Yanmar Mini Excavator SV15VT Service Manual MMB73ENMA00100

SERVICE
MANUAL
MINI EXCAVATOR
SV15VT
CHAPTER 1
GENERAL CAUTIONS FOR MAINTENANCE WORK
1-1 Correct Work...........................................................................................1-1

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

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

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

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

Not good good
1-5
MAINTENANCE WORK
1-9 Specifications of Hydraulic Hose
Specifications of the hydraulic hoses can be known by the part descriptions as explained below. (For the parts num-
ber, please refer to our Parts Catalog.)
Description ..................... Hose P 2 06 AB 075 W

1 2 3 4 5 6 7 8
8 Other accessories
1 Part name No accessories...Blank
O-ring ....................... 1
2 Hose material
Rubber hose ........... G 6 Total length 7 Hose protector
Wear-resistant high (Unit : cm) Coil spring ............... W
pressure rubber Coil tube .................. S
hose ....................... H Wire braid ................ B
5 Combination of fitting Tube (Rubber) ......... R
Plastic hose ............ P
Tube (Vinyl) ............. V
Wear-resistant Fitting type Code Sponge rubber ......... P
plastic hose ............ F Hose cover ............... K
R(PT)
Taper pipe No protection ..... Blank
A
3 Recommended thread R (PT)
working pressure
G(PF) Straight pipe
psi(Mpa) thread G (PF)
Over 2986 (20.6) ..................... 1 with male 30 B
30°
2489 to 2986 (17.2 to 20.6) ..... 2 degrees seat
1991 to 2489 (13.7 to 17.2) ..... 3 90 degrees
1564 to 1991 (10.8 to 13.7) ..... 4 90° bent type.
995 to 1564 (6.9 to 10.8) ......... 5 Straight pipe
427 to 995 (2.9 to 6.9) ............. 6 thread G (PF) C
with male 30
213 to 427 (1.5 to 2.9) ............. 7 G(PF) 30° degrees seat
Below 213 (1.5) ....................... 8
4 Nominal dia. (inch)

1 / 8" ......................... 02
Without fitting Y
3 / 16" ....................... 03 List of pipe threads
1 / 4" ......................... 04 Symbol Name
3 / 8" ......................... 06 *For the combination of fitting,
refer to the list on the following G (PF) Straight pipe thread
1 / 2" ......................... 08 page. R (PT) Male taper pipe thread
5 / 8" ......................... 10
Rc (PT) Female taper pipe thread
3 / 4" ......................... 12
1" .............................. 16
The example hose, P 2 06 AB 075 W stands for :

2 3 4 5 6 7
2 Material : Plastic
3 Working pressure : 2489 to 2986 psi (17.2 to 20.6 MPa)
4 Nominal dia. : 3 / 8"
5 Fitting type : Taper pipe thread R (PT) and straight pipe thread G (PF) with male 30 degrees seat.
6 Length : 29.5 in. (75 cm)
7 Hose protector : Coil spring
1-6
MAINTENANCE WORK
5 Combination of fitting
Fitting type Code Fitting type Code

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

Straight pipe thread G groove
D S
(PF) with male 30
G (PF) degrees seat O-ring
45° 45 degrees bent type.

Straight pipe thread G O-ring One-touch fitting (male)
E T
(PF) with male 30
G (PF) degrees seat
G (PF) Straight pipe thread G
30°
(PF) with male 30 F 90°
degrees seat
90 degrees elbow straight
pipe thread male 30 V
degrees seat
O-ring flange type G
G (PF)
30°
90°
90 degrees bent O-ring
flange type H
Eyejoint with O-ring
W
45 degrees bent O-ring O-ring groove groove
45°
flange type J
Straight pipe thread with

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

Straight pipe thread G 90° Gauge port
L
(PF) with male 30 90 degrees elbow straight
G (PF) degrees seat G (PF) pipe thread with gauge Z
NPTF
port plug male 30
Taper pipe thread NPTF M degrees seat
30°
Without fitting Y
UNF
37° UNF, thread with female Note :
37 degrees seat N
According to the combination of bending or elbow fittings, some
hoses require drawings or original hoses to locally manufacture.
1-7
MAINTENANCE WORK
1-10 Air Release of Hydraulic Equipment
When operating the machine after disassembly or parts replacement of the hydraulic equipment, piping, etc., be
sure to release air from the hydraulic system. This is necessary to prevent seizure and cavitation of the hydraulic
equipment. If the air is left in the hydraulic system, the air is compressed or expanded depending on the load, having
an adverse effect on the smooth operation of the hydraulic equipment and shortening the service life.
1. Air Release of Variable Displacement Piston Pumps

1) Make sure that all joints and fitting are not loosened.
2) Put a specified quantity of hydraulic oil into the hydraulic oil tank.
Note :
1. Set the machine at the oil level check position.
2. Keep the oil supply cap of the hydraulic oil tank removed.
3) Run the engine at low idling speed for 5 to 10 minutes.
4) Check the oil level in the hydraulic oil tank. If the oil level is lower than the specified level, supply the hydraulic oil
to the tank after stopping the engine.
5) Run the engine again at low idling speed for a few minutes.
6) Check the oil level and supply the hydraulic oil to the specified level. Then install the oil supply cap.
2. Air Release of Each Hydraulic Component

Run the engine at medium speed and activate the respective circuits for about 10 to 15 minutes.
1-8
MAINTENANCE WORK
3. Air Release of Hydraulic Cylinders

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

(50 to 100 mm) (50 to 100 mm)
Retraction stroke end Retraction stroke end
Note :
The extension and retraction stroke is up to 1.97 in. (50 mm) from each stroke end for the blade cylinder.
3) Then, Fully Extend and Retract the Cylinder 3 or 4 Times.
4. Air Release of Hydraulic Oil tank

Replace the oil supply cap of the hydraulic tank with the vacuuming cap.
Connect the vacuuming cap to the vacuum compressor, vacuum the air in the hydraulic oil tank.
ø8 (Unit: mm)
ø6 25
R2
7
16
HEX41 can be used R1
Note:
*55
" " dimensions

* be changed
3.5
can
*35
R0.7
G(PF)1
ø4
*11
29±0.1
O-ring: P29
ø41 and over
Material: SS or Aluminum
Vacuuming Cap
044068-00EN01
1-9
CHAPTER 2
TECHNICAL DATA
2-1 Specifications...................................................................................... 2-1-1

2-2 Outline Drawing and Working Area .................................................... 2-2-1
2-3 Weight List of Main Parts .................................................................... 2-3-1
2-4 Lifting Capacity List............................................................................. 2-4-1
2-5 Specifications for Attachment ............................................................. 2-5-1
2-6 Periodic Inspection and Servicing....................................................... 2-6-1
2-7 Fuel, Lube Oil and Grease Recommended ........................................ 2-7-1
2-8 Hydraulic Circuit Schematic ................................................................ 2-8-1
2-9 Wiring Diagram ................................................................................... 2-9-1
2. TECHNICAL DATA
2. Technical Data
2-1 Specifications
Item Unit SV15VT

Main specifications of machine
Dimensions
Overall length Standard 3385
(Transportation position) W/ long arm 3380
Transportation position 2335
Overall height
Cabin Traveling position 2335
Full machine width
Overall width 980 / 1170
(std/extended frame)
mm
Transportation position 2325
Overall height
Canopy Traveling position 2325
Full machine width
Overall width 980 / 1170
(std/extended frame)
Tumbler center distance (Steel track / rubber track) 1035
Track gauge (std/extended frame) 750/940
Minimum ground clearance 160
Traveling performance
Low speed (Forward/Reverse) km/hr 1,9
Steel track
High speed (Forward/Reverse) km/hr 3,7
Travel speed
Low speed (Forward/Reverse) km/hr 1,9
Rubber track
High speed (Forward/Reverse) km/hr 3,7
Permissible water depth limit mm 300
Work performance
Width (Standard) mm 300
Bucket [Standard. JIS heaped capacity] m3 0,02
Number of teeth / Installation method pcs. 3 / Rubber pin lock type
Work range
With blade raised (short arm/long arm) mm 2330 / 2470
Maximum
digging depth With blade on the ground
mm 2465<2480>/2605<2620>
(short arm/long arm <long blade>)
Maximum depth of vertically digging (short arm/long arm) mm 1430/1440
Maximum dumping height (short arm/long arm) mm 2445/2555
Minimum front swing radius Short arm mm 1520
(with boom in front center) Long arm mm 1545
Minimum front swing radius Short arm mm 865
(with boom in full swing) Long arm mm 870
2-1-1
2. TECHNICAL DATA
Item Unit SV15VT

Main specifications of machine
Work performance
Rear end swing radius mm 980
Left degrees 75
Cabin
Right degrees 60
Boom swing angle
Left degrees 75
Canopy
Right degrees 60
Bucket kN 12,9
Maximum digging force
Arm <long arm> kN 7,4 <6,7>
Maximum tractive force Rubber track kN 13,3

Maximum swing inclination angle (with standard bucket) degrees 20 or more
Swing speed rpm 9,4
Fuel consumption in practical Maximum idling speed L/h 2,1
operation Eco mode L/h -
Blade
Width <extended> × Height mm 980<1170> x 235
Capacity <extended> m3 0,049<0,059>
Standard
Lift above ground level <long blade> mm 270<400>
Digging depth <long blade> mm 270<380>
Mean contact pressure
Cabin kgf/cm² 0,3
JIS Rubber track
Canopy kgf/cm² 0,28
Mass
Cabin kg 1555
Machine mass Rubber track
Canopy kg 1465
Cabin kg 1685
Operating mass Rubber track
Canopy kg 1595
2-1-2
2. TECHNICAL DATA
Item Unit SV15VT

Hydraulic equipment
Hydraulic pump
Engine → CF Coupling
Drive method -
→ Pump (Direct drive)
Fixed displacement gear
Type of main pump -
pump
Number of pumps pcs. 2
cm3/rev 5,5x2
Theoretical discharge volume
Maximum P.T.O. discharge volume L/min 30
Control valve
Number of connected valves pcs. 11
System relief set pressure P1, P2 MPa 20,5
Boom (at rod end) MPa 24
Boom (at bottom end) MPa 17,5
Arm (at rod end) MPa -
Arm (at bottom end) MPa 23
Bucket (at rod end) MPa -
Circuit relief set pressure
Bucket (at bottom end) MPa 24
Boom swing (at rod end) MPa -
Boom swing (at bottom end) MPa -
Blade (at rod end) MPa 11,1
Blade (at bottom end) MPa -
2-1-3
2. TECHNICAL DATA
Item Unit SV15VT

Hydraulic equipment
Cylinder
Stroke mm 452
Inside diameter mm 55
Boom Piston rod diameter mm 30
Up (Ground - Max. height) sec. 1,8
Speed
Down (Max. height - Ground) sec. 2,0
Stroke mm 431
Arm Piston rod diameter mm 30
Full stroke for digging sec. 3,6
Speed
Full stroke for dumping sec. 2,4
Stroke mm 332
Bucket Piston rod diameter mm 30
Full stroke for digging sec. 2,8
Speed
Full stroke for dumping sec. 1,9
Stroke mm 125
Blade Piston rod diameter mm 35
Up (Ground - Max. height) sec. 2,0
Speed
Down (Max. height - Ground) sec. 2,4
Stroke mm 374
Boom swing Piston rod diameter mm 30
Full stroke to the right sec. 4,2
Speed
Full stroke to the left sec. 4,2
Stroke mm 198
Extension Piston rod diameter mm 30
Full stroke extension sec. 3,2
Speed
Full stroke retraction sec. 2,6
Swivel joint
G 1/4 × 15
Swivel joint port diameter × Number inch × pcs.
+ G 3/8 ×
2-1-4
2. TECHNICAL DATA
Item Unit SV15VT

Hydraulic equipment
Motor
Type - Orbit motor
Displacement cm3/rev 195

Swing motor
Type - Cross relief valve
Brake valve
Relief set pressure MPa 14.2 to 14.7
Variable displacement
Type -
piston motor
Displacement (Low/High) cm3/rev 245 (Low)/ 490 (High)
Type - Counterbalance valve

Travel motor Brake valve
System pressure MPa 20,6
Shockless valve - -
Parking brake - -
Type of reduction gear - -
Hydraulic oil tank

Hydraulic oil amount (Tank capacity / Others) L 19,5 / 9
Type - Strainer
Suction filter Filtration area cm² 440
Filtration accuracy u 90
Type - Bypass
Filtration area cm² 925

Return filter
Filtration accuracy u 10
By-pass valve opening pressure MPa 0.3
Locking device
Lever lock - Oil pressure controlled
Boom swing lock - Oil pressure controlled
Swing lock - Mechanical brake
Cut off valve
Number of valves pcs. 2
Relief set pressure (P4) MPa 3.0
Swing device
Swing bearing - Planetary gear

(with reduction mechanism)
Swing motor shaft gear →
Power transmission -
Swing gear
Type of brake - Oil pressure controlled
Brake mounting position - Swing motor
2-1-5
2. TECHNICAL DATA
Item Unit SV15VT

Undercarriage
Shoe width mm 230
Rubber track Lug height mm 17
Core metal pitch mm 72
Track carrier roller Manner of support - Guide
(Upper roller) Quantity (One side) pcs. 1
Number of shoe slide plates (One side) pcs. -
Quantity (One side) pcs. 3
Track roller
Bearing - Ball bearing
(Lower roller)
Sealing - Shaft seal
Quantity (One side) pcs. 1
Idler wheel Bearing - Ball bearing
Sealing - Shaft seal
Number of sprocket teeth pcs. 14
Track tension adjustment - Grease cylinder
2-1-6
2. TECHNICAL DATA
Item Unit SV15VT

Engine
Main specifications
Engine model - 3TNV70-MBVA
Vertical type series water-
Type -
cooled 4cycle diesel engine
Combustion system - Indirect injection
Number of cylinders - Bore × Stroke pcs - mm × 3 - 70 × 74

mm
Total displacement cm3 854
Rated output / engine speed (GROSS) kW/rpm 12,1 / 2600
Maximum torque / engine speed (N•m/rpm) 48,1 to 52,4 / 1800
Specific fuel consumption 279 at rated output

g/kW•h
Maximum idling speed rpm 2755 to 2805
Forced lubrication
Lubricating method -
with trochoid pump
Compression pressure (at 250 rpm) MPa 3,24
Cylinder head
Intake valve Open b TDC degrees 7 to 17
timing Close a BDC degrees 35 to 45
Exhaust valve Open b BDC degrees 35 to 45
timing Close a TDC degrees 7 to 17
Intake valve clearance (Cold engine)
mm 0,15 to 0,25
Exhaust valve clearance (Cold engine)
Intake valve seat angle degrees 120
Exhaust valve seat angle degrees 90
Piston
First compression Ring shape - Keystone
ring Ring quantity pcs. 3
Second Ring shape - Tapered face
compression ring Ring quantity pcs. 3
Bevel cutter
Ring shape -
Oil-ring (with coil expander)
Ring quantity pcs. 3
2-1-7
2. TECHNICAL DATA
Item Unit SV15VT

Engine
Governor
Name - -
Type - Centrifugal-all speed governor
Fuel feed system
Fuel filter - Filter paper element
Fuel filter filtration area cm² 2000
Oil/water separator - Mesh filter

Feed pump - Electrolical
Lubrication system
Lubrication pump - Trochoid pump
LO pressure regulating valve opening pressure MPa 0,29 to 0,39
LO filter - Full flow filter
LO filter filtration area cm² 800
Filter valve opening pressure MPa 0.08 to 0.12

Operating pressure of alarm switch MPa 0.04 to 0.06
Cooling device
Cooling system - Water-cooling (Radiator)
Fan belt size - A35
Thermostat opening temperature ºC 82
Thermostat full-open temperature ºC 95
Radiator cap pressure kPa 88.3
Blade 5 × 290
Radiator fan
pcs.×Ømm
Operating temperature of water temperature alarm switch ºC 107 to 113

Air cleaner
Type - Cyclone type
Filtration area cm² 4600
Fuel injection pump
Injection pump type - YPES-3ML
Injection pump plunger diameter mm 6
Injection pump cam lifting height mm 7
Fuel injection timing (FIT) degrees 15 to 18
Firing order - 1-3-2
Nozzle
Type NP-DN0PDN 159
Ømm
Nozzle hole diameter × Number of holes 1,0 × 1
×pcs.
Spray angle degrees 5 to 10
Fuel injection pressure MPa 11,8 to 12,8
2-1-8
2. TECHNICAL DATA
Item Unit SV15VT

Engine
Starting device
Cold starting aids - Quick glow plug
Starting aids capacity V-W 12-120
Battery type (JIS) - 65B24
Battery voltage - 5 hrs rate capacity V - Ah 12-45
Electrical equipment
Type Magnet
Alternator Nominal output V-A 12-40
Rated speed rpm 3500
Type RS5121
Regulator
Regulation voltage V 14.0 to 16.0
Type Reduction type
Starter motor Nominal output V - kW 12 - 1.4
Engagement - Magnet shift
Liquid Crystal Display (LCD) Monitor light V-W -
Horn V-W 12 - 18
Blade fuse A × pcs. 20 x1, 15 x 3, 10 x 6, 5 x 7,
Fuse 2x2
Slow blow fuse A × pcs. 80 × 1, 60 x 3
Boom light V-W 12 - 25
Room lamp (for cabin) V-W 12 - 5
Wiper motor (for cabin) V-W 12 - 23
Cabin heater (for cabin) V-W 12 - 83
Power outlet (for cabin) V-W 12 - 120
Beacon V-W 12 - 9
2-1-9
2. TECHNICAL DATA
2-2 Outline Drawing and Working Area
Unit : mm
A 445 O 3385 3380
B 300 P <Long blade> 3750<4065> 3745<4060>
C 515 Q 3710 3850
D 1109–205 R 3775 3910
E 209–115 S <Long blade> 2465<2480> 2605<2620>
F 980–11709 T 770 585
G R1050 U 1430 1440
H <swing> 1520<865> 1545<870> V 2330 2470
I <Long blade> 270<400> Y 2445 2555
J 235 Z 3385 3490
K Cabin / 2335/2325 160

Canopy AA
L <Long blade> 270/380 AB 230
M <Long blade> 1090<1405> AC 750–9409
N 1410 AD 980–11709
2-2-1
2. TECHNICAL DATA
2-3 Weight List of Main Parts

[Unit: kg]
SV15VT
Equipment No. Part Canopy Cabin
Front implement 1 Bucket Ass’y 32
2 Bucket arm & link Ass’y 11
3 5
3 Bucket cylinder Ass’y 9,2
4 4 Arm <Long Arm> Ass’y 32,4 <35,8>
2 7
5 Arm cylinder Ass’y 10,3
6 Boom Ass’y 71,1
1 6 7 Boom cylinder Ass’y 12,3
8
8 Boom bracket Ass’y 36,1
Undercarriage 1 Idler Ass’y 16,5 x 2
4 9 10 6 7 2 Track roller Ass’y 4x6
3 Sprocket Ass’y 6x2
4 Track frame (L/R) Ass’y 64,7 / 58,1
5 Rubber track Ass’y 46 x 2
6 Blade cylinder Ass’y 7,5
7 Blade Ass’y 73,5
8 Travel motor Ass’y 24
1 9 Swing bearing Ass’y 19,5
8 3 5 2
013866-00X 10 Swivel joint, hose & fitting Ass’y 16
Upperstructure 1 Engine hood Ass’y 8,9
2 Canopy/Cabin Ass’y 84,8 / 167
3 Hydraulic oil tank with filter Ass’y 8,0
4 Operator's seat & mount Ass’y 49,6
5 Engine Ass’y 116
2 6 Turning frame Ass’y 167,9
7 Control valve, fitting & hoses Ass’y 30
4
8 8 Control Ass’y 5
1 9 Battery Ass’y 12
10 3 10 Floor covers 3,7
5 11 Hydraulic Pump 5
12 Swing motor 23
7 12 9 6 11 - Fuel tank 4,7
- Boom swing cylinder 10,8
2-3-1
2. TECHNICAL DATA
2-4 Lifting Capacity List
1) Cabin
Machine with cab and rubber tracks.

A = Tilt from the rotation axis
B = Attachment point height (compared to the tracks)
* = hydraulic limits of the lifting force
2-4-1
2. TECHNICAL DATA
2) Canopy
Machine with canopy and rubber tracks.

A = Tilt from the rotation axis
B = Attachment point height (compared to the tracks)
* = hydraulic limits of the lifting force
2-4-2
2. TECHNICAL DATA
2-5 Specifications for Attachment

Q Unit: in. (mm)
Item/Model SV15VT
Dimensions Short Long
A 109
R P
B 105
C 206
D 200
E1 External width of arm end boss 105
S E 1' Internal width of bucket pin boss 106,5
E2 External width of bucket link boss 105
J K E 2' Internal width of bucket pin boss 106,5
O E 3 External width of bucket arm pivot pin boss 105
O’
F1 External width of bucket arm 146,5
G 1 Bucket pin diameter 30
c G 1' Arm end boss diameter 70

M
G 2 Bucket pin diameter 30
b
I G 3 Bucket arm pivot pin diameter 30
D C
II G 3' Bucket arm pivot pin boss diameter 60
B
d
H 1 Bucket cylinder rod end pin diameter 30
a I1 Bucket cylinder rod end boss thickness 40
A
T H 2 Bucket cylinder bottom pin diameter 30
II
048001-00EN00
I2 Bucket cylinder bottom boss thickness 40
J Cylinder length when it is fully retracted 584
E3 K Cylinder length when it is fully extended 916
G3
M 4,5
G3’
b O 855 995
O' 960 1100
C
I1 P 190
G3’ b
Q 146,6
R 306 446
H1
c S 185,5
G1’ a
T -
E2 D
E1
048002-00X00
View in the direction of

an arrow I of the arm G2
d
U A
F1
E1’
G1’ G1
a
E2’
E1
048003-00X00
Cross-sectional view along

048029-00X00 the line II-II (a-d-c-b)
2-5-1
2. TECHNICAL DATA
2-6 Periodic Inspection and Servicing
Check/Adjust/Supply ◇ Clean ⬜ Oil and grease ⬛ Replace � Oil sample � + = and / = or
Every Every Every Every Every Every

Check & Service items Daily 500h 1000h 2000h
50h 100h 250h
General Missing or broken parts ◇
* * **
Tightening of nuts and bolts ◇
Engine condition, exhaust and inlet hoses ◇
Machine overall ⬜
Operation manual ◇(1) ◇ ◇ ◇
Greasing Greasing points ⬛
Swing gear and crown ⬛ ⬛ ⬛ ⬛ ⬛ ⬛
Bearing rollers and bearings, idler wheels ◇ ⬛(2) ⬛ ⬛ ⬛
Engine Diesel filter �(1) � � � �
Drain ◇
Water separator Pre fuel filter � � � �
Bowl (if equipped) ⬜ ⬜ ⬜
Oil ◇ �(1) � � �
Oil filter �(1) � � �
Cooling fluid & leakage ◇ �
Radiator fins ◇+⬜
Belt ◇ ◇ ◇ ◇ ◇ �
Fuel hose, coolant hose ◇/�
Performance of engine control and engine speed ◇(1) ◇ ◇ ◇
Governor lever and accelerator device ◇(1) ◇ ◇ ◇
External air cleaner element ⬜(3) �(3) � � �
Air cleaner Safety cartridge element (if equipped) � � �
Intake and exhaust valves ◇
Injectors and injection pressure ⬜+◇
Crankcase breather system ◇
Engine silent-bloc & bracket ◇ ◇ ◇ ◇ ◇ ◇
Travel Tracks, rubber tracks & pads ◇
Track tension ◇
Play of travel lever ◇(1) ◇ ◇ ◇
Performance of travel ◇(1) ◇ ◇ ◇
Hydraulic Oil ◇ �(1) �/�(4) � �
Aspiration filter ⬜/�(4) ⬜/�(4) ⬜/�(4)
Ventilation filter � �
Hydraulic oil return filter �(1) �(4) � � �
Other filter �(4) � � �
Accumulator ◇(1) ◇ ◇ ◇
Pump pressure ◇(1) ◇ ◇ ◇
Play of control lever ◇(1) ◇ ◇ ◇
Low pressure ◇(1) ◇ ◇ ◇
Blade control ◇(1) ◇ ◇ ◇
Boom swing ◇(1) ◇ ◇ ◇
Boom ◇(1) ◇ ◇ ◇
Arm ◇(1) ◇ ◇ ◇
Bucket ◇(1) ◇ ◇ ◇
Options ◇(1) ◇ ◇ ◇
Electric Time counter ◇ ◇ ◇ ◇ ◇ ◇ ◇
Wire breakage, short circuits, loosened terminals ◇ ◇ ◇ ◇ ◇ ◇ ◇
LCD monitor ◇ ◇ ◇ ◇ ◇ ◇ ◇
Battery ◇(1) ◇ ◇ ◇
Final Sign inspection card and return to YANMAR ◇ (1) ◇ ◇ ◇ ◇
* or annualy first time occurs
** or two years
(1) First time 50-80h visit
(2) If machine does lot of digging line during one day (fiber, drop pipe, drainage…).
(3) If machine is used at dusty worksites.
(4) If a hydraulic hammer is used more than 30% of the machine operating time.
��Collect oil sample and keep analysis report. According to result replace oil if necessary.
2-6-1
2. TECHNICAL DATA
Scheduled maintenance points of the machine (lubrication, filters...)

IMPORTANT
These are frequencies : for example the operations to be carried out every 50 hours
must be carried out at 50h, 100h, 150h, 200h, etc.
= Hydraulic oil
= Engine oil
= Hydraulic oil return filter
= Oil for travel gears (oil for travel gears cannot

be changed on this machine)
= Greasing points
= Air filter
= Fuel filter
= Oil filter
Dependent on technical modifications.
2-6-2
2. TECHNICAL DATA
2-7 Fuel, Lube Oil and Grease Recommended
Cooling fluid
Temperatures °C
Quantity prescribed (L)
-40 -20 0 20 40 60 80 100
3,8 Radiator
Long-life cooling fluid YANMAR POWER COOLANT B-6
0,4 the expansion flask
Engine oil
Temperatures °C
-3 -20 -10 0 10 20 30 40
5W30
10W30 2,8
15W40
Fuel
Temperatures °C
-20 -10 0 10 20 30 40
No. 1-D / No. 2-D 27,0
Hydraulic oil
Temperatures °C
-20 -10 0 10 20 30 40
VG46 19,5 in the tank
VG68 9,0 the rest
2-7-1
2. TECHNICAL DATA
2-8 Hydraulic Circuit Schematic
2-8-1
2. TECHNICAL DATA
2-9 Wiring Diagram
2-9-1
2. TECHNICAL DATA
2-9-2
2. TECHNICAL DATA
2-9-3
CHAPTER 3
SERVICE STANDARDS
3-1 Machine Performance......................................................................... 3-1-1

3-2 Engine................................................................................................. 3-2-1
3-3 Undercarriage ..................................................................................... 3-3-1
3-3-1 Rubber Track Specifications ...................................................... 3-3-1
3-4 Controls .............................................................................................. 3-4-1
3-5 Hydraulic Equipment........................................................................... 3-5-1
3-5-1 Hydraulic Cylinders .................................................................... 3-5-1
3-6 Implement ........................................................................................... 3-6-1
3-6-1 Front Attachments...................................................................... 3-6-1
3-6-2 Blade Moving Device ................................................................. 3-6-2
3-7 List of Tightening Torque .................................................................... 3-7-1
3-7-1 Machine ..................................................................................... 3-7-1
3-7-2 Engine........................................................................................ 3-7-4
3-7-3 Tightening Torque for General Bolts and Nuts .......................... 3-7-5
3-7-4 Hydraulic Fitting ......................................................................... 3-7-6
3-8 Pressure Adjustment .......................................................................... 3-8-1
3-8-1 Relief Valves .............................................................................. 3-8-1
3-8-2 Cut-Off Valve ............................................................................. 3-8-4
3. SERVICE STANDARDS
3. Service Standards
3-1 Machine Performance
Applicable model SV15VT

Item Measuring condition Unit Standard Allowable
Machine performance
Working speed
Boom speed Machine position
Max. cylinder extension Up 1,8 2,0

No load
sec.
013868-00E
• Engine: Rated speed

• Hydraulic oil temp.: 50 to 60°C Down 2,0 2,2
Bucket teeth grounded
• Excluding cushion
• Site: Firm, flat ground
Arm speed Machine position
Max. cylinder retraction Digging 3,6 3,8
No load
sec.
013869-00E
• Engine: Rated speed Dumping 2,4 2,6

Max. cylinder extension • Hydraulic oil temp.: 50 to 60°C
Bucket speed Machine position
Max. cylinder retraction Digging 2,8 3,0
No load
sec.
013870-00E
• Engine: Rated speed Dumping 1,9 2,1

Max. cylinder extension
• Hydraulic oil temp.: 50 to 60°C
Boom swing speed Machine position
Right
4,2 4,7
Max. cylinder retraction swing
013871-00X sec
Left
• Hydraulic oil temp.: 50 to 60°C 4,2 4,7
swing
Max. cylinder extension • Site: Firm, flat ground
• Full stroke
3-1-1

Machine performance
Working speed
Blade speed Machine position
Max. cylinder retraction Up 2,0 2,2
sec.
013872-00E
• Engine: Rated speed Down 2,4 2,6

Blade grounded
• Hydraulic oil temp.: 50 to 60°C
Machine position
High
19,5 21,4
speed
Travel speed sec.

013959-00E

• Hydraulic oil temp.: 50 to 60°C Low
37,9 41,7
• Site: Firm, flat ground speed
• Traveling time for 20 m after an
approach run of 5 m or more.
Machine position
High
90° to 105° 9,3 10,2
speed
013960-00E

Track speed • Hydraulic oil temp.: 50 to 60°C sec.
• Travel lever: Full throttle
(Floating crawler side)
• Float one side of the crawler. Low
18,1 19,9
Make a mark on the crawler. speed
After turning the floating crawler side more
than once, measure the time needed for 3
turns of the crawler.
3-1-2

Machine performance
Machine position
High 190 300

speed
013959-00E

• Hydraulic oil temp.: 50 to 60 °C mm /
Track deviation
• Site: Firm, flat ground 20 m
• Measure the deviation (x) in a travel distance
of 20 m after an approach run of 5 m or
more. Low
speed 150 300
20 m
X
10 m
013961-00E
Machine position
Traveling drift 15° mm 0 120

013962-00E
• Engine: stopped
• Hydraulic oil temp.: 50 to 60 °C
• Drift of the machine after 5 min. on a slope with an
inclination of 15 degrees.
Drift of cylinders
Machine position
Boom drift
0 15
(Cylinder rod retraction)
Same
No load
height
Arm drift 013963-00E
2 15
(Cylinder rod extension)
• Engine: stopped
• Hydraulic oil temp.: 50 to 60 °C mm
Bucket drift • Make the boom and bucket pins the same height.
• Measure the retraction or extension of each 0 9
cylinder rod after leaving the machine at the
above position for 10 min.
• Lift the blade to the highest position, and
Blade drift measure the cylinder rod extension after 10 min.
- -
3-1-3

Machine performance
Drift of cylinders
Machine position
No Same
load height
15°
Boom swing drift mm 0
013964-00E 9
• Engine: stopped
• Make the boom and bucket pins the same height.
• Park the machine on a slope with an inclination of 15
degrees and turn the upperstructure 90 degrees to the
crawler and engage the swing lock.
• Measure the cylinder rod extension after 10 min.
Machine position
Same
No load
height
013965-00E
Swing drift at stopping mm 76 84

• Make match marks on the outer race and the inner
race of the swing bearing (or the track frame).
• Measure shifted distance between both marks after
making one turn with no load.
Machine position
Same
No load sec. 31,6 33,3
height
Swing time 013965-00E
[rpm] [9,5] [9,0]

• Make one idling turn with no load, then measure the
time necessary to make 5 turns.
3-1-4

Machine performance
Machine position
Engine Engine
No Same stopped: stopped:
load height 2 140
15°
013964-00E
Swing drift mm
• Engine: stopped
• Park the machine on a slope with an inclination of 15
Engine Engine
degrees and turn the upperstructure 90 degrees to the
running: running:
crawler.
2 140
• Make match marks on the outer race and the inner
race of the swing bearing (or the track frame).
• Measure shifted distance or angle between both
marks after 5 min.
3-1-5
3-2 Engine
1) Nominal and Allowable Values
Applicable model 3TNV70-MBVA

Item Unit Standard Allowable limit
Cylinder head
Adjustment of valve clearance mm 0,15 to 0,25 -
Cylinder head distortion (Flatness) mm 0,05 or less 0,15

Intake mm 0,4 to 0,6 0,9
Valve sink
Exhaust mm 0,4 to 0,6 0,8
Intake degrees (°) 120 -
Valve seat angle
Exhaust degrees (°) 90 -
Valve seat correction angle degrees (°) 40, 150 -
Guide inside diameter mm 6,000 to 6,012 6,08
Intake valve 5,96 to 5,975

Valve stem outside diameter mm 5.90
Valve stem bend mm - 0,01
Guide inside diameter mm 6,000 to 6,012 6,08
Exhaust valve Valve stem outside diameter mm 5,9

5,945 to 5,960
Valve stem bend mm - 0,01
Projection from cylinder head mm 9,8 to 10,0 -

Valve guide
Installation method - Cold fitted -
Valve stem seal projection from cylinder head mm 10.9 to 11.2 -
Push rod bend mm Less than 0,03 0,03
Arm shaft hole diameter mm 12,00 to 12,02 12,07
Rocker arm and shaft Shaft outside diameter mm 11,966 to 11,984 11,94
Oil clearance mm 0,016 to 0,054 0,13
Free length mm 37,8 -

Valve spring
Squareness mm - 1,3
3-2-1

Cam shaft and timing gear train
End play mm 0,05 to 0,15 0.25
Bend (1/2 of dial gauge reading) mm 0,00 to 0,02 0,05
Cam lobe height mm 34,135 to 34,265 33,89
Bushing inside diameter mm 40,000 to 40,075 40,15
Gear end Camshaft outside diameter mm 39,94 to 39,96 39,905

Cam shaft
Intermedi-
Camshaft outside diameter mm 39,910 to 39,935 39,875
ate
Flywheel
Camshaft outside diameter mm 39,94 to 39,96 39,905
end
Shaft outside diameter mm 36,950 to 36,975 36,9
Idle gear Bush inside diameter mm 37,000 to 37,025 37,075
Timing
gear back- Crank, cam, idle, fuel pump gears mm 0,06 to 0,12 0,14
lash
Crank shaft and piston
Bend (1/2 dial gauge reading) mm - 0.02
Journal outside diameter mm 37,952 to 37,962 37,402
Bearing inside diameter mm 37,982 to 38,01 -

Con-rod
journals
Bearing insert thickness mm 1,503 to 1,509 -
Crank Oil clearance mm 0,02 to 0,058 0,11

shaft
Journal outside diameter mm 46,952 to 46,962 46,902
Bearing inside diameter mm 46,982 to 47,002 -

Main bear-
ing journals
Bearing insert thickness mm 2,009 to 2,014 -
Thrust
Crankshaft end play mm 0,111 to 0,25 0,28
bearing
3-2-2

Crank shaft and piston
Piston outside diameter (at 90° to piston pin) mm 69,96 to 69,99 69,915
Piston diameter measure (from piston bottom) mm 22.0 to 25.0 -
Piston Bore inside diameter mm 22 to 22,009 22,039
Piston pin Pin outside diameter mm 21,995 to 22 21,965
Oil clearance mm 0 to 0,014 0,074
Ring groove width mm 1,550 to 1,57 -
Ring width mm 1,47 to 1,49 1,45

Top ring
Side clearance mm 0,06 to 0,1 -
End gap mm 0,15 to 0,3 0,39
Ring groove width mm 1,54 to 1,56 1,66

Piston ring 2nd ring
Side clearance mm 0,05 to 0,09 0,21
End gap mm 0,18 to 0,33 0,42
Ring groove width mm 3,01 to 3,03 3,13

Oil ring
Side clearance mm 0,02 to 0,06 0,18
End gap mm 0,15 to 0,35 0,44
Wrist pin bush inside diameter mm 22,025 to 22,038 22,068
Small end Wrist pin outside diameter mm 21,991 to 22 21,963

Con-rod
Large end Side clearance mm 0,2 to 0,40 -
Tappet bore (block) inside diameter mm 21 to 21,021 21,041
Tappet Tappet stem outside diameter mm 20,927 to 20,96 20,907
Cylinder block
Cylinder inside diameter mm 70,01 to 70,02 70,2
Roundness mm
Cylinder bore 0,01 or less 0,03
Taper mm
3-2-3

Lubricating oil pump
Outer rotor outside clearance mm 0,12 to 0,21 0,3
Outer rotor side clearance mm 0,02 to 0,07 0,12
Outer rotor to inner rotor tip clearance mm - 0,16
Dimension 53,05 to 53,15

Inner clearance of Gear boss diameter mm 0,6
Clearance 0,3 to 0,5
inner rotor
Rotor diameter mm 0,6

Width across flat of gear boss mm 0,7
Inner rotor and Gear Clearance 0,2 to 0,6
boss clearance Dimension 49,95 to 50,05
Width across flat of rotor mm 0,7
Others
Intake/Exhaust valve clearance mm 0,15 to 0,25 -
Fuel injection pressure MPa 11,8 to 12,8 -
Compression pressure at 250 rpm MPa 3,14 to 3,34 2,45 to 2,65
At rated output MPa 0,29 to 0,44 -

Lubricating oil pressure
When idling MPa 0,06 -
Valve opening temperature °C 70-73 -

Thermostat
8 or above
Full opening lift and its temperature mm -
[at 85 °C]
2) Test and Adjustment Specifications
Fuel Injection Valve ID Mark Fuel Injection Valve Opening Pressure Fuel Injection Timing
12.3 to 13.3 MPa Refer to Section “4-3-9. Checking and

A
Adjusting Fuel Injection Timing”
Note:
The fuel injection pressure of a new fuel injection valve is decreased by approximately 72.5 psi (0.5 MPa) after about
5 hours of engine break-in operation. When adjusting a new fuel injection valve or after disassembly of a fuel injec-
tion valve for service, set the fuel injection pressure so that it is 72.5 psi (0.5 MPa) higher than the above pressure
range.
3-2-4
3-3 Undercarriage
3-3-1 Rubber track specifications [Unit: mm]

