Takeuchi Hydraulic excavator TB1160W (Serial No. 514500002~). Operator's Manual (2016)

TRANSPORT

HOISTING THE MACHINE

Hoisting

HOISTING THE MACHINE

1. Keep the machine configuration as shown

in the figure on the right.

For machines not having the outriggers,

• Know and use the correct crane signals.

slew the upperstructure so that the dozer

• Check the hoisting equipment for

blade is at the rear of the machine (set the

damaged or missing parts on a daily

upperstructure parallel to the track frame).

basis and replace as necessary.

2. Raise the safety lock lever to the locked

• When hoisting, use a wire rope capable

position.

of lifting the machine mass.

3. Stop the engine, remove the starter key

• Hoist the machine in such a manner

and get off the machine.

described in the procedure below. Do

4. Install the wire ropes as shown in the

not do it in any other manner. Doing so

figure on the right.

is dangerous as it may result in the

Install the wire ropes and hoisting

machine losing its balance.

attachment without letting them touch the

• Do not hoist the machine with an

machine body.

operator on it.

5. Hoist the machine slowly until it leaves the

• When hoisting, hoist slowly so that the

ground.

machine does not tip.

6. Stop hoisting until the machine becomes

• Keep everyone out of the area when

stable, and then start hoisting the machine

hoisting. Do not move the machine over

slowly again.

the heads of the persons.

IMPORTANT: This hoisting method

applies to machines with standard

specifications. The center of gravity

differs according to the attachments and

optional equipment installed.

Contact your Takeuchi service agent for

details.

4-4

TRANSPORT

SECURING THE MACHINE

After loading the machine at the specified position, secure it as described below.

TRANSPORTING POSTURE

1. Lower the dozer blade.

2. Set the hoe attachment posture as above.

3. Raise the safety lock lever to the lock position, and engage the brake pedal lock and

parking brake lock.

4. Stop the engine, remove the starter key and lock all locks.

5. Engage the slew lock with the slew lock pin.

6. Place the stoppers (chocks) in front of and behind the tires.

7. Install chains or wire rope over the lower frame of the machine and fasten it securely to

prevent the machine from slipping sideways.

8. Secure the bucket with chains or wire rope.

9. For machines with outriggers, install the turnbuckles.

IMPORTANT: Place a wooden block under the bucket to protect the floor from damage

caused by the bucket.

4-6

TRANSPORT

PRECAUTIONS TO BE TAKEN DURING TRANSPORTATION

Road travel posture

PRECAUTIONS TO BE TAKEN

DURING TRANSPORTATION

• Know and follow the applicable safety

rules, vehicle code and traffic laws

when transporting the machine.

• Select the best transport route by

considering the length, width, height

and weight of the truck with the

machine loaded on it.

• Never abruptly start or stop or run at a

high speed at the sharp curves during

transport. Doing so will move or lose the

balance of the loaded machine.

If the machine is to be transported

complete, by sea, for example, the

special tie bar provided by the

manufacturer is to be used.

For enquiries, contact the manufacturer.

Precautions for transportation by low

loader and rail

For rail transport, the machine is to be

carried on a suitable type of wagon.

Information of loading procedures is available

from the relevant rail authorities.

For road or rail transport, the upperstructure

must be locked in position using the

mechanism located near the operator’s seat

in order to prevent slewing; the slewing

brake must be on; and the wheels must be

chocked.

Any attached equipment is to rest on the

floor of the transporter.

4-7

MAINTENANCE

GENERAL

CAUTIONS ON MAINTENANCE

GENERAL

MAINTENANCE OVERVIEW

Do not perform any other inspection and

maintenance works than those listed in this

To keep the machine in good condition and

manual.

use if for a long period, perform the

For works not listed in this manual, ask your

inspection and maintenance properly and

sales or a service dealer for help.

safely following the procedures

recommended by this manual.

Keep the machine clean

• Clean the machine before performing

The inspection and maintenance items are

inspection and maintenance and try to

divided into groups according to the

keep it clean.

machine’s total operating time: every 10

• Stop the engine before washing the

hours (walk-around and daily inspection),

machine. Cover the electrical parts so that

every 50 hours, every 250 hours, etc. Refer

water cannot enter. Water on electrical

to the hour meter readings to determine

parts could cause short-circuits or

when to schedule an inspection and

malfunctions. Do not use water or steam to

maintenance. Items for which it is not

wash the battery, electronic control

possible to determine the inspection and

components, sensors, connectors or the

maintenance interval are included under

operator’s compartment.

“When Required”.

Fuel, lubricant and grease

When operating the machine in extremely

• Choose fuel, lubricant and grease by

harsh environments (with high dust levels or

following to the “Fuel and lubricant table”.

high temperatures), inspection and

• Use fuels, lubricants and greases which do

maintenance should be performed earlier

not contain water, and be careful to keep

than the times specified on the Maintenance

dirt out when changing or replenishing fuel,

List.

lubricant or grease.

• Store fuels, lubricants and greases in the

prescribed places and in such a way that

no water or dirt can get in them.

Cautions on refueling

• If the port includes a strainer, do not

remove the strainer when fueling.

• After fueling, be sure to securely tighten the

fuel filler cap.

• Do not add more than the specified

amount of fuel.

5-2

MAINTENANCE

GENERAL

Do not use fuel to clean parts

Disposing of wastes

Do not use fuel to clean parts. Use a non-

• Always collect oil that is drained from the

combustible cleaning agent.

machine in containers. Improperly

disposed waste oil can cause

Keep dirt out

environmental harm.

When mounting and removing parts, do so in

• Follow appropriate laws and regulations

a place where there is no dust, clean the

when disposing of harmful objects such as

working area and the part, and keep dirt out.

oil, fuel, cooling water, coolant, filters and

batteries.

