Page 1
These operating instrustions are read and
understand, otherwise injury or death is
caused.
Operating Instructions
Language version: EN
Edition: 2011-11
Order number: 5780200633
From vehicle ID No: TL08020438>
Translation of the original operating instructions
tW9
tW9
Wheel Loader
Wheel Loader
Page 2
Please complete before commissioning the wheel loader:
Vehicle model: .........................................................................................
Vehicle ID No.: .........................................................................................
Year of construction: ........................................................................................
Commissioned on: .........................................................................................
Dealer:
This operating manual is protected by limited copyright. It may be reproduced for and used by the drive /
plant operator
Wilhelm Schäfer GmbH
Bau- und Industriemaschinen
Rebhuhnstrasse 2-4
D-68307 Mannheim
Germany
Phone +49(0)621 - 7707-0
Page 3
Table of Contents
TW9
1 Introduction.........................................................................................................................1
1.1 Warranty and Maintenance............................................................................................................ 2
1.2 Copyright........................................................................................................................................ 2
1.3 Notes on using the Operating Instructions..................................................................................... 2
1.4 Environmental standards ............................................................................................................... 3
1.5 Pictograms ..................................................................................................................................... 3
1.6 Location of safety signs ................................................................................................................. 5
2 Safety and Accident Prevention........................................................................................ 7
2.1 Introductory remarks ...................................................................................................................... 7
2.2 Intended use .................................................................................................................................. 8
2.3 General safety notes...................................................................................................................... 9
2.4 Operation ....................................................................................................................................... 9
2.5 Danger zone................................................................................................................................. 10
2.6 Transport of persons.................................................................................................................... 10
2.7 Stability......................................................................................................................................... 10
2.8 Travel operation ........................................................................................................................... 11
2.9 Working Operation ....................................................................................................................... 11
2.10 Guides........................................................................................................................................ 12
2.11 Danger of falling objects ............................................................................................................ 12
2.12 Working in the vicinity of underground power lines ................................................................... 12
2.13 Working in the vicinity of overhead power lines......................................................................... 13
2.14 Operation in closed rooms ......................................................................................................... 13
2.15 Work stoppages ......................................................................................................................... 13
2.16 Change of work attachments, maintenance, repair ................................................................... 14
2.17 Recovery, loading, transportation .............................................................................................. 15
2.18 Monitoring and inspections ........................................................................................................ 15
2.19 Fire prevention ........................................................................................................................... 16
2.20 Emergency exit .......................................................................................................................... 16
2.21 Other dangers ............................................................................................................................ 16
3 Technical data...................................................................................................................17
3.1 Views............................................................................................................................................ 17
3.2 Diesel engine ............................................................................................................................... 25
3.3 Electrical system .......................................................................................................................... 25
3.4 Transmission................................................................................................................................ 25
3.5 Brakes .......................................................................................................................................... 26
3.6 Hydraulic system.......................................................................................................................... 26
3.7 Axles ............................................................................................................................................ 27
3.8 Tires ............................................................................................................................................. 27
3.9 Consumables ............................................................................................................................... 28
3.9.1 Filling quantities..................................................................................................................... 28
3.9.2 Consumable specifications.................................................................................................... 29
3.10 Permissible loads in compliance with German Road Traffic Regulations (StVZO) ................... 31
3.11 Sound level values, vibration ..................................................................................................... 31
3.11.1 Equivalent vibration values ..................................................................................................... 31
3.12 Dimensions and weights ............................................................................................................ 32
3.13 Front loader installation.............................................................................................................. 32
3.14 Bucket with parallel kinematics.................................................................................................. 33
3.14.1 Bucket with Z kinematics..................................................................................................... 33
3.15 Fork lift attachment..................................................................................................................... 34
3.16 Optional accessories (options)................................................................................................... 35
4 Operation...........................................................................................................................37
4.1 First Instruction............................................................................................................................. 37
4.2 Display elements and operating controls.....................................................................................38
4.3 Engine .......................................................................................................................................... 42
4.3.1 Starting the engine ................................................................................................................ 42
4.3.2 Monitoring during operation................................................................................................... 43
4.3.3 Switching off the engine ........................................................................................................ 43
4.4 Driver's seat / Steering wheel tilt adjustment............................................................................... 44
4.5 Heating / ventilation...................................................................................................................... 45
4.6 Lighting in compliance with German Road Traffic Regulations (StVZO)..................................... 46
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TW9
4.7 Hydroinflation of tires ................................................................................................................... 46
4.8 Driving, steering and braking ....................................................................................................... 47
4.8.1 Driving ................................................................................................................................... 47
4.8.2 Steering ................................................................................................................................. 49
4.8.3 Brakes ................................................................................................................................... 49
4.8.4 Driving on roads .................................................................................................................... 50
4.8.5 Switching off the machine (parking) ...................................................................................... 51
5 Working Operation of the machine ................................................................................. 53
5.1 General notes............................................................................................................................... 53
5.1.1 Lever controls............................................................................................................................ 53
5.2 Operation - Loader....................................................................................................................... 54
5.3 Changing work attachments ........................................................................................................ 57
5.3.1 General notes........................................................................................................................ 57
5.3.2 Assembly of work attachments..............................................................................................58
5.4 Notes on how to work with the machine ...................................................................................... 60
5.4.1 Loading.................................................................................................................................. 60
5.4.2 Scraping and grading ............................................................................................................ 60
5.4.3 Excavating............................................................................................................................. 60
6 Recovery and transport of the machine ......................................................................... 61
6.1 Recovery of the machine ............................................................................................................. 61
6.2 Loading the machine using a crane............................................................................................. 62
6.3 Transporting the machine ............................................................................................................ 62
7 Maintenance and Care...................................................................................................... 63
7.1 General notes............................................................................................................................... 63
7.2 Intervals........................................................................................................................................ 63
7.3 Regular oil analysis...................................................................................................................... 64
7.4 Warranty....................................................................................................................................... 64
7.5 Inspection parts and aids ............................................................................................................. 65
7.6 Care and cleaning........................................................................................................................ 66
7.7 Notes for winter operation............................................................................................................ 66
7.8 Checking, maintenance and inspection plans ............................................................................. 68
7.8.1 Initial inspection (hand-over inspection)................................................................................ 68
7.8.2 Daily and weekly tasks .......................................................................................................... 70
7.8.3 Overview of lubricating points ............................................................................................... 72
7.8.4 Inspection plan ...................................................................................................................... 74
7.9 Inspection and maintenance work ............................................................................................... 76
7.9.1 Engine oil............................................................................................................................... 76
7.9.2 Engine oil filter....................................................................................................................... 77
7.9.3 Cooling system - combined hydraulic oil-water cooler.......................................................... 78
7.9.4 Fuel system ........................................................................................................................... 80
7.9.5 Air filter, air intake.................................................................................................................. 82
7.9.6 V-belt ..................................................................................................................................... 85
7.9.7 Checking Valve Lash............................................................................................................. 85
7.9.8 Brakes ................................................................................................................................... 86
7.9.9 Hydraulic oil tank ................................................................................................................... 87
7.9.10 Hydraulic oil cooler .............................................................................................................. 88
7.9.11 Hydraulic oil filter ................................................................................................................. 89
7.9.12 Breather............................................................................................................................... 90
7.9.13 Axles.................................................................................................................................... 91
7.9.14 Wheels................................................................................................................................. 93
7.9.15 Injection valves.................................................................................................................... 93
7.9.16 Control cog belt for drive motor........................................................................................... 93
7.9.17 Electrical equipment ............................................................................................................ 94
7.9.18 Cab ventilation dust filter ..................................................................................................... 95
7.9.19 Windshield washer system.................................................................................................. 95
7.10 Taking out of service.................................................................................................................. 96
7.10.1 Preservation for temporary taking out of service................................................................. 96
7.10.2 During immobilization .......................................................................................................... 96
7.10.3 After the machine had been taken out of service................................................................ 96
7.10.4 Disposing of the wheeled loader ......................................................................................... 96
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TW9
8 Troubleshooting................................................................................................................ 97
8.1 General notes............................................................................................................................... 97
8.2 Engine .......................................................................................................................................... 97
8.3 No steering movement................................................................................................................. 97
8.4 Insufficient performance of service brake .................................................................................... 97
8.5 Insufficient performance of parking brake.................................................................................... 97
8.6 Hydrostatic travel drive without neutral position .......................................................................... 97
8.7 Hydraulic oil exceeds max. admissible temperature.................................................................... 98
8.8 Sluggish acceleration and deceleration, too little propulsive power ............................................ 98
8.9 Transmission works in one direction only ....................................................................................99
8.10 Transmission works in neither direction..................................................................................... 99
8.11 Loader installation is not working............................................................................................... 99
8.12 Decrease in machine's performance (loader installation)........................................................ 100
8.13 Working cylinders not operating satisfactorily.......................................................................... 100
8.14 Faults in the electrical system.................................................................................................. 100
9 Appendix.......................................................................................................................... 101
9.1 Electrical system ........................................................................................................................ 101
9.2 Equipment options ..................................................................................................................... 102
9.3 Immobilizer................................................................................................................................. 103
9.3.1 Activating the immobilizer.................................................................................................... 103
9.3.2 Deactivating the immobilizer ............................................................................................... 103
9.3.3 Learning a new key ............................................................................................................. 103
9.3.4 Learning multiple new keys................................................................................................. 104
9.3.5 Clearing learned keys.......................................................................................................... 104
9.3.6 Security functions ................................................................................................................ 104
9.3.7 Fault causes ........................................................................................................................ 105
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TW9
Page 7
Introduction 1
TW9 1
1 Introduction
You decided to buy a TW9 Wheel Loader.
The confidence placed in this model will be
rewarded by the efficient and economical
performance of the machine.
This operating manual contains all the information
and instructions that are required to handle the
machine correctly. Please read them carefully
before putting the machine into operation and
make sure that they are kept at hand at all times.
Should you need further explanations or should
anything be unclear, please contact your dealer
immediately.
Special equipment and attachments are not
included in these Operating Instructions.
We reserve the right to make improvements on the
machine within the scope of impending technical
developments, without incurring any obligation to
change these Operating Instructions.
Any modifications of products and their
equipment using extras and work
attachments which are not included in
our product range require our written
approval. If our approval is not sought,
our warranty expires, as does our
product liability.
Please state the vehicle type and vehicle
identification number when making inquiries or
orders, and in all written correspondence.
The vehicle identification number of
the machine is stamped onto the type
label (1/1).
Fig. 1 Type label
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1 Introduction
2 TW9
1.1 Warranty and Maintenance
The warranty period covers 12 months, beginning
with the day the machine is handed over or put into
operation.
Safe working conditions and good working order of
the machine are prerequisites for efficient work.
Your wheel loader fulfils these requirements when
correctly handled and when serviced and
maintained as specified.
Careful observation of the machine whilst in
function and the use of the specified fuels,
lubricants, and coolants will prevent malfunction.
Trained specialist personnel are responsible for
any servicing of the machine which requires expert
knowledge. Inspections and repairs must therefore
be carried out by your dealer’s customer service.
In respect of possible claims for damages during
the warranty period, all work specified in the
maintenance and inspection plan must be carried
out at the specified intervals.
After the warranty period, too, regular maintenance
must be performed in order to ensure that the
machine is constantly in good working order and
enjoys a reasonable service life.
Insist that only original spare parts are used in
the event of any repair work. In this way, you will
have a product of lasting high quality, thereby
ensuring that your machine maintains its original
condition.
1.2 Copyright
This instruction book is intended for use by
personnel responsible for operation, maintenance,
repair and supervision of the machine.
This operating manual is copyrighted. It contains
technical specifications and documentation which
shall not, either in whole or in part, be reproduced,
transmitted or used for the purpose of competition
without our express permission.
1.3 Notes on using the Operating Instructions
References to pictures and items
The references to pictures and items contained in
the text, such as (Fig. 12/4) or (12/4) mean figure
12, item 4.
The figures shown in this manual partly contain
additional equipment.
Symbol "Danger "
This symbol indicates a high risk of
injuries. Strictly observe the safety
instructions.
Symbol "Warning "
Not abiding by the information indicated
by this symbol might cause substantial
property or equipment damage. Strictly
observe the safety instructions.
Symbol "Note "
This symbol is employed for information
containing important notes about the
correct use and/or how to proceed. Noncompliance may lead to malfunction.
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Introduction 1
TW9 3
1.4 Environmental standards
When operating or working on the machine the
environmental standards currently valid must be
observed at all times.
During installation, repair and maintenance tasks,
particular care must be taken that substances that
would damage the environment such as
• lubricating oil and grease
• hydraulic oil
• fuel
• coolant
• cleaning fluids containing solvents
do not seep into the ground or the sewerage
system.
These substances must be kept, transported,
collected and disposed of in suitable containers.
If above-mentioned liquids seep into the ground,
their escape must be stopped immediately and the
liquid be bound with suitable binding agents. If
necessary, the soil involved must be removed.
Absorbent materials and removed soil must be
disposed of properly. The environmental standards
currently valid must be observed.
1.5 Pictograms
The following Table explains the meaning of the
pictograms which may be attached to your
machine.
Symbol Description
Danger
In Operating Instructions:
Warning
On machine:
Caution
Note
Battery charge indicator
Preheating
Engine oil pressure
Engine oil temperature
Engine oil level
Coolant temperature
Coolant level
Air filter
Hydraulic oil
Hydraulic oil level
Hydraulic oil temperature
Hydraulic oil filter clogging
indicator
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1 Introduction
4 TW9
Symbol Description
Horn
Fuel
Fuel level
Blower
Heating/ventilation
Windshield washer and wiper
system
Parking brake
Direction indicator LT/RT
Working floodlights
High-beam indicator
Rotating beacon
V
R
Travel direction
FWD/REV
Travel speed
FAST
Travel speed
SLOW
Working hydraulics shut-off
Unlocked
Locked
Float position
Symbol Description
Hazard warning system
Operating mode indicator
Operating hours
Lashing points
Suspension points for loading
by crane
First-aid kit
Fire extinguisher
On machine:
Safety distance
Danger of crushing
Danger of injury
The relevant notes in the
operating instructions should
be observed
Grease gun
Lubricating point
Air conditioning
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Introduction 1
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1.6 Location of safety signs
The safety signs are located in the following positions on the machine:
Locations of safety signs
1 Safety distance (left and right sides of lifting frame)
2 Safety distance
3 Danger of injury
4 Danger of crushing
Servicing and replacing safety signs
- The safety of the operator always has to come first.
