YANMAR SERVICE MANUAL EXCAVATOR move. B37VFOREWORD This service manual outlines procedures for servicing YANMAR, construction machinery. It contains specifications, servicing in- structions and handling cautions. To obtain the maximum life and performance from YANMAR construction machinery, read this manual carefully and follow its instructions. Please note that all dimensions and numerical values in this manual are for service reference, and are not inspection stan- dards. Descriptions and specifications in this manual are sub- ject to change without notice due to design improvements, etc.CONTENTS CHAPTER 1 GENERAL CAUTIONS FOR MAINTENANCE monk 1-1 Corract Work 1-2 Satety Precautions 1-3 Preparations 1-4 Cautions for Disassembly end Reassembly 1.6 Cautions for Removal and Installation of Hydraulic Equipment 4.2 1-6 Cautions for Removal and Installation of Hydraulic Piping” 1-7 Cautions for Handling Seals 1-8 Correct Installation of Hydraulic Hose 1.9 Specifications of Hydraulic Hose ~ 1-10 Air Release of Hydraulic Equipment CHAPTER 2 TECHNICAL DATA 2.4 Specifications 2-2 Machine Dimensions and Working Ranges “2-2-1 22:1 Canopy Type ~ 2.2-2 Cabin Type 2.3. Component Weights 23-4 2-4 Lifting Capacities 244 CHAPTER 3 SERVICING Sano 3-1 Machine Performance ~ 344 3-2 Engine B24 3-4 Undercarriage “ 3.31 3-3-1 Rubber Crawler Specifications B34 33-2 Steel Crawler Specifications s--rr-003.3.2 3-3-3 Common Specifications of Stoo! & Rubber Crawlers: 3.33 3-4 Control Devices 36 Hydraulic Equipment 36-1 Hydraulie Cylinder « 3-6 Work Implements 2.6-1 Front Attachments 3-6-2 Blade Moving Device ~ 3-6-3 Bucket Teeth -~ 3-7 List of Tightening Torque 37-1 3-7-1 Machine “274 3-7-2 Engine “313 3-7-3 Tightening Torque for General Bolts SRGINGIR ee cece 23 CHAPTER 4 ENGINE 4-1 Measurement, Inspection and Adjustment -~-4-1-1 4-1-1 Measuring the Compression Pressure =-4-1-1 4-1-2 Adjusting the Valve Head Clearance «---4-1-3 41-8 Checking the V-belt Tension wren dtod 4-1-4 Checking the Fuel Injection Valve s-----4-1-4 41-5 Checking and Adjusting the Fuel Injection Timing 4-1-6 Adjusting the No-load Maximum (or Minimum) Revolutions “41-9 4-1-7 Checking the Cooling Water System and Radiator for Water Leakage ‘4-1-9 4-1-8 Checking the Sensors. -4-4-10 4-2 Measuring Procedure, Service Data and Corrective Action 4.24 42:1 Cylinder Head 424 4.2.2 Cylinder Block 427 4.2.8 Valve Rocker Arm 4.2.10 4-2-4 Pistons and Piston Ring" A212 4.2.6 Connecting Rod 4247 42.6 Camshaft ~~ 42-7 Crankshaft 4.2.8 Gears ~ 4-2-9 Trochoid Pump s--rsrsrersnnnneeenbeQeDT 4.3 Precautions Reassembly ~~ 434 4.4 Fuel Supply System 444 4-4-1 Fuel Injection Pump 444 44-2 Fuel Feed Pump -- 4-4-3 Fuel System 4-4-4 Fuel Injection Valve 4d 44-5 Governor Mechanismsssvsssenrnnensnnne§ib.§ 44.6 Specification of Fuel Injection Pump ‘4-8-8 4-4-7 Service Date for Fuel Injection Equipment455 Electrical Equipment 4-6-1 46-1 Starter Motor AG 45-2 Alternator 45-3 45-3 Air Heater CHAPTER 5 HYDRAULIC SYSTEM 5-1 Qutling on 5-1-1 Control Valve Operation 5-1-2 Additional Operation of Control Valve 6-2 Hydraulic Circuit Schematic 5-2:1 Standard Specifications: 5-3 Circuit Operation 5-3-1 Boom 6-3-2 Arm 5-3-3 Bucket 53.4 Swing 5-3-5 Boom Swing 5-3-6 Blade 63-7 Travel 5-3-8 Simultaneous Operation of Travel ‘and Boom/Bucket 5-3-9 Simultaneous Operation of Travel ‘and Arm/Boom Swing - 53.17 5.3.10 Simultaneous Operation of Soom and Bucket 53-19 5-3-11 Simultaneous Operation of Arm and Bucket ~~ 5.3.12 Hydraulic P.T.O. 5-4 Pressure Adjustment 5-4-1 Relief Valves 5-4-2 Swing Brake Valve 8-4-3 Cutoff Valve CHAPTER 6 HYDRAULIC EQUIPMENT 6-1 Hydraulic Pump 6-2 Control Valve ~ 6-9 Pilot Valve 6-4 Swing Motor « 6-5 Travel Motor ~ CHAPTER 7 ADJUSTMENT AND REPAIR 7-1 Electric Equipment of the Machine ~~ 7-4-1 Arrangement of Electrical Equipment and Names of Parts +" TA 7-4-2 Monitor and Alarm Systems 744 1-1-8 Wiring Diagram TAT 7-2 Undercarriage 7-24 Outline 7.2.2 Major Parts TA 124 24 7-2-4 Points of Reassembly (Rubber Crawler Models): 7-2-4 Points of Reassembly (Stes! Crawler Models) « 7-26 Disassembly and Reassembly of Idler 7-26 Installation of Idler Assembly 7-2-1 Disassembly and Reassembly of Track Roller 7-28 Disassembly and Reassembly of Carrier Roller 7.2.8 Drawing of Jig 7-4 Control 7-3-1 Control Train 7-3-2 Disassembly and Reassembly of Mechanical Control Linkage ~ 7-33 Adjustment of Lock Lever 7-3-4 Adjustment of Implements and Swing Control Levers (for Semi-long Lever Type Only) « 7-3-5 Adjustment of Travel Levers 7-3-6 Adjustment of 2-Speed Pedal 7-3-7 Adjustment of Boom Swing Pedel 7-3-8 Adjustment of Blade Lever 7-3-9 Adjustment of Engine Speed Control 7-4 Swing Bearing ~~ 7-6 Hydraulic Equipment 7-8-1 Precautions for Removal and Installation, and Assembly of Hydraulic Pump s-~7-5-1 7-5-2 Disassembly and Reassembly of Hydraulic Cylinder 7-6-3 Swivel Joint ~ 7-84 Hydraulic Oil Tank 7-8-5 Piping Layout 7-6 CabinCHAPTER 8 PERIODIC INSPECTION AND SERVICING 8. List of Periodic Inspection and Servicing: CHAPTER 8 FUEL, LUBE OIL AND GREASE RECOMMENDED 9. Fuel, Lube Oil and Grease Recommended by Yanmar ~~ 9-1-1 CHAPTER 10 TROUBLESHOOTING 10-1 Non-breakdowns a 10-1-1 10-1-1 Natural Release of Bucket 0-1-1 10-1-2 Discontinuous Arm Movement 101-1 10-1-3 Drifting of Upperstructure on Quick Travel Operation 0-1-2 10-1-8 Thermal Shock of Travel Motor :---+----10-1-3, 10-1-5 Elongation of Boom Swing Cylinder ‘on 80 degrees Swing 1061-4 10-1-6 Time Lag on Travel Speed Switching ~-10-1-5 10-1-7 Fluctuation in Oil Level of Hydraulic Oil Tank Due to Temperture Change 10-2 Troubleshooting ~~ 10-2-1 Machine and Engine 10:2-2 Electrical Equipment on Pane CHAPTER 11 REFERENCE DATA 11-1 Specifications for AttachmentCHAPTER 1 GENERAL CAUTIONS FOR MAINTENANCE WORK 14 1 1-1 Correct Work = 1-2 Safety Precautions 1-3 Preparations rstesescne 1 1-4 Cautions for Disassembly and Reassembly--=-1-1 1-5 Cautions for Removal and installation of Hydraulic Equipment ~~ 1.2 1-6 Cautions for Removal and Installation of Hydraulic Piping ------ 1-2 1-7 Cautions for Handling Seals 1-2 1-8 Correct Installation of Hydraulic Hose ---r-1-3 1.9 Specifications