Takeuchi TW80 Wheel Loader Operation and Maintenance Manual (8016657)

The TW80 is a mid-size wheel loader that spends its life in mud, gravel, and tight yards, loading trucks, feeding hoppers, and handling pallets. This Operation and Maintenance Manual is what I’d keep on hand to set a solid service rhythm and keep the loader predictable day after day. When, for example, a driver complains the steering feels “loose” after a week in rough ground, I’d use this book to walk through the recommended inspections, verify what needs greasing, and decide what should be adjusted or monitored before it turns into real downtime.

Applications & Use Cases

Plan preventive services so engine, hydraulics, and driveline get attention before wear shows up on the job.
Follow daily and weekly checks to spot leaks, loose hardware, or tire issues before an operator notices a problem.
Trace performance complaints like slow lifting or weak breakout by comparing actual behavior to normal operating checks.
Align operator habits (warm-up, shutdown, travel, loading) with what the machine is designed to handle long-term.
Verify correct service points when training new techs or operators so nothing important gets skipped or over-greased.

FAQ

Q: Can I keep this manual on a tablet in the service truck?

A: Yes, it’s practical to use digitally; you can zoom diagrams, search terms, and keep it with other machine files.

Q: Is it worth printing parts of this manual?

A: Many techs print the routine checklists and lubrication charts to hang in the shop or keep in a service binder.

Safety Note

Always follow the manual’s lockout, support, and shutdown instructions before inspecting, adjusting, or servicing the TW80.

📘 Show Index

Takeuchi TW80 Wheel Loader Index:

