Takeuchi TL220, Operator'S Manual

Page 1: ...O Serial No 222000556 Serial No 223000859 Serial No 224000570 Serial No 225000665 Book No AU1 EOOS US OE TL220 H TRACK LOADER Original instructions WARNING Read and irnersta00 these instructions Lil F...

Page 2: ...enance of this machine can cause injury or death Read and understand this manual before performing any operation inspection or maintenance on this machine Always store this manual where it is ready av...

Page 3: ...ndicates an imminently hazardous situation which if not avoided can result in serious injury or death AwARNING The word WARNING indicates a potentially hazardous situation which if not avoided could r...

Page 4: ...l storage A compartment for storing this manual is provided at the position shown in the diagram below 1 Insert the starter key and turn it counterclockwise to unlock the cover 1 2 Open the cover 1 3...

Page 5: ...noise and exhaust emissions Two way auxiliary hydraulics Pilot operated joystick controls Break in period RIGHT T7A004E When the machine is new follow the instructions below when operating the machine...

Page 6: ...4...

Page 7: ...CONTENTS Introduction 2 Machine Description 3 mSafety 7 aControls 39 Operation 73 Transport 99 mMaintenance 105 c a Troubleshooting 157 e Specifications 171 Options 181 l Index 205 5...

Page 8: ...6...

Page 9: ...ETY General Precautions 8 Preparing Precautions 15 Starting Precautions 17 Operating Precautions 19 Stopping Precautions 26 Transporting Precautions 27 Maintenance Precautions 28 Safety Signs Decals 3...

Page 10: ...hen using grinders hammers or compressed air because metal fragments or other objects can fly and cause serious injury 8 Use hearing protection when operating the machine Loud prolonged noise can caus...

Page 11: ...e sure who has the responsibility for signaling All personnel must fully understand all the signals The operator shall respond to signals only from the appointed signal person but shall obey a stop si...

Page 12: ...fluids and materials in a safe fireproof and well ventilated place 10 Fire prevention AU1E001 When working in a certain environment it is impossible to prevent combustible debris from collecting in t...

Page 13: ...parts be found repairs must be made immediately Engine exhaust leaks can cause fires Do not operate the machine until the exhaust leak is repaired 10 During daily operation of the machine the occurre...

Page 14: ...the top of the extinguisher that keeps the handle from being pressed Break the plastic seal as the pin is pulled Aim the nozzle at the base of the fire Do not aim the nozzle at the flames In order to...

Page 15: ...asbestos dust Inhaling asbestos dust has been linked to lung cancer When handling materials which may contain asbestos take the following precautions Never use compressed air for cleaning Avoid brush...

Page 16: ...njury or death The lift arms move close to the outside of the side screens never stick out arms or other portions of your body from the side screens The lift arms move close to the canopy therefore do...

Page 17: ...off the working area and prohibit entry to unauthorized persons When working in water orcrossing shallow streams or creeks check the depth of the water the firmness of the ground and the speed of the...

Page 18: ...around the operator s seat Do not leave any plastic bottles in the operator s compartment or attach any suction cups on the window glass The plastic bottle or suction cup act as a lens and can cause...

Page 19: ...of other persons before starting the machine Do not start the engine until you are sure it is safe Before starting check or perform the following Walk around the machine and warn all personnel who ma...

Page 20: ...ow the shutdown procedure and report the malfunction Warm up the engine and hydraulics Observe all gauges and warning instruments for proper operation Listen for unusual noises Test engine speed contr...

Page 21: ...m the operator s seat Operate all the controls only from the operator s seat Failure to do so can cause serious injury or death 19 Check for safety in the surrounding area before starting T7A010 Under...

Page 22: ...e ignition switch while traveling Doing so will cause sudden braking and is dangerous Before backing up visually check for safety to the rear Backing up without checking could result in contact with a...

Page 23: ...on slopes Especially when going down slopes reduce the engine r p m speed and set the stroke of the left control lever to half or less before going down Going down a slope too fast will lead to loss...

Page 24: ...celerating stopping and changing directions abruptly Remember that the road shoulder fences etc may be buried in the snow and not visible Lower the bucket when parked on unsure ground conditions 22 Do...

Page 25: ...equired safety precautions have been taken Electrocution and death can result from arcing touching or even being close to a machine that is in contact with or near an electrical source Maintain the ma...

Page 26: ...trenches Travel in narrow or congested places T7A022 To avoid contact accidents pay attention to the surroundings at narrow sites indoors and congested places and operate at speeds at which the machin...

Page 27: ...g When towing selecting the wrong wire rope inspecting improperly or towing in the wrong manner could lead to accidents resulting in serious injury or death The wire rope breaking or coming detached c...

Page 28: ...securely to prevent movement When parking on streets use barriers caution signs lights etc so that the machine can easily be seen at night to avoid collisions with other vehicles E3A070 Before leavin...

Page 29: ...tracks and secure the machine to the truck bed with load binders 27 Transport the machine safely Know and follow the safety rules vehicle code and traffic laws when transporting the machine Consider...

Page 30: ...es periodically Fuel hoses become weaker over time even if they appear to be in good condition Replace important safety parts whenever an malfunction is found even if it is before the normal time for...

Page 31: ...ontrol components sensors connectors or the operator s compartment 29 Stop the engine before performing maintenance Avoid lubrication or mechanical adjustments with the machine in motion or with the e...

