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

DISASSEMBLY AND ASSEMBLY

SHOCKLESS 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. Remove the connector (7) from the body (4), and re-

move the O-ring (11).

Connector: 34.3 N·m ± 4.9 N·m

SHOCKLESS VALVE

4K9AS00

DISASSEMBLY AND ASSEMBLY

SHOCKLESS VALVE

2. Remove the snap ring (9), and remove the sleeve.

3. Take out the connector (6), and remove the O-ring

(12).

Connector: 48.5 N·m ± 4.9 N·m

4K9AK03Z

4. Remove the spring (3) and plunger (1) from the body

(4).

Assembly

For assembly, refer to the construction diagram and re-

verse the disassembly procedure.

4K9AK04Z

Inspection and adjustments

Inspection

Part

Criteria

Action

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

Plunger

• 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

SHOCKLESS VALVE

4K9AS00

DISASSEMBLY AND ASSEMBLY

CYLINDERS

Construction

Boom cylinder

1. Buffer ring

8. Piston packing

15. Rod cover

22. Dust ring

2. Rod packing

9. O-ring

16. Bushing

23. Nut

3. Backup ring

10. Backup ring

17. Snap ring

24. Set screw

4. Dust seal

11. Tube

18. Snap ring

25. Cap screw

5. O-ring

12. Bushing

19. Cushion bearing

26. Dust seal

6. Backup ring

13. Piston rod

20. Piston

27. Grease nipple

7. O-ring

14. Bushing

21. Wear ring

28. Grease nipple

Arm cylinder

1. Buffer ring

9. O-ring

17. Snap ring

25. Stop ring

2. Rod packing

10. Backup ring

18. Cushion bearing

26. Cap screw

3. Backup ring

11. Tube

19. Piston

27. Check valve

4. Dust seal

12. Bushing

20. Wear ring

28. Dust seal

5. O-ring

13. Piston rod

21. Dust ring

29. Grease nipple

6. Backup ring

14. Rod cover

22. Nut

7. O-ring

15. Bushing

23. Set screw

8. Piston packing

16. Snap ring

24. Plunger

CYLINDERS

4L0AS00

DISASSEMBLY AND ASSEMBLY

CYLINDERS

Bucket cylinder

1. Buffer ring

8. Piston packing

15. Rod cover

22. Nut

2. Rod packing

9. O-ring

16. Bushing

23. Set screw

3. Backup ring

10. Backup ring

17. Snap ring

24. Cap screw

4. Dust seal

11. Tube

18. Snap ring

25. Dust seal

5. O-ring

12. Bushing

19. Piston

26. Grease nipple

6. Backup ring

13. Piston rod

20. Wear ring

7. O-ring

14. Bushing

21. Dust ring

Swing cylinder

1. Buffer ring

8. Piston packing

15. Rod cover

22. Dust ring

2. Rod packing

9. O-ring

16. Bushing

23. Nut

3. Backup ring

10. Backup ring

17. Snap ring

24. Set screw

4. Dust seal

11. Tube

18. Snap ring

25. Cap screw

5. O-ring

12. Bushing

19. Cushion bearing

26. Dust seal

6. Backup ring

13. Piston rod

20. Piston

27. Grease nipple

7. O-ring

14. Bushing

21. Wear ring

28. Grease nipple

CYLINDERS

4L0AS00

DISASSEMBLY AND ASSEMBLY

CYLINDERS

Special tools

Special wrench (For the piston nut)

Unit: mm

Cylinders

Arm

150

300

12 to 15

Boom

130

300

12 to 15

Bucket

Swing

159

300

12 to 15

Dozer blade

140

300

12 to 15

Special wrench (For the piston)

Unit: mm

Cylinders

Combined bolts

Arm

115

300

12 to 15

M8×20 (Qty. 2)

Boom

105

300

12 to 15

M10×20 (Qty. 2)

Bucket

Swing

150

110

300

12 to 15

M12×20 (Qty. 2)

Dozer blade

110

300

12 to 15

M10×20 (Qty. 2)

CYLINDERS

4L0AS00

DISASSEMBLY AND ASSEMBLY

CYLINDERS

Installation jig (For the piston seals)