III. Table of Contents
I. Assembly groups -overview ………………………………………………………………………………………………………4
II. Outline of the contents of this manual. ……………………………………………………………………………………….4
III. Table of Contents. …………………………………………………………………………………………………………………..5
1 General notes and Safety Instructions. …………………………………………………………. 1-1
1.1 Notes on the safety instructions. …………………………………………………………………………………………….1-1
1.2 Allocation of personnel. …………………………………………………………………………………………………………1-1
1.3 Intended use of the wheel loader. ……………………………………………………………………………………………1-2
1.3.1 Load capacity table. ………………………………………………………………………………………………………..1-2
1.4 Safety Instructions. ………………………………………………………………………………………………………………1-3
1.4.1 General. …………………………………………………………………………………………………………………………1-3
1.4.2 General use of the wheel loader. ………………………………………………………………………………………..1-3
1.4.3 Working with the wheel loader. …………………………………………………………………………………………..1-4
1.4.4 Safety instructions for emergency situations. ……………………………………………………………………….1-6
2 Getting acquainted with the wheel loader. …………………………………………………….. 2-1
2.1 Warning notices and adhesive labels ………………………………………………………………………………………2-2
2.2 Operating and control elements in the cab. ………………………………………………………………………………2-3
2.3 Dashboard. …………………………………………………………………………………………………………………………2-3
3 Starting the wheel loader. …………………………………………………………………………….. 3-1
3.1 Before entering the wheel loader. …………………………………………………………………………………………….3-1
3.2 Leaving and entering the wheel loader. …………………………………………………………………………………….3-1
3.3 Adjusting the driver`s seat. …………………………………………………………………………………………………….3-2
3.3.1 Weight adjustment. ………………………………………………………………………………………………………….3-2
3.3.2 Height adjustment. …………………………………………………………………………………………………………..3-2
3.3.3 Arm rests. ……………………………………………………………………………………………………………………..3-2
3.3.4 Arm rest inclination. …………………………………………………………………………………………………………3-2
3.3.5 Back-rest adjustment……………………………………………………………………………………………………….3-3
3.3.6 Longitudinal adjustment. …………………………………………………………………………………………………..3-3
3.3.7 Safety belt. …………………………………………………………………………………………………………………….3-3
3.4 Steering column adjustment. ………………………………………………………………………………………………….3-4
3.5 Rack. …………………………………………………………………………………………………………………………………3-4
3.6 Indoor lighting. …………………………………………………………………………………………………………………….3-4
3.7 Exterior rear view mirrors. ………………………………………………………………………………………………………3-4
3.8 Dashboard. …………………………………………………………………………………………………………………………3-5
3.9 Starting the engine. ………………………………………………………………………………………………………………3-6
3.9.1 Before starting. ……………………………………………………………………………………………………………….3-6
3.9.2 Starting the engine. ………………………………………………………………………………………………………….3-6
3.10 Driving ………………………………………………………………………………………………………………………………..3-7
3.10.1 Driving forward…………………………………………………………………………………………………………………3-7
3.10.2 Driving backward ……………………………………………………………………………………………………………..3-7
3.10.3 Changing direction. ………………………………………………………………………………………………………….3-8
3.10.4 Shifting gears ………………………………………………………………………………………………………………….3-8
3.10.4.1 Differential lock. ………………………………………………………………………………………………………………3-8
3.10.5 Safety instructions related to driving. …………………………………………………………………………………..3-9
3.10.6 Inching. ………………………………………………………………………………………………………………………….3-9
3.10.7 Braking. …………………………………………………………………………………………………………………………3-9
3.10.8 Stopping. ……………………………………………………………………………………………………………………….3-9
3.10.9 Parking. ………………………………………………………………………………………………………………………. 3-10
3.10.10 Driving at night. …………………………………………………………………………………………………………….. 3-10
3.10.11 Driving in the rain or with dirty window panes. ……………………………………………………………………. 3-11
3.10.12 Damp window panes. …………………………………………………………………………………………………….. 3-11
3.10.13 Cab heating. ………………………………………………………………………………………………………………… 3-11
Operating Manual TW 80
6
TABLE OF CONTENTS
3.10.14 Driving on public roads. ………………………………………………………………………………………………….. 3-12
3.10.15 Line-of-sight obstruction. ………………………………………………………………………………………………… 3-13
3.10.16 Cross-countryy driving
4. Working with the wheel loader. …………………………………………………………………….. 4-1
4.1 Safety instructions concerning work with the vehicle ………………………………………………………………….4-1
4.2 Connecting attachments ……………………………………………………………………………………………………….4-3
4.2.1 Using the Quick Disconnect Coupler. ………………………………………………………………………………….4-3
4.2.2 Switching the attachment hydraulics . ……………………………………………………………………………….. 4-4
4.2.3 Retracting the QDC bolts . ………………………………………………………………………………………………..4-4
4.3 Working with the bucket ……………………………………………………………………………………………………….4-5
4.3.1 Picking up material. …………………………………………………………………………………………………………4-5
4.3.2 Driving with load. ……………………………………………………………………………………………………………..4-6
4.3.3 Dumping material. ……………………………………………………………………………………………………………4-6
4.3.4 Emergency lowering. ……………………………………………………………………………………………………….4-7
4.4 Working with the pallet forks. …………………………………………………………………………………………………4-7
4.5 Road sweeping. …………………………………………………………………………………………………………………..4-8
4.6 Transportation. …………………………………………………………………………………………………………………….4-9
4.6.1 Check list for transporting the wheel loader ………………………………………………………………………….4-9
4.7 Towing. ……………………………………………………………………………………………………………………………. 4-10
4.7.1 Safety instructions towing. ……………………………………………………………………………………………… 4-10
4.7.2 Towing preparations. ……………………………………………………………………………………………………… 4-11
4.7.3 After towing. …………………………………………………………………………………………………………………. 4-12
5 Maintenance of the wheel loader. …………………………………………………………………. 5-1
5.1 Technical inspections. …………………………………………………………………………………………………………..5-1
5.2 Checklist: Maintenance plan. …………………………………………………………………………………………………5-1
5.2.1 Service intervals. ……………………………………………………………………………………………………………..5-2
5.2.2 Consumables. ………………………………………………………………………………………………………………… 5-2
5.2.3 Maintenance overview. ………………………………………………………………………………………………………5-2
5.2.4 Table of maintenance intervals. ………………………………………………………………………………………….5-3
5.3 Lubrication plan ……………………………………………………………………………………………………………………5-4
5.3.1 Notes. ……………………………………………………………………………………………………………………………5-4
5.3.2 Hoisting gear. ………………………………………………………………………………………………………………….5-4
5.3.3 Articulated pendulum joint. ………………………………………………………………………………………………..5-5
5.3.4 Steering cylinder. …………………………………………………………………………………………………………….5-5
5.4 Engine. ………………………………………………………………………………………………………………………………5-6
5.4.1 Overview. ………………………………………………………………………………………………………………………..5-6
5.4.2 Checking the engine oil level. …………………………………………………………………………………………….5-7
5.4.3 Changing the engine oil. ……………………………………………………………………………………………………5-7
5.4.4 Changing the engine oil filter. …………………………………………………………………………………………….5-8
5.4.5 Changing the fuel filter. ……………………………………………………………………………………………………..5-8
5.4.6 Changing the fuel strainer of the fuel pump …………………………………………………………………………..5-9
5.4.7 Checking the V-belt. ………………………………………………………………………………………………………..5-9
5.4.8 Cleaning the air filter. …………………………………………………………………………………………………….. 5-10
5.4.9 Cleaning the radiator. …………………………………………………………………………………………………….. 5-11
5.5 Fuel system……………………………………………………………………………………………………………………… 5-11
5.5.1 Cleaning the fuel tank. …………………………………………………………………………………………………… 5-11
5.6 Electrical installation. …………………………………………………………………………………………………………. 5-12
5.6.1 Notes. …………………………………………………………………………………………………………………………. 5-12
5.6.2 Battery. ……………………………………………………………………………………………………………………….. 5-12
5.6.3 Replacing fuses. …………………………………………………………………………………………………………… 5-13
5.6.4 Table – Fuse assignment ………………………………………………………………………………………………… 5-13
5.7 Hydraulic system. ……………………………………………………………………………………………………………… 5-14
5.7.1 Overview. ……………………………………………………………………………………………………………………… 5-14
5.7.2 Notes. …………………………………………………………………………………………………………………………. 5-14
5.7.3 Checking the hydraulic oil level ……………………………………………………………………………………….. 5-15

