Takeuchi TW40 Wheel Loader Index:

Table of contents
1 Machine designation, manufacturer and notes ………………………………………………… 9
1.1 Machine designation and intended use ……………………………………………………………………………. 9
1.1.1 Intended purpose and designated use ……………………………………………………………………………… 9
1.2 Manufacturer …………………………………………………………………………………………………………………… 9
1.2.1 Name and address of the manufacturer ……………………………………………………………………………. 9
1.2.2 Contact …………………………………………………………………………………………………………………………. 9
1.3 Type plate and serial number …………………………………………………………………………………………. 10
1.4 User instructions …………………………………………………………………………………………………………… 12
1.5 Change in ownership (e.g. by selling the wheel loader) …………………………………………………… 13
1.6 Notes on this operating and maintenance manual ………………………………………………………….. 13
1.7 Further notes on this operating and maintenance manual ………………………………………………. 13
1.7.1 Signal word panels und safety alert symbols in the operating and maintenance manual ……….. 14
2 Safety information ……………………………………………………………………………………….. 15
2.1 General use of the wheel loader …………………………………………………………………………………….. 15
2.2 Working with the wheel loader ……………………………………………………………………………………….. 16
2.3 Safety instructions in emergencies ………………………………………………………………………………… 17
2.4 Vibrations ……………………………………………………………………………………………………………………… 17
2.4.1 Hand and arm vibration ………………………………………………………………………………………………… 17
2.4.2 Whole-body vibration ……………………………………………………………………………………………………. 17
3 Technical specifications ………………………………………………………………………………. 18
3.1 Operating data ………………………………………………………………………………………………………………. 18
3.2 Tires ……………………………………………………………………………………………………………………………… 18
3.3 Fill levels ……………………………………………………………………………………………………………………….. 18
3.4 Diesel engine …………………………………………………………………………………………………………………. 18
3.5 Electrical system …………………………………………………………………………………………………………… 18
3.6 Dimensions……………………………………………………………………………………………………………………. 19
3.6.1 TW 40 with open canopy ………………………………………………………………………………………………. 19
3.6.2 TW 40 with enclosed cab ………………………………………………………………………………………………. 20
3.7 Falling-object protective structures (FOPS) ……………………………………………………………………. 21
3.8 Roll-over protection system (ROPS) ………………………………………………………………………………. 21
4 Transporting the wheel loader ………………………………………………………………………. 22
4.1 Securing the wheel loader for transport …………………………………………………………………………. 22
4.2 Loading and securing the wheel loader ………………………………………………………………………….. 22
4.2.1 Loading the wheel loader onto a flat bed truck …………………………………………………………………. 22
4.2.2 Securing the wheel loader on the transport vehicle…………………………………………………………… 23
4.2.3 Carrying out the transport ……………………………………………………………………………………………… 24

4.2.4 Crane transport ……………………………………………………………………………………………………………. 24
4.2.5 Recovery …………………………………………………………………………………………………………………….. 24
5 Getting acquainted with the wheel loader ……………………………………………………… 25
5.1 Overview: Assembly groups ………………………………………………………………………………………….. 25
5.1.1 Assembly groups: open canopy version ………………………………………………………………………….. 25
5.1.2 Assembly groups: enclosed cab version …………………………………………………………………………. 26
5.2 Overview: Cabin interior ………………………………………………………………………………………………… 27
5.2.1 Cabin interior: open canopy version ……………………………………………………………………………….. 27
5.2.2 Cabin interior: enclosed cab version ………………………………………………………………………………. 28
5.3 Warning notices and labels: open canopy version ………………………………………………………….. 29
5.4 Warning notices and labels: enclosed cab version …………………………………………………………. 30
6 Before starting the wheel loader …………………………………………………………………… 32
6.1 Prior to the initial start …………………………………………………………………………………………………… 32
6.2 Checking the wheel loader …………………………………………………………………………………………….. 32
6.2.1 Visual inspection: open canopy version ………………………………………………………………………….. 32
6.2.2 Visual inspection: enclosed cab version ………………………………………………………………………….. 32
