Disassembling the Track Tensioner Cylinder on a Takeuchi TL140 Compact Track Loader

[MikePhua]

The Takeuchi TL140 and Its Undercarriage Design
The Takeuchi TL140 compact track loader was introduced in the early 2000s as part of Takeuchi’s expansion into the North American market. Known for its robust build and smooth hydraulic response, the TL140 features a fully welded undercarriage with a track tensioning system designed for durability and ease of maintenance. With an operating weight of approximately 8,000 lbs and a rated operating capacity of over 2,000 lbs, the TL140 became a popular choice for contractors in grading, demolition, and landscaping.
Takeuchi Manufacturing, founded in Japan in 1963, pioneered the compact track loader category and remains a leader in undercarriage innovation. The TL140’s track tensioning system uses a grease-filled hydraulic cylinder to maintain proper track tension, reducing wear and improving traction.
Terminology Clarification

• Track tensioner cylinder: A hydraulic cylinder that pushes the idler forward to maintain track tension.
  
• Grease fitting (zerk): A valve used to inject grease into the cylinder to extend it.
  
• Idler: The front wheel that guides the track and receives force from the tensioner.
  
• Snap ring: A circular retaining ring used to hold components in place inside the cylinder.
  

Symptoms of Tensioner Failure
Over time, the tensioner cylinder may fail due to:

• Internal seal wear causing grease leakage
  
• Corrosion or pitting on the piston rod
  
• Broken snap rings or retaining washers
  
• Cylinder binding or uneven extension
  
• Track de-tracking during operation
  

A contractor in Maine reported that his TL140 began losing track tension after cold mornings. Upon inspection, the grease was leaking from the cylinder body, and the idler would retract under load. The issue was traced to a failed internal seal and a cracked snap ring.
Disassembly Procedure and Safety Precautions
Disassembling the tensioner cylinder requires careful handling due to the stored energy in the grease chamber. Steps include:

• Retract the cylinder fully by releasing grease through the fitting
  
• Remove the track and idler assembly to access the cylinder
  
• Clean the cylinder exterior and mark orientation points
  
• Use snap ring pliers to remove the retaining ring at the cylinder head
  
• Slide out the piston rod carefully, avoiding scoring the bore
  
• Inspect seals, washers, and wear surfaces for damage
  
• Replace components using OEM or high-quality aftermarket kits
  
• Reassemble with fresh grease and torque fittings to spec
  

Safety tips:

• Always depressurize the grease chamber before disassembly
  
• Wear eye protection and gloves to avoid injury from snap ring release
  
• Support the idler with a jack or block to prevent sudden movement
  
• Use a seal installation tool to avoid damaging new seals
  

A technician in Georgia rebuilt his TL140 tensioner using a custom seal driver and added a drain port to simplify future maintenance. The modification reduced service time and improved reliability in muddy conditions.
Seal Replacement and Component Inspection
When rebuilding the cylinder, inspect:

• Piston seals for cracks or hardening
  
• Rod wiper seals for debris intrusion
  
• Cylinder bore for scoring or rust
  
• Snap ring groove for wear or distortion
  
• Grease fitting threads for stripping
  

Recommended replacements:

• Viton or polyurethane seals rated for high-pressure grease
  
• Stainless steel snap rings for corrosion resistance
  
• OEM-spec grease fittings with check valves
  
• Anti-seize compound on threads to prevent galling
  

A fleet manager in Alberta standardized seal kits across his compact loader fleet and tracked rebuild intervals. He found that tensioner cylinders lasted 1,500–2,000 hours before requiring service, depending on terrain and operator habits.
Preventive Maintenance and Long-Term Reliability
To extend the life of the tensioner cylinder:

• Grease the fitting monthly or after heavy use
  
• Inspect track tension visually before each shift
  
• Clean mud and debris from the idler area
  
• Replace seals every 2,000 hours or during undercarriage service
  
• Store machines indoors during winter to prevent seal shrinkage
  

A crew in Oregon added tensioner checks to their daily walkaround and reduced track failures by 80% over one season.
Conclusion
Disassembling and rebuilding the track tensioner cylinder on a Takeuchi TL140 requires mechanical care and attention to hydraulic detail. With proper tools, seal selection, and safety practices, operators can restore full track tension and avoid costly downtime. Whether working in rocky terrain or soft clay, a well-maintained tensioner ensures consistent performance and protects the undercarriage investment. The TL140’s design allows for straightforward service, making it a reliable partner in compact earthmoving operations.