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

1. General

15-2

(2) Handling of lube oil

• Keep the engine oil carefully in store in order to prevent any dust or dirt entrance.
• When filling the engine oil to the engine, avoid the spillage and pay attention to be clean around the filler

port.

Contact with engine oil may result in the roughened skin. Care should be taken
so as not to contact with engine oil wearing protective gloves and clothing.
If contact, wash with soap and water thoroughly.
When handling the engine oil, make sure to use the protective gloves at any
time.
In case of contact, wash your hand or body with soap and water thoroughly.

1.3.3 Cooling water

Use clean soft water and always be sure to add LLC (Long Life Coolant) in order to prevent rust built up and
freezing. (Do not use water only.)
The recommended LLC conform to the following specifications.

• JIS K-2234
• SAEbJ814C, J1941, J1034, J2036
• ASTM D4985

IMPORTANT:

• Always be sure to add LLC to soft water. In particular, in cold season, to add LLC is important.
• Without LLC,
• Cooling performance will decrease due to scale and rust in the cooling water system.
• Cooling water may freeze to form ice; it expands approx. 9% in volume.
• This causes serious damage in the cooling system.
• Be sure to use the proper amount of coolant concentrate specified by the LLC manufacturer depending

on the ambient temperature.

• LLC concentration should be 30%as a minimum and 60%as a maximum.
• DO NOT mix the different types of brand of LLC, otherwise harmful sludge may yield.
• DO NOT use hard water.
• Water should be free from sludge and/or particles.
• Replace the coolant every once a year.

When handling LLC, use protective gloves to avoid skin contact.
In case you have a contact with your skin or eyes, wash out it with clean
water.

(R.1)

1. General

1.4 Engine external views

Starter motor

Note)

࡮

This illustration shows the 4TNV98T engine (with turbocharger).

࡮

The drain plug (engine oil) location depends on the engine installed

on the machine unit to be on the fuel injection pump side (above illustration)
or starter motor side.

Flywheel

Intake manifold

Dipstick (engine oil)

Engine oil filter

Engine oil cooler (4TNV98T, 4TNV106, 4TNV106T)

Fuel injection pump

Engine name plate

Rocker arm cover

Governor lever

Drain plug (engine oil)

Cooling fan

Lifting eye

Cooling water pump

Lifting eye

Filler port (engine oil)

Fuel filter

Fuel filter mounting

Fuel oil inlet

Crank shaft V-pulley

Filler port (engine oil)

V-belt

Exhaust manifold

Alternator

Turbocharger*

Air intake port [from air cleaner(optional)]

1. General

1.5 Structural description

2-valve cylinder head

4-valve cylinder head

4TNV84T/4TNV94L/4TNV98(T)

Noise Reduction

New Lub. Oil Pump

࡮

Change Rotor Shape for Low Pulsation

࡮

Driven by Crankshaft Directly

Noise Reduction (only applied for 4TNV84T)

New Lub. Oil Pump

࡮

Change Rotor Shape for Low Pulsation

࡮

Driven by Crankshaft Directly

Emission Reduction

New Fuel Inj. Nozzle

࡮

Low Suck Volume

࡮

Multi Injection Holes

Emission Reduction

New Fuel Injection Pump

࡮

Mono Plunger

࡮

Higher Injection Pressure

࡮

Mechanical Control of Injection

Timing
Speed Timer, Load Timer,
Cold Start Timer

Emission Reduction

Injection Nozzle

࡮

Low Suck Volume

࡮

Multi Injection Holes

Emission Reduction

Cylinder Head

࡮

Optimal Nozzle Angle

࡮

Optimal Swirl Ratio

࡮

Optimal Valve Timing

Emission Reduction

Piston

࡮

New Combustion

Chamber

Emission Reduction

Cylinder Head

࡮

4Valve / Cylinder

(intake-2, exhaust-2)

࡮

Optimal Installation

of the Injection Nozzle
Vertical Installation and
Location of the Center
of Cylinder

࡮

Optimal Valve Timing

Emission Reduction

Piston

࡮

New Combustion Chamber

Emission Reduction

New fuel injection pump

࡮

Mono Plunger

࡮

Higher Injection Pressure

࡮

Injection Timing Control

Speed Timer, _oad Timer,
Cold Start timer

Noise Reduction

Higher Stiffness Cylinder Block

Noise Reduction

Higher Stiffness Gear-Case

1. General

1.6 Exhaust gas emission regulation

The engines in this manual have been certified by the US EPA, California ARB and/or the 97/68/EC Directive.

