Yanmar SMSV15 - SV17

CONTENTS
CHAPTER 1
GENERAL CAUTIONS FOR MAINTENANCE WORK
1-1 Correct Work ...........................................................................................................................................................................1-1
1-2 Safety Precautions ..................................................................................................................................................................1-1
1-3 Preparations ............................................................................................................................................................................1-1
1-4 Cautions for Disassembly and Reassembly............................................................................................................................1-1
1-5 Cautions for Removal and Installation of Hydraulic Equipment ..............................................................................................1-2
1-6 Cautions for Removal and Installation of Hydraulic Piping......................................................................................................1-2
1-7 Cautions for Handling Seals....................................................................................................................................................1-3
1-8 Correct Installation of Hydraulic Hose .....................................................................................................................................1-3
1-9 Specifications of Hydraulic Hose.............................................................................................................................................1-6
1-10 Air Release of Hydraulic Equipment....................................................................................................................................1-11
CHAPTER 2
TECHNICAL DATA
2-1 Specifications ...................................................................................................................................................................... 2-1-1
2-2 Outline Drawing and Working Area ..................................................................................................................................... 2-2-1
2-3 Weight List of Main Parts .................................................................................................................................................... 2-3-1
2-4 Lifting Capacity List ............................................................................................................................................................. 2-4-1
CHAPTER 3
SERVICE STANDARDS
3-1 Machine Performance ......................................................................................................................................................... 3-1-1
3-2 Engine ................................................................................................................................................................................. 3-2-1
3-3 Undercarriage ..................................................................................................................................................................... 3-3-1
3-3-1 Rubber Crawler Specifications ................................................................................................................................... 3-3-1
3-4 Controls ............................................................................................................................................................................... 3-4-1
3-5 Hydraulic Equipment ........................................................................................................................................................... 3-5-1
3-5-1 Hydraulic Cylinders .................................................................................................................................................... 3-5-1
3-6 Implement ........................................................................................................................................................................... 3-6-1
3-6-1 Front Attachments ...................................................................................................................................................... 3-6-1
3-6-2 Blade Moving Device.................................................................................................................................................. 3-6-2
3-6-3 Bucket Teeth .............................................................................................................................................................. 3-6-2
3-7 List of Tightening Torque .................................................................................................................................................... 3-7-1
3-7-1 Machine...................................................................................................................................................................... 3-7-1
3-7-2 Engine ........................................................................................................................................................................ 3-7-3
3-7-3 Tightening Torque for General Bolts and Nuts........................................................................................................... 3-7-3
CHAPTER 4
ENGINE
4-1 General ............................................................................................................................................................................... 4-1-1
4-1-1 Engine External Views ............................................................................................................................................... 4-1-1
4-1-2 Exhaust Gas Emission Regulation ............................................................................................................................. 4-1-2
4-2 Measurement, Inspection and Adjustment .......................................................................................................................... 4-2-1
4-2-1 Measuring the Compression Pressure ....................................................................................................................... 4-2-1
4-2-2 Adjusting the Valve Clearance ................................................................................................................................... 4-2-2
4-2-3 Checking the V-belt Tension ...................................................................................................................................... 4-2-3
4-2-4 Checking the Fuel Injection Valve .............................................................................................................................. 4-2-3
4-2-5 Checking and adjusting the Fuel Injection Timing ...................................................................................................... 4-2-5
4-2-6 Adjusting the Maximum (or Minimum) Idling Speed ................................................................................................... 4-2-7
4-2-7 Checking the Cooling Water System and Radiator for Water Leakage ..................................................................... 4-2-7
4-2-8 Checking the Sensors ................................................................................................................................................ 4-2-8
4-3 Measurement Procedure, Service Data and Corrective Action........................................................................................... 4-3-1
4-3-1 Cylinder Head............................................................................................................................................................. 4-3-1
4-3-2 Cylinder Block ............................................................................................................................................................ 4-3-6
4-3-3 Valve Rocker Arm ...................................................................................................................................................... 4-3-8
4-3-4 Piston and Piston Rings ........................................................................................................................................... 4-3-10
4-3-5 Connecting Rod........................................................................................................................................................ 4-3-13
4-3-6 Cam Shaft ................................................................................................................................................................ 4-3-16
4-3-7 Crank Shaft .............................................................................................................................................................. 4-3-17
4-3-8 Gears........................................................................................................................................................................ 4-3-20
4-3-9 Trochoid Pump ......................................................................................................................................................... 4-3-21
4-4 Precautions for Reassembly ............................................................................................................................................... 4-4-1
4-5 Fuel Injection Pump / Governor........................................................................................................................................... 4-5-1
4-5-1 Introduction................................................................................................................................................................. 4-5-1
4-5-2 Fuel Injection Pump.................................................................................................................................................... 4-5-1
CHAPTER 6
HYDRAULIC EQUIPMENT
6-1 Hydraulic Pump ................................................................................................................................................................... 6-1-1
6-1-1 SV15........................................................................................................................................................................... 6-1-1
6-1-2 SV17(EX) ................................................................................................................................................................. 6-1-16
6-2 Control Valve...................................................................................................................................................................... 6-2-1
6-3 Pilot Valve ........................................................................................................................................................................... 6-3-1
6-4 Swing Motor ........................................................................................................................................................................ 6-4-1
6-5 Travel Motor ........................................................................................................................................................................ 6-5-1
6-5-1 SV15........................................................................................................................................................................... 6-5-1
6-5-2 SV17(EX) ................................................................................................................................................................. 6-5-24
CHAPTER 7
ADJUSTMENT AND REPAIR
7-1 Electric Equipment of Machine............................................................................................................................................ 7-1-1
7-1-1 Parts Layout of Electrical Equipment ......................................................................................................................... 7-1-1
7-1-2 Monitor and Alarm Systems ....................................................................................................................................... 7-1-2
7-1-3 Wiring Diagram........................................................................................................................................................... 7-1-5
7-1-4 Circuit Description of Engine Start and Stop, and Battery Charging .......................................................................... 7-1-6
7-1-5 Removal and Reinstallation of Engine ....................................................................................................................... 7-1-8
7-1-6 Removal and Reinstallation of Starter Motor............................................................................................................ 7-1-15
7-1-7 Removal and Reinstallation of Fuel Injection Pump ................................................................................................. 7-1-16
7-1-8 Removal and Reinstallation of Fuel Tank................................................................................................................. 7-1-18
7-1-9 Removal and Reinstallation of Radiator ................................................................................................................... 7-1-21
7-2 Undercarriage ..................................................................................................................................................................... 7-2-1
7-2-1 Outline ........................................................................................................................................................................ 7-2-1
7-2-2 Points of Reassembly................................................................................................................................................. 7-2-2
7-2-3 Crawler Tension Adjustment Procedure..................................................................................................................... 7-2-3
7-2-4 Removal and Reinstallation of Crawler ...................................................................................................................... 7-2-4
7-2-5 Disassembly and Reassembly of Idler ....................................................................................................................... 7-2-5
7-2-6 Disassembly and Reassembly of Track Roller ........................................................................................................... 7-2-7
7-2-7 Removal and Reinstallation of Track Gauge Change Cylinder .................................................................................. 7-2-9
7-3 Controls ............................................................................................................................................................................... 7-3-1
7-3-1 Control Train............................................................................................................................................................... 7-3-1
7-3-2 Mechanical Control Linkage ....................................................................................................................................... 7-3-2
7-3-3 Adjustment of Travel Levers....................................................................................................................................... 7-3-4
7-3-4 Adjustment of Boom Swing Pedal .............................................................................................................................. 7-3-5
7-3-5 Adjustment of Blade Lever (Track Gauge Change Lever) ......................................................................................... 7-3-5
7-3-6 Adjustment of Lock Lever Switch ............................................................................................................................... 7-3-6
7-3-7 Adjustment of Accelerator Lever ................................................................................................................................ 7-3-7
7-3-8 Adjustment of P.T.O. Pedal........................................................................................................................................ 7-3-8
7-4 Swing Bearing ..................................................................................................................................................................... 7-4-1
7-5 Hydraulic Equipment ........................................................................................................................................................... 7-5-1
7-5-1 Removal and Reinstallation of Hydraulic Pump ......................................................................................................... 7-5-1
7-5-2 Removal and Reinstallation of Control Valve ............................................................................................................. 7-5-4
7-5-3 Removal and Reinstallation of Swing Motor............................................................................................................... 7-5-7
7-5-4 Removal and Reinstallation of Swivel Joint.............................................................................................................. 7-5-10
7-5-5 Disassembly and Reassembly of Swivel Joint ......................................................................................................... 7-5-13
7-5-6 Disassembly and Reassembly of Hydraulic Cylinders ............................................................................................. 7-5-16
7-5-7 Hydraulic Oil Tank .................................................................................................................................................... 7-5-20
7-5-8 Piping Layout............................................................................................................................................................ 7-5-24
7-6 Implement ........................................................................................................................................................................... 7-6-1
7-6-1 Removal and Reinstallation of Implement.................................................................................................................. 7-6-1
CHAPTER 8
PERIODIC INSPECTION AND SERVICING
8-1 List of Periodic Inspection and Servicing.................................................................................................................................8-1
CHAPTER 9
FUEL, LUBE OIL AND GREASE RECOMMENDED
9. Fuel, Lube Oil and Grease Recommended ...............................................................................................................................9-1
CHAPTER 10
TROUBLESHOOTING
10-1 Non-Breakdowns............................................................................................................................................................. 10-1-1
10-1-1 Natural Release of Bucket...................................................................................................................................... 10-1-1
10-1-2 Discontinuous Arm Movement ............................................................................................................................... 10-1-1
10-1-3 Drifting of Upperstructure on Quick Travel Operation ............................................................................................ 10-1-2
10-1-4 Thermal Shock of Travel Motor .............................................................................................................................. 10-1-3
10-1-5 Time Lag on Travel Speed Switching..................................................................................................................... 10-1-4
10-1-6 Fluctuation in Oil Level of Hydraulic Oil Tank Due to Temperature Change.......................................................... 10-1-5
10-2 Troubleshooting .............................................................................................................................................................. 10-2-1
10-2-1 Machine and Engine............................................................................................................................................... 10-2-1
10-2-2 Electrical Equipment on Panel ............................................................................................................................. 10-2-22
CHAPTER 11
REFERENCE DATA
11-1 Specifications for Attachment..............................................................................................................................................11-1
CHAPTER 1
GENERAL CAUTIONS FOR MAINTENANCE WORK
1-1 Correct Work............................................................................................1-1

1-2 Safety Precautions...................................................................................1-1
1-3 Preparations ............................................................................................1-1
1-4 Cautions for Disassembly and Reassembly ............................................1-1
1-5 Cautions for Removal and Installation of Hydraulic Equipment ...............1-2
1-6 Cautions for Removal and Installation of Hydraulic Piping ......................1-2
1-7 Cautions for Handling Seals ....................................................................1-3
1-8 Correct Installation of Hydraulic Hose .....................................................1-3
1-9 Specifications of Hydraulic Hose .............................................................1-6
1-10 Air Release of Hydraulic Equipment ...................................................1-11
1. GENERAL CAUTIONS FOR
MAINTENANCE WORK
1. General Cautions for Maintenance Work
1-1 Correct Work
Correct work means the quickest possible completion of according to the correct procedures and the specified stan-
dards.
It is important when conducting certain operations always to bear in mind the equipment, tools, gauges, materials, oil
and grease, etc. that you must have ready, as well as items to be checked, adjusted, or disassembled, and cautions
to watch out for.
1-2 Safety Precautions
(1) Never attempt servicing while engine is running or immediately after stopping operation.
(2) Wear work cloths, safety shoes and helmet.
(3) Check the equipment and tools before use. Especially, be sure to check the crane, lifting equipment and tools.
(4) When working together with other persons, allocate everyone's share of job, arrange the signals and act in con-
cert with the other persons.
(5) The operation of the crane and slinging work must be performed by qualified persons.
(6) Do not enter or pass under the raised load.
(7) Lift and support the massive parts by crane before removing the installation bolts.
(8) Disconnect cables from battery before repairing the electric system.
(9) Remove the battery when welding the machine.
1-3 Preparations
(1) Check the service record of the machine. (That is, check how many months or hours the machine has been
used since the preceding overhaul, what was the trouble then and what parts were replaced.)
(2) Have all servicing tools ready, i.e., tools, measuring devices (which have received periodic maintenance), con-
tainers, oil & grease, etc.
(3) Have the service literature (operation manual, parts catalog, etc.) ready.
1-4 Cautions for Disassembly and Reassembly
(1) Clean the machine before disassembly.

(2) Check and record the condition of the machine before disassembly :
• Model, machine number, operation hours
• Reasons for repair, history of repair
• Contamination of filters
• Fuel and oil condition
• Damage to parts, etc.
(3) Place alignment marks on the necessary parts to facilitate reassembly.
(4) Clean all the removed parts and new replacement parts and put them in order.
(5) Use new seals, split pins, etc. for reassembly.
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MAINTENANCE WORK
(6) Keep the parts apt to be damaged by water or oil apart from the oily or wet parts.
e.g.: Electrical parts, rubber parts, V-belts, etc.
(7) Use the jig for press-fitting the bearings, bushes and oil seals. When Sealing tape
using a hammer, use a pad block.
(8) Clean the joint surface of all parts and keep them free from dust.
(9) Wind the sealing tape securely, leaving a space of one or two
threads from the tip of the male screw. The tape should have an
overlap of about 10 mm.
One and a half threads
1-5 Cautions for Removal and Installation of Hydraulic Equipment
(1) Check that the hydraulic oil temperature is low enough.

(2) Release air from the hydraulic tank to prevent the hydraulic oil from flowing out.
(3) Be sure to plug open the ends of hydraulic components to prevent dust from entering.
(4) Be sure to wipe hydraulic oil from the hydraulic components so that it will not be mistaken for an oil leak.
(5) Take care not to damage the plating on the cylinder rod.
(6) Remove or install cylinders with rods fully retracted.
(7) Be sure to release air after installing the hydraulic cylinders.
• Run the engine at a low speed. Extend and retract the cylinders 4 to 5 times up to 50 to 100 mm from the end
of the stroke. Then, fully extend and retract.
(8) Be sure to pressurize the hydraulic tank after installing the hydraulic components (in the case of the sealed
hydraulic tank). Otherwise, hydraulic pumps might suffer cavitation and their life will be shortened.
• To pressurize the hydraulic tank, fully extend each cylinder and tighten the oil filter port plugs.
1-6 Cautions for Removal and Installation of Hydraulic Piping
(1) Installation of hydraulic hose

Take care not to twist the hoses. (Judge whether or not the hose is twisted by Metal fitting
the hose mark.) For hoses with a metal fitting, use two wrenches to prevent
twisting.
Pipe or
Use one to fix the hose, and the other to tighten the fitting to the specified Hose connector
tightening torque. Carefully check that the hoses do not come in contact after Fixed side
tightening. If any contact is found, correct it or use tubes.
(2) When installing hoses, first tighten to the specified torque and then loosen
them a little. Then retighten to the specified torque.
• Break in the installed parts before tightening (except those using seal tapes).
(3) When installing pipes, turn the nuts more 1/4 to 1/2 turn after they reach the sharp torque rise point.
(4) When installing or removing hoses, use two wrenches, one to fasten the hose and the other to tighten or loosen
the hose to prevent twisting.
(5) Check for oil leakage by applying max. pressure 5 to 6 times after attaching hydraulic hoses or pipes.
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MAINTENANCE WORK
1-7 Cautions for Handling Seals
(1) Clean out grooves of O-rings. Remove burrs or dust if any.
Burrs
Dust
(2) Take care not to twist O-rings. Correct by your finger if it is twisted.
(3) Take care not to damage seals when inserting.
(4) Handling of floating seals :
• Completely wipe off all the oil from the O-ring and housing after detaching the floating seals.
• Before installing, apply a little gear oil to the matching face of the housing.
• Turn the seals two or three times after installation to break them in.
(5) Apply grease to the lip of the oil seals to prevent wear.
Grease
1-8 Correct Installation of Hydraulic Hose
In order to mount the hydraulic hose most effectively and economically, observe the following cautions.
(1) When a hose is used at the minimum bending radius, use elbows to avoid sharp bending.
Not good Good
(2) To prevent twisting, the hose should be bent in the same direction as it moves.
Not good Good
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MAINTENANCE WORK
(3) When the hose is pressurized, the hose length varies slightly at the bend. Allow this change to occur and do not
try to fasten the bend.
Not pressurized
When pressurized
(4) It is necessary for the hose to have ample slackness for elongation and contraction, because its length will
change by +2 % to -4 % when used at high pressure.
Not good
Good
(5) Use the proper adapters, not pipes, in order to reduce the number and length of joints and improve the external
appearance.
Not good Good
(6) Use an elbow to prevent excessive twisting or bending of the hose.
Not good Good
(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.
Not good Good
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MAINTENANCE WORK
(8) The hose should be slightly longer than is absolutely necessary. The extra allows smoother movement of the
hose and prevents sharp bending.
Not good Good
(9) When a bent hose is attached to two different planes, fix as shown in the diagram to prevent twisting.
Not good Good
(10) Use the marking on the hose as a guide to prevent twisting during installation.
Twisting of metal fitting with union nuts should be with a wrench on the hexagonal parts.
Hose mark Hose mark

Not good Good
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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
Yanmar Industrial Standards (YIS) and special parts for the respective models. Specifications of the hydraulic hoses
can be known by the code number or part descriptions as explained below. (For the parts number, please refer to our
Parts Catalog.)
(1) Yanmar Standard Type

The part code consists of 11-digit numbers :
Hose material code Fittings combination code

Hose type code Nominal length code
Nominal dia. code
Description Hose material Type of hose Hose dia. Hose length Combination
of fittings
Part code No.
Hose material
02 1
1 (SAE J517,100R1) 3
Rubber hose
2320 03 Unit : cm 4
(High pressure type) 5
2 (SAE J517,100R2)
04 6
02 1
1 (SAE J517,100R7) 03
Plastic hose 4
2327 04
(High pressure type) 5
03
2 (SAE J517,100R7) 7
04
02
03 1
04
Rubber hose 05
2325 1 (SAE J517,100R6) 4
(Medium pressure type) 06
10
12 5
14
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MAINTENANCE WORK
1) Type of Hose (Hose Dia. & Recommended Working Pressure)
Working
Inner dia. Outer dia.
Type of hose Hose dia. pressure
[in. (mm)] [in. (mm)]
[PSI (MPa)]
02 0.25 (6.3) 0.53 (13.5) 2489 (17.2)
1
03 0.37 (9.5) 0.69 (17.5) 1991 (13.7)
(SAE J517, 100R1)
04 0.50 (12.7) 0.81 (20.6) 1564 (10.8)
02 0.25 (6.3) 0.59 (15.1) 4266 (29.4)
2
03 0.37 (9.5) 0.75 (19.1) 3484 (24.0)
(SAE J517,100R7)
04 0.50 (12.7) 0.87 (22.2) 2986 (20.6)
02 0.25 (6.3) 0.49 (12.5) 2986 (20.6)
1
03 0.37 (9.5) 0.65 (16.6) 2489 (17.2)
(SAE J517, 100R6)
04 0.50 (12.7) 0.81 (20.7) 1991 (13.7)
2 03 0.37 (9.5) 0.68 (17.2) 2986 (20.6)
(SAE J517,100R7) 04 0.50 (12.7) 0.84 (21.4) 2986 (20.6)
02 0.25 (6.3) 0.50 (12.7) 427 (2.9)
03 0.37 (9.5) 0.63 (15.9) 427 (2.9)
04 0.50 (12.7) 0.78 (19.8) 427 (2.9)
1 05 0.63 (15.9) 0.91 (23.0) 427 (2.9)
(SAE J517,100R6) 06 0.75 (19.0) 1.25 (31.8) 427 (2.9)
10 1.00 (25.4) 1.50 (38.1) 427 (2.9)
12 1.25 (31.8) 1.75 (44.5) 427 (2.9)
14 1.50 (38.1) 2.04 (51.9) 427 (2.9)
2) Total Length of Hose [Unit : in. (cm)]
L L L
3 digit indication in cm. (Example) Nominal length 065 : Full length 25.6 in. (65 cm)
3) Hose Dia. (Unit : inch)
02....1/4'' 05....5/8'' 12....1 1/4''

03....3/8'' 06....3/4'' 14....1 1/2''
04....1/2'' 10....1
Note :
Please note that these code numbers are different from those for the equivalent diameters for special parts on the
next page.
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MAINTENANCE WORK
4) Combination of Fitting
Fitting 60 degrees bent type.

Code No. R(PT) 60
type Taper pipe thread Straight pipe thread
A D
R (PT) G (PF) with male 30
1 A·B G(PF) degrees seat
3 A·E
G(PF) Straight pipe thread 45 45 degrees bent type.
G (PF) with male 30 Straight pipe thread
B E
4 B·B degrees seat G (PF) with male 30
30
G(PF) degrees seat
5 B·C
90 90 degrees bent type.
6 B·E Straight pipe thread
C
G (PF) with male 30
7 B·D G(PF) 30 degrees seat
(Example) Part code 2 3 2 0 2 0 3 0 8 5 5
Rubber hose, high pressure type List of pipe threads

SAE J517, 100R2 Symbol Name
Straight pipe
G (PF)
Nominal dia., 3 / 8" thread
Male taper pipe
Hose length, 33.5 in. (85 cm) R (PT)
thread
Straight pipe thread G (PF) with Female taper
Rc (PT)
male 30 degrees seat and 90 degrees bent type. pipe thread
Straight pipe thread G (PF) with
male 30 degrees seat
Note :
All the hoses with fittings other than those listed above are special parts.
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MAINTENANCE WORK
(2) Special Parts
Description ..................... Hose P 2 06 AB 075 W

1 2 3 4 5 6 7 8
8 Other accessories
1 Part name No accessories...Blank
O-ring ....................... 1
2 Hose material 6 Total length 7 Hose protector

Rubber hose ............ G (Unit : cm) Coil spring ............... W
Wear-resistant high Coil tube .................. S
pressure rubber Wire braid ................ B
5 Combination of fitting Tube (Rubber) .......... R
hose ......................... H
Plastic hose ............. P Tube (Vinyl) .............. V
Wear-resistant Fitting type Code Sponge rubber ......... P
R(PT) Hose cover ............... K
plastic hose............... F No protection ..... Blank
Taper pipe A
thread R (PT)
3 Recommended G(PF) Straight pipe

working pressure thread G (PF)
with male 30 B
PSI(Mpa) 30
Over 2986 (20.6) ..................... 1 degrees seat
2489 to 2986 (17.2 to 20.6) ..... 2 90 degrees
1991 to 2489 (13.7 to 17.2) ..... 3 90 bent type.
Straight pipe
1564 to 1991 (10.8 to 13.7) ..... 4 thread G (PF) C
995 to 1564 (6.9 to 10.8) ......... 5 with male 30
427 to 995 (2.9 to 6.9) ............. 6 G(PF) 30 degrees seat
213 to 427 (1.5 to 2.9) ............. 7
Below 213 (1.5) ....................... 8
4 Nominal dia. (inch) Without fitting Y

List of pipe threads
1 / 8" ......................... 02
For the combination of fitting, Symbol Name
3 / 16" ....................... 03
refer to the list on the following G (PF) Straight pipe thread
1 / 4" ......................... 04
page. R (PT) Male taper pipe thread
3 / 8" ......................... 06
1 / 2" ......................... 08 Rc (PT) Female taper pipe thread
5 / 8" ......................... 10
3 / 4" ......................... 12
1" .............................. 16
The example hose, P 2 06 AB 075 W stands for :

2 3 4 5 6 7
2 Material : Plastic
3 Working pressure : 2489 to 2986 PSI (17.2 to 20.6 MPa)
4 Nominal dia. : 3 / 8"
5 Fitting type : Taper pipe thread R (PT) and straight pipe thread G (PF) with male 30 degrees seat.
6 Length : 29.5 in. (75 cm)
7 Hose protector : Coil spring
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MAINTENANCE WORK
5 Combination of fitting
Fitting type Code Fitting type Code

90
R (PT) 90 degrees bent type.
Taper pipe thread R (PT) A UNF thread with female P
UNF 37 degrees seat
37
Straight pipe thread G 60 60 degrees bent type.
G (PF)
(PF) with male 30 B UNF thread with female Q
degrees seat 37 degrees seat
30 UNF
90 degrees bent type.
90 Straight pipe thread G 45 degrees bent type.
45
(PF) with male 30 C UNF thread with female R
degrees seat 37 degrees seat
UNF
G (PF) 30
60 60 degrees bent type. UNF UNF, thread with O-ring

Straight pipe thread G groove
D S
(PF) with male 30
G (PF) degrees seat O-ring

Straight pipe thread G O-ring One-touch fitting (male)
E T
(PF) with male 30
G (PF) degrees seat
G (PF)
Straight pipe thread G
(PF) with male 30 F
30 90
degrees seat
90 degrees elbow straight
pipe thread male 30 V
degrees seat
O-ring flange type G
G (PF)
30
90 90 degrees bent O-ring

flange type H
Eyejoint with O-ring
W
45 degrees bent O-ring O-ring groove groove
45
flange type J
Straight pipe thread with

PF nut
G (PF) Straight pipe thread, jam nut female 30
30
30 female 30 degrees seat K degrees seat X
with O-ring groove
G (PF)

Straight pipe thread G 90 Gauge port
L
(PF) with male 30 90 degrees elbow straight
G (PF) degrees seat G (PF) pipe thread with gauge Z
port plug male 30
NPTF
Taper pipe thread NPTF M degrees seat
30
Without fitting Y
UNF
37
UNF, thread with female Note :
37 degrees seat N
According to the combination of bending or elbow fittings, some
hoses require drawings or original hoses to locally manufacture.
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MAINTENANCE WORK
1-10 Air Release of Hydraulic Equipment
When operating the machine after disassembly or parts replacement of the hydraulic equipment, piping, etc., be
sure to release air from the hydraulic system. This is necessary to prevent seizure and cavitation of the hydraulic
equipment. If the air is left in the hydraulic system, the air is compressed or expanded depending on the load, having
an adverse effect on the smooth operation of the hydraulic equipment and shortening the service life.
1. Air Release of Each Hydraulic Component

Run the engine at medium speed and activate the respective circuits for about 10 to 15 minutes.
2. Air Release of Hydraulic Cylinders

1) Set the Engine Speed at Low Idling Range.
2) Extend and Retract the Cylinder Up to 1.97 to 3.9 in. (50 to 100 mm) from Each Stroke End Slowly 4 or 5
Times.
1.97 to 3.9 in. 1.97 to 3.9 in.

(50 to 100 mm) (50 to 100 mm)
Retraction stroke end Retraction stroke end
Note :
The extension and retraction stroke is up to 1.97 in. (50 mm) from each stroke end for the blade cylinder.
3) Then, Fully Extend and Retract the Cylinder 3 or 4 Times.
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CHAPTER 2
TECHNICAL DATA
2-1 Specifications....................................................................................... 2-1-1

2-2 Outline Drawing and Working Area ..................................................... 2-2-1
2-3 Weight List of Main Parts ..................................................................... 2-3-1
2-4 Lifting Capacity List.............................................................................. 2-4-1
2. TECHNICAL DATA
2. Technical Data
2-1 Specifications
Item Unit SV15 SV17 SV17EX
Main specifications of machine
Dimensions
Overall length (Transportation position) mm 3450 3660 3660
Transportation position mm 2256
Overall height
Cabin Traveling position mm 2256
Overall width Full machine width mm 980 980 to 1320
Transportation position mm 2248
Overall height
Canopy Traveling position mm 2248
Overall width Full machine width (Maximum/Minimum) mm 980 980 to 1320
Tumbler center distance mm 1185
Track gauge (Maximum/Minimum) mm 750 750 to 1090
Minimum ground clearance mm 190
Traveling performance
Low speed (Forward/Reverse) km/hr -
Steel crawler
Travel High speed (Forward/Reverse) km/hr -
speed Rubber Low speed (Forward/Reverse) km/hr 2.0 2.0
crawler High speed (Forward/Reverse) km/hr - 3.5
Climbing ability degrees 30
Permissible water depth limit mm 360
Work performance
Width (Standard) mm 400
Bucket (Standard. JIS heaped capacity) m3 0.04
Number of teeth / Installation method pcs. 3 / bolt
Maximum With blade raised mm 2000 2400
digging
depth With blade on the ground mm 2150 2600
Maximum depth of vertically digging mm 1500 1900
Maximum dumping height mm 2460/2460 2760/2760
Minimum front swing radius (with boom in front) mm 1480/1480 1540/1540
Minimum front swing radius Cabin mm 1290 1340
(at 75 degrees right boom swing) Canopy mm 1290 1340
Rear end swing radius mm 980
Left degrees 40
Cabin
Right degrees 80
Boom swing angle
Left degrees 40
Canopy
Right degrees 80
Bucket kN (kgf) 13.7 (1400) 15.2 (1550)
Maximum digging force
Arm kN (kgf) 7.6 (780) 7.4 (755)
Maximum tractive force (Oil pressure force) (rubber) kN (kgf) 18.7 (1904)
Maximum swing inclination angle (with standard bucket) degrees 20 or more
Swing speed min (rpm)
-1 9.4
Fuel consumption in practical operation L/hr 2.4 2.3
2-1-1 0000604
2. TECHNICAL DATA

Main specifications of machine
Blade
Width¯Height 1320¯235 /
mm 980¯235
(Side open/close) 980¯235
Blade Capacity (Side open/close) m3 0.049 0.066 / 0.049
Lift above ground level mm 240
Digging depth mm 300
Mean contact pressure
Steel Cabin KPa (kgf/cm2) -
crawler Canopy KPa (kgf/cm )2 -
JIS
Rubber Cabin KPa (kgf/cm )2 28.4 (0.29) 30.4 (0.31) 31.3 (0.32)
crawler Canopy KPa (kgf/cm )2 26.5 (0.27) 29.4 (0.30) 30.4 (0.31)
Mass
Cabin kg -
Steel crawler
Operating mass Canopy kg -
(without operator) Rubber Cabin kg 1505 1625 1775
crawler Canopy kg 1405 1525 1675
Cabin kg -
Steel crawler
Canopy kg -
Base machine dry mass
Rubber Cabin kg 1170 1290 1410
crawler Canopy kg 1070 1190 1310
Hydraulic equipment
Hydraulic pump
Drive method Engine → Coupling → Pump (Direct drive)
Type of main pump Gear pump Variable displacement pump
Theoretical discharge volume cc/rev 13 18
Maximum allowable pressure PSI (MPa) -
Control valve
Number of connected valves pcs.
P1 MPa (kgf/cm2) 17.7 (180) 19.6 (200)
System relief set pressure
MPa (kgf/cm )2 -
Boom (at rod end) MPa (kgf/cm )2 22.6 (230)
Boom (at bottom end) MPa (kgf/cm )2 -
Arm (at rod end) MPa (kgf/cm )2 -
Arm (at bottom end) MPa (kgf/cm )2 22.6 (230)
Bucket (at rod end) MPa (kgf/cm )2 -
Circuit relief set pressure
Bucket (at bottom end) MPa (kgf/cm2) 24.5 (250)
Boom swing (at rod end) MPa (kgf/cm2) -
Boom swing (at bottom end) MPa (kgf/cm )2 -
Blade (at rod end) MPa (kgf/cm )2 -
Blade (at bottom end) MPa (kgf/cm )2 -
2-1-2 0000604
2. TECHNICAL DATA

Hydraulic equipment
Cylinder
Stroke mm 415
Inside diameter mm Ø60
Boom Piston rod diameter mm Ø35
Up (Ground → Max.) sec. 2.2
Speed
Down (Max. → Ground) sec. 2.0
Stroke mm 439 453
Arm Piston rod diameter mm Ø35
Full stroke for digging sec. 3.1
Speed
Full stroke for dumping sec. 2.3
Stroke mm 317
Bucket Piston rod diameter mm Ø30
Full stroke for digging sec. 2.2
Speed
Full stroke for dumping sec. 1.5
Stroke mm 125
Blade Piston rod diameter mm Ø35
Up (Ground → Max.) sec. 0.8 0.9
Speed
Down (Max. → Ground) sec. 0.7 0.8
Stroke mm 295
Boom
Piston rod diameter mm Ø35
swing
Full stroke to the right sec. 3.1
Speed
Full stroke to the left sec. 3.1
Stroke mm - 340
Track Inside diameter mm - Ø60

gauge Piston rod diameter mm - Ø35
change Max. track gauge sec. - 3.5
Speed
Min. track gauge sec. - 4.2
Swivel joint
Swivel joint port diameter¯Number inch¯pcs. 1/4¯18 1/4¯22
Motor
Type Orbit motor
Swing Displacement cc/rev 233
motor Type Relief valve (F072-4)
Brake valve
Relief set pressure MPa (kgf/cm2) 10.0 (102) to 11.5 (117)
Type Variable displacement piston motor
Displacement (Low/High) cc/rev 15.8 16.8 / 8.7
Travel Type Counterbalance valve
motor Brake valve
Relief set pressure MPa (kgf/cm2) -
Planetary gear
Type of reduction gear
(with double-reduction mechanism)
2-1-3 0000604
2. TECHNICAL DATA

Hydraulic equipment
Hydraulic oil tank
Tank capacity L 20.5 [tank : 16, others : 4.5]
Type Wire gauze
Suction
Filtration area cm 2 330
filter
Filtration accuracy Meshes 100
Type Cartridge (Paper filter)
Return Filtration area cm2 2200
filter Filtration accuracy μ 10
By-pass valve opening pressure MPa (kgf/cm )2 0.14 (1.5)
Locking device
Lever lock Oil pressure controlled
Boom swing lock Pedal guard
Swing lock Mechanical brake
Swing device
Swing bearing Planetary gear (with reduction mechanism)
Power transmission Swing motor shaft gear → Swing gear
Type of brake Mechanical controlled
Brake mounting position
Undercarriage
Shoe width mm -
Type -
Grouser
Height mm -
Steel
Shoe and link mounting method -
crawler
Link pitch mm -
Number of shoes (One side) pcs. -
Crawler drive method -
Shoe width mm 230
Rubber
Lug height mm 17
crawler
Core metal pitch mm 72
Manner of support -
Carrier
roller Quantity (One side) pcs. -
(Upper Bearing -
roller)
Sealing -
Number of shoe slide plates (One side) pcs. 1
Track Quantity (One side) pcs. 3
roller Bearing Ball bearing
(Lower
roller) Sealing QLF
Quantity (One side) pcs. 1
Idler Bearing Ball bearing
Sealing QLF
Number of Steel crawler pcs. -
sprocket
teeth Rubber crawler pcs. 14
Crawler tension adjustment Grease adjuster
2-1-4 0000604
2. TECHNICAL DATA

Engine
Main specifications
Engine model 3TNV70-XBVA1 3TNV70-XBVA
Vertical type series water-cooled
Type
4 cycle diesel engine
Combustion system Special swirl pre-combustion chamber
Number of cylinders - Bore¯Stroke mm¯mm 3 - 70¯74
Total displacement cc 854
kW/min -1 12.1/2600 9.5/2100
Rated output / engine speed
(PS/rpm) (16.5/2600) (12.9/2100)
N•m/min-1 48.7 to 53.0/1800 47.1 to 51.4/1500
Maximum torque / engine speed
(kgf•m/rpm) (4.97 to 5.41/1800) (4.80 to 5.24/1500)
Specific fuel consumption g/kW (PS)•h 276 (203)
Maximum idling speed min (rpm)
-1 2135 to 2185
Minimum idling speed min (rpm)
-1 1225 to 1275
Engine dry mass (excluding air cleaner and silencer) kg 110
Lubricating method Forced lubrication by trochoid pump
Specific lubricating oil consumption g/kW (PS)•h -
Compression pressure MPa (kgf/cm ) 2 3.2 (33) at 250 rpm
Cylinder head
Open bTDC degrees 7 to 17
Intake valve
Close aBDC degrees 35 to 45
Open bBDC degrees 35 to 45
Exhaust valve
Close aTDC degrees 7 to 17
Intake valve clearance (Cold engine) mm 0.2
Exhaust valve clearance (Cold engine) mm 0.2
Intake valve seat angle degrees 120
Exhaust valve seat angle degrees 90
Piston
Ring shape Keystone
First compression ring
Ring quantity pcs. 3
Ring shape Taper face
Second compression ring
Ring shape Bevel cutter (with coil expander)
Oil-ring
Governor
Name -
Type -
Fuel feed system
Fuel filter Filter paper with automatic air release device
Fuel filter filtration area cm2 432
Oil/water separator Mesh filter screen
Feed pump Electrolical
2-1-5 0000604
2. TECHNICAL DATA

Engine
Lubrication system
Lubrication pump Trochoid pump
LO pressure regulating valve opening pressure kPa (kgf/cm )
2 0.29 to 0.39 (3.0 to 4.0)
LO filter Full flow filter
LO filter filtration area cm 2 800
Filter valve opening pressure kPa (kgf/cm )
2 0.08 to 0.12 (0.8 to 1.2)
Operating pressure of alarm switch kPa (kgf/cm2) 0.04 to 0.06 (0.4 to 0.6)
Cooling device
Cooling system Water-cooling (Radiator)
Fan belt size A35.5 A35
Thermostat opening temperature ºC 71
Thermostat full-open temperature ºC 85
Radiator cap pressure kPa (kgf/cm )
2 88.3 (0.9)
Radiator fan pcs.¯mm 5¯Ø290
Operating temperature of water temperature alarm switch ºC 107 to 113
Air cleaner
Type Cyclone type
Filtration area cm 2 0.9
Fuel injection pump
Injection pump type YPES-3ML
Injection pump plunger diameter mm Ø6.0
Injection pump cam lifting height mm 7.0
Fuel injection timing (FID) degrees 15 to 17
Firing order 1→3→2
Nozzle
Type NP-DN0PDN161
Nozzle hole diameter¯Number of holes Ømm¯pcs. Ø1.0¯1
Spray angle degrees 5 to 10
Fuel injection pressure MPa (kgf/cm2) 12.3 to 13.28 (125 to 135)
Turbocharger
Type -
Revolution speed rpm -
Turbocharging pressure mmHg -
Starting device
Cold starting aids Super quick glow
Starting aids capacity V-W 12-120
Battery type 65B24
Battery voltage - 20 hrs rate capacity V-Ah 12-45
2-1-6 0000604
2. TECHNICAL DATA

Electrical equipment
Type AC generator magnet
Alternator Nominal output V-A 12-40
Rated speed min (rpm)
-1 3500
Type RS5121
Current limiter
Regulation voltage V 14.0 to 16.0
Type Reduction type
Starter motor Nominal output V-kW 12-1.4
Engagement Magnet shift
Type - -
Stop motor
Nominal output V-A -
Type - 1503ES-12S5SUC12S LC01
Stop solenoid
Maximum input V-A 12-41.5
Hour meter V-W 12-12
Horn V-W 12-48
Fuse A¯pcs. 5¯3
Battery charge alarm lamp V-W 12-2
Monitor lamps Engine oil pressure alarm lamp V-W 12-2
Water temperature alarm lamp V-W 12-2
Headlight V-W -
Boom light V-W -
Room lamp (for cabin) V-W -
Wiper motor (for cabin) V-W -
Cabin heater (for cabin) V-W -
Cigarette lighter (for cabin) V-W -
2-1-7 0000604
2. TECHNICAL DATA
2-2 Outline Drawing and Working Area
in. (mm)
Outline drawing of excavator : SV15
(165)
6.50
q
13.98
(355)
80
15.75 (400)
38.58 (980)
40q
25.00
(635)
(245)
9.65
R3 980
(R
8.5 )
8
58.27 (1480)
(Boom swing 50.79 (1290))
133.86 (3400)
88.50 (2248) Canopy

96.85 (2460)
88.82 (2256) Cabin

34.25 (870)
(240)
(190)
9.45
7.48
11.81
61.42 (1560) (300)
59.06 (1500)
9.06 135.83 (3450)

78.74 (2000)
(230)
29.53 (750)
(2150)
38.58 (980)
84.65
138.19 (3510)
142.32 (3615) 43.11 (1095)
012817-00E
2-2-1 0000604
2. TECHNICAL DATA
in. (mm)
Outline drawing of excavator with canopy : SV17 (EX)
(165)
6.50
q
80
13.98
(355)
15.75 (400)
38.58 to 51.97
(980 to 1320)
38.58 (980)
EX
40q
25.00
(635)
(245)
9.65
R3 980
(R
8.5 )
60.63 (1540)
8
(Boom swing 52.76 (1340))
145.67 (3700)
108.66 (2760)
88.50 (2248) Canopy