of Hydraulic Hose 1-10 Air Release of Hydraulic Equipment ~~1. GENERAL CAUTIONS FOR | 1-1 Correct Work Correct work means the quickest possible com- pletion of according to the correct procedures and the specified standards. It is important when conducting certain opere- tions elways to bear in mind the equipment, tools, gauges. materials, oil and grease, etc that you must have ready, as well as items to be checked, adjusted, or disassembled, and cau tions to watch out for 1-2 Safety Precautions (1) Wear work cloths, safety shoes and helmet, (2) Check the equipment and tools before use. Especially, be sure to check the crane, lift- ing equipment and tools. (3) When working together with other persons, allocate everyone's share of job, arrange the signals and act in concert with the other persons. (4) The operation of the crane and slinging work must be performed by qualified persons. (5) Do not enter or pass under the raised load. (6) Lift and support the massive parts by crane before removing the installation bolts. (7) Disconnect cables from battery before re- pairing the electric system (8) Remove the battery when welding the mac hine 1-3 Preparations (1) Check the service record of the machine. (That is, check how many months or hours the machine has been used since the pre- ceding overhaul, what wes the trouble then end what parts were replaced.) (2) Have all servicing tools ready, i.e., tools, mea- suring devices (which have received periodic maintenance), containers, oil & grease, etc (3) Have the service literature (operation manu- al, parts catalog, etc.) ready. MAINTENANCE WORK 1 Lo 1-4 Cautions for Disassembly and Reassembly (1) Clean the machine before disassembly (2) Check and record the condition of the mac- hine before disassembly + Model, machine number, operation hours + Reasons for repair, history of repair * Contamination of filters + Fuel and oil condition + Damage to parts, ete. (3) Place alignment marks on the necessary parts to facilitate reassembly. (4) Clean all the removed parts and new re- placement parts and put them in order. (5) Use new seals, split pins, etc. for reassem: bly (8) Keep the parts apt to be damaged by weter or oil apart from the oily or wet parts e.g: Electrical parts, rubber parts, V-belts, ote. (7) Use the jig for press-fitting the bearings, bushes and oil seals. When using @ ham- mer, use a pad block (8) Clean the joint surface of all parts and keep them free from dust (9) Wind the sealing tape securely, leaving a space of one or two threads from the tip of the male screw. The tape should have an overlap of about 10 mm. ‘One and a nai ead mes 9) Seaing 208 443990401. GENERAL CAUTIONS FOR MAINTENANCE WORK 1-5 Cautions for Removal and Installation of Hydraulic Equipment (1) Check that the hydraulic oil temperature is, low enough. (2) Release air from the hydraulic tank to pre- vent the hydraulic oil fram flowing out. (3) Be sure to plug open the ends of hydraulic components to prevent dust from entering, (4) Be sure to wipe hydraulic oil from the hy- draulic components so that it will not be mistaken for an oil leak (8) Take care not to damage the plating on the oylinder rod. (6) Remove or install cylinders with rods fully retracted. (7) Be sure to release air after installing the hy- draulic cylinders. Run the engine at a low speed. Extend and retract the cylinders 4 to 5 times up to 60 to 100 mm from the end of the stroke. Then, fully extend and retract. (8) Be sure to pressurize the hydraulic tank af- ter installing the hydraulic components (in the case of the sealed hydraulic tank). Oth- erwise, hydraulic pumps might suffer cavi- tation and their life will be shortened. + To pressurize the hydraulic tank, fully ox- tend each cylinder and tighten the oil filter port plugs. 1-6 Cautions for Removal and Installation of Hydraulic Piping (1) Installation of hydraulic hose Take care not to twist the hoses. (Judge whether or not the hose is twisted by the hose mark.) For hoses with a metal fitting, use two wrenches to prevent twisting Use one to fix the hose, and the other to tighten the fitting to the specified tightening torque. Carefully check thet the hoses do not come in contact after tightening. If any contact is found, correct it or use tubes. Meta ting (2) When installing hoses, first tighten to the specified torque and then loosen them a litt- le. Then retighten to the specified torque * Break in the installed parts before tighten- ing (except those using seal tapes) (3) When installing pipes, turn the nuts more 1/4 to 1/2 turn after they reach the sharp torque rise point. (4) When installing or removing hoses. use two wrenches, one to fasten the hose and the other to tighten or loosen the hose to pre- vent twisting, (5) Check for oil leakage by applying max pressure 5 to 6 times after attaching hy- draulic hoses or pipes. 1-7 Cautions for Handling Seals (1) Clean out grooves of O-rings. Remove burrs or dust if any, _ nll (2) Take care not to twist O-rings. Correct by your finger if it is twisted (3) Take care not to damage seals when in- sorting 44399040,1. GENERAL CAUTIONS FOR MAINTENANCE WORK (4) Handling of floating seals: 1-8 Correct Installation of * Completely wipe off all the oil from the Hydraulic Hose O-ring and housing after detaching the floating seals. In order to mount the hydraulic hose most ef- * Before installing, apply a little gear oil to _fectively and economically, observe the follow- the matching face of the housing. ing cautions. + Turn the seals two or three times after in- stallation to break them in. (1) When a hose is used at the minimum bend- (5) Apply grease to the lip of the oil seals to ing radius, use elbows to avoid sharp bend- prevent wear. ing {tot good! [Good} “4 (2) To prevent twisting, the hose should be bent in the same direction as it moves. (Not good) {Good (2) When the hose is pressurized, the hose length, varies slightly at the bend. Allow this change to occur and do not try to fasten the bend Not prassurized ~ wnen pressurized 13 443990401. GENERAL CAUTIONS FOR MAINTENANCE WORK | (4) It is necessary for the hose to heve ample (8) The hose should