California
Proposition 65 Warning

Diesel engine exhaust and some of its constitutions are known to the State of California to cause cancer,
birth defects, and other reproductive harm.

California
Proposition 65 Warning

Battery posts

，

terminals

，

and related accessories contain lead and lead compounds

，

chemicals known to

the State of California to cause cancer and reproductive harm

．

1.6.1 The emission standard in USA

(1) EPA Nonroad Diesel Engine Emission Standards

Note1) The EPA emission regulation under 130 kW is mentioned below.
Note2) As for Model year, the year which a regulation is applicable to is shown.

(2) California ARB Emission Regulation

The ARB emission standard is based on that of the EPA.

g/kW•hr (g/bhp•hr)

Engine Power

Tier

Model Year

NOx

NMHC + NOx

kW < 8
(hp < 11)

Tier 1

2000

10.5 (7.8)

8.0 (6.0)

1.0 (0.75)

Tier 2

2005

7.5 (5.6)

8.0 (6.0)

0.80 (0.60)

8 <= kW < 19
(11 <= hp < 25)

Tier 1

2000

9.5 (7.1)

6.6 (4.9)

0.80 (0.60)

Tier 2

2005

7.5 (5.6)

6.6 (4.9)

0.80 (0.60)

19<= kW < 37
(25 <= hp < 50)

Tier 1

1999

9.5 (7.1)

5.5 (4.1)

0.80 (0.60)

Tier 2

2004

7.5 (5.6)

5.5 (4.1)

0.60 (0.45)

37 <= kW < 75
(50 <= hp < 100)

Tier 1

1998

9.2 (6.9)

Tier 2

2004

7.5 (5.6)

5.0 (3.7)

0.40 (0.30)

Tier 3

2008

4.7 (3.5)

5.0 (3.7)

75 <= kW < 130
(100 <= hp < 175)

Tier 1

1997

9.2 (6.9)

Tier 2

2003

6.6 (4.9)

5.0 (3.7)

0.30 (0.22)

Tier 3

2007

4.0 (3.0)

5.0 (3.7)

Engine classification

Transient smoke standards % opacity

(acceleration/lug/peak modes)

Constant speed engine

Not regulated

Variable speed engine

20/15/50 or less

1. General

1.6.2 Engine identification

(1) Emission control labels of US EPA

(2) Emission control label for both EPA and ARB

(3) 97/68EC Directive label

EPA label for constant speed engines

EPA label for variable speed engines

/1&'.;'#475'2#4')7.#6+105

01041#&%+'0)+0'5%1056#0652''&10.;

75&

(7'.

)

(

/1&'.;'#475'2#4')7.#6+105

01041#&%1/24'55+10+)0+6+10'0)+0'5

75&

(7'.

)

(

)

'%&+4'%6+8'

1. General

1.6.3 Guarantee conditions for the EPA emission standard

The following guarantee conditions are set down in the operation manual. In addition to making sure that
these conditions are met, check for any deterioration that may occur before the required periodic maintenance
times.

(1) Requirement on engine installation condition

(a)Intake air depression

(b)Exhaust gas back pressure

(2) Fuel oil and lubricating oil

(a)Fuel: The diesel fuel oil US No.2 diesel fuel oil.
(b)Lube oil: API grade, class CD or CF

(3) Do not remove the seals restricting injection

quantity and engine speed.

(R.1)

kPa (mmAq)

Initial

Permissible

<= 2.94 (300)

<= 6.23 (635)

kPa (mmAq)

Engine type

Initial

Permissible

Naturally aspirated engines

<= 12.75 (1300)

<= 15.30 (1560)

4TNV98T, 4TNV106T

<= 9.81 (1000)

<= 11.77 (1200)

3,4TNV84T

<= 4.90 (500)

<= 5.88 (600)

Tamper

resistance Assy

Sealing cap

Gasket

Cap nut

Copper gasket

Plate

Nut

Seal washer

Injection quant

limit bc

Tamper resistance device
for engines certified by ARB/EPA

1. General

(4) Perform maintenance without fail.