Measuring
Part Standard Wear limit
position
Rubber track specifications
(1) Rubber track
A 17 8
A
(2) Idler & shaft
A Ø25 
B Ø30 
C Ø36 
D 20 18
E 32 24
F Ø295 Ø287
3-3-1
[Unit : mm]

Measuring
Part Standard Wear limit
position
(1) Sprocket
B
A 9 -
B 32 20
A
(2) Track roller & shaft

A Ø25 −
D
B Ø30 −
C Ø67 -
B C E
D 58 -
A
E Ø130 -
(5) Slide plate
A 42,5 37,5
A
3-3-2
3-4 Controls

Item Measuring conditions Unit Standard Allowable limit
Controls
Operating force
Right control lever • Engine : stopped up: 0,7
(Boom & Bucket) • Hydraulic oil temp. : 122 to 140 °F (50 to 60 °C) down: 0,5
• Lever operating force : Measure the force by left: 0,7
hanging the spring scale on the lever grip. right: 0,8
• Pedal operating force : Measure the force by
Left control lever applying load as shown below. up: 0,7
(Arm & Swing) down: 0,7
Spring scale Press
kg left: 0,7
right: 0,7
high < low engine speed> 1,0

Accelerator lever
low < high engine speed> 2,1
Blade lever up: 2,9 / down: 3,2

Travel levers forward: 1,3 / backward: 1,4
Play of control lever & pedal
Right control lever • Engine : stopped up: -
(Front & rear / left & right) • Hydraulic oil temp. : 122 to 140 °F (50 to 60 °C) down: -
• Play of each control lever and pedal : Measure left: - -
Left control lever
the total play (front, rear, left and right) at the right: -
(Front & rear / left & right)
lever grip end or the pedal end.
up: 99
Blade lever Play Play 109
mm down: 98
forward: 14
Right travel lever 16
backward: 14
forward: 14
Left travel lever 16
016253-00E backward: 14
high>down: 92 101
Accelerator lever
down>high: 90
Control valve
Spool stroke
Boom
AB
Stroke
Bucket
Arm
Swing
Parallel-flow divider
Inlet
013982-00E
mm 6 7
Right travel A B Stroke
Left travel
Blade
Boom swing 013983-00E
Offset
3-4-1
3-5 Hydraulic Equipment

3-5-1 Hydraulic Cylinders
1 (Max. retraction length)
3 2 (Stroke)
7-1 7-2
5 4 6-2
6-1 8 (Rod nut)

Symbol Name
G (PF) Straight pipe thread
R (PT) Taper pipe thread (male)
Rc (PT) Taper pipe thread (female)
Unit: mm
Cylinder
Boom Arm Bucket Boom swing Blade Extension
No.
1 730 686 584 618 360 541
2 452 431 332 374 125 198
3 67 88 77 74 82 192
4 Ø 55 Ø 50 Ø 50 Ø 60 Ø 60 Ø 50
5 Ø 30 Ø 30 Ø 30 Ø 30 Ø 35 Ø 30
6-1 G 1/4 G 1/4 G 1/4 G 1/4 G 1/4 G 1/4
6-2 G 1/4 G 1/4 G 1/4 G 1/4 G 1/4 G 1/4
Standard Ø 35 Ø 30 Ø 30 Ø 35 Ø 30 Ø 35
7-1
Allowable limit Ø 35.5 Ø 30,5 Ø 30,5 Ø 35,5 Ø 30,5 Ø 35,5
Standard Ø 35 Ø 30 Ø 30 Ø 35 Ø 30 Ø 35
7-2
Allowable limit Ø 35,5 Ø 30,5 Ø 30,5 Ø 35,5 Ø 30,5 Ø 35,5
Thread size M24 x 2 M24 x 2 M22 x1,5 M22 x 1,5 M22 x 2,0 M22 x 1,5
8 Tightening torque (N•m) 410 to 430 470 to 490 300 to 320 300 to 320 220 to 250 300 to 320
Screw locking agent Loctite 242 / Three Bond 1324
3-5-1
3-6 Implement
3-6-1 Front Attachments
10 7
6
4 15
1
12
11
2
16
13 14
5
013511-00X
Unit : mm
Applicable model Wear limit

No. Measuring point
SV15VT Pin Bore of bush or hole
1 Boom swing fulcrum Ø50
2 Boom fulcrum Ø35
3 Boom swing cylinder, rod Ø35
4 Boom swing cylinder, bottom Ø35
5 Boom cylinder, bottom Ø35
6 Boom cylinder, rod Ø35
7 Arm fulcrum Ø35
8 Arm cylinder, bottom Ø30
-0.5 +0.5
9 Arm cylinder, rod Ø30
10 Bucket cylinder, bottom Ø30
11 Bucket cylinder, rod Ø30
12 Link “A” arm Ø30
13 Bucket fulcrum Ø30
14 Bucket “link A” Ø30
15 Track gauge change cylinder, bottom Ø35
16 Track gauge change cylinder, rod Ø35
Note : Allowable clearance is 1.0 mm.
3-6-1
3-6-2 Blade Moving Device
3
2
Unit: mm
Applicable model Wear limit

No. Measuring point
SV15VT Pin Bore of bush or hole
1 Blade cylinder, rod Ø 30
2 Blade cylinder, bottom Ø 30 -0,5 +0,5
3 Blade fulcrum Ø 30
Note : Allowable clearance between pin and bore of bush or hole is 1,0 mm.
3-6-2
3-7 List of Tightening Torque
3-7-1 Machine

Equipment Tightening torque
Thread size Adhesive
No Tightening part N•m
Engine / Electrical equipment
1 Engine mount vibroisolating rubber Nut M10 24,5 to 32,3
2 Engine × Engine mount (Front Left) M10×25 44 to 59 ThreeBond 1324
3 Engine × Engine mount (Front Right) M10×25 44 to 59 ThreeBond 1324
4 Engine × Engine mount (Rear Left) M10×25 44 to 59 ThreeBond 1324
5 Engine × Engine mount (Rear Right) M10×25 44 to 59 ThreeBond 1324
6 Engine mount (front) × carriage M12×30 116 to 138 ThreeBond 1324
7 Engine mount (back) × carriage M10×35 67 to 79 ThreeBond 1324
Fuel line
1 Water separator M8x65 23 to 27
2 Fuel filter M8x30 23 to 27
3 Fuel pump M6x16 9,5 to 11,5
4 Fuel level gauge - >10
5 Fuel tank drain plug - 8 to 12
6 Fuel tank bracket M10x25 46 to 54
7 Fuel tank M8x30 23 to 27
Electric
1 Battery bracket M10x30 46 to 54
2 Fuse box M6x20 9,5 to 11,5
3 Boom light bracket x boom M8x16 23 to 27
4 Travel alarm M6x20 9,5 to 11,5
5 Heater x heater bracket M5x13 1,2 to 1,6
3-7-1

Frame
1 Swing bearing x upper carriage M12x60 10.9T 116 to 137 ThreeBond 1324
2 Swing bearing × track frame M12x45 10.9T 112,2 to 132,6 ThreeBond 1324
3 Track frame center x track frame L/R M16x200 291 to 339 ThreeBond 1324
4 Track roller M12x25 116 to 138 ThreeBond 1324
5 Plate shoe slide x track frame M10x35 67 to 79 ThreeBond 1324
6 Travel motor x track frame M10x30 67 to 79 ThreeBond 1324
7 Sprocket x travel motor M10x30 67 to 79 ThreeBond 1324
8 Ext frame cylinder axis x track frame M16x45 291 to 339 ThreeBond 1324
9 Tie down point (option) x upper carriage - 116 to 137 ThreeBond 1324
Other
1 Safety switch (Cut-off lever) Locknut (Fine thread) 20 19.6 to 24.5
2 Control levers x seat mount M6x20 10
3 Arm rest x arm rest bracket M8x16 14 to 16
4 Engine cover lock security nut M10 10
5 Grid x right cover M6x12 2 to 2,5
6 Air cleaner M8x30 14,8
7 Air cleaner hose clamp - 2,6 to 2,7
8 Canopy support x upper carriage M12x35 127 ThreeBond 1324
9 Cabin x upper carriage M12x40 127 ThreeBond 1324
10 Cabin x upper carriage M12x85 127 ThreeBond 1324
3-7-2

Hydraulic equipment
1 Hydraulic oil tank breather - 14,7 to 15,3
2 Hydraulic oil tank temperature sensor M12x1,5 20 to 24
3 Hydraulic oil gauge x Hydraulic oil tank M10 9,7 to 10,3
4 Drain plug x Hydraulic oil tank - 11,7 to 12,3
5 Strainer mount x Hydraulic tank M8x12 23 to 27
6 Strainer x Strainer mount M56 26 to 30
7 Strainer x Suction hose x Suction pipe Hose clip 60 2,5 to 3,5
8 Suction hose x Hyd. pump inlet fitting Hose clip 48 2,5 to 3,5
9 Hydraulic pump inlet fitting - 90
10 Hydraulic pump outlet fitting - 30
11 Radiator mount x Hydraulic oil tank M8x12 14 to 16
12 Hydraulic cooler x Hydraulic hoses Hose clip 25 5
13 Hydraulic hoses x Return fiiting Hose clip 35 5
14 Hydraulic hoses x Return fiiting Hose clip 22 2,5 to 3,5
15 Hydraulic oil tank return fitting - 38 to 42
16 Return filter x Hydraulic oil tank M8x25 11,7 to 12,3 ThreeBond 1324
17 Drain return fitting - 31,5 to 38,5
18 Swivel joint x Lower carriage M10x25 67 to 79
19 Swing motor x upper carriage M12x35 67 to 79 ThreeBond 1324
20 Air cleaner hose clamp - 2,6 to 2,7
3-7-3
3-7-2 Engine
1) Tightening torque of major components fasteners

Unit: N•m
No. Item Thread size × Pitch Tightening torque Lubricating oil
1 Cylinder head bolt M9 × 1.25 53,9 to 57,9 Applied
2 Connecting rod bolt M7 × 1.0 22,6 to 27,5 Applied
3 Flywheel bolt M10 × 1.25 80,4 to 86,4 Applied
5 Crankshaft pulley bolt M12 × 1.25 83,3 to 93,3 Applied
6 Glow plug M10 × 1.25 14,7 to 19,6 Not applied
2) Tightening torque of major fuel system components fasteners

Unit: N•m
No. Item Tightening torque Lubricating oil
1 Fuel injector 49 to 59 Not applied
2 Fuel pump drive gear nut 59 to 69 Not applied
3 High-pressure fuel piping nuts 29 to 34 Not applied
4 Fuel return line nuts 24 to 33 Not applied
5 Fuel injection pump mounting nuts 23 to 28 Not applied
6 Fuel injection nozzle case nut 29 to 49 Not applied
3-7-4
3-7-3 Tightening Torque for General Bolts and Nuts

Tightening torque
Item Thread size × Pitch Remarks
[Unit : N•m]
M5 5,5 to 6,5
M6 9,5 to 11,5
M8 23 to 27
M10 46 to 54
M12 79 to 93
Nut M14 127 to 149
M16 198 to 230
M18 283 to 329
M20 402 to 464
M22 552 to 634
M24 691 to 798
M5 5,5 to 6,5
M6 9,5 to 11,5
M8 23 to 27
M10 46 to 54
M12 79 to 93
Hexagon head bolt 8.8T M14 127 to 149
M16 198 to 230
M18 283 to 329
M20 402 to 464
M22 552 to 634
M24 691 to 798
M5 8 to 9
M6 14 to 16
M8 34 to 40
M10 67 to 79
M12 116 to 138
Hexagon head bolt 10.9T M14 187 to 219
M16 291 to 339
M18 402 to 470
M20 570 to 662
M22 783 to 905
M24 981 to 1137
M27 1452 to 1674
3-7-5
3-7-4 Hydraulic Fitting

(1) Tightening torque of parallel pipe thread Example G
For 30° sheet type joint and the O-ring sheet type joint. Parallel pipe thread
(female)(male 30° sheet)
Unit : N•m
30°
Nominal designation of Tightening torque
screw thread
G (PF) Material : Steel, Cast iron
Parallel pipe thread (female)
G
1/8 13,7 to 16,7
1/4 22,6 to 27,5 30°
3/8 44,1 to 53,9

1/2 53,0 to 64,7
3/4 106 to 129 O-ring
1 124 to 151
1 1/4 150 to 183
1 1/2 186 to 226 017498-00E
(2) Tightening torque of taper pipe thread

Apply seal tape
Unit : N•m
screw thread
Example R
1/8 6,9 to 8,8 Parallel pipe thread (female)
1/4 9,8 to 14,7
3/8 29,4 to 39,2
017501-00E
1/2 39,2 to 49,0

3/4 49,0 to 63,7
1 68,6 to 88,3
1 1/4 98,1 to 118
(3) Tightening torque of unified screw thread Example Unified

For 30° sheet type joint and the O-ring sheet type joint. Unified screw thread
37°
Unit : N•m
screw thread
Example
7/16-20UNF 17,7 to 21,6 Unified screw thread Unified
9/16-18UNF 35,3 to 43,1
37°
3/4-16UNF 44,1 to 53,9
7/8-14UNF 53 to 64,7
1 1-16-12UN 106 to 129
O-ring
1 5/16-12UN 124 to 151
1 5/8-12UN 150 to 183
017502-00E
3-7-6
3-8 Pressure Adjustment
3-8-1 Relief Valves
1) Conditions
(1) Engine: rated speed
(2) Hydraulic oil temperature: 50 to 60°C
(3) Pressure oil gauge capacity: 49 MPa
2) Relief Valve Specification
[Unit: MPa at max rpm]

Set pressure
Control valve
SV15VT
P1 20,5
System relief valve
P2 20,5
Boom (rod end) 24
Boom (bottom end) 17,5
Arm (rod end) -
Arm (bottom end) 23
Bucket (rod end) -
Bucket (bottom end) 24
Circuit relief valve Boom swing (rod end) -
Boom swing (bottom end) -
Blade (rod end) 11,1
Blade (bottom end) -
PTO (left) 16
PTO (right) 16
Extension (rod end) 11,1
Extension (bottom end) -
3-8-1
3) Measuring points on the primary relief valve MRV1

(1) Remove the cover 1.
(2) Remove the plug from the

pressure port 2 and install the
oil pressure gauge.
(3) To check the pressure of

the system relief valve MRV1
from P1 in the control valve,
retract the arm cylinder to its
stroke end, hold the lever and
read the gauge.
4) Adjustment Procedure on the primary relief valve MRV1
WARNING
The pressure is factory setting, all necessary adjustment must be done by YANMAR dealer.
(1) Remove floor mat 1.
(2) Remove the left cover 2.
(3) Adjust the pressure if necessary by unscewing

the locknut 3 and turning the adjusting screw 4 on
the hydraulic control valve until you reach the
correct pressure :
- Clockwise for increase in pressure
- Counterclockwise for reduction in pressure
(4) Tighten the locknut.
3-8-2
5) Measuring points on the primary relief valve MRV2

(1) Remove the cover 1.
(2) Remove the plug from the

pressure port 2 and install the
oil pressure gauge.
(3) To check the pressure of

the system relief valve MRV2
from P2 in the control valve,
retract the bucket cylinder to its
stroke end, hold the lever and
read the gauge.
6) Adjustment Procedure on the primary relief valve MRV2
WARNING
(3) Adjust the pressure if necessary by unscewing

the locknut 3 and turning the adjusting screw 4 on
the hydraulic control valve until you reach the
correct pressure :
3-8-3
3-8-2 Cut-Off Valve

1) Conditions
(1) Engine: rated speed
(2) Hydraulic oil temperature: 50 to 60°C
(3) Set pressure: 3 MPa
2) Measuring Procedure
(3) Remove the fitting 3 and install a Tee fitting

with a pressure port for the pressure gauge.
(4) Move the lock lever to the "UNLOCK" position,

and read the gauge.
3) Pressure Adjustment Procedure
WARNING
(1) Adjust the pressure if necessary by unscewing the

locknut 1 and turning the adjusting screw 2 on the
hydraulic control valve until you reach the correct
pressure :
3-8-4
CHAPTER 4
ENGINE
4-1 Safety ........................................................................ 4-1-1 4-6 Starter Motor ............................................................. 4-6-1

4-1-1 Safety Statements ............................................ 4-1-1 4-6-1 Before You Begin Servicing ............................. 4-6-1
4-1-2 Safety Precautions ........................................... 4-1-2 4-6-2 Introduction....................................................... 4-6-2
4-2 Engine ....................................................................... 4-2-1 4-6-3 Starter Motor Specifications ............................. 4-6-2
4-2-1 Before You Begin Servicing ............................. 4-2-1 4-6-4 Starter Motor Troubleshooting.......................... 4-6-3
4-2-2 Special Service Tools....................................... 4-2-2 4-6-5 Starter Motor Components ............................... 4-6-4
4-2-3 Measuring Instruments ..................................... 4-2-4 4-6-6 Starter Motor .................................................... 4-6-5
4-2-4 Cylinder Head................................................... 4-2-6 4-7 Alternator................................................................... 4-7-1
4-2-5 Measuring and Adjusting Valve Clearance .... 4-2-20 4-7-1 Before You Begin Servicing ............................. 4-7-1
4-2-6 Crankshaft and Camshaft Components ......... 4-2-22 4-7-2 Introduction....................................................... 4-7-2
4-3 Fuel System .............................................................. 4-3-1 4-7-3 Alternator Specifications................................... 4-7-2
4-3-1
Before You Begin Servicing ............................. 4-3-1 4-7-4 Alternator Troubleshooting ............................... 4-7-3
4-3-2
Introduction....................................................... 4-3-2 4-7-5 Alternator Components .................................... 4-7-4
4-3-3
Special Service Tools....................................... 4-3-4 4-7-6 Alternator Wiring Diagram ................................ 4-7-5
4-3-4
Measuring Instruments ..................................... 4-3-4 4-7-7 Alternator Standard Output .............................. 4-7-6
4-3-5
Fuel System Diagram....................................... 4-3-5 4-7-8 Alternator .......................................................... 4-7-7
4-3-6
Fuel System Components ................................ 4-3-6 4-8 Electric Wiring .......................................................... 4-8-1
4-3-7
Fuel Injection Lines .......................................... 4-3-7 4-8-1 Electric Wiring Precautions ............................. 4-8-1
4-3-8
Fuel Injection Pump.......................................... 4-3-9 4-9 Troubleshooting......................................................... 4-9-1
4-3-9
Checking and 4-9-1 Special Service Tools ....................................... 4-9-1
Adjusting Fuel Injection Timing ...................... 4-3-15 4-9-2 Troubleshooting By
4-3-10 Fuel Injectors............................................... 4-3-18 Measuring Compression Pressure................... 4-9-2
4-4 Cooling System ......................................................... 4-4-1 4-9-3 Quick Reference Table
4-4-1 Before You Begin Servicing ............................. 4-4-1 For Troubleshooting ......................................... 4-9-4
4-4-2 Introduction....................................................... 4-4-2
4-4-3 Cooling System Diagram.................................. 4-4-2
4-4-4 Engine Coolant Pump Components ................. 4-4-3
4-4-5 Engine Coolant System Check......................... 4-4-4
4-4-6 Engine Coolant Pump ...................................... 4-4-4
4-5 Lubrication System.................................................... 4-5-1
4-5-1 Before You Begin Servicing ............................. 4-5-1
4-5-2 Introduction....................................................... 4-5-2
4-5-3 Lubrication System Diagram ............................ 4-5-2
4-5-4 Checking Engine Oil Pressure ......................... 4-5-3
4-5-5 Trochoid Oil Pump............................................ 4-5-3
4. ENGINE
4. Engine
DANGER
4-1 Safety Danger (the word “DANGER” is in white letters
with a red rectangle behind it) - indicates an
4-1-1 Safety Statements imminently hazardous situation which, if not
avoided, will result in death or serious injury.
Yanmar is concerned for your safety and your Danger is limited to the most extreme
machine’s condition. Safety statements are one of situations.
the primary ways to call your attention to the
potential hazards associated with Yanmar TNV WARNING
engine operation. Follow the precautions listed
Warning (the word “WARNING” is in black
throughout the manual before operation, during
letters with an orange rectangle behind it) –
operation and during periodic maintenance
indicates a potentially hazardous situation
procedures for your safety, the safety of others and
which, if not avoided, could result in death or
to protect the performance of your engine. Keep
serious injury.
the labels from becoming dirty or torn and replace
them if they are lost or damaged. Also, if you need
to replace a part that has a label attached to it, CAUTION
make sure you order the new part and label at the Caution (the word “CAUTION” is in black letters
same time. with a yellow rectangle behind it) – indicates a
potentially hazardous situation which, if not
This safety alert symbol appears avoided, may result in minor or moderate
A
with most safety statements. It injury.
means attention, become alert, your
safety is involved! Please read and NOTICE
abide by the message that follows
the safety alert symbol. Caution without the safety alert symbol indicates a
potentially hazardous situation that can cause
damage to the machine, personal property and / or
the environment or cause the machine to operate
improperly.
4-1-1
4. ENGINE
4-1-2 Safety Precautions

DANGER
During Operation and Maintenance FIRE AND EXPLOSION HAZARD!
• Diesel fuel is flammable and
DANGER explosive under certain
SCALD HAZARD! conditions.
• NEVER remove the radiator cap if
the engine is hot. Steam and hot
engine coolant will spurt out and • When you remove any fuel system
seriously burn you. Allow the component to perform maintenance (such as
engine to cool down before you changing the fuel filter) place an approved
attempt to remove the radiator container under the opening to catch the fuel.
cap. • NEVER use a shop rag to catch the fuel.
• Tighten the radiator cap securely after you Vapors from the rag are flammable and
check the radiator. Steam can spurt out explosive.
during engine operation if the cap is loose. • Wipe up any spills immediately.
• ALWAYS check the level of the engine coolant • Wear eye protection. The fuel system is under
by observing the reserve tank. pressure and fuel could spray out when you
• Failure to comply will result in death or remove any fuel system component.
serious injury. • Only use the key switch to start the engine.
DANGER • NEVER jump-start the engine. Sparks caused
by shorting the battery to the starter
EXPLOSION HAZARD! terminals may cause a fire or explosion.
• Keep the area around the battery • If the unit has an electric fuel pump, when
well-ventilated. While the engine you prime the fuel system, turn the key
is running or the battery is switch to the ON position for 10 to 15
charging, hydrogen gas is seconds to allow the electric fuel pump to
produced which can be easily prime the system.
ignited.
• If the unit has a mechanical fuel pump, when
• Keep sparks, open flame and any other form you prime the fuel system, operate the fuel
of ignition away while the engine is running priming lever of the mechanical fuel pump
or battery is charging. several times until the fuel filter cup is filled
• NEVER check the remaining battery charge with fuel.
by shorting out the terminals. This will result • Only fill the fuel tank with diesel fuel. Filling
in a spark and may cause an explosion or the fuel tank with gasoline may result in a fire
fire. Use a hydrometer to check the remaining and will damage the engine.
battery charge.
• NEVER refuel with the engine running.
• If the electrolyte is frozen, slowly warm the
battery before you recharge it. • Keep sparks, open flames or any other form
of ignition (match, cigarette, static electric
• Failure to comply will result in death or source) well away when refueling.
serious injury.
• NEVER overfill the fuel tank.
• Fill the fuel tank. Store any containers
containing fuel in a well-ventilated area, away
from any combustibles or sources of ignition.
4-1-2
4. ENGINE
DANGER DANGER
FIRE AND EXPLOSION HAZARD! CRUSH HAZARD!
• Be sure to place the diesel fuel container on • When you need to transport an
the ground when transferring the diesel fuel engine for repair, have a helper
from the pump to the container. Hold the assist you to attach it to a hoist
hose nozzle firmly against the side of the and load it on a truck.
container while filling it. This prevents static
electricity buildup which could cause sparks • NEVER stand under a hoisted engine. If the
and ignite fuel vapors. hoist mechanism fails, the engine will fall on
• NEVER place diesel fuel or other flammable you, causing death or serious injury.
material such as oil, hay or dried grass close • Failure to comply will result in death or
to the engine during engine operation or serious injury.
shortly after shutdown.
• Before you operate the engine, check for fuel WARNING
leaks. Replace rubberized fuel hoses every
SEVER HAZARD!
two years or every 2000 hours of engine
operation, whichever comes first, even if the • Keep hands and other body parts
engine has been out of service. Rubberized away from moving / rotating parts
fuel lines tend to dry out and become brittle such as the cooling fan, flywheel
after two years or 2000 hours of engine or PTO shaft.
operation, whichever comes first.
• NEVER remove the fuel cap with the engine • Wear tight-fitting clothing and keep your hair
running. short or tie it back while the engine is
running.
• NEVER use diesel fuel as a cleaning agent.
• Remove all jewelry before you operate or
• Place an approved container under the air service the machine.
bleed port when you prime the fuel system.
Never use a shop rag to catch the fuel. Wipe • NEVER start the engine in gear. Sudden
up any spills immediately. ALWAYS close the movement of the engine and / or machine
air bleed port after you complete priming the could cause death or serious personal injury.
system. • NEVER operate the engine without the
• Wear eye protection. The fuel system is under guards in place.
pressure and fuel could spray out when you • Before you start the engine make sure that all
open the air bleed port. bystanders are clear of the area.
• If the unit has an electric fuel pump, turn the • Keep children and pets away while the engine
key switch to the ON position for 10 to 15 is operating.
seconds, or until the fuel coming out of the • Check before starting the engine that any
air bleed port is free of bubbles, to allow the tools or shop rags used during maintenance
electric fuel pump to prime the system. have been removed from the area.
• If the unit has a mechanical fuel pump, • Failure to comply could result in death or
operate the fuel priming pump several times serious injury.
until the fuel coming out of the air bleed port
is free of bubbles.
• Failure to comply will result in death or
serious injury.
4-1-3
4. ENGINE
WARNING WARNING
EXHAUST HAZARD! EXPOSURE HAZARD!
• NEVER operate the engine in an • Wear personal protective
enclosed area such as a garage, equipment such as gloves, work
tunnel, underground room, shoes, eye and hearing
manhole or ship’s hold without protection as required by the task
proper ventilation. at hand.
• NEVER block windows, vents, or other means
of ventilation if the engine is operating in an • NEVER wear jewelry, unbuttoned cuffs, ties
enclosed area. All internal combustion or loose-fitting clothing when you are
engines create carbon monoxide gas during working near moving / rotating parts such as
operation. Accumulation of this gas within an the cooling fan, flywheel or PTO shaft.
enclosure could cause illness or even death. • ALWAYS tie back long hair when you are
• Make sure that all connections are tightened working near moving / rotating parts such as
to specifications after repair is made to the a cooling fan, flywheel, or PTO shaft.
exhaust system. • NEVER operate the engine while wearing a
• Failure to comply could result in death or headset to listen to music or radio because it
serious injury. will be difficult to hear the alert signals.
• Failure to comply could result in death or
WARNING serious injury.
ALCOHOL AND DRUG HAZARD!
• NEVER operate the engine while WARNING
you are under the influence of BURN HAZARD!
alcohol or drugs. • If you must drain the engine oil
while it is still hot, stay clear of
the hot engine oil to avoid being
• NEVER operate the engine when you are burned.
feeling ill.
• Failure to comply could result in death or • ALWAYS wear eye protection.
serious injury. • Wait until the engine cools before you drain
the engine coolant. Hot engine coolant may
splash and burn you.
• Keep your hands and other body parts away
from hot engine surfaces such as the muffler,
exhaust pipe, turbocharger (if equipped) and
engine block during operation and shortly
after you shut the engine down. These
surfaces are extremely hot while the engine
is operating and could seriously burn you.
serious injury.
4-1-4
4. ENGINE
WARNING WARNING
BURN HAZARD! SHOCK HAZARD!
• Batteries contain sulfuric acid. • Turn off the battery switch (if
NEVER allow battery fluid to equipped) or disconnect the
come in contact with clothing, negative battery cable before
skin or eyes. Severe burns could servicing the electrical system.
result. ALWAYS wear safety
goggles and protective clothing • Check the electrical harnesses for cracks,
when servicing the battery. If abrasions, and damaged or corroded
battery fluid contacts the eyes connectors. ALWAYS keep the connectors
and / or skin, immediately flush and terminals clean.
the affected area with a large
amount of clean water and obtain • Failure to comply could result in death or
prompt medical treatment. serious injury.
• Failure to comply could result in death or WARNING
serious injury.
ENTANGLEMENT HAZARD!
WARNING • Stop the engine before you begin
HIGH-PRESSURE HAZARD! to service it.
• Avoid skin contact with the
high-pressure diesel fuel spray
caused by a fuel system leak
such as a broken fuel injection • NEVER leave the key in the key switch when
line. High-pressure fuel can you are servicing the engine. Someone may
penetrate your skin and result in accidentally start the engine and not realize
serious injury. If you are exposed you are servicing it. This could result in a
to high-pressure fuel spray, serious injury.
obtain prompt medical treatment. • If you must service the engine while it is
• NEVER check for a fuel leak with your hands. operating, remove all jewelry, tie back long
ALWAYS use a piece of wood or cardboard. hair, and keep your hands, other body parts
Have your authorized Yanmar industrial and clothing away from moving / rotating
engine dealer or distributor repair the parts.
damage. • Failure to comply could result in death or
• Failure to comply could result in death or serious injury.
serious injury.
WARNING
To prevent possible eye injury,
always wear SAFETY GLASSES
while servicing the engine.
4-1-5
4. ENGINE
WARNING CAUTION
FUME / BURN HAZARD! Be sure to secure the engine solidly to prevent
• Always read and injury or damage to parts due to the engine
follow safety related falling during work on the engine.
precautions found on
containers of CAUTION
hazardous
PINCH HAZARD!
substances like parts
cleaners, primers, Carefully rotate the alternator
sealants and sealant toward the cylinder block while
removers. loosening the V-belt. Failure to
comply may result in minor or
• Failure to comply could result in death or moderate injury.
serious injury.
CAUTION CAUTION
If any oil pump component clearance exceeds
COOLANT HAZARD!
its limit, the oil pump must be replaced as an
• Wear eye protection assembly.
and rubber gloves
when you handle long
NOTICE
life or extended life
engine coolant. If • Only use diesel fuels recommended by Yanmar
contact with the eyes for the best engine performance, to prevent
or skin should occur, engine damage and to comply with EPA / ARB
flush eyes and wash warranty requirements.
immediately with
• Only use clean diesel fuel.
clean water.
• Failure to comply may result in minor or • NEVER remove the primary strainer (if
moderate injury. equipped) from the fuel tank filler port. If
removed, dirt and debris could get into the fuel
CAUTION system causing it to clog.
FLYING OBJECT HAZARD!

NOTICE
• ALWAYS wear eye protection
when servicing the engine and If any problem is noted during the visual check, the
when using compressed air or necessary corrective action should be taken before
high-pressure water. Dust, flying you operate the engine.
debris, compressed air,
pressurized water or steam may NOTICE
injure your eyes. NEVER hold the key in the START position for
• Failure to comply may result in minor or longer than 15 seconds or the starter motor will
moderate injury. overheat.
4-1-6
4. ENGINE
NOTICE NOTICE
Make sure the engine is installed on a level Observe the following environmental operating
surface. If a continuously running engine is conditions to maintain engine performance and
installed at an angle greater than (IDI = 25°, DI = avoid premature engine wear:
30°) in any direction or if an engine runs for short
periods of time (less than three minutes) at an • The standard range of ambient temperatures for
angle greater than (IDI = 30°, DI = 35°) in any the normal operation of Yanmar engines is from
direction, engine oil may enter the combustion +5°F (-15°C) to +113°F (+45°C).
chamber causing excessive engine speed and • If the ambient temperature exceeds +113°F
white exhaust smoke. This may cause serious (+45°C) the engine may overheat and cause the
engine damage. engine oil to break down.
NOTICE • If the ambient temperature is below +5°F (-15°C)

the engine will be hard to start and the engine oil
Observe the following environmental operating may not flow easily.
conditions to maintain engine performance and
avoid premature engine wear: • Contact your authorized Yanmar industrial
engine dealer or distributor if the engine will be
• Avoid operating in extremely dusty conditions. operated outside of this standard temperature
range.
• Avoid operating in the presence of chemical
gases or fumes.
NOTICE
• Avoid operating in a corrosive atmosphere such
as salt water spray. If any indicator illuminates during engine operation,
stop the engine immediately. Determine the cause
• NEVER install the engine in a floodplain unless and repair the problem before you continue to
proper precautions are taken to avoid being operate the engine.
subject to a flood.
• NEVER expose the engine to the rain. NOTICE
• Only use the engine oil specified. Other engine
oils may affect warranty coverage, cause internal
engine components to seize and / or shorten
engine life.
• Prevent dirt and debris from contaminating the
engine oil. Carefully clean the oil cap / dipstick
and the surrounding area before you remove the
cap.
• NEVER mix different types of engine oil. This
may adversely affect the lubricating properties of
the engine oil.
• NEVER overfill. Overfilling may result in white
exhaust smoke, engine overspeed or internal
damage.
4-1-7
4. ENGINE
NOTICE NOTICE
• Only use the engine coolant specified. Other • ALWAYS be environmentally
engine coolants may affect warranty coverage, responsible.
cause an internal buildup of rust and scale and /
or shorten engine life.
• Prevent dirt and debris from contaminating the
engine coolant. Carefully clean the radiator cap • Follow the guidelines of the EPA or other
and the surrounding area before you remove the governmental agencies for the proper disposal of
cap. hazardous materials such as engine oil, diesel
fuel and engine coolant. Consult the local
• NEVER mix different types of engine coolants. authorities or reclamation facility.
This may adversely affect the properties of the
engine coolant. • NEVER dispose of hazardous materials
irresponsibly by dumping them into a sewer, on
NOTICE the ground, or into ground water or waterways.
• NEVER overfill the engine with engine oil. • Failure to follow these procedures may seriously
harm the environment.
• ALWAYS keep the oil level between the upper
and lower lines on the oil cap / dipstick.
NOTICE
NOTICE NEVER engage the starter motor while the engine
is running. This may damage the starter motor
For maximum engine life, Yanmar recommends pinion and / or ring gear.
that when shutting the engine down, you allow the
engine to idle, without load, for five minutes. This
will allow the engine components that operate at
NOTICE
high temperatures, such as the turbocharger (if New Engine Break-in:
equipped) and exhaust system, to cool slightly
before the engine itself is shut down. • 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
NOTICE leaks, engine oil leaks, coolant leaks, and for
NEVER use an engine starting aid such as ether. proper operation of the indicators and / or
Engine damage will result. gauges.
• During the first hour of operation, vary the engine
speed and the load on the engine. Short periods
of maximum engine speed and load are
desirable. Avoid prolonged operation at minimum
or maximum engine speeds and loads for the
next four to five hours.
• During the break-in period, carefully observe the
engine oil pressure and engine temperature.
• During the break-in period, check the engine oil
and coolant levels frequently.
4-1-8
4. ENGINE
NOTICE NOTICE
• NEVER attempt to modify the engine’s design or Establish a periodic maintenance plan according to
safety features such as defeating the engine the engine application and make sure you perform
speed limit control or the fuel injection quantity the required periodic maintenance at intervals
control. indicated. Failure to follow these guidelines will
impair the engine’s safety and performance
• Failure to comply may impair the engine’s safety characteristics, shorten the engine’s life and may
and performance characteristics and shorten the affect the warranty coverage on your engine.
engine’s life. Any alterations to this engine may
affect the warranty coverage of your engine.
NOTICE
NOTICE If the fuel filter / water separator is positioned
higher than the fuel level in the fuel tank, water
Protect the air cleaner, turbocharger (if equipped) may not drip out when the fuel filter / water
and electric components from damage when you separator drain cock is opened. If this happens,
use steam or high-pressure water to clean the turn the air vent screw on the top of the fuel filter /
engine. water separator 2-3 turns counterclockwise.
NOTICE Be sure to tighten the air vent screw after the water
has drained out.
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
NOTICE
fins damage easily. • When the engine is operated in dusty conditions,
clean the air cleaner element more frequently.
NOTICE • NEVER operate the engine with the air cleaner
NEVER attempt to adjust the low or high idle element(s) removed. This may allow foreign
speed limit screw. This may impair the safety and material to enter the engine and damage it.
performance of the machine and shorten its life. If
the idle speed limit screws require adjustment, see NOTICE
your authorized Yanmar industrial engine dealer or
distributor. The maximum air intake restriction, in terms of
differential pressure measurement, must not
exceed 0.90 psi (6.23 kPa; 635 mmAq). Clean or
NOTICE replace the air cleaner element if the air intake
The tightening torque in the Standard Torque restriction exceeds the above mentioned value.
Chart in General Service 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.
4-1-9
4. ENGINE
NOTICE NOTICE
It is important to perform daily checks. Do not operate the engine if the alternator is
producing unusual sounds. Damage to the
Periodic maintenance prevents unexpected alternator will result.
downtime, reduces the number of accidents due to
poor machine performance and helps extend the
life of the engine. NOTICE
If the engine coolant pump must be replaced,
NOTICE replace the engine coolant pump as an assembly
only. Do not attempt to repair the engine coolant
If the oil pump must be replaced, replace it as an pump or replace individual components.
assembly only. Do not replace individual
components.
NOTICE
NOTICE Use a new special O-ring between the engine
coolant pump and the joint. Be sure to use the
Do not loosen or remove the four bolts retaining special O-ring for each engine model. Although the
the fuel injection pump drive gear to the fuel O-ring dimensions are the same as a commercially
injection pump hub. Do not disassemble the fuel available O-ring, the material is different.
injection pump drive gear from the hub. Correct
fuel injection timing will be very difficult or
impossible to achieve. NOTICE
Remove or install the high-pressure fuel injection
NOTICE lines as an assembly whenever possible.
Disassembling the high-pressure fuel injection
The starter motor can be damaged if operated lines from the retainers or bending any of the fuel
continuously longer than 10 seconds while lines will make it difficult to reinstall the fuel lines.
performing the no-load test.
NOTICE
NOTICE
After marking the position of the pump drive gear,
Do not short-circuit the charging system between do not rotate the engine crankshaft. Rotating the
alternator terminals IG and L. Damage to the crankshaft will cause the fuel injection pump to
alternator will result. become misaligned.
NOTICE NOTICE
Do not connect a load between alternator Do not use a high-pressure wash directly on the
terminals L and E. Damage to the alternator will alternator. Water will damage the alternator and
result. result in inadequate charging.
NOTICE NOTICE
Do not remove the positive (+) battery cable from Do not reverse the positive (+) and negative (-)
alternator terminal B while the engine is operating. ends of the battery cable. The alternator diode and
Damage to the alternator will result. stator coil will be damaged.
NOTICE
Do not turn the battery switch OFF while the
engine is operating. Damage to the alternator will
result.
4-1-10
4. ENGINE
NOTICE NOTICE
When the battery indicator goes out, it should not Removing the battery cables or the battery while
come on again. The battery indicator only comes the engine is operating may cause damage to the
on during operation if the alternator fails. However, current limiter depending on the electrical
if an LED is used in the battery indicator, the LED equipment being used. This situation could cause
will shine faintly during normal operation. loss of control of output voltage. The continuous
high voltage of 23-24 volts (for 5000 rpm dynamo)
NOTICE will damage the current limiter and other electrical
equipment.
Using a non-specified V-belt will cause inadequate
charging and shorten the belt life. Use the
specified belt.
NOTICE
Reversing the battery cable connections at the
NOTICE battery or on the engine will destroy the SCR diode
in the current limiter. This will cause the charging
Agricultural or other chemicals, especially those system to malfunction and may cause damage to
with a high sulfur content, can adhere to the IC the electrical harnesses.
regulator. This will corrode the conductor and
result in battery over-charging (boiling) and
charging malfunctions. Consult Yanmar before
NOTICE
using the equipment in such an environment or the • NEVER attempt to modify the engine’s design or
warranty is voided. safety features such as defeating the engine
speed limit control or the diesel fuel injection
NOTICE quantity control.
Make sure that the combined total resistance of • Modifications may impair the engine’s safety and
the battery cable in both directions between the performance characteristics and shorten the
starter motor and the battery is within the value engine’s life. Any alterations to this engine may
indicated on the wiring diagram. The starter motor void its warranty. Be sure to use Yanmar genuine
will malfunction or break down if the resistance is replacement parts.
higher than the specified value.
NOTICE
NOTICE Identify all parts and their location using an
The starter motor is water-proofed according to JIS appropriate method. It is important that all parts
D 0203, R2 which protects the motor from rain or are returned to the same position during the
general cleaning. Do not use high-pressure wash reassembly process.
or submerse the starter motor in water.
NOTICE
NOTICE Do not rotate the crankshaft with the injection
Use a specialized battery charger to recharge a pump removed.
battery with a voltage of 8 volts or less. Booster
starting a battery with a voltage of 8 volts or less NOTICE
will generate an abnormally high voltage and
destroy electrical equipment. Keep the piston pin parts, piston assemblies, and
connecting rod assemblies together to be returned
to the same position during the reassembly
process. Label the parts using an appropriate
method.
4-1-11
4. ENGINE
NOTICE NOTICE
Do not allow the honing tool to operate in one NEVER permit anyone to operate the
position for any length of time. Damage to the engine or driven machine without
cylinder wall will occur. Keep the tool in constant proper training.
up-and-down motion.
NOTICE • Read and understand this Operation Manual

