Workshop Manual E 00

INTRODUCTION
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
• This manual consists of two portions:

the Technical Manual and the Workshop Manual.
Use the manuals according to purpose.
• Information included in the Technical Manual: • 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
• Each page has a number, located on the center

lower part of the page, and each number contains
the following information:
Example : T 1-3-5
Consecutive Page Number for Each Group

Group Number
Section Number
T: Technical Manual W: Workshop Manual
IN-01
INTRODUCTION
SAFETY ALERT SYMBOL AND HEADLINE
NOTATIONS
In this manual, the following safety alert symbol and • 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
• These are the SAFETY ALERT SYMBOLS.
• When you see these symbols on your machine or in

this manual, be alert to the potential for personal in-
jury.
• Follow recommended precautions and safe operating
practices.
SA-688
UNDERSTAND SIGNAL WORDS
• On machine safety signs, signal words designating the

degree or level of hazard - DANGER, WARNING, or
CAUTION - are used with the safety alert symbol.
• DANGER indicates an imminently hazardous situation

which, if not avoided, will result in death or serious in-
jury.
• WARNING indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury.
• CAUTION indicates a potentially hazardous situation
which, if not avoided, may result in minor or moderate
injury.
• DANGER or WARNING safety signs are located
near specific hazards. General precautions are listed
on CAUTION safety signs.
• Some safety signs don’t use any of the designated
signal words above after the safety alert symbol are
occasionally used on this machine.
SA-1223
• To avoid confusing machine protection with personal
safety messages, a signal word IMPORTANT indicates a
situation which, if not avoided, could result in damage to
the machine.
• NOTE indicates an additional explanation for an

element of information.
SA-1
SAFETY
FOLLOW SAFETY INSTRUCTIONS
• Carefully read and follow all safety signs on the machine

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

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

service, hospitals, and fire department posted near
your telephone.
SA-2
SAFETY
WEAR PROTECTIVE CLOTHING
• Wear close fitting clothing and safety equipment appro-

priate to the job.
You may need:

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

Be sure to wear the correct equipment and clothing
for the job. Do not take any chances.
• Avoid wearing loose clothing, jewelry, or other items

that can catch on control levers or other parts of the
machine.
• Operating equipment safely requires the full attention of
the operator.
• Do not wear radio or music headphones while oper-

ating the machine.
PROTECT AGAINST NOISE
• Prolonged exposure to loud noise can cause impairment

or loss of hearing.
• Wear a suitable hearing protective device such as

earmuffs or earplugs to protect against objectionable
or uncomfortably loud noises.
SA-434
INSPECT MACHINE
• If any abnormality is found, be sure to repair it immedi-

ately before operating the machine.
• In the walk-around inspection, be sure to cover all

points described in the “PRE-START INSPECTION”
chapter in the operator’s manual.
SA-435
SA-3
SAFETY
USE HANDHOLDS AND STEPS
• Falling is one of the major causes of personal injury.
• When you get on and off the machine, always face the
machine.
• Maintain a three-point contact with the steps and
handrails.
• Do not use any controls as handholds.
• Never jump on or off the machine. Never mount or
dismount a moving machine.
• In case adhered slippery material such as oil, grease,
or mud is present on steps, handrails, or platforms, SA-439
thoroughly remove such material.
FASTEN YOUR SEAT BELT

(ROLL BAR EQUIPPED MACHINES)
• If the machine should overturn, the operator may be-

come injured and/or thrown from the cab. Additionally
the operator may be crushed by the overturning machine,
resulting in serious injury or death.
• Be sure to remain seated with the seat belt securely

fastened whenever operating the machine.
• Prior to operating the machine, thoroughly examine
webbing, buckle and attaching hardware. If any item is
damaged or worn, replace the seat belt or component
before operating the machine. Replace the seat belt at SA-237
least once every 3 years regardless of appearance
SA-4
SAFETY
MOVE AND OPERATE MACHINE SAFELY
• Always be aware that there is a potential danger around

the machine while operating the machine.
• Take extra care not to run over bystanders. Confirm

the location of bystanders before moving, swinging, or
operating the machine.
• Always keep the travel alarm and horn in working
condition (if equipped).
• Before starting to move or operate the machine, sound
the travel alarm and horn to alert bystanders.
• Use a signal person when moving, swinging, or oper-
ating the machine in congested areas. Locate the SA-611
signal person so that the operator can always witness
the signal person.
• Coordinate the meanings of all safety signs, hand
signals and marks before starting the machine. Ap-
point a person who is responsible to make a signal
and/or guidance.
• Never allow any persons or obstacles to enter the
machine operation areas.
• Use appropriate illuminations.
SA-5
SAFETY
OPERATE ONLY FROM OPERATOR'S SEAT
• Inappropriate engine starting procedures may cause the

machine to runaway, possibly resulting in serious injury
or death.
• Start the engine only when seated in the operator's

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

ers are in neutral.
JUMP STARTING
• Failure to follow correct jump starting procedures could

result in a battery explosion or a runaway machine.
• If the engine must be jump started, be sure to follow

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

struck by foreign objects and being thrown off the
machine.
• Riders also obstruct the operator’s view, resulting in

the machine being operated in an unsafe manner.
• Only allow the operator is allowed on the machine.
Keep riders off.
SA-612
SA-6
SAFETY
INVESTIGATE JOB SITE BEFOREHAND
• When working at the edge of an excavation or on a road

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

the job site beforehand to prevent the machine from
falling and to prevent the ground, stockpiles, or banks
from collapsing.
• Make a work plan. Use machines appropriate to the
work and job site.
• Reinforce ground, edges, and road shoulders as
necessary. Keep the machine well back from the
edges of excavations and road shoulders.
• When working on an incline or on a road shoulder,
SA-613
employ a signal person as required.
• Never allow bystanders to enter the working area such
as swing radius or traveling range.
• When the footing is weak, reinforce the ground before
starting work.
• When working on frozen ground, be extremely alert.
As ambient temperatures rise, footing may become
loose and slippery.
• When operating the machine near open flame, sparks,
and/or dead grass, a fire may easily break out. Use
special care not to cause a fire.
SA-7
SAFETY
PROVIDE SIGNALS FOR JOBS INVOLVING
MULTIPLE NUMBERS OF MACHINES
• In case more than one machine is operated in the same

job site, accidental collision between machines may
cause serious injury or death.
• For jobs involving multiple numbers of machines, provide

signals commonly known by all personnel involved. Also,
appoint a signal person to coordinate the job site. Make
sure that all personnel obey the signal person’s direc-
tions.
SA-481
CONFIRM DIRECTION OF MACHINE TO BE

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

ous injury death.
• Before driving the machine, confirm the position of the

undercarriage in relation to the operator’s position.
• If the travel motors are located towards the front of the
cab, the machine will move in the reverse direction
when travel pedals/levers are operated.
SA-614
SA-8
SAFETY
DRIVE MACHINE SAFELY
• Driving the machine in the incorrect direction may result

in serious injury or death and/or severe damage to
property.
• Before moving the machine, confirm which way to

move travel pedals/levers for the corresponding di-
rection you wish to travel.
• Avoid passing over any obstructions. Failure to do so

may cause soil, rock fragments and/or metal pieces to
SA-615
be scatter around the machine. Keep bystanders away
from the machine.
• Traveling on a grade may cause the machine to slip or to
overturn, possibly resulting in serious injury or death.
• When traveling up or down a grade, keep the bucket in

the direction of travel, approximately 100 to 200 mm
(3.9 to 7.9 in) (A) above the ground so that lowering
the bucket onto the ground can quickly stop the ma-
chine.
• If machine starts to skid or becomes unstable, lower
the bucket immediately.
• Traveling across the face of slope or steering on a SA-616
slope may cause the machine to skid or to turnover. If

the direction must be changed on a slope, first move
the machine to level ground, then, change the travel-
ing direction to ensure safe operation.
SA-441
SA-442
SA-9
SAFETY
AVOID INJURY FROM ROLLAWAY ACCI-
DENTS
• Death or serious injury may result if you attempt to

mount or try to bodily stop a moving machine.
• Park the machine in compliance with the safe parking

procedures described on page S-16 to prevent the ma-
chine from running away.
• Block both tracks and lower the bucket to the ground,

thrust the bucket teeth into the ground if you must park
on a grade.
• Park a reasonable distance from other machines.
SA-617
SA-10
SAFETY
AVOID INJURY FROM BACK-OVER AND
SWING ACCIDENTS
• If any person is present near the machine when backing

or swinging the upperstructure, the machine may hit or
run over that person, resulting in serious injury or death.
To avoid back-over and swing accidents:

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

• Learn the meanings of all flags, signs, and markings
used on the job and confirm who has the responsibility
for signaling.
• Keep windows, mirrors, and lights clean and in good
condition.
• Dust, heavy rain, fog, etc., can reduce visibility. As
visibility decreases, reduce speed and use proper
lighting.
• Read and understand all operating instructions in the
operator’s manual.
021-E01A-0494-8
SA-11
SAFETY
KEEP PERSONNEL CLEAR FROM WORKING
AREA
• If a person is present near the operating machine, the

person may come in contact with the swinging front
attachment or counterweight and/or may be crushed
against an other object, resulting in serious injury or
death.
• Before operating the machine, set up barriers to the

sides and rear area of the bucket swing radius to
prevent anyone from entering the work area.
• Make sure that no personnel other than the signal
person or no obstacles are present in the working area
before operating the machine.
SA-618
NEVER POSITION BUCKET OVER ANYONE
• Never lift, move, or swing bucket above anyone or a

truck cab.
Serious injury or machine damage may result due to
bucket load spill or due to collision with the bucket.
• Never allow the bucket to pass over anyone to avoid

personal injury or death.
SA-619
AVOID UNDERCUTTING
• In order to retreat from the edge of an excavation if the

footing should collapse, always position the
undercarriage perpendicular to the edge of the
excavation with the travel motors at the rear.
• If the footing starts to collapse and if retreat is not

possible, do not panic raise the front attachment with a
panic. Lowering the front attachment may be safer in
most cases.
SA-620
SA-12
SAFETY
AVOID TIPPING
• The danger of tipping is always present when operating

on a grade, possibly resulting in serious injury or death.
To avoid tipping:
• Be extra careful before operating on a grade.
• Prepare machine operating area flat.

• Keep the bucket low to the ground and close to the
machine.
• Reduce operating speeds to avoid tipping or slipping.
• Avoid changing direction when traveling on grades.
• NEVER attempt to travel across a grade steeper than SA-621
15 degrees if crossing the grade is unavoidable.

• Reduce swing speed as necessary when swinging
loads.
• Be careful when working on frozen ground.
• Temperature increases will cause the ground to

become soft and make ground travel unstable.
025-E01A-0540-4
NEVER UNDERCUT A HIGH BANK
• The edges could collapse or a land slide could occur

causing serious injury or death.
SA-622
SA-13
SAFETY
DIG WITH CAUTION
• Accidental severing of underground cables or gas lines

may cause an explosion and/or fire, possibly resulting in
serious injury or death.
• Before digging check the location of cables, gas lines,

and water lines.
• Keep the minimum distance required, by law, from
cables, gas lines, and water lines.
• If a fiber optic cable should be accidentally severed,
do not look into the end. Doing so may result in SA-262
serious eye injury.
• Contact your local “diggers hot line” if available in your
area, and/or the utility companies directly.
Have them mark all underground utilities.
OPERATE WITH CAUTION
• If the front attachment or any other part of the machine

hits against an overhead obstacle, such as a bridge,
both the machine and the overhead obstacle will be
damaged, and personal injury may result as well.
• Take care to avoid hitting overhead obstacles with the

boom or arm.
SA-263
AVOID POWER LINES
• Serious injury or death can result if the machine or front

attachments are not kept a safe distance from electric
lines.
• When operating near an electric line, NEVER move

any part of the machine or load closer than 3 m (10 ft)
plus twice the line insulator length.
• Check and comply with any local regulations that may
apply.
• Wet ground will expand the area that could cause any
SA-265
person on it to be affected by electric shock. Keep all
bystanders or co-workers away from the site.
SA-14
SAFETY
DO NOT USE FOR CRANING OPERATIONS
• NEVER use the machine for craning operations. If the

machine is used for craning operations, the machine
may tip over and/or lifted load may fall, possibly resulting
in serious injury or death.
• This machine has been exclusively designed to engage
in excavation and loading works.
• This machine is not equipped with any of the necessary
safety devices that could allow the machine to be used
for craning operation.
SA-014
PROTECT AGAINST FLYING DEBRIS
• If flying debris such as soil, rock fragments or metal

pieces hit eyes or any other part of the body, serious
injury may result.
• Guard against such injuries when working in a job site

where possibility of flying pieces of metal or debris
exist, or when removing or installing pins using a
hammer; wear goggles or safety glasses.
• Keep bystanders away from the working area before
striking any object.
SA-432
SA-15
SAFETY
PARK MACHINE SAFELY
• Unless the machine is not correctly parked, any

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

machine from running away.
• Lower the bucket and/or blade to the ground.
• Pull the lock lever to the LOCK position.
SA-623
• Run engine at slow idle speed without load for 5
minutes.
• Turn key switch to OFF to stop engine. Remove the
key from the key switch.
• Before leaving the machine, close all windows, roof
vent, and cab door. Lock all access doors and
compartments
HANDLE FLUIDS SAFELY --- AVOID FIRES
• Handle fuel with care; it is highly flammable. If fuel

ignites, an explosion and/or a fire may occur, possibly
resulting in serious injury or death.
• Do not refuel the machine while smoking or when near

open flame or sparks.
• Always stop the engine before refueling the machine.
• Fill the fuel tank outdoors.
• All fuels, most lubricants, and some coolants are

flammable. SA-018
• Store flammable fluids well away from fire hazards.

• Do not incinerate or puncture pressurized containers.
• Do not store oily rags; they can ignite and burn
spontaneously.
SA-019
SA-16
SAFETY
SAFETY TRANSPORTING
• The danger of tipping is present when loading/unloading

the machine onto/from a truck or trailer bed.
• Be sure to observe local regulations when transporting

the machine on public roads.
• Provide an appropriate truck or trailer for transporting SA-624
the machine.
• Be sure to have a signal person.
• Take the following precautions when
loading/unloading the machine.
1. Select firm level ground.
2. Be sure to use a loading dock or ramp strong enough
to support the machine weight.
3. Ramps must be sufficient in width, length, and
strength. Be sure that the incline of the ramp is less
than 15 degrees.
4. Loading docks must be sufficient in width and
strength to support the machine and have a gradient
of less than 15 degrees.
5. Slowly drive the machine.
6. Avoid steering while driving up or down the ramp as it
is extremely dangerous. If steering is unavoidable,
first move back to the ground or flatbed, modify
traveling direction, and begin to drive again.
7. The top end of the ramp where it meets the flatbed is
a sudden bump. Take care when traveling over it.
8. Wedge the front and rear of tracks. Securely fasten
the machine to the trailer bed with chain or cables.
9. Do not operate any levers besides the travel levers
when driving up or down the ramp.
10. Prevent possible injury from machine tipping while the
upperstructure is rotating.
11. Keep the arm tucked under and rotate the
upperstructure slowly for best stability.
Refer to "transporting" chapter in this manual for details
SA-17
SAFETY
PRACTICE SAFE MAINTENANCE
• Inspection/maintenance work may produce hazardous

situations by contacting and/or accessing a part of body
to a moving, high pressure, and/or high temperature part
of the machine. To avoid serious personal injury or death,
follow the instructions described below.
• Thoroughly coordinate the working procedures to be
taken hereafter with the co-workers before beginning
work such as inspecting/servicing the machine, or
replacing the attachiment .
• Safely park the machine in accordance with the
instructions for “Park Machine Safely.”
• Keep the work area clean and orderly.
• Attach a “DO NOT OPERATE” tag in an easy-to-see
SA-028
location such as on a door or a control lever.
• If moisture permeates into the electrical system,
malfunction and/or erroneous movement of the
machine may result. Do not clean sensors, cable
connectors, and the cab inside using water and/or
steam.
• Wait to begin to work until the engine and hydraulic oil
temperatures have cooled down to the safety range.
• In case inspection/maintenance must be performed 90 to 110°
with the engine runnning, be sure to appoint an
overseer.
• Never lubricate or service the machine while moving it.
• Repair the cracked windowpane before servicing the
machine. Failure to do so may cause personal injury. SA-268
• Whe raising the machine above the ground using the

front attachment function, maintain the angle between
the boom and the arm in the range of 90 to 110°.
Never allow anyone to enter under the machine raised
with the front attachment function.
• In case working under the machine raised above the
ground is unavoidably required, securely hold the
machine with stays or blocks strong enough to support
the machine weight.
• Never work under the raised bucket.
• Keep all parts in good condition and properly installed.
• Always use the specified tools correctly.
• Always use a clean tool.
• Fix any damage found immediately. Replace worn or SA-527
broken parts.
• Remove any buildup of grease, oil, or debris.
• When cleaning parts, use a non-combustible cleaning
solvent. Never use an inflammable fluid such as
dieasel fuel, or gasoline.
SA-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
WARN OTHERS OF SERVICE WORK
• Unexpected machine movement can cause serious

injury.
• Before performing any work on the machine, attach a

“Do Not Operate” tag in an easy-to-see place such as
on the cab door or control lever.
• Never attempt to operate the machine with a “Do Not
Operate” tag attached.
• Make it a rule for the inspection/service person to hold
the engine start key during inspection/service work.
SA-287
SUPPORT MACHINE PROPERLY
• Never attempt to work on the machine without securing

the machine first.
• Always lower the attachment to the ground before you

work on the machine.
• If you must work on a lifted machine or attachment,
securely support the machine or attachment with stays
or blocks strong enough to support the machine
and/or attachment weight.
SA-527
SA-19
SAFETY
STAY CLEAR OF MOVING PARTS
• Contact with moving parts can cause serious injury or

death due to amputation or entanglement.
• To prevent accidents, care should be taken to ensure

that hands, feet, clothing, jewelry and hair do not
become entangled when working around rotating
parts.
SA-026
PREVENT PARTS FROM FLYING
• Grease in the track adjuster is under high pressure.

Failure to follow the precautions below may result in
serious injury, blindness, or death.
• Do not attempt to remove GREASE FITTINGS or

VALVE ASSEMBLIES.
• As pieces of parts may fly off, be sure to keep body
and face away from the valve.
• Travel reduction gears are under pressure.

SA-344
• GEAR OIL is hot. Wait for gear oil to cool, then

gradually loosen the air release plug to release
pressure.
• As pieces of parts may fly off, be sure to keep body
and face away from AIR RELEASE PLUG to avoid
injury.
SA-20
SAFETY
STORE ATTACHMENTS SAFELY
• Stored attachments such as buckets, hydraulic hammers,

and blades can fall and cause serious injury or death.
• Securely store attachments and implements to prevent

falling accidents.
• Keep children and bystanders away from storage
areas.
SA-034
PREVENT BURNS
Hot spraying fluids:

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

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

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

• Engine oil, gear oil and hydraulic oil also becomes hot
during operation.
The engine, hoses, lines and other parts become hot as
well.
• Wait for the oil and components to cool before starting

any maintenance or inspection work.
SA-225
SA-21
SAFETY
REPLACE RUBBER HOSES PERIODICALLY
• Rubber hoses that contain flammable fluids such as

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

Periodical Replacement Parts section.)
• Failure to periodically replace rubber hoses may cause a

fire, fluid injection into skin, or the front attachment to fall
SA-019
on a person nearby, which may result in severe burns,
gangrene, or otherwise serious injury or death.
AVOID HIGH-PRESSURE FLUIDS
• Fluids such as diesel fuel or hydraulic oil under pressure

can penetrate the skin or eyes causing serious injury,
blindness or death.
• Avoid this hazard by relieving pressure before

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

Wear a face shield or goggles for eye protection.
• If an accident occurs, see a doctor familiar with this
type of injury immediately. Any fluid injected into the
skin must be surgically removed within a few hours or
gangrene may result.
SA-292
SA-044
SA-22
SAFETY
PREVENT FIRES
Check for Oil Leaks:

• Fuel, hydraulic oil and lubricant leaks can lead to fires,
possibly resulting in personal injury or death.
• Check for missing or loose clamps, kinked hoses,

lines or hoses that rub against each other, damage to
the oil-cooler, and loose oil-cooler flange bolts, for oil
leaks.
• Tighten, repair or replace any missing, loose or
damaged clamps, lines, hoses, oil-cooler and SA-019
oil-cooler flange bolts.
• Do not bend or strike high-pressure lines.
• Never install bent or damaged lines, pipes or hoses.
Check for Shorts:

• Short circuits can cause fires.
• Clean and tighten all electrical connections.

• Check before each shift or after eight (8) to ten (10)
hours operation for loose, kinked, hardened or frayed
electrical cables and wires.
• Check before each shift or after eight (8) to ten (10)
hours operation for missing or damaged terminal caps.
• DO NOT OPERATE MACHINE if cable or wires are
loose, kinked, etc.
SA-23
SAFETY
Precautions for Handling Flammables
• Spilled fuel and oil, and trash, grease, debris,
accumulated coal dust, and other flammables may
cause fires.
• Prevent fires by inspecting and cleaning the machine

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

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

broken or lost, repair or replace it before operating the
machine.
Check Key Switch:

• If fire breaks out, failure to stop the engine will escalate
the fire, hampering fire fighting.
• Always check key switch function before operating the

machine every day:
1) Start the engine and run it at slow idle.
2) Turn the key switch to the OFF position to confirm
that the engine hasstopped.
If any abnormalities are found, be sure to repair
them before operating the machine.
SA-24
SAFETY
EVACUATING IN CASE OF FIRE
• If fire breaks out during machine operation, evacuate the

machine in the following way:
• Stop the engine by turning the key switch to the OFF

position.
• Use a fire extinguisher if there is time.
• Exit the machine using handrails and/or steps.
SA-393
BEWARE OF EXHAUST FUMES
• Prevent asphyxiation. Engine exhaust fumes can cause

sickness or death.
• If you must operate the machine in a building, be sure

there is adequate ventilation. Either use an exhaust
pipe extension to remove the exhaust fumes or open
doors and windows to bring enough outside air into the
area.
SA-016
SA-25
SAFETY
PRECAUTIONS FOR WELDING AND
GRINDING
• Welding may generate gas and/or small fires.
• Be sure to perform welding in a well ventilated and

prepared area. Store flammable objects in a safe
place before starting welding.
• Only qualified personnel should perform welding.
Never allow an unqualified person to perform welding.
• Grinding on the machine may create a fire hazard. Store
flammable objects in a safe place before starting
grinding.
• After finishing welding and grinding, recheck that there SA-818
are no abnormalities such as the area surrounding the

welded area still smoldering.
AVOID HEATING NEAR PRESSURIZED FLUID

LINES
• Flammable spray can be generated by heating near

pressurized fluid lines, resulting in severe burns to
yourself and bystanders.
• Do not heat by welding, soldering, or using a torch

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

CONTAINING FLAMMABLE FLUIDS
• Do not weld or flame cut pipes or tubes that contain

flammable fluids.
• Remove flammable fluids thoroughly with
nonflammable solvent before welding or flame cutting
pipes or tubes that contained flammable fluids.
SA-26
SAFETY
REMOVE PAINT BEFORE WELDING OR
HEATING
• Hazardous fumes can be generated when paint is

heated by welding, soldering, or using a torch. If inhaled,
these fumes may cause sickness.
• Remove paint before welding or heating.

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

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

Securely tighten all terminals.
• Battery electrolyte is poisonous. If the battery should

explode battery electrolyte may be splashed into eyes,
possibly resulting in blindness. If electrolyte is splashed
into eyes, flush your eyes continuosly with water for
about 15 minutes. Seek medical attention immediately.
• Be sure to wear eye protection when checking

electrolyte specific gravity.
SA-27
SAFETY
PRECAUTIONS FOR HANDLING
REFRIGERANT
• If refrigerant is splashed into eyes or spilled onto skin,

blindness or a cold contact burn may result.
• Refer to the precautions described on the refrigerant

container for handling refrigerant.
• Use a recovery and recycling system to avoid venting
refrigerant into the atmosphere.
• Never allow the skin to directly come in contact with
refrigerant.
SA-405
HANDLE CHEMICAL PRODUCTS SAFELY
• Direct exposure to hazardous chemicals can cause

serious injury. Potentially hazardous chemicals used with
your machine include such items as lubricants,
electrolyte, coolants, paints, and adhesives.
• A Material Safety Data Sheet (MSDS) provides

specific details on chemical products: physical and
health hazards, safety procedures, and emergency
response techniques.
• Check the MSDS before you start any job using a
hazardous chemical. Then follow the correct
procedures and use recommended equipment. SA-309
• See your nearest Hitachi dealer for MSDS.
DISPOSE OF WASTE PROPERLY
• Improperly disposing of waste can threaten the

environment and ecology. Potentially harmful waste
used with HITACHI equipment includes such items as oil,
fuel, coolant, brake fluid, filters, and batteries.
• When draining fluid, use a leakproof container with a

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

batteries from your local environmental or recycling
center.
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
Group 4 Bleeding Air

Bleed Air from Hydraulic Oil Tank ........... W1-4-1
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
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.
IMPORTANT: If the engine is started when air is

trapped in the hydraulic pump and
there is no hydraulic oil in it, the
pump may be damaged.
If the hydraulic motor is operated
when air is trapped in it and there is
no hydraulic oil in it, the motor may
be damaged.
If the cylinder is operated abruptly
when air is trapped in the cylinder
tube and there is no hydraulic oil in
it, the seal may be damaged or the
cylinder may be stuck.
Be sure to bleed air before starting
the engine.
• Bleeding Air from Hydraulic Pump

• Remove the air bleeding plug from top of the
pump. Then, fill the pump with hydraulic oil.
• After the pump is filled with hydraulic oil, tempo-
rarily tighten the plug. Then, start the engine and
run at slow idle speed.
• Slightly loosen the plug and bleed air from the
pump until hydraulic oil oozes out.
• After bleeding all air, securely tighten the plug.
• Bleeding Air from Travel Motor / Swing Motor

• Remove the air bleeding plug (upper) from travel
motor and swing motor. Then, fill the motor case
with hydraulic oil.
W1-1-2
• 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
level. Replenish oil as necessary.
W1-1-3
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.
2. If incorrectly assembled, oil leakage or damage

will occur. Be sure to do the following to prevent
trouble.
(1) Clean the seal mounting bores.
Use a wire brush in order to remove mud,
rust or dirt from the mounting bores.
(After cleaning, thoroughly dry the parts.)
(2) Clean the mounting bores of seal ring (A) or Correct
O-ring (B). Check the bore surface for scuff- C
ing or scoring. O-Ring
(Check by touching the seal surface by fin- Twist
gers). Incorrect
(3) After installing to seal ring (A), check that O-Ring
O-ring (B) is not twisted and deformed. Bend
(4) Check that seal ring sliding surface (C) is
parallel with seal mounting surface (D) and
O-ring (B) by measuring the distance (A) and W105-03-05-020
(D) at point (a) and (b) as illustrated. If these D

distance differ, correct the O-ring seating. Correct Incorrect
a a
b b
a=b a≠b
W110-03-05-004
W1-1-4
Precautions for Nylon Sling
1. Follow the precautions below in order to use the

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

• When lifting a load by using an eyehole (refer to Incorrect Eyebolt
Lifting Method
the right illustration), be sure to eliminate any
gaps between the sling and load. Reduce the
load weight so that it is less than 80 % of the
sling breaking force.
• Avoid using twisted, bound, connected or hitched
slings.
• Do not place any object on twisted or bent slings
(refer to the right illustration).
• When removing the slings from under the load,
do not damage the nylon slings. Avoid contact
with protrusions.
• Avoid dragging the nylon slings on the ground, W105-04-01-008
throwing the nylon slings or pushing the nylon

slings with a metal object.
• When using with other types of slings (wire rope)
or accessories (shackle) together, protect the
joint so that the nylon sling is not damaged.
• Store the nylon slings indoors so they may not
deteriorate with heat, sun light or chemicals.
Bent Sling
W162-01-01-009
W1-1-5
Broken Sewing Thread

CAUTION: If a load is lifted by using a dam- Damaged Appearance
aged nylon sling, serious personal injury may
result. Visually check the nylon sling for any
damage before using.
2. Before using a nylon sling, visually check the ny-

lon sling for any damage corresponding to exam- W162-01-01-002
Scuffing
ples shown to the right. If an corresponding
damage is found, cut and discard the nylon sling.
Even if no damage is found, do not use the nylon
slings older than 7 years.
W162-01-01-003
Fuzz
Broken Sewing 
Thread
W162-01-01-004
Broken Sewing
Thread
W162-01-01-005
Broken Sewing
Thread
Separation of
Belt W162-01-01-006
Scoring
W162-01-01-007
Scuffing
Fuzz
Broken Warp
W162-01-01-008
W1-1-6
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
(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)
NOTE: 1: Apply lubricant to the bolts and nuts in

order to reduce friction coefficient of
them.
(Example: white zinc B dissolved into
Spindle oil)
2: Remove rust, dirt and dust before in-
stalling fasteners.
W1-2-1
TIGHTENING BOLTS AND NUTS
CAUTION: Use tools appropriate for the

work to be done. Makeshift tools and proce-
dures can create safety hazards. For loosen-
ing and tightening nuts and bolts, use cor-
rect size tools. Otherwise, tightening tools
may slip, potentially causing personal injure.
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.
Specified Tightening Torque Chart
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
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
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
5. Do not use air wrenches. Using an

impact wrench often causes
tightening of one bolt fully before
tighten the others, resulting in
damage to O-rings or uneven
tightening of bolts.
W105-01-01-008
Nut and Bolt Locking
• Lock Plate
IMPORTANT: Do not reuse the lock plates. Do not Correct Incorrect
try to bend the same point twice.
• 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
use the wire.
Correct Correct Incorrect
Correct
Loosen Incorrect
Tighten
W105-01-01-010
W1-2-4
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.
IMPORTANT: 1. Do not over-tighten union nut (3).

Excessive force will be applied to
metal sealing surfaces (4) and (5),
possibly cracking the adaptor.
Tighten union nut (3) to the speci-
fications. Joint Body
2. Scratches or other damage to M202-07-051
sealing surfaces (4) or (5) will

cause oil leakage at the joint. Take
care not to damage them when 37°
connecting / disconnecting.
30°
Male Union Joint Female Union Joint

W105-01-01-017
Wrench Size Wrench Size Tightening Torque

Description mm mm
Union Nut Hose Fittings N⋅m (kgf⋅m, lbf⋅ft)
30°male 17 17 24.5 (2.5, 18)
19 19 29.5 (3.0, 22)
22 22 39 (4.0, 29)
27 27 78 (8.0, 58)
32 32 137 (14, 101)
36 36 175 (18, 129)
41 41 205 (21, 151)
37°female 17 14 24.5 (2.5, 18)
19 17 29.5 (3.0, 22)
22 19 39 (4.0, 29)
27 22 78 (8.0, 58)
32 27 137 (14, 101)
36 32 175 (18, 129)
41 36 205 (21, 151)
NOTE: Tightening torque of 37° male coupling with-
out union is similar to tightening torque of
37° female
W1-2-5
Pipe joint
Pipe connection (metal joint)
(Union Nut Wrench Size: 17)
Metal (3) of adaptor (1) and hose (2) seals pressure oil.
• Precautions for use 1 4 5 3 2

Do not damage sealing surfaces (4) and (5) when
disassembling and assembling.
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)
O-ring Seal Joint

O-ring (6) is installed against the end face of adapter
(7) and seals pressure oil.
IMPORTANT: 1. Replace O-ring (6) with a new one

when reinstalling.
2. Before tightening union nut (9),
confirm that O-ring (6) is seated
correctly in O-ring groove (8).
Tightening union nut (9) with 7 6 9
O-ring (6) displaced will damage
O-ring (6), resulting in oil leakage.
3. Do not damage O-ring groove (8)
of adapter (7) or sealing surface
(10) on the hose side. Damage to
O-ring (6) may cause oil leakage.
4. If union nut (9) is found to be
8 1 Joint Body
loose, causing oil leakage, do not
tighten it to stop the leak. Instead, M104-07-033
replace O-ring (6) with a new one,

then tighten union nut (9) after Wrench Size Tightening Torque
confirming that O-ring (6) is se- mm
curely seated in O-ring groove (8). Union Nut N⋅m (kgf⋅m, lbf⋅ft)
19 44 (4.5, 32.5)
22 74 (7.5, 55)
24 78 (8.0, 58)
27 103 (10.5, 76)
W1-2-6
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
Screw-In Connection PT PF
Depending on types of screw and sealing, different 30°
types of screw-in connection are used.
IMPORTANT: Check that the thread pitch and

thread type (tapered or straight) are
the correct type before using any
Male Tapered Thread Male Straight Thread
screw-in connection.
(In general, the screw-in connection W105-01-01-018
of male tapered thread is used ex-
cept for measurement purpose.) Male Tapered Thread
Wrench Size Tightening Torque
mm N⋅m (kgf⋅m, lbf⋅ft)
Hose Fittings FC material SS material
19 14.5 (1.5, 10.5) 34 (3.5, 25)
22 29.5 (3.0, 22) 49 (5.0, 36)
27 49 (5.0, 36) 93 (9.5, 69)
36 69 (7.0, 51) 157 (16, 116)
41 108 (11, 80) 205 (21, 151)
50 157 (16, 116) 320 (32.5, 235)
60 195 (20, 144)
NOTE: Unit:Nxm (kgfxm)
Seal Tape Application
Seal tape is used in order to seal clearances be- Internal Thread
tween male and female threads so that any leaks
between threads may be prevented. Therefore, apply
just enough seal tape to fill up thread clearances. Do
not overwrap. External Clearance
Threadnal
• Application Procedure
W105-01-01-019
Check that the thread surface is clean and, free of Leave one to two pitch threads uncovered
dirt or damage. Apply the seal tape around threads
in order to leave one to two pitch threads uncovered.
Wrap the seal tape in the same direction as the
threads.
Low-Pressure-Hose Clamp Tightening

Low-pressure-hose clamp tightening torque differs
depending on the type of clamp.
M114-07-041
T-Bolt Type Band Clamp:
4.4 N⋅m (0.4 kgf⋅m, 3.2 lbf⋅ft)
T-Bolt Type Band Clamp Worm Gear Type Band Clamp
Worm Gear Type Band Clamp:
5.9 to 6.9 N⋅m (0.6 to 0.7 kgf⋅m, 4.4 to 5.1 lbf⋅ft)
M114-07-042
M114-07-043
W1-2-8
Connecting Hose
CAUTION: When replacing the hoses, use

only genuine Hitachi service parts. Using Incorrect Correct
hoses other than genuine Hitachi hoses may
cause oil leaks, hose rupture or separation of
fitting, possibly resulting in a fire on the ma-
chine.
Do not install hoses kinked. Application of

high oil pressure, vibration, or an impact to a
kinked hose may result in oil leaks, hose W105-01-01-011
rupture or separation of fitting. Utilize the

print marks on hoses when installing in order
to prevent hose from being kinked.
Incorrect Correct
Take necessary measures to protect hoses
Rubbing Against Each Other
from rubbing against each other. If the hoses
rub against each other, wear to the hoses
may result and lead to hose rupture.
Take care so that the hoses do not come into

contact with the moving parts or sharp ob- W105-01-01-012
jects.
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
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.
Periodic Replacement Parts Replacement Intervals

Engine Fuel hose (Fuel tank to filter) Every 2 years
Fuel hose (Fuel tank to injection pump) Every 2 years
Heater hose (Heater to engine) Every 2 years
Engine cushion rubber Every 5 years
Floor mount rubber Every 5 years
Pump Coupling Every 5 years
Hydraulic Basic Machine Pump suction hose Every 2 years
System Pump delivery hose Every 2 years
Swing hose Every 2 years
Spare hose Every 2 years
Oil cooler hose (Control Valve to oil
Every 2 years
cooler)
Front-End Boom cylinder line hose Every 2 years
Attachment Arm cylinder line hose Every 2 years
Bucket cylinder line hose Every 2 years
Pilot hose Every 2 years
NOTE: Replace O-rings and the gaskets when

replacing the hoses.
W1-2-10
GENERAL / Painting
PAINTING
Surfaces to Be Painted Painting Color

Main surface of upperstructure 3.4PB3.D/0.4 (SP-424)
[Resin covers are excluded.] [Dark Gray]
Swing post, swing cylinder
Counterweight
Canopy [including front panel]
Support, floor plate
[Resin covers are excluded.]
Track, blade 3.4PB3.D/0.4 (SP-424)

[Dark Gray]
Front, upperstructure cover part 0.5YR5.6/11.2(YR1-01)

[TAXI Yellow]
Control lever [travel, blade] N-10 [N1.0]

Left stay [Black]
TAXI Yellow Dark Gray

Paint parts excluding seats
and monitors
TAXI Yellow
Dark Gray
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 Black
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
CAUTION: Escaping fluid under pressure

may penetrate the skin and eyes, and cause
serious injury. Release the pressure before
removing hydraulic or other lines.
Hot hydraulic oil just after operation may
spout and cause severe burns. Do not start
any work until the oil cools down.
Do not turn the cap on hydraulic oil tank
quickly. The cap may fly off by internal pres-
sure. Release any remaining pressure and
remove the cap.
Preparation:
1. Park the machine on a solid, level surface. Lower
the front attachment onto the ground.
2. Stop the engine. Loosen cap (1) on hydraulic oil

tank (2) and release any remaining pressure.
M1M7-05-024
3. Remove cap (1) from hydraulic oil tank (2).
4. Install adapter (3) of vacuum pump to the cap (1)

hole. Operate the vacuum pump and maintain
negative pressure in hydraulic oil tank (2). 1
M1MS-07-013
Vacuum Pump
Hose
3
W1MP-01-04-001
W1-4-1
GENERAL / Bleeding Air
(Blank)
W1-4-2
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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
Group 2 Counterweight Group 7 Pilot Valve

Remove and Install Remove and Install Left Front
Counterweight ...................................... W2-2-1 Pilot Valve ............................................ W2-7-1
Remove and Install Right Front
Group 3 Main Frame Pilot Valve ............................................ W2-7-3
Remove and Install Remove and Install Travel
Main Frame .......................................... W2-3-1 Pilot Valve ............................................ W2-7-9
Remove and Install Blade
Group 4 Pump Device Pilot Valve .......................................... W2-7-12
Remove and Install Pump Device ........... W2-4-1
Remove and Install Boom Swing
Disassemble Pump Device ..................... W2-4-4
Pilot Valve .......................................... W2-7-16
Assemble Pump Device ......................... W2-4-6
Disassemble Front Pilot Valve .............. W2-7-20
Maintenance Standard.......................... W2-4-10
Assemble Right and Left Pilot Valves.... W2-7-24
Disassemble Travel Pilot Valve ............. W2-7-28
Group 5 Control Valve
Assemble Travel Pilot Valve ................. W2-7-32
Remove and Install
Disassemble Boom Swing, Blade
Control Valve ........................................ W2-5-1
and Auxiliary Pilot Valves .................... W2-7-38
Disassemble and Assemble Control Valve . W2-5-8
Assemble Boom Swing, Blade
Disassemble Body................................... W2-5-12
and Auxiliary Pilot Valves .................... W2-7-40
Assemble Body ....................................... W2-5-16
Disassemble Spool.................................. W2-5-20
Group 8 Solenoid Valve
Assemble Spool ...................................... W2-5-26
Remove and Install Solenoid Valve ......... W2-8-1
Disassemble and Assemble
Check Valve .......................................... W2-5-32
1MSW-2-1
(Blank)
1MSW-2-2
UPPERSTRUCTURE / Canopy
REMOVE AND INSTALL CANOPY
Removal
CAUTION: Canopy weight: 61 kg (134 lb) A
1. Attach a nylon sling onto brackets (A) (3used) of

canopy (1). Hold canopy (1).
1
2. Remove bolts (2) (4 used) from canopy (1).
Remove bolts (3) (3 used) and spacers (4) (3
used) from canopy (1).
: 17 mm, 19 mm
3. Hoist and remove canopy (1) from the main frame.
3 2
Installation
4
CAUTION: Canopy weight: 61 kg (134 lb)

W1MS-02-01-001
1. Hoist canopy (1). Align the holes for bolts (2) (4

used) and (3) (3 used) on the main frame and
canopy (1).
2. Apply LOCTITE #264 onto bolts (2) (4 used) and

bolts (3) (3 used). Install canopy (1) to the main
frame with bolts (2) (4 used), (3) (3 used) and
spacers (4) (3 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
: 19 mm
: 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft)
3. Remove the nylon sling from brackets (A) (3 used)

of canopy (1).
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.)
2. Remove bolts (1) (4 used) from cover (2). Remove 2

cover (2) from main frame (3).
: 17 mm
3. Remove plugs (4) (2 used) from counterweight

(6). 3
W1MS-02-05-017
CAUTION: The counterweight (6) assembly

weight: 265 kg (584 lb)
4 5
4. Install eyebolts (M14, Pitch 2mm) (2 used) into the
plug (4) holes (2 used) on counterweight (6). At-
tach a nylon sling onto eyebolts (2 used). Hoist
and hold counterweight (6).
10
5. Remove bolts (8) (2 used) and washers (7) (2 9
used) from the bottom side of main frame (3).
6
: 30 mm
6. Remove bolt (10) and washer (9) from counter-

weight (6).
: 30 mm
7. Remove bolts (5) (3 used) from counterweight (6).

: 17 mm
3
8. Hoist and remove the counterweight (6) assembly
from main frame (3).
NOTE: Remove the counterweight (6) assembly
with the rear cover and the hinge attached. 7
7
8
8
W1MS-02-02-001
W2-2-1
UPPERSTRUCTURE / Counterweight
Installation
1. Remove plugs (4) (2 used) from counterweight 4 5
(6).
CAUTION: The counterweight weight (6)

assembly: 265 kg (584 lb) 10
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. Hoist counterweight (6). Align the bolts (8) (2

used) and (10) holes on counterweight (6) and
main frame (3).
4. Install counterweight (6) to main frame (3) with

bolts (8) (2 used), (5) (3 used), (10), washers (7)
(2 used) and (9). 3
: 30 mm
: 400 N⋅m (40 kgf⋅m, 295 lbf⋅ft)
5. Remove the nylon sling and eyebolts (2 used) 7

7
from counterweight (6).
8
8
6. Install cover (2) onto main frame (3) with bolts (1)
W1MS-02-02-001
(4 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
7. Install canopy (1) to the machine. (Refer to the

Remove and Install Canopy group on W2-1-1.)
3
W1MS-02-05-017
W2-2-2
UPPERSTRUCTURE / Main Frame
REMOVE AND INSTALL MAIN FRAME
CAUTION: Release any pressure in the

hydraulic oil tank before doing any work.
(Refer to BLEED AIR FROM HYDRAULIC OIL
TANK on W1-4-1.)
Removal
CAUTION: The front attachment (1) assembly

1. Remove the front attachment (1) assembly.

(Refer to the Remove and Install Front Attachment
group on W4-1-1.)
1
W178-02-11-072
CAUTION: Canopy (2) weight: 61 kg (134 lb)
2. Remove canopy (2) from the main frame. (Refer

to the Remove and Install Canopy group on
W2-1-1.) 2
W1MS-02-03-005
3. Remove floor mat (3) from the main frame.
W1MS-02-05-014
W2-3-1
4. Remove bolts (5) (5 used) from cover (4). Remove
cover (4) from the main frame.
: 13 mm
W1MS-02-05-015
5. Remove hoses (6) (6 used) from center joint (7).

Cap the open ends. Attach an identification tag
onto hoses (6) (6 used).
: 19 mm
7 W1MS-02-03-001
6. Remove plugs (8) (2 used) from counterweight (9).

Install eyebolts (M16, Pitch 2 mm) into the plug (8)
holes (2 used) on counterweight (9).
W1MS-02-03-002
W2-3-2
7. Install pin (10) to swing post (11) with bolt (12) and
nut (13). 10
: 17 mm
CAUTION: Main frame weight: 950 kg

(2095 lb) 11
8. Attach a nylon sling onto eyebolts (2 used) and pin

(10). Hoist and hold the main frame in a level
condition.
W1MS-04-01-004
12, 13
9. Put the matching marks on the outer race (14) of

swing bearing and the main frame. Remove bolts
(15) (16 used) and washers (16) (16 used) from
outer race (14).
: 17 mm
9
(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
Installation

(2095 lb)
1. Hoist the main frame in a level condition. Align the 9

matching marks and the bolt (15) holes (16 used)
on outer race (14) in the swing bearing and the
main frame. 14
2. Install the main frame to outer race (14) in the 15, 16

swing bearing with bolts (15) (16 used) and
washers (16) (16 used).
: 17 mm
17
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft) W1MS-02-03-004
3. Remove the nylon sling from pins (10) in swing 10

posts (11) and eyebolts (2 used) in counterweight
(9) respectively.
11
W1MS-04-01-004
12, 13
4. Remove eyebolts (2 used) from counterweight (9).