- Safety signs must always be kept in good condition and legible.
- Replace any safety sign which has been damaged or disappeared.
- Use mild detergents and water to clean the safety signs.
- Do not use any detergents containing solvents.
- Always specify machine serial number and language when ordering safety signs.
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6 TW9
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Safety and Accident Prevention 2
TW9 7
2 Safety and Accident Prevention
2.1 Introductory remarks
Declaration of Conformity
The machine complies with the
fundamental requirements stipulated in
the applicable European guidelines.
Conformity has been proven. The
respective documents and the original of
the Certificate of Conformity are kept by
the manufacturer.
A copy of the Certificate of Conformity is
attached to the sales documents.
EC declaration of conformity
according to the machinery directive 2006/42/EC
1. We hereby declare that the earth-moving machine of type TW9:
Wheel Loader: TW9
Vehicle ID No.:TL0802
Actual productivity: 44 KW
2. complies with all the relevant requirements of Machinery Directive 2006/42/EC.
3. The machine also complies with the relevant requirements of the following Directives:
2004/108/EC (EMC), 2000/14/EC Appendix VIII (noise emission), 97/68/EC (exhaust emission)
4. Representative sound power level:
100.0 dB (A)
5. Guaranteed sound power level:
101 dB (A)
6. Applied harmonized standards:
EN ISO 12100
EN 474-1
EN 474-3
7. Document editor, who is authorized to compile technical documentation:
Maik Schulze, D 74564 Crailsheim, Kraftwerkstraße 4, Germany
8. Conformity assessment procedure according to Directive 2000/14/EC Appendix VIII as well as
voluntary type examination by: DGUV Test Prüf- und Zertifizierungsstelle
Fachausschuss Bauwesen
Landsberger Straße 309
D-80687 Munich
Notified Body number: 0515
The EC declaration of conformity only applies if the earth-moving machine is used in accordance with the
operating instructions. It includes the use of original work attachments and other work attachments, which are
mentioned in the operating instructions or in other documentation for application at this earth-moving machine.
Replaceable equipment manufactured by Dealers or third party manufacturers may only be installed and used
if the installation at the affected earth-moving machine is performed by Dealer. In all other cases, special
written approval is required from Dealer.
Date of the declaration of conformity 29.12.2009
Langenburg
Terex GmbH
Geschäftsbereich Terex Schaeff
Schaeffstraße 8
74595 Langenburg, Germany
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2 Safety and Accident Prevention
8 TW9
Read the operating instructions thoroughly and
follow the notes on safe operation before putting
the earth-moving machine into operation.
National safety regulations - e.g. the Accident
Prevention Regulations, "Earth-Moving Machinery"
(BGR 500 Chapter 2.12) and "Vehicles" (BGV
D29) in the Federal Republic of Germany - must
also be complied with when operating the earthmoving machine.
In addition to the Operating Instructions, legal
regulations governing road traffic and road safety
measures must also be observed. Such duties
could also apply in respect of e.g. handling
hazardous goods or the wearing of personal safety
gear.
Furthermore, safety laws governing work in
particular locations (tunnels, adits, quarries,
pontoons, contaminated areas, etc.) must likewise
be observed.
2.2 Intended use
The earth-moving machine with standard bucket
equipment is intended solely for work which is
suitable for the function of the machine and its
work implements.
Such work involves loosening, taking up,
transporting and dumping soil, rock or other
materials as well as loading these materials on
trucks, conveyor belts or other means of transport,
when the transport of the material is normally done
by positioning the earth-moving machine.
The assembly of special work attachments such as
multi-purpose bucket, side-dump bucket, broom,
fork lift attachment etc. allows the machine to
perform the corresponding applications.
Any usage above and beyond that specified here,
e.g. the transport of persons or the usage of the lift
equipment as work platform is regarded as
improper use. The supplier cannot be held
responsible for any damage resulting from
improper use. This risk is borne solely by the user.
Strict compliance with the operating and
maintenance instructions and the performance of
maintenance work, as well as adherence to the
maintenance intervals is also part of intended use.
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Safety and Accident Prevention 2
TW9 9
2.3 General safety notes
It is important to refrain from any working methods
which impair safety.
The earth-moving machine is only to be used if it is
in a safe, operational condition.
The manufacturer’s instructions must be complied
with for operation, maintenance, repair, assembly,
and transportation.
The plant operator must provide additional special
safety instructions, wherever necessary, for
specific local conditions.
The operating instructions and any information
pertaining to safety must be carefully kept in the
driver's cab.
The operating instructions and safety notes must
be complete and fully readable.
Safety equipment on earth-moving machines must
not be deactivated or removed.
Protective clothing must be worn during operation.
Rings, scarves and unbuttoned jackets are to be
avoided. Protective goggles, protective boots,
helmets, gloves, reflecting jackets, ear-muffs, etc.
may be required.
Before commencing work, information must be
obtained on first aid and possible means of rescue
(emergency ambulance, fire brigade, helicopters).
A check must be carried out to ensure that the first
aid box is at hand and that its contents comply with
regulations.
Personnel must be aware of the location and
method of operation of the fire extinguishers on the
earth-moving machine as well as on-site firewarning and fire-fighting equipment.
Loose parts such as tools or other accessories
must be secured to the earth-moving machine.
Open doors, windows, covers, flaps, etc. must be
closed or secured so that they cannot slam shut.
2.4 Operation
Earth-moving machines shall only be
independently operated and serviced by persons
who
• are physically and mentally suitable
• have been instructed in the operation or
maintenance of earth-moving machines and
have demonstrated this ability to the plant
operator
• can be expected to perform their allocated
duties reliably.
All such persons must be of the legal minimum
age.
They must be designated by the plant operator to
operate or service the earth-moving machine.
Operating equipment and controls are only to be
operated from the driver’s seat.
The earth-moving machine is only to be ascended
and entered using the entrances and surfaces
intended for this purpose.
It is the driver’s responsibility to ensure that the
operator’s stand, entrances and other surfaces of
the earth-moving machine which have to be
stepped on are free of dirt, grease, oil, ice and
snow.
The following driving license categories are
required for driving a wheeled loader on public
highways:
Driving license categories
≤3500 kg >25 km/h = B, C1, C, T
≤7500 kg ≤25 km/h = L, C1, C, T
≤7500 kg >25 km/h = C1, C, T
>7500 kg ≤25 km/h = L, C, T
>7500 kg >25 km/h = C, T
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2 Safety and Accident Prevention
10 TW9
2.5 Danger zone
Nobody must be allowed to remain in the danger
zone of an earth-moving machine.
The danger zone encompasses the
area around the earth-moving machine
in which persons may be injured by
movements of the earth-moving
machine during operation, its work
implements and attachments, or by
swinging out or falling loads.
The machine operator is only to work the earthmoving machine if nobody is in the danger zone.
The machine operator must give a warning signal
to persons who may be in danger.
The machine operator must stop work with the
earth-moving machine if someone remains in the
danger zone despite the warning.
To ensure no danger of crushing, a sufficient
safety distance (min. 0.5 m) must be kept from
solid objects, e.g. buildings, excavation slopes,
scaffolding, other machines, etc.
If the above safety distance cannot be maintained,
the area between solid objects and the working
zone of the earth-moving machine must be blocked
off.
If conditions are such that the machine operator’s
view of the driving and working zone is restricted,
he must be guided or the driving and working zone
must be marked by a solid barricade.
2.6 Transport of persons
The transport of persons on the machine is
forbidden.
2.7 Stability
The earth-moving machine must be used, driven
and operated in such a manner that its stability
against overturning is ensured at all times.
The machine operator must drive at speeds which
are suitable for local conditions.
The permitted payload of the earth-moving
machine must not be exceeded.
The earth-moving machine must remain at a
sufficient distance from the edges of quarries, pits,
mounds and slopes to ensure there is no risk of
falling.
Earth-moving machines must be secured so that
they cannot roll or slip when in the vicinity of
excavations, shafts, ditches, pits and slopes.
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Safety and Accident Prevention 2
TW9 11
2.8 Travel operation
Before putting the earth-moving machine into
operation, the driver’s seat, mirrors and operator
controls must be adjusted so as to ensure safe
working.
A safety belt (seat belt), if installed, must always be
fastened.
The windows must be clean and free of ice.
Driving tracks must be designed so as to ensure
smooth, safe operation, i.e. they must be
sufficiently wide, on ground which has as few
slopes as possible and sufficient carrying capacity.
Downhill tracks must be set out in such a way that
earth-moving machines can be safely braked.
Before driving downhill, the appropriate gear for
the terrain must be selected and the gear lever not
be moved during downhill travel (road or off-road
gear).
On steep drops and uphill gradients, the load must
be carried on the uphill side, if possible, in order to
increase stability.
Before driving downhill, the appropriate gear for
the terrain must be selected and the gear lever
shall not be moved during downhill travel (on-road
or off-road gear).
The internal dimensions of constructions must be
noted before entering underground passages,
tunnels, etc.
It is the plant operator's responsibility to ensure
that equipment such as first-aid box, warning
triangle, hazard lights are kept with the earthmoving machine according to the traffic regulations
valid in the user’s country and that the driver has
the appropriate license as required by the national
traffic laws of the country in question.
Outside areas covered by general traffic
regulations, e.g. on factory premises, traffic
regulations should be applied in the proper
manner. This should also apply with regard to
drivers’ licenses.
2.9 Working Operation
Daily before start of operation and after every
attachment change, the machine operator must
check the correct fastening of the work
attachments as well as the correct locking of the
quick-mount hitch. Work attachments are to be
carefully moved at low height. During this check
nobody must be allowed to remain in the danger
zone of the earth-moving machine.
The machine operator shall only swing the work
equipment over occupied driver’s seats, operator
consoles and workplaces of other machines when
these are protected by overhead guards (FOPS).
If a cabin does not have the required protection,
the driver of this vehicle must leave the operator’s
stand while the work equipment is being swung
overhead.
The vehicles must be loaded in such a manner as
to ensure that there is no overloading and no
material can be lost as long as the machine is
moving. The vehicle must be loaded from the
lowest possible height.
The weight of each load must be evenly distributed
before it is moved. Unequal weight distribution can
have a negative effect on the stability of the
machine. The operator must be familiar with onsite conditions and work at a speed which is both
safe and highly efficient.
At dumping points, earth-moving machines may
only be operated if suitable measures have been
taken to prevent rolling or falling.
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2 Safety and Accident Prevention
12 TW9
2.10 Guides
Guides must be easily recognizable, e.g. by means
of reflective clothing. They must remain within the
machine operator’s field of vision.
While guiding the machine, guides shall not be
given other jobs which may distract them from their
task.
2.11 Danger of falling objects
Earth-moving machines are only to be used where
there is a danger of falling objects if the operator's
stand has a canopy (FOPS). A front guard must
be employed if there is a risk of materials breaking
through into the cabin.
In front of walls e.g. of stacked materials, earthmoving machines must be positioned and operated
in such a way that the driver's seat and entry to the
driver's seat are not situated on the side facing the
wall.
Demolition work is only to be performed by earthmoving machines where there is no danger to
persons and if the machine is equipped with
canopy, cabin-mounted front guard and the
appropriate work implement.
See regulations book "Demolition work" (ZH 1/614)
published by the German TiefbauBerufsgenossenschaft (Civil Engineering
Employer’s Liability Insurance Association).
2.12 Working in the vicinity of underground
power lines
Before commencing excavating work using earthmoving machines, it must be determined whether
any underground power lines are present in the
intended working zone which may present a
danger to persons.
If underground power lines are present, their exact
position and course must be determined in
consultation with the proprietor or operator of the
lines, and the necessary safety precautions
decided and implemented.
The course of power lines in the work area must be
clearly marked, under supervision, before
commencing any excavation work. If the position of
lines cannot be determined, search ditches must
be dug - manually, if need be.
If underground power lines are encountered
unexpectedly or they or their protective covers are
damaged, the machine operator must discontinue
work immediately and notify the supervisor.
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Safety and Accident Prevention 2
TW9 13
2.13 Working in the vicinity of overhead power
lines
If the earth-moving machine is being used in the
vicinity of overhead power lines and trolley wires, a
safety distance which varies depending on the
nominal voltage of the overhead line must be
maintained between the lines and the earthmoving machine and its work equipment, to
prevent current overspill. This also applies to the
distance between these lines and attached
implements or loads.
The safety distances specified below must be
complied with:
Nominal voltage in Volt Safety distance in
meters
- 1,000 V 1.0 m
more than 1 kV - 110 kV 3.0 m
more than 110 kV - 220
kV
4.0 m
more than 220 kV - 380
kV
5.0 m
nominal voltage unknown 5.0 m
In the observation of safety distances, all working
movements of earth-moving machines, e.g.
positions of the work equipment and the
dimensions of attached loads must be taken into
consideration. Uneven ground which would cause
the earth-moving machine to be inclined and thus
nearer to overhead lines must also be taken into
account.
During work in windy conditions, both overhead
lines and work equipment may swing out, thus
reducing the safety distance.
If it is impossible to maintain sufficient distance
from overhead power lines and trolley wires, the
plant operator must consult with the proprietor or
operator of the overhead lines to find other safety
precautions to prevent current overspill. Such
measures could be, e.g.
• Switching off the current
• Re-routing the overhead line
• Cabling, or
• Limiting the work zone of earth-moving
machines.
2.14 Operation in closed rooms
If earth-moving machines are to be used in closed
spaces, these areas must be sufficiently ventilated
and special regulations observed.
Breathing in the resulting engine fumes
in closed areas is a health hazard and
can result in unconsciousness or even
death.
• You must ensure that adequate air
supply and ventilation is available
and that you always abide by the
applicable regulations.
The working height may be restricted
when working in enclosed spaces,
under facades, superstructures, highvoltage lines, or similar.
