Takeuchi TL10 Crawler Loader Operator's Manual

 OREA NA
„=
qe
Serial No. 10031L and after
SER EA E.
Preface
Thank you for purchasing the TL10 Crawler Loader.
This manual has been prepared to inform you of the best methods for driving,
| operation, maintenance. and repairs so that you can realize the maximum effi- o
ciency and economy as you use the TL10 Crawler Loader. Please read this ~~
manual carefully to understand t the correct procedures for operation, mainte-
nance and : service.
A As
Contents
Specifications | 8 ; | : mad E dimos op
Names - Functions
Names of Components eee rer 5
Controls and instruments ................e.eeemmeeee..— 5
Seat ….….......rreresserrenseseercen ren enee scene cesser 7
Seat Belt oii nes 8
Safety Bar o.oo EEE 8
Operation
Before Starting the Engine ................e.......—..- 9
Starting the Engine ............... Lacannaese rene seance 10
Stopping the Engine... 11
Levers and Pedals Operation... 12
Steering Levers and Acceleration Pedal ........... 13
Operational Pedals ...................e....=mene=eeee. 14
Operation Outline ................—...e=.eeemeneaee 16
Cautions During Operaiton ............ er 19
Transporting the Loader 22
Inspection - Maintenance
Greasing ................eeeieemeren ener eee ET EEE 23
Adjusting the Crawler Belt Tension ............... 23
Replacing the Gear Ol ...............ene.em e. 24
Replacing the Hydraulic e eerie 24
Remove the hoad ..................eesreeeeeeenee 25
Servicing the Fuel System ces 25
Replacing the Engine Oil Filter ..............———.- 25
Cleaning and Replacing the
Air Cleaner Element er 26
| Light: Roplacing the Bulbs 28
| Other Inspection and Maintenance ........ 2
Replacing the Bucket ..............==eeeineeee 28
Handling in Cold Weather ...........000000000 29
Long-term Storage ..……...…...…..……eesseseecneceers 29
Lubricants Chart ………....……...….….esserierensenncancencenencees 30
Tightening Torques ..…......…...….….….….…—eceeeeccenencensss 31
Service ЗсПейш!е ......еенеееееененееееееенннннннененннннее) 32
ТгоиЫ!езПоойпд .....сееееееееннннннннннннннннененннннененеесее 33
Hydraulic System Diagram... 34
Electrical System Diagram ................2eeeee-eee=menmeees 35
Safety Instructions ................==e=e-=e=m eee 36
Options ................eeeeeemeieeeerer nene reee 40
Parts - Service
When ordering ..................e.--.ereenencereean 41
Consumable ltems ................eeennescernrenerececenene 41
Standard Accessories ...............eeeereereeeeverecceerete 42
Parts List ….….….........rerrrersenensaenssanenaen rene ence0e 43
Dimensions
mm 2545 990
in 100 39 .
1873 | 1046
-737 | 41.2
280
9.1
214 | 1000
39.4
8.4
Working ranges
— N
YA
An
TTT F
RITO
CE
au та
TO- 202
| 35°
50°
TO-201
2370.
93.3
1735
335
13.2
Performance
Travel Speed
Low Speed
High Speed
Gradeability
Max. traction force
Fuel, Lubricant, Coolant
Fuel Tank
Hydraulic Oil
~~ Tank Level
-— Total System
Engine oi
Max. _—
Min. -
Coolant.
Engine
Make
Model
Cooling
Rated Output
Rated Torque
Number of Cylinders
Bore & Stroke
- Total Displacement
Electrical
System Voltage
Battery
Alternator
Power Train
2 Speed, open circuit
Weight ВЕ
Operating Weight |
Ground Pressure JIS)
Standard Bucket a
Width -
© SAE Rated Capacity en
Weight -
0 ~ 2.6 km/hr (0~1.61 mph)
0 ~ 5.1 km/hr (0~3.17 mph)
30° о
“1010 kg (2227 Ib.)
34 tres 5 (9) 0 U. s. gal. )
_ „40 für tres 5 (106 6U. S. - gal, )
“ 4.0litres (1.1 U. 5. ва. ;
2.5 litres (0.7 U.S. gal.)
‘3.5 litres (0.9 U.S. gal.)
Isuzu
—3KC1
— Liquid
Diesel Е В
17.5 ps (17. 3 hp) ) @2, 200 грт
6.0 kg-fm (43 ft.-Ib) (92,000 rpm
3
75 mm x 76 mm (2.95 in. X 2.99 in.)
980 cm“ (59.8 cu.in.)
12V
529A 300 cold crank amps. @—15°C
20A
1,390 kg (3,065 Ib.)
0.26 kg/cm? (3.7 psi)
1.000 mm (39.4 in.)
0.16 m® (0.21 cu.yd.)
77 kg (170 lb.)
Names of Components
ID
©
aaa
wh
o
N
ud
OONDO BON +
Safety Bar
Bonnet
Hydraulic Oil Tank
Canopy —
Headlights
Seat ВИ
Fuel Tank
Hydraulic Return Line
Right Auxiliary Hydraulic Line
. Travel Motor a
. Track Roller
.F ront Idler
. Lift Cylin der : | | ; - | ; - sue
. Bucket Cylinder | a
.Bucket ©
. Safety Step —
. Safety Grip HS ai
. Left Auxiliary Hydraulic L Line
. Lift Arm Stopper
. Steering Levers STA
. Arm Pedal
Bucket Pedal
7 Au xiliary Pedal + се)
Acceleration Pedal ~~
. Horn Button
- Water Temp: Warning Lamp
- Oil Press. Warning. Lamp
. Charge vaming amp
Ca AO. Light Switch. cuit
0 . Throttle Lever .
. Fuses
3. Starter Swen
1. Glow Signal
Васко puma
Steering Levers .................... Refer to “Operation” on pages 12~15
Arm Pedal ......... 0 Refer to “Operation” on pages 12-15
Bucket Pedal . cnenarerecenonenenrprepcres Refer to “Operation” on pages 12—15
Auxiliary Pedal | = a ОЛ Refer to “Operation” on pages 12-15
Acceleration + Pedal e. Ан Refer to “Operation” on pages 12~15 | Ce
Horn Button
on.
