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

DISASSEMBLY AND ASSEMBLY

PILOT VALVE

8. Use the nut (18) to affix the plate (17).

• Tighten the nut (18) to the point where plate con-

tacts all four rods uniformly.

• Do not allow the plate to move when tightening the

nut.

Nut: 68.6 N·m ± 4.9 N·m

9. Apply grease to the rotating parts on the joint (16)

and to the contact surfaces of the plate (17) and rods

(11).

10. Attach the handle (24) to the boot (23) and then at-

tach the boot (23).

PILOT VALVE

4K2AS00

DISASSEMBLY AND ASSEMBLY

PILOT VALVE

Inspection and adjustments

Inspection

Part

Criteria

Action

O-rings

—

•

Replace

Seals

—

•

Replace

Spool

• When the wear on the sliding portions is 10 μm (0.0004 in.) or greater

•

Replace

compared to non-sliding portions

• When there are scratches present on the sliding portions

•

Replace

• If the spool does not move smoothly enough

•

Replace

Rods

• If the front end is worn by 1 mm (0.04 in.) or more

•

Replace

• When there are scratches present on the sliding portions

•

Replace

Plugs

• If the seal has become imperfect due to damage

•

Repair or replace

Controls

• If the pin, shaft, or joint of the controls exhibits looseness of 2 mm

•

Tighten to the specified

(0.08 in.) or more

torque

• If the pin, shaft, or joint of the controls exhibits looseness of 2 mm

•

Replace

(0.08 in.) or greater due to wear, etc.

Casing, plate

• If there are scratches, rust, or corrosion present on the parts that

•

Replace

make sliding contact with the spool

• If there are scratches, rust, or corrosion on any parts of the seal that

•

Repair or replace

make contact with the O-ring

PILOT VALVE

4K2AS00

DISASSEMBLY AND ASSEMBLY

PILOT VALVE (SWING, BLADE)

Special Jigs

(for bushing removal)

Disassembly and Assembly

General Precautions

• Perform disassembly and assembly work in a clean

place. Provide clean containers to hold parts during

disassembly.

• Clean around the ports before disassembly. Remove

paint around connectors with a wire brush.

• Clean the disassembled parts with wash oil.

• Put alignment marks on all parts to reassemble them in

the same positions.

4K5AF02Z

• After each disassembly, replace all seals and apply a

thin layer of grease to them.

• Check each part for abnormal wear or seizing. Re-

move any burrs with sandpaper.

• Do not move adjusting screws, unless absolutely nec-

essary.

Disassembly

WARNING

The spring may fly out during disassembly. Refer to the

construction diagram and take precautions.

1. Insert a cushion plate between the pilot valve and the

vise, and fasten the pilot valve.

• Pull the bellows upward to remove it from the cov-

er.

4K4AF02Z

2. Remove the cap screw with an Allen key.

• Be aware that a high torque is required to loosen

this screw.

4K4AF03Z

PILOT VALVE (SWING, BLADE)

4K3AQ00

DISASSEMBLY AND ASSEMBLY

PILOT VALVE (SWING, BLADE)

3. Place a steel bar (7 mm dia. max.) against the cam

shaft and tap it lightly with a hammer.

4K4AF04Z

4. Remove the cam.

• Treat the cam and ball as an integral assembly

(that cannot be taken apart).

• Record the positional relationship between the

cam and the cover.

4K4AF05Z

5. Remove the cap screws with an Allen key.

4K4AF06Z

6. Remove the cover.

• Record the positional relationship between the

cam and the casing.

4K4AF07Z

PILOT VALVE (SWING, BLADE)

4K3AQ00

DISASSEMBLY AND ASSEMBLY

PILOT VALVE (SWING, BLADE)

7. Remove each plugs with the push rod, packing and

O-ring.

• Record the positional relationship between the

plugs and the casing.

4K4AF08Z

8. Remove the pressure reducing valve assemblies

and the return springs from the casing.

• Record their positional relationships with the cas-

ing holes.

