Takeuchi TW9 Operating Instructions Manual
  1. Manuals
  2. Brands
  3. Takeuchi Manuals
  4. Tractor
  5. TW9
  6. Operating instructions manual

Takeuchi TW9 Operating Instructions Manual

Wheel loader
Hide thumbs
Table of Contents

Advertisement

Quick Links

tW9
Wheel Loader

Operating Instructions

These operating instrustions are read and
understand, otherwise injury or death is
caused.
EN
Language version:
2011-11
Edition:
5780200633
Order number:
TL08020438>
From vehicle ID No:
Translation of the original operating instructions

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the TW9 and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Summary of Contents for Takeuchi TW9

  • Page 1: Operating Instructions

    Wheel Loader Operating Instructions These operating instrustions are read and understand, otherwise injury or death is caused. Language version: 2011-11 Edition: 5780200633 Order number: TL08020438> From vehicle ID No: Translation of the original operating instructions...
  • Page 2 Wilhelm Schäfer GmbH Bau- und Industriemaschinen Rebhuhnstrasse 2-4 D-68307 Mannheim Germany Phone +49(0)621 - 7707-0 Please complete before commissioning the wheel loader: Vehicle model: ..................Vehicle ID No.: ..................Year of construction: ..................Commissioned on: ..................Dealer: This operating manual is protected by limited copyright. It may be reproduced for and used by the drive / plant operator...

  • Page 3: Table Of Contents

    Table of Contents 1 Introduction ......................... 1 1.1 Warranty and Maintenance......................2 1.2 Copyright............................2 1.3 Notes on using the Operating Instructions..................2 1.4 Environmental standards ....................... 3 1.5 Pictograms ............................. 3 1.6 Location of safety signs ......................... 5 2 Safety and Accident Prevention ..................7 2.1 Introductory remarks ........................
  • Page 4 Table of Contents 4.7 Hydroinflation of tires ........................46 4.8 Driving, steering and braking ....................... 47 4.8.1 Driving ........................... 47 4.8.2 Steering ..........................49 4.8.3 Brakes ........................... 49 4.8.4 Driving on roads ........................50 4.8.5 Switching off the machine (parking) ..................51 5 Working Operation of the machine .................
  • Page 5 Table of Contents 8 Troubleshooting........................ 97 8.1 General notes..........................97 8.2 Engine ............................97 8.3 No steering movement......................... 97 8.4 Insufficient performance of service brake ..................97 8.5 Insufficient performance of parking brake..................97 8.6 Hydrostatic travel drive without neutral position ................97 8.7 Hydraulic oil exceeds max.
  • Page 6 Table of Contents...

  • Page 7: Introduction 1

    Introduction 1 1 Introduction You decided to buy a TW9 Wheel Loader. The confidence placed in this model will be rewarded efficient economical performance of the machine. This operating manual contains all the information and instructions that are required to handle the machine correctly.

  • Page 8: Warranty And Maintenance

    1 Introduction 1.1 Warranty and Maintenance 1.2 Copyright The warranty period covers 12 months, beginning This instruction book is intended for use by with the day the machine is handed over or put into personnel responsible for operation, maintenance, operation. repair and supervision of the machine.

  • Page 9: Environmental Standards

    Introduction 1 1.5 Pictograms 1.4 Environmental standards The following Table explains the meaning of the When operating or working on the machine the pictograms which may be attached to your environmental standards currently valid must be machine. observed at all times. During installation, repair and maintenance tasks, particular care must be taken that substances that would damage the environment such as...
  • Page 10 1 Introduction Symbol Description Symbol Description Horn Hazard warning system Fuel Operating mode indicator Fuel level Operating hours Blower Lashing points Heating/ventilation Suspension points for loading Windshield washer and wiper by crane system First-aid kit Parking brake Direction indicator LT/RT Fire extinguisher On machine: Working floodlights...

  • Page 11: Location Of Safety Signs

    Introduction 1 1.6 Location of safety signs The safety signs are located in the following positions on the machine: Locations of safety signs Safety distance (left and right sides of lifting frame) Safety distance Danger of injury Danger of crushing Servicing and replacing safety signs The safety of the operator always has to come first.

  • Page 13: Safety And Accident Prevention 2

    A copy of the Certificate of Conformity is attached to the sales documents. EC declaration of conformity according to the machinery directive 2006/42/EC We hereby declare that the earth-moving machine of type TW9: Wheel Loader: TW9 Vehicle ID No.:TL0802 Actual productivity: 44 KW complies with all the relevant requirements of Machinery Directive 2006/42/EC.