Install plugs (8) (2 used).
W1MS-02-03-002
W2-3-4
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
7. Install floor mat (3) onto the main frame.
W1MS-02-05-014
W2-3-5
CAUTION: Canopy weight: 61 kg (134 lb)
8. Install canopy (2) to the main frame. (Refer to the

Remove and Install Canopy group on W2-1-1.)
W1MS-02-03-005
CAUTION: The front attachment (1) assembly

9. Install the front attachment (1) assembly to the

main frame. (Refer to the Remove and Install
Front Attachment group on W4-1-1.)
1
W178-02-11-072
W2-3-6
UPPERSTRUCTURE / Pump Device
REMOVE AND INSTALL PUMP DEVICE

hydraulic oil tank before doing any work
(Refer to BLEED AIR FROM HYDRAULIC OIL 1
TANK on W1-4-1.).
Removal 2
: 17 mm
3
W1MS-02-05-017
2. Operate the control lever and rotate main frame

(3) approximately 45 degrees to the left.
NOTE: Rotate main frame (3) so that cover (4)
below the pump device is located at the
center between the travel devices.
W1MS-02-04-003

: 17 mm 4
W1MS-02-04-004
W2-4-1
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
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
2. Install hose (11) to main pump (9) and secure with

13 8
band (10). Install hoses (8) (2 used) to main pump
(9). Install hoses (13) (2 used) to pilot pump (12).
: 22 mm 9
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft) 12
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 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft) 1
IMPORTANT: Release the pressure in the pump.

(Refer to W1-1-2.) 2
After completing the work, check the
oil level. Start the engine and check
for any oil leaks.
W1MS-02-05-017
W2-4-3
DISASSEMBLE 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
1 - Needle Bearing 12 - Ball Bearing 23 - Ceramic Ball (2 Used) 34 - Nut

2 - Valve Plate 13 - Stopper Pin 24 - Plunger (10 Used) 35 - Bolt
3 - Retaining Ring 14 - Coned Disc Spring 25 - Needle (3 Used) 36 - Seal Washer
(4 Used)
4- Washer (2 Used) 15 - Packing 26 - Spring Pin 37 - Body H
5- Spring 16 - Pin (2 Used) 27 - Bolt (2 Used) 38 - Spring Guide
6- Cylinder Block 17 - Body S 28 - Spring Washer (2 Used) 39 - Spring
7- Holder 18 - O-Ring 29 - Gear Pump 40 - Spring Holder
8- Retainer 19 - Plug 30 - Coupling 41 - Pin
9- Swash Plate 20 - Plug (4 Used) 31 - Collar 42 - O-Ring
10 - Retaining Ring 21 - Oil Seal 32 - O-Ring 43 - Socket Bolt (4 Used)
11 - Shaft 22 - Rod 33 - O-Ring 44 - O-Ring
W2-4-4
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
IMPORTANT: Do not drop valve plate (2) when

removing body H (37).
6. Remove body H (37) from body S (17). Remove
backing (15), pins (16) (2 used) and valve plate
(2) from body S (17).
W2-4-5
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
1- Needle Bearing 12 - Ball Bearing 23 - Ceramic Ball (2 Used) 34 - Nut

2- Valve Plate 13 - Stopper Pin 24 - Plunger (10 Used) 35 - Bolt
3- Retaining Ring 14 - Coned Disc Spring (4 Used) 25 - Needle (3 Used) 36 - Seal Washer
4- Washer (2 Used) 15 - Packing 26 - Spring Pin 37 - Body H
5- Spring 16 - Pin (2 Used) 27 - Bolt (2 Used) 38 - Spring Guide
6- Cylinder Block 17 - Body S 28 - Spring Washer (2 Used) 39 - Spring
7- Holder 18 - O-Ring 29 - Gear Pump 40 - Spring Holder
8- Retainer 19 - Plug 30 - Coupling 41 - Pin
9- Swash Plate 20 - Plug (4 Used) 31 - Collar 42 - O-Ring
10 - Retaining Ring 21 - Oil Seal 32 - O-Ring 43 - Socket Bolt (4 Used)
11 - Shaft 22 - Rod 33 - O-Ring 44 - O-Ring
W2-4-6
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).
6. Install rod (22) to body S (17).
7. Apply grease onto ceramic ball (23). Install

ceramic balls (23) (2 used) to swash plate (9).
Install the swash plate (9) to body S (17).
W2-4-7
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
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
13. Tighten socket bolts (43) (2 used).

: 8 mm
14. Remove one of the temporary bolts installed in

step 12. Install socket bolt (43). Remove other
temporary bolt. Install socket bolt (43).
: 17 mm
: 8 mm
15. Tighten socket bolts (43) (4 used) installed in

steps 13 and 14.
: 8 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
16. Install collar (31) and coupling (30) to shaft (11).

Install O-rings (33, 32, 44) to body H (37).
17. Install gear pump (29) to body H (37) with socket

bolts (27) (2 used) and spring washers (28) (2
used).
: 13 mm
: 20 N⋅m (2.0 kgf⋅m, 15 lbf⋅ft)
W2-4-9
MAINTENANCE STANDARD
1. Clearance between plunger (24) outer diameter
and cylinder block (6) bore.
(D-d): 0.050 mm (0.002 in) or less.
D d
6 24
W507-02-04-009
2. Clearance between plunger (24) and shoe

bottom. 
δ: 0.2 mm (0.008 in) or less. 24
Shoe
W107-02-06-141
3. Wear amount of the oil seal mounting surface

Check that there is no damage and / or abnormal
wear.
(D0-D1): 0.025 mm (0.001 in) or less.

W507-02-04-010
D0 -D1
W2-4-10
UPPERSTRUCTURE / Control Valve
REMOVE AND INSTALL CONTROL VALVE

TANK on W1-4-1.)
Removal
1. Remove floor mat (1) from main frame (2).
1
2 W1MS-02-05-014

: 13 mm
3
W1MS-02-05-015
2

: 17 mm
W1MS-02-05-016
6
W2-5-1
: 17 mm
7
2
W1MS-02-05-017
5. Start the engine. Rotate main frame (2)

approximately 100 degrees to the left. Stop the
engine. Release any pressure in the hydraulic oil
tank. (Refer to the Bleed Air From Hydraulic Oil
Tank on W1-4-1.)
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
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
8. Remove pin (21) from spool (20) in body (19).

Disconnect the link parts of the side frame
extend/retract lever from spool (20).
19, 20, 21 18 17 W1MS-02-05-020
Side Frame Extend/

Retract Link Parts
16
CAUTION: Control valve (16) weight: 34 kg

(75 lb)
W1MS-02-05-023
9. Remove sems bolts (22) (4 used) and washers
21 20 19
(23) (4 used) from main frame (8). Hoist and
remove control valve (16) from main frame (8).
: 17 mm
22, 23 8
W1MS-02-05-021
W2-5-3
Installation
CAUTION: Control valve (16) weight: 34 kg

(75 lb) 22, 23 8
1. Hoist and place control valve (16) onto main

frame (2). Install control valve (16) to main frame
(2) with sems bolts (22) (4 used) and washers (23)
(4 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
W1MS-02-05-021
2. Install the side frame extend/retract link parts to

Side Frame Extend/
spool (20) of body (19) and secure with pin (21). Retract Link Parts
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
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
(4 used).
: 17 mm
7
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
2 W1MS-02-05-017
(2 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
5
W1MS-02-05-016
6
W2-5-5
(5 used).
: 13 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)
3
W1MS-02-05-015
8. Install floor mat (1) onto main frame (2).
W1MS-02-05-014
2
W2-5-6
(Blank)
W2-5-7
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
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
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
1- Socket Bolt (40 Used) 21 - Spring (10 Used) 48 - O-Ring 55 - Plug

3- O-Ring (20 Used) 22 - Check Valve (8 Used) 49 - Orifice 56 - Body (Arm)
6- Plug (3 Used) 31 - Spring (9 Used) 50 - O-Ring 57 - Spool (Arm)
8- O-Ring (11 Used) 32 - Cover (18 Used) 51 - Plug 58 - Body (Travel (Left))
11 - Spring Seat (10 Used) 37 - Check Valve (3 Used) 52 - Check Valve 59 - Spool (Travel (Right))
12 - Spring Seat (10 Used) 38 - Spring (3 Used) 53 - Spring 60 - Main Relief Valve (2 Used)
19 - Plug (10 Used) 47 - Overload Relief Valve (2 Used) 54 - O-Ring 61 - Body (Inlet)
20 - O-Ring (10 Used)
W2-5-10
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
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
Installation Position of Spring (38) and Check Valve (37)
38
37
40, 58, 62
W1MS-02-05-006
W2-5-12
Installation Position of O-ring (8)
Except 56 8
W1MS-02-05-005
Installation Position of O-ring (48, 50)
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
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 W2-5-13 for the installation position of O-ring (8).

• Refer to W2-5-12 for the installation position of spring (38) and check valve (37).
W2-5-14
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.
5. Remove nuts (5) (4 used) from rods (73) (4 used)

at the body (9) side. Remove rods (73) (4 used)
from the body (71) side.
: 8 mm
W2-5-15
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
Installation Position of Spring (38) and Check Valve (37)
40, 58, 62
B
8 37
38
Section B-B
C
Section C-C W1MS-02-05-009
W2-5-16
Installation Position of O-ring (8)
A
Except 56
Section A- A A W1MS-02-05-008
Installation Position of O-ring (48, 50)

E
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
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
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).
3. Install body (27) to body (9).
4. Install body (33) to body (27). Install other bodies

(35, 40, 45, 56, 58, 61, 62, 66 and 71) in order.
CAUTION: Control valve weight: 34 kg (75 lb)
5. Secure the control valve assembly with rods (73)

(4 used) and nuts (5) (8 used).
: 8 mm
: 26.5 to 29.4 N⋅m
(2.7 to 3.0 kgf⋅m, 20 to 22 lbf⋅ft)
IMPORTANT: Do not confuse overload relief

valves (42, 47, 65, 68) (2 used for
each). Although overload relief
valves (42, 47, 65, 68) (2 used for
each) have the same shape, the
pressure settings are different.
6. Install overload relief valves (42, 47) (2 used for
each), (65) and (68) to bodies (45, 56, 66, 71).
: 24 mm
: 69 to 70 N⋅m
(7.0 to 7.9 kgf⋅m, 51 to 52 lbf⋅ft)
W2-5-19
DISASSEMBLE SPOOL
W1MS-02-05-004
71 66 62 61 58 56 45 40 35 33 27 9
Spool Structure of Body (9)
1
7
3
9
3
2
1
10
11
12 W1MS-02-05-005
13
W2-5-20
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
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
Disassemble Spool
Disassemble Spool in Body (9) Disassemble Spool in Body (27)

1. Remove socket bolts (1) (2 used) from cover (7). 1. Remove socket bolts (14) (2 used) from cover (15).
Remove O-ring (3) and cover (7) from body (9). Remove cover (15) from body (27).
: 5 mm : 5 mm
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).
IMPORTANT: Remove bolt (30) while holding

spring seat (16).
4. Clamp the spool (28) assembly in a vise by using
wooden pieces. Remove bolt (30) from spool (28).
Remove spring seats (16) (2 used) and spring
(29) from spool (28).
: 3 mm
W2-5-23
Spool Structure Except Bodies (9, 27)
31
3
32
12
11
3
31
33
1 34
11
12
W1MS-02-05-012
32
W2-5-24
Disassemble Spool Except Bodies (9, 27)
The disassembly for spool (34) in body (33) is
explained as an example.
1. Remove socket bolts (1) (2 used) from cover (32).

Remove spring seats (11, 12), spring (31), O-ring
: 5 mm
2. Remove socket bolts (1) (2 used) from cover (32).

Remove spring seats (11, 12), spring (31), O-ring
: 4 mm
3. Remove the spool (34) assembly from the cover

(32) side in body (33) by rotating.
W2-5-25
ASSEMBLE SPOOL
W1MS-02-05-004
71 66 62 61 58 56 45 40 35 33 27 9
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
W2-5-26
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)
13 - Cover Extend/Retract)
W2-5-27
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
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)
4. Install cover (15) onto body (27) with socket bolts

(14) (2 used).
: 5 mm
: 7.3 to 10 N⋅m
(0.7 to 1.0 kgf⋅m, 5 to 7 lbf⋅ft)
W2-5-29
Body (33) Section
12
31
32
1 11
34
33
3
1
11
32
31
12
T1MS-03-03-004
W2-5-30
Assemble Spool Except Bodies (9, 27)
The assembly for spool (34) in body (33) is explained
as an example.
1. Apply hydraulic oil onto the spool (34) assembly.

Install the spool (34) assembly to body (33) by
rotating.

cover (32). Install spring seat (11), the spring (31)
and spring seat (12) to spool (34). Install cover
(32) onto body (33) with socket bolts (1) (2 used).
: 5 mm
: 7.3 to 10 N⋅m
(0.7 to 1.0 kgf⋅m, 5 to 7 lbf⋅ft)

cover (32). Install spring seat (11), spring (31) and
the spring seat (12) to spool (34). Install cover
(32) onto body (33) with socket bolts (1) (2 used).
: 5 mm
: 7.3 to 10 N⋅m
(0.7 to 1.0 kgf⋅m, 5 to 7 lbf⋅ft)
W2-5-31
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
Body (27) Section Structure of Check Valve
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
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
9- Body (Flow Combiner Valve) 33 - Body (Blade) 53 - Spring 61 - Body (Inlet)

19 - Plug (10 Used) 35 - Body (Swing) 54 - O-Ring 62 - Body (Travel (Left))
20 - O-Ring (10 Used) 40 - Body (Boom Swing) 55 - Plug 66 - Body (Boom)
21 - Spring (10 Used) 43 - Check Valve 56 - Body (Arm) 69 - Check Valve
22 - Check Valve (8 Used) 45 - Body (Auxiliary) 58 - Body (Travel (Right)) 71 - Body (Bucket)
Extend/Retract) 52 - Check Valve
W2-5-33
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
Body (27) Section Structure of Check Valve
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
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.
Disassemble Check Valve Assemble Check Valve
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
(Blank)
W2-5-36
UPPERSTRUCTURE / Swing Device
REMOVE AND INSTALL SWING DEVICE

TANK on W1-4-1.)
Removal 1
W1MS-02-05-014

: 13 mm
2
W1MS-02-05-015
3. Remove hoses (4) (4 used) from swing device (5).

Cap the open ends. Attach the identification tags
onto hoses (4) (4 used).
: 19 mm, 22 mm
4
CAUTION: Swing device (5) weight: 23 kg

(51 lb)
5
4. Put the matching marks on the mating surfaces of

main frame and swing device. Remove bolts (6) (4
used) from swing device (5). Hoist and remove 4 6
swing device (5) from the main frame. W1MS-02-06-001
: 19 mm
W2-6-1
Installation
CAUTION: Swing device (5) weight: 23 kg

(51 lb)
1. Hoist swing device (5). Lower swing device (5)

onto the main frame while aligning the matching
marks on main frame and swing device (5). Install
swing device (5) to the main frame with bolts (6) (4
used).
: 19 mm
4
: 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft)
2. Install hoses (4) (4 used) to swing device (5).

: 19 mm 5
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
: 22 mm
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)
4 6
W1MS-02-06-001
3. Install cover (2) to the main frame with the bolts

(3) (5 used).
2
: 13 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)
3
W1MS-02-05-015
W1MS-02-05-014
W2-6-2
(Blank)
W2-6-3
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
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 38 - Plug (2 Used) 50 - Spring (2 Used)
9- Friction Plate (6 Used) 23 - Geroller 39 - O-Ring (2 Used) 51 - O-Ring (2 Used)
10 - Plate (7 Used) 24 - Valve Drive 40 - Spring (2 Used) 52 - O-Ring (2 Used)
11 - O-Ring 25 - Valve Plate 41 - Ball (2 Used) 53 - Seat (2 Used)
12 - Ring 26 - O-Ring 42 - O-Ring (3 Used) 54 - Adjusting Screw (2 Used)
13 - O-Ring (3 Used) 27 - Valve 55 - Lock Nut (2 Used)
14 - Piston 28 - Balancing Ring
W2-6-5
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
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).
5. Remove balancing ring (28), pins (31) (2 used),

springs (32) (2 used) and O-rings (26, 42) from
valve housing (34).
6. Remove inner face seal (29) and outer face seal

(30) from balancing ring (28).
W2-6-7
7
6
5
4
3
2
W1MS-02-06-002
W2-6-8
pinion gear (2) side facing upward. Remove
retaining ring (3) from bearing housing (8).

pinion gear (2) side facing downward. Remove
pinion gear (2) from bearing housing (8) by using
a plastic hammer.
15. Remove retaining ring (6) from pinion gear (2).

Remove collar (5) and bearing (4) from pinion
gear (2).
16. Remove X-ring (7) from bearing housing (8).
W2-6-9
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
NOTE: As for parts 33, 43 to 55, refer to W2-6-4.
W2-6-10
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
4. Install retaining ring (3) to bearing housing (8).

pinion gear (2) side facing down ward. Alternately W1MP-02-04-010
18 Outer Diameter side

install plates (10) (7 used) and friction plates (9)
(6 used) to bearing housing (8).
9. Apply grease onto the spring (20) mounting part
6. Apply grease onto O-rings (11, 13). Install O-ring of flange (18). Install springs (20) (8 used) to
(11) to the inner groove of ring (12). Install O-ring flange (18).
(13) to the outer groove of ring (12). Install ring
(12) to bearing housing (8). 10. Apply LOCTITE #242 onto socket bolt (19) (8
used). Align the matching marks and install flange
7. Apply grease onto O-ring (13). Install O-ring (13) (18) to bearing housing (8) with socket bolts (19)
to piston (14). Install piston (14) to bearing (8 used).
housing (8). : 6 mm
: 35 N⋅m (3.5 kgf⋅m, 26 lbf⋅ft)
11. Apply grease onto O-rings (21, 42). Install O-rings

(21, 42) to flange (18). Install drive (22) to flange
(18).
12. Align the matching marks and install geroller (23)

to flange (18).
W2-6-11
21 27 32 31
34
25
42
23
24
42
T1MS-03-02-001
W2-6-12
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
26 30 28 29 31
34
25
42
T1MS-03-02-001
NOTE: As for bolt (35), refer to W2-6-4.
W2-6-14
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
NOTE: The rotation direction is indicated as the

IMPORTANT: Align in 2 grooves on balancing ring rotation direction as seen from the pinion
(28) with pins (31) (2 used). Install gear shaft. If the rotation direction is
balancing ring (28) to valve housing reversed, repeat the assembly from step
(34). 13.
18. Apply grease onto balancing ring (28). Install
balancing ring (28) to valve housing (34).
34 30 28 29
W1MP-02-04-014
W2-6-15
(Blank)
W2-6-16
UPPERSTRUCTURE / Pilot Valve
REMOVE AND INSTALL LEFT FRONT
PILOT VALVE
Removal
1
hydraulic oil tank before doing any work. 2
TANK on W1-4-1.)
4, 5
1. Remove screws (2) (3 used) from covers (1, 3).
3
2. Remove caps (4) (4 used) from covers (1, 3).
W1MS-02-07-001
3. Remove bolts (5) (4 used) from covers (1, 3).

Remove covers (1, 3).
: 10 mm
4. Remove bolts (7) (4 used) from bracket (6).

Remove bracket (6) from lever stand (9). Roll up 6
boot (8).
: 13 mm 7
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
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
4. Lower boot (8) to lever stand (9). Install boot (8)

lever stand (9) with bracket (6) and bolts (7) (4
used).
: 13 mm 6
: 20 N⋅m (2.0 kgf⋅m, 15 lbf⋅ft)
7
9 W1MS-02-07-002
5. Install covers (1, 3) lever stand (9). 1
6. Install covers (1, 3) to lever stand (9) with bolts (5) 2

(4 used) and (2) (3 used).
7. Install caps (4) (4 used) to covers (1, 3). 4, 5
10
3
W1MS-02-07-001
W2-7-2
REMOVE AND INSTALL RIGHT FRONT
PILOT VALVE
Removal

TANK on W1-4-1.) 1
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
Fully open cover (4). Insert lock bar (6) into lock
hole (7) on cover (4).
M1MS-07-005
W2-7-3
4. Remove caps (9, 11) from covers (8, 13). Remove
screws (10, 12) from covers (8, 13).
5. Remove bolts (14) and (15) (2 used) from bracket

(16). 8
: 13 mm 18
9, 10
6. Remove bolts (17) (2 used) from cover (18). 11, 12
: 13 mm
17 13
14
7. Remove bolts (19) (2 used) from cover (18).
: 13 mm 16 15 W1MS-02-07-004
8. Remove grip (20) from the blade lever.

18
19
W1MS-02-07-005
20
9. Raise and remove cover (18) from the blade lever.
10. Disconnect connectors (21, 22) inside cover (18). 18

Remove cover (18).
21
W1MS-02-07-006
22
W2-7-4
11. Remove screw (25) from cover (8).
12. Remove screws (24) (2 used) from cover (13).
13. Move cover (23) to the outside in order to provide

a work space for the covers (8, 13) removal.
8
23
25
W1MS-02-07-007
13 24 13
Grip
14. Remove cover (13) from lever stand (33).
15. Raise cover (8) to the grip.

8
16. Remove bolts (29) (4 used) from bracket (28).
17. Roll boot (26) up to the grip. 26
27
W1MS-02-07-008
29 28
30, 31, 32
18. Loosen nut (30). Remove lever (32) from adapter
(31).
: 19 mm 33
19. Remove hoses (35) (4 used) from the adapters (4

used) on the bottom of pilot valve (34). Cap the 27
open end. Attach the tags to hoses (35) (4 used).
: 19 mm
34
20. Remove bolts (33) (4 used) from lever stand (27).
Remove pilot valve (34) from lever stand (27).
: 13 mm
W1MS-02-07-009
35
W2-7-5
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)
2. Install hoses (35) (4 used) to the adapters (4 27

used) on the bottom of pilot valve (34).
: 19 mm
: 29.5 N⋅m (3.0 kgf⋅m, 22 lbf⋅ft) 34
3. Install lever (32) to adapter (31) and secure with

nut (30).
: 19 mm
: 35 N⋅m (3.5 kgf⋅ml, 26 lbf⋅ft)
W1MS-02-07-009
35
4. Lower boot (26) to lever stand (27). Tighten Grip

bracket (28) with bolts (29) (4 used) and install
boot (26).
: 13 mm 8
: 20 N⋅m (2.0 kgf⋅m, 15 lbf⋅ft)
5. Install covers (8, 13) to lever stand (27).

26
27
W1MS-02-07-008
29 28
6. Install covers (8, 13) to lever stand (27) with bolts

(25) and (24) (2 used).
8
23
25
W1MS-02-07-007
13 24 13
W2-7-6
7. Connect connectors (21, 22) inside cover (18).
Install cover (18).
18
21
W1MS-02-07-006
22 Blade Lever
8. Install grip (20) to the blade lever.

18
9. Install cover (18) with bolts (19) (2 used).
: 13 mm
: 20 N⋅m (2.0 kgf⋅m, 15 lbf⋅ft)
19
W1MS-02-07-005
20
10. Install cover (18) with bolts (17) (2 used).

: 13 mm
: 20 N⋅m (2.0 kgf⋅m, 15 lbf⋅ft)
8
18
11. Install bracket (16) with bolts (14) and (15) (2 9, 10
used).
: 13 mm 11, 12
: 20 N⋅m (2.0 kgf⋅m, 15 lbf⋅ft) 17 13
12. Install covers (8, 13) with screws (10, 12).

14
Install caps (9, 11) to screws (10, 12).
W1MS-02-07-004
16 15
W2-7-7
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
REMOVE AND INSTALL TRAVEL PILOT
VALVE
Removal

TANK on W1-4-1.)
1
W1MS-02-05-014

: 13 mm 2
W1MS-02-05-015

: 17 mm
7 4
6
: 17 mm
W1MS-02-05-016
5
W2-7-9
used) from lever brackets (8) (2 used). Remove
lever brackets (8) (2 used) from pilot valve (14).
: 17 mm
6. Remove hoses (16) (6 used) from elbows (18) (4

9, 10
used) and tees (17) (2 used). Remove elbows (18)
(4 used) and adapters (15) (2 used) from pilot
valve (14). Cap the open end. Attach the tags to
hoses (16) (6 used).
: 19 mm 11, 12, 13
7. Remove socket bolts (11) (2 used), spring 9, 10

washers (12) (2 used) and washers (13) (2 used) 14
from pilot valve (14).
: 8 mm
15
8. Remove pilot valve (14) from the main frame.
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)
2. Install elbows (18) (4 used) and adapters (15) (2

used) to pilot valve (14). Install hoses (16) (6
used) to elbows (18) (4 used) and tees (17) (2
used).
: 19 mm
: 29.5 N⋅m (3.0 kgf⋅m, 22 lbf⋅ft)
3. Install lever brackets (8) (2 used) to pilot valve

(14) with bolts (9) (4 used) and washers (10) (4
used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
W2-7-10
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
5. Install cover (2) to the main frame with bolts (3) (5

used).
: 13 mm
2
: 20 N⋅m (2.0 kgf⋅m, 15 lbf⋅ft)
W1MS-02-05-015
W1MS-02-05-014
W2-7-11
REMOVE AND INSTALL BLADE PILOT
VALVE
Removal

TANK on W1-4-1.) 1
2
M1MS-07-003
2. Open cover (1). Unlock lock (4) of cover (3).
M1MS-07-004
Fully open cover (3). Insert lock bar (6) into lock
hole (7) on cover (3).
M1MS-07-005
W2-7-12
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
6. Remove bolts (14) (2 used) from lever (13). 10

Remove cover (15) and lever (13) from pilot valve
(17).
: 13 mm
W1MS-02-07-004
12 11
13 14
7. Remove bolts (16) (2 used) from pilot valve (17).

Remove brackets (12) (2 used) from pilot valve 15
(17).
: 13 mm
16
17
12
W1MS-02-07-011
8. Remove hoses (18) (4 used) from pilot valve (17).

Cap the open end. Attach the tags to hoses (18) (4
used).
17
: 19 mm
W1MS-02-07-012
18
W2-7-13
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)
3. Install cover (15) and lever (13) to pilot valve (17)

with bolts (14) (2 used). 16
: 13 mm
: 20 N⋅m (2.0 kgf⋅m, 15 lbf⋅ft)
17
4. Install bracket (12) with bolts (10) and (11) (2

used).
: 13 mm
: 20 N⋅m (2.0 kgf⋅m, 15 lbf⋅ft) 12
5. Install cover (8) to bracket (12) with bolts (9) (2

used).
: 13 mm
W1MS-02-07-011
: 20 N⋅m (2.0 kgf⋅m, 15 lbf⋅ft)
10
W1MS-02-07-004
12 11
W2-7-14
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
REMOVE AND INSTALL BOOM SWING
PILOT VALVE
Removal

TANK on W1-4-1.). 1
W1MS-02-05-014

: 13 mm
W1MS-02-05-015

: 17 mm

: 17 mm 7 4
W1MS-02-05-016
5
W2-7-16
Remove cover (8) from pilot valve (13).
: 13 mm
6. Remove hoses (15) (6 used) from pilot valve (13). 9

Cap the open end. Attach the tags to hoses (15) (6
used). 8 10
: 19 mm
11
7. Remove adapters (16) (2 used) and elbows (14)
(2 used) from pilot valve (13). Cap the open end. 12
: 19 mm
19
8. Remove pilot valve (13) from the main frame.
18 13
9. Remove bolts (11) (2 used) from pilot valve (13).
: 13 mm
17
10. Remove pedal (9) from pilot valve (13). 14
11. Remove socket bolts (17) (2 used) and washers

(18) (2 used) from bracket (10). Remove bracket 16 15
W1MS-02-07-013
(10) from pilot valve (13).

: 6 mm
17, 18
10
13
W1MS-02-07-014
W2-7-17
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
2. Install pedal (9) to pilot valve (13) with bolts (11) (2

used).
: 13 mm
: 20 N⋅m (2.0 kgf⋅m, 15 lbf⋅ft)
9
3. Install pilot valve (13) and cover (8) to the main

frame with bolts (12) (2 used). 8 10
: 13 mm 11
: 20 N⋅m (2.0 kgf⋅m, 15 lbf⋅ft)
12
4. Install adapters (19) (2 used) and elbows (14) (2
used) to pilot valve (13). Install hoses (15) (2
used) and (16) (3 used) to adapter (19), tees (17) 19
(2 used) and elbows (14) (2 used).
: 19 mm 18 13
: 29.5 N⋅m (3.0 kgf⋅m, 22 lbf⋅ft)
17
14
W1MS-02-07-013
16 15
W2-7-18
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
6. Install cover (2) to the main frame with bolts (3) (5

used).
: 13 mm
: 20 N⋅m (2.0 kgf⋅m, 15 lbf⋅ft)
2
W1MS-02-05-015
W1MS-02-05-014
W2-7-19
DISASSEMBLE FRONT PILOT VALVE
17
16
15
14
13
12
11
10
9 22
7
6 21
5 20
4 19
3 18
W178-02-07-064
1- Spacer (4 Used) 7- Spring Guide (4 Used) 13 - O-Ring (4 Used) 18 - Retaining Ring

2- Shim (Several) 8- Retaining Ring (4 Used) 14 - Plate 19 - Plug
3- Balance Spring A (2 Used) 9- Pusher A (2 Used) 15 - Universal Joint 20 - O-Ring
4- Balance Spring B (2 Used) 10 - Pusher B (2 Used) 16 - Cam 21 - Spool (4 Used)
5- Return Spring A (2 Used) 11 - Oil Seal (4 Used) 17 - Screw Joint 22 - Casing
6- Return Spring B (2 Used) 12 - Sleeve (4 Used)
W2-7-20
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).
8. Install special tool (ST 4146) to the pusher (9, 10)

3. Attach a spanner onto the upper part of universal holes (2 used) on casing (22). Hold special tool
joint (15) and remove universal joint (15). (ST 4146) and compress springs (5, 6) (2 used for
: 17 mm each). Remove retaining rings (8)(4 used) by
using a screwdriver.
: 12 mm
NOTE: Universal joint (15) has been secured on
casing (22) by using LOCTITE. NOTE: Tighten special tool (ST 4146) with socket
bolt (M14, Pitch 2.0 mm).
4. Remove plate (14). ST 4146
22
W178-02-07-048
ST 4145
W2-7-21
17
16
22
7
6 21
5
4 19
3 18
W178-02-07-064
W2-7-22
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).
IMPORTANT: The quantity of shims (2) is different

by port. Keep shim (2) carefully in
order to install shim (2) to each
former port when assembling.
10. Remove shim (2) and spacers (1) (4 used) from
spools (21) (4 used).
IMPORTANT: Spools (21) (4 used) have been

selected to match the hole of casing
(22). Replace spools (21) (4 used)
and casing (22) as an assembly.
11. Remove special tool (ST4145) from casing (22).
Slowly rotate and remove spools (21) (4 used).
12. Remove retaining ring (18) by using a screwdriver.

Install bolt (M8, Pitch 1.25 mm) to plug (19) and
remove plug (19).
: 13 mm
W2-7-23
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
1- Spacer (4 Used) 7- Spring Guide (4 Used) 13 - O-Ring (4 Used) 18 - Retaining Ring

2- Shim (Several) 8- Retaining Ring (4 Used) 14 - Plate 19 - Plug
3- Balance Spring A (2 Used) 9- Pusher A (2 Used) 15 - Universal Joint 20 - O-Ring
4- Balance Spring B (2 Used) 10 - Pusher B (2 Used) 16 - Cam 21 - Spool (4 Used)
5- Return Spring A (2 Used) 11 - Oil Seal (4 Used) 17 - Screw Joint 22 - Casing
6- Return Spring B (2 Used) 12 - Sleeve (4 Used)
W2-7-24
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
IMPORTANT: Spools (21) (4 used) has been

selected to match the port hole. ST 4144
Spools (21) (4 used) and casing (22)
must be replaced as an assembly.
IMPORTANT: Apply hydraulic oil onto each of the

parts when inserting into casing
(22).
IMPORTANT: Before inserting, check the port hole

No.
W178-02-07-049
ST 4145
1. Insert the thinner ends of spools (21) (4 used) into
the spool (21) holes (4 used) while rotating.
6. Install retaining ring (8) to special tool (ST 4144).
2. Install special tool (ST 4145) to the port hole on
casing (22).
: 6 mm
NOTE: Do not drop spools (21) (4 used) when

compressing springs (5, 6) (2 used for
each).
W2-7-25
17
16 15
9, 10
14 11
12
13
8
3, 4
22
W178-02-06-055
W2-7-26
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)
10. Apply grease to the joint part of universal joint

(15).
11. Apply grease to the inner surfaces of oil seals (11)

(4 used).
IMPORTANT: Sleeves (12) (4 used) and oil seals

(11) (4 used) must be replaced as an
assembly.
12. Install the sleeve (12) assemblies (4 used) to
casing (22). Push the sleeve (12) assemblies (4
used) by hand until O-rings (13) (4 used) are
inserted into the hole on casing (22).
13. Clamp casing (22) in a vise.
W2-7-27
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
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).
1. Clamp casing (23) in a vise. Remove bolts (1) (2

used) from cover (2). Remove cover (2) from
holder (7).
：10 mm
2. Remove socket bolts (30) (2 used) and spring

washers (29) (2 used). Remove the holder (7)
assmelby from casing (23).
：8 mm
3. Pull out pushers (16) (4 used) from casing (23).
4. Remove pushers (16) (4 used) from bushings (15)

(4 used). By using a bamboo spatula, remove oil
seals (28) (4 used) from bushings (15) (4 used).
Remove O-rings (14) (4 used) from bushings (15)
(4 used).
IMPORTANT: Put the marks on spools (24) (4

used) before keeping.
IMPORTANT: Spool (24) has been selected to
match the hole of casing (23).
Replace spool (24) (4 used) and
casing (23) as an assembly.
5. Rotate and remove the spool (24) assembly from
casing (23).
NOTE: Spring guides (17) (4 used), balance
springs (18) (4 used), shim (27) and
spacers (26) (4 used) are removed with
spools (24) (4 used) together.
W2-7-29
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
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).
12, 13 15. Remove plugs (20) (2 used) from casing (23).
11 16. Remove plugs (21) (2 used) from casing (23).

35 10
Crimped Here
Stand
W176-02-07-019
10. Remove socket bolts (9) (2 used) from dampers

(32) (2 used). Remove dampers (32) (2 used),
rubber seats (31) (2 used) and O-rings (34) (2
used) from pins (35) (2 used).
：5 mm
W2-7-31
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)
NOTE: As for the item with mark, refer to W2-6-20.
W2-7-32
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.
2. Insert return springs (25) (4 used) into casing 6

(23). W176-02-07-016
• Install bushing (6) on the opposite side in the

3. Rotate and insert the spools (24) assemblies (4
same way.
used) into casing (23). 6
NOTE: Check the port hole when inserting spool 7
ST 7256
(24) assemblies (4 used).
4. Assemble pushers (16) (4 used) as followings.

• Install oil seals (28) (4 used) to bushings (15) (4
used).
• Apply grease to the inner surface of oil seals (28) W176-02-07-015
(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).
5. Insert the pusher (16) assemblies (4 used) into Outside of

casing (23). Holder
W176-02-07-014
• Install bushing (6) in the near and opposite side

as illustrated.
6
7
ST 7256
W176-02-07-01313
W2-7-33
32 31 35 31 32 7 5 3, 4 30
29
34
9 33
23
W178-02-06-056
W2-7-34
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)
15. Apply grease to O-rings (34) (2 used). Push

W178-02-07-050
O-rings (34) (2 used) to the end most of pins (35)
(2 used).
4
9. Crimp the hole edge of cams (5) (4 used) where

spring pins (3, 4) are inserted by using a punch.
(2 places)
10. Place holder (7) onto the casing (23) assembly.

Install socket bolts (30) (2 used) and spring
washers (29) (2 used) to holder (7).
Check the mark direction and install holder (7).
：8 mm
：50 N⋅m (5 kgf⋅m,37 lfb⋅ft)
W2-7-35
11 32 1 2 35 12 13 7 1
10 1
W178-02-06-056
W2-7-36
16. Install brackets (11) (2 used) to pins (35) (2 used).
Align the inserting holes of spring pins (12, 13) (2
used for each).
NOTE: As for the direction to install bracket (11),

refer to W 2-7-1.
IMPORTANT: Place a stand under bracket (11) and

form a reaction force. If holder (7)
bears the reaction force, a strong
force acts on pin (35) and pin (35)
may be deformed.
17. Place a stand under bracket (11).

Tap spring pins (12, 13) into bracket (11) until
spring pins (12, 13) comes to the stepped end by
using special tool (ST 1237).
NOTE: Insert spring pins (12, 13) with their slits

positioned 90 degrees apart from each
other.
Crimpe
d Here Crimped
Here
11 35
Stand 12, 13
W176-02-07-011
18. Crimp the hole edge of bracket (11), where spring

pins (12, 13) are inserted, by using a punch.
(Refer to the illustration.)
19. Install bracket (11) to pin (35) at the opposite side

in the same way as steps 16 to 18.
20. Install cover (2) to holder (7) with bolts (1) (2

used).
: 10 mm
: 5 N⋅m (0.5 kgf⋅m, 4 lfb⋅ft)
21. Apply grease to the spring pins (10) (2 used)

contact parts of dampers (32) (2 used).
W2-7-37
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
1- Spacer (2 Used) 6- Spring Guide (2 Used) 11 - Casing 15 - Pusher (2 Used)

2- Cam 7- Spring (2 Used) 12 - O-Ring (2 Used) 16 - Pin
3- Socket Bolt (2 Used) 8- Spring (2 Used) 13 - Bushing (2 Used) 17 - Bushing (2 Used)
4- Boot 9- Spacer (2 Used) 14 - Oil Seal (2 Used) 18 - Set Screw
5- Holder 10 - Spool (2 Used)
W2-7-38
Disassemble Boom Swing, Blade and Auxiliary
Pilot Valves
1. Remove boot (4) and spacers (1) (2 used) from

holder (5).
2. Clamp the pilot valve in a vise. Loosen set screw

(18). Remove pin (16) by using a round bar.
Remove the cam (2) assembly from holder (5).
: 2.5 mm
IMPORTANT: Record the positions for casing (11).

The pusher (15) assemblies (2 used)
may fly out by the springs (8) (2
used) force.
3. Alternately loosen and remove socket bolts (3) (2

used) from holder (5). Remove holder (5) and the
pusher (15) assemblies (2 used) from casing (11).
: 6 mm
4. Remove pushers (15) (2 used), O-rings (12) (2

used) and oil seals (14) (2 used) from bushings
(13) (2 used).
IMPORTANT: Indicate the port number and keep

the parts in order not to confuse the
removed parts.
5. Remove the spool (10) assemblies (2 used) and

springs (8) (2 used) from each port of casing (11).
6. While compressing springs (7) (2 used), remove

spring guides (6) (2 used) from spools (10) (2
used). Remove spacers (9) (2 used) from spools
(10) (2 used).
W2-7-39
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
1- Spacer (2 Used) 6- Spring Guide (2 Used) 11 - Casing 15 - Pusher (2 Used)

2- Cam 7- Spring (2 Used) 12 - O-Ring (2 Used) 16 - Pin
3- Socket Bolt (2 Used) 8- Spring (2 Used) 13 - Bushing (2 Used) 17 - Bushing (2 Used)
4- Boot 9- Spacer (2 Used) 14 - Oil Seal (2 Used) 18 - Set Screw
5- Holder 10 - Spool (2 Used)
W2-7-40
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).
3. Install oil seals (14) (2 used) and O-rings (12) (2

used) to bushings (13) (2 used). Insert pushers
(15) (2 used) into bushings (13) (2 used).
Use grease as follows.

• Apolloil Autorex C (Idemitsu)
• Ocean 7 (Nihon Ore Louve)
• Screw Bar L60 (NOK)
W2-7-41
(Blank)
W2-7-42
UPPERSTRUCTURE / Solenoid Valve
REMOVE AND INSTALL SOLENOID VALVE
Removal

TANK on W1-4-1.)
1. Remove floor mat (1) from main frame (2).
W1MS-02-05-014
2
2. Remove (4) (5 used) from cover (3). Remove

: 13 mm
3
W1MS-02-05-015
2

: 17 mm
W1MS-02-05-016
6
W2-8-1
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
5. Remove hoses (12) (6 used) from solenoid valve 12

(13). Cap the openends. Attach the identification
tags to hoses (12) (6 used).
: 19 mm
6. Remove solenoid valve (13) from main frame (10).
13
W1MS-02-08-002
W2-8-2
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)
3. Connect connectors (11) (2 used).

9
11 10 W1MS-02-08-001
W2-8-3
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
5. Install cover (3) to main frame (2) with bolts (4) (5

used).
: 13 mm
3
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)
W1MS-02-05-015
2
6. Install floor mat (1) onto main frame (2).
W1MS-02-05-014
2
W2-8-4
(Blank)
W2-8-5
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
1- O-Ring (4 Used) 6- Lock Nut (2 Used) 10 - O-Ring (2 Used) 14 - Check valve

2- Solenoid (2 Used) 7- Plate (2 Used) 11 - Spool (2 Used) 15 - Spring
3- Plate (2 Used) 8- Solenoid (2 Used) 12 - Spring (2 Used) 16 - O-Ring
4- Wave Washer (2 Used) 9- Pin (2 Used) 13 - Body 17 - Adjuster
5- Casing (2 Used)
W2-8-6
Disassemble 2-Unit Solenoid Valve
IMPORTANT: As left and right solenoids (2) (2

used) are different. Attach an
identification tag to solenoids (2) (2
used) for assembling.
1. Remove lock nuts (6) (2 used) from casings (5) (2

used). Remove casings (5) (2 used) from body
(13).
IMPORTANT: When removing solenoids (2) (2

used), pins (9) (2 used) may fall off.
Do not lose pin (9).
2. Remove the solenoid (2) assemblies (2 used)
from body (13).
3. Remove spools (11) (2 used) and springs (12) (2

used) from body (13) by using a magnet.
4. Remove adjuster (17) and O-ring (16) from body

(13).
5. Remove spring (15) and check valve (14) by

using a magnet.
W2-8-7
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
1- O-Ring (4 Used) 6- Lock Nut (2 Used) 10 - O-Ring (2 Used) 14 - Check valve

2- Solenoid (2 Used) 7- Plate (2 Used) 11 - Spool (2 Used) 15 - Spring
3- Plate (2 Used) 8- Solenoid (2 Used) 12 - Spring (2 Used) 16 - O-Ring
4- Wave Washer (2 Used) 9- Pin (2 Used) 13 - Body 17 - Adjuster
5- Casing (2 Used)
W2-8-8
Assemble 2-Unit Solenoid Valve
1. Install check valve (14) and spring (15) to body

(13). Install adjuster (17) to body (13).
2. Install springs (12) (2 used) and spools (11) (2

used) to body (13).
3. Install pins (9) (2 used) to solenoids (8) (2 used).

Install solenoids (8) (2 used) to body (13).
4. Install plates (7) (2 used), O-rings (10) (2 used),

solenoids (2) (2 used), O-rings (1) (2 used), plates
(3) (2 used) and wave washers (4) (2 used) to
solenoids (8) (2 used).
5. Install casings (5) (2 used) to the solenoid (8)

assemblies (2 used). Secure casings (5) (2 used)
to body (13) with lock nuts (6) (2 used).
W2-8-9
(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
Group 3 Center Joint

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

Remove and Install Track Adjuster ......... W3-4-1
Disassemble Track Adjuster ................... W3-4-2
Assemble Track Adjuster ........................ W3-4-8
Group 5 Front Idler

Remove and Install Front Idler................ W3-5-1
Disassemble and Assemble Front Idler... W3-5-2
Maintenance Standard............................ W3-5-4
1MSW-3-1
(Blank)
1MSW-3-2
UNDERCARRIAGE / Swing Bearing
REMOVE AND INSTALL SWING BEARING
Removal
1. Remove the main frame from center frame (2).