Any part which is found defective as a result of before you operate or service the machine to
inspection or any part whose measured value does ensure that you follow safe operating practices
not satisfy the standard or limit must be replaced. and maintenance procedures.
• Machine safety signs and labels are additional
NOTICE reminders for safe operating and maintenance
Any part determined to not meet the service techniques.
standard or limit before the next service, as
• See your authorized Yanmar industrial engine
determined from the state of current rate of wear,
dealer or distributor for additional training.
should be replaced even though the part currently
meets the service standard limit.
NOTICE
• 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.”
NOTICE
The fuel return line is a one-piece assembly. Use
care not to bend or twist the fuel return line.
NOTICE
Never use a steel wire brush to clean fuel injectors.
Damage to the nozzle and other components is
likely to result.
4-1-12
4. ENGINE
4-2 Engine
4-2-1 Before You Begin Servicing
Before performing any service procedures within

this section, read the following safety information
and review the Safety section on page 4-1-1.
4-2-1
4. ENGINE
4-2-2 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 20 mm 75 mm 5,5 mm 9,5 mm
Valve Guides)
Locally Manufactured 0000827
L1 L2 d1 d2
Valve Guide Tool 10 mm 60 mm 11 mm 17 mm

2 (For Installing
Valve Guides) Allowance L1:
Locally Manufactured 0 to -0.3 mm
0000828
L1 L2 d1 d2
Wrist Pin Bushing
25 mm 85 mm 22 mm 25 mm
Tool
3 (For Removing /
Allowance d1: Allowance d2:
Installing of Wrist 0000829
Pin Bushings)
Locally Manufactured 0.3 to -0.6mm -0.3 to -0.6mm
Valve Spring
Compressor
Yanmar Part No.
4 (For Removing /
129100-92630
Installing Valve 0000830
Springs)
d1 d2 d3 L1 L2 L3
4 mm or
15 mm 21 mm 12 mm 11 mm 65 mm
more
Stem Seal Tool

5 (for Installing
Stem Seals)
Allowance:
d1: ±0.2 mm
L1: ±0.1 mm
Locally Manufactured
0000820
4-2-2
4. ENGINE
No Tool Name Applicable Model and Tool Size Illustration
L1 L2 d1 d2
Camshaft
18 mm 70 mm 45 mm 48 mm
Bushing Tool
6 (For Removing
Allowance d1: Allowance d2:
Camshaft
Bushing)
Locally Manufactured -0.3 to -0.6mm -0.3 to -0.6mm 0000822
Yanmar Part No. Cylinder Bore
Flex-Hone 129400-92410 70 - 76 mm
7 (For Preparing
Cylinder Walls)
0000823
Piston Ring Yanmar Part No. 955500-02476

Compressor The Piston Insertion Tool is Applicable for
8
(For Installing 60 - 125 mm
Pistons) Diameter Pistons
0000824
Piston Ring Tool

(For Removing/
9 Available Locally
Installing of
Piston Rings)
0000825
4-2-3
4. ENGINE
4-2-3 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
4-2-4
4. ENGINE
(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
4-2-5
4. ENGINE
4-2-4 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 4-2-1
4-2-6
4. 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
11 – Valve Cap can 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.
18 – Exhaust Valve
19 – Intake Valve NOTICE
20 – Cylinder Head Gasket Identify all parts and their location using an
21 – Push Rod (2 per cylinder) appropriate method. It is important that all parts
22 – Glow Plug are returned to the same position during the
23 – Glow Plug Wiring Harness
reassembly process.
24 – Cylinder Head Bolt
2. Remove the coolant pump. See Disassembly

of Engine Coolant Pump on page 4-4-4.
3. Remove the high-pressure fuel lines and fuel
injectors from the cylinder head. See Removal
of Fuel Injectors on page 4-3-18.
4-2-7
4. ENGINE
Removal of Intake Manifold / Valve Cover

1. Remove the intake manifold bolts (2)
(Figure 4- 2-2, (1)) and valve cover bolts
(Figure 4- 2-2, (2)).
2. Remove the valve cover / intake manifold (1)
(Figure 4-2-2, (3)).
Discard gasket (Figure 4- 2-2, (4)).
(1)
(2)
Figure 4-2-3
(3)
(4) Removal of Rocker Arm Assembly
1. Remove the bolts (Figure 4-2-4, (1)) and nuts
(Figure 4-2-4, (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 4-2-2
3. Remove the exhaust manifold bolts (Figure 4-
2-2, (5)) and nuts (Figure 4-2-2, (6)). Remove
the exhaust manifold (Figure 4-2-2, (7)) and
the exhaust manifold gasket (Figure 4-2-2, (8)).
(1) (2)
Removal of Glow Plugs
1. Disconnect the glow plug harness
(Figure 4- 2-3, ( 2 ) ) from the glow plugs
(Figure 4-2-3, ( 1 ) ) .
2. Remove the glow plugs from the cylinder head.
0002147
Figure 4-2-4
4-2-8
4. ENGINE
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 4-2-5, (6)) from support sequence shown in Figure 4-2-6.
(Figure 4-2-5, (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)
1 – Cooling Fan End
2 – Camshaft Side
(9)
Figure 4-2-6
2. Remove the cylinder head bolts
(Figure 4- 2-7, (1)).
3. Lift the cylinder head away from the cylinder
(8) block. Discard the cylinder head gasket
0002160 (Figure 4-2-7, (2)). Position the cylinder head
Figure 4-2-5 on the work bench to prevent damage to the
combustion surface.
Note: On 3-cylinder models, the set screw is
located in the center support. On
2-cylinder models, the set screw is (1)
located in the front (cooling fan) end
support.
2. Remove two circlips (Figure 4-2-5, (8)).
Note: The rocker arm shaft fits tightly in the
rocker arm supports. Clamp the support
in a padded vise. Twist and pull out on
the rocker arm shaft to remove. Reverse
(2)
this process when installing the rocker
arm shaft into the supports.
3. Slide the rocker arm shaft (Figure 4-2-5, (7))
out of the rocker arm supports (Figure 4-
2-5, (5)), springs (Figure 4-2-5, (4)), and
rocker arms (Figure 4-2-5, (1)).
0002150
Note: Mark the rocker arms so they can be
reinstalled with the original matching Figure 4-2-7
valve and pushrod.
4. Remove the valve adjusting screw
(Figure 4- 2-5, (3)) and lock nut (Figure 4-2-5, (2))
from the rocker arms. Mark parts so they can be
reinstalled on the same rocker arm.
4-2-9
4. ENGINE
Removal of Intake / Exhaust Valves 9. Remove the valve stem seals

1. Put the cylinder head on the work bench with (Figure 4- 2-9, (5)).
the combustion side down (Figure 4-2-8).
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 4-2-12.
If the valve guides are not within specifications,
use a drift pin and hammer to drive the valve
guides (Figure 4-2-10, (1)) out of the cylinder
0000191
Figure 4-2-8 head.

2. Remove the valve stem cap (Figure 4-2-9, (1))
and keep with the valve it was installed on. (1)
3. Using the valve spring compressor tool,
compress one of the valve springs
(Figure 4- 2-8).
4. Remove the valve keepers (Figure 4-2-9, (2)).
5. Slowly release the tension on the valve spring.
6. Remove the spring retainer (Figure 4-2-9, (3))
and valve spring (Figure 4-2-9, (4)).
(1)
0002152
(2)
Figure 4-2-10
(3)
(4)
(5)
(6)
0002151
Figure 4-2-9
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.
8. Turn the cylinder head so the exhaust port side
faces down. Remove the intake and exhaust
valves (Figure 4-2-9, (6)) from the cylinder
head.
4-2-10
4. ENGINE
Cleaning of Cylinder Head IMPORTANT

Mark all valve train components so they
Components can be installed in their original locations.
WARNING Note: Record all measurements taken during
inspection.
FUME / BURN HAZARD!
• Always read and Inspection of Push Rods
follow safety related
precautions found on Push Rod Bend
containers of Determine if the bend of the push rods is within the
hazardous specified limit.
cleaners, primers, 1. Place the push rods on a flat inspection block
sealants and sealant or layout bed.
removers. 2. Roll the push rods until a gap can be observed
• Failure to comply could result in death or between a portion of the push rod and the
serious injury. surface of the block or layout bed.
3. Use a feeler gauge to measure the gap
(Figure 4-2-11). See "3-2 Engine Service
Thoroughly clean all components using a Standard" section for the service limit.
non-metallic brush and an appropriate solvent.
Each part must be free of carbon, metal filings and
other debris.
Inspection of Cylinder Head

Components
Visually inspect the parts. Replace any parts that
are obviously discolored, heavily pitted or
otherwise damaged. Discard any parts that do not
meet its specified limits.
0000204
NOTICE Figure 4-2-11

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.
NOTICE
Any part determined to not meet the service
standard or limit before the next service, as
determined from the state of current rate of wear,
should be replaced even though the part currently
meets the service standard limit.
4-2-11
4. ENGINE
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 4- 2-12). Record the measurements. See
Use a telescoping gauge and micrometer to
"3-2 Engine Service Standard" section for the
measure the inside diameter of the valve guide.
service limit.
Measure in three places and 90° apart (Figure 4-
Inspect contact areas (Figure 4-2-12, (1)) for 2-14). Record the measurements. See "3-2 Engine
excessive wear or damage. Service Standard" section for the service limit.
Replace valve guides if not within specification.
0001869
(1)
(1) Figure 4-2-14
Inspection of Cylinder Head

0001916
Cylinder Head Distortion
Figure 4-2-12 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 4-2-15). Measure diagonally and along
diameter. Measure at each rocker arm location in each side. Record the measurements. See "3-2
two directions 90° apart (Figure 4-2-13). Record Engine Service Standard" section for the service
the measurements. See "3-2 Engine Service limit.
Standard" section for the service limit.
0000192
Figure 4-2-15
0001952 If distortion exceeds the service limit, resurface or

Figure 4-2-13 replace the cylinder head. Remove only enough
material to make the cylinder head flat, but do not
remove more than 0.008 in. (0.20 mm).
4-2-12
4. ENGINE
Inspection of Intake and Exhaust Valves Valve Recession

Visually inspect the intake and exhaust valves. Note: The valve guides must be installed to
Replace any valves that are obviously discolored, perform this check.
heavily pitted or otherwise damaged. Insert the valves into their original locations and
Valve Stem Diameter press them down until they are fully seated. Use a
depth micrometer (Figure 4-2-18) to measure the
Use a micrometer to measure the valve stem
difference between the cylinder head gasket
diameter. Measure the valve stem near the
surface and the combustion surface of each
combustion end and near the opposite end
exhaust and intake valve (Figure 4-2-19). Record
(Figure 4-2-16, (1)). Record the measurements.
the measurements. See "3-2 Engine Service
See "3-2 Engine Service Standard" section for the
service limit.
(1)
0000197
Figure 4-2-16
Valve Stem Bend

Place the valve stem on a flat inspection block or
layout bed. Roll the valve until a gap can be 0000193
observed between a portion of the valve stem and Figure 4-2-18

the surface of the block or bed. Use a feeler gauge
to measure the gap (Figure 4-2-17). Record the
measurements. See "3-2 Engine Service
0001755
Figure 4-2-19
Figure 4-2-17
4-2-13
4. ENGINE
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 "3-2 Engine Service Standard" section
for the service limit. If the clearance exceeds the (3)
(2)
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 4-2-21
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 seat location has been corrected, grind and lap the
can be lapped or ground to return them to seat angle (Figure 4-2-21, (1)) to specification.
serviceable condition. Severely worn or damaged See "3-2 Engine Service Standard" section for the
components will require replacement. service limit.
Coat the valve seat with a thin coat of bluing Grind the valve face and / or valve seat only
compound. Install valve and rotate to distribute enough to return them to serviceable condition.
bluing onto the valve face. The contact pattern Grinding is needed if the valve and the valve seat
should be approximately centered on the valve do not contact correctly. Check the valve recession
face (Figure 4-2-20, (1)) and even in width. after grinding.
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
(1)
seen, or if measurements exceed the specified
limits, replace the springs. Record the
measurements.
0001691B
Fractures
Figure 4-2-20 Check for fractures on the inside and outside
portions of the springs. If the valve spring is
Also visually inspect the valve seat for even
fractured, replace the valve spring.
contact.
Light cutting can be performed by the use of a Corrosion
hand-operated cutter (Figure 4-2-21, (3)). Check for corrosion of spring material caused by
oxidation.
4-2-14
4. ENGINE
Squareness Reassembly of Cylinder Head

Use a flat surface and a square to check each Use new gaskets, O-rings and seals on
spring for squareness (Figure 4-2-22). See "3-2 reassembly of cylinder head.
Engine Service Standard" section 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 4-2-22 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 4-2-24, (1)) in their proper positions.
(Figure 4-2-23). See "3-2 Engine Service
Standard" section for the service limit. (1)
2
3
1
4
0
5
9
6
8
7
0002152
Figure 4-2-24
0000200
Figure 4-2-23
4-2-15
4. ENGINE
3. Finish installing the valve guides 2. Measure the distance (Figure 4-2-27, (1)) from
(Figure 4- 2-25, (1)) to the proper height the cylinder head to valve stem seal to ensure
(Figure 4-2-25, (3)) using the valve guide proper clearance (Figure 4-2-27, (2)) between
installation tool (Figure 4-2-25, (2)). the valve guide and seal. See "3-2 Engine
See "3-2 Engine Service Standard" section for Service Standard" section for the service limit.
the service limit.
(2)
(2)
(1)
(3)
(1)
0001756A
0001874
Figure 4-2-25 Figure 4-2-27

Reassembly of Intake and Exhaust Valves 3. Put the cylinder head assembly on its exhaust
port side.
IMPORTANT
Always install new valve stem seals. 4. Install all the valves (Figure 4-2-28, (6)) in their
proper location in the cylinder head.
The exhaust valve stem seals are different
than the intake valve stem seals and can (1)
be identified by the color the seal spring (2)
(Figure 4-2-26, (4)). Ensure they are
installed in the correct locations. (3)
(4)
(5)
1. Oil the lip of the valve stem seal

(Figure 4- 2-26, (2)). Using the valve stem
seal installation tool (Figure 4-2-26, (1)),
install a new valve stem seal on each of the (6)
valve guides (Figure 4-2-26, (3)).
0002151
Figure 4-2-28
5. Put the cylinder head on the workbench with
(1)
the combustion side down to install the valve
springs. Reinstall the valve spring
(4) (Figure 4- 2-28, ( 4 ) ) and spring retainer
(Figure 4-2-28, ( 5 ) ) .
(2)
6. Using a valve spring compressor tool,
(3) compress the valve spring.
7. Insert the valve keeper (Figure 4-2-28, (2))
and slowly release the tension in the valve
spring. Reinstall the valve cap
0001873B
Figure 4- 2-28, (1)). Repeat steps on all
Figure 4-2-26 remaining valves.
4-2-16
4. ENGINE
Reassembly of Cylinder Head

(2)
1. Carefully clean both the combustion surface of 7 1 10
the cylinder head and the top surface of the 13 3 6 12
cylinder block. Install a new cylinder head (1)

11 5 4 14
gasket (Figure 4-2-29, (2)) on the cylinder 9 2 8
block.
2. Position the cylinder head on the cylinder head
1 – Cooling Fan End
gasket.
2 – Camshaft Side
Figure 4-2-30
(1)
4. Insert the push rods in their respective
positions.
Reassembly of Rocker Arm Assembly
(2)
(1)
(2)
(1) 0001914
0002150
Figure 4-2-31
Figure 4-2-29
IMPORTANT
3. Lightly oil the threads of the cylinder head bolts
Ensure the lubrication holes in the rocker
(Figure 4-2-29, (1)). Tighten the bolts to the
arm shaft (Figure 4-2-31, (1)). are oriented
specified torque shown in the chart below.
correctly with respect to the rocker arms
Tighten in the sequence shown in
(Figure 4-2-31, (2)).
Figure 4- 2-30.
See "3-7-2 Engine Tightening Torque" section
for tightening torque.
First Step 1/2 of final torque
Second Step Final torque
4-2-17
4. ENGINE
1. Lubricate the rocker arm shaft. Slide the rocker

arm supports (Figure 4-2-32, (5)), springs
(Figure 4-2-32, (4)) and rocker arms
(Figure 4-2-32, (1)) onto the shaft.
(8)
(2)
(1)
(3)
(4) (7)
(6)
(5)
(9)
(8)
0002160
Figure 4-2-32
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.
Note: The set screw is
located in the center support.
2. Align the hole in the rocker arm shaft
(Figure 4-2-32, (7)) and the hole in the rocker
arm support (Figure 4-2-32, (5)). Reinstall the
alignment set screw (Figure 4-2-32, (6)).
3. Place the rocker arm shaft assembly onto the
cylinder head.
4. If removed, reinstall the valve adjusting screws
(Figure 4-2-32, (3)) and lock nuts
(Figure 4- 2-32, (2)).
5. Align the push rods with their respective rocker
arms.
6. Reinstall and tighten the rocker arm shaft
retaining bolts to the specified torque.
7. Tighten the rocker arm shaft alignment screw.
8. Adjust the valve clearance. See Measuring and
Adjusting Valve Clearance on page 4-2-20.
4-2-18
4. ENGINE
Reassembly of Intake Manifold / Valve

(1)
Cover
1. Reinstall the glow plugs (Figure 4-2-33, (1))
and tighten to specification. Reinstall the
electrical harness (Figure 4-2-33, (2)). (2)
(3)
(2)
(4)
(1)
(5)
(6)
(7)
(8)
0002131
Figure 4-2-34
0002146
5. Reinstall the exhaust manifold using a new
Figure 4-2-33 gasket. Tighten the bolts and nuts
(Figure 4- 2-34, (5 and 6)) securely.
2. Lightly grease a new valve cover gasket
(Figure 4-2-34, (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 4-3-24.
(Figure 4-2-34, (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 4-3-24.
4. Reinstall and tighten bolts
(Figure 4- 2-34, (1 and 2)) securely. 8. Reinstall the coolant pump. See Reassembly
of Engine Coolant Pump on page 4-4-6.
9. Reinstall the alternator. See Alternator on
page 4-7-1.
4-2-19
4. ENGINE
4-2-5 Measuring and Adjusting Valve Clear-

ance
Measure and adjust while the engine is cold. • If adjusting each cylinder individually, the cylinder
to be adjusted first does not have to be the No. 1
Notes: cylinder. Select and adjust the cylinder where the
• The No. 1 piston position is on the flywheel end piston is nearest to the top dead center after
of the engine, opposite end of the radiator. The turning. Adjust the remaining cylinders in the
firing order is 1-3-2 . order of firing by turning the crankshaft each
time.
• 3-cylinder engines fire every 240° of crankshaft
rotation. • To decrease the number of rotations required to
• Valve clearance of both the intake and exhaust check all cylinders of a 3-cylinder engine, other
valves can be checked with the piston for that cylinders can also be checked as indicated in the
cylinder at top dead center (TDC) of the chart below. 2-cylinder engines must have each
compression stroke. When a piston is at TDC of cylinder adjusted when the piston is at TDC.
the compression stroke, both rocker arms will be
loose and the cylinder TDC mark on the flywheel Example: On a 3-cylinder engine, with the No. 1
will be visible in the timing port of the flywheel piston at TDC on the compression stroke (both
housing. valves closed), the valves indicated on the top line
of the chart can be adjusted without rotating the
• If there is no valve clearance, and the piston is at crankshaft. To adjust the remaining two valves,
TDC of the compression stroke, extreme wear or rotate the crankshaft until the No. 1 piston is at
damage to the cylinder head or valves may be TDC on the exhaust stroke (exhaust valve only
possible. open).
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 4-2-8.
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.)
4-2-20
4. ENGINE
3. Insert a feeler gauge (Figure 4-2-35, (1)) 6. Insert a feeler gauge of the correct thickness
between rocker arm and valve cap and record (Figure 4-2-37, (1)) between rocker arm and
the measured valve clearance. (Use the data valve cap. Turn the valve adjustment screw to
for estimating wear.) adjust the valve clearance so there is a slight
“drag” on the feeler gauge when sliding it
(1) between the rocker arm and valve cap. Hold
the adjusting screw while tightening the valve
adjusting screw lock nut (Figure 4-2-36, (1)).
Recheck the clearance.
Note: There is a tendency for the clearance to
decrease slightly when the lock nut is
tightened. It is suggested that the initial
clearance adjustment be made slightly
on the “loose” side before tightening the
lock nut.
(1)
0001782A
Figure 4-2-35
4. If adjustment is required, proceed to the next
step.
5. Loosen the valve adjusting screw lock nut
(Figure 4-2-36, (1)) and valve adjusting screw
(Figure 4-2-36, (2)) on the rocker arm. Check
the valve for inclination of the valve cap,
entrance of dirt, or wear.
0001782A
(2) Figure 4-2-37

7. Apply oil to the contact surface between
adjusting screw and push rod.
8. Rotate the crankshaft and measure the next
cylinder. Continue until all valves are adjusted.
(1)
0001783A
Figure 4-2-36
4-2-21
4. ENGINE
4-2-6 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 4-2-38
4-2-22
4. 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 NOTICE
12 – Camshaft End Plate
Identify all parts and their location using an
13 – Camshaft Gear
14 – Idler Gear Shaft
appropriate method. It is important that all parts
15 – Idler Gear Bushing are returned to the same position during the
16 – Idler Gear reassembly process.
17 – Oil Pickup O-Ring
18 – Oil Pickup
19 – Crankshaft IMPORTANT
20 – Crankshaft Gear Key
Mark all valve train components so they
21 – Crankshaft Gear
22 – Crankshaft Pulley
can be installed in their original locations.
23 – Main Bearing Inserts Note: Record all measurements taken during
24 – Main Bearing Cap disassembly.
25 – Crankcase Extension
26 – Oil Pan If the engine will be completely disassembled, the
27 – Thrust Bearings following preliminary steps should be performed:
28 – Flywheel
29 – Connecting Rod Cap 1. Disconnect the battery cables at the battery.
30 – Connecting Rod Bearing Inserts Always disconnect the negative (-) cable first.
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
35 – Piston
engine.
36 – Oil Ring 3. Remove the alternator. See Removal of
37 – Second Compression Ring Alternator on page 4-7-7.
38 – Top Compression Ring
4. Drain the engine coolant from the radiator and
39 – Dowel (2 used)
40 – Crankshaft Rear Seal
cylinder block. Remove the cooling system
41 – Flywheel Housing components from the engine.
NOTICE
Be sure to secure the engine solidly to prevent
injury or damage to parts due to the engine
falling during work on the engine.
5. Remove the engine from the machine. Mount

the engine to a suitable engine repair stand
having adequate weight capacity.
4-2-23
4. ENGINE
6. Clean the engine by washing with solvent, air

or steam cleaning. Carefully operate to prevent
any foreign matter or fluids from entering the
engine, fuel system, or electrical components
remaining on the engine. (3)
(1)
7. Drain the engine oil into a suitable container. (2)
Remove oil filter.
8. Remove the cylinder head. See Disassembly
of Cylinder Head on page 4-2-7.
9. Remove the fuel injection pump from the gear
case only if it must be sent out for repair, or will
interfere with other procedures such as “hot
0002181
tank” cleaning. See Removal of Fuel Injection
Pump on page 4-3-9. Figure 4-2-39
10. Remove the starter motor. See Removal of
Starter Motor on page 4-6-6.
Checking Timing Gear Backlash
Prior to removing the timing gears, measure the
Disassembly of Camshaft and gear backlash and determine the gear wear.
Timing Components Note: Check the backlash between each pair
Discard all gaskets, O-rings and seals. Use new of mating gears. If not within
gaskets, O-rings and seals on reassembly of specification, replace both mating gears.
camshaft and timing components. Do not allow the gear being checked to
move axially as excess end play could
Removal of Timing Gear Case Cover cause a false reading. See "3-2 Engine
1. Remove the bolt and washer retaining the Service Standard" section for the
crankshaft pulley. service limit.
IMPORTANT
Use care not to damage the threads in the 1
2
end of the crankshaft when removing the
crankshaft pulley. 3
C
2. Remove the crankshaft pulley with a gear C
B B
puller. A
3. Remove the bolts that retain the gear case 5 A
cover to the cylinder block and oil pan.

4 K0002190-01X
4. Remove the gear case cover
(Figure 4- 2-39, (1)). 1 – Fuel Injection Pump Drive Gear
5. Remove the dowel pins (Figure 4-2-39, (3)) 2 – Camshaft Drive Gear
and O-ring (Figure 4-2-39, (2)). 3 – Auxiliary Drive Gear (Optional)
4 – Crankshaft Drive Gear
5 – Idler Gear
Figure 4-2-40
4-2-24
4. ENGINE
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 4-2-42, (1)). Remove the idler gear
Figure 4- 2-41. shaft, idler gear (Figure 4-2-42, (3)) and
bushing (Figure 4-2-42, (2)).
(3)
(2)
(1)
00021
0002192
Figure 4-2-42
Figure 4-2-41
2. Do not remove the crankshaft gear unless it is
2. Rotate the idler gear back and forth to check damaged and requires replacement. If the gear
idler gear-to-crankshaft gear backlash. Total must be removed, remove it with a gear puller.
indicator reading is backlash. Record the
3. Removal of the camshaft gear requires the
measurement.
camshaft be removed with a press. Do not
Measuring Idler Gear-to-Camshaft Gear remove the camshaft gear unless it or the
camshaft is damaged and requires
Backlash
replacement. See Removal of Camshaft on
1. Drive a small wooden wedge between the page 4-2-27.
crankshaft gear and idler gear to prevent the
idler gear from rotating. NOTICE
2. Install a dial indicator to read camshaft gear Do not loosen or remove the four bolts retaining
backlash. Rotate camshaft drive gear against the fuel injection pump drive gear to the fuel
idler gear to measure backlash. Record the injection pump hub. Do not disassemble the fuel
measurement. injection pump drive gear from the hub. Correct
3. Check the idler gear-to-fuel injection pump fuel injection timing will be very difficult or
drive gear backlash in the same manner as the impossible to achieve.
camshaft drive gear. Record the measurement.
4-2-25
4. ENGINE
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 4-2-43, (3))
retaining pump drive gear to the hub. Only 2. Remove the oil pan (Figure 4-2-44, (2)).
remove the nut (Figure 4-2-43, (1)) and 3. Remove the crankcase extension (Figure 4-
washer (Figure 4-2-43, (2)), leaving the hub 2-44, (1)) if equipped.
attached to the gear. Remove the pump drive
gear and hub as an assembly using a gear
puller.
(3)
(1)
(1)
(2)
(2)
0002183
Figure 4-2-43
0002184
NOTICE
Figure 4-2-44
Do not loosen or remove the four bolts retaining
the fuel injection pump drive gear to the fuel 4. Remove the oil pickup tube (Figure 4-
injection pump hub. Do not disassemble the fuel 2-45, (1)) and O-ring (Figure 4-2-45, (2)).
injection pump drive gear from the hub. Correct
fuel injection timing will be very difficult or
impossible to achieve.
(2)
(1)
0002185
Figure 4-2-45
4-2-26
4. ENGINE
Removal of Camshaft 2. Remove two bolts (Figure 4-2-48, ( 3))

retaining the camshaft thrust plate
1. Before removing the camshaft, check the
(Figure 4- 2-48, ( 1 ) ) .
camshaft end play.
(5)
• Method A: Install a dial indicator
(Figure 4- 2-46, (1)) on the cylinder block.
Move the camshaft and gear
(Figure 4-2-46, (2)) in and out to measure the
end play. Record the measurement. See "3-2
Engine Service Standard" section for the
service limit.
(2)
(2)
(1)
(3)
(4)
0002186
Figure 4-2-48
3. Extract the tappets (Figure 4-2-48, (5))
through the top of the cylinder block. Mark the
(1) tappets so they can be reinstalled in the same
location.
4. Slowly pull the camshaft (Figure 4-2-48, (2))
0002191
assembly out of the engine being careful not to
damage the front camshaft bushing.
Figure 4-2-46
5. Remove the camshaft gear
• Method B: Use a feeler gauge to measure the (Figure 4-2-48, ( 4 ) ) only if the gear or
clearance between the thrust plate camshaft require replacement. Use a knife-
(Figure 4- 2-47, (1)) and front camshaft edge puller and a press to remove the gear.
bearing (Figure 4-2-47, (2)). Record the The gear is a shrink-fit and will need to be
measurement. See "3-2 Engine Service heated to 356° - 392°F (180° - 200°C) to
Standard" section for the service limit. remove.
(1)
(2)
0001710B
Figure 4-2-47
4-2-27
4. ENGINE
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 4-2-27. Removal of Pistons
1. Remove bolts (Figure 4-2-49, (4)).
NOTICE
Note: It is not necessary to remove the fuel
injection pump from the gear case to Keep the piston pin parts, piston assemblies, and
remove the gear case. If the fuel connecting rod assemblies together to be returned
injection pump does not need to be to the same position during the reassembly
repaired, leave it mounted to the timing process. Label the parts using an appropriate
gear case. See Removal of Fuel method.
Injection Pump on page 4-3-9. IMPORTANT
2. Remove the gear case (Figure 4-2-49, (1)) Engines with high operating hours may
from the cylinder block. have a ridge near the top of the cylinders
that will catch the piston rings and make it
3. Inspect and measure the camshaft bushing.
impossible to remove the pistons. Use a
See "3-2 Engine Service Standard" section for
suitable ridge reamer to remove ridges and
the service limit. If damaged or worn beyond
carbon prior to removing pistons.
service limits, remove the camshaft bushing
(Figure 4-2-49, (3)). Note: Pistons can fall from cylinder block if
4. Remove O-rings (Figure 4-2-49, (2)). engine is inverted. Rotate the engine so
the connecting rods are horizontal
before removing the connecting rod
caps.
(3)
(1)
(4)
(2)
0002187
Figure 4-2-49
4-2-28
4. ENGINE
1. Using a feeler gauge, measure the connecting 5. Reinstall the bearing cap and tighten to
rod side clearance (Figure 4-2-50). See "3-2 specification. See "3-7-2 Engine Tightening
Engine Service Standard" section for the Torque" section for tightening torque.
service limit. If the measurement is out of 6. Remove the bearing cap.
specification, replace the crankshaft,
connecting rod, or both.
(1)
0001899
Figure 4-2-52
7. Compare the width of the flattened
PLASTIGAGE (Figure 4-2-52, (1)) to the
graduation marks on the package. The mark
that most closely matches the width of the
flattened PLASTIGAGE will indicate the
0000219
bearing oil clearance. Record the
Figure 4-2-50 Standard" section for the service limit.
IMPORTANT 8. Repeat with the remaining connecting rods.
Mark the connecting rod caps and connecting
IMPORTANT
rods so the caps and connecting rods stay
Do not allow the connecting rod to contact
together.
the crankshaft journal during piston
2. Remove the bearing cap. Do not remove the removal. Damage to the bearing journal
bearing inserts at this time. may result.
3. Wipe oil from the bearing insert and crankshaft 9. Use a wooden dowel against the connecting
journal surfaces. rod and tap the piston / connecting rod
4. Place a piece of PLASTIGAGE® assembly out of the cylinder.
(Figure 4- 2-51, (1)) along the full width 10. Mark the cylinder number on the piston and
of the bearing insert. connecting rod.
(1)
0001898
Figure 4-2-51
IMPORTANT
Do not rotate crankshaft when using
PLASTIGAGE. A false reading may result.
4-2-29
4. ENGINE
11. Remove the bearing inserts

(Figure 4- 2-53, ( 2 ) ) . (2)
12. Remove the compression rings

(Figure 4- 2-53, ( 3)) from the piston using (3)
a piston ring expander.
(1)
13. Remove the oil ring (Figure 4-2-53, (4)) from
the piston using a piston ring expander.
(3)
(4) (4)
(5)
(9) (6) 0002188

(5)
Figure 4-2-54
3. Before removing the main bearing caps,
(8) measure the crankshaft end play. Use either of
(7) the following two methods:
(2) • Method A: Install a dial gauge
(Figure 4- 2-55, (1)) on the cylinder block.
(1) Move the crankshaft (Figure 4-2-55, (2))
in and out to measure the end play.
Record the measurement.
0001705A
Figure 4-2-53
14. Remove the circlips (Figure 4-2-53, (5)) from
the wrist pin.
15. Remove the wrist pin (Figure 4-2-53, (6)) and
connecting rod (Figure 4-2-53, (8)) from the
piston (Figure 4-2-53, (9)).
(1)
16. Repeat steps until all pistons are removed and
dissembled.
(2)
Removal of Crankshaft 0001961
1. Remove the flywheel (Figure 4-2-54, (1)) from Figure 4-2-55

the crankshaft.
2. Remove the bolts (Figure 4-2-54, (2)) from the
flywheel housing assembly. Remove the
flywheel housing from the engine.
4-2-30
4. ENGINE
• Method B: Use a feeler gauge to measure the

clearance (Figure 4-2-56, (3)) between the
thrust bearing (Figure 4-2-56, (1)) and
crankshaft (Figure 4-2-56, (2)). Record the (1)
measurement. See "3-2 Engine Tightening
Torque" section for tightening torque.
0001899
Figure 4-2-58
9. Compare the width of the flattened
PLASTIGAGE (Figure 4-2-58, (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 "3-2 Engine Service
(3) 0001962
10. Repeat with the remaining main bearings.
Figure 4-2-56
Note: Be sure to note the markings on the
4. Remove the bearing cap. Do not remove the main bearing caps, or make marks so
bearing inserts at this time. they can be reinstalled in the same
5. Wipe oil from the bearing insert and crankshaft order as they were removed. The
journal surfaces. “arrows” on the main bearing caps point
to the flywheel end of the engine.
6. Place a piece of PLASTIGAGE®
(Figure 4- 2-57, (1)) along the full width of
the bearing insert.
(1)
0001898
Figure 4-2-57
IMPORTANT
Do not rotate crankshaft when using
PLASTIGAGE. A false reading may result.
7. Reinstall the bearing cap and tighten to
specification. See "3-7-2 Engine Tightening
Torque" section for tightening torque.
8. Remove the bearing cap.
4-2-31
4. ENGINE
11. Remove the crankshaft from the engine. Inspection of Crankshaft and
12. Remove the bearing inserts Camshaft Components
(Figure 4- 2-59, (1)) and thrust bearings
(Figure 4- 2-59, (2)). WARNING
Note: Do not remove the crankshaft gear FUME / BURN HAZARD!
unless the gear or crankshaft are
damaged and require replacement. • Always read and
follow safety related
precautions found on
containers of
hazardous
cleaners, primers,
sealants and sealant
removers.
serious injury.
(1)
(2) Thoroughly clean all components using a brush

and appropriate solvent. Each part must be free of
carbon, gasket material, metal filings and other
0002189
debris.
Figure 4-2-59 Note: Record all measurements taken during
inspection.
13. If necessary, remove the crankshaft gear
(Figure 4-2-60, (1)) and key Replacement of Crankshaft Oil Seals
(Figure 4-2-60, (2)). If using a gear puller, be
1. Remove the seal (Figure 4-2-61, (2)) from the
careful not to damage the threads in the end
gear case cover (Figure 4-2-61, (1)).
of the crankshaft.
2. Apply a continuous bead of ThreeBond Liquid
(2)
Gasket No. 1212, Yanmar Part
No.977770-01212 to the outside diameter of a
new oil seal (Figure 4-2-61, (2)).
3. Install a new seal in the gear case cover with
(1) the lip facing in away from the crankshaft
pulley. Apply lithium grease to the lip of the
seal.
(1)
0002193
Figure 4-2-60
(2)
0002181A
Figure 4-2-61
4-2-32
4. ENGINE
4. Remove the rear oil seal (Figure 4-2-62, (1)) • Take measurements at three places (Figure 4-
from the flywheel housing (Figure 4-2-62, (2)). 2-63) (a, b, and c), and in two directions
(d and e) in each cylinder. Collect and record the
(2) measurements. See "3-2 Engine Service
a 20 mm
d
e
b
(1) c
20 mm
.) Figure 0000230B
Figure 4-2-62 4-2-63

5. Apply a continuous bead of ThreeBond Liquid Roundness
Gasket No. 1212, Yanmar Part No. Roundness can be calculated by subtracting the
977770-01212 to the outside diameter of a new smaller measured value from the larger measured
oil seal (Figure 4-2-62, (1)). value of (d or e) at each measuring location (a, b,
6. Install a new seal in the flywheel housing and c).
(Figure 4-2-62, (2)) with the lip facing in away
Taper
from the flywheel. Apply lithium grease to the
lip of the seal. Taper can be calculated by subtracting the
minimum measured value from the maximum
Crankshaft Bearing Oil Clearance measured value of locations (a, b, and c).
Oil clearance should be checked during Calculate along both the (d) axis and (e) axis and
disassembly to determine the extent of wear, and use the larger of the two calculations as the value
during assembly to ensure long engine life. The to compare to the specifications.
same procedure is done for both connecting rods
and main bearings. See Removal of Pistons on
page 4-2-28 or Removal of Crankshaft on
page 4- 2-30 for specific information.
Inspection of Cylinder Block

1. Ensure that oil passages are clear and
unobstructed.
2. Check for discoloration or evidence of cracks. If
a fracture is suspected, use the color check
method or the MAGNAFLUX® method to
determine if the cylinder block is fractured.
3. Measure cylinders for roundness, taper, and
inspect for evidence of scoring. Consider
honing, re-boring or replacing the cylinder
block if the measurements are not within
specification.
4-2-33
4. ENGINE
Inspection of Pistons, Piston Rings and 6. Measure the diameter of the wrist pin bore on
Wrist Pin both sides of the piston (Figure 4-2-65). See
"3-2 Engine Service Standard" section for the
Notes:
service limit. Record the measurements.
• On an engine with low hours, the pistons, piston
rings may be reused if they are found to be within
specifications. The pistons and piston rings must
be reinstalled in the same cylinders from which
they were originally removed.
• On an engine with high hours, the pistons rings
should be replaced and the cylinder honed (See
Honing and Boring on page 4-2-39) or replaced.
The piston should be replaced as necessary.
0000237
1. Clean piston ring grooves using a piston ring
groove cleaning tool. Follow manufacturer’s Figure 4-2-65
instructions for correct operation. 7. Measure the outside diameter of the wrist pin
2. Wash the pistons in an appropriate solvent in three places and at 90° (Figure 4-2-66). See
using a soft brush. "3-2 Engine Service Standard" section for the
3. Visually inspect each piston for cracks. Pay service limit. Record the measurements.
particular attention to the ring lands between
the piston ring grooves.
4. Measure the diameter of the piston skirt at 90°
to the wrist pin bore as shown (Figure 4-2-64).
Measurements must be taken at a specified
distance (Figure 4-2-64, (1)) from the bottom 0001889
of the piston, based on engine model. Record
the measurements. See "3-2 Engine Service Figure 4-2-66
Standard" section for the service limit. 8. Using a micrometer, measure the thickness of
each piston ring. See "3-2 Engine Service
Standard" section for the service limit. Record
the measurements.
Notes:
• On an engine with low hours, the pistons,
piston rings and cylinders may be reused if
(1) they are found to be within specifications.
• On an engine with high hours, the pistons
rings should be replaced and the cylinder
honed (See Honing and Boring on page 4-
0000235 2-39) or replaced. The piston should be
replaced as necessary.
Figure 4-2-64
9. Place each compression piston ring in the
5. Subtract the piston measurement from the groove as shown (Figure 4-2-67). Use a feeler
greatest measurement acquired during gauge to measure the clearance between the
cylinder inspection (see Inspection of Cylinder piston ring and the piston ring land. Record the
Block on page 4-2-33) to obtain piston-to- measurements. See "3-2 Engine Service
cylinder clearance. Record the measurements. Standard" section for the service limit. Replace
See "3-2 Engine Service Standard" section for the piston if not within specification.
the service limit.
4-2-34
4. ENGINE
Inspection of Connecting Rod

1. Measure the wrist pin bushing bore using a
bore gauge (Figure 4-2-69, (1)). Replace the
bushing if not within specifications. If the
bushing has been removed, measure the
inside diameter of the connecting rod small end
(Figure 4-2-69, (2)). Record the
0001892
Figure 4-2-67
10. To measure piston ring end gap, insert each
compression piston ring (Figure 4-2-68, (1)),
one at a time, into the cylinder. Use a piston
with the piston rings removed to slide the ring
into the cylinder bore until it is approximately
1.18 in. (30 mm) (Figure 4-2-68, (2)) from the (1)
bottom of the bore. Remove the piston.
Measure the end gap (Figure 4-2-68, (3)) of
each piston ring. Record the measurements. (2)
See "3-2 Engine Service Standard" section for 0001724A
the service limit.