Note

Inspections to be carried out by the user and by the maker are divided and set down in the "List of

Periodic Inspections" and should be checked carefully.

(5) Maintenance period and quality guarantee period for exhaust emission related parts

The maintenance of the parts related to the exhaust emission must be carried out in the maintenance period
as shown in the below table.
A guarantee period is that either the operation hours or years shown in the table come first in the condition
that the maintenance inspection was carried out based on the "List of Periodic Inspections".

Maintenance period

Quality Guarantee Period

Parts

Power Rating

•Fuel nozzle cleaning

Adjustment, cleaning,
repairs for fuel nozzle, fuel
pump, turbocharger,
electronic control unit etc.

For nozzle, fuel pump,
turbocharger

37 <= kW < 130

Every 1500 hours
(applied from Tier 2)

Every 3000 hours
(applied from Tier 2)

3000 hours / 5 years

19 <= kW < 37
except constant
speed engines >=
3000 min

-1

Every 1500 hours

Every 3000 hours

3000 hours / 5 years

KW < 19
And constant speed
engines beyond
3000 min

-1

under

37 kW

Every 1500 hours

Every 3000 hours

1500 hours / 2 years

2. Inspection and adjustment

2.2 Periodic inspection and maintenance procedure

2.2.1 Check before daily operation

Be sure to check the following points before starting an engine every day.

(1) Visual check around engine

If any problem is found, do not use before the engine repairs have been completed.

• Oil leak from the lubrication system
• Fuel leak from the fuel system
• Coolant water leak from the cooling water system
• Damaged parts
• Loosened or lost bolts
• Fuel, radiator rubber hoses, V belt cracked, loosened clamp

(2) Fuel tank level check and fuel supply

Check the remaining fuel oil level in the fuel tank and refuel the recommended fuel if necessary. (Refer to
1.3.(1))

(3) Lube oil level check and replenishment

(a)Checking oil level

Check the lube oil level with the dipstick, after
adjusting the posture of the machine unit so that an
engine may become a horizontality. Insert the dipstick
fully and check the oil level. The oil shall not be
contaminated heavily and have appropriate viscosity.
No coolant water or diesel fuel shall be mixed.
When lube oil is supplied after the engine running,
check the lube oil level after about 10 minutes pass
after the engine shutdown so that the lube oil inside
may be retuned the oil pan.

Standard

The level shall be between the upper and lower
limit lines on the dipstick.

No.

Inspection Item

(1)

Visual check around engine

(2)

Fuel tank level check and fuel supply

(3)

Lube oil level check and replenishment

(4)

Coolant water level check and replenishment

(5)

Fuel pipe and coolant water pipe inspection and maintenance

(6)

Inspection and adjustment of governor lever and accelerator

(7)

Warning lamp & instruments function check

Dipstick

Filler cap

Filler port

(engine oil)

Upper limit

Lower limit

2. Inspection and adjustment

Lube oil capacity may differ from the above volume depending on an engine installed on a machine unit.

(b)Replenishing oil pan with lube oil

If the remaining engine oil level is low, fill the oil pan with the specified engine oil to the specified level through
the filler port.

[NOTICE]

The oil should not be overfilled to exceed the upper limit line. Otherwise a naturally-aspirated engine may
intake lube oil in the combustion chamber during the operation, then white smoke, oil hummer or urgent
rotation may occur, because the blowby gas is reduced in the suction air flow.
In case of turbo-charged engine oil may jet out from the breather or the engine may become faulty.

(4) Coolant water inspection

Daily inspection of coolant water should be done only by Coolant recovery tank.

•Never open the radiator filler cap while the engine and radiator are still hot.

Steam and hot water will spurt out and seriously burn you. Wait until the
radiator is cooled down after the engine has stopped, wrap the filler cap with
a rag piece and turn the cap slowly to gently release the pressure inside the
radiator.

•Securely tighten the filler cap after checking the radiator. Steam can spurt

out during operation, if the cap is tightened loosely.

(a)Checking coolant water volume
Check the coolant water level in the Coolant recovery tank. If the water level is close to the LOW mark, open
the Coolant recovery tank cap and replenish the Coolant recovery tank with clean soft water to the FULL
mark.

