Takeuchi TCR50 Operator's Manual
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Takeuchi TCR50 Operator's Manual

Takeuchi TCR50 Operator's Manual

Dump carrier
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See also: Operator's Manual
E
TCR50
Dump Carrier
Serial No. 30500003~
Book No. AS2E001
OPERA
TOR'S MANUAL
WARNING
Read and understand these instructions.
Failure to do so can cause injury or death.

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  • Page 1 TCR50 Dump Carrier Serial No. 30500003~ Book No. AS2E001 OPERA TOR’S MANUAL WARNING Read and understand these instructions. Failure to do so can cause injury or death.
  • Page 2 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 provide this manual to the next owner.
  • Page 3 It is your responsibility to observe all pertinent laws and regulations and to follow the manufacturer’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. An accident can often be avoided by recognizing potentially hazardous situations beforehand.

  • Page 4: Introduction

    If you have any questions about the machine, please contact a Takeuchi sales or service outlet. Manual storage Serial numbers A compartment for storing this manual is...
  • Page 5 MACHINE DESCRIPTlON Front, rear, Ieft and right FRONT This manual refers the front, rear, left and right of the machine as seen when sitting in the operator’s seat. Designated operations LEFT RIGHT Use this machine primarily for the following operation: ¡Operation on rough terrain.
  • Page 7 CONTENTS Introduction ........2 Machine Description ...... 3 Safety ..........7 Controls .........35 Operation ........59 Transport ........79 Maintenance ........83 Troubleshooting ......123 Specifications ......135 Options ........143 Index ..........147...
  • Page 9 SAFETY General precautions ........8 Preparing precautions ......... 12 Starting precautions ........14 Operating precautions ......... 16 Stopping precautions ........23 Transporting precautions ......24 Maintenance precautions ......25 Safety signs (Decals) ........32...

  • Page 10: Safety

    SAFETY General Precautions ¡Use hearing protection when operating the Observe all safety rules machine. Loud prolonged noise can cause hearing impairments, even the total loss ¡ Operation, inspection and maintenance of of hearing. this machine must be performed only by a trained and qualified person.

  • Page 11: General Precautions

    SAFETY General Precautions Be sure to lock the safety lock lever Use a signal person and flagman before leaving the operator’s seat Know and use the hand signals required for ¡ Before leaving the operator’s seat, set the particular jobs and make sure who has the safety lock lever securely to the lock responsibility for signaling.
  • Page 12 SAFETY General Precautions Avoid fire and explosion hazards Exhaust fumes from the engine can kill ¡Do not operate the engine in an enclosed Keep flames away from fuel, hydraulic fluid, oil, grease and antifreeze. Fuel is particularly area without adequate ventilation. ¡If natural ventilation is poor, install flammable and dangerous.
  • Page 13 Doing so may compromise safety or adversely affect the machine’s operation or service life. ¡ Takeuchi will not be held responsible for any injuries, accidents or damage to its products caused by the use of a non- approved attachment.

  • Page 14: Preparing Precautions

    SAFETY Preparing Precautions Know the working area Check the strength of the bridge Before starting operation, know the working area to ensure safety. ¡ Check the topography and ground condition of the working area, or the structure of the building when working indoors, and take the necessary safety measures in dangerous spots.

  • Page 15: Preparing Precautions

    SAFETY Preparing Precautions Perform inspection and maintenance daily Failure to notice or repair machine irregularities or damage can lead to accidents. ¡ Before operating, perform the prescribed inspections and make repairs immediately should any irregularities be found. ¡ If a failure that causes loss of control such as steering, service brakes or engine occurs, stop the machine motion as quickly as possible, follow the shutdown...

  • Page 16: Starting Precautions

    SAFETY Starting Precautions ¡Check for any “DO NOT OPERATE” tags Maintain three point contact or similar warning notices on the cab door, when mounting and dismounting controls or starter switch. ¡Sound horn to alert everyone around the ¡Do not jump on or off the machine. Never machine.

  • Page 17: Starting Precautions

    SAFETY Starting Precautions Starting with jumper cables In cold weather ¡ Be careful of slippery conditions on Use jumper cables only in the recommended manner. Improper use of jumper cables can freezing ground, steps and hand holds. ¡ In severe cold weather, do not touch any result in battery explosion or unexpected machine motion.
  • Page 18 SAFETY Operating Precautions Check for safety in the Ensure good visibility surrounding area ¡ When working in dark places, turn on the machine’s working lights and headlights and/or provide extra stationary lighting if necessary. ¡ When visibility is poor due to severe weather (fog, snow or rain), stop operating the machine and wait until conditions improves.