Clean the installation surfaces

When installing and removing parts, be sure

Check after maintenance

that the surfaces of contact of the parts are

• Gradually increase the engine speed from a

clean. If the sealing grooves of the surface of

low idle to maximum speed and check that

contact are damaged, consult your sales or

there is no oil or water leaking from

service dealer for repair or release.

serviced parts.

• Operate each control lever and check that

Seals and split pins

the machine is operating properly.

• Be sure to replace all seals and cotter pins

with new ones.

Cautions on handling of battery wiring

• When installing, be careful not to damage

• Disconnect the wiring from the both

or twist the seal.

terminals (+ and -) on the battery before

working on the electrical system or doing

Sealing tape

electric welding.

Always disconnect it from the earth side

(-). When connecting, connect the earth

side last.

• Do not disconnect the battery wiring while

the engine is moving. Otherwise, the

electric circuits of the rotary converter or

others may be damaged.

Do not let the wheels spin

Do not let the wheels spin when the

undercarriage is raised. Doing so may

damage the differential gears.

• When wrapping the plug with sealing tape,

remove any old sealing tape from the

threads and clean the threads.

• Wrap the thread tight with seal tape

starting 1 or 2 threads away from the

thread end.

5-3

MAINTENANCE

SERVICE DATA

FUEL AND LUBRICANT TABLE

Select the appropriate fuel, lubricant and grease according to the temperature by referring to

the table below.

• Regardless of the specified time, change the oil if it becomes too dirty or degraded.

• When refilling, never mix oils of different brands. If a brand is to be changed, replace the

whole fuel/oil.

Fuel

Diesel fuel specifications

Diesel fuel should comply with the following specifications. The table lists several worldwide

specifications for diesel fuels.

Diesel fuel specification

Area

Diesel fuel specification

Area

EN590: 2009

Bio-diesel fuel

European union BS2869-A1 or A2

United kingdom

Biodiesel blends up to B5

EN14214, EN590

ASTM D975

No.1-D S15

No.2-D S15

USA

ISO 8217DMX

International

Canada

Bio-diesel fuel

Biodiesel blends up to B5

ASTM D6751, D7467

5-4

MAINTENANCE

SERVICE DATA

To maintain the performance and service life of the engine,

always use clean and high-quality fuel.

• To avoid freezing in cold climates, use a diesel fuel that still

functions when the temperature is at least 12°C (53.6°F) below

the lowest expected ambient temperature.

• Use a diesel fuel that has a cetane number of 45 or higher.

When operating at a very low temperature or at a high altitude,

a higher cetane number fuel will be required.

• Use fuel with sulfur content of less than 15 ppm by volume.

Especially in the U.S.A. and Canada, ultra-low sulfur fuel

should be used.

A higher sulfur content fuel may cause sulfuric acid corrosion

in the cylinders of the engines.

Fuel tank

Diesel fuel

• Never mix kerosene, used engine oil, or residual fuel with the

diesel fuel. Use of kerosene is prohibited.

• Poor quality fuel can reduce engine performance and / or

cause engine damage.

• Fuel additives are not recommended. Some fuel additives may

cause poor engine performance.

• The content of metal, such as zinc, sodium, magnesium,

silicon and aluminum, must be 1 mass ppm or less. (JPI-

5S-44-95 test analysis method)

Precautions when using bio-diesel fuel

The warranty of the engine manufacturer may be voided by

using a bio-diesel fuel that does not meet the standard or that is

deteriorated.

5-5

MAINTENANCE

SERVICE DATA

Lubricant

Type by air temperature

Location

Type

-4

86 104°F

When to replace

-20 -10

30 40°C

Diesel engine oil

Every 500 hrs.

SAE 10W-30

Engine oil pan

API: CJ-4 class

after the initial

SAE 15W-40

ACEA: E6 class

50 hrs.

Takeuchi genuine

Every 4000

ISO VG46

hydraulic oil 46

hrs.***

Hydraulic oil

ISO VG32

tank

Every 2000

Anti-wear hydraulic oil

ISO VG46

hrs.***

ISO VG68

Cooling water (water +

Engine cooling

Mixture of 50% coolant

coolant)**

Every 1000 hrs.

system

Mixture of 30% coolant

SAE: J814C or J1034

Every 1000 hrs

Slew reduction

Gear oil

SAE 90

after the initial

gear

API: GL-4

250 hrs.

Transmission*

List of lubricants TE-ML 07-07B/07D/07E/07F

Differential*

Every 2000 hrs.

List of lubricants TE-ML 05-05F/05G/05H

Hub*

Undercarriage

Every 250 hrs.

Slew bearing

Lithium based grease

Every 500 hrs.

EP-2

—

Working

NLGI No.2

Daily or every

equipment

10 hrs.

Levers

When required

: If the percentage of the traveling time within the total operating time is high or the high-

speed travel is often operated, replace the gear oil earlier than the specified time.

** : For water, use tap water (soft). Do not use well or river water. When the ambient

temperature drops below 0°C (32°F), add coolant (antifreeze). Follow the coolant

manufacturer’s instructions to determine the mixture ratio.

5-6

MAINTENANCE

SERVICE DATA

***: The hydraulic oil replacement interval depends on the type of hydraulic oil being used. New

machine are delivered with Takeuchi genuine hydraulic oil 46, and the hydraulic oil

replacement intervals indicated in this manual assume that Takeuchi genuine hydraulic oil

46 is being used. When using conventional antiwear hydraulic oil, the hydraulic oil should

be replaced every 2000 hours.