Refer to the Remove and Install Main Frame
group on W2-3-1. Matching Mark 1
2. Put the matching marks on inner race (3) of swing

bearing (1) and center frame (2).
3 2
W105-03-01-001
3. Remove bolts (4) (18 used) from inner race (3) of
swing bearing (1).
: 17 mm
1
CAUTION: Swing bearing (1) weight: 21 kg

(46 lb)
4. Install eyebolts (M10, Pitch 1.25 mm) (3 used)

onto swing bearing (1). Hoist and remove swing W1MS-03-01-001
bearing (1) from center frame (2).
W3-1-1
UNDERCARRIAGE / Swing Bearing
Installation
1. Clean the mounting surfaces of center frame (2)

and swing bearing (1).
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
IMPORTANT: If the matching marks do not align,

the position of soft zone of inner
race (3) will be dislocated.
3. Install eyebolts (M10, Pitch 1.25 mm) (3 used) 3
onto swing bearing (1). Hoist swing bearing (1)
and align the matching marks on center frame (2)
and inner race (3) of swing bearing (1).
W1MS-03-01-001
3. Install inner race (3) of swing bearing (1) to

center frame (2) with bolts (4) (18 used).
: 17 mm Machine Front 1
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
4. Install the main frame to center frame (2). Refer

to the Remove and Install Main Frame group on
W2-3-1.
3 2
W105-03-01-001
W1MS-03-01-001
W3-1-2
UNDERCARRIAGE / Travel Device
REMOVE AND INSTALL TRAVEL DEVICE
CAUTION: Bleed air from the hydraulic oil

tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on W1-4-1.)
Removal
2, 3 1
1. Remove the track. Refer to the Remove and In-
stall Track group on W3-7-1.
2. Remove bolts (2) (3 used) and washers (3) (3

used) from cover (4). Remove cover (4) from side
frame (1).
: 17 mm
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)

(7) (8 used) from side frame (1). Hoist and re- W1MS-04-02-030
move the travel device (5) from side frame (1).
: 8 mm

(14) (9 used) from sproket (12). Remove sproket
(12) from travel device (5). 12
: 8 mm
W1MP-03-02-009
5 13, 14
W3-2-1
Installation
1. Install sprocket (12) to travel device (5) with

socket bolts (13) (9 used) and washers (14) (9
used).
: 8 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
12
CAUTION: Travel Device (5) weight: 30 kg

(66 lb)
W1MP-03-02-009
5 13, 14
2. Hoist and align travel device (5) with side frame
(1). Apply LOCTITE #262 onto socket bolt (6). In-
stall travel device (5) to side frame (1) with socket
bolts (6) (8 used) and washers (7) (8 used).
: 8 mm 6, 7 5 1
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft) 8
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)
5. Install the track to side frame (1). Refer to the

Remove and Install Track group on W3-7-1.
6. After completing the work, check the hydraulic oil

level. Start the engine and check for any oil leaks. 2, 3 1
7. Perform the break-in operation in order to prevent

the travel motor from seizing.
Break-in operation conditions
1. Engine speed: Slow idle speed
2. Fast speed travel pedal: Slow speed
3. Operation duration: 2 minutes or more
4
W1MS-04-02-029
W3-2-2
(Blank)
W3-2-3
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
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).
12. Remove floating seals (26) (2 used) from body

(27) by using the screwdrivers (2 used).
W3-2-5
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
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).
4. Install bearing nut (23) to body (27) by using spe-

cial tool (ST 3169).
: 137±9.8 N⋅m (14±1 kgf⋅m, 101 lbf⋅ft)
5. Install plug (15) to body (27). Crimp plug (15) by

using a punch (2 places).
: mm
: 14.7±4.9 N⋅m (1.5±0.5 kgf⋅m, 11±4 lbf⋅ft)
6. Insert balls (25) (94 used) through the plug (20)

hole on ring gear (27).
NOTE: If it is not easy to install balls (25) (94 used),
tap the outer surface of ring gear (27).
7. Install plug (20) to ring gear (27).

: 5 mm
: 7.8±1 N⋅m (0.8±0.1 kgf⋅m, 6±1 lbf⋅ft)
W3-2-7
21 4
T1MS-03-05-001
W3-2-8
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.
13. install O-rings (2) (2 used) to plugs (1) (2 used).

Install plugs (1) (2 used) to cover (5).
: 6 mm
: 34.3 N⋅m(3.5 kgf⋅m, 25 lbf⋅ft)
W3-2-9
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
1- Pin (3 Used) 9- Spring (10 Used) 18 - Oil Seal 25 - Holder

2- O-Ring 10 - Brake Piston 19 - Bearing 26 - Pin (3 Used)
3- Valve Plate 11 - Friction Plate 20 - Shaft 27 - Rotor
4- Bearing 12 - O-Ring 21 - Steel Ball (2 Used) 28 - Washer
5- Brake Valve 13 - O-Ring 22 - Swash Plate 29 - Spring
6- Socket Bolt (6 Used) 15 - Housing 23 - Plunger (9 Used) 30 - Washer
7- O-Ring (2 Used) 16 - Spring (2 Used) 24 - Retainer 31 - Retaining Ring
8- Pin 17 - Piston (2 Used)
W3-2-10
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.
9. Remove bearing (19) from the shaft (20) assem-

bly. Put the inner race of bearing (19) on the open
end of a vise. Remove shaft (20) from bearing
(19) by using a plastic hammer.
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
2. Remove valve plate (3), O-rings (2, 7), pins (8),

(1) (3 used) and bearing (4) from brake valve (5).
3. Remove springs (9) (10 used) and brake piston W172-03-02-003
(10) from housing (15). Remove O-rings (12, 13)

from brake piston (10).
4. Remove the rotor (27) assembly, holder (25), pins

(26) (3 used), retainer (24) and plungers (23) (9
used) from housing (15). Remove friction plate
(11) from rotor (27).
5. Remove swash plate (22) from housing (15).
6. Remove steel balls (21) (2 used), springs (16) (2

used) and pistons (17) (2 used) from housing (15)
by using a magnet.
NOTE: Do not disassemble retaining ring (31),
washer (30), spring (29) and washer (28)
from rotor (27) unless necessary.
W3-2-11
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
1- Pin (3 Used) 9- Spring (10 Used) 18 - Oil Seal 25 - Holder

2- O-Ring 10 - Brake Piston 19 - Bearing 26 - Pin (3 Used)
3- Valve Plate 11 - Friction Plate 20 - Shaft 27 - Rotor
4- Bearing 12 - O-Ring 21 - Steel Ball (2 Used) 28 - Washer
5- Brake Valve 13 - O-Ring 22 - Swash Plate 29 - Spring
6- Socket Bolt (6 Used) 15 - Housing 23 - Plunger (9 Used) 30 - Washer
7- O-Ring (2 Used) 16 - Spring (2 Used) 24 - Retainer 31 - Retaining Ring
8- Pin 17 - Piston (2 Used)
W3-2-12
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
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
1- Plug (2 Used) 7- Spring (2 Used) 12 - O-Ring (3 Used) 17 - Spool

2- O-Ring (2 Used) 8- Check Valve (2 Used) 13 - O-Ring 18 - Orifice
3- Spring (2 Used) 9- Spool 14 - Plug 19 - Plug (2 Used)
4- Spring Seat (2 Used) 10 - Body 15 - Plug (2 Used) 20 - Orifice (2 Used)
5- Plug (2 Used) 11 - Plug (2 Used) 16 - Spring 21 - Plug (2 Used)
6- O-Ring (2 Used)
W3-2-14
Disassemble
IMPORTANT: Do not disassemble counterbalance

valve assemblies (5 to 9).
1. Remove plugs (1) (2 used) from body (10). Re-
move O-rings (2) (2 used) from plugs (1) (2 used).
Remove springs (3) (2 used), spring seats (4) (2
used), counterbalance valve assemblies (5 to 8)
(2 used for each) and (9) from body (10)
: 12 mm
NOTE: Do not remove counterbalance valve as-
semblies (5 to 8) (2 used for each) and (9)
unless necessary.
2. Remove plug (11) from body (10). Remove O-ring

(12) from plug (11). Remove spring (16) and
spool (17) from body (10).
: 6 mm
3. Remove plug (21) from body (10). Remove O-ring

(12) from plug (21).
: 19 mm
W3-2-15
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
1- Plug (2 Used) 7- Spring (2 Used) 12 - O-Ring (3 Used) 17 - Spool

2- O-Ring (2 Used) 8- Check Valve (2 Used) 13 - O-Ring 18 - Orifice
3- Spring (2 Used) 9- Spool 14 - Plug 19 - Plug (2 Used)
4- Spring Seat (2 Used) 10 - Body 15 - Plug (2 Used) 20 - Orifice (2 Used)
5- Plug (2 Used) 11 - Plug (2 Used) 16 - Spring 21 - Plug (2 Used)
6- O-Ring (2 Used)
W3-2-16
Assemble
1. Install O-ring (12) to plug (21). Install plug (21) to

body (10).
: 19 mm
: 37 N⋅m (3.8 kgf⋅m, 27 lbf⋅ft)
2. Apply hydraulic oil onto the spool (17).

Install spool (17) and spring (16) to body (10). In-
stall O-ring (12) to plug (11). Install plug (11) to
body (10).
: 6 mm
: 37 N⋅m (3.8 kgf⋅m, 27 lbf⋅ft)
3. Install counterbalance valve assemblies (5 to 8)

(2 used for each) and (9) to body (10). Install
spring seats (4) (2 used) and springs (3) (2 used)
to body (10). Install O-rings (2) (2 used) to plugs
(1) (2 used). Install plugs (1) (2 used) to body
(10).
: 12 mm
: 157 N⋅m (16 kgf⋅m, 116 lbf⋅ft)
W3-2-17
Travel Motor
1. Clearance between plunger outer diameter and

rotor inner bore
(D-d): 0.023 mm (0.001 in) or less.
D d
W507-02-04-009
Rotor Plunger
2. Clearance between plunger and shoe
δ: 0.3 mm (0.012 in) or less.

δ
3. Wear amount of sliding surface against valve Plunger
plate of rotor 
Check that there are no damage, wear or seizure.
Damage or wear amount: 0.02 mm (0.001 in) or
Shoe
less.
4. Wear amount of sliding surface against rotor of

valve plate
Check that there are no damage, wear or seizure.
Damage or wear amount: 0.02 mm (0.001 in) or
W107-02-06-141
less.
W3-2-18
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
(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.
2. Remove hoses (2) (12 used) from center joint (1).

Attach an identification tag to hose (2). Cap the
open ends of center joint (1) and hose (2).
: 19 mm, 22 mm 4, 5

used) from flange (3) of center joint (1). Remove
center joint (1) from the center frame. W1MS-03-03-001
: 17 mm
W3-3-1
Installation
1. Install flange (3) of center joint (1) to the center

frame with washers (4) (4 used) and bolts (5) (4
used).
: 17 mm 1
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
2
2. Install hoses (2) (12 used) to center joint (1).
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
: 22 mm
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)
4, 5
3. Install the main frame to the center frame. Refer to
the Remove and Install Main Frame group on 3
W2-3-1.
W1MS-03-03-001
IMPORTANT: After completing the work, check the

oil level. Start the engine and check
for any oil leaks.
W3-3-2
(Blank)
W3-3-3
DISASSEMBLE CENTER JOINT
16
3
15
14 4
13
5
10 9
12
11
W1MS-03-03-002
1- Pin 5- O-Ring 9- O-Ring 13 - Backup Ring

2- Body 6- Flange 10 - Plug 14 - Dust Seal
3- Thrust Ring 7- Spring Washer (4 Used) 11 - Oil Seal (9 Used) 15 - Plug (5 Used)
4- Retaining Ring 8- Bolt (4 Used) 12 - O-Ring 16 - Spindle
W3-3-4
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).
IMPORTANT: Put the matching marks on body (2)

and spindle (16).
4. Install special tool (ST 1467) to the bolt (8) hole (2
places) diagonally with bolts (M8) (2 used). Turn
bolt (M16) clockwise and push out spindle (16)
from body (2).
Pin
Bolt (M16)
11
Bolt (M8) ST 1467
W105-03-03-015
6. Remove dust seal (14), backup ring (13) and

2 O-ring (12) from body (2).
NOTE: Do not remove plugs (15) (5 used) and pin
(1) from spindle (16).
W1MP-03-03-002
W3-3-5
ASSEMBLE CENTER JOINT
16
14
13
12
11 2
6
10
7 T1MS-03-07-004
8 15 4 9
1- Pin 5- O-Ring 9- O-Ring 13 - Backup Ring

2- Body 6- Flange 10 - Plug 14 - Dust Seal
3- Thrust Ring 7- Spring Washer (4 Used) 11 - Oil Seal (9 Used) 15 - Plug (5 Used)
4- Retaining Ring 8- Bolt (4 Used) 12 - O-Ring 16 - Spindle
W3-3-6
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).
IMPORTANT: Slowly turn and push spindle (16)

into body (2). If spindle (16) is rapidly
pushed in, oil seals (11) (9 used) may
be damaged.
IMPORTANT: Apply grease onto spindle (16) and
the inside (sliding position) of body
(2).
2. Clamp spindle (16) in a vise. Align the matching
marks on spindle (16) and body (2). Lightly tap
and install body (2) to spindle (16) by using a
plastic hammer.
IMPORTANT: Install retaining ring (4) with the

chamfered surface facing to the thrust
ring (3). Check that retaining ring (4)
is installed in the groove on body (2)
and spindle (16) exactly.
3. Install thrust ring (3) and retaining ring (4) to body
(2).
W3-3-7
(Blank)
W3-3-8
UNDERCARRIAGE / Track Adjuster
REMOVE AND INSTALL TRACK ADJUSTER
Removal
1. Remove the track from side frame (3). Refer to the

1 2 3
Remove and Install Track group on W3-7-1.
2. Remove the front idler from side frame (3). Refer

to the Remove and Install Front Idler group on
W3-5-1.
3. Remove track adjuster (1) from side frame (3).
Installation 5 4
W1MS-03-04-001
IMPORTANT: Check that the valve side of track

adjuster (1) is installed in the the
bracket (4) hole of side frame (3).
1. Insert track adjuster (1) until washer (5) of track
adjuster (1) comes in contact with bracket (4) of
side frame (3). Turn track adjuster (1) and insert
nut (2) of track adjuster (1) into the bracket (4)
hole.
2. Install the front idler to side frame (3). Refer to the

Remove and Install Front Idler group on W3-5-1.
3. Install the track (rubber crawler) to side frame (3).

Refer to the Remove and Install Track group on
W3-7-1.
W3-4-1
DISASSEMBLE TRACK ADJUSTER
10
11
9
12
8
13
7 14
6
5
4
2
1
W1MS-03-04-002
15
1- Socket Bolt (3 Used) 5- U-Ring 9- O-Ring 13 - Washer

2- Flange 6- Retaining Ring 10 - Plug 14 - Spring
3- Piston Rod 7- Rod 11 - Valve 15 - Dust Seal
4- Wear Ring 8- Cylinder 12 - Nut
W3-4-2
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)
4. Install plate (ST 4140) to the bolts (4 used) of

Holder special tool (ST 4943).
Oil Jack
Plate
(ST 4140)
Base Special Tool

W105-03-04-006
(ST 4943)
Track
CAUTION: Plate (ST 4140) weight: 36 kg (79 lb) Adjuster
2. Remove the nuts (4 used) from the bolts (4 used)

of special tool (ST 4943). Hoist and remove plate
(ST 4140) from special tool. W105-03-04-011
: 46 mm
Plate (ST 4140)
W105-03-04-007
W3-4-3
10
11
9
12
8
13
7 14
6
5
4
2
1
W1MS-03-04-002
15
W3-4-4
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
6. Loosen and remove valve (11) from rod (7) slowly

CAUTION: Plate (ST 4140) weight: 36 kg (79 lb)
: 19 mm
CAUTION: Remove nut (12) and plate (ST
4140) after lowering the oil jack. If not lower-
CAUTION: Plate (ST 4140) weight: 36 kg (79 ing the oil jack, washer (13) and spring (14)
lb) may fly out by the reaction of spring (14).
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
7 14
6
5
4
2
1
W1MS-03-04-002
15
W3-4-6
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
11. Remove spring (14) from cylinder (8).
12. Remove socket bolts (1) (3 used) from flange (2).

Remove flange (2) from cylinder (8). Remove dust
seal (15) from flange (2).
: 6 mm
13. Remove piston rod (3) from cylinder (8).
14. Remove retaining ring (6), U-ring (5) and wear

ring (4) from piston rod (3).
15. Remove rod (7) from cylinder (8).
16. Remove O-ring (9) from the cylinder (8).
W3-4-7
ASSEMBLE TRACK ADJUSTER
11 12 13 7 14 1 3
T577-03-07-002
10 9 A 6 5 4 8 2 15
1- Socket Bolt (3 Used) 5- U-Ring 9- O-Ring 13 - Washer

2- Flange 6- Retaining Ring 10 - Plug 14 - Spring
3- Piston Rod 7- Rod 11 - Valve 15 - Dust Seal
4- Wear Ring 8- Cylinder 12 - Nut
W3-4-8
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).
2. Install wear ring (4), U-ring (5) and retaining ring

(6) to piston rod (3). Apply hydraulic oil onto the
outer surface of piston rod (3). 14
3. Fill grease in chamber A of cylinder (8). Push

7
piston rod (3) into cylinder (8) fully and release
pressure in cylinder (8). Apply grease onto ST 4944
O-rings (15). Install O-ring (15) to flange (2).
4. Install flange (2) to cylinder (8) with socket bolts

(1) (3 used).
： 6 mm 8
： 30 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
W105-03-04-017
6. Install washer (13) to cylinder (8).
7. Hoist and place plate (ST 4140) on special tool

(ST 4943). Install plate (ST 4140) to special tool
(ST 4944) with the nuts (4 used).
： 46 mm
Plate (ST 4140)
W105-03-04-012
W3-4-9
11 12 7 14
T577-03-07-002
10 8
W3-4-10
8. Operate the oil jack and compress spring (14) to
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
12. Remove eyebolt from cylinder (8). Install valve

(11).
: 19 mm
: 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft)
W3-4-11
(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.)
2. Insert a pry bar between front idler (1) and side

frame (2). Pry and remove front idler (1) from side
frame (2) by using a pry bar.
3 2
W1M3-03-05-001
Installation
IMPORTANT: Clean and apply grease onto the

sliding part of side frame (2) and the
yoke (3) part of front idler (1).
1. Insert yoke (3) of front idler (1) into the sliding part
of side frame (2).
2
Sliding
Part
W1MS-03-05-001
W3-5-1
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
1 - Yoke (2 Used) 4- Floating Seal (2 Used) 6- Idler 8- Plate

2 - Pin (2 Used) 5- Bushing (2 Used) 7- Axle 9- Bolt (4 Used)
3 - O-Ring (2 Used)
W3-5-2
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
Idler
C D F
A
B
W503-03-05-001
Unit: mm (in)
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) -
Axle and Bushing Unit: mm (in)

Axle Outer Dia. 25.0 (1.0) 24.2 (0.954)
Bushing Inner Dia. 25.0 (1.0) 26 (1.0) Replace
Flange 4.0 (0.16) 3.2 (0.12)
Thickness
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
CAUTION: After raising the machine, support

the center frame firmly by using the blocks.
90 to 110º
1. Put the bucket onto the ground and raise the ma-
chine. Place the block under the center frame and
support the machine.
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).
2. Loosen valve (2) on the track adjuster slowly and

drain grease until the clearance between lower
end of lower roller (6) and upper side of track (7)
W1MJ-03-06-001
is 80 mm (3.25 in) or more.
: 19 mm
3. Tighten valve (2).

: 19 mm
: 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft)
4. Remove bolts (4) (2 used) and washers (5) (2 1 2 3

used) from the inner and outer side of side frame (3).
Remove lower roller (6) from side frame (3).
: 22 mm 4, 5
7
W1MS-03-06-001
W3-6-1
Installation
CAUTION: After raising the machine, support

the center frame firmly by using the blocks.
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
2. Align the bolt (4) holes on side frame (3) and

lower roller (6).
1 2 3
3. Apply LOCTITE #262 onto bolts (4) (2 used). In-
stall lower roller (6) to side frame (3) with washers
(5) (2 used) and bolts (4) (2 used). 4, 5
: 22 mm
: 180 N⋅m (18.4 kgf⋅m, 133 lbf⋅ft) 6
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
Detail of Clearance (A)

M503-05-050
W3-6-2
STRUCTURE OF LOWER ROLLER
Replace the lower roller as an assembly.
1 2 3 4 5 6 7 8
W1MS-03-06-003
Wrench Size Tightening Torque

Item Part Name Q’ty Remarks
(mm) N⋅m (kgf⋅m) (lbf⋅ft)
1 Floating Seal 1
2 Roller 1
3 Bushing 2
4 Axle 1
5 Floating Seal 1
6 Collar 2
7 O-Ring 2
8 Stopper Ring 2
NOTE: Roller diameter varies depending on front, middle and rear lower rollers. For further details, refer to
Maintenance Standard.
W3-6-3
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)
Axle and Bushing

Unit: mm (in)
Axle Outer Dia. 25.0 (0.94) -
Inner Dia. 25.0 (0.94) -
Replace
Bushing Flange -
-
Thickness
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
CAUTION: Rubber crawler weight: 52 kg

(115 lb)
90 to 110º
CAUTION: Securely support the raised
machine by using the blocks.
1. Raise the machine by using the front attachment.
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).
3. Insert steel pipes into track (3) in front lower part

of front idler (5). Rotate sprocket (4) in reverse
direction.
After track (3) is floated from front idler (5), slide
and remove track (3) transversely. 3
Rotation 4
Direction
5 Steel Pipe
M503-07-062
W3-7-1
Installation 3
CAUTION: Rubber crawler weight: 53 kg

(113 lb) Rotation 4
Direction
CAUTION: Securely support the raised
machine by using the blocks.
1. Raise the machine by using the front attachment.
2. Mesh track (3) with sprocket (4) and attach track

5 Steel Pipe
(3) onto front idler (5). M503-07-062
Rotate sprocket (4) in reverse direction and push

in track (3).
3. Insert steel pipes into track (3) in front lower part 1 2 6

of front idler (5). Rotate sprocket (4) in reverse
direction. Attach track (3) onto front idler (5).
Check that track (3) is securely engaged with
sprocket (3) and front idler (5).
7
4. Tighten valve (2).
: 19 mm A
: 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft)
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
Rubber Crawler Crack
1. Outside of Rubber Crawler 1

4
If there is a crack on lug base (1) with depth of 3
mm (0.12 in) or more, repair track. 5
If there is a crack between lugs (2) with depth of 3 2
mm (0.12 in) or more, repair track.
If there is a crack on lugs (3) or between lugs (2)
that reaches to steel cord (5) or steel core (4) with 3
length of 30 mm (1.2 in) or more, immediately
repair track.
2. Inside of Rubber Crawler (Roller Side)

W190-03-07-001
If there is a crack that reaches to steel cord (5) or
steel core (4), immediately repair track. 4
Lug Wear
1. If lug height (A) is less than 5 mm (0.2 in), replace 5 W190-03-07-002

the rubber crawler as an assembly.
Lower Roller
Rubber Crawler
2. If any part of steel cord (5) appeared on track,

replace the worn rubber crawler as an assembly. A
Lug W190-03-07-003
5
W190-03-07-004
W3-7-3
A
A
A-A W1LA-03-07-001
Unit: mm (in)
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)
Rubber Crawler and Steel Cord Cutting
1. When either of the two rows of steel cord (5) has

cut, replace the rubber crawler as an assembly.
5
Steel Core Separation W190-03-07-005
1. When any steel core (4) has separated, replace

the rubber crawler as an assembly.
W190-03-07-006
W3-7-4
MEMO
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SECTION 4
FRONT ATTACHMENT
 CONTENTS 
Group 1 Front Attachment
Remove and Install Front Attachment ..... W4-1-1
Maintenance 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
1MSW-4-1
（Blank）
1MSW-4-2
FRONT ATTACHMENT / Front Attachment
REMOVE AND INSTALL FRONT ATTACH-
MENT
Removal

IMPORTANT: As for handling of the nylon slings,

1 2, 3, 4
refer to "Precautions for the Handling
5
of Nylon Slings" on page W1-1-5.
1. Remove bolt (8) from cover (7). Remove cover (7)

from boom (5) and boom cylinder (6).
: 17 mm 8
2. Attach a nylon sling onto boom cylinder (6) and

hold boom cylinder (6).
Remove bolt (2), washer (3) and bushing (4) from 7
6
pin (1). Remove pin (1) from boom (5) by using a
bar and hammer. Remove the shims (2 to 4 used)
between both sides of the piston rod and boom
(5).
: 19 mm
3. Operate the control lever and retract the piston W1MS-04-01-001
rod of boom cylinder (6). Secure the piston rod to

the cylinder tube by using a wire.
4. Place the piston rod side of boom cylinder (6) on Piston Rod
the stand.
Wire
W554-02-03-007
Stand
W4-1-1
CAUTION: Front attachment weight: 195 kg Front Attachment Center of Gravity

(430 lb) 5
5. Attach a nylon sling onto the front attachment

center of gravity of boom (5). Take up slack of the
nylon sling. Hold the front attachment.
W1MP-04-01-007
6. Remove plugs (9) (2 used) on the head lamp.

9
W1MS-04-01-002
IMPORTANT: Attach an identification tag onto the 10

removed hoses for assembling.
7. Remove hoses (10) (6 used) on boom (5). Cap
the open ends.
: 19 mm 5
W1MS-04-01-003
W4-1-2
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
9. Remove the thrust plates (2 used) between swing

post (12) and boom (5). Hoist and remove the
front attachment from swing post (12).
14 13 12 W1MS-04-01-004
W4-1-3
Installation
Front Attachment Center of Gravity

CAUTION: Front attachment weight: 195 kg
5
(430 lb)
1. Hoist the front attachment at center of gravity on

boom (5).
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.
3. Install pin (14) to swing post (12) by using a plas-

tic hammer.
14 13 12 W1MS-04-01-004
IMPORTANT: The clearance between nut (13) and
the boss of swing post (12) should
be 3 to 5 mm (0.12 to 0.2 in).
4. Apply LOCTITE #262 onto bolt (11). Insert bolt
(11) to swing post (12) and install bolt (11) with
nuts (13) (2 used).
: 17 mm
: 50 N⋅m (5.0 kgf⋅m, 37 lbf⋅ft)
10
5. Install hoses (10) (4 used) to the pipes on boom
(5).
: 19 mm
: 29.5 N⋅m (3.0 kgf⋅m, 22 lbf⋅ft) 5
W1MS-04-01-003
W4-1-4
6. Attach a nylon sling onto boom cylinder (6). Hold
boom cylinder (6).
CAUTION: If the air in a cylinder is suddenly

compressed, the temperature inside will rise. Piston Rod
As the temperature of the hydraulic oil will
rise, the seals and rings may be damaged.
6
Wire
W554-02-03-007
Stand
7. Start the engine with the piston rod of boom cyl-

inder (6) retracted fully to the stroke end. Extend
boom cylinder (6) slowly. Align the pin (1) holes on
piston rod of boom cylinder (6) and boom (5). In- 1 2, 3, 4
stall the shims (2 used) between both sides of the
piston rod and boom (5).
NOTE: When the work in step 7 is finished, air in
the cylinder is released. 5
8
8. Install pin (1) to boom (5) by using a plastic
hammer. Install pin (1) to boom (5) with bolt (2),
washer (3) and bushing (4).
: 19 mm 6
7
: 50 N⋅m (5.0 kgf⋅m, 37 lbf⋅ft)
9. Install the lower side of cover (7) onto boom cylinder

(6). Install cover (7) onto boom (5) with bolt (8).
: 17 mm
: 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft)
W1MS-04-01-001
W4-1-5
10. Install plug (9) on the head lamp.
11. After completing the work, add hydraulic oil to the

9
specified level. Operate every cylinder fully to the
stroke end several times and release the pressure
in the circuit. Check for any oil leaks of each hose.
W1MS-04-01-002
W4-1-6
(Blank)
W4-1-7
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
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
Side Cutter
D
A
W505-04-01-001
Unit: mm (in)
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)
A 127.5 (5.0) 63 (2.5)
B 56 (2.2) -
Replace
C 62 (2.45) -
D 51 (2.0) -
W4-1-10
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°
NOTE: Dimensions m, n: 90° means the angle for

bolt hole.
W4-1-11
(Blank)
W4-1-12
FRONT ATTACHMENT / Cylinder
REMOVE AND INSTALL CYLINDERS
Remove Bucket Cylinder

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

retract the bucket and arm cylinders, lower the 1
boom, and place the bucket onto the ground.
Insert a wooden block between bucket cylinder
(1) and the arm, and support bucket cylinder (1).
Wooden Block Arm

W571-04-02-001
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
The illustration differs from the description of step 1.

Perform the work with the arm cylinder retracted.
3. Attach a nylon sling onto bucket cylinder (1). Hoist

and hold bucket cylinder (1). Secure the piston
rod to the cylinder tube by using a wire.
1
W571-04-02-002
W4-2-1
4. Remove hoses (8) (2 used) from bucket cylinder 10, 11, 12
(1). Cap the open ends.
: 19 mm
5. Remove bolt (10), washer (11) and bushing (12)

from the plate of pin (9). Remove pin (9) from
bucket cylinder (1) by using a bar and hammer.
Remove the shims (2 used) between the boss of
cylinder tube and arm (7).
: 19 mm
7
6. Remove bucket cylinder (1) from arm (7).
W1MS-04-02-009
9 1 8
The illustration differs from the description of step 1.

Perform the work with the arm cylinder retracted.
W4-2-2
Install Bucket Cylinder
IMPORTANT: Insert the shims (2 used) into both

sides of the cylinder tube boss.
When the shims should be used in
order to adjust the clearance, the
shims should be inserted at both
sides respectively. (Clearance: 0.5
mm (0.02 in) or less).
IMPORTANT: Apply grease onto the lip of dust 10, 11, 12
seal for bucket cylinder (1), boss
side and bushing inside (both
bottom and rod sides).
1. Align the pin (9) holes on bucket cylinder (1) and
arm (7). Insert the shims (2 used) between the
boss of cylinder tube (1) and arm (7).
2. Install pin (9) to arm (7) by using a plastic hammer.

Apply LOCTITE #262 onto bolt (10). Install the
plate of pin (9) to arm (7) with bushing (12),
washer (11) and bolt (10). 7
: 19 mm
: 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft)
W1MS-04-02-009
9 1 8
3. Install hoses (8) (2 used) to bucket cylinder (1).
： 19 mm The illustration differs from the description of removal
： 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft) procedure, step 1. Perform the work with the arm
cylinder retracted.
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
The illustration differs from the description of removal

procedure, step 1. Perform the work with the bucket
cylinder retracted.
W4-2-3
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)

specified level. Operate every cylinder fully to the W1MS-04-02-008
stroke end several times and release the pressure The illustration differs from the description of removal
in the circuit. Check each connection of hoses for procedure, step 1. Perform the work with the bucket
any oil leaks. cylinder retracted.
W4-2-4
Remove Arm Cylinder
1
1. Park the machine on a solid, level surface. Fully

retract the bucket and arm cylinders, lower the
boom, and place the bucket onto the ground.
Insert a wooden block between arm cylinder (1)
and boom (2), and support arm cylinder (1).
Wooden Block 2
W571-04-02-004
2. Remove bolt (4), washer (5) and bushing (6) from

3 4, 5, 6 1
the plate of pin (3). Remove pin (3) by using a bar
and hammer. Remove the shims (2 used)
between the boss of piston rod and arm (7).
: 19 mm
7
3. Secure the piston rod to the cylinder tube by using
a wire.
4. Remove bolt (13) from clamp (12). Remove clamp

W1MS-04-02-009
(12) from arm cylinder (1). The illustration differs from the description of step 1.
: 13 mm Perform the work with the arm cylinder retracted.
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
6. Attach a nylon sling onto arm cylinder (1). Hoist

and hold arm cylinder (1). 2
14 13 12 11 8, 9, 10
W1MS-04-02-010
W4-2-5
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.
cylinder tube and boom (2).
: 19 mm
8. Remove arm cylinder (1) from boom (2).

2
14 13 12 11 8, 9, 10
W1MS-04-02-010
W4-2-6
Install Arm Cylinder
IMPORTANT: Insert the shims into both sides of

1
the cylinder boss. When the shims
should be used in order to adjust the
clearance, the shims should be
inserted at both sides respectively.
(Clearance: 0.5 mm (0.02 in) or less).
1. Apply grease onto the lip of dust seal for arm
cylinder (1), boss side and bushing inside (both
2
2. Align the pin (11) holes on arm cylinder (1) and
14 13 12 11 8, 9, 10
boom (2). Insert the shims (2 used) between the W1MS-04-02-010
boss of cylinder tube and arm (2).
3. Install pin (11) by using a plastic hammer. Apply

LOCTITE #262 onto bolt (8). Install the plate of
pin (11) to boom (2) with bushing (10), washer (9)
and bolt (8).
: 19 mm
: 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft)
4. Install hoses (14) (2 used) to arm cylinder (1).

: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
5. Install clamp (12) to arm cylinder (1) with bolt (13).

: 13 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)
W4-2-7
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.
7. Insert the shims (2 used) between the boss of

piston rod (1) and arm (7). Install pin (3) by using
a plastic hammer. Apply LOCTITE #262 onto bolt
(4). Install the plate of pin (3) to arm (7) with
bushing (6), washer (5) and bolt (4).
: 19 mm
: 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft)
W1MS-04-02-009
The illustration differs from the description of removal

8. After completing the work, add hydraulic oil to the procedure, step 1. Perform the work with the arm
specified level. Operate every cylinder fully to the cylinder retracted.
in the circuit. Check each connection of hoses for
any oil leaks.
W4-2-8
Remove Boom Cylinder
CAUTION: Bleed air from the hydraulic oil 1 2, 3, 4 5

tank before doing any work (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on
W1-4-1.).
1. Remove bolt (8) and washer (9) from cover (7).

Remove cover (7) from boom cylinder (6) and 8, 9
boom (5).
: 17 mm
7
W1MS-04-01-001
2. Attach a nylon sling onto boom cylinder (6). Hoist

and hold boom cylinder (6). Remove bolt (2),
washer (3) and bushing (4) from the plate of pin
(1). Remove pin (1) by using a bar and hammer.
piston rod and boom (3).
6
: 19 mm
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
4. Remove hoses (10) (2 used) from boom cylinder

: 19 mm
10 6 W1MS-04-02-011
W4-2-9
5. Remove nuts (12) (2 used) from bolt (11).
Remove bolt (11) from swing post (14).
: 13 mm
6. Remove pin (13) from swing post (14) by using a

bar and hammer. Remove the shims (2 used)
from both sides of the cylinder tube boss.
7. Remove boom cylinder (6) from swing post (14).

6
14 13 11, 12 W1MS-04-01-004
W4-2-10
Install Boom Cylinder
IMPORTANT: Insert the shims into both sides of

the cylinder tube boss. When the
shims should be used in order to
adjust the clearance, the shims
should be inserted at both sides
respectively. (Clearance: 0.5 mm
(0.02 in) or less).
1. Apply grease onto the lip of dust seal for boom
cylinder (6), boss side and bushing inside (both
2. Apply grease onto the surface of pin (13). Align

the pin (13) holes on boom cylinder (6) and swing
post (14). Insert the shims (2 used) between the
6
boss of cylinder tube and swing post (14).
3. Install pin (13) by using a plastic hammer.
IMPORTANT: The clearance between nuts (12) (2

used) and the boss of swing post
14 13 11, 12
(14) should be 3 to 5 mm. W1MS-04-01-004
4. Apply LOCTITE #262 onto bolt (11). Insert bolt

(11) to swing post (14) and secure bolt (11) with
nuts (12) (2 used).
: 13 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)
5. Hoist boom cylinder (6). Install hoses (10) (2

used) to boom cylinder (6).
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
10 6 W1MS-04-02-011
W4-2-11
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).
7. Insert the shims (2 used) between the boss of

boom cylinder (6) piston rod and boom (5). Install 8, 9
pin (1) by using a plastic hammer. Apply LOCTITE
#262 onto bolt (2). Install the plate of pin (1) to
boom (5) with bushing (4), washer (3) and bolt (2).
: 19 mm 7
: 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft)
8. Install cover (7) onto boom cylinder (6). Install 6

cover (7) to boom (5) with washer (9) and bolt (8).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft) W1MS-04-01-001

specified level. Operate every cylinder fully to the
in the circuit. Check each connection of hoses for
any oil leaks.
W4-2-12
Remove Boom Swing Cylinder

1. Insert a key into key hole 1 on cover (1) and

1
release the lock of cover (1). Open cover (1) and
release the lock of cover (2). Insert a key into key
hole 2 and release the lock of cover (2). Open and Key Hole 1
lock cover (2).
2
W1MS-04-02-014

Remove cover (8) from main frame (7).
: 17 mm
3. Remove bolt (5) and nuts (6) (2 used) from swing

post (4). Remove pin (3) from swing post (4) by 3
using a plastic hammer.
: 13 mm 9 4
5, 6
7 Key Hole 2 W1MS-04-02-015
4. Start the engine and rotate main frame (7) 90

degrees clockwise. Stop the engine.
NOTE: Rotate main frame (7) 90 degrees
clockwise and secure enough space to
work for removing the cover under main
frame (7).
7 W1MS-04-02-016
W4-2-13
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
8. Remove boom swing cylinder (12) from main 12
frame (7).
7 W1MS-04-02-020
W4-2-15
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
2. Align the pin (14) holes on main frame (7) and

boom swing cylinder (12). Install pin (14) to main
frame (7) by using a plastic hammer. Install the
plate of pin (14) to main frame (7) with bolt (15)
and bushing (16).
: 19 mm
: 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft)
14
15, 16 W1MS-04-02-019
3. Install hoses (13) (2 used) to boom swing cylinder 12

(12).
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
13 W1MS-04-02-018
W4-2-16
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
5. Start the engine. Align the pin (3) holes on the

piston rod of boom swing cylinder (12) and swing
post (4).
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
7. Close and lock covers (1, 2).
(2 used).
: 17 mm
1
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
W1MS-04-02-014
W4-2-17
Remove Blade Cylinder

1
Remove cover (1) from blade cylinder (3). 2
: 17 mm
3 W1MS-04-02-012
2. Remove bolt (5), washer (6) and bushing (7) from

the plate of pin (4). Remove pin (4) from the 3
center frame by using a bar and hammer. 4 5, 6, 7
: 19 mm
3. Start the engine and retract the piston rod of blade

cylinder (3) to the stroke end. Secure the piston
rod to the cylinder tube by using a wire.
4. Remove hoses (8) (2 used) from blade cylinder

: 19 mm
5. Remove bolt (10), washer (11) and bushing (12)

from the plate of pin (9). Remove pin (9) from the
blade by using a bar and hammer. 10, 11, 12 9 8
W1MS-04-02-013
: 19 mm
6. Remove blade cylinder (3) from the blade.
W4-2-18
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
2. Apply grease onto the surface of pin (9). Align the

pin (9) holes on blade cylinder (3) and the blade.
Install pin (9) into the blade by using a plastic
hammer. Install the plate of pin (9) to the blade
with bushing (12), washer (11) and bolt (10).
: 19 mm
: 110 N⋅m (11 kgf⋅m, 81 lbf⋅ft)
3. Install hoses (8) (2 used) to blade cylinder (3).

: 19 mm W1MS-04-02-013
10, 11, 12 9 8
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
4. Retract the piston rod of blade cylinder (3) to the

stroke end. Start the engine. Extend the piston
rod slowly. Align the pin (4) holes on the piston
rod of boom cylinder (3) and center frame.
1
5. Apply grease onto the surface of pin (4). Install
pin (4) by using a plastic hammer.
Install the plate of pin (4) to the center frame with 2
bushing (7), washer (6) and bolt (5).
: 19 mm
: 110 N⋅m (11 kgf⋅m, 81 lbf⋅ft)
6. Install cover (1) onto blade cylinder (3) with bolts

(2) (2 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
3 W1MS-04-02-012
W4-2-19
Remove Side Frame Extend/Retract Cylinder

1. Operate side frame extend/retract lever (2) and 1

fully extend the left and right side frames.
W1MS-04-02-026
IMPORTANT: Place the stands (4 used) under

track (6) and support the machine. 4
2. Operate control lever (1) and rotate the main
frame to the back of machine. Operate blade
lever (3), lower blade (5) and raise the front of
machine. Operate control lever (1), and set the
angle between boom (4) and arm (8) at 90° to 90° to 110°
110°. Put the bottom of bucket (7) onto the ground
and raise the rear of machine in the horizontal 8 5
position. Place the stands (4 used) under track (6)
and support the machine.
W1MS-04-02-027
7 Stand 6
W4-2-20
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
4. Remove bolts (17) (2 used) of plate (19) from tube

mounting part (B) of the side frame extend/retract
cylinder on right side frame (11). Remove plate
(19) from right side frame (11). Remove pin (18)
from right side frame (11) by using a bar and
hammer. 13 12 W1MS-04-02-024
: 13 mm
14
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
Pin (14) Hole 21 Pin (18) Hole

W1MS-04-02-025
W4-2-21
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
8. Remove bolts (26) (3 used) and washers (27) (3

used) from cover (25). Remove cover (25) from
right side frame (11).
: 17 mm 25
26, 27
11
W1MS-04-02-029
9. Remove hoses (29) (4 used) from travel device

(28). Cap the open ends. Attach an identification
tag onto the removed hoses for assembling.
: 19 mm, 22 mm
29
28
W1MS-04-02-030
W4-2-22
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
CAUTION: The right side frame (11) assembly 9

11. Remove the right side frame (11) assembly from 10

center frame (10).
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
Install Side Frame Extend/Retract Cylinder 1

tank before doing any work. (Refer to BLEED 3

frame to the right side frame (11) side. Set the
angle between boom (4) and arm (8) at from 90° 2
to 110°. Put the bottom of bucket (7) onto the
ground and raise right side frame (11). 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
W4-2-25
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
CAUTION: The right side frame (11)

assembly weight: 180 kg (397 lb)
3. Clean and apply grease to the inserting part of

center frame (10) on the right side frame (11)
assembly. Insert the right side frame (11)
assembly into center frame (10).
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
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
washers (27) (3 used) and bolts (26) (3 used).

