places when traveling in narrow sites, crowded places or indoors, operate the machine while carefully looking around the area and maintaining the safe speed to avoid contact accidents. Precautions when operating precautions when passing through tunnels or goin...

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    1-23 safety precautions when operating be careful with flying objects this machine is not equipped with protective equipment to protect the operator from flying objects. Do not use this machine in places where there are risks of the operator being hit by flying objects. Cautions when towing when towing...

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    1-24 safety precautions when stopping park safely precautions when stopping • 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, ca...

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    1-25 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 ...

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    1-26 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...

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    1-27 safety precautions on maintenance 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. Prepare work area • select a firm, lev...

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    1-28 safety stay clear of the moving parts precautions on maintenance 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 b...

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    1-29 safety precautions on tilting up the canopy (cab) • raising or lowering the canopy while the engine is running may cause the machine to move, and cause serious injury or death. Lower the working equipment to the ground and stop the engine before raising or lowering the canopy. • when the canopy...

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    1-30 safety precautions on maintenance handling of hoses 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. Be careful with hot and pressurized components a...

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    1-31 safety be careful with oil internal pressure pressure is maintained in the hydraulic circuit long after the engine has been shut down. • completely relieve the internal pressure before performing maintenance work. Precautions on maintenance ag7a083 • the hydraulic oil is high enough pressure to...

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    1-32 safety be careful with the high-pressure grease precautions on maintenance ag7a086 in the track adjuster, the grease has been injected under high pressure. If the tension is adjusted without following the prescribed procedure, the grease discharge valve may fly off, resulting in injury. • loosen...

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    1-33 safety precautions on maintenance 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 qu...

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    1-34 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 ...

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    1-35 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...

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    1-36 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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    1-37 safety safety signs (decals).

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    1-38 safety safety signs (decals).

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    1-39 safety safety signs (decals).

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    1-40 safety safety signs (decals).

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    2-1 controls.

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    2-2 controls names of components 1. Tail light 2. Hydraulic tank 3. Canopy 4. Safety bar 5. Front light 6. Lift arm stopper 7. Left control lever 8. Auxiliary hydraulic lines 9. Lift arms 10. Bucket cylinder 11. Bucket 12. Fuel filler cap 13. Lift cylinder 14. Travel motor 15. Rubber track 16. Track ...

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    2-3 controls names of components 1. Left control lever 2. Travel speed button 3. Slider switch (for auxiliary hydraulic) 4. Detent mode switch (for auxiliary hydraulic) 5. Flow selector switch (two-way/one-way) 6. Front wiper switch* 7. Rear wiper switch* 8. Safety bar 9. Seat 10. Auxiliary hydrauli...

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    2-4 controls covers ignition key the ignition key is used to start and stop the engine, as well as to lock and unlock the following components: • fuel filler cap • cab door • manual storage compartment • engine hood covers fuel filler port warning • do not smoke and keep away from heat or flame while ...

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    2-5 controls engine hood warning 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. Opening covers 1. Insert the ignition key and turn it counterclockwise to unlock the engine hood (1). 2. Remove ...

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    2-6 controls cab cab door warning • when getting on or off the cab, first open the door all the way until it is secured in the catch and check that it does not move. • be careful not to get your hands, feet or fingers caught by the door (1). If any part of the body is caught, serious injury could resu...

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    2-7 controls closing (from inside) 1. Remove the lock pin (5) from the pin hole on the cab to release the door lock. 2. Push the release lever (6) to the front to release the latch. 3. Grasp the handle (4) and slowly lower the door. 4. When the door reaches all the way down, grasp the handle (7) and...

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    2-8 controls closing (from outside) 1. Turn the handle (2) clockwise to release the latch. 2. Grasp the handle (4), and slowly lower the door while taking care not to get the hands or feet caught by the door. 3. Grasp the handle (3) and firmly pull the door to latch it. Cab side window 1. Grasp the c...

