This 490-page Takeuchi TB020 Workshop Manual (OEM #WD3-101E1) covers the Compact Excavator, tracking the D1105-B and V1505-B engine variants through every drive, slew, and hydraulic system on the machine. You get full hydraulic pump, control valve, and cylinder rebuild procedures, wiring diagrams for the control system, and a dedicated troubleshooting section that walks you from "no operations" down to specific symptoms like boom natural fall or slewing overrun. The specs are pulled straight from the factory floor: track roller outer diameter holds to 82mm allowable, and bushing-to-link interference runs 0.11 to 0.2mm before you're out of spec. No more tearing into the slew motor on a guess because a forum thread sounded confident. Bookmarked by section, with searchable text so you can jump straight from a troubleshooting symptom to the exact procedure and torque value you need.
What's Inside This Takeuchi TB020 Manual
| System | Pages | Key Topics |
|---|---|---|
| Introduction & Machine Overview | 1-4 | Foreword, Machine Front and Rear, Left and Right, Machine Serial Number, Manual Control, General, Specifications, Machine Configuration |
| General | 5-16 | Cautions During Disassembly and Assembly, Cautions During Removal and Installation of the Hydraulic Units, Cautions During Removal and Installation of Piping, Handling of Seals |
| Specifications | 17-56 | Names of Components, Dimensions, Lifting Capacities, Weights, Fluid Capacities, Servicing Standards |
| Machine Configuration | 57-114 | External View, Drive System, Slew System, Travel System, Upper Frame, Control System, Attachments, Hydraulic System |
| Hydraulic Units | 115-248 | Hydraulic Pump, Control Valve, Pilot Valve, Cylinder, Travel Motor, Slew Motor, Swivel Joint |
| Troubleshooting | 249-302 | Overall Machine (No Operations CAN Be Done, All Operations CAN Be Done, But There Is No Power, Boom, Bucket, Slew and Arm Do Not Move at All, Or the Speed Is Low) |
| Engine | 303-490 | Engine Removal and Installation, Cylinder Head, Pistons and Crankshaft, Fuel Injection System, Cooling and Lubrication |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Outer Dia. of Tread Allowable Value | 82 mm | p. 31 |
| Width of Tread Allowable Value | 78 mm | p. 27 |
| Grouser Height Allowable Value | 8 mm | p. 14 |
| Bushing and Lonk Interferance Standard | 0.11~0.2 mm | p. 38 |
| Tightening Torque | 3.9~4.4 kgfm | p. 124 |
| DEPTH OF CONTACT MARKS | A ≥ 0.15 mm | p. 125 |
| Socket Bolt Tightening Torque | 0.5+1 kgfm | p. 105 |
| Oil pressure in inlet line builds up | 98 kPa (1.0 kgf/cm², 14 psi) | p. 330 |
| Fuel injection pressure | 13.73 to 14.71 MPa (140 to 150 kgf/cm², 1991 to 2133 psi) | p. 342 |
Takeuchi TB020 Common Problems This Manual Covers
Takeuchi TB020 complete loss of hydraulic pressure, arms and bucket won't move at all
Check the hydraulic oil level per the tank inspection on page 254, then test main relief valve pressure against the standard on page 256. If oil is contaminated, verify cleanliness stays within NAS Class 9 per page 257 and refill the 54/63 l (14.3/16.6 gal) system per page 33.
Manual Section: V . TroubleshootingEngine shuts down under load or fails to start, especially in cold weather
Close the fuel filter cock per page 396 before servicing, then drain and rinse the filter cup with kerosene to clear debris. Test fuel injection pressure against the 13.73 to 14.71 MPa (140 to 150 kgf/cm²) spec on page 342; low pressure points to a worn injection pump.
Manual Section: General Engine Troubleshooting p. 342Swing motor fails to rotate or swings erratically when hydraulic pressure drops
Test slew motor relief valve pressure against the 105 kgf/cm2 @ 20 l/min setting on page 29; low readings mean worn motor seals or a sticking brake valve. Check the swing brake releases fully before travel, then inspect main control valve solenoids for pressure sensor faults tied to error code E04.
Manual Section: Slewing System ProblemsTrack tension leaks down quickly and slack is impossible to adjust or hold
Measure bushing and link interference against the 0.11~0.2 mm standard on page 38; if wear exceeds the 0.1 mm allowable limit on page 125, replace the pin and bushing set. Torque track roller installation bolts to 16.1 ±0.8 kgfm per page 83, and check the tensioning cylinder seal for leakdown after reassembly.
Manual Section: Ii . Specifications p. 38Hydraulic hoses leak frequently at boom and arm cylinder connections during operation
Disconnect the hydraulic hoses from the boom cylinder per the procedure on page 103, and from the arm cylinder per page 102. Inspect fittings for cracked O-rings, then torque socket bolts to 0.5+1 kgfm per page 105 and plugs to 7 kgfm per page 147 on reassembly to stop weeping at the joints.
Manual Section: Iii . Machine Configuration p. 103Frequently Asked Questions
What are the torque specifications for Takeuchi TB020 track adjustment bolts?
For both steel and rubber crawlers, the check valve tightening torque for track adjustment is 6 ± 1 kgfm. This specification is crucial for maintaining proper track tension. p. 81
What are the replacement specifications for Takeuchi TB020 hydraulic pump seals?
When disassembling the hydraulic pump, all seals must be replaced with new ones. It is recommended to coat them lightly with grease during assembly to ensure proper function and prevent damage. p. 120
What are the replacement specifications for Takeuchi TB020 track bushings and pins?
For double grouser crawler belts, the allowable clearance for bushing and link interference is 0.1 mm, and for master pin and link clearance, it is 0.5 mm. If these values are exceeded, the servicing procedure is to replace the components, or replace with an oversize pin for master pin clearance. p. 38
What is the engine oil capacity for the Takeuchi TB020?
The engine oil capacity for the Takeuchi TB020 is 3.4 liters (0.9 US gallons) for the upper limit and 2.1 liters (0.6 US gallons) for the lower limit. p. 53
What do I get after purchasing this Takeuchi TB020, Compact Excavator?
Instant PDF download. You get the full 490-page searchable Workshop Manual immediately after payment. Open it on your laptop, tablet, or phone right in the shop.
Are there any print restrictions on this Takeuchi TB020, Compact Excavator?
Yes. The PDF has no DRM restrictions, so print any page or section you need for your shop. Works with any standard printer.
Can I find wiring schematics in this Takeuchi TB020, Compact Excavator?
Yes, full electrical schematics are included with wire colors, connector locations, and circuit descriptions.
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