: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
25
26, 27
11
W1MS-04-02-029
IMPORTANT: Place the stands (4 used) under 1
track (6) and support the machine.
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
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)
Pin (14) Hole 21 Pin (18) Hole

W1MS-04-02-025
9. Align the pin (18) holes on the tube of side frame

extend/retract cylinder (20) and right side frame
9 10 11
(11). Install pin (18) into right side frame (11) by
using a bar and hammer. Install plate (19) to right
side frame (11) with bolts (17) (2 used).
: 13 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)
A B
10. Operate the side frame extend/retract lever, and
align the pin (14) holes on the piston rod of side
frame extend/retract cylinder (20) and left side
frame (9). Install pin (14) into left side frame (9) by
using a bar and hammer. Install plate (15) to left
side frame (9) with bolts (16) (2 used).
: 13 mm 13 W1MS-04-02-024
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)

14
15
16
Detail for Part A
W1MP-04-02-009
17
19
18
W1MP-04-02-010
Detail for Part B
W4-2-28
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
extend and retract side frame extend/retract

cylinder (20) fully for several times.
W4-2-29
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
1- Piston Rod 7- Bushing 12 - Stop Ring 17 - Piston

2- Wiper Ring 8- Backup Ring 13 - Backup Ring 18 - Steel Ball
3- Cylinder Head 9- U-Ring 14 - O-Ring 19 - Set Screw
4- O-Ring 10 - Cushion Ring 15 - Cushion Bearing 20 - Seal Ring Assembly
5- Backup Ring 11 - Spacer 16 - Slide Ring (2 Used) 21 - Cylinder Tube
6- O-Ring
W4-2-30
Arm Cylinder
16
20
19
18
17
16
9
7
6
5
4
3
2
21
W1MS-04-02-002
1- Piston Rod 5- Backup Ring 16 - Slide Ring (2 Used) 19 - Set Screw

2- Wiper Ring 6- O-Ring 17 - Piston 20 - Seal Ring Assembly
3- Cylinder Head 7- Bushing 18 - Steel Ball 21 - Cylinder Tube
4- O-Ring 9- U-Ring
W4-2-31
Bucket Cylinder
16
20
19
18
17
16
9
7
6
5
4
3
2
21
W1MS-04-02-004

4- O-Ring 9- U-Ring
W4-2-32
Blade Cylinder
16
20
19
18
17
16
9
7
6
5
4
3
2
21
W1MS-04-02-003

4- O-Ring 9- U-Ring
W4-2-33
Boom Swing Cylinder
16
20
19
18
17
16
9
7
6
5
4
3
2
21
W1MS-04-02-005

4- O-Ring 9- U-Ring
W4-2-34
Side Frame Extend/Retract Cylinder
16
20
19
18
17
16
7
9
8
6
5
4
3
2
21
W1MS-04-02-006
1- Piston Rod 5- Backup Ring 9- U-Ring 19 - Set Screw

2- Wiper Ring 6- O-Ring 16 - Slide Ring (2 Used) 20 - Seal Ring Assembly
3- Cylinder Head 7- Bushing 17 - Piston 21 - Cylinder Tube
4- O-Ring 8- Backup Ring 18 - Steel Ball
W4-2-35
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
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)
IMPORTANT: The lock washer is provided on

cylinder tube (21) and forms an Hooked Spanner
integral part. Do not 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
W4-2-37
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
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).
IMPORTANT: Slide rings (16) (2 used) cannot be

reused. When disassembling the
cylinder, replace slide ring (16) with
the new one.
IMPORTANT: When removing the seals, do not
damage the parts. ST 8055
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. 3
17 7
20
W1MP-04-02-016
W506-04-02-007
W4-2-39
Disassemble Arm Cylinder
16
20
19
18
17
16
9
7
6
5
4
3
2
21
W1MS-04-02-002
W4-2-40
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
16
20
19
18
17
16
9
7
6
5
4
3
2
21
W1MS-04-02-002
W4-2-42
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
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
Arm, Bucket, Blade and Boom Swing Cylinders

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
1- Piston Rod 7- Bushing 12 - Stop Ring 17 - Piston

2- Wiper Ring 8- Backup Ring 13 - Backup Ring 18 - Steel Ball
3- Cylinder Head 9- U-Ring 14 - O-Ring 19 - Set Screw
4- O-Ring 10 - Cushion Ring 15 - Cushion Bearing 20 - Seal Ring Assembly
5- Backup Ring 11 - Spacer 16 - Slide Ring (2 Used) 21 - Cylinder Tube
6- O-Ring
W4-2-44
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
5. Install backup rings (5, 13) and O-rings (4, 6, 14)

W1MP-04-02-018 to the outside of cylinder head (3).
W4-2-45
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
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
20B 20A, 20B
Special Tool 17
Special Tool
20A
16
W566-04-02-011
W566-04-02-010 IMPORTANT: Install slide rings (16) (2 used) with

their slits positioned 180° facing the
opposite of each other.
8. Install slide rings (16) (2 used) to piston (17).
9. Wind a tape onto the thread of piston rod (1) in

order to protect the thread from damaging.
Remove the tape just before rotating the cylinder
head (3) assembly. Rotate and install the cylinder
head (3) assembly to piston rod (1).
W4-2-47
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
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
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
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
7 4. Install wiper ring (2) to the inside of cylinder head

(3) by using special tool.
Special tool:
Arm and Blade Cylinders: ST 8044
3
Boom Swing, Bucket and Side Frame
Extend/Retract Cylinders: ST 7377
W1MP-04-02-018
Special Tool
W1MP-04-02-019
W4-2-51
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
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
IMPORTANT: Install slide rings (16) (2 used) with

their slits positioned 180° facing the
opposite of each other.
7. Install slide rings (16) (2 used) to piston (17).
8. Wind a tape onto the thread of piston rod (1) in

order to protect the thread from damaging.
Remove the tape just before rotating the cylinder
head (3) assembly. Rotate and install the cylinder
head (3) assembly to piston rod (1).
W4-2-53
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
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)
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
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)
Boom -0.025 -0.010 Bend Run Out Remedy

35 -0.064 (1.378 -0.025 in) 0.5 (0.02) 1.0 (0.039) Repair
Arm -0.025 -0.010 1.0 (0.039) 2.0 (0.079) Replace
35 -0.064 (1.378 -0.025 in)
Bucket -0.025 -0.010
30 -0.064 (1.181 -0.025 in)
Boom Swing -0.025 -0.010
30 -0.064 (1.181 -0.025 in)
Blade -0.025 -0.010
35 -0.064 (1.378 -0.025 in)
Side Frame -0.025 -0.010
30 -0.064 (1.181 -0.025 in)
Extend/Retract
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
Cooling System Electric Wiring

Before You Begin Servicing .......................... 8-3 Electric Wiring Precautions ........................ 12-3
Introduction.................................................... 8-5 Electric Wire Resistance ............................ 12-4
Cooling System Diagram ............................... 8-5 Battery Cable Resistance ............................. 12-5
Engine Coolant Pump Components .............. 8-6 Electrical Wire Sizes - Voltage Drop ........... 12-6
Engine Coolant System Check ....................... 8-7 Conversion of AWG to European Standards 12-7
Engine Coolant Pump .................................. 8-7
Troubleshooting
Lubrication System Special Service Tools .................................. 13-3
Before You Begin Servicing .......................... 9-3 Troubleshooting By Measuring
Introduction.................................................... 9-5 Compression Pressure ........................... 13-4
Oil Pump Service Information ........................ 9-5 Quick Reference Table For Troubleshooting 13-6
Lubrication System Diagram ........................ 9-7 Troubleshooting Charts .............................. 13-7
Checking Engine Oil Pressure ...................... 9-8 Electric Wiring .......................................... 13-19
Trochoid Oil Pump ......................................... 9-8
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.
ii TNV IDI Service Manual

TABLE OF
CONTENTS
Page
Table of Contents ................................................................................... iii
Introduction ......................................................................................... 1-1
Yanmar Warranties.............................................................................. 2-1
Safety.................................................................................................... 3-1
General Service Information .............................................................. 4-1
Periodic Maintenance ......................................................................... 5-1
Engine .................................................................................................. 6-1
Fuel System ......................................................................................... 7-1
Cooling System ................................................................................... 8-1
Lubrication System ............................................................................. 9-1
Starter Motor...................................................................................... 10-1
Alternator ........................................................................................... 11-1
Electric Wiring ................................................................................... 12-1
Troubleshooting ................................................................................ 13-1
TNV IDI Service Manual iii

TABLE OF CONTENTS
This Page Intentionally Left Blank
iv TNV IDI Service Manual

Section 1
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.
TNV IDI Service Manual 1-1

INTRODUCTION
1-2 TNV IDI Service Manual

Section 2
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

YANMAR WARRANTIES

Yanmar Limited Warranty YANMAR WARRANTIES
YANMAR LIMITED WARRANTY

What is Covered by this Warranty?
Yanmar warrants to the original retail purchaser that a new Yanmar TNV Series Industrial Engine will be
free from defects in material and / or workmanship for the duration of the warranty period.
Note: Yanmar engines may be equipped with external components including, but not limited to: wiring
harnesses, electrical devices, control panels, radiators, air filters, fuel filters, and / or exhaust
systems that are supplied and / or installed by manufacturers other than Yanmar. For warranty
information on such external components, please contact the machine or component manufacturer
directly or see your authorized Yanmar dealer or distributor.
THIS WARRANTY IS PROVIDED IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED.
YANMAR SPECIFICALLY DISCLAIMS ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR
FITNESS FOR A PARTICULAR PURPOSE, except where such disclaimer is prohibited by law. IF SUCH
DISCLAIMER IS PROHIBITED BY LAW, THEN IMPLIED WARRANTIES SHALL BE LIMITED IN
DURATION TO THE LIFE OF THE EXPRESSED WARRANTY.
How Long is the Warranty Period?

The Yanmar standard limited warranty period runs for a period of twenty-four (24) months or
two-thousand (2000) engine operation hours, whichever occurs first. An extended limited warranty of
thirty-six (36) months or three thousand (3000) engine operating hours, whichever occurs first, is provided
for these specific parts only: the cylinder block, cylinder head, crankshaft forging, connecting rods,
flywheel, flywheel housing, camshaft, timing gear, and gear case. The Warranty Period for both the
standard limited warranty and the extended limited warranty (by duration or operation hours) begins on the
date of delivery to the original retail purchaser and is valid only until the applicable warranted duration has
passed or the operation hours are exceeded, whichever comes first.
What the Engine Owner Must Do:

If you believe your Yanmar engine has experienced a failure due to a defect in material and / or
workmanship, you must contact an authorized Yanmar industrial engine dealer or distributor within thirty
(30) days of discovering the failure. You must provide proof of ownership of the engine, proof of the date of
the engine purchase and delivery, and documentation of the engine operation hours. Acceptable forms of
proof of delivery date include, but are not limited to: the original warranty registration or sales receipts or
other documents maintained in the ordinary course of business by Yanmar dealers and / or distributors,
indicating the date of delivery of the Yanmar product to the original retail purchaser. This information is
necessary to establish whether the Yanmar product is still within the warranty period. Thus, Yanmar
strongly recommends you register your engine as soon as possible after purchase in order to facilitate any
future warranty matters.
You are responsible for the transportation of the engine to and from the repair location as designated by
Yanmar.

YANMAR WARRANTIES Yanmar Limited Warranty
Yanmar Limited Warranty - Continued
To Locate an Authorized Yanmar Industrial Engine Dealer or Distributor:

You can locate your nearest authorized Yanmar industrial engine dealer or distributor by visiting the Yanmar
Corp., LTD. website at:
http://www.yanmar.co.jp (The Japanese language page will be displayed.) For English language “click” on
“English Page.”)
• “Click” on “Network” in the website heading to view the “Yanmar Worldwide Network.”
• Choose and “Click” on the desired product group.
• “Click” on the Icon closest to your region.
• “Click” on the desired country or Associate company to locate your nearest authorized Yanmar industrial
engine dealer or distributor.
• You may also contact Yanmar by clicking on “Inquiry” in the website heading and typing in your question
or comment.
What Yanmar Will Do:

Yanmar warrants to the original retail purchaser of a new Yanmar engine that Yanmar will make such
repairs and / or replacements at Yanmar’s option, of any parts(s) of the Yanmar product covered by this
Warranty found to be defective in material and / or workmanship. Such repairs and / or replacements will be
made at a location designated by Yanmar at no cost to the purchaser for parts or labor.
What is Not Covered by this Warranty?

This Warranty does not cover parts affected by or damaged by any reason other than defective materials or
workmanship including, but not limited to, accident, misuse, abuse, “Acts of God”, neglect, improper
installation, improper maintenance, improper storage, the use of unsuitable attachments or parts, the use
of contaminated fuels, the use of fuels, oils, lubricants, or fluids other than those recommended in your
Yanmar Operation Manual, unauthorized alterations or modifications, ordinary wear and tear, and rust or
corrosion. This Warranty does not cover the cost of parts and / or labor required to perform normal /
scheduled maintenance on your Yanmar engine. This Warranty does not cover consumable parts such as,
but not limited to, filters, belts, hoses, fuel injector nozzles, lubricants and cleaning fluids. This warranty
does not cover the cost of shipping the product to or from the warranty repair facility.

Yanmar Limited Warranty YANMAR WARRANTIES
Yanmar Limited Warranty - Continued
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.
Retail Purchaser Registration
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.

YANMAR WARRANTIES Emission System Warranty
EMISSION SYSTEM WARRANTY
YANMAR CO., LTD. LIMITED EMISSION CONTROL SYSTEM

WARRANTY - USA ONLY
Your Warranty Rights and Obligations:
California
The California Air Resources Board (CARB), the Environmental Protection Agency (EPA) and Yanmar Co.,
Ltd. hereafter referred to as Yanmar, are pleased to explain the emission control system warranty on
your industrial compression-ignition engine. In California, model year 2000 or later off-road compression-
ignition engines must be designed, built and equipped to meet the State’s stringent anti-smog standards. In
all states, 1998 and later non-road compression-ignition engines must be designed, built and equipped to
meet the United States EPA emissions standards. Yanmar warrants the emission control system on your
engine for the periods of time listed below provided there has been no abuse, neglect or improper
maintenance of your engine.
Your emission control system may include parts such as the fuel injection system and the air induction
system. Also included may be hoses, belts, connectors and other emission-related assemblies.
Where a warrantable condition exists, Yanmar will repair your non-road compression-ignition engine at no
charge to you including diagnosis, parts and labor.
Manufacturer’s Warranty Period:

The model year 1998 or later certified and labeled non-road compression-ignition engines are warranted
for the periods listed below. If any emission-related part on your engine is found to be defective during the
applicable warranty period, the part will be replaced by Yanmar.
Engine Type Warranty Period by Number of Years or Hours of Operation

The warranty period is five (5) years or 3,000 hours of use, whichever occurs first.
Constant speed engines rated at or above
In the absence of a device to measure the hours of use, the engine has a
50 hp SAE (37 kW)
warranty period of five (5) years.
Constant speed engines rated under 50 hp The warranty period is two (2) years or 3,000 hours of use, whichever occurs first.
SAE (37 kW) with rated speeds greater than In the absence of a device to measure the hours of use, the engine has a
or equal to 3,000 rpm warranty period of two (2) years.
The warranty period is five (5) years or 3,000 hours of use, whichever occurs first.
Engines rated at or above 26 hp SAE
In the absence of a device to measure the hours of use, the engine has a
(19 kW)
warranty period of five (5) years.
The warranty period is two (2) years or 3,000 hours of use, whichever occurs first.
Engines rated under 26 hp SAE (19 kW) In the absence of a device to measure the hours of use, the engine has a
warranty period of two (2) years.

Emission System Warranty YANMAR WARRANTIES
Limited Emission Control System Warranty - USA Only - Continued
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.

YANMAR WARRANTIES Emission System Warranty
Limited Emission Control System Warranty - USA Only - Continued
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.
Owner’s Warranty Responsibilities:

As the engine owner, you are responsible for the performance of the required maintenance listed in
your owner’s manual. Yanmar recommends that you retain all documentation, including receipts, covering
maintenance on your non-road compression-ignition engine, but Yanmar cannot deny warranty solely for
the lack of receipts, or for your failure to ensure the performance of all scheduled maintenance.
Yanmar may deny your warranty coverage of your non-road compression-ignition engine if a part has failed
due to abuse, neglect, improper maintenance or unapproved modifications.
Your engine is designed to operate on diesel fuel only. Use of any other fuel may result in your engine no
longer operating in compliance with applicable emissions requirements.
You are responsible for initiating the warranty process. You must present your engine to a Yanmar dealer as
soon as a problem exists. The warranty repairs should be completed by the dealer as expeditiously as
possible. If you have any questions regarding your warranty rights and responsibilities, or would like
information on the nearest Yanmar dealer or authorized service center, you should contact Yanmar
America Corporation at 1-800-872-2867.

Section 3
SAFETY
Page
Safety Statements ........................................................................... 3-3
Safety Precautions .......................................................................... 3-4

SAFETY

Safety Statements SAFETY
SAFETY STATEMENTS A CAUTION

Yanmar is concerned for your safety and your Caution (the word “CAUTION” is in black
machine’s condition. Safety statements are one of letters with a yellow rectangle behind it)
the primary ways to call your attention to the – indicates a potentially hazardous
potential hazards associated with Yanmar TNV situation which, if not avoided, may
engine operation. Follow the precautions listed result in minor or moderate injury.
throughout the manual before operation, during
0000001en
operation and during periodic maintenance
procedures for your safety, the safety of others and
to protect the performance of your engine. Keep the CAUTION
labels from becoming dirty or torn and replace Caution without the safety alert symbol
them if they are lost or damaged. Also, if you need indicates a potentially hazardous
to replace a part that has a label attached to it, situation that can cause damage to the
make sure you order the new part and label at the machine, personal property and / or the
same time. environment or cause the machine to
operate improperly.
This safety alert symbol appears 0000001en
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

SAFETY Safety Precautions
SAFETY PRECAUTIONS A DANGER

A DANGER
FIRE AND EXPLOSION HAZARD!

• Diesel fuel is flammable and explosive
under certain conditions.
SCALD HAZARD!
• When you remove any fuel system
• NEVER remove the radiator cap if the component to perform maintenance
engine is hot. Steam and hot engine (such as changing the fuel filter) place
coolant will spurt out and seriously an approved container under the
burn you. Allow the engine to cool opening to catch the fuel.
down before you attempt to remove
the radiator cap. • NEVER use a shop rag to catch the
fuel. Vapors from the rag are
• Tighten the radiator cap securely after flammable and explosive.
you check the radiator. Steam can
spurt out during engine operation if • Wipe up any spills immediately.
the cap is loose. • Wear eye protection. The fuel system
• ALWAYS check the level of the engine is under pressure and fuel could spray
coolant by observing the reserve tank. out when you remove any fuel system
component.
• Failure to comply will result in death or
serious injury. • Failure to comply will result in death or
serious injury.
0000002en
0000009en
A DANGER A DANGER
EXPLOSION HAZARD! FIRE AND EXPLOSION HAZARD!

• Keep the area around the battery • Only use the key switch to start the
well-ventilated. While the engine is engine.
running or the battery is charging,
• NEVER jump-start the engine. Sparks
hydrogen gas is produced which can
caused by shorting the battery to the
be easily ignited.
starter terminals may cause a fire or
• Keep sparks, open flame and any other explosion.
form of ignition away while the engine
is running or battery is charging.
serious injury.
• Failure to comply will result in death or 0000004en
serious injury.
0000003en

Safety Precautions SAFETY
A DANGER A DANGER
FIRE AND EXPLOSION HAZARD! FIRE AND EXPLOSION HAZARD!

• Diesel fuel is flammable and explosive • Diesel fuel is flammable and explosive
under certain conditions. under certain conditions.
• NEVER remove the fuel cap with the • Only fill the fuel tank with diesel fuel.
engine running. Filling the fuel tank with gasoline may
• Failure to comply will result in death or result in a fire and will damage the
serious injury. engine.
0000011en • NEVER refuel with the engine running.
• Wipe up all spills immediately.
A DANGER • Keep sparks, open flames or any other
form of ignition (match, cigarette,
static electric source) well away when
refueling.
• NEVER overfill the fuel tank.
• Fill the fuel tank. Store any containers
• Diesel fuel is flammable and explosive containing fuel in a well-ventilated
under certain conditions. area, away from any combustibles or
• NEVER use diesel fuel as a cleaning sources of ignition.
agent. • Failure to comply will result in death or
• Failure to comply will result in death or serious injury.
serious injury. 0000005en
0000012en

A DANGER A DANGER

• If the unit has an electric fuel pump, • Be sure to place the diesel fuel
when you prime the fuel system, turn container on the ground when
the key switch to the ON position for transferring the diesel fuel from the
10 to 15 seconds to allow the electric pump to the container. Hold the hose
fuel pump to prime the system. nozzle firmly against the side of the
• If the unit has a mechanical fuel pump, container while filling it. This prevents
when you prime the fuel system, static electricity buildup which could
operate the fuel priming lever of the cause sparks and ignite fuel vapors.
mechanical fuel pump several times • NEVER place diesel fuel or other
until the fuel filter cup is filled with flammable material such as oil, hay or
fuel. dried grass close to the engine during
• Failure to comply will result in death or engine operation or shortly after
serious injury. shutdown.
0000010en • Failure to comply will result in death or
serious injury.
0000014en

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.
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

serious injury.
0000007en

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
ALCOHOL AND DRUG HAZARD!

• NEVER operate the engine while you
are under the influence of alcohol or
drugs.
• NEVER operate the engine when you
are feeling ill.
or serious injury.
0000004en

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.
or serious injury.
BURN HAZARD! 0000008en
• Batteries contain sulfuric acid. NEVER

allow battery fluid to come in contact A WARNING
with clothing, skin or eyes. Severe
burns could result. ALWAYS wear
safety goggles and protective clothing
when servicing the battery. If battery
fluid contacts the eyes and / or skin,
immediately flush the affected area
with a large amount of clean water and SHOCK HAZARD!
obtain prompt medical treatment. • Turn off the battery switch (if
• Failure to comply could result in death equipped) or disconnect the negative
or serious injury. battery cable before servicing the
electrical system.
0000007en
• Check the electrical harnesses for
cracks, abrasions, and damaged or
corroded connectors. ALWAYS keep
the connectors and terminals clean.
or serious injury.
0000009en

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.
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.
or serious injury.
0000016en

A WARNING A CAUTION
FUME / BURN HAZARD!

• Always read and follow safety related FLYING OBJECT HAZARD!
precautions found on containers of • ALWAYS wear eye protection when
hazardous substances like parts servicing the engine and when using
cleaners, primers, sealants and compressed air or high-pressure
sealant removers. water. Dust, flying debris, compressed
• Failure to comply could result in death air, pressurized water or steam may
or serious injury. injure your eyes.
0000014en • Failure to comply may result in minor
or moderate injury.
A CAUTION 0000003en
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
• Only use clean diesel fuel.

• NEVER remove the primary strainer (if CAUTION
equipped) from the fuel tank filler port. Protect the air cleaner, turbocharger (if
If removed, dirt and debris could get equipped) and electric components
into the fuel system causing it to clog. from damage when you use steam or
0000004en high-pressure water to clean the engine.
0000014en
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 • Follow the guidelines of the EPA or

other governmental agencies for the
For maximum engine life, Yanmar proper disposal of hazardous
recommends that when shutting the materials such as engine oil, diesel
engine down, you allow the engine to fuel and engine coolant. Consult the
idle, without load, for five minutes. This local authorities or reclamation facility.
will allow the engine components that
operate at high temperatures, such as • NEVER dispose of hazardous
the turbocharger (if equipped) and materials irresponsibly by dumping
exhaust system, to cool slightly before them into a sewer, on the ground, or
the engine itself is shut down. into ground water or waterways.
0000008en • Failure to follow these procedures may
seriously harm the environment.
CAUTION 0000013en
NEVER use an engine starting aid such

as ether. Engine damage will result.
0000009en

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
minimum or maximum engine speeds

and loads for the next four to five CAUTION
hours.
NEVER use high-pressure water or
• During the break-in period, carefully compressed air at greater than 28 psi
observe the engine oil pressure and (193 kPa; 19 686 mmAq) or a wire brush
engine temperature. to clean the radiator fins. Radiator fins
• During the break-in period, check the damage easily.
engine oil and coolant levels 0000016en
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
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
after the water has drained out.

0000025en

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
Do not operate the engine if the

alternator is producing unusual sounds. CAUTION
Damage to the alternator will result. Do not use a high-pressure wash
0000039en directly on the alternator. Water will
damage the alternator and result in
inadequate charging.
CAUTION
0000049en
If the engine coolant pump must be
replaced, replace the engine coolant
pump as an assembly only. Do not CAUTION
attempt to repair the engine coolant Do not reverse the positive (+) and
pump or replace individual components. negative (-) ends of the battery cable.
0000041en The alternator diode and stator coil will
be damaged.
CAUTION 0000050en
Use a new special O-ring between the

engine coolant pump and the joint. Be CAUTION
sure to use the special O-ring for each When the battery indicator goes out, it
engine model. Although the O-ring should not come on again. The battery
dimensions are the same as a indicator only comes on during
commercially available O-ring, the operation if the alternator fails. However,
material is different. if an LED is used in the battery indicator,
0000042en the LED will shine faintly during normal
operation.
CAUTION 0000051en
Remove or install the high-pressure fuel

injection lines as an assembly whenever CAUTION
possible. Disassembling the Using a non-specified V-belt will cause
high-pressure fuel injection lines from inadequate charging and shorten the
the retainers or bending any of the fuel belt life. Use the specified belt.
lines will make it difficult to reinstall the 0000052en
fuel lines.
0000047en

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
safety and performance

characteristics and shorten the CAUTION
engine’s life. Any alterations to this
Any part which is found defective as a
engine may void its warranty. Be sure
result of inspection or any part whose
to use Yanmar genuine replacement
measured value does not satisfy the
parts.
standard or limit must be replaced.
0000079en
0000119en
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
Do not rotate the crankshaft with the

injection pump removed. CAUTION
0000083en
Never use a steel wire brush to clean
fuel injectors. Damage to the nozzle and
CAUTION other components is likely to result.
Keep the piston pin parts, piston 0000172en
assemblies, and connecting rod

assemblies together to be returned to
the same position during the
reassembly process. Label the parts
using an appropriate method.
0000088en

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

Section 4
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

GENERAL SERVICE INFORMATION
Principal Engine Specifications ...................................................... 4-20
2TNV70 .................................................................................... 4-20
3TNV70 .................................................................................... 4-21
3TNV76 .................................................................................... 4-22
Engine Service Information ............................................................ 4-23
Tightening Torques for Standard Bolts and Nuts ........................... 4-24
Abbreviations and Symbols............................................................ 4-26
Abbreviations............................................................................ 4-26
Symbols.................................................................................... 4-26
Unit Conversions ............................................................................ 4-27
Unit Prefixes ............................................................................. 4-27
Units of Length ......................................................................... 4-27
Units of Volume ........................................................................ 4-27
Units of Mass............................................................................ 4-27
Units of Force ........................................................................... 4-27
Units of Torque......................................................................... 4-27
Units of Pressure...................................................................... 4-27
Units of Power .......................................................................... 4-27
Units of Temperature................................................................ 4-27

Component Identification GENERAL SERVICE INFORMATION
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
1 – Lifting Eye (Flywheel End) 14 – Governor Lever

2 – Engine Coolant Pump 15 – Fuel Injection Pump
3 – Lifting Eye (Engine Cooling Fan End) 16 – Intake Manifold
4 – Engine Cooling Fan 17 – Air Intake Port (From Air Cleaner)
5 – V-Belt 18 – Fuel Filter
6 – Crankshaft V-Pulley 19 – Fuel Return To Fuel Tank
7 – Side Filler Port (Engine Oil) 20 – Top Filler Port (Engine Oil)
8 – Drain Plug (Engine Oil)* 21 – Rocker Arm Cover
9 – Fuel Inlet 22 – Flywheel
10 – Mechanical Fuel Pump (If Equipped) 23 – Starter Motor
11 – Fuel Priming Lever 24 – Exhaust Manifold
12 – Dipstick (Engine Oil) 25 – Alternator
13 – Engine Oil Filter
* Engine oil drain plug location may vary based on oil pan options.

GENERAL SERVICE INFORMATION Location of Labels
LOCATION OF LABELS EPA / ARB EMISSION CONTROL

Figure 4-2 shows the location of regulatory and REGULATIONS - USA ONLY
safety labels on Yanmar TNV series engines.
Yanmar TNV engines meet Environmental
Protection Agency (EPA) (U. S. Federal) emission
(2) control standards as well as the California Air
(1)
Resources Board (ARB, California) regulations.
Only engines that conform to ARB regulations can
be sold in the State of California.
Refer to the specific EPA / ARB installation (page
5-16) and maintenance (page 5-16) in the
Periodic Maintenance section of this manual. Also
refer to theYanmar Co., Ltd. Limited Emission
Control System Warranty - USA Only Yanmar Co.,
0000585A Ltd. Limited Emission Control System Warranty -
USA Only on page 2-6.
Figure 4-2
The typical location of the emission control
information label is shown (Figure 4-2, (1)). EMISSION CONTROL LABELS
Typical location of the engine nameplate is shown Since emission control regulations are being issued
(Figure 4-2, (2)). on a global basis, it is necessary to identify which
regulations a particular engine complies with. We
Engine Nameplate (Typical) have listed several different types of labels you
might find on your engine.
0003852

The 97/68/EC Directive Certified Engines GENERAL SERVICE INFORMATION
EPA / ARB Labels THE 97/68/EC DIRECTIVE
CERTIFIED ENGINES
The engines described in this manual have been
certified by the 97/68/EC Directive.
" "
To identify the engines that meet this certification,
the 97/68/EC emission control label is affixed on
the engines.
97/68/EC DIRECTIVE
(EPA) Less Than 50 HP SAE (37kW)
(97/68/EC)
(EPA & ARB)
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
Engine speed specifications
Displacement (liter)
Non-road / Off-road engine
Yanmar Diesel
*2005 Model Year
5*: 2005
6 : 2006
7 : 2007

GENERAL SERVICE INFORMATION Function of Major Engine Components
FUNCTION OF MAJOR ENGINE COMPONENTS

Component Function
The air cleaner prevents airborne contaminants from entering the
engine. Since the air cleaner is application specific, it must be
carefully selected by an application engineer. It is not part of the
Air Cleaner basic engine package as shipped from the Yanmar factory. Periodic
replacement of the air cleaner filter element is necessary. See the
Periodic Maintenance Schedule on page 5-16 for the replacement
frequency.
The dynamo is driven by a V-belt which is powered by the
Dynamo crankshaft V-pulley. The dynamo supplies electricity to the engine
systems and charges the battery while the engine is running.
The engine oil dipstick is used to determine the amount of engine
Dipstick (Engine Oil)
oil in the crankcase.
The electric fuel pump makes sure there is a constant supply of
diesel fuel to the fuel injection pump. The electric fuel pump is
electro-magnetic and runs on 12 VDC. An electric fuel pump may
Electric Fuel Pump
be installed as standard equipment based on engine model and
specification. If an electric fuel pump is installed, turn the key switch
to the ON position for 10 to 15 seconds to prime the fuel system.
The engine oil filter removes contaminants and sediments from the
engine oil. Periodic replacement of the engine oil filter is necessary.
Engine Oil Filter
See the Periodic Maintenance Schedule on page 5-16 for the
replacement frequency.
The fuel filter removes contaminants and sediments from the diesel
fuel. Periodic replacement of the fuel filter is necessary. See the
Fuel Filter Periodic Maintenance Schedule on page 5-16 for the replacement
frequency. Please note that the word “diesel” is implied
throughout this manual when the word “fuel” is used.
The fuel filter / water separator removes contaminants, sediments
and water from diesel fuel going to the fuel filter. This is a required
component of the fuel system. This is standard equipment with
Fuel Filter / Water Separator
every engine. The separator is installed between the fuel tank and
the fuel pump. Periodically drain the water from the fuel filter / water
separator using the drain cock at the bottom of the separator.
If the unit has a mechanical fuel pump, a fuel priming lever on the
mechanical fuel pump primes the fuel system. The fuel system
needs to be primed before you start the engine for the first time, if
Fuel Priming Lever
you run out of fuel, or if fuel system service is performed. To prime
the fuel system, operate the fuel priming lever until the cup in the
fuel filter is full of fuel.

Function of Major Engine Components GENERAL SERVICE INFORMATION
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.

GENERAL SERVICE INFORMATION Function of Cooling System Components
FUNCTION OF COOLING SYSTEM COMPONENTS

Component Function
The TNV engine is liquid-cooled by means of a cooling system. The
cooling system consists of a radiator, radiator cap, engine cooling
fan, engine coolant pump, thermostat, and reserve tank. Note that
all cooling system components are required for proper engine
Cooling System
operation. Since some of the components are application
specific, they must be carefully selected by an application
engineer. The application specific items are not part of the
basic engine package as shipped from the Yanmar factory.
The engine cooling fan is driven by a V-belt which is powered by the
Engine Cooling Fan crankshaft V-pulley. The purpose of the engine cooling fan is to
circulate air through the radiator.
The engine coolant pump circulates the engine coolant through the
Engine Coolant Pump cylinder block and cylinder head and returns the engine coolant to
the radiator.
The radiator acts as a heat exchanger. As the engine coolant
circulates through the cylinder block it absorbs heat. The heat in the
Radiator engine coolant is dissipated in the radiator. As the engine cooling
fan circulates air through the radiator, the heat is transferred to the
air.
The radiator cap controls the cooling system pressure. The cooling
system is pressurized to raise the boiling point of the engine
coolant. As the engine coolant temperature rises, the system
pressure and the coolant volume increases. When the pressure
reaches a preset value, the release valve in the radiator cap opens
Radiator Cap
and the excess engine coolant flows into the reserve tank. As the
engine coolant temperature is reduced, the system pressure and
volume is reduced and the vacuum valve in the radiator cap opens
allowing engine coolant to flow from the reserve tank back into the
radiator.
The reserve tank contains the overflow of engine coolant from the
Reserve Tank radiator. If you need to add engine coolant to the system, add it to
the reserve tank, not to the radiator.
A thermostat is placed in the cooling system to prevent engine
coolant from circulating into the radiator until the engine coolant
temperature reaches a preset temperature. When the engine is
Thermostat cold, no engine coolant flows through the radiator. Once the engine
reaches its operating temperature the thermostat opens. By letting
the engine warm up as quickly as possible, the thermostat reduces
engine wear, deposits and emissions.

Diesel Fuel GENERAL SERVICE INFORMATION
DIESEL FUEL • Total aromatics content should not exceed

35% by volume. Less than 30% is preferred.
Diesel Fuel Specifications • PAH (polycyclic aromatic hydrocarbons)
content should be below 10% by volume.
Diesel fuel should comply with the following
specifications. The table lists several worldwide • Metal content of Na, Mg, Si, and Al should be
specifications for diesel fuels. equal to or lower than 1 mass ppm. (Test
analysis method JPI-5S-44-95)
Diesel Fuel Specification Location • Lubricity: Wear mark of WS1.4 should be Max.
No. 2-D, No. 1-D, 0.018 in. (460 µm) at HFRR test.
USA
ASTM D975-94
Bio-Diesel Fuels
European
EN590:96 In Europe and in the United States, as well as some
Union
other countries, non-mineral oil based fuel
ISO 8217 DMX International resources such as RME (Rapeseed Methyl Ester)
United and SOME (Soybean Methyl Ester), collectively
BS 2869-A1 or A2
Kingdom known as FAME (Fatty Acid Methyl Esters), are
JIS K2204 Grade No. 2 Japan being used as extenders for mineral oil derived
diesel fuels.
KSM-2610 Korea
GB252 China Yanmar approves the use of bio-diesel fuels that do
not exceed a blend of 5% (by volume) of FAME with
Additional Technical Fuel Requirements 95% (by volume) of approved mineral oil derived
diesel fuel. Such bio-diesel fuels are known in the
• The fuel cetane number should be equal to 45 marketplace as B5 diesel fuels.
or higher.
• The sulfur content must not exceed 0.5% by These B5 diesel fuels must meet certain
volume. Less than 0.05% is preferred. requirements.
1. The bio-fuels must meet the minimum
• Bio-Diesel fuels. See Bio-Diesel Fuels on
specifications for the country in which they are
page 4-9.
used.
• NEVER mix kerosene, used engine oil, or
• In Europe, bio-diesel fuels must comply with
residual fuels with the diesel fuel.
the European Standard EN14214.
• Water and sediment in the fuel should not
• In the United States, bio-diesel fuels must
exceed 0.05% by volume.
comply with the American Standard
• Keep the fuel tank and fuel-handling ASTM D-6751.
equipment clean at all times.
2. Bio-fuels should be purchased only from
• Poor quality fuel can reduce engine recognized and authorized diesel fuel suppliers.
performance and / or cause engine damage.
• Fuel additives are not recommended. Some
fuel additives may cause poor engine
performance. Consult your Yanmar
representative for more information.
• Ash content not to exceed 0.01% by volume.
• Carbon residue content not to exceed 0.35%
by volume. Less than 0.1% is preferred.

GENERAL SERVICE INFORMATION Diesel Fuel
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.
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
Yanmar Limited Warranty on page 2-3.
serious injury.
0000005en

Diesel Fuel GENERAL SERVICE INFORMATION
A DANGER A DANGER

• Be sure to place the diesel fuel • Before you operate the engine, check
container on the ground when for fuel leaks. Replace rubberized fuel
transferring the diesel fuel from the hoses every two years or every 2000
pump to the container. Hold the hose hours of engine operation, whichever
nozzle firmly against the side of the comes first, even if the engine has
container while filling it. This prevents been out of service. Rubberized fuel
static electricity buildup which could lines tend to dry out and become
cause sparks and ignite fuel vapors. brittle after two years or 2000 hours of
engine operation, whichever comes
• NEVER place diesel fuel or other
first.
flammable material such as oil, hay or
dried grass close to the engine during • Failure to comply will result in death or
engine operation or shortly after serious injury.
shutdown. 0000015en

serious injury. CAUTION
0000014en
• Only use diesel fuels recommended by
Yanmar for the best engine
performance, to prevent engine
damage and to comply with EPA / ARB
warranty requirements.
• Only use clean diesel fuel.
• NEVER remove the primary strainer (if
equipped) from the fuel tank filler port.
If removed, dirt and debris could get
into the fuel system causing it to clog.
0000004en

GENERAL SERVICE INFORMATION Diesel Fuel
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.
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.

Engine Oil GENERAL SERVICE INFORMATION
To prime the fuel system if a mechanical fuel pump ENGINE OIL
is installed:
1. Operate the fuel priming lever (Figure 4-4, (1)) CAUTION
several times until the fuel filter cup • Only use the engine oil specified.
(Figure 4-4, (2)) is filled with fuel. Other engine oils may affect warranty
2. NEVER use the starter motor to prime the fuel coverage, cause internal engine
system. This may cause the starter motor to components to seize and / or shorten
overheat and damage the coils, pinion and / or engine life.
ring gear. • Prevent dirt and debris from
contaminating the engine oil. Carefully
clean the oil cap / dipstick and the
(2) surrounding area before you remove
the cap.
oil. This may adversely affect the
• NEVER overfill. Overfilling may result
in white exhaust smoke, engine
(1) overspeed or internal damage.
0000005en
0000649A
Figure 4-4 Engine Oil Specifications

Use an engine oil that meets or exceeds the
following guidelines and classifications:
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.

GENERAL SERVICE INFORMATION Engine Oil
2. Change the engine oil after the first 50 hours of

(4)
operation and then every 250 hours thereafter.
3. Select the oil viscosity based on the ambient
temperature where the engine is being
operated. See the SAE Service Grade Viscosity
Chart (Figure 4-5).
(4)
4. Yanmar does not recommend the use of engine
oil “additives.”
Additional Technical Engine oil

Requirements:
(5)
The engine oil must be changed when the Total
Base Number (TBN) has been reduced to 1.0
(mgKOH/g) test method; JIS K-201-5.2-2 (HCI), (1)
ASTM D4739 (HCI).
Engine Oil Viscosity

Select the appropriate engine oil viscosity based on
the ambient temperature and use the SAE Service
Grade Viscosity Chart in Figure 4-5.
(2)
SAE 10W (3)
SAE 20W 0000587C
SAE 10W-30 Figure 4-6

SAE 15W-40
SAE 20 Adding Engine Oil
SAE 30
SAE 40
1. Make sure engine is level.
SAE 20W - 50 2. Remove oil cap (Figure 4-6, (4)).
-4°F 14°F 32°F 50°F 68°F 86°F 104°F 122°F 3. Add indicated amount of engine oil at the top or
(-20°C) (-10°C) (0°C) (10°C) (20°C) (30°C) (40°C) (50°C) side engine oil filler port (Figure 4-6, (5)).
0000005A
4. Wait three minutes and check oil level.
Figure 4-5
5. Add more oil if necessary.
Checking Engine Oil 6. Replace oil cap (Figure 4-6, (4)) and
hand-tighten. Over-tightening may damage the
1. Make sure engine is level.
cap.
2. Remove dipstick (Figure 4-6, (1)) and wipe with
clean cloth.
3. Fully reinsert dipstick.
4. Remove dipstick. The oil level should be
between upper (Figure 4-6, (2)) and lower
(Figure 4-6, (3)) lines on the dipstick.
5. Fully reinsert dipstick.

Engine Coolant GENERAL SERVICE INFORMATION
Engine Oil Capacity (Typical) ENGINE COOLANT
Note: These are the engine oil capacities
associated with a “deep standard” oil A DANGER
pan. Oil capacity will vary dependant
upon which optional oil pan is used.
Refer to the operation manual provided
by the driven machine manufacturer for
the actual engine oil capacity of your
machine.
SCALD HAZARD!
The following are the engine oil capacities for
various Yanmar TNV engines: • NEVER remove the radiator cap if the
engine is hot. Steam and hot engine
coolant will spurt out and seriously
Dipstick Upper
Engine Model burn you. Allow the engine to cool
Limit/ Lower Limit
2TNV70(VM) 1.9 / 1.3 qt the radiator cap.
2TNV70(VH) (1.8 / 1.2 L)
• Tighten the radiator cap securely after
2.3 / 1.3 qt you check the radiator. Steam can
2TNV70(CH)
(2.2 / 1.2 L) spurt out during engine operation if
3TNV70(CL), the cap is loose.
3.0 / 1.6 qt
3TNV70(VM) • ALWAYS check the level of the engine
(2.8 / 1.5 L)
3TNV70(VH) coolant by observing the reserve tank.
4.0 / 2.2 qt
3TNV70(CH) • Failure to comply will result in death or
(3.8 / 2.1 L)
serious injury.
3TNV76(CL),
3.6 / 1.9 qt 0000002en
3TNV76(VM)
(3.4 / 1.8 L)
3TNV76(VH)
4.7 / 2.4 qt
A WARNING
3TNV76(CH)
(4.4 / 2.3 L)
BURN HAZARD!
• Wait until the engine cools before you
or serious injury.
0000016en

GENERAL SERVICE INFORMATION Engine Coolant
Engine Coolant Specifications

A CAUTION
Use a Long Life Coolant (LLC) or an Extended Life
Coolant (ELC) that meets or exceeds the following
guidelines and specifications:
Additional Technical Coolant

Specifications:
COOLANT HAZARD! • ASTM D6210, D4985 (US)
• Wear eye protection and rubber gloves • JIS K-2234 (Japan)
when you handle long life or extended
• SAE J814C, J1941, J1034 or J2036
life engine coolant. If contact with the
(International)
eyes or skin should occur, flush eyes
and wash immediately with clean Alternative Engine Coolant
water.
If an Extended or Long Life Coolant is not available,
• Failure to comply may result in minor you may use an ethylene glycol or propylene glycol
or moderate injury. based conventional coolant (green).
0000005en
Notes:
CAUTION 1. ALWAYS use a mix of coolant and water.
• Only use the engine coolant specified. NEVER use water only.
Other engine coolants may affect 2. Mix coolant and water per the mixing
warranty coverage, cause an internal instructions on the coolant container.
buildup of rust and scale and / or 3. Water quality is important to coolant
shorten engine life. performance. Yanmar recommends that soft,
• Prevent dirt and debris from distilled, or demineralized water be used to mix
contaminating the engine coolant. with coolants.
Carefully clean the radiator cap and 4. NEVER mix extended or long life coolants and
the surrounding area before you conventional (green) coolants.
remove the cap.
5. NEVER mix different types and / or colors of
• NEVER mix different types of engine extended life coolants.
coolants. This may adversely affect the 6. Replace the coolant every 1000 engine hours
properties of the engine coolant. or once a year.
0000006en
Filling Radiator with Engine Coolant

Fill the radiator and reserve tank as follows. This
procedure is for filling the radiator for the first time
or refilling it after it is flushed. Note that a typical
radiator is illustrated.

Engine Coolant GENERAL SERVICE INFORMATION
5. Remove the cap of the reserve tank
(2) (Figure 4-7, (3)), and fill it to the LOW (COLD)
mark (Figure 4-7, (4)) with engine coolant.
(5)
Reinstall the cap.
6. Check the hose (Figure 4-7, (5)) that connects
(3) the reserve tank (Figure 4-7, (3)) to the
radiator. Be sure it is securely connected and
(6) FULL
LOW there are no cracks or damage. If the hose is

(4) damaged, engine coolant will leak out instead
of going into the reserve tank.
7. Run the engine until it is at operating
temperature. Check the level of engine coolant
(1) in the reserve tank. When the engine is running
0000029A
and the engine coolant is at normal
Figure 4-7 temperature, the coolant level in the tank should
be at or near the FULL (HOT) mark
1. Check to be sure the radiator drain plug is
(Figure 4-7, (6)). If the engine coolant is not at
installed and tightened or the drain cock
the FULL (HOT) mark (Figure 4-7, (6)), add
(Figure 4-7, (1)) is closed. Also make sure the
coolant drain plug (Figure 4-8, (1)) in the additional engine coolant to the reserve tank to
bring the level to the FULL (HOT) mark.
cylinder block is closed.
Engine Coolant Capacity (Typical)
Note: Capacities listed are for engine only
OIL
without a radiator. Refer to the operation
manual provided by the driven machine
manufacturer for actual engine coolant
capacity on your machine.
The following are the engine coolant capacities for
various Yanmar TNV engines.
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.

