Takeuchi issued this book under document number CW4E002, and the Takeuchi TB1160W workshop manual PDF runs to 755 factory pages for the TB1160W hydraulic excavator. Hydraulic circuit diagrams trace pump, control valve and pilot circuit routing, while electrical wiring and wire harness diagrams map the switch and solenoid side of the machine. Troubleshooting is organized by symptom, from a boom cylinder that will not move to slewing that overruns when stopped, and later sections strip down the multisteer and multitrac axles, the hydrostatic steering unit and the powershift transmission. Set main relief at 34.3 MPa. Slewing relief reads 27.9 +2.8 MPa, steering 14.0 +1.0 MPa. Perhaps the job you bring to it is a slew motor or travel motor disassembly and reassembly, measured against the published service standards. Buy it once and the file stays yours for this machine, with bookmarks on each chapter and a text layer that finds any part name you type.
What's Inside This Takeuchi TB1160W Manual
| System | Pages | Key Topics |
|---|---|---|
| Safety | 3-14 | Safety Alert Symbol, Safety Precautions, Cautions When Working |
| Service Data | 15-71 | Dimensional Drawing, Specifications Tables, Lubricant and Fuel Chart, Performance Criteria, Tightening Torque, Hydraulic Circuit Diagram, Electrical Wiring Diagram |
| Function | 72-113 | Piston Pump, Gear Pump, Control Valve, Pilot Valve, Proportional Control Solenoid Valve, Emergency Shut-Off Valve, Solenoid Valve, Shockless Valve, Cylinders, Travel Motor, Slew Motor, Swivel Joint |
| Disassembly and Assembly | 114-311 | Service Standards, Drive System, Travel System, Slew System, Upper Frame, Control System, Attachment, Hydraulic Tank, Hydraulic Pump, Cylinders, Travel Motor, Slew Motor, Gear Pump, Control Valve, Pilot Valve, Proportional Control Solenoid Valve, Pilot Valve (Adjust, Dozer Blade), Solenoid Valve (1-Section), Solenoid Valve (2-Section), Solenoid Valve (5-Section), Shockless Valve |
| Troubleshooting | 312-379 | Overall Machine, No Operation Is Possible, All Systems Working, But Insufficient Force, Boom, Bucket, Slew and Arm Fail to Move or Are Too Slow, Traveling, Dozer Blade, Outrigger Cylinder, Travel Motor, Slew Motor, Air Conditioner |
| Maintenance Software Manual | 380-437 | Overview, Installation, Management Function, Maintenance Function, Amplifier Function, Lift Alarm Function |
| Operation Specifications | 438-443 | Hazard Lamp Switch, Headlight Switch, Creeping Travel Switch, Travel Speed Select Switch, Parking Brake Switch, ECO Mode Button |
| Hydrostatic Steering Unit Type | 444-475 | Exploded View OSPB, Exploded View OSPC/OSPF, Dismantling, Assembling, Pressure Relief Valve, Shock Valves |
| ZF Axle Multisteer | 476-565 | Steering, Output, Planetary Carrier, Brake/Hub, Knuckle Housing, Differential |
| ZF Axle Multitrac | 566-646 | Output, Hub Carrier/Hub, Multi Disk Brake, Planetary Carrier, Differential, Input |
| ZF Hydrostatic Powershift Transmission | 647-755 | Output, Lube Oil Pump, Downshift Interlock, Speed Transmitter, Emergency Release, Modulation Valve |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Seal tape overlap | 10 mm | p. 11 |
| Hydraulic hose Union nut (G) 1/8 | 9.8 +4.9 N·m | p. 42 |
| Frozen battery warming temperature | 15°C (60°F) | p. 10 |
| Main relief valve pressure setting | 34.3 MPa | p. 21 |
| Hydraulic oil pressure (Slewing relief valve set pressure) | 27.9 +2.8 MPa | p. 28 |
| Battery retaining rod nut (upper) torque | 12.3 ±0.8 N·m | p. 130 |
| Fuel hose bolt torque | 59 N·m | p. 119 |
| Hydraulic oil tank capacity | 95 L | p. 172 |
| Engine oil pan capacity (Upper limit) | 17 L | p. 26 |
| Engine cooling system capacity | 18.5 L | p. 26 |
| Slew reduction gears oil capacity | 5.3 L | p. 26 |
| Fuel tank capacity | 233 L | p. 27 |
Takeuchi TB1160W Common Problems This Manual Covers
Takeuchi TB1160W all systems working but insufficient force with abnormal noise from the piston pump
Check the hydraulic oil level, then treat piston pump noise as cavitation from a faulty suction line: grease suspect sections to see if air is drawn in and check the suction filter for clogging. Release internal pressure before opening a line (page 9), then replace the seal tape, O-ring and hose. Measure main relief pressure against 34.3 MPa (page 21); if a quarter turn of the setscrew gains nothing, repair or replace the valve.