  • Page 19: Operating Precautions

    SAFETY Operating Precautions Travel safety S2A009 ¡ Raising or swinging the dump body while traveling will cause the machine to become unstable and is dangerous. Lower the dump body and make it parallel with the main frame. ¡ Avoid sudden stops, starts or turns. ¡When traveling over rough or slippery terrain, slow down to prevent losing control.
  • Page 20 SAFETY Operating Precautions Cautions on traveling on slopes When traveling on slopes or grades, be careful that the machine does not tip (roll) over or slide. ¡ Never exceed the machine’s stability (maximum gradeability - 30°, lateral tipping angle - 10°). Also note that when actual S2A012E working area conditions are poor the ¡Do not change directions or cross slopes...
  • Page 21 SAFETY Operating Precautions Precautions when passing through Precautions When Loading the tunnels or under bridges Dump Body S2A015 S2A014 Careless entry into tunnels or under bridges Do not allow loading the dump body unless can lead to serious accidents such as contact the driver and personnel are in a safe place.
  • Page 22 SAFETY Operating Precautions ¡Maintain the maximum possible distance Precautions When Dumping from power lines and never violate the minimum clearance. ¡Always contact the nearest electric utility and determine jointly what specific precautions must be taken to insure safety. ¡Consider all lines to be power lines and treat all power lines as energized even though it is known or believed that the power is shut off and the line is visibly...
  • Page 23 SAFETY Operating Precautions Unstable ground is dangerous and Do not enter soft ground increases the likelihood of the machine tipping over S2A018 Entry onto soft ground can result in the S2A019 machine tilting on its own weight, tipping over, or falling in. ¡...
  • Page 24 SAFETY Operating Precautions Danger of flying objects ¡ This machine is not equipped with protective guards to protect the operator from flying objects. Do not use the machine in places where there are risks of the operator being hit by flying objects.

  • Page 25: Stopping Precautions

    SAFETY Stopping Precautions Park safely S2A020 ¡ Park the machine on firm, level ground. If you must park on a slope or incline, block the machine securely to prevent movement. ¡ When parking on streets, use barriers, caution signs, lights, etc., so that the machine can easily be seen even at night to avoid collision with other vehicles.

  • Page 26: Transporting Precautions

    SAFETY Transporting Precautions Load and unload the machine safely Transport the machine safely ¡Know and follow the safety rules, vehicle code and traffic laws when transporting the machine. Fasten to the suspension fitting ¡Consider the length, width, height and Ramp weight of the transport vehicle with the machine loaded on it when determining Stopper...
  • Page 27 SAFETY Maintenance Precautions Attach a "DO NOT OPERATE" tag Anti-explosive lighting 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. ¡...

  • Page 28: Maintenance Precautions

    SAFETY Maintenance Precautions Stop the engine before Prepare the work area performing maintenance ¡ Select a firm, level work area. Make sure ¡Av o i d l u b r i c a t i o n o r m e c h a n i c a l there is adequate light and, if indoors, adjustments with the machine in motion ventilation.
  • Page 29 SAFETY Maintenance Precautions Secure the engine hood or cover Securely block the machine or when opened any component that may fall 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. ¡...
  • Page 30 SAFETY Maintenance Precautions Use caution when fueling 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.
  • Page 31 SAFETY Maintenance Precautions Release all pressure before Be careful with hot cooling systems working on the hydraulic system Oil may spurt out if caps or filters are removed or pipes disconnected before releasing the pressure in the hydraulic system. ¡ Gradually loosen the vent plug to relieve tank pressure.
  • Page 32 SAFETY Maintenance Precautions Disconnect the battery Avoid battery hazards ¡Batteries contain sulfuric acid which will damage eyes or skin on contact. • If acid contacts eyes, flush immediately with clean water and get prompt medical attention. • If acid is accidentally swallowed, drink large quantities of water or milk and call a physician immediately.
  • Page 33 Checks after maintenance welding cracks or other damage ¡ Gradually raise the engine speed from a Ask a Takeuchi service agent to repair any low idle to maximum speed and check that welding problems which are detected. If not no oil or air is leaking from serviced parts.

  • Page 34: Safety Signs (Decals)

    SAFETY Safety Signs (Decals) The following safety signs (decals) have been placed on your machine in the areas indicated. They are intended for the personal safety of you, and those working with you. Please take this manual, walk around your machine and note the content and location of these safety signs.
  • Page 35 SAFETY Safety Signs (Decals) 1. No.03593-06500 2. No.03593-07400 3. No.08740-30107 4. No.08710-80515 CAUTION Caution for Parking Brake Do not apply parking brake Be sure to read Operator’s manual prion to operation of the machine for safety. while traveling. When starting or traveling the machine: 08710-80515 1.
  • Page 37 CONTROLS Names of Components ........ 36 Doors and Covers ........38 Seat and Seat Belt ........43 Instrument Panel .......... 46 Switches ............48 Levers ............50 Accessories ..........51...

  • Page 38: Controls

    CONTROLS Names of Components S2B001 1. Cab 10. Hydraulic tank 2. Seat 11. Dump body 3. Engine hood 12. Dump cylinder 4. Bumper 13. Swing motor 5. Front light 14. Crawler belt 6. Turn light 15. Idler 7. Rear light 16.

  • Page 39: Names Of Components

    CONTROLS Names of Components S2B002 1. Instrument cluster 9. Throttle lever 2. Starter switch 10. Left control lever 3. Light switch 11. Right control lever 4. Horn switch 12. Fuse box 5. Travel speed switch 13. Fan switch (Heater) 6. Wiper switch 14.
  • Page 40 CONTROLS Doors and Covers Opening Starter Key 1. Pull the knob (1) towards you and open the door. To open the door from inside the cab, push the lever (2) to the front. 2. Open the door fully and press it against the cab to lock it in place.