GENERAL SERVICE INFORMATION Specifications
SPECIFICATIONS
Description of Model Number
3 TNV 76 T - 0 0000
Customer Code
Rated rpm
Turbocharged (No symbol indicates naturally aspirated)
Cylinder Bore (mm)
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.
Engine Speed Specifications
Notation Available Engine Speed Intended Uses

VH 3200 ~ 3600 rpm (min-1) Lawn Mower, Construction, Industrial Machine
VM 2000 ~ 3000 rpm (min-1) Agricultural, Constructive, Industrial Machines
CH 3000 ~ 3600 rpm (min-1) 2-pole Generator Sets, Irrigation Pumps
CL 1500 or 1800 rpm (min-1) 4-pole Generator Sets, Irrigation Pumps
VH: Variable High Speed
VM: Variable Medium Speed
CH: Constant High Speed
CL: Constant Low Speed

Specifications GENERAL SERVICE INFORMATION
Engine General Specifications
Type Vertical In-line, Water Cooled, 4-Cycle Diesel Engine
Combustion System Swirl Chamber (Ball Type)
Starting System Electric Starting
Cooling System Radiator
Lubricating System Forced Lubrication with Trochoid Pump
PTO Position Flywheel End
Direction of Rotation Counterclockwise Viewed from Flywheel End
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

GENERAL SERVICE INFORMATION Principal Engine Specifications
PRINCIPAL ENGINE SPECIFICATIONS

2TNV70
Engine Model 2TNV70
Version VM CH VH
Type Vertical In-line Diesel Engine
Combustion System Ball-Type Swirl Chamber
Aspiration Natural
No. of Cylinders 2
Bore × Stroke 2.756 x 2.913 in. (70 × 74 mm)
Displacement 34.777 cu in. (0.570 L)
RPM
3000 3600
(min-1)
Continuous Rated Output hp SAE 10.9 13.1
kW 8.16 9.76
PS 11.1 13.3
RPM
2000 2200 2400 2600 2800 3000 3000 3600 3200 3400 3600
(min-1)
Max. Rated Output (Net) hp SAE 7.99 8.88 9.76 10.55 11.44 12.23 12.03 14.40 12.53 13.12 13.81
kW 5.96 6.62 7.28 7.87 8.53 9.12 8.97 10.7 9.34 9.78 10.3
PS 8.10 9.00 9.90 10.7 11.6 12.4 12.2 14.6 12.7 13.3 14.0
RPM 2160 2375 2570 2780 2995 3210 3165 3800 3400 3600 3815
High Idling
(min-1) ± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25
Engine Weight (Dry)
182.2 lb (84 kg)
with Flywheel Housing
Direction of Rotation Counterclockwise Viewed From Flywheel End
Cooling System Liquid-Cooled with Radiator
Normal Oil Pressure at
42 - 64 psi (0.29 -0.44 MPa, 2.96 - 4.49 kgf/cm2)
Rated Engine Speed
Normal Oil Pressure at
8.5 psi (0.06 MPa, 0.6 kgf/cm2) or greater
Low Idle Speed
Electric Starting - Starter Motor: DC12V, 1.3 hp (1.0 kW)**
Starting System Dynamo: DC12V, 20A**
Recommended Battery Capacity: 12V, 36 Amp-Hour (5h rating)**
16.38 x 16.81 x
16.38 x 16.81 x 19.06
16.38 x 16.81 x 19.06 in. 20.24 in.
Dimensions (L × W × H)* in.
(419 × 427 × 484 mm) (416 x 427 x
(416 x 427 x 484 mm)
514 mm)
2.4 / 1.4 qt
(2.3 / 1.3 L) 1.7 / 0.8 qt (1.6 / 0.8 L)
1.7 / 0.9 qt (1.65 / 0.8 L)
Engine Oil Pan Capacity (Dipstick Upper (Dipstick Upper Limit /
(Dipstick Upper Limit / Lower Limit)
Limit / Lower Lower Limit)
Limit)
Engine Coolant Capacity 0.2 gal (0.9 L) Engine Only
Standard Cooling Fan 10.23 in. (260 mm) O.D., 5 Blade Pusher-Type**
* Engine specifications without radiator.
** May vary depending on application.
*** Engine oil capacity for a “Deep Standard” oil pan. Refer to the operation manual provided by the driven machine
manufacturer for the actual engine oil capacity of your machine.

Principal Engine Specifications GENERAL SERVICE INFORMATION
3TNV70
Engine Model 3TNV70
Version CL VM CH VH
Aspiration Natural
No. of Cylinders 3
RPM
(min -1) 1500 1800 3000 3600
Continuous Rated Output hp SAE 8.16 9.77 16.27 19.43

kW 6.09 7.29 8.16 9.76
PS 8.27 9.91 16.5 19.7
RPM
(min -1) 1500 1800 2000 2200 2400 2600 2800 3000 3000 3600 3200 3400 3600
Max. Rated Output (Net) hp SAE 8.98 10.75 12.03 13.32 14.70 15.88 17.16 18.35 17.85 21.40 18.74 19.73 20.71
kW 6.69 8.02 8.97 9.93 11.0 11.8 12.8 13.7 13.3 16.0 14.0 14.7 15.4
PS 9.10 10.9 12.2 13.5 14.9 16.1 17.4 18.6 18.1 21.7 19.0 20.0 21.0
RPM 1600 1895 2160 2375 2570 2780 2995 3210 3165 3800 3400 3600 3815
High Idling
(min -1) ± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25
Engine Weight (Dry)
with Flywheel Housing 216.1 lb (98 kg)
35 - 51psi
Normal Oil Pressure at Rated (0.24-0.35
Engine Speed MPa, 2.44 - 42 - 64 psi (0.29 -0.44 MPa, 2.96 - 4.49 kgf/cm2)
3.57 kgf/cm2)
Normal Oil Pressure at Low
8.5 psi (0.06 MPa, 0.6 kgf/cm 2) or greater
Idle Speed
Starting System Dynamo: DC12V, 20A**
21.57 x 16.81 19.84 x 16.81 19.84 x 16.81 x
x 19.92 in. 19.84 x 16.81 x 19.92 in. x 21.10 in.
Dimensions (L × W × H)* (548 × 427 × (504 × 427 × 506 mm) (504 x 427 x 19.92 in.
506 mm) 536 mm) (504 x 427 x 506 mm)
4.0 / 2.2 qt
(3.8 / 2.1 L) 3.0 / 1.6 qt
3.0 / 1.6 qt (2.8 / 1.5 L) (2.8 / 1.5 L)
Engine Oil Pan Capacity (Dipstick
(Dipstick Upper Limit / Lower Limit) Upper Limit / (Dipstick Upper Limit /
Lower Limit)
Lower Limit)
* Engine specifications without radiator


GENERAL SERVICE INFORMATION Principal Engine Specifications
3TNV76
Engine Model 3TNV76
Version CL VM CH VH
Aspiration Natural
No. of Cylinders 3
RPM
(min -1) 1500 1800 3000 3600
Continuous Rated Output hp SAE 11.0 13.1 20.2 23.7

kW 8.2 9.8 15.1 17.7
PS 11.1 13.3 20.5 24.1
RPM
(min -1) 1500 1800 2000 2200 2400 2500 2600 2800 3000 3000 3600 3200 3400 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)
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
Starting System Alternator: DC12V, 40A**
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 specifications without radiator


Engine Service Information GENERAL SERVICE INFORMATION
ENGINE SERVICE INFORMATION

Inspection Item Standard Limit
0.006 - 0.010 in
Intake / Exhaust Valve Gap -
(0.15 - 0.25 mm)
Fuel Injection Timing See Checking and Adjusting Fuel Injection Timing on page 7-19
1711 - 1842 psi
Fuel Injection Pressure (11.8 - 12.8 MPa; -
120 - 130 kgf / cm²)
470 ± 15 psi 370 ± 15 psi
2TNV70
(3.24 ± 0.1MPa; (2.55 ± 0.1 MPa;
3TNV70
Compression Pressure at 33 ± 1 kgf / cm²) 26 ± 1 kgf / cm²)
250 rpm (250 min¯¹) 498 ± 15 psi 399 ± 15 psi
3TNV76 (3.43 ± 0.1MPa, (2.75 ± 0.1 MPa,
35 ± 1 kgf / cm²) 28 ± 1 kgf / cm²)
42 - 64 psi (0.29 - 0.44 MPa;
At rated output -
2.96 - 4.49 kgf/cm2)
Lubricating Oil Pressure
8.5 psi (0.06 MPa;
When idling -
0.6 kgf/cm2) or greater
Full Opening Lift
Valve Opening Temperature
Temperature
Thermostat 0.32 in. (8 mm) or
157 - 163°F
Above
(70 - 73°C)
185°F (85°C)
225 - 235°F
Temperature Coolant Switch -
(107 - 113°C)

GENERAL SERVICE INFORMATION Tightening Torques for Standard Bolts and Nuts
TIGHTENING TORQUES FOR STANDARD BOLTS AND NUTS

Use the correct amount of torque when you tighten
fasteners on the machine. Applying excessive CAUTION
torque may damage the fastener or component and The tightening torque in the Standard
not enough torque may cause a leak or component Torque Chart in General Service
failure. Information should be applied only to
the bolts with a “7” head. (JIS strength
classification: 7T)
• Apply 60% torque to bolts

that are not listed.
• Apply 80% torque when
tightened to aluminum alloy.
0000023enTNVIDISM
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)

Tightening Torques for Standard Bolts and Nuts GENERAL SERVICE INFORMATION
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.

GENERAL SERVICE INFORMATION Abbreviations and Symbols
ABBREVIATIONS AND SYMBOLS

Abbreviations L liter
L/hr liter per hour
A ampere lb pound
AC alternating current lbf pond force
Association des Constructeurs mL milliliter
ACEA
Européens d’Automobilies mm millimeter
Ah ampere-hour MPa megapascal
approx. approximately mV millivolt
API American Petroleum Institute N newton
ARB Air Resources Board N·m newton meter
ATDC after top dead center No. number
BTDC before top dead center O.D. outside diameter
°C degree Celsius oz ounce
CARB California Air Resources Board PS horsepower (metric)
CCA cold cranking amp psi pound per square inch
cm centimeter qt quart (U.S.)
cm³ cubic centimeter RPM revolutions per minute
cm³/min cubic centimeter per minute SAE Society of Automotive Engineers
cu in cubic inch sec. second
DC direct current t short ton 2000lb
DI direct injection TBN Total Base Number
DVA direct volt adapter TDC top dead center
EPA Environmental Protection Agency V volt
ESG electronic speed governor VAC volt alternating current
°F degree Fahrenheit VDC volt direct current
fl oz fluid ounce (U.S.) W watt
fl oz/min fluid ounce (U.S.) per minute
ft foot Symbols
ft·lb foot pound
ft·lbf/min foot pound force per minute ° angular degree
g gram + plus
gal/hr gallon (U.S.) per hour - minus
gal gallon (U.S.) ± plus or minus
GL gear lubricant Ω ohm
hp horsepower (U.S.) μ micro
hrs hours % percent
I.D. inside diameter ~ approximate
IDI indirect injection
in inch
in·lb inch pound
Japanese Automobile Standards
JASO
Organization
kg kilogram
kilogram force per square
kgf/cm²
centimeter
kgf·m kilogram force meter
km kilometers
kPa kilopascal
kW kilowatt

Unit Conversions GENERAL SERVICE INFORMATION
UNIT CONVERSIONS Units of Torque

ft·lb x 1.3558 = N·m
Unit Prefixes ft·lb x 0.1383 = kgf·m
Prefix Symbol Power in·lb x 0.1130 = N·m
mega M x 1,000,000 in·lb x 0.0115 = kgf·m
kilo k x 1,000 kgf·m x 7.2330 = ft·lb
centi c x 0.01 kgf·m x 86.8000 = in·lb
milli m x 0.001 kgf·m x 9.8070 = N·m
micro μ x 0.000001 N·m x 0.7376 = ft·lb
N·m x 8.8510 = in·lb
Units of Length N·m x 0.1020 = kgf·m
mile x 1.6090 = km Units of Pressure

ft x 0.3050 =m
in x 2.5400 = cm psi x 0.0689 = bar
in x 25.4000 = mm psi x 6.8950 = kPa
km x 0.6210 = mile psi x 0.0703 = kg/cm²
m x 3.2810 = ft bar x 14.5030 = psi
cm x 0.3940 = in bar x 100.0000 = kPa
mm x 0.0394 = in = in Hg
bar x 29.5300
(60°F)
Units of Volume kPa x 0.1450 = psi
kPa x 0.0100 = bar
gal (U.S.) x 3.78540 =L kPa x 0.0102 = kg/cm²
qt (U.S.) x 0.94635 =L kg/cm² x 98.0700 = psi
cu in x 0.01639 =L kg/cm² x 0.9807 = bar
cu in x 16.38700 = mL kg/cm² x 14.2200 = kPa
fl oz (U.S.) x 0.02957 =L in Hg (60°) x 0.0333 = bar
fl oz (U.S.) x 29.57000 = mL in Hg (60°) x 3.3770 = kPa
cm³ x 1.00000 = mL in Hg (60°) x 0.0344 = kg/cm²
cm³ x 0.03382 = fl oz (U.S.)
Units of Power
Units of Mass
hp (metric or
x 0.9863201 = hp SAE
lb x 0.45360 = kg PS)
oz x 28.35000 =g hp (metric or
x 0.7354988 = kW
kg x 2.20500 = lb PS)
g x 0.03527 = oz = hp (metric
hp SAE x 1.0138697
or PS)
Units of Force hp SAE x 0.7456999 = kW
= hp (metric
lbf x 4.4480 =N kW x 1.3596216
or PS)
lbf x 0.4536 = kgf kW x 1.3410221 = hp SAE
N x 0.2248 = lbf
N x 0.1020 = kgf Units of Temperature
kgf x 2.2050 = lbf
kgf x 9.8070 =N °F = (1.8 x °C) + 32
°C = 0.556 x (°F - 32)

GENERAL SERVICE INFORMATION Unit Conversions

Section 5
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

PERIODIC MAINTENANCE

Introduction PERIODIC MAINTENANCE
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
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.
serious injury.
serious injury.
0000002en
0000007en
A DANGER

• Only use the key switch to start the
engine.
• NEVER jump-start the engine. Sparks
caused by shorting the battery to the
starter terminals may cause a fire or
explosion.
serious injury.
0000004en

PERIODIC MAINTENANCE Introduction
A DANGER A DANGER

• Only fill the fuel tank with diesel fuel. • Before you operate the engine, check
Filling the fuel tank with gasoline may for fuel leaks. Replace rubberized fuel
result in a fire and will damage the hoses every two years or every 2000
engine. hours of engine operation, whichever
• NEVER refuel with the engine running. comes first, even if the engine has
been out of service. Rubberized fuel
• Wipe up all spills immediately. lines tend to dry out and become
• Keep sparks, open flames or any other brittle after two years or 2000 hours of
form of ignition (match, cigarette, engine operation, whichever comes
static electric source) well away when first.
refueling. • Failure to comply will result in death or
• NEVER overfill the fuel tank. serious injury.
0000015en
• Fill the fuel tank. Store any containers
containing fuel in a well-ventilated
area, away from any combustibles or
sources of ignition.
serious injury.
0000005en

A DANGER A DANGER

• Be sure to place the diesel fuel • NEVER remove the fuel cap with the
container on the ground when engine running.
transferring the diesel fuel from the • Failure to comply will result in death or
pump to the container. Hold the hose serious injury.
nozzle firmly against the side of the 0000011en
container while filling it. This prevents
static electricity buildup which could
cause sparks and ignite fuel vapors. A DANGER
• NEVER place diesel fuel or other
flammable material such as oil, hay or
dried grass close to the engine during
engine operation or shortly after
shutdown.
• Failure to comply will result in death or CRUSH HAZARD!
serious injury. • When you need to transport an engine
0000014en for repair, have a helper assist you to
attach it to a hoist and load it on a
truck.
A DANGER
• NEVER stand under a hoisted engine.
If the hoist mechanism fails, the
engine will fall on you, causing death
or serious injury.
FIRE AND EXPLOSION HAZARD! • Failure to comply will result in death or

serious injury.
0000008en
• NEVER use diesel fuel as a cleaning
agent.
serious injury.
0000012en

A DANGER A DANGER

• When you remove any fuel system • Place an approved container under the
component to perform maintenance air bleed port when you prime the fuel
(such as changing the fuel filter) place system. Never use a shop rag to catch
an approved container under the the fuel. Wipe up any spills
opening to catch the fuel. immediately. ALWAYS close the air
• NEVER use a shop rag to catch the bleed port after you complete priming
fuel. Vapors from the rag are the system.
flammable and explosive. • Wear eye protection. The fuel system
• Wipe up any spills immediately. is under pressure and fuel could spray
out when you open the air bleed port.
• Wear eye protection. The fuel system
is under pressure and fuel could spray • If the unit has an electric fuel pump,
out when you remove any fuel system turn the key switch to the ON position
component. for 10 to 15 seconds, or until the fuel
coming out of the air bleed port is free
• Failure to comply will result in death or of bubbles, to allow the electric fuel
serious injury. pump to prime the system.
0000009en
• If the unit has a mechanical fuel pump,
operate the fuel priming pump several
times until the fuel coming out of the
air bleed port is free of bubbles.
serious injury.
0000006en

A WARNING A WARNING
EXHAUST HAZARD! SEVER HAZARD!

• NEVER operate the engine in an • Keep hands and other body parts
enclosed area such as a garage, away from moving / rotating parts
tunnel, underground room, manhole or such as the cooling fan, flywheel or
ship’s hold without proper ventilation. PTO shaft.
• NEVER block windows, vents, or other • Wear tight-fitting clothing and keep
means of ventilation if the engine is your hair short or tie it back while the
operating in an enclosed area. All engine is running.
internal combustion engines create • Remove all jewelry before you operate
carbon monoxide gas during or service the machine.
operation. Accumulation of this gas
within an enclosure could cause • NEVER start the engine in gear.
illness or even death. Sudden movement of the engine
and / or machine could cause death or
• Make sure that all connections are serious personal injury.
tightened to specifications after repair
is made to the exhaust system. • NEVER operate the engine without the
guards in place.
or serious injury. • Before you start the engine make sure
0000003en
that all bystanders are clear of the
area.
• Keep children and pets away while the
engine is operating.
• Check before starting the engine that
any tools or shop rags used during
maintenance have been removed from
the area.
or serious injury.
0000002en

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
hearing protection as required by the
task at hand.
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
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.
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.
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
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
• 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
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
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
CAUTION
0000006en
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
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
• Avoid operating in extremely dusty

conditions. CAUTION
• Avoid operating in the presence of For maximum engine life, Yanmar
chemical gases or fumes. recommends that when shutting the
• Avoid operating in a corrosive engine down, you allow the engine to
atmosphere such as salt water spray. idle, without load, for five minutes. This
• NEVER install the engine in a operate at high temperatures, such as
floodplain unless proper precautions the turbocharger (if equipped) and
are taken to avoid being subject to a exhaust system, to cool slightly before
flood. the engine itself is shut down.
• NEVER expose the engine to the rain. 0000008en
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
performance and avoid premature

engine wear:
CAUTION
• The standard range of ambient Make sure the engine is installed on a
temperatures for the normal operation level surface. If a continuously running
of Yanmar engines is from +5°F (-15°C) engine is installed at an angle greater
to +113°F (+45°C). than (IDI = 25°, DI = 30°) in any direction
• If the ambient temperature exceeds or if an engine runs for short periods of
+113°F (+45°C) the engine may time (less than three minutes) at an
overheat and cause the engine oil to angle greater than (IDI = 30°, DI = 35°) in
break down. any direction, engine oil may enter the
• If the ambient temperature is below combustion chamber causing excessive
+5°F (-15°C) the engine will be hard to engine speed and white exhaust smoke.
start and the engine oil may not flow This may cause serious engine damage.
easily. 0000010enTNV
• Contact your authorized Yanmar

industrial engine dealer or distributor
if the engine will be operated outside
of this standard temperature range.
0000065en

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
engine oil and coolant levels

frequently. CAUTION
0000011en
Protect the air cleaner, turbocharger (if
equipped) and electric components
CAUTION from damage when you use steam or
NEVER engage the starter motor while high-pressure water to clean the engine.
the engine is running. This may damage 0000014en
the starter motor pinion and / or ring

gear. CAUTION
0000012en
• NEVER overfill the engine with engine
oil.
• ALWAYS keep the oil level between the
upper and lower lines on the oil
cap / dipstick.
0000015en

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
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
periodic maintenance at intervals

indicated. Failure to follow these
CAUTION
and performance characteristics, The maximum air intake restriction, in
shorten the engine’s life and may affect terms of differential pressure
the warranty coverage on your engine. measurement, must not exceed 0.90 psi
See Yanmar Warranties section. (6.23 kPa; 635 mmAq). Clean or replace
the air cleaner element if the air intake
Consult your authorized Yanmar dealer restriction exceeds the above
or distributor for assistance when mentioned value.
checking items marked with a z.
0000046en
0000024enTNVIDISM

Precautions PERIODIC MAINTENANCE
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.
or serious injury.
0000003en
Perform periodic maintenance procedures in an

open, level area free from traffic. If possible,
perform the procedures indoors to prevent
environmental conditions, such as rain, wind, or
snow, from damaging the machine.

PERIODIC MAINTENANCE Periodic Maintenance Schedule
Yanmar Replacement Parts PERIODIC MAINTENANCE

Yanmar recommends that you use genuine Yanmar SCHEDULE
parts when replacement parts are needed.
Genuine replacement parts help ensure long Daily and periodic maintenance is important to
engine life. keep the engine in good operating condition. The
following is a summary of maintenance items by
Required EPA / ARB Maintenance - periodic maintenance intervals. Periodic
maintenance intervals vary depending on engine
USA Only application, loads, diesel fuel and engine oil used
To maintain optimum engine performance and and are hard to establish definitively. The following
compliance with the Environmental Protection should be treated only as a general guideline.
Agency (EPA) Regulations Non-road Engines and
the California Air Resources Board (ARB, CAUTION
California), it is essential that you follow the
Periodic Maintenance Schedule on page 5-16 and Establish a periodic maintenance plan
Periodic Maintenance Procedures on page 5-18. according to the engine application and
make sure you perform the required
EPA / ARB Installation Requirements periodic maintenance at intervals
indicated. Failure to follow these
- USA Only
The following are the installation requirements for and performance characteristics,
the EPA / ARB. Unless these requirements are met, shorten the engine’s life and may affect
the exhaust gas emissions will not be within the the warranty coverage on your engine.
limits specified by the EPA and ARB. See Yanmar Warranties section.
Maximum Exhaust Gas Restriction shall be: Consult your authorized Yanmar dealer
or distributor for assistance when
• 2TNV70: 0.85 psi (5.88 kPa; 600 mm Aq) or checking items marked with a z.
less 0000024enTNVIDISM
• 3TNV70 and 3TNV76: 1.70 psi (11.76 kPa;

1200 mm Aq) or less
Maximum air intake restriction shall be 0.90 psi
(6.23kPa; 635mm Aq) or less. Clean or replace the
air cleaner element if the air intake restriction
exceeds the above mentioned value.

Periodic Maintenance Schedule PERIODIC MAINTENANCE
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
Engine Oil Drain and Fill Engine Oil 2nd

1st
and
Replace Engine Oil Filter time
after
Engine
Check and Adjust Governor Lever
Speed c c
and Engine Speed Control
Control
Emission Inspect, Clean and Test Fuel
z
Control Injectors
Warranty Inspect Crankcase Breather System z
Check and Refill Fuel Tank Level c
Drain Fuel Tank c
Drain Fuel Filter / Water Separator c
Fuel
Check Fuel Filter / Water Separator c
Clean Fuel Filter / Water Separator c
Replace Fuel Filter
z or
Replace Fuel System and Cooling
Hoses every 2
System Hoses
yrs.
Intake and Clean or Replace Air Cleaner
c
Exhaust Element
Complete
Overall Visual Check Daily c
Engine
Note: These procedures are considered normal maintenance and are performed at the owner’s expense.

PERIODIC MAINTENANCE Periodic Maintenance Procedures
PERIODIC MAINTENANCE CAUTION

PROCEDURES • Only use the engine oil specified.
After Initial 50 Hours of Operation coverage, cause internal engine
Perform the following maintenance after the initial engine life.
50 hours of operation. • Prevent dirt and debris from
• Replace Engine Oil and Engine Oil Filter contaminating the engine oil. Carefully
clean the oil cap / dipstick and the
• Check and Adjust Cooling Fan V-Belt surrounding area before you remove
the cap.
Replace Engine Oil and Engine Oil Filter
A WARNING oil. This may adversely affect the
0000005en
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.
or serious injury.
0000011en
responsible.
• Follow the guidelines of the EPA or
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
0000013en

Periodic Maintenance Procedures PERIODIC MAINTENANCE
The engine oil on a new engine becomes Remove the engine oil filter as follows:
contaminated from the initial break-in of internal
parts. It is very important that the initial oil and filter 1. Turn the engine oil filter (Figure 5-2, (2))
change is performed as scheduled. counterclockwise (Figure 5-2, (4)) using a filter
wrench.
Note: The oil drain plug may be in another
location if an optional oil pan is used.
Drain the engine oil as follows:
1. Make sure the engine is level.
2. Start the engine and bring it up to operating (3)
temperature. (4)
3. Stop the engine.
4. Remove the oil filler cap (Figure 5-1, (1)) to
vent the engine crankcase and allow the engine
oil to drain more easily. (2)
5. Position a container under the engine to collect
waste oil.
(1)
(1) 0000651B
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.
Applicable Engine Oil Filter Part No.

2TNV70
0000587B
3TNV70 119305-35150
Figure 5-1 3TNV76
6. Remove the oil drain plug (Figure 5-2, (1)).
4. Add new engine oil to the engine as specified in
Allow oil to drain.
Adding Engine Oil on page 4-14.
7. After all oil has been drained from the engine,
reinstall the oil drain plug (Figure 5-2, (1)) and Check and Adjust Cooling Fan V-Belt
tighten to 39.8 - 47.0 ft·lb (53.9 - 63.7 N·m, 5.5 - The V-belt will slip if it does not have the proper
6.5 kgf·m). tension. This will prevent the alternator from
8. Dispose of used oil properly. generating sufficient power. Also, the engine will
overheat due to the engine coolant pump pulley
slipping.

Check and adjust the V-belt tension (deflection) as

follows: B
1. Press the V-belt down with your thumb with a
force of approximately 22 ft·lb (98 N·m,
10 kgf·m) to check the deflection.
There are three positions to check for V-belt
tension (Figure 5-4, (A), (B) and (C)). You can A
check the tension at whichever position is the
most accessible. The proper deflection of a used
V-belt at each position is: C
(4) 0000652B
Figure 5-4
Used V-Belt Tension

(4) A B C
3/8 - 1/2 in. 1/4 - 3/8 in. 5/16 - 1/2 in.
(10 - 14 mm) (7 - 10 mm) (9 - 13 mm)
2. If necessary, adjust the V-belt tension. Loosen

(5) the adjusting bolt (Figure 5-5, (1)) and move
the alternator (Figure 5-5, (2)) with a pry bar
(Figure 5-5, (3)) to tighten the V-belt to the
(1) desired tension. Then tighten the adjusting bolt.
(3)
(2)
(3) (1)
0000587C
(2)
Figure 5-3
0000653B
Figure 5-5

3. Tighten the V-belt to the proper tension. There
must be clearance (Figure 5-6, (1)) between Every 50 Hours of Operation
the V-belt and the bottom of the pulley groove. If
there is no clearance (Figure 5-6, (2)) between After you complete the initial 50 hour maintenance
the V-belt and the bottom of the pulley groove, procedures, perform the following procedures every
replace the V-belt. 50 hours thereafter.
• Drain Fuel Filter / Water Separator
• Check Battery
Drain Fuel Filter / Water Separator

(2)
(1)
A DANGER
0000584
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.
• “New V-belt” refers to a V-belt which has been under certain conditions.
used less than 5 minutes on a running engine.
• “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
7. After adjusting, run the engine for 5 minutes or

more. Check the tension again using the
specifications for a used V-belt.
Used V-Belt Tension

A B C
3/8 - 1/2 in. 1/4 - 3/8 in. 5/16 - 1/2 in.
(10 - 14 mm) (7 - 10 mm) (9 - 13 mm)

The cup of the separator is made from

CAUTION semi-transparent material. In the cup is a
If the fuel filter / water separator is red-colored float ring. The float ring will rise to the
positioned higher than the fuel level in surface of the water to show how much needs to be
the fuel tank, water may not drip out drained. Also, some optional fuel filter / water
when the fuel filter / water separator separators are equipped with a sensor to detect the
drain cock is opened. If this happens, amount of contaminants. This sensor sends a
turn the air vent screw on the top of the signal to an indicator to alert the operator.
fuel filter / water separator 2-3 turns
Drain the fuel filter / water separator as follows:
counterclockwise.
Be sure to tighten the air vent screw 1. Position an approved container under the fuel
after the water has drained out. filter / water separator (Figure 5-7, (1)) to
0000025en
collect the contaminants.
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
proper disposal of hazardous Figure 5-7

fuel and engine coolant. Consult the 2. Close (Figure 5-7, (2)) the fuel cock
local authorities or reclamation facility. (Figure 5-7, (3)).
• 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
the fuel into an approved container and dispose
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.

8. Put the float (Figure 5-7, (7)) and retaining
spring (Figure 5-7, (6)) inside the cup. A WARNING
9. Reinstall the cup to the mounting flange
(Figure 5-7, (8)) and turn the retaining ring
(Figure 5-7, (4)) to the right (Figure 5-7, (5)).
Hand-tighten only.
10. Open the fuel cock (Figure 5-7, (3)). BURN HAZARD!
11. Be sure to prime the fuel system. See Priming • Batteries contain sulfuric acid. NEVER
the Fuel System on page 4-12. allow battery fluid to come in contact
12. Check for fuel leaks. with clothing, skin or eyes. Severe
CAUTION safety goggles and protective clothing
If the fuel filter / water separator is when servicing the battery. If battery
positioned higher than the fuel level in fluid contacts the eyes and / or skin,
the fuel tank, water may not drip out immediately flush the affected area
when the fuel filter / water separator with a large amount of clean water and
drain cock is opened. If this happens, obtain prompt medical treatment.
turn the air vent screw on the top of the • Failure to comply could result in death
fuel filter / water separator 2-3 turns or serious injury.
counterclockwise. 0000007en
Be sure to tighten the air vent screw

after the water has drained out. CAUTION
0000025en
Check Battery
A DANGER
responsible.
EXPLOSION HAZARD! proper disposal of hazardous
• 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
• If the electrolyte is frozen, slowly warm
the battery before you recharge it. • Failure to follow these procedures may
0000013en
serious injury.
0000007en

• When the amount of fluid nears the lower limit

(Figure 5-8, (1)), fill with distilled water Every 250 Hours of Operation
(Figure 5-8, (2)) so it is at the upper limit
(Figure 5-8, (3)). If operation continues with Perform the following maintenance every 250 hours
insufficient battery fluid, the battery life is of operation.
shortened, and the battery may overheat and
explode. During the summer, check the fluid • Drain Fuel Tank
level more often than specified. • Replace Engine Oil and Engine Oil Filter
• Check and Clean Radiator Fins
(3) • Check and Adjust Cooling Fan V-Belt
(2) • Check and Adjust the Governor Lever and
Engine Speed Control
• Clean Air Cleaner Element
(1)
Drain Fuel Tank
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.
is under pressure and fuel could spray
component.
serious injury.
0000009en

4. Drain the tank until clean diesel fuel with no
CAUTION water or dirt flows out. Reinstall and tighten the
drain plug firmly.
5. Reinstall the fuel cap.
6. Check for fuel leaks.
Replace Engine Oil and Engine Oil Filter

responsible. CAUTION
• Follow the guidelines of the EPA or • Only use the engine oil specified.
other governmental agencies for the Other engine oils may affect warranty
proper disposal of hazardous coverage, cause internal engine
materials such as engine oil, diesel components to seize and / or shorten
fuel and engine coolant. Consult the engine life.
• NEVER dispose of hazardous contaminating the engine oil. Carefully
materials irresponsibly by dumping clean the oil cap / dipstick and the
them into a sewer, on the ground, or surrounding area before you remove
into ground water or waterways. the cap.
• Failure to follow these procedures may • NEVER mix different types of engine
seriously harm the environment. oil. This may adversely affect the
0000013en lubricating properties of the engine oil.
Note that a typical fuel tank is illustrated. • NEVER overfill. Overfilling may result
1. Position an approved container under the diesel overspeed or internal damage.
fuel tank (Figure 5-9, (1)) to collect the 0000005en
contaminates.
(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.

Check and Clean Radiator Fins

CAUTION
A CAUTION
responsible.
• Follow the guidelines of the EPA or FLYING OBJECT HAZARD!
• ALWAYS wear eye protection when
servicing the engine and when using
compressed air or high-pressure
water. Dust, flying debris, compressed
air, pressurized water or steam may
• NEVER dispose of hazardous injure your eyes.
or moderate injury.
0000003en
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

2. If the governor lever does not make proper
contact with the high idle stop or the low idle
speed limit screw, adjust the throttle cable or
linkage as necessary.
(1) Note: DO NOT FORCE the throttle cable or
FULL
LOW linkage to move. This may damage the

the governor lever, the throttle cable or
linkage and cause irregular operation of
the engine speed control.
IMPORTANT
0000085A
The engine speed control (throttle lever,
accelerator pedal etc.), should be equipped
Figure 5-10 with stops to prevent the application of
excessive pressure by the governor lever to
Check and Adjust Cooling Fan V-Belt
either the high idle stop or low idle speed
Check and adjust the cooling fan V-belt every 250 limit screw.
hours of operation after the initial 50 hour V-belt
maintenance. See Check and Adjust Cooling Fan (2)
V-Belt on page 5-19.
Check and Adjust the Governor Lever and (3)

Engine Speed Control
The governor lever and engine speed control
(throttle lever, accelerator pedal etc.), are
connected together by a cable or linkage. If the
cable becomes stretched, or the linkage wears or (1)
loosens, the governor lever may not respond to a
change in the position of the engine speed control. Figure 5-11
CAUTION
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
0000017en
1. Check that the governor lever (Figure 5-11, (1))

makes firm contact with the high idle stop
(Figure 5-11, (2)) and the low idle speed limit
screw (Figure 5-11, (3)) when the engine
speed control is in the full speed or low idle
speed positions.

Clean Air Cleaner Element

Note that a typical air cleaner is shown in
Figure 5-12 and Figure 5-13 for illustrative
purposes only.
The engine performance is adversely affected
when the air cleaner element is clogged with dust.
(1)
Be sure to clean the air filter element periodically.
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
1. Unlatch and remove the air cleaner cover

(Figure 5-12, (1)).
2. Remove the element (Figure 5-12, (2)) (outer FLYING OBJECT HAZARD!
element if equipped with two elements). • ALWAYS wear eye protection when
(6) compressed air or high-pressure
(4)
(2) water. Dust, flying debris, compressed
(5) air, pressurized water or steam may
(3)
injure your eyes.
(1) • Failure to comply may result in minor
or moderate injury.
0000003en
3. Blow air (Figure 5-12, (3)) through the element

0000070A from the inside out using 42 - 71 psi
Figure 5-12 (0.29 - 0.49 MPa; 3.0 - 5.0 kgf/cm2)
compressed air to remove the particulates. Use
the lowest possible air pressure to remove the
dust without damaging the element.
If the air cleaner is equipped with a double
element, only remove and replace the inner
element (Figure 5-13, (1)) if the engine lacks
power or the dust indicator actuates (if
equipped).

The inner element should not be removed when
cleaning or replacing the outer element. The Every 500 Hours of Operation
inner element is used to prevent dust from
entering the engine while servicing the outer Perform the following maintenance every 500 hours
element. of operation.
4. Replace the element with a new one if the • Replace Air Cleaner Element
element is damaged, excessively dirty or oily. • Replace Fuel Filter
5. Clean inside of the air cleaner cover. • Clean Fuel Filter / Water Separator
6. Install the element into the air cleaner case
(Figure 5-12, (4)). Replace Air Cleaner Element
7. Install the air cleaner cover making sure you
match the arrow (Figure 5-12, (5)) on the cover CAUTION
with the arrow on the case (Figure 5-12, (6)). The maximum air intake restriction, in
8. Latch the air cleaner cover to the case. terms of differential pressure
measurement, must not exceed 0.90 psi
(6.23 kPa; 635 mmAq). Clean or replace
the air cleaner element if the air intake
restriction exceeds the above
mentioned value.
0000046en
Replace the air cleaner element (Figure 5-12, (2))

every 500 hours even if it is not damaged or dirty.
When replacing the element, clean the inside of the
air cleaner case (Figure 5-12, (4)).
If the air cleaner is equipped with a double element,
only remove and replace the inner element
(Figure 5-13, (1)) if the engine lacks power or the
dust indicator actuates (if equipped). This is in
addition to replacing the outer element.

Replace Fuel Filter

CAUTION
A DANGER
FIRE AND EXPLOSION HAZARD! • ALWAYS be environmentally

responsible.
under certain conditions. • Follow the guidelines of the EPA or
• When you remove any fuel system proper disposal of hazardous
component to perform maintenance materials such as engine oil, diesel
(such as changing the fuel filter) place fuel and engine coolant. Consult the
an approved container under the local authorities or reclamation facility.
opening to catch the fuel.
• NEVER use a shop rag to catch the materials irresponsibly by dumping
fuel. Vapors from the rag are them into a sewer, on the ground, or
flammable and explosive. into ground water or waterways.
• Wipe up any spills immediately. • Failure to follow these procedures may
• Wear eye protection. The fuel system seriously harm the environment.
is under pressure and fuel could spray 0000013en

component. Replace the fuel filter at specified intervals to
prevent contaminants from adversely affecting the
• Failure to comply will result in death or diesel fuel flow.
serious injury.
0000009en
1. Stop the engine and allow it to cool.
2. Close the fuel cock of the fuel filter / water
CAUTION separator.
For maximum engine life, Yanmar 3. Turn the retaining ring (Figure 5-14, (1)) to the
recommends that when shutting the left (Figure 5-14, (2)).
engine down, you allow the engine to
idle, without load, for five minutes. This
operate at high temperatures, such as
the turbocharger (if equipped) and
exhaust system, to cool slightly before (6)
the engine itself is shut down. (2)
(5) (4)
0000008en (1)
(3)
0000589A
Figure 5-14

4. Carefully remove the cup (Figure 5-14, (3)) and Clean Fuel Filter / Water Separator
pour the fuel into an approved container and
dispose of waste properly. Hold the bottom of A DANGER
the cup with a shop towel to prevent the fuel
from dripping. Wipe up any spills immediately.
5. Remove the element (Figure 5-14, (4)) by
pulling it down.
6. Replace the element with a new one. FIRE AND EXPLOSION HAZARD!
Applicable Fuel Filter Part No. • Diesel fuel is flammable and explosive
2TNV70
3TNV70 119810-55650 • NEVER use diesel fuel as a cleaning
3TNV76 agent.
7. Wash the inside of the cup with clean fuel. serious injury.
8. Check the condition of the cup O-ring 0000012en
(Figure 5-14, (6)). Replace if necessary.

9. Reinstall the cup to the mounting flange and A DANGER
turn the retaining ring (Figure 5-14, (1)) to the
right (Figure 5-14, (2)). Hand-tighten only.
10. Open the fuel cock of the fuel filter / water
separator.
11. Prime the fuel system. See Priming the Fuel FIRE AND EXPLOSION HAZARD!
System on page 4-12. • Diesel fuel is flammable and explosive
12. Check for fuel leaks. under certain conditions.
component to perform maintenance
(such as changing the fuel filter) place
an approved container under the
opening to catch the fuel.
• NEVER use a shop rag to catch the
fuel. Vapors from the rag are
flammable and explosive.
• Wipe up any spills immediately.
is under pressure and fuel could spray
component.
serious injury.
0000009en

3. Turn the retaining ring (Figure 5-15, (4)) to the

CAUTION left (Figure 5-15, (10)).
4. Carefully remove the cup (Figure 5-15, (1)) and
pour the fuel into an approved container and
dispose of properly. Hold the bottom of the cup
with a shop towel to prevent the fuel from
dripping. Wipe up any spills immediately.
• ALWAYS be environmentally 5. Keep the retaining spring (Figure 5-15, (6)) and
responsible. float (Figure 5-15, (7)) handy for reassembly.
• Follow the guidelines of the EPA or 6. Remove the element (Figure 5-15, (8)) by
other governmental agencies for the pulling it down.
7. Replace the element with a new one.
fuel and engine coolant. Consult the Applicable Mesh Filter Part No.
2TNV70
• NEVER dispose of hazardous 3TNV70 171081-55910
materials irresponsibly by dumping 3TNV76
into ground water or waterways. 8. Wash the inside of the cup with clean diesel
• Failure to follow these procedures may fuel.
seriously harm the environment. 9. Check the condition of the cup O-ring. Replace
0000013en if necessary.
Periodically clean the fuel filter / water separator 10. Put the float (Figure 5-15, (7)) and retaining
element and inside the cup. spring (Figure 5-15, (6)) inside the cup.
11. Reinstall the cup to the mounting flange
1. Position an approved container under the cup (Figure 5-15, (9)) and turn the retaining ring
(Figure 5-15, (1)) of the fuel filter / water (Figure 5-15, (4)) to the right (Figure 5-15, (5)).
separator to collect the contaminants. Hand-tighten only.
(2) 12. Open the fuel cock (Figure 5-15, (3)).
(9) 13. Prime the fuel system. See Priming the Fuel
System on page 4-12.
c
o 14. Check for fuel leaks.
(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)).

Every 1000 Hours of Operation A WARNING

Perform the following maintenance every 1000
hours of operation.
• Drain, Flush and Refill Cooling System with
New Coolant BURN HAZARD!
• Adjust Intake / Exhaust Valve Clearance • Wait until the engine cools before you
Drain, Flush and Refill Cooling System with
New Coolant
A DANGER or serious injury.
0000016en
A CAUTION
SCALD HAZARD!
• NEVER remove the radiator cap if the
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

serious injury.
0000002en

CAUTION
(1)
FULL
LOW
responsible.
materials such as engine oil, diesel (2) 0000074A
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.
seriously harm the environment. OIL
0000013en
Engine coolant contaminated with rust or scale

reduces the cooling effect. Even when extended life
engine coolant is properly mixed, the engine
coolant gets contaminated as its ingredients
deteriorate. Drain, flush and refill the cooling
system with new coolant every 1000 hours or once
a year, whichever comes first.
(1)
1. Allow engine and coolant to cool. 0002923A
2. Remove the radiator cap (Figure 5-16, (1)). Figure 5-17

3. Remove the drain plug or open the drain cock 5. After draining the engine coolant, flush the
(Figure 5-16, (2)) at the lower position of the radiator and engine block to remove any rust,
radiator and drain the engine coolant. scale and contaminants.
6. Reinstall and tighten the drain plug or close the
drain cock at the radiator. Reinstall and tighten
the engine block drain plug.
7. Fill radiator and engine with engine coolant.
See Filling Radiator with Engine Coolant on
page 4-16.

Adjust Intake / Exhaust Valve Clearance
Every 1500 Hours of Operation
Proper adjustment is necessary to maintain the
correct timing for opening and closing the valves.
Improper adjustment will cause the engine to run Perform the following maintenance every 1500
noisily, resulting in poor engine performance and hours of operation.
engine damage. See Measuring and Adjusting • Inspect, Clean and Test Fuel Injectors
Valve Clearance on page 6-34.
• Inspect Crankcase Breather System
Inspect, Clean and Test Fuel Injectors
A WARNING
• Avoid skin contact with the
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
or cardboard. Have your authorized
or serious injury.
0000008en
Proper operation of the fuel injectors is required to

obtain the optimum injection pattern for full engine
performance. The EPA / ARB requires that the fuel
injectors are inspected, cleaned and tested every
1500 hours. See Testing of Fuel Injectors on
page 7-24.
This procedure is considered normal maintenance
and is performed at the owner’s expense. This
procedure is not covered by the Yanmar Limited
Warranty.

Inspect Crankcase Breather System 2. Remove the diaphragm cover, spring,

Proper operation of the crankcase breather system diaphragm plate (Figure 5-18, (5)) and
is required to maintain the emission requirements diaphragm.
of the engine. The EPA / ARB requires that the 3. Inspect the diaphragm for tears. Inspect the
crankcase breather system is inspected every 1500 spring for distortion. Replace components if
hours. necessary.
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)).

Every 2000 Hours of Operation
Perform the following maintenance every 2000

hours of operation.
• Check and Replace Fuel Hoses and Engine
Coolant Hoses
• Lap the Intake and Exhaust Valves
Check and Replace Fuel Hoses and Engine

Coolant Hoses
CAUTION
responsible.
0000013en
Regularly check the fuel system and engine coolant

system hoses. If they are cracked or degraded,
replace them. Replace the hoses at least every two
years. See Check and Replace Fuel Hoses and
Engine Coolant Hoses on page 5-37.
Lap the Intake and Exhaust Valves

Adjustment is necessary to maintain proper contact
of the valves and seats. See Inspection of Intake
and Exhaust Valves on page 6-27.