Charge Warning Lamp
This lamp lights Up when the starter switch is turned on and goes off after a I
the engine starts.
It lights up if there is a malfunction in the charge system while the engine N
is running.
o Have the charge system. checked at a service station.
Oil Press. Warning Lamp
This lamp lights up when the starter switch is turned on and goes off after
the engine starts.
It lights up if there is trouble in the lubrication system while the engine is
running.
o Stop the engine and check the engine oil level (see page 9).
о | there is some other cause, have it checked at the service station.
CAUTION: Do not continue. driving the loader if the oil pressure warn-
| ing lamp ights up as it could cause the engine to sieze up.
Water Temp. Warning Lamp
high.
e This lamp” signals" that the engine is overheating. Stop operation
immediately and let” the > engine idle to lower the coolant temperature
o After waiting for th coolant temperature to drop, stop the engine.
e. Check the coolant level after the engine has cooled. Also check for a
broken or loose fan belt, etc.. (See page 9)
e The coolant {етре! ature could also be caused to rise abnormally high
by running the engine under too heavy a load.
Resume operation after lowering the coolant temperature, taking care
not to let the temperature rise excessively.
Throttle Lever
This lever controls the engine rpm. Push this lever ‘down for low speed,
pull up for high speed. Pushing this lever down fully stops the engine.
Hourmeter
This meter indicates the time which the loader has been operated. lt
operates only while the engine is running.
This lamp lights up when the coolant temperature becomes abnormally 4
Pressing this button € causes 5 the horn to sound when the battery switch is. © 5 5
T2-016
F2-104
F2-103
B3-222
Light Switch
This switch turns on the head lights.
Starter Switch (see pages 10 and 11)
R... TE Heats the glow plugs to facilitate engine starting.
o “(engine stop position).
ACC sess... CONNECES the accessory and ‚power supply circuits o
В (engine run position).
Sees e ...... Turns. the starter motor to start the engine. (The key
a returns to the ACC position automatically v when the Key
is released.) a
NOTE: The following two types of key are supplied | in the key holder.
1. Engine start key |
EEE Ey EE EE EEN NE EE EEE EEE EERE ENE EN]
Fuel filler cap key : nocenanrocane 2 keys DURE
Cuts off the accessory and power supply circults — cs et
Fi-028
2. BOMNGEKY ooo ceci crever 2 keys
Glow Signal
" signal indicates when the glow plugs h has been n preheated (See page
The fuses are arranged ir in order from the top as 5 shown below. o
Capacity | - Circuit ~~ un + В м _ _ | 3 ; _ - | | . . | | | a a Eg Em EI
15A | Hom >
5A IC Regulator (Alternator)
5A Warning lamps, Feed pump
15A Headlights Peng Ae
Seat
Cushion Adjustment
Moving lever “A” up and down permits the operator to select the cushion
firmness which best suits his body weight.
Top position........................ Light person
Middle position..................... Medium person
Bottom position.................... Heavy person
Seat Back Angle Adjustment
Lomo pandie “B” permits the seat back to be reclined backward between
° ап °.
Forward-Backward Adjustment
Pressing lever “C” to the right permits the seat to be adjusted backward or
forward a total of 150mm (5.9 in.) in 15mm (0.6 in.) increments.
7
Seat Belt Before Starting the Engine
eat Be
Adjusting Seat Belt Length [RIT
o Grasp the buckle so that it is at right angles to the belt, then pull on the
| belt to adjust the belt's length. Fasten the seat belt securely, making
sure it does not become unbuckled.
Release the Бей by. pressing on portion “E” in the buckle.
Checking the Coolant
At a time when the engine is cool, remove the radiator cap and check
the level of the coolant. The coolant level should be 30mm (1 2 in) ;
above the top of the radiator core to be normal. If there is insufficient J
coolant, fill the radiator back to the proper level with soft water.
WARNING: Dor not remove the radiator cap when the engine is hot.
Safety Bar a ss
The safety bar is a safety device designed to prevent the operator from
being thrown € out it toward the front in the event that the loader is tipped for- a
ward. me He
In addition, a lock mechanism connected. to each control pedal and steer- es
ing levers prevents. the pedals or levers from being operated until the bar E
has been lowered. | | a |
Checking the Fan Belt
Adjust the fan belt so that the deflection “A” is approximately 12mm
(0.5 in.) while pressing down on the center of the fan belt (with approx-
A es ee = ‘imately 10 kg/22 1b. of pressure).
Ariens .... With the safety bar not sel xt (Steering le lever and control pedal For details see the engine operation manual.
lock position) : Ва
В.о With the safety bar set t (Steering lever and control pedal
release position) -
NOTE: Push the safety bar down to the “C” and “D” positions. | mena OO 8 Ш - MET ao oo _ | В Ш a " | В / - ` = = Е | / 5 ; ‚вом
Checking t the Engine Oil Cees meals ep.
Check the oil level with the oil level ¿ gauge.
“A” is the ‚upper limit.
“B” is the lower limit.
‘For details see the engine operation manual.
Lift Arm Stopper : | | | ere
If the lift arms must be maintained | ina | raised position during repair € or
other operations, use this stopper to prevent the lift arms from dropping.
e One person must stay in the operator's seat, with the seal belt fastened
and the safety bar lowered, while another person | installs t the It arm
stopper. MS a
e Start the engine and raise the lift arms all the v way ; up.
er the rod of one lift
o lindo a second person install the lift arm stopper over Checking the e Hydrauli с О!
cylinder.
| a a | Set the loader in the posture shown in the figure.
e Install the | ar stopper oy ne following Pro ге e. mon Ч че’. AAA _ | Check the oil level, using the following points as
4 дя а E stópper 0” over the rod. a EARL EDO EN | criteria since the oil level varies according to the oil
3. Pass s pin B” through nole D7 then fasten it with snap pin A o a | «Between (he upper limit “A” and lower limit “B”
| when the oil is at normal temperature (about
20°C/68°F). e nos o TL
e Near the upper limit “A” when the oil tempera-
ture is the normal operating temperature (about |
— 60% 40°F). |
e The oil level in the tank varies approximately
1mm (0.04 in.) for every 10°C (18°F) change in
the oil temperature.
TI |
FF = E
Y
Miscellaneous
Check all piping for oil leakage, etc., and check to make sure no bolts,
nuts, split pins or other parts are damaged or missing.