API standard: American Petroleum Institute

ACEA standard: Association des Constructeurs Européens d’Automobiles

Volume

Engine oil pan

Engine cooling system

Hydraulic oil tank

Fuel tank

Upper limit:

18.5 L

System:

Level capacity

17 L (18 US qt.)

(19.5 US qt.)

215 L (56.8 US gal.)

231 L

Lower limit:

Tank:

(61.0 US gal.)

13 L (13.7 US qt.)

96 L (25.4 US gal.)

Slew reduction gear

Transmission

Differential

Hub

5.3 L (5.6 US qt.)

2.5 L (2.6 US qt.)

9.0 L (9.5 US qt.)

2.4 L (2.5 US qt.)

5-7

MAINTENANCE

SERVICE DATA

REGULARLY REPLACE THE HYDRAULIC

Replacement interval (hours)

OIL

Item

Hydraulic oil

Filter element

When a hydraulic breaker is used, the oil

deteriorates more quickly than that used for

1st time

—

a usual excavation operation. Be sure to

2nd time

—

100

replace the hydraulic oil and the return filter

elements.

Periodically

1200 (600)

200

• Failure to replace these in time can lead to

damage to the machine and the breaker

When the breaker operating ratio is 100%.

hydraulic system. To prolong the service life

Refer to “Hydraulic breaker” on page 8-4.

of the hydraulic devices, properly replace

the hydraulic oil and the return filter

elements according to the table below.

• When replacing the hydraulic oil, clean the

suction strainer.

(

): When a conventional antiwear hydraulic

oil is used.

5-8

MAINTENANCE

SERVICE DATA

LIST OF CONSUMABLES

Periodically replace consumables such as filters and elements according to the table below.

System

Item

Part name

Part No.

When to replace

Hydraulic oil

15511-03400

return filter

Every 1000 hrs after

the initial 50 hrs.

Hydraulic system

Pilot line filter

Element

15512-00601

Air breather

15520-00902

Every 1000 hrs.

filter

Engine lubrication

Every 500 hrs after the

Engine oil filter

Cartridge

I1-13240-2322

system

initial 50 hrs.

Pre-fuel filter

15520-02910

Element

Fuel system

Main fuel filter

I8-98135-4621

Every 500 hrs.

Feed pump

Repair kit

I8-98173-1650

filter

Every 1000 hrs. or

Primary (Outer)

19111-02853

after 6 cleanings

element

Air cleaner system

Air cleaner

(whichever comes first)

Secondary

When the primary

19111-02852

(Inner) element

elements are replaced.

Receiver dryer

19115-08311

Every 2 year

AC system

Ventilation filter

05746-00334

Once a year or if

Element

clogging remains after

Circulation

19115-06736

cleaning

filter

5-9

MAINTENANCE

SERVICE DATA

LIST OF TOOLS (IF EQUIPPED)

Code

Part name

Part No.

Remarks

Spanner

16900-01012

10-12

Spanner

16900-01417

14-17

Screwdriver

16902-20205

(+) (-) replaceable shank

Filter wrench

16919-03560

Hammer

16903-00330

3/4

Adjustable wrench

16904-00250

250 mm

Pliers

16905-00200

200 mm

Spanner

16900-01013

10-13

Spanner

16900-01922

19-22

Spanner

16900-02427

24-27

Spanner

16900-02730

27-30

Spanner

16900-03236

32-36

Spanner

16909-00019

Spanner

16901-00041

Hex. wrench

16906-00250

2.5 mm

Hex. wrench

16906-00500

5 mm

Hex. wrench

16906-00600

6 mm

Hex. wrench

16906-00800

8 mm

Hex. wrench

16906-01000

10 mm

Hex. wrench

16906-01200

12 mm

Tool case

16914-00005

Case

16919-00001

Grease gun

16910-60610

600 cc

Drain connector

15545-12600

Nozzle

16911-10003

5-10

MAINTENANCE

SERVICE DATA

LIST OF TIGHTENING TORQUES

Nuts and Bolts (for ISO strength category 10.9)

Tighten nuts and bolts at the torques shown on the table below, unless otherwise specified.

• The tightening torques used for the mounted plastic covers are not listed in the table below.

Consult your sales or service dealer for details. They will be damaged if over tightened.

• When replacing nuts and bolts, replace them with nuts and bolts of the same size and

standards.

• Tighten nuts and bolts alternately (top, bottom, left then right) or in 2 or 3 times so that they

are evenly tightened.

AG7G009

Tightening torque

Head width (b)

Size (a) x pitch

Classification

General connection points

N·m

ft-lb

M6 x 1.0

9.8±0.5

7.2±0.4

12, 13

M8 x 1.25

22.6±1.1

16.6±0.8

14, 17

M10 x 1.5

47.1±2.4

34.7±1.7

Coarse

17, 19

M12 x 1.75

83.4±4.1

61.5±3.0

19, 22

M14 x 2.0

134.4±6.7

99.1±4.9

22, 24

M16 x 2.0

207.9±10.4

153.3±7.7

27, 30

M20 x 2.5

410.9±20.5

303.1±15.1

12, 13

M8 x 1.0

24.5±1.2

18.1±0.9

14, 17

M10 x 1.25

50±2.5

36.9±1.8

17, 19

M12 x 1.5

87.3±4.3

64.4±3.2

Fine

19, 22

M14 x 1.5

135.3±6.8

99.8±5.0

22, 24

M16 x 1.5

220.6±11

162.7±8.1

27, 30

M20 x 1.5

452.1±22.6

333.4±16.6

5-11

MAINTENANCE

SAFETY-CRITICAL PARTS

To use the machine safely, periodically perform inspection and maintenance. The safety-critical

parts listed below must be periodically replaced for an increased safety.

