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Takeuchi Hydraulic excavator TB1140 (Serial No. 514400002~). Operator's Manual - page 12

TROUBLESHOOTING

5

CYLINDERS

CYLINDERS

“4. Disassembly and assembly, Cylinders”

Symptoms

Major causes

Remedies

Oil is leaking from the pis-

•

Foreign matter is trapped in the inside

•

Remove the foreign matter.

ton rod sliding surface (oil

diameter of the rod packing or dust

forms a ring on the piston

seal.

rod, which becomes larg-

•

Scratching or abnormality of the inter-

•

Replace the faulty part(s).

er and starts dripping)

nal lip surface of the rod packing or

dust seal.

•

Scratching on the sliding surface of the

•

Smooth the sliding surface with an oilstone

piston rod.

(1.6 S or less).

•

If the leak persists after smoothing the slid-

ing surface, replace the rod packing and

other seals.

•

If the leak persists after replacing the seals,

replace the piston rod.

•

Peeling of the hard chromium plated

•

Re-plate the hard chromium plating.

surface.

Oil leaking around the rod

•

O-ring is damaged.

•

Replace the faulty part(s).

cover.

•

Backup ring is damaged.

•

Replace the faulty part(s).

Oil leaking from welded

•

Tube welding is damaged.

•

Replace the faulty part(s).

joint.

Spontaneous cylinder

•

Foreign matter is trapped in the wear

•

Remove the foreign matter.

drop (“Spontaneous

ring sliding surface.

drop” is defined as 0.5

•

Scratching or abnormality of the wear

•

Replace the faulty part(s).

mm or greater piston

ring sliding surface.

movement in 10 minutes

•

Scratching on the piston packing slid-

•

Replace the faulty part(s).

when a static load is exert-

ing surface.

ed on the rod. The static

•

O-ring is damaged.

•

Replace the faulty part(s).

load is determined by

multiplying the maximum

operating pressure by the

cylinder area.)

1

CYLINDERS

5L0AQ00

TROUBLESHOOTING

TRAVEL MOTOR 5

TRAVEL MOTOR

“4. Disassembly and assembly, Travel motor”

Hydraulic motor

Symptoms

Major causes

Remedies

Motor fails to start

•

All the devices other than the motor and

•

Check whether the specified pressure is

the reduction gears are not working

generated in the inlet port, and then check

correctly.

and repair each device.

•

Pressure oil is not flowing properly due

•

Replace the abnormally worn out part(s).

to abnormal wear of the motor’s sliding

part.

•

Motor is faulty, as its main components

•

Replace the damaged part(s).

are damaged.

Rated speed cannot be

•

Specified volume of flow is not supplied

•

Check whether the specified pressure is

obtained

to the motor due to the faulty oil pump.

generated in the inlet port, and then check

and repair each device.

•

Motor volume efficiency becomes low.

•

Check if there is abnormal wear on the slid-

ing part; if so, repair or replace it.

Rotational fluctuations are

•

High-pressure oil is leaking from the

•

Replace the abnormally worn part, if any.

large

drain port, because the motor’s sliding

part is worn out.

•

Bearing is worn out.

•

Replace the abnormally worn part, if any.

Oil leak

•

Oil leak due to O-ring breakage.

•

Replace the oil seal and O-ring.

•

Oil seal is broken by the internal pres-

•

Repair the motor and replace the oil seal.

sure generated in the motor case due

to the abnormal wear of the sliding part

of the motor.

•

Pressure increase in the drain piping

•

Clean the clogging in the drain piping and

caused by the clogging of foreign mat-

replace the oil seal.

ter resulted in breakage of oil seal.

2nd-speed control

Symptoms

Major causes

Remedies

Straight-ahead traveling

Spool cannot be switched.

level is low, switching to

• Foreign matter is caught.

•

Remove foreign matter and correct or re-

2nd-speed travel is dis-

place the faulty part(s).

abled

• Spring is missing.

•

Install the spring.

• Spring is damaged.

•

Replace the spring.

• Oil leak due to the abnormal wear of the

•

Replace the 2nd-speed control piston.

