Manual No.

: KM-1M9-E
Vol. No. : W1M9-E-00

40U-2 50U-2 Excavator Workshop Manual

Workshop Manual

40U-2
50U-2
Excavator

Service Manual (Manual No. KM-1M9-E) consists of the following two separate volumes;
Technical Manual : Vol. No. T1M9-E
Workshop Manual : Vol. No. W1M9-E

PRINTED IN SINGAPORE (PS) 2004.11

Zaxis40U-2/50U-2-Wsh 1 29/10/04, 19:24

 INTRODUCTION
TO THE READER

• This manual is written for an experienced technician
to provide technical information needed to maintain
and repair this machine.
• Be sure to thoroughly read this manual for cor-
rect product information and service procedures.
• If you have any questions or comments, at if you
found any errors regarding the contents of this
manual, please contact using “Service Manual
Revision Request Form” at the end of this man-
ual.
(Note: Do not tear off the form. Copy it for us-
age.):
Publications Marketing & Product Support
Hitachi Construction Machinery Co. Ltd.
TEL: 81-298-32-7173
FAX: 81-298-31-1162

ADDITIONAL REFERENCES

• Please refer to the materials listed below in addition • Operation Manual of the Engine
to this manual. • Parts Catalog of the Engine
• Hitachi Training Material
• The Operator’s Manual
• The Parts Catalog

MANUAL COMPOSITION

• This manual consists of two portions:

the Technical Manual and the Workshop Manual.
Use the manuals according to purpose.

• Information included in the Technical Manual:
technical information needed for redelivery and
delivery, operation and activation of all devices
and systems, operational performance tests, and
troubleshooting procedures.
• Information included in the Workshop Manual:
technical information needed for maintenance
and repair of the machine, tools and devices
needed for maintenance and repair, maintenance
standards, and removal/installation and assem-
ble/disassemble procedures.

PAGE NUMBER
• Each page has a number, located on the center
lower part of the page, and each number contains
the following information:

Example : T 1-3-5

Consecutive Page Number for Each Group

Group Number
Section Number
T: Technical Manual W: Workshop Manual

IN-01
 INTRODUCTION
SAFETY ALERT SYMBOL AND HEADLINE
NOTATIONS
In this manual, the following safety alert symbol and
signal words are used to alert the reader to the
potential for personal injury of machine damage.
This is the safety alert symbol. When you see this
symbol, be alert to the potential for personal injury.
Never fail to follow the safety instructions prescribed
along with the safety alert symbol.
The safety alert symbol is also used to draw attention
to component/part weights.
To avoid injury and damage, be sure to use appropri-
ate lifting techniques and equipment when lifting
heavy parts.
• CAUTION:
Indicated potentially hazardous situation which
could, if not avoided, result in personal injury or
death.
• IMPORTANT:
Indicates a situation which, if not conformed to the
instructions, could result in damage to the machine.
• NOTE:
Indicates supplementary technical information or
know-how.

UNITS USED

• SI Units (International System of Units) are used in Example : 24.5 MPa (250 kgf/cm2, 3560 psi)
this manual.
MKSA system units and English units are also A table for conversion from SI units to other system
indicated in parenthheses just behind SI units. units is shown below for reference purposees.

To Convert To Convert
Quantity Into Multiply By Quantity Into Multiply By
From From
2
Length mm in 0.03937 Pressure MPa kgf/cm 10.197
mm ft 0.003281 MPa psi 145.0
Volume L US gal 0.2642 Power kW PS 1.360
L US qt 1.057 kW HP 1.341
m3 yd3 1.308 Temperature °C °F °C×1.8+32
Weight kg lb 2.205 Velocity km/h mph 0.6214
Force N kgf 0.10197 min-1 rpm 1.0
N lbf 0.2248 Flow rate L/min US gpm 0.2642
Torque N⋅m kgf⋅m 1.0197 mL/rev cc/rev 1.0
N⋅m lbf⋅ft 0.7375

IN-02
 SAFETY
RECOGNIZE SAFETY INFORMATION

• These are the SAFETY ALERT SYMBOLS.

• When you see these symbols on your machine or in

this manual, be alert to the potential for personal in-
jury.
• Follow recommended precautions and safe operating
practices.

SA-688

UNDERSTAND SIGNAL WORDS

• On machine safety signs, signal words designating the

degree or level of hazard - DANGER, WARNING, or
CAUTION - are used with the safety alert symbol.

• DANGER indicates an imminently hazardous situation

which, if not avoided, will result in death or serious in-
jury.
• WARNING indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury.
• CAUTION indicates a potentially hazardous situation
which, if not avoided, may result in minor or moderate
injury.
• DANGER or WARNING safety signs are located
near specific hazards. General precautions are listed
on CAUTION safety signs.
• Some safety signs don’t use any of the designated
signal words above after the safety alert symbol are
occasionally used on this machine.
• CAUTION also calls attention to safety messages in this SA-1223

manual.

• To avoid confusing machine protection with personal

safety messages, a signal word IMPORTANT indicates a
situation which, if not avoided, could result in damage to
the machine.

• NOTE indicates an additional explanation for an

element of information.

SA-1
 SAFETY
FOLLOW SAFETY INSTRUCTIONS

• Carefully read and follow all safety signs on the machine

as well as all safety messages in this manual.
• Safety signs must be installed, maintained and replaced
if damaged.
• If a safety sign or this manual is damaged or missing,
order a replacement from your nearest Hitachi dealer
in the same way you order other replacement parts
(be sure to state machine model and serial number
when ordering).
• Allow only properly trained, qualified, authorized per-
SA-003
sonnel to operate the machine.
• Learn how to correctly operate and service the machine.
• Keep your machine in proper working condition.
• Always operate the machine within the specification.
• Unauthorized modifications of the machine may impair
the functions and/or safety and affect machine life and
the warranty will become void.
• The safety messages in this SAFETY chapter are in-
tended to illustrate basic safety procedures of machines.
However it is impossible for these safety messages to
cover every possible hazardous situation you may en-
counter. If you have any questions concerning safety,
you should first consult your supervisor and/or your
nearest Hitachi dealer before operating or performing
maintenance work on the machine.

PREPARE FOR EMERGENCIES

• Be prepared if a fire starts or if an accident occurs.

• Keep a first aid kit and fire extinguisher on hand.

• Thoroughly read and understand the label attached on
the fire extinguisher and use it properly.
• To ensure that a fire-extinguisher can be always used
when necessary, check and service the
fire-extinguisher at the recommended intervals as
specified in the fire-extinguisher manual.
• Establish emergency procedure guidelines to cope
with any fire or accidents which may occur. SA-437

• Keep emergency numbers for doctors, ambulance

service, hospitals, and fire department posted near
your telephone.

SA-2
 SAFETY
WEAR PROTECTIVE CLOTHING

• Wear close fitting clothing and safety equipment appro-

priate to the job.

You may need:

A hard hat
Safety belt
Safety shoes
Safety glasses, goggles, or face shield
Heavy gloves
Hearing protection
Reflective clothing
Wet weather gear SA-438

Respirator or filter mask.

Be sure to wear the correct equipment and clothing
for the job. Do not take any chances.

• Avoid wearing loose clothing, jewelry, or other items

that can catch on control levers or other parts of the
machine.
• Operating equipment safely requires the full attention of
the operator.

• Do not wear radio or music headphones while oper-

ating the machine.

PROTECT AGAINST NOISE

• Prolonged exposure to loud noise can cause impairment

or loss of hearing.

• Wear a suitable hearing protective device such as

earmuffs or earplugs to protect against objectionable
or uncomfortably loud noises.

SA-434

INSPECT MACHINE DAILY

• If any abnormality is found, be sure to repair it immedi-

ately before operating the machine.

• In the walk-around inspection, be sure to cover all

points described in the “PRE-START INSPECTION”
chapter in the operator’s manual.

SA-435

SA-3
 SAFETY
TIDY UP INSIDE CAB

• Always keep inside the cab clean by observing instruc-

tions below, to prevent any personal accidents from oc-
curring.
• Remove mud and/or oily material from the shoe soles
before entering the cab. If pedals are operated without
removing mud or oily matter, the foot may slip off the
pedal, possibly creating a hazardous situation.
• Do not leave parts and/or tools around the operator’s
seat.
• Do not keep a transparent water bottle in the cab. The
transparent water bottle may concentrate the sun light
like a lens, possibly causing a fire.
• Do not wear radio or music headphones and do not use
a cell phone while traveling or operating the machine.
• Never allow hazardous materials such as combustible
and/or explosive material in the cab.
• Do not leave a lighter in the cab. If the temperature in the
cab increases, the lighter may explode.

USE HANDHOLDS AND STEPS

• Falling is one of the major causes of personal injury.

• When you get on and off the machine, always face the
machine.
• Maintain a three-point contact with the steps and
handrails.
• Do not use any controls as handholds.
• Never jump on or off the machine. Never mount or
dismount a moving machine.
• In case adhered slippery material such as oil, grease,
or mud is present on steps, handrails, or platforms, SA-439

thoroughly remove such material.

SA-4
 SAFETY
ADJUST THE OPERATOR'S SEAT

• A poorly adjusted seat for either the operator or for the

work at hand may quickly fatigue the operator leading to
mis-operation of the machine.

• The seat should be adjusted whenever the operator

for the machine changes.
• The operator should be able to fully depress the ped-
als and to correctly operate the control levers with his
back firmly against the seat back.
• If not, readjust the seat forward or backward, and
check again. SA-378

FASTEN YOUR SEAT BELT

• If the machine should overturn, the operator may be-

come injured and/or thrown from the cab. Additionally
the operator may be crushed by the overturning machine,
resulting in serious injury or death.

• Be sure to remain seated with the seat belt securely

fastened whenever operating the machine.
• Prior to operating the machine, thoroughly examine
webbing, buckle and attaching hardware. If any item is
damaged or worn, replace the seat belt or component
before operating the machine. Replace the seat belt at
least once every 3 years regardless of appearance SA-237

SA-5
 SAFETY
MOVE AND OPERATE MACHINE SAFELY

• Always be aware that there is a potential danger around

the machine while operating the machine.

• Take extra care not to run over bystanders. Confirm

the location of bystanders before moving, swinging, or
operating the machine.
• Always keep the travel alarm and horn in working
condition (if equipped).
• Before starting to move or operate the machine, sound
the travel alarm and horn to alert bystanders.
• Use a signal person when moving, swinging, or oper- SA-1291

ating the machine in congested areas. Locate the

signal person so that the operator can always witness
the signal person.
• Coordinate the meanings of all safety signs, hand
signals and marks before starting the machine. Ap-
point a person who is responsible to make a signal
and/or guidance.
• Never allow any persons or obstacles to enter the
machine operation areas.
• Use appropriate illuminations.

SA-6
 SAFETY
OPERATE ONLY FROM OPERATOR'S SEAT

• Inappropriate engine starting procedures may cause the

machine to runaway, possibly resulting in serious injury
or death.

• Start the engine only when seated in the operator's

seat.
• NEVER start the engine while standing on the tracks
or on ground.
• Do not start engine by shorting across starter termi-
nals. A hazardous situation may be created and/or
possible damage to the machine may result. SA-444

• Before starting the engine, confirm that all control lev-

ers are in neutral.

JUMP STARTING

• Failure to follow correct jump starting procedures could

result in a battery explosion or a runaway machine.

• If the engine must be jump started, be sure to follow

the instructions shown in the “OPERATING THE EN-
GINE” chapter.
• The operator must be seated in the operator’s seat so
that the machine will be under control when the engine
starts. Jump starting is a two-person operation.
• Never use a frozen battery.
SA-032
• Failure to follow correct jump starting procedures
could result in a battery explosion or a runaway ma-
chine.

KEEP RIDERS OFF MACHINE

• Riders on machine are subject to injury such as being

struck by foreign objects and being thrown off the
machine.

• Riders also obstruct the operator’s view, resulting in

the machine being operated in an unsafe manner.
• Only allow the operator is allowed on the machine.
Keep riders off.

SA-1292

SA-7
 SAFETY
INVESTIGATE JOB SITE BEFOREHAND

• When working at the edge of an excavation or on a road

shoulder, the machine could tip over due to collapse of
the ground, possibly resulting in serious injury or death.

• Investigate the configuration and ground conditions of

the job site beforehand to prevent the machine from
falling and to prevent the ground, stockpiles, or banks
from collapsing.
• Make a work plan. Use machines appropriate to the
work and job site.
• Reinforce ground, edges, and road shoulders as
necessary. Keep the machine well back from the
edges of excavations and road shoulders.
• When working on an incline or on a road shoulder, SA-1293

employ a signal person as required.

• Never allow bystanders to enter the working area such
as swing radius or traveling range.
• Confirm that your machine is equipped a FOPS cab
before working in areas where the possibility of falling
stones or debris exist.
• When the footing is weak, reinforce the ground before
starting work.
• When working on frozen ground, be extremely alert.
As ambient temperatures rise, footing may become
loose and slippery.
• When operating the machine near open flame, sparks,
and/or dead grass, a fire may easily break out. Use
special care not to cause a fire.

SA-8
 SAFETY
PROVIDE SIGNALS FOR JOBS INVOLVING
MULTIPLE NUMBERS OF MACHINES

• In case more than one machine is operated in the same

job site, accidental collision between machines may
cause serious injury or death.

• For jobs involving multiple numbers of machines, provide

signals commonly known by all personnel involved. Also,
appoint a signal person to coordinate the job site. Make
sure that all personnel obey the signal person’s direc-
tions.

SA-481

CONFIRM DIRECTION OF MACHINE TO BE

DRIVEN

• Incorrect travel pedal/lever operation may result in seri-

ous injury death.

• Before driving the machine, confirm the position of the

undercarriage in relation to the operator’s position.
• If the travel motors are located towards the front of the
cab, the machine will move in the reverse direction
when travel pedals/levers are operated.

SA-1294

SA-9
 SAFETY
DRIVE MACHINE SAFELY

• Driving the machine in the incorrect direction may result

in serious injury or death and/or severe damage to
property.

• Before moving the machine, confirm which way to A

move travel pedals/levers for the corresponding di-
rection you wish to travel.

• Avoid passing over any obstructions. Failure to do so

may cause soil, rock fragments and/or metal pieces to
be scatter around the machine. Keep bystanders away SA-1295

from the machine.

• Traveling on a grade may cause the machine to slip or to
overturn, possibly resulting in serious injury or death.

• When traveling up or down a grade, keep the bucket in

the direction of travel, approximately 200 to 300 mm (8
to 12 in) (A) above the ground so that lowering the
bucket onto the ground can quickly stop the machine.
• If machine starts to skid or becomes unstable, lower
the bucket immediately.

• Traveling across the face of slope or steering on a A

slope may cause the machine to skid or to turnover. If SA-1296

the direction must be changed on a slope, first move

the machine to level ground, then, change the travel-
ing direction to ensure safe operation.

SA-441

SA-442

SA-10
 SAFETY
AVOID INJURY FROM ROLLAWAY
ACCIDENTS

• Death or serious injury may result if you attempt to

mount or try to bodily stop a moving machine.

• Park the machine in compliance with the safe parking

procedures described on page S-15 to prevent the
machine from running away.

• Block both tracks and lower the bucket to the ground,

thrust the bucket teeth into the ground if you must park
on a grade.
• Park a reasonable distance from other machines.

SA-1297

SA-11
 SAFETY
AVOID INJURY FROM BACK-OVER AND
SWING ACCIDENTS

• If any person is present near the machine when backing

or swinging the upperstructure, the machine may hit or
run over that person, resulting in serious injury or death.

To avoid back-over and swing accidents:

• Always look around BEFORE YOU BACK UP AND
SWING THE MACHINE. BE SURE THAT ALL
BYSTANDERS ARE CLEAR.
• Keep the travel alarm in working condition (if
equipped). SA-383
ALWAYS BE ALERT FOR BYSTANDERS MOVING
INTO THE WORK AREA. USE THE HORN OR
OTHER SIGNAL TO WARN BYSTANDERS BEFORE
MOVING MACHINE.
• USE A SIGNAL PERSON WHEN BACKING UP IF
YOUR VIEW IS OBSTRUCTED. ALWAYS KEEP THE
SIGNAL PERSON IN VIEW.
Use hand signals, which conform to your local
regulations, when work conditions require a signal
person.
• No machine motions shall be made unless signals are
clearly understood by both signalman and operator. SA-384

• Learn the meanings of all flags, signs, and markings

used on the job and confirm who has the responsibility
for signaling.
• Keep windows, mirrors, and lights clean and in good
condition.
• Dust, heavy rain, fog, etc., can reduce visibility. As
visibility decreases, reduce speed and use proper
lighting.
• Read and understand all operating instructions in the
operator’s manual.

021-E01A-0494-8

SA-12
 SAFETY
KEEP PERSONNEL CLEAR FROM WORKING
AREA

• If a person is present near the operating machine, the

person may come in contact with the swinging front
attachment or counterweight and/or may be crushed
against an other object, resulting in serious injury or
death.

• Before operating the machine, set up barriers to the

sides and rear area of the bucket swing radius to
prevent anyone from entering the work area.
• Make sure that no personnel other than the signal
person or no obstacles are present in the working area
before operating the machine.

SA-667

NEVER POSITION BUCKET OVER ANYONE

• Never lift, move, or swing bucket above anyone or a

truck cab.
Serious injury or machine damage may result due to
bucket load spill or due to collision with the bucket.

• Never allow the bucket to pass over anyone to avoid

personal injury or death.

SA-668

AVOID UNDERCUTTING

• In order to retreat from the edge of an excavation if the

footing should collapse, always position the
undercarriage perpendicular to the edge of the
excavation with the travel motors at the rear.

• If the footing starts to collapse and if retreat is not

possible, do not panic raise the front attachment with a
panic. Lowering the front attachment may be safer in
most cases.

SA-1300

SA-13
 SAFETY
AVOID TIPPING

• The danger of tipping is always present when operating

on a grade, possibly resulting in serious injury or death.

To avoid tipping:
• Be extra careful before operating on a grade.

• Prepare machine operating area flat.

• Keep the bucket low to the ground and close to the
machine.
• Reduce operating speeds to avoid tipping or slipping.
• Avoid changing direction when traveling on grades.
• NEVER attempt to travel across a grade steeper than
15 degrees if crossing the grade is unavoidable.
SA-1301
• Reduce swing speed as necessary when swinging
loads.

• Be careful when working on frozen ground.

• Temperature increases will cause the ground to

become soft and make ground travel unstable.
025-E01A-0540-4

NEVER UNDERCUT A HIGH BANK

• The edges could collapse or a land slide could occur

causing serious injury or death.

SA-1302

SA-14
 SAFETY
DIG WITH CAUTION

• Accidental severing of underground cables or gas lines

may cause an explosion and/or fire, possibly resulting in
serious injury or death.

• Before digging check the location of cables, gas lines,

and water lines.
• Keep the minimum distance required, by law, from
cables, gas lines, and water lines.
• If a fiber optic cable should be accidentally severed,
do not look into the end. Doing so may result in
serious eye injury.
• Contact your local “diggers hot line” if available in your SA-672

area, and/or the utility companies directly.

Have them mark all underground utilities.

OPERATE WITH CAUTION

• If the front attachment or any other part of the machine

hits against an overhead obstacle, such as a bridge,
both the machine and the overhead obstacle will be
damaged, and personal injury may result as well.

• Take care to avoid hitting overhead obstacles with the

boom or arm.

SA-673

AVOID POWER LINES

• Serious injury or death can result if the machine or front

attachments are not kept a safe distance from electric
lines.

• When operating near an electric line, NEVER move

any part of the machine or load closer than 3 m (10 ft)
plus twice the line insulator length.
• Check and comply with any local regulations that may
apply.
• Wet ground will expand the area that could cause any SA-1305

person on it to be affected by electric shock. Keep all

bystanders or co-workers away from the site.

SA-15
 SAFETY
DO NOT USE FOR CRANING OPERATIONS

• NEVER use the machine for craning operations. If the

machine is used for craning operations, the machine
may tip over and/or lifted load may fall, possibly resulting
in serious injury or death.
• This machine has been exclusively designed to engage
in excavation and loading works.
• This machine is not equipped with any of the necessary
safety devices that could allow the machine to be used
for craning operation.

SA-014

PROTECT AGAINST FLYING DEBRIS

• If flying debris such as soil, rock fragments or metal

pieces hit eyes or any other part of the body, serious
injury may result.

• Guard against such injuries when working in a job site

where possibility of flying pieces of metal or debris
exist, or when removing or installing pins using a
hammer; wear goggles or safety glasses.
• Keep bystanders away from the working area before
striking any object.
SA-432

SA-16
 SAFETY
PARK MACHINE SAFELY

• Unless the machine is not correctly parked, any

hazardous situations such as running away of the
machine or damage by vandalism may result, causing
the machine to operate unsafely when the engine is
re-started. Follow instructions described below when
parking the machine.

• Park the machine on solid level surface to prevent the

machine from running away.
• Lower the bucket and/or blade to the ground.
SA-1306

• Pull the lock lever to the LOCK position.

• Turn the auto-idle switch (optional) OFF. Failure to do
so may create a hazarduos condition as the engine
speed may unexpectedly increase.
• Run engine at slow idle speed without load for 5
minutes.
• Turn key switch to OFF to stop engine. Remove the
key from the key switch.
• Before leaving the machine, close all windows, roof
vent, and cab door. Lock all access doors and
compartments

HANDLE FLUIDS SAFELY --- AVOID FIRES

• Handle fuel with care; it is highly flammable. If fuel

ignites, an explosion and/or a fire may occur, possibly
resulting in serious injury or death.

• Do not refuel the machine while smoking or when near

open flame or sparks.
• Always stop the engine before refueling the machine.
• Fill the fuel tank outdoors.

• All fuels, most lubricants, and some coolants are

flammable. SA-018

• Store flammable fluids well away from fire hazards.

• Do not incinerate or puncture pressurized containers.
• Do not store oily rags; they can ignite and burn
spontaneously.

SA-019

SA-17
 SAFETY
SAFETY TRANSPORTING

• The danger of tipping is present when loading/unloading

the machine onto/from a truck or trailer bed.

• Be sure to observe local regulations when transporting

the machine on public roads.
SA-1307
• Provide an appropriate truck or trailer for transporting
the machine.
• Be sure to have a signal person.
• Take the following precautions when loading/unloading
the machine.
1. Select firm level ground.
2. Be sure to use a loading dock or ramp strong enough
to support the machine weight.
3. Ramps must be sufficient in width, length, and
strength. Be sure that the incline of the ramp is less
than 15 degrees.
4. Loading docks must be sufficient in width and
strength to support the machine and have a gradient
of less than 15 degrees.
5. Be sure to turn the auto-idle switch (13) OFF. 13
6. Slowly drive the machine.
7. Avoid steering while driving up or down the ramp as it
is extremely dangerous. If steering is unavoidable,
first move back to the ground or flatbed, modify
traveling direction, and begin to drive again.
8. The top end of the ramp where it meets the flatbed is M1M7-01-028

a sudden bump. Take care when traveling over it.

9. Wedge the front and rear of tracks. Securely fasten
the machine to the trailer bed with chain or cables.
10. Do not operate any levers besides the travel levers
when driving up or down the ramp.
11. Prevent possible injury from machine tipping while the
upperstructure is rotating.
12. Keep the arm tucked under and rotate the
upperstructure slowly for best stability.

Refer to "transporting" chapter in operator’s manual for

details

SA-18
 SAFETY
PRACTICE SAFE MAINTENANCE

• Inspection/maintenance work may produce hazardous

situations by contacting and/or accessing a part of body
to a moving, high pressure, and/or high temperature part
of the machine. To avoid serious personal injury or death,
follow the instructions described below.
• Thoroughly coordinate the working procedures to be
taken hereafter with the co-workers before beginning
work such as inspecting/servicing the machine, or
replacing the attachiment .
• Safely park the machine in accordance with the
instructions for “Park Machine Safely.”
• Keep the work area clean and orderly.
• Attach a “DO NOT OPERATE” tag in an easy-to-see
SA-028
location such as on a door or a control lever.
• If moisture permeates into the electrical system,
malfunction and/or erroneous movement of the
machine may result. Do not clean sensors, cable
connectors, and the cab inside using water and/or
steam.
• Wait to begin to work until the engine and hydraulic oil
temperatures have cooled down to the safety range.
• In case inspection/maintenance must be performed 90 to 110°
with the engine runnning, be sure to appoint an
overseer.
• Never lubricate or service the machine while moving it.
• Repair the cracked windowpane before servicing the M1M7-04-006

machine. Failure to do so may cause personal injury.

• Whe raising the machine above the ground using the
front attachment function, maintain the angle between
the boom and the arm in the range of 90 to 110°.
Never allow anyone to enter under the machine raised
with the front attachment function.
• In case working under the machine raised above the
ground is unavoidably required, securely hold the
machine with stays or blocks strong enough to support
the machine weight.
• Never work under the raised bucket.
• Keep all parts in good condition and properly installed.
• Always use the specified tools correctly.
• Always use a clean tool. SA-527

• Fix any damage found immediately. Replace worn or

broken parts.
• Remove any buildup of grease, oil, or debris.
• When cleaning parts, use a non-combustible cleaning
solvent. Never use an inflammable fluid such as
dieasel fuel, or gasoline.

SA-19
 SAFETY
• Disconnect battery ground cable (−) before making
adjustments to electrical systems or before welding on
the machine.
• Sufficiently illuminate the work site. Use a
maintenance work light when working under or inside
the machine.
• Always use a work light protected with a guard. In
case the light bulb is broken, spilled fuel, oil, antifreeze
fluid, or window washer fluid may catch fire.

SA-037

WARN OTHERS OF SERVICE WORK

• Unexpected machine movement can cause serious

injury.

• Before performing any work on the machine, attach a

“Do Not Operate” tag in an easy-to-see place such as
on the cab door or control lever.
• Never attempt to operate the machine with a “Do Not
Operate” tag attached.
• Make it a rule for the inspection/service person to hold
the engine start key during inspection/service work.
SA-287

SUPPORT MACHINE PROPERLY

• Never attempt to work on the machine without securing

the machine first.

• Always lower the attachment to the ground before you

work on the machine.
• If you must work on a lifted machine or attachment,
securely support the machine or attachment with stays
or blocks strong enough to support the machine
and/or attachment weight.

SA-527

STAY CLEAR OF MOVING PARTS

• Contact with moving parts can cause serious injury or

death due to amputation or entanglement.

• To prevent accidents, care should be taken to ensure

that hands, feet, clothing, jewelry and hair do not
become entangled when working around rotating
parts.

SA-026

SA-20
 SAFETY
PREVENT PARTS FROM FLYING

• Grease in the track adjuster is under high pressure.

Failure to follow the precautions below may result in
serious injury, blindness, or death.

• Do not attempt to remove GREASE FITTINGS or

VALVE ASSEMBLIES.
• As pieces of parts may fly off, be sure to keep body
and face away from the valve.

• Travel reduction gears are under pressure.

SA-344

• As pieces of parts may fly off, be sure to keep body

and face away from AIR RELEASE PLUG to avoid
injury.
• GEAR OIL is hot. Wait for gear oil to cool, then
gradually loosen the air release plug to release
pressure.

STORE ATTACHMENTS SAFELY

• Stored attachments such as buckets, hydraulic hammers,

and blades can fall and cause serious injury or death.

• Securely store attachments and implements to prevent

falling accidents.
• Keep children and bystanders away from storage
areas.

SA-034

SA-21
 SAFETY
PREVENT BURNS

Hot spraying fluids:

• After operation, engine coolant is hot and under pressure.
Hot water or steam is contained in the engine, radiator
and heater lines.
Skin contact with escaping hot water or steam can cause
severe burns.

• To prevent possible injury from hot spraying water,

stop the engine. Begine to work after the engine and
radiator are sufficiently cooled
• DO NOT remove the radiator cap until the engine is
cool. When opening, turn the cap slowly to the stop. SA-039

Allow all pressure to be release before removing the

cap.
• The hydraulic oil tank is pressurized. Again, be sure to
release all pressure by slowly removing the cap.

Hot fluids and surfaces:

• Engine oil, gear oil and hydraulic oil also becomes hot
during operation.
The engine, hoses, lines and other parts become hot as
well.

• Wait for the oil and components to cool before starting

any maintenance or inspection work.

SA-225

SA-22
 SAFETY
REPLACE RUBBER HOSES PERIODICALLY

• Rubber hoses that contain flammable fluids such as

hydraulic oil or fuel under pressure may break due to
aging, fatigue, and abrasion. It is very difficult to gauge
the extent of deterioration due to aging, fatigue, and
abrasion of rubber hoses by visual inspection alone.

• Periodically replace the rubber hoses. (Refer to the

“Periodical Replacement Parts” section in the
operator’s manual.)

• Failure to periodically replace rubber hoses may cause a

SA-019
fire, fluid injection into skin, or the front attachment to fall
on a person nearby, which may result in severe burns,
gangrene, or otherwise serious injury or death.

AVOID HIGH-PRESSURE FLUIDS

• Fluids such as diesel fuel or hydraulic oil under pressure

can penetrate the skin or eyes causing serious injury,
blindness or death.

• Avoid this hazard by relieving pressure before

disconnecting hydraulic or other lines. Make sure that
all connectors are completely connected before
applying pressure.
• Search for leaks with a piece of cardboard; take care
SA-031

to protect hands and body from high-pressure fluids.

Wear a face shield or goggles for eye protection.
• If an accident occurs, see a doctor familiar with this
type of injury immediately. Any fluid injected into the
skin must be surgically removed within a few hours or
gangrene may result.

SA-292

SA-044

SA-23
 SAFETY
PREVENT FIRES

Check for Oil Leaks:

• Fuel, hydraulic oil and lubricant leaks can lead to fires,
possibly resulting in personal injury or death.

• Check for missing or loose clamps, kinked hoses,

lines or hoses that rub against each other, damage to
the oil-cooler, and loose oil-cooler flange bolts, for oil
leaks.
• Tighten, repair or replace any missing, loose or
damaged clamps, lines, hoses, oil-cooler and
oil-cooler flange bolts. SA-019

• Do not bend or strike high-pressure lines.

• Never install bent or damaged lines, pipes or hoses.

Check for Shorts:

• Short circuits can cause fires.

• Clean and tighten all electrical connections.

• Check before each shift or after eight (8) to ten (10)
hours operation for loose, kinked, hardened or frayed
electrical cables and wires.
• Check before each shift or after eight (8) to ten (10)
hours operation for missing or damaged terminal caps.
• DO NOT OPERATE MACHINE if cable or wires are
loose, kinked, etc.

SA-24
 SAFETY
Precautions for Handling Flammables
• Spilled fuel and oil, and trash, grease, debris,
accumulated coal dust, and other flammables may
cause fires.

• Prevent fires by inspecting and cleaning the machine

daily, and by removing spilled or accumulated
flammables immediately.
• Don’t store flammable fluid near open flames.
• Don’t burn or crush a pressurerized container.
• Don’t store oily cloths. They are liable to catch fire.
• Don’t wind easy-to-absorb-oil asbestos or glass wool
around high-temperature parts such as a muffler or
exhaust pipe.

Check Heat Shield Covers around Engine

Compartment
• If the engine compartment heat shield cover becomes
broken or lost, fire may break out.

• If the engine compartment heat shield cover becomes

broken or lost, repair or replace it before operating the
machine.

Check Key Switch:

• If fire breaks out, failure to stop the engine will escalate
the fire, hampering fire fighting.

• Always check key switch function before operating the

machine every day:
1) Start the engine and run it at slow idle.
2) Turn the key switch to the OFF position to confirm
that the engine hasstopped.
If any abnormalities are found, be sure to repair
them before operating the machine.

SA-25
 SAFETY
EVACUATING IN CASE OF FIRE

• If fire breaks out during machine operation, evacuate the

machine in the following way:

• Stop the engine by turning the key switch to the OFF

position.
• Use a fire extinguisher if there is time.
• Exit the machine using handrails and/or steps.
• In an emergency, if the cab door or front window can
not be opened, break the front or rear window panes
with the emergency evacuation hammer to escape
SA-393
from the cab.
Refer to the explanation pages on the “Emergency
Evacuation Method” in the operator’s manual.

SS-1510

BEWARE OF EXHAUST FUMES

• Prevent asphyxiation. Engine exhaust fumes can cause

sickness or death.

• If you must operate the machine in a building, be sure

there is adequate ventilation. Either use an exhaust
pipe extension to remove the exhaust fumes or open
doors and windows to bring enough outside air into the
area.

SA-016

SA-26
 SAFETY
PRECAUTIONS FOR WELDING AND GRIND-
ING

• Welding may generate gas and/or small fires.

• Be sure to perform welding in a well ventilated and

prepared area. Store flammable objects in a safe
place before starting welding.
• Only qualified personnel should perform welding.
Never allow an unqualified person to perform welding.
• Grinding on the machine may create a fire hazard. Store
flammable objects in a safe place before starting grind-
ing.

• After finishing welding and grinding, recheck that there SA-818

are no abnormalities such as the area surrounding the

welded area still smoldering.

AVOID HEATING NEAR PRESSURIZED FLUID

LINES

• Flammable spray can be generated by heating near

pressurized fluid lines, resulting in severe burns to
yourself and bystanders.

• Do not heat by welding, soldering, or using a torch

near pressurized fluid lines or other flammable
materials.
• Pressurized lines can be accidentally cut when heat
goes beyond the immediate flame area. Install
temporary fire resistant guards to protect hoses or
other materials before engaging in welding, soldering, SA-030

etc.

AVOID APPLYING HEAT TO LINES

CONTAINING FLAMMABLE FLUIDS

• Do not weld or flame cut pipes or tubes that contain

flammable fluids.
• Remove flammable fluids thoroughly with
nonflammable solvent before welding or flame cutting
pipes or tubes that contained flammable fluids.

SA-27
 SAFETY
REMOVE PAINT BEFORE WELDING OR
HEATING

• Hazardous fumes can be generated when paint is

heated by welding, soldering, or using a torch. If inhaled,
these fumes may cause sickness.

• Remove paint before welding or heating.

• Avoid potentially toxic fumes and dust.
• Do all such work outside or in a well-ventilated area.
Dispose of paint and solvent properly.
• Allow fumes to disperse at least 15 minutes after
SA-029
welding or heating.
• Use attention to the following points when removing
paint.
1. If you sand or grind paint, avoid breathing the dust
which is created.
Wear an approved respirator.
2. If you use solvent or paint stripper, remove stripper
with soap and water before welding.
3. Remove solvent or paint stripper containers and
other flammable material from area.

PREVENT BATTERY EXPLOSIONS

• Battery gas can explode.

• Keep sparks, lighted matches, and flame away from

the top of battery.
• Never check battery charge by placing a metal object
across the posts. Use a voltmeter or hydrometer.
• Do not charge a frozen battery; it may explode. Warm
the battery to 16 °C (60 °F) first.
• Do not continue to use or charge the battery when the
electrolyte level is lower than specified. Explosion of
the battery may result. SA-032

• When a terminal become loose, it may induce sparks.

Securely tighten all terminals.

• Battery electrolyte is poisonous. If the battery should

explode battery electrolyte may be splashed into eyes,
possibly resulting in blindness. If electrolyte is splashed
into eyes, flush your eyes continuosly with water for
about 15 minutes. Seek medical attention immediately.

• Be sure to wear eye protection when checking

electrolyte specific gravity.

SA-28
 SAFETY
PRECAUTIONS FOR HANDLING REFRIG-
ERANT

• If refrigerant is splashed into eyes or spilled onto skin,

blindness or a cold contact burn may result.

• Refer to the precautions described on the refrigerant

container for handling refrigerant.
• Use a recovery and recycling system to avoid venting
refrigerant into the atmosphere.
• Never allow the skin to directly come in contact with
refrigerant.
SA-405

HANDLE CHEMICAL PRODUCTS SAFELY

• Direct exposure to hazardous chemicals can cause

serious injury. Potentially hazardous chemicals used with
your machine include such items as lubricants,
electrolyte, coolants, paints, and adhesives.

• A Material Safety Data Sheet (MSDS) provides

specific details on chemical products: physical and
health hazards, safety procedures, and emergency
response techniques.
• Check the MSDS before you start any job using a
hazardous chemical. Then follow the correct
procedures and use recommended equipment. SA-309

• See your nearest Hitachi dealer for MSDS.

SA-29
 SAFETY SIGNS
DISPOSE OF WASTE PROPERLY

• Improperly disposing of waste can threaten the

environment and ecology. Potentially harmful waste
used with HITACHI equipment includes such items as oil,
fuel, coolant, brake fluid, filters, and batteries.

• When draining fluid, use a leakproof container with a

capacity larger than the drained fluid volume to
receive it.
• Do not pour waste onto the ground, down a drain, or
into any water source.
• Inquire on the proper way to dispose of harmful waste SA-226
such as oil, fuel, coolant, brake fluid, filters, and
batteries from your local environmental or recycling
center.

BEFORE RETURNING THE MACHINE TO THE

CUSTOMER

• After maintenance or repair work is complete, confirm

that:

• The machine is functioning properly, especially the

safety systems.
• Worn or damaged parts have been repaired or
replaced

SA-435

S517-E01A-0435

SA-30
 SECTION 1 GENERAL INFORMATION
SECTION AND GROUP
CONTENTS Group 1 Precautions for disassembling
and Assembling
Group 2 Tightening Torque
Group 3 Painting
Group 4 Bleeding Air from Hydraulic Oil
Tank
WORKSHOP MANUAL Group 5 Floor-Tilting Device
SECTION 2 UPPERSTRUCTURE
Group 1 Canopy
Group 2 Counterweight
Group 3 Pump Device
Group 4 Control Valve
Group 5 Swing Device
Group 6 Pilot Valve
Group 7 Solenoid Valve
Group 8 Revolution Sensing Valve
Group 9 Auxiliary Flow Selector Valve
(Optional)
SECTION 3 UNDERCARRIAGE
Group 1 Swing Bearing
Group 2 Travel Device
All information, illustrations and speci-
Group 3 Center Joint
fications in this manual are based on
the latest product information available
Group 4 Track Adjuster
at the time of publication. The right is Group 5 Front Idler
reserved to make changes at any time
without notice. Group 6 Upper and Lower Roller
Group 7 Track
SECTION 4 FRONT ATTACHMENT
Group 1 Front Attachment
COPYRIGHT(C)2004
Hitachi Construction Machinery Co., Ltd.
Group 2 Cylinder
Tokyo, Japan
All rights reserved
SECTION 5 ENGINE
TECHNICAL MANUAL
SECTION 1 GENERAL
Group 1 Specification
Group 2 Component Layout
Group 3 Component Specifications
SECTION 2 SYSTEM
Group 1 Control System
Group 2 Hydraulic System
Group 3 Electrical System
SECTION 3 COMPONENT OPERATION
Group 1 Pump Device
Group 2 Revolution Sensing Valve
Group 3 Swing Device
Group 4 Control Valve
Group 5 Pilot Valve
Group 6 Travel Device
Group 7 Others (Upperstructure)
Group 8 Others (Undercarriage)
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 1 Introduction
Group 2 Standard
Group 3 Engine Test
Group 4 Excavator Test
Group 5 Component Test
Group 6 Adjustment
SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure
Group 2 Troubleshooting A
Group 3 Troubleshooting B
Group 4 Troubleshooting C
Group 5 Electrical System Inspection
 SECTION 1
GENERAL INFORMATION

 CONTENTS 
Group 1 Precautions for Disassembling
and Assembling
Precautions for Disassembling and
Assembling........................................... W1-1-1
Maintenance Standard Terminology ........ W1-1-7

Group 2 Tightening
Tightening Torque Specifications .............. W1-2-1
Torque Chart .......................................... W1-2-2
Piping Joint ............................................ W1-2-5
Periodic Replacement of Parts ............. W1-2-10

Group 3 Painting
Painting .................................................. W1-3-1

Group 4 Bleeding Air

Bleed Air from Hydraulic Oil Tank ........... W1-4-1

Group 5 Floor-Tilting Device

Floor-Tilting Device Operetion
Procedure............................................. W1-5-1
Procedure for Floor Tilting up ................. W1-5-2
Procedure for Floor Tilting down ............. W1-5-4

1M9W-1-1
(Blank)

1M9W-1-2
 GENERAL / Precautions for Disassembling and Assembling
PRECAUTIONS FOR DISASSEMBLING
AND ASSEMBLING
Precautions for Disassembling and Assembling
• Clean the Machine
Thoroughly wash the machine before bringing it into
the shop. Bringing a dirty machine into the shop
may cause machine components to be
contaminated during disassembling/assembling,
resulting in damage to machine components, as
well as decreased efficiency in service work.
• Inspect the Machine
Be sure to thoroughly understand all
disassem-bling/assembling procedures beforehand,
to help avoid incorrect disassembling of
components as well as personal injury.
Check and record the items listed below to prevent
problems from occurring in the future.
• The machine model, machine serial number, and
hour meter reading.
• Reason for disassembly (symptoms, failed parts,
and causes).
• Clogging of filters and oil, water or air leaks, if
any.
• Capacities and condition of lubricants.
• Loose or damaged parts.
• Prepare and Clean Tools and Disassembly Area
Prepare the necessary tools to be used and the
area for disassembling work.
W1-1-1
• Precautions for Disassembling
• To prevent dirt from entering, cap or plug the
removed pipes.
• Before disassembling, clean the exterior of the
components and place on a work bench.
• Before disassembling, drain gear oil from the
reduction gear.
• Be sure to provide appropriate containers for
draining fluids.
• Use matching marks for easier reassembling.
• Be sure to use the specified special tools, when
instructed.
• If a part or component cannot be removed after
removing its securing nuts and bolts, do not
attempt to remove it forcibly. Find the cause(s),
then take the appropriate measures to remove it.
• Orderly arrange disassembled parts. Mark and
tag them as necessary.
• Store common parts, such as bolts and nuts with
reference to where they are to be used and in a
manner that will prevent loss.
• Inspect the contact or sliding surfaces of
disassembled parts for abnormal wear, sticking,
or other damage.
• Measure and record the degree of wear and
clearances.
 GENERAL / Precautions for Disassembling and Assembling
• Precautions for Assembling
• Be sure to clean all parts and inspect them for
any damage. If any damage is found, repair or
replace part.
• Dirt or debris on the contact or sliding surfaces
may shorten the service life of the machine. Take
care not to contaminate any contact or sliding
surfaces.
• Be sure to replace O-rings, backup rings, and oil
seals with new ones once they are disassembled.
Apply a film of grease before installing.
• Be sure that liquid-gasket-applied surfaces are
clean and dry.
• If an anti-corrosive agent has been used on a
new part, be sure to thoroughly clean the part to
remove the agent.
• Utilize matching marks when assembling.
• Be sure to use the designated tools to assemble
bearings, bushings and oil seals.
• Keep a record of the number of tools used for
disassembly/assembly. After assembling is
complete, count the number of tools, so as to
make sure that no forgotten tools remain in the
assembled machine.
W1-1-2
Bleeding Air from Hydraulic System
When hydraulic oil is drained, the suction filter or the
suction lines are replaced, or the removal and instal-
lation of the pump, swing motor, travel motor or cyl-
inder is done, bleed air from the hydraulic system in
the following procedures:
IMPORTANT: If the engine is started with air
trapped in the hydraulic pump hous-
ing, damage to the pump may result.
If the hydraulic motor is operated
with air trapped in the hydraulic
motor housing, damage to the motor
may result.
If the cylinder is operated with air
trapped in the cylinder tube, damage
to the cylinder may result.
Be sure to bleed air before starting
the engine.
• Bleeding Air from Hydraulic Pump
• Remove the air bleeding plug from the top of the
pump and fill the pump housing with hydraulic oil.
• After the pump housing is filled with hydraulic oil,
temporarily tighten the plug. Then, start the en-
gine and run at slow idle speed.
• Slightly loosen the plug to bleed air from the
pump housing until hydraulic oil oozes out.
• After bleeding all the air, securely tighten the plug.
• Bleeding Air from Travel Motor / Swing Motor
• With the drain plug / hose on travel motor / swing
motor removed, fill the motor case with hydraulic
oil.
 GENERAL / Precautions for Disassembling and Assembling
• Bleeding Air from Hydraulic Circuit

• After refilling hydraulic oil, start the engine. While

operating each cylinder, swing motor and travel
motor evenly, operate the machine under light
loads for 10 to 15 minutes. Slowly start each op-
eration (never fully stroke the cylinders during ini-
tial operation stage). As the pilot oil circuit has an
air bleed device, air trapped in the pilot oil circuit
will be bled while performing the above operation
for approx. 5 minutes.
• Reposition the front attachment to check hydrau-
lic oil level.
M1M7-05-024
• Stop the engine. Recheck hydraulic oil level. Re-
plenish oil as necessary.

W1-1-3
 GENERAL / Precautions for Disassembling and Assembling
Floating Seal Precautions A

1. In general, replace the floating seal with a new

one after disassembling.
If the floating seal is to be reused, follow these
procedures:

(1) Keep seal rings together as a matched set with

seal ring faces together. Insert a piece of
cardboard to protect surfaces.
B W105-03-05-019
(2) Check the slide surface on seal ring (A) for
scuffing, scoring, corrosion, deformation or
uneven wear.

(3) Check O-ring (B) for tears, breaks,

deformation or hardening.

2. If incorrectly assembled, oil leakage or damage

will occur. Be sure to do the following, to prevent
trouble.

(1) Clean the floating seal and seal mounting

Correct
bores with cleaning solvent.
Use a wire brush to remove mud, rust or dirt.
After cleaning, thoroughly dry parts with
Incorrect
compressed air.

(2) Clean the floating seal and seal mounting

bores. Check the bore surface for scuffing or
scoring by touching the surface with touch.

(3) Check that the O-ring is not twisted, and that it W105-03-05-020

is installed correctly on the seal ring. Correct D Incorrect

a a
(4) After installing the floating seal, check that seal
ring surface (A) is parallel with seal mating C
face (C) by measuring the distances (A) and
(C) at point (a) and (b), as illustrated. If these
distances differ, correct the O-ring seating.

b b

a=b a≠b

W110-03-05-004

W1-1-4
 GENERAL / Precautions for Disassembling and Assembling
Precautions for Using Nylon Sling

1. Follow the precautions below to use nylon slings

safely.
• Attach protectors (soft material) on the corners of
Correct Eyehole
the load so that the nylon sling does not directly Lifting Method
contact the corners. This will prevent the nylon
sling from being damaged and the lifted load from
slipping.
• Lower the temperature of the lifted load to lower
than 100 °C (212 °F). If unavoidably lifting a load
with a temperature of 100 °C (212 °F) or more,
reduce the load weight.
• Do not lift acid or alkali chemicals.
• Take care not to allow the sling to become wet.
The load may slip.
• When required to use more than one sling, use
slings with the same width and length to keep the W102-04-02-016

lifted load balanced. Incorrect Eyehole

• When lifting a load using an eyehole, be sure to Lifting Method
eliminate any gaps between the sling and load.
(Refer to the right illustration.) Reduce the load
weight so that it is less than 80 % of the sling
breaking force.
• Avoid using twisted, bound, connected, or hitched
slings.
• Do not place any object on twisted or bent slings.
(Refer to the right illustration.)
• When removing the slings from under the load,
take care not to damage the nylon slings. Avoid
contact with protrusions.
• Avoid dragging slings on the ground, throwing W105-04-01-008
slings or pushing slings with a metal object.
• When using with other types of slings (wire rope)
or accessories (shackle), protect the joint so that
the nylon sling is not damaged.
• Store the nylon slings indoors so they won’t dete-
riorate with heat, sun light, or chemicals.

Bent Sling W162-01-01-009

W1-1-5
 GENERAL / Precautions for Disassembling and Assembling

Damaged Appearance
CAUTION: If a load is lifted with a damaged Broken Sewing Thread
nylon sling, serious personal injury may re-
sult. Be sure to visually check the nylon sling
for any damage before using.

W162-01-01-002
Scuffing
2. Before using a nylon sling, visually check the ny-
lon sling for any damage corresponding to exam-
ples shown to the right. If any damage is found,
cut and discard the sling. Even if no damage is
found, do not use slings older than 7-years. W162-01-01-003

Fuzz

Broken Sewing
Thread

W162-01-01-004

Broken Sewing
Thread

W162-01-01-005
Broken Sewing
Thread

Scoring Separation of W162-01-01-006

Belt

W162-01-01-007
Fuzz Scuffing
Broken Warp

W162-01-01-008

W1-1-6
 GENERAL / Precautions for Disassembling and Assembling
MAINTENANCE STANDARD TERMINOL-
OGY
“Standard”
1. Dimension for parts on a new machine.

2. Dimension of new components or assemblies

adjusted to specification.

“Allowable Limit”
1. Normal machine performance cannot be accom-
plished after exceeding this limit.

2. Repair or adjustment is impossible after exceed-

ing this limit.

3. Therefore, in consideration of operation efficiency

and maintenance expense, proper maintenance
shall be carried out before reaching the “Allow-
able Limit”.

W1-1-7
 GENERAL / Precautions for Disassembling and Assembling
(Blank)

W1-1-8
 GENERAL INFORMATION / Tightening
TIGHTENING TORQUE SPECIFICATIONS

Bolt Dia. Wrench Size Torque

No. Descriptions Q’ty
mm mm N⋅m (kgf⋅m) (lbf⋅ft)
1. Engine cushion rubber mounting bolt 12 4 19 88 (9) (65)
2. Engine bracket mounting bolt (Front) 10 8 17 49 (5) (36)
3. Hydraulic oil tank mounting bolt 12 4 19 88 (9) (65)
4. Fuel tank mounting nut 10 3 17 20 (2) (15)
7/16-20UNF 17 24.5 (2.5) (18)
19 29.5 (3) (22)
Metal face seal 9/16-18UNF
22 39 (4) (29)
Union joints fitting for hydraulic
3/4-16UNF 27 93 (9.5) (69)
for hydraulic hoses and piping
5. 1-1/16-12UNF 36 175 (18) (129)
hoses and
pipes 1-5/16-12UNF 41 205 (21) (151)
9/16 UNF 19 44 (4.5) (32)
ORS 11/16 UNF 22 74 (7.5) (55)
13/16 UNF 27 103 (10.5) (76)
6. Pump mounting bolt 12 2 10 (Socket) 88 (9) (65)
7. Pump cover mounting bolt 10 8 17 49 (5) (36)
Control valve mounting bolt 10 4 17 49 (5) (36)
8.
Control valve base mounting bolt 10 4 17 49 (5) (36)
9. Swing device mounting bolt 16 8 24 205 (21) (101)
10. Battery mounting nut 6 2 10 5 (0.5) (3.5)
12 5 19 88 (9) (65)
11. Canopy mounting bolt
10 5 17 49 (5) (36)
12 5 19 88 (9) (65)
12. Cab mounting bolt
10 5 17 49 (5) (36)
Swing bearing Upperstructure 12 27 19 108 (11) (80)
13.
mounting bolt Undercarriage 12 24 19 108 (11) (80)
14. Travel device mounting bolt 14 24 22 175 (18) (130)
15. Sprocket mounting bolt 14 24 22 175 (18) (130)
16. Upper roller mounting bolt 16 2 24 231 (23.5) (170)
17. Lower roller mounting bolt 14 16 22 177 (18) (130)
6 10 5 (0.5) (3.5)
18. Cover mounting bolt 8 13 9.8 (1) (7)
10 17 49 (5) (36)
19. Counterweight mounting bolt 24 3 36 930 (95) (398)
10 17 49 (5) (36)
12 19 88 (9) (65)
20. Front pin lock plate bolts 14 22 137 (14) (101)
16 24 205 (21) (152)
18 27 390 (40) (290)
21. Side-cutter mounting bolts 14 6 22 175 (18) (130)
22 Track roller guard mounting bolt 16 12 24 265 (27) (196)

NOTE: (1) Apply lubricant (i.e. white zinc B

dissolved into spindle oil) to reduce
their friction coefficients.
(2) Remove rust, dirt, and dust before
installing fasteners.

W1-2-1
 GENERAL INFORMATION / Tightening
TORQUE CHART

CAUTION: Use tools appropriate for the

work to be done. Makeshift tools and
procedures can create safety hazards. For
loosening and tightening nuts and bolts, use
correct size tools. Otherwise, tightening
tools may slip, potentially causing personal
injury.

Bolt Types

Tighten nuts or bolts correctly to torque specifications.

Four different types and grades of bolt are employed. SA-040

Make sure to employ correct bolts and tighten them

correctly when assembling the machine or
components.

Hexagon T Bolt Hexagon H Bolt Hexagon M Bolt Socket Bolt

W162-01-01-001

Specified Tightening Torque Chart

Hexagon
Wrench
Bolt Dia. Wrench
Size
Size M552-07-091 M552-07-090 M157-07-225
Socket Bolt
Nxm (kgfxm) (lbfxft) Nxm (kgfxm) (lbfxft) Nxm (kgfxm) (lbfxft)
M8 13 6 30 (3.1) (22) 20 (2.0) (15.0) 10 (1.0) (7.4)
M10 17 8 65 (6.6) (48) 50 (5.1) (37) 20 (2.0) (15.0)
M12 19 10 110 (11.0) (81) 90 (9.2) (66) 35 (3.6) (26.0)
M14 22 12 180 (18.5) (135) 140 (14.0) (103) 55 (5.6) (41)
M16 24 14 270 (27.5) (200) 210 (21.5) (155) 80 (8.2) (59)
M18 27 14 400 (41.0) (295) 300 (30.5) (220) 120 (12.0) (89)
M20 30 17 550 (56.0) (410) 400 (41.0) (295) 170 (17.0) (125)
M22 32 17 750 (76.5) (550) 550 (56.0) (410) 220 (22.5) (162)
M24 36 19 950 (97.0) (700) 700 (71.5) (520) 280 (28.5) (205)
M27 41 19 1400 (143) (1030) 1050 (107) (770) 400 (41.0) (295)
M30 46 22 1950 (200) (1440) 1450 (148) (1070) 550 (56.0) (410)
M33 50 24 2600 (265) (1920) 1950 (200) (1440) 750 (76.5) (550)
M36 55 27 3200 (325) (2360) 2450 (250) (1810) 950 (97.0) (700)

W1-2-2
 GENERAL INFORMATION / Tightening
IMPORTANT: The following items are applied to
both fine and coarse pitch threads.
1. Apply lubricant (i. e. white zinc B
dissolved Into Spindle oil) to
nuts and bolts to reduce their
friction coefficients.
The plated bolts require no
lubricant.
2. Torque tolerance is ±10 %.
3. Be sure to use bolts of correct
length. Bolts that are too long
cannot be tightened, as the bolt
tip comes into contact with the
bottom of the bolt hole. Bolts
that are too short cannot develop
sufficient tightening force.
4. The torques given in the chart
are for general use only. Do not
use these torques if a different
torque is given for a specific
application.
5. Make sure that nut and bolt
threads are clean before
installing.
Remove dirt or corrosion, if any.

Bolt Tightening Order

When tightening two or more bolts, tighten them

alternately, as shown, to ensure even tightening.

Tighten from center and diagonally

Equally tighten upper and lower Tighten

1 12 9 4 1 6 7 14
6 3
1st to 4th

4 5
2 13 8 5 2 3 10 11

2nd to 3rd
W105-01-01-003

W1-2-3
 GENERAL INFORMATION / Tightening
Service Recommendations for Split Flange

IMPORTANT: 1. Be sure to clean and inspect

sealing surfaces. Scratches /
roughness cause leaks and seal
wear.
Unevenness causes seal
extrusion. If defects cannot be
polished out, replace the
component. W105-01-01-015

2. Be sure to use only specified WRONG

O-rings. Inspect O-rings for any
damage. Take care not to file
O-ring surfaces. When installing
an O-ring into a groove, use
grease to hold it in place.
3. While lightly tightening split
flange halves, check that split is
centered and perpendicular to W105-01-01-016
the port. Hand-tighten bolts to
hold parts in place. Take care not
to pinch the O-ring.
4. Tighten bolts alternately and
diagonally, as shown, to ensure
even tightening.
5. Do not use air wrenches. Using
an air wrench often causes W105-01-01-008

tightening of one bolt fully before RIGHT WRONG

tightening of the others, resulting
in damage to O-rings or uneven
tightening of bolts.

Bend along edge sharply Do not bend it round

Nut and Bolt Locking

RIGHT RIGHT WRONG
• Lock Plate
IMPORTANT: Do not reuse lock plates. Do not try
to bend the same point twice.

• Cotter Pin
IMPORTANT: Do not reuse cotter pins. Match the
holes in the bolt and nut while Bend along edge sharply
tightening, not while loosening. W105-01-01-009

RIGHT RIGHT WRONG

• Lock Wire
IMPORTANT: Apply wire to bolts in the
bolt-tightening direction, not in the
bolt-loosening direction.

Loosen WRONG
RIGHT

Tighten

W105-01-01-010

W1-2-4
 GENERAL INFORMATION / Tightening
PIPING JOINT
IMPORTANT: The torques given in the chart are
for general use only.
Do not use these torques if a
different torque is given for a
specific application.

Union Joint 1 4 3 5 2

Metal sealing surfaces (4) and (5) of adaptor (1) and

hose (2) fit together to seal pressure oil. Union joints
are used to join small-diameter lines.

IMPORTANT: 1. Do not over-tighten nut (3).

M202-07-051
Excessive force will be applied to Joint Body
metal sealing surfaces (4) and (5),
possibly cracking adaptor (1). Be
sure to tighten nut (3) to 37°
specifications.
30°
2. Scratches or other damage to
sealing surfaces (4) or (5) will
cause oil leakage at the joint.
Take care not to damage them Male Union Joint Female Union Joint
when connecting/disconnecting.
W105-01-01-017

Wrench Size Wrench Size Tightening Torque

Description mm mm
Union Nut Hose Fittings N⋅m (kgf⋅m, lbf⋅ft)
30°male 17 17 24.5 (2.5,18)
19 19 29.5 (3.0,22)
22 22 39 (4.0,28.5)
27 27 64 (6.5,47)
32 32 137 (14,101)
36 36 175 (18,129)
41 41 205 (21,151)
37°female 17 14 24.5 (2.5,18)
19 17 29.5 (3.0,22)
22 19 39 (4.0,28.5)
27 22 64 (6.5,47)
32 27 137 (14,101)
36 32 175 (18,129)
41 36 205 (21,151)
NOTE: Tightening torque of 37°male coupling without union is similar
to tightening torque of 37°female.

W1-2-5
 GENERAL INFORMATION / Tightening
Piping Joint

Pipe Joint (Metal Joint) 1 4 5 3 2

(Union Nut Wrench size 17 mm)

Metal sealing surfaces (3) (Metal) of pipe (2) and

adapter (1) seal pressure oil.

Take care not damage sealing surfaces when

connecting / disconnecting pipe. M1M7-07-005

Tightening Torque Chart

Wrench Size (mm) 17
N⋅m 39
Tightening
(kgf⋅m) (4.0)
Torque
(lbf⋅ft) (29)

7 6 9
O-ring Seal Joint

O-ring (6) seats against the end face of adaptor (7) to

seal pressure oil.

IMPORTANT: 1. Be sure to replace O-ring (6) with

a new one when reconnecting.
Hose Fittings
2. Before tightening nut (9), confirm 8 10 M104-07-033
that O-ring (6) is seated correctly
in O-ring groove (8). Tightening
nut (9) with O-ring (6) displaced
will damage O-ring (6), resulting Wrench Size Wrench Size Tightening Torque
in oil leakage. mm mm
3. Take care not to damage O-ring Union Nut Hose Fittings N⋅m (kgf⋅m, lbf⋅ft)
groove (8) or sealing surface
19 17 29.5 (3.0,22)
(10).
22 19 69 (7.0,51)
Damage to O-ring (6) will cause
27 22 93 (9.5,69)
oil leakage.
32 27 137 (14,101)
4. If nut (9) is loose and oil is
36 30,32 175 (18,129)
leaking, do not re-tighten nut (9).
41 36 205 (21,151)
Replace O-ring (6) with a new
46 41 205 (21,151)
one and check that O-ring (6) is
correctly seated in place, tighten
nut (9).

W1-2-6
 GENERAL INFORMATION / Tightening
Quick Coupler

1. Connection Procedure
3 1
• While pulling and fully turning socket ring (1)
counterclockwise, insert socket ring (1) onto plug
(3) until the end face of socket ring (1) comes in
contact with plug (3).
• Release socket ring (1). Check that socket ring
(1) is slightly move backward by the spring force
and the coupler is held in position with balls (2). M1M7-07-006
Be sure to check that socket ring (1) has been 2
moved back fully to the right original position.

2. Disconnection Procedure

• While pulling and fully turning socket ring (1)

counterclockwise, disconnect the coupler. As no
check valve is provided in the coupler, take care
that oil may flow out of the coupler when the
coupler is disconnected.
• After the coupler is disconnected, plug the holes
with the exclusively prepared plugs.

CAUTION: Take care not to damage the joint

surfaces when disconnecting or connecting
the coupler.

Before disconnecting or connecting the

coupler, clean the coupler and its
surroundings with a cleaning solvent and
completely wipe off the cleaning solvent. Use
extra care not to allow foreign matter such as
dirt to enter the coupler.

Disconnect or connect the coupler in the

correct procedure. Sufficiently check that no
oil leak is present after connecting the
coupler.

After connecting the coupler, check that that

socket ring (1) has been moved back fully to
the right original position.

W1-2-7
 GENERAL INFORMATION / Tightening
Screw-In Connection
PT PF
Depending on types of screw and sealing, different 30°
types of screw fittings are used.

IMPORTANT: Be sure to confirm that the thread

pitch and thread type (tapered or
straight) are the correct type before Male Tapered Thread Male Straight Thread
using any screw-in connection.
W105-01-01-018

Male Tapered Thread

Wrench Size Tightening Torque
mm N⋅m (kgf⋅m, lbf⋅ft)
Hose Fittings FC material SS material
19 14.5 (1.5,10.5) 34 (3.5,25)
22 29.5 (3.0,21.5) 49 (5.0,36)
27 49 (5.0,36) 93 (9.5,69)
36 69 (7.0,51) 157 (16,116)
41 108 (11,80) 205 (21,151)
50 157 (16,116) 320 (33,235)
60 195 (20,144)
Seal Tape Application
Internal Thread
Seal tape is used to seal clearances between male
and female threads, so as to prevent any leaks
between threads.
Be sure to apply just enough seal tape to fill up thread External Thread
Clearance
clearances. Do not overwrap.

• Application Procedure W105-01-01-019

Leave one to two pitch threads uncovered

Confirm that the thread surface is clean and, free of
dirt or damage.
Apply seal tape around threads as shown. Wrap seal
tape in the same direction as the threads.

Low-Pressure-Hose Clamp Tightening Torque

Low-pressure-hose clamp tightening torque differs

depending on the type of clamp. M114-07-041
T-Bolt Type Band Clamp:
4.4 N⋅m (0.45 kgf⋅m, 3.25 lbf⋅ft)
T-Bolt Type Worm Gear Type
Worm Gear Type Band Clamp:
5.9 to 6.9 N⋅m (0.6 to 0.7 kgf⋅m, 4.3 to 5.1 lbf⋅ft)

M114-07-043 M114-07-042

W1-2-8
 GENERAL INFORMATION / Tightening
Connecting Hose
WRONG RIGHT
CAUTION: When replacing hoses, be sure to
use only genuine Hitachi service parts. Using
hoses other than genuine Hitachi hoses may
cause oil leaks, hose rupture or Separation of
fitting, possibly resulting in a fire on the
machine.
W105-01-01-011
Do not install hoses kinked. Application of
high oil pressure, vibration, or an impact to a
kinked hose may result in oil leaks, hose RIGHT
WRONG
rupture or separation of fitting. Utilize Print
Rubbing Against
marks on hoses when installing to prevent Each Other
hose from being kinked.

If hoses rub against each other, wear to the

hoses will result, leading to hose rupture.
Take necessary measures to protect hoses
W105-01-01-012
from rubbing against each other.
WRONG RIGHT
Take care so that hoses do not come into Clamp Clamp
contact with moving parts or sharp objects.

Rubbing Against
Each Other

W105-01-01-013

WRONG RIGHT

Rubbing Against
Each Other Clamp
W105-01-01-014

W1-2-9
 GENERAL INFORMATION / Tightening
PERIODIC REPLACEMENT OF PARTS
To ensure safe operation, be sure to conduct periodic
inspection of the machine. In addition, the parts listed
below, if defective, may pose serious safety/fire
hazards. It is very difficult to gauge the extent of
deterioration, fatigue, or weakening of the parts listed
below simply by visual inspection alone. For this
reason, replace these parts at the intervals shown in
the table below. However, if any of these parts are
found to be defective, replace before starting
operation, regardless of the interval.
Also, when replacing hoses, check the clamps for
deformation, cracks, or other deterioration, and
replace if necessary.
Be sure to perform periodic inspection of all hoses, as
shown below, and replace or retighten any defective
parts found, if necessary.
Consult your authorized dealer for correct
replacement.

Periodic Replacement Parts Replacement Interval

Fuel hose (Fuel tank to filter) Every 2 years or 4000 hours
Fuel hose (Fuel tank to injection pump) Every 2 years or 4000 hours
Heater hose (Heater to engine) Every 2 years or 4000 hours
Engine
Engine rubber vibration insulator Every 5 years or 5000 hours
Floor mount rubber Every 5 years or 5000 hours
Pump coupling Every 5 years or 5000 hours
Pump suction hose Every 2 years or 4000 hours
Pump delivery hose Every 2 years or 4000 hours
Base Machine Swing hose Every 2 years or 4000 hours
Auxiliary hose Every 2 years or 4000 hours
Hydraulic
Oil cooler hose (C/V to oil cooler) Every 2 years or 4000 hours
System
Boom cylinder line hose Every 2 years or 4000 hours
Arm cylinder line hose Every 2 years or 4000 hours
Front Attachment
Bucket cylinder line hose Every 2 years or 4000 hours
Pilot hose Every 2 years or 4000 hours

NOTE: Be sure to replace seals, such as O-rings

and gaskets, when replacing hoses.

W1-2-10
 GENERAL / Painting
PAINTING
Section Surfaces to Be Painted Painting Color
• Upperstructure Outer cover (Right, Left, Rear and Top) YR1-01 [TAXI yellow]
Skirt (Front, Right and Left) SP-424 [Dark gray]
Main frame SP-424 [Dark gray]
Inside (Oil, Fuel tank) SP-424 [Dark gray]
Canopy (Pole) SP-424 [Dark gray]
Stay ( Left) Black
Lever (Travel, Blade) N-10 [N1.0]
Pedal (Travel, Boom swing) SP-424 [Dark gray]
Floor plate, Seat base SP-424 [Dark gray]
Console (Right, Left) SP-424 [Dark gray]
Counterweight SP-424 [Dark gray]
• Undercarriage Track frame (Including idler, upper and SP-424 [Dark gray]
lower roller)
Swing bearing Black
Blade (Including cylinder) SP-424 [Dark gray]
• Front attachment Boom, Arm, Bucket and Link YR1-01 [TAXI yellow]
(Including cylinder)
Swing post (Including cylinder) SP-424 [Dark gray]

Dark Gray

Cab Type
Dark Gray

Black
TAXI Yellow
Dark Gray

Dark Gray
Dark
Gray

W1M9-01-03-001

Black TAXI Yellow Dark Gray Dark Gray TAXI Yellow

W1-3-1
 GENERAL / Painting
(Blank)

W1-3-2
 GENERAL / Bleeding Air
BLEED AIR FROM HYDRAULIC OIL TANK

CAUTION: Escaping fluid under pressure

may penetrate the skin and eyes, and cause
serious injury. Release the pressure before
removing hydraulic or other lines.
Hot hydraulic oil just after operation may
spout and cause severe burns. Wait for oil in
order to cool before starting any work.
Do not turn the cap on hydraulic oil tank
quickly. The cap may fly off by internal
pressure. Release any remaining pressure
and remove the cap.

Preparation

1. Park the machine on a solid, level surface. Lower

the front attachment onto the ground.

2. Stop the engine. Loosen cap (1) on hydraulic oil

tank (2) and release any remaining pressure. M1M7-05-024

3. Remove cap (1) on hydraulic oil tank (2). 1

2
4. Install a vacuum pump to the hole without cap (1).
Operate the vacuum pump and maintain negative
pressure in the hydraulic oil tank.
Run the vacuum pump continuously while
working.
W1M9-01-04-001

Vacuum Pump

Hose

Adapter

W1M9-01-04-002

W1-4-1
 GENERAL / Bleeding Air
(Blank)

W1-4-2
 GENERAL / Floor-Tilting Device
FLOOR-TILTING DEVICE OPERATION
PROCEDURE

Preparation
• Park the machine in a flat and solid place.
• Lower the blade.
• Roll-in the arm and bucket, and put them on the
front wooden block or something.

CAUTION: Be careful because interference

of the boom and canopy (cab) takes place
unless the front end attachment is lowered in
advance.
M1M7-07-060

• Close the door of the cab (optional).

W1-5-1
 GENERAL / Floor-Tilting Device
PROCEDURE FOR FLOOR TILTING UP

CAUTION: If tilting up operation is made with 1

the door open, it interferes with the cover (3).

1. Remove two bolts (2), and remove (3) from the

canopy or cab (1).
: 17 mm
2

IMPORTANT: Near bolts (4), two bolts for fixing the 3

canopy or cab (1) are fitted. Never
4 M1M7-07-061
remove these two bolts in tilting up 4-Pillar Canopy
operation.
A bolt never to be removed can be
identified by the attached cap or red 1
paint.

2. Remove three bolts (4) from the canopy or cab

(1).
: 19 mm

Not to be
removed 4 M1M7-07-063

2-Pillar Canopy

Not to be M1M7-07-062

Cab removed 4

M1M7-07-064

Not to be
removed

W1-5-2
 GENERAL / Floor-Tilting Device
IMPORTANT: The operating torque of adjuster
screw (5) is 24.5 N⋅m (2.5 kgf⋅m) or
lower. In case larger torque is
required, it is probable that bolts (4)
remain unremoved. Re-check from
this perspective.

3. Turn adjuster screw (5). Tilt the canopy or cab (1)

assembly toward front.
5
: 17 mm

4. Turn adjuster screw (5) clockwise until disc (6) on

the side face of the tilting device moves to the
M1M7-07-065
farthest end.
2-Pillar / 4-Pillar Canopy

M1M7-07-066

CAUTION: Do not tilt up cab (1) as far as the Cab

striped region. If done so, cab (1) tilts forward
because the center of gravity overhangs the
balancing point, which is dangerous.

5. In cab (1) version machines, stop tilting up 50 mm

before the farthest end [before the striped region
6
(6)].

50 mm

W1M9-01-05-001

IMPORTANT: Do not make tilting up operation by

other means (e.g. by crane) than the
Support
tilting device. The tilting device or
floor could be damaged otherwise.
6. In case of work done lying under the floor, put a
support at the opening space of the raised floor for
security.

M1M7-07-067

W1-5-3
 GENERAL / Floor-Tilting Device
PROCEDURE FOR FLOOR TILTING DOWN

CAUTION: Do not lower the floor abruptly. If

adjuster screw (5) is rotated abruptly in
lowering the floor, the floor trembles
enormously, which is dangerous.

1. Slowly turn adjuster screw (5) anticlockwise.

8
: 17 mm
9
2. Turn adjuster screw (5) counterclockwise until the
farthest end contacts receiver seat (7). 7

CAUTION: After the floor has been lowered 5 M1M7-07-068

completely, if adjuster screw (5) is kept
turned, it will not be turned any longer when 10 11
unscrewed by about 15 mm because washer
(10) touches pin (11). Be careful not to turn
adjuster screw (5) further because washer
(10) deforms and gets damaged, causing fall
of bolt (12).
12
3. When the floor has been lowered completely,
adjuster screw (5) is drawn. Make adjustment so
that the clearance between collar (8) of adjuster
screw (5) and contact face (9) becomes 2 to 5
mm. W1M9-01-05-002

W1-5-4
 GENERAL / Floor-Tilting Device
4. Install the canopy or cab (1) with three bolts (4). 2-Pillar Canopy
4
: 19 mm
: 90 N⋅m (9.2 kgf⋅m)

M1M7-07-063

4
4-Pillar Canopy

M1M7-07-062

Cab 4

M1M7-07-064

W1-5-5
 GENERAL / Floor-Tilting Device
(Blank)

W1-5-6
 MEMO

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 MEMO

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UPPERSTRUCTURE
 CONTENTS 
Group 1 Canopy
Remove and Install Canopy.................... W2-1-1
Group 2 Counterweight
Remove and Install Counterweight ......... W2-2-1
Group 3 Pump Device
Remove and Install Pump Device ........... W2-3-1
Disassemble Pump Device ................... W2-3-4
Assemble Pump Device ......................... W2-3-6
Maintenance Standard.......................... W2-3-10
Group 4 Control Valve
Remove and Install Control Valve ........... W2-4-1
Disassemble And Assemble
Control Valve ...................................... W2-4-6
Remove and Install Relief Valve
and Make-up Valve ........................... W2-4-12
Disassemble and Assemble Body ....... W2-4-14
Disassemble Unload Section ................ W2-4-16
Assemble Unload Section..................... W2-4-18
Disassemble and Assemble Spool ........ W2-4-20
Disassemble and Assemble
Boom Anti-Drift Valve ........................ W2-4-22
Disassemble and Assemble Shuttle Valve and
Pressure Compensation Valve .......... W2-4-24
Group 5 Swing Device
Remove and Install Swing Device........... W2-5-1
Disassemble Swing Device .................... W2-5-6
Assemble Swing Device ......................... W2-5-8
Disassemble Swing Motor .................... W2-5-14
Assemble Swing Motor ......................... W2-5-16
Maintenance Standards ........................ W2-5-20
1M9W-2-1
SECTION 2
Group 6 Pilot Valve
Remove and Install Front Pilot Valve ...... W2-6-1
Remove and Install Travel Pilot Valve ..... W2-6-3
Remove and Install Blade Pilot Valve...... W2-6-7
Remove and Install
Boom Swing Pilot Valve ...................... W2-6-9
Disassemble Front Pilot Valve .............. W2-6-12
Assemble Front Pilot Valve ................... W2-6-16
Disassemble Travel Pilot Valve ............. W2-6-20
Assemble Travel Pilot Valve ................. W2-6-24
Disassemble Pilot Valves for Boom Swing,
Blade and Auxiliary............................ W2-6-30
Assemble Pilot Valves for Boom Swing,
Blade and Auxiliary............................ W2-6-32
Group 7 Solenoid Valve
Remove and Install
2-Unit Solenoid Valve .......................... W2-7-1
Disassemble 2-Unit Solenoid Valve ........ W2-7-6
Assemble 2-Unit Solenoid Valve ............. W2-7-8
Remove and Install
1-Unit Solenoid Valve ........................ W2-7-10
Structure of 1-Unit Solenoid Valve ...... W2-7-12
Group 8 Revolution Sensing Valve
Remove and Install
Revolution Sensing Valve.................... W2-8-1
Disassemble Revolution Sensing Valve .. W2-8-4
Assemble Revolution Sensing Valve ....... W2-8-6
Group 9 Auxiliry Flow Selector Valve
(Optional)
Remove and Install
Auxiliary Flow Selector Valve .............. W2-9-1
Disassemble Auxiliary
Flow Selector Valve............................. W2-9-4
Assemble Auxiliary
Flow Selector Valve............................. W2-9-6
(Blank)

1M9W-2-2
 UPPERSTRUCTURE / Canopy
REMOVE AND INSTALL CANOPY
Removal 1

1. Attach a nylon sling onto the center of canopy (1).

W1M9-02-07-001

2. Remove bolts (2) (3 used) from canopy (1). 1

: 19 mm

W1M9-02-01-002

1 3, 4
CAUTION: Canopy (1) weight: 63 kg (140 lb)

3. Remove bolts (3) (3 used) and spacers (4) (3

used) from canopy (1). Hoist and remove canopy
(1) from main frame (5).
: 17 mm

W1M9-02-01-001
5

W2-1-1
 UPPERSTRUCTURE / Canopy
Installation

1
CAUTION: Canopy (1) weight: 63 kg (140 lb)

1. Hoist and align canopy (1) with the mounting hole

on main frame (5).