Page 32: ...Disconnecting or loosening any hydraulic line hose fitting or component or a parts failure can cause the lift arms to drop 30 Service the lift arm stop if damaged or if parts are missing Using a damag...

Page 33: ...cleaning purposes Usethe correct fuel gradeforthe operating season 31 Handling of hoses Fuel oil and hydraulic fluid leaks can cause a fire Do not twist bend or hit the hoses Never use twisted bent or...

Page 34: ...be removed within a few hours by a doctor familiar with this type of injury 32 Release all pressure before working on the hydraulic system Oil maysprayout ifcaps orfilters are removed or pipes discon...

Page 35: ...hen working with batteries Batteries generate flammable and explosive gases Keep arcs sparks flames and lighted tobacco away Use aflashlightto check batteryelectrolyte level Stop the engine and shut o...

Page 36: ...ore working Vibrations operators are subject to According to the results of the tests carried out to determine the vibrations transmitted to the operator by the machine the upper limbs are subjected t...

Page 37: ...of the operator and co workers Please take this manual walk around the machine and note the content and location of these safety signs Review these signs and the operating instructions in this manual...

Page 38: ...ace hands or arms through screen opening Sign indicates a burn hazard from spurting hot water or oil if radiator or hydraulic tank is uncapped while hot Allow radiator or hydraulic tank to cool before...

Page 39: ...0kg 2624LBS 12 No 08800 30015 14 No 06893 00035 4 CAUTION ALWAYS INSPECT COUPLER LATCHES PIN ENGAGEMENT BEFORE OPERATING VEHIC LE 13 No 03393 75040 A_CAUTION DO NOT USE ETHER USAGEOFETHERFORSTARTING P...

Page 40: ...indow be sure to lock it in place with lock pins Except for TL220 27 No 08710 84350 for EU lwA Noise Outside the Cab This value indicates the noise level outside the machine and refers to 105dB the no...

Page 41: ...G CONTROLS Names of Components 40 Doors and Covers 42 Seat and Seat Belt 50 Instrument Panel 54 Switches 56 Levers and Pedals 61 Accessories 63 39...

Page 42: ...Bucket cylinder 2 Hydraulic tank 11 Bucket 3 Canopy 12 Fuel filler cap 4 Safety bar 13 Arm cylinder 5 Front light 14 Travel motor 6 Lift arm stop 15 Rubber track 7 Left control lever 16 Track roller...

Page 43: ...wiper switch option 7 Rear wiper switch option 8 Safety bar 9 Seat 10 Auxiliary hydraulic buttons 11 Instrument panel 41 12 Float button 13 Horn button 14 Right control lever 15 Ignition switch 16 Hi...

Page 44: ...r grasp the handle securely and move the door slowly Opening the door suddenly could result in it hitting your head or your hands or feet could get caught T3B004 42 Preparation before Opening and Clos...

Page 45: ...or 1 and house it under the roof of the cab Open the door fully and press it against the catch at the back of the cab to lock it in place Always lock the door when opening the door Preparation before...

Page 46: ...and secure the door 44 Opening from Inside 1 Push the release lever 6 to the front 2 Pull the handle 7 toward you and open the door Ifthe release lever 6 does not work move the emergency unlock lever...

Page 47: ...lowly lower the door half way Be careful not to catch your hands or feet by lowering the door too much at this time 3 Grasp the handle 3 pull it toward you and close the door Side Window 1 Grasp the c...

Page 48: ...until a click is heard at the front 2 Insert the ignition key and turn it clockwise to lock the engine hood 46 Rear Door AcAUTION When opening the rear door open it firmly to the locked position When...

Page 49: ...out There are two ways to remove the rear window In case of emergency Kick out the rear window Note that the glass may break Be careful not to be injured In case of need 1 Pull off ring A and remove...

Page 50: ...or attachment 2 Lower the lift arms to the ground and stop the engine 3 Align the hook 4 on the tip of the locking pin 1 with the locking pin 48 4 Support the lift arm stop 2 by hand and pull out the...

Page 51: ...t the locking pin 1 through lift arm stop and bracket 8 To prevent the locking pin 1 from falling off set the hook 4 at a right angle to the locking pin 49 Fuel Filler Cap AwARNING Do not smoke or per...

Page 52: ...ll be locked in that position Adjustment range 15 deg B Fore and aft adjustment 1 Pull on lever 2 and slide the seat rearward or forward to bring it to the optimum position for operating the machine 2...

Page 53: ...ur torso and sit back firmly into the seat 2 Pull on adjuster A in the manner shown in the diagram to adjust the seat belt to the desired length 3 Make sure that the belt is not twisted and then inser...

Page 54: ...e the seat rearward or forward to bring it to the optimum position for operating the machine 2 Release the lever 2 atthe desired position and the seat will be locked there Adjustment range 15 steps 15...

Page 55: ...raise your torso and sit back firmly into the seat 2 Pull the seat belt to the desired length E48023 3 Make sure that the belt is not twisted and then insert the tongue plate A into the buckle B of t...

Page 56: ...re _____ c 48 01 2 rises abnormally while the engine is running 3 Battery Charge Warning Lamp r J C48030 This lamp flashes and an alarm is sounded if a problem arises in the charging system while the...

