Factory Takeuchi TL140 Shop Manual for Crawler Loaders

Takeuchi TL140 Workshop Manual - 2005 Edition

Engineered for professional service technicians, this workshop manual provides the definitive framework for the maintenance, disassembly, and overhaul of the TL140 crawler loader series. Critical to long-term system health is the air bleeding of the hydraulic pump casing—achieved by supplying oil through the specific plug hole until overflow occurs—which prevents cavitation and immediate component failure during initial startup. This authoritative resource eliminates technical ambiguity, ensuring field-ready performance through factory-certified procedures and calibration benchmarks.

Machine Identification: Technical Applicability & Serial Ranges

• Technical Generation 1 (Early Series)
  • Machine Serial Numbers: 21400011 through 21402000
  • Distinguishing Feature: Integrated TH06VB Piston Motors (86 kg unit mass)
• Technical Generation 2 (Current Series)
  • Machine Serial Numbers: 21402001 and higher
  • Distinguishing Feature: BMVT41B Travel Motors with upgraded 24.362 reduction ratio

Operational Value & ROI Proof Points

• System Longevity: Precise adherence to the ISO Strength Category 10.9 bolt torque specifications (e.g., M20 coarse thread at 410.9 Nm) prevents catastrophic structural fatigue and frame failure.
• Safety Protocol: Detailed lift arm stop engagement and disengagement sequences provide a verified safety envelope for technicians working beneath raised attachments.
• Diagnostic Accuracy: Standardized "Standards for Judging Performance" allow for immediate comparison between field readings and factory-new values, reducing downtime.

Documentation Metadata

• Print Number: BOOK No. CT9E001 (REV. 1)
• Engine Reference: Isuzu AA-4JG1TPA 4-Cycle Diesel
• Total Pagination: 302 Pages
• Technical Scope: General, Specifications, Machine Configuration, Hydraulic Units, Troubleshooting, Engine

Technical Depth & Factory Benchmarks

The TL140 utilizes a sophisticated dual-path hydrostatic transmission coupled with a tandem gear pump architecture. Technicians must verify the following relief settings to ensure operational integrity:

• HST Relief Valve Setting: 34.5 MPa
• Main Hydraulic Relief Valve: 20.6 MPa @ 88 L/min
• Charge Pressure (High): 2.0 ± 0.2 MPa (Serial 21402001~)
• Pilot Pressure: 3.1 ± 0.4 MPa

Visual Navigation Aids & System Architecture

• Hydraulic Circuit Diagrams: Detailed schematics for both standard and high-flow configurations including self-leveling logic.
• Electrical Wiring Layouts: Comprehensive mapping of fuse locations, relay units (Heater, Safety, Emergency), and the Proportional Control Solenoid interface.
• Component Localization: Cross-sectional views of the PVM4141 HST Pump and SD1A series gear pumps.

Table of Contents

• Section I: General
  • Safety Precautions, Disassembly/Assembly Cautions, and Universal Tightening Torques.
• Section II: Specifications
  • Dimensions, Performance Tables, Recommended Lubricants, and Service Standards.
• Section III: Machine Configuration
  • Drive System, Travel System, Frame, Control Systems, and Hydraulic Layout.
• Section IV: Hydraulic Units
  • Overhaul procedures for HST Pumps, Gear Pumps, Control Valves, and Travel Motors.
• Section V: Troubleshooting
  • System-wide fault isolation for Lift Arms, Buckets, and Auxiliary Hydraulics.
• Section VI: Engine
  • Specific references to Isuzu AA-4JG1TPA maintenance and interface.

Operational Limits & Specifications

• Fluid Capacities:
  • Hydraulic System (Total): 83 L (Tank Level: 52 L)
  • Engine Oil Pan: 9.6 L (Upper Limit)
  • Engine Cooling System: 15 L
  • Travel Reduction Gear: 2.2 L (Serial 21402001~)
• Critical Lubricants:
  • Engine/Hydraulics: API Service CD (SAE 10W-30)
  • Travel Gears: API-GL-4 (SAE 90)
  • Working Equipment: Lithium Grease EP-2
• Torque Sequences:
  • Engine Mount Bolts: 256 N·m (Thread-locking compound required)
  • Hydraulic Pump Cap Screws: 116 N·m (Molybdenum disulfide grease on splines)
  • Travel Motor Sprocket Bolts: 241 N·m

FAQ

Does this manual cover all serial ranges for the Takeuchi TL140 series? The documentation specifically covers the TL140 Crawler Loader starting from Serial Number 21400011 and above. It distinguishes between early units (up to serial 21402000) using the TH06VB travel motor and later units (serial 21402001 and higher) equipped with the BMVT41B travel motor, ensuring technical accuracy for both generations.

What is the specific relief valve setting for the primary hydraulic system? The main hydraulic relief valve is factory-set to 20.6 MPa (approximately 3000 psi) at a flow rate of 88 liters per minute. For the hydrostatic transmission (HST) circuit, the relief valves are set significantly higher at 34.5 MPa to manage the high-torque demands of the track drive system.

Can I find detailed electrical and hydraulic schematics within this manual? Yes, the manual includes comprehensive system diagrams, specifically in Section III (Machine Configuration) and Section IV (Hydraulic Units). These schematics detail the routing for the proportional control solenoid valves, the pilot piping for the travel and auxiliary systems, and the complete electrical harness layout including the emergency relay and safety bar proximity switches.

Is there a specific procedure for ensuring the longevity of the hydraulic pumps after a service? Section IV dictates a critical "Air Bleeding" procedure that must be performed whenever the hydraulic oil is replaced or the pump is removed. Technicians must remove the air bleeding plug from the top of the hydraulic pump casing and fill it with oil until it overflows; failure to do this can lead to immediate pump cavitation and catastrophic failure upon engine start.

How does this digital workshop manual improve diagnostic speed for field repairs? The digital format provides instant navigability to the Troubleshooting section (Section V), which contains diagnostic flowcharts for specific failure modes like "Switching between 2-way and 1-way flow is impossible." Technicians can immediately identify test points, such as checking continuity on the 0.85YR and 0.85L wiring at the resistor, or verifying the flow selector solenoid, allowing for rapid resolution without searching through physical volumes.