2nd-speed control piston.

• 2nd-speed control piston is missing.

•

Install the 2nd-speed control piston.

• Ball is abnormally worn out.

•

Replace the ball.

1

TRAVEL MOTOR

5M0AQ00

TROUBLESHOOTING

TRAVEL MOTOR 5

Parking brake

Symptoms

Major causes

Remedies

Braking force is insuffi-

• Disc surface is faulty.

• Repair or replace

cient or not evenly applied

• Spring is damaged.

• Replace the spring.

• Bolt for manual releasing is being fitted.

• Remove the bolt for manual release, and fit

the plug.

Abnormal heat generation

• Release of braking is faulty.

due to brake drag

• Oil leak due to O-ring breakage.

• Replace the O-ring.

• Orifice is clogged.

• Clean the orifice.

• Pilot pressure for the releasing is not

• Check whether the specified pressure is

working.

generated in the pilot port, and then check

and repair each device.

2

TRAVEL MOTOR

5M0AQ00

TROUBLESHOOTING

SLEW MOTOR 5

SLEW MOTOR

Abnormal noise or heat indicates that a defect has occurred. If such a symptom occurs, immediately stop the machine

and locate the position of the fault.

The table below shows the causes of problems that can occur in the hydraulic circuits and the appropriate remedies.

Hydraulic motor, brake valve

Symptoms

Description/location

Major causes

Remedies

Motor fails to start.

•

No pressure at the motor inlet

•

Relief valve set pressure is too

•

Set correctly.

port.

low.

•

Faulty pump.

•

Repair or replace.

•

Faulty control valve.

•

Repair or replace.

•

Pressure is applied at the motor

•

Excessive load.

•

Reduce the load.

inlet port.

•

Faulty hydraulic motor.

•

Repair or replace.

•

Faulty reduction gears.

•

Replace the reduc-

tion gears.

Motor speed does

•

Inadequate pump discharge vol-

•

Excessive pump drain volume.

•

Repair or replace

not increase.

ume.

the pump.

•

Problem with motor function.

•

Poor hydraulic motor volumetric

•

Replace the motor.

efficiency.

Oil leaks.

•

Leaking from oil seal.

•

Damage to the seal lip.

•

Replace the oil

seal.

•

Leaking from mating surface.

•

Loose bolts.

•

Retighten the bolts.

•

Defective O-ring.

•

Replace

•

Scratches on mating surface.

•

Repair surface with

oilstone or sandpa-

per.

Abnormal noise

•

Noise from piping.

•

Pipes are inadequately support-

•

Clamp the pipes.

from motor.

ed.

Temperature in-

•

Lubricating oil.

•

Low oil level.

•

Add oil.

creases in the re-

•

Hydraulic oil in the casing.

•

Replace the reduc-

duction gear cas-

tion gears.

ing.

•

Gear unit.

•

Damaged bearing.

•

Replace the reduc-

tion gears.

•

Damaged gear surfaces.

•

Replace the reduc-

tion gears.

1

SLEW MOTOR

5N0AQ00

TROUBLESHOOTING

SLEW MOTOR 5

Parking brake

Symptoms

Major causes

Remedies

Brake cannot be re-

• Release pressure PB and valve switch-

•

Set the release pressure PB and signal

leased.

ing signal pressure SH are not generat-

pressure SH to the prescribed pressure.

Low brake force.

ed. Or, low supply pressure.

Brake slips, generating

• Valve does not operate due to high

•

Check the drain circuit for clogging, and re-

noise and heat.

drain pressure.

pair if necessary. If drain from the motor is

excessive, check and repair the motor.

Timing valve does not switch.

• Scratched or worn sliding parts.

•

Repair or replace the sliding parts.

• Trapped foreign matter.

•

Remove foreign matter and repair or re-

place the faulty part(s).

• Damaged spring.

•

Replace

Brake piston does not operate.

• Damaged O-ring.

•

Replace

• Scratched or worn sliding parts.

•

Repair or replace the sliding parts.

• Trapped foreign matter.

•

Remove foreign matter and repair or re-

place the faulty part(s).