4K4AF09Z

4K4AF10Z

9. Lay the cover sideways on a flat surface. Place the

special jig against the bushing and tap it lightly with

a hammer to remove the bushing.

4K4AF11Z

PILOT VALVE (SWING, BLADE)

4K3AQ00

DISASSEMBLY AND ASSEMBLY

PILOT VALVE (SWING, BLADE)

10. To disassemble the pressure reducing valve, push

down the spring seat to compress the secondary

pressure spring. At the same time, move the spring

seat sideways and pull out the spool through the

larger hole.

• Take care not to scratch the spool surface.

• Do not push down the spring seat more than 4

mm.

• During re-assembly, assemble the parts above as

a set.

4K4AF12Z

11. Separate the spool, secondary pressure spring,

shim and washer.

• During re-assembly, assemble the parts above as

a set.

• The washer adjusts the preset value of the sec-

ondary pressure spring. The washer thickness

differs for each spool assembly. In some cases

this washer is omitted.

4K4AF13Z

12. Remove the push rod from the plug.

4K4AF14Z

13. Remove the packing from the plug.

• Use a small flat head screwdriver to remove the

packing.

• Take care not to scratch the inner surface of the

plug.

4K4AF15Z

PILOT VALVE (SWING, BLADE)

4K3AQ00

DISASSEMBLY AND ASSEMBLY

PILOT VALVE (SWING, BLADE)

Assembly

1. In sequence, install the washer, shim, secondary

pressure spring and spring seat onto the spool.

• The washer adjusts the preset value of the sec-

ondary pressure spring. The washer thickness

differs for each spool assembly. In some cases

this washer is omitted.

4K4AF17Z

2. Insert the spool through the larger hole of the spring

seat. Push down the spring seat to compress the

secondary pressure spring and move the spring seat

sideways to install it.

• Take care not to scratch the spool surface.

• Do not push down the spring seat more than 4

mm.

4K4AF18Z

3. Fasten the casing in a vice.

• Install the return springs in the casing.

• Install them in the positions they were in before

disassembly.

4K4AF19Z

4. Install the pressure reducing valve sub-assemblies

in the casing.

• Install them in the positions they were in before

disassembly.

• When installing the pressure reducing valve sub-

assemblies, do not allow the lower end of the

spools to hit hard against the corners of the cas-

ing.

4K4AF20Z

PILOT VALVE (SWING, BLADE)

4K3AQ00

DISASSEMBLY AND ASSEMBLY

PILOT VALVE (SWING, BLADE)

5. Attach the O-ring to the plug.

4K4AF21Z

6. Insert the packing in the plug.

• Insert the packing in the correct orientation.

• Apply a thin layer of grease to the packing before

inserting it.

4K5AF36Z

4K4AF22Z

7. Insert the push rod into the plug.

• Apply hydraulic oil to the push rod before installa-

tion.

• Do not force in the push rod hard enough to dam-

age the packing lip.

4K4AF23Z

8. Install the push rod sub-assemblies assembled at

step 7 above into the casing.

4K4AF24Z

PILOT VALVE (SWING, BLADE)

4K3AQ00

DISASSEMBLY AND ASSEMBLY

PILOT VALVE (SWING, BLADE)

9. Lay the cover sideways on a flat surface. Place the

special jig against the bushing and tap it lightly with

a hammer to press-fit the bushing into the cover.

• Ensure that the end of the bushing does not pro-

trude into the inside of the cover.

4K4AF11Z

10. Attach the cover to the casing.

• Install it in the same position as before disassem-

bly.

• Make sure that the cover is not lifted by the return

springs.

4K4AF25Z

11. Tighten the cap screws to the specified torque.

• Ensure that the cover is level.

Cap screw: 8.8 ± 0.1 N·m

4K4AF26Z

12. Attach the cam to the cover.

• Install it in the same position as before disassem-

bly.

4K4AF27Z

PILOT VALVE (SWING, BLADE)

4K3AQ00

DISASSEMBLY AND ASSEMBLY

PILOT VALVE (SWING, BLADE)

13. Insert the cam shaft while holding down the cam.

Apply grease to the sliding surfaces of the cam

shaft bearing.