  • Page 41: Doors And Covers

    CONTROLS Doors and Covers Opening inside and turn them to the locked position to unlock the front window. If the lock pins (1) are partially sticking out they may cause damage. 2. Grasp the front (lower) handle (2) with the left hand, the rear (upper) handle (3) with Released Locked...
  • Page 42 CONTROLS Doors and Covers Side Window Battery Cover C4C007 S2B007 1. Grasp the catch (7), unlock it and open Lock and unlock the side window. 1. I n s e r t a n d t u r n t h e s t a r t e r k e y 2.
  • Page 43 CONTROLS Doors and Covers Closing Engine Hood 1. Support the engine hood by hand, remove stay (1), and fix it to the original position. WARNING 2. Close the engine hood and press it down until a click is heard at the front. ¡...
  • Page 44 CONTROLS Doors and Covers Fuel Filler Cap Raised Body Prop WARNING WARNING ¡ Do not smoke or permit open flames If you must work beneath the raised dump w h i l e f u e l i n g o r n e a r f u e l i n g body, securely engage the raised body operations.

  • Page 45: Seat And Seat Belt

    CONTROLS Seat and Seat Belt ¡Lower lever (2) to adjust the front angle of Seat the seat cushion. 1. To raise the front angle of the seat cushion, WARNING apply your weight to the backrest while ¡ Adjust, secure and latch the operator's holding the lever down.

  • Page 46: Seat And Seat Belt

    CONTROLS Seat and Seat Belt (D) Fore-and-aft adjustment 1. Pull on lever (4) and slide the seat backward or forward to bring it to the optimum position for operating the machine. 2. Release the lever (4) at the desired position and the seat will remain fixed there.
  • Page 47 CONTROLS Seat and Seat Belt Seat Belt CAUTION ¡ Always fasten the seat belt securely before starting the engine. Fastening the seatbelt 1. Adjust the seat to the optimum position for operating, raise your torso, and sit back firmly into the seat. 2.
  • Page 48 CONTROLS Instrument Panel " & 6%*$ 3. Coolant Temperature Warning Lamp Warning Lamps This lamp flashes and an alarm is sounded if the IMPORTANT: If a warning lamp flashes engine coolant temperature and an alarm is sounded, stop all rises abnormally while the C4B012 operations immediately and inspect and engine is running.

  • Page 49: Instrument Panel

    CONTROLS Instrument Panel Indicators Dump Body Alignment Indicator 7. Glow Lamp This lamp turns off when e n g i n e p r e h e a t i n g i s completed. C4B013 8. Travel Speed Lamp This lamp lights when the S2B011 travel speed switch is set to...
  • Page 50 CONTROLS Switches Starter Switch Turn Switch PREHEAT START E4B010 S2B013 IMPORTANT: Do not repeatedly switch Press the left button (A) on this switch to blink the key from OFF to ON and ON to OFF the left turn light and press the right button over a short period.

  • Page 51: Switches

    CONTROLS Switches Travel Speed Switch Wiper Switch IMPORTANT: If no washer fluid is discharged, do not operate the washer. Doing so may damage the pump. IMPORTANT: Operating the wiper with no moisture on the windshield will scratch the glass. Apply water or washer fluid when operating the wiper.
  • Page 52 CONTROLS Levers and Pedals Safety Lock Lever Throttle Lever WARNING WARNING ¡ Before leaving the operator's seat, set the safety lock lever to the lock position and stop the engine. If any controls should be touched accidentally when the safety lock lever has not be locked, the machine will move suddenly, and S2B016 cause severe injury or death.

  • Page 53: Levers

    CONTROLS Accessories Air Outlets Heater WARNING ¡ Always be sure to allow sufficient ventilation. ¡ Do not place combustible or explosive objects near the air outlets. S2B018 Move knob (1) up and down or left and right Fan Switch to adjust the direction of the air. Supplement: Use the heater with care in warm seasons.

  • Page 54: Accessories

    CONTROLS Accessories External Power Socket (for EU) Cub Light IMPORTANT: The battery capacity will WARNING decrease if the cab light is left on for long ¡ Only use applicable electric products periods of time the engine stopped. Turn with this socket. the light off when leaving the machine.
  • Page 55 CONTROLS Accessories Cigarette Lighter Ashtray WARNING WARNING ¡ Do not leave the cigarette lighter’s ¡ Be sure to extinguish cigarettes and knob pressed in. Doing so heats up the matches completely before putting lighter, and could be dangerous. them in the ashtray, and always close ¡...
  • Page 56 CONTROLS Accessories Car Stereo Operating precautions ¡ To ensure safe operation of the machine, always be sure to keep the volume of the car stereo down to a level where you can easily hear sounds from outside the machine. ¡ Do not keep the car stereo playing for long periods of time with the engine stopped. Doing so will drain the battery of its charge and make it difficult or impossible to restart the engine.
  • Page 57 CONTROLS Accessories (4) Program indicators (8) Fast-forward/rewind/program Indicates tape direction. When s lamp is changeover button on. Upper side of a tape is playback, t indicates playback of lower side. Fast-forward (5) Display MTL LOUD ST MTL LOUD ST L2C003 Fast-rewind/Stop L2C002 (A) Band...
  • Page 58 CONTROLS Accessories (12) Band select switch Pressing the “BAND” button changes over KRH–M867 DC12V/24V between FM1, FM2 and AM (MW) bands. AUTO REVERSE CASSETTE STEREO RECEIVER The display indicates the receiving band MTL LOUD ST name and frequency. (13) Metal switch METAL Press the “MTL”...
  • Page 59 CONTROLS Accessories ¡ ¡ ¡ ¡ ¡ Set the time (15) DISP(Time/Frequency) button This system is equipped with a clock which BASS can show the accurate time. Even if the radio is off, the clock still shows the time. (16) PS/AS switch LOUD DISP PS/AS...
  • Page 61 OPERATION Before Starting Operation ......60 Starting and Stopping the Engine ....61 Machine Operation ........64 Operating Procedures ......... 70 Parking the Machine ........73 Handling in Cold Weather ......74 Handling Rubber Crawlers ......75...