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    2-9 controls emergency exit rear window if you are trapped inside the cab, remove the rear window to get out. There are two ways to remove the rear window. In case of emergency kick off the rear window. Note that the glass may break. Be careful not to get injured. When necessary 1. Pull off the ring...

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    2-10 controls lift arm stopper danger • if you must work under the raised lift arms, use the lift arm stopper to securely support the lift arms. Never get under the lift arms and bucket if they are not sufficiently supported. • immediately repair or replace with a new one if any damage or missing par...

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    2-11 controls removing the stopper 1. Align the orientation of the hook (4) on the tip with that of the lock pin (1). 2. Pull out the lock pin (1) from the lift arm stopper (2). 3. Pick up the end loop of the spring (3) with your fingers, and then hang it onto the hook (5) of the lift arm stopper (2)...

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    2-12 controls seat and seat belt seat warning adjust and secure the seat. Seat and seat belt 1 2 3 4 a e b ag7b021 (a) adjusting the backrest warning • 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 caus...

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    2-13 controls seat belt caution 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. Seat and seat belt ag7b023 b a 3. Make...

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    2-14 controls instrument cluster warning lamps important: if a warning lamp flashes and an alarm is sounded, immediately stop all operations and check the corresponding component. Refer to “troubleshooting” on page 6-10 to 6-11. 1. Battery charge warning lamp this lamp flashes and an alarm is sounded ...

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    2-15 controls instrument cluster indicators 8. Glow lamp this lamp goes out when the engine preheating is completed. 9. Travel speed lamp this lamp lights up when the travel speed button is set to the 2nd (high) speed. 10. Arm float indicator lamp this lamp light up when the float button is pressed to...

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    2-16 controls multi-data display lcd multi-data display when the ignition key is turned to on, the hour meter screen appears following the message “check the engine oil”. Addition to the hour meter and the hour meter trip display, the battery voltage and error codes are displayed. Important: if an e...

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    2-17 controls 3. Battery voltage 4. Error code displays five two-digit error codes, with the latest code in the left. Refer to “error code list” on page 6-9. Important: if an error code appears, immediately stop the operation and contact a takeuchi sales or service outlet for help. 5. Press the butto...

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    2-18 controls switches ignition switch switches ag7b029 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. Preheat position for preheating the engine. Off ......... Position for stopping the engine and inserting or remo...

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    2-19 controls float button warning • it is very dangerous to set the lift arms to the float mode while the bucket is raised too high, as the bucket is likely to fall. Lower the bucket to a height of 30 cm (12 in.) or less above the ground before setting the lift arms to the float mode. • do not travel...

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    2-20 controls 2. To install the female connector or the cap (1), align the notches and turn it clockwise to tighten. Hdb34-18-14pn-059 total max. Working current: 20 a max. Working current at each terminal: 13 a switches auxiliary hydraulic switches auxiliary hydraulic buttons (a), (b) press auxilia...

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    2-21 controls 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. Change the operation mode of the auxiliary hydraulic switch (a) as follows. To set to the detent mode, pre...

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    2-22 controls switches travel speed button press this button to set the travel speed to 2nd (high) speed. Press it again to return to 1st (low) speed. Auxiliary low operation switch this switch is used to decrease the flow rate in the auxiliary hydraulic line so that the low- pressure operation can b...

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    2-23 controls front light switch when this switch is turned while the ignition switch is at on, the lights turn on as follows: o ........Off i ..........Meter light and front lights will be lit. Switches tail light switch when this switch is turned while the ignition switch is at on, the lights turn...

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    2-24 controls levers and pedal safety bar warning • before leaving the operator’s seat, raise the safety bar to engage the lock and stop the engine. If any controls are accidentally touched when the safety bar is not locked, the machine will suddenly move and cause serious injury or death. • be care...

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    2-25 controls right control lever use this lever to operate the lift arms and bucket. Refer to “lever pattern” on page 3-6. Refer to “operating the working equipment” on page 3-12. Levers and pedal left control lever use this lever to move forward and in reverse and to change directions. Refer to “l...