4K4AF28Z

14. Apply Loctite to the cap screw.

Cap screw: Loctite #241, or equivalent.

4K4AF29Z

15. Tighten the cap screw to the specified torque.

Cap screw: 6.9 ± 1.0 N·m

4K4AF30Z

16. Tilt the cam and apply grease to the top of the push

rods.

Apply the grease with a soft spatula to avoid

scratching the surfaces of the push rods or

plugs.

4K4AF31Z

PILOT VALVE (SWING, BLADE)

4K3AQ00

DISASSEMBLY AND ASSEMBLY

PILOT VALVE (SWING, BLADE)

17. Engage the top of the bellows with the cam, and in-

sert the bottom of the bellows into the groove in the

cover.

• Before inserting the bottom of the bellows into the

groove in the cover, spray the inside of the bel-

lows with rust-inhibiting oil.

• Be sure to attach the bellows correctly. The dust-

proof and waterproof properties will be compro-

mised if the bellows is not firmly inserted into the

groove or is twisted in the groove.

4K4AF32Z

4K4AF33Z

PILOT VALVE (SWING, BLADE)

4K3AQ00

DISASSEMBLY AND ASSEMBLY

PILOT VALVE (SWING, BLADE)

Inspection and adjustment

Checking the parts

Part

Criteria

Action

O-ring

—

• Replace

Seal

—

• Replace

Spool

• Wear on the sliding surfaces is 10 μm or more than the non-sliding

• Replace

surfaces.

• Scratches on the sliding surfaces

• Replace

• Spool does not move smoothly.

• Replace

Push rod

• Tip is worn 1 mm or more

• Replace

• Scratches on the sliding surfaces

• Replace

Plug

• Imperfect sealing due to damage

• Repair or replace

Controls

• Looseness in the pin, shaft or joint of the controls results in 2 mm

• Tighten to the specified

play, or more.

torque

• Wear of the pin, shaft or joint of the controls results in 2 mm play, or

• Replace

more.

Casing, port

• Scratches, rust, or corrosion at the parts in sliding contact with the

• Replace

plate

spool.

• Scratches, rust, or corrosion of the seal area in contact with the O-

• Repair or replace

ring

PILOT VALVE (SWING, BLADE)

4K3AQ00

DISASSEMBLY AND ASSEMBLY

PILOT VALVE (TRAVEL)

Construction

Loctite #241

1. Casing

9. O-ring

17. Cap screw

25. Bushing

2. Casing

10. Push rod

18. Spool

26. Shaft

3. Cover

11. Washer 1

19. Spring seat

27. Cam

4. Plug

12. Washer 2

20. Washer 3

28. Cap screw

5. Grease cup

13. Spring seat

21. Spring

29. Screw

6. Seal

14. Cap screw

22. Spring

30. Nut

7. O-ring

15. Piston

23. Spring

31. Boot

8. O-ring

16. Ball

24. Spring

PILOT VALVE (TRAVEL)

4K3AQ01

DISASSEMBLY AND ASSEMBLY

PILOT VALVE (TRAVEL)

Disassembly and Assembly

The numbers in parentheses () listed after the names of

parts in this document match the numbers used in the

construction diagrams and parts lists.

General Precautions

• Perform disassembly and assembly work in a clean

place. Provide clean containers to hold parts during

disassembly.

• Clean around the ports before disassembly. Remove

paint around connectors with a wire brush.

• Clean the disassembled parts with wash oil.

• Put alignment marks on all parts to reassemble them in

the same positions.

• After each disassembly, replace all seals and apply a

thin layer of grease to them.

• Check each part for abnormal wear or seizing. Re-

move any burrs with sandpaper.

• Do not move adjusting screws, unless absolutely nec-

essary.

Special Jigs

(for bushing removal)

Disassembly

WARNING

The spring may fly out during disassembly. Refer to the

construction diagram and take precautions.