Figure 4-2-69
2. Measure the connecting rod twist (Figure 4-
2-70, (1)) and bend (Figure 4-2-70, (2)) using
a connecting rod alignment tool (Figure 4-
2-71). Record the measurements. See "3-2
Engine Service Standard" section for the
service limit.
(1)
(2)
(2)
(3)
0001964
Figure 4-2-68
(1)
Note: Always check the piston ring end gap
when installing new piston rings. See "3-
2 Engine Service Standard" section for
the service limit. Use a piston ring end 0001896
gap filing tool to adjust the piston ring

end gap on new piston rings. Figure 4-2-70
11. Repeat the above steps for each cylinder and

piston assembly.
4-2-35
4. ENGINE
3. Measure the tappet bores in the cylinder block.

Record the measurements. See "3-2 Engine
Service Standard" section for the service limit.
Inspection of Crankshaft
1. Put the crankshaft end journals
(Figure 4- 2-74, (4)) on V-blocks.
0000242
2. Place a dial indicator (Figure 4-2-74, (3)) on a
Figure 4-2-71 center main bearing surface.
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 (2)
(1)
specified torque.
4. Measure the inside diameter. Record the
Inspection of Tappets
(3)
1. Inspect the tappet contact surfaces for
abnormal wear (Figure 4-2-72, (1)). Normal
wear will be even as shown in
(Figure 4- 2-72, (2)). Slight surface defects
can be corrected using an oilstone.
(4) (4) 0000232A
Figure 4-2-74
3. Rotate the crankshaft and observe runout.
4. Use the color check method or MAGNAFLUX
(1) (2) 0002194 to inspect the crankshaft for cracks. Replace
Figure 4-2-72 the crankshaft if evidence of fractures is found.
2. Measure the outside diameter of the tappet

stem (Figure 4-2-73, (1)). Record the
0002195
Figure 4-2-73
4-2-36
4. ENGINE
5. Measure the outside diameter of each crankpin Reconditioning the Crankshaft

(Figure 4-2-75, (2)) and main bearing journal
(Figure 4-2-75, (1)). See "3-2 Engine Service If any of the crankshaft journals do not meet the
Standard" section for the service limit. Take specifications, it may be possible to grind any or all
measurements at several places around each of them to an undersize. The connecting rod
bearing surface. If not within specification, bearings, main bearings, and thrust bearing
grind the journals and install undersize inserts are available as 0.010 in. (0.25 mm)
bearings, or replace the crankshaft. Record the undersize. If the journals are ground undersize, the
measurements. following finishing standards (Figure 4-2-76) must
be adhered to:
(1)
Ry
Ry
R R
R 0000234A
Figure 4-2-76
R
Item Finishing Precision
Connecting Rod Journal
41.702 - 41.712 mm
Undersize Finished Size
(1) Main Bearing Journal
46.702 - 46.712 mm
(2) 0001733A Undersize Finished Size
Figure 4-2-75 Journal Radius (R) 3.5 - 3.8 mm
Journal Face Finish (Ry) 0.8S (Super Polish)

Thrust Face Finish (1) 1.6
Inspection of Camshaft
1. Use V-blocks and a dial indicator to check
camshaft bend (Figure 4-2-77). Place the
indicator on the center bearing journal.
0002196
Figure 4-2-77
2. Rotate the camshaft and observe the runout.
4-2-37
4. ENGINE
3. Measure the height of each lobe Inspection of Camshaft Bushing and Bores
(Figure 4- 2-78, ( 1 ) ) . Record the
1. Measure the I.D. of the front bushing and the
remaining bores in the cylinder block. Record
the measurements. See "3-2 Engine Service
If the camshaft bushing is not within specification,
(1) replace using the appropriate service tool. If the
remaining bores are not within specification, the
cylinder block will require replacement as there are
no bearing inserts used.
Inspection of Idler Gear and Shaft

0001712A
1. Measure the outside diameter
Figure 4-2-78 (Figure 4-2-80, (1)) of the idler gear shaft
4. Measure the diameter of the gear end (Figure 4-2-80, (2)). Record the
(Figure 4-2-79, (1)), intermediate measurements. See "3-2 Engine Service
(Figure 4- 2-79, (2)), and flywheel end Standard" section for the service limit.
(Figure 4-2-79, (3)) bearing journals. 2. Measure the inside diameter
Record the measurements. (Figure 4-2-80, (3)) of the idler gear bushing
See "3-2 Engine Service Standard" section (Figure 4- 2-80, (4)). Record the
for the service limit. measurements. See "3-2 Engine Service
(3) (4)
(2)
(1) (1) (3)
(2)
0001713A Figure 4-2-80

Figure 4-2-79
4-2-38
4. ENGINE
Honing and Boring (1)

Pistons must move freely in the cylinders while
maintaining adequate compression and oil sealing.
If the cylinder walls are scuffed, scored,
out-of-round, or tapered beyond specifications,
rebore and hone to restore cylinders to usable
condition. Slight imperfections can be corrected by
honing alone.
1. Boring - Significant cylinder damage may be
corrected by boring the cylinder to an oversize
dimension. Refer to the appropriate parts 0000248A
catalog for available oversize pistons and
Figure 4-2-81
piston rings.
• Boring a cylinder should always be done in a • Use a 50:50 mixture of diesel fuel and engine
properly equipped machine shop. oil as a honing fluid.
• A bored cylinder should always be finished • Use a 300-grit hone at 300 - 1200 rpm
with a hone to properly prepare the cylinder (Figure 4-2-82).
surface so the new piston rings will seat
(1)
properly.
• After the cylinder has been bored and honed, (2)
install the appropriate oversize pistons and
piston rings.
2. Honing - Minor cylinder imperfections may be
corrected by using a rigid cylinder hone
(Figure 4-2-82, (1)). Be sure not to exceed the 0000249B
maximum cylinder bore specification.
Deglazing - A used cylinder that did not require Figure 4-2-82
boring or honing, should always be deglazed
with a ball hone (Figure 4-2-82, (2)) before IMPORTANT
installing new piston rings. This will properly Solvents will not adequately remove honing
prepare the cylinder surface to allow new piston residue, resulting in premature piston and
rings to seat properly. ring wear. Always wash cylinders using hot,
soapy water.
Note: When honing a cylinder, with either a
ridged hone or a ball hone • When honing is completed, wash the cylinder
(Figure 4- 2-81, (1)), move the rotating block with hot water and soap. The cylinder
hone up and down in the cylinder bore wall is adequately cleaned when a white rag
to accomplish a 30° to 40° crosshatch wiped in cylinder comes out clean. Use
pattern (Figure 4-2-81). This will brushes to clean all passages and crevices.
provide the ideal surface for the proper Rinse with hot water and dry with compressed
seating of new piston rings. air. Apply clean engine oil to all steel surfaces
to prevent rusting.
NOTICE
Do not allow the honing tool to operate in one
position for any length of time. Damage to the
cylinder wall will occur. Keep the tool in constant
up-and-down motion.
4-2-39
4. ENGINE
Reassembly of Crankshaft and Reassembly of Pistons

Piston Components 1. Select the parts needed to assemble the piston
and connecting rod for one cylinder.
Notes:
2. If removed, install a new wrist pin bushing
• Proceed slowly. Make no forced assemblies (Figure 4-2-83, (7)) using a press and the
unless a pressing operation is called for. All appropriate service tool. Be sure to align the oil
parts must be perfectly clean and lightly holes.
lubricated when assembled.
(3)
• Use new gaskets, seals and O-rings during
assembly. (4)
• Liberally apply clean engine oil to all internal
parts during assembly. (5)
• All fasteners should be tightened to a given (9) (6)

torque. If a special torque is not provided in the (5)
See "3-7-2 Engine Tightening Torque" section
for tightening torque, tighten to standard
torque specifications. (8)
(7)
(2)
(1)
0001705A
Figure 4-2-83
3. Reinstall one circlip (Figure 4-2-83, (5)) into
the piston. Ensure the circlip is securely seated
in the groove.
IMPORTANT
The piston and connecting rod must be
assembled with the correct orientation.
When correctly assembled, the piston
identification mark (Figure 4-2-84, (1))
stamped into the top of the piston will be on
the opposite side of the connecting rod as
the match marks (Figure 4-2-84, (3))
stamped into the connecting rod and
connecting rod cap. When reinstalled in the
cylinder, the embossed mark
(Figure 4- 2-84, (2)) cast into the beam of
connecting rod will face the flywheel end of
the engine.
Note: The actual appearance of the match
marks will vary but they will always be in
the same locations.
4-2-40
4. ENGINE
(6) (1)
CHMS
(2) (5)
(3)
(1) 0002464
(4)
(2)
0000227A
E106 R 1 – Fuel Injection Pump Side of Engine

2 – Piston Identification Mark
3 – Embossed Mark on Connecting Rod
0002090 4 – Connecting Rod and Cap Match Marks
5 – Flywheel End of Engine
(3) 6 – Camshaft Side of Engine
Figure 4-2-85
80 80
0002089
Figure 4-2-84
4. Place the connecting rod into the piston. The
match marks (Figure 4-2-85, (4)) on the
connecting rod and cap must be on the
opposite side as the piston identification mark
(Figure 4-2-85, (2)) on the top of the piston.
4-2-41
4. ENGINE
5. Lubricate and install the wrist pin IMPORTANT

(Figure 4- 2-86, (6)) through the piston and Always use a piston ring expander when
connecting rod. installing piston rings. Never attempt to
6. Reinstall the second circlip (Figure 4-2-86, (5)) install piston rings by hand.
and ensure it is securely seated in the groove. 7. Reinstall the oil ring expander
Note: If installing new piston rings the end gap (Figure 4- 2-88, ( 4 ) ) . Install the oil ring
must be checked and adjusted as (Figure 4-2-88, ( 3)) with the end gap at
necessary. See Inspection of Pistons, 180° from the expander end gap.
Piston Rings and Wrist Pin on page 4- 8. Reinstall the second compression ring
2-34. Use a piston ring end gap filing (Figure 4-2-88, (2)). This ring is identified by
tool to adjust the piston ring end gap on its dark color and tapered face profile.
new piston rings.
9. Reinstall the top compression ring
(3) (Figure 4- 2-88, ( 1 ) ) . This ring is identified
by its silver color and barrel-shaped face
(4) profile.
(5) IMPORTANT
(9) (6) The oil ring expander (Figure 4-2-88, (4))
(5) end gap must be located 180° from the oil
ring (Figure 4-2-88, (3)) end gap.
(8) (1)
(7)
(2)
(2)
(1)
(3)
0001705A
Figure 4-2-86 (4)

0001722B
Note: Reinstall the top and second piston
rings with the stamped “makers mark” Figure 4-2-88
(Figure 4-2-87, (1)) facing the top of the 10. Stagger the piston ring end gaps at 120°
piston. The “makers mark” may vary in intervals (Figure 4-2-89, (1, 2, and 3)). Do not
appearance but will always be located position the top piston ring end gap in line with
on the top surface of the piston ring the wrist pin.
adjacent to the piston ring gap. The oil
ring and oil ring expander can be
installed either side up.
(1)
0000225A
Figure 4-2-87
4-2-42
4. ENGINE
(1) IMPORTANT
The main bearing caps are numbered and
have arrows for proper positioning. The No.
1 cap is at the flywheel end. The arrows
(2) point toward the flywheel end of the engine.
4. Reinstall the main bearing caps.
(3)
5. Apply a light coat of clean engine oil to the
bearing cap bolts and tighten the bolts to the
specified torque in two stages (1/2 then full
torque). See "3-7-2 Engine Tightening Torque"
section for tightening torque.
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
1 – Top Compression Ring End Gap (Figure 4-2-91, (2)).
2 – Second Compression Ring End Gap
8. Align the flywheel housing with the two dowel
3 – Oil Ring End Gap
pins (Figure 4-2-91, (3)).
Figure 4-2-89 9. Reinstall flywheel housing and seal assembly.
Installation of Crankshaft 10. Reinstall the flywheel (Figure 4-2-91, (1)) and
tighten the bolts to the specified torque. See
1. If removed, reinstall the key and timing gear on
"3-7-2 Engine Tightening Torque" section for
crankshaft.
tightening torque.
2. Install new bearing inserts (Figure 4-2-90, (1))
and thrust bearing (Figure 4-2-90, (2)) in the (2)
cylinder block and main bearing caps. Be sure
the oil holes in the upper bearing shells align
with the oil ports in the cylinder block. Apply a (3)
liberal coat of clean engine oil to the bearings
(1)
and crankshaft journals.
(4)
0002188
Figure 4-2-91
(1)
(2)
0002189
Figure 4-2-90
3. Install the crankshaft in the engine.
4-2-43
4. ENGINE
Installation of Pistons IMPORTANT

The piston and connecting rod must be
IMPORTANT reinstalled with the correct orientation.
Do not allow the connecting rod to contact When installed correctly, the identification
the crankshaft journal during piston mark (Figure 4-2-93, (2)) stamped into the
installation. Damage to the crankshaft top of the piston will be on the same side of
bearing journal may result. the engine as the fuel injection pump
1. Lubricate piston, piston rings, and cylinder with (Figure 4-2-93, (1)) and the embossed
clean engine oil or assembly lubricant. mark (Figure 4-2-93, (3)) cast into the
connecting rod beam will face the flywheel
2. Rotate the crankshaft so the crankpin for the
end of the engine (Figure 4-2-93, (5)).
piston being installed is near bottom dead
center. 4. Carefully reinstall the piston and rod assembly.
Be sure the match marks (Figure 4-2-93, (4))
(1) stamped into the connecting rod and cap are
facing the fuel injection pump side of the
cylinder block, and the piston identification
mark (Figure 4-2-93, (2)) stamped into the
(2) piston top is facing the camshaft side
(Figure 4-2-93, (6)). The embossed mark cast
(3)
into the connecting rod beam (Figure 4-
2-93, (3)) will be facing the flywheel end of the
engine (Figure 4-2-93, (5)).
(6) (1)
0000226A (2) (5)

1 – Top Compression Ring End Gap
2 – Second Compression Ring End Gap
3 – Oil Ring End Gap
Figure 4-2-92 (3)
IMPORTANT
Ensure piston ring gaps are located
(4)
correctly (Figure 4-2-92).
3. Using a piston ring compressor, compress the
0000227A
piston rings.
1 – Fuel Injection Pump Side of Engine
2 – Piston Identification Mark
3 – Embossed Mark on Connecting Rod
4 – Rod and Cap Match Marks
5 – Flywheel End of Engine
6 – Camshaft Side of Engine
Figure 4-2-93
5. Reinstall the bearing insert
(Figure 4- 2-94, (1)) in the connecting
rod and cap.
4-2-44
4. ENGINE
6. Apply a liberal coat of clean engine oil to the

bearing inserts and crankshaft journal.
(3)
7. Apply a light coat of clean engine oil to the rod (1)
cap bolts. Reinstall the connecting rod cap
(Figure 4-2-94, (2)). Tighten the connecting (4)
rod bolts to the specified torque in two stages
(1/2 then full torque). See "3-7-2 Engine
Tightening Torque" section for tightening
torque. (2)
0002187
Figure 4-2-95
4. Reinstall the gear case (Figure 4-2-95, (1)).
(1) Tighten the bolts (Figure 4-2-95, (4)) to the
specified torque.
(2)
Installation of Camshaft
Note: The gear housing must be installed prior
to reinstalling the camshaft. See
Installation of Gear Case on page 4-
0001965 2-45.
Figure 4-2-94 1. If removed, reinstall the camshaft end plate
(Figure 4-2-96, (1)), key, and camshaft gear
8. Reinstall the remaining pistons in their
(Figure 4-2-96, (4)) onto the camshaft using a
respective cylinders.
press.
Reassembly of Camshaft and Timing • Heat the gear to 180 - 200°C and press onto
Components the end of the camshaft.
2. Lubricate the camshaft (Figure 4-2-96, (2))
Installation of Gear Case with clean engine oil or assembly lube. Slowly
1. If removed, install a new camshaft bushing insert the camshaft through the front of the
(Figure 4-2-95, (3)) using the appropriate engine.
service tool. 3. Reinstall and tighten the cap screws
2. Apply a continuous bead of ThreeBond Liquid (Figure 4- 2-96, (3)).
Gasket No. 1212, Yanmar Part No.
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 4- 2-95, (2)).
(2)
(1)
(3)
(4)
0002186
Figure 4-2-96
4-2-45
4. ENGINE
4. Lubricate the camshaft lobes and tappets with

clean oil or assembly lube. Reinstall the 1
tappets in their respective locations in the 2
cylinder block. Push the tappets fully into the
3
tappet bores until they make solid contact with C
C
the camshaft. B B
5. If removed, reinstall the fuel injection pump. A
Adjust the fuel injection timing after installation. 5 A
See Checking and Adjusting Fuel Injection

4 K0002190-01X
Timing on page 4-3-15.
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 4- 2-98, ( C ) ) is approximately at
the 9 o’clock position. Figure 4-2-98
3. Lubricate the idler gear (Figure 4-2-97, (3)), 7. When all gears are properly aligned, tighten
bushing (Figure 4-2-97, (2)) and idler gear the idler gear retaining bolts to specified
shaft (Figure 4-2-97, (1)) with clean engine oil torque. See "3-7-2 Engine Tightening Torque"
or assembly lube. section for tightening torque.
Installation of Gear Case Cover

977770-01212 to the mounting area of the gear
(3) case cover (Figure 4-2-99, (1)). Be sure to
(2) circle the bolt holes.
(1)
0002182
(3)
Figure 4-2-97 (1)
(2)
4. Align the timing gears as shown in
Figure 4- 2-98.
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 4- 2-98, (A, B, and C)) are 0002181
aligned. Figure 4-2-99

2. Reinstall the dowels (Figure 4-2-99, (3)) and a
new O-ring (Figure 4-2-99, (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.
4. Reinstall and tighten the gear case cover bolts.
4-2-46
4. ENGINE
5. Reinstall the crankshaft pulley. Final Assembly of Engine

6. Reinstall the washer and bolt. Tighten to the 1. Reinstall the starter motor.
specified torque. See "3-7-2 Engine Tightening 2. Reinstall the cylinder head. See Reassembly
Torque" section for tightening torque. of Cylinder Head on page 4-2-15.
Installation of Oil Pan 3. Reinstall the engine in the machine.
1. Reinstall the oil pickup tube 4. Reconnect the fuel and coolant lines.
(Figure 4- 2-100, (1)) and a new O-ring 5. Reinstall the alternator.
(Figure 4- 2-100, (2)).
6. Reconnect and adjust the throttle cable.
7. Reconnect all electrical connections.
8. Fill the engine with oil and coolant.
9. Reconnect the battery cables, negative (-)
cable last.
(2)
(1)
0002185
Figure 4-2-100
977770-01212 to the mounting surface of the
oil pan (Figure 4-2-101, (2)) and crankcase
extension (if equipped) (Figure 4-2-101, (1)).
Be sure to circle each bolt hole.
3. If equipped, reinstall the crankcase extension
(Figure 4-2-101, (1)). Reinstall the oil pan and
tighten the bolts securely.
(1)
(2)
0002184
Figure 4-2-101
4-2-47
4. ENGINE
4-3 Fuel System

4-3-1
4. ENGINE
4-3-2 Introduction
(4)
(3)
(1)
(2)
(5) (6)
0002238
Figure 4-3-1
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 4-3-1, (1)) for each cylinder, a camshaft
system components. This fuel injection pump is (Figure 4-3-1, (2)), and a pump housing
representative of the fuel injection pumps used on (Figure 4-3-1, (3)). A delivery valve
other TNV IDI model engines. (Figure 4- 3-1, (4)) connects to a high-pressure
fuel line for each cylinder. The fuel injection pump
Fuel Injection Pump housing contains a governor (Figure 4-3-1, (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 4-3-1, (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.
4-3-2
4. ENGINE
NOTICE Stop Solenoid

The ML fuel injection pumps are equipped with a
stop solenoid that controls the fuel flow inside the
fuel injection pump.
adjusting screw or the high-speed throttle limit
screw on the fuel injection pump and governor With the starter switch in the OFF position, no
assembly. These adjustments have been made current flows to the stop solenoid and the solenoid
at the factory to meet all applicable emissions plunger is extended holding the fuel injection pump
regulations and then sealed. fuel rack in the “closed” position and not allowing
fuel to flow through the injection pump and to the
engine.
these sealed adjustment screws. If adjustments
are required, they can be made only by a When the starter switch is turned to the start
qualified fuel injection shop that will ensure the position, the “pull coil” (36.5 Amp draw / white wire)
injection pump continues to meet all applicable inside the solenoid is activated and pulls the
emissions regulations and then replace the solenoid plunger into the solenoid. This releases
tamper-proof seals. the fuel injection pump fuel rack, allowing fuel to
flow through the injection pump and allowing the
• Tampering with or removing these devices may
engine to start and run.
void the “Yanmar Limited Warranty.”
When the starter switch is returned to the ON or
RUN position, the “pull coil” no longer receives
The fuel injector is essentially a spring-loaded current and the “hold coil” (0.5 Amp draw / red
valve. When fuel pressure from the fuel injection wire) inside the solenoid is activated. The “hold
pump reaches a pre-determined level, the pintle coil” holds the solenoid plunger in the RUN
(valve) is forced off its seat and fuel is atomized as position, allowing fuel to continue flowing and the
it passes between the pintle and seat. The timing engine to continue running.
and quantity of the fuel injected into the cylinder is
To stop the engine, the key switch is turned to the
controlled by the fuel injection pump and governor
OFF position. Current no longer flows to the stop
assembly.
solenoid “hold coil,” and the solenoid plunger
extends and moves the injection pump fuel rack to
the “closed” position, and shutting off the fuel flow
and stopping the engine.
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.
4-3-3
4. ENGINE
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
4-3-4 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.
4-3-4
4. ENGINE
4-3-5 Fuel System Diagram
(9)
(8)
(10)
(12)
(7)
(11)
(1)
(3)
(6)
(5) (2)
(4)
0001058A
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
Figure 4-3-2
4-3-5
4. ENGINE
4-3-6 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 4-3-3
4-3-6
4. ENGINE
1 – High-Pressure Fuel Injection Lines 4-3-7 Fuel Injection Lines

2 – Fuel Return Line Nut
3 – Fuel Return Line Removal of High-Pressure Fuel
4 – Fuel Injector
5 – Gasket
Injection Lines
6 – Protector
7 – Fuel Return Hose NOTICE
8 – Fuel Injection Pump Drive Gear Nut Remove or install the high-pressure fuel injection
9 – Lock Washer
lines as an assembly whenever possible.
10 – Fuel Injection Pump Drive Gear Assembly
(DO NOT remove or loosen the four bolts
that fasten the injection pump drive gear to lines from the retainers or bending any of the fuel
the injection pump drive gear hub!) lines will make it difficult to reinstall the fuel lines.
11 – Fuel Injection Pump
12 – Lube Oil Line
13 – Mechanical Fuel Supply Pump (Optional on Note: To prevent “rounding” the fuel line nuts
some models) always use a “line” or “flare nut” wrench.
14 – Fuel Return Fitting
15 – Low Pressure Fuel Inlet Fitting 1. Close any fuel valves in the fuel supply line.
16 – Fuel / Water Separator
2. Clean the area to keep contaminants from
17 – Electric Fuel Supply Pump
18 – Fuel Filter
entering the fuel system.
19 – Fuel Filter Mount 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 4-3-4). Repeat with the remaining fuel
injectors.
0002237
Figure 4-3-4
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.
4-3-7
4. ENGINE
Installation of High-Pressure Fuel Removal of Fuel Return Line

Injection Lines 1. Clean the area to keep contaminants from
NOTICE 2. Remove the high-pressure fuel injection lines
Remove or install the high-pressure fuel injection as an assembly. See Removal of High-
lines as an assembly whenever possible. Pressure Fuel Injection Lines on page 4-3-7.
lines from the retainers or bending any of the fuel NOTICE
lines will make it difficult to reinstall the fuel lines. The fuel return line is a one-piece assembly. Use
care not to bend or twist the fuel return line.
Note: To prevent “rounding” the fuel line nuts

always use a “line” or “flare nut” wrench.
1. Start all the fuel line nuts by hand. Then use a
(1)
wrench to just “snug” all the fuel line nuts.
(2)
2. Tighten the fuel line nuts on the fuel injection
pump to the specified torque.
3. When tightening the fuel line nuts on the fuel
(3)
injectors, use one wrench to hold the fuel
return line nut and fuel return line from rotating.
Use a second wrench to tighten the fuel line (4)
nuts (Figure 4-3-5).
Figure 4-3-6
3. Remove all fuel return line nuts
0002237
(Figure 4- 3-6, (2)) from the injectors
Figure 4-3-6, (4)).
Figure 4-3-5 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 4-3-6, (3)).
6. Remove and discard the copper gasket
(Figure 4-3-6, (1)) from each fuel injector.
7. Plug or cap all openings to minimize leakage
and prevent contamination.
4-3-8
4. ENGINE
Installation of Fuel Return Line 4-3-8 Fuel Injection Pump

1. Install a new copper gasket on each fuel Removal of Fuel Injection Pump
injector.
1. Loosen the cooling fan V-belt.
NOTICE 2. Remove the engine cooling fan guard
The fuel return line is a one-piece assembly. Use (if equipped),
care not to bend or twist the fuel return line. engine cooling fan (Figure 4- 3-7, (2)),
spacer (Figure 4-3-7, (3)) if equipped,
V-pulley (Figure 4-3-7, (4)) and cooling
fan V-belt (Figure 4-3-7, (1)).
2. Carefully reinstall the fuel return line assembly.
3. Reinstall and hand-tighten the fuel return line
nuts.
4. Tighten the fuel return line nuts to the specified
torque.
(3) (2)
5. Reinstall the fuel return hose.
6. Reinstall the high-pressure fuel injection line
assembly. See Installation of High-Pressure
Fuel Injection Lines on page 4-3-8.
(1)
(4) 0000163A
Figure 4-3-7
3. Close any fuel valves in the fuel supply line.
4. Place a drain pan under the fuel injection pump
to catch any spillage.
5. Clean the area to keep contaminants from
6. Remove the high-pressure fuel injection lines
as an assembly. See Removal of High-
Pressure Fuel Injection Lines on page 4-3-7.
7. Disconnect the fuel return lines from the fitting
on the fuel injection pump (Figure 4-3-8, (1)).
Plug the open ends of the lines to minimize
leakage and prevent contamination.
4-3-9
4. ENGINE
Note: The cover is secured with an adhesive

sealant. Use a gasket scraper to
separate the cover from the gear case
cover.
(2) (2)
(1)
(3)
(1)
0002211
Figure 4-3-10
14. To aid in reassembly, make reference marks
0002210
(Figure 4-3-11, (1)) on the drive gear and idler
Figure 4-3-8 gear.
8. Remove the fuel supply line (Figure 4-3-8, (2)) NOTICE

from the fitting on the fuel injection pump.
After marking the position of the pump drive
9. Plug or cap all openings to minimize leakage gear, do not rotate the engine crankshaft.
and prevent contamination. Rotating the crankshaft will cause the fuel
10. Remove the throttle cable from the fuel injection pump to become misaligned.
injection pump.
11. Separate the stop solenoid wiring connector
(Figure 4-3-8, (3)).
12. Remove the lube oil line (Figure 4-3-9, (1))
from the fuel injection pump and cylinder block.
IMPORTANT
Take care to not damage or bend the lube
oil line.
(1)
(1) 0002096
Figure 4-3-11
NOTICE
0002239 Do not loosen or remove the four bolts retaining
the fuel injection pump drive gear to the fuel
Figure 4-3-9
injection pump hub. Do not disassemble the fuel
13. Remove the fuel injection pump drive gear injection pump drive gear from the hub. Correct
access cover (Figure 4-3-10, (1)) from the fuel injection timing will be very difficult or
gear case cover (Figure 4-3-10, (2)). impossible to achieve.
4-3-10
4. ENGINE
15. Do not loosen or remove the four bolts 18. Once the fuel injection pump drive gear and
(Figure 4-3-12, (3)) holding the pump drive hub assembly have “popped” loose from the
gear to the hub. Only remove the single drive tapered fuel injection pump drive shaft,
gear nut (Figure 4-3-12, (1)) and washer carefully remove the drive gear nut (Figure 4-
(Figure 4-3-12, (2)), leaving the hub attached 3-14, (1)) and lock washer (Figure 4-3-14, (2)).
to the gear.
(3)
(1)
(1)
(2)
(2) 0002183A

16. Hold the gear train stationary using a large 19. Locate the mark (Figure 4-3-15, (1)) stamped
socket wrench on the crankshaft pulley bolt. into the upper outside mounting boss of the
Loosen the fuel injection pump drive gear fuel injection pump. Highlight this mark and
retaining nut (Figure 4-3-12, (1)) and turn it out make a corresponding mark on the gear case
to the end of the fuel injection pump shaft. or front plate.
17. Remove the injection pump drive gear and hub
from the injection pump drive shaft as an
assembly using an appropriate gear puller
(Figure 4-3-13).
(1)
0002416
Figure 4-3-15
20. Remove the three nuts fastening the fuel
injection pump to the gear case. Remove the
0002209
fuel injection pump. Leave the fuel injection
Figure 4-3-13 pump drive gear in the gear case and meshed
with the idler gear.
Note: The injection pump drive gear can be
removed from the gear case; however, it NOTICE
is best to let it remain in the gear case.
Do not rotate the crankshaft with the injection
pump removed.
4-3-11
4. ENGINE
21. If the fuel injection pump requires servicing, it Installation of Fuel Injection Pump
must be sent to an authorized Yanmar FIE
repair facility for repair and calibration, or 1. Ensure the fuel injection pump drive gear is
replaced with a new fuel injection pump. aligned with the idler gear using the reference
marks made earlier (Figure 4-3-16, (1)).
NOTICE
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. (1)
these sealed adjustment screws. If
adjustments are required, they can be made
only by a qualified fuel injection shop that will 0002096
ensure the injection pump continues to meet

Figure 4-3-16
all applicable emissions regulations and then
replace the tamper-proof seals. 2. If installing the fuel injection pump on an
• Tampering with or removing these devices engine with the front gear case cover removed,
may void the “Yanmar Limited Warranty.” the fuel injection pump drive gear can be
aligned with the idler gear by aligning the
stamped marks (Figure 4-3-17, (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
2
3
C
C
B B
5 A
4 K0002190-01X
1 – Fuel Injection Pump Drive Gear

2 – Camshaft Drive Gear
3 – Optional Accessory Drive Gear
4 – Crankshaft Drive Gear
5 – Idler Gear
Figure 4-3-17
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.
4-3-12
4. ENGINE
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 4-3-18, (2)) and nut (Figure 4-
3-18, (1)). Do not lubricate threads of the nut or
shaft. Hold the crankshaft pulley bolt with a (1)
socket wrench and tighten the drive gear nut to
the specified torque.
0002416
Figure 4-3-19
7. Tighten the fuel injection pump retaining nuts
to specification.
8. Reconnect the fuel supply and return lines to
the fuel injection pump.
9. Reconnect the throttle linkage and stop
(1) solenoid connector.
10. If installing a new or recalibrated fuel injection
pump, check the fuel injection timing before
completing the installation of the fuel injection
(2)
pump. See Checking and Adjusting Fuel
Injection Timing on page 4-3-15.
0002183A
Note: While it is not required to check the
Figure 4-3-18 injection timing when reinstalling the
6. Align the reference marks (Figure 4-3-19, (1)) original fuel injection pump, it is
made during disassembly on both the fuel recommended that it be done.
injection pump mounting flange and gear case. 11. Reinstall the lube oil line (Figure 4-3-20, (1)).
If installing a replacement fuel injection pump,
align the manufacturer-applied mark on the
pump mounting flange with the mark made on
the timing gear cover.
(1)
0002239
Figure 4-3-20
4-3-13
4. ENGINE
12. Apply ThreeBond Liquid Gasket No. 1212,