Unit: mm

Cylinders

Arm

109.5 ± 0.1

111 ± 0.1

100

22.0

Boom

99.5 ± 0.1

101 ± 0.1

23.0

Bucket

Swing

139.5 ± 0.1

141 ± 0.1

130

120

26.0

Dozer blade

114.5 ± 0.1

116 ± 0.1

105

28.0

Corrective jig (For the piston seals)

Unit: mm

Cylinders

Arm

120

128

112 ± 0.1

Boom

110

118

102 ± 0.1

Bucket

10 to 15

100

Swing

150

158

142 ± 0.1

Dozer blade

125

133

117 ± 0.1

CYLINDERS

4L0AS00

DISASSEMBLY AND ASSEMBLY

CYLINDERS

Press-fitting jig (For the pin bushing)

Unit: mm

Cylinders

Arm

79.5

-0.1

94.5 ± 0.1

115

6.5 ± 0.1

120

Boom

74.5

0-0.1

89.5 ± 0.1

110

5.5 ± 0.1

125

Rod side

5.0 ± 0.1

120

Bucket

64.5

-0.1

79.5 ± 0.1

100

Head side

4.5 ± 0.1

115

Swing

99.5

-0.1

114.5 ± 0.1

135

115

4.5 ± 0.1

115

145

Dozer blade

69.5

0-0.1

84.5 ± 0.1

105

6.0 ± 0.1

105

Press-fitting jig (For the dust seals)

Unit: mm

Cylinders

Arm

108

5.5

25.5

Boom

Bucket

5.0

Dozer blade

Swing

103

118

CYLINDERS

4L0AS00

DISASSEMBLY AND ASSEMBLY

CYLINDERS

Disassembly and assembly

This section provides a description of procedures mainly

for standard cylinders. Complete actual work proce-

dures while studying the construction of the parts provid-

ed in this section.

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

Cylinder assembly

1. Secure the cylinder horizontally by securing the cle-

vis of the tube in a vice and placing a wooden sup-

port under the other end.

2. Drain out any hydraulic oil left remaining in the cylin-

der.

• Move the piston rod slowly to prevent the hydrau-

lic oil from spraying out.

4LAA07Z

CYLINDERS

4L0AS00

DISASSEMBLY AND ASSEMBLY

CYLINDERS

3. Loosen the cap screw (1), and remove the pipe (2).

4. Take out the cap screw (3) in the rod cover.

• Cover the piston rod to prevent it from becoming

damaged.

5. Remove the piston rod assembly (4) from the tube

(5).

a. Raise and temporarily suspend the rod with a

crane such that the rod and tube are straight.

b. Tap the end corner of the pipe port flange to cre-

ate a clearance.

c. Insert the end of a flat-bladed screwdriver into the

clearance to widen the clearance further.

d. Remove the piston rod assembly from the tube.

• Pull it straight out so as not to damage sliding

surfaces.

CYLINDERS

4L0AS00

DISASSEMBLY AND ASSEMBLY

CYLINDERS

Cylinder assembly (Blade cylinder)

1. Secure the cylinder horizontally by securing the cle-

vis of the tube in a vice and placing a wooden sup-

port under the other end.

2. Drain out any hydraulic oil left remaining in the cylin-

der.

• Move the piston rod slowly to prevent the hydrau-

lic oil from spraying out.

4LAA07Z

3. Loosen the cap screw (1), and remove the pipe (2).

4. Disengage the anti-rotation lock for the rod cover.

• As the anti-rotation lock is built directly into the

cylinder tube, take care not to damage the tube

when releasing the lock.

4LAA08Z

5. Loosen the rod cover.

• Pull the piston rod outward about 200 mm (7.9 in.)

in advance.

• Cover the piston rod to prevent it from becoming

damaged.

6. Remove the piston rod assembly from the tube.

• Pull it straight out so as not to damage sliding sur-

faces.

4LAA09Z

CYLINDERS

4L0AS00

DISASSEMBLY AND ASSEMBLY

CYLINDERS

Piston rod assembly

1. Secure the piston rod assembly horizontally.

4LAA10Z

2. Remove the piston section.

a. Take out the set screw (8).

