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

MAINTENANCE

WHEN REQUIRED

INSPECTING AND REPLENISHING THE

Inspection

WINDSHIELD WASHER FLUID

1. Open the left side cover.

2. Inspect the washer tank (1) and add

washer fluid if the level is low.

• Choose ethyl alcohol as washer

Replenishing

solution.

1. Mix the washer fluid to the prescribed

Do not use methyl alcohol as washer

concentration.

solution. It could damage the eyes.

2. Remove the cap (2) and add washer fluid.

• Before performing maintenance on top

Keep the dust away while replenishing the

of the work bench, clean the footing and

washer fluid.

observe the following precautions to

3. Install the cap (2).

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.

Use a windshield washer fluid designed

specifically for motor vehicles. Follow the

instructions included with the washer fluid.

5-75

MAINTENANCE

WHEN REQUIRED

DRAINING THE WATER FROM THE

If the water does not drain easily, loosen

WATER SEPARATOR

the plug (2).

4. Close the drain valve (1) and tighten the

plug (2).

Refer to “Bleeding air from the fuel

• Do not smoke or permit open flames

system” on page 6-10.

while handling fuel or working on the

fuel system.

• Stop the engine in a well-ventilated

place and allow it to cool down before

performing maintenance.

• Clean up spilled fuel immediately.

• 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. Open the right side cover.

2. Place a pan under the drain valve (1) to

catch fuel.

3. Open the drain valve (1) and drain the

water.

5-76

MAINTENANCE

WHEN REQUIRED

LUBRICATING THE LEVERS AND PEDAL

Dozer blade lever

Set the machine to the parking posture,

stop the engine, remove the starter key

and store it. Failure to do so may result in

the machine moving abruptly, leading to

serious injury or death.

If the levers or pedals no longer move

smoothly, grease them.

Operating levers

1. Remove the lower mount section of the

boot (1) and turn it upward.

2. Wipe off the old grease.

3. Apply grease to points (A) and (B).

4. Set the boot (1) back as it was.

Second boom pedal

5-77

MAINTENANCE

MAINTENANCE DURING EXTENDED STORAGE PERIOD

Starting the machine after storage

MAINTENANCE DURING

IMPORTANT: If the above “Storage

EXTENDED STORAGE PERIOD

procedures” have not been followed

Storage procedures

during the extended storage periods,

If the machine is to be stored for 30 days or

consult your sales or service dealer

more, store it indoors. If it must be stored

before starting the machine again.

outdoors, park the machine on a surface laid

with lumber on a flat ground, and place a

1. Wipe off the rust-inhibiting oil that was

waterproof cover over it so that it stays dry.

applied on the piston rods of the hydraulic

1. Clean the machine.

oil cylinders.

2. Inspect for oil leakage, water leakage,

2. Add oil or grease as necessary.

cracks and loose nuts and bolts.

3. Add fuel and replace the hydraulic oil and

Returning the engine to service

oil.

1. Perform the daily checks.

4. To prevent rusting and freezing, replace

2. The engine should be pre-oiled before

the engine coolant with long-life coolant

startup.

(LLC).

a. Crank the engine, leaving the fuel

Refer to “Cleaning the engine cooling

system shut off so the engine will not

system” on page 5-57.

start, for 15 seconds.

5. Use the grease gun to lubricate the grease

b. Then pause for 30 seconds.

fittings.

c. Repeat the procedure until you have

6. Fully retract the bucket and arm cylinders

cranked the engine for a total of one

and lower the bucket and dozer blade to

minute. This will circulate the oil in the

the ground.

engine’s lubrication system.

7. Apply rust-inhibiting oil to the hydraulic

3. Prime the fuel system.

cylinder rods.

4. Start the engine. Allow the engine to idle

8. Disconnect the negative cable from the

for approximately 15 minutes while you

battery and cover the battery to prevent

check for:

freezing.

· Proper oil pressure

· Fuel, engine oil or coolant leaks

During storage

· Proper operation of the indicators and/or

gauges

5. Avoid prolonged operation at minimum or

• Do not operate the machine in an

maximum engine speeds and loads for the

enclosed area without adequate

remainder of the first hour of operation.

ventilation.

• If natural ventilation is not possible,

install ventilators, fans, exhaust

extension pipes or other venting

devices.

1. To prevent rusting, operate the machine

once a month so that the oil can be

circulated throughout the system.

2. Inspect the battery and recharge it as

necessary.

Ask your sales or service dealer for

recharging.

5-79

TROUBLESHOOTING

SYMPTOMS THAT ARE NOT MALFUNCTIONS

• It becomes less easy to operate the

SYMPTOMS THAT ARE NOT

machine when an attachment weighing

more than a standard arm or bucket is

MALFUNCTIONS

installed.

