Replacing the Bucket Extend Hose on Takeuchi TB135: A Comprehensive Guide

[MikePhua]

The Takeuchi TB135 is a versatile mini excavator that has earned a reputation for its performance and durability in a variety of construction and landscaping tasks. However, like any piece of machinery, it requires proper maintenance to ensure longevity and optimal functionality. One common maintenance task involves replacing the bucket extend hose, a key component of the hydraulic system that controls the extendable arm of the excavator's bucket. In this article, we will explore the steps for replacing this hose, the tools required, and tips to avoid common pitfalls during the process.
Understanding the Role of the Bucket Extend Hose
The bucket extend hose is part of the hydraulic system that facilitates the extension and retraction of the excavator’s bucket arm. This hydraulic hose is under constant pressure and wear due to its continuous use in the arm’s movement. Over time, hydraulic hoses can deteriorate due to age, abrasion, or physical damage. Replacing a faulty or leaking hose is crucial to maintaining the performance and safety of the excavator.
Symptoms Indicating the Need for Replacement
Before beginning the hose replacement process, it’s important to identify whether the bucket extend hose actually needs replacement. The most common signs of a worn or damaged hose include:

1. Visible Leaks
   If hydraulic fluid is leaking from the hose, it’s a clear indicator that the hose needs replacing. Leaks can lead to a loss of hydraulic pressure, reducing the excavator’s effectiveness.
   
2. Reduced Performance
   If the bucket’s extension or retraction feels sluggish, or if the arm is not moving with the usual precision, this could be a sign of an issue with the hydraulic hose.
   
3. Excessive Vibration
   A worn hose can cause uneven pressure distribution in the hydraulic system, which may result in erratic bucket movement or excess vibration.
   

Steps to Replace the Bucket Extend Hose on the Takeuchi TB135
Replacing the bucket extend hose on a Takeuchi TB135 is a task that requires mechanical skill and knowledge of hydraulic systems. Below are the steps to replace the hose, along with some useful tips.

1. Preparation and Safety
   • Turn Off the Engine: Always begin by shutting off the excavator and ensuring that the hydraulic system is depressurized. This can be done by lowering the arm and bucket to the ground and activating the control lever to release any remaining pressure in the hydraulic lines.
     
   • Use Protective Gear: Hydraulic fluid is under high pressure, so wearing gloves and safety goggles is essential to protect yourself from any accidental fluid sprays.
     
2. Accessing the Hose
   • Locate the Bucket Extend Hose: The bucket extend hose typically runs along the arm of the excavator and connects to the hydraulic cylinder. You will need to carefully examine the machine to identify both ends of the hose. One end of the hose will be attached to the hydraulic pump, while the other end is connected to the hydraulic cylinder.
     
   • Remove Obstructions: Before you can disconnect the hose, you may need to remove other components or parts that are obstructing access. This could include guards, covers, or other hoses that are in the way. Be sure to keep track of any bolts, screws, or fasteners you remove during this process.
     
3. Disconnecting the Old Hose
   • Loosen Hydraulic Fittings: Using a suitable wrench or hydraulic fitting tool, loosen the hydraulic fittings that connect the old hose to the hydraulic cylinder and the pump. Be mindful of the direction of the fittings, as some are designed to turn in a specific direction.
     
   • Drain Excess Hydraulic Fluid: When the hose is disconnected, hydraulic fluid will likely spill out. Have a container ready to catch the fluid, and be sure to properly dispose of any waste hydraulic fluid in accordance with local regulations.
     
4. Installing the New Hose
   • Prepare the New Hose: Ensure that the replacement hose is the correct size and pressure rating for the TB135. Using an incorrect hose could result in failure under pressure, leading to more damage to the hydraulic system.
     
   • Attach the New Hose: Begin by connecting the new hose to the hydraulic pump side, and then to the hydraulic cylinder. Tighten the fittings securely but avoid over-tightening, as this can damage the threads or fittings.
     
   • Ensure Proper Routing: Make sure that the new hose is routed exactly as the old one was to avoid any potential kinks or abrasions. Using protective sleeves can help prevent future damage to the hose.
     
5. Testing the System
   • Check for Leaks: Once the new hose is installed, start the engine and run the hydraulic system to check for leaks. Operate the bucket to ensure smooth extension and retraction of the arm. If there are no leaks and the movement is as expected, the replacement is complete.
     
   • Top Up Hydraulic Fluid: If any hydraulic fluid was lost during the replacement, make sure to top up the hydraulic system to the recommended level. Check the fluid level using the excavator's dipstick and ensure that it is within the proper range.
     

Common Pitfalls to Avoid
While replacing the bucket extend hose on a Takeuchi TB135 is a manageable task, there are some common mistakes to avoid:

1. Incorrect Hose Sizing
   Always ensure that the replacement hose is the correct size and pressure rating. Using a hose that is too small or too large can lead to system failure or reduced performance.
   
2. Damaging Fittings
   Over-tightening the hydraulic fittings can cause damage to the threads, leading to leaks. Always tighten the fittings with the proper torque specification, and use the right tools.
   
3. Forgetting to Depressurize the System
   Never attempt to replace a hydraulic hose without first depressurizing the system. Failing to do so can result in hydraulic fluid spraying out under high pressure, which can be dangerous.
   

Maintaining the Bucket Extend Hose
Once the replacement is complete, regular maintenance is crucial to ensure the longevity of the hydraulic system. Here are some tips to keep the bucket extend hose in good condition:

1. Routine Inspections
   Regularly inspect the hydraulic hoses for signs of wear, damage, or leaks. A quick visual check can help catch problems before they become serious.
   
2. Cleaning
   Keeping the hydraulic hoses clean and free from dirt and debris can help prevent abrasion and reduce the risk of leaks. Clean the hoses gently using a non-abrasive cloth and mild soap if necessary.
   
3. Fluid Changes
   Regularly changing the hydraulic fluid will ensure the system operates efficiently and reduces the risk of contamination or breakdowns.
   

Conclusion
Replacing the bucket extend hose on a Takeuchi TB135 is an essential maintenance task that ensures the excavator continues to operate at peak efficiency. By following the proper steps, using the right tools, and avoiding common mistakes, operators can extend the life of their machines and minimize costly repairs. Regular maintenance of hydraulic systems, including routine inspections and fluid changes, will keep the excavator in optimal condition for years of reliable service.