• Worn friction material.

•

Replace

• Damaged spring.

•

Replace

2

SLEW MOTOR

5N0AQ00

6

2. CONNECTION METHODS

2-2. Installation of the PLUS+1 GUIDE Service Tool

a. Start up the setup.exe file.ʢCD for installationʣ

• You must have administrator privileges to start

up the Setup Tool. Contact your system admin-

istrator for assistance if you are unable to exe-

cute the file.

b. Once you have executed the setup.exe file, the screen shown below will appear. Click the [Next] on the screen

to proceed.

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2. CONNECTION METHODS

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2. CONNECTION METHODS

c. Click [Next] to proceed.

d. Click [Next] to proceed.

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2. CONNECTION METHODS

6S1AS01

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2. CONNECTION METHODS

e. Select “I accept the agreement” and then click [Next] to confirm and proceed.

f. Specify the folder for installation (continue as is unless wanting to use a folder other than the one selected) and

then click [Next] to proceed.

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2. CONNECTION METHODS

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2. CONNECTION METHODS

g. Click [Next] to proceed.

• Uncheck the box if you do not wish to create a desktop icon.

h. Click [Install] to start the installation.

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2. CONNECTION METHODS

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2. CONNECTION METHODS

i. The screen shown below will appear if the installation is successful.

Installation of the Maintenance Tool driver will start once the installation of the above file is completed. Proceed

to Step 2-3 to continue.

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2. CONNECTION METHODS

6S1AS01

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2. CONNECTION METHODS

2-3. Installation of the Maintenance Tool driver

1. Install the Maintenance Tool driver.

a. The window shown below will appear once Step 2-2 has finished. Click the [Next] in the window to proceed.

b. Select “I accept the agreement” and then click [Next] to confirm and proceed.

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2. CONNECTION METHODS

6S1AS01

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2. CONNECTION METHODS

c. Specify the folder for installation of the driver (continue as is unless wanting to use a folder other than the one

selected) and then click [Next] to proceed.

d. Click [Install] to start the installation.

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2. CONNECTION METHODS

6S1AS01

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2. CONNECTION METHODS

e. The screen shown below will appear if the installation is successful.

Click [Finish] to complete the installation and close the window.

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2. CONNECTION METHODS

6S1AS01

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2. CONNECTION METHODS

2-4. Connection to the machine and startup of the Maintenance Software

1. Connect the Maintenance Tool (product no. 17301-

41810) to the USB port on your computer.

a. The message shown at right will appear as soon

as you connect the Maintenance Tool to the USB

port on your computer and the device is recog-

nized.

Click on the message to start the Found New Hard-

ware Wizard.

6S1AT22

b. Select 2

“Yes, now and every time I connect a device” and then click 4

[Next] to proceed.

1

“Yes, this time only.”

2

“Yes, now and every time I

connect a device.”

3

“No, not this time.”

4

Next

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2. CONNECTION METHODS

6S1AS01

6

2. CONNECTION METHODS

c. Select 1

“Install the software automatically.” Click 4

[Next] to start the Search wizard.

1

“Install the software auto-

matically.”

2

“Install from a list or specific

location.”

3

Next

d. A message such as the one shown below will appear to inform you that the installation has been completed.

Click 1

[Finish] to end the Wizard and close the window.

1

Finish

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2. CONNECTION METHODS

6S1AS01

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2. CONNECTION METHODS

2. Start up the PLUS+1 GUIDE Service Tool installed in Step 2-2.

a. Select [Program] from the Start menu and then click on [Sauer-Danfoss]. Click on PLUS+1 GUIDE 5.1, and se-

lect PLUS+1 GUIDE Service Tool.

• You can also start the program by clicking on the desktop icon if you chose to create one.

b. When the window shown below appears, confirm that [CG150] has been selected and then click [OK] to pro-

ceed.

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2. CONNECTION METHODS

6S1AS01

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2. CONNECTION METHODS

c. When the window shown below appears, confirm that [Sauer-Danfoss CG150 #0 (Channel 0)] has been select-

ed and then click [Set] to proceed.