This can lead to damage.
2.15 Work stoppages
Before rest periods and at the end of the working
day, the driver of the earth-moving machine must
park the machine on ground which has sufficient
carrying capacity and is as level as possible, and
must secure it against unintended movement.
Before rest periods and at the end of the working
day, the driver must lower the work equipment onto
the ground or secure it so that it cannot move.
The driver is not to leave the earth-moving
machine if the work equipment has not been
lowered to the ground or secured.
Earth-moving machines shall only be parked in
places where they do not present an obstacle, e.g.
on the construction site or to plant traffic. Warning
devices, e.g. triangles, warning cordons, flashing
or hazard lights are to be used if necessary.
Before leaving the operator stand, the driver must
bring all operating equipment and controls into
home position, switch off the working hydraulics
and apply the brakes.
If the driver is leaving the earth-moving machine
unattended, he must first turn off the drive motors
and ensure that they cannot be started up by
unauthorized persons (e.g. removing ignition keys).
Page 20
2 Safety and Accident Prevention
14 TW9
2.16 Change of work attachments,
maintenance, repair
Earth-moving machines shall only be converted,
maintained or serviced under the guidance of a
suitable person designated by the plant operator
and following the manufacturer’s Operating
Instructions.
After every change of work attachments, the driver
must convince himself that the quick-attach system
is correctly fastened and locked.
Work on e.g.
• brake systems,
• steering systems,
• hydraulic and
• electric systems
of the machine is only to be carried out by expert
personnel specially trained in these areas.
Stability must be ensured during all type of work on
the machine at all times.
The work equipment must be secured against
movement by lowering it to the ground or
equivalent measures, e.g. cylinder supports,
trestles. With the engine running, the unprotected
articulation range of articulated loaders shall not be
entered.
When jacking up earth-moving machines, jacking
devices must be positioned so that they cannot
slip. Jacks must be positioned and applied
absolutely straight, without tilting.
Raised earth-moving machines must be supported
by suitable structures such as crosswise stacks of
planks, square timbers or steel trusses.
Stabilize the earth-moving machine that has been
lifted with the work attachment, immediately after
lifting with a supporting structure. Work under
raised machines which are only supported by their
hydraulics is forbidden.
The engine/motor(s) must be turned off prior to all
maintenance and repair work. These requirements
may only be ignored in the case of maintenance or
repair work which cannot be performed without the
engine/motor(s) running.
When performing maintenance and repair work on
the hydraulic system, the hydraulic system must be
relieved of pressure. With the engine turned off,
lower the work equipment to the ground and
actuate all hydraulic control levers until there is no
pressure in the hydraulic system.
Before working on the electrics or when performing
arc-welding on the machine, the connection to the
battery must be disconnected.
When disconnecting the battery, first the negative
pole then the positive pole must be disconnected.
The battery must be re-connected in reverse order.
During repair work around the battery, it must be
covered with insulating material. Tools should
never be placed on or near the battery.
Protective devices of moving machine parts are
only to be opened or removed after the drive has
been switched off and cannot be switched on
again by unauthorized persons. Protective devices
are e.g. engine/motor covers, doors, protective
grating, trim.
Upon completion of assembly, maintenance or
repair work, all protective devices must once more
be attached in the proper manner.
Load-bearing parts of earth-moving machines are
only to be welded following consultation with the
manufacturer and in accordance with recognized
welding principles.
Protective structures (ROPS; FOPS) are not to be
welded or drilled in any way.
Page 21
Safety and Accident Prevention 2
TW9 15
Before commencing work on the hydraulic system,
the operating pressure, pilot pressure, back
pressure and pressure inside the tank must be let
off.
Alterations, such as welding of the hydraulic
system, are only to be undertaken with the
manufacturer’s permission.
Swallowing lubricants as well as long and repeated
skin contact can be hazardous to health and
should therefore be avoided. When used properly,
there is no particular danger to health. The safety
specification sheets from the mineral companies
must be observed.
Only the hoses specified by the manufacturer shall
be used.
Hydraulic hoses must be routed and assembled by
expert personnel.
In the vicinity of fuel or batteries, smoking and
naked flames are prohibited.
2.17 Recovery, loading, transportation
Earth-moving machines are only to be loaded onto
recovery vehicles if adequate towing vehicles are
used.
The tow fixing points specified by the manufacturer
must be employed.
For loading and transportation, earth-moving
machines and all necessary auxiliary equipment
must be secured against unwanted movement.
The traveling gear and crawler unit of earth-moving
machines must be sufficiently cleaned of mud,
snow and ice to ensure that ramps can be driven
up without risk of slipping.
When transporting the earth-moving machine on
trucks, flatbed trailers, or by rail, it must be
sufficiently secured with chocks and by attachment
to the lashing points.
Before setting off, the route to be taken must be
examined to determine whether the roads are wide
enough, entrances and passages under bridges
are large enough and that roads and bridges have
sufficient carrying capacity.
2.18 Monitoring and inspections
The machine must be submitted to a general
inspection according to the existing UVVregulations (Accident Prevention Regulations).
This inspection must be carried out by an expert
(e.g. machine engineer or machine foreman):
• before the machine is put into operation for the
first time and before the machine is again put
into operation after essential modifications have
been made
• at least once a year
• in the meantime, according to operating
conditions and local environments.
The results of this inspection have to be recorded
in writing and this record kept until the next
inspection takes place.
Prior to every work shift, the machine operator
must check the earth-moving machine according to
the inspection and maintenance plan.
Hydraulic hoses must be replaced as soon as the
following damage is recognized:
• Damage to the outer layer which reaches the
intermediate layer,
• Embrittled patches on the outer layer,
• Deformations when under pressure or without
pressure which differ from the original shape of
the installed hose,
• Leaks,
• Damage to hose fittings or to the connection
between the fitting and the hose.
The coolant level may only be checked after the
engine has cooled down; the cap must be turned
carefully in order to let off excess pressure.
Prior to operations, the machine operator must
check the function of the safety devices.
The machine operator must advise the supervisor
immediately - and his replacement, if there is a
change of operator - with regard to any
shortcomings.
In the event of shortcomings which jeopardize the
operating safety of the earth-moving machine, it is
not to be used until these have been eliminated.
Page 22
2 Safety and Accident Prevention
16 TW9
2.19 Fire prevention
• Switch off the engine when filling the fuel tank
and take special care as long as the engine is
hot.
• Never smoke or handle open flames whilst
refueling the tank of the machine.
MTK115002
The fire extinguisher must be kept in
the cabin (operator’s stand). The fire
extinguisher symbol must be
attached.
2.20 Emergency exit
The right-hand cab door acts as an emergency
exit.
2.21 Other dangers
Failure of hydraulic system
If the hydraulic system fails because the diesel
engine is not running, the hydraulic pump is
damaged or hydraulic oil has been lost, only the
following emergency functions can still be
performed:
• manual steering (without servo assistance) and
• lower work equipment (only if ignition is
switched on).
Page 23
Technical data 3
TW9 17
3 Technical data
3.1 Views
• General-purpose bucket and parallel kinematics
Fig. 3 Dimensioned drawing - standard bucket and parallel kinematics
Tires 405/70 R18
Page 24
3 Technical data
18 TW9
• Multi-purpose bucket and parallel kinematics
Fig. 4 Dimensioned drawing - multi-purpose bucket and parallel kinematics
Tires 405/70 R 18
Page 25
Technical data 3
TW9 19
• Fork lift attachment and parallel kinematics
Fig. 5 Dimensioned drawing - fork lift attachment and parallel kinematics
Tires 405/70 R 18
Page 26
3 Technical data
20 TW9
• General-purpose bucket and Z kinematics
Fig. 6 Dimensioned drawing - standard bucket and Z kinematics
Tires 405/70 R18
Page 27
Technical data 3
TW9 21
• Multi-purpose bucket and Z kinematics
Fig. 7 Dimensioned drawing - multi-purpose bucket and Z kinematics
Tires 405/70 R18
Page 28
3 Technical data
22 TW9
• Fork lift attachment and Z kinematics
Fig. 8 Dimensioned drawing - fork lift attachment and Z kinematics
Tires 405/70 R18
Page 29
Technical data 3
TW9 23
• Low profile canopy with general-purpose bucket 0.8 m³
Fig. 9 Dimensioned drawing - low profile canopy with standard bucket 0.8 m³
Tires 15.5/55 R18
Page 30
3 Technical data
24 TW9
• Fold-down bar with general-purpose bucket 0.8 m³
Fig. 10 Dimensioned drawing - fold-down bar with standard bucket 0.8 m³
Tires 15.5/55 R18
Page 31
Technical data 3
TW9 25
3.2 Diesel engine
Manufacturer, model Deutz, D 2011 L04 W
Type 4-cylinder diesel engine
Exhaust-optimized engine EU level III EPA-Interim tier 4
Combustion 4-stroke cycle, direct fuel injection
Stroke displacement 3600 cm³
Output 44.0 kW (67 HP) at n=2,200 rpm
Performance and exhaust standards ISO 14396 / EC-R-120
Torque Max 210 Nm / 1,700 rpm
Specific fuel consumption at nominal
engine speed
235 g/kWh
Cooling Water-antifreeze mixture for all-year operation
Heating Fresh air with heat exchanger connected to coolant circuit
3.3 Electrical system
Nominal voltage 12 V
Battery 12 V / 100 Ah / 900 A (EN) (DIN EN50342)
Generator 14 V 95 A
Starter 12 V / 2.6 kW
Cold starting aid Heater plug 12 V
Lighting system in compliance with German and European standards
3.4 Transmission
Transmission Variable displacement pump, flange-mounted directly onto
diesel engine, two-stage variable displacement motor with
power shift on rear axle reduction gear.
High-speed version featuring rear axle manual transmission
shiftable in standstill position.
Suction return filter in the form of a tank insert filter.
Travel speed Forward - Reverse
TW9 TW9 S
Travel range I Travel range
II
Travel range
"Work"
0 - 7 km/h 0 - 7.0 km/h 0 - 14 km/h
Travel range
"Road"
0 - 20 km/h 0 - 18 km/h 0 - 36 km/h
Power transmission
Hydrostatic travel drive, closed circuit, independent from loader
installation. Automatic optimization and adjustment of drawbar
pull and speed. The travel drive in closed circuit additionally
acts as non-wearing service brake. Continuous speed
regulation both forward and in reverse. Four-wheel drive via
propeller shaft connection.
Operating pressure - driving max. 420 bar
Page 32
3 Technical data
26 TW9
3.5 Brakes
Service brake Hydraulically actuated center-mounted disk brake, combined with
hydrostatic brake of travel drive.
Brake acts on all 4 wheels via 4-wheel drive.
Parking brake Mechanically actuated center-mounted disk brake at front axle.
Additional brake The hydrostatic travel drive in closed circuit additionally acts as
non-wearing service brake.
3.6 Hydraulic system
Hydraulic pump Gear pump on throughdrive of variable displacement pump.
Pump capacity: max. 64 l/min.
Working pressure, steering: 175 bar
Working pressure, loading: 250 bar
Priority valve Priority supply of hydraulic oil to steering through load-sensing
system, ensuring that all the available oil can be provided if
necessary. Rapid steering movements even at low engine revs.
Steering Fully hydraulic, proportionally acting articulated steering.
One steering cylinder with end-position damping at both ends.
Total steering angle 80°
Loader installation
Parallel kinematics
Double-acting work cylinders, one lift cylinder, and one tilt cylinder.
Z kinematics
Double-acting work cylinders, two lift cylinders, and one tilt
cylinder.
Hydraulic proportionally-actuated control valve with 3 control
circuits. Work functions: “Lift / lower”, “Dump / tilt-back”, “Additional
control circuit”.
Third control circuit as fingertip control, electro-proportional
control, oil flow limited via potentiometer, continuous operation
circuit, installation on loading frame incl. plug-in couplings.
Hydraulically-operated float position for the "Lower" work function
if "lowering" pressure point on joystick is exceeded, electricallyactivated locking effect for continuous "Float" operation.
Single, four-way control lever (joystick) with integrated travel
direction switch and switch for additional control circuit.
Additional control circuit Max. oil flow 64 l/min
Max. operating pressure 230 bar
Hydraulic oil cooler Thermostatically controlled.
Page 33
Technical data 3
TW9 27
3.7 Axles
Front axle Rigidly-mounted planetary drive with integrated center-mounted
disc brake.
Self-locking differential (45%) as standard.
Rear axle (standard) Oscillating planetary drive axle with self-locking differential and
integrated reduction gear.
Rear axle (high-speed version) Oscillating planetary drive axle with self-locking differential and
integrated 2-stage reduction gear.
Angle of oscillation ± 10°
3.8 Tires
Tire size Tire pressures
front
Tire pressures
rear
12.5-18 MPT 2.8 1.8
12.5-20 MPT 2.5 1.8
14.5-20 MPT 2.0 1.5
335/80 R20 XM 2.5 1.7
335/80 R20 EM 2.5 2.5
405/70 R18 3.0 2.5
Special tires available on request!
If solid-rubber or foamed tires are used, special measures must be taken and restrictions apply.
The tire pressure refers to standard equipment.
During fork lift operations, the tire pressure of the front wheels must be increased by at least
0.5 bar.
Page 34
3 Technical data
28 TW9
3.9 Consumables
3.9.1 Filling quantities
All values stated are approximate.
Fluid capacities in
liters
Fuels and lubricants
Fuel tank approx. 75.0 Diesel fuel
Engine with oil filter approx. 9.0 Engine oil (change quantity)
Hydraulic oil, tank and system approx. 55.0* Hydraulic oil
Hydraulic oil tank approx. 46.0 Hydraulic oil (change quantity)
Service brake approx. 0.25 ATF-oil
Front axle center housing approx. 3.8 Transmission oil
Rear axle center housing and transmission
(standard)
approx. 4.5 Transmission oil
Rear axle center housing and transmission
(high-speed version)
approx. 6.0 Transmission oil
Wheel hubs, front / rear axle each
approx.
0.6 Transmission oil
Coolant each
approx.