After the above check, make all necessary adjustments, referring to the
items on “Inspection - Maintenance”.
The operator should be sure to adjust the seat to the proper position
and fasten the seat belt during operation (See page 8).
8 9
Starting the Engine |
Start the engine by the following procedure.
1. Insert the key in the starter switch and turn it to the “ACC” position.
The charge warning lamp and oil pressure lamp will light up. |
2. Pull the throttle lever to the center position.
3. Turn the starter switch to the “R” position and hold it there until the
| indi d hot.
low signal indicates that the glow plugs are re |
(This normally takes about 15 seconds, but in cold weather it takes
about 30 seconds.) —
4. Turn the starter switch to the “S” position and start the engine. The
“starter switch will return automatically to the “ACC” position when the
key is released.
5. Return the throttle lever to the Idling position and let the engine warm
up for about 5 minutes. ; |
10
TO-036
TO-040
Stopping the Engine
Before stopping the engine, let it idle for 5 minutes to cool, then stop it by
the following procedure.
1. Push the throttle lever down fully. This will stop the engine.
2. Turn the starter switch to the “OFF” position. . |
CAUTION:
1.
Do not run the starter motor continuously for longer than 10 seconds.
2. If the engine fails to start, wait for about 30 secodns in order to protect
3.
the battery, then try starting the engine again.
Be sure to leave the starter switch in the “ACC” position while driving
the loader. The electrical system will not function properly, and
damage could result if the starter switch is in the “OFF” position.
Make sure that no warning lamps are lighted up (See page 6).
11
ii
Steering Levers and Acceleration Pedal
The steering levers control forward
and reverse > travel and turning of
5. Reverse
the loader. Forward I | ©
Forward travel
Push both levers forward.
E Reverse travel |
Pull both levers ‚backward,
1
PET
TIT i LiF REEL
Move one of the levers more than
the other lever.
2 a Spin turn Ш
Push one lever forward and pull
the other lever backward.
= Changing travel speed
Depressing. the acceleration pedal e DADA A
while traveling at low speed - Left Turn o Right Turn —
causes the loadér to speed ue.
Letting up on the pedal causes it
to slow down again. $
ss Stopping
Return both. levers ; slowly to the
neutral position. ~The parking
brake engages automatically when
the loader 15 stopped.
CAUTION: о
Fasten the seat belt snugly and
lower the safety bar when driv-
ing the loader.
T0-045
TO-Q47
A Left Crawler Forward F Lift Arm Raise
B Left Crawler Reverse G Lift Arm lower ; дано ® 7 I SP 14
с Right Crawler Forward H | lift Arm Float
D | Right Crawler Reverse | Bucket Rollback
J Bucket Dump
E Travel, Acceleration
TO-048
12 | 13
Operational Pedals
Arm Pedal
The arm pedal controls the lift
arm.
Raise
Depress the heel side of the
pedal. |
Lower |
Auxiliary Pedal
The auxiliary pedal controls the flow +
of hydraulic fluid in the left and right —
auxiliary lines.
B Depressing the toe end of the
auxiliary pedal causes high pres-
sure hydraulic oil to flow from port
“A”. Depressing the still further
Depress the toe side of the pedal.
moves the control valve to the
detent position, allowing the con-
stant flow of hydraulic oil. Pushing
the heel end of the pedal releases
the control valve from the detent
position. o
M Float position a
With the bucket lowered, depress-
ing the toe side of the pedal to the
lock position (detent) sets the arm
in the Float position. |
Use the Float position of the lift
arms to level loose material while
driving backwards. In this position,
there is no hydraulic force on the
lift arms so the bucket is held
down only by gravity.
Push on the heel of the pedal to
unlock the pedal from the Float
position.
@ Depressing the heel end of the
sure hydraulic oil to flow from port = © CA
e В” ; Lee ES edo DP EE be Te 5 : E E E en re 4
NOTE: Hydraulic oil passing through port “T” returns dire ; | ;
| er ctly to the hydraulic tank. It is used ret il
tank when the breaker is used. Fer 5 7 y Ko re um oro the
Bucket Dump
Bucket Pedal >
The bucket pedal controls the Ш N PA \ >
bucket tilting function. * SE =
E Dump ; |
Depress the toe side of the pedal.
E Rollback
Depress the heel side of the
pedal.
Se]
SIT [Ty
TEL
NS Fa LS x
Re ramet ЧЕТ
14 | 15
Operation Outline
Scooping Operation | A
Lower the lift arm and bring the bucket down to the ground with the front end tilted slightly forward, then
drive the loader forward until the bucket is filled with the material. Next tilt the bucket backward and scoop
up the material.
Grading Operation E a
Tilt the front edge of the bucket down at an angle which is appropriate for the ground hardness, then drive
the loader forward slowly, digging into the ground with the cutting edge of the bucket. When the bucket is
full, tilt it backward.
Leveling Operation | a |
Raise the lift arm and tilt the bucket forward, then release it as the loader is driven forward. Next tilt the
bucket forward and lower the front edge until it is slightly above the ground surface, then back the loader
over the load which was just released.
16
Backfilling Operation E EE бы
With the bucket lowered, drive near the hole and tilt the front edge of the bucket downward as soon as it
passes over the near side of the hole. Raise the bucket and empty the load only when necessary. . -
Leveling Operation using the Float position. _ a
Lower the bucket onto the ground, then put the lift arms in a Float position. Tilt the bucket forward to stand
it on its cutting edge, then level the loose material while driving backward.
CAUTION: « Do not use the Float position to lower a full bucket.
e Do not drive the loader forward with the lift arms in Float position.
Loading Operation
Approach the truck and stop, then raise the bucket until its lower edge clears the truck bed. Drive the loader
slowly forward, stop at the position where the bucket is to be tilted forward, then tilt the bucket forward,
releasing the material in the bucket into the truck bed. When the truck is half loaded, use the bucket to
spread the load evenly.
17
ен ees 1: Cautions During Operation :
Travel up and down slopes or hillsides with the heavier end of the loader facing toward the top of the hill. Carry out operations on level ground. Use maximu
T ravel straight up and down the grade. Do not travel sideways or tilted. OEA UL | ling on slopes or hillsides.
m caution when-travel- .. “E
e When the bucket is ful
с
AC
CAA
; E
LE
|
Te X
Keep the bucket as low as possible during travel. Do not travel or attempt
to change directions with the bucket raised.
