Takeuchi TW40 Wheel Loader Index:

Table of contents
1 User instructions for this service manual ……………………………………………… 12
1.1 Using this manual …………………………………………………………………………………………………… 12
1.1.1 Further notes on this service manual …………………………………………………………………….. 12
1.1.2 Safety alert symbols in this service manual ……………………………………………………………. 13
1.1.3 Symbols to identify different wheel loader types and features …………………………………… 13
1.2 Overview: Assembly groups & chapters …………………………………………………………………….. 14
1.3 Technical description of the wheel loader ………………………………………………………………….. 15
1.4 Safety information for repair and maintenance work ……………………………………………………. 17
1.4.1 General safety information and references to further publications ……………………………… 17
1.4.2 Creating a safe work environment …………………………………………………………………………. 17
1.4.3 Personal protective equipment ……………………………………………………………………………… 21
1.5 International Measuring Units …………………………………………………………………………………… 22
1.6 Tightening torques ………………………………………………………………………………………………….. 22
1.6.1 Hose couplings …………………………………………………………………………………………………… 22
1.6.2 Metric set screws with standard thread ………………………………………………………………….. 23
1.6.3 Metric set screws with fine thread …………………………………………………………………………. 23
1.6.4 Serrated flange bolts with cylindrical head and hexagon socket ………………………………… 24
1.6.5 Serrated flange bolts and nuts with cylindrical hexagon head …………………………………… 24
1.6.6 Self-locking screws and nuts with serrated bearing surface and hexagon head ………….. 24
1.6.7 Installation of hydraulic hoses ………………………………………………………………………………. 25
2 Front and rear end ……………………………………………………………………………….. 27
2.1 General information ………………………………………………………………………………………………… 27
2.1.1 Assembly groups ………………………………………………………………………………………………… 27
2.2 Repair work at the front end …………………………………………………………………………………….. 27
2.2.1 Checking the articulated pendulum joint ………………………………………………………………… 28
2.2.2 Faults in the articulated pendulum joint ………………………………………………………………….. 28
2.2.3 Checking the installation dimensions …………………………………………………………………….. 29
2.3 Separating the front end from the rear end ………………………………………………………………… 30
2.3.1 Securing the wheel loader ……………………………………………………………………………………. 30
2.3.2 Gaining access to the control block ……………………………………………………………………….. 31
2.3.3 Severing the hydraulic connections of the front end ………………………………………………… 31
2.3.4 Severing the hydraulic connections of the steering cylinder and the front axle ……………. 32
2.3.5 Dismantling the steering cylinder from the articulated pendulum joint ………………………… 32
2.3.6 Dismantling the fuel lines ……………………………………………………………………………………… 33
2.3.7 Severing electrical connections …………………………………………………………………………….. 33
2.3.8 Remove the drive shaft from the front axle …………………………………………………………….. 34
2.3.9 Putting aside the hydraulic hoses and cables …………………………………………………………. 34

2.3.10 Separating the front end from the rear end …………………………………………………………. 34
2.3.11 Determining the cutoff point ………………………………………………………………………………. 35
2.4 Checking and dismantling the pivoting joint, and replacing components ………………………… 35
2.4.1 Dismantling the pendulum bearing ………………………………………………………………………… 35
2.4.2 Pulling the front end from the rear end …………………………………………………………………… 36
2.4.3 Replacing the components of the spherical bearing ………………………………………………… 36
2.4.4 Glueing in metal bushes ………………………………………………………………………………………. 37
2.5 Installing the pivoting joint ……………………………………………………………………………………….. 38
2.6 Checking the articulated joint, dismantling it and replacing components ………………………… 39
2.6.1 Pulling the front end from the rear end …………………………………………………………………… 39
2.6.2 Dismantling the articulation bolts …………………………………………………………………………… 39
2.6.3 Separating the front and the rear end ……………………………………………………………………. 40
2.6.4 Dismantling the components of the articulation joint ………………………………………………… 40
2.6.5 Installing the components of the articulation joint …………………………………………………….. 40
2.7 Installing the articulation joint …………………………………………………………………………………… 41
2.7.1 Completing the front end ……………………………………………………………………………………… 41