  • Page 62: Operation

    OPERATION Before Starting Operation Mounting and Dismounting Walk-Around Inspection Perform the walk-around inspections once WARNING a day before starting the engine the first time ¡ Do not jump on or off the machine. that day. Never attempt to mount or dismount a Perform the inspections as described under moving machine.
  • Page 63 4. Check that the control levers are in the If a lamp does not light or the alarm does not neutral position. sound, the bulb may be burnt out or a wire may be damaged. Contact a Takeuchi sales or service outlet for repairs.
  • Page 64 OPERATION Starting and Stopping the Engine Starting in Cold Weather Starting the Engine WARNING ¡ Clear the area of all persons. ¡ Sound horn to alert everyone around the machine. IMPORTANT: Do not run the starter motor S2D004 for more than 15 consecutive seconds. If 1.
  • Page 65 OPERATION Starting and Stopping the Engine Warming Up the Engine Stopping the Engine IMPORTANT: Avoid racing the engine IMPORTANT: Do not stop the engine until it is warmed up. suddenly when operating with heavy Do not warm up the engine for long loads or at maximum speed.
  • Page 66 OPERATION Machine Operation Lever Pattern S2D006 Crawler Forward Dump body Lower Crawler Reverse Dump body Dump Left Spin Turn Dump body Swing Left Right Spin Turn Dump body Swing Right Left Pivot Turn Right Pivot Turn Right Pivot Turn Reverse Left Pivot Turn Reverse...
  • Page 67 OPERATION Machine Operation Warming Up the Machine (Hydraulic Oil) WARNING Operating the working equipment without warming up the machine (hydraulic oil) is dangerous, as response will be slow S2D008 and the equipment may move in 3. Extend and retract the dump cylinders unexpected ways.
  • Page 68 OPERATION Machine Operation Inspection After Warm-up Traveling the Machine After warming up the engine and hydraulic WARNING oil, perform the checks and inspections ¡Never allow anyone to enter the described below, and repair if there is a problem. machine working range and machine path.
  • Page 69 OPERATION Machine Operation a To turn left while traveling forward: Move the left control lever forward to the left. e To turn left while traveling backward: Move the left control lever backward to the right. Right Turn S2D011 3. Make sure that the dump body is lowered and is parallel to the main frame.
  • Page 70 OPERATION Machine Operation Stopping Travel WARNING ¡ Park the machine on firm, level ground. If you must park on a slope or incline, block the machine securely to prevent movement. ¡ Before leaving the operator's seat, set the safety lock lever to the lock position and stop the engine.
  • Page 71 OPERATION Machine Operation Swing Operating the Dump Body WARNING ¡Check the surrounding area for safety before operating the dump body. ¡ Raising or swinging the dump body while traveling will cause the machine to become unstable and is dangerous. S2D017 Lower the dump body and make it a To swing left: parallel with the main frame.
  • Page 72 OPERATION Operating Procedures Cautions on Operating Precautions When Loading the Dump Body Cautions on Traveling S2A015 Do not allow loading the dump body unless S2A010 the driver and personnel are in a sage place. Traveling over obstacles (rocks, stumps, etc.) Load on a firm location, do not load on a may subject the body to strong shocks and slope.
  • Page 73 OPERATION Operating Procedures Cautions on Use in Water S2D020 If you enter water at a sharp angle, the front of the machine may be submerged, exposing the radiator fan to water and damaging them. Do not let the front of the machine get submerged.
  • Page 74 OPERATION Operating Procedures Cautions on Traveling on Slopes WARNING ¡ Never exceed the machine's stability ° (maximum gradeability - 30 , lateral ° tipping angle - 10 ). Also note that when actual working area conditions are S2A012E poor the machine's stability may be ¡Do not change directions or cross lower.
  • Page 75 OPERATION Parking the Machine Inspection and Checks After Parking Stopping the Engine WARNING 1. Check for oil and water leakage and inspect the dump body, covers and main frame. If any irregularities are found, repair. 2. Fill the fuel tank. Refer to page 97 “Inspecting the Fuel Level”.