Page 57: ...ndicates the ft O amount of fuel in the tank r Be sure to top off the tank E L39021 before running out of fuel 55 Engine Fault Warning Lamp TL220 I TL230 I TL240 TL230 I TL240 Applicable machine model...

Page 58: ...at Button A WARNING Make sure the bucket is lowered to the ground before putting the lift arms in the Float mode Putting the lift arms in the Float mode while they are raised will cause the bucket to...

Page 59: ...n the cap 1 counterclockwise and remove it 2 To install the female connector or the cap 1 align the notches and turn it clockwise to tighten 14P connector M HDB34 18 14PN 059 Total max working current...

Page 60: ...e Auxiliary Hydraulics Slider Switch Proportional control Proportional control allows for slow to fast movement of auxiliary functions 58 Example If you move the slider switch half way the auxiliary f...

Page 61: ...hydraulic switch returns to normal and the lamp turns off IMPORTANT Do not operate the machine in the detent mode for a long time Doing so will increase the hydraulic oil temperature and shorten the...

Page 62: ...turn on Tail light switch O Off 1 Tail lights turn on 60 Wiper Switches Option IMPORTANT If no washer fluid is discharged do not operate the washer Doing so may damage the pump IMPORTANT Operating th...

Page 63: ...se serious injury or death Be careful not to touch the control levers and pedal when lowering or raising the safety bar T7B0 15 This device is for locking the control levers and selector detent mode a...

Page 64: ...th before beginning operations Use this lever to operate the lift arms and bucket Refer to page 78 Lever Pattern Refer to page 84 Operating the Right Control Lever 62 Left Control Lever Use this lever...

Page 65: ...is socket as an external power supply When using this socket be careful not to exceed 12V 5A To use raise the cap 1 63 Interior Light Option IMPORTANT The battery charge will decrease if the interior...

Page 66: ...flow selector switch C Refer to page 58 Flow Selector Switch 64 Some attachments may have a case drain which needs to be connected to the small port T 4 When connecting is complete purge air from the...

Page 67: ...residual pressure is released from the a port line and pressure is generated in the b port line 3 Turn on the flow selector switch C The residual pressure is released from the b port line 4 Turn the k...

Page 68: ...in 36 3 US gpm TL250 1521 min 40 1 US gpm Rated Pressure 20 6 MPa 2987 psi 1 Connect the attachment hydraulic lines to ports a and b Refer to page 64 Connecting the Hydraullic Circuits 66 Some attachm...

Page 69: ...CONTROLS Accessories IMPORTANT Operation over long periods with Detent mode switch pressed will cause the hydraulic oil temperature to rise and will shorten the life of the hydraulic units 67...

Page 70: ...off the radio 2 TONE control button Use this button to select the tone Press the button to select low tone The TONE LOW display appears on the LCD Press the button again to select high tone 3 LCD Dis...

Page 71: ...rce is chosen the AUX display appears on the LCD 69 13 AUX IN jack Use this jack to connect an external audio source Pull off the rubber cap and plug the stereo mini plug of the external audio device...

Page 72: ...tor into the headphone jack of the audio player Plug a stereo mini plug 3 5 mm into the AUX IN jack on the radio To listen to the audio player press the AUX button The AUX display appears and the freq...

Page 73: ...3 8 W 10 distortion 4Q at DC 14 4V input Dimensions 178 W x 50 H X 92 D mm without projections Receiving frequency MW AM 530 to 1602 kHz EU Asia 1710 kHz North Central and South America FM 87 9 to 108...

Page 74: ...MEMO 72...

Page 75: ...OPERATION Before Starting Operation 74 Starting and Stopping the Engine 75 Machine Operation 78 Operating Procedures 86 Parking the Machine 94 Operating in Cold Weather 95 Using RubberTracks 96 73...

Page 76: ...e point contact with the handholds and steps while getting on and off the machine Keep steps and platform clean Never use the control levers as hand holds 74 Walk Around Inspection Perform the walk ar...

Page 77: ...n then perform the following inspection 75 IJ J0 1 1ill00 1 1 1 lP r III T7D0033 All the warning lamps flash and an alarm is sounded for 2 seconds The instruments also start functioning After 2 second...

Page 78: ...automatically returns to the ON position 4 Check that the warning lamps are off 5 Return the throttle lever to idle position and warm up the engine Refer to page 77 Warming Up the Engine 76 Starting i...

Page 79: ...nd idle the engine for about 5 minutes with no load 77 Stopping the Engine IMPORTANT Do not stop the engine suddenly when operating with heavy loads or at maximum speed Doing so maycause theengineto o...

Page 80: ...ing operations The explanations in this manual are for this pattern U1D005 Crawler Forward Lift Arm Lower lJ Crawler Reverse Lift Arm Raise l Left Spin Turn Bucket Rollback t l Right Spin Turn it Buck...

Page 81: ...ut if operations must be performed at lower temperatures heat up the hydraulic oil to at least 20 C 68 F Normal Warm up 1 Run the engine at medium speed for about 5 minutes with no load T7D008 2 Set t...

Page 82: ...oblem iJFslO UL c GD ID 00 8 rn m T700123 1 Check that the warning lamps and instruments are as follows Are all the warning lamps off Is the water temperature gauge needle within the green range 2 Che...