2.7.2 Establishing the hydraulic connections ………………………………………………………………….. 42
2.7.3 Installing the hydraulic connections of the steering cylinder and the front axle ……………. 42
2.7.4 Installing the steering cylinder at the articulated pendulum joint ………………………………… 43
2.7.5 Connecting the fuel lines ……………………………………………………………………………………… 43
2.7.6 Establishing the electrical connections again ………………………………………………………….. 43
2.7.7 Attaching hydraulic hoses and cables ……………………………………………………………………. 44
2.7.8 Installing the drive shaft ……………………………………………………………………………………….. 44
2.7.9 Venting the work and steering hydraulics……………………………………………………………….. 44
2.8 Repair work: Rear end …………………………………………………………………………………………….. 45
2.8.1 Dismantling the engine hood ………………………………………………………………………………… 45
2.9 Preservation measures……………………………………………………………………………………………. 46
3 Loader …………………………………………………………………………………………………. 47
3.1 General information ………………………………………………………………………………………………… 47
3.1.1 Assembly groups ………………………………………………………………………………………………… 47
3.2 Trouble-shooting: Loader ………………………………………………………………………………………… 48
3.3 Maintenance work: Loader ………………………………………………………………………………………. 48
3.3.1 Lubricating the loader ………………………………………………………………………………………….. 48
3.3.2 Overview: Greasing points of the loader ………………………………………………………………… 49
3.3.3 Lubrication: ………………………………………………………………………………………………………… 49
3.4 Repair work: Loader and hydraulic system of the loader ……………………………………………… 50
3.4.1 Preparing the loader ……………………………………………………………………………………………. 50
3.4.2 Dismantling the loader …………………………………………………………………………………………. 50
3.4.3 Removing the hydraulic connections from the front end …………………………………………… 50
3.4.4 Dismantling the loader with attached hydraulic cylinder……………………………………………. 51
User instructions for this service manual
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3.5 Replacing components of the loader …………………………………………………………………………. 53
3.5.1 Checking the bearing bushes of the loader …………………………………………………………….. 53
3.5.2 Replacing the hydraulic cylinders of the loader ……………………………………………………….. 54
3.6 Reassembling the loader …………………………………………………………………………………………. 55
3.6.1 Assembling the loader with installed hydraulic cylinders ………………………………………….. 55
3.6.2 Re-establishing hydraulic and electrical connections ……………………………………………….. 56
4 Hydraulic system …………………………………………………………………………………. 57
4.1 General information ………………………………………………………………………………………………… 57
4.1.1 Assembly groups ………………………………………………………………………………………………… 57
4.2 Trouble-shooting: Hydraulic system ………………………………………………………………………….. 58
4.3 Adjusting instructions: Hydraulic system ……………………………………………………………………. 61
4.3.1 Basic information ………………………………………………………………………………………………… 61
4.3.2 Checks prior to making any adjustments ……………………………………………………………….. 61
4.3.3 Operating conditions for correct test results ……………………………………………………………. 62
4.3.4 Measuring instruments ………………………………………………………………………………………… 63
4.3.5 Accessing the pump and the measuring points ……………………………………………………….. 63
4.3.6 Safety information for measurements, tests, and adjustments ………………………………….. 63
4.4 Adjusting instructions ………………………………………………………………………………………………. 64
4.4.1 Table of default values ………………………………………………………………………………………… 64
4.4.2 Overview: Measuring connections …………………………………………………………………………. 64
4.4.3 Step 1: Min. diesel engine idle speed …………………………………………………………………….. 65
4.4.4 Step 2: Min. charge pressure ……………………………………………………………………………….. 66
4.4.5 Step 3. Max. diesel engine idle speed ……………………………………………………………………. 67
4.4.6 Step 4: Max. charge pressure ………………………………………………………………………………. 68
4.4.7 Step 5: Starting speed …………………………………………………………………………………………. 69
4.4.8 Step 6: Maximum driving pressure ………………………………………………………………………… 70
4.4.9 Step 7: Work hydraulics: First measuring cycle without work motions ………………………… 71
4.4.10 Step 8: Work hydraulics: Second measuring cycle with work motions ……………………. 72
4.4.11 Step 9: Diesel engine speed ……………………………………………………………………………… 74
4.4.12 Step 10: Steering hydraulics……………………………………………………………………………… 74
4.4.13 Step 11: Maximum wheel loader speed ……………………………………………………………… 75