88.82 (2256) Cabin
31.89 (810)
(240)
(190)
9.45
7.48
11.81
(300)
9.06 61.42 (1560)
(230)
74.80 (1900)
144.09 (3660)
29.53 (750)
(2600)
94.49 (2400)
38.58 (980)
102.36
EX
29.53 to 42.91
(750 to 1090)
EX
38.58 to 51.97
(980 to 1320)
154.72 (3930)
158.66 (4030) 43.11 (1095)
012819-00E
2-2-2 0000604
2. TECHNICAL DATA
2-3 Weight List of Main Parts

Unit : kg
SV15 SV17 SV17EX
Equipment No. Part Canopy
Rubber crawler
Front implement
1 Bucket Ass’y 31.2
5 2 Bucket arm & link Ass’y 7.8
3 3 Bucket cylinder Ass’y 10.5
4 Arm Ass’y 30.5 34
2 5 Arm cylinder Ass’y 12.0 12.6
4 6 Boom Ass’y 51.5 54
7 Boom cylinder Ass’y 19.8
7 6 8 Boom bracket Ass’y 24.0
1
Undercarriage
1 Idler Ass’y 8.4¯2
2 Crawler guard Ass’y −
3 Crawler adjuster Ass’y 6¯2
7 12 6 13 9 10
4 Track roller Ass’y 3.5¯6
5 Sprocket Ass’y 6.5¯2
6 Carrier roller Ass’y −
7 Track frame Ass’y 134.2 210
8 Rubber crawler Ass’y 52¯2
9 Blade cylinder Ass’y 10
10 Blade Ass’y 53 80
11 5 8 14 4 3 2 1 11 Travel motor Ass’y 23¯2
12 Swing bearing Ass’y 20
13 Swivel & hose or fitting Ass’y 11 16
14 Variable cylinder Ass’y − 8
Upperstructure
1 Engine hood Ass’y 8.5
2 Hydraulic oil tank & filters Ass’y 36.6
10 3 Engine 104.8
4 Operator's seat & mount Ass’y 71.4
8 2 5 Counter weight Ass’y −
6 Turning frame Ass’y 235
9 7 7 Controls (4 cords) Ass’y 65
4 8 Battery Ass’y 19.1
11 1 9 Fuel tank & piping Ass’y 23
10 Canopy & mount Ass’y 65
5 11 Swing lock, covers, steps and panels 25.5
12 Swing motor Ass’y 16
12 6 3 13 16 13 Pump & mount and hoses Ass’y 7.5
14 Control valve & fitting and hoses Ass’y 30
15 Boom swing cylinder Ass’y 15
16 Additional weight Ass’y − 100
2-3-1 0000604
2. TECHNICAL DATA
2-4 Lifting Capacity List
SV15
With:
( Cabin Canopy) Type
A ( Steel Rubber) Crawler
This load includes bucket weight.
Bucket : 31.2 kg (Width : 400 mm)
P A : Reach from swing center line [in. (m)]
B : Load point height [in. (m)]
B C : Lifting load [lbs. (kg)]
C P : Load point
: Rating over front
: Rating over side or 180 degrees
Blade on ground Unit : kg

A [m] Max. 2.5 2.0 1.5
B [m]
2.5 230 *305 - - - - - -
2.0 185 *310 230 *290 - - - -
1.5 165 *320 225 *320 - - - -
1.0 150 *325 210 *370 295 *465 - -
0.5 155 *340 215 *430 280 *575 - -
0 165 *350 205 *455 275 *625 395 *990
-0.5 180 *365 200 *435 275 *600 405 *880
-1.0 230 *370 - - 280 *510 455 *735
Blade above ground Unit : kg

A [m] Max. 2.5 2.0 1.5
B [m]
2.5 225 *305 - - - - - -
2.0 185 *310 225 *290 - - - -
1.5 160 250 215 *320 - - - -
1.0 145 215 205 290 285 *465 - -
0.5 150 215 210 285 275 390 - -
0 155 220 200 280 265 380 375 570
-0.5 175 245 195 280 265 380 375 570
-1.0 220 305 - - 265 390 420 625
Note :
The lifting load with the asterisk (*) mark is limited by hydraulic lifting capacity rather than tipping. The lifting capacity
shown in the above list is based on the ISO Standard No. 10567 and represents either 87 % of hydraulic lifting
capacity or 75 % of tipping load, which is smaller.
2-4-1 0000604
2. TECHNICAL DATA
SV17
With:
C P : Load point
: Rating over front

A [m] Max. 3.0 2.5 2.0
B [m]
3.0 *290 *300 - - - - - -
2.5 205 *290 - - - - - -
2.0 180 *295 205 *270 - - - -
1.5 160 *290 200 *290 - - - -
1.0 155 *300 200 *320 *295 *300 350 *465
0.5 155 *310 190 *350 255 *370 340 *585
0 160 *325 195 *385 250 *430 315 *645
-0.5 170 *340 190 *390 245 *480 320 *675
-1.0 200 *350 - - 245 *500 320 *620
-1.0 250 *355 - - 240 *475 335 *540

A [m] Max. 2.5 2.0 1.5
B [m]
3.0 *290 *300 - - - - - -
2.5 200 *290 - - - - - -
2.0 170 *295 200 *270 - - - -
1.5 155 230 195 *290 *295 *300 - -
1.0 145 210 185 *320 250 *370 350 *465
0.5 150 215 185 265 240 350 320 480
0 155 220 185 260 230 330 300 455
-0.5 165 240 185 275 235 335 305 470
-1.0 190 270 - - 230 330 300 425
-1.0 240 *350 - - - - 315 *540
Note :
2-4-2 0000604
2. TECHNICAL DATA
SV17EX
With:
C P : Load point
: Rating over front

A [m] Max. 3.0 2.5 2.0
Reduction Extend Reduction Extend Reduction Extend Reduction Extend
B [m]
3.0 *290 *290 *300 - - - - - - - - -
2.5 *290 *290 *290 - - - - - - - - -
2.0 190 *295 *295 *270 *270 *270 - - - - - -
1.5 170 *290 *290 210 *290 *290 *295 *295 *300 - - -
1.0 160 *300 *300 210 *320 *320 270 *370 *370 *465 *465 *465
0.5 160 240 *310 200 *350 *350 255 *430 *430 360 *585 *585
0 165 250 *325 200 295 *385 265 395 *480 345 535 *645
-0.5 180 270 *340 195 295 *390 255 385 *500 335 525 *675
-1.0 205 *350 *350 - - - 255 375 *475 345 525 *620
-1.5 255 *355 *355 - - - - - - 355 *540 *540

A [m] Max. 3.0 2.5 2.0
Reduction Extend Reduction Extend Reduction Extend Reduction Extend
B [m]
3.0 *290 *290 *300 - - - - - - - - -
2.5 *290 *290 *290 - - - - - - - - -
2.0 180 *295 *295 *270 *270 *270 - - - - - -
1.5 165 *290 *290 210 *290 *290 *295 *295 *300 - - -
1.0 155 235 230 205 *320 *320 260 *370 *370 *465 *465 *465
0.5 155 235 220 195 *350 *350 255 *430 *430 350 *585 *585
0 160 245 230 195 285 280 255 395 355 345 525 505
-0.5 180 265 255 190 285 280 255 375 365 330 515 500
-1.0 200 *350 275 - - - 245 375 340 335 525 500
-1.5 255 *355 *355 - - - - - - 345 *540 *540
Note :
2-4-3 0000604
CHAPTER 3
SERVICE STANDARDS
3-1 Machine Performance.......................................................................... 3-1-1

3-2 Engine.................................................................................................. 3-2-1
3-3 Undercarriage ...................................................................................... 3-3-1
3-3-1 Rubber Crawler Specifications................................................... 3-3-1
3-4 Controls ............................................................................................... 3-4-1
3-5 Hydraulic Equipment............................................................................ 3-5-1
3-5-1 Hydraulic Cylinders .................................................................... 3-5-1
3-6 Implement ............................................................................................ 3-6-1
3-6-1 Front Attachments...................................................................... 3-6-1
3-6-2 Blade Moving Device ................................................................. 3-6-2
3-6-3 Bucket Teeth.............................................................................. 3-6-2
3-7 List of Tightening Torque ..................................................................... 3-7-1
3-7-1 Machine ..................................................................................... 3-7-1
3-7-2 Engine........................................................................................ 3-7-4
3-7-3 Tightening Torque for General Bolts and Nuts .......................... 3-7-4
3. SERVICING STANDARDS
3. Service Standards
3-1 Machine Performance

Applicable model SV15/SV17(EX)
Item Measuring condition Unit Standard Allowance
Machine performance
Working speed
Boom speed Machine position
Max. cylinder extension Up 2.2 2.4
sec.
• Engine : rated speed

• Hydraulic oil temp. : 50 to 60 °C Down 2.0 2.2
Bucket teeth grounded • Site : Firm, flat ground
• Excluding cushion
Arm speed Machine position
Max. cylinder retraction Extend 2.3 2.5
sec.
• Engine : rated speed Retract 3.1 3.3

Max. cylinder extension • Hydraulic oil temp. : 50 to 60 °C
• Site : Firm, flat ground
Bucket speed Machine position
Max. cylinder retraction Dump 1.5 1.7
sec.
• Engine : rated speed Curl 2.2 2.4

Max. cylinder extension • Hydraulic oil temp. : 50 to 60 °C
Boom offset speed Machine position
Right swing 3.1 3.4

Max. cylinder retraction
sec.
• Hydraulic oil temp. : 50 to 60 °C Left swing 3.1 3.4
Max. cylinder extension • Full stroke
Blade speed Machine position
Max. cylinder retraction Up 0.9 1.0
sec.
• Engine : rated speed Down 0.8 0.9

Blade grounded • Hydraulic oil temp. : 50 to 60 °C
3-1-1 0000604

Machine performance
Machine position
High speed
20.6 23.0
sec./
Travel speed
20 m

• Hydraulic oil temp. : 50 to 60 °C Low speed
• Traveling time for 20 m after an 36.0 41.0
approach run of 5 m or more.
Machine position
High speed
90 to 105
degrees 10.5 12.0

• Hydraulic oil temp. : 50 to 60 °C
Track speed • Site : Firm, flat ground sec. / 3 rev.
• Travel lever : Full throttle
(Floating crawler side)
• Float one side of the crawler. Low speed
Make a mark on the crawler.
After turning the floating crawler side more 17.5 20.0
than once at full throttle, measure the time
needed for 3 turns of the crawler.
Machine position

Track deviation • Hydraulic oil temp. : 50 to 60 °C mm / 20 m 500 or less 600
• Measure the deviation (χ) in a travel distance
of 20 m after an approach run of 5 m or more.
20 m
10 m
3-1-2 0000604

Machine performance
Machine position
mm /
Traveling drift 120 or less 180
15 degrees 5 min.
• Engine : stopped
• Drift of the machine after 5 min. on a slope with
an inclination of 15 degrees.
Drift of cylinders
Machine position
Boom drift
8 or less 15
(Cylinder rod retraction)
Arm drift
8 or less 15
(Cylinder rod extension)
• Engine : stopped mm /
• Hydraulic oil temp. : 50 to 60 °C 10 min.
Bucket drift • Site : Firm, flat ground
• Make the boom and bucket pins the same 5 or less 9
(Cylinder rod extension)
height.
• Measure the retraction or extension of each cyl-
inder rod after leaving the machine at the above
Blade drift position for 10 min.
5 or less 9
(Cylinder rod extension) • Lift the blade to the highest position, and mea-
sure the cylinder rod extension after 10 min.
Machine position
15 degrees
Boom offset drift mm /
5 or less 7.5
(Cylinder rod extension) 10 min.
• Engine : stopped
• Make the boom and bucket pins the same
height.
• Park the machine on a slope with an inclination
of 15 degrees and turn the upperstructure 90
degrees to the crawler and engage the swing
lock.
• Measure the cylinder rod extension after 10 min.
3-1-3 0000604

Machine performance
Machine position
mm or 120 or less, 180 or less,

Swing drift at stopping
• Engine : rated speed degrees 30 or less 45 or less
• Make the boom and bucket pins the same height.
• Make match marks on the outer race and the
inner race of the swing bearing (or the track
frame).
• Measure shifted distance between both marks
after making one turn with no load.
Machine position
sec. /
Swing time 32 37
5 turns

• Make one idling turn with no load, then mea-
sure the time necessary to make 5 turns.
Machine position
( at engine
stop ) 0
15 degrees
Swing drift • Engine : stopped mm

• Make the boom and bucket pins the same height.
• Park the machine on a slope with an inclination
of 15 degrees and turn the upperstructure 90
degrees to the crawler.
• Make match marks on the outer race and the
inner race of the swing bearing (or the track
( at engine
operating ) ¹40
(¹10 degrees)
frame).
• Measure shifted distance or angle between
both marks after 5 min.
3-1-4 0000604
3-2 Engine
1) Nominal and Allowable Values

SV15/17(EX)
Applicable model 3TNV70-XBV1 / 3TNV70-XBVA
Item Unit Standard Wear limit
Cylinder head
Cylinder head distortion mm 0.05 or less 0.15
Intake degrees 120 -
Valve seat angle
Exhaust (°) 90 -
Intake -
Valve seat width mm
Exhaust -
Stem outside dia. Ø5.960 to 5.975 5.9
Intake valve Guide inside dia. mm Ø6.0 to 6.012 6.08
Oil clearance 0.025 to 0.052 0.16
Stem outside dia. Ø5.945 to 5.960 5.9
Exhaust valve Guide inside dia. mm Ø6.0 to 6.012 6.08
Valve guide projection mm 9.8 to 10.0 -
Intake 0.4 to 0.6
Valve sinkage mm 0.8
Exhaust 0.4 to 0.6
Valve head Intake 0.9 to 1.1
mm 0.5
thickness Exhaust 1.0 to 1.2
Stem bend - 0.01
Cylinder head mm
Stem outside dia. 86.8 to 87.2 86.6
Intake valve Open b. TDC degrees 7 to 17 -
operating timing Close a. BDC (°) 35 to 45 -
Exhaust valve Open b. BDC degrees 35 to 45 -
operating timing Close a. TDC (°) 7 to 17 -
Free length mm 37.8 -
Valve spring Inclination mm - 1.3
Tension [1 mm compressed] N (kg) 8.95 (11.49) -
Intake / exhaust valve clearance mm 0.15 to 0.25 -
Cylinder block
Cylinder bore dia. 70.00 to 70.03
L mark 76.02 to 76.03
76.20
Cylinder bore dia. M mark 76.10 to 76.02
mm
S mark 76.00 to 76.01
Roundness of cylinder sleeve bore 0.01 or less 0.03
Cylindricity of cylinder sleeve bore 0.01 or less 0.03
Valve
Shaft outside dia. Ø11.966 to 11.984 Ø11.94
Intake / exhaust
Bush inside dia. Ø12.000 to 12.020 Ø12.07
valve rocker arm
Push rod bend mm - 0.03 or less
Stem outside dia. Ø20.927 to 20.960 Ø20.907
Tappet Guide hole inside dia. Ø21.0 to 21.021 Ø21.041
3-2-1 0000604

Piston
Piston outside dia. Ø69.960 to 69.990
L mark Ø75.975 to 75.985
ML mark Ø75.970 to 75.975 Ø75.920
Piston outside dia.
MS mark Ø75.965 to 75.970
S mark Ø75.955 to 75.965
mm
Minimum clearance between piston and cylinder 0.03 to 0.05 -
Top clearance 0.696 to 0.84 -
Outside dia. Ø21.995 to 22.0 Ø21.965
Piston pin Bush inside dia. Ø22.0 to 22.009 Ø22.039
Piston ring
Ring groove width 1.55 to 1.57 -
Ring width 1.47 to 1.49 -
Top ring
Clearance between groove and ring 0.060 to 0.10 1.450
End gap 0.15 to 0.30 0.390
mm
Ring groove width 1.580 to 1.595 1.695
Ring width 1.43 to 1.45 1.410
Second ring
End gap 0.18 to 0.33 0.420
Ring groove width 3.01 to 3.025 3.125
Ring width 2.970 to 2.990 2.950
Oil ring mm
End gap 0.2 to 0.45 0.540
Connecting rod
Crank pin metal inside dia. Ø45.0 to 45.016 -
Crank pin metal thickness 1.503 to 1.509 -
Crank pin outside dia. Ø41.952 to 41.962 Ø41.902
Crank pin side
Deviation from circular form
mm 0.01 or less 0.02
(Drill diameter method)
Bush inside dia. Ø22.025 to 20.038 Ø22.068
Piston pin side Piston pin outside dia. Ø21.991 to 22.0 Ø21.963
Twist and parallelism 0.03 or less for 100 0.08
Cam
Cam shaft outside dia. Ø39.94 to 39.96 Ø39.85
Gear side Bush inside dia. 40.000 to 40.075 40.150
Oil clearance 0.04 to 0.135 -
Intermediate Bearing inside dia. 40.000 to 40.025 40.100
mm
Flywheel side Bearing inside dia. 40.000 to 40.025 40.100
Bend 0.02 or less 0.05
Intake cam 34.135 to 34.265 33.89
Cam height
Exhaust cam 34.135 to 34.265 33.89
3-2-2 0000604

Crank shaft
Outside dia. Ø46.952 to 46.962 Ø46.902
Main metal thickness 2.009 to 2.014 -
Journal Oil clearance 0.020 to 0.050 0.120
Deviation from circular form
mm 0.01 or less 0.02
(Drill diameter method)
Crank pin Outside dia. 41.952 to 41.962 41.900
Bend - 0.01 or less
Thrust metal width 1.930 to 1.980 1.850
Shaft outside dia. 44.950 to 44.975 44.900
Idle gear Bush inside dia. mm 45.00 to 45.025 45.075
Outside clearance of outer rotor 0.12 to 0.21 0.30
Trochoid pump Side clearance of outer rotor mm 0.02 to 0.07 0.12
Inside clearance of inner rotor 0.13 to 0.20 0.25
Crank shaft 0.111 to 0.250 -
Cam shaft 0.05 to 0.15 -
Side gap mm
Connecting rod 0.2 to 0.4 -
Idle gear 0.05 to 0.25 -
Crank gear 0.06 to 0.12 -
Cam gear 0.06 to 0.12 -
Backlash Idle gear mm 0.06 to 0.12 -
Fuel injection pump drive gear 0.06 to 0.12 -
Lubricating oil pump gear 0.06 to 0.12 -
Others
15 or more
Lube oil pump discharge volume L/min -
(Oil temperature : 60°C)
kPa 294.2 to 441.3
Oil pressure regulating valve opening pressure -
(kgf/cm2) (3.0 to 4.5)
kPa 39.2 to 58.8
Oil pressure switch operating pressure -
(kgf/cm2) (0.4 to 0.6)
Cooling water pump discharge volume L/min 50 [at 3350 min-1 (rpm)] -
Temperature °C 69.5 to 72.5 -
Thermostat valve opening
8.0 or more
temperature Lift at opening mm -
at 85°C or higher
Thermo-switch operating ON 107 to 113 -
°C
temperature OFF 100 or more -
3-2-3 0000604
3-3 Undercarriage
3-3-1 Rubber Crawler Specifications
Unit : mm
Applicable model SV15/17(EX)

Measuring
Part Standard Wear limit
position
Rubber crawler specifications
(1) Rubber crawler
A 17 8
A
(2) Idler & shaft

A 30 −
B
B 32 26
C Ø295 Ø290
C
A
3-3-1 0000604
Unit : mm

Measuring
Part Standard Wear limit
position
(3) Track roller & shaft
B
A Ø25 -
B 69 63
C 130 124
A
(4) Sprocket
B
A 20 10
A
C
B 18 13
C 81 −
(5) Slide plate
A 42.5 37.5
A
3-3-2 0000604
3-4 Controls

Item Measuring conditions Unit Standard Allowable limit
Controls
Operating force
Right control lever • Engine : stopped
10.8 (1.1) 15.7 (1.6)
(Boom & Bucket) • Hydraulic oil temp. : 50 to 60 °C
• Lever operating force : Measure the force by
Left control lever
hanging the spring scale on the lever grip. 10.8 (1.1) 15.7 (1.6)
(Arm & Swing)
• Pedal operating force : Measure the force by
Blade lever applying load as shown below. 21.6 (2.2) 31.4 (3.2)
Spring scale Forward Forward
Press
N (kgf) 12.7 (1.3) 17.6 (1.8)
Travel levers
Reverse Reverse
18.6 (1.9) 23.5 (2.4)
Boom swing lever Pull − −
Boom swing pedal 70.6 (7.2) 80.4 (8.2)
P.T.O. pedal − −
Play of control lever & pedal

Right control lever • Engine : stopped
10 or less −
(Front & rear / left & right) • Hydraulic oil temp. : 50 to 60 °C
• Play of each control lever and pedal :
Left control lever
Measure the total play (front & rear and left & 10 or less −
(Front & rear / left & right)
right) at the lever grip end or the pedal end.
Blade lever Play 15 or less −
mm
Play
Travel levers 20 or less −
Boom swing pedal 10 or less −
P.T.O. pedal − −
Control valve
Spool stroke
Boom
A B
Stroke
Bucket
Arm mm 6 −
Swing
Parallel-flow divider
Right travel
A B Stroke
Left travel
Blade mm 6 −
Boom swing
Offset
3-4-1 0000604
3-5 Hydraulic Equipment
3-5-1 Hydraulic Cylinders

SV15/17(EX)
1 (Max. retraction length)

3 2 (Stroke)
8
7-1 7-2
5 4
6-1 6-2
Unit : mm
No. 7-1 / 7-2 8
1 2 3 4 5 6-1 / 6-2 Tightening torque
Standard Allowable limit Nut size
Cylinder N•m (kgf•m)
490.3 to 588.4
Boom 675 415 72 Ø60 Ø35 G1/4 Ø35 Ø35.5 M24
(50 to 60)
490.3 to 588.4
Arm (SV15) 686 439 63 Ø55 Ø35 G1/4 / G3/8 Ø30 Ø30.5 M24
(50 to 60)
490.3 to 588.4
Arm (SV17(EX)) 902 453 265 Ø55 Ø35 G1/4 / G3/8 Ø30 Ø30.5 M24
(50 to 60)
294.2 to 343.2
Bucket 554 317 64 Ø55 Ø30 G1/4 Ø30 Ø30.5 M20
(30 to 35)
490.3 to 588.4
Boom swing 550 295 81 Ø65 Ø35 G1/4 Ø40 Ø40.5 M24
(50 to 60)
220 to 250
Blade 360 125 82 Ø60 Ø35 G1/4 Ø30 Ø30.5 M22
(22.4 to 25.5)
Track gauge change 220 to 250
551 340 49 Ø60 Ø35 G1/4 Ø35 Ø35.5 M22
(SV17EX) (22.4 to 25.5)
Nut for pipe
Symbol Name
G (PF) Straight pipe thread
R (PT) Taper pipe thread (male)
Rc (PT) Taper pipe thread (female)
3-5-1 0000604
3-6 Implement
3-6-1 Front Attachments

SV15/17(EX)
9
10 7
6
4 15
1
12
11
2
16
13 14
5
013511-00X
Unit : mm
Applicable model : SV15/17(EX) Wear limit
No. Standard
Measuring point Pin Bore of bush or hole
1 Boom swing fulcrum Ø50
2 Boom fulcrum Ø35
3 Boom swing cylinder, rod Ø40
4 Boom swing cylinder, bottom Ø40
5 Boom cylinder, bottom Ø35
6 Boom cylinder, rod Ø35
7 Arm fulcrum Ø35
8 Arm cylinder, bottom Ø30
-0.5 +0.5
9 Arm cylinder, rod Ø30
10 Bucket cylinder, bottom Ø30
11 Bucket cylinder, rod Ø30
12 Link “A” arm Ø30
13 Bucket fulcrum Ø30
14 Bucket “link A” Ø30
15 Track gauge change cylinder, bottom Ø40
16 Track gauge change cylinder, rod Ø40
Note : Allowable clearance is 1.0 mm.
3-6-1 0000604
3-6-2 Blade Moving Device
2 3
013512-00X
Unit : mm
Applicable model : SV15/17(EX) Wear limit
No. Standard
Measuring point Pin Bore of bush or hole
1 Blade cylinder, rod Ø30
2 Blade cylinder, bottom Ø30
3 Blade fulcrum Ø30 -0.5 +0.5
4 Track gauge change blade fulcrum pin Ø25
5 Track gauge change blade steady pin Ø25
Note : Allowable clearance between pin and bore of bush or hole is 1.0 mm.
3-6-3 Bucket Teeth

Unit : mm
Measuring point Standard Wear limit Measure
A
195 165 Replace
3-6-2 0000604
3-7 List of Tightening Torque
3-7-1 Machine
Unit : N•m (kgf•m)
Applicable model: SV15/17(EX)
Equipment
Thread size Tightening torque Adhesive
No. Tightening part
Engine / Electrical equipment
24.5 to 32.3
1 Engine mount vibroisolating rubber Nut M10 4T torque
(250 to 330)
2 Engine × Engine mount M10 × 25 Three Bond 1324
3 Engine × Engine mount M10 × 25 Three Bond 1324
4 Stopper plate × Mount base M10 × 25 Three Bond 1324
5 Mount base × Turning frame M12 × 30 Three Bond 1324

1.18 to 1.47
6 Fuel gauge unit M5 × 12
(12 to 15)
2.45 to 3.43
7 Air cleaner intake hose Hose clamp 60
(25 to 35)
3.92 to 4.91
8 Radiator hose Hose clamp 35
(40 to 50)
3.92 to 4.91
9 Radiator hose Hose clamp 25
(40 to 50)
19.6 to 22.6
10 Air cleaner M8 × 16
(200 to 230)
2.45 to 2.94
11 Fuel tank × Band Nut M10 For tension
(25 to 30)
24.5 to 29.4
12 Fuel tank × Band Nut M10 For lock nut
(250 to 300)
1.18 to 1.47
13 Fuel gauge M5 × 20
(12 to 15)
29.4 to 34.3
14 Safety switch Nut M18
(300 to 350)
1.96 to 2.94
(20 to 30)
15 Battery × Rod Nut M6
4.9 to 5.88
(50 to 60)
2.94 to 3.92
16 Battery code (+) (-) Nut M6
(30 to 40)
Travel device
17 Nipple valve M16 49 (500)
18 Track roller × Lower frame M12 × 25 Loctite 243
19 Idler fork × Ider spring M10 × 30 Three Bond 1324
20 Slide plate M10 × 40 Loctite 243
21 Sprocket × Travel motor M10 × 25 Loctite 243
22 Travel motor × Lower frame M10 × 25 Loctite 243

8.83 to 9.81
23 Adjust cylinder plug R1/8 Loctite 243
(90 to 100)
3-7-1 0000604

Applicable model: SV15/17(EX)
Equipment
Thread size Tightening torque Adhesive
No. Tightening part
Control equipment
12.7 to 16.7
24 Link ball 8, El ball 8 × Link Nut 8
(130 to 170)
1.96 to 2.94
25 Link ball 8 × Wire cable Nut 5
(20 to 30)
7.84 to 9.8
26 El ball 8 × Rod Nut 8
(80 to 100)
3.92 to 4.9
27 Cable accelerator Nut M6
(40 to 50)
24.6 to 32.3
28 Accelerator lock nut Nut M10
(250 to 330)
1.76 to 2.55
29 Travel grip M4 × 12 Three Bond 1324
(18 to 26)
19.6 to 24.5
30 Cable Nut M12 Blade PTO boom swing
(200 to 250)
Equipment
M12 × 40 107.9 to 128.5
31 Swing bearing M12 × 45 Loctite 262
(1100 to 1300)
M12 × 55
19.6 to 29.4
32 Key lock plate U nut 10
(200 to 300)
107.9 to 128.5
33 Canopy M12 × 30 Three Bond 1324
(1100 to 1300)
107.9 to 128.5
34 Cabin M12 × 60 Three Bond 1324
(1100 to 1300)
Hydraulic equipment
49 to 58.8
35 Coupring M10 × 20 Three Bond 1324
(500 to 600)
36 Swing motor M12 × 40 Three Bond 1324
37 Swivel joint M10 × 30 Three Bond 1324
38 Travel motor M10 × 30 Three Bond 1324

14.7 to 15.7
39 Reservoir oil gauge M10 × 30
(150 to 160)
2.5 to 3.4
40 Hose clip 13 −
(25 to 35)
3.92 to 4.90
41 Hose clip 22 −
(40 to 50)
3.92 to 4.90
42 Hose clip 25 −
(40 to 50)
3.92 to 4.90
43 Hose clip 35 −
(40 to 50)
3.92 to 4.90
44 Hose clip 41 − Suction
(40 to 50)
35.3 to 47.0
45 Pump × Suction flange M10 × 20
(360 to 480)
46 Lock plate of swing cylinder pin M10 × 20 Three Bond 1324
47 Lock bolt of pins M10 × 16 Three Bond 1324
48 Boom cylinder slide cover M10 × 16 Three Bond 1324
3-7-2 0000604
3-7-2 Engine
Tightening torque for major bolts and nuts
Tightening torque
No. Item Thread size × Pitch Lubricating oil
1 Cylinder head bolt M9 × 1.25 53.9 to 57.9 (5.5 to 5.5) Yes
2 Connecting rod bolt M7 × 1.0 22.6 to 27.5 (2.3 to 2.8) Yes
3 Flywheel mounting bolt M10 × 1.25 80.4 to 86.4 (8.2 to 8.8) Yes
4 Metal cap bolt M10 × 1.25 75.5 to 81.5 (7.7 to 8.3) Yes
5 Crankshaft pulley fastening bolt M12 × 1.25 83.3 to 93.3 (8.5 to 9.5) Yes
6 Fuel injection nozzle retainer clamp nut M20 × 1.5 49.0 to 53.0 (5.0 to 5.4) No
7 Glow plug M10 × 1.25 14.7 to 19.6 (1.5 to 2.0) No
8 Governor weight support nut M12 × 1.25 68.7 to 73.7 (7.0 to 7.5) Yes
9 High pressure pipe nut M12 × 1.25 29.4 to 34.3 (3.0 to 3.5) No
10 Fuel pump cam end nut M12 × 1.75 58.8 to 68.8 (6.0 to 7.0) Yes
11 Fuel oil pump fastening bolt M8 × 1.0 32.3 to 36.3 (3.3 to 3.7) No
3-7-3 Tightening Torque for General Bolts and Nuts

Tightening torque
Item Thread size × Pitch Remarks
M6 × 1 9.8 to 11.8 (1.0 to 1.2)
M8 × 1.25 22.6 to 28.4 (2.3 to 2.9)
M10 × 1.5 44.1 to 58.9 (4.5 to 6.0)
M12 × 1.75 78.5 to 98.1 (8.0 to 10.0) 1) Apply 80% of tightening torque
Coarse
when tightened to aluminum.
thread M14 × 2 112.8 to 142.2 (12.0 to 15.0) 2) Apply 60% of tightening torque
Hexagon head bolt (7T)
Nut M16 × 2 166.8 to 206.0 (17.0 to 21.0) for 4T bolts and lock nuts.
3) Use fine screw threads for
M18 × 2.5 235.5 to 284.5 (24.0 to 29.0) engine only.
M20 × 2.5 323.8 to 402.2 (33.0 to 41.0)
Fine M14 × 1.5 127.5 to 147.1 (13.0 to 15.0)
thread M16 × 1.5 210.9 to 240.3 (21.5 to 24.5)
1/8 9.8 (1.0)
1/4 19.6 (2.0)
R (C) plug
3/8 29.4 (3.0)
1/2 58.9 (6.0)
M8 12.7 to 16.7 (1.3 to 1.7)
M12 24.5 to 34.3 (2.5 to 3.5)
Pipe joint bolt
M14 39.2 to 49.0 (4.0 to 5.0)
M16 49.1 to 58.9 (5.0 to 6.0)
3-7-3 0000604
CHAPTER 4
ENGINE
4-1 General ................................................................................................ 4-1-1

4-1-1 Engine External Views ............................................................... 4-1-1
4-1-2 Exhaust Gas Emission Regulation............................................. 4-1-2
4-2 Measurement, Inspection and Adjustment .......................................... 4-2-1
4-2-1 Measuring the Compression Pressure....................................... 4-2-1
4-2-2 Adjusting the Valve Clearance................................................... 4-2-2
4-2-3 Checking the V-belt Tension...................................................... 4-2-3
4-2-4 Checking the Fuel Injection Valve.............................................. 4-2-3
4-2-5 Checking and adjusting the Fuel Injection Timing ..................... 4-2-5
4-2-6 Adjusting the Maximum (or Minimum) Idling Speed .................. 4-2-7
4-2-7 Checking the Cooling Water System and Radiator for Water Leakage...... 4-2-7
4-2-8 Checking the Sensors................................................................ 4-2-8
4-3 Measurement Procedure, Service Data and Corrective Action ........... 4-3-1
4-3-1 Cylinder Head ............................................................................ 4-3-1
4-3-2 Cylinder Block ............................................................................ 4-3-6
4-3-3 Valve Rocker Arm ...................................................................... 4-3-8
4-3-4 Piston and Piston Rings........................................................... 4-3-10
4-3-5 Connecting Rod ....................................................................... 4-3-13
4-3-6 Cam Shaft ................................................................................ 4-3-16
4-3-7 Crank Shaft .............................................................................. 4-3-17
4-3-8 Gears ....................................................................................... 4-3-20
4-3-9 Trochoid Pump......................................................................... 4-3-21
4-4 Precautions for Reassembly ................................................................ 4-4-1
4-5 Fuel Injection Pump / Governor ........................................................... 4-5-1
4-5-1 Introduction ................................................................................ 4-5-1
4-5-2 Fuel Injection Pump ................................................................... 4-5-1
4-6 Starter Motor ........................................................................................ 4-6-1
4-6-1 Specifications............................................................................. 4-6-1
4-6-2 Characteristics ........................................................................... 4-6-1
4-6-3 The Structure of a Starting Motor and the Wiring Diagram........ 4-6-2
4-6-4 Performance .............................................................................. 4-6-3
4-7 Alternator ............................................................................................. 4-7-1
4-7-1 Components............................................................................... 4-7-1
4-7-2 Specifications............................................................................. 4-7-2
4-7-3 Wiring Diagram .......................................................................... 4-7-2
4-7-4 Standard Output Characteristics................................................ 4-7-3
4-7-5 Inspection................................................................................... 4-7-3
4-7-6 Troubleshooting ......................................................................... 4-7-4
4. ENGINE
4. Engine
4-1 General
4-1-1 Engine External Views
Lifting eye
Cooling water pump
Lifting eye
Fuel filter
Air intake port
(from air cleaner)
Intake manifold
Fuel injection pump
Governor lever
Cooling fan
V-belt
Engine oil filter V-pulley
Dipstick (lube oil)
Fuel priming lever Filler port (lube oil)
Mechanical fuel feeding pump Drain plug (lube oil)
Fuel oil inlet
Bonnet (Rocker arm cover)

Filler port (lube oil) Engine name plate
Alternator
Flywheel
Exhaust manifold
Starter motor
4-1-1 0000604
4. ENGINE
4-1-2 Exhaust Gas Emission Regulation
The engines in this manual have been certified by the US EPA and/or California.
California
Proposition 65 Warning
Diesel engine exhaust and some of its constitutions are known to the State of California to cause cancer, birth
defects, and other reproductive harm.
California
Proposition 65 Warning
Battery posts，
terminals，and related accessories contain lead and lead compounds，chemicals known to the State
of California to cause cancer and reproductive harm. Wash hands after handling.
1) The Emission Standard in USA

(1) EPA nonroad diesel engine emission standards
g/kW•hr (g/bhp•hr)
Engine Power Tier Model Year NOx HC NMHC + NOx CO PM
kW < 8 Tier 1 2000 - - 10.5 (7.8) 8.0 (6.0) 1.0 (0.75)
(hp < 11)
Tier 2 2005 - - 7.5 (5.6) 8.0 (6.0) 0.80 (0.60)
8 <= kW < 19 Tier 1 2000 - - 9.5 (7.1) 6.6 (4.9) 0.80 (0.60)
(11 <= hp < 25)
Tier 2 2005 - - 7.5 (5.6) 6.6 (4.9) 0.80 (0.60)
Notes :
1) The EPA emission regulation under 19 kW is mentioned above.
2) As for Model year, the year which a regulation is applicable to is shown.
Transient smoke standards % opacity

Engine classification
(acceleration/lug/peak modes)
Constant speed engine Not regulated
Variable speed engine 20/15/50 or less
(2) California ARB emission regulation

The ARB emission standard is based on that of the EPA.
4-1-2 0000604
4. ENGINE
2) Engine Identification
To identify the engines, the following emission control labels are affixed on the engines.
(1) Emission control labels of US EPA
# /1&'.;'#475'2#4')7.#6+105 # /1&'.;'#475'2#4')7.#6+105
01041#&%+'0)+0'5%1056#0652''&10.; 01041#&%1/24'55+10+)0+6+10'0)+0'5
"75&"(7'. "75&"(7'.
% & % &
' ( ' (
) * + ) * +
EPA label for constant speed engines EPA label for variable speed engines
(2) Emission control label for both EPA and ARB
$ %
&
' ( )
4-1-3 0000604
4. 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 con-
ditions are met, check for any deterioration that may occur before the required periodic maintenance times.
(1) Requirement on engine operation condition

(a) Intake air depression
kPa (mmAq)
Initial Permissible
<= 2.94 (300) <= 6.23 (635)
(b) Exhaust gas back pressure

kPa (mmAq)
Initial Permissible
<= 12.75 (1300) <= 15.30 (1560)
(2) Fuel oil

The diesel fuel oil US No.2 diesel fuel oil.
(3) Tamper resistance Sealing cap

Do not remove the seals restricting injection quantity and Gasket
Cap nut
engine speed. Gasket
Plate
Nut
Injection quant
limit bc
Tamper Seal washer

resistance Assy
Tamper resistance device
for engines certified by ARB/EPA
4-1-4 0000604
4. ENGINE
(4) Perform maintenance without fail.

