Takeuchi TB153FR Compact Excavator Workshop Manual (CJ2E001-1)

Format: PDF (Printable Document)

File Language: English

File Pages: 728

File Size: 22.97 MB (Speed Download Link)

Brand: Takeuchi

Model: TB153FR Compact Excavator

Book No: CJ2E001-1

Serial No: 15820004_

Type of Document: Workshop Manual

Categories: PDF, Takeuchi PDF

$ 50

Takeuchi TB153FR Compact Excavator Workshop Manual (CJ2E001-1)

Takeuchi TB153FR Compact Excavator Workshop Manual (CJ2E001-1) (SN 15820004_)

This TB153FR compact excavator spends its life in tight sites—utility trenches, street repairs, foundation work—where you can’t afford downtime or sloppy reassembly. This workshop manual is what I’d pull out when I’m doing deeper work than daily checks: tracing a hydraulic issue, pulling a final drive, or reinstalling a swing motor. For example, if the boom won’t hold position or drifts under load, I’d use this book to follow a step‑by‑step sequence to isolate the fault, inspect the components in the right order, and verify everything is aligned and sealed correctly when it goes back together.

Applications & Use Cases

Plan a full teardown and rebuild of major components with a logical, shop-proven sequence.
Trace hydraulic faults by following the recommended order of tests instead of guessing at parts.
Inspect undercarriage and slew gear with the correct checks before reassembly and torqueing.
Verify adjustments on controls and linkages after reinstalling valves, pedals, or cylinders.
Route hoses and harnesses so nothing rubs, pinches, or interferes with the zero‑tail swing.

FAQ

Q: Can I use this manual on a tablet in the field?

A: Yes, it’s practical to keep it on a tablet or laptop so you can zoom diagrams and search terms while working beside the machine.

Q: Is it worth printing sections?

A: I usually print just the procedures I’m doing that day, so I can mark notes, keep it at the bench, and avoid getting a device dirty.

Safety Note

Always lock out the machine, support raised components, and bleed stored pressure before starting any repair.

📘 Show Index

Takeuchi TB153FR Compact Excavator Index:

I . GENERAL
II . SPECIFICATIONS
III . MACHINE CONFIGURATION
IV . HYDRAULIC UNITS
V . TROUBLESHOOTING
VI . ENGINE
- 3TNV/4TNV series
  - Cover
  - History of Revision
  - PREFACE
  - SAFETY LABELS
  - CONTENTS
  - 1. General
    - 1.1 Engine nomenclature
    - 1.2 Specifications
    - 1.3 Fuel oil, lubricating oil and cooling water
      - 1.3.1 Fuel oil
      - 1.3.2 Lubricating oil
      - 1.3.3 Cooling water
    - 1.4 Engine external views
    - 1.5 Structural description
    - 1.6 Exhaust gas emission regulation
      - 1.6.1 The emission standard in USA
      - 1.6.2 Engine identification
      - 1.6.3 Guarantee conditions for the EPA emission standard
  - 2. Inspection and adjustment
    - 2.1 Periodic maintenance schedule
    - 2.2 Periodic inspection and maintenance procedure
      - 2.2.1 Check before daily operation
      - 2.2.2 inspection after initial 50 hours operation
      - 2.2.3 Inspection every 50 hours
      - 2.2.4 Inspection every 250 hours or 3 months
      - 2.2.5 Inspection every 500 hours or 6 months
      - 2.2.6 Inspection every 1,000 hours or one year
      - 2.2.7 Inspection every 2000 hours or 2 years
    - 2.3 Adjusting the no-load maximum or minimum speed
    - 2.4 Sensor inspection
      - 2.4.1 Oil pressure switch
      - 2.4.2 Thermo switch
    - 2.5 Water leak check in cooling water system
    - 2.6 Radiator cap inspection
    - 2.7 Thermostat Inspection
    - 2.8 Adjusting operation
    - 2.9 Long storage
  - 3. Troubleshooting
    - 3.1 Preparation before troubleshooting
    - 3.2 Quick reference table for troubleshooting
    - 3.3 Troubleshooting by measuring compression pressure
  - 4. Disassembly, inspection and reassembly of engines
    - 4.1 Complete disassembly and reassembly
      - 4.1.1 Introduction
      - 4.1.2 Special service tools
      - 4.1.3 Complete disassembly
      - 4.1.4 Precautions before and during reassembly
      - 4.1.5 Adjusting operation
    - 4.2 Cylinder head: Disassembly, inspection and reassembly
      - 4.2.1 Components (2-valve cylinder head)
      - 4.2.2 Disassembly procedure:
      - 4.2.3 Reassembly procedure:
      - 4.2.4 Servicing points
      - 4.2.5 Parts Inspection and measurement
      - 4.2.6 Valve seat correction
      - 4.2.7 Valve guide replacement
      - 4.2.8 Valve stem seal replacement
    - 4.3 Gear train and camshaft
      - 4.3.1 Components
      - 4.3.2 Disassembly procedure:
      - 4.3.3 Reassembly procedure:
      - 4.3.4 Servicing points
      - 4.3.5 Parts inspection and measurement
      - 4.3.6 Oil seal replacement (Gear case side)
      - 4.3.7 Camshaft bushing replacement
    - 4.4 Cylinder block
      - 4.4.1 Components
      - 4.4.2 Disassembly procedure:
      - 4.4.3 Reassembly procedure:
      - 4.4.4 Servicing points
      - 4.4.5 Parts inspection and measurement
      - 4.4.6 Cylinder bore correction
      - 4.4.7 Piston pin bushing replacement
      - 4.4.8 Oil seal replacement (Flywheel housing side)
  - 5. Lubrication system
    - 5.1 Lubrication system diagram
    - 5.2 Trochoid pump components
    - 5.3 Disassembly (Reverse the procedure below for assembly)
    - 5.4 Servicing points
    - 5.5 Parts Inspection and measurement
      - 5.5.1 Trochoid pump inspection and measurement
    - 5.6 Lube oil filter
      - 5.6.1 Lube oil filter construction
      - 5.6.2 Lube oil filter replacement
  - 6. Cooling system
    - 6.1 Cooling water system
    - 6.2 Cooling water pump components
    - 6.3 Disassembly (Reverse the procedure below for assembly)
    - 6.4 Servicing points
  - 7. Fuel injection pump / Governor
    - 7.1 Introduction
    - 7.2 Fuel injection pump
      - 7.2.1 Fuel system diagram
      - 7.2.2 External view and components
      - 7.2.3 Disassembly procedure:
      - 7.2.4 Assembly procedure
      - 7.2.5 Servicing points
      - 7.2.6 C.S.D. (Cold Start Device)
  - 8. Turbocharger: Disassembly, inspection and reassembly
    - 8.1 Structure and functions
      - 8.1.1 Main specifications
      - 8.1.2 Construction
      - 8.1.3 Structural and functional outline
      - 8.1.4 Components
    - 8.2 Service standards and tightening torque
      - 8.2.1 Service standards
      - 8.2.2 Tightening torque
    - 8.3 Periodic inspection procedure
      - 8.3.1 Periodic inspection intervals
      - 8.3.2 Inspection procedure
      - 8.3.3 Waste gate valve adjustment procedure
    - 8.4 Disassembly procedure
      - 8.4.1 Preparation for disassembly
      - 8.4.2 Inspection before disassembly
      - 8.4.3 Disassembly
    - 8.5 Washing and inspection procedure
      - 8.5.1 Washing
      - 8.5.2 Inspection procedure
    - 8.6 Reassembly procedure
      - 8.6.1 Preparation for reassembly
      - 8.6.2 Reassembly
    - 8.7 Handling after disassembly and reassembly
      - 8.7.1 Instructions for turbocharger installation
    - 8.8 Troubleshooting
      - 8.8.1 Excessively exhaust smoke
      - 8.8.2 White smoke generation
      - 8.8.3 Sudden oil decrease
      - 8.8.4 Decrease in output
      - 8.8.5 Poor (slow) response (starting) of turbocharger
      - 8.8.6 Abnormal sound or vibration
  - 9. Starting motror
    - 9.1 For 4TNV94L/ 98
      - 9.1.1 Specifications
      - 9.1.2 Components
      - 9.1.3 Troubleshooting
      - 9.1.4 Names of parts and disassembly procedure
      - 9.1.5 Inspection and maintenance
      - 9.1.6 Service standards
      - 9.1.7 Assembly
      - 9.1.8 Characteristic test
    - 9.2 For 4TNV106 (T)
      - 9.2.1 Specifications
      - 9.2.2 Congiguration drawing
      - 9.2.3 Troubleshooting
      - 9.2.4 Component names and disassembly procedure
      - 9.2.5 Disassembly procedure
      - 9.2.6 Inspection and maintenance
      - 9.2.7 Assembly
      - 9.2.8 Adjustment
      - 9.2.9 Service standards
    - 9.3 For 3TNV82A to 3/4TNV88
      - 9.3.1 Specifications
      - 9.3.2 Characteristics
      - 9.3.3 Disassembly drawing
      - 9.3.4 Connecting diagram of a starting motor
  - 10. Alternator
    - 10.1 The 40A alternator for 3TNV84 and other models
      - 10.1.1 Components
      - 10.1.2 Specifications
      - 10.1.3 Wiring diagram
      - 10.1.4 Standard output characteristics
      - 10.1.5 Inspection
      - 10.1.6 Troubleshooting
  - 11. Electric wiring
    - 11.1 Electric wiring diagram
    - 11.2 Precaution on electric wiring
      - 11.2.1 Alternator
      - 11.2.2 Starter
      - 11.2.3 Current limiter
      - 11.2.4 Section area and resistance of electric wire
  - 12. Service standards
    - 12.1 Engine tuning
    - 12.2 Engine body
      - 12.2.1 Cylinder head
      - 12.2.2 Gear train and camshaft
      - 12.2.3 Cylinder block
    - 12.3 Lubricating oil system (Trochoid pump)
  - 13. Tightening torque for bolts and nuts
  - Back cover
- YPD-MP2/YPD-MP4
ENGINE TROUBLE DIAGNOSTICS TOOL AND MAINTENANCE TOOL
MAINTENANCE SOFTWARE