be slightly longer than is slackness for elongation and contraction, absolutely necessary. The extra allows because its length will change by +2% to —4% smoother movement of the hose and pre- when used at high pressure. vents sharp bending. Not good) {not good! {Good} oe, far "iy [Pleo orn ” INot good) a Ring wiath (B) 1.97010 1.960 : Second ring Creeeswnen | ae - | End gap a 0.200 to 0.400 1, 5 | Ring groove width 14.015 104.080 - Ring width (B) 2.07010 3.090 : a | 0.028 00.060 - End gap 0200 t0 0400, 1s 322 s9003. SERVICING STANDARDS Anplzable mode TTNEaH BTA, STE CBI Item ~ Unit Standard Wear limit Gannecing rod Buahhol side da aioe : panne [eushehikness——] TAB 1.50 = Outsie aie ata w #72 wai Oileeorones 008100074 0.6 Bush Pole insde da “76.025 0 2.08 25.0 Piston pin side Ousidedia ae 25 087106 0 2530 Oil clearance 0.025 to 0.051 0.2 Disorton ar 0.08/16 0.08 Cam Z cme Gam hele EE “a Oil clearance 060.180 | Cam shel aio 8100 4.85 85 Inermediat an —| Oil clearance 08 60.118 | cna Cam shalt a ze 2598 50 85 Citclearence 0.080700.100 : rank shal Guide da amone [am Journal Bush thickness mm 7.995 102.010 Oilclearance 0.038 10 0.068 0.15 Bend ae 30.02 : Crank shal 0.001907 : Cam haf 0.05 100.25 cece Connecting rod =m __0.20 100.40 = Idle gear 0.1010 0.30 ~ Crank torso por ide gar fot ee 0119018 : Backlash tion pump drive gear mm | Cube oi up gear | owe | Cher Lubeoil pump discharge | Miohspaed min 1270 APM : bid Low speed no a | anon | Frat aig vaca re | ga as : Pressure for operating hydraulic oil switch alt kgf/cm’? 0.410 0.6 ~ Cooling weter pump aecharge volume min waneiapw ; Temperature co | 69.5 to 72.5 ~ - Thermostat valve open Lift at opening mm S80 _ - e188 o higher Thermo-switch ON 107 to 113 = cperetng temperature [OFF S100 = 32-3 44399040| 3. SERVICING STANDARDS 3-3 Undercarriage 3-3-1 Rubber Crawler Specifications (Unit : mm) Applica mode wav van wharetobe | standara | Allowable nent i (1) Rubber crawler A x ‘0 SS (2) Idler & shaft A on = = B 635 _ td c 980 —_ é > een = > J E 2 x | . v0 B Tes 3.31 443990403. SERVICING STANDARDS 3-3-2 Steel Crawler Specifications (Unit: mm) Applicable model B37V Where to be Meretobe | standard | Wear limit Part (1) Crawler link (Double grouser) ¥ A 8 38 8 A 8 165 65 = (Note) For the link pitch, measure § links at three c sore a places and obtain the average value (2) Master pin (_—— or A | 65 = A 8 19 ov | ain A 5 ; = q £ 8 o19 on a 2 | (4) Bush & moster bush A 5 _ i: £ ~~. q & A | eee | c oz 630 (5) Idler & shaft A 430 _— ft —__|——— 8 $35 — UI [ = ; -4 1 (. ; = i E 28 20 HUT a alee aa iB 7 3.3.2 443990403. SERVICING STANDARDS 3-3-3 Common Specifications of Steel & Rubber Crawlers (Unit: mm) Car measured camden limit (1) Sprocket B A 5 10 H 6 5 Track roller & shaf | 2) Treck rier & shat 7 = _ « Ld 8 62 _ & +—_2__- % c oes $70 3 alcle > 2 8 3 i-F=F a oe ee i i é (3) Carrier roller & shaft : ra eee : aa 333 443990403. SERVICING STANDARDS 3-4 Control Devices Applicable model 537V tem Measuring conditions Unit| Standard | Allowance Pear onee Engine : stopped 14 2a [(Boom & Bucket) | @ Hydraulic oil temp. : 80 to 60°C Left contro! lever © Lever operating load 14 2a (Arm & Swing) “Measure hanging the spring scale at the | Blade lever lever grip. 17 25 & ‘Pedal operation load fal enema Measure applying load as shown below. | kat | 2.0 a S | Boom swing lever in eee emer rina sae 4 Boom swing pedal LY Easy 70 10.0 | _[ortsetpesa ~ |. B| [Right controt ever | Engine: stopped Z| g | (Front & Rear/Left| @ Hydraulic oil temp. : 5010 60°C a | &) 3 |& Right) Play in the control levers and pedals 3 |tomeonrot my | Mesure ta oly rot 6 rar 's | (Front & Rear/Left 20 - B|& Right) § | Blade tever ire eee % 2 | Travel lever 20 8 Z | Boom swing pedet 10 2 Offset pedal - - Boom control valve Bucket control valve 72 ‘Arm control velve 5 | & |swing contro! valve 60 B | 3 |Ramwrevaing 5 | B [control valve eye Left traveling control valve va Blade control valve Boom swing aa 7 control valve Offset control valve - - 34-1 443990403. SERVICING STANDARDS 3-5 Hydraulic Equipment 3-5-1 Hydraulic Cylinder it © (Max.retraction length) (Stroke) (Hydraulic hose connection thread) (8) (Rod nut) Unit: mm Position ® ® o/ele|oa|e Thread | Tightening Standard| Wear limit| size | torque (mm) | _{kgt-m) Boom 45 | 586 | 119 | #80 | 645 |PT 3/8} 45 | 4455 | Maz | 105t0115 Arm gor | s90 | 68 | 80 | 45 |pTave} 45 | 445.5 | M33 | t05t0 115 Bucket 70 | 515 | 93 | 670 | #40 [PTs/e] 38 | gas | m2 | 76t085 Boom swing sco | 605 | 70 | da5 | o40 |priva] 39 | gan6 | m2 | 75t085 Blade 4g | 177 | 120 | @80 | d40 [pris] o40 | 405 | mar | 751085 36-1 44399040| 3. SERVICING STANDARDS | 3-6 Work Implements 3-6-1 Front Attachments Ones (Unit: mm) Wear limit No. Measuring Point Standard ~ Pin Bore of bush or hole ®__| 800m swing fulcrum eo | e Boom fulerum $45 Boom swing cylinder. rod s 638 Boom swing cylinder, bottom ®© _| Boomcylinder. bottom = O45 © _| Boomeylinder, rod @® | Armfulerum O48 - 0.5 405 @ _| Armeylinder, bottom 45 @ | Armoylinder. rod ® | Bucket cylinder, bottom | | | Bucket eylinder, rod | @ | Link “As arm 638 | Bucket fulerum @ _| Bucket link “A* e [Note] Allowable clearance between pin and bore of bush or hole is 1.0mm. 3.61 443990403. SERVICING STANDARDS 3-6-2 Blade Moving Device (Unit: mm) | Wear limit No. Measuring point Standard | —-——______-___-- [Pin Bore of bush or hole @D__| Blade cylinder, rod 640 @ _| Blade cylinder, bottom $40 08 40.5 @ [Blade tutcrum cE] [Note] Allowable clearance between pin and bore of bush or hole is 1.0mm. 3-6-3 Bucket Teeth 362 443990403. SERVICING STANDARDS 3-7 List of Tightening Torque 3-7-1 Machine Applicable model Ba7V, a Thresdsia | “argue” | Ser tacking INo Tightening part (kgt-m) agent ngine/Elecirieal equipment 1] Engine flexible mount mie 451060 2 | Radiator flexible mount Nut ma 130017 | 3 | Engine x Engine mount (redietor side) Mi Ttt013 | These Bond 1324 4 | Engine x Engine mount (flywheel side) M10 6.5t07.6 | Three Bond 1324 5 | Stopper X Engine mount M10 45106.0 | Three Bond 1324 6 | Braket. engine X Turning frame mia 8.010 10.0 | Three Bond 1326 7 | Hose clip 70 (air cleaner side) = 0.21003 a 