Professional Documents
Culture Documents
Workshop Manual E 00
Workshop Manual E 00
TO THE READER
• This manual is written for an experienced technician • If you have any questions or comments, at if you
to provide technical information needed to maintain found any errors regarding the contents of this
and repair this machine. manual, please contact using “Service Manual
Revision Request Form” at the end of this manual.
• Be sure to thoroughly read this manual for correct (Note: Do not tear off the form. Copy it for us-
product information and service procedures. age.):
Publications Marketing & Product Support
Hitachi Construction Machinery Co. Ltd.
TEL: 81-29-832-7084
FAX: 81-29-831-1162
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
• Information included in the Technical Manual: • Information included in the Workshop Manual:
technical information needed for redelivery and technical information needed for maintenance
delivery, operation and activation of all devices and repair of the machine, tools and devices
and systems, operational performance tests, and needed for maintenance and repair, maintenance
troubleshooting procedures. standards, and removal/installation and assem-
ble/disassemble procedures.
PAGE NUMBER
Example : T 1-3-5
IN-01
INTRODUCTION
SAFETY ALERT SYMBOL AND HEADLINE
NOTATIONS
In this manual, the following safety alert symbol and • CAUTION:
signal words are used to alert the reader to the Indicated potentially hazardous situation which could,
potential for personal injury of machine damage. if not avoided, result in personal injury or death.
This is the safety alert symbol. When you see this • IMPORTANT:
symbol, be alert to the potential for personal injury. Indicates a situation which, if not conformed to the
Never fail to follow the safety instructions prescribed instructions, could result in damage to the machine.
along with the safety alert symbol.
The safety alert symbol is also used to draw attention
to component/part weights. • NOTE:
To avoid injury and damage, be sure to use appropri- Indicates supplementary technical information or
ate lifting techniques and equipment when lifting heavy know-how.
parts.
UNITS USED
2
• SI Units (International System of Units) are used in Example : 24.5 MPa (250 kgf/cm , 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
3 3
m yd 1.308 Temperature °C °F °C×1.8+32
Weight kg lb 2.205 Velocity km/h mph 0.6214
-1
Force N kgf 0.10197 min 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
SA-688
SA-1
SAFETY
FOLLOW SAFETY INSTRUCTIONS
SA-2
SAFETY
WEAR PROTECTIVE CLOTHING
SA-434
INSPECT MACHINE
SA-435
SA-3
SAFETY
USE HANDHOLDS AND STEPS
• 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
SA-4
SAFETY
MOVE AND OPERATE MACHINE SAFELY
SA-5
SAFETY
OPERATE ONLY FROM OPERATOR'S SEAT
JUMP STARTING
SA-612
SA-6
SAFETY
INVESTIGATE JOB SITE BEFOREHAND
SA-7
SAFETY
PROVIDE SIGNALS FOR JOBS INVOLVING
MULTIPLE NUMBERS OF MACHINES
SA-481
SA-614
SA-8
SAFETY
DRIVE MACHINE SAFELY
SA-441
SA-442
SA-9
SAFETY
AVOID INJURY FROM ROLLAWAY ACCI-
DENTS
SA-617
SA-10
SAFETY
AVOID INJURY FROM BACK-OVER AND
SWING ACCIDENTS
021-E01A-0494-8
SA-11
SAFETY
KEEP PERSONNEL CLEAR FROM WORKING
AREA
SA-618
SA-619
AVOID UNDERCUTTING
SA-620
SA-12
SAFETY
AVOID TIPPING
To avoid tipping:
• Be extra careful before operating on a grade.
SA-622
SA-13
SAFETY
DIG WITH CAUTION
SA-263
SA-14
SAFETY
DO NOT USE FOR CRANING OPERATIONS
SA-014
SA-15
SAFETY
PARK MACHINE SAFELY
SA-019
SA-16
SAFETY
SAFETY TRANSPORTING
SA-17
SAFETY
PRACTICE SAFE MAINTENANCE
SA-18
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
SA-527
SA-19
SAFETY
STAY CLEAR OF MOVING PARTS
SA-026
SA-20
SAFETY
STORE ATTACHMENTS SAFELY
SA-034
PREVENT BURNS
SA-225
SA-21
SAFETY
REPLACE RUBBER HOSES PERIODICALLY
SA-292
SA-044
SA-22
SAFETY
PREVENT FIRES
SA-23
SAFETY
Precautions for Handling Flammables
• Spilled fuel and oil, and trash, grease, debris,
accumulated coal dust, and other flammables may
cause fires.
SA-24
SAFETY
EVACUATING IN CASE OF FIRE
SA-016
SA-25
SAFETY
PRECAUTIONS FOR WELDING AND
GRINDING
etc.
SA-26
SAFETY
REMOVE PAINT BEFORE WELDING OR
HEATING
SA-27
SAFETY
PRECAUTIONS FOR HANDLING
REFRIGERANT
SA-28
SECTION 1 GENERAL
SECTION AND GROUP
CONTENTS Group 1 Precautions for disassembling
and Assembling
Group 2 Tightening
Group 3 Painting
Group 4 Bleeding Air
SECTION 2 UPPERSTRUCTURE
WORKSHOP MANUAL Group 1 Canopy
Group 2 Counterweight
Group 3 Main Frame
Group 4 Pump Device
Group 5 Control Valve
Group 6 Swing Device
Group 7 Pilot Valve
Group 8 Solenoid Valve
SECTION 3 UNDERCARRIAGE
Group 1 Swing Bearing
Group 2 Travel Device
Group 3 Center Joint
Group 4 Track Adjuster
Group 5 Front Idler
Group 6 Upper and Lower Roller
All information, illustrations and speci- Group 7 Track
fications in this manual are based on
the latest product information available SECTION 4 FRONT ATTACHMENT
at the time of publication. The right is
reserved to make changes at any time Group 1 Front Attachment
without notice.
Group 2 Cylinder
SECTION 5 ENGINE
COPYRIGHT(C)2007
Hitachi Construction Machinery Co., Ltd.
Tokyo, Japan
All rights reserved
TECHNICAL MANUAL
SECTION 1 GENERAL SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 1 Specification Group 1 Introduction
Group 2 Component Layout Group 2 Standard
Group 3 Component Specifications Group 3 Engine Test
SECTION 2 SYSTEM Group 4 Excavator Test
Group 1 Hydraulic System Group 5 Component Test
Group 2 Electrical System Group 6 Adjustment
SECTION 3 COMPONENT OPERATION SECTION 5 TROUBLESHOOTING
Group 1 Pump Device Group 1 Diagnosing Procedure
Group 2 Swing Device Group 2 Troubleshooting B
Group 3 Control Valve Group 3 Troubleshooting C
Group 4 Pilot Valve Group 4 Electrical System Inspection
Group 5 Travel Device
Group 6 Others (Upperstructure)
Group 7 Others (Undercarriage)
SECTION 1
GENERAL
CONTENTS
Group 1 Precautions for Disassembling
and Assembling
Precautions for Disassembling and
Assembling........................................... W1-1-1
Group 2 Tightening
Tightening Torque................................... W1-2-1
Tightening Bolts and Nuts....................... W1-2-2
Piping Joint ............................................ W1-2-5
Periodic Replacement of Parts ............. W1-2-10
Group 3 Painting
Painting .................................................. W1-3-1
1MSW-1-1
(Blank)
1MSW-1-2
GENERAL / Precautions for Disassembling and Assembling
PRECAUTIONS FOR DISASSEMBLING
AND ASSEMBLING
Preparation before Disassembling
• Clean the Machine • If a part or component cannot be removed after
Thoroughly wash the machine before bringing it into removing its securing nuts and bolts, do not at-
the shop. Bringing a dirty machine into the shop tempt to remove it forcibly. Find the cause (s) and
may cause machine components to be contaminated take the appropriate measures to remove it.
during disassembling / assembling and result in • Orderly arrange disassembled parts. Put the
damage to machine components, as well as de- mark and tag as necessary.
creased efficiency in service work. • Store the common parts, such as bolts and nuts
with reference to where they are to be used and
• Inspect the Machine in a manner that will prevent loss.
Thoroughly understand all disassembling / assembling • Inspect the contact or sliding surfaces of disas-
procedures beforehand in order to help avoid in- sembled parts for abnormal wear, sticking or
correct disassembling of components as well as other damage.
personal injury. • Measure and record the degree of wear and
Check and record the items listed below in order to clearances.
prevent problems from occurring in the future.
• The machine model, machine serial number and • When assembling
hour meter. • Clean all parts and inspect them for any damage.
• Symptoms, failed parts and causes. If any damage is found, repair or replace the part.
• Contamination and clogging of filters, quality and • Dirt or debris on the contact or sliding surfaces
quantity of lubricants and leakage of oil, air or may shorten the service life of machine. Do not
water. contaminate any contact or sliding surfaces.
• Damage and loosening of various parts. • Apply hydraulic oil or gear oil onto the inner parts
when assembling. Especially apply clean hydrau-
• Prepare and Clean Tools and Disassembly Area lic oil or gear oil onto the sliding part in order not
Prepare the necessary tools to be used and the to stick.
area for disassembling work. In addition, clean the • Replace O-rings, backup rings, oil seals and
tools and area. floating seals with new ones once they are dis-
assembled. Apply a film of grease before install-
When disassembling and assembling ing.
• Disassemble • Clean and dry the liquid-gasket-applied surfaces.
• In order to prevent dirt from entering, cap or plug • If an anti-corrosive agent has been used on a
the removed pipes. new part, thoroughly clean the part to remove the
• Before disassembling, clean the exterior of the agent.
machine and place it on a workbench. • Align the matching marks when assembling.
• Before disassembling, drain gear oil from the re- • Use the designated tools when assembling the
duction gear. bearings, bushings and oil seals.
• Provide appropriate containers for draining fluids. • After assembling is complete, count the number
• Put the matching marks for easier reassembling. of tools in order not to leave the tools in the as-
• Use the specified special tools when instructed. sembled machine.
W1-1-1
GENERAL / Precautions for Disassembling and Assembling
Bleeding Air from Hydraulic System
When hydraulic oil is drained, the suction filter or the
suction lines are replaced or removal and installation
of the pump, swing motor, travel motor or cylinder is
done, bleed air from the hydraulic system in the fol-
lowing procedures.
W1-1-2
GENERAL / Precautions for Disassembling and Assembling
• Bleeding Air from Hydraulic Circuit
• While operating each cylinder, swing motor and
travel motor evenly, operate the machine under
light loads for 10 to 15 minutes. Slowly start each
operation. (Do not fully stroke the cylinders during
initial operation stage.)
As the pilot circuit has an air bleed device, air
trapped in the pilot circuit will be bled while per-
forming the above operation for approx. 5 min-
utes.
• Reposition the front attachment in order to check
hydraulic oil level.
• After stopping the engine, check hydraulic oil M1M7-05-024
W1-1-3
GENERAL / Precautions for Disassembling and Assembling
Precautions for Floating Seal
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 the seal rings together as a matched
set. Apply oil onto sliding surface (C) on seal
ring (A). Insert a piece of cardboard to protect
surfaces.
(2) Check sliding surface (C) on seal ring (A) for
scuffing, scoring, corrosion, deformation or B W105-03-05-019
uneven wear.
Check the step part.
(3) Check O-ring (B) for tears, breaks, deforma-
tion of hardening.
b b
a=b a≠b
W110-03-05-004
W1-1-4
GENERAL / Precautions for Disassembling and Assembling
Precautions for Nylon Sling
Bent Sling
W162-01-01-009
W1-1-5
GENERAL / Precautions for Disassembling and Assembling
Fuzz
Broken Sewing
Thread
W162-01-01-004
Broken Sewing
Thread
W162-01-01-005
Broken Sewing
Thread
Separation of
Belt W162-01-01-006
Scoring
W162-01-01-007
Scuffing
Fuzz
Broken Warp
W162-01-01-008
W1-1-6
GENERAL / Precautions for Disassembling and Assembling
MAINTENANCE STANDARD TERMINOLOGY
“Standard”
1. Dimension for parts on a new machine.
2. Dimension of new components or assemblies
adjusted to specification. Allowable tolerance will
be indicated as necessary.
“Allowable Limit”
1. Normal machine performance cannot be accom-
plished after exceeding this limit.
2. Repair or adjustment is impossible after exceeding
this limit. Therefore, in consideration of operation
efficiency and maintenance expense, proper
maintenance shall be carried out before reaching
the “Allowable Limit”.
W1-1-7
GENERAL / Precautions for Disassembling and Assembling
(Blank)
W1-1-8
GENERAL / Tightening
TIGHTENING TORQUE
Wrench Torque
Item Descriptions Bolt Dia. Q'ty
Size 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)
7/16-20UNF 17 24.5 (2.5) (18)
19 29.5 (3) (22)
Union joint for hydraulic hoses 9/16-18UNF
4. Metal joint 22 39 (4) (29)
and piping
3/4-16UNF 27 93 (9.5) (69)
1-1/16-12UNF 36 175 (18) (129)
5. Pump mounting bolt 12 2 19 88 (9) (65)
6. Pump cover mounting bolt 10 8 17 49 (5) (36)
Control valve mounting bolt 10 4 17 49 (5) (36)
7.
Control valve mounting bolt 10 4 17 49 (5) (36)
8. Swing device mounting bolt 12 4 19 88 (9) (65)
9. Battery mounting nut 6 4 10 5 (0.5) (3.5)
10 3 17 49 (5) (36)
10. Canopy mounting bolt
12 4 19 88 (9) (65)
Upperstructure 10 16 17 49 (5) (36)
11. Swing bearing mounting bolt
Track 10 18 17 49 (5) (36)
12. Travel device mounting bolt 10 16 8 (Socket) 64 (6.5) (47)
13. Sprocket mounting bolt 10 18 8 (Socket) 64 (6.5) (47)
14. Iron-crawler guide mounting bolt 10 8 17 49 (5) (36)
15. Lower roller mounting bolt 14 12 22 177 (18) (130)
6 10 5 (0.5) (3.5)
16. Covers mounting bolt 8 13 9.8 (1) (7)
10 17 49 (5) (36)
17. Counterweight mounting bolt 20 3 30 400 (41) (295)
8 13 20 (2) (15)
10 17 49 (5) (36)
18. Front pin retaining bolt 12 19 88 (9) (65)
14 22 137 (14) (101)
16 24 205 (21) (151)
W1-2-1
GENERAL / Tightening
TIGHTENING BOLTS AND NUTS
SA-040
Bolt Types
Tighten the nuts or bolts correctly to the torque speci- As the different types and grades of bolt are used,
fications. use and tighten the correct bolts correctly when as-
sembling the machine or components.
Hexagon
Wrench
Bolt Dia. Wrench
Size
Size M552-07-091 M552-07-090 M552-07-092
Socket Bolt
N⋅m (kgf⋅m) (lbf⋅ft) N⋅m (kgf⋅m) (lbf⋅ft) N⋅m (kgf⋅m) (lbf⋅ft)
M6 10 5 3.3 to 4.2 (0.3 to 0.4) (2.4 to 3.0)
M8 13 6 29.5 (3.0) (22) 19.5 (2.0) (14.5) 9.8 (1.0) (7.2)
M10 17 8 64 (6.5) (47) 49 (5.0) (36) 19.5 (2.0) (14.5)
M12 19 10 108 (11) (80) 88 (9.0) (65) 34 (3.5) (25)
M14 22 12 175 (18) (129) 137 (14) (101) 54 (5.5) (40)
M16 24 14 265 (27) (195) 205 (21) (151) 78 (8.0) (58)
M18 27 14 390 (40) (290) 295 (30) (220) 118 (12) (87)
M20 30 17 540 (55) (400) 390 (40) (290) 167 (17) (123)
M22 32 740 (75) (550) 540 (55) (400) 215 (22) (159)
M24 36 930 (95) (690) 690 (70) (510) 275 (28) (205)
M27 41 1 370 (140) (1010) 1 030 (105) (760) 390 (40) (290)
M30 46 1 910 (195) (1410) 1 420 (145) (1050) 540 (55) (400)
M33 50 2 550 (260) (1880) 1 910 (195) (1410) 740 (75) (550)
M36 55 3 140 (320) (2320) 2 400 (245) (1770) 930 (95) (690)
W1-2-2
GENERAL / Tightening
IMPORTANT: The following items are applied to
both fine and coarse pitch threads.
1. Apply lubricant to the bolts and
nuts in order to reduce friction
coefficient of them. (for example,
spindle oil with white zinc B dis-
solved in it)
2. Torque tolerance is ±10 %.
3. Use the bolts of correct length.
The bolts that are too long cannot
be tightened as the bolt tip comes
into contact with the bottom of
bolt hole. Also the bolts that are
too short cannot develop suffi-
cient tightening force.
4. The torques given in the chart on
the previous page are for general
use only, however, a different
torque is given for a specific ap-
plication. Use the specified
torques.
5. Clean the nut and bolt threads
and remove dirt or corrosion be-
fore installing.
Tightening Order
When tightening two or more bolts, tighten them al-
ternately, as shown, to ensure even tightening.
Equally tighten upper and lower alternately Tighten diagonally Tighten from center diagonally
1 12 9 4 1 6 7 14
1.4 6 3
4 5
2 13 8 5 2 3 10 11
2.3
W105-01-01-003
W1-2-3
GENERAL / Tightening
Precautions for Spilt Flange
IMPORTANT: 1. Clean the sealing surfaces. Check
if there are any scratches and
roughness on the surface of the
seal that cause oil leaks and
damage to the O-ring.
2. Use only specified O-rings. In-
spect O-rings for any damage. Do
not file the O-ring surfaces. When
installing O-ring into a groove,
use grease in order to hold O-ring W105-01-01-015
in place.
3. While tightening the bolt by hand,
Incorrect
check that flange is installed to
the port correctly. Do not pinch
the O-ring.
4. Tighten the bolts up and down,
left and right alternately, in order
to ensure even tightening to the
specified torque. W105-01-01-016
• Split Pin
Bend along edge Do not bend it
IMPORTANT: Do not turn in the loosening direc- sharply round
tion in order to align the grooves
and holes on the nut. Always turn in Correct Correct Incorrect
the tightening direction. Do not re-
use the split pins.
• Wire
IMPORTANT: Attach wire to bolts in the Bend along
bolt-tightening direction. Do not re- edge sharply W105-01-01-009
Correct
Loosen Incorrect
Tighten
W105-01-01-010
W1-2-4
GENERAL / Tightening
PIPING JOINT
IMPORTANT: The torques given in table below are
for general use only, however, a dif-
ferent torque is given for a specific
application. Use the specified
torques.
Union Joint
Metal sealing surfaces (4) and (5) of adaptor (1) and
hose (2) fit together to seal pressure oil. Union joints
1 4 3 5 2
are used to join small-diameter lines.
W1-2-5
GENERAL / Tightening
Pipe joint
Pipe connection (metal joint)
(Union Nut Wrench Size: 17)
Metal (3) of adaptor (1) and hose (2) seals pressure oil.
Tightening Torque
Use the specified tightening torque in the table below.
Wrench Size (mm) 17
N⋅m 39
Tightening M1M7-07-005
(kgf⋅m) (4.0)
Torque
(lbf⋅ft) (29)
W1-2-6
GENERAL / Tightening
Quick Coupling
1. Coupling procedure
• Push socket ring (1) into plug (3) by rotating it
fully counterclockwise and then pulling it toward
you.
3 1
• Release socket ring (1). Check that socket ring
(1) is returned by the spring force and the cou-
pling is locked completely by ball (2). At this time,
check if socket ring (1) is returned to the original
position (to the rightmost direction).
2. Separating procedure
• Remove the hose by rotating socket ring (1) fully
counterclockwise and then pulling it. Because no
2
check function is attached inside, be careful that
oil flows out.
M1M7-07-006
• Cap the removed hoses using special plug.
CAUTION:
• When disconnecting, do not damage joint
surface.
• When disconnecting, clean the joint part
and thoroughly wipe off the cleaning solu-
tion to prevent any foreign material from
entering.
• Complete the joint disconnecting / con-
necting procedure. Check enough if oil
leaks especially after installation.
• After installation, check if socket ring (1) is
returned to the original position (to the
rightmost direction).
W1-2-7
GENERAL / Tightening
Screw-In Connection PT PF
Depending on types of screw and sealing, different 30°
types of screw-in connection are used.
M114-07-042
M114-07-043
W1-2-8
GENERAL / Tightening
Connecting Hose
Incorrect Correct
Clamp Clamp
Rubbing
Against
Each Other
W105-01-01-013
Incorrect Correct
Rubbing Against
Each Other
Clamp
W105-01-01-014
W1-2-9
GENERAL / Tightening
PERIODIC REPLACEMENT PARTS
In order to ensure safe operation, conduct periodic
inspection of the machine. For this reason, replace
these parts at the intervals shown in the table below.
These parts may lead to serious disaster/fire hazards
because of deterioration, fatigue, or weakening. It is
very difficult to gauge the remnant life by sense of op-
eration or visual inspection. Perform periodic inspec-
tion and maintenance and replace any defective parts
if necessary.
W1-2-10
GENERAL / Painting
PAINTING
Black
Dark Gray
TAXI Yellow [Spin-dyeing]
TAXI Yellow
TAXI Yellow TAXI Yellow
Dark Gray
Dark Gray
Dark Gray
[Including boom Black
swing cylinder] [Manufacture-paint
parts]
Dark Gray
[Including blade Dark Gray
cylinder]
Dark Gray
Dark Gray
Dark Gray
TAXI Yellow
W1MS-01-03-001
W1-3-1
GENERAL / Painting
(Blank)
W1-3-2
GENERAL / Bleeding Air
BLEED AIR FROM HYDRAULIC OIL TANK
Preparation:
1. Park the machine on a solid, level surface. Lower
the front attachment onto the ground.
M1MS-07-013
Vacuum Pump
Hose
3
W1MP-01-04-001
W1-4-1
GENERAL / Bleeding Air
(Blank)
W1-4-2
MEMO
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SECTION 2
UPPERSTRUCTURE
CONTENTS
Group 1 Canopy Group 6 Swing Device
Remove and Install Canopy.................... W2-1-1 Remove and Install Swing Device........... W2-6-1
1MSW-2-1
(Blank)
1MSW-2-2
UPPERSTRUCTURE / Canopy
REMOVE AND INSTALL CANOPY
Removal
3 2
Installation
4
W2-1-1
UPPERSTRUCTURE / Canopy
(Blank)
W2-1-2
UPPERSTRUCTURE / Counterweight
REMOVE AND INSTALL COUNTER-
WEIGHT
Removal
1. Remove canopy (1) from main frame (3). (Refer to
the Remove and Install Canopy group on 1
W2-1-1.)
8
8
W1MS-02-02-001
W2-2-1
UPPERSTRUCTURE / Counterweight
Installation
1. Remove plugs (4) (2 used) from counterweight 4 5
(6).
9
2. Install eyebolts (M14, Pitch 2 mm) (2 used) into
the plug (4) holes (2 used) on counterweight (6). 6
Attach a nylon sling onto eyebolts (2 used).
3
W1MS-02-05-017
W2-2-2
UPPERSTRUCTURE / Main Frame
REMOVE AND INSTALL MAIN FRAME
Removal
W1MS-02-03-005
W1MS-02-05-014
W2-3-1
UPPERSTRUCTURE / Main Frame
4. Remove bolts (5) (5 used) from cover (4). Remove
cover (4) from the main frame.
: 13 mm
W1MS-02-05-015
7 W1MS-02-03-001
W1MS-02-03-002
W2-3-2
UPPERSTRUCTURE / Main Frame
7. Install pin (10) to swing post (11) with bolt (12) and
nut (13). 10
: 17 mm
W1MS-04-01-004
12, 13
9
CAUTION: Main frame weight: 950 kg
(2095 lb)
14
10. Hoist the main frame in a level condition. Remove
the main frame from center frame (17).
15, 16
17
W1MS-02-03-004
W2-3-3
UPPERSTRUCTURE / Main Frame
Installation
11
W1MS-04-01-004
12, 13
W1MS-02-03-002
W2-3-4
UPPERSTRUCTURE / Main Frame
5. Install hoses (6) (6 used) to center joint (7).
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
NOTE: Check that pin (18) is inserted in the
stopper groove on the main frame.
18
7 W1MS-02-03-001
6. Install cover (4) onto the main frame with bolts (5)
(5 used).
: 13 mm
4
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)
W1MS-02-05-015
W1MS-02-05-014
W2-3-5
UPPERSTRUCTURE / Main Frame
W1MS-02-03-005
1
W178-02-11-072
W2-3-6
UPPERSTRUCTURE / Pump Device
REMOVE AND INSTALL PUMP DEVICE
Removal 2
1. Remove bolts (1) (4 used) from cover (2). Remove
cover (2) from main frame (3).
: 17 mm
3
W1MS-02-05-017
W1MS-02-04-003
W1MS-02-04-004
W2-4-1
UPPERSTRUCTURE / Pump Device
4. Remove hoses (13) (2 used) from pilot pump (12).
Remove hoses (8) (2 used) from main pump (9).
Loosen band (10) and remove hose (11) from 6
main pump (9). Cap the open ends. Attach an
identification tag onto the removed hoses for 7
assembling.
: 22 mm
13 8
5. Remove bolts (6) (2 used) from main pump (9).
Remove main pump (9) from engine (7). 9
: 19 mm 12
W1MS-02-04-005
11 10
W2-4-2
UPPERSTRUCTURE / Pump Device
Installation
1. Install main pump (9) to engine (7) with bolts (6) (2
used). 6
: 19 mm
: 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft) 7
W1MS-02-04-005
11 10
3
3. Attach cover (4) onto main frame (3) with bolts (5)
(4 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft) 4
W1MS-02-04-004
4. Install cover (2) onto main frame (3) with bolts (1)
(4 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft) 1
W1MS-02-05-017
W2-4-3
UPPERSTRUCTURE / Pump Device
10
1
11
2
3 12
4
5
4
6
7
8
9
13
26 14
15
25 16
24 17 18 19
23
22 20
27
28 29 20
21
30
31
32
33 34
35
36
37 20
38
39
44
40
43
20
42
41 W1MS-02-04-001
W2-4-4
UPPERSTRUCTURE / Pump Device
Disassemble Pump Device
1. Remove bolts (27) (2 used) and spring washers 7. Remove spring guide (38), spring (39), spring
(28) (2 used) from gear pump (29). Remove gear holder (40) and the cylinder block (6) assembly
pump (29) from body H (37). from body S (17).
: 13 mm
8. Remove plungers (24) (10 used), retainer (8),
IMPORTANT: As the setting of pump delivery flow holder (7) and needles (25) (3 used) from the
rate changes by turning bolt (35), do cylinder block (6) assembly.
not disassemble bolt (35) and nut
(34). IMPORTANT: Do not disassemble the cylinder
2. Remove O-rings (33, 32, 44), collar (31) and block (6) assembly unless
coupling (30) from body H (37). necessary.
CAUTION: Remove retaining ring (3) while
CAUTION: Use a temporary bolt (M10, pushing the washer (4) and spring (5) by
Length 65 mm (2.6 in)) and remove body H using a press, etc.
(37) as spring (39) may fly off with socket bolt If removing only retaining ring (3), washer (4)
(43) removed. and spring (5) may fly out.
3. Remove socket bolts (43) (2 used) from the upper 9. Remove swash plate (9) and ceramic balls (23) (2
side. Install a temporary bolt (M10, Length 65 mm used) from body S (17).
(2.6 in)) into the socket bolt (43) hole.
: 17 mm 10. Remove stopper pin (13), coned disc springs (14)
: 8 mm (4 used) and rod (22) from body S (17).
4. Remove other socket bolts (43) (2 used). 11. Remove shaft (11) from body S (17) by using a
: 8 mm plastic hammer.
5. Alternately loosen and remove the temporary 12. Remove retaining ring (10), ball bearing (12) and
bolts (M10, Length 65 mm (2.6 in)) (2 used) from oil seal (21) from body S (17).
body H (37).
: 17 mm
W2-4-5
UPPERSTRUCTURE / Pump Device
ASSEMBLE PUMP DEVICE
14 13 40 24 36 25 6 4 15 3 38 37 1
36 34 35
32 33 31 30
22
11
21
12 T1MS-03-01-001
17 10 23 9 7 8 4 5 2 42 41 16 20 44 29
43
28
27
29
W1MS-02-04-002
W2-4-6
UPPERSTRUCTURE / Pump Device
Assemble Pump Device
1. Install oil seal (21) and ball bearing (12) to body S 8. Place body S (17) horizontally. Install the cylinder
(17). Secure ball bearing (12) to body S (17) with block (6) assembly to body S (17) while rotating
retaining ring (10). shaft (11).
2. Insert shaft (11) into body S (17). 9. Place body S (17) vertically. Insert spring holder
(40), spring (39) and spring guide (38) into body S
3. Install needles (25) (3 used) to cylinder block (6). (17).
Place holder (7) on needle (25).
10. Apply grease onto the body H (37) side of valve
4. Install plungers (24) (10 used) and retainer (8) to plate (2). Install valve plate (2) to body H (37).
cylinder block (6).
11. Install pins (16) (2 used) and packing (15) to body
5. Install coned disc springs (14) (4 used) to stopper S (17).
pin (13). Install stopper pin (13) to body S (17).
W2-4-7
UPPERSTRUCTURE / Pump Device
39 37
32 33 31 30
11
T1MS-03-01-001
17 44 29
43
28
27
29
W1MS-02-04-002
W2-4-8
UPPERSTRUCTURE / Pump Device
12. Install body H (37) to body S (17). Install a
temporary bolt (M10, Length 65 mm (2.6 in)) into
the socket bolt (43) holes (2 used) at the spring
(39) side.
: 17 mm
W2-4-9
UPPERSTRUCTURE / Pump Device
MAINTENANCE STANDARD
1. Clearance between plunger (24) outer diameter
and cylinder block (6) bore.
D d
6 24
W507-02-04-009
Shoe
W107-02-06-141
W2-4-10
UPPERSTRUCTURE / Control Valve
REMOVE AND INSTALL CONTROL VALVE
Removal
1. Remove floor mat (1) from main frame (2).
1
2 W1MS-02-05-014
W1MS-02-05-015
2
W1MS-02-05-016
6
W2-5-1
UPPERSTRUCTURE / Control Valve
4. Remove bolts (7) (4 used) from cover (8). Remove
cover (8) from main frame (2).
: 17 mm
7
2
W1MS-02-05-017
2 W1MS-02-05-018
9 10 11
6. Remove bolt (9) from bracket (10). Disconnect
connector (11).
: 13 mm
W1MS-02-05-019
W2-5-2
UPPERSTRUCTURE / Control Valve
7. Remove hoses (12, 13, 17, 18) (44 used tin total)
from control valve (16). Cap the open end of 13
control valve (16) and hoses (12, 13, 17, 18). 16
Attach the identification tag onto hoses (12, 13, 17,
18) (44 used in total). 12
: 19 mm, 22 mm, 27 mm
16
W1MS-02-05-021
W2-5-3
UPPERSTRUCTURE / Control Valve
Installation
W1MS-02-05-021
16
W1MS-02-05-023
21 20 19
13
3. Install hoses (12, 13, 17 and 18) (44 used in total)
to control valve (16). 16
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft) 12
: 22 mm
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)
: 27 mm
: 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft)
19, 20, 21
18 17 W1MS-02-05-020
W2-5-4
UPPERSTRUCTURE / Control Valve
4. Install connector (11) to bracket (10) with bolt (9).
Connect connector (11). 9 10 11
: 13 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)
W1MS-02-05-019
5. Install cover (8) onto main frame (2) with bolts (7)
(4 used).
: 17 mm
7
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
2 W1MS-02-05-017
6. Install cover (5) onto main frame (2) with bolts (6)
(2 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
5
W1MS-02-05-016
6
W2-5-5
UPPERSTRUCTURE / Control Valve
7. Install cover (3) onto main frame (2) with bolts (4)
(5 used).
: 13 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)
3
W1MS-02-05-015
W1MS-02-05-014
2
W2-5-6
UPPERSTRUCTURE / Control Valve
(Blank)
W2-5-7
UPPERSTRUCTURE / Control Valve
DISASSEMBLE AND ASSEMBLE CONTROL VALVE
1/4 (Flow Combiner Valve, Side Frame Extend/Retract, Blade)
1
7
6 3
5 Flow Combiner
Valve
4
9
8
3
2 19
1 20
10 21
22
11
12 23
24
13 18
25
18
16 Side Frame
Extend/Retract
17
16 27 1
8
15
14 28 31
25
24 19 3
29 20
30 21 32
22 12
11
Blade
3
31
1 33
34 8
11
12 W1MS-02-05-001
32
1- Socket Bolt (40 Used) 10 - Spool (Flow Combiner Valve) 19 - Plug (10 Used) 27 - Body (Side Frame Extend/Retract)
2- Spring 11 - Spring Seat (10 Used) 20 - O-Ring (10 Used) 28 - Spool (Side Frame Extend/Retract)
3- O-Ring (20 Used) 12 - Spring Seat (10 Used) 21 - Spring (10 Used) 29 - Spring
4- Main Relief Valve 13 - Cover 22 - Check Valve (8 Used) 30 - Bolt
5- Nut (8 Used) 14 - Socket Bolt (2 Used) 23 - Socket Bolt (2 Used) 31 - Spring (9 Used)
6- Plug (3 Used) 15 - Cover 24 - Seal Plate (2 Used) 32 - Cover (18 Used)
7- Cover 16 - Spring Seat (2 Used) 25 - O-Ring (2 Used) 33 - Body (Blade)
8- O-Ring (11 Used) 17 - O-Ring 26 - O-Ring 34 - Spool (Blade)
9- Body (Flow Combiner Valve) 18 - Wiper Ring
W2-5-8
UPPERSTRUCTURE / Control Valve
2/4 (Swing, Boom Swing, Auxiliary)
31
19 3
20
21
32
22 12
11
3 Swing
31 39
35 1
1 8
36
19 31
11 20 3
21
12
22
32 32
12
38 11
37
Boom Swing
3
31
1 40
8
41
19
20 42
11
1
12 21
19 22
32 12
20
21
43
32
42
31
11
3
Auxiliary
3
31
1
45
46
11
12 W1MS-02-05-002
32
1- Socket Bolt (40 Used) 20 - O-Ring (10 Used) 36 - Spool (Swing) 41 - Spool (Boom Swing)
3- O-Ring (20 Used) 21 - Spring (10 Used) 37 - Check Valve (3 Used) 42 - Overload Relief Valve (2 Used)
8- O-Ring (11 Used) 22 - Check Valve (8 Used) 38 - Spring (3 Used) 43 - Check Valve
11 - Spring Seat (10 Used) 31 - Spring (9 Used) 39 - Make-Up Valve 45 - Body (Auxiliary)
12 - Spring Seat (10 Used) 32 - Cover (18 Used) 40 - Body (Boom Swing) 46 - Spool (Auxiliary)
19 - Plug (10 Used) 35 - Body (Swing)
W2-5-9
UPPERSTRUCTURE / Control Valve
3/4 (Arm, Travel (Left), Inlet)
47
1
19 12
50 20
49 12
48 21
8 22 32
31
47
51 3
52
53
3 54
31
56 55 1
32
1 Arm
57
31
11
3
12
6 32
12
8 11
Travel (Left)
3
31 37
38
1 58
59
60
11
12 8
32
60
Inlet
61 W1MS-02-05-003
8
W2-5-10
UPPERSTRUCTURE / Control Valve
4/4 (Travel (Right), Boom, Bucket)
31
3
6
32
12
38 11
37
Travel (Right)
3
31
62
1 8 65 1
63
31
11
3
12
19
32 20
64 32
21
12
22
11
Boom
3
31 1
1 66
8 31
67
19 3
70
11 20
21
12
69 32
32 19 12
20
21 11
68
22 Bucket
3
31 71
1
72
73
11
12 5 W1MS-02-05-022
32
1- Socket Bolt (40 Used) 19 - Plug (10 Used) 37 - Check Valve (3 Used) 66 - Body (Boom)
3- O-Ring (20 Used) 20 - O-Ring (10 Used) 38 - Spring (3 Used) 67 - Spool (Boom)
6- Plug (3 Used) 21 - Spring (10 Used) 62 - Body (Travel (Left)) 68 - Overload Relief Valve
8- O-Ring (11 Used) 22 - Check Valve (8 Used) 63 - Spool (Travel (Left)) 69 - Check Valve
11 - Spring Seat (10 Used) 31 - Spring (9 Used) 64 - Make-Up Valve 70 - Make-Up Valve
12 - Spring Seat (10 Used) 32 - Cover (18 Used) 65 - Overload Relief Valve 71 - Body (Bucket)
72 - Spool (Bucket)
73 - Rod (4 Used)
W2-5-11
UPPERSTRUCTURE / Control Valve
DISASSEMBLE BODY
68 64 60 47 42 4
5 73
73 5
W1MS-02-05-004
71 70 66 65 62 61 60 58 47 56 42 45 39 40 35 33 27
38
37
40, 58, 62
W1MS-02-05-006
W2-5-12
UPPERSTRUCTURE / Control Valve
Installation Position of O-ring (8)
Except 56 8
W1MS-02-05-005
50
48
8
56
W1MS-02-05-007
4- Main Relief Valve 37 - Check Valve (3 Used) 48 - O-Ring 62 - Body (Travel (Left))
5- Nut (8 Used) 38 - Spring (3 Used) 50 - O-Ring 64 - Make-Up Valve
8- O-Ring (11 Used) 39 - Make-Up Valve 56 - Body (Arm) 65 - Overload Relief Valve
9- Body (Flow Combiner Valve) 40 - Body (Boom Swing) 58 - Body (Travel (Right)) 66 - Body (Boom)
27 - Body (Side Frame Extend/Retract) 42 - Overload Relief Valve (2 Used) 60 - Main Relief Valve 68 - Overload Relief Valve
33 - Body (Blade) 45 - Body (Auxiliary) 61 - Body (Inlet) 70 - Make-Up Valve
35 - Body (Swing) 47 - Overload Relief Valve (2 Used) 71 - Body (Bucket)
73 - Rod (4 Used)
W2-5-13
UPPERSTRUCTURE / Control Valve
68 64 60 47 42 4
5 73
73 5
W1MS-02-05-004
71 70 66 65 62 61 60 58 47 56 42 45 39 40 35 33 27
W2-5-14
UPPERSTRUCTURE / Control Valve
Disassemble Body
1. Remove main relief valves (4) and (60) (2 used) IMPORTANT: When disassembling the bodies
from bodies (9, 61). (between 35 and 40, between 58 and
: 24 mm 61, and between 61 and 62), springs
(38) (3 used) will come out of bodies
2. Remove make-up valves (39, 64, 70) from bodies (40, 58, 62). Do not lose springs (38)
(40, 66, 71). (3 used).
