Takeuchi TW9, Operating Instructions Manual

Page 1: ...nderstand otherwise injury or death is caused Operating Instructions Language version EN Edition 2011 11 Order number 5780200633 From vehicle ID No TL08020438 Translation of the original operating ins...

Page 2: ...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 Wilhelm Sch fer GmbH Bau und Indust...

Page 3: ...tion 16 2 20 Emergency exit 16 2 21 Other dangers 16 3 Technical data 17 3 1 Views 17 3 2 Diesel engine 25 3 3 Electrical system 25 3 4 Transmission 25 3 5 Brakes 26 3 6 Hydraulic system 26 3 7 Axles...

Page 4: ...g 66 7 7 Notes for winter operation 66 7 8 Checking maintenance and inspection plans 68 7 8 1 Initial inspection hand over inspection 68 7 8 2 Daily and weekly tasks 70 7 8 3 Overview of lubricating p...

Page 5: ...ission works in one direction only 99 8 10 Transmission works in neither direction 99 8 11 Loader installation is not working 99 8 12 Decrease in machine s performance loader installation 100 8 13 Wor...

Page 6: ...Table of Contents TW9...

Page 7: ...Special equipment and attachments are not included in these Operating Instructions We reserve the right to make improvements on the machine within the scope of impending technical developments without...

Page 8: ...ist that only original spare parts are used in the event of any repair work In this way you will have a product of lasting high quality thereby ensuring that your machine maintains its original condit...

Page 9: ...entioned liquids seep into the ground their escape must be stopped immediately and the liquid be bound with suitable binding agents If necessary the soil involved must be removed Absorbent materials a...

Page 10: ...REV Travel speed FAST Travel speed SLOW Working hydraulics shut off Unlocked Locked Float position Symbol Description Hazard warning system Operating mode indicator Operating hours Lashing points Susp...

Page 11: ...er of injury 4 Danger of crushing Servicing and replacing safety signs The safety of the operator always has to come first Safety signs must always be kept in good condition and legible Replace any sa...

Page 12: ...6 TW9...

Page 13: ...B A 6 Applied harmonized standards EN ISO 12100 EN 474 1 EN 474 3 7 Document editor who is authorized to compile technical documentation Maik Schulze D 74564 Crailsheim Kraftwerkstra e 4 Germany 8 Con...

Page 14: ...standard bucket equipment is intended solely for work which is suitable for the function of the machine and its work implements Such work involves loosening taking up transporting and dumping soil ro...

Page 15: ...method of operation of the fire extinguishers on the earth moving machine as well as on site fire warning and fire fighting equipment Loose parts such as tools or other accessories must be secured to...

Page 16: ...chines etc If the above safety distance cannot be maintained the area between solid objects and the working zone of the earth moving machine must be blocked off If conditions are such that the machine...

Page 17: ...ate license as required by the national traffic laws of the country in question Outside areas covered by general traffic regulations e g on factory premises traffic regulations should be applied in th...

Page 18: ...nopy cabin mounted front guard and the appropriate work implement See regulations book Demolition work ZH 1 614 published by the German Tiefbau Berufsgenossenschaft Civil Engineering Employer s Liabil...

Page 19: ...k zone of earth moving machines 2 14 Operation in closed rooms If earth moving machines are to be used in closed spaces these areas must be sufficiently ventilated and special regulations observed Bre...

Page 20: ...hich are only supported by their hydraulics is forbidden The engine motor s must be turned off prior to all maintenance and repair work These requirements may only be ignored in the case of maintenanc...

Page 21: ...nd passages under bridges are large enough and that roads and bridges have sufficient carrying capacity 2 18 Monitoring and inspections The machine must be submitted to a general inspection according...

Page 22: ...the cabin operator s stand The fire extinguisher symbol must be attached 2 20 Emergency exit The right hand cab door acts as an emergency exit 2 21 Other dangers Failure of hydraulic system If the hy...

Page 23: ...Technical data 3 TW9 17 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 18 TW9 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 TW9 19 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 20 TW9 General purpose bucket and Z kinematics Fig 6 Dimensioned drawing standard bucket and Z kinematics Tires 405 70 R18...