Standard

The water level of the Coolant recovery tank shall be between the upper and lower limit lines.

(b)Replenishing engine with water

If the Coolant recovery tank water level is lower than the LOW mark, open the radiator cap and check the
coolant water level in the radiator. Replenish the radiator with the coolant water, if the level is low.

• Check the coolant water level while the engine is

cool.
Checking when the engine is hot is dangerous.
And the water volume is expanded due to the
heat.

• Daily coolant water level check and replenishing

shall be done only at the Coolant recovery tank.
Usually do not open the radiator cap to check or
replenish.

(Unit: liter)

Model

Total volume (L)

Effective volume (L)

3TNV82A

5.5

1.9

3TNV84 (T)•88

6.7

2.8

4TNV84 (T)•88

7.4

3.4

4TNV94L98•(T)

10.5

4.5

4TNV106 (T) (CL class)

14.0

9.0

4TNV106 (T) (VM class)

14.0

7.5

Radiator cap

Loosen

Tighten

2. Inspection and adjustment

IMPORTANT:

If the coolant water runs short quickly or when the radiator runs short of water with the Coolant recovery
tank level unchanged, water may be leaking or the air tightness may be lost. Increase in the Coolant
recovery tank water level during operation is not abnormal.
The increased water in the Coolant recovery tank returns to the radiator when the engine is cooled down.
If the water level is normal in the Coolant recovery tank but low in the radiator, check loosened clamping of
the rubber hose between the radiator and Coolant recovery tank or tear in the hose.

Standard

Engine: The radiator shall be filled up.

Engine coolant water capacity may differ from the above

volume depending on an engine installed on a machine unit.

(5) Fuel pipe and coolant water pipe inspection and maintenance

Check the rubber hoses for fuel and coolant water pipes cracked. If the cracked hose is found, replace it with
new one. Check the loosened clamp. If found, tighten it.

(6) Inspection and adjustment of governor lever and accelerator

Make sure the accelerator of the machine unit can be operated smoothly before starting the engine. If it feels
heavy to manipulate, lubricate the accelerator cable joints and pivots. Adjust the accelerator cable if there is a
dislocation or excessive play between the accelerator and the governor lever. Refer to 3.2.3.

(7) Warning lamp & instruments function check

Before and after starting the engine, check to see that the alarm function normally. Failure of alarm cannot
warn the lack of the engine oil or the coolant water. Make it a rule to check the alarm operation before and
after starting engine every day. Refer to each manual for machine units in details.

2.2.2 inspection after initial 50 hours operation

Be sure to check the following points after initial 50 hours operation, thereafter every 250 hours or 3 months
operation.

(1) Lube oil and filter replacement (1st time)

When an engine is still hot, be careful with a splash of engine oil which may
cause burns. Replace engine oil after the engine oil becomes warm. It is
most effective to drain the engine oil while the engine is still warm.

(Unit: liter)

Model

Coolant water volume In an engine

3TNV82A

1.8

3TNV84 (T)
3TNV88

2.0

4TNV84 (T)
4TNV88

2.7

4TNV94L
4TNV98 (T)

4.2

4TNV106 (T)

6.0

No.

Inspection Item

(1)

Lube oil and filter replacement

(2)

V-belt tension check

2. Inspection and adjustment

In early period of use, the engine oil gets dirty rapidly
because of the initial wear of internal parts. Replace the
engine oil earlier.
Lube oil filter should also be replaced when the engine
oil is replaced.
The procedure of lube oil and lube oil filter replacement
is as follows.

(a)Drain engine oil

• Prepare a waste oil container collecting waste oil.
• Remove the oil filler cap to drain easily while draining

the lube oil.

• Loosen the drain plug using a wrench (customer pro-

cured) to drain the lube oil.

• Securely tighten the drain plug after draining the lube

oil.

[NOTICE]

Use a socket wrench or a closed wrench when
removing or tightening a drain plug.
Don’t use a spanner because it has the possibility
that the spanner will slip and it will get hurt.

(b)Replacing oil filter

• Turn the lube oil filter counter-clockwise using a filter

wrench (customer procured) to remove it.

