Takeuchi TL8 Operator'S Manual Download Page 231

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6-21

TROUBLESHOOTING

EXHAUST GAS CONTROL SYSTEM ERROR

ERROR CODE LIST

If the exhaust gas control system detects an error, the ECM error warning lamp turns on or

flashes and the following error codes are displayed.

If an error code appears, immediately repair the fault part detected, or consult your sales or

service dealer for help.

Error code

Error description

DTC

NCD

PCD

Error*

Limited

engine

(Inducement)

SPN

FMI

Fault location

Cause

3936

DPF system

Removal of the DPF system

P1A28

DPF system

Loss of function of the DPF

system

P3015

3251

DPF system

Failures of the PCD system

P2455

523578

EGR system

Removal of the EGR system

U0076

√

132

MAF system

Removal of the MAF sensor

P0102

√

N: NCD (NOx Control Diagnostic system)

P: PCD (Particulate Control Diagnostic system)

Summary of Contents for TL8

Page 1: ......

Page 2: ...ration inspection and maintenance of this machine can cause injury or death Read and understand this manual before performing any operation inspection or maintenance on this machine Always store this...

Page 3: ...es a hazard with a low level of risk which if not avoided could result in minor moderate injury IMPORTANT The word IMPORTANT is used to alert operators and maintenance personnel about situations which...

Page 4: ...from those provided in the machine you are using Please note that the information and specifications in this manual are subject to change without prior notice INTRODUCTION MANUAL STORAGE COMPARTMENT A...

Page 5: ...ERIAL NUMBERS IMPORTANT Do not remove the machine name plate with the serial number Check the serial numbers of the machine and engine and write them down in the spaces below Machine number Engine num...

Page 6: ...w engine noise and exhaust emissions Electronic control of auxiliary hydraulic circuit BREAK IN PERIOD When the machine is new operate the machine for the first 100 hours as indicated on the hour mete...

Page 7: ...0 5...

Page 8: ...s manual may not be applicable to your machine The numbers used in the illustration are with circles around them The same numbers appear between the parentheses in the text Example 1 Symbols used in t...

Page 9: ...select switch 2 30 Auxiliary 1st flow rate select switch 2 32 Parking brake switch TL12 optional 2 32 Ride control switch TL10 TL12 optional 2 33 Aux 2nd 14 pin connector select switch TL10 TL12 opti...

Page 10: ...5 18 Inspecting and replenishing the engine oil 5 19 Inspecting the water separator 5 20 Inspecting the fuel level 5 20 Inspecting the hydraulic oil tank level and replenishing 5 21 Lubricating the wo...

Page 11: ...oubleshooting 6 1 Symptoms that are not malfunctions 6 2 If the engine overheats 6 3 If the battery goes dead 6 4 If a fuse blows 6 6 Inspecting and replacing the fuse 6 6 Inspecting the fusible link...

Page 12: ...0 10...

Page 13: ...1 1 SAFETY...

Page 14: ...ol drugs medication fatigue or insufficient sleep GENERAL PRECAUTIONS When a problem is found on the machine If any problem noise vibration smell disorder of instrument smoke oil leak wrong indication...

Page 15: ...tion when operating the machine Loud prolonged noise can cause hearing impairments even the total loss of hearing Install a fire extinguisher and first aid kit Be prepared for fire and accidents Insta...

Page 16: ...efore standing up from the operator s seat lower the bucket to the ground If the lift arms must be left in a raised position engage the lift arm stopper set the safety bar to the lock position and sto...

Page 17: ...r flammable material are not stored on the machine Handle all solvents and dry chemicals foam type fire extinguisher according to procedures identified on manufacturer s containers Work in a well vent...

Page 18: ...requently when working in severe conditions where large amounts of combustible debris are present Engine exhaust systems provide numerous small pockets where flammable debris can gather Even small acc...

Page 19: ...e provincial and local regulations dealing with fire fighting in effect in your specific geographic region Ensure that all information necessary for you to immediately contact all sources of help loca...

Page 20: ...t the base of the fire until the fire is completely out or the fire extinguisher is empty Only if you can safely do so open the access panels to the machine in the area of the fire Failing all attempt...

Page 21: ...cuum equipped with a high efficiency particulate air filter HEPA Wear the stipulated respirator if there is no other way to control the dust When working indoors install a ventilation system with a ma...

Page 22: ...use of a non approved optional product Product usage Note that the high output type brush cutter attachment can be used only if it is equipped with the easy brush cleaning function and the proper coo...

Page 23: ...ag person and or a signal Fence off the working area and keep off unauthorized persons When working in water or crossing shallow streams or creeks check the depth of the water the solidity of the grou...

Page 24: ...tenance every day Failure to identify or repair the irregularities or damage on machine can lead to accidents Before operating perform the specified inspection and make prompt repairs where necessary...

Page 25: ...on of the machine After smoking be sure to tightly close the lid of the ashtray to put out the match or cigarette Do not leave the cigarette lighter in the operator s compartment When the room tempera...

Page 26: ...s as hand holds Do not go under the raised lift arms to get in and out of the operator s compartment Always lower the lift arms to the ground beforehand Before starting the machine ask any unauthorize...

Page 27: ...tion Make sure that no one is near the machine Start and operate the machine only from the operator s seat Never attempt to start the engine by shorting across the ignition terminals AG7A024 PRECAUTIO...

Page 28: ...t the engine speed control Operate each control to ensure they are properly working In cold climates Be careful of slippery conditions on freezing ground steps and hand holds In severe cold climates d...

Page 29: ...sibility Adjust the mirror and camera to the best positions so that the operator can see the rear view blind spots from the operator s seat Unauthorized machine modifications or installation of unappr...

Page 30: ...ow anyone to enter the machine s turning radius and path Signal your intention to move by sounding the horn There is a blind spot in the rear of the machine Before traveling in reverse check that the...

Page 31: ...braking and is dangerous Before backing up visually check for safety to the rear Backing up without checking could result in contact with a worker or obstacle If the working equipment must be operate...

Page 32: ...30 cm 8 to 12 in above the ground In emergencies lower the bucket to the ground and stop the machine When traveling on slopes or grades drive slowly in 1st low speed Especially on down slopes slow dow...

Page 33: ...k at low speeds Operate the machine on snow or ice with extra care When traveling on snow or on frozen surfaces drive at a low speed and avoid starting stopping or changing directions abruptly In the...