W1M9-02-07-001
5

2. Install canopy (1) onto main frame (5) with bolts

(3) (3 used) and spacers (4) (3 used). 1 3, 4
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)

W1M9-02-01-001
5

3. Install canopy (1) onto main frame (5) with bolts

(2) (3 used). 1
: 19 mm
: 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft)

W1M9-02-01-002

W2-1-2
 UPPERSTRUCTURE / Counterweight
REMOVE AND INSTALL COUNTERWEIGHT
1 2
Removal

CAUTION: Counterweight (2) weight:

ZAXIS40U-2: 351 kg (780 lb)
ZAXIS50U-2: 675 kg (1490 lb)
4
1. Remove bolts (2) (3 used) from canopy (1).
: 19 mm
3
2. Remove bolts (4) (3 used). Remove cover (5) from
counterweight (2). 5
: 17 mm
W1M9-02-01-002

3. Remove bolts (6) (2 used). Remove cover (7) from 1 6

main frame (8).
: 17 mm

W1M9-02-01-001
8

4. Turn adjusting screw (9) and lay down the canopy

(1) assembly to the front side.
: 17 mm

Tilt Device

9
W1M9-02-01-003

W2-2-1
 UPPERSTRUCTURE / Counterweight
5. Remove bolts (11) (2 used). Remove cover (10)
from main frame (8).
: 13 mm

6. Remove bolts (12) (4 used). Remove covers (13)

(2 used) from main frame (8). 10, 11
: 17 mm

12

7. Open cover (14).

8. Remove bolts (15) (5 used). Remove covers (16)

(2 used) from main frame (8). 8 12 13 W1M9-02-07-001

: 17 mm

14

9. Install eyebolts (M16, Pitch 2.5 mm) (2 used) to

counterweight (2). Hold counterweight (2).

15 8 16 15 W1M9-02-02-001

Eyebolt
Mounting
Position

W1M9-02-02-003

W2-2-2
 UPPERSTRUCTURE / Counterweight
10. Remove bolts (17) (3 used) from counterweight
(2).
: 36 mm

11. Float counterweight (2) a little and slide backward. 2

Hoist and remove counterweight (2) from main
frame (8).

W1M9-02-02-002

17 8

W2-2-3
 UPPERSTRUCTURE / Counterweight
Installation

CAUTION: Counterweight (2) weight:

2
ZAXIS40U-2: 351 kg (780 lb)
ZAXIS50U-2: 675 kg (1490 lb)

1. Install eyebolts (M16, Pitch 2.5 mm) (2 used) to

counterweight (2) and hoist counterweight (2). Eyebolt
Mounting
Place counterweight (2) onto main frame (8) and Position
slide counterweight (2) forward.

2. Install counterweight (2) to main frame (8) with

bolts (17) (3 used). W1M9-02-02-003

: 36 mm
: 700 N⋅m (71 kgf⋅m, 520 lbf⋅ft)

3. Install covers (16) (2 used) onto main frame (8)

with bolts (15) (5 used). W1M9-02-02-002

: 17 mm 17 8
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)

4. Shut cover (14).

14

15 8 16 15 W1M9-02-02-001

W2-2-4
 UPPERSTRUCTURE / Counterweight
5. Install covers (13) (2 used) onto main frame (8)
with bolts (12) (4 used).
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)

6. Install cover (10) onto main frame (8) with bolts

(11) (2 used). 10, 11
: 13 mm
: 20 N⋅m (2.0 kgf⋅m, 15 lbf⋅ft)
12

7. Turn adjusting screw (9) and lower the canopy (1)

assembly. 8 12 13 W1M9-02-07-001

: 17 mm

8. Install cover (7) onto main frame (8) with bolts (6)
(2 used).
: 17 mm Tilt Device
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)

9
W1M9-02-01-003

W1M9-02-01-001
8

W2-2-5
 UPPERSTRUCTURE / Counterweight
9. Install canopy (1) with bolts (3) (3 used).
: 19 mm 1 2
: 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft)

10. Install cover (5) onto counterweight (2) with bolts

(4) (3 used).
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
4

W1M9-02-01-002

W2-2-6
 UPPERSTRUCTURE / Pump Device
REMOVE AND INSTALL PUMP DEVICE
Removal

CAUTION: Release any pressure in the

hydraulic oil tank before doing any work.
(Refer to BLEED AIR FROM HYDRAULIC OIL
TANK on W1-4-1.)

1. Remove bolts (1) (4 used). Remove covers (2, 3)

from frame (4).
: 17 mm

4 1 3 2
IMPORTANT: Attach an identification tag onto the W1M9-02-07-001

removed hoses for assembling.

2. Remove hoses (9) (5 used) from pump device (6). 5 6
Cap the open ends.
： 19 mm, 22 mm, 36 mm

3. Loosen band (8). Remove rubber hose (7) from

pump device (6).

CAUTION: Pump device (6) weight: 19 kg

7
(42 lb)

4. Remove socket bolts (5) (2 used) from pump

device (6). Hoist and remove pump device (6).
: 10 mm

W1M9-02-03-004
9 8

W2-3-1
 UPPERSTRUCTURE / Pump Device
Installation

CAUTION: Pump device (6) weight: 19 kg 5 6

(42 lb)

1. Install pump device (6) onto the engine flywheel

housing with socket bolts (5) (2 used).
: 10 mm
: 108 N⋅m (11 kgf⋅m, 80 lbf⋅ft)

2. Install hoses (9) (5 used) onto pump device (6).

7
: 19 mm
: 29.5 N⋅m (3.0 kgf⋅m, 22 lbf⋅ft)
: 22 mm
: 39 N⋅m (4.0 kgf⋅m, 29 lbf⋅ft)
: 36 mm
: 175 N⋅m (18 kgf⋅m, 129 lbf⋅ft)

3. Install rubber hose (7) to pump device (6) with

band (8).

4. Install covers (2, 3) to frame (4) with bolts (1) (4 W1M9-02-03-004

used). 9 8
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)

IMPORTANT: Release any pressure in the pump

device. (Refer to W1-1-2.)
After completing the work, check the
hydraulic oil level. Start the engine
and check for any oil leaks.

4 1 3 2 W1M9-02-07-001

W2-3-2
 UPPERSTRUCTURE / Pump Device
(Blank)

W2-3-3
 UPPERSTRUCTURE / Pump Device
DISASSEMBLE PUMP DEVICE
7
29
6
28
27
26
25
24 5
23
22
21 4
20
3
19
2
1
17
16
15
11
10 8
9
18
48
47
46
45 14
13
44
12
42
41
40
39

38

32

31

43 30

36
35
37
34
33
W1M9-02-03-002

1- Retaining Ring 14 - Stopper Pin 27 - Retaining Ring 39 - Body H

2- O-Ring 15 - Control Piston 28 - Valve Plate 40 - Seal Washer
3- Seal Holder 16 - Ceramic Ball (2 Used) 29 - Needle Bearing 41 - Adjusting Screw
4- Oil Seal 17 - Swash Plate 30 - Spring Holder 42 - Nut
5- Shaft 18 - Plunger (11 Used) 31 - Spring 43 - Socket Bolt (7 Used)
6- Ball Bearing 19 - Retainer 32 - Spring Guide 44 - Coupling
7- Retaining Ring 20 - Holder 33 - Control Piston 45 - Collar (2 Used)
8- Plug 21 - Washer 34 - Sleeve 46 - Gear Pump
9- O-Ring 22 - Needle (3 Used) 35 - O-Ring 47 - Washer (4 Used)
10 - Body S 23 - Cylinder Block 36 - Choke 48 - Socket Bolt (4 Used)
11 - Gasket 24 - Washer 37 - LS Valve
12 - Knock Pin (2 Used) 25 - Spring 38 - Knock Pin
13 - Spring 26 - Washer
NOTE: Control piston (15) is not equipped for the
machine with the air conditioner.

W2-3-4
 UPPERSTRUCTURE / Pump Device
Disassemble Pump Device
1. Remove socket bolts (48) (4 used). Remove gear
pump (46) from body H (39).
: 6 mm
2. Remove collars (45) (2 used) from gear pump
(46) and remove coupling (44) from body H (39)
respectively.
IMPORTANT: Do not turn adjusting screw (41) and
nut (42) as the setting of pump flow
rate changes.
3. Remove LS valve (37) from body H (39).
: 24 mm
CAUTION: Use a bolt (M10, Length 60 mm
(2.36 in)) for temporary assembly and remove
body H (39) from body S (10) as spring (31)
may fly off.
4. Remove socket bolts (43) (2 used) on spring (31)
side. Install the bolt (M10, Length 60 mm (2.36
in)) for temporary assembly in the hole.
: 8 mm
5. Remove other socket bolts (43) (5 used).
: 8 mm
6. Loosen and remove the bolts (M10, Length 60
mm (2.36 in)) (2 used) for temporary assembly
from body H (39) alternately.
IMPORTANT: Do not fall off valve plate (28) when
removing body H (39). Do not
remove needle bearing (29) unless
replacing needle bearing (28).
7. Remove body H (39) from body S (10). Remove
gasket (11), knock pins (12) (2 used) and valve
plate (28) in this order.
W2-3-5
8. Remove control piston (33), sleeve (34) and
choke (36) from body H (39).
: 35 mm
9. Remove spring guide (32) from body H (39) and
remove spring (31), spring holder (30) and the
cylinder block (23) assembly from body S (10).
10. Remove plungers (18) (11 used), retainer (19),
holder (20), washer (21) and needles (22) (3
used) from cylinder block (23).
CAUTION: Push spring (25) by using a press
when remove retaining ring (27) as spring
(25) may fly off.
11. Remove retaining ring (27) from cylinder block
(23). Remove washer (26), spring (25) and
washer (24) in this order.
12. Remove swash plate (17) from body S (10).
Remove ceramic balls (16) (2 used). Remove
stopper pin (14), spring (13) and control piston
(15) from body S (10).
IMPORTANT: Do not remove ball bearing (6)
unless replacing ball bearing (6).
13. Remove retaining ring (1) from body S (10). Tap
and remove the body H (39) side on shaft (5)
assembly by using a plastic hammer lightly.
Remove seal holder (3), retaining ring (7) and ball
bearing (6) from shaft (5). Remove oil seal (4) and
O-ring (2) from seal holder (3).
 UPPERSTRUCTURE / Pump Device
ASSEMBLE PUMP DEVICE
7 30 31 20 21 24 25 26 11 27 28 29 32 40
42
15
41
2 44

1 45

3 46
47
16
48

4
38

10 36

39
W1M9-02-03-001

6 13 14 17 22 19 18 23 33 34 35

43

47, 48

37

W1M9-02-03-003

1- Retaining Ring 14 - Stopper Pin 27 - Retaining Ring 39 - Body H

2- O-Ring 15 - Control Piston 28 - Valve Plate 40 - Seal Washer
3- Seal Holder 16 - Ceramic Ball (2 Used) 29 - Needle Bearing 41 - Adjusting Screw
4- Oil Seal 17 - Swash Plate 30 - Spring Holder 42 - Nut
5- Shaft 18 - Plunger (11 Used) 31 - Spring 43 - Socket Bolt (7 Used)
6- Ball Bearing 19 - Retainer 32 - Spring Guide 44 - Coupling
7- Retaining Ring 20 - Holder 33 - Control Piston 45 - Collar (2 Used)
8- *Plug 21 - Washer 34 - Sleeve 46 - Gear Pump
9- *O-Ring 22 - Needle (3 Used) 35 - O-Ring 47 - Washer (4 Used)
10 - Body S 23 - Cylinder Block 36 - Choke 48 - Socket Bolt (4 Used)
11 - Gasket 24 - Washer 37 - LS Valve
12 - *Knock Pin (2 Used) 25 - Spring 38 - Knock Pin
13 - Spring 26 - Washer
NOTE: As for the item with * mark, refer to W2-3-4.

W2-3-6
 UPPERSTRUCTURE / Pump Device
Assemble Pump Device
IMPORTANT: When replacing ball bearing (6),
install ball bearing (6) to shaft (5)
first and install retaining ring (7).
1. Install ball bearing (6) to shaft (5) and install
retaining ring (7). Insert the shaft (5) assembly
into body S (10).
IMPORTANT: Apply grease onto O-ring (2) on the
outer diameter on seal holder (3) and
the lip part of oil seal (4).
2. Install oil seal (4) and O-ring (2) onto seal holder
(3). Install seal holder (3) onto shaft (5) by using
special tool (ST 7274). Install retaining ring (1).
3. Install O-ring (9) to plug (8). Install plug (8) into
body S (10).
: 6 mm
NOTE: As for parts (8, 9), refer to W2-3-4.
4. Install spring (13), stopper pin (14) and control
piston (15) to body S (10).
IMPORTANT: Apply grease onto ceramic balls (16)
(2 used) and swash plate (17) sliding
surface.
5. Install ceramic balls (16) (2 used) on the spherical
part of body S (10). Install swash plate (17).
6. Install washer (24), spring (25) and washer (26) in
cylinder block (23) in this order.
7. Push washer (26) and spring (25) by using a
press and install retaining ring (27).
W2-3-7
8. Turn cylinder block (23) upside down and install
needles (22) (3 used). Place washer (21) and
holder (20).
9. Install plungers (18) (11 used) and retainer (19) to
cylinder block (23).
10. Align the hole in swash plate (17) on body S (18)
with the spherical part of spring holder (30). Install
spring holder (30) and spring (31).
11. Install the cylinder block (23) assembly to body S
(10). Install coupling (44) onto the end of shaft (5).
12. Install O-ring (35) onto sleeve (34). Install choke
(36) and sleeve (34) to body H (39). Install control
piston (33) to sleeve (34).
(Choke)
: 4 mm
: 6 to 9 N⋅m (0.6 to 0.9 kgf⋅m, 4 to 6.6 lbf⋅ft)
(Sleeve)
: 35 mm
: 50 to 60 N⋅m
(5.1 to 6.1 kgf⋅m, 37 to 44 lbf⋅ft)
13. Install knock pin (38) for valve plate (28), valve
plate (28), spring guide (32), knock pins (12) (2
used) and gasket (11) to body H (39).
NOTE: As for parts (12), refer to W2-3-4.
 UPPERSTRUCTURE / Pump Device

31

45

46
47
48

10

39
W1M9-02-03-001

43

47, 48

37

W1M9-02-03-003

W2-3-8
 UPPERSTRUCTURE / Pump Device
14. Align knock pin (12) and cover body S (10) with
body H (39). Install and tighten the bolts (M10,
Length 60 mm (2.36 in)) (2 used) for temporary
assembly into the socket bolt (43) holes on spring
(31) side.
: 8 mm

15. Tighten socket bolts (43) (5 used) into other

socket bolt (44) holes in body H (39) lightly.
: 8 mm

16. Remove the one of bolt (M10, Length 60 mm

(2.36 in)) for temporary assembly. Install and
tighten socket bolt (43) lightly. Remove the other
bolt (M10, Length 60 mm (2.36 in)) for temporary
assembly. Tighten socket bolt (43) lightly in the
same procedures.
: 8 mm

17. Tighten socket bolts (43) (7 used).

: 8 mm
: 51 to 65 N⋅m
(5.2 to 6.6 kgf⋅m, 38 to 48 lbf⋅ft)

18. Install LS valve (37) to body H (39).

: 24 mm
: 59 to 69 N⋅m
(6.0 to 7.0 kgf⋅m, 44 to 51 lbf⋅ft)

19. Install collars (45) (2 used) to gear pump (46).

Install gear pump (46) to body H (39) with socket
bolts (48) (4 used) and washers (47) (4 used).
: 6 mm
: 24.5 to 27.5 N⋅m
(2.5 to 2.8 kgf⋅m, 18 to 20.5 lbf⋅ft)

W2-3-9
 UPPERSTRUCTURE / Pump Device
MAINTENANCE STANDARD
1. Clearance between plunger outer diameter and
cylinder block bore

(D-d): 0.05 mm (0.002 in) or less.

D d

W507-02-04-009

Cylinder Plunger
Block

2. Clearance between plunger and shoe bottom Plunger

δ: 0.2 mm (0.008 in) or less.

δ Shoe

W107-02-06-140
3. Wear amount of oil seal mounting surface
Check that there are no damage and / or
abnormal wear.

Wear amount: 0.025 mm (0.001 in) or less.

W2-3-10
 UPPERSTRUCTURE / Control Valve
REMOVE AND INSTALL CONTROL VALVE
Removal
1 Counterweight
CAUTION: Release any pressure in the
hydraulic oil tank before doing any work.
(Refer to BLEED AIR FROM HYDRAULIC OIL
TANK on W1-4-1.)

1. Remove bolts (2) (3 used) in canopy (1). 2

: 19 mm

W1M9-02-01-002

2. Remove bolts (3) (2 used). Remove cover (4) from

main frame (5). 3
: 17 mm

5 W1M9-02-01-001

3. Turn adjusting screw (6). Lay down the canopy (1)

assembly to the front side.
: 17 mm

W1M9-02-01-003
Tilt Device 6

W2-4-1
 UPPERSTRUCTURE / Control Valve
IMPORTANT: Attach an identification tag onto the
disconnected hoses for assembling.
4. Disconnect all the hoses, pipes and connectors
from control valve (7). Cap the open ends.
: 19 mm, 22 mm, 27 mm, 36 mm, 41 mm

CAUTION: Control valve (7) weight: 58 kg

(130 lb)

5. Remove bolts (8) (4 used) from control valve (7).

: 17 mm

6. Pass a nylon sling under the cap on control valve

(7).
Hoist and remove control valve (7) from main
frame (9). 9 7, 8 W1M9-02-07-003

W2-4-2
 UPPERSTRUCTURE / Control Valve
Installation

CAUTION: Control valve (7) weight: 58 kg

(130 lb)

1. Pass a nylon sling under the cap on control valve

(7).
Hoist and install control valve (7) onto main frame
(9) with bolts (4) (4 used).
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)

2. Install all the hoses onto control valve (7).

: 19 mm
: 29.5 N⋅m (3.0 kgf⋅m, 22 lbf⋅ft)
: 22 mm
: 39 N⋅m (4.0 kgf⋅m, 29 lbf⋅ft)
: 27 mm
: 78 N⋅m (8.0 kgf⋅m, 58 lbf⋅ft)
: 36 mm 9 7, 8 W1M9-02-07-003

: 175 N⋅m (18 kgf⋅m, 129 lbf⋅ft)

: 41 mm
: 205 N⋅m (21 kgf⋅m, 151 lbf⋅ft)

3. Turn adjusting screw (6). Lower the canopy (1)

assembly.

W1M9-02-01-003
Tilt Device 6

W2-4-3
 UPPERSTRUCTURE / Control Valve
4. Install cover (4) onto main frame (5) with bolts (3)
(2 used).
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
3

W1M9-02-01-001
5

1
5. Install canopy (1) with bolts (2) (3 used). Counterweight
: 19 mm
: 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft)

W1M9-02-01-002

W2-4-4
 UPPERSTRUCTURE / Control Valve
(Blank)

W2-4-5
 UPPERSTRUCTURE / Control Valve
DISASSEMBLE AND ASSEMBLE
CONTROL VALVE
21
20 14
18 13
23
19 18 24
9
25
17 26
16 27
15 29 28
12 30
11
10 29a 33
31
2 1a 32 34
3 29
4 45
5
6 46
7 44
8 9 29
30 43
47 42
29 48 41
40
49
1b 30 31 50 39
85 87 29b
86 29 51
52 56
57
58
59
53
55
54
1c
29b
60 61
45
36 46
37
38 44
43
42
41
47 40
48
39
49
50
51
52 56
57
58
59
55 53

54
1d

36
37 W1M9-02-04-010
38

W2-4-6
 UPPERSTRUCTURE / Control Valve

88
89

90

91
89
88

92

W1M9-02-04-001

1a - Body (Unload) 16 - Spring 42 - Retainer (9 Used) 68 - Piston

1b - Body (Piping Port) 17 - Strainer 43 - Bolt (9 Used) 69 - O-Ring P22-1B
1c - Body (Swing) 18 - Choke (2 Used) 44 - O-Ring (10 Used) G25-1B 70 - Sleeve
1d - Body (Travel) 19 - Stocking Plug 45 - Socket Bolt (18 Used) 71 - Backup Ring
1e - Body (Blade) 20 - O-Ring 46 - Cover (9 Used) 72 - O-Ring
1f - Body (Travel) 21 - Plug 47 - Plug (9 Used) 73 - Steel Ball
1g - Body (Boom Swing) 23 - Main Relief Valve 48 - O-Ring (9 Used) 74 - Choke
1h - Body (Boom) 24 - Plug 49 - Seat (8 Used) 75 - Spring
1i - Body (Arm) 25 - O-Ring P14-1B 50 - Backup Ring (8 Used) 75a - Spring
1j - Body (Bucket) 26 - Piston 51 - O-Ring (8 Used) 76 - Poppet
1k - Body (Auxiliary) 27 - Spring 52 - Steel Ball (8 Used) 77 - Overload Relief Valve (6 Used)
2- Steel Ball 28 - Spool 53 - O-Ring (8 Used) 78 - Make-Up Valve
3- Spring Seat 29 - O-Ring (61 Used) 54 - Cover (8 Used) 79 - Plug (3 Used)
4- Spring 29a - O-Ring P8-1B 55 - Socket Bolt (16 Used) 80 - O-Ring (3 Used) P20-1B
5- O-Ring 29b - O-Ring (2 Used) P12-1B 56 - Plug (9 Used) 81 - Backup Ring (3 Used)
6- Retainer 30 - O-Ring (22 Used) 57 - O-Ring (9 Used) 82 - O-Ring (3 Used)
7- O-Ring 31 - O-Ring (11 Used) 58 - Piston (9 Used) 83 - Plug (2 Used)
8- Adjuster 32 - O-Ring (11 Used) 59 - Spool (9 Used) 84 - O-Ring (2 Used) P18-1B
9- Metal Plug M6 (12 Used) 33 - Plug 60 - Check Valve (7 Used) 85 - Plug
9a - Metal Plug M5 (10 Used) 34 - O-Ring P14-1B 61 - Spring (7 Used) 86 - Choke
10 - Differential Pressure 36 - Spring (4 Used) 62 - Cover 87 - Choke
Reducing Valve
11 - Stocking Plug 37 - O-Ring (11 Used) 63 - Choke 88 - Nut (8 Used)
12 - Choke 38 - Plug (11 Used) 64 - Socket Bolt (2 Used) 89 - Washer (8 Used)
13 - O-Ring 39 - Spool (9 Used) 65 - Socket Bolt (2 Used) 90 - Tie Rod (4 Used)
14 - Plug 40 - Retainer (9 Used) 66 - Plug 91 - Block
15 - Plug 41 - Spring (9 Used) 67 - O-Ring G25-1B 92 - Plug

W2-4-7
 UPPERSTRUCTURE / Control Valve

45
46
44
79 43
47 80 42
81 41
48 82 40
49
50 39
51 56
52 57
58
59

55 53

54
45
1e 46
44
60 43
61 42
47 41
37 48 40
38
49 39
50
51
56
52 57
58
59
53 45
55
46
54 44
43
1f 42
47 78 41
48 40
49
36 50 39
37 51
38 56
52 57
58
59
53 29
55 30
54 31
29
1g 30
29
32
60
61
37
38 W1M9-02-04-011

W2-4-8
 UPPERSTRUCTURE / Control Valve

88
89

90

91
89
88

92

W1M9-02-04-001

1a - Body (Unload) 16 - Spring 42 - Retainer (9 Used) 68 - Piston

1b - Body (Piping Port) 17 - Strainer 43 - Bolt (9 Used) 69 - O-Ring P22-1B
1c - Body (Swing) 18 - Choke (2 Used) 44 - O-Ring (10 Used) G25-1B 70 - Sleeve
1d - Body (Travel) 19 - Stocking Plug 45 - Socket Bolt (18 Used) 71 - Backup Ring
1e - Body (Blade) 20 - O-Ring 46 - Cover (9 Used) 72 - O-Ring
1f - Body (Travel) 21 - Plug 47 - Plug (9 Used) 73 - Steel Ball
1g - Body (Boom Swing) 23 - Main Relief Valve 48 - O-Ring (9 Used) 74 - Choke
1h - Body (Boom) 24 - Plug 49 - Seat (8 Used) 75 - Spring
1i - Body (Arm) 25 - O-RingP14-1B 50 - Backup Ring (8 Used) 75a - Spring
1j - Body (Bucket) 26 - Piston 51 - O-Ring (8 Used) 76 - Poppet
1k - Body (Auxiliary) 27 - Spring 52 - Steel Ball (8 Used) 77 - Overload Relief Valve (6 Used)
2- Steel Ball 28 - Spool 53 - O-Ring (8 Used) 78 - Make-Up Valve
3- Spring Seat 29 - O-Ring (61 Used) 54 - Cover (8 Used) 79 - Plug (3 Used)
4- Spring 29a - O-Ring P8-1B 55 - Socket Bolt (16 Used) 80 - O-Ring (3 Used) P20-1B
5- O-Ring 29b - O-Ring (2 Used) P12-1B 56 - Plug (9 Used) 81 - Backup Ring (3 Used)
6- Retainer 30 - O-Ring (22 Used) 57 - O-Ring (9 Used) 82 - O-Ring (3 Used)
7- O-Ring 31 - O-Ring (11 Used) 58 - Piston (9 Used) 83 - Plug (2 Used)
8- Adjuster 32 - O-Ring (11 Used) 59 - Spool (9 Used) 84 - O-Ring (2 Used) P18-1B
9- Metal Plug M6 (12 Used) 33 - Plug 60 - Check Valve (7 Used) 85 - Plug
9a - Metal Plug M5 (10 Used) 34 - O-Ring P14-1B 61 - Spring (7 Used) 86 - Choke
10 - Differential Pressure 36 - Spring (4 Used) 62 - Cover 87 - Choke
Reducing Valve
11 - Stocking Plug 37 - O-Ring (11 Used) 63 - Choke 88 - Nut (8 Used)
12 - Choke 38 - Plug (11 Used) 64 - Socket Bolt (2 Used) 89 - Washer (8 Used)
13 - O-Ring 39 - Spool (9 Used) 65 - Socket Bolt (2 Used) 90 - Tie Rod (4 Used)
14 - Plug 40 - Retainer (9 Used) 66 - Plug 91 - Block
15 - Plug 41 - Spring (9 Used) 67 - O-Ring G25-1B 92 - Plug

W2-4-9
 UPPERSTRUCTURE / Control Valve

69
68
67
66
62 45
65 46
64 44
44 43
77 42
47 41
40
49 48
9
50
51 39
77 52 56
57
58
75 59
74
73
71
76
75a 1h
72
70 63 60
36 61
37
38

47 42 45
77 46
41
48 40
44
49 43
50 39
51 56
77 52 57
58 45
53 59 46
55 44
43
54 77 42
1i 41
40
60 39
61
37 56
38 57
77 58 37
53 59 38
45
55 46
54 60 44
1j 61 81 80 79 43
82 42
47 83 41
48
83 84 40
82 84 39
37 56
38 81 57
80 58
79 29 59
53 30
55 31
54 29
1k
30
29 32
38 37 60
37 61
38
W1M9-02-04-012

W2-4-10
 UPPERSTRUCTURE / Control Valve

88
89

90

91
89
88

92

W1M9-02-04-001

1a - Body (Unload) 16 - Spring 42 - Retainer (9 Used) 68 - Piston

1b - Body (Piping Port) 17 - Strainer 43 - Bolt (9 Used) 69 - O-Ring P22-1B
1c - Body (Swing) 18 - Choke (2 Used) 44 - O-Ring (10 Used) G25-1B 70 - Sleeve
1d - Body (Travel) 19 - Stocking Plug 45 - Socket Bolt (18 Used) 71 - Backup Ring
1e - Body (Blade) 20 - O-Ring 46 - Cover (9 Used) 72 - O-Ring
1f - Body (Travel) 21 - Plug 47 - Plug (9 Used) 73 - Steel Ball
1g - Body (Boom Swing) 23 - Main Relief Valve 48 - O-Ring (9 Used) 74 - Choke
1h - Body (Boom) 24 - Plug 49 - Seat (8 Used) 75 - Spring
1i - Body (Arm) 25 - O-Ring P14-1B 50 - Backup Ring (8 Used) 75a - Spring
1j - Body (Bucket) 26 - Piston 51 - O-Ring (8 Used) 76 - Poppet
1k - Body (Auxiliary) 27 - Spring 52 - Steel Ball (8 Used) 77 - Overload Relief Valve (6 Used)
2- Steel Ball 28 - Spool 53 - O-Ring (8 Used) 78 - Make-Up Valve
3- Spring Seat 29 - O-Ring (61 Used) 54 - Cover (8 Used) 79 - Plug (3 Used)
4- Spring 29a - O-Ring P8-1B 55 - Socket Bolt (16 Used) 80 - O-Ring (3 Used) P20-1B
5- O-Ring 29b - O-Ring (2 Used) P12-1B 56 - Plug (9 Used) 81 - Backup Ring (3 Used)
6- Retainer 30 - O-Ring (22 Used) 57 - O-Ring (9 Used) 82 - O-Ring (3 Used)
7- O-Ring 31 - O-Ring (11 Used) 58 - Piston (9 Used) 83 - Plug (2 Used)
8- Adjuster 32 - O-Ring (11 Used) 59 - Spool (9 Used) 84 - O-Ring (2 Used) P18-1B
9- Metal Plug M6 (12 Used) 33 - Plug 60 - Check Valve (7 Used) 85 - Plug
9a - Metal Plug M5 (10 Used) 34 - O-Ring P14-1B 61 - Spring (7 Used) 86 - Choke
10 - Differential Pressure 36 - Spring (4 Used) 62 - Cover 87 - Choke
Reducing Valve
11 - Stocking Plug 37 - O-Ring (11 Used) 63 - Choke 88 - Nut (8 Used)
12 - Choke 38 - Plug (11 Used) 64 - Socket Bolt (2 Used) 89 - Washer (8 Used)
13 - O-Ring 39 - Spool (9 Used) 65 - Socket Bolt (2 Used) 90 - Tie Rod (4 Used)
14 - Plug 40 - Retainer (9 Used) 66 - Plug 91 - Block
15 - Plug 41 - Spring (9 Used) 67 - O-Ring G25-1B 92 - Plug

W2-4-11
 UPPERSTRUCTURE / Control Valve
REMOVE AND INSTALL RELIEF VALVE
AND MAKE-UP VALVE
Auto-Idle Pressure
Sensor

2, 3, 4, 5, 6, 7, 8
23

10

78

78

77
77

78
38

T1M9-03-04-001

79 83 79

2- Unload Valve 6- Unload Valve 23 - Main Relief Valve 79 - Plug

3- Unload Valve 7- Unload Valve 38 - Plug 83 - Plug
4- Unload Valve 8- Unload Valve 77 - Overload Relief Valve (6
Used)
5- Unload Valve 10 - Differential Pressure 78 - Make-Up Valve
Reducing Valve

W2-4-12
 UPPERSTRUCTURE / Control Valve
Removal Installation

1. Remove differential pressure reducing valve (10). 1. Install plugs (79) (2 used).
: 24 mm : 21 mm
: 64 to 68 N⋅m
2. Remove main relief valve (23). (6.5 to 6.9 kgf⋅m, 47 to 50 lbf⋅ft)
: 26 mm
2. Install plugs (38) (2 used) and (83) (2 used).
3. Remove overload relief valves (77) (6 used). : 6 mm
: 26 mm : 29.5 to 34 N⋅m
(3.0 to 3.5 kgf⋅m, 22 to 25 lbf⋅ft)
4. Remove make-up valve (78). : 10 mm
: 26 mm : 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft)

5. Remove plugs (79) (2 used). 3. Install make-up valve (78).

: 21 mm : 26 mm
: 59 to 63 N⋅m
6. Remove plugs (38) (2 used) and (83) (2 used). (6.0 to 6.4 kgf⋅m, 44 to 46 lbf⋅ft)
: 6 mm, 10 mm
4. Install overload relief valves (77) (6 used).
: 26 mm
: 59 to 63 N⋅m
(6.0 to 6.4 kgf⋅m, 44 to 46 lbf⋅ft)

5. Install main relief valve (23).

: 26 mm
: 69 to 78 N⋅m
(7.0 to 8.0 kgf⋅m, 51 to 58 lbf⋅ft)

6. Install differential pressure reducing valve (10).

: 24 mm
: 79 to 83 N⋅m
(8.1 to 8.5 kgf⋅m, 58 to 61 lbf⋅ft)

W2-4-13
 UPPERSTRUCTURE / Control Valve
DISASSEMBLE AND ASSEMBLE BODY

Unload Section Tie Rod Nut Washer

Piping Port
Section

B B

Block
W1M9-02-04-003
T1M9-03-04-001

NOTE: The illustration shows the swing section.

A
29

60

61

T1M9-03-04-021
32 A
1c Section B-B

Section A-A
T566-03-03-009

1c - Body 30 - *O-Ring 32 - O-Ring 61 - Spring

29 - O-Ring 31 - *O-Ring 60 - Check Valve

NOTE: As for the item with * mark, refer to W2-4-6

to 7.

W2-4-14
 UPPERSTRUCTURE / Control Valve
Disassemble
IMPORTANT: Do not fall off O-rings (29 to 32).
1. Remove the nuts (4 used). Remove the washers
(4 used) and tie rods (4 used). Divide the control
valve into each section.
: 17 mm
2. Remove O-rings (29 to 32) from each section.
Remove spring (61) and check valve (60) by
using a magnet.
NOTE: As for parts (30, 31), refer to W2-4-6 to 7.
W2-4-15
Assemble
1. Install check valve (60) and O-rings (29 to 32) to
each section. Install spring (61) to the inner bore
of check valve (60).
NOTE: As for parts (30, 31), refer to W2-4-6 to 7.
IMPORTANT: Check the direction of tie rod. Install
the tie rod with its longer thread side
facing to the unload section.
IMPORTANT: Place the plate under the unload
section piping port and the section
except block and install the function
section.
W1M9-02-04-004
Plate 1 mm (0.039 in)
2. Place the plate (thickness: 1 mm (0.039 in)) under
the function sections (9 used) as illustrated. Place
bodies (1) in each section as before
disassembling. Tighten the tie rod by using the
washers (4 used) and the nuts (4 used).
: 17 mm
: 65.7 to 70.6 N⋅m
(6.7 to 7.2 kgf⋅m, 48 to 52 lbf⋅ft)
 UPPERSTRUCTURE / Control Valve
DISASSEMBLE UNLOAD SECTION
B C C B

W1M9-02-04-006

9 12 19

A 11

10
A

23

24

8 7 6 5 4 3 2 1a 28 27 26 25
W1M9-02-04-005 T1M9-03-04-005
Unload Valve

16 17 13 14 20 21

15
18 18

Section A-A Section B-B Section C-C

W1M9-02-04-007

1a - Body 8- Adjuster 14 - Plug 21 - Plug

2- Steel Ball 9- Metal Plug M6 (4 Used) 15 - Plug 23 - Main Relief Valve
3- Spring Seat 9a - Metal Plug M5 (9 Used) 16 - Spring 24 - Plug
4- Spring 10 - Differential Pressure 17 - Strainer 25 - O-Ring
Reducing Valve
5- O-Ring 11 - Stocking Plug 18 - Choke (2 Used) 26 - Piston
6- Retainer 12 - Choke 19 - Stocking Plug 27 - Spring
7- O-Ring 13 - O-Ring 20 - O-Ring 28 - Spool

W2-4-16
 UPPERSTRUCTURE / Control Valve
Disassemble Unload Section

IMPORTANT: As the setting pressure changes, do IMPORTANT: As the setting pressure changes, do
not loosen the lock nut of main relief not loosen the lock nut of differential
valve (23). pressure reducing valve (10).
1. Remove main relief valve (23) from body (1). 4. Remove differential pressure reducing valve (10)
: 27 mm from body (1a). Remove the piston and spring
from body (1a) by using a magnet.
IMPORTANT: Do not disassemble steel ball (2) in : 24 mm
spring seat (3). Guide Spring
When removing retainer (6) from
body (1a), spring (4) and spring seat
(3) are removed together. When
removing retainer (6), do not fall off 10 23
spring (4) and spring seat (3).
IMPORTANT: As the setting pressure changes, do
not loosen adjuster (8) and the nut of
retainer (6).
2. Remove retainer (6) from body (1a). Remove
spring (4) and spring seat (3) by using a
magnet.
: 24 mm T1M9-03-04-005

IMPORTANT: When removing piston (26) from
body (1a), spring (27) is removed
together. When removing piston (26),
do not fall off spring (27).
3. Remove plug (24) from body (1a). Remove piston
(26) and spring (27) by using a magnet.
: 8 mm
Piston 1a
5. Install bolt (M8, Pitch 1.25 mm) into the
pulling-out hole on guide. Remove the guide from
body (1a).
6. Remove plug (15) from the side of body (1a).
Remove spring (16) and strainer (17).
: 8 mm

IMPORTANT: Metal plug (9) and choke (18) cannot

be disassembled.

W2-4-17
 UPPERSTRUCTURE / Control Valve
ASSEMBLE UNLOAD SECTION
B C C B

W1M9-02-04-006

9 12 19

A 11

10
A

23

24

8 7 6 5 4 3 2 1a 28 27 26 25
W1M9-02-04-005 T1M9-03-04-005
Unload Valve

16 17 13 14 20 21

15
18 18

Section A-A Section B-B Section C-C

W1M9-02-04-007

1a - Body 8 - Adjuster 14 - Plug 21 - Plug

2- Steel Ball 9 - Metal Plug M6 (4 Used) 15 - Plug 23 - Main Relief Valve
3- Spring Seat 9a - Metal Plug M5 (9 Used) 16 - Spring 24 - Plug
4- Spring 10 - Differential Pressure 17 - Strainer 25 - O-Ring
Reducing Valve
5- O-Ring 11 - Stocking Plug 18 - Choke (2 Used) 26 - Piston
6- Retainer 12 - Choke 19 - Stocking Plug 27 - Spring
7- O-Ring 13 - O-Ring 20 - O-Ring 28 - Spool

W2-4-18
 UPPERSTRUCTURE / Control Valve
Assemble Unload Section

• Apply grease onto the seals. 4. Install plug (24) to body (1a).
: 8 mm
1. Wind the seal tape onto plug (15). Install strainer : 59 to 69 N⋅m
(17), spring (16) and plug (15) to the side of body (6.0 to 7.0 kgf⋅m, 44 to 51 lbf⋅ft)
(1a).
: 8 mm 5. Insert spring (4) into retainer (6) until spring (4)
: 54 to 58 N⋅m comes in contact with adjuster (8). Install spring
(5.5 to 5.9 kgf⋅m, 40 to 43 lbf⋅ft) seat (3) to spring (4).

2. Install the guide, piston, and spring to differential 6. Install the retainer (6) assembly to body (1a) in
pressure reducing valve (10). Install differential order not to fall off spring seat (3) and spring (4).
pressure reducing valve (10) to body (1a) in order : 24 mm
not to fall off the guide, piston and spring. : 54 to 59 N⋅m
: 24 mm (5.5 to 6.0 kgf⋅m, 40 to 44 lbf⋅ft)
: 79 to 83 N⋅m
(8.1 to 8.5 kgf⋅m, 58 to 61 lbf⋅ft) 7. Install main relief valve (23) into body (1a).
Guide Spring : 27 mm
: 69 to 78 N⋅m
(7.0 to 8.0 kgf⋅m, 51 to 58 lbf⋅ft)
10 23

T1M9-03-04-005

Piston 1a
3. Install spring (27) into piston (26) in the unload
valve. Install the piston (26) assembly to spool
(28) in order not to fall off spring (27).

W2-4-19
 UPPERSTRUCTURE / Control Valve
DISASSEMBLE AND ASSEMBLE SPOOL

NOTE: The illustration shows the swing section.

55 39 40 41 46

T1M9-03-04-021
54 53 1c 44 45 42 43

1c - Body 41 - Spring 44 - O-Ring 53 - O-Ring

39 - Spool 42 - Retainer 45 - Socket Bolt (2 Used) 54 - Cover
40 - Retainer 43 - Bolt 46 - Cover 55 - Socket Bolt (2 Used)

W2-4-20
 UPPERSTRUCTURE / Control Valve
Disassemble Assemble

1. Remove socket bolts (45) (2 used) from body (1c). 1. Install the spool (39) assembly to body (1c).
Remove cover (46) and O-ring (44) from body
(1c). 2. Install O-ring (53) on cover (54). Install cover (54)
: 5 mm onto body (1c). Tighten socket bolts (55) (2 used).
: 5 mm
2. Remove spool (39) as an assembly from body : 10 to 12 N⋅m
(1c). (1.0 to 1.2 kgf⋅m, 7.4 to 8.9 lbf⋅ft)
NOTE: The spool (39) assembly consists of spool
(39), bolt (43), retainer (42), spring (41), 3. On the opposite side install O-ring (44) onto cover
and retainer (40). (46) in the same procedures. Install cover (46)
onto body (1c). Tighten socket bolts (45) (2 used).
NOTE: Replace spool (39), bolt (43), retainer (42),
: 5 mm
spring (41) and retainer (40) as an
: 10 to 12 N⋅m
assembly.
(1.0 to 1.2 kgf⋅m, 7.4 to 8.9 lbf⋅ft)
3. Remove socket bolts (55) (2 used) from body (1c).
Remove cover (54) and O-ring (53) from body
(1c).
: 5 mm

W2-4-21
 UPPERSTRUCTURE / Control Valve
DISASSEMBLE AND ASSEMBLE BOOM
ANTI-DRIFT VALVE

66 70 67 69 71 72 75 76

65

68

62 73 75a 74 1h

T1M9-03-04-011

1h - Body 66 - Plug 70 - Sleeve 74 - Choke

62 - Cover 67 - O-Ring 71 - Backup Ring 75 - Spring
64 - *Socket Bolt (2 Used) 68 - Piston 72 - O-Ring 75a - Spring
65 - Socket Bolt (2 Used) 69 - O-Ring 73 - Steel Ball 76 - Poppet

NOTE: As for the item with * mark, refer to W2-4-10.

W2-4-22
 UPPERSTRUCTURE / Control Valve
Disassemble Assemble

IMPORTANT: Plug (66) and choke (74) cannot be
disassembled.
IMPORTANT: When removing cover (62), piston
(68) is removed together. Do not fall
off piston (68).
1. Remove socket bolts (64) (2 used) and (65) (2
used) from body (1h). Remove cover (62) and
piston (68).
: 5 mm
2. Install bolt (M12, Pitch 1.75 mm) into the
pulling-out hole on sleeve (70). Remove the
sleeve (70) assembly from body (1h).
NOTE: The sleeve (70) assembly consists of
sleeve (70), steel ball (73), choke (74) and
spring (75a).
IMPORTANT: Check if spring (75) stays in body
(1h).
3. Remove spring (75) and poppet (76) from body
(1h) by using a magnet.
1. Install poppet (76) to body (1h). Install spring (75)
into the hole of poppet (76).
IMPORTANT: Apply grease onto O-rings (69, 72).
Install sleeve (70) so that spring (75)
can be aligned with the spring (75)
mounting position in sleeve (70).
2. Install O-rings (69, 72) and backup ring (71) onto
sleeve (70). Install the sleeve (70) assembly to
body (1h).
3. Install piston (68) and O-ring (67) into cover (62).
4. Install the cover (62) assembly to body (1h) in
order not to fall off piston (68). Tighten socket
bolts (65) (2 used) and washers (64) (2 used).
: 5 mm
: 10 to 12 N⋅m
(1.0 to 1.2 kgf⋅m, 7.4 to 8.9 lbf⋅ft)

4. Remove O-rings (69, 72) and backup ring (71)

from sleeve (70).

W2-4-23
 UPPERSTRUCTURE / Control Valve
DISASSEMBLE AND ASSEMBLE
SHUTTLE VALVE AND PRESSURE
COMPENSATION VALVE

NOTE: The illustration shows the swing section.

52 49 47 48 50 51 1c

38 37 36 59 58 57 56 T1M9-03-04-021

1c - Body 47 - Plug 51 - O-Ring 57 - O-Ring

36 - Spring 48 - O-Ring 52 - Steel Ball 58 - Piston
37 - O-Ring 49 - Seat 56 - Plug 59 - Spool
38 - Plug 50 - Backup Ring

W2-4-24
 UPPERSTRUCTURE / Control Valve
Disassemble
1. Remove plug (47) from body (1c).
: 6 mm
IMPORTANT: When removing seat (49), steel ball
(52) is removed together. Do not fall
off steel ball (52).
2. Attach seat (49) from the inside of seat (49) by
using a pair of plier. Remove seat (49) and steel
ball (52) from body (1c).
3. Remove O-Ring (51) and backup ring (50) from
seat (49).
4. Remove plug (38) from body (1c). Remove spring
(36) by using a magnet.
: 8 mm
NOTE: Spring (36) is equipped for the swing,
boom, right travel, and left travel.
IMPORTANT: When removing the spool (59)
assembly, piston (58) may fall off.
5. Remove plug (56). Remove the spool (59)
assembly with piston (58) attached on spool (59)
from body (1c).
6. Remove piston (58) from spool (59).
W2-4-25
Assemble
1. Install piston (58) into spool (59). Insert spring
(36) into the spring (36) hole in spool (59)
completely.
NOTE: Spring (36) is equipped for the swing,
boom, right travel, and left travel.
2. Install the spool (59) assembly to body (1c) in
order not to fall off piston (58).
3. Install O-ring (57) to plug (56) and O-ring (37) to
plug (38). Install plugs (56, 38) to body (1c) in this
order.
: 8 mm
: 59 to 69 N⋅m
(6.0 to 7.0 kgf⋅m, 44 to 51 lbf⋅ft)
4. Apply grease onto O-ring (51). Install backup ring
(50), O-ring (51) and steel ball (52) onto seat (49).
5. Install the seat (49) assembly into body (1c).
6. Install plug (47) to body (1c).
: 6 mm
: 30 to 34 N⋅m
(3.1 to 3.5 kgf⋅m, 22 to 25 lbf⋅ft）
 UPPERSTRUCTURE / Control Valve
(Blank)

W2-4-26
 UPPERSTRUCTURE / Swing Device
REMOVE AND INSTALL SWING DEVICE
Removal
1 Counterweight
CAUTION: Release any pressure in the
hydraulic oil tank before doing any work.
(Refer to BLEED AIR FROM HYDRAULIC OIL
TANK on W1-4-1.)

1. Remove bolts (2) (3 used) in canopy (1).

: 19 mm 2

W1M9-02-01-002

2. Remove bolts (3) (2 used). Remove cover (4) from

main frame (5).
: 17 mm 3

5
W1M9-02-01-001
3. While turning adjusting screw (6), lay down the
canopy (1) assembly to the front side.
: 17 mm

W1M9-02-01-003
Tilt Device 6

W2-5-1
 UPPERSTRUCTURE / Swing Device

CAUTION: Swing device weight: 43 kg (95 lb)

IMPORTANT: Attach an identification tag onto the 7 8

removed hoses for assembling.

4. Remove hoses (7) (5 used) from swing device (8).

Cap the open ends.
: 19 mm, 22 mm
7
5. Remove bolts (9) (8 used). Hoist and remove
swing device (8) from the main frame.
: 24 mm

W1M9-02-05-001
9

W2-5-2
 UPPERSTRUCTURE / Swing Device
Installation

CAUTION: Swing device weight: 43 kg (95 lb)

1. Install swing device (8) to the main frame with 7 8

bolts (9) (8 used).
: 24 mm
: 210 N⋅m (21.5 kgf⋅m, 155 lbf⋅ft)

2. Install hoses (7) (5 used) to swing device (8).

: 19 mm
7
: 29.5 N⋅m (3.0 kgf⋅m, 22 lbf⋅ft)
: 22 mm
: 39 N⋅m (4.0 kgf⋅m, 29 lbf⋅ft)

3. While turning adjusting screw (6), lower the

canopy (1) assembly.
W1M9-02-05-001
9

W1M9-02-01-003
Tilt Device 6

4. Install cover (4) onto main frame (5) with bolts (3)
(2 used).
: 17 mm 3
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
4

W1M9-02-01-001
5

W2-5-3
 UPPERSTRUCTURE / Swing Device
5. Install canopy (1) with bolts (2) (3 used).
: 19 mm
1
: 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft) Counterweight

W1M9-02-01-002

W2-5-4
 UPPERSTRUCTURE / Swing Device
(Blank)

W2-5-5
 UPPERSTRUCTURE / Swing Device
DISASSEMBLE SWING DEVICE

27 28 1 2 3

5
26
25

6
24
23 7
22
21
8

20 9

19
10
18
17 11

16
12

15
14

13

W1M9-02-05-002

1- Swing Motor 8 - Washer 15 - Spring Plate 22 - Needle Bearing (4 Used)

2- Second Stage Sun Gear 9 - Collar 16 - Roller Bearing 23 - First Stage Planetary Gear
(3 used)
3- First Stage Sun Gear 10 - Ring Gear 17 - Housing 24 - O-Ring
4- Bolt (4 Used) 11 - Roller Bearing 18 - Socket Bolt (11 Used) 25 - Needle Bearing (3 Used)
5- Socket Bolt (2 Used) 12 - Oil Seal 19 - Second Stage Carrier 26 - Inner Ring (3 Used)
6- First Stage Carrier 13 - Shaft 20 - Second Stage Planetary 27 - Plate
Gear (4 used)
7- Plate 14 - Spacer 21 - Inner Ring (4 Used) 28 - Bolt (3 Used)

W2-5-6
 UPPERSTRUCTURE / Swing Device
Disassemble Swing Device

CAUTION: Swing motor weight: 18 kg (40 lb)

1. Remove socket bolts (5) (2 used) from swing 6. Remove collar (9) and washer (8) from shaft (13).
motor (1). Remove swing motor (1) from ring gear
(10). 7. Remove shaft (13) from housing (17) by using a
: 10 mm plastic hammer.

2. Remove the first stage carrier (6) assembly, 8. Remove the inner race of roller bearing (16),
second stage sun gear (2) and the second stage spring plate (15) and spacer (14) from shaft (13)
carrier (19) assembly. by using a press.

3. Remove socket bolts (18) (11 used) from ring
gear (10). Remove ring gear (10) from housing
(17).
: 10 mm
4. Remove bolts (28) (3 used) from the first stage
carrier (6) assembly. Remove plate (27), first
stage sun gear (3), first stage planetary gears (23)
(3 used), needle bearings (25) (3 used) and inner
rings (26) (3 used).
: 4 mm
IMPORTANT: Do not remove the outer races of
roller bearings (16, 11) from housing
(17). Failure to follow these
instructions will shorten service life
of roller bearings (16, 11) as press-fit
force of roller bearings (16, 11) outer
races is reduced. Replace housing
(17) with a new one if roller bearings
(16, 11) are removed.
9. Remove oil seal (12) from housing (17).

5. Remove bolts (4) (4 used) from the second stage

carrier (19) assembly. Remove second stage
planetary gears (20) (4 used), needle bearings
(22) (4 used) and inner rings (21) (4 used).
: 4 mm

W2-5-7
 UPPERSTRUCTURE / Swing Device
ASSEMBLE SWING DEVICE

27 28 1 2 3

5
26
25

6
24
23 7
22
21
8

20 9

19
10
18
17 11

16
12

15
14

13

W1M9-02-05-002

1- Swing Motor 8 - Washer 15 - Spring Plate 22 - Needle Bearing (4 Used)

2- Second Stage Sun Gear 9 - Collar 16 - Roller Bearing 23 - First Stage Planetary Gear
(3 used)
3- First Stage Sun Gear 10 - Ring Gear 17 - Housing 24 - O-Ring
4- Bolt (4 Used) 11 - Roller Bearing 18 - Socket Bolt (11 Used) 25 - Needle Bearing (3 Used)
5- Socket Bolt (2 Used) 12 - Oil Seal 19 - Second Stage Carrier 26 - Inner Ring (3 Used)
6- First Stage Carrier 13 - Shaft 20 - Second Stage Planetary 27 - Plate
Gear (4 used)
7- Plate 14 - Spacer 21 - Inner Ring (4 Used) 28 - Bolt (3 Used)

W2-5-8
 UPPERSTRUCTURE / Swing Device
Assemble Swing Device

IMPORTANT: Install oil seal (12) with the metallic

surface facing upward (motor side).
1. Install oil seal (12) to housing (17).

2. Remove roller bearings (16, 11). If roller bearings

(16, 11) are replaced with new ones together with
housing (17), install the outer races of roller
bearings (16, 11) to housing (17) by using a press.

3. Install spacer (14), spring plate (15) and the inner

race of roller bearing (16) to shaft (13) by using a
press.

4. Apply grease to roller bearing (16).

Grease: 60g

IMPORTANT: Do not damage oil seal (12) by the

spline part of shaft (13).
5. Install the shaft (13) assembly into housing (17).

6. Install roller bearing (11).

W2-5-9
 UPPERSTRUCTURE / Swing Device

17 11

12

13

W1M9-02-05-002

W2-5-10
 UPPERSTRUCTURE / Swing Device
7. Adjust the roller bearing pre-load.
• Push roller bearing (11) by using special tool. • Measure clearance A between roller bearing (11)
ST 4147 and shaft (13).

W1M9-02-05-003

• Turn housing (17) over 10 turns with the pushing

force (3430 N (350 kgf, 780 lbf)) by special tool W1M9-02-05-004
(ST 4147) kept.
3430 N • Check the table and select washer (8) according
to clearance A.
ST 4147

Measured value of Thickness of Parts No.

clearance A (mm) washer (mm)
6.54 to 6.65 6.70 4613141
6.66 to 6.80 6.85 4613142
17
6.81 to 6.95 7.00 4613143

11 6.96 to 7.10 7.15 4613144

7.11 to 7.25 7.30 4613145
7.26 to 7.40 7.45 4613146
NOTE: 1 mm=0.03937 in
12 13 W1M9-02-05-005

8. Push roller bearing (11) with the pushing force

(1618 N (165 kgf, 370 lbf)) further and install
washer (8).

9. Install collar (9).

W2-5-11
 UPPERSTRUCTURE / Swing Device

27 28 1 2 3

5
26
25

6
24
23 7
22
21

20

19
10
18
17

W1M9-02-05-002

W2-5-12
 UPPERSTRUCTURE / Swing Device
10. Apply THREEBOND #1215 onto ring gear (10) 14. Install O-ring (24) to ring gear (10).
mounting surface of housing (17).
Install ring gear (10) to housing (17). Tighten 15. Add approx. 0.6 litter (0.63 US qt) of hydraulic oil
socket bolts (18) (11 used). to the swing reduction gear.
: 10 mm
: 108 N⋅m (11 kgf⋅m, 80 lbf⋅ft) 16. Install swing motor (1) to ring gear (10) with
socket bolts (5) (2 used).
IMPORTANT: As reused bolts (4, 28) are loosened, : 10 mm
use new bolts (4, 28). : 108 N⋅m (11 kgf⋅m, 80 lbf⋅ft)
11. Install inner rings (26) (3 used), needle bearings
(25) (3 used) and first stage planetary gears (23)
(3 used) to first stage carrier (6). Install plate (27)
with bolts (28) (3 used).
: 4 mm
: 15 N⋅m (1.5 kgf⋅m, 11 lbf⋅ft)

12. Tighten inner rings (21) (4 used), needle bearings

(22) (4 used) and second stage planetary gears
(20) (4 used) to second stage carrier (19). Tighten
plate (7) with socket bolts (4) (4 used).
: 4 mm
: 15 N⋅m (1.5 kgf⋅m, 11 lbf⋅ft)

13. Install the second carrier (20) assembly, second

stage sun gear (2), the first stage carrier (6)
assembly and second stage sun gear (3) to the
housing (17) assembly.

W2-5-13
 UPPERSTRUCTURE / Swing Device
DISASSEMBLE SWING MOTOR 8
7
6
5
4
3
2
1

17
16
15

14
13
12
11
10
9

26
25
24
23
22
21
19
20 27
19

18
28

W1M9-02-05-008

1 - Casing 8- Holder 15 - Disc Plate 22 - Valve Plate

2 - Socket Bolt (2 Used) 9- Pin (3 Used) 16 - O-Ring 23 - Pin (2 Used)
3 - Bearing 10 - Rotor 17 - O-Ring 24 - Bearing
4 - Shaft 11 - Collar 18 - Brake Piston 25 - Pin (2 Used)
5 - Swash Plate 12 - Spring 19 - Spring Seat (2 Used) 26 - Cover
6 - Plunger (9 Used) 13 - Washer 20 - Disc Spring (2 Used) 27 - Socket Bolt (5 Used)
7 - Retainer 14 - Retaining Ring 21 - O-Ring 28 - O-Ring (2 Used)

W2-5-14
 UPPERSTRUCTURE / Swing Device
Disassemble Swing Motor

IMPORTANT: When removing cover (26), valve

CAUTION: Push spring (12) by using a press
plate (22) may fall off first.
when removing retaining ring (14).
1. Remove socket bolts (27) (5 used). Remove
If only retaining ring (14) is removed, washer
cover (26), valve plate (22) and O-ring (21).
(13) and spring (12) may fly out.
: 10 mm
8. Remove retaining ring (14) from rotor (10).
2. Remove bearing (24) and O-rings (28) (2 used)
Remove washer (13), spring (12), and collar (11).
from cover (26).
9. Tap and remove shaft (4) from casing (1) by using
3. Remove disc springs (20) (2 used) and spring a plastic hammer lightly.
seats (19) (2 used) from casing (1).
10. Remove bearing (3) from shaft (4) by using a
4. Remove brake piston (18) from casing (1). press.

5. Remove O-rings (16, 17) from brake piston (18).

IMPORTANT: Do not damage the sliding surface of

swash plate (5).
6. Remove rotor (10), the plunger (6) assembly,
swash plate (5) and disc plate (15) from casing
(1).

7. Remove plungers (6) (9 used), retainer (7), holder

(8) and pins (9) (3 used) from rotor (10).

W2-5-15
 UPPERSTRUCTURE / Swing Device
ASSEMBLE SWING MOTOR

28 27 26 20 19 22 12 13 24 14 23 10 18

25

21
11
17
16
15

9 7

8 4 3

W1M9-02-05-006

1 - Casing 8- Holder 15 - Disc Plate 22 - Valve Plate

2 - *Socket Bolt (2 Used) 9- Pin (3 Used) 16 - O-Ring 23 - Pin
3 - Bearing 10 - Rotor 17 - O-Ring 24 - Bearing
4 - Shaft 11 - Collar 18 - Brake Piston 25 - Pin (2 Used)
5 - Swash Plate 12 - Spring 19 - Spring Seat (2 Used) 26 - Cover
6 - Plunger (9 Used) 13 - Washer 20 - Disc Spring (2 Used) 27 - Socket Bolt (5 Used)
7 - Retainer 14 - Retaining Ring 21 - O-Ring 28 - O-Ring (2 Used)
NOTE: As for the item with *, refer to W2-5-14.

W2-5-16
 UPPERSTRUCTURE / Swing Device
Assemble Swing Motor

IMPORTANT: Install bearing (3) with its retaining 6. Install the assembly of plungers (6) and retainer
ring upward as illustrated. (7) into rotor (10).
1. Install bearing (3) on shaft (4).
IMPORTANT: Insert swash plate (5) with the
chamfered surface facing
4 downward.
7. Install swash plate (5) into casing (1).
Retaining Ring

8. Install the assembly of rotor (10) and plunger (6)

to casing (1).

3
W1M9-02-05-007

IMPORTANT: Push shaft (4) until the retaining ring

of bearing (3) comes in contact with
casing (1).
2. Install the assembly of shaft (4) and bearing (3) to
casing (1).

IMPORTANT: Insert collar (11) with its chamfered

surface facing downward.
3. Install collar (11), spring (12) and washer (13) into
rotor (10).

4. Push washer (13) and spring (12) by using a

press and install retaining ring (14).

5. Apply grease onto pins (9) (3 used). Install pins

(9) (3 used) into rotor (10). Place holder (8) onto
pin (9).

W2-5-17
 UPPERSTRUCTURE / Swing Device

28 27 26 20 19 22 24 18

21
17
16

W1M9-02-05-006

W2-5-18
 UPPERSTRUCTURE / Swing Device
9. Install O-rings (16, 17) onto brake piston (18).
Install brake piston (18) into casing (1).

IMPORTANT: Install spring seat (19) and disc

spring (20) as illustrated.
10. Install spring seats (19) (2 used) and disc springs
(20) (2 used) to casing (1).

19

20

19

W565-02-05-004

11. Install O-ring (21) to casing (1).

12. Install bearing (24) onto cover (26).

13. Install O-rings (28) (2 used) and valve plate (22)

onto cover (26).
NOTE: Apply grease onto valve plate (22) in order
to prevent valve plate (22) from falling from
cover (26).

14. Install cover (26) to casing (1). Tighten cover (26)

with socket bolts (27) (5 used).
: 10 mm
: 128 N⋅m (13 kgf⋅m, 94 lbf⋅ft)

W2-5-19
 UPPERSTRUCTURE / Swing Device
MAINTENANCE STANDARD
1. Clearance between plunger outer diameter and
rotor inner bore

(D-d): 0.04 mm (0.002 in) or less.

D d

Rotor Plunger

W507-02-04-009

2. Clearance between plunger and shoe

δ: 0.4 mm (0.016 in) or less. Plunger

δ
Shoe

W107-02-06-140

W107-02-06-141

W2-5-20
 UPPERSTRUCTURE / Pilot Valve
REMOVE AND INSTALL FRONT PILOT
VALVE
Removal

CAUTION: Release any pressure in the

hydraulic oil tank before doing any work.
(Refer to BLEED AIR FROM HYDRAULIC OIL
TANK on W1-4-1.)

1. Remove cap (3) and bolts (4) (7 used). Remove

covers (2, 5) from lever stand (11).
: 10 mm

2. Remove the clip band and plug from pilot valve 1

(13). (Left stand only)
2
3. Move boots (1) (2 used) up and remove (12) (4
used). Remove plates (14) (4 used) from lever
stand (11).

4. Move boots (1) (2 used) up and loosen lock nuts

(9) (2 used). Remove levers (8) (2 used) with grip 3, 4
(6) together.
: 19 mm

5. Remove boots (1) (2 used).

5 W1M9-02-06-004

IMPORTANT: Attach an identification tag onto the

removed hoses for assembling.
6. Remove the hoses (12 used) from pilot valves 7
6 8
(13) (2 used). Cap the open ends. 9
: 19 mm 10
11
IMPORTANT: Put the matching marks on pilot
valve (13) and lever stand (11) for 14
assembling.
7. Remove bolts (10) (8 used). Remove pilot valves
Pilot Shut-Off
(13) (2 used) from lever stand (11). Lever 12
: 13 mm
13

W1M9-02-06-005

W2-6-1
 UPPERSTRUCTURE / Pilot Valve

Installation

1. Align the matching marks and insert pilot valves

(13) (2 used) into lever stand (11).
6 7
8
2. Install pilot valves (13) (2 used) to lever stand (11) 9
10
with bolts (10) (8 used). 11
: 13 mm
: 20 N⋅m (2.0 kgf⋅m, 15 lbf⋅ft)
14

3. Install the hoses (12 used) onto pilot valves (13)

(2 used). Pilot Shut-Off
: 19 mm Lever 12
: 29.5 N⋅m (3.0 kgf⋅m, 22 lbf⋅ft)
13
4. Insert levers (8) (2 used) (with grip (6)) into boots
(1) (2 used). Install levers (8) (2 used) to pilot
valves (13) (2 used). Install lever (8) with the horn
button on the left side. W1M9-02-06-005

5. Tighten and secure levers (8) (2 used) to pilot

valves (13) (2 used) with lock nuts (9) (2 used).
: 19 mm
: 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft)
1
6. Install the clip band and plug to pilot valve (13).
2
(Left stand only)

7. Install boots (1) (2 used) with plates (14) (4 used)

and bolts (12) (4 used).
: 10 mm
: 3.3 to 4.2 N⋅m
(0.3 to 0.4 kgf⋅m, 2.4to 3.1 lbf⋅ft) 3, 4

8. Install covers (2, 5) on lever stand (11) with bolts

(4) (7 used). Install cap (3) to bolt (4) (7 used).
5 W1M9-02-06-004
9. After completing the work, check the oil level. Start
the engine and check for any oil leaks.

W2-6-2
 UPPERSTRUCTURE / Pilot Valve
REMOVE AND INSTALL TRAVEL PILOT
VALVE
Removal 1 2

CAUTION: Release any pressure in the

hydraulic oil tank before doing any work.
(Refer to BLEED AIR FROM HYDRAULIC OIL
TANK on W1-4-1.)

1. Remove bolts (2) (4 used). Remove the levers (1)

(2 used) assembly from pilot valve (4).
: 17 mm

4, 5 3 W1M9-02-06-008

6 Counterweight

2. Remove bolts (7) (3 used) from canopy (6).

: 19 mm

W1M9-02-01-002

3. Remove bolts (8) (2 used). Remove cover (9) from

main frame (10).
: 17 mm

10 W1M9-02-01-001

W2-6-3
 UPPERSTRUCTURE / Pilot Valve
4. Turn adjusting screw (11). Lay down the canopy
(6) assembly to the front side.
: 17 mm

W1M9-02-01-003
Tilt Device 11

4, 5 3
IMPORTANT: Attach an identification tag onto the
disconnected hoses for assembling.
5. Disconnect pilot hoses (12) (6 used) from pilot
valve (4). Cap the open ends.
: 19 mm

6. Remove bolts (5) (2 used). Remove pilot valve (4)

from bracket (3).
: 17 mm

12

W1M9-02-06-003

12

W2-6-4
 UPPERSTRUCTURE / Pilot Valve
Installation 4, 5 3

1. Install pilot valve (4) to bracket (3) with bolts (5) (2

used).
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)

2. Install hoses (12) (6 used) onto pilot valve (4).

: 19 mm
: 29.5 N⋅m (3.0 kgf⋅m, 22 lbf⋅ft)

12

W1M9-02-06-003

12

3. Turn adjusting screw (11). Lower the canopy (6)

assembly.

W1M9-02-01-003
11
Tilt Device

4. Install cover (9) onto main frame (10) with bolts (8)
(2 used). 8
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft) 9

W1M9-02-01-001
10

W2-6-5
 UPPERSTRUCTURE / Pilot Valve
5. Install canopy (6) with bolt (7) (3 used).
: 19 mm
6
: 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft) Counterweight

6. Install the levers (1) (2 used) assembly to pilot

valve (4) with bolts (2) (4 used).
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft) W1M9-02-01-002

1
7. After completing the work, check the oil level. Start
the engine and check for any oil leaks.

4 2 W1M9-02-06-008

W2-6-6
 UPPERSTRUCTURE / Pilot Valve
REMOVE AND INSTALL BLADE PILOT
VALVE
Removal

CAUTION: Release any pressure in the

hydraulic oil tank before doing any work.
(Refer to BLEED AIR FROM HYDRAULIC OIL
TANK on W1-4-1.)

1. Remove cap (3) and bolts (4) (7 used). Remove

cover (1) from lever stand (2).
: 10 mm

2. Remove bolts (6) (4 used) from bracket (5).

: 13 mm

3. Move the pilot valve (7) assembly up.

4. Secure hoses (8) (4 used) by using a wire in order 1

not to fall off.

IMPORTANT: Attach an identification tag onto the

disconnected hoses for assembling. M1M7-05-009
5. Disconnect hoses (8) (4 used) from pilot valve (7). 6 5 3, 4 2
Cap the open ends.
: 19 mm

6. Remove the pilot valve (7) assembly from lever

stand (2).

W1M9-02-06-007
8

W2-6-7
 UPPERSTRUCTURE / Pilot Valve
Installation

1. Insert the pilot valve (7) assembly into lever stand

(2).

2. Install hoses (8) (4 used) onto pilot valve (7).

: 19 mm
: 29.5 N⋅m (3.0 kgf⋅m, 22 lbf⋅ft)
5
3. Install bracket (5) in the pilot valve (7) assembly to
lever stand (2) with bolts (6) (4 used). 7
: 13 mm
: 20 N⋅m (2.0 kgf⋅m, 15 lbf⋅ft)
2
4. Install cover (1) onto lever stand (2) with bolts (4)
(7 used).
: 10 mm
: 3.3 to 4.2 N⋅m
(0.3 to 0.4 kgf⋅m, 2.4 to 3.1 lbf⋅ft) W1M9-02-06-007
8
5. Install cap (3) to bolt (4) (7 used).

6. After completing the work, check the oil level. Start

the engine and check for any oil leaks.

M1M7-05-009

6 5 3, 4 2

W2-6-8
 UPPERSTRUCTURE / Pilot Valve
REMOVE AND INSTALL BOOM SWING
PILOT VALVE
Auxiliary Pilot Valve
Removal

CAUTION: Release any pressure in the

hydraulic oil tank before doing any work.
(Refer to BLEED AIR FROM HYDRAULIC OIL
TANK on W1-3-1.)

1. Remove bolts (2) (2 used). Remove pedal (1) from

bracket (6).
: 13 mm

2. Remove bolts (7) (2 used). Remove bracket (6)

from pilot valve (3). Boom Swing Pilot W1M9-02-06-008

: 13 mm Valve

3. Lay down the canopy assembly to the front side.

1
NOTE: Refer to the “REMOVE AND INSTALL
TRAVEL PILOT VALVE” section.

2
3

IMPORTANT: Attach an identification tag onto the

disconnected hoses for assembling.
4. Disconnect hoses (9) (4 used) from pilot valve (3).
Cap the open ends.
: 19 mm 8 6, 7 5 4
W1M9-02-06-009

5. Remove bolts (4) (2 used). Remove pilot valve (3)

and cover (5) from main frame (8).
: 13 mm

9
3

W1M9-02-06-003
9

W2-6-9
 UPPERSTRUCTURE / Pilot Valve
Installation

1. Install bracket (5) and pilot valve (3) to main frame

(8) with bolts (4) (2 used).
: 13 mm
: 20 N⋅m (2.0 kgf⋅m, 15 lbf⋅ft)

2. Install hoses (9) (4 used) onto pilot valve (3).

: 19 mm
: 29.5 N⋅m (3.0 kgf⋅m, 22 lbf⋅ft)

3. Lower the canopy assembly.

9
4. Install bracket (6) to pilot valve (3) with bolts (7) (2
used). 3
: 13 mm
: 20 N⋅m (2.0 kgf⋅m, 15 lbf⋅ft)
W1M9-02-06-003

5. Install pedal (1) to pilot valve (3) with bolts (2) (2 9

used).
: 13 mm
: 20 N⋅m (2.0 kgf⋅m, 15 lbf⋅ft) 1

6. After completing the work, check the oil level. Start

the engine and check for any oil leaks.

2
3

W1M9-02-06-009
8 6, 7 5 4

W2-6-10
 UPPERSTRUCTURE / Pilot Valve
(Blank)

W2-6-11
 UPPERSTRUCTURE / Pilot Valve
DISASSEMBLE FRONT PILOT VALVE

17

16

15

14

13

12

11
10

9 22

7
6 21
5 20
4 19
3 18

W178-02-07-064

1- Spacer (4 Used) 7- Spring Guide (4 Used) 13 - O-Ring (4 Used) 18 - Retaining Ring

2- Shim (Several) 8- Retaining Ring (4 Used) 14 - Plate 19 - Plug
3- Balance Spring A (2 Used) 9- Pusher A (2 Used) 15 - Universal Joint 20 - O-Ring
4- Balance Spring B (2 Used) 10 - Pusher B (2 Used) 16 - Cam 21 - Spool (4 Used)
5- Return Spring A (2 Used) 11 - Oil Seal (4 Used) 17 - Screw Joint 22 - Casing
6- Return Spring B (2 Used) 12 - Sleeve (4 Used)

W2-6-12
 UPPERSTRUCTURE / Pilot Valve
Disassemble Front Pilot Valve
IMPORTANT: Casing (22) is made of aluminium.
As too strong a force can deform, or
damage them, handle them with
care.
IMPORTANT: Spool (21) has been selected to
match the hole of casing (22). The
dimensions of balance springs A (3),
B (4) and return springs A (5), B (6)
as well as those of pushers A (9), B
(10) are different. Indicate the port
number from which it is removed.
Port numbers are stamped on
casing (22).
IMPORTANT: Do not remove screw joint (17) while
clamping casing (22) in a vise. The
strong torque may act on screw joint
(17).
1. Clamp screw joint (17) in a vise. Turn cam (16) by
using a spanner. Remove screw joint (17).
: 19 mm, 32 mm
2. Clamp the flat surface of casing (22) in a vise
lightly. Remove cam (16) from universal joint (15).
: 32 mm
3. Attach a spanner onto the upper surface of
universal joint (15) and remove universal joint
(15).
: 17 mm
NOTE: Universal joint (15) has been secured on
casing (22) by using LOCTITE.
4. Remove plate (14).
W2-6-13
IMPORTANT: Insert the soft rubber between
sleeve (12) and the tool in order not
to damage the surface of sleeve (12).
Oil seal (11) cannot be removed from
sleeve (12).
Sleeve (12) and oil seal (11) must be
replaced as an assembly.
5. Pull up sleeve (12) by using a pair of pliers.
IMPORTANT: The dimensions of pushers (9, 10)
for ports 1, 3 and ports 2, 4 are
different. Indicate the port number
from which it is removed in order to
keep by the port number.
6. Remove pushers (9, 10) from casing (22).
7. Install special tool (ST 4145) to the port hole on
casing (22) in order not to lower the spool when
pushing the spring.
: 6 mm
8. Install special tool (ST 4145) to the pusher hole
on casing (22). Push special tool and compress
the spring. Tighten special tool (ST 4146) by
using the socket bolt (M14, Pitch 2.0 mm).
Remove retaining rings (8) (4 used) by using a
screwdriver.
: 12 mm
ST 4146
22
W178-02-07-048
ST 4145
 UPPERSTRUCTURE / Pilot Valve

17

16

22

7
6 21
5
4 19
3 18

W178-02-07-064

W2-6-14
 UPPERSTRUCTURE / Pilot Valve
9. Remove special tool (ST 4146). Remove spring
guides (7) (4 used), return springs A (5) (2 used),
B (6) (2 used), balance springs A (3) (2 used) and
B (4) (2 used).

IMPORTANT: The quantity of shims (2) has been

determined for each port during the
performance testing at the factory.
Do not lose shims (2). Keep shims
(2) carefully in order to install shims
(2) to each former port when
assembling.
10. Remove shim (2) and spacers (1) (4 used) from
spools (21) (4 used).

IMPORTANT: Spool (21) has been selected to

match the hole of casing (22).
Replace spool (21) and casing (22)
as an assembly.
11. Remove special tool (ST 4145) from casing (22).
Slowly turn and remove spool (21).

12. Remove retaining ring (18) by using a screwdriver.

Install the bolt (M8, Pitch 1.25 mm) to plug (19)
and remove plug (19).
： 13 mm

W2-6-15
 UPPERSTRUCTURE / Pilot Valve
ASSEMBLE FRONT PILOT VALVE

17

16 15

11 9, 10
14
12
13
8
7

3, 4

5, 6
2

19
1
19
22 21

18
W178-02-06-055

1- Spacer (4 Used) 7- Spring Guide (4 Used) 13 - O-Ring (4 Used) 18 - Retaining Ring

2- Shim (Several) 8- Retaining Ring (4 Used) 14 - Plate 19 - Plug
3- Balance Spring A (2 Used) 9- Pusher A (2 Used) 15 - Universal Joint 20 - O-Ring
4- Balance Spring B (2 Used) 10 - Pusher B (2 Used) 16 - Cam 21 - Spool (4 Used)
5- Return Spring A (2 Used) 11 - Oil Seal (4 Used) 17 - Screw Joint 22 - Casing
6- Return Spring B (2 Used) 12 - Sleeve (4 Used)

W2-6-16
 UPPERSTRUCTURE / Pilot Valve
Assemble Front Pilot Valve

IMPORTANT: The pilot valve is susceptible to
contamination. Keep the parts clean
when assembling.
NOTE: Table below shows the relations between
each port and the components. Do not
confuse them when assembling.
IMPORTANT: Refer to the table in order to
assemble them correctly.
3. Install spacer (1), shim (2) and balance springs (3,
4) to spool (21). Install return springs (5, 6) to
casing (22).
4. Install spring guide (7) onto return spring (5, 6)
with the protrusion facing upward.