The symptoms listed below are not

• In some cases smoke may be emitted from

malfunctions.

the tail pipe while the DPD regeneration is

being performed. This is not a failure; it is

due to burning of the particulate matter

(PM).

• In some cases the noise associated with

the DPD regeneration operation or cancel

operation may change; this is not a failure.

AG7J002

• The arm retracting speed momentarily

slows down when it reaches an almost

vertical position while the engine is running

at low speed.

AG7J003

• The bucket teeth moving speed

momentarily slows down when it reaches

an almost horizontal position while the

engine is running at low speed.

• The slew motor produces noise at the

beginning and end of the slewing.

• The travel motor produces noise when

stopped suddenly from its high speed

traveling.

• The control valve produces noise if

excessive force is applied to the working

equipment or when it moved to the stroke

end.

6-2

TROUBLESHOOTING

IF THE ENGINE OVERHEATS

The symptoms listed below indicate

IF THE ENGINE OVERHEATS

overheating.

• Do not open the engine hood when

steam is coming from it. The steam or

hot water may spurt out and cause

burns.

• Do not remove the radiator cap or the

drain plug when the coolant is hot. Stop

the engine and wait until the engine and

the radiator cool. Then, slowly loosen

the radiator cap to release the internal

pressure.

• Before performing maintenance, stop

the engine and allow the machine to

cool down.

• 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

• An alarm is sounded and the vehicle/

be evenly distributed among the three

engine emergency lamp and the coolant

contact points (one hand and two feet

temperature warning lamp start flashing.

or two hands and one foot).

• The water temperature gauge needle is in

• Do not stand on the dozer blade and

the red zone.

perform maintenance work. Doing so is

• Steam comes from the engine room.

dangerous because of the unsteady

foothold. Use the work bench.

6-4

TROUBLESHOOTING

IF THE ENGINE OVERHEATS

Remedy procedure

1. Park the machine in a safe place.

2. Check if steam is coming out of the closed

engine hood.

3. If there is steam, stop the engine

immediately and contact your sales or

service dealer for repair. If steam, is not

coming out run the engine at low idle and

let the water temperature cool down.

4. When the water temperature gauge

needle drops in the green zone, stop the

engine.

5. Perform the inspections and the remedies

listed below once the engine cools down.

· V belt slack

Adjust

Refer to page 5-30.

· Coolant level

Add

Refer to page 5-20.

· Water leakage

Repair

· Radiator fins

Clean

Refer to page 5-42.

· Sediment in cooling system

............................... Clean

Refer to page 5-57.

If the problem persists after the above

remedies, contact your sales or service

dealer for repair.

6-5

TROUBLESHOOTING

IF THE BATTERY GOES DEAD

Connecting the jumper cables

IF THE BATTERY GOES DEAD

The symptoms below indicate that the

IMPORTANT: Set the starter keys of the

battery is dead.

booster vehicle and the dead machine to

• The starter motor does not turn or fails to

the OFF position.

start the engine.

• The horn is too weak.

Remedy procedure

Start the engine using the booster battery on

the other vehicle (booster vehicle) and the

jumper cables.

• When starting the engine using the

jumper cables, be sure to connect the

cables by following the proper steps.

Improper use of jumper cables can

1. Connect the clip of jumper cable (R) to the

result in battery explosion or

positive (+) battery terminal of the dead

unexpected machine motion.

machine.

· Do not allow the booster vehicle and

2. Connect the other clip of jumper cable (R)

the machine with a dead battery (dead

to the positive (+) battery terminal of the

machine) to touch each other.

booster vehicle.

· Do not allow the positive (+) and the

3. Connect the clip of jumper cable (B) to the

negative (-) clips of the jumper cables

negative (-) battery terminal of the booster

to touch each other.

vehicle.

· When connecting, attach the jumper

4. Connect the other clip of jumper cable (B)

cable to the positive (+) terminals first.

to the engine block of the dead machine.

When disconnecting, remove the

Connect the clip to a place as far from the

cable from the negative (-) terminal

battery as possible.

(ground) first.

· Connect the last clip of the jumper

Starting the engine

cable to a point as far away from the

1. Check that the clips are securely

battery as possible.

connected to the terminals.

• Always wear the protective goggle when

2. Start the engine of the booster vehicle and

jump starting the engine by using the

run it at high speed.

jumper cables.

3. Start the engine of the dead machine.

IMPORTANT: Use the jumper cables and

clips of a size suited to the capacity of

battery. Do not use damaged or corroded

jumper cables and clips.

IMPORTANT: Be sure that the battery of

the booster vehicle has the same

capacity as the battery of the dead

machine.

IMPORTANT: Be sure to connect the clips

securely.

6-6

TROUBLESHOOTING

IF THE BATTERY GOES DEAD

Disconnecting the jumper cables

Once the dead machine is successfully

running, remove the jumper cables by

following the same steps as for connection in

the reverse order.