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    2-26 controls accessories air conditioner cautions on use ventilate periodically • when using the air conditioner over an extended period of time, open the windows about once each hour to let in fresh air. • your eyes may become irritated if you smoke while using the air conditioner. If this happens...

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    2-27 controls names of components 1. Defroster 2. Condenser 3. Receiver drier 4. Foot outlets 5. Rear outlets 6. Control panel 7. Compressor 8. Air conditioner unit 9. Inner filter 10. Outer filter control panel 11. Air conditioner switch 12. Temperature control dial 13. Fan switch accessories.

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    2-28 controls air conditioner switch 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. Accessories use this switch to turn on or off the air conditioner. When this switch is pressed while t...

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    2-29 controls outlets accessories move the louvers up and down or left and right to adjust the air flow direction and amount. Operation dehumidifying and heating (in cold climates or when the humidity is high) 1. Set the desired temperature by turning the temperature control dial to between the cente...

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    2-30 controls defrosting the windows note: if the air conditioner fan is set to high, 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 c...

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    2-31 controls external power socket (for eu) warning use only those electric products which comply with the specifications of this socket. Accessories use this socket to connect the external power supply. When using, be careful not to exceed 12v/5a. After use, pull out the plug and put the cap (1) on...

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    2-32 controls 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 th...

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    2-33 controls (7) tune button use this button to tune to a radio station. Press and hold this button ( or ) for two seconds or more to start seeking the audible stations. The seeking stops when a station is found. To cancel tuning in progress, press the button again. Pressing the button will start s...

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    2-34 controls presetting stations 1. Select the band (fm or am) and the station you want to preset. 2. To set the selected station to a preset button, choose the button to be set and then press and hold the button for three seconds or more. The number of the preset button chosen appears on the lcd. ...

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    2-35 controls resetting the radio if there are any problems, such as the abnormal display of frequency or failure of selection, reset the radio by pressing the power button and the zero button together. Note: that the memory containing the clock setting and the channel setting is cleared after reset...

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    2-36 controls auxiliary hydraulic lines (optional) warning oil may spurt out if the caps or filters are removed or pipes disconnected before releasing the pressure in the hydraulic system. • when removing plugs or disconnecting hoses, release the internal pressure before removing. • when disconnectin...

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    2-37 controls releasing residual pressure after the auxiliary hydraulic circuits have been used, pressure remains in the circuits. This is called the residual pressure. Release this residual pressure before disconnecting the lines. Accessories 1. Start the engine and lower the safety bar to the rele...

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    2-38 controls high-flow hydraulic system (if equipped) caution note that the high-output type brush cutter attachment can be used only if it is equipped with the easy brush-cleaning function and the proper cooling system, for a short period of time at a moderate ambient temperature. Pay careful atte...

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    3-1 operation.

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    3-2 operation before starting operation getting on or off the machine warning • 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 open the door to the locked position and check that it does not move. (if equipped ...

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    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 bar is in the lock position. 4. Check that all levers and the pedal are in the neutral...

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    3-4 operation starting the engine warning • 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 10 consecutive seconds. If the engine fails to start, wait for 30 seconds, and then try again to start the eng...

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    3-5 operation starting and stopping the engine 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. Run the engine at m...

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    3-6 operation operating the machine lever pattern warning before starting operation, be sure to check which lever pattern you are going to use. This manual explains the operation by using the pattern described below. Operating the machine travel forward lift arms lower travel reverse lift arms raise...

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    3-7 memo.

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    3-8 operation warming up the machine (hydraulic oil) warning 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 s...

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    3-9 operation warm-up in cold climates 1. Perform the normal warm-up procedure. 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. Inspection after warm-up after warmin...

  • Page 98

    3-10 operation traveling the machine warning • never allow anyone to enter the machine’s slewing radius and path. • signal your intention to move by sounding the horn. • traveling and turning should be performed with the bucket cylinder fully retracted and the bucket at a height of approximately 30 ...