  • Page 14: Intended Use

    2 Safety and Accident Prevention 2.2 Intended use Read the operating instructions thoroughly and The earth-moving machine with standard bucket follow the notes on safe operation before putting equipment is intended solely for work which is the earth-moving machine into operation. suitable for the function of the machine and its work implements.

  • Page 15: General Safety Notes

    Safety and Accident Prevention 2 2.3 General safety notes 2.4 Operation It is important to refrain from any working methods Earth-moving machines shall only which impair safety. independently operated and serviced by persons The earth-moving machine is only to be used if it is •...

  • Page 16: Danger Zone

    2 Safety and Accident Prevention 2.6 Transport of persons 2.5 Danger zone The transport of persons on the machine is Nobody must be allowed to remain in the danger forbidden. zone of an earth-moving machine. The danger zone encompasses the area around the earth-moving machine in which persons may be injured by 2.7 Stability...

  • Page 17: Travel Operation

    Safety and Accident Prevention 2 2.8 Travel operation 2.9 Working Operation Before putting the earth-moving machine into Daily before start of operation and after every operation, the driver’s seat, mirrors and operator attachment change, the machine operator must controls must be adjusted so as to ensure safe check correct fastening...

  • Page 18: Guides

    2 Safety and Accident Prevention 2.10 Guides 2.12 Working in the vicinity of underground power lines Guides must be easily recognizable, e.g. by means of reflective clothing. They must remain within the Before commencing excavating work using earth- machine operator’s field of vision. moving machines, it must be determined whether any underground power lines are present in the While guiding the machine, guides shall not be...

  • Page 19: Working In The Vicinity Of Overhead Power Lines

    Safety and Accident Prevention 2 2.13 Working in the vicinity of overhead power 2.14 Operation in closed rooms lines If earth-moving machines are to be used in closed If the earth-moving machine is being used in the spaces, these areas must be sufficiently ventilated vicinity of overhead power lines and trolley wires, a and special regulations observed.

  • Page 20: Change Of Work Attachments, Maintenance, Repair

    2 Safety and Accident Prevention The engine/motor(s) must be turned off prior to all 2.16 Change work attachments, maintenance and repair work. These requirements maintenance, repair may only be ignored in the case of maintenance or Earth-moving machines shall only be converted, repair work which cannot be performed without the maintained or serviced under the guidance of a engine/motor(s) running.

  • Page 21: Recovery, Loading, Transportation

    Safety and Accident Prevention 2 Before commencing work on the hydraulic system, 2.18 Monitoring and inspections the operating pressure, pilot pressure, back The machine must be submitted to a general pressure and pressure inside the tank must be let inspection according existing UVV-...

  • Page 22: Fire Prevention

    2 Safety and Accident Prevention 2.19 Fire prevention • Switch off the engine when filling the fuel tank and take special care as long as the engine is hot. • Never smoke or handle open flames whilst refueling the tank of the machine. The fire extinguisher must be kept in the cabin (operator’s stand).

  • Page 23: Technical Data 3

    Technical data 3 3 Technical data 3.1 Views • General-purpose bucket and parallel kinematics Fig. 3 Dimensioned drawing - standard bucket and parallel kinematics Tires 405/70 R18...
  • Page 24 3 Technical data • Multi-purpose bucket and parallel kinematics Fig. 4 Dimensioned drawing - multi-purpose bucket and parallel kinematics Tires 405/70 R 18...
  • Page 25 Technical data 3 • Fork lift attachment and parallel kinematics Fig. 5 Dimensioned drawing - fork lift attachment and parallel kinematics Tires 405/70 R 18...
  • Page 26 3 Technical data • General-purpose bucket and Z kinematics Fig. 6 Dimensioned drawing - standard bucket and Z kinematics Tires 405/70 R18...
  • Page 27 Technical data 3 • Multi-purpose bucket and Z kinematics Fig. 7 Dimensioned drawing - multi-purpose bucket and Z kinematics Tires 405/70 R18...
  • Page 28 3 Technical data • Fork lift attachment and Z kinematics Fig. 8 Dimensioned drawing - fork lift attachment and Z kinematics Tires 405/70 R18...
  • Page 29 Technical data 3 • Low profile canopy with general-purpose bucket 0.8 m³ Fig. 9 Dimensioned drawing - low profile canopy with standard bucket 0.8 m³ Tires 15.5/55 R18...
  • Page 30 3 Technical data • Fold-down bar with general-purpose bucket 0.8 m³ Fig. 10 Dimensioned drawing - fold-down bar with standard bucket 0.8 m³ Tires 15.5/55 R18...

