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Takeuchi
Compact Loader
TL150
Takeuchi TL150 Workshop Manual
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TL
150
T
rack Loader
BOOK No.
CT7E901
WORK
SHOP MANUAL
Serial No.
21500004~
2
Table of Contents
Contents
3
General
5
Table of Contents
6
Safety Precautions
7
Signal Words
7
Anti-Explosive Lighting
8
Prepare the Work Area
8
Handling of Hoses
10
Use Caution When Fueling
10
Cautions on Working on the Machine
10
Cautions During Disassembly and Assembly
13
Cautions During Removal and Installation of the Hydraulic Units
13
Cautions During Removal and Installation of Piping
14
Handling of Seals
14
Hydraulic Hoses
15
Bite Type Pipe Fitting for Steel Pipe
15
Tightening Torques
15
Joints for Piping
16
Joints for Piping (O-Ring Seal Type)
16
Bolts and Nuts (for ISO Strength Category 10.9)
17
Specifications
19
Names of Components
21
Canopy Type
22
Machine Dimensions
22
Operating Range
22
Specification Diagrams
22
Cab Type
23
Specifications Tables
24
Standard Bucket
24
Standard Bucket
25
Mass Tables
28
Unit Weight (Dry Mass)
28
Recommended Lubricants
29
Service Standards
30
Track Roller a
30
Travel System
30
Track Roller B
31
Track Roller C
32
Drive Sprocket
33
Idler
34
Track Adjuster
35
Pin and Bushing Clearance
36
Reference Value Table
37
Standards for Judging Performance
37
Hydraulic Oil Pressure
38
Lift Arm, Bucket
38
Methods for Inspecting Performance
38
Charge Pressure
39
Measuring the Pilot Pressure
39
Travel Curve
40
Travel Posture
40
Travel Speed (10M)
40
Travel Speed (5 Revolutions)
40
Arm Cylinder Speed
41
Bucket Cylinder Speed
41
Natural Cylinder Drop
41
Natural Travel Drop
41
Level of Front Edge of Bucket
43
Lever Operating Force
43
Lever Play
43
Track Tension
43
Machine Configuration
44
Drive System Construction
46
Engine Mount
46
Radiator
47
Engine Mount (High Flow)
48
Radiator (High Flow)
49
Pump Coupling
50
Fuel Tank and Lines
51
Engine Control
52
Disassembly and Assembly
53
Installing the Engine
53
Removing the Engine
53
Installing the Radiator
54
Removing the Radiator
54
Installing the Hydraulic Pump
55
Purging Air from the HST Pump
55
Removing the Hydraulic Pump
55
Installing the Fuel Tank
57
Removing the Fuel Tank
57
Adjusting the Throttle Lever
58
Control Force
58
Engine Speed
58
Inspection and Adjustment
58
Travel System Construction
59
Installing the Steel Track
62
Removing the Steel Track
62
Installing the Idler and Track Adjuster
63
Installing the Track Roller
63
Removing the Idler and Track Adjuster
63
Removing the Track Roller
63
Installing the Travel Motor
64
Removing the Travel Motor
64
Frame
65
Floor Frame
66
Safety Bar
67
Cover
68
Canopy
69
Cab
70
Lowering
71
Raising (Tilt Up)
71
Tilting up the Canopy
71
Installing the Floor Frame
72
Removing the Floor Frame
72
Installing the Covers
73
Removing the Covers
73
Installing the Canopy
74
Removing the Canopy
74
Engagement
75
Lift Arm Stop
75
Disengagement
76
Control System
77
Hydraulic Pilot Unit
77
Installing the Lever Stands
79
Removing the Lever Stands
79
Attachments
80
Piping
81
Piping (High Flow)
82
Air Bleeding Operation
83
General Cautions
83
Removing the Quick-Hitch
83
Installing the Lift Arm
84
Removing the Lift Arm
84
Adjusting the Bucket Stopper
85
Arm Stopper
85
Installing the Arm Stopper
85
Lock Pin
85
Adjusting the Bucket Stoppers
86
Adjusting the Arm Stopper
87
Hydraulic Circuit Diagram
89
Hydraulic System
89
Hydraulic System
90
Hydraulic Tank
90
Reference
91
Installing the Hydraulic Tank
92
Removing the Hydraulic Tank
92
Bleeding the Air
93
Filling with Hydraulic Oil
93
Hydraulic Oil Level Inspection Posture
93
Hydraulic Pump
93
Electrical System
94
Electrical Wiring Diagram
94
Electrical System
95
Relay Assembly
96
Air Conditioner System
97
Compressor Assembly
97
Overview of System Operation
101
Truck and Heavy Equipment Systems
101
Air Conditioner—System Operation
102
Compressor/Clutch Assembly
103
System Operation
103
Condenser
104
Receiver-Drier
105
Evaporator Coil
106
Expansion Valve (Refrigerant Metering Device)
106
Operating Range
107
Heater System Operation
108
Defrosters and Ducts
109
Environmental Effects on System Operation
109
Heater Core
109
Water Valves
109
Chapter Review
110
Discussion of Inspection & Maintenance Survey Results
111
Inspection & Maintenance Survey
111
Inspection and Maintenance-Without Gauges
111
Inspect Parts
112
Observe the System
112
Visual Inspection - System off
112
Components under the Hood
113
Check for Refrigerant Leaks
114
Check Hoses and Fittings
114
Electrical System Inspection
115
Performance Inspection – Engine Running
117
Check Clutch Cycling under Load
118
Check Sight Glass
118
Check Heater Control Valve Function
