Operators Manual Tw60-2 8069521 Ver 1.5 Rev 06042021
Operators Manual Tw60-2 8069521 Ver 1.5 Rev 06042021
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TW 60-2
Wheel Loader
The reproduction, distribution and utilization of this document as well as the communication of its contents to
others without express authorization is prohibited. Offenders will be held liable for the payment of damages.
All rights reserved in the event of the grant of a patent, utility model or design.
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Operating & maintenance manual
Table of contents
1 Machine designation, manufacturer and notes ......................................................... 8
1.1 Machine designation and intended use ........................................................................................ 8
1.1.1 Intended purpose and designated use .......................................................................................... 8
1.2 Manufacturer .................................................................................................................................... 8
1.2.1 Name and address of the manufacturer ........................................................................................ 8
1.2.2 Contact ........................................................................................................................................... 8
1.3 Technical description of the wheel loader .................................................................................... 9
1.4 Type plate and serial number ....................................................................................................... 10
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Designation:
Wheel loader
Type:
TW 60 SERIES 2
1.2 Manufacturer
1.2.2 Contact
Phone: + 49 (0) 4431 981 - 0
Fax: + 49 (0) 4431 981 - 139
E-Mail: [email protected]
Web: www.weycor.de
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Scope of application
Structural design
Hydraulic system
Operator`s station
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__ __ __ __ __ __ __ E123456
1
The serial number (1) features reference numbers in
order to identify optional features. The serial number can
be found on the type plate (2) on the right side of the
front end. In addition to this, it has been engraved on the
a
front end.
b f
g
d h
e i
The following information is provided by the type plate:
2 Product identification number (serial number) (a)
Type (b)
Fig. 1 Type plate Service weight (f)
Permissible total weight (g)
Engine power (d)
Permissible axle weight, front (h)
Maximum tractive effort (e)
Permissible axle weight, rear (i)
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2 User instructions
2.1 Responsibility of the contractor
The contractor is the owner or hirer of the wheel loader.
The responsibility to ensure that the wheel loader is
exclusively operated, serviced and maintained by staff that
is physically, mentally and professionally fit and
has read and understood the operating and
maintenance manual rests entirely with the owner or
hirer of the vehicle.
Prompt the operating and service staff to confirm this in
written form before authorizing them to use the vehicle.
Individuals under the influence of alcohol or drugs must
not operate the wheel loader.
Make sure that, in addition to the instructions and
guidelines stated in this manual, the mandatory national
or local safety regulations and laws referring to the
operation of construction machinery are observed.
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2.4.1 Signal word panels und safety alert symbols in the operating and maintenance manual
DANGER Indicates a hazardous situation which, if not avoided, will result in death or
serious injury.
WARNING Indicates a hazardous situation which, if not avoided, could result in death or
serious injury.
CAUTION Indicates a hazardous situation which, if not avoided, may result in minor or
moderate injury.
NOTICE This signal word is used to address practices not related to physical injury.
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This is the safety alert symbol. It is used to alert you to potential physical injury
hazards. Obey all safety messages that follow this symbol to avoid possible
injury or death!
20 km/h
The wheel loader is available in two versions, with different maximum travel speeds:
1) 20 km/h / 12.4 mph or 2) 28 km/h / 17.4 mph (high-speed version)
The label on the left indicates that the respective section exclusively refers to the 20 km/h (12.4 mph)
version, so it is only relevant to you if the maximum travel speed of your wheel loader is 20 km/h
(12.4 mph).
12.4 mph
28 km/h
The wheel loader is available in two versions, with different maximum travel speeds:
1) 20 km/h / 12.4 mph or 2) 28 km/h / 17.4 mph (high-speed version)
High-
The label on the left indicates that the respective section exclusively refers to the 28 km/h (17.4 mph)
speed
version, so it is only relevant to you if the maximum travel speed of your wheel loader is 28 km/h
(17.4 mph).
17.4 mph
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3 Safety information
3.1 General use of the wheel loader
Risk of accidents!
WARNING In order to avoid accidents caused by ignorance and faulty operation, inform
yourself of the specific safety requirements for work in danger zones before
starting wheel loader operation. Make sure the necessary precautions have
been taken. Do not start your work unless this is the case!
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For information about the safety measures and instructions referring to the
NOTICE operation of the vehicle, see the operating and maintenance manual for your
wheel loader.
Construction sites
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Workshops
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SAFETY Be sure to use the default measuring and test devices and to observe all
instructions regarding the use of special tools when making adjustments or
INSTRUCTIONS carrying out repair work.
Prevention of accidents and injuries by securing the vehicle and its parts
WARNING against inadvertent movement!
Take adequate measures, such as engaging the parking brake, turning off the
diesel engine, securing the wheels with wheel chocks and the loader by
means of a stabilizer. In case of doubt, inform yourself of the applicable
national laws and standards.
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Protective clothing
Protective clothing is personal safety equipment which aims at protecting the
torso and the extremities against external damage. Both pieces of clothing
which protect certain parts of the body and protective clothing that protects the
entire body are available.
