Takeuchi TB1160W User manual

SAFETY ALERT SYMBOL
This symbol represents the safety alert.
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 contents of this
manual.
All operators must be instructed on the
proper functions of the excavator 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.
AG7O003
Improper operation, inspection and
maintenance of this machine can cause
injury or death.
Read and understand this manual before
performing any operation, inspection or
maintenance on this machine.
Always store this 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 hand this manual to the next
owner.
Takeuchi supplies machines complying with
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.

0-1
SIGNAL WORDS
Safety messages appearing in this manual
and on machine decals are identified by the
words “DENGER”, “WARNING” and
“CAUTION”. These signal words mean the
following:
DANGER indicates a hazard with a high
level of risk which, if not avoided, will
result in death or serious injury.
WARNING indicates a hazard with a
medium level of risk which, if not avoided,
could result in death or serious injury.
CAUTION indicates a hazard with a low
level of risk which, if not avoided, could
result in minor moderate injury.
IMPORTANT: The word IMPORTANT is
used to alert operators and maintenance
personnel about situations which could
result in 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.

0-2
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.
INTRODUCTION
MANUAL STORAGE COMPARTMENT
A compartment for storing this manual is
provided at the position shown on the
diagram below.
1. Open the cover behind the seat.
2. After using the manual, place it in the
plastic pouch and store it back in the
manual storage compartment.
SERIAL NUMBERS
IMPORTANT: Do not remove the machine
name plate with the serial number.
Check the serial numbers of the machine
and engine and write them down in the
spaces below.
Machine number:
Engine number:

0-3
FRONT, REAR, LEFT AND RIGHT
MACHINE DESCRIPTION
Equipped with outrigger
DESIGNATED OPERATIONS
Use this machine primarily for the following
operations:
• Excavation
• Digging ditches
• Leveling
• Loading
FEATURES
• Hydromounted cab minimizes vibration
• Low engine noise and exhaust emissions
• Electronic control of auxiliary hydraulic
circuit
• Automatic and manual operation for engine
deceleration
• Engine emergency stop system
BREAK-IN PERIOD
When the machine is new, operate the
machine for the first 100 hours (as indicated
on the hour meter) by following the
instructions below.
Using a new machine without a break-in
period will lead to quicker deterioration of
machine performance and may shorten the
machine’s service life.
• Sufficiently warm up the engine and
hydraulic oil.
• Avoid heavy loads and rapid operations.
Operate with a load of about 80% the
maximum load.
• Do not abruptly start up, accelerate,
change directions, or stop unless
necessary.
This manual refers the front, rear, left and
right of the machine as seen when sitting in
the operator’s seat with the steering device
visible to the front.

0-4
NOTES ON READING THIS
MANUAL
Please note that the descriptions and
diagrams included in this manual may not be
applicable to your machine.
The numbers used in the illustration are with
circles around them. The same numbers
appear between the parentheses in the text.
(Example: (1))
Symbols used in this manual
The symbols used in this manual have the
following meanings.
........ Prohibition
.............. Lock
............. Unlock

0-5
CONTENTS
Introduction .....................................0-2
Machine description........................0-3
Safety ..............................................1-1
General precautions ................................ 1-2
Precautions when preparing .................... 1-8
Precautions when starting ..................... 1-12
Precautions when operating .................. 1-14
Precautions when stopping ................... 1-25
Precautions when transporting .............. 1-26
Precautions on maintenance ................. 1-28
Safety signs (decals) .............................. 1-39
Controls ...........................................2-1
Names of components ........................... 2-2
Covers..................................................... 2-4
Starter key........................................... 2-4
Front cover (tool box)........................... 2-4
Tool box............................................... 2-5
Fuel filler port ....................................... 2-5
Right side cover................................... 2-6
Left side cover .................................... 2-6
Engine hood ........................................ 2-7
Maintenance cover .............................. 2-7
Cab ......................................................... 2-8
Cab door ............................................. 2-8
Front window....................................... 2-9
Lower front window ........................... 2-10
Side window...................................... 2-11
Emergency exit.................................. 2-11
Seat and seat belt ................................. 2-12
Air Suspension Seat .......................... 2-12
Seat belt............................................ 2-15
Multi-information display........................ 2-16
Main Menu screen ............................. 2-16
Screen navigation .............................. 2-28
Switching images .............................. 2-33
Control console ..................................... 2-35
Switches............................................ 2-35
BUttons ............................................. 2-39
Switches ............................................... 2-41
Starter switch .................................... 2-41
Engine shutdown switch.................... 2-41
Throttle controller............................... 2-41
Horn button ....................................... 2-42
Deceleration button ........................... 2-42
Travel select button ........................... 2-43
First auxiliary hydraulic switches......... 2-43
Second /Fourth auxiliary hydraulic
switch................................................ 2-44
Outrigger switches (If equipped)......... 2-44
Third auxiliary hydraulic switch and
button................................................ 2-44
Aux. 2/4 select button ....................... 2-44
Light switch ....................................... 2-45
Lift overload warning switch
(If equipped)....................................... 2-45
Auxiliary 1st flow rate select switch .... 2-46
Detent mode switch (Auxiliary 1st) ..... 2-46
Beacon lamp switch .......................... 2-47
Lower wiper switch (If equipped)........ 2-47
Image select switch (CAMERA).......... 2-47
Levers and pedals ................................. 2-48
Safety lock lever ................................ 2-48
Slew lock pin ..................................... 2-48
Steering wheel................................... 2-49
Turn signal lever................................. 2-50
Brake pedal ....................................... 2-50
Travel pedal ....................................... 2-51
Second boom pedal (2-piece boom).. 2-51
Operating levers ................................ 2-52
Blade lever......................................... 2-52
Blade /Outrigger lever
(if equipped)....................................... 2-52
Air conditioner ....................................... 2-53
Cautions on use ................................ 2-53
Names of components ...................... 2-54
Control panel operation ..................... 2-55
General system operation .................. 2-56
Defrosting or defogging operation...... 2-56
Air conditioner (A/C) operation ........... 2-57
Ventilation (Fresh /Recirc) .................. 2-57
Outlets............................................... 2-57
Accessories........................................... 2-58
Cup holder ........................................ 2-58
Cigarette lighter ................................. 2-58
Ashtray .............................................. 2-59
Interior light........................................ 2-59
Mirrors............................................... 2-59
12 V power socket ............................ 2-60
24 V external power sockets.............. 2-60
Radio (for cab) ................................... 2-61
Auxiliary hydraulic lines ...................... 2-65
Operating the machine with an
accumulator ...................................... 2-70
Load safety device............................. 2-71
Outrigger ........................................... 2-73
Fuel Supply Pump ............................. 2-74