  • Page 31: Diesel Engine

    High-speed version featuring rear axle manual transmission shiftable in standstill position. Suction return filter in the form of a tank insert filter. Travel speed Forward - Reverse TW9 S Travel range Travel range Travel range 0 - 7 km/h 0 - 7.0 km/h 0 - 14 km/h "Work"...

  • Page 32: Brakes

    3 Technical data 3.5 Brakes Service brake Hydraulically actuated center-mounted disk brake, combined with hydrostatic brake of travel drive. Brake acts on all 4 wheels via 4-wheel drive. Parking brake Mechanically actuated center-mounted disk brake at front axle. Additional brake The hydrostatic travel drive in closed circuit additionally acts as non-wearing service brake.

  • Page 33: Axles

    Technical data 3 3.7 Axles Front axle Rigidly-mounted planetary drive with integrated center-mounted disc brake. Self-locking differential (45%) as standard. Rear axle (standard) Oscillating planetary drive axle with self-locking differential and integrated reduction gear. Rear axle (high-speed version) Oscillating planetary drive axle with self-locking differential and integrated 2-stage reduction gear.

  • Page 34: Consumables

    3 Technical data 3.9 Consumables 3.9.1 Filling quantities All values stated are approximate. Fluid capacities Fuels and lubricants liters Fuel tank approx. 75.0 Diesel fuel Engine with oil filter approx. Engine oil (change quantity) Hydraulic oil, tank and system approx. 55.0* Hydraulic oil Hydraulic oil tank...

  • Page 35: Consumable Specifications

    Technical data 3 3.9.2 Consumable specifications Stipulated consumables for Central Europe Application Designation Specification, standards, Remark quality Engine Diesel fuel EN 590 Before using RME fuels (rape oil methyl ASTM D975 1-D / 2-D ester), it is essential that you consult your responsible dealer for further details.
  • Page 36 3 Technical data Alternative recommendation for other temperature ranges Engine oil Hydraulic oil In compliance with API CH-4 or CI-4 and In compliance with DIN 51524.T3 HVLP In compliance with ACEA E3 / E4 0W-30 0W-40 5W-30 5W-40 10W-30 10W-40 15W-40 20W-50 Viskode...

  • Page 37: Permissible Loads In Compliance With German Road Traffic Regulations (Stvzo)

    Technical data 3 3.10 Permissible loads in compliance with German Road Traffic Regulations (StVZO) Permissible total weight see type label, Permissible axle load, front and / or Permissible axle load, rear (General AllgemeineBetriebsErlaubnis Certification) 3.11 Sound level values, vibration Sound level values in compliance with directive 2000/14/EC and EN 474 Guaranteed sound power level = 101 dB (A) Sound pressure level (at driver's ear)

  • Page 38: Dimensions And Weights

    3 Technical data 3.12 Dimensions and weights Specifications refer to general-purpose bucket and 405/70 R18 tires Parallel kinematics kinematics Operating weight with standard equipment according to ISO 4,900 4,900 6016 Total length, standard bucket on ground 5,060 5,085 Total width 1,850 1,850 Total height (cab roof)

  • Page 39: Bucket With Parallel Kinematics

    Technical data 3 3.14 Bucket with parallel kinematics Width Capacity, heaped Max. density (γ) m³ General-purpose bucket 1850 Bucket with bolt-on cutting edge 1,850 Earth bucket 1850 Earth bucket with bolt-on cutting edge 1,850 Multi-purpose bucket 1,850 0.75 Multi-purpose bucket with bolt-on cutting edge 1,850 0.75 Light-material bucket with bolt-on cutting edge...

  • Page 40: Fork Lift Attachment

    3 Technical data 3.15 Fork lift attachment Fork-arm connection in compliance with ISO/FEM Class 2 Form B, DIN 15 173 / ISO 2328 respectively Width of fork carrier 1,240 Length of forks 1,100 Fork cross section 100x45 Max. stacking height 3,070 The payloads are determined in compliance with DIN 24094 / ISO 14397-1 and EN ISO 474-3 respectively with a safety factor of 1.25 or 80% of the tipping load and the machine moving over level ground.

