ViO45 - 55-5 - B - Service Manual - 1-5 PDF

ae a NU EXCAVATOR WiOQs.58) ViG@s.50)FOREWORD ‘his service manual outlines procedures for servicing YANMAR construction machinery. It contains specifications, servicing Instructions and handling cautions. To obtain the maximum ife and performance from YANMAR construction machinery, read this ‘manual carefully and follow its instructions, Please note that all dimensions and numerical values in this manual are for service reference, and are not inspection standards. Descriptions and specifications in this manual are subject to change without notice due to design improvements, et. Pe) California Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects and other reproductive harm. A WARNING 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, Wash hands after handlingCONTENTS CHAPTER 1 General Cautions for Maintenance Work 4 Contect Work 112 Safety Precautions +3 Preparations. +44 Cautons for Disassembly and Reassemby +15 Caubons for Removal and Instalation of Hydraule Equipment “18 Cautons for Removal and Installation of Hydraulic Piping +17 Cautons for Handing Sea's. +18 Contec nsatiton of Hydraule Hose 1-9 Speciications of Hydraulic Hose. 1-10 Ar Release of Hyéraulc Equipment CHAPTER 2 Technical Data 2.1 Specieations 2.2 Outine Drawing and Working Area 22-1 Canopy ype 22-2.Cabin ype 2.3 Weight List of Main Pats 2-4 Ling Capacty List CHAPTER 3 Service Standards 3:1 Machine Performance S:2Engine 2-3 Undercarriage 3.94 Rubber Track Specifcaions 3-32 Steel Track Specifications 3.98 Common Specifeations of Ste! & Rubber Tracks 2.4 Contols 3:5 Hydraule Equipment. 3.541 Hydraule Gyinders 346 implement 3.6-1 Front Attachments 3.62 Blade Moving Deve. 3.6.3 Bucket Teeth 3:7 List of Tightoning Torque 3.741 Machine 37-2 Engine 3.7 Tightoning Torque for General Bolts and Nuts a4 424 1341 as 152 142 193 193 196 0-11 2as 224 224 222 at 2a oat ae4 oat oat 392 333 oat 354 354 364 364 362 362 or or ora oTCHAPTER 4 Engine 441 General 4-1-1 How to Read This Manual 4-1-2 Precautions fr Service Werk 4-4-3 Engine Extomal Views 4-14 Structural Description 4-1-5 Exhaust Gas Emission Regulation 4.2 Troubleshooting 4-2-1 Quick Reference Table for Troubleshooting 4.2.2 Troubleshooting by Measuting Compression Pressure 4-3 Inspection and Agjstment 4-3-1 Of inspection 4.3.2 Cooling Water Inspection 4-3-3 Inspecting Water Leak fom Cooling Water System and Rachator. 4-3-4 Fan Bet Tension Inspection and Adjustment 4-345 Adjusting the Valve Clearance 4-3-6 Inspecting the Fuel njecton Vive Injection Pressure and Spray Patter, 4-3-7 Fuel Injaction Timing Agjustment/ Fue Injection Pump Inspection and Aajustment. 4-2-8 Sensor Inspection, 4-9-9 Battery Inspection 4-3-10 Agusting Operation 43-11 Long Storage, 4-3-12 Periodic Maintenance Schedule 4-4 Engine Body 4-441 Invoducton, 4-42 Cylinder Head. 444.3 Gear Train and Came 4-44 Cylinder Block 45 Lubrication System. 4-5-1 Lubrication System Diagram 4-5-2 Trochoid Pump (VIO4S-5, VIOSS-5 4TNVEE-PRV). 4-5-3 Trochoid pump (VIO45-5B, VIOSS.5B: 4TNVES-BXBV) 48 Cooling System, 4-6-1 Cooling Water System, 4-6-2 Coolng Water Pump Components, 48.3 Disassembly (Reverse the Procedure Below for Assembly) 4-6-4 Serving Pons, 4-7 Fue! Injection Pump / Governor. 4-7-1 Invodueton, 4-7-2 Fuel injection Pur. 4-8 Electrical Equipment 4-8-1 Stater Motor 4-8-2 Aerator 4-0-3 AirHeator 4a 413 43415 4318 4a7 444 444 442 san 4416 4541 454 454 453 464 464 464 462 462 art ar 4r4 464 464 403 406CHAPTER 5 Hydraulic System 541 Outing 5-1-1 Control Valve Operation 5-12 Adaitional Operation of Conta! Valve 5:2 Hydraule Grout Schematic 5:3 Creut Operation 5-3-1 Boom 532 Am. 5.33 Bucket 52-4 Swing 53.5 Boom Swing 52.5 Blade 52:7 Travel 5.28 Non-Devition rave with Boom, Arm or Boom Swing Operation) 5.3.9 Non-Deviation Travel with Bucket Operon) 53:10 Simultaneous Operation of Boom Up and Arm Retract 53:11 Simultaneous Operation of Boom Up and Bucket 53:12 Simuitaneous Operation of Boom Up and Swing 53:13 Simultaneous Operation of Arm and Bucket 53:14 Hyeraulie PTO 5-3-15 Quick Coupler 5:4 Pressure Adjustment 5.1 Rolet Valves. 5-4-2 Swing Brake Valve 5.4.3 CuLOM Vaive CHAPTER 6 Hydraulic Equipment 61 Hyéraule Purp 6.2 Control vahe 6.3 Pot VaNe 6-4 Swing Motor 65 Travel Motor 6-6 Bade Control Pot VaNve 6-7 Solenoid Vale for P.T.0. Operation. 16-8 Plot Check Valve (For Quick Coupler Cicut) eas 624 eat eat ost ers oatCHAPTER T Adjustment and Repair 7-1 Blettic Equpment of Machine, 7-14 Patt Layout of Electrical Equipment 7-4-2 Monitor and Alarm Systems 7-48 Wing Diagram. 7-4-4 Cheut Description of Engine Stat and Stop, and Battery Charging 7-46 Removal and Reinstalation of Engine 7-146 Removal and Reassembiy of Starter Motor 7-4-7 Removal and Reassembly of rive Bets for Generator and Compressor 7-2Undercariage 7-244 Outline. 7-2-2 Main Parts 7-2: Paints of Reassembly (Rubber Track) 7-2-4 Points of Reassembly (Steel Track). 7-25 Removal and Reinstllation of Track 7-24 Removal and Renstallation of Stel Track 7-2: Disassembly and Reasserbly of Front idle. 7-248 Disassembly and Reasserbly of Track Roller. 17-29 instalation ofFlosting Seal 7-2-0 Drawings of Jigs 7-241 Disassembly and Resssembly of Cartier Roller 7-8 contol 7-344 Conta Train 7-9-2 Mechanical Contra Linkage 7-39 Adjustment of Travel Levers 7-34 Adjustment of Boom Swing Pedal 7-3 Adjustment ofLock Lever. 7-346 Adjustment of Accelerator Lever 7-4 Swing Bearing 7-8 Hydeaule Equipment. 7-5-1 Removal and Reinstallation of Hydraue Pump 7-5: Removal and Reinstaliation of Control Valve 7-5: Removal and Reintallation of Swing Moto. 7-544 Removal and Renstallation of Swivel Joint. 7-5 Disassembly and Reasserbly of Sve Joint. 7-54 Disassembly and ReasserBly of Hydraulic Cyinders 7-5-7 Hydraulic Oi Tank 7-58 Piping Layout 7-8 Work implements 7-6-1 Removal and Reinstallation of Work Implements 7-62 Quick Coupler. T7Cabin 774 CabinCHAPTER 8 Periodic Inspection and Servicing {1 List of Penoaie Inspection and Servicing, CHAPTER 9 Fuel, Lube Oil and Grease Recommended 19, Fuel, Lube Oil and Grease Recommended CHAPTER 10 Troubleshooting 40-4 Non treakowne 40-1-1 Natural Release of Bucket. 40-1-2 Discontinuous Arm Movement 40-13 Dring of Upperstructure on Quick Travel Operation 40.1.4 Thermal Shock of Travel Motor 410-1.5 Elongation of Boom Swing Cylinder on 70 degrees Swing 10-14 Telescopic Maton of Boom Swing Cyinder with Lock Lever Set to Lock Postton 1041-7 Timo Lag on Travel Speed Switching 10-1-8Fluctuaton in Ol Level of Hydraule Oi Tank Ove to Temperature Change 10-1-9 Operation of Quick Coupler Cylinder (or Quek Coupler Type) 10-2 Troubleshooting 102-1 Machine and Engine, 10.2.2 Elecical Equpment on Pane! CHAPTER 11 Reference Data ‘1-1 Dimensions and Specifications for Attachment soa so4s so4-4 so42 10.43 s04-4 10.45 10-45 10-47 10-18 1024 1024 10223 144CHAPTER 1 GENERAL CAUTIONS FOR MAINTENANCE WORK 141 Conect Work, 4.2 Safety Precautions 1-3 Preparations 1-4 Cautions fr Disassembly and Resssemby 1-5 Cautions fr Removal and Installation of Hysraulle Equipment 1-6 Cautions for Removal and instalation of Hyraul ping 1-7 Cautions for Handling Seals 1-8 Correct Installation of Hydraulle Hose 1-9 Spectiatons of Hysraulc Hose 1-10 Air Release of Hydraulic Equipment. “4 us 12 13 13 18 at1. GENERAL CAUTIONS FOR MAINTENANCE WORK 4. General Cautions for Maintenance Work 4-1 Correct Work Correct work means the quickest possible completion of according to the correct procedures and the specified standards. tis important when conducting certain operations always to bear in mind the equipment, tools, gauges, material, oll and grease, etc. that you must have ready, as well as items to be checked, adjusted, o disassembled, and cautions towateh out for. 1-2 Safety Precautions (1) Never attempt servicing while engine fs running or immediately ater stopping operation, (@) Wear work cloths, safety shoes and helmet (@) Check the equipment and tools before use. Especially, be sure to check the crane, liting equipment and tools, @ When working together with other persons, allocate everyone's share of job, atrange the signals and actin con- cert withthe other persons, (©) The operation ofthe crane and slinging work must be performed by qualified persons. © Do not enter or pass under the raised load Lift and suppor the massive pars by crane before removing the instalation bots. @) Disconnect cables from battery before repairing the electri system. (® Remove the battery when welding the machine 4-3 Preparations (1) Check the service record ofthe machine. (That is, check how many months or hours the machine has been used since the preceding overnaul, what was the trouble then and what parts were replaced) (@) Have all servicing too's ready, Le, tools, measuring devices (which have received periodic maintenance), con- talners, oll & grease, etc @ Have the service literature (operation manual, parts catalog, etc.) ready. 1-4 Cautions for Disassembly and Reassembly (1) Clean the machine before disassembly. (@) Check and record the condition of the machine before disassembly + Model, machine number, operation hours + Reasons for repr, history of pair + Contamination of fiters + Fuel and oil condition + Damage to parts, ete (@) Pace alignment marks on the necessary parts to facilitate reassembly, (4) Clean al the removed parts and new replacement parts and put them in order. (8) Use new seais, spit pins, ete. for reassembly. a4 Anaros081. GENERAL CAUTIONS FOR MAINTENANCE WORK © Keep the parts apt to be damaged by water or oll apart fom the oly or wet parts. 2. Electrical pats, cubber parts, V-belts, etc (7) Use the jg for press-fiting the bearings, bushes and oll seals, When using a hammer, use a pad block. @ Clean the joint surface of al parts and keep them free from dust (® Wind the seaing tape securely, leaving a space of one or two threads from the tip of the malle screw, The tape should have an overlap of about 10 mm, Sealing tne 1-5 Cautions for Removal and Installation of Hydraulic Equipment (1) Check thatthe hydraulic ol temperature is low enough @) Release air from the hydraulic tank to prevent the hydraulic ol from flowing out (@ Be sure to plug open the ends of hydraulic components to prevent dust from entering @)_Be sure to wipe hydraulic oll from the hydraulic components so that it will not be mistaken for an ol leak. (© Take care not to damage the plating onthe oylinder rod. © Remove or install cylinders with rods fully retracted @) Be sure to release air after insaling the hydraulic cylinders + Run the engine at a low speed. Extend and retract the cylinders 4 to § times up to $0 to 100 mm from the end ofthe stroke. Then, fully extend and retract, ® Be sure to pressurize the hydraulic tank after instaling the hydraulic components (in the case of the sealed hydraulic tank). Otherwise, hydraulic pumps might suffer cavitation and their fe will be shortened. + To pressurize the hydraulic tank, fully extend each cylinder and tighten the oil fiter port plugs. 4-6 Cautions for Removal and Installation of Hydraulic (1) Installation of hydraulic hose Take care not to twist the hoses. (Judge whether or not the hose is twisted by Meu ttng the hose mark) For hoses with a metal ting, use two wrenches to prevent ~ twisting Use one to fix the hose, and the other to tighten the fiting to the specified soe = tightening torque. Carefully check thatthe hoses do not come in contact after Fixed sito tightening I any contact is found, correct itor use tubes. @ When instaing hoses, fst tighten to the specified torque and then loosen them a litle, Then retighten to the specified torque. + Break in the installed parts before tightening (except those using seal tapes). @) When insalig pipes, tum the nuts more 1/4 to 1/2 tum ater they reach the sharp torque rise point @) When insaling or eemoving hoses, use two wrenches, one to fasten the hose and the other to tighten or loosen the hose to prevent twisting, (©) Check for oil leakage by applying max. pressure 5 to 6 times after attaching hydraulic hoses or pipes. (Fev 12 Aaros081. GENERAL CAUTIONS FOR MAINTENANCE WORK 1-7 Cautions for Handling Seals (1) Clean out grooves of O-ings. Remove burrs or dust if any. iy uy Dust (2) Take care not to twist O-rings. Correct by your finger iit is twisted @) Take care not to damage seats when inserting (@) Handling of floating seals, + Completely wip off all he ol from the O-ring and housing after detaching the lating seals. + Before instaling, apply a litle gear oll to the matching face of the housing, + Turn the seals two of theee times after installation to break them in, (©) Apply grease to the lip ofthe oll seas to prevent wear. 4-8 Correct Installation of Hydraulic Hose In order to mount the hydraulic hose most effectively and economically, observe the folowing cautions. (1) When a hse is used at the minimum bending radius, use elbows to avoid sharp bending, 13 Anaros081. GENERAL CAUTIONS FOR MAINTENANCE WORK (@ When the hase is pressurized, the hose length varies slightly atthe bend. Allow this change to occur and do not tty to fasten the bend. (@ Its necessary for the hose to have ample slackness for elongation and contraction, because its length will change by +2 % 10-4 % when used at high pressure. POS ons (©) Use the proper adapters, not pipes, in order to reduce the number and lengt of joints and improve the external (© Use an elbow to prevent excessive twisting or bending of the hose, "UU (7) Use adapters to make the hose as straight as possible. The outside appearance can be improved by avoiding the use of hoses that are too long 4 naros081. GENERAL CAUTIONS FOR MAINTENANCE WORK (® The hose should be slightly longer than is absolutely necessary. The extra allows smoother movement of the hose and prevents sharp bending, Notaees (10) Use the marking on the hose as a guide to prevent twisting during installation. “Twisting of metal iting with union nuts should be with a wrench on the hexagonal parts as 18 Aaros081. GENERAL CAUTIONS FOR MAINTENANCE WORK 1-9 Specifications of Hydraulic Hose ‘Two types of hydraulic hoses are used in Yanmar Construction Machinery : the standard parts specified in the Yan- ‘mar Industral Standards (VIS) and special pars for the respective models. Specifications ofthe hydraulic hoses can be known by the code number or part descriptions as explained below. (For the parts number, please refer to our Pars Catalog.) (1) Yanmar Standard Type ‘The part code consists of 11-tigt numbers Hose material code —! Hose type code ‘L_—Fittings combination code |__ Nominal length code L____Nominal dia. code Description Part code No, Hose matedal Hose material Type of hose Hose aa combination of ngs 0000 ° 0° 000 ° Rubber hose (High pressure type) 2320 (SAE J517,100R) @ (SAE J517,100R2) a e Unit: em Plastic hose (High pressure type) zat (SAE J517,10087) ia a3 0 (SAE J517,100R7) ‘a a Rubber hose (Medium pressure type) 2328 (SAE J517,100R6) a a oe 0 06 "i 2 4 18 Aaros081. GENERAL CAUTIONS FOR MAINTENANCE WORK 4) Type of Hose (Hose Dia, & Recommended Working Pressure) Wark Type of hose Hose da Pig inten pressure 7 iW ieee {PSI (MPa)] ; w TET TSBs) 2489372) eevee 3 as7 5) ‘36017 5) 961 187) 08 Ts0(2 7) 081 208) 1568 (708) 7 @ 725163) 50115.) 7266 204) Teeth @ oaT 5) ETA 384 B80) 08 T8027) Oar 22) 7006 206) ; w 125163) 40725) 7296 206) ‘ederim 3 oa7 8) 085168) 2489772) 8 Tso") 087 207) 7961 (137) 2 03 T3785) ‘oe8ti72) 7996 208) (646 97,1007) 8 Ts0(127 oaa za) 7995,208) a2 025163) oso) 27129) 3 oar 5) 0651159) #27129) 08 Ts0(2 7) O 75108) #27129) 1 35 763 (159) 091 230) #2729) (SAE 0517, 10086) 8 T7590}, TasiaT ay a7 (23) 7 7.00 (254) 150 a1) #2729) 7% 135318) 1751445) 729) 74 150,98) 204519) #2729) 2) Total Length of Hose [Unit : in. (cm)] SoS cop 62> o>) 65 COR, L L L 3 digit indication in em, (Example) Nominal length 065 : Full length 25.6 in. (65 cm) 3) Hose Dia. (Unit : inch) Oat ae Tee 03..318" 05.3 ee 04a 10.04 Note Please note that these code numbers are diferent from those for the equivalent diameters for special parts on the next page. 17 naros081. GENERAL CAUTIONS FOR MAINTENANCE WORK 4) Combination of Fitting (Gxample) Partcode 2.32.0 2 — oso8s Rubber hose, high pressure type SAE S17, 10082 Nominal ia, 2/8" 5 Code No. | "ype ‘ Taper ip thread $ Straight pipe tread oe Sees a | ae 5) Staight pipe tread 45 degrees bent ype ze of Se Sees oro Sand SAF] 90 degrees bont ype Sera Tstofppe treads Hose length, 33.5 (85 om) ‘Straight pipe thread G (PF) with ‘male 30 degrees seat an 00 degrees bent type, cory _| Saher REPT ae =e pipe thread Straight pipe Bead G (PF) wih male 30 degrees seat Note Allthe hoses with fitings other than those Iisted above are special pats. 1 ‘4706081. GENERAL CAUTIONS FOR MAINTENANCE WORK (2) special Pans Desapton owe P20 AB OW 1 234 8 6 7 8 L__| 8 other accessories 1 art name Mo sccosanes. Blank oats ‘ 2 Hose metre! ‘+ Rubber hose: cS faire Dae 7 Hose protector ‘+ Wear-resistant high (Unit: cm) += Coll spring w pressure rubber 7 Gol tbe 7 foce 4 Eola iis * Plastic hose. P ea + Tube (Rubber) R “esses = 5 {Tube Ving oY tent r ee Teberie {| {NS ptt in 3. Recommended thread R (PT) working pressure ; PSKMpa) thread G (PF) ver 2986 (206), 1 eer vith maieso” | & He ptbs 2206) 2 Segrose sot tet bate ir 172) 3 30 degres tet st oa tan) ¢ wag sete Seb (HE 108) 8 (CA Seales e095 26068) 8 tnealg'h] powartise2a) nt arr mnie st Baw 213113) : 4 Nominal da. (ooh ve ms Without iti a/te" 03 8 Y | List of pipe threads Va oe mel Tae «For combraon of fn aie % Icorehewtonte oot — [O(PF) | Sraghipipe head He 7 pose IPT) [ Mal por nib ead sie a PT) Fora taper po vad ‘6 ‘The examplenose, B 2 08 AB O75 W_ stands for 34 5 6 7 Material: Plastic Working pressure : 2489 to 2986 PSI (17.2 10 20.6 MPa) Nominal dia, :3/8" Fitting type : Taper pipe thread R (PT) and straight pipe thread G (PF) with male 30 degrees seat Lenath : 28.5 in, (75 cm) Hose protector : Col spring 19 Aaros081. GENERAL CAUTIONS FOR MAINTENANCE WORK 5 Combination of iting FTE a FETE ae Gh Taper pipe ead RPT) | ak Gierestwn tie |» i Jegrees seat cpa Sastre Feas SERRE eres Tas Gite |g om Straight pipe thread G 48 45 degrees bent ype ' oer ° Semen. |g Dagny roa) Soonmenens |p Eas 7 eee Soeur a Sommmenens |e os onetahitnginae) | 5 ate ereerbow so , | wo Gepost doegrens stew mah — pipe thread male 30 v Berea cerns ben on tamwamnors | | EXO) ewprivenoena | w SARTO camjrom Some fosebne » | ae Te) RR Ta ‘Straight pipe thread, Asp: amnut female 30 teraesdacgeessen | «| =IQST "Spee sen x Sree ll Wages : Soest en Lag oon tpeteeciougene”| 7 Fg 8 Tier pipe tveanene | Septet - aR . aM UNE thread wth formate IWote = GEG or seowee a [Rode cntiaton teria ar ton mg, sone Jhoses require drawings or orginal hoses to localy manufacture s40 4706081. GENERAL CAUTIONS FOR MAINTENANCE WORK 4-10 Air Release of Hydraulic Equipment ‘When operating the machine after disassembly or parts replacement of the hydraulic equipment, piping, ete, be ‘sure to release air from the hydraulic system. This is necessary to prevent seizure and cavitation of the hydraulic equipment. Ifthe airis If in the hydraulic system, the iris compressed ar expanded depending on the load, having an adverse effect on the smooth operation ofthe hydraulic equipment and shortening the service Ite, 1. Air Release of Variable Displacement Piston Pumps 1) Puta Specified Quantity of Hydraulic Oil into the Hydraulic Oil Tank, Note 1. Set the machine atthe oil level check position. 2, Refer to the hydraulic ol supply procedure for how to put hydraulic onto the tank. 2) Keep the Oil Supply Cap of the Hydraulic Oi Tank Removed. 