Port Spool Shim Pushers A, B 5. Install special tool (ST 4146) to the pusher hole
No. (21) (2) (9, 10) on casing (22). Push special tool (ST 4146) and
1 Outer Groove compress the spring. Tighten special tool (ST
Same to Same to (3 Used) 4146) by using the bolt (M14, Pitch 2.0 mm).
2 the former the former without outer : 12 mm
one one groove
3 Outer Groove ST 4146
(3 Used)
4 without outer ST 4144
groove

Unit: mm (in)
Port Return Springs Blance Springs A, B
No. (5, 6) (3, 4)
1 43 (1.69) 29.9 (1.18)
2 48 (1.89) 30.1 (1.19)
3 43 (1.69) 29.9 (1.18)
4 48 (1.89) 30.1 (1.19)
W178-02-07-049
ST 4145
IMPORTANT: Spool (21) has been selected to
6. Install retaining ring (8) to ring holder (ST 4144).
match the port hole. Spool (21) and
casing (22) must be replaced as an
assembly.
IMPORTANT: When inserting the parts into casing
(22), apply hydraulic oil onto the
parts.
1. Check the port hole number and insert spool (21)
to the original port. Insert the thinner end of spool
(21) to the port hole in casing (22) while rotating.

2. Install special tool (ST 4145) to the port hole on

casing (22) in order not to lower the spool when
pushing the spring.
: 6 mm

W2-6-17
 UPPERSTRUCTURE / Pilot Valve

17

16 15

11 9, 10
14
12
13
8

3, 4

22

W178-02-06-055

W2-6-18
 UPPERSTRUCTURE / Pilot Valve
7. Install retaining ring (8) to the groove on the head
of spool (21) out of special tool (ST 4146).
IMPORTANT: Check the mounting positions of
pushers (9, 10).
8. Install pushers (9, 10).
Push pushers (9, 10) by hand several times and
remove pushers (9, 10). Check if retaining ring (8)
falls off or springs (3, 4) are located correctly.
After checking, install pushers (9, 10) to casing
(22).
9. Apply grease to the ball at the ends of pushers (9,
10).
10. Apply grease to the joint part of universal joint
(15).
14. Align the bolt hole on plate (14) and the screw
hole on casing (22). Place plate (14) onto casing
(22). Tighten universal joint (15).
: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
IMPORTANT: Check the tightness of cam (16).
15. Install cam (16) to universal joint (15). The
clearance between cam (16) and pushers (9, 10)
should be 0 to 0.2 mm (0 to 0.008 in).
16. Secure cam (16) by using a spanner. Tighten
screw joint (17) by using a spanner.
: 19 mm, 32 mm
: 68.4 N⋅m (7.0 kgf⋅m, 50 lbf⋅ft)

11. Apply grease to the inner surface of oil seals

(11) (4 used).

NOTE: Sleeve (12) and oil seal (11) must be

replaced as an assembly.
12. Install the sleeve (12) assembly. Push the sleeve
(12) assembly by hand until O-ring (13) is inserted
into the hole on casing (22).

13. Clamp casing (22) in a vise lightly.

W2-6-19
 UPPERSTRUCTURE / Pilot Valve
DISASSEMBLE TRAVEL PILOT VALVE
1

3
4

35
7 34
33
32
8
9 31
30
10
29
11
28

14 27

26
12
13 15
25
16

24
17

18

23
19

20
21 22
W178-02-07-063

1- Bolt (2 Used) 10 - Spring Pin (2 Used) 19 - O-Ring (2 Used) 28 - Oil Seal (4 Used)
2- Cover 11 - Bracket (2 Used) 20 - Plug (2 Used) 29 - Spring Washer (2 Used)
3- Spring Pin (2 Used) 12 - Spring Pin (2 Used) 21 - Plug (2 Used) 30 - Socket Bolt (2 Used)
4- Spring Pin (2 Used) 13 - Spring Pin (2 Used) 22 - O-Ring (2 Used) 31 - Rubber Seat (2 Used)
5- Cam (2 Used) 14 - O-Ring (4 Used) 23 - Casing 32 - Damper (2 Used)
6- Bushing (4 Used) 15 - Bushing (4 Used) 24 - Spool (4 Used) 33 - O-Ring (2 Used)
7- Holder 16 - Pusher (4 Used) 25 - Spring (4 Used) 34 - O-Ring (2 Used)
8- Spring Washer (4 Used) 17 - Spring Guide (4 Used) 26 - Spacer (4 Used) 35 - Pin (2 Used)
9- Socket Bolt (4 Used) 18 - Balance Spring (4 Used) 27 - Shim (12 Used)

W2-6-20
 UPPERSTRUCTURE / Pilot Valve
Disassemble Travel Pilot Valve

IMPORTANT: Casing (23) is made of aluminium.
As too strong a force can deform, or
damage them, handle them with
care.
IMPORTANT: Spool (24) has been selected to
match the hole of casing (23).
Indicate the port number from which
it is removed.
Port numbers are stamped on the
periphery of casing (23).
1. Clamp casing (23) in a vise. Remove bolts (1) (2
used). Remove cover (2) from holder (7).
: 10 mm
IMPORTANT: The quantity of shims (27) has been
determined for each port during the
performance testing at the factory.
Do not lose shims (27). Keep shims
(27) carefully in order to install
shims (27) to each former port when
assembling.
6. Push balance spring (18). Remove spring guides
(17) (4 used), balance springs (18) (4 used),
shims (27) (12 used) and spacers (26) (4 used)
from spools (24) (4 used).
7. Remove springs (25) (4 used) from casing (23).

2. Remove socket bolts (30) (2 used) and spring

washers (29) (2 used). Remove the holder (7)
assembly from casing (23).
: 8 mm

3. Remove pushers (16) (4 used) from casing (23).

4. Remove pushers (16) (4 used) from bushings (15)

(4 used). By using a bamboo spatula, remove oil
seals (28) (4 used) from bushings (15) (4 used).
Remove O-rings (14) (4 used).

IMPORTANT: Put the mark on spools (24) (4 used)

in order to easily install spool (17)
into the original hole.
5. Turn and remove the spools (24) (4 used)
assembly from casing (23).
Spring guide (17), balance spring (18), shim (27)
and spacer (26) are removed with spool (24)
together.
NOTE: Spool (24) has been selected to match the
hole of casing (23). Replace spool (24) and
casing (23) as an assembly.

W2-6-21
 UPPERSTRUCTURE / Pilot Valve

3
4
6
3
4

5 10
11
5 12
6 13
6
35
7 34
33
32
9 31

10
31
11 32
33
34
35

12
13

23
19

20
21 22
W178-02-07-063

W2-6-22
 UPPERSTRUCTURE / Pilot Valve
IMPORTANT: Place a stand under bracket (11) and
form a reaction force. If holder (7)
bears the reaction force, a strong
force acts on pin (35) and pin (35)
may be deformed.
8. Place a stand under bracket (11).
Remove both spring pins (12, 13) from bracket
(11) at the same time by using special tool (ST
1237).
NOTE: The hole insides of spring pins (12, 13) in
bracket (11) are in stepped-shape. The
spring pin can only be removed in one
direction.
9. Remove bracket (11) from pin (35). (2 places)
NOTE: The outside end of spring pin (10) has been
crimped. Do not remove spring pin (10) on
bracket (11) unless necessary.
11. Remove O-ring (33) from pin (35). (2 places)
12. Place holder (7) with the casing (23) mounting
surface facing upward.
13. Remove spring pins (3, 4) from cam (5) at the
same time by using special tool (ST 1237). The
hole insides of spring pins (3, 4) in cam (5) are in
stepped-shape. Tap the bottom of cam (5). As the
holes of spring pins (3, 4) are crimped, spring pins
(34, 35) may feel tight when removing.
14. Remove pin (35) by using a round bar and
hammer. At the same time cam (5) is also
removed. Do not remove bushings (6) (4 used) in
holder (7) unless necessary. When removing, tap
bushing (6) by using special tool (ST7256).
15. Remove plugs (20) (2 used) from casing (23).
O-ring (19) is removed with plug (20) together.

16. Remove plugs (21) (2 used) from casing (23).

O-ring (22) is removed together with plug (21).
12, 13

11
35 10
Crimped Here

Stand

W176-02-07-019

10. Remove socket bolts (9) (2 used). Remove

damper (32) and rubber seat (31) from pin (35).
O-ring (34) is removed together. (2 places)
: 5 mm

W2-6-23
 UPPERSTRUCTURE / Pilot Valve
ASSEMBLE TRAVEL PILOT VALVE

11 32 31 1 2 35 6 12 10 13 7 5 3, 4 30

29
34 15
9 33 28
17
8 18
14
25

27
16
26

24
23

W178-02-06-056

1- Bolt (2 Used) 10 - Spring Pin (2 Used) 19 - *O-Ring (2 Used) 28 - Oil Seal (4 Used)
2- Cover 11 - Bracket (2 Used) 20 - *Plug (2 Used) 29 - Spring Washer (2 Used)
3- Spring Pin (2 Used) 12 - Spring Pin (2 Used) 21 - *Plug (2 Used) 30 - Socket Bolt (2 Used)
4- Spring Pin (2 Used) 13 - Spring Pin (2 Used) 22 - *O-Ring (2 Used) 31 - Rubber Seat (2 Used)
5- Cam (2 Used) 14 - O-Ring 23 - Casing 32 - Damper (2 Used)
6- Bushing (4 Used) 15 - Bushing (4 Used) 24 - Spool (4 Used) 33 - O-Ring (2 Used)
7- Holder 16 - Pusher (4 Used) 25 - Spring (4 Used) 34 - O-Ring (2 Used)
8- Spring Washer (4 Used) 17 - Spring Guide (4 Used) 26 - Spacer (4 Used) 35 - Pin (2 Used)
9- Socket Bolt (4 Used) 18 - Balance Spring (4 Used) 27 - Shim (12 Used)

NOTE: As for the parts with * mark, refer to

W2-6-20.

W2-6-24
 UPPERSTRUCTURE / Pilot Valve
Assemble Travel Pilot Valve

IMPORTANT: Check the direction to install spring
guide (17).
1. Assemble spool (24) into the assembly. (4 used)
• Insert spacer (26), shim (27) and balance spring
(18) into spool (24) in this order. Install the shim
as the same condition before disassembling.
• Push the balance spring by hand. Install spring
guide (17) to spool (24) with the stepped-end
facing downward.
6. If bushing (6) has been removed from holder (7),
install bushing (6) on holder (7) by using special
tool (ST 7256) in the following procedures.
NOTE: Bushings (6)(4 used) are identical.
• Insert bushing (6) into special tool (ST 7256). Tap
special tool (ST 7256) and install bushing (6) into
the hole of holder (7) by using a hammer.
Stop tapping when bushing (6) end is flush with
the inside wall.

IMPORTANT: Before inserting the parts into holder ST 7256

(7) and casing (23), apply hydraulic 7
oil onto the parts.
2. Insert spring (25) into casing (23). (4 places)

3. Insert the spool (24) assembly into the former port. W176-02-07-016
6
Turn and install the spool (24) assembly into
• Install bushing (6) on the opposite side in the
casing (23). (4 places)
same procedure.
6
4. Assemble plunger (16) into the assembly. (4 7
used) ST 7256
• Install oil seal (28) onto bushing (15).
• Apply grease to the inner surface on oil seal (28).
• Install O-ring (14) to bushing (15).
• Insert pusher (16) into bushing (15). W176-02-07-015

• Apply grease to the head of pusher (16).
5. Insert the pusher (16) assembly into casing (23).
(4 places)
• Install bushing (6) in near side as illustrated. Stop
tapping when the bushing (6) end is flush with the
outside of holder (7).
6
7 ST 7256

Outside of
Holder
W176-02-07-014

• Install bushing (6) in the near and opposite side

as illustrated.

6
7
ST 7256

W176-02-07-01313

W2-6-25
 UPPERSTRUCTURE / Pilot Valve

32 31 35 31 32 7 5 3, 4 30

29
9 34
8 33

23

W178-02-06-056

W2-6-26
 UPPERSTRUCTURE / Pilot Valve
7. Install O-ring (33) to pin (35). Assemble pin (35) to
holder (7) with cam (5). (2 places)
IMPORTANT: Check the direction to install spring
pins (3, 4).
8. Install spring pins (3, 4) to cam (5) by using
special tool (ST 1237). Secure cam (5) and pin
(35). Spring pins (3, 4) should be displaced with
their slits at 90°. (2 places)
Tap and install spring pins (3, 4) until spring pins
(34, 35) make contact with the stepped part in the
hole.
3 Slit Slit
11. Install rubber seat (31) to pin (35). (2 places)
12. Apply grease to O-ring (33). (2 places)
IMPORTANT: Check the direction of damper (32).
The inner bore of damper (32) is
edged-shape. If damper (32) is pried
when installing, O-ring (33) will be
damaged.
13. Install damper (32) to pin (35) with the lever facing
upward. (2 places)
14. Secure damper (32) and rubber seat (31) to
holder (7) with socket bolts (9) (2 used) and spring
washers (8) (2 used). (2 places)
: 5 mm
: 7 N⋅m (0.7 kgf⋅m, 5.2 lbf⋅ft)

4 W178-02-07-050 15. Apply grease to O-ring (34). Push O-ring (34) to

the endmost of pin (35). (2 places)

9. Crimp the hole edge of cam (5) where spring pins

(3, 4) are inserted by using a punch.

10. Place holder (7) on the casing (23) assembly.

Install holder (7) with socket bolts (30) (2 used)
and spring washers (29) (2 used).
Check the mark direction and install holder (7).
: 8 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)

W2-6-27
 UPPERSTRUCTURE / Pilot Valve

11 32 1 2 35 12 10 13 7 1 1

W178-02-06-056

W2-6-28
 UPPERSTRUCTURE / Pilot Valve
16. As for the direction to install bracket (11), refer to
the figure in the disassemble section. Install
bracket (11) to pin (35). Align the inserting holes
of spring pins (12, 13).

IMPORTANT: Place a stand under bracket (26) and

form a reaction force. If holder (7)
bears the reaction force, a strong
force acts on pin (35) and pin (35)
may be deformed.
17. Place a stand under bracket (11).
Tap spring pins (12, 13) into bracket (11) until
spring pins (12, 13) comes to the stepped end by
using special tool (ST 1237). The spring pins (2
used) are displaced with their slits in 90°.

Crimped Here
Crimped Here

11 35

Stand 12, 13

W176-02-07-011

18. Crimp the hole edge of bracket (11) where spring

pins (12, 13) are inserted by using a punch.
(2 places) (Refer to the figure.)

19. Install bracket (11) on the opposite side to pin (35)

in the same procedures as steps 16 to 18.

20. Install cover (2) to holder (7) with bolts (1) (2 used).
: 10 mm
: 5 N⋅m (0.5 kgf⋅m, 3.7 lbf⋅ft)

21. Apply grease to the spring pin (10) contact part of

damper (32). (2 places)

W2-6-29
 UPPERSTRUCTURE / Pilot Valve
DISASSEMBLE PILOT VALVES FOR
BOOM SWING, BLADE AND AUXILIARY

17 18 1
16

15
3

4
14
5

7
13

8
12

10

11 W1CF-02-07-001

1- Spacer (2 Used) 6- Spring Guide (2 Used) 11 - Casing 15 - Pusher (2 Used)

2- Cam 7- Spring (2 Used) 12 - O-Ring (2 Used) 16 - Pin
3- Socket Bolt (2 Used) 8- Spring (2 Used) 13 - Bushing (2 Used) 17 - Bushing (2 Used)
4- Boot 9- Spacer (2 Used) 14 - Oil Seal (2 Used) 18 - Set Screw
5- Holder 10 - Spool (2 Used)

W2-6-30
 UPPERSTRUCTURE / Pilot Valve
Disassemble Pilot Valves for Boom Swing, Blade
and Auxiliary

1. Remove boot (4) and spacers (1) (2 used) from

holder (5).

2. Secure the pilot valve in a vise. Loosen set screw

(18) and remove pin (16) by using a round bar.
Remove the cam (2) assembly from holder (5).
: 2.5 mm
8 mm or less

IMPORTANT: Record the positions for casing (11).

The pusher (15) assembly may fly off
by spring (8).
3. Loosen and remove socket bolts (3) (2 used)
alternately. Remove holder (5) and the pusher
(15) assemblies (2 used) from casing (11).
: 6 mm

4. Remove pushers (15) (2 used), O-rings (12) (2

used) and oil seals (14) (2 used) from bushings
(13) (2 used).

IMPORTANT: Indicate the port number in order not

to confuse.
5. Remove the spool (10) assemblies (2 used) and
springs (8) (2 used) from each port of casing (11).

6. Push spring (7). Remove spring guide (6) from

spool (10). Remove spacer (9) from spool (10). (2
places)

W2-6-31
 UPPERSTRUCTURE / Pilot Valve
ASSEMBLE PILOT VALVES FOR BOOM
SWING, BLADE AND AUXILIARY

17 18 1
16

15
3

4
14
5

7
13

8
12

10

11
W1CF-02-07-001

1- Spacer (2 Used) 6- Spring Guide (2 Used) 11 - Casing 15 - Pusher (2 Used)

2- Cam 7- Spring (2 Used) 12 - O-Ring (2 Used) 16 - Pin
3- Socket Bolt (2 Used) 8- Spring (2 Used) 13 - Bushing (2 Used) 17 - Bushing (2 Used)
4- Boot 9- Spacer (2 Used) 14 - Oil Seal (2 Used) 18 - Set Screw
5- Holder 10 - Spool (2 Used)

W2-6-32
 UPPERSTRUCTURE / Pilot Valve
Assemble Pilot Valves for Boom Swing, Blade
and Auxiliary

IMPORTANT: Install spring guide (6) with the
groove side facing to spring (7).
When installing spring guide (6), do
not lower spring guide (6) over 6
mm.
1. Install spacers (9) (2 used) and springs (7) (2
used) to spools (10) (2 used). While pushing
spring (7), install spring guides (6) (2 used) to
spool (10).
4. Place the pusher (15) assemblies (2 used) onto
the spool (10) assemblies (2 used). Place holder
(5). Alternately tighten socket bolts (3) (2 used)
and install holder (5) to casing (11).
: 5 mm
: 11.5 to 21.5 N⋅m
(1.2 to 2.2 kgf⋅m, 8.5 to 16 lbf⋅ft)
5. Install cam (2) on holder (5) with pin (16).

IMPORTANT: Insert the spool (10) assembly to the 6. Apply LOCTITE #262 to set screw (18). Install set
original condition. screw (18) to cam (2).
2. Insert springs (8) (2 used) and the spool (10) : 2.5 mm
assembly into casing (11). (2 places) : 7.0 N⋅m (0.7 kgf⋅m, 5.2 lbf⋅ft)

IMPORTANT: Check the direction of oil seals (14) 7. Tilt cam (2) and apply grease to the ends of
(2 used). Apply grease to the lips of pushers (15) (2 used).
oil seal (14) and to the inside of
bushing (13). 8. Install boot (4) and spacers (1) (2 used) on holder
3. Install oil seals (14) (2 used) and O-rings (12) (2 (5).
used) to bushings (13) (2 used). Insert pushers
(15) (2 used) into bushing (13).

Use one of the following greases.

• Apolloil Autorex C (Idemitsu)
• Ocean 7 (Nihon Ore Louve)
• Screw Bar L60 (NOK)

W2-6-33
 UPPERSTRUCTURE / Pilot Valve
(Blank)

W2-6-34
 UPPERSTRUCTURE / Solenoid Valve
REMOVE AND INSTALL SOLENOID VALVE
2-Unit Solenoid Valve

Removal Counterweight
1

CAUTION: Release any pressure in the

hydraulic oil tank before doing any work.
(Refer to BLEED AIR FROM HYDRAULIC OIL
TANK on W1-4-1.)

1. Remove bolts (2) (2 used) in canopy (1). 2

: 19 mm

W1M9-02-01-002

2. Remove bolts (3) (2 used). Remove cover (4) from

main frame (5). 3
: 17 mm

5
W1M9-02-01-001

3. Turn adjusting screw (6) and lay down the canopy

(1) assembly to the front side.
: 17 mm

W1M9-02-01-003
Tilt Device 6

W2-7-1
 UPPERSTRUCTURE / Solenoid Valve
IMPORTANT: Attach an identification tag onto the 7
removed hoses for assembling.
4. Remove hoses (7) (6 used) from solenoid valve
(8).
Cap the open ends.
: 17 mm, 19 mm, 22 mm

5. Remove bolts (10) (2 used). Remove solenoid

valve (8) from bracket (9).
: 17 mm
8

7 9 10 W1M9-02-07-003

W2-7-2
 UPPERSTRUCTURE / Solenoid Valve
Installation 7

1. Install solenoid valve (8) to bracket (9) with bolts

(10) (2 used).
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)

2. Install hoses (7) (6 used) and the connector to

solenoid valve (8).
: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft) 8
: 19 mm
: 29.5 N⋅m (3.0 kgf⋅m, 22 lbf⋅ft)
: 22 mm
: 39 N⋅m (4.0 kgf⋅m, 29 lbf⋅ft)
7 9 10 W1M9-02-07-003
3. Turn adjusting screw (6) and lower the canopy (1)
assembly.

W1M9-02-01-003
Tilt Device 6

4. Install cover (4) onto main frame (5) with bolts (3)
(2 used).
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft) 3

W1M9-02-01-001
5

W2-7-3
 UPPERSTRUCTURE / Solenoid Valve
5. Install canopy (1) with bolt (2) (3 used).
: 19 mm
1
: 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft) Counterweight

W1M9-02-01-002

W2-7-4
 UPPERSTRUCTURE / Solenoid Valve
(Blank)

W2-7-5
 UPPERSTRUCTURE / Solenoid Valve
DISASSEMBLE 2-UNIT SOLENOID VALVE

17

16

15

14
4
7
12

8
3
9
2

13
12
1
10

11

W1LD-02-07-001

1- Check Valve 6- Solenoid (2 Used) 11 - Body 15 - Wave Washer (2 Used)

2- Spring 7- Pin (2 Used) 12 - O-Ring (4 Used) 16 - Casing (2 Used)
3- O-Ring 8- O-Ring (2 Used) 13 - Solenoid (2 Used) 17 - Lock Nut (2 Used)
4- Adjuster 9- Spool (2 Used) 14 - Plate (2 Used)
5- Plate (2 Used) 10 - Spring (2 Used)

W2-7-6
 UPPERSTRUCTURE / Solenoid Valve
Disassemble 2-Unit Solenoid Valve

IMPORTANT: As the right and left of solenoid (3)

are different, attach an identification
tag onto solenoid (13) for
assembling.

1. Remove lock nuts (17) (2 used) and remove

casings (16) (2 used).

IMPORTANT: When removing solenoid coils (13)

(2 used), pins (7) (2 used) may fall off.
Do not lose pin (7).
2. Remove the solenoid (13) assemblies (2 used)
from body (11).

3. Remove spools (9) (2 used) and springs (10) (2

used) from body (11) by using a magnet.

4. Remove adjuster (4) and O-ring (3) from body

(11).

5. Remove spring (2) and check valve (1) from body

(11) by using a magnet.

W2-7-7
 UPPERSTRUCTURE / Solenoid Valve
ASSEMBLE 2-UNIT SOLENOID VALVE

17
15
12 16
14

13

6 11 4 3 2 1

7 12
5 11
8

10

T1LA-03-06-001 T1LA-03-06-002

1- Check Valve 6- Solenoid (2 Used) 11 - Body 15 - Wave Washer (2 Used)

2- Spring 7- Pin (2 Used) 12 - O-Ring (4 Used) 16 - Casing (2 Used)
3- O-Ring 8- O-Ring (2 Used) 13 - Solenoid (2 Used) 17 - Lock Nut (2 Used)
4- Adjuster 9- Spool (2 Used) 14 - Plate (2 Used)
5- Plate (2 Used) 10 - Spring (2 Used)

W2-7-8
 UPPERSTRUCTURE / Solenoid Valve
Assemble 2-Unit Solenoid Valve

1. Install check valve (1) and spring (2) to body (11)

with adjuster (4).

2. Install springs (10) (2 used) and spools (9) (2

used) to body (11).

3. Install pins (7) (2 used) into solenoids (6)(2 used).

Install solenoid (6) to body (11).

4. Install plates (5) (2 used), O-rings (8) (2 used),

solenoids (13) (2 used), O-rings (12) (2 used),
plates (14) (2 used) and wave washers (15) (2
used) to solenoids (6) (2 used).

5. Install casings (16) (2 used) to the solenoid (6)

assemblies (2 used) with lock nuts (17) (2 used).

W2-7-9
 UPPERSTRUCTURE / Solenoid Valve
REMOVE AND INSTALL 1-UNIT SOLENOID
VALVE
Removal

CAUTION: Release any pressure in the

hydraulic oil tank before doing any work.
(Refer to BLEED AIR FROM HYDRAULIC OIL
TANK on W1-4-1.)

1. Remove bolts (1) (4 used). Remove covers (2) (2

used) from main frame (3).
: 19 mm

W1M9-02-07-001
1 3 2

4, 5

IMPORTANT: Attach an identification tag onto the

removed hoses for assembling.
2. Remove hoses (6) (3 used) and connector (7)
from solenoid valve (4). 6
Cap the open ends.
: 19 mm

3. Remove bolts (5) (2 used). Remove solenoid

valve (4) from main frame (3).
: 13 mm
7 Pilot Filter 3
W1M9-02-07-002

W2-7-10
 UPPERSTRUCTURE / Solenoid Valve
Installation
4, 5
1. Install solenoid valve (4) to main frame (3) with
bolts (5) (2 used).
: 13 mm
: 20 N⋅m (2.0 kgf⋅m, 15 lbf⋅ft)

2. Install hoses (6) (3 used) and connector (7) to 6

solenoid valve (4).
: 19 mm
: 29.5 N⋅m (3.0 kgf⋅m, 22 lbf⋅ft)

7 Pilot Filter 3
W1M9-02-07-002

3. Install covers (2) (2 used) onto main frame (3)

with bolts (1) (4 used).
: 19 mm
: 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft)

W1M9-02-07-001
1 3 2

W2-7-11
 UPPERSTRUCTURE / Solenoid Valve
STRUCTURE OF 1-UNIT SOLENOID
VALVE A 1 2 3

16 4

5
15
6

14 7

13

8
9

10
12

Section A
11
W1M9-02-07-004

T1M9-03-07-003

Wrench Tightening Torque

Part Name Qty Remark
Size N⋅m (kgf⋅m) (lbf⋅ft)
1 Main Pipe 1
2 Lock Nut 1
3 Casing 1
4 Plunger 1
5 Shim 1
6 Shaft 1
7 Solenoid Coil 1
8 O-Ring 1 (1A-1.9×13.8)
9 Bushing 1
10 Spool 1
11 Spring 1
12 Block 1
13 Casing Plate 1
14 O-Ring 2 (1A-1.5×13.5)
15 Plate 1
16 Wave Washer 1

W2-7-12
 UPPERSTRUCTURE / REVOLUTION SENSING VALVE
REMOVE AND INSTALL REVOLUTION
SENSING VALVE
Removal

CAUTION: Release any pressure in the

hydraulic oil tank before doing any work.
(Refer to BLEED AIR FROM HYDRAULIC OIL Pilot Filter 1 2
TANK on W1-4-1.)

1. Remove bolts (5) (7 used). Remove cover (4) from

frame (7).
: 17 mm

IMPORTANT: Attach an identification tag onto the 3

removed hoses for assembling.
2. Remove hoses (1) (6 used) from revolution
sensing valve (3).
Cap the open ends.
: 19 mm, 22 mm
W1M9-02-08-001
3. Remove bolts (2) (2 used). Remove revolution 7 6 4, 5
sensing valve (3) from bracket (6).
: 13 mm

W2-8-1
 UPPERSTRUCTURE / REVOLUTION SENSING VALVE
Installation

1. Install revolution sensing valve (3) to bracket (6)

with bolts (2) (2 used).
: 13 mm
: 20 N⋅m (2.0 kgf⋅m, 15 lbf⋅ft)
Pilot Filter 1 2
2. Install hoses (1) (6 used) onto revolution sensing
valve (3).
: 19 mm
: 29.5 N⋅m (3.0 kgf⋅m, 22 lbf⋅ft)
: 22 mm
: 39 N⋅m (4.0 kgf⋅m, 29 lbf⋅ft)
3
3. Install cover (6) to frame (7) with bolts (5) (7
used).
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)

W1M9-02-08-001
7 6 4, 5

W2-8-2
 UPPERSTRUCTURE / REVOLUTION SENSING VALVE
(Blank)

W2-8-3
 UPPERSTRUCTURE / REVOLUTION SENSING VALVE
DISASSEMBLE REVOLUTION SENSING
VALVE

5
4
4

4 6

2
W566-02-08-001

3 11 12 13 4 14 4

15

2 22 10 21 1 20 9 8 18 17 7 19 16
W566-02-08-002

1- Body 7- Plug 13 - Spool 18 - Piston

2- Differential Pressure 8- O-Ring 14 - O-Ring 19 - Backup Ring
Reducing Valve
3- Variable Orifice Valve 9- O-Ring 15 - Spring 20 - Spool
4- Plug (3 Used) 10 - O-Ring 16 - O-Ring 21 - Spring
5- Plug 11 - O-Ring 17 - Guide 22 - Spring Guide
6- Orifice 12 - Spring

W2-8-4
 UPPERSTRUCTURE / REVOLUTION SENSING VALVE
Disassemble Revolution Sensing Valve

IMPORTANT: Do not remove plugs (5, 7).

IMPORTANT: Do not turn the lock nuts of

differential reducing valve (2) and
variable orifice valve (3) as the
setting pressure changes.
Lock Nut
Cartridge

W176-02-06-017

1. Remove differential pressure reducing valve (2)

from body (1). Remove piston (18) and spring
(15) from body (1) by using a magnet.
: 24 mm

2. Install bolt (M8, Pitch 1.25 mm) into the

pulling-out hole on guide (17). Remove guide (17)
from body (1).

IMPORTANT: When removing variable orifice

valve (3) from body (1), spool (13)
and spring (12) may be left inside
body (1). Remove spool (13) and
spring (12) by using a magnet.
3. Remove variable orifice valve (3), spring (12) and
spool (13) from body (1).
: 24 mm

4. Remove plugs (4) (3 used) and orifice (6) from

body (1).
: 5 mm, 6 mm

W2-8-5
 UPPERSTRUCTURE / REVOLUTION SENSING VALVE
ASSEMBLE REVOLUTION SENSING
VALVE

5
4
4

4 6

2
W566-02-08-001

3 11 12 13 4 14 4

15

2 10 1 9 8 18 17 7 19 16
W566-02-08-002

1- Body 6- Orifice 11 - O-Ring 16 - O-Ring

2- Differential Pressure 7- Plug 12 - Spring 17 - Guide
Reducing Valve
3 - Variable Orifice Valve 8 - O-Ring 13 - Spool 18 - Piston
4 - Plug (3 Used) 9 - O-Ring 14 - O-Ring 19 - Backup Ring
5 - Plug 10 - O-Ring 15 - Spring

W2-8-6
 UPPERSTRUCTURE / REVOLUTION SENSING VALVE
Assemble Revolution Sensing Valve

1. Install orifice (6) and plugs (4) (3 used) to body IMPORTANT: Install differential pressure reducing
(1). valve (2) with the guide (17)
: 5 mm assembly facing upward.
: 9.8 to 11 N⋅m In case differential pressure
(1.0 to 1.1 kgf⋅m, 7.2 to 8.1 lbf⋅ft) reducing valve (2) cannot be
: 6 mm installed to body (1) by hand, the
: 30.5 to 34 N⋅m guide (17) assembly may be off from
(3.1 to 3.5 kgf⋅m, 22.5 to 25 lbf⋅ft) differential pressure reducing valve
(2). Check if the sliding surfaces of
IMPORTANT: Apply grease onto O-rings (14, 11). piston (18) and guide (17) are
2. Install spring (12) and spool (13) to variable orifice damaged after removing differential
valve (3). reducing valve (2) from body (1).

IMPORTANT: Install variable orifice valve (3) with 5. Install differential pressure reducing valve (2) to
spool (13) and spring (12) upward. body (1) and turn 1 to 2 turns. Tighten differential
In case variable orifice valve (3) reducing valve (2).
cannot be installed to body (1) by : 24 mm
hand, spool (13) may be off. Check if : 79 to 83 N⋅m
the sliding surface of spool is (8.1 to 8.5 kgf⋅m, 58 to 61 lbf⋅ft)
damaged after removing variable
orifice valve (3) from body (1).
3. Install variable orifice valve (3) to body (1) and
turn 1 to 2 turns. Tighten variable orifice valve (3).
: 24 mm
: 54 to 59 N⋅m
(5.5 to 6.0 kgf⋅m, 40 to 44 lbf⋅ft)

IMPORTANT: Apply grease on O-rings (10, 9, 8, 16)

and spring (16).
4. Install piston (18) and spring (15) to guide (17).
Install the guide (17) assembly to differential
pressure reducing valve (2).

W2-8-7
 UPPERSTRUCTURE / REVOLUTION SENSING VALVE
(Blank)

W2-8-8
 UPPERSTRUCTURE / Auxiliary Selector Valve(Optional)
REMOVE AND INSTALL AUXILIRY
SELECTOR VALVE
Removal

IMPORTANT: Release any pressure in the

hydraulic oil tank before doing any
work. (Refer to BLEED AIR FROM
HYDRAULIC OIL TANK on W1-4-1.)

CAUTION: The auxiliary flow selector valve

is located under the right console box.
A

W1M9-02-09-004
Detail A

1. Remove hoses (4) (3 used) and connector (5)

from auxiliary flow selector valve (2). Cap the 1
open ends.
: 19 mm

2. Remove bolts (3) (3 used). Remove auxiliary flow

selector valve (2) from main frame (1).
: 13 mm
5

W1M9-02-09-005

3 4

W2-9-1
 UPPERSTRUCTURE / Auxiliary Selector Valve(Optional)
Installation
Detail A

1. Install auxiliary flow selector valve (2) to main

frame (1) with bolts (3) (3 used).
1
: 13 mm
: 20 N⋅m (2.0 kgf⋅m, 15 lbf⋅ft)

2. Install hoses (4) (3 used) and connector (5) to

auxiliary flow selector valve (2).
: 19 mm
: 29.5 N⋅m (3.0 kgf⋅m, 22 lbf⋅ft)
5

W1M9-02-09-005

3 4

W2-9-2
 UPPERSTRUCTURE / Auxiliary Selector Valve(Optional)
(Blank)

W2-9-3
 UPPERSTRUCTURE / Auxiliary Selector Valve(Optional)
DISASSEMBLE AUXILIARY FLOW
SELECTOR VALVE
Flow Selector Pressure Reducing
Solenoid Valve Valve

2 1

21

20

3 19

4
18
17
16
5

15

6
7
14
8

10

11

10 13

11 12

W1M9-02-09-002

1- Solenoid 7- Spring 13 - O-Ring 18 - O-Ring

2- Socket Bolt (2 Used) 8- Stopper 14 - Spool 19 - Plug
3- O-Ring 9- Body 15 - Spring 20 - Adjusting Screw
4- Spool 10 - O-Ring (4 Used) 16 - O-Ring 21 - Lock Nut
5- Sleeve 11 - Plug (4 Used) 17 - Plug
6- Washer 12 - Plug

W2-9-4
 UPPERSTRUCTURE / Auxiliary Selector Valve(Optional)
Disassemble Flow Selector Solenoid Valve Disassemble Pressure Reducing Valve

1. Clamp the flow selector solenoid valve in a vise. 1. Remove the plug (19) assembly from body (9).
Remove socket bolt (2) and remove solenoid (1) Remove O-ring (18) from plug (19).
from body (9). The push rod may fall off. : 27 mm
: 4 mm
IMPORTANT: Adjust the pressure when
disassembling the plug (19)
assembly.
1
2. Remove lock nut (21), adjusting screw (20) and
plug (17) from the plug (19) assembly. Remove
O-ring (16) from plug (17).
: 17 mm

3. Remove spring (15) from body (9).

Push Rod
W1M9-02-09-003
2. Remove O-ring (3) from solenoid (1).
3. Remove the sleeve (5) assembly from body (9).
Remove spool (4) from sleeve (5).
4. Remove spool (14) from body (9) by using a
magnet.
5. Remove plugs (11) (4 used), O-rings (10) (4 used),
plug (12) and O-ring (13) from body (19).
: 4 mm, 6 mm

4. Remove washer (6), spring (7) and stopper (8)

from body (9) by using a magnet.

W2-9-5
 UPPERSTRUCTURE / Auxiliary Selector Valve(Optional)
ASSEMBLE AUXILIARY FLOW SELECTOR
VALVE
Flow Selector Pressure Reducing
Solenoid Valve Valve

20
1
21

19

16
2 17

3
18
4

15

11

10

11
6
7

8
14
13
9

W1M9-02-09-001
10 11 12

1- Solenoid 7- Spring 13 - O-Ring 18 - O-Ring

2- Socket Bolt (2 Used) 8- Stopper 14 - Spool 19 - Plug
3- O-Ring 9- Body 15 - Spring 20 - Adjusting Screw
4- Spool 10 - O-Ring (4 Used) 16 - O-Ring 21 - Lock Nut
5- Sleeve 11 - Plug (4 Used) 17 - Plug
6- Washer 12 - Plug

W2-9-6
 UPPERSTRUCTURE / Auxiliary Selector Valve(Optional)
Assemble Pressure Reducing Valve
1. Install O-ring (13) to plug (12). Install O-rings (10)
(4 used) to plugs (11) (4 used).
2. Install plug (12) and the plug (11) assemblies (4
used) to body (9).
: 4 mm
: 4.9 N⋅m (0.5 kgf⋅m, 3.6 lbf⋅ft)
: 6 mm
: 26.5 N⋅m (2.7 kgf⋅m, 19.5 lbf⋅ft)
3. Clamp body (9) in a vise.
Apply hydraulic oil onto spool (14) and spring (15).
Install spool (14) and spring (15) to body (9).
4. Install O-rings (16, 18) to plugs (17, 19).
5. Install the plug (17) assembly, adjusting screw
(20) and lock nut (21) to plug (19).
: 17 mm
: 78.6 N⋅m (8.0 kgf⋅m, 58 lbf⋅ft)
NOTE: Change in pressure reducing of pressure
2
reducing valve: 540 kPa (5.5 kgf/cm , 78.5
psi) / 1turn
6. Install the plug (19) assembly to body (9).
: 27 mm
: 49 N⋅m (5.0 kgf⋅m, 36 lbf⋅ft)
W2-9-7
Assemble Auxiliary Flow Selector Solenoid Valve
1. Install stopper (8) to body (9).
2. Remove the body (9) assembly from the vise.
Place the body (9) assembly onto the workbench
with the flow selector solenoid valve facing
upward.
3. Apply hydraulic oil onto spool (4), sleeve (5),
washer (6) and spring (7).
4. Install spool (4) into sleeve (5). Install washer (6)
and spring (7) to spool (4).
5. Install the spool (4) assembly to body (9) in order
not to fall off spring (7).
6. Clamp the body (9) assembly in a vise. Check if
spool (4) moves by fingers.
7. Install O-ring (3) to solenoid (1). Apply hydraulic
oil onto O-ring (3).
8. Install solenoid (1) to body (9) with socket bolts
(2) (2 used).
: 4 mm
: 6.2 N⋅m (0.6 kgf⋅m, 4.6 lbf⋅ft)
 UPPERSTRUCTURE / Auxiliary Selector Valve(Optional)
(Blank)

W2-9-8
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 MEMO

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 SECTION 3
UNDERCARRIAGE

 CONTENTS 
Group 1 Swing Bearing
Remove and Install Swing Bearing ......... W3-1-1
Group 2 Travel Device
Remove and Install Travel Device .......... W3-2-1
Disassemble Travel Device .................... W3-2-4
Assemble Travel Device ....................... W3-2-12
Disassemble and Assemble
Brake Valve ........................................ W3-2-20
Maintenance Standard ........................ W3-2-23
Group 6 Upper and Lower Roller
Remove and Install Upper Roller ............ W3-6-1
Remove and Install Lower Roller ............ W3-6-3
Disassemble and Assemble
Lower Roller ......................................... W3-6-6
Maintenance Standard ............................ W3-6-8
Group 7 Track
Remove and Install Rubber Track........... W3-7-1
Maintenance Standard ............................ W3-7-3

Group 3 Center Joint

Remove and Install Center Joint............. W3-3-1
Disassemble Center Joint....................... W3-3-4
Assemble Center Joint ........................... W3-3-6

Group 4 Track Adjuster

Remove and Install Track Adjuster ......... W3-4-1
Disassemble Track Adjuster ................... W3-4-2
Disassemble Track Adjuster ................... W3-4-8

Group 5 Front Idler

Remove and Install Front Idler................ W3-5-1
Disassemble and Assemble
Front Idler............................................. W3-5-2
Maintenance Standard............................ W3-5-4

1M9W-3-1
(Blank)

1M9W-3-2
 UNDERCARRIAGE / Swing Bearing
REMOVE AND INSTALL SWING BEARING
In this section, the procedure starts on the premise
that the upperstructure has already been removed.

Removal

1. Put the matching marks on inner race (1) of Matching Mark

swing bearing (4) and track frame (2).

1 2 W105-03-01-001
2. Remove bolts (3) (24 used) from swing bearing
(4).
: 19 mm

CAUTION: Swing bearing (4) weight: 59 kg

(130 lb)

3. Attach lifting tools (ST 0052) onto the outer race

of swing bearing (4). Hoist and remove swing
bearing (4). 4 W1M9-03-01-002

W3-1-1
 UNDERCARRIAGE / Swing Bearing
Installation

Clean the mounting surfaces of track frame and swing Machine Front
bearing.
Position for Grease “S” (Soft Zone) Marking
1. Apply THREEBOND # 1102 to the mounting Fitting Position on Outer Race
surfaces of track frame and swing bearing.

6.5° Hole for

Knock Pin

CAUTION: Swing bearing (4) weight: 59 kg

(130 lb)

IMPORTANT: Otherwise, the soft zone position 9°

Hole for
will be dislocated. Knock Pin
7.5°
2. Hoist swing bearing (4). Align the matching marks
S
on track frame and inner race of swing bearing
(4).
“S” (Soft Zone) Marking
Position on Inner Race
W1M9-03-01-001

3. Tighten bolts (3) (24 used) to the inner race of

swing bearing (4). 3
: 19 mm
: 110 N⋅m (11 kgf⋅m, 81 lbf⋅ft)

4 W1M9-03-01-002

W3-1-2
 UNDERCARRIAGE / Travel Device
REMOVE AND INSTALL TRAVEL DEVICE
Removal
1 2
IMPORTANT: Release any pressure in the
hydraulic oil tank before doing any
work. (Refer to BLEED AIR FROM
HYDRAULIC OIL TANK on W1-4-1.)

1. Remove bolts (1) (3 used) and remove travel

motor cover (3) from track frame (2).
: 8 mm

IMPORTANT: Attach an identification tag onto the

removed hoses for assembling.
W1M9-03-02-001
2. Remove hoses (4) (4 used) from travel motor (5). 3
Cap the open ends.
： 19 mm, 24 mm, 27 mm
4 6 2

CAUTION: Travel device (5) weight: 65 kg

(145 lb)

3. Remove bolts (6) (12 used) and remove travel

device (5) from track frame (2).
: 22 mm

5 W1M9-03-02-002

W3-2-1
 UNDERCARRIAGE / Travel Device
Installation

CAUTION: Travel device (5) weight: 65 kg

(145 lb)
4 6 2
1. Hoist and install travel device (5) to track frame (2)
with bolts (6) (12 used).
: 22 mm
: 176.4 N⋅m (18 kgf⋅m, 130 lbf⋅ft)

2. Install hoses (4) (4 used) to travel device (5).

: 19 mm
: 36 to 63 N⋅m
(3.7 to 6.4 kgf⋅m, 26.5 to 46 lbf⋅ft)
: 24 mm
: 59 to 98 N⋅m 5 W1M9-03-02-002
(6.0 to 10 kgf⋅m, 44 to 72 lbf⋅ft)
: 27 mm
: 84 to 132 N⋅m
(8.6 to 13.5 kgf⋅m, 62 to 97 lbf⋅ft) 1 2

IMPORTANT: After completing the work, check the

oil level. Start the engine and check
for any oil leaks.
In order to prevent the travel motor
from seizing, perform the break-in
operation after installation.

Conditions:
1.Engine speed: Minimum speed
2.Travel pedal: Low speed
3.Operation duration: Over 2 minutes
W1M9-03-02-001

3. Install cover (3) to track frame (2) with socket bolts 3

(1) (3 used).
: 8 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)

W3-2-2
 UNDERCARRIAGE / Travel Device
(Blank)

W3-2-3
 UNDERCARRIAGE / Travel Device
DISASSEMBLE TRAVEL DEVICE
13
12
11
10
9
8
7
6
5
4
3 27
2 26
1
25
24
23
20
19
18
17
16
15

22 37 61
14 62
36 63
64
35 65 67
21 66
34
31
30 54 74
55 73
29 56
57 59
28
58 60
33 74
32 53 68
52
51 71
81 50
82 49 70
83
47 69
48
47 76 72
46 75
75
45
44 74 74
43 80 78
42 77
79
41
40
39
38

W1LD-03-02-001

W3-2-4
 UNDERCARRIAGE / Travel Device

1- Plug (3 Used) 23 - Bearing Nut 44 - Valve Plate 65 - Spool

2- O-Ring (3 Used) 24 - Bearing 45 - Ball Bearing 66 - Valve Body
3- Cover 25 - Steel Ball (99 Used) 46 - O-Ring 67 - Socket Bolt (3 Used)
4- O-Ring 26 - Floating Seal (2 Used) 47 - Disc Plate (2 Used) 68 - O-Ring (3 Used)
5- Wire 27 - Body 48 - Friction Plate 69 - Plug
6- Thrust Plate 28 - Oil Seal 49 - Sleeve 70 - Brake Valve Body
7- First Stage Planetary Gear 29 - Ball Bearing 50 - Spool 71 - Spring (8 Used)
(3 used)
8- Needle Bearing (3 Used) 30 - Shaft 51 -
Spring 72 - O-Ring (3 Used)
9- Inner Race (3 Used) 31 - Steel Ball (2 Used) 52 -
Spring Seat 73 - Orifice (2 Used)
10 - Thrust Washer 32 - Spring (2 Used) 53 -
Plug 74 - Plug (3 Used)
11 - First Stage Carrier 33 - Piston (2 Used) 54 -
Cap (2 Used) 75 - Orifice (4 Used)
12 - Drive Gear 34 - Swash Plate 55 -
O-Ring (2 Used) 76 - Piston
13 - Sun Gear 35 - Plunger (9 Used) 56 -
Spring (2 Used) 77 - Backup Ring
14 - Screw (4 Used) 36 - Retainer Plate 57 -
Counterbalance Valve 78 - O-Ring
(2 Used)
15 - Thrust Plate 37 - Holder 58 - Pin (4 Used) 79 - O-Ring
16 - Second Stage Planetary 38 - Pin (3 Used) 59 - Plug (2 Used) 80 - Backup Ring
Gear (4 used)
17 - Needle Bearing (4 Used) 39 - Rotor 60 - O-Ring (2 Used) 81 - Collar
18 - Inner Race (4 Used) 40 - Collar 61 - Plug (2 Used) 82 - O-Ring
19 - Thrust Washer (4 Used) 41 - Spring 62 - O-Ring (2 Used) 83 - Backup Ring
20 - Ring Gear 42 - Washer 63 - Spring (2 Used) 84 - *Socket Bolt (8 Used)
21 - Plug (2 Used) 43 - Retaining Ring 64 - Spring Seat (2 Used) 85 - *Pin
22 - Plug (2 Used)
NOTE: As for the item with *, refer to W3-2-12.

W3-2-5
 UNDERCARRIAGE / Travel Device

13
12
11
10
9
8
7
6
5
4
3 27
2 26
1
25
24
23
20
19
18
17
16
15

22 37 61
14 62
36 63
64
35 65 67
21 66
34
31
30 54 74
55 73
29 56
57 59
28
58 60
33 74
32 53 68
52
51 71
81 50
82 49 70
83
47 69
48
47 76 72
46 75
75
45
44 74 74
43 80 78
42 77
79
41
40
39
38

W1LD-03-02-001

W3-2-6
 UNDERCARRIAGE / Travel Device
Disassemble Travel Device
IMPORTANT: When removing socket bolts (84) (8
used), brake valve body (70) is
floated by the reacting force of
spring (71). Record the clearance
between brake valve body (70) and
body (27) or between the flange part
of brake valve body (70) and the end
of body (27) for assembling.
IMPORTANT: When removing brake valve body
(70), do not fall off valve plate (44).
CAUTION: Travel device weight: 65 kg
(145 lb)
1. Remove socket bolts (84) (8 used). Remove
brake valve body (70) and valve plate (44).
: 14 mm
IMPORTANT: Do not remove pin (85) forcedly. Pin
(85) has been crimped at two places.
2. Remove pins (85, 58) (4 used) and O-rings (72) (3
used) from brake valve body (70).
3. Remove springs (71) (8 used) and O-ring (46)
from body (27).
IMPORTANT: When removing the piston (76)
assembly, put the matching mark on
piston (76) and body (27).
4. Remove the piston (76) assembly from body (27).
5. Remove backup rings (77, 80) and O-rings (78,
79) from the piston (76) assembly.
W3-2-7
6. Remove the collar (81) assembly from body (27).
7. Remove backup ring (83) and O-ring (82) from
the collar (81) assembly.
8. Remove disc plates (47) (2 used) and friction
plate (48) from body (27).
9. Remove the rotor (39) assembly, swash plate (34),
steel balls (31) (2 used), control pistons (33) (2
used) and springs (32) (2 used) from body (27).
10. Remove plungers (35) (9 used), retainer plate
(36), holder (37) and pins (38) (3 used) from rotor
(39).
CAUTION: Push washer (42) and spring (41)
by using a press when remove retaining ring
(43) as washer (42) and spring (41) may fly
off.
11. Remove retaining ring (43) from rotor (39).
Remove washer (42), spring (41) and collar (40).
12. Install eyebolt (M12, Pitch 1.75 mm) into the
mounting hole for socket bolt (84) on body (27).
Hoist and turn over body (27) onto the wooden
block (50 mm × 400 mm (1.97 in × 15.7 in)).
13. Remove plugs (1) (3 used) from cover (3) and
remove plugs (21) (2 used) from ring gear (20).
Plug (21)
: 5 mm
Plug (1)
: 8 mm
 UNDERCARRIAGE / Travel Device

13
12
11
10
9
8
7
6
5
4
3 27
2
1
25

23
20
19
18
17
16
15

22
14

21

30
29

W1LD-03-02-001

W3-2-8
 UNDERCARRIAGE / Travel Device
14. Install eyebolts (PF1/4) (2 used) into the plug (1)
mounting hole on cover (3). Insert a steel pipe into
the hole on eyebolt.
15. While rotating cover (3) by using a steel pipe, pull
out wire (5) through the plug (21) mounting hole
on the cover (3) mounting side in ring gear (20).
NOTE: Rotate cover (3) until wire (5) is seen from
plug (21) mounting hole.
When wire (5) is seen, pull out wire (5) by
using a screwdriver.
16. Move eyebolt (1 place) on cover (3). Hoist and
remove cover (3) from ring gear (20).
Wooden
17. Remove O-ring (4) from cover (3).
18. Remove thrust plate (6), drive gear (12), the first
stage carrier (11) assembly and sun gear (13)
from ring gear (20).
19. Remove first stage planetary gears (7) (3 used),
needle bearings (8) (3 used), inner races (9) (3
used) and thrust washers (10) (3 used) from first
stage carrier (11).
20. Remove screws (14) (4 used), thrust plate (15),
second stage planetary gears (16) (4 used),
needle bearings (17) (4 used), inner races (18) (4
used) and thrust washers (19) (4 used) from body
(27).
21. Remove steel balls (25) (99 used) from plug (21)
mounting hole.
W3-2-9
22. Install the bolts (M14, Pitch 2.0 mm) (3 used) into
the sprocket mounting hole. Tighten the bolts
evenly and remove body (27) from ring gear (20).
: 22 mm
20
Plate
27
Wooden
Block Block
W1LA-03-02-011
IMPORTANT: Attach a bar onto the shaft (30)
assembly. Lightly tap by using a
plastic hammer and remove the
shaft (30) assembly.
Do not remove ball bearing (29)
unless replacement is required.
23. Remove the shaft (30) assembly from body (27).
24. Remove plugs (22) (2 used) from bearing nut
(23).
: 8 mm
25. Clamp body (27) in a vise. Remove bearing nut
(23) by using special tool (ST 3150).
 UNDERCARRIAGE / Travel Device

27

26

24

28

W1LD-03-02-001

W3-2-10
 UNDERCARRIAGE / Travel Device
IMPORTANT: Attach a bar onto the groove for
steel ball of bearing (24). Lightly tap
by using a hammer and remove
bearing (24).
Replace bearing (24) with a new one
if disassembling bearing (24).
26. Remove bearing (24) from body (27).

27. Remove floating seals (26) (2 used) from body

(27).
NOTE: For handling of floating seal, refer to the
section “Precautions for Floating Seal
Handling" on page W1-1-4.

28. Remove oil seal (28) from body (27).

W3-2-11
 UNDERCARRIAGE / Travel Device
ASSEMBLE TRAVEL DEVICE

72 35 79 80 36 34 27 26 21 25 24 23 22 20 28 11 7 21
39
58

42 4

43 2

45 1

68 73 3

67
9
8

10

12
61
13

66 6

30 14

70

44

41

85

40

71 84 46 76 77 78 82 83 81 48 47 38 37 29 33 32 19 16 17 18 15 5

T1LD-03-05-001

W3-2-12
 UNDERCARRIAGE / Travel Device

1- Plug (3 Used) 23 - Bearing Nut 44 - Valve Plate 65 - Spool

2- O-Ring (3 Used) 24 - Bearing 45 - Ball Bearing 66 - Valve Body
3- Cover 25 - Steel Ball (99 Used) 46 - O-Ring 67 - Socket Bolt (3 Used)
4- O-Ring 26 - Floating Seal (2 Used) 47 - Disc Plate (2 Used) 68 - O-Ring (3 Used)
5- Wire 27 - Body 48 - Friction Plate 69 - Plug
6- Thrust Plate 28 - Oil Seal 49 - Sleeve 70 - Brake Valve Body
7- First Stage Planetary Gear 29 - Ball Bearing 50 - Spool 71 - Spring (8 Used)
(3 used)
8- Needle Bearing (3 Used) 30 - Shaft 51 -
Spring 72 - O-Ring (3 Used)
9- Inner Race (3 Used) 31 - *Steel Ball (2 Used) 52 -
Spring Seat 73 - Orifice (2 Used)
10 - Thrust Washer 32 - Spring (2 Used) 53 -
Plug 74 - *Plug (3 Used)
11 - First Stage Carrier 33 - Piston (2 Used) 54 -
Cap (2 Used) 75 - *Orifice (4 Used)
12 - Drive Gear 34 - Swash Plate 55 -
O-Ring (2 Used) 76 - Piston
13 - Sun Gear 35 - Plunger (9 Used) 56 -
Spring (2 Used) 77 - Backup Ring
14 - Screw (4 Used) 36 - Retainer Plate 57 -
Counterbalance Valve (2 78 - O-Ring
Used)
15 - Thrust Plate 37 - Holder 58 - Pin (4 Used) 79 - O-Ring
16 - Second Stage Planetary 38 - Pin (3 Used) 59 - Plug (2 Used) 80 - Backup Ring
Gear (4 used)
17 - Needle Bearing (4 Used) 39 - Rotor 60 - O-Ring (2 Used) 81 - Collar
18 - Inner Race (4 Used) 40 - Collar 61 - Plug (2 Used) 82 - O-Ring
19 - Thrust Washer (4 Used) 41 - Spring 62 - O-Ring (2 Used) 83 - Backup Ring
20 - Ring Gear 42 - Washer 63 - Spring (2 Used) 84 - Socket Bolt (8 Used)
21 - Plug (2 Used) 43 - Retaining Ring 64 - Spring Seat (2 Used) 85 - Pin
22 - Plug (2 Used)
NOTE: As for the item with *, refer to W3-2-4.

W3-2-13
 UNDERCARRIAGE / Travel Device

72 35 79 80 36 34 27 26 21 25 24 23 22 20 28 11 7 21
39
58

42 4

43 2

45 1

68 73 3

67
9
8

10

12
61
13

66 6

30 14

70

44

41

85

40

71 84 46 76 77 78 82 83 81 48 47 38 37 29 33 32 19 16 17 18 15 5

T1LD-03-05-001

W3-2-14
 UNDERCARRIAGE / Travel Device
Assemble Travel Device

1. Install oil seal (28) to body (27).
2. Install floating seal (26) into body (27) and ring
gear (20).
NOTE: For handling of floating seal, refer to the
section “Precautions for Floating Seal
Handling" on page W1-1-4.
3. Install bearing (24) to body (27). Tighten bearing
nut (23) by using special tool (ST 3150).
: 235±9.8 N⋅m
(24±1.0 kgf⋅m, 175±7.2 lbf⋅ft)
IMPORTANT: Apply LOCTITE #262 to screw (14).
8. Install thrust washers (19) (4 used), inner races
(18) (4 used), needle bearings (17) (4 used),
second stage planetary gears (16) (4 used) and
thrust plate (15) to body (27) in this order with
screws (14) (4 used).
: 12.7±0.6 N⋅m
(1.3±0.06 kgf⋅m, 9.4±0.4 lbf⋅ft)
9. Install sun gear (13) into ring gear (20).
10. Install first stage carrier (11) onto sun gear (13).

ST 3150 11. Install thrust washers (10) (3 used), inner races

20 (9) (3 used), needle bearings (8) (3 used) and first
27 stage planetary gears (7) (3 used) onto first stage
23
carrier (11) in this order.

24 12. Install drive gear (12) into ring gear (20).

13. Install thrust plate (6) onto first stage carrier (11).

14. Install O-ring (4) on cover (3).

15. Install cover (3) onto ring gear (20).

W505-03-02-003

4. Install plugs (22) (2 used) to bearing nut (23). 16. Install eyebolts (PF1/4) (2 used) into the plug (1)
: 8 mm mounting hole on cover (3). Insert a steel pipe into
: 34.3±4.9 N⋅m the hole on eyebolt.
(3.5±0.5 kgf⋅m, 25.5±3.6 lbf⋅ft)

5. Crimp plug (22) at two places by using a punch in

order not to loosen.

6. Tap and install ring gear (20) into body (27) by

using a plastic hammer.

IMPORTANT: Wind the seal tape onto plug (21).

7. Insert steel balls (25) (99 used) into the plug (21)
mounting hole. Tighten plug (21).
: 5 mm
: 7.8±1 N⋅m (0.8±0.1 kgf⋅m, 5.8±0.7 lbf⋅ft)

W3-2-15
 UNDERCARRIAGE / Travel Device

35 79 80 36 34 27 20 21
39

42
43

30

41

40

71 46 76 77 78 82 83 81 48 47 38 37 33 32 5

T1LD-03-05-001

W3-2-16
 UNDERCARRIAGE / Travel Device
17. Bend wire (5) 90°at approximately 6 mm (0.24 26. Install disc plate (47), friction plate (48) and disc
in) from its tip and insert wire (5) into the plug (21) plate (47) to body (27) in this order.
mounting hole.
While turning cover (3) by using a steel pipe, wind 27. Install O-ring (82) and backup ring (83) into collar
up wire (5). (81).

IMPORTANT: Wind the seal tape onto plug (21). 28. Install O-rings (78, 79) and backup rings (77, 80)
18. Install plug (21) to ring gear (20). into piston (76).
: 5 mm 81
83
: 7.8±1.0 N⋅m (0.8±0.1 kgf⋅m, 5.8±0.7 lbf⋅ft)
82
19. Install the shaft (30) assembly into body (27) by 80
78
using a plastic hammer.
79
IMPORTANT: Apply hydraulic oil onto the sliding 77
surface of swash plate (34).
20. Install steel balls (31) (2 used), springs (32) (2
76
used), pistons (33) (2 used), and swash plate (34) W1LD-03-02-002

into body (27). 29. Install the collar (81) assembly to the piston (76)
assembly.
NOTE: As for steel ball (31), refer to W3-2-4.
30. Tap and install the piston (76) assembly into body
21. Install collar (40), spring (41), and washer (42)
(27) by using a plastic hammer evenly.
into rotor (39) in this order.
31. Install O-ring (46) to body (27).
22. Push washer (42) and spring (41) by using a
press and install retaining ring (43).
32. Install springs (71) (8 used) onto piston (76).

23. Install pins (38) (3 used) into rotor (39). Place

holder (37) onto pin (38).

24. Install plungers (35) (9 used) and the retainer

plate (36) assembly to rotor (39).

25. Install the rotor (39) assembly to body (27).

W3-2-17
 UNDERCARRIAGE / Travel Device

72 27

58

70

44

84

T1LD-03-05-001

W3-2-18
 UNDERCARRIAGE / Travel Device
IMPORTANT: Apply grease onto the contacting
surfaces of brake valve body (70)
and valve plate (44) in order not to
fall off.
33. Install O-rings (72) (3 used) and valve plate (44)
to brake valve body (70).

IMPORTANT: When placing brake valve body (70)

onto body (27) while aligning the pin
(58) holes, check if the clearance
between body (27) and brake valve
body (70) is equal to that recorded
when disassembling.
In case the clearance is not equal,
the parts are not installed correctly.
Disassemble and assemble the parts
again.
34. Install brake valve body (70) on body (27) with
socket bolts (84) (8 used).
: 8 mm
: 63.7±4.9 N⋅m
(6.5±0.5 kgf⋅m, 47±3.6 lbf⋅ft)

35. Add gear oil through the plug (1) mounting hole
on cover (3). Tighten plug (1).
: 6 mm
: 22.6±1.0 N⋅m
(2.3±0.1 kgf⋅m, 16.5±0.7 lbf⋅ft)
NOTE: Mitsubishi Diamond Hypoid Gear Oil #90 or
equivalent (GL-4 or equivalent)
Gear oil amount: 0.9 L (1.0 US qt)

W3-2-19
 UNDERCARRIAGE / Travel Device
DISASSEMBLE AND ASSEMBLE BRAKE
VALVE
73 57
74
86
87
59
56

60

55

54

70 53

69

49

75 52

51
50 74 T1LD-03-05-009

61

62

67 66 65 64 63
T1LD-03-05-010

49 - Sleeve 56 - Spring (2 Used) 64 - Spring Seat (2 Used) 73 - Orifice (2 Used)

50 - Spool 57 - Counterbalance Valve 65 - Spool 74 - Plug (3 Used)
(2 Used)
51 - Spring 59 - Plug (2 Used) 66 - Valve Body 75 - Orifice (4 Used)
52 - Spring Seat 60 - O-Ring (2 Used) 67 - Socket Bolt (3 Used) 86 - Collar (2 Used)
53 - Plug 61 - Plug (2 Used) 68 - *O-Ring (3 Used) 87 - Orifice (2 Used)
54 - Cap (2 Used) 62 - O-Ring (2 Used) 69 - Plug
55 - O-Ring (2 Used) 63 - Spring (2 Used) 70 - Brake Valve Body
NOTE: As for the item with *, refer to W3-2-4.

W3-2-20
 UNDERCARRIAGE / Travel Device
Disassemble Brake Valve
1. Remove plugs (61) (2 used), springs (63) (2 used),
spring seat (64) and spool (65) from valve body
(66).
: 8 mm
2. Remove socket bolts (67) (3 used) and remove
valve body (66) from brake valve body (70).
: 6 mm
3. Remove plug (53), spring seat (52) and spring
(51) from brake valve body (70).
: 8 mm
4. Remove plug (69), sleeve (49) and spool (50)
from brake valve body (70).
: 22 mm
5. Remove caps (54) (2 used) from brake valve
body (70) and remove springs (56) (2 used).
: 36 mm
NOTE: Counterbalance valve (57) cannot be
disassembled. When removing
counterbalance valve (57), do not fall off
collars (86) (2 used).
6. Remove counterbalance valves (57) (2 used) in
brake valve body (70) straightly. Remove collars
(86) (2 used) from counterbalance valve (57).
7. Remove plug (59) from brake valve body (70).
: 8 mm
W3-2-21
Assemble Brake Valve
1. Install plugs (59) (2 used) to brake valve body
(70).
: 12 mm
: 31.9±2.45 N⋅m
(3.3±0.2 kgf⋅m, 23.5±1.8 lbf⋅ft)
2. Install counterbalance valves (57) (2 used),
collars (86) (2 used) and springs (56) (2 used) to
brake valve body (70) with caps (54) (2 used).
: 36 mm
: 240±5.0 N⋅m
(24.5±0.5 kgf⋅m, 175±3.7 lbf⋅ft)
3. Install plug (69) to brake valve body (70).
: 22 mm
: 53.9±4.9 N⋅m
(5.5±0.5 kgf⋅m, 40±3.6 lbf⋅ft)
4. Install spool (50), sleeve (49), spring (51) and
spring seat (52) to brake valve body (70). Tighten
plug (53) to brake valve body (70).
: 8 mm
: 53.9±4.9 N⋅m
(5.5±0.5 kgf⋅m, 40±3.6 lbf⋅ft)
5. Install valve body (66) to brake valve body (70)
with socket bolts (67) (3 used).
: 6 mm
: 36.9±1.9 N⋅m
(3.8±0.2 kgf⋅m, 27±1.4 lbf⋅ft)
6. Install spool (65), spring seat (64) and spring (63)
to valve body (66). Tighten plug (61) to valve body
(66).
: 8 mm
: 53.9±4.9 N⋅m
(5.5±0.5 kgf⋅m, 40±3.6 lbf⋅ft)
 UNDERCARRIAGE / Travel Device
MAINTENANCE STANDARD
Travel Motor

1. Clearance between plunger outer diameter and

rotor inner bore

(D-d): 0.04 mm (0.002 in) or less.

D d

W507-02-04-009
Rotor Plunger

2. Clearance between plunger and shoe bottom

δ: 0.4 mm (0.016 in) or less.

δ

Plunger

Shoe

3. Wear amount of sliding surface against valve W107-02-06-141

plate of rotor
Check that there are no damage, wear, or seizure.
Damage or wear amount is 0.02 mm (0.0008 in)
or less.

4. Wear amount of sliding surface against rotor of

valve plate. Check that there are no damage,
wear, or seizure.
Damage or wear amount is 0.02 mm (0.0008 in)
or less.

W3-2-22
 UNDERCARRIAGE / Travel Device

Sprocket

C
B

A
D
W1LD-03-02-003
W1LD-03-02-004

Unit: mm (in)
Standard Allowable Limit Remedy

A 33.0 (1.30) 30 (1.18)

Bulid up
B 380.3 (15) 368 (14.5)
and
423.99 finishing
C 412 (16.2)
(16.7)

D 26.0 (1.02) 24 (0.94)

W3-2-23
 UNDERCARRIAGE / Travel Device
(Blank)

W3-2-24
 UNDERCARRIAGE / Center Joint
REMOVE AND INSTALL CENTER JOINT
Removal
1 2
IMPORTANT: Release any pressure in the
hydraulic oil tank before doing any
work. (Refer to BLEED AIR FROM
HYDRAULIC OIL TANK on W1-4-1.)
1. Lay down the canopy assembly to the front side.
NOTE: As for the procedure to lay down the
1
canopy assembly to the front side, refer to
the section for solenoid valve.

IMPORTANT: Attach an identification tag onto the

removed hoses for assembling.
2. Remove hoses (1) (9 used) from center joint (2).
Cap the open ends.
: 19 mm, 22 mm, 27 mm W1M9-02-05-001

4 3
3. Remove bolts (4) (2 used) from center joint (2) in
the frame. Remove lock plate (3).
: 19 mm

4. Remove bolts (5) (4 used) from the frame.

Remove under cover (6).
: 17 mm
5
5. Remove hoses (7) (10 used) from center joint (2).
Cap the open ends.
: 22 mm, 27 mm

CAUTION: Center joint (2) weight: 17 kg

(37 lb) 6 W1M9-03-03-003

6. Install eyebolt to center joint (2). Attach a wire

rope. Hoist center joint (2) and take up the slack
7
of wire rope.
Remove bolts (8) (4 used). Slowly lower and
remove center joint (2).
: 19 mm

W1M9-03-03-004
8 7

W3-3-1
 UNDERCARRIAGE / Center Joint
Installation 7

CAUTION: Center joint (2) weight: 17 kg

(37 lb)

1. Install center joint (2) onto the frame with bolts (8) 2
(4 used).
: 19 mm
: 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft)

2. Install hoses (7) (10 used) in the spindle side to

center joint (2).
: 22 mm
: 39 N⋅m (4.0 kgf⋅m, 29 lbf⋅ft) W1M9-03-03-004
8 7
: 27 mm
: 78 N⋅m (8.0 kgf⋅m, 58 lbf⋅ft)

3. Install under cover (6) onto the frame with bolts

(5) (4 used).
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
5
4. Install lock plate (3) onto center joint (2) in the
frame with bolts (4) (2 used).
: 19 mm
: 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft)

5. Install hoses (1) (9 used) in the body side to

6 W1M9-03-03-003
center joint (2).
: 19 mm
: 29.5 N⋅m (3.0 kgf⋅m, 22 lbf⋅ft)
: 22 mm
: 39 N⋅m (4.0 kgf⋅m, 29 lbf⋅ft)
: 27 mm
: 78 N⋅m (8.0 kgf⋅m, 58 lbf⋅ft) 1 2

6. Return the canopy assembly to the original

position.
NOTE: As for the procedure to return the canopy
assembly, refer to the section for solenoid
valve. 1

IMPORTANT: After completing the work, start the

engine and check for any oil leaks.

W1M9-02-05-001

4 3

W3-3-2
 UNDERCARRIAGE / Center Joint
(Blank)

W3-3-3
 UNDERCARRIAGE / Center Joint
DISASSEMBLE CENTER JOINT

1
2

4
5

13

14
15
10
11

12

W1M9-03-03-001

1- Socket Bolt (4 Used) 5- Thrust Washer 9- Oil Seal (7 Used) 13 - Spindle

2- Cover 6- Body 10 - O-Ring 14 - Plug (5 Used) PT1/8
3- O-Ring 7- Plug (5 Used) PF1/8 11 - Backup Ring 15 - Plug (4 Used) PT1/4
4- Retaining Ring 8- Plug PF1/4 12 - Dust Seal

W3-3-4
 UNDERCARRIAGE / Center Joint
Disassemble Center Joint

IMPORTANT: Do not damage the seal sliding

CAUTION: Center joint weight: 17 kg (37 lb)
surface of spindle (13).
When laying spindle (13)
1. Clamp the center joint in a vise.
horizontally on the ground, do not
damage or contaminate the spindle
2. Remove socket bolts (1) (4 used) from body (6).
surfaces with hard materials such
Remove cover (2).
as sand.
: 6 mm
Put the matching marks on body (6)
and spindle (13).
3. Remove O-ring (3), retaining ring (4) and thrust
5. Remove body (6) from spindle (13).
washer (5) from body (6).
IMPORTANT: For easy removal, use the pins (2
4. Install special tool onto body (6) with bolts (M8,
used) when removing oil seals (9).
Pitch 1.25 mm) (2 used).
Do not damage the seal groove by
: 13 ㎜
the pins.
6. Remove oil seals (7) (7 used) from body (6).

W1M9-03-03-005

W1M9-03-03-006

7. Remove dust seal (12), backup ring (11) and

O-ring (10) from body (6).

W3-3-5
 UNDERCARRIAGE / Center Joint
ASSEMBLE CENTER JOINT

1 2

5 3

7
8

10
11

12

13

W1M9-03-03-002

1- Socket Bolt (4 Used) 5- Thrust Washer 9- Oil Seal (7 Used) 13 - Spindle

2- Cover 6- Body 10 - O-Ring 14 - *Plug (3 Used) PF1/8
3- O-Ring 7- Plug (5 Used) PF1/8 11 - Backup Ring 15 - *Plug (4 Used) PF1/4
4- Retaining Ring 8- Plug PF1/4 12 - Dust Seal

NOTE: As for the item with *, refer to W3-3-4.

W3-3-6
 UNDERCARRIAGE / Center Joint
Assemble Center Joint

IMPORTANT: Before installing kinds of seals into IMPORTANT: Install retaining ring (4) with the
the seating grooves, apply grease or chamfered surface facing to inside
hydraulic oil onto the seals. After (downward). Check that retaining
installing O-ring (10), dust seal (12) ring (4) is correctly installed.
and oil seals (9), apply grease onto 5. Install retaining ring (4) to spindle (13). Install
the lips. O-ring (3) to body (6).
CAUTION: Center joint weight: 17 kg (37 lb)
6. Install cover (2) onto body (6) with socket bolts (1)
(4 used).
1. Install O-ring (10), backup ring (11), dust seal (12)
: 6 mm
and oil seals (9) (7 used) to body (6).
: 20 N⋅m (2.0 kgf⋅m, 15 lbf⋅ft)
IMPORTANT: Align the matching marks made
when disassembling.
2. Place spindle (13) onto a workbench. Install body
(6) to spindle (13).

IMPORTANT: When installing body (6), face body

(6) upward. Push spindle (13) into
body (6) slowly. If spindle (13) is
rapidly pushed in, the seal may be
damaged.
3. Lightly tap and install body (6) to spindle (13).

4. Install thrust washer (5) onto body (6).

W3-3-7
 UNDERCARRIAGE / Center Joint
(Blank)

W3-3-8
 UNDERCARRIAGE / Track Adjuster
REMOVE AND INSTALL TRACK
ADJUSTER

CAUTION: Track adjuster weight: 16 kg

(35 lb)

Before removing and installing the track adjuster, the

tracks and front idler must be removed first. As for
removal and installation of the track and the front idler,
refer to REMOVE AND INSTALL TRACK (W3-7-1)
and REMOVE AND INSTALL FRONT IDLER 2
(W3-5-1).
In this section, the procedure starts on the premise
that the tracks and front idler have already been
removed.
1

Removal

1. Remove track adjuster (1) from track frame (2) by

using a crane or forklift.
1

W1LA-03-04-001

Installation 3 2

IMPORTANT: Check that track adjuster (1) is

installed in the hole on track frame
(2) and bracket (3) is installed
completely. Check that bracket (3)
comes into contact with the end of
plate (4).
1. Install track adjuster (1) to track frame (2) as
illustrated.

4
W1M9-03-04-001

W3-4-1
 UNDERCARRIAGE / Track Adjuster
DISASSEMBLE TRACK ADJUSTER

7 6 5 4 3 2 1

W1LD-03-04-004

7 9 3 6

W1LD-03-04-003

10 11 12 13

1- Fitting 5- Bracket 9 - Retaining Ring 12 - Ring

2- Valve 6- Spring 10 - Spacer 13 - O-Ring (1B, P40)
3- Cylinder 7- Rod 11 - Dust Seal
4- Lock Bolt 8- Nut

W3-4-2
 UNDERCARRIAGE / Track Adjuster
Disassemble Track Adjuster
CAUTION: Plate (ST 4140) weight: 36 kg
(79 lb)
CAUTION: Special tool weight: 225 kg 2. Loosen the nuts (4 used) and remove plate (ST
(496 lb) 4140).
Use special tool (ST 4943) when : 46 mm
assembling/disassembling the track adjuster.
As the spring force of track adjuster is
extremely large, carry out the disassembly
and assembly work carefully. Inspect special Plate (ST 4140)
tool for any damage thoroughly in order to
perform the work safely.

1. Place an oil jack (30 ton) between the holder and

base of special tool (ST 4943).

Nut

W105-03-04-007
3. Attach a wire rope onto the track adjuster. Hoist
Special Tool (ST4943)
and set the track adjuster onto the holder of
special tool.
Holder
Track Adjuster
Oil Jack

Base
W105-03-04-006
Holder

W105-03-04-009
4. Place plate (ST 4140) on special tool (ST 4943) in
order to cover the track adjuster.