  • Page 41: Optional Accessories (Options)

    Technical data 3 3.16 Optional accessories (options) • Orthopedic air-cushioned driver's seat • Fire extinguisher • Pressurized cab • Air-conditioning • Independent diesel heating with timer • FOPS-roof guard • Sliding window in right-hand door • Working floodlight, rear • Yellow rotating beacon •...
  • Page 42 3 Technical data...

  • Page 43: Operation 4

    Operation 4 4 Operation 4.1 First Instruction The machine must be entered from the left-hand side as seen in the direction of travel. The right-hand cab door acts as an emergency exit. If the cab is entered by the right-hand door, the joystick may be operated unintentionally.

  • Page 44: Display Elements And Operating Controls

    4 Operation 4.2 Display elements and operating controls The following list includes non-standard equipment! • Operating controls Fig. 10.1 Operator controls...
  • Page 45 Operation 4 Description of fig. 10.1 - Operator controls Direction indicator, horn, low/-high beam (steering-column switch) Brake-inching pedal Accelerator pedal Steering wheel - tilt and height adjustment Stop button - additional control circuit Control light Actuation – potentiometer, 3rd control circuit Travel direction switch (without function if working hydraulics are deactivated) Impulse mode - float position Power socket...
  • Page 46 4 Operation • Instrument panel Fig. 10.2 Operator controls...
  • Page 47 Operation 4 Preselection button for actuation – 3rd Description of fig. 10.2 - Instrument panel control circuit Not assigned Preselection button – float position ORANGE - pre-heating monitor continuous operation RED - battery charge indicator Not assigned* RED - parking brake Glow plug and starter switch GREEN - travel direction, forward Hazard warning switch...

  • Page 48: Engine

    4 Operation 4.3 Engine 4.3.1 Starting the engine Each time before putting the machine into operation, inspections according to section 7.8 must be carried out. Before switching on the engine, take care to ensure that no one is in the immediate vicinity of the machine or in the danger zone.

  • Page 49: Monitoring During Operation

    Operation 4 4.3.2 Monitoring during operation If the engine and the machine are put into operation without prior remedy of the defect, severe damage to the engine may result! • If the battery charge control lamp (12/22) or the engine oil pressure indicator lamp (12/31) light up, switch off the engine immediately and determine the cause, or call for service personnel.

  • Page 50: Driver's Seat / Steering Wheel Tilt Adjustment

    4 Operation 4.4 Driver's seat / Steering wheel tilt adjustment Driver's seat The comfort seat is spring-mounted with oil- pressure operated shock absorbers and lap belt. The seat meets international quality and safety standards in compliance with ISO 7096 and ISO 6683 (fig.

  • Page 51: Heating / Ventilation

    Operation 4 4.5 Heating / ventilation Heating • The heater is connected to the engine oil circuit. • The fan is operated using the switch (15/44); temperature is adjusted using the control (15/57) and can be operated with fresh air and re-circulating air.

  • Page 52: Lighting In Compliance With German Road Traffic Regulations (Stvzo)

    4 Operation 4.6 Lighting in compliance with German Road Traffic Regulations (StVZO) The lighting of the loader is switched on and off by turning the steering-column switch (15/1). Light Off Setting 0 Parking light Setting 1 Driving light (low beam / high Setting 2 beam).

  • Page 53: Driving, Steering And Braking

    Operation 4 4.8 Driving, steering and braking 4.8.1 Driving When driving on public roads, the wheel loader, as a self-propelled work machine, is subject to the legal regulations valid in the user's country. (For example, in the Federal Republic of Germany, StVZO and StVO).
  • Page 54 4 Operation Driving off • Set the travel direction preselection switch on the joystick (17/8) and on the instrument panel (17/36) to "0" (neutral position). • The indicator lamps (17/24 and 17/28) must not light up. • Start engine. • Raise lift frame as far as the "Travel”...

  • Page 55: Steering

    Operation 4 4.8.2 Steering • The wheel loader features a fully hydraulic, proportionally acting articulated steering. • Priority supply of hydraulic oil to steering through load-sensing system. In the event of steering malfunctions, determine the cause immediately (see Trouble-Shooting Table) and call for service personnel if necessary.