8 | Fuel gauge hose = 03 9 | Fuel gauge unit MB 02 10|| Battery fastening rod Nut Ma Lock nut 13101 7katm | 11 Cooling weter hose clip = 03 Driving equipment _ 1] Sprocket wa 8.010 10.0 | Three Bond 1928 ravel equipment 1 | Plug (idler track roller & carrier roller) PT Qa1010 | Loctites72 2 | ldler seal cover x Track spring mie 8.010 10.0_| Three Bond 1926 3 | Track roller tightening nut Cap nut Mi6 141019 | Three Bond 1324 4 | Nipple valve M6 5.0 Control equipment _ 1 | Lever installation Mata 751065 | Three Bond 1324 2 | Knob installation Ma 0.2t00.3 | Three Bond 1324 3 | L-ball 8 X Link bail8, 8L Umut Ma 13t017 4 | Link bell €(@L) x Rod Nut Ma 131017 5 | b-ball’ x Rod : Nut M8 0.8 101.0 6 | Valve mount x Frame _ Mio 2.0102.6 | Three Bond 1324 7 | Lover lock fulerum Nutt Server operate load @ | Rodend 14 mia Toes | 1 | Swing bearing X Lower frame wa Loctite 262 Swing bearing X Turning frame Mt Loctite 262 Counter weight X Turning frame Mia Three Bond 1326 Center weight x Turning frame m2 Three Bond 1226 ide weight Turning frame mi2 Taree Bond 1326] 37-1 443990403. SERVICING STANDARDS Applicable model Ba7V Equipment nn aa ‘S| Screw locking No. Tightening part { (kgf-m) aor Hydraulic equipment = : 1 | Coupling _[WiHexagonholemt2 | 851094 | Three Bond 1324 2 | Swivel joint % Track frame mia 451060 _| Three Bond 1324 3 | Swing motor X Upper frame Mi6 171021 | Three Bond 1326 [4 [Travel motor % Track frame mia 81010 | Three Bond 1924 5 | Hydraulic oil tank X Turning frame mia [731015 | Three Bond 1324 6 | Brain plug 24 X Hydraulic oil tank | Mz 21025 | Three Bond 1324 7 [Oi gauge x Hydraulic oil tank m0 151017 | Loctite 572 8 | Hose clamp (et boom rear) M0) “45t06.0 | Three Bond 1324 @ | Hose clamp (for P.T.O selector valve hose) Miz 81010 | Three Bond 1324 [10] Hose clip (16) mae 0.21003 11 | Hose clip 22, 36,47, 60& 70 “| = 0.21003 12 | Hose hold (clamp for 6 hoses between CV-boom) Mio) 2.5103.0 7 73 | Hose clamp (for P.T.0 hose) eau Mi2 81010 | Three Bond 1328 14| Breather cap Ms 031004 [15 Plug (port P of remote control vaive) __wi6 3.01035 - |__| 76[ Evebolt (port T of remote control valve) Mia 2.01025 Rigging - 1 | Canopy pole Mia 1210 15 __| 2 | Roller 35 x Glass frame M6 08 Three Bond 1324 3 | Glass x Glass frame - Me 0.8 | Three Bond 1324 4 | Gloss X Hand rail MB 05 Three Bond 1324 |_ [5 [Under cover x Frame Miz 81010 | Threa Bond 1324 Work implement [1 [Lock ptate (boom bracket verticalpiny | Mi6 [ri | three Bona tame 2 | Lock plate (swing cylinder bottom pin) M10) [451060 | Three Bond 1324 3 | Lock plate (blade arm link pin) _ Mio 4.51060 | Three Bond 1324 4 [ Bucket teeth : Nut 2it025 | Loctite 262 5 | Bucket side cutter Mi 151018 | Loctite 262 37-2 443990403. SERVICING STANDARDS 3-7-2 Engine Tightening torque for major bolts and nuts (Unit: kgf-m) Part STNESS-BIA Cylinder head bolt 6.8 107.2 (M9x1.25) Connecting rod bolt 3.810 4.2 (MBX1.0) Flywheel installation bolt B5t090(MI0x12) = Main bearing cap bolt 7.8 t0 8.2 (Mi0X1.5) Crankshaft pulley installation bolt 11.5 10 12.5 (M14X1.5) Fuel injection nozzle retainer clamp bolt 0.7 10.0.9 (MBX1.0) 3% Fuel injection nozzle case nut 4.010 4.5 (605-40, UNS-2B) Nut for timer 6.0 to 7.0 (MI2X1.75) 3-7-3 Tightening Torque for General Bolts and Nuts Note 1) (_ ) value indicate thread size X pitch 2) Oil wet condition except tuel injection items 9) meeds special tool (Unit kaf-m) tem Thread sizexPitch | Tightening torque Remarks M 6x10 1.01012 M 8Xx1.25 2.31020 1) Apply 80% of tightening torque | MIO 25 4106.0 when tightened to aluminum a Ios | SORmIeD 2) Apply 60% of tightening torque Hexagon head | thread MiaX20 aor oT] __ f0F AT bolts and tock nuts bolt (77) 3) Use fine thread screws for en Nut Mi6x2.0 17.01021.0 eae MiBx2.5 24.010 29.0 M20%2.6 33.010 41.0 Fine MUXt5 | 13010150 thread Miext.s 26tows 7 va 10 wa 20 aon 3/8 3.0 v2 60 M8 131017 Mi2 251035 Pipe joint bolt anid Toaea M16 5.0106.0 37.3 443990404-1 Measurement, Inspection and Adjustment -~4-1-1 4-1-1 Measuring the Compression Pressure 4-1-1 4-1-2 Adjusting the Valve Head Clearance “4-1-3 4-1-3 Checking the V-belt Tension ~ 4-1-4 Checking the Fuel Injection Valve hotel 4-1-5 Checking and Adjusting the Fuel Injection Timing 4-1-6 Adjusting the No-load Maximum (or Minimum) Revolutions ~ 4-1-7 Checking the Cooling Water System and Radiator for Water Leakage 4-1-8 Checking the Sensors 4.2 Measuring Procedure, Service Data and Corrective Action « 42:1 Cylinder Head 4.2.2 Cylinder Block 4.2.3 Valve Rocker Arm 4-2-4 Piston and Piston Ring 4.2.5 Connecting Rod 4.2.6 Camshaft 4-2-7 Crankshaft 4.2.8 Gears 42.9 Trochoid Pump « 4-3 Precautions Reassembly CHAPTER 4 ENGINE 4-4 Fuel Supply System 44.1 Fuel Injection Pump =~ 4.4.2 Fuel Feed Pump 4-4-3 Fuel System « 44-4 Fuel Injection Valve 5 Governor Mechanism 4-8-1 Service Date for Fuel Injection Equipment ~~ 4.6 Electrical Equipment 4-5-1 Starter Motor 45-2 Alternator 4.8.3 Air Heater 6 Specification of Fuel Injection Pump ~~ 44-1 ohbet 443 444 14-4 4.45 4.484, ENGINE 4-1 Measurement, Inspection and Adjustment 4-1-1 Measuring the Compression Pressure 1. Measuring Procedure (1) Warm up the engine. Remove the fuel in- jection pipe and fuel injection valve from the cylinder to be measured. (2) Crank the engine before attaching the compression gauge adapter. XK 1. Crank the engine when the regulator handle has been turned to “STOP* position (no injection state) ® (3) Attach the compression gauge adapter and compression gauge to the cylinder to be measured XK Never fail to attach the gasket to the tip of the adapter. Compression gauge Measuring the compression pressure (4) Crank the engine by the starting motor until the reading of the compression gauge is stabilized, by taking steps shown in (2), 31 [Reference: List of Engine Compression Pressures] ‘Compression pressure at 300 ram Dispersion of compression Model kot/em’ _ pressure among cylinders Standard Limit kat/em" STNETBA 311038, B02 e STNEB2A 30 10 32 241028 STNEB(T) | 32 10 34 21027 2103 STNEBS 34 10 36 210% aTNEBS a1 443990402. Trouble diagnosis through measurement of compression pressure Reduction in the compression pressure of the cylinder is one of the major causes of the increase in blow-by gas (which causes contamination and increased consumption of lubricating oil, and other trouble) as well as the engine starting failure. The compression Pressure is influenced by the following fac: tors: 4, ENGINE over a long period of time. by measuring the compression pressure. 