Travel at a speed which is appropriate for the conditions. Travel at low
speed when the field of view is obstructed and take extra precautions with
hazardous materials.
Do not use this loader in areas where there is danger of explosion from
volatile gases. Also avoid using the loader where the exhaust gases could
come in contact with flammable items.
Oi- 004
Lower the lift arm fully and let the bucket rest on the ground before finish-
ing operation or leaving the loader for short periods of time. Engage the
parking brake and switch off the engine. Be careful in dismounting the
loader.
01-005
When parking the loader on a hillside, be sure to place wheel blocks in
front of and behind the track belt. In addition, drive the loader forward
when moving it a long distance. Moving it long distances in reverse
accelerates wear of the track belts (link bushings).
18
19
Failure to observe the following cautions could cause the crawler belts to
slop off and cause them to wear out rapidly.
The following operation methods should not be used since they bring
excessive loads to bear on the loader and cause breakdowns.
o Do not attempt a spin turn or pivot turn at high speeds.
* Do not exceed the loader’s rated operation capacity.
. Do - not cut ; across
e Do not use buckets or attachments which exceed the loader's operaiton
capacity.
° Do not travel at high speeds over rough terrein or over cobblestones.
* Do not use the downward force of the loader to drive piles.
Do not travel over objects with sharp edges such as crushed rock. e Do not rush the loader into a pile of material.
| 21
20
INSPECTION -
Greasing e
Apply grease to the portions marked. with
every day or after every 10 hours of operation. Apply
grease a little more frequently depending on the sev-
erity of operating conditions. Е
Туре of grease: Multipurpose jithium - . soap based
grease No. 2
Transporting the Loader
Е } [rT] AJ
o Select a ramp length which will yield an angle of ] Adjusting the Crawler Belt Tension
inclination “A” of 18° or less (Refer to the chart at H
м © mm (ft. in.) mm (ft. in.) * Check the tension of the crawler belts daily or after
right). | ‘ 4-1 reater every 10 hours of operation.
> Make: width 1.2 times the shoe width. 1,300 (4-3).............. 4,300 (14-1) org
Mak rm gs edge of the ramp so that it is like 1,110 (3-8)... 3,700 (12-2) or greater a ° Lower the lift arms and tilt the bucket to raise the
o Be ; © ow m he above figure. 930 (3-1)............. 3,100 (10-2) or greater front of the loader fully off the ground.
8 ass ecurely with stays, etc. to prevent 750 (2-6)............... 2,500 ( 8-2) or greater | ° Measure the clearance between the center track
» Fasten the ramp 5 the truck. roller and the surface of the crawler belt where it
it from separating rom I a
e Setting a support “C” underneath the ramp inthe ; Standa a values the roller.
center makes the ramp safer. Rubber crawler ......... 20~25mm (0.8~1 0 in.)
CAUTION: e Be sure to load and unload the loader in an area with | Steel. crawler eee 20—40mM (0.8—1.6 iN.)
| -—. level, hard packed ground.
Engage the truck's parking brake and set wheel blocks | = an
| “un der the wheels. | Tightening the Belt
о we. Move the loader up and down the ramp with the bucket | Apply grease to check valve “A”
“end facing downward. (See the above figure.) until the tension of the crawler
— belt is correct.
Posture During Transport
o Secure the loader with chains or wire ropes, etc.
o Set wheel blocks in front of and behind the crawler belts.
Loosening t the Belt
Loosen check valve “A” to drain
some of the grease out. Be sure
to loosen the ckeck valve gradu-
“ally.
CAUTION: The grease nipple
should not be \_ | В, AER 64
loosened. a 82-089
CAUTION: Applying too much tension to the crawler belt will cause it
to break. Loosening the crawler belt too much will cause it
to SP off.
22 8 23
Replacing the Gear Oil
Track Gearbox |
» Replace the oil after the first 500 hours of opera- ой
tion, then every 1,000 hours thereafter.
e Drain the oil from drain port “A”.
e Pour oil’ into oil filling port “B” until oil starts 10 flow
out of oil level check pot “С”.
° Type of off : Gear 0 oil il SAE 90
Eos | API GL-4
o oil capacity : 0. 35 liters (0.7 74 U. S. pt.) то-ото
Replacing the Hydraulic Oil
— Replace the oil every | ‚000 hours of operation.
Type of oil : Antiwear hydraulic oil | | .
ISO VG 32 or VG 46
Total system capacity - 40 liters (10.6 U.S. gal.)
Tank leve! | capacity о — 34 liters (9.0 U.S. gal. )
Replacement Procedure
e Set the bottom of the bucket flat on the ground.
e Remove the oil filler cap “SAT.
e Remove plug “B” to drain out the oil.
» Remove cover “D”, remove the. suction filter “E and clean it in
kerosene.
e Replace the return filter (refer t to “Replacing the Return Filter”).
» Remove the other parts and clean the inside of the tank.
Supplying Hydraulic Oil
» After assembling each component pour in new oil at oil filler “A”.
o Start the engine and operate the loader lightly.
» Set the bottom of the bucket flat on the ground. (see Fig. 1)
ne. Level Check Posture
» Check the hydraulic oil level, refilling to the proper level if insufficient.
« Raise the lift arms fully and tilt the bucket all the way forward. (see Fig. 3)
не. Tank Pressurization Posture.
» Install the oil filler cap “A”.
cs Tank Pressurization Complete.
CAUTION: If the tank is not pressurized, the hydraulic pump will be
damaged. Always follow the above procedure.
Replacing the Return Filter
First time ovine, after 50 hours
Thereafter every 500 hours
e Loosen the oil filer cap “A” on the tank and bleed out the air.
e Loosen plug “G” and bleed out the air.
e Remove the 4 bolts “H”, then remove the flange “Jv.
» Remove the case “K”, then remove the element “L” and replace it.
e Replace the packing with a new packing if it is scratched or deformed.
24
— INSPECTION - M
Remove the hood | Eta Du mA Da
Removing the hood makes maintenance within the € engine r room ‘ easier.