  • Page 56: Driving On Roads

    4 Operation 4.8.4 Driving on roads Before driving on open roads, the following points have to be observed: The wheel loader must be equipped as stipulated by the regulations authorizing the use of vehicles for road traffic in the user's country. When travelling longer...

  • Page 57: Switching Off The Machine (Parking)

    Operation 4 4.8.5 Switching off the machine (parking) • Set the travel direction preselection switches (21/8 and 21/36) to "0". • Lower the work attachment onto the ground. • Switch off the working hydraulics (21/35). • Apply the parking brake (21/16). •...
  • Page 58 4 Operation...

  • Page 59: Working Operation Of The Machine 5

    Working Operation of the machine 5 5 Working Operation of the machine 5.1 General notes Daily before start of operation and after every attachment change, check the correct fastening of the work attachments as well as the correct locking of the quick-mount hitch.

  • Page 60: Operation - Loader

    5 Working Operation of the machine 5.2 Operation - Loader • Switch on the work equipment (22/35). Operation - Bucket • Operate joystick (22/6). Fig. 22 Operation...
  • Page 61 Working Operation of the machine 5 Fingertip control (electro-proportional control) Third control circuit • Proportional actuation of the control circuit • In continuous operation, the amount can be controlled. • Sensitive control of hydraulically-driven work attachments, such as multi-purpose bucket, sweeper, etc.
  • Page 62 5 Working Operation of the machine Operation - Float position The float position for continuous mode must always be switched off when not in use. Switch (23a/48) in position "0". Fingertip control and float position are deactivated as soon as the ignition (23a/50) is switched off.

  • Page 63: Changing Work Attachments

    Working Operation of the machine 5 5.3 Changing work attachments 5.3.1 General notes To achieve maximum utilization of the machine for a variety of applications, a great number of work attachments and accessories are available. The machine is equipped with a quick-attach system, to shorten the time it takes to change attachments.

  • Page 64: Assembly Of Work Attachments

    5 Working Operation of the machine 5.3.2 Assembly of work attachments The bearings on the lifting frame, quick- attach system and work attachment must free dirt. The system must be relieved of pressure before hydraulic connections disconnected. Procedure for changing directly mounted work attachments attachment hydraulically...
  • Page 65 Working Operation of the machine 5 Procedure for changing work attachments with hydraulic quick-attach system • Lower the work attachment onto the ground and position so that it cannot tilt. • Switch off the diesel engine. • In the case of a hydraulically activated work attachment, start the ignition and press the rocker switch (25/47) once.

  • Page 66: Notes On How To Work With The Machine

    5 Working Operation of the machine 5.4 Notes on how to work with the machine 5.4.1 Loading During transport, the bucket - either filled or empty - must be kept as close to the ground as possible. If possible, avoid long transport distances! For loading, lower the bucket and position the cutting edge parallel to the ground.

  • Page 67: Recovery And Transport Of The Machine 6

    Recovery and transport of the machine 6 6 Recovery and transport of the machine 6.1 Recovery of the machine Towing of the wheel loader must be restricted to clearing a junction or a road, to prevent damage to the hydrostatic travel drive. If possible, let the diesel engine run at low idle during towing.

  • Page 68: Loading The Machine Using A Crane

    6 Recovery and transport of the machine 6.2 Loading the machine using a crane Use a crane lifting harness and a crane with adequate lifting capacity! Take note of the total machine weight! Only use approved and undamaged sling gear. •...

  • Page 69: Maintenance And Care 7

    Maintenance and Care 7 7 Maintenance and Care 7.1 General notes The good operating condition and life expectancy The type-specific maintenance and inspection plan of machines are largely influenced by care and lists all work to be performed on the machine at maintenance.

  • Page 70: Regular Oil Analysis

    7 Maintenance and Care 7.3 Regular oil analysis 7.4 Warranty Oil analysis are not intended as a substitute for the During the warranty period thorough inspections oil change intervals but - apart from a possible are stipulated which are obligatory and must be reduction of maintenance costs and as a form of carried out by trained specialist dealer personnel.

  • Page 71: Inspection Parts And Aids

    Maintenance and Care 7 7.5 Inspection parts and aids Service parts for inspections should be ordered well in advance! Contact your dealer for further information! Lubricants • The machine’s life expectancy and operating condition largely depend on the use of the specified lubricants and compliance with the service intervals.