4.5 Checking further hydraulic components …………………………………………………………………….. 76
4.5.1 Adjustment procedure: Sealing the pump aggregate ……………………………………………….. 76
4.6 Rexroth A4VG: Measuring points / gauge ports ………………………………………………………….. 77
4.7 Hydraulic circuit diagram …………………………………………………………………………………………. 78
4.7.1 Captions referring to the hydraulic circuit diagram …………………………………………………… 78
4.7.2 Hydraulic circuit diagram ……………………………………………………………………………………… 79
4.8 Repair work: Pump aggregate ………………………………………………………………………………….. 80
4.9 Repair work: Travel pump ……………………………………………………………………………………….. 80
4.9.1 Replacing the feeding pressure valve ……………………………………………………………………. 80

4.9.2 Settings and installation of the feeding pressure valve …………………………………………….. 81
4.9.3 Checking the high-pressure valves ……………………………………………………………………….. 81
4.9.4 Swapping the high pressure valves ……………………………………………………………………….. 81
4.9.5 Replacing the high pressure valves ……………………………………………………………………….. 82
4.9.6 Checking the solenoid valves “Direction of motion” …………………………………………………. 82
4.9.7 Checking the electrical switching function of the solenoid valves ………………………………. 83
4.9.8 Replacing the valve block (direction of motion) ……………………………………………………….. 84
4.9.9 Checking and replacing the temperature transmitter ……………………………………………….. 84
4.10 Repair work: Working pump …………………………………………………………………………………….. 85
4.10.1 Priority valve of the work / steering hydraulics …………………………………………………….. 85
4.10.2 Checking the working pump ……………………………………………………………………………… 86
4.11 Repair work: Feed pump …………………………………………………………………………………………. 88
4.12 Repair work: pump aggregate and travel pump ………………………………………………………….. 90
4.13 Replacing the coupling between the engine and the pump aggregate …………………………… 94
4.13.1 Checking the coupling ……………………………………………………………………………………… 94
4.13.2 Replacing the coupling …………………………………………………………………………………….. 94
4.14 Repair work: Traction motor …………………………………………………………………………………….. 95
4.14.1 Checking the traction motor in the travel hydraulics ……………………………………………… 95
4.14.2 Checking the solenoid valve for the 1st/2nd gear …………………………………………………… 95
4.14.3 Replacing the switching magnet ………………………………………………………………………… 96
4.14.4 Checking the traction motor ………………………………………………………………………………. 96
4.14.5 Dismantling the traction motor …………………………………………………………………………… 96
4.14.6 Dismantling the hydraulic components of the traction motor …………………………………. 97
4.14.7 Removing the traction motor from the rear axle …………………………………………………… 98
4.14.8 Checking the shaft seal of the traction motor ………………………………………………………. 98
4.14.9 Installing the traction motor ………………………………………………………………………………. 99
4.14.10 Establishing the hydraulic connections……………………………………………………………….. 99
4.14.11 Venting the hydraulic system …………………………………………………………………………… 100
4.14.12 Installing the drive shaft ………………………………………………………………………………….. 100
4.15 Repair work: Control block of the work hydraulics …………………………………………………….. 101
4.15.1 Preparing the repair work ……………………………………………………………………………….. 101
4.15.2 Checking the primary valve …………………………………………………………………………….. 101
4.15.3 Replacing the secondary valves ………………………………………………………………………. 102
4.15.4 Checking the slide valves ……………………………………………………………………………….. 102
4.15.5 Checking the control block ……………………………………………………………………………… 103
4.15.6 Dismantling the control block of the hydraulic system …………………………………………. 103
4.15.7 Dismantling the joystick ………………………………………………………………………………….. 104
4.15.8 Dismantling the control block …………………………………………………………………………… 104
4.15.9 Preparing a new control block …………………………………………………………………………. 104
4.15.10 Installing the control block ………………………………………………………………………………. 105
4.15.11 Installing the joystick ………………………………………………………………………………………. 105
User instructions for this service manual
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4.15.12 Establishing the hydraulic connections of the control block …………………………………. 105
4.15.13 Venting the work hydraulics …………………………………………………………………………….. 106
4.15.14 Checking the gaskets of the control plate …………………………………………………………. 106