Serious injury or a fire could result if they are worn or damaged.

List of safety-critical parts

Unit

Safety-critical parts to be replaced periodically

When to replace

Fuel hoses

Fuel system

Packing on fuel filler cap

Engine

Engine oil filter hoses

Cooling system

Rubber hoses

Heater hoses

Heater & Air conditioner

systems

Air conditioner hoses

Hydraulic hoses (pump - delivery)

Hydraulic hoses (pump - suction)

Main body

Hydraulic hoses (slew motor)

Hydraulic hoses (travel motor)

Every 2 years

Hydraulic hoses (boom cylinder piping)

Hydraulic hoses (second boom cylinder piping)

Hydraulic hoses (arm cylinder piping)

Hydraulic

system

Hydraulic hoses (bucket cylinder piping)

Hydraulic hose (brake line)

Working

equipment

Hydraulic hoses (outrigger cylinder)

Hydraulic hoses (blade cylinder)

Hydraulic hoses (ram lock cylinder)

Hydraulic hoses (pilot valve)

Hydraulic hoses (auxiliary piping)

Seat belt

Every 3 years

5-12

MAINTENANCE

SAFETY-CRITICAL PARTS

The material of the safety-critical part listed on the left tends to change over time and cause

wear or deterioration. It is difficult to determine the degree of deterioration at the periodic

inspection, and thus they need to be replaced with new ones after a certain time to maintain

their proper performance even if they appear in good condition. Note that regardless of the

replacement schedule, replacement must be performed immediately if a symptom of wear is

found. If a hose clamp is deformed or cracked, replace it together with the hose immediately.

When replacing the safety-critical parts, ask your sales or service dealer.

In addition to the safety-critical parts, inspect the hydraulic hoses and retighten or replace as

necessary. When replacing the hydraulic hoses, replace the O-rings and seals at the same

time.

Check the fuel and hydraulic hoses according to the periodic schedule described below.

Refer to “Maintenance”.

Type of inspection

Inspection item

Leakage from the connecting parts of hydraulic or fuel hoses

Daily inspection

Damage to cab replace*

Leakage from the connecting parts of hydraulic or fuel hoses

Monthly inspection

Damaged hydraulic or fuel hoses (cracks, wear and tear)

Leakage from the connecting parts of hydraulic or fuel hoses

Annual inspection

Deteriorated, twisted, damaged hydraulic or fuel hoses (cracks, wear

and tear) or hoses in contact with other parts of the machine

*: Cab parts No. 05786-05100

5-13

MAINTENANCE

MAINTENANCE LIST

Inspection and maintenance item

Page

Walk-around inspection

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)

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)

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

Draining the water from the fuel tank

5-35

Inspecting the battery fluid level and replenishing

5-36

*: (AC) / Air conditioner

5-14

MAINTENANCE

MAINTENANCE LIST

Inspection and maintenance item

Page

After the initial 250 hours (only for new machines)

Replacing the slew motor gear oil

5-38

Every 250 hours

Inspecting and adjusting the V-belt

5-39

Inspecting and adjusting the compressor belt (AC)

5-39

Lubricating the undercarriage

5-40

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

*: (AC) / Air conditioner

5-15

MAINTENANCE

MAINTENANCE LIST

Inspection and maintenance item

Page

Every 500 hours

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

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

Inspecting, cleaning and checking operation of the engine fuel injectors

5-62

Inspecting and replacing the air filter case for cracking

5-62

5-16

MAINTENANCE

MAINTENANCE LIST

Inspection and maintenance item

Page

Every 2000 hours

Replacing the transmission gear oil

5-63

Replacing the differential gear oil

5-64

Replacing the hub gear oil

5-65

Every 4000 hours

Replacing the hydraulic oil and cleaning the suction strainer

5-66

Every 4500 hours

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

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 pedals

5-77

Every 2 years

Replacing the receiver dryer

5-78

5-17

MAINTENANCE

WALK-AROUND INSPECTION

Perform the following inspections every day before starting the engine for the first time.

• Before operating, perform the walk-around inspections and make repairs immediately

where necessary.

• Be sure to secure the engine hood or cover before working the inside. Do not keep the

hood or cover open on a windy day or if the machine is parked on a slope.

Before starting the engine, look around the machine and clean any combustibles from the

surroundings of the engine. Also, inspect if oil or water is leaking and any nuts, bolts or electric

wiring are loosened or damaged.

INSPECTING BY OPENING THE ENGINE

3. Check for oil leakage from the hydraulic

HOOD AND COVERS

tank, hydraulic devices, hoses or

connections.

1. Check for any twigs, leaves, oil or other

combustible materials around the engine

and battery.

2. Check for oil or engine coolant water

leakage around the engine.

5-18

MAINTENANCE

WALK-AROUND INSPECTION

INSPECTING BY WALKING AROUND THE

INSPECTING WHILE SITTING IN THE

MACHINE

OPERATOR’S SEAT

4. Check lights for dirt, damage and burnt

14. Check the windshield for dirt or damage.

out bulbs.

15. Check the seat and seat belt for dirt or

5. Check attachments and hoses for

damage.

Check the operator’s seat for dirt, oil or

6. Check the bucket, bucket teeth and side

other combustible materials.

cutter for wear, damage and looseness.

16. Check the monitor, instruments and

7. Check the hook, slip stopper and hook

switches for dirt or damage.

mount of buckets with hooks for damage.

(Option)

8. Check the handrail, the steps and the

slip-resistant surfaces for damage and

loose bolts.

9. Check the tires, wheels, axles and drive

shaft for damage, wear and loose bolts.

10. Check for oil leakage from the travel

motor, transmission, differential and

hubs.