15 Mixture of water, additives and
glycol
* The hydraulic oil quantity depends on the equipment level of the machine
The filling level indication is always the decisive factor
Page 35
Technical data 3
TW9 29
3.9.2 Consumable specifications
Stipulated consumables for Central Europe
Application Designation
Specification, standards,
quality
Remark
Engine Diesel fuel EN 590
ASTM D975 1-D / 2-D
Before using RME fuels (rape oil methyl
ester), it is essential that you consult your
responsible dealer for further details.
Engine Engine oil SAE 15W-40
API CH-4 or CI-4
ACEA E3 / E4
See also engine manufacturer’s instructions
Hydraulic system
Hydraulic oil or
multi-grade
engine oil
HVLP 46
or
SAE 10W-40
The following viscosity limit values must be
observed (according to ASTM 445)
at 100°C min. 8 mm 2/s (cSt)
at -10°C approx. 1,500 mm 2/s (cSt)
Bio-degradable
hydraulic oil
based on
synthetic ester
Filling according to customer
specifications. Brand label on
machine.
Do not mix bio-
degradable oils from
different manufacturers.
The same viscosity values apply as for mineral
hydraulic oils.
When changing from mineral to bio-
degradable hydraulic oils, the tank and
hydraulic system must be completely drained,
cleaned, and flushed.
For further details, please consult your
responsible dealer before changing oils.
Axles Transmission oil SAE 85W-90LS
API-GL 5
Alternative recommendations
SAE 90LS
SAE 80W-90LS
Lubrication points
Multi-purpose,
lithium-soap
based grease
K2K-30
DIN 51825
Brake Brake oil ATF
Type A Suffix A
Dexron-IID
Cooler
Mixture of water,
additives and
glycol
Machine damage
due to incorrect coolant
and mix proportions.
Observe the cooling
system information
provided in the engine
manufacturer's
Operating and
Maintenance Manual.
The antifreeze is factory-set to approx. -25°C.
Page 36
3 Technical data
30 TW9
Alternative recommendation for other temperature ranges
Engine oil
In compliance with API CH-4 or CI-4 and
In compliance with ACEA E3 / E4
Hydraulic oil
In compliance with DIN 51524.T3 HVLP
-30
-22
-20
-4
-10
14
0
32
10
50
20
68
30
86
°C
°F
Umgebungstemperatur/Ambient temperature/Température ambiante
0W-30
0W-40
5W-30
5W-40
10W-30
10W-40
15W-40
20W-50
Viskode
Cold weather kit
A cold weather kit is optionally available for wheeled loader operation below -15°C.
Note that 5W-30 engine oil is changed back
to standard oil with viscosity class SAE
15W-40 at temperatures >+30°C.
Page 37
Technical data 3
TW9 31
3.10 Permissible loads in compliance with German Road Traffic Regulations (StVZO)
Permissible total weight see type label,
Permissible axle load, front and / or
Permissible axle load, rear AllgemeineBetriebsErlaubnis (General
Certification)
3.11 Sound level values, vibration
Sound level values in compliance with directive 2000/14/EC and EN 474
Guaranteed sound power level LWA = 101 dB (A)
Sound pressure level (at driver's ear) LPA = 76 dB (A)
Vibration values in compliance with directive 2002/44/EC and EN 474
Effective values of acceleration below 0.5 m/s2 for entire body
and 2.5 m/s2 for the upper body limb
dimensions
3.11.1 Equivalent vibration values
Equivalent vibration values for entire body vibration emission according to ISO/TR 25398
Average value Standard deviation
1,4*α
w,eqx
1,4*α
w,eqy
a
w,eqz
1,4*Sx 1,4*Sy Sz
Type of
machine
Typical
operating
condition
m/s²
Compact
wheeled
loader
<4500kg
Load & carry 0.94 0.86 0.65 0.27 0.29 0.13
Load & carry 0.84 0.81 0.52 0.23 0.20 0.14
Use in quarrying 1.27 0.97 0.81 0.47 0.31 0.47
Transition travel 0.76 0.91 0.49 0.33 0.35 0.17
Wheeled
loader
>4500kg
V-shaped motion 0.99 0.84 0.54 0.29 0.32 0.14
Page 38
3 Technical data
32 TW9
3.12 Dimensions and weights
Specifications refer to general-purpose bucket and 405/70 R18 tires
Parallel
kinematics Z kinematics
Operating weight with standard equipment according to ISO
6016
kg 4,900 4,900
Total length, standard bucket on ground mm 5,060 5,085
Total width mm 1,850 1,850
Total height (cab roof) mm 2,640 2,640
Unladen weight mm 4,800 4,800
Wheel base mm 2,100 2,100
Track width FR / RR mm 1,390 1,390
Rear overhang angle ° 35 35
Ground clearance below propeller shaft mm 435 435
Turning radius at outside edge of bucket in transport position mm 4,160 4,160
Turning radius at outside edge of tires mm 3,780 3,780
Turning radius at inside edge of tires mm 1,980 1,980
3.13 Front loader installation
Specifications refer to general-purpose bucket and 405/70 R18 tires
Parallel
kinematics
Z kinematic
s
Width of bucket mm 1,850 1,850
Capacity in accordance with ISO 7546 (max. density = 1.8 t/m ³) approx. m³ 0.8 0.8
Payload in bucket 0.8 m³ x 1.8 t/m³ or 0.9 m³ x 1.6 t/m³
kg 1,440 1,440
Dump height at 45° dump angle approx. mm 2,550 2,550
Dump reach at max. dump height approx. mm 700 710
Max. bucket hinge pin height approx. mm 3,200 3,220
Reset angle ° 50 50
Dump angle at max. dump height ° 45 45
Digging depth, horizontal bucket approx. mm 100 110
Lift capacity at ground level according to ISO 14397-2 N 48,000 48,400
Ripping force at cutting edge of bucket according to ISO 14397-2 N 45,900 47,300
Tipping load, straight according to ISO 14397-1 kg 3,720 3,720
Tipping load, articulated according to ISO 14397-1 kg 3,280 3,280
Work cycle times, "Lift" sec. 4.7 4.9
Work cycle times “Lower” sec. 3.2 3.4
Dumping in uppermost position "In" sec. 1.1 1.1
Dumping in uppermost position, "Out" sec. 1.3 0.8
Stability conforms to ISO 14397-1
Page 39
Technical data 3
TW9 33
3.14 Bucket with parallel kinematics
Width
mm
Capacity, heaped
m³
Max. density (γ)
t/m3
General-purpose bucket 1850 0.8 1.8
Bucket with bolt-on cutting edge 1,850 0.8 1.8
Earth bucket 1850 0.9 1.6
Earth bucket with bolt-on cutting edge 1,850 0.9 1.6
Multi-purpose bucket 1,850 0.75 1.6
Multi-purpose bucket with bolt-on cutting edge 1,850 0.75 1.6
Light-material bucket with bolt-on cutting edge 1,850 1.0 1.2
Light-material bucket with bolt-on cutting edge 1,950 1.2 0.8
Side-dump bucket 1,850 0.7 1.8
High-tip bucket 1,850 0.7 1.2
3.14.1 Bucket with Z kinematics
Width
mm
Capacity,
heaped
m³
Max. density (γ)
t/m³
Standard bucket 1,850 0.8 1.8
Bucket with bolt-on cutting edge 1,850 0.8 1.8
Earth bucket 1,850 0.9 1.6
Earth bucket with bolt-on cutting edge 1,850 0.9 1.6
Multi-purpose bucket 1,850 0.75 1.6
Multi-purpose bucket with bolt-on cutting edge 1,850 0.75 1.6
Light-material bucket with bolt-on cutting edge 1,850 1.0 1.2
Light-material bucket with bolt-on cutting edge 1,950 1.2 0.8
Side-dump bucket 1850 0.7 1.8
High-tip bucket 1850 0.7 1.2
Page 40
3 Technical data
34 TW9
3.15 Fork lift attachment
Fork-arm connection in compliance with ISO/FEM Class 2 Form B, DIN 15 173 / ISO 2328 respectively
Width of fork carrier mm 1,240
Length of forks mm 1,100
Fork cross section mm 100x45
Max. stacking height mm 3,070
The payloads are determined in compliance with DIN 24094 / ISO 14397-1 and EN ISO 474-3 respectively
with a safety factor of 1.25 or 80% of the tipping load and the machine moving over level ground.
The payloads in crane operation are determined with load hooks on the forks, at a 500 mm load radius from
the rear of the fork, according to ISO 14397-1 with a stability factor of 2.0 / 50% of the tipping load.
The payloads are valid for a machine fitted with 12.5-20MPT 10PR tires and in a condition in compliance with
ISO 6016.
Total lift range
S=2.0 S=1.25
kg
1,250
2,050
lbs
2,750 4,400
kg
lbs
kg
1,380
2,250
500mm
19,7inch
+0,5bar
+7,3psi
+
kg
lbs
kg
lbs
lbs
3,030 4,840
Transport position
S=1.67 S=1.25
kg 1,720 2,300
lbs 3,790 5,060
kg
lbs
kg 1,870 2,500
500mm
19,7inch
+0,5bar
+7,3psi
+
kg
lbs
kg
lbs
lbs 4,120 5,500
kg
lbs
If screw-on rear axle weights or rear tires with hydroinflation are used.
During fork lift operations, the tire pressure of the front wheels must be increased by at least
0.5 bar.
Page 41
Technical data 3
TW9 35
3.16 Optional accessories (options)
• Orthopedic air-cushioned driver's seat
• Fire extinguisher
• Pressurized cab
• Air-conditioning
• Independent diesel heating with timer
• FOPS-roof guard
• Sliding window in right-hand door
• Working floodlight, rear
• Yellow rotating beacon
• Radio installation kit
• Sliding window, right-hand door
• Diesel exhaust cleaner
• Catalyst
• High-speed version
• Anti-teft device (immobilizer)
• Back-up alarm system
• Overload warning device
• Bucket return positioner
• Electrical tank refilling pump
• Quick-attach system, hydraulically operated
• Snow blade
• Sweeper
• Load hook for attaching to forks
• Rear axle weights
• Outlet for hydraulic hand hammer
• Filling with biodegradable hydraulic oil (ester-based "BIO-E-HYD-HEES")
• Hitch for agricultural or forestry tractor
Further optional equipment available on request!
Any modifications of products and their equipment using extras and work attachments which are
not included in our product range require our written approval. If our approval is not sought, our
warranty expires, as does our product liability for any resulting consequential damage.
Page 42
3 Technical data
36 TW9
Page 43
Operation 4
TW9 37
4 Operation
4.1 First Instruction
The machine must be entered from
the left-hand side as seen in the
direction of travel.
The right-hand cab door acts as an
emergency exit.
If the cab is entered by the right-hand
door, the joystick may be operated
unintentionally.
If you are not familiar with the operator controls
and display elements of this machine, read this
Chapter carefully before operating the machine.
This Chapter deals with all functions.
Before driving and working with the machine it is
necessary to thoroughly familiarize yourself with
the display elements and operator controls.
Each time before putting the machine into
operation it must be subjected to a thorough visual
inspection. Ensure that there is no damage, loose
or missing screws, oil accumulations, oil or fuel
leakage. Shortcomings must be remedied
immediately. In the event of shortcomings which
jeopardize the operating safety, the machine must
not be put into operation until these have been
eliminated.
Before putting the machine into operation, the
inspections according to chapter 7.8 must be
carried out.
Page 44
4 Operation
38 TW9
4.2 Display elements and operating controls
The following list includes non-standard equipment!
• Operating controls
Fig. 10.1 Operator controls
Page 45
Operation 4
TW9 39
Description of fig. 10.1 - Operator controls
1 Direction indicator, horn, low/-high beam (steering-column switch)
2 Brake-inching pedal
3 Accelerator pedal
4 Steering wheel - tilt and height adjustment
5 Stop button - additional control circuit
6 Control light
7 Actuation – potentiometer, 3rd control circuit
8 Travel direction switch (without function if working hydraulics are deactivated)
9 Impulse mode - float position
10 Power socket
11 Fuse carrier
12 Fresh air - recirculating air
13 Radio
14 Control rod for mechanical quick-attach device
15 Washer fluid tank
16 Parking brake
Page 46
4 Operation
40 TW9
• Instrument panel
Fig. 10.2 Operator controls
Page 47
Operation 4
TW9 41
Description of fig. 10.2 - Instrument panel
20 Not assigned
21 ORANGE - pre-heating monitor
22 RED - battery charge indicator
23 RED - parking brake
24 GREEN - travel direction, forward
25 Coolant temperature
26 Operating hour meter
27 Fuel-level indicator
28 GREEN - travel direction, reverse
29 GREEN - direction indicator
30 BLUE - high beam
31 RED - engine oil pressure
32 RED - air filter indicator
33 Travel speed - FAST - SLOW
34 High-gear changeover switch
Only press if machine is at
standstill!
35 Multi-function switch with lock for
"working equipment" cut-off and
change-over of the "travel direction
preselection switches" from pos. 8 to
pos. 36
Only press if machine is at
standstill!
36 Preselection of travel direction -
Function only active if working
hydraulics are disabled
37 Not assigned*
38 Not assigned*
39 Not assigned*
40 Windshield washer function front/rear
41 Windshield wiper, front
42 Windshield wiper, rear
43 --
44 Fan switch - heating
45 Switch - air-conditioning
46 Not assigned*
47 Preselection button for actuation – 3rd
control circuit
48 Preselection button – float position
continuous operation
49 Not assigned*
50 Glow plug and starter switch
51 Hazard warning switch
52 Working floodlight front - switch on the
parking light (fig. 10.1, pos. 1)
53 Working floodlight rear - switch on the
parking light (fig. 10.1, pos. 1)
54 Not assigned*
55 Not assigned*
56 Potentiometer "flow rate" - 3rd control
circuit
57 Control - heating/air-conditioning
58 Monitor - indicator "manual
transmission range I"
59 Monitor - indicator "manual
transmission range II"
60 Monitor - indicator "manual
transmission not ready for operation"
If this symbol comes up, the
manual transmission is in an
intermediate position. The
machine is not ready for
driving! This can be remedied
by performing brief steering
movements until the manual
transmission engages.