3) Install the Air Bleeder Hose onto the Bleeder Valve ‘and Loosen the Bleeder Valve Half a Turn. (Inside Diameter of the Hose : 0.20 in. [5 mm) Note : Since the top end of the bleeder valve is acting as @ seat surface, the ai is released only by loosening the Dleeder valve. 4) Check that All the Air has be Bleeder Valve. 5) Tighten the Bleeder Valve, Remove the Hose and Install the Cap on the Bleeder Valve. Released from the Bleder Yabo Bieedervake | With across fats O40 Om) Tightening Torque | 36110506 RIOT (AST BTN 2. Air Release of Each Hydraulic Component Run the engine at medium speed and activate the respective circuits for about 10 to 1 minutes. 3. Air Release of Hydraulic Cylinders 41) Set the Engine Speed at Low Idling Range. 2) Extend and Retract the Cylinder Up to 4.97 to 8.9 in. (60 to 100 mm) from Each Stroke End Slowly 4 or 5 Times, Goioroomm) DWM) Reason stoke end. == Retacton stoke end Note : Tne extension and retraction stroke is up to 1.97 in. (50 mm) from each stroke end forthe blade cylinder. 3) Then, Fully Extend and Retract the Cylinder 3 or 4 Times. a1 naro608CHAPTER 2 TECHNICAL DATA 2-1 Specieations 24 2.2 Outine Orawing and Working Area 224 22-1 Canopy ype 224 22:2 Cabin ype 222 2.3 Weight List of Main Parts 234 2-4 Ling Capacity List. 2442. TECHNICAL DATA 2. Technical Data 2-1 Specifications Note : <> : W/O Quick coupler a oe Toes Tian spose fmt Siens vera eth Tanpotaton potion) wee [207 amo) eee SOP creat ean eeeaioNES i 7037) cabin stg potion’ i 1237 2) Sah [ra macie wih in 7a are Soak ean [aneion eS i 7237 2) canopy eveng poion in) 708525) Sawn [ra macie wih in rare Taras’ dos (tera) in amt [ BOT Soy BOTY Track goige in 7 (670 ina ground dearance i er 72) Faveing prtomance Tecoaan RE Foran) [MPFR Tea rove righ speed FovaraRvese) | MP 28188) poet | Tow pve Fora Roerse)—[ WP ate oe) igh speed Forvaravese) | MPA 29166) Feist water doom 7) 797 00 Work perfomance (Sanda) “hag ae oer a Baw, uct [Standard 15 hoped capaci) Tat (can) | TOOTH OM IS ASSO aber ofa stato reo res 1 rae nope Taira |W dered ia omy [Ta 80) 78 OOP 29°2_|nlao on he wound intr) | 1916 (280) 1657 r00> axe dep overly o99%@ Taam | Tee TOO TE SOP xian duping eth any ab inn) [188 (90) T875 000% arson eng reds boom on) enone) [in (ron) | 91.9) <1 OHO tar font swing as aba inten) [70.3 (100) <0.1 (1700 ot degree boom ein) caren in) [78 (990) : WO Quick coupler ia m Wor ee haenperaner aa acs Ws OT Ree ea) | ORES finan any raion sp wansarsoa cay [segs Sang ed = = ee aa TEs ea Ta cc eT acu co ar ny aes aero in| eT ia een [esa oncom Seana [Para | RTT 7 canny ——[ Fattoay | sar ca aor er mwa eH | Pasay | —aopa7=) aT TS Ganny ——[ patteay-[ sonar aro a a ie aE cee anny at] aa a> a Tish 907 |< 80> anspy |g) | — a0 000 <0 > ao Ts isto 5 st D> See a A ec is ist 6 G55 50 BSED eaeny [sat] S88 > Bove rs i ores oe eager theoretical charge volume cuir, | toatteayes 132 188) a lotion esis) | BPR sare Sonar Taber cea as = a me rT) TB ap tt st ree 5 Fst) sia Soon aaron eis) Ssiat5 ee So ei PH) Ssst5 Sateen ara Sts Pore oer Pais) S815 242 ‘4706082. TECHNICAL DATA Note : <>: WO Quick coupler Te Tat Woes penn eontsiave Bak aT en Fara) SA Boek (tbo Pal (vP=) 2555845) cuatwattpuinse ESRaWogia ed | FEIN 555/845) Boom svg tater era) | PSP 2555(845) Bla ere Pala) (7) Blas (ota ed) Pala) Sader re mA ee oro in) TE, 2 BUTT com [itn dana in 21871650) meno ESE vee waa 4224 wn xn) tes #12542 20 re Ta 79790) ee Te 23:3(605) Jam | eno dona i 220(050) Soe Pasa reaaee tee 25 Fl stoke aur ee aa te Tem 29 50 ine a i 2295(075) uctet [Pond dana i 31951050) cece [Ensoiersore ws a0 Fal stote aed ws Za te Ta Tos re Ta i B54 (690) lose [Buono donate io 31871659) sea Sa ee a own x= Gend) tee im re Ta Hae ide a i 29.5400 Boom vn [Pen ro donee in ai 7T1685) oe (Fastener we as Ful stoke tele tee as te Tem 330005 oe, [ie a i) 3299(005) ono drei re) 21381035) Ser Suelo daar Tae aT "FT SIN 5007 To SOEDT, AD_ SIN'SOSSD and afer 24-3 A4705082. TECHNICAL DATA Note : <>: WO Quick coupler Tem Tak Voss yaraue equipment Meter Tyee Fixed displacement piston moter camirer Displacement 239,391 swing motor | (cucrten) eon awe Pe Crass relief valve Role set pressure PSIMPa} 3128 218), Type Variable dplacement piston molar Displacement (Low/igh) (quam 1.89 (9190.98 (15.5), Hravelmetor|— Type SSCS~SCSSSS*d Trance vl Brake valve | Role set pressure PSIMPa} : Planetary gear Maier (vith doubie-teduction mechanism) Fyoraute tank al tala : 163 (64) Tank capacity SAIS | tank: 10.0 (88), otners 68 26)} Tipe ereiaw Suction iter [Fivaion area sai (soem 108 (697) Fivation accuracy Meshes 750) Type Yas Fivation area sa (ea om 706 8 (2860) Rewen ter an (sger) (seh Fitton accuracy H 70 By-pass valve opening pressure PSIMPa) 213 (0147) Toeking device Lever eck Gi pressure controled [Boom swing lek Pedal guard Sing Tock chara! brake Swing eee Swing bearing Spur gear ‘Svng motor -+ Reaucton gear > Labietieaat Pinon + Intemal gar ‘Oil pressure conrad > Type or bake Mechanical brake Brake mourting positon ‘Swing motor undercarriage Shoe wih in om 138 (50) anid [Tipe “Tbe grouser eight ie 055,14) Steeltrack [Shoe and ink mounting method Bok Link ph in ESTES [Number of shoes (One sds) Pos 2 Track dive method Tak arving 24-4 A4705002. TECHNICAL DATA Note : <>: WO Quick coupler Tem oH Wows oraorarage Sicaweh nD Bae hee EI i 79825) core meta ER in ey 207755) Hamer Fpp0R Ovetang bre care rer fern 7 eae z 1 upper Tasers = Seana Sat ea Rarer hoe se s(n) ra rack rover [S¥entty (One sds) Pos z (tower [Boeing Suen fer) [Seat sing sa any One a) mS 1 jae [Beating Suan [Sealing Floating seal ararat | ee wack S a seco Ter rack ps 8 Trac einacuiret Cease ade 218 asros082. TECHNICAL DATA Note : <>: WO Quick coupler Tem Tak Wousss Main specticatons of machine Dimensions [Gveralllengih Transportation poston) in. (rom) [__ 207.4 (6260) <2028 (5160 overt nage [TORBEN ponen in. (ram) 103.1 (2020) cabin Traveling poston inom) 103-1 (2520) (Gveraliwith [Fall machine with intron) 776 (1870), overt negin | Boraon poston intra) 103.1 (2620) [canopy Traveling postion in (rom) 108-1 (2620) (Gveraliwith [Full machine with intra) 776 (1870), Tumbler conier distance (steaVrubber) ins (eam) BOT (2050yB1.5 (2070) rack gauge intra) (657 (1670) iim ground clearance intra 142 (860) Traveing perfomance [scl racy [LOW S608 ForwardReverse) [PH nih 1425) rave High speed (Forward/Reverse) | MPH kr 29148) sPeetT oortracy [LOW S664 ForwardReverse) — [MPH nih 1423) High speed (ForwaraiReverse) | MPH (kr) 2948) Permiclbe water depth lm in (rom) 18:7 (600) ‘Work performance [wath (Standard) snataing side cater inom 26 (650), Bucket _[(Standard JIS heaped capacty) Gan (cum) | 494 (0-14)[01d IS 450,019) Number affect instalation method Pes 4 Frubber pin ook ype aamam [With bade raised in. (rim) | _ 144.9 (9080) <197 8 (9500 etn [tha onthe grouna intmmy | 1616(9850) <145,7 (2700 Maxaman depth ofvertealy daae Trem) | __ 1083 (2700) <1122 (2880 Maxima dumping height (canopyeabiny in-(ram) | 188.9 (9610) 187.5 (4000) Minimum front swing ralus (with boomin Fort) (eanopyleabin) | _in.(rwm) | 01.3 (2320) B11 (2060)> Minimums rot wing radius [cabin in-trom) | __78.3 (1960) 68.1 (1730 [at 80 degrees ight boom swing) [Canopy in.(mwm) | 78.1980) <68.1 (1730)> Rear end swing rave in. (rom) 38.4075) fae Lat cegrees 70 Boom swing angle Fier Searees 2 ney La cegrees 70 Ri cegrees 70 Bucket Tes (eM) 6725 (29.8) <8480 BT Ti» Maximum aigging force ar Tes (eM) | 4631 20.6) 5202 235 246 A4705082. TECHNICAL DATA Note : <>: WO Quick coupler ia m OE haenperaner aa acs sO ae ea) Be TA OTE fisanan nin ren spe wensarsoa cay [segs Sang ed = = ee Taam Tea Ta a aT acu cor ar ny aes aero ie ey | eT ia een [aaa oncom Seana [ER Pa | ETE 7 Gaeny ——[ Patton, | ses ar ae GTO aon ——[ ratte | aap ora oa amy —[ rateea, | Sus nae a Ta ORT ROS cee canopy —— |g) 30 Ten 00> a Taf a0 TOS Eanspy |r g)| 0 oe 6 ao Tis nT D> See remy os at | Bs rim ri» ec Tiss at) Te atO> a Bove rs i ores amas ee theoretical charge volume cuiney, |toatteayes 132 188) amar lotion esicuen) | BPR sara Conca Taber canes as = a me rT) TB apm lst eae 5 Fst) sia EE eis) Ssiat5 ee oo ais) Ssst5 Sateen aH Sts Pore ee Pai Ps) S815 aaa ‘4706082. TECHNICAL DATA Note : <>: WO Quick coupler Te Tat TORI pero eontsiave Bak Te FSrwPa) SA Boek (tbo Pal(vP=) 2555845) cnatwattipeinse ESRaWegia ed | FELNPR 555/845) Boom sgt ator era) | PSP 2555(045) Bla re Pala) (7) Ble (ota ed) Pala) inde re mA ee oro a Bas 700 com [itn dana in 31871650) fmenn | ESeay vee za wn iin) tes ze re Tee Ea ie i 2331605) Jam | ron rod dana i 220(050) Soe (Pause breaaee ee 25 Fl stoke arn ee aa re Te 29 50 ine aa i 2295(075) ustet [Pond amet i 3951050) cece [Enwoiersoe we <0 Fil sote dred ws Za te Ta Tosa oo i Ba s4 (690) lose [Puonrod dona on 31871659) see SoD ee a own Goud) tee ni re Ta Hae sie a i ea 29.54 (060 Boom svn [Pen ode .() a17T1685) coe (Paso tee as Fol eoketotheiek tee as to Term 330085 osc, [ine dare (rm) 32 99(005) ion od dane i 21381035) Seo Sel Ba pe daar Ta TETAS 24-6 4705002. TECHNICAL DATA Note : <>: WO Quick coupler Tem Tak Wousss yaraue equipment Meter Tyee Fixed displacement piston mater canoe Displacement 229,391 swing motor | (cucmten) eon Garvne PP Crone relief valve Role sot pressure PSIMPa} 3128 218), Type Variabe deplacement piston molar Displacement (Low/Migh) que 1.89 (9190.98 (15.5), Hravelmetor|— Type SSCSC~SsCSSC*d Tatra vi Brake valve | Role sot pressure PSIMPa} : Planetary gear Makin (ith doubie-reduction mechanism) Fyoraute tank al tala : 163 (64) Tank capacity SASH | tank: 10.0 (88), otners 69 26)} Tipe ereiaw Suction iter [Fivation area sac (saem) 108 (697) Fitton accuracy Meshes 750) Type Yas Fivation area sa (ea om 706 8 (2860) Rewen ter an (sger) (seh Fitton accuracy H 70 By-Pass valve opening pressure PSIMPa) 213 (0147) Toeking device Lever eck Gi pressure cooled [Boom swing lek Pedal guard Suing Tock chanical brake Swing eens Swing bearing Spur gear ‘Svng motor -+ Reaucton gear > Labial Pinon + Intemal gar ‘Oil pressure conrad > Type or bake Mechanical brake Brake mourting positon ‘Swing motor undercarriage Shoe wih in om 138 (50) anid [Tipe “Tbe grouser eight ie 055,14) Steeltrack [Shoe and ink mounting method Bok Link ph in ESTES [Number of shoes (One sds) Pos 2 Track dive method Tak arving 24.9 4705082. TECHNICAL DATA Note : <>: WO Quick coupler Tem Tat TORI Troan wh nD Bae unser rsa i 398025) Gere et ph io 207755) Hamer of sip Creag pe carer mn = set aire nese z 1 oper aig ag Seng Sat ea Rarer hoe se soe) rs rack ter [venti (One side) Pos z (tower [Boeing Suen fer) [Seana sig a any One a) mS 1 ame [Bang Suan [Sealing Floating seal Tarboro |e vo S @ fag frac ck ps a Tikes seine Cease ade aso asros082. TECHNICAL DATA Note : <>: WO Quick coupler Tem Tak Voss Main specticatons of machine Dimensions [Gvera length raneporation poston) in. (rom) [_ 278.9 (6560) <216-1 (S500 overt nage [Ota ponen in. (ram) 103.1 (2820), cabin Traveling postion intra) 703-1 (2520) (Gveraliwith [Fall machine with in team) 73.3 (1800), overt nein [ABoraHon poston in. (ram) 103.1 (2620), [canopy Traveling postion in teom) 108-1 (2620) (Overaliwith [Full machine with intra) 78.3 (1880), Tumbler center dstanes (steatrubber) ins (eam) BOT (2050yB1.5 (2070) rack gauge intra) 657 (1670) inmurnground clearance intra 74:1 (860) Traveing perfomance [soltracx [LOW e604 ForwardRevese) [PH Grit 1425) rave High speed (Forward/Reverse) | MPH kr 27a) sree portracy [LOW sDe6d FervardReverse) — [MPH rit) 1423) High speed (ForwaraiReverse) | MPH kr) aria) Permisibe water depth int in (rom) 18:7 (500) ‘Work performance [wath (Standard) “nating side cater in rm 27.8700) Bucket —_[(Standard JIS heaped capacity) un (cum) | 865,0-16)[014 1S 494 0 14 Number ofteeth instalation method Pes (rubber pin lock type) aman [With bade raised in. (ram) | _ 198.7 (9980) <149.6 (3800 etn [tha onthe grouna int) | 163.8 4700) <166,7 (2900 Maxaman depth ofvertealy daae Tn) _|_ 1142 (2800) «1220 (3100 Maxima dumping height (canopyeabiny intro) [178.2 (4400) <177 2 (4500 Minimurs front swing ralus (with boomin Fort) (eanopyleabin) | _in.(rwm) | 01.3 (2320) <705 2020)> Minimums rot wing radius [cabin intro) |__77.2 (1960) <68.4(1660)> [at 80 degrees ight boom swing) [Canopy in.(ewm) | __ 7721960) Rear end swing rave in. (rom) 302 (098) fae Lat cegrees 70 Boom swing angle Fier Searees 2 ney La cegrees 70 Ri cegrees 70 Bucket Tes (eN) | __ 7607 (93.8) <0502 27> Maximum aigging force ar Ts (oN) | 5570 24.8) 5002 235 2a a4705002. TECHNICAL DATA Note : <>: WO Quick coupler Tem Tak Voss Main specticatons of machine (Work performance [Maximum tractive force (Ol pressure fore) (steetrubber) Be (eM) | Oreo a7 OVTaOHO ES) Maximum swing incination angle (wih standard bucket) cegrees 18 (at loading) [Sving speed re 10 Fuel consumplion in pradical operation Gan (UR) 78 (58) Blade wan Height nee 778 TOTO) rawertex [om PstkPa) | 992,270) ass Tpeorvex Tes. (kg)_| 11201 (6080) <17060 6020 alae [Canopy Tes. (kg) | 10848 (4820) <10776 @860> muwerten on Tes.(ka)_| 1047 (6010) <109T5 (4950 [Carepy Tes (ka) | 10604 (4850) <10562 (4790)> re Tes (kg) | 8879 (3800) SSCL [Canopy Tes (ka) | 86026 (9640) Ruwerten [oabr Tes (kg) | 8225 (3720) [Canopy Tes (ka) | __7872 (8870) <7872 3670)> Fyarauc equipment yareule pump Basinior Engine > OF Couping > Pump (Direct dnve) Variable caplacementpaton pum ype of main pure * Gear pups uriber of pumps Piston pump 2+ Gear pune 2 cuinirey | 102(16.8)%2, 1.02(168), -theeretical discharge volume jee, ae 3555 (2A5)%2, 3565 2B Maximum atowable pressure PSI(MPa) apa Conor vave Number of comneded valves Pe 7 PIP2 PSIiwPa) 3555 245) system rele set pressure P3 PS (MPa) 3555 24.5) Boom {atrod end) PSI(MPa) 3982 27.5) Boom at atom end PSI (MPa) 3082 275) circu eet set pressure E a wre) er) Air (atrod end) PSI(MPa) 3982 27.5) Air (at bottom end) Pl MPa) 3082 27.5) 22 a4705002, TECHNICAL DATA Note: <> : W Quick coupler Te Tat Wome penn eontsiave Bak aT en Fara) Ba Boek (tbo Pal (vP=) 9982 278) cuatwattpuinse ESRaWogia ed | FEIN 2982 75) Boom svg tater era) | PSP 2982 075) Bla ere Pala) (7) Blas (ota ed) Pala) Sader re mA ee oro in) TE, 2 BUTT com [itn dana in 21871650) meno ESE vee #2, 42-20 wn xn) tes #2542 32 re Tee 739790) ee i 25:35 (605) Jom | eno dona i 21871050) oe (Pashetreaaee tee zs Fl stoke aur ee aa te Tem 29 50 ine a i 2295(075) uctet [Pond dana i 31951050) cece [Ensoiersore ws a0 Fal stote aed ws Za te Ta Tosa oo i B34 (690) lose [Buono dona a 31871655) Up ound Wa) ee 70 scoed own i= Gd) tee 72 re Ta Hae ie a i 22.54 (060 Boom vn [Pen ro donee (a a 7TI685) oe (Pasooner we as Ful eoketoteieh tee as te Tem 330005 oe, [ie a i) 3290(005) ono drei re) 21381035) Ser Seve pe arto Rber Tae TRA TaS "FT SIN 50607 To BUGOD, #2” SIN'SOBDT and aor 213 A4705002. TECHNICAL DATA Note : <>: WO Quick coupler Tem Tak Voss yaraue equipment Meter Tyee Fixed displacement piston moter camirer Displacement 239,391 swing motor | (cucrten) eon awe Pe Crass relief valve Role set pressure PSIMPa} 3128 218), Type Variable dplacement piston molar Displacement (Low/igh) (quam 2.06 (33.8)/1.08 (16.9) Hravelmetor|— Type SSCS~SCSSSS*d Trance vl Brake valve | Role set pressure PSIMPa} : Planetary gear Maier (vith doubie-teduction mechanism) Fyoraute tank al tala : 163 (64) Tank capacity S28 | tank: 10.0 (88), otners 6.9 26)} Tipe ereiaw Suction iter [Fivaion area sai (soem 108 (697) Fivation accuracy Meshes 750) Type Yas Fivation area sa (ea om 706 8 (2860) Rewen ter an (sger) (seh Fitton accuracy H 70 By-pass valve opening pressure PSIMPa) 213 (0147) Toeking device Lever eck Gi pressure controled [Boom swing lek Pedal guard Sing Tock chara! brake Swing eee Swing bearing Spur gear ‘Svng motor -+ Reaucton gear > Labietieaat Pinon + Intemal gar ‘Oil pressure conrad > Type or bake Mechanical brake Brake mourting positon ‘Swing motor undercarriage Shoe wih in om 157 (400) anid [Tipe “Tbe grouser eight ie 055,14) Steeltrack [Shoe and ink mounting method Bok Link ph in ESTES [Number of shoes (One sds) Pos 2 Track dive method Tak arving 218 04705002. TECHNICAL DATA Note : <>: WO Quick coupler Tem oH Wores oraorarage Sicaweh nD 357 00 hee EI i 398,25) core meta ER in ey 207755) Hamer Fpp0R Overs bre care rer fern 7 eae z 1 upper Tasers = Seana Sat ea Rarer hoe se s(n) ra rack rover [S¥entty (One sds) Pos z (tower [Boeing Suen fer) [Seat sing sa any One a) mS 1 jae [Beating Suan [Sealing Floating seal ararat | ee wack S a seco Ter rack ps 8 Trac einacuiret Cease ade 2418 asros082. TECHNICAL DATA Note : <>: WO Quick coupler Tem Tak VWOsSaS Main specticatons of machine Dimensions [Gveralllengih Transportation poston) in. (rom) [__ 276.9 (6560) <216.1 (S500 overt nage [TORBEN ponen in. (ram) 103.1 (2820), cabin Traveling poston inom) 703-1 (2520) (Gveraliwith [Fall machine with intron) 73.3 (1800), overt negin | Boraon poston intra) 103.1 (2620), [canopy Traveling postion in (rom) 108-1 (2620) (Gveraliwith [Full machine with intra) 78.3 (1880), Tumbler conier distance (steaVrubber) ins (eam) B07 (2O5OVB1.5 (2070) rack gauge intra) (657 (1670) iim ground clearance intra 74.1860) Traveing perfomance [scl racy [LOW S608 ForwardReverse) [PH nih 1423) rave High speed (Forward/Reverse) | MPH kr a7(aa) sPeetT oortracy [LOW S664 ForwardReverse) — [MPH nih 1423) High speed (ForwaraiReverse) | MPH (kr) ar(aa) Permiclbe water depth lm in (rom) 19:7 (600) ‘Work performance [wath (Standard) snataing side cater inom 27.8700) Bucket [(Standard JIS heaped capacty) un (cum) | 865/0-16)[014 1S 494 (0-74) Number ofteeth instalation method Pes (rubber pin lock type) aamam [With bade raised in. (ram) | _ 198.7 (9980) <149.6 (3800 etn [tha on the grouna incmmy | 163.8 (4700) <166,7 (2000) axiom depih ofvertealy daane intr) _|_1142 (2800) «1220 (3100, Maxima dumping height (canopyeabiny inten) [178.2 (4400) <177 2 (4500 Minimums front swing ralus (vith boom in Fort) (eanopyleabin) | _in.(rwm) | 01.8 2820) <7085 2020)> Minimums rot wing radius [cabin in-(mm) | _ 772 (1960) <68.4(1660)> [at 80 degrees ight boom swing) [Canopy in.(ewm) | 7721960) <05.4(1060)> Rear end swing radius intron 38.2095) ae Lat cegrees 70 Boom swing angle Fier Searees 2 lL La cegrees 70 Ri cegrees 70 Bucket Tes (eN) | _ 7607 (83.8) <0500 27> Maximum cigging force ar Ts (oN) | 5570 (24.8) 5202 235 24-18 A4705002. TECHNICAL DATA Note : <>: WO Quick coupler Tem Tak VWOsSaS Main specticatons of machine (Work performance [Maximum tractive force (Ol pressure fore) (steetrubber) Be (eM) | 1oveo a7 TARO ES) Maximum swing inclination angle (wih standard bucket) cegrees 18 (at loading) [Swing speed re 10 Fuel consumplion in pradical operation Gan (UR) 728 (58) Blade wan Height nee 778 TOTO) ela [Canopy Tes.(ka)_| 10781 (4890) «11023 (6000) muwerten on Tes. (ka)_| 11965 (6000) <11990 (6170)> [Carepy Tes (ka) | 10737 (4870) <10979 (4980 re Tes (kg) _| 8422 (9820) SSCL [Canopy Tes (ka) | 8003 (9630) Ruwerten [oabr Tes (ka) | 378 9800) [Canopy Tes (ka) | 7950 (3810) <7980 3670)> Fara equipment yareule pump Basinior Engine > OF Couping > Pump (Direct dnve) Variable caplacementpaton pumps ype of main pure * Gear pups urier of pares Piston pump 2 + Gear pune 2 cuinirey | 102(16.8)%2, 1.02(168), -theeretical discharge volume jee, ue 3555 (2A5)%2, 3565 BABI, Maximum atowable pressure PSI(MPa) an paes Conor vave Number of comeded valves Pe 7 PIP2 PSIiwPa) 3555 245) system rele set pressure P3 PS (MPa) 3555 24.5) Boom {atrod end) PSI(MPa) 3982 27.5) Boom at atom end PSI (MPa) 3082 275) circu eet set pressure E a wre) er) Air (atrod end) PSI(MPa) 3982 27.5) Air (at bottom end) Pl MPa) 3082 27.5) 2a a4705082. TECHNICAL DATA Note : <>: WO Quick coupler Te Tat TOR pero eontsiave Bak Te FSrwPa) Ba Boek (tbo Pal(vP=) 9982 278) cnatwattipeinse ESRaWegia ed | FELNPR 2982 B75) Boom sgt ator era) | PSP 2982 075) Bla re Pala) (7) Ble (ota ed) Pala) inde re mA ee oro a Bas 700 com [itn dana in 31871650) fmenn | ESeay vee z8 wn iin) tes 32 re Tee B75) ie aa i 25:35 (005) Jam | ron rod dana (rm) 21871650) Soe (Paste breaaee ee 2 Fl stoke arn ee aa re Te 29 50 ine aa i 2295(075) ustet [Pond amet i 3951050) cece [Enwoiersoe we <0 Fil sote dred ws Za te Ta Tosa oo i Ba s4 (690) lose [Puonrod dona on 31871659) see SoD ee 70 own Goud) tee 72 re Ta Hae sie a i ea 29.54 (060 Boom svn [Pen ode .