1. Disconnect the clip of jumper cable (B)

from the engine block of the dead

machine.

2. Disconnect the other clip of jumper cable

(B) from the negative (-) battery terminal of

the booster vehicle.

3. Disconnect the clip of jumper cable (R)

from the positive (+) battery terminal of the

booster vehicle.

4. Disconnect the clip of jumper cable (R)

from the positive (+) battery terminal of the

dead machine.

Recharging

Ask your sales or service dealer for

recharging the dead battery.

6-7

TROUBLESHOOTING

IF A FUSE BLOWS

Fuse layout and circuits protected

IF A FUSE BLOWS

If a light does not come on or the electrical

Capacity

Symbol

Protected circuit

system does not work, a fuse may be blown.

Inspect the fuses.

10A

Head light low Beam (2)

INSPECTING AND REPLACING THE FUSE

10A

Head light low Beam (1)

Position lamps (3)

If the fuse blows again soon after

10A

Turn Signal (3)

replacement, then the electric system is

likely faulty. It may pose a fire hazard if

10A

Turn Signal (2)

not properly repaired. Contact your sales

or service dealer for advice.

10A

Starter switch

Brake lamp

1. Turn the starter key to the OFF position to

10A

/Reverse light

stop the engine.

20A

Head light high Beam (2)

10A

Turn Signal (1)

Head light high Beam (1)

Air conditioner

20A

compressor

25A

AC motor

2. Open the fuse box covers (1) and (2).

3. Inspect for blown fuses.

10A

Reverse light

10A

Brake lamp

10A

Head light high Beam (4)

10A

Head light high Beam (3)

4. If a fuse is blown, replace it with a spare

fuse of the same capacity.

6-8

TROUBLESHOOTING

IF A FUSE BLOWS

INSPECTING THE FUSIBLE LINK

Capacity

Symbol

Protected circuit

10A

ECM (2) power source

25A

Option

10A

Starter switch

Immobilizer power

source

Multi-information

If the machine is not turned on after turning

20A

display

the starter switch to the ON position, the

cartridge type fusible links (1) is likely blown.

30A

Cab power supply

Open the left side cover for inspection. If the

fusible link is blown, contact your sales or

Feed pump

service dealer.

10A

Controller power supply

Note: Fusible links are large type fuses used

in high current applications. Like a regular

15A

Lever lock

fuse, they act as fuses by protecting the

electric components and wirings from

10A

ECM (1) power source

damage caused by excessive current draw.

10A

Wiper

20A

Light

Position lamps (2)

Cab interior power

supply

10A

Horn

Position lamps (1)

6-9

TROUBLESHOOTING

RESTARTING AFTER ADDING FUEL

4. Retighten the vent plug (5) when air

RESTARTING AFTER ADDING

bleeding is finished and fuel starts leaking

out from around the vent plug (5).

FUEL

· Tightening torque: 8 to 12 N·m (6 to 9

BLEEDING AIR FROM THE FUEL SYSTEM

ft-lb)

5. Turn and hold the starter key to the ON

IMPORTANT: NEVER use the starter

position for three minutes before turning it

motor to crank the engine in order to

back to the OFF position.

prime the fuel system. This may cause the

starter motor to overheat and damage the

Note: Air in the fuel system causes the

coils, pinion gear and/or ring gear.

engine to fail to start or to have other

IMPORTANT: If the engine stalls due to

problems. Always bleed air when the fuel

fuel shortage, add fuel, turn the key to the

tank is emptied or when there is air in the

ON position for 60 seconds, and then turn

fuel system.

it to the START position. Running the

starter for a long time before there is

enough fuel is going through can cause

the starter to fail.

1. Add fuel.

2. Loosen the vent plug (5) of the main fuel

filter (2).

3. Turn the starter key to the ON position and

wait for the air to be bled from the vent

plug (5).

6-10

TROUBLESHOOTING

IF A WARNING LAMP FLASHES

If an alarm is sounded or a warning lamp starts flashing during operation, park the machine in

a safe place and perform the remedy procedures described below.

Warning lamp

Lamp name

Causes and remedies

Vehicle and

There is a problem in the machine.

engine

Refer to the respective warning lamp below.

emergency

Get the vehicle or engine error code number from the

lamp

multi-information display and consult your sales or

service dealer referring to the “Vehicle error code list” or

“Engine error code list”.

Refer to “Vehicle error code list” on page 6-14.

Refer to “Engine error code list” on page 6-16.

ECM error

There is a problem in the engine.

warning lamp

If an error code is displayed on the multi-information

display, inform your sales or service dealer of the code

and ask for help.

Refer to “Multi-information display” on 2-16.

Refer to “Engine error code list” on page 6-16.

Battery charge

There is a problem with the V-belt or charger.

warning lamp

Check the fan belt for slack or breakage and adjust as

necessary.