119
Heater System Inspection
119
Inspect Other Functions
120
Preventive Maintenance Worksheet
120
Warm up Engine
120
Troubleshooting & Service Procedures
123
The Key–Understanding System Function
124
Manifold Gauge Set Installation
128
Purging Air from Gauge Set Hoses
129
Stabilizing the AC System
131
Low Refrigerant Charge in the System
132
Troubleshooting by Manifold Gauge Set Readings
132
Extremely Low Refrigerant Charge in the System
133
Air And/Or Moisture in the System
134
Excessive Air And/Or Moisture in the System
135
Expansion Valve (TXV) Stuck Closed or Plugged
135
Expansion Valve (TXV) Stuck Open
137
System High Pressure Side Restriction
138
Compressor Malfunction
139
Condenser Malfunction or System Overcharge
140
Thermostatic Switch Malfunction
142
Review of Frequent Problem Areas
143
Refrigerant
144
Refrigerant Lines, Hoses and Fittings
144
Refrigerant Metering Valve
144
Conclusion
145
Hydraulic Units
147
Hst Pump
149
Pump Assembly
149
Displacement Control
153
Charge Check and High Pressure Relief Valve
155
Charge Check Valve
155
Charge Relief Valve
155
High Pressure Relief Valve
155
Assemble the Cylinder Block
163
Assemble the Cylinder Block Assembly
163
Assemble the Servo Piston
163
Pump
163
Checking the Parts
171
Cylinder Block
171
Piston and Slipper of the Cylinder Block
171
Valve Plate
171
Input Shaft
172
Shaft Roller Bearing
172
Swash Plate
172
Swash Plate Bearings
172
Adjustment of Rotational Torque of the Servo Piston
173
Measurement of the Servo Piston’s Rotational Torque
173
Neutral Adjustment of the Pump
174
Adjustment of Displacement Limiter of the Remote Hydraulic Control
176
Gear Pump
179
Bushing
182
Checking Parts
182
Housing
182
Gear
183
Seals
183
Test Operation
183
Measuring the Discharge Volume
184
Gear Pump (High Flow)
186
Control Valve
190
Auxiliary Section
191
Bucket Section
191
Lift Arm Section
191
Main Relief Valve
192
Port Relief Valve
192
Arm, Bucket Section
193
When the Spool Is in the Neutral Position
193
When the Spool Is Moved
193
Load Check Valve
194
When the Relief Valve Is NOT Operating
194
When the Relief Valve Is Operating
194
Relieving Operation
195
Suction Operation
195
Valve Assembly
196
Adjusting the Main Relief Valve Pressure
199
Control Valve (High Flow)
202
Switching Valve
203
When the Spool Is Operating
203
Unload Relief Valve
204
Adjusting the Relief Valve Pressure
208
Control Valve (Sub)
210
When the Solenoid a Is Electrified
211
When the Solenoid a Is Not Electrified
211
When the Solenoid B Is Electrified
212
When the Solenoid B Is Not Electrified
212
Solenoid Valve a
214
Pilot Valve
217
When the Handle Is in Neutral
218
When the Handle Is Tilted
218
Table of Special Tools
219
Pilot Valve (Auxiliary)
227
Self-Level Valve
231
Self-Leveling Operation
232
At Bucket Tilt (Forward)
233
At Bucket Tilt (Rear)
233
At Lowering of the Arm
233
Bucket Spool In, Arm Spool Neutral
233
Arm Cylinder
238
Bucket Cylinder
238
Cylinders
238
Cushion Mechanism
239
Cylinder Assembly
240
Piston Rod Assembly
241
Piston
242
Retainer
242
Rod Cover
243
Clevis
244
Piston Rod
250
Tube
250
Bleeding Air from the Hydraulic Cylinder
251
External Leakage
251
Internal Leakage
251
No Load Operation Test
251
Hydraulic Motor
255
Travel Motor (Daikin)
255
Reduction Gears
257
1St Speed
258
2-Speed Mechanism
258
2Nd Speed
258
Flushing Valve
259
Parking Brake
259
Floating Seal
267
Use Limit for Parts
279
2Nd Speed Control
280
Mechanical Releasing of the Brake
281
Troubleshooting
283
Cautions in Troubleshooting and Repairs
284
Complete Failure of All Systems
286
Overall Machine
286
All Systems Working, but with Insufficient Power
289
Lift Arms and Bucket Fail to Move/Speed of Operation Poor
291
Machine Travel
292
Travel Train Fault
292
Speed Falls and Machine Veers to One Side
294
The Travel System Is Operating at an Unusually High Temperature
296
Machine will Not Travel in Second Speed
298
Lift Arm Cylinders Fail to Move
300
Movement of the Lift Arm Cylinders Is Slow or Lacks Power
302
Slowly Pulling the Control Lever of the Lift Arms Causes the Lift Arms to Drop Momentarily
304
The Amount of Lift Arms Natural Drop Is Great
305
Bucket Cylinders Fail to Move
306
Movement of the Bucket Cylinders Is Slow or Lacks Power
308
The Amount of Bucket Natural Drop Is Great
310
Auxiliary Hydraulics
311
Switching between 2-Way Flow and 1-Way Flow Is Impossible
311
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Operator's Manual
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Takeuchi TL150 Specifications
General
Travel Speed - High
11.2 mph (18 km/h)
Max Travel Speed
12.4 km/h
Width
1880 mm
Height
2320 mm
Lift Height
10.5 ft (3.2 m)
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