Note :
Inspections to be carried out by the user and by the maker are divided and set down in the “List of Periodic Inspec-
tions” and should be checked carefully.
(5) Maintenance period and Quality guarantee period for exhaust emission related parts
The maintenance of the parts related to the exhaust emission must be carried out in the maintenance period as
shown in the below table.
A guarantee period is that either the operation hours or years shown in the table come first in the condition that the
maintenance inspection was carried out based on the “List of Periodic Maintenance Schedule”.
Maintenance period Quality Guarantee Period

Parts Fuel nozzle cleaning Adjustment, cleaning, For nozzle, fuel pump,
repairs for fuel nozzle, fuel turbocharger
pump, turbocharger,
Power Rating electronic control unit etc.
kW < 19 Every 1500 hours Every 3000 hours 1500 hours / 2 years
And constant speed
engines beyond
3000 min-1 under 37 kW
4-1-5 0000604
4. ENGINE
4-2 Measurement, Inspection and Adjustment
4-2-1 Measuring the Compression Pressure
1) Measurement Procedure
(1) Warm up the engine. Remove the fuel injection pipe
and the fuel injection valve from the cylinder to be
measured.
Compression gauge
(2) Crank the engine before attaching the compression
gauge adapter.
Note :
Crank the engine when the regulator handle has been
turned to "STOP" position (no injection state).
(3) Attach the compression gauge adapter and the
compression gauge to the cylinder to be measured.
Note : Measuring the compression pressure
Never fail to attach the gasket to the tip of the adapter.
(4) Crank the engine with the starter motor until the
reading of the compression gauge is stabilized,
according to the above step (2) and Note.
[Engine compression pressure (Reference values)]

Compression pressure at 250 rpm MPa (kgf/cm2) Variations of compression
pressure among cylinders
Standard Limit MPa (kgf/cm2)
3.14 to 3.34 (32 to 34) 2.45 to 2.65 (25 to 27) 0.2 to 0.3 (2 to 3)
2) Trouble Diagnosis Through Measurement of Compression Pressure

Reduction in the compression pressure of the cylinder is one of the major causes of the increase in blow-by gas
(which causes contamination and increased consumption of lubricating oil, and other trouble) and the engine starting
failure. The compression pressure is influenced by the following factors :
(1) Degree of the clearance between the piston and the cylinder ;
(2) Degree of the clearance around the intake / exhaust valve seats ; and
(3) Gas leak through the nozzle gasket or the cylinder head gasket.
This means that the compression pressure decreases as the engine parts are worn and lose durability through the
use of the engine over a long period of time.
In addition, the compression pressure is also decreased by scratches on the cylinder or the piston which are caused
by dust or other foreign matters drawn in through the soiled filter element of the air cleaner, and wear or breakage of
any piston rings. Therefore, the condition of the engine should be diagnosed by measuring the compression pres-
sure.
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4. ENGINE
Causes and countermeasures to be taken when the compression pressure is less than the limit value.
No. Item Causes Countermeasures
• Filter element of air cleaner • Clogged filter element • Clean the filter element.
1 • Broken filter element • Replace the filter element.
• Defective filter element seal portion
• Valve clearance • Excessive or no valve clearance • Adjust the valve clearance.
2
(Refer to Section 4-2-2.)
• Valve timing • Improper valve timing • Adjust the valve clearance.
• Improper valve clearance (Refer to Section 4-2-2.)
3
• Inspect and adjust the valve rocker arm.
(Refer to Sections 4-3-3, 4-3-6 and 4-3-8.)
• Cylinder head gasket • Gas leak through the gasket • Replace the gasket.
• Nozzle gasket • Re-tighten the cylinder head and the nozzle at the
4
specified torque.
(Refer to Section 3-7-2 of Chapter 3.)
• Intake/exhaust valve • Gas leak due to worn valve seats or • Lap the valve seats.
5 • Valve seat trapped foreign matters (Refer to Section 4-3-1 2).)
• Sticking of valves • Replace the intake/exhaust valves.
• Piston • Gas leak due to scratches or wear of • Do the honing and use oversize parts.
6 • Piston ring the piston, piston ring or cylinder (Refer to Sections 4-3-2 3) and 4-3-4 8).)
• Cylinder
4-2-2 Adjusting the Valve Clearance
(1) Inspect and adjust the intake / exhaust valve clear-

ance while the engine is in the cold state.
(2) Set the piston in the cylinder to be measured to the
top dead center (TDC) of compression.
(3) Loosen the lock nut and the adjust screw. Check
that the valve cap is free from inclination or foreign
matter.
(4) Insert a thickness gauge between the rocker arm
and the valve cap. Tighten the adjust screw until the
clearance listed below is attained.
Intake / exhaust valve Refer to Section "3-2 1) Nominal

clearance and Allowable Values". Adjust screw
Notes : Valve clearance Lock nut

1. If the valve cap is worn or otherwise damaged in the
head, replace it with a new one.
2. Check that the valve cap is fitted on the head of
intake/exhaust valve.
Valve cap (Adjusting the valve clearance)
Normal Abnormal
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4. ENGINE
4-2-3 Checking the V-belt Tension
Push the center of the V-belt between the alternator

and the cooling water pump with a finger. If the slack
is 10 to 15 mm, the V-belt tension is proper. If not,
adjust the V-belt tension using the adjuster at the
alternator.
Adjust the tension of

the V-belt using a bar.
Adjuster
10 to 15 mm
Alternator
Cooling water pump
Crank pulley
Alternator
(Adjusting the V-belt tension)
4-2-4 Checking the Fuel Injection Valve
1) Measuring the Fuel Injection Pressure
Note :
Thoroughly remove carbon deposits from the injection
nozzle hole before the measurement.
(1) Connect the fuel injection valve to the high pressure

pipe of the nozzle tester.
(2) While pumping the lever of the nozzle tester slowly, Nozzle tester
read the pressure gauge on the nozzle tester the
moment the nozzle starts fuel injection.
(For the fuel injection pressure, refer to Section "2-1
Specifications".)
Injection nozzle
(3) If the measured fuel injection pressure is lower than
the specified value, replace the pressure adjusting ( Measuring the fuel injection pressure
with a nozzle tester )
shim with a thicker one.
Types of pressure adjusting shim thickness

Fuel injection pressure adjustment
(mm)
Increase the pressure adjusting shim thickness by 0.1 mm to increase the fuel
0.1, 0.2, 0.3, 0.4, 0.5
injection pressure by about 6.9 to 9.8 MPa (7 to 10 kgf/cm2).
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4. ENGINE
[Reference : Structure of fuel injection valve]
Nozzle holder
Pressure adjusting shim
Nozzle spring
Nozzle spring seat
Valve stop spacer
Nozzle valve
Nozzle
Nozzle body
Nozzle case nut
2) Checking the Spray Pattern

While pumping the lever of the nozzle tester once or twice per second at the specified fuel injection pressure (Refer to
Section "2-1 Specifications".), check the spray pattern. If the spray pattern is not normal, clean or replace the nozzle.
(1) Check that the pattern is neither like a stream nor slivered.
(2) Check that fuel is sprayed conically around the nozzle center line and that the spray angle is 5 to 10 degrees.
[Normal spray pattern] [Abnormal spray pattern]
5 to 10 degrees
(3) Spray fuel on a sheet of white paper placed about 30 cm below the nozzle. The injection spray should form a
perfect circle.
(4) No fuel should drip from the nozzle after injection.
(5) Fuel should not ooze from the nozzle hole when the fuel injection pressure rises to a value that is a little lower
than the specified value : 1.96 MPa (20 kgf/cm2).
(6) Test the injection with a nozzle tester ; retighten the nozzle holder and test it again if there is excessive fuel leak
from the overflow coupling. Replace the nozzle as a set if the fuel leak is still excessive.
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4. ENGINE
3) Nozzle Valve Sliding Test

Thoroughly wash the nozzle valve using clean fuel. Hold the nozzle
body vertical, and put the nozzle valve approx. 1 / 3 of its length into
the body.
Check if the nozzle valve falls smoothly by self-weight when
released. If so, the nozzle valve is good. In case of a new nozzle,
remove the seal peel, and immerse it in clean light oil or the like to
clean its inner and outer surfaces and thoroughly remove rust-pre-
ventive oil before using the nozzle. Note that a new nozzle is
(Nozzle valve sliding test by self-weight)
immersed in rust-preventive oil and then is pasted with a seal peel
to shut off the outside air.
4) Nozzle Body Identification Number

Y DN - O S D YD1
Design code
No code : Pintle type

Code D : Throttle type
Size : Size P (or S)

YDN
- OSD -YDN
Spray angle Identification
number
Type : Pintle type
YANMAR
4-2-5 Checking and adjusting the Fuel Injection Timing
1) Replacing the Fuel Injection Pump

When the pump has become old and worn, replace the pump.
Replacing only the fuel pump

As with the standard engine, injection timing adjusting shims are inserted between the gear case and the fuel pump
for adjustment. Check the injection timig with the FID method.
Note :
Do not separate the FIP coupling and driving gear.
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4. ENGINE
2) Checking and Adjusting the Fuel Injection Timing

(1) Using the crankshaft pulley, turn the engine in the specified
direction. Check the injection timing with the delivery valve
spring holder of the fuel injection pump for the cylinder
No.1. (Cylinder are numbered from No.1 sequentially from
Crankshaft pulley
the flywheel side).
(2) When the crankshaft is turned in the specified direction, the

fuel level rises at the tip of the delivery valve spring holder.
At that time, stop turning the crankshaft.
(3) Check the timing mark imprinted on the flywheel through the Flywheel housing
peep hole in the flywheel housing.
(For the fuel injection timing, refer to Section "2-1 Specifica-
tions".
Peep hole
Timing mark
(4) If the fuel injection timing differs from the specified timing,
remove the fuel injection pump to adjust the timing by
increasing or reducing the adjusting shim thickness
between the fuel injection pump and the gear case.
• Increase the shim thickness to delay the injection timing.
• Reduce the shim thickness to advance the injection timing. Adjusting shim
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4. ENGINE
4-2-6 Adjusting the Maximum (or Minimum) Idling Speed
(1) First warm up the engine. Then, gradually increase the

engine speed up to the high idling speed. (Refer to Section
"2-1 Specifications".)
(2) If the maximum idling speed differs from the specified one,
adjust the high idling speed using the high idling speed
High idling speed
adjusting bolt. limiting bolt
(3) Set the low idling speed to the specified value, (Refer to Governor lever
Section "2-1 Specifications".) by turning the low idling Accelerating wire

Accelerating wire bracket High Low
speed adjusting bolt.
Low idling speed
limiting bolt
4-2-7 Checking the Cooling Water System and Radiator for Water Leakage
1) Checking the Cooling Water System for Water Leakage

Note :
The cooling water system can be checked effectively while the
engine is warm.
(1) Supply cooling water up to the normal water level in the

radiator. Attach the cap tester body to the radiator.
(2) Start operating the cooling water pump, and set the pres- Cap tester
sure of the tester to 0.075 to 0.105 MPa (0.75 to 1.05 kgf/
Checking the cooling water system
cm2). Any lower reading of the pressure gauge on the cap ( for water leakage )
tester indicates water leakage from the cooling water sys-
tem. Then, find out the portion of the cooling water system
from which cooling water leaks.
2) Checking the Radiator Cap

Attach the radiator cap to a cap tester. Set the pressure of the
tester to 0.075 to 0.105 MPa (0.75 to 1.05 kgf/cm2). Check if
the cap is opened at the set pressure. If not, replace the cap,
because it is defective.
Radiator cap
(Checking the radiator cap)
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4. ENGINE
4-2-8 Checking the Sensors
1) Checking the Thermostat and the Thermoswitch

(1) Thermostat
Put the thermostat into the water in a container. While
measuring the water temperature, heat the water. Check
that the thermostat functions at a temperature of 69.5 to
72.5 °C.
Themostat
Thermometer
Thermostat
Thermo switch Cooling water pump
(2) Thermoswitch
Put the thermoswitch into the antifreeze or oil in a con- Thermometer
tainer. While measuring the liquid temperature, heat the
liquid. If the tester shows continuity at a temperature of
107 to 113 °C, the thermoswitch is normal.
Tester probes
2) Hydraulic Switch Oil pressure switch Cylinder block

Remove the connector from the hydraulic switch. While (flywheel side)
running the engine, bring the tester probes into contact
with the switch terminal and the cylinder block. If the
tester shows continuity, the hydraulic switch is defective.
Tester probes
Continuity test
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4. ENGINE
4-3 Measurement Procedure, Service Data and Corrective Action
For the maintenance of all parts, make measurements according to the following measurement procedure. If any
part is found to be defective or if any part is not within the allowable value, replace it with a new one. However, if it is
expected that any part within the allowable value will exceed the value before the next maintenance based on the
record of its use, be sure to replace such a part beforehand.
4-3-1 Cylinder Head
1) Checking the Combustion Surface for Distortion

(1) Remove the intake / exhaust valves and the fuel
Straight-edge
injection valve from the engine. Clean the surface of
the cylinder head.
(2) Place a straight-edge along each of the four sides
and each diagonal of the cylinder head. Measure
the clearance between the straight-edge and the
combustion surface with a thickness gauge.
Cylinder head
combustion Standard Wear limit Thickness gauge
surface distortion
Refer to Section "3-2 1) Nominal and Allowable Values". ( Measuring the combustion
surface distortion )
(3) Visually check if the combustion surface is free from
discoloration, cracks, and crazing. In addition, use the color check kit for cracks and crazing.
2) Intake / Exhaust Valve Seat

(1) Valve sinkage
Over long periods of use and repeated lappings, combustion efficiency may drop. Measure the sinking depth and
replace the valve and valve seat if the valve sinking depth exceeds the standard value.
Standard. Wear limit
Intake
Valve valve Refer to Section "3-2 1) Nominal and
sinkage Exhaust Allowable Values".
valve
Valve sinkage
Depth micrometer
(Measuring the valve sinkage)
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4. ENGINE
(2) Width and angle of the valve seat

Remove carbon deposits from the seat surface. Mea-
sure the seat width and angle using vernier calipers and
an angle gauge respectively.
Standard Wear limit
Valve Intake
seat
Exhaust
width Refer to Section "3-2 1) Nominal and
Valve Intake Allowable Values".
seat
Exhaust
angle
(Measuring the valve seat width)
[Valve seat correction procedure]

(1) If the seat surface is worn or roughened slightly, lap Seat grinder
the seat surface to a smooth state with a valve com-
pound mixed with oil.
(2) If the seat surface is worn or roughened exces-
sively, correct the seat surface using a seat grinder
or a seat cutter, and finish it according to the above
step (1).
Grindstone
[Procedure for using seat grinder and seat cutter]

(1) Correct the roughened seat surface with a seat
grinder or a seat cutter.
70
Seat grindstone Angle θ (degrees)

Intake valve 30
15
Seat width
Exhaust valve 45
(2) When the seat width is enlarged from the initial

value, correct it by grinding the seat surface with a
Valve seat
70 degrees seat grinder or a seat cutter. Then, grind
the seat surface with a 15 degrees grinder so that
the seat width should be the standard value.
Note :
When using a seat cutter, apply pressure evenly taking
care not to cut the seat surface unevenly.
(3) Knead a valve compound with oil and finish the valve seat by lapping with the compound.
Note :
If any valve requires correction, be sure to measure the oil clearance between the valve stem outside dia. and the
valve guide inside dia. If the oil clearance exceeds the wear limit, replace the valve or the valve guide before correct-
ing the valve seat surface. (For the oil clearance between the valve and the valve guide, refer to the subsection 3 in
this section.)
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4. ENGINE
(4) Last, lap the valve using only oil.

Notes :
1. After correcting the valve seat, thoroughly clean the valve and the cylinder head using light oil or the like. Thor-
oughly remove the valve compound or the grindstone powder.
2. For slightly poor contact, take the steps (3) and (4) only.
3) Intake / Exhaust Valve

(1) Wear and bend of the valve stem
Replace the valve stem if bent or worn excessively. In this case, replace the valve guide together with the valve
stem.
(2) Valve stem and valve guide
Oil clearance is the difference between the valve guide inside diameter measured with a three-point micrometer or a
cylinder gauge and the stem outside diameter measured with a micrometer. If the oil clearance is near the wear limit,
replace both the intake / exhaust valve and the valve guide with new ones.
Note :
Three-point micrometer : Used for an inside diameter of 4 to 8 mm.
Cylinder gauge : Used for an inside diameter of 6 mm or more.
Standard Wear limit
Stem
outside dia.
Intake
Guide
valve
inside dia.
Oil clearance Refer to Section "3-2 1) Nominal
Stem and Allowable Values".
outside dia.
Exhaust
Guide (Measuring the valve stem outside diameter)
valve
inside dia.
Oil clearance
(3) Thickness of valve head

Measure the thickness of the valve head with a micrometer.
If the measured value is near the wear limit, replace the
valve with a new one.
Standard Wear limit
Intake
Thickness valve Refer to Section "3-2 1) Nominal
of valve
Exhaust and Allowable Values".
head
valve Seat width
Thickness
Valve diameter
Seat angle
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4. ENGINE
[Valve guide replacement procedure]

(1) Extract the valve guide from the cylinder head using a
Valve guide insertion tool
valve guide extraction tool.
(2) Put the valve guide into a container containing liquid
Valve guide
nitrogen, ether or alcohol together with dry ice. Then, hit projection
the sufficiently cooled valve guide to fit it into the cylinder
head using a valve guide insertion tool.
(3) After inserting the valve guide, finish the inside of the Valve guide
valve guide with a reamer.

(4) Check the projection of the valve guide.
Projection
Standard Wear limit
Refer to Section "3-2 1) Nominal

Valve guide projection
and Allowable Values".
(Valve guide projection)

4) Valve Stem Seal Valve stem seal
[Time of replacement]
(1) When oil loss is found excessive.
Valve guide
(2) When the valve stem seal is removed.
Cylinder head
(3) When the intake / exhaust valve is removed.
[Precautions on installation]
Before reinstalling the intake / exhaust valve, thoroughly
remove the burrs on the valve stem surface and then apply
sufficient lubricating oil to the valve stem.
( Hatched portion indicates

where to apply lubricating oil. )
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4. ENGINE
5) Checking the Valve Spring

(1) Visually check if the valve spring is free from flaws
and corrosion.
(2) Measure the free length (length of the spring) and
inclination (squareness of the side of the coil).
Standard Wear limit
Free length
Inclination
Valve Refer to Section "3-2 1) Nominal
Tension
spring and Allowable Values".
N (kg)
(1 mm (Measuring the free length)
compressed)
(Measuring the inclination of valve spring)
6) Checking Valve Spring Holder and Cotter Inclination

Check the contact of the inner surface of the valve
spring holder with the outer surface of the cotter as well Square
as the contact of the inner surface of the cotter with the Free length
notch in the head of the valve stem. If such contact is
uneven or if the cotter has sunk due to wear, replace the
cotter with a new one. Surface plate
(Measuring the inclination of valve spring)
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4. ENGINE
4-3-2 Cylinder Block

Cylinder gauge
1) Checking the Cylinder Block
(1) Visually check if the cylinder block is free from water
leak, oil leak and cracks. If any portion of the cylin-
der block might be cracked, check the portion by
color check.
(2) Replace the cylinder block if badly damaged and
unreparable.
(3) Thoroughly clean each oil hole. Make sure that it is
not clogged.
(Measuring the cylinder bore diameter)
2) Measuring the Cylinder Bore and the Distortion of the Cylinder

Measure each cylinder bore with a cylinder gauge. Mea-
sure the cylinder bore diameters at the point a, approx. 20 mm
a
20 mm below the crest of the liner, and at the points b
and c at equal intervals.
Obtain the distortion of the cylinder (the roundness and
cylindricity of each cylinder) from the following measured b
values :
• Roundness :
Difference between the max. and min. bore values on
c
the same cross section of each liner.
• Cylindricity :
Difference between the max. and min. bore values in
the same direction of each liner.
Apply honing (honing and boring) if any measured value
A
exceeds the allowable limit.
Note :
For oversized pistons and piston rings, refer to Section "4-
3-4 Piston and Piston Rings".
B
Standard Wear limit
Cylinder bore dia. Note : Measurement should be made at the points

Refer to Section "3-2 1) Nominal a, b and c in the directions of A and B
Roundness of cylinder
Cylinder bore measuring
Cylindricity of cylinder
( points )
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4. ENGINE
3) Honing
(1) Application of honing
Apply honing or boring to the cylinder if it is partially
worn, flawed, or otherwise damaged. If the partial wear,
flaw or other damage is minor, it can be repaired only by
honing with a Flex-Hone. However, if it is not minor,
apply honing after boring. In this case, taking the maxi-
mum wear into consideration, it is important to examine
whether the cylinder can attain perfect roundness after
honing and / or boring, and whether prepared oversized
pistons and piston rings can be used. (For the oversized (Flex-Hone)
pistons and piston rings, refer to Section "4-3-4 Piston
and Piston Rings".)
(2) Procedure for using the Flex-Hone Flex-Hone
It is common practice to use the Flex-Hone for honing.
The procedure for using it is described below. Any mate-
rial needs a honing allowance of approx. 1 / 1000 mm for
honing with the Flex-Hone.
[1] Items to be prepared Power drill
Flex-Hone, power drill, and honing liquid

Engine oil Light oil
Flex-Hone Applicable bore dia.
50% 50%
Yanmar code No. (mm)
129400-92410 70 to 76
Honing liquid
[2] Handling procedure
Soak the Flex-Hone in the honing liquid. Insert the Flex-
Hone into the cylinder and move it up and down for about
30 seconds while turning it at a cross hatch angle of about
30 to 40 degrees. Then, extract the Flex-Hone while turn- 30 to 40 degrees
ing it.
Notes :
1. Use the Flex-Hone at a speed of 300 to 1200 rpm. Use
of the Flex-Hone at a higher speed may be hazardous.
2. Never insert into or extract from the cylinder the Flex-
Hone, with the power drill stopped.
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4. ENGINE
4) Overhaul of Cylinder (Reference)

Service life of cylinder block (H3)
(H3 = 3H1)
Time for boring and honing (H2)

(H2 = 1.5H1)
Time for honing (H1)
Increase in L.O.C* Increase in L.O.C Increase in L.O.C Increase in L.O.C

and blow-by and blow-by and blow-by and blow-by
Honing Boring
( )
Examine the applicability
of oversized
pistons and piston rings.
*L.O.C = lubricating oil consumption
4-3-3 Valve Rocker Arm
1) Measuring the Rocker Arm Shaft Outside Diame-

ter and the Rocker Arm Bush Inside Diameter
Oil clearance is the difference between the rocker arm
bush inside diameter measured with a cylinder gauge
and the rocker arm shaft outside diameter measured
with a micrometer. If the oil clearance is near the wear
limit, replace the rocker arm shaft and the rocker arm
( Measuring the rocker arm shaft
outside diameter )
with new ones.
Standard Wear limit
Shaft
Intake / outside dia.
Refer to Section "3-2 1)
exhaust
Bush inside Nominal and Allowable Val-
valve rocker
dia. ues".
arm
Oil clearance
( Measuring the rocker arm

busu inside diameter )
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4. ENGINE
2) Checking the Push Rod Bend, Measuring the Tappet

Stem Outside Diameter and Checking the Tappet Con-
tact Surface
Put the push rod on the surface plate to check that there is no
clearance between the push rod and the surface plate. Mea-
sure the tappet stem outside diameter with a micrometer.
Standard Wear limit
Push rod bend

Thickness gauge
Stem outside
diameter Refer to Section "3-2 1)
Guide hole Nominal and Allowable Val-
Tappet ues".
inside
diameter
Oil clearance (Measuring the push rod bend)
3) Other Inspections
(1) Valve rocker arm shaft spring
Check if the rocker arm shaft spring is free from corro-
sion and wear. If not, replace it with a new one.
(2) Wear of intake/exhaust valve rocker arm and valve cap
Check the intake / exhaust valve rocker arm for the con-
tact surface with the valve cap. If any of them is exces-
sively worn or partially flaked, replace it.
(3) Check the portion where the valve clearance adjust
screw is in contact with the push rod. If the portion is (Measuring the tappet stem outside diameter)
worn or flaked, replace the push rod or the adjust screw.
Adjust screw
Check of contact surface
Check of contact
surface of rocker arm
Push rod
Abnormal contact surface Normal contact surface
(Checking the tappet contact surface)
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4. ENGINE
4-3-4 Piston and Piston Rings
1) Checking the Piston

(1) Remove carbon deposits from the head and com-
bustion surface of the piston while taking care not to
damage the piston. Check if there are any cracks or
damage.
(2) Check the outer surface and ring grooves of the pis-
ton, and replace it if worn or damaged.
Measuring
position
22 to 25 mm
2) Measuring the Piston Outside Diameter

To measure the piston outside diameter, measure the long
diameter of the oval hole in the vertical direction to the
piston pin bush hole at a position which is 22 to 25 mm
above from the lower end of the piston.
Standard Wear limit
Piston outside dia.

Minimum clearance Refer to Section "3-2 1) Nominal
between piston and Allowable Values".
and cylinder
(Measuring the piston outside diameter)
3) Shapes of Piston Rings

Top ring
Second ring
Oil ring
Ring components
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4. ENGINE
4) Measuring the Ring Groove Width, the Ring Width (B), and the End Gap
To measure the piston ring groove width, first measure the
width (B) of the piston ring. Then, fit the piston ring into
the ring groove after cleaning the groove carefully. Insert a
thickness gauge between the piston ring and the groove
to measure the clearance between them. Obtain the ring
groove width by adding the ring width to the measured
clearance.
Width
(B)
Thickness
(Measuring the ring groove width)
To measure the end gap, push the piston ring into the End gap
sleeve using the piston head, insert a thickness gauge
between both ends of the piston ring. If the sleeve is worn,
measure the end gap after pushing the piston ring into the Approx. 30 mm
sleeve to the portion which is less worn (approx. 30 mm

Piston ring
from the lower end of the sleeve).
Standard Wear limit
Ring groove
Cylinder block
width
Ring width (B)
Top
ring Clearance
between
groove and ring
End gap
Ring groove
width
Second
Ring width (B)
( Measuring the end gap
of piston ring )
ring Clearance and Allowable Values".
between
groove and ring
End gap
Ring groove
width
Ring width (B)
Oil ring Clearance
between
groove and ring
End gap
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4. ENGINE
5) Installation of Piston Rings

(1) Using a piston ring replacer, fit the piston ring into
the ring groove, with the manufacturer's mark near
the end of the piston ring facing upward (to the com-
bustion chamber side). After fitting the piston ring,
check that the piston ring moves smoothly. The side with manufacturer’s
mark shall face upward
(2) After fitting all the piston rings, shift the end gaps of
them at 120 degrees intervals, so that they are not
aligned along the piston. Apply lubricating oil to the
Top ring
piston pin before inserting it into the piston.
6) Measuring the Outside Diameter and Bush Hole Second ring

Inside Diameter of the Piston Pin
Measure the outside diameter and bush hole inside
diameter of the piston pin. Replace the piston pin if one Oil ring
or both of the measured values exceed the wear limit.
Apply lubricating oil to the piston pin before inserting it
Top ring
into the piston.
120
120
Second ring
120
Oil ring
(Measuring points of the piston pin

outside diameter )
Standard Wear limit
Outside dia.
Piston Bush hole Refer to Section "3-2 1) Nomi-
pin inside dia. nal and Allowable Values".
Oil clearance
Apply oil to piston pin
(Measuring the piston pin outside diameter) Circlip
(Inserting piston pin)
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4. ENGINE
7) Top Clearance (Reference)
Top clearance
Refer to Section "3-2 1) Nominal and Allowable Values".
8) Oversized Piston and Piston Ring
(0.250S : Oversized by 0.25 mm)
Piston assembly code

Size classification Piston ring assembly code
(including piston ring assembly)
0.250S 119717-22950
Cylinder bore machining dimension Ø76.250
4-3-5 Connecting Rod
1) Visual Inspection
Inspect the following portions for cracks, distortion and discoloration :
(1) Portions close to the boundaries between the chamfered parts of the large and small ends, and the I-beam sec-
tion of the connecting rod
(2) Portion around the oil hole in the bush at the small end
2) Measuring the Twist and Parallelism

Measure the twist and parallelism of the connecting rod with a connecting rod aligner.
Twist and parallelism
Refer to Section "3-2 1) Nominal and Allowable Values".
m
0m
10
m
0m Parallelism
10
Connecting
rod aligner
Twist
Reference axis
( Measuring
connecting rod aligner )
the twist with
(Measuring the twist and parallelism)
4-3-13 0000604
4. ENGINE
3) Measuring the Clearance Between the Crank Pin and Bush

To measure the oil clearance between the crank pin and
the crank pin metal, measure the inside diameter of the
crank pin metal and the outside diameter of the crank
pin, and calculate the difference between them.
If the measured oil clearance exceeds or near the wear
limit, replace the crank pin metal. If the crank pin is
excessively or partially worn, grind the crank pin, and
use an oversized crank pin metal.
Note : Cylinder gauge
To measure the inside diameter of the crank pin metal,
install the metal into the large end of the connecting rod
and tighten the rod bolts at a specified tightening torque,
making sure that each half of the metal is set in the cor-
rect way.
Rod bolt tightening torque Refer to Section "3-7-2
(Apply lubricating oil to
the rod bolt)
Engine Tightening torque for
major bolts and nuts".
( Measuring the inside diameter of
the crank pin metal )
Standard Wear limit
Crank
pin metal
inside dia.
Crank
Crank pin metal Refer to Section "3-2 1) Nomi-
pin side thickness nal and Allowable Values".
Crank
pin outside
dia.
Oil clearance
4) Measuring the Oil Clearance Between the Piston

Pin Bush and the Piston Pin
To measure the oil clearance between the piston pin
bush and the piston pin, measure the inside diameter of
the piston pin bush and the outside diameter of the pis-
ton pin, and calculate the difference between them.
Standard Wear limit
Bush
inside dia. Cylinder gauge
Piston Refer to Section "3-2 1) Nomi-
Piston pin
pin side. nal and Allowable Values".
outside dia
Oil clearance
( Measuring the inside diameter of

the piston pin bush
)
4-3-14 0000604
4. ENGINE
5) Checking the Contact of the Crank Pin Metal

Apply a blue ink or a minium to the inside surface of the
crank pin metal. Instal the crank pin metal to the crank
shaft, and tighten the rod bolts at a specified tightening
torque (refer to the above 3 of this section) to check the
contact of the metal. If the contacted surface of the metal
occupies 75 % or more of the total surface, the crank pin
metal is good in terms of contact.
Install the connecting

rod so that the Crank pin metal
punched marks
6) Installing the Piston and the Connecting Rod
of large end
Install the piston with the connecting rod, with the marks faces the fuel
injection pump
at the large end of the connecting rod facing the fuel
injection pump. Also, install the piston so that the recess
of the combustion chamber is on the fuel injection pump
side as seen from the top.
7) Side Gap of the Connecting Rod

After installing the connecting rod to the crank shaft,
Cam shaft side
tighten the rod bolts at a specified tightening torque Combustion
chamber recess
(refer to the above 3 of this section). Measure the side
I.D. mark
gap by inserting a thickness gauge between the con-
necting rod and the crank arm. If the measured value
exceeds the wear limit, replace the crank pin metal or
Fuel injection
the connecting rod. pump side
Side gap Nominal and Allowable Val-
ues".
8) Undersized Crank Pin Metal

Undersized by 0.25 mm
Crank pin metal
Metal thickness (mm)
Part code No.
Standard
119717-23610 -
Crankpin bore machining

Ø41.702 to 41.712 mm
dimension
Crank shaft
Thickness gauge
(Measuring the connecting rod side gap)
4-3-15 0000604
4. ENGINE
4-3-6 Cam Shaft
1) Side Gap Around the Cam Shaft

Cam shaft gear
Before extracting the cam shaft, contact a dial gauge
with the cam shaft gear to measure the side gap around
Thrust metal
the cam shaft. If the measured value exceeds the wear
limit, replace the thrust metal with a new one.
ues".
2) Checking the Cam Shaft Appearance

Check the cam shaft for the contact surface of the cam
with the tappet, seizure and wear of the bearing, and
damage of the cam gear.
3) Measuring the Bend of the Cam Shaft

Support the cam shaft with V-blocks. Using a dial gauge, Side gap
measure the runout of the journal at the center of the
Dial gauge
cam shaft while rotating the cam shaft.
Take 50 % of the measured runout as bend.
Standard Wear limit

Cam shaft bend
4) Measuring the Intake / Exhaust Cam Height
V-block
Standard Wear limit
Intake (Measuring the cam shaft bend)

Cam cam Refer to Section "3-2 1) Nominal and
height Exhaust Allowable Values".
cam
Micrometer
Cam height
(Measuring the cam height)
4-3-16 0000604
4. ENGINE
5) Measuring the Outside Diameters of the Cam Shaft

Measure the outside diameters of the cam shaft with a Flywheel side
micrometer. Calculate the oil clearance from the mea-
sured cam shaft outside diameter and the cam shaft Intermediate
bush inside diameter measured with a cylinder gauge
Gear side
after inserting the cam shaft bush into the cylinder block.
Standard Wear limit
Cam shaft
Gear outside dia.
side Oil
clearance
Cam shaft
Inter- outside dia. Refer to Section "3-2 1) Nominal and
medi-
Oil Allowable Values".
ate
clearance
Cam shaft
Fly- outside dia.
wheel
side Oil
clearance
6) Extracting the Cam Shaft Bush

Extract the bush with a cam shaft bush tool.
4-3-7 Crank Shaft
1) Side Gap Around the Crank Shaft

Before extracting the crank shaft and when installing it,
contact a dial gauge with the end of the crank shaft.
Press the crank shaft to each of the right and left sides in
the axial direction to measure the side gap. Alternatively,
insert a thickness gauge directly into the clearance
between the thrust metal in the reference part and the
thrust face of crank shaft to measure the side gap. If the
measured value exceeds the wear limit, replace the
thrust metal with a new one.
ues".
Dial gauge
Crank shaft
4-3-17 0000604
4. ENGINE
2) Color Check of Crank Shaft

Clean the crank shaft and check it using a color check kit
or a magnetic inspector. Replace the crank shaft if it is
cracked or badly damaged. If the damage is minor, cor-
rect it by re-grinding.
3) Checking the Metals

Check the metals for flaking, melting, seizure, and the
state of the contact spur face. Replace any of the metals
if it is damaged.
(Inspection by color check)
4) Bend of the Crank Shaft
Support the journals of the crank shaft with V-blocks at
both ends. Measure the runout at the center journal with Bend
a dial gauge while rotating the crank shaft to check the
bend of the crank shaft.
Bend Nominal and Allowable Val- Runout
ues".
Dial gauge
5) Measuring the of Crank Pin and Journal

Measure the outside diameters, roundness, taper angles
of the crank pin and journal. If the partial wear or the
roundness exceeds the wear limit but the measured out-
side diameter is within the limit, correct it by regrinding.
V-block V-block
Replace the crank shaft with a new one, if it is unrepara-
(Measuring the crank shaft bend)
ble. An under sized crank pin metal by 0.25 mm is avail-
able. (Refer to Section 4-3-5, 4-3-8 in this chapter.)
Crank journal
Crank pin
( Measuring
and journal
points of the crank pin
)
4-3-18 0000604
4. ENGINE
Standard Wear limit
Crank Crank pin

pin outside dia.
Outside
dia. Refer to Section "3-2 1) Nominal and
Crank Main metal Allowable Values".
journal thickness
Oil
clearance
6) Precautions for Installation of the Metal Caps

(1) The lower half of the metal on the cap side has no oil groove.
(2) The upper half of the metal on the cylinder block side has an oil groove.
(3) Check the cylinder block alignment No.
(4) Place the embossed mark "FW" of the cap on the flywheel side.
(5) Place the main metal as a reference one on the flywheel side.
Main metal (reference)
Thrust metal (flywheel side)
Main metal
Metal cap (reference)
Metal cap
Metal cap
7) Undersized Main Metal by 0.25 mm and Oversized Thrust Metal by 0.25 mm

Main metal Thrust metal
Metal thickness Metal thickness
Part code No. mm Part code No. mm
Standard Standard
719717-02910 - 119810-02940 -
Crankshaft journal machining dimension Ø46.702 to 46.712 mm
4-3-19 0000604
4. ENGINE
4-3-8 Gears
1) Checking the Gears

Check the teeth surfaces of each gear and replace the gear if the teeth are damaged, worn, or flaked.
2) Measuring the Backlashes

Apply a dial gauge onto the pitch circle of the gear, and measure the backlash.
Standard Wear limit
Crank gear, cam gear,

idle gear and fuel injec- Refer to Section "3-2 1)
Backlash tion pump drive gear Nominal and Allowable
Lubricating oil pump Values".
gear
3) Checking and Measuring the Idle Gear Shaft and the Idle Gear
(1) Measure the idle gear bush inside diameter and the
idle gear shaft outside diameter, and replace the bush
or the idle gear shaft if the oil clearance exceeds the
wear limit.
(2) Check that the oil holes in the idle gear shaft and the
bush are aligned.
Idle gear
Standard Wear limit Bush
Idle gear shaft
Shaft outside dia.
Idle gear Bush inside dia. Nominal and Allowable
Values".
Oil clearance
4) Gear Train
After installing all the gears, check that the matchmarkes A, B and C on the idle gear are aligned with those on the
crank gear the fuel injection pump drive gear and the cam gear respectively.
(From the gear case side)

Fuel injection pump drive gear
Cam gear
B
B C
C
A
Idle gear
A *P.T.O. (Option)
Crank gear
Lubricating oil pump gear
Direction of rotation
4-3-20 0000604
4. ENGINE
4-3-9 Trochoid Pump
1) Servicing Points
Point 1
Disassemble :
• Check if the pump rotates smoothly and see that there is no play between the shaft and gear, and inner rotor.
Reassemble :
• Install the outer rotor in the gear case so that the punch mark on the end face is seen.
• For installation on the gear case, tighten four bolts uniformly in several steps.
Note :
Always check if the pump rotates smoothly after installation on the gear case.
Running the engine when the pump rotation is heavy may cause the pump to be burnt.
• When replacing the lubricating oil pump, replace the whole ass’y.
Point 2
Disassemble - Reassemble :
• Only wash the pressure regulating valve. Disassembly is unnecessary unless any abnormality in operation is
detected.
2) Parts Inspection and Measurement

(1) Outside diameter clearance and side clearance of outer Gear case
Outer rotor
rotor
Insert a gap gauge between the outer rotor and the gear case
cover, and measure outside diameter gap.
Put a ruler on the end face of the gear case cover, and insert a
gap gauge between rotor, and measure a side gap.
Outside clearance mm
Inner rotor
Standard Limit
Outer diameter clearance
0.12 to 0.21 0.30
Side clearance mm
Standard Limit
0.02 to 0.07 0.12
Outer rotor
Side clearance
(2) Outside diameter clearance of inner rotor centering location part

Measure the outside diameter of inner rotor centering location part and the hole diameter of gear case cover.
Calculate the clearance from that difference.
mm
Inspection item Standard Limit
Gear case cover I.D. 46.13 to 46.18 -
Inner rotor O.D. 45.98 to 46.00 -
Rotor clearance 0.13 to 0.20 0.25
4-3-21 0000604
4. ENGINE
3) Trochoid Pump Components Cover

Outer rotor
Control valve Inner rotor
Gear case
4-3-22 0000604
4. ENGINE
4-4 Precautions for Reassembly
Reassemble the engine components in the reverse order of the disassembly procedure. Follow the precautions
below particularly before and during the reassembly.
1) Cleaning the Components

Clean the cylinder block, the cylinder head, the crank shaft, and the cam shaft carefully so that they are free from
chips, dust, sand, and other foreign matter.
2) Parts to be Replaced in Reassembly

Be sure to replace the following parts with new ones in reassembly.
(1) Valve stem seal
(2) Head gasket packing
(3) Nozzle protector of the fuel injection valve
(4) All of the copper packings, O-rings and gasket packings.
3) Measuring the Side Gap Around the Crank Shaft

Apply a dial gauge to the end of the crank shaft. Press the
crank shaft to each of the right and left sides in the axial
direction to measure the side gap. Alternatively, insert a
thickness gauge directly into the clearance between the ref-
erence thrust metal and the thrust surface of the crank shaft
to measure the side gap. If the measured value exceeds the
wear limit, replace the thrust metal with a new one.
Dial gauge
Refer to Section "3-2 1) Nom-
Side gap
inal and Allowable Values". Crank shaft
4) Gear Train
After installing all the gears, check (From the gear case side)
that the match marks A, B and C on
the idle gear are aligned with those
Cam gear
on the crank gear, the fuel injection
pump drive gear and camshaft
gear respectively, as shown below.
B
B C
C
A
Idle gear
A *P.T.O. (Option)
Crank gear
Lubricating oil pump gear
Direction of rotation
4-4-1 0000604
4. ENGINE
5) Where to Use Liquid Packing

(1) Between the cylinder block and the gear case flange
(2) Between the gear case flange and the gear case cover
(3) Oil pan mounting surface
Notes :
1. Use Three Bond No. 005 (Yanmar part code : 97777-001212) as the liquid packing.
2. Apply the liquid packing so that there should no break halfway. Otherwise, oil leakage or other trouble may be
caused.
6) Applying Lubricating Oil to the Intake / Exhaust Valve guide

Valve Stem
Apply lubricating oil to the valve stem so that the oil
spreads over the lower surface (hatched portion in the fig-
ure) of the valve guide, before reinstalling the valve stem.
7) Reinstalling the Piston Rings

(1) Fit the piston ring into the ring groove, with the manu-
facturer's mark near the end of the piston ring facing
upward (to the combustion chamber side), using a
piston ring replacer. After fitting the piston ring, check
that it moves smoothly. The side with manufacturer’s
mark shall face upward
(2) Install the piston their end gaps rings into their
respective ring grooves so that their end gaps are
shifted at 120 degrees intervals, making sure that
Top ring
they are not aligned along the piston. Apply lubricat-
ing oil to the outside surface of the piston.
Second ring
Oil ring
Top ring
120
120
Second ring
120
Oil ring
4-4-2 0000604
4. ENGINE
8) Applying Lubricating Oil to the Push Rod Adjust Screw

Contact Portion
Apply lubricating oil to the hatched portion of the push rod as Apply lubricating oil
shown in the figure, before reassembly.
9) Installation Direction of the Piston and the Connecting Piston ID mark

Rod
Camshaft side
Nozzle side
Embossed mark
(Flywheel side)
10) Tightening Order and Tightening Torque of the Cylinder Head Bolts
Tighten the cylinder head bolts at a specified tightening torque in the numerical order as shown below.
Cam shaft side
7 1 10
(Three cylinders) 13 3 6 12
Flywheel side Gear case side
11 5 4 14
9 2 8
Fuel pump side
Refer to Section "3-7-2

Tightening torque Engine Tightening torque for
major bolts and nuts".
11) After Completing the Reassembly, Carry Out a Verification Run of the Engine to Check That There is No
Water or Oil Leakage.
4-4-3 0000604
4. ENGINE
4-5 Fuel Injection Pump / Governor
4-5-1 Introduction
A fuel injection pump is the most important device which

Fuel
adjusts an injection quantity precisely corresponding to the injection pump
change of engine load.
Therefore, not only a very precise machining should be neces-
sary all parts but also the assembling, adjustment which top- Governor
level is excellent in should be necessary.