If the lamp continues flashing after maintenance, there is

likely a problem with the charger. Consult your sales or

service dealer for help.

Refer to “Inspecting and adjusting the V-belt” on page

5-30.

Water

Water is in the water separator. Drain water.

separator

Refer to “Draining the water from the water separator” on

warning lamp

page 5-76.

Engine oil

There is a problem in the engine lubrication system.

pressure

warning lamp

Check the engine oil level. If the lamp is flashing when

the level is normal or even after replenishment of oil or

coolant, consult your sales or service dealer.

Refer to “Inspecting and replenishing the engine oil” on

page 5-21.

Air cleaner

The air cleaner is clogged. Clean it.

warning lamp

Refer to “Cleaning the air cleaner” on page 5-43.

6-12

TROUBLESHOOTING

IF A WARNING LAMP FLASHES

Warning lamp

Lamp name

Causes and remedies

Fuel filter

The fuel filter is clogged. Replace the fuel filter.

warning lamp

Refer to “Replacing the fuel filter” on page 5-53.

Third auxiliary

Pressure in the third auxiliary hydraulic line is too low

hydraulic

warning lamp

Consult your sales or service dealer for help.

Brake oil

The brake oil pressure is too low.

pressure

warning lamp

Consult your sales or service dealer for help.

Coolant

The coolant temperature is too high and the engine is

temperature

overheating.

warning lamp

Refer to “If the engine overheats” on page 6-4.

Fuel level

The fuel level is too low. Add fuel.

warning lamp

Refer to “Inspecting the fuel level” on page 5-23.

6-13

TROUBLESHOOTING

ERROR CODE LIST

VEHICLE ERROR CODE LIST

If an error code appears on the display, consult your sales or service dealer.

Error code

Error details

Impossible to sense ACC key

Parameter version mismatching

402

CAN 0 communication error

502

CAN communication error (ECM)

602

CAN communication error (cluster gauge)

612

CAN communication error (MOX024)

622

CAN communication error (MIX024)

632

CAN communication error (SOX024)

642

CAN communication error (SIX024)

702

CAN communication error (HVAC)

1703

Main power supply voltage error (too high)

1704

Main power supply voltage error (too low)

1713

MOX024 power supply voltage error (too high)

1714

MOX024 power supply voltage error (too low)

1723

MIX024 power supply voltage error (too high)

1724

MIX024 power supply voltage error (too low)

1733

SOX024 power supply voltage error (too high)

1734

SOX024 power supply voltage error (too low)

1743

SIX024 power supply voltage error (too high)

1744

SIX024 power supply voltage error (too low)

2503

Sensor voltage error (too high) MMC

2504

Sensor voltage error (too low) MMC

2513

Sensor voltage error (too high) MIX

2514

Sensor voltage error (too low) MIX

2523

Sensor voltage error (too high) SIX

2524

Sensor voltage error (too low) SIX

3300

Alternator charge faulty

3401

Engine oil pressure error

3500

Overheat

3600

Air cleaner clogged

3700

Water separator alarm

3820

Hydraulic oil temp. overheat

6-14

TROUBLESHOOTING

ERROR CODE LIST

Error code

Error details

3825

Wire break in hydraulic oil temp. sensor

3350

Fuel filter clogged (phase 1)

3359

Fuel filter clogged (phase 2)

3360

DPD over trapping

5303

Accelerator sensor error (too high)

5304

Accelerator sensor error (too low)

5313

Foot accelerator sensor error (high pressure)

5314

Foot accelerator sensor error (low pressure)

5505

Fuel gauge resistance value error(too low)

5603

Lift alarm sensor error (too high)

5604

Lift alarm sensor error (too low)

6503

AUX1 slide switch voltage value error (too high)

6504

AUX1 slide switch voltage value error (too low)

6509

AUX1 slide switch neutral error

6519

AUX1 (L) switch error

6529

AUX1 (R) switch error

6603

AUX2 slide switch voltage value error (too high)

6604

AUX2 slide switch voltage value error (too low)

6609

AUX2 slide switch neutral error

6709

AUX3 button error (Grip)

6719

AUX3 switch error (Foot)

6809

Ram lock switch error

6819

Blade/outrigger switch error

8005

Pump PWM output voltage error (too low)

8006

Pump PWM output voltage error (too high)

8015

AUX1 (L) PWM output voltage error (too low)

8016

AUX1 (L) PWM output voltage error (too high)

8025

AUX1 (R) PWM output voltage error (too low)

8026

AUX1 (R) PWM output voltage error (too high)

8035

AUX2 (L) PWM output voltage error (too low)

8036

AUX2 (L) PWM output voltage error (too high)

8045

AUX2 (R) PWM output voltage error (too low)

8046

AUX2 (R) PWM output voltage error (too high)

8055

Fan drive PWM output voltage error (low pressure)

8056

Fan drive PWM output voltage error (high pressure)

PWM = Pulse width modulation

6-15

TROUBLESHOOTING

ENGINE ERROR CODE LIST

If an error code appears on the display, consult your sales or service dealer.