4.15.15 Checking the impermeability of the control plate ………………………………………………… 107
4.15.16 Replacing the gaskets of the control plate ………………………………………………………… 108
4.15.17 Installing the control plate ……………………………………………………………………………….. 108
4.16 Repair work: Hydraulic cylinders …………………………………………………………………………….. 109
4.16.1 Preparing the repair work ……………………………………………………………………………….. 109
4.16.2 Checking the hydraulic cylinders ……………………………………………………………………… 110
4.16.3 Checking the steering cylinder ………………………………………………………………………… 110
4.16.4 Removing the hydraulic connections from the steering cylinder …………………………… 110
4.16.5 Dismantling the steering cylinder ……………………………………………………………………… 111
4.16.6 Replacing the gasket set of the steering cylinder ……………………………………………….. 111
4.16.7 Installing the components of the steering cylinder ……………………………………………… 112
4.16.8 Replacing the joint bearing of the steering cylinder …………………………………………….. 112
4.16.9 Installing the steering cylinder …………………………………………………………………………. 112
4.16.10 Venting the steering hydraulics ……………………………………………………………………….. 113
4.16.11 Checks and dismantling preparations for the lifting and work cylinders …………………. 113
4.16.12 Dismantling the work cylinder ………………………………………………………………………….. 114
4.16.13 Removing the lifting cylinder ……………………………………………………………………………. 114
4.16.14 Replacing the gasket set of the lifting and work cylinders ……………………………………. 115
4.16.15 Installing the components of the hydraulic cylinders …………………………………………… 115
4.16.16 Replacing the joint bearings of the hydraulic cylinders ……………………………………….. 115
4.16.17 Installing the hydraulic cylinders ………………………………………………………………………. 116
4.16.18 Venting the work hydraulics …………………………………………………………………………….. 116
4.16.19 Checking the HQC hydraulics …………………………………………………………………………. 116
4.16.20 Separating the HQC from the loader ………………………………………………………………… 117
4.16.21 Installing the HQC hydraulics ………………………………………………………………………….. 117
4.16.22 Venting the HQC hydraulics ……………………………………………………………………………. 118
4.17 Repair work: Steering hydraulics …………………………………………………………………………….. 119
4.17.1 Checking the steering hydraulics ……………………………………………………………………… 119
4.17.2 Checking the prioritiy valve at the work and steering hydraulics …………………………… 120
4.17.3 Checking the steering cylinder ………………………………………………………………………… 120
4.17.4 Checking the steering unit ………………………………………………………………………………. 121
4.17.5 Checking the primary valve in the steering unit ………………………………………………….. 121
4.17.6 Dismantling the steering unit …………………………………………………………………………… 121
4.17.7 Replacing and installing the steering unit ………………………………………………………….. 122
4.17.8 Venting the steering hydraulics ……………………………………………………………………….. 122
4.18 Repair work: Hydraulic components ………………………………………………………………………… 123
4.18.1 Testing the function of the inching valve …………………………………………………………… 123

4.18.2 Checking and adjusting the function of the inching pedal and the transfer
to the inching valve ……………………………………………………………………………………….. 123
4.18.3 Dismantling the inching valve ………………………………………………………………………….. 124
4.18.4 Installing the inching valve ………………………………………………………………………………. 125
4.18.5 Cleaning the hydraulic oil cooler ………………………………………………………………………. 126
4.18.6 Replacing the combined cooler ……………………………………………………………………….. 127
4.18.7 Installing a new combined cooler …………………………………………………………………….. 128
4.19 Checking the hydraulic system ……………………………………………………………………………….. 129
4.19.1 Checking the hydraulic oil level and adding hydraulic oil …………………………………….. 129
4.19.2 Checking and replacing the hydraulic oil filter ……………………………………………………. 130
4.19.3 Replacing the hydrostatic filter ………………………………………………………………………… 131
4.19.4 Draining hydraulic oil ……………………………………………………………………………………… 131
4.20 Venting the hydraulic system ………………………………………………………………………………….. 132
4.20.1 Venting the hydraulic system after repair work ………………………………………………….. 132
4.20.2 Venting the travel hydraulics after repair work …………………………………………………… 132
4.20.3 Changing the oil type in the hydraulic system – Basic information ……………………….. 133
4.20.4 Changing the oil type in the hydraulic system ……………………………………………………. 134
