Takeuchi compact excavator TB125, TB135, TB145 / diesel TNE / diesel Yanmar. Service Manual - page 49

(Direct Injection System)

series

Printed in Japan
M9961-02E050

Publication No.

M9961-02E050

History of Revision

Manual Name

Service Manual for Industrial Diesel Engine

Engine Model:

3TNV, 4TNV series (Direct Injection System)

Number
of
revision

Date of
revision

Reason for
correction

Outline of correction

Correction item
No (page)

Corrected
by

New edition Oct 2003

R.1

June,
2004

Revision,
addition &
correction

1) Revision of the fuel injection

timing adjustment

2) Addition of the compression

gauge adopter

3) Addition of C.S.D.
4) Addition of copy right
5) Revision of the long storage
6) Addition of tip clearance
7) Revision of cover page
8) Revision of FO,LO & coolant
9) Addition of starting moter.

10) Other corrections

1) P46,47,48-1,48-2

2) P64

3) P117
4) (Preface)
5) P52
6) P110
7) Cover page
8) P14,15-1,15-2
9) 175-1,175-2,

175-3

10) P5,20,50,57,61,

41,79,84,92,94,
81,102,103,108,
109-1,109-2,
111-1,111-2,109,
185-1,185-2,188,
193,195,196

Quality
Assurance
Dept.
Small
Engine
Factory

PREFACE

This manual describes the service procedures for the TNV series engines of indirect injection system that
have been certified by the US EPA, California ARB and/or the 97/68/EC Directive for industrial use.

Please use this manual for accurate, quick and safe servicing of the said engine. Since the explanation in this
manual assumes the standard type engine, the specifications and components may partially be different from
the engine installed on individual work equipment (power generator, pump, compressor, etc.). Please also
refer to the service manual for each work equipment for details.

The specifications and components may be subject to change for improvement of the engine quality without
notice. If any modification of the contents described herein becomes necessary, it will be notified in the form of
correction information each time.

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2003 YANMAR CO., LTD
All rights reserved. This manual may not be
reproduced or copied, in whole or in part,
without the written permission of YANMAR
CO., LTD.

SAFETY LABELS

• Most accidents are caused by negligence of basic safety rules and precautions. For accident prevention, it

is important to avoid such causes before development to accidents.

Please read this manual carefully before starting repair or maintenance to fully under-
stand safety precautions and appropriate inspection and maintenance procedures.

Attempting at a repair or maintenance job without sufficient knowledge may cause an unexpected accident.

• It is impossible to cover every possible danger in repair or maintenance in the manual. Sufficient consider-

ation for safety is required in addition to the matters marked

. Especially for safety precautions

in a repair or maintenance job not described in this manual, receive instructions from a knowledgeable
leader.

• Safety marks used in this manual and their meanings are as follows:

DANGER

-indicates an imminently hazardous situation which,

if not avoided, WILL result in death or serious injury.

WARNING

-indicates a potentially hazardous situation which, if not

avoided, COULD result in death or serious injury.

CAUTION

-indicates a potentially hazardous situation which, if not

avoided, MAY result in minor or moderate injury.

•

NOTICE

-indicates that if not observed, the product performance or quality may not be guaranteed.

Safety Precautions

(1) SERVICE AREA

•Sufficient

Ventilation

Inhalation of exhaust fumes and dust particles may be hazardous to ones
health. Running engines welding, sanding, painting, and polishing tasks
should be only done in well ventilated areas.

•Safe / Adequate Work Area

The service area should be clean, spacious, level and free from holes in the
floor, to prevent “slip” or “trip and fall” type accidents.

•Bright, Safely Illuminated Area

The work area should be well lit or illuminated in a safe manner. For work in
enclosed or dark areas, a “drop cord” should be utilized. The drop cord must
have a wire cage to prevent bulb breakage and possible ignition of flammable
substances.

•Safety Equipment

Fire extinguisher(s), first aid kit and eye wash / shower station should be
close at hand (or easily accessible) in case of an emergency.

(2) WORK – WEAR (GARMENTS

•Safe Work Clothing

Appropriate safety wear (gloves, special shoes/boots, eye/ear protection,
head gear, harness’, clothing, etc.) should be used/worn to match the task at
hand. Avoid wearing jewelry, unbuttoned cuffs, ties or loose fitting clothes
around moving machinery. A serious accident may occur if caught in moving/
rotating machinery.

(3) TOOLS

•Appropriate Lifting / Holding

When lifting an engine, use only a lifting device (crane, jack, etc.) with
sufficient lifting capacity. Do not overload the device. Use only a chain, cable,
or lifting strap as an attaching device. Do not use rope, serious injury may
result.
To hold or support an engine, secure the engine to a support stand, test bed
or test cart designed to carry the weight of the engine. Do not overload this
device, serious injury may result.
Never run an engine without being properly secured to an engine support
stand, test bed or test cart, serious injury may result.

•Appropriate Tools

Always use tools that are designed for the task at hand. Incorrect usage of
tools may result in damage to the engine and or serious personal injury.

(4) GENUINE PARTS and MATERIALS

•Genuine Parts

Always use genuine YANMAR parts or YANMAR recommended parts and
goods. Damage to the engine, shortened engine life and or personal injury
may result.

(5) FASTENER TORQUE

•Torquing Fasteners

Always follow the torque values and procedures as designated in the service
manual. Incorrect values, procedures and or tools may cause damage to the
engine and or personal injury.

(6) ELECTRICAL

•Short Circuits

Always disconnect the (-) Negative battery cable before working on the
electrical system. An accidental “short circuit” may cause damage, fire and or
personal injury. Remember to connect the (-) Negative battery cable (back
onto the battery) last.
Fasten the terminals tightly.