0-6
Operation .........................................3-1
Before starting operation ......................... 3-2
Getting on or off the machine............... 3-2
Walk-around inspection ....................... 3-2
Daily inspection.................................... 3-2
Starting and stopping the engine ............. 3-3
Before starting the engine.................... 3-3
Starting the Engine .............................. 3-4
Warming up the engine........................ 3-5
Stopping the engine ............................ 3-5
Operating the machine ............................ 3-6
Lever pattern (ISO pattern)................... 3-6
Warming up the machine
(hydraulic oil)........................................ 3-8
Inspection after warm-up................... 3-10
Traveling the machine ........................ 3-11
Stopping travel .................................. 3-15
Operating the working equipment...... 3-16
Operating procedures............................ 3-19
Prohibited operations......................... 3-19
Precautions for operation................... 3-22
Precautions when traveling on slopes 3-23
Getting out of mud ............................ 3-25
Operations possible with this
machine............................................. 3-26
Parking the machine.............................. 3-27
Parking .............................................. 3-27
Inspection and checks after stopping
the engine.......................................... 3-28
Handling in cold climates....................... 3-29
Preparing for cold climates ................ 3-29
Cautions after operations................... 3-29
After the cold climate......................... 3-29
Handling tires ........................................ 3-30
Prohibitions........................................ 3-30
Precautions ....................................... 3-31
Transport .........................................4-1
Loading and unloading ............................ 4-2
Hoisting the machine............................... 4-4
Securing the machine.............................. 4-6
Transporting posture............................ 4-6
Precautions to be taken during
transportation .......................................... 4-7
Maintenance....................................5-1
General.................................................... 5-2
Maintenance overview ......................... 5-2
Cautions on maintenance .................... 5-2
Service data ............................................ 5-4
Fuel and lubricant table........................ 5-4
Regularly replace the hydraulic oil ........ 5-8
List of consumables............................. 5-9
List of tools (If equipped).................... 5-10
List of tightening torques ................... 5-11
Safety-critical parts................................ 5-12
Maintenance list..................................... 5-14
Walk-around inspection ......................... 5-18
Inspecting by opening the engine
hood and covers................................ 5-18
Inspecting by walking around the
machine............................................. 5-19
Inspecting while sitting in the operator’s
seat ................................................... 5-19
Daily inspection (every 10 hours)............ 5-20
Inspecting and replenishing the
coolant .............................................. 5-20
Inspecting and replenishing the
engine oil ........................................... 5-21
Cleaning the dust screen ................... 5-22
Inspecting the water separator and
the fuel filters ..................................... 5-22
Inspecting the fuel level...................... 5-23
Inspecting the hydraulic oil tank level
and replenishing ................................ 5-24
Lubricating the working equipment .... 5-25
Inspecting and inflating the tires......... 5-26
Checking the wheel nut torques......... 5-27
After the initial 50 hours
(only for new machines) ......................... 5-28
Replacing the engine oil and the oil
filter ................................................... 5-28
Inspecting and adjusting the V-belt .... 5-30
Inspecting and adjusting the
compressor belt (AC)......................... 5-32
Replacing the hydraulic oil return filter 5-33
Replacing the pilot line filter................ 5-34
Every 50 hours ..................................... 5-35
Draining the water from the fuel tank.. 5-35
Inspecting the battery fluid level and
replenishing ....................................... 5-36
After the initial 250 hours
(only for new machines) ......................... 5-38
Replacing the slew motor gear oil ...... 5-38
Every 250 hours ................................... 5-39
Inspecting and adjusting the V-belt .... 5-39
Inspecting and adjusting the
compressor belt (AC) ........................ 5-39
Lubricating the undercarriage ............ 5-40