Page 34: ...cially when the bucket is loaded Avoid overloading and off center loading Filling the bucket in excess of the rated loading mass or loading an off center load could cause the machine to become unstabl...

Page 35: ...th Always maintain a safe distance between the machine and the high voltage electric cable Check with the local power company about safe operating procedure before starting operations Consider all cab...

Page 36: ...acted it could result in a serious accident Watch out for hazardous working conditions Never undercut a high bank Doing so is dangerous as it may cause ground collapse Do not operate in places where t...

Page 37: ...cause the machine to tilt under its own weight resulting in a machine tipping over or sinking into the ground Do not drive on soft surface such as a back filled ground Loaders are NOT designed for li...

Page 38: ...nappropriate or not properly inspected Do not tow using only a towing hole on one side It becomes dangerous if the wire rope breaks or becomes disengaged Use a wire rope appropriate for the required t...

Page 39: ...hts etc so that the machine can easily be seen even at night to avoid collision with other vehicles Never leave the machine with the engine running or the lift arms raised If the lift arms are left in...

Page 40: ...then get on the ramps again Do not raise the lift arms on the ramp The machine may tip over When raising the lift arms on the truck bed do it slowly as the footing should be unstable Lock the cab door...

Page 41: ...porting the machine Select the best transport route by considering the length width height and weight of the truck with the machine loaded on it Never abruptly start or stop or run at a high speed at...

Page 42: ...E alert sign on easy to see locations such as on the ignition switch or on control levers Use the correct tools Do not use damaged or weakened tools or tools designed for other purposes Use tools appr...

Page 43: ...u could be injured by flying debris from the machine Prepare work area Select a firm level work area Make sure there is adequate light and if indoors ventilation Clear obstacles and dangerous objects...

Page 44: ...or tool becomes trapped in the rotating or moving part serious injury or death could result If a tool or other objects is dropped or inserted in the fan or fan belt it will be flown or cut in pieces D...

Page 45: ...ear door or radiator before working the inside Do not keep the rear door or radiator open on a windy day or if the machine is parked on a slope Precautions on tilting up the canopy cab Raising or lowe...

Page 46: ...capacity Allow room for oil expansion Clean up spilled fuel immediately Securely tighten the fuel filler cap If the fuel cap is lost replace it only with the genuine cap Use of a non approved cap wit...

Page 47: ...n loosening the cap or plug Working on the machine under these conditions could result in burns or injuries due to the hot oil spurting out The DPF and the exhaust gas emitted from the exhaust line ca...

Page 48: ...ure before working on the hydraulic system Oil may spurt out if caps or filters are removed or pipes are disconnected before releasing the pressure in the hydraulic system Gradually loosen the vent pl...

Page 49: ...keuchi service agent for repair Never disassemble the track adjuster There is a very strong spring contained in the track adjuster If the track adjuster is accidentally disassembled the spring can pop...

Page 50: ...l tools or any metal objects come into contact with the battery terminals and cause a short circuit Loose battery terminals may result in sparks Be sure to fasten terminals tightly Make sure the batte...

Page 51: ...ON MAINTENANCE Jump starting with booster cables When starting the engine using the booster cables be sure to connect the cables in the proper order described below Wrongly connected cables can resul...

Page 52: ...nd the earth ground Do not connect the earth ground around the pins for the working equipment or hydraulic cylinders When welding is to be done on the machine body disconnect the connectors for the el...

Page 53: ...regulations when disposing of harmful objects such as oil fuel coolant solvent filters and batteries Handling of poisonous chemicals Poisonous chemicals will cause serious injury if directly contacted...

Page 54: ...ty signs Review these signs and the operating instructions in this manual with your machine operators Keep the signs clean and legible If any of the safety labels is peeling or damaged and becomes dif...

Page 55: ...1 43 SAFETY SAFETY SIGNS DECALS With Lift arm lower button TL10 TL12...

Page 56: ...1 44 SAFETY SAFETY SIGNS DECALS...

Page 57: ...1 45 SAFETY SAFETY SIGNS DECALS...

Page 58: ...1 46 SAFETY SAFETY SIGNS DECALS...

Page 59: ...2 1 CONTROLS...

Page 60: ...ght 2 Hydraulic oil tank 3 Canopy 4 Safety bar 5 Front light 6 Lift arm stopper 7 Left control lever 8 Auxiliary hydraulic lines 9 Lift arms 10 Bucket cylinder 11 Bucket 12 Fuel filler cap 13 Lift cyl...

Page 61: ...al NAMES OF COMPONENTS 19 Front light switch 20 Tail light switch 21 Hydraulic quick hitch switch 22 Multifunction buttons 23 Engine shutdown switch 24 Trip Data switch 25 Blow by heater lamp 26 Ride...

Page 62: ...el tank Fill the fuel tank in a well ventilated place with the engine turned off Clean up spilled fuel immediately Do not fill the fuel tank to capacity Allow room for oil expansion Securely tighten t...

Page 63: ...of it until a click is heard 2 Insert the ignition key and turn it clockwise to lock the engine hood REAR DOOR When opening the rear door use a stay to securely lock it When opening or closing the rea...

Page 64: ...ace When opening or closing the door grasp the handle securely and move the door slowly When lowering the door be careful not to hit your head or get your hands or feet caught by the door Open the doo...

Page 65: ...n grasp the handle 7 and firmly push the door in to engage the latch Opening from inside 1 Push the release lever 6 to the front to release the latch If the release lever 6 does not work move the emer...

Page 66: ...handle 4 and slowly lower the door while taking care not to get the hands or feet caught by the door 3 Grasp the handle 3 and firmly pull the door to latch it SIDE WINDOW CAB 1 Grasp the catch 8 rele...

Page 67: ...h them Remove the glass pieces from the window sill so as not to cut yourself when evacuating Broken glass will fall from the window so be careful of your footing and do not slip on the glass When nec...

Page 68: ...If the lift arms are raised use an authorized lift arm stopper by observing the following procedures Installing the stopper 1 Park the machine on a flat and rigid ground and remove the bucket 2 Lower...

Page 69: ...the hook 4 on the tip with that of the lock pin 1 2 Pull out the lock pin 1 from the lift arm stopper 2 3 Pick up the end loop of the spring 3 with your fingers and then hang it onto the hook 5 of the...