  • Page 76: Handling In Cold Weather

    As the temperature drops, the battery performance decreases. After Cold Weather is Over Inspect the battery. If the charge is low, contact a Takeuchi sales or service outlet to Perform the following after cold weather is have the battery charged. over: Refer to page 104 “Inspecting the Battery...
  • Page 77 OPERATION Handling Rubber Crawlers Rubber crawlers have an inherent weakness due to their use of rubber. Be sure to heed the prohibitions and cautions below so as to prevent damage to the crawlers and crawler slippage. Prohibited Actions S2D024 Do not travel or operate the machine in the ¡...
  • Page 78 OPERATION Handling Rubber Crawlers Preventing the Rubber Crawlers from Cautions Slipping Off Heed the following in order to prevent the Heed the following cautions when operating rubber crawlers from slipping off: the machine: ¡Always keep the crawlers at the proper ¡...
  • Page 79 OPERATION Handling Rubber Crawlers ¡ Do not change directions when the crawler belts are slack as shown in the diagram.
  • Page 81 TRANSPORT Loading and Unloading ....... 80 Securing the Machine ........81 Cautions on Transporting ......82...

  • Page 82: Transport

    TRANSPORT Loading and Unloading 1. Apply the truck’s parking brake and place WARNING stoppers against its tires. The machine may roll or tip over or fall 2. Fasten the ramps securely to the truck bed while loading or unloading it. Take the so that they will not come off.

  • Page 83: Securing The Machine

    TRANSPORT Securing the Machine After loading the machine in the designated position, secure it as described below. Transporting Posture S2F003 1. Stop the engine and remove the starter key. 2. Set the safety lock lever securely to the locked position. 3.
  • Page 84 TRANSPORT Cautions on Transporting WARNING ¡ Know and follow the safety rules, vehicle code and traffic laws when transporting the machine. ¡ Consider the length, width, height and weight of the truck with the machine loaded on it when determining the best route.
  • Page 85 MAINTENANCE General ............84 Service Data ..........86 Maintenance Chart ........91 Walk-Around Inspection ......93 Daily Inspection (Every 10 Hours) ....95 After First 50 Hours (New Machines Only) ......100 Every 50 Hours ........... 103 Every 100 Hours ......... 106 After First 250 Hours (New Machines Only) ......

  • Page 86: Maintenance

    Have inspection and maintenance as recommended in this manual. procedures not prescribed in this manual performed by a Takeuchi sales or service The inspection and maintenance items are outlet. divided according to the machine’s total operating time (inspection and maintenance Always keep the machine clean.
  • Page 87 If the sealing grooves of the surface serviced parts. ¡ Operate all the operating levers and check of contact are damaged, consult a Takeuchi sales or service outlet. that the machine is operating properly. Seals and split pins ¡...
  • Page 88 MAINTENANCE Service Data Fuel and Lubricant Chart Use different fuels, lubricants and greases according to the temperature, referring to the chart below. ¡ Change the lubricant earlier than as shown in the table if it is extremely dirty or its performance has deteriorated severely.
  • Page 89 MAINTENANCE Service Data Expendables Replace expendables such as filters and elements periodically, referring to the table below. Item Part name Part No. Replacement interval Line filter Element 15511-02103 After first 50 hrs. Every 500 hrs. Every 500 hrs. Fuel filter Cartridge 119000-55600 Engine oil filter...
  • Page 90 MAINTENANCE Service Data Tools S2G001 Part name Remarks Part name Part No. Remarks Part No. Spanner 19100-47081 10-12 10 Pliers 16905-00200 200mm Spanner 19100-47082 14-17 11 Hammer 16903-00330 Screwdriver 19100-06112 (+) (–) 12 Hex. wrench 16906-00600 Filter wrench 19100-65081 13 Hex. wrench 16906-00800 Monkey wrench 16904-00250 250mm...
  • Page 91 ¡ Tightening torques when mounting plastic covers differ from the values on the table below. Consult a Takeuchi sales or service outlet. Tightening too strongly will break the cover. ¡ When replacing nuts and bolts, replace them with nuts and bolts of the same size and standards.