1. Degree of the clearance between the pis ton and the cylinder; 2. Degree of the clearance around the in- take/exhaust valve seats; and 3. Gas leak through the nozzle gasket or the cylinder head gasket. This means that the compression pressure decreases as the engine parts are worn and lose durability through the use of the engine In addition, the compression pressure is also decreased by scratches on the cylinder or the piston which are caused by dust or other foreign matters drawn in through the soiled filter element of the air cleaner, and wear or breakage of any piston rings. Therefore, the condition of the engine should be diagnosed (1) Causes and countermeasures to be taken when the compression pressure is less than the limit value % For the compression pressure limit val- ues. refer to the section “4-1-1, surement of compression pressure” Mea- Ne Them Causes Countermeasures + Filter element of air eleaner + Clogged filter element + Broken filter element + Defective filter element seal + Clean the filter element + replace the filter element. 2 | ‘Valve clearance + Excossive or no valve clearance + Adjust the valve clearance. (Reler to the section 4-1-2.) + Valve timing + Improper valve timing + Adjust the valve clearance. + Improper valve clearance (Reler to the section 4-1-2.) a + Inspect and adjust the valve rocker arm. (Reler to the sections 423, 426 and 428.) + Cylinder head gasket + Nozzle gasket sak through the gasket + Replace the gasket + Reetighten the cylinder head and the nozzle at the specified torque (Reler to the section 7-2 of Chapter 3.) + Intake/exhaust valve + Gas loak due to worn valve seats or + Lap the valve seats 5 | + Valve seat trapped foreign matters (Relar to the section 4-2-1-(2).) + Seizure of valves + Roplace the intake/exhaust valves, + Piston + Gas leak due to scratches or wear of | *Do the honing and use oversize parts. 6 | + Piston ring the piston, piston ring or cylinder (Reler to the sections 422-(3) and “Cylinder 42-4-(8).) 4424, ENGINE 4-1-2 Adjusting the Valve Head Clearance Intake/Exhaust valve head clearance (1) Inspect and adjust a valve head clearance ofer to the section "3-2 Nominal and Allowance Valves” while the engine is in cold state, 3K 1. If the valve cap is worm or otherwise dam- (2) Raise the piston in the cylinder to be mea- aged on the head, replace it with a new sured to the top dead center (TDC) of one. compression. 2. Make sure that the valve cap is nested on (3) Loosen the lock nut and adjusting screw. the head of intakelexhaust valves. Make sure that the vaive cap is free from inclination or trapped dirt. Normal (4) Insert @ thickness gauge in between the rocker arm and valve cap. Tighten the adjusting screw until the clearance listed below is attained. e Valve clearance ‘Adjusting serow Lock nut (Adjusting the vaive head clearance) 44-3 44399040 ‘Abnormal| 4, ENGINE 4-1-3 Checking the V-belt Tension Push the center of the V-belt between the al- ternator and cooling water pump with a finger. If the deflection is 10 to 15mm, the V-belt tension is acceptable. If not, adjust the V-belt tension using the adjuster at the alternator. 10 t0 mm poner = @ Cooling water pump Crankshat piley (Adjustment of the V-belt tension) 4-1-4 Checking the Fuel Injection Valve 1. Measuring the injection pressure % Thoroughly remove carbon deposits from the injection nozzle before making mea- surement. (1) Connect the fuel injection valve to the high pressure pipe of the nozzle tester (2) While pumping the lever of the nozzle tester slowly, read the pressure gauge on the nozzle tester the moment the nozzle starts fuel injection 2% For injection pressure of each engine, re fer to Chapter 1, *Specitications and Per: formance” (3) If the measured injection pressure is low. Measuring the Injection pressure with ) anozzle tester er than the specified value, replace the Pressure adjusting shim with a thicker one. 41.4 44399040Type of pressure adjusting shim Injection pressure adjustment thickness (me) Direct 0.13 0.15 Increase the pressure adjusting shim thickness by injection 018 04 0.1 mm and the injection pressure is increased by system os 08 about 19 kaf/em [Reference: Structure of fuel injection valve] (Direct injection system) —F.0. retum pipe joint Nozzle holder Norse vave Dowal pin Nozzle foe by 2. Checking the spray patterns (1) Make sure that the pattern is neither stream While pumping the lever of the nozzle tester nor sliver: 4-6 times per second at the specified injection pressure (Refer to section "2, Specifications (2) Ensure that fuel is sprayed conicatly around and Performance”), check the spray pat- the nozzle center line and that a fuel injec: terns. If the following trouble is found, clean tion spreading angle is 150 degrees in the or replace the nozzle direct injection system. 41-8 443990404. ENGINE [Normal spray pattern] i ~ 150° [Abnormal spray patterns) a SD (3) Place a sheet of white paper 30 cm below the nozzle. The injection spray should form a perfect circle. (4) No oil should drip from the nozzle after injection (5) Oil should not ooze from the injection hole when the pressure is raised to a little less than the specified 20 kgf/cm’ (6) Test the injection with a nozzle tester ; retighten and test again if there is exces- sive oil leak from the overflow coupling Replace the nozzle as @ set if the leaking oil is still excessive 44-6 443990404. E 3, Nozzle valve sliding test Thoroughly wash the nozzle valve using clean diesel oil. Hold the nozzle body vertically, and lift the nozzle valve epprox. 