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    3-11 operation moving the machine forward and backward 1. Operate the left control lever as below. Operating the machine to move forward: push the left control lever forward. To move backward: pull the left control lever backward. Traveling in 2nd (high) speed press the travel speed button on the le...

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    3-12 operation stopping travel warning • 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. • before standing up from the operator’s seat, raise the safety bar to engage the lock. If any controls are accidental...

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    3-13 operation operating the machine operating the lift arms to lower the lift arms: push the right control lever forward. To raise the lift arms: pull the right control lever backward. Operating the bucket to roll back: tilt the right control lever to the left. To dump: tilt the right control lever...

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    3-14 operation operating procedures prohibited operations warning • do not operate on bedrock (hard or soft). • if you must operate the lift arms and/or bucket while traveling, operate at speeds slow enough so that you have complete control at all times. Operating procedures do not perform any opera...

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    3-15 operation do not cut across or go diagonally across a slope. Doing so may cause the machine to tip over or the tracks to come off and/or extremely wear. Operating procedures do not use this machine beyond the specifications or overfill the bucket. Do not use the downward force of the bucket to dr...

  • Page 104

    3-16 operation do not fully extend the bucket cylinders, push the bucket into the ground and move the machine to use the traveling force for digging. Doing so could damage the bucket cylinders. Operating procedures.

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    3-17 operation cautions on operating cautions on traveling operating procedures 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 bucket near the ground, tra...

  • Page 106

    3-18 operation cautions on traveling on slopes warning • do not perform any operation on a slope. The machine may lose its balance and tip over if the working equipment is operated on a slope. • when traveling on a slopes of 15 degrees or more, position the heavier end of the machine (front or back,...

  • Page 107

    3-19 operation braking when descending slopes operating procedures when descending slopes, the brakes are applied automatically once the left control lever are returned to the neutral position. If the engine stops if the engine stops when descending a slope, set the left control lever to the neutral...

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    3-20 operation operations possible with this machine important: do not fully extend the bucket cylinders, push the bucket into the ground and move the machine to use the traveling force for digging. Doing so could damage the bucket cylinders. Scooping operating procedures lower the bucket to the gro...

  • Page 109

    3-21 operation raise the lift arms and tilt the bucket forward, then release it as the machine is driven forward. Next tilt the bucket forward and lower the front edge until it is slightly above the ground surface, then back the machine over the load that was just released. Backfilling with the bucke...

  • Page 110

    3-22 operation lower the bucket to the ground before setting the lift arms to the float mode. Tilt the bucket forward to stand it on its cutting edge, and then level the loose ground while driving in reverse. Loading operating procedures move the machine, stop close to the truck, and then raise the b...

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    3-23 operation parking the machine parking warning parking the machine • 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 112

    3-24 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 113

    3-25 operation handling rubber tracks rubber tracks 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 tracks from being damaged or coming off. Prohibitions do not travel or operate the machine in the followi...

  • Page 114

    3-26 operation cautions observe the following cautions when operating the machine: • avoid changing course abruptly or spin- turning on concrete surfaces whenever possible. Doing so may wear or damage the rubber tracks. • avoid drops that may expose the rubber tracks to strong shocks. • salt, potass...

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    3-27 operation • avoid traveling by setting one track on a slope or projecting portion and the other track on a flat surface (with the machine at a tilt of 10° or more). Travel with both tracks set on flat surfaces. • do not change directions when the tracks are slack as shown in the figure. Handling r...

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    3-28.

  • Page 117

    4-1 transport.

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    4-2 transport loading and unloading warning 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 s...

  • Page 119

    4-3 transport hoisting the machine warning • 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 descr...

  • Page 120

    4-4 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 bucket. 2. Raise the safety bar to the lock position. 3. Stop the engine, remove the ignition key and lock all locks. 4. Place t...

  • Page 121

    5-1 maintenance.

  • Page 122

    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 123

    5-3 maintenance 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 sure to...