Plate (ST 4140)

Special Tool
(ST4943)

Track Adjuster

W105-03-04-011

W3-4-3
UNDERCARRIAGE / Track Adjuster

6 5 4 3 2

W1LD-03-04-004

3 6

W1LD-03-04-003

W3-4-4
 UNDERCARRIAGE / Track Adjuster

5. Operate an oil jack. Jack up the holder by the 8. Remove lock bolt (4) and remove nut (2) from
specified amount (64 mm) (2.52 in). cylinder (3).
NOTE: Spring free length: 302 mm (11.9 in) : 13 mm, 36 mm
set length of Spring: 202.2mm (7.96 in)
Holder
8 3 4

Oil Jack

W105-03-04-013
IMPORTANT: Loosen and remove valve (2) slowly W105-03-04-014
because of the pressure of cylinder
CAUTION: Plate (ST 4140) weight: 36 kg
(3).
(79 lb)
6. Remove valve (2) from cylinder (3).
Remove the nut and plate (ST 4140) after
: 19 mm
lowering the oil jack. If not lowering the oil
jack, bracket (5) and spring (6) fly off by the
CAUTION: Plate (ST 4140) weight: 36 kg reaction of spring (6).
(79 lb)
7. Install the nuts (4 used) on plate (ST 4140) and 9. Lower the oil jack slowly. Remove the nuts (4
secure the track adjuster. Operate the oil jack and used) and plate (ST 4140). Remove bracket (5)
jack up until the clearance between bracket (5) from cylinder (3).
and nut (8) is about 10 mm (0.39 in).
: 46 mm
Plate (ST 4140)

Nut

Plate (ST 4140) 5

W105-03-04-012

W105-03-04-016

W3-4-5
 UNDERCARRIAGE / Track Adjuster

7 6 3

W1LD-03-04-004

7 9 3 6

W1LD-03-04-003

10 11 12 13

W3-4-6
 UNDERCARRIAGE / Track Adjuster

10. Install eyebolt (M16, Pitch 1.5 mm) to cylinder (3).

Remove the spring (6) assembly from special
tool.

Special Tool

W105-03-04-017
11. Remove spring (6) from cylinder (3).

12. Remove rod (7) from cylinder (3).

13. Remove retaining ring (9), Spacer (10), and dust

seal (11) from cylinder (3).

14. Remove ring (12) and O-ring (13) from cylinder

(3).

W3-4-7
 UNDERCARRIAGE / Track Adjuster
ASSEMBLE TRACK ADJUSTER

7 6 5 4 3 2 1

W1LD-03-04-004

7 9 3 6 Chamber B

W1LD-03-04-003

10 11 12 13

1- Fitting 5- Bracket 9 - Retaining Ring 12 - Ring

2- Valve 6- Spring 10 - Spacer 13 - O-Ring (1B, P40)
3- Cylinder 7- Rod 11 - Dust Seal
4- Lock Bolt 8- Nut

W3-4-8
 UNDERCARRIAGE / Track Adjuster
Assemble Track Adjuster

1. Install O-ring (13) and ring (12) to cylinder (3). 5. Install spring (6) on cylinder (3). Place the spring
(6) assembly on special tool (ST 4944).
2. Apply hydraulic oil onto spacer (10) and retaining
ring (9). Install dust seal (11) with the lips of dust
seal (11) facing to the retaining ring (9) side.
Install dust seal (11), spacer (10), and retaining
ring (9) on cylinder (3).

3. Apply hydraulic oil to cylinder (3) and rod (7). Fill

grease in chamber B of cylinder (3). Push rod (7)
in cylinder (3) and release the pressure in cylinder ST 4944
(3) completely.

4. Install eyebolt (M16, Pitch 1.5 mm) to cylinder (3).

W105-03-04-017
6. Install bracket (5) on cylinder (3).

CAUTION: Plate (ST 4140) weight: 36 kg

(79 lb)
7. Hoist and place plate (ST 4140) in order to cover
the track adjuster. Secure with the nuts (4 used).
: 46 mm

Plate (ST 4140)

W105-03-04-012

W3-4-9
 UNDERCARRIAGE / Track Adjuster

7 6 5 4 3 2 1

W1LD-03-04-004

7 9 3 6

W1LD-03-04-003

10 11 12 13

W3-4-10
 UNDERCARRIAGE / Track Adjuster
8. Operate the oil jack and push spring (6) to the
CAUTION: Plate (ST 4140) weight: 36 kg
specified length.
(79 lb)
Rubber crawler: 202.2 mm (7.96 in)
10. Lower the oil jack and loosen the nuts (4 used).
Iron crawler: 238.2 mm (9.38 in)
Remove plate (ST 4140).
: 46 mm

6
Plate (ST 4140)

Oil Jack

W105-03-04-011
11. Attach a wire rope onto the track adjuster.
W105-03-04-026 Remove the track adjuster from special tool.

9. Install nut (8) on cylinder (3). Install lock bolt (4)

on nut (8).
: 36 mm Track adjuster
: 13 mm
: 29.5 N⋅m (3.0 kgf⋅m, 22 lbf⋅ft)

8 3 4

W105-03-04-027

12. Remove eyebolt from cylinder (3). Install valve

(2).
: 19 mm
W105-03-04-014

W3-4-11
 UNDERCARRIAGE / Track Adjuster
(Blank)

W3-4-12
 UNDERCARRIAGE / Front Idler
REMOVE AND INSTALL FRONT IDLER
Before removing and installing the front idler, the rub-
ber track must be removed first. For removal and in-
stallation of the rubber track, refer to “REMOVE AND
INSTALL TRACK” section.
In this section, the procedure starts on the premise
that the rubber track has already been removed.

Removal

CAUTION: Front idler weight: 36 kg (79 lb)

If the track adjuster is broken, the parts may W1M3-03-05-001

fly out. 1
Do not stand in front of the track adjuster
(the direction to shaft).

1. Remove the front idler (1) assembly from track

frame (2).
Insert a pry bar between front idler (1) and track
frame (2). Hoist and remove front idler (1) with
the yoke.

CAUTION: When storing the front idler for a W1LD-03-05-003

while, place the front idler horizontally on
wooden blocks. 2

Installation

1. Install the front idler in the reverse procedures

when removing.

• Clean and apply grease onto the sliding part in

track frame and yoke.

Track
Frame

Sliding
Part

W1M9-03-05-001

W3-5-1
 UNDERCARRIAGE / Front Idler
DISASSEMBLE AND ASSEMBLE FRONT
IDLER

3 4 5 6 7

1 8

11 10 4
W1LD-03-05-002

1 - Axle 4 - Yoke (2 Used) 7 - Cover 10 - Bolt (2 Used)

2 - Bushing (2 Used) 5 - O-Ring (2 Used) 8 - Bolt (2 Used) 11 - Floating Seal (2 Used)
3 - Idler 6 - Plate 9 - Bolt (4 Used)

W3-5-2
 UNDERCARRIAGE / Front Idler
Disassemble Assemble

1. Remove bolts (8) (2 used) and remove cover (7)
from plate (6).
: 19 mm
2. Remove bolts (9) (4 used) and plate (6) from
yokes (4) (2 used).
: 19 mm
IMPORTANT: For handling of floating seals (11) (2
3. Remove bolts (10) (2 used) from yoke (4) (2
used).
: 17 mm
IMPORTANT: For handling of floating seals (11) (2
used), refer to the section “Precau-
tions for Floating Seal Handling” on
page W1-1-4.
4. Remove yokes (4) (2 used) and floating seals
(11) (2 used) from idler (3).
1. Install bushings (2) (2 used) into idler (3) by using
a press.
2. Install axle (1) to idler (3).
3. Install O-ring (5) (2 used) to axle (1).
used), refer to the section “Precau-
tions for Floating Seal Handling” on
page W1-1-4.
4. Install floating seals (11) (2 used) and yokes (4)
(2 used) into idler (3).
5. Apply liquid adhesive onto bolts (8, 9, 10).
Install bolts (10) (2 used) to yokes (4) (2 used).
: 17 mm
: 65 N⋅m (6.5 kgf⋅m, 47 lbf⋅ft)

5. Remove O-rings (5) (2 used) from axle (1). 6. Install plate (6) to yokes (4) (2 used) with bolts (9)
(4 used).
6. Remove axle (1) from idler (3) by using a press. : 19 mm
: 110.5±12.5 N⋅m
IMPORTANT: Do not remove bushings (2) (2 used) (11.5±1.3 kgf⋅m, 83±9.4 lbf⋅ft)
unless necessary.
7. Weld four places, 90 degrees apart from each
others on the bushing (2) (2 used) bore as illus- 7. Install cover (7) to plate (6) with bolts (8) (2 used).
trated. Shrink and remove bushings (2). : 19 mm
: 110.5±12.5 N⋅m
(11.5±1.3 kgf⋅m, 83±9.4 lbf⋅ft)
90°

90°

W105-03-05-012

W3-5-3
 UNDERCARRIAGE / Front Idler
MAINTENANCE STANDARD

C D F

A
B

W503-03-05-001

Unit: mm (in)

Standard Allowable Limit Remedy

A 39 (1.54) −

B 75 (2.95) −

C 42 (1.65) − Cladding by
welding and
D 335 (13.2) − finish, or replace

E 9 (0.35) −

F 377 (14.8) −

Axle and Bushing Unit: mm (in)

Standard Allowable Limit Remedy

Axle Outer Dia. 35.0 (1.38) −

Inner Dia. 35.0 (1.38) − Replace

Bushing
Flange Thickness 3.5 (0.14) −

NOTE: Lubrication Oil

Engine Oil: SAE30 CD Class.
Engine Oil Amount: 20 mL (0.02 US qt)

W3-5-4
 UNDERCARRIAGE / Upper And Lower Roller
REMOVE AND INSTALL UPPER ROLLER
Removal
1

CAUTION: Grease pressure in the track ad-

juster is high. Do not loosen valve (1) quickly
or too much as valve (1) may fly off or
high-pressure grease in the track adjuster
may gush out. Keep body parts and face
away from valve (1) and loosen valve (1)
carefully. Do not loosen grease fitting (2). W105-03-07-002

2 1 Grease Outlet

IMPORTANT: Remove gravel or mud between

sprockets and tracks before loos-
ening valve (1). It is enough to
loosen valve (1) by only one turn.

1. Loosen valve (1) on the track adjuster. Drain

grease and loosen the track tension.
: 19 mm
M1LA-07-036

IMPORTANT: Use a nonskid cloth between track

frame (3) and oil jack (4) in order not
to slip.

2. Jack up track (6) by using oil jack (4) in order to

get clearance between track (6) and upper roller
(5). Place wooden blocks between track frame (3)
and track (6). 1

3. Remove bolt (7) and remove upper roller (5).

: 22 mm
W507-03-06-001

6 Wooden Block 5 7 3

W507-03-06-003

W3-6-1
 UNDERCARRIAGE / Upper And Lower Roller
Installation

6 Wooden Block 5 7
1. Install upper roller (5) onto track frame (3) with 3
bolt (7).
: 22 mm
: 137 N⋅m (14 kgf⋅m, 101 lbf⋅ft)

2. Remove the wooden blocks.

4

3. Lower oil jack (4). Lower track (6) and remove oil
jack (4). W507-03-06-003

4. Tighten valve (1) on the track adjuster.

: 19 mm
: 88 N⋅m (9.0 kgf⋅m, 65 lbf⋅ft) １ 2

CAUTION: Support the jacked up machine

firmly by using wooden blocks.
5. Jack up the track to be adjusted and rotate the
track in reverse direction a little.

6. Apply grease through valve fitting (2) and adjust

the track tension.

Track sag specifications (A):

10 to 15 mm (0.39 to 0.59 in) (Rubber track)

W507-03-06-005
Lower Roller

90 to 110°

Rubber Track
M503-05-050

M1M7-04-006
7. Jack up the machine by using the front attach-
ment. Remove the wooden blocks under the track
frame.

W3-6-2
 UNDERCARRIAGE / Upper And Lower Roller
REMOVE AND INSTALL LOWER ROLLER
Removal

CAUTION: Support the jacked up machine

firmly by using wooden blocks.
90 to 110°
1. Jack up the machine by using the front attach-
ment.

M1M7-04-006

CAUTION: Grease pressure in the track ad-

juster is high. Do not loosen valve (1) quickly
or too much as valve (1) may fly off or
Grease Outlet
high-pressure grease in the track adjuster 2 1
may spurt out. It is enough to loosen valve
(1) by only one turn.
Keep body parts and face away from valve (1)
and loosen valve (1) carefully. Do not loosen
grease fitting (2).

IMPORTANT: Remove gravel or mud from the

sprocket.
2. Loosen valve (1) in the track adjuster slowly. M1LA-07-036

Drain grease until the clearance is enough to re-

move lower roller (4) in the track.
: 19 mm

3. After loosening the track, tighten valve (1) as the

original condition.
: 19 mm
: 88 N⋅m (9.0 kgf⋅m, 65 lbf⋅ft)

4. Remove bolts (3) (2 used) and remove lower 3

roller (4).
: 22 mm

M588-07-052

W3-6-3
 UNDERCARRIAGE / Upper And Lower Roller
Installation
• The work should be carried out with the track be-
ing jacked up.
1
1. Install lower roller (4) under the track frame. Align
the bolt (3) holes.
2

2. Apply LOCTITE #262 on bolts (3) (2 used). Install

lower roller (4) with bolts (3) (2 used).
: 22 mm
: 156.9 to 215.8 N⋅m
(16 to 22 kgf⋅m, 116 to 159 lbf⋅ft)

3
3. Apply grease through valve fitting (2) and adjust
the track tension.

NOTE: The joint part of track (rubber track) should

be in the center when measuring the rub-
ber track tension. Turn the rubber track in M588-07-052

reverse direction so that the rubber track 4

sag faces downward.

Track sag specifications (A):

10 to 15 mm (0.39 to 0.59 in) (Rubber
track)
Lower Roller

Rubber Track
M503-05-050
Side a W567-03-07-007

Joint Part
4. Jack up the machine by using the front attach-
ment. Remove the wooden blocks under the track
frame.
Joint Part

M102-07-075

W3-6-4
 UNDERCARRIAGE / Upper And Lower Roller
(Blank)

W3-6-5
 UNDERCARRIAGE / Upper And Lower Roller
DISASSEMBLE AND ASSEMBLE LOWER
ROLLER

1 2 3 4 5 6 7 9

W1LA-03-06-001

1 - Floating Seal 4 - Axle 6 - Collar 8 - Plug

2 - Roller 5 - Floating Seal 7 - O-Ring 9 - Stopper Ring
3 - Bushing (2 Used)

W3-6-6
 UNDERCARRIAGE / Upper And Lower Roller
Disassemble Lower Roller
1. Remove plug (8) from collar (6). Drain engine oil
from the roller.
: 5 mm
IMPORTANT: The collar (6) without axle (4) and
the plug (8) cannot be removed. Re-
place the parts with the axle (4) as-
sembly.
2. Remove stopper ring (9) from collar (6). Remove
the axle (4) assembly from roller (2) through col-
lar (6) side by using a press.
IMPORTANT: As for the handling of floating seal
(1, 5), refer to “Precautions for
Floating Seal Handling” on page
W1-1-4.
3. Remove collar (6) from roller (2). Remove floating
seals (1, 5) from the both sides of roller (2).
IMPORTANT: Do not remove bushings (3) (2 used)
from roller (2). In case bushing (3)
must be replaced, replace the roller
(2) assembly.
W3-6-7
Assemble Lower Roller
IMPORTANT: As for the handling of floating seal
(1, 5), refer to “Precautions for
Floating Seal Handling” on page
W1-1-4.
1. Install floating seal (1) to roller (2) and the axle (4)
assembly. Install the axle (4) assembly in roller
(2) through the side installing floating seal (1) by
using a press.
2. Install floating seal (5) to roller (2) and collar (6).
3. Install O-ring (7) onto axle (4). Align axle (4) and
the stopper ring (9) mounting groove of collar (6).
Install collar (6) and stopper ring (9) onto axle (4).
4. Add engine oil 35 mL (SAE30, class CD) through
the plug (8) hole on collar (6).
5. Apply LOCTITE #503 to plug (8). Install plug (8)
to collar (6).
: 5 mm
: 9.8 N⋅m (1.0 kgf⋅m, 7.2 lbf⋅ft)
 UNDERCARRIAGE / Upper And Lower Roller
MAINTENANCE STANDARD

Upper Roller

W1LA-03-06-002

Unit: mm (in)
Standard Allowable Limit Remedy
A 100 (3.94) -
Replace
B 70 (2.76) -

IMPORTANT: The upper roller cannot be disas-

sembled. Replace as an assembly.

Lubricant Oil
Engine Oil SAE30 CD class.
Engine Oil Amount: 30 mL (0.03 US qt)

W3-6-8
 UNDERCARRIAGE / Upper And Lower Roller

Lower Roller

C D E

W1LA-03-06-001

Unit: mm (in)
Standard Allowable Limit Remedy
A 41 (1.61) [35 (1.38)]
B 110 (4.33) - Cladding by
welding and
C 42 (1.65) - finishing, or
D 95 (3.74) 87 (3.43) replace
E 123 (4.84) -

Axle and Bushing

Unit: mm (in)
Standard Allowable Limit Remedy
Axle Outer Dia. 35.0 (1.38) -
Inner Dia. 35.0 (1.38) - Replace
Bushing Flange 3.5 (0.14) -
Thickness

NOTE: Values in [ ] are just for reference.

Lubricant Oil
Engine Oil SAE30 CD class.
Engine Oil Amount: 70 mL (0.07 US qt)

W3-6-9
 UNDERCARRIAGE / Upper and Lower Roller
(Blank)

W3-6-10
 UNDERCARRIAGE/ Track
REMOVE AND INSTALL TRACK
Removal

CAUTION: Rubber track weight: 238 kg

(530 lb)
90～110º
CAUTION: Support the jacked up machine
firmly by using wooden blocks.

1. Jack up the machine by using the front

attachment.
M1M7-04-006

CAUTION: Grease pressure in the track

adjuster is high. Do not loosen valve (1)
quickly or too much as valve (1) may fly off
or high-pressure grease in the track adjuster
may gush out.
It is enough to loosen valve (1) by only one
2 1 Grease Outlet
turn. Keep body parts and face away from
valve (1) and loosen valve (1) carefully.
Do not loosen grease fitting (2).

IMPORTANT: Remove gravel or mud from the

sprocket.
2. Loosen valve (1) in the track adjuster slowly and
drain grease.
: 19 mm
M1LA-07-036
NOTE: If rotating the sprocket with valve (1)
loosened, removal and installation of the
track is easy.

3. Insert a steel pipe into the track. Rotate the Rotating

sprocket in reverse direction. Direction
Float the track from the front idler by using the
steel pipe. Slide the track transversely and
remove the track.

Steel Pipe
M503-07-062

W3-7-1
 UNDERCARRIAGE/ Track
Installation

CAUTION: Rubber track weight: 238 kg

(530 lb) Rotating
Direction
CAUTION: Support the jacked up machine
firmly by using wooden blocks.

1. Jack up the machine by using the front

attachment.
Steel Pipe
2. Mesh the sprocket with the track and install the M503-07-062

track to the front idler.

Rotate the sprocket in reverse direction and push
the track.
1
IMPORTANT: Check that the track is securely
engaged with the sprocket and front
idler. 2
3. Insert a steel pipe into the track. Rotate the
sprocket in reverse direction. Attach the track
onto the front idler.

4. Tighten valve (1).

: 19 mm
: 88 N⋅m (9.0 kgf⋅m, 65 lbf⋅ft)

5. Apply grease through valve fitting (2) and adjust M588-07-052

the track tension.

NOTE: The joint part of track (rubber track) should
be in the center when measuring the
rubber track tension. Turn the track in
reverse direction so that the track sag
faces downward. a

Track sag specifications (A):

10 to 15 mm (0.39 to 0.59 in) (Rubber
track)
Lower Roller

Joint Part M1LG-07-021

M102-07-075
Joint Part
Rubber Track
Side M503-05-050

W3-7-2
 UNDERCARRIAGE/ Track
MAINTENANCE STANDARD
Rubber Track Crack

1. Outside of Rubber Track 1

4
If there is a crack on lug base (1) in depth of 3
mm (0.12 in) or more, repair the track. 5
If there is a crack between lugs (2) with depth of 3 2
mm (0.12 in) or more, repair track.
If there is a crack on lugs (3) or between lugs (2)
that reaches to steel code (5) or steel core (4) 3
with length of 30 mm (1.2 in) or more,
immediately repair track.

2. Inside of Rubber Track (Roller Side)

W190-03-07-001
If there is a crack that reaches to steel code (5) or
steel core (4), immediately repair track. 4

Lug Wear

1. If the lug height (A) is less than 5 mm (0.2 in), 5 W190-03-07-002

replace the rubber track as an assembly.
Lower
Roller

Rubber Track
2. If any part of steel code (5) appeared on track,
replace the worn rubber track as an assembly.

Lug W190-03-07-003

5
W190-03-07-004

W3-7-3
 UNDERCARRIAGE/ Track

A
A

A-A W1LA-03-07-001
Unit: mm (in)
Standard Allowable Limit Remedy
1 25 (0.98) 5 (0.2)
2 47 (1.85) 60 (2.36) Replace
3 23 (0.91) 27 (1.06)

Rubber Track and Steel Code Cutting

1. When either of the two rows of steel code (5) has

cut, replace the rubber track as an assembly.

5
Steel Core Separation W190-03-07-005

1. When any steel core (4) has separated, replace

the rubber track as an assembly.

W190-03-07-006

W3-7-4
 MEMO

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 SECTION 4
FRONT ATTACHMENT

 CONTENTS 
Group 1 Front Attachment
Remove and Install Front Attachment ..... W4-1-1
Maintenance Standards .......................... W4-1-6

Group 2 Cylinder
Remove and Install Cylinders ................. W4-2-1
Disassemble Boom Cylinder................. W4-2-14
Assemble Boom Cylinder ..................... W4-2-18
Disassemble Arm Cylinder .................. W4-2-24
Assemble Arm Cylinder ........................ W4-2-28
Disassemble Bucket Cylinder ............. W4-2-34
Assemble Bucket Cylinder .................... W4-2-38
Disassemble Boom Swing Cylinder....... W4-2-44
Assemble Boom Swing Cylinder ........... W4-2-48
Disassemble Blade Cylinder ................. W4-2-54
Assemble Blade Cylinder .................... W4-2-58
Maintenance Standards ....................... W4-2-64

1M9W-4-1
(Blank)

1M9W-4-2
 FRONT ATTACHMENT / Front Attachment
REMOVE AND INSTALL FRONT
ATTACHMENT
Removal

1. Remove bolt (5). Remove cover (3) from boom 1

cylinder (2).
: 19 mm
2

CAUTION: Boom cylinder (2) weight:

ZAXIS40U-2: 55 kg (110 lb)
ZAXIS50U-2: 60 kg (130 lb)

IMPORTANT: As for handling of the nylon slings,

refer to “Precautions for the 5 4 3 W1LD-04-01-002

Handling of Nylon Slings” on page

W1-1-5.
2. Attach a nylon sling onto boom cylinder (2). Hold
boom cylinder (2) lightly.
Remove bolt (1) and pin (4).
: 22 mm
NOTE: When pin (4) cannot be removed, start the
engine and operate the boom lever in order
2
to adjust the hole position of boom cylinder
(2) piston rod end.
Wire
3. Operate the boom lever and retract the boom
cylinder (3).
W554-02-03-007
4. Place the boom cylinder (2) rod side on the
support.
In order not to extend the rod, pass a wire through
the rod hole and secure the rod. Stop the engine.
NOTE: Height of support: 700 mm (27.6 in) or
more.

W4-1-1
 FRONT ATTACHMENT / Front Attachment
ZAXIS40U-2
CAUTION: Front attachment weight: Boom Center of
ZAXIS40U-2: 555 kg (1230 lb) Gravity
ZAXIS50U-2: 582 kg (1290 lb)

5. Attach a nylon sling onto the boom. Take up slack

of nylon sling.

A
Front Attachment
Center of Gravity Arm and Bucket
Center of Gravity
W1M9-04-02-001

ZAXIS50U-2

Boom Center of
Gravity

Front Attachment A
Center of Gravity Arm and Bucket
NOTE: Attach an identification tag onto the Center of Gravity
W1M9-04-02-002
removed hoses for assembling.
6. Remove hoses (6) (6 used). Cap the open ends.
Unit: mm (in)
: 22 mm, 27 mm
ZAXIS40U-2 ZAXIS50U-2
A 2579 (101.5) 2660 (104.7)
B 867 (34.1) 783 (30.8)

6 W1M9-04-02-006

W4-1-2
 FRONT ATTACHMENT / Front Attachment
7. Remove nuts (9) (2 used) of bolt (7) from boom
foot pin (7). Remove bolt (7).
: 22 mm
7

CAUTION: Front attachment weight:

ZAXIS40U-2: 555 kg (1230 lb)
ZAXIS50U-2: 582 kg (1290 lb)

8. Remove boom foot pin (8).

9. Hoist and remove the front attachment. W1M9-04-02-008

Remove the thrust plate from left and right sides

of the boom foot pin.

W4-1-3
 FRONT ATTACHMENT / Front Attachment
Installation ZAXIS40U-2
Boom Center of
Gravity
CAUTION: Front attachment weight:
ZAXIS40U-2: 555 kg (1230 lb)
ZAXIS50U-2: 582 kg (1290 lb)

1. Hoist the front attachment. Align the boom foot pin

hole with that on swing post.
Insert the thrust plate to both right and left of the
boom foot part and adjust the right and left B
clearances within 1 mm (0.039 in).

A
Front Attachment
Center of Gravity Arm and Bucket
Center of Gravity
W1M9-04-02-001

ZAXIS50U-2
Boom Center of
Gravity

A
Front Attachment Arm and Bucket
2. Align the boom foot with the mounting hole on Center of Gravity Center of Gravity
W1M9-04-02-002
swing post. Install boom foot pin (8).

Unit: mm (in)
IMPORTANT: Apply LOCTITE #262 onto the double
nut part. Tighten the double nut so ZAXIS40U-2 ZAXIS50U-2
that the clearance of boss may A 2579 (101.5) 2660 (104.7)
become 2 to 3 mm (0.079 to 0.12 in).
B 867 (34.1) 783 (30.8)
3. Install bolt (7) and nuts (9) (2 used) to boom foot
pin (8).
: 22 mm 7
: 137 N⋅m (14 kgf⋅m, 101 lbf⋅ft)
8

W1M9-04-02-008

W4-1-4
 FRONT ATTACHMENT / Front Attachment
4. Install hoses (6) (6 used).
: 22 mm
: 39 N⋅m (4.0 kgf⋅m, 29 lbf⋅ft)
: 27 mm
: 78 N⋅m (8.0 kgf⋅m, 58 lbf⋅ft)

CAUTION: Boom cylinder weight:

ZAXIS40U-2: 55 kg (120 lb)
ZAXIS50U-2: 60 kg (130 lb) 6

5. Remove the boom cylinder.

Refer to “Install Boom Cylinder (W4-2-6).

IMPORTANT: After completing the work, add

6 W1M9-04-02-006
hydraulic oil to the specified level.
Operate every cylinder fully to the
stroke end several times and release
the pressure in the circuit. Check for
any oil leaks.

W4-1-5
 FRONT ATTACHMENT / Front Attachment
MAINTENANCE STANDARD
Pin, Bushing

M
N

B L

A W1M9-04-01-002

C A

B
E
D

I K J
G

P
Q O

W1M9-04-01-001

Unit: mm (in)
Item Standard Allowable Limit Remedy
Pin 50 (1.97) 49.0 (1.93)
A
Bushing (Boom) 50 (1.97) 51.5 (2.03)
Pin 50 (1.97) 49.0 (1.93)
B
Bushing (Boom Cylinder) 50 (1.97) 51.5 (2.03)
Pin 50 (1.97) 49.0 (1.93)
C
Bushing (Boom Cylinder) 50 (1.97) 51.5 (2.03)
Pin 50 (1.97) 49.0 (1.93)
D Replace
Bushing (Arm) 50 (1.97) 51.5 (2.03)
Pin 45 (1.77) 44.0 (1.73)
E
Bushing (Arm Cylinder) 45 (1.77) 46.5 (1.83)
Pin 45 (1.77) 44.0 (1.73)
F
Bushing (Arm Cylinder) 45 (1.77) 46.5 (1.83)
Pin 45 (1.77) 44.0 (1.73)
G
Bushing (Bucket Cylinder) 45 (1.77) 46.5 (1.83)

W4-1-6
 FRONT ATTACHMENT / Front Attachment

Unit: mm (in)
Item Standard Allowable Limit Remedy
Pin 45 (1.77) 44.0 (1.73)
Bushing (Bucket Cylinder) 45 (1.77) 46.5 (1.83)
H
Bushing (Link A) 45 (1.77) 46.5 (1.83)
Bushing (Link B) 45 (1.77) 46.5 (1.83)
Pin 45 (1.77) 44.0 (1.73)
I Bushing (Arm) 45 (1.77) 46.5 (1.83)
Link B 45 (1.77) 46.5 (1.83)
Pin 45 (1.77) 44.0 (1.73)
J
Bushing (Link A) 45 (1.77) 46.5 (1.83)
Pin 45 (1.77) 44.0 (1.73)
K
Bushing (Arm) 45 (1.77) 46.5 (1.83)
Pin 90 (3.54) 89.0 (3.50)
L
Bushing (Main Frame) 90 (3.54) 91.5 (3.60) Replace
Pin 50 (1.97) 49.0 (1.93)
M Bushing
50 (1.97) 51.5 (2.03)
(Boom Swing Cylinder)
Pin 50 (1.97) 49.0 (1.93)
N Bushing
50 (1.97) 51.5 (2.03)
(Boom Swing Cylinder)
Pin 35 (1.38) 34.0 (1.34)
O
Bushing (Blade) 35 (1.38) 36.5 (1.44)
Pin 55 (2.17) 54.0 (2.13)
P
Bushing (Blade Cylinder) 55 (2.17) 56.5 (2.22)
Pin 55 (2.17) 54.0 (2.13)
Q
Bushing (Blade Cylinder) 55 (2.17) 56.5 (2.22)

W4-1-7
 FRONT ATTACHMENT / Front Attachment
Side Cutter

D
A

W505-04-01-001
Unit: mm (in)

Standard Allowable Limit Remedy

A 127 (5.00) 85 (3.35)
B 163 6.42) -
Replace
C 223 (8.78) -
D 130 (5.12) -

Point

B C

W554-04-01-003
Unit: mm (in)

Standard Allowable Limit Remedy

A 128 (5.04) 65 (2.56)
B 56 (2.20) -
Replace
C 62 (2.44) -
D 51 (2.01) -

W4-1-8
 FRONT ATTACHMENT / Cylinder
REMOVE AND INSTALL CYLINDER
Remove Bucket Cylinder
1

CAUTION: Release any pressure in the 7

hydraulic oil tank before doing any work.
(Refer to BLEED AIR FROM HYDRAULIC OIL 3
TANK on W1-4-1.)
2
1. Insert wooden block (3) under the arm (2) top and 3
between arm (2) and bucket cylinder (1).
W554-04-02-006
IMPORTANT: Before removing pin (7), fasten the
4 5
link by using a wire in order not to
fall off.
2. Remove ring (4) and stopper pin (6) from the link.
Remove pin (7).

3. Secure piston rod (5) by using a wire in order not

to extend. 6
Link

7
W527-04-02-002
Link

CAUTION: Bucket cylinder weight:

ZAXIS40U-2: 27 kg (60 lb)
ZAXIS50U-2: 32 kg (71 lb)

4. Attach a nylon sling to bucket cylinder (1) and hold 1

bucket cylinder (1).

W571-04-02-002
9 10
8

5. Remove bolt (9). Remove pin (8) from arm (10).

1
Remove bucket cylinder (1).
: 22 mm

6. Disconnect hoses (11) (2 used) from the bottom of

bucket cylinder (1). Cap the open ends.
: 22 mm

7. Hoist and remove bucket cylinder (1). 11

W1M9-04-02-007

W4-2-1
 FRONT ATTACHMENT / Cylinder
Install Bucket Cylinder
9 10
8
CAUTION: Bucket cylinder (1) weight:
ZAXIS40U-2: 27 kg (60 lb) 1
ZAXIS50U-2: 32 kg (71 lb)

1. Hoist bucket cylinder (1). Connect hoses (11) (2

used) to bucket cylinder (1).
: 22 mm
: 39 N⋅m (4.0 kgf⋅m, 29 lbf⋅ft)
11
W1M9-04-02-007
2. Align the pin holes on the cylinder tube and arm.
Install pin (8) and secure with bolt (9).
: 22 mm 7
: 137 N⋅m (14 kgf⋅m, 101 lbf⋅ft)

3. Start the engine. Extend piston rod (5). Align the

piston rod hole on piston rod (5) with the hole on
link. Install pin (7).

W507-04-02-004

4. Insert stopper pin (6) into the link and pin (7). 4
Install ring (4).

IMPORTANT: After completing the work, operate

the bucket cylinder several times to
the stroke end and release the
pressure in the circuit. 6

Link

W527-04-02-002
Link

W4-2-2
 FRONT ATTACHMENT / Cylinder
Remove Arm Cylinder
1
1. Insert wooden block (3) between arm cylinder (1) 6
and boom (2). 5
4
2. Remove bolt (5). Remove pin (6) from arm (4).
: 22 mm

3. In order not to extend the arm cylinder, secure the

piston rod by using a wire.

4. Disconnect hoses (7) (2 used) from arm cylinder

(5). Cap the open ends.
: 27 mm 2
3
W571-04-02-004

CAUTION: Arm cylinder (1) weight: 1

ZAXIS40U-2: 42 kg (93 lb)
ZAXIS50U-2: 43 kg (95 lb)

5. Attach a nylon sling to arm cylinder (1) and hold

arm cylinder (1).

7
W527-04-02-006

W571-04-02-006
8
6. Remove bolt (9). Remove pin (10) from boom (8).
： 22 mm
1

7. Hoist and remove arm cylinder (1).

10 9 W527-04-02-008

W4-2-3
 FRONT ATTACHMENT / Cylinder
Install Arm Cylinder 8

CAUTION: Arm cylinder (1) weight: 1

ZAXIS40U-2: 42 kg (93 lb)
ZAXIS50U-2: 43 kg (95 lb)

1. Hoist arm cylinder (1) and align the pin holes on

the cylinder bottom side and boom (8).

2. Install pin (10). Secure pin (10) with bolt (9).

: 22 mm 10 9
: 137 N⋅m (14 kgf⋅m, 101 lbf⋅ft)
W527-04-02-008

3. Connect hoses (7) (2 used) to arm cylinder (1).

: 27 mm 1
: 78 N⋅m (8.0 kgf⋅m, 58 lbf⋅ft)

7
W527-04-02-006

4. Start the engine. Extend arm cylinder (1). Align the

1
piston rod hole on arm cylinder (1) with the hole
on arm. 6
5
4
5. Install pin (6). Secure pin (6) with bolt (5).
: 22 mm
: 137 N⋅m (14 kgf⋅m, 101 lbf⋅ft)

IMPORTANT: When completing the work, operate

the arm cylinder several times to the
stroke end and release the pressure
in the circuit.
2
3
W571-04-02-004

W4-2-4
 FRONT ATTACHMENT / Cylinder
Remove Boom Cylinder

1. Remove bolt (5). Remove cover (3) from boom 1

cylinder (2).
: 19 mm 2

2. Attach a nylon sling onto boom cylinder (2). Hoist

boom cylinder (2) slightly and remove bolt (1).
Remove pin (4) bolt (6).
: 22 mm

CAUTION: Boom cylinder (2) weight:

ZAXIS40U-2: 55 kg (120 lb)
ZAXIS50U-2: 60 kg (130 lb) 6 5 4
3
W1LD-04-01-002

3. Place a support under the end of boom cylinder

(2) tube. Operate the boom lever and retract the
boom cylinder. In order not to extend the piston
rod, pass a wire through the piston rod hole and
secure boom cylinder (2). 2

Wire

W554-02-03-007
4. Disconnect hoses (7) (2 used) from boom cylinder
(2). Cap the open ends.
: 27 mm

2 W1M9-04-02-006

5. Remove nuts (10) (2 used) and bolt (8). Remove 8

pin (9) from swing post (11). 2
: 19 mm

6. Hoist and remove boom cylinder (2).

W1M9-04-02-009
11 10 9

W4-2-5
 FRONT ATTACHMENT / Cylinder
Install Boom Cylinder

CAUTION: Boom cylinder (2) weight:

ZAXIS40U-2: 55 kg (120 lb) 8
ZAXIS50U-2: 60 kg (130 lb)
2
1. Hoist boom cylinder (2) and align the pin holes on
the cylinder bottom side and swing post (11).

IMPORTANT: Apply LOCTITE #262 onto the double

nut part.
Tighten the double nut so that the
clearance between double nut and
boss should be 2 to 3 mm. W1M9-04-02-009
2. Install pin (9). Secure with bolt (8) and nuts (10) (2 11 10 9
used).
: 19 mm
: 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft)

3. Connect hoses (7) (2 used) to boom cylinder (2).

: 27 mm
: 78 N⋅m (8.0 kgf⋅m, 58 lbf⋅ft)

2 W1M9-04-02-006

4. Hoist boom cylinder (2). Start the engine. Extend 1

the piston rod of boom cylinder (2). Align the pin
hole on boom (6). 2

5. Install pin (4). Secure pin (4) with bolt (1).

: 22 mm
: 137 N⋅m (14 kgf⋅m, 101 lbf⋅ft)

6. Install cover (3) onto boom cylinder (2) with bolt

(5).
: 19 mm
: 88 N⋅m (9.0 kgf⋅m, 65 lbf⋅ft) 4
6 5 3
IMPORTANT: When all work is completed, operate W1LD-04-01-002

the boom cylinder for several times

to stroke end and bleed air from the
circuit.

W4-2-6
 FRONT ATTACHMENT / Cylinder
Remove Boom Swing Cylinder
1 2 3
CAUTION: Boom swing cylinder weight:
44 kg (97 lb)

1. Make the front attachment swing to left and

remove the cover.

2. Insert a wooden block between boom swing

cylinder (1) and main frame (6) and support boom
swing cylinder (1). Remove nuts (5) (2 used) and 6 4, 5
remove bolt (4). Remove pin (2) from swing post
(3).
: 19 mm W1M9-04-02-010

NOTE: Pin (2) may come off when removing bolt

(4).
It is easy to align the bolt (4) holes if putting
the matching marks on the boss of swing
post (3) and pin (2).

3. Start the engine. Retract the piston rod to the

stroke end. In order not to extend the piston rod,
pass a wire through the boss of piston rod.

W4-2-7
 FRONT ATTACHMENT / Cylinder
4. Remove bolts (9) (9 used). Remove covers (8) (2
used) from main frame (6). 10, 11, 12 1
: 17 mm

IMPORTANT: Attach an identification tag onto the

disconnected hoses for assembling.
5. Disconnect hoses (7) (2 used) from boom swing
cylinder (1). Cap the open ends.
: 19 mm

W1M9-04-01-004

6 8, 9 7

6. Remove bolt (11). Remove pin (10) from main

frame (6). Remove spacer (12).
: 19 mm

7. Remove boom swing cylinder (1).

W4-2-8
 FRONT ATTACHMENT / Cylinder
Install Boom Swing Cylinder
10, 11, 12 1
1. Apply grease onto the lip of dust seal for boom
swing cylinder (1).

2. Attach a nylon sling onto boom swing cylinder (1).

Hoist boom swing cylinder (1).
Place the cylinder tube boss on main frame (6).
Insert a wooden block between boom swing
cylinder (1) and main frame (6) and support boom
swing cylinder (1).
W1M9-04-01-004

6 8, 9 7
3. Apply grease onto the surface of pin (10). Align
the pin (10) holes on main frame (6) and boom
swing cylinder (1). Install spacer (12) to pin (10).
Insert pin (10). Secure pin (10) to main frame (6)
with bolt (11).
: 19 mm
: 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft)

4. Connect hoses (7) (2 used) onto boom swing

cylinder (1).
: 19 mm
: 29.5 N⋅m (3.0 kgf⋅m, 22 lbf⋅ft)

5. Install cover (8) onto main frame (6) with bolts (9)
(9 used).
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)

W4-2-9
 FRONT ATTACHMENT / Cylinder
IMPORTANT: If the air in a cylinder is suddenly
compressed, the temperature inside 1 2 3
will rise. As the temperature of the
hydraulic oil will rise, the seals and
rings may be damaged.
5. Start the engine with the piston rod retracted fully
to the stroke end. Extend the piston rod slowly.
Align the pin (2) holes on boom swing cylinder (1)
and swing post (3).
NOTE: When the work in step 5 is finished, almost
all air in the cylinder has been released.

6. Apply grease onto the surface of pin (2). Align the

bolt (4) holes on swing post (3) and pin (2). Install
6 4, 5
pin (2).

IIMPORTANT: Install nut (5) so that the clearance W1M9-04-02-010

between swing post (3) boss and nut

(5) should be 2 to 3 mm (0.079 to 0.12
in).
7. Apply LOCTITE #262 on nuts (5) (2 used). Install
bolt (4) and nuts (5) (2 used).
: 19 mm
: 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft)

8. Install the cover onto main frame (6) with the bolts
(2 used).
: 13 mm
: 19.5 N⋅m (2.0 kgf⋅m, 14.5 lbf⋅ft)

IMPORTANT: After completing the work, fill

hydraulic oil to the specified level.
Operate every cylinder fully to the
stroke end several times and release
the pressure in the circuit. Check
each connection of hoses for any oil
leaks.

W4-2-10
 FRONT ATTACHMENT / Cylinder
Remove Blade Cylinder

CAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protection,
such as goggle, hard hats, etc in order to
prevent personal injury.

1. Remove bolts (1) (3 used). Remove cover (2) from

blade cylinder (3). 1 2 3
: 17 mm
4
CAUTION: Blade cylinder (3) weight: 34 kg
(75 lb) 4
6
7
8
2. Attach a nylon sling onto blade cylinder (3). Hold
blade cylinder (3).

3. Disconnect hoses (5) (2 used) from blade cylinder

(3). Cap the open ends.
: 27 mm 5

4. Remove bolts (8) (4 used) and plates (7) (2 used).

Remove pins (6) (2 used) from blade (9).
Remove thrust plate (4) between blade cylinder
(3) cylinder tube and blade (9), piston rod and
track frame. 6
: 19 mm 7
9 8
W1LD-04-02-012
5. Hoist and remove blade cylinder (3) from blade
(9).

W4-2-11
 FRONT ATTACHMENT / Cylinder
Install Blade Cylinder

CAUTION: Blade cylinder (3) weight: 34 kg

(75 lb) 1 2 3

4
1. Hoist blade cylinder (3) and align the pin holes on
bottom and blade (9), piston rod and track frame.
4
Insert thrust plates (4). Install pins (6) (2 used). 6
Secure pin (6) with bolts (8) (4 used) and plates 7
8
(7) (2 used).

2. Connect hoses (5) (2 used) onto blade cylinder

(3).
: 27 mm
: 78 N⋅m (8.0 kgf⋅m, 58 lbf⋅ft) 5

3. Install cover (2) onto blade cylinder (3) with bolts

(1) (3 used).

IMPORTANT: When all work is completed, operate

the blade cylinder for several times 6
to stroke end and bleed air from the 7
circuit. 9 8
W1LD-04-02-012

W4-2-12
 FRONT ATTACHMENT / Cylinder
(Blank)

W4-2-13
 FRONT ATTACHMENT / Cylinder
DISASSEMBLE BOOM CYLINDER

14

11
10
8
13
12
9
7
6
3
5
4
2
19
1
20
21 18
22
17
18
16

15

W1M9-04-02-013

1- Wiper Ring 7- O-Ring 13 - Spacer 19 - Seal Ring

2- Cylinder Head 8- Holder 14 - Piston Rod 20 - O-Ring
3- O-Ring 9- Collar 15 - Cylinder Tube 21 - Set Screw
4- Bushing 10 - Backup Ring 16 - Cushion Bearing 22 - Steel Ball
5- U-Ring 11 - O-Ring 17 - Piston
6- Backup Ring 12 - Cushion Seal 18 - Slide Ring (2 Used)

W4-2-14
 FRONT ATTACHMENT / Cylinder
Disassemble Boom Cylinder
• The procedures start on the premise that the pipe 3. Loosen cylinder head (2) by using a hooked
has been removed. spanner with the protective cover attached on
piston rod (14). Remove piston rod (14) from
CAUTION: Boom cylinder weight: cylinder tube (15).
ZAXIS40U-2: 55 kg (120 lb) Diameter of cylinder head (2)
ZAXIS50U-2: 60 kg (130 lb) ZAXIS40U-2: 110 mm
ZAXIS50U-2: 115 mm
IMPORTANT: Move piston rod (14) slowly and Hooked Spanner
drain hydraulic oil from the cylinder.
1. Clamp the bottom side of cylinder tube (15)
horizontally in a vise. Drain hydraulic oil from the
cylinder.
15
IMPORTANT: The lock washer in cylinder head (2)
is provided on cylinder tube (15) and
forms an integral part. Do not
damage cylinder tube (15) and
2
cylinder head (2) when bending and
extending the lock washer.
2. Pull out piston rod (14) approximately 200 mm
(7.87 in). Install a protective cover on piston rod 14 W506-04-02-004

(14). Extend the lock washer in cylinder head (2).

IMPORTANT: Set screw (21) was crimped by using
a punch at two places. Loosen set
screw (21) after cutting the crimped
Lock Washer part by using a hand drill.
4. Secure piston rod (14) horizontally. Remove set
screw (21) and steel ball (22) from piston (17).
: 5 mm

5. Remove piston (17) and cushion bearing (16)

from piston rod (14).
: 65 mm

14 2
W506-04-02-003

W4-2-15
 FRONT ATTACHMENT / Cylinder

14

11
10
8
13
12
9
7
6
3
5
4
2
19
1
20
18

17
18

15

W1M9-04-02-013

W4-2-16
 FRONT ATTACHMENT / Cylinder
6. Wind the tape onto the thread part of piston rod
(14) in order to protect the seal of cylinder head
(2). Remove the cylinder head (2) assembly from
piston rod (14).
IMPORTANT: Slide rings (18) (2 used) cannot be
reused. When disassembling the
cylinder, replace slide rings (18) with
the new one.
7. Clamp piston (17) in a vise. Remove slide rings
(18) (2 used) from piston (17).
9. Remove the holder (8) assembly from cylinder
head (2).
10. Remove backup ring (10) and O-ring (11) from the
outer side of holder (8).
11. Remove spacer (13), cushion seal (12) and collar
(9) from the inner side of holder (8).
12. Remove wiper ring (1) and U-ring (5) from the
inner side of cylinder head (2).

IMPORTANT: When removing the seals, do
damage piston (17).
8. Insert the screwdriver between piston (17)
seal ring (19). Raise seal ring (19). Cut seal
(19) by using a pair of pliers. Remove seal
(19) from piston (17).
Remove O-ring (20) in the same procedures.
17
19, 20
not 13. Remove O-ring (3), backup ring (6) and O-ring (7)
from the outer side of cylinder head (2).
and
ring IMPORTANT: Bushing (4) cannot be reused. When
ring removing bushing (4), replace
bushing (7) with the new one.
14. Remove bushing (7) by using special tool (copper
spatula).
NOTE: Bushing (4) cannot be tapped and removed
from cylinder head (2). Cut off bushing (4)
by using a lathe. Insert special tool (copper
spatula) strongly and remove bushing (4).

W506-04-02-007

W4-2-17
 FRONT ATTACHMENT / Cylinder
ASSEMBLE BOOM CYLINDER

8 9 10 11 12 13

Hole (1 Place) Detail A

1

2 3 4 5 6 7 14 15 16 17 18 19 20 21 22

W1M9-04-02-003

1- Wiper Ring 7- O-Ring 13 - Spacer 19 - Seal Ring

2- Cylinder Head 8- Holder 14 - Piston Rod 20 - O-Ring
3- O-Ring 9- Collar 15 - Cylinder Tube 21 - Set Screw
4- Bushing 10 - Backup Ring 16 - Cushion Bearing 22 - Steel Ball
5- U-Ring 11 - O-Ring 17 - Piston
6- Backup Ring 12 - Cushion Seal 18 - Slide Ring (2 Used)

W4-2-18
 FRONT ATTACHMENT / Cylinder
Assemble Boom Cylinder

IMPORTANT: Check the mounting direction of

CAUTION: Boom cylinder weight:
U-ring (5).
ZAXIS40U-2: 55 kg (120 lb)
2. Install U-ring (5) to cylinder head (2).
ZAXIS50U-2: 60 kg (130 lb)
2
IMPORTANT: Apply hydraulic oil onto the inside of
cylinder head (2).
Check that bushing (4) is not out 5
from the mounting part for U-ring (5)
in cylinder head (2) in order not to
damage U-ring (5).

Check that W1LD-04-02-004

bushing (4) is
not out.
3. Install wiper ring (1) to cylinder head (2) by using
special tool (ST 8048).

W1M9-04-02-011
ST 8048

1. Install bushing (4) into cylinder head (2) by using 2

special tool (ST 7275).

ST 7275
1
4
W506-04-02-012

2
4. Install O-ring (3), backup ring (6) and O-ring (7) to
the outer of cylinder head (2).

5. Install collar (9), cushion seal (12) and spacer (13)

to the inner side of holder (8).
Install O-ring (11) and backup ring (10) to the
outer side of holder (8).
W506-04-02-010

6. Install the holder (8) assembly to cylinder head

(2).

W4-2-19
 FRONT ATTACHMENT / Cylinder

8 9 10 11 12 13

1 Hole (1 Place) Detail A

2 3 4 5 6 7 14 15 16 17 18 19 20 21 22

W1M9-04-02-003

W4-2-20
 FRONT ATTACHMENT / Cylinder
IMPORTANT: Check that O-ring (20) is not twisted. 9. Install slide rings (18) (2 used) to piston (17) in
7. Install O-ring (20) to piston (17). Install seal ring order not to align their split portions.
(19) by using special tool 1 and 2.
Special tool 1 10. Wind the tape onto the thread of piston rod (14).
ZAXIS40U-2: ST 2594 Rotate and install the cylinder head (2) assembly
ZAXIS50U-2: ST 2335 to piston rod (14).
Special tool 2
ZAXIS40U-2: ST 2590 11. Install cushion bearing (16) and the piston (17)
ZAXIS50U-2: ST 2334 assembly to piston rod (14).
ZAXIS40U-2
Special Tool 1 : 65 mm
: 1950 N⋅m (200 kgf⋅m, 1440 lbf⋅ft)
24
ZAXIS50U-2
Special Tool 2 : 65 mm
: 2170 N⋅m (220 kgf⋅m, 1600 lbf⋅ft)
20
12. Install steel ball (22) into piston (17). Install set
17 screw (21). Crimp set screw (21) by using a punch
(2 places).
: 5 mm
: 31.5 N⋅m (3.2 kgf⋅m, 23 lbf⋅ft)
W566-04-02-010

IMPORTANT: When inserting the piston rod (14)

IMPORTANT: If not adjusting seal ring (19), piston
assembly, do not drop slide rings
(17) cannot be installed to cylinder
(18) (2 used) from piston (17).
tube (15).
Apply hydraulic oil onto the packing
8. Pass special tools through piston (17). Adjust seal
parts.
ring (19).
13. Secure cylinder tube (15) in a vise horizontally.
Special tool
Insert the piston rod (14) assembly into cylinder
ZAXIS40U-2: ST2598
tube (15) straightly in order not to damage.
ZAXIS50U-2: ST2336

17

19

Special Tool

W566-04-02-011

W4-2-21
 FRONT ATTACHMENT / Cylinder

Hole (1 Place) Detail A

2 15

W1M9-04-02-003

W4-2-22
 FRONT ATTACHMENT / Cylinder
IMPORTANT: Apply hydraulic oil onto the packing
parts.
14. Tighten cylinder head (2) to cylinder tube (15) by
using a hooked spanner. Bend the lock washer in
order not to loosen.

ZAXIS40U-2: 110 mm
: 530 N⋅m (54 kgf⋅m, 390 lbf⋅ft)
ZAXIS50U-2: 115 mm
: 569 N⋅m (58 kgf⋅m, 420 lbf⋅ft)

Hooked Spanner

15
W506-04-02-019

W4-2-23
 FRONT ATTACHMENT / Cylinder
DISASSEMBLE ARM CYLINDER

14

11
10
8
13
12
9
7
6
3
5
4
2
1
23 26
25
24
18
21 20
19
22

17
18
16

15

W1M9-04-02-014

1- Wiper Ring 8- Holder 15 - Cylinder Tube 22 - Steel Ball

2- Cylinder Head 9- Collar 16 - Cushion Bearing 23 - Retaining Ring
3- O-Ring 10 - Backup Ring 17 - Piston 24 - Cushion Seal
4- Bushing 11 - O-Ring 18 - Slide Ring (2 Used) 25 - Cushion Bearing
5- U-Ring 12 - Cushion Seal 19 - Seal Ring 26 - Stopper
6- Backup Ring 13 - Spacer 20 - O-Ring
7- O-Ring 14 - Piston Rod 21 - Set Screw

W4-2-24
 FRONT ATTACHMENT / Cylinder
Disassemble Arm Cylinder
• The procedures start on the premise that the pipe 3. Loosen cylinder head (2) by using a hooked
has been removed. spanner with the protective cover attached on
piston rod (14). Remove piston rod (14) from
cylinder tube (15).
CAUTION: Arm cylinder weight:
Diameter of cylinder head (2): 100 mm
ZAXIS40U-2: 42 kg (93 lb)
ZAXIS50U-2: 43 kg (95 lb)
Hooked Spanner
IMPORTANT: Move piston rod (14) slowly and
drain hydraulic oil from the cylinder.
1. Clamp the bottom side of cylinder tube (15)
horizontally in a vise. Drain hydraulic oil from the 15
cylinder.

IMPORTANT: The lock washer in cylinder head (2)

2
is provided on cylinder tube (15) and
forms an integral part. Do not 14
damage cylinder tube (15) and
cylinder head (2) when bending and
extending the lock washer.
2. Pull out piston rod (14) approximately 200 mm W506-04-02-004

(7.87 in). Install a protective cover on piston rod

(14). Extend the lock washer in cylinder head (2).
Lock Washer
IMPORTANT: Set screw (21) was crimped by using
a punch at two places. Loosen set
screw (21) after cutting the crimped
part by using a hand drill.
4. Secure piston rod (14) horizontally. Remove set
screw (21) and steel ball (22) from piston (17).
: 5 mm

5. Remove piston (17) and cushion bearing (16)

from piston rod (14).
: 60 mm

14 6. Remove retaining ring (23) from piston rod (14).

2
W506-04-02-003 7. Slide cushion bearing (25) to the thread side of
piston rod (14) and remove stopper (26).

8. Remove cushion bearing (25). Remove cushion

seal (24) from piston rod (14).

W4-2-25
FRONT ATTACHMENT / Cylinder

14

11
10
8
13
12
9
7
6
3
5
4
2
1
23 26
25
24
18
21 20
19
22

17
18
16

15

W1M9-04-02-014

W4-2-26
 FRONT ATTACHMENT / Cylinder
9. Wind the tape onto the thread part of piston rod
(14) in order to protect the seal of cylinder head
(2). Remove the cylinder head (2) assembly from
piston rod (14).
IMPORTANT: Slide rings (18) (2 used) cannot be
reused. When disassembling the
cylinder, replace slide ring (18) with
the new one.
10. Clamp piston (17) in a vise. Remove slide rings
(18) (2 used) from piston (17).
IMPORTANT: When removing the seals, do not
damage piston (17).
11. Insert the screwdriver between piston (17) and
seal ring (19). Raise seal ring (19). Cut seal ring
(19) by using a pair of pliers. Remove seal ring
(19) from piston (17).
Remove O-ring (20) in the same procedures.
14. Remove spacer (13), cushion seal (12) and collar
(9) from the inner side of holder (8).
15. Remove wiper ring (1) and U-ring (5) from the
inner side of cylinder head (2).
16. Remove O-ring (3), backup ring (6) and O-ring (7)
from the outside of cylinder head (2).
IMPORTANT: Bushing (4) cannot be reused. When
removing bushing (4), replace
bushing (4) with the new one.
17. Remove bushing (4) by using special tool (copper
spatula).
NOTE: Bushing (4) cannot be tapped and removed
from cylinder head (2). Cut off bushing (4)
by using a lathe. Insert special tool (copper
spatula) strongly and remove bushing (4).

17

19, 20

W506-04-02-007

12. Remove the holder (8) assembly from cylinder

head (2).

13. Remove backup ring (10) and O-ring (11) from the
outer side of holder (8).

W4-2-27
 FRONT ATTACHMENT / Cylinder
ASSEMBLE ARM CYLINDER

8 9 10 11 12 13 24

Detail B
Hole (1 Place) Detail A
1

2 3 4 5 6 7 14 15 16 17 18 19 20 21 22 23 25 26

B
A

W1M9-04-02-004

1- Wiper Ring 8- Holder 15 - Cylinder Tube 22 - Steel Ball

2- Cylinder Head 9- Collar 16 - Cushion Bearing 23 - Retaining Ring
3- O-Ring 10 - Backup Ring 17 - Piston 24 - Cushion Seal
4- Bushing 11 - O-Ring 18 - Slide Ring (2 Used) 25 - Cushion Bearing
5- U-Ring 12 - Cushion Seal 19 - Seal Ring 26 - Stopper
6- Backup Ring 13 - Spacer 20 - O-Ring
7- O-Ring 14 - Piston Rod 21 - Set Screw

W4-2-28
 FRONT ATTACHMENT / Cylinder
Assemble Arm Cylinder

IMPORTANT: Check the mounting direction of

CAUTION: Arm cylinder weight:
U-ring (5).
ZAXIS40U-2: 42 kg (93 lb)
2. Install U-ring (5) to cylinder head (2).
ZAXIS50U-2: 43 kg (95 lb)

IMPORTANT: Apply hydraulic oil onto the inside of

2
cylinder head (2).
Check that bushing (4) is not out
from the mounting part for U-ring (5) 5
in cylinder head (2) in order not to
damage U-ring (5).

4
2

Check that
bushing (4) is W1LD-04-02-004
not out.

3. Install wiper ring (1) to cylinder head (2) by using

special tool (ST 8047).

W1M9-04-02-011

1. Install bushing (4) into cylinder head (2) by using

ST 8047
special tool (ST 7325).
2

ST 7325

4
2

1
W506-04-02-012

4. Install O-ring (3), backup ring (6) and O-ring (7) to

the outer side of cylinder head (2).

W506-04-02-010 5. Install collar (9), cushion seal (12) and spacer (13)
to the inner side of holder (8).
Install O-ring (11) and backup ring (10) to the
outer side of holder (8).

6. Install the holder (8) assembly to cylinder head

(2).

W4-2-29
 FRONT ATTACHMENT / Cylinder

24

Detail B
Hole (1 Place) Detail A

2 14 15 16 17 18 19 20 21 22 23 25 26

B
A

W1M9-04-02-004

W4-2-30
 FRONT ATTACHMENT / Cylinder
IMPORTANT: Check that O-ring (20) is not twisted. 10. Wind the tape onto the thread of piston rod (14).
7. Install O-ring (20) to piston (17). Install seal ring Rotate and install the cylinder head (2) assembly
(19) by using special tools (ST 2625, ST 2623). to piston rod (14).

11. Install cushion seal (24) and cushion bearing (25)

ST 2625
to piston rod (14).

19
ST 2623

20

17 Face the slit side to the

piston. W1M9-04-02-012

12. Install stopper (26) and retaining ring (23) to

W566-04-02-010
piston rod (14).
IMPORTANT: If not adjusting seal ring (19), piston
(17) cannot be installed to cylinder 13. Install cushion bearing (16) and the piston (17)
tube (15). assembly to piston rod (14).
8. Install special tool (ST 2627) through piston (17). : 60 mm
Adjust seal ring (19). : 1435 N⋅m (146 kgf⋅m, 1060 lbf⋅ft)

17
14. Install steel ball (22) into piston (17). Install set
screw (21). Crimp set screw (21) at two places by
19 using a punch in order not to loosen.
: 5 mm
: 16.2 N⋅m (1.7 kgf⋅m, 12 lbf⋅ft)
ST 2627
IMPORTANT: When inserting the piston rod (14)
assembly, do not drop slide rings
(18) (2 used) from piston (17).
Apply hydraulic oil onto the packing
W566-04-02-011
parts.
15. Secure cylinder tube (15) in a vise horizontally.
9. Install slide rings (18) (2 used) to piston (17) in Insert the piston rod (14) assembly into cylinder
order not to align their split portions. tube (15) straightly in order not to damage.

W4-2-31
 FRONT ATTACHMENT / Cylinder

Detail B
Hole (1 Place) Detail A

2 15

B
A

W1M9-04-02-004

W4-2-32
 FRONT ATTACHMENT / Cylinder
IMPORTANT: Apply hydraulic oil onto the packing
parts.
16. Tighten cylinder head (2) to cylinder tube (15) by
using a hooked spanner. Bend the lock washer in
order not to loosen.
Diameter of cylinder head (2): 100 mm
: 451 N⋅m (46 kgf⋅m, 330 lbf⋅ft)

Hooked Spanner

15
W506-04-02-019

W4-2-33
 FRONT ATTACHMENT / Cylinder
DISASSEMBLE BUCKET CYLINDER

12
13
11
14
10 15
11

7
6
3
5
4

2
1

W1M9-04-02-015

1- Wiper Ring 5- U-Ring 9- Cylinder Tube 13 - O-Ring

2- Cylinder Head 6- Backup Ring 10 - Piston 14 - Set Screw
3- O-Ring 7- O-Ring 11 - Slide Ring (2 Used) 15 - Steel Ball
4- Bushing 8- Piston Rod 12 - Seal Ring

W4-2-34
 FRONT ATTACHMENT / Cylinder
Disassemble Bucket Cylinder
• The procedures start on the premise that the pipe 3. Loosen cylinder head (2) by using a hooked
has been removed. spanner with the protective cover attached on
piston rod (8). Remove the piston rod (8)
CAUTION: Bucket cylinder weight: assembly from cylinder tube (9).
ZAXIS40U-2: 27 kg (60 lb) Diameter of cylinder head (2)
ZAXIS50U-2: 32 kg (71 lb) ZAXIS40U-2: 90 mm
ZAXIS50U-2: 92 mm
IMPORTANT: Move piston rod (1) slowly and drain Hooked
hydraulic oil from the cylinder. Spanner
1. Clamp the bottom side of cylinder tube (9)
horizontally in a vise. Drain hydraulic oil from the
cylinder.

IMPORTANT: The lock washer in cylinder head (2) 9

is provided on cylinder tube (9) and
forms an integral part. Do not
damage cylinder tube (9) and
cylinder head (2) when bending and
2
extending the lock washer.
2. Pull out piston rod (8) approximately 200 mm
(7.87 in). Install a protective cover on piston rod
(8). Extend the lock washer in cylinder head (2). 8 W506-04-02-004

IMPORTANT: Set screw (14) was crimped by using

a punch at two places. Remove set
Lock Washer
screw (14) after cutting the crimped
part by using a hand drill.
4. Secure piston rod (8) horizontally. Remove set
screw (14) and steel ball (15) from piston (10).
: 4 mm

5. Remove piston (10) from piston rod (8).

ZAXIS40U-2
: 50 mm
9 2 ZAXIS50U-2
W506-04-02-003
: 55 mm

6. Wind the tape onto the thread part of piston rod

(8) in order to protect the seal of cylinder head (2).
Remove cylinder head (2) from piston rod (8).

W4-2-35
 FRONT ATTACHMENT / Cylinder

12
13
11

10
11

7
6
3
5
4

2
1

W1M9-04-02-015

W4-2-36
 FRONT ATTACHMENT / Cylinder
IMPORTANT: Slide rings (11)(2 used) cannot be
reused. When disassembling the
cylinder, replace slide ring (11) with
the new one.
7. Clamp piston (10) in a vise. Remove slide rings
(11) (2 used) from piston (10).
IMPORTANT: When removing the seals, do not
damage piston (10).
8. Insert the screwdriver between piston (10) and
seal ring (12). Raise seal ring (12). Cut seal ring
(12) by using a pair of pliers. Remove seal ring
(12) from piston (10).
Remove O-ring (13) in the same procedures.
IMPORTANT: Bushing (4) cannot be reused. When
removing bushing (4), replace
bushing (4) with the new one.
11. Remove bushing (4) by using special tool (copper
spatula).
NOTE: Bushing (4) cannot be tapped and removed
from cylinder head (2). Cut off bushing (4)
by using a lathe. Insert special tool (copper
spatula) strongly and remove bushing (4).

10

12, 13

W506-04-02-007

9. Remove wiper ring (1) and U-ring (5) from the

inner side of cylinder head (2).

10. Remove O-ring (7), backup ring (6) and O-ring (3)
from the outer side of cylinder head (2).

W4-2-37
 FRONT ATTACHMENT / Cylinder
ASSEMBLE BUCKET CYLINDER

1 Hole (1 Place)

2 3 4 5 6 7 8 9 10 11 12 13 14 15

W1M9-04-02-005

1- Wiper Ring 5- U-Ring 9- Cylinder Tube 13 - O-Ring

2- Cylinder Head 6- Backup Ring 10 - Piston 14 - Set Screw
3- O-Ring 7- O-Ring 11 - Slide Ring (2 Used) 15 - Steel Ball
4- Bushing 8- Piston Rod 12 - Seal Ring

W4-2-38
 FRONT ATTACHMENT / Cylinder
Assemble Bucket Cylinder

IMPORTANT: Check the mounting direction of

CAUTION: Bucket cylinder weight:
U-ring (5).
ZAXIS40U-2: 27 kg (60 lb)
2. Install U-ring (5) to cylinder head (2).
ZAXIS50U-2: 32 kg (71 lb)

IMPORTANT: Apply hydraulic oil onto the inside of 2

cylinder head (2).
Check that bushing (4) is not out
from the mounting part for U-ring (5)
in cylinder head (2) in order not to 5
damage U-ring (5).

Check that
bushing (4) is
not out. W1LD-04-02-004

3. Install wiper ring (1) to cylinder head (2) by using

special tools.
Special tool
W1M9-04-02-011
ZAXIS40U-2: ST 8045
ZAXIS50U-2: ST 8046
1. Install bushing (4) into cylinder head (2) by using
special tools.
Special Tool
ZAXIS40U-2: ST 7277
ZAXIS50U-2: ST 7276
Special Tool
Special Tool

2
4
2

1
W506-04-02-012

4. Install O-ring (3), backup ring (6) and O-ring (7) to

W506-04-02-010 the outer side of cylinder head (2).

W4-2-39
 FRONT ATTACHMENT / Cylinder

Hole (1 Place)

2 8 9 10 11 12 13 14 15

W1M9-04-02-005

W4-2-40
 FRONT ATTACHMENT / Cylinder
IMPORTANT: Check that O-ring (13) is not twisted. 7. Install slide rings (11) (2 used) to piston (10) in
5. Install O-ring (13) to piston (10). Install seal ring order not to align their split portions.
(12) by using special tool 1 and 2.
Special tool 1 8. Wind the tape onto the thread of piston rod (8).
ZAXIS40U-2: ST 2624 Rotate and install the cylinder head (2) assembly
ZAXIS50U-2: ST 2596 to piston rod (8).
Special tool 2
ZAXIS40U-2: ST 2622 9. Install the piston (10) assembly to piston rod (8).
ZAXIS50U-2: ST 2592 ZAXIS40U-2
: 50 mm
Special Tool 1 : 679 N⋅m (69 kgf⋅m, 500 lbf⋅ft)
ZAXIS50U-2
12 : 55 mm
: 861 N⋅m (88 kgf⋅m, 640 lbf⋅ft)
Special Tool 2
10. Install steel ball (15) into piston (10). Install set
screw (14). Crimp set screw (14) at two places by
13
using a punch in order not to loosen.
10 : 4 mm
: 16.2 N⋅m (1.7 kgf⋅m, 12 lbf⋅ft)

W566-04-02-010

IMPORTANT: If not adjusting seal ring (12), piston

(10) cannot be installed to cylinder
tube (9).
6. Install special tool through piston (10). Adjust seal
ring (12).
Special tool
ZAXIS40U-2: ST 2626
ZAXIS50U-2: ST 2600

10

12

Special Tool

W566-04-02-011

W4-2-41
 FRONT ATTACHMENT / Cylinder

Hole (1 Place)

2 8 9 10

W1M9-04-02-005

W4-2-42
 FRONT ATTACHMENT / Cylinder
IMPORTANT: When inserting the piston rod (8)
assembly, do not drop slide rings
(11)(2 used) from piston (10).
Apply hydraulic oil onto the packing
parts.
11. Secure cylinder tube (9) in a vise horizontally.
Insert the piston rod (8) assembly into cylinder
tube (9) straightly in order not to damage.

IMPORTANT: Apply hydraulic oil onto the packing

parts.
12. Tighten cylinder head (2) to cylinder tube (9) by
using a hooked spanner. Bend the lock washer in
order not to loosen.

Diameter of cylinder head (2)

ZAXIS40U-2: 90 mm
: 382 N⋅m (39 kgf⋅m, 280 lbf⋅ft)
ZAXIS50U-2: 92 mm
: 422 N⋅m (43 kgf⋅m, 310 lbf⋅ft)

Hooked Spanner

9
W506-04-02-019

W4-2-43
 FRONT ATTACHMENT / Cylinder
DISASSEMBLE BOOM SWING CYLINDER

12
13
11
14
10 15
11

7
6
3
5
4
2
1

W1M9-04-02-016

1- Wiper Ring 5- U-Ring 9- Cylinder Tube 13 - O-Ring

2- Cylinder Head 6- Backup Ring 10 - Piston 14 - Set Screw
3- O-Ring 7- O-Ring 11 - Slide Ring (2 Used) 15 - Steel Ball
4- Bushing 8- Piston Rod 12 - Seal Ring

W4-2-44
 FRONT ATTACHMENT / Cylinder
Disassemble Boom Swing Cylinder
• The procedures start on the premise that the pipe 3. Loosen cylinder head (2) by using a hooked
has been removed. spanner with the protective cover attached on
piston rod (8). Remove the piston rod (8)
assembly from cylinder tube (9).
CAUTION: Boom swing cylinder weight:
Diameter of cylinder head (2): 110 mm
44 kg (97 lb)
Hooked Spanner
IMPORTANT: Move piston rod (8) slowly and drain
hydraulic oil from the cylinder.
1. Clamp the bottom side of cylinder tube (9)
horizontally in a vise. Drain hydraulic oil from the
cylinder.
9

IMPORTANT: The lock washer in cylinder head (2)

is provided on cylinder tube (9) and
forms an integral part. Do not
damage cylinder tube (9) and 2
cylinder head (2) when bending and
extending the lock washer.
2. Pull out piston rod (8) approximately 200 mm 8 W506-04-02-004
(7.87 in). Install a protective cover on piston rod
(8). Extend the lock washer in cylinder head (2).
IMPORTANT: Set screw (14) was crimped by using
a punch at two places. Loosen set
screw (14) after cutting the crimped
part by using a hand drill.
Lock Washer 4. Secure piston rod (8) horizontally. Remove set
screw (14) and steel ball (15) from piston (10).
: 4 mm

5. Remove piston (10) from piston rod (8).

: 60 mm

6. Wind the tape onto the thread part of piston rod

(8) in order to protect the seal of cylinder head (2).
8 2 Remove cylinder head (2) from piston rod (8).
W506-04-02-003

W4-2-45
 FRONT ATTACHMENT / Cylinder

12
13
11

10
11

7
6
3
5
4
2
1

W1M9-04-02-016

W4-2-46
 FRONT ATTACHMENT / Cylinder
IMPORTANT: Slide rings (11)(2 used) cannot be
reused. When disassembling the
cylinder, replace slide ring (11) with
the new one.
7. Clamp piston (10) in a vise. Remove slide rings
(11) (2 used) from piston (10).
IMPORTANT: When removing the seals, do not
damage piston (10).
8. Insert the screwdriver between piston (10) and
seal ring (12). Raise seal ring (12). Cut seal ring
(12) by using a pair of pliers. Remove seal ring
(12) from piston (10).
Remove O-ring (13) in the same procedures.
IMPORTANT: Bushing (4) cannot be reused. When
removing bushing (4), replace
bushing (4) with the new one.
11. Remove bushing (4) by using special tool (copper
spatula).
NOTE: Bushing (4) cannot be tapped and removed
from cylinder head (2). Cut off bushing (4)
by using a lathe. Insert special tool (copper
spatula) strongly and remove busing (4).

10

12, 13

W506-04-02-007

9. Remove wiper ring (1) and U-ring (5) from the

inner side of cylinder head (2).

10. Remove O-ring (3), backup ring (6) and O-ring (7)
from the outer side of cylinder head (2).

W4-2-47
 FRONT ATTACHMENT / Cylinder
ASSEMBLE BOOM SWING CYLINDER

1 Hole (1 Place)

2 3 4 5 6 7 8 9 10 11 12 13 14 15

W1M9-04-02-005

1- Wiper Ring 5- U-Ring 9- Cylinder Tube 13 - O-Ring

2- Cylinder Head 6- Backup Ring 10 - Piston 14 - Set Screw
3- O-Ring 7- O-Ring 11 - Slide Ring (2 Used) 15 - Steel Ball
4- Bushing 8- Piston Rod 12 - Seal Ring

W4-2-48
 FRONT ATTACHMENT / Cylinder
Assemble Boom Swing Cylinder

IMPORTANT: Check the mounting direction of

CAUTION: Boom swing cylinder weight:
U-ring (5).
44 kg (97 lb)
2. Install U-ring (5) to the inside of cylinder head (2).
IMPORTANT: Apply hydraulic oil onto the inside of
cylinder head (2). 2
Check that bushing (4) is not out
from the mounting part for U-ring (5)
in cylinder head (2) in order not to 5
damage U-ring (5).

4
2

Check that
bushing (4) is
not out.
W1LD-04-02-004

3. Install wiper ring (1) to cylinder head (2) by using

special tool.
W1M9-04-02-011

1. Install bushing (4) into cylinder head (2) by using

special tool. ST 8047

2
ST 7325

2
1
W506-04-02-012

4. Install O-ring (3), backup ring (6) and O-ring (7) to

the outer side of cylinder head (2).
W506-04-02-010

W4-2-49
 FRONT ATTACHMENT / Cylinder

Hole (1 Place)

2 8 9 10 11 12 13 14 15

W1M9-04-02-005

W4-2-50
 FRONT ATTACHMENT / Cylinder
IMPORTANT: Check that O-ring (13) is not twisted. 8. Wind the tape onto the thread of piston rod (8).
5. Install O-ring (13) to piston (10). Install seal ring Rotate and install the cylinder head (2) assembly
(12) by using special tool. to piston rod (8).

9. Install the piston (10) assembly to piston rod (8).

ST 2192 : 60 mm
: 1820 N⋅m (185 kgf⋅m, 1340 lbf⋅ft)
12
ST 2180 10. Install steel ball (15) into piston (10). Install set
screw (14). Crimp set screw (14) at two places by
using a punch in order not to loosen.
13
: 4 mm
: 16.2 N⋅m (1.7 kgf⋅m, 12 lbf⋅ft)
10
IMPORTANT: When inserting the piston rod (8)
assembly, do not drop slide rings
W566-04-02-010
(11) (2 used) from piston (10).
Apply hydraulic oil onto the packing
IMPORTANT: If not adjusting seal ring (14), piston parts.
(10) cannot be installed to cylinder 11. Secure cylinder tube (9) in a vise horizontally.
tube (9). Insert the piston rod (8) assembly into cylinder
6. Install special tool through piston (10). Adjust seal tube (9) straightly in order not to damage.
ring (12).

10

12

ST 2598

W566-04-02-011

7. Install slide rings (11) (2 used) to piston (10) in

order not to align their split portions.

