Takeuchi Compact Excavator Tb80frcl4e000 Workshop Manual

Full download: http://manualplace.com/download/takeuchi-compact-excavator-tb80frcl4e000-workshop-manual/

TB80FR
Compact Excavator

BOOK No. CL4E000

WORKSHOP MANUAL

Serial No. 17820001~

0-1 TB80FR

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TB80FR 0-2
0-3 TB80FR
 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 improve 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 driver’s 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.

TB80FR 0-4
FOOT OF THE PAGE

L4A100

1. Page number
The following page numbers are assigned to each respective page. And if there are additional pages, an addition
code is supplied. Please file the sheets in the order of the page numbers.

Page No.
X–XX
Page number within section
Section Number

Page Addition
X–XX–X
Addition Code

Example: II-8
II-9
II-9-1 ............... A page is added between page 9 and page 10.
II-10

If a page has been revised, it is to be used in place of the page used before revision and it is not necessary to keep
the old page.

2. Revision number
Indicates the latest revision of this manual. This number is printed on the page that reflects this revision.

3. Model (s)

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.

0-5 TB80FR
TB80FR 0-6
 I . GENERAL
II . SPECIFICATIONS
III . MACHINE CONFIGURATION
IV . HYDRAULIC UNITS
V. TROUBLESHOOTING
VI . ENGINE

0-7 TB80FR
TB80FR 0-8
I . GENERAL

I-1 TB80FR
GENERAL

CONTENTS

Safety Precautions ................................................................................................................................................. 3

Cautions during Disassembly and Assembly ........................................................................................................ 9
Cautions during Removal and Installation of the Hydraulic Units ..................................................................... 10
Cautions during Removal and Installation of Piping .......................................................................................... 11
Handling of Seals ................................................................................................................................................ 12
Tightening Torques ............................................................................................................................................. 13

TB80FR I-2
 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:

DANGER WARNING CAUTION

The word “DANGER” indicates The word “WARNING” indi- The word “CAUTION” indi-
an imminently hazardous situ- cates a potentially hazardous cates a potentially hazardous
ation which, if not avoided, can situation which, if not avoided, situation which, if not avoided,
result in serious injury or death. could result in serious injury or may result in minor or moder-
death. ate injury.

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 ma-

chine must be performed only by a trained and
qualified person.
• All rules, regulations, precautions and safety pro-
cedures 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 ad-
verse influence of alcohol, drugs, medication, fa-
tigue, or insufficient sleep.

• Wear a hard hat, safety shoes, safety glasses, filter

Wear appropriate clothing and personal mask, heavy gloves, ear protection and other pro-
protective equipment tective equipment as required by job conditions.
Wear required appropriate equipment such as safety
• Do not wear loose clothing or any accessory that glasses and filter mask when using grinders, ham-
can catch on controls or in moving parts. mers or compressed air, as metal fragments or
• Do not wear oily or fuel stained clothing that can other objects can fly and cause serious personal
catch fire. injury.
• Use hearing protection when operating the ma-
chine. Loud prolonged noise can cause hearing
impairments, even the total loss of hearing.

I-3 TB80FR
GENERAL
Provide a fire extinguisher and first aid Anti-explosive lighting
kit

Use anti-explosive electrical fixtures and lights when

• Know where a fire extinguisher and first aid kit are inspecting fuel, oil, coolant, battery fluid, etc. If
located and understand how to use them. lighting that is not anti-explosive should break, the
• Know how to contact emergency assistance and substance could ignite, resulting in serious injury or
first aid help. death.

Attach a “DO NOT OPERATE” tag Do not allow unauthorized personnel in

the work area
Severe injury could result if an unauthorized person
should start the engine or touch controls during in-
spection or maintenance.
• Stop the engine and remove the key before per-
forming maintenance.
• Attach a “DO NOT OPERATE” tag to the starter
switch or control lever.

Use the correct tools

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
Do not use damaged or weakened tools or tools slippery areas.
designed 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.

TB80FR I-4
 GENERAL
Always clean the machine Securely block the machine or any
component that may fall

• Clean the machine before performing maintenance.