  • Page 124

    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 125

    5-5 maintenance lubricant location type type by air temperature when to replace -4 14 32 50 68 86 104°f -20 -10 0 10 20 30 40°c engine oil pan diesel engine oil api: cf class or higher every 250 hrs. After the initial 50 hrs. Hydraulic oil tank diesel engine oil api: cf class every 1000 hrs. Engine ...

  • Page 126

    5-6 maintenance volume engine oil pan engine cooling system hydraulic oil tank fuel tank travel reduction gear upper limit 11.2 l (11.8 us qt.) lower limit 8.2 l (8.7 us qt.) 13.0 l (13.7 us qt.) system 58 l (15.3 us gal.) tank 38.7 l (10.2 us gal.) 75 l (19.8 us gal.) 1.0 l x 2 (1.06 us qt.) x 2 se...

  • Page 127

    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 1551102600 every 500 hrs after the initial 50 hrs. Pilot line filter elemen...

  • Page 128

    5-8 maintenance list of tools code part name part no. Remarks 1 spanner 1690001012 10-12 2 spanner 1690001113 11-13 3 spanner 1690001417 14-17 4 spanner 1690001922 19-22 5 spanner 1690002427 24-27 6 spanner 1690100030 30 7 spanner 1690100041 41 8 screwdriver 1690220205 (+) (–) replaceable shank 9 l-...

  • Page 129

    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 130

    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 131

    5-11 maintenance the material of the safety-critical part listed on the left tends to change over time and cause wear or deterioration. It is difficult to determine the degree of deterioration at the periodic inspection, and thus they need to be replaced with new ones after a certain time to maintain...

  • Page 132

    5-12 maintenance maintenance list inspection and maintenance item page walk-around inspection inspecting by opening the engine hood and rear door 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) inspecting and r...

  • Page 133

    5-13 maintenance inspection and maintenance item page every 250 hours replacing the engine oil and the oil filter 5-33 inspecting and adjusting the fan belt 5-33 inspecting and adjusting the compressor belt (ac) 5-33 replacing the air cleaner elements 5-34 cleaning the radiator fins and oil cooler fins...

  • Page 134

    5-14 maintenance walk-around inspection perform the following inspections every day before starting the engine for the first time. Warning • before operating, perform the walk-around inspections and make repairs immediately where necessary. • be sure to secure the rear door or radiator before working...

  • Page 135

    5-15 maintenance walk-around inspection 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 for wear, damage and looseness. 7. Check the handrail and steps for damage and loose bolts. 8. Check t...

  • Page 136

    5-16 maintenance daily inspection (every 10 hours) perform the following inspections every day before starting the engine for the first time. Warning • before operating, perform the daily inspections and make repairs immediately where necessary. • be sure to secure the rear door or radiator before wo...

  • Page 137

    5-17 maintenance inspecting and replenishing the engine oil warning 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 ...

  • Page 138

    5-18 maintenance inspecting the fuel level warning • do not smoke or permit open flames while handling fuel or working on the fuel system. • never remove the fuel cap or add fuel when the engine is running or still hot. Do not spill fuel on the hot surface of the machine. • fill the fuel tank in a we...

  • Page 139

    5-19 maintenance inspecting the hydraulic oil tank level and replenishing warning oil may spurt out if caps or filters are removed or pipes are disconnected before releasing the pressure in the hydraulic system. • when removing plugs or screws, or when disconnecting hoses, stand to the side and loose...

  • Page 140

    5-20 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. Daily inspection (every 10 hou...

  • Page 141

    5-21 maintenance after the initial 50 hours (only for new machines) replacing the engine oil and the oil filter warning 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...

  • Page 142

    5-22 maintenance after the initial 50 hours (only for new machines) replacing the hydraulic oil return filter warning • 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 afte...

  • Page 143

    5-23 maintenance replacing the pilot line filter warning • 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 burn...

  • Page 144

    5-24 maintenance inspecting and adjusting the fan belt warning • 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. Touch...