Skin protection
Generally, whenever possible, exposing your skin to substances which can
cause harm to it should be avoided. In case this is not possible, be sure to use
appropriate skin cleaning and skin care products.
Head protection
In case the type of work you are about to perform bears the risk of head
injuries, be sure to wear proper headgear, such as hard hats (DIN EN 397),
etc.
Whenever you are exposed to noise at work, use appropriate ear protection
equipment to prevent damage to your health.
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3.5 Vibrations
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4 Technical specifications
20 km/h
Maximum travel speed: 20 km/h (12.4 mph)
12.4 mph
28 km/h
Maximum travel speed: 28 km/h (17.4 mph)
High-
speed
17.4 mph
4.1 Operating data *Specifications Subject to Change Due to Tire and Attachment Selections
Service weight 4850 kg (10692 lbs)
Permissible total weight 5000 kg (11023 lbs)
Permissible axle weight, front 3000 kg (6614 lbs)
Permissible axle weight, rear 3500 kg (7716 lbs)
Track width 1460 mm (57.5 in)
Wheelbase 2000 mm (78.7 in)
Bucket capacity SAE 0.73 m3 (25.8 ft3)
Forces w/ bucket:
Tear-out force 2590 daN (5823 pound-force)
Thrust 3660 daN (8228 pound-force)
Lifting capacity at ground level 2970 daN (6677 pound-force)
Tipping load, straight 3531 kg (7785 lbs)
Tipping load, articulated 3118 kg (6874 lbs)
Forces w/ pallet forks (500 mm (19.69 in) distance to center of gravity, transporting load at ground level)
Static tipping load, articulated (lift arm straight) 2339 kg (5157 lbs)
Lifting capacity, articulated 1871 daN (4206 pound-force)
Payload 80% even surface (ISO 8313 & EN 474-3) 1871 kg (4125 lbs)
Payload 60% uneven surface (ISO 8313 & EN 474-3) 1403 kg (888 lbs)
Noise level:
Average sound power level LWA (2000/14/EG & annexes) 100 dB (A)
Guaranteed sound power level LW A 101 dB (A)
(2000/14/EG & annexes)
Sound pressure level LPA (ISO 6396) 79 dB (A)
Vibration levels:
Hand-Arm- /Whole-body vibration level ( ISO 8041) < 2.5 / 0.5 m/s2 (< 8.2 /1.6 ft/ s2)
4.2 Tires *Specifications Subject to Change Due to Tire and Attachment Selections
Standard 12.5-18 MPT
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4.8 Dimensions
R
α
46°
E C
C1
B C2
F 43°
G
M D
A
R1
E
I
R
α
E1
E2
B C1
B1 H
C2
G
D
A
R1
Fig. 7 Dimensions
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Remove the bolt with the splint (1) from the fitting
1 4 of the articulation-lock device (2) at the front end
3
(3).
Swing the articulation-lock device horizontally
(see photo on the left).
Fasten the bolt with the splint pin (1) by inserting
it into the articulation-lock device and the drill
hole at the rear end (4).
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Ring bolts at
the rear end
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5.1.4 Recovery
In order to recover the wheel loader, use the lifting
lugs at the front, the ring bolts at the rear end and
the towing lug, as described above (see Crane
Transport, for example).
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3
2
5
1
7
9
10 8
6
7
11
1 Attachment (Bucket)
2 Loader
3 Front end
4 Cab
5 Engine compartment
6 Rear end
7 Rear axle
8 Diesel engine
9 Hydraulic pump aggregate
10 Front axle
11 Hydraulic quick coupler (HQC)
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8
5 1
2
9 1
1
1
6 0
4
8
3
7
Fig. 14 Cab
1 Dashboard
8 2 Joystick
3 Steering column lever
4 Steering wheel
5 Exterior mirrors
6 Front window
7 Pedals: Inching (creeping motion), brake & gas pedal
8 Safety belt
9 Driver´s seat
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Diesel fuel specifications: Diesel fuel should comply with one of the following specifications. The
table lists several specifications for acceptable fuels.
ASTM D975 Bio-diesel fuel
No. 1-D S15 Biodiesel blends up to B5
No. 2-D S15 ASTM D6751, D7467
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Lift the seat to the desired height and make sure it clicks
into place.
If you lift the seat beyond its maximum height (limit
stop), it will move back to its lowest position.
2 Fuel gauge
Fig. 27 Dashboard
Display reverse motion Activation (light) indicates that the wheel loader
(green) is moving backward.
Display road mode Indicates that the road mode has been set.
(yellow)
Control lamp turn signals wheel loader Flashes when the turn signals have been
(green) activated.
Control lamp turn signals trailer Flashes when the turn signals for operation with
(green) a trailer have been activated.
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Warning light Diesel engine In case this lamp lights up, stop the wheel
oil temperature (red) loader immediately and let the engine idle so
that the engine oil can cool down!