Page 83: ...us Before backing up visually check for safety to the rear Backing up without checking could result in contact with a worker or obstacle If unavoidable while traveling when operating the working equip...

Page 84: ...to 2nd high speed and press it again to return to 1st speed low speed 82 Pivot Turn I JJ T7D015 Turning to the left To turn forward to the left Tilt the left control lever forward to the left To turn...

Page 85: ...the safety bar is lowered the machine will move suddenly and may cause serious injury or death AcAUTION Never bring the machine to a sudden stop except in the case of a true emergency Stop as gently a...

Page 86: ...ter the bucket cylinder has reached fall stroke will result in the lift arms rising or stopping without going lower Be cautious of any unexpected movement of the lift arms Use the right control lever...

Page 87: ...n using detent mode switch D IMPORTANT Operation over long periods with Detent mode switch pressed will L__ocl____J___ut _ L__ _ _ _ _ ____ u1 so o4 cause the hydraulic oil temperature to rise To deli...

Page 88: ...ng the working equipment and there is the danger of the machine tipping over Keep the bucket as low as possible during travel Do not travel or attempt to change directions with the bucket raised 86 Tr...

Page 89: ...e wear and or the tracks to come off Do not exceed the loader s rated operating capacity Do not use buckets or attachments that exceed the loader s operating capacity 87 Do not use the downward force...

Page 90: ...bucket cylinders and this may damage them 88 Cautions on Operating Cautions on Traveling T7A013 Traveling overobstacles rocks stumps etc may subject the machine to strong shocks and result in damage A...

Page 91: ...of the machine become submerged T7D033 Allowable water depth In water only use the machine up to a depth at which the water comes up to the bottom of the chassis When greasing places used under water...

Page 92: ...the left control lever to halfor less before going down Going down a slope too fast will lead to loss of control When going up or down slopes having a gradient of 15 degrees or more travel up and dow...

Page 93: ...If the engine stops Descending T7D035E If the engine stops when traveling down a slope set the control levers and pedal to the neutral position stop the machine and re start the engine 91 Do not open...

Page 94: ...il the bucket is filled with the material Next tilt the bucket rearward and scoop up the material Grading T7D0381 Tilt the front edge of the bucket down at an angle that is appropriate for the ground...

Page 95: ...ll rapidly and is dangerous Do not drive the loader forward with the lift arms in Float position T7D041 1 Lower the bucket onto the ground then put the lift arms in Float position Tilt the bucket forw...

Page 96: ...ST be restrained by the lift arm stop 94 Before leaving the machine do the following 1 Set the control levers and pedal to the neutral position 2 Return the throttle lever to idle position and idle th...

Page 97: ...stuck on the machine as well as the lower chassis from freezing Remove any dirt or water from the chassis In particular water droplets on the hydraulic cylinder rod surfaces could freeze and if dirt...

Page 98: ...s may cause the tracks to slip off or be damaged due to rocks getting stuck in them Do not use on the seashore The salt may corrode the metal cores of the tracks 96 Do not letfuel oil salt orchemical...

Page 99: ...s the tracks tend to slip Use rubber tracks only at temperatures between 25 C to 55 C 14 F to 131 F When storing the rubber tracks for long periods of time 3 months or more do so indoors in a place no...

Page 100: ...OPERATION Using Rubber Tracks T7EOOB Do not change directions when the tracks are slack as shown in the diagram 98...

Page 101: ...TRANSPORT Hoisting the Machine 100 Loading and Unloading 102 Securing the Machine 103 Cautions on Transporting 104 99...

Page 102: ...the area when hoisting Do not move the machine over the heads of the persons IMPORTANT This hoisting method applles to machines with standard specifications The center of gravity differs according to...

Page 103: ...1525 60 1590 62 6 D 950 37 4 960 37 8 E 575 22 6 635 25 F 585 23 1 440 17 3 G 425 16 7 600 23 6 Units mm inches TL240 TL250 A 1660 65 3 1705 67 1 B 940 37 1 950 37 4 c 1720 67 7 1895 74 6 D 985 38 8 1...

Page 104: ...ramps The machine may tip over Block both tracks and secure the machine to the truck bed with load binders When loading or unloading the machine be sure to use ramps and follow the procedure below 102...

Page 105: ...ion I I c 1 Lower the bucket 2 Stop the engine and remove the ignition key 3 Set the safety bar securely to the locked position 4 Set stoppers in front and behind the tracks 5 Put a chain or wire rope...

Page 106: ...ting AwARNING 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 d...

Page 107: ...spection Every 10 Hours 118 After First 50 Hours New Machines Only 124 Every 50 Hours 130 Every 100 Hours 136 After First 250 Hours New Machines Only 137 Every 250 Hours 138 Every 500 Hours 140 Every...

Page 108: ...al Have inspection and maintenance procedures not prescribed in this manual performed by a Takeuchi dealer Always keep the machine clean Always keep the machine clean and wash it before performing ins...

Page 109: ...the threads Wrap the sealing tape tight leaving 1 or 2 threads at the tip free 107 Disposing of wastes Collect waste fluids from the machine in containers Disposing of wastes irresponsibly damages the...

Page 110: ...TL230 10 2 10 8 TL240 10 2 10 8 Engine oil APl CF or SAE 10W 30 hrs TL250 13 2 13 9 oil pan higher I SAE 15W 40 Every 250 hrs System TL220 45 11 9 US gal TL230 58 15 3 US gal TL240 75 19 8 US gal Die...

