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This 552-page Takeuchi TL120 Workshop Manual (OEM #CT3E001) covers the crawler loader chassis, HST drive, and the 4TNV94L/98 and 4TNV106 engine family in one bound reference. Open it up and you get complete hydraulic schematics for the HST pump, control valve, and self-level valve circuits, plus electrical wiring diagrams and wire harness routing you'd otherwise chase with a multimeter. You also get a real troubleshooting section, broken into symptom trees like insufficient power, lift arm drop, and travel veer, so you're not guessing which valve is bad. Set drive belt tension to 120 lbs max and confirm AC system pressure sits between 150 and 250 PSI before you close the hood. No more flipping between three forum threads to confirm a torque spec. This PDF carries bookmarked navigation, so you jump straight from Service Data to Turbocharger disassembly without scrolling, right from your phone in the shop.
What's Inside This Takeuchi TL120 Manual
| System | Pages | Key Topics |
|---|---|---|
| Safety | 3-12 | Safety Alert Symbol, Safety Precautions, Cautions When Working |
| Service Data | 13-42 | Dimensional Drawing, Specifications Tables, Fuel and Lubricant Table, Performance Criteria, Tightening Torque, Hydraulic Circuit Diagram, Electrical Wiring Diagram |
| Operation | 43-84 | HST Pump, Gear Pump, Control Valve, Sub Valve, Self-Level Valve, Pilot Valve, Proportional Control Solenoid Valve, Cylinders |
| Disassembly and Assembly | 85-200 | Service Standards, Drive System, Travel System, Frame, Control System, Attachments, Hydraulic Tank, HST Pump |
| Troubleshooting | 201-264 | Overall Machine (No Operation Is Possible, All Systems Working, But Insufficient Power, Lift Arm and Bucket Fail to Move or Are Too Slow) |
| Yanmar Engine Manual: Introduction & Safety | 265-281 | Safety Precautions, Manual Scope, Engine Nomenclature, Applicable Engine Models |
| Yanmar Engine: General | 282-303 | Engine Nomenclature, Specifications, Fuel Oil, Lubricating Oil and Cooling Water |
| Yanmar Engine: Inspection and Adjustment | 304-335 | Periodic Maintenance Schedule, Periodic Inspection and Maintenance Procedure, Check Before Daily Operation, Inspection After Initial 50 Hours Operation |
| Yanmar Engine: Troubleshooting | 336-341 | Preparation Before Troubleshooting, Quick Reference Table for Troubleshooting, Troubleshooting by Measuring Compression Pressure |
| Disassembly, Inspection and Reassembly of Engines | 342-390 | Complete Disassembly and Reassembly, Introduction, Special Service Tools, Complete Disassembly |
| Lubrication System | 391-396 | Lubrication System Diagram, Trochoid Pump Components, Disassembly (Reverse the Procedure Below for Assembly), Servicing Points |
| Cooling System | 397-398 | Cooling Water System, Cooling Water Pump Components, Disassembly (Reverse the Procedure Below for Assembly), Servicing Points |
| Fuel Injection Pump / Governor | 399-402 | Introduction, Fuel Injection Pump, Fuel System Diagram, External View and Components |
| Turbocharger: Disassembly, Inspection and Reassembly | 403-424 | Structure and Functions, Main Specifications, Construction, Structural and Functional Outline |
| Starting Motor | 425-462 | For 4Tnv94L/ 98, Specifications, Components, Troubleshooting |
| Alternator | 463-466 | The 40A Alternator for 3TNV84 and Other Models, Components, Specifications, Wiring Diagram |
| Electric Wiring | 467-483 | Electric Wiring Diagram, Precaution on Electric Wiring, Alternator, Starter |
| Tightening Torque for Bolts and Nuts | 484 | Tightening Torques for Main Bolts and Nuts |
| Service Standards | 485-552 | Tightening Torques for Main Bolts and Nuts, Tightening Torques for Standard Bolts and Nuts, Engine Tuning, Engine Body |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| AC system high side pressure (R-12) | 150 to 250 pounds per square inch | p. 69 |
| Drive belt tension | 120 pounds maximum | p. 76 |
| Condenser clearance | 1-1/2 inches | p. 259 |
| Minimum turning radius | 1.995 m | p. 287 |
| Engine Displacement (Yanmar 3TNV84T, bundled engine manual) | 1.496 L | p. 342 |
| Engine Rated Output (Yanmar 4TNV94L at 1500 rpm, bundled engine manual) | 29.1 kW | p. 342 |
Takeuchi TL120 Common Problems This Manual Covers
TL120 AC system high pressure gauge readings stay unchanged after full refrigerant recovery
Recover all refrigerant per the procedure on page 259, then flush the system since a stuck gauge usually points to a partially plugged condenser. Normal high side operating pressure runs 150 to 250 psi per page 69. If pressure will not drop after flushing, replace the condenser rather than chasing the charge further.