Error code

Error details

DTC

SPN

FMI

DPD differential pressure high

P2453

DPD differential pressure low

P2452

Zero-point learning error in the DPD differential pressure

P2456

sensor

DPD differential pressure sensor error (high-voltage error)

P2455

DPD differential pressure sensor error (low-voltage error)

P2454

Accelerator sensor 1 error (high-voltage error)

P2123

Accelerator sensor 1 error (low-voltage error)

P2122

Accelerator sensor 1-2 comparison error

P2138

Accelerator sensor 2 error (high-voltage error)

P2128

Accelerator sensor 2 error (low-voltage error)

P2127

Engine oil pressure sensor error (high-voltage error)

P0523

100

Engine oil pressure sensor error (low-voltage error)

P0522

Turbo boost pressure, over

P0234

Turbo boost pressure, under

P0299

102

Boost pressure sensor error (high-voltage error)

P0238

Boost pressure sensor error (low-voltage error)

P0237

Turbo boost temp. sensor error (high-voltage error)

P1113

105

Turbo boost temp. sensor error (low-voltage error)

P1112

Barometric sensor error

P2227

108

Barometric sensor error (high-voltage error)

P2229

Barometric sensor error (low-voltage error)

P2228

Engine overheat

P0217

Water temp. sensor error

P0116

110

Water temp. sensor error (high-voltage error)

P0118

Water temp. sensor error (low-voltage error)

P0117

6-16

TROUBLESHOOTING

ENGINE ERROR CODE LIST

Error code

Error details

DTC

SPN

FMI

Air flow sensor error

P0101

132

Air flow sensor error (high-voltage error)

P0103

Air flow sensor error (low-voltage error)

P0102

Common rail pressure sensor error (high-voltage error)

P0193

Common rail pressure sensor error (low-voltage error)

P0192

157

Common rail pressure rise (2nd stage)

P0088

Common rail pressure error (over pumping)

P0089

Common rail pressure rise (1st stage)

P0088

Battery line high-voltage error

P0563

158

Battery line low-voltage error

P0562

Air-intake temp. sensor error (high-voltage error)

P0113

172

Air-intake temp. sensor error (low-voltage error)

P0112

Exhaust temp. sensor 1 high-temp. error (CSF inlet)

P0426

Exhaust temp. sensor 1 low-temp. error (CSF inlet)

P0426

173

Exhaust temp. sensor 1 error (CSF inlet) (high-voltage error)

P0428

Exhaust temp. sensor 1 error (CSF inlet) (low-voltage error)

P0427

Fuel temp. sensor error

P0181

174

Fuel temp. sensor error (high-voltage error)

P0183

Fuel temp. sensor error (low-voltage error)

P0182

190

Engine overspeed

P0219

628

ROM error

P0601

633

Pressure limitter open

P0087

Cam sensor error (no signal)

P0340

636

Cam sensor error (abnormal signal)

P0340

Cam-Crank phase error

P0016

CAN timeout error

U0101

639

CAN BusOff error

U0073

651

Injector #1 failure

P0201

652

Injector #2 failure

P0202

653

Injector #3 failure

P0203

654

Injector #4 failure

P0204

675

Glow lamp failure

P0381

676

Glow relay failure

P0380

677

Starter cut relay failure

P0615

6-17

TROUBLESHOOTING

ENGINE ERROR CODE LIST

Error code

Error details

DTC

SPN

FMI

Crank sensor error (no signal)

P0335

723

Crank sensor error (abnormal signal)

P0336

968

Idle up/down switch failure

P256A

987

Check engine lamp error

P0650

1077

CPU error

P0606

1079

5V power system 1 error

P0641

1080

5V power system 2 error

P0651

Manifold temp. sensor error (high-voltage error)

P041C

1131

Manifold temp. sensor error (low-voltage error)

P041D

Common rail pressure drop (no pumping)

P0093

Common rail pressure drop (insufficient pumping)

P1093

1239

Common rail pressure drop (no pumping) <at low fuel temp.>

P0093

Common rail pressure drop (insufficient pumping) <at low fuel

P1093

temp.>

SCV high-voltage error

P0092

1347

SCV low-voltage error

P0091

Fuel filter clogging sensor error (high-voltage error)

P1294

1381

Fuel filter clogging sensor error (low-voltage error)

P1293

Main relay system error (not activated)

P0685

1485

Main relay line error (not shut off)

P0687

EGR Open faulty

P042F

2791

EGR Close faulty

P042E

EGR flow rate error

P0401

EGR position sensor error (brushless specified)

