Takeuchi TB228 User manual

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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 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.

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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.

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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. Insert the starter key and turn it
counterclockwise to open the cover under
the seat.
2. 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:


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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
• Tilting up the operator seat floor for easier
maintenance
• Automatic travel shift-down system
• Short pitch rubber crawler
• Low engine noise and exhaust emissions
• Electronic control of auxiliary hydraulic
circuit
• Single button operation for engine
deceleration
• Slew motors are equipped with shockless
valves
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.


 


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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

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CONTENTS
Introduction .....................................0-2
Machine description ........................0-3
Safety ..............................................1-1
General precautions ................................ 1-2
Precautions when preparing .................... 1-7
Precautions when starting ....................... 1-9
Precautions when operating .................. 1-11
Precautions when stopping ................... 1-19
Precautions when transporting .............. 1-20
Precautions on maintenance ................. 1-21
Safety signs (decals) ..............................1-30
Controls ...........................................2-1
Names of components (Canopy) ............. 2-2
Names of components (Cab) ................... 2-4
Covers ..................................................... 2-6
Starter key ........................................... 2-6
Front cover (tool box) ...........................2-6
Fuel lid ................................................. 2-7
Fuel filler port ....................................... 2-7
Side cover ........................................... 2-8
Engine hood ........................................ 2-8
Cab ......................................................... 2-9
Cab door .............................................2-9
Emergency exit .................................... 2-9
Front window ..................................... 2-10
Lower front window ...........................2-11
Side window ......................................2-11
Emergency hammer (optional) ........... 2-11
Seat and seat belt ................................. 2-12
Seat < TB228 > ................................. 2-12
Seat belt <TB228> ............................ 2-13
Seat < TB235 / TB250 > ................... 2-14
Seat belt <TB235 / TB250> ............... 2-15
Instrument cluster .................................. 2-16
Warning lamps ................................... 2-16
Indicators .......................................... 2-17
Meters ...............................................2-17
Hour meter ........................................ 2-17
Switches ...............................................2-18
Starter switch .................................... 2-18
Horn button .......................................2-18
Deceleration button ........................... 2-18
Automatic deceleration switch ........... 2-19
Auxiliary hydraulic switches ................ 2-19
Third auxiliary hydraulic switch and
buttons (Option) ................................. 2-20
Travel speed switch ........................... 2-21
Light switch ....................................... 2-21
Wiper switch ...................................... 2-21
Levers and Pedals .................................2-22
Safety lock lever ................................2-22
Throttle lever ...................................... 2-22
Operating levers ................................2-23
Blade lever ......................................... 2-23
Travel levers/pedals ........................... 2-24
Boom swing pedal ............................. 2-24
Auxiliary hydraulic pedal (option) ........ 2-25
Accessories ........................................... 2-26
Heater ............................................... 2-26
Heater (for cold climates) ................... 2-27
Air conditioner ................................... 2-28
Cup holder ........................................2-33
Cigarette lighter ................................. 2-34
Ashtray ..............................................2-34
Interior light ........................................ 2-35
Mirrors ............................................... 2-35
External power sockets (for EU) ......... 2-35
Radio (Cab type) ................................ 2-36
Auxiliary hydraulic lines ...................... 2-40
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
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 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

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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 .............................. 4-5
Precautions to be taken during
transportation ...................................... 4-5
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 engine oil 5-17
Inspecting the water separator ........... 5-17
Inspecting the fuel level ...................... 5-18
Inspecting the hydraulic oil tank level
and replenishing ................................ 5-18
Lubricating the working equipment ....5-20
After the initial 50 hours (only for new
machines) .............................................. 5-21
Replacing the engine oil and the oil filter ... 5-21
Inspecting and adjusting the fan belt .. 5-22
Inspecting and adjusting the
compressor belt (AC) ......................... 5-22
Every 50 hours ...................................... 5-24
Inspecting and adjusting the crawler
tension ..............................................5-24
Lubricating the slew bearing .............. 5-26
Draining the water from the fuel tank .. 5-27
Inspecting the battery fluid level and
replenishing ....................................... 5-28
Every 100 hours .................................... 5-30
Cleaning the water separator .............5-30
After the initial 250 hours (only for new
machines) .............................................. 5-31
Replacing the hydraulic oil return filter 5-31
Replacing the pilot line filter ................ 5-32
Replacing the travel motor gear oil ..... 5-33
Every 250 hours .................................... 5-34
Replacing the engine oil and the oil filter ... 5-34
Inspecting and adjusting the fan belt .. 5-34
Inspecting and adjusting the
compressor belt (AC) ........................ 5-34
Cleaning the air cleaner .....................5-34
Cleaning the radiator fins and oil cooler
fins .................................................... 5-35
Cleaning the air filters ......................... 5-36
Cleaning the condenser (AC) ............. 5-36
Inspecting the refrigerant (gas) level (AC) .. 5-37
Every 500 hours .................................... 5-39
Replacing the fuel filter ....................... 5-39
Every 1000 hours .................................. 5-40
Replacing the hydraulic oil return filter 5-40
Replacing the pilot line filter ................ 5-40
Replacing the travel motor gear oil ..... 5-40
Cleaning the engine cooling system ... 5-40
Replacing the air cleaner element ...... 5-42
Replacing the air breather filter (If
equipped) .......................................... 5-43
Inspecting and adjusting the engine
valve clearance ..................................5-43
Retightening the engine cylinder head bolt 5-43
Every 1500 hours .................................. 5-44
Inspecting and cleaning the engine fuel
injectors ............................................. 5-44
Inspecting the crankcase breather system 5-44
Every 2000 hours .................................. 5-45
Lapping the engine valve seats ..........5-45
Every 4000 hours .................................. 5-46
Replacing the hydraulic oil and
cleaning the suction strainer .............. 5-46
When required ....................................... 5-48
Replacing the bucket teeth and the side
cutters ...............................................5-48

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Replacing the bucket ......................... 5-52
Adjusting the gap between the bucket
and arm (If equipped) ......................... 5-54
Inspecting and replenishing the
windshield washer fluid ...................... 5-55
Lubricating the levers and pedals ....... 5-56
Inspecting the rubber crawlers ........... 5-57
Replacing the rubber crawlers ........... 5-58
Tilting up the platform ............................ 5-60
Maintenance during extended storage period 5-62
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 ......................... 6-9
Other symptoms .................................... 6-10
Lowering the boom to the ground ......... 6-12
Towing ................................................... 6-13
Specifications ..................................7-1
Basic Specifications ................................. 7-2
Machine dimensions ................................ 7-6
Operating ranges ................................... 7-12
Lifting Capacities ................................... 7-15
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
Hydraulic breaker .................................... 8-6
Cautions on operating ......................... 8-6
Replacing the hydraulic oil regularly ..... 8-7
Load safety device ................................... 8-8
Emergency shut-off valve ..................... 8-8
Overload warning device ..................... 8-9
Accumulator .......................................... 8-10
Operating the machine with an
accumulator ......................................8-10
Battery switch ........................................ 8-11
Selecting a lever pattern ........................ 8-12
Switching the lever pattern ................ 8-12
Travel alarm ........................................... 8-13
3-hole bucket ........................................ 8-14
Arm-in restriction system ....................... 8-15
Optional equipment mass ..................... 8-16
Biodegradable oil ................................... 8-18
Replacing the hydraulic oil with
biodegradable oil ............................... 8-18
Angle dozer blade .................................. 8-19

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