Yanmar Part No. 977770-01212, or equivalent
sealant to the sealing surface of the fuel
injection pump drive gear access cover.
Reinstall the cover on the front of the gear case
and tighten the bolts.
13. Reinstall the fuel injection high-pressure lines.
See Installation of High-Pressure Fuel Injection
Lines on page 4-3-8.
IMPORTANT
When installing a new or repaired fuel
injection pump, add 5 - 7 oz (150 - 200 cc)
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 4-
3-21, (4)), spacer (Figure 4-3-21, (3)) (if
equipped) and engine cooling fan (Figure 4-
3-21, (2)).
(3) (2)
(1)
(4) 0000163A
Figure 4-3-21
15. Reinstall the cooling fan V-belt (Figure 4-
3-21, (1)).
16. Reinstall the cooling fan guard (if equipped).
17. Prime the fuel system.
18. Operate the engine and check for fuel and lube
oil leaks.
4-3-14
4. ENGINE
4-3-9 Checking and Adjusting Fuel Injection 5. Using a wrench on the crankshaft pulley bolt,
Timing rotate the crankshaft in a clockwise direction
while looking through the flywheel inspection
Note: The following procedure is performed on port (Figure 4-3-23, (1)). Rotate the crankshaft
the No. 1 cylinder. While checking and until the injection timing marks on the flywheel
adjusting the timing on only No. 1 are visible for No. 1 cylinder.
cylinder is usually sufficient, the same
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 (1) 00020
fuel.
2. Clean the area around the fuel injection pump. Figure 4-3-23
Note: The stop solenoid must be removed to 6. Typical flywheel markings are as shown in
allow fuel to flow through the fuel (Figure 4-3-24).
injection pump. Note: A typical flywheel will have multiple
3. Remove two screws (Figure 4-3-22, (1)). timing grids depending on the number of
Remove the stop solenoid (Figure 4-3-22, (2)) cylinders. Any grid and its
and O-ring (Figure 4-3-22, (3)). corresponding cylinder can be used to
check the fuel injection timing.
(3)
(2)
(4)
(2)
(1)
(3)
1
(1)
(5)
0002071A
1 – 15° BTDC (Before Top Dead Center)

2 – 20° BTDC
3 – 25° BTDC
4 – Direction of Rotation
5 – TDC (Top Dead Center)
0002468
Figure 4-3-24
Figure 4-3-22
7. The flywheel shown in (Figure 4-3-24) is for a
4. Set the throttle to the HIGH-IDLE position. 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.
4-3-15
4. ENGINE
Note: The TDC (Top Dead Center) mark can

be identified by the cylinder numbers (1)
stamped near the TDC mark (Figure 4- (2)
3-25, (5)) on the flywheel.
1
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° 0002065A
apart.) Then measure the distance from the
Figure 4-3-25
TDC mark to the first “longer” mark on the
timing grid. Divide that measurement by the
distance between the two “longer” marks. The (2)
resulting answer will tell you how many (1)
degrees there are between the TDC mark and
the first “longer” mark.
• EXAMPLE: If the distance between the two
“longer” marks is approximately 2.0 cm and
the distance from the TDC mark is
approximately 4.0 cm, the answer is
approximately 2. This indicates there is 10°
(2 x 5°) between the TDC mark and the first 0002142
“longer” mark on the timing grid. That means Figure 4-3-26
the first “longer” mark on the timing grid
indicates 10° BTDC, the second “longer” mark 10. Highlight the target timing mark (Figure 4-
indicates 15° BTDC and the third timing mark 3-26, (1)), (Figure 4-3-27, (1)) on the flywheel
indicates 20°. If the answer is 3, that indicates timing grid as determined in the Fuel Injection
there is 15° (3 x 15°) between the TDC mark Timing Chart below.
and the first “longer” mark and that the first
“longer” mark indicates 15° BTDC with the
second and third “longer” marks indicating 20°
BTDC and 25° BTDC respectively. (1)
(2)
9. Highlight the timing reference mark on the
flywheel housing (Figure 4-3-25, (2)) or engine
back plate (Figure 4-3-26, (2)). Highlight the
TDC (Top Dead Center) mark (Figure 4-
3-25, (1)), (Figure 4-3-26, (1)) on the flywheel.
0002066
Figure 4-3-27
4-3-16
4. ENGINE
Fuel Injection Timing Chart

Model VM
Engine Speed (rpm) 2000 to 2100 2200 2300 to 2600 2700 to 3000
Injection Timing BTDC ±1 15° 16° 18°
11. Remove all high-pressure fuel injection lines. 14. Slowly rotate the crankshaft clockwise using a
See Removal of High-Pressure Fuel Injection wrench on the crankshaft pulley bolt until fuel is
Lines on page 4-3-7. pumped from the nozzle of the “spill-timing”
12. Turn on all fuel supply valves. tool or delivery valve.
Note: As the injection pump injects fuel to a 15. Slowly rotate the crankshaft clockwise
cylinder only once every two engine approximately two more revolutions until the
revolutions, it may be necessary to timing grid on the flywheel (for the cylinder
rotate the crankshaft twice to see fuel being checked) is at approximately 30° BTDC.
being pumped from the timing tool or Note: The fuel injection pump injects fuel to a
delivery valve of the cylinder you are cylinder only once every two engine
using to check injection timing. revolutions.
13. Install the “spill-timing” tool (Figure 4-3-28, (1)) 16. “Flick” the nozzle of the timing tool with a finger
onto the delivery valve for the cylinder being to remove bubbles and establish a fuel level of
checked. See Measuring Instruments on approximately 1/2 the height of the nozzle.
page 4-3-4. 17. Very slowly rotate the crankshaft clockwise
Note: If a timing tool is not available, timing until the fuel level in the nozzle of the “spill
can be checked by watching the fuel in timing” tool, or in the delivery valve, just begins
the delivery valve itself. to move. Immediately stop rotating the
crankshaft.
(1) 18. Check the position of the flywheel target timing
mark (Figure 4-3-27, (1)) on the flywheel grid
in relation to the timing reference mark
(Figure 4-3-27, (2)) on the flywheel housing or
back plate. If the two marks are aligned, the
fuel injection timing is correct. If the marks do
not align, the fuel injection timing must be
adjusted. See Adjusting Fuel Injection Timing
on page 4-3-18.
19. Repeat Steps 13-17 two or three times to verify
timing.
20. Remove the “spill-timing” tool.
21. Reinstall the shut-off solenoid.
0000592A 22. Reinstall the high-pressure fuel injection lines.
Figure 4-3-28 See Installation of High-Pressure Fuel Injection
Lines on page 4-3-8.
Note: The following references to the direction
of rotation are made facing the cooling 23. Replace the flywheel inspection port cover.
fan end of the engine and are adjusted 24. Prime the fuel system. Operate the engine and
by turning the crankshaft. check for leaks.
4-3-17
4. ENGINE
Adjusting Fuel Injection Timing 6. Recheck the fuel injection timing. Repeat the
fuel injection timing and adjustment procedures
If the timing marks did not align when performing until the timing is correct. See Checking Fuel
the Checking Fuel Injection Timing on page 4- Injection Timing on page 4-3-15 and repeat
3-15, the following steps must be performed to steps 3 - 6.
properly time the engine.
7. Remove the “spill-timing” tool.
1. Leave the “spill-timing” tool installed in the fuel 8. Reinstall the shut-off solenoid.
injection pump.
9. Reinstall the high-pressure fuel injection lines.
2. Determine if the timing is “advanced” or See Installation of High-Pressure Fuel Injection
“retarded” by comparing the position of the Lines on page 4-3-8.
target timing mark on the flywheel grid
(Figure 4-3-29, (1)) with the timing mark on the 10. Replace the flywheel inspection port cover.
flywheel housing or back plate (Figure 4- 11. Prime the fuel system. Operate the engine and
3-29, (2)). check for leaks.
4-3-10 Fuel Injectors
Removal of Fuel Injectors

(2) (1)
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
entering the engine or fuel system.
3. Remove the high-pressure fuel injection lines
as an assembly. See Removal of High-
Pressure Fuel Injection Lines on page 4-3-7.
0002469 4. Remove nut (Figure 4-3-30, (1)). Remove the
fuel return line (Figure 4-3-30, (2)) and copper
Figure 4-3-29
washer (Figure 4-3-30, (3)) from the fuel
3. Loosen the nuts fastening the fuel injection injectors. See Removal of Fuel Return Line on
pump to the gear case. page 4-3-8.
4. If the injection timing was less than the target Note: The fuel injectors used on IDI engines
timing, the injection timing is “retarded” and will screw into the cylinder head.
need to be “advanced.” 5. Remove the fuel injectors (Figure 4-3-30, (4)).
To “advance” the injection timing: Rotate the
top of the fuel injection pump away from the
engine.
If the injection timing was greater than the target
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.
5. Adjust the position of the fuel injection pump
and tighten the fuel injection pump mounting
nuts.
4-3-18
4. ENGINE
(1)
(2) OFF
P-
OFF
E-
ON AG
(3)
-G
(4)
(6)
Figure 4-3-31
(5) WARNING
HIGH-PRESSURE HAZARD!
• Avoid skin contact with the
high-pressure diesel fuel spray
0002213
caused by a fuel system leak
such as a broken fuel injection
Figure 4-3-30 line. High-pressure fuel can
6. Remove the injector nozzle gaskets (Figure 4- penetrate your skin and result in
3-30, (5)) and protector (Figure 4-3-30, (6)) serious injury. If you are exposed
from the cylinder head. to high-pressure fuel spray,
obtain prompt medical treatment.
Testing of Fuel Injectors • NEVER check for a fuel leak with your hands.
ALWAYS use a piece of wood or cardboard.
NOTICE Have your authorized Yanmar industrial
Never use a steel wire brush to clean fuel injectors. engine dealer or distributor repair the
Damage to the nozzle and other components is damage.
likely to result. • Failure to comply could result in death or
serious injury.
1. Thoroughly clean the fuel injector nozzle using WARNING

clean diesel fuel and a brass wire brush. To prevent possible eye injury,
2. Visually inspect the fuel injectors and nozzle always wear SAFETY GLASSES
protectors for deposits or damage. Clean, while servicing the engine.
repair or replace as necessary.
Note: Test the fuel injector using an injection
nozzle tester. Operate the tester
following the information provided by the 4. Pump the operating lever of the tester slowly,
tester manufacturer. Use clean, filtered observing the pressure reading at the point
fuel or FIE calibration fluid for the test. where the fuel injector begins spraying fuel.
3. Using the correct adapter, connect a fuel Note: Opening pressure of a new fuel injector
injector to a nozzle tester. Aim the fuel injector will be approximately 0.5 MPa; 5 kgf/cm2
into a suitable container to catch the fuel spray higher than one that has been operated
(Figure 4-3-31). for five hours or longer.
4-3-19
4. ENGINE
5. Pump the operating lever slowly to hold the

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
return line fitting or nozzle.
6. Pump the operating lever more rapidly to
repeatedly “pop” the injector and observe the
spray pattern. The pattern should be a very
fine uniform spray. If dripping or an uneven
pattern is seen, service or replace the injector.
See Fuel Injector Test Results on page 4-3-21.
4-3-20
4. ENGINE
Fuel Injector Test Results

A B C D E
Injection Pattern

120 120 120 120 120
0 0 0 0 0
Pressure Gauge

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 4-3-23.
4-3-21
4. ENGINE
Disassembly and Inspection of Fuel 5. Turn the injector over and remove the nozzle
Injectors body, nozzle valve, valve stop spacer, nozzle
spring seat, nozzle spring, and shims.
NOTICE 6. Inspect the sealing surfaces (Figure 4-
3-33, (2)) between the valve stop spacer and
Never use a steel wire brush to clean fuel injectors. nozzle body for nicks or scratches. Check the
Damage to the nozzle and other components is contact area between the valve stop spacer
likely to result. and the nozzle valve (Figure 4-3-33, (1)) for
scoring or pitting. Use a magnifying glass to
inspect.
1. Clean carbon from used injectors using clean
diesel fuel. Hardened deposits or varnish can 1
be cleaned using a brass wire brush.
2
(1)
(2)
(3)
(4) 033108-00X
Figure 4-3-33
(5)
(6) 7. Perform a nozzle valve slide test:
(7) (a) Wash nozzle body and valve in clean diesel
fuel.
(8)
(b) While holding the nozzle body vertical, pull
the nozzle valve about 2/3 of the way out
(9)
(Figure 4-3-34).
(c) Release the valve. It should fall smoothly to
(10) its seat by its own weight.
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 033109-00X
10 – Nozzle Case Nut
Figure 4-3-34
Figure 4-3-32
Replace the fuel injector assembly if it fails any
2. Place the fuel injector in a soft-jawed vise with inspection.
the nozzle pointing up.
3. Remove the nozzle case nut.
4. Carefully remove the injector from the vise.
4-3-22
4. ENGINE
Adjusting Fuel Injector Pressure

The fuel injectors open when pressure reaches a (1)
predetermined pressure threshold. They close (2)
when the pressure is reduced below that
threshold. The pressure threshold can be adjusted
(3)
by adding or removing shims (Figure 4-3-35, (4)).
Fuel Injector Shim Kit

(4)
Yanmar Part No. 129901-53800
(Includes one each of the following shims)
(5)
129901-53810 0.10 mm
(6)
129901-53820 0.20 mm 0002093
(7)
129901-53830 0.30 mm
129901-53840 0.40 mm (8)
129901-53850 0.50 mm
(9)
129901-53860 0.52 mm
129901-53870 0.54 mm
129901-53880 0.56 mm (10)
129901-53890 0.58 mm 0002214
129901-53900 0.80 mm 1 – Return Fuel Fitting Nut

2 – Fuel Return 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 4-3-35
The injection pressure will change by
approximately 0.69 - 0.98 MPa; 7 - 10 kgf/cm2
for every 0.1 mm shim thickness.
See the parts catalog for available shims.

1. Disassemble the fuel injector assembly. See
Disassembly and Inspection of Fuel Injectors
on page 4-3-22.
2. Remove or add adjusting shims as needed.
3. Reassemble the fuel injector assembly. See
Reassembly of Fuel Injectors on page 4-3-24.
4. Retest the fuel injector. See Testing of Fuel
Injectors on page 4-3-19. If the injector cannot
be adjusted to the appropriate pressure,
discard the fuel injector.
4-3-23
4. ENGINE
Reassembly of Fuel Injectors

1. Secure the injector in a soft-jawed vise with the
nozzle end up.
2. Reinstall the shims, nozzle spring, nozzle
spring seat, valve stop spacer, nozzle valve,
and nozzle body.
3. Reinstall the nozzle case nut. Tighten it to
specification.
Installation of the Fuel Injectors

1. Insert the nozzle gaskets (Figure 4-3-36, (5))
and nozzle protector (Figure 4-3-36, (6)) in the
cylinder head.
2. Reinstall the fuel injector (Figure 4-3-36, (4)) in
the cylinder head and tighten to specification.
3. Reinstall new copper washers (Figure 4-
3-36, (3)), high-pressure and return fuel lines
(Figure 4-3-36, (2)). See Installation of
High-Pressure Fuel Injection Lines on page 4-
3-8 and Installation of Fuel Return Line on
page 4-3-9. Tighten fuel line nuts (Figure 4-
3-36, (1)) to specifications.
4. Prime the fuel system.
5. Operate the engine and check for fuel leaks.
(1)
(2)
(3)
(4)
(6)
(5)
0002213
Figure 4-3-36
4-3-24
4. ENGINE
4-4 Cooling System

4-4-1
4. ENGINE
4-4-2 Introduction
This section of the Service Manual describes the procedures necessary to service the 3TNV70 engine
coolant pump.
4-4-3 Cooling System Diagram
(1)
(2)
(3)
(4)
(6)
(5)
0002046
1 – Cylinder Head 4 – Radiator

2 – Thermostat 5 – Coolant Recovery Tank
3 – Engine Coolant Pump 6 – Cylinder Block
Figure 4-4-1
4-4-2
4. ENGINE
4-4-4 Engine Coolant Pump Components
1
7 2
3 4
9
11
6
5
8
10
0001959
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
Figure 4-4-2
4-4-3
4. ENGINE
4-4-5 Engine Coolant System Check 3. Loosen the alternator mounting bolts. Loosen
and remove the V-belt and rotate the alternator
Check the engine coolant system for leakage. away from the engine and out of the way.
1. With the radiator properly filled, install a cooling
CAUTION
system tester (Figure 4-4-3, (1)).
PINCH HAZARD!
Carefully rotate the alternator
toward the cylinder block while
loosening the V-belt. Failure to
moderate injury.
(1)
0000577A 4. Remove the engine coolant fan guard (if
Figure 4-4-3 equipped), engine coolant fan (Figure 4-
4-4, (1)), spacer (Figure 4-4-4, (2)) and engine
2. Apply 75 - 105 kPa; coolant pump V-pulley (Figure 4-4-4, (3)).
0.75 - 1.05 kgf/cm² to the cooling system. If
the pressure reading drops, the engine coolant (4)
system is leaking. Identify the source of the
leak and repair. (3)
(2)
4-4-6 Engine Coolant Pump (1)
Disassembly of Engine Coolant

Pump
Verify the condition of the engine coolant pump
before disassembling it from the engine. Check the
0001959B
engine coolant pump shaft bearing for abnormal
noise, sticking, excessive play and water leakage. Figure 4-4-4
Replace the coolant pump if any of these
5. Disconnect the coolant hoses and the
conditions are present.
temperature switch lead wire from the engine
coolant pump.
NOTICE
6. Remove the engine coolant pump (Figure 4-
If the engine coolant pump must be replaced, 4-4, (4)). Discard the gasket.
replace the engine coolant pump as an assembly
7. Remove the thermostat cover (Figure 4-
only. Do not attempt to repair the engine coolant
4-5, (1)).
pump or replace individual components.
1. Make sure the engine and engine coolant are

not hot.
2. Before removing the engine coolant pump or
thermostat, it will be necessary to drain the
engine coolant. Drain the coolant into a clean
container if the coolant is to be reused.
Otherwise, properly dispose of the coolant.
• Drain the coolant from the radiator.
4-4-4
4. ENGINE
4. The temperature switch is normal if the

continuity light or ohmmeter indicates
(1)
continuity when the fluid temperature reaches
107°C - 113°C.
(2)
Thermostat
1. Check for proper operation of the thermostat.
Place the thermostat (Figure 4-4-7, (1)) and
an accurate thermometer (Figure 4-4-7, (2)) in
(4)
(3) warm water.
(2)
0001959A
Figure 4-4-5
8. Remove the thermostat (Figure 4-4-5, (2)). (1)
Remove the temperature switch (Figure 4-
4-5, (3)) and gasket (Figure 4-4-5, (4)).
Discard the gasket.
Cleaning and Inspection

0000578A
Temperature Switch Figure 4-4-7

1. Check for proper operation of the temperature 2. Slowly increase temperature of the water using
switch. Connect a continuity light or ohmmeter an external heat source.
to the temperature switch. Connect one lead to
the terminal of the switch (Figure 4-4-6, (1)) 3. The thermostat is normal if it starts to open at
and the other lead to the metal portion of the the temperature value stamped on the flange
switch (Figure 4-4-6, (2)). of the thermostat, and fully opens as the
temperature of the water is increased.
(3) (1) Radiator Cap
1. Check for proper operation of the radiator cap.
Install the radiator cap (Figure 4-4-8, (1)) on a
(2)
cooling system tester.
0000577A
Figure 4-4-6
(1)
2. Place the temperature switch and an accurate 0000579A
thermometer (Figure 4-4-6, (3)) in engine
coolant. Figure 4-4-8
3. Slowly increase temperature of the fluid using 2. Apply 75 - 105 kPa; 0.75 - 1.05 kgf/cm² to
an external heat source. the radiator cap. The radiator cap relief valve
must open within the specified range.
4-4-5
4. ENGINE
Reassembly of Engine Coolant (4)

Pump
1. Reinstall the thermostat (Figure 4-4-9, (1)). (3)
(2)
(1)
(2)
(6)
(1)
0001959B
(5) Figure 4-4-10

8. Inspect the condition of the V-belt. There must
be clearance (Figure 4-4-11, (1)) between the
V-belt and the bottom of the pulley groove. If
there is no clearance (Figure 4-4-11, (2))
(4)
between the V-belt and the bottom of the pulley
(3) 0001959C
groove, replace the V-belt.
Figure 4-4-9
2. Reinstall the thermostat cover (Figure 4-
4-9, (2)). Tighten the thermostat cover bolts.
3. Reinstall the temperature switch (Figure 4-
4-9, (3)) and a new gasket (Figure 4-4-9, (4)). (2)
4. Position the engine coolant pump on the (1)
engine and install a new gasket (Figure 4-
4-9, (6)). Use a new special O-ring (Figure 4-
4-9, (5)) on assembly between the engine 0000584
coolant pump and the joint.

Figure 4-4-11
NOTICE
9. Reinstall the V-belt. Tighten the V-belt to the
Use a new special O-ring between the engine proper tension.
coolant pump and the joint. Be sure to use the
10. Reinstall and tighten the drain plug or close the
special O-ring for each engine model. Although
drain cock in the radiator. Reinstall and tighten
the O-ring dimensions are the same as a
the engine block drain plug or reconnect the
commercially available O-ring, the material is
coolant hose at the oil cooler.
different.
11. Fill radiator and engine with engine coolant.
5. Reinstall the engine coolant pump bolts.

Tighten the bolts.
6. Inspect and reinstall the coolant hoses and the
temperature switch lead wire.
7. Reinstall the engine coolant pump V-pulley
(Figure 4-4-10, (3)), spacer (Figure 4-
4-10, (2)) engine coolant fan (Figure 4-
4-10, (1)) and engine coolant fan guard (if
equipped).
4-4-6
4. ENGINE
NOTICE
• Only use the engine coolant specified. Other
engine coolants may affect warranty
coverage, cause an internal buildup of rust
and scale and / or shorten engine life.
• Prevent dirt and debris from contaminating
the engine coolant. Carefully clean the
radiator cap and the surrounding area before
you remove the cap.
• NEVER mix different types of engine
coolants. This may adversely affect the
properties of the engine coolant.
4-4-7
4. ENGINE
4-5 Lubrication System

4-5-1
4. ENGINE
4-5-2 Introduction
This section of the Service Manual describes the procedures necessary to service the trochoid oil pumps.
4-5-3 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 4-5-1
4-5-2
4. ENGINE
4-5-4 Checking Engine Oil Pressure 4-5-5 Trochoid Oil Pump
Perform an engine oil pressure check if there is Oil Pump Components

any indication of low oil pressure such as the oil
pressure indicator is on or the oil pressure gauge
indicates low oil pressure. (1)
(2)
1. Disconnect the wire lead from the oil pressure
(5)
switch or sending unit (Figure 4-5-2, (1)). (6)
(3)
(1)
(4)
0001955A
1 – Crankshaft
2 – Oil Pump Cover
3 – Oil Pressure Regulator
4 – Gear Case Cover
5 – Outer Rotor
0000020A
6 – Inner Rotor
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 4-9-6. Repair as necessary.
4-5-3
4. ENGINE
Disassembly of Oil Pump (2)

(1)
NOTICE (3)
If the oil pump must be replaced, replace it as an (4)
assembly only. Do not replace individual
components.
1. Remove the engine cooling fan guard (if

equipped), engine cooling fan (Figure 4-
5-4, (1)), spacer (Figure 4-5-4, (2)), engine
coolant pump V-pulley (Figure 4-5-4, (3)) and
V-belt. 0001955B
(4) Figure 4-5-5

4. Remove the oil pump cover (Figure 4-5-5, (1))
(3) from the gear case.
(2) 5. Remove the outer rotor (Figure 4-5-5, (3)) and
(1)
inner rotor (Figure 4-5-5, (4)) from the gear
case cover.
6. Remove the oil pressure regulator valve
(Figure 4-5-6, (1)) from the oil pump cover
(Figure 4-5-6, (2)).
0001959B
(2)
Figure 4-5-4
2. Remove the front crankshaft pulley and gear
case cover. See Removal of Timing Gear Case
Cover on page 4-2-24.
3. Remove the seven oil pump cover screws
(Figure 4-5-5, (2)). (1)
Note: The oil pump cover screws are installed 0001958A
using a liquid thread lock. It may be Figure 4-5-6

necessary to used “localized heat”
(small propane torch) and an impact-
type screwdriver to remove these
screws.
4-5-4
4. ENGINE
Cleaning and Inspection

Wash the oil pump cover, the oil pressure regulator
valve, the oil pump cavity and the inner and outer
rotors. Inspect the parts for wear or damage.
Replace as necessary.
Note: If the oil pump cavity is damaged, the
gear case cover must be replaced.
NOTICE
If any oil pump component clearance exceeds its
limit, the oil pump must be replaced as an
assembly. (1) (2)
0001150B
Figure 4-5-8
Check Outer Rotor Outside Clearance Record the measurement.

1. Reinstall the outer and inner rotors. The dots Check Outer Rotor Side Clearance
on the rotor faces must face “up.” Make sure
that the pilot on the back of the inner rotor fits Determine the side clearance of the outer rotor
into the bore of the oil pump cavity and the top across the pump cavity. While pressing down on
surface of the inner rotor is flush with the top the outer rotor, measure the depression using a
surface of the outer rotor. depth micrometer (Figure 4-5-9).
2. Determine the outside clearance of the outer
rotor. Insert a feeler gauge between the outer
rotor (Figure 4-5-7, (1)) and the gear case oil
pump cavity (Figure 4-5-7, (2)).
(1)
(2)
Figure 4-5-9
0001151A
Figure 4-5-7
Outer Rotor to Inner Rotor Tip Clearance

Determine the outer rotor to inner rotor tip
clearance. Insert a feeler gauge between the top of
an inner rotor tooth (Figure 4-5-8, (1)) and the top
of an outer rotor tooth (Figure 4-5-8, (2)) and
measure the clearance.
4-5-5
4. ENGINE
Check Inner Rotor and Gear Boss 3. Reinstall the inner rotor into the gear case
Clearance cover with the dot mark also facing up. Make
sure that the pilot on the back side of the inner
(5) rotor fits into the bore in the gear case cover
and the top surface of the inner rotor is flush
(3) with the top surface of the outer rotor.
4. Reinstall the oil pressure regulator valve
(Figure 4-5-11, (4)) into the oil pump cover
(Figure 4-5-11, (5)). Apply LOCTITE® 242
(red) to the valve plug, following the
(1) manufacturer’s instructions.
(6)
(4) 5. Reinstall the oil pump cover (Figure 4-
(2)
5-11, (5)). Apply LOCTITE 290 (green) or
1 – Crank Gear LOCTITE 262 (red) to the oil pump cover
2 – Inner Rotor screws. Tighten the pump cover screws to 52 -
3 – Inside Width Across Flats of Inner Rotor 70 in·lb (5.9 - 7.9 N·m, 0.6 - 7.9 kgf·m).
4 – Overall Inside Diameter of Inner Rotor
5 – Overall Inside Diameter of Gear Boss 6. Reinstall the crankshaft pulley and gear case
6 – Outside Width Across Flats of Gear Boss cover. See Removal of Timing Gear Case
Cover on page 4-2-24.
Figure 4-5-10
7. Reinstall the engine coolant pump V-pulley
Record the measurement. (Figure 4-5-12, (3)), spacer (Figure 4-
5-12, (2)), engine cooling fan (Figure 4-
Reassembly of Oil Pump 5-12, (1)) and engine cooling fan guard (if
equipped).
(5)
(1) (4)
(2)
(3)
(2)
(1)
(4)
(3) 0001959B
0001976A
Figure 4-5-12
Figure 4-5-11
1. Lubricate the outer rotor (Figure 4-5-11, (1)),
proper tension.
inner rotor (Figure 4-5-11, (2)) and pump bore
in the gear case cover (Figure 4-5-11, (3)) with
clean engine oil.
2. Reinstall the outer rotor in the gear case. The
dot mark on the face of the outer rotor must
face up toward the oil pump cover.
4-5-6
4. ENGINE
4-6 Starter Motor

4-6-1
4. ENGINE
4-6-2 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.
4-6-3 Starter Motor Specifications
Yanmar code 119540-77010

Starter motor model RA1.4
Nominal output / Weight kW / kg 1.4 / 3.8
Rotation direction (Viewed from pinion side) Clockwise
Engagement method Magnetic shift
Terminal voltage / Current V/A 11 / ≦ 90
No load
Speed rpm ≧ 3000
Load Terminal voltage / Current V/A 2.4 / ≦ 500
characteris-
tics Torque 12
N•m
Clutch type Over running
Pinion coming out voltage V ≦8
Pinion DP or module /
M2.54 / 15
Number of pinion teeth
Starter performance (standard)

Speed (min-1)
Torque (N·m)
Output (kW)
Voltage (V)
Battery 6V-550A 12V 1.4kW (JIS D1607 12-D)
6000 24 1.2 12
Voltage Torque
5000 20 1.0 10
4000 16 0.8 8 Output
3000 12 0.6 6
R
2000 8 0.4 4
Speed
1000 4 0.2 2
0 0 0 0
0 200 400 600 800 1000
Current (A) 026588-00E
4-6-2
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.
• Inspect shift lever for deformation,
4-6-4 Starter Motor Troubleshooting
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.
4-6-3
YES
Solenoid switch assembly If starter motor becomes wet, replace solenoid switch
contact defective. Repair assembly even if function is normal.
4. ENGINE
NO or replace.
(slow revolution) NO
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
4. ENGINE
4-6-5 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 4-6-1
4-6-4
4. ENGINE
1 – Nut 4-6-6 Starter Motor

2 – Needle Bearing
3 – Pinion Housing
4 – Pinion Retaining Ring WARNING
5 – Pinion Stop SHOCK HAZARD!
6 – Pinion
7 – Shift Lever • Turn off the battery switch (if
8 – Solenoid Switch Assembly equipped) or disconnect the
9 – Snap Ring negative battery cable before
10 – Washer servicing the electrical system.
11 – Bushing
12 – Intermediate Housing
• Check the electrical harnesses for cracks,
13 – Reduction Gear
14 – Washer
abrasions, and damaged or corroded
15 – Through Bolt connectors. ALWAYS keep the connectors
16 – End Housing and terminals clean.
17 – Brush Plate and Holder • Failure to comply could result in death or
18 – Field Assembly serious injury.
19 – Armature
20 – Bushing
21 – Plate
22 – Planetary Gear (3 used) Note: While starter motor design varies
23 – Washer (3 used) between models, the basic repair
24 – Pinion Shaft procedures are the same. The following
procedures are typical and may differ
from the starter being serviced.
4-6-5
4. ENGINE
Removal of Starter Motor 3. Remove the two bolts or nuts retaining the
solenoid switch assembly (Figure 4-6-4, (1)) to
1. Disconnect the battery cables at the battery, the pinion housing. Remove the solenoid
negative (-) cable first. switch assembly and dust covers (Figure 4-
2. Remove the electrical wires from the solenoid 6-4, (2)). Remove the plunger (Figure 4-
switch assembly. 6-4, (4)) and torsion spring (Figure 4-6-4, (3))
3. Remove the starter mounting bolts (Figure 4- from the pinion housing.
6-2, (1)). Remove the starter motor from the
flywheel housing.
(1)
(4)
(3)
(2) (1)
0000140A
0002126
Figure 4-6-4
Figure 4-6-2
4. Remove the two bolts (Figure 4-6-5, (1))
Disassembly of Starter Motor securing the rear cover (Figure 4-6-5, (2)) to
the brush holder assembly (Figure 4-6-5, (3)).
1. Make alignment marks across all mating joints.
2. Disconnect the field wire from the solenoid
switch (Figure 4-6-3). (2)
(3)
(1)
0000142A
Figure 4-6-5
5. Remove the two through bolts. Remove the
rear cover (Figure 4-6-5, (2)).
6. Pull the brush springs up using a brush spring
puller. On the negative (-) side, bring the brush
0000138
spring into contact with the side of the brushes
Figure 4-6-3 to hold the brushes clear of the commutator
surface. On the positive (+) side, remove the
brushes from the brush holder assembly
(Figure 4-6-6).
4-6-6
4. ENGINE
(1)
(2)
(3)
(4)
0000148A
0000143
7. Remove the brush plate and holder (Figure 4- 12. Pull the pinion stop (Figure 4-6-9, (1)) down to
6-7, (1)). expose the retaining ring. Using a flat-blade
screwdriver, remove the retaining ring
(2) (1) (Figure 4-6-9, (2)) from the pinion shaft.
(3)
0000144A
Figure 4-6-7 (2) (1)

8. Pull the field assembly (Figure 4-6-7, (3)) off 0000151A
from the armature assembly (Figure 4- Figure 4-6-9

6-7, (2)).
9. Remove the armature from the intermediate
housing.
10. Remove the intermediate housing, gear and
pinion shaft assembly (Figure 4-6-8, (4)) from
the pinion housing (Figure 4-6-8, (3)).
Disengage from the shift lever as it is removed.
11. Remove the shift lever (Figure 4-6-8, (2)), pin,
and spacer (Figure 4-6-8, (1)).
4-6-7
4. ENGINE
13. Remove the pinion stop (Figure 4-6-10, (3)), Cleaning and Inspection
return spring (if equipped), and pinion clutch
assembly (Figure 4-6-10, (2)), from the pinion Armature
shaft (Figure 4-6-10, (1)).
Commutator Surface Inspection
(2) If the commutator surface is rough, polish the
surface with a #500 to #600 emery cloth.
(1)
(4) (3) 0000152B
Figure 4-6-10
0000117
14. Remove the snap ring (Figure 4-6-11, (1)).
Remove the pinion shaft (Figure 4-6-11, (5)), Figure 4-6-12
planetary gears (Figure 4-6-11, (6)), washers, Measure Commutator Outside Diameter
and reduction gear (Figure 4-6-11, (4)) from
Measure the commutator outside diameter.
the intermediate housing (Figure 4-6-11, (3)).
Replace the armature if the measurement is less
(4) than the limit. See Starter Motor Specifications on
page 4-6-2.
(3)
(2)
(1)
0000113
Figure 4-6-13
(7)
(6)
(5) 0002487
Figure 4-6-11
15. Inspect the intermediate bushing (Figure 4-
6-11, (2)) and replace if worn or damaged.
16. Inspect armature bushing (Figure 4-6-11, (7))
and replace if worn or damaged.
4-6-8
4. ENGINE
Measure Commutator Insulation Depth Armature Coil Insulation Test

Measure the depth of the insulating material Check for continuity between a commutator
(Figure 4-6-14, (1)) between commutator segment and the shaft or armature using a
segments (Figure 4-6-14, (2)). If the depth multimeter (Figure 4-6-16). The multimeter should
measures less than the limit, use a hacksaw blade not indicate continuity.
(Figure 4-6-14, (3)) to remove the insulating
material until the depth is within the limit. See If the multimeter indicates continuity, replace the
Starter Motor Specifications on page 4-6-2 for armature.
service limit.
A normal commutator condition is indicated in
(Figure 4-6-14, (4)). An abnormal commutator
condition is indicated in (Figure 4-6-14, (5)).
(3)
0000115
Figure 4-6-16
(2) Measure Armature and Commutator Run-Out

(1)
Measure the armature core run-out and the
commutator run-out using a dial indicator
(Figure 4-6-17). Replace the armature if either of
the measurements is not within specifications. See
(5) (4) Starter Motor Specifications on page 4-6-2 for
0000118
service limit.
Figure 4-6-14
Armature Coil Continuity Test

Check for continuity between the commutator
segments using a multimeter (Figure 4-6-15). The
multimeter should indicate continuity.
If the multimeter does not indicate continuity,
replace the armature.
0000116
Figure 4-6-17
0000114
Figure 4-6-15
4-6-9
4. ENGINE
Field Coil Measure Brush Length

Measure the length of the brush (Figure 4-6-20).
Field Coil Continuity Test
Replace the brush if the length is less than the
Check for continuity between the field coil limit. See Starter Motor Specifications on page 4-
terminals using a multimeter (Figure 4-6-18). The 6-2 for service limit.
replace the field coil assembly.
0000121
Figure 4-6-20
0000119 Brush Holder

Figure 4-6-18 Brush Holder Insulation Test
Field Coil Insulation Test Check for continuity between each brush holder
and the base using a multimeter (Figure 4-6-21).
Check for continuity between either field coil
The multimeter should not indicate continuity.
terminal and the yoke using a multimeter
(Figure 4-6-19). The multimeter should not If the multimeter indicates continuity, replace the
indicate continuity. brush holder.
If the multimeter indicates continuity, replace the
field coil assembly.
0000122
0000120 Figure 4-6-21

Figure 4-6-19
4-6-10
4. ENGINE
Brush Spring Test If the multimeter does not indicate continuity,

Test the spring force for each brush spring replace the solenoid switch.
(Figure 4-6-22). Replace the brush spring if the
force is not within the range. See Starter Motor
Specifications on page 4-6-2 for the service limit.
0000125
Figure 4-6-24
Coil Resistance Test

0000123
See Starter Motor Specifications on page 4-6-2 for
Figure 4-6-22 service limit.
Solenoid Switch Contact Continuity Test
If the starter motor becomes wet, replace the Depress the plunger at the bottom of the solenoid
solenoid switch even if the solenoid switch switch. Check for continuity between the “B” and
assembly function is normal. “M” terminals using a multimeter (Figure 4-6-25).
The multimeter should indicate continuity.
Shunt Coil Continuity Test
Check for continuity between the “S” terminal and If the multimeter does not indicate continuity,
the switch body using a multimeter (Figure 4- replace the solenoid switch.
6-23). The multimeter should indicate continuity.
replace the solenoid switch.
0000126
Figure 4-6-25
0000124
Figure 4-6-23
Series Coil Continuity Test

Check for continuity between the “S” and “M”
terminals using a multimeter (Figure 4-6-24). The
4-6-11
4. ENGINE
Pinion Clutch Assembly Reassembly of Starter Motor

Pinion Clutch Assembly Inspection 1. Apply a appropriate starter bendix grease
Manually rotate the pinion clutch assembly in the (obtain locally) to the pinion shaft.
drive direction. It should rotate freely in the drive 2. Reassemble the reduction gear (Figure 4-
direction and is locked by turning it in the opposite 6-28, (4)), pinion shaft (Figure 4-6-28, (5)),
direction (Figure 4-6-26). Replace the pinion planetary gears (Figure 4-6-28, (6)), and
clutch assembly if the results are different. washers into the intermediate housing
(Figure 4-6-28, (3)). Reinstall snap ring
(Figure 4-6-28, (1)).
(4)
(3)
(2)
(1)
0000127
Figure 4-6-26
Slide the pinion clutch assembly on the shaft
(Figure 4-6-27). It should slide smoothly on the
shaft. Rust, too much grease, or damage could (7)
prevent the pinion clutch from sliding smoothly. If
the pinion clutch assembly does not slide (6)
smoothly, clean the shaft and pinion clutch
assembly or replace the damaged component.
(5) 0002487
Figure 4-6-28
3. Reinstall the pinion clutch assembly (Figure 4-
6-29, (2)), return spring (if equipped) and
pinion stop (Figure 4-6-29, (3)) onto the pinion
shaft (Figure 4-6-29, (1)). Reinstall the
retaining ring (Figure 4-6-29, (4)) in the groove
in the pinion shaft. Slide the pinion stop over
the retaining ring.
0000128
Figure 4-6-27
4-6-12
4. ENGINE
(2) (2) (1)
(3)
(1)
(4) (3) 0000152B

0000144A
Figure 4-6-29
Figure 4-6-31
4. Apply a small amount of high temperature
lithium grease (obtain locally) to the contact 9. Reinstall the field assembly (Figure 4-
surfaces of the shift lever. Reassemble the shift 6-31, (3)) over the armature assembly and
lever (Figure 4-6-30, (2)), spacer (if equipped) align to the pinion housing.
(Figure 4-6-30, (1)), and pin. 10. Position the brush springs in brush holders.
5. Reinstall the pinion shaft assembly (Figure 4- Reinstall the brushes in the brush holders.
6-30, (4)) in the pinion housing (Figure 4- Reversing the brushes will cause the starter
6-30, (3)). Be sure the shift lever properly motor to turn backwards.
engages the pinion. 11. Carefully reinstall the brush holder (Figure 4-
6-32, (3)) assembly.
(1) 12. Reinstall the rear cover (Figure 4-6-32, (2))
(2)
(3) and secure with two bolts (Figure 4-6-32, (1)).
(2)
(4)
0000148A
(3)
Figure 4-6-30 (1)
6. Apply a small amount of high temperature
lithium grease (obtain locally) to the surface of 0000142A
the plunger and the hole that engages the shift Figure 4-6-32
lever.
13. Reinstall the two through bolts and tighten
7. Attach the plunger to the shift lever. securely.
8. Reinstall the plate onto the intermediate
housing and carefully reinstall the armature
assembly (Figure 4-6-31, (2)) into the pinion
shaft assembly.
4-6-13
4. ENGINE
14. Reinstall the return spring (if equipped) Check Pinion Projection Length
(Figure 4-6-33, (3)) on the solenoid plunger
(Figure 4-6-33, (4)). Reinstall the solenoid 1. Connect the positive (+) lead from a battery to
switch coil (Figure 4-6-33, (1)) and dust covers the “S” terminal.
(Figure 4-6-33, (2)). Secure with nuts or bolts. 2. Connect the negative (-) lead to the “M”
terminal.
3. Lightly pull the pinion away from the gear
housing.
4. Turn the switch ON and measure the pinion
moving distance L in the thrust direction
(4) (Figure 4-6-35). Perform this test within 10
seconds.
(3)
(2) (1)
0000140A
Figure 4-6-33
15. Reconnect the wire to the solenoid switch
assembly. Tighten the nut. Reinstall the cover 0000132
over the connection. Figure 4-6-35

See Starter Motor Specifications on page 4-6-2 for
service limit.
5. If the measured L dimension is outside the
standard range, adjust the dust covers to
obtain the standard range. Dust covers
(Figure 4-6-36, (1)) are available in 0.020 in.
(0.5 mm) and 0.031 in. (0.8 mm) thicknesses.
(1)
0000138
Figure 4-6-34
0000133
Figure 4-6-36
4-6-14
4. ENGINE
No-Load Test 6. Use a suitable tachometer to monitor the rpm

of the starter.
Test the characteristics of the starter motor by
performing a no load test. 7. Turn the switch to the ON position to energize
the solenoid and operate the starter. Monitor
the rpm, amperage draw and voltage.
NOTICE
The starter motor can be damaged if operated Installation of Starter Motor
continuously longer than 10 seconds while 1. Reinstall the starter motor to the flywheel
performing the no-load test. housing.
2. Reinstall the starter mounting bolts (Figure 4-
6-38, (1)). Tighten the bolts to specification.
1. Secure the starting motor in a vise or other
suitable fixture. (1)
2. Connect an ammeter (Figure 4-6-37, (1)) in
series between the battery positive (+) terminal
(Figure 4-6-37, (2)) and the main positive (+)
terminal (Figure 4-6-37, (3)) on the starter
motor.
Note: The ammeter and all wire leads used in
this test must have a capacity equal to
or greater than the amperage draw
specification for the starter motor being
tested.
0002126
Figure 4-6-38
(3) 3. Reconnect the electrical wires to the solenoid
(6) (1) switch assembly. Be sure to place the cover
over the battery positive (+) cable connection.
M (8)
(2) 4. Reconnect the battery, negative (-) cable last.
(7)
(5)
(4)
0002127A
Figure 4-6-37
3. Connect a wire lead between the mounting
base of the starter motor (Figure 4-6-37, (4))
and the battery negative terminal (Figure 4-
6-37, (5)).
4. Connect a voltmeter (Figure 4-6-37, (7)) to the
battery negative (-) terminal (Figure 4-
6-37, (5)) and the main positive (+) battery
terminal (Figure 4-6-37, (3)) on the starter
motor.
5. Install a switch (Figure 4-6-37, (6)) in a circuit
between the battery positive (+) terminal
(Figure 4-6-37, (2)) and the starter solenoid
switch terminal (Figure 4-6-37, (8)) on the
starter motor.
4-6-15
4. ENGINE
4-7 Alternator

4-7-1
4. ENGINE
4-7-2 Introduction
This section of the Service Manual describes the servicing of the alternators.
Yanmar Part No. 129423- 77200 alternator is used in this section to show the service procedures for
the representative alternator.
4-7-3 Alternator Specifications

Yanmar Part Number 129423-77200
Nominal Output (13.5 Volts Heat) 40A
Weight 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 69.2 mm
Belt Shape Type A
4-7-2
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.
ON ON Inspect rotor assembly and

brushes.
Start Engine.
Inspect or replace V-belt.