P0409

10001

EGR zero-point learning error

P1404

10002

EGR valve control error

P0404

10003

Injector com 1 error

P2146

10004

Injector com 2 error

P2149

10005

Charge circuit error (bank 1)

P1261

10006

Charge circuit error (bank 2)

P1262

10007

Sub CPU error

P0606

10008

A/D converter error

P060B

10009

5V power system 3 error

P0697

10010

5V power system 4 error

P1655

10012

12V power system error

P0560

10013

EEPROM error

P1621

6-18

TROUBLESHOOTING

ENGINE ERROR CODE LIST

Error code

Error details

DTC

SPN

FMI

Intake throttle control error

P0638

10022

Intake throttle position sensor error (high-voltage error)

P0123

Intake throttle position sensor error (low-voltage error)

P0122

EVRV vacuum sensor error (high-voltage error)

P2528

10023

EVRV vacuum sensor error (low-voltage error)

P2527

Turbo EVRV error

P0045

Exhaust temp. sensor 2 error (DOC inlet) (high-voltage error)

P042D

10024

Exhaust temp. sensor 2 error (DOC inlet) (low-voltage error)

P042C

10025

DPD lamp error

P1669

DPD PM excessive trapping 2

P1455

10026

DPD PM excessive trapping

P242F

10027

DPD purification judgment error

P1471

Exhaust temp. sensor 2 high-temp. error (DOC inlet)

P042B

10028

Exhaust temp. sensor 2 low temp. error (DOC inlet)

P042B

10029

DPD regeneration timeout count too many

P2458

10030

Starter degradation alarm

P1500

10031

Starter switch error

P0512

10032

QR code error

P0602

10033

RAM error

P0604

10034

Wheel loader CAN timeout error

U2106

10040

CAN bus error (ISO-CAN)

U0001

6-19

TROUBLESHOOTING

OTHER SYMPTOMS

For symptoms not included in the table below or if the problem persists after the proper

remedies have been taken, consult your sales or service dealer.

Symptoms

Major causes

Action

Operating levers or pedals do

• Insufficient grease on the

• Grease the levers and/or

not move smoothly

operating levers or pedals.

pedals.

Refer to page 5-77.

Steering operation is not

• Steering device is faulty

• Consult your sales or

possible.

service dealer.

Operation of hoe attachment,

• Safety lock lever is raised

• Lower the safety lock lever.

dozer blade, auxiliary

Refer to page 2-48.

hydraulics, slewing or

• Fuse is blown

• Replace the fuse.

traveling is not possible.

Refer to page 6-8.

Digging force is insufficient

• Hydraulic oil level is too low

• Add up to the specified level

Refer to page 5-24.

• Hydraulic oil is too cold

• Perform the warm-up .

Refer to page 3-8 to 3-9.

• Air cleaner is clogged

• Clean the air cleaner

Refer to page 5-43.

• Hydraulic oil is not of

• Replace the hydraulic oil.

suitable type

Refer to page 5-66.

Traveling is not possible or

• Stones or foreign objects

• Remove the foreign object.

not smooth

are stuck

• Blake pedal is locked

• Release the brake pedal

lock.

Refer to page 2-50.

• Parking brake is activated

• Turn off the parking brake

switch

Refer to page 2-39.

• Release the safety lock lever

Refer to page 2-48.

Machine veers to the right/

• Stones or foreign objects

• Remove the foreign object.

left.

are stuck

• Tires have different air

• Make sure tires have the

pressure in them.

same air pressure.

Refer to page 5-26.

6-20

TROUBLESHOOTING

OTHER SYMPTOMS

Symptoms

Major causes

Action

Travel speed cannot be

• Fuse is blown

• Replace the fuse.

changed

Refer to page 6-8.

Slewing is not possible or not

• Insufficient grease on slew

• Add grease.

smooth.

bearing

Refer to page 5-52.

Hydraulic oil temperature is

• Hydraulic oil level is too low

• Add up to the specified level

too high

Refer to page 5-24.

Starter motor turns but

• Insufficient fuel

• Add fuel.

engine does not start

Refer to page 5-23.

• Air in fuel system

• Bleed air.

Refer to page 6-10.

• Water in fuel system

• Drain water.

Refer to page 5-35.

• Fuel is frozen

• Warm the fuel pipe with hot

water or wait until the

ambient temperature

becomes high.

• Engine control system is

• Adjust or repair (ask your

faulty.

sales or service dealer).

• Fuel line is faulty.

• Adjust or repair (ask your

sales or service dealer).

• Preheating device is faulty.

• Adjust or repair (ask your

sales or service dealer).

Engine exhaust is white or

• Excessive engine oil

• Adjust to the specified level.

bluish

Refer to page 5-21.

• Insufficient engine warm-up.

• Perform the warm-up

operation.

Refer to page 3-5.

• Engine control system is

• Adjust or repair (ask your

faulty.

sales or service dealer).

• Fuel line is faulty.

