Download Terex TL120 Whell Loader Workshop Repair Service Manual –

Repairing the reverse gear in a Terex TL120 wheel loader, or any heavy machinery, is a complex task that requires mechanical knowledge and experience. click here for more details on the download manual…..

Below is a detailed guide on how to approach reverse gear repair, including descriptions of every component involved. Please note that this is a general guide; consult the specific service manual for the Terex TL120 for precise instructions, torque specifications, and any specific procedures.

### Tools and Equipment Needed:
– Basic hand tools (wrenches, sockets, screwdrivers)
– Torque wrench
– Gear puller
– Pliers
– Hammer
– Inspection mirror
– Flashlight
– Shop crane or hoist
– Transmission jack
– Safety equipment (gloves, goggles)

### Components Involved:
1. **Transmission Assembly**: This is the main component housing the reverse gear. It contains various gears, shafts, and bearings.
2. **Reverse Gear**: Specifically designed to change the direction of the wheel loader. It engages with other gears within the transmission to facilitate reverse motion.
3. **Gear Selector Fork**: This component engages and disengages the reverse gear when shifting.
4. **Shafts**: These include the main shaft and countershaft, which transfer power to the reverse gear.
5. **Bearings**: Support the shafts and allow smooth rotation.
6. **Seals and Gaskets**: Prevent fluid leaks and protect components from dirt and debris.
7. **Oil**: Transmission fluid that lubricates moving parts.

### Repair Procedure:

1. **Preparation**:
– Ensure the loader is parked on a level surface and turned off.
– Engage the parking brake and remove the key from the ignition.

2. **Safety Precautions**:
– Wear safety goggles, gloves, and appropriate clothing.
– Use caution when lifting heavy components.

3. **Remove the Loader’s Protective Cover**:
– Locate the protective cover over the transmission.
– Remove bolts or fasteners holding the cover in place, then lift it off carefully.

4. **Drain the Transmission Fluid**:
– Place a drain pan underneath the transmission.
– Remove the drain plug and allow the fluid to completely drain out.

5. **Remove the Transmission Assembly**:
– Disconnect any electrical connectors and linkages Attached to the transmission.
– Using a transmission jack, support the transmission assembly.
– Remove the bolts securing the transmission to the engine and any brackets holding it in place.
– Carefully lower the transmission from the loader.

6. **Disassemble the Transmission**:
– Place the transmission on a clean workbench.
– Remove the bolts securing the transmission case.
– Gently pry open the case, taking care not to damage any sealing surfaces.
– Note the positioning of components as you remove them.

7. **Inspect the Reverse Gear**:
– Locate the reverse gear, typically found on the main shaft.
– Check for excessive wear, chips, or other damage.
– Inspect the gear selector fork for wear and ensure it moves freely.

8. **Replace Damaged Components**:
– If the reverse gear is damaged, remove it using a gear puller.
– Install a new reverse gear, ensuring proper alignment.
– Replace any worn bearings and seals as necessary.

9. **Reassemble the Transmission**:
– Reinstall the transmission components in the reverse order of disassembly.
– Ensure that all components are clean and properly lubricated.
– Use new gaskets and seals to prevent leaks.
– Tighten bolts to the manufacturer’s specified torque settings.

10. **Reinstall the Transmission Assembly**:
– Lift the transmission back into position using the transmission jack.
– Secure it to the engine and attach any brackets or linkages removed earlier.
– Reconnect electrical connectors.

11. **Refill Transmission Fluid**:
– Replace the drain plug and refill the transmission with the appropriate type and amount of fluid.
– Check the manufacturer’s specifications for the correct fluid type.

12. **Reattach Protective Cover**:
– Install the protective cover over the transmission.
– Secure with bolts or fasteners.

13. **Testing**:
– Start the loader and allow it to warm up.
– Test the reverse gear by shifting into reverse and observing its operation.
– Listen for any unusual noises and ensure smooth engagement.

14. **Final Inspection**:
– Check for leaks underneath the loader.
– Make sure all tools are removed from the work area.

### Conclusion:
This guide outlines the basic steps for repairing the reverse gear in a Terex TL120 wheel loader. Always refer to the specific service manual for your machine for detailed instructions, torque specifications, and safety warnings. If you are not comfortable performing this repair, it is advisable to seek the help of a qualified technician.
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