Battery indicator ON. Inspect alternator.
4-7-4 Alternator Troubleshooting
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

Excessive voltage drop between
4-7-3
L terminal voltage is
greater than 0.5 volt. BAT and batt ( + side) terminal.
Does battery indicator Battery indicator With engine idling,
come ON? is dim. measure voltage at L
terminal and at battery.
4. ENGINE
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
4. ENGINE
4-7-5 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
1 – Nut 17 – Insulation Bushing
2 – Pulley 18 – Spring (2 used)
3 – Collar 19 – Brush Holder
4 – Front Frame Housing 20 – Rear Frame Housing
5 – Stator Assembly 21 – Bolt (2 used)
6 – Stud (2 used) 22 – Holder
7 – Front Frame Housing Bearing 23 – IC Regulator Assembly
8 – Bearing Cover 24 – Bolt (2 used)
9 – Bearing Cover Bolt (4 used) 25 – Bolt
10 – Rotor Assembly 26 – Brush (2 used)
11 – Rear Frame Housing Bearing 27 – Bolt
12 – Bearing Cover 28 – Rear Cover
13 – Thrust Washer 29 – Bolt (3 used)
14 – Thrust Washer
15 – Nut (2 used)
16 – Nut
Figure 4-7-1
4-7-4
4. ENGINE
4-7-6 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 4-7-2
NOTICE NOTICE
Do not short-circuit the charging system between Do not remove the positive (+) battery cable from
alternator terminals IG and L. Damage to the alternator terminal B while the engine is operating.
alternator will result. Damage to the alternator will result.
NOTICE
Do not connect a load between alternator
terminals L and E. Damage to the alternator will
result.
4-7-5
4. ENGINE
4-7-7 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 4-7-3
4-7-6
4. ENGINE
4-7-8 Alternator Disassembly of Alternator

1. Remove the nut (Figure 4-7-5, (1)) from the
WARNING shaft of the rotor assembly. Remove the pulley
SHOCK HAZARD! (Figure 4-7-5, (2)).
• Turn off the battery switch (if
equipped) or disconnect the
negative battery cable before
servicing the electrical system.
• Check the electrical harnesses for cracks,

abrasions, and damaged or corroded
connectors. ALWAYS keep the connectors
and terminals clean.
serious injury.
Removal of Alternator 2
1 0000256
1. Disconnect the electrical wires from the
alternator. Figure 4-7-5
2. Loosen the V-belt.
CAUTION
PINCH HAZARD!
Carefully rotate the alternator
toward the cylinder block while
loosening the V-belt. Failure to
moderate injury.
3. Remove the V-belt adjuster from the alternator

bolt (Figure 4-7-4, (1)).
4. Remove the nut (Figure 4-7-4, (2)) from the
gear case stud. Remove the alternator.
2 1
0000264
Figure 4-7-4
4-7-7
4. ENGINE
2. Remove the three bolts (Figure 4-7-6, (1)) 7. Remove the two bolts (Figure 4-7-8, (1)) and
retaining the rear cover (Figure 4-7-6, (2)) to two nuts (Figure 4-7-8, (2)) securing the rear
the rear frame assembly. frame housing to the front frame housing.
3 1
1
4 2
5
0000265A
Figure 4-7-8
0000257A
8. Using a press, remove the rotor assembly
Figure 4-7-6 (Figure 4-7-9, (1)) from the front frame
housing (Figure 4-7-9, (2)) and rear frame
3. Remove the brush holder (Figure 4-7-6, (3)). housing (Figure 4-7-10, (1)).
Remove the brush springs (Figure 4-7-6, (4))
and brushes (Figure 4-7-6, (5)). 3
4. Remove the bolt retaining the regulator
assembly (Figure 4-7-7, (1)) to the holder 1
(Figure 4-7-7, (2)). 2
3
1
4
100266A
Figure 4-7-9
0000258A
Figure 4-7-7
5. Remove the bolts retaining the holder
(Figure 4-7-7, (2)) to the rear frame housing.
Remove the holder.
6. Remove the nut (Figure 4-7-7, (3)) retaining
the insulation bushing (Figure 4-7-7, (4)).
Remove the insulation bushing.
4-7-8
4. ENGINE
9. Remove the stator assembly (Figure 4- Reassembly of Alternator

7-10, (1)) from the front frame housing.
1. If removed, reinstall the two thrust washers
4 (Figure 4-7-12, (3)) and bearing cover
(Figure 4-7-12, (2)) in the rear frame housing.
Lubricate the outside diameter of a new
3 bearing (Figure 4-7-12, (1)). Press the bearing
into the rear frame housing.
1 3
2
1
0000259A
Figure 4-7-10
10. If it is necessary to replace the bearing
(Figure 4-7-10, (2)) in the front frame housing,
remove the four bolts (Figure 4-7-10, (3))
0000260A
securing the plate (Figure 4-7-10, (4)) to the Figure 4-7-12

front frame housing. Remove the plate. Use a
2. If removed, lubricate the outside diameter of a
puller to remove the bearing. Discard the
new front frame housing bearing. Press the
bearing.
bearing (Figure 4-7-13, (2)) into the front
11. If it is necessary to replace the bearing frame housing. Reinstall the plate (Figure 4-
(Figure 4-7-11, (1)) in the rear frame housing, 7-13, (4)) to the front housing. Tighten the four
use a puller to remove. Discard the bearing. bolts (Figure 4-7-13, (3)).
Remove the bearing cover (Figure 4-7-11, (2))
and two thrust washers (Figure 4-7-11, (3)).
4
3
2
2
1
0000260A 0000259A
Figure 4-7-11
Figure 4-7-13
3. Position the stator assembly (Figure 4-
7-13, (1)) on the front frame housing studs.
4-7-9
4. ENGINE
4. Lubricate the shaft of the rotor assembly 6. Reinstall the insulation bushing (Figure 4-
(Figure 4-7-14, (1)). Press the rotor assembly 7-16, (4)) and nut (Figure 4-7-16, (3)).
into the front frame housing (Figure 4-
7-14, (2)) and rear frame housing (Figure 4-
7-14, (3)).
3
3 1
4
1
100266A
Figure 4-7-14 0000258A
5. Align the front frame housing with the rear Figure 4-7-16
frame housing. Reinstall the two bolts 7. Reassemble the regulator assembly (Figure 4-
(Figure 4-7-15, (1)) and two nuts (Figure 4- 7-16, (1)) to the holder (Figure 4-7-16, (2)).
7-15, (2)).
8. Reinstall the brush holder (Figure 4-7-17, (3)),
2 springs (Figure 4-7-17, (4)) and brushes
(Figure 4-7-17, (5)).
9. Reattach the regulator assembly and holder to
the rear frame housing.
1
3 1
0000265A
4 2
Figure 4-7-15
5
0000257A
Figure 4-7-17
4-7-10
4. ENGINE
10. Reinstall the rear cover (Figure 4-7-17, (2)) to

the rear frame housing with three bolts NOTICE
(Figure 4-7-17, (1)). Do not operate the engine if the alternator is
producing unusual sounds. Damage to the
alternator will result.
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 4-7-18
11. Reassemble the pulley (Figure 4-7-18, (2))
and nut (Figure 4-7-18, (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 4-7-19, (2)) on
the gear case stud and the V-belt adjuster bolt
(Figure 4-7-19, (1)).
2 1
0000264
Figure 4-7-19
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).
proper tension.
4. Start the engine. Listen for any unusual sounds
from the alternator.
4-7-11
4. ENGINE
4-8 Electric Wiring
4-8-1 Electric Wiring Precautions
Failure to follow these precautions may result in

the failure of an electrical component and the loss
of warranty coverage on that item as well as
related items. Make sure that all users read and
understand these precautions.
NOTICE
Do not reverse the positive (+) and negative (-)
ends of the battery cable. The alternator diode and
stator coil will be damaged.
NOTICE
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.
NOTICE
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.
NOTICE
Removing the battery cables or the battery while
the engine is operating may cause damage to the
current limiter depending on the electrical
equipment being used. This situation could cause
loss of control of output voltage. The continuous
high voltage of 23-24 volts (for 5000 rpm dynamo)
will damage the current limiter and other electrical
equipment.
NOTICE
Reversing the battery cable connections at the
battery or on the engine will destroy the SCR diode
in the current limiter. This will cause the charging
system to malfunction and may cause damage to
the electrical harnesses.
4-8-1
4. ENGINE
4-9 Troubleshooting
For measuring compression pressure

Compression Gauge Kit
Yanmar Part No. TOL-97190080
0000849
4-9-1
4. ENGINE
4-9-2 Troubleshooting By Measuring Compres- 4. Install one injector gasket at the tip end of the
sion Pressure compression gauge adapter. Install the
compression gauge and the compression
Compression pressure drop is one of major gauge adapter at the cylinder to be measured.
causes of increasing blow-by gas (engine oil
5. Crank the engine until the compression gauge
contamination or increased engine oil consumption
reading is stabilized.
as a resultant phenomenon) or starting failure. The
compression pressure is affected by the following
factors:
1. Degree of clearance between piston and
cylinder 1
2. Degree of clearance at intake / exhaust valve
seat
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.
Figure 4-9-1
A pressure drop may also be caused by scratched
cylinder or piston by dust entrance from the dirty 6. After performing the compression check,
air cleaner element or worn or broken piston ring. remove the compression gauge and
Measure the compression pressure to determine compression gauge adapter from the cylinder.
the condition of the engine. Reinstall the fuel injector, high-pressure fuel
injection lines and reconnect the stop solenoid.
Compression Pressure See Installation of the Fuel Injectors on page 4-
Measurement Method 3-24 and Installation of High-Pressure Fuel
Injection Lines on page 4-3-8.
1. Warm up the engine.
7. Turn on the fuel supply valve and reconnect the
2. Stop the engine. Remove the high-pressure injection pump stop solenoid.
fuel injection lines as an assembly from the
engine. See Removal of High-Pressure Fuel 8. Prime the fuel system. Check for leaks. Test
Injection Lines on page 4-3-7. Remove the fuel the engine.
injector from the cylinder to be measured. See
Removal of Fuel Injectors on page 4-3-18.
NOTICE
Remove or install the high-pressure fuel
injection lines as an assembly whenever
possible. Disassembling the high-pressure fuel
injection lines from the retainers or bending any
of the fuel lines will make it difficult to reinstall the
fuel lines.
3. Turn off the fuel supply valve in the fuel supply

line. Wrap the fuel discharge port of the fuel
injection pump in a waste cloth. This prevents
fuel from splashing.
4-9-2
4. ENGINE
Standard Compression Pressure

Engine compression pressure list (reference value)
Compression Pressure at 250 rpm (250 min-1)
Deviation Between Cylinders
Standard Limit
3.24 ± 0.1 MPa; 33 ± 1 kgf/cm² 2.55 ± 0.1 MPa; 26 ± 1 kgf/cm² 0.2 to 0.3 MPa; 2 to 3 kgf/cm²
Engine Speed and Compression Pressure (Use for Reference)
3.92 MPa
40 kgf/cm2
Compression pressure
3TNV70
3.43 MPa
35 kgf/cm2
2.94 MPa
30 kgf/cm2
2.45 MPa
25 kgf/cm2
1.96 MPa
20 kgf/cm2
200 250 300 350 400
Engine speed (min-1) 062106-00EN01
Figure 4-9-2
4-9-3
4. ENGINE
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
4-9-3 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.
4-9-4
Insufficient Poor
Engine Engine Air
Starting Problem Engine Exhaust Engine Oil
Surging Coolant Intake
Output Color
Engine
Exhaust During
Starts But
Color Work
Stops Soon.
Exhaust
Smoke Corrective Action Reference Page
Trouble Symptom
Cause
Troubleshooting Charts
Engine Does Not Start

None
Little
Much
Ordinary
White
Black
White
Black
High Knocking Sound During Combustion
Abnormal Engine Sound
Uneven Combustion Sound
During Idling
During Work Operation
Excessive Engine Vibration
Difficulty in Returning to Low Speed
Excessive Fuel Consumption
Excessive Oil Consumption
Dilution by Diesel Fuel
Oil with Water
Low Oil Pressure
Excessive Blow-by Gas
Overheat
Low Water Temperature
Pressure Drop
Pressure Rise
Exhaust Temperature Rise
Improper Intake/Exhaust Valve See Measuring and Adjusting
O O O O O O Adjust the Valve Clearance.
Clearance Valve Clearance on page 4-2-20
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 4-2-14
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 4-2-13
See Disassembly of Cylinder
Cylinder Head Gasket Blowout O O O Replace the Gasket
Head on page 4-2-7
Replace the Piston Ring. See Reassembly of Cylinder
Seized or Broken Piston Ring O O O O O O O O O O O O
Head on page 4-2-17
4-9-5
Perform Honing and Use See Honing and Boring on
Worn Piston Ring, Piston or Cylinder O O O O O O O
Oversize Parts. page 4-2-39
See Inspection of Crankshaft and
Seized Crankpin Metal or Bearing O O O O O O O Repair or Replace Camshaft Components on page
4-2-32
4. ENGINE
Improper Arrangement of Piston Ring See Reassembly of Pistons on

O O O O Correct the Ring Joint Positions
Gaps page 4-2-40
See Reassembly of Pistons on
Reverse Assembly of Piston Rings O O O O Reassemble Correctly
page 4-2-40
Engine System
See Inspection of Crankshaft and
Worn Crankpin and Journal Bearing O O O O O O Measure and Replace. Camshaft Components on page
4-2-32
See "3-7-2 Engine Tightening
Loose Connecting Rod Bolt O O O Tighten to the Specified Torque. Torque" section for tightening
torque.
See Disassembly of Cylinder
Foreign Matter Trapped in Combustion
O O O O Disassemble and Repair. Block Components on page 4-
Chamber
2-23
See Checking Timing Gear
Excessive Gear Backlash O Adjust Gear Meshing.
Backlash on page 4-2-24
See Inspection of Valve Guides
Worn Intake/Exhaust Valve Guide O O O Measure and Replace.
on page 4-2-12
Governor Adjusted Incorrectly O O O O O Make Adjustment.
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 4-2-20
Insufficient Poor
Engine Engine Air
Output Color
Engine
Exhaust During
Starts But
Color Work
Stops Soon.
Exhaust
Trouble Symptom
Cause
None
Little
Much
Ordinary
White
Black
White
Black
During Idling
Oil with Water
Low Oil Pressure
Overheat
Pressure Drop
Pressure Rise
See Disassembly of Engine
Excessive Radiator Cooling O O O Replace Thermostat
Coolant Pump on page 4-4-4
Replace Thermostat or Check for See Disassembly of Engine
Insufficient Radiator Cooling O O O
Loose Fan Belt. Coolant Pump on page 4-4-4
Check Water Leakage from See Engine Coolant System
Insufficient Engine Coolant Level O O O
Engine Coolant System. Check on page 4-4-4
Cracked Water Jacket O O O Repair or Replace
Stretched Fan Belt O O O Adjust the Belt Tension.
Engine Coolant System

Defective Thermostat O O O O Check or Replace
Incorrect Engine Oil O O O O O O Use Correct Engine Oil
See Disassembly of Oil Pump on
Engine Oil System Leakage O O Repair
page 4-5-4
Insufficient Delivery Capacity of See Disassembly of Oil Pump on
O Check and repair
Trochoid Pump page 4-5-4
4-9-6
Clogged Engine Oil Filter O O Clean or Replace
See Disassembly of Oil Pump on
Defective Pressure Regulating Valve O Clean, Adjust or Replace
page 4-5-4
Engine Oil System

4. ENGINE
Insufficient Engine Oil Level O O Add Correct Engine Oil

Overfilled Engine Crankcase O Check Engine Oil
See Checking and Adjusting Fuel
Too Early Timing of Fuel Injection Pump O O O Check and Adjust
Injection Timing on page 4-3-15
See Checking and Adjusting Fuel
Too Late Timing of Fuel Injection Pump O O O O Check and Adjust
Injection Timing on page 4-3-15
Incorrect Diesel Fuel O O O O O O Use Correct Fuel Oil.
Water in Fuel System O O O O O O O Draining the Fuel Filter
Fuel System
Clogged Fuel System O O O Clean or Replace.
Air in Fuel System O O O Bleed the Air.
Clogged or Cracked Fuel Line O O O Clean or Replace.
Check the Fuel Tank Cock, Fuel
Insufficient Fuel Supply to Fuel Injection
O O O Filter, Fuel Line, and Fuel Feed
Pump
Pump.
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 4-3-19
See Testing of Fuel Injectors on
Excessive Fuel Injection Vo lume O O O O O O O Check and Adjust.
page 4-3-19
Fuel System
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 4-3-19
Foreign Matter Trapped in the
See Fuel System Components on
Priming Failure O Valve Inside the Priming Pump
page 4-3-6
(Disassemble and Clean).
Clogged Strainer at Feed Pump Inlet O Clean the Strainer.
Insufficient Poor
Engine Engine Air
Output Color
Engine
Exhaust During
Starts But
Color Work
Stops Soon.
Exhaust
Trouble Symptom
Cause
None
Little
Much
Ordinary
White
Black
White
Black
During Idling
Oil with Water
Low Oil Pressure
Overheat
Pressure Drop
Pressure Rise
Clogged Air Filter O O O O O Clean Air Filter.
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.
Air/Exhaust Gas System

Starting Motor Defect O Repair or Replace Stater Motor. See Starter Motor on page 4-6-1
Alternator Defect O Repair or Replace Alternator.
Open-Circuit in Wiring O Repair Open Circuit.
Battery Voltage Drop O Inspect and Change the Battery.
Electrical System
4-9-7
4. ENGINE
4. ENGINE
4-9-8
CHAPTER 5
ELECTRIC SYSTEM
5-1 Electric Equipment of Machine ........................................................... 5-1-1

5-1-1 Parts Layout of Electrical Equipment ......................................... 5-1-1
5-2 Circuit Description of Engine Start and Stop ...................................... 5-2-1
5-2-1 Engine Start and Stop................................................................ 5-2-1
5-2-2 Battery charge............................................................................ 5-2-1
5. ELECTRIC SYSTEM
5. Electric System
5-1 Electric Equipment of Machine
5-1-1 Parts Layout of Electrical Equipment
1) Harness A
5-1-1
5. ELECTRIC SYSTEM
Ref. No. Part Ref. No. Part

A1 Battery A11 Switch water pump
A2 Starter motor A12 Ground
A3 Generator A13 Valve two speed
A4 Sensor water temp A14 Valve cut off
A5 Sensor hydro temp A15 Valve cut off
A6 Plug glow A16 Horn
A7 Stop solenoid A17 Not used on this machine
A8 Diode hold A18 Not used on this machine
A9 Switch oil pressure A19 Boom lamp
A10 Feed pump A20 Diode pulse
5-1-2
5. ELECTRIC SYSTEM
2) Harness B
5-1-3
5. ELECTRIC SYSTEM
5-1-4
5. ELECTRIC SYSTEM

B1 Slow blow fuse starter B22 Diode buzzer
B2 Slow blow fuse glow B23 Track extend switch
B3 Slow blow fuse generator B24 Fuse box
B4 Slow blow fuse main B25 Relay glow
B5 Digital monitor B26 Relay safety
B6 Buzzer B27 Relay power
B7 Socket 12V B28 Relay cabin
B8 Fuel gauge B29 Relay desel
B9 Horn switch B30 Relay engine control
B10 USB B31 Relay high level

B11 Starter switch B32 Timer 1s
B12 Switch light B33 Timer 3s
B13 Switch beacon B34 Timer 3s
B14 Switch second speed B35 Safety relay
B15 Shunt B36 Stop solenoid valve
B16 Diode reverse B37 Panel data
B17 Diode timer 3s B38 Service connector
B18 Diode glow B39 Power option 1
B19 Diode buzzer pulse B40 Selector valve
B20 Not used on this machine B41 Travel alarm
B21 Switch cut off B42 Power option 2
5-1-5
5. ELECTRIC SYSTEM
3) Heater harness

C1 Heater C3 Switch heater
C2 Switch wiper
5-1-6
5. ELECTRIC SYSTEM
4) Cabin harness

D1 Speaker L D7 Wiper motor
D2 Green beacon D8 Speaker R
D3 Front led left D9 Rear led
D4 Room lamp D10 Beacon
D5 Washer pump D11 Radio
D6 Front led right
5-1-7
5. ELECTRIC SYSTEM
5) SAR harness

E1 SA-R unit E3 Diode travel signal
E2 SA-R antenna
5-1-8
5. ELECTRIC SYSTEM
6) Seat harness

F1 Sensor seat belt F3 Buzzer seat belt
F2 Seat electronic box F4 Alarm seat belt
5-1-9
5. ELECTRIC SYSTEM
5-2 Circuit Description of Engine Start and Stop
5-2-1 Engine Start and Stop
1. Engine Start
The starter switch B11 is always supplied at B port with power from the battery flowing through the slow blow fuse B4 (80A).
When the starter switch B11 is turned to the position 2, the three lines C1, BR1 and BR2 are powered.
The BR1 line goes through a 10A fuse (Engine) and powers the relay timer 1s B32 which then powers the coil of the stop
solenoid relay B35 for 1s. The stop solenoid relay switch which is plugged to the batteryl shuts to let the current flow to the
stop solenoid A7. The stop solenoid core is pulled and held in this position which allows the feeding of fuel in the fuel
injection valves.
The BR1 also powers the fuel feed pump A10 and the safety relay B36.
The BR2 line goes through a 10A fuse (Imobi) and the cut off switch B21. If the lock levers are in the lock position (up) the
safety relay B26 is powered and the switch of the safety relay is open.
The C1 line goes through a 5A fuse (Safety) and the switch of the engine control relay B30 which is controlled by the anti
theft device. It then goes through the switch of the safety relay B26. If the lock levers are in the lock position (up) the
starting order is sent to the safety relay B36 which will activate the relay of the starter motor A2. The starter motor is then
powered by the battery and starts the engine.
Once the engine is started, the generator A3 is driven by the engine. The generator sends a signal to the safety relay B36
to avoid any new starting order while the engine is already running.
2. Engine Stop
When the starter switch B11 is turned to the position OFF, the polarity sent to the stop solenoid A7 is reversed. The stop
solenoid core is no longer pulled and the feeding of fuel in the injection valves is stopped.
5-2-2 Battery charge
The electric current generated The electric current flows from the generator A3 to the battery A1 through the
by the generator A3 flows to the slow blow fuse B3 (Generator) to charge the battery.
battery + terminal to be charged.
When the voltage generated by the alternator decreases, the logical circuit in the
The battery lamp glows for alternator is turned on so that the battery lamp of the digital monitor B5 turns on
poor battery charging. over poor charging.
5-2-1
CHAPTER 6
HYDRAULIC SYSTEM
6-1 Outline ........................................................................ 6-1-1 6-6 Swing Motor.......................................................... 6-6-1

6-2 Circuit Operation.......................................................... 6-2-1 6-6-1 Structure and fuctions ......................................6-6-1
6-2-1 Boom.................................................................. 6-2-1 6-6-2 Mechanical brake ............................................ 6-6-3
6-2-2 Arm .................................................................... 6-2-3 6-6-3 Theory of operation for brake valve ................. 6-6-4
6-2-3 Bucket.................................................................6-2-5 6-6-4 Disassembly and reassembly .......................... 6-6-5
6-2-4 Swing ................................................................. 6-2-7 6-7 Travel Motor ............................................................. 6-7-1
6-2-5 Boom Swing........................................................6-2-9 6-7-1 Outline ............................................................. 6-7-1
6-2-6 PTO ................................................................... 6-2-11 6-7-2 Theory of operation ......................................... 6-7-2
6-2-7 Blade ................................................................. 6-2-13 6-7-3 Exploded view and parts comprised ................ 6-7-5
6-2-8 Lower frame extension ...................................... 6-2-15 6-7-4 Disassembly ans reassembly .......................... 6-7-7
6-2-9 Travel ................................................................ 6-2-17 6-7-5 Failure cause and measure ............................. 6-7-15
6-3 Hydraulic Pump .......................................................... 6-3-1
6-3-1 Routine maintenance ......................................... 6-3-1
6-3-2 Service ............................................................... 6-3-1
6-4 Control Valve .............................................................. 6-4-1
6-4-1 Introduction ........................................................ 6-4-1
6-4-2 Troubleshooting ................................................. 6-4-3
6-4-3 Fundamental Rules ............................................ 6-4-4
6-4-4 Installation of the control valve ........................... 6-4-4
6-4-5 Port symbols and recommended fastening
torque ........................................................................ 6-4-5
6-4-6 Disassembly ...................................................... 6-4-6
6-4-7 Assembly ........................................................... 6-4-18
6-4-8 Maintenance standards ..................................... 6-4-27
6-4-9 Storage .............................................................. 6-4-28
6-4-10 Disposal ...........................................................6-4-28
6-5 Pilot Valve................................................................... 6-5-1
6-5-1 Remote Control Valve ........................................ 6-5-1
6-5-2 Troubleshooting ................................................. 6-5-2
6-5-3 Fundamental Rules ............................................ 6-5-3
6-5-4 Removal / Installation of the Pilot Control
Unit Connection ................................................ 6-5-3
6-5-5 Pilot Control Unit Repair Procedures ................. 6-5-4
6. HYDRAULIC SYSTEM
6. Hydraulic System
6-1 Outline
The hydraulic system consists of an engine, a gear pump, a cut-off valve, a control valve, a deviation valve, a
PTO valve, an accumulator, a boom cylinder, an arm cylinder, a bucket cylinder, a boom swing cylinder, a blade
cylinder, an extension cylinder, a swing motor, a swivel joint, two travel motors and a hydraulic oil tank.
The oil discharged from the pump flow to the actuators through the control valve.
The hydraulic pilot control system comprises a cut-off valve, an accumulator and a pilot valve.
The oil discharged from the pump flows into the pilot ports of the control valve through the cut-off valve and the
pilot valve.
1= Arm cylinder
2= Bucket cylinder
3= Boom cylinder
4= Boom swing cylinder
5= Blade cylinder
6= Extension cylinder
7= Pilot valve R
8= Pilot valve L
9= Swing motor
10= Swivel joint
11= Hydraulic oil tank
12= Hydraulic pump
13= Control valve
14= Travel motor
15= Accumulator
16= Cut-off valve
17= Deviation valve
18= Hydraulic manifold
19= PTO valve
6-1-1
6. HYDRAULIC SYSTEM
1) Hydraulic Pump
The pump is linked to the flywheel of the engine through the coupling. The number of revolutions of the
hydraulic pump is identical to the engine speed.
cm3 / rev
No. Pump SV15VT
P1 5,5
1 Variable pump
P2 5,5
2) Oil Flow
The pump takes in oil through the suction filter from the hydraulic oil tank and discharges it.
The discharged oil flows to the ports P1 and P2 of the cut-off valve and to the ports P1 and P2 of the
control valve.
The flow from the port P1 of the inlet section feeds the boom cylinder, the bucket cylinder, the boom
swing cylinder, the right travel motor and the PTO.
The flow from the port P2 of the inlet section feeds the swing motor, the arm cylinder, the left travel
motor and the blade cylinder.
Then oil flows through port T of the control valve back to the hydraulic oil tank.
3) System Relief Valve

The system relief valves of the control valve regulate the discharge pressure of the pump.
4) Cut-off valve
When the lock lever is set to the "LOCK" position, the spool in the Safety part of the cut-off valve returns
the pilot oil to the tank through the port T1 of the cut-off valve.
Therefore, the implement does not operate and the machine does not travel even when the control or travel
lever is operated.
6-1-2
6. HYDRAULIC SYSTEM
6-1-3
6. HYDRAULIC SYSTEM
6-2 Circuit Operation
6-2-1 Boom
1) Boom “Up”
(1) Pilot oil flow
When the boom control lever is pulled back to raise the boom, the oil from the pump flows through the cut-off
valve and the port 1 of the pilot valve (R) to the port Pb9 of the boom section to operate its spool.
(2) Oil flow from hydraulic pump
The oil discharged from the pump P2 flows to the boom section through the port P2 of the inlet section.The oil
flows through the port B9 to the rod port of the boom cylinder to retact its cylinder rod, raising the boom. The
return oil from the bottom port of the boom cylinder flows back to the hydraulic oil tank through the port A9 and T
of the control valve. The oil from the port T flows back to the tank through the oil cooler and the return filter.
2) Boom "Down"
(1) Pilot oil flow
When the boom control lever is pushed forward to lower the boom, the oil from the pump flows through
the cut-off valve and the port 3 of the pilot valve (R) to the port Pa9 of the boom section its spool.

The oil discharged from the pump P2 flows through the port P2 of the inlet section to the boom section.
In this operation, the oil flows in the opposite direction to the oil flow in the Boom "Up" operation with regard to
the boom cylinder.
6-2-1
6. HYDRAULIC SYSTEM
6-2-2
6. HYDRAULIC SYSTEM
6-2-2 Arm
1) Arm “Retract”
(1) Pilot oil flow
When the arm control lever is pulled back to retract the arm, the oil from the pump flows through the cut-off
valve and the port 1 of the pilot valve (L) to the port Pb2 of the arm section to operate its spool.
The oil discharged from the pump P1 flows to the arm section through the port P1 of the inlet section. The oil
flows through the port B2 to the bottom port of the arm cylinder to extend its cylinder rod, retracting the arm.
The return oil from the rod port of the arm cylinder flows back to the hydraulic oil tank through the port A2 and
T of the control valve. The oil from the port T flows back to the tank through the oil cooler and the return filter.
2) Arm "Extend"
(1) Pilot oil flow

When the arm control lever is pushed forward to extend the arm, the oil from the pump flows through the cut-off
valve and the port 3 of the pilot valve (L) to the port Pa2 of the arm section to operate its spool.

The oil discharged from the pump P1 flows through the port P1 of the inlet section to the arm section.
In this operation, the oil flows in the opposite direction to the oil flow in the Arm "Retract" operation with regard
to the arm cylinder.
6-2-3
6. HYDRAULIC SYSTEM
6-2-4
6. HYDRAULIC SYSTEM
6-2-3 Bucket
1) Bucket “Curl”
(1) Pilot oil flow
When the bucket control lever is moved to the left to curl the bucket, the oil from the pump flows through the cut-off
valve and the port 2 of the pilot valve (R) to the port Pb8 of the bucket section to operate its spool.
The oil discharged from the pump P2 flows to the bucket section through the port P2 of the inlet section. The oil
flows through the port B8 to the bottom port of the bucket cylinder to extend its cylinder rod, curling the bucket.
The return oil from the rod port of the bucket cylinder flows back to the hydraulic oil tank through the port A8 and T
of the control valve. The oil from the port T flows back to the tank through the oil cooler and the return filter.
2) Bucket "Dump"
(1) Pilot oil flow
When the bucket control lever is moved to the right to dump the bucket, the oil from the pump flows through
the cut-off valve and the port 4 of the pilot valve (R) to the port Pa8 of the arm section to operate its spool.

The oil discharged from the pump P2 flows through the port P2 of the inlet section to the bucket section.
In this operation, the oil flows in the opposite direction to the oil flow in the Bucket "Curl" operation with regard to the
bucket cylinder.
6-2-5
6. HYDRAULIC SYSTEM
6-2-6
6. HYDRAULIC SYSTEM
6-2-4 Swing
1) Right Swing
(1) Pilot oil flow
When the swing control lever is moved to the right, the oil from the pump flows through the cut-off valve,
the port 4 of the left pilot valve (L) to the port Pa1 of the swing section to move its spool.
The oil discharged from the pump P1 flows to the swing section through the port P1 of the inlet section. The oil
flows through the port A1 to the port A of the brake valve of the swing motor, so that the swing motor is rotated.
The return oil from the port B of the brake valve flows back to the hydraulic oil tank through the port B1 and T of
the control valve. The oil from the port T flows back to the tank through the oil cooler and the return filter.
2) Left Swing
(1) Pilot oil flow
When the swing control lever is moved to the left, the oil from the pump flows through the cut-off valve,
the port 2 of the left pilot valve (L) to the port Pb1 of the swing section to move its spool.