() a17T1685) coe (Paso tee as Fol eoketotheiek tee as to Term 330085 osc, [ine dare (rm) 32 99(005) ion od dane i 21381035) Seo Sel Ba pe daar Ta TETAS 24-18 4705002. TECHNICAL DATA Note : <>: WO Quick coupler Tem Tak VWOsSaS yaraue equipment Meter Tyee Fixed displacement piston mater canoe Displacement 229,391 swing motor | (cucmten) = Garvne PP Crone relief valve Role sot pressure PSIMPa} 3128 218), Type Variabe deplacement piston molar Displacement (Low/Migh) que 2.06 (33.8)/1.08 (16.9) Hravelmetor|— Type SSCSC~SsCSSC*d Tatra vi Brake valve | Role sot pressure PSIMPa} : Planetary gear Makin (ith doubie-reduction mechanism) Fyoraute tank al tala : 163 (64) Tank capacity SASH | tank: 10.0 (88), otners 69 26)} Tipe ereiaw Suction iter [Fivation area sac (saem) 108 (697) Fitton accuracy Meshes 750) Type Yas Fivation area sa (ea om 706 8 (2860) Rewen ter an (sger) (seh Fitton accuracy H 70 By-Pass valve opening pressure PSIMPa) 213 (0147) Toeking device Lever eck Gi pressure cooled [Boom swing lek Pedal guard Suing Tock chanical brake Swing eens Swing bearing Spur gear ‘Svng motor -+ Reaucton gear > Labial Pinon + Intemal gar ‘Oil pressure conrad > Type or bake Mechanical brake Brake mourting positon ‘Swing motor undercarriage Shoe wih in om 157 (400) anid [Tipe “Tbe grouser eight ie 055,14) Steeltrack [Shoe and ink mounting method Bok Link ph in ESTES [Number of shoes (One sds) Pos 2 Track dive method Tak arving 2-19 A4705002. TECHNICAL DATA Note : <>: WO Quick coupler Tem Tat TOR Troan wh nD 357 00 unser rsa i 098026) Gere et ph io 207755) Hamer of sip rena pe carer mn = set aire nese z 1 oper aig ag Seng Sat ea Rarer hoe se soe) rs rack ter [venti (One side) Pos z (tower [Boeing Suen fer) [Seana sig a any One a) mS 1 ame [Bang Suan [Sealing Floating seal Tarboro |e vo S @ fag frac ck ps a Tikes seine Cease ade 220 atrooe2. TECHNICAL DATA Note : <>: WO Quick coupler Te oH VOSS. VORES reine einpestestons Eran ode WEFT Veale sors waincooea Type 4 cycle diesel engine coneuran ope rect nston ero ner - ore xSroKe eR 45x 954 (60500) oi cpa aun ex. RSE) ated cpt enge speed (fewer | a5 20 a 040 eaeidalel bor Sawmera09 een eeerenghe mer (Neirpm) (139.3 to 145,1/1300) spect conurpton oat 0540285) aang eed em a nian ig bee eae wh em 9 Enger ras escsng af cere na ener Ts.) S70) bsg mates Fereatabeston beach Te spec uoreng ol onsureton TERE | oootz orien (05tt rian orpresionprestire Psiupay | ar Tea Sinder eed aablge open pbs age or SoeeYaBe eres 10% Open pane aeons Sie exaust vane jGaee —_JarD aeorees oH nate ve cance Gad ogre) inom) | 06065190 eo (05 HOA] Exhaust ae carance (C0 eae) inten) | 055 0.0098 (015 025) nike ve seat arg cree 723 Exh vae vat ng cerees © Fon Rag are aac (cone pated st corpresion ng ing ava mS z cu ng sare Tapers Go) cond coreresson ing [RBS = : Fig shape Belcan col pare JOi-ring _— ‘ penser ing assy oe Z Sonnet ame Teron aT apees FE ripe Conia! ype 2-21 A4705002. TECHNICAL DATA Note : <>: WO Quick coupler ia oar WOE WORE aad aon nde ae te Fata we a ae 510 200) tena spear Tish Feed une Tecan dap We Tact pare Teaeianp Tomar ara am aD ee Fieve sponte naa Paiva) [Tae TeseTTT Sprang ress ai pariva) [ST wESTTO TENT Soin eve ey War cea Faas) Fonbatsze Bs Terre png Tape FH Tam Theron pen erpeabre FS) 7508 Rain pss Para) 7280683) peag epee ovat area wa FO) | Ra ER A TOTO TS Tie Same alone AD rac) Fintona ten a WORMED nce up nga TT mr 205 (2) itor pp am ig im 028079) ig rer Tae Nozze hole dameter= Number of holes oo) 2.0071 (29.10)%4 strech ae Fei ay | Be Be ETO) re : Tabane pea Fara] : 2-22 A4705082. TECHNICAL DATA Note : <>: WO Quick coupler Tem Tak VOSS, VOSS Engine ‘Starting davies [Cord staring aide ‘Airheater Starting ais capacty vw 2-400 Battery type SDH Battery votage 5 hs rate capacty Van 122 Elecical equipment Te Magnet Aerator Nominal ouput va 12-40 Rated speed ‘pm 5000 aie Type ie ype: Regulation vokage v T4210 148 Type Reduction ype Starter motor Nominal outpet vw 7223 Engagement Magnet shit Step meter ui 7 Nominal output va our meter vw Be om vw 12.30 Fuse Axe BON 8X6 Battery charge alarm lamp vw 122 Montor lames Engine ol pressure alamiamp | VW 72, Water temperature alarm amp [va 722. Reaatght ew 125 Boom hah vw 1255 Room lamp (or cabin) vw 25 Wiper mote (or eabin) vw 7248 [Cabin heater fr eabin) vw 71235 External energizer socket ve 2120 24-28 A4705082. TECHNICAL DATA Note : <>: WO Quick coupler Te oH YORI VOR reine einpestestons Erpe rege TESST ‘rial pe sors waincooea Type 4 cycle diesel engine coneune ope rect nston reer ot yn -erexSrake a RT ox 954(60%00) a dapacorre aun ex. RSE) ated atten speed (tere | 3520 a 072400 eaeidalel ber seawmera00 een eeerenghe mer (Neirpm) (139.3 to 145,1/1300) spect conurpton oat 540 (245) Taxa ig eed em a narnia bee eae Bm 9 Enger ras escng af cere nd ener Ts) S70) bss mstios Ferceaiobeston beach Te Spec uoretng oi onsreton TSE | ooorz ores 054 ores) Eareressen peaire Palives) | a7 aaa Finder bod ables pen aT ages or SoeeYaBe eres 10% [Open Yoav aerees Sie exaust vane jGaee —_JarD aeorees oH nate ve caarce Gad ogre) in (on) | 6055190 co (OTS HOA] Exon ve csance (Co eae) inom) [0005516 008601510075) nike ve seat ange ores 723 Exh vae vat ng cerees © Fon Rag are Saree eons pes) rt corpresion ng Fig vor mS z ccanaconpenonny [Rove Tapers Go) Fig aor mS z Fig shape Belcan col pare a ha (win col panded) Ring aor mS Z Sonnet ame Tectonics aT apeeSFE ripe Conrial pe 24-28 A4705002. TECHNICAL DATA Note : <>: WO Quick coupler raed oon nae Taam ate Fata we a ae 310 200) tena spear Tier Feed une Tecan dap We actos pare Teasiannp Tomar Bear ae a aD ee Fieve opera nana alive) [Tider Teste TTT Sprang ress parivay [ST WEST TENT ing eee ey War cea Faas) Fonbatsze Bs erie opamp FH aim Therrien pen enpeaure FS) ras Racy press Para) 7280663) eager ow area WaT Fr) | aR ERA TETO TS Tie Cpa bee raion ea a AD ac) Fintona ite ie WORMED nist pu na TT mr 205 (2) itor pp am igh im 028079) ig rer Tae Nozze hole dameter= Number of holes om) 2.0071 (29.10)%4 strech ae Bai ay | Be Be ETO) re : Tabane pea Fara] : 24.28 4705002. TECHNICAL DATA Note : <>: WO Quick coupler Tem Tak VOus5, VOSSSE Engine ‘Starting davies [Cod sarng aide ‘Airheater Starting ais capacty vw 2-400 Battery type SDH Battery votage 5 is rate capacty Van 122 Flecical equipment Te Magnet Aternator Nominal ouput va 12-40 Rated speed ‘pm 5000 aie Type ie ype: Regulation vokage v T4210 148 Type Reduction ype Starter motor Nominal outpet vw 7223 Engagement Magnet shit Step meter ui 7 Nominal output va our meter vw az om vw 12:30 Fuse Axe BON 186 OT Battery charge alarm lamp vw 122. aa Engine ol pressure alamiamp | VW 72, Weter temperature alarm amp | VaW 722. [Glow plug pict amp vw 12. Readight vw 125 Boom hah vw 1255 Room lamp (or cab) vw 25 Wiper mote (or eabin) vw 71248 [Cabin heater for eabin) vw 12.85 Exeral energizer socket ew 2-120 24.28 4705002, TECHNICAL DATA 2-2 Outline Drawing and Working Area 224 Canopy type ttn my + g s i oo + g & & é 2 3 2 Hie | wll [Arse ate Ramones] 8 Tepe peptrpsTayoys Ries seisrasm | Sorae | Dew [Haw peer | imewo paws | maae | WH | we isto) | 330) vioss-se| (2340 <1990>) | (6260) | (6760) | (6900) | (2asoy | (2700) | (aa80) | (5950) fviosss | o1a4 | 21890 | 24409 | 25000 | 19378 | 11417 | 16009 | 25388 | 17020 | soe jwioss.s8] (2320.) | ¢sse0) | (6200) | 16350) | (4160) | (2900) | (a9e0) | 6440) | (4400) | (1520), % iwicass | vare | Terr | asso | 519 | 187 | Raeae vioas.se| (350) | (1950) | (650) | (130) | ao) _| (975) fwicsss | 1s75 | reas | arse [sa | 177 | wantr jwioss.se| (200) | (1960) | (roo) | (135) | as)_| (995)2. TECHNICAL DATA ‘Unit in. (mm) 222 A470508 . | & g3 4 “ F / at wl LL ssi dss (pi 0670, iyo ~ [8 te ‘| g 4 - 8 L 1 fps, SS A faces | wats res» | aorce | mae | maze | e157 | too | tase | aeaae | Team | Sa8 jwoas.se| (2040 <13e0) | isaeo) | (760) | (590) | (aso | (270) | (ses | teas) | caer) | cr880) foes | ore crr-r> | 210.0 | 2aa.o | 25000] 10378 | naar | see | 2506 | 17a20 | see ywoss.se| (2020 <1360) | sens | 200) | wso) | cate | case | (see | coxa) | cas00) | i820) a wuss | Tare | wer | ase | a | var | reas foss-s0) (250) | cres0) | soy | ciao | 4a) | mare) wosss [175 | 7ea5 | arse | sat} arr [Raoar fioss-se| 00) | cree0) | (roo) | tae, | t4s)_| dae)2. TECHNICAL DATA 2:3 Weight List of Main Parts Note : <>: WO Quick coupler [Unt bs. (ka) WOES Equipment No Part ‘Canopy abi See! | Rubber | Steel | Rubber track _| “face | track | ‘track Frontimpiement 7 [Bucket AY) BABES 2 [Buexet arm 8 Tak Assy 817 8) 3. [Bucket cyinder Assy 706 (32) [Am Assy 786.2 (88) 3 [Am ayinder ASS. 348 (63) & [Boom ASE) 3749 170) 7 [Boom ayinder ‘Assy | #1 O04 t), #2 TOE @ [Boom bracket ASE, 7005 (85), [Quick coupler cyinger ASE, 194188) 0 [Gui coupler ASE 7082 (46.8) indercarvage 7 [ier RY) ee 3262 9262 2 [rack guara assy eal - faa] 3 [reccaguster Tay, HATO? 7126 13° 9 10 [eyrmacoier Aeey BSB S) W/O Quick coupler toe Toa enn 7 = Seat] Fuasar | Sea Faber ao a ATL 7 faccctam a ay 178) Sacra way roa ian fay Ties) + oar fay ora 5) “em fay ST) ear oa a Tate) + ferent aa Bas) Tae Tr a TET, 2 fret gr ay ea [e8a - + ar may aaa 712.6 13° 9 10 [4 TTrack oler ‘Assy 276 (12.5) x8 Tao aa BTat 7 [fae a si) PAREN CRAs 0 [avoiiocneRamervex avy] SOS] SPs | IST TE ios fay] BST aT TOE W584 32 TH [Travel motor Assy 124.3 (55) x2 12 song ag ay TE 13 fewer ean wing — Bey e620) me [Engine hood Assy 86.2 (30) ra waa — ay 355138) Ee Sr TT Spam sa a — ay Ta) coast fay 28017 San a ay coz) Sey ay wes) ae ay ea) [Canopy (& pole) oF cabin Assy| 123160) | S072 (200) Sai on a SB Tare Sg or om S280) Pane tana — ay 3620) Sava iy aay oe Soaring oe aay Tos Een a Be 232 4705002. TECHNICAL DATA <> W/O Quick coupler [Unit bs. (kg) VOSS Equipment No Part ‘Canopy cab Slee! | Rubber | Sloat ] Rubber track _| “wack | tack | ‘wack Frontimpiement 7 [Bucket FRY) Brees) 2 [Bucket arm @ ink Assy 617 (28) 3 [Bucket eyinaer Assy 708 (32) [am Assy 2359 107) 3 [Am avinder ASS. 345 (43) @ [Boom ASE, BOLT 25) 7 [Boom eyinder Assy | #1 G04 Gt) a2 TOE) & [Boom bracket ASEy 2085 (5) 3 [Quick coupler oyinaer ASE, 794188) 0 | Gviek coupler ASEy 7082 (48 8) nderearrage Ter Tay) ween 3262 9262 2 [rack guara assy ea - [ees] - 3 [ireocaguster Asay, CRTC 7 12.6 13 9 10 Fa Frreck roller ‘Assy 276 (12.5) x8 [Sprocket ASE 2B (13) 2 © [Carer roier ASEy 221 (10) «2 T [Track fame assy 1125 10) BOD] TTD | 628.22 | ITD 8 [Steeltrack& Rubber rack Assy | -25q)2|282)-2) | (286)-2]| (262-2) 3 [Blade cyinaer Tay, 708 (32) 158432 1 ([iO[Biade ‘Assy | __ SB57 (252) <607 2 (OS «it [reaver ator ASE, 421.3155) 2 72 [Swing bearing ASE, O52 88), 73 [Swivel hose orig Assy 662 (20) Tppertroctre Engine hood TY) 2) Hysraule lank wih Wer Assy 33.8 (38) Engine 35.3 280) (Operators seat & mount ay 123.5 66) Counter weight Assy 71292 (586) Turing fame ASS, 1226 (556) Contos (4 cables) ASE. 52 (20) Bate ASS 85 (2) Fusliank & Bm ASE, 38 38) [Canopy & pow) orcabn Assy] 1323160) | _ S072 (230), Swing lock, covers tops and panels ar Swing motor Ase 33512) [Pump & mourt and hoses Ase 82 (40) [Cont vaive & fing and osee_Asey 743.3 5) Boom swing eyinder Assy 706 (92) Engine mourt Assy 7249 102) °#7 SIN 50501 to 50800, #2. SN 50801 and ater 233 A4705082. TECHNICAL DATA Note : <>: WO Quick coupler [Unt bs. (ba) WORSE Equipment No Part ‘Canopy abi See! | Rubber | Steel | Rubber track _| “face | track | ‘track Frontimpiement 7 [Bucket AY) BITS TS 2 [Buexet arm 8 Tak Assy 817 8) 3. [Bucket cyinder Assy 708 (32) [Am Assy 735 9107) 3 [Am ayinder ASS. 348 3) © [Boom ASE. 363 2705), 7 [Boom eyinder ASS, 7130152), @ [Boom bracket ASE, 200.5 85) [Quick coupler cyinger ASE, 794188) 0 [Gui coupler ASE 7082 (46.8) ndercarage 7 [ier RY) ee 3262 9262 2 | rack guare aval eal - 3 [rec aguster Tay, HATO? 7126 13) 9 10 [a frreckroler ASSY. BIS S)| eas8ieri6) | aaoe(o70H = 35400) | 378,09 ee @ ) = | eesearen | eoraoise a | one | a 3 | emo | lc © | asrsieen) | eze0or) ut i © 472,120) : k faraera san £ a | orsroin) | orse;ooos) A 8 | orsremn | orsoroao4) A © | oreo | > reas) | 12000 e 2505 | 916000 + | erase (ones | ora.21 on) 333 4706083. SERVICING STANDARDS, 3-4 Controls Tepieable east Vi0#S5, VOUS SB Vi056-5, VOSS 58 Term ‘Measuring conditions Unt [Standard Alowable iit Contos (Operating force Right contol lever» Engine - stopped Boom & Bucket) _|+ Hydraulic ol temp. 122 to 140 F (S00 60°C) ao ee Tet contoriover Lever operating force: Measure the force by Peter ranging the spring scale onthe Iver grip so9(14) | 465(21) 1) _|- Pedal operating force - Measure the force by Blade ever ‘applying load a8 shown below 44120) | 662180) tvs. to) (aan) | 48720 revel overs Spring wae (18) 20) cor ewing lever ec = = Boor swing pedal a) 1430(68) | 17.64/80) PTO. pedal 7 : = Play of control lever & pedal Right contol ever |» Engine stopped |For rear ag) |+ Hydraulic of temp. 122 ta 140°F (S0t0 60°C) area - Tot conmal eer | Pls of each conto lever and pedal enemas | Measure te toa pay (font & ear and ot & 079,20) - ‘ght atthe lover grip end a the pedal end Blade lever a 05915) c " in mm) Travel evers : 0.79(20) : Boom swing pedal \ 0.184) [ PTO. pedal » : = Conia vaive [Spool sroke Boom Bucket AB ue lar [Swing =a in.mm)| 028(70) - Blade f i Paralerfow divider e— niet Right travel Ap Basroke Len wave! (a (| 0.28(70) int) z Boom swing => lorset| : S41 4706083. SERVICING STANDARDS 3-5 Hydraulic Equipment 3-5-1 Hydraulic Cylinders 4 lax raracton eng) 2 iso) | 6-4 2 tse) 6-4. (Quick coupler cylinder) 8 “1 toe. evacton oh) Unit in_(mm Te TATE z oy Thread | Tightening TY] 27S 1 4 |S | 62] standart | atowabie time | “sze | “torque lovinaer (amy | abet a6 | 0 | 3H ears] oaT 7274 14a pemee (031)| (660) | (e4) | (22s) | caso) | 68 | 1971280) | @1.890505) | M3| ‘reG0t0 1960) 406 | 0 | 331 [oao4]o2.17 "378 to 14a [Boom #2 031] (660) | (64) |or00)| cass) | 628 | er 971250) | @r.20 (2605) | M32 | (1660 0 1960) 456 | 299 | 335 | 5:35] 01.97 | GaBT 1049to 1721 a 1188)| (760) | (@5) | (ees) | (as0)| G2 | @1-971250) | @r.99 (e505) | m9 | (44200 1520) 266 | 248 | 335 [o2os] ora Te to 839 tae 220) | (620) | (25) | (07s) | (as0)| S98 | 21.77 (48) | 1701045.) | M89 (xo20 40 1190) 3a | 218 | 205 [oasé | O177 O13 to 1085 [Poem swing | cas | (658) | (75) | 50] caasy | M4 | 187 (240) | 21.50(040.8) | ME | (137010 1470) 335 | 866 | 803 [e354] o1.97 : 1049 1121 eiace ee | BS [B55 [BS BS | Rese | 1.7245) or79 1025.5) woo | i089 1, 740 | 338 | 181 [e256] 01.36 (Bi 38 (85) | OT WO RSE 2i7 10253 [ouiekcoupter | cigs | tee) | ca6) | iaes)| ais) | OM | oi's7 @4o)| 591905) | M2? | sete 343) Tutor pipe Symbol Tame GBSPP) _|Siaight pe tivead TR (GSPT) | Taper pipe tread (male) Re (BSPT) | Teper pipe thread (female) Vi045-5, W045 5B 1: SIN 50501 to 50591, 42 : SN 50592 and ater \Vi0S5.5, VOSS 5B 41 SIN 050% to 50800, #2 S/N 50801 and ater as1 Aso0083. SERVICING STANDARDS, 3-6 Implement 3-6-1 Front Attachments Unto (on) Tt ‘Applicable model: Vose-e vrore en, dah ‘Wear limit ‘Measuring pent Pin Dare af bush or hale 7 [Beem swing teram a76 (aro) [Boom tera 122.36 (260), 3___ [Boom swing oyiader od 2157 (80) [Boom swing evinder Batom 21.87 (80) 5__ [Boom evinder, bottom 21.97 80) [Boom ovine, roa 21.97 (250), 7 [Arm tec 122.36 (260) @_|Armevinder botom 31.57 (250) 002 (05) +0102 (+05) 8 [Am oyinder roa 21.87 (250) TO [Bucket eyinder baton 177 45) Tt [Bucket eyindor, rod 21.77 (245) 72 [unk"A am 177 (285), a [Bucket fleur ai.77 (288), Ta [Bucket ink 1.77 (45) 15 [Ouick coupler eyinder baters Eo) 16 [euiek coupler evinder. roa 21.38 (285), ‘ote : Allowabje clearance Is 0.04 in (1.0mm). 361 4706083. SERVICING STANDARDS, 3-6-2 Blade Moving Device Unit: in (re Voss OSES wo, | Aerablemadel: ORES Vices Se | standard Wear lint ‘Measuring pont Pin Bore of buch orale 1 __ [Blade eyindor, roa 177 285) Blade cylinder, bation 21.77 (45) | -002(-05) +0102 (+05) Blade tuerum 21.77 (45) ‘Note : Allowable cearance between pin and bore of bush or hole is 0.04. (1.0 mm). 3-6-3 Bucket Teeth Unit in (nm Measuing pont ‘Slander Wear imi Measure 0.17 2330) 705 (178.0) Replace 362 ‘4706083. SERVICING STANDARDS, 3-7 List of Tightening Torque 3-7-1 Machine Unt feof Nem) Vaiss WORE ‘Applicable model: yor avons. Eewert ead size ightening torque ese a = Thvead 3 Tightening tora an Engine / Electrical equipment Fss0t 700 Bacaould 1 Enaie mount vibrasoiating rubber ms es ‘Three Bond 1324 a70t0 43 2 [Engine » Engine mount Fiynee! sie) ‘m0 (10.07) anos ‘Three Bond 1324 a0 S43 3 [Engine = Engine mount (Radiator side) m0 (10.87) iaaraseaeh ‘Three Bond 1924 4 [hose cp 70 (ir cleaner intake sie) on Hose cp 70 (Ar cleaner intake side) Goets) 220028 5 [Hose tip 70 intake hose instalation) - Geese Taw 25 6 |Hose clio (Resonator - seas) OT it 7 [vet gauge nove Hose bang 14 nie ‘O9to11 8 [Fuet gauge unit Pan head serew MS ngeiy Bebo aS © [Fost tank mia nana ‘Three Bond 1224 ri Tocknat 10 | Battery noiaing roa Nome _ oto 123 tbr (12710 167 Nem) qew2s 11 [ownose ipa, 48 - ees Taw 166 12 [Ar ceaner Me aoe ea TewIe 13 [Hester hose Hose clip 22 ae 430 14 [orain pos ma any Tires 15 | Satety switc (2-speed, cut-om Locknutmra (Fine) | 35.4t094.3) Diane system Tara Ie 1 [sorocket ia iaeacaneal Loctite 262, [Travel aevies Ssw72 1 |Ptugs (ier REPT) 18 eeceay Loctite 572 S79t 723 2 |lder coal cover» Track spring mia aswel ‘Three Bond 1924 {519% 1608 8 [Track ter tghtening not cap nutins ospoaal Loctte 262 Mack guard Track Fame 230% 1518 4 [steel tack spec. only) ae (106.7 to 208.9) Loctite 262 362 5 [Track tensioner valve mie a 371 A4r06083. SERVICING STANDARDS, nt Nem) Area ose Votes ose PS | Teron at] ‘Thwead size Tightening torque Adnesive: com 1 [Bae wer ” + Disassembly procedure 1 Follow steps 1 to 15 ofthe cylinder head disassembly procedure. 2 Remove the cooling water pump. '3 Remove the crankshaf pulley. (Point 1)-»Operation point to be explained on a later page. + Operation points Disassemble : Service point fr removal Reassemble : Service point for instalation Disassemble-Reassemble : Service point requied in both removal and instalation 41 a4705004. ENGINE + Contents omitted in this manual ‘Though the following jobs are omitted in the explanation in this manual, they should be conducted in actual work (1) Jacking up and titing (@) Cleaning and washing of removed parts as required @) Visual inspection 3) Definition of Terms [Notice : Instruction which negligence is very likely to cause an accident. Abvays 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 76. ‘Top dead conor ‘Sub-Aes'y ‘Subassembly Eo Bottom dead center atoe. ‘Afr top dead center os Oversize pIOG Betore top deadcenter | US Undereze 310, ‘Sandard RPM Revoltons per minute WN Tota HP (ew) Oupat 3 Exhaust T Bolunut tightening wraue 412 A4705004. ENGINE 4-1-2 Precautions for Service Work 1) Precautions for Safety Read the safety precautions given at he 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. (1) Preceding service date (@) Period/aperation hours afer preceding service (@) Problems and actions in preceding service @) Replacement parts expected to be required for service ©) Recording formicheck sheet required for service 3) Preparation before Disassembly (1) Prepare general tools, special service tools, measuring instruments, ol, grease, non-reusable parts, and parts expected to be required for replacement. (2) When disassembling complicated portions, put matchmarks and other marks at places not adversely affecting the function for easy reassembly. 