Page 70: ...ment 1 Pull up the lever 2 and slide the seat backward or forward to the desired position for operation of machine 2 Release the lever 2 at the desired position to secure the seat Adjustment range 15...

Page 71: ...and then insert the tongue plate A into the buckle B of the seat belt until you hear a clicking sound as it locks in place 4 Check if the belt is securely locked by pulling it and arrange the belt ar...

Page 72: ...rning lamp This lamp flashes and an alarm is sounded if the lubricant oil pressure abnormally low while the engine is running 3 Air cleaner warning lamp This lamp flashes and an alarm is sounded if th...

Page 73: ...sed to set the lift arms to the float mode 13 Auxiliary 1st flow rate indicator lamp This lamp lights up to indicate which flow rate setting is selected in the auxiliary 1st 1 Flow rate setting 1 2 Fl...

Page 74: ...r help INSTRUMENT CLUSTER When the ignition switch is turned to ON the display of hour meter trip meter or the various data items on the machine appears The initial screen displays the hour meter the...

Page 75: ...ls according to the time displayed on the hour meter 2 Trip meter A pattern of desired operating hour can be displayed To reset the meter to 0 press and hold the TRIP side for three seconds 3 PM accum...

Page 76: ...rror code list on pages 6 13 to 6 15 3 Auxiliary 1st 1 setting information The flow rate of the Aux 1st is displayed The flow rate except the flow rate of the Aux 2nd can be changed when the engine is...

Page 77: ...switch is pressed e Press and hold the Aux 1st flow rate select switch for approximately three seconds to end changing flow rate operation INSTRUMENT CLUSTER TL12 Initial condition LR common standard...

Page 78: ...w 3 High flow display optional e High flow is selected f Enlarged view 4 Parking brake display TL12 optional g Parking brake is on h Enlarged view Refer to Auxiliary 1st 1 setting information above 5...

Page 79: ...ine error code list on pages 6 13 to 6 15 8 1 PCD warning display If the particulate after treatment system such as the DPF detects any error the ECM warning display turns on and the alarm sounds If e...

Page 80: ...generation if the machine is surrounded by flammable items such as plants trees dry grass wastepaper oil and waste tires There is a risk of fire due to the high temperature exhaust gas emitted from th...

Page 81: ...to be regenerated manually to complete the auto regeneration Try not to stop the engine while the auto regeneration is being performed Note DPF auto regeneration is performed if both of the following...

Page 82: ...released the switch automatically returns to the ON position Note The engine immediately stops when the ignition switch is turned to the OFF position but the other electric components take a few secon...

Page 83: ...ove the ground 1 Tilt the right control lever forward a little Lift Arms Lower For the H pattern tilt the left control lever to the right 2 Depress the float button while the lever is tilted forward T...

Page 84: ...FF every time the button is pressed To switch to the detent mode use the detent mode switch D If the selector switch C has been turned on to select the one way oil flow only the switch A can be used A...

Page 85: ...the detent mode To change it to the momentary mode press the switch again until the built in lamp orange goes out Flow Selector Switch C SWITCHES The flow of the auxiliary hydraulic system lines a and...

Page 86: ...et in the auxiliary hydraulic lines To set the high flow function to ON press this switch until the built in lamp green lights up The flow of the auxiliary hydraulic line is changed from two way to on...

Page 87: ...reeze to the glass Operating the wiper forcibly may damage the wiper motor Front wiper switch Rear wiper switch O Off I Wiper operates PUSH Sprays washer fluid when pressed Stops when released FRONT L...

Page 88: ...al position or to the opposite mode Refer to Instrument cluster on page 2 14 The DPF and the exhaust gas emitted from the exhaust line can be very hot while the engine is running or the regeneration i...

Page 89: ...el press the switch again Turning the ignition switch to OFF will also cancel the regeneration Refer to 9 DPF manual regeneration display and 10 DPF regeneration inhibit display on page 2 22 Refer to...

Page 90: ...turned off or the safety bar is raised Refer to Parking brake display on page 2 20 AUXILIARY 1ST FLOW RATE SELECT SWITCH This switch is used to select and set the flow rate of the auxiliary 1st The au...

Page 91: ...ppears on the display Press the front side E of the button to discharge from the Aux 2nd port e Press the rear side F of the button to discharge from the Aux 2nd port f Refer to Aux 2nd display on pag...

Page 92: ...S AND PEDAL This device is used to lock the functions of control levers and switches listed below Selector switch Detent mode switch Trip Data switch High flow switch Quick hitch switch Ride control s...

Page 93: ...he working equipment on pages 3 14 to 3 15 LEVERS AND PEDAL LEFT CONTROL LEVER Use this lever to move forward and in reverse and to change directions An alarm will sound if the machine is driven in re...

Page 94: ...conditioner off or turn the temperature control dial clockwise to increase the internal temperature Mist may blow out of the air outlets This is not a malfunction When moist air passes through the eva...

Page 95: ...RIES 1 Defroster 2 Condenser 3 Receiver drier 4 Foot outlets 5 Rear outlets 6 Control panel 7 Compressor 8 Air conditioner unit 9 Inner filter 10 Outer filter Control panel 11 Air conditioner switch 1...

Page 96: ...r O OFF I ON Note To prevent leakage of refrigerant gas from the compressor s seal operate the air conditioner at least once a week regardless of the season Note The air conditioner will not function...

Page 97: ...ually becomes dirty Switch to the ventilation to ventilate once a comfortable temperature is obtained Excessive cooling can be harmful to your health It is best to keep the air inside the cab only abo...

Page 98: ...ntrol dial to between the center and HOT 2 Set the fan switch to the desired positions 3 Arrange the outlets so that they are directed to the front window EXTERNAL POWER SOCKET Use only those electric...

Page 99: ...e Be careful not to allow water or other liquids to come into contact with the radio Otherwise it may result in malfunction FEATURES Features of the Jensen JHD910 mobile audio system include Waterproo...

Page 100: ...ume will default to the programmed turn on level when the unit is turned back on ACCESSORIES 3 Display Press DISP 3 momentarily to toggle the LCD display between function mode showing tuner auxiliary...

Page 101: ...l operation will resume ACCESSORIES 9 Audio and Menu Adjustment Audio Adjustment Press AUDIO MENU 9 momentarily to step through the following audio adjustment options Bass Treble and Balance left to r...