The oil discharged from the pump P1 flows through the port P1 of the inlet section to the swing section.
In this operation, the oil flows in the opposite direction to the oil flow in the Right Swing operation with regard to
the swing motor.
6-2-7
6. HYDRAULIC SYSTEM
6-2-8
6. HYDRAULIC SYSTEM
6-2-5 Boom Swing

The boom swing pedal is linked to the spool of the control valve through an L-ball and a rod.
1) Right Boom Swing
(1) Control
When the boom swing pedal is moved on the right, the spool is pulled backward.
(2) Oil Flow from Hydraulic Pump
The oil from the pump P2 flows through the port P2 of the inlet section and the port A7 of the boom swing
section to A7 of the boom swing cylinder to retract its cylinder rod, swinging the boom to the right.
The return oil from the bottom port of the boom swing cylinder flows back to the hydraulic oil tank through the
port B7 and T of the control valve. The oil from the port T flows back to the tank through the oil cooler and the
return filter.
2) Left Boom Swing

(1) Control
When the boom swing pedal is moved on the left, the spool is pushed forward.
The oil discharged from the pump P2 flows through the port P2 of the inlet section to the boom swing section.
In this operation, the oil flows in the opposite direction to the oil flow in the right boom swing operation with
regard to the boom swing cylinder.
6-2-9
6. HYDRAULIC SYSTEM
6-2-10
6. HYDRAULIC SYSTEM
6-2-6 P.T.O.
The PTO pedal is linked to the spool of the control valve through an L-ball and a rod.
1) Switching between Single Acting and Double Acting

Open or close the P.T.O. stop valve to select single or double acting of the P.T.O.
2) Single Acting P.T.O.

(P.T.O. stop valve is open)
(1) Control
When the PTO pedal is moved on the left, the spool is pushed forward.
The oil discharged from the pump P2 flows to the PTO section through the port P2 of the inlet section.
The oil flows through the port B5 to the P port of the PTO line to operate the accessory.
The return oil from the T port of the PTO line flows back to the hydraulic oil tank through the opened P.T.O.
stop valve and through the ports A5 and T of the control valve.
3) Double Acting P.T.O.

(P.T.O. stop valve is closed)
(1) Control
When the PTO pedal is moved on the left, the spool is pushed forward and the oil flow is the same as the flow in
"Single Acting P.T.O."
When the PTO pedal is moved on the right, the spool is pulled backward.
When the PTO pedal is moved on the left, the oil flow is the same as the flow in "Single Acting P.T.O."
When the PTO pedal is moved on the right, the oil flows in opposite direction to the oil flow when the PTO pedal is
moved on the left.
6-2-11
6. HYDRAULIC SYSTEM
6-2-12
6. HYDRAULIC SYSTEM
6-2-7 Blade
The blade lever is linked to the spool of the control valve through a blade cable.
1) Blade "Down"
When the blade lever is pushed forward to lower the blade, the spool is pushed.
Oil Flow from Hydraulic Pump
The oil discharged from the pumps P1 and P2 flows to the blade section through the port P1 and P2 of the inlet
section, the port B4 of the blade section and the ports J of the swivel joint to the bottom side of the blade cylinder.
The return oil from the rod port of the blade cylinder flows back through the ports E of the swivel joint to the
hydraulic oil tank through the ports 3 and 2 of the deviation valve and A4 and T of the control valve. The oil from
the port T flows back to the tank through the oil cooler and the return filter.
2) Blade "UP"
When the blade lever is pulled back to raise the blade, the spool is pulled.
The oil discharged from the pumps P1 and P2 flows through the port P1 and P2 of the inlet section to the blade
section.
In this operation, the oil flows in the opposite direction to the oil flow in the blade down operation with regard
to the blade cylinder.
3) Circuit Relief Valve Installed in Blade "Up" Circuit
When the blade is forcibly raised while the machine is traveling or ground leveling, the oil quantity control function
of the hydraulic pump operates to reduce its discharge volume, and the travel speed is slowed down.
To minimize such speed reduction, a circuit relief valve with the set pressure lower than that of the system relief
valve is installed in the blade cylinder circuit for raising the blade.
6-2-13
6. HYDRAULIC SYSTEM
6-2-14
6. HYDRAULIC SYSTEM
6-2-8 Lower frame extension

The lower frame extension is controlled through the blade lever. The blade lever is linked to the spool of the control
valve through a blade cable.
1) Lower frame "Extend"
When the blade lever is pushed forward to extend the lower frame, the spool is pushed.
The oil discharged from the pumps P1 and P2 flows to the blade section through the port P1 and P2 of the inlet
section, the port B4 of the blade section and the ports J of the swivel joint to the bottom side of the extension
cylinder. The return oil from the rod port of the extension cylinder flows back through the ports F of the swivel joint
to the hydraulic oil tank through the ports 1 and 2 of the deviation valve and A4 and T of the control valve. The oil
from the port T flows back to the tank through the oil cooler and the return filter.
2) Lower frame "Retract"

When the blade lever is pulled back to retract the lower frame, the spool is pulled.
The oil discharged from the pumps P1 and P2 flows through the port P1 and P2 of the inlet section to the blade
section.
In this operation, the oil flows in the opposite direction to the oil flow in the lower frame extension operation
with regard to the extension cylinder.
6-2-15
6. HYDRAULIC SYSTEM
6-2-16
6. HYDRAULIC SYSTEM
6-2-9 Travel
Each travel lever is linked to the spool of the control valve through an L-ball and a rod.
1) Forward Travel (Right)

When the right travel lever is pushed forward, the spool of the right travel section is pressed down.
The oil from the pump P2 flows through the port P2 of the inlet section, the port A6 of the right travel section
and the ports B of the swivel joint to the port B of the right travel motor to rotate it.
The return oil from the port A of the right travel motor flows back to the hydraulic oil tank through the ports D
of the swivel joint, the portB6 of the right travel section and the port T of the control valve. The oil from the port
T flows back to the tank through the oil cooler and the return filter.
2) Forward Travel (Left)
When the left travel lever is pushed forward, the spool of the leftt travel section is pressed down.
The oil from the pump P1 flows through the port P1 of the inlet section, the port A3 of the left travel section
and the ports C of the swivel joint to the port A of the left travel motor to rotate it.
The return oil from the port B of the left travel motor flows back to the hydraulic oil tank through the ports C of
the swivel joint, the port B3 of the left travel section and the port T of the control valve. The oil from the port T
flows back to the tank through the oil cooler and the return filter.
3) Reverse Travel (Right and Left)

When the right or left travel lever is pulled back, the spool of the travel section is pulled up.
The oil flows in the opposite direction to the oil flow in the Forward Travel operation with regard to the right or
left travel motor.
4) High-Speed Function
When the high-speed travel switch is pressed, the signal is transmitted from the switch to the 2 Speed solenoid
valve to increase the travel speed.
(1) Pilot oil flow
The oil from the pump flows through the port R1 of the solenoid valve to the port G of the swivel joint and is
divided into two flows to the ports Pp of each travel motor.
(2) Increase in output speed of travel motor
The pilot oil from the pump moves the swash plate control piston to reduce the inclination angle of the swash
plate, which shortens the piston stroke of the travel motor and decreases the travel motor capacity to increase its
output speed. This increases the travel speed.
Meanwhile, the travel driving force weakens as the output torque of the travel motor becomes smaller due to the
shortened piston stroke.
6-2-17
6. HYDRAULIC SYSTEM
6-2-18
6. HYDRAULIC SYSTEM
6-3 Hydraulic Pump

The machine is equipped with a fixed displacement gear pump.
6-3-1 Routine maintenance

No routine maintenance is necessary other than a periodic check for tightness of the mounting bolts and a visual
check for oil leakage. Keep the pump clean externally, especially in the area of the shaft seal. Abrasive dirt can
accelerate seal wear and cause oil leakage.
The pump must be operated only with clean oil. Strictly observe the perdiodic inspection and servicing for oil
replacement and oil filter element cleaning/replacement.
6-3-2 Service
Service of this pump must only be performed by its manufacturer.
6-3-1
6. HYDRAULIC EQUIPMENT
6-4 Control Valve
Left side
6-4-1 Introduction
1) Foreword
This manual deals with the instructions relative to servicing and maintenance operations for the control valve. For
the inspections and servicing operations associated with the hydraulic system of the machine to which the block is
connected, please consult the maintenance manual supplied by the equipment manufacturer.
It is recommended that only qualified personnel perform the installation, connection and maintenance of this device,
and that all operations be carried out in compliance with the technical standards in force and the cleanliness regula-
tions specific to this type of installation.
To ensure maximum performance and safety during maintenance operations we advise you to
Read this manual thoroughly
All information, illustrations, instructions and characteristics contained in this document are based on the
latest product information available at the time of publication. In its attempts to maintain a high-quality product,
NABTESCO reserves the right to make design or technical modifications at any time and without prior notification.
2) Safety Instructions
Please pay a particular attention to the signals of the safety alerts and special instructions in this manual.
They are indicated in the following manner:
Indicates information or instructions which must be followed to guarantee your safety during
operations.
CAUTION :
Warning against possible equipment damage.
Note :
Useful information.
6-4-1
3) General safety cautions

If you modify the shape or performance of the control valve from the delivery condition, there could be
degradation, failure, or breakage in it. Do not modify the product. If not, we shall not be responsible for any
accident after modification.
If you use the control valve under conditions not mentioned in the delivery specifications, there could be
degradation, failure, or breakage in it. Keep the working conditions as described in the specifications.
Be more careful handling the control valve during or immediately after the operation, the surface of the control
valve can be hot.
6-4-2
6-4-2 Troubleshooting
CAUTION :
Since cause of trouble occured in hydraulic devices might be a complexity of various factors, first check whether
the trouble occurs in any control valve, the other hydraulic device, or the circuit if you find any abnormality.
It is necessary to measure the pressure, flow rate, and son on of each important point.
Before disassembling even a part, follow the disassembly and assembly procedures of this manual.
Abnormal operation of the actuators connected to the control block

Malfunction Probable cause Remedy
Spool's sliding movement is Storage of foreign matter. Disassemble, check, correct or replace it.
not smooth.
Oil-film shortage between spool and body due Decrease oil temperature or change
to abnormal rise of oil temperature. hydraulic oil.
Friction of spool. Replace spool.
Insufficient lubrication due to oil deterioration. Change hydraulic oil and carry out
flashing of circuit.
Set or breakage of return spring. Replace string.
Bend of spool. Replace spool.
Distortion of valve due to fitting surface failure. Loosing fitting bolts, carry out check and
correction.
Abnormal tightening of fitting surface. Retighten them with specified torque.
Failure in link fitting. Inspect and correct link fitting.
Oil leakage from spool seals. Damaged or cut O-rings. Replace O-rings.
Dent or score on sliding part of spool seal. Correct or replace spool.
Paint adhered on sliding part of spool seal. Remove paint with thinner or the like.
Attachment does not Storage of foreign matter on the seat of Relief Disassemble, check and replace it.
operate, is slow or outputs Valve (RV) or Overload Relief Valve (ORV).
less power. Loosened adjusting screw in RV or ORV. Readjust with specified torque.
Storage of foreign matter on the seat of Disassemble, check and replace it.
Anticavitation Valve (ACV) or on the seat of If the seat contacting with ORV's
Relief Plug. body is damaged, replace body also.
Even when spool position Damaged body or spool. Replace body and/or spool.
is neutral, cylinder sinks
Storage of foreign matter between body and Disassemble, check, correct, or replace it.
under its own weight.
spool, or stick. When there is a stick, replace body and
spool as a set.
Set or breakage of Spring-Check Valve or Replace spring.
Return Spring.
Storage of foreign matter on the seat of ORV. Disassemble, check and replace it.
If the seat contacting with ORV's body is
damaged, replace body also.
Loosened adjusting screw in ORV. Readjust it with specified torque.
Storage of foreign matter on the seat of Disassemble, check and replace it.
Anticavitation Valve (ACV) or on the seat of If the seat contacting with ACV's body is
Relief Plug. damaged, replace body also.
When operating it Storage of foreign matter between Load After disassembling and clearing, replace
upward, cylinder falls Check Valve and Comp. Body's Seat. body if damage is serious.
conversely. Stick of Check Valve. Replace Check Valve and Plug-Check
Valve as a set.
Set or breakage of Spring-Check Valve. Replace spring.
6-4-3
6-4-3 Fundamental Rules
When removing the block, all openings must be plugged immediately to prevent any contamination of the hydraulic
system.
When replacing the block, remove the plastic plugs from the openings and lines just before making the connections.
Do not tighten connectors to a torque greater than that specified in the assembly instructions.
Check the hydraulic installation's oil quality and filtration capacity during all servicing/maintenance operations. The
use of Teflon tape, hemp and joint filler is prohibited.
Hydraulic lines and connections must not be under any strain whatsoever.
6-4-4 Installation of the control valve

Before installation, remove masking plugs in the ports to check whether there is abnormality. When installing the
control valve in the excavator, observe the following precautions:
1. When unpacking or installing the control valve, make sure not to let it fall or hit on any places.
2. When handling the control valve, be careful to not hold the pilot cover of the spool or accessory valves such as
relief valves and overload relief valves anticavitation valves and relief plug.
3. Mount the control valve securely to a flat surface; at that time, do not use a hammer for positioning by hitting.
4. Clean piping materials sufficiently before use.
5. Make sure to prevent the port openings from being entered with dust or foreign matters.
6. Tighten the port connectors surely with the recommended fastening torque shown in 6-4-5.
7. Arrange the piping so that the back pressure on tank port is to be 0.98 MPa (10kg/cm²) or less.
8. Connect the linkage for operating each spool firmly to move smoothly and not to drop out.
Fallling or hitting the control valve may cause a bend in the spool, resulting in an accident
due to an operation failure.
If the control valve is mounted on an uneven surface, the control valve body may be
deformed, which resuluts in a malfunction or external leakage. Besides moving the control
valve itself may vause the operation stroke shortage of manual spools or the malfunction of
linkage, resulting in an accident.
If there are foreign matters in any port, the control valve operation may fail, resulting in an
accident.
Do not tighten connectors with torque more than the recommended value. If not, there may
be strains or damage to control valve and/or connectors, resulting in a serious accident
such as the falling of ATT.
If there is a mistake in piping between the ports, unintentional movement could result in an
accident.
If the linkage is dropped out or cling, it might make operating the control valve impossible.
6-4-4
6-4-5 Port symbols and recommended fastening torque
Port symbol Port position Use Port size Recommended fastening torque
P1
P1, P2 Inlet Comp. Pump port G3/8 39.2~49.0 N.m (4.0~5.0 kgf.m)
P1
T P1 Inlet Comp. Tank port G3/8 39.2~49.0 N.m (4.0~5.0 kgf.m)
A1
Swing Comp.
B1
A2
Arm Comp.
B2
A3
Travel Comp.
B3
A4
Blade Comp.
B4
A5
PTO Comp. Actuator port G1/4 24.5~29.4 N.m (2.5~3.0 kgf.m)
B5
A6
Travel Comp.
B6
A7
Boom Swing Comp.
B7
A8
Bucket Comp.
B8
A9
Boom Comp.
B9
6-4-5
6-4-6 Disassembly
1) Precautions for disassembly
Observe the following precautions and carry out the work at a factory where there are engineers with sufficient
technique for hydraulic devices.
1. Since hydraulic devices are all machined precisely with clearances being very little, carry out the disassembly
and assembly work at a clean place and make sure to prevent the device from being entered with dust, sand, and
the like.
2. Before disassembly work, check that there is no dust on the outside of the control valve and then place it on a
workbench with actuator ports facing upward.
3. Before disassembly work, prepare necessary material such as the structural drawing for valves to fully
understand the structure and others.
4. When removing the control valve from the machine, put a dustproof cap on each port and then clean the
outside of assembly after checking the installation of caps.
Furthermore, prepare a suitable workbench with clean papre or rubber mat on it for the work.
5. Since there is a possibility of rust when the disassembled pars are left, apply anti-corrosive oil to the parts and
seal them.
6. When carrying or moving the control valve, hold the body. Especially, after removing a pilot cover from the
control valve, never hold the exposed spool.
7. Even if a control valve does not move smoothly, never hit it.
8. It is recommended to carry out various tests (reliev valve setting, leak test, internal pressure loss check, etc.)
after the disassembly and assembly of the control valve, which requires a hydraulic test device.
Accordingly, when the disassembly might be possible technically but the test and/or adjustment might be
impossible, do not carry out the work.
Before removing the pipes, attach suitable indications on them to be able to locate their
positions later. If there is a mistake between the ports, unintentional movement could result
in an accident.
Falling or hitting the control valve could bend the spool, which could result in an accident.
If foreign matter enters any port, there could be a control valve malfunction, resulting in an
accident.
Since the load side port could hold an empty weight or enclosed pressure, release the inside
pressure before loosening the piping. If not, there could be a fall of attachments or a jet of
high temperature hydraulic fluid, and it is dangerous.
CAUTION :
The control valve becomes hot after operating the machine. Start the work once the temperature is sufficiently
low.
The control valve has complicated connections and seals through the internal passages, which means that
there could be enclosed pressure, resulting in an oil jet after disassembly. Wear safety goggles during
disassembly work.
6-4-6
2) Necessary tools and others
Before disassembling the control valve, prepare the following tools.

The tools below are used to disassmble the control valve only. Tools for disassembling the ports fittings are
not included.
Name Quantity Application

Hexagonal wrench Each 1 4mm - 6mm - 8mm
Spanner Each 1 13mm - 19mm - 22mm
Socket wrench Each 1 13mm - 19mm - 22mm
Torque wrench 1 1.96N.m ~ 19.6N.m (0.2kgf.m ~ 2.0kgf.m)
Magnets 1
Pliers 1
Screwdriver for cross 1
Tweezers 1
Prepare clean wash, hydraulic fluid, grease, tag paper, oil marker pen, and others before work.
6-4-7
3) Spool draw-out
Procedure
Manual operation type:
Taking the Travel spool as an example, the extraction
procedures are as follows:
1) Remove 2 Hex. socket head cap screws (12) by using

4mm hexagonal wrench.
2) Remove the spring cover (11).
3) Since the spring part of the travel spool is exposed, pull out
the spool ass'y gently and horizontally (parallel to the spool
holes) by holding the spring. At this time, be careful that
carrying out the extraction carelessly could cause spool seals
(backup ring(2c), O-ring(2b)) to move to the edge, resulting in SpoolAss'y
their damage.
Replace O-ring with new one; do not reuse the removed
O-ring.
If reuse of the O-ring is unavoidable, check it for flaw,
deformation, or the adhesion of foreign matter sufficiently.
4) The other manual operation type spools can also be pulled

out in the same way.
Hydraulic pilot type:

Taking the Swing spool as an example, the draw-out
1) Remove 2 Hex. socket bolts with wa shers (5) by using 4-

mm hexagonal wrench.
2) Remove the pilot cover (4). At this time, check whether the
O-ring (3) falls off from the bottom of body side flange.
3) With a spring in Swing spool exposed, pull out Spool Ass'y

from the contral valve slowly and horizontally (parallel to the
spool hole) by holding the spring.
4) The other hydraulic pilot type spools can also be pulled out
in the same way.
6-4-8
4) Check valve (load check valve) disassembly procedure

Procedure
Using Swing Comp. as an example, the disassembly

1) Loosen and remove the plug-check valve (10) by using
6-mm hexagonal wrench.
2) Pull out check valve spring-check Valve (8) and check valve
(7) from the body (1 ).
3) The other comp. can also be pulled out in the same way,
even though reference numbers are different.
Note :
There is no check valve in for the Travel Comp.
6-4-9
5) Accessory valve removal procedures

Procedure
Relief valve (RV) and Overlaod relief valve (ORV):
Loosen and remove RV and ORV by using 22mm spanner
or socket wrench.
- Put spanner (socket wrench) to 22mm hexagonal part of

pressure regulating body.
- If there is no 22mm spanner (socket wrench), it is also

possible to loosen and remove by putting 19mm spanner to
the hexagonal part as shown in the figure.
CAUTION :
Removing ORV causes the seat to be exposed.
Flaws on the seat causes internal leakage, which
makes the holding capacity of actuator worse.
When storing it, be careful not to damage the seat.
When using 19mm spanner to remove, never put it
to the Iock nut part.
If not, only Iock nut is loosened to change the
settings of RV and ORV, which could result in the
degradation in performance or damage.
Anticavitation valve :
As for the ORV, loosen and remove anticavitation valve by
using 22mm spanner or socket wrench.
CAUTION :
Removing anticavitation valve causes the seat to be
exposed. Flaws on the seat causes internal leakage,
which makes the holding capacity of actuator worse.
When storing it, be careful not to damage the seat.
6-4-10
Procedure
Relief plug
Loosen and remove relief plug by using 8mm hexagonal
wrench.
6-4-11
6) Plug and screw removal procedures

Procedure
Plug (PF3/8, PF1/4) of Inlet Comp.:
Loosen the plug (2) by using 6mm hexagonal wrench to
remove it from the inlet body (1).
Remove the plug (4) in P1 side Inlet Comp. by using 8mm
hexagonal wrench.
Plug (PF3/8) of Blade Comp.:

Remove the plug (14) from the body (1) by using 8mm
hexagonal wrench.
Link installation part (Travel, Blade, PTO, Boom Swing

Comp.):
1. Loosen and remove 2 M5 cross recessed head screws (6)
by using screwdriver for cross.
2. Remove the seal plate (5) and then remove the back-up
ring (4) and the O-ring (3) from the body (1) with caution to
not damage them.
Pilot cover (Swing, Arm, Bucket, Boom Comp.):

1. Loosen and remove 2 hexagonal socket bolts with washers
(5) by using 4mm hexagonal wrench.
2. Remove the pilot cover (6).

Chek whether the O-ring (3) falls off from the bottom of the
body side flange.
6-4-12
7) Comp. Body disassembly procedure

Procedure
1) Loosen and remove the 3 M8 nuts from both end faces of

the control valve, which are for assembling Comp. Body, by
using 13mm spanner or socket wrench.
2) When pulling out the 3 M8 tie bolts from the side faces,
each Comp. Body can be in individual condition.
Be careful not to drop or lose O-rings mounted on mating
surfaces of each Comp. Body.
Comp. Body Name ID

Swing VA
Arm UA
Travel ZA
Blade WG
PTO WF
Travel ZA
B-Swing XA
Bucket NK
Boom SA
6-4-13
8) Accessory valves disassembly procedures
Accessory valves are the most important parts for performance and safety, in particular, the
relief valve is very difficult to readjust the setting so that Assy's replacement is recommended if
any malfuntion occurs.
Procedure
Relief valve (RV) (for P1 and P2):
1. Lightly hold any two surfaces of hexagonal body-inlet (5) in
a vise bench, whose intervals are 22 mm.
2. Loosen and remove the nut M14 (8) by using 19mm

spanner.
3. Loosen and remove the adjustable screw (7) by using 4mm

hexagonal wrench.
4. Take out the spring (9) by using tweezers or the like.
5. Loosen and remove the body ( 4) by using 19mm spanner.
6. The other parts can also be removed in the following order:

Socket (1) - Piston (3) - Spring (10) - Valve (2)
No. Description
1 SOCKET
2 VALVE
3 PISTON
4 BODY
5 BODY-INLET
6 POPPET
7 ADJUSTABLE SCREW
8 NUT M14
9 SPRING
10 SPRING
11 O-RING 1B P15
12 O-RING 1B S10
13 O-RING 1A P7
14 BACK-UP RING
15 O-RING 1B P14
16 O-RING 1B P10
17 SPRING GUIDE
6-4-14
Procedure
Overload relief valve (ORV) (for B2, A4, A5, B5, B8, A9,
B9):
1. Lightly hold any two surfaces of hexagonal body (5) in a

vise bench, whose intervals are 22 mm.
2. Loosen and remove the nut M14 (8) by using 19mm

spanner.
3. Loosen and remove the adjustable screw (7) by using 4mm

hexagonal wrench.
5. Loosen and remove the body ( 4) by using 19mm spanner.
6. The other parts can also be removed in the following order:

Socket (1) - Piston (3) - Spring (10) - Valve (2)
No. Description
1 SOCKET
2 VALVE
3 PISTON
4 BODY
5 BODY
6 POPPET
7 ADJUSTABLE SCREW
8 NUT M14
9 SPRING
10 SPRING
11 O-RING 1B P15
12 O-RING 1B S10
13 O-RING 1A P7
14 BACK-UP RING
15 O-RING 1B P14
16 SPRING GUIDE
6-4-15
Procedure
Anticavitation valve:
1. Lightly hold any two surfaces of hexagonal body (2) in a

vise bench, whose intervals are 22 mm.
2. Loosen and remove the plug (3) by using 8mm hexagonal

wrench.
4. Remove the valve (1) from body (2).
No. Description
1 VALVE
2 BODY
3 PLUG
4 SPRING
5 BACK-UP RING
6 O-RING 1A P10A
7 O-RING 1B P14
8 O-RING 1B P15
Relief plug:
1. Remove the plug (1) by air-pressuring it into hole part.
2. After removing the plug (1), the inner plain washer (4) and
the spring washer (3) can be taken out.
No. Description
1 PLUG
2 BODY
3 SPRING LOCK WASHER
4 PLAIN WASHER
5 BACK-UP RING
6 O-RING 1B P7
7 O-RING 1B P14
6-4-16
9) Precautions after disassembly
CAUTION :
For the parts already removed in the work, store and/or transport them with attention on flaws and dirt.
When carrying out another work, storage, or transportation with the parts removed, apply caps or plastic tape to
the holes from which the parts have been taken out, protecting the holes from being entered with dust or the like.
6-4-17
6-4-7 Assembly
1) Precautions for assembly
Observe the following precautions and carry out the work at a factory where there are engineers with sufficient
technique for hydraulic devices.
1. Be careful that the unevenness of tightening torque and the contamination of dust during assembly work could
result in malfunction.
ln addition, observe tightening torque values specified in the delivery specifications.
2. During assembly work, compare valves with valve structural drawing and check the number of parts to check
whether there is any improper assembly and/or the omission of parts.
3. For the parts to be used in assembly, dip in fluid oil as the need arises to reassemble after washing well in
washing oil and being dried.
4. After cleaning and degreasing the surface sufficiently, apply Locktite to 2 threads of the screw from the tip.(Too
much Locktite could result in malfunction after squeezing out.)
5. For the part to be attached or assembled with two or more bolts and nuts, tighten them evenly and alternately
for several times, not once with the specified torque.
If not, the unevenness of tightening torque could result in the leakage of hydraulic fluid to the outside and/or
malfunctions.
2) Precautions for assembling seal parts
1. All seals are to be renewed at assembly.

2. Check seals for defects in molding and flaws in handling.
Do not use seals with defect and/or flaw.
3. The seals used on sliding surfaces and the places to be installed with seals are to be applied with grease or
hydraulic fluid for sufficient lubrication where not specially noted.
4. Never make seals longer up to permanent deformation.
5. O-rings are not to be twisted during assembly.
Kinked O-rings could cause oil leakage after installation because kinks are hard to restore.
6-4-18
3) Necessary tools and others
Before assembling the control valve, prepare the following tools.

The tools below are used to assemble the control valve only. Tools for assembling the ports fittings are not
included.
Name Quantity Application

Hexagonal wrench Each 1 4mm - 6mm - 8mm
Spanner Each 1 13mm - 19mm - 22mm
Socket wrench Each 1 13mm - 19mm - 22mm
Magnets 1
Pliers 1
Screwdriver for cross 1
Tweezers 1
Prepare clean wash, hydraulic fluid, grease, tag paper, oil marker pen, and others before work.
6-4-19
3) Comp. Body assembly

Procedure
1) Place Comp· Bodies with each mating surface facing up in

the order of assembling.
Then, mount O-rings on mating surfaces of each Comp. Body.
However, do not apply hydraulic oil or grease to these O-
rings. (There is a possibility of mistaking them for oil leakage
when oozing out from mating surfaces.)
2) On a surface plate or the like with flatness prepared, place

each Comp. Body with actuator port surface facing down in
the same order with the above.
CAUTION :
Then, check the mating surfaces in each Comp. Body for
dust or the like and check whether O-rings shown in the
delivery specifications are surely put in each groove for O-
ring.
Kinked O-rings could cause the leakage of hydraulic fluid to
the outside due to the malfunction of sealing performance.
If O-rings are not installed surely in O-ring grooves, there
would be the nip of 0-ring, resulting in the leakage of
hydraulic fluid to the outside when assembling the Bodies.
3) Put 3 M8 tie bolts through each Comp. Body from the side,
and screw M8 nuts on both ends lightly. At this time, pat the
bodies with plastic hammer or the like to align the port
surface of each Comp. Body. Then, tighten one-side nuts
with the opposite side nuts fixed by 13mm spanner.
Tlghten 3 nuts equally and mutually, not all at once with
specified torque.
Be careful that applying not specified torque causes the
deformation of body or oil leakage.
Note :
M8 nut fastening torque: 13.7~14.7N·m {1.4~1.5kgf·m}
6-4-20
4) Accessory valves fitting procedures

Procedure
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If using a 19mm spanner to fit, never put it

to the Iock nut part.
If not, tightening the Iock nut part causes
the settings of RV and ORV to change,
which could result in the degradation in
performance or damage.
CAUTION :
Before installing accessory valves (RV, ORV, Anticavitation
Valve, Relief Plug), check that there is no flaw or dust on the
seat.
The presence of flaw or dust on the seat can cause internal
leakage, resulting in the holding failure of actuator.
Anticavitation valve:
1. As well as ORV, fit anticavitation valve by using a 22mm

spanner or socket wrench.
CAUTION :
Before installing accessory valves (RV, ORV, Anticavitation
Valve, Relief Plug), check that there is no flaw or dust on
the seat.
The presence of flaw or dust on the seat can cause internal
leakage, resulting in the holding failure of actuator.
6-4-21
Procedure
Relief plug:
1. Tighten relief plug (14) by using a 8mm hexagonal wrench.
CAUTION :
When installing a relief plug to the body, be careful not to
damage the seat of socket that projects out above the tip. If
the seat is damaged, there will be internal leakage, resulting
in the malfunction of holding attachment.
6-4-22
5) Check valves (load check valve) assembly procedure

Procedure
Using the blade comp. as an exemple, the assembly
procedure is as follows:
1) Fix the control valve body on a working bench or hold it by

two or more persons.
2) lnsert the check valve (7) with its bevel facing down
vertically into the upper center of the control valve's body(1).
Then, insert the spring-check valve (8) into the body of the
check valve (7).
Be careful that inclined check valve (7) cannot be inserted into
the hole of the plug-check valve (10).
(lt is necessary to check that the check valve is almost at the
center.)
3) After checking that the plug-check valve (10) is surely

mounted with the O-ring (9), screw it in and tighten with
specified torque by using a 6mm hexagonal wrench.
Meanwhile, since travel comp. does not have a check valve (7)
nor check valve spring-check valve(8), the step in 2) can be
omitted and check valve retainer (10) is to be tightened as well.
6-4-23
6) Spool assembly procedures

Procedure
Manual operation type:
Taking the travel spool as an example, the assembly
1) After checking that there is no adhesion of dust on each

spool ass'y or each comp. body's spool hole, insert each
spool ass'y into the spool hole of comp. body.
At this time, use caution not to mistake the insertion position
and direction.
Before insertion, apply little hydraulic oil to spools.
When there is no feeling of wrongness, check for any heavy
movement or a feeling of catches.
Carefully insert it into the spool hole

horizontally.
If it is hard to insert, forcible insertion could
cause impressions on spool holes and/or
spools, resulting in malfunction.
If you feel a feeling of wrongness such as
catches or strong resistance, pull it out
once to check whether there is the adhesion
of dust or the development of flaw or burr.
If there are flaws or burrs, there could be
malfunction so that it is recommended to
replace it together with the body in a set.
2) Put the spring cover (11) over the spring of spool ass'y,
and tighten 2 hexagonal socket head cap screws (12) with
specified torque by using a 4mm hexagonal wrench.
At this time, tighten the 2 hexagonal socket head cap screws
little by little and altemately to push the spring cover (11)
forward evenly, not all at once with specified torque.
3) Then, put the O-ring (3), backup ring (4), and seal plate (5)
over the spool projected from the opposite side of comp.
body in order, and then tighten them with the cross recessed
head screw (6) by using a screwdriver for cross with
specitied torque.
Tighten the two screws little by little and altemately to push
the seal plate (5) forward evenly, not all at once with
specitied torque.
4)The other manual operation type spools can be assembled

in the same way.
6-4-24
Procedure
Hydraulic pilot type:
Taking the swing spool as an example, the assembly
1) After checking whether there is dust or the like in the

spool holes of spool ass'y and/or body and that the flange
bottom of the body is securely installed with O-ring (3),
insert each spool ass'y into spool holes of the body with
attention on the position and direction.
At this time, use caution not to mistake the insertion position
and direction.
Apply little hydraulic fluid to the spools before the insertion.
When there is no feeling of wrongness, check for any heavy
movement or a feeling of catches.
Carefully insert it into the spool hole

horizontally.
If it is hard to insert, forcible insertion could
cause impressions on spool holes and/or
spools, resulting in malfunction.
If you feel a feeling of wrongness such as
catches or strong resistance, pull it out
once to check whether there is the adhesion
of dust or the development of flaw or burr.
If there are flaws or burrs, there could be
malfunction so that it is recommended to
replace it together with the body in a set.
2) With the pilot cover (4) being pressed in a direction from

the spring side of the spool ass'y to the flange of the body,
tighten the bolt with washers (5) with specified torque by
using a 4mm hexagonal wrench.
3) With the pilot cover (6) into the opposite flange of the
body , tighten the bolt with washers (5) with specified torque
by using a 4mm hexagonal wrench.
4) The other spools can be assembled in the same way.
6-4-25
6) Fitting plug procedures

Procedure
Plug (PF3/8, PF1/4) of Inlet Comp.:
After checking that the plug (2) is mounted with O-ring (3),
screw the plug into the inlet body (1) loosely and then tighten
it with specified torque by using a 6mm hexagonal wrench.
Use the same method for the plug (4) of P1 side inlet comp.
Plug (PF3/8) of body work comp.:

After checking that the plug (14) is mounted with O-ring (13),
screw the plug into the comp. body (1) loosely and then
tighten it with specified torque by using a 8mm hexagonal
wrench.
6-4-26
6-4-8 Maintenance standards
- Spool seals (O-ring, backup ring)

ln principle, it is recommended to replace them with new ones once a year; however, it can be longer
according to use environment (such as deposit of dust on spool) or the frequency of use.
Since the storage of a valve for a long time (such as more than six months) before being installed in a
machine can cause spool seals to be deformed or to adhere to the spool, it is recommend to replace spool
seals with new ones before use.
- Spool
As long as its sliding part has not been damaged due to foreign matter in hydraulic oil or its link fitting has not
bent or broken due to unexpected extemal force, it is not necessary to replace the spool.
- Check valve (load check valve)

If its seat is damaged or defective due to foreign matter in hydraulic oil, the cast body is necessary to be
replaced.
The check valve is also necessary to be replaced when it has a flaw.
When a plug has been overhauled even once, its O-rings are recommendable to be replaced with new ones.
- Relief valve
If the set value decreases or becomes abnormal, carry out readjustrnents.
If the condition cannot be restored, replace it by cartridge.
- Overload relief vavle

replaced.
When its seat has a flaw, the overload relief valve is necessary to be replaced in cartridge.
- Anticavitation valve
replaced.
When its seat has a flaw, the anticavitation valve is necessary to be replaced in cartridge.
- Relief plug
replaced.
When its seat has a flaw, the relief plug is necessary to be replaced in cartridge. ^
- O-ring replacement
When the parts (relief valve, overload reliefvalve, anticavitation valve, and various plugs) removed from the
body are reassembled, their O-rings and the like are recommendable to be replaced with new ones.
When a body is disassembled individually, replace O-rings on mating surfaces with new ones.
6-4-27
6-4-9 Storage
To protect control valve from deteriorating, do not store them in the following places:
- A place with high temperature, high humidity.
- A place subject to direct weather.
- A place near medicines such as organic solvent, acis, and alkali, or affected by vaporized gas.
- A place with great temperature difference and in danger of condensation.
6-4-10 Disposal
When disposing of the control valve, first drain the hydraulic fluid completely and dispose of it as industrial
waste.
6-4-28
6-5 Pilot Valve
6-5-1 Remote Control Valve

Pilot valve unit for arm rest installation
Type 4TH5
Maintenance Instructions
1) Foreword
This manual deals with the instructions relative to servicing and maintenance operations for the hydraulic pilot con-
trol unit 4TH5 for the inspections and servicing operations associated with the hydraulic system of the machine to
which they are connected. Please consult the maintenance manual supplied by the equipment manufacture.
It is recommended that only qualified personnel perform the installation, connection and maintenance of this
device, and that all operations shall be carried out in compliance with the technical standards in force and the
cleanliness regulations specific to this type of installation.
To ensure maximum performance and safety during maintenance operations we advise you
to Read this manual thoroughly
All information, illustrations, instructions and characteristics contained in this document are based on the latest
product information available at the time of publication. In its attempts to maintain a high-quality product,
MANNESMANN REXROTH reserves the right to make design or technical modifications at any time and without
prior notification.
2) Safety Instructions
Please pay a special attention to the signals of safety alerts and special instructions in this manual. They
are indi-cated in the following manner:
Indicates information or instructions which must be followed to guarantee your safety during
opera-tions.
CAUTION :
Warning against possible equipment damage.
Note :
Useful information.
6-5-1
6-5-2 Troubleshooting
CAUTION :
Before starting any procedures of troubleshooting or removing the hydraulic pilot control unit, inspect the global
machine's hydraulic system to eliminate all possible malfunctions not related to the pilot control unit.
Abnormal operation of equipment connected to the hydraulic pilot unit

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

Handle does not automati-
cally return to neutral posi-
tion:
(1) Manual return with fric- (1) Faulty cardan Replace cardan
tion
Handle does not automati-
cally return to neutral posi-
tion:
(2) Manual return without (1) Lip seal too hard inside Replace guides + plungers
friction guide
(2) Regulation unit setting Remove the regulation Replace pilot control unit
spring broken unit for visual inspection
(3) Regulation unit plater
broken
Handle turns (1) Handle parts loose Tighten all handle parts
Visual Defects
Rubber boot damaged Replace boot
Leak on arm rest originating Leak between guide Lift the boot to perform Replace guides + plungers
from under the boot and push buttons a visual inspection
Seepage on body Porous body Replace the pilot unit
6-5-2
6-5-3 Fundamental Rules

1) General Information Concerning Pilot Control Unit Connection
When removing the pilot control unit, all openings must be plugged immediately to prevent any contamination of
the hydraulic system.
When replacing the pilot control unit, remove the plastic plugs from the openings and lines just before making the
connections.
Do not tighten connectors to a torque greater than that specified in the assembly instructions.
Check the hydraulic installation's oil quality and filtration capacity during all servicing/maintenance operations.
The use of teflon tape, hemp and joint filler is prohibited.
Hydraulic lines and connections must not be under any strain whatsoever.
6-5-4 Removal / Installation of the Pilot Control Unit Connection

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

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

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

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

clamp. Fold down the boot.
6-5-5
2) Cardan Replacement
Procedure
Remove the pilot control unit from the machine's arm rest.
Secure the pilot control unit in a vice (clamp onto the
body). Remove the handle.
Note :
It is recommended to remove the pilot control unit from the
machine. Nevertheless, the servicing on machine is possible
by securing the unit into a vice-grip wrench (65 opening). This
is performed by extracting the body from the arm rest so as to
clamp the vice-grip wrench onto the body in order to hold it
above the arm rest.
Removal of the cardan

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

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

selecting the shims necessary to obtain play-free contact
between the switch-plate and the plungers. In neutral position,
the depression of the plungers must not exceed 0.2 mm. In
order to check this value, observe the displacement of the
plunger located opposite to the one being pressed.
Note :
The pre-depression may be difficult to achieve on site. Could
be necessary to readjust it after reassembly and system
work-ing control.
6-5-6
3) Guide / Plunger and Regulation Unit Replacement
Procedure
Remove the pilot control unit from the machine's arm
rest. Remove the handle.
Remove the cardan.
Note :
It is recommended to remove the pilot control unit from the
machine. Nevertheless, the servicing on machine is possible
by securing the unit into a vice-grip wrench (65 opening). This
is performed by extracting the body from the arm rest so as to
clamp the vice-grip wrench onto the body in order to hold it
above the arm rest.
Removal
Secure the pilot control unit to a vice.
Remove the retaining plate.
Reassembly : Line up the notches for the grommet in both
the plate and the body.
Insert the end of a thin screwdriver between the guide and

the body, carefully lift the guide to remove it from the body.
Note :
Hold the guide with the other hand during the extraction
oper-ation to limit the effect of the return spring.
Remove the guide / plunger assembly.

