Takeuchi TB285 andTB290 operators manual

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 and safe operation of all equipment. All persons using this machine should thoroughly familiarize themselves with the contents of this manual. All operators must be instructed on the proper functions of the excavator before running the machine. Learn and practice correct use of the machine controls in a safe, clear area before operating this machine on a job site. WARNING Improper operation, inspection and maintenance of this machine can cause injury or death. Read and understand this manual before performing any operation, inspection or maintenance on this machine. Always store this manual near at hand preferably on the machine itself. If it should be lost or damaged, immediately order a new one from your Takeuchi dealer. When transferring ownership of this machine, be sure to hand this manual to the next owner. Takeuchi supplies machines complying with the local regulations and standards of the country of export. If your machine has been purchased in another country or from a person or company of another country, it may not have the safety devices or safety standards required for use in your country. Should you have any question about whether your machine complies with the regulations and standards of your country, contact a Takeuchi dealer.

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 injury. WARNING WARNING indicates a hazard with a medium level of risk which, if not avoided, could result in death or serious injury. CAUTION CAUTION indicates a hazard with a low level of risk which, if not avoided, could result in minor moderate injury. IMPORTANT: The word IMPORTANT is used to alert operators and maintenance personnel about situations which could result in damage to the machine and its components. It is impossible to foresee every possible circumstance that might involve a potential hazard. The warnings in this manual or on the machine can not cover all possible contingencies. You must exercise all due care and follow normal safety procedures when operating the machine so as to ensure that no damage occurs to the machine, its operators or other persons.

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 compartment for storing this manual is provided at the position shown on the diagram below. 1. After using the manual, place it in the plastic pouch and store it back in the manual storage compartment. SERIAL NUMBERS IMPORTANT: Do not remove the machine name plate with the serial number. Check the serial numbers of the machine and engine and write them down in the spaces below. Machine number: Engine number: <TB285> <TB290>

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 dozer blade visible to the front. DESIGNATED OPERATIONS Use this machine primarily for the following operations: • Excavation • Digging ditches • Digging side ditches • Leveling • Loading FEATURES • Hydromounted cab minimizes vibration • Automatic travel shift-down system • Self-adjusting shoe tension system • Short pitch rubber crawler • Low engine noise and exhaust emissions • Electronic control of auxiliary hydraulic circuit • Automatic and manual operation for engine deceleration • Engine emergency stop system BREAK-IN PERIOD When the machine is new, operate the machine for the ﬁrst 100 hours (as indicated on the hour meter) by following the instructions below. Using a new machine without a break-in period will lead to quicker deterioration of machine performance and may shorten the machine’s service life. • Sufﬁciently warm up the engine and hydraulic oil. • Avoid heavy loads and rapid operations. Operate with a load of about 80% the maximum load. • Do not abruptly start up, accelerate, change directions, or stop unless necessary.