Page 111: ...n the performance and service life of the engine always use clean and high quality fuel To avoid freezing in cold climates use a diesel fuel that still functions when the temperature is at least 12 C...

Page 112: ...1 TL230 Y129907 55801 TL240 Y129907 55801 TL250 K16631 43560 Engine oil filter Cartridge TL220 After first 50 hrs Y129150 35152 Every 250 hrs TL230 Y129150 35153 TL240 Y129150 35153 TL250 K1 C020 3243...

Page 113: ...1690400250 11 Pliers 1690500200 Remarks 10 12 11 13 14 17 19 22 24 27 30 41 19 250mm 200mm 111 13 14 15 16 17 21 T7G0013 No Part name Part No Remarks 12 Hammer 1690300330 3 4 13 Allen wrench 16906005...

Page 114: ...bolts alternately top bottom left then right or in 2 or 3 times so that they are tightened uniformly 1 6 3 b 5 4 2 E4G003 OSOG010 Head width Size a X Pitch Torque Thread b General Connection Points mm...

Page 115: ...uring periodic service To maintain their proper function at all times therefore replace them with new ones after using them for a specific period of time even if no abnormality is found with the parts...

Page 116: ...urs New Machines Only Replacing the hydraulic oil return filter Replacing the engine oil and oil filter Inspecting and adjusting the fan belt Replacing the pilot line filter Every 50 Hours Inspecting...

Page 117: ...strainer Inspecting and adjusting the engine valve clearance Retightening the engine cylinder head bolts Every 1500 Hours Inspecting and cleaning the engine fuel injectors Inspecting the crankcase bre...

Page 118: ...pes or in strong winds Before starting the engine look around the machine and lower chassis clean any combustible materials off high temperature parts of the engine and inspect for irregularities such...

Page 119: ...leakage from the travel motor 10 Check the canopy I cab and guard for damage and loose nuts and bolts Check the rearview mirrors for dirt damage and angle adjustment 11 Check the decals for dirt and...

Page 120: ...radiator cap or drain plugs when the coolant is hot Stop the engine let the engine and radiator cool and loosen the radiator cap or drain plugs slowly Inspection U1G001 1 Open the rear door 2 Inspect...

Page 121: ...er too low or too high 3 Tighten the oil supply cap 2 4 Start the engine run it at low idle for about 3 minutes then stop it 5 After about 10 minutes inspect the oil level 119 Inspecting the Water Sep...

Page 122: ...Cleaning the Water Separator 120 Inspecting the Fuel Level AwARNING Do not smoke or permit open flames while fueling or near fueling operations Stop the engine in a well ventilated place when adding f...

Page 123: ...level in the hydraulic oil level inspection position shown in the diagram Hydraulic oil level inspection position 1 Start the engine and run it at low speed 2 Fully retract the lift arms and bucket c...

Page 124: ...ours Lubricating the Working Equipment 1 Set the machine to the lubrication position shown in the diagram above ground the bucket then stop the engine 2 Use the grease gun to lubricate the grease fitt...

Page 125: ...MEMO 123...

Page 126: ...tions could result in burns or injuries due to hot oil spraying out Oil may spray out if caps or filters are removed or pipes disconnected before releasing the pressure in the hydraulic system When re...

Page 127: ...under these conditions could result in burns 1 Open the engine hood 2 Tilt up the canopy Refer to page 153 Tilting Up the Canopy 3 Remove the oil supply cap 2 4 Place a pan under the under cover 3 5 L...

Page 128: ...ter by hand 13 Tighten one more turn after the filter packing comes in contact with the surface 14 Supply oil up to the upper limit H of the dipstick 1 Problems could arise if the oil level is either...

Page 129: ...etween the fan pulley 2 and alternator pulley 3 and check the tension about 98N or 22 lbf The slack A should be about 7 to 10 mm 0 28 to 0 4 in 4 Inspect the fan belt 4 and replace it if there are cut...

Page 130: ...the pressure in the hydraulic system When removing plugs or screws or disconnecting hoses stand to the side and loosen slowly to gradually release the internal pressure before removing 1 Tilt up the c...

Page 131: ...MEMO 129...

Page 132: ...resulting in injury Loosen the grease discharge valve slowly Do not put your face arms legs or body in front of the grease discharge valve If no grease is expelled when the grease discharge valve is...

Page 133: ...e valve 1 3 Check the track tension Decreasing the tension 1 Remove the cover 2 Use the wrench to slowly loosen the grease discharge valve 1 and drain the grease If the grease does not drain easily mo...

Page 134: ...t prompt medical attention If acid is accidentally swallowed drink large quantities of water or milk and call a physician immediately If acid contacts skin or clothing wash off immediately with clean...

Page 135: ...s the fluid to swell and the plate appears distorted Level too low B The fluid does not reach up to the bottom edge of the sleeve 3 so the plate appears laminar not distorted 4 Also check the terminal...

Page 136: ...filler cap 2 2 Place a pan under the drain plug 3 3 Remove the cover 4 4 Remove the drain plug 3 and drain the water and sediment from the bottom of the tank 5 Tighten the drain plug 3 6 While watchin...