Warning light Diesel engine If this lamp lights up during operation, stop the
oil pressure (red) Diesel engine immediately!
Contact the Takeuchi service team.
Warning light hydraulic oil temperature Indicates that the hydraulic oil temperature is too
(red) high. Stop the Diesel engine and all movements
of the attachment immediately! Let the Diesel
engine idle until the hydraulic oil has cooled
down. Make sure that the electric fan of the
hydraulic oil cooler is activated. Contact the
Takeuchi service team.
Warning light Diesel engine air filter Lights up if the air flow rate through the air filter
(yellow) is too low, see Maintenance instructions.
Fuel gauge Bar graph which indicates the fuel level in the
Diesel tank.
The exhaust system needs to be cleaned (see
Regeneration / DPF lamp
operating manual Yanmar diesel engine)
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9 13
(14) (15)
6
9
12
18
17 8
11 10
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6
5
Fig. 31 Forward motion
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Take your right foot off the gas pedal (5) and step on the
1 brake pedal (6).
Press down the brake pedal (6) until the wheel loader
comes to a stop.
Activate the parking brake by means of the switch (1).
The symbol indicating the application of the parking
6 brake (9) lights up.
9 5
Use your left foot to step on the inching pedal (7), see
7 section on inching (creeping motion) in this manual.
If you use your left foot and activate the inching pedal by
stepping on it, the power of the Diesel engine is made
available to the working hydraulics.
Take your right foot off the gas pedal (5) and step on the
1 brake pedal (6).
Press down the brake pedal (6) until the wheel loader
comes to a stop.
Activate the parking brake by means of the switch (1).
The symbol indicating the application of the parking
6 brake (9) lights up.
9 5
1
9.3.8 Stopping and parking the wheel loader
Take your right foot off the gas pedal (5) and step
on the brake pedal (6).
Press down the brake pedal (6) until the wheel
1 loader comes to a stop.
4 Move the slide switch (4) on the joystick into the
6 5
middle position (neutral).
Activate the parking brake by means of the
switch (1). The corresponding symbol (9) lights
up to indicate its activation.
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After leaving the cab, lock the door (11) and the
11 engine hood (12).
Make sure the window is closed and secured
12 before leaving the vehicle.
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20 km/h
With the wheel loader set to the road mode, a driving speed of 0 to 20 km/h (12.4 mph) is possible.
12.4 mph
28 km/h
With the wheel loader set to the road mode, a driving speed of 0 to 28 km/h (17.4 mph) is possible.
High-
speed
17.4 mph
For work at construction sites and off-road operation, the wheel loader disposes
NOTICE of the following features:
Work mode = ensures a high lifting capacity at a low speed
Differential lock = improves the thrust on slippery soil
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28 km/h
High- Temporary noise generation while pressing down the inching pedal
NOTICE With the hydraulic pilot control set to “OFF” via the corresponding switch (14)
speed
and the inching pedal pressed down completely, there is an increase in
rotational speed. This is indicated by a distinctly audible sound.
17.4 mph Note that this noise generation is only temporary and part of the normal
14 functioning.
Risk of wheelspin
NOTICE On wet and soft grounds, wheelspin may impair the transfer of the vehicle`s
thrust to the soil. Activation of the differential lock can help avoid this problem.
However, the differential lock can only be used if the work mode is selected and
may not be used at a driving speed of more than 6 km/h (3.7 mp/h).
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Driving uphill:
In order to drive uphill (forward motion), the attachment
(in this case, the bucket) needs to point in the direction of
motion.
Driving downhill:
In order to drive downhill (reverse motion), the
attachment (in this case, the bucket) needs to point in the
direction contrary to the direction of motion.
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9.4.3 Brights
Turn on the low beam lights by means of the light switch
2 (1, see illustration above).
In order to activate the brights, pull the drop-arm (2)
towards the steering wheel, past the limit stop.
The corresponding symbol on the dashboard (3) lights
up to indicate the activation of the brights.
3
Fig. 53 Brights
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9.4.5 Horn
Fig. 55 Horn
NOTICE In order to avoid harassing other road users, the horn is to be used as an
acoustic warning device in exceptional cases only!
Press the switch for the hazard warning lights (5), which
is installed next to the ignition lock.
The switches for the front (4) and rear (5) work lights are
installed on the panel of switches.
5
4
6
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7 8
NOTICE The Diesel engine needs to have reached operating temperature before it can
effectively feed the heating unit-
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9.7.1 Required checks prior to operating the wheel loader on public roads
Fig. 67 Checks
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SAFETY Please note that the towing preparations and the towing process itself may
only be carried out by experienced and skilled persons who have
INSTRUCTIONS undergone the specific training required for these measures.
Ensure that the preparations at the driving hydraulics (see instructions
below) have been completed before towing the wheel loader!
Be sure to take the following precautionary measures for towing the
wheel loader and make sure that:
the towing vehicle disposes of the required tractive force,
the towing ropes are long enough and their breaking strength corresponds
to at least triple the tractive force of the wheel loader.