The careful consideration to avoid dust and rust at the time of
disassembly, adjustment, reassembly of the fuel injection pump
in the market is necessary.
Fuel injection pumps manufactured by Yanmar, YPES-ML type
series are inline type.
A cam shaft is driven through the timing gear, and mechanical
type fuel feed pump driven by a cam shaft sends fuel to the fuel
filter from the fuel tank.
The fuel which passed through the fuel filter is supplied to the
storeroom of the pump housing, and the pressure of the fuel
rises by the plunger The fuel passes through the fuel high pres-
sure pipe and the fuel is injected to each cylinder from the fuel
injection nozzle.
The manual of the separate volume is referred to for the disas-
sembly and assembly, adjustment procedure of only the YPES-
ML type fuel pump.
4-5-2 Fuel Injection Pump
1) Fuel System Diagram
Fuel injection valve
Fuel injection pipe
Fuel return pipe
To fuel tank
Fuel injection pump
Fuel filter OIl / water separator

(Option)
From fuel tank

Feed pump
4-5-1 0000604
4. ENGINE
2) Disassembly Procedure:
The procedure to remove a fuel injection pump from the gear
case is shown.
Note :
Be sure to remove a flange and a fuel injection pump drive
gear with a pair without loosening the flange installation bolts.
Fuel injection pump
(1) Remove fuel injection pipes, fuel pipes and a remote con-
Flange
trol wire. Block the entrance with tape so that trash may
Fuel injection
not enter the fuel injection pipes and the fuel injection drive gear
Flange bolt
pump.
Spring
(2) Mark the position of the timing marks of a fuel pump and a washer
gear case. Or, put a mark on the gear case at the position Don't disassemble
to agree the timing mark of a fuel pump.
(3) Remove a pump cover from the gear case. Pump drive gear nut
(4) Give the marks on a fuel injection pump drive gear and a
idle gear with paint or the like.
(5) Loosen fuel injection pump installation nuts (three nuts).
(6) Loosen a installation nut of a fuel injection pump drive
gear.
(7) Move a pump drive gear and a flange with a pair to your
side by gear puller.
(8) Remove an installation nut and a washer.
(9) Remove a fuel injection pump. Leave the pump drive gear
in the gear case.
3) Reassembly Procedure
Notes :
• Use a new O-ring on the fuel pump flange and apply grease.
• Confirm whether the marks 2) - (4) of the pump drive gear and the idle gear is correct.
(1) Turn a cam shaft so that the key of the pump cam shaft may almost agree in a position of the key groove of a
pump drive gear.
(2) Insert a fuel injection pump into the installation hole of the gear case straight to prevent the damage of the O-
ring. Insert a fuel pump with confirming whether the key of a camshaft and the key groove of a drive gear agree.
(3) Assemble a pump drive gear installation nut and a washer together temporarily.
(4) Turn a fuel injection pump to the position where the marks 2) - (2) of the fuel injection pump and the gear case
agrees.
(5) Fasten pump installation nuts (three nuts).
(6) Tighten the pump installation nut which was assembled temporarily by the specified standard torque. Tightening
torque of the gear installation nut (with lube oil)
N•m (kgf•m)
Tightening torque
58.8 to 68.8 (6 to 7)
4-5-2 0000604
4. ENGINE
4) Confirmation and Adjustment of Fuel Injection Timing

Refer to 4-2-5.
5) Confirmation and Adjustment of No-load Maximum and Minimum Speed

Refer to 4-2-6. And, fuel injection pipes, fuel pipes and a remote control wire are installed in the former condition.
Note :
Monitor the oil and fuel leakage from the fuel pump system or the oil leakage from the fuel pump flange during the
engine running.
4-5-3 0000604
CHAPTER 6
HYDRAULIC EQUIPMENT
6-1 Hydraulic Pump ................................................................................... 6-1-1

6-2 Control Valve ...................................................................................... 6-2-1
6-3 Pilot Valve ............................................................................................ 6-3-1
6-4 Swing Motor ......................................................................................... 6-4-1
6-5 Travel Motor......................................................................................... 6-5-1
6. HYDRAULIC EQUIPMENT
6. Hydraulic Equipment
6-1 Hydraulic Pump
6-1-1 SV15
1. Disassembling
Loose the bolts.

Put the pump on the working
bench and remove the bolts
and the washers.
013659-00E
Loose the bolts.

Put the pump on the working
bench and remove the bolts
and the washers.
6-1-1 0000604
2. Pump Disassembling
013660-00X
Remove the front cover using a mallet.
013661-00E
Make sure all the dowels are in place

(on the body or on the flange)
6-1-2 0000604
3. Components Disassembling
Using a marker, draw a reference mark on the plate and body; it will be used later, during reassembling.
Reference mark
013662-00E
Remove the upper plate.
013663-00X
6-1-3 0000604
Remove the gears.

It is useful, during this operation, to rotate the gears by hands.
013664-00X
Remove the rear plate.
013665-00X
6-1-4 0000604
4. Seals Disassembling
013666-00X
Remove from the plates the back-up rings 1 and the seals 2.
1
013667-00X
2
013668-00X
6-1-5 0000604
013669-00X
Remove the static seal from the gear housing.
013670-00X
6-1-6 0000604
5. Seals Replacement
Fit the new balance plate seals 1 and back-up rings 2 on the plates.
1
013671-00X
The plate seal has a seat to let the back-up ring fit.
013695-00X
Use clean grease to help the seals staying in place.
013696-00X
6-1-7 0000604
013697-00X
Place on the body the new static seal.

Use clean grease to keep the seal in place.
013698-00X
6-1-8 0000604
6. Reassembling Components
Reassemble the gears and the plates, using as reference the mark previously made.
Insert in the body the rear plate 1.
Please remember that the seal tips are turned toward the suction side and that the flat surfaces are turned toward
the gear sides.
Seal tip
013699-00E
Insert the gears 2 in their previous position.

Insert the upper plate 3 (reference sign).
013700-00X
6-1-9 0000604
7. Reassembling Section
The unit is ready.
013701-00X
6-1-10 0000604
8. Front Cover Seal Replacement

Remove the snap-ring 1.
013702-00X
2
013703-00X
Turn the flange upside down and, using a screw driver (flat head), remove the shaft seal 2.
Keep attention to do not damage the seat.
013704-00X
6-1-11 0000604
9. Front Cover Seal Replacement

Put some clean grease into the seal seat 1.
013705-00X
Insert in place the shaft seal 2.
013706-00X
Insert the snap-ring 3.
013707-00X
6-1-12 0000604
10. Reassembling Front Cover

Make sure all the pins are in place (on the body or on the flange)
013708-00X
Put some clean grease on the spline area or use some thin tape to cover it.
013709-00X
6-1-13 0000604
11. Reassembling Front Cover
013622-00X
Assemble the front flange on the pump.

Be careful to do not damage the shaft seal lip.
Use a mallet to fit the flange flush with the body.
013710-00X
6-1-14 0000604
12. Final Bolting and Check

Insert the 4 bolts + washers; screw the bolts by hand to obtain a one thing unit.
013711-00X
Lock the pump into a vice and thighten the 4 bolts with a torque wrench.
Tightening torque: M=70 Nm
013712-00X
Verify the shaft of the pump can turn after the operation (use lockpliers).
If the shaft is locked, this means some of the seals went out of their seat during the assembling. The whole operation
needs to be done again.
6-1-15 0000604
6-1-2 SV17(EX)
1. First Step Before Disassembly
It’s important measure the

lenght of the grub screw
from the nut to the end of
the grub screw
The dimesion A is importat A

during the step of the
reassemble, to replace
the excact torque.
013713-00E
6-1-16 0000604
2. Disassembly
Put the pump on the working bench.

Loosen the NUT M 12 UNI
5589-A-8G
Unscrew the NUT M 12 UNI 5589-A-8G

Remove the WASHER KSA GM2000 M12
(9,8X19X1,5) Code 37860202
Unscrew the GRUB SCREW M 12X40 - 5923 - 12,9 013715-00E
6-1-17 0000604
3. Pump Disassembly
Disassembly position
Remove the n° 4 SCREW
TCEI M 10X50 UNI 5931-12.9
013717-00E
6-1-18 0000604
4. Components Disassembly
Remove the rear cover

from the pump body, keep
attention to the valve plate.
Keep the pump in

the disassebly position
013718-00E
6-1-19 0000604
5. Seals Disassembly
Put the cover on the working bench.

Remove:
-O-RING SEAL OR 3575 70 DEG SH.A (145,72X2,62) code 38302000
-O-RING SEAL OR 2025 70 DEG SH.A (6,07X1,78) code 37890000
013719-00E
6-1-20 0000604
Remove the O-RING SEAL PH 2-02890

DEG.SH.A(34,65X1,78)
Screw the grub screw code 38710000
M 12X40 - 5923 - 12,9
as soon as the PILOT
PISTON DVP TYPE D is
outside the cover
013720-00E
6-1-21 0000604
6. Seals Reassemble
Place on the cover the new static seal Place on the cover the new
-O-RING SEALOR 3575 70 DEG SH.A static seal - O-RING SEAL
(145,72X2,62) code 38302000 PH 2-028 90
-O-RING SEAL OR 2025 70 DEG SH.A DEG.SH.A(34,65X1,78)
(6,07X1,78) code 37890000 Code 38710000
Use clean grease to keep the seal inplace. Use clean grease.
Reassemble the PILOT PISTON
DVP TYPE D into the cover used
a mallet or a buffer
013721-00E
6-1-22 0000604
7. Reassemble Components
Reassemble the cover on the pump boby:

screw the n° 4 SCREW TCEI M 10X50 UNI 5931-12.9
It’s important the cover must be horizontal during this operations.
013722-00E
6-1-23 0000604
Pull the n° 4 screws thight.

Screw the WASHER KSA

GM2000 M12(9,8X19X1,5)
code 37860202 on the
grub screw to the plane of
the cover
013723-00E
6-1-24 0000604
Lock the NUT M 12 UNI 5589-A-8G

013726-00E
To replace the exact setting torque

it’s necessary screwthe grub screw
(torque limiter) in the same dimension
measusramentat the first step.
6-1-25 0000604
8. Plug Disassembly
013727-00E
Remove the PLUG GSA 22 code 50116105

Used a screwdriver, drill the plug in the center (used an hammer
on the screwdriver as soon as the point is into the plug)
Make lever and exctrat the plug keep attention don’t damage the
plug housing
(to removethe plug seal It’s necessary to damage it)
6-1-26 0000604
9. Plug Reassemble
Change the PLUG GSA 22 code

50116105 and check its plug housing
Assemblethe plug witha buffer
013728-00E
6-1-27 0000604
10. Sealing the Drive Shaft
Remove the circlip 52 UNI 7437

Remove the SHAFT SEAL BAUM3SLX7 25X52X7 code 39950510 to
front (to remove the shaft seal It’s necessary to damage it)
013729-00E
6-1-28 0000604
11. Sealing the Drive Shaft Reassemble
Change the SHAFT SEAL BAUM3SLX7

25X52X7 code 39950510 and check
its sliding surface
(drive shaft) and housing, grease the
sealing ring.
Assemblethe sealing ring with a buffer
Assemblethe snapring, and visual check

to ensure that the circlip is corretly
located in the groove
013730-00X
6-1-29 0000604
12. Final Check
013733-00X
Verify the shaft of the pump can turn after the operation (use lockpliers).
If the shaft is locked, this means some of the components went out of their seat during the assembling. The whole
operation needs to be done again.
6-1-30 0000604
6-2 Control Valve
Directional control block with flow distribution inde-

pendent of the pressure and available flow
Type SX 10, series 1X
1. Introduction
1) Foreword
This manual deals with the instructions relative to servicing and maintenance operations for the SX 10 control block.
For the inspections and servicing operations associated with the hydraulic system of the machine to which the block
is connected, please consult the maintenance manual supplied by the equipment manufacturer.
It is recommended that only qualified personnel perform the installation, connection and maintenance of this device,
and that all operations be carried out in compliance with the technical standards in force and the cleanliness regula-
tions specific to this type of installation.
To ensure maximum performance and safety during maintenance operations we advise you to
Read this manual thoroughly
All information, illustrations, instructions and characteristics contained in this document are based on the latest prod-
uct information available at the time of publication. In its attempts to maintain a high-quality product, BOSCH
REXROTH reserves the right to make design or technical modifications at any time and without prior notification.
2) Safety Instructions
Please pay a particular attention to the signals of the safety alerts and special instructions in this manual. They are
indicated in the following manner:
Indicates information or instructions which must be followed to guarantee your safety during opera-
tions.
CAUTION :
Warning against possible equipment damage.
Note :
Useful information.
6-2-1 0000604
2. Troubleshooting
CAUTION :
Before starting any procedures of trouble shooting or removing the control block, inspect the global machine's
hydraulic system to eliminate all possible malfunctions not related to the SX 10 control block.
Abnormal operation of the actuators connected to the control block

Malfunction Probable cause Additional checks Remedy
Lack of strength at all actua- (1) LS pressure relief valve Take a pressure measure- Replace LS pressure relief
tors defective ment valve
(2) LS pressure relief valve Make necessary adjustments
out of adjustment
Lack of force on one actuator Secondary pressure relief Replace secondary pressure
only valve defective or unsuitable relief valve
Lack of speed in the perfor- (1) Spool stroke incorrect Manual control: measure If stroke is incorrect: replace
mance of a movement or all spool stroke housing + spool assembly
movements
(2) Hydraulic operator Make necessary adjustments
adjustable stopnut out of
adjustment
(3) Individual compensator Replace housing + pressure
pressure blocked compensator assembly
Lack of load hold (1) Load hold check valve Replace check valve
failure
(2) Excessive clearance Replace housing + spool
between the housing and assembly
the spool
Simultaneous movement (1) Blockage of the individual Remove and clean individual
malfunction compensator orifice compensator
(2) Individual pressure com- Replace the housing + pres-
pensator blocked sure compensator assembly
(3) LS line leakage Replace flow regulator
Abnormal machine operation

Malfunction Probable Cause Additional Checks Remedy
Engine remains under load (1) Flow regulator blocked Replace flow regulator
after spools are returned to
(2) Flow regulator filter Replace the filter
neutral
clogged
Abnormal machine operation

Increase of force on controls (1) Control block assembly Check tightening torque Loosen and tighten to torque
or spool return defective tie rods too tight 15 ± 10% N.m.
CAUTION :
Remove control block from its
fixation points
(2) Spool seals obsolete Replace spool seals
6-2-2 0000604
Visual defects
Spool leaking oil (1) Spool seals defective Replace spool seals
(2) Tongue seal or spool Replace tongue seal or spool
adapter seal defective extremity seal
Oil leakage at secondary Seals defective Remove pressure relief
valves valve, anti-cavitation check
valve or plug and replace
seal
Oil leakage between ele- Seals plates defective Remove working sections
ments and replace seals plates
Oil leaking from hydraulic (1) Seal between housing Replace seal
operator housing and body defective
(2) Tightness of adjustable Check nut tightening torque Tighten to torque
stop nut defective 30 ± 10% N.m.
or replace nut and screw
3. Fundamental Rules
1) General information Concerning Control Block Connection
When removing the block, all openings must be plugged immediately to prevent any contamination of the hydraulic
system.
When replacing the block, remove the plastic plugs from the openings and lines just before making the connections.
Do not tighten connectors to a torque greater than that specified in the assembly instructions.
Check the hydraulic installation's oil quality and filtration capacity during all servicing/maintenance operations.
The use of Teflon tape, hemp and joint filler is prohibited.
Hydraulic lines and connections must not be under any strain whatsoever.
4. Removal / Installation of the SX 10 Control Block

1) General Recommendations
CAUTION :
Before removing the sx 10 control block from the machine, the block and its surroundings must be thoroughly
cleaned (do not direct the jet of a pressure washing unit directly at the unit).
No impurities must enter the hydraulic system. plastic plugs are to be fitted on lines and orifices immediately follow-
ing their removal.
Wear protective clothing and use suitable equipment to prevent accidents, particularly concerning
the hydraulic fluid.
Use the lifting eyes and suitable handling equipment.
Set all actuators connected to the machine in neutral position (on the ground, at lower limit ...) to
avoid accidents which could result from uncontrolled movements of the equipment when the
hydraulic system is disconnected.
With the machine off, release the pressure remaining in the system by manipulating all of the distri-
bution spools. This is performed by moving the handle in all directions.
6-2-3 0000604
2) Removal of the SX 10 Control Block

Install a vacuum pump on the tank to limit oil leakage when connections are removed.
After disconnecting the lines from the block, immediately fit the sealing plugs. Make sure to collect any possible oil
leakage in a suitable receptacle.
Unscrew the mounting screws and remove the control block.
3) Installation of the SX 10 Control Block

Contact faces must be perfectly clean.
Check the evenness of support area on the machine (Tolerance: 0.5 mm).
Check the condition of line connector seals.
Clean the block if it has been in storage for a long period of time.
Correctly place and secure the control block onto the machine with the mounting screws.
Connect the lines to the block as per the connecting diagram and tighten to the torque specification (refer to the
table in the Data sheet).
Ensure that hoses are not twisted or rub.
Once correctly installed, the unit can be placed into operation.
4) Starting, Maximal Pressure Set Up

• Decalibrate the LS pressure relief valve (19 mm open end spanner on counternut) before starting the machine,
• Maintain one of the control block spool valve in action before the linked hydraulic receiver is at the end of stroke.
CAUTION :
On the spool valve, the value of the secondary valve pressure must be greater than that of the ls pressure relief valve to adjust.
• Adjust the maximum pressure measured in M using the LS pressure relief valve (6 mm socket wrench).
• Tighten the counternut of the adjusting screw to the torque : 20 ± 10% N.m.
6-2-4 0000604
5. Inlet Elements Repair Procedure

1) LS Pressure Relief Valve Replacement
Procedure
Note :
The control block does not need to be removed from the
machine to perform this operation.
Machine off :
- place all of the machine's actuators connected
to the control block in neutral position,
- release stored pressure by operating all the
spools.
Note :
Install a vacuum pump on the tank to limit oil leakage during
this operation.
Collect possible leaks with a suitable receptacle.
On the inlet element, unscrew the LS pressure relief valve (24

mm open end spanner).
Reassembly :
- install the LS pressure relief valve on the inlet element,
torque : 45 ± 10% N.m.
- set the LS pressure relief valve to the specified value.
- fit a new appropriate locking cover.
6-2-5 0000604
2) Flow Regulator Replacement

Procedure
Note :
Machine off :
- release stored pressure by operating all the
spools.
Note :
this operation.
On the inlet element, unscrew the flow regulator (22 mm open

end spanner).
Reassembly :
- install the flow regulator on the inlet element,
torque : 20 ± 10% N.m.
Flow regulator filter replacement

Using pliers, extract the filter from the end of the flow regula-
tor.
Be careful not to damage the seal and the end of the flow reg-
ulator.
Filter
013739-00E
6-2-6 0000604
3) Removal of the Flushing Valve

Procedure
Note :
Machine off :
- release stored pressure by manipulating all the
spools.
Note :
this operation.
On the inlet element, unscrew the flushing valve plug (27 mm

open end spanner).
Reassembly : torque : 70 ± 10% N.m.
Remove: - plug,
- shim, Plug
- spring,
- piston. Shim
Replace parts assembly. Spring
Reassemble parts in reverse order.
Piston
013740-00E
6-2-7 0000604
6. Distribution Element Repair Procedure

1) Secondary Valves Replacement
Procedure
Note :
Machine off :
spools.
Note :
this operation.
Pressure relief valve replacement

On the distribution element in question, unscrew the pressure
relief valve plug (10 mm socket wrench).
Remove: - plug,
- conical spring,
- pressure relief valve.
Replace seal of pressure relief valve plug.
6-2-8 0000604
Procedure
Anti-cavitation check valve replacement
On the distribution element in question, unscrew the anticavi-
tation
Remove: - plug,
- anti-cavitation check valve.
Replace seal of pressure relief valve plug.
Plug replacement
On the distribution element in question, unscrew the plug (8
mm socket wrench).
Replace plug seal or plug.
6-2-9 0000604
2) Spool Stroke Measurement

Procedure
Move the control lever of the element in question in all possi-
ble positions, and measure the corresponding spool stroke
values at the tongue.
6
Position 1 and 2
6 013741-00E
6-2-10 0000604
3) Removal of Spool with Spring Return

Procedure
Note :
Machine off :
spools.
Note :
this operation.
Tongue side
Remove mounting screws and plate (3 mm socket wrench).
Remove wiper ring and O-ring.
Reassembly :
- grease and install the new seals.
CAUTION :
Position the wiper ring lip on the outside.
Cover side
Remove mounting screws and cover (3 mm socket wrench).
Remove the spool from the working section.
6-2-11 0000604
Procedure
Return system removal for seals replacement
Note :
Use the spool clamp (DSI.-No: 08102858) and a vice to
secure the spool.
CAUTION : Tongue
Mounting screw
In order to avoid breaking the clamp, place it approximately Tongue O-ring
15 mm from the end of the spool (never in the centre).
Wiper ring
Beforehand, heat the spool to 200°C in an oven or, failing Clamp DSI.-No: 08102858
that, with a heat gun. Loctite 242
Plate
Wear thick protective gloves when handling the O-ring O-ring
hot spool. Plate
Note :
Spring
Keep the load hold check valve located inside each spool side Loctite 242
clean. Wiper ring
Remove: - 2 spring retainers,
- spring,
Spring retainers
- plate,
013742-00E Slotted head screw
- wiper ring and O-ring.
Reassembly :
CAUTION :
Position the wiper ring lip on the outside.
- priory to spool system reassembly, the new O-ring and wiper

ring must be fitted onto the end of the spool so that they are
not damaged on the spool grooves.
- grease the spring,
- apply a droplet of Loctite 262 on the end of the spool adapter
internal thread,
- reassemble the return system parts in reverse order after.
- slotted head screw torque: 5 ± 10% N.m.
CAUTION :
Wait for 8 hours before using the machine to let the Loctite
262 dry completely.
6-2-12 0000604
Procedure
Tongue replacement (if necessary)
Beforehand, heat the spool to 200°C in an oven or, failing
that, with a heat gun.
Wear thick protective gloves when handling the

hot spool.
CAUTION :
Do not use a welding torch to heat the tongue as spool defor-
mation may result.
Note :
Keep the load hold check valve located inside each spool side
clean.
Loosen the tongue using an open end wrench (6 mm open

end spanner).
Note :
Keep the load hold check valve located inside each spool side
clean.
Reassembly :
- replace tongue seal
- apply a droplet of Loctite 262 on the end of the tongue
thread,
- torque: 5 ± 10% N.m.
CAUTION :
262 dry completely.
6-2-13 0000604
4) Hydraulic Operation Removal

Procedure
Note :
Machine off :
spools.
Note :
this operation.
Tongue replacement (if necessary)

Note :
Using a vernier, measure before
replacement the dimension y
between the stopnut screw and the
nut tip (see diagram below).
This value y is to be thoroughly
respected when reassembling to y
ensure an identical flow adjustment. 013743-00X
Remove: - nut (13 mm open end spanner)

- screw (4 mm socket wrench)
Hydraulic control housing removal

Remove the 2 mounting screws (screwdriver Torx Tx20 for
Torx screws, or 3 mm socket wrench for CHc screws).
Remove: - housing
- spring
- spring retainer
Replace the O-ring.
6-2-14 0000604
5) Individual Pressure Compensator Removal

Procedure
Preliminary operations
Remove the control block from the machine.
Disassemble the control block.
Note :
Secure the distribution element taking care not to damage the
element faces in contact with the seals plate.
On the distribution element in question, unscrew the compen-

sator plug (6 mm socket wrench).
Remove: - plug
- compensator piston using a magnet to extract it
from its bore.
Reassembly :
- replace the assembly,
torque : 30 ± 10% N.m
Clean the piston’s nozzle with compressed air to remove all

traces of pollution.
Check the condition of the bore in the distribution element

body.
6-2-15 0000604
6) Load Hold Check Valve Removal

Procedure
Note :
Machine off :
spools.
Note :
this operation.
On the distribution element in question, remove the mechani-

cal operation or hydraulic operation.
Note :
Use the spool clamp (DSI.-No: 08102858) and a vice to
secure the spool.
On the spool, unscrew the spool end:

- hydraulic operation : 6 mm open end spanner.
- mechanical operation : 4 mm socket wrench.
Reassembly :
- replace the spool adapter seal
- apply a droplet of Loctite 262 on the end of the spool adapter
thread,
- torque : 5 ± 10% N.m.
CAUTION :
262 dry completely.
Remove: - spring
- check valve
Visually check the condition of parts and replace the assembly

check valve and spring if necessary.
6-2-16 0000604
7) Control Block Disassembly / Assembly

Procedure
Preliminary operations:
Remove the 3 nuts (13 mm ring wrench).

Remove the outlet element.
Separate the working sections from the inlet element.
Reassembly :
- replace seals plates located between the working sections,
the inlet element and the outlet element.
- check the cleanliness of the element faces.
- place the control block horizontally on an even support area
to tight the nuts.
CAUTION :
When reassembling, make sure the seals plates are correctly
positionned so that the seals location fit with the canals to
tighten.
If the inlet element is to be replaced, remove the tie rods.
Reassembly :
- make sure that the tie rods are tightened to the specified
torque (30 ± 10% N.m)
6-2-17 0000604
MA = 70 Nm
5
22
2
6
MA = 20 Nm
MA = 45 Nm
I
m P
n
MA = 20 Nm
8 MA = 20 Nm
25 103
qp
o LS 103
7
MA = 20 Nm
Pil T M
MA = 30 Nm
230
9
013744-00E
6-2-18 0000604
7. Maintenance Instruction of Inlet and Distribution element equipped with Translation Stand-by
1. Introduction
• This dedicated manual deals with the instructions relative to servicing and maintenance operations for SX10
Translation Inlet and distribution element (See maintenance instruction manual RE 64132-S for further informa-
tion) .
• It is recommended that only qualified personnel perform the installation, connection and maintenance of this
device, and that all operations shall be carried out in compliance with the technical standards in force and the
cleanliness regulations specific to this type of installation.
Read the manual RE64132-S together with this instruction thoroughly
• All information, illustrations, instructions and characteristics contained in these documents are based on the latest
product information available at the time of publication. In its attempts to maintain a high-quality product, BOSCH
4. 1) General Recommendations
• Before removing the parts, the unit and its surroundings must be thoroughly cleaned (Do not direct the jet of a
pressure washing unit directly at the unit).
• No impurities must enter the hydraulic system.
• Make sure to collect any possible oil leakage in a suitable receptacle.
• Wear protective clothing and use suitable equipment to prevent accidents, particularly concerning the hydraulic
fluid.
• Set all actuators connected to the machine in neutral position (on the ground, at lower limit...) to avoid accidents
which could result from uncontrolled movements of the equipment when the hydraulic system is disconnected or
open.
• With the machine off, release the pressure remaining in the system by manipulating all of the distribution spools.
6-2-19 0000604
5. 3) Removal of Flushing Valve on Translation Inlet

Procedure
Note :
Machine off :
spools.
Note :
this operation.
On the inlet element, unscrew and remove the flushing valve

plug (27 mm open end spanner).
Remove: - 2 shims
- spring Plug
- piston
Reassembly : replace the complete assembly. Shim
Spring
Piston
013745-00E
6-2-20 0000604
5. 4) Removal of Translation Stand-by Kit on Translation Inlet

Procedure
Note :
Machine off :
spools.
Note :
this operation.
On the inlet element, unscrew and remove the translation

stand-by plug (6 mm socket wrench).
Remove: - spring
- piston
Reassembly : replace the complete assembly. Plug
Spring
Note :
Check that the piston is correctly oriented.
Piston
013746-00E
6-2-21 0000604
6. 5) Individual Pressure Compensator Removal on Translation Pair Element

Procedure
Disassemble the control block.
Note :
Secure the distribution element taking care not to damage the
element faces in contact with the seals plate.
On the distribution element in question, unscrew and remove

Plug
the compensator plug (6 mm socket wrench).
Spring
Piston
Remove: - Spring
- Compensator piston using a magnet to extract it
from its bore. Seals plate
Reassembly : replace the complete assembly.

Throttle
013747-00E
Clean the piston’s nozzle with compressed air to remove all

traces of pollution.
Check the condition of the bore in the distribution element

body.
6-2-22 0000604
6-3 Pilot Valve
Pilot valve unit for arm rest installation

Type 4TH5
Maintenance Instructions
1. Introduction
1) Foreword
This manual deals with the instructions relative to servicing and maintenance operations for the hydraulic pilot con-
trol unit 4TH5 for the inspections and servicing operations associated with the hydraulic system of the machine to
which they are connected. Please consult the maintenance manual supplied by the equipment manufacture.
It is recommended that only qualified personnel perform the installation, connection and maintenance of this device,
and that all operations shall be carried out in compliance with the technical standards in force and the cleanliness
regulations specific to this type of installation.
Read this manual thoroughly
All information, illustrations, instructions and characteristics contained in this document are based on the latest prod-
uct information available at the time of publication. In its attempts to maintain a high-quality product, MANNESMANN
2) Safety Instructions
Please pay a special attention to the signals of safety alerts and special instructions in this manual. They are indi-
cated in the following manner:
Indicates information or instructions which must be followed to guarantee your safety during opera-
tions.
CAUTION :
Warning against possible equipment damage.
Note :
Useful information.
6-3-1 0000604
2. Troubleshooting
CAUTION :
Before starting any procedures of troubleshooting or removing the hydraulic pilot control unit, inspect the global
machine's hydraulic system to eliminate all possible malfunctions not related to the pilot control unit.
Abnormal operation of equipment connected to the hydraulic pilot unit

Malfunction Probable case Additional checks Remedy
No machine movement (for (1) Leak See <Visual defects>
hydraulic signal receivers
(2) Control valve seized or Replace pilot unit
only)
blocked
Lack of speed of one or sev- (1) Poor pressure signal Replace pilot unit
eral machine movement(s)
(2) Leak See <Visual defects>
(for hydraulic signal receivers
only)
No machine movement (for (1) Electric function failure Replace handle
electric signal receivers only)
(2) Handle poorly connect Check the connection
Abnormal Hydraulic Pilot Unit Operation

Handle does not automati-
cally return to neutral posi-
tion:
(1) Manual return with fric- (1) Faulty cardan Replace cardan
tion
Handle does not automati-
cally return to neutral posi-
tion:
(2) Manual return without (1) Lip seal too hard inside Replace guides + plungers
friction guide
(2) Regulation unit setting Remove the regulation unit Replace pilot control unit
spring broken for visual inspection
(3) Regulation unit plater
broken
Handle turns (1) Handle parts loose Tighten all handle parts
Visual Defects
Handle push buttons worn Replace push buttons
out
Rubber boot damaged Replace boot
Leak on arm rest originating Leak between guide and Lift the boot to perform a Replace guides + plungers
from under the boot push buttons visual inspection
Seepage on body Porous body Replace the pilot unit
6-3-2 0000604
3. Fundamental Rules
1) General Information Concerning Pilot Control Unit Connection
When removing the pilot control unit, all openings must be plugged immediately to prevent any contamination of the
hydraulic system.
When replacing the pilot control unit, remove the plastic plugs from the openings and lines just before making the
connections.
Do not tighten connectors to a torque greater than that specified in the assembly instructions.
Check the hydraulic installation's oil quality and filtration capacity during all servicing/maintenance operations.
The use of teflon tape, hemp and joint filler is prohibited.
Hydraulic lines and connections must not be under any strain whatsoever.
4. Removal / Installation of the Pilot Control Unit Connection

1) General Recommendations
CAUTION :
Before removing the pilot control unit from the machine, the block and its surroundings must be thoroughly cleaned
with a high-pressure cleaner.
No impurities must enter the hydraulic system. Plastic plugs are to be fitted on lines and orifices immediately follow-
ing their removal.
Wear protective clothing and use suitable equipment to prevent accidents, particularly concerning
the hydraulic fluid.
Set all actuators connected to the machine in neutral position (on the ground, at lower limit...) to
avoid accidents which could result from uncontrolled movements of the equipment when the
hydraulic system is disconnected.
With the machine off, release the pressure remaining in the system by manipulating all of the distri-
bution spools. This is performed by moving the handle in all directions.
2) Pilot Control Unit Removal

Immediately after disconnecting the lines from the control device, fit the sealing plugs. Make sure to collect any pos-
sible oil leakage in a suitable receptacle.
Unscrew the mounting screws and remove the control device.
3) Installation of the Hydraulic Pilot Control Unit

Contact faces must be perfectly clean.
Check the evenness of the support area on the machine (tolerance : 0.5 mm).
Check the condition of the line connector seals.
Clean the pilot control unit if it has been in storage for a long period of time.
Correctly place and secure the pilot control unit onto the machine with the mounting screw (maxi torque : 10 N·m).
Connect the lines to the control unit as per the connecting diagram and tighten to the torque specification (maxi
torque : 30 N·m).
Ensure that the hoses are not twisted or rubbed.
Once correctly installed, the unit can be placed into operation.
6-3-3 0000604
5. Pilot Control Unit Repair Procedures

1) Push Button Replacement
Procedure
Note :
The pilot control unit does not need to be removed from the
Machine off :
- place all of the machine's equipment connected
to the pilot control unit in neutral position,
- release stored pressure by operating all of the
pilot unit's control valves by moving the handle
in all directions.
Remove worn out push button (s) using a small screwdriver.
The installation of new elements is performed without any

special tools ; the parts are simply pressed into place.
6-3-4 0000604
2) Boot or Handle Replacement

Procedure
Remove the pilot control unit from the machine's arm rest of
free the unit by unscrewing the 4 screws fixing the plate in
order to release the electrical cable.
Hold the pilot control unit using a vice or a vice-grip wrench
(clamp onto the body above the arm rest, 65 opening).
Note :
The pilot control unit does not need to be removed from the
machine to release the cable. However, it is recommended to
lift the control unit by undoing the 4 fixing screws on the arm
rest.
It is unnecessary to remove the units without electrical func-
tions.
Machine off :
- place all of the machine's equipment connected
to the pilot control unit in neutral position,
- release stored pressure by operating all of the
pilot unit's control valves by moving the handle
in all directions.
Handle removal
Lift and turn the boot inside out.
Remove the grommet from its emplacement to free the cable.
Loosen the handle mounting nut (19 mm open-end wrench).
Reassembly : torque : 30±3 N·m
Unscrew and remove the handle.
Boot replacement
Remove the faulty boot and replace it with a new boot.
Replace the handle following the disassembly instructions in
reverse order.
6-3-5 0000604
Procedure
Handle replacement
Clamp the threaded section of the bent lever in a vice fitting
with V-shaped vice clamps.
Remove the pin (5 mm pin driver)
Remove : - pin,
- bent lever,
- handle.
Replace the bent lever onto the new handle and secure it with
the pin (5 mm pin driver)
Note :
Respect the position of the bent lever to ensure that the han-
dle is correctly oriented as indicated by the machine's techni-
cal specifications.
Replace the nut on the threaded section and replace the boot.
Screw the handle onto the pilot control unit and tighten the nut
(19 mm open-end wrench).
Connect the new handle's electrical wiring to the machine's
electric system.
Fit the grommet into its emplacement while leaving enough
cable length so as to enable the correct handle operation.
Secure the cable to the grommet with a cable clamp.

Fold down the boot.
6-3-6 0000604
3) Cardan Replacement
Procedure
Remove the pilot control unit from the machine's arm rest.
Secure the pilot control unit in a vice (clamp onto the body).
Remove the handle.
Note :
It is recommended to remove the pilot control unit from the
machine. Nevertheless, the servicing on machine is possible
by securing the unit into a vice-grip wrench (65 opening). This
is performed by extracting the body from the arm rest so as to
clamp the vice-grip wrench onto the body in order to hold it
above the arm rest.
Removal of the cardan

Fit an Allen wrench into the assembly screw and unscrew it (8
mm Allen wrench).
Reassembly : torque : 45±4 N·m

Remove : - the cardan,
- the shim (s)
Reassembly : Adjust the pre-depression of the cardan by

selecting the shims necessary to obtain play-free contact
between the switch-plate and the plungers. In neutral position,
the depression of the plungers must not exceed 0.2 mm. In
order to check this value, observe the displacement of the
plunger located opposite to the one being pressed.
Note :
The pre-depression may be difficult to achieve on site. Could
be necessary to readjust it after reassembly and system work-
ing control.
6-3-7 0000604
4) Guide / Plunger and Regulation Unit Replacement

Procedure
Remove the pilot control unit from the machine's arm rest.
Remove the handle.
Remove the cardan.
Note :
It is recommended to remove the pilot control unit from the
machine. Nevertheless, the servicing on machine is possible
by securing the unit into a vice-grip wrench (65 opening). This
is performed by extracting the body from the arm rest so as to
clamp the vice-grip wrench onto the body in order to hold it
above the arm rest.
Removal
Secure the pilot control unit to a vice.
Remove the retaining plate.
Reassembly : Line up the notches for the grommet in both the
plate and the body.
Insert the end of a thin screwdriver between the guide and the
body, carefully lift the guide to remove it from the body.
Note :
Hold the guide with the other hand during the extraction oper-
ation to limit the effect of the return spring.
Remove the guide / plunger assembly.