: 24 mm Arrange each of bodies (9, 27, 33, 35,
40, 45, 56, 58, 61, 62, 66 and 71) in
IMPORTANT: Do not confuse overload relief the order that are removed.
valves (42, 47, 64, 67) (2 used for Although the parts have a similar
each). Although overload relief shape, the spools are different.
valves (42, 47, 64, 67) (2 used for 6. Disassemble bodies (9, 27, 33, 35, 40, 45, 56, 58,
each) have the same shape, the 61, 62, 66 and 71) from the control valve
pressure settings are different. assembly. Remove O-rings (8) (11 used), (48, 50)
3. Remove overload relief valves (42, 47) (2 used for between each of the bodies.
each), (66) and (71) from bodies (45, 56, 66, 71). NOTE: O-rings (48, 50) are between body (45) and
: 24 mm body (56).
CAUTION: Control valve weight: 34 kg (75 lb) 7. Remove springs (38) (3 used) and check valves
(37) (3 used) from bodies (40, 58, 62).
4. Place the control valve assembly on the
workbench with the port holes (A1 to A10, B1 to
B10, P1 to P3, T3) facing up ward.
W2-5-15
UPPERSTRUCTURE / Control Valve
ASSEMBLE BODY
68 64 60 47 42 4
5 73
73 5
W1MS-02-05-004
71 70 66 65 62 61 60 58 47 56 42 45 39 40 35 33 27
40, 58, 62
B
8 37
38
Section B-B
C
Section C-C W1MS-02-05-009
W2-5-16
UPPERSTRUCTURE / Control Valve
Installation Position of O-ring (8)
A
Except 56
Section A- A A W1MS-02-05-008
56
D D
48 50
Section D-D
Section E-E E
W1MS-02-05-010
4- Main Relief Valve 37 - Check Valve (3 Used) 48 - O-Ring 62 - Body (Travel (Left))
5- Nut (8 Used) 38 - Spring (3 Used) 50 - O-Ring 65 - Overload Relief Valve
8- O-Ring (11 Used) 39 - Make-Up Valve 56 - Body (Arm) 66 - Body (Boom)
9- Body (Flow Combiner Valve) 40 - Body (Boom Swing) 58 - Body (Travel (Right)) 70 - Overload Relief Valve
27 - Body (Side Frame Extend/Retract) 42 - Overload Relief Valve (2 Used) 60 - Main Relief Valve 71 - Body (Bucket)
33 - Body (Blade) 45 - Body (Auxiliary) 61 - Body (Inlet) 73 - Rod (4 Used)
35 - Body (Swing) 47 - Overload Relief Valve (2 Used)
W2-5-17
UPPERSTRUCTURE / Control Valve
68 64 60 47 42 4
5 73
73 5
W1MS-02-05-004
71 70 66 65 62 61 60 58 47 56 42 45 39 40 35 33 27
NOTE: • Refer to W2-5-17 for the installation position of O-rings (8, 48, 50).
• Refer to W2-5-16 for the installation position of spring (38) and check valve (37).
W2-5-18
UPPERSTRUCTURE / Control Valve
Assemble Body 7. Install make-up valves (39, 64, 70) to bodies (40,
IMPORTANT: Check the installation direction and 66, 71).
the order, and arrange bodies (9, 27, : 24 mm
33, 35, 40, 45, 56, 58, 61, 62, 66 and : 69 to 70 N⋅m
71) on the workbench. (7.0 to 7.9 kgf⋅m, 51 to 52 lbf⋅ft)
1. Apply grease onto O-rings (8) (11 used), (48) and
(50). Install O-ring (8) to bodies (9, 27, 33, 35, 40, 8. Install main relief valve (4) to body (9). Install
45, 58, 61, 62 and 66). Install O-rings (8, 48, 50) main relief valves (60) (2 used) to body (61).
to body (56). : 24 mm
: 69 to 70 N⋅m
2. Apply grease onto springs (38) (3 used). Install (7.0 to 7.9 kgf⋅m, 51 to 52 lbf⋅ft)
check valves (37) (3 used) and springs (38) (3
used) to bodies (40, 58, 62).
W2-5-19
UPPERSTRUCTURE / Control Valve
DISASSEMBLE SPOOL
W1MS-02-05-004
71 66 62 61 58 56 45 40 35 33 27 9
1
7
3
9
3
2
1
10
11
12 W1MS-02-05-005
13
W2-5-20
UPPERSTRUCTURE / Control Valve
Spool Structure of Body (27)
23
24
18
25
18
16
27
17
16
28
15
25
14 24
29
30 W1MS-02-05-011
1
Spool Structure Except Bodies (9, 27)
31
3
32
12
11
3
31
Except 9, 27
1 34
11
12
W1MS-02-05-012
32
1- Socket Bolt (40 Used) 14 - Socket Bolt (2 Used) 28 - Spool (Side Frame) 40 - Body (Boom Swing)
2- Spring 15 - Cover 29 - Spring 45 - Body (Auxiliary)
3- O-Ring (20 Used) 16 - Spring Seat 30 - Bolt 56 - Body (Arm)
7- Cover 17 - O-Ring 31 - Spring (9 Used) 58 - Body (Travel (Right))
9- Body (Flow Combiner Valve) 18 - Wiper Ring 32 - Cover (18 Used) 61 - Body (Inlet)
10 - Spool (Flow Combiner Valve) 23 - Socket Bolt (2 Used) 33 - Body (Blade) 62 - Body (Travel (Left))
11 - Spring Seat (10 Used) 24 - Seal Plate (2 Used) 34 - Spool (Blade) 66 - Body (Boom)
12 - Spring Seat (10 Used) 25 - O-Ring (2 Used) 35 - Body (Swing) 71 - Body (Bucket)
27 - Body (Side Frame
13 - Cover Extend/Retract)
W2-5-21
UPPERSTRUCTURE / Control Valve
Spool Structure of Body (9)
1
7
3
9
3
2
1
10
11
12 W1MS-02-05-005
13
23
24
18
25
18
16
27
17
16
28
15
25
14 24
29
30 W1MS-02-05-011
W2-5-22
UPPERSTRUCTURE / Control Valve
Disassemble Spool
2. Remove socket bolts (1) (2 used) from cover (13). 2. Remove socket bolts (23) (2 used) from seal plate
Remove spring seats (11, 12), spring (2), O-ring (24). Remove seal plate (24) from body (27).
(3) and cover (13) from body (9).
: 5 mm 3. Remove the spool (28) assembly from the cover
(15) side in body (27) by rotating. Remove the
3. Remove the spool (10) assembly from the cover seal plate (24), wiper rings (18) (2 used) and
(13) side in body (9) by rotating. O-rings (25) (2 used) from body (27).
W2-5-23
UPPERSTRUCTURE / Control Valve
31
3
32
12
11
3
31
33
1 34
11
12
W1MS-02-05-012
32
W2-5-24
UPPERSTRUCTURE / Control Valve
Disassemble Spool Except Bodies (9, 27)
The disassembly for spool (34) in body (33) is
explained as an example.
W2-5-25
UPPERSTRUCTURE / Control Valve
ASSEMBLE SPOOL
W1MS-02-05-004
71 66 62 61 58 56 45 40 35 33 27 9
25
27
9 28
25
3
18 24
1
T1MS-03-03-003
7 23
T1MS-03-03-002
W2-5-26
UPPERSTRUCTURE / Control Valve
Section Except Bodies (9, 27)
12
31
32
1 11
34
33
3
1
11
32
31
12
T1MS-03-03-004
1- Socket Bolt (40 Used) 14 - Socket Bolt (2 Used) 28 - Spool (Side Frame) 40 - Body (Boom Swing)
2- Spring 15 - Cover 29 - Spring 45 - Body (Auxiliary)
3- O-Ring (20 Used) 16 - Spring Seat 30 - Bolt 56 - Body (Arm)
7- Cover 17 - O-Ring 31 - Spring (9 Used) 58 - Body (Travel (Right))
9- Body (Flow Combiner Valve) 18 - Wiper Ring 32 - Cover (18 Used) 61 - Body (Inlet)
10 - Spool (Flow Combiner Valve) 23 - Socket Bolt (2 Used) 33 - Body (Blade) 62 - Body (Travel (Left))
11 - Spring Seat (10 Used) 24 - Seal Plate (2 Used) 34 - Spool (Blade) 66 - Body (Boom)
12 - Spring Seat (10 Used) 25 - O-Ring (2 Used) 35 - Body (Swing) 71 - Body (Bucket)
27 - Body (Side Frame
13 - Cover Extend/Retract)
W2-5-27
UPPERSTRUCTURE / Control Valve
Body (9) Section Body (27) Section
14
13 12
15
2
1 16
11 14
3 29
24
10 16
18
25
27
9 28
25
3
18 24
1
T1MS-03-03-003
7 23
T1MS-03-03-002
W2-5-28
UPPERSTRUCTURE / Control Valve
Assemble Spool in Body (9) Assemble Spool in Body (27)
1. Apply hydraulic oil onto the spool (10) assembly. 1. Clamp spool (28) in a vise by using wooden
Install the spool (10) assembly to the cover (13) pieces. LOCTITE #242 onto socket bolt (14).
side in body (9) by rotating. Install spring seats (16) (2 used) and spring (29)
to spool (28). Install spring seat (16) to spool (28)
2. Apply onto O-ring (3). Install O-ring (3) to cover with socket bolt (14).
(7). Install cover (7) onto body (9) with socket : 3 mm
bolts (1) (2 used). : 19 to 22 N⋅m
(2.0 to 2.2 kgf⋅m, 14 to 16 lbf⋅ft)
3. Apply grease onto O-ring (3). Install O-ring (3) to
cover (13). Install spring seat (11), spring (2) and 2. Apply grease onto O-ring (25). Install O-ring (25),
spring seat (12) to spool (10). Install cover (13) wiper ring (18) and seal plate (24) to body (27).
onto body (9) with socket bolts (1) (2 used). Apply hydraulic oil onto the spool (28) assembly.
: 5 mm Install the spool (28) assembly to the cover (15)
: 7.3 to 10 N⋅m side in body (27) by rotating.
(0.7 to 1.0 kgf⋅m, 5 to 7 lbf⋅ft)
3. Apply grease onto O-ring (25). Install O-ring (25),
wiper ring (18) and seal plate (24) to body (27).
Install seal plate (24) to body (27) with socket
bolts (23) (2 used).
: 2.5 to 2.9 N⋅m
(0.2 to 0.3 kgf⋅m, 2 to 2.5 lbf⋅ft)
W2-5-29
UPPERSTRUCTURE / Control Valve
12
31
32
1 11
34
33
3
1
11
32
31
12
T1MS-03-03-004
W2-5-30
UPPERSTRUCTURE / Control Valve
Assemble Spool Except Bodies (9, 27)
The assembly for spool (34) in body (33) is explained
as an example.
W2-5-31
UPPERSTRUCTURE / Control Valve
DISASSEMBLE AND ASSEMBLE CHECK VALVE
19 to 22 19 to 21, 43
19 to 22
19 to 22
19 to 21, 69
19 to 22
W1MS-02-05-004
71 66 62 61 58 56 45 40 35 33 27 9
27
19, 55
22
20, 54
20
21, 53
18 22, 43, 69
W1MS-02-05-013
21
T1MS-03-03-003
W2-5-32
UPPERSTRUCTURE / Control Valve
Body (56) Section Body (71) Section
56 68 21
22
20
20
19
19
21
19
55
20
D D
54 53 52 22 21
Cross Section D-D
T1MS-03-03-008 T1MS-03-03-013
W2-5-33
UPPERSTRUCTURE / Control Valve
19 to 22 19 to 21, 43
19 to 22
19 to 22
19 to 21, 69
19 to 22
W1MS-02-05-004
71 66 62 61 58 56 45 40 35 33 27 9
27
19, 55
22
20, 54
20
21, 53
19 22, 43, 69
W1MS-02-05-013
21
T1MS-03-03-003
W2-5-34
UPPERSTRUCTURE / Control Valve
Disassemble and Assemble Check Valve
The check valve structure for bodies (27, 33, 35, 40,
45, 56, 66, 71) is the same. The disassembly and
assembly for the check valve in body (27) are
explained as an example.
1. Remove plug (19) from body (27). Remove O-ring 1. Install check valve (22) and spring (21) to body
(20) from plug (19). (27).
: 14 mm
2. Apply grease onto O-ring (20). Install O-ring (20)
IMPORTANT: 2 check valves are installed to to plug (19). Install plug (19) to body (27).
bodies (45, 56, 71). Do not confuse : 14 mm
the check valves as their : 29.4 N⋅m (3.0 kgf⋅m, 22 lbf⋅ft)
specifications are different.
2. Remove spring (21) and check valve (22) from
body (27).
W2-5-35
UPPERSTRUCTURE / Control Valve
(Blank)
W2-5-36
UPPERSTRUCTURE / Swing Device
REMOVE AND INSTALL SWING DEVICE
Removal 1
1. Remove floor mat (1) from the main frame.
W1MS-02-05-014
W1MS-02-05-015
W2-6-1
UPPERSTRUCTURE / Swing Device
Installation
W1MS-02-05-015
W1MS-02-05-014
W2-6-2
UPPERSTRUCTURE / Swing Device
(Blank)
W2-6-3
UPPERSTRUCTURE / Swing Device
Disassemble Swing Device
10
1 9
8
7
6
5
4
3 18
2
17
1
13
16
19
15
13
20
14
13
35
12
11
34 33 41 40
33 39
38
32
31
30
29 38
28 39
27 40
26 41
25
42
24 32
21 33
31
23
55
54
22 53
52
21 51
42 50
49
48
47
42 46 Overload Relief Valve
45 W1MS-02-06-002
44
43
W2-6-4
UPPERSTRUCTURE / Swing Device
W2-6-5
UPPERSTRUCTURE / Swing Device
10
1 9
8
7
6
5
4
3 18
2
17
1
13
16
19
15
13
20
14
13
35
12
11
34 33 41 40
33 39
38
32
31
30
29 38
28 39
27 40
26 41
25
42
24 32
21 33
31
23
55
54
22 53
52
21 51
42 50
49
48
47
42 46 Overload Relief Valve
45 W1MS-02-06-002
44
43
W2-6-6
UPPERSTRUCTURE / Swing Device
Disassemble Swing Device
1. Before disassembling, put the matching marks 7. Remove valve plate (25) and valve drive (24) from
between valve housing (34) and valve plate (25), geroller (23). Remove O-rings (21, 42) from valve
between valve plate (25) and geroller (23), plate (25).
between geroller (23) and flange (18) and
between flange (18) and bearing housing (8). 8. Remove geroller (23) and drive (22) from flange
(18). Remove O-rings (21, 42) from geroller (23).
2. Secure bearing housing (8) in a vise with the
pinion gear (2) side facing downward. 9. Remove socket bolts (19) (8 used) from flange
(18).
IMPORTANT: Do not disassemble overload relief : 6 mm
valve assembly (43 to 55) unless
necessary. 10. Remove the flange (18) assembly and springs
3. Remove overload relief valve assemblies (43 to (20) (8 used) from bearing housing (8). Remove
55) (2 used) and bolts (35) (4 used) from valve O-rings (13, 21 and 42) from the flange (18)
housing (34). assembly. Remove retaining ring (15), bearing
: 14 mm (16) and seal (17) from the flange (18) assembly.
4. Put the matching marks between valve plate (25) 11. Remove piston (14) and ring (12) from bearing
and valve (27). Remove valve (27) and valve housing (8). Remove O-ring (13) from piston (14).
housing (34) from valve plate (25). Remove O-rings (11, 13) from ring (12).
NOTE: Springs (32) (2 used) and pins (31) (2 12. Alternately remove friction plates (9) (6 used) and
used) may be removed from valve housing plates (10) (7 used) from bearing housing (8).
(34). Do not to lose spring (32) and pin
(31).
W2-6-7
UPPERSTRUCTURE / Swing Device
7
6
5
4
3
2
W1MS-02-06-002
W2-6-8
UPPERSTRUCTURE / Swing Device
13. Secure bearing housing (8) in a vise with the
pinion gear (2) side facing upward. Remove
retaining ring (3) from bearing housing (8).
W2-6-9
UPPERSTRUCTURE / Swing Device
Assemble Swing Device
21 26 30 28 29 27 32 31 38
39
34
40
25 41
42
23
24
16 42
21
18 42
19
13 17
13 20
14
15
12
13
11
9 22
10 8
4
1
3
7
2
T1MS-03-02-001
6 5 1
1- Plug (2 Used) 15 - Retaining Ring 29 - Inner Face Seal 43 - O-Ring (2 Used)
2- Pinion Gear 16 - Bearing 30 - Outer Face Seal 44 - Plug (2 Used)
3- Retaining Ring 17 - Seal 31 - Pin (2 Used) 45 - O-Ring (2 Used)
4- Bearing 18 - Flange 32 - Spring (2 Used) 46 - Sleeve (2 Used)
5- Collar 19 - Socket Bolt (8 Used) 33 - Plug (3 Used) 47 - Poppet (2 Used)
6- Retaining Ring 20 - Spring (8 Used) 34 - Valve Housing 48 - Spring (2 Used)
7- X-Ring 21 - O-Ring (2 Used) 35 - Bolt (4 Used) 49 - Spring Seat (2 Used)
8- Bearing Housing 22 - Drive 36 - Screw (2 Used) 50 - Spring (2 Used)
9- Friction Plate (6 Used) 23 - Geroller 38 - Plug (2 Used) 51 - O-Ring (2 Used)
10 - Plate (7 Used) 24 - Valve Drive 39 - O-Ring (2 Used) 52 - O-Ring (2 Used)
11 - O-Ring 25 - Valve Plate 40 - Spring (2 Used) 53 - Seat (2 Used)
12 - Ring 26 - O-Ring 41 - Ball (2 Used) 54 - Adjusting Screw (2 Used)
13 - O-Ring (3 Used) 27 - Valve 42 - O-Ring (3 Used) 55 - Lock Nut (2 Used)
14 - Piston 28 - Balancing Ring
W2-6-10
UPPERSTRUCTURE / Swing Device
Assemble Swing Device 8. Apply grease onto O-ring (13). Install O-ring (13),
seal (17), bearing (16) and retaining ring (15) to
1. Install bearing (4), collar (5) and retaining ring (6) flange (18).
to pinion gear (2).
NOTE: Install seal (17) with the inner-diameter
2. Install X-ring (7) to bearing housing (8). side positioned above the outer diameter
side as illustrated.
3. Install pinion gear (2) assembly to bearing
housing (8) by using a plastic hammer. 17
Inner Diameter side
W2-6-11
UPPERSTRUCTURE / Swing Device
21 27 32 31
34
25
42
23
24
42
T1MS-03-02-001
W2-6-12
UPPERSTRUCTURE / Swing Device
IMPORTANT: Align the end of selected outer tooth IMPORTANT: Check the positions to install valve
(C) of the rotor inside geroller (23) drive (24) and valve (27). Install valve
with matching mark (B). (27) to valve plate (25). If the
13. Put matching mark (B) on selected tooth (B) at the positions of valve drive (24) and
lower side gear part of valve drive (24). Put valve (27) are incorrect, the rotation
matching mark (A) on tooth (A) at the upper side direction will be reversed.
gear part corresponding to the lower side gear 15. Move the center of cross hole on valve (27) by 15
part of valve drive (24). Align the end of selected degrees towards matching mark (A) on valve
outer tooth (C) of the rotor inside geroller (23) with drive and install valve (27) to valve drive (25).
matching mark (B) on valve drive (24).
24
A
Matching
Mark (A)
B
Matching
Mark (A)
24
Matching 27
Mark (B)
15° Cross-Hole
Rotor
Selected Tooth (C) End
W1MP-02-04-011 W1MP-02-04-012
14. Apply grease onto O-rings (21, 42). Install O-rings 16. Apply grease onto springs (32) (2 used) and pins
(21, 42) to valve plate (25). Align the matching (31) (2 used). Install springs (32) (2 used) and
marks and install valve plate (25) to geroller (23). pins (31) (2 used) to valve housing (34).
W2-6-13
UPPERSTRUCTURE / Swing Device
26 30 28 29 31
34
25
42
T1MS-03-02-001
W2-6-14
UPPERSTRUCTURE / Swing Device
IMPORTANT: Check the direction to install outer 19. Apply grease onto O-rings (26, 42). Install O-rings
face seal (30) and inner face seal (26, 42) to valve housing (34).
(29). Face the outer side of outer
face seal (30) and the inner side of 20. Align the matching marks and install valve
inner face seal (29) upward housing (34) to valve plate (25). Secure valve
respectively when installing. housing (34) to bearing housing (8) with bolts (35)
17. Install outer face seal (30) to the outside and inner (4 used).
face seal (29) to the inside of the balancing ring : 14 mm
(28). : 53 N⋅m (5.4 kgf⋅m, 39 lbf⋅ft)
Inner Diameter side 29 Outer Diameter side
21. Install the hoses (4 used) to the swing device.
Operate the control lever and check the rotation
of the pinion gear.
Right swing: Counter clockwise rotation
W1MP-02-04-013 Left swing: Clockwise rotation
30 28
34 30 28 29
W1MP-02-04-014
W2-6-15
UPPERSTRUCTURE / Swing Device
(Blank)
W2-6-16
UPPERSTRUCTURE / Pilot Valve
REMOVE AND INSTALL LEFT FRONT
PILOT VALVE
Removal
1
CAUTION: Release any pressure in the
hydraulic oil tank before doing any work. 2
(Refer to BLEED AIR FROM HYDRAULIC OIL
TANK on W1-4-1.)
4, 5
1. Remove screws (2) (3 used) from covers (1, 3).
3
W1MS-02-07-001
9 W1MS-02-07-002
10
5. Loosen nut (11). Remove lever (10) from adapter
(12). 11
: 19 mm
12
6. Remove hoses (15) (6 used) from the elbows (6
used) on the bottom of pilot valve (14). Cap the 13
open end. Attach the tags to hoses (15) (6 used).
: 19 mm
9
7. Remove bolts (13) (4 used) from lever stand (9).
Remove pilot valve (14) from lever stand (9).
: 13 mm 14
15 W1MS-02-07-003
W2-7-1
UPPERSTRUCTURE / Pilot Valve
Installation
1. Attach pilot valve (14) to lever stand (9) with bolts 10
(13) (4 used).
11
: 13 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)
12
2. Install hoses (15) (6 used) to the elbows (6 used)
on the bottom of pilot valve (14). 13
: 19 mm
: 29.5 N⋅m (3.0 kgf⋅m, 22 lbf⋅ft)
9
3. Install lever (10) to adapter (12). Tighten nut (11).
: 19 mm
: 35 N⋅m (3.5 kgf⋅m, 26 lbf⋅ft) 14
15 W1MS-02-07-003
9 W1MS-02-07-002
10
3
W1MS-02-07-001
W2-7-2
UPPERSTRUCTURE / Pilot Valve
REMOVE AND INSTALL RIGHT FRONT
PILOT VALVE
Removal
1. Insert the key into door lock (2). Unlock cover (1).
2
2. Open cover (1). Unlock lock (4) of cover (3).
M1MS-07-003
M1MS-07-004
3. Insert the key into door lock (5). Unlock cover (4).
Fully open cover (4). Insert lock bar (6) into lock
hole (7) on cover (4).
M1MS-07-005
W2-7-3
UPPERSTRUCTURE / Pilot Valve
4. Remove caps (9, 11) from covers (8, 13). Remove
screws (10, 12) from covers (8, 13).
14
7. Remove bolts (19) (2 used) from cover (18).
: 13 mm 16 15 W1MS-02-07-004
19
W1MS-02-07-005
20
21
W1MS-02-07-006
22
W2-7-4
UPPERSTRUCTURE / Pilot Valve
11. Remove screw (25) from cover (8).
8
23
25
W1MS-02-07-007
13 24 13
Grip
14. Remove cover (13) from lever stand (33).
27
W1MS-02-07-008
29 28
30, 31, 32
18. Loosen nut (30). Remove lever (32) from adapter
(31).
: 19 mm 33
W1MS-02-07-009
35
W2-7-5
UPPERSTRUCTURE / Pilot Valve
30, 31, 32
Installation
1. Install pilot valve (34) to lever stand (27) with bolts
(33) (4 used).
: 13 mm 33
: 20 N⋅m (2.0 kgf⋅m, 15 lbf⋅ft)
W1MS-02-07-009
35
27
W1MS-02-07-008
29 28
8
23
25
W1MS-02-07-007
13 24 13
W2-7-6
UPPERSTRUCTURE / Pilot Valve
7. Connect connectors (21, 22) inside cover (18).
Install cover (18).
18
21
W1MS-02-07-006
22 Blade Lever
19
W1MS-02-07-005
20
W2-7-7
UPPERSTRUCTURE / Pilot Valve
13. Remove lock bar (6) from lock hole (7) on cover
(4). Unlock cover (4). Close cover (4). Insert the
key into door lock (5) and lock it.
M1MS-07-005
14. Insert the key into door lock (2). Open cover (1).
Lock cover (4) of cover (3). 1
15. Close cover (1). Insert the key into door lock (2)
and lock it. 4
M1MS-07-004
M1MS-07-003
W2-7-8
UPPERSTRUCTURE / Pilot Valve
REMOVE AND INSTALL TRAVEL PILOT
VALVE
Removal
W1MS-02-05-014
W1MS-02-05-015
7 4
4. Remove bolts (7) (2 used) from cover (6). Remove
cover (6) from the main frame.
6
: 17 mm
W1MS-02-05-016
5
W2-7-9
UPPERSTRUCTURE / Pilot Valve
5. Remove bolts (9) (4 used) and washers (10) (4 8
used) from lever brackets (8) (2 used). Remove
lever brackets (8) (2 used) from pilot valve (14).
: 17 mm
Installation
1. Install pilot valve (14) to the main frame with
socket bolts (11) (2 used), spring washers (12) (2 W1MS-02-07-010
used) and washers (13) (2 used).
16 18 17 16
: 8 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
W2-7-10
UPPERSTRUCTURE / Pilot Valve
4. Install covers (4, 6) to the main frame with bolts (5,
7) (2 used for each).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
7 4
W1MS-02-05-016
5
W1MS-02-05-015
W1MS-02-05-014
W2-7-11
UPPERSTRUCTURE / Pilot Valve
REMOVE AND INSTALL BLADE PILOT
VALVE
Removal
2
1. Insert the key into door lock (2). Unlock cover (1).
M1MS-07-003
M1MS-07-004
3. Insert the key into door lock (5). Unlock cover (3).
Fully open cover (3). Insert lock bar (6) into lock
hole (7) on cover (3).
M1MS-07-005
W2-7-12
UPPERSTRUCTURE / Pilot Valve
4. Remove bolts (9) (2 used) from cover (8). Remove
cover (8) from bracket (12).
: 13 mm
8
5. Remove bolts (10) and (11) (2 used) from bracket
(12).
: 13 mm
NOTE: The lengths of bolts (10, 11) are different. 9
13 14
16
17
12
W1MS-02-07-011
W1MS-02-07-012
18
W2-7-13
UPPERSTRUCTURE / Pilot Valve
Installation
1. Attach hoses (18) (4 used) to pilot valve (17).
: 19 mm
: 29.5 N⋅m (3.0 kgf⋅m, 22 lbf⋅ft)
17
W1MS-02-07-012
18
13 14
2. Install pilot valve (17) to bracket (12) with bolts
(16) (2 used).
: 13 mm
15
: 20 N⋅m (2.0 kgf⋅m, 15 lbf⋅ft)
10
W1MS-02-07-004
12 11
W2-7-14
UPPERSTRUCTURE / Pilot Valve
6. Remove lock bar (6) from lock hole (7) on cover
(3). Open cover (3). Insert the key into door lock
(5) and lock it.
M1MS-07-005
7. Insert the key into door lock (2). Open cover (1).
Lock lock (4) of cover (3).
1
8. Close cover (1). Insert the key into door lock (2)
and lock it.
4
M1MS-07-004
M1MS-07-003
W2-7-15
UPPERSTRUCTURE / Pilot Valve
REMOVE AND INSTALL BOOM SWING
PILOT VALVE
Removal
W1MS-02-05-014
W1MS-02-05-015
W1MS-02-05-016
5
W2-7-16
UPPERSTRUCTURE / Pilot Valve
5. Remove bolts (12) (2 used) from cover (8).
Remove cover (8) from pilot valve (13).
: 13 mm
10
13
W1MS-02-07-014
W2-7-17
UPPERSTRUCTURE / Pilot Valve
17, 18
Installation
1. Install bracket (10) to pilot valve (13) with socket
bolts (17) (2 used) and washers (18) (2 used).
: 6 mm 10
: 20 N⋅m (2.0 kgf⋅m, 15 lbf⋅ft)
13
W1MS-02-07-014
W1MS-02-07-013
16 15
W2-7-18
UPPERSTRUCTURE / Pilot Valve
5. Install covers (4, 6) to the main frame with bolts (5,
7) (2 used for each).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
7 4
W1MS-02-05-016
5
W1MS-02-05-015
W1MS-02-05-014
W2-7-19
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
W2-7-20
UPPERSTRUCTURE / Pilot Valve
Disassemble Right and Left Pilot Valves IMPORTANT: Insert a soft rubber between sleeves
(12) (4 used) and the tool in order
IMPORTANT: Casing (22) is made of aluminium. not to damage the surfaces of
As too strong a force may deform or sleeves (12) (4 used).
damage them, handle them with Oil seals (11) (4 used) cannot be
care. removed from sleeves (12) (4 used).
Sleeves (12) (4 used) and oil seals
IMPORTANT: Spools (21) (4 used) have been (11) (4 used) must be replaced as an
selected to match the hole of casing assembly.
(22). The dimensions of balance
springs A (3) (2 used), B (4) (2 used) 5. Remove sleeves (12) (4 used) upward by using a
and return springs A (5) (2 used), B pair of pliers.
(6) (2 used) as well as those of
pushers A (9) (2 used), B (10) (2
used) are different. Indicate the port IMPORTANT: The dimensions of pushers (9, 10) (2
number from which it is removed. used for each) for ports (1, 3) and
Ports numbers are stamped on the ports (2, 4) are different. Indicate the
periphery of casing (22). port number from which it is
removed in order to keep by the port
IMPORTANT: Do not remove screw joint (17) with number.
casing (22) clamped in a vise. The
strong torque may act on screw joint 6. Remove springs (9, 10) (2 used for each) from
(17). casing (22).
1. Clamp screw joint (17) in a vise. Turn cam (16) by
using a spanner. Remove screw joint (17). 7. Install special tool (ST 4145) to the port hole on
: 19 mm、32 mm casing (22).
: 6 mm
2. Clamp the flat surface of casing (22) in a vise. NOTE: Do not drop spools (21) (4 used) when
Remove cam (16) from universal joint (15). compressing springs (5, 6) (2 used for
: 32 mm each).
22
W178-02-07-048
ST 4145
W2-7-21
UPPERSTRUCTURE / Pilot Valve
17
16
22
7
6 21
5
4 19
3 18
W178-02-07-064
W2-7-22
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), B
(4) (2 used) from casing (22).
W2-7-23
UPPERSTRUCTURE / Pilot Valve
ASSEMBLE RIGHT AND LEFT PILOT VALVES
17
16 15
11 9, 10
14
13 12
8
7
3, 4
5, 6
19
1
19
22 21
18
W178-02-06-055
W2-7-24
UPPERSTRUCTURE / Pilot Valve
Assemble Right and Left Pilot Valves IMPORTANT: Refer to the table in order to
assemble them correctly.
IMPORTANT: Assemble the pilot valve while
cleaning each of the parts. 3. Install spacers (1) (4 used), shim (2) and balance
springs (3, 4) (2 used for each) to spools (21) (4
NOTE: Table below shows the relations between
used). Install return springs (5, 6) (2 used for
each port and the components. Do not
each) to casing (22).
confuse them when assembling.
Port Spool Shim Pushers A, B 4. Install spring guides (7) (4 used) onto return
No. (21) (2) (9, 10) springs (5, 6) (2 used for each) with the protrusion
1 Same Same Outer grooves (3 used) facing upward.
2 to the to the Without outer groove
3 former former Outer grooves (3 used) 5. Install special tool (ST 4146) to the pusher hole
4 one one Without outer groove on casing (22). Hold special tool (ST 4146) and
Unit: mm (in) compress springs (3 to 6).
Port Return Spring Balance Spring A, B : 12 mm
No. (5, 6) (3, 4)
1 43 (1.7) 29.9 (1.2) NOTE: Tighten special tool (ST 4146) by using bolt
2 48 (1.9) 30.1 (1.2) (M14, Pitch 2.0 mm).
3 43 (1.7) 29.9 (1.2)
4 48 (1.9) 30.1 (1.2)
ST 4146
W2-7-25
UPPERSTRUCTURE / Pilot Valve
17
16 15
9, 10
14 11
12
13
8
3, 4
22
W178-02-06-055
W2-7-26
UPPERSTRUCTURE / Pilot Valve
7. Install retaining rings (8) (4 used) to the heads of 14. Align the bolt holes on plate (14) and casing (22).
spools (21) (4 used) out of special tool (ST 4146). Place plate (14) onto casing (22). Tighten
universal joint (15).
IMPORTANT: Check the positions to install :17 mm
pushers (9, 10) (2 used for each). :24.5 N⋅m (2.5 kgf⋅m, 18 lfb⋅ft)
8. Install pushers (9, 10) (2 used for each) to casing
(22). IMPORTANT: Check the tightness of cam (16).
After pushing pushers (9, 10) (2 used for each) by
hand several times, remove them. Check if 15. Install cam (16) to universal joint (15). The
retaining rings (8) (4 used) fall off or balance clearance between cam (16) and pushers (9, 10)
springs (3, 4) (2 used for each) are located (2 used for each) should be 0 to 0.2 mm (0 to
correctly. 0.008 in).
After checking, install pushers (9, 10) (2 used for
each) to casing (22). 16. Secure cam (16) by using a spanner. Tighten
screw joint (17) by using a spanner.
9. Apply grease to the ball part at the ends of :19 mm,32 mm
pushers (9, 10) (2 used for each). :68.4 N⋅m (7.0 kgf⋅m, 50 lfb⋅ft)
W2-7-27
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)
W2-7-28
UPPERSTRUCTURE / Pilot Valve
Disassemble Travel Pilot Valve
IMPORTANT: Casing (23) is made of aluminum. As IMPORTANT: The number of shims (27) has been
too strong a force may deform or determined for each port. Keep
damage them, handle them with shims (27) carefully in order to
care. install shims (27) to each former port
when reassembing.
IMPORTANT: Spools (24) (4 used) have been
selected to match the hole of casing 6. Compress balance springs (18) (4 used). Remove
(23). spring guides (17) (4 used), balance springs (18)
Indicate the port number from which (4 used), shims (27) (12 used) and spacers (26)
it is removed. (4 used) from spools (24) (4 used).
Ports numbers are stamped on the
periphery of casing (23). 7. Remove springs (25) (4 used) from casing (23).
W2-7-29
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
W2-7-30
UPPERSTRUCTURE / Pilot Valve
IMPORTANT: Place a stand under brackets (11) (2 11. Remove O-rings (33) (2 used) from pins (35) (2
used) and form an reaction force. If used).
holder (7) bears the reaction force, a
strong force acts on pins (35) (2 12. Place holder (7) with the casing (23) mounting
used) and pins (35) (2 used) may be surface facing upward.
deformed.
13. Remove spring pins (3, 4) (2 used for each) from
8. Place a stand under bracket (11). cams (5) (2 used) at the same time by using
Tap and remove both spring pins (12, 13) (2 used special tool (ST 1237).
for each) from bracket (11) at the same time by The hole insides of spring pins (3, 4) (2 used for
using special tool (ST 1237). each) in cams (5) (2 used) are in stepped-shape.
NOTE: The hole inside of spring pins (12, 13) (2 Tap the bottom of cam (5).
used for each) in bracket (11) are in NOTE: As the holes of spring pins (3, 4) (2 used for
stepped-shape. Spring pins (12, 13) (2 each) are crimped, spring pins (3, 4) may
used for each) can only be removed in one feel tight when removing.
direction.
14. Remove pins (35) (2 used) and cams (5) (2 used)
9. Remove bracket (11) from pins (35) (2 used). from holder (7) by using a bar and hammer.
NOTE: As the removed sides of spring pins (10) (2 NOTE: Do not remove bushings (6) (4 used)
used) are crimped by bracket (11), do not unless necessary. When removing, tap
remove spring pins (10) (2 used) unless bushings (6) (4 used) by using special tool
necessary. (ST7256).
Stand
W176-02-07-019
W2-7-31
UPPERSTRUCTURE / Pilot Valve
ASSEMBLE TRAVEL PILOT VALVE
11 32 31 1 2 35 6 12 10 13 30
7 5 3, 4
29
34 15
9 33 17
28
18
8
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 (2 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)
W2-7-32
UPPERSTRUCTURE / Pilot Valve
Assemble Travel Pilot Valve
IMPORTANT: Check the direction to install spring 6. If bushings (6) (4 sued) have been removed from
guides (17) (4 used). holder (7), install bushings (6) (4 used) to holder
(7) as follows.