The total weight of the wheel loader needs to be taken into account, see
Technical specifications.
Risk of property damage and accidents if the towing distance is too long!
WARNING The wheel loader may only be towed within the working zone.
The towing distance is to be kept as short as possible and may not exceed
1000 meters (0.6 miles)!
Risk of property damage and accidents if the towing speed is too high!
WARNING In order to tow the wheel loader, set the towing vehicle in motion very
slowly.
The maximum towing speed may not exceed 5 km/h (3.1 mph).
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Risk of injury and death to people in the working range of the wheel
WARNING loader!
Using the attachment to transport, lift or lower people is strictly prohibited!
Make sure other individuals at the construction site keep off the operating
range of the wheel loader.
Secure the work zone against unauthorized trespassing.
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18
f 3
b
g
d
e
WE
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Operating conditions
The attachments approved by Takeuchi are intended for
operation on even and uneven grounds. The permissible
payloads may not be exceeded (see Technical
Specifications). The stability of the vehicle must be ensured
at all times.
NOTICE Contact your local Takeuchi dealer to order approved attachments and
accessories.
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C
f
g 18
NOTICE Please note that, as a safety precaution, the HQC pins automatically move
outwards after releasing the attachment.
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30-40 cm
(12-16 in)
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Driving uphill:
In order to drive uphill (forward motion), the bucket must
point in the direction of motion.
Driving downhill:
In order to drive downhill (reverse motion), the bucket
must point in the direction contrary to the direction of
motion.
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12-16 inches
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Continuous operation:
In order to start the continuous operation of the third
section, actuate the switch (19).
Press the thumbwheel upwards (f).
19 Continuous operation is started.
As long as the thumbwheel is still actuated, the oil
flow increases steadily.
If necessary, you can adjust the oil flow by moving
the thumbwheel (4) slightly downwards again.
Press the thumbwheel down to its lowest position
Fig. 84 Relieving the hydraulic circuit and use the switch (19) to deactivate the continuous
operation of the third section.
NOTICE Please note that, as a safety precaution, the HQC pins automatically move
outwards!
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In case the Diesel engine or the hydraulic system loses power during operation,
NOTICE the hydraulic pilot control of the attachment can be used to bring the
attachment to its lowest position.
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NOTICE To avoid further damage, in case faults or failures occur which you cannot detect
or repair yourself, contact the service staff immediately.
The Diesel engine Environmental temperature too low►►►► Preheat sufficiently; repeat the
does not starting procedure
start No fuel (Diesel) in the tank ►►►► Add Diesel; have the fuel system
ventilated by the service staff.
See Maintenance instructions.
Fuel filter plugged ►►►► Clean or replace the fuel filter
After activating the ignition, ►►►► Check the charge condition of the
The control lamp for the battery battery. If necessary, charge the
does not light up Make sure no hydraulic oil or fuel penetrates the ground,
battery.
pollutes water or leaks into the carry
If required, sewerout
system.
a jumpCollect
start. the
oil in suitable waste containers. When working in nature
protection
The wheel areas,
loader use environmentally
disposes friendly
of an electrical hydraulic
system with an
NOTICE oil.
operating voltage of 12 V. Be sure to take this into
account when jump-starting the vehicle!
After starting the Defective contact in the ►►►► Cable or plug-in connections are loose or
Diesel engine, the electrical system defective. Contact the service staff.
charge control
lamp does not go
out The rotational speed of the ►►►► Insufficient V-belt tension.
generator is too low Tension the V-belt. *
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After starting the The parking brake is applied ►►►► Deactivate the parking brake.
Diesel engine, the
wheel loader does The desired direction of motion ►►►► Contact the Takeuchi service team.
not move. has been set, but the wheel loader
does not move.
The HP valves have not been ►►►► Close the HP valves, see section
tightened after a towing process Towing the wheel loader.
The driving hydraulics is not active►►►► Contact the Takeuchi service team.
The wheel loader Electrical switch road/work ►►►► Contact the Takeuchi service team.
runs in the work mode is defective
mode only
The joystick switch for setting the ►►►► Repeatedly actuate the switch for the
mode is defective gear (mode) selection. Contact the
Takeuchi service team if the problem
persists.
The environmental temperature ►►►► Let the Diesel engine idle in order to
Hydraulic is too high. cause the hydraulic oil to cool down.
temperature The hydraulic system is overcharged. Do not perform any driving or working
too high motions.
The hydraulic oil cooler is dirty. Clean the hydraulic cooler (see
Maintenance instructions).
The warning light The filter cartridge is dirty ►►►► Clean the air filter and the air filter
for the air filter cartridge. For operation with a high
lights up formation of dust, insert a new filter
cartridge and be sure to store a
sufficient amount of filter cartridges.
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The warning lamp Insufficient brake fluid level ►►►► Add brake fluid according to the
for brake fluid specifications in the Maintenance
lights up instructions.