•Charging Batteries

Charging wet celled batteries produces hydrogen gas. Hydrogen gas is
extremely explosive. Keep sparks, open flame and any other form of ignition
away. Explosion may occur causing severe personal injury.

•Battery Electrolyte

Batteries contain sulfuric acid. Do NOT allow it to come in contact with
clothing, skin and or eyes, severe burns will result.

(7) WASTE MANAGEMENT

Observe the following instructions with regard to hazardous waste disposal.
Negligence of these will have a serious impact on environmental pollution
concerns.

1)Waste fluids such as lube oil, fuel and coolant shall be carefully put into sep-

arate sealed containers and disposed of properly.

2)Do NOT dispose of waste materials irresponsibly by dumping them into the

sewer, overland or into natural waterways.

3)Waste materials such as oil, fuel, coolant, solvents, filter elements and bat-

teries, must be disposed of properly according to local ordinances. Consult
the local authorities or reclamation facility.

(8) FURTHER PRECAUTIONS

•Fueling / Refueling

Keep sparks, open flames or any other form of ignition (match, cigarette, etc.)
away when fueling/refueling the unit.

Fire and or an explosion may result.

•Hot Surfaces.

Do NOT touch the engine (or any of its components) during running or shortly
after shutting it down.

Scalding / serious burns may result.

Allow the engine to

cool down before attempting to approach the unit.

•Rotating Parts

Be careful around moving/rotating parts. Loose clothing, jewelry, ties or tools
may become entangled causing damage to the engine and or severe
personal injury.

•Preventing burns from scalding

1)Never open the radiator filler cap shortly after shutting the engine down.

Steam and hot water will spurt out and seriously burn you. Allow the engine
to cool down before attempt to open the filler cap.

2)Securely tighten the filler cap after checking the radiator.

Steam can spurt out during engine running, if tightening loose.

Precautions for Service Work

(1) Precautions for Safety

Read the safety precautions given at the beginning of this manual carefully and always mind safety in work.

(2) Preparation for Service Work

Preparation is necessary for accurate, efficient service work. Check the customer ledger file for the history of
the engine.

• Preceding service date
• Period/operation hours after preceding service
• Problems and actions in preceding service
• Replacement parts expected to be required for service
• Recording form/check sheet required for service

(3) Preparation before Disassembly

• Prepare general tools, special service tools, measuring instruments, oil, grease, nonreusable parts, and

parts expected to be required for replacement.

• When disassembling complicated portions, put match-marks and other marks at places not adversely

affecting the function for easy reassembly.

(4) Precautions in Disassembly

• Each time a parts is removed, check the part installed state, deformation, damage, roughening, surface

defect, etc.

• Arrange the removed parts orderly with clear distinction between those to be replaced and those to be

used again.

• Parts to be used again shall be washed and cleaned sufficiently.
• Select especially clean locations and use clean tools for disassembly of hydraulic units such as the fuel

injection pump.

(5) Precautions for Inspection and Measurement

Inspect and measure parts to be used again as required to determine whether they are reusable or not.

(6) Precautions for Reassembly

• Reassemble correct parts in correct order according to the specified standards (tightening torques, and

adjustment standards). Apply oil important bolts and nuts before tightening when specified.

• Always use genuine parts for replacement.
• Always use new oil seals, O-rings, packing and cotter pins.
• Apply sealant to packing depending on the place where they are used. Apply of grease to sliding contact

portions, and apply grease to oil seal lips.

(7) Precautions for Adjustment and Check

Use measuring instruments for adjustment to the specified service standards.

How to Read this Manual

(1) Range of Operation Explanation

This manual explains the troubleshooting, installation/removal, replacement, disassemble/reassembly,
inspection, adjustment and adjusting operation procedures for the TNV series engines with direct injection
system.
Refer to the manufacturer’s manual for each of the fuel injection pump, governor, starting motor and alternator
except for their installation.

(2) How to Read the Explanations

• An exploded view, sectional views, a system diagram, etc. are shown at the beginning of each section as

required for easy understanding of the mounted states of the components.

• For the removal/installation of each part, the procedure is shown with the procedural step No. in the illus-

tration.

• Precautions and key points for disassembly and reassembly of parts are described as

points

. In the expla-

nation for each point, detailed operation method, information, standard and precautions are described.

Description Example

The job contents are described in the disassembly procedure for Nos. not shown in the illustration.

• Disassembly procedure
1)Follow steps (1) to (15) of the cylinder head disassembly procedure.
2)Remove the cooling water pump.
3)Remove the crankshaft pulley. (

Point 1

)

Operation point to be explained on a later page.

• Operation points

Disassemble: Service point for removal
Reassemble: Service point for installation
Disassemble-Reassemble: Service point required in both removal and installation.

Flywheel

Gear case flange

Camshaft

Cooling water pump

Camshaft driving gear

Starter

Flywheel housing

Fuel pump spacer

Fuel injection pump

Fuel pump drive gear

Flange bolt

Don't disassemble!

Pump flange

Note) This figure shows the 3TNV84.

Gear case

Crankshaft
gear

Oil seal

Crankshaft pulley

Idle gear

• Contents omitted in this manual

Though the following jobs are omitted in the explanation in this manual, they should be conducted in actual
work:
3)Jacking up and lifting
4)Cleaning and washing of removed parts as required
5)Visual inspection

(3) Definition of Terms

[NOTICE]: Instruction whose negligence is very likely to cause an accident. Always observe it.
Standard: Allowable range for inspection and adjustment.
Limit: The maximum or minimum value that must be satisfied during inspection or adjustment.

(4) Abbreviations

Abbreviation

Meaning

Abbreviation

Meaning

Assy

assembly

T.D.C.

top dead center

Sub-Assy

sub-assembly

B.D.C.