Takeuchi TB138FR Compact Hydraulic Excavator Service & Repair Manual

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0-2 FOREWORD This manual is intended for persons who engage in maintenance operations, and explains procedures for disassembly and reassembly of the machine, check and maintenance procedures, maintenance reference values, troubleshooting and outline specifications, etc. Please use this manual as a reference in service activities to im- prove maintenance techniques. Further, please be advised that items contained in this manual are subject to change without notice due to design modifications, etc. MACHINE FRONT AND REAR, LEFT AND RIGHT The end where the dozer blade is mounted is the front and the end with the travel motors is the rear. Also the right and left sides of the operator when he is seated in the operatorʼs seat are the right and left sides of the machine. MACHINE SERIAL NUMBER The machine serial number is stamped on the identification plate. When sending reports and inquiries, and when ordering parts, etc., be sure to include this number. MANUAL CONTROL Information on those to whom this manual is distributed is recorded in the ledger in the section in charge at this company, so please decide on a person to be in charge of it and control it. When there are updates or additions, etc., we will notify the person in charge. SYMBOLS means “Please refer to the section quoted.” Indicates the tightening torque at the specific section that requires special attention in designing. Indicates the mass of a part or device. chodina@live.co.uk chodina@live.co.uk

0-3 I . GENERAL II . SPECIFICATIONS III . MACHINE CONFIGURATION IV . HYDRAULIC UNITS V . TROUBLESHOOTING VI . ENGINE chodina@live.co.uk chodina@live.co.uk

0-4 chodina@live.co.uk chodina@live.co.uk

1-1 I . GENERAL chodina@live.co.uk chodina@live.co.uk

GENERAL I-2 CONTENTS Safety precautions .................................................................................................................................................... 3 Cautions during disassembly and assembly............................................................................................................. 9 Cautions during removal and installation of the hydraulic units ............................................................................. 9 Cautions during removal and installation of piping............................................................................................... 10 Handling of seals.................................................................................................................................................... 10 Tightening torques ................................................................................................................................................. 11 chodina@live.co.uk chodina@live.co.uk

I-3 GENERAL SAFETY PRECAUTIONS SAFETY ALERT SYMBOL This symbol means Attention! Be Alert! Your Safety Is Involved. The message that follows the symbol contains important information about safety. Read and understand the message to avoid personal injury or death. ■ SIGNAL WORDS Safety messages appearing in this manual and on machine decals are identified by the words “DANGER”, “WARNING” and “CAUTION”. These signal words mean the following: IMPORTANT: The word “IMPORTANT” is used to alert against operators and maintenance personnel about situations which can result in possible damage to the machine and its components. This manual is intended for trained and qualified personnel only. Warnings or cautions described in this manual do not necessarily cover all safety measures. For maintenance work, each person must take adequate safety precautions against possible hazards present in the respective working environment. Observe all safety rules • Operation, inspection and maintenance of this machine must be performed only by a trained and qualified person. • All rules, regulations, precautions and safety procedures must be understood and followed when performing operation, inspection and maintenance of this machine. • Do not perform any operation, inspection and maintenance of this machine when under the adverse influence of alcohol, drugs, medication, fatigue, or insufficient sleep. Wear appropriate clothing and personal protective equipment • Do not wear loose clothing or any accessory that can catch on controls or in moving parts. • Do not wear oily or fuel stained clothing that can catch fire. • Wear a hard hat, safety shoes, safety glasses, filter mask, heavy gloves, ear protection and other protective equipment as required by job conditions. Wear required appropriate equipment such as safety glasses and filter mask when using grinders, hammers or compressed air, as metal fragments or other objects can fly and cause serious injury. • Use hearing protection when operating the machine. Loud prolonged noise can cause hearing impairments, even the total loss of hearing. The word “DANGER” indicates an imminently hazardous situation which, if not avoided, can result in serious injury or death. DANGER The word “WARNING” indicates a potentially hazardous situation which, if not avoided, could result in serious injury or death. WARNING The word “CAUTION” indicates a potentially hazardous situation which, if not avoided, may result in minor or moder- ate injury. CAUTION chodina@live.co.uk chodina@live.co.uk