The warning lamp Insufficient engine oil pressure ►►►► Immediately stop the Diesel engine!
for engine oil or pressure does not build up after
pressure lights up starting the Diesel engine
General fault Indicates general faults related to ►►►► See Yanmar operating manual for the
message the diesel engine diesel engine.
diesel engine
►►►► Please contact the Yanmar customer
CHECK
service.
Critical fault Indicates critical faults related ►►►► Stop the Diesel engine immediately!
message to the engine.
Diesel engine ►►►► Please contact the Yanmar customer
service.
STOP
Indicates that the Diesel ►►►► Please contact the Yanmar customer
Ash lamp particulate filter is permanently service.
(Ash charge) plugged and that regeneration
lights up is not possible any more.
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Proceed as follows:
2. Stop the wheel loader, but do not turn off the engine.
3
3. Set the slide switch on the joystick to the neutral
5 (middle) position (3).
4 4. Engage the parking brake (4).
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To keep the diesel particulate filter free of soot particles for as long as possible,
NOTICE do not let the diesel engine idle for no reason and always warm it up sufficiently
before you start working with the wheel loader.
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13 Maintenance instructions
Obligation to inform yourself!
SAFETY
INSTRUCTIONS • starting
Read the safety instructions and warnings in this operating manual before
any maintenance work and follow them!
• Be sure to take all safety precautions and to observe all instructions
regarding the operation of the wheel loader when carrying out
maintenance work!
Spare parts
NOTICE Use genuine Takeuchi spare parts only!
For information about spare parts, including safety-relevant ones, see the
separately available spare parts catalogue.
OK
operating condition.
Check the hydraulic system of the wheel loader
for leaks after starting it.
Test the functions of the wheel loader.
Do not resume your work with the wheel loader
Fig. 92 Checking the wheel loader before thoroughly checking the vehicle.
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1 8
6
9
3
b
7
a
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2
5
7 4
8
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3 5
7 6
10 8
1 Front end
2 Loader
3 Working cylinder
4 Front headlights
5 Deflection lever
6 HQC (Hydraulic quick coupler)
7 HQC bolts
8 Front axle
9 Wheels
10 Loader cylinder
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14.3 Maintenance certificate A: Daily maintenance work prior to starting the wheel
loader
14.3.2 Lubrication
Fig. 99 Lubrication
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1
1
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Risk of accidents!
WARNING In order to check the hydraulic oil, the wheel loader needs to be parked on
level ground.
The loader and the attachment need to be in their lowest position.
14.3.5 Brakes
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12.5-18 MPT 2.2 bars 1.5 bars 3.5 bars 1.5 bars
(31.9 psi) (21.8 psi) (50.8 psi) (21.8 psi)
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* Change the hydraulic oil after the initial 1500 operating hours and
carry out the subsequent oil changes at intervals of 3000
operating hours (or after 24 months, at the latest)!
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SAFETY Before carrying out the maintenance measures described in this chapter, be
INSTRUCTIONS sure to complete the work for Maintenance Certificate A.
15.3.1 Lubrication:
Lubricate the two hinge bearings (1) of the
steering cylinder.
5
2
Fig. 106 Lubrication
15.3.2 Wheels
Tighten 8 nuts per wheel by means of a torque
wrench.
Tightening torque: 450 Nm.
450 Nm
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Risk of serious physical harm and death caused by hot water and rotating
WARNING parts!
• To prevent scalding, exercise caution - hot water may escape!
• Never carry out checks and maintenance work with the engine running!
• Turn off the engine and make sure it has cooled down before adding
coolant!
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As soon as the corresponding display on the dashboard indicates the
NOTICE accumulation of dirt in the air filter for the combustion air of the Diesel
engine, the air filter has to be cleaned or replaced.
Clean the interior of the air filter housing. If necessary, vacuum it.
After a maximum of five cleanings by means of compressed air, replace the
filter cartridge.
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Oil change:
The following oil changes need to be performed after
initial 500 operating hours and subsequently, at intervals
of 1500 operating hours:
□ Oil change front axle
□ Oil change rear axle
□ Oil change brake system
The hydraulic oil has to be replaced after the initial 1500
operating hours and subsequently, at intervals of 3000
operating hours (after 24 months at the latest).
Screw connections:
□ Check and adjust the screw connections at the Diesel
engine mounting.
□ Tighten the screw connections of the front and rear axle
(tightening torque: 550 Nm) at the front and rear end.
□ Tighten the screw connections at the articulated
pendulum joint (see workshop manual and Maintenance
instructions for the initial operation).
□ Tighten the screw connections of the cardan shaft
(tightening torque 42 Nm).
□ Check all other screw connections.
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Hydraulic system:
□ Clean the hydraulic oil cooler.
□ Replace the filter cartridge at the pump assembly.
□ Replace the filter cartridge in the hydraulic oil tank.
□ Replace the ventilation filters of the hydraulic oil tank.
□ Check the hydraulic hoses and screw connections for
leaks.