Page 102: ...ly in the selected direction until the button is released 12 Seek Tuning Press SEEK 12a or SEEK 12b momentarily to automatically tune the frequency down or up to the next strong station 13 Preset Stat...

Page 103: ...ved the NO SIG icon will flash in the display and the tuner will scan all seven NOAA frequencies every 30 seconds How will I know I am tuned to the weather band When you select the weather band the WB...

Page 104: ...C The fuse is blown Replace the fuse No reception Volume turned down too low Adjust volume until sound is heard Wiring not connected properly Check wiring connections Radio does not work Antenna cable...

Page 105: ...tem power 15 Watts Maximum Signal to Noise 70dB Specifications subject to change without notice Note The manufacturer is not responsible for any radio or TV interference caused by unauthorized modific...

Page 106: ...ressure remaining in the lines Refer to Releasing residual pressure on page 2 49 2 Remove the plugs 3 Connect the attachment hydraulic lines to the ports a b and T When a hydraulic breaker is installe...

Page 107: ...lic buttons or the slider switch 1 Select the direction of the hydraulic oil flow by operating the flow selector switch C One way flow or two way flow Refer to Flow selector switch on page 2 27 ACCESS...

Page 108: ...for operating the attachments ACCESSORIES Flow rate TL10 65 L min 17 2 US gpm TL12 65 L min 17 2 US gpm Rated Pressure 21 MPa 3040 psi Connecting the hydraulic circuits To connect the attachment hydra...

Page 109: ...ocedures for purging air as instructed by the attachment manufacturer if applicable 6 Check for oil leaks ACCESSORIES Operating the auxiliary hydraulic circuits 1 Operate the auxiliary hydraulic butto...

Page 110: ...tandard cooling package is not permitted for use in high airborne debris applications such as mulching mower or land clearing IMPORTANT Do not operate the machine in the detent mode for a long time Do...

Page 111: ...le the lift arm is being raised Do not lower the lift arm until you are certain that no one is around the machine IMPORTANT The lift arm can be lowered even when the engine is stopped or the safety le...

Page 112: ...e lamp does not turn on or goes off the heater is faulty If this is the case consult your sales or service dealer for help ACTIVE POWER CONTROL IF EQUIPPED This system helps prevent the engine from st...

Page 113: ...3 1 OPERATION...

Page 114: ...chine and holding the handrail to support your weight in a three point secure stance hand and feet Never use the safety bar or control levers as hand holds BEFORE STARTING OPERATION WALK AROUND INSPEC...

Page 115: ...perform the following inspections All warning lamps flash and an alarm is sounded for two seconds The meters also start functioning After two seconds only the battery charge warning lamp 1 and engine...

Page 116: ...ning lamps are off 4 Warm up the engine Refer to Warming up the engine on page 3 5 Starting in cold climates Never use starting fluid on this engine as the starting fluid could cause an explosion 1 Tu...

Page 117: ...ed up Do not warm up the engine for a long time 20 minutes or more When idling is required occasionally place a load or run the engine at medium speed TL8 1 Run the engine at medium speed with no load...

Page 118: ...y loads or at the maximum speed Doing so may cause the engine to overheat or seize Never stop running the engine suddenly except in emergency TL8 1 Return the throttle lever or throttle controller 2 I...

Page 119: ...3 7 MEMO...

Page 120: ...he operation by using the ISO pattern described below OPERATING THE MACHINE Travel Forward Lift Arms Lower Travel Reverse Lift Arms Raise Left Spin Turn Bucket Rollback Right Spin Turn Bucket Dump Lef...

Page 121: ...sing the ISO pattern Travel Forward Left track Travel Forward Right track Travel Reverse Left track Travel Reverse Right track Lift Arms Raise Bucket Rollback Lift Arms Lower Bucket Dump Lift Arms Flo...

Page 122: ...emperature is below 20 C 68 F The proper hydraulic oil temperature during operation is 50 to 80 C 122 to 176 F If operations must be performed at lower temperatures heat up the hydraulic oil to at lea...

Page 123: ...fter warming up the engine and machine hydraulic oil perform the checks and inspections described below and repair if necessary OPERATING THE MACHINE 1 Check that the warning lamps and meters are as f...

Page 124: ...l motors to operate and apply the brakes abruptly Do not switch off the ignition switch while traveling Doing so will cause sudden braking and is dangerous Before backing up visually check for safety...

Page 125: ...2nd High speed Press the travel speed button on the left control lever to switch to 2nd high speed and press it again to return to 1st low speed Pivot turn Turning to the left To turn forward to the...

Page 126: ...ety bar is raised OPERATING THE MACHINE OPERATING THE WORKING EQUIPMENT Before starting operation carefully check which lever pattern you are going to use Make sure the bucket is lowered to the ground...

Page 127: ...ift arms Pull the right control lever backward Operating the bucket To roll back Tilt the right control lever to the left To dump Tilt the right control lever to the right To float the lift arms Tilt...

Page 128: ...travel or turn with the bucket raised Keep the bucket as low as possible during traveling Travel at a speed appropriate for the operating conditions Travel at low speeds with care in the places where...

Page 129: ...verfill the bucket Do not use the downward force of the bucket to drive piles Do not dig down too deeply at a time Doing so could damage the bucket and the lift arms Do not allow the bucket to bump ag...

Page 130: ...PERATION Do not fully extend the bucket cylinders push the bucket into the ground and move the machine to use the traveling force for digging Doing so could damage the bucket cylinders OPERATING PROCE...

Page 131: ...eed and avoid starting stopping or changing directions abruptly Cautions on using machine in water If the rear of the machine is submerged in water as shown in the figure above it causes the radiator...

Page 132: ...emergencies lower the bucket to the ground and stop the machine When traveling on slopes or grades drive slowly in 1st low speed Especially on down slopes slow down the engine speed and limit the str...

Page 133: ...engine stops If the engine stops when descending a slope set the left control lever to the neutral position stop the machine then start the engine Do not open the door while traveling on slopes if equ...

Page 134: ...nders Scooping OPERATING PROCEDURES Lower the bucket to the ground and set it parallel to the ground or tilt it slightly downward Move the machine forward push the bucket well into the material and sc...

Page 135: ...ront edge until it is slightly above the ground surface then back the machine over the load that was just released Backfilling With the bucket lowered drive near the hole and tilt the front edge of th...