I-4 GENERAL Provide a fire extinguisher and first aid kit • Know where a fire extinguisher and first aid kit are located and understand how to use them. • Know how to contact emergency assistance and first aid help. Attach a “DO NOT OPERATE” tag Severe injury could result if an unauthorized person should start the engine or touch controls during inspection or maintenance. • Stop the engine and remove the key before performing maintenance. • Attach a “DO NOT OPERATE” tag to the starter switch or control lever. Use the correct tools Do not use damaged or weakened tools or tools de- signed for other purposes. Use tools suited for the operation at hand. Replace important safety parts periodically • Replace fuel hoses periodically. Fuel hoses be- come weaker over time, even if they appear to be in good shape. • Replace important safety parts whenever an ir- regularity is found, even if it is before the normal time for replacement. Anti-explosive lighting Use anti-explosive electrical fixtures and lights when inspecting fuel, oil, coolant, battery fluid, etc. If lighting that is not anti-explosive should break, the substance could ignite, resulting in serious injury or death. Do not allow unauthorized personnel in the work area Do not allow unauthorized personnel in the work area. Chips or other debris can fly off machine parts when grinding, welding or using a hammer. Prepare the work area • Select a firm, level work area. Make sure there is adequate light and, if indoors, ventilation. • Clear obstacles and dangerous objects. Eliminate slippery areas. chodina@live.co.uk chodina@live.co.uk

I-5 GENERAL Always clean the machine • Clean the machine before performing maintenance. • Cover electrical parts when washing the machine. Water on electrical parts could cause short-circuits or malfunctions. Do not use water or steam to wash the battery, sen- sors, connectors or the operatorʼs seat area. Stop the engine before performing maintenance • Avoid lubrication or mechanical adjustments with the machine in motion or with the engine running while stationary. • If maintenance must be performed with the engine running, always work as a 2-person team with one person sitting in the operatorʼs seat while the other works on the machine. • When performing maintenance, be sure to keep your body and clothing away from moving parts. Stay clear of moving parts • Stay clear of all rotating and moving parts. Wrap- ping or entanglement may result in serious injury or death. • Keep hands, clothing and tools away from the rotating fan and running fan belts. Securely block the machine or any com- ponent that may fall • Before performing maintenance or repairs under the machine, set all working equipment against the ground or in the lowermost position. • Securely block the tracks. • If you must work beneath the raised machine or equipment, always use wood blocks, jack-stands or other rigid and stable supports. Never get under the machine or working equipment if they are not sufficiently supported. This procedure is especially important when working on hydraulic cylinders. Securely block the working equipment To prevent unexpected movement, securely block the working equipment when repairing or replacing the cutting edges or bucket teeth. Secure the engine hood or cover when opened Be sure to secure the engine hood or cover when opening it. Do not open the engine hood or cover on slopes or in strong wind. Cautions on tilting up the platform • Raising or lowering the platform 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 platform. • When the floor is tilted up, support it firmly with the stopper to prevent it from falling. chodina@live.co.uk chodina@live.co.uk

I-6 GENERAL Place heavy objects in a stable position When removing or installing the hoe attachment, place it in a stable position so that it does not tip over. Use caution when fueling • Do not smoke or permit open flames while fueling or near fueling operations. • Never remove the fuel cap or refuel with the engine running or hot. Never allow fuel to spill on hot machine components. • Maintain control of the fuel filler nozzle when fill- ing the tank. • Do not fill the fuel tank to capacity. Allow room for expansion. • Clean up spilled fuel immediately. • Tighten the fuel tank cap securely. Should the fuel cap be lost, replace it only with the original manufacturerʼs approved cap. Use of a non-approved cap without proper venting may result in pressurization of the tank. • Never use fuel for cleaning purposes. • Use the correct fuel grade for the operating sea- son. Handling of hoses Fuel, oil or hydraulic fluid leaks can cause a fire. • Do not twist, bend or hit the hoses. • Never use twisted, bent or cracked hoses, tubes and pipes. They may burst. • Retighten loose connections. Be careful with hot and pressurized components Stop the engine and allow the machine to cool down before performing inspection and maintenance. • The engine, muffler, radiator, hydraulic lines, slid- ing parts and many other parts of the machine are hot directly after the engine is stopped. Touching these parts will cause burns. • The engine coolant, oil and hydraulic fluid are also hot and under high pressure. Be careful when loosening caps and plugs. Work- ing on the machine under these conditions could result in burns or injuries due to the hot oil spurt- ing out. Be careful with hot cooling systems Do not remove the radiator cap or drain plugs when the coolant is hot. Stop the engine, let the engine and radiator cool and loosen the radiator cap or drain plugs slowly. chodina@live.co.uk chodina@live.co.uk

Takeuchi TB138FR Compact Hydraulic Excavator Service & Repair Manual

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