• Clean the mounting face of the oil filter.
• Moisten the new oil filter gasket with the engine oil

and install the new engine oil filter manually turning it
clockwise until it comes into contact with the mount-
ing surface, and tighten it further to 3/4 of a turn with
the filter wrench.

Tightening torque: 20 to 24 N•m (2.0 to 2.4 kgf•m)

(c)Filling oil and inspection

• Fill with new engine oil until it reaches the specified

level.

IMPORTANT:

Do not overfill the oil pan with engine oil.
Be sure to keep the specified level between upper
and lower limit on the dipstick.

• Warm up the engine by running for 5 minutes while

checking any oil leakage

• Stop the engine after warming up and leave it stop-

ping for about 10 minute to recheck the engine oil
level with dipstick and replenish the engine oil. If any
oil is spilled, wipe it away with a clean cloth.

Model

Applicable oil filter Part No.

3TNV82A to 4TNV98 (T)

129150-35151

4TNV106 (T)

119005-35100

Loosen

Tighten

Engine oil filter

2. Inspection and adjustment

(2) V-belt tension check

When there is not enough tension in the V-belt, the V-
belt will slip making it impossible for the alternator to
generate power and cooling water pump and cooling
fan will not work causing the engine to overheat.
Check and adjust the V-belt tension (deflection) in
the following manner.

[NOTICE]

Be especially careful not to splash engine oil on
the V-belt, because it will cause slipping,
stretching and aging of the belt.

1)Press the V-belt with your thumb [approx.

98N (10 kgf)] at the middle of the V-belt span to
check the tension (deflection).
Available positions to check and adjust the V-belt
tension (deflection) are at the A, B or C direction
as shown in the illustration right.
You may choose a position whichever you can
easily carry out the check and adjustment on the
machine unit.

• "New V-belt" refers to a V-belt which has been

used less than 5 minutes on a running engine.

• "Used V-belt" refers to a V-belt, which has been

used on a running engine for 5 minutes or more.

The specified deflection to be measured at each
position should be as follows.

2)If necessary, adjust the V-belt tension (deflection).

To adjust the V-belt tension, loosen the set bolt and
move the alternator to tighten the V-belt.
After replacing with a new V-belt and adjusting it,
run the engine for 5 minutes and readjust the deflec-
tion to the value in the table above.

3)After replacing with a new V-belt and adjusting it,

run the engine for 5 minutes and readjust the deflec-
tion to the value in the table above.

4)Visually check the V-belt for cracks, oiliness or wear.

If any, replace the V-belt with new one.

(Unit: mm)

Direction

For used V-belt

10 to 14

7 to 10

9 to 13

For new V-belt

8 to 12

5 to 8

7 to 11

Radiator fan

Set bolt

Alternator

Deflection

V-belt

Crankshaft
V-pulley

Press with thumb

Adjuster

Adjust the V-belt tension
inserting a bar

Alternator

Tension adjustment

2. Inspection and adjustment

2.2.3 Inspection every 50 hours

Be sure to check the following points every 50 hours operation.

(1) Fuel tank draining

1)Prepare a waste oil container.
2)Remove the drain plug of the fuel tank to drain

(water, dust, etc.) from the fuel tank bottom.

3)Drain until fuel with no water and dust flow out.

Then tighten the drain plug firmly.

(2) Water separator draining

Drain off the water separator whenever there is a lot of
drain collected in the water separator at the bottom of
the cup even if not the time for periodic inspection hour.
The cup of the water separator is made from semi-
transparency material and in the cup, the red colored
float ring which rises on the surface of the drain is
installed to visualize the amount of drain. Also, the
water separator with sensor to detect the drain for
warning device on a control panel is provided as the
optional.
Drain off the water separator in the following manner.

1)Prepare a waste oil container.
2)Close the fuel cock.
3)Loosen the drain cock at the bottom of the water

separator, and drain off any water collected inside.

4)Tighten the drain cock with hand.
5)Be sure to bleed air in the fuel system.

NOTE:
If no drain drips when the drain cock is opened, loosen the air bleeding bolt on the top of the water separator
by turning counter-clockwise 2 to 3 times using screw driver.
(This may occur in case of the water separator position is higher than the fuel oil level in the fuel tank). After
draining, be sure to tighten the air bleeding bolt.

No.