W4-2-51
 FRONT ATTACHMENT / Cylinder

Hole (1 Place)

2 9

W1M9-04-02-005

W4-2-52
 FRONT ATTACHMENT / Cylinder
IMPORTANT: Apply hydraulic oil onto the packing
parts.
12. Tighten cylinder head (2) to cylinder tube (9) by
using a hooked spanner. Bend the lock washer in
order not to loosen.
Diameter of cylinder head (2): 110 mm

: 530 N⋅m (54 kgf⋅m, 390 lbf⋅ft)

Hooked Spanner

9
W506-04-02-019

W4-2-53
 FRONT ATTACHMENT / Cylinder
DISASSEMBLE BLADE CYLINDER

9
8
7
6
5

4
3
2

14

13
12
11
10

W1LA-04-02-012

1- Piston Rod 5- Bushing 9- O-Ring 13 - Nut

2- Snap Ring 6- U-Ring 10 - Piston Ring 14 - Cylinder Tube
3- Wiper Ring 7- O-Ring 11 - Piston
4- Cylinder Head 8- Backup Ring 12 - Seal Ring

W4-2-54
 FRONT ATTACHMENT / Cylinder
Disassemble Blade Cylinder
• The procedures start on the premise that the pipe 3. Loosen cylinder head (4) by using a hooked
has been removed. spanner with the protective cover attached on
piston rod (1). Remove the piston rod (1)
CAUTION: Blade cylinder weight: 34 kg assembly from cylinder tube (14).
(75 lb) Cylinder head (4) diameter: 125 mm

Hooked Spanner
IMPORTANT: Move piston rod (1) slowly and drain
hydraulic oil from the cylinder.
1. Clamp the bottom side of cylinder tube (14)
horizontally in a vise. Drain hydraulic oil from the
cylinder.
14
IMPORTANT: The lock washer in cylinder head (4)
is provided on cylinder tube (14) and
forms an integral part. Do not
damage cylinder tube (14) and
4
cylinder head (4) when bending and
extending the lock washer.
2. Pull out piston rod (1) approximately 200 mm
(7.78 in). Install a protective cover on piston rod 1 W506-04-02-004

(1). Extend the lock washer in cylinder head (4).

4. Remove nut (13) from piston rod (1).
: 55 mm
Lock Washer
5. Remove piston (11) from piston rod (1).

6. Wind the tape onto the thread part of piston rod

(1) in order to protect the seal of cylinder head (4).
Remove cylinder head (4) from piston rod (1).

7. Clamp piston (11) in a vise. Remove piston ring

(10) from piston (11).

1 4
W506-04-02-003

W4-2-55
FRONT ATTACHMENT / Cylinder

9
8
7
6
5

4
3
2

12
11

W1LA-04-02-012

W4-2-56
 FRONT ATTACHMENT / Cylinder
IMPORTANT: When removing the seals, do not
damage piston (11).
8. Insert the screwdriver between piston (11) and
seal ring (12). Raise seal ring (12). Cut seal ring
(12) by using a pair of pliers. Remove seal ring
(12) from piston (11).

11

12

W506-04-02-007

9. Remove U-ring (6) and snap ring (2) from the

inner side of cylinder head (4). Remove wiper ring
(3) from cylinder head (4).

10. Remove O-ring (9), backup ring (8) and O-ring (7)
from the outer side of cylinder head (4).

IMPORTANT: Bushing (5) cannot be reused. When

removing bushing (5), replace
bushing (5) with the new one.
11. Remove bushing (5) from cylinder head (4).

W4-2-57
 FRONT ATTACHMENT / Cylinder
ASSEMBLE BLADE CYLINDER

2 3 4 7 6 14 1 11 13

5 8 9 10 12

W1LA-04-02-013

1- Piston Rod 5- Bushing 9- O-Ring 13 - Nut

2- Snap Ring 6- U-Ring 10 - Piston Ring 14 - Cylinder Tube
3- Wiper Ring 7- O-Ring 11 - Piston
4- Cylinder Head 8- Backup Ring 12 - Seal Ring

W4-2-58
 FRONT ATTACHMENT / Cylinder
Assemble Blade Cylinder

IMPORTANT: Check the mounting direction of

CAUTION: Blade cylinder weight: 34 kg
U-ring (6).
(75 lb)
2. Install U-ring (6) to the inner side of cylinder head
(4).
IMPORTANT: Apply hydraulic oil onto the inside of 4
cylinder head (4).
Check that bushing (5) is not out
from the mounting part for U-ring (6)
in cylinder head (4) in order not to 6
damage U-ring (6).

5
4

Check that
bushing (5) is
not out.
W1LD-04-02-004

3. Install wiper ring (3) to cylinder head (4) with snap

ring (2) by using special tool.
W577-04-02-007

Special Tool
1. Install bushing (5) into cylinder head (4) by using
special tool.
4

Special Tool

5
4
3
W506-04-02-012

4. Install O-ring (7), backup ring (8) and O-ring (9) to

the outer side of cylinder head (4).

W506-04-02-010

W4-2-59
FRONT ATTACHMENT / Cylinder

4 14 1 11 13

10 12

W1LA-04-02-013

W4-2-60
 FRONT ATTACHMENT / Cylinder
5. Install O-ring (15) to piston (11). Install piston ring 7. Wind the tape onto the thread of piston rod (1).
(10) and seal ring (12) by using special tool. Rotate and install the cylinder head (4) assembly
to piston rod (1).

ST 7339 8. Install the piston (11) assembly to piston rod (1)

with nut (13).
12 : 55 mm
ST 7338 : 1420±140 N⋅m
(145±14.5 kgf⋅m, 1050±103 lbf⋅ft)
10
IMPORTANT: When inserting the piston rod (1)
11 assembly, do not drop piston ring
(10) and seal ring (12) from piston
W1LD-04-02-014 (11).
Apply hydraulic oil onto the packing
IMPORTANT: If not adjusted piston ring (10) and parts.
seal ring (12), piston (11) cannot be 9. Secure cylinder tube (14) in a vise horizontally.
installed to cylinder tube (14). Insert the piston rod (1) assembly into cylinder
6. Install special tool through piston (11). Adjust tube (14) straightly in order not to damage.
piston ring (10) and seal ring (12).

11

10

12
ST 7340

W1LD-04-02-015

W4-2-61
FRONT ATTACHMENT / Cylinder

4 14

W1LA-04-02-013

W4-2-62
 FRONT ATTACHMENT / Cylinder
IMPORTANT: Apply hydraulic oil onto the packing
parts.
10. Tighten cylinder head (4) to cylinder tube (14) by
using a hooked spanner. Bend the lock washer in
order not to loosen.
Cylinder head (4) diameter: 125 mm
: 863±86.5 N⋅m
(88±8.8 kgf⋅m, 640±64 lbf⋅ft)

Hooked Spanner

14
W506-04-02-019

W4-2-63
 FRONT ATTACHMENT / Cylinder
MAINTENANCE STANDARD
Piston Rod
Rod Bend and Run Out
A
Dial Gauge
Piston Rod

W105-04-02-094

ZAXIS40U-2 Unit: mm (in) W166-04-02-022

Cylinder Name Recommended Size After 1 m (39.4 in)

V Block
Re-manufacturing (A)
+0.023 +0.0009 Unit: mm (in)
Boom 55 -0.043 (2.17 -0.0017 )
Bend Run Out Remedy
Arm 50 +0.023 +0.0009
(1.97 -0.0017 )
-0.043 0.5 1.0
+0.023 +0.0009
Repair
Bucket 40 ) (0.020) (0.039)
-0.043 (1.58 -0.0017
1.0 2.0
50 +0.023 +0.0009 Replace
Boom Swing -0.043 (1.97 -0.0017
) (0.039) (0.079)
+0.023 +0.0009
Blade 50 (1.97 )
-0.043 -0.0017
NOTE: 1 mm=0.039 in

ZAXIS50U-2 Unit: mm (in)

Cylinder Name Recommended Size After

Re-manufacturing (A)
+0.023 +0.0009
Boom 55 -0.043 (2.17 -0.0017 )
Arm 50 +0.023 +0.0009
(1.97 -0.0017 )
-0.043
+0.023 +0.0009
Bucket 45 (1.77 -0.0017 )
-0.043
+0.023 +0.0009
Boom Swing 50 (1.97 -0.0017 )
-0.043
+0.023 +0.0009
Blade 50 (1.97 -0.0017 )
-0.043

Wear to Inner Diameter of Rod Bushing

Unit: mm (in)

Cylinder Standard Inner Allowable

Name Limit Remedy
Diameter (C)
+0.21 +0.008 +0.3
Boom 55 ( ) (+0.012)
Replace
+0.16 +0.006
+0.21 +0.008 C
+0.3
Arm 50 ( ) (+0.012)
Replace
+0.16 +0.006
+0.16 +0.008 +0.3
40U-2 40 +0.11 ( +0.006 ) (+0.012)
Replace
Bucket
+0.16 +0.008 +0.3
50U-2 45 ( ) Replace
+0.11 +0.006 (+0.012)
+0.21 +0.008 +0.3
Boom Swing 50 ( ) Replace
+0.16 +0.006 (+0.012)

W4-2-64
 MEMO

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ENGINE AND ACCESSORY
 CONTENTS 
General
Engine Nomenclature ....................................... 1
Specifications ................................................... 1
Fuel Oil, Lubricating Oil and Cooling Water .... 14
Engine External Views.................................... 18
Structural Description ..................................... 19
Exhaust Gas Emission Regulation.................. 20
Inspection and Adjustment
Periodic Maintenance Schedule...................... 24
Periodic Inspection and
Maintenance Procedure .............................. 25
Adjusting the No-load Maximum or
Minimum Speed .......................................... 52
Sensor Inspection .......................................... 53
Water Leak Check in Cooling Water System .. 53
Radiator Cap Inspection ................................. 54
Thermostat Inspection .................................... 54
Adjusting Operation........................................ 55
Long Storage.................................................. 55
Troubleshooting
Preparation before Troubleshooting................ 56
Quick Reference Table for Troubleshooting .... 57
Troubleshooting by Measuring
Compression Pressure ............................... 60
Disassembly, Inspection and Reassembly
of Engines
Complete Disassembly and Reassembly ........ 62
Cylinder Head: Disassembly, Inspection
and Reassembly ......................................... 73
Gear Train and Camshaft ............................... 86
Cylinder Block ................................................ 93
1M9W-5-1
SECTION 5
Lubrication System
Lubrication System Diagram .........................111
Trochoid Pump Components . ...................... 112
Disassembly (Reverse the Procedure
below for Assembly) .................................. 112
Servicing Points............................................ 112
Parts Inspection and Measurement .............. 113
Cooling System
Cooling Water System. ................................. 115
Cooling Water Pump Components ................ 115
Disassembly (Reverse the Procedure
below for Assembly) .................................. 116
Servicing Points............................................ 116
Fuel Injection Pump / Governor
Introduction .................................................. 117
Fuel Injection Pump...................................... 117
Turbocharger: Disassembly, Inspection
and Reassembly
Structure and Functions................................ 121
Service Standards and Tightening Torque..... 124
Periodic Inspection Procedure ...................... 126
Disassembly Procedure ................................ 130
Washing and Inspection Procedure .............. 133
Reassembly Procedure ................................ 137
Handling after Disassembly and
Reassembly .............................................. 140
Troubleshooting............................................ 141
Starting Motor
For 4TNV94L/ 98.......................................... 143
For 4TNV106 (T) .......................................... 159

Alternator
The 40A Alternator for 3TNV84 and
Other Models ............................................ 179

Electric Wiring
Electric Wiring Diagram................................ 183
Precaution on Electric Wiring ....................... 184

Service Standards
Engine Tuning .............................................. 188
Engine Body ................................................. 189
Lubricating Oil System (Trochoid Pump)....... 198

Tightening Torque for Bolts and Nuts

Tightening Torques for Main
Bolts and Nuts .......................................... 199
Tightening Torques for Standard
Bolts and Nuts .......................................... 200

1M9W-5-2
 PREFACE

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

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

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

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c 2003 YANMAR CO., LTD

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

(R.1)
 SAFETY LABELS

• Most accidents are caused by negligence of basic safety rules and precautions. For accident prevention, it
is important to avoid such causes before development to accidents.
Please read this manual carefully before starting repair or maintenance to fully under-
stand safety precautions and appropriate inspection and maintenance procedures.
Attempting at a repair or maintenance job without sufficient knowledge may cause an unexpected accident.

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

ation for safety is required in addition to the matters marked . Especially for safety precautions
in a repair or maintenance job not described in this manual, receive instructions from a knowledgeable
leader.

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

DANGER-indicates an imminently hazardous situation which,

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

WARNING-indicates a potentially hazardous situation which, if not

avoided, COULD result in death or serious injury.

CAUTION-indicates a potentially hazardous situation which, if not

avoided, MAY result in minor or moderate injury.

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

(1) SERVICE AREA

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

•Safe / Adequate Work Area

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

•Bright, Safely Illuminated Area

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

•Safety Equipment
Fire extinguisher(s), first aid kit and eye wash / shower station should be
close at hand (or easily accessible) in case of an emergency.
(2) WORK – WEAR (GARMENTS

•Safe Work Clothing

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

(3) TOOLS

•Appropriate Lifting / Holding

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

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

(4) GENUINE PARTS and MATERIALS

•Genuine Parts
Always use genuine YANMAR parts or YANMAR recommended parts and
goods. Damage to the engine, shortened engine life and or personal injury
may result.
(5) FASTENER TORQUE

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

(6) ELECTRICAL

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

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

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

(7) WASTE MANAGEMENT

Observe the following instructions with regard to hazardous waste disposal.

Negligence of these will have a serious impact on environmental pollution
concerns.
1)Waste fluids such as lube oil, fuel and coolant shall be carefully put into sep-
arate sealed containers and disposed of properly.
2)Do NOT dispose of waste materials irresponsibly by dumping them into the
sewer, overland or into natural waterways.
3)Waste materials such as oil, fuel, coolant, solvents, filter elements and bat-
teries, must be disposed of properly according to local ordinances. Consult
the local authorities or reclamation facility.
(8) FURTHER PRECAUTIONS

•Fueling / Refueling
Keep sparks, open flames or any other form of ignition (match, cigarette, etc.)
away when fueling/refueling the unit. Fire and or an explosion may result.

•Hot Surfaces.
Do NOT touch the engine (or any of its components) during running or shortly
after shutting it down. Scalding / serious burns may result. Allow the engine to
cool down before attempting to approach the unit.

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

•Preventing burns from scalding

1)Never open the radiator filler cap shortly after shutting the engine down.
Steam and hot water will spurt out and seriously burn you. Allow the engine
to cool down before attempt to open the filler cap.
2)Securely tighten the filler cap after checking the radiator.
Steam can spurt out during engine running, if tightening loose.
Precautions for Service Work
(1) Precautions for Safety
Read the safety precautions given at the beginning of this manual carefully and always mind safety in work.

(2) Preparation for Service Work

Preparation is necessary for accurate, efficient service work. Check the customer ledger file for the history of
the engine.
• Preceding service date
• Period/operation hours after preceding service
• Problems and actions in preceding service
• Replacement parts expected to be required for service
• Recording form/check sheet required for service

(3) Preparation before Disassembly

• Prepare general tools, special service tools, measuring instruments, oil, grease, nonreusable parts, and
parts expected to be required for replacement.
• When disassembling complicated portions, put match-marks and other marks at places not adversely
affecting the function for easy reassembly.

(4) Precautions in Disassembly

• Each time a parts is removed, check the part installed state, deformation, damage, roughening, surface
defect, etc.
• Arrange the removed parts orderly with clear distinction between those to be replaced and those to be
used again.
• Parts to be used again shall be washed and cleaned sufficiently.
• Select especially clean locations and use clean tools for disassembly of hydraulic units such as the fuel
injection pump.

(5) Precautions for Inspection and Measurement

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

(6) Precautions for Reassembly

• Reassemble correct parts in correct order according to the specified standards (tightening torques, and
adjustment standards). Apply oil important bolts and nuts before tightening when specified.
• Always use genuine parts for replacement.
• Always use new oil seals, O-rings, packing and cotter pins.
• Apply sealant to packing depending on the place where they are used. Apply of grease to sliding contact
portions, and apply grease to oil seal lips.

(7) Precautions for Adjustment and Check

Use measuring instruments for adjustment to the specified service standards.

How to Read this Manual

(1) Range of Operation Explanation
This manual explains the troubleshooting, installation/removal, replacement, disassemble/reassembly,
inspection, adjustment and adjusting operation procedures for the TNV series engines with direct injection
system.
Refer to the manufacturer’s manual for each of the fuel injection pump, governor, starting motor and alternator
except for their installation.
(2) How to Read the Explanations
• An exploded view, sectional views, a system diagram, etc. are shown at the beginning of each section as
required for easy understanding of the mounted states of the components.
• For the removal/installation of each part, the procedure is shown with the procedural step No. in the illus-
tration.
• Precautions and key points for disassembly and reassembly of parts are described as points. In the expla-
nation for each point, detailed operation method, information, standard and precautions are described.
Description Example

ԠFlywheel
Flywheel housing

ԟStarter ԢGear case flange

ԡCamshaft
ԙCooling water pump

Fuel pump spacer ԝ Camshaft driving gear

Idle gear

ԜFuel injection pump

Pump flange
Don't disassemble! Fuel pump drive gear Crankshaft
gear
Flange bolt
ԛGear case

ԣOil seal

ԚCrankshaft pulley
Note) This figure shows the 3TNV84.

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

• Disassembly procedure
1)Follow steps (1) to (15) of the cylinder head disassembly procedure.
2)Remove the cooling water pump.
3)Remove the crankshaft pulley. (Point 1) I Operation point to be explained on a later page.

• Operation points
Disassemble: Service point for removal
Reassemble: Service point for installation
Disassemble-Reassemble: Service point required in both removal and installation.
 • Contents omitted in this manual
Though the following jobs are omitted in the explanation in this manual, they should be conducted in actual
work:
3)Jacking up and lifting
4)Cleaning and washing of removed parts as required
5)Visual inspection

(3) Definition of Terms

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

(4) Abbreviations

Abbreviation Meaning Abbreviation Meaning

Assy assembly T.D.C. top dead center
Sub-Assy sub-assembly B.D.C. bottom dead center
a.T.D.C after top dead center OS oversize
b.T.D.C before top dead center US undersize
STD Standard Min-1 revolutions per minute
IN Intake PS Output (metric horsepower)
EX Exhaust T Bolt/nut tightening torque
 CONTENTS
1. General ............................................................................................................................ 1
1.1 Engine nomenclature ...............................................................................................................1
1.2 Specifications ...........................................................................................................................1
1.3 Fuel oil, lubricating oil and cooling water ...............................................................................14
1.3.1 Fuel oil ............................................................................................................................................ 14
1.3.2 Lubricating oil.................................................................................................................................. 16
1.3.3 Cooling water .................................................................................................................................. 17
1.4 Engine external views ...........................................................................................................18
1.5 Structural description ............................................................................................................19
1.6 Exhaust gas emission regulation ...........................................................................................20
1.6.1 The emission standard in USA ...................................................................................................... 20
1.6.2 Engine identification........................................................................................................................ 21
1.6.3 Guarantee conditions for the EPA emission standard .................................................................... 22

2. Inspection and adjustment ............................................................................................. 24

2.1 Periodic maintenance schedule .............................................................................................24
2.2 Periodic inspection and maintenance procedure ...................................................................25
2.2.1 Check before daily operation .......................................................................................................... 25
2.2.2 inspection after initial 50 hours operation ....................................................................................... 27
2.2.3 Inspection every 50 hours............................................................................................................... 30
2.2.4 Inspection every 250 hours or 3 months......................................................................................... 34
2.2.5 Inspection every 500 hours or 6 months......................................................................................... 37
2.2.6 Inspection every 1,000 hours or one year....................................................................................... 39
2.2.7 Inspection every 2000 hours or 2 years.......................................................................................... 48
2.3 Adjusting the no-load maximum or minimum speed ..............................................................52
2.4 Sensor inspection ...................................................................................................................53
2.4.1 Oil pressure switch.......................................................................................................................... 53
2.4.2 Thermo switch................................................................................................................................. 53
2.5 Water leak check in cooling water system .............................................................................53
2.6 Radiator cap inspection ..........................................................................................................54
2.7 Thermostat Inspection ............................................................................................................54
2.8 Adjusting operation ................................................................................................................55
2.9 Long storage ..........................................................................................................................55

3. Troubleshooting ............................................................................................................. 56
3.1 Preparation before troubleshooting ........................................................................................56
3.2 Quick reference table for troubleshooting ..............................................................................57
3.3 Troubleshooting by measuring compression pressure ..........................................................60
4. Disassembly, inspection and reassembly of engines .................................................... 62
4.1 Complete disassembly and reassembly .................................................................................62
4.1.1 Introduction ..................................................................................................................................... 62
4.1.2 Special service tools ....................................................................................................................... 63
4.1.3 Complete disassembly.................................................................................................................... 68
4.1.4 Precautions before and during reassembly .................................................................................... 72
4.1.5 Adjusting operation ......................................................................................................................... 72
4.2 Cylinder head: Disassembly, inspection and reassembly ......................................................73
4.2.1 Components (2-valve cylinder head) .............................................................................................. 73
4.2.2 Disassembly procedure: ................................................................................................................. 73
4.2.3 Reassembly procedure: .................................................................................................................. 74
4.2.4 Servicing points............................................................................................................................... 75
4.2.5 Parts Inspection and measurement ................................................................................................ 79
4.2.6 Valve seat correction ...................................................................................................................... 83
4.2.7 Valve guide replacement ................................................................................................................ 84
4.2.8 Valve stem seal replacement.......................................................................................................... 85
4.3 Gear train and camshaft .........................................................................................................86
4.3.1 Components.................................................................................................................................... 86
4.3.2 Disassembly procedure: ................................................................................................................. 86
4.3.3 Reassembly procedure: .................................................................................................................. 86
4.3.4 Servicing points............................................................................................................................... 87
4.3.5 Parts inspection and measurement ................................................................................................ 90
4.3.6 Oil seal replacement (Gear case side)............................................................................................ 92
4.3.7 Camshaft bushing replacement ...................................................................................................... 92
4.4 Cylinder block .........................................................................................................................93
4.4.1 Components.................................................................................................................................... 93
4.4.2 Disassembly procedure: ................................................................................................................. 93
4.4.3 Reassembly procedure: .................................................................................................................. 93
4.4.4 Servicing points............................................................................................................................... 94
4.4.5 Parts inspection and measurement ................................................................................................ 98
4.4.6 Cylinder bore correction................................................................................................................ 109
4.4.7 Piston pin bushing replacement.................................................................................................... 110
4.4.8 Oil seal replacement (Flywheel housing side) .............................................................................. 110

5. Lubrication system ....................................................................................................... 111

5.1 Lubrication system diagram .................................................................................................111
5.2 Trochoid pump components .................................................................................................112
5.3 Disassembly (Reverse the procedure below for assembly) .................................................112
5.4 Servicing points ....................................................................................................................112
5.5 Parts Inspection and measurement .....................................................................................113
 5.5.1 Trochoid pump inspection and measurement............................................................................... 113

6. Cooling system ............................................................................................................ 115

6.1 Cooling water system ...........................................................................................................115
6.2 Cooling water pump components .........................................................................................115
6.3 Disassembly (Reverse the procedure below for assembly) .................................................116
6.4 Servicing points ....................................................................................................................116

7. Fuel injection pump / Governor ................................................................................... 117

7.1 Introduction ..........................................................................................................................117
7.2 Fuel injection pump ..............................................................................................................117
7.2.1 Fuel system diagram..................................................................................................................... 117
7.2.2 External view and components ..................................................................................................... 118
7.2.3 Disassembly procedure: ............................................................................................................... 118
7.2.4 Assembly procedure ..................................................................................................................... 119
7.2.5 Servicing points............................................................................................................................. 119
7.2.6 C.S.D. (Cold Start Device) ............................................................................................................ 120

8. Turbocharger: Disassembly, inspection and reassembly ............................................ 121

8.1 Structure and functions ........................................................................................................121
8.1.1 Main specifications........................................................................................................................ 121
8.1.2 Construction.................................................................................................................................. 121
8.1.3 Structural and functional outline.................................................................................................... 122
8.1.4 Components.................................................................................................................................. 123
8.2 Service standards and tightening torque ..............................................................................124
8.2.1 Service standards ......................................................................................................................... 124
8.2.2 Tightening torque .......................................................................................................................... 125
8.3 Periodic inspection procedure ..............................................................................................126
8.3.1 Periodic inspection intervals ......................................................................................................... 126
8.3.2 Inspection procedure .................................................................................................................... 127
8.3.3 Waste gate valve adjustment procedure....................................................................................... 128
8.4 Disassembly procedure ........................................................................................................130
8.4.1 Preparation for disassembly ......................................................................................................... 130
8.4.2 Inspection before disassembly...................................................................................................... 131
8.4.3 Disassembly.................................................................................................................................. 131
8.5 Washing and inspection procedure ......................................................................................133
8.5.1 Washing ........................................................................................................................................ 133
8.5.2 Inspection procedure .................................................................................................................... 134
8.6 Reassembly procedure ........................................................................................................137
8.6.1 Preparation for reassembly........................................................................................................... 137
8.6.2 Reassembly .................................................................................................................................. 137
8.7 Handling after disassembly and reassembly ........................................................................140
 8.7.1 Instructions for turbocharger installation ....................................................................................... 140
8.8 Troubleshooting ...................................................................................................................141
8.8.1 Excessively exhaust smoke .......................................................................................................... 141
8.8.2 White smoke generation ............................................................................................................... 141
8.8.3 Sudden oil decrease ..................................................................................................................... 142
8.8.4 Decrease in output........................................................................................................................ 142
8.8.5 Poor (slow) response (starting) of turbocharger ........................................................................... 142
8.8.6 Abnormal sound or vibration ......................................................................................................... 142

9. Starting motror ............................................................................................................. 143

9.1 For 4TNV94L/ 98 ..................................................................................................................143
9.1.1 Specifications................................................................................................................................ 143
9.1.2 Components.................................................................................................................................. 144
9.1.3 Troubleshooting ............................................................................................................................ 145
9.1.4 Names of parts and disassembly procedure................................................................................. 146
9.1.5 Inspection and maintenance ......................................................................................................... 150
9.1.6 Service standards ......................................................................................................................... 155
9.1.7 Assembly ...................................................................................................................................... 156
9.1.8 Characteristic test ......................................................................................................................... 158
9.2 For 4TNV106 (T) ..................................................................................................................159
9.2.1 Specifications................................................................................................................................ 159
9.2.2 Congiguration drawing .................................................................................................................. 159
9.2.3 Troubleshooting ............................................................................................................................ 160
9.2.4 Component names and disassembly procedure........................................................................... 161
9.2.5 Disassembly procedure ................................................................................................................ 162
9.2.6 Inspection and maintenance ......................................................................................................... 170
9.2.7 Assembly ...................................................................................................................................... 176
9.2.8 Adjustment .................................................................................................................................... 177
9.2.9 Service standards ......................................................................................................................... 178

10. Alternator ................................................................................................................... 179

10.1 The 40A alternator for 3TNV84 and other models .............................................................179
10.1.1 Components................................................................................................................................ 179
10.1.2 Specifications.............................................................................................................................. 180
10.1.3 Wiring diagram............................................................................................................................ 180
10.1.4 Standard output characteristics .................................................................................................. 181
10.1.5 Inspection.................................................................................................................................... 181
10.1.6 Troubleshooting .......................................................................................................................... 182

11. Electric wiring ............................................................................................................ 183

11.1 Electric wiring diagram .......................................................................................................183
11.2 Precaution on electric wiring ..............................................................................................184
 11.2.1 Alternator .................................................................................................................................... 184
11.2.2 Starter ......................................................................................................................................... 185
11.2.3 Current limiter ............................................................................................................................. 186
11.2.4 Section area and resistance of electric wire ............................................................................... 187

12. Service standards ...................................................................................................... 188

12.1 Engine tuning .....................................................................................................................188
12.2 Engine body .......................................................................................................................189
12.2.1 Cylinder head.............................................................................................................................. 189
12.2.2 Gear train and camshaft ............................................................................................................. 192
12.2.3 Cylinder block ............................................................................................................................. 193
12.3 Lubricating oil system (Trochoid pump) .............................................................................198

13. Tightening torque for bolts and nuts .......................................................................... 199

13.1 Tightening torques for main bolts and nuts ........................................................................199

13.2 Tightening torques for standard bolts and nuts ..................................................................200

 1. General

1. General
1.1 Engine nomenclature

4 TNV ٤٤ (A) (T) - ٤٤ ٤

Destination code

Nominal engine speed or output code

T: With turbocharger
None: Natural aspirated engine

The subdivision code of the model name

Cylinder bore (in mm)

Model series

Number of cylinders

The engine specification class

Classification Load Engine speed Available engine speed (min-1)

CL Constant load Constant speed 1500/1800
VM Variable load Variable speed 2000-3000

Ú The engine specification class (CL or VM) is described in the specifications table.

1.2 Specifications
NOTE:
1)The information described in the engine specifications tables (the next page and after) is for "standard"
engine. To obtain the information for the engine installed in each machine unit, refer to the manual pro-
vided by the equipment manufacturer.
2)Engine rating conditions are as follows (SAE J1349, ISO 3046/1)
• Atmospheric condition: Room temp. 25 °C, Atmospheric press. 100 kPa (750 mm Hg), Relative humidity
30 %
• Fuel temp: 25 °C (Fuel injection pump inlet)
• With cooling fan, air cleaner, exhaust silencer (Yanmar standard parts)
• After running-in hours. Output allowable deviation: ± 3 %

1
1. General

(1) 3TNV82A
Engine name Unit 3TNV82A
Engine specification class - CL VM
Type - Vertical, in-line, 4-cycle, water-cooled diesel engine
Combustion chamber - Direct injection
Number of cylinders - 3
Cylinder bore × stroke mm × mm 82 × 84
Displacement L 1.331
Revolving
speed Min-1 1500 1800 -
Continuous
rating kW 9.9 12.0
Output -
(ps) (13.5) (16.3)
Revolving
speed Min-1 1500 1800 2000 2200 2400 2500 2600 2800 3000
Rated output
kW 11.0 13.2 14.6 16.0 17.5 18.2 19.0 20.4 21.9
Output
(ps) (14.9) (17.9) (19.9) (21.8) (23.8) (24.8) (25.8) (27.8) (29.8)
Max. no-load speed (± 25) min-1 1600 1895 2180 2375 2570 2675 2780 2995 3180
Ignition order - 1-3-2-1 (No.1 cylinder on flywheel side)
Power take off - Flywheel
Direction of rotation - Counterclockwise (viewed from flywheel)
Cooling system - Radiator
Lubrication system - Forced lubrication with trochoid pump
Starting system - Electric
Diesel oil-ISO 8217 DMA, BS 2869 A1 or A2
Applicable fuel -
(Cetane No.45 min.)
Applicable lubricant - API grade class CD or CF
Lubricant capacity Total L 5.5
(oil pan) * Effective L 1.9
Cooling water capacity
L 1.8
(engine only)
Overall
mm 553 528
Engine Dimensions ** length
(with flyw Crankshaft Overall
mm 489
V pulley diameter & width
heel housing) *
Overall
mm 565
height
Engine mass (dry) *,**
kg 138 128
(with flywheel housing)
Cooling fan (std.) * mm 335 mm O/D, 6 blades pusher type F
Fun V pulley diameter (std.) * mm 120 × 90 110 × 110

* Items marked * may differ from the above depending on an engine installed on a machine unit.
** Engine mass and dimensions without radiator

2
 1. General

(2) 3TNV84
Engine name Unit 3TNV84
Engine specification class - CL VM
Type - Vertical, in-line, 4-cycle, water-cooled diesel engine
Combustion chamber - Direct injection
Number of cylinders - 3
Cylinder bore × stroke mm × mm 84 × 90
Displacement L 1.496
Revolving
speed Min-1 1500 1800 -
Continuous
rating kW 11.3 13.5
Output -
(ps) (15.3) (18.3)
Revolving
speed Min-1 1500 1800 2000 2200 2400 2500 2600 2800 3000
Rated output
kW 12.4 14.8 16.4 18.1 19.7 20.5 21.3 23.0 24.6
Output
(ps) (16.8) (20.1) (22.3) (24.6) (26.8) (27.9) (29.0) (31.3) (33.5)
Max. no-load speed (± 25) min-1 1600 1895 2180 2400 2590 2690 2810 2995 3210
Ignition order - 1-3-2-1 (No.1 cylinder on flywheel side)
Power take off - Flywheel
Direction of rotation - Counterclockwise (viewed from flywheel)
Cooling system - Radiator
Lubrication system - Forced lubrication with trochoid pump
Starting system - Electric
Diesel oil-ISO 8217 DMA, BS 2869 A1 or A2
Applicable fuel -
(Cetane No.45 min.)
Applicable lubricant - API grade class CD
Lubricant capacity Total L 6.7
(oil pan) * Effective L 2.8
Cooling water capacity
L 2.0
(engine only)
Overall
mm 589 564
length
*
Overall
Engine dimensions ** mm 486
width
(with flywheel housing)
Overall
mm 622
height
Engine mass (dry) *,**
kg 161 155
(with flywheel housing)
Cooling fan (std.) * mm 335 mm O/D, 6 blades pusher type F
Crankshaft V pulley diameter &
mm 120 × 90 110 × 110
Fun V pulley diameter (std.) *

* Items marked * may differ from the above depending on an engine installed on a machine unit.
** Engine mass and dimensions without radiator

3
1. General

(3) 3TNV84T
Engine name Unit 3TNV84T
Engine specification class - CL VM
Type - Vertical, in-line, 4-cycle, water-cooled diesel engine
Combustion chamber - Direct injection
Number of cylinders - 3
Cylinder bore × stroke mm × mm 84 × 90
Displacement L 1.496
Revolving
speed Min-1 1500 1800 -
Continuous
rating kW 14.0 16.5
Output -
(ps) (19.0) (22.5)
Revolving
speed Min-1 1500 1800 2000 2200 2400 2500 2600 2800 3000
Rated output
kW 15.8 18.8 25.0 26.0 26.8 29.1 30.9
Output
(ps) (21.5) (25.5) (34.0) (35.3) (36.5) (39.5) (42.0)
Max. no-load speed (± 25) min-1 1600 1895 2590 2700 2810 2995 3210
Ignition order - 1-3-2-1 (No.1 cylinder on flywheel side)
Power take off - Flywheel
Direction of rotation - Counterclockwise (viewed from flywheel)
Cooling system - Radiator
Lubrication system - Forced lubrication with trochoid pump
Starting system - Electric
Diesel oil-ISO 8217 DMA, BS 2869 A1 or A2
Applicable fuel -
(cetane No.45 min.)
Applicable lubricant - API grade class CD or CF
Lubricant capacity Total L 6.7
(oil pan) * Effective L 2.8
Cooling water capacity
L 2.0
(engine only)
Overall
mm 589 564
length
*
Overall
Engine dimensions ** mm 486
width
(with flywheel housing)
Overall
mm 622
height
Engine mass (dry) *,**
kg 161 155
(with flywheel housing)
Cooling fan (std.) * mm 350 mm O/D, 6 blades pusher type F
Crankshaft V pulley diameter &
mm 120 × 90 110 × 110
Fun V pulley diameter (std.) *

* Items marked * may differ from the above depending on an engine installed on a machine unit.
** Engine mass and dimensions without radiator

4
 1. General

(4) 3TNV88
Engine name Unit 3TNV88
Engine specification class - CL VM
Type - Vertical, in-line, 4-cycle, water-cooled diesel engine
Combustion chamber - Direct injection
Number of cylinders - 3
Cylinder bore × stroke mm × mm 88 × 90
Displacement L 1.642
Revolving
speed Min-1 1500 1800 -
Continuous
rating kW 12.3 14.8
Output -
(ps) (16.7) (20.1)
Revolving
speed Min-1 1500 1800 2000 2200 2400 2500 2600 2800 3000
Rated output
kW 13.5 16.3 18.0 19.9 21.6 22.6 23.5 25.2 27.1
Output
(ps) (18.4) (22.1) 24.5) (27.0) (29.4) (30.7) (31.9) (34.2) (36.8)
Max. no-load speed (± 25) min-1 1600 1895 2180 2400 2590 2700 2810 2995 3210
Ignition order - 1-3-2-1 (No.1 cylinder on flywheel side)
Power take off - Flywheel
Direction of rotation - Counterclockwise (viewed from flywheel)
Cooling system - Radiator
Lubrication system - Forced lubrication with trochoid pump
Starting system - Electric
Diesel oil-ISO 8217 DMA, BS 2869 A1 or A2
Applicable fuel -
(Cetane No.45 min.)
Applicable lubricant - API grade class CD or CF
Lubricant capacity Total L 6.7
(oil pan) * Effective L 2.8
Cooling water capacity
L 2.0
(engine only)
Overall
mm 589 564
length
*
Overall
Engine dimensions ** mm 486
width
(with flywheel housing)
Overall
mm 622
height
Engine mass (dry) *,**
kg 155
(with flywheel housing)
Cooling fan (std.) * Mm 335 mm O/D, 6 blades pusher type F
Crankshaft V pulley diameter &
Mm 120 × 90 120 × 90
Fun V pulley diameter (std.) *

* Items marked * may differ from the above depending on an engine installed on a machine unit.
** Engine mass and dimensions without radiator

5
1. General

(5) 4TNV84
Engine name Unit 4TNV84
Engine specification class - CL VM
Type - Vertical, in-line, 4-cycle, water-cooled diesel engine
Combustion chamber - Direct injection
Number of cylinders - 4
Cylinder bore × stroke mm × mm 84 × 90
Displacement L 1.995
Revolving
speed Min-1 1500 1800 -
Continuous
Rating kW 14.9 17.7
Output -
(ps) (20.3) (24.1)
Revolving
speed Min-1 1500 1800 2000 2200 2400 2500 2600 2800 3000
Rated output
kW 16.4 19.5 21.9 24.1 26.3 27.4 28.5 30.7 32.9
Output
(ps) (22.3) (26.5) (29.8) (32.8) (35.8) (37.3) (38.7) 41.7) (44.7)
Max. no-load speed (± 25) min-1 1600 1895 2180 2400 2590 2700 2810 2995 3210
Ignition order - 1-3-4-2-1 (No.1 cylinder on flywheel side)
Power take off - Flywheel
Direction of rotation - Counterclockwise (viewed from flywheel)
Cooling system - Radiator
Lubrication system - Forced lubrication with trochoid pump
Starting system - Electric
Diesel oil-ISO 8217 DMA, BS 2869 A1 or A2
Applicable fuel -
(cetane No.45 min.)
Applicable lubricant - API grade class CD or CF
Lubricant capacity Total L 7.4
(oil pan) * Effective L 3.4
Cooling water capacity
L 2.7
(engine only)
Overall
mm 683 658
length
*
Overall
Engine dimensions ** mm 498.5
width
(with flywheel housing)
Overall
mm 617
height
Engine mass (dry) *,**
kg 183 170
(with flywheel housing)
Cooling fan (std.) * mm 370 mm O/D, 6 blades pusher type F
Crankshaft V pulley diameter &
mm 120 × 90 110 × 110
Fun V pulley diameter (std.) *

* Items marked * may differ from the above depending on an engine installed on a machine unit.
** Engine mass and dimensions without radiator

6
 1. General

(6) 4TNV84T
Engine name Unit 4TNV84T
Engine specification class - CL VM
Type - Vertical, in-line, 4-cycle, water-cooled diesel engine
Combustion chamber - Direct injection
Number of cylinders - 4
Cylinder bore × stroke mm × mm 84 × 90
Displacement L 1.995
Revolving
speed Min-1 1500 1800 -
Continuous
rating KW 19.1 24.3
Output -
(ps) (26.0) (33.0)
Revolving
speed Min-1 1500 1800 2000 2200 2400 2600 2800 3000
Rated output
KW 21.3 26.9 27.9 30.5 33.5 35.7 38.6 41.2
Output
(ps) (29.0) (36.5) (38.0) (41.5) (45.5) (48.5) (52.5) (56.0)
Max. no-load speed (± 25) min-1 1600 1895 2180 2400 2590 2810 2995 3210
Ignition order - 1-3-4-2-1 (No.1 cylinder on flywheel side)
Power take off - Flywheel
Direction of rotation - Counterclockwise (viewed from flywheel)
Cooling system - Radiator
Lubrication system - Forced lubrication with trochoid pump
Starting system - Electric
Diesel oil-ISO 8217 DMA, BS 2869 A1 or A2
Applicable fuel -
(Cetane No.45 min.)
Applicable lubricant - API grade class CD or CF
Lubricant capacity Total L 7.4
(oil pan) * Effective L 3.4
Cooling water capacity
L 3.2
(engine only)
Overall
mm 683 649
length
Engine Overall
mm 498.5
dimensions *,** width
Overall
mm 713
height
Engine mass (dry) *,**
kg 183 170
(with flywheel housing)
Cooling fan (std.) * mm 370 mm O/D, 6 blades pusher type F
Crankshaft V pulley diameter &
mm 120 × 90 110 × 110
Fun V pulley diameter (std.) *

* Items marked * may differ from the above depending on an engine installed on a machine unit.
** Engine mass and dimensions without radiator

7
1. General

(7) 4TNV88
Engine name Unit 4TNV88
Engine specification class - CL VM
Type - Vertical, in-line, 4-cycle, water-cooled diesel engine
Combustion chamber - Direct injection
Number of cylinders - 4
Cylinder bore × stroke mm × mm 88 × 90
Displacement L 2.190
Revolving
speed Min-1 1500 1800 -
Continuous
rating kW 16.4 19.6
Output -
(ps) (22.3) (26.7)
Revolving
speed Min-1 1500 1800 2000 2200 2400 2500 2600 2800 3000
Rated output
kW 18.0 21.6 24.1 26.5 28.8 30.1 31.3 33.7 35.4
Output
(ps) (24.5) (29.4) (32.7) (36.0) (39.2) (40.9) (42.5) (45.8) (48.1)
Max. no-load speed (± 25) min-1 1600 1895 2180 2400 2590 2700 2810 2995 3210
Ignition order - 1-3-4-2-1 (No.1 cylinder on flywheel side)
Power take off - Flywheel
Direction of rotation - Counterclockwise (viewed from flywheel)
Cooling system - Radiator
Lubrication system - Forced lubrication with trochoid pump
Starting system - Electric
Diesel oil-ISO 8217 DMA, BS 2869 A1 or A2
Applicable fuel -
(cetane No.45 min.)
Applicable lubricant - API grade class CD or CF
Lubricant capacity Total L 7.4
(oil pan) * Effective L 3.4
Cooling water capacity
L 2.7
(engine only)
Overall
mm 683 658
length
*
Overall
Engine dimensions ** mm 498.5
width
(with wheel housing)
Overall
mm 618
height
Engine mass (dry) *,**
kg 183 170
(with flywheel housing)
Cooling fan (std.) * mm 370 mm O/D, 6 blades pusher type F
Crankshaft V pulley diameter &
mm 120 × 90 110 × 110
Fun V pulley diameter (std.) *

* Items marked * may differ from the above depending on an engine installed on a machine unit.
** Engine mass and dimensions without radiator

8
 1. General

(8) 4TNV94L
Engine name Unit 4TNV94L
Engine specification class - CL VM
Type - Vertical, in-line, 4-cycle, water-cooled diesel engine
Combustion chamber - Direct injection
Number of cylinders - 4
Cylinder bore × stroke mm × mm 94 × 110
Displacement L 3.054
Revolving
speed Min-1 1500 1800 -
Continuous
rating kW 26.1 31.3
Output -
(ps) (35.5) (42.5)
Revolving
speed Min-1 1500 1800 2000 2200 2400 2500
Rated output
kW 29.1 34.6 35.3 38.2 41.6 43.0
Output
(ps) (39.5) (47.0) (48.0) (52.0) (56.5) (58.5)
Max. no-load speed (± 25) min-1 1600 1895 2180 2400 2590 2700
Ignition order - 1-3-4-2-1 (No.1 cylinder on flywheel side)
Power take off - Flywheel
Direction of rotation - Counterclockwise (viewed from flywheel)
Cooling system - Radiator
Lubrication system - Forced lubrication with trochoid pump
Starting system - Electric
Diesel oil-ISO 8217 DMA, BS 2869 A1 or A2
Applicable fuel -
(Cetane No.45 min.)
Applicable lubricant - API grade class CD or CF
Lubricant capacity Total L 10.5
(oil pan) * Effective L 4.5
Cooling water capacity
L 4.2
(engine only)
Overall
mm 719
length
*
Overall
Engine dimensions ** mm 498
width
(with flywheel housing)
Overall
mm 742
height
Engine mass (dry) *,** 245 235
kg
(with flywheel housing) (equivalent to SAE # 3) (equivalent to SAE # 4)
Cooling fan (std.) * mm 410 mm O/D, 6 blades pusher type F
Crankshaft V pulley diameter &
mm 130 × 130
Fun V pulley diameter (std.) *

* Items marked * may differ from the above depending on an engine installed on a machine unit.
** Engine mass and dimensions without radiator

9
1. General

(9) 4TNV98
Engine name Unit 4TNV98
Engine specification class - CL VM
Type - Vertical, in-line, 4-cycle, water-cooled diesel engine
Combustion chamber - Direct injection
Number of cylinders - 4
Cylinder bore × stroke mm × mm 98 × 110
Displacement L 3.319
Revolving
speed Min-1 1500 1800 -
Continuous
rating kW 30.9 36.8
Output -
(ps) (42.0) (50.0)
Revolving
speed Min-1 1500 1800 2000 2200 2400 2500
Rated output
kW 34.6 41.2 41.9 45.6 49.3 51.1
Output
(ps) (47.0 (56.0) (57.0) (62.0) (67.0) (69.5)
Max. no-load speed (± 25) min-1 1600 1895 2180 2400 2590 2700
Ignition order - 1-3-4-2-1 (No.1 cylinder on flywheel side)
Power take off - Flywheel
Direction of rotation - Counterclockwise (viewed from flywheel)
Cooling system - Radiator
Lubrication system - Forced lubrication with trochoid pump
Starting system - Electric
Diesel oil-ISO 8217 DMA, BS 2869 A1 or A2
Applicable fuel -
(Cetane No.45 min.)
Applicable lubricant - API grade class CD or CF
Lubricant capacity Total L 10.5
(oil pan) * Effective L 4.5
Cooling water capacity
L 4.2
(engine only)
Overall
mm 719
length
*
Overall
Engine dimensions ** mm 498
width
(with flywheel housing)
Overall
mm 742
height
Engine mass (dry) *,** 248 235
kg
(with flywheel housing) (equivalent to SAE # 3) (equivalent to SAE # 4)
Cooling fan (std.) * mm 410 mm O/D, 6 blades pusher type F
Crankshaft V pulley diameter &
mm 130 × 130
Fun V pulley diameter (std.) *

* Engine oil capacity may differ from the above depending on an engine installed on a machine unit.
** Engine mass and dimensions without radiator

10
 1. General

(10)4TNV98T
Engine name Unit 4TNV98T
Engine specification class - CL VM
Type - Vertical, in-line, 4-cycle, water-cooled diesel engine
Combustion chamber - Direct injection
Number of cylinders - 4
Cylinder bore × stroke mm × mm 88 × 110
Displacement L 3.319
Revolving
speed Min-1 1500 1800 -
Continuous
rating kW 37.9 45.6
Output -
(ps) (51.5) (62.0)
Revolving
speed Min-1 1500 1800 2000 2200 2400 2500 2600
Rated output
kW 41.9 50.4 50.7 55.5 60.3 62.5 64.0
Output
(ps) (57.0) (68.5) (69.0) (75.5) (82.0) (85.0) (87.0)
Max. no-load speed (± 25) min-1 1600 1895 2180 2400 2590 2700 2810
Ignition order - 1-3-4-2-1 (No.1 cylinder on flywheel side)
Power take off - Flywheel
Direction of rotation - Counterclockwise (viewed from flywheel)
Cooling system - Radiator
Lubrication system - Forced lubrication with trochoid pump
Starting system - Electric
Diesel oil-ISO 8217 DMA, BS 2869 A1 or A2
Applicable fuel -
(cetane No.45 min.)
Applicable lubricant - API grade class CD or CF
Lubricant capacity Total L 10.5
(oil pan) * Effective L 4.5
Cooling water capacity
L 4.2
(engine only)
Overall
mm 715
length
*
Overall
Engine dimensions ** mm 575
width
(with flywheel housing)
Overall
mm 804
height
Engine mass (dry) *,** 258 245
kg
(with flywheel housing) (equivalent to SAE # 3) (equivalent to SAE # 4)
Cooling fan (std.) mm 430 mm O/D, 8 blades suction type
Crankshaft V pulley diameter &
mm 130 × 130
Fun V pulley diameter (std.) *

* Items marked * may differ from the above depending on an engine installed on a machine unit.
** Engine mass and dimensions without radiator

11
1. General

(11)4TNV106
Engine name Unit 4TNV106
Engine specification class - CL VM
Type - Vertical, in-line, 4-cycle, water-cooled diesel engine
Combustion chamber - Direct injection
Number of cylinders - 4
Cylinder bore × stroke mm × mm 106 × 125
Displacement L 4.412
Revolving
speed Min-1 1500 1800 -
Continuous
rating kW 41.2 49.3
Output -
(ps) (56.0) (67.0)
Revolving
speed Min-1 1500 1800 2000 2200 2400 2500
Rated output
kW 45.6 54.4 56.6 61.4 65.5 67.7
Output
(ps) (62.0 (74.0) (77.0) (83.5) (89.0) (92.0)
Max. no-load speed (± 25) min-1 1600 1895 2180 2400 2590 2700
Ignition order - 1-3-4-2-1 (No.1 cylinder on flywheel side)
Power take off - Flywheel
Direction of rotation - Counterclockwise (viewed from flywheel)
Cooling system - Radiator
Lubrication system - Forced lubrication with trochoid pump
Starting system - Electric
Diesel oil-ISO 8217 DMA, BS 2869 A1 or A2
Applicable fuel -
(Cetane No.45 min.)
Applicable lubricant - API grade class CD or CF
Lubricant capacity Total L 14.0
(oil pan) * Effective L 9.0 7.5
Cooling water capacity
L 6.0
(engine only)
Overall
mm 808 776
length
*
Overall
Engine dimensions ** mm 629 629
width
(with flywheel housing)
Overall
mm 803 803
height
Engine mass (dry) *, ** 345 330
kg
(with flywheel housing) (equivalent to SAE # 3) (equivalent to SAE # 3)
500 mm O/D, 500 mm O/D,
Cooling fan (std.) * mm
7 blades pusher type 7 blades suction type
Crankshaft V pulley diameter &
mm 150 × 150
Fun V pulley diameter (std.) *

* Items marked * may differ from the above depending on an engine installed on a machine unit.
** Engine mass and dimensions without radiator

12
 1. General

(12)4TNV106T
Engine name Unit 4TNV106T
Engine specification class - CL VM
Type - Vertical, in-line, 4-cycle, water-cooled diesel engine
Combustion chamber - Direct injection
Number of cylinders - 4
Cylinder bore × stroke mm × mm 106 × 125
Displacement L 4.412
Revolving
speed Min-1 1500 1800 -
Continuous
rating kW 51.5 61.8
Output -
(ps) (70.0) (84.0)
Revolving
speed Min-1 1500 1800 2000 2200
Rated output
kW 56.8 68.0 69.9 72.0
Output
(ps) (77.2 (92.5) (95.0) (97.9)
Max. no-load speed (± 25) min-1 1600 1895 2180 2400
Ignition order - 1-3-4-2-1(No.1 cylinder on flywheel side)
Power take off - Flywheel
Direction of rotation - Counterclockwise (viewed from flywheel)
Cooling system - Radiator
Lubrication system - Forced lubrication with trochoid pump
Starting system - Electric
Diesel oil-ISO 8217 DMA, BS 2869 A1 or A2
Applicable fuel -
(Cetane No.45 min.)
Applicable lubricant - API grade class CD or CF
Lubricant capacity Total L 14.0
(oil pan) * Effective L 9.0 7.5
Cooling water capacity
L 6.0
(engine only)
Overall
mm 808 776
length
*
Engine dimensions ** Overall
mm 629 629
(with flywheel width
housing) Overall
mm 866 866
height
Engine mass (dry) *, ** 355 340
kg
(with flywheel housing) (equivalent to SAE # 3) (equivalent to SAE # 3)
500 mm O/D, 500 mm O/D,
Cooling fan (std.) * mm
7 blades pusher type 7 blades suction type
Crankshaft V pulley diameter &
mm 150 × 150
Fun V pulley diameter (std.) *

* Items marked * may differ from the above depending on an engine installed on a machine unit.
** Engine mass and dimensions without radiator

13
1. General

1.3 Fuel oil, lubricating oil and cooling water

1.3.1 Fuel oil

IMPORTANT:
Only use the recommended fuel to obtain the best engine performance and to keep the durability of the
engine, also to comply with the emission regulations.

(1) Selection of fuel oil

Diesel fuel oil should comply with the following specifications.
• The fuel specifications need to comply with each national standard or international standards.
• ASTM D975 No.1-D
No.2-D ------------- for USA
• EN590:96-------------------------------------- for EU
• ISO 8217 DMX -------------------------------------- International
• BS 2869-A1 or A2 ---------------------------------- for UK
• JIS K2204 ---------------------------------------- for JAPAN
The following requirements also need to be fulfilled.
• Cetane number should be equal to 45 or higher.
• Sulphur content of the fuel
It should not exceed 0.5%by volume. (Preferably it should be below 0.05 %)
• For alternative fuel (Bio fuel such as FAME, JP-8), please contact YANMAR.
• Water and sediment in the fuel oil should not exceed 0.05% by volume.
• Ash should not exceed 0.01%by mass.
• 10% Carbon residue content of the fuel
It should not exceed 0.35%by volume. (Preferably it should be below 0.1 %)
• Aromatics(total) content of the fuel
It should not exceed 35% by volume. (Preferably it should be below 30%
and aromatics(PAH*) content of the fuel preferably it should be below 10%)
PAH*:polycyclic aromatic hydrocarbons
• DO NOT use Biocide.
• DO NOT use Kerosene, residual fuels.
• DO NOT mix winter fuel and summer fuel.

Note : Engine breakdown can be attributed to insufficient quality of fuel oil.

14
 1. General

(2) Fuel handling

• Water and dust in the fuel oil can cause operation
failure. Use containers which are clean inside to store
fuel oil. Store the containers away from rain water
and dust.
Pump up only the fuel
• Before supplying fuel, let the fuel container rest for in the upper half to
leave dregs near the bottom
several hours so that water and dust in the fuel are
deposited on the bottom. Pump up only the clean
fuel.

(3) Fuel tank

Fuel tank inside should be always clean enough and dry
it inside for the first use.
Drain the water according to the maintenance (section 5) Filler port
with a drain valve. Fuel return
connection

Primary
strainer

Outlet
(to engine)
Drain cock

15
1. General

1.3.2 Lubricating oil

IMPORTANT:
Only use the recommended engine oil to keep the durability of the engine.
(1) Selection of lube oil
Engine oil shoud comply with the following specifications.
1)Classification
• API classification  CD, CF, CF-4, CI-4
TBN value : º9(CD), º9(CF), º7(CF-4), º7(CI-4)
• ACEA classification  E-3, E-4, E-5
TBN value : º10(E-3), º10(E-4), º10(E-5)
• JASO classification  DH-1
TBN value : º10(DH-1)

The oil must be changed when the Total Base Number (TBN) has been reduced to 2.0.
*TBN(mgKOH/g) test method; JIS K-2501-5.2-2(HCI), ASTM D4739(HCI)

DO NOT use The following engine oils.

• API : CG-4 , CH-4
• ACEA : E-1, E-2 , B grade
• JASO : DH-2 , DL-1

Reason
API CG-4, CH-4
In case CG-4, CH-4 is to be used for YANMAR TNV diesel engine series, there is a possibility that
excessive wears occur on the valve train system due to the content of oil.

ACEA E-1,E-2, B
These fuels are developed for the different type of diesel engines.

JASO DH-2, DL-1

These fuels are developed for the different type of diesel engines.

2)Viscosity Selection of viscosity

Selection of viscosity will be determined depending (SAE Service grade)
on the ambient temperature.
9
(Refer to the chart on the right.) 9
9
The following requirements are also need to be 9
fulfilled. 
• Standard engine oil service interval is 250 hrs or 

every 12 months. 

• DO NOT add any additives to the engine oil. ‫ ޓ ޓ ޓ ޓ ޓ ޓ ޓ‬
• DO NOT mix the different types (brand) of engine Atmospheric temperature ( C)
oil.
• DO NOT use synthetic oil.
15W-40/10W-30 can be used
almost throughout the year.

16
 1. General

(2) Handling of lube oil

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

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

1.3.3 Cooling water

Use clean soft water and always be sure to add LLC (Long Life Coolant) in order to prevent rust built up and
freezing. (Do not use water only.)
The recommended LLC conform to the following specifications.
• JIS K-2234
• SAEbJ814C, J1941, J1034, J2036
• ASTM D4985
IMPORTANT:
• Always be sure to add LLC to soft water. In particular, in cold season, to add LLC is important.
• Without LLC,
• Cooling performance will decrease due to scale and rust in the cooling water system.
• Cooling water may freeze to form ice; it expands approx. 9% in volume.
• This causes serious damage in the cooling system.
• Be sure to use the proper amount of coolant concentrate specified by the LLC manufacturer depending
on the ambient temperature.
• LLC concentration should be 30%as a minimum and 60%as a maximum.
• DO NOT mix the different types of brand of LLC, otherwise harmful sludge may yield.
• DO NOT use hard water.
• Water should be free from sludge and/or particles.
• Replace the coolant every once a year.

When handling LLC, use protective gloves to avoid skin contact.

In case you have a contact with your skin or eyes, wash out it with clean
water.

17
1. General

1.4 Engine external views

Filler port (engine oil)

Turbocharger*
Lifting eye Air intake port [from air cleaner(optional)]

Lifting eye

Fuel filter mounting Cooling water pump

Fuel oil inlet

Fuel filter
Intake manifold

Governor lever
Fuel injection pump

Cooling fan

Crank shaft V-pulley

V-belt
Dipstick (engine oil) Filler port (engine oil)
Engine oil filter Drain plug (engine oil)
Engine oil cooler (4TNV98T, 4TNV106, 4TNV106T)

Engine name plate

Rocker arm cover

Flywheel

Alternator

Exhaust manifold
Starter motor

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

࡮The drain plug (engine oil) location depends on the engine installed
on the machine unit to be on the fuel injection pump side (above illustration)
or starter motor side.

18
 1. General

1.5 Structural description

2-valve cylinder head

Noise Reduction Emission Reduction
New Lub. Oil Pump Injection Nozzle
࡮Change Rotor Shape for Low Pulsation ࡮Low Suck Volume
࡮Driven by Crankshaft Directly ࡮Multi Injection Holes

Emission Reduction
Emission Reduction
New fuel injection pump
Cylinder Head
࡮Mono Plunger
࡮Optimal Nozzle Angle
࡮Higher Injection Pressure
࡮Optimal Swirl Ratio
࡮Injection Timing Control
࡮Optimal Valve Timing
Speed Timer, _oad Timer,
Cold Start timer

Emission Reduction
Noise Reduction Piston
Higher Stiffness Cylinder Block ࡮New Combustion
Chamber

Noise Reduction
Higher Stiffness Gear-Case

4-valve cylinder head

Noise Reduction (only applied for 4TNV84T)
New Lub. Oil Pump
࡮Change Rotor Shape for Low Pulsation
࡮Driven by Crankshaft Directly
Emission Reduction
New Fuel Inj. Nozzle
࡮Low Suck Volume
࡮Multi Injection Holes
Emission Reduction
New Fuel Injection Pump
࡮Mono Plunger
࡮Higher Injection Pressure
࡮Mechanical Control of Injection
Timing
Speed Timer, Load Timer,
Cold Start Timer
Emission Reduction
Cylinder Head
࡮4Valve / Cylinder
(intake-2, exhaust-2)
࡮Optimal Installation
of the Injection Nozzle
Vertical Installation and
Location of the Center
of Cylinder
࡮Optimal Valve Timing
Emission Reduction
Piston
࡮New Combustion Chamber
4TNV84T/4TNV94L/4TNV98(T)

19
1. General

1.6 Exhaust gas emission regulation

The engines in this manual have been certified by the US EPA, California ARB and/or the 97/68/EC Directive.
California
Proposition 65 Warning
Diesel engine exhaust and some of its constitutions are known to the State of California to cause cancer,
birth defects, and other reproductive harm.
California
Proposition 65 Warning
Battery posts，terminals，and related accessories contain lead and lead compounds，chemicals known to
the State of California to cause cancer and reproductive harm．

1.6.1 The emission standard in USA

(1) EPA Nonroad Diesel Engine Emission Standards

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)
19<= kW < 37 Tier 1 1999 - - 9.5 (7.1) 5.5 (4.1) 0.80 (0.60)
(25 <= hp < 50) Tier 2 2004 - - 7.5 (5.6) 5.5 (4.1) 0.60 (0.45)
Tier 1 1998 9.2 (6.9) - - - -
37 <= kW < 75
Tier 2 2004 - - 7.5 (5.6) 5.0 (3.7) 0.40 (0.30)
(50 <= hp < 100)
Tier 3 2008 - - 4.7 (3.5) 5.0 (3.7)
Tier 1 1997 9.2 (6.9) - - - -
75 <= kW < 130
Tier 2 2003 - - 6.6 (4.9) 5.0 (3.7) 0.30 (0.22)
(100 <= hp < 175)
Tier 3 2007 - - 4.0 (3.0) 5.0 (3.7)

Note1) The EPA emission regulation under 130 kW is mentioned below.

Note2) As for Model year, the year which a regulation is applicable to is shown.

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.

20
 1. General

1.6.2 Engine identification

(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

$ %
&
' ( )

(3) 97/68EC Directive label

'%&+4'%6+8'
#
$
%

21
1. General

1.6.3 Guarantee conditions for the EPA emission standard

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

(1) Requirement on engine installation condition

(a)Intake air depression
kPa (mmAq)
Initial Permissible
<= 2.94 (300) <= 6.23 (635)

(b)Exhaust gas back pressure

kPa (mmAq)
Engine type Initial Permissible
Naturally aspirated engines <= 12.75 (1300) <= 15.30 (1560)
4TNV98T, 4TNV106T <= 9.81 (1000) <= 11.77 (1200)
3,4TNV84T <= 4.90 (500) <= 5.88 (600)

(2) Fuel oil and lubricating oil

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

(3) Do not remove the seals restricting injection

Sealing cap
quantity and engine speed. Gasket
Cap nut
Gasket
Plate
Nut
Injection quant
limit bc

Tamper Seal washer

resistance Assy
Tamper resistance device
for engines certified by ARB/EPA

22
 1. General

(4) Perform maintenance without fail.

Note: Inspections to be carried out by the user and by the maker are divided and set down in the "List of
Periodic Inspections" and should be checked carefully.

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

Maintenance period Quality Guarantee Period

Parts •Fuel nozzle cleaning Adjustment, cleaning, For nozzle, fuel pump,
repairs for fuel nozzle, fuel turbocharger
pump, turbocharger,
Power Rating electronic control unit etc.
37 <= kW < 130 Every 1500 hours Every 3000 hours 3000 hours / 5 years
(applied from Tier 2) (applied from Tier 2)
19 <= kW < 37 Every 1500 hours Every 3000 hours 3000 hours / 5 years
except constant
speed engines >=
3000 min-1
KW < 19 Every 1500 hours Every 3000 hours 1500 hours / 2 years
And constant speed
engines beyond
3000 min-1 under
37 kW

23
2. Inspection and adjustment

2. Inspection and adjustment

2.1 Periodic maintenance schedule
The engine periodic inspection timing is hard to determine as it varies with the application, load status,
qualities of the fuel and lubricating oils used and handling status. General rules are described here.

c: User-maintenance : Parts replacement z: Shop-inspection

Maintenance period
Every Every Every Every
Every 250 500 1000 2000
Classification Item Daily
50 hours or hours hours hours
hours 3 or 6 or one or two
months months year years
Whole Visual check around engine c
Fuel tank level check and fuel supply c
Fuel tank draining c
Fuel oil Water separator (Option) draining c
system Bleeding the fuel system c
Water separator cleaning c
Fuel filter element replacement
Lube oil level check and replenishment c
Lubricating Lube oil replacement
oil system 2nd time
1st time and
Lube oil filter replacement thereafter
Coolant water level check and
c
replenishment
Radiator fin cleaning c
Cooling c
c
water V-belt tension check 2nd time
st and
1 time
system thereafter

Coolant water replacement

Coolant water path flushing and
maintenance
Rubber Fuel pipe and coolant water pipe
c z
house inspection and maintenance
Inspection and adjustment of governor
Governor c c z
lever and accelerator
Air cleaner cleaning and element
c
replacement
Air intake
system Diaphragm assy inspection z
(2 years)
Turbocharger blower cleaning* z*
Warning lamp & instruments function
c
Electrical check
system Battery electrolyte level check and battery
c
recharging
Intake/exhaust valve head clearance
Cylinder z
adjustment
head
Intake/exhaust valve seat lapping z
Fuel Fuel injection nozzle pressure inspection z*
injection pump Fuel injection timing adjustment
and Fuel injection pump inspection and z*
nozzle adjustment
*) EPA allows to maintain the emission related parts every 1,500 or 3,000 hours as shown in 1.6.3 of chapter1.

24
 2. Inspection and adjustment

2.2 Periodic inspection and maintenance procedure

2.2.1 Check before daily operation
Be sure to check the following points before starting an engine every day.

No. Inspection Item

(1) Visual check around engine
(2) Fuel tank level check and fuel supply
(3) Lube oil level check and replenishment
(4) Coolant water level check and replenishment
(5) Fuel pipe and coolant water pipe inspection and maintenance
(6) Inspection and adjustment of governor lever and accelerator
(7) Warning lamp & instruments function check

(1) Visual check around engine

If any problem is found, do not use before the engine repairs have been completed.
• Oil leak from the lubrication system
• Fuel leak from the fuel system
• Coolant water leak from the cooling water system
• Damaged parts
• Loosened or lost bolts
• Fuel, radiator rubber hoses, V belt cracked, loosened clamp

(2) Fuel tank level check and fuel supply

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

(3) Lube oil level check and replenishment

(a)Checking oil level Filler cap
Check the lube oil level with the dipstick, after
adjusting the posture of the machine unit so that an
engine may become a horizontality. Insert the dipstick Filler port
(engine oil)
fully and check the oil level. The oil shall not be
contaminated heavily and have appropriate viscosity.
No coolant water or diesel fuel shall be mixed.
When lube oil is supplied after the engine running,
check the lube oil level after about 10 minutes pass
after the engine shutdown so that the lube oil inside
may be retuned the oil pan.
Dipstick Dipstick
Standard
The level shall be between the upper and lower
limit lines on the dipstick. φ Upper limit
φ Lower limit

25
2. Inspection and adjustment

(Unit: liter)
Model Total volume (L) Effective volume (L)
3TNV82A 5.5 1.9
3TNV84 (T)•88 6.7 2.8
4TNV84 (T)•88 7.4 3.4
4TNV94L98•(T) 10.5 4.5
4TNV106 (T) (CL class) 14.0 9.0
4TNV106 (T) (VM class) 14.0 7.5
Lube oil capacity may differ from the above volume depending on an engine installed on a machine unit.

(b)Replenishing oil pan with lube oil

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

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

(4) Coolant water inspection

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

•Never open the radiator filler cap while the engine and radiator are still hot.
Steam and hot water will spurt out and seriously burn you. Wait until the
radiator is cooled down after the engine has stopped, wrap the filler cap with
a rag piece and turn the cap slowly to gently release the pressure inside the
radiator.
•Securely tighten the filler cap after checking the radiator. Steam can spurt
out during operation, if the cap is tightened loosely.
(a)Checking coolant water volume
Check the coolant water level in the Coolant recovery tank. If the water level is close to the LOW mark, open
the Coolant recovery tank cap and replenish the Coolant recovery tank with clean soft water to the FULL
mark.
Standard
The water level of the Coolant recovery tank shall be between the upper and lower limit lines.

(b)Replenishing engine with water

If the Coolant recovery tank water level is lower than the LOW mark, open the radiator cap and check the
coolant water level in the radiator. Replenish the radiator with the coolant water, if the level is low.
• Check the coolant water level while the engine is
cool.
Checking when the engine is hot is dangerous.
And the water volume is expanded due to the Loosen
Tighten
heat.
• Daily coolant water level check and replenishing
shall be done only at the Coolant recovery tank.
Radiator cap
Usually do not open the radiator cap to check or
replenish.
26
 2. Inspection and adjustment

IMPORTANT:
If the coolant water runs short quickly or when the radiator runs short of water with the Coolant recovery
tank level unchanged, water may be leaking or the air tightness may be lost. Increase in the Coolant
recovery tank water level during operation is not abnormal.
The increased water in the Coolant recovery tank returns to the radiator when the engine is cooled down.
If the water level is normal in the Coolant recovery tank but low in the radiator, check loosened clamping of
the rubber hose between the radiator and Coolant recovery tank or tear in the hose.
Standard
Engine: The radiator shall be filled up.
(Unit: liter)
Model Coolant water volume In an engine
3TNV82A 1.8
3TNV84 (T)
2.0
3TNV88
4TNV84 (T)
2.7
4TNV88
4TNV94L
4.2
4TNV98 (T)
4TNV106 (T) 6.0
Engine coolant water capacity may differ from the above
volume depending on an engine installed on a machine unit.

(5) Fuel pipe and coolant water pipe inspection and maintenance
Check the rubber hoses for fuel and coolant water pipes cracked. If the cracked hose is found, replace it with
new one. Check the loosened clamp. If found, tighten it.

(6) Inspection and adjustment of governor lever and accelerator

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

(7) Warning lamp & instruments function check

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

2.2.2 inspection after initial 50 hours operation

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

No. Inspection Item

(1) Lube oil and filter replacement
(2) V-belt tension check

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

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

27
2. Inspection and adjustment

In early period of use, the engine oil gets dirty rapidly

because of the initial wear of internal parts. Replace the
engine oil earlier.
Lube oil filter should also be replaced when the engine
oil is replaced.
The procedure of lube oil and lube oil filter replacement
is as follows.

(a)Drain engine oil

• Prepare a waste oil container collecting waste oil. Dipstick
• Remove the oil filler cap to drain easily while draining
the lube oil.
• Loosen the drain plug using a wrench (customer pro- Oil pan

cured) to drain the lube oil.

• Securely tighten the drain plug after draining the lube Drain plug
oil.
The location depends on the engine
installed on the machine unit
[NOTICE]
Use a socket wrench or a closed wrench when
removing or tightening a drain plug.
Don’t use a spanner because it has the possibility
that the spanner will slip and it will get hurt.

(b)Replacing oil filter

• Turn the lube oil filter counter-clockwise using a filter
wrench (customer procured) to remove it.
• Clean the mounting face of the oil filter.
• Moisten the new oil filter gasket with the engine oil
n
and install the new engine oil filter manually turning it gh
te
Ti
clockwise until it comes into contact with the mount-
Loosen

Engine oil filter

ing surface, and tighten it further to 3/4 of a turn with
the filter wrench.
Tightening torque: 20 to 24 N•m (2.0 to 2.4 kgf•m)

Model Applicable oil filter Part No.

3TNV82A to 4TNV98 (T) 129150-35151
4TNV106 (T) 119005-35100

(c)Filling oil and inspection

• Fill with new engine oil until it reaches the specified
level.

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

• Warm up the engine by running for 5 minutes while

checking any oil leakage
• Stop the engine after warming up and leave it stop-
ping for about 10 minute to recheck the engine oil
level with dipstick and replenish the engine oil. If any
oil is spilled, wipe it away with a clean cloth.
28
 2. Inspection and adjustment

(2) V-belt tension check

When there is not enough tension in the V-belt, the V-
Radiator fan Set bolt
belt will slip making it impossible for the alternator to $
generate power and cooling water pump and cooling
fan will not work causing the engine to overheat. Alternator

Check and adjust the V-belt tension (deflection) in

Deflection
the following manner.
% #
[NOTICE] V-belt
Be especially careful not to splash engine oil on
Crankshaft
the V-belt, because it will cause slipping, V-pulley Press with thumb
stretching and aging of the belt.

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

98N (10 kgf)] at the middle of the V-belt span to
check the tension (deflection).
Available positions to check and adjust the V-belt
tension (deflection) are at the A, B or C direction
as shown in the illustration right.
You may choose a position whichever you can
easily carry out the check and adjustment on the
machine unit.
• "New V-belt" refers to a V-belt which has been
used less than 5 minutes on a running engine.
• "Used V-belt" refers to a V-belt, which has been
used on a running engine for 5 minutes or more.
The specified deflection to be measured at each
position should be as follows.

(Unit: mm)
Direction A B C
For used V-belt 10 to 14 7 to 10 9 to 13
For new V-belt 8 to 12 5 to 8 7 to 11

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

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

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

run the engine for 5 minutes and readjust the deflec-
tion to the value in the table above. Alternator
Tension adjustment
4)Visually check the V-belt for cracks, oiliness or wear.
If any, replace the V-belt with new one.

29
2. Inspection and adjustment

2.2.3 Inspection every 50 hours

Be sure to check the following points every 50 hours operation.
No. Inspection Item
(1) Fuel tank draining
(2) Water separator draining
(3) Bleeding the fuel system
(4) Battery electrolyte level check and battery recharging

(1) Fuel tank draining

1)Prepare a waste oil container.
2)Remove the drain plug of the fuel tank to drain
Fuel tank
(water, dust, etc.) from the fuel tank bottom.
3)Drain until fuel with no water and dust flow out.
Then tighten the drain plug firmly.

Drain plug

OPTION

(2) Water separator draining

Drain off the water separator whenever there is a lot of Air bleeding bolt
Outlet
Inlet
drain collected in the water separator at the bottom of
the cup even if not the time for periodic inspection hour. Close
The cup of the water separator is made from semi- Fuel cock
transparency material and in the cup, the red colored
float ring which rises on the surface of the drain is Open

installed to visualize the amount of drain. Also, the Cup

water separator with sensor to detect the drain for Float ring
warning device on a control panel is provided as the
Drain cock
optional.
Water separator
Drain off the water separator in the following manner.
1)Prepare a waste oil container.
2)Close the fuel cock.
3)Loosen the drain cock at the bottom of the water
separator, and drain off any water collected inside.
4)Tighten the drain cock with hand.
5)Be sure to bleed air in the fuel system.

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

30
 2. Inspection and adjustment

(3) Bleeding the fuel system

Bleed the fuel system according to the following Fuel filter Fuel return hose
procedures. When there is air in the fuel system, the
fuel injection pump will not be able to function.
1)Check the fuel oil level in the fuel tank. Refuel if
insufficient.
2)Open the cock of the water separator.
3)Loosen the air bleeding bolt on the water separator
by turning 2 to 3 times to the counter-clockwise Fuel injection
pump
using screw driver or spanner.
4)When the fuel coming out is clear and not mixed
with any bubble, tighten the air bleeding bolt. Air bleeding bolt
Outlet
5)Feed the fuel with the fuel priming pump or electro- Inlet
magnetic fuel feed pump. Close

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

feed pump. Fuel cock
Fuel priming
Turn the starter switch to the ON position and hold it pump Open
in the position for 10 to 5 seconds to operate the fuel Air bleeding
bolt
feed pump.
• In case of the engine installed the fuel filter mounting
Drain cock
with the fuel priming pump.
Water separator
The priming pump is on the top of the fuel filter (installed on the pipe line)
mounting. Move the priming pump up and down to Fuel filter
Fuel filter mounting with
feed fuel until feel your hand slightly heavy. fuel priming pump (option)

(4) Battery electrolyte level check and battery recharging

Fire due to electric short-circuit

•Make sure to turn off the battery switch or disconnect the negative cable (-)
before inspecting the electrical system. Failure to do so could cause short-
circuiting and fires.
•Always disconnect the (-) Negative battery cable first before disconnecting
the battery cables from battery. An accidental "Short circuit" may cause
damage, fire and or personal injury.
And remember to connect the (-) Negative battery cable (back onto the bat-
tery) LAST.