  • Page 72: Care And Cleaning

    7 Maintenance and Care 7.6 Care and cleaning 7.7 Notes for winter operation The following points and the relevant notes in the The machine must be cleaned on a engine instruction manual should be observed suitable surface with an oil separator. during winter operation.
  • Page 73 Maintenance and Care 7 Fuel • Only use commercially available brand-name diesel fuel with a sulfur content of less than 0.5%. • Use only winter diesel fuel in winter to prevent line connections becoming blocked through paraffin deposits. At very low temperatures, troublesome deposits may also occur when winter diesel is used.

  • Page 74: Checking, Maintenance And Inspection Plans

    7 Maintenance and Care 7.8 Checking, maintenance and inspection plans 7.8.1 Initial inspection (hand-over inspection) Fig. 31 Initial inspection...
  • Page 75 Maintenance and Care 7 Work to be carried out by trained specialist dealer personnel: Chapter Check machine for presence of machine-specific operating instructions Check the engine oil level 7.9.1 Hydraulic oil level 7.9.9 Check the fuel level 7.9.4 Check oil level of differential and axle hubs 7.9.13 Check tire pressure and tightness of wheel nuts 7.9.14...

  • Page 76: Daily And Weekly Tasks

    7 Maintenance and Care 7.8.2 Daily and weekly tasks Inspection and maintenance jobs to be performed by service personnel Fig. 32 Inspection and service schedule...
  • Page 77 Maintenance and Care 7 Daily Chapter Check hydraulic oil level 7.9.9 Check the engine oil level 7.9.1 Check fuel level (fuel gauge on instrument panel) 7.9.4 Check windshield washer fluid level 7.9.19 Visual check (general) for material cracks, external damage, completeness, etc. Check for leaks: Pipes, hoses, control valves, hydraulic pumps, cylinders, etc.

  • Page 78: Overview Of Lubricating Points

    7 Maintenance and Care 7.8.3 Overview of lubricating points Replace defective grease nipples immediately and check if grease passes through! Fig. 33 Lubrication schedule - parallel kinematics L824-033_Z-Kine_2010 Fig. 33 Lubrication schedule - Z kinematics...
  • Page 79 Maintenance and Care 7 Grease all lubricating points with multi-purpose grease The intervals stated are valid for one-shift operation Item Number daily weekly Chapter Lubricating point Tilt cylinder - Tilt control lever Lift frame - Tilt control lever Lift cylinder - Lift frame 1 (2)* Tilt cylinder - Front-end Lift frame - Front-end...

  • Page 80: Inspection Plan

    7 Maintenance and Care 7.8.4 Inspection plan Work to be carried out by trained specialist dealer personnel: O = Checking, maintenance Operating hours X = Replace after every every every year- year- Chapter Perform work with machine at operating temperature 1000 2000 Check machine for presence of machine-specific...
  • Page 81 Maintenance and Care 7 O = Checking, maintenance Operating hours X = Replace Perform work with machine at operating temperature after every every every year- year- Chapter 1000 2000 Check that door catches function perfectly, and replace if necessary Clean or replace the dust filter for cab ventilation 7.9.18 Check electrical indicating and warning elements as well as lighting equipment.

  • Page 82: Inspection And Maintenance Work

    7 Maintenance and Care 7.9 Inspection and maintenance work • Check oil level and refill oil (emptied cooler has 7.9.1 Engine oil filled with oil). Checking the engine oil level • Start the engine and run at low idle speed for •...

  • Page 83: Engine Oil Filter

    Maintenance and Care 7 7.9.2 Engine oil filter The engine oil filter must be replaced every time the engine oil is changed. • Place oil drip pan below the engine oil filter. • Clean the outside of the engine oil filter. •...

  • Page 84: Cooling System - Combined Hydraulic Oil-Water Cooler

    7 Maintenance and Care 7.9.3 Cooling system - combined hydraulic oil- water cooler 7.9.3.1 Checking the coolant level • Check the coolant level daily before starting, with the machine parked on level ground. To do so, use the sight glass (37-1/2) of the combined cooler.
  • Page 85 Maintenance and Care 7 7.9.3.3 Cleaning cooling fins Machine damage due to overheated engine. • Thoroughly clean cooler prevent overheating of the engine and/or the hydraulic oil. Only perform cleaning after stopping the engine and letting it cool down! • Clean the combined cooler from the outlet side with compressed air.