  • Page 145

    5-25 maintenance inspecting and adjusting the compressor belt (ac) warning • 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 st...

  • Page 146

    5-26 maintenance every 50 hours inspecting and adjusting the track tension warning • 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 ...

  • Page 147

    5-27 maintenance decreasing the tension every 50 hours 1. Remove the cover (1). 2. Slowly loosen (one turn) the grease discharge valve (2) with a spanner to discharge grease. If grease does not come out well, move the machine back- and-forth. 3. Tighten the grease discharge valve (2). · tightening t...

  • Page 148

    5-28 maintenance inspecting the battery fluid level and replenishing danger • 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...

  • Page 149

    5-29 maintenance • 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 reache...

  • Page 150

    5-30 maintenance inspecting the bucket stoppers (bolts/nuts) warning before performing maintenance or repairs under the machine, lower all movable working equipment to the ground or in the lowermost position. 1. Park the machine on a flat and rigid ground, and remove the bucket. 2. Retract the bucket...

  • Page 151

    5-31 maintenance every 100 hours cleaning the water separator warning • do not smoke or permit open flames while handling fuel or working on the fuel system. • stop the engine in a well-ventilated place and allow it to cool down before performing maintenance. • clean up spilled fuel immediately. • be...

  • Page 152

    5-32 maintenance after the initial 250 hours (only for new machines) replacing the travel motor gear oil warning • 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 ...

  • Page 153

    5-33 maintenance every 250 hours replacing the engine oil and the oil filter refer to “replacing the engine oil and the oil filter” on page 5-21. Every 250 hours inspecting and adjusting the fan belt refer to “inspecting and adjusting the fan belt” on page 5-24. Inspecting and adjusting the compresso...

  • Page 154

    5-34 maintenance replacing the air cleaner element warning stop the engine and allow the machine to cool down before performing maintenance. • the engine, muffler, radiator and many other parts of the machine are hot immediately after the engine is stopped. Touching these parts will cause burns. Impo...

  • Page 155

    5-35 maintenance cleaning the radiator fins and oil cooler fins warning • 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. • be sure to secure the rear door or radiator before ...

  • Page 156

    5-36 maintenance cleaning the air filters (ac) warning wear required appropriate equipment such as protective goggle and filter mask when using compressed air, as metal fragments or other objects can fly and cause serious injury. Clean the filters immediately after operating in dusty places. If the filt...

  • Page 157

    5-37 maintenance inspecting the refrigerant (gas) level (ac) warning • exposure of the eyes or hands to the cooler’s refrigerant could result in blindness or frostbite. Never touch the refrigerant or loosen the parts of the cooling circuit. • keep flames away if the refrigerant gas is leaking. • the ...

  • Page 158

    5-38 maintenance check list for refrigerant volume air conditioner normal abnormal high/low pressure pipe temperature high pressure pipe is hot (80 to 120°c or 176 to 248°f), low pressure pipe is cold (8 to 15°c or 46 to 59°f). Clear difference in temperature between the pipes. High pressure pipe is...

  • Page 159

    5-39 maintenance every 500 hours replacing the hydraulic oil return filter refer to “replacing the hydraulic oil return filter” on page 5-22. Every 500 hours replacing the pilot line filter refer to “replacing the pilot line filter” on page 5-23. Replacing the travel motor gear oil refer to “replacing...

  • Page 160

    5-40 maintenance adjusting or replacing the bucket stoppers (bolts/nuts) danger • if you must work beneath the raised lift arms, use the lift arm stopper to securely support the lift arms. Never get under the lift arms and bucket if they are not sufficiently supported. • immediately repair or replace...

  • Page 161

    5-41 maintenance every 500 hours 4. Start the engine, and raise the lift arm until the lift arm stopper (2) falls on the cylinder rod. 5. Slowly lower the lift arms until the lift arm stopper (2) hits against the edge of the cylinder tube and becomes fixed, and then stop the engine. 6. Insert the loc...