Diesel engine:
□ Replace the air filter cartridge of the Diesel engine.
Clean the air filter housing.
□ Tighten the screw connections of the exhaust
system.
□ Check all connections of the air intake system for
leakage and tighten all clamps and fastening screws
(after the initial 50 operating hours and subsequently,
at intervals of 500 operating hours).
Electrical system:
□ Check the wiring and the plug-in connections of the
vehicle.
□ Check (and, if necessary, clean) all visible cables and
plugs.
□ Clean and grease the battery contacts.
□ Check the entire electrical system:
o Lighting equipment
o Turn signals, work lights
o Front and rear wipers
o Rear window defroster
o Ventilation system / fan
o Backup lights
o Switching functions concerning the direction of
motion, the off-road mode, the pilot control and the
differential lock.
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Risk of explosions and serious injury caused by battery gases and acid!
WARNING Battery gases are explosive!
Keep away sparks and open fire from the battery!
Do not smoke!
Battery acid can cause chemical burns!
Protect your eyes and your skin!
NOTICE Please note that the electrical system disposes of an operating voltage of 12V.
Battery:
Check the battery poles (2) for corrosion and the
2 accumulation of dirt.
Lubricate the poles and the terminal (Grease: order
no.0830684).
4
3 Printed circuit board, fuses and relays:
1
4 Check the printed circuit board and the fuses and
relays on the printed circuit board.
Open the cover (3) of the printed circuit board (4) and
carry out a visual inspection.
Check the fuses and relays for the accumulation of
dirt or damage.
Always replace defective fuses!
For information on the allocation of the fuses, see
Survey of fuses
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15.5.5 Fuses and relays in the engine compartment (on the left, in the rear)
K59
K13
K43
F29
K20
K19
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Operating & maintenance manual
Compressed air:
Compressed air is to be used to remove minor, dry dirt
only. Start blowing at the exhaust side.
Water and solvent:
In case water and solvent are used to clean the engine,
use solvents which dissolve compounds of dust, fuel and
lubricants. Apply the solvent by means of a brush. Let it
set before washing it down with water.
□ Clean the protective grid, the engine cooling fan and the
air guiding plates.
□ Never point directly at sensitive parts, e.g. the fan wheel.
□ Prevent the cleaning fluid from reacting with electrical
components.
□ After a thorough and careful cleaning, run up the engine
in order to cause the remaining water to vaporize, thus
preventing corrosion.
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17 Initial operation
SAFETY In order to ensure that the customer will be able to operate the machine safely,
make sure that all checks and maintenance measures related to the initial
INSTRUCTIONS operation are carried out in the presence of the customer or his/her staff. Obtain
a written confirmation.
SAFETY In order to enable the customer to operate the machine safely, make sure that
all checks and maintenance measures related to the initial operation are carried
INSTRUCTIONS out in the presence of the customer or his/her staff. Obtain a written
confirmation.
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Screw connections:
Hydraulic system:
SAFETY In order to enable the customer to operate the machine safely, bear in mind
INSTRUCTIONS that, after your initial instruction and demonstration, the operating and
maintenance manual will be the only resource for obtaining information on the
operation of the wheel loader.
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17.2.5 Maintenance
□ After any operation, leaks are to be eliminated and the
correct functioning of the electrical system and the
brakes needs to be ascertained.
□ Refer to the verifications of inspections and maintenance
certificates when explaining all maintenance and service
work.
□ Be sure to adhere to the instructions in the operating
manual of the Diesel engine manufacturer when carrying
out and demonstrating any maintenance measures
related to the Diesel engine.
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SAFETY
See Note of delivery and verification of inspections for the required form.
INSTRUCTIONS
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18 Verification of inspections
Maintenance Inspection 1:
50 operating hours
After the execution of the required maintenance work by the authorized Takeuchi dealer,
complete this form and send a copy to the Takeuchi customer service.
___________________ _________________
____________________________________________________________________
(City, Date)
____________________________ ____________________________
(Signature Takeuchi service staff) (Signature Customer)
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SAFETY Please continue to carry out the required maintenance work according to this
schedule. This ensures that your wheel loader is always ready for operation and
INSTRUCTIONS that maximum safety is attained!
Oil change at the front axle (differential, planets), the rear axle (differential,
gear box, planets) and the brake system after the initial 500 operating
hours; subsequently, at intervals of 1500 operating hours or once a year.
Hydraulic oil change: after the initial 1500 operating hours; subsequently,
at intervals of 3000 operating hours but after 24 months at the latest.