1/3 of its length with one hand, Check to see if the nozzle falls smoothly by it- self gravity when released. If so, the nozzle valve is good. In case of @ new nozzle, remove the seal peel, and immerse it in clean diesel oil or the like to clean the inner and outer sur- faces and to thoroughly remove rust-preventive oil before using the nozzle. Note thet @ new nozzle is coated with rust-preventive oil and is pasted with the seal peel to shut off outer air. 4, Nozzle body identification number Y DLL A— 150 P 244J0 Size: siz0 P Loe Injocton angle “Design code “Type: DLL (soiong ype) YANMAR idontteation ‘umber NGINE YAN 3 ( Nozzle valve stising check by gravity for direct injection system 41-7 443990404. ENGINE 4-1-5 Checking and Adjusting the Fuel Injection Timing 1, STNES8-B1A (1) Using the crankshaft pulley, turn the en- gine in the specified direction. Check the injection timing at the delivery valve of the fuel injection pump for cylinder No.1 (Cylinders are numbered _se-quentially from cylinder No.1 from the flywheel side) (2) When the cranksheft is turned in the specified direction, the oil level rises at the tip of the delivery valve spring holder At that time, stop the crankshaft (3) Identify the timing mark stamped on the flywheel through the access hole of the flywheel housing. %X For fuel injection timing for each engine model, refer to section “2, Specifications and Performance” 418 Timing mark y (4) If the measured injection timing differs from the specified timing, adjust the in- jection timing by turning down the fuel injection pump toward the engine or to the opposite side after loosening the lock nut of the fuel injection pump. + If injection timing is late, turn down the fuel injection pump away from the engine, + If the injection timing too early, turn the injection pump down toward the en- gine Leek nui 443990404, ENGINE 2. 3TNES8-EB1 (1) Structure of driving parts of fuel injection pump. @ Standard engine model (3TNE88-B1A) + Structure of driving parts : A driving gear is installed directly at the edge of the fuel pump cam shaft. + Adjustment of fuel injection timing : FID system whereby the body of the fuel pump is shifted to the outer circumference of the cam shaft. Figure 1: Standard engine model End nut UW ES\EIP riving gear @ EPA certified engine (3TNE88-EB1) + Structure of driving parts : A coupling is fitted to the edge of the fuel pump cam shaft. After the FIC is attached, the cam shaft does not revolve and the coupling and pump body are fixed in place with the lock bolt. (YANMAR : Fuel pump manufacturer) + Adjustment of fuel injection timing : Adjusted by a FIC fixed system ; @ FID system is not used. Figure 2: EPA certified engine 41-84 443990404, ENGINE (2) Adjusting the fuel injection timing @ Factory installation (YANMAR : Biwa factory) Procedure a) Align the fuel injection pump with the carved seal line as shown in figure 3 and attach to the gear case. Figure 3 : Lining up the gear case and the carved seal line Fuel! pump attachment flange (Gear case Note: Align the carved seal line on the fuel pump with the center line (th line from the top) on the gear case. Note: *Before installing the fuel injection pump, confirm that the FIC lock is stil! attached. Under normal conditions the cam shaft does not turn. Do not use it there is a problem. “The carved seal lines on the gear case and the fuel pump have no relation to the fuel in- Jection timing and are the same on all engine ‘models. The attachment angle for the pump is fixed and fuel injection timing is not adjusted as with the FID system. b) Temporarily attach the FIP driving gear. Do not fix with bolts, but allow the FIP cou- pling to revolve freely within the centering location, ©) Adjust the timing for the crank shaft, idle, cam shaft, and the gears of the FIP and at- tach Figure 4 : Adjusting the timing of the gear train. Fuel injection pump driving gear Removal gear Crank gear Lube oil pump gear Direction of revolution (Gear train) Note: When adjusting the timing. put the piston for the No.1 cylinder in the top pressure position. align the English letters and assemble. The cylinder on the flywheel side is no. 44-88 443990404, ENGINE 4 Align the crank shaft with the FIC fuel in. jection angle (b,TDC) and fix. To reduce variation in the firing timing, the crank an. gle is determined by measuring the piston stroke of the cylinders noted below and cal- culating the average value. The piston stroke is determined by measuring the TDC when the piston is in the top position. + S-cylinder engine : No.1, 3 cylinders + 4-cylinder engine : No.1.2 cylinders Note: The series of operations described in d) are performed automatically. e) Keeping the gear backlash on hold, fix the FIP driving gear to the FIP coupling by auto. matically tightening the 2 bolts (marked E) + Tightening torque 34,321.96 Nem (3.50.2 kgf-m) Figure 6: FIP coupling driving gear unit f) Tighten the remaining 2 attachment bolts for the FIP driving gear by hand + Tightening torque 34,32 1.96N+m (3.50.2 kgf-m) a) Remove the FIC lock bolt. See figure 2 This completes the adjustment for the inj tion firing timing Adjustment is not done by a FID system. Note: +After removing the FIC lock bolts, do not separate the FIP coupling and the FIP driving gear. If they are seperated, this will confuse the FIC setup and it will be necessary to ad- just the fuel injection timing from the begin- ning. “If the fuel pump should have to be removed. Joosen the end nuts to do it Coupling-gearbolt CMP 41-86 44399040@ Replacing the fuel pump on location When the pump has become old and worn, re- place the pump in the following manner. Note: The assistant fuel pump is the same as that used in the standard engine (see figure 1 no coupling) Procedure a) Remove the current pump from the gear case. Loosen the end nuts to remove the fuel pump. (Leave the FIP coupling and driving gear in the gear case, CMP.) Note: Do not separate the FIP coupling and driving gear. Do not touch the attachment bolts (E : 4 bolts). b) Align the assistant fuel pump with the carved seal line, and attach it to the gear case. See figure 3 on aligning with the carved seal line ©) Attach the FIP coupling and driving gear, cme + Tightening torque 49.03 to 58.84 N-m (5 to 6 kgf-m) This completes the replacement of the fuel pump. Check the fuel injection timing with the FID system, 41-8-0 443990404, ENGIN: 4-1-6 Adjusting the No-load Maximum (or Minimum) Revolutions NoJoad maximum revolution adjusting bolt (1) First warm up the engine. Then, gradu- Decrease | Increase LS ally increase the engine speed up to the no-load max. revolution (Refer to section “2, Specifications and Performance”) Nostoad min. ravolution none tan (2) If the present no-load max. revolution differ from the specified one, adjust the no-load max. revolution using the no-load max. revolution adjusting bolt. (3) Set the engine to the idling revolution, (Re- fer to section "2, Specifications and Perfor- mance”) by turning the no-load min. revo. lution adjusting bolt. % The illustration shows the partial per- spective view of the governor for the direct injection system. 