Proper ventilation of the battery area

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

Do not come in contact with battery electrolyte

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

31
2. Inspection and adjustment

Battery structure

Terminal Cap
Cover

Cathode
plate
Separator
Glass mat
Battery
case
Anode plate

(1) Electrolyte level

• Check the level of fluid in the battery.
When the amount of fluid nears the lower limit, fill GREASE

with battery fluid (available in the market) to the

upper limit. If operation continues with insufficient
battery fluid, the battery life is shortened, and the
battery may overheat and explode. Upper limit UPPER LEVEL
• Battery fluid tends to evaporate more quickly in the LOWER LEVEL Lower limit

summer, and the fluid level should be checked ear-

lier than the specified times. OK Too low Excessive
• If the engine cranking speed is so slow that the
engine does not start up, recharge the battery.
• If the engine still will not start after charging, replace
the battery. Electrolyte level
• Remove the battery from the battery mounting of the
machine unit after daily use if letting the machine unit
leave in the place that the ambient temperature
could drop at -15 °C or less. And store the battery in
a warm place until the next use the unit to start the
engine easily at low ambient temperature.

(2) Battery charge

Use a battery tester or hydrometer and check the
battery condition. If the battery is discharged, recharge
it.
(a)Measurement with a battery tester
When checking the battery with the batter tester,
connect the red clip of the tester to the battery positive
(+) terminal and black clip to the battery negative (-)
terminal by pinching them securely, and judge the
battery charge level from the indicator position.

Green zone: Normal

Yellow zone: Slightly discharged Battery tester
Red zone: Defective or much discharged
Battery charge measurement
with battery tester

32
 2. Inspection and adjustment

(b)Measurement with hydrometer

When using a hydrometer, the measured specific gravity
must be corrected according to the temperature at the
time of measurement. The specific gravity of battery
electrolyte is defined with 20 °C as the standard. Since
Float
the specific gravity increases or decreases by 0.0007
when the temperature varies by 1 °C, correct the value
according to the equation below.

S20 = St + 0.007(t-20)
Electrolyte temperature
at measurement
Specific gravity at measurement
Converted specific gravity at 20͠
Battery charge measurement
with a hydrometer

(c)Specific gravity and remaining battery charge

Rubber bulb
Specific Discharged Remaining
gravity quantity charge
of electricity Glass tube
(20 °C) (%) (%)
1.28 0 100
1.26 10 90 Float

1.24 20 80
1.23 25 75

Hydrometer structure

(3) Terminals
Clean if corroded or soiled.

(4) Mounting bracket

Repair or replace it if corroded.
Retighten if loosened.

(5) Battery appearance

Replace the battery if cracked or deformed. How to read hydrometer
Clean with fresh water if contaminated.

33
2. Inspection and adjustment

2.2.4 Inspection every 250 hours or 3 months

Be sure to check the following points every 250 hours or 3 months operation, whichever comes first.
No. Inspection Item
(1) Lube oil and filter replacement
(2) Radiator fin cleaning
(3) V-belt tension check
(4) Inspection and adjustment of governor lever and accelerator
(5) Air cleaner cleaning and element replacement

(1) Lube oil and filter replacement (The second replacement and after)
Replace the engine oil every 250 hours operation from 2nd time and on. Replace the engine oil filter at the
same time. Refer to 2.2.1.(1).

(2) Radiator fin cleaning

Beware of dirt from air blowing

Wear protective equipment such as goggles to protect your eyes when
blowing compressed air. Dust or flying debris can hurt eyes.

Dirt and dust adhering on the radiator fins reduce the

cooling performance, causing overheating. Make it a
Dust, dirt
rule to check the radiator fins daily and clean as Radiator fins
needed.
• Blow off dirt and dust from fins and periphery with
Air blow
compressed air [0.19MPa (2 kgf/cm2) or less] not to
damage the fins with compressed air.
• If contaminated heavily, apply detergent, thoroughly
clean and rinse with tap water shower.
IMPORTANT:
Never use high pressure water or air from close by
fins or never attempt to clean using a wire brush.
Radiator fins can be damaged.

(3) V-belt tension check (The second time and after)

Check and adjust the V-belt tension. Refer to 2.2.2(2)

34
 2. Inspection and adjustment

(4) Inspection and adjustment of governor lever and accelerator

The governor lever and accelerating devices
(accelerating lever, pedal, etc.) of the machine unit are
connected by an accelerating wire or rod. If the wire
becomes stretched or the connections loose, the
deviation in the position may result and make operation
unsafe. Check the wire periodically and adjust if
Low idle
necessary. limiting bolt
High Low Govenor lever
Do not strongly move the accelerating wire or
accelerating pedal. It may deform the governor lever or Accelerating
stretch the wire to cause irregular engine speed control. wire bracket

Checking and adjusting procedure are as follows.

1)Check that the governor lever of the engine makes
uniform contact with the high idling and low idling High idle
limiting bolt Accelerating wire fixing nut
limiting bolt when the accelerating devices is in the
high idling speed or low idling speed position. Accelerating wire bracket
2)If either the high or the low idling speed side does MP2 Fuel Injection pump
not make contact with the limiting bolt, adjust the
accelerating wire.
Loosen the accelerating wire fixing nut and adjust
the wire to contact with the limiting bolt.

Never release the limiting bolts. It will impair the safety and performance of the product and functions and
result in shorter engine life.
(5) Air cleaner cleaning and element replacement

Beware of dirt from air blowing

Wear protective equipment such as goggles to protect your eyes when
blowing compressed air. Dust or flying debris can hurt eyes.

The engine performance is adversely affected when the

air cleaner element is clogged by dust. So periodical Air cleaner case
Arrow mark
cleaning after disassembly is needed. Arrow
Element mark
1)Undo the clamps on the dust pan and remove the
dust pan.
2)Loosen the wing bolt on the element and pull out the
element.
Air blow
Dust pan
latch
OPTION

35
2. Inspection and adjustment

3)Blow air [0.29 to 0.49 MPa (3.0 to 5.0 kgf/cm2)] from

Dust indicator (optional)
inside the element to blow dust off as shown in the Air cleaner case
illustration right. Arrow mark
Inner element
Apply the air blowing pressure as low as possible so Outer element
as not to damage the element. Arrow
mark
If having the air cleaner with double elements, never
Dust pan
remove and clean the inner element.
The aim of installing the inner element is for back up
protecting from intaking dust during engine running
when leaving the outer element to reinstall after latch
Double elements type air cleaner
removing it or when damaging the outer element OPTION with inner and outer element
unexpectedly during engine running.
4)Replace the element with new one, If the element is
damaged, excessively dirty or oily.
5)Remove the inside dust cover of the dust pan, and
clean inside of the dust pan.
6)Reinstall the element with the wing bolt. (do not
leave the gasket.) Reattach the inside dust cover to
the dust pan and install the dust pan to the air
cleaner case placing the TOP mark upward.

IMPORTANT:
• When the engine is operated in dusty conditions,
clean the element more frequently.
• Do not run the engine with removed air cleaner or
element, as this may cause foreign material to enter
and damage the engine.

36
 2. Inspection and adjustment

2.2.5 Inspection every 500 hours or 6 months

Be sure to check the following points every 500 hours or 6 months operation, whichever comes first.

No. Inspection Item

(1) Water separator cleaning
(2) Fuel filter element replacement
(3) Air cleaner cleaning and element replacement

(1) Water separator cleaning

Periodically wash the water separator element and
Air bleeding bolt
inside cup with clean fuel oil. Outlet
Inlet
1)Prepare a waste oil container.
2)Close the fuel cock. Close

3)Loosen the drain cock and drain. Fuel cock

Refer to 2.2.3.(2)
Open
4)Turn the retaining ring counter-clockwise and
remove the cup. Cup

(Disconnect the coupler of the lead wire for drain Float ring
sensor before removing the cup if it is with drain
Drain cock
sensor). Water separator
5)Wash the element and inside cup with clean fuel oil.
Replace the element with new one if any damaged.

Model Applicable element Part No.

3TNV82A to
119802-55710
4TNV106 (T)

6)Insert the element to the bracket (O-ring) and after

putting the float ring in the cup, install it to the
bracket by tightening the retaining ring clockwise.
Tightening torque: 15 to 20 N•m (1.5 to 2.0 kgf•m)
7)Close the drain cock (connect the coupler if with
drain sensor).
8)Bleed the fuel system. Refer to 2.2.3.(3)

37
2. Inspection and adjustment

(2) Fuel filter element replacement

Replace the fuel filter at specified intervals, before it is
clogged with dust to adversely affect the fuel flow. Also,
replace the fuel filter after the engine has fully been
cooled.
1)Close the fuel cock of the water separator.
ߪࠆ
Tighten
2)Remove the fuel filter using a filter wrench (customer Loosen ψ
ψ
procured). When removing the fuel filter, hold the φ
bottom of the fuel filter with a piece of rag to prevent
the fuel oil from dropping. If you spill fuel, wipe such
spillage carefully.
3)Clean the filter mounting surface and slightly apply
fuel oil to the gasket of the new fuel filter.
4)Install the new fuel filter manually turning until it
comes into contact with the mounting surface, and
tighten it further to 1/2 of a turn using a filter wrench.
Tightening torque for 3TNV82A to 4TNV106 (T):
20 to 24 N•m (2.0 to 2.4 kgf•m)

Model Applicable fuel filter Part No.

3TNV82A to
119802-55800
4TNV88
4TNV98 (T) to
123907-55800
4TNV106 (T)

5)Bleed the fuel system. Refer to 2.2.3.(3)

IMPORTANT:
Be sure to use genuine Yanmar part (super fine mesh
filter). Otherwise, it results in engine damage, uneven
engine performance and shorten engine life.

(3) Air cleaner cleaning and element replacement

Replace the air cleaner element periodically even if it is not damaged or dirty.
When replacing the element, clean inside of the dust pan at the time.
If having the air cleaner with double elements, do not remove the inner element. If the engine output is still not
recover (or the dust indicator still actuates if having the air cleaner with a dust indicator) even though the outer
element has replaced with new one, replace the inner element with new one.

38
 2. Inspection and adjustment

2.2.6 Inspection every 1,000 hours or one year

Be sure to check the following points every 1,000 hours or one year operation, whichever comes first.

No. Inspection Item

(1) Cooling water replacement
(2) Diaphragm assy inspection
(3) Turbocharger blower cleaning*
(4) Intake/exhaust valve clearance adjustment
(5) Fuel injection nozzle pressure inspection

(1) Cooling water replacement

Cooling water contaminated with rust or water scale OPTION
reduces the cooling effect. Even when antifreeze agent Radiator cap
(LLC) is mixed, the cooling water gets contaminated due
to deteriorated ingredients. Replace the cooling water at
least once a year.
Rubber hose

Beware of scalding
by hot water FULL
Coolant (Max.limit)
Wait until the temperature recovery tank
goes down before draining
the coolant water. Otherwise,
hot water may splash to
cause scalding. LOW
(Min.limit)
Drain plug
(Drain plug location depends on the machine unit)
1)Remove the radiator cap.
2)Loosen the drain plug at the lower portion of the radi-
ator and drain the cooling water.
3)After draining the cooling water, tighten the drain
plug.
4)Fill radiator and engine with cooling water.
a)Before filling, check to be sure the drain plug is closed.
b)Remove the radiator cap of the radiator by turning the radiator cap counter-clockwise about 1/3 of a
turn.
c)Pour the cooling water slowly into the radiator up to the lip of the filler port so that air bubbles do not
develop.
d)After supplying the cooling water, surely tighten the radiator cap. To fasten the radiator cap, align the
detents on the back face of the radiator cap with the slot of the filler port and turn clockwise pushing it
downward approx. 1/3 of a turn until contact with each other.
e)Remove the cap of the coolant recovery tank, supply the cooling water to the FULL mark and fasten the
cap.
f)Check the rubber hose connecting the coolant recovery tank to the radiator. Be sure the rubber is
securely connected and there is no looseness or damage. When the rubber hose is not water tight, an
excessive amount of cooling water will be consumed.

39
2. Inspection and adjustment

g)When filling with the cooling water for the first time or replacing, the air contains in the cooling water
system. So, as the air in the cooling water system is self-bleeded during engine operation, the cooling
water level in the radiator and coolant recovery tank will be lowered. Replenish the cooling water into the
radiator and coolant recovery tank until it reaches the FULL mark of the coolant recovery tank.

ƒ Daily check of the cooling water level and refilling can be done by observing the coolant recovery
tank.

ƒ The cooling water capacity of the radiator depends on the machine unit. Refer to the operation
manual provided by the equipment manufacturer.

ƒ Check the cooling water level when the engine is cold. Cooling water flows to the coolant
recovery tank when the radiator is still hot and makes accurate checks impossible.

ƒ Check the radiator and hoses for leakage.

(2) Diaphragm assy inspection

Inspect the diaphragm assy on the rocker arm cover
every 1000 hours or 2 years. Refer to 4.2.4 point 6 for
Spring Diaphragm
the function of the diaphragm. Center plate cover
Diaphragm
1)Loosen screws, and remove a diaphragm assy, and Rocker arm
cover
check whether oil and so on doesn’t enter between
the diaphragm and the cover. If oil and so on enters
into the diaphragm assy, the diaphragm doesn’t work
well. Breather pipe

2)Check the damages of the diaphragm rubber and

Breather
the spring. If necessary, replace with new ones. baffle
Intake
[NOTICE] maniforld Baffle plate
• When a diaphragm is damaged, pressure control
inside the crankcase becomes insufficient, and trou-
Breather system componert
bles such as combustion defect and so on occur.
• At lubricating oil replacement or lubricating oil supply,
the amount of lubricating oil isn’t to be beyond the
standard upper limit. If the lubricating oil quantity is
beyond the upper limit or an engine is operated
beyond the allowable maximum angle of an engine,
the amount of oil mist may be inducted in the com-
bustion chamber and the oil hammer sometimes may
occur.

40
 2. Inspection and adjustment

(3) Turbocharger blower cleaning*

When engine speed seems sluggish or the exhaust color looks poor, the blades of the turbocharger-blower
may be dirty.
Wash the turbine blower in such a case.
(a)General items
1)As for washing, use washing liquid and clear water.
2)Washing time is the time when about 10% of the boost pressure decreases more than that of usual oper-
ation state as a standard.
3)Disassemble and clean a turbocharger periodically because the whole of the turbocharger can’t be
cleaned in this method.
(b)Washing point
1)A specified quantity of washing liquid/water is poured with a filler (ex. Oil sprayer) from the air inlet of the
blower gradually (about ten seconds) at the normal load (3/4-4/4) of an engine.
And, perform this work at no-load after load running of the engine, if it is difficult to pour the liquid into the
blower at load running.

Specified quantity of washing liquid/water

Turbocharger model RHB31, RHB51
Injection amount, one time 20 cc

It causes an accident when large quantity of washing liquid is poured rapidly into a turbocharger.

2)Pour the same amount of clear water as washing liquid/water into the blower about 3-5 minutes later after
the washing liquid/water injection and wash it.

It causes an accident when large quantity of water is poured rapidly into a turbocharger.

3)Repeat the washing after then minutes when there is no change with the boost pressure or the exhaust
gas temperature after washing.
When there is no change at all even if it repeats 3-4 times, disassemble and maintain the turbocharger
because of the cruel dirt of the blower or other causes.
4)Operate the engine at load for at least 15 minutes after washing, and dry.

41
2. Inspection and adjustment

(4) Intake/exhaust valve clearance adjustment

Make measurement and adjustment while the engine is
No.1 cylinder
cold.
(a)Valve clearance measurement
1)Remove the rocker arm cover above cylinder head.
2)Set the No.1 cylinder in the compression TDC
Turn the crankshaft to bring the piston of the No.1 cyl-
Crankshaft
inder to its compression top dead center while watch- 4TNV94L pulley
ing the rocker arm motion, timing scale and the top
mark position of the crankshaft pulley.
Top mark
(Position where both the intake and exhaust valves
Rotational direction
are closed.)
Top mark
Notes:
• The crankshaft shall be turned clockwise as seen from
the radiator side.
• The No.1 cylinder position is on the opposite side of
the radiator and the ignition order shall be 1-3-4-2-1 at
180° intervals. Rocker arm Adjusting screw
• Since the intake and exhaust valve rocker arms are Valve
clearance Lock nut
operated the same and there is a clearance between
the arm and valve generally at the top dead center, the
position can be checked by means of the play when
the arm head is held with a hand. Also see that the
crankshaft pulley top mark is positioned at zero on the
Valve clearance (2-valve head)
timing scale. If there is no valve clearance, inspection
in the disassembled state is necessary since the valve
seat may be worn abnormally.
3)Valve clearance measurement
In case of 2-valve cylinder head insert a thickness
Valve clearance Rocker arm
gage between the rocker arm and valve cap, and
record the measured valve clearance. Valve bridge

In case of 4-valve head insert a thickness gage

between the rocker arm and the valve bridge, and
record the measured valve clearance.
(Use it as the data for estimating the wear state.)
4)Adjusting other cylinders
In case of 4-cylinder engines, turn the crankshaft
180° and make adjustment for the No.3 cylinder. Valve clearance (4-valve head)
Then adjust the No.4 and No.2 cylinders in this order.
The cylinder to be adjusted first does not have to be
the No.1 cylinder. Select and adjust the cylinder
where the piston is the nearest to the top dead center
after turning, and make adjustment for other cylinders
in the order of ignition by turning the crankshaft 180°
each time.
In case of 3-cylinder engines, turn the crankshaft
240° and make adjustment for the No.3 cylinder.
Then adjust the No.2 cylinder in this order.

42
 2. Inspection and adjustment

The cylinder to be adjusted first does not have to be the No.1 cylinder. Select and adjust the cylinder
where the piston is the nearest to the top dead center after turning, and make adjustment for other cylin-
ders in the order of ignition by turning the crankshaft 240° each time.
The adjustment method of reducing the flywheel turning numbers (for reference):
For 3 cylinder engines
Set No.1 cylinder to the compression T.D.C.and adjust the clearance of the z mark of the below table.
Next, turn the flywheel once (the suction / exhaust valve of No.1 cylinder is in the position of the overlap
T.D.C. at this time), and adjust the clearance of the c mark.
Ignition order of 3 cylinder engines: 1J3J2
Cylinder No. 1 2 3
Valve Suction Exhaust Suction Exhaust Suction Exhaust
No.1
compression z z z z The first time
T.D.C
No.1
overlap c c The second time
T.D.C

For 4 cylinder engines

Set No.1 cylinder to the compression T.D.C. and adjust the clearance of the z mark of the bottom table.
Next, turn the flywheel once, and adjust the clearance of the c mark.

Ignition order of 4 cylinder engines: 1J3J4J2

Cylinder No. 1 2 3 4
Valve Suction Exhaust Suction Exhaust Suction Exhaust Suction Exhaust
No.1
The first
compression z z z z
time
T.D.C
No.4 The
compression c c c c second
T.D.C time

(b)Valve clearance inspection and adjustment

1) Loosen adjusting bolts
In case of 2-valve cylinder head loosen the lock
nut and adjusting screw, and check the valve for
any inclination of valve cap, entrance of dirt or Valve cap

wear.
Normal Abnormal

In case of 4-valve cylinder head loosen the lock

nut and adjusting screw of rocker arm. Be careful Loosen
Adjusting
that excessive tension isn't applied to the valve bolt
bridge, and loosen a locknut of valve bridge. Loosen

[NOTICE]
Valve
When loosening a locknut of a valve bridge, loosen bridge
the locknut while fixing the valve bridge with a Wrench
wrench so that the valve may not lean. 4 Valve cylinder head

(R.1)
43
2. Inspection and adjustment

Push the bridge head so that a valve bridge and two

valve stem heads may contact each other uniformly, Hold
Adjusting bolt
and adjust an adjusting bolt so that a gap of the valve
stem head may become 0. Tighten a locknut after a Rock nut Valve bridge
valve bridge is fixed with a wrench. Clearance 0

Adjust
clearance
to 0

4-Valve cylinder head

2)Measuring valve clearance

Insert a 0.2 or 0.3 mm thickness gage between the
rocker arm and valve cap / valve bridge, and adjust
the valve clearance. Tighten the adjusting screw.

mm
Model Standard valve clearance
3TNV82A to 98 0.15 to 0.25
4TNV106 (T) 0.25 to 0.35

[NOTICE] Valve clearance adjustment

When tightening a valve bridge locknut of 4-valve head,
tighten a locknut after fixing a valve bridge with a wrench
so that a bridge may not rotate and a valve may not lean.
3)Apply oil to the contact surface between adjusting
Tighten
screw and push rod. Adjusting
bolt
4)Adjusting other cylinders Tighten
In case of 4-cylinder engines turn the crankshaft 180°
then and make adjustment for the No.3 cylinder. Valve
Then adjust the No.4 and No.2 cylinders in this order. bridge
Wrench
The cylinder to be adjusted first does not have to be
4 Valve cylinder head
the No.1 cylinder. Select and adjust the cylinder
where the piston is the nearest to the top dead center
after turning, and make adjustment for other cylinders
in the order of ignition by turning the crankshaft 180°
each time.
In case of 3-cylinder engines turn the crankshaft 240°
then and make adjustment for the No.3 cylinder.
Then adjust the No.2 cylinder in this order.
The cylinder to be adjusted first does not have to be
the No.1 cylinder. Select and adjust the cylinder
where the piston is the nearest to the top dead center
after turning, and make adjustment for other cylinders
in the order of ignition by turning the crankshaft 240°
each time.
44
 2. Inspection and adjustment

(5) Fuel injection nozzle pressure inspection

Wear protective glasses when testing injection from the fuel injection valve. Never approach the injection
nozzle portion with a hand. The oil jetting out from the nozzle is at a high pressure to cause loss of sight or
injury if coming into careless contact with it.

(a)Injection pressure measurement

Standard
Model
MPa (kgf/cm2)
19.6-20.6
3TNV82A to TNV88 (CL)
(200-210)
Nozzle tester
3TNV82A to TNV88 (VM) 21.6-22.6
4TNV94L4 to TNV106(T) (220-230)

[NOTICE]
As for the opening pressure of the brand-new fuel Injection nozzle

nozzle, about 0.5 Mpa (5 kgf/cm) declines by the

engine operation for about 5 hours because of the
Injection pressure measurement
initial wear-out of a spring etc. Therefore, adjust with nozzle tester
0.5 MPa (5 kgf/cm) higher than the standard value of
the above table when adjusting a new fuel nozzle of a
spare part.
Remove carbon deposit at the nozzle hole thoroughly
before measurement.

1)Connect the fuel injection valve to the high pressure

pipe of the nozzle tester.
2)Operate the nozzle tester lever slowly and read the
pressure at the moment when the fuel injection from
the nozzle starts.
3)If the measured injection pressure is lower than the
standard level, replace the pressure adjusting shim
with a thicker one.

Thickness of pressure adjusting shims

Injection pressure adjustment
mm

0.13, 0.15, 0.18, 0.4, 0.5, 0.8 The injection pressure is increased by approx. l.9 MPa (l9 kgf/cm2),
when the adjusting shim thickness is increased by 0.l mm.

45
2. Inspection and adjustment

[Informative: Fuel injection valve structure]

F.O. return pipe joint

Nozzle holder Nozzle holder

Pressure adjusting shim Pressure adjusting shim

Nozzle spring Nozzle spring

Nozzle spring seat Nozzle spring seat

Valve stop spacer Valve stop spacer

Nozzle valve Nozzle valve

Nozzle Nozzle

Nozzle body Nozzle body

Nozzle case nut Nozzle case nut

Tightening torque: Tightening torque:
39.2 to 44.1 Nm (4 to 4.5 kgf࡮m) 39.2 to 44.1 Nm (4 to 4.5 kgf࡮m)
2-valve head 4-valve head

(b)Spray pattern inspection

After adjustment to the specified valve opening
pressure, use a nozzle tester and check the spray Normal
pattern and seat oil-tightness.
Seat oil tightness check
• After injecting a few times, increase the pressure
ǰ ǰ
gradually. Hold the pressure for about 5 seconds at a
little before the valve opening pressure of
1.96 MPa (20 kgf/cm2), and check to see that oil
does not drip from the tip end of the nozzle.
• If extreme oil leak from the overflow joint exists dur- Uniform spray pattern from each nozzle
ing injection by the nozzle tester, check after retight-
ening. If much oil is leaking, replace the nozzle
assembly.

46
 2. Inspection and adjustment

Spray and injection states

• Operate the nozzle tester lever at a rate of once or
twice a second and check no abnormal injection.
• If normal injection as shown below cannot be
obtained, replace the fuel injection valve.
• No extreme difference in angle (θ)
• No extreme injection angle difference (α)
• Finely atomized spray
• Excellent spray departure

(c)Nozzle valve sliding test

Wash the nozzle valve in clean fuel oil. Place the nozzle
body vertically and insert the nozzle into the body to
about 1/3 of its length. The valve is normal if it smoothly
falls by its own weight into the body. In case of a new
nozzle, remove the seal peel, and immerse it in clean
diesel oil or the like to clean the inner and outer surfaces
and to thoroughly remove rust-preventive oil before
using the nozzle. Note that a new nozzle is coated with
rust-preventive oil and is pasted with the seal peel to Nozzle valve sliding check by gravity
shut off outer air.

(d)Nozzle punch mark

A ࡯ 150 P 24 4 JO
Design code
Number of hole
(4 holes)
Diameter of hole
(Ǟ0.24)
Size: sizeP
Injection angle sizeS
Nozzle insertion angle
CodeA: angled
No code: no angle

YANMAR

Punch mark

47
2. Inspection and adjustment

2.2.7 Inspection every 2000 hours or 2 years

Be sure to check the following points every 2,000 hours or two years operation, whichever comes first.
No. Inspection Item
(1) Coolant water path flushing and maintenance
(2) Fuel pipe and coolant water pipe inspection and maintenance
(3) Intake/exhaust valve seat lapping
Fuel injection timing adjustment
(4)
Fuel injection pump inspection and adjustment

(1) Coolant water path flushing and maintenance

Rust and water scale will accumulate in the cooling system through many hours of operation. This lowers the
engine cooling effect. Oil coolers (attached to turbocharged engines and some of naturally aspirated engines)
quickly deteriorate the lube oil. The cleaning and maintenance of the following parts are necessary in
accordance with the coolant water replacement.
Cooling system parts: radiator, cooling water pump, thermostat, cylinder block, cylinder head, oil cooler.
(2) Fuel pipe and coolant water pipe inspection and maintenance
Regularly check the rubber hoses of the fuel system and cooling water system. If cracked or degraded,
replace them with new one. Replace the rubber hoses at least every 2 years even if 2,000 hours doesn’t
come.
(3) Intake/exhaust valve seat lapping
The adjustment is necessary to maintain proper contact of the valves and seats. Refer to 4.2.6 in Chapter 4.
(4) Fuel injection timing adjustment / Fuel injection pump inspection and adjustment
The fuel injection timing and the fuel injection pump are adjusted so that engine performance may become the
best condition. As for the inspection and adjustment of the fuel pump, it is based on the service manual of the
MP pump of the separate volume. The fuel injection timing is adjusted by the following procedure.
As for the engine, which adopts a MP type fuel injection
Fuel injection angle
pump, the fuel injection angle θi (note) is adjusted for the i T.D.C
Nozzle lift
fuel injection timing adjustment.
Note) The fuel injection angle θi (cam angle) is the
0
difference from the injection valve opening Cam angle
angle(FIR) while the fuel injection pump being Valve opening angle (FIR)
driven by a motor and the angle(FIR) at the Angle (FIT) at plunger lift 2.5 mm

plunger lift 2.5mm of the fuel pump. Fuel injection angle

And, as for the actual fuel injection angle θi , the
measured value is recorded on the pump body by
each every fuel pump as shown in the right figure.
The engraved mark is shown by the value that 10
is mulitiplied by the injection angle θi as shown in
Engraved mark
the below table. position
(Examle)
Non operation side
Fuel injection angle θi (Engine side)
Mark
(degree, cam angle)
8.5 85
7.7 77

Operation side
(R.1)
48
 2. Inspection and adjustment

The adjustment of fuel injection angle θi

In case that the fuel pump are removed, and
Fuel injection pump
reassembled, the procedure of fuel injection angle
adjustment is as follows. (As for the disassembly of a I.D.mark
fuel injection pump, refer to 7.2.3 in chapter 7.)
[NOTICE] Flange bolt
Never loosen four flange bolts, which fasten a pump Don't loosen!
flange and a fuel pump drive gear at the time of the
removal of the fuel pump. When it is loosened, the
Gear
adjustment of the fuel injection timing becomes very installation nut
difficult.
1)Before removing a fuel pump drive gear, make ID Fuel pump Idle gear
drive gear
marks on the gearing part of the pump drive gear and
the idle gear with paint and so on.
Fuel pump installation angle
2)Make the mark-off line to the gear case precisely in
accordance with the position of mark-off line of the Fuel pump side Gear case side
fuel pump. Mark-off line
Mark-off line on gear case
on fuel pump

Marking

Marking on gear case

3)Before removing a fuel pump, put the standard mark

1 cam
of a sticker for fuel injection angle adjustment in Standard mark 2 cam
accordance with the mark-off line of the fuel pump
and paste it on the gear case.

0.5 cam

Sticker for adjusting injection angle

Mark sticker

Fuel injection pump

Gear case
Mark-off line

(R.1)
49
2. Inspection and adjustment

4)Remove a fuel pump, and read the fuel injection angle recorded in that fuel pump.

5)Read the injection angle recorded on a newly assembled fuel pump and calculate the difference from the
injection angle of the disassembled fuel pump. (When re-installation does the same fuel pump, the angu-
lar difference is zero.)
Fuel injection angle difference ∆ θi (cam angle) = (the fuel injection angle θi2 of a new fuel pump)
- (the fuel injection angle θi1 of a disassembled previous fuel pump)
Calculation example
Fuel injection angleFuel injection angle Fuel injection angle
difference of a new fuel pump of a disassembled
Fuel pump installation method
θi2 fuel pump θi1
(degree, cam angle) (degree, cam angle) (degree, cam angle)
Turn the fuel pump body in the outside
directon of the cylinder block at 0.5
+0.5 8.5 8.0
degree(cam angle).
[Advanced injection timing]
Turn the fuel pump body in the inside
direction of the cylinder block at 0.3
-0.3 7.7 8.0
degree(cam angle).
[Delayed injection timing]

[NOTICE]
Tell the fuel pump number to Yanmar, and inquire the injection angle of the pump when it is hard to find out.
6)Put the fuel pump on the gear case temporarily and install the drive gear on the cam shaft with checking
the ID marks, which were put on the fuel pump drive gear and the idle gear at the time of the disassem-
bling.

Tighten the installation nut of a pump drive gear.

Tightening torque Lubricating oil application
Model Fuel pump model
N•m (kgf•m) (thread portion, and seat surface)
3TNV82A to TNV88 MP2 78 to 88 (8 to 9)
Not applied
4TNV94L/98/106 (T) MP4 113 to 123 (11.5 to 12.5)

7)Adjust the installation angle of the fuel pump while

Mark-off ling on fuel pump
reading the injection angle difference, calculated in Mark sticker
the above 5), withe the mark (minimum 0.5°, cam
angle) of the adjustment mark sticker.. 1 cam
Standard
0.5 cam
[NOTICE] mark
Push down the fuel pump in the outside direction of the 0.5 cam
1 cam
cylinder block at +0.5 degree(cam) when a injection
angle difference ∆ θi is +0.5 degree(cam). In case of + 0.5 cam Incase of -0.3 cam
And, push it down to the cylinder block side at 0.3 Injection angle adjustment
degree(cam) when a difference is -0.3 degree(cam).

8)Tighten the fuel pump installation nuts.

(R.1)
50
 2. Inspection and adjustment

(Supplementary explanation 1)
ǰ
The installation angle of the fuel pump is as follows.
Installation angle
Model
θ (deg.)
3TNV82A to TNV88 25 Cylinder block side
4TNV94L/98/106 (T) 13
4TNV106 (T) 11.5

Fuel pump installation angle

(Supplementary explanation 2)
When fuel injection timing is advanced or delayed, the Delayed
installation angle of the fuel pump is adjusted. Advanced
When fuel injection timing is advanced for example at
0.5 degrees(cam), loosen the nuts, which fix the fuel
Cylinder block side
pump on the gear case, and turn the fuel pump body in
the inside direction of the cylinder block at 0.5
degree(cam), and tighten the pump installation nuts.
And, when fuel injection timing is delayed, a pump is
turned in that reverse direction.

Pump installation bolts

Injection timing adjustment

(R.1)
51
2. Inspection and adjustment

2.3 Adjusting the no-load maximum or minimum speed

1)After warming the engine up, gradually raise the speed and set it at the no-load maximum revolution.
2)If the no-load maximum speed is out of the stan-
dard, adjust it by turning the high idle limiting bolt.
The no-load maximum speed standard is shown in
the specification tables in 1.2 of the chapter 1.
3)Then set the no-load minimum speed by adjusting
the low idle limiting bolt.
Low idle
limiting bolt
High Low Govenor lever

No-load minimum speed standards (Unit: min-1) Accelerating

wire bracket
Engine application No-load minimum speed
class (± 25)
CL 1200
High idle
800 limiting bolt Accelerating wire fixing nut
VM
(1100 for 4TNV106 (T))
Accelerating wire bracket
Note) The engine speed may differ from the above
MP2 Fuel Injection pump
standard depending on an engine installed on a
machine unit.

52
 2. Inspection and adjustment

2.4 Sensor inspection

2.4.1 Oil pressure switch
Disconnect the connector from the oil pressure switch.
Keep the voltameter probes in contact with the switch Cylinder block
Oil pressure switch (flywheel side)
terminal and cylinder block while operating the engine. It Tester probes
is abnormal if circuit is closed.

Continuity test
2.4.2 Thermo switch
Place the thermo switch in a container filled with
antifreeze or oil. Heat it while measuring the fluid Thermometer
temperature. The switch is normal if the voltameter Tester probes
shows continuity when the fluid temperature is
107 to 113 deg C.

Thermo switch

Hot water

2.5 Water leak check in cooling water system

Check coolant water leakage from the cooling water
system visually. If any problem is found, Inspect as
follows.
1)Fill coolant water to the normal level in the radiator,
and install the cap tester on the radiator.
2)Operate the manual pump to set the pressure to
0.09 ± 0.015 MPa (0.9 ± 0.15 kgf/cm2). If the cap
tester pressure gage reading drops then, water is Cap tester
leaking from the cooling water system. Check the
water leaking point. Water leak check in cooling water system

53
2. Inspection and adjustment

2.6 Radiator cap inspection

Install the radiator cap on the cap tester. Set the tester
pressure to 0.09 ± 0.015 MPa (0.9 ± 0.15 kgf/cm2) and
see that the cap is opened. If the cap does not open,
replace the cap since it is abnormal.

Radiator cap

Radiator cap inspection

2.7 Thermostat Inspection

Place the thermostat in a container filled with water.
Heat it while measuring the water temperature, and see To radiator

that the thermostat is actuated at temperature of

following table. Cover

Valve opening Full open lift

Model Temperature (Temperature)
(deg C)* (mm) Thermostat

All models 69.5 to 72.5 8 or more (85 deg C)

* Valve opening temperature is carved on the flange.

Thermo switch

Thermometer

Thermostat

54
 2. Inspection and adjustment

2.8 Adjusting operation

Perform the adjusting operation of a engine as follows after the maintenance job:
1)Supply the fuel oil, lubricating oil and coolant water.

Note:
Check the levels of the lubricating oil and coolant water again after test running (for about 5 minutes) and add
as required.

2)Start the engine, and carry out idling at a low revolution (700 to 900 rpm) for a few minutes.
3)Run in the engine for about five minutes at the rated revolution (no-load). Check any water, fuel or oil leak
and existence of abnormal vibration or noise. Also check the oil pressure, coolant water temperature and
exhaust gas color.
4)Adjust the no-load minimum and maximum revolutions according to the specifications.
5)Perform loaded operation as required.

2.9 Long storage

Observe the following instructions when the engine is to be stored for a long period without operation:
1)Be sure to use clean soft water added Long Life Coolant Antifreeze (LLC) in the cooling water system and
do not drain the coolant before long-term storage.
If drain the cooling water, it will cause to built up rust due to the residual water in the cooling water system.
2)Remove the mud, dust and oil deposit and clean the outside.
3)Perform the nearest periodic inspection before the storage.
4)Drain or fill the fuel oil fully to prevent condensation in the fuel tank.
5)Disconnect the battery cable from the battery negative (-) terminal.
6)Cover the silencer, air cleaner and electric parts with PVC (Poly Vinyl Chloride) cover to prevent water and
dust from depositing or entrance.
7)Select a well-ventilated location without moisture and dust for storage.
8)Perform recharging once a month during storage to compensate for self-discharge.
9)When storing an engine for long time, run the engine or do motoring periodically according to the following
procedure. Because the rust occurrence inside the engine, the rack agglutination of the fuel pump, and so
on are likely to occur. (In case that the engine is equipped with a machine unit,)

a)Replace the lube oil and the filter before the engine running.
b)Supply fuel if the fuel in the fuel tank was removed, and bleed the fuel system.
c)Confirm that there is the coolant in the engine.
d)Operate the engine at the low idling speed for about five minutes. (If it can be done, one a month)

55
3. Troubleshooting

3. Troubleshooting

3.1 Preparation before troubleshooting

If the signs of a trouble appear, it is important to lecture on the countermeasure and treatment before
becoming a big accident not to shorten the engine life.

When the signs of a trouble appear in the engine or a trouble occurs, grasp the trouble conditions fully by the
next point and find out the cause of sincerity according to the troubleshooting. Then repair the trouble, and
prevent the recurrence of the trouble.

1)What’s the occurrence phenomenon or the trouble situation? ⋅⋅⋅⋅⋅ (e.g. Poor exhaust color)
2)Investigation of the past records of the engine
Check a client control ledger, and examine the history of the engine.
• lInvestigate the engine model name and the engine number. (Mentioned in the engine label.)
Examine the machine unit name and its number in the same way.
• lWhen was the engine maintained last time?
• lHow much period and/or time has it been used after it was maintained last time?
• lWhat kind of problem was there on the engine last time, and what kind of maintenance was dane?

3)Hear the occurrence phenomenon from the operator of the engine in detail.
5W1H of the occurrence phenomenon : the investigation of when (when), where (where), who (who), what
(what), why (why) and how (how)
• lWhen did the trouble happen at what kind of time?
• lWas there anything changed before the trouble?
• lDid the trouble occur suddenly, or was there what or a sign?
• lWas there any related phenomenon.
⋅⋅⋅⋅⋅. (e.g. Poor exhaust color and starting failure at the same time)

4)After presuming a probable cause based on the above investigation, investigate a cause systematically by
the next troubleshooting guide, and find out the cause of sincerity.

56
 3. TROUBLESHOOTING

3.2 Quick reference table for troubleshooting

The following table summarizes the general trouble symptoms and their causes. If any trouble symptom occurs, take corrective action before it becomes a serious problem so as not to shorten the engine service life.

Poor

High knocking sound during combustion

Insufficient Cooling Air
Trouble symptom Starting failure exhaust Hunting Lubricating oil
engine output water intake
color

Difficulty in returning to low speed

Engine starts
Exhaust During
but stops

Excessive fuel consumption

color work

Uneven combustion sound

soon.

Exhaust temperature rise

Abnormal engine sound

Excessive consumption

Low water temperature

Large engine vibration
Engine does not start.
Exhaust Corrective action
smoke

Low L.O. pressure

Mixture with water

Much blow-by gas

Dilution by fuel oil

Pressure drop

Pressure rise
During idling

During work

Overheat
Ordinary
Cause

White

White
Black

Black
Much
None

Improper clearance of intake/exhaust valve
Compression leakage from valve seat
Seizure of intake/exhaust valve
Blowout from cylinder head gasket
Seized or broken piston ring
Worn piston ring, piston or cylinder
Seized crankpin metal or bearing
Improper arrangement of piston ring joints
Engine system
Little
c c
c c
c c
c c
c c
c c
c c c c Adjust the valve clearance. (See 2.2.6 (4) in Chapter2.)
c c c c c c c c Lap the valve seat. (See 4.2.6 in Chapter4.)
c c c c c c c c c Correct or replace.
c c c Replace the gasket. (See 4.2.2-12) in Chapter4.)
c c c c c c c c c c Replace the piston ring. (See 4.4.2-5) & 10) in Chapter4.)
Perform honing and use oversize parts.
c c c c c
(See 4.4.5-1)4) and 4.4.6 in Chapter4.)
c c c c c Repair or replace.
c c Correct the ring joint positions. (See 4.4.4-point 6 in Chapter4.)

Reverse assembly of piston rings c c c c Reassemble correctly. (See 4.4.4-point 6 in Chapter4.)

Worn crankpin and journal bearing
Loosened connecting rod bolt
Foreign matter trapped in combustion chamber
Excessive gear backlash
Worn intake/exhaust valve guide
Defective governor
Improper open/close timing of intake/exhaust valves c
c c c c c c Measure and replace. (See 4.4.5-(2) in Chapter4.)
c c c Tighten to the specified torque. (See 4.4.4-point 2 in Chapter4.)
c c c c Disassemble and repair.
c Adjust gear meshing. (See 4.3.4-point 2 in Chapter4.)
c c c Measure and replace. (See 4.2.5-(2) and 4.2.7 in Chapter4.)
c c c c c Make adjustment.
c c c c c Adjust the valve clearance. (See 2.2.6-(4) in Chapter2.)

Fouled blower c c Wash the blower.

Waste gate malfunction c c Disassemble and inspect.
Turbocharger

Worn floating bearing c c Disassemble and inspect.

57
 3. TROUBLESHOOTING

Poor

High knocking sound during combustion

Insufficient Cooling Air
Trouble symptom Starting failure exhaust Hunting Lubricating oil
engine output water intake
color

Difficulty in returning to low speed

Engine starts
Exhaust During
but stops

Excessive fuel consumption

color work

Uneven combustion sound

soon.

Exhaust temperature rise

Abnormal engine sound

Excessive consumption

Low water temperature

Large engine vibration
Engine does not start.
Exhaust Corrective action
smoke

Low L.O. pressure

Mixture with water

Much blow-by gas

Dilution by fuel oil

Pressure drop

Pressure rise
During idling

During work

Overheat
Ordinary
Cause

White

White
Much

Black

Black
None

Little
Excessive cooling effect of radiator c c c Defective thermostat (kept closed) (See 2.2.7 in Chapter2.)
Defective thermostat (kept opened) (See 2.2.7 in Chapter2.)
Cooling Water System

Insufficient cooling effect of radiator c c c

or slipping fan belt (See 2.2.2-2) in Chapter2.)
Check water leakage from cooling water system.
Insufficient coolant water level c c c
(See 2.2.1-4) in Chapter2.)
Cracked water jacket c c c Repair or replace.
Slackened fan belt c c c Adjust the belt tension. (See 2.2.2-2) in Chapter2.)
Defective thermostat c c c c Check or replace. (See 2.2.7 in Chapter2.)

Improper properties of lubricating oil c c c c c c Use proper lubricating oil. (See 1.3.2 in Chapter1.)
Lubricating System

Leakage from lubricating oil piping system c c Repair.

Insufficient delivery capacity of trochoid pump c Check and repair. (See 5.5 in Chapter5.)
Clogged lubricating oil filter c c Clean or replace.
Defective pressure regulating valve c Clean, adjust or replace.
Insufficient lubricating oil level c c Add proper lubricating oil. (See 2.2.1-3) in Chapter2.)

Too early timing of fuel injection pump
Too late timing of fuel injection pump
Improper properties of fuel oil
Water entrance in fuel system
Clogged fuel filter
Air entrance in fuel system
Fuel system
c c c c Check and adjust. (See 2.2.7-4) in Chapter2.)
c c c c c c Check and adjust. (See 2.2.7-4) in Chapter2.)
c c c c c c Use proper fuel oil. (See 1.3.1 in Chapter1.)
c c c c c c c Perform draining from the fuel filter. (See 2.2.3 and 2.2.5 in Chapter2.)
c c c Clean or replace. (See 2.2.5 in Chapter2.)
c c c Perform air bleeding. (See 2.2.3 in Chapter2.)

Clogged or cracked fuel pipe c c c Clean or replace.

Insufficient fuel supply to fuel injection pump c c c Check the fuel tank cock, fuel filter, fuel pipe, and fuel feed pump.
Uneven injection volume of fuel injection pump c c c c c c c c c Check and adjust.
Excessive fuel injection volume c c c c c c c Check and adjust.
Poor spray pattern from fuel injection nozzle c c c c c c c c c Check and adjust. (See 2.2.6 in Chapter2.)
Foreign matter trapped in the valve inside the priming pump.
Priming failure c
(Disassemble and clean.)
Clogged strainer at feed pump inlet c Clean the strainer.

58
 3. TROUBLESHOOTING

Poor

High knocking sound during combustion

Insufficient Cooling Air
Trouble symptom Starting failure exhaust Hunting Lubricating oil
engine output water intake
color

Difficulty in returning to low speed

Engine starts
Exhaust During
but stops

Excessive fuel consumption

color work

Uneven combustion sound

soon.

Exhaust temperature rise

Abnormal engine sound

Excessive consumption

Low water temperature

Large engine vibration
Engine does not start.
Exhaust Corrective action
smoke

Low L.O. pressure

Mixture with water

Much blow-by gas

Dilution by fuel oil

Pressure drop

Pressure rise
During idling

During work

Overheat
Ordinary
Cause

White

White
Much

Black

Black
None

Little
Clogged air filter c c c c c Clean. (See 2.2.4 in Chapter2.)
Air/Exhaust Gas System

Engine used at high temperatures or at high altitude c c c c c Study output drop and load matching.
Clogged exhaust pipe c c c c Clean.

Starting motor defect c Repair or replace. (See Chapter8.)

Alternator defect c Repair or replace. (See Chapter9.)
Open-circuit in wiring c Repair. (See Chapter10.)
Electrical System

Battery voltage drop c Inspect and change the battery. (See 2.2.3 in Chapter2.)

59
 3. TROUBLESHOOTING

3.3 Troubleshooting by measuring compression pressure

Compression pressure drop is one of major causes of increasing blowby gas (lubricating oil contamination or
increased lubricating oil consumption as a resultant phenomenon) or starting failure. The compression
pressure is affected by the following factors:
1)Degree of clearance between piston and cylinder
2)Degree of clearance at intake/exhaust valve seat
3)Gas leak from nozzle gasket or cylinder head gasket
In other words, the pressure drops due to increased parts wear and reduced durability resulting from long use
of the engine.
A pressure drop may also be caused by scratched cylinder or piston by dust entrance from the dirty air
cleaner element or worn or broken piston ring. Measure the compression pressure to diagnose presence of
any abnormality in the engine.

(1) Compression pressure measurement method

1)After warming up the engine, remove the fuel
injection pipe and valves from the cylinder to be
measured.
2)Crank the engine before installing the compres-
Compression
sion gage adapter. gage
*1) Perform cranking with the stop handle at the
stop position (no injection state).
*2) See 12.2-18 in Chapter 12 for the compression
gage and compression gage adapter.
3)Install the compression gage and compression
gage adapter at the cylinder to be measured. Measurement of the compression pressure
*1) Never forget to install a gasket at the tip end of
the adapter.
4)With the engine set to the same state as in 2)*1),
crank the engine by the starter motor until the
compression gage reading is stabilized.

(2) Standard compression pressure

Engine compression pressure list (reference value)
Compression pressure
at 250 min-1 Deviation among cylinders
Engine mode
MPa (kgf/cm2)
MPa (kgf/cm2)
Standard Limit
3TNV82A 3.16 ± 0.1 (31 ± 1) 2.45 ± 0.1 (25 ± 1)
3/4TNV84 3.24 ± 0.1 (33 ± 1) 2.55 ± 0.1 (26 ± 1)
0.2 to 0.3 (2 to 3)
3/4TNV84T 2.94 ± 0.1 (30 ± 1) 2.45 ± 0.1 (25 ± 1)
TNV88 to 106 (T) 3.43 ± 0.1 (35 ± 1) 2.75 ± 0.1 (28 ± 1)

60
3. TROUBLESHOOTING

(3) Engine speed and compression pressure (for reference)

3/4TNV88㨪4TNV106(T)
Compression pressure (kgf/cm2)

40 4

Compression pressure (MPa)

3/4TNV84
35

30 3

3TNV82A
25
3/4TNV84T
20 2

200 250 300 350 400

Engine speed (min-1)

(4) Measured value and troubleshooting

When the measured compression pressure is below the limit value, inspect each part by referring to the table
below.

No. Item Cause Corrective action

• Air cleaner element • Clogged element • Clean the element.
• Broken element • Replace the element.
1
• Defect at element seal
portion
• Valve clearance • Excessive or no clear- • Adjust the valve clearance.
2
ance (See 3.5 in Chapter 3.)
• valve timing • Incorrect valve clearance • Adjust the valve clearance.
3
(See 3.5 in Chapter 3.)
• Cylinder head gasket • Gas leak from gasket • Replace the gasket.
• Retighten the cylinder head bolts to the spec-
4
ified torque.
(See 4.2 (2) 12) in Chapter 4.)
• Intake/exhaust vale • Gas leak due to worn • Lap the valve seat.
• Valve seat valve seat or foreign mat- (See 4.2 (6) in Chapter 4.)
5
ter trapping • Replace the intake/exhaust valve.
• Sticking valve
• Piston • Gas leak due to scratch- • Perform honing and use an oversized part.
6 • Piston ring ing or wear (See 4.4 (5)-(5-1), (5-4) and (6) in Chapter 4.)
• Cylinder

61
 4. Disassembly, inspection and reassembly of engines

4. Disassembly, inspection and reassembly of engines

4.1 Complete disassembly and reassembly

4.1.1 Introduction
Make preparation as follows before starting engine inspection and service:
1)Fix the engine on a horizontal base.

Be sure to fix the engine securely to prevent injury or damage to parts due to falling during the work.
2)Remove the coolant water hose, fuel oil pipe, wire harness, control wires etc. connecting the driven
machine and engine, and drain coolant water, lubricating oil and fuel.
3)Clean soil, oil, dust, etc. from the engine by washing with solvent, air, steam, etc. Carefully operate so as
to prevent any foreign matter from entering the engine.

Always wear glasses or other protectors when using compressed air or steam to prevent any foreign matter
from getting in the eyes.

[NOTICE]
• Any part which is found defective as a result of inspection or any part whose measured value does not sat-
isfy the standard or limit shall be replaced.
• Any part predicted to dissatisfy the standard or limit before the next service as estimated from the state of
use should be replaced even when the measured value then satisfies the standard or limit.

62
4. Disassembly, inspection and reassembly of engines

4.1.2 Special service tools

(1) Special Tools

No. Tool name Applicable model and tool size Illustration

Valve guide tool
(for extracting valve চ
guide) Model L1 L2 d1 d2
3TNV82A
4TNV94L 98(T) 20 75 6.5 10
4TNV106(T)
1 4TNV84
3TNV84(T) 20 75 7.5 11
3/4TNV88
4TNV84T 20 75 5.5 9

̪Locally manufactured
Valve guide tool
(for inserting valve চ
guide) Model L1 L2 d1 d2
3TNV82A 12 60 13 19
4TNV84
3TNV84(T) 15 65 14 20
3/4TNV88
2
4TNV84T 8.5 60 11 17

4TNV94L 98(T) 7 60 13 16

4TNV106(T) 13.6 65 13 16

̪Locally manufactured
Connecting rod
bushing replacer চ
(for removal / Model L1 L2 d1 d2
installation of 3TNV82A 25 85 23 26
connecting rod
bushing) TNV84 88 20 100 26 29

3 4TNV94L 98 20 100 30 33

4TNV106(T) 20 100 37 40

Allowance: d1-- 00..36 d2 -- 00..36

̪Locally manufactured
Valve spring
compressor
(for removal /
installation of valve
spring) yanmar code No.
4
129100-92630

63
 4. Disassembly, inspection and reassembly of engines

No. Tool name Applicable model and tool size Illustration

Stem seal inserter      চ
(for inserting stem Model d1 d2 d3 L1 L2 L3
seal)
3TNV82A 15.2 21 12 15.8 65 4
4TNV84
3TNV84(T) 16.2 22 13.5 18.8 65 4
4TNV88 
5 4TNV84T 12.9 19 11.5 10.0 65 4

4TNE94L 98 15.2 21 12 11.8 65 4

4TNE106(T) 15.2 21 12 15.5 65 4


̪ Locally manufactured

Filter wrench
(for removal /
6 Available on the market
installation of L.O.
filter)
Camshaft bushing
tool চ
(for extracting Model L1 L2 d1 d2
camshaft bushing) TNV82A 88 18 70 45 48

7 4TNV94L 98 18 70 50 53

4TNV106(T) 18 70 58 61

Allowance: d1 -- 00..36 d2 -- 00..36

̪Locally manufactured
Flex-Hone
(For re-honing of Cylinder
cylinder liner) Model Parts No. bore
(চ)
TNV82A 129400-92420 78 84
8
TNV88 4TNV94L 129400-92430 83 95

4TNV98 129400-92440 89 101

4TNV106(T) 129400-92450 95 108

Piston insertion
tool Yanmar code No. 95550-002476
9 (for inserting ̪The above piston insertion tool is applicable
piston) to 60-125 mm diameter pistons.

Piston ring replacer

(for removal /
10 installation of Available on the market
piston ring)

Crankshaft pulley
installing tool Locally manufactured
11 (for 4TNV94L)
(Refer to 4.3.6 in detail)

64
4. Disassembly, inspection and reassembly of engines

(2) Measuring instruments

No. Instrument name Application Illustration

Measurements of shaft bending, and strain
and gap of surfaces

1 Dial gage

Measurements of narrow or deep portions

that cannot be measured by dial gage

2 Test indicator

For holding the dial gage when measuring

using a dial gage, standing angles adjustable

3 Magnetic stand

For measuring the outside diameters of

crankshaft, pistons, piston pins, etc.

4 Micrometer

For measuring the inside diameters of

cylinder liners, rod metal, etc.

5 Cylinder gage

For measuring outside diameters, depth,

thickness and width

6 Calipers

For measuring of valve sink

7 Depth micrometer

For measuring valve spring inclination and

straightness of parts
8 Square

65
 4. Disassembly, inspection and reassembly of engines

No. Instrument name Application Illustration

For measuring shaft bend

9 V-block

For tightening nuts and bolts to the

specified torque

10 Torque wrench

For measuring gaps between ring and ring

groove, and shaft joints during assembly

11 Thickness gage

For checking water leakage

12 Cap tester

For checking concentration of antifreeze

and the battery electrolyte charge status

13 Battery coolant tester

For measuring injection spray pattern of

fuel injection nozzle and injection pressure

14 Nozzle tester

For measuring temperatures

abcdefghijklmn
abcd efghijk

abcdefghijklmn

abcdefghijklmn
abcdefghijklmn

15 Digital thermometer
abcdefghijklmnabcdefghijklmn
abcdefghijklmnabcdefghijklmn

Float

66
4. Disassembly, inspection and reassembly of engines

(R.1)
No. Instrument name Application Illustration
For measuring revolution by contacting
the mortise in the revolving shaft

Contact type

16 Speedometer
For measuring revolution by sensing
the reflecting mark on the outer
Revolving shaft
periphery of the revolving shaft

Photoelectric type

Reflection mark

For measuring resistance, voltage and

continuity of electrical circuits

17 Circuit tester

For measuring compression pressure

Gauge set code NO. TOL-97190080

Adapter for direct injection 2-valve head

Adapter code No. 119802-92950

130
18 Compression gage kit

Adapter for direct injection 4-valve head

for 4TNV94L/98/98T

Adapter code No. 129906-92950

165

Adapter for direct injection 4-valve head

for 4TNV106/106T

Adapter code No. 123907-92950

179

67
 4. Disassembly, inspection and reassembly of engines

4.1.3 Complete disassembly

Peripheral parts such as air cleaner, muffler and radiator differ in installation and types for each application.
Therefore, description in this Chapter is started with the steps to be taken just after the peripheral parts have
been removed.

Step Removal Parts Remarks

1)Thoroughly remove sand, dust, dirt and soil
from the surface of the engine.
1
2)Drain coolant water and lubricating oil from the
engine.
1)Remove turbocharger and exhaust manifold.
2
2)Remove intake manifold and surge tank.
1)Close the fuel cock valve of the fuel tank. 1)If nozzle seat is left on the cylinder head,
2)Remove high-pressure fuel pipe. remove the cylinder head before extracting noz-
3)Remove fuel return pipe. zle seat.
4)Loosen the tightening nut on fuel injection noz- 2)To prevent dust from entering fuel injection noz-
3 zle retainer and extract the retainer and fuel zle, fuel injection pump and high-pressure fuel
injection nozzle. pipe, seal their respective threads with a tape or
*) Fuel injection nozzle for Indirect injection the like.
system is screwed type. 3)Whenever extracting fuel injection nozzle,
replace nozzle protector with a new one.
1)Remove rocker arm cover assembly.
4

1)Remove valve rocker arm shaft assembly. 1)Attach a tag to push rod for each cylinder No. to
2)Remove push rod. put the push rod in order.
2)Remove valve cap from the intake/exhaust
valve head.
5 3)Note that tappet of the indirect injection system
can be removed at the same time when push
rod is extracted.
4)Attach a tag to tappet for each cylinder No. to
put the tappet in order.
1)Remove fan mounting bolt, and then remove 1)Never turn down alternator vigorously toward
fan. the cylinder block. Otherwise, your finger may
2)Loosen adjusting bolt for the V-belt adjuster, and be nipped and alternator broken.
6
then remove V-belt.
3)Remove alternator.
4)Remove the spacer for cooling fan and V-pulley.
1)Remove lubricating oil filter assembly.
7 2)Extract dipstick form the oil dip-stick hole.

1)Disconnect fuel return pipes to.

8 2)Remove fuel filter.

68
4. Disassembly, inspection and reassembly of engines

Step Removal Parts Remarks

1)Disconnect coolant water pipe from the cooling
water pump.
9
2)Remove thermostat assembly.
3)Remove cooling water pump.
1)Remove cylinder head tightening bolt. 1)Lay a cardboard or the like on the floor and
2)Remove cylinder head assembly. place cylinder head assembly on it so as not to
3)Remove cylinder head gasket. damage the combustion surface.
2)Order of loosening the cylinder head tightening
bolts.

Disassembly
Camshaft side
8 14 5

Fan side
2 12 9 3

4 10 11 1
6 13 7
Head bolt disassembly order
3 cylinder head
Disassembly
10 Camshaft side

Fan side
7 16 14 6
1 9 18 12 4

3 11 17 10 2
5 13 15 8

Head bolt disassembly order

4 cylinder head

3)To remove the intake/exhaust valves from cylin-

1)Remove crankshaft V-pulley clamping bolt.
11 2)Using a puller, extract crankshaft V-pulley.
der head assembly, take the following steps.
a)Using a valve spring compressor (see Chapter
5, 5-1), compress valve spring and remove
valve cotter.
b)Remove valve retainer and valve spring.
c)Remove intake valve and exhaust valve.
1)Extract crankshaft V-pulley by hitting the bolt of
the puller using a plastic hammer or the like.

1)Remove oil pan mounting bolt under gear case. 1)Never fail to removes stiffener bolt at the center
2)Remove gear case mounting bolt. of the gear case.
12
3)Remove gear case. 2)When removing the gear case, carefully protect
oil seal from damage.
1)Remove the nut from fuel injection pump drive 1)Before removing fuel injection pump, make sure
gear. Extract fuel injection pump drive gear of the position of the arrow of the pump body for
13 using a puller. adjusting fuel injection timing as well as the posi-
tion of the scribed line of the gear case flange.
(Applies only to direct injection system.)

69
 4. Disassembly, inspection and reassembly of engines

Step Removal Parts Remarks

1)Remove lubricating oil pump.
14

1)Remove starting motor from flywheel housing

15 sing.

1)Remove flywheel mounting bolt. 1)Carefully protect the ring gear from damage
16 2)Remove flywheel. mage.

1)Remove flywheel housing. 1)Carefully protect the oil seal from damage.
2)Remove oil seal case with a screwdriver or the
17
like by utilizing grooves on both sides of oil seal
case.
1)Remove oil pan and spacer. 1)Put the cylinder block with the attaching surface
of the cylinder head facing down.
2)Carefully protect the combustion surface of the
cylinder block from damage.
18
3)For indirect injection system, be careful to the
possibility of the tapped to drop off when the cyl-
inder block is turned upside down, because the
tappet is cylindrical in shape.
1)Remove idle gear shaft, and then remove idle 1)Turn the cylinder block aside and carefully pre-
gear. vent tappet from jamming on the cam.
19 2)Remove mounting bolt of thrust bearing through 2)Preheat camshaft gear and camshaft assembly
the hole of the camshaft gear. Remove cam- to 180° to 200° which are shrink fitted, before
shaft assembly. removing them.
1)Remove gear case flange.
20

1)Remove lubricating oil strainer.

21

1)Remove crankpin side cap of the connecting 1)Before extracting piston, remove carbon depos-
rod. its from the upper wall of the cylinder using fine
While turning crankshaft, place piston in the sandpaper, while taking care not to damage the
bottom dead center (BDC). inner surface of the cylinder.
22
2)Make sure than cap No. of connecting rod
agrees with cylinder No.
3)Take care not to let crankpin metal fall when
removing connecting rod crankpin side cap.

70
4. Disassembly, inspection and reassembly of engines

Step Removal Parts Remarks

1)Remove main bearing cap bolt. While shaking 1)Before extracting crankshaft, measure the side
main bearing cap, remove main bearing cap gap around it.
together with lower main bearing metal.
2)Extract crankshaft, taking care not to damage it.
3)Remove upper main bearing metal.

Dial gauge
23 Crankshaft

Apply a dial gauge to the end of crankshaft.

Force the crankshaft on both sides in the axial
direction to measure the thrust gap.
Alternatively, insert a thickness gauge directly
between the base thrust metal and the thrust
surface of the crankshaft to measure the gap.
If the limit size is exceeded, replace the thrust
metal with a new one.

Thrust gap (All models)

2)Notice on the removal of thrust metal.
a)When removing thrust metal, ascertain the
position and direction where thrust metal is
installed in relation to the cap.
b)Make sure that the thrust metal groove is
outward in relation to the cap.
1)Remove piston and connecting rod assembly. 1)To selectively remove a desired piston and con-
necting rod assembly without extracting crank-
shaft, take the steps itemized below:
a)Remove carbon deposits from the upper wall of
the cylinder using fine sandpaper, taking care
not to damage the inner surface of the cylinder.
24 b)While turning the crankshaft, with the
connecting rod cap removed, raise the piston up
to the top dead center (TDC).
c)Extract the piston/connecting rod assembly
while tapping the connecting rod at the large end
with the handle of a plastic hammer or the like.
2)Remove tappet.
25

71
 4. Disassembly, inspection and reassembly of engines

4.1.4 Precautions before and during reassembly

To reassemble engine components, reverse the procedure of disassembly. However, follow the precautions
below and the precautions from in chapter 4 to in chapter 7 particularly before and during reassembly.

(1) Cleaning the component

Use particular care to clean the cylinder block, cylinder head, crankshaft, and camshaft. Ensure that they are
free from chips, dust, sand, and other foreign matter.

(2) Parts to be replaced during reassembly

Be sure to replace the following parts with new ones during assembly.
• Valve stem seal
• Head gasket packing
• Nozzle protector and nozzle seat of the fuel injection valve
• Various copper packing, O-rings and gasket packing.

4.1.5 Adjusting operation

Make sure to perform adjusting operation after completing reassembly. Refer to section 2.5 in chapter 2 for
the operation procedure.

72
4. Disassembly, inspection and reassembly of engines

4.2 Cylinder head: Disassembly, inspection and reassembly

4.2.1 Components (2-valve cylinder head)

ԡRocker arm cover

ԞFuel injection pipe ԠExhaust manifold

Cylinder head
ԛFuel filter ԘOil cooler

Joint

ԚThermostat

ԟIntake maniforld
Head gasket
Thermo switch Cooling water pump
Oil/water separator

ԙV-pulley
Cylinder block
Spacer

ԙFan

ԝOil filter Gear case

Note) This figure shows the 3TNV84.

4.2.2 Disassembly procedure:

Disassemble in the order of the numbers shown in the illustration.
1)Remove the alternator assy. (Point1)
2)Remove the fan, pulley and V belt.
3)Remove the thermostat case. (Point2)
4)Remove the fuel filter and fuel oil piping. (Point3)
5)Remove the oil level gage assy.
6)Remove the oil filter. (Point4)
7)Remove the fuel injection pipes. (Point5)
8)Remove the intake manifold assy.
9)Remove the exhaust manifold assy.
10)Remove the rocker arm cover assy.
11)Remove the rocker shaft assy, push rods and valve caps. (Point6)
12)Remove the cylinder head assy and head gasket. (Point7)
13)Remove the fuel injection valves and fuel return pipe. (Point8)
14)Remove the intake/exhaust valves, stem seals and valve springs. (Point9)
15)Remove the rocker arms from the rocker shaft.
73
 4. Disassembly, inspection and reassembly of engines

Rocker arm
cover
Rocker arm suport
Rocker arm
cover

Rocker arm shaft

Rocker arm Rocker arm shaft
Adjusting bolt Rocker arm
Valve bridge
Valve cap
Cotter Cotter
Spring holder Spring holder
Valve spring Rocker arm Valve spring
Stem seal suport Stem seal
Valve guide Valve guide

Cylinder head
Cylinder head
Exhaust valve

Suction valve Exhaust vlave Suction valve

4-Valve cylinder head 2-Valve cylinder head

4.2.3 Reassembly procedure:

Reverse order of the disassembly procedure.

74
4. Disassembly, inspection and reassembly of engines

4.2.4 Servicing points

Point1
Adjust the V-belt tension
[Disassemble] inserting a bar
• Loosen the mounting bolt while supporting the alter-
nator.
Adjuster

Do not tilt the alternator toward the cylinder block in

haste since it may damage the alternator or pinch a
finger.
[Reassemble] Alternator
• The belt deflection shall be checked according to Tension adjustment
2.2.2. in Chapter2.
[Reassemble]
• Replace the belt with a new one if cracked, worn or 98N (10kgf)
Set bolt
damaged.
• Carefully prevent the belt from being smeared with oil
Deflection
or grease.
Alternator

C.W. pump
V belt

Crank pulley

V-belt tention

Point2
[Reassemble]
• Check the thermostat function. (See3.9 in Chapter 3
for the check procedure.)
Pont3
[Reassemble]
• Replace the fuel filter element with a new one.
[Disassemble]
• Cover the fuel pipe opening with tape to prevent
intrusion of foreign matters.
Point4
[Reassemble]
• Replace the oil filter with a new one.
• After fully tightening the filter manually, retighten it
with a filter wrench (see 11.1-6 in Chapter 11) by 3/4
turn.
Point5
[Disassemble]
• Cover the fuel injection pipe and pump inlets and out-
lets with tape or the like to prevent intrusion of foreign
matters.

75
 4. Disassembly, inspection and reassembly of engines

Point6
Pipe seal
1)Removing pipe seals of 4 valve head.
[Disassemble]
• Take off a rocker arm cover in case of 4 valve head
after removing fuel injection pipes and pipe seals.
[NOTICE] Fuel injection pipe
Attention is necessary because a fuel nozzle is caught Fuel nozzle
in a pipe seal and the pipe seal is damaged when a
rocker arm cover is lifted with a pipe seal sticking to
the rocker arm cover. Slit of bonnet
Pipe seal
• Insert a minus driver in the slit part of the rocker arm
cover, and remove it when removing a pipe seal.
Minus driver
[Reassemble]
• Replace the used pipe seal with a new one when
removing a pipe seal.
Cap nut of fuel injection pipe
Pipe seal replacement

2)Breather system (A redactor to intake air system of

blowby gas) Spring
Center plate
Emitting blowby gas is harmful to natural environ- Diaphragm Diaphragm cover
ment. Therefore blowby gas redactor is adopted to Rocker arm cover
TNV series naturally- aspirated engines as breather
system (Turbocharged engines emitblowby gas).
The system of model 3/4TNV84 is shown as a repre- Breather pipe
sentative of that breather system in the right figure.
Breather
Some of the combustion gas passes through the baffle
clearance between the cylinder and the piston, pis- Intake
maniforld Baffle plate
ton ring, and flows to the crankcase. This is said as
blowby gas. While it passes into the cylinder head
and the rocker arm cover, the blowby gas mixes with Breather system componert

splash oil, and becomes oil mist-blowby gas mixes

with splash oil, and becomes oil mist-blowby gas it
passing through the baffle plate inside a rocker arm
cover. And it passes through a diaphragm assy, and
a intake manifold, and is reduced in the combustion
chamber. Pressure inside a crankcase is controlled Diaphragm Spring Cover
Center plate
by the function of the diaphragm assy, and suitable Blowby gas flow Rocker arm
amount of blowby gas is reduced in intake air sys- Blowby gas flow cover
to diaphragm
tem. space Baffle plate
Diaphragm part
[Disassemble]
When a rocker arm cover is taken off, check whether
oil or the like enter the diaphragm space from a small
hole on the side of a diaphragm cover or not without
Blowby gas flow
disassembling the diaphragm.

76
4. Disassembly, inspection and reassembly of engines

[NOTICE]
1)When a diaphragm is damaged, pressure control inside the crankcase becomes insufficient, and troubles
occur. When the internal pressure of the crankcase decreases too much due to the damage of a spring,
much blowby gas containing oil is reduced in intake air system, and it may cause the combustion defect
by the early dirt of the intake valve or the urgent rotation of the engine by the oil burning.
When pressure progresses in the crank case too much due to the wrong operation of the diaphragm and
so on, it is considered that oil leakage from the joint of a oil pan, a oil seal and so on will occur. When a
diaphragm is damaged, blowby is discharged from the breathing hole on the side of diaphragm cover, and
not reduced in the intake manifold. Therefore, be careful of the diaphragm trouble.
2)At lubricating oil replacement or lube oil supply
The amount of lubricating oil isn't to be beyond the standard upper limit (in the engine horizontally, the
upper limit mark of the dip stick). Since the blowby gas redactor is adopted, be careful that the amount of
oil mist may be inducted in the combustion chamber and the oil hammer sometimes may occur, when the
lubricating oil quantity is beyond the upper limit or an engine is operated beyond the allowable maximum
angle of an engine.

[Reassembly]
Replace the diaphragm with new one, when it is damaged.

Point7
Disassembly
[Disassemble] Camshaft side
• Keep the removed push rods by attaching tags show-
8 14 5

Fan side
ing corresponding cylinder Nos. 2 12 9 3
[Reassemble]
4 10 11 1
• Always apply oil to the contact portions of the push 6 13 7
rods and clearance adjusting screws.
Head bolt disassembly order
Point8
3 cylinder head
[Disassemble] Assembly
Camshaft side
• Loosen the cylinder head bolts in two steps in the
illustrated order. 7 1 10
Fan side
13 3 6 12
• Place the cylinder head assy on a paper board to pre-
vent the combustion face from any damage. 11 5 4 14
9 2 8
[Reassemble]
• Remove the head gasket with a new one. Head bolt tightning order

• Uniformly install the head bolts manually after apply- 3 cylinder head
Disassembly
ing oil on the threaded and seat portions. Camshaft side
• They shall be tightened in two steps in the reverse of
Fan side

7 16 14 6
1 9 18 12 4
the order for disassembly.
• Tightening torque 3 11 17 10 2
5 13 15 8
N•m (kgf•m)
Head bolt disassembly order
TNV82A TNV84-88
4 cylinder head
30.0 to 34.0 41.1 to 46.9
First step Assembly
(3.1 to 3.5) (4.2 to 4.8) Camshaft side
61.7 to 65.7 85.3 to 91.1
Fan side

12 3 5 13
Second step
(6.3 to 6.7) (8.7 to 9.3) 18 10 1 7 15

16 8 2 9 17
14 6 4 11
4TNV94L/98 4TNV106 (T)
49.0 to 58.8 88.3 to 98.1 Head bolt tightning order
First step
(5.0 to 6.0) (9.0 to 10.0) 4 cylinder head
103.1 to 112.9 188.0 to 197.8
Second step
(10.5 to 11.5) (19.0 to 20.0)

77
 4. Disassembly, inspection and reassembly of engines

Point9
[Disassemble]
• Carefully remove the fuel injection valve so as not to
leave the top end protector from being left inside the
cylinder.
[Reassemble]
• Replace the fuel injection valve protector with a new
one.

Point10
[Disassemble]
• When removing each intake/exhaust valve from the
cylinder head, use a valve spring compressor (see
11.1-4 in Chapter 11) and compress the valve spring
and remove the valve cotter.)
• Keep each removed intake/exhaust valve after
Valve spring compressor
attaching a tag showing the corresponding cylinder
No.
• If cotter burr is seen at the shaft of each intake/
exhaust valve stem, remove it with an oilstone and
extract the valve from the cylinder head.

[Reassemble]
• Replace the stem seal with a new one when an
intake/exhaust valve is disassembled.
• Carefully install each valve after oil application so as
not to damage the stem seal.
• Different stem seals are provided for the intake and
exhaust valves. Do not confuse them since those for
exhaust valves are marked with yellow paint.
• After assembling the intake/exhaust valve, stem seal,
valve spring, seat, and cotter, tap the head of the
valve stem lightly for settling.
• Do not forget to install the valve cap.