61 Speed indicator
* for non-standard equipment
Page 48
4 Operation
42 TW9
4.3 Engine
4.3.1 Starting the engine
Each time before putting the machine
into operation, the inspections
according to section 7.8 must be
carried out.
Before switching on the engine, take
care to ensure that no one is in the
immediate vicinity of the machine or in
the danger zone.
• All gearshift levers to neutral.
• Parking brake (11/9) applied, travel direction
preselectors (11/8; 11/36) in position "0".
• Insert ignition key in pre-heat/ starter switch
(11/50).
Hot start
• Switch on ignition and wait for approx. 5 sec.
The display establishes the internal
readiness for operation. As a result, all
indicator lamps are briefly activated for
a functional check.
• Turn clockwise to "1"; the indicator lamps
(11/22, 11/31) light up.
• Pre-heating starts; the indicator lamp (11/21)
lights up.
• Press the accelerator pedal (11/3) completely
down for normal start and to the quarter-open
position for hot start.
• After the indicator lamp (11/21) has gone out,
turn the pre-heat/ starter switch to "Start". As
soon as the engine is running, turn the ignition
key to "1" and decrease the revs to low idle
speed. The indicator lamps should go out.
• If the engine has not started after max.
20 seconds, turn the ignition key to "1" or "0",
and pause for at least 1 minute before trying
again. Repeat the start-up procedure.
Do not drive the engine at full throttle
straight away. Drive with restraint until
the operating temperature of the engine
has been reached.
II
3
36
31
22
21
16
8
50
L1002_011
Fig. 11 Operation
Page 49
Operation 4
TW9 43
4.3.2 Monitoring during operation
If the engine and the machine are put
into operation without prior remedy of
the defect, severe damage to the engine
may result!
• If the battery charge control lamp (12/22) or the
engine oil pressure indicator lamp (12/31) light
up, switch off the engine immediately and
determine the cause, or call for service
personnel.
• If the permitted engine oil temperature (12/25)
is exceeded, stop work, open the engine hood
and keep the engine running at idle speed to
allow it to cool down.
Once the engine has cooled down, turn it off
and determine the cause of overheating, or call
for service personnel.
• If the air filter service indicator lamp (12/32)
lights up, perform the necessary air filter
maintenance.
4.3.3 Switching off the engine
Do not switch off the engine when
running at full throttle, but allow it to run
for a short time without load at low idlerunning speed.
• Turn the ignition key to "0". The engine stops
automatically.
22
25
31
32
L824-012
Fig. 12 Operation
Page 50
4 Operation
44 TW9
4.4 Driver's seat / Steering wheel tilt adjustment
Driver's seat
The comfort seat is spring-mounted with oilpressure operated shock absorbers and lap belt.
The seat meets international quality and safety
standards in compliance with ISO 7096 and ISO
6683 (fig. 13).
1. Horizontal adjustment
2. Weight adjustment
3. Seat back adjustment
4. Vertical adjustment
Raising seat:
Raise seat until it clicks audibly into place.
Lowering seat:
Raise seat as far as the stop; the seat then
sinks to its lowest position.
Tilt adjustment of steering wheel
• Push down lever (14/4)
• Adjust steering-wheel tilt.
• Release lever.
Steering wheel height adjustment
• Push up lever (14/4).
• Adjust steering-wheel height.
• Release lever.
Fig. 13 Operator’s seat
4
L824-014
Fig. 14 Operation
Page 51
Operation 4
TW9 45
4.5 Heating / ventilation
Heating
• The heater is connected to the engine oil
circuit.
• The fan is operated using the switch (15/44);
temperature is adjusted using the control
(15/57) and can be operated with fresh air and
re-circulating air.
• Open aspirating hole (15/12) for re-circulating
air mode.
• The air is distributed by adjusting the air vents.
Ventilation
• In ventilation mode, the valve towards the
engine oil circuit remains closed.
• The fan is operated using the switch (15/44).
• The air is distributed by adjusting the air vents.
Air-conditioning system (optional)
The air conditioning system should be
switched on for approx. 5 minutes at
least once a month to lubricate the
compressor seals.
• Adjust ventilation to circulating air mode, open
aspirating holes (15/12).
• Control (15/57) in position "Cold".
• Turn the air conditioning system on with the
rotary switch (15/43).
• Switch on the blower (15/44).
How to achieve good cooling
performance:
• After switching on the air conditioning
system, open the windows for 2-3
minutes to allow the hot air (stored
heat) to escape.
• Keep windows and doors closed.
• In order to achieve optimum cooling
circulation, close the foot and front air
vents and only open the rear air vents
(15/60).
• It is recommended to cool down the
vehicle interior temperature by no
more than 6 to 8°C below outside
temperature.
60
57
60
Fig. 15 Operation
Page 52
4 Operation
46 TW9
4.6 Lighting in compliance with German Road
Traffic Regulations (StVZO)
The lighting of the loader is switched on and off by
turning the steering-column switch (15/1).
Setting 0
Light Off
Setting 1
Parking light
Setting 2
Driving light (low beam / high
beam).
Switch from one to another by
lifting the steering-column switch
(15/1).
Blue indicator light for high-beam
(15/30) lights up
4.7 Hydroinflation of tires
When the loader is used with a fork lift attachment,
the rear wheels may be filled with a waterantifreeze mixture to increase the lifting capacity.
Prepare the mixture in an appropriately sized
container. Allow it to cool and stir until there are no
more lumps.
Always pour magnesium chloride into
the water, not the other way round!
Do not allow the solution to come into
contact with eyes, skin or clothing.
Caustic substance!
Recommendation when filled to 75% with
antifreeze protection to -30
℃
Values per wheel:
Type of tire MgCl2
approx.
kg
H2O l Total
kg
405/70 SPT 55 70 125
12.5-20 MPT 57 74 131
335/80 XM 59 73 132
335/80 SPT 51 66 117
12.5-18 MPT 45 58 103
14.5-20 MPT 57 74 131
MgCl2 = Magnesium chloride
H
2
O = Water
Fig. 16 Operation
Page 53
Operation 4
TW9 47
4.8 Driving, steering and braking
4.8.1 Driving
When driving on public roads, the wheel
loader, as a self-propelled work machine,
is subject to the legal regulations valid in
the user's country. (For example, in the
Federal Republic of Germany, StVZO
and StVO).
The machine has two preselection
switches for travel direction, which are
alternately active.
These are changed via the multi-function
switch (16/35).
One preselection switch for travel
direction (16/36) is located on the
instrument panel and another such
switch on the joystick (16/8) for
controlling the working hydraulics.
The multi-function switch (16/35) is
only to be pressed if the machine is at
a standstill and both travel direction
preselection switches are in neutral
position. If the two direction-of-travel
preselection switches are pressed in a
contradictory manner, the machine stops.
When driving on roads, the joystick
(16/8) for the working equipment must be
deactivated via the multi-function switch
(16/35).
This also deactivates the travel direction
preselection switch on the joystick (16/8).
The direction of travel is preselected
using the switch (16/36) on the
instrument panel.
In working operation, the joystick (16/8)
for the working equipment must be
activated via the multi-function switch
(16/35).
This also deactivates the switch (16/36)
on the instrument panel.
The direction of travel is preselected
using the travel direction preselection
switch on the joystick (16/8).
Drive carefully down gradients at a
moderate speed. Do not press
accelerator pedal fully down.
Reduce travel speed before switching
from hydraulic high-speed gear to
hydraulic low-speed gear.
The machine must be stopped before
switching from mechanical gear speed 2
to mechanical gear speed 1.
Fig. 16 Operation
Page 54
4 Operation
48 TW9
Driving off
• Set the travel direction preselection switch on
the joystick (17/8) and on the instrument panel
(17/36) to "0" (neutral position).
• The indicator lamps (17/24 and 17/28) must
not light up.
• Start engine.
• Raise lift frame as far as the "Travel” height
mark (18/1).
• Select speed range "FAST" or "SLOW" (17/33)
as required.
• High-speed version (option) - select speed
range I or II.
Observe the indicator light (17/58-60).
• Release the parking brake (17/16).
• Adjust the desired travel direction using the
preselection switches (17/8 or 17/36
respectively).
• The indicator lamp (17/24 or 17/28) lights up.
• Press accelerator pedal (17/3). The machine
only drives off once a certain engine speed is
reached.
• Travel speed is increased and decreased using
the accelerator pedal. Travel speed directly
depends on engine speed.
• The direction of travel may be changed quickly
by operating the preselector switches (17/8 or
17/36 respectively).
Coming to a halt
• Travel speed is reduced by releasing the
accelerator pedal. The hydrostatic travel drive
acts as a non-wearing auxiliary brake.
• Operate the brake-inching pedal (17/2) as
required.
See also chapter "4.8.3 Brakes".
Fig. 17 Operation
Fig. 18 Height mark
Page 55
Operation 4
TW9 49
4.8.2 Steering
• The wheel loader features a fully hydraulic,
proportionally acting articulated steering.
• Priority supply of hydraulic oil to steering
through load-sensing system.
In the event of steering malfunctions,
determine the cause immediately (see
Trouble-Shooting Table) and call for
service personnel if necessary.
4.8.3 Brakes
Service and auxiliary brake
• To bring the machine to a halt, release the
accelerator pedal (19/3). The hydrostatic travel
drive then acts as an auxiliary brake.
• Operate the brake-inching pedal (19/2) as
required.
Parking brake
• Only apply the parking brake (19/9) if the
machine is stationary.
Once the parking brake is applied
(19/16), the travel drive is deactivated.
Brake-inching mechanism
• The machine features a brake-inching
mechanism altering the relationship between
travel speed and engine speed.
• When the brake-inching pedal (19/2) is
operated, travel speed is reduced - irrespective
of engine speed - until the machine comes to a
stop.
This mechanism permits sensitive driving at
maximum engine speed, e.g. when loading a
truck, where fast working cycles are required.
Fig. 19 Operation
Page 56
4 Operation
50 TW9
4.8.4 Driving on roads
Before driving on open roads, the following points
have to be observed:
The wheel loader must be equipped as
stipulated by the regulations authorizing
the use of vehicles for road traffic in the
user's country.
When travelling longer distances,
schedule breaks so that tires and
components are able to cool down.
• Empty the bucket and tilt back completely.
• Attach the protective device on the front bucket
edge.
• Secure the side-dump bucket with socket pins.
• Completely retract the high-tip bucket.
• Fold up the forks of the fork lift attachment, lock
in place and secure against lateral shifting.
Rigid forks must be dismounted
before driving on public roads!
• Raise the lift frame as far as the height color
mark (18/1) until sufficient ground clearance is
secured.
• Set the travel direction preselection switch on
the joystick (20/8) and on the instrument panel
(20/36) to "0" (neutral position).
• Switch off the working hydraulics (20/35).
Only shift when machine is at
standstill!
• Check the function of the direction indicators,
hazard warning lights, horn, low/high beam.
• Close the cab door.
Fig. 18 Height color mark
Fig. 20 Operation
Page 57
Operation 4
TW9 51
4.8.5 Switching off the machine (parking)
• Set the travel direction preselection switches
(21/8 and 21/36) to "0".
• Lower the work attachment onto the ground.
• Switch off the working hydraulics (21/35).
• Apply the parking brake (21/16).
• Switch the engine off and remove the ignition
key.
• Lock the cab after finishing work to keep
unauthorized persons from getting in.
If necessary, use chocks to stop the
machine from rolling away.
Fig. 21 Operation
Page 58
4 Operation
52 TW9
Page 59
Working Operation of the machine 5
TW9 53
5 Working Operation of the machine
5.1 General notes
Daily before start of operation and after
every attachment change, check the
correct fastening of the work attachments
as well as the correct locking of the
quick-mount hitch.
The bucket is to be carefully moved at
low height.
• Before commencing loading work, memorize
the lever controls well.
• During loading operations, driving and work
movements should flow in smooth succession.
• Drive slowly when familiarizing yourself with the
controls.
5.1.1 Lever controls
1 Lowers the lifting frame, float position
2 Opens
3 Closes
4 Dumps
5 Travels forwards and backwards
6 Lifts lifting installation
7 Tilts back
* For grading work, only tilt the joystick
half way, because if it is tilted all the way
the "regeneration" function takes effect.
L1002_Hebelst
2
3
4
5
6
7
1
Fig. – Lever controls
Page 60
5 Working Operation of the machine
54 TW9
5.2 Operation - Loader
• Switch on the work equipment (22/35).
Operation - Bucket
• Operate joystick (22/6).
Fig. 22 Operation
Page 61
Working Operation of the machine 5
TW9 55
Fingertip control (electro-proportional control)
Third control circuit
• Proportional actuation of the control circuit
• In continuous operation, the amount can be
controlled.
• Sensitive control of hydraulically-driven work
attachments, such as multi-purpose bucket,
sweeper, etc.
Fingertip control and float position are
deactivated as soon as the ignition is
switched off.
No oil flow if the potentiometer (23a/56)
is turned as far to the left as it will go.
Impulse mode
• Press the "Continuous operation - additional
control circuit" (23a/47) button once.
• Push the roller (23a/7) on the joystick until the
required amount of hydraulic oil is achieved.
• For sensitive movements, the flow rate can be
reduced by using the potentiometer (23a/56).
Continuous operation
• Turn the potentiometer (23a/56) as far as it will
go to the left.
• Press the "Continuous operation - additional
control circuit" (23a/47) button once.
• Select the direction of rotation using the roller
(23a/7) on the joystick.
• With the roller pushed, press the stop button
(23a/5) on the rear until the control light (23a/6)
flashes on the front of the handle.
• Release the roller (23a/7) and stop button
(23a/5).
• Set the flow rate/rotational speed using the
potentiometer (23a/56).
• To deactivate continuous operation, press the
button (23a/47) or the roller on the joystick
(23a/7).
The oil flow also depends on the engine
speed.
If an attachment is used repeatedly,
continuous operation can also be
activated via preset potentiometer
(23a/56).
The continuous and impulse mode
functions are deactivated as soon as
the ignition is switched off.