11. Check the cab and guard for damage

and loose nuts and bolts.

12. Check the rear view mirror and room

mirror for dirt, damage and angle

adjustment.

13. Check the labels for dirt and damage.

5-19

MAINTENANCE

DAILY INSPECTION (EVERY 10 HOURS)

• Do not stand on the dozer blade and

DAILY INSPECTION (EVERY

perform maintenance work. Doing so is

dangerous because of the unsteady

10 HOURS)

foothold. Use the work bench.

Perform the following inspections every day

before starting the engine for the first time.

Inspection

• Before operating, perform the daily

inspections and make repairs

immediately where necessary.

• Be sure to secure the engine hood or

cover before working the inside. Do not

keep the hood or cover open on a windy

day or if the machine is parked on a

slope.

INSPECTING AND REPLENISHING THE

COOLANT

1. Open the engine hood and the left side

cover.

2. Inspect the cooling water level in the

reserve tank (1).

• Do not remove the radiator cap or the

The level should be between the upper

drain plug when the cooling water is

limit (H) and the lower limit (L).

hot. Stop the engine and wait until the

If it is below the lower limit (L), replenish.

engine and the radiator cool before

slowly loosening the radiator cap and

Replenishing

the drain plug to remove them.

1. Remove the cap (2) of the reserve tank (1).

• Always wear the protective goggle and

2. Add cooling water up to the upper limit (H)

gloves when handling coolant

of the reserve tank (1).

(antifreeze). If any coolant (antifreeze)

If the reserve tank (1) is found empty at the

comes in contact with eyes or skin,

inspection, check for water leakage and

wash it off with clean water. Otherwise,

then the water level in the radiator (3). Add

it could result in injures.

water to the radiator (3) as required, and

• Before performing maintenance on top

then to the reserve tank (1).

of the work bench, clean the footing and

3. Install the cap (2).

observe the following precautions to

prevent falling.

Note: Use only clean water (soft water) to

· Do not spill oil or grease.

replenish the cooling water loss due to

· Do not leave tools scattered around.

evaporation. Use coolant (antifreeze) and

· Watch your step when walking.

clean water (soft water) of the specified

• Never jump down from the machine or

mixing ratio to replenish the cooling water

the work bench. When getting on or off

loss due to leaking.

the machine or work bench, use the

steps, handrails or work bench to

support your body. Your weight should

be evenly distributed among the three

contact points (one hand and two feet

or two hands and one foot).

5-20

MAINTENANCE

DAILY INSPECTION (EVERY 10 HOURS)

INSPECTING AND REPLENISHING THE

3. Fully insert the dipstick (1) again, and then

ENGINE OIL

pull it out.

4. Check the oil left on the dipstick (1).

The level should be between the upper

limit (H) and the lower limit (L).

• Stop the engine and allow each part of

If it is below the lower limit (L), replenish.

the machine to cool down before

performing maintenance.

Replenishing

• Before performing maintenance on the

top of the machine or the work bench,

clean the footing and observe the

following precautions to prevent falling.

· Do not spill oil or grease.

· Do not leave tools scattered around.

· Watch your step when walking.

• Never jump down from the machine.

Use the steps and handrails when

climbing up and down the machine, and

always support your body at three

points with your hands and feet.

1. Open the maintenance cover.

2. Remove the oil filler cap (2).

Inspection

3. Add oil up to between the upper limit (H)

and the lower limit (L) of the dipstick (1).

Problems could arise if the oil level is either

too low or too high.

4. Tighten the oil filler cap (2).

5. Start the engine, run it at low idle for about

5 minutes, and then stop it.

6. After about 15 minutes, inspect the oil

level.

1. Open the engine hood.

2. Take out the dipstick (1) and wipe off the

oil with a rag.

5-21

MAINTENANCE

DAILY INSPECTION (EVERY 10 HOURS)

CLEANING THE DUST SCREEN

1. Turn the starter switch to the ON position.

2. Inspect the water separator warning lamp.

3. If the warning lamp is flashing, drain the

water.

Stop the engine and allow each part of

Refer to “Draining the water from the

the machine to cool down before

water separator” on page 5-76.

performing maintenance.

Pre-fuel filter, main fuel filter

1. Open the left side cover.

2. Inspect if any dirt or bugs are on the dust

1. Open the right side cover.

screen.

2. Check if there is water in the pre-fuel filter

3. Clean the dust screen.

(1) and the main fuel filter (2).

If water collects in the filter, the float (red

ring) (3) goes up. Be sure to drain water

INSPECTING THE WATER SEPARATOR

before the float (3) goes up to the element

AND THE FUEL FILTERS

(4).

3. Loose the vent plug (5) and then the drain

plug (6) to discharge water collected

inside.

• Do not smoke or permit open flames

4. After drainage of water, tighten each plug

while handling fuel or working on the

and bleed air from the fuel system.

fuel system.

Refer to “Bleeding air from the fuel

• Stop the engine in a well-ventilated

system” on page 6-10.

place and allow it to cool down before

performing maintenance.

• Clean up spilled fuel immediately.

Water separator

5-22

MAINTENANCE

DAILY INSPECTION (EVERY 10 HOURS)

INSPECTING THE FUEL LEVEL

• Never jump down from the machine.

Use the steps and handrails when

climbing up and down the machine, and

always support your body at three

points with your hands and feet.

• Do not smoke or permit open flames

while handling fuel or working on the

fuel system.

• Never remove the fuel cap or add fuel

when the engine is running or still hot.

Do not spill fuel on the hot surface of

the machine.

• Fill the fuel tank in a well ventilated

place.

• Clean up spilled fuel immediately.

• Do not fill the fuel tank to capacity.

Allow room for oil expansion.