Section 6
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

ENGINE
Cylinder Head ................................................................................ 6-20
Cylinder Head Components ..................................................... 6-20
Disassembly of Cylinder Head ................................................. 6-21
Cleaning of Cylinder Head Components .................................. 6-25
Inspection of Cylinder Head Components................................ 6-25
Reassembly of Cylinder Head.................................................. 6-29
Measuring and Adjusting Valve Clearance .............................. 6-34
Cylinder Block ................................................................................ 6-36
Crankshaft and Camshaft Components ................................... 6-36
Disassembly of Cylinder Block Components............................ 6-37
Disassembly of Camshaft and Timing Components ................ 6-38
Disassembly of Crankshaft and Piston Components ............... 6-42
Inspection of Crankshaft and Camshaft Components.............. 6-46
Reconditioning the Crankshaft ................................................. 6-51
Honing and Boring.................................................................... 6-53
Reassembly of Crankshaft and Piston Components................ 6-54
Reassembly of Camshaft and Timing Components ................. 6-60

Before You Begin Servicing ENGINE
BEFORE YOU BEGIN A WARNING

SERVICING
A WARNING
FUME / BURN HAZARD!

• Always read and follow safety related
precautions found on containers of
hazardous substances like parts
To prevent possible eye injury, always cleaners, primers, sealants and
wear SAFETY GLASSES while servicing sealant removers.
the engine.
0000013en
or serious injury.
A WARNING
0000014en
A CAUTION
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

ENGINE Before You Begin Servicing
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
surrounding area before you remove

the cap. CAUTION
• NEVER mix different types of engine Identify all parts and their location using
oil. This may adversely affect the an appropriate method. It is important
lubricating properties of the engine oil. that all parts are returned to the same
• NEVER overfill. Overfilling may result position during the reassembly process.
in white exhaust smoke, engine 0000080en

0000005en CAUTION
Keep the piston pin parts, piston
CAUTION assemblies, and connecting rod
Any part which is found defective as a assemblies together to be returned to
result of inspection or any part whose the same position during the
measured value does not satisfy the reassembly process. Label the parts
standard or limit must be replaced. using an appropriate method.
0000088en
0000119en
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
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
0000120en

Introduction ENGINE
INTRODUCTION
This section of the Service Manual describes servicing of the engine.
CYLINDER HEAD SPECIFICATIONS

Adjustment Specifications
Model Valve Clearance
0.006 - 0.010 in.
All
(0.15 - 0.25 mm)
Cylinder Head
Reference
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

ENGINE Cylinder Head Specifications
Intake / Exhaust Valve and Guide

Reference
Page
0.2362 - 0.2367 in. 0.2394 in.
Guide Inside Diameter
(6.000 - 6.012 mm) (6.08 mm)
Valve Stem Outside 0.2346 - 0.2352 in. 0.2323 in.
Diameter (5.960 - 5.975 mm) (5.90 mm)
Intake
0.0010 - 0.0020 in. 0.0063 in.
Oil Clearance
(0.025 - 0.052 mm) (0.15 mm)
0.0004 in. See
Valve Stem Bend - Inspection of
(0.010 mm)
Valve
0.2362 - 0.2367 in. 0.2394 in. Springs on
Guide Inside Diameter
(6.000 - 6.012 mm) (6.08 mm) page 6-28
Valve Stem Outside 0.2341 - 0.2346 in. 0.2323 in.
Diameter (5.945 - 5.960 mm) (5.90 mm)
Exhaust
0.0016 - 0.0026 in. 0.0067 in.
Oil Clearance
(0.040 - 0.067 mm) (0.17 mm)
0.0004 in.
Valve Stem Bend -
(0.010 mm)
0.3858 - 0.3937 in. See
Valve Guide Projection From Cylinder Head -
(9.8 - 10.0 mm) Reassembly
0.429 - 0.441 in. of Valve
Valve Stem Seal Projection From Cylinder Head
(10.9 - 11.2 mm) Guides on
Valve Guide Installation Method Cold-fitted - page 6-29
Push Rod
Reference
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
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

Camshaft and Timing Gear Train Specifications ENGINE
Rocker Arm and Shaft
Reference
Page
0.4724 - 0.4732 in. 0.4752 in.
Arm Shaft Hole Diameter See
(12.000 - 12.020 mm) (12.07 mm)
Inspection of
0.4711 - 0.4718 in. 0.4701 in.
Shaft Outside Diameter Rocker Arm
(11.966 - 11.984 mm) (11.94 mm)
Assembly on
Oil Clearance
0.0006 - 0.0021 in. 0.0051 in. page 6-26
(0.016 - 0.054 mm) (0.13 mm)
CAMSHAFT AND TIMING GEAR TRAIN SPECIFICATIONS

Camshaft
Reference
Page
See Removal
0.0020 - 0.0059 in. 0.0098 in.
End Play of Camshaft
(0.05 - 0.15 mm) (0.25 mm)
on page 6-41
0 - 0.0008 in. 0.0020 in.
Bend (1/2 the dial gauge reading)
(0 - 0.02 mm) (0.05 mm)
1.3439 - 1.3490 in. 1.3343 in.
Cam Lobe Height
(34.135 - 34.265 mm) (33.89 mm)
1.5748 - 1.5778 in. 1.5807 in.
Bushing Inside Diameter
(40.000 - 40.075 mm) (40.150 mm)
1.5724 - 1.5732 in. 1.5711 in.
Gear End Camshaft Outside Diameter
(39.940 - 39.960 mm) (39.905 mm)
0.0016 - 0.0053 in. 0.0096 in.
Oil Clearance
(0.040 - 0.135 mm) (0.245 mm) See
1.5748 - 1.5758 in. 1.5787 in. Inspection of
Shaft Outside (40.000 - 40.025 mm) (40.100 mm) Camshaft on
Diameter /
1.5713 - 1.5722 in. 1.5699 in. page 6-52
Bearing Intermediate Camshaft Outside Diameter
(39.910 - 39.935 mm) (39.875 mm)
Inside
Diameter 0.0026 - 0.0045 in. 0.0089 in.
Oil Clearance
(0.065 - 0.115 mm) (0.225 mm)
1.5748 - 1.5758 in. 1.5787 in.
(40.000 - 40.100 mm) (40.100 mm)
1.5724 - 1.5732 in. 1.5711 in.
Flywheel End Camshaft Outside Diameter
(39.940 - 39.960 mm) (39.905 mm)
0.0016 - 0.0033 in. 0.0077 in.
Oil Clearance
(0.040 - 0.085 mm) (0.195 mm)

ENGINE Crankshaft and Pistons Specifications
Idler Gear Shaft and Bushing

Reference
Page
1.4547 - 1.4557 in. 1.4528 in.
Shaft Outside Diameter See
(36.950 - 36.975 mm) (36.900 mm)
Inspection of
1.4567 - 1.4577 in. 1.4596 in.
Bushing Inside Diameter Idler Gear
(37.000 - 37.025 mm) (37.075 mm)
and Shaft on
Oil Clearance
0.0010 - 0.0030 in. 0.0069 in. page 6-53
(0.025 - 0.075 mm) (0.175 mm)
Timing Gear Backlash

Reference
Page
See
Checking
Crank Gear, Cam Gear, Idler Gear, Fuel Injection Pump Gear 0.0024 - 0.0047 in. 0.0055 in.
Timing Gear
and PTO Gear (0.06 - 0.12 mm) (0.14 mm)
Backlash on
page 6-38
CRANKSHAFT AND PISTONS SPECIFICATIONS

Crankshaft
Note: Check appropriate parts catalog for undersized replacement main bearing inserts.
Reference
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 and Pistons Specifications ENGINE
(Crankshaft Cont.)
Reference
Page
Journal Outside 1.8485 - 1.8489 in. 1.8465 in.
Diameter (46.952 - 46.962 mm) (46.902 mm)
Bearing Inside 1.8497 - 1.8505 in. See
-
Diameter (46.982 - 47.002 mm) Inspection of
Main Bearing Journal
Bearing Insert 0.0791 - 0.0793 in. Crankshaft
- on page 6-51
Thickness (2.009 - 2.014 mm)
0.0008 - 0.0020 in. 0.0047 in.
Oil Clearance
(0.020 - 0.050 mm) (0.120 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
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
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)

Crankshaft and Pistons Specifications ENGINE
Piston Ring
Reference
Model Inspection Item Standard Limit
Page
0.0610 - 0.0618 in.
Ring Groove Width -
(1.550 - 1.570 mm)
0.0579 - 0.0587 in. 0.0571 in.
Ring Width
(1.470 - 1.490 mm) (1.450 mm)
Top Ring
0.0024 - 0.0039 in.
Side Clearance -
(0.060 - 0.100 mm)
0.0059 - 0.0118 in. 0.0154 in.
End Clearance
(0.150 - 0.300 mm) (0.390 mm)
0.0606 - 0.0614 in. 0.0654 in.
Ring Groove Width
(1.540 - 1.560 mm) (1.660 mm)
0.0579 - 0.0587 in. 0.0571 in. See Inspection
Ring Width of Pistons,
2TNV70 (1.470 - 1.490 mm) (1.950 mm)
Second Ring Piston Rings
3TNV70 0.0020 - 0.0035 in. 0.0083 in.
Side Clearance and Wrist Pin on
(0.050 - 0.090 mm) (0.210 mm) page 6-48
0.0071 - 0.0130 in. 0.0165 in.
End Clearance
(0.180 - 0.33 mm) (0.42 mm)
0.1185 - 0.1193 in. 0.1232 in.
Ring Groove Width
(3.010 - 3.030 mm) (3.130 mm)
0.1170 - 0.1177 in. 0.1161 in.
Ring Width
(2.970 - 2.990 mm) (2.950 mm)
Oil Ring
0.0008 - 0.0024 in. 0.0071 in.
Side Clearance
(0.020 - 0.060 mm) (0.180 mm)
0.0059 - 0.0138 in. 0.0173 in.
End Clearance
(0.150 - 0.350 mm) (0.440 mm)

(Piston Ring Cont.)

Reference
Page
0.0610 - 0.0618 in.
Ring Groove Width -
(1.550 - 1.570 mm)
0.0579 - 0.0587 in. 0.0571 in.
Ring Width
(1.470 - 1.490 mm) (1.450 mm)
Top Ring
0.0024 - 0.0039 in.
Side Clearance -
(0.060 - 0.100 mm)
0.0059 - 0.0118 in. 0.0154 in.
End Clearance
(0.150 - 0.300 mm) (0.390 mm)
0.0622 - 0.0628 in. 0.0667 in.
Ring Groove Width
(1.580 - 1.595 mm) (1.695 mm)
0.0563 - 0.0571 in. 0.0555 in. See Inspection
Ring Width of Pistons,
(1.430 - 1.450 mm) (1.410 mm)
3TNV76 Second Ring Piston Rings
0.0005 - 0.0065 in. 0.0112 in. and Wrist Pin on
Side Clearance
(0.013 - 0.165 mm) (0.285 mm) page 6-48
0.0071 - 0.0130 in. 0.0165 in.
End Clearance
(0.180 - 0.33 mm) (0.42 mm)
0.1185 - 0.1193 in. 0.1232 in.
Ring Groove Width
(3.010 - 3.030 mm) (3.130 mm)
0.1169 - 0.1177 in. 0.1161 in.
Ring Width
(2.970 - 2.990 mm) (2.950 mm)
Oil Ring
0.0008 - 0.0024 in. 0.0071 in.
Side Clearance
(0.020 - 0.060 mm) (0.180 mm)
0.0079 - 0.0177 in. 0.0213 in.
End Clearance
(0.200 - 0.450 mm) (0.540 mm)
Connecting Rod
Connecting Rod Small End
Reference
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)

Cylinder Block Specifications ENGINE
Connecting Rod Big End
Reference
Page
0.0079 - 0.0157 in. See
Side Clearance -
(0.20 - 0.40 mm) Inspection of
Connecting
Bearing Inside Diameter and Oil Clearance See Crankshaft on page 6-8 Rod on
page 6-49
Connecting Rod Distortion

Reference
Page
See
Less than Inspection of
Twist and Bend per 0.003 in.
All Models 0.001 in. Connecting
3.937 in.(100 mm) (0.08 mm)
(0.03 mm) Rod on
page 6-49
Tappet
Reference
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)
CYLINDER BLOCK SPECIFICATIONS

Cylinder Block
Reference
Inspection Item Model Standard Limit
Page
2TNV70 2.7563 - 2.7567 in. 2.7638 in.
3TNV70 (70.010 - 70.020 mm) (70.200 mm) See
Cylinder Inside Diameter Inspection of
2.9925 - 2.9929 in. 3.0000 in.
3TNV76 Cylinder
(76.010 - 76.020 mm) (76.200 mm)
Block on
Roundness 0.0004 in. (0.01 mm) 0.0012 in. page 6-47
Cylinder Bore
Taper or less (0.03 mm)

ENGINE
SPECIAL TORQUE CHART
Torque for Bolts and Nuts
Lubricating Oil
Thread Diameter and Application (Thread
Component Tightening Torque Reference Page
Pitch Portion and Seat
Surface)
40 - 43 ft·lb See Reassembly of
Cylinder Head Bolts M9 x 1.25 mm (53.9 - 57.9 N·m; Applied Cylinder Head on
5.5 - 5.9 kgf·m) page 6-31
17 - 20 ft·lb
See Installation of
Connecting Rod Bolts M7 x 1.0 mm (22.6 - 27.5 N·m; Applied
Pistons on page 6-58
2.3 - 2.8 kgf·m)
59 - 64 ft·lb See Installation of
Flywheel Bolts M10 x 1.25 mm (80.4 - 86.4 N·m; Applied Crankshaft on
8.2 - 8.8 kgf·m) page 6-57
56 - 60 ft·lb See Installation of
Main Bearing Cap Bolts M10 x 1.25 mm (75.5 - 81.5 N·m; Applied Crankshaft on
7.7 - 8.3 kgf·m) page 6-57
61 - 69 ft·lb
Cast
(83.4 - 93.1 N·m;
FC250 See Installation of
Crankshaft 8.5 - 9.5 kgf·m)
M12 x 1.25 mm Applied Crankshaft on
Pulley Bolts 83 - 90 ft·lb
Forged page 6-57
(113 - 123 N·m;
PS48C
11.5 - 12.5 kgf·m)
11 - 15 ft·lb See Reassembly of
Glow Plug M10 x 1.25 (14.7 - 19.6 N·m; Not Applied Intake Manifold / Valve
1.5 - 2.0 kgf·m) Cover on page 6-33
See Tightening Torques for Standard Bolts and Nuts on page 4-25 for standard hardware torque values.

Special Service Tools ENGINE
SPECIAL SERVICE TOOLS

Note: Tools not having Yanmar part numbers must be acquired locally.
No Tool Name Applicable Model and Tool Size Illustration
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)
Locally Manufactured 0000827
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)

ENGINE Special Service Tools
No Tool Name Applicable Model and Tool Size Illustration
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
Stem Seal Tool

5 (for Installing
Stem Seals)
Allowance:
d1: ±0.00787 in. (±0.2 mm)
L1: ±0.00393 in. (±0.1 mm)
Locally Manufactured
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)
Yanmar Part No. Cylinder Bore
Flex-Hone 2.756 - 2.992 in.

129400-92410
7 (For Preparing (70 - 76 mm)
Cylinder Walls)
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
Piston Ring Tool

(For Removing/
9 Available Locally
Installing of
Piston Rings)
0000825

Measuring Instruments ENGINE
MEASURING INSTRUMENTS
No. Instrument Name Application Illustration
1 Dial Indicator (Available Locally) Measure shaft bend and end play
0000831
Measurements of narrow or deep portions that

2 Test Indicator (Available Locally)
cannot be measured by dial gauge
0000832
3 Magnetic Stand (Available Locally) For holding the dial gauge when measuring.
0000833
For measuring the outside diameters of

4 Micrometer (Available Locally)
crankshaft, pistons, piston pins, etc.
0000834
For measuring the inside diameters of cylinder

5 Cylinder Bore Gauge (Available Locally)
liners, bearing bores, etc.
0000835
For measuring outside diameters, depth,

6 Calipers (Available Locally)
thickness and width
0000836
7 Depth Micrometer (Available Locally) For measuring of valve recession
0000837
For measuring valve spring inclination and

8 Square (Available Locally)
straightness of parts
0000838

ENGINE Measuring Instruments
(Measuring instruments Cont.)

9 V-Block (Available Locally) For measuring shaft bend
0000839
For tightening nuts and bolts to the specified

10 Torque Wrench (Available Locally)
torque
0000840
For measuring piston ring gaps, piston ring

11 Feeler Gauge (Available Locally)
clearance, and valve adjustment clearance
0000841

Measuring Instruments ENGINE

ENGINE Cylinder Head
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

Cylinder Head ENGINE
1 – Baffle Plate Disassembly of Cylinder Head
2 – Oil Fill Cap
3 – Valve Cover / Intake Manifold Prepare a clean, flat working surface on a
4 – Gasket workbench large enough to accommodate the
5 – Rocker Arm Shaft cylinder head assembly. Discard all gaskets,
6 – Rocker Arm Shaft Support O-rings and seals. Use new gaskets, O-rings and
7 – Adjuster Lock Nut seals on reassembly of cylinder head.
8 – Valve Adjuster Screw
9 – Rocker Arm IMPORTANT
10 – Circlip Mark all valve train components so they can
11 – Valve Cap be installed in their original locations.
12 – Keeper
13 – Valve Spring Retainer Note: Record all measurements taken during
14 – Valve Spring disassembly.
15 – Valve Stem Seal
1. Drain coolant from engine into a suitable
16 – Valve Guide
17 – Cylinder Head
container. See Drain, Flush and Refill Cooling
18 – Exhaust Valve System with New Coolant on page 5-33.
19 – Intake Valve
20 – Cylinder Head Gasket CAUTION
21 – Push Rod (2 per cylinder) Identify all parts and their location using
22 – Glow Plug
23 – Glow Plug Wiring Harness
that all parts are returned to the same
24 – Cylinder Head Bolt
position during the reassembly process.
0000080en
2. Remove the coolant pump. See Disassembly of

Engine Coolant Pump on page 8-7.
3. Remove the high-pressure fuel lines and fuel
injectors from the cylinder head. See Removal
of Fuel Injectors on page 7-23.

Removal of Intake Manifold / Valve Cover

1. Remove the intake manifold bolts (2)
(Figure 6-2, (1)) and valve cover bolts
(Figure 6-2, (2)).
2. Remove the valve cover / intake manifold (1)
(Figure 6-2, (3)). Discard gasket
(Figure 6-2, (4)).
(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

Disassembly of Rocker Arm Assembly Removal of Cylinder Head
1. Remove the rocker arm shaft alignment set 1. Loosen the cylinder head bolts following the
screw (Figure 6-5, (6)) from support sequence shown in Figure 6-6.
(Figure 6-5, (5)).
(2)
(8)
(2) 2
8
12
14
9
5
3
(1) (1)
(3)
4 10 11 1
(4) (7) 6 13 7
(6)
(5)
(2)
(9) 8 5
4 10 1
(1)
2 9 3
6 7
0002148
1 – Cooling Fan End

(8) 2 – Camshaft Side
0002160
Figure 6-5 Figure 6-6
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)).
Removal of Valve Guides

Note: Removal of valve guides should be
postponed until inspection and
measurement procedures have been
performed. See Inspection of Valve
Guides on page 6-26.
0000191
If the valve guides are not within specifications, use
Figure 6-8
a drift pin and hammer to drive the valve guides
2. Remove the valve stem cap (Figure 6-9, (1)) (Figure 6-10, (1)) out of the cylinder head.
and keep with the valve it was installed on.
3. Using the valve spring compressor tool, (1)
compress one of the valve springs (Figure 6-8).
4. Remove the valve keepers (Figure 6-9, (2)).
5. Slowly release the tension on the valve spring.
6. Remove the spring retainer (Figure 6-9, (3))
and valve spring (Figure 6-9, (4)).
(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.

Cleaning of Cylinder Head
CAUTION
Components
Any part determined to not meet the
service standard or limit before the next
A WARNING service, as determined from the state of
current rate of wear, should be replaced
even though the part currently meets the
0000120en
FUME / BURN HAZARD! IMPORTANT

Mark all valve train components so they can
be installed in their original locations.
hazardous substances like parts Note: Record all measurements taken during
cleaners, primers, sealants and inspection.
sealant removers.
Inspection of Push Rods
or serious injury. Push Rod Bend
0000014en
Determine if the bend of the push rods is within the
Thoroughly clean all components using a specified limit.
non-metallic brush and an appropriate solvent. 1. Place the push rods on a flat inspection block or
Each part must be free of carbon, metal filings and layout bed.
other debris.
2. Roll the push rods until a gap can be observed
Inspection of Cylinder Head between a portion of the push rod and the
surface of the block or layout bed.
Components
3. Use a feeler gauge to measure the gap
Visually inspect the parts. Replace any parts that (Figure 6-11). See Push Rod on page 6-6 for
are obviously discolored, heavily pitted or otherwise the service limit.
damaged. Discard any parts that do not meet its
specified limits.
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

Inspection of Rocker Arm Assembly Inspection of Valve Guides

Rocker Arm Shaft Hole Diameter Visually inspect the valve guides for distortions,
scoring or other damage.
Use a telescoping gauge and micrometer to
measure the inside diameter of all the rocker arm Note: Measure valve guides while they are
support brackets and the rocker arms installed in cylinder head.
(Figure 6-12). Record the measurements. See
Use a telescoping gauge and micrometer to
Rocker Arm and Shaft on page 6-7 for the service
measure the inside diameter of the valve guide.
limit.
Measure in three places and 90° apart
Inspect contact areas (Figure 6-12, (1)) for (Figure 6-14). Record the measurements. See
excessive wear or damage. Intake / Exhaust Valve and Guide on page 6-6 for
the service limit. Replace valve guides if not within
specification.
0001869
(1)
(1) Figure 6-14
Inspection of Cylinder Head

0001916
Cylinder Head Distortion
Figure 6-12 Put the cylinder head flat and inverted (combustion
side up) on the bench. Use a straightedge and
Rocker Arm Shaft Outside Diameter feeler gauge to measure cylinder head distortion
Use a micrometer to measure rocker arm shaft (Figure 6-15). Measure diagonally and along each
diameter. Measure at each rocker arm location in side. Record the measurements. See Cylinder
two directions 90° apart (Figure 6-13). Record the Head on page 6-5 for the service limit.
measurements. See Rocker Arm and Shaft on
page 6-7 for the service limit.
0000192
Figure 6-15
0001952
Figure 6-13

If distortion exceeds the service limit, resurface or Valve Recession
replace the cylinder head. Remove only enough Note: The valve guides must be installed to
material to make the cylinder head flat, but do not perform this check.
remove more than 0.008 in. (0.20 mm).
Insert the valves into their original locations and
Inspection of Intake and Exhaust Valves press them down until they are fully seated. Use a
Visually inspect the intake and exhaust valves. depth micrometer (Figure 6-18) to measure the
Replace any valves that are obviously discolored, difference between the cylinder head gasket
heavily pitted or otherwise damaged. surface and the combustion surface of each
exhaust and intake valve (Figure 6-19). Record the
Valve Stem Diameter measurements. See Cylinder Head on page 6-5 for
Use a micrometer to measure the valve stem the service limit.
diameter. Measure the valve stem near the
combustion end and near the opposite end
(Figure 6-16, (1)). Record the measurements. See
Intake / Exhaust Valve and Guide on page 6-6 for
the service limit.
(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

Valve Face and Valve Seat

Always check the clearance between the valve and (1)
150° 40°
valve guide before grinding or lapping the valve
seats. See Intake / Exhaust Valve and Guide on
page 6-6 for the service limit. If the clearance (3)
(2)
exceeds the limit, replace the valve and / or valve
guide to bring the clearance within the limit.
0001862
Roughness or burrs will cause poor seating of a
valve. Visually inspect the seating surfaces of each Figure 6-21
valve and valve seat to determine if lapping or Valve seat diameter can be adjusted by
grinding is needed. top-grinding with a 150° stone to make the seat
Visually inspect all valve faces and valve seats for diameter smaller, and bottom-grinding using a 40°
pitting, distortion, cracking, or evidence of stone to make the seat diameter larger. Once the
overheating. Usually the valves and valve seats can seat location has been corrected, grind and lap the
be lapped or ground to return them to serviceable seat angle (Figure 6-21, (1)) to specification. See
condition. Severely worn or damaged components Cylinder Head on page 6-5 for the service limit.
will require replacement. Grind the valve face and / or valve seat only
Coat the valve seat with a thin coat of bluing enough to return them to serviceable condition.
compound. Install valve and rotate to distribute Grinding is needed if the valve and the valve seat
bluing onto the valve face. The contact pattern do not contact correctly. Check the valve recession
should be approximately centered on the valve face after grinding.
(Figure 6-20, (1)) and even in width. If the valve or seat require grinding, lap the valve
after grinding. Lap the valve face to the valve seat
using a mixture of valve lapping compound and
engine oil.
Be sure to thoroughly wash all parts to remove all
grinding powder or compound.
Inspection of Valve Springs

Inspect the valve springs. If damage or corrosion is
seen, or if measurements exceed the specified
(1)
limits, replace the springs. Record the
measurements.
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.

Squareness Reassembly of Cylinder Head
Use a flat surface and a square to check each Use new gaskets, O-rings and seals on reassembly
spring for squareness (Figure 6-22). See Valve of cylinder head.
Spring on page 6-6 for the service limit.
IMPORTANT
Liberally oil all components during
assembly to prevent premature wear or
damage.
Reassembly of Valve Guides

1. The valve guides are installed into the cylinder
head with an extremely tight press-fit. Before
installing the valve guides, place the valve
guides in a freezer for at least twenty minutes.
This will cause the valve guides to contract,
0000201
making it easier to install the valve guides in
Figure 6-22 place.
2. Immediately after removing the valve guides
Free Length
from the freezer, insert the valve guides
Use a caliper to measure the length of the spring (Figure 6-24, (1)) in their proper positions.
(Figure 6-23). See Valve Spring on page 6-6 for
the service limit. (1)
2
3
1
4
0
5
9
6
8
7
0002152
Figure 6-24
0000200
Figure 6-23

3. Finish installing the valve guides

(Figure 6-25, (1)) to the proper height
(Figure 6-25, (3)) using the valve guide
installation tool (Figure 6-25, (2)). See valve (1)
guide projection specification on page 6-6.
(4)
(2)
(2)
(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.
The exhaust valve stem seals are different

than the intake valve stem seals and can be
identified by the color the seal spring
(Figure 6-26, (4)). Ensure they are installed
in the correct locations. (2)
(1)
Marking
Engine Model
Intake Exhaust
2TNV70, 3TNV70, White (Seal Black (Seal
3TNV76 Spring) Spring)
0001874
1. Oil the lip of the valve stem seal Figure 6-27

(Figure 6-26, (2)). Using the valve stem seal
3. Put the cylinder head assembly on its exhaust
installation tool (Figure 6-26, (1)), install a new
port side.
valve stem seal on each of the valve guides
(Figure 6-26, (3)). 4. Install all the valves (Figure 6-28, (6)) in their
proper location in the cylinder head.

(1)
(2) (1)
(3)
(4)
(5)
(2)
(6)
0002151
Figure 6-28 0002150
5. Put the cylinder head on the workbench with Figure 6-29

the combustion side down to install the valve 3. Lightly oil the threads of the cylinder head bolts
springs. Reinstall the valve spring (Figure 6-29, (1)). Tighten the bolts to the
(Figure 6-28, (4)) and spring retainer specified torque shown in the chart below.
(Figure 6-28, (5)). Tighten in the sequence shown in Figure 6-30.
6. Using a valve spring compressor tool, See Torque for Bolts and Nuts on page 6-14.
compress the valve spring.
First Step 1/2 of final torque
7. Insert the valve keeper (Figure 6-28, (2)) and
slowly release the tension in the valve spring. Second Step Final torque
Reinstall the valve cap (Figure 6-28, (1)).
Repeat steps on all remaining valves. (2)
Reassembly of Cylinder Head 13

7
3
1
6
10
12
1. Carefully clean both the combustion surface of (1)

11 5 4 14
the cylinder head and the top surface of the 9 2 8
cylinder block. Install a new cylinder head

gasket (Figure 6-29, (2)) on the cylinder block.
(2)
2. Position the cylinder head on the cylinder head
gasket. 7
3
1
6
10
(1)
9 2 8
5 4
0002149
1 – Cooling Fan End

2 – Camshaft Side
Figure 6-30

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.

Reassembly of Intake Manifold / Valve
(1)
Cover
1. Reinstall the glow plugs (Figure 6-33, (1)) and
tighten to specification. Reinstall the electrical
harness (Figure 6-33, (2)). (2)
(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 • •
1. Remove the intake manifold / valve cover. See

Removal of Intake Manifold / Valve Cover on
page 6-22.
2. Rotate the crankshaft clockwise as seen from
the coolant pump end, to bring No. 1 piston to
TDC of the compression stroke while watching
the rocker arm motion and timing grid on the
flywheel. (Position so both the intake and
exhaust valves are closed.)
3. Insert a feeler gauge (Figure 6-35, (1))
between rocker arm and valve cap and record
the measured valve clearance. (Use the data
for estimating wear.)

6. Insert a feeler gauge of the correct thickness
(1)
(Figure 6-37, (1)) between rocker arm and
valve cap. Turn the valve adjustment screw to
adjust the valve clearance so there is a slight
“drag” on the feeler gauge when sliding it
between the rocker arm and valve cap. Hold the
adjusting screw while tightening the valve
adjusting screw lock nut (Figure 6-36, (1)).
Recheck the clearance (see Adjustment
Specifications on page 6-5).
Note: There is a tendency for the clearance to
decrease slightly when the lock nut is
tightened. It is suggested that the initial
0001782A
clearance adjustment be made slightly
Figure 6-35 on the “loose” side before tightening the
lock nut.
4. If adjustment is required, proceed to the next
step. (1)
5. Loosen the valve adjusting screw lock nut
(Figure 6-36, (1)) and valve adjusting screw
(Figure 6-36, (2)) on the rocker arm. Check the
valve for inclination of the valve cap, entrance of
dirt, or wear.
(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

ENGINE Cylinder Block
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

Cylinder Block ENGINE
1 – Cylinder Block Disassembly of Cylinder Block
2 – Camshaft Bushing
3 – Gear Case Components
4 – Dowel (2 used) Prepare a clean, flat working surface on a
5 – O-Ring workbench large enough to accommodate the
6 – Gear Case Cover engine components. Discard all used gaskets,
7 – Front Crankshaft Seal
O-rings and seals. Use new gaskets, O-rings and
8 – Fuel Injection Pump Gear Cover
seals for reassembly of engine.
9 – Tappets
10 – Camshaft
11 – Camshaft Gear Key CAUTION
12 – Camshaft End Plate
Identify all parts and their location using
13 – Camshaft Gear
14 – Idler Gear Shaft
15 – Idler Gear Bushing that all parts are returned to the same
16 – Idler Gear position during the reassembly process.
17 – Oil Pickup O-Ring 0000080en
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

5. Remove the engine from the machine. Mount

the engine to a suitable engine repair stand
having adequate weight capacity.
6. Clean the engine by washing with solvent, air or
steam cleaning. Carefully operate to prevent (3)
(1)
any foreign matter or fluids from entering the (2)
engine, fuel system, or electrical components
remaining on the engine.
7. Drain the engine oil into a suitable container.
Remove oil filter.
8. Remove the cylinder head. See Disassembly of
Cylinder Head on page 6-21.
0002181
9. Remove the fuel injection pump from the gear
case only if it must be sent out for repair, or will Figure 6-39
interfere with other procedures such as “hot
tank” cleaning. See Removal of Fuel Injection
Checking Timing Gear Backlash
Pump on page 7-13. Prior to removing the timing gears, measure the
10. Remove the starter motor. See Removal of gear backlash and determine the gear wear.
Starter Motor on page 10-10. Note: Check the backlash between each pair of
mating gears. If not within specification,
Disassembly of Camshaft and Timing replace both mating gears. Do not allow
Components the gear being checked to move axially
Discard all gaskets, O-rings and seals. Use new as excess end play could cause a false
gaskets, O-rings and seals on reassembly of reading. See Timing Gear Backlash on
camshaft and timing components. page 6-8 for service limits.
Removal of Timing Gear Case Cover (1)

(2)
1. Remove the bolt and washer retaining the
crankshaft pulley. (3)
B
B
IMPORTANT C C
Use care not to damage the threads in the A
end of the crankshaft when removing the (5) A
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

Measuring Idler Gear-to-Crankshaft Gear Removal of Timing Gears
Backlash 1. Remove the bolts from the idler gear shaft
1. Install a dial indicator as shown in Figure 6-41. (Figure 6-42, (1)). Remove the idler gear shaft,
idler gear (Figure 6-42, (3)) and bushing
(Figure 6-42, (2)).
(3)
(2)
(1)
00021
0002192

2. Rotate the idler gear back and forth to check 2. Do not remove the crankshaft gear unless it is
idler gear-to-crankshaft gear backlash. Total damaged and requires replacement. If the gear
indicator reading is backlash. Record the must be removed, remove it with a gear puller.
measurement.
3. Removal of the camshaft gear requires the
Measuring Idler Gear-to-Camshaft Gear camshaft be removed with a press. Do not
remove the camshaft gear unless it or the
Backlash
camshaft is damaged and requires
1. Drive a small wooden wedge between the replacement. See Removal of Camshaft on
crankshaft gear and idler gear to prevent the page 6-41.
idler gear from rotating.
2. Install a dial indicator to read camshaft gear CAUTION
backlash. Rotate camshaft drive gear against Do not loosen or remove the four bolts
idler gear to measure backlash. Record the retaining the fuel injection pump drive
measurement. gear to the fuel injection pump hub. Do
3. Check the idler gear-to-fuel injection pump not disassemble the fuel injection pump
drive gear backlash in the same manner as the drive gear from the hub. Correct fuel
camshaft drive gear. Record the measurement. injection timing will be very difficult or
0000031en

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
0000031en
(2)
(1)
0002185
Figure 6-45

Removal of Camshaft 2. Remove two bolts (Figure 6-48, (3)) retaining
1. Before removing the camshaft, check the the camshaft thrust plate (Figure 6-48, (1)).
camshaft end play.
• Method A: Install a dial indicator (5)
(Figure 6-46, (1)) on the cylinder block. Move
the camshaft and gear (Figure 6-46, (2)) in
and out to measure the end play. Record the
measurement. See Camshaft on page 6-7 for
the service limit.
(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

Removal of Gear Case Disassembly of Crankshaft and

Note: The camshaft must be removed before Piston Components
the gear case can be removed. See
Removal of Camshaft on page 6-41. Removal of Pistons
1. Remove bolts (Figure 6-49, (4)).
CAUTION
Note: It is not necessary to remove the fuel
injection pump from the gear case to Keep the piston pin parts, piston
remove the gear case. If the fuel injection assemblies, and connecting rod
pump does not need to be repaired, assemblies together to be returned to
leave it mounted to the timing gear case. the same position during the
See Removal of Fuel Injection Pump on reassembly process. Label the parts
page 7-13. using an appropriate method.
0000088en
2. Remove the gear case (Figure 6-49, (1)) from
the cylinder block. IMPORTANT
3. Inspect and measure the camshaft bushing. Engines with high operating hours may
See Camshaft on page 6-7 for service limits. If have a ridge near the top of the cylinders
damaged or worn beyond service limits, remove that will catch the piston rings and make it
the camshaft bushing (Figure 6-49, (3)). impossible to remove the pistons. Use a
suitable ridge reamer to remove ridges and
4. Remove O-rings (Figure 6-49, (2)). carbon prior to removing pistons.
Note: Pistons can fall from cylinder block if
engine is inverted. Rotate the engine so
(3) the connecting rods are horizontal before
(1) removing the connecting rod caps.
(4)
(2)
0002187
Figure 6-49

1. Using a feeler gauge, measure the connecting IMPORTANT
rod side clearance (Figure 6-50). See Do not rotate crankshaft when using
Connecting Rod on page 6-12 for the standard PLASTIGAGE. A false reading may result.
limit. If the measurement is out of specification,
replace the crankshaft, connecting rod, or both. 5. Reinstall the bearing cap and tighten to
specification. See Special Torque Chart on
page 6-14.
6. Remove the bearing cap.
(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

11. Remove the bearing inserts (Figure 6-53, (2)).

(2)
12. Remove the compression rings
(Figure 6-53, (3)) from the piston using a piston
ring expander.
(3)
13. Remove the oil ring (Figure 6-53, (4)) from the
piston using a piston ring expander. (1)
(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.
Removal of Crankshaft (2)

0001961
1. Remove the flywheel (Figure 6-54, (1)) from
the crankshaft. Figure 6-55
2. Remove the bolts (Figure 6-54, (2)) from the
flywheel housing assembly. Remove the
flywheel housing from the engine.

• Method B: Use a feeler gauge to measure the
clearance (Figure 6-56, (3)) between the
thrust bearing (Figure 6-56, (1)) and
crankshaft (Figure 6-56, (2)). Record the (1)
measurement. See Thrust Bearing on
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.
FUME / BURN HAZARD!

cleaners, primers, sealants and
sealant removers.
(1) • Failure to comply could result in death
or serious injury.
(2) 0000014en
Thoroughly clean all components using a brush

0002189 and appropriate solvent. Each part must be free of
carbon, gasket material, metal filings and other
Figure 6-59 debris.
13. If necessary, remove the crankshaft gear Note: Record all measurements taken during
(Figure 6-60, (1)) and key (Figure 6-60, (2)). If inspection.
using a gear puller, be careful not to damage
the threads in the end of the crankshaft. Replacement of Crankshaft Oil Seals
1. Remove the seal (Figure 6-61, (2)) from the
(2) gear case cover (Figure 6-61, (1)).
2. Apply a continuous bead of ThreeBond Liquid
Gasket No. 1212, Yanmar Part No.
977770-01212 to the outside diameter of a new
(1) oil seal (Figure 6-61, (2)).
3. Install a new seal in the gear case cover with
the lip facing in away from the crankshaft pulley.
Apply lithium grease to the lip of the seal.
0002193
Figure 6-60

(1) Inspection of Cylinder Block

1. Ensure that oil passages are clear and
unobstructed.
2. Check for discoloration or evidence of cracks. If
(2) a fracture is suspected, use the color check
method or the MAGNAFLUX® method to
determine if the cylinder block is fractured.
0002181A 3. Measure cylinders for roundness, taper, and
Figure 6-61 inspect for evidence of scoring. Consider
honing, re-boring or replacing the cylinder block
4. Remove the rear oil seal (Figure 6-62, (1)) from if the measurements are not within
the flywheel housing (Figure 6-62, (2)). specification.
(2) • Take measurements at three places
(Figure 6-63) (a, b, and c), and in two
directions (d and e) in each cylinder. Collect
and record the measurements. See Cylinder
Block on page 6-13 for specifications.
a 20 mm
(0.75 in.)
d
e
b
(1)
c
20 mm
Figure 6-62 (0.75 in.) 0000230B
5. Apply a continuous bead of ThreeBond Liquid Figure 6-63

977770-01212 to the outside diameter of a new Roundness
oil seal (Figure 6-62, (1)). Roundness can be calculated by subtracting the
6. Install a new seal in the flywheel housing smaller measured value from the larger measured
(Figure 6-62, (2)) with the lip facing in away value of (d or e) at each measuring location (a, b,
from the flywheel. Apply lithium grease to the lip and c).
of the seal.
Taper
Crankshaft Bearing Oil Clearance Taper can be calculated by subtracting the
Oil clearance should be checked during minimum measured value from the maximum
disassembly to determine the extent of wear, and measured value of locations (a, b, and c).
during assembly to ensure long engine life. The Calculate along both the (d) axis and (e) axis and
same procedure is done for both connecting rods use the larger of the two calculations as the value
and main bearings. See Removal of Pistons on to compare to the specifications.
page 6-42 or Removal of Crankshaft on page 6-44
for specific information.

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

• On an engine with high hours, the pistons rings
should be replaced and the cylinder honed
(See Honing and Boring on page 6-53) or
replaced. The piston should be replaced as
necessary.
9. Place each compression piston ring in the
groove as shown (Figure 6-67). Use a feeler
gauge to measure the clearance between the
piston ring and the piston ring land. Record the (1)
measurements. See Piston Ring on page 6-11 (2)
for specifications. Replace the piston if not
within specification.
(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.

3. Place the connecting rod bearing inserts into

the connecting rod and connecting rod cap.
Install the rod cap and tighten the bolts to the
specified torque.
4. Measure the inside diameter. Record the
measurements. See Crankshaft on page 6-8 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.
(1) (2) 0002194
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
0000242
Figure 6-71

Inspection of Crankshaft
1. Put the crankshaft end journals
(Figure 6-74, (4)) on V-blocks.
2. Place a dial indicator (Figure 6-74, (3)) on a
center main bearing surface.
(2)
(1)
(3)
(1)
(2) 0001733A
Figure 6-75
Reconditioning the Crankshaft

(4) (4) 0000232A If any of the crankshaft journals do not meet the
specifications, it may be possible to grind any or all
Figure 6-74
of them to an undersize. The connecting rod
3. Rotate the crankshaft and observe runout. bearings, main bearings, and thrust bearing inserts
Record the measurements. See Crankshaft on are available as 0.010 in. (0.25 mm) undersize. If
page 6-8 for specifications. the journals are ground undersize, the following
4. Use the color check method or MAGNAFLUX to finishing standards (Figure 6-76) must be adhered
inspect the crankshaft for cracks. Replace the to:
crankshaft if evidence of fractures is found.
5. Measure the outside diameter of each crankpin
(Figure 6-75, (2)) and main bearing journal
(Figure 6-75, (1)). See Crankshaft on page 6-8
for specifications. Take measurements at
several places around each bearing surface. If
not within specification, grind the journals and
install undersize bearings, or replace the
crankshaft. Record the measurements.

(1)
Ry (1)
Ry
R
R
R
0001712A
0000234A Figure 6-78

Figure 6-76 4. Measure the diameter of the gear end
(Figure 6-79, (1)), intermediate
Item Finishing Precision (Figure 6-79, (2)), and flywheel end
Connecting Rod Journal 1.6418 - 1.6422 in. (Figure 6-79, (3)) bearing journals. Record the
Undersize Finished Size (41.702 - 41.712 mm) measurements. See Camshaft on page 6-7 for
Main Bearing Journal 1.8387 - 1.8391 in. specifications.
Undersize Finished Size (46.702 - 46.712 mm)
0.138 - 0.150 in. (3)
Journal Radius (R)
(3.5 - 3.8 mm)
Journal Face Finish (Ry) 0.8S (Super Polish)
(2)
Thrust Face Finish (1) 1.6
(1)
Inspection of Camshaft
1. Use V-blocks and a dial indicator to check
camshaft bend (Figure 6-77). Place the
indicator on the center bearing journal. 0001713A
Figure 6-79
0002196
Figure 6-77
2. Rotate the camshaft and observe the runout.
Record the measurements. See Camshaft on
3. Measure the height of each lobe
(Figure 6-78, (1)). Record the measurements.
See Camshaft on page 6-7 for specifications.

Inspection of Camshaft Bushing and Bores Honing and Boring
1. Measure the I.D. of the front bushing and the Pistons must move freely in the cylinders while
remaining bores in the cylinder block. Record maintaining adequate compression and oil sealing.
the measurements. See Camshaft on page 6-7 If the cylinder walls are scuffed, scored,
for specifications. out-of-round, or tapered beyond specifications,
If the camshaft bushing is not within specification, rebore and hone to restore cylinders to usable
replace using the appropriate service tool. If the condition. Slight imperfections can be corrected by
remaining bores are not within specification, the honing alone.
cylinder block will require replacement as there are
1. Boring - Significant cylinder damage may be
no bearing inserts used.
corrected by boring the cylinder to an oversize
Inspection of Idler Gear and Shaft dimension. Refer to the appropriate parts
catalog for available oversize pistons and piston
1. Measure the outside diameter rings.
(Figure 6-80, (1)) of the idler gear shaft
(Figure 6-80, (2)). Record the measurements. • Boring a cylinder should always be done in a
See Idler Gear Shaft and Bushing on page 6-8 properly equipped machine shop.
for specifications. • A bored cylinder should always be finished with
2. Measure the inside diameter (Figure 6-80, (3)) a hone to properly prepare the cylinder surface
of the idler gear bushing (Figure 6-80, (4)). so the new piston rings will seat properly.
Record the measurements. See Idler Gear • After the cylinder has been bored and honed,
Shaft and Bushing on page 6-8 for install the appropriate oversize pistons and
specifications. piston rings.
2. Honing - Minor cylinder imperfections may be
(4)
corrected by using a rigid cylinder hone
(Figure 6-82, (1)). Be sure not to exceed the
maximum cylinder bore specification.
(1) (3) Deglazing - A used cylinder that did not require
boring or honing, should always be deglazed with
(2) a ball hone (Figure 6-82, (2)) before installing
new piston rings. This will properly prepare the
Figure 6-80 cylinder surface to allow new piston rings to seat
properly.
Note: When honing a cylinder, with either a
ridged hone or a ball hone
(Figure 6-81, (1)), move the rotating
hone up and down in the cylinder bore to
accomplish a 30° to 40° crosshatch
pattern (Figure 6-81). This will provide
the ideal surface for the proper seating of
new piston rings.