  • Page 162

    5-42 maintenance every 1000 hours cleaning the engine cooling system warning • stop the engine and allow the machine to cool down before performing maintenance. · the engine, muffler, radiator and many other parts of the machine are hot immediately after the engine is stopped. Touching these parts wi...

  • Page 163

    5-43 maintenance 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. ...

  • Page 164

    5-44 maintenance replacing the hydraulic oil and cleaning the suction strainer warning • stop the engine and allow the machine to cool down before performing maintenance. · the engine and the hydraulic system and many other parts of the machine are hot immediately after the engine is stopped. Touchi...

  • Page 165

    5-45 maintenance 6. Temporarily suspend the radiator/oil cooler (b). 7. Remove the split pin and pull out the pins (6). 8. Lift the radiator/oil cooler (b) and remove it. 9. Remove the plug (1). 10. Remove the return filter (5). Refer to “replacing the hydraulic oil return filter” on page 5-22. 11. Lo...

  • Page 166

    5-46 maintenance • cylinders 1. Start the engine, and let it run at a low- idling speed for 10 minutes. 2. Maintain the engine at low idle, then extend and retract each cylinder 4 or 5 times, without let them reach the stroke end. 3. Run the engine at high speed, then extend and retract each cylinde...

  • Page 167

    5-47 maintenance every 3000 hours inspecting and cleaning the engine fuel injectors this operation requires experience. Ask your sales or service dealer for it. Every 3000 hours inspecting the turbocharger (wash blower as necessary) this operation requires experience. Ask your sales or service deale...

  • Page 168

    5-48 maintenance when required replacing the bucket or attachment warning • use only the attachments recommended by us. Using the attachments not approved by us may cause safety problems. Also, it may adversely affect the machine’s operation or service life. • before performing maintenance or repair...

  • Page 169

    5-49 maintenance 8. Push both lock levers (2) until they are horizontal to engage the latch. 9. Check that the tips of the pins (4) are projecting through the bracket holes on the bucket to indicate that the latch is properly engaged. 10. If the pins (4) do not come down to the lock position, do not...

  • Page 170

    5-50 maintenance inspecting and replenishing the windshield washer fluid warning 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 wit...

  • Page 171

    5-51 maintenance inspecting the rubber tracks repair or replace the rubber tracks if their condition becomes as described below. Consult your sales or service dealer for repair or replacement. Rubber track replace the track if the entire track is stretched and cannot be adjusted. (1) lug replace if ...

  • Page 172

    5-52 maintenance tilting up the canopy (cab) for inspection and maintenance, the canopy is designed so that it can be tilted up. Warning • raising or lowering the canopy while the engine is running may cause the machine to move, resulting in serious injury or death. Stop the engine before raising or...

  • Page 173

    5-53 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 174

    5-54.

  • Page 175

    6-1 troubleshooting.

  • Page 176

    6-2 troubleshooting symptoms that are not malfunctions the symptoms listed below are not malfunctions. • the lift arms go up or stop by themselves at the stroke end, when the bucket operation is performed at the same time as the lowering of the lift arms. • the travel motor produces noise when stopp...

  • Page 177

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

  • Page 178

    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 179

    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 180

    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 warning if the fuse blows again soon after replacement, then the electric system is likely faulty. It may pose a fire hazar...

  • Page 181

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

  • Page 182

    6-8 troubleshooting restarting after adding fuel bleeding air from the fuel system warning be sure to secure the rear door or radiator before working the inside. 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...

  • Page 183

    6-9 troubleshooting error code list on the multi-data display, five error codes are displayed (the leftmost code is the most recent error). If an error code appears on the multi-data display, inform your sales or service dealer of the code and ask for help. Error code error details 01 repeated short-...

  • Page 184

    6-10 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 battery charge warning lamp there is a problem with ...

  • Page 185

    6-11 troubleshooting warning lamp lamp name causes and remedies pilot line filter warning lamp the hydraulic oil pilot line filter is clogged. Stop the engine and replace the filter immediately. Continuing to operate the machine while the lamp is flashing could damage the line filter and hydraulic equipm...