3. Select [Communication]-[Gateway]-[CG150]-[Sauer-Danfoss CG150 #0 (Channel 0)].

• The Maintenance Tool may not be properly connected if the above is not available as a selection. Make sure

that the Maintenance Tool is firmly connected and then try again.

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2. CONNECTION METHODS

6S1AS01

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2. CONNECTION METHODS

4. Start up the Maintenance Software.

a. Select [File]-[Open].

b. Open the Maintenance Software file (File name: TB1140_***.P1D).

• The file should be located in the save location selected for the CD for installation (product no. 05701-

00005) that was selected in Step 2-1 above.

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2. CONNECTION METHODS

6S1AS01

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2. CONNECTION METHODS

5. Connect to the actual machine.

a. Remove the cover (B) on the floor space on the right side in back of the seat.

• Remove the two screws (C) and then remove the cover (B).

b. There is a connector (D) that is marked with a

“CAN_0” mark tube. Connect the cable assembly

(E) to this connector (D).

c. Connect the cable assembly (E) to the Mainte-

nance Tool (A).

1

To actual machine

2

To computer

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2. CONNECTION METHODS

6S1AS01

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3. DESCRIPTION OF FUNCTIONS

3. DESCRIPTION OF FUNCTIONS

3-1. Main screen

Click the different buttons to jump to the associated pages.

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3. DESCRIPTION OF FUNCTIONS

6S1AS01

6

3. DESCRIPTION OF FUNCTIONS

3-2. Machine status

Inputs

1

Pin wiring diagram for the main controller: C1P**

2

Pin wiring diagram for the extension module (IX012):

C1P**

1. Input signal

5. Input signal to the main controller from the aux-

ON: Switch ON

iliary line piping switches

OFF: Switch OFF

Top: Voltage value

2. Input signal to the main controller from the

Bottom: Stroke (-100% to +100%)

switches

6. Input signal to the extension module (IX012)

3. Input signal to the main controller by throttle

from the switches

operation

7. Input signal to the extension module (IX012)

Top: Voltage value

from the pressure sensor

Bottom: Degree of release for the accelerator

8. Input signal to the extension module (IX012)

pedal

from the fuel sender

4. Input value to the controller from the pressure

Top: Resistance value

sensor

Bottom: Level of fuel remaining (0% to 100%)

9. Return to the Main screen

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3. DESCRIPTION OF FUNCTIONS

6S1AS01

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3. DESCRIPTION OF FUNCTIONS

Outputs

1

Pin wiring diagram for the IX012

2

A-key (Gray): C1P**

3

B-key (Black): C2P**

1. Output signal

ON: Switch ON

OFF: Switch OFF

2. Output signals to the devic-

es from the controller

3. Target output current to the

devices from the extension

module (IX012)

Feedback

1. Actual output current for the

devices

2. Power supply voltage (12 V)

Top: Main engine control

unit (ECU)

Middle: Extension module

(OX_024)

Bottom: Extension module

(IX_012)

3. Sensor voltage (5 V)

Top: Main controller

Bottom: Extension module

(IX_012)

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3. DESCRIPTION OF FUNCTIONS

6S1AS01

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3. DESCRIPTION OF FUNCTIONS

CAN

1. CAN communications state

Switching back and forth

between ON/OFF: Normal

Staying OFF: Abnormal

Error_Code

1. Current malfunction codes for the machine

4. Current malfunction codes for the engine

2. Past malfunction codes for the machine

5. Past malfunction codes for the engine

3. Current malfunction codes triggered on the ma-

Read: Used to display a list of malfunction codes.

chine are read out.

Write: Current malfunction codes triggered on the

machine are read out in CSV format.

The P1A and CSV files for the extension modules

are created with the same content.

Delete: Used to delete the malfunction code log.

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3. DESCRIPTION OF FUNCTIONS

6S1AS01

6

3. DESCRIPTION OF FUNCTIONS

Error_Code_HVAC

1. This function displays the

HVAC (air conditioner) error

codes.

