Takeuchi TCR50 User manual

C-1
Dump Carrier
TCR50
TCR50
OPERA TOR’S MANUAL
Read and understand these instructions.
Failure to do so can cause injury or death.
OPERATOR’S MANUAL
E
Book No. AS5E000
Serial No. 30530002~
WARNING
Code No. OE-TCR50-C
305200001~

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SAFETY ALERT SYMBOL
This symbol means Attention! Be Alert! Your Safety Is Involved.
The message that follows the symbol contains important information
about safety.
Read and understand the message to avoid personal injury or death.
 It is the owner or employer’s responsibility to fully instruct each operator in the proper
and safe operation of all equipment. All persons using this machine should thoroughly
familiarize themselves with the following sections.
 All operators must be instructed on the proper functions of the dump carrier before
running the machine.
 Learn and practice correct use of the machine controls in a safe, clear area before
operating this machine on a job site.
Improper operation, inspection and maintenance of this ma-
chine can cause injury or death.
Read and understand this manual before performing any op-
eration, inspection or maintenance on this machine.
 Always store this manual near at hand preferably on the machine itself. If it should be lost or
damaged, immediately order a new one from your Takeuchi dealer.
When transferring ownership of this machine, be sure to provide this manual to the next
owner.
 Takeuchi supplies machines complying to the local regulations and standards of the
country of export. If your machine has been purchased in another country or from a person
or company of another country, it may not have the safety devices or safety standards
required for use in your country. Should you have any question about whether your machine
complies with the regulations and standards of your country, contact a Takeuchi dealer.
 Please note that the contents and diagrams included in this manual may not match your
machine exactly.
CAUTION

1
It is your responsibility to observe all pertinent laws and regulations and to follow the
manufacturer’s instructions on machine operation, inspection and maintenance.
Virtually all accidents occur as the result of a failure to observe basic safety rules and
precautions. An accident can often be avoided by recognizing potentially hazardous situations
beforehand. Read and understand all of the safety messages which explain how to prevent
these accidents from occurring. Do not operate the machine until you are sure that you have
gained a proper understanding of its operation, inspection and maintenance.
 SlGNAL WORDS
Safety messages appearing in this manual and on machine decals are identified by the words
“DANGER”, “WARNING” and “CAUTION”. These signal words mean the following:
IMPORTANT: The word “IMPORTANT” is used to alert against operators and
maintenance personnel about situations which can result in possible damage to the
machine and its components.
It is impossible to foresee every possible circumstance that might involve a potential hazard.
The warnings in this manual or on the machine can not cover all possible contingencies. You
must exercise all due care and follow normal safety procedures when operating the machine
so as to ensure that no damage occurs to the machine, its operators or other persons.
 EXPLANATION OF GRAPHICAL SYMBOLS
Following is an explanation of symbols used in this manual.
, X ............prohibition
/ ..........Lock
/ .........Unlock
The word “DANGER”
indicates an imminently
hazardous situation
which, if not avoided,
can result in serious
injury or death.
The word “WARNING”
indicates a potentially
hazardous situation
which, if not avoided,
could result in serious
injury or death.
The word “CAUTlON”
indicates a potentially
hazardous situation
which, if not avoided,
may result in minor or
moderate injury.
DANGER WARNING CAUTION

2
Foreword
This manual describes operation, inspection
and maintenance of the machine, as well
as safety instructions to be heeded during
these operations.
If you have any questions about the machine,
please contact a Takeuchi sales or service
outlet.
 Manual storage
A compartment for storing this manual
is provided at the position shown on the
diagram below.
1. To open the lid, push the button.
2. Always store the manual here after using.
INTRODUCTION
 Serial numbers
Check the serial numbers of the machine
and the engine and write them in the spaces
provided below.
Machine number :
Engine number :
S2A001
S2A002

3
 Front, rear, Ieft and right
This manual refers the front, rear, left and
right of the machine as seen when sitting in
the operator’s seat.
 Designated operations
Use this machine primarily for the following
operation :
 Operation on rough terrain.
MACHINE DESCRIPTlON
 Features
 Dump body can be hydraulically rotated through 90°.
 Hydrostatic drive system.
 ROPS / FOPS cabine.
 Low engine noise and exhaust emissions.
 Isolation mounted cab minimizes vibration.
 Pilot operated joystick controls.
 Engine emergency stop system.
 Break-in period
When the machine is new, heed the instructions below when operating the machine for the
first 100 hours (as indicated on the hour meter).
Using a new machine roughly without breaking it in will lead to quicker deterioration of machine
performance and may shorten the machine’s service life.
 Warm up the engine and hydraulic oil sufficiently.
 Avoid heavy loads and rapid operations. Operate with a load of about 80% the maximum
load.
 Do not start up, accelerate, change directions, or stop abruptly unless necessary.
RIGHTLEFT
REAR
FRONT
S2A003E