Manual Section: Overall machine p. 315Pilot circuit and lever lock check when boom, bucket, slew and arm fail to move or are too slow
Check the gear pump supplying the pilot valve and clean the line filter if clogged. Check the lever lock solenoid valve fuse, then use a tester to confirm voltage at the solenoid with the lever stand turning the limit switch on. Press the solenoid and feel for spool vibration. Measure pilot relief pressure against 3.9 +0.5 MPa (page 28).
Manual Section: Overall machine p. 317Travel circuit check when boom, bucket and slew work but the machine cannot travel
Release internal hydraulic pressure before disconnecting any hose (page 9), then work down the chain with a gauge. Check the accelerator valve and forward/reverse solenoid valve for 0 to 3.9 MPa by pedal angle, the control valve and travel motor MA or MB port for 34.3 MPa, and the travel speed solenoid for 3.9 MPa. If a solenoid shows no voltage, check the harness to its switch.
Manual Section: Traveling p. 321Wheel brake circuit with engine on or off, brake not working or not working properly
Release hydraulic pressure before disconnecting hoses (page 9). Engine on: check pressure at test port P4, then gauge the brake valve hose at the swivel joint and press the pedal for 6.0 MPa. No braking pressure past a good brake valve means a faulty swivel joint; check the axle last. Engine off: check the accumulators, and never disassemble, drill, weld or bring flame near them (page 326).
Manual Section: Traveling p. 325Upperstructure turns in one direction only, slew right or left not possible
Check pilot valve and control valve spools on the dead side. Swap left and right slew relief valves; if slewing returns, repair or replace the faulty relief valve. Inspect the check valves in the slew brake valve for trapped foreign matter or sticking, since a fouled check valve returns oil to the tank. If all pass, repair or replace the slew motor.
Manual Section: Slewing p. 329Slew circuit and slew bearing check when slewing is slow, lacks force, or stops entirely
Release hydraulic pressure before disconnecting hoses (page 9). Check pilot valve output at the slew section for 0 to 3.9 MPa, then control valve discharge for 34.3 MPa. Measure both slew relief valves against 27.9 +2.8/0 MPa (page 28); adjust, or repair or replace if pressure will not rise. Separate the slew motor from the turntable: if the turntable will not turn, replace the slew bearing.
Manual Section: Slewing p. 328Frequently Asked Questions
What are the hydraulic pressure specifications for the boom and travel circuits on the Takeuchi TB1160W?
The main relief valve pressure setting for the boom and travel circuits is 34.3 MPa. For travel circuits with increased pressure, the setting is 37.3 MPa. p. 28
What is the tightening torque for the bolts on the Takeuchi TB1160W upper frame counterweight?
The tightening torque for the bolts on the counterweight is 840 N·m. p. 142
What is the procedure for bleeding air from the hydraulic pump after replacement?
After installing the hydraulic pump, loosen the air-bleeding plug (4) and tighten it again once oil starts to flow out from the hole. The plug should be tightened to 110 N·m. After starting, run the engine at low idle for a while to bleed all air from the circuit. p. 126
What is the required tightening torque for the bolts on the Takeuchi TB1160W slew motor?
The bolts fixing the slew motor must be tightened to 476 N·m using ThreeBond #1324 thread-locking compound. p. 137
What is the capacity of the fuel tank for the TB1160W?
The fuel tank capacity for the TB1160W is 233 liters. p. 27
What exactly do I receive with this Takeuchi TB1160W Workshop Manual?
You get a 755-page searchable PDF that downloads instantly after checkout. Open it on your laptop, tablet, or phone, and bring it right to the shop floor.
Am I able to print pages from this Takeuchi TB1160W manual?
Yes. Print a chapter or just the pages for the job at hand, for use in your own shop. Any home or office printer works.