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19 Table of figures
Fig. 1: Type plate ......................................................... 10 Fig. 61: Ventilation system ........................................... 52
Fig. 2: Type plate cab ................................................... 10 Fig. 62: Heating unit ..................................................... 52
Fig. 3: Type plate Diesel engine ................................... 10 Fig. 63: Drying the windows without the heating .......... 52
Fig. 4: Construction sites .............................................. 16 Fig. 64: Drying the windows with the defroster ............. 53
Fig. 5: Ventilation ......................................................... 17 Fig. 65: Rear window defroster..................................... 53
Fig. 6: Safety measures ............................................... 18 Fig. 66: Air conditioner ................................................. 53
Fig. 7: Dimensions........................................................ 24 Fig. 67: Checks ............................................................ 55
Fig. 8: Driving onto a flat bed truck ............................... 25 Fig. 68: Wheel chocks .................................................. 56
Fig. 9: Articulation-lock device ...................................... 25 Fig. 69: Opening the HP valves .................................... 57
Fig.10: Tying the wheel loader to the transport Fig. 70: Deactivating the parking brake ........................ 57
vehicle .............................................................. 26 Fig. 71: Closing the HP valves ..................................... 58
Fig.11: Carrying out the transport ................................. 26 Fig. 72: After towing ..................................................... 58
Fig.12: Crane transport ................................................ 27 Fig. 73: Joystick and related functions ......................... 60
Fig.13: Assembly groups .............................................. 28 Fig. 74: Hooking in the attachment ............................... 61
Fig.14: Cab ................................................................... 29 Fig. 75: Locking the attachment ................................... 62
Fig.15: Decals and labels ............................................. 30 Fig. 76: Putting down an attachment ............................ 62
Fig.16: Visual inspection .............................................. 32 Fig. 77: Driving with load .............................................. 63
Fig.17: Fuel .................................................................. 32 Fig. 78: Dumping material ............................................ 64
Fig.18: Accessing the cab ............................................ 33 Fig. 79: Driving uphill .................................................... 64
Fig.19: Releasing and closing the door ........................ 33 Fig. 80: Driving downhill ............................................... 64
Fig.20: Opening and securing the window ................... 34 Fig. 81: Picking up material .......................................... 65
Fig.21: Weight adjustment............................................ 35 Fig. 82: Driving with load on pallet forks ....................... 65
Fig.22: Longitudinal adjustment ................................... 35 Fig. 83: Unloading material........................................... 65
Fig.23: Backrest inclination .......................................... 35 Fig. 84: Relieving the hydraulic circuit .......................... 66
Fig.24: Height adjustment ............................................ 36 Fig. 85: Road sweeping ................................................ 67
Fig.25: Safety belt ........................................................ 36 Fig. 86: Regeneration ................................................... 71
Fig.26: Exterior mirrors ................................................. 36 Fig. 87: Initiation of regeneration .................................. 71
Fig.27: Dashboard ........................................................ 37 Fig. 88: Regeneration process ..................................... 72
Fig.28: Control elements in the cab .............................. 39 Fig. 89: Completion of the regeneration process .......... 72
Fig.29: Battery main switch .......................................... 40 Fig. 90: Securing the wheel loader ............................... 73
Fig.30: Starting the Diesel engine ................................ 40 Fig. 91: Articulation-lock device .................................... 73
Fig.31: Forward motion ................................................ 41 Fig. 92: Checking the wheel loader .............................. 73
Fig.32: Stopping the forward motion............................. 42 Fig. 93: Engine compartment ....................................... 74
Fig.33: Stopping to work............................................... 42 Fig. 94: Diesel engine overview.................................... 75
Fig.34: Reverse motion ................................................ 42 Fig. 95: Loader and front end ....................................... 76
Fig.35: Stopping the reverse motion............................. 43 Fig. 96: Right cab panel ............................................... 77
Fig.36: Steering motions .............................................. 43 Fig. 97: Grease gun ...................................................... 78
Fig.37: Turn signals ...................................................... 43 Fig. 98: Daily checks .................................................... 81
Fig.38: Stopping and parking ....................................... 43 Fig. 99: Lubrication ....................................................... 81
Fig.39: Stopping the Diesel engine .............................. 44 Fig.100: Engine oil level ............................................... 82
Fig.40: Battery main switch .......................................... 44 Fig.101: Hydraulic oil level ........................................... 82
Fig.41: Leaving the wheel loader ................................. 44 Fig.102: Brakes ............................................................ 83
Fig.42: Securing the vehicle on slopes ......................... 45 Fig.103: Cooler ............................................................. 83
Fig.43: Driving position ................................................. 45 Fig.104: Windshield washer system ............................. 84
Fig.44: Road mode ....................................................... 46 Fig.105: Cleaning ......................................................... 84
Fig.45: Work mode ....................................................... 46 Fig.106: Lubrication ...................................................... 88
Fig.46: Inching pedal .................................................... 47 Fig.107: Wheel nuts ..................................................... 88
Fig.47: Differential lock ................................................. 47 Fig.108. Electrical system............................................. 89
Fig.48: Deactivating the differential lock ....................... 48 Fig.109: Cleaning the combined cooler ........................ 89
Fig.49: Driving uphill ..................................................... 48 Fig.110: Brake fluid level .............................................. 90
Fig.50: Driving downhill ................................................ 48 Fig.111: Air filter ........................................................... 90
Fig.51: Securing the vehicle on slopes ......................... 48 Fig.112 Axles................................................................ 93
Fig.52: Light switch....................................................... 49 Fig.113 Electrical system ............................................. 93
Fig.53: Brights .............................................................. 49 Fig.114 Fuses and relays ............................................. 95
Fig.54: Headlamp flasher ............................................. 49 Fig.115 Articulated pendulum joint ............................. 103
Fig.55: Horn ................................................................. 50
Fig.56: Hazard warning lights ....................................... 50
Fig.57: Work lights........................................................ 50
Fig.58: Front wipers...................................................... 51
Fig.59: Front windshield washer system ...................... 51
Fig.60: Rear wiper & windshield washer system .......... 51
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20 Index
A F
Accessing the vehicle .......................................... 33 Failures ................................................................ 68