Repeat the operation for the other 3 sub-assemblies.
Reassembly : Use the retaining plate to insert the 4 guides
into the body simultaneously and perpendicularly.
Reassemble in reverse order.
Regulation unit verification

Extract the regulation units from the body (using flat nose pli-
ers).
Visually check that the guides / plungers are in good condi-

tion. If defects are present, replace the 4 sub-assemblies.
Inspect the regulation units and particularly their spring. If
defects are detected, replace the 4 units.
6-3-8 0000604
6-3-9 0000604
Item Description Reference N° Dimensions

1 Handle TT 07 213 322
3 Lever kit 07 213 213
4 Rubber boot 07 259 959
7 Retaining plate 07 261 225
8 Cardan kit composed of : 1 cardan + shims 07 213 399
10 Plunger kit composed of : 07 213 396
4 plunger guides a
4 plain plungers b
4 spring rings c
Item Description Reference N° Dimensions

1 Handle ST with cable socket AMP 08 200 133
2 Push button kit 07 213 314
3 Lever kit 07 213 213
4 Rubber boot 07 259 959
7 Retaining plate 07 261 225
8 Cardan kit composed of : 1 cardan + shims 07 213 399
10 Plunger kit composed of : 07 213 396
4 plunger guides a
4 plain plungers b
4 spring rings c
6-3-10 0000604
6-4 Swing Motor
6-4-1 0000604
1. Dismantling
The listed item numbers refer to the sectional drawing and the spare parts list on pages 2 and 3.
Fix the motor in a holding tool, with the motor shaft pointing downwards.
Item Part to remove Comments

9 Screw (2 off)
116 Valve block
8 & 10 O-ring
44 Screw (4 off)
16 Valve housing
19 Disc valve
22 Spacer
18 Balance plate Half fill balance plate center hole with hydraulic oil. Rapidly press
mandrel (Ø14.5) into hole. The balance plate will now be pressed out
by the oil and can be removed.
46 ,47 & 48 O-ring
24 Spring washer
20 Channel plate
21 Valve drive
42 Gear wheel set Carefully lift out the gear wheel set. Hold one hand underneath to
prevent gear wheel rollers from sliding out.
48 O-ring
43 Cardan shaft
61 Intermediate plate
50 Seal ring
56 Nut Bearing nut is locked.
49 O-ring
54 Shaft Fix the bearing housing in a press and push shaft out of bearing
housing.
57 & 55 Roller bearing and spacer Press roller bearing and spacer out of bearing housing.
39 & 45 Shaft seal and back-up ring Take the shaft seal and back-up ring out of bearing housing.
2. Cleaning
Clean all parts carefully in low aromatic kerosene.
3. Inspection & Replacement

Check all parts carefully and make any replacement necessary.
4. Lubrication
Before assembly, lubricate all parts with hydraulic oil and grease rubber parts with vaseline.
6-4-2 0000604
5. Assembly
Replace all O-rings and seals with new O-rings and seals.
Item Part to mount Comments

39 & 45 Shaft seal & back-up ring Assemble shaft seal and back-up ring into the bearing housing.
54 Shaft Grease seal and carefully mount shaft in bearing housing. Don't dam-
age seal. Support shaft by tool A.
57 Roller bearing (front) Press front inner-ring onto the shaft and thereafter the outer-ring into
the bearing housing.
55 Spacer Place spacerring.
57 Roller bearing (rear)) Press rear outer-ring into the bearing housing and thereafter the
inner-ring onto the shaft. Control that there is no backlash in the
bearing package.
56 Nut Tighten bearing nut to 120+/-10 Nm, and secure by blowing with
mandrel and hammer in the appropriate grove.
50 Seal ring Mount vaseline greased seal ring in intermediate plate.
49 O-ring
61 Intermediate plate
43 Cardan shaft
48 O-ring
42 Gear wheel set Carefully place gear wheel set on intermediate plate with O-ring
groove pointing upwards. Hold one hand underneath to prevent rotor
and rollers from sliding out during assembly. Place hole in gear wheel
rim (Ø6 mm) in line with corresponding hole in intermediate plate.
With a pen, mark rotor of gear wheel set at the point where the root of
a tooth in splines is opposite the root of a tooth in outside toothing of
rotor.
6-4-3 0000604
6. Assembly (Continued)

48 O-ring
21 Valve drive Mark a spline tooth tip on valve drive.
Fit valve drive into gear wheel set so that markings on rotor and valve
drive correspond to one another.
20 Channel plate Mount channel plate so that hole (Ø6 mm) lines up with hole in gear
wheel set.
48 O-ring
19 Disc valve Place disc valve on channel plate so that hole (A) in outer rim lines
up with marking on valve drive. Turn disc valve counter-clockwise till
splines engage with splines on valve drive.
The drawing shows the correct fitting of the disc valve in relation to
valve drive and rotor.
6-4-4 0000604

24 Spring washer Fit spring washer into valve housing.
46 & 47 O-ring Mount two vaseline greased O-rings in balance plate grooves.
18 Balance plate Place balance plate in valve housing and carefully press into position
using a brass block and a hammer.
22 Spacer Grease spacer with vaseline and guide into center hole of balance
plate.
16 Valve housing Mount valve housing so that hole (Øloch 6 mm) lines up with hole in
channel plate.
44 Screw (4 off) Tightening torque 7.5 +0.5/0 daNm
AF 16 mm
8 & 10 O-ring
9 Screw (2 off) Tightening torque 4.5 0.5 daNm
AF 8 mm
6-4-5 0000604
6-5 Travel Motor
6-5-1 SV15
1. External Drawing
013520-00E
6-5-1 0000604
2. Section Drawing and Spare Part List
013521-00X
N° Code Description Q’ty

1 1725.008.025 Output housing 1
2 1725.110.001 End cover 1
3 1725.333.097 Motor mor 15,76 1
4 1725.517.042 Sun gear 1
5 1725.806.099 Lappeda bearing + Front seal 1
6 4725.007.200 Planetary gear set 1
8 1725.825.042 Pad 1
9 9010.603.000 External retaining ring 1
10 9010.646.000 Internal retaining ring 1
12 9030.234.951 O-ring 2,62¯139,37 1
13 9030.235.001 O-ring 2,62¯145,72 1
14 9110.624.000 Ball bearing 16019 1
15 9479.008.014 Shims kit 12,2¯19,8 1
16 9510.018.059 1/8" gas plug with o-ring 2
17 20M16.027 Valve plug 2
18 24OR2-119 O-RING 2,62¯23,47 2
19 20M16.028 Valve spring 2
20 20M16.029 Valve washer 2
21 6.701880003 Counterbalance valve spool 1
5725.KIT.0026 : Basic seal kit

5725.KIT.0027 : Major rebuilt kit (5725.KIT.0026 + item 5)
6-5-2 0000604
3. Disassembly
Procedure
After having drained the lubricant, unscrew the two drain
plugs, remove the internal snap ring securing the reduction
gear cover.
013522-00X
Remove the reduction gear cover.
013523-00X
To remove the reduction gear cover, insert two screwdriver

into the upper groove and lift the cover from the housing.
013524-00X
An alternative solution for removal of the cover.
May be ottained by unscrew the two drain plugs and install

two threaded pins (1/8" GAS) wich will be used to lift the cover
from the housing.
013525-00X
6-5-3 0000604
Procedure
Remove the O-ring from the cover.
013526-00X
The first stage planetary carrier can now be removed from the
unit by hands.
013527-00X
To disassemble the first stage planetary carrier assembly,

remove the retaining rings, the antirotation washer, planetary
gears, needle bearings and the thrust washer.
013528-00X
Remove the retaining ring from the second reduction sun gear
and push it down to slide it out from the planetary carrier.
013529-00X
6-5-4 0000604
Procedure
The second stage planetary carrier can now be removed from
the unit by hands.
013530-00X
To disassemble the stage planetary carrier assembly, remove

the retaining rings, the antirotation washer, planetary gears,
needle bearings and the thrust washer.
013531-00X
Remove the retaining ring from the hub to free the two bear-
ings, ring gear and motor.
013532-00X
To separated the hub from the ring gear, use three M10
screws as indicated in the illustration.
013533-00X
6-5-5 0000604
Procedure
Remove the O-ring from the ring gear, and the retaining ring
securing the bearing.
013534-00X
Now remove the ball bearing by pushing from underneath.
013535-00X
Remove the lapped bearing/front seal will require the use of a

commercial bearing extractor and supporting cap as shown.
Caution :
Be careful not to damage the bottom polished/lapped surface
of the bearing.
013536-00X
The front seal ring may now be removed by hands.
013537-00X
6-5-6 0000604
Procedure
The following valve parts many now be removed by hands:
plugs with O-rings, springs and washers.
013538-00X
Remove the valve from the motor cover.
013539-00X
Remove the six head socket cap screw and relatives washers
securing the motor cover.
Remove the cover and the two dowel pins.
Note :
Remove the dowel pins is optional.
013540-00X
Remove the O-ring from the motor cover, remove the roller
bearing from the cover with a bearing puller.
013541-00X
6-5-7 0000604
Procedure
Remove the bronze motor valve plate and the dowel pin.
Note :
Remove the dowel pin is optional.
013542-00X
After inverting the motor hub the rotating block will now slide
out.
013543-00X
Remove the internal retaining ring retaining the bearing/drive

shaft, push from beneath as shown in the illustration.
Note :
It is understood that the seal ring will be damaged and must
require replacement.
013544-00X
The angle faced plate can be removed by hands.

Remove the pin and the oil seal can now be removed.
Note :
Remove the dowel pin is optional; remove the oil seal in case
if it is damaged.
013545-00X
6-5-8 0000604
Procedure
Remove the first external retaining ring, the ball bearing can
now be removed.
The second external retaining ring can now be removed.
013546-00X
The unit can now be re-assembled by reversing the above

procedure.
Please keep in mind the following requirements:
1) If one of the gears of the planetary units has been dam-
aged it is advisable to replace the damaged planetary
stage assembly complete with the sun gear.
The reason is obvious, in that damage from one gear can
cause microscopic fatigue cracks in mating gear teeth,
leading to premature failure after servicing.
2) Use standard mechanical procedures, such lubricating O-
rings, seals, etc..., upon reassembly.
6-5-9 0000604
4. Reassembly
Procedure
Fit the oil seal onto the drive shaft. Install the external retain-
ing ring in the first retaining ring seat A.
013547-00E
Install the ball bearing into the motor hub, lock it into place
with the internal retaining ring.
013548-00X
Invert the hub and install the drive shaft as shown in the illus-
tration.
013549-00X
Invert the hub and install the external retaining ring which
secures the drive shaft into the hub.
013550-00X
6-5-10 0000604
Procedure
Insert the angled face plate onto the hub taking care to use
the centering pin.
013551-00X
Install the rotating block into the motor hub, bringing it into
contact with the angled face plate.
013552-00X
Install the roller bearing onto the motor cover, proceeding so

that it extends from the face of the cover by 2,5 to 2,8 mm
(0.098 to 0.110 inches).
Mount the O-ring onto the motor cover.
013553-00X
Install the valve plate and relative centering pin on the motor
cover.
013554-00X
6-5-11 0000604
Procedure
Install the motor cover onto the hub with the six head cap
screw with relatives washers and tighten to a torque.
M8 - 42/50Nm
013555-00E
Clean the two M5 restrictors with air.

In case they are damaged or very dirty removing the restric-
tors with a key, clean the calibrated holes and reinstalling in
their threaded holes.
Restrictor
Air
013556-00E
Install the valve in the following sequence: valve piston, wash-

ers, springs, plugs and relatives O-rings.
After assembly of the hydraulic motor, check that the drive

shaft turns freely with no binding.
013538-00X
Using the tool (Code M725.000.16.01) shown on page 6-5-21

as a support, install the first ball bearing.
013557-00X
6-5-12 0000604
Procedure
Secure the ball bearing by means of an internal retaining ring,
install the O-ring.
Note :
Be sure to use grease on the O-ring.
013558-00X
Using the same tool (Code M725.000.16.01) mentioned for

the first ball bearing, install the second ball bearing keeping
Lapped face
the lapped part up and using extreme caution not to damage
the lapped surface of the bearing.
013559-00E
Install the front seal.

See the installation procedure at page 6-5-17.
013560-00X
Using a press, insert the reduction unit and motor assembly

into the seat of the ball bearing.
013561-00X
6-5-13 0000604
Procedure
Install the external retaining ring so as to secure the bearing
and motor reduction unit.
013562-00X
Assemble the secondary planetary stage in the following

sequence: bottom thrust washer, planetary gears and rela-
tives needle bearing, antirotation thrust washer and external
retaining rings.
Note :
Always turn the opening of the retaining ring towards the out-
side.
013531-00X
Install the secondary planetary stage into the ring gear/hous-

ing.
013563-00X
Install the secondary planetary sun gear into the primary plan-
etary carrier assembly and lock with the retaining ring.
013529-00X
6-5-14 0000604
Procedure
Assemble the primary planetary carrier assembly in the fol-
lowing sequence: bottom thrust washer, planetary gears and
relatives needle bearing, antirotation thrust washer and exter-
nal retaining rings.
Note :
side.
013528-00X
Install the primary planetary stage into the ring gear/housing.
013564-00X
Install the primary planetary sun gear.
013565-00X
Check the following measurement:

Measurement A - The distance between the cover support
face and the sun gear height.
Measurement B - The distance between the cover face and Shims position
the pad.
The clearance given by the difference between the two mea-
sures shall be between 0,4mm and 0,6mm; in case such
clearance was higher, remove the thrust pad and increase the A Sun gear face
thickness by adding more shims underneath.
B Pad face
Note :
In case after the assembly there is no clearance or a slight
interference, please check if the assembly was made correctly. 013566-00E
6-5-15 0000604
Procedure
Install the O-ring on the cover.
013526-00X
Install th reduction cover in the rotating housing.
013523-00X
Install the reatining ring and lock the cover.
Install the lubrication oil as described, close the two holes with
the drain plugs.
013522-00X
FINAL FUNCTIONAL TESTINGS

After the assembly the following operations and tests shall be
carried out to assure the good function of the unit.
1) Leakage test, by pressurizzing the unit at 0,4bar through
the hole of the breather plug previously removed. The unit
connected with an air hose shall be immersed in water to
find out if there is any leakages identified by bubbles.
2) Connect the hydraulic hoses to the value and carry out a
rotation test of the unit in both directions for about 30 sec.
3) Fill the unit with oil according to the procedure described in
the service manual introduction pages.
6-5-16 0000604
5. Installation Procedure Duo-Cone Seals

Seal rings, torics, and housings must be clean and free of
any oil film, dust, or other foreign matter. Use a solvent
that evaporates quickly, leaves no residue, and is compat-
ible with the rubber toric rings. The recommended solvent
is 1-1-1 Trichloroethane. (Note: Follow all safety guide-
lines for use on the solvent’s Material Safety Data Sheet).
Ring and housings should be wiped with a solvent-soaked
1.Seal Ring 4.Housing Ramp
lint free cloth or paper towel. 2.Rubber Toric Ring 5.Seal Ring Housing
3.Housing Retaining Lip 013567-00X
After all components have been wiped clean, the torics should be installed on the metal seal rings so that they rest in
the radius on the tail of the metal ring. Insure that the torics are not twisted by inspecting the mold flash line on the
outside diameter of the toric for for true circumferential tracking around the seal. Twisted torics will cause nonuniform
face load that can result in leakage of lubricant and pumping of debris past the toric. If a twist is apparent, it can be
eliminated by gently pulling a section of a toric radially away from the metal seal ring and letting it "snap" back.
Repeating this in several places around the ring will eliminate any twist in the toric ring.
Put the toring ring 2 on seal The toric ring 2 can twist if it is not wet all around Eliminate toric twist by gently pulling a section
ring 1, at the bottom of the during installation or if there are burrs or fins on the of the toric 2 rapidly away from the seal ring 1
seal ring ramp 7 and retaining lip 3 of the housing 5. and letting it "sanp" back.
against the retaining lip 8. 013568-00X
After the torics are installed on the seal rings, teh seal
assembly is ready to be installed into the retainer housing.
It is recommended to use installation tools available
through Comer Industries (tool A05) to insure accurate
assembly.
These durable installation tools are designed to locate on
the toric ring and slide it past the housing retaining lip.
A sedond locator is designed into larger seal installation A05 013623-00X
tools to insure the proper seal stand out height. Improper

seal assembly installation into the reatainer housing can
result in poor seal performance due to nonuniform loding.
Duo-Cone Seal installation tools help insure precise
installation. Seal ring locator
Toric ring locator 013624-00E
6-5-17 0000604
Place the installation tool around the seal ring and dip the
seal ring into a pan of 1-1-1 Trichloroethane solvent to
lubricate the toric ring.
It is essential to lubricate the toric with Ttichlor so that the
toric will slip past the housing retaining lip and seal uni-
formly in the housing nose radius.
Insufficient lubrication can cause poor seal performance 013625-00X
due to nonuniform loading (twisted torics or cocked Put the installation tool 9 onto the seal ring 1 with
toric ring 2. Lower the rings into a container with
seals). Use solvents other than 1-1-1 Trichloroethane can Trichloroethane until all surfaces of the toric 2 are wet.
leave a residue on the toric or ramps and allow the toric to
slide rather than roll in the seat. This can also result in
poor seal performance due to nonuniform loading.
013626-00X
After dipping the seal assembly in the solvent, shake the excess solvent from the seal assembly and immediately
"pop" the seal into the housing with a firm push of the installation tool. Remove the installation tool and check the
seal standout height at several places around the circumference of the ring to verify an accurate installation. If the
seal does not meet the height specification, inspect the toric for twists or obvious bulges.
013629-00X
With all surfaces of the toric ring 2 wet with 1-1-1 Trichloroethane,
use the installation tool 9 to position seal ring 1 and the toric ring 2
squarely against the housing 5 as shown. Use sudden and even
pressure to pop (push) the toric ring 2 under the retaining lip 3 of
the housing 5.
(1.00 mm)
013630-00X
Check the assembled height A in at least four

places, 90q apart. Refer to the chart for standout
height specification.
6-5-18 0000604
The seal can be adjusted by gently pushing the toric into position by hand or by using a fabricated adjustment hook.
If the seal can not be adjusted to meet the standout height specification, remove the seal and repeat the procedure.
013631-00X
If small adjustments are necessary, do not push directly on the seal

ring 1 ; use the installation tool 9 to push down or the adjustment
tool 11 to pull up.
A thin film of light oil should be applied to the seal faces

prior to assembly. Use an applicator, a disposable tissue
or a clean finger to distribute the oil evenly. Be careful not
to get any oil on the rubber toric rings.
013632-00X
Be sure there is no visible debris on either of the seal

faces-even a small piece of lint can hold the seal faces
apart and cause leakage.
013633-00X
After successful installation, wait one minute for the Trichlor to dry before assembling the two seal halves in the final
loaded position. This delay is to allow any excess solvent to dry so thet the torics roll, rather than slide, in the hous-
ingas the faceload is increased. If the toric slide, this can produce a nonuniform load that can result in poor seal per-
formance.
6-5-19 0000604
Results of Incorrect Assembly:

Point "A" and point "B" remain stationary.
Point "X" and point "Y" rotate 180°.
This causes high pressure at "A"/"Y" and possible galling. When rotated, points "B"/"X" has low pressure and possi-
ble leakage.
013634-00X
Original "As Assembled" Position Rotated 180qFrom "Original Position"
After the unit to be sealed is assembled, a post-assembly leakage test can be performed to insure the seal is prop-
erly installed. A vacuum check is recommended rather than a pressure check as vacuum checks are more sensitive.
Many users find this is an easy check to combine with a vacuum fill technique for the lubricant. It is recommended
yhe compartment be filled to the correct level with lubricant and then rotated slowly several revolutions to seat the
seals. Avacuum test will catch gross seal damage such as broken seal rings or cut torics that may be caused in the
last phases of assembly. The Duo-Cone-Seals is not designed to seal air, so come leakage can be expected using
such a procedure.
Follow these guidelines and recommendations should insure optimum performance from your The Duo-Cone-Seals.
6-5-20 0000604
6. Geared Motor Assembly Tool

(Code M725.000.16.01)
Mat.C40 Bon. UNI7620 / 1042 Hardened ASTM
013636-00X
6-5-21 0000604
7. Torque Wrench Setting (N x m)

Screw on steel or cast iron
ISO METRIC THREAD - coarse pitch

Nom. size pitch quality 4.8 quality 6.8 quality 8.8 quality 10.9 quality 12.9
(mm) (mm) min max min max min max min max min max
4 0,7 1,5 1,9 2,3 2,8 3,1 3,8 4,4 5,3 5,2 6,3
5 0,8 3,0 3,7 4,5 5,5 6,0 7,3 8,5 10,3 10,2 12,4
6 1 5,2 6,3 7,8 9,5 10,4 12,7 14,7 17,8 17,6 21,4
8 1,25 12,5 15,2 18,7 22,7 25,0 30,3 35,1 42,6 42,1 51,1
10 1,5 25,0 30,3 37,4 45,5 49,9 60,6 70,2 85,2 84,2 102,3
12 1,75 42,5 51,6 63,7 77,4 85,0 103,2 119,5 145,1 143,4 174,2
14 2 67,6 82,1 101,5 123,2 135,3 164,3 190,2 231,0 228,3 277,2
16 2 102,4 124,3 153,6 186,5 204,8 248,6 287,9 349,6 345,5 419,6
18 2,5 142,7 173,3 214,1 259,9 285,4 346,6 401,4 487,4 481,7 584,9
20 2,5 200 243 300 364 400 486 562 683 675 819
22 2,5 268 326 402 489 537 652 755 916 906 1.100
24 3 346 420 518 629 691 839 972 1.180 1.166 1.416
27 3 504 612 756 918 1.008 1.224 1.418 1.721 1.701 2.066
30 3,5 688 835 1.032 1.253 1.375 1.670 1.934 2.349 2.321 2.818
ISO METRIC THREAD - fine pitch

8 1 13,1 15,9 19,7 23,9 26,2 31,8 36,9 44,8 44,2 53,7
10 1,25 26,0 31,5 38,9 47,3 51,9 63,0 73,0 88,6 87,6 106,4
12 1,25 45,3 55,0 67,9 82,4 90,5 109,9 127,3 154,6 152,8 185,5
12 1,5 43,9 53,3 65,8 79,9 87,8 106,6 123,4 149,9 148,1 179,8
14 1,5 71,4 86,7 107,1 130,0 142,8 173,4 200,8 243,8 241,0 292,6
16 1,5 107,2 130,1 160,8 195,2 214,3 260,3 301,4 366,0 361,7 439,2
18 1,5 154,9 188,0 232,3 282,1 309,7 376,1 435,6 528,9 522,7 634,7
20 1,5 215 261 322 391 430 522 604 734 725 881
22 1,5 286 347 429 521 572 695 805 977 966 1.173
24 2 367 446 551 669 734 891 1.032 1.254 1.239 1.504
27 2 531 645 797 968 1.063 1.291 1.495 1.815 1.793 2.178
30 2 739 897 1.108 1.345 1.477 1.794 2.077 2.522 2.493 3.027
Above mentioned torque tables correspond to an axial preload, which is between 70% and 85% of the screw mate-
rial yield stress.
Coefficient of Friction: 0,14
With lubricated thread use 70% of above mentioned tables.

When quality 12,9 fasteners are used in tapped holes in grey cast iron, the fasteners should be torqued to quality
10.9 specifications.
6-5-22 0000604
8. Technical Information
Liquid bonding agents (Loctite) must always be used in the following cases:
(1) Screws assembled inside reduction gears.
(2) Screws tightened on aluminum boxes.
(3) Bearing adjustment ring nuts including ring nuts but not ring nuts with safety washers and ring nuts of axle wheel
hubs which do not require adhesives.
(4) Cranks and extensions.
(5) Data Sheet requirements.
When assembling with adhesives, the following must be degreased and free of washing residues:
(1) Ring nuts, screws, stud bolts, nuts, cranks, and extensions if their surfaces are not protected by galvanizing or
Dacromet 320.
(2) Threads on shafts and boxes.
When liquid bonding agents are required, use:
Description Size Loctite

Screws tightened on cast iron or steel up to and including M8 243
over M8 270
Screws tightened on aluminum all diameters 243
Stud bolt root (box) up to and including M12 243
over M12 270
Stud (nut) up to and including M12 no
over M12 243
Bearing adjustment ring nuts all diameters 270
Cranks and extensions for caps all diameters 243
When there are no washers, O-rings, or other types of seals, use Loctite 518 as a sealer.
All of these instructions are valid unless otherwise specified in the "Technical Manual".
6-5-23 0000604
6-5-2 SV17(EX)
1. External Drawing
013637-00E
6-5-24 0000604
2. Section Drawing and Spare Part List
013638-00X
N° Code Description Q’ty

1 1725.008.025 Output housing 1
2 1725.110.001 End cover 1
3 1725.332.097 Motor morv 16,8/8,7 1
4 1725.517.042 Sun gear 1
5 1725.806.099 Lappeda bearing + Front seal 1
12 9030.234.951 O-ring 2,62¯139,37 1
13 9030.235.001 O-ring 2,62¯145,72 1
14 9110.624.000 Ball bearing 16019 1
15 9479.012.020 Shims kit 12,2¯19,8 1
16 9510.018.059 1/8" gas plug with o-ring 2
5725.KIT.0024 : Basic seal kit

5725.KIT.0025 : Major rebuilt kit (5725.KIT.0024 + item 5)
6-5-25 0000604
3. Disassembly
Procedure
After having drained the lubricant, unscrew the two drain
plugs, remove the internal snap ring securing the reduction
gear cover.
013522-00X
Remove the reduction gear cover.
013523-00X
To remove the reduction gear cover, insert two screwdriver

into the upper groove and lift the cover from the housing.
013524-00X
An alternative solution for removal of the cover.
May be ottained by unscrew the two drain plugs and install

two threaded pins (1/8" GAS) wich will be used to lift the cover
from the housing.
013525-00X
6-5-26 0000604
Procedure
Remove the O-ring from the cover.
013526-00X
Remove the retaining ring, the shims and the sun gear.
The first stage planetary carrier can now be removed from the
unit by hands.
013639-00X
To disassemble the first stage planetary carrier assembly,

remove the retaining rings, the antirotation washer, planetary
gears, needle bearings and the thrust washer.
013528-00X
Remove the retaining ring from the second reduction sun gear
and push it down to slide it out from the planetary carrier.
013529-00X
6-5-27 0000604
Procedure
The second stage planetary carrier can now be removed from
the unit by hands.
013530-00X
To disassemble the stage planetary carrier assembly, remove

the retaining rings, the antirotation washer, planetary gears,
needle bearings and the thrust washer.
013531-00X
Remove the retaining ring from the hub to free the two bear-
ings, ring gear and motor.
013532-00X
Separated the motor hub from the ring gear.
013640-00X
6-5-28 0000604
Procedure
Remove the O-ring from the ring gear, and the retaining ring
securing the bearing.
013534-00X
Now remove the ball bearing by pushing from underneath.
013535-00X
Remove the lapped bearing/front seal will require the use of a

commercial bearing extractor and supporting cap as shown.
Caution :
Be careful not to damage the bottom polished/lapped surface
of the bearing.
013536-00X
The front seal ring may now be removed by hands.
013537-00X
6-5-29 0000604
Procedure
plugs with O-rings, springs, washers and valve piston.
013641-00X

plugs with O-rings, springs, valve piston and the other plug.
013642-00X
Remove the six head socket cap screw and relatives washers
securing the motor cover.
Remove the cover and the two dowel pins.
Note :
Remove the dowel pins is optional.
013643-00X
Remove from the motor cover the O-ring, the Orings, the pin
and the roller bearing with a bearing puller.
Note :
Remove the dowel pin is optional.
013644-00X
6-5-30 0000604
Procedure
Remove the bronze motor valve plate.
013645-00X
After inverting the motor hub the rotating block will now slide
out.
013646-00X
The angle faced plate can be removed by hands.

Remove the sphere and the change displacement parts: pis-
tons, springs and washers.
013647-00X
Remove the internal retaining ring retaining the bearing/drive

shaft, push from beneath.
Now rwmovw the oil seal.
013648-00X
6-5-31 0000604
Procedure
Remove the first external retaining ring, the ball bearing can
now be removed.
The second external retaining ring can now be removed.
013649-00X
The unit can now be re-assembled by reversing the above

procedure.
Please keep in mind the following requirements:
1) If one of the gears of the planetary units has been dam-
aged it is advisable to replace the damaged planetary
stage assembly complete with the sun gear.
The reason is obvious, in that damage from one gear can
cause microscopic fatigue cracks in mating gear teeth,
leading to premature failure after servicing.
2) Use standard mechanical procedures, such lubricating O-
rings, seals, etc..., upon reassembly.
6-5-32 0000604
4. Reassembly
Procedure
Fit the first external retaining ring on the drive shaft. Second
Mount on the shaft the ball bearing and insert the second
external retaining ring.
First
Second
First
013650-00E
Fit the oil seal in its seat in the hub.
013651-00X
Install the drive shaft in the hub centering the oil seal and lock
with internal retaining ring.
013652-00X
Insert the two sphere in their seats on the hub.

Insert the washers, the springs, the pistons and the angled
face plate onto the hub.
013647-00X
6-5-33 0000604
Procedure
Install the rotating block into the motor hub, bringing it into
contact with the angled face plate.
013646-00X
Install the valve plate into the motor hub, bringing it into con-
tact with the rotating block face plate.
013645-00X
Install the needle bearing onto the motor cover, proceeding so

that it extends from the face of the cover by 2,5 to 2,8 mm
(0.098 to 0.110 inches).
Mount the O-rings and the pin onto the motor cover.
013653-00X
Install the motor cover onto the hub with the six head cap
screw with relatives washers and tightening a torque.
M8 - 42/50Nm
013654-00E
6-5-34 0000604
Procedure
Clean the two restrictors with air.
In case they are damaged or very dirty removing the restric-
tors with a key, clean the calibrated holes and reinstalling in
their threaded holes.
Restrictor
Air
013556-00E
Install the change displacement valve in the following

sequence: left plug, piston valve, spring and the other plug
with relatives O-ring.
Install the valve in the following sequence: valve, washers,

springs, plugs and relatives O-rings.
After assembly of the hydraulic motor, check that the drive

shaft turns freely with no binding.
013569-00X
Using the tool (Code M725.000.16.01) shown on page 6-5-44

as a support, install the first ball bearing.
013557-00X
Secure the ball bearing by means of an internal retaining ring,

install the O-ring.
Note :
Be sure to use grease on the O-ring.
013558-00X
6-5-35 0000604
Procedure
Using the same tool (Code M725.000.16.01) mentioned for
the first ball bearing, install the second ball bearing keeping
Lapped face
the lapped part up and using extreme caution not to damage
the lapped surface of the bearing.
013559-00E
Install the front seal.

See the installation procedure at page 6-5-40.
013560-00X
Using a press, insert the reduction unit and motor assembly

into the seat of the ball bearing.
013640-00X
Install the external retaining ring to secure the bearing and

motor reduction unit.
013562-00X
6-5-36 0000604
Procedure
Assemble the secondary planetary stage in the following
sequence: bottom thrust washer, planetary gears and rela-
tives needle bearing, antirotation thrust washer and external
retaining rings.
Note :
side.
013531-00X
Install the secondary planetary stage into the ring gear/hous-

ing.
013563-00X
Install the secondary planetary sun gear into the primary plan-
etary carrier assembly and lock with the retaining ring.
013529-00X
Assemble the primary planetary carrier assembly in the fol-

lowing sequence: bottom thrust washer, planetary gears and
relatives needle bearing, antirotation thrust washer and exter-
nal retaining rings.
Note :
side.
013528-00X
6-5-37 0000604
Procedure
Install the primary planetary stage into the ring gear/housing.
Spread with grease contact surface P. P
013655-00X
Install the primary planetary sun gear, the shims (theoretical

shimming 0,5mm) and lock with the retaining ring.
Spread with grease contact surface P.
013656-00X
Install the O-ring on the cover.
013526-00X
Install th reduction cover in the rotating housing.
013657-00X
6-5-38 0000604
Procedure
Install the reatining ring and lock the cover.
Install the lubrication oil as described, close the two holes with
the drain plugs.
013658-00X
FINAL FUNCTIONAL TESTINGS

After the assembly the following operations and tests shall be
carried out to assure the good function of the unit.
1) Leakage test, by pressurizzing the unit at 0,4bar through
the hole of the breather plug previously removed. The unit
connected with an air hose shall be immersed in water to
find out if there is any leakages identified by bubbles.
2) Connect the hydraulic hoses to the value and carry out a
rotation test of the unit in both directions for about 30 sec.
3) Fill the unit with oil according to the procedure described in
the service manual introduction pages.
6-5-39 0000604
5. Installation Procedure Duo-Cone Seals

Seal rings, torics, and housings must be clean and free of
any oil film, dust, or other foreign matter. Use a solvent
that evaporates quickly, leaves no residue, and is compat-
ible with the rubber toric rings. The recommended solvent
is 1-1-1 Trichloroethane. (Note: Follow all safety guide-
lines for use on the solvent’s Material Safety Data Sheet).
Ring and housings should be wiped with a solvent-soaked
1.Seal Ring 4.Housing Ramp
lint free cloth or paper towel. 2.Rubber Toric Ring 5.Seal Ring Housing
3.Housing Retaining Lip 013567-00X
After all components have been wiped clean, the torics should be installed on the metal seal rings so that they rest in
the radius on the tail of the metal ring. Insure that the torics are not twisted by inspecting the mold flash line on the
outside diameter of the toric for for true circumferential tracking around the seal. Twisted torics will cause nonuniform
face load that can result in leakage of lubricant and pumping of debris past the toric. If a twist is apparent, it can be
eliminated by gently pulling a section of a toric radially away from the metal seal ring and letting it "snap" back.
Repeating this in several places around the ring will eliminate any twist in the toric ring.
Put the toring ring 2 on seal The toric ring 2 can twist if it is not wet all around Eliminate toric twist by gently pulling a section
ring 1, at the bottom of the during installation or if there are burrs or fins on the of the toric 2 rapidly away from the seal ring 1
seal ring ramp 7 and retaining lip 3 of the housing 5. and letting it "sanp" back.
against the retaining lip 8. 013568-00X
After the torics are installed on the seal rings, teh seal
assembly is ready to be installed into the retainer housing.
It is recommended to use installation tools available
through Comer Industries (tool A05) to insure accurate
assembly.
These durable installation tools are designed to locate on
the toric ring and slide it past the housing retaining lip.
A sedond locator is designed into larger seal installation A05 013623-00X
tools to insure the proper seal stand out height. Improper

seal assembly installation into the reatainer housing can
result in poor seal performance due to nonuniform loding.
Duo-Cone Seal installation tools help insure precise
installation. Seal ring locator
Toric ring locator 013624-00E
6-5-40 0000604
Place the installation tool around the seal ring and dip the
seal ring into a pan of 1-1-1 Trichloroethane solvent to
lubricate the toric ring.
It is essential to lubricate the toric with Ttichlor so that the
toric will slip past the housing retaining lip and seal uni-
formly in the housing nose radius.
Insufficient lubrication can cause poor seal performance 013625-00X
due to nonuniform loading (twisted torics or cocked Put the installation tool 9 onto the seal ring 1 with
toric ring 2. Lower the rings into a container with
seals). Use solvents other than 1-1-1 Trichloroethane can Trichloroethane until all surfaces of the toric 2 are wet.
leave a residue on the toric or ramps and allow the toric to
slide rather than roll in the seat. This can also result in
poor seal performance due to nonuniform loading.
013626-00X
After dipping the seal assembly in the solvent, shake the excess solvent from the seal assembly and immediately
"pop" the seal into the housing with a firm push of the installation tool. Remove the installation tool and check the
seal standout height at several places around the circumference of the ring to verify an accurate installation. If the
seal does not meet the height specification, inspect the toric for twists or obvious bulges.
013629-00X
With all surfaces of the toric ring 2 wet with 1-1-1 Trichloroethane,
use the installation tool 9 to position seal ring 1 and the toric ring 2
squarely against the housing 5 as shown. Use sudden and even
pressure to pop (push) the toric ring 2 under the retaining lip 3 of
the housing 5.
(1.00 mm)
013630-00X
Check the assembled height A in at least four

places, 90q apart. Refer to the chart for standout
height specification.
6-5-41 0000604
The seal can be adjusted by gently pushing the toric into position by hand or by using a fabricated adjustment hook.
If the seal can not be adjusted to meet the standout height specification, remove the seal and repeat the procedure.
013631-00X
If small adjustments are necessary, do not push directly on the seal

ring 1 ; use the installation tool 9 to push down or the adjustment
tool 11 to pull up.
A thin film of light oil should be applied to the seal faces

prior to assembly. Use an applicator, a disposable tissue
or a clean finger to distribute the oil evenly. Be careful not
to get any oil on the rubber toric rings.
013632-00X
Be sure there is no visible debris on either of the seal

faces-even a small piece of lint can hold the seal faces
apart and cause leakage.
013633-00X
After successful installation, wait one minute for the Trichlor to dry before assembling the two seal halves in the final
loaded position. This delay is to allow any excess solvent to dry so thet the torics roll, rather than slide, in the hous-
ingas the faceload is increased. If the toric slide, this can produce a nonuniform load that can result in poor seal per-
formance.
6-5-42 0000604
Results of Incorrect Assembly:

Point "A" and point "B" remain stationary.
Point "X" and point "Y" rotate 180°.
This causes high pressure at "A"/"Y" and possible galling. When rotated, points "B"/"X" has low pressure and possi-
ble leakage.
013634-00X
Original "As Assembled" Position Rotated 180qFrom "Original Position"
After the unit to be sealed is assembled, a post-assembly leakage test can be performed to insure the seal is prop-
erly installed. A vacuum check is recommended rather than a pressure check as vacuum checks are more sensitive.
Many users find this is an easy check to combine with a vacuum fill technique for the lubricant. It is recommended
yhe compartment be filled to the correct level with lubricant and then rotated slowly several revolutions to seat the
seals. Avacuum test will catch gross seal damage such as broken seal rings or cut torics that may be caused in the
last phases of assembly. The Duo-Cone-Seals is not designed to seal air, so come leakage can be expected using
such a procedure.
Follow these guidelines and recommendations should insure optimum performance from your The Duo-Cone-Seals.
6-5-43 0000604
6. Geared Motor Assembly Tool

(Code M725.000.16.01)
Mat.C40 Bon. UNI7620 / 1042 Hardened ASTM
013636-00X
6-5-44 0000604
7. Torque Wrench Setting (N x m)

Screw on steel or cast iron
ISO METRIC THREAD - coarse pitch

4 0,7 1,5 1,9 2,3 2,8 3,1 3,8 4,4 5,3 5,2 6,3
5 0,8 3,0 3,7 4,5 5,5 6,0 7,3 8,5 10,3 10,2 12,4
6 1 5,2 6,3 7,8 9,5 10,4 12,7 14,7 17,8 17,6 21,4
8 1,25 12,5 15,2 18,7 22,7 25,0 30,3 35,1 42,6 42,1 51,1
10 1,5 25,0 30,3 37,4 45,5 49,9 60,6 70,2 85,2 84,2 102,3
12 1,75 42,5 51,6 63,7 77,4 85,0 103,2 119,5 145,1 143,4 174,2
14 2 67,6 82,1 101,5 123,2 135,3 164,3 190,2 231,0 228,3 277,2
16 2 102,4 124,3 153,6 186,5 204,8 248,6 287,9 349,6 345,5 419,6
18 2,5 142,7 173,3 214,1 259,9 285,4 346,6 401,4 487,4 481,7 584,9
20 2,5 200 243 300 364 400 486 562 683 675 819
22 2,5 268 326 402 489 537 652 755 916 906 1.100
24 3 346 420 518 629 691 839 972 1.180 1.166 1.416
27 3 504 612 756 918 1.008 1.224 1.418 1.721 1.701 2.066
30 3,5 688 835 1.032 1.253 1.375 1.670 1.934 2.349 2.321 2.818
ISO METRIC THREAD - fine pitch

8 1 13,1 15,9 19,7 23,9 26,2 31,8 36,9 44,8 44,2 53,7
10 1,25 26,0 31,5 38,9 47,3 51,9 63,0 73,0 88,6 87,6 106,4
12 1,25 45,3 55,0 67,9 82,4 90,5 109,9 127,3 154,6 152,8 185,5
12 1,5 43,9 53,3 65,8 79,9 87,8 106,6 123,4 149,9 148,1 179,8
14 1,5 71,4 86,7 107,1 130,0 142,8 173,4 200,8 243,8 241,0 292,6
16 1,5 107,2 130,1 160,8 195,2 214,3 260,3 301,4 366,0 361,7 439,2
18 1,5 154,9 188,0 232,3 282,1 309,7 376,1 435,6 528,9 522,7 634,7
20 1,5 215 261 322 391 430 522 604 734 725 881
22 1,5 286 347 429 521 572 695 805 977 966 1.173
24 2 367 446 551 669 734 891 1.032 1.254 1.239 1.504
27 2 531 645 797 968 1.063 1.291 1.495 1.815 1.793 2.178
30 2 739 897 1.108 1.345 1.477 1.794 2.077 2.522 2.493 3.027
Above mentioned torque tables correspond to an axial preload, which is between 70% and 85% of the screw mate-
rial yield stress.
Coefficient of Friction: 0,14
With lubricated thread use 70% of above mentioned tables.