Inspection Item

(1)

Fuel tank draining

(2)

Water separator draining

(3)

Bleeding the fuel system

(4)

Battery electrolyte level check and battery recharging

Fuel tank

Drain plug

OPTION

Air bleeding bolt

Outlet

Inlet

Open

Cup

Float ring

Drain cock

Water separator

Fuel cock

2. Inspection and adjustment

(3) Bleeding the fuel system

Bleed the fuel system according to the following
procedures. When there is air in the fuel system, the
fuel injection pump will not be able to function.

1)Check the fuel oil level in the fuel tank. Refuel if

insufficient.

2)Open the cock of the water separator.
3)Loosen the air bleeding bolt on the water separator

by turning 2 to 3 times to the counter-clockwise
using screw driver or spanner.

4)When the fuel coming out is clear and not mixed

with any bubble, tighten the air bleeding bolt.

5)Feed the fuel with the fuel priming pump or electro-

magnetic fuel feed pump.

• In case of the engine using the electro-magnetic fuel

feed pump.
Turn the starter switch to the ON position and hold it
in the position for 10 to 5 seconds to operate the fuel
feed pump.

• In case of the engine installed the fuel filter mounting

with the fuel priming pump.
The priming pump is on the top of the fuel filter
mounting. Move the priming pump up and down to
feed fuel until feel your hand slightly heavy.

(4) Battery electrolyte level check and battery recharging

Fire due to electric short-circuit

•Make sure to turn off the battery switch or disconnect the negative cable (-)

before inspecting the electrical system. Failure to do so could cause short-
circuiting and fires.

•Always disconnect the (-) Negative battery cable first before disconnecting

the battery cables from battery. An accidental "Short circuit" may cause
damage, fire and or personal injury.
And remember to connect the (-) Negative battery cable (back onto the bat-
tery) LAST.

Proper ventilation of the battery area

Keep the area around the battery well ventilated, paying attention to keep
away any fire source. During operation or charging, hydrogen gas is
generated from the battery and can be easily ignited.

Do not come in contact with battery electrolyte

Pay sufficient attention to avoid your eyes or skin from being in contact with
the fluid. The battery electrolyte is dilute sulfuric acid and causes burns.
Wash it off immediately with a large amount of fresh water if you get any on
you.

Fuel filter

Fuel injection
pump

Fuel priming

pump

Drain cock

Water separator
(installed on the pipe line)

Fuel filter mounting with
fuel priming pump (option)

Fuel filter

Air bleeding bolt

Outlet

Inlet

Open

Fuel return hose

Air bleeding

bolt

Fuel cock

2. Inspection and adjustment

Battery structure

(1) Electrolyte level

• Check the level of fluid in the battery.

When the amount of fluid nears the lower limit, fill
with battery fluid (available in the market) to the
upper limit. If operation continues with insufficient
battery fluid, the battery life is shortened, and the
battery may overheat and explode.

• Battery fluid tends to evaporate more quickly in the

summer, and the fluid level should be checked ear-
lier than the specified times.

• If the engine cranking speed is so slow that the

engine does not start up, recharge the battery.

• If the engine still will not start after charging, replace

the battery.

• Remove the battery from the battery mounting of the

machine unit after daily use if letting the machine unit
leave in the place that the ambient temperature
could drop at -15 °C or less. And store the battery in
a warm place until the next use the unit to start the
engine easily at low ambient temperature.

(2) Battery charge

Use a battery tester or hydrometer and check the
battery condition. If the battery is discharged, recharge
it.

(a)Measurement with a battery tester

When checking the battery with the batter tester,
connect the red clip of the tester to the battery positive
(+) terminal and black clip to the battery negative (-)
terminal by pinching them securely, and judge the
battery charge level from the indicator position.

Green zone: Normal
Yellow zone: Slightly discharged
Red zone: Defective or much discharged

Terminal

Cap

Cover

Cathode

plate

Separator

Glass mat

Anode plate

Battery

case

GREASE

UPPER LEVEL

LOWER LEVEL

Lower limit

Excessive

Upper limit

Too low

Electrolyte level

Battery tester

Battery charge measurement
with battery tester

Takeuchi compact excavator TB125, TB135, TB145 / diesel TNE / diesel Yanmar. Service Manual - page 51