  • Page 186

    6-12 troubleshooting 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 control levers do not move smoothly • insufficient grease on the l...

  • Page 187

    6-13 troubleshooting symptoms major causes remedies hydraulic oil temperature is too high • hydraulic oil level too low • add up to the specified level. Refer to page 5-19. Starter motor turns but engine does not start • insufficient fuel • add fuel. Refer to page 5-18. • air in fuel system • bleed ai...

  • Page 188

    6-14 troubleshooting lowering the lift arms to the ground if the lift arms 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 warning • keep away from the work...

  • Page 189

    6-15 troubleshooting towing warning 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 t...

  • Page 190

    6-16.

  • Page 191

    7-1 specifications.

  • Page 192

    7-2 specifications basic specifications type canopy cab mass operating mass kg (lb) rubber tracks 3770 (8310) 3850 (8490) performance bucker capacity (standard bucket) m 3 (cu. Ft.) heaped 0.351 (12.4) struck 0.260 (9.18) travel speed km/h (mph) rubber tracks 1st 7.4 (4.6) 2nd 11.0 (6.84) gradeabili...

  • Page 193

    7-3 memo.

  • Page 194

    7-4 specifications machine dimensions machine dimensions.

  • Page 195

    7-5 specifications unit: mm (inch) item standard bucket rubber tracks a overall length 3430 (135.1) b overall length (without bucket) 2740 (107.8) c track base 1390 (54.7) d overall height 2130 (83.9)/2235 (88.0)* e ground clearance of undercarriage 310 (12.1) f overall width (without bucket) 1580 (...

  • Page 196

    7-6 specifications operating ranges operating ranges.

  • Page 197

    7-7 specifications unit: mm (inch) item standard bucket rubber tracks a maximum raised height of bucket 3905 (153.8) b bucket hinge pin height 3030 (119.3) c dumping clearance (at 45-degree forward tipping) 2370 (93.4) d dumping reach (at 45-degree forward tipping) 730 (28.8) e minimum turning radiu...

  • Page 198

    7-8.

  • Page 199

    8-1 options.

  • Page 200

    8-2 options general precautions safety precautions warning 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 pr...

  • Page 201

    8-3 options cautions when operating attachments warning heavy 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 ...

  • Page 202

    8-4 options hydraulic quick-hitch replacing the bucket or attachment warning • use only the attachments recommended by us. Using the attachments not approved by us may cause safety problems. Also, it may adversely affect the machine’s operation or service life. • before performing maintenance or rep...

  • Page 203

    8-5 options 6. Press the side of the switch (5) to lock the quick-hitch and the bucket. 7. Check that the tips of the pins (4) are projecting through the bracket hole on the bucket to indicate that the latch is properly engaged. 8. If the pins (4) do not come down to the lock position, do not contin...

  • Page 204

    8-6 options quick-couplers warning oil may spurt out if caps or filters are removed or pipes are disconnected before releasing the pressure in the hydraulic system. • when removing plugs or screws, or when disconnecting hoses, stand to the side and loosen them slowly to gradually release the internal...

  • Page 205

    8-7 options seat (with a switch function) warning do not lift your body off the seat while the machine is traveling. Doing so is dangerous; the lever lock and parking brake will be activated and the machine will stop abruptly. This seat is equipped with a switch for operating the lever lock, which f...

  • Page 206

    8-8 options optional equipment mass standard machine mass (not including operator) canopy cab 3695 (4125) 3775 (4400) option high-flow hydraulic device 60 (130) air conditioner 35 (75) hydraulic quick-hitch 20 (45) optional equipment mass units: kg (lb) *: mass of optional equipment is added to the s...

  • Page 207

    8-9 first published june 2010 fifth published may 2012 printed in japan by station m co., ltd. Operator’s manual no.40085 track loader tl230 edited and issued by takeuchi mfg. Co., ltd..

  • Page 208

    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...