4-1-7 Checking the Cooling Water System and Radiator for Water Leakage 1. Checking the cooling water system for water leakage XK The cooling water system can be checked effectively while the engine is warm. (1) Supply cooling water up to the normal water level in the radiator. Attach the cap tester body to the radiator (2) Start the cooling water pump, and set it ‘Checking the cooling water system to @ pressure of 0.75 to 1.05 kgf/em’. Any (or water leakage ) lower reading of the pressure gauge on the cap tester indicates water leak from the cooling water system. Then, detect the portion where cooling water leaks from the cooling water system. 2. Checking the radiator cap Attach the radiator cap to a cap tester. Set Radiator cap the tester to a pressure of 0.75 to 1.05 kgf/cm’, Check to see if the cap is opened at the set pressure. If not, replace the cap, because it is defective. (Checking the radiator cap) 41-9 443990404, ENGINE | 1g the Sensors (2) Thermoswitch Put @ thermoswitch into an antifreeze or 1. Checking the thermostat and thermoswitch oil in a container. While measuring liquid temperature, heat the liquid. If the tester (1) Thermostat shows continuity at @ temperature of 107 Put a thermostat into water in @ container to 113°C, the thermoswitch is acceptable. While measuring water temperature, heat the water, Make sure that the thermostat functions at a temperature of 69.5 to 72.5 ©. 2. Hydraulic switch Remove the connector from the hydraulic switch. While running the engine, bring the tester probes into contact with the switch terminal and cylinder block. If the tester shows conti- nuity, the hydraulic switch is defective. Cylinder block (fiywnael sido) Tester probes (Continuity test) 41-10 443990404, ENGINE 4-2 Measuring Procedure, Service Data and Corrective Action In maintaining various parts, make measure- ment according to the following measurement procedure. If any trouble is found and if any part deviates from the standard size, replace it with a new one. However, if any part within the limit is expected to deviate from the stan- dard presumably because of the record of its use, be sure to replace such a part beforehand, 4-2-1 Cylinder Head 1. Distortion and inspection of the combustion surface (1) Remove intake/exhaust valves and fuel in- jection valve from the engine, Clean the surface of the cylinder head (2) Place @ straight-edge along each of the four sides and each diagonal of the cylin der head. Measure the clearance between the straight-edge and combustion surface with a thickness gauge. Cylinder heed Zombustion surface distortion Standard Wear limit Refer to the section “2.2 Nominal and Allowance Val Thickness gauge (Measuring the combustion ) ‘surface distortion (3) Visually check to see if the combustion surface is free from discoloration, cracks, and crazing. In addition, use the color check kit for cracks and crazing. 424 2, Intake/exhaust valve seats (1) Valve sinking Over long periods of use and repeated lap- pings, combustion efficiency may drop. Measure the sinking depth and replace the valve and valve seat if the valve sinking depth exceeds the standard value. Stoners [Weer ii Inteke 7 Yate | valve | Rater tothe soation "3:2 Siro Eau | Nominal and Allowance Vale” valve So Cem oO gst tp (Measuring the valve sinkage) 443990404, ENGINE vehi. aig Ste (2) Width and angle of the valve seat Remove carbon deposits from the seat surface. Measure width and angle of the seat using vernier calipers end an angle gauge. Standard Limit Intake width | Exhaust | peter to the section “3-2 Vane | intake | Nominal and Allowance Valve" angle _| Exhaust (1) When the seat surface is worn or rough- ened slightly, lap the seat surface with @ valve compound mixed with oil to a smooth state. (2) When the seat surface is worn or rough- ened heavily, correct seat surface using a seat grinder or seat cutter, and finish it according to step (1) ‘Grindstone [Procedure for Using The Seat Grinder and Seat Cutter] (1) Correct the roughened seat surface with a seat grinder or seat cutter Seat grinder ‘Angle 8 (degrees) 0 Intake valve Exhaust valve 46 (2) When the seat width is enlarged from the initial value, correct it by grinding the seat surface with a 70 degrees seat grinder or seat cutter. Then, grind the seat to the standard width with a 50 degrees grinder % When using a seat cutter, evenly apply pressure taking care of avoiding uneven cutting. 4.2.2 443990404, ENGINE oon ee ((Gaseeyacueswteson Grind to @ smalior dimension than the outer diameter of tho Ze (Valve seat correction angle) (3) Knead valve compound with oil and finish Weld the valve with valve seat the valve seat by lapping. oe KI any valve requires correction, be sure to measure the oil clearance between the valve stem outside dia. and valve guide yinder heed — inside dia. If the oil clearance exceeds the limit. replace the valve or valve guide be- fore correcting the valve seat surface. (For oil clearance between the valve and valve guide, refer to section 3 in this chapter.) Valve seat (4) Finally, lap the valve using only oil XK 1. Alter the valve seat is corrected, thor- oughly clean the valve and cylinder head using diesel off or the like. Thor- oughly remove the valve compound or grindstone powder. 2. For slightly poor contact, take steps (3) and (4). 