4

5
Introduction ..........................................2
Machine Description ..........................3
Safety ....................................................7
Controls ............................................. 35
Operation ........................................... 63
Transport ........................................... 83
Maintenance ..................................... 87
Troubleshooting .............................. 131
Specifications ................................. 145
Options ............................................ 153
Index ................................................. 157
CONTENTS

6

7
General precautions ......................................... 8
Preparing precautions ....................................12
Starting precautions .......................................14
Operating precautions ...................................16
Stopping precautions .....................................23
Transporting precautions ..............................24
Maintenance precautions ..............................25
Safety signs (Decals) ......................................32
SAFETY

8
SAFETY
Observe all safety rules
 Operation, inspection and maintenance
of this machine must be performed only
by a trained and qualified person.
 All rules, regulations, precautions and
safety procedures must be understood
and followed when performing operation,
inspection and maintenance of this
machine.
 Do not perform any operation, inspection
and maintenance of this machine when
under the adverse influence of alcohol,
drugs, medication, fatigue, or insufficient
sleep.
General Precautions
Wear appropriate clothing and
personal protective equipment
 Do not wear loose clothing or any
accessory that can catch on controls or in
moving parts.
 Do not wear oily or fuel stained clothing
that can catch fire.
 Wear a hard hat, safety shoes, safety
glasses, filter mask, heavy gloves, ear
protection and other protective equipment
as required by job conditions. Wear
required appropriate equipment such as
safety glasses and filter mask when using
grinders, hammers or compressed air, as
metal fragments or other objects can fly
and cause serious injury.
 Use hearing protection when operating
the machine. Loud prolonged noise can
cause hearing impairments, even the total
loss of hearing.

9
SAFETY
General Precautions
Provide a fire extinguisher and
first aid kit
 Know where a fire extinguisher and first
aid kit are located and understand how to
use them.
 Know how to contact emergency
assistance and first aid help.
Never remove safety equipment
 Make sure all protective guards, covers,
doors, etc., are in place and secure.
Repair or replace damaged components
before operating the machine.
 Know how to use the safety lock lever,
seat belt, raised body prop and other
safety equipment and use them properly.
 Never remove any safety equipment
except for service. Keep all safety
equipment in good operating condition.
Use a signal person and flagman
Know and use the hand signals required for
particular jobs and make sure who has the
responsibility for signaling.
 All personnel must fully understand all the
signals.
 The operator shall respond to signals only
from the appointed signal person, but
shall obey a stop signal at any time from
anyone.
 The signal person must stand in a clearly
visible location when giving signals.

10
SAFETY
Be sure to lock the safety lock
lever before leaving the operator’s
seat
 Before leaving the operator’s seat, set
the safety lock lever securely to the
lock position and stop the engine. If any
controls should be touched accidentally
when the safety lock lever has not be
locked, the machine will move suddenly,
and cause serious injury or death.
 Before leaving the operator’s seat, lower
the dump body, lock the safety lock lever,
and stop the engine. Also, be sure to
remove the key and take it with you.
General Precautions
Avoid fire and explosion hazards
Keep flames away from fuel, hydraulic fluid,
oil, grease and antifreeze. Fuel is particularly
flammable and dangerous.
 When handling these combustible
materials, keep lit cigarettes, matches,
lighters and other flames or sources of
flames away.
 Do not smoke or permit open flames while
fueling or near fueling operations.
 Never remove the fuel cap or refuel with
the engine running or hot. Never allow fuel
to spill on hot machine components.
 Clean up spilled fuel, oil or other flammable
fluids immediately.
 Check for fuel, oil or hydraulic fluid leaks.
Stop all leaks and clean the machine
before operating.
 Do not cut or weld on pipes or tubes that
contain flammable fluids. Clean thoroughly
with nonflammable solvent before cutting
or welding.
 Remove all trash or debris from the
machine. Make sure that oily rags or other
flammable material are not stored on the
machine.
 Handle all solvents and dry chemicals
according to procedures identified on
manufacturers’ containers. Work in a well-
ventilated area.
 Never use fuel for cleaning purposes.
Always use a nonflammable solvent.
 Store all flammable fluids and materials in
a safe and well-ventilated place.