4) Precautions in Disassembly (1) Each time a pars is removed, check the part installed state, deformation, damage, roughening, surface defect ete (@) 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 especialy clean locations and use clean tools for disassembly of hydraulic units such as the fuel injection pump. '5) Precautions for Inspection and Measurement (1) Inspect and measure pars to be used again as required to determine whether they are reusable or not. 6) Precautions for Reassembly (1) Reassemble correct parts in correct order according to the specified standards (tightening torques, and adjust- ‘ment standards). Apply ol to important bolts and nuts before tightening when specified @ Aways use genuine pars for replacement © Always use new oil seals, O-rings, packings and cotter pins. @ Apply sealant to packings depending on the place where they are used. Apply oll or grease to sliding contact Portions, and apply grease to ol seal lips 7) Precautions for Adjustment and Check (1) Use measuring instruments for adjustment tothe specified service standards, 41.3 A4705004. ENGINE 41-3 Engine Extemal Views: Rocker aim cover ‘Starter motor Note : This istration does not show the 4TNV88 engine. 441-4 Structural Description Toe Reduction Eniesion Revlon New Lib, 1 Pump Tijection Nozae + Change Rotor Shape for Low Pulsation] | Low Suck Volume + Driven by Crankshaft Dredly ca I Forp | int injection Hotes Erion Reset BIT aL! ersten Tiron - Gran Ne ee ‘Optimal Swit Ratio Optimal Vaive Timing ‘Speed Timer, oad Timer, (Cold Star nse Enission Reduction Nise Redvston Higher Suttness Cynder Blodk Chamber Noise Reduction Higher Sutiness Gear-Case 414 A4705004. ENGINE 41-5 Exhaust Gas Emission Regulation “The engines inthis manual have been certified by the US EPA, Calfornia ARB andlor the 87I68/EC Directive. Califor Proposition 66 Warning Diesel engine exhaust and some of its constitutions are known to the Slate of California to cause cancer, bith defects, and other reproductive harm, california Proposition 66 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. 4) The Emission Standard in USA (1) EPA Nonroad Diesel Engine Emission Standards wkWehr (gtbhpeh) Ene Power [er] Waser [NO [RE [WRETT —GO | P tes Tert [200 = 05a | soem | 10TH m= Tere | 208 [7565 | 8060 [0e0050) Trt | ~2a00—f = [esa] 6849 [ee0050) Tere | 008 J [7560] 649 [000000 19<= KW < 37 Tier 1 1999 = * 95(7.1) 5.5(4.1) | 0.80 (0.60) (25 <= hp < 50) Tier 2 2004 = = 75 (5.6) 5.5(41) | 0.60 (0.45) Ter [1868 | ez6H | : : : frecuwers Pera [300 [= [7565 [569 To oxy Tors | 2008 paras | 8007 tert | tar] ey | : : : sks 190, ere | aa [851567 com Tier 3 (2007 = a 4.0 (3.0) 5.0 (3.7) Notes : + The EPA emission regulation under 130 kWis mentioned below. + As for Model year, the year which a regulation is applicable to is shown. Engine classinication ‘Transient smoke Standards 9s opaaly (accelerationugipeak modes) [Constant speed engine Not regulated Variable speed engine OSTEO orfess (2) Califomia ARB Emission Regulation ‘The ARB emission standard is based on that of the EPA. 41.5 A4705004. ENGINE 2) Engine Identification (1) Emission contro labels of US EPA IMPORTANT ENGNE INFORMATION IMPORTANT ENGINE NFORMATION A label for constant speed engines {@) Emission contro abel for both EPA and ARB. (PORTANT ENGINE INFORMATION) ‘© YANMAR CO.,LTD. @ 87188EC Directive label IMPORTANT ENGNE FORMATION 418 EPA label for variable speed engines ‘4706084. ENGINE 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. (4) Requirement on engine installation condition {@)intake air depression kPa (mag) Taital Permissible = 254 G00) 23635) (Exhaust gas back pressure kPa (mmaq) Engine WP Trial Penvissibne Naturally aspirated engines 12.75 (1900) 5.90 (1560) (@) Fuol oil and lubricating ot (@)Fuel: The diesel fuel oll US No.2 diesel velo @yLube ol: API grade, class CD or CF @) Do not remove the seals restricting injection quantity and engine speed. ala can Vd, 2 eke 6, Plate Injection quant srcbe" Tamper i festSance Assy “Tamper resistance device forengines ceried by ARBIEPA vasher 417 a4705004. ENGINE @) Perform maintenance without fal Note : Inspections o be cared out by the user and by the maker are dlvided and set down inthe List of Perioaic Inspec tions" and should be checked caret. (6) Maintenance period and Quality quarantee period for exhaust emission related parts ‘The maintenance ofthe parts related to the exhaust emission must be caried out in the maintenance period as shown inthe below table, ‘A guarantee period is that either the operation hours or years shown inthe table come frst in the condition thatthe maintenance inspection was carried out based on the “List of Periodic Inspections” ‘Maintenance period Gualty Guarantee Period Pars|-Fuel nozzle cleaning [Adjustment cleaning, repairs [For nozzle, fuel pump, for fuel nozzie, fuel pump, {turbocharger turbocharger, electronic Power Rating [control unit et. S7 <= KW=130 [Every 1800 hours [Every 3000 hours 3000 hours /5 years (applied from Tier 2) |epplied from Tier 2) fie KW= 37 [Every 1800 hours [Every 8000 hours 3000 hours /5 years Jexcept constant speed engines >= '3000 min" Kw <9 Every 1500 hours [Every 3000 hours "1500 hours /2 years JAnd constant speed Jengines beyond 3000 min"! under 37 kW 41.8 A4705004, ENGINE 4.2 Troubleshooting 4-2-4 Quick Reference Table for Troubleshooting “The folowing table summarizes the general rouble symptoms and their causes. If ant trouble symptom occurs, take corrective action before it develops into serious problem so as not to shorten the engine service life, sreubie sympom| [Enema ars | Exhoustexor | Ounee | £ 3 pace oon can’ | & i aust smote f| le 5/8]. : z elas sleleteselilel2| jel. g BlelElel Arceaner * Gogged element ~ Clean the element + Broken element + Replace the element + Detect at element seal portion 2 |= Vane clearance > Excessive or no learance Adjust he valve dearance 3_[ valve timing correct valve clearance + Aajust the vale Gearance |» Cylinder head gasket ~ Gas leak from gasket ~ Replace the gasket + Retighten the oyinder head bots to the specied torque, 5 |= intakelexhaust valve ~ Gas leak due to worn vale seat or |= Lap te vale seat + Valve seat foreign matter rapping + Replace the intakelexnaust valve + Sticking vane [> Paton ~ Gas leak due ta seralehing or wear |» Perform honing and use an over = Piston cng sized part + oyinger 425 4705004. ENGINE 4-3 Inspection and Adjustment 4-3-4 Oil Inspection + Standard ‘The level shal be between the upper and lower limit ines on the dipstick Vous VOESS Total volume viows58 wioss-68 oa Gi (@9L) (4) The oll shall not be contaminated heavily and have appropriate viscosiy. No cooling water or diesel gas oil shall be mixed, (2) Insert the dipstick fully and check the oil level 4.3.2 Cooling Water Inspection + Standard Engine : The radiator shall be filed up. ‘Sub-tank : The water level shall be between the upper ‘and lowe limit ines. Engine 6am (630) Capacity Coolant senor | 042 Gis (OAL) (The cooling water shall be checked when the engine 's cold (@) Ifthe water level is normal in the sub-tank but low in the radiator, check loosened clamping of the rubber hose between the radiator and coolant reservoir or tear in the hose, Notice The oil should not be overflled to exceed the upper lit tne Otherwise, of! may jet out from the breather or the engine may become faulty. 7a, ||P — cont reserir NS H7 4 rs G 4.3.3 Inspecting Water Leak from Cooling Water System and Radiator 41) Water Leak Check in Cooling Water System (1) Fill coating water to the normal level In the radiator, ‘and install the cap tester on the radiator. (2) Operate the manual purnp to set the pressure to 10.7 {0 14.9 PSI (736 to 103.0 kPa). Ifthe cap tester pressure gage reading drops then, water is leaking from the cooling water system. Check the water leaking point 434 iter leak ceckincocing water aystem ‘4706084. ENGINE 2) Radiator Cap Inspection Install the radiator cap on the cap tester. Set the tester pressure to 10.7 to 14.9 PSI (73.6 to 103.0 KPa) and see thatthe cap is opened. Iv the cap does not open, replace the cap since itis abnor mal esata cop Radiator cap inspection 4-3-4 Fan Belt Tension Inspection and Adjustment Standard : 0.99 t0 0.59 in. (10 0 15 mmy/ 72.3 Ib. (88 N) 72500 (991) q aan Ph na cx of Vat sre ar & emetien ey eared ge eee acct rerate the deflection is 0,39 to 0.59 in. (10 to 15 mm). If not, T" ‘Alterator Sater eon esr ae aE a bet teason ‘Adjust ine bot tron byineting aa, 432 4705004. ENGINE 4-3-5 Adjusting the Valve Clearance ‘Standard : 0.006 to 0.01 in. (0.15 to 0.25 mm) Make measurement and adjustment while the engine is cod (@)Valve clearance measurement Not einer [1] Remove the rocker arm cover above cylinder head, [2] Set the No. cylinder in the compression TOC ‘Tum the crankshaft to bring the piston of the No.1 cylinder to its compression top dead center while watching the rocker arm motion, timing scale and the top mark position of the crankshat pulley Position where both the intake and exhaust valves are closed.) Wa! Flatonal direction + The crankshaft shall be fumed clockwise as seen from the Top mark radiator sido + The No.1 cylinder postion is onthe opposite side ofthe raa- {or and the ignition order shal be 1-3-4-2-1 at 160° intervals + Since the intake and exhaust valve rocker arms are operated the same and there sa clearance between the am and valve ‘generally atthe top dead contr, the poston can be checked bby means ofthe play when the arm head i held witha hand. Also see thatthe crankshef pulley top mark is postoned at 2210 0n the timing scale. If there is no valve clearance Inspection in the disassembled state is necessary sine the valve seat may be worn abnormally [3] Valve clearance measurement Rocker arm Insert a thickness gage between the rocker arm and the YEN. valve cap, and record the measured valve clearance. (Use it as the data for estimating the wear state.) gusting ther cylinders Turn the crankshatt 180° and make adjustment for he No.3 cylinder. Then adust the No.« and No2 oylinders in tis : order. The cylinder to be adjusted fist does not have to be the No. cylinder, Select and adjust the cylinder where the ps- tom isthe nearest tothe top dead center ater turing, and make adjustment fr other cylinder inthe order of igation by turing the crankshaft 180" each tine esting see ia 433° A4705084, ENGINE “The adjustment method of reducing the flywheel turning numbers (for reference): ‘Set No.1 cylinder to the compression TD.C. and adjust the clearance of the @ mark ofthe below table, Next tum the flywheel once, and adjust the clearance of the © mark. Ignition order of 3 cylinder engines: 1-93-r4-»2 Lmpesion| @ | @ | o . ine et orpresson o | o © | oF [pts feta se {tos dosing es Loakaut Assy bat 424 A4700084. ENGINE [2] Measuring valve clearance Insert a 0.008 or 0.012 in. (0.2 or 0.3 mm) thickness ‘gage between the racker arm and valve cap and adjust the valve clearance. Tighten the adjusting screw. ‘Standard valve clearance 0.006 to 0.01 in, (0.15 to 0.25 mm) a Apply illo the contact surface between adjusting serew and push rod ‘Adjusting other cylinders Turn the crankshaft 180° then and make adjustment for the No cylinder, Then adjust the No.4 and No.2 cylin- ‘ders inthis order. ‘The oylinder to be agjusted frst does not have to be the NNo.t cylinder. Select and adjust the cylinder where the piston isthe nearest to the top dead center ater turning, ‘and make adjustment for other eylinders in the order of ignition by tuming the crankshaft 180° each time a 4.36 Inspecting the Fuel Injection Valve Injection Pressure and Spray Pattern Wear protective glasses when testing injection from the fuel injection valve. Never approach the injection nozzle portion with a hand. The oil jetting out from the nozzle is at a high pressure to cause loss of, ‘sight or injury if coming into careless contact with it 41) Injection Pressure Measurement ‘Standard : 2850 to 2950 PSI (19.6 to 20.6 MPa) “Remove carbon deposit at the nozzle hole thoroughly before 435 4705004. ENGINE [1] Connect the fuel injection valve tothe high pressure pipe ofthe nozzle tester. [2] Operate the nozzle tester lever slowly and read the pressure at the moment when the fuel injection from the nozzle stats, [3] If te measured injection pressure is lower than the standard level, replace the pressure adjusting shim with a thicker one, wat none tsar “Type of pressure adjusting shim thickness in (mA) Tnjcton pressure aghstment ‘0.0064 (013) 0:0059 (0.15) ‘0.0071 (018) 0.0187 (0.4) 0.0187 (05) 0.0318 (08) The injacton pressure is increased by approx 270 PSI (1863, KPa) when he adusting shim thickness increased by 1.0039 in (0.1 mm) [Reference : Fuel injection valve structure] E ue {ret ppo jen. Sy Nozze sing seat 2} — Valve stop spacer 438 “Tpenng ters: Nim (do 4skgby ‘4706084. ENGINE 2) Spray Pattern Inspection ‘After adjustment to the specified valve opening pressure, use a nozzle tester and check the spray pattem and seat oittightness. (1) Seat ol-tighiness check + Aller injecting a few times, increase the pressure gradu- ally. Hold the pressure for about § seconds at a litle before the valve opening pressure of 284 PS! (1961 KPa), and check to see that oll does not crip from the tip fend of the nozzle + If extreme oll leak from the overtlow joint exists during injection by the nozzle tester, check after retightening. much olf leaking, replace the nozzle assembly. (2) Spray and injection states + Operate the nozzle tester lever ata rate of once or twice ‘a second and check no abnormal injection, normal injection as shown below cannot be obtained, replace the fuel injection valve. “No extreme dtference in angle () No extreme injection angle diference (x) “Finely atomized spray “Excellent spray departure 437 A470508 Unto spay patem tom each nla Extreme dtarence in angle (2) Extreme iterent nection ange (2) Nonsaterzed spay Stognnt say4. ENGINE 3) Nozzle Valve Sliding Test ‘Wash the nozzle valve in clean fuel oll. Place the nozzle body vertically and insert the nozzle into the body to about 118 of ts length. The valve Is normal iit smoothly fais by iis own weight Into the body. In case of a new nozzle, remove the seal peel, and immerse it in clean diesel ol or the lke to clean the inner and outer surfaces and to thor- ‘oughly remove rust-preventive ol before using the nozzle, Note that a new nozzle is coated with rust-preventive oil and is pasted with the seal peel to shut off outer at. 4) Nozzle Punch Mark Nz valve sing check by gray A150 2 2% 4 Jo lanai noe oes" | —rjecon angle Nae meen ane ‘odes angles 438° A4705004. ENGINE 4.3.7 Fuel Injection Timing Adjustment / Fuel Injection Pump Inspection and Adjustment ‘The fuel injection timing and the fuel injection pump are adjusted so that engine performance may become the best condition. As forthe inspection and adjustment ofthe fuel pump, itis based on the service manual of the MP pump ofthe separate volume. The fue injection ting is adjusted by the following procedure. {As forthe engine, which adopts a MP type fuel injection pump, tne uel injecton angle rae) adusted forte ueinecton | Fumeonande | ac timing adjustment, because the adjusting method of fuel ee injection timing Ike an nine ful pump cant be apt. Note carvan, P The fe nection angle (cam ange) ithe erence fom the Vale opening ane injection valve opening angle while the fuel injection pump being See ee driven by @ motor and the angle at the plunger lift 0.098 in. (2.5 ae ‘mm) ofthe fuel pump. And, a8 forthe actual fuel injection angle 4, the measured value ‘is recorded on the pump body by each every fuel pump. Fuel njocton pump ‘The adjustment of fuel injection angle 0, In case that a fuel pump cover, installed with a gear case cover and the fuel pump are removed, and reassembled, the procedure of fel injection angle adjustment is as follows. Notice Never loosen four flange bolts, which fasten a pump Mange and 4 fuel pump drive gear at the time of the removal of the fue! ‘pump. Wen itis loosened, the adjustment ofthe fuel injection timing becomes very difficult Fuel pump ‘tng gear Fuel pump installation angle 439 4705004. ENGINE [1] Before removing a fuel pump drive gear, make ID marks on the gearing part of the pump drive gear and the ile gear Fuel panp site ) Gear case ste with paint and so on, Markcottine | Gngesr case foal pun [2] Make the mark-off line to the gear case precisely in accor- ‘dance withthe postion of mark-of line ofthe fuel pump, Yaarking [3] Boore removing @ fuel pump, put the standard mark of a sticker for fue injection angle adjustment in accordance wath the mark-off ine ofthe fuel pump and paste it on the gear Marking on gear case re Stangard marke los ‘Sticker for adjusting injection angle Mark sticker Fal iecion pans 72h Markoff ing 22" S982 [4] Remove a fuel pump, and read the fuel injection angle recorded in that fuel pump [5] Read the injection angle recorded on a reassembled fuel pump and calculate the difference from the injection angle ofthe disassembled fuel pump. (When reinstallation does the same fuel pump, the angular diference is zero) Fuel injection angle difference (cam angle) = (the fuel injection angle ofa reassembled fuel purnp) + (the fuel injection angle ofa disassembled previous fuel pump) Notice : Tell the fuel pump number to Yanmar, and inuire the infection angle ofthe pump when itis hard fo find out [6] Put the fuet pump on the gear case temporarily and instal the drive gear onthe cam shaft with checking the ID ‘marks, which were put on the fuel pump drive gear and the idle gear atthe time of the disassembling, “Tighten the installation nut of @ pump drive gear. Tightening torque: elf (Nem) Lubricating ol appication {thread portion, and seat surface) 58 t0 65 (7810 88) Not applied 43.10 4705004. ENGINE [7] Adjust the injection angle diiference, calculated in the above §), at 0.25° in the unit in the installation angle of the fuel pump while reading the mark (minimum 0.5° and cam angle) ofthe adjustment sticker. Notice : Push down the fuel pump in he outside direction ofthe cylin- dor block at +1 degree when a injection angle difference is +1 degree. And, push it down to the cylinder block side when a ference is ~1 degree. [B] Tighten the fue! pump instalation nuts. (Supplementary explanation 1) ‘The installation angle ofthe fuel pump is as follows. Tnslallation angle Model ea) lamnves es (Supplementary explanation 2) ‘When fuel injection timing is advanced or delayed, the instalia- tion angle ofthe fuel pump is adjusted ‘When fuel injection timing is advanced for example at 2 degrees, loosen the nuts, which fh the fuel pump on the gear case, and tur the fuel pump body in the outside direction of the cylinder block at 1 degree, and tighten the pump installation nuts ‘And, when fuel injection timing is delayed, a pump is turned in ‘that reverse direction aan Markoff ing on fuel pump Incaseel 1° Incase of +0.25° Injection angle adjustment Purp instalation bolts Injection timing adjustment ‘4706084. ENGINE 4.3.8 Sensor Inspection 41) Thermostat and Thermal Switch Inspection (1) Thermostat Place the thermostat ina container filed with water. Heat it while measuring the water temperature, and see that the thermostat is actuated at 157.1 to 162.5 °F (69.5 to 725°0) Thermometer 2) Thermo switen Place the thermo switch in a container filed with anti ‘reeze or oil, Heat it while measuring the fluid temperature. The switch is normal if the voltammeter shows continuity when the fuid temperature Is 224.6 to 235.4°F (107 10 113°¢) 2) Ol Pressure Switch Disconnect the connector fom the oil pressure switch, Keep the vollammeter probes in contact with the switch terminal and cylinder block while operating the engine, It Is abnormal if circultis closed yn ook (Piet ise) Tecan obes conti est 43.12 A4705004. ENGINE 4-3-9 Battery Inspection 41) Battery Structure Terma sate ee Jp seee mt Ande 2) Battery Inspection (1) Electrolyte level ‘Add distilled water to the upper limit the levels low. 2) Battery charge Use a battery tester or hydrometer and check the battery condition. If the battery is discharged, recharge it + Measurement with a battery tester ‘When checking the battery with the batter tester, con- nec the red clip ofthe tester to the battery postive (+) terminal and black clip tothe battery negative (-) terminal by pinching them securely, and judge the battery ‘charge level from the indicator postion. ‘Green zone : Normal Yellow zone : Slightly discharged Red zone : Defective of much discharged Baty charge measurement vim baer eter 43.13 4705004. ENGINE + Measurement with hydrometer ‘When using a hydrometer, the measured specific gravity must be corrected according to the temperature at the time of measurement. The specific gravity of battery ‘electrolyte is defined with 68°F (20°C) as the standard Since the specific graviy increases or decreases by 0.0007 when the temperature varies by 93.6°F (1°C), correct the value according to the equation below. Seo = St-+ 0.007 (20) Lecrye eee Sater charge mensions, spect ony t measareert Baten nage Converted specie ravty at 68°F (20°C) usber bu. Tecowvet | ine | Wally by tase tuse Temperature [— S “C= 58 © . (P= 22) ‘Specific gravity and remaining battery charge Secife Discharged Remaining Hydiometersucice gravy ‘want of charge 'F (20°C) | _electcty (%) (6) 1260 ° 100 1210 2 75 160 o 50 730 76 25 060 100 o © Terminals Clean if corroded or soled (@) Mounting bracket Repair or replace itif corroded. Retighten if loosened, (©) Battery appearance Replace the battery if cracked or deformed Clean with fresh water if contaminated How trea hytometer 43.16 A4705004. ENGINE 4.3.10 Adjusting Operation Perform adjusting operation as follows after the maintenance jo: (1) Supply the fuel |, lubricating oll and cooling water. Note Check the levels ofthe lubricating ol! and cooling water again after test running (for about § minutes) and add #5 roquited. (@) Saat the engine, and carry out idling ata low revolution (700 to 800 RPM) fora few minutes, {@) Run in the engine for about five minutes at the rated revolution (no-load). Check any water, fuel or oll leak and existence of abnormal vibration or noise, Also check the oll pressure, cooling water temperature and exaust ‘928 color (4) Adjust the no-load minimum and maximum revolutions according to the specifications, (©) Perform loaded operation as required. 