Articulation-lock device ........................................ 25 Falling objects...................................................... 15
Assembly groups ................................................. 28 Faults ................................................................... 68
Attachments ......................................................... 61 Fill level, engine oil .............................................. 82
Fill level, hydraulic oil .......................................... 82
B Fill levels .............................................................. 23
Brakes.................................................................. 83 Flat-bed truck....................................................... 25
Brights.................................................................. 49 Forward motion.................................................... 41
Bucket .................................................................. 63 Front end ........................................................... 102
Bucket capacity .................................................. 22 Fuel specifications ............................................... 32
Fuses ................................................................... 94
C
Cab ...................................................................... 29 G
Change of direction ............................................. 43 Gear shifting ........................................................ 45
Check................................................................... 55
Cleaning the engine ............................................. 96 H
Contractor ............................................................ 11 Hazard warning lights .......................................... 50
Control ................................................................. 37 Headlamp flasher ................................................ 49
Cooler .................................................................. 83 Horn ..................................................................... 50
Crane transport .................................................... 27 Hydraulic failure ................................................... 67
Creeping motion .................................................. 42
I
D Inching pedal ....................................................... 47
Daily maintenance ............................................... 81 Initial operation .................................................... 98
Darkness.............................................................. 49
Dashboard ........................................................... 37 L
Designated use ...................................................... 8 Lifting capacity ..................................................... 22
Diesel ................................................................... 23 Loader ................................................................. 76
Diesel engine ....................................................... 23 Long term storage ............................................... 96
Dimensions .......................................................... 24 Lighting ................................................................ 49
Direction of motion ............................................... 43 Light switch .......................................................... 49
Displays ............................................................... 37 Line-of-sight obstruction ...................................... 54
Driver ................................................................... 78 Loading ................................................................ 25
Driver`s seat ........................................................ 35 Lubricants ............................................................ 78
Driving position .................................................... 45 Lubrication ........................................................... 81
E M
Emergency........................................................... 20 Machine designation ............................................. 8
Emergency lowering ............................................ 67 Manufacturer ......................................................... 8
Engine compartment ........................................... 74 Maintenance instructions ..................................... 73
Exterior mirrors .................................................... 36 Maintenance intervals ......................................... 88
N
Noise level ........................................................... 22
O
Operating data ..................................................... 22
Operating voltage ................................................ 23
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Operating & maintenance manual
P U
Pallet forks ........................................................... 64 User instructions .................................................. 11
Parking brake ....................................................... 37
Payloads .............................................................. 22 V
Power loss ........................................................... 67 Ventilation ............................................................ 52
Printed circuit board ............................................. 89 Vibrations ............................................................. 21
Public traffic ......................................................... 54 Vibration level....................................................... 21
Visual inspection .................................................. 32
R
Recovery .............................................................. 27 W
Reverse motion .................................................... 42 Warning notes ...................................................... 12
Road mode .......................................................... 45 Warranty ............................................................... 98
Road sweeping .................................................... 67 Wheels ................................................................. 88
Road travel........................................................... 54 Work mode ........................................................... 46
ROPS ................................................................... 23
S
Safety belt ............................................................ 36
Safety information ................................................ 14
Seat adjustment ................................................... 35
Securing the vehicle on slopes ............................ 45
Selling the wheel loader....................................... 11
Serial number ...................................................... 10
Service staff ......................................................... 86
Service weight ..................................................... 22
Shutdown ............................................................. 97
Slopes .................................................................. 44
Start ..................................................................... 40
Starting................................................................. 40
Steering................................................................ 43
Stickers ................................................................ 30
Stopping ............................................................... 40
Storage ................................................................ 96
Sweeping ............................................................. 67
Symbols ............................................................... 12
T
Table of lubricants ............................................... 79
Tank capacity ....................................................... 22
Technical specifications ....................................... 22
Tie-down .............................................................. 26
Third section ........................................................ 66
Tipping load ......................................................... 22
Tires ..................................................................... 22
Tools .................................................................... 78
Towing ................................................................. 56
Transport.............................................................. 25
Transport vehicle ................................................. 25
Turn signals ......................................................... 43
Type plate ............................................................ 10
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