5 Electrical system ……………………………………………………………………………….. 135
5.1 General information and technical specifications ………………………………………………………. 135
5.1.1 Main components ……………………………………………………………………………………………… 135
5.1.2 Technical specifications……………………………………………………………………………………… 135
5.1.3 Overview electrical system: Enclosed cab ……………………………………………………………. 136
5.1.4 Captions overview electrical system: Enclosed cab ……………………………………………….. 137
5.1.5 Overview electrical system: Open canopy version …………………………………………………. 138
5.1.6 Captions overview electrical system: Open canopy version ……………………………………. 139
5.1.7 Required lamps for the lighting system ………………………………………………………………… 139
5.1.8 Overview electrical system operator`s station: Enclosed cab ………………………………….. 140
5.1.9 Captions overview electrical system operator`s station: Enclosed cab ……………………… 140
5.1.10 Overview electrical system operator`s station: Open canopy version ……………………. 141
5.1.11 Captions overview electrical system operator`s station: Open canopy version ………. 141
5.1.12 Fuses …………………………………………………………………………………………………………… 142
5.2 Circuit diagrams ……………………………………………………………………………………………………. 143
5.3 Captions for the circuit diagrams …………………………………………………………………………….. 155
5.3.1 Relays ……………………………………………………………………………………………………………… 155
5.3.2 Overview: Right panel of the driver`s compartment: enclosed cab version ……………….. 155
5.3.3 Overview: Area around the driver´s seat: open canopy version ………………………………. 155
5.3.4 Switches ………………………………………………………………………………………………………….. 157
5.3.5 Solenoid valves …………………………………………………………………………………………………. 157
5.3.6 Sensors……………………………………………………………………………………………………………. 157
5.3.7 Voltage supply ………………………………………………………………………………………………….. 157
User instructions for this service manual
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5.3.8 Engines / motors ……………………………………………………………………………………………….. 157
5.3.9 Lighting and other appliances ……………………………………………………………………………… 158
5.3.10 Components …………………………………………………………………………………………………. 158
5.4 Trouble-shooting: Electrical system …………………………………………………………………………. 159
5.5 Maintenance ………………………………………………………………………………………………………… 160
5.5.1 Maintenance work related to the battery ………………………………………………………………. 160
5.5.2 Maintenance work related to the lighting system …………………………………………………… 160
5.5.3 Maintenance work related to the electrical system …………………………………………………. 160
5.6 Adjusting instructions …………………………………………………………………………………………….. 161
5.6.1 Headlights ………………………………………………………………………………………………………… 161
5.6.2 Repair work ………………………………………………………………………………………………………. 161
5.6.3 Electrical system – Points of installation: Enclosed cab ………………………………………….. 162
5.6.4 Electrical system – Points of installation: Open canopy version ………………………………. 163
5.6.5 Display and steering column: Enclosed cab ………………………………………………………….. 163
5.6.6 Preheating relay and fuse: Enclosed cab ……………………………………………………………… 163
5.6.7 Display and steering column: Open canopy version ………………………………………………. 164
5.6.8 Preheating relay and fuse: Open canopy version ………………………………………………….. 164
5.6.9 Plug connection rear wiper motor ………………………………………………………………………… 164
5.6.10 Brake light switch …………………………………………………………………………………………… 165
5.6.11 Joystick functions …………………………………………………………………………………………… 165
5.6.12 Further control elements …………………………………………………………………………………. 165
5.6.13 Electrical power generation …………………………………………………………………………….. 166
5.6.14 Electrical appliances ………………………………………………………………………………………. 166
5.6.15 Repair work: Lighting system ………………………………………………………………………….. 166
5.6.16 Replacing fuses on the printed circuit board ……………………………………………………… 167
5.6.17 Replacing relays on the printed circuit board …………………………………………………….. 167
5.6.18 Replacing relays in the engine compartment: Enclosed cab ……………………………….. 168
5.6.19 Replacing switches: Enclosed cab …………………………………………………………………… 168
5.6.20 Replacing relays in the engine compartment: Open canopy version …………………….. 168
5.6.21 Replacing switches: Open canopy version ………………………………………………………… 168
5.6.22 Replacing the display and the steering column: Enclosed cab …………………………….. 169