43.18 4705004. ENGINE 4.3-11 Long Storage Observe the following instructions when the engine isto be stored for a long period without operation: (1) Always drain cooling water in a cold season or before 2 long storage. (This is unnecessary when antifreeze isusea) Notice : [Negligence of water draining will cause the cooling water remaining ins the engine fo be frozen and expandod to damage the engine parts. Water draining procedure [1] Remove the radiator cap, [2] Loosen the water draining cock under the radiator to drain water from the inside. [9] Loosen the drain cock on the side surface ofthe oyinder to drain water from the inside. [4] After draining water, tighten the radiator cap and drain plug and cocks. (@) Remove the mud, dust and oll deposit and clean the outside. (@) Perform the nearest periodic inspection before the storage. (4) Drain or fl the fuel ol fully to prevent condensation inthe fuel tank (6) Disconnect the battery cable from the battery negative (-) terminal © Cover the silencer, air cleaner and electric parts with PVC cover to prevent water and dust from depositing or entrance () Select a well-ventilated locaton without moisture and dust for storage. @) Perform recharging once a month during storage to compensate for self-discharge. 43.16 44705004. ENGINE 4.312 Periodic Maintenance Schedule ‘The engine periodic inspection timing is hard to determine as it varies with the application, load status, qualities of the fuel and lubricating ots used and handling status. General rules are described here, (©: Inspection © : Parts replacement Taran poea Cision tem oaiy [Env ] Ben | Brey | Boy | Sey 3” | S50" | Sse’ | Soos | Sot news | teu | tere | pou | hoe Talonienlaekaaideumy | Foslion ana 3 rue fuscia ag OT Dey otowe tar spartan (Oren 3 oa cle epcoret 3 Cae lint heck 3 Lube oil il replacemer Latest [Te arapacornt ~ 1.2. Lube oil fiter replacement Sst imme | ine afr cing rival ca ropenan | air leaing 3 cooing water | Ong Ve ers Te 3 Steam [sca water eponent 3 coin wath fishing rd mao 2 oe an ing wares CER 3 rneroue_| Fes 019 Weep PEIN os and maintenance c Ti deane can an ret aoe Air intake ment % ° ° coum Tiocae Dove dara : Warr iap 8 tirnt nan ack [ 0 Besa Shine" [eatey saan etcneckand ate] —o reowrons Syma mas | none eater ae 7 Fuargeatan | Fel aon va prose Rapes 3 ove gare [rutting rpecton 3 43.17 A4705004. ENGINE 4-4 Engine Body 4-44 Introduction Make preparation as follows before starting engine inspection and service (1) Focthe engine on a horizontal base. Be sure to fix the engine securely to prevent injury or damage to parts due to falling during the work. {@) Remove the cooling water hose, fue ol pipe, wire harness, control wires ete. connecting the driven machine and engine, and drain cooling water, lubricating ol and fuel {@ Clean sol, o, dust, ete, fom the engine by washing with solvent, air, steam, ete. Carefully operate so as not to let any foreign mater ener the engine Oe ‘Always wear glasses or other protectors when using compressed air or steam to prevent any foreign ‘matter from getting in the eyes. Notice : + Any part which is found defective as a result of inspection or any part whose measured value does not satisty the standard or mit shal be replaced. + Any part predicted to dissatisty the standard or limit before the next service as estimated from the state of use should be replaced even when the measured valve then satisfies the standard or limit 441 4705004. ENGINE 4-42 Cylinder Head 41) Components 9 Exhaust maniols ee Fuel iter A Oitcodter °@ ot © Some 6, Boi titer 2) Disassembly Procedure Disassemble in the order of the numbers shown in the illustration, ¥ Remove the alternator ass', (Point 1) z ay Remove the fan pulley and V bel Rosi arm sport 8 Remove the thermostat case. (Point 2) \ Rocker arm A a, Remove the fuel fiter and fuel ol piping. (Point 3) : RG ‘ 2 3 ‘ 5 Remove the o evel gage ass ! $ 7 3 Remove the oil fiter, Point 4) RM Remove the fuel injection pipes. (Point §) Remove the intake manifold ass'y 9 Remove the exhaust manifold ass. 10 Remove the rocker arm cover ass'y. (Point 6) ‘11 Remove the rocker shaft ass'y, push rods and valve caps. (Point 7) 12 Remove the cylinder head ass'y and head gasket. (Point 8) 13 Remove the fuel injection valves and fuel retun pipe. (Point 9) 114 Remove the intake/exhaust valves, stem seals and valve springs. (Point 10) 45 Remove the rocker ams from the rocker shaft t cxhan vné“ scene 442 4705004. ENGINE 3) Reassembly Procedure : Reverse order of he disassembly procedure, 723.1991) 4) Servicing Points Point 1 / Disassemble } aves + Loosen the mounting bot while supporting the alternator PSTN ian Do not tit the alternator toward the cylinder block | Crrisht ny in a haste since it may damage the alternator or asa pinch a finger Auto vibe enon Reassemble + The belt deflection shall be 0.39 0 0.88 in, (10 to 15 min) (0.28 to 0.35 in. (7 to 9 mm)) fora new bet), Reassemble + Replace the belt with anew one If cracked, wom or damaged. + Carefully prevent the bett fom being smeared wit ol ‘grease Point 2 Reassemble + Check the thermostat function Point 3 Reassemble + Replace the fuel iter element with a new one. Disassemble + Cover the fuel pipe opening with tape to prevent intrusion of foreign matters. Point 4 Reassemble + Replace the ol fiter with a new one. + After fully tightening the fiter manually, retighten it witha fiter wrench by 2/4 turn, Point § Disassemble + Cover the fuel injection pipe and pump inlets and outlets with tape or the like to prevent intrusion of foreign mat- tors, 443° A4705004. ENGINE Point 6 we 3} Breather system (A redactor to intake aie system of bl ing vstem 7 Genie 92) Breer, Shoroom cover Emiting blowby gas Is harmful to natural envionment. There- (Speyer ormconer {ore blowby gas redactor is adopted tothe engine. Some of the ‘combustion gas passes through the clearance between the cy K J g inder and the piston, piston ring, and flows to the crankcase, 0 sea This is said as blowby ges. While passes into the cylinder | head and the rocker arm cover, the blowby gas mixes with QZ east yeu splash ol, and becomes oll mis-blowby gas mixes with splash wy iste baffle plate inside a rocker arm cover. And it passes through a SS diaphragm assy, and @ intake manifoki, and is reduced in the Breather system componert ‘combustion chamber. Pressure inside a crankcase is controled by the function ofthe diaphragm assy, and suitable amount of blowoy gas is reduced in intake ar system, Disassemble + When a rocker arm cover is taken off, check whether oll or Secon 1¢ like enter the diaphragm space from a small hole on the Ls ton me” eerie plte the lke enter the diaphragm space fr Hole on th sieve ges tow Secrets side of a diaphragm cover or not without disassembling the reaver diaphragm. =] Batis pate Diaphragm part Pp Blowby gas flow Notice + When @ diaphragm is damaged, pressure control inside the crankcase becomes insufficient, and troubles occur When the internal pressure of the crankcase decreases foo much due fo the damage of a spring, much blowby 938 containing oil is reduced in intake air system, and it may cause the combustion defect by the early dit of the Intake valve or the urgent rotation of the engine by the oil uring When pressure progresses in the orank case 00 much due fo the wrong operation of the diaphragm and so on, It is considered that oi! leakage rom the joint ofa oil pan, @ oll seal and so on will occur. When a dlaphragm is dam aged, blowby is discharged ftom the breathing hole on the side of diaphragm cover, and not reduced in the Intake ‘manifold. Therefore, be careful ofthe diaphragm trouble. + At lubricating oil replacement or lube oll supply The amount of lubricating ol isn fo be beyond the standard upper lit (in the engine horizontally, the upper limit ‘mark of the dip stick). Since the biowby gas redactor Is adopted, be careful that the amount of oll mist may be Jnducted in the combustion chamber and the oil hammer sometimes may oceur, when the lubricating oll quantity is ‘beyond the upper lit or an engine is operated beyond the allowable maximum angie of an engine. Reassemble + Replace the diaphragm with new one, when its damaged. 444 4705004. ENGINE Point 7 Disassemble + Keep the removed push rods by attaching tags showing corresponding cylinder Nos. Reassemble + Always apply oil o the contact portions ofthe push rods and valve clearance adjusting screws, prints Soren gee EEE "tons eid he ata wo soe ae mis PY _ ee pst eAeAeAoSal: «Pace he eynder hood as} on paperboard to prevent i ‘the combustion face from any damage. ®@ ®@ & ® rensorbe cree "Remove hand gta vith are ona jet Tay aad had Bod tay arog cl ‘on the threaded and seat portions. exo Xo2ofels ae eet nite mens te PO IO order for disassembly. ® @® First step : T= 31.0 10 34.0 fbf. (41.1 0.48.9 Nem) Head bat iginng eer ‘Second step : T = 63.0 1067.0 fbf. (85.3 0.91.1 Nem) Point 9 Disassemble + Carefully remove the fuel injection valve so as not to leave the tip end protector from being lft inside the cylinder Reassemble + Replace the fuel injection valve protector with a new one. Point 10 Disassemble + When removing each intakefexhaust valve from the cytin- der head, use a valve spring compressor and compress the valve spring and remove the valve cotter. « + Keep each removed intakelexhaust valve afer attaching @ tag showing the corresponding cylinder No, + If cotter bur is seen atthe shaft of each intakefexhaust valve stem, remove it with an oilstone and extrac the valve {rom the eylinder head. Reassemble + Replace the stem seal with a new one when an intake/exhaust valve is disassembled. + Carefully install each valve after oil application so as not to damage the stem seal + Diflerent stem seals are provided forthe intake and exhaust valves. Do not confuse them since those for exhaust ‘valves are marked with yellow paint. + After assembing the ntakefexhaust valve, stem seal, valve spring, seat, and cotter, tap the head of the valve stem lightly for setting, + Do not forget to install the valve cap. ‘ave srng compressor 445 4705004. ENGINE 5) Parts Inspection and Measurement (1 Cylinder nead Clean the cylinder head, mainly the combustion surface, valve seats and intake/exhaust ports, remove carbon deposit and bonding agent, and check the surface state. [1] Appearance check Check mainly discoloration and crack crack s suspected, perform color check. [2] Combustion surface distortion Apply a strait-edge in two diagonal directions and on {our sides of the cylinder head, and measure distortion with a thickness gage in.(om) Sandaré Tmt bistorton Doc osjortess | 0006/05) [3] Valve sink Measure withthe valve inserted tothe cylinder head. in. (rm Sandaré Tmt ‘dare 0020 Intake nore 002 | oat 08) valve sink — exaust ] 92150020 | acer (oe) 446 Tien 9 Sraighaoge ‘ao sinking dont ‘4706084. ENGINE [4] Seat contact Apply a thin coat of minium on the valve seat. Insert the valve in the cylinder and push lt against the seat to check seat contact ‘Standard : Continuous contact all around ave seatcanact (2) Vawve guide seat Mainly check damage and wear on the inside wal, Apply f supply part code 129007-11810 wien replacing the pat. 11) Inside ciameter in (om eas estos Sanded [unt leuasio | OatStoos1 | on10 ab _e (@o1r8025) | (10) — omsweoa | oa nakevane fstemoD. | rossto7a7s) | (790) Nocoanee | 000141000028 | 0071 av gui ine ameter (0.038'00070) | (078) louasin | o26tosI7 | 0310 (015108030) | (6.10) oataooaa | om (7985107970) | (7.90) Dooet a0080 | O0NT! (088 t0.0078) | (0.18) Exnaust vaive [stemo, Measureg poston ctearance (3) Intake/exhaust valve See : Mainly clean and check damage and wear at the valve stem and seat [1] Seat contact: See (1) [5] above. [2] Stem outside diameter : See (2) [1] above. [3] Valve head thickness. sea fe | womeoestaee Ta | vera mre T fExaust | cosa teo0er (1st 188) | 0081 (08) [4] Valve stem bend ime (0100088101 Fa) ‘eben artongth 447 4705004. ENGINE [5] Overall engtn intr) ‘Siandard Unit retake a] #220! 409 100716 100:) | 4272 1008) ate (4) Valve spring Mainly inspect damage and corrosion. nna Free engin Sandard Ut Free length “1964 (420) | 16044415) incination = (0.056 (14) ve (5) Valve rocker arm: , Mainly inspect valve head cap contact surface, inside sur- {ace defects and wear. Slight surface defects shall be cortected with an olstone. in. tem) ‘Sanders Lint Os2v9 06007 | 08s27 [Arohole ameter (16.00% 1602) | (16.07) os2a7 06201 | 06276 Sran oD, (15971 1598) | (1598) Gainntal ‘000600021 | 0051 (aorstoo0s4) | (013) (© Valve rocker arm shaft Mainly inspect seizure and wear at the surface in siding contact wih the arm. The rocker shat diameter shall be Recker am hole diameter as specified in (6) above, © Push rod Mainly inspect the surface in contact with the tappet and adjusting screw. Slight defects shall be corrected with an oilstone. fend ime 0.0072 im (O03 mn) orless Rocker shat uti ameter @) Valve clearance adjusting screw Mainly inspect the surface in contact withthe push rod Slight detects shall be corrected with an oitston. (©) Rocker arm spxing Mainly inspect surface defects and corrosion iden ge 448 4705004. ENGINE 6) Valve Seat Correction Notice : Always check the ol clearance between the valve and valve guide before correcting the valve seat. It exceeds the limit, replace the valve or valve guide fist fo make the clearance satsty the standard. Aer correction, wash the valve and the cylinder head sufficiently with diese! oll fo remove all grinding power or compound, [1] Ifthe seat surface is slightly roughened : perform [A] ‘and [8] below. [2] Irthe seat is heavily roughened but the width is almost normal, correct with a seat grinder or seat cuter fst “Then perform lapping [A] and [8] below. degrees : : Trae Exhaust 7 120 oy [3] Ifthe seat is heavily roughened and the width ts much enlarged, grind the seat inner surface with a seat ‘grinder whose center angle is 40 degrees, then grind the seat outer surface with a grinder whose center angle is 150 degrees to make the seat width match the standard, Then perform seat correction as ‘described in [2], and then catty out lapping [A] and [B] below. degrees o oe Grinding whee! angle a 7 TA]: Lap the valve and seat with a mixure of valve com: Pound and engine oil [IB]: Lapwith engine oll only. 449 80° seotale_ me Seatarnder . ‘one uephng ‘4706084. ENGINE 7) Valve Guide Replacement {1} Use a valve guide exraction tool and extract the valve vv gudeeptacanant uid rom the eyinder head. rome ectcing [2} Put kid trogen or ether (or alcho) with dy ice aid m canara tesa gt g replacement init for cooling, Then inser iin with @ valve uide inserting too! {3} Check the insite diameter and fnish to the standard t inside ameter as required wth a ream. | {41 Check he projection fom the cyinder head 7 Projection : 0.579 to 0591 in (147 to 15.0 mm) l Proecton POT Do not touch the cooled valve guide with bare hands to avoid skin damage. €) Valve Stem Seal Replacement ‘Aways use a new seal arte ilaklexhaus vate is dses- Vote sons eng tl serbled Since the one forthe exhaust valve is marked wth ye lo ait, do nt confuse the irtake an exaust valves, 4 {1} Apply engine oil to the tp BB} Push withthe inserting too for instalation a) Neve gad Oytncor has [3] Measure and check the projection of vaive stem seal to keep proper clearance between valve guide and stem seal ‘Stem seal projection: 0.736 to 0.748 in, (18.7 to 19.0 mm) I LL sms Stem seat projectn 44.10 44705004. ENGINE 4-43 Gear Train and Camshaft 41) Components 9 Fiywheet a4 Flywhee housing 111 Gear case ange Bstarer ¢ 10 Camshat 2 cooling water pump i \6 late gear Fuel pump spacér %, G 5 Fue injection pur Don cisassomth 420i seal 3 Crankshatt play 2) Disassembly Procedure : Disassemble in the order ofthe numbers inthe illustration, 1 Perform steps 1 to 12 ofthe cylinder head disassembly procedure. Remove the cooling water pump. Remove the crankshaft pulley. (See Point 1) Remove the gear case cover. (See Point 2) Remove the {uel injection pump. (See Point 3) Remove the idle gear assy. (See Point 4) Remove the P'TO. drive gear. (See Point 5) Remove the stating motor. 9 Remove the flywheel. (See Point 6) 410 Remove the camshat assy, (See Point 7) 11 Remove the gear case. (See Point 8) 12 Remove the oll seal from the gear case cover. 