• Adjust or repair (ask your

sales or service dealer).

• Prolonged idling (approx.

• Increase the engine RPM

two hours or more)

and check for smoke.

• Poor fuel

• Replace the fuel.

6-21

TROUBLESHOOTING

OTHER SYMPTOMS

Symptoms

Major causes

Action

Engine exhaust is

• Air cleaner is clogged

• Clean the air cleaner

occasionally black

Refer to page 5-43.

• Engine control system is

• Adjust or repair (ask your

faulty.

sales or service dealer).

• Fuel line is faulty.

• Adjust or repair (ask your

sales or service dealer).

• Clogging in the exhaust line.

• Adjust or repair (ask your

sales or service dealer).

• DPD is faulty.

• Adjust or repair (ask your

sales or service dealer).

Irregular noise is produced

• Low quality fuel is being

• Replace the fuel.

from the engine

used

(combustion or mechanical

• Engine is overheating

• Refer to “If the engine

noise)

overheats” on page 6-4.

• Damage inside the muffler

• Replace the muffler.

For replacement, ask your

sales or service dealer.

6-22

TROUBLESHOOTING

LOWERING THE BOOM TO THE GROUND

1. Check that the load being lifted and the

LOWERING THE BOOM TO

machine are secure and the work area is

safe.

THE GROUND

2. Place a pan under the plug (E) to catch

If the hoe attachment must be lowered to the

the used oil.

ground while the engine is stopped, use the

3. Loosen the plugs (E) slowly to lower the

following procedure.

boom. The hydraulic oil flows from the

holes of plugs (E).

Procedure

4. Check for safety and stability of the

machine.

5. Tighten the plugs (E).

• Keep away from the working area when

the hoe attachment is lowered. You may

be hit by dirt falling out of the bucket or

the hoe attachment as it drops.

• Gradually lower the boom by slowly

turning the plug on the shut-off valve.

Perform the residual pressure releasing

within 30 minutes after the engine stopping.

1. Check that the safety lock lever is in the

released position.

2. Check that the starter switch is in the ON

position.

3. Slowly push the operating lever forward to

lower the boom.

4. Check that the load being lifted and the

machine are secure and the work area is

safe.

If the boom cannot be lowered using the

above procedure, use the following

procedure.

This operation is dangerous and requires

experience. Ask your sales or service dealer

for it.

6-23

TROUBLESHOOTING

TOWING

IMPORTANT: The transmission could be

TOWING

damaged during operation if the

emergency actuator is wrongly released.

Be sure to follow the steps below to

When towing, serious injury or death

correctly release the parking brake.

could result, if performed incorrectly or

the wire rope being used is inappropriate

In case of hydraulic oil pressure failure or

or not properly inspected.

hydraulic motor failure, the emergency

• It becomes dangerous if the wire rope

actuator disconnects the reduction gear

breaks or becomes disengaged. Use a

clutch (manual release of parking brake) so

wire rope appropriate for the required

that the emergency machine towing can be

tractive force.

performed.

• Do not use a wire rope that is kinked,

twisted or otherwise damaged.

1. Stop the engine.

• Do not apply heavy loads abruptly to

2. To prevent the vehicle from moving after

the wire rope.

the parking brake is released, chock the

• Wear safety gloves when handling the

wheels.

wire rope.

• Make sure there is an operator on the

machine being towed as well as on the

machine that is towing.

• Never tow on slopes.

• Do not let anyone come near to the wire

rope while towing.

• The machine should be towed only

when it gets stuck in mud.

• Be sure to use a towing truck with

sufficient braking power.

IMPORTANT: Do not tow machines that

are not operable and no lubrication in the

transmission. Doing so could damage the

hydraulic devices due to a lack of oil

supplied. It is best to use a low loader to

transport the disabled vehicle for a long

distance.

Manually releasing the parking brake

3. Remove the cap, and then inject grease

• Brake malfunction can cause death or

through the grease fitting (1) with the

injury. Do not operate the machine with

grease gun.

a faulty brake. Resolve the problems

4. The vehicle towing can be performed

before trying to operate the machine.

when it is visually confirmed that the

• Be sure to secure the vehicle by

grease comes out of the pressure relief

chocking the wheels before releasing

valve of the emergency actuator (3).

the parking brake.

6-24

TROUBLESHOOTING

TOWING

Towing the machine

7. Depress the “Hare” symbol on low/high-

speed travel switch to change to the

1. Attach the wire rope to the shackle (1).

high-speed travel gear.

2. Make sure that the wire rope is horizontal

(Creeping travel switch: OFF)

and is lined up straight with the travel

8. Alternately switch between the low-speed

frame.

and the high-speed until the grease is

3. Move the machine to tension the wire

completely removed from the grease

rope.

discharge valve (2). Be sure to thoroughly

4. Move the machine slowly and tow.

remove the grease even in cold climates

· Towing speed: 2 km/h(1.24 mph) or less

when it becomes harder to discharge due

· Towing distance: 5 km (3.1 miles) or less

to the hardened/thickened grease.