6.3 Refueling (Diesel) ………………………………………………………………………………………………………….. 33
6.4 Accessing the operator`s station ……………………………………………………………………………………. 33
6.4.1 Accessing the operator`s station: open canopy version …………………………………………………….. 33
6.4.2 Accessing the operator`s station: enclosed cab version ……………………………………………………. 34
6.5 Individual settings …………………………………………………………………………………………………………. 35
6.5.1 Adjusting the driver`s seat: open canopy version ……………………………………………………………… 35
6.5.2 Right armrest ………………………………………………………………………………………………………………. 36
6.5.3 Angle of the steering column …………………………………………………………………………………………. 36
6.5.4 Adjusting the driver`s seat: enclosed cab version …………………………………………………………….. 37
6.6 Fastening the safety belt ………………………………………………………………………………………………… 38
6.6.1 Adjusting the exterior mirrors: enclosed cab version …………………………………………………………. 38
7 Control elements and displays ……………………………………………………………………… 39
7.1.1 The dashboard: open canopy version ……………………………………………………………………………. 39
7.1.2 Table of displays, symbols and lights: open canopy version ………………………………………………. 39
7.1.3 The dashboard: enclosed cab version …………………………………………………………………………….. 41
7.1.4 Table of displays, symbols and lights: enclosed cab version ……………………………………………… 41
8 Starting, driving and stopping the wheel loader …………………………………………….. 43
8.1 Prior to the initial start …………………………………………………………………………………………………… 43
8.2 Starting the Diesel engine ………………………………………………………………………………………………. 43
8.2.1 Checks prior to starting the Diesel engine ……………………………………………………………………….. 43
8.2.2 Starting the Diesel engine: open canopy version ……………………………………………………………… 43
8.2.3 Starting the Diesel engine: enclosed cab version……………………………………………………………… 44
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8.2.4 Problems regarding the Diesel engine start …………………………………………………………………….. 44
8.3 Driving the wheel loader ………………………………………………………………………………………………… 45
8.3.1 Forward motion: open canopy version ……………………………………………………………………………. 45
8.3.2 Forward motion: enclosed cab version ……………………………………………………………………………. 45
8.3.3 Stopping the forward motion: open canopy version ………………………………………………………….. 46
8.3.4 Stopping the forward motion: enclosed cab version ………………………………………………………….. 46
8.3.5 Stopping the wheel loader to work………………………………………………………………………………….. 46
8.3.6 Reverse motion: open canopy version ……………………………………………………………………………. 47
8.3.7 Stopping the reverse motion: open canopy version ………………………………………………………….. 47
8.3.8 Reverse motion: enclosed cab version ……………………………………………………………………………. 48
8.3.9 Stopping the reverse motion: enclosed cab version ………………………………………………………….. 48
8.3.10 Changing direction ……………………………………………………………………………………………………. 48
8.3.11 Turn signals: open canopy version ……………………………………………………………………………… 49
8.3.12 Stopping and parking the wheel loader: open canopy version ………………………………………… 49
8.3.13 Stopping the Diesel engine: open canopy version ………………………………………………………… 49
8.3.14 Turn signals: enclosed cab version …………………………………………………………………………….. 50
8.3.15 Stopping and parking the wheel loader: enclosed cab version ……………………………………….. 50
8.3.16 Stopping the Diesel engine: enclosed cab version ………………………………………………………… 50
8.3.17 Leaving the wheel loader: enclosed cab version …………………………………………………………… 50
8.3.18 Parking and securing the wheel loader on slopes …………………………………………………………. 51
8.3.19 Driving on non-public roads ……………………………………………………………………………………….. 51
8.3.20 Establishing the driving position …………………………………………………………………………………. 51
8.3.21 Setting the road mode ………………………………………………………………………………………………. 52
8.3.22 Off-road operation on non-public terrain ………………………………………………………………………. 52
8.3.23 Setting the work mode: open canopy version ……………………………………………………………….. 52