Manual Section: Air Conditioner System Troubleshooting p. 259Machine instability or tipping forward during bucket loading operations
Check the troubleshooting procedures for lift arm and bucket response. Verify the load is centered in the bucket and does not exceed rated operating capacity. Inspect the port relief valve on the arm cylinder; a valve stuck open lets the arm drop under load and shifts the center of gravity forward.
Manual Section: Hydraulic System Troubleshooting (General)Crawler track jumps the sprocket or shows abnormal edge wear after sharp turns
Inspect track tension and sprocket teeth for rounding; avoid spin turns or pivot turns at full throttle, since they overload one track and strip the guide lugs. Check the travel motor troubleshooting steps for veering and confirm the parking brake releases fully before turning. Retension the track to the running clearance specified in the service data section.
Manual Section: Travel Motor TroubleshootingAC system blows warm air even though the sight glass shows a full refrigerant charge
Overcharging is a common cause of poor cooling; connect the manifold gauge set and compare readings against the 150 to 250 psi high side spec on page 72. If the gauge stays high after partial recovery, replace the receiver-drier per page 254 and recheck moisture content before recharging to the correct weight.
Manual Section: Air Conditioner System Troubleshooting p. 254Condenser airflow restricted by dirt or debris, AC cooling output drops noticeably
Shut down and inspect the condenser fins for dirt, bugs, and debris buildup. Maintain the 1-1/2 inch clearance around the condenser specified on page 259 so airflow is not blocked by nearby panels or brackets. Wash the fins from the engine side outward with low pressure water and check fan clutch operation per page 256 afterward.
Manual Section: Air Conditioner System Troubleshooting p. 259Drive belt squeals under load or shows a glazed, slipping surface on the pulley
Check belt deflection against the 120 lb maximum tension spec on page 76; a belt that is too loose slips and glazes under load. Adjust the fan belt until it yields approximately 8 mm of deflection per page 197, then retorque the mounting bracket bolts and recheck tension after ten minutes of running.
Manual Section: Operation p. 76Frequently Asked Questions
What are the torque specifications for the Takeuchi TL120 track roller fixing bolts?
The torque specification for the track roller fixing bolt on the Takeuchi TL120 is 241 N·m. This is specified for installation of the track roller, and ThreeBond #1324 is also mentioned in relation to the bolt. p. 96
Where can I find the torque specifications for the Takeuchi TL120?
General torque specifications for bolts and nuts can be found in the 'TIGHTENING TORQUE' section starting on page 28, which includes tables for bite-type pipe fittings, piping joints, and JIS strength category bolts. More specific tightening torques for main engine bolts and nuts are detailed in section 13.1 on page 196, and for standard bolts and nuts in section 13.2 on page 197. p. 196
How do I adjust the hydraulic pressure on the Takeuchi TL120?
Procedures for adjusting hydraulic pressure are detailed in the 'PERFORMANCE CRITERIA' section. Specifically, the adjusting method for charge pressure is on page 23, and for pilot pressure is on page 24. These sections provide step-by-step instructions for setting the correct pressure values. p. 23
What is the tightening torque for the cylinder head bolts on the Takeuchi TL120?
For the Takeuchi TL120, the cylinder head bolts (M9 × 1.25) should be tightened in two steps. The first step requires 61.7 to 65.7 N·m (6.3 to 6.7 kgf·m), and the second step requires 85.3 to 91.1 N·m (8.7 to 9.3 kgf·m). Lubricating oil should be applied to the thread portion and seat surface before tightening. p. 484
What are the engine oil capacities for the Takeuchi TL120?
The engine oil capacities for the Takeuchi TL120 vary by engine model. For 3TNV82A, the total volume is 5.5 L with an effective volume of 1.9 L. For 4TNV84(T)/88, the total volume is 7.4 L with an effective volume of 3.4 L. For 4TNV106(T) (CL class), the total volume is 14.0 L with an effective volume of 9.0 L. p. 472
What do I get after purchasing this Takeuchi TL120, Crawler Loader, YDP-MP2?
A 552-page Workshop Manual in searchable PDF format, available the moment you complete checkout. View on computer, tablet, or phone, with no shipping wait.
Can I print this Takeuchi TL120, Crawler Loader, YDP-MP2, YDP-MP4 manual?
Yes. The PDF has no DRM restrictions, so print any page or section you need for your shop. Works with any standard printer.
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