Status of other parts and sections

1. Starter switch position

6. Travel speed

2. Engine status

ON: 2nd-speed

ON: Engine running

OFF: 1st-speed

OFF: Engine stopped

7. 3rd auxiliary line piping

3. Hour meter

8. 2nd/4th auxiliary line piping

4. Trip meter

9. Air conditioner status

5. Fuel gauge (0% to 100%)

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3. DESCRIPTION OF FUNCTIONS

6S1AS01

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3. DESCRIPTION OF FUNCTIONS

3-3. Engine status

Engine_Status

1. Engine status

DPF_Status

1. DPF status

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3. DESCRIPTION OF FUNCTIONS

6S1AS01

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3. DESCRIPTION OF FUNCTIONS

3-4. AUX1 Settings

AUX1 status

1. Current settings for the 1st

auxiliary line piping

2. Download: Used to down-

load the settings to the con-

troller.

3. Upload: Used to upload the

current settings from the

controller.

4. Flow rate for the flow select

mode

Making adjustments

DANGER

Make sure to exercise extreme caution after making adjustments as the machine could run in an unexpected way, which

could in certain cases cause severe injury or even death. Be extremely careful when operating the auxiliary line piping.

a. Click on (3) to pull up the current setting conditions (4).

b. Click above or below (4) to set the flow rate to any desired value.

c. Click on the box to the left of “Download” to check it.

d. Click on (2) to download the setting values set in b. to the controller.

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3. DESCRIPTION OF FUNCTIONS

6S1AS01

6

3. DESCRIPTION OF FUNCTIONS

Grip_Settings

1. Set voltage

2. Voltage

(mV)-Current

(%)

characteristics graph

3. Download: Used to down-

load the settings to the con-

troller.

4. Upload: Used to upload the

current settings from the

controller.

5. Set Default: Used to return

the settings to the default

values.

Making adjustments

DANGER

Make sure to exercise extreme caution after making adjustments as the machine could run in an unexpected way, which

could in certain cases cause severe injury or even death. Be extremely careful when operating the auxiliary line piping.

The amount of voltage applied to the solenoid valve and the flow rate for the auxiliary line piping may vary depending

on the slide switch operation. Here, an explanation will be given for a method for adjusting the flow rate varying with

changes in voltage.

a. Click on (4) to pull up the current setting conditions (1) and (2).

b. Click above or below (1) to set the option setting to any desired value.

c. Click on (3) to download the setting values set in b. to the controller.

Example settings

For settings with Center: 2500 mV, Neutral Dead Band: 200 mV, Range: 1100 mV

There will be no operation within the 2500 mV ± 200 mV band.

There will be operation within the 1200 mV to 2300 mV and 2700 mV to 3800 mV bands.

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3. DESCRIPTION OF FUNCTIONS

6S1AS01

6

3. DESCRIPTION OF FUNCTIONS

Current_Settings

1. Set current

2. Slide switch stroke (%)-Cur-

rent (×0.1 mA) characteris-

tics graph

3. Download: Used to down-

load the settings to the con-

troller.

4. Upload: Used to upload the

current settings from the

controller.

Making adjustments

DANGER

Make sure to exercise extreme caution after making adjustments as the machine could run in an unexpected way, which

could in certain cases cause severe injury or even death. Be extremely careful when operating the auxiliary line piping.

The amount of voltage applied to the solenoid valve and the flow rate for the auxiliary line piping may vary depending

on the slide switch operation. Here, an explanation will be given for a method for adjusting the current according to

slide switch operation.

a. Click on (4) to pull up the current setting conditions (1) and (2).

b. Click above or below (1) to set the option setting to any desired value.

c. Click on (3) to download the setting values set in b. to the controller.

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3. DESCRIPTION OF FUNCTIONS

6S1AS01

6

3. DESCRIPTION OF FUNCTIONS

3-6. Others

Options

1. Option settings

2. Download: Used to down-

load the settings to the con-

troller.

3. Upload: Used to upload the

current settings from the

controller.

Setting the option settings

a. Click on (3) to pull up the current setting conditions (1).

b. After making settings for the different options, check the set items and then click (2).

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3. DESCRIPTION OF FUNCTIONS

6S1AS01

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