Page 27: ...Technical data 3 TW9 21 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 22 TW9 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 TW9 23 Low profile canopy with general purpose bucket 0 8 m Fig 9 Dimensioned drawing low profile canopy with standard bucket 0 8 m Tires 15 5 55 R18...

Page 30: ...3 Technical data 24 TW9 Fold down bar with general purpose bucket 0 8 m Fig 10 Dimensioned drawing fold down bar with standard bucket 0 8 m Tires 15 5 55 R18...

Page 31: ...liance with German and European standards 3 4 Transmission Transmission Variable displacement pump flange mounted directly onto diesel engine two stage variable displacement motor with power shift on...

Page 32: ...steering cylinder with end position damping at both ends Total steering angle 80 Loader installation Parallel kinematics Double acting work cylinders one lift cylinder and one tilt cylinder Z kinemati...

Page 33: ...ocking differential and integrated 2 stage reduction gear Angle of oscillation 10 3 8 Tires Tire size Tire pressures front Tire pressures rear 12 5 18 MPT 2 8 1 8 12 5 20 MPT 2 5 1 8 14 5 20 MPT 2 0 1...

Page 34: ...ulic oil change quantity Service brake approx 0 25 ATF oil Front axle center housing approx 3 8 Transmission oil Rear axle center housing and transmission standard approx 4 5 Transmission oil Rear axl...

Page 35: ...ster Filling according to customer specifications Brand label on machine Do not mix bio degradable oils from different manufacturers The same viscosity values apply as for mineral hydraulic oils When...

Page 36: ...DIN 51524 T3 HVLP 30 22 20 4 10 14 0 32 10 50 20 68 30 86 C F Umgebungstemperatur Ambient temperature Temp rature ambiante 0W 30 0W 40 5W 30 5W 40 10W 30 10W 40 15W 40 20W 50 Viskode Cold weather kit...

Page 37: ...ance with directive 2002 44 EC and EN 474 Effective values of acceleration below 0 5 m s2 for entire body and 2 5 m s2 for the upper body limb dimensions 3 11 1 Equivalent vibration values Equivalent...

Page 38: ...rpose bucket and 405 70 R18 tires Parallel kinematics Z kinematics Width of bucket mm 1 850 1 850 Capacity in accordance with ISO 7546 max density 1 8 t m approx m 0 8 0 8 Payload in bucket 0 8 m x 1...

Page 39: ...t material bucket with bolt on cutting edge 1 950 1 2 0 8 Side dump bucket 1 850 0 7 1 8 High tip bucket 1 850 0 7 1 2 3 14 1 Bucket with Z kinematics Width mm Capacity heaped m Max density t m Standa...

Page 40: ...forks at a 500 mm load radius from the rear of the fork according to ISO 14397 1 with a stability factor of 2 0 50 of the tipping load The payloads are valid for a machine fitted with 12 5 20MPT 10PR...

Page 41: ...ning device Bucket return positioner Electrical tank refilling pump Quick attach system hydraulically operated Snow blade Sweeper Load hook for attaching to forks Rear axle weights Outlet for hydrauli...

Page 42: ...3 Technical data 36 TW9...

Page 43: ...th all functions Before driving and working with the machine it is necessary to thoroughly familiarize yourself with the display elements and operator controls Each time before putting the machine int...

Page 44: ...4 Operation 38 TW9 4 2 Display elements and operating controls The following list includes non standard equipment Operating controls Fig 10 1 Operator controls...

Page 45: ...height adjustment 5 Stop button additional control circuit 6 Control light 7 Actuation potentiometer 3rd control circuit 8 Travel direction switch without function if working hydraulics are deactivat...

Page 46: ...4 Operation 40 TW9 Instrument panel Fig 10 2 Operator controls...

Page 47: ...Windshield washer function front rear 41 Windshield wiper front 42 Windshield wiper rear 43 44 Fan switch heating 45 Switch air conditioning 46 Not assigned 47 Preselection button for actuation 3rd co...

Page 48: ...ted for a functional check Turn clockwise to 1 the indicator lamps 11 22 11 31 light up Pre heating starts the indicator lamp 11 21 lights up Press the accelerator pedal 11 3 completely down for norma...