Fig. 23a Operation
Potentiometer (23a/56)
1 = lower oil flow = greater precision
2 = increased oil flow = higher speed
Page 62
5 Working Operation of the machine
56 TW9
Operation - Float position
The float position for continuous mode
must always be switched off when not in
use. Switch (23a/48) in position "0".
Fingertip control and float position are
deactivated as soon as the ignition
(23a/50) is switched off.
Impulse mode
• Lower the bucket onto the ground.
• The "float position" function is activated if the
"lowering" pressure point on joystick is
exceeded (23a/9).
• For the "float operation" the joystick (23a/9)
must be held in the "float position", otherwise it
returns to the neutral position.
Continuous operation
• Lower the bucket onto the ground.
• Continuous "float" operation is activated by
pressing the button (23a/48) and putting the
joystick (23a/9) into "float position".
• To end continuous operation, return the joystick
(23a/9) to the neutral position or deactivate the
button (23a/48).
Fig. 23a Operation
Page 63
Working Operation of the machine 5
TW9 57
5.3 Changing work attachments
5.3.1 General notes
To achieve maximum utilization of the machine for
a variety of applications, a great number of work
attachments and accessories are available.
The machine is equipped with a quick-attach
system, to shorten the time it takes to change
attachments.
When mounting a multi-purpose bucket, front
sweeper, etc., an additional control circuit is
required.
Under certain circumstances, it is
possible to use the work attachments of
predecessor models on our machines.
When mounting work attachments of
predecessor models, however, these
may have to be adjusted and/or are
subject to utilization restrictions. The
installation of work attachments which
are not included in our product range
requires our written approval. It is
essential to consult your dealer before
mounting such a work attachment.
When the attachments have been
removed, they must be secured against
tilting and overturning to avoid possible
injuries to persons.
Page 64
5 Working Operation of the machine
58 TW9
5.3.2 Assembly of work attachments
The bearings on the lifting frame, quickattach system and work attachment must
be free of dirt.
The system must be relieved of pressure
before hydraulic connections are
disconnected.
Procedure for changing directly mounted work
attachments
If an attachment is hydraulically
operated, disconnect the hydraulic
connection first of all (system must be
without pressure).
• Lower the work attachment onto the ground and
position so that it cannot tilt.
• Remove the pin of the linkage and the pin of the
lift frame.
• Move the lift frame out of the work attachment
and install a new one.
Procedure for changing work attachments with
mechanical quick-attach system
If an attachment is hydraulically
operated, disconnect the hydraulic
connection first of all (system must be
without pressure).
• Lower the work attachment onto the ground
and position so that it cannot tilt.
• Raise pin (24/2) and open the quick-mount
hitch using the control rod (24/1) until the
locking bolts are completely retracted.
• Check the function of the quick-attach
system lock and grease the pins if
necessary.
• Attach another work attachment and close the
quick-mount hitch until the locking bolts are
completely extended and the lock clicks in.
• Ensure that the work attachment and the lock
are properly seated.
• The control rod is kept in the left-hand storage
box in the cab.
L823B22
12
Fig. 24 Quick-attach system
Page 65
Working Operation of the machine 5
TW9 59
Procedure for changing work attachments with
hydraulic quick-attach system
• Lower the work attachment onto the ground
and position so that it cannot tilt.
• Switch off the diesel engine.
• In the case of a hydraulically activated work
attachment, start the ignition and press the
rocker switch (25/47) once.
• Push the roller (25/7) forwards and backwards
repeatedly to relieve the pressure of the quick
couplings.
• Switch off the ignition.
• Release the hydraulic quick couplings on both
distributor blocks.
• Switch the ball valve (26/1) to the "Unlock
quick-attach system" position.
• Start the diesel engine.
• Activate the auxiliary circuit with the rocker
switch (25/47).
• Unlock the quick-attach system with the roller
(25/7) and move out of tool.
• Pick up new tool and lock with the roller (25/7).
Perform a visual check to ensure
that the quick-attach system is
correctly locked.
• Switch off the diesel engine.
• In the case of a hydraulically activated work
attachment, start the ignition and press the
rocker switch (25/47) once.
• Push the roller (25/7) forwards and backwards
repeatedly to relieve the pressure of the quick
couplings.
• Switch off the ignition.
• Ball valve (26/1) in position "Quick-attach
system locked".
• Connect the hydraulically operated work
attachment to the connection of the additional
control circuit.
The additional control circuit (25/47)
must be switched off unless a
hydraulically operated additional
attachment is connected.
7
47
L1002_25
Fig. 25 Operation
Fig. 26 Hydraulic quick-attach system
Page 66
5 Working Operation of the machine
60 TW9
5.4 Notes on how to work with the machine
5.4.1 Loading
During transport, the bucket - either filled or empty
- must be kept as close to the ground as possible.
If possible, avoid long transport distances!
For loading, lower the bucket and
position the cutting edge parallel to the
ground. Reduce driving speed by inching
as required.
Move the bucket into the material to be
loaded.
As soon as the bucket is filling, slightly
raise the lift frame and tilt back the
bucket.
For dumping, raise the bucket until it is
above the point of dumping and dump
the material.
5.4.2 Scraping and grading
• Lower the lift frame and move the cutting edge
into the ground keeping a flat angle of
inclination. Do not penetrate too deeply to
ensure smooth removal of earth.
• During this operation, the depth is only to be
leveled by moving the bucket in and out.
5.4.3 Excavating
• To dig out an excavation, strip layers which are
as regular as possible.
• Plan the excavating work in such a way as to
enable the wheel loader to drive forward with
full bucket out of the excavation.
• Keep the outward run of the excavation as flat
as possible.
Page 67
Recovery and transport of the machine 6
TW9 61
6 Recovery and transport of the machine
6.1 Recovery of the machine
Towing of the wheel loader must be restricted to
clearing a junction or a road, to prevent damage to
the hydrostatic travel drive.
If possible, let the diesel engine run at low idle
during towing.
Towing lugs
• front: right and left on the axle plates.
• rear: bottom right and left on the side plates of
the rear end.
Max. load suspension of towing lugs
approx. 5,300 kg.
• Whenever the wheel loader has to be towed
(maximum 50m when the engine is stopped),
"Travel” oil circuit must be opened so that the
hydrostatic transmission no longer acts as an
auxiliary brake.
• On both high pressure limiting valves (27/1)
with bypass, in connection plate of hydro
pump, loosen nut (28/1) and screw in screw
(28/2) until even with nut.
• Re-tighten the nut (28/1).
• After towing, screw back screw (28/2) until the
stop.
• Re-tighten the nut (28/1).
Torque: 30 Nm
Absolute cleanliness is essential when
working on the hydraulic system. Always
secure the machine with chocks and
relieve the hydraulic system of pressure
before carrying out maintenance and
repair work.
1
L824-027
1
Fig. 27 Hydraulic pump
Fig. 28 High-pressure relief valve
Page 68
6 Recovery and transport of the machine
62 TW9
6.2 Loading the machine using a crane
Use a crane lifting harness and a crane
with adequate lifting capacity!
Take note of the total machine weight!
Only use approved and undamaged
sling gear.
• Do not pull sling gear over sharp
edges.
To load the machine by use of a crane, the
following preparations are required:
• Empty the bucket and tip back.
• Move the lift frame to travel position.
• Apply the pin of the articulation lock (29/1).
• Stop the engine.
• Dismount from the machine and close the
doors.
• Attach the loader to the hoisting appliance at
the specified, marked points (fig. 29) in the
correct manner.
6.3 Transporting the machine
To transport the machine onto a flat bed trailer,
railway goods wagon, etc. the following measures
must be taken:
• Empty the bucket and tilt back.
• Drive the machine onto the flat bed trailer,
goods wagon, etc., or lift by crane if required.
• Replace the articulation lock (30/1).
• Lower the work attachment onto the ground.
• Stop the engine.
• Dismount from the machine and close the
doors.
• Attach the excavator to the points illustrated
(fig. 30) in the correct manner.
Be aware of the total transport height.
Risk of accident when driving in
tunnels, under bridges, etc.!
Transport dimensions see chap. 3
Technical data.
Fig. 29 Loading the machine using a crane
L824-030
1
Fig. 30 Lashing for transport
Page 69
Maintenance and Care 7
TW9 63
7 Maintenance and Care
7.1 General notes
The good operating condition and life expectancy
of machines are largely influenced by care and
maintenance.
For this reason, it is in every machine owner’s
interest to perform the specified maintenance work
and comply with the service intervals. This chapter
deals in detail with periodic maintenance,
inspection and lubricating tasks.
The type-specific maintenance and inspection plan
lists all work to be performed on the machine at
regular intervals. Maintenance and inspection
plans for this purpose are contained in every
Instruction Book.
It is essential that the recommendations in
chapter 2 "Safety and Accident Prevention",
are observed.
7.2 Intervals
Initial inspection Once before first putting into operation Chapter 7.8.1
Daily tasks Every 10 operating hours or every shift 1) Chapter 7.8.2
Weekly tasks Weekly or after 50 operating hours 1) Chapter 7.8.2
100 operating hours Once after first putting into operation 2) Chapter 7.8.4
Every 500 operating hours After every 500 operating hours or 6 months Chapter 7.8.4
Every 1,000 operating hours After every 1,000 operating hours or 12 months Chapter 7.8.4
Every 2,000 operating hours After every 2,000 operating hours or after 2
years
Chapter 7.8.4
1)
The first date to arrive always applies
2)
also applicable if new or overhauled diesel engines are put into operation.
Page 70
7 Maintenance and Care
64 TW9
7.3 Regular oil analysis
Oil analysis are not intended as a substitute for the
oil change intervals but - apart from a possible
reduction of maintenance costs and as a form of
preventive maintenance - they take into account
the increasing environmental awareness.
Advantages of an oil analysis
• Extension of the oil change intervals under
standard or light-duty operating conditions.
• Minimum wear of high-quality components with
optimum use of the lubricants.
• Periodic laboratory analyses enable an early
detection of imminent damage.
• Repairs performed before they actually
become absolutely necessary help prevent
serious and unexpected damage.
• Resulting damage will also be prevented.
How often should the oil be analyzed?
Regular oil analysis will indicate any developing
trends regarding the state of the oil and the
machine. The oils should be analyzed at the
following intervals:
• Hydraulic oil: 1,000 running hours
• Transmission oil: 500 running hours
• Engine oil: 100 running hours
Based on the first results, the laboratory
recommends the interval for the next sampling.
Ask your dealer for an information booklet detailing
the scope and procedures of the oil analysis.
7.4 Warranty
During the warranty period thorough inspections
are stipulated which are obligatory and must be
carried out by trained specialist dealer personnel.
The inspections are obligatory and
must be paid for.
The performance of inspections as
specified must be confirmed on the
inspection cards in the
warranty/handing-over certificate.
Failure to do so may adversely affect
our warranty coverage.
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Maintenance and Care 7
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7.5 Inspection parts and aids
Service parts for inspections should be ordered well in advance!
Contact your dealer for further information!
Lubricants
• The machine’s life expectancy and operating condition largely depend on the use of the specified
lubricants and compliance with the service intervals.
• If lubricants which do not conform to our recommendations are used, consequential damage may occur
for which we will not assume liability, even inside the warranty period.
• For lubricant specifications see section 3.9.
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7 Maintenance and Care
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7.6 Care and cleaning
The machine must be cleaned on a
suitable surface with an oil separator.
• Neither a steam-jet appliance nor a high-
pressure cleaning apparatus may be used for
cleaning during the first two months after the
machine has been used for the first time, or
when newly painted, to ensure that the paint
can harden sufficiently.
• Do not use aggressive detergents to clean the
machine. We recommend using commercially
available cleaning agents for passenger cars.
• When cleaning with a steam-jet appliance, the
hot water jet should not exceed 80 °C and a
spray pressure of 70 bar.
• Linings (insulating materials, etc.) should not
be exposed directly to water, steam or highpressure jets.
• When cleaning with water or steam jets, take
care not to spray exhaust-gas and air filter
openings.
• When cleaning the engine with water or steam
jets, do not expose sensitive engine parts,
such as generator, cabling, oil pressure
switches, etc. directly to the jet.
• After each wet clean, the machine must be
lubricated in accordance with the lubricating
plan and a test of all work cycles, steering and
driving functions carried out.
7.7 Notes for winter operation
The following points and the relevant notes in the
engine instruction manual should be observed
during winter operation.
Hydraulic oil
• If the machine is not used for longer periods at
temperatures around and below freezing, warm
up the engine by running at medium revs for
approx. 3-5 min.
Engine oil
• The oil viscosity (SAE class) should be
selected according to the ambient temperature
at the machine's place of operation.
Note that 5W-30 engine oil is changed back
to standard oil with viscosity class SAE
15W-40 at temperatures >+30°C.
Coolant
• Before the beginning of the cold season, check
the level of antifreeze and adjust in line with
the ambient temperature if necessary. The
antifreeze is factory-set to -25 °C.
Condition of the battery
• A good cold start performance requires a wellcharged battery. By warming the battery to
approx. +20° (remove the battery after the
engine has been turned off and store it in a
warm room), the minimum starting
temperatures can be lowered by 4-5 °C.
• When installing the battery, ensure good
contact of terminal connections.
• Only tighten terminal screws so that they are
"hand-tight", to prevent deformation of the
terminal cones!
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Maintenance and Care 7
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Fuel
• Only use commercially available brand-name
diesel fuel with a sulfur content of less than
0.5%.
• Use only winter diesel fuel in winter to prevent
line connections becoming blocked through
paraffin deposits. At very low temperatures,
troublesome deposits may also occur when
winter diesel is used.
• If only summer diesel is available, or if winter
diesel must be used at very low temperatures,
we recommend the addition of petroleum (fig.
36) or additives.
These mixtures should only be used
temporarily, never for longer periods.
Only mix the components in the tank!
First fill the required quantity of
petroleum and then add the diesel fuel.
Flow improvement agents are to be
selected according to the specifications
of your fuel supplier.
Petrol shall not be added.
Danger of explosion!