• Securely tighten the fuel filler cap.

• Use the correct grade of fuel for the

operating season.

1. Check the fuel level using the fuel gauge

(1).

F: Full

E: Empty

2. If the level is low, add fuel from the fuel

port (2) while watching the fuel gauge (1).

Refer to “Fuel filler port” on page 2-5.

5-23

MAINTENANCE

DAILY INSPECTION (EVERY 10 HOURS)

INSPECTING THE HYDRAULIC OIL TANK

5. Inspect the oil level using the sight gauge

LEVEL AND REPLENISHING

(1).

· When the oil temperature is about 20°C

(68°F):

The level should be between the upper

• Before performing maintenance on the

limit (H) and the lower limit (L).

top of the machine or the work bench,

If it is below the lower limit (L), replenish.

clean the footing and observe the

· When the oil temperature is about 50 to

following precautions to prevent falling.

80°C (122 to 176°F):

· Do not spill oil or grease.

The level should be slightly below the

· Do not leave tools scattered around.

upper limit (H).

· Watch your step when walking.

• Never jump down from the machine.

Replenishing

Use the steps and handrails when

climbing up and down the machine, and

always support your body at three

points with your hands and feet.

• Oil may spurt out if caps or filters are

removed or pipes are disconnected

before releasing the pressure in the

hydraulic system.

· Press the air breather button to relieve

the internal pressure from the tank.

Inspection

The oil level changes with the oil

IMPORTANT: Do not fill up to the level

temperature. Inspect the oil by maintaining

higher than the upper limit (H). It will

the machine posture as shown in the figure.

damage the hydraulic circuits or result in

• Machine posture for inspecting the

oil spurting. If accidentally done, stop the

hydraulic oil level

engine and wait the hydraulic oil to cool,

and then let the excessive oil to drain

from the drain plug.

1. Remove the air breather cap and press

the button (2) to relieve the internal

pressure from the tank

2. Remove the plug (3).

3. Add the hydraulic oil up to the middle of

the sight gauge (1).

4. Tighten the plug (3).

1. Start the engine and run it at low speed.

2. Fully retract the cylinders (second boom,

arm and bucket), and lower the bucket to

the ground.

3. Lower the dozer blade, and then stop the

engine.

4. Open the right side cover.

5-24

MAINTENANCE

DAILY INSPECTION (EVERY 10 HOURS)

LUBRICATING THE WORKING EQUIPMENT

• Before performing maintenance on top of the work bench, clean the footing and

observe the following precautions to prevent falling.

· Do not spill oil or grease.

· Do not leave tools scattered around.

· Watch your step when walking.

• Never jump down from the machine or the work bench. When getting on or off the

machine or work bench, use the steps, handrails or work bench to support your body.

Your weight should be evenly distributed among the three contact points (one hand

and two feet or two hands and one foot).

• Do not stand on the dozer blade and perform maintenance work. Doing so is

dangerous because of the unsteady foothold. Use the work bench.

1. Keep the machine configuration as shown in the diagram above, lower the working

equipment to the ground, and then stop the engine.

2. Use the grease gun to lubricate the grease fittings.

3. Wipe off the excess grease.

5-25

MAINTENANCE

DAILY INSPECTION (EVERY 10 HOURS)

INSPECTING AND INFLATING THE TIRES

• Do not inflate tires with flammable

gases or from systems using an alcohol

injector.

• Never cut or weld on a wheel with an

inflated tire mounted on it. This could

cause an explosive decompression.

• Tires should be replaced only by an

authorized person using the proper

procedures and safety equipment. New

or replacement tires and wheels should

always be checked for proper size

before mounting.

• Always use a cable restraint device or

safety cage when reinflating a repaired

tire.

• Disassembling a tire or rim can cause

an explosion, resulting in serious injury

Recommended air pressure must be

or death. Always ask a service shop or

maintained in every tire. Dairy checks assure

dealer for maintenance.

that inflation is correct. If your periodic check

• Special tools and procedures are

discloses a tire that is continuously losing air,

required to change tires. To do it safely,

a leak is indicated and must be repaired.

it must be done correctly. Changing

tires is a job better done by your tire

service company.

• Always maintain the correct tire

pressure. Do not inflate the tires above

the recommended pressure.

• Inspect tires and wheels every day. Do

not operate the machine if the tire is

underinflated or has cuts or bubbles, or

if the rim is damaged.

• A rise in tire pressure during operation

is normal, and should NOT be reduced.

During your pressure checks, also inspect

for:

• Objects wedged between duals or

embedded in tires.

• Mismatched duals. Diameters should be

equal as well as amount of tread wear.

• Any missing valve caps.

• Cuts, tears, and breaks that may need

repair.

• Abnormal or uneven wear.

• Damaged or poor fitting rim or rim flanges.

• Projecting body hardware, loose fender

• When putting air in a tire, do so from a

bolts, spring clips - anything that could

distance. Use a long hose with self-

contact a tire.

attaching chuck. Always stand behind

• Any tire portions with no-grooves. Replace

the tread when adjusting tire pressure.

the tire with a new one if there is a portion

with no grooves.

5-26

MAINTENANCE

DAILY INSPECTION (EVERY 10 HOURS)

Inflating the tires

CHECKING THE WHEEL NUT TORQUES

These instructions are for adding air to a tire

which is already inflated. If the tire has lost all

its air pressure, call in a qualified tire

mechanic. The tire mechanic should use a

If, for whatever reason, wheel nut is

tire inflation cage and the correct equipment

renewed, all the nuts for that wheel must

to do the job.

be changed as a set, since the remaining

nuts may have been damaged.