11
SAFETY
General Precautions
Exhaust fumes from the engine
can kill
 Do not operate the engine in an enclosed
area without adequate ventilation.
 If natural ventilation is poor, install
ventilators, fans, exhaust extension pipes
or other artificial venting devices.
Handling asbestos dust
Inhaling asbestos dust has been linked to
lung cancer. When handling materials which
may contain asbestos, take the following
precautions :
 Never use compressed air for cleaning.
 Avoid brushing or grinding of the
materials.
 For clean up, use wet methods or a
vacuum equipped with a high efficiency
particulate air (HEPA) filter.
 Wear an approved respirator if there is
no other way to control the dust. When
working indoors, install a ventilation
system with a macro molecular filter.
Be careful not to get crushed or
cut
Your body, hands, feet, or other body parts
must not be inserted between the dump
body and the main frame, or between the
cylinder and the dump body, or other moving
parts. Operation of the dump body under
such circumstances may lead to you getting
caught between the moving parts and can
cause death or serious injury.
Using optional products
 Consult with a Takeuchi dealer before
installing optional attachments.
 Do not use attachments that have not
been approved by Takeuchi or a Takeuchi
dealer. Doing so may compromise safety
or adversely affect the machine’s operation
or service life.
 Takeuchi will not be held responsible for
any injuries, accidents or damage to its
products caused by the use of a non-
approved attachment.
Never modify the machine
Unauthorized modifications to this machine
can cause injury or death. Never make
unauthorized modifications to any part of
this machine.
S2A004

12
SAFETY
Preparing Precautions
Know the working area
Before starting operation, know the working
area to ensure safety.
 Check the topography and ground
condition of the working area, or the
structure of the building when working
indoors, and take the necessary safety
measures in dangerous spots.
 Note and avoid all hazards and
obstructions such as ditches, holes, trees,
cliffs, overhead electrical wires or areas
where there is danger of a slide.
 When working on roads, be sure to take
into account the safety of pedestrians and
vehicles.
• Use a flagman and / or signals.
• Fence off the working area and prohibit
entry to unauthorized persons.
 When working in water or crossing shallow
streams or creeks, check the depth of the
water, the solidity of the ground, and the
speed of the current beforehand. Make
sure the water is not deeper than the
allowable depth.
Refer to the section titled “Cautions on
Use in Water” for further instructions.
Check the strength of the bridge
When traveling over a bridge or other
structure, check the permissible load.
If the strength is insufficient, reinforce it.
Always keep the machine clean
 Clean windows, mirrors and lights to
ensure good visibility.
 Wipe off any oil, grease, mud, snow or ice,
to prevent accidents due to slipping.
 Remove all loose objects stored in the
machine and all objects which do not
belong in or on the machine and its
equipment.
 Remove any dirt, oil or grease from the
engine area, to prevent fires.
 Clean the area around the operator’s seat,
removing any potential obstacles.
S2A005
S2A006
S2A007

13
SAFETY
Perform inspection and
maintenance daily
Failure to notice or repair machine irregularities
or damage can lead to accidents.
 Before operating, perform the prescribed
inspections and make repairs immediately
should any irregularities be found.
 If a failure that causes loss of control such
as steering, service brakes or engine
occurs, stop the machine motion as
quickly as possible, follow the shutdown
procedure, and keep machine securely
parked until the malfunction is corrected.
Preparing Precautions

14
SAFETY
Starting Precautions
Maintain three point contact when
mounting and dismounting
 Do not jump on or off the machine. Never
attempt to mount or dismount a moving
machine.
 When mounting and dismounting the
cab, first open the door fully to the locked
position and check that it does not move.
(For machines with cabs)
 Always face the access system and
maintain a three point contact with the
recommended handrails and steps while
getting on and off the machine. Keep
steps and platform clean.
 Never use the safety lock lever or control
levers as hand holds.
Clear the area of other persons
before starting the machine
Do not start the engine until you are sure it
is safe. Before starting, check or perform the
following.
 Walk around the machine and warn all
personnel who may be servicing the
machine or are in the machine path. Do
not start until all personnel are clearly
away from the machine.
 Check for any “DO NOT OPERATE” tags
or similar warning notices on the cab door,
controls or starter switch.
 Sound horn to alert everyone around the
machine.
Start the engine from the
operator’s seat
 Adjust, secure and latch the operator’s
seat.
 Fasten the seat belt.
 Check that the parking device is applied
and place all controls in the neutral
position.
 Check that the safety lock lever is in the
lock position.
 Clear the area of all persons.
 Start and operate the engine from the
operator’s seat only.
 Never attempt to start the engine by
shorting across the starter terminals.