Page 49: ...rature 12 25 is exceeded stop work open the engine hood and keep the engine running at idle speed to allow it to cool down Once the engine has cooled down turn it off and determine the cause of overhe...

Page 50: ...1 Horizontal adjustment 2 Weight adjustment 3 Seat back adjustment 4 Vertical adjustment Raising seat Raise seat until it clicks audibly into place Lowering seat Raise seat as far as the stop the sea...

Page 51: ...air conditioning system should be switched on for approx 5 minutes at least once a month to lubricate the compressor seals Adjust ventilation to circulating air mode open aspirating holes 15 12 Contro...

Page 52: ...rear wheels may be filled with a water antifreeze mixture to increase the lifting capacity Prepare the mixture in an appropriately sized container Allow it to cool and stir until there are no more lu...

Page 53: ...ravel preselection switches are pressed in a contradictory manner the machine stops When driving on roads the joystick 16 8 for the working equipment must be deactivated via the multi function switch...

Page 54: ...using the preselection switches 17 8 or 17 36 respectively The indicator lamp 17 24 or 17 28 lights up Press accelerator pedal 17 3 The machine only drives off once a certain engine speed is reached T...

Page 55: ...travel drive then acts as an auxiliary brake Operate the brake inching pedal 19 2 as required Parking brake Only apply the parking brake 19 9 if the machine is stationary Once the parking brake is ap...

Page 56: ...et with socket pins Completely retract the high tip bucket Fold up the forks of the fork lift attachment lock in place and secure against lateral shifting Rigid forks must be dismounted before driving...

Page 57: ...0 Lower the work attachment onto the ground Switch off the working hydraulics 21 35 Apply the parking brake 21 16 Switch the engine off and remove the ignition key Lock the cab after finishing work t...

Page 58: ...4 Operation 52 TW9...

Page 59: ...ncing loading work memorize the lever controls well During loading operations driving and work movements should flow in smooth succession Drive slowly when familiarizing yourself with the controls 5 1...

Page 60: ...5 Working Operation of the machine 54 TW9 5 2 Operation Loader Switch on the work equipment 22 35 Operation Bucket Operate joystick 22 6 Fig 22 Operation...

Page 61: ...eter 23a 56 Continuous operation Turn the potentiometer 23a 56 as far as it will go to the left Press the Continuous operation additional control circuit 23a 47 button once Select the direction of rot...

Page 62: ...e float position function is activated if the lowering pressure point on joystick is exceeded 23a 9 For the float operation the joystick 23a 9 must be held in the float position otherwise it returns t...

Page 63: ...onal control circuit is required Under certain circumstances it is possible to use the work attachments of predecessor models on our machines When mounting work attachments of predecessor models howev...

Page 64: ...achment and install a new one Procedure for changing work attachments with mechanical quick attach system If an attachment is hydraulically operated disconnect the hydraulic connection first of all sy...

Page 65: ...t with the rocker switch 25 47 Unlock the quick attach system with the roller 25 7 and move out of tool Pick up new tool and lock with the roller 25 7 Perform a visual check to ensure that the quick a...

Page 66: ...t frame and tilt back the bucket For dumping raise the bucket until it is above the point of dumping and dump the material 5 4 2 Scraping and grading Lower the lift frame and move the cutting edge int...

Page 67: ...er has to be towed maximum 50m when the engine is stopped Travel oil circuit must be opened so that the hydrostatic transmission no longer acts as an auxiliary brake On both high pressure limiting val...

Page 68: ...liance at the specified marked points fig 29 in the correct manner 6 3 Transporting the machine To transport the machine onto a flat bed trailer railway goods wagon etc the following measures must be...

Page 69: ...nstruction Book It is essential that the recommendations in chapter 2 Safety and Accident Prevention are observed 7 2 Intervals Initial inspection Once before first putting into operation Chapter 7 8...

Page 70: ...be prevented How often should the oil be analyzed Regular oil analysis will indicate any developing trends regarding the state of the oil and the machine The oils should be analyzed at the following...

Page 71: ...ricants The machine s life expectancy and operating condition largely depend on the use of the specified lubricants and compliance with the service intervals If lubricants which do not conform to our...