When quality 12,9 fasteners are used in tapped holes in grey cast iron, the fasteners should be torqued to quality
10.9 specifications.
6-5-45 0000604
8. Technical Information
Liquid bonding agents (Loctite) must always be used in the following cases:
(1) Screws assembled inside reduction gears.
(2) Screws tightened on aluminum boxes.
(3) Bearing adjustment ring nuts including ring nuts but not ring nuts with safety washers and ring nuts of axle wheel
hubs which do not require adhesives.
(4) Cranks and extensions.
(5) Data Sheet requirements.
When assembling with adhesives, the following must be degreased and free of washing residues:
(1) Ring nuts, screws, stud bolts, nuts, cranks, and extensions if their surfaces are not protected by galvanizing or
Dacromet 320.
(2) Threads on shafts and boxes.
When liquid bonding agents are required, use:
Description Size Loctite

Screws tightened on cast iron or steel up to and including M8 243
over M8 270
Screws tightened on aluminum all diameters 243
Stud bolt root (box) up to and including M12 243
over M12 270
Stud (nut) up to and including M12 no
over M12 243
Bearing adjustment ring nuts all diameters 270
Cranks and extensions for caps all diameters 243
When there are no washers, O-rings, or other types of seals, use Loctite 518 as a sealer.
All of these instructions are valid unless otherwise specified in the "Technical Manual".
6-5-46 0000604
CHAPTER 7
ADJUSTMENT AND REPAIR
7-1 Electric Equipment of Machine................................... 7-1-1 7-3 Controls ...................................................................... 7-3-1

7-1-1 Parts Layout of Electrical Equipment ................ 7-1-1 7-3-1 Control Train...................................................... 7-3-1
7-1-2 Monitor and Alarm Systems .............................. 7-1-2 7-3-2 Mechanical Control Linkage .............................. 7-3-2
7-1-3 Wiring Diagram.................................................. 7-1-5 7-3-3 Adjustment of Travel Levers.............................. 7-3-4
7-1-4 Circuit Description of Engine Start and Stop, 7-3-4 Adjustment of Boom Swing Pedal ..................... 7-3-5
and Battery Charging ........................................ 7-1-6 7-3-5 Adjustment of Blade Lever
7-1-5 Removal and Reinstallation of Engine .............. 7-1-8 (Track Gauge Change Lever) ........................... 7-3-5
7-1-6 Removal and Reinstallation 7-3-6 Adjustment of Lock Lever Switch ...................... 7-3-6
of Starter Motor ............................................... 7-1-15 7-3-7 Adjustment of Accelerator Lever ....................... 7-3-7
7-1-7 Removal and Reinstallation 7-3-8 Adjustment of P.T.O. Pedal ............................... 7-3-8
of Fuel Injection Pump .................................... 7-1-16 7-4 Swing Bearing ............................................................ 7-4-1
7-1-8 Removal and Reinstallation of Fuel Tank........ 7-1-18 7-5 Hydraulic Equipment .................................................. 7-5-1
7-1-9 Removal and Reinstallation of Radiator .......... 7-1-21 7-5-1 Removal and Reinstallation
7-2 Undercarriage ............................................................ 7-2-1 of Hydraulic Pump............................................. 7-5-1
7-2-1 Outline ............................................................... 7-2-1 7-5-2 Removal and Reinstallation
7-2-2 Points of Reassembly........................................ 7-2-2 of Control Valve................................................. 7-5-4
7-2-3 Crawler Tension Adjustment Procedure............ 7-2-3 7-5-3 Removal and Reinstallation of Swing Motor...... 7-5-7
7-2-4 Removal and Reinstallation of Crawler ............. 7-2-4 7-5-4 Removal and Reinstallation
7-2-5 Disassembly and Reassembly of Idler .............. 7-2-5 of Swivel Joint ................................................. 7-5-10
7-2-6 Disassembly and Reassembly 7-5-5 Disassembly and Reassembly
of Track Roller................................................... 7-2-7 of Swivel Joint ................................................. 7-5-13
7-2-7 Removal and Reinstallation 7-5-6 Disassembly and Reassembly
of Track Gauge Change Cylinder...................... 7-2-9 of Hydraulic Cylinders ..................................... 7-5-16
7-5-7 Hydraulic Oil Tank ........................................... 7-5-20
7-5-8 Piping Layout................................................... 7-5-24
7-6 Implement................................................................... 7-6-1
7-6-1 Removal and Reinstallation of Implement ......... 7-6-1
7. ADJUSTMENT AND REPAIR
7. Adjustment and Repair

7-1 Electric Equipment of Machine
7-1-1 Parts Layout of Electrical Equipment
1) Electric Wiring
9
7
17
17 4
18
14 5
19
11
20
16
13
13
3
22
10 7
21
8 2
8
12
15
15
11
013585-00X
No. Part No. Part No. Part

1 Harness A 9 Timer (1 sec.) 17 Battery cable (positive)
2 Harness B Ass’y 10 Safety relay 18 Battery cable (negative)
3 Harness (for boom light) 11 Extend switch track 19 Battery
4 Slow blow fuse (50A) 12 Engine ground cable 20 Safety switch (lever lock R)
5 Fuse box 13 Safety switch (lever lock L) 21 Timer relay
6 Starter switch 14 Monitor Ass’y 22 Heater relay
7 Relay 15 Horn
8 Glow relay 16 Work lamp
7-1-1 0000604
7-1-2 Monitor and Alarm Systems
For safer machine operation, the operator needs to have a clear understanding of the machine’s condition. How-
ever, it is difficult for the operator to keep an eye on every aspect of the machine he/she operating.
Therefore, gauges and alarms are installed to warn the operator of any trouble of the machine at the early stage.
Note :
The monitors do not give a full assurance of the machine’s condition. The indications shown on them should be used
as a guide for daily check and periodic maintenance according to the operation and maintenance manual.
1) Part Name
Panel
ON
OFF
6 1 Engine oil pressure alarm lamp

F HOUR METER
FUEL
1/10h
2 Water temp. meter
5 3 Water temp. alarm lamp
4 Battery charge alarm lamp
E
H 5 Fuel gauge
W.TEMP
3 6 Hour meter
2
C
4 1
2) Function of Alarm Sensor
• All the lamps should go on for a few seconds when the starter switch is turned on.
• All the lamps should go off when the engine is running.
• The engine oil pressure and battery charge alarm lamps should go on when the engine is stopped.
• The buzzer should sound when a lamp goes on while the engine is running.
3) Alarm Sensor Operation

(1) Lube oil pressure drop monitoring (engine oil pressure switch)
When the engine oil pressure falls, the lamp goes on and the buzzer sounds.
Starter SW Engine start

ON Lamp
Lamp OFF
Engine oil ON Lamp
ON Alarm sound
pressure
Normal
Pressure drop
<0.04 to 0.06 MPa
(<0.4 to 0.6 kgf/cm2)
The switch monitors the lube oil pressure drop of the engine and
causes the engine oil pressure alarm lamp to go on and the alarm PT 1/8
buzzer to sound.
Working pressure : 39.2 to 58.8 kPa (0.4 to 0.6 kgf/cm2)
Installation position : Engine block Terminal
24 mm
7-1-2 0000604
When the alarm buzzer sounds, check the following items.

[1] Degeneration of engine oil
[2] Clogging of oil filter element
[3] Malfunction of engine oil pressure switch
Refer to Section "4-1-8 Checking the Sensors" for the checking procedure of the engine oil pressure switch.
[4] Malfunction of pressure control valve
[5] Wear or breakage of engine oil pressure pump
(2) Overheating sensor (water temperature switch)

The water temp. meter indicates the engine cooling water temperature.
The pointer should be within the white range while the engine is running.
If the pointer goes up to the red range, the engine is overheating.
Red
Starter SW
ON White
2 to 3 seconds later, Engine start
lamp out Lamp
ON Alarm sound
Engine Lamp Lamp
cooling water ON OFF
temperature Water temperature rise
>107 to 113
Normal
Turned on : Cooling water temp. : 107 to 113°C

21 mm
Turned off : Cooling water temp. : 100°C or less 16 1.5
Installation position : Cooling water pump on engine
Terminal

[1] Refer to Section "4-1-7 Checking the Cooling Water System and Radiator for Water Leakage" and "10. Trouble-
shooting".
(3) Battery charge

When there occurs a potential difference between the output voltage of the alternator and the voltage of the battery,
the lamp goes on and the buzzer sounds.
Starter SW Engine start

Lamp
ON Lamp ON Alarm sound
OFF
Terminal Lamp
voltage of ON Voltage of
alternator battery
Normal Potential difference

(Voltage drop)

[1] Degeneration or malfunction of battery.
[2] Refer to Section "7-1-4 Circuit Description of Engine Start and Stop, and Battery Charging".
7-1-3 0000604
(4) Fuel gauge

When the starter switch is turned on, the fuel gauge starts to work to
indicate the oil level in the fuel tank.
• It is normal for the fuel gauge to take some time to indicate the cor-
rect level after the starter switch is turned on.
• The remaining oil level indication can change depending on the incli-
nation of the machine body.
Fuel gauge unit
FULL
3/4
87.3 to 95.3 mm
69.3 mm
1/2
14.9 to 22.9 mm
55
55
1/4
65.6 to 73.6 mm
27.7 mm
EMPTY
Float position Resistance (Ω)

FULL 9.5 to 11.0
1/2 29 to 35
EMPTY 82 to 92
(5) Hour meter

When the starter switch is turned on, the hour meter starts to work.
HOUR METER
1/10h
7-1-4 0000604
7-1-3 Wiring Diagram
1) Standard Specifications
RELAY RELAY
SWITCH SWITCH SWITCH SWITCH CIGAR RELAY
WIPER RADIO(OPT) SWITCH HEATER SAFETY TIMER TIMER
ROOM
LAMP MOTOR CABIN WASHER CIGAR
CAT-OFF WIPER HEATER SWITCH
HORN
CAT-OFF WORK CABIN
LIGHTER
L LAMP PUMP LIGHTER L L RELAY
(CABIN) B
B1 M M 2A 1E 4 3 2 1
Y M P
WB S B E P C ACC 3 1
B B
GND
ACC
BACK
L W 4
RW
0.85 LW
26 25A 5G 24B 2
R
B
Y
LB
0.85 R
0.5 Lg
0.5 Lg
5F 12A 39A 3C 1D 6A 32A 31A
0.85 RW
1.25 Or
1.25 R
1.25 B
0.85 LR
33 32 7B 6C
0.85 L
PATROL
0.85 RW
1.25 YW
1.25 YW
0.85 Or
32 31 5E 3B 17A 39 5N 7B
0.85 R
0.85 B
1.25LW
0.5 YL
0.85 B
LIGHT
1.25LB
0.5 B
0.85 WL
1.25B
1.25 RB
0.85 YR
1.25L
0.5 RW
3.0 RG
7A 9 34A 26A33A 8A 5J 9A 22A 23A 28
3.0 RL
0.85 B
3.0 RL
3.0 G
5I 33 34 26C5H
0.5 Y
0.85 YR
0.5 RW
0.85 B
0.5 Y
1.25 RB
1.25 RB
1.25 YG
1.25 YB
1.25 YB
1.25 YL
0.85 GW
1.25 YW
P L W B1 B
0.5 YB
0.85YW
1.25 YB
1.25 YB
1.25 Or
5M 26B
1.25 Or
0.5 B
1.25 R
0.85B
0.85 B
1.25 R
1.25 B
7 8 3 9 36 35 40 24C 24A
1.25 YW
0.5 YW
1.25 B
1.25 LY
0.85 BrR
1.25 YW
0.85 BrB
0.85 RW
0.85 BrR
0.5 B
0.85 BrB
0.85 BrB
1.25 B
0.85 YL
1.25 YL
1.25 B
0.85 B
0.85 YW
0.85 RL
0.85 RL
0.85 B
3.0 W 3.0 WB
25B
1.25 YW 4B 5B 19
1.25W 3.0 W
0.85 RW
40A
0.85 RW 20 5A 17 STARTING
3.0 RL 3.0 R
0.85 BrB
36A
0.85 BrB 1C 1A 30 SWITCH
1.25 RB 3.0 RB
0.85 BrB
35A
0.85 BrR 17 17 50 AC
3.0 RW 3.0 RW
0.85 RL
38A
1.25 RL 18 18
1.25 B 1.25 B
5K
1.25 YW 1.25 YW
26D
1.25 LY 1.25 YL
28A
3.0 RW
1B
0.85 RL 5A 5A
1.25 RL 38
1.25 YR 22 3A
1.25 YB 15A 15A
1.25 YG
18D 18A
3.0RW
1.25 YL 24 23
1.25 YW 15A 15A
3.0 RL
18C 18B
3.0 RL 25
30A 15A
1G 1A
FUSE BOX
INDICATOR BOX
0.5YB
22B 13 0.5 YB + - HOUR
3.0 B 0.5 B METER
5A 14
L H WATER
TEMP
E F FUEL
METER
1 1.25W
1 2 20A
2
5L 1.25B
5.0W
4A
0.85 WG
LAMP
0.85 WL
0.85GW
3
0.5 LgR
1.25YL
0.5 LB
3.0RL
0.5 Lg
4 3 4 1F
0.5 L
0.85
RELAY 0.85 YB YB
22C 5 SLOW
28B8 1112 13 14 15 10 0.5 LB 0.5 LB DOWN
15A 3
22 8 1112 13 14 15 25 0.5 L 0.5 L (OPT)
10A 4
1.25YG
1.25YR
1.25YB
3.0 RG
0.5 YL 0.5 YL
28D
3.0 G
1
5.0W
3.0 B
0.85 WG
0.85 WL
0.85GW
0.5 GB OIL
0.5 LgR
1.25YL
0.5 LB
0.5 Lg
0.5 L
0.5LgR 0.5LgR
13A 11
23B 2 3 4 5 6 7 0.5 Lg
14A 10 0.5 Lg WATER
24A 1.25 L 23 2A 3 4 5 6 7 0.5 B 0.5 B TEMP
5B 2 BUZZER
5K 1.25 B 6
1.25YG
1.25YR
1.25YB
3.0 RG
0.5 WG
16B 12 0.85 WG LAMP
5.0 W
3.0 G
3.0 B
0.5 YB CHECK
EXTENSION 22D 8 0.5 YB CIRCUIT
0.85 WG 0.85 WG 0.85 WG
VALVE 16
16A 7 0.85 WG
11A
1.25 B
CHARGE
5J
24B 1.25 L
1
7C 1.25YB
0.5 B
STARTER SW.DIAGRAM
0.5 L
24 1.25 L
5
25A5L 19 30 17 50 AC
1.25 YR
3.0 B
1.25 B
0.85 YR
1.25 YG
0.5 LgR
TRACK EXTEND 5A
0.5 LB
0.85 G
HEAT
3D
0.5 Lg
SWITCH
1.25YL
1.25B
0.85 YB
3A 5F
0.85 G
OFF
0.85 B
0.85 B
1.25YB
5G
0.85 WG
0.85 B
0.85 YR
0.85B
1 2 13A 14A 15A
0.85 WL
23A 9
22A 5I ON
0.85 GW
0.85 YG
1 2 7B 5C 9A 5D 5E 7A
11A 3C 1A 2A
START
1.25YR
12A
3.0 G
3.0 B
BUZZER FUEL
3.0 RL
5.0 W
23B 8A L IG
3.0 RG
DRIVE SENSOR Y :Yellow RW :Red White

1 6A 5B 3B YB :Yellow Black RB :Red Black
5.0R
4A
P G H RG :Red Green
SLOW BLOW 2 B.E. B.E. B.E. YR :Yellow Red
FUSE(50A) E P FO-FEED
S LAMP
B CUT OFF TWO SPEED PUMP OIL
TEMP TEMP YL :Yellow Blue G :Green
21 AVf30 20A (BOOM) SWITCH HORN VALVE VALVE PRESSURE W :White GW :Green White
EB20 B 20 SWITCH SENSOR
SWITCH
3.0 RL
TWO SPEED WB :White Black GR :Green Red

21A B.E. L :Blue B :Black
(-) (+) 5.0R
LW :Blue White BR :Black Red
ENGINE-STOP GROW LR :Blue Red BW :Black White
STARTER AC SOLENOID PLUG
(65B24R) MOTOR GENERATOR LB :Blue Black LgR :Young Leaves Red
LG :Blue Green Gr :Gray
BATTERY B.E. Lg :Young Leaves Or :Orange
R :Red Br :Brown
RY :Red Yellow
013606-00E
7-1-5 0000604
7-1-4 Circuit Description of Engine Start and Stop, and Battery Charging
RELAY RELAY
1. Start Engine SWITCH
CAT-OFF
SWITCH
CAT-OFF
RELAY SAFETY TIMER TIMER
The starter switch 30 is always supplied with electric current from Y :Yellow RELAY
Turn on the starter switch. YB :Yellow Black
the battery. (Battery -Slow blow fuse-Starter switch 30) YR :Yellow Red 2A 1E
S B E P C ACC
4 3
3
2 1
1
YL :Yellow Blue
↓
4
RW
26 25A 5G 24B 2
R
B
W :White
Y
5F 12A 39A 3C 1D 6A 32A 31A
WB :White Black 33 32 7B 6C
Starter switch 30, AC-Lead wire RW-Fuse 15 A-Lead wire YR-
1.25 YW
1.25 YW
L :Blue 32 31 5E 3B 17A 39 5N 7B
0.5 YL
The timer is supplied with electric current.
0.5 B
0.85 WL
1.25 RB
0.85 YR
LW :Blue White
0.5 RW
3.0 RG
7A 9 9A 22A
3.0 RL
0.85 B
Timer R (Lead wire)
3.0 RL
3.0 G
0.5 Y
0.85 YR
0.5 RW
LR :Blue Red
0.85 B
0.5 Y
1.25 RB
1.25 RB
1.25 YB
1.25 YB
0.5 YB
1.25 YB
1.25 YB
LB :Blue Black
0.5 B
↓ LG :Blue Green
Lg :Young Leaves
The timer relay is supplied with electric cur- Timer RW-Timer relay 2, Timer relay 1-Timer Y R :Red
RY :Red Yellow
rent from the timer and the 1 and 2 are RW :Red White
connected. RB :Red Black 3.0 W
4B 5B
3.0 WB
19
RG :Red Green 1.25W
20 5A
3.0 W
17 STARTING
↓
3.0 RL 3.0 R
G :Green 1.25 RB
1C 1A
3.0 RB
30 SWITCH
GW :Green White 3.0 RW
17 17
3.0 RW
50 AC
18 18
GR :Green Red
The timer relay operates, and the 3 and 4 The relay 4 is always supplied with electric current from the battery B :Black
are connected. through the slow blow fuse. BR :Black Red
BW :Black White
↓ LgR :Young Leaves Red 3.0 RW
0.85 RL
1B
Gr :Gray 1.25 RL
5A 5A
:Orange 38
The engine stop solenoid P (pull) is sup- The engine stop solenoid H (hold) is supplied with electric current Or
Br :Brown
1.25 YR 22 3A
1.25 YB
plied with electric current from the timer when the starter switch is turned on. 1.25 YG
15A
18D
15A
18A
3.0RW
relay 3 to press the engine control lever.
1.25 YL 24 23
1.25 YW 15A 15A
3.0 RL
18C 18B
↓ 3.0 RL 25
30A 15A
The engine stop solenoid P is stopped In about one second after the starter switch is turned on, the timer 1G 1A
being supplied with electric current. operates to stop electric current from flowing to the engine stop FUSE BOX
solenoid P.
However, the engine stop solenoid H is still supplied with electric
↓ current when the starter switch is on, so that the control lever stays
pushed.
Turn the starter switch to "START" position. The starter motor B is always supplied with electric current from the
↓ battery.
The electric current is supplied from the When the lock lever is pulled up (cut-off switch is turned off), the
starter switch 50, cut-off relay 3, 4, to the cut-off relays 3 and 4 are connected.
safety relay, and from safety relay S to the The magnet switch of the starter motor operates to allow the pinion
starter motor S to rotate the starter motor. to jump out. At the same time, the crankshaft of the engine rotates
0.85 WG
0.85 WL
0.85GW
0.5 LgR
1.25YL
0.5 LB
0.5 Lg
and the engine starts to run.
0.5 L
↓ 28B 8 1112 13 14 15 10
22 8 1112 13 14 15 25
1.25YG
1.25YR
1.25YB
3.0 RG
The safety relay operates. When the engine speed reaches the rated speed, the dynamo L, R
3.0 G
5.0W
3.0 B
0.85 WG
0.85 WL
0.85GW
0.5 LgR
1.25YL
0.5 LB
0.5 Lg
and current limiter sb, sb are connected. And also current limiter Br
0.5 L
23B 2 3 4 5 6 7
and safety relay Br are connected. 23 2A 3 4 5 6 7
Therefore, the dynamo, the current limiter and the safety relay are
1.25YG
1.25YR
1.25YB
3.0 RG
5.0 W
3.0 G
3.0 B
supplied with electric current.
The signal from the current limiter Br flows to the safety relay Br
and cuts off the connection between the safety relay s and starter
motor S, which causes the pinion to be pulled back and the engine
to be prevented from overrunning.
3.0 B
5A 0.85 YR
3D
2. Stop Engine
5G
0.85 WG
0.85 B
0.85 YR
0.85 WL
Turn off the starter switch.
11A 3C
↓
1.25YR
12A
3.0 G
3.0 B
3.0 RL
L IG
3.0 RG
The engine stop solenoid H is stopped The control lever blocks a flow of fuel oil to stop the engine. 1 6A 5B 3B
5.0R
being supplied with the electric current to SLOW BLOW
FUSE(50A)
2
E P
P G H
S
pull back the control lever. 21 AVf30 20A
B
B
EB20 20
3.0 RL
21A B.E.
(-) (+) 5.0R

ENGINE-STOP
STARTER AC SOLENOID
(65B24R) MOTOR GENERATOR
BATTERY B.E. 013607-00E
7-1-6 0000604
3. Charge Battery
The electric current flows from the dynamo L, R to the battery
The electric current generated by the INDICATOR BOX
through the current limiter sb, sb, R and the slow blow fuse to
dynamo flows to the battery to be charged. Y :Yellow 0.5YB
22B 13 0.5 YB + - HOUR
charge the battery. YB :Yellow Black 3.0 B
5A 14
0.5 B METER
YR :Yellow Red
↓ YL :Yellow Blue
W :White
When the voltage generated by the dynamo is low, the circuit in the WB :White Black L H WATER
TEMP
L :Blue
alternator is turned on, and the electric current flows from the bat-
When the battery charge alarm lamp goes LW :Blue White
tery charge alarm lamp in the indicator box to the alternator to light LR :Blue Red
on, the battery charges poorly. LB :Blue Black
the alarm lamp. LG :Blue Green
E F FUEL
METER
(Indicator box→Lead wire WG→Alternator L) Lg :Young Leaves
R :Red
RY :Red Yellow
RW :Red White LAMP
RB :Red Black
RG :Red Green 0.85 YB
0.85
YB SLOW
G :Green 0.5 LB
22C 5
0.5 LB
15A 3 DOWN
GW :Green White 0.5 L 0.5 L (OPT)
10A 4
GR :Green Red 0.5 YL
28D 1
0.5 YL
B :Black 0.5 GB OIL
BR :Black Red 0.5LgR
13A 11 0.5LgR
WATER
0.5 Lg 0.5 Lg
BW :Black White 0.5 B
14A 10
0.5 B TEMP
LgR :Young Leaves Red 5B 2 BUZZER
6
Gr :Gray 0.5 WG
16B 12 0.85 WG LAMP
Or :Orange 0.5 YB
22D 8 0.5 YB
CHECK
CIRCUIT
Br :Brown 0.85 WG
11A
0.85 WG
16
0.85 WG
16A 7 0.85 WG
CHARGE
0.85 WG
0.85 WL
0.85GW
0.5 LgR
1.25YL
0.5 LB
0.5 Lg
0.5 L
28B 8 1112 13 14 15 10
22 8 1112 13 14 15 25
0.85 WG
0.85 WL
0.85GW
0.5 LgR
1.25YL
0.5 LB
0.5 Lg
0.5 L
0.85 WG
0.85 YR
0.85 WL
11A 3C
12A
3.0 RL
L IG
3.0 RG
1
5.0R
SLOW BLOW 2
FUSE(50A) S E P
21 20A B
AVf30 B
EB20 20
3.0 RL
21A B.E.
(-) (+) 5.0R

STARTER AC
(65B24R) MOTOR GENERATOR
BATTERY B.E. 013608-00E
7-1-7 0000604
7-1-5 Removal and Reinstallation of Engine
1) Removal
Procedure
(1) Swing the upperstructure so that the drain plug 1 of the
hydraulic oil tank and the cooling water drain plug 2 are
positioned halfway between the right and left crawlers.
Then, lower the bucket to the ground and stop the engine. 1
(2) Remove the drain plug 1 from the hydraulic oil tank and
2
drain the hydraulic oil.
Type YANMAR SUPER HYDRO OIL

(VG 46 class) or its equivalent
Quantity 16 L
(3) Remove the drain plug 2 from the two-way cock for cool-
ing water and drain the cooling water.
Cooling water quantity 2.5 L

2
1
013582-00X
(4) Remove the step B 1, the arm rest 2, the panel L 3 and 2
the panel R 4. 5 2
4
(5) Remove the indicator box 5, and then disconnect the har-
ness connectors. 3
1 013583-00X
(6) Disconnect the battery cable (negative) 1 and the battery

cable (positive) 2 and remove the battery clamp 3. Then
remove the battery 4.
3
2
1
013584-00X
7-1-8 0000604
Procedure
(7) Remove the cover R 1, the cover L 2, the bonnet 3 and
the lim 4.
3
4
1
2
013586-00X
(8) Remove twelve pilot control hoses from both the remote 1
Viewed from upper
control valves L and R 1. 1 1
T P T P
4 2 4 2
3 3
Right side Left side P T
Front
1
P
T
013590-00E
(9) Remove the operator's seat plate 1 (with the operator's

seat).
4
(10) Remove the cover (accelerator, remove the snap pin 2
and disconnect the accelerator cable 3 from the acceler- 1
ator lever 4.
3
(11) Remove the accelerator cable 3 from the seat mount. 2
013587-00X
7-1-9 0000604
Procedure
(12) Remove the nuts 1 from the L-balls of the cable con-
nected to the blade lever and the cable 2 and disconnect
those cables from the levers.
(13) Remove the blade cable from the seat mount.
2
013588-00X
(14) Disconnect the harnesses 35 from the fuel gauge unit

respectively.
(15) Disconnect the wire harness from the plus (+) terminal of
the battery.
(16) Disconnect the connectors 37 of the harnesses A 35 and

B 36 from each other.
(17) Disconnect the connectors 42 and 43 of the horn and the 44

boom light (working lamp) respectively.
(18) Disconnect the connectors of the fuel transfer pump and 37

selector valve switch.
(19) Disconnect the wire harnesses of the selector valve, cut-

off valve and two-speed valve. 36
(20) Remove the bracket 44 from the operator's seat mount
43 50
50.
35
42
013589-00X
7-1-10 0000604
Procedure
(21) Remove the canopy 45.
(22) Remove the radiator support 46 and the filler 47.

45
(23) Loosen the hose clip 49 on the intake manifold side and
remove the air cleaner hose B 48 from the intake mani-
fold.
(24) Disconnect the fuel hose (fuel tank - water separator)

from the separator.
(25) Disconnect two fuel hose (fuel filter - engine) from the fil-
ter.
(26) Disconnect the fuel return hose (fuel filter - tank) from the
filter.
(27) Rope the operator's seat mount 50 and lift it up, to

remove it.
Note :
Take care that the harnesses and clamps do not catch on any
other parts when lifting up the operator's seat mount.
51
48
49
46
47
50
013591-00X
7-1-11 0000604
Procedure
(28) Remove the hoses connected to the hydraulic oil tank 1.
a. Suction hose
b. Return hose (control valve to hydraulic oil tank)
c. Return hose (joint to hydraulic oil tank)
Note :
Remove the return hose from the joint. b
d. Hydraulic oil drain hose
013592-00X
(29) Remove the hydraulic hoses from the hydraulic pump.

a. Hose (MAIN)
b. Hose (PILOT)
c. Hose (MESUR EMENT) c
a
b
013593-00X
(30) Remove the cooling water drain hose 1.
(31) Remove the hydraulic hoses 2, 3 from the oil cooler.
2
1
3 013594-00X
7-1-12 0000604
Procedure
(32) Remove the PTO valve and selector valve from the bat-
tery mount to dismantle it.
013605-00X
(33) Remove the engine ground cable 1, battery ground cable

and wire harness ground from the base mount.
(34) Remove the base mount from the frame.
013595-00X
(35) Rope the engine using its lifting lugs and lift it up, to
remove it.
013596-00X
7-1-13 0000604
2) Reinstallation
Reinstall the engine in the reverse order of the removal procedure.
Adhesive and tightening torque

No. Parts Size Adhesive Tightening torque
5 Mount base¯Turning frame M12¯30 Three Bond 1324
7 Air cleaner intake hose Hose clamp 60 - 1.45 to 3.43 N•m (25 to 35 kgf•cm)
15 Battery Nut M6 - 1.96 to 2.94 N•m (20 to 30 kgf•cm)
15 Rod Nut M6 - 4.9 to 5.88 N•m (50 to 60 kgf•cm)
16 Battery code (+) (-) Nut M6 - 2.94 to 3.92 N•m (30 to 40 kgf•cm)
24 EL ball¯Link Nut M8 - 12.7 to 16.7 N•m (130 to 170 kgf•cm)
27 Cable accelerator Nut M6 - 3.92 to 4.9 N•m (40 to 50 kgf•cm)
30 Cable Nut M12 - 19.6 to 24.5 N•m (200 to 250 kgf•cm)
33 Canopy M12¯30 Three Bond 1324 107.9 to 128.5 N•m (1100 to 1300 kgf•cm)
40 Hose clip 13 - - 2.5 to 3.4 N•m (25 to 35 kgf•cm)
7-1-14 0000604
7-1-6 Removal and Reinstallation of Starter Motor
1) Removal
Procedure
(1) Lower the bucket to the ground and stop the engine.
013638-00X
(2) Disconnect the battery cable (negative) 1 and the battery

cable (positive) 2 and remove the battery clamp 3 from
the battery 4. Then remove the battery 4.
3
2
1
013597-00X
(3) Disconnect the wire harness 2 from the starter motor 1.
(4) Remove the mounting bolts 3 and remove the starter

motor 1. 3
1
2
013598-00X
2) Reinstallation
Reinstall the starter motor in the reverse order of the removal procedure.
Note :
Secure the harness with a band.
Starter motor mounting bolt (M10)

Tightening torque 44.1 to 58.8 N•m (4.5 to 6.0 kgf•m)
7-1-15 0000604
7-1-7 Removal and Reinstallation of Fuel Injection Pump
1) Removal
Procedure
(1) Loosen the hose clip 2 of the air cleaner hose B 1 to dis-
connect with the air intake manifold of engine, and A
remove the air cleaner assembly with the hose B 1. 4
3
(2) Loosen the sleeve nuts 5 at the fuel injectors after remov-
ing the retainers 4 for the fuel injection pipes 3 and then
loosen the sleeve nuts 7 at the fuel injection pump 6.
(3) Disconnect the fuel hoses 8 (filter-fuel injection pump) and 5 A

9 (fuel injection pump-filter).
(4) Remove the engine oil pipe 10 (cylinder block-fuel injec- 2 1 4

INT
tion pump). 7
(5) Remove the end nut 13 after removing the HO-P cover 12 8
from the gear case 11.
6
Note :
• Put a mark 15 on the engaging point of the FIP gear 14 and
the idle gear. 10
• Do not remove the FIP gear 14 from the gear case 11.
(6) Remove three nuts 16 to remove the fuel injection pump 6

from the gear case 11.
9
Note :
• Remove the fuel injection pump 6 after putting a mark on it Marking 11
and the gear case 11.
• Do not turn the crankshaft after removing the fuel injection 16
pump 6. When a mark 15 on the engaging point of the FIP
gear 14 and the idle gear does not align, match the marks
of the idle gear with the crankshaft gear 17, cam gear 18
and FIP gear 14.
• Never loosen the FIP coupling 19 and FIP gear 14 holding
screws 20. 12
14
20
6
13
19
From the gear case side
Cam gear
15
B
B C C
A
Idol gear 18
A
17
Lubricating oil
Crank gear
pump gear 013600-00E
7-1-16 0000604
2) Reinstallation
Reinstall all parts in the reverse order of disassembly.
Note :
• Do not use the FIP coupling 19 assembled on a new fuel injection pump assembly.
• The injection timing should be verified by the FID method.
End nut
Apply engine oil
Tightening torque 58.8 to 68.8 N•m (6.0 to 7.0 kgf•m)
7-1-17 0000604
7-1-8 Removal and Reinstallation of Fuel Tank
1) Removal
Procedure
(1) Swing the upperstructure so that the under cover 1 of the
fuel tank is positioned halfway between the right and left
crawlers. Then, lower the bucket to the ground and stop
the engine.
013601-00X
(2) Remove the under cover.
(3) Take the end of fuel drain hose out from the frame and
pull out the plug pin to drain fuel.
1
Fuel quantity 24.5 L
013602-00X
(4) Remove the cover R 1 and the step B 2.
2 013603-00X
7-1-18 0000604
Procedure
(5) Remove the hose clips 2 of the fuel hose 3, 4 (the fuel fil-
ter to the fuel tank) and the fuel hose 5 (the fuel tank to
the water separator), and remove the hoses.] 3
(6) Disconnect the wire harness from the fuel level gauge 2
unit.
(7) Remove the fuel tank clamp 6 and the support 7, and then 6 1
remove the fuel tank 1.
5
2
2 7
013604-00X
7-1-19 0000604
2) Reinstallation
Reinstall the fuel tank in the reverse order of the removal procedure.
Note :
Before reinstalling the fuel tank, clean up the inside of it. In particular, remove the deposits on the bottom of the fuel
tank completely.
7-1-20 0000604
7-1-9 Removal and Reinstallation of Radiator
1) Removal
Procedure
(1) Swing the upperstructure so that the cooling water drain
plug 1 is positioned halfway between the right and left
crawlers. Then, lower the bucket to the ground and stop
the engine.
1
(2) Remove the drain plug 1 from the two-way cock 2 for cool-
ing water and drain the cooling water.
Cooling water quantity 2.5 L
013843-00X
(3) Remove the cover R 3, the lim 4 and the radiator support
5. 4
(4) Remove the filler 7. 5
7
3
013855-00X
7-1-21 0000604
Procedure
(5) Remove the hoses A 1 and C 2 from the engine.
(6) Remove the cooling water drain hose 3. 6

7
(7) Remove two hoses 4, 5 from the oil cooler.
2
(8) Remove the radiator 6 (with the shroud 7) from the fuel 1
tank mount 8.
3
4
8
5 013844-00X
7-1-22 0000604
2) Reinstallation
Reinstall the radiator in the reverse order of the removal procedure.
Hose clip 60
Tightening torque 3.92 to 4.91 N•m (40 to 50 N•m)
Table of Mixing Ratio of Anti-freeze to Water

Lowest temperature °C -5 -10 -15 -20 -25 -33 -35 -40
Amount of anti-freeze L 0.4 0.7 0.8 0.9 1.0 1.2 1.3 1.4
Amount of water L 2.2 1.9 1.8 1.7 1.6 1.4 1.3 1.2
Note :
At the delivery from the factory, water and anti-freeze are mixed in the ratio shown above for the -35 °C temperature.
7-1-23 0000604
7-2 Undercarriage
7-2-1 Outline
The undercarriage consists of travel motors, frame, track rollers, front idlers, rubber crawlers and other parts.
Hydraulic oil fed through the control valve and the swivel joint from the hydraulic pump causes the travel motors to
rotate, so that the power is transmitted to the crawlers via the sprockets.
The track frame can be widened and narrowed by the track gauge change cylinder (track gauge change type).
Viwed from the top

Slide plate
Idler Stopper bolt Track gauge Travel motor

change cylinder
Track roller
Swivel joint
A Section A-A
A
Grease adjuster Track roller Sprocket
013678-00E
7-2-1 0000604
7-2-2 Points of Reassembly
Bolt 1035, 1025

Apply Three Bond 1324 or its equivalent.
Tightening torque:
44.1 to 58.8 N㨯m (4.5 to 6.0 kgf㨯m)
Install rubber crawler

so that lug is set in di-
rection as shown in
top view below.
Bolt 1225
Tightening torque:
78 to 98 N㨯m (8.0 to 10.0 kgf㨯m)
Bolt 1040
Tightening torque: Check that track roller
44.1 to 58.8 N㨯m (4.5 to 6.0 kgf㨯m) moves smoothy after
Section A-A installing it into frame.
Idler should smoothly

move back and forth. A
A
Apply heavy-duty Check that track roller moves
grease to moving smoothly after installing it into
area of idler. frame.
Track gauge change cylinder

Stopper bolt
Nut M16
Tightening torque :
166.7 to 205.9 N㨯m (17 to 21 kgf㨯m)
Bolt 1645
Tightening torque :
Standard length 166.7 to 205.9 N㨯m (17 to 21 kgf㨯m)
226.5 mm
Shoe slide plate 013681-00E
7-2-2 0000604
7-2-3 Crawler Tension Adjustment Procedure
(1) Raise one crawler using the boom. Track roller

(2) Position the mark on the inside surface of the rub-
ber crawler on the slide plate.
(3) Measure the clearance H shown in the figures
below, and adjust the crawler tension so that the
clearance H will be within the specified range.
Crawler
Clearance to be measured for
tension adjustment
H=60 to 65 mm
7-2-3 0000604
7-2-4 Removal and Reinstallation of Crawler
! When rasing the machine, support it with safety blocks of sufficient strength.
When loosening or removing the nipple valve 1, the high internal pressure could cause grease to eject or the nipple valve
! to blow. Do not bring your face close to the nipple valve 1.
1) Removal of Rubber Crawler

Handle the rubber crawlers with great care, as they are heavy.
!
Rubber crawler : 52 kg each
Procedure
(1) Lower the bucket to the ground, and remove the nipple
valve 1 to loosen the rubber crawler tension.
Note :
Move the machine back and forth if the grease is not dis-
charged smoothly.
(2) Swing the upperstructure to position the implement in the

direction opposite to the blade, and raise the machine
slightly with the implement.
Rubber crawler
to remove
(3) Insert steel pipes between the crawler frame and the rub-
ber crawler 2, as shown in the figure at the right, and turn
the sprocket in the reverse direction. Slide the rubber
crawler off when the rubber crawler is separated from the
idler by the steel pipes.
2
Rotating direction
Steel pipes
7-2-4 0000604
7-2-5 Disassembly and Reassembly of Idler
1) Structure and Component Parts
2
7 8
3
4
9
10
6
11
No. Part Q’ty No. Part Q’ty

1 Idler 1 7 Internal snap ring C62 1
2 Internal snap ring C62 1 8 Idler fork R 1
3 Idler fork L 1 9 External snap ring C25 1
4 Seal QLN306213.2Y 1 10 Seal QLN306213.2Y 1
5 Shaft 1 11 Bearing 6206 1
6 Bearing 6206 1
2) Disassembly
Procedure
(1) Remove the idler assembly from the crawler frame.
Crawler frame
Idler assembly
7-2-5 0000604
Procedure
(2) Remove the mounting bolts to remove the crawler adjust-
ing spring. Mounting bolt
(3) Remove the snap ring C 9 and then remove the idler fork
R 8, the seal 10 and the snap ring C 7. Crawler adjusting
spring
(4) Drain the lube oil inside the idler. Then, pull out the shaft 5
(with the bearing 11) using a press.
Oil quantity 25 cc
98
(5) Remove the seal 4, and then remove the snap ring C 2 10
and the bearing 6. 7
11
Note :
The shaft 5 is press-fitted into the idler fork L 3. 1
5
6
24
3
3) Reassembly
Reassemble the idler in the reverse order of the disas-
sembly procedure.
Notes :
[1] Clean all the parts and check them for damage or
defects.
[2] Replace the seals with new ones.
[3] Apply multipurpose grease to the lips of seals 4 and 4, 10
10.
[4] When installing the seal 10, to release air from the
inside of the idler, remove the sleeve from the seal
and install the seal, then install the sleeve.
Crawler adjusting spring mounting bolt (M10)
Adhesive Three Bond 1324 or its equivalent.
Tightening torque 44 to 58.8 N•m (4.6 to 6.0 kgf•m)
[5] Oil to be used for idler:

Sleeve
Type Engine oil SAE 30
Quantity 25 cc
7-2-6 0000604
7-2-6 Disassembly and Reassembly of Track Roller
1) Structure and Component Parts
1 2 3 4 5 6 7
For rubber crawlers

8

1 Seal TW 25 52 18 1 5 Shaft 1
2 Roller 1 6 Bearing 6205 1
3 Internal snap ring C52 1 7 Internal snap ring C52 1
4 Bearing 6205 1 8 Seal TW 25 52 18 1
2) Disassembly
Procedure
(1) Remove the mounting bolts and remove the track roller Mounting bolt
from the crawler frame.
Crawler frame
Track frame
7-2-7 0000604
Procedure
(2) Remove the seal 1 from the track roller 2 and drain the
lube oil.
1
Oil quantity 40 cc 3
4
(3) Remove the snap ring C 3 and pull out the shaft 5 (with 5
the bearing 4) using a press.
2
(4) Remove the seal 8, and then remove the snap ring C 7
and the bearing 6.
6
7
8
3) Reassembly
Reassemble the track roller in the reverse order of the
disassembly procedure.
1, 8
Notes :
[1] Clean all the parts and check them for damage or
defects.
[2] Replace the seals with new ones.
[3] Apply multipurpose grease to the lips of seals 1 and
8.
[4] When installing the seal 1, to release air from the
inside of the track roller, remove the sleeve from the
seal and install the seal, then install the sleeve.
Track roller mounting bolt (M12)
Tightening torque 78 to 98 N•m (8 to 10 kgf•m)
[5] Oil to be used for track rollers :
Sleeve
Type Engine oil SAE 30
Quantity 40 cc
7-2-8 0000604
7-2-7 Removal and Reinstallation of Track Gauge Change Cylinder
1) Removal of Track Gauge Change Cylinder

Procedure
(1) Widen the track frame fully by operating the track gauge
change cylinder, and then remove the right rubber crawler
1.
Note :
Refer to Section "7-2-5 Removal and Reinstallation of
Crawler".
1
Rotating direction
Steel pipes
(2) Raise the machine using the implement and the blade,
and then place blocks under the lower center frame 2.
Note : 2
Place blocks which have sufficient height to allow work under
the lower center frame 2.
Blocks
013685-00E

hydraulic oil tank is positioned halfway between the right
and left crawlers, and then stop the engine.
(4) Remove the drain plug 3 from the hydraulic oil tank and 3
Hydraulic oil quantity 16.0 L
013686-00X
7-2-9 0000604
Procedure
(5) Remove the hose cover 4 and the motor cover 5, and
then remove the hydraulic hoses 7 from the left travel 7 T
motor 6.
5 P1
P2
Note :
Mark the hydraulic hoses 7 to identify their respective fitting
positions. 6
(6) Remove the under cover (SJ) 8.
8 013687-00X
(7) Remove the mounting bolts 12 for the pin 10 at the rod
end and the pin 11 at the bottom end of the track gauge
change cylinder 9, and pull out the pins.
(8) Remove the left stopper bolt 13, and then pull out the
crawler frame (L) 14 from the lower center frame 2. 13
(9) Remove the hydraulic hose 16 of the cylinder from the
lower part of the lower center frame 2. 11
12
(10) Remove the track gauge change cylinder 9 from the
lower center frame 2.
2
9
12
A
10
13
A
14
013688-00X
7-2-10 0000604
2) Reinstallation of Track Gauge Change Cylinder

Reinstall the track gauge change cylinder in the reverse order of the removal procedure.
Notes :
[1] Clean the square pipes of the crawler frames and the square pipe holes of the lower center frame.
[2] Apply heavy-duty grease to the four sides of each square pipe hole of the lower center frame over 200 mm from
the entrance.
[3] Stopper bolt setting procedure:
After fully screwing the stopper nut onto the stopper bolt, loosen the nut one turn. Then tighten the bolt.
226.5 mm
013846-00X
Stopper bolt and stopper nut (M16)

Tightening torque 166.7 to 205.9 N•m
(17 to 21 kgf•m)
[4] Hydraulic oil to be used :
Quantity 16 L
7-2-11 0000604
7-3 Controls
7-3-1 Control Train
1) Control Lever (R)

Control Lever (L) 2) Travel Levers
013847-00X 013848-00X
3) Boom Swing Pedal

4) P.T.O. Pedal 5) Lock Lever
013849-00X 013850-00X
6) Blade Lever
7) Track Gauge Change Lever 8) Accelerator Lever
013851-00X 013852-00X
7-3-1 0000604
7-3-2 Mechanical Control Linkage
1) Points of Assembly
(1) Use a jig to install the bushing into the link.
Bushing installation
Bushing press-fitting jig Press-fit

Unit : mm
Jig
Jig No.
L1
F-001 F-002 Bushing
L2
D 30
d 14 20
D
L1 120 Link
L2 14
C1
Notes : F-001 : Cut-off lever (R)
C1 Operator’s seat mount
R0.2 (Blade lever, Cut-off lever)
F-002 : Swing pedal, Cut-off lever (L)
P.T.O. pedal, Control lever (L)
Travel lever
(2) Set the crevices of the control valve spools vertically.