423° 443990403 4, ENGIN: Intake/exhaust valve (1) Wear and bend of the valve stem Replace a valve stem if bent or worn bad- ly. In this case, replace the valve guide at the same time. (2) Valve stem and valve guide Oil clearance is a difference between the valve guide inside diemeter measured with a three-point micrometer or a cylin- der gauge and the stem outside diameter measured with @ micrometer. When oil clearance is near the limit, replace both the intake/exhaust valve and valve guide with new ones. (Measuring the valve stem outside diameter) Intake valve Standard Wear limit Stem 0.0. Guide |.0 or clearance | Refer to the section “3-2 Exhaust valve om 0.0, | Nominal and Aliowance Veive* Guide 1.0 OW clearance 42k (3) Thickness of valve head Measure the thickness of the valve head with a micrometer When the measured value is near the wear limit, replace the valve with a new one Standard | Weer limit inate Thiekness | valve” | taro the section 32 ofvaie Favs | Nominal ond alionance Valve" tee 43990094, ENGINE [Replacing the Valve Guide] (1) Extract the valve guide from the cylinder head using the valve guide extraction tool. (2) In a container containing liquefied nitro- gen, ether or alcohol together with dry ice, put the valve guide to cool it. Then hit the sufficiently cooled valve guide to fit into the cylinder head using the valve guide insertion tool. (3) After inserting the valve guide, finish the inside of the valve guide with @ reamer. (4) Check the projection of the valve guide. Standard Wear limit Refer tothe section “3-2 Norninal and Allowance Valve" Valve guide projection ‘Valve guide insertion tool Valve guide projection Valve guide Projection EA (Valve guide projection) 4, Valve stem seal [Time of Replacement] (1) When oil loss is found excessive (2) When the valve stem seal is removed. (3) When intake/exhaust valves are removed. [Precautions on Installation] Make sure that the entire surface of valve stem is smooth, and sufficiently apply lubri- cating oil to the valve stem before reassem- bling intake/exhaust valves. Vale stom soal Valve guide ylindor head (stoned portion indicates |) where to apply lubricating oll. 425 443990404, ENGINE 5. Checking the valve spring (1) Visually check to see if the valve spring is free from flaws and corrosion (2) Measure the free length (length of the spring) and inclination (squereness of the side of the coil) Standard Wear limit Free length Valve [Inclination | Refer tothe section “3-2 soring Nominal and Allowance Valve" Tension (kg) teby nm (Measuring the valve spring inclination) 6. Checking valve spring holder and cotter Check contact of the inner surface of the valve spring holder with the circumference of the cotter as well as contact of the inner circum- ference of the cotter with the notch on the head of the valve stem. If such contact is un- even or if the cotter sinks, replace the cotter with a new one. Indination ‘Surface plato (Measuring the Inclination of vaive spring) 42.6 443990404, ENGINE — ee 4-2-2 Cylinder Block 1. Checking the cylinder block (1) Visually check to see if the cylinder block is free from water leak, oil leak and cracks. If any cylinder block is suspected to be cracked, check it by color check. (2) Replace the cylinder block if badly dam. aged and incorrectable. (3) Thoroughly clean each oil hole. Make sure e that it is not clogged. 2, Measuring the bore and distortion of the cylin- der Measure the bore of each cylinder with e cylinder gauge. Measure the cylinder at point 8, approx. 20mm below the crest of the liner, and et points b and c at equal pitch (ab = b-c) Obtain distortion (roundness and cylindricity of each cylinder) from the measured values as follows: © Roundness: Difference between max. and min. bore values on the same cross section of each liner OCylindricity Difference between max and min. bore values in the same direction of each liner Honing (honing and boring) is required when the measured value exceeds the limit. For oversized piston and piston ring, refer to section “4-2-4 Piston and piston ring” 427 (Measuring the cylinder bore) A Note: Measurement should be made at a,b and © In the directions of A and & Cylinder bore measuring (positions ) 443990404, ENGINE Standard Wear limit Cylinder bore Rotor to the section “3-2 Cylinder roundness | Nominal and Allowance Valve" Cylindricity 3. Honing (1) Practice of honing Honing or boring the cylinder if unevenly worn, flawed, or otherwise damaged. Slight uneven worn, flaws, etc. may well be only honing with a Flex-Hone. However, sig- nificant uneven wear should be first bored and then honed. It is important to take into careful consideration as to whether the cylinder can attain perfect roundness after honing, boring, or both, considering maximum wear. In addition, carefully study @s to whether prepared oversized pistons and piston rings are ap- plicable. (For the oversized piston and piston ring, refer to section "4-2-8 Piston and Piston Ring”.) 428 (Flex-Hone) (2) Procedure for using the Flex-Hone It is common practice to use the Flex- Hone for honing. The procedure for using appears in the following table. Any material must allow for approx. 1/1000mm when honed with the Flex-Hone. 1, Necessary items Flex-Hone, power drill, and honing fluid Flex-Hone | Applicable bore eae Yanmar code No. mam ‘STNETBA/B2A Teer 29400-92420 78 080 S/ATNERS ‘29400-92430 831095 Honing quid 443990404. ENGINE 2. Handling procedure Apply the honing fluid to the Flex-Hone. Insert the Flex-Hone into the cylinder while turning it, move it up and down for about 30 sec for a cross hatch angle of 30 to 40 degrees. Extract the Flex-Hone while turning it Use the Flex-Hone at a speed of 300 to 1200 RPM. Use of the Flex-Hone at a higher speed may be hazardous. Never insert into or extract from the cylinder the Flex-Hone. with the power rill left stopped. 4. Overhaul of cylinder (Reference) Service life of slooveless cylinder block (Hs) He= 3H) ‘Time for boning and honing (H,) (He= 15H Time for horing (Hi) Incroaso in LO.C. increase in L.O.C, : . or biow-by Increase in LOC. ‘or blow-by erblowby Honing Boring Consideration con the applicability of oversized pistons and piston rings 4.2.9 44399040