78
4. Disassembly, inspection and reassembly of engines

4.2.5 Parts Inspection and measurement

(1) Cylinder head
Clean the cylinder head, mainly the combustion surface,
valve seats and intake/exhaust ports, remove carbon
Straight-edge
deposit and bonding agent, and check the surface state.
(a)Appearance check
Check mainly discoloration and crack. If crack is
suspected, perform color check.
(b)Combustion surface distortion
Apply a strait-edge in two diagonal directions and on
four sides of the cylinder head, and measure distortion
with a thickness gage.
Thickness gage
mm
Distortion at combustion surface
Standard Limit
Distortion 0.05 or less 0.15

(c)Valve sink
Measure with the valve inserted to the cylinder head. Depth micrometer
mm
Standard Limit
3TNV82A Intake 0.35 to 0.55 0.8
(2-valve head) Exhaust 0.30 to 0.50 0.8
4TNV84 Intake 0.30 to 0.50 0.8
3TNV84 (T)
3/4TNV88 Exhaust 0.30 to 0.50 0.8 Valve sink
(2-valve head)
4TNV84T Intake 0.36 to 0.56 0.8
4TNV94/98 (T) Valve sinking depth
(4-valve head) Exhaust 0.35 to 0.55 0.8

4TNV106 (T) Intake 0.5 to 0.7 1.0

(4-valve head) Exhaust 0.7 to 0.9 1.2

Valve sink depth

(d)Seat contact
Apply a thin coat of minimum on the valve seat. Insert
the valve in the cylinder and push it against the seat to
check seat contact.
Standard: Continuous contact all around

Seat

Valve seat contact

79
 4. Disassembly, inspection and reassembly of engines

(2) Valve guide

Mainly check damage and wear on the inside wall.
Measuring positions
Apply the service part code when replacing a part.
Model Service part code
a b c
3TNV82A Suction 124060-11800 A B
(2-valve) Exhaust 119802-11810
4TNV84 Suction 120130-11860
3TNV84(T) Valve guide inside diameter
3/4TNV88
(2-valve) Exhaust 129150-11810
Measuring positions
4TNV84T
Suc./Exh. 119717-11800
(4-valve)
4TNV94L
4TNV98(T) Suc./Exh. 129907-11800
(4-valve)
Suction 123907-11800 Valve stem outside diameter
4TNV106(T)
(4-valve) Exhaust 123907-11810

Valve stem clearance

Model Part name Place Standard Limit
Guide I.D. 7.000 to 7.015 7.08
Intake value Stem O.D. 6.945 to 6.960 6.90
3TNV82A Clearance 0.040 to 0.070 0.18
(2-valve head) Guide I.D. 7.000 to 7.015 7.08
Exhaust value Stem O.D. 6.940 to 6.955 6.90
Clearance 0.045 to 0.075 0.18
Guide I.D. 8.010 to 8.025 8.10
4TNV84 Intake value Stem O.D. 7.955 to 7.975 7.90
3TNV84 (T) Clearance 0.035 to 0.070 0.18
3/4TNV88 Guide I.D. 8.015 to 8.030 8.10
(2-valve head) Exhaust value Stem O.D. 7.955 to 7.970 7.90
Clearance 0.045 to 0.075 0.18
Guide I.D. 6.000 to 6.015 6.08
Intake value Stem O.D. 5.960 to 5.975 5.90
4TNV84T Clearance 0.025 to 0.055 0.15
(4-valve head) Guide I.D. 6.000 to 6.015 6.08
Exhaust value Stem O.D. 5.945 to 5.960 5.90
Clearance 0.040 to 0.070 0.17
Guide I.D. 7.000 to 7.015 7.08
Intake value Stem O.D. 6.945 to 6.960 6.90
4TNV94L Clearance 0.040 to 0.070 0.17
4TNV98 (T)
Guide I.D. 7.000 to 7.015 7.08
(4-valve head)
Exhaust value Stem O.D. 6.940 to 6.955 6.90
Clearance 0.045 to 0.075 0.17
Guide I.D. 7.008 to 7.020 7.08
Intake value Stem O.D. 6.960 to 6.975 6.92
4TNV106(T) Clearance 0.033 to 0.060 0.16
(4-valve head) Guide I.D. 7.008 to 7.020 7.08
Exhaust value Stem O.D. 6.945 to 6.960 6.90
Clearance 0.048 to 0.075 0.18

80
4. Disassembly, inspection and reassembly of engines

(3) Intake/exhaust valve

Mainly clean and check damage and wear at the valve stem and seat.
(a)Seat contact: See (1)-(d) above.
(b)Stem outside diameter: See (2) above.
(c)Valve head thickness

mm
Model Part Standard Limit
3TNV82A to 88 Intake 1.24-1.44 0.8
4TNV84
(2-valve head) Exhaust 1.35-1.55 0.8 Thickness

4TNV84T Intake 1.00-1.20 0.6

(4-valve head) Exhaust 1.00-1.20 0.6 Valve head thickness

4TNV94L•98 (T) Intake 1.44-1.84 1.0

(4-valve head) Exhaust 1.70-2.10 1.0
Length
4TNV106(T) Intake 1.60-2.00 1.2
(4-valve head) Exhaust 1.80-2.20 1.2

(d)Valve stem bend

Stool
mm
Limit 0.01

(e)Overall length Valve bend and length

mm
Standard Limit
3TNV82A Intake/Exhaust 97.2-97.8 97.0
3/4TNV84 to 88 Intake/Exhaust 108.7-109.3 108.5
4TNV84T Intake/Exhaust 100.0-100.6 99.8
4TNV94L Intake 102.3-103.1 102.1 Free length
4TNV98(T) Exhaust 102.4-103.2 102.2
Intake 117.3-118.1 117.1
4TNV106(T)
Exhaust 117.1-117.9 116.9
Valve spring

(4) Valve spring

Mainly inspect damage and corrosion. Inclination

mm
Free length Inclination
Standard Limit limit
3TNV82A 44.4 43.9
1.4
3/4TNV84 to 88 42.0 41.5
4TNV84T 37.4 36.9 1.3 Valve spring
4TNV94L•98(T) 39.7 39.2 1.4
4TNV106(T) 50.6 50.1 1.5

81
 4. Disassembly, inspection and reassembly of engines

(5) Valve rocker arm

Mainly inspect valve head cap contact surface, inside
surface defects and wear.
Slight surface defects shall be corrected with an
oilstone.

mm
Model Items Standard Limit
Arm hole
16.00 to 16.02 16.07
3TNV82A diameter
3/4TNV84(T)
Shaft O.D. 15.97 to 15.98 15.94
3/4TNV88
Clearance 0.016 to 0.054 0.13 Rocker arm hole diameter

Arm hole
18.50 to 18.52 18.57
diameter
4TNV94L/98(T)
4TNV106(T) Shaft O.D. 18.47 to 18.49 18.44
Clearance 0.01 to 0.05 0.13

(6) Rocker arm shaft

Mainly inspect seizure and wear at the surface in sliding
contact with the arm. The rocker shaft diameter shall be
as specified in (5) above.

Rocker shaft outside diameter

(7) Push rod

Mainly inspect the surface in contact with the tappet and
adjusting screw. Slight defects shall be corrected with an
oilstone.

Bend limit 0.03 mm

(8) Valve clearance adjusting screw Thickness gage

Mainly inspect the surface in contact with the push rod.

Slight defects shall be corrected with an oilstone.
Push rod bend
(9) Rocker arm spring
Mainly inspect surface defects and corrosion.

(R.1)
82
4. Disassembly, inspection and reassembly of engines

4.2.6 Valve seat correction

[NOTICE]
Always check the oil clearance between the valve and valve guide before correcting the valve seat. If it
exceeds the limit, replace the valve or valve guide first to make the clearance satisfy the standard. After
correction, wash the valve and the cylinder head sufficiently with diesel oil to remove all grinding powder or
compound.

1)If the seat surface is slightly roughened: perform

[A] and [B] below.
[A]: Lap the valve and seat with a mixture of valve
compound and engine oil.
[B]: Lap with engine oil only.

2)If the seat is heavily roughened but the width is

almost normal, correct with a seat grinder or seat Seat angle
150q
cutter first. Then perform lapping [A] and [B]. 40q
Seat width
intake Exhaust
Seat cutter angle 120 90

Seat cutter

Cylinder head correction angle

3)If the seat is heavily roughened and the width is

much enlarged, grind the seat inner surface with a
Grinder
seat grinder whose center angle is 40°, then grind
the seat outer surface with a grinder whose center
angle is 150° to make the seat width match the stan-
dard. Then perform seat correction as described in
2), and then carry out lapping [A] and [B].
θ1 θ2
Grinding wheel angle Grindstone
40 150
Seat grinder

83
 4. Disassembly, inspection and reassembly of engines

4.2.7 Valve guide replacement

1)Use a valve guide extraction tool (12.1-1 in Chapter 12) and extract the valve guide from the cylinder
head.
2)Put liquid nitrogen or ether (or alcohol) with dry ice added in a container and put the valve guide for
replacement in it for cooling. Then insert it in with a valve guide inserting tool (Refer to No.2 of 4.1.2 in
Chapter 4).

Do not touch the cooled valve guide with bare hands to avoid skin damage.

3)Check the inside diameter and finish to the standard

inside diameter as required with a reamer.
4)Check the projection from the cylinder head.
Valve guide extracting
& inserting tool

mm
Model Number of valves Projection Projection
3TNV82A 11.7 to 12.0
Cylinder head
4TNV84 2 valves
3TNV84 (T) 14.7 to 15.0
4TNV88
4TNV84T 8.2 to 8.5 Valve guide
4TNV94L
4 valves 9.7 to 10.
4TNV98(T) Valve guide replacement
4TNE106(T) 13.4 to 13.6

84
4. Disassembly, inspection and reassembly of engines

4.2.8 Valve stem seal replacement

Always use a new seal after the intake/exhaust valve is
disassembled. Since the one for the exhaust valve is Valve stem seal inserting tool
marked with yellow paint, do not confuse the intake and
exhaust valves.
1)Apply engine oil to the lip.
2)Push with the inserting tool (Refer to No.5 of 4.1.2 in
Chapter 4) for installation.

Stem seal

Valve guide

Cylinder head

Stem seal insertion

3)Measure and check the projection of valve stem seal

to keep proper clearance between valve guide and
stem seal.
mm Stem seal
Model Number of valves Projection
3TNV82A 15.7 to 16.0
Clearance

4TNV84 2 valves
3TNV84 (T) 18.7 to 19.0
4TNV88
Valve guide
4TNV84T 9.9 to 10.2
4TNV94L
4 valves 11.7 to 12.0
4TNV98 (T)
4TNE106 (T) 15.4 to 15.6

Valve guide projection

Stem seal projection

85
 4. Disassembly, inspection and reassembly of engines

4.3 Gear train and camshaft

4.3.1 Components

ԠFlywheel
Flywheel housing

ԟStarter ԢGear case flange

ԡCamshaft
ԙCooling water pump

Fuel pump spacer ԝ Camshaft driving gear

Idle gear

ԜFuel injection pump

Pump flange
Don't disassemble! Fuel pump drive gear Crankshaft
gear
Flange bolt
ԛGear case

ԣOil seal

ԚCrankshaft pulley
Note) This figure shows the 3TNV84.

4.3.2 Disassembly procedure:

Disassemble in the order of the numbers in the illustration.
1)Perform steps 1) to 12) of the cylinder head disassembly procedure.
2)Remove the cooling water pump.
3)Remove the crankshaft pulley. (See Point 1 of 4.3.4)
4)Remove the gear case cover. (See Point 2 of 4.3.4)
5)Remove the fuel injection pump. (See Point 3 of 4.3.4)
6)Remove the idle gear assy. (See Point 4 of 4.3.4)
7)Remove the PTO drive gear. (See Point 5 of 4.3.4)
8)Remove the starting motor.
9)Remove the flywheel. (See Point 6 of 4.3.4)
10) Remove the camshaft assy. (See Point 7 of 4.3.4)
11) Remove the gear case. (See Point 8 of 4.3.4)
12) Remove the oil seal from the gear case cover. (See 4.3.6)

4.3.3 Reassembly procedure:

Reverse of the disassembly procedure.

86
4. Disassembly, inspection and reassembly of engines

4.3.4 Servicing points

Point1
[Disassemble]
• Remove the crankshaft pulley using a gear puller
after removing the crankshaft pulley set bolt. When
removing the pulley using the gear puller, use a pad
and carefully operate so as not to damage the thread.
Set the gear puller securely to prevent the pulley from
being damaged.
[Reassemble]
• Apply lithium grease to the oil seal lips. For the oil
seal with double lips dust seal, further slightly apply
engine oil on the lips so as not to damage them.
• Clean by wiping off any oil on both taper surfaces
using detergent.
• Be sure to use the crankshaft pulley installing tool so
as not to damage the oil seal lips. (See 4.3(6) Oil seal
replacement)
• When installing the crankshaft pulley, apply lube oil to
the set bolt to tighten and carefully assemble so as
not to damage the oil seal.
N•m (kgf•m)
Model Tightening torque
3TNV82A to TNV88 112.7 to 122.7 (11.5 to 12.5)
4TNV94L/98/106(T) 107.9 to 127.5 (11.0 to 3.0)
Fuel injection pump
drive gear
Point2 Camshaft gear
[Reassemble]
• When installing the gear case, do not forget to install
B
the two reinforcing bolts at the center. B C C
A
• Measure the backlash of each gear. Idle gear
A
mm PTO gear
3TNV82A to 88 Standard Limit Crankshaft gear
Crankshaft gear, Lubricating oil
Direction of rotation
Camshaft gear, pump gear
0.07 to 0.15 0.17
Fuel injection pump gear, Gear train (4TNV94L to 106)
Idle gear, PTO gear,
Fuel injection pump
drive gear
4TNV94L-106(T) Standard Limit Camshaft gear
Crankshaft gear,
Camshaft gear,
0.08 to 0.14 0.16
Fuel injection pump gear,
B
Idle gear, PTO gear, B C C
Balancer gear
0.12 to 0.18 0.20 A
(only 4TNV106(T)) Idle gear
Lubricating oil pump gear 0.09 to 0.15 0.17 PTO gear
• Apply sealant and install the gear case by correctly
positioning the two dowel pins. Crankshaft gear
Direction of rotation

(R.1)
Gear train (3TNV82A to 4TNV88)
87
 4. Disassembly, inspection and reassembly of engines

Point3: (Refer to 7.2.5 in chapter 7)

[Disassemble]
• Remove the mounting nut of the fuel injection pump
drive gear, remove the gear using the gear puller, and
remove the fuel injection pump. Do not forget to
remove the stay on the rear side. When extracting
the gear using the gear puller, use a pad at the shaft
and carefully operate so as not to damage the thread.
[Reassemble]
• Tightening torque for fuel pump drive gear nut (with-
out lube. Oil)
N•m (kgf•m)
Model Tightening torque
TNV82A to 88 78 to 88 (8.0 to 9.0)
4TNV94L/98/106 (T) 113 to 123 (11.5 to 12.5)

Point4
[Reassemble]
• Assemble crankshaft gear A, fuel injection pump
drive gear B and camshaft gear C at the same time
by aligning with idle gear A, B and C marks.
• Install the idle gear shaft with the oil hole facing
upward.
Point5
[Reassemble]
• Install the PTO drive gear with its inner spline side
facing the flywheel.
Point6
[Disassemble]
• Install a bolt as a handle in the hole at the end face of
the flywheel and remove carefully so as not to dam-
age the ring gear.
[Reassemble]
Flywheel mounting bolt : apply lube oil
N•m (kgf•m)
Model Tightening torque
3TNV82A to 88 83.3 to 88.2 (8.5 to 9.0) Fuel injection pump
drive gear
4TNV94L/98/106 (T) 186.2 to 205.8 (19.0 to 21.0) Camshaft gear

Point7
[Disassemble]
B
• Measure the camshaft side gap. B C C
mm A
Idle gear
Item Standard Limit PTO gear
Side gap 0.05 to 0.20 0.30
Crankshaft gear
• If the measured side gap exceeds the limit, replace Direction of rotation
the thrust metal.
Gear train (3TNV82A to 4TNV88)
88
4. Disassembly, inspection and reassembly of engines

[Disassemble]
• Since the camshaft gear is shrink-fit, heat it to
180°C to 200°C for extraction.
• For camshaft removal, raise the engine with its mount-
ing flange at the bottom. After removing the thrust
metal mounting bolt from the camshaft gear hole,
extract the camshaft carefully so as not to damage the
bearing bushing.
• Rotate the camshaft a few turns before extracting it to
prevent the tappet from being caught by the cam.
• After removing the camshaft, set the engine horizontal
and fix it on the base.

Unforeseen injury may arise due to falling of slipping

when raising the engine vertically or returning it to the
horizontal position. Proceed carefully so as not to lose
balance.

Point8: Gear case

[Reassemble]
• Do not forget to install the oil pan mounting bolts on the
bottom side when installing the gear case.
• Apply sealant (code No.977770-01212) and install the
gear case by matching the two dowel pints.

89
 4. Disassembly, inspection and reassembly of engines

4.3.5 Parts inspection and measurement

(1) Camshaft
Mainly check the contact between the tappet and cam contact surface, bearing seizure and wear, and gear
damage.
(a)Shaft bend measurement
Support the camshaft with V blocks. Rotate the camshaft
and measure the runout at the center of the camshaft
and at each journal with a dial gage. Half of the runout is
the bend.
mm
Item Standard Limit
Bend 0 to 0.02 0.05 Cap tester

Water leak check in cooling water system

(b)Intake/exhaust cam height measurement

mm
Model Standard Limit
3TNV82A to 88 38.600 to 38.800 38.350
4TNV94L•98 43.400 to 43.600 43.150
4TNV106 (T) 50.900 to 51.100 50.650

(c)Camshaft and bearing hole measurement

Measure the camshaft outside diameter with a
micrometer. The oil clearance shall be calculated by Flywheel side
subtracting the measured camshaft outside diameter Micrometer
from the inside diameter of the camshaft bearing or
bushing. The camshaft bushing at gear case side is
measured with a cylinder gage after insertion to the
cylinder.

Camshaft outside diameter

90
4. Disassembly, inspection and reassembly of engines

mm
Model Place Item Standard Limit
Bushing I.D. 44.990 to 45.055 45.130
Gear side Camshaft O.D. 44.925 to 44.950 44.890
Oil clearance 0.040 to 0.130 0.240
Bushing I.D. 45.000 to 45.025 45.100
3TNV82A to TNV88 Intermediate position Camshaft O.D. 44.910 to 44.935 44.875
Oil clearance 0.065 to 0.115 0.225
Bushing I.D. 45.000 to 45.025 45.100
Wheel side Camshaft O.D. 44.925 to 44.950 44.890
Oil clearance 0.0500.100 0.210
Bushing I.D. 49.990 to 50.055 50.130
Gear side Camshaft O.D. 49.925 to 49.950 49.890
Oil clearance 0.040 to 0.130 0.240
Bushing I.D. 50.000 to 50.025 50.100
TNV94L/98 (T) Intermediate position Camshaft O.D. 49.910 to 49.935 49.875
Oil clearance 0.065 to 0.115 0.225
Bushing I.D. 50.000 to 50.025 50.100
Wheel side Camshaft O.D. 49.925 to 49.950 49.890
Oil clearance 0.05 to 0.100 0.210
Bushing I.D. 57.980 to 58.050 58.105
Gear side Camshaft O.D. 57.910 to 57.940 57.875
Oil clearance 0.040 to 0.140 0.250
Bushing I.D. 58.000 to 58.030 58.105
4TNV106(T) Intermediate position Camshaft O.D. 57.895 to 57.925 57.860
Oil clearance 0.075 to 0.135 0.245
Bushing I.D. 58.000 to 58.030 58.105
Wheel side Camshaft O.D. 57.910 to 57.940 57.875
Oil clearance 0.050 to 0.120 0.230

(2) Idle gear

Mainly check the bushing seizure and wear, and gear
damage. Idle gear
Shaft
Shaft outside diameter and bushing inside diameter
Inside diameter
Shaft diameter

measurement
mm
Item Standard Limit
Shaft outside diameter 45.950 to 49.975 45.900
Bushing inside diameter 46.000 to 46.025 46.075
Clearance 0.025 to 0.075 0.175 Idle gear

(3) PTO drive gear

Mainly check sticking of bearings on both sides, gear
damage and looseness, and gear shaft damage and
wear.

91
 4. Disassembly, inspection and reassembly of engines

4.3.6 Oil seal replacement (Gear case side)

1)Replace the oil seal with a new one when the gear case is disassembled.
Extract the used oil seal.
2)Insert a new oil seal. Fit the position of the oil seal insertion to the end face of the gear case. (Refer to the
below figure.)
3)Apply lithium grease to the oil seal tips. For the oil seal with double lips dust seal, further,
slightly apply engine oil on the oil seal lip so as not to damage them, when installing the
pulley.
[NOTICE]
Pay attention not to drop any oil on the taper surface of the crankshaft. If dropped, clean by wiping off using
detergent.
4)Carefully install the crankshaft pulley so as not to damage the oil seal lips. Especially for the engine
installed the oil seal with double lips dust seal, be sure to use the crankshaft pulley-installing tool.

Crankshaft pulley
25
Oil seal with doule lips dust seal

0.2 A
46
Guiding
26 20 M14˜1.5
Knurled head
(Rollet) 1.6
1 A
Ǟ39 


Ǟ35
C1

.5
C0
C0

C0
.5

.5

Ǟ # 16 17

Crankshaft pulley installing tool

Detail of crankshaft pulley
installing tool (Scale: free)
(Local supply)
For 4TNV94L engine installed
the oil seal with double lips
dust seal

Oil seal with double lips dust seal

4.3.7 Camshaft bushing replacement

Replace the bushing using the special service tool (Refer to No.7 of 4.1.2 in Chapter 4).

92
4. Disassembly, inspection and reassembly of engines

4.4 Cylinder block

4.4.1 Components

ԡPiston ring

Flywheel ԜPiston & Connecting rod

ԝFlywheel hausing

Gear case flange

ԠTappet
Oil seal
ԢOil seal case

Oil filter
ԛOil suction pipe

ԞBearing cap

ԚOil pan spacer

ԟCrankshaft

ԚOil pan

Note) This figure shows the 3TNV84.

4.4.2 Disassembly procedure:

Disassemble in the order of the numbers in the illustration.
1)Perform steps 1) to 12) in the cylinder head disassembly procedure.
2)Perform steps 1) to 12) in the gear train disassembly procedure.
3)Remove the oil pan. (See Point 1 of 4.4.4)
4)Remove the lubricating oil suction pipe.
5)Remove the piston w/rod. (See Point 2 of 4.4.4)
6)Remove the mounting flange. (See Point 3 of 4.4.4)
7)Remove the bearing metal caps. (See Point 4 of 4.4.4)
8)Remove the crankshaft. (See Point 5 of 4.4.4)
9)Remove the tappets.
10)Remove the pistons and rings. (See Point 6 of 4.4.4)
11)Remove the oil seal from the mounting flange. (See 4.4.8 of 4.4.4)

4.4.3 Reassembly procedure:

Reverse of the disassembly procedure.

93
 4. Disassembly, inspection and reassembly of engines

4.4.4 Servicing points

Point1: Oil pan
[Disassemble]
• Sealant is applied to the oil pan mounting surface on
the block. Carefully operate soas not to damage or
distort the bonding surface.
[Reassemble]
• Apply sealant (code No.977770-01212) before reas-
sembly.
Point2: Piston w/rod Crankshaft
[Disassemble] Thickness gage
• Measure the connecting rod side gap.
mm
Standard 0.20 to 0.40 Connecting rod side gap

• Carefully remove the carbon deposit on top of the cyl-

inder so as not to damage the inner side of the cylin-
der.
• Set the piston at the BDC position and remove the
connecting rod cap. Then set the piston at the TDC
position, and push the connecting rod big end with
the wooden shaft of a hammer. Proceed carefully so
as not to cause the cylinder block catch the rod big
end. Set the rod caps and crankpin metals in their
correct combinations.

[Reassemble]
• Apply oil especially carefully to the sliding contact
surfaces of the pistons, rods and rings.
• Use the piston insertion tool (see 12.1-9 in Chapter
12) to insert each piston w/rod in the cylinder block
and install the bearing metal cap.

Rod bolt tightening torque N•m (kgf•m)

Model Standard (apply lube oil)
3TNV82A 37.2 to 41.2 (3.8 to 4.2)
TNV84 to 88 44.1 to 49.0 (4.5 to 5.0)
4TNV94L•98 53.9 to 58.8 (5.5 to 6.0)
4TNV106(T) 78.5 to 83.4 (8.0 to 8.5)

Point3: mounting flange

[Disassemble]
Place the engine on a stable base with the cylinder
block upper surface facing down, and remove the
mounting flange carefully so as not to damage the
combustion surface.

94
4. Disassembly, inspection and reassembly of engines

[Reassemble]
Apply sealant (code No.977770-01212) and install the
mounting flange by matching the two dowel pins. After
assembly, raise the engine with its mounting flange on
the bottom side.

Unforeseen injury may arise due to falling of slipping

when raising or reversing the engine. Carefully
operate so as not to lose balance.
Point4: Journal bearing cap
[Disassemble]
• Before removing the journal bearing, measure the
crankshaft side gap. Measure it in either method
because there are the next two methods.
1)Install a dial gage on the cylinder block, and move a
crankshaft in front and back, and measure the side
gap as shown in the right figure.
Side gap measurement 1

2)Put a thickness gauge in the clearance between

thrust metal and crankshaft directly, and measure it. Cylinder block

Side gap standard

mm
Crankshaft
Model Standard Limit Standard
3TNV82A to 88 0.140 to 0.220 0.28 width
Thrust metal
4TNV94L to 106 0.130 to 0.230 0.28 Thrust
face
[Reassemble] Bearing cap
• If the side gap exceeds the standard, replace the
thrust metal with an oversize one.
Machine the standard width of the crankshaft thrust Thickness gauge
part into the dimension of the below table at the same
time.
Refer to a parts catalog when ordering the part.
Side gap measurement 2
The surface finishing precision (refer to 4.4.5(2) in
Chapter4): 1.6

0.25 mm Oversized thrust metal (0.25 DS) mm

0.25DS Thrust metal assy code Standard thickness
3TNV82A 119810-02940 2.055 to 2.105
TNV84 to 88 129150-02940 2.055 to 2.105
4TNV94L•98 129900-02940 2.055 to 2.105
4TNV106(T)
The standard width 123900-02940
of the crankshaft thrust2.555
part to 2.605
mm
Model Standard thickness
3TNV82A 25.250 to 25.271
TNV84 to 88 28.250 to 28.271
4TNV94L•98 32.250 to 32.275
4TNV106(T) 36.250 to 36.275

(R.1)
95
 4. Disassembly, inspection and reassembly of engines

[Disassemble]
• Remove the bearing caps, cap side bearings, and

Wheel side
Block side main
thrust metals. Place each thrust metal with identifica- bearing metals
Cap side main
tion of the position and direction. bearing metals
The position number of reassembling is punched on
a metal cap (except for both ends) and a cylinder
block.

Gear side
Thrust metals

Main bearing

[Reassemble]
Upper main bearing metal
• Carefully install each thrust metal so that the grooved
Oil hole
one is positioned away from the cap.
Lower
• Do not confuse the upper and lower main bearing Thrust metal
metals. The upper main bearing metal (block side)
has an oil hole, and the lower one does not. The
“arrow” marks on the cap shall face the flywheel.
Tighten main bearing cap bolts. Groove

Main bearing cap

Main bearing cap bolt tightening torque

(apply lube oil)
N•m (kgf•m)
Model Standard
3TNV82A 76.4 to 80.4 (7.8 to 8.2)
(9
Mark
TNV848 to 8 93.2 to 98.1 (9.5 to 10.5)
Position number
4TNV94L•98 108.1 to 117.9 (11.0 to 12.0) ࡎࠗ࡞
of reassembling
4TNV106(T) 186.2 to 205.8 (19.0 to 21.0)

Point5: Crankshaft
[Disassemble]
Journal bearing cap
• Remove the crankshaft. Remove each main bearing
metal upper (block side) and pair it with the metal cap
side lower metal.

Carefully prevent damage to the bearing or finger

injury when removing the crankshaft because it is
heavy.

96
4. Disassembly, inspection and reassembly of engines

Point6: Piston pin and rings

[Disassemble]
• Using the piston ring replacer (see 4.1.2 in Chapter Make the punched manufacturer's
mark face upward.
4), remove the piston rings.
• Remove the circlip and remove the piston pin by
Piston ring
pushing it out.
[Reassemble]
• Install each piston ring on the piston, with the Oil ring joint
punched manufacturer’s mark facing upward.
[Reassemble]
• The piston ring joints shall be staggered at by 120° Second
intervals. Do not position the top ring joint vertical to ring joint
Top ring joint
the piston pin. The coil expander joint shall be oppo-
site to the oil ring joint.

Expander joint

[Reassemble]
Ring joints
• When installing the piston pin to the rod and piston,
the punched match mark on the big end of the con-
necting rod shall be opposite to the size mark on the Piston ID mark
Camshaft side

piston top.
Nozzle side

[Reassemble]
• Install the piston in the cylinder clock with the
punched mark on the big end of the rod on the nozzle
side. (The embossed mark at the connecting rod I-
(Flywheel side)
beam section shall be on the flywheel side.)
Cylinder size mark

Engraved mark Piston ID mark

Camshaft side

Embossed mark
(Flywheel side)

Match mark
Flywheel side

( Assembly direction of connecting

rod and piston )
( Assembly direction of connecting
)
4TNV106(T)
rod and piston

(R.1)
97
 4. Disassembly, inspection and reassembly of engines

4.4.5 Parts inspection and measurement

(1) Cylinder block

Especially clean head surface, cylinder bores and oil
holes, and check after removing any carbon deposit and
bonding agent.

(a)Appearance inspection
Check if there is any discoloration or crack. If crack is
suspected, perform color check. Sufficiently clean the oil
holes and check they are not clogged.

(b)Cylinder bore and distortion

Measure at 20 mm below the crest of the liner, at 20 mm
from the bottom end and at the center.
Roundness:
Roundness is found as follows though it is the simple
method. Measure cylinder diameters of the A direction
Cylinder bore
and the B direction on each section of a, b and c.
Roundness is the maximum value among those
difference values.
Cylindricity:
a 20mm
Cylindricity is found as follows though it is the simple A
method.
Measure cylinder diameters of a, b and c sections in b
B
the A direction, and calculate the difference in
Measure in two directions
maximum value and minimum value of the measured c A and B at points a,b and c.
20mm
diameters.
In the same way measure and calculate the difference Cylinder bore measurement positions
in the B direction.
Cylindricity is the maximum value between those
difference values.

mm
Item Model Standard Limit
3TNV82A 82.000 to 82.030 82.200
TNV84 84.000 to 84.030 84.200
TNV88 88.000 to 88.030 88.200
Cylinder inside diameter
4TNV94L 94.000 to 94.030 94.130
4TNV98 98.000 to 98.030 98.130
4TNV106(T) 106.000 to 106.030 106.130
Roundness
Cylinder bore all TNV 0.01 or less 0.03
Cylindricity

98
4. Disassembly, inspection and reassembly of engines

(c)If the limit is exceeded or any surface defect is

found, repair by boring and honing. Use an
oversized piston (and new piston rings) as
required.

Oversized piston (0.25 mm, with piston rings)

Model Code No. Standard (mm)
3TNV82A 719802-22900 82.250
3TNV84 (T)
129004-22900 84.250
4TNV84
4TNV84T 129508-22900 84.250
3/4TNV88 129005-22900 88.250
4TNV94L 729906-22900 94.250
4TNV98 129902-22700 98.250
4TNV106 729907-22900 106.250
4TNV106T 723907-22910 106.250

Piston ring assy for oversized (0.25 mm)

Model Piston ring code No.
3TNV82A 719802-22950
3TNV84 (T)
129004-22950
4TNV84
4TNV84T 129004-22950
3/4TNV88 129005-22950
4TNV94L 729906-22950
4TNV98 729907-22950
4TNV106 (T) 723907-22950

Cylinder dimension after boring and honing

Cylinder dimension Honing angle Roundness/Cylindricity
Model Surface roughness
(mm) (deg.) (mm)
3TNV82A 82.250 to 82.280
3TNV84 (T)
84.250 to 84.280
4TNV84
3/4TNV88 88.250 to 88.280 Rmax
30 to 40 deg. 0.01 or less
1.0 to 3.5S
4TNV94L 94.250 to 94.280
4TNV98 98.250 to 98.280
4TNV106 (T) 106.250 to 106.280

99
 4. Disassembly, inspection and reassembly of engines

(2) Crankshaft
Mainly check seizure and wear of the crankpins and
journals. Since the crankshaft gear is shrink-fitted, heat
to 180 to 200°C when extraction is necessary.
(a)Shaft portion color check
After washing the crankshaft, inspect it by means of
color check or a magnaflux inspector. Replace it if
cracked or heavily damaged. Slight defects shall be
corrected by grinding.

Inspection by color check

(b)Crankshaft bend
Support the crankshaft journals at both ends with V-
blocks. Use a dial gage and measure the runout at the Bend
center journal while rotating the shaft to inspect the
bend.

Limit 0.02 mm or less

Deflection
Dial gage

V-block V-block
Crankshaft bend measurement

(c)Crankpin and journal measurement

Measure the outside diameter, roundness and taper at
each crankpin and journal.
Correct by grinding if unevenly wear, roundness
exceeding the limit or insufficient outside diameter is
found. Replace if the defect is excessive.

Limit (Diameter)
Item
(mm)
Roundness
0.01
Taper

To look for the oil clearance of crank pin, measure the

inside diameter of crank pin metal according to (5) (d)
described later and calculate.
Crankshaft
journal
Crankpin
Measuring position of the crankpin
and crank journal

100
4. Disassembly, inspection and reassembly of engines

Crankpin mm
Model & Item Standard Limit
Pin outside diameter 42.952 to 42.962 42.902
3TNV82A Metal thickness 1.487 to 1.500 -
Oil clearance 0.038 to 0.090 0.150
Pin outside diameter 47.952 to 47.962 47.902
TNV84 to 88 Metal thickness 1.492 to 1.500 -
Oil clearance 0.038 to 0.074 0.150
Pin outside diameter 57.952 to 57.962 57.902
4TNV94L•98 Metal thickness 1.492 to 1.500 -
Oil clearance 0.038 to 0.074 0.150
Pin outside diameter 63.952 to 63.962 63.902
4TNV106(T) Metal thickness 1.984 to 1.992 -
Oil clearance 0.054 to 0.090 0.150
If the oil clearance exceeds the limit, use an undersized bearing.

Undersized crankpin bearing (0.25 mm)

Model Code No. Standard thickness (mm)
3TNV82A 119810-23610 1.612 to 1.625
TNV84 to 88 129150-23610 1.617 to 1.625
4TNV94L•98 129900-23610 1.617 to 1.625
4TNV106(T) 123900-23610 2.109 to 2.117

Pin machining dimension

Model Pin machining dimension (mm)
3TNV82A ø 42.702 to 42.712
TNV84 to 88 ø 47.702 to 47.712
4TNV94L•98 ø 57.702 to 57.712
4TNV106 (T) ø 63.702 to 63.712

101
 4. Disassembly, inspection and reassembly of engines

Crank journal mm
Model Item Standard Limit
Journal O.D. 46.952 to 46.962 46.902
3TNV82A Metal thickness 1.987 to 2.000 -
Oil clearance 0.038 to 0.080 0.150
Journal O.D. 53.952 to 53.962 53.902
TNV84 to 88
Metal thickness 1.995 to 1.990 -
(Selective assembly)
Oil clearance 0.038 to 0.068 0.150
Journal O.D. 64.952 to 64.962 64.902
4TNV94•98
Metal thickness 1.995 to 2.010 -
(Selective assembly)
Oil clearance 0.038 to 0.068 0.150
Journal O.D. 75.952 to 75.962 75.902
4TNV106(T)
Metal thickness 2.488 to 2.503 -
(Selective assembly)
Oil clearance 0.052 to 0.082 0.150

If the clearance limit is exceeded, use an undersized bearing.

Undersized bearing (0.25 mm)

Model Code No. Standard thickness (mm)
3TNV82A 119810-02870 2.112 to 2.125
TNV84 to 88 129150-02870 2.112 to 2.125
4TNV94L•98 129900-02340 2.112 to 2.125
4TNV106 (T) 12900-02340 2.605 to 2.618

Crankshaft Journal machining dimension

Model Journal machining dimension (mm)
3TNV82A ø 46.702 to 46.712
TNV84 to 88 ø 53.702 to 53.712
4TNV94/98 ø 64.702 to 64.712
4TNV106 (T) ø 75.702 to 75.712

102
4. Disassembly, inspection and reassembly of engines

• Dimension R and finishing precision of crankshaft

journal and pin
As for grinding processing of journal and pin, Super
polishing
machine it by using the grinding wheel of the dimen- Ry=0.8S

sion R of below table. Super

polishing
Thrust
face
Surface finishing precision standard on journal and Ry=0.8S

pin: R

R
R
Ry=0.8S super polishing R

R
Surface finishing precision standard on the thrust
Crank Pin Crank Journal
side of crankshaft arm: 1.6
Crankshaft R machining

mm
Finishing precision standard
Model
of dimension R
3TNV82A
3.5 +0.3/ 0
3/4TNV84(T) to 88
4TNV94L/98(T)
4.0 +0.3/ 0
4TNV106(T)

[NOTICE]
1)If the oil clearance is excessive though the thicknesses of the journal and crankpin metals are normal or if
partial uneven wear is observed, re-grind the crankshaft and use an oversized metals.
2)If rust or surface roughening exists on the rear side of the metals, coat it with blue or minimum. Then
assemble the crankpin metal to the connecting rod, and tighten the rod bolt to the specified torque to
check the metal for contact. If the contact surface occupies 75% or more, the metal is normal. If the con-
tact surface is insufficient, the metal interference is insufficient. Replace the metal with a new one.

(3) Thrust metal inspection

(a)Inspect any damage or wear.
(b)Measure side gap and thrust metal thickness

Side gap and thrust metal thickness mm

Side gap Thrust metal thickness
Model
Standard Limit Standard Limit
3TNV82A
0.14 to 0.22 1.930 to 1.980 1.850
3/4TNV84 (T) to 88
0.28
4TNV94L•98 0.13 to 0.23 1.930 to 1.980 1.850
4TNV106 (T) 0.13 to 0.23 2.430 to 2.480 2.35
If the side gap is exceeded, use an oversized thrust metal. (Refer to point 4 of 4.4.4.)

Oversized metal (0.25 mm)

Model Code No. (Up-down combination)
3TNV82A 119810-02940
3/4TNV84(T) to 88 129150-02940
4TNV94L to 4TNV106 (T) 129900-02940

103
 4. Disassembly, inspection and reassembly of engines

(4) Piston
Especially clean the combustion surface, circumference,
ring grooves and piston pin bosses, and check after
removing any carbon deposit. Any burr at a ring groove
or snap ring groove shall be removed. If crack is
suspected, inspect by color check.
(a)Piston outside diameter measurement
Measure the long diameter at H mm from the bottom end
of the piston of the oval hole in the vertical direction to Measurement
position
the piston pin hole.
H mm
Piston outside diameter
Piston outside diameter
mm
Outside diameter Clearance between Measurement
Model Limit
Standard piston and cylinder position (H)
3TNV82A 81.950 to 81.980 81.905 0.040 to 0.060 16
3,4TNV84(T) 83.940 to 83.970 83.895 24
0.050 to 0.070
3,4TNV88 87.940 to 87.970 87.895 24
4TNV94L 93.935 to 93.965 93.900 0.055 to 0.075 22
4TNV98 (T) 97.930 to 97.960 97.895 22
0.060 to 0.080
4TNV106 (T) 105.930 to 105.960 105.880 30

If the piston outside diameter exceed the limit, replace the piston with new one.
If the clearance between piston and cylinder exceeds the limit, use an oversized piston. (Refer to the tables of
oversized pistons, oversized piston rings and cylinder boring dimension in (1) (c) above.)
Selective pairing of cylinder and piston
Piston must be paired with cylinder according to the below table. The size mark of a piston is shown on
the top surface of the piston and the size mark of a cylinder block is shown on the non-operating side of
the cylinder block. The service parts of pistons are provided.

Piston outside diameter. D2

+0.015 max. below +0.005 below 0 below -0.005
Tolerance
+0.005 min. 0 min. -0.005 min. -0.015 min.
Size mark L ML MS S
+0.030 max.
L c c ° °
Cylinder +0.020 min.
inside below +0.020
M ° c c °
diameter +0.010 min.
D1 below +0.010
S ° ° c c
0 min.

Cylinder inside diameter Piston outside diameter.

Model
D1 D2
3TNV82A 82 81.965
3,4TNV84 (T) 84 83.955
3,4TNV88 88 87.955
4TNV94L 94 93.950
4TNV98 (T) 98 97.945
4TNV106 (T) 106 105.945

104
4. Disassembly, inspection and reassembly of engines

(b)Piston pin hole measurement

Measure the outside diameter of piston pin and the Measure at positions a,b and c
in directions A and B.
inside diameter of piston pin hole. Calculate the
a b c
clearance between piston pin and piston pin hole. If any A
data exceeds the limit, replace the part with a new one.
mm
Model Item Standard Limit
B
Pin I.D. 23.000 to 23.009 23.039
Piston pin outside diameter
3TNV82A Pin O.D. 22.995 to 23.000 22.965
Clearance 0.000 to 0.014 0.074
Pin I.D. 26.000 to 26.009 26.039
TNV84 to 88 Pin O.D. 25.995 to 26.000 25.965
Clearance 0.000 to 0.014 0.074
Pin I.D. 30.000 to 30.009 30.039
4TNV94L•
Pin O.D. 29.989 to 30.000 29.959
4TNV98 (T)
Clearance 0.000 to 0.020 0.080
Pin I.D. 37.000 to 37.011 37.039
4TNV106 (T) Pin O.D. 36.989 to 37.000 36.959
Clearance 0.000 to 0.022 0.080

(c)Piston ring, ring groove and end clearance

measurement
• Except for the top ring, to measure the piston ring Top ring
groove width, first measure the width of the piston
ring. Then insert the piston ring into the ring. Then Second ring
insert the piston ring into the ring groove. Insert a
thickness gage in between the piston ring and groove
to measure the gap between them. Obtain the ring Oil ring
groove width by adding ring width to the measured
side clearance.
• To measure the end clearance, push the piston ring
Ring components
into the sleeve using the piston head, insert a thick-
ness gage in end clearance to measure. The ring
shall be pushed in to approx. 30 mm above the bot-
tom end of the cylinder. For the top ring, measure
Head surface
only the piston ring joint end clearance in normal
state.

Cylinder block

Pistonring

Approx.
30mm
Width

Joint end clearance

Thickness
Ring joint end clearance
Measuring side clearance measurement

105
 4. Disassembly, inspection and reassembly of engines

Piston ring dimension

mm
Model Part Item Standard Limit
Ring groove width 2.065 to 2.080 -
Ring width 1.970 to 1.990 1.950
Top ring
Side clearance 0.075 to 0.110 -
End clearance 0.200 to 0.400 0.490
Ring groove width 2.035 to 2.050 2.150
Ring width 1.970 to 1.990 1.950
TNV82A/84 Second ring
Side clearance 0.045 to 0.080 0.200
End clearance 0.200 to 0.400 0.490
Ring groove width 4.015 to 4.030 4.130
Ring width 3.970 to 3.990 3.950
Oil ring
Side clearance 0.025 to 0.060 0.180
End clearance 0.200 to 0.400 0.490
Ring groove width 2.060 to 2.075 -
Ring width 1.970 to 1.990 1.950
Top ring
Side clearance 0.070 to 0.105 -
End clearance 0.200 to 0.400 0.490
Ring groove width 2.025 to 2.040 2.140
Ring width 1.970 to 1.990 1.950
TNV88 Second ring
Side clearance 0.035 to 0.070 0.190
End clearance 0.200 to 0.400 0.490
Ring groove width 4.015 to 4.030 4.130
Ring width 3.970 to 3.990 3.950
Oil ring
Side clearance 0.025 to 0.060 0.180
End clearance 0.200 to 0.400 0.490
Ring groove width 2.040 to 2.060 -
Ring width 1.940 to 1.960 1.920
Top ring
Side clearance 0.080 to 0.120 -
End clearance 0.250 to 0.450 0.540
Ring groove width 2.080 to 2.095 2.195
Ring width 1.970 to 1.990 1.950
4TNV94L•98 Second ring
Side clearance 0.090 to 0.125 0.245
End clearance 0.450 to 0.650 0.730
Ring groove width 3.015 to 3.030 3.130
Ring width 2.970 to 2.990 2.950
Oil ring
Side clearance 0.025 to 0.060 0.180
End clearance 0.250 to 0.450 0.550
Ring groove width 2.520 to 2.540 -
Ring width 2.440 to 2.460 2.420
Top ring
Side clearance 0.060 to 0.100 -
End clearance 0.300 to 0.450 0.540
Ring groove width 2.070 to 2.085 2.185
Ring width 1.970 to 1.990 1.950
4TNV106 (T) Second ring
Side clearance 0.080 to 0.115 0.235
End clearance 0.450 to 0.600 0.680
Ring groove width 3.015 to 3.030 3.130
Ring width 2.970 to 2.990 2.950
Oil ring
Side clearance 0.025 to 0.060 0.180
End clearance 0.300 to 0.500 0.600

106
4. Disassembly, inspection and reassembly of engines

(5) Connecting rod

(a)Appearance inspection
Inspect the portion near the boundary of the chamfered
m
portion and I-beam section of the big and small ends of 0m
10
the connecting rod as well as the portion near the oil hole m
0m Parallelism
of the bushing at the small end for cracks, deformation, 10
and discoloration.
(b)Twist and parallelism measurement Use a
connecting rod aligner and measure the twist and
bend. Twist

mm
Item Standard dimension Limit dimension Mandrel
Twist and 0.03 or less
0.08
parallelism per 100 mm
Twist and parallelism measurement
(c)Rod small end measurement
Measure the pin outside diameter according to
4.4.5.(4) (a) described above.
mm
Model Item Standard Limit
Piston pin
23.025 to 23.038 23.068
I.D. bushing
3TNV82A
Pin O.D. 22.995 to 23.000 22.967
Clearance 0.025 to 0.043 0.101
Piston pin Connecting rod
26.025 to 26.038 26.068 aligner
I.D. bushing
TNV84 to 88
Pin O.D. 25.995 to 26.000 25.967
Clearance 0.025 to 0.043 0.101
Piston pin
30.025 to 30.038 30.068
I.D. bushing
4TNV94L•98
Pin O.D. 29.987 to 30.000 29.959
Clearance 0.025 to 0.051 0.109 Twist measurement using
a connecting rod aligner
Piston pin
37.025 to 37.038 37.068
I.D. bushing
4TNV106 (T)
Pin O.D. 36.989 to 37.000 36.961
Clearance 0.025 to 0.049 0.107

If the bushing is to be replaced because the oil clearance

exceeds the limit, use spare part.

Model Service part code

3TNV82A 119810-23910
TNV84 to 88 129100-23910
4TNV94L•98 (T) 129900-23910
4TNV106 (T) 123900-23910
Cylinder gage

Connecting rod small end

107
 4. Disassembly, inspection and reassembly of engines

(d)Rod big end measurement

Measure the crankpin and bushing according to
4.4.5.(2) (c) described above.
Calculate the oil clearance of a crank pin metal and a
crank pin from the measured values of the crank pin metal
inner diameter and the crank pin outside diameter.
Replace a crank pin metal if the oil clearance becomes
about the limit dimension of the below table.
Correct by grinding if unevenly wear, roundness
exceeding the limit or insufficient outside diameter is Cylinder gage
found. Also use an undersized metal. (Refer to the above
(2) c.)
[NOTICE]
When measuring the inside diameter of the rod big end,
install the crankpin metals in the rod big end not to
mistake the top and bottom of the metals and tighten
the rod bolts by the standard torque. Rod bushing I.D. measurement

Tightening torque of rod bolt

Tightening torque Lubricating oil application
Model
N•m (kgf•m) (threaded portion, and bearing seat surface)
37.2 to 41.2
3TNV82A
(3.8 to 4.2)
44.1 to 49.0
TNV84/88
(4.5 to 5.0)
Lube. oil applied
53.9 to 58.8
4TNV94L/98
(5.5 to 6.0)
78.5 to 83.4
4TNV106 (T)
(8.0 to 8.5)

Standard of rod big end mm

Model Item Standard Limit
Rod I.D. bushing 42.952 to 42.962 42.902
Crankpin O.D. 43.000 to 43.042 -
3TNV82A
Metal thickness 1.487 to 1.500 -
Clearance 0.038 to 0.090 0.150
Rod I.D. bushing 47.952 to 47.962 47.902
Crankpin O.D. 48.000 to 48.026 -
TNV84/88
Metal thickness 1.492 to 1.500 -
Clearance 0.038 to 0.074 0.150
Rod I.D. bushing 57.952 to 57.962 57.902
Crankpin O.D. 58.000 to 58.026 -
4TNV94L/98
Metal thickness 1.492 to 1.500 -
Clearance 0.038 to 0.074 0.150
Rod I.D. bushing 63.952 to 63.962 63.902
Crankpin O.D. 64.016 to 64.042 -
4TNV106 (T)
Metal thickness 1.984 to 1.992 -
Clearance 0.054 to 0.090 0.150

108
4. Disassembly, inspection and reassembly of engines

(6) Tappet
Mainly check the tappet contact surface with the cam and
push rod. Slight surface defects shall be corrected with an
oilstone.
(a)Tappet stem outside diameter measurement

mm
Model Item Standard Limit
Tappet
12.000 to 12.025 12.045 Abnormal contact Normal contact
hole I.D.
surface surface
TNV82A to 88
Stem O.D. 11.975 to 11.990 11.955
Tappet
Clearance 0.010 to 0.050 0.090
Tappet
12.000 to 12.018 12.038
hole I.D.
4TNV94L•98
Stem O.D. 11.975 to 11.990 11.955
Clearance 0.010 to 0.043 0.083
Tappet
14.000 to 14.018 14.038
hole I.D.
4TNV106 (T)
Stem O.D. 13.966 to 13.984 13.946
Clearance 0.015 to 0.052 0.092
Tappet stem outside diameter measuremen

4.4.6 Cylinder bore correction

1)Slight uneven worn, flawed, etc. shall be corrected by
Flex-Hone
honing only. If the cylinder is unevenly worn partially,
flawed or otherwise damaged and cannot be repaired
simply by honing, rebore the cylinder first and then
Electric drill
hone. See 4.4.5.(1) (c) for the boring dimension.
Lube oil Diesel oil
2)Items to be prepared for honing 50% 50%
• Flex-Hone
(see No.8 of 4.1.2 in Chapter 4)
Flex-Hone Honing fluid
• Electric drill
Items to be prepared for honing
• Honing fluid
(50:50 mixture of lube oil and diesel oil)

109
 4. Disassembly, inspection and reassembly of engines

3)Apply the honing fluid to the Flex-Hone and turn the

electric drill at 300 to 1200 rpm. Then insert the Flex-
Hone into the cylinder bore while turning it, and move
it up and down for about 30 sec. to obtain a honing
mark with a cross hatch angle of 30 to 40°.
㨪40q
30q
[NOTICE]
1)Avoid faster revolution than 1200 rpm since it may
cause breakdown.
2)Do not insert or extract the Flex-Hone in stopped state
because the cylinder will be damaged.
Honing cross hatch

Service life of cylinder block (H3)

(H3=3H1)
Boring and honing interval (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.

or blow-by or blow-by or blow-by or blow-by

Honing Boring Honing

Study if an oversized piston or piston ring is usable

4.4.7 Piston pin bushing replacement

Replace bushing by using the special service tool (see 4.1.2 No.3 in Chapter 4).

4.4.8 Oil seal replacement (Flywheel housing side)

1)Replace oil seal, when a flywheel housing is removed. Extract the used oil seal.
2)Insert a new oil seal with the oil seal insertion tool.
3)Apply lithium grease.

110
5. Lubrication system

5. Lubrication system
5.1 Lubrication system diagram

Oil filter

Bypass valve Fuel injection

pump

Hydraulic
swich

Cylinder body࡮Main gallery

Regulator
valve
Intermediate Camshaft Crank
Oil pump gear syaft bearing journal

Rocker arm Crank pin

Oil suction pipe bearing
(strainer)

Rocker arm

Tappet࡮
Cam face

Oil pan

Note: It varies in the specifications of each model whether Oil cooler and Piston cooling of the * mark are
attached.

111
 5. Lubrication system

5.2 Trochoid pump components

Trochoid pump (3TNV82A to TNV88) Trochoid pump (4TNV94L/98/106)

Outer rotor Gear case

Crankshaft Inner rotor

Pump cover Outer rotor

Control valve
Control valve
Plug

Gear case Punch mark Crankshaft

5.3 Disassembly (Reverse the procedure below for assembly)

1)Loosen the belt, and remove the radiator pulley, fan and V-belt. See 4.2.2. 2) in Chapter 4.
2)Remove the crankshaft pulley. See 4.3.2.3) in Chapter 4.
3)Remove the gear case cover. See 4.3.2. 4) in Chapter 4.
4)Remove the lubricating oil pump assy from the gear case for 4TNV94/98/106. (5.4 Point 1)
Remove the lube oil cover from gear case cover for 3TNV82A-88. (5.4 Point 1)
5)Remove the pressure regulating valve from the lubricating oil pump body. (5.4 Point 2)

5.4 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]
[NOTICE]
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.

1)3TNV82A-88
• Apply lube oil to rotor (outer/inner) insertion part.
• Assemble the outer rotor so that the mark of the end face may become a cover side when inserting it in the
gear case.
• Fasten a lube oil pump cover by the standard torque.
• Tightening torque: 6.9 ± 1.5 N•m (0.7 ± 0.15 kgf•m)
• When replacing the lube oil pump, replace the whole assy.
2)4TNV94L/98/106
• Apply lube oil to lube oil pump insertion part of gear case.
• Install the outer rotor in the gear case so that the punch mark on the end face is seen.
• When replacing the lube oil pump, replace the whole assy.

Point 2
[Disassemble-Reassemble]
• Only wash the pressure regulating valve. Disassembly is unnecessary unless any abnormality in operation
is detected.
(R.1)
112
5. Lubrication system

5.5 Parts Inspection and measurement

5.5.1 Trochoid pump inspection and measurement
(1) Outside clearance and side clearance of
outer rotor Outer rotor

Insert a gap gage between a outer rotor and a pump Gear case

body, and measure the clearance.

Outside clearance mm
Model Standard Limit
3TNV82A to 88 0.12 to 0.21 0.30 Outer diameter clearance
4TNV94L/98 0.100 to 0.155 0.25
4TNV106(T) 0.100 to 0.165 0.25

(2) Tip clearance between outer rotor and

inner rotor
Insert a gap gage between an outer rotor and an inner
rotor, and measure the tip clearance.
Tip clearance mm
Standard Limit
- 0.16
Side clearance

(3) Side clearance of outer rotor

When measuring a side clearance, put a right-angle
gage to the pump body, insert a gap gage and measure
the clearance.

Side clearance mm
Model Standard Limit
3TNV82A to 88 0.02 to 0.07 0.12
4TNV94L/98 0.05 to 0.10 0.15
4TNV106(T) 0.03 to 0.12 0.17

(R.1)
113
 5. Lubrication system

(4) Inner rotor and gear boss clearance (3TNV82A-4TNV88)

Standard Standard Standard

Item Part dimension clearance clearance limit
(mm) (mm) (mm)
Inside clearance Gear boss diameter 53.05 to 53.15
0.3 to 0.5 0.6
of inner rotor Rotor inner diameter 53.45 to 53.55
Width across flat Width across flat of gear boss 49.45 to 49.75
0.2 to 0.6 0.7
clearance of inner rotor Width across flat of rotor 49.95 to 50.05

Width across
flat of rotor

Crank gear
Rotor inner
diameter
Inner rotor

(5) Rotor shaft clearance (4TNV94L/98/106)

Rotor shaft
Measure the outside diameter of rotor shaft and the shaft
hole diameter of gear case. Calculate the clearance from Shaft
that difference. O.D.

Bearing
I.D.

Gear case
Lube oil pump bearing

Model Inspection item Standard Limit

Gear case bearing I.D. 12.980 to 13.020 13.05
4TNV94L/98 Rotor shaft O.D. 12.955 to 12.970 12.945
Rotor clearance 0.035 to 0.065 0.105
Gear case bearing I.D. 13.000 to 13.020 13.05
4TNV106(T) Rotor shaft O.D. 12.955 to 12.965 12.945
Rotor clearance 0.035 to 0.065 0.105

114
6. Cooling system

6. Cooling system
6.1 Cooling water system

Thermostat

Cylinder head

Bypass

Radiator
Coolant recovery tank
Cylinder block

Cooling water pump

L.O. cooler

6.2 Cooling water pump components

Cylinder head

Thermostat cover
Joint

Thermostat

Cooling water pump

Thermo switch

V-pulley
Spacer

Note) This figure shows the 4TNV84

Fan

115
 6. Cooling system

6.3 Disassembly (Reverse the procedure below for assembly)

1)Remove the alternator. See 4.2.2. 1) in Chapter 4.
2)Remove the fan, V-belt and pulley. See 4.2.2. 2) in Chapter 4.
3)Remove the cooling water pump. (Point 1, in below 6.4)
4)Remove the thermostat. (Point 2 in below 6.4)

6.4 Servicing points

Point 1
Disassemble-Reassemble:
• Check to see that the cooling water pump bearing is free from abnormal noise, sticking or play and water
leakage from the bearing. If replacement is necessary, replace the whole cooling water pump assy.

[NOTICE]
Replace the O-ring of the cooling water pump with
new one when disassembling. And, be sure to use the O-Ring
special O-ring for each engine model, because the
material is different, although the dimension is the
Joint
same as a commercial part. (Refer to the right figure.)

Point 2 Cooling water pump

Disassemble:
• Check the thermostat function. See 2.7 in Chapter 2
for the inspection method.

116
7. Fuel injection pump / Governor

7. Fuel injection pump / Governor

Only the outline of the MP fuel pump is explained in this chapter. Refer to the MP pump service manual of the
separate volume for the disassembly and assembly.

7.1 Introduction
It is described about the features of the fuel injection
pump, YDP-MP, manufactured by Yanmar, disassembly,
assembly and adjustment procedure.

Fuel injection pump is the most important equipment,

which is enable to make the sensitive adjustment
according to the variable load of the engine.

Therefore all of the parts are required not only very

precise machining but also finest, assembling with top
level.
The careful arrangement of keeping off the dust and the
rust when disassemble, adjustment and reassemble of
the fuel injection pump is made in the market.

Yanmar YDP-MP Pump is a distributor type pump which is unified of Mono-plunger, a distributing shaft, a
hydraulic head which equipped the delivery valve for each cylinder, pump housing which has a cam shaft
internally and governor.
The fuel, which is pressurized by the up and down movement of the plunger driven by the cam-rotation, is
supplied through the distributor shaft, which is rotating accordingly.

There are a model YDP-MP2 and a model YDP-MP4, and plunger diameter and fuel cam speed are different.

7.2 Fuel injection pump

7.2.1 Fuel system diagram

117
 7. Fuel injection pump / Governor

7.2.2 External view and components

ԙFuel injection pipe

Cylinder head

Fuel
filter

Fuel injection valve

Cooling water pump

ԘV-belt/V-pulley
ԘCooling fan
Intake maniforld

Water separator
ԜFuel pump spacer
Camshaft driving gear
ԟFuel injection pump

Crankshaft gear

Pump flange
Don't disassemble!
ԛFuel pump drive gear
ԜDrive gear nut
Gear case

Oil seal

Note) This figure shows the 3TNV84 Crankshaft pulley

7.2.3 Disassembly procedure:

Disassembly from the engine body
1)Remove the cooling fan, pulley and V-belt.
2)Remove the fuel injection pipe, fuel oil piping, fuel return pipe and rear stay. See point 1 of 7.2.5.
3)Remove the fuel injection pump cover (the cover of the drive gear).
4)Make ID marks on the gearing part of the pump drive gear and the idle gear with paint and so on.
See Point 2 of 7.2.5.
5)Loosen a fuel pump drive gear nut, and remove a pump drive gear from the fuel pump by using a gear
puller. See Point 3 of 4.3.4.
6)Remove a drive gear nut carefully not to drop it to the inside of the gear case.
7)Record the installation angle of the fuel pump precisely by using a mark-off line and a sticker.
See (4) of 2.2.7.
8)Remove the fuel injection pump. See Point 3 of 7.2.5.

118
7. Fuel injection pump / Governor

Fuel Cylinder No.

injection Cylinder No.
pipe 1 Injection 1
Governor side pipe
B

Engine
2 2

Engine
Governor
side
3 3
B C

Fuel 4 Fuel pump C

pump A

Drive side
A D
Drive side
Fuel pump (3 cylinder)
Fuel pump (4 cylinder)

7.2.4 Assembly procedure

Reverse the disassembly procedure and adjust the fuel injection timing finally. See (4) of 2.2.7.

7.2.5 Servicing points

Fuel injection pump
Point 1
[Disassemble]
I.D. mark
• Block an entrance with the tape so that trash may not
enter the fuel injection pipe and the fuel injection Flange
pump. bolt

Point 2
[Disassemble]
Gear
• After putting the I.D. marks on the gearing part of the installation nut
pump drive gear and the idle gear with paint and so Idle gear
on, remove the gear installation nut. Fuel pump driving gear
Fuel pump driving gear
[NOTICE]
Don't remove four flange bolts.

[Reassemble]
• Reassemble the pump driving gear while checking the I.D. marks on the driving gear and idle gear.
Tightening torque of the gear installation nut
Lubricating oil application
Model N•m (kgf•m)
(thread portion, and seat surface)
TNV82A to 88 78 to 88 (8 to 9)
Not applied
4TNV94 to 106 (T) 113 to 123 (11.5 to 12.5)

119
 7. Fuel injection pump / Governor

Point 3
[Disassemble]
There is an acoustic material part to name as fuel pump spacer between the fuel pump and the cylinder
block. Loosen fuel pump installation bolts with a closed wrench when disassembling a fuel pump.
[NOTICE]
An intake manifold may obstruct the disassembly of the fuel pump by the engine model. Remove the fuel
pump after removing the intake manifold first.

Cylinder block Fuel pump spacer Cylinder head Suction manifold

Closed wren

Fuel pump

Fuel pump Disassembling a fuel pump

[Reassemble]
When installing a fuel pump on the gear case, put a fuel pump spacer between the cylinder blocks, and
install it.

7.2.6 C.S.D. (Cold Start Device)

In order to facilitate easy engine starting under cold temperature, the cold starting advancer senses the
cooling water temperature and advances the fuel injection timing.
[NOTICE]
When engine starts under cold temperature, the minimum engine speed is automatically about 100-300
min-1 higher than the normal low speed by the function of C.S.D.. A few minutes later the engine speed will
reduce gradually to the normal minimum speed. Therefore it has the possibility that the machine unit begins
to work because of the higher engine speed right after the engine start, and very dangerous.
Attention is especially necessary when the throttle lever of the governor is put in half-throttle position to
hasten the warming up of the engine.

(R.1)
120
8. TURBOCHARGER

8. Turbocharger: Disassembly, inspection and reassembly

8.1 Structure and functions
8.1.1 Main specifications
3TNV84T (CL, VM)
Applicable engine model (application) 3TNV84T (VM) 4TNV106T (CL, VM)
4TNV84T (CL)
Turbocharger model RHB31 RHB51 RHF5
Turbocharger specification Standard (w/waste gate)
Turbine type Radial flow
Blower (compressor) type Centrifugal
Lubrication method External lubrication
Max．continuous allowable speed 250,000 180,000
Max．continuous allowable gas inlet
750
temperature
Dry weight
24 (2.4) 41 (4.2) 46 (4.7)
N (kgf)
Note) VM application is provided with the waste gate.

8.1.2 Construction

13 14 12 15 8 9 10 17
Air outlet

Oil inlet

Air inlet
Gas outlet

19

18
Oil outlet

2
Gas inlet 11 1 20 3 5 16 6 4 7

121
 8. TURBOCHARGER

8.1.3 Structural and functional outline

No. Part name

1 Turbine shaft
2 OiN thrower
3 Turbine side seal ring
4 Seal plate
5 Journal bearing
6 Thrust bearing
7 Compressor housing
8 M5 hexagon bolt
9 M5 spring washer
10 Compressor side clamp
11 Turbine housing
12 M6 hexagon bolt
13 Turbine side clamp
14 Lock washer
15 Bearing housing
16 Retaining ring
17 M3 countersunk flat head screw
18 Compressor wheel
19 Shaft end nut
20 Heat protector

(1) Turbine
The exhaust gas from the engine is accelerated at the nozzle portion in the turbine housing and blown onto
the turbine impeller to rotate the turbine shaft.
This is called the turbine. A seal ring and heat insulating plate are installed to prevent the bearing from
adverse influence of the gas.
(2) Compressor
The compressor impeller installed on the turbine shaft rotates with the shaft to suck and compress air for
feeding into the intake manifold.
This is called the blower or compressor.
(3) Bearings
Thrust bearing
As the turbine shaft is constantly applied with a thrust force, this bearing prevents the shaft from being
moved by the thrust force.
Radial bearing
A floating bearing is adopted. Since the bearing moves with the turbine shaft as the oil films are formed
both inside and outside the bearing, the bearing sliding speed is slower than the turbine shaft speed,
resulting in higher dynamic stability.
(4) Compressor side sealing mechanism
To prevent the intake air and oil form leaking, a seal ring and a seal plate are provided to form a double wall
structure on the rear side of the compressor impeller.
(5) Waste gate
When the blower side pressure (intake air pressure) exceeds the specified level, the exhaust gas at the
turbine inlet is partially bypassed to the exhaust discharge side to control the turbine rpm so as to maintain the
intake pressure at the specified level for improving the response to load variation in the low to medium speed
range and to minimize black smoke generation. It consists of a control assembly separated from the
turbocharger and a valve assembly installed in the turbine impeller chamber.

122
8. TURBOCHARGER

8.1.4 Components

12

15 8 7
14
13 9

45
11 3
2 23 22

20
21
28
10 29
24
27
6
19
1 29

14
13
17

18 26

16 32
25 31 30

No. Part name No. Part name

1 Turbine shaft 17 Bolt
2 Thrust bushing 18 Lock plate
3 Oil thrower 19 Bearing housing
4 Seal ring 20 Retaining ring
5 Seal ring 21 Screw
6 Seal ring (turbine side) 22 Screw
7 Lock nut 23 Lock washer
8 Impeller 24 Heat protector
9 Seal plate 25 Liquid gasket
10 Journal bearing 26 Waste gate actuator
11 Thrust bearing 27 Hose
12 Compressor housing 28 Adapter
13 Flanged bolt 29 Clip
14 Spring washer 30 Retaining ring
15 Clamp 31 Waste gate valve
16 Turbine housing 32 Link plate

123
 8. TURBOCHARGER

8.2 Service standards and tightening torque

8.2.1 Service standards

F
B D C A H2 H1

K
Turbine side Compresson side
E G1 G2

(1) RHF5 type

Unit: mm
Standard dimension Wear limit
Turbine shaft journal outside diameter (A) 7.99 to 8.00 7.98
Turbine shaft seal ring groove width (E) 1.25 to 1.28 1.29
Turbine
Compressor side seal ring groove width (G1) 1.22 to 1.23 1.31
shaft
Compressor side seal ring groove width (G2) 1.02 to 1.03 1.11
Turbine shaft run-out 0.002 0.011
Journal bearing inside diameter (C) 8.01 to 8.03 8.04
Bearing Journal bearing outside diameter (D) 12.32 to 12.33 12.31
Bearing housing inside diameter (B) 12.40 to 12.41 12.42
Thrust Thrust bearing width (J) 3.99 to 4.01 3.98
bearing Thrust bushing groove dimension (K) 4.04 to 4.05 4.07
Turbine side (bearing housing) (F) 15.00 to 15.02 15.05
Seal ring
fixing Compressor side (seal ring) (H1) 12.40 to 12.42 12.45
area
Compressor side (seal ring) (H2) 10.00 to 10.02 10.05
Rotor play in axial direction 0.03 to 0.06 0.09
Rotor play in radial direction 0.08 to 0.13 0.17

124
8. TURBOCHARGER

(2) RHB31/RHB51 type

Unit: mm
Standard dimension Wear limit
RHB31 RHB51 RHB31 RHB51
Turbine shaft journal outside diameter (A) 6.257 to 6.263 7.99 to 8.00 6.25 7.98
Turbine shaft seal ring groove width (E) 1.038 to 1.062 1.25 to 1.28 1.07 1.29
Turbine
Compressor side seal ring groove width (G1) 1.02 to 1.03 1.22 to 1.23 1.04 1.31
shaft
Compressor side seal ring groove width (G2) 0.82 to 0.83 1.02 to 1.03 0.84 1.11
Turbine shaft run-out 0.002 0.002 0.005 0.011
Journal bearing inside diameter (C) 6.275 to 6.285 8.01 to 8.03 6.29 8.04
Bearing Journal bearing outside diameter (D) 9.940 to 9.946 12.32 to 12.33 9.93 12.31
Bearing housing inside diameter (B) 9.995 to 10.005 12.40 to 12.41 10.01 12.42
Thrust Thrust bearing width (J) 3.59 to 3.61 3.99 to 4.01 3.58 3.98
bearing Thrust bushing groove dimension (K) 3.632 to 3.642 4.04 to 4.05 3.65 4.07
Turbine side (bearing housing) (F) 11.00 to 11.018 15.00 to 15.02 11.03 15.05
Seal ring
fixing Compressor side (seal ring) (H1) 9.987 to 10.025 12.40 to 12.42 10.04 12.45
area Compressor side (seal ring) (H2) 7.968 to 8.00 10.00 to 10.02 8.01 10.05
Rotor play in axial direction 0.022 to 0.053 0.03 to 0.06 0.07 0.09
Rotor play in radial direction 0.061 to 0.093 0.08 to 0.13 0.12 0.17

8.2.2 Tightening torque

(1) RHF5 type

N•m (kgf•cm)
Part Thread diameter Tightening torque
Turbine housing set bolt M8 27 to 29 (275 to 295)
Compressor housing set bolt M5 4.2 to 5.2 (43 to 53)
Thrust bearing set screw M3 1.2 to 1.4 (12 to 14)
Seal plate set screw M3 1.2 to 1.4 (12 to 14)
Blower impeller set nut
M5 1.8 to 2.2 (18 to 22)
(left-handed screw)

(2) RHB31/ RHB51 type

Part
Waste gate actuator set bolt
Lock plate set bolt
Thrust bearing set screw
Seal plate set screw
Blower impeller set nut
(left-handed screw)
N•m (kgf•cm)
Tightening torque
Thread diameter
RHB31 RHB51
M5 3.9 to 4.9 (40 to 50) 3.9 to 4.9 (40 to 50)
M6 11.8 to 12.8 (120 to 130) 11.8 to 12.8 (120 to 130)
M8 11.8 to 12.8 (120 to 130) 27.0 to 28.9 (275 to 295)
M3 1.2 to 1.4 (12 to 14) 1.2 to 1.4 (12 to 14)
M3 1.2 to 1.4 (12 to 14) 1.2 to 1.4 (12 to 14)
M5 0.9 to 1.1 (9 to 10) 1.8 to 2.2 (18 to 22)

125
 8. TURBOCHARGER

8.3 Periodic inspection procedure

8.3.1 Periodic inspection intervals

Periodically inspect the turbocharger for the overall conditions and fouling.
The inspection interval varies with the operating conditions, but refer to the table below for the guideline for
each application.

Application Inspection interval

Every 6 months Every 12 months Every 24 months
For vehicles (automobiles)
or 60,000km or 150,000km or 300,000km
Every 6 months Every 12 months Every 24 months
For construction machinery
or 500hrs or 1,000hrs or 2,000hrs
Every 6 months Every 12 months Every 24 months
For faming machinery
or 200hrs or 400hrs or 800hrs
Every 6 months Every 12 months Every 24 months
For marine use
or 1,500hrs or 3,000hrs or 6,000hrs
Rotor rotation c
Rotor play c
Overhaul and overall
c
inspection
Oil filter cleaning and
inspection Based on engine operation manual
Engine oil replacement

126
8. TURBOCHARGER

8.3.2 Inspection procedure

(1) Rotor rotation inspection

Inspect the rotor rotation by listening to any abnormal sound generation during rotation.
For inspection with a sound detecting bar, bring the tip end of the bar into strong contact with the turbocharger
case and raise the engine speed gradually.
If any high pitch sound is generated at intervals of 2 to 3 seconds, the rotation is abnormal. Since the bearing
or rotor may be defective in this state, either replace or overhaul the turbocharger.

(2) Rotor play inspection

Remove the turbocharger from the engine and inspect the rotor play in the axial and radial directions
according to the procedure below.
After removing the turbocharger from the engine, always bind the oil inlet and outlet holes with adhesive tape.

Rotor play in axial direction

Turbine wheel chamber

Magnet base

Move the turbine shaft

in the axial direction.
Dial gage

Axial play Service standard: 0.03 to 0.06 mm

Wear limit : 0.09 mm

127
 8. TURBOCHARGER

8.3.3 Waste gate valve adjustment procedure

Rotor play in radial direction

Dial gage
Magnet base

Oil outlet

Move the turbine shaft in the radial

Radial play direction at the same time on the
left and right sides.

Oil inlet

Service standard: 0.08 to 0.13 mm

Wear limit : 0.17 mm

It is indispensable to adjust the waste gate valve opening pressure and lift after its overhaul or inner parts
replacement.
Negligence of this adjustment will adversely affect the engine performance.
[NOTICE]
If the adjustment is impossible, give up overhaul but replace the whole turbocharger assembly.

(1) Method for checking the waste gate valve opening pressure and lift
(a)Equipment
Prepare the equipment shown in the figure below.

128
8. TURBOCHARGER

(b)Measuring instruments and devices

Dial gage Capable of measuring 0 to 10 mm (A flat head type is recommendable.)
Manometer Mercury column or electrical type (capable of measuring 0 to 1500 mmHg)
Pressure regulating valve Allowing gradual adjustment in a range between 0 and 2 kgf/cm2 (0.196 Mpa)
Pressure reducing valve Used for suppressing the air supply pressure at 5 kgf/cm2 (0.49 Mpa) or less.
Pressure gage Bourdon tube pressure gage (0 to 10 kgf/cm2 (0.98 Mpa))

Waste gate actuator

Rod
Pressure gage
Clip
Dial gage
Hose
Compressed air

Adapter <5 kg/cm2

(0.49 Mpa)
Waste gate valve Pc Pressure regulating valve
Pressure reducing valve

Manometer

[Note] Pc (controller pressure) varies with the set

output in a range between 600 and 750 mmHg.

(c)Check method
1)Set the manometer control pressure (Pc) applied to the waste gate actuator to 0 and set the dial gage to
the zero point.
2)Gradually open the pressure regulating valve and measure the Pc value when the actuator rod is oper-
ated by 2 mm.
3)For the hysteresis, let the rod move to 3 mm first. The gradually close the pressure regulating valve, mea-
sure the pressure when the rod is moved to 2mm and obtain the difference from the pressure measured in
b. above.
4)Precautions
• Set the dial gage on the extension line of the actuator rod.
• The piping and joints shall completely be free from leak.
• Fix the turbocharger and dial gage securely.
• If an electric manometer is used, it shall have sufficient precision.
• Even when an electric manometer is used, use of a mercury column type manometer in combination is
recommended for calibration and daily check.
• The speed for increasing/decreasing Pc by means of the pressure regulating valve shall be very slow near
the measuring point. If the mm position is exceeded, restart from the beginning.
• Do not apply over 0.49 MPa (5 kgf/cm2) to the actuator.

(2) Waste gate actuator leak test

Apply 0.12 Mpa (1.2 kgf/cm2) to the actuator and hold the state for minute. The actuator is good if the
pressure then is 0.11 Mpa (1.1 kgf/cm2) or above.

129
 8. TURBOCHARGER

8.4 Disassembly procedure

8.4.1 Preparation for disassembly
In addition to the general tools, the following special tools are required for turbocharger disassembly and reas-
sembly:

Tool name Use Illustration

For removing thrust bearing and
thrust bushing 75
(mm)
Ǟ7.5
Bar

Material: Copper or brass

For removing floating bearing circlip

Pliers

For removing seal ring

Pliers

For thrust bearing installation Item sold on market

(for M3) : 1.3 N•m (13 kgf•cm)
Torque driver for TORX bolt
(multifunctional type) For seal plate installation
0.5 to 4.9 N•m (5 to 50 kgf•cm) (for M3) : 1.3 N•m (13 kgf•cm)

(Type: TORX TT20 or equivalent)

For fixing turbine shaft
(mm × dodecagonal)
Box wrench

Box only may be used.

For following bolts and nuts:
Torque wrench M8 : mm, kgf•cm (N•m)
(single purpose) M5 : mm, kgf•cm (N•m)
M5 : mm, kgf•cm (N•m)
For measuring play in axial and radial directions: To be installed on a dial
gage

R10 Ǟ5(0.1968) mm (in.)

(0.3937)
To be knurled here
Probe
7(0.2755)
R5(0.1968)

M2.6 1(0.0393)
P0.45 8 40 10 15
(1.5748) (0.3937) (0.5905) Mount to dial gauge
(0.3149)

130
8. TURBOCHARGER

8.4.2 Inspection before disassembly

1)Inspect the turbine wheel and compressor impeller for any undesirable contact and the rotor for smooth
rotation.
2)Measure the rotor play as described in section 8.3 (2.2).
• Rotor axial play Wear limit: mm
• Rotor radial play Wear limit : mm

8.4.3 Disassembly
The mounting angles of the turbine housing, bearing housing and compressor housing are determined
according to its mounting state on the engine. Put match marks before starting disassembly.
Note: The number after each part is the one described in the structural drawing in 8.1(2).

(1) Compressor housing removal

1)Remove flanged hexagon bolt 8 and compressor side keep plate 10.
2)Remove compressor housing 7.
Note:
1)Liquid gasket is applied on the surface of compressor housing 7 where bearing housing 15 is mounted.
2)When disassembling compressor housing 7, carefully operate so as not to damage the compressor impel-
ler.

(2) Compressor impeller removal

1)Set a box spanner (10 mm) on the turbine side end of the turbine shaft, and remove shaft end clamp 18.
Note: Pay attention to the loosening direction since the shaft end nut has left-handed screw.
2)Remove compressor impeller 18.

(3) Turbine housing removal

1)Remove hexagon nut 12 and turbine side keep plate 13.
2)Remove turbine housing 11.

(4) Turbine shaft extraction

1)Hold heat insulating plate 20 lightly with a hand, and extract turbine shaft 1.
Note: If the turbine shaft is hard to be extracted, tap the compressor side end of the shaft lightly with a
wooden hammer.
2)Remove heat insulating plate 20.

(5) Seal plate removal

1)Use the Torx driver and loosen M3 Torx T-type machine screw 17 for seal plate mounting.
2)Remove seal plate 4.
Note: Liquid gasket has been applied to the seal plate and bearing housing mounting surface.
3)Remove oil thrower 2 from the seal plate.

(6) Slide bearing and thrust bushing removal

1)Use the Torx driver and loosen the M3 Torx T-type machine screw for thrust bearing installation.
2)Use the bar (copper) and remove thrust bearing 6 and thrust bushing.