1. Remove the boot (31) from the cover (3).

PILOT VALVE (TRAVEL)

4K3AQ01

DISASSEMBLY AND ASSEMBLY

PILOT VALVE (TRAVEL)

2. Loosen the cap screws (28).

3. Remove the shaft (26).

• Use a rod (8 mm dia. max.) and tap it with a ham-

mer.

4. Remove the cam (27) with the screws (29) and nuts

(30) attached.

• Take care to prevent the push rod (10) flying out.

• Neutral adjustment is required for the screws (29)

and nuts (30). Do not remove them, unless abso-

lutely necessary.

5. Remove the cap screws (17) and remove the cover

(3).

PILOT VALVE (TRAVEL)

4K3AQ01

DISASSEMBLY AND ASSEMBLY

PILOT VALVE (TRAVEL)

6. Remove the push rod (10) from the plug (4).

• Take care not to scratch the push rod (10) surfac-

es.

7. Remove the plug (4) from the casing (2), with the

grease cup (5) and seal (6) attached.

8. Remove the piston (15) and the springs (23) (24)

from the casing (2).

9. Remove the spring seat (13) from the casing (2).

PILOT VALVE (TRAVEL)

4K3AQ01

DISASSEMBLY AND ASSEMBLY

PILOT VALVE (TRAVEL)

14. Remove the bushings (25) from the cover (3).

• Use the jig.

15. Disassemble the pressure reducing valve.

a. Remove washer 1 (11).

• Stand the spool (18) on a flat surface. Push down

the spring seat (19).

• Do not push down the spring seat (19) more than

4 mm.

b. Remove the spring seat (19), spring (21), washer

2 (12), and washer 3 (20) from the spool (18).

• Washer 2 is used for adjustment. In some cases

this washer is omitted.

16. Remove the grease cup (5) from the plug (4).

PILOT VALVE (TRAVEL)

4K3AQ01

DISASSEMBLY AND ASSEMBLY

PILOT VALVE (TRAVEL)

Assembly

1. Assemble the pressure reducing valve.

a. Install washer 2 (12), washer 3 (20), spring (21),

and the spring seat (19) onto the spool (18).

b. Attach washer 1 (11) to the spool (18).

• Stand the spool (18) on a flat surface. Push down

the spring seat (19).

• Do not push down the spring seat (19) more than

4 mm.

• Engage the sharp edge of washer 1 (11) onto the

head of the spool (18).

2. Install the springs (22) and the pressure reducing

valves in the casing.

3. Fit the O-rings (7) (9) to the casing (1).

PILOT VALVE (TRAVEL)

4K3AQ01

DISASSEMBLY AND ASSEMBLY

PILOT VALVE (TRAVEL)

8. Attach the seal (6) and O-ring (8) to each plug (4).

• Insert the seal (6) in the correct orientation.

9. Attach the grease cup (5) to the plug (4).

10. Insert the push rod (10) into the plug (4).

• Apply hydraulic oil to the push rod (10) before in-

stallation.

11. Install the plugs (4) and push rods (10) assembled at

step 10 above into the casing.

PILOT VALVE (TRAVEL)

4K3AQ01

DISASSEMBLY AND ASSEMBLY

PILOT VALVE (TRAVEL)

12. Install the bushings (25) in the cover (3).

• Use the jig.

13. Attach the cover (3) to the casing (2) using the cap

screws (17).

• Ensure that the cover (3) is level.

Cap screw: 55 ± 9.8 N·m

14. Attach the cam (27) to the cover (3).

• If the screw (29) and nut (30) have been removed,

reattach them temporarily.

15. Insert the shaft (26).

PILOT VALVE (TRAVEL)

4K3AQ01

DISASSEMBLY AND ASSEMBLY

PILOT VALVE (TRAVEL)

16. Attach the cap screws (28).

Cap screw: 6.9 ± 1 N·m

Loctite #241

17. Adjust the cam (27) and cover (3) level.

a. Turn the screws to adjust the cams (27) and cover

(3) level.

• Ensure that the screws are not loose.

b. Tighten to the specified torque.

Nut: 33 ± 3.4 N·m

18. Apply grease to the top of the push rods and fill the

grease cups with grease.