8.3.24 Setting the work mode: enclosed cab version ………………………………………………………………. 53
8.3.25 Inching ……………………………………………………………………………………………………………………. 53
8.3.26 Driving on slopes ……………………………………………………………………………………………………… 53
8.3.27 Parking and securing the vehicle on slopes …………………………………………………………………. 54
8.4 Driving in the dark or in poor visibility conditions…………………………………………………………… 55
8.4.1 Activating the lighting: open canopy version ……………………………………………………………………. 55
8.4.2 Light switch: open canopy version ………………………………………………………………………………….. 55
8.4.3 Brights : open canopy version ……………………………………………………………………………………….. 55
8.4.4 Headlamp flasher: open canopy version …………………………………………………………………………. 55
8.4.5 Horn: open canopy version ……………………………………………………………………………………………. 55
8.4.6 Hazard warning lights: open canopy version ……………………………………………………………………. 56
8.4.7 Work lights: open canopy version …………………………………………………………………………………… 56
8.4.8 Further switches on the dashboard: open canopy version …………………………………………………. 56
8.4.9 Activating the lighting: enclosed cab version ……………………………………………………………………. 57
8.4.10 Light switch: enclosed cab version ……………………………………………………………………………… 57
8.4.11 Brights: enclosed cab version …………………………………………………………………………………….. 57
8.4.12 Headlamp flasher: enclosed cab version ……………………………………………………………………… 57

8.4.13 Horn: enclosed cab version ……………………………………………………………………………………….. 58
8.4.14 Hazard warning lights: enclosed cab version ……………………………………………………………….. 58
8.4.15 Work lights & rotating light (optional equipment – enclosed cab version) …………………………. 58
8.4.16 Electrical socket for work lamp: enclosed cab version …………………………………………………… 58
8.5 Driving in spite of unfavorable weather conditions: enclosed cab version ………………………. 59
8.5.1 Wipers and windshield washer system ……………………………………………………………………………. 59
8.5.2 Front windshield washer system…………………………………………………………………………………….. 59
8.5.3 Rear wiper and windshield washer system ……………………………………………………………………… 59
8.5.4 Cabin heating and ventilation ………………………………………………………………………………………… 60
8.5.5 Heating unit …………………………………………………………………………………………………………………. 60
8.5.6 Drying the windows without the heating ………………………………………………………………………….. 61
8.5.7 Drying the windows with the heating ………………………………………………………………………………. 61
8.5.8 Rear window defroster ………………………………………………………………………………………………….. 61
8.6 Line-of-sight obstruction ……………………………………………………………………………………………….. 62
8.7 Driving on public roads ………………………………………………………………………………………………….. 62
8.7.1 Approved attachments ………………………………………………………………………………………………….. 63
8.7.2 Required checks prior to operating the wheel loader on public roads………………………………….. 63
9 Towing the wheel loader ………………………………………………………………………………. 64
9.1 Safety information referring to the towing process …………………………………………………………. 64
9.2 Measures to be taken prior to towing ……………………………………………………………………………… 64
9.2.1 Securing the wheel loader against rolling ………………………………………………………………………… 64
9.2.3 Lifting or removing the driver´s seat: open canopy version ………………………………………………… 65
9.2.4 Removing the driver`s seat: enclosed cab version ……………………………………………………………. 66
9.2.5 Opening (releasing) the HP valves at the traction pump ……………………………………………………. 66
9.2.6 Installing the driver`s seat for the towing process: open canopy version ……………………………… 67
9.2.7 Installing the driver`s seat for the towing process: enclosed cab version …………………………….. 67
9.2.8 Carrying out the towing process …………………………………………………………………………………….. 67
9.2.9 After towing …………………………………………………………………………………………………………………. 68
9.2.10 Closing the HP valves at the traction pump ………………………………………………………………….. 68
9.2.11 Installing the driver`s seat after the towing process ………………………………………………………. 68
10 Working with the wheel loader ……………………………………………………………………… 69
10.1 Safety information referring to work with the wheel loader ……………………………………………… 69