5.7.5 Draining water/oil (if organic oil is used). …………………………………………………………………………… 5-15
5.7.6 Changing the hydraulic oil filter ……………………………………………………………………………………….. 5-16
5.7.7 Cleaning the hydraulic oil cooler. ……………………………………………………………………………………… 5-18
5.7.8 Changing the hydrostatic filter. ………………………………………………………………………………………… 5-19
5.8 Brake system. ………………………………………………………………………………………………………………….. 5-19
5.8.1 Checking the brake fluid…………………………………………………………………………………………………. 5-19
5.9 Chassis. ………………………………………………………………………………………………………………………….. 5-20
5.9.1 Checking the axle oil level (front and rear axle)…………………………………………………………………… 5-21
5.9.2 Changing the axle oil (front and rear axle). ………………………………………………………………………… 5-21
5.9.3 Changing the axle oil (wheel hub). ……………………………………………………………………………………. 5-22
5.10 Windscreen washer system ………………………………………………………………………………………………… 5-22
5.10.1 Cleaning agent. …………………………………………………………………………………………………………….. 5-22
5.11 Cleaning and preservation. ………………………………………………………………………………………………….. 5-23
5.11.1 Cleaning the engine. ……………………………………………………………………………………………………… 5-23
5.11.2 Preservation. ………………………………………………………………………………………………………………… 5-23
6 Faults. ………………………………………………………………………………………………………… 6-1
6.1 Table of fault messages. ……………………………………………………………………………………………………….6-1
7 Technical data. ……………………………………………………………………………………………. 7-1
7.1 Table of general technical data. ………………………………………………………………………………………………7-1
7.2 Table of dimensions. …………………………………………………………………………………………………………….7-2
7.3 Consumables. ……………………………………………………………………………………………………………………..7-3
7.3.1 Table of lubricants and oils. ……………………………………………………………………………………………….7-3
7.3.2 Fuel. ……………………………………………………………………………………………………………………………..7-4
7.3.3 Table of filling quantities. …………………………………………………………………………………………………..7-4
7.4 Tire pressures. …………………………………………………………………………………………………………………….7-5
7.5 Miscellaneous. …………………………………………………………………………………………………………………….7-5
7.5.1 Noise level. …………………………………………………………………………………………………………………….7-5
7.5.2 Vibrations of earth-moving machinery. …………………………………………………………………………………7-5
7.5.3 Space for a fire extinguisher. ……………………………………………………………………………………………..7-5
8 Service. ………………………………………………………………………………………………………. 8-1
8.1 Certificate of delivery. ……………………………………………………………………………………………………………8-1
8.1.1 Checklist to be completed upon delivery of the wheel loader in conjunction with a demonstration. ..8-1
8.1.2 Checklist 1st inspection (50 operating hours). ………………………………………………………………………8-2
8.1.3 Checklist Maintenance Certificate A. …………………………………………………………………………………..8-4
8.1.4 Checklist Maintenance Certificate B. ………………………………………………………………………………….8-4
8.1.5 Checklist Maintenance Certificate C. ………………………………………………………………………………….8-5
8.1.6 Summary of periodical maintenance measures …………………………………………………………………….8-7
Appendix C: Proof of Inspections. ……………………………………………………………………………. C-1
C.1 Proof of lubrication and maintenance work. …………………………………………………………………………….. C-1