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

0-5 CONTENTS Introduction .....................................0-2 Machine description ........................0-3 Safety ..............................................1-1 General precautions ................................ 1-2 Precautions when preparing .................... 1-8 Precautions when starting ..................... 1-10 Precautions when operating .................. 1-12 Precautions when stopping ................... 1-21 Precautions when transporting .............. 1-22 Precautions on maintenance ................. 1-24 Safety signs (decals) .............................. 1-33 Controls ...........................................2-1 Names of components ............................ 2-2 Covers..................................................... 2-4 Starter key ........................................... 2-4 Side cover ........................................... 2-4 Fuel lid ................................................. 2-5 Fuel ﬁller port ....................................... 2-5 Engine hood ........................................ 2-6 Fuse box cover .................................... 2-6 Cab ......................................................... 2-7 Cab door ............................................. 2-7 Emergency exit .................................... 2-7 Front window....................................... 2-8 Lower front window ............................. 2-9 Side window ........................................ 2-9 Emergency hammer (optional) ............. 2-9 Seat and seat belt ................................. 2-10 Seat .................................................. 2-10 Seat belt ............................................ 2-11 Air Suspension Seat .......................... 2-12 Instrument cluster .................................. 2-16 Warning lamps................................... 2-16 Indicators........................................... 2-17 Meters ............................................... 2-17 Multi-data display .............................. 2-18 Switches ............................................... 2-24 Starter switch .................................... 2-24 Engine shutdown switch .................... 2-24 Throttle controller ............................... 2-24 Horn button ....................................... 2-25 Deceleration button ........................... 2-25 Travel speed button ........................... 2-25 Auxiliary 1st switch ............................ 2-26 Auxiliary 2nd/4th switch ..................... 2-26 Swing/Second boom select button .... 2-27 Third auxiliary hydraulic button ........... 2-27 Auxiliary 2/4 select button .................. 2-27 Wiper switch...................................... 2-28 Washer switch ................................... 2-28 Automatic deceleration switch ........... 2-28 ECO mode switch ............................. 2-29 Highland mode switch ....................... 2-29 Auxiliary 1st ﬂow select switch ........... 2-29 Detent mode switch (Auxiliary 1st) ..... 2-29 Light switch ....................................... 2-30 Overload warning switch.................... 2-30 Beacon lamp switch .......................... 2-30 Levers and Pedals ................................. 2-31 Safety lock lever ................................ 2-31 Operating levers ................................ 2-31 Blade lever......................................... 2-32 Travel levers/pedals ........................... 2-33 Boom swing pedal ............................. 2-33 Accessories ........................................... 2-34 Air conditioner ................................... 2-34 Cup holder ........................................ 2-39 Cigarette lighter ................................. 2-40 Ashtray .............................................. 2-40 Interior light ........................................ 2-41 Mirrors ............................................... 2-41 External power sockets .................... 2-41 Radio (for cab) ................................... 2-42 Auxiliary hydraulic lines ...................... 2-46 Operating the machine with an accumulator ...................................... 2-51 Load safety device............................. 2-52 Overload warning device ................... 2-53 Fuel Supply Pump ............................. 2-54 Operation .........................................3-1 Before starting operation ......................... 3-2 Getting on or off the machine............... 3-2 Walk-around inspection ....................... 3-2 Daily inspection.................................... 3-2 Starting and stopping the engine ............. 3-3 Before starting the engine .................... 3-3 Starting the Engine .............................. 3-4 Warming up the engine ........................ 3-5 Stopping the engine ............................ 3-5 Operating the machine ............................ 3-6 Lever pattern (ISO pattern)................... 3-6 Lever pattern (JCB pattern).................. 3-7 Warming up the machine (hydraulic oil) 3-8 Inspection after warm-up ..................... 3-9 Operating the travel levers ................. 3-10

0-6 Stopping travel .................................. 3-13 Operating the working equipment ...... 3-14 Operating procedures ............................ 3-16 Prohibited operations......................... 3-16 Cautions on operating ........................... 3-19 Cautions on traveling ......................... 3-19 Cautions on traveling on slopes ........ 3-20 Getting out of mud ............................ 3-22 Operations possible with this machine............................................. 3-22 Parking the machine .............................. 3-24 Parking .............................................. 3-24 Inspection and checks after stopping the engine.......................................... 3-24 Handling in cold climates ....................... 3-25 Preparing for cold climates ................ 3-25 Cautions after operations ................... 3-25 After the cold climate ......................... 3-25 Handling rubber crawlers ....................... 3-26 Prohibitions........................................ 3-26 Cautions ............................................ 3-27 Preventing the rubber crawlers from coming off ......................................... 3-27 Transport .........................................4-1 Loading and unloading ............................ 4-2 Hoisting the machine ............................... 4-4 Securing the machine .............................. 4-6 Maintenance ....................................5-1 General.................................................... 5-2 Maintenance overview ......................... 5-2 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 .......................................... 5-8 List of tightening torques ..................... 5-9 Safety-critical parts ................................ 5-10 Maintenance list..................................... 5-12 Walk-around inspection ......................... 5-14 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) ............ 5-16 Inspecting and replenishing the coolant .............................................. 5-16 Inspecting and replenishing the engine oil ........................................... 5-17 Inspecting the water separator and the fuel filters ..................................... 5-18 Inspecting the fuel level ...................... 5-19 Inspecting the hydraulic oil tank level and replenishing ................................ 5-20 Lubricating the working equipment .... 5-21 After the initial 50 hours (only for new machines) ......................... 5-22 Replacing the engine oil and the oil filter ................................................... 5-22 Inspecting and adjusting the fan belt .. 5-24 Inspecting and adjusting the compressor belt (AC) ......................... 5-26 Every 50 hours ...................................... 5-28 Inspecting the crawler belt tension ..... 5-28 Lubricating the slew bearing .............. 5-30 Draining the water from the fuel tank.. 5-31 Inspecting the battery fluid level and replenishing ....................................... 5-32 After the initial 250 hours (only for new machines) ......................... 5-34 Replacing the hydraulic oil return filter 5-34 Replacing the pilot line filter................ 5-35 Replacing the travel motor gear oil ..... 5-36 Every 250 hours .................................... 5-37 Replacing the engine oil and the oil filter ................................................... 5-37 Inspecting and adjusting the fan belt .. 5-37 Inspecting and adjusting the compressor belt (AC) ........................ 5-37 Cleaning the air cleaner ..................... 5-38 Cleaning the radiator fins and oil cooler fins .......................................... 5-39 Cleaning the air filters (air conditioner) 5-40 Cleaning the condenser (AC) ............. 5-41 Inspecting the refrigerant (gas) level (AC) ................................................... 5-42 Every 500 hours .................................... 5-44 Replacing the fuel filter ....................... 5-44 Replacing the water separator filter <TB285> ........................................... 5-46 Replacing the feed pump filter <TB290> ........................................... 5-47 Every 1000 hours .................................. 5-48 Replacing the hydraulic oil return filter 5-48 Replacing the pilot line filter................ 5-48