1. Open the hood fully.
2. Slide the hood to the left.
° When checking the engine without removing t the hood, fasten t he hood odin - В — -
~ place with hook “A”. — нЕ ) so
TO-21I8
Servicing the Fuel System
Draining the Fuel Tank
e Drain out the water, dirt and other debris which has accumulated in 1 the a.
bottom of the tank through drain cock “A”. a.
e Repeat this procedure after every 50 hours of operation.
Replacing the Fuel Filter Element
Draining ………………… every 100 hours
Replacement ..................... every 500 hours
Loosen the center bolt “A” and drain out the fuel, then remove the center
bolt “A” and take out the element “B”. Be sure to replace the O-ring and
packing.
geo
Bleeding Air out of the Fuel System a A TÍ .
After draining or replacement of the fuel filter element, or when cutting a of НН
the fuel supply, bleed the air out by the following procedure. -
1. Loosen the air bleeder screw plug “A” on the fuel injection pump.
2. Turn the starter switch ON.
3. Tighten the screw plug “A” after air bubbles disappear from the fuel. . eu”
Replacing the Engine Oil Filter
First time ooo, after 50 hours
cercssenacn nes every 250 nours
1. The oil filter is a cartridge type oil filter, so remove the filter c case > and ос
replace it with a new one. | ВЕ
2. Apply a small amount of oil to the fuel filter © ring when instaling à the § a 7 A
iter Go
3. Tighten the filter by hand, turning it 2/3 turn beyond the point where the
O-ring and fuel filter bracket come in contact with each other.
25
Cleaning EE RI every 250 hours
Replacement Geasrece rence annee every 1,000 hours
Disassemble the air cleaner in the following sequence.
1. Loosen clamp “A”, then remove dust cup “В”. © |
2. Remove baffle “С” from dust cup “B”, then clean them both.
3. Remove wing nut “D” and remove element “E”. Clean the air cleaner
Unit.
CAUTION: e If the packing in the element is deformed or scratched,
— replace it.
« Clean the dust cup each day. Clean it more often if the a
dust level is extremely bad.
e Be sure to install the dust cup with the arrows pointing В | В 1 ) x 8 Во 5 о
ир рат the top).
Cleaning Procedure
Blow out the filter with clean, dry compressed air (at 7 kg/cm? (99 psi) or
less), moving the nozzle along the folds from top to bottom. Maintain an
appropriate distance between the nozzle and the element.
Lights: Replacing the Bulbs
Headlights
« Remove the 4 screws “A”, then remove the housing “B”.
e Remove the reflector “C” from the rim “G”.
e Remove the bulb “D” from the reflector “C” by pushing in the bulb “D”
lightly € and tuming it counterclockwise.
Other Inspection and Maintenance
Checking the Coolant |
o Ata time when. the engine is cool, remove the radiator cap and check
the level of the coolant. The coolant level should be 30mm (1.2 in.)
above the top of the radiator core to be normal. If there is insufficient
coolant, fill the radiator back to the proper level with soft water.
“WARNING: Do not remove the radiator cap when the engine is hot.
Adjusting 1 the Fan Belt
e The fan belt should have a deflection of approximately 12mm (0.47 in.)
when a finger pressure (approximately 10 kg/22 Ib.) is applied be-
tween the fan pulley and the generator pulley.
° For further details, refer to the engine operation manual.
Replacing the Engine Oil
First time essen after 50 hours
Thereafter ............. emmm... every 250 hours
26
E2-077
Battery Fluid Check
e The battery fluid level should be between the Upper Level “A” and the
upper limit of the Check Zone B. Replenish the battery fluid with distilled
water if the fluid level drops to the Check Zone.
Precautions when handling the battery
o Fire or explosion could occur, so take the following precautions.
A, Be careful to prevent shorts and sparks, and keep all fires, such as —
| cigarettes, away from the battery. N
2. Work in a well ventilated area.
е | battery fluid gets in the eyes or on one’s skin, rinse immediately with Ш
large quantities of water. Particularly in the case of eyes, have a physi-
cian examine them after they have been rinsed well with water.
Refer to the engine operation manual, supplied with the engine, for
checks and servicing of the engine. |
27
sE | Handling in Cold Weather
Replacing the Bucket o a В ни o
Carry out replacement on level ground. о FR 5 I o Battery
Removing the Bucket e Check the amount of battery fluid and its specific gravity, and charge it quickly.
» Clean around the bucket pins. |
. Set the bucket on the ground as shown in the figure
o on ve the bolt “C”, then drive out the bucket pin
“A” Raise the bucket slightly to give it a little play in
“order to make the operation a little easier.
« Wipe the pins and pin holes clean to keep soiland
other debris from them.
CAUTION: To prevent the distilled water from freezing, fill the battery first thing in the morning, not after
operations in the afternoon. also, have qualified service personnel check and charge the
Coolant
+ Add antifreeze to the radiator when the temperature drops below 0°C (32°F). =
e Water and Antifreeze Fluid Mixing Chart. =.
°C | -5 | —10 | —15 | -20 | -25 | —30 | -35 | —40 |
(°F) | (+23) | (+15) | (+5) | (+4) | (-13) | (-22)
Minimum Temo. a
| 70-285 imam emp. (—31) (— 40) te
LS it. | 053 | 088 | 1.05 | 1.23 | 1.40 | 1.58 | 1.75 | 1.93 |
Antifreeze |
Installing the Poe « first — (US.at) | (0.56) | (0.93) | (1.11) | (1.30) | (1.48) | (1.67) | (1.85) | (2.04) |
e Fasten pin hole BTs” | — —— —— ee —
. mo af “ A» ten it. |
« Move the bucket cylinder to align it with pin hole A”, then fas Water lit. 597 2 62 2.45 2927 | 210 192 | 475 | 157
(U.S.at.) | (3.14) | (2.77) | (2.59) | (2.40) | (2.22) | (2.03) (1.85) | (1.66)
NOTE: Be sure to add antifreeze in the proper amount to achieve the proper mixing ratio as specified
by the antifreeze maker.
e The pin seal “D” will be damaged if the pin holes are not correctly
aligned before the pin is driven in.
» Replace the pin seal if it is deformed or torn.