• When honing is completed, wash the cylinder

CAUTION block with hot water and soap. The cylinder wall
Do not allow the honing tool to operate is adequately cleaned when a white rag wiped
in one position for any length of time. in cylinder comes out clean. Use brushes to
Damage to the cylinder wall will occur. clean all passages and crevices. Rinse with hot
Keep the tool in constant up-and-down water and dry with compressed air. Apply clean
motion. engine oil to all steel surfaces to prevent
0000090en rusting.
(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.

Reassembly of Pistons Note: The actual appearance of the match
1. Select the parts needed to assemble the piston marks will vary but they will always be in
and connecting rod for one cylinder. the same locations.
2. If removed, install a new wrist pin bushing

(Figure 6-83, (7)) using a press and the
appropriate service tool. Be sure to align the oil
holes.
(3)
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
assembled with the correct orientation. Figure 6-84

When correctly assembled, the piston
identification mark (Figure 6-84, (1)) 4. Place the connecting rod into the piston. The
stamped into the top of the piston will be on match marks (Figure 6-85, (4)) on the
the opposite side of the connecting rod as connecting rod and cap must be on the
the match marks (Figure 6-84, (3)) opposite side as the piston identification mark
stamped into the connecting rod and (Figure 6-85, (2)) on the top of the piston.
connecting rod cap. When reinstalled in the
cylinder, the embossed mark
(Figure 6-84, (2)) cast into the beam of
connecting rod will face the flywheel end of
the engine.

(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.

7. Reinstall the oil ring expander
(1)
(Figure 6-88, (4)). Install the oil ring
(Figure 6-88, (3)) with the end gap at 180° from
the expander end gap.
8. Reinstall the second compression ring (2)
(Figure 6-88, (2)). This ring is identified by its
dark color and tapered face profile. (3)
9. Reinstall the top compression ring
(Figure 6-88, (1)). This ring is identified by its
silver color and barrel-shaped face profile.
IMPORTANT
The oil ring expander (Figure 6-88, (4)) end
gap must be located 180° from the oil ring
(Figure 6-88, (3)) end gap.
1 – Top Compression Ring End Gap

(1)
2 – Second Compression Ring End Gap
3 – Oil Ring End Gap
Figure 6-89
(2)
Installation of Crankshaft
(3) 1. If removed, reinstall the key and timing gear on
crankshaft.
2. Install new bearing inserts (Figure 6-90, (1))
(4) and thrust bearing (Figure 6-90, (2)) in the
0001722B cylinder block and main bearing caps. Be sure
Figure 6-88 the oil holes in the upper bearing shells align
with the oil ports in the cylinder block. Apply a
10. Stagger the piston ring end gaps at 120° liberal coat of clean engine oil to the bearings
intervals (Figure 6-89, (1, 2, and 3)). Do not and crankshaft journals.
position the top piston ring end gap in line with
the wrist pin.

(2)
(3)
(1)
(1)
(4)
(2)
0002188
0002189
3. Install the crankshaft in the engine. Installation of Pistons
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.

4. Carefully reinstall the piston and rod assembly.
(1)
Be sure the match marks (Figure 6-93, (4))
stamped into the connecting rod and cap are
facing the fuel injection pump side of the
(2) cylinder block, and the piston identification
mark (Figure 6-93, (2)) stamped into the piston
(3) top is facing the camshaft side
(Figure 6-93, (6)). The embossed mark cast
into the connecting rod beam (Figure 6-93, (3))
will be facing the flywheel end of the engine
(Figure 6-93, (5)).
(6) (1)
0000226A
1 – Top Compression Ring End Gap (2) (5)

2 – Second Compression Ring End Gap
3 – Oil Ring End Gap
Figure 6-92
(3)
IMPORTANT
Ensure piston ring gaps are located
correctly (Figure 6-92).
(4)
3. Using a piston ring compressor, compress the
piston rings.
0000227A
IMPORTANT
1 – Fuel Injection Pump Side of Engine
The piston and connecting rod must be
2 – Piston Identification Mark
reinstalled with the correct orientation.
3 – Embossed Mark on Connecting Rod
When installed correctly, the identification 4 – Rod and Cap Match Marks
mark (Figure 6-93, (2)) stamped into the 5 – Flywheel End of Engine
top of the piston will be on the same side of 6 – Camshaft Side of Engine
the engine as the fuel injection pump
(Figure 6-93, (1)) and the embossed mark Figure 6-93
(Figure 6-93, (3)) cast into the connecting 5. Reinstall the bearing inserts (Figure 6-94, (1))
rod beam will face the flywheel end of the in the connecting rod and cap.
engine (Figure 6-93, (5)).
6. Apply a liberal coat of clean engine oil to the
bearing inserts and crankshaft journal.

7. Apply a light coat of clean engine oil to the rod

cap bolts. Reinstall the connecting rod cap
(3)
(Figure 6-94, (2)). Tighten the connecting rod
(1)
bolts to the specified torque in two stages (1/2
then full torque). See Special Torque Chart on (4)
page 6-14.
(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

4. Lubricate the camshaft lobes and tappets with
(1)
clean oil or assembly lube. Reinstall the tappets (2)
in their respective locations in the cylinder
block. Push the tappets fully into the tappet (3)
bores until they make solid contact with the B
B
C C
camshaft.
A
5. If removed, reinstall the fuel injection pump. (5) A
Adjust the fuel injection timing after installation.

See Checking and Adjusting Fuel Injection (4)
Timing on page 7-19. 0002190
1 – Fuel Injection Pump Gear

Installation of Timing Gears 2 – Camshaft Gear
1. Set No. 1 piston to top dead center. 3 – Optional Accessory Drive Gear
4 – Crankshaft Gear
2. Rotate the camshaft until mark
5 – Idler Gear
(Figure 6-98, (C)) is approximately at the
9 o’clock position. Figure 6-98
3. Lubricate the idler gear (Figure 6-97, (3)), 7. When all gears are properly aligned, tighten the
bushing (Figure 6-97, (2)) and idler gear shaft idler gear retaining bolts to specified torque.
(Figure 6-97, (1)) with clean engine oil or See Special Torque Chart on page 6-14 for
assembly lube. specifications.
Installation of Gear Case Cover

1. Apply a continuous bead of ThreeBond Liquid
977770-01212 to the mounting area of the gear
(3) case cover (Figure 6-99, (1)). Be sure to circle
(2) the bolt holes.
(1)
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)
Installation of Oil Pan

1. Reinstall the oil pickup tube (Figure 6-100, (1))
and a new O-ring (Figure 6-100, (2)).
0002184
Figure 6-101
Final Assembly of Engine

1. Reinstall the starter motor.
2. Reinstall the cylinder head. See Reassembly of
Cylinder Head on page 6-31.
3. Reinstall the engine in the machine.
4. Reconnect the fuel and coolant lines.
(2) 5. Reinstall the alternator.
(1) 6. Reconnect and adjust the throttle cable.
7. Reconnect all electrical connections.
0002185
8. Fill the engine with oil and coolant.
Figure 6-100 9. Reconnect the battery cables, negative (-) cable
2. Apply a continuous bead of ThreeBond Liquid last.
977770-01212 to the mounting surface of the oil
pan (Figure 6-101, (2)) and crankcase
extension (if equipped) (Figure 6-101, (1)). Be
sure to circle each bolt hole.
3. If equipped, reinstall the crankcase extension
(Figure 6-101, (1)). Reinstall the oil pan and
tighten the bolts securely.

Section 7
FUEL SYSTEM
Page
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

FUEL SYSTEM
Disassembly and Inspection of Fuel Injectors .......................... 7-27
Adjusting Fuel Injector Pressure .............................................. 7-28
Reassembly of Fuel Injectors ................................................... 7-29
Installation of the Fuel Injectors................................................ 7-29

Before You Begin Servicing FUEL SYSTEM

SERVICING
A WARNING
To prevent possible eye injury, always

wear SAFETY GLASSES while servicing
ENTANGLEMENT HAZARD! the engine.
0000013en
service it.
• NEVER leave the key in the key switch A CAUTION
engine and not realize you are
serious injury.
is operating, remove all jewelry, tie FLYING OBJECT HAZARD!
back long hair, and keep your hands, • ALWAYS wear eye protection when
other body parts and clothing away servicing the engine and when using
from moving / rotating parts. compressed air or high-pressure
• Failure to comply could result in death water. Dust, flying debris, compressed
or serious injury. air, pressurized water or steam may
0000010en
injure your eyes.
A WARNING or moderate injury.
0000003en
A CAUTION
FUME / BURN HAZARD!

cleaners, primers, sealants and PINCH HAZARD!
sealant removers. Carefully rotate the alternator toward the
or serious injury.
0000014en
0000014en

FUEL SYSTEM Before You Begin Servicing
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
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.
0000048en
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
gear to the fuel injection pump hub. Do
not disassemble the fuel injection pump
0000031en

Introduction FUEL SYSTEM
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.

FUEL SYSTEM Introduction
Stop Solenoid
CAUTION
The ML fuel injection pumps are equipped with a
stop solenoid that controls the fuel flow inside the
the tamper-proof devices from the
fuel injection pump.
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.
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.

Fuel System Specifications FUEL SYSTEM
FUEL SYSTEM SPECIFICATIONS

Special Torque Chart
Lubricating Oil Application
Component Tightening Torque
(Thread Portion and Seat Surface)
36.1 - 43.5 ft·lb
Fuel Injector (49 - 59 N·m, Not Applied
5.0 - 60 kgf·m)
44 - 51 ft·lb
Fuel Pump Drive Gear Nut (59 - 69 N·m; Not Applied
6 - 7 kgf·m)
22 - 25 ft·lb
High -Pressure Fuel Injection Line Nuts (29 - 34 N·m; Not Applied
3.0 - 3.5 kgf·m)
18 - 24 ft·lb
Fuel Return Line Nuts (24 - 33 N·m; Not Applied
2.5 - 3.3 kgf·m)
17 - 21 ft·lb
Fuel Injection Pump Mounting Nuts (23 - 28 N·m; Not Applied
2.3 - 2.9 kgf·m)
21.4 - 36.1 ft·lb
Fuel Injector Nozzle Case Nut (29 - 49 N·m; Not Applied
3.0 - 5.0 kgf·m)
Test and Adjustment Specifications

Fuel Injector Pressure Fuel Injection Timing
1784 - 1929 psi
See Checking and Adjusting Fuel Injection Timing on
(12.3 - 13.3 MPa;
page 7-19
125 - 136 kgf/cm2)
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.

FUEL SYSTEM Special Service Tools

Note: Tools not having Yanmar part numbers must be acquired locally.
No. Tool Name Application Illustration
For tightening nuts and bolts to the specified

1 Torque Wrench (Locally Available)
torque
0000840
MEASURING INSTRUMENTS
For observing injection spray pattern of fuel

1 Fuel Injector Tester (Locally Available) injection nozzle and measuring injection
OFF
P-
OFF
E-
ON AG
-G
pressure
2 “Spill-Timing” Tool (Shop Fabricated)* Used to set fuel injection timing
* 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.

Fuel System Diagram FUEL SYSTEM
FUEL SYSTEM DIAGRAM
(9)
(8)
(10)
(12)
(7)
(11)
(1)
(3)
(6)
(5) (2)
(4)
0001058A
Figure 7-2
1 – Diesel Fuel Supply 6 – Fuel Filter

2 – Fuel Filter / Water Separator 7 – Fuel Injection Pump
3 – Mechanical Fuel Pump (Used in place of the 8 – High-Pressure Fuel Injection Lines
electric fuel pump on some models) 9 – Fuel Injectors
4 – Electric Fuel Pump (Used on models 10 – Fuel Return from Fuel Injectors
without mechanical fuel pump) 11 – Air Bleed Orifice
5 – Low-Pressure Fuel Supply Lines 12 – Fuel Return to Tank

FUEL SYSTEM Fuel System Components
FUEL SYSTEM COMPONENTS

(19)
(18) (1)
(17) (2)
(3)
(16)
(7)
(15) (4)
(6)
(7)
(5)
(11)
(14)
(10)
(9)
(8)
(13)
(12)
0002208
Figure 7-3

Fuel Injection Lines FUEL SYSTEM
1 – High-Pressure Fuel Injection Lines FUEL INJECTION LINES
2 – Fuel Return Line Nut
3 – Fuel Return Line
4 – Fuel Injector
Removal of High-Pressure Fuel
5 – Gasket Injection Lines
6 – Protector
7 – Fuel Return Hose CAUTION
8 – Fuel Injection Pump Drive Gear Nut
9 – Lock Washer Remove or install the high-pressure fuel
10 – Fuel Injection Pump Drive Gear Assembly injection lines as an assembly whenever
(DO NOT remove or loosen the four bolts possible. Disassembling the
that fasten the injection pump drive gear to high-pressure fuel injection lines from
the injection pump drive gear hub!) the retainers or bending any of the fuel
11 – Fuel Injection Pump lines will make it difficult to reinstall the
12 – Lube Oil Line fuel lines.
13 – Mechanical Fuel Supply Pump (Optional on
0000047en
some models)
14 – Fuel Return Fitting Note: To prevent “rounding” the fuel line nuts
15 – Low Pressure Fuel Inlet Fitting always use a “line” or “flare nut” wrench.
16 – Fuel / Water Separator
17 – Electric Fuel Supply Pump 1. Close any fuel valves in the fuel supply line.
18 – Fuel Filter
2. Clean the area to keep contaminants from
19 – Fuel Filter Mount
entering the fuel system.
3. Place a drain pan under the fuel injection pump
to catch any spillage.
4. Loosen the fuel line nuts at the fuel injection
pump.
5. Next, loosen the fuel line nuts at the fuel
injectors. Use one wrench to hold the fuel return
line nut and fuel return line from rotating. Use a
second wrench to loosen the fuel line nut
(Figure 7-4). Repeat with the remaining fuel
injectors.
0002237
Figure 7-4

FUEL SYSTEM Fuel Injection Lines
6. Finish loosening all the fuel line nuts and

remove the high-pressure fuel lines as an
assembly being careful not to bend any of the
fuel lines. Be sure to protect the fuel system
from contamination by plugging or covering all
open connections.
7. Plug or cap all openings to minimize leakage
and prevent contamination. 0002237
Installation of High-Pressure Fuel

Figure 7-5
Injection Lines
Removal of Fuel Return Line
CAUTION 1. Clean the area to keep contaminants from
Remove or install the high-pressure fuel entering the fuel system.
injection lines as an assembly whenever 2. Remove the high-pressure fuel injection lines
possible. Disassembling the as an assembly. See Removal of High-Pressure
high-pressure fuel injection lines from Fuel Injection Lines on page 7-11.
the retainers or bending any of the fuel
lines will make it difficult to reinstall the
CAUTION
fuel lines.
0000047en
assembly. Use care not to bend or twist
Note: To prevent “rounding” the fuel line nuts the fuel return line.
always use a “line” or “flare nut” wrench. 0000171en
1. Start all the fuel line nuts by hand. Then use a

wrench to just “snug” all the fuel line nuts.
(1)
2. Tighten the fuel line nuts on the fuel injection
pump to the specified torque. See Special (2)
Torque Chart on page 7-7.
3. When tightening the fuel line nuts on the fuel
injectors, use one wrench to hold the fuel return (3)
line nut and fuel return line from rotating. Use a
second wrench to tighten the fuel line nuts
(Figure 7-5). See Special Torque Chart on (4)
page 7-7.
Figure 7-6
3. Remove all fuel return line nuts
(Figure 7-6, (2)) from the injectors
(Figure 7-6, (4)).

Fuel Injection Pump FUEL SYSTEM
4. Remove the fuel return hose from the fuel
return fitting on the fuel injection pump.
5. Carefully remove the fuel return line assembly
(Figure 7-6, (3)).
6. Remove and discard the copper gasket
(3) (2)
(Figure 7-6, (1)) from each fuel injector.
7. Plug or cap all openings to minimize leakage
and prevent contamination.
Installation of Fuel Return Line (1)

1. Install a new copper gasket on each fuel
injector.
CAUTION (4) 0000163A

assembly. Use care not to bend or twist Figure 7-7
the fuel return line.
3. Close any fuel valves in the fuel supply line.
0000171en
4. Place a drain pan under the fuel injection pump
2. Carefully reinstall the fuel return line assembly. to catch any spillage.
3. Reinstall and hand-tighten the fuel return line 5. Clean the area to keep contaminants from
nuts. entering the fuel system.
4. Tighten the fuel return line nuts to the specified 6. Remove the high-pressure fuel injection lines
torque. See Special Torque Chart on page 7-7. as an assembly. See Removal of High-Pressure
5. Reinstall the fuel return hose. Fuel Injection Lines on page 7-11.
6. Reinstall the high-pressure fuel injection line 7. Disconnect the fuel return lines from the fitting
assembly. See Installation of High-Pressure on the fuel injection pump (Figure 7-8, (1)).
Fuel Injection Lines on page 7-12. Plug the open ends of the lines to minimize
leakage and prevent contamination.
FUEL INJECTION PUMP

Removal of Fuel Injection Pump
1. Loosen the cooling fan V-belt.
2. Remove the engine cooling fan guard (if
equipped), engine cooling fan (Figure 7-7, (2)),
spacer (Figure 7-7, (3)) if equipped, V-pulley
(Figure 7-7, (4)) and cooling fan V-belt
(Figure 7-7, (1)).

FUEL SYSTEM Fuel Injection Pump
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
13. Remove the fuel injection pump drive gear

Figure 7-8
access cover (Figure 7-10, (1)) from the gear
8. Remove the fuel supply line (Figure 7-8, (2)) case cover (Figure 7-10, (2)).
from the fitting on the fuel injection pump. Note: The cover is secured with an adhesive
9. Plug or cap all openings to minimize leakage sealant. Use a gasket scraper to
and prevent contamination. separate the cover from the gear case
cover.
10. Remove the throttle cable from the fuel injection
pump.
11. Separate the stop solenoid wiring connector
(Figure 7-8, (3)). (2)
(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
(1) 16. Hold the gear train stationary using a large

socket wrench on the crankshaft pulley bolt.
Loosen the fuel injection pump drive gear
retaining nut (Figure 7-12, (1)) and turn it out to
the end of the fuel injection pump shaft.
0002096
17. Remove the injection pump drive gear and hub
Figure 7-11
from the injection pump drive shaft as an
assembly using an appropriate gear puller
CAUTION (Figure 7-13).
Do not loosen or remove the four bolts
gear to the fuel injection pump hub. Do
not disassemble the fuel injection pump
0000031en
15. Do not loosen or remove the four bolts

(Figure 7-12, (3)) holding the pump drive gear
to the hub. Only remove the single drive gear
nut (Figure 7-12, (1)) and washer
(Figure 7-12, (2)), leaving the hub attached to
the gear. 0002209
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
21. If the fuel injection pump requires servicing, it

must be sent to an authorized Yanmar FIE
repair facility for repair and calibration, or
replaced with a new fuel injection pump.
(1)
CAUTION
(2) the tamper-proof devices from 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
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)).

4. Align the key on the fuel injection pump shaft
with the keyway in the fuel injection pump drive
gear hub. Reinstall the fuel injection pump into
the fuel injection pump drive gear and gear
housing. Install the pump retaining nuts
finger-tight.
5. Reinstall the fuel injection pump drive gear lock
washer (Figure 7-18, (2)) and nut
(Figure 7-18, (1)). Do not lubricate threads of
(1)
the nut or shaft. Hold the crankshaft pulley bolt
with a socket wrench and tighten the drive gear
nut to the specified torque. See Special Torque
Chart on page 7-7.
0002096
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.

11. Reinstall the lube oil line (Figure 7-20, (1)).
(1)
(1)
0002416
Figure 7-19
7. Tighten the fuel injection pump retaining nuts to 0002239
specification. See Special Torque Chart on Figure 7-20

page 7-7.
8. Reconnect the fuel supply and return lines to 12. Apply ThreeBond Liquid Gasket No. 1212,
Yanmar Part No. 977770-01212, or equivalent
the fuel injection pump.
sealant to the sealing surface of the fuel
9. Reconnect the throttle linkage and stop injection pump drive gear access cover.
solenoid connector. Reinstall the cover on the front of the gear case
10. If installing a new or recalibrated fuel injection and tighten the bolts.
pump, check the fuel injection timing before 13. Reinstall the fuel injection high-pressure lines.
completing the installation of the fuel injection See Installation of High-Pressure Fuel Injection
pump. See Checking and Adjusting Fuel Lines on page 7-12.
Injection Timing on page 7-19.
Note: While it is not required to check the IMPORTANT
injection timing when reinstalling the When installing a new or repaired fuel
original fuel injection pump, it is injection pump, add 5 - 7 oz (150 - 200 cc)
recommended that it be done. of new, clean engine oil to the fuel injection
pump at the fill plug located in the upper
outside section of the governor housing.
14. Reinstall the coolant pump V-pulley
(Figure 7-21, (4)), spacer (Figure 7-21, (3)) (if
equipped) and engine cooling fan
(Figure 7-21, (2)).

Checking and Adjusting Fuel Injection Timing FUEL SYSTEM
2. Clean the area around the fuel injection pump.
Note: The stop solenoid must be removed to
allow fuel to flow through the fuel
(3)
injection pump.
(2)
3. Remove two screws (Figure 7-22, (1)).
Remove the stop solenoid (Figure 7-22, (2))
and O-ring (Figure 7-22, (3)).
(1)
(4) 0000163A (2)

Figure 7-21 (3)
(1)
15. Reinstall the cooling fan V-belt
(Figure 7-21, (1)). Adjust as described in
Check and Adjust Cooling Fan V-Belt on
page 5-27.
16. Reinstall the cooling fan guard (if equipped).
17. Prime the fuel system. See Priming the Fuel
18. Operate the engine and check for fuel and lube
oil leaks. 0002468
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.
Checking Fuel Injection Timing

Note: Some fuel may drain from the fuel
injection pump during this process. Make
provisions to contain and dispose of any
such spillage.
1. Ensure the fuel injection pump is primed with
fuel. See Priming the Fuel System on
page 4-12.

FUEL SYSTEM Checking and Adjusting Fuel Injection Timing
(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.

Checking and Adjusting Fuel Injection Timing FUEL SYSTEM
• EXAMPLE: If the distance between the two
“longer” marks is approximately 2.0 cm and the (2)
distance from the TDC mark is approximately (1)
4.0 cm, the answer is approximately 2. This
indicates there is 10° (2 x 5°) between the TDC
mark and the first “longer” mark on the timing
grid. That means the first “longer” mark on the
timing grid indicates 10° BTDC, the second
“longer” mark indicates 15° BTDC and the third
timing mark indicates 20°. If the answer is 3,
that indicates there is 15° (3 x 15°) between
0002142
the TDC mark and the first “longer” mark and Figure 7-26
that the first “longer” mark indicates 15° BTDC
with the second and third “longer” marks 10. Highlight the target timing mark
indicating 20° BTDC and 25° BTDC (Figure 7-26, (1)), (Figure 7-27, (1)) on the
respectively. flywheel timing grid as determined in the Fuel
9. Highlight the timing reference mark on the Injection Timing Chart below.
flywheel housing (Figure 7-25, (2)) or engine
back plate (Figure 7-26, (2)). Highlight the TDC
(Top Dead Center) mark (Figure 7-25, (1)),
(1)
(Figure 7-26, (1)) on the flywheel.
(2)
(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°
11. Remove all high-pressure fuel injection lines.

See Removal of High-Pressure Fuel Injection
Lines on page 7-11.
12. Turn on all fuel supply valves.

FUEL SYSTEM Checking and Adjusting Fuel Injection Timing
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.
Note: The following references to the direction

of rotation are made facing the cooling
fan end of the engine and are adjusted
by turning the crankshaft.
14. Slowly rotate the crankshaft clockwise using a
wrench on the crankshaft pulley bolt until fuel is
pumped from the nozzle of the “spill-timing” tool
or delivery valve.
15. Slowly rotate the crankshaft clockwise
approximately two more revolutions until the
timing grid on the flywheel (for the cylinder
being checked) is at approximately 30° BTDC.

Fuel Injectors FUEL SYSTEM
Adjusting Fuel Injection Timing 5. Adjust the position of the fuel injection pump
and tighten the fuel injection pump mounting
If the timing marks did not align when performing nuts.
the Checking Fuel Injection Timing on page 7-19,
the following steps must be performed to properly 6. Recheck the fuel injection timing. Repeat the
time the engine. fuel injection timing and adjustment procedures
until the timing is correct. See Checking Fuel
1. Leave the “spill-timing” tool installed in the fuel Injection Timing on page 7-19 and repeat steps
injection pump. 3 - 6.
2. Determine if the timing is “advanced” or 7. Remove the “spill-timing” tool.
“retarded” by comparing the position of the 8. Reinstall the shut-off solenoid.
target timing mark on the flywheel grid
(Figure 7-29, (1)) with the timing mark on the 9. Reinstall the high-pressure fuel injection lines.
flywheel housing or back plate See Installation of High-Pressure Fuel Injection
(Figure 7-29, (2)). Lines on page 7-12.
10. Replace the flywheel inspection port cover.
11. Prime the fuel system. Operate the engine and
check for leaks.
(2) (1)
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.

FUEL SYSTEM Fuel Injectors
(1) Testing of Fuel Injectors
(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
(6) 1. Thoroughly clean the fuel injector nozzle using

clean diesel fuel and a brass wire brush.
(5) 2. Visually inspect the fuel injectors and nozzle
protectors for deposits or damage. Clean, repair
or replace as necessary.
Note: Test the fuel injector using an injection
nozzle tester. Operate the tester
0002213
following the information provided by the
tester manufacturer. Use clean, filtered
Figure 7-30 fuel or FIE calibration fluid for the test.
6. Remove the injector nozzle gaskets 3. Using the correct adapter, connect a fuel
(Figure 7-30, (5)) and protector injector to a nozzle tester. Aim the fuel injector
(Figure 7-30, (6)) from the cylinder head. into a suitable container to catch the fuel spray
(Figure 7-31).
OFF
P-
OFF
E -
ON AG
-G
Figure 7-31

5. Pump the operating lever slowly to hold the
A WARNING pressure steady at a point just below the
opening pressure and hold that pressure for five
seconds. Observe the injector to see that it is
sealing properly and is not “dripping.” If fuel
leaks from the return line fitting, check that the
nozzle case nut is tight. Service or replace the
injector if fuel continues to leak from either the
• Avoid skin contact with the return line fitting or nozzle.
6. Pump the operating lever more rapidly to
by a fuel system leak such as a broken
repeatedly “pop” the injector and observe the
fuel injection line. High-pressure fuel
spray pattern. The pattern should be a very fine
can penetrate your skin and result in
uniform spray. If dripping or an uneven pattern
serious injury. If you are exposed to
is seen, service or replace the injector. See
high-pressure fuel spray, obtain
Fuel Injector Test Results on page 7-26.
or cardboard. Have your authorized
or serious injury.
0000008en
A WARNING
To prevent possible eye injury, always

wear SAFETY GLASSES while servicing
the engine.
0000013en
4. Pump the operating lever of the tester slowly,

observing the pressure reading at the point
where the fuel injector begins spraying fuel.
See Test and Adjustment Specifications on
page 7-7 for correct pressure readings.
Note: Opening pressure of a new fuel injector
will be approximately 72.5 psi (0.5 MPa;
5 kgf/cm2) higher than one that has been
operated for five hours or longer.

Fuel Injector Test Results

A B C D E
Injection Pattern
0001742
0001743 0001744
120 120 120 120 120
0 0 0 0 0
Pressure Gauge 0001748

0001747 0001749 0001750 0001751
Reading Gauge needle Gauge needle Gauge needle Although the Pressure does not
fluctuates around fluctuates around stays at a position gauge needle increase even
the valve opening the valve opening near the valve reaches the valve when the tester
pressure. pressure. opening pressure. opening pressure, lever is operated.
the pressure drop
is large.
Although atomized
Atomization is Bar shape with
Atomization 5°-10° cone and (burner like
excessively excessive after Drops.
Pattern roughly uniform. shape), the needle
one-sided. drops.
does not pulsate.
Sticking of needle.
Excessively
Normally caused
Caused by Damage to the damaged or worn
by carbon
excessive carbon seat. seat.
contamination of
contamination of Contamination of Contamination of
(Normal, injector is the nozzle tip.
Possible Cause the nozzle tip. seat by fine foreign seat by foreign
good) Sometimes caused
Sometimes caused particles. matter.
by flaws in or
by internal Excessively worn Damaged or
damage to the
contamination. seat. broken internal
needle tip.
parts or nozzle
case nut.
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.

Disassembly and Inspection of Fuel 3. Remove the nozzle case nut.
Injectors 4. Carefully remove the injector from the vise.
5. Turn the injector over and remove the nozzle
CAUTION body, nozzle valve, valve stop spacer, nozzle
Never use a steel wire brush to clean spring seat, nozzle spring, and shims.
fuel injectors. Damage to the nozzle and 6. Inspect the sealing surfaces (Figure 7-33, (2))
other components is likely to result. between the valve stop spacer and nozzle body
0000172en for nicks or scratches. Check the contact area
between the valve stop spacer and the nozzle
1. Clean carbon from used injectors using clean valve (Figure 7-33, (1)) for scoring or pitting.
diesel fuel. Hardened deposits or varnish can Use a magnifying glass to inspect.
be cleaned using a brass wire brush.
(1)
(1)
(2)
(2)
(3)
(4)
(5)
(6)
0001333A
(7)
Figure 7-33
(8)
(9)
(10)
0002214
1 – Return Fuel Fitting Nut

2 – Return Fuel Fitting
3 – Injector Body
4 – Pressure Adjusting Shims
5 – Spring
6 – Spring Seat
7 – Valve Stop Spacer
8 – Nozzle Valve
9 – Nozzle Body
10 – Nozzle Case Nut
Figure 7-32
2. Place the fuel injector in a soft-jawed vise with
the nozzle pointing up.

7. Perform a nozzle valve slide test:

(a) Wash nozzle body and valve in clean diesel (1)
fuel. (2)
(b) While holding the nozzle body vertical, pull
the nozzle valve about 2/3 of the way out
(3)
(Figure 7-34).
(c) Release the valve. It should fall smoothly to
its seat by its own weight. (4)
(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
Fuel Injector Shim Kit The injection pressure will change by

approximately 100 - 142 psi (0.69 - 0.98 MPa;
Yanmar Part No. 129901-53800
7 - 10 kgf/cm2) for every 0.004 in. (0.1 mm) shim
(Includes one each of the following shims)
thickness.
129901-53810 0.0039 in. (0.10 mm)
129901-53820 0.0079 in. (0.20 mm) See the parts catalog for available shims.
129901-53830 0.0118 in. (0.30 mm) 1. Disassemble the fuel injector assembly. See
129901-53840 0.0157 in. (0.40 mm) Disassembly and Inspection of Fuel Injectors
129901-53850 0.0197 in. (0.50 mm) on page 7-27.
129901-53860 0.0205 in. (0.52 mm) 2. Remove or add adjusting shims as needed.
129901-53870 0.0213 in. (0.54 mm) 3. Reassemble the fuel injector assembly. See
129901-53880 0.0220 in. (0.56 mm) Reassembly of Fuel Injectors on page 7-29.
129901-53890 0.0228 in. (0.58 mm)
129901-53900 0.0315 in. (0.80 mm)

4. Retest the fuel injector. See Testing of Fuel (1)
Injectors on page 7-24. If the injector cannot be
adjusted to the appropriate pressure, discard
(2)
the fuel injector.
Reassembly of Fuel Injectors (3)
1. Secure the injector in a soft-jawed vise with the (4)

nozzle end up.
2. Reinstall the shims, nozzle spring, nozzle (6)
spring seat, valve stop spacer, nozzle valve,
and nozzle body.
(5)
3. Reinstall the nozzle case nut. Tighten it to
specification.
Installation of the Fuel Injectors

1. Insert the nozzle gaskets (Figure 7-36, (5)) and 0002213
nozzle protector (Figure 7-36, (6)) in the

Figure 7-36
cylinder head.
2. Reinstall the fuel injector (Figure 7-36, (4)) in
the cylinder head and tighten to specification.
3. Reinstall new copper washers
(Figure 7-36, (3)), high-pressure and return
fuel lines (Figure 7-36, (2)). See Installation of
High-Pressure Fuel Injection Lines on
page 7-12 and Installation of Fuel Return Line
on page 7-13. Tighten fuel line nuts
(Figure 7-36, (1)) to specifications.
4. Prime the fuel system. See Priming the Fuel
5. Operate the engine and check for fuel leaks.


Section 8
COOLING SYSTEM
Page
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

COOLING SYSTEM

Before You Begin Servicing COOLING SYSTEM

SERVICING
A DANGER
service it.
SCALD HAZARD! • NEVER leave the key in the key switch

• NEVER remove the radiator cap if the Someone may accidentally start the
engine is hot. Steam and hot engine engine and not realize you are
coolant will spurt out and seriously servicing it. This could result in a
burn you. Allow the engine to cool serious injury.
the radiator cap. • If you must service the engine while it
• Tighten the radiator cap securely after back long hair, and keep your hands,
you check the radiator. Steam can other body parts and clothing away
spurt out during engine operation if from moving / rotating parts.
the cap is loose.
• ALWAYS check the level of the engine or serious injury.
coolant by observing the reserve tank. 0000010en

serious injury.
0000002en
A WARNING
A WARNING
FUME / BURN HAZARD!

BURN HAZARD! hazardous substances like parts
• Wait until the engine cools before you cleaners, primers, sealants and
drain the engine coolant. Hot engine sealant removers.
• Failure to comply could result in death or serious injury.
or serious injury. 0000014en
0000016en

COOLING SYSTEM Before You Begin Servicing
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
• 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.
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.
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
pump or replace individual components.

0000041en

Introduction COOLING SYSTEM
INTRODUCTION
This section of the Service Manual describes the procedures necessary to service the 2TNV70, 3TNV70
and 3TNV76 engine coolant pump.
COOLING SYSTEM DIAGRAM
(1)
(2)
(3)
(4)
(6)
(5)
0002046
Figure 8-1
1 – Cylinder Head 4 – Radiator

2 – Thermostat 5 – Coolant Recovery Tank
3 – Engine Coolant Pump 6 – Cylinder Block

COOLING SYSTEM Engine Coolant Pump Components
ENGINE COOLANT PUMP

COMPONENTS
1
7 2
3 4
9
11
6
5
8
10
0001959
Figure 8-2
1 – Thermostat Cover 7 – Engine Coolant Pump Gasket

2 – Thermostat 8 – V-Belt
3 – Special O-Ring 9 – Engine Coolant Pump V-Pulley
4 – Engine Coolant Pump 10 – Spacer
5 – Temperature Switch 11 – Engine Coolant Fan
6 – Gasket

Engine Coolant System Check COOLING SYSTEM
ENGINE COOLANT SYSTEM 2. Before removing the engine coolant pump or

thermostat, it will be necessary to drain the
CHECK engine coolant. Drain the coolant into a clean
Check the engine coolant system for leakage. container if the coolant is to be reused.
Otherwise, properly dispose of the coolant.
1. With the radiator properly filled, install a cooling
• Drain the coolant from the radiator. See steps
system tester (Figure 8-3, (1)).
1 - 4 in Drain, Flush and Refill Cooling System
with New Coolant on page 5-33.
3. Loosen the alternator mounting bolts. Loosen
and remove the V-belt and rotate the alternator
away from the engine and out of the way.
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
ENGINE COOLANT PUMP 0000014en
4. Remove the engine coolant fan guard (if

Disassembly of Engine Coolant equipped), engine coolant fan (Figure 8-4, (1)),
Pump spacer (Figure 8-4, (2)) and engine coolant
pump V-pulley (Figure 8-4, (3)).
Verify the condition of the engine coolant pump
before disassembling it from the engine. Check the (4)
engine coolant pump shaft bearing for abnormal
noise, sticking, excessive play and water leakage.
(3)
Replace the coolant pump if any of these conditions
are present. (2)
(1)
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
pump or replace individual components. Figure 8-4

0000041en
5. Disconnect the coolant hoses and the
1. Make sure the engine and engine coolant are temperature switch lead wire from the engine
not hot. coolant pump.

COOLING SYSTEM Engine Coolant Pump
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.
Cleaning and Inspection

Temperature Switch
0000577A
1. Check for proper operation of the temperature
switch. Connect a continuity light or ohmmeter Figure 8-7
to the temperature switch. Connect one lead to 2. Slowly increase temperature of the water using
the terminal of the switch (Figure 8-6, (1)) and an external heat source.
the other lead to the metal portion of the switch
(Figure 8-6, (2)). 3. The thermostat is normal if it starts to open at
the temperature value stamped on the flange of
(3) the thermostat, and fully opens as the
(1)
temperature of the water is increased.
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

Engine Coolant Pump COOLING SYSTEM
CAUTION
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.

COOLING SYSTEM Engine Coolant Pump
(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.
Carefully clean the radiator cap and
the surrounding area before you
remove the cap.
0000006en

Section 9
LUBRICATION
SYSTEM
Page
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

LUBRICATION SYSTEM

Before You Begin Servicing LUBRICATION SYSTEM

SERVICING
CAUTION
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
• Read and understand this Operation
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
and maintenance techniques.
• 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
surfaces are extremely hot while the
seriously burn you.
or serious injury.
0000015en

LUBRICATION SYSTEM Before You Begin Servicing
A WARNING CAUTION
coverage, cause internal engine
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
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

compressed air or high-pressure
air, pressurized water or steam may
injure your eyes.
or moderate injury.
0000003en

Introduction LUBRICATION SYSTEM
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 PUMP SERVICE INFORMATION

Engine Oil Pressure
Model at Rated Engine rpm at Low Idle Speed
2TNV70 - VM
42 - 64 psi (0.29 - 0.44 MPa 2.96 - 4.49
3TNV70 - VH
kgf/cm2)
3TNV76 - CH 8.8 psi (0.06 MPa; 0.6 kfg/cm2) or greater
3TNV70 - CL 35 - 51 psi (0.24 - 0.35 MPa 2.44 - 3.57
3TNV76 - CL kgf/cm2)
Outer Rotor Outside Clearance

Reference
Model Standard Limit
Page
Check Outer
2TNV70
0.0047 - 0.0083 in. 0.0118 in. Rotor Outside
3TNV70
(0.12 - 0.21 mm) (0.30 mm) Clearance on
3TNV76
page 9-10
Outer Rotor Side Clearance

Reference
Page
Check Outer
2TNV70
0.0008 - 0.0028 in. 0.0047 in. Rotor Side
3TNV70
(0.02 - 0.07 mm) (0.12 mm) Clearance on
3TNV76
page 9-10
Outer Rotor to Inner Rotor Tip

Clearance
Reference
Page
Outer Rotor to
2TNV70
0.0063 in. Inner Rotor Tip
3TNV70 -
(0.16 mm) Clearance on
3TNV76
page 9-10

LUBRICATION SYSTEM Oil Pump Service Information
Inner Rotor and Gear Boss Clearance

Standard
Standard Standard Reference
Item Parts Clearance
Dimension Clearance Page
Limit
2.0886 - 2.0925 in.
Gear Boss Diameter
Inside Clearance of (53.05 - 53.15 mm) 0.012 - 0.020 in. 0.024 in.
Inner Rotor 2.1043 - 2.1083 in. (0.3 - 0.5 mm) (0.6 mm) Check Inner
Rotor Diameter Rotor and
(53.45 - 53.55 mm)
Gear Boss
Width Across Flat of 1.9468 - 1.9587 in. Clearance on
Inner Rotor Width Gear Boss (49.45 - 49.75 mm)
Across Flat
0.008 - 0.024 in. 0.028 in. page 9-11
Width Across Flat of 1.9665 - 1.9705 in. (0.2 - 0.6 mm) (0.7 mm)
Clearance
Rotor (49.95 - 50.05 mm)

Lubrication System Diagram LUBRICATION SYSTEM
LUBRICATION SYSTEM DIAGRAM
Oil Filter
Bypass Valve
Fuel
Injection Pump
Oil Pressure
Switch
Cylinder Body - Main Gallery

Pressure
Regulator Valve
Idle Gear Camshaft Crank
Oil Pump Shaft Bearing Journal
Rocker Arm Crank Pin

Oil Suction Pipe Bearing
Strainer
Rocker Arm
Tappet
Cam Face
Oil Pan
0001624
Figure 9-1

LUBRICATION SYSTEM Checking Engine Oil Pressure
CHECKING ENGINE OIL TROCHOID OIL PUMP

PRESSURE Oil Pump Components
Perform an engine oil pressure check if there is any
indication of low oil pressure such as the oil
pressure indicator is on or the oil pressure gauge (1)
indicates low oil pressure. See Engine Oil Pressure (2)
on page 9-5 for the engine oil pressure (5)
specification. (6)
1. Disconnect the wire lead from the oil pressure

switch or sending unit (Figure 9-2, (1)).
(3)
(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.

Trochoid Oil Pump LUBRICATION SYSTEM
Disassembly of Oil Pump (2)
(1)
CAUTION (3)
If the oil pump must be replaced, replace (4)
it as an assembly only. Do not replace
individual components.
0000030en
1. Remove the engine cooling fan guard (if

equipped), engine cooling fan (Figure 9-4, (1)),
spacer (Figure 9-4, (2)), engine coolant pump
V-pulley (Figure 9-4, (3)) and V-belt.
(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.

LUBRICATION SYSTEM Trochoid Oil Pump
Cleaning and Inspection Outer Rotor to Inner Rotor Tip Clearance

Wash the oil pump cover, the oil pressure regulator Determine the outer rotor to inner rotor tip
valve, the oil pump cavity and the inner and outer clearance. Insert a feeler gauge between the top of
rotors. Inspect the parts for wear or damage. an inner rotor tooth (Figure 9-8, (1)) and the top of
Replace as necessary. an outer rotor tooth (Figure 9-8, (2)) and measure
the clearance.
Note: If the oil pump cavity is damaged, the
gear case cover must be replaced.
A CAUTION
If any oil pump component clearance
exceeds its limit, the oil pump must be
replaced as an assembly.
0000015en
Check Outer Rotor Outside Clearance

1. Reinstall the outer and inner rotors. The dots on
the rotor faces must face “up.” Make sure that
the pilot on the back of the inner rotor fits into
(1) (2)
the bore of the oil pump cavity and the top 0001150B
surface of the inner rotor is flush with the top
Figure 9-8
surface of the outer rotor.
2. Determine the outside clearance of the outer Record the measurement. See Outer Rotor to Inner
rotor. Insert a feeler gauge between the outer Rotor Tip Clearance on page 9-5 for the service
rotor (Figure 9-7, (1)) and the gear case oil limit.
pump cavity (Figure 9-7, (2)).
Check Outer Rotor Side Clearance
(1) Determine the side clearance of the outer rotor
across the pump cavity. While pressing down on
the outer rotor, measure the depression using a
depth micrometer (Figure 9-9).
(2)
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.