10.2 Control elements related to working with the wheel loader ……………………………………………… 70
10.2.1 Functions regarding work with the wheel loader …………………………………………………………… 70
10.2.2 Functions of the control levers ……………………………………………………………………………………. 70
10.2.3 Right control lever HQC …………………………………………………………………………………………….. 70
10.3 Connecting attachments ………………………………………………………………………………………………… 71
10.3.1 Using attachments ……………………………………………………………………………………………………. 71
10.3.2 Using the HQC to connect an attachment ……………………………………………………………………. 71
10.3.3 Locking (securing) the attachment………………………………………………………………………………. 72
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10.3.4 Putting down or changing attachments ……………………………………………………………………….. 72
10.4 Working with attachments ……………………………………………………………………………………………… 73
10.4.1 Working and driving with the bucket and load ………………………………………………………………. 73
10.4.2 Transporting material ………………………………………………………………………………………………… 73
10.4.3 Dumping material ……………………………………………………………………………………………………… 74
10.4.4 Transporting material on slopes …………………………………………………………………………………. 74
10.4.5 Working and driving with the pallet forks ……………………………………………………………………… 74
10.4.6 Picking up material with the pallet forks ………………………………………………………………………. 75
10.4.7 Transporting material on the pallet forks ……………………………………………………………………… 75
10.4.8 Unloading material from the pallet forks ………………………………………………………………………. 75
10.5 Working with attachments ……………………………………………………………………………………………… 76
10.5.1 Using the third section ………………………………………………………………………………………………. 76
10.6 Road sweeping ……………………………………………………………………………………………………………… 77
10.7 Emergency lowering in case of a breakdown of the hydraulic system …………………………….. 77
11 Failures and trouble shooting ………………………………………………………………………. 78
11.1 Detecting faults and failures…………………………………………………………………………………………… 78
12 Maintenance instructions ……………………………………………………………………………… 81
12.1 Safety information referring to maintenance work ………………………………………………………….. 81
12.1.1 Safety instructions referring to maintenance work …………………………………………………………. 81
12.1.2 After completing maintenance work ……………………………………………………………………………. 81
12.2 Overview: Maintenance ………………………………………………………………………………………………….. 82
12.2.1 Overview: Engine compartment ………………………………………………………………………………….. 82
12.2.2 Overview: Below the driver`s compartment ………………………………………………………………….. 83
12.2.3 Overview: Loader and front end …………………………………………………………………………………. 83
12.2.4 Overview: Area around the driver´s seat: open canopy version ………………………………………. 84
12.2.5 Overview: Right panel of the driver`s compartment: enclosed cab version ………………………. 84
13 Maintenance instructions for the driver …………………………………………………………. 85
13.1.1 Required maintenance measures ……………………………………………………………………………….. 85
13.1.2 Tools and lubricants for maintenance work ………………………………………………………………….. 85
13.1.3 Required spare parts for maintenance work: Maintenance kits ………………………………………. 85
13.1.4 Table of lubricants ……………………………………………………………………………………………………. 86
13.2 Maintenance certificate A: Daily maintenance work ………………………………………………………… 87
13.2.1 Check / clean before starting the wheel loader …………………………………………………………….. 87
13.2.2 Lubrication ………………………………………………………………………………………………………………. 87
13.2.3 Engine oil level …………………………………………………………………………………………………………. 88
13.2.4 Hydraulic oil level ……………………………………………………………………………………………………… 88
13.2.5 Brakes: open canopy version …………………………………………………………………………………….. 89
13.2.6 Brakes: enclosed cab version …………………………………………………………………………………….. 89
13.2.7 Cooler …………………………………………………………………………………………………………………….. 90

13.2.8 Tire inflation pressure ……………………………………………………………………………………………….. 90
13.2.9 Cleaning the wheel loader after each operation: open canopy version ……………………………. 91