Page 136: ...uck bed Slowly move the machine forward and stop at the position where the bucket is to dump Tilt the bucket forward to release the material in the bucket into the truck bed When the truck bed is fill...

Page 137: ...em from falling by engaging the lift arm stopper Before leaving the machine do the following 1 Set the control levers to the neutral position 2 Return the throttle lever to idle the engine at low spee...

Page 138: ...ng and making it impossible for the machine to move Remove all mud and water from the machine body In particular wipe the hydraulic cylinder rod clean to prevent damage to the seal caused by mud or di...

Page 139: ...e are large numbers of boulders may cause the stones to get caught and damage the tracks or make the tracks come off Do not use the machine on the seashore The salt may corrode the steel core Do not l...

Page 140: ...especially careful on snowy or frozen surfaces in winter as the tracks tend to slip in such conditions Use rubber tracks at temperatures between 25 C to 55 C 14 F to 131 F When storing the rubber tra...

Page 141: ...n a slope or projecting portion and the other track on a flat surface with the machine at a tilt of 10 or more Travel with both tracks set on flat surfaces Do not change directions when the tracks are...

Page 142: ...e If the exhaust gas control system is not properly functioning the ECM error warning lamp turns on or flashes and an error code appears If an error code appears immediately repair the fault detected...

Page 143: ...4 1 TRANSPORT...

Page 144: ...s the footing should be unstable Lock the cab door after being loaded if applicable Otherwise the door may open during transport Chock the tracks and secure the machine to the truck bed with wire rope...

Page 145: ...This hoisting method applies to machines with standard specifications This method is not applicable for the machines with non standard attachments and or optional products because the center of gravi...

Page 146: ...80 38 7 1515 59 7 855 33 7 660 25 9 890 35 0 500 19 7 TL10 1660 65 3 940 37 1 1720 67 7 985 38 8 735 28 9 880 34 7 630 24 7 TL12 1705 67 1 950 37 4 1895 74 6 1110 43 7 785 30 9 880 34 7 615 24 2 Unit...

Page 147: ...urely to prevent the machine from slipping sideways 6 Secure the bucket with a chain or wire rope IMPORTANT Place a wooden block under the bucket to protect the floor from damage caused by the bucket...

Page 148: ...4 6...

Page 149: ...5 1 MAINTENANCE...

Page 150: ...l For works not listed in this manual ask your sales or a service dealer for help Keep the machine clean Clean the machine before performing inspection and maintenance and try to keep it clean Stop th...

Page 151: ...e thread end Disposing of wastes Always collect oil that is drained from the machine in containers Improperly disposed waste oil can cause environmental harm Follow appropriate laws and regulations wh...

Page 152: ...ds If a brand is to be changed replace the whole fuel oil Fuel Diesel fuel specifications Diesel fuel should comply with the following specifications The table lists several worldwide specifications f...

Page 153: ...ow sulfur fuel should be used A higher sulfur content fuel may cause sulfuric acid corrosion in the cylinders of the engines Never mix kerosene used engine oil or residual fuels with the diesel fuel P...

Page 154: ...s Travel reduction gear Gear oil API GL 4 SAE 90 Every 500 hrs after the initial 250 hrs Working equipment Lithium based grease EP 2 NLGI No 2 Daily or every 10 hrs Levers When required SERVICE DATA M...

Page 155: ...l Tank 48 L 12 7 US gal Level capacity 90 L 23 8 US gal 1 6 L X 2 1 7 US qt X 2 TL12 Engine oil pan Engine cooling system Hydraulic oil tank Fuel tank Travel reduction gear Upper limit 13 2 L 13 9 US...

Page 156: ...lter elements Failure to replace these in time can lead to damage to the machine and the attachment hydraulic system To prolong the service life of the hydraulic devices properly replace the hydraulic...

Page 157: ...itial 50 hrs Engine oil separator Element kit TL8 K1J770 05810 Every 1500 hrs TL10 TL12 K1J419 05810 Fuel system Pre fuel filter Cartridge K16631 43560 Every 500 hrs Main fuel filter Cartridge K1J301...

Page 158: ...Spanner 16901 00041 41 8 Screwdriver 16902 20205 replaceable shank 9 L type wrench 16908 30019 19 10 Hammer 16903 00330 3 4 11 Monkey wrench 16904 00250 250 mm 12 Pliers 16905 00200 200 mm 13 Hex wren...

Page 159: ...alternately top bottom left then right or in 2 or 3 times so that they are evenly tightened Classification Head width b Size a x pitch Tightening torque General connection points mm mm N m ft lb Coar...

Page 160: ...to replace Fuel system Fuel hoses Every 2 years Packing on fuel filler cap Cooling system Rubber hoses Engine Engine oil filter hoses Heater AC systems Heater hoses Air conditioner hoses Hydraulic sys...

Page 161: ...e the O rings and seals at the same time Check the fuel and hydraulic hoses according to the periodic schedule described below Refer to Maintenance Type of inspection Inspection item Daily inspection...

Page 162: ...e initial 50 hours only for new machines Replacing the engine oil and the oil filter 5 24 Replacing the hydraulic oil return filter 5 26 Replacing the pilot line filter 5 27 Inspecting and adjusting t...

Page 163: ...ing the PCV valve TL10 TL12 5 54 Every 3000 hours Inspecting the turbocharger 5 55 Inspecting the EGR system 5 55 Every 6000 hours Cleaning the DPF 5 55 When required Replacing the bucket or attachmen...

Page 164: ...chine is parked on a slope Before starting the engine look around the machine and clean any combustibles from the surroundings of the engine Also inspect if oil or water is leaking and any nuts bolts...

Page 165: ...d loose bolts 9 Check for oil leakage from the travel motor 10 Check the canopy cab and guard for damage and loose nuts and bolts 11 Check the rear view mirror and room mirror for dirt damage and angl...

Page 166: ...goggle and gloves when handling coolant antifreeze If any coolant antifreeze comes in contact with eyes or skin wash it off with clean water Otherwise it could result in inflammation DAILY INSPECTION...

Page 167: ...if the oil level is either too low or too high 3 Tighten the oil filler cap 2 4 Start the engine run it at low idle for about 5 minutes then stop it 5 After about 10 minutes inspect the oil level Not...