3) Reassembly Procedure : Reverse of the disassembly procedure 4am 04705004. ENGINE 4) Servicing Points Point 1 Disassemble + Remove the crankshaft pulley using @ gear puller after removing the mounting bot. When removing the pulley with the gear puller, use a pad and carefully operate so as not to damage the thread, Set the gear puller securely 10 prevent the pulley from being damaged. Reassemble + When installing the crankshat pulley, apply lube oil o the bolt and carefully assemble so as not to damage the oil seal 7 33.2 10 90.4 fbf. (113 t0 123 Nem) Point 2 Reassemble + When installing the gear case cover, do not forget to install the two reinforcing bots atthe center + Measure the backlash of each gear. Futian pump int) ive gest camera gear Sandard Tim crankshat gear, [camenat gear, 0028 0 00059 | 0.0087 Fuel injecion pump gear, (aorto015) | (017) ole gear, P.O. gear Dow aa07S | Oo0es Lubricating oll pump gear feo cttoe ola pea recto ftnton + Apply sealant and install the gear case cover by correctly positioning the two dowel pins. Point 3 Disassemble + Remove the fuel injection pump drive gear mounting nut, remove the gear using the gear puller, and remove the {uel injection pump. Do not forget to remove the stay on the rear side. When extracting the gear using the gear puller, use a pad at the shaft and carefully operate so as not to damage the thread. Reassemble : + Drive gear nut T= $79 to 65.1 lb. (78 to 88 Nem) Point 4 Reassemble + Assemble crankshaft gear A, fuel injection pump drive gear B and camshaft gear C at the same time by aligning with idle gear A, B and C marks. + Insta the idle gear shaft with the oil hole facing upward, Point § Reassemble + Install the P.0, drive gear with its inner spline side facing the fywheel 4412 A4705004. ENGINE Point 6 Disassemble + Install a bolt as a handle in the hole at the end face of the flywheel and remove carefully so as not to damage the ring gear. Reassemble : Flywheel! mounting bot T 1.510 66.1 lb. (83.3 10 88.2 Nem), apply lube ol Point 7 camnat gese Disassemble ican + Measure the camsha side gap. : inom andere mt cial ‘D002 0.0078 Done Es (005 100.20) (0.20) + Trthe measured side gap exceeds the imi, replace the thrust metal aa Disassemble + Since the camshaft gear is shrink, heat it to 356 to '392°F (180 to 200°C) for extraction am + For camshaft removal, raise the engine wit ts mount- eee ing Nange atthe boom, Aer removing the thrust metal mounting bol from the camshaft gear hole, extract the ccamshalt carey $0 a8 not fo damage the bearing bushing + Rotate the camshaft few tums before extracting ito prevent the tappet fom being caught by the cam. + After removing the camshat, set the engine horizontal and fxit on the bas. Unforeseen injury may arise due to falling of slipping when raising the engine vertically or returning it to the horizontal position. Proceed carefully £0 as not to lose balance. Point Reassemble + Do not forget to install the oil pan mounting bolts on the bottom side when instaling the gear case. + Apply sealant (code No.977770-01212) and install the gear case by matching the two dowel pins. Point 9 Reassemble + Replace the oll seal whenever disassembled. + Apply Iithium grease atthe time of assembly 441304705004. ENGINE 5) Parts Inspection and Measurement (1) Camshaft Mainly check the contact between the tappet and cam contact surface, bearing seizure and wear, and gear damage, [1] Shaft bend measurement ‘Suppor the camshaft with V blocks. Rotate the camshaft and measure the runout at the center of the camshaft and at each joumal with a dial gage. Half of the runout isthe bend inom Sander int i te 0.0008 ‘0.0025 (toc) (005) [2] Intake/exhaust cam height measurement in.(rm) Standare Let 7520 1828 7510 fandii (8600 to 36.800) | (98.350) [3] Camshan outside diameter and bearing hole diameter measurement Measure the camshaft outside diameter with a ‘micrometer. The oll clearance shall be calculated by subtracting the measured camshaft outside diameter {rom the camshaft bushing inside diameter afer insertion tothe cylinder measured witha cylinder gage. intr) Sanderé [um {Teer t0 1 7687 | a7678 [CamenatOO | i44.025 044.950) | (44.800) ‘irate 17798 | 17768 Gearside JPusting |. | (4490010 45.055) | (45.190) lee! ‘006% 00081 | 0.0088 (@040%00.130) | (0-240) "7681101 760% | 1.7667 [Camenato0 | i4a at0t0 44.995) | (44.875) ntermesiste occhng a, 177i7t0 17726 | 17758 positon a (45.000 to 45.025) | (45.100) Noacioerance | 00028t00.0065 | 0.0089 (008s to ots) | (0225) 17687 t0 1 7607 | 17678 [CamenatOO | i4a.025 to 44.950) | (44.890) ‘avi 17726 | 17786 [Weetside [Busing 1. | 145,000 048.025) | (48.100) Noacoarance | 00020%0 0.0080 | 0.0083 (0050%00.100) | (0.210) ‘4706084. ENGINE @) late gear Mainly check the bushing seizure and wear, and gear damage [1] Shan outside diameter and bushing inside diameter mea- cee aay sae in. (men) ry i Tana Tne ii Sata Taoor 187s | “a0 fog diameter (45.950 to 49.975) (45.009) i zt Bsr node Tariow e120] 16140 ener eoroteasess) | dears) sae mua coor0© 00080 —] oom (aozswoors | errs) @ PTO. drive gear Mainly check sticking of bearings on both sides, gear damage and looseness, and gear shaft damage and wear. 6) Oil Seal Replacement (Gear Case Side) [1] Replace the ol seal with a new one when the gear case is disassembled Extract the used ol seal [2] Insert a new oil seal. Fit the positon ofthe oll seal insertion to the end face of the gear case. (Refer tothe below figure.) [31 Apply ithium grease tothe ol seal tips. For the oil seal with double lips dust seal, further, lightly apply engine ail Con the ol seal lip so as not to damage them, when instaling the pulley. Notice Pay attention not to drop any oil on the taper surface ofthe crankshat. If dropped, clean by wiping off using deter- ‘gent. [4] Careful install tne crankshaft pulley so as not to damage the oll sea ip. 7) Camshaft Bushing Replacement Replace the bushing using the special service tool 4415 44705004. ENGINE 4-4-4 Cylinder Block 41) Components gore "Sanson comes i noi & 2) Disassembly Procedure : Disassemble in the order ofthe numbers inthe illustration, 1 Perform steps 1 to 12 in the cylinder head disassembly procedure 2 Perform steps 1 to 12in the gear train disassembly procedure 3 Remove the oilpan. (See Point 1) 4 Remove the lubricating oll suction pipe. 5 Remove the piston wirod. (See Point 2) 6 Remove the mounting flange. (See Point 3) 7 Remove the bearing metal caps. (See Point 4) ‘8 Remove the crankshaft (See Point 5) 9 Remove the tappets. 410 Remove the pistons and sings. (See Point 6) 11. Remove the oil eal fom the mounting flange. 3) Reassembly Procedure : Reverse ofthe disassembly procedure, 4416 44705004. ENGINE 4) Servicing Points Point 1 oi pan Disassemble + Sealant is applied to the oll pan mounting surface on the block. Carefully operate so as not fo damage or distort the bonding surface. Reassemble + Apply sealant (code No.977770-01212) before reas sembly, Point 2 Piston wrod Disassemble + Measure the connecting rod side Gap. Commetngratets gp 7 ‘Standard: 0.0079 to 0.0187 in, (0.200 0.40 mm) + Carefully remove the carbon deposit ontop ofthe cyinder so as nat to damage the inner sie ofthe cyinder. + Set the piston at the BDC position and remove the connecting rod cap. Then set the piston atthe TOC poston, ‘and push the connecting ro big end withthe wooden shat ofa hammer. Proceed caretlly so as no fo cause the cylinder block catch the rod big end. Set the rod caps and crankpin metals in their correct combinations. Reassemble + Apply oil especially carfuly to the sliding contact suraces ofthe pistons, rods and rings. + Use the piston insertion too to insert each piston wirod inthe cylinder block and install the bearing metal cap Rd bot tightening torque :T = $3.0 t0 36.0 lb. (44.1 to 49.0 Nem), apply tbe oil Point 3 Mounting flange Disassemble + Place the engine on a stable base with the cylinder block upper surface facing down, and remove the mounting flange carefully so as not to damage the combustion surface Reassemble + Apply sealant (code No.977770-01212) and install the mounting flange by matching the two dowel pins. After ‘assembly, raise the engine with its mounting flange on the bottom side POT Unforeseen injury may arise due to falling of slipping when raising or reversing the engine. Carefully ‘operate so as not to lose balanc: 4417 A4705004. ENGINE Point 4 Journal bearing cap Disassemble + Before removing the journal bearing, measure the crankshaft side gap. Measure it in either method because there are the next two methods, [1] Install a dial gage on the cylinder block, and move a crankshaft in front and back, and measure the side gap as shown inthe right figure. [2] Put a thickness gauge in the clearance between thrust ‘metal and crankshaf directly, and measure it Side gap standard ftom ct ck Woda | Sanat Tra < anmoace | 26261299991” por10 020 oT Terni a ea Reassemble em = te sd ap exons standard, pace test metal teerocp ‘han overize one ; Machine the standard wath of the crankshaft thrust part into the dimension of the below table atthe same time Refer to a parts catalog when ordering the par. hickness gauge ‘The surface finishing precision (refer to 4.4.5(2) in chapters): Side gap measuroment? v 0.0098 in, (0.25 mm) Oversized thrust metal (0.25 DS) in, (mm) “Tarust metal assy code | _ Standard thickness 0.0808 100.0829 Seen | (2.055 02.108) ‘The standard width ofthe crankshaft thrust part in (mm ‘Model ‘Standard thickness 1.11220 1.1130 pees (28.250 to 28.271) 4418 04705004. ENGINE Disassnble pa "Remove te Rearing cop, ap teas at Of sess ais Pace each vist metal win deniteaten ote pston tra cretion, ssa 0°65 oo The poston bat ase prt oa Cap net bm ot sind bk ee 8 se cat Reassemble ete pee man Lower main i + Carefuly install each thrust metal so that the grooved one is _besrng metal bearing ota positioned away from the cap. + Do not confuse the upper and lower main bearing metals, ‘The upper main bearing metal (block side) has an oll hale, ‘and the lower one does not, The “arrow” marks on the cap shall face the flywheel, Tighten main bearing cap bolts. Ms gap Main bearing cap bolt lightening torque (apply lube of) telos em) ~ oa Position number 69.010 76.0 (08.2 1098.1) AFA olresttembing Point § Crankshaft Disassemble + Remove the crankshaft. Remove each main bearing metal upper (block side) and pair it with the metal cap side lower oural bac cap metal PN ied) Carefully prevent damage to the bearing or finger injury when removing the crankshaft because it is heavy. 4419 04705004. ENGINE Point 6 Piston pin and rings Disassemble + Use the piston ring replacer, remove the piston rings. + Remove the cicip and remove the piston pin by push- ing itout Reassemble + Install each piston ring on the piston, with the punched manufacturer's mark facing upward Reassemble + The piston ring joints shall be staggered at by 120 degrees intervals. Do not position the top ring joint vert- ‘al to the piston pin. The coil expander joint shall ‘opposite to the oil ing joint Reassemble be + When installing the piston pin o the rod and piston, the punched match mark on the big end of the connecting fod shall be opposite tothe size mark onthe piston top, Reassemble + Instal the piston in the cylinder block withthe punched mark on the big end ofthe rod on the nozzle side.(The ‘embossed mark at the connecting rod -beam section shall be on the ywhee! side.) 4420 rare ope a) eng jont op goat ing jan . Paton 10 man ror J ennossed mar (Phot ie) teh ark (Agempusgrconet main) ‘4706084. ENGINE Point7 oil seat Reassemble + Replace the oll seal wth a new one whenever disassembled. Apply Ithiumn grease atthe time of assembly '5) Parts Inspection and Measurement (1) Cylinder block Especially clean head surface, cylinder bores and oll holes, and check ater removing any carbon deposit and bonding agent [1] Appearance inspection Check if there is any discoloration or crack. If crack is ‘suspected, perform color check. Sufficient clean the ol holes and check they are not clogged. Cylinder bore and distortion Measure at 0.39 in,(10 mm) below the crest ofthe liner, at 0.79 in.(20 mm) from the bottom end and at the center. Roundness : Maximum value of the diference between the measured values in the same crass section. Cylindicty : Maximum value of the diference between the measured values in te same direction, Oyler bre a ea oe dioweeee | amy | J pras A Roundness once oorjortess | 9.0012 [3] Ifthe limit is exceeded or any surface defect is found, ‘omn) repair by boring and honing. Use an oversized piston ‘ytnder be measurement postions - (and new piston rings) as required 02508 | _Patonassy cde Piston rng assy code Boing dnension (ineliPiton ng 288) in (mm) "29005-22000 "29005-22050 3.4748 1 03.4756 (288 250 to 286 280) 4421 A4705004. ENGINE (@) Crankshan Mainly check seizure and wear of the crankpins and journals. Since the crankshaft gear is shrink-fited, neat to 358 10 392°F (180 to 200°C) when extraction s necessary. [1] Shaft portion color check ‘Alter washing the crankshaft, Inspect it by means of color check or a magnaflux inspector, Replace it if cracked oF heavily damaged, Shght defects shall be comected by grinding Inspection by exer chock [2] Crankshaft bend ‘Support the crankshaft journals at both ends with Ve blocks. Use a dia gage and measure the runout atthe oa center journal while rotating the shaft to inspect the bend fume [5.00076 in. (0.02 mim ores — iat 290 4422 4705004. ENGINE [8] Crankpin and journal measurement Measure the outside dlameter, roundness and taper at each crankpin and joumal. Correct by grinding if unevenly wear, roundness ‘exceeding the limit or insufficient outside diameter is found, Replace ifthe defect is excessive, + Crankpin in. Gandara ont "eeTot0 18088 | 22706 Pin oxtsice diameter (47952t0 47.962) | (47.002) etl thickness 10.0687 1 0.050% (1.49210 1500) catemitat Dovrstoao02 | —000se (osstoaora) | (0.150) bearing 0.25 US bearing Ifihe oll clearance exceeds the limi, use an undersized intr) Pan code 720150.23510 (0.0897 190.0540 standard thickness cee oeae Pin machining dimension 1.876010 0.8708 (247-702 0 047712) rants 4 TH Moasuing poston o he crantpn and crank ural Ifthe clearance lim is exceeded, use an undersized bearing, Notice : + Crank journal + 0.25 US Crank joumal bearing in. (me in (em) Standard Limit lear code 129160-02870, onnae: Diew2ras | 212% (639521053862) | (63.902) (0.0851 t 0.0837 |sandars thickness eres Metal thickness ee eoee - (1.995 10 1880), \ioumal bearing machining) — 2.114210 02 1148 as poets iwoona | O00 laimension (958.702 t0 053.712) (0038100068) | (0.180) + It the oll clearance is excessive though he thicknesses ofthe joumal and orankpin metals are normal or if partial uneven wear is observed, re-grind the crankshaft and use an oversized metals. + Uftust or surface roughening exists on the rear side ofthe metals, coat it with blue or minimum. Then assemble the ‘rankpin metal tothe connecting rod, and tighten the rod bolt fo the specified torque fo check the metal for contact Ifthe contact surface occupies 75% or more, the metal is normal. If the contact surface is insufficient, the metal interference is insufficlent. Replace the metal with a new one. 4428 ‘4706084. ENGINE @) Thrust metal inspection Inspect any damage or wear. [1] Thickness in. (re Sandard et (00760 90.0780 0.0728 eee (1.890 01980), (6.850) [2] Side gap in.(om) Sandard Unt (0.0085 0 0.0087 ono iad (0.1419 022) (028) Ifthe side gap is exceeded, use an oversized thrust metal 208 120160-02940 10.0800 0 0.0829 in standard thickness peer eanetea @ Piston Especially clean the combustion surface, circumference, Piston cuts diameter fing grooves and piston pin bosses, and check after removing any carbon deposit. Any burr ata ring groove of ‘snap ring groove shall be removed. If crack is suspected, inspect by color check [1] Piston outside diameter measurement Measure the long diameter at 0.95 in. (24 mm) from the bottom end of the piston of the oval hole in the vertical direction tothe piston pin hole. ‘eaauraran pases Into 95% (mm) ‘andar Timi ara 3aG2210 34684 | 34008 ong diameter (27.940 to 87 970) | (87.895) Moana tegong. Bande es ‘00018 ‘00076 Pee aeeethett te ciearance between (0.045) (0.040) a ft i t piston andeyinder ‘0.0030 ‘0.0028 (0075) (0.070) Ir the clearance between piston and cylinder exceeds the BOF T T lit, use an oversized piston. Piston pin uso amor pasos Piston assy code Psion ing assy code Boing dimension {ine\Piton ng 288) in. (mm) 120005-22000 "728005. 22850 3.a7a 195 A786 (288 250 to 286 280) 4426 4705004. ENGINE [2] Piston pin hole measurement in. (rm) ‘Sanderd it 4 aandb decions Toxas te 10240 | 4.0250 Pinhole ciametor (28.000 t2 28.009) | (26.030) omaete 10236 | 1.0222 Pin outside diameter | (25.005 0 26.000) | (25.965) ‘oonote og00 | 00028 (aki (000%.0014) | (0074) [2] Piston ring, rng groove and end clearance measurement + Except forthe top ring, to measure the piston ring groove ith, frst measure the width ofthe piston ring, Then insert the piston ring into the ring groove, Insert a thickness gage in between the piston ring and groove to measure the gap between them. Obtain the ring groove width by adding ring Width to the measured sie clearance. + To measure the end clearance, push the piston ring into the sleeve using the piston head, inset thickness gage in ‘end clearance to measure. The ring shall be pushed in to approx 1.18 in. (30 mm) above the bottom end of the cylinder. For the top ring, measure only the piston ring joint end ‘clearance in normal sate. intr Sanat Tim Ring groove 0.0641 to 0.0897 jit (20sotez075) | oo7rewoores | 00765 Rng win (1.970% 1.980) | (1.960) Hop tng sie clearance | 09028120008 | (0.070% 0.105) oo07s 00187 | 00195 [Endclearance | (0200100400) _| (0480) Ring roo | 00797 00805 | o0a4s jth (20251 2040) | (2140) oorTewoores | 00765 secon [ROMO (1.970% 1.980) | (7.960) ing ‘00141900028 | 00075 Seeclearance | '(0.03810.0070)_| (0.180) End cearance | 000791000787 | 0.0188 (020000400) _| (0480) Ringoroowe | 075811001887 | 01626 ith (4015%0.4030) | (4130) 075631007571 | 07555 ert feer (3.970% 3080) | (3950) itrng swe cearance | 00010%000024 | 00071 (0.025.080) | (0.180) ‘oo07stoo01s7 | 0013 [Endctearance | (0200100400) _| (0490) Paton ig S557 comm Sate Rng intend caorance measuramont 4425 4705004. ENGINE (©) Connecting rod [1] Appearance inspection Inspect the portion near the boundary of the cham- fered portion and L-beam section of the big and small lends of the connecting rod as well as the portion near the oll hole ofthe bushing at the small end for cacks, deformation, and discoloration, a “Twist and parailelsm measurement Use @ connecting rod aligner and measure the twist and bend inte) ‘Standard mension [Lim amension Fwist and 0.0012 (0.08) 4 peraletsm | orless per3.0a(100) | 90081 (008) [3] Rod small end measurement Measure the pin outside diameter according to (4 [1] described above. intr Gandara mt Tontet0 10251 | 10268 Piston pin 'D- bushing | (26.025 t0 26.038) | (26.086) Tomei te 10796 | 10220 eee (25.995 028.000) | (25.967) co teaaa ‘ooniato007 | aco (@o2st00088) | 0.101) Ifthe bushing is tobe replaced because the ol clearance exceeds the limit, use spare part code No.129100-23910, {4} Rod big end measurement Measure the crankpin and bushing according to 2) [3] described above. 