  • Page 86: Fuel System

    7 Maintenance and Care 7.9.4 Fuel system Checking the fuel level • Check the fuel level using the fuel gauge (38/27). • Top up fuel every day after use to prevent condensation from forming before the machine is next put into operation. Draining the fuel filter •...
  • Page 87 Maintenance and Care 7 Cleaning fuel pump, sieving filter • Loosen and unscrew the hexagonal screw (41/1). • Take out the fuel sieve (41/2 - cover and sieve forming a unit). • Clean the sieve in fuel and replace it, if necessary.

  • Page 88: Air Filter, Air Intake

    7 Maintenance and Care 7.9.5 Air filter, air intake All maintenance work on the air intake system must be carried out with the engine off. Do not start the engine after the filter cartridge has been removed. 7.9.5.1 Dust ejection valve •...
  • Page 89 Maintenance and Care 7 7.9.5.4. Cartridge replacement Main cartridge • Release the wire tighteners (45/1) and remove the bottom of the housing (45/4). • Withdraw the main cartridge (45/2) by twisting slightly to and fro. • Check whether the safety cartridge (45/3) must be replaced.
  • Page 90 7 Maintenance and Care 7.9.5.5 Cleaning the main cartridge Never wash or brush out the main cartridge. Make sure that no dust ends up on the inside of the main cartridge when blowing out. • The main cartridge can be cleaned up to five times if necessary.

  • Page 91: V-Belt

    Maintenance and Care 7 Changing the V-belt 7.9.6 V-belt • Slacken the fastening screws (47/1). Checking the condition of the V-belt • Swivel the generator against the direction of tensioning. Check or tension V-belts only when the engine is turned off. •...

  • Page 92: Brakes

    7 Maintenance and Care 7.9.8 Brakes Checking the brake oil level • Visual inspection (49/1) of brake oil level. Only top up with ATF-oil! Changing brake oil and bleeding the brake Collect the waste oil, do not allow it to seep into the ground.

  • Page 93: Hydraulic Oil Tank

    Maintenance and Care 7 7.9.9 Hydraulic oil tank Checking hydraulic oil level • Check the oil level using the oil dipstick (51/1); top up hydraulic oil if required. Changing the hydraulic oil Danger of scalding when hot oil is drained! •...

  • Page 94: Hydraulic Oil Cooler

    7 Maintenance and Care 7.9.10 Hydraulic oil cooler Dirt accumulation in coolers causes the hydraulic overheat. Only perform cleaning after stopping the engine and letting it cool down The machine is equipped with a combined radiator and hydraulic oil cooler. Both cooler components must be cleaned during maintenance (see also Chap.

  • Page 95: Hydraulic Oil Filter

    Maintenance and Care 7 7.9.11 Hydraulic oil filter After major repairs the filter cartridge of the hydraulic oil filter must also be replaced after the test run. Changing the filter insert • Unscrew the oil dipstick (51/1). • With the aid of a tool, remove the filter cover (53/1).

  • Page 96: Breather

    7 Maintenance and Care 7.9.12 Breather Replace the breather if it is dirty, e.g. due to oil fumes. • Unscrew the oil dipstick (54/1). • Remove the breather (54/2) and dispose of according to regulations. • Clean the screen (54/4) and check for damage; replace if required.

  • Page 97: Axles

    Maintenance and Care 7 7.9.13 Axles General The axle oil must be changed at operating temperature. Collect the waste oil, do not allow it to seep into ground. Dispose of according to regulations! After filling the axles with oil, move the machine for approx.
  • Page 98 7 Maintenance and Care 7.9.13.2 Differential of rear axle with transmission Serie Checking the axle oil level • Remove the inspection plug (56/1) check and top up oil if required. Changing axle oil rear axle differential transmission have combined oil filling. •...

  • Page 99: Wheels

    Maintenance and Care 7 7.9.13.3 Wheel hub Checking the axle oil level • Remove the inspection plug (57/1) check and top up oil if required. Changing axle oil wheel combined inspection, filling and drain plug! Ölstand Level • Turn the wheel until the screw plug (57/1) on the hub is at the bottom.

  • Page 100: Electrical Equipment

    7 Maintenance and Care 7.9.17 Electrical equipment Battery Follow the instructions of the battery manufacturer when taking a battery into service for the first time. • The acid level should be approximately 10 mm above the plate edges. If necessary, top up with pure distilled water.