• The set screw (8) is swaged with a punch in two

places. Apply oil while gently loosening it.

b. Remove the piston nut

(9) using the special

wrench (for the piston nut).

c. Remove the piston (10) using the special wrench

(for the piston).

CYLINDERS

4L0AS00

DISASSEMBLY AND ASSEMBLY

CYLINDERS

3. Remove the rod cover assembly (12) from the rod.

Piston

1. Remove the wear ring (13) and dust ring (14) from

the piston (10).

2. Remove the piston seals.

a. Remove the backup ring (15).

b. Remove the seal ring (16) and backup ring (17).

• Secure the piston so that it does not move, and

remove the seal ring and backup ring using a

flat-bladed screwdriver and a hammer.

3. Remove the O-ring (18) and backup ring (19) from

the inside of the piston.

• Use a spatula to scrape away the rings.

CYLINDERS

4L0AS00

DISASSEMBLY AND ASSEMBLY

CYLINDERS

Rod cover

1. Remove the O-rings (20) and (21) and backup ring

(22) from the rod cover.

2. Remove the buffer seal (23) and rod packing (24).

3. Remove the retaining ring (26).

4. Remove the dust seal (27).

a. Place the rod cover in a vice.

b. Insert the blade of a flat-bladed screwdriver into

the groove on the dust seal, and tap the screw-

driver with a hammer to remove the seal.

5. Scrape away the bushing to remove it.

• Do not remove the bushing unless it is badly dam-

aged by wear or seizing.

CYLINDERS

4L0AS00

DISASSEMBLY AND ASSEMBLY

CYLINDERS

Clevises

1. Remove the dust seals from the clevises of the tube

and piston rod.

4LAA22Z

2. Remove the bushing from the piston rod.

• Pull out the bushing using a press with a support-

ing metal plate.

Assembly

Clevises

1. Press-fit the bushing into the piston rod and tube.

• Complete using the press-fitting jig (28) (for the

bushing).

2. Attach the dust seal using a press with a supporting

metal plate.

CYLINDERS

4L0AS00

DISASSEMBLY AND ASSEMBLY

CYLINDERS

Rod cover

1. Attach the dust seal (27).

• Use the press-fitting jig (29) (for the dust seal) to

press-fit the dust seal into the cover to ensure that

an equal amount of pressure is applied around

the circumference of the dust seal.

• Apply grease to the inner sides of the dust seal.

2. Attach the buffer ring (23), rod packing (24), and

backup ring (25).

• Shape the seal into a heart, and insert it from the

direction of the arrow side.

• Position the R part on the backup ring (30) for the

buffer ring (23) as shown in the diagram.

3. Attach the O-ring (20).

4. Attach the O-ring (21) and backup ring (22).

CYLINDERS

4L0AS00

DISASSEMBLY AND ASSEMBLY

CYLINDERS

Piston

WARNING

Wear gloves when completing this procedure to keep

from getting burned on the heated seal ring.

1. Insert the back ring (17) into the piston.

2. Place the special jig (for the piston seal) (31) onto the

piston, and use it to attach the seal ring (16).

• Heat the hydraulic oil to a temperature of around

150°C to 180°C (302°F to 356°F) using an electri-

cal heater, and dip the seal ring into the heated oil

for five minutes and then attach it to the back ring

while it is still warm.

3. Correct the shape and length of the seal ring using

the corrective jig (for the piston seal) (32) as the seal

ring may become stretched during attachment.

4. Attach the backup ring (15) to both sides of the seal

ring (16).

• Position the R part on the backup ring as shown in

the diagram.

5. Attach the O-ring (18) and backup ring (19).

CYLINDERS

4L0AS00

DISASSEMBLY AND ASSEMBLY

CYLINDERS

Piston rod assembly

1. Attach the rod cover assembly to the piston rod.

• Secure the piston rod assembly horizontally.

• Use the installation jig (33) (for the rod cover) to

attach the rod cover assembly.

• Apply hydraulic oil to the surfaces of the installa-

tion jig and rod.