  • Page 92: Important Parts

    Fuel hose Water separator (B) - Feed pump (C) Fuel hose Feed pump (C) - Feed pump (D) Please contact a Every Takeuchi sales or Fuel hose Feed pump (D) - Fuel filter (E) 2 years service outlet. Fuel hose...
  • Page 93 MAINTENANCE Maintenance Chart See page Maintenance Items Walk-Around Inspection Inspecting by opening the engine hood and covers Inspecting by walking around the machine Inspecting while sitting in the operator’s seat Daily Inspection (Every 10 Hours) Inspecting and replenishing the coolant Inspecting and replenishing the engine oil Inspecting the water separator Inspecting the fuel level...
  • Page 94 MAINTENANCE Maintenance Chart See page Maintenance Items Every 500 Hours Cleaning the radiator and oil cooler fins Replacing the fuel filter Replacing the line filter Every 1000 Hours Cleaning the engine cooling system Replacing the air cleaner elements Replacing the hydraulic oil and cleaning the suction strainer Replacing the travel motor gear oil Inspecting and adjusting the engine valve clearance Retightening the engine cylinder head bolts...
  • Page 95 MAINTENANCE Walk-Around Inspection Perform the following inspections once every day before starting the engine the first time. WARNING ¡ Before operating, perform the walk-around inspections and make repairs immediately should any irregularities be found. ¡ 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.
  • Page 96 MAINTENANCE Walk-Around Inspection Inspecting by Walking Around Inspecting While Sitting in the the Machine Operator’s Seat 3. Check for oil leakage from the hydraulic 12.Check the windshield for dirt or damage. tank, hydraulic devices, hoses and 13.Check the operator’s seat for dirt, oil or connections.
  • Page 97 MAINTENANCE Daily Inspection (Every 10 Hours) Perform the following inspections once every day before starting the engine the first time. WARNING ¡ Before operating, perform the Daily inspections and make repairs immediately should any irregularities be found. ¡ 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.
  • Page 98 MAINTENANCE Daily Inspection (Every 10 Hours) Inspecting and Replenishing the Inspecting the Water Separator Engine Oil Inspection S2G006 S : Closed S2G005 Inspect the water separator (1). 1. Open the engine hood. If the red indicator ring (6) is sunk to the 2.
  • Page 99 MAINTENANCE Daily Inspection (Every 10 Hours) Inspecting the Hydraulic Oil Inspecting the Fuel Level Level and Replenishing WARNING WARNING ¡ Do not smoke or permit open flames ¡Oil may spurt out if caps or filters are w h i l e f u e l i n g o r n e a r f u e l i n g removed or pipes disconnected before operations.
  • Page 100 MAINTENANCE Daily Inspection (Every 10 Hours) ¡ When the oil temperature is about 50 to 80°C (122 to 176°F): The level should be near the middle (M). (When the dump body is lowerd, the oil level rises to the middle point berween the “M”...
  • Page 101 MAINTENANCE Daily Inspection (Every 10 Hours) Lubricating the Dump body and Track Rollers S2G010 1. Set the machine to the lubrication posture shown in the diagram above, lower the dump body, then stop the engine. 2. Use the grease gun to lubricate the grease nipples. 3.
  • Page 102 MAINTENANCE After First 50 Hours (New Machines Only) Replacing the Line Filter WARNING ¡ Stop the engine and allow the machine to cool down before performing maintenance. • The engine, hydraulic lines and many S2G011 other parts of the machine are hot 5.
  • Page 103 Touching these parts will cause burns. contains large amounts of metal powder, ¡ The engine oil is also hot. consult a Takeuchi sales or service outlet. Be careful when loosening caps and plugs. Working on the machine under 4. Tighten the drain plug (3).
  • Page 104 MAINTENANCE After First 50 Hours (New Machines Only) Adjustment Inspecting and Adjusting the Fan Belt WARNING Stop the engine and allow the machine to cool down before performing inspection and maintenance. ¡ The engine, muffler, radiator, hydraulic lines, sliding parts and many other S2G013 parts of the machine are hot directly 1.
  • Page 105 The standard slack of (A) and (B) 2. Tighten the grease discharge valve (1). is 5 to 15 mm (0.2 to 0.6 in.). ¡Tightening torque: 59 N·m (43.4 ft.lb.) If the crawler cannot be loosened, contact a Takeuchi sales or service outlet for repairs.
  • Page 106 MAINTENANCE Every 50 Hours 2. Inspect the indicator (1). Inspecting the Battery Fluid ¡(A) Blue: Good Level and Replenishing ¡(B) Red: Charging needed ¡(C) White: Insufficient battery fluid DANGER ¡ Do not use the battery when the fluid 3. Also check the terminals for looseness and dirt.
  • Page 107 MAINTENANCE Every 50 Hours Draining the Fuel Tank 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.
  • Page 108 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.
  • Page 109 MAINTENANCE After First 250 Hours (New Machines Only) Replacing the Travel Motor Gear Oil WARNING ¡ Stop the engine and allow the machine to cool down before performing maintenance. • The travel motors are hot directly after S2G021 the engine is stopped. Touching them 1.
  • Page 110 MAINTENANCE Every 250 Hours Cleaning the Air Cleaner WARNING ¡ Stop the engine and allow the machine to cool down before performing maintenance. • The engine, muffler, radiator and E4G033 many other parts of the machine are 6. Clean the outer element (3) with dried hot directly after the engine is compressed air {686 kPa (99.5 psi) or stopped.
  • Page 111 MAINTENANCE Every 250 Hours 5. Repeat step 2. Lubricating the Swing Bearing 6.Start the engine and swing the dump body counterclockwise 180°. WARNING 7.Repeat step 2. 8. Wipe off the grease expelled from the Do not swing while lubricating. Doing so swing bearing and grease nipple.
  • Page 112 MAINTENANCE Every 250 Hours Replacing the Engine Oil and Oil Filter Refer to page 101“Replacing the Engine Oil and Oil Filter”. Inspecting and Adjusting the Fan Belt Refer to page 102 “Inspecting and Adjusting the Fan Belt”.
  • Page 113 MAINTENANCE Every 500 Hours Cleaning the Radiator and Oil Replacing the Fuel Filter Cooler Fins WARNING WARNING ¡ Do not smoke or permit open flames Wear required appropriate equipment while handling fuel or working on the such as safety glasses and filter mask fuel system.
  • Page 114 MAINTENANCE Every 1000 Hours 1. Open the engine hood. Cleaning the Engine Cooling System WARNING ¡ Stop the engine and allow the machine FU LL to cool down before performing LO W maintenance. • The engine, muffler, radiator and many other parts of the machine are hot directly after the engine is S2G004 stopped.
  • Page 115 MAINTENANCE Every 1000 Hours 8. After cleaning is completed, tighten the Replacing the Air Cleaner Elements drain plug (4) and add new coolant up to the specified level. WARNING 9. Run the engine at a low idle, bleed the air, then stop the engine once the coolant level Stop the engine and allow the machine stabilizes at the specified level.
  • Page 116 MAINTENANCE Every 1000 Hours 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, hydraulic lines and many other parts of the machine are hot directly after the engine is stopped.
  • Page 117 MAINTENANCE Every 1000 Hours 17.Set the machine to the hydraulic oil level Bleeding the air inspection posture and inspect the level once the temperature of the oil has IMPORTANT: After replacing the hydraulic oil, bleed the air from the hydraulic circuit dropped.
  • Page 118 Refer to page 107 “Replacing the Travel Motor Gear Oil”. Inspecting and Adjusting the Engine Valve Clearance This operation requires experience. Have it performed by a Takeuchi sales or service outlet. Retightening the Engine Cylinder Head Bolts This operation requires experience. Have it performed by a Takeuchi sales or service outlet.
  • Page 119 MAINTENANCE Every 2000 Hours Inspecting the Engine Fuel Injection Timing This operation requires experience. Have it performed by a Takeuchi sales or service outlet. Inspecting the Engine Fuel Injection Valve This operation requires experience. Have it performed by a Takeuchi sales or service...
  • Page 120 MAINTENANCE When Required Inspecting and Replenishing the Lubricating the Levers Windshield Washer Fluid WARNING Use a windshield washer fluid designed specifically for motor vehicles. Follow the Set the machine to the parking posture, instructions including with the washer fluid. stop the engine, remove the starter key and store it.
  • Page 121 Inspecting the Rubber Crawlers (3) Metal core Repair or replace the rubber crawlers if their conditions are as described below. Consult a Takeuchi sales or service outlet about repairs or replacement. Rubber crawler Replace the crawler if the entire crawler is stretched and cannot be adjusted.
  • Page 122 MAINTENANCE When Required Replacing the Rubber Crawlers WARNING ¡ 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 S2G031 the machine or raised dump body if 3.Jack up until there is a gap between the they are not sufficiently supported.
  • Page 123 MAINTENANCE When Required Another installation 1. Engage the crawler (2) on the idler(3). 2. Set the crawler (2) on the sprocket (4). 3. Set the projecting part of the crawler core inward of the carrier roller. 4. Slide the projecting part of the crawler core to the sprocket (4).
  • Page 124 2. Inspect the battery and recharge it if Refer to page 112 “Cleaning the Engine necessary. Cooling System”. Have the battery charged by a Takeuchi 5. Use the grease gun to supply grease to sales or service outlet. the grease nipples.
  • Page 125 TROUBLESHOOTING Symptoms that are not Malfunctions ..124 If the Engine Overheats ......125 If the Battery Goes Dead ......126 After the Fuel Runs Out ......127 If a Fuse Blows ........... 128 If a Warning Lamp Flashes ......130 Other Symptoms ........