1. Assemble spools (24) (4 used) as followings.
Insert spacers (26) (2 used), shim (27) and NOTE: Bushings (6) (4 used) are identical.
balance springs (18) (4 used) into spools (24) (4 Insert bushing (6) into special tool (ST
used) in this order. Insert the same quantity of 7256). Tap special tool (ST 7256) and
shims (27) before disassembling. install bushing (6) into the hole of holder (7)
• Push balance springs (18) (4 used) by hand. by using a hammer. Stop tapping when
Install spring guides (17) (4 used) to spools (24) bushing (6) end is flush with the inside wall.
(4 used) with the stepped-end facing downward.
7 ST 7256
IMPORTANT: Before inserting the parts into holder
(7) and casing (23), apply hydraulic
oil onto the parts.
(4 used).
• Install bushing (6) in near side as illustrated. Stop
tapping when the bushing (6) end is flush with the
• Install O-rings (14) (4 used) to bushings (15) (4
outside of holder (7).
used).
• Insert pushers (16) (4 used) into bushings (15) (4 6
used).
• Apply grease to the heads of pushers (16) (4 7 ST 7256
used).
6
7
ST 7256
W176-02-07-01313
W2-7-33
UPPERSTRUCTURE / Pilot Valve
32 31 35 31 32 7 5 3, 4 30
29
34
9 33
23
W178-02-06-056
W2-7-34
UPPERSTRUCTURE / Pilot Valve
7. Install O-rings (33) (2 used) to pins (35) (2 used). 11. Install rubber seats (31) (2 used) to pins (35) (2
Install pins (35) (2 used) and cams (5) (2 used) to used).
holder (7). (2 places)
12. Apply grease to O-rings (33) (2 used).
IMPORTANT: Check the directions to install spring
pins (3, 4) (2 used for each). IMPORTANT: Check the direction of dampers (32)
(2 used).
8. Install spring pins (3, 4) (2 used for each) to cams The inner bores of dampers (32) (2
(5) (2 used) by using special tool (ST 1237). used) are edged-shape. When prying
Secure cams (5) (2 used) and pins (35) (2 used). dampers (32) (2 used), O-rings (33)
(2 used) are damaged.
NOTE: Install spring pins (3, 4) (2 used for each)
with their slits positioned 90 degrees apart 13. Install dampers (32) (2 used) to pins (35) (2 used)
from each other. Tap and install spring pins with the levers facing upward.
(3, 4) (2 used for each) until spring pins (3,
4) make contact with the stepped part in 14. Secure dampers (32) (2 used) and rubber seats
the hole. (31) (2 used) to holder (7) with socket bolts (9) (2
used) and spring washers (8) (2 used).
3 Slit Slit :5 mm
:7 N⋅m (0.7 kgf⋅m, 5 lfb⋅ft)
W2-7-35
UPPERSTRUCTURE / Pilot Valve
11 32 1 2 35 12 13 7 1
10 1
W178-02-06-056
W2-7-36
UPPERSTRUCTURE / Pilot Valve
16. Install brackets (11) (2 used) to pins (35) (2 used).
Align the inserting holes of spring pins (12, 13) (2
used for each).
Crimpe
d Here Crimped
Here
11 35
Stand 12, 13
W176-02-07-011
W2-7-37
UPPERSTRUCTURE / Pilot Valve
DISASSEMBLE BOOM SWING, BLADE
AND AUXILIARY PILOT VALVES
17 18 1
16
15
3
4
14
5
7
13
8
12
10
11 W1CF-02-07-001
W2-7-38
UPPERSTRUCTURE / Pilot Valve
Disassemble Boom Swing, Blade and Auxiliary
Pilot Valves
W2-7-39
UPPERSTRUCTURE / Pilot Valve
ASSEMBLE BOOM SWING, BLADE AND
AUXILIARY PILOT VALVES
17 18 1
16
15
3
4
14
5
7
13
8
12
10
11 W1CF-02-07-001
W2-7-40
UPPERSTRUCTURE / Pilot Valve
Assemble Boom Swing, Blade and Auxiliary Pilot
Valves
4. Attach the pusher (15) (2 used) assemblies on top
IMPORTANT: Install spring guides (6) (2 used) with of the spool (10) assemblies (2 used). Alternately
the groove side facing to the spring tighten the holder (5) to the casing (11) with
(7) side. When installing spring socket bolts (3) (2 used).
guides (6) (2 used), do not compress : 5 mm
spring (7) 6 mm or more. : 11.5 to 21.5 N⋅m (1.2 to 2.2 kgf⋅m, 8 to 16 lbf⋅ft)
1. Install spacers (9) (2 used) and springs (7) (2 5. Attach the cam (2) to the holder (5) with the pin
used) to spools (10) (2 used). While compressing (16).
springs (7) (2 used), install spring guides (6) (2
used) to spools (10) (2 used). 6. Apply LOCTITE #262 to the set screw (18). Attach
the set screw (18) to the cam (2).
IMPORTANT: Insert the spool (10) assemblies (2 : 2.5 mm
used) to the former port before : 7.0 N⋅m (0.7 kgf⋅m, 5 lbf⋅ft)
disassembling.
7. Tilt the cam (2) and apply grease to the ends of
2. Insert springs (8) (2 used) and the spool (10) the pushers (15) (2 used).
assemblies (2 used) into casing (11).
8. Attach the boot (4) and spacers (1) (2 used) to the
IMPORTANT: Check the direction of oil seals (14) holder (5).
(2 used). Apply grease to the lip
parts of oil seal (14) (2 used) and to
the inside of bushings (13) (2 used).
W2-7-41
UPPERSTRUCTURE / Pilot Valve
(Blank)
W2-7-42
UPPERSTRUCTURE / Solenoid Valve
REMOVE AND INSTALL SOLENOID VALVE
Removal
W1MS-02-05-014
2
W1MS-02-05-015
2
W1MS-02-05-016
6
W2-8-1
UPPERSTRUCTURE / Solenoid Valve
7
4. Remove bolts (7, 9) (2 used for each) from plate
(8). Remove plate (8) from main frame (10).
Disconnect connectors (11) (2 used).
8
: 17 mm
11 10 W1MS-02-08-001
13
W1MS-02-08-002
W2-8-2
UPPERSTRUCTURE / Solenoid Valve
Installation
1. Install hoses (12) (6 used) to solenoid valve (13). 12
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
13
W1MS-02-08-002
7
2. Install solenoid valve (13) to plate (8) with bolts (7)
(2 used). Install plate (8) to main frame (10) with
8
bolts (9) (2 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37lbf⋅ft)
11 10 W1MS-02-08-001
W2-8-3
UPPERSTRUCTURE / Solenoid Valve
4. Install cover (5) to main frame (2) with bolts (6) (2
used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
W1MS-02-05-016
6
W1MS-02-05-015
2
W1MS-02-05-014
2
W2-8-4
UPPERSTRUCTURE / Solenoid Valve
(Blank)
W2-8-5
UPPERSTRUCTURE / Solenoid Valve
Disassemble 2-Unit Solenoid Valve
7
6
8 6
9
4
3
9 5
1 10
10 11 4
2 17 3
11
12
16 1
1
12 15
14
2
13
W1MS-02-08-003
W2-8-6
UPPERSTRUCTURE / Solenoid Valve
Disassemble 2-Unit Solenoid Valve
W2-8-7
UPPERSTRUCTURE / Solenoid Valve
Assemble 2-Unit Solenoid Valve
6
4
1 5
3
8 13 17 16 15 14
9 2
7 13
10
11
12
T1LA-03-06-001 T1LA-03-06-002
W2-8-8
UPPERSTRUCTURE / Solenoid Valve
Assemble 2-Unit Solenoid Valve
W2-8-9
UPPERSTRUCTURE / Solenoid Valve
(Blank)
W2-8-10
MEMO
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SECTION 3
UNDERCARRIAGE
CONTENTS
Group 1 Swing Bearing Group 6 Upper and Lower Roller
Remove and Install Swing Bearing ......... W3-1-1 Remove and Install Lower Roller ............ W3-6-1
Structure of Lower Rollre ........................ W3-6-3
Group 2 Travel Device Maintenance Standards .......................... W3-6-4
Remove and Install Travel Device .......... W3-2-1
Disassemble Travel Reduction Gear....... W3-2-4 Group 7 Track
Assemble Travel Reduction Gear ........... W3-2-6 Remove and Install Track ....................... W3-7-1
Disassemble Travel Motor .................... W3-2-10 Maintenance Standard ............................ W3-7-3
Assemble Travel Motor......................... W3-2-12
Disassemble Brake Valve ..................... W3-2-14
Assemble Brake Valve.......................... W3-2-16
Maintenance Standard.......................... W3-2-18
1MSW-3-1
(Blank)
1MSW-3-2
UNDERCARRIAGE / Swing Bearing
REMOVE AND INSTALL SWING BEARING
Removal
3 2
W105-03-01-001
3. Remove bolts (4) (18 used) from inner race (3) of
swing bearing (1).
: 17 mm
1
W3-1-1
UNDERCARRIAGE / Swing Bearing
Installation
Machine Front
2. Apply THREEBOND #1102 onto the swing bearing
(1) mounting surfaces of center frame (2).
[S] (Soft Zone)
Marking Portion
CAUTION: Swing bearing (1) weight: 21 kg [S] (Soft Zone)
1
(46 lb) Marking Portion
3 2
W105-03-01-001
W1MS-03-01-001
W3-1-2
UNDERCARRIAGE / Travel Device
REMOVE AND INSTALL TRAVEL DEVICE
Removal
2, 3 1
1. Remove the track. Refer to the Remove and In-
stall Track group on W3-7-1.
4
W1MS-04-02-029
6, 7 5 1
3. Remove hoses (8 to 11) from travel device (5).
Cap the open ends. 8
Attach the identification tags onto the removed
hoses. 9
: 19 mm, 22 mm 10
11
Caution: Travel Device (5) weight: 30 kg
(66 lb)
W1MP-03-02-009
5 13, 14
W3-2-1
UNDERCARRIAGE / Travel Device
Installation
9
3. Install hoses (8 to 11) to travel device (5).
: 19 mm 10
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
11
: 22 mm
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)
4. Install cover (4) onto side frame (1) with bolts (2)
(3 used) and washers (3) (3 used).
: 17 mm
W1MS-04-02-030
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
4
W1MS-04-02-029
W3-2-2
UNDERCARRIAGE / Travel Device
(Blank)
W3-2-3
UNDERCARRIAGE / Travel Device
DISASSEMBLE TRAVEL REDUCTION GEAR
14
13
12
11
10
9
8
7
6 29
5 28
4
2 15
3 27
1
26
25
24
23
22
19 21
18
17 20
16 W1MS-03-02-002
1 - Plug (2 Used) 9- First Stage Planetary Gear 16 - Second Stage Planetary 23 - Bearing Nut
(3 Used) Gear (4 Used)
2- O-Ring (2 Used) 10 - Needle Bearing (3 Used) 17 - Needle Bearing (4 Used) 24 - Angular Bearing
3- Stopper Ring 11 - Inner Race (3 Used) 18 - Inner Race (4 Used) 25 - Ball (94 Used)
4- O-Ring 12 - Carrier 19 - Thrust Washer (4 Used) 26 - Floating Seal (2 Used)
5- Cover 13 - Retaining Ring 20 - Plug 27 - Body
6- Pin (3 Used) 14 - Sun Gear 21 - Ring Gear 28 - Spring (2 Used)
7- Thrust Plate 15 - Plug 22 - Plug 29 - Piston (2 Used)
8- Drive Gear
W3-2-4
UNDERCARRIAGE / Travel Device
Disassemble Travel Reduction Gear 7. Remove second stage planetary gears (16) (4
used), needle bearings (17) (4 used), inner races
1. Remove plugs (1) (2 used) from cover (5). Drain (18) (4 used) and thrust washers (19) (4 used)
gear oil from the plug (1) hole (DRAIN). from body (27).
: 6 mm
NOTE: Gear oil: 0.25 L (0.07 US gal) IMPORTANT: Do not lose balls (25) (94 used).
8. Remove plug (20) from ring gear (21). Remove
2. Remove stopper ring (3) from cover (5). Remove balls (25) (94 used) from the plug (20) hole.
cover (5) from ring gear (21). : 5 mm
NOTE: When degreasing ball (25) by using white
3. Remove O-ring (4) from cover (5). gasoline, remove ball (25) by air blowing.
4. Remove thrust plate (7) and drive gear (8) from 9. Insert bolts (M10, Pitch 1.5 mm, Length 70 mm)
body (27). (3 used) into the hole (3 places) for sprocket on
ring gear (21). Tighten the bolts (3 used) evenly.
Remove ring gear (21) from body (27).
5. Remove first stage planetary gears (9) (3 used),
needle bearings (10) (3 used) and inner races
(11) (3 used) from the carrier (12) assembly. 10. Remove plug (15) from body (27). Remove bear-
ing nut (23) by using special tool (ST 3169).
: 6 mm
6. Remove retaining ring (13) from sun gear (14).
Remove sun gear (14) from body (27).
11. Evenly tap the outer surface of ball (25) groove on
angular bearing (24) by using a round bar and
hammer. Remove angular bearing (24) from body
(27).
W3-2-5
UNDERCARRIAGE / Travel Device
ASSEMBLE TRAVEL REDUCTION GEAR
28 27 26 20 15 21 12 11 9 10 4
5
1
T1MS-03-05-001
25 24 23 19 16 17 18 14 13
1 - Plug (2 Used) 9- First Stage Planetary Gear 16 - Second Stage Planetary 23 - Bearing Nut
(3 Used) Gear (4 Used)
2- O-Ring (2 Used) 10 - Needle Bearing (3 Used) 17 - Needle Bearing (4 Used) 24 - Angular Bearing
3- Stopper Ring 11 - Inner Race (3 Used) 18 - Inner Race (4 Used) 25 - Ball (94 Used)
4- O-Ring 12 - Carrier 19 - Thrust Washer (4 Used) 26 - Floating Seal (2 Used)
5- Cover 13 - Retaining Ring 20 - Plug 27 - Body
6- Pin (3 Used) 14 - Sun Gear 21 - Ring Gear 28 - Spring (2 Used)
7- Thrust Plate 15 - Plug 22 - Plug 29 - Piston (2 Used)
8- Drive Gear
W3-2-6
UNDERCARRIAGE / Travel Device
Assemble Travel Reduction Gear 8. Install thrust washers (19) (4 used), inner races
(18) (4 used), needle bearings (17) (4 used) and
1. Apply grease onto floating seals (26) (2 used). In- second stage planetary gears (16) (4 used) to
stall floating seal (26) to body (27). body (27).
2. Evenly tap the outer race surface on angular 9. Install retaining ring (13) to sun gear (14). Install
bearing (24) by using a round bar and hammer. sun gear (14) and carrier (12) to body (27).
Install angular bearing (24) to ring gear (21).
10. Install pins (6) (3 used), inner races (11) (3 used),
3. Install floating seal (26) to ring gear (21). Apply oil needle bearings (10) (3 used), first stage planetary
onto the sliding surface of floating seals (26) (2 gears (9) (3 used), drive gear (8) and thrust plate
used) on body (27) and ring gear (21). Align ring (7) to carrier (12).
gear (21) with body (27). Evenly tap the outer
surface of ring gear (21) by using a plastic ham-
mer and install ring gear (21) to body (27).
W3-2-7
UNDERCARRIAGE / Travel Device
21 4
T1MS-03-05-001
W3-2-8
UNDERCARRIAGE / Travel Device
11. Apply grease onto O-ring (4).
Install O-ring (4) to cover (5). Add gear oil (0.25 L,
0.07 US gal).
12. Align the plug (1) hole on cover (5) with the notch
on ring gear (21). Install cover (5) onto ring gear
(21) with stopper ring (3).
NOTE: Attach a screwdriver onto the end of stop-
per ring (3). Secure cover (5) while tapping
stopper ring (3) by using a hammer.
W3-2-9
UNDERCARRIAGE / Travel Device
DISASSEMBLE TRAVEL MOTOR
6
4
3
1
8
31
30
9 29
28
10
27
11
26
12 25
24
13
23
22
21
20
19
18
17
16
W1MS-03-02-003
15
W3-2-10
UNDERCARRIAGE / Travel Device
Disassemble Travel Motor 7. Remove the shaft (20) assembly from housing
(15) by using a bar and plastic hammer.
IMPORTANT: Do not damage the seat surface of
brake valve (5). 8. Remove oil seal (18) from housing (15) by using
5 a screwdriver.
W172-03-02-006
Bar
Seat Surface
19
1. Remove socket bolts (6) (6 used) from brake
valve (5). Remove the brake valve (5) assembly 20
from housing (15).
: 8 mm
W3-2-11
UNDERCARRIAGE / Travel Device
ASSEMBLE TRAVEL MOTOR
9 5 2 12 10 13 11 15 22 21 19
31
30
T1MS-03-05-001
29 8 1 28 7 27 23 26 25 24 20 16, 17 18
W3-2-12
UNDERCARRIAGE / Travel Device
Assemble Travel Motor 7. Apply hydraulic oil onto the mounting holes (9
places) for plunger (23) on rotor (27). Install
1. Clean the oil seal (18) mounting position of hous- plungers (24) (9 used) to retainer (24). Install the
ing (15). Apply grease onto the inner and outer plunger (23) assembly to rotor (27).
surfaces of oil seal (18). Install oil seal (18) to
housing (15) in order not to deform oil seal (18). 8. Align spline of the rotor (27) assembly with shaft
NOTE: Use OCEAN #7 as the grease. (20). Install the rotor (27) assembly to housing
(15).
2. Install bearing (19) into shaft (20).
9. Add hydraulic oil (0.33 L, 0.09 US gal) to housing
IMPORTANT: The lip mounting surface of oil seal (15).
(18) is located on the mounting side
for bearing (19) in shaft (20). Do not 10. Align the splines and install friction plate (11) to
damage the lip mounting surface of rotor (27).
oil seal (18).
3. Install the shaft (20) assembly to housing (15) by 11. Install O-rings (12, 13) to brake piston (10). Install
using a plastic hammer. brake piston (10) to housing (15).
4. Apply grease onto steel balls (21) (2 used). Install 12. Install bearing (4), O-rings (2), (7) (2 used), pins
springs (16) (2 used), pistons (17) (2 used) and (8) and (1) (3 used) to brake valve (5).
steel balls (21) (2 used) to housing (15).
IMPORTANT: Install valve plate (3) with the thrust
5. Align the hollow (2 places) on the back of swash surface in brass facing upward.
plate (22) with the position for steel ball (21). 13. Align pin (7) of brake valve (5) with valve plate (3).
Install swash plate (22) to housing (15). Install valve plate (3).
6. Apply grease onto pins (26) (3 used). Install pins IMPORTANT: If valve plate (3) falls off when as-
(26) (3 used) to rotor (27). Install holder (25) to sembling, aligning becomes difficult
rotor (27). or valve plate (3) might be lost.
14. Align brake valve (5) with the hole on socket bolts
(6) (6 used). Install brake valve (5) to housing
(15). Tighten brake valve (5) to housing (15) with
socket bolts (6) (6 used) evenly.
: 8 mm
: 51 to 56.4 N⋅m
(5.2 to 6.6 kgf⋅m, 38 to 42 lbf⋅ft)
W3-2-13
UNDERCARRIAGE / Travel Device
DISASSEMBLE BRAKE VALVE
1
2
3
4 11
5
12
6
7
8
9
14 15
10 13
11
12
16
17
8
18 7
6
5
4
3
2
18 1
12
21
15
20
20
19 W1MS-03-02-004
W3-2-14
UNDERCARRIAGE / Travel Device
Disassemble
W3-2-15
UNDERCARRIAGE / Travel Device
ASSEMBLE BRAKE VALVE
3 5 7 8 9 8 7 4 3
11
12
2
2
5
6
4 11
14, 13
12
10
W1MS-03-02-005
21 12 17 14, 13 16
W3-2-16
UNDERCARRIAGE / Travel Device
Assemble
W3-2-17
UNDERCARRIAGE / Travel Device
MAINTENANCE STANDARD
Travel Motor
D d
W507-02-04-009
Rotor Plunger
W3-2-18
UNDERCARRIAGE / Travel Device
Sprocket
D C B
A
W503-03-02-004
Unit: mm (in)
Standard Allowable Limit Remedy
A 20 (0.8) 10 (0.4)
B 253 (10.0) 243 (9.6)
C - - Replace
D 282 (11.1) 272 (10.7)
E - -
W3-2-19
UNDERCARRIAGE / Travel Device
(Blank)
W3-2-20
UNDERCARRIAGE / Center Joint
REMOVE AND INSTALL CENTER JOINT
Removal
1
1. Remove the main frame from the center frame.
Refer to the Remove and Install Main Frame
2
group on W2-3-1.
W3-3-1
UNDERCARRIAGE / Center Joint
Installation
W3-3-2
UNDERCARRIAGE / Center Joint
(Blank)
W3-3-3
UNDERCARRIAGE / Center Joint
DISASSEMBLE CENTER JOINT
16
3
15
14 4
13
5
10 9
12
11
W1MS-03-03-002
W3-3-4
UNDERCARRIAGE / Center Joint
Disassemble
1. Clamp the center joint in a vise. IMPORTANT: Do not to damage the lip surface of
oil seals (11) (9 used) in spindle (16).
2. Remove bolts (8) (4 used) and spring washers (7) Avoid entry of the dust when placing
(4 used) from flange (6). Remove flange (6) from spindle (16) horizontally.
body (2). IMPORTANT: When removing oil seals (11) (9
: 13 mm used) by using the pins (2 used), do
not damage the seal groove by the
pins.
3. Remove O-Ring (5) from body (2). Remove 5. Remove oil seals (11) (9 used) from body (2).
retaining ring (4) and thrust ring (3) from spindle
(16).
Bolt (M16)
11
Bolt (M8) ST 1467
W105-03-03-015
W1MP-03-03-002
W3-3-5
UNDERCARRIAGE / Center Joint
ASSEMBLE CENTER JOINT
16
14
13
12
11 2
6
10
7 T1MS-03-07-004
8 15 4 9
W3-3-6
UNDERCARRIAGE / Center Joint
Assemble
IMPORTANT: Apply grease or hydraulic oil onto 4. Install O-ring (5) to body (2).
O-ring (12) and oil seals (11) (9 used).
After installing O-ring (12) and oil 5. Install flange (6) to body (2) with bolts (8) (4 used)
seals (11) (9 used) to body (2), apply and spring washers (7) (4 used).
grease onto dust seal (14) and the lip : 13 mm
part of oil seals (11) (9 used). : 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)
IMPORTANT: Check the direction to install dust
seal (14) and oil seals (11) (9 used).
1. Install O-ring (12), backup ring (13), oil seals (11)
(9 used) and dust seal (14) to body (2).
W3-3-7
UNDERCARRIAGE / Center Joint
(Blank)
W3-3-8
UNDERCARRIAGE / Track Adjuster
REMOVE AND INSTALL TRACK ADJUSTER
Removal
Installation 5 4
W1MS-03-04-001
W3-4-1
UNDERCARRIAGE / Track Adjuster
DISASSEMBLE TRACK ADJUSTER
10
11
9
12
8
13
7 14
6
5
4
2
1
W1MS-03-04-002
15
W3-4-2
UNDERCARRIAGE / Track Adjuster
Disassemble Track Adjuster
3. Hoist and place the track adjuster onto the holder
of special tool (ST 4943).
CAUTION: Use special tool (ST 4943) when
assembling/disassembling the track adjuster.
Track Adjuster
As the spring (14) force is extremely large,
carry out the disassembly and assembly
work carefully. Inspect special tool for any
damage thoroughly in order to perform the
work safely.
Special tool weight: 225 kg (496 lb)
1. Place an oil jack (30 ton) between the holder and Holder
base of special tool (ST 4943).
Bolt
W105-03-04-009
Nut
Special Tool (ST 4943) CAUTION: Plate (ST 4140) weight: 36 kg (79 lb)
Oil Jack
Plate
(ST 4140)
Track
CAUTION: Plate (ST 4140) weight: 36 kg (79 lb) Adjuster
: 46 mm
W105-03-04-007
W3-4-3
UNDERCARRIAGE / Track Adjuster
10
11
9
12
8
13
7 14
6
5
4
2
1
W1MS-03-04-002
15
W3-4-4
UNDERCARRIAGE / Track Adjuster
5. Operate the oil jack and raise the holder 64 mm 8. Remove plug (10) from nut (12). Remove nut (12)
(2.5 in). from rod (7).
NOTE: Free length of spring: 211 mm (8.3 in) : 13 mm, 36 mm
Set length of spring: 150 mm (5.9 in)
Holder 12 7 10
Oil Jack
W105-03-04-013 W105-03-04-014
7. Install plate (ST 4140) to special tool (ST 4943) 9. Lower the oil jack slowly. Remove the nuts (4
with the nuts (4 used). Operate and raise the oil used) from plate (ST 4140). Remove plate (ST
jack until the clearance between washer (13) and 4140) from special tool (ST 4943). Remove
nut (12) is approximately 10 mm (0.4 in). washer (13) from cylinder (8).
: 46 mm : 46 mm
Nut
Plate (ST 4140)
Plate
(ST 4140)
13
W105-03-04-012
14
W105-03-04-016
W3-4-5
UNDERCARRIAGE / Track Adjuster
7 14
6
5
4
2
1
W1MS-03-04-002
15
W3-4-6
UNDERCARRIAGE / Track Adjuster
10. Install eyebolt (M14, Pitch 1.5 mm) to rod (7).
Hoist and remove cylinder (8) from special tool
(ST 4943).
14
Special Tool
7 (ST 4943)
W105-03-04-017
W3-4-7
UNDERCARRIAGE / Track Adjuster
ASSEMBLE TRACK ADJUSTER
11 12 13 7 14 1 3
T577-03-07-002
10 9 A 6 5 4 8 2 15
W3-4-8
UNDERCARRIAGE / Track Adjuster
Assemble Track Adjuster
1. Install O-ring (9) to cylinder (8). Apply hydraulic oil 5. Install eyebolt (M14, Pitch 1.5 mm) to rod (7).
onto the inner surface of cylinder (8) and the outer Hoist and place cylinder (8) on special tool (ST
surface of rod (7). Install rod (7) to cylinder (8). 4944). Install spring (14) to cylinder (8).
W105-03-04-017
W105-03-04-012
W3-4-9
UNDERCARRIAGE / Track Adjuster
11 12 7 14
T577-03-07-002
10 8
W3-4-10
UNDERCARRIAGE / Track Adjuster
8. Operate the oil jack and compress spring (14) to
CAUTION: Plate (ST 4140) weight: 36 kg (79 lb)
150 mm (5.9 in) length.
10. Lower the oil jack fully. Remove the nuts (4 used)
from plate (ST 4140). Remove plate (ST 4140)
from special tool (ST 4943).
: 46 mm
14
Plate (ST 4140)
Oil Jack
W105-03-04-026 W105-03-04-011
9. Install nut (12) to rod (7). Install plug (10) to nut 11. Attach a nylon sling onto the track adjuster. Hoist
(12). and remove the track adjuster from special tool
: 36 mm (ST 4943).
: 5 mm
: 15 N⋅m (1.5 kgf⋅m, 11.5 lbf⋅ft)
Track Adjuster
12 7 10
W105-03-04-027
W105-03-04-014
W3-4-11
UNDERCARRIAGE / Track Adjuster
(Blank)
W3-4-12
UNDERCARRIAGE / Front Idler
REMOVE AND INSTALL FRONT IDLER
Removal
1
1. Remove the track (rubber crawler). (Refer to the
Remove and Install Track group on W3-7.)
3 2
W1M3-03-05-001
Installation
2
Sliding
Part
W1MS-03-05-001
W3-5-1
UNDERCARRIAGE / Front Idler
DISASSEMBLE AND ASSEMBLE FRONT IDLER
2
3
4
1 5
6
4
3
2
8
9
1 W1MS-03-05-002
2
5
1
7 3 6
8
8
W1MS-03-05-003
9 9
W3-5-2
UNDERCARRIAGE / Front Idler
Disassemble Assemble
1. Remove bolts (9) (4 used) from plate (8). Re- 1. Install bushings (5) (2 used) to idler (6) by using a
move plate (8) from yokes (1) (2 used). press.
: 17 mm
2. Install axle (7) to idler (6).
2. Remove pins (2) (2 used) from yokes (1) (2 used)
by using a hammer and round bar. 3. Install O-rings (3) (2 used) to axle (7).
3. Remove yokes (1) (2 used) and floating seals (4) 4. Install floating seals (4) (2 used) and yokes (1) (2
(2 used) from idler (6). used) to idler (6).
4. Remove O-rings (3) (2 used) from axle (7). IMPORTANT: Apply LOCTITE #262 or equivalent
onto bolts (9) (4 used).
5. Remove axle (7) from idler (6) by using a press. 5. Install pins (2) (2 used) to yokes (1) (2 used).
IMPORTANT: Do not remove bushings (5) (2 used) 6. Install plate (8) to yokes (1) (2 used) with bolts (9)
unless necessary. (4 used).
6. Weld four places, 90 degrees apart from each : 17 mm
others on the bushing (5) (2 used) bore. Shrink : 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft)
and remove bushing (5) from idler (6).
90º
5
90º
W105-03-05-012
W3-5-3
UNDERCARRIAGE / Front Idler
MAINTENANCE STANDARD
Idler
C D F
A
B
W503-03-05-001
Unit: mm (in)
Standard Allowable Limit Remedy
A 24 (0.95) 24 (0.95)
B 60 (2.4) -
Cladding by welding
C 25 (1.0) 25 (1.0)
and finish
D 216 (8.5) -
or replace
E 10 (0.4) -
F 249 (9.8) -
Lubricant Oil:
Engine Oil: SAE#30 CD class.
3
Engine Oil Amount: 18 mL (18 cm or 0.048 USgal)
W3-5-4
UNDERCARRIAGE / Upper and Lower Roller
REMOVE AND INSTALL LOWER ROLLER
The upper roller is not equipped. Removal / installation
of the lower roller and its structure are explained here.
Removal
M1M7-04-006
CAUTION: Grease pressure in the track ad-
juster is high. As valve (2) may fly out and the
highly pressurized grease may spout out, do
not loosen valve (2) quickly and/or exces-
sively.
Do not loosen valve (2) one turn or more. 1 2 Grease Outlet
Keep body parts and face away from valve (2).
Do not loosen grease fitting (1).
7
W1MS-03-06-001
W3-6-1
UNDERCARRIAGE / Upper and Lower Roller
Installation
1. Put the bucket onto the ground and raise the ma-
chine. Place the block under the center frame and 90 to 110º
support the machine.
M1M7-04-006
7
W1MS-03-06-001
4. Apply grease through grease fitting (1) and adjust
track (7) tension.
NOTE: Check clearance (A) between lower roller
(6) immediately below grease fitting (1) and
track (7).
Track sag specifications (A): 10 to 15 mm
(0.39 to 0.59 in)
6
5. Raise the machine and remove the blocks under
A
side frame (3).
7
W3-6-2
UNDERCARRIAGE / Upper and Lower Roller
STRUCTURE OF LOWER ROLLER
Replace the lower roller as an assembly.
1 2 3 4 5 6 7 8
W1MS-03-06-003
NOTE: Roller diameter varies depending on front, middle and rear lower rollers. For further details, refer to
Maintenance Standard.
W3-6-3
UNDERCARRIAGE / Upper and Lower Roller
MAINTENANCE STANDARD
Lower Roller
C D E
W1MS-03-06-003
B
Unit: mm (in)
Standard Allowable Limit
Front Lower Middle and Rear Front Lower Middle and Rear Remedy
Roller Lower Roller Roller Lower Roller
A 24 (0.94) 24 (0.94) - -
B 106 (4.2) 106 (4.2) - - Cladding by
welding and
C
hand finishing or
D 75 (2.95) 75 (2.95) replace
E 94 (3.7) 111 (4.37) 88 (3.46) 105 (4.13)
Lubricant Oil:
Engine Oil: SAE#30 CD class.
Oil Amount: 30 mL (0.080 USgal)
W3-6-4
UNDERCARRIAGE / Track
REMOVE AND INSTALL TRACK
Removal
M1M7-04-006
CAUTION: Grease pressure in the track
adjuster is high. As valve (2) may fly out and
the highly pressurized grease may spout out,
do not loosen valve (2) quickly and/or
excessively.
Do not loosen valve (2) more than one turn.
Keep body parts and face away from valve (2)
and loosen valve (2) slowly.
Do not loosen grease fitting (1).
1 2 Grease Outlet
IMPORTANT: Remove gravel or mud from the
sprocket.
2. Loosen valve (2) in the track adjuster slowly and
drain grease.
: 19 mm
NOTE: Rotate track (3) in forward and reverse
W1MJ-03-06-001
direction alternately with valve (2)
loosened and remove track (3).
Rotation 4
Direction
5 Steel Pipe
M503-07-062
W3-7-1
UNDERCARRIAGE / Track
Installation 3
3
5. Apply grease through grease fitting (1) and adjust W1MS-03-06-001
tracks (3) tension.
NOTE: Rotate track (3) in reverse direction before
checking the sag under track (3). Check
clearance (A) between lower roller (6) Lower Roller
immediately below grease fitting (1) and
track (7).
Track sag specifications (A): 10 to 15 mm
(0.39 to 0.59 in) A
Rubber Crawler
M503-05-050
W3-7-2
UNDERCARRIAGE / Track
MAINTENANCE STANDARD
Rubber Crawler Crack
Lug Wear
Lower Roller
Rubber Crawler
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 23 (0.9) 5 (0.2)
2 30 (1.18) 40 (1.6)
Replace
3 23 (0.9) 18 (0.7)
4 22 (0.87) 15 (0.6)
5
Steel Core Separation W190-03-07-005
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 Standard............................ W4-1-8
Standard Dimensions for Arm and
Bucket Connection ............................W4-1-11
Group 2 Cylinder
Remove and Install Cylinders ................. W4-2-1
Disassemble Cylinders ......................... W4-2-30
Assemble Cylinders.............................. W4-2-44
Maintenance Standard.......................... W4-2-56
1MSW-4-1
(Blank)
1MSW-4-2
FRONT ATTACHMENT / Front Attachment
REMOVE AND INSTALL FRONT ATTACH-
MENT
Removal
4. Place the piston rod side of boom cylinder (6) on Piston Rod
the stand.
Wire
W554-02-03-007
Stand
W4-1-1
FRONT ATTACHMENT / Front Attachment
W1MP-04-01-007
W1MS-04-01-002
W1MS-04-01-003
W4-1-2
FRONT ATTACHMENT / Front Attachment
8. Remove nuts (13) (2 used) from bolt (11). Remove 11
bolt (11) from pin (14). Remove pin (14) from 5
swing post (12) by using a bar and hammer.
: 17 mm
14 13 12 W1MS-04-01-004
W4-1-3
FRONT ATTACHMENT / Front Attachment
Installation
W1MP-04-01-007
11 5
2. Align the pin (14) holes on the boom (5) foot and
swing post (12).
Insert the thrust plates (2 used) between swing
post (12) and boom (5). Check that each of the
clearances at left and right is within 1 mm (0.04
in). If the clearance exceeds 1 mm (0.04 in),
change the thickness or the number of thrust
plate.
W1MS-04-01-003
W4-1-4
FRONT ATTACHMENT / Front Attachment
6. Attach a nylon sling onto boom cylinder (6). Hold
boom cylinder (6).
Wire
W554-02-03-007
Stand
W4-1-5
FRONT ATTACHMENT / Front Attachment
10. Install plug (9) on the head lamp.
W1MS-04-01-002
W4-1-6
FRONT ATTACHMENT / Front Attachment
(Blank)
W4-1-7
FRONT ATTACHMENT / Front Attachment
MAINTENANCE STANDARD
Pin and Bushing
Main Frame
C
B
E D J
I
Side Frame
G K W1MP-04-01-010
Unit: mm (in)
Parts Name Standard Allowable Limit Remedy
Pin 30 (1.2) 29 (1.14)
A
Bushing (Boom) 30 (1.2) 31.5 (1.24)
Pin 35 (1.38) 34 (1.34)
B
Bushing (Boom Cylinder) 35 (1.38) 36.5 (1.44)
Pin 35 (1.38) 34 (1.34)
C
Bushing (Boom Cylinder) 35 (1.38) 36.5 (1.44)
Pin 30 (1.2) 29 (1.14) Replace
D
Bushing (Arm) 30 (1.2) 31.5 (1.24)
Pin 35 (1.38) 34 (1.34)
E
Bushing (Arm Cylinder) 35 (1.38) 36.5 (1.44)
Pin 35 (1.38) 34 (1.34)
F
Bushing (Arm Cylinder) 35 (1.38) 36.5 (1.44)
Pin 30 (1.2) 29 (1.14)
G
Bushing (Bucket Cylinder) 30 (1.2) 31.5 (1.24)
W4-1-8
FRONT ATTACHMENT / Front Attachment
P
M
W1MP-04-01-008 N
W1MP-04-01-009
Unit: mm (in)
Parts Name Standard Allowable Limit Remedy
Pin 30 (1.2) 29 (1.14)
Bushing (Bucket Cylinder) 30 (1.2) 31.5 (1.24)
H
Bushing (Link A) 30 (1.2) 31.5 (1.24)
Link B 30 (1.2) 31.5 (1.24)
Pin 30 (1.2) 29 (1.14)
I Bushing (Arm) 30 (1.2) 31.5 (1.24)
Link B 30 (1.2) 31.5 (1.24)
Pin 30 (1.2) 29 (1.14)
J
Bushing (Link A) 30 (1.2) 31.5 (1.24)
Pin 30 (1.2) 29 (1.14)
K
Bushing (Arm) 30 (1.2) 31.5 (1.24)
Pin 45 (1.77) 44 (1.73)
L Bushing (Swing Post) 45 (1.77) 46.5 (1.83)
Replace
Bushing (Main Frame) 45 (1.77) 46.5 (1.83)
Pin 30 (1.2) 29 (1.14)
M Bushing
30 (1.2) 31.5 (1.24)
(Boom Swing Cylinder)
Pin 35 (1.38) 34 (1.34)
N Bushing
35 (1.38) 36.5 (1.44)
(Boom Swing Cylinder)
Pin 30 (1.2) 29 (1.14)
O
Bushing (Blade) 30 (1.2) 31.5 (1.24)
Pin 30 (1.2) 29 (1.14)
P
Bushing (Blade Cylinder) 30 (1.2) 31.5 (1.24)
Pin 30 (1.2) 29 (1.14)
Q
Bushing (Blade Cylinder) 30 (1.2) 31.5 (1.24)
W4-1-9
FRONT ATTACHMENT / Front Attachment
Side Cutter
D
A
W505-04-01-001
Unit: mm (in)
Standard Allowable Limit Remedy
A 104 (4.1) 70 (2.76)
B 138 (5.43) -
Replace
C 153 (6.0) -
D 90 (3.54) -
Point
B C
W554-04-01-003
Unit: mm (in)
Standard Allowable Limit Remedy
A 127.5 (5.0) 63 (2.5)
B 56 (2.2) -
Replace
C 62 (2.45) -
D 51 (2.0) -
W4-1-10
FRONT ATTACHMENT / Front Attachment
STANDARD DIMENSIONS FOR ARM AND BUCKET CONNECTION
I n g
m
k
h
i
j
Sections A, B W1MW-04-01-003
Unit: mm (in)
Standard
a 100 (3.4)
b 5 (0.2)
c 185 (7.3)
d 178 (7.0)
e 118 (4.65)
f 538 (21.2)
g 118 (4.65)
h 30 (1.2)
i 162 (6.4)
j 195 (7.7)
k 0
l 118 (4.65)
m 90°
n 90°
W4-1-11
FRONT ATTACHMENT / Front Attachment
(Blank)
W4-1-12
FRONT ATTACHMENT / Cylinder
REMOVE AND INSTALL CYLINDERS
Remove Bucket Cylinder
2
2. Put the matching marks on the boss of link B (2)
and pin (3). Remove nuts (4) (2 used) and bolt (5)
from link B (2). Remove pin (3) from bucket
cylinder (1) by using a bar and hammer. Remove
the shims (2 used) between the boss of piston rod 1
and link A (6). Remove O-rings (2 used) and 3
shims (2 used) between link A (6) and links B (2
used).