2. Attach the piston to the piston rod.

• Attach the piston together with the cushion ring if

using a cushion ring.

• Use the special wrench (for the piston) to attach

the piston.

• Gently tighten the piston taking care not to tighten

it too far.

Piston (Blade cylinder): 735 N·m ± 69 N·m

Piston (Other cylinders): 981 N·m ± 98 N·m

3. Fasten on the piston nut (9).

• Use the special wrench (for the piston nut) to

screw on the piston nut.

• Gently tighten the piston nut taking care not to

tighten it too far.

• If using a cushion ring, after fastening on the pis-

ton nut, do not tighten down the cushion ring but

instead leave a clearance of around 0.5 mm (0.02

in.) in the direction of the shaft, and check to en-

sure that the cushion ring moves freely.

Piston nuts (For the arm, boom, and bucket cyl-

inders): 1274 N·m ± 127 N·m

Piston nut (For the swing cylinder): 1860 N·m ±

186 N·m

Piston nut (For the blade cylinder): 1274 N·m ±

130 N·m

4. Fasten on the set screw (8) and swage it into place

in two places using a punch.

Set screw: Apply Loctite #242.

Set screw: 15 N·m ± 1.5 N·m

CYLINDERS

4L0AS00

DISASSEMBLY AND ASSEMBLY

CYLINDERS

Cylinder assembly

1. Secure the tube horizontally, and insert the piston

rod assembly into the tube.

• Insert the tube straight into the piston rod, lining

up the center of the tube with the center of the pis-

ton rod shaft.

2. Attach the rod cover, and fasten it in place with the

cap screw (3).

• Make sure that the pipe flange of the rod cover is

oriented properly when attaching the rod cover.

Cap screws (Arm, boom, and bucket cylinders):

211 N·m ± 5 N·m

Cap screw (Swing cylinder): 353 N·m ± 10 N·m

3. Insert the check valves (for the arm cylinder, swing

cylinder).

• Attach parts in order of valve, spring, spring re-

tainer, and then plug with attached O-ring.

Plug: 49.0 N·m ± 4.9 N·m

Cylinder assembly (Blade cylinder)

1. Secure the tube horizontally, and insert the piston

rod assembly into the tube.

• Insert the tube straight into the piston rod, lining

up the center of the tube with the center of the pis-

ton rod shaft.

2. Attach the rod cover and tighten it down with screws.

• Make sure that the pipe flange of the rod cover is

oriented properly when attaching the rod cover.

Rod cover: 588 N·m ± 98 N·m

3. Bend the lock rib on the tube and lock it into place.

4LAA36Z

CYLINDERS

4L0AS00

DISASSEMBLY AND ASSEMBLY

CYLINDERS

Inspection and adjustments

Inspection after disassembly

Clean each part thoroughly with cleaning oil, then carry

out the following checks. When a cylinder has been dis-

assembled, replace all the seals with new ones.

1. Piston rod

• Replace the rod if it has any cracks.

• Repair any damaged threads, or replace the rod

entirely if there are damaged threads.

• Replace the rod if the plating layer of the plated

portion is broken, rusted, or scratched.

• Replace the rod if it is bent by more than the limit

of 1 mm in 1 m. (For the measurement method, re-

fer to the figure on the right.)

• Replace the bushing if the inner diameter of the

clevis bushing is worn.

Measuring the bend

a. Place the portion of the rod with the same diame-

ter at both ends on V-blocks to support it.

b. Place a dial gauge at the center point between the

two blocks.

c. Rotate the rod, and record the readings for maxi-

mum and minimum run-out shown on the dial

gauge.

If the amount of bending in the rod is within the

above limit but is great across a short distance so

1/2

that the rod does not move smoothly, replace the

rod if it makes a squeaking sound during the op-

eration test after reassembly or if it catches during

4LAA37Z

movement.

2. Tube

• Replace the tube if there are cracks in the welded

portion.

• Replace the tube if the inside surface is scratched

or if it leaks hydraulic oil.

• Replace the bushing if the inner diameter of the

clevis bushing is worn.