Trochoid Oil Pump LUBRICATION SYSTEM
Check Inner Rotor and Gear Boss 2. Reinstall the outer rotor in the gear case. The
Clearance dot mark on the face of the outer rotor must
face up toward the oil pump cover.
(5)
3. Reinstall the inner rotor into the gear case cover
with the dot mark also facing up. Make sure that
(3) the pilot on the back side of the inner rotor fits
into the bore in the gear case cover and the top
surface of the inner rotor is flush with the top
surface of the outer rotor.
4. Reinstall the oil pressure regulator valve
(1) (6)
(Figure 9-11, (4)) into the oil pump cover
(4) (Figure 9-11, (5)). Apply LOCTITE® 242 (red) to
(2) the valve plug, following the manufacturer’s
1 – Crank Gear instructions.
2 – Inner Rotor
5. Reinstall the oil pump cover (Figure 9-11, (5)).
3 – Inside Width Across Flats of Inner Rotor
4 – Overall Inside Diameter of Inner Rotor
Apply LOCTITE 290 (green) or LOCTITE 262
5 – Overall Inside Diameter of Gear Boss (red) to the oil pump cover screws. Tighten the
6 – Outside Width Across Flats of Gear Boss pump cover screws to 52 - 70 in·lb
(5.9 - 7.9 N·m, 0.6 - 7.9 kgf·m).
Figure 9-10
6. Reinstall the crankshaft pulley and gear case
Record the measurement. See Inner Rotor and cover. See Removal of Timing Gear Case
Gear Boss Clearance on page 9-6 for service Cover on page 6-38.
limits. 7. Reinstall the engine coolant pump V-pulley
(Figure 9-12, (3)), spacer (Figure 9-12, (2)),
Reassembly of Oil Pump engine cooling fan (Figure 9-12, (1)) and
engine cooling fan guard (if equipped).
(5)
(1) (4)
(2)
(3)
(2)
(1)
(4)
(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.

LUBRICATION SYSTEM Trochoid Oil Pump

Section 10
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

STARTER MOTOR

Before You Begin Servicing STARTER MOTOR

SERVICING
A WARNING
SHOCK HAZARD!
• Turn off the battery switch (if
ENTANGLEMENT HAZARD! equipped) or disconnect the negative
electrical system.
service it.
• NEVER leave the key in the key switch
servicing it. This could result in a • Failure to comply could result in death
serious injury. or serious injury.
0000009en
back long hair, and keep your hands, A WARNING
or serious injury.
0000010en
FUME / BURN HAZARD!
cleaners, primers, sealants and
sealant removers.
or serious injury.
0000014en

STARTER MOTOR Before You Begin Servicing
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

servicing the engine and when using CAUTION
compressed air or high-pressure Use a specialized battery charger to
water. Dust, flying debris, compressed recharge a battery with a voltage of
air, pressurized water or steam may 8 volts or less. Booster starting a battery
injure your eyes. with a voltage of 8 volts or less will
• Failure to comply may result in minor generate an abnormally high voltage
or moderate injury. and destroy electrical equipment.
0000056en
0000003en
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 STARTER MOTOR
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.
STARTER MOTOR INFORMATION

YANMAR Mfg. No Load Loaded
Part Mfg. Model Specification Terminal Amperage Terminal Amperage
Number Number RPM Torque RPM
Voltage Draw Voltage Draw
42 in.-lb
119515- 428000- DC12V -1.3 hp 3000 1240
Denso 11.5 90A (Max) 8.0 200 (Max) (4.7 N·m;
77010 2190 (1.0 kW) (Min) 0.48 kgf·m) (Min)
119717- 428000- DC12V -1.5 hp 3000 61 in.-lb 1130

77010 Denso 1590 (1.1 kW) 11.5 90A (Max) (Min) 8.7 230 (Max) (6.9 N·m; (Min)
0.70 kgf·m)
119740- 428000- DC12V -1.9 hp 3000 119 in.-lb 1000

Denso 11.5 90A (Max) 8.5 350 (Max) (13.5 N·m;
77010 3310 (1.4 kW) (Min) (Min)
1.38 kgf·m)

STARTER MOTOR Starter Motor Specifications
STARTER MOTOR SPECIFICATIONS

Yanmar Part Number 119717-77010 119515-77010
Nominal Output 1.5 hp (1.1 kW) 1.34 hp (1.0 kW)
6.6 lb 6.3 lb
Weight
(3.0 kg) (2.85 kg)
Revolution Direction (As Viewed From Pinion) Clockwise Clockwise
Engagement System Magnetic Shift Magnetic Shift
Terminal Voltage/Current 11.5 V / 90 A max 11.5 V / 90 A max
No-load
Revolution 3000 rpm (min-1) 3000 rpm (min-1)
Terminal Voltage/Current 8.7 V / 230 A 8.0 V / 230 A
Loaded Torque 61 in·lb (6.9 N·m; 0.70 kgf·m) 41.7 in·lb (4.7 N·m; 0.48 kgf·m)
Revolution 1130 rpm (min) 1240 rpm (min)
Terminal Voltage/Current 2.5 V / 325 A max 2.5 V / 260 A max
Stalled 73 in.-lb 43.5 in.-lb
Torque
(8.24 N·m; 0.84 kgf·m) minimum (4.9 N·m; 0.5 kgf·m) minimum
Clutch System Overrunning Overrunning
Pinion Projection Voltage at 212°F (100 °C) 8.0 V max 8.0 V max
Pinion DP or Module/Number of Teeth M2.54/9 M2.54/9
Application Standard Standard
3.1 - 4.0 lbf 3.1 - 4.0 lbf
Spring Force
(13.7 - 17.6 N; 1.4 - 1.8 kgf) (13.7 - 17.6 N; 1.4 - 1.8 kgf)
Brush
Standard 0.55 in. (14 mm) 0.55 in. (14 mm)
Length
Service Limit 0.44 in. (11.1 mm) 0.44 in. (11.1 mm)
Solenoid Pull-In Coil Resistance 0.484 W at 68°F (20°C) 0.484 W at 68°F (20°C)
Switch Hold-In Coil Resistance 1.055 W at 68°F (20°C) 1.055 W at 68°F (20°C)
Outside Standard 1.102 in. (28.0 mm) 1.102 in. (28.0 mm)
Diameter Service Limit 1.063 in. (27.0 mm) 1.063 in. (27.0 mm)
Standard 0.001 in. (0.02 mm) 0.001 in. (0.02 mm)
Commutator Run-Out
Service Limit 0.002 in. (0.05 mm) 0.002 in. (0.05 mm)
Insulation Standard 0.024 in. (0.6 mm) 0.024 in. (0.6 mm)
Depth Service Limit 0.008 in. (0.2 mm) 0.008 in. (0.2 mm)

Is the shift lever at NO Move shift lever to Is battery fully charged NO • Charge or replace battery.
NEUTRAL position? NEUTRAL position. and terminals clean? • Clean terminals.
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
• Inspect shift lever for deformation,

Pinion and ring gear NO return spring for fatigue and pinion

meshing normal? for sliding.
YES • Repair meshing between pinion and
ring gear or replace as needed.
YES
Connect M terminal of starter NO • Inspect brush and replace if worn.
Pinion roller clutch or motor directly to battery. • If brushes are not worn, replace armature
reduction gear damaged. Does starter motor operate? assembly.
Inspect and replace.
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
Inspect condition of engine.
0000102
STARTER MOTOR
10-7
STARTER MOTOR Starter Motor Components
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

Starter Motor STARTER MOTOR
1 – Nut STARTER MOTOR
2 – Needle Bearing
3 – Pinion Housing
4 – Pinion Retaining Ring A WARNING
5 – Pinion Stop
6 – Pinion
7 – Shift Lever
8 – Solenoid Switch Assembly
9 – Snap Ring
10 – Washer
11 – Bushing SHOCK HAZARD!
12 – Intermediate Housing
13 – Reduction Gear
14 – Washer equipped) or disconnect the negative
15 – Through Bolt battery cable before servicing the
16 – End Housing electrical system.
17 – Brush Plate and Holder • Check the electrical harnesses for
18 – Field Assembly cracks, abrasions, and damaged or
19 – Armature
20 – Bushing
21 – Plate
22 – Planetary Gear (3 used) • Failure to comply could result in death
23 – Washer (3 used) or serious injury.
24 – Pinion Shaft 0000009en
Note: While starter motor design varies

between models, the basic repair
procedures are the same. The following
procedures are typical and may differ
from the starter being serviced.

STARTER MOTOR Starter Motor
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

6. Pull the brush springs up using a brush spring 11. Remove the shift lever (Figure 10-8, (2)), pin,
puller. On the negative (-) side, bring the brush and spacer (Figure 10-8, (1)).
spring into contact with the side of the brushes
to hold the brushes clear of the commutator (1)
(2)
surface. On the positive (+) side, remove the (3)
brushes from the brush holder assembly
(Figure 10-6).
(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)
(4) (3) 0000152B
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
(3) Measure Commutator Outside Diameter

Measure the commutator outside diameter.
Replace the armature if the measurement is less
than the limit. See Starter Motor Specifications on
(2) page 10-6.
(1)
(7)
(6)
0000113
(5) 0002487 Figure 10-13

Figure 10-11

Measure Commutator Insulation Depth
Measure the depth of the insulating material
(Figure 10-14, (1)) between commutator segments
(Figure 10-14, (2)). If the depth measures less
than the limit, use a hacksaw blade
(Figure 10-14, (3)) to remove the insulating
material until the depth is within the limit. See
Starter Motor Specifications on page 10-6 for
service limit.
0000114
A normal commutator condition is indicated in
(Figure 10-14, (4)). An abnormal commutator Figure 10-15
condition is indicated in (Figure 10-14, (5)). Armature Coil Insulation Test
Check for continuity between a commutator
(3) segment and the shaft or armature using a
multimeter (Figure 10-16). The multimeter should
not indicate continuity.
If the multimeter indicates continuity, replace the
armature.
(2)
(1)
(5) (4)
0000118
Figure 10-14
Armature Coil Continuity Test 0000115
Check for continuity between the commutator Figure 10-16

segments using a multimeter (Figure 10-15). The
multimeter should indicate continuity.
If the multimeter does not indicate continuity,
replace the armature.

Measure Armature and Commutator Run-Out Field Coil Insulation Test

Measure the armature core run-out and the Check for continuity between either field coil
commutator run-out using a dial indicator terminal and the yoke using a multimeter
(Figure 10-17). Replace the armature if either of (Figure 10-19). The multimeter should not indicate
the measurements is not within specifications. See continuity.
Starter Motor Specifications on page 10-6 for
service limit. If the multimeter indicates continuity, replace the
field coil assembly.
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

Brush Holder Solenoid Switch
Brush Holder Insulation Test If the starter motor becomes wet, replace the
solenoid switch even if the solenoid switch
Check for continuity between each brush holder assembly function is normal.
and the base using a multimeter (Figure 10-21).
The multimeter should not indicate continuity. Shunt Coil Continuity Test
If the multimeter indicates continuity, replace the Check for continuity between the “S” terminal and
brush holder. the switch body using a multimeter (Figure 10-23).
The multimeter should indicate continuity.
replace the solenoid switch.
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.
replace the solenoid switch.
0000123
Figure 10-22
0000125
Figure 10-24

Coil Resistance Test

service limit.
Contact Continuity Test

Depress the plunger at the bottom of the solenoid
switch. Check for continuity between the “B” and
“M” terminals using a multimeter (Figure 10-25).
The multimeter should indicate continuity.
replace the solenoid switch. 0000127
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
Pinion Clutch Assembly

Pinion Clutch Assembly Inspection
Manually rotate the pinion clutch assembly in the
0000128
drive direction. It should rotate freely in the drive
direction and is locked by turning it in the opposite Figure 10-27
direction (Figure 10-26). Replace the pinion clutch
assembly if the results are different.

Reassembly of Starter Motor (2)
1. Apply a appropriate starter bendix grease
(obtain locally) to the pinion shaft.
2. Reassemble the reduction gear
(Figure 10-28, (4)), pinion shaft
(Figure 10-28, (5)), planetary gears
(Figure 10-28, (6)), and washers into the
intermediate housing (Figure 10-28, (3)).
Reinstall snap ring (Figure 10-28, (1)).
(1)
(4)
(4) (3) 0000152B
(3) Figure 10-29

4. Apply a small amount of high temperature
lithium grease (obtain locally) to the contact
(2)
surfaces of the shift lever. Reassemble the shift
lever (Figure 10-30, (2)), spacer (if equipped)
(1) (Figure 10-30, (1)), and pin.
5. Reinstall the pinion shaft assembly
(Figure 10-30, (4)) in the pinion housing
(Figure 10-30, (3)). Be sure the shift lever
properly engages the pinion.
(7)
(1)
(2)
(6) (3)
(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
retaining ring (Figure 10-29, (4)) in the groove

Figure 10-30
in the pinion shaft. Slide the pinion stop over the
retaining ring. 6. Apply a small amount of high temperature
lithium grease (obtain locally) to the surface of
the plunger and the hole that engages the shift
lever.
7. Attach the plunger to the shift lever.

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

Check Pinion Projection Length No-Load Test
1. Connect the positive (+) lead from a battery to Test the characteristics of the starter motor by
the “S” terminal. performing a no load test.
2. Connect the negative (-) lead to the “M”
terminal. CAUTION
3. Lightly pull the pinion away from the gear The starter motor can be damaged if
housing. operated continuously longer than
4. Turn the switch ON and measure the pinion 10 seconds while performing the
moving distance L in the thrust direction no-load test.
(Figure 10-35). Perform this test within 10 0000034en
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.
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.

5. Install a switch (Figure 10-37, (6)) in a circuit Installation of Starter Motor

between the battery positive (+) terminal
(Figure 10-37, (2)) and the starter solenoid 1. Reinstall the starter motor to the flywheel
switch terminal (Figure 10-37, (8)) on the housing.
starter motor. 2. Reinstall the starter mounting bolts
6. Use a suitable tachometer to monitor the rpm of (Figure 10-38, (1)). Tighten the bolts to
the starter. specification. See Tightening Torques for
Standard Bolts and Nuts on page 4-25.
7. Turn the switch to the ON position to energize
the solenoid and operate the starter. Monitor (1)
the rpm, amperage draw and voltage. For test
specifications, see Starter Motor Information on
page 10-5 for the appropriate 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.

Section 11
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

ALTERNATOR
Dynamo ........................................................................................ 11-20
Removal of Dynamo............................................................... 11-20
Disassembly of Dynamo......................................................... 11-21
Reassembly of Dynamo ......................................................... 11-21
Installation of Dynamo............................................................ 11-22

Before You Begin Servicing ALTERNATOR

SERVICING
A WARNING
SHOCK HAZARD!
ENTANGLEMENT HAZARD! equipped) or disconnect the negative
electrical system.
service it.
• NEVER leave the key in the key switch
servicing it. This could result in a • Failure to comply could result in death
serious injury. or serious injury.
0000009en
back long hair, and keep your hands, A WARNING
or serious injury.
0000010en
BURN HAZARD!
• Keep your hands and other body parts
surfaces are extremely hot while the
seriously burn you.
or serious injury.
0000015en

ALTERNATOR Before You Begin Servicing
A WARNING A CAUTION
FUME / BURN HAZARD!

PINCH HAZARD!
precautions found on containers of Carefully rotate the alternator toward the
hazardous substances like parts cylinder block while loosening the
cleaners, primers, sealants and V-belt. Failure to comply may result in
sealant removers. minor or moderate injury.
0000014en
or serious injury.
0000014en
CAUTION
A CAUTION
NEVER permit anyone to operate the

engine or driven machine without proper
training.
FLYING OBJECT HAZARD! • Read and understand this Operation

Manual before you operate or service
• ALWAYS wear eye protection when the machine to ensure that you follow
servicing the engine and when using safe operating practices and
compressed air or high-pressure maintenance procedures.
air, pressurized water or steam may • Machine safety signs and labels are
injure your eyes. additional reminders for safe operating
and maintenance techniques.
or moderate injury. • See your authorized Yanmar industrial
engine dealer or distributor for
0000003en
additional training.
0000002en
CAUTION
Do not short-circuit the charging system
between alternator terminals IG and L.
0000035en

Before You Begin Servicing ALTERNATOR
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

ALTERNATOR Introduction
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.
STANDARD AND OPTIONAL DYNAMO INFORMATION

YANMAR Part Number Mfg. Mfg. Part Number Specification
171301-77201 Kokusan GP8138 DC12V-15A
119910-77200 Kokusan GP9191 DC12V-20A
STANDARD AND OPTIONAL ALTERNATOR INFORMATION

YANMAR Part Number Mfg. Mfg. Part Number Specification
119620-77201 Denso 100211-4531 DC12V-40A
129423-77200 Denso 101211-1170 DC12V-40A with Pulse
129961-77200 Denso 101211-2591 DC12V-55A
119626-77210 Denso 101211-2951 DC12V-55A with Pulse
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 ALTERNATOR
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

11-8
Turn key switch ON. OFF Disconnect harness L terminal Ground drive machine side OFF Replace the battery indicator.
Does battery indicator and IG terminal at alternator L terminal. Does battery Battery indicator is available from
turn ON? indicator turn on? driven machine manufacturer.
ALTERNATOR
ON ON Inspect rotor assembly and

brushes.
Start Engine.
Inspect or replace V-belt.

Battery indicator ON. Inspect alternator.
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 minus

L terminal voltage is Excessive voltage drop between
BAT and batt ( + side) terminal.
ALTERNATOR TROUBLESHOOTING
greater than 0.5 volt.

Does battery indicator Battery indicator With engine idling,
come ON? is dim. measure voltage at L
terminal and at battery.
Battery voltage minus Check condition of L terminal.
L terminal voltage is Inspect diode negative (-) side.
OFF less than 0.5 volt.
With engine running at 1500
rpm, measure voltage at Battery voltage greater
than 15.5 volts. Replace regulator.
battery.
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

2) DC voltmeter: 0 to 30 V, 0.5 class
3) The check method is also applicable to the bench test
Alternator Troubleshooting
Alternator Components ALTERNATOR
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
1 – Nut 20 – Rear Frame Housing

2 – Pulley 21 – Bolt (2 used)
3 – Collar 22 – Holder
4 – Front Frame Housing 23 – IC Regulator Assembly
5 – Stator Assembly 24 – Bolt (2 used)
6 – Stud (2 used) 25 – Bolt
7 – Front Frame Housing Bearing 26 – Brush (2 used)
8 – Bearing Cover 27 – Bolt
9 – Bearing Cover Bolt (4 used) 28 – Rear Cover
10 – Rotor Assembly 29 – Bolt (3 used)
11 – Rear Frame Housing Bearing
12 – Bearing Cover
13 – Thrust Washer
14 – Thrust Washer
15 – Nut (2 used)
16 – Nut
17 – Insulation Bushing
18 – Spring (2 used)
19 – Brush Holder

ALTERNATOR Alternator Wiring Diagram
ALTERNATOR WIRING DIAGRAM
IG 1
IG P
B
PI P L
2
F
IC
L
3 3
0.5μF
B
4A
E T
5 6
1 – Key Switch 4 – Battery

2 – Charge Lamp (3.4 Watts Max.) 5 – Alternator Assembly
3 – Load 6 – IC Regulator Assembly
Figure 11-2
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

Alternator Standard Output ALTERNATOR
ALTERNATOR STANDARD OUTPUT
Output Current
60
Cold
50
13.5 Volts, Constant Ambient

Temperature at 77˚F (25˚C)
Hot
40
30
20
10
0 1 2 3 4 5 6 7 8
Alternator RPM (x10³ min¯¹)
Figure 11-3

ALTERNATOR Alternator
ALTERNATOR
A WARNING
SHOCK HAZARD! 2 1
• Turn off the battery switch (if 0000264
equipped) or disconnect the negative Figure 11-4

electrical system. Disassembly of Alternator
• Check the electrical harnesses for 1. Remove the nut (Figure 11-5, (1)) from the
cracks, abrasions, and damaged or shaft of the rotor assembly. Remove the pulley
corroded connectors. ALWAYS keep (Figure 11-5, (2)).
or serious injury.
0000009en
Removal of Alternator
1. Disconnect the electrical wires from the
alternator.
2. Loosen the V-belt.
A CAUTION
2
1 0000256
PINCH HAZARD! Figure 11-5

Carefully rotate the alternator toward the
0000014en
3. Remove the V-belt adjuster from the alternator

bolt (Figure 11-4, (1)).
4. Remove the nut (Figure 11-4, (2)) from the
gear case stud. Remove the alternator.

Alternator ALTERNATOR
2. Remove the three bolts (Figure 11-6, (1)) 5. Remove the bolts retaining the holder
retaining the rear cover (Figure 11-6, (2)) to the (Figure 11-7, (2)) to the rear frame housing.
rear frame assembly. Remove the holder.
6. Remove the nut (Figure 11-7, (3)) retaining the
insulation bushing (Figure 11-7, (4)). Remove
the insulation bushing.
7. Remove the two bolts (Figure 11-8, (1)) and
3 1 two nuts (Figure 11-8, (2)) securing the rear
frame housing to the front frame housing.
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

9. Remove the stator assembly Reassembly of Alternator

(Figure 11-10, (1)) from the front frame
housing. 1. If removed, reinstall the two thrust washers
(Figure 11-12, (3)) and bearing cover
4 (Figure 11-12, (2)) in the rear frame housing.
Lubricate the outside diameter of a new bearing
(Figure 11-12, (1)). Press the bearing into the
3 rear frame housing.
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

Alternator ALTERNATOR
3. Position the stator assembly (Figure 11-13, (1))
on the front frame housing studs.
4. Lubricate the shaft of the rotor assembly
(Figure 11-14, (1)). Press the rotor assembly 3
into the front frame housing (Figure 11-14, (2)) 1
4
and rear frame housing (Figure 11-14, (3)).
0000258A
100266A Figure 11-16
Figure 11-14 7. Reassemble the regulator assembly

(Figure 11-16, (1)) to the holder
5. Align the front frame housing with the rear (Figure 11-16, (2)).
frame housing. Reinstall the two bolts 8. Reinstall the brush holder (Figure 11-17, (3)),
(Figure 11-15, (1)) and two nuts springs (Figure 11-17, (4)) and brushes
(Figure 11-15, (2)). (Figure 11-17, (5)).
2 9. Reattach the regulator assembly and holder to
the rear frame housing.
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)).

4. Start the engine. Listen for any unusual sounds

from the alternator.
CAUTION
alternator is producing unusual sounds.
0000039en
5. Verify that the charge indicator is ON while the

engine is operating. If the charge indicator is
not ON, repair the problem before operating the
engine.
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

Dynamo Component Location ALTERNATOR
DYNAMO COMPONENT LOCATION

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.
(1)
(2)
(3)
(4)
(7)
(5)
(8) (9)
0002140
(6) (10)
(11) (12)
(13)
(14)
0002140
Figure 11-20
1 – Rear Cover 8 – Spacer

2 – Nut 9 – Stator Assembly
3 – Lock Washer 10 – Front Bearing (2 used)
4 – Flat Washer 11 – Flat Washer
5 – Rear Bearing 12 – Flywheel Assembly
6 – Output Wire and Connector 13 – Pulley Half
7 – Plate 14 – Through Bolt

ALTERNATOR Dynamo Wiring Diagram
DYNAMO WIRING DIAGRAM
(3)
(5) (6)
(2) (4)
(1)
0002137
Figure 11-21
1 – Dynamo 4 – Charge Lamp (3.4 Watts Max.)

2 – Current Limiter Assembly 5 – Battery
3 – Key Switch 6 – Load
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.

Dynamo Standard Output ALTERNATOR
DYNAMO STANDARD OUTPUT
0002138
Figure 11-22

ALTERNATOR Testing of Dynamo
TESTING OF DYNAMO DYNAMO

Use a circuit tester or multimeter to perform the
following tests.
Removal of Dynamo
1. Disconnect the output wire connector from the
Testing Stator Coil Continuity dynamo.
1. Disconnect the dynamo output wire connector. 2. Loosen the V-belt.
2. Connect one meter lead to each of the stator
wire terminals and read the meter. A CAUTION
Results: The meter reading should indicate
continuity. If continuity is not indicated, the windings
are open and the stator must be replaced.
Testing Stator Coil Short-to-Ground

1. Disconnect the dynamo output wire connector. PINCH HAZARD!
2. Test continuity between each stator wire Carefully rotate the alternator toward the
terminal and engine ground. cylinder block while loosening the
Results: The meter reading should indicate infinity. V-belt. Failure to comply may result in
If the meter reading indicates continuity, the minor or moderate injury.
windings are shorted to ground and the stator must 0000014en
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.
2. Start the engine and operate it at normal

operating rpm.
3. Check the battery voltage with the engine
running.
Results: The meter reading with the engine
running must be higher than with the engine not
running.
(1) 0002141
• If results are not correct, test the stator for (2)
continuity and shorts to the ground.
Figure 11-23
• Check the charging system wiring.
• If no problems are found in previous checks,
replace the IC regulator.

Dynamo ALTERNATOR
Disassembly of Dynamo
(3)
1. Remove the rear cover (Figure 11-24, (1)).
2. Remove the nut (Figure 11-23, (2)), lock
washer (Figure 11-24, (3)), and flat washer
(Figure 11-24, (4)).
(2)
(1)
(2) (1)
(3)
(4)
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

4. Remove the screws (Figure 11-26, (1)) and the
stator assembly (Figure 11-26, (2)).
5. Remove the rear bearing (Figure 11-26, (3)).

ALTERNATOR Dynamo
6. Reinstall the flat washer (Figure 11-28, (4)), Installation of Dynamo

lock washer (Figure 11-28, (3)), and nut
(Figure 11-28, (2)). Tighten the nut to the 1. Position the dynamo on the gear case. Loosely
specified torque. reinstall the nut (Figure 11-29, (2)) on the gear
case stud and the V-belt adjuster bolt
7. Reinstall the rear cap (Figure 11-28, (1)). (Figure 11-29, (1)).
(1)
(2)
(3)
(4)
(1) 0002141
(2)
Figure 11-29
0002143 2. Reconnect the dynamo output wire connector.

Figure 11-28 3. Reinstall the V-belt. Tighten the V-belt to the
4. Start the engine. Listen for any unusual sounds
from the alternator.
CAUTION
alternator is producing unusual sounds.
0000039en
5. Verify that the charge indicator is ON while the

engine is operating. If the charge indicator is
not ON, repair the problem before operating the
engine.

Section 12
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

ELECTRIC WIRING

Electric Wiring Precautions ELECTRIC WIRING
ELECTRIC WIRING CAUTION

PRECAUTIONS Removing the battery cables or the
Failure to follow these precautions may result in the battery while the engine is operating
failure of an electrical component and the loss of may cause damage to the current limiter
warranty coverage on that item as well as related depending on the electrical equipment
items. Make sure that all users read and being used. This situation could cause
understand these precautions. loss of control of output voltage. The
continuous high voltage of 23-24 volts
(for 5000 rpm dynamo) will damage the
CAUTION current limiter and other electrical
Do not reverse the positive (+) and equipment.
negative (-) ends of the battery cable. 0000058en
The alternator diode and stator coil will
be damaged.
0000050en
CAUTION
Reversing the battery cable connections
at the battery or on the engine will
CAUTION destroy the SCR diode in the current
When the battery indicator goes out, it limiter. This will cause the charging
should not come on again. The battery system to malfunction and may cause
indicator only comes on during damage to the electrical harnesses.
operation if the alternator fails. However, 0000059en
if an LED is used in the battery indicator,
the LED will shine faintly during normal
operation.
0000051en
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

ELECTRIC WIRING Electric Wire Resistance
ELECTRIC WIRE RESISTANCE

Metric
AWG Ohms / Foot
Nominal mm²
20 0.5 0.009967
18 0.8 0.006340
16 1.25 0.004359
14 2 0.002685
12 3 0.001704
10 5 0.001073
8 8 0.000707
6 15 0.000421
4 20 0.000270
2 30 0.000158
1 40 0.000130
0 (1/0) 50 0.000103
00 (2/0) 60 0.000087
000 (3/0) 85 0.000066
0000 (4/0) 100 0.000051
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]

Battery Cable Resistance ELECTRIC WIRING
BATTERY CABLE RESISTANCE

Maximum Total Battery Cable Length
(Positive Cable + Negative Cable + a*)
AWG mm² 12V Starter Motor Output
Less Than 2.68 hp (2 kW) Greater Than 2.68 hp (2 kW)
m ft m ft
6 15 1.5 4.75 N/A N/A
4 20 2.3 7.4 N/A N/A
2 30 3.8 12.6 2.3 7.5
1 40 4.6 15.3 2.8 9.2
0 (1/0) 50 5.9 19.5 3.5 11.6
00 (2/0) 60 7.0 22.8 4.2 13.7
000(3/0) 85 9.3 30.5 5.6 18.3
0000 (4/0) 100 11.9 39.0 7.1 23.4
00000 (5/0) 125 N/A N/A 8.3 27.3
000000 (6/0) 150 N/A N/A 10.1 33.3
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.

ELECTRIC WIRING Electrical Wire Sizes - Voltage Drop
ELECTRICAL WIRE SIZES - VOLTAGE DROP

Total Length of conductor from source of current to device and back to source (in feet)
current on
circuit in 10 15 20 25 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170
amps.
12 Volts Wire Size (AWG)
5 18 16 14 12 12 10 10 10 8 8 8 6 6 6 6 6 6 6 6
10 14 12 10 10 10 8 6 6 6 6 4 4 4 4 2 2 2 2 2
15 12 10 10 8 8 6 6 6 4 4 2 2 2 2 2 1 1 1 1
20 10 10 8 6 6 6 4 4 2 2 2 2 1 1 1 0 0 0 2/0
25 10 8 6 6 6 4 4 2 2 2 1 1 0 0 0 2/0 2/0 2/0 3/0
30 10 8 6 6 4 4 2 2 1 1 0 0 0 2/0 2/0 3/0 3/0 3/0 3/0
40 8 6 6 4 4 2 2 1 0 0 2/0 2/0 3/0 3/0 3/0 4/0 4/0 4/0 4/0
50 6 6 4 4 2 2 1 0 2/0 2/0 3/0 3/0 4/0 4/0 4/0
60 6 4 4 2 2 1 0 2/0 3/0 3/0 4/0 4/0 4/0
70 6 4 2 2 1 0 2/0 3/0 3/0 4/0 4/0
80 6 4 2 2 1 0 3/0 3/0 4/0 4/0
90 4 2 2 1 0 2/0 3/0 4/0 4/0
100 4 2 2 1 0 2/0 3/0 4/0
24 Volts
5 18 18 18 16 16 14 12 12 12 10 10 10 10 10 8 8 8 8 8
10 18 16 14 12 12 10 10 10 8 8 8 6 6 6 6 6 6 6 6
15 16 14 12 12 10 10 8 8 6 6 6 6 6 4 4 4 4 4 2
20 14 12 10 10 10 8 6 6 6 6 4 4 4 4 2 2 2 2 2
25 12 12 10 10 8 6 6 6 4 4 4 4 2 2 2 2 2 2 1
30 12 10 10 8 8 6 6 4 4 4 2 2 2 2 2 1 1 1 1
40 10 10 8 6 6 6 4 4 2 2 2 2 1 1 1 0 0 0 2/0
50 10 8 6 6 6 4 4 2 2 2 1 1 0 0 0 2/0 2/0 2/0 3/0
60 10 8 6 6 4 4 2 2 1 1 0 0 0 2/0 2/0 3/0 3/0 3/0 3/0
70 8 6 6 4 4 2 2 1 1 0 0 2/0 2/0 3/0 3/0 3/0 3/0 4/0 4/0
80 8 6 6 4 4 2 2 1 0 0 2/0 2/0 3/0 3/0 3/0 4/0 4/0 4/0 4/0
90 8 6 4 4 2 2 1 0 0 2/0 2/0 3/0 3/0 4/0 4/0 4/0 4/0 4/0
100 6 6 4 4 2 2 1 0 2/0 2/0 3/0 3/0 4/0 4/0 4/0

Conversion of AWG to European Standards ELECTRIC WIRING
CONVERSION OF AWG TO EUROPEAN STANDARDS

Conductor Size Conductor Diameter Conductor Cross-sectional Area
(AWG) (mm) (mm2)
25 0.455 0.163
24 0.511 0.205
23 0.573 0.259
22 0.644 0.325
21 0.723 0.412
20 0.812 0.519
19 0.992 0.653
18 1.024 0.823
17 1.15 1.04
16 1.29 1.31
15 1.45 1.65
14 1.63 2.08
13 1.83 2.63
12 2.05 3.31
11 2.30 4.15
10 2.59 5.27
9 2.91 6.62
8 3.26 8.35
7 3.67 10.6
6 4.11 13.3
5 4.62 16.8
4 5.19 21.2
3 5.83 26.7
2 6.54 33.6
1 7.35 42.4
0 (1/0) 8.25 53.4
00 (2/0) 9.27 67.5
000(3/0) 10.40 85.0
0000 (4/0) 11.68 107.2
00000 (5/0) 13.12 135.1
000000 (6/0) 14.73 170.3
1.1 circular mil (CM) ≅ 0.0005067 mm
2

ELECTRIC WIRING Conversion of AWG to European Standards

Section 13
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

TROUBLESHOOTING

Special Service Tools TROUBLESHOOTING
For measuring compression pressure

Compression Gauge Kit
Yanmar Part No. TOL-97190080
0000849

TROUBLESHOOTING Troubleshooting By Measuring Compression Pressure
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.
Compression Pressure Measurement

Method
Figure 13-1
1. Warm up the engine.
6. After performing the compression check,
2. Stop the engine. Remove the high-pressure fuel
remove the compression gauge and
injection lines as an assembly from the engine.
compression gauge adapter from the cylinder.
See Removal of High-Pressure Fuel Injection
Reinstall the fuel injector, high-pressure fuel
Lines on page 7-11. Remove the fuel injector
injection lines and reconnect the stop solenoid.
from the cylinder to be measured. See Removal
See Installation of the Fuel Injectors on
of Fuel Injectors on page 7-23.
page 7-29 and Installation of High-Pressure
Fuel Injection Lines on page 7-12.
CAUTION
7. Turn on the fuel supply valve and reconnect the
Remove or install the high-pressure fuel
injection pump stop solenoid.
injection lines as an assembly whenever
possible. Disassembling the 8. Prime the fuel system. Check for leaks. Test the
high-pressure fuel injection lines from engine.
the retainers or bending any of the fuel
lines will make it difficult to reinstall the
fuel lines.
0000047en

Troubleshooting By Measuring Compression Pressure TROUBLESHOOTING
Standard Compression Pressure
Engine compression pressure list (reference value)
Compression Pressure at 250 rpm (250 min-1)
Engine Model Deviation Between Cylinders
Standard Limit
2TNV70 470 ± 15 psi 370 ± 15 psi
3TNV70 (3.24 ± 0.1 MPa; 33 ± 1 kgf/cm²) (2.55 ± 0.1 MPa; 26 ± 1 kgf/cm²) 29 to 43 psi
498 ± 15 psi 399 ± 15 psi (0.2 to 0.3 MPa; 2 to 3 kgf/cm²)
3TNV76
(3.43 ± 0.1 MPa; 35 ± 1 kgf/cm²) (2.75 ± 0.1 MPa; 28 ± 1 kgf/cm²)
Engine Speed and Compression Pressure (Use for Reference)
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)
200 250 300 350 400

Engine Speed (min-1)
0001915
Figure 13-2

TROUBLESHOOTING Quick Reference Table For Troubleshooting
Measured Value and Troubleshooting

When the measured compression pressure is below the limit value, inspect each part by referring to the
table below.
No. Item Cause Corrective Action

Clogged element Clean the element.
1 Air Cleaner Element Broken element
Replace the element.
Defect at element seal portion
2 Valve Clearance Excessive or no clearance Adjust the valve clearance.
3 Valve Timing Incorrect valve clearance Adjust the valve clearance.
Replace the gasket.
4 Cylinder Head Gasket Gas leak from gasket Retighten the cylinder head bolts to the specified
torque.
Intake / Exhaust Valve Sticking valve Replace the intake / exhaust valve.
5 Gas leak due to worn valve seat

Valve Seat or foreign matter trapped in Lap the valve seat.
valve
Piston
Gas leak due to scratching or
6 Piston Ring Perform honing and use an oversized part.
wear
Cylinder
QUICK REFERENCE TABLE

FOR TROUBLESHOOTING
The following table summarizes the general trouble
symptoms and their causes. If any trouble symptom
occurs, take corrective action before it becomes a
serious problem so as not to shorten the engine
service life.

Troubleshooting Charts TNV IDI Service Manual TROUBLESHOOTING
Troubleshooting Charts
Insufficient Poor
High Knocking Sound During Combustion

Engine Engine Air
Trouble Symptom Starting Problem Engine Exhaus Engine Oil
Surging Coolant Intake
Output t Color
Difficulty in Returning to Low Speed

Engine
Exhaust During
Starts But
Excessive Fuel Consumption

Color Work
Uneven Combustion Sound
Excessive Oil Consumption

Stops Soon.
Excessive Engine Vibration
Exhaust Temperature Rise

Abnormal Engine Sound
Low Water Temperature

Exhaust
Excessive Blow-by Gas

During Work Operation
Engine Does Not Start
Dilution by Diesel Fuel

Smoke Corrective Action Reference Page
Low Oil Pressure
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
See “Disassembly of Cylinder

Cylinder Head Gasket Blowout O O O Replace the Gasket.
Head” on page 6-21.
See “Reassembly of Cylinder
Seized or Broken Piston Ring O O O O O O O O O O O O Replace the Piston Ring.
Head” on page 6-31.
Perform Honing and Use Oversize See “Honing and Boring” on
Worn Piston Ring, Piston or Cylinder O O O O O O O
Parts. page 6-53.
See “Inspection of Crankshaft and
Seized Crankpin Metal or Bearing O O O O O O O Repair or Replace. Camshaft Components” on
page 6-46.
Improper Arrangement of Piston Ring See “Reassembly of Pistons” on
O O O O Correct the Ring Joint Positions.
Gaps page 6-55.

TROUBLESHOOTING Troubleshooting Charts

Troubleshooting Charts TROUBLESHOOTING
Insufficient Poor

Engine Engine Air
Trouble Symptom Starting Problem Engine Exhaus Engine Oil
Surging Coolant Intake
Output t Color

Engine
Exhaust During
Starts But

Color Work

Stops Soon.



Exhaust

Engine Does Not Start.

Smoke Corrective Action Reference Page
Low Oil Pressure
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

Insufficient
Exhaus Engine Engine Air
Trouble Symptom Starting Problem Engine Engine Oil
t Surging Coolant Intake

Output
Color
Engine

Starts Exhaust During


but Stops Color Work


Soon. Corrective Action Reference Page
Exhaust
Low Oil Pressure

Smoke
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.
Replace Thermostat or Check for Coolant Pump” on page 8-7. or
Engine Coolant System
Insufficient Radiator Cooling O O O

Loose Fan Belt. Check and Adjust Cooling Fan V-
Belt on page 5-27
Check Water Leakage from See “Engine Coolant System
Insufficient Engine Coolant Level O O O
Engine Coolant System. Check” on page 8-7.
Cracked Water Jacket O O O Repair or Replace.
See “Check and Adjust Cooling
Stretched Fan Belt O O O Adjust the Belt Tension.
Fan V-Belt” on page 5-19.
Defective Thermostat O O O O Check or Replace.
See “Engine Oil Specifications” on
Incorrect Engine Oil O O O O O O Use Correct Engine Oil.
page 4-13.
See “Disassembly of Oil Pump” on
Engine Oil System Leakage O O Repair.
page 9-9.
Engine Oil System
Insufficient Delivery Capacity of See “Disassembly of Oil Pump” on

O Check and Repair.
Trochoid Pump page 9-9.
See “Replace Engine Oil and
Clogged Engine Oil Filter O O Clean or Replace.
Engine Oil Filter” on page 5-25.
See “Disassembly of Oil Pump” on
Defective Pressure Regulating Valve O Clean, Adjust or Replace.
page 9-9.
See “Adding Engine Oil” on
Insufficient Engine Oil Level O O Add Correct Engine Oil.
page 4-14.
See “Checking Engine Oil” on
Overfilled Engine Crankcase O Check Engine Oil
page 4-14.


Poor

Insufficient

Output
Color
Engine





Soon. Corrective Action Reference Page
Exhaust
Low Oil Pressure

Smoke
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
See “Drain Fuel Filter / Water

Water in Fuel System O O O O O O O Draining the Fuel Filter.
Separator” on page 5-21.
See “Drain Fuel Filter / Water
Clogged Fuel Filter O O O Clean or Replace.
Separator” on page 5-21.


Poor

Insufficient

Output
Color
Engine





Soon. Corrective Action Reference Pages
Exhaust
Low Oil Pressure

Smoke
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
Uneven Injection Volume from Fuel See “Testing of Fuel Injectors” on

O O O O O O O O O Check and Adjust.
Injection Pump page 7-24.
See “Testing of Fuel Injectors” on
Excessive Fuel Injection Volume O O O O O O O Check and Adjust.
page 7-24.
Poor Spray Pattern from Fuel Injection See “Testing of Fuel Injectors” on
O O O O O O O O O Check and Adjust.
Nozzle page 7-24.
Foreign Matter Trapped in the
See “Fuel System Components”
Priming Failure O Valve Inside the Priming Pump
on page 7-10.
(Disassemble and Clean).
See “Drain Fuel Tank” on
Clogged Strainer at Feed Pump Inlet O Clean the Strainer.
page 5-24.


Poor

Insufficient

Output
Color
Engine





Soon. Corrective Action Reference Pages
Exhaust
Low Oil Pressure

Smoke
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
Clogged Air Filter O O O O O Clean Air Filter.

on page 5-28.
Engine Used at High Temperatures or at Study Output Drop and Load
O O O O O
High Altitude Matching.
Clogged Exhaust Pipe O O O O Clean Exhaust Pipe.
Starting Motor Defect O Repair or Replace Stater Motor. See “Starter Motor” on page 10-9.
Electrical System
See “Removal of Alternator” on

Alternator Defect O Repair or Replace Alternator. page 11-12. or Removal of
Dynamo on page 11-20
Open-Circuit in Wiring O Repair Open Circuit.
See “Check Battery” on
Battery Voltage Drop O Inspect and Change the Battery.
page 5-23.


Electric Wiring TNV IDI Service Manual WIRING DIAGRAM
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.
KEY SWITCH* 30A

FUSE*
EMERGENCY
STOP
SWITCH*
YAZAKI NO.
LA206 7122 - 3016
Items marked with * are

YAZAKI NO.
7123 - 3010 not provided by Yanmar.
GLOW PLUG
11V-9 ±1.0 A/PER ONE 0002427A
119717 - 77800
PRE-HEAT TIME 3 sec

WIRING DIAGRAM Electric Wiring

MEMO
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Hitachi Construction Machinery Co. Ltd Hitachi Ref. No.
Attn: Publications, Marketing & Product Support
Fax: 81-29-831-1162
SERVICE MANUAL REVISION REQUEST FORM
NAME OF COMPANY: MODEL:

PUBLICATION NO.:
YOUR NAME: (Located at the right top corner in the cover page)
DATE: PAGE NO.:

(Located at the bottom center in the page. If two or more re-
FAX: visions are requested, use the comment column)
YOUR COMMENTS / SUGGESTIONS:

Attach photo or sketch if required.
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REPLY:
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INTRODUCTION

• This manual consists of two portions:

• Each page has a number, located on the center

Consecutive Page Number for Each Group

• These are the SAFETY ALERT SYMBOLS.

• When you see these symbols on your machine or in

UNDERSTAND SIGNAL WORDS

• On machine safety signs, signal words designating the

• DANGER indicates an imminently hazardous situation

• NOTE indicates an additional explanation for an

• Carefully read and follow all safety signs on the machine

PREPARE FOR EMERGENCIES

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

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

• Keep emergency numbers for doctors, ambulance

• Wear close fitting clothing and safety equipment appro-

You may need:

Respirator or filter mask.

• Avoid wearing loose clothing, jewelry, or other items

• Do not wear radio or music headphones while oper-

PROTECT AGAINST NOISE

• Prolonged exposure to loud noise can cause impairment

• Wear a suitable hearing protective device such as

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

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

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

thoroughly remove such material.

FASTEN YOUR SEAT BELT

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

• Be sure to remain seated with the seat belt securely

least once every 3 years regardless of appearance

• Always be aware that there is a potential danger around

• Take extra care not to run over bystanders. Confirm

• Inappropriate engine starting procedures may cause the

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

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

• Failure to follow correct jump starting procedures could

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

KEEP RIDERS OFF MACHINE

• Riders on machine are subject to injury such as being

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

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

• Investigate the configuration and ground conditions of

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

• For jobs involving multiple numbers of machines, provide

CONFIRM DIRECTION OF MACHINE TO BE

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

• Before driving the machine, confirm the position of the

• Driving the machine in the incorrect direction may result

• Before moving the machine, confirm which way to

• Avoid passing over any obstructions. Failure to do so

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

• Traveling across the face of slope or steering on a SA-616

slope may cause the machine to skid or to turnover. If

• Death or serious injury may result if you attempt to

• Park the machine in compliance with the safe parking

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

• If any person is present near the machine when backing

To avoid back-over and swing accidents:

clearly understood by both signalman and operator.

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

• Before operating the machine, set up barriers to the

NEVER POSITION BUCKET OVER ANYONE

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