Page 168: ...k is empty 2 If the level is low add fuel from the fuel port 2 while watching the fuel gauge 1 Refer to Fuel filler port on page 2 4 DAILY INSPECTION EVERY 10 HOURS INSPECTING THE WATER SEPARATOR Do n...

Page 169: ...3 Stop the engine 4 Inspect the oil level using the sight gauge 2 When the oil temperature is about 20 C 68 F The level should be between the upper limit H and the lower limit L If it is below the low...

Page 170: ...NT 1 Keep the machine configuration as shown in the diagram above lower the working equipment to the ground and then stop the engine 2 Use the grease gun to lubricate the grease fittings 3 Wipe off th...

Page 171: ...hips dust fuel oil and other combustible material Remove any combustible material prior to machine operation to reduce the risk of fire 1 Open the engine hood 1 and the rear door 2 2 Remove materials...

Page 172: ...he machine under these conditions could result in burns or injuries IMPORTANT Check the waste oil for metal powder If it contains large amounts of metal powder consult your sales or service dealer TL8...

Page 173: ...l the new filter by hand 14 Securely tighten the filter by hand after its packing comes in contact with the surface of installation 15 Add oil up to between the upper limit H and the lower limit L of...

Page 174: ...in burns or injuries due to the hot oil spurting out Oil may spurt out if caps or filters are removed or pipes are disconnected before releasing the pressure in the hydraulic system When removing plu...

Page 175: ...ected before releasing the pressure in the hydraulic system When removing plugs or screws or when disconnecting hoses stand to the side and loosen them slowly to gradually release the internal pressur...

Page 176: ...r pump or bearing and belt used to drive the alternator IMPORTANT Do not let any oil or grease get on the belt Inspection 1 Open the rear door TL10 TL12 AFTER THE INITIAL 50 HOURS ONLY FOR NEW MACHINE...

Page 177: ...ension of the fan belt 3 Tighten Clockwise Loosen Counterclockwise 3 Tighten the lock nuts 4 Note When replacing with a new belt run the engine at low idle speed for about 3 to 5 minutes to break in t...

Page 178: ...belt tension to the standard value approximately 8 mm or 0 3 in Inspection 1 Open the rear door and radiator 2 Press on the center of the belt 1 with a finger The belt s tension is normal if it bends...

Page 179: ...valve slowly Do not turn it more than one turn Do not put your face arms legs or body in front of the grease discharge valve If grease does not come out when the grease discharge valve is loosened th...

Page 180: ...o not fill the fuel tank to capacity Allow room for oil expansion Clean up spilled fuel immediately Securely tighten the fuel filler cap Use the correct grade of fuel for the operating season Do the d...

Page 181: ...and call a physician immediately If acid contacts skin or clothing wash off immediately with a lot of water Be sure to secure the rear door or radiator before working the inside Do not block the exha...

Page 182: ...Before performing maintenance or repairs under the machine lower all movable working equipment to the ground or in the lowermost position 1 Park the machine on a flat and rigid ground and remove the...

Page 183: ...kin if contacted If eye contact occurs flush immediately with clean water and get prompt medical attention If accidentally swallowed drink large quantities of water or milk and call a physician immedi...

Page 184: ...nd the battery clamp 5 7 Remove the battery 8 Remove any combustibles such as twigs dead leaves oil and grease from the area where the battery 6 was installed 9 Install the battery 6 to the machine 10...

Page 185: ...to secure the rear door or radiator before working the inside TL8 EVERY 100 HOURS S Closed 1 Open the rear door 2 Close the valve 2 3 Loosen the case 4 and then remove and clean the case 4 the element...

Page 186: ...reduction gear case of travel motor may cause oil or the plug to fly out Loosen the plug slowly to release the pressure IMPORTANT If the percentage of the traveling time within the total operating ti...

Page 187: ...Y 250 HOURS INSPECTING AND ADJUSTING THE FAN BELT Refer to Inspecting and adjusting the fan belt on pages 5 28 to 5 29 INSPECTING AND ADJUSTING THE COMPRESSOR BELT AC Refer to Inspecting and adjusting...

Page 188: ...and dust cap securely If not dust could be drain into the cylinder damaging the engine 1 Open the engine hood 2 Push down the lever 6 to tilt up the air cleaner 3 Loosen the clamps 1 and remove the du...

Page 189: ...the machine in very dusty places perform inspection and maintenance operations every day 1 Open the rear door 2 Blow compressed air on the fins to remove mud and dirt stuck on them CLEANING THE CONDEN...

Page 190: ...ters Outer filter EVERY 250 HOURS 1 Remove the cover 1 2 Remove the filter 2 Ventilation filter 2 parts No 19115 06052 Inner filter 1 Lift the filter 3 and remove it Cleaning 1 Blow dry compressed air...

Page 191: ...using the sight glass 2 on the top of the receiver drier 1 EVERY 250 HOURS 1 Loosen the bolts and remove the cover 3 2 Inspect the places for the conditions below Places for inspection Conditions Cab...

Page 192: ...es Fully transparent when the engine speed is increased or decreased Flow of bubbles can be seen constantly Sometimes transparent or white with bubbles Mist like flow is faintly visible No bubbles are...

Page 193: ...he canopy on page 5 61 2 Turn the Pre fuel filter 1 counterclockwise with the filter wrench and remove it 3 Clean the surface of installation of the filter stand 4 Apply a thin layer of oil on the pac...

Page 194: ...parts of the machine For the adjustment of the bucket stoppers install the lift arm stopper 2 used for the lift arms adjustment on the lift cylinder while the pin hole 1 of the lift arms should be po...

Page 195: ...falling off set the hook 5 at a right angle to the lock pin 8 Loosen the lock nuts 7 and fully screw in the stopper bolts 8 9 Start the engine extend the bucket cylinders to the maximum length and th...

Page 196: ...er 2 is disconnected and then stop the engine 14 Align the orientation of the hook 5 with that of the lock pin 3 and then pull out the lock pin 3 from the lift arm stopper 2 15 Remove the lift arm sto...

Page 197: ...chine could move suddenly Never stand at the back of the machine while the engine is running Do not remove the radiator cap or the drain plug when the cooling water is hot Stop the engine and wait unt...

Page 198: ...that there are no irregularities in the cooling system at this time 15 Increase the water temperature to at least 90 C 194 F Then run the engine for about 10 minutes with the thermostat open 16 Stop t...