1. Prepare the wheel.

Before you add air to the tire, make sure it

On new machines, and whenever a wheel

is correctly fitted on the machine or

has been removed, check the wheel nut

installed in a tire inflation cage.

torques every two hours until they become

2. Prepare the equipment.

proper.

Use only an air supply system which

Every day, before starting work, check that

includes a pressure regulator.

the wheel nuts are tight.

Set the regulator no higher than above the

· Tightening torque:

recommended tire pressure. (See below).

M22 X P1.5: 653 N·m (481.8 ft-lb.)

Use an air hose fitted with a self locking air

chuck and remote shut-off valve.

3. Add the air.

Make sure that the air hose is correctly

connected to the tire valve.

Clear other people from the area.

Stand behind the tread of the tire while

adding the air.

Inflate the tire to the recommended

pressure. Do not over-inflate.

10.00 - 20 Twin tires

· Tire pressure: 700 kPa (101.5 psi)

5-27

MAINTENANCE

AFTER THE INITIAL 50 HOURS (ONLY FOR NEW MACHINES)

1. Open the maintenance cover and remove

AFTER THE INITIAL 50

the oil filler cap (2).

HOURS (ONLY FOR NEW

MACHINES)

REPLACING THE ENGINE OIL AND THE

OIL FILTER

• Stop the engine and allow the machine

to cool down before performing

maintenance.

· The engine, muffler, radiator, hydraulic

2. Loosen the bolts and remove the under

lines, sliding parts and many other

cover (3).

parts of the machine are hot

3. Place a pan under the plug (4) to catch the

immediately after the engine is

waste oil.

stopped. Touching these parts will

4. Remove the cap (A), install connector (B)

cause burns.

and drain the oil. (The oil comes out when

· The engine oil is also hot.

the screw is tightened.)

Be careful not to touch the hydraulic

5. Remove the connector (B) and install the

oil when loosening the cap or plug.

cap (A).

Working on the machine under these

conditions could result in burns or

IMPORTANT: Check the waste oil for

injuries.

metal powder. If it contains large amount

• Before performing maintenance on the

of metal powder, consult your sales or

top of the machine or the work bench,

service dealer.

clean the footing and observe the

following precautions to prevent falling.

6. Install the under cover (3).

· Do not spill oil or grease.

· Do not leave tools scattered around.

· Watch your step when walking.

• Never jump down from the machine.

Use the steps and handrails when

climbing up and down the machine, and

always support your body at three

points with your hands and feet.

7. Open the right side cover.

8. Turn the filter (5) counterclockwise with the

filter wrench and remove it.

9. Clean the surface on which the filter stand

is installed.

10. Apply a thin layer of oil on the packing of

the new filter.

5-28

MAINTENANCE

AFTER THE INITIAL 50 HOURS (ONLY FOR NEW MACHINES)

11. Install the new filter by hand.

12. Tighten one more turn after the filter

packing comes in contact with the

surface of installation.

13. Add oil up to between the upper limit (H)

and the lower limit (L) of the dipstick (1).

Problems could arise if the oil level is

either too low or too high. It takes around

15 minutes for all of the added oil to go

down to the oil pan.

14. Tighten the oil filler cap (2).

15. After about 15 minutes, start the engine,

run it at low idle for about 5 minutes, and

then stop it.

16. After about 15 minutes, inspect the oil

level.

5-29

MAINTENANCE

AFTER THE INITIAL 50 HOURS (ONLY FOR NEW MACHINES)

INSPECTING AND ADJUSTING THE

2. Press the midpoint of the V-belt between

V-BELT

the pulley (2) and alternator pulley (3) to

check the tension. (approx. 98 N or 22

lbs.).

The slack (A) should be 6.6 to 7.4 mm

Stop the engine and allow the machine to

(0.26 to 0.29 in).

cool down before performing

3. Inspect the V-belt (4) and replace if it is as

maintenance.

follows.

• The engine, muffler, radiator, hydraulic

There are cuts or cracks.

lines, sliding parts and many other parts

The belt is worn and touches the bottom

of the machine are hot immediately after

of the V groove in the pulley.

the engine is stopped. Touching these

The belt stretched too loose to be

parts will cause burns.

adjusted.

• Before performing maintenance on the

top of the machine, clean the place you

will work on and observe the following

to prevent falling.

· Do not spill oil or grease.

· Do not leave tools scattered around.

· Watch your step when walking.

• Never jump down from the machine.

Use the steps and handrails when

climbing up and down the machine, and

always support your body at three

points with your hands and feet.

IMPORTANT: The loose belts could result

in bad battery charge, overheat of engine

or early wear of belt. Too tight belts could

damage the water pump or bearing and

belt used to drive the alternator.

IMPORTANT: Do not let any oil or grease

get on the belt.

Inspection

1. Open the engine hood and the

maintenance cover.

5-30

MAINTENANCE

AFTER THE INITIAL 50 HOURS (ONLY FOR NEW MACHINES)

Adjustment

1. Loosen the bolt (7) and locking nut (6).

2. Turn the adjustment bolt (5) to adjust the

V-belt (4).

· Tighten: Clockwise

· Loosen: Counterclockwise

3. Tighten the bolt (7) and locking nut (6).

Tightening torque:

· Locking nut (6) 25 N·m (18.1 ft-lb)

· Bolt (7) 51N·m (37.6 ft-lb)

Note: When replacing with a new belt, run

the engine at low idle speed for about 3 to 5

minutes to break in the new belt, before

adjusting the tension again.

5-31

MAINTENANCE

AFTER THE INITIAL 50 HOURS (ONLY FOR NEW MACHINES)

INSPECTING AND ADJUSTING THE

COMPRESSOR BELT (AC)

• Stop the engine and allow each part of

the machine to cool down before

performing maintenance.