4426 Frag ffi “wt and pralleism maasurement Connecting od Signer Connecting 8 mal end ‘4706084. ENGINE Calculate the oll clearance of a crank pin metal and a crank pin ‘om the measured values ofthe crank pin metal inner diameter and the crank pin outside diameter Replace a crank pin metal ithe oll clearance becomes about the lt dimension of the below table. Correct by grinding if unevenly wear, roundness exceeding the limit oF Insufcient outside diameter is found, Also use an Undersized metal Notice : Wien measuring the inside diameter of the rod big end, install the crankpin metals inthe rod big end not to mistake the top and bottom of the metals and tighten the rod bolts by the standard torque. ‘Tightening torque of rod bolt Tightening torque “Lubricating ol application ‘tb (Nem | threaded portion, and bearing seat surface) 331038 aie sem Lube. ol applied Standard of rod big end in. rm) item Standard imi 1.8878 to 1.8883 1.8859 Pee eee (47,982 to 47.962) 47.902) 7.8808 to 1.8908 (48.000 to 48.026) (0.0887 to 0.059% (1492 to 1.500) 10.0015 10 0.0029 0.0059 (0.038 to 0.074) @.150) Crankpin 0.0. Metal thickness clearance: 4427 470500 Rod bushing 0. measurement4. ENGINE © Tappet Mainly check the tappet contact surface with the cam and push rod, Sight surface defects shall be corrected with an oilstone. [1] Tappet stem outside diameter measurement in. (rm Sua = Aormatcontaet suraca Neral anacTertace Sano aarisiooa7a0 | 04707 i (11.978 10 11990) | (11955) ‘aaraetooa7ea | 04742 (adioara (1200010 12028) | (12086) uiieadt (0.0004t— 0.0020 | 0.0036 (01010050) | (0090) 6) Cylinder Bore Correction [1] Slignt uneven worn, faved, et. shall be corrected by honing only, If the cylinder is unevenly wom partially, flawed or otherwise damaged and cannot be repaired simply by honing, rebore the cylinder fst and then hone, See 6) (1) [3] fr the boring dimension, [2] tems to be prepared for honing + FlexHone Electric ari Honing fluid (60 : 50 mixture of ube oil and diesel oi) 4428 ‘470608 tars tobe prepared orhoning4. ENGINE [8] Apply the honing fuid to the Flex-Hone and tum the electric dil at 300 to 1200 RPM. Then insert the Flex- Hone into the cylinder bore while tuming it, and move It up and down for about 30 sec. to obtain a honing ‘mark with a cross hatch angle of 30 to 40 degrees in. (rm [Gyinder bore ater exinder borg ate | 9.4744 10..4759 68.2500 68.280 surtace roughness | Rmax0.04 100.14 8(7.0t0355) Roundness (Cvinaercty) eee Notice + Avoid faster revolution than 1200 RPM since it may cause breakdown, + Do not insert or extract the Fiex-hione in stopped state because the cylinder will be damaged. + Oylinder overhaul (eference) Serie ite of etinor lck co) Boring ae honing tra (Hi) TSH) “efor aning Ingease no Incense MLO. Ineensa 9 LO. rt Inegaasin LOS, Honing ore Honing ‘Study # an oversized piston or piston mgs usable ) Piston pin bushing replacement Replace bushing by using the special service tool © Oil seal replacement [1] Replace oil seal, when mounting flange is removed. Extract the used oil seal [2] Insert a new oil seal with the ol seal insertion tool [3] Apply ithium grease, 4429 A4705004, ENGINE 4-5 Lubrication System 4-5-4 Lubrication System Diagram poe ( i \ i eSstra"* }-— | | i 1 7 “7 \ te a ‘Ollpan 4-5-2 Trochoid Pump (Vi045-5, ViOS5-5: 4TNV88-PBV) 1) Components 2) Disassembly (Reverse the Procedure Below for Assembly) [1] Loosen the bel, and remove the radiator pulley, fan and V-belt. See 4-4-2 2) 2 in Chapter 4-4 [2] Remove the crankshaft pulley. See 4-4-3 2) 3 in Chapter 4-4 [3] Remove the gear case cover, See 4-4-3 2) 4 in Chapter 4-4 [4] Remove the lubricating oil pump ass'y from the gear case. (Point 4) [5] Remove the pressure regulating valve from the lubricating oll pump body. (Point 2) 451 Asro0084, ENGINE 3) Servicing Points Point 1 Disassemble + Check ifthe pump rotates smoothly and see that there is no play between the shaft and gear, and inner rotor. Reassemble + Install the outer rotor inthe gear case so thatthe punch mark on the end face is seen * When replacing the lubricating oil pump, replace the whole ass'y. mer olor outer ot Point 2 r Disassemble-reassemble + Only wash the pressure regulating valve, Disassembly is unnecessary unless any abnormality in operation is detected 4) Parts Inspection and Measurement [1] Outer Rotor + Oil clearance between the outer rotor and inside diameter of |“ the gear case hole. + Side clearance between outer rotor and gear case hole. ‘Sane unt Giewaance | S0087 0000s | cone (or2w021) (020) ‘Guecewance | 00008%000025 | 0.0047 (oczteo0r (072) [2] Inner Rotor and Gear Boss Clearance pases Sandara Sanda] Sandars tam Par cimensen | ceerance clearance it in (rm) in rm) in mm) 7069 12 093 ‘Gear boss ameter Inside clearance (530505315) | oor2to020 | 002 ation rr aiore2 10a] (081008) (06) Rotorinner damter gee. oar wo 950 With across ato gear boss Wath srs at 9 (424514975) | oowrooazs | 0028 lerance of ner tor TeeTei or | (021008) on With acs tof oor ge ete 7 _ wit ao attra S Wi 452 As700084, ENGINE 4-5-3 Trochoid pump (Vi045-5B, ViOS5-5B: 4TNV88-BXBV) 1) Components The oil pump on these model engines is located in the front gear case and is driven by the same gear train that drives the camshaft and fuel injection pump. You must remove the font gear case cover to gain access to the oil pump. 6 —Drive gear 7 ~Pressure regulator valve 2) Disassembly and Reassembly Figure 9-14 [1] Disessembiy of Of Pump {the oll pump must be replaced, replace it as an assembly only. Do not replace individual compo- rents. Remove cooling fan (Figure 9-15, 3), spacer (Figure @- 18,2), cooling water pump V-pulley (Figure 9-15, 1), and Vebett Figure 9-15 452° Ad700084, ENGINE 1. Remove the crank shaft pulley and gear case cover. ‘See 4-4-3 2) in Chapter 44 2. Remove the lubricating oll pump assembly mounting bolts. Remove the lubricating ol pump assembly (Fig- ure 9-16, 1) from the gear case flange (Figure 9-16, 2) 3. You can remove by hand the lubricating ol! pump cover (Figure 8-14, §) and outer rotor (Figure 9-14, 4). [2] Cleaning and inspection CCean the lubricating ol pump, pressure regulator valve (Figure 8-14, 7), ad rotor inserting portion. Check the parts for wear or flaw. Replace the parts with new ones as needed. CAUTION sNEVER overfill the engine with engine cil. “ALWAYS keep the oil evel between the upper and ower lines on the oll capidipstick. [3] Reassembly of Oi Pump 1. Apply clean lubricating oil to the lubricating ol pump body and inner rotor assembly as well as to the outer rotor. 2. Insert the outer roto into the lubricating oll pump body and inner rotor assembly and install the cover. 3. Replace the packing with new one. 4, Install the lubricating oll pump assembly to the gear case flange by tightening the bots withthe specified torque. 5. Install the gear case cover. For more information, See 4-4-3 2) in Chapter 4-4 6. Install the crank shaft pulley aar0008 Figure 9-164, ENGINE 7. Install the cooling water pump V-pulley (Figure 8-21 1), spacer (Figure 8-21, 2), cooling water fan (Figure 9.21, 3) 8. Install the V-bet. Adjust the belt to uniform tensile strength in accordance with the instructions given in 4-3-4 Fan Belt Tension Inspection and Adjustment. 3) Parts Inspection and Measurement [1] Check Outer Rotor Outside Clearance Inspect the outside diameter clearance of the outer rotor. To inspect this, insert a feeler gauge between the outer rotor Figure 9-17, 1) and the lubricating oil pump body (Figure 9-17, 2), Record the measurement(s) and refer to Section "2-2 1) [Nominal and Allowable Values [2] Rotorto Inner Rotor Tip Clearance Inspect the tip clearance between the outer and inner rotors, To inspect this, insert a feeler gauge between the Inner rotor tooth tip (Figure $-18, 1) and the outer rotor tooth tip Figure 8-18, 2), and measure the clearance. Record the measurement(s) and refer to Section “2-2 1) Nominal and Allowable Values 455 aar0008 Figuro 9-17 Figure 9-184, ENGINE [3] Outer Rotor Side Clearance Inspect the side clearance between the lubricating oil pump body and the outer rotor. To measure the side Clearance, use a straight edge and feeler gauge (as shown in Figure 9-19 or a depth micrometer. Record the measurement(s) and refer to Section “3-2 1) Nominal and Allowable Values" [4] Rotor Shaft Clearance Inspect the rotor shat clearance. Measure the outside diameter of the rotor shat (Figure 8-20, 1) and the Inside diameter of the cover. Determine the clearance by subtracting the outside diameter of the rotor from the inside diameter of the cover. Record the measurements) and refer to Section °3-2 1), Nominal and Allowable Values" 456 aar00084. ENGINE 4-6 Cooling System 4-6-1 Cooling Water System pom a 4-6-2 Cooling Water Pump Components Cynder head From het inocton pure 461 A4705004. ENGINE 4.63 Disassembly (Reverse the Procedure Below for Assembly) [1] Remove the alternator. See 4-4-2 2) 1 in Chapter 4-4 [2] Remove the fan, V-belt and pulley. See 4-4-2 2) 2 in Chapter 4-4 [8] Remove the thermostat cover. See 4-4-2 2) 3 in Chapter 44. [4] Remove the cooling water purnp. (Point 4) [5] Remove the thermostat. (Point 2) 4.6-4 Servicing Points Point 1 Disassemble-Reassemble + Check to see thatthe cooling water pump bearing i fee from abnormal noise, sticking or play and water leakage {rom the bearing, If replacement is necessary replace the whole cooling water pump assy. Notice : Replace the O-ring of the cooling water pump with new one vahien disassembling. And, be sure fo use the special O-ring for each engine model, because the material is diferent, although the dimension isthe same as a commercial part. (Refer to the sight fur.) Point 2 Disassemble + Check the thermostat function. See 4-2-8 (1 [1] in Chapter 4- 3 for the inspection method. 462 4705004. ENGINE 4-7 Fuel Injection Pump / Governor ‘Only the outine of the MP fuel pump is explained in this chapter Refer to the MP pump service manual of the sepa rate volume forthe disassembly and assembly 4.74 Introduction It is described about the features of the fuel injection pump, ‘YOP-MP, manufactured by Yanmar, disassembly, assembly and adjustment procedure Fuel injection pump is the most important equipment, which is ‘enable to make the sensitive adjustment according to the vari- ‘able load ofthe engine ‘Therefore all of the parts are required not only very precise ‘machining but also finest, assembling wth top level ‘The careful arrangement of keeping of the dust and the rust when disassemble, adjustment and reassemble of the fuel injection pump is made in the market ‘Yanmar YOP-MP Pump is a distributor type pump which is unified of Mono-plunger, a dstibuting shaft a hydraulic head ‘which equipped the delivery valve for each cykinder, pump housing which has a cam shaft intemal and governor ‘The fuel, whichis pressurized by the up and down movement ofthe plunger driven by the cameotation, is supplied through the distributor shat, which is rotating accordingly, ‘There are a model YDP-MP2 and a model YDP.MP4, and plunger diameter and fuel cam speed are different. 4-7-2 Fuel Injection Pump 41) Fuel System Diagram inten re] ger Glam egal gn rer te 471 A4705004. ENGINE 2) External View and Components BF et injecion ripe 4 Sag me EY yecuvetny ef, fons a ‘Water separator |S Fuel pump spacer “Fuel injection pump Fuel pump drive gear ‘Brive gear nut Catena, oP 70, ‘Ceankshan pully 3) Disassembly Procedure : Disassembly from the engine body (1) Remove the cooling fan, pulley and V-belt (2) Remove the fuel injection pipe, fuel ol piping, fuel return pipe and rear stay. See point 1 of 5). {@ Remove the fuel injection pump cover (the cover ofthe drive gear) (@) Make 1D marks on the gearing pat ofthe pump drive gear and the ile gear with paint and so on. ‘See Point 2 of 5) (©) Loosen a fuel pump drive gear nut, and remove a pump drive gear from the fuel pump by using a gear puller. See Point 3 of 44-3 4) © Remove a drive gear nut carefully not to drop itto the inside ofthe gear case. ) Record the installation angle ofthe fuel pump precisely by using a mark-of line and a sticker. See 437, @) Remave the fuel injection pump. See Point 3 of 5). 472 4705084. ENGINE Fat Ftion Pe i +6, Fo pure 4) Assembly Procedure Reverse the disassembly procedure and adjust the fuel injection timing nally. See (4) of 4-3-7 5) Servicing Points, Point 1 Disassemble + Block an entrance withthe tape so that trash may not enter the fue injection pipe and the fue injection pur. fame J) velinjecton pump LD. mark Point 2 Disassemble mae + After putting the I.D, marks on the gearing part of the pump Frsttation nub drive gear and the idle gear with paint and so on, remove the ‘gear installation nut Fe pump ering gear Fuel pump driving gear Notice : Dont remove four flange bolts Reassemble + Reassemble the pump diving gear while checking the .D. marks on the driving gear and idle gear. Tightening torque ofthe gear installation nut Tabrcating ov appration (thread portion, and seat surface) 561065 (781088) Not applied feof (Nem) 473 A4705084. ENGINE Point 3 Disassemble ‘There is an acoustic material part to name as fuel pump spacer between the fuel pump and the cylinder block Loosen fuel pump installation bots with a closed wrench when disassembling a fuel pump. Notice : ‘An intake manifold may obstruct the disassembly ofthe fuel pump by the engine model. Remove the fuel pump alter removing the intake manifold frst. lider block Fuel pump spacer (vine head Ssution manifold Fesl pump Disassembling afuol pump Reassemble ‘When installing @ fuel pump on the gear case, put @ fuel pump spacer between the cylinder block and the pump, ‘See the Service Manual of "Fuel Injection Equipment (Model YPD-MP2 /YPD-MP4 series)" for further information of the fuel injection pump. 474 4705004. ENGINE 4-8 Electrical Equipment 4-8-4 Starter Motor ‘To start the engine, the starter motor rotates the ring gear installed on the engine flywheel with the pinion gear ‘engaged with the ring gear so thatthe force generated by the rotation exceeds the resistance including the engine ‘compression pressure and all tional force. The starter motor consists ofthe following major parts: a motor which ‘generates torque ; a pinion which transmits the torque to the engine ring gear ; a clutch ; and @ magnetic switch ‘which pushes out the pinion and tums on and off the principal curent 41) Specifications and Service Data Ranmar code TERE TTON Papbicabie moder TIVE POY, Sater meter rdeT S138 Nominal ouput Weight RATS a BT EH Rotaten érecion (Viewed Fam pion ee) Clockwise Engagement maths agri shi Terminal vokage / Gurart Via ‘e710 No lose Speed im 4100 eae erminal votage Curent Vim 2511080 chracerstes Forge Speed TEA eT 3185250) uh ype Grerunning Such Pinon coming oavotoge v 87 Pnen OP or module / Numba of pen et Dror a Standard sping free x0 Towa pi ew Standar eight Wear mn inom) 089 150)7095 60) agree ses Tecttance at Seve col/ Shut cal a 0371082 eer 20°C) Ouse Tanda ear it 21.43 (955)/0140 955) Diference commutator [betweon max. |Carcecton ist in (om) 10079 02)/0.0012 0.03) and min da Ivica undereut | Gerecton tat? (0.00787 (02)/0.02t0003(05t008) farmatre ace | shat cater” bearing. | Bearing inside dameter ‘Armature 62082 / Beating (FR) 6082 non cttch | Sha dameer Standard [bearing Bearing inside diameter (mm ae pees Cee 1 ea epee siameters Pinion siding | Shaf diameter 7 in. (om) [section Bearing inside diameter hts Pion ade] Shak dameer? [bearing Bearing inside diameter = [Gap bebveen pon and pian sopper iA oe GIW IA 401 4705004. ENGINE 2) Construction of Starter Motor Ne. Part Te, Pat Rear cover 0 _| Pinon gear 2 [Brush holder 11 [Gear case 3 [armature 2 | Center Noung [Yoke 3 [Dust cover [Ball bearing "14 Torsion spring [Bal bering 15 [Shit ever 7 [Pinon exter 16 [Magnetic sth [Bal bearing 17 [Brush [ea bering 78 [col 402 4705004. ENGINE 4.8.2 Alternator ‘The alternator is @ revolving-feld type three-phase AC generator. The AC electricity generated by the altemator is ‘converted to DC through the fullavave rectification by the diode and is stored in the battery. ‘The altemator contains @ regulator using an IC and can detect the battery voltage to adjust the generated voltage in the aternator. 41) Components We Par Te, Pat We Far Te Pat 7 [atemnater 70 | Cap screw 79 [Brush rower 28 [Ik 2 [ht 1 [Stud bot 20 [Brush assy 23 [Sud bot 3 [Rowrassy 12 [Rear tame assy 21 [Spring 30 [Flange nut ‘4 [Ball bearing 13 [Rear end cover 22 [Cap screw 31 [Bot tension aduster 5 [Bearing ower 7 [Puley 23 [Cap screw 32 [Adjuster bow [Washer 5 [Nut 2 [Bat 35 [Plated bolt O45 7 [Drive rare assy 76 [colar 25 [Cap sore 34 | Spacer © [Bal bearing 77 [Regulator assy 26 [Bor © [Retainer plate 18 [Holder 27 insulation busting 485 A4705004. ENGINE 2) Specifications [akerator moder AGFABE Yanmar Pit : 20422-77200 Batary vokage v 2 Nemnsl ouput fat 13.5 V shot conden) a «0 Rated speed rin 5000) [Operating speed in 350 18000 [Ground polarity Negatve Rotation direction (viewed rom puley se) Clockwise Regulation method 1 Regulator weight Biko) 62128) Pulley ameter in mm) 272,692) Vbet ype - Atype 3) Connections Wing ogra oleced 404 4705004. ENGINE 4) Standard Output Characteristics “The standard performance is shown tothe righ. Standard reverent woe + Be careful not fo connect wrong terminals and short cir- so ca out + Do not directly connect the terminals of 1G f0 L. Always zal Hot ‘sate cag anes beeen hn 5 + no ad etoen te toms and i * bo nt dsconmod ho tra Band at oe bate \while the alternator is running 8 + Cut-off the battery switch while the alternator is not run- 2) rn «Teton ca tinal to 12500 170 mD (1729 em ‘erator speed (0%) 405 4705004. ENGINE 4.8.3 Air Heater “The air heater installed on the intake manifold isa starting aid in cold weather, which serves to warm the air and ‘send itto the combustion chamber to start the engine easly at low ambient temperature. “The air heater is operated to warm the sucked air by setting the starter switch key to "AIR HEATER” position and ‘supplying electricity for about 10 to 15 seconds If electric is supplied to the air heater for mare than 15 seconds, this wll cause breaking ofthe heater lead or battery trouble ‘Specifications (Airheater circuit) Rated ouput a00W es Rated current BGA Rated votage Dorav Rated operating time 30 see, man ‘Ground polarty Negative Acheter 4.173006) in. (rm 307 (7) Desay | 2982 60) (a goss 39) 406 470500CHAPTER 5 HYDRAULIC SYSTEM 5-1 Outine 5-1-4 Control Valve Operation, 5-1-2 Additional Operation of Control Valve, 5-2 Hydraule Circuit Schemate 5.2-1 Quick Coupler 5.2-2 WIO Quick Coupler 5.3 Creult Operation 5.3-1 Boom 53:2 arm 53-3 Bucket 5-3-4 Swing 5.3.5 Boom Suing 5-36 Blade 5-37 Travel 5.2.8 Non-Deviaton Travel loth Boom, Arm or Boom Swing Operation), 5-3-9 Non-Devation Travel wth Bucket Operation), 53-10 Simultaneous Operation of Boom Up and Arm Retract 5.3:11 Simultaneous Operation of Boom Up and Bucket 5.9:12 Simuttaneous Operation of Boom Up and Swing '5.3:13 Simultaneous Operation of Arm and Bucket, 53-14 Hydraule PTO. 5.3-15 Quick Coupler 5-4 Pressure Adjustment 54-1 Rele! Vanes. 5-4-2 Swing Brake Vai. 5.4.3 CuLOMVaNe oa Sad 516 524 524 522 534 534 533 535 so7 539 oan oan 5015 sa47 5349 5221 5323 5305 5327 5329 Sat at 943 5445. HYDRAULIC SYSTEM 5. Hydraulic System 5-1 Outline ‘The hydraulic system consists of an engine, variable displacement piston pumps, @ gear pump, a control valve, a ‘boom cylinder, an arm cylinder, a bucket cylinder, a boom swing cylinder, a blade cylinder, a swing motor, a swivel joint, two travel motors, 2 way valve and a hydraulic oll tank. The oil discharged from the variable displacement piston pumps and that from the gear pump flow tothe actuators through the contro valve. “The hydraulic pilot contrl system comprises a plot pump, a cut-off valve mounted on the hydraulic pump and two pilot valves. The ol discharged from the pilot pump flows into the pilot ports of the control valve through the cutoff valve, the pilot valves and 2 way valve to contol the valve spool movernent in proportion tothe pressure atthe port ‘meiner Suivi ack o Front iz S11 4706085. HYDRAULIC SYSTEM 4) Hydraulic Pump ‘The variable displacement piston pumps, the gear pump and the pilot pump are linked t0 the fiywhee! of the fengine through the coupling. The number of revolutions ‘of each hydraulic pump is identical to the engine speed. xin. (ou. cm) ev VOweS | VOSS es id vioss.s8 | vi085.58 [Piston pump [PA 702766) 2 [Piston pump | Pa 92 (168) S| Gear pump P3 02 (16.6) + [Pitot pump Pa 93049) 2) Oil Flow (1) Piston pumps P1 and P2, and gear pump P3 ‘The pumps take in ol through the suction fier from the hhydraulic oll tank and discharge it. The discharged oil flows tothe ports P1, P2 and 3 ofthe control valve and returns from the ports T1 and T2 tothe hydraulic ol tank through the return fiter. This circulation is repeated. ‘The bypass valve in the relum fiter opens at a differen- tial pressure of 21.3 PSI (0.147 MPa) 2) Pilot pump Pa ‘The oll rom the pilot pump P4 flows back to the hydraulic oll tank through the port B81 of the cut-off valve inte- {grated into the pump, the pilot valves, the blade control Blot valve and the return fiter 3) System Relief Valve ‘The system relief valves RV1, RV2 and RV3 of the con- {rol valve contsol the discharge pressure ofthe pumps. 