Spool
Crevice
Rod
(3) Apply grease to the links and take care not to damage the O-rings A when installing the links.
(4) Add grease to the grease nipples B after installation.
A 013748-00X
7-3-2 0000604
2) Tightening Torque and Mounting Angle for Rod Joints
013749-00X
A
A Tightening torque : L-ball 8 B Tightening torque : Link-ball BL8DL
Tightening torque : Tightening torque :

7.8 to 9.8 N㨯m (0.8 to 1.0 kgf㨯m) 1.96 to 2.94 N㨯m (0.2 to 0.3 kgf㨯m)
Tightening torque : Tightening torque :

12.7 to 16.7 N㨯m (1.3 to 1.7 kgf㨯m) 12.7 to 16.7 N㨯m (1.3 to 1.7 kgf㨯m)
L-ball mounting angle L-ball mounting angle
es es
gre gre
de de
90 90
The angle should be 90 degrees. The angle should be 90 degrees.
7-3-3 0000604
7-3-3 Adjustment of Travel Levers
1) Position of Travel Lever Grips

Remove the step and the boots bracket.
(1) Difference in side level between the right and
left lever grips : Within 3 mm
(2) Adjustment
Difference in side level
• Loosen the nut 1 of the L-ball and rotate the rod
2 to adjust the position of the lever grip to 242
mm from the frame cover front end (for each
lever grip).
• After adjusting the difference in side level
between both levers to 3 mm or less, tighten the Frame cover front end Defference in side lever between both
lever qrips : within 3 mm
nuts 1. 242 (in neutral and full stroke position)
71 71
2) Adjustment of Stopper Bolts
(For Forward Travel and Reverse)
(1) Loosen the lock nuts 4 of the stopper bolts 3.
(2) Screw in the stopper bolts 3 so that the travel
lever will not touch them.
(3) Move the travel lever to its stroke end, and
Boots bracket
loosen the stopper bolt 3 until the bolt head
touches the travel lever (for each stopper
bolt).
(4) Loosen the stopper bolt 3 half a turn further
and tighten the lock nut 4 to fix it. 3
4
1 2
4 3
Mounting angle of L-ball Tightening torque :

12.7 to 16.7 N㨯m
es (1.3 to 1.7 kgf㨯m)
gre
de
90
Tightening torque :
7.8 to 9.8 N㨯m
(0.8 to 1.0 kgf㨯m)
013809-00X
7-3-4 0000604
7-3-4 Adjustment of Boom Swing Pedal
1) Setting Pedal Level Swing pedal

Remove the step.
(1) Loosen the nut 1.
(2) Adjust the boom swing pedal by turning the nut
1 so that the pedal will be level.
(3) Tighten the nut 1.
2) Adjustment of Stopper Bolts (For Right and

1
Left Boom Swing)
(1) Loosen the lock nuts 2 and screw in the stopper
bolts 3 so that they will not touch the boom
swing pedal.
(2) Move the boom swing pedal to its stroke end,
and loosen the stopper bolt 3 until the bolt head
touches the pedal (for each stopper bolt).
(3) Loosen the stopper bolt 3 one more turn and 3
tighten the lock nut 2 to fix it.
2
013807-00E
57 mm In neutral position
7-3-5 Adjustment of Blade Lever
(Track Gauge Change Lever)
Blade lever
Remove the side cover R and the panel R. Side cover

356 mm
1) Grip Position of Blade Lever

(1) Loosen the nut 1 and adjust the blade lever so
that it will be figure right dimensions in the neu-
tral position. Lock lever (R)
2) Adjustment of Stopper Bolt

(1) Loosen the lock nuts 2 and loosen the stopper
bolts 3 so that they will not touch the blade lever.
(2) Move the blade lever to its stroke end, and
tighten the stopper bolt 3 until the bolt end
touches the blade lever (for each stopper bolt).
3
(3) Tighten the stopper bolt 3 one more turn and
2
tighten the lock nut 2 to fix it.
013805-00E
7-3-5 0000604
7-3-6 Adjustment of Lock Lever Switch

1
Note :
The implement should not operate even if the control
lever is moved when the lock lever is in the lock position.
4.5
to 5 2
.5 m
m
4
A
Tightening torque :
29.4 to 34.3 N m (3.0 to 3.5 kgf m)
Note : Overtorque may cause
damage to the switch.
Detail of A
3
Lock lever switch operation
Cut-off Imple-
Lever Switch Switch
valve ment
position state circuit
operation operation
Pushed 013875-00X
Unlock ON Operate Operate
Normal
Can not
Lock OFF Stop
operate
7-3-6 0000604
7-3-7 Adjustment of Accelerator Lever
1. Adjustment of Maximum Idling Speed

(1) Loosen the stopper bolt 1, and then move the acceler-
ator lever 4 back until the regulator handle 7 on the
5 4
engine side touches the adjusting bolt 8 for the maxi-
mum idling speed in the governor case.
(2) Check that the maximum idling speed is within a spec- 3 2 A
ified range (SV15 : 2575 to 2625 rpm, SV17(EX) :
2075 to 2125 rpm).
(3) Make adjustments with the accelerator cable 6 in the
part A shown in the figure so that the stopper 9 for the
1
10 6
maximum idling speed for the accelerator lever 4 will
touch the accelerator arm 3. To the engine
2. Adjustment of Minimum Idling Speed

(1) Move the accelerator lever 4 forward.
(2) When the regulator handle 7 on the engine side
touches the stopper bolt 6 for the minimum idling
speed, check whether the minimum idling speed is
within a specified range (1125 to 1175 rpm).
(3) If the minimum idling speed is not within the range,
make adjustments to the speed by tightening or loos-
ening the stopper bolt 6.
(4) After the adjustment of the minimum idling speed,
screw in the stopper bolt 1 for the accelerator lever 4
until the bolt end touches the accelerator arm 3 and fix
it with the nut 2. Maximum 8
idling speed
6
7
Increase Decrease
Minimum
idling speed 013804-00E
7-3-7 0000604
7-3-8 Adjustment of P.T.O. Pedal ln neutral position
1) Setting Pedal Level
96 to 98 mm
(1) Remove the step.
(2) Loosen the nut 2.
(3) Adjust the boom swing pedal by turning the nut 2 so
that the pedal will be level.
(4) Tighten the nut 2.
Pedal
2
2) Adjustment of Stopper Bolts
Control valve
(1) Loosen the lock nuts 4 and screw in the stopper
bolts 5 so that they will not touch the boom swing
pedal. 013796-00X
(2) Move the boom swing pedal to its stroke end, and
loosen the stopper bolt 5 until the bolt head touches
the pedal (for each stopper bolt). 5
(3) Loosen the stopper bolt 5 one more turn and tighten
the lock nut 4 to fix it.
4
3) Adjustment of Pedal Lock

P.T.O. pedal
(1) After the adjustment of the pedal stroke, move the
P.T.O. pedal to its stroke end on the left and place
the P.T.O. pedal lock 6 on the P.T.O. pedal.
(2) Adjust the clearance H between the P.T.O. pedal
lock 6 and the P.T.O. pedal to 2 mm or less with the
bolt 9.
(3) Adjust the operating force for the P.T.O. pedal lock 6 6
at the end A, with the double nut 7, to a value within
a specified range : 10.7 to 18.7 N (1.0 to 2.0 kg). 6
H
9
7 Pedal
013797-00X
7-3-8 0000604
7-4 Swing Bearing 1 3

1) Removal and Reinstallation of Swing Bearing 2 4
(1) Remove the implement.
Refer to Section "7-6-1 Removal and Reinstallation
of Implement".
(2) Remove the engine.
of Engine".
(3) Remove the swing motor.
013806-00X
of Swing Motor".
(4) Remove the hydraulic hoses from the swivel joint.
of Swivel Joint".
(5) Rope the turning frame 1 at three points and sus-
pend it temporarily.
(6) Remove the sixteen mounting bolts 2 with which the
turning frame 1 is mounted on the outer race of the 1
swing bearing.
(7) Lift up the turning frame 1.
(8) Remove the eighteen mounting bolts 3 with which
the inner race of the swing bearing is mounted on
the track frame.
(9) Remove the swing bearing 4.
2) Points of Installation
The inner and outer races of the swing bearing have a
Soft zone of
soft zone, and the soft zone of the inner race is marked Soft zone S 3 outer race
of inner race
with "S".
The soft zone of the outer race is located at the steel ball 5
insertion port.
To reduce the load to be applied to the soft zones, as 4 2 Steel ball
shown in the figure at the right, install the swing bearing insertior port
with the "S" mark on the right side of the track frame and
the steel ball insertion port on the left side of it.
013793-00X
7-4-1 0000604
3) Service Standards
Standard Wear limit
Axial clearance B
Outer race
Dial gauge Load 200 kgf
B 0.03 to 0.15 mm 0.4 mm
Outer race PCD
Radial clearance A
A Load 0.03 to 0.25 mm 0.5 mm

25 kgf
Inner race
Steel ball diameter Ø17.4625 mm ⎯

M12¯40
Tuning frame¯outer race M12¯45 107.9 to 128.5 N·m Apply Loctite 262
Tightening torque (10.9 T)
Track frame¯inner race M12¯55 (11 to 13 kgf·m) or its equivalent.
(Bolt 10.9)
Note :
Put multipurpose grease into the swing bearing.
4) Parts of Swing Bearing

5 7 1, 4 2 6
No. Part Q'ty
1 Steel ball 60
2 Seal A 1
3 Seal B 1
8
4 Support 60
5 Outer race 1
6 Inner race 1
7 Taper pin 1
8 Plug 1
3
5) Inspection
(1) Check the gear teeth surfaces for nicks, flaws, cracks, wear and breakage. Replace the swing bearing if the
damage is excessive.
(2) Check for abnormal sound. Clean, grease or replace the swing bearing if necessary.
(3) Check the inner and outer races for play and irregular rotation. Refer to the service standards for repair or
replacement.
(4) Check for grease leak from the swing bearing seal. Replace the swing bearing if the leakage is excessive.
7-4-2 0000604
7-5 Hydraulic Equipment
7-5-1 Removal and Reinstallation of Hydraulic Pump

1) Removal
Procedure
and left crawlers. Then, lower the bucket to the ground
and stop the engine. 1
(2) Remove the under cover 2. 2
1
2
013680-00X
(4) Open the bonnet center 1 and remove the cover L 2.

1
2
013609-00X
7-5-1 0000604
Procedure
(5) Remove the hydraulic hoses from the hydraulic pump 12.
a. Hose (MAIN)
b. Hose (PILOT)
c
c. Hose (MESUR EMENT) 12
(6) Remove the mounting bolts 13 and remove the hydraulic
pump 12.
a
b
13
013610-00X
7-5-2 0000604
2) Reinstallation
Reinstall the hydraulic pump in the reverse order of the removal procedure.
Notes :
• Apply heavy-duty grease to the spline shaft of the hydraulic pump.
Hydraulic pump installation bolt M12
Tightening torque 78.5 to 98.1 N•m (8 to 10 kgf•m)
• Hydraulic oil to be used :

(VG 46 class) or its equivalen
Quantity 16.0 L
• After the installation of the hydraulic pump, make a test run and operate the relief valves to check for oil leak or
other abnormality.
7-5-3 0000604
7-5-2 Removal and Reinstallation of Control Valve
1) Removal
Procedure
hydraulic oil tank and the under cover (CV) 2 are posi-
tioned halfway between the right and left crawlers. Then, 1
lower the bucket to the ground and stop the engine.
(2) Remove the under cover (CV) 2.

2
1
2
013752-00X
(4) Remove the step 3 and the cover L 4.
4
013753-00X
(5) Remove the hydraulic hoses and the pilot hoses from the
control valve 6. B9 A9 TRAVEL.R
Right side
B8 A8 TRAVEL.L
Notes : B7 A7 BOOM SWING
• Remove the hydraulic hoses and the pilot hoses from the Forward B6 A6 OPTION
control valve in right-to-left order. B5 A5
BLADE
• Mark the removed hoses to identify their respective fitting B4 A4 BOOM
positions. B3 A3 BUCKET
B2 A2 SWING
B1 A1 ARM
6 P1 Pil
P1
Left side
013794-00X
7-5-4 0000604
Procedure
(6) Remove the nuts 12 from the L-balls 11 connected to the
travel (R) section 8 and the travel (L) section 10, to dis- 14
connect those sections from the links 13.
16 14
(7) Remove the pins 16 to disconnect the cable 14 connected
to the blade lever, the cable 14 connected to the P.T.O. 16 14
and the cable 14 connected to the swing from the spools
of the control valve 6. 16
13
6
13
12
8
12
10
11
11 014038-00X
(8) Remove the mounting bolts 17, and then remove the con-
trol valve 6 from the valve plate 18. 17
18
013750-00X
7-5-5 0000604
2) Reinstallation
Reinstall the control valve in the reverse order of the removal procedure.
Notes :
[1] Install the hoses so that each of them is not in contact with any other hoses or parts.

Quantity 16.0 L
[3] After the installation of the control valve, raise the hydraulic oil temperature to 50 to 60 °C and operate the relief
valves, to check for oil leak.
B9 A9
B8 A8
B7 A7
B6 A6
Forward
B5 A5
B5 A5
B3 A3
B2 A2
B1 A1
Pil
P1
10°
013795-00X
7-5-6 0000604
7-5-3 Removal and Reinstallation of Swing Motor
1) Removal
Procedure
013611-00X
(3) Remove the step 2.
013751-00X
7-5-7 0000604
Procedure
(4) Remove the hydraulic hoses from the swing motor 8.
• Hose 9 (control valve to swing motor) 13 G
• Hose 10 (control valve to swing motor)
• Drain hose 11 (swing motor to drain block) 12
• Drain hose 12 (control valve T to swing motor)
• Drain hose 13 (swing motor to oil cooler)
Dr B
T
H
11
8
9
10
013757-00X
(5) Remove the mounting bolts 14 and remove the swing

motor 8.
14
013758-00X
7-5-8 0000604
2) Reinstallation
Reinstall the swing motor in the reverse order of the removal procedure.
Notes :
Swing motor mounting bolt (M12)
Adhesive Apply three bond 1324 or its equivalent.
Tightening torque 78.5 to 98.1 N•m (8 to 10 N•m)
[1] Install the hoses so that each of them is not in contact with any other hoses or parts.

Quantity 16.0 L
[3] After the installation of the swing motor, raise the hydraulic oil temperature to 50 to 60 °C and operate the relief
valves, to check for oil leak.
7-5-9 0000604
7-5-4 Removal and Reinstallation of Swivel Joint
1) Removal
Procedure
(1) Operate the implement and the blade to raise the
machine.
(2) After raising the machine, place blocks under the

machine.
Notes :
• To prevent the machine from dropping down, be sure to
place blocks under it.
• Place blocks which have sufficient height to allow work
under the machine.
Blocks 013755-00X

and stop the engine.
(4) Remove the under cover (SJ) 2.

1
1
2
013756-00X
(6) Remove the step 3.
013754-00X
7-5-10 0000604
Procedure
(7) Remove the hydraulic hoses from the swivel hub of the
swivel joint.
a (10) : For travel motor (R) (reverse)
b (9) : For travel motor (L) (reverse)
c (3) : For blade cylinder (bottom side)
d (4) : For blade cylinder (rod side)
e (8) : For travel motor (R) (forward travel)
f (7) : For travel motor (L) (forward travel)
g (1) : For high-speed (R) (SV17(EX) only)
h (1) : For high-speed (L) (SV17(EX) only)
j (2) : For travel motor (R) (drain)
j (2) : For travel motor (L) (drain)
- (5) : For track gauge change cylinder (bottom side)
- (6) : For track gauge change cylinder (rod side)
Notes : Swivel joint Swivel joint

• Remove the hydraulic hoses from the swivel hub in bottom- E
to-top order. e 2
1
• Mark the removed hoses to identify their respective fitting G 6
positions. e g
F 3
8 1 2
c C
Dr H 4
f 10
D h
j 5
a Dr
A
B 9 7
d
C
SV15 / SV17 SV17EX 013759-00X
(8) Remove the hydraulic hoses from the swivel joint.

(SV15/SV17) C4
F : For travel motor (L) (reverse) 4 C1
I : For travel motor (R) (reverse)
C : For blade cylinder (rod side) C3
3 P2
C2
D : For travel motor (R) (forward travel) P1
G : For blade cylinder (bottom side) 6 R2
I : For travel motor (L) (forward travel) 5 11
(8) Remove the hydraulic hoses from the swivel joint. 2
(SV17EX) 7
(10) : For travel motor (R) (reverse) 8 9
(9) : For travel motor (L) (reverse) D I
10 1
(3) : For blade cylinder (bottom side) C G F E
(4) : For blade cylinder (rod side) 11 2
(8) : For travel motor (R) (forward travel)
(7) : For travel motor (L) (forward travel)
(1) : For high-speed (R)
(1) : For high-speed (L)
(2) : For travel motor (R) (drain) B8 A8 A8
(2) : For travel motor (L) (drain) B9 A9 B5 A5 A9 B8
B9 A5
(5) : For track gauge change cylinder (bottom side) B5
(6) : For track gauge change cylinder (rod side)
Note :
Mark the removed hoses to identify their respective fitting
positions.
(9) Remove the mounting bolts for the swivel joint.
(10) Remove the swivel joint from the upper frame. SV15 / SV17 SV17EX
014042-00X
7-5-11 0000604
2) Reinstallation
Reinstall the swivel joint in the reverse order of the removal procedure.
Notes :
[1] Install each connector at a specified mounting angle.
Swivel joint mounting bolt (M10)
Adhesive Apply Three Bond 1324 or its equivalent.
Tightening torque 44.1 to 58.9 N•m (4.5 to 6 kgf•m)

Quantity 16.0 L
6
C B 7
9
1
F
G
2
4
D
A
3
E 8
C F D E A G B 6 7 1 2 3 8 4 9
G H 2 2
F 1 1
20q 20q
E 4 15q 15q 3
D
6 5
20q
C
B
20q 25q 7 8 25q
A
30q 45q 45q
20q 10 9
SV15 / SV17 SV17EX 014077-00X
7-5-12 0000604
7-5-5 Disassembly and Reassembly of Swivel Joint
1) Structure
The swivel joint is used to prevent the hydraulic piping from twisting when the upperstructure swings. The swivel
joint consists of the shaft, hub and seal kit. The shaft and hub have holes and grooves, and the oil supplied from the
port of the shaft, passing through the hub groove, is fed to the actuators of the undercarriage.
13
10
9
7
8 6
AYR Modify 5
12
11
Confirm
15 parts quantity 3
and illustration.
No info. in Japan. 14
Q’ty Q’ty
No. Part No. Part
Standard Variable leg Standard Variable leg
1 Swivel joint assembly 1 1 8 Seal (O-ring 55.76¯5.7) 8 7
2 Swivel shaft 1 1 9 Back-up ring 1 1
Swivel flange 10 O-ring 1A P 75.0 1 1
3 1 1
(with spring washer 10¯30) 11 O-ring 1A G 70.0 1 1
4 Swivel hub 1 1 12 External snap ring 1 1
5 Swivel spacer 1 1 13 Screw plug PT 1/4 7
6 Seal kit 1 1 14 Bolt M 10 3 3
7 O-ring 55.76¯5.7 1 1 15 Bolt M 10 4 4
7-5-13 0000604
2) Disassembly and Reassembly of Swivel Joint
• Disassembly
(1) Remove the bolts 14.
(2) Remove the swivel flange 3 and the O-ring 11.
13
(3) Remove the external snap ring C 12 and the swivel
spacer 5 from the swivel shaft 2. 1
(4) Pull the swivel shaft 2 out of the swivel hub 4 and
remove O-ring 10. 2
(5) Remove the swivel seals 8, O-ring 7 and back-up 10
ring 9 from the swivel hub 4. 9
7
• Reassembly
(1) Install swivel seals 8, O-ring 7 and back-up ring 9 8
into swivel hub 4.
(2) Apply multi-purpose grease to the inner surface of
swivel hub 4. 4
(3) Install the O-ring 10 on the swivel shaft 2 and
insert the shaft into the swivel hub 4 slowly.
• Use a jig E-004 5
• Apply multi-purpose grease to the outer surface of 12
11
the shaft.
15 3
(4) Install the swivel spacer 5 and the external snap
ring 12 to the swivel shaft 2.
14
(5) Install the swivel flange 3 with O-ring 11, on the
swivel hub 4 in this order and tighten bolts 14.
Insertion of shaft
Shaft insertion jig No.E-004
Unit : mm
70
22
R1
Swivel shaft 2
54.94 to 54.97
45 to 45.1
C0.5
50
Insertion jig
Swivel seal 8
Swivel hub 4
R0.1
AYR Modify
Note : The areas must be hard chromium plated.
Confirm above description

and illustration.
No info. of local parts in Japan.
7-5-14 0000604
3) Cautions for Handling and Storing Seals

(1) O-rings are packed in the package that is suitable for storage.
(2) Do not leave the O-rings outside the package.
(3) For storing, put the O-rings in the packages and place them in a dark and cool place (in a parts box or cardboard
box) under 40°C to avoid direct sunlight. If the stored condition is proper, it can be stored for four or five years.
(4) Do not put anything on the O-rings, or they may be distorted.
4) How to Fit O-rings (for Inner Side)

• Fitting
(1) Use lithium soap group multi-purpose grease.
(2) For fitting a seal ring, make it heart-shaped as shown in the
right figures and press one end of it into the groove. Then, fit
the whole seal ring while pressing it with your finger (Figs. 1
and 2).
(3) When using jigs for fitting seal rings, use the jigs with round Fig. 1 Fig. 2
edges to avoid damaging the seal rings. (Fig. 3)
(4) If the seal ring is distorted after fitting, correct the distortion
with the jig before assembly. (Fig. 4)
5) Repair and Replacement of Parts

(1) Disassemble and reassemble at a place free from dust.
(2) Completely remove the contamination, foreign matter
(sludge), etc. from the disassembled parts. Fig. 3 Fig. 4
(3) Check for flaws or nicks on the seal surface of the shaft.
Repair or replace the part when necessary.
(4) Replace the shaft if it is worn.
(5) Replace all seals in reassembly.
AYR Modify
Local made parts. Check the above
description and illustration according
to actual parts and instruction of the
local vendor.
7-5-15 0000604
7-5-6 Disassembly and Reassembly of Hydraulic Cylinders
1) Sectional View and Component Parts
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
16
Track gauge
Boom Arm Bucket Boom swing Blade
No. Part change
cylinder cylinder cylinder cylinder cylinder
cylinder
1 Dust seal c c c c c c
2 Lock washer c c c c c c
3 O-ring c c c c c c
4 Head c c c c c c
5 O-ring c ⎯ ⎯ ⎯ ⎯ ⎯
6 ISI packing c c c c c c
7 Back-up ring c ⎯ ⎯ ⎯ ⎯ ⎯
8 O-ring c c c c c c
9 Cylinder tube c c c c c c
10 Cushion collar c ⎯ ⎯ ⎯ ⎯ ⎯
11 Cushion plunger c ⎯ ⎯ ⎯ ⎯ ⎯
12 RGU packing c c c c c c
13 RWL bearing c c c c c c
14 Piston c c c c c c
15 U-nut c c c c c c
16 Rod c c c c c c
7-5-16 0000604
2) Precautions for Disassembly and Reassembly

(1) Parts are high precision-made. Be careful not to damage any parts by dropping them or knocking them together
when handling them.
(2) If there are any burrs on the surface of seal installation parts or O-ring grooves, remove them.
(3) Never use the lock washer removed once.
(4) Replace once removed seals and O-rings with new ones.
(5) Clean all the parts and dry them by air blow.
3) Disassembly
Procedure
(1) Drain the oil from the hydraulic cylinder. Pipe
Cylinder
(2) Hold the cylinder at the bottom end or using the pin hole Jig
Hook wrench
at the bottom end, and put the rod side of the cylinder on
a block.
(3) Raise the pawl of the lock washer 2 on the head 4 and
loosen the head 4.
Note : 4 2
Use a hook wrench or a jig to loosen the head 4. Bolt
Adjuster
(4) Pull out the rod assembly 16 from the cylinder tube 9, and
then hold the cylinder rod assembly at the rod end or
using the pin hole at the rod end.
16
Hold cylinder rod assembly
(5) Disassembly of boom cylinder

Remove the U-nut 15, and then the piston 14, the cushion
plunger 11, the cushion collar 10, and the head 4 in that 14
order. 11
10
4
9
16 15
7-5-17 0000604
Procedure
(6) Disassembly of bucket, arm, boom swing, blade and track
gauge change cylinders
Remove the U-nut 15, and then the piston 14 and the 15
head 4 in that order. 14
4
16
9
(7) Remove the O-rings 3, 5 and 8, the dust seal 1, the ISI
packing 6, the RGU packing 12 and the PWL bearing 13. 7
5
Note : 3
Use a sharp tool to raise each of the O-rings, the ISI packing,
the RGU packing or the PWL bearing, and then insert a spat- 4 6
ula to remove it.
8
1
12, 13
14
7-5-18 0000604
4) Reassembly
Reassemble the hydraulic cylinder in the reverse order of the disassembly procedure.
Notes :
• Take care not to install the cushion plunger 11 of the boom cylinder in the wrong direction.
• Replace the O-rings, packings and seals with new ones.
11
Head side
U-nut Size end Tightening Torque

No. Cylinder U-nut size U-nut tightening torque Adhesive
1 Boom M24 490 to 588 N•m (50 to 60 kgf•m)
2 Arm M24 490 to 588 N•m (50 to 60 kgf•m)
3 Bucket M20 294.3 to 343 N•m (30 to 35 kgf•m)
Three Bond 1324 or its equivalent
4 Boom swing M24 490 to 588 N•m (50 to 60 kgf•m)
5 Blade M22 392 to 490 N•m (40 to 50 kgf•m)
6 Track gauge change M20 490 to 588 N•m (50 to 60 kgf•m)
AYR Modify
Local made cylinder. Check and modify
the above illustration as required.
No info. in Japan.
7-5-19 0000604
7-5-7 Hydraulic Oil Tank
1. Structure and Component Parts
12
1
4
2 15
14
3
8
6
5 7
6
13
10
9
13
11
12
013876-00X

1 Return flange 1 8 Bolt M10 2
2 Return filter 1 9 O-ring 1A G75.0 1
3 Oil supply port cap 1 10 Suction filter 1
4 Packing G110.0 1 11 Suction flange 1
5 Hydraulic oil tank 1 12 Bolt (with spring washer) 8¯16 7
6 O-ring 4 13 Bolt (with spring washer) 12¯25 3
7 Oil level gauge 1
7-5-20 0000604
2. Removal and Reinstallation of Hydraulic Oil Tank

1) Removal
Procedure
(3) Remove the cabin (or canopy) and seat mount (refer to
Disassembly/Reassembly of engine).
013770-00X
(4) Remove the hoses connected to the hydraulic oil tank 1.

a. Suction hose
b. Return hose (oil cooler to hydraulic oil tank) 1
c. Return hose (joint to hydraulic oil tank)
d. Return hose (control valve to hydraulic oil tank)
e. Drain hose b
Note : 2
Remove the return hose from the joint.
d. Hydraulic oil drain hose
(5) Remove the mounting bolts 2 and remove the hydraulic

oil tank 1.
a
c
d
013771-00X
7-5-21 0000604
2) Reinstallation
Reinstall the hydraulic oil tank in the reverse order of the
removal procedure.
Notes :
[1] Completely drain the oil from the hydraulic oil tank and
wipe off the deposits from the bottom of the tank.
2
[2] Replace the return filter 2 with a new one.
[3] Clean the suction filter 10. Replace it if the wire gauze is
damaged.
[4] Replace the oil when it reaches the replacement time or
it has been deteriorated. If reusing the oil, maintain the 6
67
oil quality so that it has no impurities.
[5] Check the O-rings 6 of the oil level gauge 7 for oil leak.
If any oil leak is found, replace the O-ring.
[6] Hydraulic oil to be used : 10

Quantity 16.0 L
013772-00X
7-5-22 0000604
3) Oil Level Check

(1) Place the machine on firm and flat ground when check-
ing the hydraulic oil level. Upper limit
(2) Check the hydraulic oil level with the oil level gauge 10 mm Float
when the oil temperature is between 0°C and 30°C.
Middle
(3) The proper oil level is 10 mm above the middle of the oil
level gauge. The hydraulic oil level increases or
decreases depending on the hydraulic oil temperature Lower limit
due to its nature; therefore, check it when the oil is

cooled.
Oil level gauge
4) Machine Position for Oil Level Check

(1) Retract the bucket and arm cylinder rods fully to lower
the bucket to the ground.
(2) Lower the blade to the ground.
013773-00X
7-5-23 0000604
7-5-8 Piping Layout

1) Upperstructure
(Hydraulic oil tank → Hydraulic pump → Control valve)
C
A
B
A
D
B
D
SV17 Hyd.oil tank
Engine
Hyd.oil pump
D
C
LO-HI valve
Control valve
A P1
013776-00E
7-5-24 0000604
2) Upperstructure
(Control valve ←→ Swing motor)
(Control valve ←→ Boom cylinder)
D
A C
B
Turning motor
Boom cylinder
Control valve
Swing cylinder
C
D
G
H
B2
A4
B4 A2
013777-00E
7-5-25 0000604
3) Upperstructure
(Implement)
Arm cylinder
Bucket cylinder
Control valve
013778-00E
7-5-26 0000604
4) Upperstructure (SV15/17)
(Control valve → Swivel joint)
(Control valve → Boom swing cylinder)
J
R2
I
SV17 only
G
Lo-Hi valve
Swivel joint
SV17 only
Control valve
D
F C
E
G
E
B A
F
B
C G A D A8
E J I
D A9 B8 A5
F B9 B5
B
C A
A7
B7
013779-00E
7-5-27 0000604
5) Upperstructure (SV17EX)
(Control valve → Swivel joint)
(Control valve → Boom swing cylinder)
C4
G C1
R2
C3 P2
H C2
P1
I
J B
A K
Selector valve
LO-HI valve
Swivel joint
D
Control valve
F C
K E
E J D
I B A
C
5
H 1 10 7 A8
6 A9 B8
9 B9 A5
G B5
3
F 8 4
014111-00E
7-5-28 0000604
6) Upperstructure
(Control valve, Swivel joint → Hydraulic oil tank)
(Hydraulic pump → Swing motor → Control valve)
㧴
6
㧱
㧵
㧲㧵㧯
Lub. oil cooler 㧰

㧳
㧳
㧲
Hyd. oil tank
&T
㧮
6
LO-HI valve
㧴
Turning motor
Swivel joint
㧭
㧰
㧮
Control valve
㧱 SV17
㧱
㧭
6 㧯
&T
013780-00E
7-5-29 0000604
7) Pilot Control for Implements

(Hydraulic pump → Pilot valves → Control valve)
Viewed from upper
1 1
P T P T
T
4 2 4 2
1
3 3 3 2
Right side Front Left side
4 P
D
Remote control valve A
T
B
1 E F C
3
4 P
2
B
H C
A G
LO-HI valve
D
D
E C
F B
G A Control valve
b1
H b2 a4 C
b3 a3 E
b4 a2
a1
R1
A
E
013781-00E
7-5-30 0000604
8) Undercarriage (SV15/17)
(Swivel joint → Travel motor)
(Swivel joint → Blade cylinder)
(Swivel joint → Track gauge change cylinder)
SV17 only
I PS
T
T P1
A P2
P2
P1 PS
D
B
C
E J
F
SV17 only
Swivel joint Travel motor (R)
Blade cylinder
Travel motor (L)
G E
F
D J
G C
G H
Dr B
F D I
H Dr A
A B
013782-00E
7-5-31 0000604
9) Undercarriage (SV17EX)
(Swivel joint → Travel motor)
(Swivel joint → Blade cylinder)
(Swivel joint → Track gauge change cylinder)
I PS
T
T
P1
P2 A P2
PS
D P1
B
E J C
F Driving motor(R)
Swivel joint
Variable leg widen / K
Shorten cylinder
Blade cylinder
L
Driving motor(L)
E J
D
G K
G F
H
A
H I B
L C
014076-00E
7-5-32 0000604
10) Upperstructure
(Control valve → P.T.O.)
B
D C
E
B6 F
A6
Control valve
D E
A
C
014074-00E
7-5-33 0000604
7-6 Implement
7-6-1 Removal and Reinstallation of Implement
Notes :
• When removing a pin, check the number of shims installed and their positions.
• When removing a hose, put a plug into the hose connection port to keep the oil from flowing out.
1) Removal of Bucket
Procedure
(1) Lower the bucket 1 to the ground with its back face down.
(2) Remove the lock pins 2 (M10) and remove the pins 3.
3
(3) Remove the bucket 1.
1
2
013677-00X
7-6-1 0000604
2) Removal of Arm
Procedure
(1) Remove the bucket.
5
(2) Remove the nuts 1 (M10) and pull out the pins 2. Then 4
remove the bucket link 3 and the bucket arms 4.
1
(3) Lightly place the top end of the arm 5 on the ground per- 2
pendicularly to the ground. 5
3
About 90 degrees
4
013676-00E
(4) Remove the hydraulic hoses from the bucket cylinder 6,

and remove the bolt 7 (M10) to pull out the pin 8. Then
remove the bucket cylinder 6.
Rope
Note :
Rope the bucket cylinder and remove it using a lifting device.
8
7
6
013675-00E
(5) Remove the hydraulic hoses from the hydraulic hose.
(6) Remove the bolt 13 (M8) and remove the plate.
13
014075-00X
(7) After roping the arm 5, remove the bolt 10 (M10) and 11
remove the pin 12 from the arm cylinder 11 (on the rod Block
side). 10
Note : 12
Place a block under the arm cylinder.
(8) Remove the bolt 13 (M10) and pull out the arm pin 14.
Then remove the arm 5 using a lifting device. 14
13

5 013674-00E
7-6-2 0000604
3) Removal of Boom
Procedure
(1) After raising the boom 12 fully, remove the slide cover 2
from the boom cylinder 1.
1
(2) Place the top end of the boom 12 on the ground.
12
Note :
Install an expansion plug to the connector from which the
hydraulic hose has been removed and start the engine.
2
1
013621-00X
(3) After roping the arm cylinder 3, remove the hydraulic

hoses from the arm cylinder. 5
Rope
(4) Remove the bolt 4 (M10) and pull out the pin 5. Then
remove the arm cylinder 3.
3
Note : 4
Remove the arm cylinder using a lifting device.
013620-00X
(5) After roping to the boom cylinder 1, remove the hydraulic

hoses from the boom cylinder. 7
7
(6) Remove the bolts 6 (M10) and pull out the pins 7. Then
remove the boom cylinder 1. 6
Note : Rope
6
Remove the boom cylinder using a lifting device.
1
013619-00X
(7) Disconnect the connectors 8 of the boom light wiring har-

ness.
(8) Remove the boom light 9 and cover 10 (light cover). 9

10
8
013618-00X
7-6-3 0000604
Procedure
(9) Disconnect the hydraulic hoses from the P.T.O. tubes and
remove tube clamp bolts (M10) to remove the P.T.O.
tubes.
013617-00X
(10) After roping the boom 12, remove the bolt 13 (M10) and
pull out the pin 14. Then remove the boom 12. Rope
Notes :
12
• Remove the boom using a lifting device.
• Take care that the hoses do not catch on any other parts.
14
13 013616-00E
7-6-4 0000604
4) Removal of Blade
Procedure
(1) Turn the implement to the blade side, lower the bucket
and the blade 1 to the ground and stop the engine. 4
(2) Remove the protector 2 and remove the hydraulic hoses. 3 7
6
(3) Remove the bolts 3 (M10) and pull out the pins 4. Then
remove the blade cylinder 5.
(4) After roping the blade 1, remove the bolts 6 (M10) and pull 6 7
out the pins 7. Then remove the blade.
Note : 2
Remove the blade using a lifting device. 5
3
4
1
013515-00X
7-6-5 0000604
5) Removal of Boom Bracket

Procedure
(1) Remove the bucket 1.
Refer to Section "7-6-1 1) Removal of Bucket".
(2) Remove the arm 2. 3

Refer to Section "7-6-1 2) Removal of Arm".
(3) Remove the boom 3. 2

Refer to Section "7-6-1 3) Removal of Boom".
1
(4) Remove the bolt 4 (M12) and pull out the pin 5 (for the
boom swing cylinder).
(5) Remove the bolt 6 (M12) and the snap ring C 7, and pull
out the pin 8. Then remove the boom bracket 9.
Note :
Rope the boom bracket and remove it using a lifting device. 7
5
9
4 6 013514-00X
7-6-6 0000604
6) Removal of Boom Swing Cylinder

Procedure
(1) Swing the upperstructure so that the pin 1 at the bottom
end of the boom swing cylinder is positioned halfway
between the right and left crawlers. Then, lower the
bucket to the ground and stop the engine.
(2) Remove the frame cover R 2 and supports 9 to move the

fuel tank outside from its original position. Then remove
the hydraulic hoses 4 from the boom swing cylinder 3. 2
(3) Remove the bolt 5 (M12) and pull out the pin 6 at the rod
end of the boom swing cylinder 3.
(4) Remove the plate 7 and pull out the pin 1 at the bottom
end of the boom swing cylinder 3.
(5) Remove the boom swing cylinder 3 from the turning frame
8.
9 4
8
5 013513-00X
7-6-7 0000604
7) Reinstallation
Reinstall the implement in the reverse order of the removal procedure.
10 9
4 8
1
6 7
013512-00X
Tightening Torque and Adhesive

No. Size Tightening torque Adhesive
1 M10
2 M10
3 M10
44.1 to 58.8 N·m (4.5 to 5.6 kgf·m) Apply Three Bond 1324 or its equivalent.
4 M10
5 M10
6 M10
7 M12 ⎯ ⎯
8 M12 78.4 to 98.1 N·m (8 to 10 kgf·m) Apply Three Bond 1324 or its equivalent.
9 M10 Apply Three Bond 1324 or its equivalent.
44.1 to 58.8 N·m (4.5 to 5.6 kgf·m)
10 M10 ⎯
7-6-8 0000604
CHAPTER 8
PERIODIC INSPECTION AND SERVICING
8-1 List of Periodic Inspection and Servicing .................................................8-1

8. PERIODIC INSPECTION AND SERVICING
8. Periodic Inspection and Servicing
8-1 List of Periodic Inspection and Servicing
: Check c : Supply z : Replace : Adjust (clean) : Oil & grease

