Takeuchi TL120 Crawler Loader Workshop Manual (CT3E002)

Format: PDF (Printable Document)

File Language: English

File Pages: 552

File Size: 24.28 MB (Speed Download Link)

Brand: Takeuchi

Model: TL120 Crawler Loader

Book No: CT3E002

Serial No: 21200008-

Type of Document: Workshop Manual

Categories: PDF, Takeuchi PDF

$ 50

Takeuchi TL120 Crawler Loader Workshop Manual (CT3E002)

Takeuchi TL120 Crawler Loader Workshop Manual (CT3E002) (SN 21200008-)

The TL120 is a compact track loader that spends its life in mud, gravel, and tight construction sites, so things wear, bend, and leak. This workshop manual is what I’d keep open when I’m doing real repairs—pulling a drive motor, chasing a hydraulic issue, or rebuilding a control linkage. If, for example, the machine starts crab-tracking and chewing up tracks, this book walks you through how to systematically inspect the undercarriage, trace the fault, repair it, and reinstall everything so it runs straight again.

Applications & Use Cases

Plan major teardown work on the undercarriage, loader arms, or hydraulic components with a clear, step‑by‑step sequence.
Verify wear limits and clearances during scheduled inspections so you know whether to adjust, rebuild, or replace.
Trace hydraulic or drive complaints—slow travel, weak lift, or noisy pumps—without guessing or swapping parts blindly.
Align and reinstall components like final drives, sprockets, and cylinders so seals seat correctly and hoses route cleanly.
Perform post-repair checks to confirm the TL120 is bled, adjusted, and safe before it goes back into digging or loading work.

FAQ

Q: Can I use this manual on a tablet in the field?

A: Yes, it’s practical to keep it on a tablet or laptop so you can zoom diagrams and search procedures right next to the machine.

Q: Is it still worth printing parts of it?

A: Many techs print the procedures and torque charts they use often, then keep them in a binder that can handle grease and dirt.

Safety Note

Always lock out the machine, support raised components mechanically, and follow the manual’s warnings before loosening any pressurized or suspended parts.

📘 Show Index

Takeuchi TL120 Crawler Loader Index:

SAFETY
- Safety alert symbol
- Safety precautions
- Cautions when working
SERVICE DATA
- Dimensional drawing
- Specifications tables
- Fuel and lubricant table
- Performance criteria
- Tightening torque
- Hydraulic circuit diagram
- Electrical wiring diagram
- Wire harness diagram
OPERATION
- HST pump
- Gear pump
- Control valve
- SUB valve
- Self-level valve
- Pilot valve
- Proportional control solenoid valve
- Cylinders
- Travel motor
- Proportional control
- Air conditioner system
Disassembly and assembly
- Service standards
- Drive system
- Travel system
- Frame
- Control system
- Attachments
- Hydraulic tank
- HST pump
- Gear pump
- SUB valve
- Self-level valve
- Pilot valve
- Proportional control solenoid valve
- Cylinders
- Travel motor
- Proportional control
- Air conditioner
TROUBLESHOOTING
- Overall machine
  - No operation is possible.
  - All systems working, but insufficient power.
  - Lift arm and bucket fail to move or are too slow.
- Traveling
  - Traveling fails.
  - Right or left travel speed decelerates and the machine veers to one side.
  - Operating temperature of the travel system is too high.
  - 2nd speed travel is not possible.
- Lift arm
  - Arm cylinder fails.
  - Arm cylinder is slow or the power is insufficient.
  - When the control lever is pulled slowly, the lift arm drops once.
  - Spontaneous drop of the lift arm is too large.
- Bucket
  - Bucket cylinder fails to move.
  - Bucket cylinder is slow or the power is insufficient.
  - Spontaneous drop of the bucket is too large.
- Auxiliary hydraulics
  - Proportional control is not possible
- HST pump
- Gear pump
- Control valve
- SUB valve
- Self-level valve
- Pilot valve
- Proportional control solenoid valve
- Cylinders
- Travel motor
- Air conditioner system
ENGINE
- 3TNV/4TNV series
  - Cover
  - History of Revision
  - PREFACE
  - SAFETY LABELS
  - CONTENTS
  - 1. General
    - 1.1 Engine nomenclature
    - 1.2 Specifications
    - 1.3 Fuel oil, lubricating oil and cooling water
      - 1.3.1 Fuel oil
      - 1.3.2 Lubricating oil
      - 1.3.3 Cooling water
    - 1.4 Engine external views
    - 1.5 Structural description
    - 1.6 Exhaust gas emission regulation
      - 1.6.1 The emission standard in USA
      - 1.6.2 Engine identification
      - 1.6.3 Guarantee conditions for the EPA emission standard
  - 2. Inspection and adjustment
    - 2.1 Periodic maintenance schedule
    - 2.2 Periodic inspection and maintenance procedure
      - 2.2.1 Check before daily operation
      - 2.2.2 inspection after initial 50 hours operation
      - 2.2.3 Inspection every 50 hours
      - 2.2.4 Inspection every 250 hours or 3 months
      - 2.2.5 Inspection every 500 hours or 6 months
      - 2.2.6 Inspection every 1,000 hours or one year
      - 2.2.7 Inspection every 2000 hours or 2 years
    - 2.3 Adjusting the no-load maximum or minimum speed
    - 2.4 Sensor inspection
      - 2.4.1 Oil pressure switch
      - 2.4.2 Thermo switch
    - 2.5 Water leak check in cooling water system
    - 2.6 Radiator cap inspection
    - 2.7 Thermostat Inspection
    - 2.8 Adjusting operation
    - 2.9 Long storage
  - 3. Troubleshooting
    - 3.1 Preparation before troubleshooting
    - 3.2 Quick reference table for troubleshooting
    - 3.3 Troubleshooting by measuring compression pressure
  - 4. Disassembly, inspection and reassembly of engines
    - 4.1 Complete disassembly and reassembly
      - 4.1.1 Introduction
      - 4.1.2 Special service tools
      - 4.1.3 Complete disassembly
      - 4.1.4 Precautions before and during reassembly
      - 4.1.5 Adjusting operation
    - 4.2 Cylinder head: Disassembly, inspection and reassembly
      - 4.2.1 Components (2-valve cylinder head)
      - 4.2.2 Disassembly procedure:
      - 4.2.3 Reassembly procedure:
      - 4.2.4 Servicing points
      - 4.2.5 Parts Inspection and measurement
      - 4.2.6 Valve seat correction
      - 4.2.7 Valve guide replacement
      - 4.2.8 Valve stem seal replacement
    - 4.3 Gear train and camshaft
      - 4.3.1 Components
      - 4.3.2 Disassembly procedure:
      - 4.3.3 Reassembly procedure:
      - 4.3.4 Servicing points
      - 4.3.5 Parts inspection and measurement