131
 8. TURBOCHARGER

(7) Floating bearing removal

1)Use the stop ring pliers and remove circlip 16 from bearing housing 15.
2)Remove floating bearing 5 from bearing housing 15.

(8) Seal ring removal

1)Remove turbine side seal ring 3 from turbine shaft 1.
2)Remove compressor side seal ring (small) and compressor side seal ring (large) from oil thrower 2.

132
8. TURBOCHARGER

8.5 Washing and inspection procedure

8.5.1 Washing
(1) Inspection before washing
Visually inspect each part before washing to check trace of seizure, wear, foreign matter or carbon adhesion.
Carefully inspect for identifying the cause of trouble especially when a fault has occurred.

Major inspection items

Check point Checking position
1)Turbine shaft 1, turbine side seal ring and rear side of turbine wheel
Carbon adhesion state 2)Heat insulating plate 20 mounting portion and inside of bearing hous-
ing 15
1)Turbine shaft 1, journal portion and thrust bushing oil thrower 2
Lubrication status
2)Floating bearing 5 and thrust bearing 6
(wear, seizure, discoloration, etc.)
3)Bearing housing 15 and inner wall of bearing fitting ring
1)Inner wall of turbine housing 11
2)Outer surface of bearing housing 11 and heat insulating plate 20
mounting portion
3)Turbine shaft 1 turbine side seal ring portion and rear side of turbine
Oil leak state
wheel
4)Inner wall of compressor housing 7
5)Rear side of compressor impeller 18
6)Surface and seal ring inserting portion of seal plate 4

(2) Washing procedure

Keep the following in mind when washing the parts.
Part Tools and detergent Procedure
a)Turbine s haft •Tools 1)Boil the turbine in the washing bucket.
1)Bucket (500 × 500) Do not strike the blade to remove the carbon.
2)Heat source: 2)Immerse in the detergent until the carbon and other
Steam or gas burner deposits are softened.
3)Brush 3)Use a plastic scraper or hand hair scrubber to remove
•Detergent the softened deposits.
Standard carbon 4)Protect the bearing surface and seal ring groove on
removing agent the turbine shaft so as not to be damaged.
5)Any deposit remaining on the turbine shaft due to
improper washing may cause unbalancing. Be sure to
remove thoroughly. Never use a wire brush.
b)Turbine wheel •Tools 1)Boil the turbine in the washing bucket.
chamber Same as for turbine shaft 2)Immerse in the detergent until the carbon and other
deposits are softened.
•Detergent 3)Use a plastic scraper or hard hair scrubber to remove
Same as for turbine shaft the softened deposits.

c)Blower blade •Tools 1)Immerse in the washing bucket until the deposit is
and chamber 1)Bucket (500 × 500) softened.
2)Brush 2)Use a plastic scraper or hard hair scrubber to remove
the softened deposits.
•Detergent Never use a wire brush.
d)Others 1)Wash all other parts with diesel oil.
2)Clean the lubricating oil path by blowing with compressed air.
3)Be especially careful so as not to damage or corrode the parts.

133
 8. TURBOCHARGER

8.5.2 Inspection procedure

(1) Compressor housing 7
Inspect the compressor housing for any contact trace
with the compressor impeller, surface defect, dent or
crack at joint surface, and replace it if defective.

(2) Turbine housing 11

Inspect any trace of contact with the turbine wheel,
exfoliation due to degradation by oxidation of the cast
surface, thermal deformation or crack.
Replace with a new one of defective.

(3) Compressor impeller 18

Inspect any contact trace, chipping, corrosion or
deformation.
Replace with a new one if defective.

(4) Turbine shaft 1

1)Inspect any contact trace, chipping, thermal discolor-
ation or deformation at the turbine wheel. Check the
E
shaft portion for bend, the journal portion for thermal
discoloration or abnormal wear, and the seal ring
groove for surface defect or wear. Replace with a A
new one if defective.
2)Measure the turbine shaft journal outside diameter
(A) and seal ring groove width (E).
V block
Replace with a new turbine shaft if beyond the wear
limit.
Wear limit of journal outside diameter (A)
RHF5  7.98 mm
RHB51  7.98 mm
RHB31  6.25 mm
Wear limit of ring groove width (E)
RHF5  1.29 mm
RHB51  1.29 mm
RHB31  1.07 mm
3)Measure the turbine shaft run-out, and replace with
a new turbine shaft if it exceeds 0.011 mm.

(5) Heat insulating plate 20

Inspect the heat insulating plate for any contact trace,
thermal deformation or corrosion Replace with a new
one if defective.

134
8. TURBOCHARGER

(6) Thrust bushing, oil thrower 2 and thrust

Thrust bushing G1
bearing 6 Inspect each part for wear, sur- G2
face defect and discoloration.
Replace with a new one if defective even within the wear
limit.
(a)Thrust bushing
Measure the distance between grooves (K) of the thrust
bushing, and replace with a new one if the wear limit is K
Oil throwe
exceeded.
Wear limit
RHF5  4.07 mm
RHB51  4.07 mm
RHB31  3.65 mm
(b)Oil thrower 2
Measure the seal ring groove widths (G1) and (G2), and replace with a new one if the wear limit is exceeded.
Wear limits
RHF5--- G1: 1.31 mm, G2: 1.11 mm
RHB51--- G1: 1.31 mm, G2: 1.11 mm
RHB31--- G1: 1.04 mm, G2: 0.84 mm
(c)Thrust bearing 6
Measure the thrust bearing width (J), and replace with
a new one if the wear limit is exceeded.
Wear limit
RHF5  3.98 mm
RHB51  3.98 mm
RHB31  3.58 mm

(7) Floating bearing 5

1)Inspect the floating bearing for abnormal wear,
discoloration or surface defect.
Replace with a new one if defective.
2)Measure the inside diameter (C) and outside diameter (D).
Replace the bearing if either wear limit is exceeded.
Wear limits
RHF5  Outside diameter (D): 12.31 mm,
Inside diameter (C): 8.04 mm
RHB51  Outside diameter (D): 12.31 mm,
Inside diameter (C): 8.04 mm
RHB31  Outside diameter (D): 9.93 mm,
Inside diameter (C): 6.29 mm

135
 8. TURBOCHARGER

(8) Bearing housing 15

Bearing fitting ring
1)Inspect the housing for cast surface exfoliation due
to oxidation and degradation, dent or crack. Inner plate
2)Inspect circlip 16 for chipping or crack, and replace
with a new one if defective.
3)Measure the (B) and (F) portions of the bearing
housing shown in the figure below.
Replace with a new one if either wear limit is
exceeded. F

Wear limit of bearing housing inside diameter (B)

RHF5  12.42 mm
RHB51  12.42 mm
RHB31  10.01 mm
Compresser
Wear limit of turbine side seal ring inserting Turbine side side
portion (F)
RHF5  15.05 mm
RHB51  15.05 mm
RHB31  11.03 mm

(9) Seal plate 4

1)Inspect the seal plate for any contact trace, joint sur-
face defect, dent or crack.
Replace it if defective.
2)Measure the seal ring inserting dimensions (H1 and
H1 H2
H2) on the compressor side, and replace the seal
ring with a new one if either wear limit is exceeded.
Wear limits
RHF5  H1: 12.45 mm, H2: 10.05 mm
RHB51  H1: 12.45 mm, H2: 10.05 mm
RHB31  H1: 10.04 mm, H2: 8.01 mm

(10)Seal rings
Replace seal rings with new ones.

(11)Inspect keep plates 10, 13 and bolts for

any deformation, and replace defective
parts with new ones. Also replace M3 Torx
machine screws with new ones.

136
8. TURBOCHARGER

8.6 Reassembly procedure

Applicable only to the one
closest to the turbine
8.6.1 Preparation for reassembly Lubricating oil inlet
1)Prepare general tools, special tools, liquid gasket Circlip
(Three Bond No.1207) and Locktite No.242 before
reassembling the turbocharger. Floating metal

2)Always replace the following parts with new ones:

• Turbine side seal ring 1pc.

View from the turbine

• Compressor side seal ring (large) 1pc.
• Compressor side seal ring (small) 1pc. Match up contact surface
• M3 machine screws 3pcs.
Lubricating oil inlet
• M3 machine screws 4pcs.

8.6.2 Reassembly
(1) Floating bearing installation
1)Use the snap ring pliers and install inner circlip 16 on
bearing housing 15.
2)Install floating bearing 5 in bearing housing 15. For all other than above
3)Use the snap ring pliers and install outer circlip 16 on
bearing housing 15.
Note:
1)The circlip joint shall be positioned as shown in the
figure at right above.
The rounded side of the circlip shall face the
bearing.
2)Apply lubricating oil on the floating bearing before
reassembly.

(2) Turbine shaft installation

1)Fit the seal ring onto turbine shaft 1.
2)Install heat insulating plate 20 on the turbine side of
bearing housing 15.
3)Apply lubricating oil on the journal portion of the tur-
bine shaft and insert the shaft from the turbine side
of bearing housing 15.
Note: Carefully operate so as not to damage the floating
bearing by the turbine shaft.
The seal ring joint shall be positioned on the
lubricating oil inlet side after centering with the
turbine shaft.

137
 8. TURBOCHARGER

(3) Thrust bearing installation

1)Fit thrust bushing on turbine shaft 1.
2)Apply lubricating oil on the bearing portion of thrust
bearing 6 and install it in bearing housing 15.
3)Apply Locktite on the threaded portion of M3 Torx T
machine screw 17 for thrust bearing installation, and
use Torx torque driver for installation by tightening to
the specified torque.
Tightening torque: 1.3 ± 0.1 N•m (13 ± 1 kgf•cm)

(4) Seal plate installation

L.O. inlet
1)Fit the seal ring on oil thrower 2.
2)Insert oil thrower 2 into seal plate 4.
Note: The seal ring joint portion shall be positioned as
illustrated at right.
3)Apply liquid gasket (Three Bond No.1207) on the
seal plate mounting surface on the compressor side
of bearing housing 15. 45q
Note: See the illustration below for the applying
View from the compressor
position.
Applying thickness: 0.1 to 0.2 mm

4)Install seal plate 4 on bearing housing 15.

5)Apply Locktite on the threaded portion of M3
machine screw for seal plate mounting, and tighten it
with a torque screwdriver.
Tightening torque: 1.3 ± 0.1 N•m (131 kgf•cm)

Liquid gasket Carefully prevent the liquid

applying position gasket from leaking out to
this area

138
8. TURBOCHARGER

(5) Compressor impeller installation

1)Fit compressor impeller 18 onto turbine shaft 1.
2)Set a box spanner (10 mm) on the turbine side end
of turbine shaft 1, and tighten shaft end nut 19.
Note: Since the shaft end nut has left-handed screw,
pay attention to the tightening direction.
Tightening torque: 2.0 ± 0.2 N•m (20 ± 2 kgf•cm)

(6) Turbine housing installation

1)Install bearing housing 15 on turbine housing 11 by
aligning the match marks put before disassembly.
Note: In case of part replacement, check the oil inlet
and outlet positions and the exhaust gas inlet
position before reassembly.
2)Install the turbine side keep plate and tighten M8
hexagon bolt 12.
Tightening torque: 285 ± 10 N•m (28 ± 1 kgf•cm)

(7) Compressor housing installation

1)Apply liquid gasket (Three Bond No.1207) on the
compressor side flange of bearing housing 15.
Note: See section (4)3) for the portion to be applied.
Applying thickness: 0.1 to 0.2 mm
2)Check the mark and install the compressor housing
7 on the bearing housing 15.
Note: When a part is replaced, confirm a position of an
oil entrance and a position of an air exit, and
assemble it.
3)Install the keep plate 10 on compressor side, and
tighten M8 hexagon bolt 8.
Tightening torque: 48 N•m (4.7 ± 0.5 kgf•cm)

(8) Rotor play measurement

See the inspection procedure in section 8.3.2 for the
measurement method.
If the rotor play does not satisfy the standard,
reassembly is necessary since assembly error or use of
a wrong part is conceivable.
Service standard of rotor play in axial direction
RHF5  0.03 to 0.06 mm
RHB51  0.03 to 0.06 mm
RHB31  0.022 to 0.053 mm
Service standard of rotor play in radial direction
RHF5  0.08 to 0.13 mm
RHB51  0.08 to 0.13mm
RHB31  0.061 to 0.093mm

139
 8. TURBOCHARGER

8.7 Handling after disassembly and reassembly

When installing the turbocharger on the engine or handling the turbocharger after installation, strictly observe
the instructions given below.
Especially pay careful attention for preventing foreign matter entrance into the turbocharger.

8.7.1 Instructions for turbocharger installation

Lubrication system
1)Pour new lubricating oil through the oil filler port before installation on the engine, and manually turn the
turbine shaft to lubricate the floating and thrust bearings.
2)Flush the oil inlet pipe from the engine and outlet pipe, and check no crushed pipe nor dirt or foreign mat-
ter remaining in the pipes.
3)Connect the pipes securely so as to ensure no oil leak from joints.
Intake system
1)Check no foreign matter or dirt in the intake line.
2)Connect securely to prevent any air leak from joints with the intake duct and air cleaner.
Exhaust system
1)Check no dirt or foreign matter in the exhaust system.
2)Since heat resistant steel is used for the bolts and nuts, do not use general bolts and nuts for installation.
Always apply anti-seizure agent on fastening bolts and nuts to be tightened.
(Use heat-resistant hexagon bolts for the turbine housing.)
3)Connect exhaust pipes securely to prevent gas leak from each pipe joint.

140
8. TURBOCHARGER

8.8 Troubleshooting
Sufficient turbocharger performance and required engine output cannot be obtained if there is any fault. In
such a case, first check each engine part to see there is no engine fault. Then inspect the turbocharger for
troubleshooting according to the procedure shown below.

8.8.1 Excessively exhaust smoke

(1) Insufficient intake air volume
Cause Corrective action
1)Clogged air cleaner element •Replace or wash the element.
2)Blocked air intake port •Correct to the normal state.
3)Leak from a joint in intake line •Inspect and repair.

(2) Turbocharger revolution failure

Cause Corrective action
1)Deposit of impurities in oil sticking on the turbine •Turbocharger overhaul (disassembly and washing)
side seal portion to make turbine revolution heavy with lubricating oil replacement

2)Sticking bearing •Turbocharger overhaul (disassembly and repair)

•Insufficient lubrication or clogged lubrication piping
•Excessively high oil temperature
•Unbalanced rotating part
•Insufficient warming up or sudden stoop from loaded
operation (no-load operation)
•Lubricating oil line inspection, repair of defective
portion and lubricating oil replacement
•Rotating part replacement or washing
•Strict observance of instructions in operation man-
ual

3)Contact or breakdown of turbine wheel or blower •Inspection and repair of each engine part
vane •Perfect foreign matter elimination in disassembled
•Excessive revolution state, followed by inspection and repair of individual
•Excessive exhaust temperature rise air cleaner and engine components
•Foreign matter invasion •Turbocharger overhaul (disassembly and repair)
•worn bearing •Reassembly
•Assembly defect

(3) Influence of exhaust resistance

Cause Corrective action
1)Exhaust gas leak before the turbocharger to •Joint inspection and correction
decrease its revolutions
2)Deformed or clogged exhaust pipe to decrease tur- •Correct to the normal state.
bocharger revolutions

8.8.2 White smoke generation

Cause Corrective action
1)Clogged or deformed oil return pipe causing oil flow •Repair or pipe replacement
to the blower or turbine side
2)Excessive bearing wear causing abnormal wear or •Turbocharger disassembly and repair
damage of seal ring

141
 8. TURBOCHARGER

8.8.3 Sudden oil decrease

Cause Corrective action
1)Excessive bearing wear causing abnormal wear or •Turbocharger disassembly and repair
damage of seal ring

8.8.4 Decrease in output

Cause
1) Gas leak from any part in exhaust piping
2)Air leak from discharge side of blower
3)Clogged air cleaner element
4)Fouled or damaged turbocharger
Corrective action
•Inspection and repair of defective portion
•Element cleaning or replacement
•Turbocharger disassembly and repair or replace-
ment

8.8.5 Poor (slow) response (starting) of turbocharger

Cause Corrective action
1)Hard carbon deposit on the turbine side (wheel seal- •Turbocharger disassembly and washing with lubri-
ing portion) to make turbine shaft revolution heavy cating oil replacement

2)Incomplete combustion •Engine combustion state inspection, followed by

improvement of combustion to normal state

8.8.6 Abnormal sound or vibration

(1) Abnormal sound generation
Cause Corrective action
1)Excessively narrowed gas path due to clogged noz- •Turbocharger disassembly and washing
zle in turbine wheel chamber or reverse flow of
blower discharge in acceleration (generally called
surging)
2)Contact rotating part •Turbocharger disassembly and repair or replace-
ment

(2) Vibration
Cause
1)Loosened intake, exhaust or oil pipe connection with
the turbocharger
2) Damaged bearing, contact between rotating part and
adjacent part, or chipping of turbine wheel or blower
vane due to foreign matter in version
3) Unbalanced rotating part
Corrective action
•Turbocharger installation status check and repair of
defective portion
•Turbocharger disassembly with repair or replace-
ment, or perfect removal of foreign matters in case
of foreign matter invasion
•Repair or replacement of rotating part

142
9. Starting motror

9. Starting motror
As a representative example of starter, the one for 4TNV94L98 and 4TNV106 (T) is shown in this chapter.

9.1 For 4TNV94L/ 98

9.1.1 Specifications

Manufacturer’s model (Hitachi) - S13-204 S13-205

Yanmar code - 129900-77010 129900-77020
Nominal output kW 2.3 ←
Weight kg 5.5 ←
Revolution direction (as viewed from pinion) - Clockwise ←
Engagement system - Magnetic shift ←
No-load Terminal voltage/current V/A 11/140 or less ←
Revolution rpm 4100 or above ←
Loaded Terminal voltage/current V/A 2.5/1050 or less ←
Torque N•m (kgf•m) 24.5 (2.5) or above ←
Clutch system - Overrunning ←
Pinion projection voltage (at 100 °C) V 8.6 or less ←
Pinion DP or module/number of teeth - M3/9 ←
difference (O-ring, oil seal) - Dry (none) Wet (with)
Application - Standard Option

143
 Magnetic switch
9.1.2 Components

Field coil Shift lever

Gear case

Brush

Oil seal

144
Pinion shaft
Through bolt

Rear cover Armature

Clutch Assy Bearing retainer

O-ring
9. Starting motror
 NO Set the shift lever at Are the battery charge and NO ٨Charge or replace the battery
Is the shift lever at terminal connection normal ٨Connect the battery terminal and
the neutral position? the neutral position
without any corrosion? repair corrosion.

YES
Engine starting failure? Inspect the wiring up to the magnetic
9. Starting motror

Is the starting motor switch and repair if necessary.

NO ٨Key switch
magnetic switch actuating
YES ٨Safety relay
sound head?
٨Magnetic switch
٨Connection state
Can the engine be NO Is the starting motor NO
cranked? sound heard? YES
9.1.3 Troubleshooting

YES ٨Adjust / dimension.

Pinion and ring gear
meshing normal?
YES
YES
Pinion roller clutch damage,
inspection and replacement
Reduction gear damage,
inspection and replacement
NO
Connect the M terminal of
the individual starting motor
with the battery. Does the
motor run?
٨Inspect the shift lever for deformation,
the return spring for fatigue and the
pinion for sliding.
٨Repair meshing between pinion and
ring gear or replace as needed..
٨Inspect the brush and replace if worn.
NO
٨If
brushes are not worn, replace the
motor (yoke assy or armature).

145
YES

Magnetic switch con- ψWhen the starting motor is wetted with water,
tact defect. Replace it. always replace the magnetic switch even if the
function is normal.
NO
(slow revolution) Are the battery charge
and terminal connection NO For an abnormality (Immediately disconnect the
Is the revolution normal? ̪
normal without any battery negative terminal.)
corrosion?

YES YES

Inspect the fuel systems Is the Lube oil NO The motor does not stop
Replace the Lube oil.
viscosity normal? even when the key switch is
turned OFF.
YES
Does the engine run
when the starting motor YES Repair or replace the Repair or replace the key switch, starting
is replaced with a starting motor. motor relay or magnetic switch.
new one?

Slow revolution

Inspection Causes and Inspect the inside of

item remedies the engine.
 9. Starting motror

9.1.4 Names of parts and disassembly procedure

(1) Disassembling order
1)Nut M8 (Disconnect the connecting wire.)  See the disassembly drawing.
2)Screw M4 (2)
3)Through bolt M5 (2)
4)Rear cover
5)Brush holder
6)Yoke assy.
7)Armature
8)Bolt M6 (2)
9)Magnetic switch
10)Dust cover
11)Shift lever
12)Screw M4 (3)
13)Bearing retainer
14)Gear case
15)Pinion stopper clip
16)Pinion stopper
17)Return spring
18)Pinion shaft
19)Clutch assy.
Disassembly drawing

14 12
8
10
1

11 3

15
16
17
19
13 2
18
4
5

146
9. Starting motror

(2) Disassembly procedure

1)Nut M8
1
Remove the magnetic switch nut M8 (12 mm), and
disconnect the connecting wire.

Connecting wire

Fig. 1

2)Screw M4 (2)

3)Through bolt M5 (2) 3

4)Rear cover
Remove the M4 screw fastening the brush holder
and remove through bolt M5 for rear cover removal.
2

4
Fig. 2

5)Brush holder
Pull the brush spring up with the brush spring puller.
On the negative (-) side, bring the brush spring into
contact with the side of the brush for lifting from the
commutator surface. On the positive (+) side, extract
the brush from the brush holder.

Fig. 3

147
 9. Starting motror

6)Yoke Assy.
5

7)Armature
Remove the brush holder. The armature and yoke
assy can now be removed.

7
Fig. 4

8)Bolt M6 (2)
9

9)Magnetic switch 8
Remove bolt M6 (10 mm), and the magnetic switch
can be removed.

Fig. 5

10)Dust cover

11)Shift lever 10
Take the dust cover out from the gear case. The shift
lever can be removed.

11
Fig. 6

148
9. Starting motror

12)Screw M4 (3)

13)Bearing retainer 14

14)Gear case 19
Remove screw M4, and the bearing retainer and
clutch assy can be removed.
12

13
Fig. 7

15)Pinion stopper clip

Pinion stopper clip 15
Remove the bearing retainer at the edge and the
bearing, and shift the pinion stopper toward the pin-
ion. Use a plain screwdriver and pry to remove the
pinion stopper clip. Plain
( straight-edge
screwdriver )

Fig. 8

16)Pinion stopper
15 16 17 19

17)Return spring
18

18)Pinion shaft

19)Clutch Assy
Remove the pinion stopper clip. The pinion stopper, 13
return spring, pinion shaft and bearing retainer can
Fig. 9
be removed.

Disassembly is completed now.

149
 9. Starting motror

9.1.5 Inspection and maintenance

(1) Armature
(a)Commutator outside diameter
Measure the commutator outside diameter and replace
the commutator if the measured value is less than the
limit.
mm
Standard Limit
36.5 35.5 Fig. 10

(b)Armature coil continuity test

Multimeter
Check continuity between commutator segments with a
multimeter. Good if continuity exists.

In case of no continuity (coil disconnection), replace the

armature.

Fig. 11

(c)Armature coil insulation test

Multimeter
Inspect the continuity between a commutator segment
and the shaft or core with a multimeter. Good if no
continuity exists.

If continuity exists (coil short circuit), replace the

armature.

Fig. 12

150
9. Starting motror

(d)Armature and commutator run-out

Use a dial gage and measure the armature core run-out Armature
and commutator run-out. Correct or replace if the limit is Commutator

exceeded.

mm
Standard Limit
Armature 0.03 0.2
Commutator 0.03 0.2
Fig. 13

(e)Commutator surface inspection

If the commutator surface is roughened, grind with #500
to #600 emery cloth.

Fig. 14

(f)Commutator insulation depth

Measure the depth of the insulating material between
Hack-saw
commutator segments, and correct it if it is less than the
limit.
Commutator

mm Commutator Insulating Commutator

segment material 0.5㨪0.8mm
Standard Limit
0.5 to 0.8 0.2

Abnormal Normal
Fig. 15

151
 9. Starting motror

(2) Field coil

(a)Field coil continuity test
Check continuity between field coil terminals. Good if Multimeter
continuity exists.

If no continuity (coil disconnection), replace the field coil.

Fig. 16

(b)Field coil insulation test

Check continuity between field coil terminal and yoke. Multimeter
Good if no continuity exists.

If continuity exists (coil short circuit), replace the

armature.

Fig. 17

(3) Brush
Measure the length of the brush. Replace with a good
one if the length is less than the limit.

mm
Standard Limit
15 9 Brush

Fig. 18

152
9. Starting motror

(4) Brush holder

(a)Brush holder insulation test
Check the continuity between the brush holder (+ side)
and base (- side) with a multimeter. Good if no continuity
exists.

If continuity exists (insulation defect), replace the brush

holder.
Multimeter

Fig. 19

(b)Brush spring inspection

Inspect the brush spring pressure.
N (kgf)
Standard spring force
31 to 39 (3.1 to 3.9)

Fig. 20

(5) Magnetic switch

When the starting motor is wetted with water, always
replace the magnetic switch with a new even if the
function is normal.
(a)Shunt coil continuity test Multimeter
Check the continuity between the S terminal and the
switch body. Good if continuity exists.

If no continuity (coil disconnection), replace the

magnetic switch.

Fig. 21

153
 9. Starting motror

(b)Series coil continuity test

Check continuity between the S and M terminals.
Good if continuity exists.

If no continuity (coil disconnection), replace the

magnetic switch. Multimeter

Fig. 22

(c)Contact continuity test

Depress the magnetic switch with the plunger at the Multimeter
bottom. Check continuity between the B and M terminals
with a multimeter. Good if continuity exists.

If no continuity (coil continuity defect), replace the

magnetic switch.

Fig. 23

(6) Pinion clutch

(a)Pinion inspection
Manually rotate the pinion. Inspect if it is rotated
smoothly in the driving direction, and is locked in the
opposite direction. Replace the pinion clutch if abnormal.

Fig. 24

154
9. Starting motror

(b)Pinion sliding inspection

Check if the pinion slide smoothly in the axial direction.
If damaged, rusted or heavy in sliding, repair it.
If grease is applied too much on the pinion shaft, sliding
becomes heavy.

Fig. 25

(c)Ball bearing inspection

Rotate the ball bearing while holding the outer race with
fingertips. Inspect if it is sticking or it there is play.

Fig. 26

9.1.6 Service standards

Spring force N (kgf) 35 (3.6)

Brush
Standard height/wear limit mm 15/9
Magnetic switch resistance, series coil/shunt coil (at 20°C) Ω 0.27/0.60
Standard diameter/limit diameter mm 36.5/35.5
Difference between maximum
Commutator Repair limit/repair accuracy mm 0.2/0.03
and minimum diameter
Mica undercut depth chips Repair limit/repair accuracy mm 0.2/0.5 to 0.8
Armature fount - 6903DDU
Armature rear - 608DDU
Bearing type Nominal number
Pinion front - 60004DDU
Pinion rear - 6904DDU
L dimension (pinion projection length) mm 0.3-1.5

155
 9. Starting motror

9.1.7 Assembly
The assembly procedure is the reverse of the
disassembly procedure, but pay attention to the
following points:
(1) Grease application points
• Gears in the gear case
• Shift lever operating portion
• Pinion sliding portion
• Magnetic switch plunger sliding portion
Use the specified grease as below table at all points.
Pinion and magnetic switch plunger sliding portions NPCFG-6A
Gears MALTEMP SRL
Shift lever operating portion ALBANIA No.1

(2) Magnetic switch assembly

1)Install the shift lever on the magnetic switch with the
torsion spring in-between.

Fig. 27

2)For installation on the gear case, install the magnetic

switch with the shift lever on the gear case after pull-
ing the pinion out. Fix the magnetic switch by tight-
ening a built-in bolt M6. Do not forget to install the
dust cover (adjusting shim).

Fig. 28

156
9. Starting motror

(3) Pinion projection length

Connect the positive (+) lead from the battery to terminal S
S and negative (-) lead to terminal M. Turn the switch M
ON and measure the pinion moving distance L in the
thrust direction.
Perform this test within 10 seconds.
mm
l
Standard 0.3㨪1.5mm
Fig. 29
L 0.31.5

Note: Before measuring the dimension, pull the

pinion out lightly in the direction of the arrow.

If the measured L dimension is outside the standard

range, either insert or remove the dust cover (adjusting
shim 0.5 mm, 0.8 mm) for adjustment.

Dust cover
(adjusting shim:
0.5mm, 0.8mm)

Fig. 30

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 9. Starting motror

9.1.8 Characteristic test

Since the characteristics can be checked roughly by means of a simple no-load test as explained below.
NOTE: Complete the test quickly since the rating of the starting motor is 30 seconds.

(1) No-load test

Fix the starting motor on a test bench and connect wiring as shown in Fig.31. When the switch is closed, a
current flows in the starting motor, which is rotated at no-load. Measure the current, voltage and number of
revolutions then and check if they satisfy the specified characteristics.

SW

Ammeter
S

Voltmeter

Battery

Fig. 31

158
9. Starting motror

9.2 For 4TNV106 (T)

9.2.1 Specifications
Manufacturer’s model (Hitachi) - S13-138
Yanmar code - 129953-77010
Nominal voltage V 12
Nominal output kW 3.0
Rating Sec 30
Revolution direction (as viewed from pinion) - Clockwise
Clutch system - Roller clutch
Engagement system - Magnetic shift
Pinion: Module/number of teeth - M3/9
Weight kg 7.3
Pinion projection voltage (at 100) V 8 or less
Terminal voltage/current V/A 12/180 or less
No-load
Revolution rpm 3000 or more
Terminal voltage/current V/A 9/500
Loaded Torque N•m (kgf•m) 16.7 (1.7) or more
Revolution min-1 1270 or more

9.2.2 Congiguration drawing

Magnetic switch
Gear case

Shift lever

Pinion
Brush Gear shaft
O-ring
Ball bearing

Terminal, E Pinion stopper

Through bolt Needle bearing

Oil seal
Rear cover Armature Yoke Ball bearing

159
 Engine does not start.

NO NO Are the battery charge and NO ٨Charge or replace the battery

Can the engine be Does the starting motor terminal connection normal ٨Connect
cranked? the battery terminal or repair
revolve? without any corrosion? corrosion.

YES YES YES

Inspect the starting motor relay wiring
NO system and repair if necessary.
Does the starting motor ٨Key switch
relay operate? ٨Starting motor relay
9.2.3 Troubleshooting

Does the gear shift
revolve?
NO
Inspect the reduction gear
(armature, gear shaft) for
damage and replace if
necessary.
Inspect pinion
٨Connection state
YES roller clutch for YES
damage and
replace if necessary.
Is the starting motor NO ٨Inspect the wiring up to the magnetic
magnetic switch actuating  switch and repair if necessary.
sound heard?
YES
٨Adjust the dimension.
٨Inspect the shift lever for deformation,
Are pinion and ring gear NO the return spring for fatigue and the
engaging normally? pinion for sliding.
٨Repair engagement between pinion and

YES ring gear or replace as needed.

160
NO Does the motor ravolve ٨Inspect the brush and replace if worn.
when M terminal of NO
(slow ٨If brushes are not worn, replace the
revolution) starting motor is connected motor (yoke assy or armature).
to the battery?
Are the battery charge
and terminal connection NO
Is the revolution normal? ̪ YES
normal without any
corrosion?
Are pinion and ring gear
YES YES engaging normally?
Inspection Causes and
Inspect the ignition and item remedies
fuel systems. Is the engine oil NO
Replace the engine oil. Upon abnormality:
viscosity normal?
Immediately disconnect the battery negative terminal.

YES The motor does not stop

Does the engine run
when the starting motor
is replaced with a
new one?
NO
Inspect the inside of
the engine.
even when the key switch is
turned OFF.
YES Repair or replace the
starting motor.
Repair or replace the key switch, starting
motor relay or magnetic switch.
9. Starting motror
9. Starting motror

9.2.4 Component names and disassembly procedure

(1) Disassembly procedure
1)Disconnect the lead.
2)Remove the magnetic switch.
3)Remove the rear cover.
4)Remove the brush holder.
5)Disassemble the gear case and center bracket.
6)Remove the shift lever pin.
7)Remove the gear case dust cover.
8)Remove the pinion.

(2) Disassembly diagram

ԟ ԝ

Ԟ
Ԙ
Ԛ

161
 9. Starting motror

9.2.5 Disassembly procedure

(1) Disconnecting the lead
Loosen the M8 nut (12 mm) of the magnetic switch and disconnect the lead.

162
9. Starting motror

(2) Removal of magnetic switch

Remove the M6 bolts (10 mm × 2).

163
 9. Starting motror

(3) Removal of rear cover

Remove the brush holder tightening screws (4 mmø × 2) and the M5 through bolts (× 2).
Next, disconnect the rear cover from the yoke using a – screwdriver.

164
9. Starting motror

(4) Removal of brush holder

For the negative (–) brush, bring the brush spring into contact with the side of the brush for lifting from the
commutator surface.
For the positive (+) brush, extract the pull out the brush from the brush holder.
After the brush holder is removed, the armature and yoke can be disassembled.

165
 9. Starting motror

(5) Separating gear case from center bracket

Remove three M6 bolts (10 mm) fastening the gear case to the center bracket.
After removal of the M6 bolts, the center bracket and oil seal can be removed.

166
9. Starting motror

(6) Removal of shift lever pin

Remove the M6 nut (10 mm) and pull out the shift lever pin.
Now. the dustcover, shift lever, gear case and gear shaft can be removed.

167
 9. Starting motror

(7) Removal of gear case dust cover

Remove the two M5 bolts (using 4 mm hexagon wrench) to disassemble the dust cover from the gear case.

168
9. Starting motror

(8) Removal of pinion

Slide the pinion stopper towards the pinion and remove the pinion stopper clip using a – screwdriver.

169
 9. Starting motror

9.2.6 Inspection and maintenance

(1) Armature
1)Check the commutator for rough surface. If so, smooth the surface using #500 to #600 emery cloth.
If the outside periphery of the commutator has been deflected over 0.2 mm, repair by a lathe.

2)Measure the depth of the insulating material between commutator segments, and correct if it is less than
0.2 mm.

0.5㨪0.8 OO

Undercutmethod

170
9. Starting motror

3)Armature coil continuity and earth tests

Test type Measurement point Normal Abnormal (cause)

Continuity test Across commutator Yes None (open circuit)
Earth test Between commutator and shaft or armature None Yes (short-circuiting)

Replace if needed
.

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 9. Starting motror

(2) Field coil

1)Field coil continuity and earth tests

Test type Measurement point Normal Abnormal (cause)

Continuity test Across commutator Yes None (open circuit)
Earth test Between commutator and shaft or armature None Yes (short-circuiting)

Replace if needed
.

172
9. Starting motror

(3) Brush
1)Check wear of the brush and the brush spring force.

12
18
6 Limit

New Used

3.5 kg

2.9 kg

173
 9. Starting motror

2)Check of brush movement

If the brush does not move smoothly, inspect the brush holder for bending and the brush holder sliding
surface for dirt. Repair or clean as needed.

3)Check the continuity between the insulated brush holder (positive (+)) and the brush holder base (nega-
tive (-)).
If they are electrically continuous, replace since the holder is grounded.

174
9. Starting motror

(4) Magnetic switch continuity test

Test type Measurement point Normal Abnormal (cause)

Shunt coil Between C and ground Yes None (open circuit)
Series coil C and M None Yes (short-circuiting)

Replace if needed.
C

S13-138
Resistance (at 20°C)
B
Shunt coil 0.6
Series coil 0.218
M

175
 9. Starting motror

(5) Pinion
1)Check the pinion teeth for wear and damage. Replace with a new one, if necessary.
2)Check if the pinion slides smoothly. If it is damaged or rusted or does not slide smoothly, repair.
3)Check springs for damage, and replace if necessary.

(6) Ball bearing

If abnormalities such as irregular noises are detected to the ball bearing, replace with a new one.

9.2.7 Assembly
The assembly procedure is reverse of the disassembly procedure, but pay attention to the following points.

(1) Apply grease as instructed below.

Greasing point Grease type
Sliding portions and head of plunger
Pinion metal and metal portions of gear case
NPC-FC6A Grease
Spline portions of pinion
Sliding portions of shift lever
Deceleration gear MALTEMP SRL Grease

(2) Armature thrust

No adjustments are needed for the thrust.

(3) Gear shaft thrust

Some thrust washers of 1.0 and 0.25 mm thickness are provided between the center bracket and gear shaft
supporting surface. Make sure to check them at reassembly.
If washers are deformed or worn, replace them with new ones.
The appropriate thrust is from 0.05 to 0.3mm. If it is over 0.3mm, and the appropriate thrust washer, but pay
attention so that the thrust is not 0.

176
9. Starting motror

9.2.8 Adjustment

(1) Pinion projection length L by magnetic switch

Switch

Battery

Measure the pinion moving distance L (0.3 to 1.5 mm) in the thrust direction when the pinion is protruded by
the magnetic switch.
If the distance L is outside the standard range, adjust by the dust cover as shown below.

177
 9. Starting motror

Dust cover

9.2.9 Service standards

Spring force N (kgf) 31.4 (3.2)

Brush
Standard / Limit height 18/6
Standard 37
Outside diameter
Limit 36
Limit 0.2
Commutator Deflection
Correction accuracy 0.05
Limit 0.2
Depth of insulation mica
Correction accuracy 0.5 to 0.8
Front 25
Armature shaft diameter
Rear 12
Standard Gear shaft diameter 13.95 to 13.968
Bearing on gear case side
dimensions Hole diameter 14.00 to 14.018
Shaft diameter 13.95 to 13.968
Sliding portion of pinion
Hole diameter 14.03 to 14.05
Front 6905DDU
Ball bearing Armature
Rear 6001DDU
Length L (pinion projection length) 0.3 to 1.5

178
10. Alternator

10. Alternator
As a representative example of alternator, the alternator of 40A is shown in this chapter.

10.1 The 40A alternator for 3TNV84 and other models

10.1.1 Components
(1) Parts related to the alternator

(2) Alternator components of the disassembly and assembly

179
 10. Alternator

10.1.2 Specifications
Manufacturer’s model (Hitachi) - ACFA68
Yanmar code - 129423-77200
Rating - Continuous
Battery voltage V 12
Nominal output (13.5 V heat) A 40
Rated revolution min-1 5,000
Operating revolution min-1 1,350 to 18,000
Grounding characteristics - Minus side grounding
Direction of revolution (viewed from pulley) - Clockwise
Integrated regulator IC regulator
Weight kg 2.8
Pulley (outside diameter) mm 69.2
Belt shape - Type A

10.1.3 Wiring diagram

WIRING DIAGRAM

IG Key switch
IG P
B

PI P L
Charge lamp
F (Max. 3.4W)
IC
L
L L
O O
0.5ǴF

A B A
D Battery A D
E T

ALTERNATOR ASSY IC REGURATOR

[NOTICE]
1)Don't do miss-wiring and short-circuit of each terminal.
2)Don’t short-circuit between IG and L. (Connect it through the charge lamp.)
3)Don’t connect a load between L and E.
4)Don't remove a battery terminal and a B terminal when rotating.
5)Shut out a battery switch during the alternator stop.
6)Tightening torque of each terminal: 1.7-2.3 N•m (17-23 kgf•cm)

180
10. Alternator

10.1.4 Standard output characteristics

The standard output characteristics of this alternator are STANDAED CHAEACTERISTICS
13.5V CONSTANT
shown as the right figure. AMBIENT TEMP:25͠
60

Cold
50

Hot

OUTPUT CURRENT
40

30

20

(A)
10

0 1 2 3 4 5 6 7 8
ALTERNATOR SPEED (X103 min-1)

10.1.5 Inspection
(1) V belt inspection
Normal Defect
1)Inspect the matter whether there are not crack, stickiness
and wear on the belt visually.
Check that a belt doesn't touch the bottom part of the pul-
ley groove. If necessary, replace the V belt set.
2)V belt tension: Clearance
Push the center of the V belt and check the belt deflec-
tion. The V belt tension is normal if the deflection is within
the standard. If not, adjust the V belt tension by the alter- Inspection of V pulley
nator adjuster.
(Refer to 2.2.2 in Chapter 2.)

(2) Visual check of wiring and check of unusual sound

1)Confirm whether wiring is right or there is no looseness of the terminal part.
2)Confirm that there is no unusual sound from the alternator during the engine operation.

(3) Inspection of charge lamp circuit

1)Move a start switch to the position of on. Confirm lighting of the charge lamp.
2)Start an engine, and confirm the lights-out of the lamp. Repair a charge lamp circuit when a lamp doesn't
work.

181

Turn key switch to ON.
Does the charge lamp
come ON?
Ground L-terminal of the
OFF Disconnect GN coupler driven machine side coupler OFF
(L, IG). Replace the charge lamp
(L, IG)
Does the charge lamp
come ON? The charge lamp is available from
the driven machine manufacturer.

ON ON Inspect the rotor coil and

brush IC-RG
Turn the key switch to START.
(The engine starts.)
Inspect or replace the fan belt,
10.1.6 Troubleshooting

At idling ON and inspect the alternator

Does the charge lamp The lamp flashes

goes OFF? Inspect the diode ( + side)

The lamp is lit

OFF dimly
Increase the engine speed to
1500 rpm and turn the light
switch to ON.

182
Excessive voltage drop between
VB - VL > 0.5V BAT and batt ( + side) terminal
Does the charge lamp The lamp is lit Measure VB and VL at
come ON? dimly BAT L-terminal during
idling
VB - VL < 0.5V L-terminal defective conduction
Inspect the diode ( - side)
OFF

Measure VB at BAT terminal

with the engine running at VB > 15.5 Replace IC-RG
1500 rpm

VB = 13㨪15 Turn the light switch Does the charge lamp ON Inspect the auxiliary diode
to ON during idling come ON?

OFF
̪ Remarks Explanation on abbreviations: Not abnormal
1) Use a fully charged battery GN : Alternator
2) DC voltmeter: 0 to 30 V, 0.5 class IC-RG : IC regulator
3) The check method is also applicable to VB : BAT terminal voltage
the bench test VL :L-terminal voltage
10. Alternator
 11. Electric wiring

11. Electric wiring

11.1 Electric wiring diagram

183
 11. ELECTRIC WIRING

11.2 Precaution on electric wiring

11.2.1 Alternator
In the cases listed below the warranty shall not be deemed to apply. Please be sure to read these conditions
carefully when planning to use it with other equipment. Also be certain to give appropriate guidance on usage
to the user.

(1) When the battery cable can be connected backwards

The alternator diode will be damaged and recharging made impossible if the plus and minus ends of the
battery cable are confused. The stator coil will also be burned as a result. To prevent this, supply the user with
a cable of such a length or structure that the plus and minus ends cannot be confused. Also warn the user not
to connect the cable backwards.

(2) When charging output voltage is used for control purposes

The engine speed at starting is not proportional to the output voltage of the alternator, so this output voltage
must not be used for any control systems. It is especially wrong to use it for the control signal of the safety
relay for cutting the starter motor because this will damage the starter motor and cause engine starting failure.

(3) When the L line is used for control purposes

Consult with Yanmar first before connecting any load other than the charge lamp to the L line. Damage to the
alternator and related equipment will not be warranted without such prior consultation.

(4) Non-use of the Yanmar wiring diagram

Use without prior consultation of any wiring diagram other than that provided by Yanmar removes any
breakdown of any electrical equipment from the warranty.

(5) Regarding lamp control

Once the charge lamp goes out after the start of charging, it does not come on again even if the engine speed
falls and charging is insufficient. The lamp will not light again if the charging circuit is normal. The lamp only
comes on during operation if the alternator itself is broken or the drive V-belt breaks. However, when an LED
is used for the charge lamp, the LED will shine faintly even during normal operation. This is due to the control
system for the alternator lamp and is not an abnormality.

(6) Use of a non-specified V-belt

Use of a non-specified V-belt will cause inadequate charging and shorten the life of the belt. Use a belt of the
specified type.

(7) Direct high pressure washing is prohibited

Water will enter the brush if the alternator is washed directly at high pressure, causing inadequate charging.
Warn users not to use direct, high-pressure washing.

(8) Use of agricultural or other chemicals (direct contact or airborne)

Adhesion of agricultural and other chemicals, especially those with high sulfur content, to the IC regulator
corrodes the conductor on the substrate, leading to over-charging (battery boiling) and charging malfunctions.
Consult with Yanmar prior to use in such an environment. Use without prior consultation removes any
breakdown from the warranty.

184
11. ELECTRIC WIRING

11.2.2 Starter
In the cases listed below the warranty shall not be deemed to apply. Please be sure to read these conditions
carefully when planning to use it with other equipment. Also be certain to give appropriate guidance on usage
to the user.

(1) Starting performance in the case of using an untested battery

The starting performance of the engine is closely dependent on the battery capacity. This battery capacity is
itself affected by the climate and the type of equipment installation. The details regarding ambient temperature
and equipment installation vary depending on the OEM, so Yanmar cannot decide the battery capacity on its
own. Confer with Yanmar in advance after checking these conditions and fix the battery capacity on the basis
of confirmatory tests.

(2) When the resistance of the battery cable exceeds the specified value
The combined total resistance of the battery cable in both directions between the starting motor and battery
should be within the value indicated on the wiring diagram. The starting motor will malfunction or break down
if the resistance is higher than the specified value.

(3) When the resistance of the starter circuit exceeds the specified value
The combined total resistance of the wiring between the starting motor and key switch (or power relay or
safety relay, depending on the application) should be within the value indicated on the wiring diagram. Engine
starting will be difficult if the resistance is higher than the specified value. This can also cause welding of the
magnet switch at the point of contact and resultant burning of the armature coil.

(4) When there is no safety relay

Over-running (when the electric current flows for too long) is a major cause of starting failure. This burns the
armature coil and causes clutch failure. Excessive work and failure of the key switch to return properly are the
main causes of over-running. The user must be given sufficient warning about this.
Be sure to use the safety relay to prevent over-running. This safety relay is supplied as an option. Consult
Yanmar first when planning to install a safety relay at your own company. In the case of failure to consult with
Yanmar, our warranty will not be applied to all the electrical equipment.

(5) When there is too much rust due to the entry of water
The water-proofing of the starting motor is equivalent to R2 of JIS D 0203. This guarantees that there will be
no damage from the sort of exposure encountered in rain or when water is poured on from a bucket. You
should, however, avoid the use of high-pressure washing and steeping in water.

(6) Regarding the heat resistance of the starter motor

The starter motor has heat resistance for an ambient temperature of 80°C and surface temperature of 100°C.
Insulators must be installed to prevent overheating when used near high temperature parts such as the
exhaust system.

(7) Corrosion of magnet switch contact point by corrosive gas.

When using equipment with a dry clutch, ammonium gas generated by friction is liable to corrode the contact
of the magnet switch. Be sure to install a vent in the clutch case.

185
 11. ELECTRIC WIRING

11.2.3 Current limiter

In the cases listed below the warranty shall not be deemed to apply. Please be sure to read these conditions
carefully when planning to use it with other equipment. Also be certain to give appropriate guidance on usage
to the user.

(1) When an over-discharged battery is used

Use of booster starting with an over-discharged battery (when the voltage has dropped to 8 V or less) will
destroy other electrical equipment by generating an abnormally high voltage. A specialized battery charger
should be used to recharge such an over-discharged battery (when the voltage has dropped to 8 V or less).

(2) When checks for malfunctioning are not performed

When high voltage noise from other electrical equipment is impressed on the current limiter upon turning off
the key switch, the current limiter can be damaged and cause loss of control over the output voltage. Other
electrical equipment may also be damaged if this happens, so surge killers should be fitted to the electrical
equipment whenever necessary. Be sure to check prior to mass production whether electrical noise might
damage the current limiter by turning the key switch and other electrical equipment on and off while the
engine is running, using both the vehicle and the wire harness that will be used in mass production.

(3) Removal of the battery cable during operation

The current limiter may malfunction if the battery cable and/or battery are removed during operation,
depending on the kind of electrical equipment being used, causing loss of control over the output voltage. In
such cases, the current limiter and other electrical equipment will be damaged by the generation of a
continuous high voltage of 24-43 V (for 5,000 rpm dynamo). All electrical equipment falls outside the scope of
the warranty under these circumstances. Be sure to warn the user not to remove the battery cable and/or
battery during operation.

(4) If the battery cable can be attached in reverse

The current limiter’s SCR diode will be destroyed if the plus and minus ends of the battery cable are
connected the wrong way around. This causes charging malfunctioning and burns the harness. Give the user
a cable of such a length that it cannot be connected the wrong way and warn the user against connecting the
cable backwards.

(5) Non-use of the Yanmar wiring diagram

Use without prior consultation of any wiring diagram other than that provided by Yanmar removes any
breakdown of any electrical equipment from the warranty.

(6) Installation environment

Observe the following when installing the current limiter:
1)Do not install it on the engine.
2)Place it in a well-ventilated place with an ambient temperature of 65 °C or less.
3)Ensure that the cooling air flows in the right direction for the current limiter’s cooling fins.
4)Do not use the earth wire of the current limiter to earth any other electrical equipment.

186
11. ELECTRIC WIRING

11.2.4 Section area and resistance of electric wire

(1) Allowable maximum cable length （Terminal resistance is not included.）

Cable size Cable construction Resistance 2 mΩ Note1 20 mΩ Ref. 50 mΩ Note2

2 (Ω/m)
mm Element No. Cable dia. (m) (m) (m)
3 41 ø 0.32 0.005590 0.36 3.58 8.94
5 65 ø 0.32 0.003520 0.57 5.68 14.20
8 50 ø 0.45 0.002320 0.86 8.62 21.55
15 84 ø 0.45 0.001380 1.45 14.49 36.23
20 41 ø 0.80 0.000887 2.25 22.55 56.37
30 70 ø 0.80 0.000520 3.85 38.46 96.15
40 85 ø 0.80 0.000428 4.67 46.73 116.82
50 108 ø 0.80 0.000337 5.93 59.35 148.37
60 127 ø 0.80 0.000287 6.97 69.69 174.22
85 169 ø 0.80 0.000215 9.30 93.02 232.56
100 217 ø 0.80 0.000168 11.90 119.05 297.62
Note1) Allowable maximum resistance of Battery cable
Note2) Allowable maximum resistance of Starting motor circuit

(2) Terminal resistance

Generally, a terminal resistance is 15 mΩ per coupler and 0 Ω per screw setting. This resistance should be
included in allowable maximum resistance when the cable length is planned.

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 12. Service standards

12. Service standards

12.1 Engine tuning
Reference
No. Inspection item Standard Limit
page
Gap at intake/exhaust valve heads TNV82 to A98 0.15 to 0.25 -
1 2.2.6.(4)
mm 4TNV106(T) 0.25 to 0.35 -
Between alternator Used part 10 to 14 -
and crank pulley New part 8 to 12 -
V-belt tension
Between alternator Used part 7 to 10
2 mm 2.2.2.(2)
and radiator fan New part 5 to 8
at 98N (10 kgf)
Between radiator fan Used part 9 to 13
and crank pulley New part 7 to 11
3TNV82A to TNV88(VM) 21.57 to 22.55
Fuel injection
4TNV94L to 106(T) (220 to 230)
3 pressure - 2.2.6.(3)
19.6 to 20.6
MPa (kgf/cm2) 3TNV82A to TNV88(CL)
(200 to 210)
Compression TNV82A 3.16 (31) ± 0.1 (1) 2.45(25) ± 0.1(1)
pressure TNV84 3.24 (33) ± 0.1 (1) 2.55(26) ± 0.1(1)
4 3.3
(at 250 min-1) 3/4TNV84T 2.94 (30) ± 0.1 (1) 2.45(25) ± 0.1(1)
MPa (kgf/cm2) TNV88-106 3.43 (35) ± 0.1 (1) 2.75(28) ± 0.1(1)
Coolant water 3TNV82A, 84 1.8 -
Capacity 3TNV84T, 88 2.0 -
5 (Only engine 4TNV84(T), 88 2.7 - 2.2.1.(4)
body) 4TNV94L•98(T) 4.2 -
(Liter) 4TNV106(T) 6.0 -
- Full Effective -
3TNV82A 5.5 1.9 -
Lubricating oil 3TNV84(T)/88 6.7 2.8 -
capacity
6 4TNV84(T)/88 7.4 3.4 - 2.2.1.(3)
(oil pan)
4TNV94L/98(T) 10.5 4.5 -
(Liter)
4TNV106(T)(CL class) 14.0 9.0 -
4TNV106(T)(VM class) 14.0 7.5 -
- at rated speed at low idle speed -
3TNV82A to 98 0.29(3.0) to 0.39(4.0)
4TNV98T
Lubricating oil 4TNV106(T) 0.39(4.0) to 0.49(5.0)
7 pressure (VM, WO balancer) 0.06 (0.6)
-
MPa (kgf/cm2) 4TNV106(T) or above
0.31(3.2) to 0.49(5.0)
(CL, WO balancer)
4TNV106(T)
0.34(3.5) to 0.44(4.5)
(VM, W balancer)
Oil pressure switch operating pressure 0.05 ± 0.01
8 - -
MPa (kgf/cm2) (0.5 ± 0.1)
valve opening Full opening lift
temperature (mm)
deg. C (temperature)
9 Thermostat 8 or above 2.7
All models 69.5 to 72.5
(85 deg.C)
All models 10 or above
80 to 84
option (95 deg.C)
10 Thermo switch actuating temperature (deg.C) 107 to 113 - 2.4.2

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12. Service standards

12.2 Engine body

12.2.1 Cylinder head

(1) Cylinder head

Inspection item Standard Limit Reference page
Combustion surface distortion mm 0.05 or less 0.15
3TNV82A Intake 0.35 to 0.55 0.8
(2-valve head) Exhaust 0.30 to 0.50 0.8
TNV84 to 88 Intake 0.30 to 0.50 0.8
(2-valve head)
Valve sink 4TNV84T(4-valve) Exhaust 0.30 to 0.50 0.8 4.2.5.(1)
mm
4TNV94L•98(T) Intake 0.36 to 0.56 0.8
(4-valve head) Exhaust 0.35 to 0.55 0.8
4TNV106(T) Intake 0.5 to 0.7 1.0
(4-valve head) Exhaust 0.7 to 0.9 1.2
Intake 120 -
Valve seat Seat angle Deg.
Exhaust 90 - 4.2.6.
(2-valve, 4-valve)
Seat correction angle deg. 40, 150 -

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 12. Service standards

(2) Intake/exhaust valve and guide

mm
Reference
Inspection item Standard Limit
page
Guide inside diameter 7.000 to 7.015 7.08
Intake Valve stem outside diameter 6.945 to 6.960 6.90
3TNV82A Clearance 0.040 to 0.070 0.18
(2-valve head) Guide inside diameter 7.000 to 7.015 7.08
Exhaust Valve stem outside diameter 6.940 to 6.955 6.90
Clearance 0.045 to 0.075 0.18
Guide inside diameter 8.010 to 8.025 8.10
Intake Valve stem outside diameter 7.955 to 7.975 7.90
4TNV84
3TNV84(T) Clearance 0.035 to 0.070 0.18
3/4TNV88 Guide inside diameter 8.015 to 8.030 8.10
(2-valve head)
Exhaust Valve stem outside diameter 7.955 to 7.960 7.90
Clearance 0.045 to 0.075 0.18
Guide inside diameter 6.000 to 6.015 6.08
Intake Valve stem outside diameter 5.960 to 5.975 5.90
4TNV84T Clearance 0.025 to 0.055 0.15
4.2.5.(2)
(4-valve head) Guide inside diameter 6.000 to 6.015 6.08
Exhaust Valve stem outside diameter 5.945 to 5.960 5.90
Clearance 0.040 to 0.070 0.17
Guide inside diameter 7.000 to 7.015 7.08
Intake Valve stem outside diameter 6.945 to 6.960 6.90
4TNV94L Clearance 0.040 to 0.070 0.17
4TNV98(T)
(4-valve head) Guide inside diameter 7.000 to 7.015 7.08
Exhaust Valve stem outside diameter 6.940 to 6.955 6.90
Clearance 0.045 to 0.075 0.17
Guide inside diameter 7.008 to 7.020 7.08
Intake Valve stem outside diameter 6.945 to 6.960 6.92
4TNV106(T) Clearance 0.048 to 0.075 0.16
(4-valve head) Guide inside diameter 7.008 to 7.020 7.08
Exhaust Valve stem outside diameter 6.960 to 6.975 6.90
Clearance 0.033 to 0.060 0.18
3TNV82A 11.7 to 12.0 -
4TNV84, 3TNV84(T), 4TNV88 14.71 to 5.0 -
Valve guide projection
4TNV84T 8.2 to 8.5 -
from cylinder head 4.2.7.
4TNV94L, 4TNV98(T) 9.7 to 10.0 -
4TNV106(T) 13.4 to 13.6 -
Valve guide driving-in method Cold-fitted -

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12. Service standards

(3) Valve spring

mm
Reference
Inspection item Standard Limit
page
3TNV82A(2-valve) 44.4 43.9
4TNV84,3TNV84(T), 4TNV88(2-valve) 42.0 41.5
Free length 4TNV84T(4-valve) 37.4 36.9
4TNV94L, 4TNV98(T),(4-valve) 39.7 39.2
4TNV106(T)(4-valve) 50.6 50.1
4.2.5.(4)
3TNV82A(2-valve) - 1.4
4TNV84, 3TNV84(T), 4TNV88(2-valve) - 1.4
Inclination 4TNV84T(4-valve) - 1.3
4TNV94L, 4TNV98(T), (4-valve) - 1.4
4TNV106(T)(4-valve) - 1.5

(4) Rocker arm and shaft

mm
Reference
Model Inspection item Standard Limit
page
Arm shaft hole diameter 16.000 to 16.020 16.07
TNV82A to 88 Shaft outside diameter 15.966 to 15.984 15.94
Clearance 0.016 to 0.054 0.13
4.2.5.(5)
Arm shaft hole diameter 18.500 to 18.520 18.57
4TNV94L/98(T)/106(T) Shaft outside diameter 18.470 to 18.490 18.44
Clearance 0.010 to 0.050 0.13

(5) Push rod

mm
Inspection item Standard Limit Reference page
Bend Less than 0.03 0.03 4.2.5.(7)

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 12. Service standards

12.2.2 Gear train and camshaft

(1) Camshaft
mm
Reference
Inspection item Standard Limit
page
Side gap 0.05 to 0.20 0.30 4.3.4
Bending (1/2 the dial gage reading) 0 to 0.02 0.05
3TNV82A-TNV88 38.600 to 38.800 38.350
4.3.5.(1)
Cam height 4TNV94L•98 43.400 to 43.600 43.150
4TNV106(T) 50.900 to 51.100 50.650
Shaft outside diameter / Metal inside diameter
Bushing inside diameter 44.990 to 45.055 45.130
Gear side Camshaft outside diameter 44.925 to 44.950 44.890
Clearance 0.040 to 0.130 0.240
Bushing inside diameter 45.000 to 45.025 45.100
TNV82A to TNV88 Intermediate Camshaft outside diameter 44.910 to 44.935 44.875
Clearance 0.065 to 0.115 0.225
Bushing inside diameter 45.000 to 45.025 45.100
Wheel side Camshaft outside diameter 44.925 to 44.950 44.890
Clearance 0.050 to 0.100 0.210
Bushing inside diameter 49.990 to 50.055 50.130
Gear side Camshaft outside diameter 49.925 to 49.950 49.890
Clearance 0.040 to 0.130 0.240
Bushing inside diameter 50.000 to 50.025 50.100
4TNV94L/98(T) Intermediate Camshaft outside diameter 49.910 to 49.935 49.875 4.3.5.(1)
Clearance 0.065 to 0.115 0.225
Bushing inside diameter 50.000 to 50.025 50.100
Wheel side Camshaft outside diameter 49.925 to 49.950 49.890
Clearance 0.05 to 0.100 0.210
Bushing inside diameter 57.980 to 58.050 58.105
Gear side Camshaft outside diameter 57.910 to 57.940 57.875
Clearance 0.040 to 0.140 0.250
Bushing inside diameter 58.000 to 58.030 58.105
4TNV106(T) Intermediate Camshaft outside diameter 57.895 to 57.925 57.860
Clearance 0.075 to 0.135 0.245
Bushing inside diameter 58.000 to 58.030 58.105
Wheel side Camshaft outside diameter 57.910 to 57.940 57.875
Clearance 0.050 to 0.120 0.230

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12. Service standards

(2) Idle gear shaft and bushing

mm
Inspection item Standard Limit Reference page
Shaft outside diameter 45.950 to 45.975 45.900
Bushing inside diameter 46.000 to 46.025 46.075 4.3.5.(2)
Clearance 0.025 to 0.075 0.175

(3) Backlash of each gear

mm
Reference
Model Inspection item Standard Limit
page
3TNV82A
Crank gear, cam gear, idle gear,
3/4TNV84(T) 0.07 to 0.15 0.17
fuel injection pump gear and PTO gear
3/4TNV88
Crank gear, cam gear, idle gear,
0.08 to 0.14 0.16 4.3.4.
fuel injection pump gear and PTO gear
4TNV94L
4TNV98(T) Lubricating oil pump gear 0.09 to 0.15 0.17
4TNV106(T) Balancer drive gear
0.12 to 0.18 0.20
(only for 4TNV106(T))

12.2.3 Cylinder block

(1) Cylinder block

mm
Reference
Inspection item Standard Limit
page
3TNV82A 82.000 to 82.030 82.200
3/4TNV84(T) 84.000 to 84.030 84.200
3/4TNV88 88.000 to 88.030 88.200
Cylinder inside diameter
4TNV94L 94.000 to 94.030 94.130
4.4.5.(1)
4TNV98 98.000 to 98.030 98.130
4TNV106(T) 106.000 to 106.030 106.130
Roundness
Cylinder bore 0.01 or less 0.03
Inclination

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 12. Service standards

(2) Crankshaft
mm
Reference
Inspection item Standard Limit
page
Bending (1/2 the dial gauge reading) - 0.02
Pin outside diameter 42.952 to 42.962 42.902
Metal inside diameter 43.000 to 43.042 -
3TNV82A
Metal thickness 1.487 to 1.500 -
Clearance 0.038 to 0.090 0.150
Pin outside diameter 47.952 to 47.962 47.902
Metal inside diameter 48.000 to 48.026 -
TNV84 to 88
Metal thickness 1.492 to 1.500 -
Clearance 0.038 to 0.074 0.150
Crank pin
Pin outside diameter 57.952 to 57.962 57.902
Metal inside diameter 58.000 to 58.026 -
4TNV94L•98
Metal thickness 1.492 to 1.500 -
Clearance 0.038 to 0.074 0.150
Pin outside diameter 63.952 to 63.962 63.902
Metal inside diameter 64.016 to 64.042 -
4TNV106(T)
Metal thickness 1.984 to 1.992 -
Clearance 0.054 to 0.090 0.150 4.4.5.(2)
Journal outside diameter 46.952 to 46.962 46.902
Metal inside diameter 47.000 to 47.032 -
3TNV82A
Metal thickness 1.987 to 2.000 -
Clearance 0.038 to 0.080 0.150
Journal outside diameter 53.952 to 53.962 53.902
TNV84 to 88 Metal inside diameter 54.000 to 54.020 -

Selective pairing Metal thickness 1.995 to 1.990 -

Clearance 0.038 to 0.068 0.150
Crank journal
Journal outside diameter 64.952 to 64.962 64.902
4TNV94L•98 Metal inside diameter 65.000 to 65.020 -

Selective pairing Metal thickness 1.995 to 2.010 -

Clearance 0.038 to 0.068 0.150
Journal outside diameter 75.952 to 75.962 75.902
4TNV106(T) Metal inside diameter 76.014 to 76.034 -

Selective pairing Metal thickness 2.488 to 2.503 -

Clearance 0.052 to 0.082 0.150

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12. Service standards

(3) Thrust bearing

mm
Inspection item Standard Limit Reference page
Crankshaft side gap All models 0.13 to 0.23 0.28 4.4.4

(4) Piston and ring

Piston
mm
Reference
Inspection item Standard Limit
page
3TNV82A 81.950 to 81.980 81.905
3,4TNV84(T) 83.940 to 83.970 83.895
Piston outside diameter 3,4TNV88 87.940 to 87.970 87.895
(Measure in the direction
vertical to the piston pin.) 4TNV94L 93.935 to 93.965 93.900
4TNV98(T) 97.930 to 97.960 97.895
4TNV106(T) 105.930 to 105.960 105.880
3TNV82A 16 -
3,4TNV84(T) 24 -
Piston diameter
measure position 3,4TNV88 24 -
(Upward from the bottom 4TNV94L 22 -
end of the piston)
4TNV98(T) 22 -
4TNV106(T) 30 -
4.4.5.(4)
Hole inside diameter 23.000 to 23.009 23.039
3TNV82A Pin outside diameter 22.995 to 23.000 22.965
Clearance 0.000 to 0.014 0.074
Hole inside diameter 26.000 to 26.009 26.039
3,4TNV84(T)
Pin outside diameter 25.995 to 26.000 25.965
3,4TNV88
Clearance 0.000 to 0.014 0.074
Piston pin
Hole inside diameter 30.000 to 30.009 30.039
4TNV94L•98 Pin outside diameter 29.989 to 30.000 29.959
Clearance 0.000 to 0.020 0.080
Hole inside diameter 37.000 to 37.011 37.039
4TNV106(T) Pin outside diameter 36.989 to 37.000 36.959
Clearance 0.000 to 0.022 0.080

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 12. Service standards

Piston ring
mm
Reference
Model Inspection item Standard limit
page
Ring groove width 2.065 to 2.080 -
Ring width 1.970 to 1.990 1.950
Top ring
Side clearance 0.075 to 0.110 -
End clearance 0.200 to 0.400 0.490
Ring groove width 2.035 to 2.050 2.150
3TNV82A Ring width 1.970 to 1.990 1.950
Second ring
TNV84 Side clearance 0.045 to 0.080 0.200
End clearance 0.200 to 0.400 0.490
Ring groove width 4.015 to 4.030 4.130
Ring width 3.970 to 3.990 3.950
Oil ring
Side clearance 0.025 to 0.060 0.180
End clearance 0.200 to 0.400 0.490
Ring groove width 2.060 to 2.075 -
Ring width 1.970 to 1.990 1.950
Top ring
Side clearance 0.070 to 0.105 -
End clearance 0.200 to 0.400 0.490
Ring groove width 2.025 to 2.040 2.140
Ring width 1.970 to 1.990 1.950
TNV88 Second ring
Side clearance 0.035 to 0.070 0.190
End clearance 0.200 to 0.400 0.490
Ring groove width 4.015 to 4.030 4.130
Ring width 3.970 to 3.990 3.950
Oil ring
Side clearance 0.025 to 0.060 0.180
End clearance 0.200 to 0.400 0.490
4.4.5.(4)
Ring groove width 2.040 to 2.060 -
Ring width 1.940 to 1.960 1.920
Top ring
Side clearance 0.080 to 0.120 -
End clearance 0.250 to 0.450 0.540
Ring groove width 2.080 to 2.095 2.195
Ring width 1.970 to 1.990 1.950
4TNV94L/98 Second ring
Side clearance 0.090 to 0.125 0.245
End clearance 0.450 to 0.650 0.730
Ring groove width 3.015 to 3.030 3.130
Ring width 2.970 to 2.990 2.950
Oil ring
Side clearance 0.025 to 0.060 0.180
End clearance 0.250 to 0.450 0.550
Ring groove width 2.520 to 2.540 -
Ring width 2.440 to 2.460 2.420
Top ring
Side clearance 0.060 to 0.100 -
End clearance 0.300 to 0.450 0.540
Ring groove width 2.070 to 2.085 2.185
Ring width 1.970 to 1.990 1.950
4TNV106(T) Second ring
Side clearance 0.080 to 0.115 0.235
End clearance 0.450 to 0.600 0.680
Ring groove width 3.015 to 3.030 3.130
Ring width 2.970 to 2.990 2.950
Oil ring
Side clearance 0.025 to 0.060 0.180
End clearance 0.300 to -0.500 0.600

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12. Service standards

(5) Connecting rod

mm
Inspection item Standard Limit Reference page
Thrust clearance 0.2 to 0.4 - 4.4.4

Rod small end mm

Reference
Model Item Standard Limit
page
Bushing inside diameter 23.025 to 23.038 23.068
3TNV82A Pin outside diameter 22.995 to 23.000 22.967
Clearance 0.025 to 0.043 0.101
Bushing inside diameter 26.025 to 26.038 26.068
TNV84-88 Pin outside diameter 25.995 to 26.000 25.967
Clearance 0.025 to 0.043 0.101
4.4.5.(5)
Bushing inside diameter 30.025 to 30.038 30.068
4TNV94L/98 Pin outside diameter 29.987 to 30.000 29.959
Clearance 0.025 to 0.051 0.109
Bushing inside diameter 37.025 to 37.038 37.068
4TNV106(T) Pin outside diameter 36.989 to 37.000 36.961
Clearance 0.025 to 0.049 0.107

(6) Tappet
mm
Reference
Inspection item Standard Limit
page
Tappet hole (block) inside diameter 12.000 to 12.025 12.045
TNV82A-88 Tappet stem outside diameter 11.975 to 11.990 11.955
Clearance 0.010 to 0.050 0.090
Tappet hole (block) inside diameter 12.000 to 12.018 12.038
4TNV94L•98 Tappet stem outside diameter 11.975 to 11.990 11.955 4.4.5.(6)
Clearance 0.010 to 0.043 0.083
Tappet hole (block) inside diameter 14.000 to 14.018 14.038
4TNV106(T) Tappet stem outside diameter 13.966 to 13.984 13.946
Clearance 0.015 to 0.052 0.092

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 12. Service standards

12.3 Lubricating oil system (Trochoid pump)

(1) Outside clearance of outer rotor
mm
Model Standard Limit Reference page
3TNV82A to 88 0.12 to 0.21 0.30
4TNV94L/98 0.100 to 0.155 0.25 5.5.1.(1)
4TNV106(T) 0.100 to 0.165 0.25

(2) Side clearance of outer rotor

mm
Model Standard Limit Reference page
3TNV82A to 88 0.02 to 0.07 0.12
4TNV94L/98 0.05 to 0.10 0.15 5.5.1.(1)
4TNV106(T) 0.03 to 0.12 0.17

(3) Tip clearance between outer rotor and inner rotor

Insert a gap gage between an outer rotor and an inner rotor, and measure the tip clearance.
Tip clearance mm
Standard Limit
- 0.16

(4) Inside clearance of inner rotor

mm
Reference
Item Parts Standard Standard Limit
page
Inside clearance Gear boss diameter 53.05 to 53.15
0.3 to 0.5 0.6
of inner rotor Rotor diameter 53.45 to 53.55
Width across flat of 5.5.1.(2)
49.45 to 49.75
Width across flat Gear boss
0.2 to 0.6 0.7
clearance of inner rotor Width across flat of
49.95 to 50.05
rotor

(5) Rotor shaft clearance

mm
Reference
Model Inspection item Standard Limit
page
Gear case bearing I.D. 12.980 to 13.02 13.05
4TNV94L/ 98 Rotor shaft O.D. 12.955 to 12.975 12.945
Rotor clearance 0.035 to 0.065 0.105
5.5.1.(3)
Gear case bearing I.D. 13.00 to 13.02 13.05
4TNV106(T) Rotor shaft O.D. 12.955 to 12.965 12.945
Rotor clearance 0.035 to -0.065 0.105

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13. Tightening torque for bolts and nuts

13. Tightening torque for bolts and nuts

13.1 Tightening torques for main bolts and nuts
Thread Lubricating oil
diameter Tightening torque application Reference
Part and engine model
× pitch (thread portion, page
mm N•m (kgf•m) and seat surface)
61.7 to 65.7
3TNV82A M9 × 1.25
(6.3 to 6.7)
85.3 to 91.1
TNV84 to 88 M10 × 1.25
Cylinder (8.7 to 9.3)
Applied 4.2.4
head bolt 103.1 to 112.9
4TNV94L•98 M11 × 1.25
(10.511.5)
188.0 to 197.8
4TNV106(T) M13 × 1.5
(19.0 to 20.0)
37.2 to 41.2
3TNV82A M8 × 1.0
(3.8 to 4.2)
44.1 to 49.0
TNV84 to 88 M9 × 1.0
Connecting (4.5 to 5.0)
Applied 4.4.4
rod bolt 53.9 to 58.8
4TNV94L•98 M10 × 1.0
(5.5 to 6.0)
78.5 to 83.4
4TNV106(T) M11 × 1.0
(8.0 to 8.5)
83.3 to 88.2
TNV82A to 88 M10 × 1.25
Flywheel (8.5 to 9.0)
Applied 4.3.4
set bolt 186.2 to 205.8
4TNV94L•98•106(T) M14 × 1.5
(19 to 21)
76.4 to 80.4
3TNV82A M10 × 1.25
(7.8 to 8.2)
93.2 to 98.1
TNV84 to 88 M12 × 1.5
Bearing cap (9.5 to 10.5)
Applied 4.4.4
set bolt 108.1 to 117.9
4TNV94L•98 M11 × 1.25
(11.0 to 12.0)
186.2 to 205.8
4TNV106(T) M14 × 1.5
(19 to 21)
112.7 to 122.7
TNV82A to 88 M14 × 1.5
Crankshaft (11.5 to 12.5)
Applied 4.3.4
pulley set bolt 107.9 to 127.5
4TNV94L•98•106(T) M14 × 1.5
(11.0 to 13.0)
24.4 to 28.4
TNV82A to 88 M8 × 1.25
Fuel nozzle (2.5 to 2.9)
Not applied -
set bolt 22.6 to 28.4
4TNV94L•98•106(T) M8 × 1.25
(2.3 to 2.9)
TNV82A to 88 M14 × 1.5 78 to 88 (8 to 9)
Fuel pump drive
113 to 123 Not applied 4.3.4
gear set nut 4TNV94L•98•106(T) M18 × 1.5
(11.5 to 12.5)
29.4 to 34.3
TNV82A to 88 M12 × 1.5
Fuel injection (3.0 to 3.5)
Not applied -
pipe set bolt 19.6 to 24.5
4TNV94L•98•106(T) M12 × 1.5
(2.0 to 2.5)
Fuel return 7.8 to 9.8
4TNV94L98106(T) M6 × 1.0 Not applied -
pipe joint bolt (0.8 to 1.0)
Rocker arm 16.7 to 22.5
4TNV106(T) M8 × 1.25 Not applied -
cover set bolt (1.7 to 2.3)
EPA flange 113 to 123
4TNV106(T) M18 × 1.5 Not applied -
set bolt (11.5 to 12.5)

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 13. Tightening torque for bolts and nuts

13.2 Tightening torques for standard bolts and nuts

Nominal thread diameter Tightening torque

Item Remarks
× pitch N•m (kgf•m)
9.8 to 11.8 Use 80 % of the value at left
M6 × 1
(1.0 to 1.2) when the tightening part is
aluminum.
22.6 to 28.4
M8 × 1.25 Use 60 % of the value at left for
(2.3 to 2.9)
4T bolts and lock nuts.
44.1 to 53.9
M10 × 1.5
Hexagon bolt (7T) (4.5 to 5.5)
and nut 78.4 to 98.0
M12 × 1.75
(8.0 to 10)
127.5 to 147.1
M14 × 1.5
(13 to 15)
215.7 to 235.4
M16 × 1.5
(22 to 24)
9.8
1/8
(1.0)
19.6
1/4
(2.0)
PT plug -
29.4
3/8
(3.0)
58.8
1/2
(6.0)
12.7 to 16.7
M8
(1.3 to 1.7)
19.6 to 25.4
M10
(2.0 to 2.6)
24.5 to 34.3
Pipe joint bolt M12 -
(2.5 to 3.5)
39.2 to 49.0
M14
(4.0 to 5.0)
49.0 to 58.8
M16
(5.0 to 6.0)
Note) Lubricating oil is not applied to threaded portion and seat surface.

200
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Hitachi Construction Machinery Co. Ltd Hitachi Ref. No.
Attn: Publications, Marketing & Product Support
Fax: 81-29-831-1162

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