: 13 mm 6
4, 5
W1MS-04-02-008
W571-04-02-002
W4-2-1
FRONT ATTACHMENT / Cylinder
4. Remove hoses (8) (2 used) from bucket cylinder 10, 11, 12
(1). Cap the open ends.
: 19 mm
W1MS-04-02-009
9 1 8
W4-2-2
FRONT ATTACHMENT / Cylinder
Install Bucket Cylinder
2
IMPORTANT: If the air in a cylinder is suddenly
compressed, the temperature inside
will rise. As the temperature of the
hydraulic oil will rise, the seals and
rings may be damaged. 1
3
4. Start the engine with the piston rod of bucket
cylinder (1) retracted fully to the stroke end.
Extend the piston rod slowly. Align the pin (3)
6
holes on bucket cylinder (1), link A (6) and links B
(2) (2 used).
4, 5
W1MS-04-02-008
W4-2-3
FRONT ATTACHMENT / Cylinder
5. Install the shims (2 used) between the boss of 2
piston rod (1) and link A (6). Insert O-rings (2
used) and shims (2 used) between link A (6) and
links B (2 used). Install pin (3) by using a plastic
hammer. 1
NOTE: If the clearance exceeds 0.5 mm (0.02 in), 3
change the thickness (0.5 mm, 1.0 mm) or
the number of shim.
6
6. Apply LOCTITE #262 onto bolt (5). Install pin (3)
to link B (2) with bolt (5) and nuts (4) (2 used).
: 13 mm 4, 5
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)
W4-2-4
FRONT ATTACHMENT / Cylinder
Remove Arm Cylinder
1
CAUTION: Bleed air from the hydraulic oil
tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on W1-4-1.)
Wooden Block 2
W571-04-02-004
1
IMPORTANT: Attach an identification tag onto the
removed hoses for assembling.
5. Remove hoses (14) (2 used) from arm cylinder (1).
Cap the open ends.
: 19 mm
14 13 12 11 8, 9, 10
W1MS-04-02-010
W4-2-5
FRONT ATTACHMENT / Cylinder
7. Remove bolt (8), washer (9) and bushing (10) 1
from the plate of pin (11). Remove pin (11) from
arm cylinder (1) by using a bar and hammer.
Remove the shims (2 used) between the boss of
cylinder tube and boom (2).
: 19 mm
14 13 12 11 8, 9, 10
W1MS-04-02-010
W4-2-6
FRONT ATTACHMENT / Cylinder
Install Arm Cylinder
W4-2-7
FRONT ATTACHMENT / Cylinder
IMPORTANT: If the air in a cylinder is suddenly
compressed, the temperature inside
will rise. As the temperature of the
hydraulic oil will rise, the seals and
rings may be damaged.
6. Start the engine with the piston rod of arm cylinder 3 4, 5, 6 1
(1) retracted fully to the stroke end. Extend piston
rod (1) slowly. Align the pin (3) holes on piston rod
(1) and arm (7).
NOTE: If it is difficult to align the pin (3) holes, raise 7
the boom a little.
W4-2-8
FRONT ATTACHMENT / Cylinder
Remove Boom Cylinder
W1MS-04-01-001
Wire
3. Place boom cylinder (6) on a stand. Start the
engine. Retract the piston rod to the stroke end.
Secure the piston rod to the cylinder tube by using
a wire.
W554-02-03-007
10 6 W1MS-04-02-011
W4-2-9
FRONT ATTACHMENT / Cylinder
5. Remove nuts (12) (2 used) from bolt (11).
Remove bolt (11) from swing post (14).
: 13 mm
14 13 11, 12 W1MS-04-01-004
W4-2-10
FRONT ATTACHMENT / Cylinder
Install Boom Cylinder
10 6 W1MS-04-02-011
W4-2-11
FRONT ATTACHMENT / Cylinder
IMPORTANT: If the air in a cylinder is suddenly
compressed, the temperature inside
will rise. As the temperature of the
hydraulic oil will rise, the seals and
rings may be damaged.
6. Start the engine with the piston rod of boom 1 2, 3, 4 5
cylinder (6) retracted fully to the stroke end.
Extend the piston rod slowly. Align the pin (1)
holes on boom cylinder (6) and boom (5).
W4-2-12
FRONT ATTACHMENT / Cylinder
Remove Boom Swing Cylinder
W1MS-04-02-014
5, 6
7 W1MS-04-02-016
W4-2-13
FRONT ATTACHMENT / Cylinder
5. Remove bolts (11) (6 used) from cover (10) under 7 10 11
main frame (7).
: 17 mm
W1MS-04-02-017
12
6. Remove hoses (13) (2 used) from boom swing
cylinder (12). Cap the open ends.
: 19 mm
13 W1MS-04-02-018
7
7. Remove bolt (15) and bushing (16) from the plate
of pin (14). Remove pin (14) from main frame (7)
while swinging pin (14) to the left and right.
: 19 mm
14
15, 16 W1MS-04-02-019
W4-2-14
FRONT ATTACHMENT / Cylinder
8. Remove boom swing cylinder (12) from main 12
frame (7).
7 W1MS-04-02-020
W4-2-15
FRONT ATTACHMENT / Cylinder
Install Boom Swing Cylinder 12
1. Insert the cylinder tube side of boom swing
cylinder (12) into main frame (7).
7 W1MS-04-02-020
15, 16 W1MS-04-02-019
13 W1MS-04-02-018
W4-2-16
FRONT ATTACHMENT / Cylinder
4. Install cover (10) onto main frame (7) with bolts 7 10 11
(11) (6 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
W1MS-04-02-017
6. Insert pin (3) into swing post (4). Secure pin (3)
with bolt (5) and nuts (6) (2 used).
: 13 mm 3
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft) 9 4
5, 6
8 12
7 Key Hole 2 W1MS-04-02-015
8. Install cover (8) onto main frame (7) with bolts (9)
(2 used).
: 17 mm
1
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
W1MS-04-02-014
W4-2-17
FRONT ATTACHMENT / Cylinder
Remove Blade Cylinder
3 W1MS-04-02-012
: 19 mm
W4-2-18
FRONT ATTACHMENT / Cylinder
Install Blade Cylinder
3 4 5, 6, 7
1. Apply grease onto the bushing inside for blade
cylinder (3) and the lip part of dust seal (both
bottom and rod sides).
W4-2-19
FRONT ATTACHMENT / Cylinder
Remove Side Frame Extend/Retract Cylinder
W1MS-04-02-026
7 Stand 6
W4-2-20
FRONT ATTACHMENT / Cylinder
3. Remove bolts (16) (2 used) of plate (15) from 9 10 11
piston rod mounting part (A) of the side frame
extend/retract cylinder on left side frame (9).
Remove plate (15) from left side frame (9).
Remove pin (14) from left side frame (9) by using
a bar and hammer.
: 13 mm A B
: 13 mm
14
5. Remove bolts (12) (4 used) from cover (13).
Remove cover (13) from center frame (10).
: 17 mm
15
16
Detail for Part A
W1MP-04-02-009
17
19
18
W1MP-04-02-010
Detail for Part B
20
6. Remove hoses (21) (2 used) from side frame
extend/retract cylinder (20). Cap the open ends.
: 19 mm
W4-2-21
FRONT ATTACHMENT / Cylinder
7. Remove bolts (24) (4 used) from plates (23) (2 10 22
used). Remove plates (23) (2 used) and pins (22) 23
(4 used) from center frame (10). Raise the blade
and boom, and lower the machine.
: 13 mm 24
W1MS-04-02-028
9 24 22 23 11
26, 27
11
W1MS-04-02-029
29
28
W1MS-04-02-030
W4-2-22
FRONT ATTACHMENT / Cylinder
10. Operate control lever (1) and rotate the main 1
frame to the right side frame (11) side. Set the
angle between boom and arm at 90° to 110°. Put
the bottom of bucket (7) onto the ground and raise
the machine until track (11) on the right side is off 3
the ground. Place a stand under center frame (10)
and support the machine.
W1MS-04-02-026
90° to 110°
M1M7-04-006
7 11 Stand 10
W4-2-23
FRONT ATTACHMENT / Cylinder
W1MS-04-02-021
11 W1MS-04-02-022
10
12. Remove side frame extend/retract cylinder (20)
from center frame (10).
20
W1MS-04-02-023
W4-2-24
FRONT ATTACHMENT / Cylinder
Install Side Frame Extend/Retract Cylinder 1
W1MS-04-02-026
90° to 110°
M1M7-04-006
7 11 Stand 10
W4-2-25
FRONT ATTACHMENT / Cylinder
2. Insert side frame extend/retract cylinder (20) into 9 10
center frame (10) with the piston rod side facing to
the left side frame (9) side.
20
20
Left Side Frame (9) Mounting Side
W1MP-04-02-011
W1MS-04-02-023
11 W1MS-04-02-022
10
W1MS-04-02-021
10 22
4. Install pins (22) (4 used) to center frame (10) by
23
using a plastic hammer. Install plates (23) (2
used) to center frame (10) with bolts (24) (4 used).
Lower right side frame (11).
24
: 13 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)
W1MS-04-02-028
9 24 22 23 11
W4-2-26
FRONT ATTACHMENT / Cylinder
5. Install hoses (29) (4 used) to travel device (28).
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
: 22 mm
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)
29
28
6. Install cover (25) onto right side frame (11) with W1MS-04-02-030
26, 27
11
W1MS-04-02-029
IMPORTANT: Place the stands (4 used) under 1
track (6) and support the machine.
7. Operate control lever (1) and rotate the main
frame to the back of machine. Operate blade 3
lever (3), lower the blade and raise the front of
machine. Set the angle between boom (4) and
arm (8) at 90° to 110°. Put the bottom of bucket
(7) onto the ground and raise the rear of machine
in the horizontal position. Place the stands (4
2
used) under track (6) and support the machine.
W1MS-04-02-026
90° to 110°
8 5
W1MS-04-02-027
7 Stand 6
W4-2-27
FRONT ATTACHMENT / Cylinder
8. Install hoses (21) (2 used) to side frame
extend/retract cylinder (20) from the mounting 20
side for cover (13).
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
15
16
Detail for Part A
W1MP-04-02-009
17
19
18
W1MP-04-02-010
Detail for Part B
W4-2-28
FRONT ATTACHMENT / Cylinder
11. Install cover (13) onto center frame (10) with bolts 10
(12) (4 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
A B
12. Raise the blade and boom and lower the machine.
Operate the side frame extend/retract lever, 13 12 W1MS-04-02-024
W4-2-29
FRONT ATTACHMENT / Cylinder
DISASSEMBLE CYLINDERS
Boom Cylinder
16
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
21
W1MS-04-02-002
W4-2-30
FRONT ATTACHMENT / Cylinder
Arm Cylinder
16
20
19
18
17
16
9
7
6
5
4
3
2
21
W1MS-04-02-002
W4-2-31
FRONT ATTACHMENT / Cylinder
Bucket Cylinder
16
20
19
18
17
16
9
7
6
5
4
3
2
21
W1MS-04-02-004
W4-2-32
FRONT ATTACHMENT / Cylinder
Blade Cylinder
16
20
19
18
17
16
9
7
6
5
4
3
2
21
W1MS-04-02-003
W4-2-33
FRONT ATTACHMENT / Cylinder
Boom Swing Cylinder
16
20
19
18
17
16
9
7
6
5
4
3
2
21
W1MS-04-02-005
W4-2-34
FRONT ATTACHMENT / Cylinder
Side Frame Extend/Retract Cylinder
16
20
19
18
17
16
7
9
8
6
5
4
3
2
21
W1MS-04-02-006
W4-2-35
FRONT ATTACHMENT / Cylinder
Boom Cylinder
16
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
21
W1MS-04-02-001
W4-2-36
FRONT ATTACHMENT / Cylinder
Disassemble Boom Cylinder
1. Clamp the pin mounting part (clevis part) of 3. Loosen cylinder head (3) by using a hooked
cylinder tube (21) in a vise horizontally. Extend spanner. Remove the piston rod (1) assembly
piston rod (1) and drain hydraulic oil from the from cylinder tube (21).
cylinder. Cylinder head (3) diameter: 78 mm (3.07 in)
21
Lock Washer
1 3 W506-04-02-004
1 3
W506-04-02-003
W4-2-37
FRONT ATTACHMENT / Cylinder
16
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
21
W1MS-04-02-001
W4-2-38
FRONT ATTACHMENT / Cylinder
IMPORTANT: Cut away the crimped part (2 places) 8. Remove backup rings (5, 13) and O-rings (4, 6,
by using a hand drill and loosen set 14) from the outside of cylinder head (3).
screw (19).
4. Secure piston rod (1) horizontally. Remove set 9. Remove stop ring (12), spacer (11) and cushion
screw (19) and steel ball (18) from piston (17). ring (10) from the inside of cylinder head (3).
: 3 mm
10. Remove wiper ring (2), U-ring (9) and backup ring
5. Remove piston (17) and cushion bearing (15) (8) from the inside of cylinder head (3).
from piston rod (1).
: 36 mm IMPORTANT: Bushing (7) cannot be reused. When
removing bushing (7), replace
6. Wind a protection tape onto the thread of piston bushing (7) with the new one.
rod (1). Remove cylinder head (3) from piston rod 11. Remove bushing (7) from cylinder head (3) by
(1). using a press and special tool (ST 8055).
17 7
20
W1MP-04-02-016
W506-04-02-007
W4-2-39
FRONT ATTACHMENT / Cylinder
Disassemble Arm Cylinder
16
20
19
18
17
16
9
7
6
5
4
3
2
21
W1MS-04-02-002
W4-2-40
FRONT ATTACHMENT / Cylinder
Disassemble Arm, Bucket, Blade, Boom Swing 3. Loosen cylinder head (3) by using a hooked
and Side Frame Extend/Retract Cylinders spanner. Remove the piston rod (1) assembly
• Disassembly of the arm cylinder is explained as from cylinder tube (21).
an example. Cylinder head (3) diameter:
Arm Cylinder: 78 mm (3.07 in)
1. Clamp the pin mounting part (clevis part) of Bucket Cylinder: 73 mm (2.87 in)
cylinder tube (21) in a vise horizontally. Extend Blade Cylinder: 82 mm (3.23 in)
piston rod (1) and drain hydraulic oil from the Boom Swing Cylinder: 78 mm (3.07 in)
cylinder. Side Frame Extend/Retract Cylinder: 63 mm
(2.48 in)
IMPORTANT: The lock washer in cylinder head (3)
is provided on cylinder tube (21) and
forms an integral part. Do not Hooked Spanner
damage cylinder tube (21) and
cylinder head (3) when extending the
lock washer.
2. Pull out piston rod (1) from cylinder tube (21) 21
approx. 50 mm (2 in). Install a protective cover on
piston rod (1). Extend the lock washer in cylinder
head (3) by using a chisel and hammer.
21
Lock Washer
1 3 W506-04-02-004
1 3
W506-04-02-003
W4-2-41
FRONT ATTACHMENT / Cylinder
16
20
19
18
17
16
9
7
6
5
4
3
2
21
W1MS-04-02-002
W4-2-42
FRONT ATTACHMENT / Cylinder
IMPORTANT: Cut away the crimped parts (2 8. Remove backup ring (5) and O-rings (4, 6) from
places) by using a hand drill and the outside of cylinder head (3).
loosen set screw (19).
4. Secure piston rod (1) horizontally. Remove set 9. Remove wiper ring (2) and U-ring (9) from the
screw (19) and steel ball (18) from piston (17). inside of cylinder head (3).
: 3 mm
IMPORTANT: Bushing (7) cannot be reused. When
5. Remove piston (17) from piston rod (1). removing bushing (7), replace
bushing (7) with the new one.
6. Wind a protection tape onto the thread of piston 10. Remove bushing (7) from cylinder head (3) by
rod (1). Remove cylinder head (3) from piston rod using a press and special tool.
(1). Special tool:
Arm Cylinder, Blade Cylinders: ST 8055
IMPORTANT: Slide rings (16) (2 used) cannot be Boom Swing, Bucket and Side Frame
reused. When disassembling the Extend/Retract Cylinders: ST 1518, ST 7375
cylinder, replace slide ring (16) with
the new one.
IMPORTANT: When removing the seals, do not
damage the parts.
7. Clamp piston (17) in a vise. Remove slide rings
(16) (2 used) from piston (17). Cut off and remove
seal ring assembly (20) from piston (17) by using
a screwdriver.
Special Tool
17
3
20
W506-04-02-007
W1MP-04-02-016
W4-2-43
FRONT ATTACHMENT / Cylinder
ASSEMBLE CYLINDERS
Boom Cylinder
19 16 20 16 15 21 14 13 5, 6 4 3
W1MS-04-02-007
18 20 17 1 12 11 10 9 8 7 2
W1MP-04-02-028
18 20 9 7 2
19 16 20 16 21 1 21 5, 6 4 3 1
W1MP-04-02-025
18 20 17 7 9 8 2
W4-2-44
FRONT ATTACHMENT / Cylinder
Assemble Boom Cylinder
IMPORTANT: Install U-ring (9) with the groove 3. Install cushion ring (10), spacer (11) and stop ring
facing to the piston (17) side. (12) to the inside of cylinder head (3).
1. Install bushing (7) to the inside of cylinder head
(3) by using a press and special tool (ST 8085). 4. Install wiper ring (2) to cylinder head (3) by using
special tool (ST 8044).
2. Install backup ring (8) and U-ring (9) to the inside
of cylinder head (3).
Special Tool
2
Special Tool
3 W1MP-04-02-019
W4-2-45
FRONT ATTACHMENT / Cylinder
Boom Cylinder
19 16 20 16 15 21 14 13 5, 6 4 3
W1MS-04-02-007
18 20 17 1 12 11 10 9 8 7 2
W4-2-46
FRONT ATTACHMENT / Cylinder
IMPORTANT: Check that O-ring (20) of seal ring IMPORTANT: If not adjusting seal ring (20), piston
assembly (20) is not twisted. (17) cannot be installed to cylinder
6. Install O-ring (20A) to piston (17). Install seal ring tube (21).
(20B) to piston (17) by using special tool (ST 7. Attach piston (17) to special tool (ST 2936).
2936). Adjust seal ring (20).
Special Tool
Special Tool 17
Special Tool
20A
16
W566-04-02-011
W4-2-47
FRONT ATTACHMENT / Cylinder
Boom Cylinder
19 16 20 16 15 21 14 13 5, 6 4 3
W1MS-04-02-007
18 20 17 1 12 11 10 9 8 7 2
W4-2-48
FRONT ATTACHMENT / Cylinder
IMPORTANT: Check the direction to install IMPORTANT: When inserting the piston rod (1)
cushion bearing (15). assembly into cylinder tube (21), do
10. Install cushion bearing (15) and the piston (17) not drop slide rings (16) (2 used)
assembly to piston rod (1). from piston (17).
: 41 mm 12. Apply hydraulic oil onto the packing parts. Secure
: 470 N⋅m (48 kgf⋅m, 347 lbf⋅ft) cylinder tube (21) in a vise horizontally. Insert the
piston rod (1) assembly into cylinder tube (21).
11. Insert steel ball (18) into piston (17) and install set
screw (19). Crimp set screw (19) by using a punch 13. Tighten cylinder head (3) to cylinder tube (21) by
(2 places). using a hooked spanner. Bend the lock washer in
: 3 mm order not to loosen.
: 7 N⋅m (0.7 kgf⋅m, 5 lbf⋅ft) Cylinder diameter:78 mm (3.07 in)
: 304 N⋅m (31 kgf⋅m, 224 lbf⋅ft)
Hooked Spanner
21 W506-04-02-019
W4-2-49
FRONT ATTACHMENT / Cylinder
19 16 20 16 17 21 5, 6 4 3 1
W1MP-04-02-028
18 20 9 7 2
19 16 20 16 21 1 21 5, 6 4 3 1
W1MP-04-02-025
18 20 17 7 9 8 2
W4-2-50
FRONT ATTACHMENT / Cylinder
Assemble Arm, Bucket, Blade, Boom Swing and
Side Frame Extend/Retract Cylinders
1. Install backup ring (6) and O-rings (4, 5) to the IMPORTANT: Check the direction to install U-ring
outside of cylinder head (3). (9).
3. Install U-ring (9) to the inside of cylinder head (3).
2. Install bushing (7) to the inside of cylinder head NOTE: For assembling the side frame
(3) by using a press and special tool. extend/retract cylinder, steps 2 and 3 are
Special tool: performed in the reverse order.
Arm and Blade Cylinders: ST 8055
Boom Swing, Bucket and Side Frame
Extend/Retract Cylinders: ST 1518 3
NOTE: For assembling the side frame
extend/retract cylinder, steps 2 and 3 are
performed in the reverse order. 9
Special Tool
W1LD-04-02-004
Special Tool
W1MP-04-02-019
W4-2-51
FRONT ATTACHMENT / Cylinder
19 16 20 16 17 21 5, 6 4 3 1
W1MP-04-02-028
18 20 9 7 2
19 16 20 16 21 1 21 5, 6 4 3 1
W1MP-04-02-025
18 20 17 7 9 8 2
W4-2-52
FRONT ATTACHMENT / Cylinder
IMPORTANT: Check that O-ring (20A) is not IMPORTANT: If not adjusting seal ring (20B),
twisted. piston (17) cannot be installed to
5. Install O-ring (20A) to piston (17). Install seal ring cylinder tube (21).
(20B) to piston (17) by using special tool. 6. Attach special tool to position (17). Adjust seal
Special tool: ring (20B).
Side Frame Extend/Retract Cylinder: ST 2933 Special tool:
Bucket Cylinder: ST 2935 Side Frame Extend/Retract Cylinder: ST 2933
Arm and Boom Swing Cylinders: ST 2936 Bucket Cylinder: ST 2935
Blade Cylinder: ST 2937 Arm and Boom Swing Cylinders: ST 2936
Blade Cylinder: ST 2937
Special Tool
20B
20B
20A
17
Special Tool
17
W566-04-02-010 W566-04-02-011
W4-2-53
FRONT ATTACHMENT / Cylinder
19 16 20 16 17 21 5, 6 4 3 1
W1MP-04-02-028
18 20 9 7 2
19 16 20 16 21 1 21 5, 6 4 3 1
W1MP-04-02-025
18 20 17 7 9 8 2
W4-2-54
FRONT ATTACHMENT / Cylinder
9. Install the piston (16) assembly to piston rod (1). IMPORTANT: When inserting the piston rod (1)
Arm Cylinder assembly into cylinder tube (21), do
: 36 mm not drop slide rings (16) (2 used)
: 325 N⋅m (33 kgf⋅m, 240 lbf⋅ft) from piston (16).
Bucket Cylinder 11. Apply hydraulic oil onto the packing parts. Secure
: 36 mm cylinder tube (21) in a vise horizontally . Insert the
: 260 N⋅m (26 kgf⋅m, 192 lbf⋅ft) piston rod (1) assembly into cylinder tube (21).
Boom Swing Cylinder
: 36 mm 12. Tighten cylinder head (3) to cylinder tube (21) by
: 310 N⋅m (32 kgf⋅m, 229 lbf⋅ft) using a hooked spanner. Bend the lock washer in
Blade Cylinder order not to loosen.
: 41 mm Arm Cylinder
: 441 N⋅m (45 kgf⋅m, 325 lbf⋅ft) Cylinder diameter: 78 mm (3.07 in)
Side Frame Extend/Retract Cylinder : 275 N⋅m (28 kgf⋅m, 203 lbf⋅ft)
: 36 mm Blade Cylinder
: 245 N⋅m (25 kgf⋅m, 181 lbf⋅ft) Cylinder diameter: 82 mm (3.23 in)
: 343 N⋅m (35 kgf⋅m, 253 lbf⋅ft)
10. Insert steel ball (18) into piston (16) and install set Bucket Cylinder
screw (19). Crimp set screw (19) by using a punch Cylinder diameter: 73 mm (2.87 in)
(2 places). : 275 N⋅m (28 kgf⋅m, 203 lbf⋅ft)
: 3 mm Boom Swing Cylinder
: 6.8 N⋅m (0.7 kgf⋅m, 5 lbf⋅ft) Cylinder diameter: 78 mm (3.07 in)
: 304 N⋅m (30 kgf⋅m, 224 lbf⋅ft)
Side Frame Extend/Retract Cylinder
Cylinder diameter: 63 mm (2.48 in)
: 255 N⋅m (26 kgf⋅m, 188 lbf⋅ft)
Hooked Spanner
21 W506-04-02-019
W4-2-55
FRONT ATTACHMENT / Cylinder
MAINTENANCE STANDARD
Piston Rod Rod Bend and Run Out of Piston Rod
A
Dial Gauge
Cylinder Rod
W105-04-02-094
W166-04-02-022
1 m (39.5 in)
Unit: mm (in) V Block
Cylinder Name Recommended Size After
Re-Manufacturing (A) Unit: mm (in)
W4-2-56
MEMO
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SECTION 5
ENGINE
CONTENTS
Introduction ....................................................... 1-1 Periodic Maintenance
Introduction.................................................... 5-3
Yanmar Warranties
Precautions ................................................ 5-15
Yanmar Limited Warranty .............................. 2-3
Periodic Maintenance Schedule ................... 5-16
Emission System Warranty ............................ 2-6
Periodic Maintenance Procedures .............. 5-18
Yanmar Co., Ltd. Limited Emission
Control System Warranty - USA Only ......... 2-6 Engine
Before You Begin Servicing .......................... 6-3
Safety
Introduction.................................................... 6-5
Safety Statements ........................................ 3-3
Cylinder Head Specifications ........................ 6-5
Safety Precautions ....................................... 3-4
Camshaft and Timing Gear Train
General Service Information Specifications ............................................. 6-7
Component Identification ............................... 4-3 Crankshaft and Pistons Specifications ......... 6-8
Location of Labels ........................................ 4-4 Cylinder Block Specifications ..................... 6-13
EPA / ARB Emission Control Special Torque Chart ................................. 6-14
Regulations - USA Only.............................. 4-4 Special Service Tools .................................. 6-15
Emission Control Labels ................................ 4-4 Measuring Instruments................................. 6-17
The 97/68/EC Directive Certified Engines ...... 4-5 Cylinder Head ............................................ 6-20
Engine Family ................................................ 4-5 Cylinder Block ............................................ 6-36
Function of Major Engine Components ......... 4-6
Function of Cooling System Components ..... 4-8
Diesel Fuel ................................................... 4-9
Engine Oil .................................................... 4-13
Engine Coolant ............................................ 4-15
Specifications ............................................ 4-18
Principal Engine Specifications .................. 4-20
Engine Service Information ........................ 4-23
Tightening Torques for Standard
Bolts and Nuts ........................................ 4-24
Abbreviations and Symbols .......................... 4-26
Unit Conversions ......................................... 4-27
1MSW-5-1
Fuel System Alternator
Before You Begin Servicing .......................... 7-3 Before You Begin Servicing ........................ 11-3
Introduction.................................................... 7-5 Introduction.................................................. 11-6
Fuel System Specifications .......................... 7-7 Standard and Optional Dynamo Information 11-6
Special Service Tools .................................... 7-8 Standard and Optional Alternator Information11-6
Measuring Instruments .................................. 7-8 Alternator Specifications .............................. 11-6
Fuel System Diagram .................................... 7-9 Dynamo Specifications................................. 11-7
Fuel System Components .......................... 7-10 Alternator Troubleshooting ......................... 11-8
Fuel Injection Lines .................................... 7-11 Alternator Components .............................. 11-9
Fuel Injection Pump ..................................... 7-13 Alternator Wiring Diagram.......................... 11-10
Checking and Adjusting Fuel Alternator Standard Output ....................... 11-11
Injection Timing ...................................... 7-19 Alternator ................................................. 11-12
Fuel Injectors ............................................... 7-23 Dynamo Component Location .................... 11-17
Disassembly and Inspection of Dynamo Wiring Diagram ............................ 11-18
Fuel Injectors .......................................... 7-27 Operation of Dynamo ............................... 11-18
Adjusting Fuel Injector Pressure ................ 7-28 Dynamo Standard Output ......................... 11-19
Reassembly of Fuel Injectors ..................... 7-29 Testing of Dynamo ................................... 11-20
Installation of the Fuel Injectors ................... 7-29 Dynamo ..................................................... 11-20
Starter Motor
Before You Begin Servicing ........................ 10-3
Introduction.................................................. 10-5
Starter Motor Information ........................... 10-5
Starter Motor Specifications ....................... 10-6
Starter Motor Troubleshooting...................... 10-7
Starter Motor Components ......................... 10-8
Starter Motor .............................................. 10-9
1MSW-5-2
TNV IDI Service Manual
TNV series
SERVICE MANUAL
2TNV70
3TNV70
3TNV76
P/N: 0BTNV-G00200
INDUSTRIAL
ENGINES
This Service Manual has been developed for the exclusive use of service and repair professionals such as
Yanmar authorized Distributors and Yanmar authorized Dealers. It is written with these professionals in
mind and may not contain the necessary detail or safety statements that may be required for a non-
professional to perform the service or repair properly and / or safely. Please contact an authorized Yanmar
repair or service professional before working on your Yanmar product.
Disclaimers:
All information, illustrations and specifications in this manual are based on the latest information available
at the time of publishing. The illustrations used in this manual are intended as representative reference
views only. Moreover, because of our continuous product improvement policy, we may modify information,
illustrations, and / or specifications to explain and / or exemplify a product, service, or maintenance
improvement. We reserve the right to make any change at any time.
Yanmar and are registered trademarks of Yanmar Co., Ltd. in Japan, the United States and /
or other countries.
All Rights Reserved:
No part of this publication may be reproduced or used in any form by any means - graphic, electronic, or
mechanical, including photocopying, recording, taping, or information storage and retrieval systems -
without the written permission of Yanmar Co., Ltd.
© 2005 Yanmar Co. Ltd.
INTRODUCTION
This Service Manual describes the service
procedures for the TNV series indirect injection
engines. These engines are certified by the U.S.
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 engine. Since the directions in this
manual are for a typical engine, some
specifications and components may be different
from your engine. Refer to the documentation
supplied by the optional equipment manufacturer
for specific service instructions.
Yanmar products are continuously undergoing
improvement. This Service Manual might not
address possible field modifications to the
equipment. Contact an authorized Yanmar
industrial engine dealer or distributor for answers to
any questions relating to field modifications.
YANMAR
WARRANTIES
Page
Yanmar Limited Warranty................................................................ 2-3
What is Covered by this Warranty? .......................................... 2-3
How Long is the Warranty Period? ........................................... 2-3
What the Engine Owner Must Do: ............................................ 2-3
To Locate an Authorized Yanmar Industrial Engine Dealer
or Distributor: ............................................................................. 2-4
What Yanmar Will Do: .............................................................. 2-4
What is Not Covered by this Warranty? ................................... 2-4
Warranty Limitations: ................................................................ 2-5
Warranty Modifications: ............................................................ 2-5
Questions: ................................................................................. 2-5
Retail Purchaser Registration.................................................... 2-5
Emission System Warranty ............................................................. 2-6
Yanmar Co., Ltd. Limited Emission Control System Warranty -
USA Only......................................................................................... 2-6
Your Warranty Rights and Obligations: ..................................... 2-6
Manufacturer’s Warranty Period:............................................... 2-6
Warranty Coverage: .................................................................. 2-7
Warranted Parts: ....................................................................... 2-7
Exclusions: ................................................................................ 2-8
Owner’s Warranty Responsibilities:........................................... 2-8
Warranty Limitations:
The foregoing is Yanmar's only obligation to you and your exclusive remedy for breach of warranty.
Failure to follow the requirements for submitting a claim under this Warranty may result in a waiver of all
claims for damages and other relief. In no event shall Yanmar or any authorized industrial engine
dealer or distributor be liable for incidental, special or consequential damages. Such consequential
damages may include, but not be limited to, loss of revenue, loan payments, cost of rental of substitute
equipment, insurance coverage, storage, lodging, transportation, fuel, mileage, and telephone costs. The
limitations in this Warranty apply regardless of whether your claims are based on breach of contract, tort
(including negligence and strict liability) or any other theory. Any action arising hereunder must be brought
within one (1) year after the cause of action accrues or it shall be barred. Some states and countries do not
allow certain limitations on warranties or for breach of warranties. This Warranty gives you specific legal
rights, and you may also have other rights which vary from state to state and country to country.
Limitations set forth in this paragraph shall not apply to the extent that they are prohibited by law.
Warranty Modifications:
Except as modified in writing and signed by the parties, this Warranty is and shall remain the complete and
exclusive agreement between the parties with respect to warranties, superseding all prior agreements,
written and oral, and all other communications between the parties relating to warranties. No person or
entity is authorized to give any other warranty or to assume any other obligation on behalf of
Yanmar, either orally or in writing.
Questions:
If you have any questions or concerns regarding this Warranty, please call or write to the nearest
authorized Yanmar industrial engine dealer / distributor or other authorized facility.
It is very important for the original retail purchaser to register the Yanmar product. Registration
enables Yanmar to provide the best support for your Yanmar product.
As soon as possible after the purchase of your engine, Yanmar highly recommends that you use the
following website to register your purchase:
http://www.yanmar.co.jp
If it is not possible to access the web site, please contact the nearest Yanmar dealer or distributor.
Warranty Coverage:
This warranty is transferable to each subsequent purchaser for the duration of the warranty period. Repair
or replacement of any warranted part will be performed at an authorized Yanmar industrial engine dealer or
distributor.
Warranted parts not scheduled for replacement as required maintenance in the Operation Manual shall be
warranted for the warranty period. Warranted parts scheduled for replacement as required maintenance in
the operation manual are warranted for the period of time prior to the first scheduled replacement. Any part
repaired or replaced under warranty shall be warranted for the remaining warranty period.
During the warranty period, Yanmar is liable for damages to other engine components caused by the failure
of any warranted part during the warranty period.
Any replacement part which is functionally identical to the original equipment part in all respects may be
used in the maintenance or repair of your engine, and shall not reduce Yanmar’s warranty obligations. Add-
on or modified parts that are not exempted may not be used. The use of any non-exempted add-on or
modified parts shall be grounds for disallowing a warranty.
Warranted Parts:
This warranty covers engine components that are a part of the emission control system of the engine as
delivered by Yanmar to the original retail purchaser. Such components may include the following:
• Fuel Injection System
• Cold Start Enrichment System
• Intake Manifold
• Turbocharger Systems
• Exhaust Manifold
• Positive Crankcase Ventilation System
• Hoses, belts, connectors and assemblies associated with emission control systems
Since emissions-related parts may vary slightly between models, certain models may not contain all of
these parts and other models may contain the functional equivalents.
Exclusions:
Failures other than those arising from defects in material and / or workmanship are not covered by this
warranty. The warranty does not extend to the following: malfunctions caused by abuse, misuse, improper
adjustment, modification, alteration, tampering, disconnection, improper or inadequate maintenance or use
of non-recommended fuels and lubricating oils; accident-caused damage, and replacement of expendable
items made in connection with scheduled maintenance. Yanmar disclaims any responsibility for incidental
or consequential damages such as loss of time, inconvenience, loss of use of equipment / engine or
commercial loss.
SAFETY
Page
Safety Statements ........................................................................... 3-3
Safety Precautions .......................................................................... 3-4
A
with most safety statements. It
means attention, become alert, your
safety is involved! Please read and
abide by the message that follows
the safety alert symbol.
A DANGER
Danger (the word “DANGER” is in white
letters with a red rectangle behind
it) - indicates an imminently hazardous
situation which, if not avoided, will
result in death or serious injury. Danger
is limited to the most extreme
situations.
0000001en
A WARNING
Warning (the word “WARNING” is in
black letters with an orange rectangle
behind it) – indicates a potentially
hazardous situation which, if not
avoided, could result in death or serious
injury.
0000001en
A DANGER A DANGER
A DANGER A DANGER
0000012en
A DANGER A DANGER
A DANGER A WARNING
SEVER HAZARD!
CRUSH HAZARD!
• Keep hands and other body parts
• When you need to transport an engine away from moving / rotating parts
for repair, have a helper assist you to such as the cooling fan, flywheel or
attach it to a hoist and load it on a PTO shaft.
truck.