HM23-052
0102030405060%
0
- 5
-10
-15
-20
-25
-30
+32
+23
+14
+ 5
- 4
-13
-22
°F
°C
A
B
C
D
D2011
D2012
Fig. 36 Table for the addition of petroleum or additives
A = Summer diesel
B = Winter diesel
C = Added proportion of petroleum
D = Outside temperature
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7.8 Checking, maintenance and inspection plans
7.8.1 Initial inspection (hand-over inspection)
Fig. 31 Initial inspection
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Maintenance and Care 7
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Work to be carried out by trained specialist dealer personnel:
Chapter
1 Check machine for presence of machine-specific operating instructions --
2 Check the engine oil level 7.9.1
3 Hydraulic oil level 7.9.9
4 Check the fuel level 7.9.4
5 Check oil level of differential and axle hubs 7.9.13
6 Check tire pressure and tightness of wheel nuts 7.9.14
7 Check brake oil level 7.9.8
8 Check the battery fluid level and charge condition 7.9.17
9 Top up windshield washer system 7.9.19
10 Lubricate the machine (all lubrication points) 7.8.3
11 Test run, hydraulic function check and test work. --
12 Visual inspection of all hoses, pipes, cylinders, etc. for leak tightness --
13 Check function of electrical indicating and warning elements, as well as the light system --
14 Sign hand-over card and return to manufacturer --
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7.8.2 Daily and weekly tasks
Inspection and maintenance jobs to be performed by service personnel
23
23
21
10
Fig. 32 Inspection and service schedule
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Maintenance and Care 7
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Daily
Chapter
1 Check hydraulic oil level 7.9.9
2 Check the engine oil level 7.9.1
3 Check fuel level (fuel gauge on instrument panel) 7.9.4
4 Check windshield washer fluid level 7.9.19
5 --
6 Visual check (general) for material cracks, external damage, completeness, etc. --
7 Check for leaks:
Pipes, hoses, control valves, hydraulic pumps, cylinders, etc.
--
The screw-in couplings must be locked when tightening hose or line
connections to prevent rotation.
8 Check electrical indicating and warning elements, and the lighting system --
9 Check smooth running of operator controls --
Weekly
Chapter
11 Clean cooling fins on hydraulic oil cooler 7.9.10
Machine damage due to strong accumulation of dust.
• Shorten the cleaning intervals!
12 Clean cooling fins on water cooler 7.9.3
Machine damage due to strong accumulation of dust.
• Shorten the cleaning intervals!
12 Check the coolant level 7.9.3
13 Check that door catches function perfectly --
14 Check tire pressure and tightness of wheel nuts 7.9.14
15 Check fastening of axles and propeller shaft --
16 Check bearing bushings and bolts of work equipment --
17 Check pins/bolts, bushings, and the linkage assembly of the articulated steering --
18 Check that pneumatic springs of engine hood function perfectly --
19 Drain the fuel filter 7.9.4
20 Check brake oil level 7.9.8
21 Check function of brakes --
22 Check if the dust filter for cab ventilation is dirty and clean if required 7.9.18
Machine damage due to strong accumulation of dust.
• Shorten the inspection and cleaning intervals!
23 Check function, condition and completeness of safety equipment --
24 Lubricate the machine according to overview of lubricating points 7.8.3
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7 Maintenance and Care
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7.8.3 Overview of lubricating points
Replace defective grease nipples immediately and check if grease passes through!
Fig. 33 Lubrication schedule - parallel kinematics
15
12
7
10
L824-033_Z-Kine_2010
Fig. 33 Lubrication schedule - Z kinematics
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Maintenance and Care 7
TW9 73
Grease all lubricating points with multi-purpose grease
The intervals stated are valid for one-shift operation
Item
Lubricating point
Number daily weekly Chapter
1 Tilt cylinder - Tilt control lever 1 X --
2 Lift frame - Tilt control lever 1 X --
3 Lift cylinder - Lift frame 1 (2)* X --
4 Tilt cylinder - Front-end 1 X --
5 Lift frame - Front-end 2 X --
6 Lift cylinder - Front-end 1 (2)* X --
7 Lift frame - Quick-attach system 2 X --
8 Linkage - Quick-attach system 1 X --
9 Tilt control lever - Linkage 1 X --
10
Mechanical quick-attach system
Hydraulic quick-attach system
3
2
X
X
--
11 Steering cylinder - Front-end 1 X --
12 Articulation 3 X --
13 Steering cylinder - Rear-end 1 X --
14 Rear axle bearing 1 X --
15 Door hinges 4 X --
16 Multi-purpose bucket 2 X --
17 Multi-purpose bucket cylinder 4 X --
* ( ) Z kinematics
In the case of special operating conditions, e.g. working on sandy ground, the lubrication intervals
should be shortened, in order to encourage self-cleaning of bearing points.
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7 Maintenance and Care
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7.8.4 Inspection plan
Work to be carried out by trained specialist dealer personnel:
O = Checking, maintenance
X = Replace
Operating hours
min
2x
min
1x
Perform work with machine at operating temperature
after
100
every
500
every
1000
every
2000
yearly
yearly
Chapter
1
Check machine for presence of machine-specific
operating instructions
O O
--
2 Change the engine oil
X X
7.9.1
3 Change the engine oil filter
X X
7.9.2
4 Drain water from the fuel tank
O O O
7.9.4
5 Replace the fuel filter
X X
7.9.4
6 Clean fuel pump, sieve filter
O
7.9.4
7 Check air intake
O O
7.9.5
8 Replace main air filter cartridge
according to the service
indicator
X
7.9.5
9 Replace the air filter safety cartridge
as required
1)
7.9.5
10 Clean cooling fins on hydraulic oil cooler
O O O
7.9.10
Machine damage
due to strong accumulation of dust.
• Shorten the cleaning intervals!
11 Clean cooling fins of water cooler (combined cooler)
O O O
7.9.3
Machine damage
due to strong accumulation of dust.
• Shorten the cleaning intervals!
12 Check antifreeze level in coolant
O
7.9.3
13 Change coolant
as required 1)
7.9.3
14 Check V-belt tension
O O
7.9.6
15 Check engine mount and pump attachment
O O --
16
Check engine speed setting, upper and lower idle
speeds
O O --
17 Check valve lash of engine and adjust if necessary
1x every 500 OH and as required
--
18 Check injection valves
O
--
19 Check or replace the fuel leakage oil line
O X
1)
7.9.4
20 Replace toothed belt 3)
--
21 Check crankcase breather in valve cover
O
--
22 Check acid level and battery connections
O O
7.9.17
23
Check condition of tires, tire pressure and fastening
of wheel nuts
O O
7.9.14
24 Check fastening of axles and propeller shaft
O O --
25
Check bearing bushings and bolts of work
equipment and replace if necessary
O O --
26
Check bushings and bolts of the articulation and the
articulated steering and replace if necessary
O O --
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Maintenance and Care 7
TW9 75
O = Checking, maintenance
X = Replace
Operating hours
min
2x
min
1x
Perform work with machine at operating temperature
after
100
every
500
every
1000
every
2000
yearly
yearly
Chapter
27
Check that door catches function perfectly, and
replace if necessary
O O --
28 Clean or replace the dust filter for cab ventilation
O X X
7.9.18
29
Check electrical indicating and warning elements as
well as lighting equipment.
O
O --
30
Check smooth running of operator controls and
adjust if necessary
O O --
31
Check tightness of all pipes, hoses, control valves,
hydraulic pumps, cylinders, etc.
O O --
When tightening hose and pipe connections,
screw-in couplings must be locked to
prevent rotation.
32 Check or change hydraulic oil
O O X 2) X
7.9.9
33 Replace insert of hydraulic oil return suction filter
X X X
7.9.11
34 Replace the breathing filter
X X
7.9.12
35 Check function of brakes, replace brake oil
O O X X
7.9.8
36 Bleed brake
O O
7.9.8
37
Differential of rear axle with transmission / option:
manual transmission, oil check and/or oil change
X O X X
7.9.13
38 Differential - front axle oil: check or oil change resp.
X O X X
7.9.13
39
Wheel hubs of front and rear axles: oil check or oil
change
X O X X
7.9.13
40
Lubricate the machine according to overview of
lubricating points
O O
7.8.3
41
Check function, condition and completeness of
safety equipment
O O
--
42 Hydraulic function check with function pressure test
O O
--
43 Test run and test work
O O
--
44 Sign inspection card and return to manufacturer
O
O 4)
7.4
1) at least every 2 years
2) Extension of oil change intervals according to oil sample analysis and laboratory report.
For further information see section 7.3.
3) every 5 years or 3,000 running hours
4) Within warranty.
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7.9 Inspection and maintenance work
7.9.1 Engine oil
Checking the engine oil level
• The oil level must be checked daily before
start-up with the machine standing on level
ground.
• The notches on the oil dipstick (35/1) indicate
the min. and max. oil levels.
• Top up engine oil if necessary. Unscrew the
closure cap (35/2) and pour in oil using a clean
container.
Changing the engine oil
Collect the waste oil, do not allow it to
seep into the ground.
Dispose of according to regulations!
• Run the engine until it reaches operating
temperature, engine oil temperature approx.
80°C.
• Park the machine on level ground.
• Stop the engine.
• Remove the cover from the bottom rear-end.
• Place suitable drip pans under the opening
• Screw the oil drain hose onto the oil-change
valve (35/3).
Danger of scalding when hot oil is
drained!
• Remove the oil drain hose and screw the
protective cap onto the valve.
• Close the service opening with the cover.
• To change the engine oil filter (35/4), see
section 7.9.2.
• Top up engine oil to the "MAX” mark on the oil
dipstick (35/1) using the filling hole (35/2).
• Start the engine and run at low idle speed for
approx. 2 min.
• Stop the engine.
• Check oil level and refill oil (emptied cooler has
filled with oil).
• Start the engine and run at low idle speed for
approx. 2 min.
• Stop the engine.
• Check the oil level and top up oil if required.
2
L824-035
1
4 3
Fig. 35 Engine oil
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Maintenance and Care 7
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7.9.2 Engine oil filter
The engine oil filter must be replaced every time
the engine oil is changed.
• Place oil drip pan below the engine oil filter.
• Clean the outside of the engine oil filter.
• Unscrew the filter cartridge (36/4) using a
commercially available tool and check that the
fastening stud is firmly secured in the filter
head.
• Dispose of the filter cartridge according to
regulations.
• Check filter head condition and clean.
• Fill the new filter with oil, wet the sealing ring
with oil and tighten firmly by hand.
• After a test run, check the tightness of the
engine oil filter cartridge.
L824-036
4
Fig. 36 Engine oil filter
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78 TW9
7.9.3 Cooling system - combined hydraulic oil-
water cooler
7.9.3.1 Checking the coolant level
• Check the coolant level daily before starting,
with the machine parked on level ground. To do
so, use the sight glass (37-1/2) of the combined
cooler. If the coolant level is insufficient, top up
accordingly.
Danger of scalding
due to hot oil getting into contact with
skin or eyes.
• Only open the cooler cap after the
engine has cooled down.
• Remove the cap (37-1/1) and top up coolant if
required. With the engine cooled down, the
compensation tank should be half full.
Refill with a 50%-50% mixture of water
and antifreeze.
7.9.3.2 Checking antifreeze
Before the beginning of the cold season, check the
level of antifreeze.
• The antifreeze is factory-set to -25 °C. If
temperatures are lower, the level of antifreeze
must be adjusted accordingly.
Fig. 37-1 Combined cooler
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Maintenance and Care 7
TW9 79
7.9.3.3 Cleaning cooling fins
Machine damage
due to overheated engine.
• Thoroughly clean the cooler to
prevent overheating of the engine
and/or the hydraulic oil.
Only perform cleaning after stopping the
engine and letting it cool down!
• Clean the combined cooler from the outlet side
with compressed air.
• If necessary, e.g. if there is oil in the cooler,
clean with cold cleaner or steam jet device with
oil separator over a suitable surface. Do not
spray generator directly with water or jet
stream.
• After cleaning, the engine must be brought to
operating temperature in order to dry the cooler.
7.9.3.4 Changing coolant
Danger of scalding
due to hot oil getting into contact with
skin or eyes.
• Only open the cooler cap after the
engine has cooled down.
• Park the machine on a level surface.
• Switch off the engine and allow the cooling
system to cool down.
• Remove the cooler cap (37/1).
• Unscrew the water drain plug (37/3) and drain
coolant.
• If necessary, flush the cooling system with
clean water.
• Re-fit the drain plug and the water hose.
• Fill the cooling system with coolant and close
the cap.
• Start the engine and bring to operating
temperature; turn off the engine and allow to
cool.
• Check the coolant level and top up coolant
(several times, if necessary).
Fig. 37-2 Combined cooler
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7 Maintenance and Care
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7.9.4 Fuel system
Checking the fuel level
• Check the fuel level using the fuel gauge
(38/27).
• Top up fuel every day after use to prevent
condensation from forming before the machine
is next put into operation.
Draining the fuel filter
• Open the fuel filter on the water drain (39/2)
until pure fuel escapes.
• Close again the water drain.
Replacing the fuel filter
• Clean the outside of the fuel filter (39/1).
• Unscrew the filter cartridge using a
commercially available tool and check that the
fastening stud is firmly secured in the filter
head.
Collect fuel and dispose of
according to regulations!
• Dispose of the filter cartridge according to
regulations.
• Check filter head condition and clean.
• Wet the seal with oil or fuel and tighten firmly
by hand.
• Check tightness.
The fuel system does not have to
be vented.
Fuel tank
• Drain water from the fuel tank via the drain
plug (40/1).
• Clean the filler screen (40/2) and check for
damage.
27
L824-038
Fig. 38 Operation
L824-039
1 2
Fig. 39 Fuel filter
1
2
L824-040
Fig. 40 Fuel tank
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Maintenance and Care 7
TW9 81
Cleaning fuel pump, sieving filter
• Loosen and unscrew the hexagonal screw
(41/1).
• Take out the fuel sieve (41/2 - cover and sieve
forming a unit).
• Clean the sieve in fuel and replace it, if
necessary.
• Put the seals (41/3 and 41/4) into position.
• Install cover fuel strainer (41/2) and tighten
with screw.
• Check tightness.
Replacing the fuel leakage oil line
• Separate the rubber hoses (42/3) from the
injection valves.