19. Install the boot (31).

• Spray the inside of the boot with rust-inhibiting oil.

PILOT VALVE (TRAVEL)

4K3AQ01

DISASSEMBLY AND ASSEMBLY

PILOT VALVE (TRAVEL)

Inspection and adjustment

Checking the parts

Part

Criteria

Action

O-ring

—

• Replace

Seal

—

• Replace

Spool

• Wear on the sliding surfaces is 10 μm or more than the non-sliding

• Replace

surfaces.

• Scratches on the sliding surfaces

• Replace

• Spool does not move smoothly.

• Replace

Push rod

• Tip is worn 1 mm or more

• Replace

• Scratches on the sliding surfaces

• Replace

Plug

• Imperfect sealing due to damage

• Repair or replace

Controls

• Looseness in the pin, shaft or joint of the controls results in 2 mm

• Tighten to the specified

play, or more.

torque

• Wear of the pin, shaft or joint of the controls results in 2 mm play, or

• Replace

more.

Casing, port

• Scratches, rust, or corrosion at the parts in sliding contact with the

• Replace

plate

spool.

• Scratches, rust, or corrosion of the seal part in contact with the O-ring

• Repair or replace

PILOT VALVE (TRAVEL)

4K3AQ01

DISASSEMBLY AND ASSEMBLY

PROPORTIONAL CONTROL SOLENOID VALVE

Disassembly and assembly

The numbers in parentheses, ( ), listed after the names of

parts throughout this document do not necessarily match

the numbers of the same parts listed in the construction

diagrams and parts lists. The numbers listed are for part

numbers used in illustrations.

General precautions

•

Perform disassembly and assembly work in a clean

place. Provide clean containers to hold parts during

disassembly.

•

Clean around the ports before disassembly. Remove

paint around connectors with a wire brush.

•

Clean the disassembled parts with wash oil.

•

Put alignment marks on all parts to ensure that they are

reassembled in the same positions.

•

After each disassembly, replace all seals and apply a

thin layer of grease to each.

•

Check each part for abnormal wear or seizing. Re-

move any burrs with sandpaper.

•

Remove adhesive from screw holes that use adhesive

through the tap. Do not reuse mounting bolts or

screws.

•

Do not use cloth gloves during assembly. Fibers from

the gloves could fall off and clog valves, etc., which

could cause parts to become faulty.

•

During assembly, be sure to apply clean hydraulic oil

to all moving parts in and sliding parts that come into

contact with the hydraulic motor and valve parts be-

fore installing or attaching the part.

•

Plug all ports once assembly has been completed in

order to prevent dust and dirt from entering.

•

Do not attempt to adjust the adjusting screws at times

other than when necessary.

Disassembly

1. Take out the bolts, and remove the proportional con-

trol solenoid valve (1).

Bolt: 7 N·m ± 0.5 N·m

T9H204

PROPORTIONAL CONTROL SOLENOID VALVE

4K4AS00

DISASSEMBLY AND ASSEMBLY

PROPORTIONAL CONTROL SOLENOID VALVE

2. Remove the O-ring from the proportional control so-

lenoid valve (1).

• Do not attempt to remove the sleeve (2) that is

united to the solenoid (4) by the retaining ring (3)

as the parts are swaged together.

• Make sure that the spool (5) moves back and forth

a little if pushed from the sleeve (2) end.

Assembly

For assembly, refer to the construction diagram and re-

verse the disassembly procedure.

T9H205

Inspection and adjustments

Inspection

Part

Criteria

Action

Coil

• If the solenoid is burned out, shorted out, or suffering from wiring dis-

• Replace

connects

• If the wiring is shorted out or broken

• Replace

Body

• If there are scratches, rust, or corrosion present on the parts that

• Replace

make sliding contact with the spool

• If there are scratches, rust, or corrosion on the seal part in contact

• Replace

with the O-ring

• If there is other damage present that could possibly impair normal

• Replace

operation of the machine

• If there are scratches on the outer circumference that could easily

• Replace

Spool

get caught on by a fingernail

• If the spool does not move smoothly enough

• Repair or replace

Spring

• If there is rust, corrosion, deformation, or breakage present

• Replace

O-rings

—

• Replace

PROPORTIONAL CONTROL SOLENOID VALVE

4K4AS00

DISASSEMBLY AND ASSEMBLY

SOLENOID VALVE (DUAL-SECTION)

Disassembly and assembly

The numbers in parentheses, ( ), listed after the names of

parts throughout this document do not necessarily match

the numbers of the same parts listed in the construction

diagrams and parts lists. The numbers listed are for part

numbers used in illustrations.