• Wear tight-fitting clothing and keep
• NEVER stand under a hoisted engine. your hair short or tie it back while the
If the hoist mechanism fails, the engine is running.
engine will fall on you, causing death
or serious injury. • Remove all jewelry before you operate
or service the machine.
• Failure to comply will result in death or
serious injury. • NEVER start the engine in gear.
0000008en
Sudden movement of the engine
and / or machine could cause death or
serious personal injury.
A DANGER • NEVER operate the engine without the
guards in place.
• Before you start the engine make sure
that all bystanders are clear of the
area.
EXPLOSION HAZARD! • Keep children and pets away while the
• NEVER check the remaining battery engine is operating.
charge by shorting out the terminals. • Check before starting the engine that
This will result in a spark and may any tools or shop rags used during
cause an explosion or fire. Use a maintenance have been removed from
hydrometer to check the remaining the area.
battery charge. • Failure to comply could result in death
• If the electrolyte is frozen, slowly warm or serious injury.
the battery before you recharge it. 0000002en
A WARNING A WARNING
EXHAUST HAZARD!
• NEVER operate the engine in an EXPOSURE HAZARD!
enclosed area such as a garage,
tunnel, underground room, manhole or • Wear personal protective equipment
ship’s hold without proper ventilation. such as gloves, work shoes, eye and
hearing protection as required by the
• NEVER block windows, vents, or other task at hand.
means of ventilation if the engine is
operating in an enclosed area. All • NEVER wear jewelry, unbuttoned
internal combustion engines create cuffs, ties or loose-fitting clothing
carbon monoxide gas during when you are working near
operation. Accumulation of this gas moving / rotating parts such as the
within an enclosure could cause cooling fan, flywheel or PTO shaft.
illness or even death. • ALWAYS tie back long hair when you
• Make sure that all connections are are working near moving / rotating
tightened to specifications after repair parts such as a cooling fan, flywheel,
is made to the exhaust system. or PTO shaft.
• Failure to comply could result in death • NEVER operate the engine while
or serious injury. wearing a headset to listen to music or
radio because it will be difficult to hear
0000003en
the alert signals.
• Failure to comply could result in death
A WARNING or serious injury.
0000005en
A WARNING A WARNING
HIGH-PRESSURE HAZARD!
BURN HAZARD!
• Avoid skin contact with the
• If you must drain the engine oil while it high-pressure diesel fuel spray caused
is still hot, stay clear of the hot engine by a fuel system leak such as a broken
oil to avoid being burned. fuel injection line. High-pressure fuel
• ALWAYS wear eye protection. can penetrate your skin and result in
• Failure to comply could result in death serious injury. If you are exposed to
or serious injury. high-pressure fuel spray, obtain
prompt medical treatment.
0000011en
• NEVER check for a fuel leak with your
hands. ALWAYS use a piece of wood
A WARNING or cardboard. Have your authorized
Yanmar industrial engine dealer or
distributor repair the damage.
• Failure to comply could result in death
or serious injury.
BURN HAZARD! 0000008en
A WARNING A WARNING
ENTANGLEMENT HAZARD!
• Stop the engine before you begin to To prevent possible eye injury, always
service it. wear SAFETY GLASSES while servicing
the engine.
• NEVER leave the key in the key switch 0000013en
when you are servicing the engine.
Someone may accidentally start the
engine and not realize you are A WARNING
servicing it. This could result in a
serious injury.
• If you must service the engine while it
is operating, remove all jewelry, tie
back long hair, and keep your hands,
other body parts and clothing away BURN HAZARD!
from moving / rotating parts. • Keep your hands and other body parts
• Failure to comply could result in death away from hot engine surfaces such
or serious injury. as the muffler, exhaust pipe,
turbocharger (if equipped) and engine
0000010en
block during operation and shortly
after you shut the engine down. These
A WARNING surfaces are extremely hot while the
engine is operating and could
seriously burn you.
• Failure to comply could result in death
or serious injury.
0000015en
BURN HAZARD!
• Wait until the engine cools before you
drain the engine coolant. Hot engine
coolant may splash and burn you.
• Failure to comply could result in death
or serious injury.
0000016en
A WARNING A CAUTION
A CAUTION
Be sure to secure the engine solidly to
prevent injury or damage to parts due to
the engine falling during work on the
COOLANT HAZARD! engine.
0000009en
• Wear eye protection and rubber gloves
when you handle long life or extended
life engine coolant. If contact with the A CAUTION
eyes or skin should occur, flush eyes
and wash immediately with clean
water.
• Failure to comply may result in minor
or moderate injury.
0000005en
PINCH HAZARD!
Carefully rotate the alternator toward the
cylinder block while loosening the
V-belt. Failure to comply may result in
minor or moderate injury.
0000014en
A CAUTION CAUTION
If any oil pump component clearance Make sure the engine is installed on a
exceeds its limit, the oil pump must be level surface. If a continuously running
replaced as an assembly. engine is installed at an angle greater
0000015en than (IDI = 25°, DI = 30°) in any direction
or if an engine runs for short periods of
time (less than three minutes) at an
CAUTION angle greater than (IDI = 30°, DI = 35°) in
• Only use diesel fuels recommended by any direction, engine oil may enter the
Yanmar for the best engine combustion chamber causing excessive
performance, to prevent engine engine speed and white exhaust smoke.
damage and to comply with EPA / ARB This may cause serious engine damage.
warranty requirements. 0000010enTNV
CAUTION
If any problem is noted during the visual CAUTION
check, the necessary corrective action Observe the following environmental
should be taken before you operate the operating conditions to maintain engine
engine. performance and avoid premature
0000021en engine wear:
• Avoid operating in extremely dusty
CAUTION conditions.
NEVER hold the key in the START • Avoid operating in the presence of
position for longer than 15 seconds or chemical gases or fumes.
the starter motor will overheat.
• Avoid operating in a corrosive
0000007en
atmosphere such as salt water spray.
• NEVER install the engine in a
floodplain unless proper precautions
are taken to avoid being subject to a
flood.
• NEVER expose the engine to the rain.
0000003en
CAUTION CAUTION
Do not loosen or remove the four bolts If any indicator illuminates during
retaining the fuel injection pump drive engine operation, stop the engine
gear to the fuel injection pump hub. Do immediately. Determine the cause and
not disassemble the fuel injection pump repair the problem before you continue
drive gear from the hub. Correct fuel to operate the engine.
injection timing will be very difficult or 0000029en
impossible to achieve.
0000031en
CAUTION
• Only use the engine oil specified.
CAUTION Other engine oils may affect warranty
If the oil pump must be replaced, replace coverage, cause internal engine
it as an assembly only. Do not replace components to seize and / or shorten
individual components. engine life.
0000030en
• Prevent dirt and debris from
contaminating the engine oil. Carefully
CAUTION clean the oil cap / dipstick and the
surrounding area before you remove
Observe the following environmental
the cap.
operating conditions to maintain engine
performance and avoid premature • NEVER mix different types of engine
engine wear: oil. This may adversely affect the
lubricating properties of the engine oil.
• The standard range of ambient
temperatures for the normal operation • NEVER overfill. Overfilling may result
of Yanmar engines is from +5°F (-15°C) in white exhaust smoke, engine
to +113°F (+45°C). overspeed or internal damage.
0000005en
• If the ambient temperature exceeds
+113°F (+45°C) the engine may
overheat and cause the engine oil to CAUTION
break down. • Only use the engine coolant specified.
• If the ambient temperature is below Other engine coolants may affect
+5°F (-15°C) the engine will be hard to warranty coverage, cause an internal
start and the engine oil may not flow buildup of rust and scale and / or
easily. shorten engine life.
• Contact your authorized Yanmar • Prevent dirt and debris from
industrial engine dealer or distributor contaminating the engine coolant.
if the engine will be operated outside Carefully clean the radiator cap and
of this standard temperature range. the surrounding area before you
0000065en remove the cap.
• NEVER mix different types of engine
coolants. This may adversely affect the
properties of the engine coolant.
0000006en
CAUTION CAUTION
• NEVER overfill the engine with engine
oil.
• ALWAYS keep the oil level between the
upper and lower lines on the oil
cap / dipstick.
0000015en
• ALWAYS be environmentally
responsible.
CAUTION CAUTION
New Engine Break-in: • NEVER attempt to modify the engine’s
• On the initial engine start-up, allow the design or safety features such as
engine to idle for approximately 15 defeating the engine speed limit
minutes while you check for proper control or the fuel injection quantity
engine oil pressure, diesel fuel leaks, control.
engine oil leaks, coolant leaks, and for • Failure to comply may impair the
proper operation of the indicators engine’s safety and performance
and / or gauges. characteristics and shorten the
• During the first hour of operation, vary engine’s life. Any alterations to this
the engine speed and the load on the engine may affect the warranty
engine. Short periods of maximum coverage of your engine. Yanmar
engine speed and load are desirable. Limited Warranty on page 2-3.
Avoid prolonged operation at 0000044TNVIDISM
frequently.
0000011en CAUTION
NEVER attempt to adjust the low or high
CAUTION idle speed limit screw. This may impair
NEVER engage the starter motor while the safety and performance of the
the engine is running. This may damage machine and shorten its life. If the idle
the starter motor pinion and / or ring speed limit screws require adjustment,
gear. see your authorized Yanmar industrial
engine dealer or distributor.
0000012en
0000017en
CAUTION
The starter motor can be damaged if
operated continuously longer than
10 seconds while performing the
no-load test.
0000034en
CAUTION CAUTION
The tightening torque in the Standard • When the engine is operated in dusty
Torque Chart in General Service conditions, clean the air cleaner
Information should be applied only to element more frequently.
the bolts with a “7” head. (JIS strength • NEVER operate the engine with the air
classification: 7T) cleaner element(s) removed. This may
allow foreign material to enter the
• Apply 60% torque to bolts engine and damage it.
that are not listed.
0000026en
• Apply 80% torque when
tightened to aluminum alloy.
CAUTION
0000023enTNVIDISM
The maximum air intake restriction, in
terms of differential pressure
CAUTION measurement, must not exceed 0.90 psi
Establish a periodic maintenance plan (6.23 kPa; 635 mmAq). Clean or replace
according to the engine application and the air cleaner element if the air intake
make sure you perform the required restriction exceeds the above
periodic maintenance at intervals mentioned value.
indicated. Failure to follow these 0000046en
guidelines will impair the engine’s safety
and performance characteristics,
shorten the engine’s life and may affect
CAUTION
the warranty coverage on your engine. Do not short-circuit the charging system
See Yanmar Warranties section. between alternator terminals IG and L.
Damage to the alternator will result.
Consult your authorized Yanmar dealer
0000035en
or distributor for assistance when
checking items marked with a z.
0000024enTNVIDISM CAUTION
Do not connect a load between
CAUTION alternator terminals L and E. Damage to
the alternator will result.
If the fuel filter / water separator is
0000036en
positioned higher than the fuel level in
the fuel tank, water may not drip out
when the fuel filter / water separator CAUTION
drain cock is opened. If this happens, Do not remove the positive (+) battery
turn the air vent screw on the top of the cable from alternator terminal B while
fuel filter / water separator 2-3 turns the engine is operating. Damage to the
counterclockwise. alternator will result.
Be sure to tighten the air vent screw 0000037en
CAUTION CAUTION
Do not turn the battery switch OFF while After marking the position of the pump
the engine is operating. Damage to the drive gear, do not rotate the engine
alternator will result. crankshaft. Rotating the crankshaft will
0000038en cause the fuel injection pump to become
misaligned.
CAUTION 0000048en
CAUTION CAUTION
Agricultural or other chemicals, Make sure that the combined total
especially those with a high sulfur resistance of the battery cable in both
content, can adhere to the IC regulator. directions between the starter motor
This will corrode the conductor and and the battery is within the value
result in battery over-charging (boiling) indicated in the Battery Cable
and charging malfunctions. Consult Resistance chart in the Electric Wiring
Yanmar before using the equipment in Section of this manual. The starter
such an environment or the warranty is motor will malfunction and fail if the
voided. resistance is higher than the specified
0000053en value.
0000057en
CAUTION
Make sure that the combined total CAUTION
resistance of the battery cable in both Removing the battery cables or the
directions between the starter motor battery while the engine is operating
and the battery is within the value may cause damage to the current limiter
indicated on the wiring diagram. The depending on the electrical equipment
starter motor will malfunction or break being used. This situation could cause
down if the resistance is higher than the loss of control of output voltage. The
specified value. continuous high voltage of 23-24 volts
0000054en (for 5000 rpm dynamo) will damage the
current limiter and other electrical
equipment.
CAUTION
0000058en
The starter motor is water-proofed
according to JIS D 0203, R2 which
protects the motor from rain or general CAUTION
cleaning. Do not use high-pressure Reversing the battery cable connections
wash or submerse the starter motor in at the battery or on the engine will
water. destroy the SCR diode in the current
0000055en limiter. This will cause the charging
system to malfunction and may cause
damage to the electrical harnesses.
CAUTION
0000059en
Use a specialized battery charger to
recharge a battery with a voltage of
8 volts or less. Booster starting a battery CAUTION
with a voltage of 8 volts or less will It is important to perform daily checks.
generate an abnormally high voltage Periodic maintenance prevents
and destroy electrical equipment. unexpected downtime, reduces the
0000056en
number of accidents due to poor
machine performance and helps extend
the life of the engine.
0000060en
CAUTION CAUTION
• NEVER attempt to modify the engine’s Do not allow the honing tool to operate
design or safety features such as in one position for any length of time.
defeating the engine speed limit Damage to the cylinder wall will occur.
control or the diesel fuel injection Keep the tool in constant up-and-down
quantity control. motion.
• Modifications may impair the engine’s 0000090en
CAUTION CAUTION
Identify all parts and their location using
Any part determined to not meet the
an appropriate method. It is important
service standard or limit before the next
that all parts are returned to the same
service, as determined from the state of
position during the reassembly process.
current rate of wear, should be replaced
0000080en
even though the part currently meets the
service standard limit.
CAUTION 0000120en
CAUTION
• NEVER remove or attempt to remove
the tamper-proof devices from the
full-load fuel adjusting screw or the
high-speed throttle limit screw on the
fuel injection pump and governor
assembly. These adjustments have
been made at the factory to meet all
applicable emissions regulations and
then sealed.
• NEVER attempt to make any
adjustments to these sealed
adjustment screws. If adjustments are
required, they can be made only by a
qualified fuel injection shop that will
ensure the injection pump continues
to meet all applicable emissions
regulations and then replace the
tamper-proof seals.
• Tampering with or removing these
devices may void the “Yanmar Limited
Warranty.”
0000146en
CAUTION
The fuel return line is a one-piece
assembly. Use care not to bend or twist
the fuel return line.
0000171en
GENERAL SERVICE
INFORMATION
Page
Component Identification................................................................. 4-3
Location of Labels ........................................................................... 4-4
EPA / ARB Emission Control Regulations - USA Only.................... 4-4
Emission Control Labels.................................................................. 4-4
EPA / ARB Labels ..................................................................... 4-5
The 97/68/EC Directive Certified Engines ....................................... 4-5
Engine Family.................................................................................. 4-5
Function of Major Engine Components ........................................... 4-6
Function of Cooling System Components ....................................... 4-8
Diesel Fuel ...................................................................................... 4-9
Diesel Fuel Specifications ......................................................... 4-9
Filling the Fuel Tank ................................................................ 4-10
Priming the Fuel System ......................................................... 4-12
Engine Oil...................................................................................... 4-13
Engine Oil Specifications ........................................................ 4-13
Service Categories .................................................................. 4-13
Engine Oil Viscosity................................................................. 4-14
Checking Engine Oil ................................................................ 4-14
Adding Engine Oil.................................................................... 4-14
Engine Oil Capacity (Typical) .................................................. 4-15
Engine Coolant.............................................................................. 4-15
Engine Coolant Specifications................................................. 4-16
Filling Radiator with Engine Coolant........................................ 4-16
Engine Coolant Capacity (Typical) .......................................... 4-17
Specifications ................................................................................ 4-18
Description of Model Number .................................................. 4-18
Engine Speed Specifications................................................... 4-18
Engine General Specifications ................................................ 4-19
COMPONENT IDENTIFICATION
Figure 4-1 shows where major engine components are located.
(1)
(19) (2) (21)
(20)
(3)
(18)
(17)
(16)
(25)
(15)
(14) (4)
(24)
(13) (5)
(12)
(6) (23)
(11)
(8) (7) (22) 0000583A
(10)
(9)
Figure 4-1
0003852
97/68/EC DIRECTIVE
(EPA) Less Than 50 HP SAE (37kW)
(97/68/EC)
ENGINE FAMILY
The EPA / ARB labels and the 97/68/EC label all
have an Engine Family field. The following is an
explanation of the Engine Family designation:
3 YDX L 1.33 M 3 N
Method of air aspiration
Number of cylinders
Displacement (liter)
Yanmar Diesel
5*: 2005
6 : 2006
7 : 2007
Component Function
The fuel tank is a reservoir that holds diesel fuel. When fuel leaves
the fuel tank it goes to the fuel filter / water separator. Next, fuel is
pumped to the fuel filter by the fuel pump. Next the fuel goes to the
fuel injection pump. Since fuel is used to keep the fuel injection
Fuel Tank
pump cool and lubricated, more fuel than necessary enters the
injection pump. When the injection pump pressure reaches a preset
value, a relief valve allows excess fuel to be returned back to the
fuel tank. The fuel tank is a required engine component.
The mechanical fuel pump is a diaphragm type of pump and is
installed on the fuel injection pump body. The mechanical fuel
pump is standard equipment on some engine models and is driven
Mechanical Fuel Pump
by a cam on the camshaft of the fuel injection pump. The
mechanical fuel pump is not installed on the fuel injection pump if
the electric fuel pump is installed.
Side and Top Filler Port (Engine You can fill the crankcase with engine oil from either the side or
Oil) top filler port depending upon which one is most convenient.
The starter motor is powered by the battery. When you turn the key
switch in the operator’s console to the START position, the starter
Starter Motor
motor engages with the ring gear installed on the flywheel and
starts the flywheel in motion.
Precautions and concerns regarding the use of Filling the Fuel Tank
bio-fuels:
1. Free methanol in FAME may result in corrosion A DANGER
of aluminum and zinc FIE components.
2. Free water in FAME may result in plugging of
fuel filters and increased bacterial growth.
3. High viscosity at low temperatures may result in
fuel delivery problems, injection pump seizures, FIRE AND EXPLOSION HAZARD!
and poor injection nozzle spray atomization.
• Diesel fuel is flammable and explosive
4. FAME may have adverse effects on some under certain conditions.
elastomers (seal materials) and may result in
fuel leakage and dilution of the engine • Only fill the fuel tank with diesel fuel.
lubricating oil. Filling the fuel tank with gasoline may
result in a fire and will damage the
5. Even bio-diesel fuels that comply with a suitable
engine.
standard as delivered, will require additional
care and attention to maintain the quality of the • NEVER refuel with the engine running.
fuel in the equipment or other fuel tanks. It is • Wipe up all spills immediately.
important to maintain a supply of clean, fresh
fuel. Regular flushing of the fuel system, • Keep sparks, open flames or any other
and / or fuel storage containers, may be form of ignition (match, cigarette,
necessary. static electric source) well away when
refueling.
6. The use of bio-diesel fuels that do not comply
with the standards as agreed to by the diesel • NEVER overfill the fuel tank.
engine manufacturers and the diesel fuel • Fill the fuel tank. Store any containers
injection equipment manufacturers, or bio- containing fuel in a well-ventilated
diesel fuels that have degraded as per the area, away from any combustibles or
precautions and concerns above, may affect sources of ignition.
the warranty coverage of your engine. See
• Failure to comply will result in death or
Yanmar Limited Warranty on page 2-3.
serious injury.
0000005en
A DANGER A DANGER
Note that a typical fuel tank is shown. The fuel tank Priming the Fuel System
on the equipment being serviced may be different.
1. Clean the area around the fuel cap A DANGER
(Figure 4-3, (1)).
2. Remove the fuel cap (Figure 4-3, (1)) from the
fuel tank (Figure 4-3, (2)).
3. Observe the fuel level sight gauge
(Figure 4-3, (3)) and stop fueling when gauge FIRE AND EXPLOSION HAZARD!
shows fuel tank is full. NEVER overfill the fuel • Diesel fuel is flammable and explosive
tank. under certain conditions.
4. Replace the fuel cap and hand-tighten. Over • If the unit has an electric fuel pump,
tightening the fuel cap will damage it. when you prime the fuel system, turn
the key switch to the ON position for
(1) 10 to 15 seconds to allow the electric
fuel pump to prime the system.
• If the unit has a mechanical fuel pump,
(2) when you prime the fuel system,
operate the fuel priming lever of the
mechanical fuel pump several times
until the fuel filter cup is filled with
(3) fuel.
• Failure to comply will result in death or
0000002A
serious injury.
0000010en
Figure 4-3
The fuel system needs to be primed under certain
conditions:
• Before starting the engine for the first time
• After running out of fuel and fuel has been
added to the fuel tank
• After fuel system maintenance such as
changing the fuel filter and draining the fuel
filter / water separator, or replacing a fuel
system component
To prime the fuel system if an electric fuel pump is
installed:
1. Turn the key to the ON position for 10 to 15
seconds. This will allow the electric fuel pump
to prime the fuel system.
2. NEVER use the starter motor to prime the fuel
system. This may cause the starter motor to
overheat and damage the coils, pinion and / or
ring gear.
Service Categories
• API Service Categories CD or higher
• ACEA Service Categories E-3, E-4, and E-5
• JASO Service Category DH-1
Definitions
• API Classification (American Petroleum
Institute)
• ACEA Classification (Association des
Constructeurs Européens d'Automobilies)
• JASO (Japanese Automobile Standards
Organization)
Note:
1. Be sure the engine oil, engine oil storage
containers, and engine oil filling equipment are
free of sediments and water.
BURN HAZARD!
• Wait until the engine cools before you
drain the engine coolant. Hot engine
coolant may splash and burn you.
• Failure to comply could result in death
or serious injury.
0000016en
Engine Coolant
Engine Model
Capacity
(1) 0002923
2TNV70 0.6 qt (0.6 L)
Figure 4-8
3TNV70 1.0 qt (0.9 L)
2. Remove the radiator cap (Figure 4-7, (2)) by 3TNV76 1.0 qt (0.9 L)
turning it counterclockwise about 1/3 of a turn.
3. Pour the engine coolant slowly into the radiator
until it is even with the lip of the engine coolant
filler port. Make sure that air bubbles do not
develop as you fill the radiator.
4. Reinstall the radiator cap (Figure 4-7, (2)).
Align the tabs on the back of the radiator cap
with the notches on the engine coolant filler
port. Press down and turn the cap clockwise
about 1/3 of a turn.
SPECIFICATIONS
Description of Model Number
3 TNV 76 T - 0 0000
Customer Code
Rated rpm
Engine Series
No. of Cylinders
When ordering parts or making an inquiry about the engine you are working on, be sure to include the
complete model and serial numbers as shown on the engine nameplate. See Location of Labels on
page 4-4.
Note: The information described in Principal Engine Specifications is for a “standard” engine. To obtain the
information for the engine installed in your driven machine, please refer to the manual provided by
the driven machine manufacturer. Engine rating conditions are as follows (SAE J1349, ISO 3046/1):
• Atmospheric Condition: Room temperature 77°F (25°C), Atmospheric pressure 29.53 in Hg (100 kPa,
750 mm Hg), Relative humidity 30%
• Fuel Temperature at Fuel Injector Pump Inlet: 104°F (40°C)
• With Cooling Fan, Air Cleaner, Muffler: Yanmar Standard
• After Engine Break-In Period; Output Allowable Deviation: ± 3%
• 1 PS = 0.7355 kW
• 1 hp SAE (Society of Automotive Engineers) = 0.7457 kW
3TNV76
Engine Model 3TNV76
Version CL VM CH VH
Type Vertical In-line Diesel Engine
Combustion System Ball-Type Swirl Chamber
Aspiration Natural
No. of Cylinders 3
Bore × Stroke 2.992 x 3.228 in. (76 × 82 mm)
Displacement 68.029 cu in. (1.115 L)
RPM
(min -1) 1500 1800 3000 3600
Max. Rated Output (Net) hp SAE 12.1 14.3 15.9 17.7 19.2 20.0 20.8 22.4 24.0 22.1 26.1 24.4 25.9 26.1
kW 9 10.7 11.8 13.2 14.3 14.9 15.5 16.7 17.9 16.5 19.5 18.2 19.3 19.5
PS 12.2 14.5 16.1 17.9 19.5 20.3 21.1 22.7 24.3 22.4 26.5 24.7 26.2 26.5
RPM 1600 1900 2160 2375 2570 2675 2780 2995 3210 3200 3800 3400 3600 3815
High Idling (min -1) ± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25
Engine Weight (Dry)
with Flywheel Housing 247.0 lb (112 kg)
PTO Position Flywheel End
Direction of Rotation Counterclockwise Viewed from Flywheel End
Cooling System Liquid-Cooled with Radiator
Lubricating System Forced Lubrication with Trochoid Pump
35 - 51psi
Normal Oil Pressure at Rated (0.24-0.35
42 - 64 psi (0.29 -0.44 MPa, 2.96 - 4.49 kgf/cm2)
Engine Speed MPa, 2.44 -
3.57 kgf/cm2)
Normal Oil Pressure at Low 8.5 psi (0.06 MPa, 0.6 kgf/cm2) or greater
Idle Speed
Electric Starting - Starter Motor: DC12V, 1.5 hp (1.1 kW)**
Starting System Alternator: DC12V, 40A**
Recommended Battery Capacity: 12V, 36 Amp-Hour (5h rating)**
22.32 x 20.59 x 20.59 x 16.81 x
16.81 x 20.59 x 16.81 x 20.94 in. 16.81 x 20.94 in.
Dimensions (L × W × H)* 20.94 in. (532 × 427 × 532 mm) 22.01 in. (532 × 427 × 532
(567 × 427 × (532 × 427 × mm)
532 mm) 559 mm)
4.7 / 2.4 qt
(4.4 / 2.3 L) 3.6 / 1.9 qt (3.4 / 1.8
Engine Oil Pan Capacity 3.6 / 1.9 qt (3.4 / 1.8 L) (Dipstick Upper Limit / Lower Limit) (Dipstick L) (Dipstick Upper
Upper Limit / Limit / Lower Limit)
Lower Limit)
Engine Coolant Capacity 0.2 gal (0.9 L) Engine Only
Standard Cooling Fan 13.19 in. (335 mm) O.D., 6 Blade Pusher-Type**
Nominal Thread
Item x Pitch Tightening Torque Remarks
Diameter
87 - 104 in·lb
M6 x 1.0 mm (9.8 - 11.8 N·m;
1.0 - 1.2 kgf·m)
200 - 251 in·lb
M8 x 1.25 mm (22.6 - 28.4 N·m;
2.3 - 2.9 kgf·m)
33 - 40 ft·lb
M10 x 1.5 mm (44.1 - 53.9 N·m; Use 80% of the value at left
4.5 - 5.5 kgf·m) when the tightening part is
Hexagon Bolt (7T)
aluminum.
and Nut 58 - 72 ft·lb Use 60% of the value at left
M12 x 1.75 mm (78.4 - 98.0 N·m; for 4T bolts and lock nuts.
8.0 - 10 kgf·m)
94 - 108 ft·lb
M14 x 1.5 mm (127.5 - 147.1 N·m;
13 - 15 kgf·m)
159 - 174 ft·lb
M16 x 1.5 mm (215.7 - 235.4 N·m;
22 - 24 kgf·m)
87 in·lb
1/8 mm
(9.8 N·m; 1.0 kgf·m)
173 in·lb
1/4 mm
(19.6 N·m; 2.0 kgf·m)
PT Plug -
22 ft·lb
3/8 mm
(29.4 N·m; 3.0 kgf·m)
43 ft·lb
1/2 mm
(58.8 N·m; 6.0 kgf·m)
Nominal Thread
Item x Pitch Tightening Torque Remarks
Diameter
112 - 148 in·lb
M8 (12.7 - 16.7 N·m;
1.3 - 1.7 kgf·m)
173 - 225 in·lb
M10 (19.6 - 18.734 N·m,;
2.0 - 3.5 kgf·m)
18 - 25 ft·lb
Pipe Joint Bolt M12 (24.5 - 34.3 N·m; -
2.5 - 3.5 kgf·m)
29 - 36 ft·lb
M14 (39.2 - 49.0 N·m;
4.0 - 5.0 kgf·m)
36 - 43 ft·lb
M16 (49.0 - 58.8 N·m;
5.0 - 6.0 kgf·m)
Note: Torque values shown in this manual are for clean, non-lubricated fasteners unless otherwise
specified.
PERIODIC
MAINTENANCE
Page
Introduction...................................................................................... 5-3
Precautions ................................................................................... 5-15
The Importance of Periodic Maintenance................................ 5-15
Performing Periodic Maintenance ........................................... 5-15
Yanmar Replacement Parts .................................................... 5-16
Required EPA / ARB Maintenance - USA Only....................... 5-16
EPA / ARB Installation Requirements - USA Only .................. 5-16
Periodic Maintenance Schedule.................................................... 5-16
Periodic Maintenance Procedures ................................................ 5-18
After Initial 50 Hours of Operation ........................................... 5-18
Every 50 Hours of Operation................................................... 5-21
Every 250 Hours of Operation ................................................. 5-25
Every 500 Hours of Operation ................................................. 5-30
Every 1000 Hours of Operation ............................................... 5-33
Every 1500 Hours of Operation ............................................... 5-36
Every 2000 Hours of Operation ............................................... 5-37
INTRODUCTION A DANGER
This section of the Service Manual describes the
procedures for proper care and maintenance of the
engine.
A DANGER
SCALD HAZARD!
• NEVER remove the radiator cap if the
engine is hot. Steam and hot engine
coolant will spurt out and seriously
burn you. Allow the engine to cool
EXPLOSION HAZARD! down before you attempt to remove
• NEVER check the remaining battery the radiator cap.
charge by shorting out the terminals.
• Tighten the radiator cap securely after
This will result in a spark and may
you check the radiator. Steam can
cause an explosion or fire. Use a
spurt out during engine operation if
hydrometer to check the remaining
the cap is loose.
battery charge.
• ALWAYS check the level of the engine
• If the electrolyte is frozen, slowly warm
coolant by observing the reserve tank.
the battery before you recharge it.
• Failure to comply will result in death or
• Failure to comply will result in death or
serious injury.
serious injury.
0000002en
0000007en
A DANGER
A DANGER A DANGER
A DANGER A DANGER
A DANGER A DANGER
A WARNING A WARNING
A WARNING A WARNING
BURN HAZARD!
• Keep your hands and other body parts EXPOSURE HAZARD!
away from hot engine surfaces such
• Wear personal protective equipment
as the muffler, exhaust pipe,
such as gloves, work shoes, eye and
turbocharger (if equipped) and engine
hearing protection as required by the
block during operation and shortly
task at hand.
after you shut the engine down. These
surfaces are extremely hot while the • NEVER wear jewelry, unbuttoned
engine is operating and could cuffs, ties or loose-fitting clothing
seriously burn you. when you are working near
moving / rotating parts such as the
• Failure to comply could result in death
cooling fan, flywheel or PTO shaft.
or serious injury.
0000015en
• ALWAYS tie back long hair when you
are working near moving / rotating
parts such as a cooling fan, flywheel,
A WARNING or PTO shaft.
• NEVER operate the engine while
wearing a headset to listen to music or
radio because it will be difficult to hear
the alert signals.
• Failure to comply could result in death
ALCOHOL AND DRUG HAZARD! or serious injury.
• NEVER operate the engine while you 0000005en
are under the influence of alcohol or
drugs.
• NEVER operate the engine when you
are feeling ill.
• Failure to comply could result in death
or serious injury.
0000004en
A WARNING A WARNING
BURN HAZARD!
SHOCK HAZARD!
• Batteries contain sulfuric acid. NEVER
allow battery fluid to come in contact • Turn off the battery switch (if
with clothing, skin or eyes. Severe equipped) or disconnect the negative
battery cable before servicing the
burns could result. ALWAYS wear
electrical system.
safety goggles and protective clothing
when servicing the battery. If battery • Check the electrical harnesses for
fluid contacts the eyes and / or skin, cracks, abrasions, and damaged or
immediately flush the affected area corroded connectors. ALWAYS keep
with a large amount of clean water and the connectors and terminals clean.
obtain prompt medical treatment. • Failure to comply could result in death
• Failure to comply could result in death or serious injury.
or serious injury. 0000009en
0000007en
A WARNING
A WARNING
ENTANGLEMENT HAZARD!
HIGH-PRESSURE HAZARD!
• Stop the engine before you begin to
• Avoid skin contact with the service it.
high-pressure diesel fuel spray caused
by a fuel system leak such as a broken • NEVER leave the key in the key switch
fuel injection line. High-pressure fuel when you are servicing the engine.
can penetrate your skin and result in Someone may accidentally start the
serious injury. If you are exposed to engine and not realize you are
high-pressure fuel spray, obtain servicing it. This could result in a
prompt medical treatment. serious injury.
• NEVER check for a fuel leak with your • If you must service the engine while it
hands. ALWAYS use a piece of wood is operating, remove all jewelry, tie
or cardboard. Have your authorized back long hair, and keep your hands,
Yanmar industrial engine dealer or other body parts and clothing away
distributor repair the damage. from moving / rotating parts.
• Failure to comply could result in death • Failure to comply could result in death
or serious injury. or serious injury.
0000010en
0000008en
A WARNING A CAUTION
BURN HAZARD!
COOLANT HAZARD!
• If you must drain the engine oil while it
is still hot, stay clear of the hot engine • Wear eye protection and rubber gloves
oil to avoid being burned. when you handle long life or extended
life engine coolant. If contact with the
• ALWAYS wear eye protection. eyes or skin should occur, flush eyes
• Failure to comply could result in death and wash immediately with clean
or serious injury. water.
0000011en • Failure to comply may result in minor
or moderate injury.
A CAUTION 0000005en
CAUTION
• Only use the engine oil specified.
Other engine oils may affect warranty
coverage, cause internal engine
components to seize and / or shorten
FLYING OBJECT HAZARD! engine life.
• ALWAYS wear eye protection when • Prevent dirt and debris from
servicing the engine and when using contaminating the engine oil. Carefully
compressed air or high-pressure clean the oil cap / dipstick and the
water. Dust, flying debris, compressed surrounding area before you remove
air, pressurized water or steam may the cap.
injure your eyes. • NEVER mix different types of engine
• Failure to comply may result in minor oil. This may adversely affect the
or moderate injury. lubricating properties of the engine oil.
0000003en • NEVER overfill. Overfilling may result
in white exhaust smoke, engine
overspeed or internal damage.
0000005en
CAUTION CAUTION
• Only use diesel fuels recommended by • Only use the engine coolant specified.
Yanmar for the best engine Other engine coolants may affect
performance, to prevent engine warranty coverage, cause an internal
damage and to comply with EPA / ARB buildup of rust and scale and / or
warranty requirements. shorten engine life.
• Only use clean diesel fuel. • Prevent dirt and debris from
• NEVER remove the primary strainer (if contaminating the engine coolant.
equipped) from the fuel tank filler port. Carefully clean the radiator cap and
If removed, dirt and debris could get the surrounding area before you
into the fuel system causing it to clog. remove the cap.
0000004en • NEVER mix different types of engine
coolants. This may adversely affect the
properties of the engine coolant.
CAUTION
0000006en
• Only use the engine oil specified.
Other engine oils may affect warranty
coverage, cause internal engine CAUTION
components to seize and / or shorten • NEVER attempt to modify the engine’s
engine life. design or safety features such as
• Prevent dirt and debris from defeating the engine speed limit
contaminating the engine oil. Carefully control or the diesel fuel injection
clean the oil cap / dipstick and the quantity control.
surrounding area before you remove • Modifications may impair the engine’s
the cap. safety and performance
• NEVER mix different types of engine characteristics and shorten the
oil. This may adversely affect the engine’s life. Any alterations to this
lubricating properties of the engine oil. engine may void its warranty. Be sure
to use Yanmar genuine replacement
• NEVER overfill. Overfilling may result parts.
in white exhaust smoke, engine 0000079en
overspeed or internal damage.
0000005en
CAUTION CAUTION
Observe the following environmental NEVER hold the key in the START
operating conditions to maintain engine position for longer than 15 seconds or
performance and avoid premature the starter motor will overheat.
engine wear: 0000007en
0000003en
CAUTION
CAUTION NEVER use an engine starting aid such
Observe the following environmental as ether. Engine damage will result.
operating conditions to maintain engine 0000009en
CAUTION CAUTION
New Engine Break-in:
• On the initial engine start-up, allow the
engine to idle for approximately 15
minutes while you check for proper
engine oil pressure, diesel fuel leaks,
engine oil leaks, coolant leaks, and for • ALWAYS be environmentally
proper operation of the indicators responsible.
and / or gauges. • Follow the guidelines of the EPA or
• During the first hour of operation, vary other governmental agencies for the
the engine speed and the load on the proper disposal of hazardous
engine. Short periods of maximum materials such as engine oil, diesel
engine speed and load are desirable. fuel and engine coolant. Consult the
Avoid prolonged operation at local authorities or reclamation facility.
minimum or maximum engine speeds • NEVER dispose of hazardous
and loads for the next four to five materials irresponsibly by dumping
hours. them into a sewer, on the ground, or
• During the break-in period, carefully into ground water or waterways.
observe the engine oil pressure and • Failure to follow these procedures may
engine temperature. seriously harm the environment.
• During the break-in period, check the 0000013en
CAUTION CAUTION
NEVER use high-pressure water or If the fuel filter / water separator is
compressed air at greater than 28 psi positioned higher than the fuel level in
(193 kPa; 19 686 mmAq) or a wire brush the fuel tank, water may not drip out
to clean the radiator fins. Radiator fins when the fuel filter / water separator
damage easily. drain cock is opened. If this happens,
0000016en turn the air vent screw on the top of the
fuel filter / water separator 2-3 turns
counterclockwise.