      - 4.3.6 Oil seal replacement (Gear case side)
      - 4.3.7 Camshaft bushing replacement
    - 4.4 Cylinder block
      - 4.4.1 Components
      - 4.4.2 Disassembly procedure:
      - 4.4.3 Reassembly procedure:
      - 4.4.4 Servicing points
      - 4.4.5 Parts inspection and measurement
      - 4.4.6 Cylinder bore correction
      - 4.4.7 Piston pin bushing replacement
      - 4.4.8 Oil seal replacement (Flywheel housing side)
  - 5. Lubrication system
    - 5.1 Lubrication system diagram
    - 5.2 Trochoid pump components
    - 5.3 Disassembly (Reverse the procedure below for assembly)
    - 5.4 Servicing points
    - 5.5 Parts Inspection and measurement
      - 5.5.1 Trochoid pump inspection and measurement
    - 5.6 Lube oil filter
      - 5.6.1 Lube oil filter construction
      - 5.6.2 Lube oil filter replacement
  - 6. Cooling system
    - 6.1 Cooling water system
    - 6.2 Cooling water pump components
    - 6.3 Disassembly (Reverse the procedure below for assembly)
    - 6.4 Servicing points
  - 7. Fuel injection pump / Governor
    - 7.1 Introduction
    - 7.2 Fuel injection pump
      - 7.2.1 Fuel system diagram
      - 7.2.2 External view and components
      - 7.2.3 Disassembly procedure:
      - 7.2.4 Assembly procedure
      - 7.2.5 Servicing points
      - 7.2.6 C.S.D. (Cold Start Device)
  - 8. Turbocharger: Disassembly, inspection and reassembly
    - 8.1 Structure and functions
      - 8.1.1 Main specifications
      - 8.1.2 Construction
      - 8.1.3 Structural and functional outline
      - 8.1.4 Components
    - 8.2 Service standards and tightening torque
      - 8.2.1 Service standards
      - 8.2.2 Tightening torque
    - 8.3 Periodic inspection procedure
      - 8.3.1 Periodic inspection intervals
      - 8.3.2 Inspection procedure
      - 8.3.3 Waste gate valve adjustment procedure
    - 8.4 Disassembly procedure
      - 8.4.1 Preparation for disassembly
      - 8.4.2 Inspection before disassembly
      - 8.4.3 Disassembly
    - 8.5 Washing and inspection procedure
      - 8.5.1 Washing
      - 8.5.2 Inspection procedure
    - 8.6 Reassembly procedure
      - 8.6.1 Preparation for reassembly
      - 8.6.2 Reassembly
    - 8.7 Handling after disassembly and reassembly
      - 8.7.1 Instructions for turbocharger installation
    - 8.8 Troubleshooting
      - 8.8.1 Excessively exhaust smoke
      - 8.8.2 White smoke generation
      - 8.8.3 Sudden oil decrease
      - 8.8.4 Decrease in output
      - 8.8.5 Poor (slow) response (starting) of turbocharger
      - 8.8.6 Abnormal sound or vibration
  - 9. Starting motror
    - 9.1 For 4TNV94L/ 98
      - 9.1.1 Specifications
      - 9.1.2 Components
      - 9.1.3 Troubleshooting
      - 9.1.4 Names of parts and disassembly procedure
      - 9.1.5 Inspection and maintenance
      - 9.1.6 Service standards
      - 9.1.7 Assembly
      - 9.1.8 Characteristic test
    - 9.2 For 4TNV106 (T)
      - 9.2.1 Specifications
      - 9.2.2 Congiguration drawing
      - 9.2.3 Troubleshooting
      - 9.2.4 Component names and disassembly procedure
      - 9.2.5 Disassembly procedure
      - 9.2.6 Inspection and maintenance
      - 9.2.7 Assembly
      - 9.2.8 Adjustment
      - 9.2.9 Service standards
    - 9.3 For 3TNV82A to 3/4TNV88
      - 9.3.1 Specifications
      - 9.3.2 Characteristics
      - 9.3.3 Disassembly drawing
      - 9.3.4 Connecting diagram of a starting motor
  - 10. Alternator
    - 10.1 The 40A alternator for 3TNV84 and other models
      - 10.1.1 Components
      - 10.1.2 Specifications
      - 10.1.3 Wiring diagram
      - 10.1.4 Standard output characteristics
      - 10.1.5 Inspection
      - 10.1.6 Troubleshooting
  - 11. Electric wiring
    - 11.1 Electric wiring diagram
    - 11.2 Precaution on electric wiring
      - 11.2.1 Alternator
      - 11.2.2 Starter
      - 11.2.3 Current limiter
      - 11.2.4 Section area and resistance of electric wire
  - 12. Service standards
    - 12.1 Engine tuning
    - 12.2 Engine body
      - 12.2.1 Cylinder head
      - 12.2.2 Gear train and camshaft
      - 12.2.3 Cylinder block
    - 12.3 Lubricating oil system (Trochoid pump)
  - 13. Tightening torque for bolts and nuts
  - Back cover
- YPD-MP2/YPD-MP4