« Replacing the Pin Seal | | |
Sot the new pin seal in the direction shown in the figure at right, then
pressure insert the seal a little at a time using a wooden mallet or
similar tool. Be careful not to deform or tear the seal.
Precautions after Operations
Clean off any mud or water adhering to the loader body, park the loader on a concrete surface or on dry
ground, or lay timbers down to park it on, then cover it with a sheet or similar covering.
Wipe off any water drops on the hydraulic cylinder piston rod completely. Frozen water droplets mixed with
mud, etc. could get into the seal and damage it.
ss
-
F2-397
Long-term Storage
Take the following measures when storing the loader for extended periods of time.
o Store the loader indoors in a dry place after cleaning and drying it thoroughly. Do not store it outdoors.
If the loader must be kept outdoors, select a level area and place it on top of a row of timbers. Cover
the seat securely to protect it.
* Add oil, apply grease and change the oil regularly.
Apply an adequate amount of grease to the piston rod of the hydraulic cylinder.
Disconnect the cable from the ground terminal of the battery or remove it from the loader and store it
indoors.
Add antifreeze to the coolant or drain all the coolant from the engine if the temperature drops below 0°C
(32°F).
Following long term storage of the loader, carry out the following measures before use.
e Wipe the grease off the hydraulic cylinder piston rod.
e Start the engine, drive and operate it under no load, letting the oil circulate completely.
NOTE: If the loader is not operated for 1 month or longer, carry out the above procedure once a month.
28 29
Lubricated
Track gearbox
SHELL
Tellus oil 46
Spirax EP 90
Part Hydraulic oil Pump spline section Grease fittings
Capacities Total system As required 0.35 lit. (0.74 U.S.pt.) As required E.
40 lit. (10.6 U.S.gal.) | | DS
| Tanklevel
© | 84lit(9.0USgal) A
Interval Every 1,000 hours first 500 hours. each Everyday or every 10
succeeding 1,000 hours. | hours
Application a
Takeuchi Antiwear hydraulic oil | Grease with molybde- | API, GL-4 or GL-5 | EP-2Lithiumsoap —
specification num disulphide added | SAESO | basedgrease —_
ESSO: Nuto H46 Gear oil GP 90 Beacon EP 2
MOBIL DTE25 | | Mobilube GX90 Mobiluxe EP 2
GULF Harmony 46 AW | | Guifcrown No.2 EP
TEXACO | Regal RO46 7 Thuban Universal 90 | Multifak EP2
Retinax AM Alvania EP 2
30
Reference
figure
‘Principle parts needing retightening
Tightening torque
SW N —
Travel motor installation bolts
Drive sprocket installation bolts
Track roller installaiton bolts
Shoe slide installation bolts
5.6 kgm (40.51 -Ib.)
5.6 kg.m (40.5 ft. Ib.)
9.9 kg-m (71.6 ft. -Ib.)
5.6 kg-m (40.5 ft. -Ib.)
Figure 2
31
CAUTION: Do not attempt to retighten the engine installation bolts sinc
Retighten these parts after the first 50 hours of operation, and thereafter retighten them after every 500
hours of operation. 5 |
e they are tightened with screw
-
= то С
an 6
amara ran ¿O
TO-092
Figure 3 - ST.
Trouble
Main causes
Countermeasure
Operation pedals are stiff or | e Stones or mud are lodged under the | e Remove the stones or mud.
don’t return automatically. ‚ рейда. -
e The control valve is defective. e Have it repaired at the service station.
No operation can be done, or | e Insufficient hydraulic oil. e Replenish the hydraulic oil to the
there is no operating power. specified level. о
В e Hydraulic oil is not warm. e Warm up the loader.
e. The engine's output is low. e Clean the air cleaner and check the
fuel system.
e The pump or coupling is defective. e Have it repaired at the service station.
e Viscosity of the hydraulic oil is impro- | e Replace it with the recommended
| рег. hydraulic oil.
Either the left, right or both | e A stone or foreign object is caught in | e Remove the foreign object.
crawlers do not move. — the tracks.
| e Steering lever system is disconnected. | e Have it repaired at the service station.
e Control valve is defective. == e Have it repaired at the service station.
e Pump is defective. … | —|e Haveitrepaired at the service station.
e Travel motor or track gear box speed | e
reducing gear is defective.
Brake valve is defective.
e
- Have it repaired at the service station.
Have it repaired at the service station.
Straight line travel is poor.
A stone or foreign object is caught.
Crawler tension adjustment is defec-
tive.
- Steering lever system is damaged.
Pump is defective.
Travel motor or brake valve is defec-
tive.
Remove the foreign object.
Adjust both left and right standard
dimensions.
Have it repaired at the service station.
Have it repaired at the service station.
Have it repaired at the service station.
Digging power is insufficient.
©
6 6 806
Pump is defective. E
Relief valve set pressure has dropped.
Insufficient hydraulic oil
Hydraulic oil is not warm. ~~ —-
Hydraulic oil is not appropriate.
The engine's output is low.
Hydraulic cylinder is defective.
Control valve is defective. - —
©
000 0
Replenish the hydraulic oil to the
specified level.
Warm up the loader.
Replace it with the recommended
hydraulic oil.
Clean the air cleaner and check the
fuel system.
‘Have it repaired at the service station.
Have it repaired at the service station.
‘Have it repaired at the service station.
Have it repaired at the service station.
32
Check or service item Daily | Every | Every | Every | Every Every
50 hrs. | 100 hrs. | 250 hrs. | 500 hrs. 11000 hrs.