Page 72: ...g plan and a test of all work cycles steering and driving functions carried out 7 7 Notes for winter operation The following points and the relevant notes in the engine instruction manual should be ob...

Page 73: ...we recommend the addition of petroleum fig 36 or additives These mixtures should only be used temporarily never for longer periods Only mix the components in the tank First fill the required quantity...

Page 74: ...7 Maintenance and Care 68 TW9 7 8 Checking maintenance and inspection plans 7 8 1 Initial inspection hand over inspection Fig 31 Initial inspection...

Page 75: ...9 13 6 Check tire pressure and tightness of wheel nuts 7 9 14 7 Check brake oil level 7 9 8 8 Check the battery fluid level and charge condition 7 9 17 9 Top up windshield washer system 7 9 19 10 Lub...

Page 76: ...7 Maintenance and Care 70 TW9 7 8 2 Daily and weekly tasks Inspection and maintenance jobs to be performed by service personnel 23 23 21 10 Fig 32 Inspection and service schedule...

Page 77: ...vals 12 Clean cooling fins on water cooler 7 9 3 Machine damage due to strong accumulation of dust Shorten the cleaning intervals 12 Check the coolant level 7 9 3 13 Check that door catches function p...

Page 78: ...3 Overview of lubricating points Replace defective grease nipples immediately and check if grease passes through Fig 33 Lubrication schedule parallel kinematics 15 12 7 10 L824 033_Z Kine_2010 Fig 33...

Page 79: ...ront end 1 2 X 7 Lift frame Quick attach system 2 X 8 Linkage Quick attach system 1 X 9 Tilt control lever Linkage 1 X 10 Mechanical quick attach system Hydraulic quick attach system 3 2 X X 11 Steeri...

Page 80: ...on of dust Shorten the cleaning intervals 11 Clean cooling fins of water cooler combined cooler O O O 7 9 3 Machine damage due to strong accumulation of dust Shorten the cleaning intervals 12 Check an...

Page 81: ...rt of hydraulic oil return suction filter X X X 7 9 11 34 Replace the breathing filter X X 7 9 12 35 Check function of brakes replace brake oil O O X X 7 9 8 36 Bleed brake O O 7 9 8 37 Differential o...

Page 82: ...C Park the machine on level ground Stop the engine Remove the cover from the bottom rear end Place suitable drip pans under the opening Screw the oil drain hose onto the oil change valve 35 3 Danger...

Page 83: ...ew the filter cartridge 36 4 using a commercially available tool and check that the fastening stud is firmly secured in the filter head Dispose of the filter cartridge according to regulations Check f...

Page 84: ...calding due to hot oil getting into contact with skin or eyes Only open the cooler cap after the engine has cooled down Remove the cap 37 1 1 and top up coolant if required With the engine cooled down...

Page 85: ...ine must be brought to operating temperature in order to dry the cooler 7 9 3 4 Changing coolant Danger of scalding due to hot oil getting into contact with skin or eyes Only open the cooler cap after...

Page 86: ...lter 39 1 Unscrew the filter cartridge using a commercially available tool and check that the fastening stud is firmly secured in the filter head Collect fuel and dispose of according to regulations D...

Page 87: ...ng the fuel leakage oil line Separate the rubber hoses 42 3 from the injection valves Separate the rubber hose 42 1 from the fuel tank Separate the rubber hoses 42 4 42 3 42 1 from the connection piec...

Page 88: ...for damage Replace defective parts immediately 7 9 5 3 Cartridge maintenance intervals Air filter main cartridge The air filter main cartridge must be replaced as soon as the filter maintenance indica...

Page 89: ...starting with the open side and check that it is correctly positioned Fit the lower part of the housing Pay attention to the position of the dust extraction valve Place the wire fasteners in the groo...

Page 90: ...e the end of which is bent at 90 should be attached to a compressed air pistol It must be sufficiently long to reach the floor of the cartridge Blow out the main cartridge from the inside to the outsi...

Page 91: ...measure the sag Using medium thumb pressure of approx 45 N the V belt sag A should equal approx 10 15 mm Tensioning the V belt Slacken the fastening screws 47 1 Swing the generator 47 2 until the tens...