Page 137: ...tion Parallel T8G006E 1 Park the machine on firm level ground and remove the bucket 2 Retract the bucket cylinders and lift arm cylinders to the minimum length 3 Inspect the adjusting bolts 1 and lock...

Page 138: ...e are any scratches or other irregularities replace it 5 Assemble the indicator ring 6 case 4 and element 5 and tighten the ring 3 6 Open the valve 2 7 Loosen the vent plug 8 and bleed the air 8 Tight...

Page 139: ...el motor reduction gears case may cause oil or the plug to fly out Loosen the plug slowly to release the pressure IMPORTANT If the percentage of the travel time within the total operating time is high...

Page 140: ...st could be drawn into the cylinder damaging the engine IMPORTANT Besuretolocktheaircleaner after completing the maintenance 1 Open the engine hood 2 Push down the lever 6 to tilt up the air cleaner 1...

Page 141: ...IMPORTANT When using water cover the electrical system to prevent water from getting in IMPORTANT When operating the machine in very dusty places inspection and maintenance should be performed everyd...

Page 142: ...I TL240 1 Open the engine hood 140 TL250 1 Tilt up the canopy 2 Place a pan under the filter 1 3 Using a filter wrench turn the filter 1 counterclockwise and remove it 4 Clean the surface of installa...

Page 143: ...il Return Filter Refer to page 124 Replacing the Hydraulic Oil Return Filter Replacing the Pilot Line Filter Refer to page 128 Replacing the Pilot Line Filter Replacing the Travel Motor Gear Oil Refer...

Page 144: ...tall the lift arm stop 2 used for the lift arm adjustment on the lift arm cylinder while the pin hole 1 of the lift arm should be positioned at the heightofapproximately 1500mm 59 1in or 1600 mm 63 in...

Page 145: ...ts 8 143 9 Start the engine extend the bucket cylinders to the maximum length and then stop the engine 10 Adjust each plate 9 right left and the stopper bolt 8 so that they evenly contact each other 1...

Page 146: ...ver stand at the back of the machine while the engine is running Do not remove the radiator cap or drain plugs when the coolant is hot Stop the engine let the engine and radiator cool and loosen the r...

Page 147: ...Close the radiator cap 3 14 Warm up the engine Use the instruments to check that there are no irregularities in the cooling system at this time 15 Raise the coolant temperature to at least 90 C 195 F...

Page 148: ...to hot oil spraying out Oil may spray out if caps or filters are removed or pipes disconnected before releasing the pressure in the hydraulic system When removing plugs or screws or disconnecting hos...

Page 149: ...he flange 9 20 Tighten the drain plug 7 147 21 Replenish hydraulic oil up to the middle of the sight gauge 2 through the port for plug 1 22 Tighten the plug 1 23 Follow the procedure Bleeding the air...

Page 150: ...d and retract all the cylinders 4 or 5 times to the stroke ends Inspecting and Adjusting the Engine Valve Clearance This operation requires experience Have it performed by a Takeuchi dealer Retighteni...

Page 151: ...i dealer 149 MAINTENANCE Every 3000 Hours Inspecting the Turbocharger Blower wash as necessary TL220 I TL240 I TL250 This operation requires experience Have it performed by a Takeuchi dealer Inspectin...

Page 152: ...uick hitch 3 lock levers 2 are in the unlocked position 2 While sitting in the operator s seat with the safety bar down start the engine and tilt the quick hitch 3 forward 150 T9G010 3 Move the machin...

Page 153: ...e the attachment and investigate the cause 151 Removal 1 Raise the bucket 1 or attachment 25 to 50 mm 1 to 2 in off the ground 2 Stop the engine raise the safety bar and release the seat belt 3 Pull b...

Page 154: ...t section of the boot 1 and turn it upwards 2 Wipe off the old grease 3 Apply grease to points A and B 4 Re install the boot 1 152 Inspecting and Replenishing the Windshield Washer Fluid Use a windshi...

Page 155: ...king equipment to the ground and stop the engine 2 Set the safety bar to the lock position 3 Remove a R pin and remove the stopper pin B 4 Remove the lock bolts A 153 5 Slowly raise the canopy 6 Inser...

Page 156: ...annot be adjusted 1 Lug Replace if the height of the lugs A is 5 mm 0 2 in or less 2 Steel cord E4G063 Replace if the steel cord is exposed over 2 or more links Replace if half or more of the steel co...

Page 157: ...ly rust prevention oil to the hydraulic cylinder rods 8 Disconnect the cable from the battery s negative terminal and cover the battery to prevent freezing 155 During storage AwARNING Donotoperatethee...

Page 158: ...156...

Page 159: ...that Are Not Malfunctions 158 If the Engine Overheats 159 If the Battery Goes Dead 160 After the Fuel Runs Out 161 If a Fuse Blows 162 If a Warning Lamp Flashes 164 Other Symptoms 166 To Lower the Lif...

Page 160: ...noise if excessive force is applied to the working equipment and when the stroke end is reached At times of combined operation of bucket and lift arm lowering continuation of the combined operation af...

Page 161: ...er decreases Steam comes from the engine compartment 159 Procedure 1 Park the machine in a safe place 2 Inspect whether the coolant temperature warning lamp is flashing or if there is steam coming out...