9. Raise the safety lock lever to the lock

Reactivating the parking brake

position.

10. Stop the engine.

11. Tighten the grease discharge valve (2),

and then attach the cap.

• Completely drain the grease injected.

12. Remove the wheel chocks.

Otherwise, it will be dangerous to travel;

the parking brake cannot be operated

due to the slipping clutch. Also, the

clutch could be damaged due to the

heat generated by the slipping clutch.

• Be sure to secure the vehicle by

chocking the wheels before reactivating

the parking brake.

1. Park the machine on a flat, rigid and safe

ground. Stop the engine.

2. To immobilize the vehicle, chock the

wheels.

3. Remove the cap on the grease discharge

valve (2), and then loosen the valve to

open it, in order to release pressure and

activate the parking brake.

4. Depress the brake pedal all the way down

to lock it.

5. Start the engine.

6. Lower the safety lock lever to the unlock

position.

6-25

SPECIFICATIONS

BASIC SPECIFICATIONS

Type

2-Piece boom

MASS

Machine with an Outriggers

15070 (33225)

Operating mass***

kg (lb)

Equipped with a rear blade

14570 (32120)

Maximum Operating mass**

kg (lb)

16000 (35274)

PERFORMANCE

Heaped

0.505

(17.83)

Bucket capacity

m³ (cu. ft.)

(Standard bucket)

Struck

0.369

(13.02)

Slew speed

min^-1 (rpm)

10.8

(10.8)

Creep

0 to 4.3 (2.67)

Forward

Low-speed travel

0 to 8.5 (5.28)

High-speed travel

0 to 29.2 (18.14)/ 0 to 20 (12.43)*

km/h

Travel speed

(mph)

Creep

0 to 4.3 (2.67)

Reverse

Low-speed travel

0 to 8.5 (5.28)

High-speed travel

0 to 29.2 (18.14)/ 0 to 20 (12.43)*

Gradeability

(degrees)

Sound power level

LWA 99

Noise level dB (A)

Emission sound pressure level at the

LpA 75

operator’s position (ISO 6396,2008:)

ENGINE

Manufacturer and model

ISUZU AM-4JJ1XZSB-03

Rated output

Net (ISO 14396)

kW/min^-1 (hp/rpm)

95.0/2200 (127.4/2200)

Displacement

ml (cu.in.)

2999 (183)

Starter

V-kW

24 - 4.0

Alternator

V-kW

24 - 1.2

Battery (IEC 60095-1)

V-A·h

12 - 104 X 2

: Option

** : Maximum operating mass:

Optional parts can be added until the total mass of the machine reaches this mass value.

***: Equipped with fourth auxiliary hydraulic lines (15kg or 33lb.).

7-2

SPECIFICATIONS

MACHINE DIMENSIONS

Unit: mm (inch)

Item

2-Piece boom

Overall length

6030 (237.5)*/ 6085 (239.5)

Overall width

2525 (99.4)

Overall height

3985 (156.9)

Slew radius

2065 (81.4)

Clearance height under upperstructure

1245 (49.0)

Wheel base

2565 (101)

Tread

1945 (76.5)

Overall length of undercarriage

4600 (181.1) *

Overall height of base machine

3130 (123.1)

Ground clearance of undercarriage

275 (10.8) *

Front distance to axis of rotation

3860 (152.0)

Rear distance to axis of rotation

2170 (85.4)

Dozer blade width

2480 (97.6)

Dozer blade height

600 (23.6)

Swing angle of axles

7.5°

Minimum turning radius (Tire)

6380 (251.2)

Minimum turning radius (Dozer blade)

7025 (276.5)

Outside machine clearance radius

7295 (287.2)

Width of pad outrigger retracted

2500 (98.4) *

Width of pad outrigger extended

3555 (140.0) *

Overall width of upperstructure

2460 (96.9)

*: With an outrigger

7-5

SPECIFICATIONS

OPERATING RANGES

2-Piece boom

Unit: mm (inch)

Item

2570 mm (101.2 in) arm

Maximum reach

8885 (349.8)

Maximum reach at ground reference plane

8705 (342.8)

Maximum digging depth

5555 (218.7)

Maximum vertical digging depth

4965 (195.5)

Reach at maximum vertical digging depth

4480 (176.4)

Maximum height of cutting edge

10030 (394.8)

Maximum dumping height

7580 (298.3)

Minimum dumping height

3020 (118.8)

Dozer blade maximum lifting

480 (18.9)

Dozer blade maximum lowering

140 (5.6)

7-7

Takeuchi Hydraulic excavator TB1160W (Serial No. 514500002~). Operator's Manual (2016) - page 7