Page 199: ...to the hot oil spurting out Oil may spurt out if caps or filters are removed or pipes are disconnected before releasing the pressure in the hydraulic system When removing plugs or screws or when disco...

Page 200: ...ll the suction strainer 10 on the flange 9 16 Install the flange 9 on the hydraulic oil tank 17 Connect the hose 8 to the flange 9 18 Tighten the drain plug 7 19 Mount a new return filter and install...

Page 201: ...the vent plug hole 1 tighten the vent plug 1 EVERY 1000 HOURS INSPECTING AND ADJUSTING THE ENGINE VALVE CLEARANCE This operation requires experience Ask your sales or service dealer for it TL10 TL12 C...

Page 202: ...G THE INJECTOR TIP This operation requires experience Ask your sales or service dealer for it INSPECTING THE EGR COOLER This operation requires experience Ask your sales or service dealer for it INSPE...

Page 203: ...ience Ask your sales or service dealer for it Do not modify the DPF without permission If modified it may be damaged or malfunction may occur As a result an expensive repair work may be required Do no...

Page 204: ...rvice agents Installation Before installing a bucket clean the connecting sections of the bucket 1 and the quick hitch 3 and their surrounding area WHEN REQUIRED 1 Make sure the quick hitch 3 lock lev...

Page 205: ...ing disconnect the quick hitch and determined the cause instead 3 Pull both lock levers 2 until they are vertical to release the latch 4 Sit in the operator s seat lower the safety bar fasten the seat...

Page 206: ...low Replenishing 1 Mix the washer fluid to the prescribed concentration 2 Remove the cap 2 and add washer fluid Keep the dust away while replenishing the washer fluid 3 Install the cap 2 LUBRICATING...

Page 207: ...d and cannot be adjusted 1 Lug Replace if the height of A is 5 mm 0 2 in or below 2 Steel cord WHEN REQUIRED Replace if the steel cord is exposed for two links or more Replace if the half or more of t...

Page 208: ...5 60 MAINTENANCE EVERY YEAR EVERY YEAR REPLACING THE RECEIVER DRIER This operation requires experience Ask your sales or service dealer for it...

Page 209: ...Remove the lock bolts A 4 Take out the R pin and pull out the stopper pin B 5 Slowly raise the canopy 6 Insert the stopper pin B through the holder hole on the machine body and the canopy and then ins...

Page 210: ...event rusting operate the machine once a month so that the oil can be circulated throughout the system 2 Inspect the battery and recharge it as necessary Ask your sales or service dealer for rechargin...

Page 211: ...6 1 TROUBLESHOOTING...

Page 212: ...e produces noise if excessive force is applied to the working equipment or when it moved to the stroke end It becomes less easy to operate the machine when an attachment weighing more than a standard...

Page 213: ...temperature gauge LED is in the red zone Steam comes from the engine room Remedy procedure 1 Park the machine in a safe place 2 Check if steam is coming out of the closed engine hood 3 If there is ste...

Page 214: ...ng the engine by using the jumper cables Be sure to secure the rear door or radiator before working the inside IMPORTANT Use the jumper cables and clips of a size suited to the capacity of battery Do...

Page 215: ...p of jumper cable B from the engine block of the dead machine 2 Disconnect the other clip of jumper cable B from the negative battery terminal of the booster vehicle 3 Disconnect the clip of jumper ca...

Page 216: ...crew and remove the fuse box cover 1 3 Check for any blown fuses 4 If a fuse is blown replace it with a spare fuse of the same capacity Fuse layout and circuits protected 1 TL8 Capacity Symbol Protect...

Page 217: ...r 4 11 Open the fuse box 12 Check for any blown fuses 13 If a fuse is blown replace it with a spare fuse of the same capacity TL10 TL12 Capacity Symbol Protected circuit 20A Front light 20A Tail light...

Page 218: ...e fusible link is blown please contact your sales or service dealer Note Fusible links are large type fuses used in high current applications Like a regular fuse they act as fuses by protecting the el...

Page 219: ...r 60 seconds and then turn it to the START position Running the starter for a long time before there is enough fuel is going through can cause the starter to fail RESTARTING AFTER ADDING FUEL 1 Add fu...

Page 220: ...charger Check the fan belt for slack or breakage and adjust as necessary If the lamp continues flashing after maintenance there is likely a problem with the charger Consult your sales or service deale...

Page 221: ...Pilot line filter warning lamp The hydraulic oil pilot line filter is clogged Stop the engine and replace the filter immediately Continuing to operate the machine while the lamp is flashing could dam...

Page 222: ...sor voltage error too high IX012 2514 Sensor voltage error too low IX012 3300 Alternator charge faulty 3380 Ash accumulation amount 3401 Engine oil pressure error 3500 Overheat 3600 Air cleaner clogge...

Page 223: ...4 Air mass flow MAF sensor Low 15 Turbo boost rise insufficient error hose disconnected between blower out and air intake flange 157 0 Rail pressure abnormally high 3 Rail pressure sensor High 4 Rail...

Page 224: ...e 2 Low 3701 0 PM accumulation error level 5 15 PM accumulation error level 3 16 PM accumulation error level 4 3936 2 Removal of DPF system PCD 7 Loss of Function DPF system PCD 4765 0 Exhaust temp ri...

Page 225: ...reakdown cable break 523580 2 Air intake throttle feedback FB error 523582 3 Air intake throttle lift sensor error High 4 Air intake throttle lift sensor error Low 523589 17 Water temp rise insufficie...

Page 226: ...es 3 10 to 3 11 Air cleaner is clogged Replace the air cleaner elements Refer to page 5 40 Hydraulic oil is not of suitable type Replace the hydraulic oil Refer to pages 5 51 to 5 53 Traveling is not...

Page 227: ...air ask your sales or service dealer Fuel line is faulty Adjust or repair ask your sales or service dealer Prolonged idling approx two hours or more Increase the engine RPM and check for smoke Poor fu...

Page 228: ...the set screw on the port relief valve Do not turn the screw more than the specified amount 1 Tilt up the canopy 3 Loosen the lock nut 3 while holding the adjusting screw 2 in place with a hexagonal...

Page 229: ...oes not start or if the machine does not run Doing so could damage the machine being towed IMPORTANT Be sure to follow the steps below closely when towing Failure to heed even one of the steps may cau...