• Cover electrical parts when washing the machine. • Before performing maintenance or repairs under
Water on electrical parts could cause short-circuits the machine, set all working equipment against the
or malfunctions. ground or in the lowermost position.
Do not use water or steam to wash the battery, • Securely block the tracks.
sensors, connectors or the operator’s seat area. • 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
Stop the engine before performing the machine or working equipment if they are not
maintenance sufficiently supported. This procedure is espe-
cially important when working on hydraulic cylin-
• Avoid lubrication or mechanical adjustments with ders.
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 operator’s seat while the other Securely block the working equipment
works on the machine.
• When performing maintenance, be sure to keep To prevent unexpected movement, securely block the
your body and clothing away from moving working equipment when repairing or replacing the
parts. cutting edges or bucket teeth.

Stay clear of moving parts

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.

• Stay clear of all rotating and moving parts. Wrap-

ping or entanglement may result in serious injury Cautions on tilting up the platform
or death.
• Keep hands, clothing and tools away from the • Raising or lowering the platform while the engine
rotating fan and running fan belts. is running may cause the machine to move, and
cause serious injury or death.
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.

I-5 TB80FR
GENERAL
Place heavy objects in a stable position 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
When removing or installing the hoe attachment,
place it in a stable position so that it does not tip over.

Use caution when fueling

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-
• Do not smoke or permit open flames while fueling ing on the machine under these conditions could
or near fueling operations. result in burns or injuries due to the hot oil spurting
• Never remove the fuel cap or refuel with the engine out.
running or hot. Never allow fuel to spill on hot
machine components.
• Maintain control of the fuel filler nozzle when Be careful with hot cooling systems
filling 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
manufacturer’s approved cap. Use of a non-ap-
proved 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 season. 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.

TB80FR I-6
 GENERAL
Be careful with fluids under pressure Be careful with grease under pressure

The track adjuster contains highly pressurized grease.

If the tension is adjusted without following the pre-
Pressure can be maintained in the hydraulic circuit scribed procedure, the grease discharge valve may fly
long after the engine has been shut down. off, resulting in injury.
• Release all pressure before working on the hydrau- • Loosen the grease discharge valve slowly. Do not
lic system. unfasten it more than one full turn.
• Hydraulic fluid under pressure can penetrate the • Do not put your face, arms, legs or body in front of
skin or eyes and cause injury, blindness or death. the grease discharge valve.
Fluid escaping from a small hole can be almost
invisible. Wear a safety goggles and heavy gloves
and use a piece of cardboard or wood to search for Disconnect the battery
suspected leaks.
If fluid is injected into the skin, it must be removed
within a few hours by a doctor familiar with this
type of injury.

Release all pressure before working on

the hydraulic system

Oil may spurt out if caps or filters are removed or

pipes disconnected before releasing the pressure in Disconnect the battery before working on the electri-
the hydraulic system. cal system or doing any welding. Remove the nega-
• Gradually loosen the vent plug to relieve tank tive (–) battery cable first. When reconnecting the
pressure. battery, connect the negative (–) battery cable last.
• Move all the control levers and pedals several
times in all directions to release the pressure from
the working equipment circuitry. (For link type
controls)
• When removing plugs or screws or disconnecting
hoses, stand to the side and loosen slowly to gradu-
ally release the internal pressure before removing.

I-7 TB80FR
GENERAL
Avoid battery hazards Checks after maintenance

• Batteries contain sulfuric acid which will damage • Gradually raise the engine speed from a low idle to
eyes or skin on contact. maximum speed and check that no oil or air is
• If acid contacts eyes, flush immediately with leaking from serviced parts.
clean water and get prompt medical attention. • Move the controls and check that the machine is
• If acid is accidentally swallowed, drink large operating properly.
quantities of water or milk and call a physician
immediately.
• If acid contacts skin or clothing, wash off imme-
diately with clean water.
• Wear safety glasses and gloves when working with Disposing of wastes
batteries.
• Batteries generate flammable and explosive gases.
Keep arcs, sparks, flames and lighted tobacco
away.
• Use a flashlight to check battery electrolyte level.
• Stop the engine and shut off electrical equipment
while inspecting or handling the battery.
• Do not short circuit the battery posts with metal
items.
• Always unfasten the negative (–) battery cable first
when disconnecting the battery cable. Always con- • Funnel spent fluids from the machine into contain-
nect the negative (–) battery cable last when fasten- ers. Disposing of fluids improperly destroys the
ing the battery cable. environment.
• Loose battery terminals may result in sparks. Be • Follow the prescribed regulations when disposing
sure to fasten terminals tightly. of oil, fuel, engine coolant, refrigerant, solvents,
• Make sure the vent caps are tightened securely. filters, batteries or other harmful substances.
• Do not charge a battery or jump-start the engine if
the battery is frozen. Warm to 15°C (60°F) or the
battery may explode.