Page 92: ...sert it into collecting bottle Connect the bleeding device to the brake oil container 49 1 Change brake oil and bleed the brake according to the Bleeding Device Operating Instructions Remove the bleed...

Page 93: ...ve the drain plug 51 4 on the hydraulic oil tank and drain oil into a clean receptacle Collect the waste oil do not allow it to seep into the ground Dispose of according to regulations Flush and clean...

Page 94: ...lic oil cooler Both cooler components must be cleaned during maintenance see also Chap 7 9 3 Clean the cooler components 52 1 by blowing it out with compressed air from the air discharge side If neces...

Page 95: ...same time Remove the filter element from the inlet connection and dispose of according to regulations Ensure that the seal 53 2 in the cover and the O ring 53 4 on the inlet connection are in faultles...

Page 96: ...il 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 Screw in new breather 54 2 with O...

Page 97: ...heck the oil level again and top up if necessary 7 9 13 1 Front axle differential Checking the axle oil level Remove the inspection plug 55 1 check and top up oil if required Changing axle oil Park th...

Page 98: ...nsmission have combined oil filling Park the machine on level ground Open the inspection filling plug 56 1 Open the drain plugs on the differential 56 2 and the transmission 56 3 and drain oil Flush o...

Page 99: ...lly close the screw plug 7 9 14 Wheels Checking the tire pressure Check the air pressure in accordance with the pressure chart given in chapter 3 8 Checking the tightness of wheel nuts During the firs...

Page 100: ...isolator switch First disconnect the battery ground cable and then the positive cable Remove the clamping bracket 59 1 Lift out the battery Installing the battery Place the battery into the machine an...

Page 101: ...n a flat and hard surface Using dry compressed air max 5 bar blow against the direction of flow Check the filter for damage to the paper bellows and seal Never continue to use damaged dust filters Ins...

Page 102: ...es must be brought to operating temperature and maneuvered for approx 15 min Beforehand the anti corrosion coat must be removed from the piston rods and the openings of the air filter system and the e...

Page 103: ...and repair suction line 2 Hydraulic pump damaged Repair or replace 3 Priority valve damaged Remedy fault call Service Agent 4 Hand metering unit damaged Remedy fault call Service Agent 5 Steering cyli...

Page 104: ...heck diesel engine 2 Brake has got stuck Check remedy damage 3 No tank pressurization Check ventilation filters and breathers replace 4 Suction filter clogged Replace filter 5 FAST SLOW gear not funct...

Page 105: ...el engine faulty Check repair 3 Charge pump damaged no charge pressure Remove pump and examine install new pump if necessary 4 Switch for travel direction damaged Repair or replace if necessary 5 Sole...

Page 106: ...inders worn Re seal cylinders 2 Secondary valves defective Check secondary valves and replace completely if necessary 8 14 Faults in the electrical system 1 Outside and or internal lighting damaged Ch...

Page 107: ...serve FL 7 10 Optional socket attachment FR 7 10 Signal horn FL 8 10 E module inputs FR 8 10 Main beam headlight FL 9 10 Instrument clusters FR 9 10 Dipped beam FL 10 10 Radio ignition lock FR 10 10 S...

Page 108: ...etaining valves option are without function as long as the ride control system is activated Operation 20 km h version Operate the ride control system toggle switch 80 11 The green indicator lamp light...

Page 109: ...m before the electronic key is inspected A manipulation of the immobilizer with the ignition deactivated is thereby impossible 9 3 3 Learning a new key Learning a new key takes place with a master key...

Page 110: ...ll learned keys are cleared and all available keys can be relearned The master key code is not deleted during the clearing process This function is only available if the control unit relay is addition...

Page 111: ...ng not possible 1 Terminal 30 not connected to control unit 2 No or incorrect master key used previously red grip 3 Time for master key in ignition too short or too long 4 Key to be learned does not h...

Page 112: ...9 Appendix 106 TW9...

Page 113: ...Lubrication intervals and points of lubrication according to lubrication chart and demonstration of these points on the machine Handing over of Diesel Engine Operating Instructions 2 Spare parts list...

Page 114: ...rk equipment and replace if necessary O O 26 Check bushings and bolts of the articulation and the articulated steering and replace if necessary O O 27 Check that door catches function perfectly and re...