Page 162: ...when using jumper cables to start the machine IMPORTANT Usejumpercables and clips of a size suited to the battery s capacity Do not used damaged orcorroded jumper cables and clips IMPORTANT The rescue...

Page 163: ...ssary have a Takeuchi dealer recharge any dead batteries 161 TROUBLESHOOTING After the Fuel Runs Out Bleeding the Air from the Fuel System IMPORTANT NEVER use the starter motor to crank the engine in...

Page 164: ...ed TL220 I TL230 I TL240 Capacity Protected circuit Capacity Protected circuit 1SA Front light 30A Lever lock Radio ACC 10A Instrument 30A Air conditioner cluster OPl 10A Immobilizer 20A Reserve ACC M...

Page 165: ...pe fusible links 1 might be blown Open the rear door and inspect If the fusible link is blown please contact your dealer Note A fusible link is a large piece of fuse wiring that is mounted in a circui...

Page 166: ...tes the coolant temperature has risen irregularly temperature and the engine is overheating warning lamp Refer to page 159 If the Engine Overheats C48012 Battery This indicates there is a problem with...

Page 167: ...r is clogged Stop the engine and replace the filter Replace the filter immediately if the lamp flashes Refer to page 128 Replacing the Pilot Line Filter IMPORTANT Continuing to operate the machine whi...

Page 168: ...ient level Refer to page 121 Hydraulic oil is not heated Perform the warm up procedure Refer to page 79 Air cleaner is clogged Replace the air cleaner Refer to page 138 Hydraulic oil is not of suitabl...

Page 169: ...nally black Irregular noise is Low quality fuel is being used produced from the Engine is overheating engine combustion or mechanical noise Damage in muffler 167 Procedure Add fuel Refer to page 120 B...

Page 170: ...lift arms lowers slowly Do not turn the screw more than the specified amount TL220 I TL230 I TL240 TL250 1 Tilt up the canopy 168 2 Put mark M on the plug of the port relief valve 1 and set screw 2 3...

Page 171: ...ow to tow light weight objects or the machine itself if it is stuck in the mud and not able to get out on its own IMPORTANT Do not tow a machine if its engine does not start or if the machine does not...

Page 172: ...170...

Page 173: ...15 SPECIFICATIONS Main Specifications 172 Machine Dimensions 176 Operating Range 178 171...

Page 174: ...bber 1st 6 5 4 04 Travel speed km h mph tracks 2nd 9 3 5 78 Gradeability degrees 30 Ground pressurekPa psi Rubber tracks 32 1 4 65 32 8 4 75 Noise level Sound power level LwA 103 For EU dB A Sound pre...

Page 175: ...54 Travel speed km h mph tracks 2nd 10 9 6 77 Gradeability degrees 30 Ground pressurekPa psi Rubber tracks 35 7 5 18 36 6 5 31 36 3 5 26 37 2 5 39 Noise level Sound power level LwA 103 For EU dB A Sou...

Page 176: ...4 72 Travel speed km h mph tracks 2nd 11 6 7 21 Gradeability degrees 30 Ground pressurekPa psi Rubber tracks 28 8 4 18 29 4 4 27 29 1 4 22 29 7 4 31 Noise level Sound power level LwA104 For EU dB A So...

Page 177: ...5 Travel speed km h mph tracks 2nd 12 0 7 46 Gradeability degrees 30 Ground pressurekPa psi Rubber tracks 31 3 4 54 32 0 4 64 31 7 4 59 32 4 4 69 Noise level Sound power level LwA 105 For EU dB A Soun...

Page 178: ...SPECIFICATIONS Machine Dimensions c B A 176 H J 1 1 1 D D F T7K0012...

Page 179: ...970 77 6 2235 88 0 I 2130 83 9 2270 89 4 250 9 8 310 12 1 325 12 8 1470 57 9 1580 62 2 1770 69 7 300 11 8 320 12 6 450 17 7 1360 53 5 1430 56 3 1500 59 1 925 36 4 985 38 7 I 980 38 6 985 38 7 1600 63...

Page 180: ...SPECIFICATIONS Operating Range A B C H G T7K0021 178...

Page 181: ...0 52 1470 57 9 30 Units mm inches TL230 TL240 TL250 Standard Bucket Rubber Tracks 3905 153 8 4080 160 7 4245 167 2 3030 119 3 3120 122 9 3205 126 1 2370 93 4 2405 94 8 2430 95 7 730 28 8 875 34 4 985...

Page 182: ...180...

Page 183: ...ecautions 182 Seat with Switch 184 Air Conditioner 185 Hydraulic Quick Hitch 194 Quick Couplers 196 4 port Quick Coupler TL240 TL250 197 Optional equipment mass 199 U S OPTIONS TL250 High Ambient Cool...

Page 184: ...emoving or installing a attachment place it in a stable position so that it does not tip over Due to the risk of loads falling and or hitting people do not allow unauthorized personnel in the work are...

Page 185: ...slopes the attachment lifted Turning on slopes When heavy attachments are installed the overrun the distance from where the control movement to stop traveling is performed until traveling stops comple...

Page 186: ...rake will be activated the track will stop abruptly This seat is equipped with switch for operating the lever lock The safety bar function in the same way The lever lock can be released when you sit i...

Page 187: ...ndows If this happens either turn off the air conditioner or turn the temperature control dial clockwise to increase the inside temperature Mist may blow out of the air outlets This is not a malfuncti...

