1999 Takeuchi TB020 Compact Excavator Workshop Manual (WD3-101E1)

This Takeuchi TB020 workshop manual covers the 1999 compact excavator configurations listed for serial numbers 1203001 and up. Identified on the cover as WD3-101E1, it includes cabin and canopy machines, rubber and steel crawlers, and standard- and long-arm configurations.

The single PDF contains 490 pages, organized into six chapters: General, Specifications, Machine Configuration, Hydraulic Units, Troubleshooting, and Engine. The engine chapter includes Kubota's 78.4 mm Stroke Series workshop material.

• Engine repair: Mechanical condition testing, internal engine disassembly, cylinder head and crankshaft inspection, and lubrication, cooling, and fuel-system service.

• Hydraulic repair: Pump and control valve disassembly, pilot valve testing, cylinder seal replacement, swivel joint inspection, and travel and slew motor servicing.

• Undercarriage and structure: Removal and assembly of crawler belts, track tensioners, track rollers, idlers, slew bearings, cabins, and floor frames.

• Troubleshooting: Symptom-based fault charts for weak hydraulics, travel deviation, slew faults, and boom, arm, bucket, and blade drift.

• Electrical testing: Wiring diagrams, starting and charging system checks, glow plug tests, and pilot-control interlock diagnosis.

• Service standards: Torque tables, fluid capacities, dimensional drawings, performance benchmarks, pin clearance tables, and wear limits.

Written for personnel engaged in maintenance operations, this manual is suited to mechanics experienced in hydraulic equipment and diesel engine repair. Pressure testing, component lifting, and internal engine work require appropriate workshop equipment and measurement skills.

Structural and Maintenance Overview

Removal and assembly procedures cover engine mounting, the radiator, fuel tank, and attachment cylinders. Separate steel and rubber crawler replacement instructions and track roller, idler, and bucket-linkage clearance charts support wear assessment before replacement decisions.

The specifications distinguish cabin/canopy and standard/long-arm configurations and include digging-force data and standard-arm rated lift capacity charts. Performance tests address travel speed, steering deviation, cylinder drift, and slew bearing play.

Hydraulic and Mechanical Specifications

Hydraulic circuit diagrams identify pump sections, control valve connections, the pilot circuit, and attachment cylinders. The hydraulic units chapter distinguishes manually operated and pilot-operated control valve sections and provides separate slew motor procedures for versions with and without a parking brake.

The triple gear pump section includes output testing and component inspection, while the control valve material covers main relief adjustment and port relief settings. Damaged matched spools and valve bodies require replacement as a section assembly; the manual also identifies port relief valves that must not be completely disassembled.

Troubleshooting and Electrical Diagnosis

Symptom-based flowcharts distinguish travel-motor, pump, pilot-control, and cylinder faults. For example, the boom-drift checks help separate internal cylinder leakage from control valve leakage, giving a technician a targeted basis for deciding which assembly needs repair.

Standard and EU electrical wiring diagrams show starting, charging, warning, and cabin circuits, including heater and wiper connections. Pilot-control troubleshooting checks the lever limit switch and solenoid circuit; the engine section adds starter, alternator, rectifier, and IC-regulator tests.

Advanced Shop Procedures

Advanced procedures include centering the swivel joint with a dial gauge, cylinder air bleeding, and leakage tests for cylinders and swivel joints. The hydraulic tank pressurization instructions explain that omitting this operation after hydraulic-unit installation can cause pump cavitation and shorten pump life.

Engine coverage extends to valve-seat correction, crankshaft bearing clearances, piston rings, and cylinder-liner wear. It also explains how incorrect piston installation can scratch plated surfaces and damage the liner.

Fuel-system content covers injection timing, nozzle opening pressure, and spray-pattern checks; pump-element replacement requires fuel-delivery adjustment on a specified test bench. Special-tool listings identify the nozzle tester (07909-31361) and flywheel puller (07916-32011), alongside drawings for locally made service jigs.

The shared engine material also includes V1505-B data; the TB020 machine specifications identify the D-1105-B. Factory safety instructions and component-specific handling cautions accompany the repair procedures.

PDF Contents and Navigation

Of the 490 pages, 302 cover the front matter and chapters I-V, and 188 make up the engine chapter; the total includes one cover, eight section dividers, and 17 blank or header/footer-only pages. The Takeuchi chapters are in English, while the Kubota engine material includes English, French, and German. PDF text is not searchable, but bookmarks link to the six main chapters; small wiring labels are readable when enlarged.