3. Rod cover

• Replace the bushing if the bushing inner diameter

is worn and the clearance with the piston rod is

greater than 0.25 mm (0.0098 in.).

• Replace the bushing if the inside surface of the

bushing is scratched and the scratches penetrate

beyond the coating layer.

CYLINDERS

4L0AS00

DISASSEMBLY AND ASSEMBLY

CYLINDERS

Inspection after assembly

No load operation test

1. Place the cylinder in a horizontal position with no

load.

2. Apply gentle pressure alternately to the ports at the

ends, and operate the piston rod 5 or 6 times.

3. Make sure that there are no errors or abnormal oper-

ating conditions.

4LAA38Z

Leak test

• External leak

1. Apply a test pressure to the retraction side and to the

extension side for 3 minutes each.

2. Make sure that there are no abnormalities such as

external leakage or permanent deformation, etc. in

the rod seal or rod cover mount or in any welded por-

tion.

• Internal leak

1. Disconnect the hose on the extension side.

4LAA39Z

2. Apply the test pressure to the retraction side for 3

minutes.

3. Measure the amount of oil that has leaked from the

extension side.

• The amount of leakage should be 1 mL/3 min. or

less.

Bleeding air from the hydraulic cylinder

Bleed air out of the cylinder when the cylinder is removed

or when the hydraulic piping or other parts are discon-

nected.

1. Start the engine, and let it idle for approximately 5

minutes.

2. With the engine running at slow speed, extend and

retract the cylinder 4 or 5 times.

• Move the piston rod to a position 100 mm (3.94

in.) before the end of the stroke, being careful not

to relieve air.

3. With the engine running at top speed, repeat the op-

eration outlined in (2), and then, with the engine run-

ning at slow speed, move the piston rod to the stroke

end to bleed off the air in the cylinder.

CYLINDERS

4L0AS00

DISASSEMBLY AND ASSEMBLY

TRAVEL MOTOR 4

1. Gear case

102. Driving shaft

205. Plug

376. Orifice

2. Motor housing

103. Swash plate

206. Spring

377. Filter

3. Carrier

104. Cylinder block

207. O-ring

378. Steel ball

4. Sun gear

105. Piston

208. Backup ring

379. Plug

5. Planet gear

106. Shoe

209. O-ring

380. Plug

6. Pin

107. Shoe holder

210. Backup ring

381. Piston

7. Carrier

108. Guide

211. O-ring

383. O-ring

8. Sun gear

109. Valve plate

212. O-ring

384. Orifice

9. Planet gear

110. Washer

213. Shim

396. Plug

10. Pin

112. Break piston

301. Valve body

398. Plug

11. Thrust washer

113. Spring

323. Spool

399. Plate

12. Thrust washer

114. Spring

324. Plug

13. Thrust plate

115. Friction disc

325. Washer

14. Cover

116. Center disc

326. Plug

15. Coupling

132. Oil seal

327. Valve

16. Pin

135. O-ring

328. Spring

17. Pin

139. O-ring

329. Orifice

22. Lock washer

145. Retaining ring

330. Spring

23. Shim

149. Bearing

331. O-ring

24. Angular bearing

150. Bearing

336. O-ring

27. Bearing

151. Pin

341. Pin

28. Bearing

161. Piston

343. Cap screw

29. Floating seal

162. Shoe

352. Plug

30. Plug

167. Pivot

353. Ball

31. O-ring

171. Pin

354. Plug

32. O-ring

185. Spring

357. Plug

33. O-ring

201. Valve seat

358. O-ring

34. Pin

202. Valve

359. O-ring

35. Cap screw

203. Sleeve

363. Spool

36. Retaining ring

204. Collar

366. Spring

TRAVEL MOTOR

4M0AS00

DISASSEMBLY AND ASSEMBLY

TRAVEL MOTOR

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 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. Remove the cover.

a. Take out the cap screws.

b. Place a supporting metal plate over the protrusion

on the cover, and tap the plate with a hammer.

TRAVEL MOTOR

4M0AS00

Takeuchi Hydraulic excavator TB1140 (Serial No. 514400002~). Operator's Manual - page 8