12 ack cnpl er SaaS PN ee ah ah i Asro6085. HYDRAULIC SYSTEM 124706085. HYDRAULIC SYSTEM & 1 Control Valve Operation 1) Oil Flow from Hydraulic Pump (1) Piston pump P1 “The ol rom the piston pump Pt is fed to the right travel ‘motor and the boom and bucket cylinders through the port Pt of the inlet section, the travel (R), boom and bucket sections, 2) Piston pump P2 ‘The oil from the piston pump P2 is fed to the let travel ‘motor, the boom swing and arm cylinders and the P.T.O. through the port P2 of the inlet section, the travel (L), ‘boom swing, arm and PT.O. sections. @) Gear pump P3 “The ol rom the gear pump P3 flows through the port P3 of the paralleLflow divider to the swing and blade sections, and also to the arm and P.O, sections to be combined withthe oil rom the piston pump P2. 2) Simultaneous Operation of Boom and Bucket ‘A parallel passage is provided for the boom and bucket sections. The parallel passage has a thratle in the ‘bucket section, so thatthe ail can flaw to the boom section more smoothly than to the bucket section when the ‘boom is given a heavier load. Therefore, the boom and the bucket can be operated simultaneously. 3) Anti-Drift Valve (Reduction of Boom Drifting) ‘The antici valve is installed in the boom section to reduce the boom driting 4) Track Drive Lock ‘When the lock lever is set to the “LOCK position, the ‘spool ofthe inlet section i in the neutral position, so that the oll from the piston pumps P1 and P2 flows back to the hydraulic ol tank through the return passage. There- fore, the implement does not operate and the machine does not travel even when the control ar travel lever is operated 14 FD aa Asro6085. HYDRAULIC SYSTEM esp) Hye pump, etum er OX ‘Suction st Hyatt OO Od 1 AO 6O OOO OOO O00 T]OOOF 1 @ OOO Lil Ooo r 1 ©} (| O Qe ° Conta vabe Po re [re 15 As706085. HYDRAULIC SYSTEM 5-1-2 Additional Operation of Control Valve Safety Lock. (1) With Tock lever in "LOCK" position {2) With lock lever in "UNLOCK" postion seaton is moved ‘motors to operate them, ‘The spool ofthe Init Section Is in the neutral postion, and the oll rom the pump port P' and that from the pump port P2 flow back to the hydraulic ol tank through the retum passage. Therefore, no oil is supplied to any sections, and cylinders and ‘motors do not operate even when a spool of every section is moved. ‘The oil from the pilot pump Pé flows to the port a2 of the inlet section through the cut-off valve, and the spool ofthe iniet ‘The oll ftom the pump P1 and that from the pump P2 can flow to sections to move their spools, and flow to cyinders and ‘Simultaneous Operation of Boom and Buckot The bucket section has a parallel passage 50 that the boom and bucket can be operated simultaneously and a check valve (60.13 in. (2.3 ‘rim)} 80 that the oll can flow to the boom section prior to the bucket section even wien the boom is, Fighly loaded: ‘Combined Oil Flow for Arm Retract Operation When the arm is retracted, the ol rom the port 1 of the pilot valve (LH) flows to the port PLb of the arm section f’nd the parallefiow divider to move their spoals. The oil from the gear pump P3 flows through the paralieHiow divider and the parallel passage to the arm section and ‘combines with the ol from the piston pump P2. ‘Simultaneous Operation of "Boom Up" and “Arm Retract™ ‘Anti-Drift Valve (Reduction of Boom Drifting) When the arm control lever is pulled back to retract the arm while the boom is raising, the ol from the port 1 of the pilot valve (LH) flows tothe port PLp. The pilot oll Moves the spoo! of the paralie-fow divider to the neutral position to let the il from the gear pump PS flow into the arm Section prior to the boom ‘The anti-drt valve is installed inthe part AQ of the ‘boom section to reduce the boom driting. The valve blocks the oil n the bottom end circuit of the ‘boom eyiinder to prevent the boom from driting ‘due to intemal leakage when the control valve isin the neutral postion. When the boom contr! lever 's pushed forward to lower the boom, the al from the port 3 of the pilot valve (RH) flows to the ports Pos! and Pb8" to open the check valve, so thatthe return ol can flow back tothe hydraulic ol tan section, Non-deviation Travel 2 ‘When the bucket is operated while traveling, the spools of travel and bucket sections are moves to block the pilot ol passage, and then the inlet section spool Is moved, The bil discharged from the pump P1 and that from the pump 2 are led tothe travel sections and the bucket secton, so that the bucket operation while traveling does not cause any deviation, Non-Deviation Travel 1 When the arm and the boom are simultaneously or individually operated While the machine is traveling, the all rom the pot vave flows to the port ba? andior b8' to move the respective spools. The oll from the gear pump P3 is divided atthe parale-iow divider and flows to the arm andlor boom sections through the parallel passage. Consequenty, even when the oll rom the piston pumps P1 and P2 flows only to the left and right travel sections, respectively, in the most upstream for the pumps P' and P2, the arm and the boom can be operated. In other words, the machine can travel with no deviation even when the conto levers are moved while the machine is traveling, ‘Combined Oil Flow for Boom Up Operation When the boom is operated, the oil from the port 1 Cf the pilot valve (RH) flows to the port a8 of the boom section and the port a8 of the parallel-iow divider to move their spools. The oll rom the gear pump P3 lows through the paraleliow divider ‘and parallel passage to the boom section and ‘combines with the al from the piston pump P2. 618 As70608 Note : The 2svay valve in the schematic shows the SAE lever patter position5. HYDRAULIC SYSTEM 5-2 Hydraulic Circuit Schematic Applicable model : VIO45-S, VIO4S-SB, VIOSS-5, VIOSS.B ote gu 501 sao, os. 550 nn SE SN Shs ng ater Vls-8 SW sae Se after 3 ete’ SN S00 and ator Vos.8 SI StH an ater [eae nat a Tet nog ee Rell vale set pressure (PS! (MPa ne] OES VOSS ViO85.38 i083 58, 1 [21930047 | 2133.0(147) 2 | sizsa ere) | 35500245) 3 | a5s0.0;@45) | 081.6275) 4 [35800 (265) | 3901.6027.5) 5 | sss00@e5) | 30816075) | sss00 85) | seet6@7s) 7 @ 2 31284 @1.6) | 35500245) si2e4 a6) | 35500 (245) (3550.0 (24.5) 3981.6 (27.5) 0] 38800 248) | 268: (20403) Tr] sss00;@45) | soar6¢ers) 2 | ass00 45) | s8t6 (75) “| rea rey | a1204 @16) Ta] size ere) | s1284 216) 15] e888 (09) | 500809) ve] _3ou7y | 23,0107) 521 As706085. HYDRAULIC SYSTEM 5:3 Circuit Operation 5-3-1 Boom oom ey 1) Boom “Up” (1) Pilot oil flow When the boom control lever is pulled back to raise the ‘boom, the oil from the plot pump P4 flows through the cut-off valve and the port 1 of the pilot valve (RH) to the port Rb of the control valve and the port a8" ofthe parallel-fiow divider through the port a8" and the boom section to move their spools. @) Oilfow from hydraulic pump ‘The oll discharged from the piston pump P1 flows to the ‘boom section through the port Pt of the inlet section, \while the ol discharged from the gear pump P3 flows to the boom section through the port P3 ofthe paralleL-Now divider and the parallel passage, and combines with the cil from the piston pump Pt. Then the combined oi ‘opens the check valve ofthe antici valve in the boom amyiave section and flows through the port A@ to A8 of the boom cylinder to extend its cylinder rod, raising the boom. The return ol rom B8 ofthe boom cylinder fows back to the hhydraulic oll tank through the port B8 of the boom section, the ports Tt and 72 of the control valve and the oil cooler, 2) Boom "Down" (1) Pilt oil ow \When the boom conto! lever is pushed forward to lower, the boom, the ol from the plat pump P4 flows to the port 1" of the anti-drift valve through the cutoff valve and the port 3 ofthe pilot vaive (RH) and flows to the port RF fof the control valve to move its spool. The pilot oll also presses the piston of the ant-drit valve to open tt ‘check valve @) Oilflow from hydraulic purnp fae ‘The oil discharged from the piston pump P1 flows through the port Pt of the inlet section tothe boom section, In this operation, the oil lows inthe opposite direction to the ol fow in the Boom Up operation with regard Resanictnk to the boom cylinder. 4 Fon cot ve x \ : enjne eae cosmo es/L/L \ abe Pot pump Pa : Psion pump Pt suction ter Gaermaz sar As706085. HYDRAULIC SYSTEM Boom yinor lt vave (RH lot ave ys pump 4) Hyaraute tan ‘Suetont Cont vabe Asro608 a25. HYDRAULIC SYSTEM 5-3-2 Arm 4) Arm “Retract” (1) Pilot oil flow When the arm conto! lever is pulled back to retract the arm, the al from the pilat pump P4 flows through the cut- off valve and the por of the plot valve (LH) to the port Lp of the control valve, then flows to the paralleLfow divider and the arm sections to move their spooks. @) Oilfow from hydraulic pump ‘The oil from the piston pump P2 flows through the port 2 of the inlet section to the arm section. The oil from the gear pump P3 flows through the port P3 ofthe paral- lebfiow divider and the parallel passage to the arm section and combines with the oll rom the piston pump P2. ‘The combined ol flows through the port A3 ofthe control valve to-A3 of the arm cylinder to extend its cylinder rod. ‘The return oil from B3 of the arm cylinder flows back to the hydraulic ol tank through the port B3 ofthe arm section, the ports T1 and T2 of the control valve and the oil cooler. 2) Arm “Extend” (1) Pilot oil flow When the arm control lever is pushed forward to extend the arm, the ol from the plat pump P4 flows through the cut-off valve and the port 3 ofthe pilot valve (LH) to the arm section through the port Lf of the control valve to ‘move is spool @) Oilfow from hydraulic pump “The oil from the piston pump P2 flows through the port 2 of the inlet section to the arm section. The oil from the gear pump P3 flows through the port P3 ofthe parallelfiow divider and the parallel passage to the arm section and combines with the oll from the port P2. The ‘contol aie ‘combined oil flows in the opposite direction tothe oll flow Accumulate, Inthe arm retract operation with regard to the arm cylinder. | Resanictnk cat ve, i Engne Bross vive (ea pun P3, eu fer Pilot pump Pa Psion pump Pt suction ter Paap Ps 522 As70608 Blade plot vive i 3 : i i?5. HYDRAULIC SYSTEM 504 4706085. HYDRAULIC SYSTEM 5-33 Bucket 1) Bucket “Curt” (1) Pilot oi flow When the bucket control lever is moved to the left to curl the bucket, the ol from the pilot pump P4 flows through the cutoff vaive, the port 2 ofthe pilot valve (RH) and the port RI of the control valve to the bucket section to ‘move its spool @) Oilfow from hydraulic pump ‘The oil from the piston pump P1 flows through the port 1 ofthe init section tothe bucket section, the port A10 ‘of the contol valve and tothe A10 ofthe bucket cylinder to extend its cylinder rod. ‘The return oll rom B10 of the bucket cylinder flows back to the hydraulic oll tank through the port B10 of the bucket section, the ports T1 and 72 of the contro valve ‘and the oil cooler. 2) Bucket "Dump" (1) Pitt oi flow When the bucket control lever is moved to the right to dump the bucket, the oil from the pilot pump PA flows through the cutoff valve, the port 4 of the pilot valve (RH) and the port Rr of the control valve to the bucket section to move ils spool @) Oil fow from hydraulic pump ‘The oil lows inthe opposite direction to the cl flow inthe ‘Bucket Curt operation with regard tothe bucket cylinder. sas ocumulats, Asro608 Resanictnk aan \ \gvsassvave (ea pun P3, eu fer Pilot pump Pa Psion pump Pt suction ter Paap Ps5. HYDRAULIC SYSTEM color org lever or the ot sw 2y@08) Sig. ae SPM (Unin) o> + u. Ta 4) Ol Flow from Hydraulic Pump J ‘Tum the knob on the PTO. relum selector valve to select single or double acting ofthe P.O. Boake acing Sings acing Selector vas 2) Single Acting PTO. When the left postion of the lever switch or the foot switch is pressed, the solenoid of the PLO. solenoid \ valve SOL b is exted to move its spool, The oll rom the Pe.Olove switch pilot pump P4 flows through the port B1 of the cut-off valve, and the port B ofthe P.O. solenoid valve to the ‘ort b4 ofthe PT.O. section to move its spool, Ol Flow from Hydraulic Pump ‘The oll rom the piston pump P2 flows to the P.O. section through the port P2 ofthe inlet section. The ol from the gear pump P3 flows through the parallelfiow divider section and the parallel ol passage to the PT.O. section 7 ‘and is combined with the oll from the piston pump P2. fi f the remaining returns through the port Aé of the P.O. section and the port Tt or T2 and the oil cooler to the “The combined oil ows tothe port B4 of the P.T.O. sec- ‘ick coupe ender tion =a f ony ae ‘Some retum oll directly ows back to the reservoir and ee 3) Double Acting P.T.0. When the left position ofthe lever switch is pressed, oll flow is the same as that when the single acting P.O. is selected When the right postion of the lever switch is pressed, the solenoid of the P.O. solenoid valve SOL a is exited to move ils spool. The ol fom the pilot pump PA flows through the port A ofthe P-T.O. solenaid valve to the port ‘a of the PT.O, section to move its spool Cl Flow from Hydraulic Pump When the right postion ofthe lever switch is pressed, oll flows inthe opposite direction to that when the let position is pressed socmmieee 7 Ot estar - fam Ay cto vate iL othe Ber : \ \ evasive Plot purp Pa Piston pure Pt ct tr S027 As706085. HYDRAULIC SYSTEM 5228 4706085. HYDRAULIC SYSTEM 5-315 Quick Coupler “The quick coupler is operated by turing the control ‘switch fo the mounting or dismounting position il Flow from Hydraulic Pump 4) Control Switch in Mounting Position ‘The oil rom the pilot pump P4 flows through the port C1 of the cut-off valve and the operate check valve to the bottom side of the quick coupler cylinder to extend its 7 = . oars 7 auiek coup evinder ‘The return oil flows through the operate check valve and (Ses O 35-86) $ 2 control suteh Dlsmovatiog Postion ae The ot rome pet pe Pets tne ie Pot C2 sro nininas apart check vv owt rds of euch ais ‘coupler cylinder, so thatthe oylinder rod is retracted, ae ‘The retum oil flows through the operate check valve and Re $ the port C1 of the cutoff valve to the suction circuit of #F + the plot pump P4, Psa pInE PZ a 5229 4706085. HYDRAULIC SYSTEM 5220 4706085. HYDRAULIC SYSTEM 5-4 Pressure Adjustment 5-4-1 Relief Valves. 1) Conditions (1) Engine : rated speed @) Hydraulic oi temperature : 122 to 140 °F (60 to 60°C) (@ Pressure gauge capacity : 5000 to 6000 PSI (35 to 40 MPa) 2) Relief Valve Specifications [Unit PSI (MPa) at GPM (Linin] Set reste vee um TOES ORES vosses roses i Ron pump PT | Hea re) 8O SOY | BS easy aLE TY systems vave [RZ ton purp P2 | 518-4 (21.8) t80(30) | e860 (48) =t80 30) i GearpurpPS | 9129. (16) a6 (eo) | 3655 OTR} aTEO OT Boor (ed end) FiatorponpPt | Beebo mes aT) | SOHT THATS) com Getomenay _[ewtnpunper | asssoaceyarray) | WSR TST [a od oa Fan pp Pe | SOAS ATI | STO ET Sata lara oh itn up Pa | esas oaasyatt 3s) | 368167 =) a17 3) Circuit reliet valve eet (rod end) [Piston pump P1 3865.0 (24.5) at 1.3(5) | 3981.6 (27.5) at 1.3 (5) [Bucket (botom end) Piston pump Pt 3555.0 (248) at 13 (8) 39618 275) at 1315) [Boom swing rod end) Piston pump P2 3555.0 (248) at 13 (8) 30818 275) 318) [Boom suing botiom end) Piston pump P2 355500 (248) at 13 (6) 30816 27 5)at 1315) Blade rod end) [Gear pump PS 213500147) at 105 40) 2is90 (147) at 105 40) 3) Measuring Points (1) Open the bonnet L4 @ Remove the plugs (BSPT 1/8) 2 and install the oil pressure gauge. TF VIOASS GIN S050T to SDS, VIOSE-S GIN 60507 to 60800 “2 ViO85-5 SIN 50592 and above, VIO55-5 SIN 50801 and above 549 ‘4706085. HYDRAULIC SYSTEM 4) Adjustment Procedure (1) Remove step 4 @) Use hex bar wrench through the holes in the crced area to adjust pressure forthe relief valves near | the oo. 542 4706085. HYDRAULIC SYSTEM @ To check the pressure of he system relief valve Rt (or the piston pump P1) in the control valve, retract the bucket cylinder to its stroke end, hold the lever and read the gauge. Adjust the pressure ifnecessary. (@ To check the pressure of the system relief valve R2 (for the piston pump P2), retract the arm cylinder to its stroke end, hold the ever and read the gauge. Adjust the pressure if necessary (©) To check the pressure of the system relief valve R3 (for the gear pump P3), extend the blade cylinder to its stroke end, hold the lever and read the gauge. Adjust the pressure if necessary System reef valve Rate vate) att vane ea) \\ rattan (© To adjust the pressure of each circuit relief valve, extend or retract the cylinder to its stroke end, hold the lever and read the gauge. Whether the pressure ofthe circuit relief valve is lower than that ofthe system relief valve can be read on the gauge. Increase the pressure of the system relief valve and that ofthe circuit relief valve by turns, and lock the adjust ‘screw when the specified pressure of the circuit relief valve is obtained. Then lower the pressure ofthe system relief valve tothe specified pressure and lock the adjust screw. Circuito valve Boom oyindr (a soon gine baton) Sins Bechler od) oes ancora’ J \ Metts ‘Am eylderbotomy —_/ ‘sing ein (tom) 7 '5) Pressure Change by One Turn of Adjust Screw Pressure charge Number fast Taxes ore PSI iPa) seen tne ee Sytem eet va a 1740 (12.0) " 14471196) Creu et vave 543 4706085. HYDRAULIC SYSTEM 5-4-2 Swing Brake Valve <— 1 contons {) Erone ted spes (2) Hydraulic oil temperature : 122 to 140 “F (50 to 60°C) ©) Presi gig taacty S000 6200 SI @510 40 MS) fetal (Sars 3180 016M) 2) Measuring Procedure (1) Open the bonnet L4 @) Remove the plug (BSPT 1/8) 2 to install the pressure gauge. (@) Fixthe upper structure and mave the swing ever tothe right and the lef, hold the lever with relief pressure applied and read the gauge. 3) Adjustment Procedure (Relief Valve Replacement Procedure) Since the relief valve is a fixed-pressure type, replace the relief valve assembly with a new one i the relief pressure needs to be adjusted (1) Remove the step 4 (2) Remove the relie valve assembly 4 from the brake valve 8 Tightening torque for reef valve 50 t0 128.0 RIbF(127 §to168.7 Nm) Swing meter 544 4706085. HYDRAULIC SYSTEM 5-4-3 Cut-Off Valve 41) Conditions (1) Engine : rated speed @) Hydraulic oll temperature : 122 to 140 °F (60 to 60°C) @ Pressure gauge capacity : 1500 PSI (10 MPa) @) Set pressure : 569 PSI (3. 9MPa) 2) Measurement Procedure (1) Open the engine hood A 4 (@) Remove the plug (BSPT 1/8) 2for the hose connector and instal the pressure gauge. @) Move the lock lever to the "UNLOCK" position, and read the gauge. 3) Pressure Adjustment Procedure (1) Remove the gil assembly 1 (@) Remove the plug (with O-ring) 2. @) Increase or decrease the number of shims 3 to adjust the pressure tothe specified value, Prossure change with a shim Pressure change | Tightening torque forlock nut 26.410 356 PSI (02t00.25 mPa) 21.7 bf (294 Nm) 545 470608

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