Check & service items Daily Every Every Every Every Every
50 100 250 500 1000 hrs
General Check falling off, breakage of parts
Check loosened bolts & nuts, retighten
Check engine condition
Clean
Lube oil *Swing gear case oil Check, resupply /c
Replace z1st time z
Travel reduction gear oil Check, resupply /c
Replace z1st time z
*Transmission oil Check, resupply /c
Replace z1st time z
*Differential gear oil Check, resupply /c
Replace z1st time z
Hydraulic Hydraulic oil Check, resupply /c
system Replace z
Clean suction filter 1st time
Replace return filter z z
1st time
Check for abnormality of hydraulic pump
Grease Check grease-up positions, grease
Greasing the swing gears and the swing bearings
Greasing the track gauge change cylinder and the link fulcrum
Undercarriage Check, adjust track tension /
*Check air pressure, wear, flaw in tyres
Steering *Check performance, play of steering lever
equipment Check performance, play of travel lever
*Check performance of speed change lever
*Check performance of forward/reverse pedal
*Check performance, play of steering wheel
*Brake pedal Stroke
Performance
*Parking brake Stroke
Performance
Check performance of accel. lever
Electric Check front & work lights, horn
equipment Check hourmeter function
Check function of change, oil and pilot lamps
Check wire breakage, short-circuits, loosened
terminals retighten
Check, resupply battery fluid /c
Check specific gravity of electrolyte As required
Check function of OK monitor
8-1 0000604
8. PERIODIC INSPECTION AND SERVICING
: Check c : Supply z : Replace : Adjust (clean) : Oil & grease

Check & service items Daily Every Every Every Every Every
50 200 400 1000 2000 hrs
Fuel oil Check & supply of oil to the tank /c
Drain the fuel tank
Clean the oil/water separator
Replace the fuel filter element, pre-filter z
Lube oil Check the quantity of engine oil /c
Replace the engine oil z z
1st time
Replace the engine oil filter element z z
1st time
Cooling water Check & supply of cooling water /c
Clean radiator fins
Check the fan-belt tension /
Replace the cooling water z
Clean & check the cooling water system zwithin one year
Rubber hose Check & replace fuel oil pipe, cooling water pipe z
Operation Check & adjust governor lever, accelerator
system
Intake system Clean air cleaner & replace element z
*Check turbocharger, adjust
Cylinder Adjust the intake and exhaust valve clearance
head Lapping the intake and exhaust valve
Fuel pump & Check fuel valve nozzle, clean
injection valve Check & adjustment of fuel injection pressure &
atomizing condition
Check fuel pump, adjust
*Applicable to models with the relevant equipment
Note :
• When machine is used at dusty worksites clean and replace filter element twice or more frequently than specified
in the table.
• Execution of periodic inspection and servicing is indispensable to conform the EPA emission control regulations.
Keep a record of the results.
8-2 0000604
CHAPTER 9
FUEL, LUBE OIL AND GREASE RECOMMENDED
9. Fuel, Lube Oil and Grease Recommended ...............................................9-1

9. REFERENCE DATA
9. Fuel, Lube Oil and Grease Recommended
Item Type
Engine oil Engine oil SAE10W30, CD class
Travel reduction gear oil SAE 90 (GL-4)
Hydraulic oil ISO VG46
Fuel Diesel light oil
Engine cooling water YANMAR genuine long-life coolant (LLC) 51% added water
Recommendations based on temperature ranges Prescribed Amount of oil

Part be refilled Oil type
-4 14 32 50 68 86 amount of oil to be changed
(-20) (-10) (0) (10) (20) (30)
SAE 10WCD
Engine oil pan Engine oil SAE 10W-30CD 3.0 Qts. (2.8 L) 3.0 Qts. (2.8 L)
SAE 15W-40CD
0.53 Qts. (0.5 L) 0.53 Qts. (0.5 L)

Travel reduction gear Gear oil SAE 90 (GL-4) (For right and left each) (For right and left each)
In the tank 4.2 Gals. (16.0 L)

Hydraulic oil system Hydraulic oil ISO VG46 Other parts 2.2 Gals. (8.5 L) 4.2 Gals. (16.0 L)
No.2-D
Fuel tank Light oil No.3-D 6.5 Gals. (24.5 L)
No.3-D (S)
Radiator 2.6 Qts. (2.5 L)

Cooling system Water YANMAR genuine long-life coolant (LLC) added Subtank 0.42 Qts. (0.4 L)
°F 23 14 5 -4 -13 -22 -31 -40

Lowest temperature
(°C) (-5) (-10) (-15) (-20) (-25) (-30) (-35) (-40)
Qts. 0.42 0.85 0.95 1.06 1.16 1.37 1.59 1.69
Amount of anti-freeze
(L) (0.4) (0.8) (0.9) (1.0) (1.1) (1.3) (1.5) (1.6)
Qts. 2.64 2.22 2.11 2.01 1.90 1.69 1.48 1.37
Amount of water
(L) (2.5) (2.1) (2.0) (1.9) (1.8) (1.6) (1.4) (1.3)
Note :
At the delivery, water and antifreeze are mixed at the ratio for -31 °F (-35 °C) temperature above.
9-1 0000604
CHAPTER 10
TROUBLESHOOTING
10-1 Non-Breakdowns ............................................................................. 10-1-1

10-1-1 Natural Release of Bucket ..................................................... 10-1-1
10-1-2 Discontinuous Arm Movement ............................................... 10-1-1
10-1-3 Drifting of Upperstructure on Quick Travel Operation............ 10-1-2
10-1-4 Thermal Shock of Travel Motor.............................................. 10-1-3
10-1-5 Time Lag on Travel Speed Switching .................................... 10-1-4
10-1-6 Fluctuation in Oil Level of Hydraulic Oil Tank Due to
Temperature Change............................................................. 10-1-5
10-2 Troubleshooting ............................................................................... 10-2-1
10-2-1 Machine and Engine .............................................................. 10-2-1
10-2-2 Electrical Equipment on Panel ............................................. 10-2-22
10. TROUBLESHOOTING
10. Troubleshooting
10-1 Non-Breakdowns
10-1-1 Natural Release of Bucket
Phenomenon
When the arm is extended while scooping with the
bucket, the scooping side of the bucket is restricted by
the arm and causes back pressure because oil cannot
be supplied to the bucket cylinder in time.
When the boom is raised immediately in this condition,
the bucket is released naturally because of the back
pressure in the piston side of the cylinder
Operation
This problem can be solved by using a sequence of
three actions of bucket scooping, arm extension and
boom raising.
(For the models that cannot make the triple sequence
actions, extend the arm after raising the boom.)
10-1-2 Discontinuous Arm Movement
When scooping with the arm, the arm tends to move

slower as it draws near to the perpendicular and it may
stop momentarily.
Reason
This may happen because the oil supply cannot catch
up with the cylinder extension speed. This is a charac-
teristic of hydraulic equipment.
Specifically, this phenomenon appears when the engine

speed is in the low to medium speed range.
Advise your users fully that this will happen in hydraulic
equipment and that this is not a breakdown.
Discontinuous phenomenon appears in this range.
10-1-1 0000604
10. TROUBLESHOOTING
10-1-3 Drifting of Upperstructure on Quick Travel Operation
Phenomenon
The upperstructure drifts on quick travel operation (especially, on spin-or pivot-turning).
Drift
Reason
Inertial force is given to the upperstructure through the quick operation of the undercarriage, and high pressure is
applied to the swing motor. The relief valve is activated to turn the swing motor.
Swing motor
10 MPa
A DR B
(Right) (Left)
10-1-2 0000604
10. TROUBLESHOOTING
10-1-4 Thermal Shock of Travel Motor
Phenomenon
When the travelling operation is made for pivot turning in cold temperatures after raising the hydraulic oil to more
than 140°F (60°C) higher than the ambient temp. through relief valve operation, etc., without travelling after starting
the engine, the machine may travel straight instead of making a pivot turn.
(Travel straight in spite of turning operation.)

Reason
Spool
Motor
Brake valve
Swivel joint
Motor
When the hot hydraulic oil is suddenly fed to the cold brake valve and motor, the spool in the brake valve sticks
momentarily due to thermal expansion, canceling the braking force.
Evaluation
Since the phenomenon disappears in 20 to 30 seconds and this situation is generally rare, this phenomenon pre-
sents no problem.
10-1-3 0000604
10. TROUBLESHOOTING
10-1-5 Time Lag on Travel Speed Switching

(SV17/SV17EX)
Phenomenon
In cold temperatures, there is a time lag in switching from the high-travel speed to low-travel speed (with the high-
speed switch released).
Reason
The shock caused during switching from the high-speed to low-speed is lightened by the throttles of A. In cold tem-
peratures, however, the passage resistance of the throttles becomes larger and it takes more time for the swash
plate of the travel motor to return to the low speed.
Travel motor PS
Swash plate angel switch piston A

T
1 P2
36.8 P1 High-speed switch
High-speed switch valve

Travel motor swash plate
10-1-4 0000604
10. TROUBLESHOOTING
10-1-6 Fluctuation in Oil Level of Hydraulic Oil Tank Due to Temperature Change
Phenomenon
The oil level of the hydraulic oil tank varies between before operation (the machine is cool) and after operation (the
machine is warm).
After operation (machine warm)
Before operation (machine cool)
Reason
The oil level changes because the thermal expansion factor of oil is far larger (about 20 times) than that of steel.
1. Liner thermal expansion factor of steel : 11.7×10 -6

2. Cubical thermal expansion factor of steel : 3.51×10 -5
3. Cubical thermal expansion factor of hydraulic oil : 7.7×10 -4
(Example)
1.925 L Expansion by temp. rise
20 70
Hydraulic oil
50 L 50 L
0.088 L Expansion by temp. rise
20 70
Hydraulic oil
tank (Steel) 50 L 50 L
10-1-5 0000604
10. TROUBLESHOOTING
10-2 Troubleshooting
10-2-1 Machine and Engine
(How to use the charts)
Trouble
A Aa Ab
B Ba Bb Bc
C Ca Cb Cc Ce
Factors related to the trouble are enumerated

in the columns and instructions for corrective
procedures are given below. It is recommended
that the troubles be inspected and corrected
one by one according to the chart.
Inspection item
Remedy for failure
10-2-1 0000604
10. TROUBLESHOOTING
Low output
Does the work Hydraulic Set relief pressure

implement work power
normally? source of control valve
Excessive in- Clogging of Clogging of

take resistance air cleaner intake pipe
Clean Clean
Excessive Clogging of Clogging of Clogging of

exhaust exhaust port of
resistance muffler exhaust pipe cylinder head
Clean or replace Clean Clean
Defective fuel Air in fuel Clogging of Clogging of

system system fuel filter fuel pipe
Release the air Clean or replace Clean
Clogging of air release port in

fuel tank
Insufficient fuel
discharge from
feed pump
Improper ad- Fuel injection Clogging of fuel Sticking of fuel

Governor injection nozzle
justment pressure hole injection valve
Adjust Adjust Clean or replace Replace
Defective lever Improper Malfunction of Defective delivery Wear of

injection plunger
link timing fuel pump rack valve barrel
Repair or replace Adjust Repair or replace Repair or replace Replace
Low compres- Improper clear- Defective seat Seizing of intake Deterioration or

ance of intake of intake or or exhaust valve breakage of
sion pressure or exhaust valve exhaust valve stem valve spring
Adjust Smooth or Replace Replace
replace seat
Compression leak from
head gasket
Replace
Sticking, damage, or Scuffing or Scuffing or

wear of
wear of piston ring piston wear of liners
Replace Replace Replace
Overheating Refer to Overheating
10-2-2 0000604
10. TROUBLESHOOTING
Overheating

implement work
normally? power source of control valve
Cooling water Low cooling Damage or Clogging of Excessive

Loose fan belt wear of fan exhaust
system water level belt radiator resistance
Supply Adjust Replace Clean Clean
Clogging or Defective Clogging of Malfunction Malfunction

defect of of cooling
radiator cap thermostat radiator hose water pump of radiator
Clean or replace Replace Clean Replace Replace
Excessive intake Clogging of Clogging of

resistance air cleaner intake pipe
Clean or replace Clean
Excessive exhaust Clogging of Clogging of Clogging of

cylinder head
resistance muffler exhaust pipe exhaust port
Clean Clean Clean
Gas leak from Crack of

Cylinder head
head gasket cylinder head
Replace Replace
Improper Defective fuel

Fuel system
injection timing injection valve
Correct Repair or replace
Intake or exhaust Improper clear- Improper valve

valve opening/ ance of intake or opening/closing
closing timing exhaust valve timing
Adjust Adjust
Piston Seizing
Replace
10-2-3 0000604
10. TROUBLESHOOTING
Black smoke
emission

implement work
normally? power source of control valve
Low output See Low output
Fuel Improper fuel
Replace
Fuel injection Advanced Excessive Uneven injec-

pump injection timing injection volume tion volume
Adjust Adjust Adjust or replace
Improper Defective lever or

Governor
adjustment link
Adjust Repair or replace
White smoke
emission
Mixing with low

Fuel Water in fuel quality fuel or
impurities
Replace Replace
Lubricating oil Improper grade
Replace
Excessive intake Clogging of air Clogging of
resistance cleaner intake pipe
Clean or replace Clean or replace
Fuel injection Delayed injection

pump timing
Adjust
Defective valve Damage or Damage or

Oil down wear of valve wear of valve
stem seal stem guide
Sticking, damage Scuffing or Scuffing or
Oil up or wear of piston
ring wear of piston wear of liners
Gas leak from
head gasket
Excessive Replace
Malfunction of thermostat
cooling
Replace
10-2-4 0000604
10. TROUBLESHOOTING
Starter motor does not turn Except seizure of engine and

or output is low. trouble of any work implement
Disconnection Disconnection Connection

or connection Battery terminal Ground terminal failure of
failure of wire coupler
Repair Repair Repair Repair
Battery Specific gravity Voltage Damaged battery
Recharge Supply electrolyte Replace

or recharge
Damage or rust of Internal contact Damaged

Starter switch
terminal failure of switch switch
Replace or repair Replace Replace
Damage or rust Malfunction of

Safety relay
of terminal relay
Replace or repair Replace
Malfunction or
Damage or rust Defective Burnout of Layer
Starter motor poor contact of
of terminal magnetic switch brushes coil short-circuit
Replace or repair Replace Replace starter Replace starter

motor motor
Clutch slipping
Replace
Inspection procedures
When the starter motor cannot be started by turning the starter switch on, check it as follows.
(Battery, starter switch and wiring assumed to be normal.)
(1) Safety relay & starter motor magnetic switch
Connect the S-and B-terminals of the starter motor directly.
[1] When the starter motor turns : The safety relay is faulty.
[2] When the starter motor does not turn : Either the starter motor magnetic switch or the starter motor is faulty.
(2) Starter motor

Connect the B-and M-terminals of the starter motor directly. S
[1] When the starter motor turns : Magnetic switch is faulty. M
B
[2] When the starter motor does not turn : Starter motor is faulty.
10-2-5 0000604
10. TROUBLESHOOTING
Battery dies or battery

cannot be charged (during operation)
Charging failure Discharges
Disconnection Battery Ground Discon- Connection Starter

or connection nection of failure of ON
failure terminal terminal wire coupler switch
Repair Repair Repair Repair Turn off
Damaged
Battery Wiring Short-circuit
battery
Replace Replace
Starter Damage Internal contact

or rust of Electrical
switch failure of switch Alternator
terminal equipment
Repair or Replace
replace
Electrical Damaged
Alternator Regulator
equipment diode
Replace
Short-circuit or Short-circuit
Loose fan belt
breakage of lead wire of coil
Adjust Replace Replace
alternator
Damaged diode Defective IC regulator

Replace Replace alternator
Defective
brushes
Repalace or replace
Burnout
of coil
Replace alternator
Layer short-circuit
Replace alternator
10-2-6 0000604
10. TROUBLESHOOTING
Work implement does not move

at all or its operation is slow.
Hydraulic oil
ψ Insufficient ψ Deterioration ψ Viscosity
quantity
Supply Replace Specified
hydraulic oil
Piping ψ Faulty joint (Aeration or cavitation)
Repair
Hydraulic Insufficient dis- Wear of spline of Breakage Inner part

ψ Oil leak ψ ψ ψ ψ
pump charge volume joint of shaft failure
Repair or replace Replace Replace Replace Replace
Cut-off valve
Malfunction of
ψ solenoid valve spool ( Inspect pilot valve by replacing
hoses with those of another
normal pilot circuit.
)
Replace
Filter ψ Clogging
Clean or replace 013499-00E
10-2-7 0000604
10. TROUBLESHOOTING
Work Implements
Weak digging force 㨇Boom, arm and bucket cylinders㨉
Do other
Cut-off valve ψ implements work
normally?
Pump P4 ψ Relief valve

pressure
Check the pressure
and adjust it. Refer
to section 5-4 ̍Pres-
sure Adjustment̍
Inspect pilot valve by switching

Internal leakage or malfunction
Pilot valve ψ Lever stroke ψ hose with hose of other normal
of valve spool
circuit
Replace Replace
System relief Dust in Malfunction of Improper Defective pilot

Control valve ψ valve pressure ψ control valve ψ system relief ψ circuit relief ψ
valve valve pressure poppet seat
Check the pressure Clean Replace Adjust Replace system
and adjust it. Refer relief valve
sure Adjustment̍
Movement of
valve spool ψ
Internal leakage
Replace Repair of parts

Movement of main valve
Hydraulic Internal spool in inlet section
cylinder ψ Oil leak ψ leakage
Replace
Repair or replace Replace seal or
whole assembly
Unintended descent of hydraulic cylinder =Boom and arm cylinders]
Anti-drift Dust in
valve
ψ control valve
Clean
Circuit relief Dust in Defective seat of
Control valve ψ valve pressure ψ control valve ψ circuit relief
valve
Check the pressure Clean Replace circuit
and adjust it. Refer relief valve
sure Adjustment̍
Hydraulic Internal
cylinder ψ Oil leak ψ leakage
Repair or Replace seal or
replace whole assembly 013500-00E
Inspection procedure
Switch the hose with the hose of the other circuit using the control valve.
[1] No descent : Control valve is faulty.
[2] Descent : Cylinder is faulty.
10-2-8 0000604
10. TROUBLESHOOTING
Slow implement working speed 㨇Boom, arm and bucket cylinders㨉
Relief valve
Cut-off valve ψ pressure
Check the pressure
sure Adjustment̍
Internal leakage or malfunction Inspect by switching hose

Pilot valve ψ Lever stroke ψ of valve spool with hose of other normal
circuit
Replace Replace
System relief Movement of Internal Movement of valve

Control valve ψ ψ ψ ψ spool in parallel-
valve pressure valve spool leakage flow divider
Check the pressure Repair or replace Repair or Replace
and adjust it. Refer replace
sure Adjustment̍
Movement of main valve

Hydraulic spool in inlet section
cylinder ψ Oil leak ψ Internal leakage
Replace
whole assembly
Hydraulic Insufficient oil discharge

ψ volume from pump
pump
Replace
Control lever cannot be held at

neutral position 㨇Travel, blade and boom swing cylinders㨉
Wear of
Control valve ψ Cap ψ Spring ψ
spring seat
Replace Replace Replace 013501-00E
10-2-9 0000604
10. TROUBLESHOOTING
Drifting of boom swing
Extent of Measure telescopic motion amount of

drifting cylinder rod on 15-degrees slope
Steering Boom swing Sticking of swing

equipment pedal pedal link
Adjust neutral Repair pedal link or apply grease
position Replace bush
Control Circuit relief Dust in circuit Wear of circuit relief

valve valve pressure relief valve valve seat surface
Check the pressure
and adjust it. Refer Clean or replace Replace circuit
to section 5-4 Pres- relief valve
sure Adjustment
Dust in control Wear of anti-void valve

valve seat surface
Clean or replace Replace
Defective spool
fitting
Replace spool section
Hydraulic Internal
Oil leak
cylinder leakage

whole assembly
Inspection procedure
Switch the hose with the hose of the other circuit using the control valve.
[1] No boom swing drifting : Control valve is faulty.
[2] Boom swing drifting : Hydraulic cylinder is faulty.
10-2-10 0000604
10. TROUBLESHOOTING
Boom swing cannot be made or is slow
Hydraulic Do other work implements

source work normally?
Boom swing Sticking of swing Slackness or Breakage

Controls
pedal pedal link of push-pull cable
Adjust neutral Repair pedal link or apply grease Install or replace
position Replace bush
Circuit relief Dust in circuit relief Permanent set of circuit relief

Control valve
valve pressure valve valve seat surface
Check the pressure Clean or replace Replace circuit relief valve
to section 5-4 "Pres-
sure Adjustment"
Malfunction Fall or wear of

of spool spool link pin
Adjust lever stroke. Install or replace
Internal
Hydraulic cylinder Oil leak
leakage
whole assembly 013502-00E
10-2-11 0000604
10. TROUBLESHOOTING
Upperstructure cannot swing or

swing speed is slow
No outside Remove the

resistance? ψ resistance source
Hydraulic Do other implements

power source ψ work normally?
Operation of Relief valve

Cut-off valve ψ solenoid
ψ pressure
Replace Check pressure. Refer
to section 5-4 Pres-
sure Adjustment
Movement of [Inspect by switching hose with

Pilot valve ψ
valve spool hose of other normal circuit.]
Repair or replace
Relief valve Movement of Dust in

Control valve ψ pressure
ψ valve spool ψ control valve
Check pressure. Refer Repair or replace Clean
sure Adjustment
Hydraulic motor ψ Oil leak ψ Internal leakage ψ Internal breakage

Replace seal or Replace Replace
whole assembly
Breakage of swing Wear or rust of
Swing braring ψ bearing gear
ψ swing bearing ball
Replace Replace 013503-00E
10-2-12 0000604
10. TROUBLESHOOTING
Swing only to one side
Relief valve
Cut-off valve ψ pressure
Check pressure. Refer
sure Adjustment
Movement of [Inspect pilot by switching hose with

Pilot valve ψ valve spool hose of other normal circuit]
Repalr or replace
Movement of
Control valve ψ valve spool
Repalr or replace
Drifting of swing [Brake does not work]
Extent of drifting ψ Measure drifting
Compare with service

standard valve
Is valve spool
Pilot valve ψ returned to neutral?
Repair or replace
Hydraulic motor ψ Oil leak ψ Internal leakage
Replace seal or Replace

10-2-13 0000604
10. TROUBLESHOOTING
Drifting of swing [Unintended drifting on slopes]
Measure motion amount of swing bearing

Extent of drifting ψ outer race on 15 degrees slope.
Refer to 3-1 "Machine Performance"
Is valve spool
Pilot valve ψ returned to neutral?
Repair of replace
Defective spool
Control valve ψ fitting
Hydraulic motor ψ Oil leak ψ Internal leakage

10-2-14 0000604
10. TROUBLESHOOTING
Travel Equipment
No travelling
Crawler tension Before making checks, remove dirt from

and clogging undercarriage and adjust crawler tension

lock lever
power source work normally?
Release
R and L relief Dust in

Control valve
valves pressure control valve
Check the pressure and Clean
adjust it. Refer to sec-
tion 5-4 Pressure Ad-
justment
Spool link pin

comes off
Install
Swivel joint Internal leakage
Replace seal
Driving Lift machine body and check undercar-

mechanism riage turns under external force
Brake valve (or Loosen ports P1 and P2 Dust in plunger Plunger plug
Sticki of plunger
counterbalance valve) joints and check oil flow orifice loosened
Clean Retighten Repair or replace
Hydraulic motor
Oil leak Internal leakage Internal breakage
and reduction gear
Replace seal or Replace Replace motor
whole assembly
10-2-15 0000604
10. TROUBLESHOOTING
Cannot travel straight
Crawler tension, Before making checks, remove dirt from

clogging undercarriage, and adjust crawler tension.
Hydraulic Do other implements work Lift machine body and Check hydraulic
power source normally? check R and L revolutions pump
Replace hydraulic
pump
Improper adjustment of
lever stopper bolt
Readjust
Controls Link operation Wear of link joint
Repair or replace Replace
R and L relief valves Dust in Wear of relief

Control valve
pressure control valve valve seat surface
Check the pressure and Clean Replace
adjust it. Refer to section
5-4 Pressure Adjustment"
Internal
Swivel joint Oil leak
leakage
Replace seal Replace seal
Brake valve Sticking of Dust in Wear of check

(or counter balance valve) plunger check valve valve seat surface
Repair or replace Clean Repair or replace
Hydraulic Internal Malfunction of

Oil leak
motor leakage 2-speed spool
Replace seal or Replace motor Replace
whole assembly 2-spool valve
10-2-16 0000604
10. TROUBLESHOOTING
1. When the hydraulic tester is not used :
(1) Reverse the hoses between the control valve and the swivel joint.
Phenomenon : Reversed ...........................................Overhaul or replace the control valve.
(2) Reverse the hoses between the swivel joint and the brake valve (or counter balance valve).
Phenomenon : Reversed ...................Overhaul or replace the swivel joint.
(3) Reverse the left and right hydraulic motors.
Phenomenon : Reversed ...........................................Replace the counter balance valve (or counter balance
valve) or the motor.
2. When the hydraulic tester is used :

(1) Flow volume at no load (Check the difference between the right and left motors.)
(2) Flow volume when loaded (Check the difference between the right and left motors.)
Conditions :
(1) Discharge volume at no load
Make judgment by reading the difference
between the right and left motors.
(2) Discharge volume when loaded
(3) Engine at rated speed.
(4) Hydraulic oil temp. at 122 to 140 F (50 to 60 C)
10-2-17 0000604
10. TROUBLESHOOTING
Cannot make spin

turning
Site condition Dry ground Wet ground Sndy
Crawler tension Before making checks, remove dirt from

and clogging under carriage and adjust crawler tension.

power source work normally?
R and L relief Wear of relief valve

Control valve Dust in control valve
valves pressure seat surface
Lift machine body Clean Replace
Check the pressure and
R and L relief Wear of relief valve

Brake valve Dust in brake valve
valves pressure spring and seat surface
Lift machine body Clean Replace
Check the pressure and
Hydraulic motor Oil leak Internal leakage

whole assembly
10-2-18 0000604
10. TROUBLESHOOTING
Drift of machine
body on slopes
Check the drift with machine

Extent of drift
placedon a 15 degrees slope.
Hydraulic Internal
Oil leak
motor leakage
whole assembly
Brake valve (or counter Leakage from Dust in check Wear of check Breakage of
balance valve plunger valve valve seat surface spring
Replace valve Clean Repair or replace Replace
Check the drift with the machine placed on a slope with an inclination angle below 15 degrees.
[1] Continuous drift : Brake valve (or counter balance valve) is faulty.
[2] Discontinuous drift : Hydraulic motor is faulty.
10-2-19 0000604
10. TROUBLESHOOTING
No switching to high-speed
One side? Both side?
High-speed Switch
switch operation
Replace
Solenoid Relief valve

Cut-off valve
operation pressure
Replace Check the pressure
Oil leak
Pipings
from joint
Repair or replace
Internal
Swivel joint Oil leak
leakage
Repair or replace Replace seal
Hydraulic Operation of Internal

Oil leak
motor high-speed spool failure of motor
Repair or replace Overhaul or replace
assembly
Breakage
Orifice clogged Dust in spool
of spring
Clean Clean Replace
013506-00E
10-2-20 0000604
10. TROUBLESHOOTING
Travelling speed is switched to high-speed naturally

or high-speed cannot be cancelled
One side? Both side?
High-speed Switch
switch operation
Replace
Solenoid Spool
Cut-off valve
operation operation
Replace Repair or replace
Hydraulic Operation of Internal

motor high-speed spool failure of motor
Faulty spool
Dust in spool
movement
Clean or replace Repair or replace
013507-00E
10-2-21 0000604
10. TROUBLESHOOTING
10-2-2 Electrical Equipment on Panel
(1) How to read the chart
Trouble
Inspection/repair instructions
Check item
Factors in trouble or treatment
(2) Refer to the wiring diagram for the number of the connector terminal and lead wire color.
(3) Color marks of leads

W (White) B(Black) R (Red) Y (Yellow)
G (Green) L (Blue) Br (Brown) Lg (Light green)
O (Orange) Gr (Grey)
Combination of colors
Example : W R ..............(Red stripes on white background)
Marking color
Background color
10-2-22 0000604
10. TROUBLESHOOTING
Monitor Lamps
Starter switch is turned on, but monitor lamp does not go on
Failure of YES
all lamps?
NO Check the power line :

Replace fuse
Check wire harness
Check connector contact
Check starter switch
Others
Only one lamp does not go on
YES
Filament blown?
NO Replace bulb
Check :
Rapair according to the trou-
bleshooting procedure for the
relevant lamp.
10-2-23 0000604
10. TROUBLESHOOTING
Hourmeter
Hourmeter does not work while engine is running
YES
Fuse blown?
NO Replace fuse
Disconnect the bipole connecter on the back

of the instrument panel, and check whether a
voltage of 10V or more is applied to the termi-
nal No.22B (YB) with the starter switch turned
on.
YES
Voltage rises?
NO Replace wire harness B
Disconnect the terminal No.14 (B) on the back

of the instrument panel and ground it.
(Keep the terminal No.22B connected.)
YES
Activated?
NO Grounding cable is defective
Replace hourmeter
10-2-24 0000604
10. TROUBLESHOOTING
Water Temp. Alarm Lamp
Failure of water temp. alarm lamp
Lamp does not go on Lamp goes on even when

even on overheating. water temp. is low.
Disconnect the wire harness

YES
Fuse blown? No.14A (Lg) from the water
temp. switch terminal.
NO Replace fuse
YES
YES
Filament blown? Lamp goes off?
NO Replace lamp NO Replace water temp. switch
Disconnect the wire harness Replace wire harness A or B

No.14A (Lg) from the water
temp. switch terminal and
ground it.
(Turn on the starter switch.)
YES
Lamp goes on?
NO Replace water temp. switch
Replace wire harness A or B
10-2-25 0000604
10. TROUBLESHOOTING
Battery Charge Alarm Lamp
Failure of battery charge alarm lamp
Starer switch is turned on, Lamp goes on while running

but lamp does not go on the engine
YES
Fuse blown?
Replace fuse Stop the engine

NO
YES
Filament blown?
Replace bulb Disconnect the L-terminal of the

NO
alternator.
(Turn on the starter switch)
Disconnect the L-terminal of the
alternator and ground it.
YES YES
Lamp goes on? Lamp goes on?
Check the alternator Check the alternator

NO NO
Disconnect the terminal No.7 Disconnect the terminal No.7

(WG) of the 12-pole connector in (WG) of the 12-pole connector in
the indicator box and ground it. the indicator box.
YES YES
Replace wire harness A or B Replace wire harness A or B

NO NO
Replace the indicator box Replace the indicator box
10-2-26 0000604
10. TROUBLESHOOTING
Engine Oil Pressure Alarm Lamp
Failure of engine oil pressure alarm lamp
Starer switch is turned on, Lamp goes on while running

but lamp does not go on the engine
YES
Fuse blown?
Stop the engine
Replace fuse
NO
YES YES
Insufficient
Filament blown? engine oil?
Replace bulb Supply engine oil
NO NO
Disconnect the terminal No.13A Disconnect the terminal No.13A

(LgR) from the oil pressure (LgR) from the oil pressure
switch terminal and ground it. switch terminal.
YES YES
Replace oil pressure switch Replace oil pressure switch

NO NO
Replace wire harness A or B Disconnect the terminal No.11

(LgR) of the 12-pole connector
on the monitor lamp side.
YES
Lamp goes on?
Replace wire harness A or B

NO
Replace indicator box
10-2-27 0000604
10. TROUBLESHOOTING
Warning Buzzer
Buzzer sounds while Starter switch is turned on,

running engine but buzzer does not sound
Is engine oil NO Is engine oil NO

pressure alarm pressure alarm
lamp on? lamp on?
YES Normal YES Repair the lamp according

to the troubleshooting
procedure for engine oil
pressure alarm lamp.
Is battery NO
charge alarm
lamp on?
YES Normal
Is water NO
temp. alarm
lamp on?
YES Normal
Replace the indicator box Replace the indicator box
10-2-28 0000604
10. TROUBLESHOOTING
Fuel Level Gauge
Fuel level gauge is faulty
Pointer indicates a value

Pointer does not work Unstable pointer
larger than the real fuel level
Check the connection of the Disconnect the terminal No.25A Check if the fuel in the fuel
terminal No.25A of the fuel of the fuel level sensor, connect tank is shaking.
lever sensor. 80ǡ resistance to the female
terminal (harness side) and
ground it.
(Turn on starter switch)
Is the fuel
Is the terminal YES Does the pointer YES level gauge pointer YES
unstable due to the shaking
No.25A loosened? move to "E"? of fuel in the fuel
tank?
Contact failure of Replace the fuel Normal
NO the terminal No.25A NO level sensor NO
Disconnect the terminal No.25 A Disconnect the terminal No.4 Check the connection of the
(L) of the fuel level sensor, (L) of the female connecter of terminal No.25A of the fuel
connect 10ǡ resistance to the the fuel level gauge, connect lever sensor.
female terminal (harness side) 80ǡ resistance and ground it.
and ground it.
Does the pointer YES Does the pointer YES Is the terminal YES
move to "F"? move to "E"? loosened?
Replace the fuel Harness is faulty Contact failure of
NO level sensor NO (Short-circuit) NO the terminal
Replace the fuel

level gauge
Disconnect the terminal No.4 Disconnect the terminal No.25A

(L) of the female connecter of of the fuel level sensor, connect
the fuel level gauge, connect 10ǡ resistance to the female
10ǡ resistance and ground it. terminal (harness side) and
ground it.
Does the pointer YES Does the pointer YES

move to "F"? move to "F"?
Replace wire harness Replace the fuel
NO A or B (Wire breakage) level sensor
NO
Replace the fuel level gauge Replace the fuel level gauge 013508-00E
10-2-29 0000604
10. TROUBLESHOOTING
Water Temperature
Water temperature gauge is faulty

Pointer does not work
larger than the real temperature
Check the connection of the Disconnect the terminal No.15A

terminal No.15A (LB) of the of the water temp. sensor,
water temp. sensor. connect 80 resistance to the
female terminal (harness side)
and ground it.
Is the terminal Does the

YES YES
No.15A loosened? pointer move to the
bottom?
Contact failure of Replace the water
NO the terminal No.15A NO temp. sensor
Disconnect the terminal No.15A Disconnect the terminal No.3

(LB) of the water temp. sensor, (LB) of the female connecter of
connect 10 resistance to the the water temp. gauge, connect
female terminal (harness side) 80 resistance and ground it.
and ground it.
Does the Does the

YES YES
pointer move to the pointer move to the
red zone? bottom?
Replace the water Harness is faulty
NO temp. sensor NO (Short-circuit)
Replace the water

temp. gauge
Disconnect the terminal No.3

(LB) of the female connecter of
the water temp. gauge, connect
10 resistance and ground it.
Does the
YES
pointer move to the
red zone?
Replace wire harness
NO A or B (Wire breakage)
Replace the water temp. gauge
10-2-30 0000604
10. TROUBLESHOOTING
Water Temperature
Water temperature gauge is faulty

Pointer does not work
larger than the real temperature
Check the connection of the Disconnect the terminal No.15A

terminal No.15A (LB) of the of the water temp. sensor,
water temp. sensor. connect 80 resistance to the
female terminal (harness side)
and ground it.
Is the terminal Does the

YES YES
No.15A loosened? pointer move to the
bottom?
Contact failure of Replace the water
NO the terminal No.15A NO temp. sensor
Disconnect the terminal No.15A Disconnect the terminal No.3

(LB) of the water temp. sensor, (LB) of the female connecter of
connect 10 resistance to the the water temp. gauge, connect
female terminal (harness side) 80 resistance and ground it.
and ground it.
Does the Does the

YES YES
pointer move to the pointer move to the
red zone? bottom?
Replace the water Harness is faulty
NO temp. sensor NO (Short-circuit)
Replace the water

temp. gauge
Disconnect the terminal No.3

(LB) of the female connecter of
the water temp. gauge, connect
10 resistance and ground it.
Does the
YES
pointer move to the
red zone?
Replace wire harness
NO A or B (Wire breakage)
Replace the water temp. gauge
10-2-30 0000604
CHAPTER 11
REFERENCE DATA
11-1 Specifications for Attachment ..............................................................11-1

11. REFERENCE DATA
11.Reference Data
11-1 Specifications for Attachment
Min. J
D
Max. K
A
a
b M
C
B
G’ G
Arm
E’
F
b a
Unit : mm
Model
SV15 SV17(EX)
Item
Specifications for bucket installation
A (Distance between bucket pins) 109
B (Distance between bucket and bucket arm pivot pins) 105
C (Distance between bucket arm pins) 190
D (Distance between bucket link pins) 190
E (External width of arm-stick end boss) 105
E' (Internal width of bucket pin boss) 106.5
F (External width of bucket pin boss) 146.5
G / G' (Outer diameter of bucket pin) Ø30 / Ø30
J (Cylinder length when it is fully retracted) 554
K (Cylinder length when it is fully extended) 871
M (Bucket arm pin height from arm-stick and bucket pivot pins) 5
Oil pressure specifications
Hydraulic pump discharge volume (L / min) P 33.8 37.8
Set pressure of system relief valve MPa (kgf/cm ) 2 17.6 (180) 19.6 (200)
Set pressure of bucket circuit relief valve MPa (kgf/cm )
2 24.5 (250)
11-1 0000604
SV15/17(EX)
Service Manual
First Edition : Apr. 2006
Published by : Engineering & Development Dept.

Edited by : Quality Assurance Dept.
Finished by : Yanmar Technical Service Co., Ltd.
Copyright c 2006 YANMAR CONSTRUCTION EQUIPMENT CO., LTD. All Rights Reserved.
This manual may not be reproduced or copied in whole or in part, without the written consent of
YANMAR CONSTRUCTION EQUIPMENT CO., LTD.

Yanmar SMSV15 - SV17

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Yanmar SMSV15 - SV17

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CONTENTS

GENERAL CAUTIONS FOR MAINTENANCE WORK

1-1 Correct Work............................................................................................1-1

1. General Cautions for Maintenance Work

1-1 Correct Work

1-2 Safety Precautions

1-4 Cautions for Disassembly and Reassembly

(1) Clean the machine before disassembly.

One and a half threads

1-5 Cautions for Removal and Installation of Hydraulic Equipment

(1) Check that the hydraulic oil temperature is low enough.

1-6 Cautions for Removal and Installation of Hydraulic Piping

(1) Installation of hydraulic hose

1-7 Cautions for Handling Seals

(1) Clean out grooves of O-rings. Remove burrs or dust if any.

1-8 Correct Installation of Hydraulic Hose

Not good Good

Not good Good

Not good Good

(6) Use an elbow to prevent excessive twisting or bending of the hose.

Not good Good

Not good Good

Not good Good

Not good Good

Hose mark Hose mark

1-9 Specifications of Hydraulic Hose

(1) Yanmar Standard Type

Hose material code Fittings combination code

1) Type of Hose (Hose Dia. & Recommended Working Pressure)

2) Total Length of Hose [Unit : in. (cm)]

3) Hose Dia. (Unit : inch)

02....1/4'' 05....5/8'' 12....1 1/4''

Fitting 60 degrees bent type.

(Example) Part code 2 3 2 0 2 0 3 0 8 5 5

Rubber hose, high pressure type List of pipe threads

(2) Special Parts

Description ..................... Hose P 2 06 AB 075 W

2 Hose material 6 Total length 7 Hose protector

3 Recommended G(PF) Straight pipe

4 Nominal dia. (inch) Without fitting Y

The example hose, P 2 06 AB 075 W stands for :

Fitting type Code Fitting type Code

60 60 degrees bent type. UNF UNF, thread with O-ring

45 45 degrees bent type.

90 90 degrees bent O-ring

Straight pipe thread with

30 30 degrees bent type.

1-10 Air Release of Hydraulic Equipment

1. Air Release of Each Hydraulic Component

2. Air Release of Hydraulic Cylinders

1.97 to 3.9 in. 1.97 to 3.9 in.

2-1 Specifications....................................................................................... 2-1-1

Item Unit SV15 SV17 SV17EX

Item Unit SV15 SV17 SV17EX

Track Inside diameter mm - Ø60

Item Unit SV15 SV17 SV17EX

Item Unit SV15 SV17 SV17EX

Item Unit SV15 SV17 SV17EX

Item Unit SV15 SV17 SV17EX

2-2 Outline Drawing and Working Area

Outline drawing of excavator : SV15

88.50 (2248) Canopy

88.82 (2256) Cabin