  • Page 101: Cab Ventilation Dust Filter

    Maintenance and Care 7 7.9.18 Cab ventilation dust filter • The air intake for the heater and fresh air supply of the cab features a dust filter, optionally a charcoal/ pollen filter. Removing • Remove the ventilation louver (60/1). • Remove the angle bracket (60/2).

  • Page 102: Taking Out Of Service

    7 Maintenance and Care 7.10 Taking out of service 7.10.1 Preservation for temporary taking out of 7.10.3 After the machine had been taken out of service service In order to prevent damage (corrosion, etc.) from Before putting the machine into operation once storage during shutdown periods over three more, the following measures must be carried out: months, certain preservation measures must be...

  • Page 103: Troubleshooting 8

    Troubleshooting 8 8 Troubleshooting 8.2 Engine 8.1 General notes All defects and faults in the diesel engine must be Operating problems are often the result of incorrect examined as described in the separate engine handling of the machine, the use of unsuitable instruction book.

  • Page 104: Hydraulic Oil Exceeds Max. Admissible Temperature

    8 Troubleshooting Fault Possible cause Remedy 8.7 Hydraulic oil exceeds max. admissible temperature Thermo switch damaged Replace Oil level too low Top up oil to mark on dipstick Oil cooler dirty or damaged Clean, check and replace if required Suction filter clogged Replace High-pressure valves do not respond all Check high-pressure valves, re-adjust or replace...

  • Page 105: Transmission Works In One Direction Only

    Troubleshooting 8 Fault Possible cause Remedy 8.9 Transmission works in one direction only Switch for travel direction damaged Repair or replace if necessary Solenoid valve gets stuck or is damaged Repair or replace if necessary Power supply towards switch for travel Check and repair (incl.

  • Page 106: Decrease In Machine's Performance (Loader Installation)

    8 Troubleshooting Fault Possible cause Remedy 8.12 Decrease in machine's performance (loader installation) Insufficient engine power Check diesel engine and adjust if necessary Hydraulic oil level too low Top up hydraulic oil to mark on dipstick Pump is sucking up air Re-tighten hose connections.

  • Page 107: Appendix 9

    Appendix 9 9 Appendix 9.1 Electrical system • Fuse box – assignment diagram Fuses Fuses Position Amps Assigned to Position Amps Assigned to FL 1 Heater fan, air conditioning FR 1 Working floodlights, front FL 2 Windshield wiper FR 2 Working floodlight, rear washer system, front FL 3...

  • Page 108: Equipment Options

    9 Appendix 9.2 Equipment options Ride control system (RCS) Depending on the machine's operating weight, road conditions, and speed, there may be pitching oscillations when driving wheel loaders. The ride control system reduces pitching oscillation, which results in the following advantages: •...

  • Page 109: Immobilizer

    Appendix 9 9.3 Immobilizer 9.3.3 Learning a new key Learning a new key takes place with a master key 9.3.1 Activating the immobilizer that is identified with a red key pommel. The immobilizer is self-activating; that is, The master key must be stored carefully; only one without additional activation or divergent master key is available for each immobilizer.

  • Page 110: Learning Multiple New Keys

    9 Appendix 9.3.4 Learning multiple new keys 9.3.6 Security functions • Insert the keys to be learned into the ignition If more than 5 keys are activated in the ignition lock within 1 minute with different invalid codes, the lock one after the other. immobilizer remains active for 15 minutes and •...

  • Page 111: Fault Causes

    Appendix 9 9.3.7 Fault causes Immobilizer has no function Inspect voltage supply on plug contacts Check antenna plug-in connection Check antenna cable (see ‘Checking antenna’) Use key with learned transponder Key learning not possible Terminal 30 not connected to control unit No or incorrect master key used previously (red grip) Time for master key in ignition too short or too long Key to be learned does not have transponder...
  • Page 112 9 Appendix...
  • Page 113 DELIVERY AND HANDING-OVER INSTRUCTIONS The following checklist is to be followed when handing over the machine to the dealer/ customer: 1. Operating Instructions The Operating Instructions should be read side by side, and be explained in detail through practical training on the machine. Items which are particularly important include: •...
  • Page 114 I n s p e c t i o n p l a n Work to be carried out by trained specialist dealer personnel O = Checking, maintenance O = Checking, maintenance X = Replace Operating hours X = Replace Operating hours after every...

Table of Contents

Save PDF