13.2.10 Windshield washer system: enclosed cab version ………………………………………………………… 91
13.2.11 Cleaning the wheel loader after operation: enclosed cab version ……………………………………. 91
13.3 Overview: Further maintenance and service intervals …………………………………………………….. 92
13.3.1 At intervals of 100 operating hours (Maintenance certificate B) ………………………………………. 92
13.3.2 At intervals of 500 operating hours (Maintenance certificate C) ………………………………………. 92
13.3.3 Check list: 1. Inspection after 50 operating hours …………………………………………………………. 92
13.3.4 Summary: Periodical maintenance measures ………………………………………………………………. 92
14 Maintenance instructions for the service staff ……………………………………………….. 93
14.1 Required maintenance measures …………………………………………………………………………………… 93
14.1.1 Tools and lubricants for maintenance work ………………………………………………………………….. 93
14.1.2 Required spare parts for maintenance work: Maintenance kits ………………………………………. 93
14.2 At intervals of 100 operating hours (Maintenance certificate B) ………………………………………. 94
14.2.1 Lubrication ………………………………………………………………………………………………………………. 94
14.2.2 Wheels ……………………………………………………………………………………………………………………. 94
14.2.3 Electrical system ………………………………………………………………………………………………………. 94
14.2.4 Cooler …………………………………………………………………………………………………………………….. 95
14.2.5 Air filter and engine compartment ……………………………………………………………………………….. 95
14.3 At intervals of 500 operating hours (Maintenance certificate C) ………………………………………. 96
14.3.1 Axles ………………………………………………………………………………………………………………………. 96
14.3.2 Electrical system ………………………………………………………………………………………………………. 96
14.3.3 Fuses: Overview ………………………………………………………………………………………………………. 97
14.3.4 Required lamps for the lighting system ……………………………………………………………………….. 97
14.3.5 Summary of required work for maintenance certificate C ………………………………………………. 98
15 Cleaning and preservation ………………………………………………………………………….. 100
15.1 Cleaning the engine ……………………………………………………………………………………………………… 100
15.2 Preservation ………………………………………………………………………………………………………………… 100
15.3 Final shutdown of the wheel loader ………………………………………………………………………………. 101
16 Initial operation ………………………………………………………………………………………….. 102
16.1 Delivery receipt of the wheel loader ……………………………………………………………………………… 102
16.1.1 Checking the operating state of the wheel loader ……………………………………………………….. 102
16.2 Instruction and demonstration at the machine ……………………………………………………………… 103
16.2.1 Vehicle documents and operating manual …………………………………………………………………. 103
16.2.2 Control elements and displays………………………………………………………………………………….. 104
16.2.3 Working with the wheel loader ………………………………………………………………………………….. 104
16.2.4 Driving the wheel loader ………………………………………………………………………………………….. 105
16.2.5 Maintenance ………………………………………………………………………………………………………….. 105
16.3 Check list: 1st inspection after 50 operating hours ………………………………………………………… 106
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16.3.1 Checking the fill levels …………………………………………………………………………………………….. 106
16.3.2 Lubricating the front end and the loader …………………………………………………………………….. 106
16.3.3 Screw connections ………………………………………………………………………………………………….. 106
16.3.4 Checking the axles …………………………………………………………………………………………………. 107
16.3.5 Hydraulic system…………………………………………………………………………………………………….. 107
16.3.6 Diesel engine …………………………………………………………………………………………………………. 107
16.3.7 Checking functions …………………………………………………………………………………………………. 107
17 Verification of inspections ………………………………………………………………………….. 108
17.1 Verification: 1st inspection (50 operating hours) ……………………………………………………………. 108
17.2 Verification: Correct delivery procedure and execution of all lubrication and
maintenance work ………………………………………………………………………………………………………… 109
18 Table of figures ………………………………………………………………………………………….. 110
19 Index …………………………………………………………………………………………………………. 112