· The engine, the hydraulic system and

many other parts of the machine are

hot immediately after the engine is

stopped. Touching these parts will

cause burns.

Inspection

• The high-pressure pipes of the air

1. Open the engine hood.

conditioner can be very hot (80 to 120°C

2. Press on the center of the belt (1) with a

or 176 to 248°F). Be careful not to burn

finger. The belt tension is normal if the

yourself.

slack in the belt is 8 mm (0.31 in.) when

• Before performing maintenance on the

pressed with a force of 98 N (22 lbs).

top of the machine, clean the place you

will work on and observe the following

Adjustment

to prevent falling.

If the belt tension is not normal, adjust it with

· Do not spill oil or grease.

the adjuster bolt (2).

· Do not leave tools scattered around.

1. Loosen the locking nut (3) and bolts (4).

· Watch your step when walking.

2. Turn the adjuster bolt (2) as follows.

• Never jump down from the machine.

· Tighten: Clockwise

Use the steps and handrails when

· Loosen: Counterclockwise

climbing up and down the machine, and

3. Tighten the locking nut (3) and bolts (4)

always support your body at three

after adjustment.

points with your hands and feet.

Note: When replacing with a new belt, run

the engine at low idle speed for about 3 to 5

IMPORTANT: Do not let any oil or grease

minutes to break in the new belt, before

get on the belt. It will cause the belt to

adjusting the tension again.

slip, decrease the cooling capacity or

shorten the service life of the air

Replacing

conditioner.

Replace the belt in the following cases:

· There are cuts or cracks.

If the belt is too slack, it will slip and vibrate,

· The belt is worn and touches the bottom of

resulting in decreased cooling capacity. The

the V groove in the pulley.

service life of the air conditioner also will be

· The belt stretched too loose to be

shortened. Adjust the belt tension to the

adjusted.

standard value (approximately 8 mm or 0.31

in).

5-32

MAINTENANCE

AFTER THE INITIAL 50 HOURS (ONLY FOR NEW MACHINES)

REPLACING THE HYDRAULIC OIL

RETURN FILTER

• Stop the engine and allow each part of

the machine to cool down before

performing maintenance.

· The engine, the hydraulic system and

many other parts of the machine are

hot immediately after the engine is

stopped. Touching these parts will

cause burns.

· The hydraulic oil is also hot and under

high pressure.

Be careful not to touch the hydraulic

oil when loosening the cap or plug.

Working on the machine under these

conditions could result in burns or

1. Press the air breather button (2) to relieve

injuries due to the hot oil spurting out.

the internal pressure from the tank.

• Before performing maintenance on the

2. Loosen the bolts and remove the flange

top of the machine, clean the place you

(4).

will work on and observe the following

3. Remove the return filter (5).

to prevent falling.

4. Install a new return filter.

· Do not spill oil or grease.

5. Install the flange (4) on its original position.

· Do not leave tools scattered around.

6. Inspect the level with the sight gauge (1),

· Watch your step when walking.

and replenish if the level is too low.

• Never jump down from the machine.

Refer to “Inspecting the hydraulic oil tank

Use the steps and handrails when

level and replenishing” on page 5-24.

climbing up and down the machine, and

always support your body at three

points with your hands and feet.

• Oil may spurt out if caps or filters are

removed or pipes are disconnected

before releasing the pressure in the

hydraulic system.

· Press the air breather button to relieve

the internal pressure from the tank.

· When removing plugs or screws, or

when disconnecting hoses, stand to

the side and loosen them slowly to

gradually release the internal pressure

before removing.

5-33

MAINTENANCE

AFTER THE INITIAL 50 HOURS (ONLY FOR NEW MACHINES)

REPLACING THE PILOT LINE FILTER

• Stop the engine and allow each part of

the machine to cool down before

performing maintenance.

· The engine, the hydraulic system and

many other parts of the machine are

hot immediately after the engine is

stopped. Touching these parts will

cause burns.

1. Press the air breather button (2) to relieve

· The hydraulic oil is also hot and under

the internal pressure from the tank.

high pressure immediately after the

engine is stopped.

Be careful not to touch the oil when

loosening the cap or plug. Working on

the machine under these conditions

could result in burns or injuries due to

the hot oil spurting out.

• Oil may spurt out if caps or filters are

removed or pipes are disconnected

before releasing the pressure in the

hydraulic system.

· Press the air breather button to relieve

the internal pressure from the tank.

2. Open the right side cover.

• Before performing maintenance on top

3. Turn the case (3) counterclockwise and

of the work bench, clean the footing and

remove it.

observe the following precautions to

4. Remove the element (4) and O-ring (5).

prevent falling.

5. Clean the inside of the case (3).

· Do not spill oil or grease.

6. Apply a thin layer of oil on the O-ring of the

· Do not leave tools scattered around.

new filter.

· Watch your step when walking.

7. Install the new element on the filter stand

• Never jump down from the machine or

(6).

the work bench. When getting on or off

8. Apply a thin layer of oil on the new O-ring

the machine or work bench, use the

(5).

steps, handrails or work bench to

9. Install the new O-ring (5) and the case (3)

support your body. Your weight should

on the filter stand (6).

be evenly distributed among the three

10. Inspect the level with the sight gauge (1)

contact points (one hand and two feet

and replenish if the level is too low.

or two hands and one foot).

Refer to “Inspecting the hydraulic oil tank

• Do not stand on the dozer blade and

level and replenishing” on page 5-24.

perform maintenance work. Doing so is

dangerous because of the unsteady

foothold. Use the work bench.

5-34

Takeuchi Hydraulic excavator TB1160W (Serial No. 514500002~). Operator's Manual (2016) - page 5