Grease application A
Crawler belt tension O
| Track gearbox oil X 1st X
Hydraulic oil O X
Return filter ‚X 15! x
Suction filter X 1 st О
Operation pedal operation, looseness O
Steering lever operation, looseness O
Fuel filter О X |
Oil filter ~~ X 1st X
Air cleaner -— 0 x
Coolant — О
Radiator fins О
Fan belt O
Engine oil O “| Xist X
Draining fuel tank of water О
Head Lights, Operation Light, Horn O
Hourmeter operation O
Warning lamps O
O
Battery Fluid (Sp. Gravity)
Retightening of Bolts O 1st O
O: Check A: Replenish []: Clean X: Replace
33
(HH) HOLOW TAAVHL
наше | — 1 MALE : AVE © HOLMS
- a o Alaavs 21 atuvis
NN. gi} = 2 9 on S a Ne =
; + — a 5 =
a 4s 3]
в ВЫ =
1 Ce, ;
| |
HOLVNH3LTY
A | od
‘ Y Si '
dANd 0334 - с
S - G
2 не | 6 5
| :
| р X08 3504 о
SON1d MOTO | -
3
tf NOLLNS NHOH A
— |
H3L3NHNOH IVN9IS MOT9
; HOLIMS =
dW3L HILYM N > —— | | - _ -.
e X08 TOHINOD
HOLIMS —=
JHNSSIH NO Lg
INONT Ш
NHOH | |
AVI NEVM «ИМ СММ AVI NEYM. — HOLIMS
ANAL ESIVAM — 'SS3Hd ЛЮ 3JDUVHO LHON S1HONAV3H
“AdONVO a a oC
MNYL ONNVHOAH (unwed 92)
€00-01 | “ai N _ a eq 001 “Unuri 982
po | и 1HOd AUVIIXNY
| NOLLONS
|
Do] © |
o JANd =
po! “ANI9N3 “ dWnd HvaD | О |
, | L UVID 7 -
-
| |
a > []
| 5
« | _ H3ONIAO LAN
` | HALT
; NENIAH —
— рНа
г.
}
(HT HOLON 13AVHL |
- - a - HIANITAD 13M9NE
| |
+
f
]
|
- 3
|
{
s [4 | LA
f ) ' 1
E Y |
: 5 |
E |
| Cid
| 3ATVA TOHLNOD КВНе o
| O aval NOILYE3dO USONNAO 1340NE
. | =
|
|
fmm me Sm J
y | H3ONNAO LAN
| |
Know the machine well.
+ Know the machine’s capabilities, capacity, size and weight well.
Read this manual well so that you understand it, and carry out
inspection and maintenance faithfully.
» Correct machine operation is the basis of safety.
+ Perform the starting inspection and the daily and other periodic inspec-
tions thoroughly and carefully.
Wear you clothing neatly.
se Wear a safety hat (or helmet), safety shoes and work clothes.
Perform all necessary repairs before using the machine.
e Post a “DO NOT OPERATE” sign on any machine that has not been
fully repaired. | |
e Repair any problems that were discovered the previous day and inspect
the machine thoroughly before starting work.
Check the work area before beginning operations.
e Check for any danger areas.
Check the ground or floor surface.
Be careful of objects buried in the ground.
Be careful of low objects which could cause head injury.
36
01-020
SAFETY INSTRUCTIONS
Post an assistant wherever the visibility is poor or there is =
danger. E. =
» Decide on hand or other signals ahead of time 5, CN
- - | E oo . . æ : E,
Watch out for others! (Keep a close watch on persons who are
engine and moving the machine.
e Do not let persons come within the work area during operations.
e Make sure there are no other persons in the way when starting the
01-026
Always make sure there is adequate ventilation.
e Exhaust fumes from diesel engines are extremely toxic. |
e Always provide adequate ventilation when running the engine in an -
enciosed area... —
No Riders!
e Do not let any person other than the operator ride on the machine in 5
any place. HASH RE пла
The operator must not let any part of his body hang out of the = =
operator’s compartment during operations.
ro ret work with hands or feet sticking out of the operators compart-
ment. 1
Wh
37
FETE
01-030
Biden the engine is running or when it is hot is for- >
» Fire and sparks are forbidden.
Check the following when parking.
o When parking or stopping on level ground.
1. Make sure that the bucket is resting on the ground.
2. Make sure that the engine is stopped.
« When parking or stopping on sloping ground.
1. Make sure that the bucket is dug into the ground.
>. Make sure that the engine is stopped. —
3. Make sure that wheel blocks are placed in front of and behind the
Exchange signals for effective communication, and check
everything carefully! В
38
o over service or adjust machine with engine running unless instructed
o do so.
Place safety blocks under the machine! ВЕ
» When performing inspection and maintenance work underneath the
machine, always lay safety blocks under it to. prevent it from falling. . LR
Fire is prohibited!
Just in case, make sure that Le extinau
156, you know where a fire extinguisher |
located and how to operate it. a "E
Performing inspection and maintenance work while smoking can cause
a fire, so don't do it.
39
Maintenance work during machine operaiton is prohibited!
Is =
D ons
The following optional equipments are available for use when circumstances demand. 6 When ordering
NA E В В LL 6088 When ordering parts or sending notification of trouble, always include the machine model and machine
+ Quick Attachment — o o serial number stamped on the machine identification plate also include information on the number of hours
aa UU the machine has been in use. -
. Buckets to be attached to the Quick Attachment. He
Dumping Dumping * Identification Plate
Type | W dth Rated Capacity Weight Reach Clearance
a | 4000 mm (39.4 in) | 0.16 m (0.21 cuyd) | 79kg(1741b.) | 335mm (13.2 in.) | 1735 mm (68.3 in)
КН
ET
hid |
LW 7
Lily]
DST
¡UNA A UN
A LT
че
CET
WANN
mn
Ll)
WL TE A
a
NS
SCS
NS
LA
Hi
B 1000 mm (39.4 in) | 0.16 m? (0.21 cu.yd.) 87 kg (192 Ib.) 335 mm (13.2 in.) | 1735 mm (68.3 in.)
core
LA UN
LA
\
\
€ | 1000 mm (39.4 in) | 0,18 m°(0.24 cu.yd.) 83 kg (183 Ib.) | 375 mm (14.8 in.) 1685 mm (66.3 in.)
D |4500mm (51 2 in) | 0.23 m° (0.30 cu.yd.) | 102kg(2251b) | 375 mm (14.8 in.) | 1685 mm (66.3 in.)
e Hourmeter
HOUR METER À
3
E o
"E 3
4 4 ES Es
к E
я N Vv H К $
A E
к Е г. 8
Ea Y en м 3
5
NILES
83-316 TO-117
Consumable Items
Check and replace consumable items such as filter elements periodically. Periodic replacement of consum-
able items will prevent many troubles from occurring.
o Major Consumable Items (Items to be periodically replaced)
o 4-in-1 Bucket Part Name Q'ty. Replacement Interval
Width 1000 mm (39.4 in.)