15
SAFETY
Starting with jumper cables
Use jumper cables only in the recommended
manner. Improper use of jumper cables can
result in battery explosion or unexpected
machine motion.
Refer to the section titled “If the Battery
Goes Dead” for proper instructions.
After starting the engine
After starting the engine, perform the
following operations and checks in a safe
place with no persons or obstacles in the
area. If any malfunctions are found, follow
the shutdown procedure and report the
malfunction.
 Warm up the engine and hydraulic fluid.
 Observe all gauges or warning instruments
for proper operation.
 Listen for unusual noises.
 Test engine speed control.
 Operate each control to insure proper
operation.
In cold weather
 Be careful of slippery conditions on
freezing ground, steps and hand holds.
 In severe cold weather, do not touch any
metal parts of the machine with exposed
flesh, as flesh can freeze to the metal and
Cause injury.
 Do not use ether or starting fluids on this
engine. These starting aids can cause
explosion and serious injury or death.
 Warm up the engine and hydraulic fluid
before operating.
Starting Precautions

16
SAFETY
Operating Precautions
Check for safety in the
surrounding area before starting
 Understand the machine limitations.
 Never allow anyone to enter the machine
working range and machine path.
 Signal your intention to move by sounding
the horn.
 There are blind spots to the rear of the
machine. Check that the area is safe and
clear.
 Use a signal person where clearances are
close or your vision is obstructed.
Ensure good visibility
 When working in dark places, turn on the
machine’s working lights and headlights
and / or provide extra stationary lighting if
necessary.
 When visibility is poor due to severe
weather (fog, snow or rain), stop operating
the machine and wait until conditions
improves.
Do not permit riders on the
machine
 Do not allow anyone to ride on any part of
the machine at any time while traveling.
 Do not allow anyone to be on any part of
the machine while operating.
S2A008

17
SAFETY
Travel safety
 Raising or swinging the dump body
while traveling will cause the machine
to become unstable and is dangerous.
Lower the dump body and make it parallel
with the main frame.
 Avoid sudden stops, starts or turns.
 When traveling over rough or slippery
terrain, slow down to prevent losing
control.
 Avoid crossing over obstacles whenever
possible. If obstacles are unavoidable,
travel slowly and cross at an angle. Never
cross obstacles if they will seriously tilt the
machine (to an angle of 10° or greater).
 When roading a machine, know and use
the signaling devices required on the
machine. Provide an escort for road travel
when required.
Operating Precautions
S2A009
S2A010

18
SAFETY
Operating Precautions
Cautions on traveling on slopes
When traveling on slopes or grades, be
careful that the machine does not tip (roll)
over or slide.
 Never exceed the machine’s stability
(maximum gradeability – 30°, lateral
tipping angle – 10°). Also note that when
actual working area conditions are poor
the machine’s stability may be lower.
 When going up or down slopes having a
gradient of 15 degrees or more, travel up
and down the slope with the heavy end of
the dump carrier pointed uphill.
 Travel at slow speed on slopes. Especially
when going down slopes, reduce the
engine (r.p.m.) speed and set the stroke of
the travel lever to half or less before going
down. Going down a slope too fast will
lead to loss of control.
 Sudden stopping on slopes may lead to
loss of balance of the vehicle and it could
tip over.
 Traveling across an inclined surface at
an angle or traveling straight across an
inclined surface could result in slipping
sideways or tipping over. Travel straight
up and down the slope.
 Do not change directions or cross slopes
sideways. First return to a flat surface then
redirect the machine.
 On grass, dead leaves, wet metal or frozen
surfaces, the machine may slide sideways
even on very gentle slopes. Make sure
the machine never faces sideways with
respect to the slope.
Travel in narrow or congested
places
To avoid contact accidents, pay attention to
the surroundings at narrow sites, indoors,
and congested places and operate at a
speed at which the machine can be safely
operated.
S2A011
S2A012E
S2A013