CAUTION
Be sure to tighten the air vent screw
NEVER attempt to adjust the low or high
after the water has drained out.
idle speed limit screw. This may impair
0000025en
the safety and performance of the
machine and shorten its life. If the idle
speed limit screws require adjustment, CAUTION
see your authorized Yanmar industrial • When the engine is operated in dusty
engine dealer or distributor. conditions, clean the air cleaner
0000017en
element more frequently.
• NEVER operate the engine with the air
CAUTION cleaner element(s) removed. This may
Establish a periodic maintenance plan allow foreign material to enter the
according to the engine application and engine and damage it.
make sure you perform the required 0000026en
CAUTION PRECAUTIONS
The tightening torque in the Standard The Importance of Periodic
Torque Chart in General Service
Information should be applied only to
Maintenance
the bolts with a “7” head. (JIS strength Engine deterioration and wear occurs in proportion
classification: 7T) to length of time the engine has been in service and
the conditions the engine is subject to during
• Apply 60% torque to bolts operation. Periodic maintenance prevents
that are not listed. unexpected downtime, reduces the number of
• Apply 80% torque when accidents due to poor machine performance and
tightened to aluminum alloy. helps extend the life of the engine.
0000023enTNVIDISM
Performing Periodic Maintenance
CAUTION A WARNING
It is important to perform daily checks.
Periodic maintenance prevents
unexpected downtime, reduces the
number of accidents due to poor
machine performance and helps extend
EXHAUST HAZARD!
the life of the engine.
0000060en
• NEVER operate the engine in an
enclosed area such as a garage,
tunnel, underground room, manhole or
ship’s hold without proper ventilation.
• NEVER block windows, vents, or other
means of ventilation if the engine is
operating in an enclosed area. All
internal combustion engines create
carbon monoxide gas during
operation. Accumulation of this gas
within an enclosure could cause
illness or even death.
• Make sure that all connections are
tightened to specifications after repair
is made to the exhaust system.
• Failure to comply could result in death
or serious injury.
0000003en
c:Check :Replace z: Contact your authorized Yanmar industrial engine dealer or distributor
Periodic Maintenance Interval
System Check Item Daily Every Every Every Every Every Every
50 250 500 1000 1500 2000
hours hours hours hours hours hours
Check and Refill Engine Coolant c
Check and Clean Radiator Fins c
Check and Adjust Cooling Fan V- c1st c 2nd
Belt time and after
Cooling
or
System
every 1
Drain, Flush and Refill Cooling yr. which-
System with New Coolant ever
comes
first
Adjust Intake / Exhaust Valve
Cylinder z
Clearance
Head
Lap Intake / Exhaust Valve Seats z
Electrical Check Indicators c
Equipment Check Battery c
Check Engine Oil Level c
Note: These procedures are considered normal maintenance and are performed at the owner’s expense.
BURN HAZARD!
• If you must drain the engine oil while it CAUTION
is still hot, stay clear of the hot engine
oil to avoid being burned.
• ALWAYS wear eye protection.
• Failure to comply could result in death
or serious injury.
0000011en
• ALWAYS be environmentally
responsible.
• Follow the guidelines of the EPA or
other governmental agencies for the
proper disposal of hazardous
materials such as engine oil, diesel
fuel and engine coolant. Consult the
local authorities or reclamation facility.
• NEVER dispose of hazardous
materials irresponsibly by dumping
them into a sewer, on the ground, or
into ground water or waterways.
• Failure to follow these procedures may
seriously harm the environment.
0000013en
Figure 5-2
2. Clean the engine oil filter mounting face.
3. Lightly coat the gasket on the new oil filter with
(1) clean engine oil. Install the new engine oil filter
manually by turning it clockwise
(Figure 5-2, (3)) until it contacts the mounting
surface. Tighten to 14 - 17 ft·lb (19.6 - 23.5 N·m,
2.0 - 2.4 kgf·m or one additional turn using the
filter wrench.
(4) 0000652B
Figure 5-4
(3)
(2)
(3) (1)
0000587C
(2)
Figure 5-3
0000653B
Figure 5-5
Figure 5-6
4. Check the V-belt for cracks, oil or wear. If any of FIRE AND EXPLOSION HAZARD!
these conditions exist, replace the V-belt.
• Diesel fuel is flammable and explosive
• “New V-belt” refers to a V-belt which has been under certain conditions.
used less than 5 minutes on a running engine.
• When you remove any fuel system
• “Used V-belt” refers to a V-belt which has been component to perform maintenance
used on a running engine for 5 minutes or (such as changing the fuel filter) place
more. an approved container under the
5. Inspect the condition of the used V-belt. There opening to catch the fuel.
must be clearance (Figure 5-6, (1)) between • NEVER use a shop rag to catch the
the V-belt and the bottom of the pulley groove. If fuel. Vapors from the rag are
there is no clearance (Figure 5-6, (2)) between flammable and explosive.
the V-belt and the bottom of the pulley groove,
replace the V-belt. • Wipe up any spills immediately.
6. Install the new V-belt. Refer to the table for • Wear eye protection. The fuel system
proper tension. is under pressure and fuel could spray
out when you remove any fuel system
New V-Belt Tension component.
A B C • Failure to comply will result in death or
5/16 - 7/16 in. 3/16 - 5/16 in. 1/4 - 7/16 in. serious injury.
(8 - 12 mm) (5 - 8 mm) (7 - 11 mm) 0000009en
CAUTION (8)
(5) (11)
(9) (4) (6)
• ALWAYS be environmentally (3) (10)
responsible. (1)
(7)
• Follow the guidelines of the EPA or (2)
other governmental agencies for the 0000590A
• NEVER dispose of hazardous 3. Turn the retaining ring (Figure 5-7, (4)) to the
materials irresponsibly by dumping left (Figure 5-7, (9)).
them into a sewer, on the ground, or 4. Carefully remove the cup (Figure 5-7, (1)).
into ground water or waterways. Remove the retaining spring (Figure 5-7, (6))
and float (Figure 5-7, (7)) from the cup. Pour
• Failure to follow these procedures may
the fuel into an approved container and dispose
seriously harm the environment.
properly. Hold the bottom of the cup with a shop
0000013en
towel to prevent the fuel from dripping. Wipe up
Drain the fuel filter / water separator whenever any spills immediately.
there are contaminants, such as water, collected in 5. Clean the inside of the cup.
the bottom of the cup. NEVER wait until the 6. Inspect the condition of the mesh filter
scheduled periodic maintenance if contaminants (Figure 5-7, (10)). Clean the mesh filter if
are discovered. necessary.
7. Inspect the condition of the O-ring
(Figure 5-7, (11)). Replace the O-ring if
necessary.
Check Battery
A DANGER
• ALWAYS be environmentally
responsible.
• Follow the guidelines of the EPA or
other governmental agencies for the
EXPLOSION HAZARD! proper disposal of hazardous
materials such as engine oil, diesel
• NEVER check the remaining battery fuel and engine coolant. Consult the
charge by shorting out the terminals. local authorities or reclamation facility.
This will result in a spark and may
cause an explosion or fire. Use a • NEVER dispose of hazardous
hydrometer to check the remaining materials irresponsibly by dumping
battery charge. them into a sewer, on the ground, or
into ground water or waterways.
• If the electrolyte is frozen, slowly warm
the battery before you recharge it. • Failure to follow these procedures may
seriously harm the environment.
• Failure to comply will result in death or
0000013en
serious injury.
0000007en
A DANGER
0000067A
Figure 5-8
• If the engine cranking speed is so slow that the
engine does not start, recharge the battery. FIRE AND EXPLOSION HAZARD!
• If the engine still will not start after charging, • Diesel fuel is flammable and explosive
have your authorized Yanmar industrial engine under certain conditions.
dealer or distributor check the battery and the • When you remove any fuel system
engine’s starting system. component to perform maintenance
• If operating the machine where the ambient (such as changing the fuel filter) place
temperature could drop to 5°F (-15°C) or less, an approved container under the
remove the battery from the machine at the end opening to catch the fuel.
of the day. Store the battery in a warm place • NEVER use a shop rag to catch the
until the next use. This will help start the engine fuel. Vapors from the rag are
easily at low ambient temperatures. flammable and explosive.
• Wipe up any spills immediately.
• Wear eye protection. The fuel system
is under pressure and fuel could spray
out when you remove any fuel system
component.
• Failure to comply will result in death or
serious injury.
0000009en
(3)
(1)
(2)
0000065A
Figure 5-9
2. Remove the fuel cap (Figure 5-9, (3)).
3. Remove the drain plug (Figure 5-9, (2)) of the
fuel tank to drain the contaminates (water, dirt,
etc.) from the bottom of the tank.
• ALWAYS be environmentally
responsible.
• Follow the guidelines of the EPA or FLYING OBJECT HAZARD!
other governmental agencies for the
• ALWAYS wear eye protection when
proper disposal of hazardous
servicing the engine and when using
materials such as engine oil, diesel
compressed air or high-pressure
fuel and engine coolant. Consult the
water. Dust, flying debris, compressed
local authorities or reclamation facility.
air, pressurized water or steam may
• NEVER dispose of hazardous injure your eyes.
materials irresponsibly by dumping
• Failure to comply may result in minor
them into a sewer, on the ground, or
or moderate injury.
into ground water or waterways.
0000003en
• Failure to follow these procedures may
seriously harm the environment. Dirt and dust adhering to the radiator fins reduce
0000013en
the cooling performance, causing overheating.
Make it a rule to check the radiator fins daily and
Change the engine oil every 250 hours of operation clean as needed.
after the initial change at 50 hours. Replace the
engine oil filter at the same time. See Replace Note that a typical radiator is shown in Figure 5-10
Engine Oil and Engine Oil Filter on page 5-18. for illustrative purposes only.
• Blow off dirt and dust from fins and radiator with
28 psi (0.19 MPa; 2 kgf/cm2) or less of
compressed air (Figure 5-10, (1)). Be careful
not to damage the fins with the compressed air.
• If there is a large amount of contamination on
the fins, apply detergent, thoroughly clean and
rinse with tap water.
CAUTION
NEVER use high-pressure water or
compressed air at greater than 28 psi
(193 kPa; 19 686 mmAq) or a wire brush
to clean the radiator fins. Radiator fins
damage easily.
0000016en
CAUTION
NEVER attempt to adjust the low or high
idle speed limit screw. This may impair
the safety and performance of the
machine and shorten its life. If the idle
speed limit screws require adjustment,
see your authorized Yanmar industrial
engine dealer or distributor.
0000017en
CAUTION
0000071A
• When the engine is operated in dusty
conditions, clean the air cleaner Figure 5-13
element more frequently.
• NEVER operate the engine with the air A CAUTION
cleaner element(s) removed. This may
allow foreign material to enter the
engine and damage it.
0000026en
0000589A
Figure 5-14
(5)
(10) (4) (6)
(3) (8)
(1)
(7)
0000590B
Figure 5-15
2. Close (Figure 5-15, (2)) the fuel cock
(Figure 5-15, (3)).
A CAUTION
SCALD HAZARD!
• NEVER remove the radiator cap if the
engine is hot. Steam and hot engine
coolant will spurt out and seriously COOLANT HAZARD!
burn you. Allow the engine to cool • Wear eye protection and rubber gloves
down before you attempt to remove when you handle long life or extended
the radiator cap. life engine coolant. If contact with the
• Tighten the radiator cap securely after eyes or skin should occur, flush eyes
you check the radiator. Steam can and wash immediately with clean
spurt out during engine operation if water.
the cap is loose. • Failure to comply may result in minor
• ALWAYS check the level of the engine or moderate injury.
coolant by observing the reserve tank. 0000005en
CAUTION
(1)
FULL
LOW
• ALWAYS be environmentally
responsible.
• Follow the guidelines of the EPA or
other governmental agencies for the
proper disposal of hazardous
materials such as engine oil, diesel (2) 0000074A
fuel and engine coolant. Consult the
local authorities or reclamation facility. Figure 5-16
• NEVER dispose of hazardous 4. Drain the coolant from the engine block.
materials irresponsibly by dumping Remove the coolant drain plug
them into a sewer, on the ground, or (Figure 5-17, (1)) from the engine block.
into ground water or waterways.
• Failure to follow these procedures may
seriously harm the environment. OIL
0000013en
A WARNING
HIGH-PRESSURE HAZARD!
• Avoid skin contact with the
high-pressure diesel fuel spray caused
by a fuel system leak such as a broken
fuel injection line. High-pressure fuel
can penetrate your skin and result in
serious injury. If you are exposed to
high-pressure fuel spray, obtain
prompt medical treatment.
• NEVER check for a fuel leak with your
hands. ALWAYS use a piece of wood
or cardboard. Have your authorized
Yanmar industrial engine dealer or
distributor repair the damage.
• Failure to comply could result in death
or serious injury.
0000008en
There are three different crankcase breather 4. Reinstall the diaphragm, diaphragm plate,
systems used on the TNV engines. Only the spring and diaphragm cover. Tighten the
non-turbo TNV engines crankcase breather system diaphragm bolts to the specified torque. See
requires periodic maintenance. Tightening Torques for Standard Bolts and Nuts
on page 4-25.
The non-turbo TNV engines use a crankcase Failure of the diaphragm and / or spring will cause
breather system that has a spring-backed the loss of pressure control and allow an excessive
diaphragm (Figure 5-18, (1)) in the valve cover amount of crankcase fumes to be routed to the
(Figure 5-18, (2)). When the crankcase pressure intake manifold. This could result in excessive
reaches a predetermined value, the diaphragm deposits in the intake system, high engine exhaust
opens a passage that allows crankcase fumes to smoke levels, excessive engine oil consumption,
be routed to the intake manifold. and / or engine run-on due to the burning of the
engine oil.
(4)
(3)
(5)
(1)
(2)
0004055
Figure 5-18
To inspect the diaphragm and spring
(Figure 5-18, (3)):
1. Remove the bolts retaining the diaphragm cover
(Figure 5-18, (4)).
CAUTION
• ALWAYS be environmentally
responsible.
• Follow the guidelines of the EPA or
other governmental agencies for the
proper disposal of hazardous
materials such as engine oil, diesel
fuel and engine coolant. Consult the
local authorities or reclamation facility.
• NEVER dispose of hazardous
materials irresponsibly by dumping
them into a sewer, on the ground, or
into ground water or waterways.
• Failure to follow these procedures may
seriously harm the environment.
0000013en
ENGINE
Page
Before You Begin Servicing ............................................................ 6-3
Introduction...................................................................................... 6-5
Cylinder Head Specifications .......................................................... 6-5
Adjustment Specifications ......................................................... 6-5
Cylinder Head............................................................................ 6-5
Intake / Exhaust Valve and Guide ............................................. 6-6
Push Rod................................................................................... 6-6
Valve Spring .............................................................................. 6-6
Rocker Arm and Shaft ............................................................... 6-7
Camshaft and Timing Gear Train Specifications ............................. 6-7
Camshaft ................................................................................... 6-7
Idler Gear Shaft and Bushing .................................................... 6-8
Timing Gear Backlash ............................................................... 6-8
Crankshaft and Pistons Specifications ............................................ 6-8
Crankshaft ................................................................................. 6-8
Crankshaft Reconditioning ........................................................ 6-9
Thrust Bearing ........................................................................... 6-9
Piston....................................................................................... 6-10
Piston Ring .............................................................................. 6-11
Connecting Rod....................................................................... 6-12
Tappet ..................................................................................... 6-13
Cylinder Block Specifications ........................................................ 6-13
Cylinder Block.......................................................................... 6-13
Special Torque Chart .................................................................... 6-14
Torque for Bolts and Nuts........................................................ 6-14
Special Service Tools .................................................................... 6-15
Measuring Instruments .................................................................. 6-17
A WARNING
0000014en
A CAUTION
ENTANGLEMENT HAZARD!
• Stop the engine before you begin to
service it.
• NEVER leave the key in the key switch FLYING OBJECT HAZARD!
when you are servicing the engine. • ALWAYS wear eye protection when
Someone may accidentally start the servicing the engine and when using
engine and not realize you are compressed air or high-pressure
servicing it. This could result in a water. Dust, flying debris, compressed
serious injury. air, pressurized water or steam may
• If you must service the engine while it injure your eyes.
is operating, remove all jewelry, tie • Failure to comply may result in minor
back long hair, and keep your hands, or moderate injury.
other body parts and clothing away 0000003en
from moving / rotating parts.
• Failure to comply could result in death CAUTION
or serious injury.
NEVER use an engine starting aid such
0000010en
as ether. Engine damage will result.
0000009en
CAUTION CAUTION
• Only use the engine oil specified. Do not loosen or remove the four bolts
Other engine oils may affect warranty retaining the fuel injection pump drive
coverage, cause internal engine gear to the fuel injection pump hub. Do
components to seize and / or shorten not disassemble the fuel injection pump
engine life. drive gear from the hub. Correct fuel
• Prevent dirt and debris from injection timing will be very difficult or
contaminating the engine oil. Carefully impossible to achieve.
clean the oil cap / dipstick and the 0000031en
CAUTION CAUTION
• Only use the engine coolant specified. Do not allow the honing tool to operate
Other engine coolants may affect in one position for any length of time.
warranty coverage, cause an internal Damage to the cylinder wall will occur.
buildup of rust and scale and / or Keep the tool in constant up-and-down
shorten engine life. motion.
0000090en
• Prevent dirt and debris from
contaminating the engine coolant.
Carefully clean the radiator cap and CAUTION
the surrounding area before you Any part determined to not meet the
remove the cap. service standard or limit before the next
• NEVER mix different types of engine service, as determined from the state of
coolants. This may adversely affect the current rate of wear, should be replaced
properties of the engine coolant. even though the part currently meets the
0000006en
service standard limit.
0000120en
INTRODUCTION
This section of the Service Manual describes servicing of the engine.
Cylinder Head
Reference
Inspection Item Standard Limit
Page
0.0020 in. (0.05 mm) or 0.0059 in.
Combustion Surface Distortion (Flatness)
less (0.15 mm)
See Valve
0.0157 - 0.0236 in. 0.0354 in.
Intake Recession on
(0.4 - 0.6 mm) (0.9 mm)
Valve Recession page 6-27
0.0157 - 0.0236 in. 0.0315 in.
Exhaust
(0.4 - 0.6 mm) (0.8 mm)
Intake 120° - See Valve Face
Seat Angle
Valve Seat Exhaust 90° - and Valve Seat
Seat Correction Angle 40°, 150° - on page 6-28
Push Rod
Reference
Inspection Item Standard Limit
Page
See Push
Less than 0.0012 in. 0.0012 in.
Push Rod Bend Rod Bend on
(0.03 mm) (0.03 mm)
page 6-25
Valve Spring
Reference
Inspection Item Standard Limit
Page
1.4882 in. See
Free Length -
(37.8 mm) Inspection of
Valve
0.0512 in. Springs on
Squareness -
(1.3 mm) page 6-28
Reference
Inspection Item Standard Limit
Page
0.0008 in.
Bend (1/2 the dial gauge reading) -
(0.02 mm)
0.0004 in.(0.01 mm) 0.0008 in.
Roundness
or less (0.02 mm)
Journal Outside 1.6517 - 1.6520 in. 1.6497 in. See
Diameter (41.952 - 41.962 mm) (42.902 mm) Inspection of
Bearing Inside 1.6528 - 1.6536 in. Crankshaft
- on page 6-51
Diameter (41.982 - 42.002 mm)
Connecting Rod Journals
Bearing Insert 0.0592 - 0.0594 in.
-
Thickness (1.503 - 1.509 mm)
0.0008 - 0.0020 in. 0.0043 in.
Oil Clearance
(0.020 - 0.050 mm) (0.110 mm)
Crankshaft Reconditioning
Reference
Item Finishing Precision
Page
1.6418 - 1.6422 in.
Connecting Rod Journal Undersize Finished Size
(41.702 - 41.712 mm)
1.8387 - 1.8391 in. See
Main Bearing Journal Undersize Finished Size
(46.702 - 46.712 mm) Reconditioning
0.138 - 0.150 in. the Crankshaft
Journal Radius
(3.5 - 3.8 mm) on page 6-51
Journal Face Finish 0.8S (Super Polish)
Thrust Face Finish 1.6
Thrust Bearing
Reference
Inspection Item Standard Limit
Page
0.0044 - 0.0098 in. 0.0110 in.
Crankshaft End Play - All Models See Removal
(0.111 - 0.250 mm) (0.28 mm)
of Crankshaft
0.0760 - 0.0780 in. 0.0728 in. on page 6-44
Bearing Thickness
(1.930 - 1.980 mm) (1.850 mm)
Piston
Reference
Inspection Item Standard Limit
Page
2.7543 - 2.7555 in. 2.7526 in.
2/3TNV70
Piston Outside Diameter (69.960 - 69.990 mm) (69.915 mm)
(Measure at 90° to the Piston Pin.) 2.9904 - 2.9915 in. 2.9886 in.
3TNV76
(75.955 - 75.985 mm) (75.910 mm)
Piston Diameter Measurement Location 0.8661 - 0.9843 in.
-
(Upward From the Bottom of the Piston) (22.0 - 25.0 mm)
See
0.0012 - 0.0020 in. Inspection of
2/3TNV70 -
(0.030 - 0.050 mm) Pistons,
Piston-to-Cylinder Clearance
0.0014 - 0.0022 in. Piston Rings
3TNV76 - and Wrist Pin
(0.035 - 0.055 mm)
on page 6-48
0.8661 - 0.8665 in. 0.8677 in.
Hole Inside Diameter
(22.000 - 22.009 mm) (220.039 mm)
0.8659 - 0.8661 in. 0.8648 in.
Wrist Pin Pin Outside Diameter
(21.995 - 22.000 mm) (21.965 mm)
0.0000 - 0.0006 in. 0.0029 in.
Oil Clearance
(0.000 - 0.014 mm) (0.074 mm)
Connecting Rod
Connecting Rod Small End
Reference
Inspection Item Standard Limit
Page
0.8671 - 0.8676 in. 0.8688 in.
Wrist Pin Bushing Inside Diameter See
(22.025 - 22.038 mm) (22.068 mm)
Inspection of
0.8658 - 0.8661 in. 0.8647 in.
Wrist Pin Outside Diameter Connecting
(21.991 - 22.000 mm) (21.963 mm)
Rod on
Oil Clearance
0.0010 - 0.0019 in. 0.0041 in. page 6-49
(0.025 - 0.047 mm) (0.105 mm)
Tappet
Reference
Inspection Item Standard Limit
Page
0.8268 - 0.8276 in. 0.8284 in.
Tappet Bore (Block) Inside Diameter
(21.000 - 21.021 mm) (21.041 mm) See
0.8239 - 0.8252 in. 0.8231 in. Inspection of
Tappet Stem Outside Diameter
(20.927 - 20.960 mm) (20.907 mm) Tappets on
0.0016 - 0.0037 in. 0.0053 in. page 6-50
Oil Clearance
(0.040 - 0.094 mm) (0.134 mm)
See Tightening Torques for Standard Bolts and Nuts on page 4-25 for standard hardware torque values.
L1 L2 d1 d2
Valve Guide Tool
1 (For Removing 0.787 in. 2.953 in. 0.217 in. 0.374 in.
Valve Guides) (20 mm) (75 mm) (5.5 mm) (9.5 mm)
L1 L2 d1 d2
Valve Guide Tool 0.394 in. 2.362 in. 0.433 in. 0.669 in.
2 (For Installing (10 mm) (60 mm) (11 mm) (17 mm)
Valve Guides) Allowance L1:
0 to -0.0118 in.
Locally Manufactured
(0 to -0.3 mm) 0000828
L1 L2 d1 d2
Wrist Pin Bushing 0.984 in. 3.346 in. 0.866 in. 0.984 in.
Tool (25 mm) (85 mm) (22 mm) (25 mm)
3 (For Removing /
Allowance d1: Allowance d2:
Installing of Wrist 0000829
-0.0118 to -0.0118 to
Pin Bushings)
Locally Manufactured -0.0236 in. -0.0236 in.
(-0.3 to -0.6 (-0.3 to -0.6
mm) mm)
Valve Spring
Compressor
Yanmar Part No.
4 (For Removing /
129100-92630
Installing Valve 0000830
Springs)
d1 d2 d3 L1 L2 L3
0.157 in.
0.591 in. 0.827 in. 0.472 in. 0.433 in. 2.559 in.
(4 mm) or
(15 mm) (21 mm) (12 mm) (11 mm) (65 mm)
more
0000820
L1 L2 d1 d2
Camshaft 0.709 in. 2.756 in. 1.772 in. 1.890 in.
Bushing Tool (18 mm) (70 mm) (45 mm) (48 mm)
6 (For Removing
Allowance d1: Allowance d2:
Camshaft
-0.0118 to -0.0118 to
Bushing)
Locally Manufactured -0.0236 in. -0.0236 in. 0000822
(-0.3 to -0.6 (-0.3 to -0.6
mm) mm)
0000823
Piston Ring
Yanmar Part No. 955500-02476
Compressor
8 The Piston Insertion Tool is Applicable for
(For Installing
2.362 - 4.921 in. (60 - 125 mm) Diameter Pistons
Pistons)
0000824
MEASURING INSTRUMENTS
No. Instrument Name Application Illustration
1 Dial Indicator (Available Locally) Measure shaft bend and end play
0000831
0000832
3 Magnetic Stand (Available Locally) For holding the dial gauge when measuring.
0000833
0000834
0000837
0000838
0000839
0000840
0000841
CYLINDER HEAD
Cylinder Head Components
(1)
(30)
(2)
(29)
(28)
(27) (3)
(4)
(26)
(5)
(6) (7)
(24) (8)
(25)
(23)
(9)
(11)
(22) (10)
(12)
(13)
(14)
(21) (15)
(16)
(17)
(18)
(20)
(19)
0002130
Figure 6-1
(1)
(2)
Figure 6-3
(3)
(4) Removal of Rocker Arm Assembly
1. Remove the bolts (Figure 6-4, (1)) and nuts
(Figure 6-4, (2)) that retain the rocker arm shaft
supports.
(5) 2. Remove the rocker arm shaft assembly from
the cylinder head.
(6)
(7) Note: Identify the push rods so they can be
reinstalled in their original locations.
(8)
3. Remove the push rods and identify for
reinstallation.
0002131
(2)
Figure 6-2
3. Remove the exhaust manifold bolts
(Figure 6-2, (5)) and nuts (Figure 6-2, (6)).
Remove the exhaust manifold (Figure 6-2, (7))
and the exhaust manifold gasket
(Figure 6-2, (8)). (1) (2)
Removal of Glow Plugs
1. Disconnect the glow plug harness
(Figure 6-3, (2)) from the glow plugs
(Figure 6-3, (1)).
2. Remove the glow plugs from the cylinder head.
0002147
Figure 6-4
(2)
(9) 8 5
4 10 1
(1)
2 9 3
6 7
0002148
Note: On 3-cylinder models, the set screw is 2. Remove the cylinder head bolts
located in the center support. On (Figure 6-7, (1)).
2-cylinder models, the set screw is 3. Lift the cylinder head away from the cylinder
located in the front (cooling fan) end block. Discard the cylinder head gasket
support. (Figure 6-7, (2)). Position the cylinder head on
the work bench to prevent damage to the
2. Remove two circlips (Figure 6-5, (8)). combustion surface.
Note: The rocker arm shaft fits tightly in the
rocker arm supports. Clamp the support
in a padded vise. Twist and pull out on (1)
the rocker arm shaft to remove. Reverse
this process when installing the rocker
arm shaft into the supports.
3. Slide the rocker arm shaft (Figure 6-5, (7)) out
of the rocker arm supports (Figure 6-5, (5)),
springs (Figure 6-5, (4)), and rocker arms
(Figure 6-5, (1)).
(2)
Note: Mark the rocker arms so they can be
reinstalled with the original matching
valve and pushrod.
4. Remove the valve adjusting screw
(Figure 6-5, (3)) and lock nut (Figure 6-5, (2))
from the rocker arms. Mark parts so they can
0002150
be reinstalled on the same rocker arm.
Figure 6-7
Removal of Intake / Exhaust Valves 8. Turn the cylinder head so the exhaust port side
1. Put the cylinder head on the work bench with faces down. Remove the intake and exhaust
the combustion side down (Figure 6-8). valves (Figure 6-9, (6)) from the cylinder head.
9. Remove the valve stem seals (Figure 6-9, (5)).
(1)
(2)
(3) 0002152
(4)
Figure 6-10
(5)
(6)
0002151
Figure 6-9
7. Repeat procedure with all remaining valves.
Note: If the valves are to be reused, identify
them so they can be reinstalled in their
original location.
CAUTION
Any part which is found defective as a
result of inspection or any part whose
measured value does not satisfy the
standard or limit must be replaced.
0000119en
0000204
Figure 6-11
0001869
(1)
(1) Figure 6-14
0000192
Figure 6-15
0001952
Figure 6-13
(1)
0000193
0000197
Figure 6-18
Figure 6-16
Valve Stem Bend
Place the valve stem on a flat inspection block or
layout bed. Roll the valve until a gap can be
observed between a portion of the valve stem and
the surface of the block or bed. Use a feeler gauge
to measure the gap (Figure 6-17). Record the
measurements. See Intake / Exhaust Valve and
Guide on page 6-6 for the service limit.
0001755
Figure 6-19
Figure 6-17
0001691B
Fractures
Check for fractures on the inside and outside
Figure 6-20 portions of the springs. If the valve spring is
fractured, replace the valve spring.
Also visually inspect the valve seat for even
contact. Corrosion
Light cutting can be performed by the use of a Check for corrosion of spring material caused by
hand-operated cutter (Figure 6-21, (3)). oxidation.
4
0
5
9
6
8
7
0002152
Figure 6-24
0000200
Figure 6-23
(3)
(3)
(1) 0001873B
0001756A
Figure 6-26
Figure 6-25 2. Measure the distance (Figure 6-27, (1)) from
the cylinder head to valve stem seal to ensure
Reassembly of Intake and Exhaust Valves
proper clearance (Figure 6-27, (2)) between
IMPORTANT the valve guide and seal. See valve stem seal
Always install new valve stem seals. projection specification on page 6-6.
(1)
(2) (1)
(3)
(4)
(5)
(2)
(6)
0002151
(1)
9 2 8
5 4
0002149
4. Insert the push rods in their respective Note: On 3-cylinder models, the set screw is
positions. located in the center support. On
2-cylinder models, the set screw is
Reassembly of Rocker Arm Assembly located in the front (cooling fan) end
support.
(2)
2. Align the hole in the rocker arm shaft
(Figure 6-32, (7)) and the hole in the rocker
(1) arm support (Figure 6-32, (5)). Reinstall the
alignment set screw (Figure 6-32, (6)).
3. Place the rocker arm shaft assembly onto the
cylinder head.
4. If removed, reinstall the valve adjusting screws
(Figure 6-32, (3)) and lock nuts
(1) 0001914 (Figure 6-32, (2)).
Figure 6-31 5. Align the push rods with their respective rocker
arms.
IMPORTANT
Ensure the lubrication holes in the rocker 6. Reinstall and tighten the rocker arm shaft
arm shaft (Figure 6-31, (1)) are oriented retaining bolts to the specified torque.
correctly with respect to the rocker arms 7. Tighten the rocker arm shaft alignment screw.
(Figure 6-31, (2)). 8. Adjust the valve clearance. See Measuring and
1. Lubricate the rocker arm shaft. Slide the rocker Adjusting Valve Clearance on page 6-34.
arm supports (Figure 6-32, (5)), springs
(Figure 6-32, (4)) and rocker arms
(Figure 6-32, (1)) onto the shaft.
(8)
(2)
(1)
(3)
(4) (7)
(6)
(5)
(9)
(8)
0002160
Figure 6-32
Note: The rocker arm shaft fits tightly in the
rocker arm supports. Clamp the support
in a padded vise. Twist and push on the
rocker arm shaft to reinstall.
(3)
(2)
(4)
(1)
(5)
(6)
(7)
(8)
0002131
Figure 6-34
0002146
5. Reinstall the exhaust manifold using a new
Figure 6-33 gasket. Tighten the bolts and nuts
(Figure 6-34, (5 and 6)) securely.
2. Lightly grease a new valve cover gasket
(Figure 6-34, (4)). Place the gasket in the 6. Reinstall the fuel injectors. See Installation of
groove of the intake manifold / valve cover the Fuel Injectors on page 7-29.
(Figure 6-34, (3)). 7. Reinstall the high pressure and return fuel
3. Place the valve cover on the cylinder head. injection lines. See Installation of the Fuel
Injectors on page 7-29.
4. Reinstall and tighten bolts
(Figure 6-34, (1 and 2)) securely. 8. Reinstall the coolant pump. See Reassembly of
Engine Coolant Pump on page 8-9.
9. Reinstall the alternator. See Installation of
Alternator on page 11-16.
Measuring and Adjusting Valve • If there is no valve clearance, and the piston is
at TDC of the compression stroke, extreme
Clearance
wear or damage to the cylinder head or valves
Measure and adjust while the engine is cold. may be possible.
Notes: • If adjusting each cylinder individually, the
cylinder to be adjusted first does not have to be
• The No. 1 piston position is on the flywheel end the No. 1 cylinder. Select and adjust the
of the engine, opposite end of the radiator. The cylinder where the piston is nearest to the top
firing order is 1-3-2 for 3-cylinder engines and dead center after turning. Adjust the remaining
1-2 for 2-cylinder engines. cylinders in the order of firing by turning the
• 3-cylinder engines fire every 240° of crankshaft crankshaft each time.
rotation. • To decrease the number of rotations required
• 2-cylinder engines are an uneven firing engine. to check all cylinders of a 3-cylinder engine,
No. 2 cylinder fires 180° after No. 1. The other cylinders can also be checked as
crankshaft then rotates 540° before No. 1 indicated in the chart below. 2-cylinder engines
cylinder fires again. must have each cylinder adjusted when the
• Valve clearance of both the intake and exhaust piston is at TDC.
valves can be checked with the piston for that Example: On a 3-cylinder engine, with the No. 1
cylinder at top dead center (TDC) of the piston at TDC on the compression stroke (both
compression stroke. When a piston is at TDC valves closed), the valves indicated on the top line
of the compression stroke, both rocker arms of the chart can be adjusted without rotating the
will be loose and the cylinder TDC mark on the crankshaft. To adjust the remaining two valves,
flywheel will be visible in the timing port of the rotate the crankshaft until the No. 1 piston is at TDC
flywheel housing. on the exhaust stroke (exhaust valve only open).
3-Cylinder Engines
Cylinder No. 1 2 3
Valve Intake Exhaust Intake Exhaust Intake Exhaust
No. 1 Cylinder at TDC
• • • •
Compression
No. 1 Cylinder at TDC Exhaust • •
(2)
0001782A
Figure 6-37
7. Apply oil to the contact surface between
adjusting screw and push rod.
8. Rotate the crankshaft and measure the next
(1) cylinder. Continue until all valves are adjusted.
0001783A
Figure 6-36
CYLINDER BLOCK
Crankshaft and Camshaft Components
(1)
(3)
(5)
(2) (6)
(39) (4)
(9) (5)
(41) (40)
(10)
(11)
(12) (7)
(13) (8)
(16)
(38) (15)
(37) (14)
(36) (34)
(35) (33)
(31) (32)
(30) (17)
(29) (18)
(28)
(19) (20)
(21)
(22)
(27)
(23)
(24)
(25)
(26)
0002180
Figure 6-38
18 – Oil Pickup
19 – Crankshaft IMPORTANT
20 – Crankshaft Gear Key Mark all valve train components so they can
21 – Crankshaft Gear be installed in their original locations.
22 – Crankshaft Pulley
23 – Main Bearing Inserts Note: Record all measurements taken during
24 – Main Bearing Cap disassembly.
25 – Crankcase Extension
If the engine will be completely disassembled, the
26 – Oil Pan
following preliminary steps should be performed:
27 – Thrust Bearings
28 – Flywheel 1. Disconnect the battery cables at the battery.
29 – Connecting Rod Cap Always disconnect the negative (-) cable first.
30 – Connecting Rod Bearing Inserts
31 – Connecting Rod 2. Remove the throttle cable, electrical
32 – Wrist Pin Bushing connections, intake and exhaust system
33 – Circlip connections, and fuel supply lines from the
34 – Wrist Pin engine.
35 – Piston
3. Remove the alternator. See Removal of
36 – Oil Ring
Alternator on page 11-12.
37 – Second Compression Ring
38 – Top Compression Ring 4. Drain the engine coolant from the radiator and
39 – Dowel (2 used) cylinder block. See Drain, Flush and Refill
40 – Crankshaft Rear Seal Cooling System with New Coolant on
41 – Flywheel Housing page 5-33. Remove the cooling system
components from the engine.
A CAUTION
Be sure to secure the engine solidly to
prevent injury or damage to parts due to
the engine falling during work on the
engine.
0000009en
crankshaft pulley.
(4)
2. Remove the crankshaft pulley with a gear puller. 0002190
3. Remove the bolts that retain the gear case 1 – Fuel Injection Pump Drive Gear
cover to the cylinder block and oil pan. 2 – Camshaft Drive Gear
4. Remove the gear case cover (Figure 6-39, (1)). 3 – Auxiliary Drive Gear (Optional)
4 – Crankshaft Drive Gear
5. Remove the dowel pins (Figure 6-39, (3)) and 5 – Idler Gear
O-ring (Figure 6-39, (2)).
Figure 6-40
(3)
(2)
(1)
00021
0002192
4. Do not remove the fuel injection pump drive Removal of Oil Pan
gear unless absolutely necessary due to 1. Invert the engine (oil pan up) on the engine
damage to the gear or pump. Do not loosen or stand.
remove the four bolts (Figure 6-43, (3))
retaining pump drive gear to the hub. Only 2. Remove the oil pan (Figure 6-44, (2)).
remove the nut (Figure 6-43, (1)) and washer 3. Remove the crankcase extension
(Figure 6-43, (2)), leaving the hub attached to (Figure 6-44, (1)) if equipped.
the gear. Remove the pump drive gear and hub
as an assembly using a gear puller.