0-7 Replacing the travel motor gear oil ..... 5-48 Cleaning the engine cooling system ... 5-48 Replacing the air cleaner element ...... 5-50 Replacing the air breather filter .......... 5-51 Inspecting and adjusting the engine valve clearance .................................. 5-51 Retightening the engine cylinder head bolt <TB285> .................................... 5-51 Inspecting the engine compression pressure <TB290>............................. 5-51 Inspecting and cleaning the engine starter and the alternator <TB290> .... 5-51 Every 1500 hours .................................. 5-52 Inspecting and cleaning the engine fuel injectors <TB285>....................... 5-52 Inspecting the crankcase breather system <TB285> ............................... 5-52 Every 2000 hours .................................. 5-53 Lapping the engine valve seats <TB285> ........................................... 5-53 Every 4000 hours .................................. 5-54 Replacing the hydraulic oil and cleaning the suction strainer .............. 5-54 When required ....................................... 5-58 Replacing the bucket teeth and the side cutters........................................ 5-58 Replacing the bucket ......................... 5-60 Adjusting the gap between the bucket and arm (If equipped) ............. 5-62 Inspecting and replenishing the windshield washer fluid ...................... 5-63 Draining the water from the water separator ........................................... 5-63 Lubricating the levers and pedals....... 5-64 Inspecting the rubber crawlers ........... 5-65 Replacing the rubber crawlers ........... 5-66 Maintenance during extended storage period .................................................... 5-68 Troubleshooting ...............................6-1 Symptoms that are not malfunctions ....... 6-2 If the engine overheats............................. 6-3 If the battery goes dead ........................... 6-4 If a fuse blows ......................................... 6-6 Inspecting and replacing the fuse......... 6-6 Inspecting the fusible link ..................... 6-7 Restarting after adding fuel ...................... 6-8 Bleeding air from the fuel system ......... 6-8 If a warning lamp flashes ....................... 6-10 Vehicle error code list............................. 6-12 Engine error code list ............................. 6-14 Other symptoms.................................... 6-18 Lowering the boom to the ground ......... 6-20 Towing................................................... 6-21 Specifications ..................................7-1 Basic Specifications................................. 7-2 Machine dimensions ................................ 7-4 Operating ranges ..................................... 7-8 Lifting Capacities ................................... 7-13 Options ............................................8-1 General precautions ................................ 8-2 Safety precautions ............................... 8-2 Cautions when installing attachments .. 8-2 Cautions when operating attachments . 8-3 Attachment combination table ................. 8-4 Selecting a lever pattern .......................... 8-5 Switching the lever pattern .................. 8-5 Hydraulic breaker .................................... 8-6 Cautions on operating ......................... 8-6 Replacing the hydraulic oil regularly ..... 8-7 Travel alarm ............................................. 8-8 Optional equipment mass ....................... 8-9 Biodegradable oil ................................... 8-10 Replacing the hydraulic oil with biodegradable oil ............................... 8-10 Cab options........................................... 8-11 Angle dozer blade.................................. 8-12 Operating lever switch kit 1.................... 8-13 Horn button ....................................... 8-13 Deceleration button ........................... 8-13 Travel speed button ........................... 8-13 Auxiliary 1st switch ............................ 8-14 Auxiliary 2nd/4th switch ..................... 8-14 Auxiliary 2/4 select button .................. 8-15 Swing/Second boom select button .... 8-15

Takeuchi TB285 andTB290 operators manual

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