General precautions

•

Perform disassembly and assembly work in a clean

place. Provide clean containers to hold parts during

disassembly.

•

Clean around the ports before disassembly. Remove

paint around connectors with a wire brush.

•

Clean the disassembled parts with wash oil.

•

Put alignment marks on all parts to ensure that they are

reassembled in the same positions.

•

After each disassembly, replace all seals and apply a

thin layer of grease to each.

•

Check each part for abnormal wear or seizing. Re-

move any burrs with sandpaper.

•

Remove adhesive from screw holes that use adhesive

through the tap. Do not reuse mounting bolts or

screws.

•

Do not use cloth gloves during assembly. Fibers from

the gloves could fall off and clog valves, etc., which

could cause parts to become faulty.

•

During assembly, be sure to apply clean hydraulic oil

to all moving parts in and sliding parts that come into

contact with the hydraulic motor and valve parts be-

fore installing or attaching the part.

•

Plug all ports once assembly has been completed in

order to prevent dust and dirt from entering.

•

Do not attempt to adjust the adjusting screws at times

other than when necessary.

Disassembly

1. Take out the plug (1), and remove the spring (2) and

plunger (3).

Plug: 21.6 N·m ± 2.0 N·m

2. Remove the O-ring from the plug (1).

3. Take out the cap screws, and remove the cover (4)

and O-ring.

Cap screw: 3.9 N·m ± 1.0 N·m

N0H102

SOLENOID VALVE (DUAL-SECTION)

4K6AS00

DISASSEMBLY AND ASSEMBLY

SOLENOID VALVE (DUAL-SECTION)

4. Take out the plug (5), and remove the O-ring.

Plug: 9.8 N·m ± 1.0 N·m

N0H103

5. Take out the cap screws, and remove the solenoid

coil (6).

• Mark the body and coil with alignment indicators

to ensure that parts are put back in the proper

places during reassembly.

• Take care not to lose the push rod.

6. Remove the O-ring from the solenoid coil (6).

N0H104

7. Take out the plug (7), and remove the O-ring.

Plug: 26.5 N·m ± 2.9 N·m

N0H105

8. Remove the spool (8) and spring (9) from the body.

• Mark the spool and spring with alignment indica-

tors to ensure that parts are put back in the proper

places during reassembly.

Assembly

For assembly, refer to the construction diagram and re-

verse the disassembly procedure.

N0H106

SOLENOID VALVE (DUAL-SECTION)

4K6AS00

DISASSEMBLY AND ASSEMBLY

SOLENOID VALVE (DUAL-SECTION)

Inspection and adjustments

Inspection

Part

Criteria

Action

Coil

• If the solenoid is burned out, shorted out, or suffering from wiring dis-

• Replace

connects

• If the wiring is shorted out or broken

• Replace

Body

• If there are scratches, rust, or corrosion present on the parts that

• Replace

make sliding contact with the spool

• If there are scratches, rust, or corrosion on the seal part in contact

• Replace

with the O-ring

• If there is other damage present that could possibly impair normal

• Replace

operation of the machine

Spool

• If there are scratches on the outer circumference that could easily

• Replace

get caught on by a fingernail

• If the spool does not move smoothly enough

• Repair or replace

Spring

• If there is rust, corrosion, deformation, or breakage present

• Replace

O-rings

—

• Replace

SOLENOID VALVE (DUAL-SECTION)

4K6AS00

Takeuchi Hydraulic excavator TB1140 (Serial No. 514400002~). Operator's Manual - page 7