(3)
(1)
(1)
(2) (2)
0002183
Figure 6-43
0002184
CAUTION
Do not loosen or remove the four bolts Figure 6-44
retaining the fuel injection pump drive
gear to the fuel injection pump hub. Do 4. Remove the oil pickup tube (Figure 6-45, (1))
not disassemble the fuel injection pump and O-ring (Figure 6-45, (2)).
drive gear from the hub. Correct fuel
injection timing will be very difficult or
impossible to achieve.
0000031en
(2)
(1)
0002185
Figure 6-45
(2)
(2)
(1)
(3)
(4)
0002186
Figure 6-48
3. Extract the tappets (Figure 6-48, (5)) through
(1) the top of the cylinder block. Mark the tappets
so they can be reinstalled in the same location.
4. Slowly pull the camshaft (Figure 6-48, (2))
assembly out of the engine being careful not to
0002191
damage the front camshaft bushing.
Figure 6-46 5. Remove the camshaft gear (Figure 6-48, (4))
• Method B: Use a feeler gauge to measure the only if the gear or camshaft require
clearance between the thrust plate replacement. Use a knife-edge puller and a
(Figure 6-47, (1)) and front camshaft bearing press to remove the gear. The gear is a
(Figure 6-47, (2)). Record the measurement. shrink-fit and will need to be heated to
See Thrust Bearing on page 6-9 for the service 356° - 392°F (180° - 200°C) to remove.
limit.
(1)
(2)
0001710B
Figure 6-47
(4)
(2)
0002187
Figure 6-49
(1)
0001899
Figure 6-52
7. Compare the width of the flattened
0000219 PLASTIGAGE (Figure 6-52, (1)) to the
Figure 6-50 graduation marks on the package. The mark
that most closely matches the width of the
IMPORTANT flattened PLASTIGAGE will indicate the bearing
Mark the connecting rod caps and oil clearance. Record the measurements. See
connecting rods so the caps and connecting Crankshaft on page 6-8.
rods stay together.
8. Repeat with the remaining connecting rods.
2. Remove the bearing cap. Do not remove the
bearing inserts at this time.
IMPORTANT
Do not allow the connecting rod to contact
3. Wipe oil from the bearing insert and crankshaft the crankshaft journal during piston
journal surfaces. removal. Damage to the bearing journal
4. Place a piece of PLASTIGAGE® may result.
(Figure 6-51, (1)) along the full width of the
9. Use a wooden dowel against the connecting
bearing insert.
rod and tap the piston / connecting rod
assembly out of the cylinder.
(1) 10. Mark the cylinder number on the piston and
connecting rod.
0001898
Figure 6-51
(3)
(4)
(4)
(5)
(9) (6)
(5) 0002188
Figure 6-54
(8) 3. Before removing the main bearing caps,
(7) measure the crankshaft end play. Use either of
the following two methods:
(2)
• Method A: Install a dial gauge
(1) (Figure 6-55, (1)) on the cylinder block. Move
the crankshaft (Figure 6-55, (2)) in and out to
measure the end play. Record the
measurement.
0001705A
Figure 6-53
14. Remove the circlips (Figure 6-53, (5)) from the
wrist pin.
15. Remove the wrist pin (Figure 6-53, (6)) and
connecting rod (Figure 6-53, (8)) from the
piston (Figure 6-53, (9)).
16. Repeat steps until all pistons are removed and (1)
dissembled.
0001899
Figure 6-58
9. Compare the width of the flattened
PLASTIGAGE (Figure 6-58, (1)) to the
(1)
graduation marks on the package. The mark
(2) that most closely matches the width of the
flattened PLASTIGAGE will indicate the bearing
oil clearance. Record the measurement. See
Crankshaft on page 6-8 for clearance
specifications.
(3) 0001962
10. Repeat with the remaining main bearings.
Figure 6-56
Note: Be sure to note the markings on the main
4. Remove the bearing cap. Do not remove the bearing caps, or make marks so they can
bearing inserts at this time. be reinstalled in the same order as they
5. Wipe oil from the bearing insert and crankshaft were removed. The “arrows” on the main
journal surfaces. bearing caps point to the flywheel end of
the engine.
6. Place a piece of PLASTIGAGE®
(Figure 6-57, (1)) along the full width of the
bearing insert.
(1)
0001898
Figure 6-57
IMPORTANT
Do not rotate crankshaft when using
PLASTIGAGE. A false reading may result.
7. Reinstall the bearing cap and tighten to
specification. See on page 6-14.
8. Remove the bearing cap.
11. Remove the crankshaft from the engine. Inspection of Crankshaft and
12. Remove the bearing inserts (Figure 6-59, (1)) Camshaft Components
and thrust bearings (Figure 6-59, (2)).
Note: Do not remove the crankshaft gear A WARNING
unless the gear or crankshaft are
damaged and require replacement.
Figure 6-60
a 20 mm
(0.75 in.)
d
e
b
(1)
c
20 mm
Figure 6-62 (0.75 in.) 0000230B
Inspection of Pistons, Piston Rings and 5. Subtract the piston measurement from the
Wrist Pin greatest measurement acquired during cylinder
inspection (see Inspection of Cylinder Block on
Notes:
page 6-47) to obtain piston-to-cylinder
• On an engine with low hours, the pistons, clearance. Record the measurements. See
piston rings may be reused if they are found to Piston on page 6-10 for specifications.
be within specifications. The pistons and piston 6. Measure the diameter of the wrist pin bore on
rings must be reinstalled in the same cylinders both sides of the piston (Figure 6-65). See
from which they were originally removed. Piston on page 6-10 for specifications. Record
• On an engine with high hours, the pistons rings the measurements.
should be replaced and the cylinder honed
(See Honing and Boring on page 6-53) or
replaced. The piston should be replaced as
necessary.
1. Clean piston ring grooves using a piston ring
groove cleaning tool. Follow manufacturer’s
instructions for correct operation.
2. Wash the pistons in an appropriate solvent
using a soft brush.
0000237
3. Visually inspect each piston for cracks. Pay
particular attention to the ring lands between Figure 6-65
the piston ring grooves.
7. Measure the outside diameter of the wrist pin in
4. Measure the diameter of the piston skirt at 90° three places and at 90° (Figure 6-66). See
to the wrist pin bore as shown (Figure 6-64). Piston on page 6-10 for specifications. Record
Measurements must be taken at a specified the measurements.
distance (Figure 6-64, (1)) from the bottom of
the piston, based on engine model. Record the
measurements. See Piston on page 6-10 for
specifications.
0001889
Figure 6-66
8. Using a micrometer, measure the thickness of
each piston ring. See Piston Ring on page 6-11
(1) for specifications. Record the measurements.
Notes:
• On an engine with low hours, the pistons,
piston rings and cylinders may be reused if they
0000235
are found to be within specifications.
Figure 6-64
(3)
0001964
Figure 6-68
Note: Always check the piston ring end gap
when installing new piston rings. See
Piston Ring on page 6-11 for
specifications. Use a piston ring end gap
filing tool to adjust the piston ring end
gap on new piston rings.
0001892
11. Repeat the above steps for each cylinder and
Figure 6-67 piston assembly.
10. To measure piston ring end gap, insert each Inspection of Connecting Rod
compression piston ring (Figure 6-68, (1)), one 1. Measure the wrist pin bushing bore using a
at a time, into the cylinder. Use a piston with the bore gauge (Figure 6-69, (1)). Replace the
piston rings removed to slide the ring into the bushing if not within specifications. If the
cylinder bore until it is approximately 1.18 in. bushing has been removed, measure the inside
(30 mm) (Figure 6-68, (2)) from the bottom of diameter of the connecting rod small end
the bore. Remove the piston. Measure the end (Figure 6-69, (2)). Record the measurements.
gap (Figure 6-68, (3)) of each piston ring. See Connecting Rod on page 6-12 for
Record the measurements. See Piston Ring on specifications.
page 6-11 for specifications.
Inspection of Tappets
(1)
1. Inspect the tappet contact surfaces for
abnormal wear (Figure 6-72, (1)). Normal wear
(2) will be even as shown in (Figure 6-72, (2)).
0001724A
Slight surface defects can be corrected using
an oilstone.
Figure 6-69
2. Measure the connecting rod twist
(Figure 6-70, (1)) and bend (Figure 6-70, (2))
using a connecting rod alignment tool
(Figure 6-71). Record the measurements. See
Connecting Rod on page 6-12 for
specifications.
Figure 6-72
(2)
2. Measure the outside diameter of the tappet
stem (Figure 6-73, (1)). Record the
measurements. See Tappet on page 6-13 for
the service limit.
(1)
0001896
Figure 6-70
0002195
Figure 6-73
3. Measure the tappet bores in the cylinder block.
Record the measurements. See Tappet on
page 6-13 for the service limit.
0000242
Figure 6-71
(2)
(1)
(3)
(1)
(2) 0001733A
Figure 6-75
(1)
Ry (1)
Ry
R
R
R
0001712A
Figure 6-79
0002196
Figure 6-77
2. Rotate the camshaft and observe the runout.
Record the measurements. See Camshaft on
page 6-7 for specifications.
3. Measure the height of each lobe
(Figure 6-78, (1)). Record the measurements.
See Camshaft on page 6-7 for specifications.
(1)
Reassembly of Crankshaft and
Piston Components
Notes:
• Proceed slowly. Make no forced assemblies
unless a pressing operation is called for. All
parts must be perfectly clean and lightly
lubricated when assembled.
• Use new gaskets, seals and O-rings during
assembly.
• Liberally apply clean engine oil to all internal
0000248A
parts during assembly.
Figure 6-81
• All fasteners should be tightened to a given
• Use a 50:50 mixture of diesel fuel and engine torque. If a special torque is not provided in the
oil as a honing fluid. Special Torque Chart on page 6-14, tighten to
• Use a 300-grit hone at 300 - 1200 rpm standard torque specifications. See Tightening
(Figure 6-82). Torques for Standard Bolts and Nuts on
page 4-25.
(1)
(2)
0000249B
Figure 6-82
IMPORTANT
Solvents will not adequately remove honing
residue, resulting in premature piston and
ring wear. Always wash cylinders using hot,
soapy water.
C H MS
(4)
(5)
(9) (6)
(5)
(8)
(7) (1) 0002464
(2) (2)
(1)
E106 R
0001705A 0002090
Figure 6-83
(3)
3. Reinstall one circlip (Figure 6-83, (5)) into the
piston. Ensure the circlip is securely seated in
the groove. 80 80
IMPORTANT
The piston and connecting rod must be 0002089
(1) (3)
(6)
(4)
(5)
(9) (6)
(5)
(2) (5)
(8)
(7)
(3) (2)
(1)
(4)
0001705A
0000227A
Figure 6-86
1 – Fuel Injection Pump Side of Engine
2 – Piston Identification Mark Note: Reinstall the top and second piston rings
3 – Embossed Mark on Connecting Rod with the stamped “makers mark”
4 – Connecting Rod and Cap Match Marks (Figure 6-87, (1)) facing the top of the
5 – Flywheel End of Engine piston. The “makers mark” may vary in
6 – Camshaft Side of Engine appearance but will always be located on
Figure 6-85 the top surface of the piston ring
adjacent to the piston ring gap. The oil
5. Lubricate and install the wrist pin ring and oil ring expander can be
(Figure 6-86, (6)) through the piston and installed either side up.
connecting rod.
6. Reinstall the second circlip (Figure 6-86, (5)) (1)
and ensure it is securely seated in the groove.
Note: If installing new piston rings the end gap
must be checked and adjusted as
necessary. See Inspection of Pistons, 0000225A
Piston Rings and Wrist Pin on
Figure 6-87
page 6-48. Use a piston ring end gap
filing tool to adjust the piston ring end IMPORTANT
gap on new piston rings. Always use a piston ring expander when
installing piston rings. Never attempt to
install piston rings by hand.
(2)
(3)
(1)
(1)
(4)
(2)
0002188
0002189
IMPORTANT IMPORTANT
The main bearing caps are numbered and Do not allow the connecting rod to contact
have arrows for proper positioning. The the crankshaft journal during piston
No. 1 cap is at the flywheel end. The arrows installation. Damage to the crankshaft
point toward the flywheel end of the engine. bearing journal may result.
4. Reinstall the main bearing caps. 1. Lubricate piston, piston rings, and cylinder with
clean engine oil or assembly lubricant.
5. Apply a light coat of clean engine oil to the
bearing cap bolts and tighten the bolts to the 2. Rotate the crankshaft so the crankpin for the
specified torque in two stages (1/2 then full piston being installed is near bottom dead
torque). See Special Torque Chart on center.
page 6-14.
6. Rotate the crankshaft to ensure it turns freely.
7. Apply ThreeBond Liquid Gasket No. 1212,
Yanmar Part No. 977770-01212 to the mounting
flange of the flywheel housing
(Figure 6-91, (2)).
8. Align the flywheel housing with the two dowel
pins (Figure 6-91, (3)).
9. Reinstall flywheel housing and seal assembly.
10. Reinstall the flywheel (Figure 6-91, (1)) and
tighten the bolts to the specified torque. See
Special Torque Chart on page 6-14.
(6) (1)
0000226A
(2)
0002187
(1)
Figure 6-95
(2) 4. Reinstall the gear case (Figure 6-95, (1)).
Tighten the bolts (Figure 6-95, (4)) to the
specified torque.
Installation of Camshaft
0001965
Note: The gear housing must be installed prior
Figure 6-94 to reinstalling the camshaft. See
Installation of Gear Case on page 6-60.
8. Reinstall the remaining pistons in their
respective cylinders. 1. If removed, reinstall the camshaft end plate
(Figure 6-96, (1)), key, and camshaft gear
Reassembly of Camshaft and Timing (Figure 6-96, (4)) onto the camshaft using a
Components press.
• Heat the gear to 356 - 392°F (180 - 200°C) and
Installation of Gear Case press onto the end of the camshaft.
1. If removed, install a new camshaft bushing 2. Lubricate the camshaft (Figure 6-96, (2)) with
(Figure 6-95, (3)) using the appropriate service clean engine oil or assembly lube. Slowly insert
tool. the camshaft through the front of the engine.
2. Apply a continuous bead of ThreeBond Liquid 3. Reinstall and tighten the cap screws
Gasket No. 1212, Yanmar Part No. (Figure 6-96, (3)).
977770-01212 to the mounting area of the gear
case. Be sure to circle each bolt hole.
3. Reinstall dowels and new O-rings
(Figure 6-95, (2)).
(2)
(1)
(3)
(4)
0002186
Figure 6-96
0002182
(3)
Figure 6-97 (1)
(2)
4. Align the timing gears as shown in Figure 6-98.
5. Reinstall the idler gear and idler gear shaft. Be
sure the oil hole in the bushing is facing toward
the top of the engine.
6. Ensure all three timing marks
(Figure 6-98, (A, B, and C)) are aligned.
0002181
Figure 6-99
2. Reinstall the dowels (Figure 6-99, (3)) and a
new O-ring (Figure 6-99, (2)).
IMPORTANT
Be sure to align the flats on the oil pump
with the flats on the crankshaft gear.
3. Reinstall the timing gear case cover. (1)
4. Reinstall and tighten the gear case cover bolts.
5. Reinstall the crankshaft pulley.
6. Reinstall the washer and bolt. Tighten to the
specified torque. See Special Torque Chart on
(2)
page 6-14 for specifications.
Figure 6-101
FUEL SYSTEM
Page
Before You Begin Servicing ............................................................ 7-3
Introduction...................................................................................... 7-5
Fuel Injection Pump................................................................... 7-5
Stop Solenoid ............................................................................ 7-6
Fuel System Specifications ............................................................. 7-7
Special Torque Chart................................................................. 7-7
Test and Adjustment Specifications .......................................... 7-7
Special Service Tools ...................................................................... 7-8
Measuring Instruments .................................................................... 7-8
Fuel System Diagram ...................................................................... 7-9
Fuel System Components ............................................................. 7-10
Fuel Injection Lines ....................................................................... 7-11
Removal of High-Pressure Fuel Injection Lines ...................... 7-11
Installation of High-Pressure Fuel Injection Lines ................... 7-12
Removal of Fuel Return Line................................................... 7-12
Installation of Fuel Return Line................................................ 7-13
Fuel Injection Pump....................................................................... 7-13
Removal of Fuel Injection Pump.............................................. 7-13
Installation of Fuel Injection Pump........................................... 7-16
Checking and Adjusting Fuel Injection Timing .............................. 7-19
Checking Fuel Injection Timing ............................................... 7-19
Adjusting Fuel Injection Timing................................................ 7-23
Fuel Injectors................................................................................. 7-23
Removal of Fuel Injectors........................................................ 7-23
Testing of Fuel Injectors .......................................................... 7-24
A CAUTION
CAUTION CAUTION
• NEVER remove or attempt to remove Remove or install the high-pressure fuel
the tamper-proof devices from the injection lines as an assembly whenever
full-load fuel adjusting screw or the possible. Disassembling the
high-speed throttle limit screw on the high-pressure fuel injection lines from
fuel injection pump and governor the retainers or bending any of the fuel
assembly. These adjustments have lines will make it difficult to reinstall the
been made at the factory to meet all fuel lines.
applicable emissions regulations and 0000047en
then sealed.
• NEVER attempt to make any CAUTION
adjustments to these sealed
After marking the position of the pump
adjustment screws. If adjustments are
drive gear, do not rotate the engine
required, they can be made only by a
crankshaft. Rotating the crankshaft will
qualified fuel injection shop that will
cause the fuel injection pump to become
ensure the injection pump continues
misaligned.
to meet all applicable emissions
0000048en
regulations and then replace the
tamper-proof seals.
• Tampering with or removing these CAUTION
devices may void the “Yanmar Limited Do not rotate the crankshaft with the
Warranty.” injection pump removed.
0000146en 0000083en
CAUTION CAUTION
Never use a steel wire brush to clean The fuel return line is a one-piece
fuel injectors. Damage to the nozzle and assembly. Use care not to bend or twist
other components is likely to result. the fuel return line.
0000172en 0000171en
CAUTION
Do not loosen or remove the four bolts
retaining the fuel injection pump drive
gear to the fuel injection pump hub. Do
not disassemble the fuel injection pump
drive gear from the hub. Correct fuel
injection timing will be very difficult or
impossible to achieve.
0000031en
INTRODUCTION
(4)
(3)
(1)
(2)
0002238
(5) (6)
Figure 7-1
This section of the Service Manual describes the The Yanmar ML Fuel Injection Pump is an in-line
procedures necessary to remove, install, and time type pump which consists of a fuel supply plunger
the ML fuel injection pump and its associated (Figure 7-1, (1)) for each cylinder, a camshaft
system components. This fuel injection pump is (Figure 7-1, (2)), and a pump housing
representative of the fuel injection pumps used on (Figure 7-1, (3)). A delivery valve (Figure 7-1, (4))
other TNV IDI model engines. connects to a high-pressure fuel line for each
cylinder. The fuel injection pump housing contains
Fuel Injection Pump a governor (Figure 7-1, (5)).
Note: If the ML fuel injection pump itself Fuel from the fuel tank to the fuel injection pump is
requires servicing, it must be taken to an delivered by a low-pressure electric fuel pump. On
authorized Yanmar FIE (Fuel Injection a few special models, a mechanical fuel pump is
Equipment) repair facility. used instead of an electric pump. The mechanical
The following describes the features of the ML fuel fuel pump is mounted to the fuel injection pump
injection pump, manufactured by Yanmar. housing in place of the cover plate
(Figure 7-1, (6)).
The fuel injection pump is a very important
component of the engine. It is capable of making Fuel to be injected into the cylinders is pressurized
very precise fuel delivery adjustments according to by the up and down motion of each
the varied loads applied to the engine. camshaft-driven plunger, and is then supplied by
the high-pressure fuel lines to the respective fuel
All of the fuel injection pump components are very injector.
precisely machined. It is extremely important to
follow good service practices and maintain
cleanliness when servicing the fuel injection pump.
Stop Solenoid
CAUTION
The ML fuel injection pumps are equipped with a
• NEVER remove or attempt to remove
stop solenoid that controls the fuel flow inside the
the tamper-proof devices from the
fuel injection pump.
full-load fuel adjusting screw or the
high-speed throttle limit screw on the With the starter switch in the OFF position, no
fuel injection pump and governor current flows to the stop solenoid and the solenoid
assembly. These adjustments have plunger is extended holding the fuel injection pump
been made at the factory to meet all fuel rack in the “closed” position and not allowing
applicable emissions regulations and fuel to flow through the injection pump and to the
then sealed. engine.
• NEVER attempt to make any When the starter switch is turned to the start
adjustments to these sealed position, the “pull coil” (36.5 Amp draw / white wire)
adjustment screws. If adjustments are inside the solenoid is activated and pulls the
required, they can be made only by a solenoid plunger into the solenoid. This releases
qualified fuel injection shop that will the fuel injection pump fuel rack, allowing fuel to
ensure the injection pump continues flow through the injection pump and allowing the
to meet all applicable emissions engine to start and run.
regulations and then replace the
tamper-proof seals. When the starter switch is returned to the ON or
• Tampering with or removing these RUN position, the “pull coil” no longer receives
devices may void the “Yanmar Limited current and the “hold coil” (0.5 Amp draw / red wire)
Warranty.” inside the solenoid is activated. The “hold coil”
holds the solenoid plunger in the RUN position,
0000146en
allowing fuel to continue flowing and the engine to
The fuel injector is essentially a spring-loaded continue running.
valve. When fuel pressure from the fuel injection
To stop the engine, the key switch is turned to the
pump reaches a pre-determined level, the pintle
OFF position. Current no longer flows to the stop
(valve) is forced off its seat and fuel is atomized as
solenoid “hold coil,” and the solenoid plunger
it passes between the pintle and seat. The timing
extends and moves the injection pump fuel rack to
and quantity of the fuel injected into the cylinder is
the “closed” position, and shutting off the fuel flow
controlled by the fuel injection pump and governor
and stopping the engine.
assembly.
Failure of the stop solenoid could result in the
engine not starting, the engine stopping suddenly
or the engine continuing to run with the key switch
returned to the ON or RUN position, or the engine
failing to stop when the key switch is turned to the
OFF position. Use a VOA multimeter or continuity
light to check for a good ground and 12V at the stop
solenoid in the correct sequence.
Note: Fuel injector pressures given are for used parts. New injectors (5 hours operation or less) will read
approximately 72.5 psi (0.5 MPa; 5 kgf/cm2) higher.
0000840
MEASURING INSTRUMENTS
No. Instrument Name Application Illustration
OFF
E-
ON AG
-G
pressure
* Make from a short piece of the end of a high-pressure fuel line, a high-pressure fuel line nut, and a short piece of
clear plastic tubing (a thin nozzle from an aerosol spray can works well). Drill out the end of the fuel line to accept
the nozzle. Use a small amount of silicone sealant to seal the nozzle into the fuel line.
(9)
(8)
(10)
(12)
(7)
(11)
(1)
(3)
(6)
(5) (2)
(4)
0001058A
Figure 7-2
(18) (1)
(17) (2)
(3)
(16)
(7)
(15) (4)
(6)
(7)
(5)
(11)
(14)
(10)
(9)
(8)
(13)
(12)
0002208
Figure 7-3
0002237
Figure 7-4
Figure 7-6
3. Remove all fuel return line nuts
(Figure 7-6, (2)) from the injectors
(Figure 7-6, (4)).
12. Remove the lube oil line (Figure 7-9, (1)) from
the fuel injection pump and cylinder block.
IMPORTANT
Take care to not damage or bend the lube
oil line.
(2)
(1)
(1)
(3)
0002239
Figure 7-9
0002210
(1)
0002211
Figure 7-10
14. To aid in reassembly, make reference marks
(Figure 7-11, (1)) on the drive gear and idler
gear.
CAUTION
After marking the position of the pump
drive gear, do not rotate the engine
crankshaft. Rotating the crankshaft will
cause the fuel injection pump to become
misaligned. (3)
0000048en
(1)
(2)
Figure 7-12
Figure 7-13
Note: The injection pump drive gear can be
removed from the gear case; however, it
is best to let it remain in the gear case.
18. Once the fuel injection pump drive gear and 20. Remove the three nuts fastening the fuel
hub assembly have “popped” loose from the injection pump to the gear case. Remove the
tapered fuel injection pump drive shaft, carefully fuel injection pump. Leave the fuel injection
remove the drive gear nut (Figure 7-14, (1)) pump drive gear in the gear case and meshed
and lock washer (Figure 7-14, (2)). with the idler gear.
CAUTION
Do not rotate the crankshaft with the
injection pump removed.
0000083en
CAUTION
• NEVER remove or attempt to remove
(2) the tamper-proof devices from the
full-load fuel adjusting screw or the
0002183A
high-speed throttle limit screw on the
Figure 7-14 fuel injection pump and governor
assembly. These adjustments have
19. Locate the mark (Figure 7-15, (1)) stamped
been made at the factory to meet all
into the upper outside mounting boss of the fuel
applicable emissions regulations and
injection pump. Highlight this mark and make a
then sealed.
corresponding mark on the gear case or front
plate. • NEVER attempt to make any
adjustments to these sealed
adjustment screws. If adjustments are
required, they can be made only by a
qualified fuel injection shop that will
ensure the injection pump continues
to meet all applicable emissions
regulations and then replace the
tamper-proof seals.
• Tampering with or removing these
(1) devices may void the “Yanmar Limited
Warranty.”
0000146en
0002416
Installation of Fuel Injection Pump
Figure 7-15 1. Ensure the fuel injection pump drive gear is
aligned with the idler gear using the reference
marks made earlier (Figure 7-16, (1)).
Figure 7-16
2. If installing the fuel injection pump on an engine
with the front gear case cover removed, the fuel
injection pump drive gear can be aligned with
the idler gear by aligning the stamped marks
(Figure 7-17, (A, B, C)) on the fuel injection
pump drive gear, idler gear, and crankshaft
drive gear. Ensure all three timing marks
(A, B, C) are aligned.
(1)
(1)
(2)
(2)
(3)
B
B
C C 0002183A
A
A Figure 7-18
(5)
6. Align the reference marks (Figure 7-19, (1))
(4)
made during disassembly on both the fuel
0002190
injection pump mounting flange and gear case.
1 – Fuel Injection Pump Drive Gear
2 – Camshaft Drive Gear If installing a replacement fuel injection pump,
3 – Optional Accessory Drive Gear align the manufacturer-applied mark on the
4 – Crankshaft Drive Gear pump mounting flange with the mark made on
5 – Idler Gear the timing gear cover.
Figure 7-17
3. Install a new O-ring on the fuel injection pump
mounting flange. Apply some grease to the
O-ring to hold it in place during the installation
of the fuel injection pump.
Note: Ensure the tapered surface of the fuel
injection pump shaft is clean and dry.
(1)
(1)
0002416
Figure 7-19
7. Tighten the fuel injection pump retaining nuts to 0002239
(1)
Figure 7-22
CHECKING AND ADJUSTING 4. Set the throttle to the HIGH-IDLE position.
FUEL INJECTION TIMING 5. Using a wrench on the crankshaft pulley bolt,
rotate the crankshaft in a clockwise direction
Note: The following procedure is performed on while looking through the flywheel inspection
the No. 1 cylinder. While checking and port (Figure 7-23, (1)). Rotate the crankshaft
adjusting the timing on only No. 1 until the injection timing marks on the flywheel
cylinder is usually sufficient, the same are visible for No. 1 cylinder.
procedure can be performed on any or
all cylinders.
(3)
(2)
(4)
(1)
1
(5)
00020
(1)
0002071A
Figure 7-23
1 – 15° BTDC (Before Top Dead Center)
6. Typical flywheel markings are as shown in 2 – 20° BTDC
(Figure 7-24). 3 – 25° BTDC
Note: A typical flywheel will have multiple 4 – Direction of Rotation
timing grids depending on the number of 5 – TDC (Top Dead Center)
cylinders. Any grid and its corresponding Figure 7-24
cylinder can be used to check the fuel
injection timing. 7. The flywheel shown in (Figure 7-24) is for a
Yanmar “Standard Specification” IDI engine.
Flywheels used on some “OEM Specific” IDI
engines may be marked differently. You should
contact that specific OEM for information on the
identification of the timing marks.
Note: The TDC (Top Dead Center) mark can
be identified by the cylinder numbers
stamped near the TDC mark
(Figure 7-24, (5)) on the flywheel.
8. If you are uncertain as to the timing degree
designation of the timing marks on the flywheel
timing grid, you can determine the timing
degree designation by measuring the timing
grid.
• First measure the distance between two of the
“longer” marks on the timing grid. (They are 5°
apart.) Then measure the distance from the
TDC mark to the first “longer” mark on the
timing grid. Divide that measurement by the
distance between the two “longer” marks. The
resulting answer will tell you how many
degrees there are between the TDC mark and
the first “longer” mark.
(1)
(2)
1
0002066
Figure 7-27
0002065A
Figure 7-25
Fuel Injection Timing Chart
Model VM CH VH
Engine Speed (rpm) 2000-2100 2200 2300-2600 2700-3000 3000-3600 3100-3400 3500-3600
2TNV70 Injection 15° 16° 18° - - -
3TNV70 Timing BTDC 15° 16° 18° 21° 20° 21°
3TNV76 ±1° 15° 16° 18° 21° 20° 21°
Note: As the injection pump injects fuel to a Note: The fuel injection pump injects fuel to a
cylinder only once every two engine cylinder only once every two engine
revolutions, it may be necessary to rotate revolutions.
the crankshaft twice to see fuel being
16. “Flick” the nozzle of the timing tool with a finger
pumped from the timing tool or delivery
to remove bubbles and establish a fuel level of
valve of the cylinder you are using to
approximately 1/2 the height of the nozzle.
check injection timing.
17. Very slowly rotate the crankshaft clockwise until
13. Install the “spill-timing” tool (Figure 7-28, (1)) the fuel level in the nozzle of the “spill timing”
onto the delivery valve for the cylinder being tool, or in the delivery valve, just begins to
checked. See Measuring Instruments on move. Immediately stop rotating the crankshaft.
page 7-8.
18. Check the position of the flywheel target timing
Note: If a timing tool is not available, timing can mark (Figure 7-27, (1)) on the flywheel grid in
be checked by watching the fuel in the relation to the timing reference mark
delivery valve itself. (Figure 7-27, (2)) on the flywheel housing or
back plate. If the two marks are aligned, the fuel
(1) injection timing is correct. If the marks do not
align, the fuel injection timing must be adjusted.
See Adjusting Fuel Injection Timing on
page 7-23.
19. Repeat Steps 13-17 two or three times to verify
timing.
20. Remove the “spill-timing” tool.
21. Reinstall the shut-off solenoid.
22. Reinstall the high-pressure fuel injection lines.
See Installation of High-Pressure Fuel Injection
Lines on page 7-12.
23. Replace the flywheel inspection port cover.
0000592A 24. Prime the fuel system. Operate the engine and
Figure 7-28 check for leaks.
FUEL INJECTORS
Removal of Fuel Injectors
1. Close any fuel valves in the fuel supply line.
2. Clean the area around the fuel injection pump
and fuel injectors to keep contaminants from
0002469 entering the engine or fuel system.
Figure 7-29 3. Remove the high-pressure fuel injection lines
as an assembly. See Removal of High-Pressure
3. Loosen the nuts fastening the fuel injection Fuel Injection Lines on page 7-11.
pump to the gear case.
4. Remove nut (Figure 7-30, (1)). Remove the
4. If the injection timing was less than the target fuel return line (Figure 7-30, (2)) and copper
timing, the injection timing is “retarded” and will washer (Figure 7-30, (3)) from the fuel
need to be “advanced.” injectors. See Removal of Fuel Return Line on
To “advance” the injection timing: Rotate the page 7-12.
top of the fuel injection pump away from the Note: The fuel injectors used on IDI engines
engine. screw into the cylinder head.
If the injection timing was greater than the target 5. Remove the fuel injectors (Figure 7-30, (4)).
timing, the injection timing is “advanced” and will
need to be “retarded.”
To “retard” the injection timing: Rotate the top
of the fuel injection pump toward the engine.
(2) CAUTION
Never use a steel wire brush to clean
(3) fuel injectors. Damage to the nozzle and
other components is likely to result.
(4)
0000172en
OFF
P-
OFF
E -
ON AG
-G
Figure 7-31
A WARNING
Injection Pattern
0001742
0001743 0001744
0 0 0 0 0
Note: If the fuel injector fails any tests, it should be serviced or replaced as necessary. If the pressure is
outside specified limits, adjust the pressure. See Adjusting Fuel Injector Pressure on page 7-28.
(1)
(2)
(2)
(3)
(4)
(5)
(6)
0001333A
(7)
Figure 7-33
(8)
(9)
(10)
0002214
(5)
(6)
0002093
(7)
(8)
(9)
(10)
0001332A
0002214
Figure 7-34 1 – Return Fuel Fitting Nut
2 – Fuel Return Fitting
Replace the fuel injector assembly if it fails any
3 – Injector Body
inspection. 4 – Pressure Adjusting Shims
5 – Spring
Adjusting Fuel Injector Pressure 6 – Spring Seat
The fuel injectors open when pressure reaches a 7 – Valve Stop Spacer
predetermined pressure threshold. They close 8 – Nozzle Valve
when the pressure is reduced below that threshold. 9 – Nozzle Body
The pressure threshold can be adjusted by adding 10 – Nozzle Case Nut
or removing shims (Figure 7-35, (4)). Figure 7-35
COOLING SYSTEM
Page
Before You Begin Servicing ............................................................ 8-3
Introduction...................................................................................... 8-5
Cooling System Diagram................................................................. 8-5
Engine Coolant Pump Components ................................................ 8-6
Engine Coolant System Check........................................................ 8-7
Engine Coolant Pump ..................................................................... 8-7
Disassembly of Engine Coolant Pump ...................................... 8-7
Cleaning and Inspection ............................................................ 8-8
Reassembly of Engine Coolant Pump....................................... 8-9
ENTANGLEMENT HAZARD!
• Stop the engine before you begin to
service it.
A WARNING
A WARNING A CAUTION
BURN HAZARD!
• If you must drain the engine oil while it
PINCH HAZARD!
is still hot, stay clear of the hot engine Carefully rotate the alternator toward the
oil to avoid being burned. cylinder block while loosening the
V-belt. Failure to comply may result in
• ALWAYS wear eye protection. minor or moderate injury.
• Failure to comply could result in death 0000014en
or serious injury.
0000011en
CAUTION
• Only use the engine coolant specified.
A CAUTION Other engine coolants may affect
warranty coverage, cause an internal
buildup of rust and scale and / or
shorten engine life.
• Prevent dirt and debris from
contaminating the engine coolant.
Carefully clean the radiator cap and
FLYING OBJECT HAZARD! the surrounding area before you
• ALWAYS wear eye protection when remove the cap.
servicing the engine and when using • NEVER mix different types of engine
compressed air or high-pressure coolants. This may adversely affect the
water. Dust, flying debris, compressed properties of the engine coolant.
air, pressurized water or steam may 0000006en
injure your eyes.
• Failure to comply may result in minor CAUTION
or moderate injury.
Use a new special O-ring between the
0000003en
engine coolant pump and the joint. Be
sure to use the special O-ring for each
CAUTION engine model. Although the O-ring
If the engine coolant pump must be dimensions are the same as a
replaced, replace the engine coolant commercially available O-ring, the
pump as an assembly only. Do not material is different.
attempt to repair the engine coolant 0000042en
INTRODUCTION
This section of the Service Manual describes the procedures necessary to service the 2TNV70, 3TNV70
and 3TNV76 engine coolant pump.
(1)
(2)
(3)
(4)
(6)
(5)
0002046
Figure 8-1
3 4
9
11
6
5
8
10
0001959
Figure 8-2
A CAUTION
(1)
0000577A
Figure 8-3
2. Apply 10.8 - 14.8 psi (75 - 105 kPa;
0.75 - 1.05 kgf/cm²) to the cooling system. If the
pressure reading drops, the engine coolant PINCH HAZARD!
system is leaking. Identify the source of the leak Carefully rotate the alternator toward the
and repair. cylinder block while loosening the
V-belt. Failure to comply may result in
minor or moderate injury.
ENGINE COOLANT PUMP 0000014en
CAUTION
If the engine coolant pump must be
replaced, replace the engine coolant
pump as an assembly only. Do not
attempt to repair the engine coolant 0001959B
6. Remove the engine coolant pump 2. Place the temperature switch and an accurate
(Figure 8-4, (4)). Discard the gasket. thermometer (Figure 8-6, (3)) in engine
7. Remove the thermostat cover (Figure 8-5, (1)). coolant.
3. Slowly increase temperature of the fluid using
an external heat source.
(1)
4. The temperature switch is normal if the
continuity light or ohmmeter indicates continuity
(2) when the fluid temperature reaches
225°F - 235°F (107°C - 113°C).
Thermostat
1. Check for proper operation of the thermostat.
(4)
(3) Place the thermostat (Figure 8-7, (1)) and an
accurate thermometer (Figure 8-7, (2)) in warm
water.
0001959A (2)
Figure 8-5
8. Remove the thermostat (Figure 8-5, (2)).
Remove the temperature switch
(Figure 8-5, (3)) and gasket (Figure 8-5, (4)). (1)
Discard the gasket.
Radiator Cap
(2)
1. Check for proper operation of the radiator cap.
Install the radiator cap (Figure 8-8, (1)) on a
cooling system tester.
0000577A
Figure 8-6
CAUTION
Use a new special O-ring between the
engine coolant pump and the joint. Be
sure to use the special O-ring for each
engine model. Although the O-ring
(1) dimensions are the same as a
commercially available O-ring, the
0000577A
material is different.
Figure 8-8 0000042en
2. Apply 10.8 - 14.8 psi (75 - 105 kPa; 5. Reinstall the engine coolant pump bolts.
0.75 - 1.05 kgf/cm²) to the radiator cap. The Tighten the bolts.
radiator cap relief valve must open within the 6. Inspect and reinstall the coolant hoses and the
specified range. temperature switch lead wire.