Have a Takeuchi service agent repair

welding cracks or other damage

Ask a Takeuchi service agent to repair any welding

problems which are detected. If not feasible, make
sure the welding is done by a qualified person in a
properly equipped workplace.

Safety signs

• Keep all safety signs clean and legible.

• Replace all missing, illegible or damaged safety
and warning signs.

TB80FR I-8
 GENERAL
CAUTIONS DURING DISASSEMBLY AND
ASSEMBLY

1. Clean the machine before disassembly operation.

2. Before disassembly, check the machine condi-

tions and record them.
• Model, Machine Serial Number, Hourmeter
• Reason for Repairs, Repair History
• Dirtiness of Filters
• Fuel and Oil Conditions
• Damage to each parts, etc.

3. To make reassembly operations easy, make match-

ing marks at the necessary points.

4. Clean all disassembled parts and new parts, then

arrange them in the proper sequence.

5. Be sure to replace all seals and cotter pins, etc.,

with new parts.

6. Keep parts which should not come in contact with

oil and water separate from parts with oil on them.
• Electrical Parts, Rubber, V-Belts, etc.

7. When installing bearings, bushings and oil seals,

as a rule, use a press. When a hammer, etc., is
used, it leaves bruises.

8. Wipe all joining surfaces clean so that there is no

dirt or dust adhering to them.

9. Wrap seal tape from the front end, Wrapping it SEALING TAPE
tight and leaving 1 or 2 threads bare, Overlap the
tape by about 10 mm.

LEAVE 1 OR 2 THREAD MARGIN

10. When fitting the snap rings, the bigger, rounder

side of their circumferences should face the mat-
ing surfaces.

I-9 TB80FR
GENERAL
CAUTIONS DURING REMOVAL AND
INSTALLATION OF THE HYDRAULIC UNITS

1. Make sure that the hydraulic oil’s temperature

has dropped.

2. To prevent a loss of flow of the hydraulic oil, the

residual pressure in the piping and the internal
pressure in the hydraulic oil tank should be bled
out.

3. Be sure to install caps or plugs on all openings in PLUG

the hydraulic unit to prevent dirt from getting into

the unit through the openings.

PLUG

4. It is easy to mistake hydraulic oil adhering to the

hydraulic unit for an oil leak, so wipe the unit off
thoroughly.

5. Be sure that no damage is done to the plating on

the rod in the hydraulic cylinder.

6. As a rule, removal and installation of the hydrau-

lic cylinder should be done with the rod fully
retracted.

7. Be sure to bleed the air after replacing the hydrau-

lic oil or removing any of the hydraulic devices.
“III. Machine Configuration, Hydraulic Sys-
tem”

8. After installation of the hydraulic unit, be sure to

pressurize the hydraulic oil tank. If this operation
is forgotten, it could cause cavitation of the hy-
draulic pump. Also, it could have a drastic effect
on the life of the hydraulic pump.
“III. Machine Configuration, Hydraulic Sys-
tem”

TB80FR I-10
 GENERAL
CAUTIONS DURING REMOVAL AND
INSTALLATION OF PIPING

1. When hydraulic hoses are installed, tighten them

once to the prescribed torque, then loosen them
slightly and retighten them to the prescribed
torque.
• Tighten the fittings after the installation sur-
faces fit snugly together.
• Pieces wrapped with seal tape are excluded.

2. Use 2 spanners, each on an opposite side, to

remove and tighten fittings so that the hoses or
steel pipes are not twisted.

3. After installation of hydraulic hoses or steel pipes,

apply the maximum working pressure 5 or 6 times
and confirm that there is no leakage.

I-11 TB80FR
Takeuchi Compact Excavator Tb80frcl4e000 Workshop Manual
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GENERAL
HANDLING OF SEALS

1. Clean the grooves for O-rings and if there is any RIDGE

ridge, etc., remove it.

DIRT

2. Be careful not to twist O-rings. If an O-ring is

twisted, remove the twist with the fingertips.

3. During insertion, be careful not to damage the

seal.

4. Handling of Floating Seals

• Wipe all oil off the O-ring and housing of the
floating seal.
• When assembling, apply a thin coating of gear
oil to the contact surface of the housing.
• After assembly, turn the seal 2 or 3 times to get
it to fit snugly.

5. Apply grease to the lip of the oil seal.

• This is to prevent wear when it is first started up
after assembly.

GREASE

TB80FR I-12

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