Hydraulic Oil Tank Return Filter 1 Every 500 hrs. of operation
Fuel Filter Element 1 Every 500 hrs. of operation
Engine Oil Filter 1 Every 250 hrs. of operation
Air Cleaner Element 1 Every 1,000 hrs. of operation
» Steel Crawler (Factory Option)
40 41
Part Name
Specification
250mm _
Spanner
10x12
Spanner
14x17
| Spanner В -
19x22
24x27
| spanner 4
Pliers ——
200mm |
Screwdriver
_+and —re-
; Hammer
“\versible type
3/4
L-type Wrench
26
Pipe
20x 330
Hex. Wrench
4mm
Hex. Wrench
5mm
42
No.
Part Name
Specification |Q'
14
Hex. Wrench —
emm ВЕ
15
Hex. Wrench
16
Hex. Wrench
10mm
17
Grease Gun
600cc
18 |
Nozzle - Sel. AS
20
Tool Bag
‘ Split Pin N - —_ RO. |
22
Key Holder
23
Operators Manual
24
Engine Operation Manual
25
Engine Parts Catalog
e This parts list includes mainly consumable items for the TL 10 Crawler
e When ordering parts, include not only the reference number, description
and necessary quantity, but also the machine model and serial number
together with the number of hours the machine has been used.
Parts in the list with an “x” before the part name are not sold sepa-
Loader.
rately.
Refer to the Engine Parts Catalog concerning engine parts.
This is subject to change without prior notice due to improvements in
Using the Parts List
performance or design.
CONTENTS
TRACK ROLLER
FRONT IDLER oo
TRACK SPRING
TRAVEL DEVICE
ATTACHMENT ic
PIPING; ATTACHMENT
HER EY EEA PAA NEA EA REE EEA EERE EAA A
AFB ERS EASE ESE ERS ERE EEE
43
Ref.
pm
!
;
!
}
}
|
|
|
i
|
1
TO-040-0-0
Description
da WO NE
ms mu
ROLLER ASSY, track
A ROLLER
УЗНАЕТ
Y¢BEARING
SEAL, oil
RING, snap
PLUG
BOLT
WASHER, spring
FO-Oda-0-L
Q'ty
PR ee сб
TRACK ROLLER
Remarks
44
TO-050- 1-0
Ref.
Description
HW N= =
O oo “Now
T0-05a-1-L
IDLER ASSY, front
IDLER, front
WSHAFT
YrYOKE (R.H.)
Yr BEARING
YeRING, snap
SEAL, oil
PIN, spring
A PLUG
A YOKE (L. H.)
Q'ty
a = M
a A RNE
Remarks
FRONT IDLER
45
TO-089—-0-D
Ref. Description
1 CYLINDER, grease
2 PISTON
3 PLATE
4 PLATE
5 SPRING
6 BOLT
7 STOPPER
8 WASHER
9 VALVE ASSY, check
10 PACKING
11 O-RING
12 RING, back-up
13 SEAL, oil
14 BOLT
15 WASHER, spring
16 WASHER, spring
T0-06a-1-L
Qty
Ко M9 M PO + Ny BBY NOM
o O го RON
TRACK SPRING
@
Remarks
46
TO-07a0-1-D
RUBBER
Ref. Description
1 MOTOR, travel
2 BOLT
3 SPROCKET, drive
SPROCKET, drive
4 WASHER, spring
5 SLIDE
6 BOLT
7 GROMMET
0-1 BELT, crawler
0-2 BELT, crawler
8 YY SHOE
g YY PIN, track
10 YY WASHER
11 Y PIN, spring
TO-07a-1-L
Q'ty
SMS M9 MOD 45
30
30
30
30
TRAVEL DEVICE
Remarks
rubber
steel
rubber
steel
steel
steel...
steel
steel
TO-39b-0-D
Ref. Description
0-1 ARM ASSY, It (L.H.)
1 XYARM, lift (L.H.)
2 # BUSHING
3 Yr BUSHING
4 Yr BUSHING
0-2 ARM ASSY, lift {R.H.)
5 XXARM, lift {R.H.)
6 FH BUSHING
7 “A BUSHING
8 “Y BUSHING
0-3 ROD ASSY, reach
9 XY7ROD, reach
10 Yr BUSHING
11 * BUSHING
12 PLATE, rocker
13 PLATE, rocker (A. HH.)
14 BAR, main
15 STOPPER
16 STOPPER
17 LOCK, arm
18 PIN ASSY
19 RUBBER
20 PIN
21 STOPPER
22 PLATE, rocker
23 PIN
24 PIN
25 PIN
26 PIN
27 PIN
T0-39b-0-1.
ATTACHMENT
Qty Remarks
e M5 = ой Py) == — — RL же не 8 wd ame —_— 8 wd uur ed
wet PNY eed eed ed
BB RY 3 N
48
Ref. Description
28 PIN
29 PIN
30 CYLINDER, lift
31 CYLINDER, bucket
32 RING, snap
33 BOLT
34 WASHER, spring
35 SEAL, dust
36 NIPPLE, grease
37 WASHER
38 PIN, split
39 RING, seeger
40 BUCKET ASSY
41 TBUSHING .
DETAIL “A”
Q'ty
PIO M3 >
O + NO
Remarks
/
TO-4b-0-D
Ref. Description
TUBE ASSY
TUBE ASSY
CLAMP
HOLDER
CLAMP
UD UNO
HOLDER
BOLT
WASHER, spring
HOSE ASSY
HOSE ASSY
© © © = с
—
11 HOSE ASSY
12 HOSE ASSY
13 HOSE ASSY
14 ADAPTOR
15 ADAPTOR
16 PLUG
17 PLUG
18 HOLDER
19 BOLT
20 WASHER, spring
21 CLAMP
22 RUBBER
23 WASHER, spring
24 BOLT
T0-41b-0-L
Q'ty
& 89: à — N
Mm
RP) BIO О RN
PIPING; ATTACHMENT
Remarks
49
.
:
Printed in Japan by NICHIEI Co., Ltd.
TL 10 Crawler Loader
OPERATORS MANUAL
Edited and issued by TAKEUCHI MFG, CO., LTD.
First Published July 1987
Second Published April 1988
HER O mm Ee E
os : + 3 AS E E e ; ;
2 ; : : E, 3 nn
">