5.6.23 Replacing the display and the steering column: Open canopy version ………………….. 170
5.6.24 Replacing the printed circuit board: Enclosed cab ……………………………………………… 171
5.6.25 Replacing the printed circuit board: Open canopy version …………………………………… 172
6 Axles and brakes ……………………………………………………………………………….. 174
6.1 General information ………………………………………………………………………………………………. 174
6.1.1 Assembly groups ………………………………………………………………………………………………. 174
6.1.2 Technical specifications……………………………………………………………………………………… 174
6.2 Trouble-shooting …………………………………………………………………………………………………… 175
6.3 Maintenance work: Axles ……………………………………………………………………………………….. 176

6.3.1 Lubricants and fill levels …………………………………………………………………………………….. 176
6.3.2 Checking the oil level in the axles ……………………………………………………………………….. 176
6.3.3 Checking the oil level in the axles ……………………………………………………………………….. 177
6.3.4 Oil change in the axles ………………………………………………………………………………………. 178
6.3.5 Checking the oil level and oil change in the wheel hubs …………………………………………. 179
6.3.6 Checking the brake fluid level ……………………………………………………………………………… 179
6.3.7 Changing brake fluid ………………………………………………………………………………………….. 180
6.3.8 Venting the brake system …………………………………………………………………………………… 180
6.4 Repair work ………………………………………………………………………………………………………….. 181
6.4.1 Dismantling the drive shaft …………………………………………………………………………………. 181
6.4.2 Replacing the front axle ……………………………………………………………………………………… 182
6.4.3 Replacing the rear axle ………………………………………………………………………………………. 183
6.4.4 Repair work: Drum brake ……………………………………………………………………………………. 184
6.4.5 Disassembling the hydraulic drum brake ……………………………………………………………… 185
6.4.6 Assembling the hydraulic drum brake ………………………………………………………………….. 189
6.4.7 Replacing the hand brake cable ………………………………………………………………………….. 194
6.4.8 Dismantling the flanged reduction gear ………………………………………………………………… 195
6.4.9 Replacing the flanged reduction gear …………………………………………………………………… 197
7 Cab ……………………………………………………………………………………………………. 198
7.1 Assembly groups ………………………………………………………………………………………………….. 198
7.2 Trouble-shooting …………………………………………………………………………………………………… 199
7.3 Maintenance work ………………………………………………………………………………………………… 200
7.3.1 Cleaning the wheel loader ………………………………………………………………………………….. 200
7.4 Adjusting instructions …………………………………………………………………………………………….. 202
7.4.1 Adjusting the door lock ………………………………………………………………………………………. 202
7.4.2 Adjusting the locking bolt of the door …………………………………………………………………… 202
7.5 Repair work ………………………………………………………………………………………………………….. 203
7.5.1 Dismantling and installing the steering column paneling ………………………………………… 203
7.5.2 Replacing the door ……………………………………………………………………………………………. 204
7.5.3 Replacing window panes ……………………………………………………………………………………. 205
7.5.4 Adjusting the driver`s seat: open canopy version …………………………………………………… 207
7.5.5 Lifting the driver`s seat: open canopy version …………………………………………………… 207
7.5.6 Removing the driver`s seat: open canopy version …………………………………………………. 208
7.5.7 Installing the driver`s seat: open canopy version …………………………………………………… 208
7.5.8 Removing the driver`s seat: enclosed cab version …………………………………………………. 209
7.5.9 Installing the driver`s seat: enclosed cab version …………………………………………………… 209
7.5.10 Replacing a wiper motor …………………………………………………………………………………. 210
7.5.11 Repair work: Heating / Ventilation ……………………………………………………………………. 212
7.5.12 Replacing the heating unit ………………………………………………………………………………. 214
7.5.13 Replacing pedals: Open canopy version …………………………………………………………… 215
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7.5.14 Replacing pedals: Enclosed cab ……………………………………………………………………… 215
7.5.15 Removing the gas pedal …………………………………………………………………………………. 216
7.5.16 Replacing the inching pedal ……………………………………………………………………………. 216
7.5.17 Removing the gas pedal …………………………………………………………………………………. 217
7.5.18 Replacing the inching pedal ……………………………………………………………………………. 217
7.5.19 Access to the traction motor: open canopy ……………………………………………………….. 218
7.5.20 Access to the printed circuit board and the service valve: enclosed cab ……………….. 218