Page 188: ...TS 1 Defroster 2 Condenser 3 Receiver drier 4 Foot outlets 5 Rear outlets 6 Control panel Compressor 8 Air conditioner unit 9 Inner filter 1o Outer filter 186 Control Pannel 11 Air conditioner switch...

Page 189: ...l ON Note To prevent leakage of refrigerant gas from the compressor s seal operate the air conditioner at least once a week regardless of the season Note The air conditioner will not function if the...

Page 190: ...l and fan switch to the desired positions 188 Cooling AcAUTION Excessive cooling can be harmful to your health It is best to keep the air inside the cab only about 5 to 6 C 41 to 43 F cooler than the...

Page 191: ...temperatures increases and fog may form on the outside of the windows If this happens either turn the air conditioner OFF or turn the temperature control dial clockwise WARM T9L008 After starting the...

Page 192: ...life and reducing the air conditioner s cooling capacity If the belt is slack it will slip and vibrate shortening its service life and reducing the air conditioner s cooling capacity The belt should...

Page 193: ...ending on how dirty it is 191 Cleaning AcAUTION Wear safety glasses when using compressed air 1 Blow dry compressed air 138 kPa 20 psi or less directly on the filter from the inside moving up and down...

Page 194: ...efrigerant _A CAUTION The high pressure pipe becomes hot 80 to 120 C 176 to 248 F so be careful not to burn yourself when inspecting the refrigerant level TL220 I TL230 I TL240 4 Open the radiator Ref...

Page 195: ...vily refrigerant can be barely seen flowing temperature between the oily places Refrigerant has leaked and high and low pressure almost none is left pipes Excess No bubbles can be seen High pressure p...

Page 196: ...f the bucket 1 and the quick hitch 3 are clean U1L0021 1 Open the cover and press the dJ side of the switch 5 to unlock the quick hitch 194 2 While sitting in the operator s seat with the safety bar d...

Page 197: ...ted attachment or hydraulic quick hitch When the attachment hoses are connected to the quick coupler the plate is pushed to turn on the switch which prevents the hydraulic quick hitch from being activ...

Page 198: ...6 Releasing the Residual Pressure Connecting Push the quick couplers tightly together and hold for five seconds the pressure is automatically released as the couplers are installed Disconnecting Push...

Page 199: ...ng the residual pressure THEN UP t rmr FOR UPPER PORT PULL RED KNOB OUT U1L012E Coupling and uncoupling 1 Before coupling clean the flat mating surfaces of quick coupling to avoid the inclusion of dir...

Page 200: ...e the auxiliary hydraulics switch repeatedly approx 10 times to purge air from the hydraulic lines c Stop the engine and wait for more than 5 minutes until bubbles escape from the hydraulic oil in the...

Page 201: ...4520 5120 5225 not including operator 5995 6130 8015 8210 9765 9965 11290 11520 IOPTION I High flow hydraulic 60 130 50 110 65 145 system Air Conditioner 30 65 35 75 Hydraulic quick hitch 20 45 Units...

Page 202: ...hing or unexpected move ment Cleaning of the coolers should be done with the engine stopped and the key in the off position to prevent unexpected movement of the fans Wear proper personal protective e...

Page 203: ...pivot area 3 No 8004894 Sign indicates rotating fan hazard Keep hands hair cloth ing and other objects away from area to prevent injury Turn engine off before entering area_ 4 No 8004896 Sign indicate...

Page 204: ...g and proper maintenance 202 Cleaning the Polycarbonate Window A WARNING The polycarbonate window provides additional protection for the operator but is not a permanent barrier against flying objects...

Page 205: ...The roof mounted hydraulic oil cooler has a hinged cover to allow for easy access to the cooler core for cleaning and servicing The engine must be stopped and the key turned to the off position before...

Page 206: ...204...

Page 207: ...l INDEX 205...

Page 208: ...aution on tilting of cab enclosure 200 Cautions 97 Cautions after Completing Operations 95 Cautions in the operator s compartment 16 Cautions on Maintenance 106 Cautions on Operating 88 Cautions on ti...

Page 209: ...g and Adjusting the Air Conditioner Belt 190 Inspecting and adjusting the track tension 130 Inspecting and adjusting the engine valve clearance 148 Inspecting and adjusting the fan belt 127 Inspecting...

Page 210: ...4 Off Season Inspection 192 Operate on snow or ice with extra caution 22 Operate the machine only from the operator s seat 19 Operating in Cold Weather 95 Operating Precautions 19 Operating Procedures...

Page 211: ...m the operator s seat 17 Starting and Stopping the Engine 75 Starting Precautions 17 Starting the Engine 76 Starting with jumper cables 18 Stay clear of moving parts 29 Stop the engine before performi...

Page 212: ...First Published October 2007 Nineth Published August 2011 OPERATOR S MANUAL TL220 TLl30 Track Loader TL240 TL250 Edited and issued by TAKEUCHI MFG CO LTD No 32794 Printed in Japan by STATION M Co Ltd...

Page 213: ...s certificate loses its validity Designation of the machine Crawler Skid Steer Loader Manufacturer TAKEUCHI MFG CO LTD 205 Uwadaira Sakaki machi Hanishina gun Nagano 389 0605 Japan Model TL220 TL230 T...