Page 230: ...t is complete Do not try to repair the damaged cab or canopy by welding Doing so could endanger the safety of the cab canopy Canopy TL8 part number 06684 00012 Canopy TL10 part number 06884 03100 Cano...

Page 231: ...tected or consult your sales or service dealer for help Error code Error description DTC NCD or PCD Error Limited engine Inducement SPN FMI Fault location Cause 3936 7 DPF system Removal of the DPF sy...

Page 232: ...by turning on the warning lamp and displaying an engine error code The engine output is limited depending on the type of fault PARTICULATE CONTROL DIAGNOSTIC SYSTEM PCD The PCD system warns the operat...

Page 233: ...ith a shorter pre operation Normal Limited output Pre operation 1 If an error is detected the warning lamp turns on or starts flashing the engine output is not limited Pre operation 2 Pre operation 2...

Page 234: ...6 24...

Page 235: ...7 1 SPECIFICATIONS...

Page 236: ...sition ISO 6396 2008 LpA 82 ENGINE Manufacturer and model Applicable machine models 200800002 or later KUBOTA V3307 CR TE4B Applicable machine models 200900001 or later KUBOTA V3307 CR TE5B Rated outp...

Page 237: ...4 36 30 7 4 45 Noise level dB A Sound power level ISO 6395 2008 LWA 104 Emission sound pressure level at the operator s position ISO 6396 2008 LpA 87 ENGINE Manufacturer and model KUBOTA V3800 CR TE4B...

Page 238: ...Rubber tracks 32 0 4 64 32 7 4 74 Noise level dB A Sound power level ISO 6395 2008 LWA 105 Emission sound pressure level at the operator s position ISO 6396 2008 LpA 82 ENGINE Manufacturer and model...

Page 239: ...7 5 MEMO...

Page 240: ...7 6 SPECIFICATIONS MACHINE DIMENSIONS MACHINE DIMENSIONS...

Page 241: ...7 H Body width 1430 56 3 J Canopy Cab width 980 38 6 985 38 7 K Bucket width 1675 66 0 L Bucket height 510 20 0 M Departure angle 30 With a cab TL10 Unit mm inch Item Standard bucket Rubber tracks A O...

Page 242: ...t bucket 3135 123 4 C Track base 1595 62 8 D Overall height 2320 91 3 E Ground clearance of undercarriage 345 13 5 F Overall width without bucket 1860 73 2 G Track shoe width 450 17 7 H Body width 157...

Page 243: ...7 9 MEMO...

Page 244: ...7 10 SPECIFICATIONS OPERATING RANGES OPERATING RANGES...

Page 245: ...ket hinge pin height 3120 122 8 C Dumping clearance at 39 degree forward tipping 2405 94 7 D Dumping reach at 39 degree forward tipping 875 34 4 E Minimum turning radius bucket outside 2295 90 4 F Min...

Page 246: ...7 12...

Page 247: ...8 1 OPTIONS...

Page 248: ...e position Use the proper procedure when mounting an attachment otherwise serious damage could result Consult your sales or service dealer for help When hoisting be sure to designate a person to act a...

Page 249: ...ing time distance a machine will travel from the point where its brakes are fully applied to when it comes to a complete stop gets longer This increases the accident risk Operate the machine allowing...

Page 250: ...the other attachments consult Takeuchi or one of our service agents Installation Before installing a bucket clean the connecting sections of the bucket 1 and the quick hitch 3 and their surrounding ar...

Page 251: ...vation of the attachment or hydraulic quick hitch installed When the attachment hoses are connected to the quick coupler the plate is pushed to turn on the switch which prevents the hydraulic quick hi...

Page 252: ...ing clean the flat mating surfaces of quick coupling to avoid the inclusion of dirt into the circuit 2 Release the residual pressure from the upper coupling a by pulling the knob 1 outward first and t...

Page 253: ...gested to use the protection caps IMPORTANT Before uncoupling be sure to release the residual pressure 4 PORT QUICK COUPLER Releasing residual pressure Coupling and uncoupling 1 Before coupling clean...

Page 254: ...low idle with no load for 10minutes b With the engine running at low idle operate the auxiliary hydraulics switch repeatedly approx 10 times to purge air from the hydraulic lines c Stop the engine and...

Page 255: ...ing levers are set SELECTING A LEVER PATTERN SWITCHING THE LEVER PATTERN A ISO pattern H H pattern 1 Park the machine on a flat and rigid ground and stop the engine 2 Loosen the screws and open the co...

Page 256: ...hine will stop abruptly This seat is equipped with a switch for operating the lever lock which functions in the same way as the safety bar The lever lock is released when you sit in the seat and lower...

Page 257: ...nits kg lb TL10 TL12 Standard machine mass Not including operator Canopy Cab Canopy Cab 4605 10150 4695 10350 5195 11455 5300 11685 OPTION High flow hydraulic device 50 110 60 130 Air conditioner 40 9...

Page 258: ...8 12 OPTIONS TAKEUCHI FLEET MANAGEMENT TAKEUCHI FLEET MANAGEMENT If equipped please contact your local dealer for activation and use information TM...

Page 259: ...a risk of tipping over if traveling on slopes with optional equipment installed ask your sales or service dealer for advice The figure above illustrates the rear of the machine without optional equip...

Page 260: ...8 14 First Published January 2014 Thirteenth Published August 2019 AU8E012 Printed in Japan by STATION M Co Ltd OPERATOR S MANUAL Track loader TL 8 TL10 TL12 Edited and issued by TAKEUCHI MFG CO LTD...

Page 261: ...8 15...

Page 262: ...of EU directives 1 Machine directive 2006 42 EC and appendix 2 Electromagnetic compatibility regulation 2014 30 EU and appendix 3 Noise directive 2000 14 EC Evaluation procedure according to appendix...

Page 263: ...machi Hanishina gun Nagano 389 0605 Japan Model Engine type Engine power The machine is in accordance with the requirements of EU directives 1 Machine directive 2006 42 EC and appendix 2 Electromagne...

Page 264: ...machi Hanishina gun Nagano 389 0605 Japan Model Engine type Engine power The machine is in accordance with the requirements of EU directives 1 Machine directive 2006 42 EC and appendix 2 Electromagne...

Page 265: ...r and birth defects or other reproductive harm Always start and operate the engine in a well ventilated area If in an enclosed area vent the exhaust to the outside Do not modify or tamper with the exh...

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Takeuchi TL8, Operator'S Manual

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