  • Page 126: Troubleshooting

    TROUBLESHOOTING Symptoms that are not Malfunctions T h e f o l l o w i n g s y m p t o m s a r e n o t malfunctions: ¡ The swing motor produces noise at the beginning and end of the swing operation.
  • Page 127 ¡ Do not remove the radiator cap or drain 3. If there is steam, stop the engine plugs when the coolant is hot. Stop the immediately and contact a Takeuchi sales engine, let the engine and radiator cool or service outlet for repairs.

  • Page 128: If The Battery Goes Dead

    TROUBLESHOOTING If the Battery Goes Dead The following symptoms indicate that the Connecting the jumper cables battery is dead: ¡ The starter motor does not turn or turns IMPORTANT: Set the starter keys of both the rescue vehicle and problem vehicle weakly, and the engine does not start.
  • Page 129 3. Disconnect the clip of jumper cable (R) from the rescue vehicle’s “+” terminal. 4. Disconnect the other clip of jumper cable (R) from the problem vehicle’s “+” terminal. Recharging Have a Takeuchi sales or service outlet recharge batteries that have gone dead.
  • Page 130 10A Cigarette lighter 20A Safety relay there is a problem with the electric system. Continued use may lead to fire. 10A Traveling back 10A Instrument panel Consult a Takeuchi sales or service alarm outlet. 20A External power 20A Lights socket...
  • Page 131 TROUBLESHOOTING If a Fuse Blows Inspecting the Fusible Link S2J0011 If the power is not switched on after turning the starter switch to the ON position, the cartridge type fusible link (1) might be blown open. Open the battery cover and inspect. If the fusible link is blown, please contact your dealer.
  • Page 132 If the lamp continues flashing after maintenance, there is a problem with the charger. Consult a Takeuchi sales or service outlet. OSOB080 Refer to page 102 “Inspecting and Adjusting the Fan Belt”.
  • Page 133 TROUBLESHOOTING If a Warning Lamp Flashes Warning lamp Procedure Lamp name Line filter Hydraulic oil line filter is clogged. warning lamp Stop the engine and replace the filter. Continuing to operate the machine while the lamp is lit could damage the line filter and hydraulic equipment. T7B008 Replace the filter immediately should the lamp flashes.
  • Page 134 TROUBLESHOOTING Other Symptoms For symptoms not included on the table below or if the problem persists after the proper procedures have been taken, consult a Takeuchi sales or service outlet. Symptom Main cause Procedure ¡Insufficient grease on left and ¡Add grease.
  • Page 135 TROUBLESHOOTING Other Symptoms Symptom Main cause Procedure ¡Insufficient fuel ¡Add fuel. Starter motor turns but engine does not start Refer to page 97. ¡Air in fuel system ¡Bleed the air. Refer to page 127. ¡Water in fuel system ¡Drain the water. Refer to page 106.