0-7
Inspecting the slew motor gear oil ..... 5-41
Cleaning the cooler fins...................... 5-42
Cleaning the air cleaner ..................... 5-43
Cleaning the air filters (AC) ................. 5-45
Cleaning the condenser (AC) ............. 5-46
Inspecting the refrigerant (gas) level
(AC) ................................................... 5-47
Every 500 hours .................................... 5-49
Replacing the engine oil and the oil
filter ................................................... 5-49
Inspecting the transmission gear oil .. 5-49
Inspecting the differential gear oil ....... 5-50
Inspecting the hub gear oil................. 5-51
Lubricating the slew bearing .............. 5-52
Replacing the fuel filters ..................... 5-53
Replacing the feed pump filter ........... 5-54
Inspecting and cleaning the supply
pump strainer .................................... 5-55
Every 1000 hours .................................. 5-56
Replacing the hydraulic oil return
filter ................................................... 5-56
Replacing the pilot line filter................ 5-56
Replacing the slew motor gear oil ...... 5-56
Cleaning the engine cooling system... 5-57
Replacing the air cleaner element ...... 5-59
Replacing the air breather filter........... 5-60
Inspecting and adjusting the engine
valve clearance .................................. 5-61
Inspecting the engine compression
pressure ............................................ 5-61
Inspecting and cleaning the engine
starter and the alternator ................... 5-61
Every 1500 hours .................................. 5-62
Inspecting, cleaning and checking
operation of the engine fuel injectors.. 5-62
Inspecting and replacing the air filter
case for cracking ............................... 5-62
Every 2000 hours .................................. 5-63
Replacing the transmission gear oil.... 5-63
Replacing the differential gear oil ....... 5-64
Replacing the hub gear oil ................. 5-65
Every 4000 hours .................................. 5-66
Replacing the hydraulic oil and
cleaning the suction strainer .............. 5-66
Every 4500 hours .................................. 5-69
Inspecting the turbocharger
(blow wash as necessary) .................. 5-69
Inspecting and cleaning the EGR
valve.................................................. 5-69
Cleaning the EGR cooler.................... 5-69
Inspecting and maintenance the
DPD or its related parts...................... 5-69
Inspecting the engine controller
(ECM) ................................................ 5-69
Inspecting and cleaning the injector ... 5-69
When required....................................... 5-70
Replacing the bucket teeth and the
side cutters........................................ 5-70
Replacing the bucket......................... 5-72
Adjusting the gap between the bucket
and arm (If equipped)......................... 5-74
Inspecting and replenishing the
windshield washer fluid...................... 5-75
Draining the water from the water
separator........................................... 5-76
Lubricating the levers and pedal ........ 5-77
Every 2 years......................................... 5-78
Replacing the receiver dryer............... 5-78
Maintenance during extended storage
period.................................................... 5-79
Troubleshooting ...............................6-1
Symptoms that are not malfunctions ....... 6-2
If the engine overheats............................. 6-4
If the battery goes dead........................... 6-6
If a fuse blows ......................................... 6-8
Inspecting and replacing the fuse......... 6-8
Inspecting the fusible link..................... 6-9
Restarting after adding fuel.................... 6-10
Bleeding air from the fuel system ....... 6-10
If a warning lamp flashes ....................... 6-12
Vehicle Error code list ............................ 6-14
Engine error code list............................. 6-16
Other symptoms.................................... 6-20
Lowering the boom to the ground ......... 6-23
Towing................................................... 6-24
If the cab is damaged ........................... 6-26
Specifications..................................7-1
Basic Specifications................................. 7-2
Machine dimensions................................ 7-4
Operating ranges..................................... 7-6
Lifting Capacities ..................................... 7-9
Options ............................................8-1
General precautions ................................ 8-2
Safety precautions............................... 8-2
Precautions when installing
attachments ........................................ 8-2

0-8
Precautions when operating
attachments ........................................ 8-3
Hydraulic breaker .................................... 8-4
Cautions on operating ......................... 8-4
Replacing the hydraulic oil regularly ..... 8-5
Biodegradable oil..................................... 8-6
Replacing the hydraulic oil with
biodegradable oil ................................. 8-6
Operating lever switch kit 1...................... 8-8
Horn button ......................................... 8-8
Deceleration button ............................. 8-8
Auxiliary 1st switches........................... 8-9
Auxiliary 2nd/4th switch....................... 8-9
Auxiliary 2/4 select button.................. 8-10