• Separate the rubber hose (42/1) from the fuel
tank.
• Separate the rubber hoses (42/4, 42/3, 42/1)
from the connection pieces (42/2).
• Dispose of the rubber hoses (42/4, 42/3, 42/1)
in an environmentally friendly manner.
• Connect the new rubber hoses with the
connection pieces
• Connect the rubber hoses (42/3) to the
injection valves.
• Connect the rubber hose (42/1) to the fuel
tank.
• Check tightness.
L824-041
1
2
43
Fig. 41 Fuel pump
L824-042
4 3
1
2
Fig. 42 Fuel leakage oil lines
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7 Maintenance and Care
82 TW9
7.9.5 Air filter, air intake
All maintenance work on the air intake
system must be carried out with the
engine off.
Do not start the engine after the filter
cartridge has been removed.
7.9.5.1 Dust ejection valve
• Dust ejection valves (43/1) are largely
maintenance-free.
• Any baked-on dust can be removed by
squeezing the valve together.
7.9.5.2 Air intake
• Check the air filter attachment and retaining
straps for damage.
• Check the tightness of the air intake between
the air filter and the engine.
• Examine rubber parts for damage.
Replace defective parts immediately!
7.9.5.3 Cartridge maintenance intervals
Air filter main cartridge
• The air filter main cartridge must be replaced
as soon as the filter maintenance indicator
lamp (44/32) on the instrument panel lights up
during operation.
• A brief delay in maintenance does not result in
lower filter efficiency.
Air filter safety cartridge
The air filter - safety cartridge must be replaced in
the following cases:
• after the fifth maintenance of the main
cartridge.
• after 2 years of operation at the latest.
• if the service indicator switches on after the
main cartridge has just been serviced.
• if the main cartridge is damaged.
• if the safety cartridge is defective.
1
S515-41
Fig. 43 Air filter
32
L824-044
Fig. 44 Operation
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Maintenance and Care 7
TW9 83
7.9.5.4. Cartridge replacement
Main cartridge
• Release the wire tighteners (45/1) and remove
the bottom of the housing (45/4).
• Withdraw the main cartridge (45/2) by twisting
slightly to and fro.
• Check whether the safety cartridge (45/3) must
be replaced.
Remove the safety cartridge only in
the case of necessary maintenance
work. Only open the seal (45/5) of
the safety cartridge for the purpose
of replacement.
• Note down the date of maintenance in the
appropriate sections of the safety cartridge
(45/3).
• Insert the new or cleaned main cartridge
carefully into the filter housing starting with the
open side and check that it is correctly
positioned.
• Fit the lower part of the housing. (Pay attention
to the position of the dust extraction valve).
• Place the wire fasteners in the groove of the
flange on the filter housing and tighten.
Safety cartridge
• Remove the main cartridge.
Do not clean the safety cartridge and,
once it has been removed, do not
use it again.
• Using a suitable tool (e.g. screwdriver), pierce
the seal (45/5) of the safety cartridge (45/3)
from the inside, then lift up the two clips (45/6).
• Grasp the safety cartridge (45/3) by the two
clips (45/6), withdraw by moving slightly to and
fro, and dispose of it.
• Insert a new safety cartridge and check that it
is correctly positioned.
• Re-install the main cartridge.
3
2
1
4
5
6
HR32-053
3.
2.
1.
Fig. 45 Replacing air filter cartridge
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7 Maintenance and Care
84 TW9
7.9.5.5 Cleaning the main cartridge
Never wash or brush out the main
cartridge.
Make sure that no dust ends up on the
inside of the main cartridge when blowing
out.
• The main cartridge can be cleaned up to five
times if necessary. It must be replaced once it
reaches its maximum service life of two years,
at the latest. The number of times it is cleaned
must be marked.
• For cleaning (46/1), a pipe the end of which is
bent at 90° should be attached to a
compressed-air pistol. It must be sufficiently
long to reach the floor of the cartridge. Blow
out the main cartridge from the inside to the
outside with dry compressed air (max. 72.5 psi)
by moving the pipe up and down in the
cartridge and continue until no more dust
escapes.
• Check the clean main cartridge for damage to
the paper bellows and rubber seals (46/2).
Tears and perforations in the paper bellows
can be determined using a torch.
Never continue to use damaged main
cartridges. If in doubt, use a new one.
S515-45
max. 5 bar
1
2
Fig. 46 Cleaning the main cartridge
Page 91
Maintenance and Care 7
TW9 85
7.9.6 V-belt
Checking the condition of the V-belt
Check or tension V-belts only when the
engine is turned off.
Risk of injury!
• Check the entire V-belt for damage (visual
inspection).
Replace damaged or worn V-belts
immediately.
Checking V-belt tension
We recommend the use of a belt
tensioner gauge in order to check the Vbelt tension. The tension check must be
carried out according to the
manufacturer’s manual.
Checking Tension Without Using a Belt
Tensioner Gauge
• To check the tension, press the V-belt with
your thumb in the middle of the greatest free
length, and measure the sag.
• Using medium thumb pressure of approx.
45 N, the V-belt sag (A) should equal approx.
10-15 mm.
Tensioning the V-belt
• Slacken the fastening screws (47/1).
• Swing the generator (47/2) until the tension is
correct.
• Re-tighten the fastening screws.
• Check the tension again.
7.9.7 Checking Valve Lash
The valve lash must be checked by your service
specialist.
Changing the V-belt
• Slacken the fastening screws (47/1).
• Swivel the generator against the direction of
tensioning.
• Remove the used V-belt and fit new one.
• Rotate the generator (47/2) in the direction of
the arrow until the V-belt tension is correct.
• Re-tighten the fastening screws.
• Check the tension again.
When new V-belts are mounted, their
tension has to be checked after the first
15 min. and adjusted if necessary.
L824-047
2
1
A
Fig. 47 V-belt
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7 Maintenance and Care
86 TW9
7.9.8 Brakes
Checking the brake oil level
• Visual inspection (49/1) of brake oil level.
Only top up with ATF-oil!
Changing brake oil and bleeding the brake
Collect the waste oil, do not allow it to
seep into the ground.
Dispose of according to regulations!
Use a bleeding device for changing
brake oil and bleeding.
• Remove the cover on the front-end above the
axle.
• Release the bleeder screw (50/1), connect the
bleeder hose and insert it into collecting bottle.
• Connect the bleeding device to the brake oil
container (49/1).
• Change brake oil and bleed the brake
according to the Bleeding Device Operating
Instructions.
• Remove the bleeder hose and re-tighten the
bleeder screw.
• Release the bleeder screw (50/2) on the inch
valve of the "travel" hydraulic pump; connect
the bleeder hose and insert it in the collecting
bottle.
• Perform the bleeding process.
• Remove the bleeder hose and re-tighten the
bleeder screw.
• Dismount the bleeding device and close the
brake oil container using the original cover.
• Re-mount the cover on the front-end.
1
L824-049
Fig. 49 Brake oil
1
Fig. 50 Venting the brake
Page 93
Maintenance and Care 7
TW9 87
7.9.9 Hydraulic oil tank
Checking hydraulic oil level
• Check the oil level using the oil dipstick (51/1);
top up hydraulic oil if required.
Changing the hydraulic oil
Danger of scalding when hot oil is
drained!
• Retract all hydraulic cylinders.
• Stop the engine.
• Unscrew the oil dipstick (51/1).
• Remove the drain plug (51/4) on the hydraulic
oil tank and drain oil into a clean receptacle.
Collect the waste oil, do not allow it
to seep into the ground.
Dispose of according to
regulations!
• Flush and clean the hydraulic tank as required
(to do so, completely remove the suction filter
51/2).
• Screw back on the drain plug carefully.
• Fill up with clean hydraulic oil using the
breather. To do so, remove the filter head
(51/3).
• Screw back on the breather head.
• Screw back in the oil dipstick.
L834-051
3 1 2
4
Fig. 51 Hydraulic oil tank
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7 Maintenance and Care
88 TW9
7.9.10 Hydraulic oil cooler
Dirt accumulation in coolers causes the
hydraulic oil to overheat.
Only perform cleaning after stopping the
engine and letting it cool down
The machine is equipped with a combined radiator
and hydraulic oil cooler. Both cooler components
must be cleaned during maintenance (see also
Chap. 7.9.3)
• Clean the cooler components (52/1) by blowing
it out with compressed air from the air
discharge side.
If necessary, clean with cold cleaner or
steam jet device with oil separator over a
suitable surface. Do not spray generator
directly with water or jet stream while
doing so.
Run engine hot afterward to prevent
formation of rust.
L824-037
1
Fig. 52 Hydraulic oil cooler
Page 95
Maintenance and Care 7
TW9 89
7.9.11 Hydraulic oil filter
After major repairs the filter cartridge of
the hydraulic oil filter must also be
replaced after the test run.
Changing the filter insert
• Unscrew the oil dipstick (51/1).
• With the aid of a tool, remove the filter cover
(53/1).
• Remove the filter element (53/5) along with the
inlet connection (53/3) by pulling and turning at
the same time.
• Remove the filter element from the inlet
connection and dispose of according to
regulations.
• Ensure that the seal (53/2) in the cover and the
O-ring (53/4) on the inlet connection are in
faultless condition and replace any damaged
parts.
• Push a new filter element onto the inlet
connection and insert together in filter.
• Screw back on the filter cover (53/1) and tighten
using a torque of 20Nm.
• Screw back in the oil dipstick.
• Check the tightness of the filter by means of a
test run.
L834-051-1
3 1 2
4
Fig. 51 Hydraulic oil tank
1
2
3
4
5
L834-053
Fig. 53 Hydraulic oil filter
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7 Maintenance and Care
90 TW9
7.9.12 Breather
Replace the breather if it is dirty, e.g. due
to oil fumes.
• Unscrew the oil dipstick (54/1).
• Remove the breather (54/2) and dispose of
according to regulations.
• Clean the screen (54/4) and check for damage;
replace if required.
• Screw in new breather (54/2) with O-ring (54/3)
and tighten by hand.
• Screw back in the oil dipstick.
L834-054
1
2
4
3
Fig. 54 Breather
Page 97
Maintenance and Care 7
TW9 91
7.9.13 Axles
General
The axle oil must be changed at operating
temperature.
Collect the waste oil, do not allow it to
seep into the ground.
Dispose of according to regulations!
After filling the axles with oil, move the
machine for approx. 5 minutes to ensure
that the oil is evenly distributed.
Check the oil level again and top up if
necessary.
7.9.13.1 Front axle differential
Checking the axle oil level
• Remove the inspection plug (55/1) check and
top up oil if required.
Changing axle oil
• Park the machine on level ground.
• Open the inspection-filling plug (55/1).
• Open the drain plug (55/2) on the differential
and drain oil.
• Flush out the axle if necessary.
• Screw back on the drain plug carefully.
• Pour in oil using the inspection-filling hole until
oil escapes.
• Carefully close the inspection-filling plug.
Fig. 55 Front axle
Page 98
7 Maintenance and Care
92 TW9
7.9.13.2 Differential of rear axle with transmission
Checking the axle oil level
• Remove the inspection plug (56/1) check and
top up oil if required.
Changing axle oil
The rear axle differential and the
transmission have combined oil filling.
• Park the machine on level ground.
• Open the inspection-filling plug (56/1).
• Open the drain plugs on the differential (56/2)
and the transmission (56/3) and drain oil.
• Flush out the axle if necessary.
• Carefully close the drain plugs.
• Pour in oil using the inspection-filling hole
(56/1) until oil escapes.
• Carefully close the inspection-filling plug.
L844-056
1
X
X
2
3
X
1
X
2
3
Serie
“S”-Version
Fig. 56 Rear axle
Page 99
Maintenance and Care 7
TW9 93
7.9.13.3 Wheel hub
Checking the axle oil level
• Remove the inspection plug (57/1) check and
top up oil if required.
Changing axle oil
The wheel hub has a combined
inspection, filling and drain plug!
• Turn the wheel until the screw plug (57/1) on
the hub is at the bottom.
• Open the screw plug and catch the escaping
oil.
• Flush out if necessary.
• Turn the wheel to the filling and inspection
position; the inspection mark must be
horizontal.
• Fill in oil up to the lower edge of the hole.
• Carefully close the screw plug.
7.9.14 Wheels
Checking the tire pressure
• Check the air pressure in accordance with the
pressure chart given in chapter 3.8.
Checking the tightness of wheel nuts
• During the first 50 operating hours, check the
tightness of the wheel nuts (M 20x1,5) daily
and subsequently every week, and tighten to
the correct torque if necessary.
Fastening torque: 460 Nm
• When fitting a wheel, tighten the nuts to the
correct torque crosswise in several stages.
7.9.15 Injection valves
Injection valves must be checked by your service
specialist.
7.9.16 Control cog belt for drive motor
The toothed belt must be replaced by your service
specialist.
Ölstand
Level
1
L834-057
Ablaßstellung/Drain
Fig. 57 Wheel hub
Page 100
7 Maintenance and Care
94 TW9
7.9.17 Electrical equipment
Battery
Follow the instructions of the battery
manufacturer when taking a battery into
service for the first time.
• The acid level should be approximately 10 mm
above the plate edges. If necessary, top up
with pure distilled water.
• Only check the battery with the engine
switched off.
• Only check the battery isolator after the engine
has been switched off.
For maintenance-free batteries, this
check is not necessary.
Disconnecting the battery
• Deactivate the battery isolator switch
• First disconnect the battery ground cable (-)
and then the positive cable (+).
• Remove the clamping bracket (59/1).
• Lift out the battery.
Installing the battery
• Place the battery into the machine and secure
it with the clamping bracket (59/1).
• Connect the positive cable (+), then the battery
ground cable (-).
Ensure that the negative terminal is
attached to the negative pole (-) and
the positive terminal to the positive
pole (+).
• Switch the battery isolator switch on.
In winter, in particular, take care to ensure that the
battery is well charged.
Lighting and warning equipment
• Check the function of the lighting equipment.
• Check the function of the indicator lamps.
• Check the function of the warning equipment.
L824-059
1
Fig. 59 Battery
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