  • Page 137: Specifications

    SPECIFICATIONS Main Specifications ........137 Machine Dimensions ......... 138 Operating Range ........140...
  • Page 138 MEMO...
  • Page 139 SPECIFICATIONS Main Specifications TYPE MASS 5640 (12435) Machine mass kg (lb.) (not including operator) PERFORMANCE Heaped 2.055 (72.57) Dump body capacity m (cu.ft.) (standard dump body) – – Maximum loading mass kg (lb.) 3700 (8155) –1 Swing speed min (rpm) 180°...
  • Page 140 SPECIFICATIONS Machine Dimensions S2K001...
  • Page 141 SPECIFICATIONS Machine Dimensions Units: mm (inches) 2675 (105.4) 1040 (41.0) 4660 (183.5) 2500 (98.4) 3155 (124.2) 1330 (52.3) 1615 (63.5) 2000 (78.7) 450 (17.7) 435 (17.1) 990 (39.0) 2620 (103.1) 1795 (70.6) 285 (11.2)
  • Page 142 SPECIFICATIONS Operating Range S2K002...
  • Page 143 SPECIFICATIONS Operating Range Units: mm (inches) 4785 (188.4) 885 (34.8) 3610 (142.1) 980 (38.6) 1765 (69.4) 2870 (112.9) 90° 90° 65°...
  • Page 145 OPTIONS General Precautions ........144 Fuel Supply Pump ........146...

  • Page 146: Options

    Precautions on Safety ¡ Consult with a Takeuchi dealer before installing optional attachments. ¡ Do not use attachments that have not been approved by Takeuchi or a Takeuchi dealer. Doing so may compromise safety or adversely affect the machine’s operation or service life.
  • Page 147 OPTIONS General Precautions Precautions on Operating Attachments WARNING Long or big attachments reduce machine stability. When traveling down steep slopes or turning on slopes, the machine may loose its balance and tip over. The following operations are particularly dangerous. Do not perform them. ¡...
  • Page 148 OPTIONS Fuel Supply Pump This device automatically supplies fuel to the fuel tank and stops automatically when the fuel tank is full. DANGER ¡ Do not use the fuel supply pump for gasoline or hydraulic oil. Doing so could result in explosion or damage. Only use the fuel supply pump for diesel fuel.
  • Page 149 INDEX...

  • Page 150: Index

    INDEX A ~ D Cautions on Operating ........... 70 Cautions on Transporting ........82 Accessories ............51 Cautions on traveling on slopes ......18 After Cold Weather is Over ........74 Cautions on Traveling on Slopes ......72 After First 250 Hours (New Machines Only) ..107 Cautions on working on the machine .....
  • Page 151 Inspecting the water separator ......96 Handling Rubber Crawlers ........75 Inspecting while sitting in the operator’s seat ..94 Have a Takeuchi service agent repair welding cracks Inspection After Warm-up ........66 or other damage ..........31 Inspection and Checks After Stopping the Engine ..73 Heater ..............
  • Page 152 INDEX K ~ R Never remove safety equipment ......8 Keep a safe distance from electrical power lines ... 20 Know the working area .......... 12 Observe all safety rules ........... 8 Operate on snow or ice with extra care ....19 Operating precautions ...........
  • Page 153 INDEX R ~ W Release all pressure before working Starting the Engine ..........62 on the hydraulic system ........29 Starting with jumper cables ........15 Replace important safety parts periodically ... 25 Stay clear of moving parts ........26 Replacing the air cleaner elements ......
  • Page 154 INDEX Warming Up the Engine ......... 63 Warming Up the Machine (Hydraulic Oil) ....65 Warning Lamps ............. 46 Wear appropriate clothing and personal protective equipment ..... 8 When Required ........... 118 Wiper Switch ............49...
  • Page 155 First Published October 2000 No. 18703 Second Published June 2001 OPERATOR’S MANUAL TCR50 Dump Carrier Edited and issued by TAKEUCHI MFG. CO., LTD. Printed in Japan by STATION M Co., Ltd.
  • Page 156 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.

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