Reassembly of Engine Coolant Pump 7. Reinstall the engine coolant pump V-pulley
(Figure 8-10, (3)), spacer (Figure 8-10, (2))
1. Reinstall the thermostat (Figure 8-9, (1)). engine coolant fan (Figure 8-10, (1)) and
engine coolant fan guard (if equipped).
(4)
(2)
(6) (3)
(1) (2)
(1)
(5)
0001959B
(4)
0001959C Figure 8-10
(3)
Figure 8-9 8. Inspect the condition of the V-belt. There must
be clearance (Figure 8-11, (1)) between the
2. Reinstall the thermostat cover (Figure 8-9, (2)). V-belt and the bottom of the pulley groove. If
Tighten the thermostat cover bolts. there is no clearance (Figure 8-11, (2))
3. Reinstall the temperature switch between the V-belt and the bottom of the pulley
(Figure 8-9, (3)) and a new gasket groove, replace the V-belt.
(Figure 8-9, (4)).
4. Position the engine coolant pump on the engine
and install a new gasket (Figure 8-9, (6)). Use
a new special O-ring (Figure 8-9, (5)) on
assembly between the engine coolant pump
and the joint.
(2)
(1)
0000584
Figure 8-11
9. Reinstall the V-belt. Tighten the V-belt to the
proper tension. See Check and Adjust Cooling
Fan V-Belt on page 5-27.
10. Reinstall and tighten the drain plug or close the
drain cock in the radiator. Reinstall and tighten
the engine block drain plug or reconnect the
coolant hose at the oil cooler.
11. Fill radiator and engine with engine coolant.
See Drain, Flush and Refill Cooling System
with New Coolant on page 5-33.
CAUTION
• Only use the engine coolant specified.
Other engine coolants may affect
warranty coverage, cause an internal
buildup of rust and scale and / or
shorten engine life.
• Prevent dirt and debris from
contaminating the engine coolant.
Carefully clean the radiator cap and
the surrounding area before you
remove the cap.
• NEVER mix different types of engine
coolants. This may adversely affect the
properties of the engine coolant.
0000006en
LUBRICATION
SYSTEM
Page
Before You Begin Servicing ............................................................ 9-3
Introduction...................................................................................... 9-5
Oil Pump Service Information.......................................................... 9-5
Engine Oil Pressure................................................................... 9-5
Outer Rotor Outside Clearance ................................................. 9-5
Outer Rotor Side Clearance ...................................................... 9-5
Outer Rotor to Inner Rotor Tip Clearance ................................. 9-5
Inner Rotor and Gear Boss Clearance ...................................... 9-6
Lubrication System Diagram ........................................................... 9-7
Checking Engine Oil Pressure ........................................................ 9-8
Trochoid Oil Pump........................................................................... 9-8
Oil Pump Components .............................................................. 9-8
Disassembly of Oil Pump .......................................................... 9-9
Cleaning and Inspection .......................................................... 9-10
Reassembly of Oil Pump ......................................................... 9-11
ENTANGLEMENT HAZARD!
• Stop the engine before you begin to
service it.
NEVER permit anyone to operate the • NEVER leave the key in the key switch
engine or driven machine without proper when you are servicing the engine.
training. Someone may accidentally start the
engine and not realize you are
• Read and understand this Operation
servicing it. This could result in a
Manual before you operate or service
serious injury.
the machine to ensure that you follow
safe operating practices and • If you must service the engine while it
maintenance procedures. is operating, remove all jewelry, tie
back long hair, and keep your hands,
• Machine safety signs and labels are
other body parts and clothing away
additional reminders for safe operating
from moving / rotating parts.
and maintenance techniques.
• Failure to comply could result in death
• See your authorized Yanmar industrial
or serious injury.
engine dealer or distributor for
0000010en
additional training.
0000002en
A WARNING
BURN HAZARD!
• Keep your hands and other body parts
away from hot engine surfaces such
as the muffler, exhaust pipe,
turbocharger (if equipped) and engine
block during operation and shortly
after you shut the engine down. These
surfaces are extremely hot while the
engine is operating and could
seriously burn you.
• Failure to comply could result in death
or serious injury.
0000015en
A WARNING CAUTION
• Only use the engine oil specified.
Other engine oils may affect warranty
coverage, cause internal engine
components to seize and / or shorten
engine life.
FUME / BURN HAZARD! • Prevent dirt and debris from
• Always read and follow safety related contaminating the engine oil. Carefully
precautions found on containers of clean the oil cap / dipstick and the
hazardous substances like parts surrounding area before you remove
cleaners, primers, sealants and the cap.
sealant removers. • NEVER mix different types of engine
• Failure to comply could result in death oil. This may adversely affect the
or serious injury. lubricating properties of the engine oil.
0000014en
• NEVER overfill. Overfilling may result
in white exhaust smoke, engine
A CAUTION overspeed or internal damage.
0000005en
CAUTION
If the oil pump must be replaced, replace
it as an assembly only. Do not replace
individual components.
FLYING OBJECT HAZARD! 0000030en
INTRODUCTION
This section of the Service Manual describes the procedures necessary to service the 2TNV70, 3TNV70
and 3TNV76 trochoid oil pumps.
Note: See Replace Engine Oil and Engine Oil Filter on page 5-25 for engine oil and engine oil filter
replacement procedures.
Oil Filter
Bypass Valve
Fuel
Injection Pump
Oil Pressure
Switch
Rocker Arm
Tappet
Cam Face
Oil Pan
0001624
Figure 9-1
(4)
(1) 0001955A
1 – Crankshaft
2 – Oil Pump Cover
3 – Oil Pressure Regulator
4 – Gear Case Cover
5 – Outer Rotor
6 – Inner Rotor
Figure 9-3
0000020A
Figure 9-2
2. Remove the oil pressure switch.
3. Install a mechanical oil pressure gauge in the
oil pressure switch port.
4. Start the engine:
• If the mechanical oil pressure test gauge
indicates good oil pressure, replace the faulty
oil pressure switch or sending unit or faulty
machine oil pressure gauge in instrument
panel.
• If the mechanical oil pressure test gauge
indicates low oil pressure, troubleshoot the
lubrication system to locate the cause of the
low oil pressure. See Troubleshooting Charts
on page 13-7. Repair as necessary.
(4) 0001955B
Figure 9-5
(3)
4. Remove the oil pump cover (Figure 9-5, (1))
(2) from the gear case.
(1)
5. Remove the outer rotor (Figure 9-5, (3)) and
inner rotor (Figure 9-5, (4)) from the gear case
cover.
6. Remove the oil pressure regulator valve
(Figure 9-6, (1)) from the oil pump cover
0001959B (Figure 9-6, (2)).
Figure 9-4
(2)
2. Remove the front crankshaft pulley and gear
case cover. See Removal of Timing Gear Case
Cover on page 6-38.
3. Remove the seven oil pump cover screws
(Figure 9-5, (2)).
Note: The oil pump cover screws are installed (1)
using a liquid thread lock. It may be 0001958A
necessary to used “localized heat” (small
propane torch) and an impact-type Figure 9-6
screwdriver to remove these screws.
A CAUTION
If any oil pump component clearance
exceeds its limit, the oil pump must be
replaced as an assembly.
0000015en
0001151A
Figure 9-7
Record the measurement. See Outer Rotor Outside
Clearance on page 9-5 for the service limit.
Figure 9-9
Record the measurement. See Outer Rotor Side
Clearance on page 9-5 for the service limit.
(3) 0001959B
0001976A
1. Lubricate the outer rotor (Figure 9-11, (1)), 8. Reinstall the V-belt. Tighten the V-belt to the
inner rotor (Figure 9-11, (2)) and pump bore in proper tension. See Check and Adjust Cooling
the gear case cover (Figure 9-11, (3)) with Fan V-Belt on page 5-27.
clean engine oil.
STARTER MOTOR
Page
Before You Begin Servicing .......................................................... 10-3
Introduction.................................................................................... 10-5
Starter Motor Information .............................................................. 10-5
Starter Motor Specifications .......................................................... 10-6
Starter Motor Troubleshooting....................................................... 10-7
Starter Motor Components ............................................................ 10-8
Starter Motor ................................................................................. 10-9
Removal of Starter Motor ...................................................... 10-10
Disassembly of Starter Motor ................................................ 10-10
Cleaning and Inspection ........................................................ 10-12
Reassembly of Starter Motor................................................. 10-17
Check Pinion Projection Length ............................................ 10-19
No-Load Test......................................................................... 10-19
Installation of Starter Motor ................................................... 10-20
SHOCK HAZARD!
• Turn off the battery switch (if
ENTANGLEMENT HAZARD! equipped) or disconnect the negative
battery cable before servicing the
• Stop the engine before you begin to
electrical system.
service it.
• Check the electrical harnesses for
• NEVER leave the key in the key switch
cracks, abrasions, and damaged or
when you are servicing the engine.
corroded connectors. ALWAYS keep
Someone may accidentally start the
the connectors and terminals clean.
engine and not realize you are
servicing it. This could result in a • Failure to comply could result in death
serious injury. or serious injury.
0000009en
• If you must service the engine while it
is operating, remove all jewelry, tie
back long hair, and keep your hands, A WARNING
other body parts and clothing away
from moving / rotating parts.
• Failure to comply could result in death
or serious injury.
0000010en
FUME / BURN HAZARD!
• Always read and follow safety related
precautions found on containers of
hazardous substances like parts
cleaners, primers, sealants and
sealant removers.
• Failure to comply could result in death
or serious injury.
0000014en
A CAUTION CAUTION
The starter motor is water-proofed
according to JIS D 0203, R2 which
protects the motor from rain or general
cleaning. Do not use high-pressure
wash or submerse the starter motor in
water.
FLYING OBJECT HAZARD! 0000055en
CAUTION
The starter motor can be damaged if
operated continuously longer than
10 seconds while performing the
no-load test.
0000034en
CAUTION
Make sure that the combined total
resistance of the battery cable in both
directions between the starter motor
and the battery is within the value
indicated on the wiring diagram. The
starter motor will malfunction or break
down if the resistance is higher than the
specified value.
0000054en
INTRODUCTION
This section of the Service Manual covers the servicing of starter motor. Yanmar Part No. 119717-77010 is
standard equipment on 3TNV76 model engines and is used in this section to show the service procedures
for a representative starter motor. For specific part detail, see the Yanmar Parts Catalog for the engine
being serviced.
YES
Engine does not start? Inspect wiring up to solenoid switch
Is starter motor solenoid and repair if necessary.
NO • Key switch
switch actuating sound
YES heard? • Safety relay
• Solenoid switch assembly
NO NO • Electrical connections
Does engine crank? Is starter motor operating? YES
YES
• Adjust / pinion projection length.
Starter Motor Troubleshooting
YES
Solenoid switch assembly If starter motor becomes wet, replace solenoid switch
contact defective. Repair assembly even if function is normal.
NO or replace.
(slow revolution) NO
STARTER MOTOR TROUBLESHOOTING
Is revolution normal? Is battery fully charged • Charge or replace battery. If a problem occurs:
and terminals clean? • Clean terminals. Immediately disconnect battery negative terminal.
YES YES
Inspect fuel system. Is the engine oil NO Engine does not stop
Replace engine oil.
viscosity correct? even when key switch is
turned OFF.
YES
Does engine turn when YES Repair or replace Repair or replace key switch, starting
starter motor is replaced? starter motor. motor relay or magnetic switch assembly.
Slow Revolution
0000102
STARTER MOTOR
10-7
STARTER MOTOR Starter Motor Components
(8)
(14)
(13)
(11) (12)
(3) (10)
(9) (15)
(2) (7) (17)
(1) (6)
(5)
(4)
(16)
(19)
(21)
(20) (18)
(22)
(23)
(24)
0002486
Figure 10-1
Removal of Starter Motor 3. Remove the two bolts or nuts retaining the
solenoid switch assembly (Figure 10-4, (1)) to
1. Disconnect the battery cables at the battery, the pinion housing. Remove the solenoid switch
negative (-) cable first. assembly and dust covers (Figure 10-4, (2)).
2. Remove the electrical wires from the solenoid Remove the plunger (Figure 10-4, (4)) and
switch assembly. torsion spring (Figure 10-4, (3)) from the pinion
3. Remove the starter mounting bolts housing.
(Figure 10-2, (1)). Remove the starter motor
from the flywheel housing.
(1)
(4)
(3)
(2) (1)
0000140A
0002126
Figure 10-4
Figure 10-2
4. Remove the two bolts (Figure 10-5, (1))
Disassembly of Starter Motor securing the rear cover (Figure 10-5, (2)) to the
brush holder assembly (Figure 10-5, (3)).
1. Make alignment marks across all mating joints.
2. Disconnect the field wire from the solenoid
switch (Figure 10-3). (2)
(3)
(1)
0000142A
Figure 10-5
5. Remove the two through bolts. Remove the rear
cover (Figure 10-5, (2)).
0000138
Figure 10-3
(4)
0000148A
Figure 10-8
12. Pull the pinion stop (Figure 10-9, (1)) down to
expose the retaining ring. Using a flat-blade
screwdriver, remove the retaining ring
0000143
(Figure 10-9, (2)) from the pinion shaft.
Figure 10-6
7. Remove the brush plate and holder
(Figure 10-7, (1)).
(2) (1)
(3)
(2) (1)
0000151A
Figure 10-9
0000144A
Figure 10-7
8. Pull the field assembly (Figure 10-7, (3)) off
from the armature assembly (Figure 10-7, (2)).
9. Remove the armature from the intermediate
housing.
10. Remove the intermediate housing, gear and
pinion shaft assembly (Figure 10-8, (4)) from
the pinion housing (Figure 10-8, (3)).
Disengage from the shift lever as it is removed.
13. Remove the pinion stop (Figure 10-10, (3)), 15. Inspect the intermediate bushing
return spring (if equipped), and pinion clutch (Figure 10-11, (2)) and replace if worn or
assembly (Figure 10-10, (2)), from the pinion damaged.
shaft (Figure 10-10, (1)). 16. Inspect armature bushing (Figure 10-11, (7))
and replace if worn or damaged.
(2)
Cleaning and Inspection
Armature
Commutator Surface Inspection
If the commutator surface is rough, polish the
surface with a #500 to #600 emery cloth.
(1)
Figure 10-10
14. Remove the snap ring (Figure 10-11, (1)).
Remove the pinion shaft (Figure 10-11, (5)),
planetary gears (Figure 10-11, (6)), washers,
and reduction gear (Figure 10-11, (4)) from the
intermediate housing (Figure 10-11, (3)).
0000117
(4)
Figure 10-12
(7)
(6)
0000113
(5) (4)
0000118
Figure 10-14
Armature Coil Continuity Test 0000115
0000116
Figure 10-17
0000120
Field Coil
Figure 10-19
Field Coil Continuity Test
Measure Brush Length
Check for continuity between the field coil terminals
using a multimeter (Figure 10-18). The multimeter Measure the length of the brush (Figure 10-20).
should indicate continuity. Replace the brush if the length is less than the limit.
See Starter Motor Specifications on page 10-6 for
If the multimeter does not indicate continuity, service limit.
replace the field coil assembly.
0000121
0000119
Figure 10-20
Figure 10-18
0000122
Figure 10-21
0000124
Brush Spring Test
Test the spring force for each brush spring Figure 10-23
(Figure 10-22). Replace the brush spring if the Series Coil Continuity Test
force is not within the range. See Starter Motor
Specifications on page 10-6 for the service limit. Check for continuity between the “S” and “M”
terminals using a multimeter (Figure 10-24). The
multimeter should indicate continuity.
If the multimeter does not indicate continuity,
replace the solenoid switch.
0000123
Figure 10-22
0000125
Figure 10-24
Figure 10-26
Slide the pinion clutch assembly on the shaft
(Figure 10-27). It should slide smoothly on the
shaft. Rust, too much grease, or damage could
prevent the pinion clutch from sliding smoothly. If
the pinion clutch assembly does not slide smoothly,
clean the shaft and pinion clutch assembly or
replace the damaged component.
0000126
Figure 10-25
(5) 0002487
Figure 10-28
3. Reinstall the pinion clutch assembly
(Figure 10-29, (2)), return spring (if equipped)
and pinion stop (Figure 10-29, (3)) onto the (4)
pinion shaft (Figure 10-29, (1)). Reinstall the 0000148A
8. Reinstall the plate onto the intermediate 13. Reinstall the two through bolts and tighten
housing and carefully reinstall the armature securely.
assembly (Figure 10-31, (2)) into the pinion 14. Reinstall the return spring (if equipped)
shaft assembly. (Figure 10-33, (3)) on the solenoid plunger
(Figure 10-33, (4)). Reinstall the solenoid
(2) (1)
switch coil (Figure 10-33, (1)) and dust covers
(Figure 10-33, (2)). Secure with nuts or bolts.
(3) (4)
0000144A
(3)
Figure 10-31 (2) (1)
9. Reinstall the field assembly (Figure 10-31, (3))
0000140A
over the armature assembly and align to the
pinion housing. Figure 10-33
10. Position the brush springs in brush holders. 15. Reconnect the wire to the solenoid switch
Reinstall the brushes in the brush holders. assembly. Tighten the nut. Reinstall the cover
Reversing the brushes will cause the starter over the connection.
motor to turn backwards.
11. Carefully reinstall the brush holder
(Figure 10-32, (3)) assembly.
12. Reinstall the rear cover (Figure 10-32, (2)) and
secure with two bolts (Figure 10-32, (1)).
(2)
(3)
(1)
0000138
0000142A
Figure 10-34
Figure 10-32
seconds.
1. Secure the starting motor in a vise or other
suitable fixture.
2. Connect an ammeter (Figure 10-37, (1)) in
series between the battery positive (+) terminal
(Figure 10-37, (2)) and the main positive (+)
terminal (Figure 10-37, (3)) on the starter
motor.
Note: The ammeter and all wire leads used in
this test must have a capacity equal to or
0000132
greater than the amperage draw
specification for the starter motor being
Figure 10-35 tested.
See Starter Motor Specifications on page 10-6 for
service limit.
(3)
5. If the measured L dimension is outside the
standard range, adjust the dust covers to obtain (6) (1)
the standard range. Dust covers M (8)
(Figure 10-36, (1)) are available in 0.020 in. (2)
(0.5 mm) and 0.031 in. (0.8 mm) thicknesses. (7)
(5)
(1) (4)
0002127A
Figure 10-37
3. Connect a wire lead between the mounting
base of the starter motor (Figure 10-37, (4))
and the battery negative terminal
(Figure 10-37, (5)).
4. Connect a voltmeter (Figure 10-37, (7)) to the
0000133
battery negative (-) terminal (Figure 10-37, (5))
and the main positive (+) battery terminal
Figure 10-36 (Figure 10-37, (3)) on the starter motor.
0002126
Figure 10-38
3. Reconnect the electrical wires to the solenoid
switch assembly. Be sure to place the cover
over the battery positive (+) cable connection.
4. Reconnect the battery, negative (-) cable last.
ALTERNATOR
Page
Before You Begin Servicing .......................................................... 11-3
Introduction.................................................................................... 11-6
Standard and Optional Dynamo Information ................................. 11-6
Standard and Optional Alternator Information............................... 11-6
Alternator Specifications................................................................ 11-6
Dynamo Specifications .................................................................. 11-7
Alternator Troubleshooting ............................................................ 11-8
Alternator Components ................................................................. 11-9
Alternator Wiring Diagram ........................................................... 11-10
Alternator Standard Output ........................................................ 11-11
Alternator .................................................................................... 11-12
Removal of Alternator............................................................ 11-12
Disassembly of Alternator...................................................... 11-12
Reassembly of Alternator ...................................................... 11-14
Installation of Alternator......................................................... 11-16
Dynamo Component Location..................................................... 11-17
Dynamo Wiring Diagram ............................................................. 11-18
Operation of Dynamo .................................................................. 11-18
Dynamo Standard Output ........................................................... 11-19
Testing of Dynamo ...................................................................... 11-20
Testing Stator Coil Continuity ................................................ 11-20
Testing Stator Coil Short-to-Ground ...................................... 11-20
Testing Dynamo Regulated Output ....................................... 11-20
SHOCK HAZARD!
• Turn off the battery switch (if
ENTANGLEMENT HAZARD! equipped) or disconnect the negative
battery cable before servicing the
• Stop the engine before you begin to
electrical system.
service it.
• Check the electrical harnesses for
• NEVER leave the key in the key switch
cracks, abrasions, and damaged or
when you are servicing the engine.
corroded connectors. ALWAYS keep
Someone may accidentally start the
the connectors and terminals clean.
engine and not realize you are
servicing it. This could result in a • Failure to comply could result in death
serious injury. or serious injury.
0000009en
• If you must service the engine while it
is operating, remove all jewelry, tie
back long hair, and keep your hands, A WARNING
other body parts and clothing away
from moving / rotating parts.
• Failure to comply could result in death
or serious injury.
0000010en
BURN HAZARD!
• Keep your hands and other body parts
away from hot engine surfaces such
as the muffler, exhaust pipe,
turbocharger (if equipped) and engine
block during operation and shortly
after you shut the engine down. These
surfaces are extremely hot while the
engine is operating and could
seriously burn you.
• Failure to comply could result in death
or serious injury.
0000015en
A WARNING A CAUTION
A CAUTION
CAUTION
Do not short-circuit the charging system
between alternator terminals IG and L.
Damage to the alternator will result.
0000035en
CAUTION CAUTION
Do not connect a load between Using a non-specified V-belt will cause
alternator terminals L and E. Damage to inadequate charging and shorten the
the alternator will result. belt life. Use the specified belt.
0000036en 0000052en
CAUTION CAUTION
Do not operate the engine if the Agricultural or other chemicals,
alternator is producing unusual sounds. especially those with a high sulfur
Damage to the alternator will result. content, can adhere to the IC regulator.
0000039en This will corrode the conductor and
result in battery over-charging (boiling)
and charging malfunctions. Consult
CAUTION Yanmar before using the equipment in
Do not remove the positive (+) battery such an environment or the warranty is
cable from alternator terminal B while voided.
the engine is operating. Damage to the 0000053en
alternator will result.
0000037en
CAUTION
Do not use a high-pressure wash
CAUTION directly on the alternator. Water will
Do not turn the battery switch OFF while damage the alternator and result in
the engine is operating. Damage to the inadequate charging.
alternator will result. 0000049en
0000038en
CAUTION
Do not reverse the positive (+) and
negative (-) ends of the battery cable.
The alternator diode and stator coil will
be damaged.
0000050en
CAUTION
When the battery indicator goes out, it
should not come on again. The battery
indicator only comes on during
operation if the alternator fails. However,
if an LED is used in the battery indicator,
the LED will shine faintly during normal
operation.
0000051en
INTRODUCTION
This section of the Service Manual describes the servicing of the dynamos and alternators. Yanmar Part
No. 129423-77200 alternator is used in this section to show the service procedures for the representative
alternator. Yanmar Part No. 171301-77201 dynamo is used in this section to show the service procedures
for the representative dynamo. For specific part detail, see the Parts Catalog for the engine you are working
on.
ALTERNATOR SPECIFICATIONS
Yanmar Part Number 129423-77200
Nominal Output (13.5 Volts Heat) 40 Amps
Weight 6.17 lb (2.8 kg)
Revolution Direction (As Viewed From Pulley) Clockwise
Rating Continuous
Battery Voltage 12 Volts
Rated Revolution 5000 rpm (min-1)
Operating Range 1350 - 18000 rpm (min-1)
Grounding Characteristics Negative (-) Side of Circuit
Integrated Regulator IC Regulator
Outside Diameter of Pulley 2.724 in. (69.2 mm)
Belt Shape Type A
DYNAMO SPECIFICATIONS
Yanmar Part Number 119910-77200
Nominal Output 20 Amps
Weight 3.97 lb (1.8 kg)
Revolution Direction (As Viewed From Pulley) Clockwise
Rating Continuous
Battery Voltage 12 Volts
Rated Revolution 3500 rpm
Operating Range 1400 - 6600 rpm
Grounding Characteristics Negative (-) Side of Circuit
Regulator Current Limiter (Part No. 119653-77710)
A-Belt 2.56 in. (65 mm)
Outside Diameter of Pulley
Special M-Belt 2.28 in. (58 mm)
Belt Shape Type A or Type Special M
At idle, does battery Battery indicator flashes. Inspect diode positive (+) side.
indicator turn OFF?
Battery indicator
OFF is dim.
Increase engine speed to
1500 rpm. Turn light switch ON.
Battery voltage
is between 13 With engine idling, Does battery indicator ON Inspect auxiliary diode.
and 15 volts. turn light switch ON. come ON?
OFF
Notes: Not abnormal.
1) Use a fully charged battery
ALTERNATOR COMPONENTS
Yanmar Part No. 129423-77200 alternator is used in this section to show the service procedures for the
representative alternator. For specific part detail, see the Parts Catalog for the engine you are working on.
14
12 13
10 11
8 9
6
5
29
4
3 7 19
2
16 18
1 17
25
15 28
27
26
24
23
22 0000255
21
20
Figure 11-1
IG 1
IG P
B
PI P L
2
F
IC
L
3 3
0.5μF
B
4A
E T
5 6
CAUTION CAUTION
Do not short-circuit the charging system Do not remove the positive (+) battery
between alternator terminals IG and L. cable from alternator terminal B while
Damage to the alternator will result. the engine is operating. Damage to the
0000035en alternator will result.
0000037en
CAUTION
Do not connect a load between
alternator terminals L and E. Damage to
the alternator will result.
0000036en
Output Current
60
Cold
50
30
20
10
0 1 2 3 4 5 6 7 8
Alternator RPM (x10³ min¯¹)
Figure 11-3
ALTERNATOR
A WARNING
SHOCK HAZARD! 2 1
• Turn off the battery switch (if 0000264
Removal of Alternator
1. Disconnect the electrical wires from the
alternator.
2. Loosen the V-belt.
A CAUTION
2
1 0000256
4 2
5
1
0000257A
Figure 11-6
3. Remove the brush holder (Figure 11-6, (3)).
0000265A
Remove the brush springs (Figure 11-6, (4))
and brushes (Figure 11-6, (5)). Figure 11-8
4. Remove the bolt retaining the regulator 8. Using a press, remove the rotor assembly
assembly (Figure 11-7, (1)) to the holder (Figure 11-9, (1)) from the front frame housing
(Figure 11-7, (2)). (Figure 11-9, (2)) and rear frame housing
(Figure 11-10, (1)).
3 3
1
4
1
2
100266A
Figure 11-9
0000258A
Figure 11-7
3
1 2
1
0000259A
Figure 11-10
10. If it is necessary to replace the bearing
0000260A
(Figure 11-10, (2)) in the front frame housing,
remove the four bolts (Figure 11-10, (3)) Figure 11-12
securing the plate (Figure 11-10, (4)) to the
2. If removed, lubricate the outside diameter of a
front frame housing. Remove the plate. Use a
new front frame housing bearing. Press the
puller to remove the bearing. Discard the
bearing (Figure 11-13, (2)) into the front frame
bearing.
housing. Reinstall the plate (Figure 11-13, (4))
11. If it is necessary to replace the bearing to the front housing. Tighten the four bolts
(Figure 11-11, (1)) in the rear frame housing, (Figure 11-13, (3)).
use a puller to remove. Discard the bearing.
Remove the bearing cover (Figure 11-11, (2))
and two thrust washers (Figure 11-11, (3)). 4
2
3
2
1
0000259A
0000260A
0000258A
1 1
3
4 2
0000265A 5
Figure 11-15
6. Reinstall the insulation bushing
0000257A
(Figure 11-16, (4)) and nut (Figure 11-16, (3)).
Figure 11-17
10. Reinstall the rear cover (Figure 11-17, (2)) to
the rear frame housing with three bolts
(Figure 11-17, (1)).
CAUTION
Do not operate the engine if the
alternator is producing unusual sounds.
Damage to the alternator will result.
0000039en
2
1 0000256
Figure 11-18
11. Reassemble the pulley (Figure 11-18, (2)) and
nut (Figure 11-18, (1)) to the shaft of the rotor
assembly. Tighten the nut.
Installation of Alternator
1. Position the alternator on the gear case.
Loosely reinstall the nut (Figure 11-19, (2)) on
the gear case stud and the V-belt adjuster bolt
(Figure 11-19, (1)).
2 1
0000264
Figure 11-19
2. Reconnect the electrical wires to the alternator.
Tighten the nuts to 15 - 20 in.-lb (1.7-2.3 N·m;
17-23 kgf·m).
3. Reinstall the V-belt. Tighten the V-belt to the
proper tension. See Check and Adjust Cooling
Fan V-Belt on page 5-27.
(1)
(2)
(3)
(4)
(7)
(5)
(8) (9)
0002140
(6) (10)
(11) (12)
(13)
(14)
0002140
Figure 11-20
(3)
(5) (6)
(2) (4)
(1)
0002137
Figure 11-21
OPERATION OF DYNAMO
The dynamo consists of a series of permanent
magnets that rotate around a stationary stator coil.
The magnets are attached to the flywheel which is
rotated via the engine cooling fan drive belt. The
resultant output is an AC (alternating current)
signal. The AC is converted to DC (direct current)
by the current limiter. The current limiter outputs
charging DC current to the battery.
0002138
Figure 11-22
be replaced.
3. Remove the V-belt adjuster from the dynamo
Testing Dynamo Regulated Output bolt (Figure 11-23, (1)).
1. Test and record the battery voltage with the 4. Remove the nut (Figure 11-23, (2)) from the
engine OFF. gear case stud. Remove the dynamo.
0002145
Figure 11-26
Reassembly of Dynamo
1. Reinstall the rear bearing (Figure 11-26, (3)).
0002143
2. Reinstall the stator (Figure 11-26, (1)).
Figure 11-24 3. Reinstall screws (Figure 11-26, (1)).
3. Remove the through bolt (Figure 11-25, (1)), 4. Reinstall the front bearings (Figure 11-27, (5))
pulley half (Figure 11-25, (2)), flywheel and spacer (Figure 11-27, (6)).
(Figure 11-25, (3)), flat washer 5. Reinstall the flat washer (Figure 11-27, (4)),
(Figure 11-25, (4)), bearings flywheel (Figure 11-27, (3)), pulley half
(Figure 11-25, (5)), and spacer (Figure 11-27, (2), and through bolt
(Figure 11-25, (6)). (Figure 11-27, (1)).
(6) (6)
(5) (5)
(4) (4)
(3) (3)
(2) (2)
(1) (1)
0002144 0002144
(1) 0002141
(2)
Figure 11-29
CAUTION
Do not operate the engine if the
alternator is producing unusual sounds.
Damage to the alternator will result.
0000039en
ELECTRIC WIRING
Page
Electric Wiring Precautions .......................................................... 12-3
Electric Wire Resistance ............................................................... 12-4
Battery Cable Resistance.............................................................. 12-5
Electrical Wire Sizes - Voltage Drop ............................................. 12-6
Conversion of AWG to European Standards................................. 12-7
CAUTION
Make sure that the combined total
resistance of the battery cable in both
directions between the starter motor
and the battery is within the value
indicated in the Battery Cable
Resistance chart in the Electric Wiring
Section of this manual. The starter
motor will malfunction and fail if the
resistance is higher than the specified
value.
0000057en
Wiring voltage drop should not exceed 5% [0.05] x 12 Volts = 0.6 Volts.
Voltage Drop = Current [Amps] x Length of Wire [Feet] x Resistance per Foot [Ohms]
Example:
Current draw of 100 Amps x 3 feet of 4 AWG wire
100 Amps x 3 Feet x 0.000270 = 0.08 Volts [Voltage Drop]
Note: Total allowable resistance of the complete battery cable circuit (positive cable + negative cable + a*)
(a*: Resistance (:) of a battery switch or other electrical equipment having high resistance)
Note: For starter motors of less than 2.68 HP (2 kW): the total resistance must be less than 0.002 Ω. For
starter motors of greater than 2.68 HP (2 kW): the total resistance must be less than 0.0012 Ω.
TROUBLESHOOTING
Page
Special Service Tools .................................................................... 13-3
Troubleshooting By Measuring Compression Pressure ................ 13-4
Compression Pressure Measurement Method ........................ 13-4
Standard Compression Pressure ............................................ 13-5
Engine Speed and Compression Pressure
(Use for Reference) ................................................................. 13-5
Measured Value and Troubleshooting..................................... 13-6
Quick Reference Table For Troubleshooting ................................ 13-6
Troubleshooting Charts ................................................................. 13-7
Electric Wiring ............................................................................. 13-19
0000849
TROUBLESHOOTING BY 3. Turn off the fuel supply valve in the fuel supply
line. Disconnect the fuel injection stop solenoid
MEASURING COMPRESSION at the connector. Crank the engine for a few
PRESSURE seconds with the stop solenoid disconnected
(no injection state) before installing the
Compression pressure drop is one of major causes compression gauge adapter (Figure 13-1, (1)),
of increasing blow-by gas (engine oil contamination this will expel any residual fuel from the
or increased engine oil consumption as a resultant cylinder.
phenomenon) or starting failure. The compression
pressure is affected by the following factors: 4. Install one injector gasket at the tip end of the
compression gauge adapter. Install the
1. Degree of clearance between piston and compression gauge and the compression
cylinder gauge adapter at the cylinder to be measured.
2. Degree of clearance at intake / exhaust valve 5. Crank the engine until the compression gauge
seat reading is stabilized.
3. Gas leak from nozzle gasket or cylinder head
gasket
The pressure will drop due to increased parts wear.
Pressure drop reduces the durability of the engine.
1
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 determine
the condition of the engine.
569 psi
3.92 MPa
(40 kgf/cm2)
Compression Pressure
498 psi
3.43 MPa
(35 kgf/cm2)
427 psi
2.94 MPa
(30 kgf/cm2)
356 psi
2.45 MPa
(25 kgf/cm2)
285 psi
1.96 MPa
(20 kgf/cm2)
Figure 13-2
Pressure Drop
Pressure Rise
Oil with Water
During Idling
Cause
Overheat
Ordinary
White
White
Much
Black
Black
None
Little
Improper Intake/Exhaust Valve See “Measuring and Adjusting
O O O O O O Adjust the Valve Clearance.
Clearance Valve Clearance” on page 6-34.
See “Valve Face and Valve Seat”
Compression Leakage from Valve Seat O O O O O O O O Lap the Valve Seat.
on page 6-28.
Correct or Replace Intake/ See “Inspection of Intake and
Intake/Exhaust Valve Seizure O O O O O O O O O O O
Exhaust Valve. Exhaust Valves” on page 6-27.
Engine System
Insufficient Poor
Pressure Drop
Pressure Rise
Oil with Water
During Idling
Cause
Overheat
Ordinary
White
White
Black
Black
Much
None
Little
See “Reassembly of Pistons” on
Reverse Assembly of Piston Rings O O O O Reassemble Correctly.
page 6-55.
See “Inspection of Crankshaft and
Worn Crankpin and Journal Bearing O O O O O O Measure and Replace. Camshaft Components” on
page 6-46.
Engine System - Continued
Loose Connecting Rod Bolt O O O Tighten to the Specified Torque. See “” on page 6-14.
Foreign Matter Trapped in Combustion See “Disassembly of Cylinder
O O O O Disassemble and Repair.
Chamber Block Components” on page 6-37.
See “Checking Timing Gear
Excessive Gear Backlash O Adjust Gear Meshing.
Backlash” on page 6-38.
See “Inspection of Valve Guides”
Worn Intake/Exhaust Valve Guide O O O Measure and Replace.
on page 6-26.
See “Check and Adjust the
Governor Adjusted Incorrectly O O O O O Make Adjustment. Governor Lever and Engine
Speed Control” on page 5-27.
Improper Open/Close Timing of Intake/ See “Measuring and Adjusting
O O O O O O Adjust the Valve Clearance.
Exhaust Valves Valve Clearance” on page 6-34.
Poor
Pressure Drop
Pressure Rise
Oil with Water
During Idling
Overheat
Ordinary
Cause
White
White
Black
Black
Much
None
Little
See “Disassembly of Engine
Excessive Radiator Cooling O O O Replace Thermostat.
Coolant Pump” on page 8-7.
See “Disassembly of Engine
Replace Thermostat or Check for Coolant Pump” on page 8-7. or
Engine Coolant System
Poor
Pressure Drop
Pressure Rise
Oil with Water
During Idling
Overheat
Ordinary
Cause
White
White
Black
Black
Much
None
Little
See “Checking and Adjusting Fuel
Too Early Timing of Fuel Injection Pump O O O Check and Adjust.
Injection Timing” on page 7-19.
See “Checking and Adjusting Fuel
Too Late Timing of Fuel Injection Pump O O O O Check and Adjust.
Injection Timing” on page 7-19.
See “Diesel Fuel Specifications”
Incorrect Diesel Fuel O O O O O O Use Correct Fuel Oil.
on page 4-9.
Fuel System
Poor
Pressure Drop
Pressure Rise
Oil with Water
During Idling
Overheat
Ordinary
Cause
White
White
Black
Black
Much
None
Little
See “Priming the Fuel System” on
Air in Fuel System O O O Bleed the Air.
page 4-12.
See “Check and Replace Fuel
Clogged or Cracked Fuel Line O O O Clean or Replace. Hoses and Engine Coolant
Hoses” on page 5-37.
Check the Fuel Tank Cock, Fuel
Insufficient Fuel Supply to Fuel Injection See the appropriate procedure in
O O O Filter, Fuel Line, and Fuel Feed
Pump Periodic Maintenance on page 5-1
Pump.
Fuel System
Poor
Pressure Drop
Pressure Rise
Oil with Water
During Idling
Overheat
Ordinary
Cause
White
White
Black
Black
Much
None
Little
See “Clean Air Cleaner Element”
Air/Exhaust Gas System
Starting Motor Defect O Repair or Replace Stater Motor. See “Starter Motor” on page 10-9.
Electrical System
ELECTRIC WIRING
Note: The following wiring diagram is “representative” of a common installation using a Yanmar engine. The actual installation may be equipped with a variety of electrical components and wiring harnesses. Contact the machine
manufacturer for specific information.
EMERGENCY
STOP
SWITCH*
YAZAKI NO.
LA206 7122 - 3016
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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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