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

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

tion. If defects are present, replace the 4 sub-assemblies.
Inspect the regulation units and particularly their spring. If
defects are detected, replace the 4 units.
6-5-7
3
Loctite 262
MA =30Nm
MA =45Nm
8
10
12 b
10
15
6-5-8
Item Description
1 Handle TT
3 Lever kit
4 Rubber boot
7 Retaining plate
8 Cardan kit composed of : 1 cardan + shims
10 Plunger kit composed of :
a. 4 plunger guides
b. 4 plain plungers
c. 4 spring rings
12 Regulating kit
15 Set of 4 return springs
Item Description
1 Handle SH1 PRAH + Deutsch connectors 2 & 6 pins
3 Lever kit
4 Rubber boot
7 Retaining plate
8 Cardan kit composed of : 1 cardan + shims
10 Plunger kit composed of :
a. 4 plunger guides
b. 4 plain plungers
c. 4 spring rings
6-5-9
6-6 Swing Motor

6-6-1 Structure and Functions
11 1 14 2 20 22 41 24
Mechanical brake mechanism 21 23 026948-00E
This hydraulic swing motor consists of an orbit motor and a pinion gear assembly.
The swing motor with a mechanical brake has friction plates splined to the pinion gear 3 and steel plates splined to
the bearing housing 1. In this structure, the brake is operated under the brake torque which is produced by frictional
force generated by the piston ring and the coil springs.
The hydraulic motor has six holes in the valve 24 and seven holes in the valve plate 22, and the displacement per
revolution is 14.9 cu. in. (244 cu. cm).
The pinion gear assembly consists of the pinion gear 3 and the two bearings 11 and 14 supporting the pinion gear.
The hydraulic oil which flows in through the brake valve is fed to the valve housing 41.
No. Part
1 Bearing housing
2 Flange mounting
3 Pinion gear
11 Front bearing
14 Rear bearing
20 Roller
21 Drive
22 Valve plate
23 Valve drive
24 Valve
41 Valve housing
6-6-1
High pressure
1 2
21 Front : Port A Back : Port B
Low pressure (High pressure) (Low pressure)
Drain 20 22 41
23 24
Drain line 026949-00E
When hydraulic oil is fed to the port A, the oil flows into the oil hole in the valve 24 corresponding to the port A and
runs through the oil hole in the valve plate 22 to rotate the roller 20. When the valve 24 is rotated via the valve drive
23, the positional relation between the six holes in the valve 24 and the seven holes in the valve plate 22 is changed
and, in turn, the relative position of the hydraulic oil which flows into the roller 20 is shifted successively. The oil flow
is converted into rotational force and outputted to the drive 21 splined to the roller 20. Then, the rotational force is
transmitted to the pinion gear 3.
The oil which has leaked in the motor lubricates the parts, and then, is drained from the drain port.
6-6-2
6-6-2 Mechanical Brake
The friction plates are splined to the pinion gear and the steel plates are splined to the bearing housing. When no
hydraulic oil flows into the brake release port, the springs press the piston against the end face of the bearing hous-
ing through the steel plates and the friction plates which causes the pinion gear (output shaft) to be locked.
When hydraulic oil flows into the piston chamber through the brake release port, the piston is moved up against the
springs to the bottom of the flange mounting and the friction plates and the steel plates are disengaged, which
causes the mechanical brake to be released.
Flange mounting Coil spring
Piston
Piston chamber
Blake release
port
Friction plate
Steel plate
Ring
Bearing housing
Pinion gear
6-6-3
6-6-3 Theory of Operation for Brake Valve
Normally, the needle valve 45 is seated on the seat portion of the cartridge 42 and both the high pressure (port A)
and the low pressure (port B) are shutoff.
At starting or stopping, high pressure oil flows through the orifice of the orifice plug 48 into the damper chamber and
when the pressure is greater than the set pressure of the spring 49, the needle valve 45 opens and high pressure oil
flows to the low pressure side.
When the passage opens and the pressure decreases, the needle valve 45 is pushed back by the spring 49 and
seated again to shutoff the high pressure and low pressure..
42
48 45 49
Damper chamber
026950-00E
No. Part
42 Cartridge
45 Needle valve
48 Orifice plug
49 Spring
6-6-4
6-6-4 Disassembly and Reassembly

1) Precautions for Disassembly and Reassembly
(1) Since the parts of the hydraulic equipment are precision-made for tight clearances, be sure to perform disassem-
bly and reassembly in a clean area that is free from dust.
(2) Prepare clean tools and treated oil and handle the parts carefully.
(3) First clean the external surface of the removed assemblies.
(4) Before beginning disassembly, review the drawings of the internal construction and prepare the required parts
according to the purpose and extent of the disassembly.
(5) After disassembly, replace the removed seals and O-rings with new ones in principle. As some replacement
parts are available only as subassemblies, see the parts catalogue to prepare the necessary subassemblies in
advance.
(6) Handling of O-rings
[1] Lubricate the O-rings and the O-ring fitting seats with clean grease or hydraulic oil.
[2] The O-rings may not be damaged in handling or distorted by heat.
[3] Do not extend any O-rings with such great force as to permanently deform them.
[4] Avoid rolling the O-rings when fitting them.
A distorted O-ring may not return to its original shape, and therefore, may cause oil leak.
2) Tools for Disassembly

Tool Remarks
Torque wrench Capacity : 7.2 to 72.3 ft•lbf (9.8 to 98.0 N•m)
Socket Width across flats : 0.55 in. (14 mm)
Hexagon sockets Width across flats : 0.20 in. (5 mm)
Width across flats : 0.31 in. (8 mm)
Retaining pliers Internal snap ring : Ø1.85 in. (47 mm), Ø4.72 in. (120 mm)
External snap ring : Ø1.77 in. (45 mm)
Screw driver
Plastic hammer
Press ~3 ton
Vice
6-6-5
18
2
10
19
16
14
30
16
3) Exploded View and Parts Names
5
16
6
17
34 43
26 47
8 9
6-6-6
4 28
55
1 57 52
15 59 56 44 53
13 58
7 41 49 46 50
11 33 45
12 55
29 42
27
25 51
3 24 54 48
4
32
22
33
23
31
20
33
21
31
No. Parts Q’ty No. Parts Q’ty

1 Bearing housing 1 31 O-ring 2
2 Flange mounting 1 32 O-ring 1
3 Pinion gear 1 33 O-ring 3
4 Plug 2 34 Hexagon head bolt 4
5 Piston 1 40 Valve housing assembly 1
6 Ring 1 41 Valve housing (1)
7 Collar 1 42 Cartridge (2)
8 Friction plate 6 43 Thread guide (2)
9 Opposite plate 7 44 O-ring (2)
10 Spring 8 45 Needle valve (2)
11 Front bearing 1 46 Spring seat (2)
12 C-shaped snap ring for hole 1 47 Spring press (2)
13 C-shaped snap ring for shaft 1 48 Orifice plug (2)
14 Rear bearing 1 49 Spring (2)
15 X-ring 1 50 O-ring (2)
16 O-ring 3 51 O-ring (2)
17 O-ring 1 52 Hexagon socket set screw (2)
18 Hexagon socket head bolt (M8 x 20) 8 53 Hexagon nut (2)
19 Shaft face seal 1 54 O-ring (2)
20 Roller 1 55 Plug (2)
21 Drive 1 56 Plug (2)
22 Valve plate 1 57 O-ring (2)
23 Valve drive 1 58 Spring (2)
24 Valve 1 59 Steel ball (2)
25 Balancing ring 1
26 Spring 2
27 Inner face seal 1
28 Pin 2
29 Outer face seal 1
30 Snap ring 1
[Note]
The valve housing assembly 40 include No.41-59.
6-6-7
4) Disassembly
Procedure
(1) Hold the flange part in a vice with the pinion gear 3 side
down.
Remove the hexagon head bolts 34.
34
41
(2) Remove the valve housing 41. When removing it, take
care not to lose pins 28 and springs 26. 26
Note :
Do not disassemble the valve housing 41 if not required. 28
(3) Remove the balancing ring 25, the valve 24, the valve
plate 22 and the valve drive 23.
22
20
23
(4) Remove the roller 20 and the drive 21.

20
21
6-6-8
Procedure
(5) Remove the hexagon socket head bolts 18.
18
(6) Remove the flange mounting 2, and then remove the

springs 10. 2
Note :
Do not remove the shaft face seal 19, the rear bearing 14 and 10
the internal snap ring 30, if not required.
(7) Remove the piston 5.
(8) Remove the ring 6.
6-6-9
Procedure
(9) Remove one of the steel plates 9.
(10) Remove one of the friction plates 8. Alternately remove

the rest of the steel plates 9 and the friction plates 8.
8
(11) Remove the internal snap ring 12 to remove the pinion

gear assembly such as the bearing from the bearing Pinion gear assembly 15 1
housing 1.
Remove the blind plug 4 and the X-ring 15 from the bear- 3
ing housing 1. 11
11
(12) Remove the external snap ring 13 from the pinion gear 3
to remove the collar 7 and the front bearing 11.
3
Note :
Do not remove them, if not required.
11
41
12 13
6-6-10
5) Reassembly
Procedure
(1) Press-fit the front bearing 11 and the collar 41 into the pin-
ion gear 3.
At this time, pay attention to the direction of press-fitting.
(2) Install the external snap ring 13. 3
13 11
41
Collar Chamfered
No shield
Front
bearing
Shield
(3) Install the X-ring 15 into the bearing housing 1.
15
(4) Install the pinion gear assembly into the bearing housing
1.
After installation, install the internal snap ring 12, and then
tighten the blind plug 4 into the bleeder.
Tightening torque : 7.2 ft lbf (9.8 N m)
Pinion gear assembly
6-6-11
Procedure
(5) Insert one of the seven steel plates 9 into the bearing
housing 1. 1
9
(6) Insert one of the six friction plates 8 into the bearing hous-
ing 1.
8
Note :
Alternately install the steel plates and the friction plates.
Finally, the steel plate should be seen on the top.
(7) Install the O-rings (for inner and outer faces) 17 and 16
onto the ring 6.
17
6
(8) Insert the ring 6 with O-rings into the bearing housing 1.
1
(9) Install the O-ring (for outer face) 16 onto the piston 5.
(10) Insert the piston 5 into the bearing housing 1. 5
6-6-12
Procedure
(11) Install the shaft face seal 19 into the flange mounting 2.
10
2
(12) Insert the rear bearing 14 and fasten it with the internal 14
snap ring 30. 19
(13) Apply grease to the springs 10, and install them into the
flange mounting 2. 30
(14) Install the O-ring 16 into the flange mounting 2.
16
(15) Install the flange mounting 2

on the bearing housing 1.
Pilot port 2
Notes :
• Take care not to drop the
springs 10.
• The drain hole should be posi-
tioned as shown in the figure at 1
the right.
Position of drain hole
(16) Tighten the hexagon socket head bolts 18.
Note :
Apply Loctite #242 or its equivalent to the hexagon socket
head bolts 18.
18
(17) Install the two types of O-rings 31 and 32 into the O-ring
grooves in the flange mounting 2.
21
(18) Insert the drive 21.
33
31
6-6-13
Procedure
(19) Install the roller 20.
Note :
20
The drain hole in the roller 20 must be aligned with the drain
hole in the flange mounting 2.
(20) Insert the valve drive 23 into the roller.
23
grooves in the valve plate 22.
(22) Install the valve plate 22 on the roller 20. 22
Note :
The drain hole in the valve plate 22 must be aligned with the
drain hole in the roller 20. 20
(23) Install the valve 24.
24
6-6-14
Procedure
Note : Valve
The installation of the valve is important because the position
of the valve determines the revolving direction of the motor.
Refer to the right figure for the installation of the valve.
Valve drive 15
Horizontal hole
15
Roller star External gear tooth 050285-00EN00
(24) Install the steel balls 59, the springs 58 and the plugs 56
into the valve housing 41.
58
41
56
59
(25) Install the springs 26 and the pins 28 into the valve hous-
ing 41. Outer face seal 29
Valve housing 41
(26) Install the outer face seal 29 and the inner face seal 27
Inner face seal 27
into the balancing ring 25.
Note :
When installing the balancing ring 25 into the valve housing
41, the notches in the balancing ring 25 must be aligned with
the pins 28. Spring 26
Balancing Pin 28
ring 25
026952-00E
grooves in the valve housing 41.
(28) Insert a slender bar such as a driver into the port B side
of the valve housing 41, and install the valve housing 41
on the valve 24 while holding the balancing ring 25 to
prevent it from coming off.
33
Note :
The drain hole in the valve housing 41 must be aligned with
the drain hole in valve 24. 24
6-6-15
Procedure
(29) Tighten the hexagon head bolts 34.
Note : 34
Apply Loctite #242 or its equivalent to the bolts 34.
Tightening torque : 39.1 ft lbf (53 N m)
(30) The procedure for reassembling the swing motor is com-

pleted.
Make sure that the swing motor rotates in the correct
direction before being installed to the actual device.
Rotation direction viewed from the pinion shaft side :
When pressure is applied to the port A : Clockwise
When pressure is applied to the port B : Counterclock-
wise
6-6-16
5. Troubleshooting
Trouble Cause Measure
1. Motor does not rotate (1) Insufficient hydraulic oil volume in Supply hydraulic oil to the specified level.
hydraulic oil tank.
(2) Breakage of pump. Replace the pump.
(3) Malfunction of relief valve or low set Disassemble and clean the relief valve and set the
pressure of it. pressure to the specified value.
(4) Excessive wear or scuffing of motor. Disassemble the motor to check the parts. Replace
any damaged parts.
(5) Short-circuit inside motor. The face seals or other parts may be damaged.
Disassemble the motor to check the parts. Replace
any damaged parts.
(6) Insufficient brake release pressure. Apply a pilot pressure of 145 PSI (1.0 MPa) to the
brake release port.
2. Unstable rotation (1) Low relief set pressure. Check whether the specified volume of hydraulic oil
is fed to the motor suction side. Then, check and
repair each part.
(2) Air in pump on the suction side. Check the piping of the suction side. Tighten the
piping if necessary.
3. Reverse rotation (1) Reversed piping. Correct the piping.
(2) Reversed valve timing of motor. Correct the valve timing.
4. Oil leak from joint (1) Loosened bolt. Tighten the bolt at the specified tightening torque.
(2) Caught or damaged O-ring. Replace the O-ring.
5. Low brake torque (1) Worn friction plates. Replace the friction plates.
(2) Pressure remaining in pilot line. Check the piping of the pilot line.
6-6-17
6-7 Travel Motor
6-7-1 Outline
The travel motor on this machine is a kind of orbit motor, and consists of the followings units.
(1) HYDRAULIC MOTOR unit with OUTPUT WHEEL (10).
The motor units includes VALVE(19) which has 12 holes of oil flow paths and VALVE PLATE (17) which has 7
holes of oil flow paths.
DRIVE SHAFT (20) moves precessional rotation, but not rotate itself. The rotation of the DRIVE SHAFT(20) is
fixed with END COVER(27) on the track frame. The OUTPUT WHEEL(10) is rotated by hydraulic power.
(2) END COVER UNIT (27) with counter balance valve.
End cover units includes low-high speed switching units and counter balance valve.
A
27
10
D B
C
Counter balance valve
20
C 19
Low-high speed
17 switching unit
A-A
D END COVER(27)
B-B
D-D C-C VALAVE, which has 12pcs. of
Pressurized hyd. oil come into VALVE PLATE, which has 7pcs. flow path, does not rotate.
chamber from VALVE PLATE, of flow path, rotates with
and rotates the outer housing OUTPUT WHEEL(10).
with OUTPUT WHEEL(10)
6-7-1
6-7-2 Theory of Operation

1) Motor (Low speed)
High pressurized hydraulic oil comes in Port A or B and the low pressure hydraulic oil goes out from the other port.
It depends on the traveling derection. In this section, a case where high pressurized oil comes in Port A is
described.
The high pressurized hydraulic oil from port A on END COVER UNIT(27) goes into VALAVE(19) through counter bal-
ance valve, low-high speed switching unit and VALVE SLEEVE(7).
And the hydraulic oil goes into chambers via VALVE PLATE(17), Then the hydraulic oil turn RING (1). After that,
hydraulic oil goes out from port B via VALVE PLATE(17), VALVE(19) and VALVE SLEEVE(7).
DRIVE SHAFT(20) moves precessional rotation, but not rotate itself, because rotation of the DRIVE SHAFT(20) is
fixed with FLANGE(6) on track frame. Then OUTER WHEEL(10) which is fixed on RING(1) and VALVE PLATE(17)
rotates. Sprocket is fixed on OUTER WHEEL(10).
24 1 4 17 19 10 20
A Port A Port B
Port A Port B
D
C B
Chamber
a b c d
B
C
D
A a b c d
6 7 27 A-A
Pressurized oil comes from "a" or "b". Hydraulic oil goes out through "c" or "d".
abc d
D-D C-C B-B

Chamber where hydraulic oil goes out from the motor.
Chamber where pressurized oil comes in.
6-7-2
2) Low-High speed switching scheme

When the pilot oil, that switches high speed, comes in pilot port, Pilot oil pushes PILOT POPPET(52). And path,
which is from COULNTER BALANCE SPOOL(39) chamber to SWITCHING SPOOL(34) chamber, is open. Then
pressurized hydraulic oil goes to chamber of SWITCHING SPOOL(34) and pushes SWITCHING SPOOL(34). As
the result, three paths(a, b and c) of hydraulic oil are open. Hydraulic oil from counter balance goes to orbit motor
via three oil paths(a, b and c), and return oil goes out via only one path(d).
At low speed At high speed

Pilot port for Low-High PILOT POPPET(52) Chamber of COUNTER BALANCE SPOOL(39)
speed switching
Chamber of SWITCHING SPOOL(34) SWITCHING SPOOL(34)
Though number of the hydraulic oil flow paths is increased at hight speed, amount of supplied hydraulic oil flow at
high speed is same as at low speed. Rotation speed is controled by capacity of returned oil flow.
At high speed, oil returns/goes out via flow path "d", and flow path "d" is connected to three paths on VALVE(19).
Capacity of returned oil flow is actually determined by number of flow path on VALVE(19). Number of returned oil
flow path on VALVE(19) is six at low speed. The capacity of returned oil flow at high speed is half of the capacity at
low speed. Because same amount of hydraulic oil is fed to the orbit motor, the motor must rotate at double speed to
discharge same amount of oil from the motor.
a b c d
At low speed
Return oil flow path

on VALVE(19) Return oil flow path on VALVE(19)
6-7-3
3) Return flow of normal inner leakage

Inner leaked oil goes through clearance between DIRVE SHAFT(20) and it's housing to END COVER(27). When
the pressure of inner leakage rises up higher than check valve, the oil goes out from the motor and returns through
darain hoses to reservoir tank.
24 1 4 17 19 10 20
Port A Port B
Check valve
7 27
4) Counter balance valve

When traveling levers are at neutral positions, COUNTER BALANCE SPOOL(39) is kept at neutral position by two
pcs. of SPRING(41) on both sides. COUNTER BALANCE SPOOL(39) at neutral position prevents hydraulic oil to
flow out. Then motor does not rotate.
Hydraulic oil, which is fed to Port "A", goes chamber "a" through ORIFICE(38). At the same time, POPPET(38)
starts open, and hydraulic oil starts to go into motor. But ORIFICE on opposite side is still closed. Then hydraulik oil
is not goes out from the motor via Port "B" and motor does not rotate.
When hydraulic oil pressure in Camber "A" rises up more than cracking pressure, COUNTER BALANCE
SPOOL(39) moves to right hand. Then oil flow path on Port "B" is open and hydraulic oil goes out from the motor.
Oil in chamber "b" goes out via ORIFICE, when the COUNTER BALANCE SPOOL(39) moves to right hand. But
amount of oil flow is small due to ORIFICE, moving speed of COUNTER BALANCE SPOOL is slow.
In a case where the motor speed rise up higher than rated speed due to outer load, amount of supplied hydraulic oil
is insufficient to rotate such high speed. Hydraulic oil pressure in chamver "a" falls down, and COUNTER BALANCE
SPOOL return back to balanced position. Then the oil flow path is reduced and the hydraulic oil flow is reduced and
rotation speed is also reduced.
Depend on this function, travel speed is kept at rated speed even on steep grade.
38 40 Port A 39 Port B
42
41
Chamber "a" Chamber "b"
Chamber "c" Chamber "d"
6-7-4
6-7-3 Exploded View and Parts Comprised

43
47
41 36
45 37
27 INC. 33~56 44 35
52 46
53 42
55 34
40
56
51 39 38
49
54
48
49 29
50
32 33 38
26 56
21 40 35
42 37
46 36
44
45
20 28 41
22 47
14
13 43
15
16
19
23
6
7
8
5 9
26 11
30
17
26 10
1 12
3
2
4 21
26
24
18
31
25
6-7-5
No Part Q'ty No Part Q'ty
1 Ring 1 31 Washer 7
2 Star 1 32 Hexagon socket head bolt 4
3 Roller 7 33 Valve housing 1
4 Roller assy 1 34 Low high switching spool 2
5 Spindle/wheel assy 1 35 Spring 2
6 Flange/spindle 1 36 Plug 1
7 Valve sleeve 1 37 O-ring 2
8 Floating seal 1 38 Orifice 2
9 Retaining ring 1 39 Counter balance spool 1
10 Output wheel 1 40 Counter balance poppet 2
11 Ball bearing 1 41 Spring 2
12 Retaining ring 1 42 Spring 2
13 O-ring 12 43 Plug 2
14 Backup ring 12 44 Check plug 2
15 Coil spring 12 45 Washer 2
16 Pin 2 46 O-ring 2
17 Valve plate 1 47 O-ring 2
18 Roller cover 1 48 Check plug 2
19 Valve 1 49 O-ring 4
20 Drive shaft 1 50 Ball 2
21 Spacer 2 51 Pilot plug 2
22 Sleeve 12 52 Pilot poppet 2
23 X-ring 1 53 Spring 2
24 Hexagon socket head bolt 7 54 Plug 2
25 Hexagon socket head bolt 7 55 Orifice plate 2
26 O-ring 4 56 Plug 2
27 End cover assy 1
28 Valve assy 1
29 O-ring 4
30 Plug 1
6-7-6
6-7-4 Disassembly and Reassembly

(1) Since the parts of the hydraulic equipment are generally precision-made for tight clearances, be sure to perform
disassembly and reassembly in a clean place that is free from dust.
(2) Prepare clean tools and treated oil, and handle the parts carefully.
(3) First clean the external surface of the removed assemblies.
(4) Before beginning disassembly, review the drawings of the internal structure and prepare the required parts
according to the purpose and extent of the disassembly.
(5) In principle, replace the removed seals and O-rings with new ones. Since some replacement parts are available
only as subassemblies, refer to the parts catalog to prepare the necessary subassemblies in advance.
(6) Handling of O-rings
[1] Lubricate the O-rings and the O-ring fitting seats with clean grease or hydraulic oil.
[2] The O-rings may not have any defects in molding or be damaged in handing or distorted by heat.
[3] Do not extend any O-rings with such great force as to permanently deform them.
[4] Avoid rolling the O-rings when fitting them.
[A distorted O-ring may not return to its original shape, and therefore, may cause oil leakage.]
(7) Before beginning reassembly, check that there is no treated oil or hydraulic oil on the outer surface of the O-ring
groove in the mating face of each section.
[If reassembly is performed without cleaning such oil, it may be mistaken for oil leakage.]
2) Tools for Disassembly and Reassembly

No. Tool Remarks
1 Torque wrench Capacity 66.4ft-lbf (90N-m)
2 Hexagon socket Hexagon width across flat 8mm, 6mm
3 Wire brush
4 Flathead screwdriver
5 Eye bolt For M8, 1 or 2 pieces
6 Screw locking Locktite#242 or equivalent
7 Gear oil Shell Spirax EP90 55cm3
8 Grease Small amount
6-7-7
3) Disassembly Procedure
At the time of disassembly, clean the worksites and prepare the clean plastic case for storing parts. Clean around
the port of the motor before removal of the piping and bolts, and remove the paint film and dirt from each joint with
the wire brush.
Note :
Do not disassemble the following assy except when required:
Roller assy 4
Spindle/wheel assy 5
End cover assy 27
Valve assy 28
Procedure
(1) Place the wheel side as the top surface, fix the body by
pinching the end cover assy 27 with a vise. 25
(2) Loosen 7 pieces of the M10 bolts 24 and 7 pieces of the
M8 bolts 25 to remove them.
Note :
The Locktite residue is adhered in the bolts and tap holes. 24
Remove the Locktite residue cleanly before assembly.
27
(3) Remove the roller cover 18.
18
(4) Remove the spacer 21.
(5) Remove the roller assy 4.

4
21
6-7-8
Procedure
(6) Attach the eye bolt (M8) in the valve plate 17, and lift the
valve plate 17 up with the flathead screwdriver. Flathead driver Eye bolt (M8)
17
(7) Remove the drive 20.

20
(8) Remove the valve plate 17 by inserting the flathead

screwdriver between the valve plate 17 and the wheel 10.
17
10
Flathead driver
(9) Remove the valve assy 28.
28
6-7-9
Procedure
(10) Remove the spacer 21.
Note : 21
Take care not to lose the spacer, as it drops at the time of
turning upside down.
(11) Place the end cover side as the top surface by fixing the
wheel side with a vise.
32
Note :
When turned up side down, gear oil flows out from the spin-
dle/wheel assy 5. Receive it with the oil pan.
(12) Loosen 4 pieces of the M8 bolts 32 to remove them.
6-7-10
4) Reassembly Procedure
Wash all the parts using clean fuel and remove grease by air blow.
Handle all the parts with care so that they are free from dust, damage or dent.
Replace the removed O-rings with new ones and apply grease in advance.
Procedure
(1) Fix the wheel side with a vise, place the O-rings 26 on the
spindle 6, and tighten the end cover assy 27 with 4 pieces
of the M8 bolts 32. 32
• Tightening torque 25.3ft-lbf (34.3N-m) 27
(2) Place the wheel side as the top surface, fix the body by
pinching the end cover assy 27 with a vise. 21
(3) Insert the spacer 21 in the back of the valve sleeve 7.
7
27
(4) Apply grease to the X-ring 23 and mount it in the spindle

6.
23
6-7-11
Procedure
(5) When the parallel pins 16 are mounted on the valve 19,
apply grease to the pins so that they don’t drop in the
upside down position. 19
(6) Mark inside the position of the parallel pins 16 in the valve
19 with a magic marker in advance (either position in the
two positions).
16
(7) Mount the valve assy 28 on the valve sleeve 7.

Align the phases to accommodate the pins.
28
(8) Put gear oil in the spindle/wheel assy 5.

• Shell Spirax EP90 55cm3 17
Note :
Fill gear oil slowly in the part where the bearing is seen.
(9) Mount the O-rings 26 on the valve plate 17.
26
(10) Mount the valve plate 17.
Note : 17
Mount it horizontally so that the O-rings 26 don’t bite.
6-7-12
Procedure
(11) Mark one position of the teeth without the claw mark on
the end face of the drive 20.
20
(12) Place the side with the claw mark on the end face of the
drive 20 as the lower side, align the phases of the mark
of the drive 20 and the inside mark position of the valve
19 to insert the drive 20 to the spline part of the valve 17
sleeve 7.
Note :
When there is a gap in the phases, the motor rotates in a
reverse direction, which could cause serious injury, so be cau-
tious.
(13) Put the O-rings 26 on the valve plate 17.
(14) Align the phases of one position of the six ridges of the
2
roller star 2 and the mark of the drive 20 to mount.
1
Note :
when there is a gap in the phases, the motor rotates in a
reverse direction, which could cause serious injury, so be cau- 20
tious.
(15) To align the phases of the bolt hole of the roller ring 1
and the tap hole of the valve plate 17, it is necessary to 10
rotate the wheel 10.
(16) Put the O-rings 26 on the roller assy 4.
(17) Put the G roller cover 18 on the roller assy 4.

18
(18) Mount the seal washers 31 on 7 pieces of the M8 bolts

25.
(19) Apply Locktite#242 or equivalent to 7 pieces of the M10

bolts 24 and 7 pieces of the M8 bolts 25 and tighten 25 31
them.
24
• Tightening torque: M8 22.1ft-lbf (30N-m)
M10 41.3ft-lbf (56N-m)
6-7-13
6-7-5 Failure Cause and Measure
Trouble Cause Measure
Motor does not rotate • Insufficient hydraulic oil volume in the • Supply hydraulic oil to the specified level.
hydraulic oil tank.
• Breakage of pump. • Replace the pump.
• Malfunction of relief valve or low set pres- • Disassemble and clean the relief valve and
sure of it. set the pressure to the specified value.
• Excessive wear or scuffing of motor. • Disassemble the motor to check the parts.
Replace any damaged parts.
• Short-circuit inside motor, dust in the valve • Disassemble and clean.
and valve plate.
Unstable rotation • Low relief set pressure. • Set the relief valve at the specified pres-
sure.
• Air in pump on the suction side.
Reverse rotation • Reversed piping. • Correct the piping.

• Reversed valve timing of motor. • Correct the valve timing.
Oil leak from joint • Loosened bolt. • Tighten the bolt at the specified tightening
torque.
• Caught or damaged O-ring. • Replace the O-ring.
• Wear or damage of floating seal. • Replace the floating seal.
Abnormal sound • Occurrence of flaking, peeling off, and • Replace the bearing.
during rotation indentation in bearing.
• Gear oil is completely empty. • Replace the floating seal and refill the gear
oil.
Speed cannot be shifted • Dual speed spool, stick in pilot poppet, or • Replace the end cover assy.
large leakage.
• Dust choking in orifice plate. • Clean the orifice plate.
• Insufficient dual speed pilot pressure. • Increase the pilot pressure to 19kgf/cm2
and above the drain pressure.
• High drain pressure. • Conduct the drain piping or increase the
pilot pressure.
6-7-14
CHAPTER 7
ADJUSTMENT AND REPAIR
7-1 Engine and Electric Equipment ................................. 7-1-1 7-5-6 Disassembly and Reassembly of
7-1-1 Removal and Reinstallation of Engine ............. 7-1-1 Hydraulic Cylinders......................................... 7-5-13
7-1-2 Removal and Reinstallation of 7-5-7 Removal and Reinstallation of
Starter Motor .................................................... 7-1-7 Hydraulic Oil Tank.......................................... 7-5-16
7-1-3 Removal and Reinstallation of Generator ........ 7-1-8 7-5-8 Piping Layout.................................................. 7-5-19
7-1-4 Removal and Reinstallation of 7-6 Implement ............................................................... 7-6-1
Fuel Injection Pump ......................................... 7-1-9 7-6-1 Removal and Reinstallation of
7-1-5 Removal and Reinstallation of Fuel Tank .......... 7-1-11 Implement ...................................................... 7-6-1
7-1-6 Removal and Reinstallation of Radiator ........... 7-1-13
7-2 Undercarriage ........................................................... 7-2-1
7-2-1 Outline .............................................................. 7-2-1
7-2-2 Points of Reassembly ..................................... 7-2-2
7-2-3 Removal and Reinstallation of Crawler............. 7-2-3
7-2-4 Disassembly and Reassembly of Idler ............. 7-2-4
7-2-5 Disassembly and Reassembly of Track Roller .. 7-2-6
7-3 Controls..................................................................... 7-3-1
7-3-1 Adjustment of Lock Lever Switch ....................... 7-3-1
7-3-2 Adjustment of Accelerator Lever....................... 7-3-2
7-3-3 Adjustment of Travel Levers ........................... 7-3-3
7-3-4 Adjustment of Blade Lever .............................. 7-3-4
7-4 Swing Bearing ........................................................... 7-4-1
7-5 Hydraulic Equipment ................................................. 7-5-1
7-5-1 Removal and Reinstallation of
Hydraulic Pump................................................ 7-5-1
7-5-2 Removal and Reinstallation of Control Valve ... 7-5-3
7-5-3 Removal and Reinstallation of Swing Motor..... 7-5-5
7-5-4 Removal and Reinstallation of Swivel Joint...... 7-5-8
7-5-5 Disassembly and Reassembly of
Swivel Joint ...................................................... 7-5-11
7. ADJUSTMENT AND REPAIR
7. Adjustment and Repair
7-1 Engine and Electric Equipment
7-1-1 Removal and Reinstallation of Engine
1) Removal
Procedure
(1) Swing the upperstructure so that the drain plug 1
of the hydraulic oil tank and the cooling fluid drain plug 2
are positioned halfway between the right and left
crawlers. Then, lower the bucket to the ground and stop
the engine.
(2) Open the cover under the seat to access to the

battery cable, then disconnect the battery cables.
Note :
Place a MAINTENANCE IN PROGRESS label on the
machine.
(3) Remove the drain plug 1 from the hydraulic oil tank
through the hole in the cover 2 and drain the hydraulic oil.
Hydraulic oil quantity 34 L (in tank and circuit)
Warning : Put a container under hydraulic oil drain plug.
(4) Remove the cover 1 on the right of the machine.
(5) Remove the drain plug 2 from the cooling fluid drain hose
and drain the cooling fluid.
Cooling fluid quantity 3,8 L
Warning : Put a container under the coolant drain plug.
(6) Remove the bolts 1 and 2, then remove the plate 3.
7-1-1
Procedure
(7) Remove the bolts 1, then remove the plate 2.
(8) Remove the hose clip 3 of the oil hose 4 and the hose
clip 5 of the oil hose 6.
Warning : Put a container under oil hoses to collect

the hydraulic oil from the hydraulic circuit.
(9) Remove the hose clip 1 of the coolant hose 2, the hose
clip 3 of the coolant hose 4 and the hose clip 5 of
the coolant hose 6.
(10) Remove the radiator 7.
(11) Remove the bolt 1.

(12) Remove the hose clip of the suction hose 2.
(13) Disconnect the connector 3 of the harness B from
the oil temp gauge.
(14) Remove the hose 4, then remove the hydrulic tank 5.

(15) Remove the bolts 1 to remove the left cover 2.
(16) Remove the pins 1 and the bolt 2 to remove the bonnet 3.
7-1-2
Procedure
(17) Remove the cabin bolts 1, 2 and 3, disconnect the cabin

harness 4 to remove the cabin 5.
(18) Turn the locks by 1/4 turn 1 to remove the floor mat 2
and 3.
(19) Remove the bolts 1 to remove the seat 2 with the bracket.
Note: If the machine is equiped of seat bealt sensor,
take care to disconnect the seat harness before to
remove the seat.
(20) Remove the bolts 1 to remove the arm rests 2.

(21) Remove the screws 3 to remove the panel R 4.
Note: When removing the panel R 4, take care about

the harnesses which are connected to the switches.
(22) Remove the screws 5 to remove the upper panel L 6
and the bolts 7 to remove the lower panel L 8.
(23) Remove six pilot control hoses from the remote control
valves L 1 and R 2.
Note : Mark the removed hoses to identify their

respective fitting positions.
7-1-3
Procedure
(24) Remove the pin 1 to remove the cable 2 from

the engine bracket then clamp the accelerator cable
on the seat mount.
(25) Remove the pin 1 and remove the cable 2 from

the link angle then clamp the blade cable on the seat
mount.
(26) Remove the screws L 1, the cover 2, disconnect

the harness 3, then remove the digital monitor 4.
(27) Remove the rivets 1, the screws 2, to remove

the bonnet 3 and the bonnet A 4.
(28) Remove the screws 5 to remove the bonnet C 6 and
bonnet A 7.
7-1-4
Procedure
(29) Disconnect the connectors 1 of the harness A from

the stop solenoid, the pluc glow and the switch oil
pressure.

the feed pump.

the switch water temp.

the sensor water temp.
(33) Disconnect the two connectors 5 of the harness B

from the generator.

the starter motor.
(35) Remove the bolts 1 on both side, then remove

the seat mount Assy 2.
Note:
• Take care to use lifting accessories suitable for the load
to be lifted and which are in good condition.
• First, slowly lift the seat mount to check that there is no
still component linked with the machine.
(36) Disconnect the connectors 1 of the harness A from

the stop solenoid, the pluc glow and the the switch
oil pressure.
(37) Disconnect the connector 2 of the harness A from

the feed pump.

the switch water temp.

the sensor water temp.
(40) Disconnect the two connectors 5 of the harness A

from the generator.

the starter motor.
(42) Remove the clamp 1, then remove the bolts 2

to remove the air filter 3.
(43) Remove the hose clamps 4 and hoses, remove

the bolt 5 then remove the filter 6.
(44) Remove the hose clamps 7 and hoses, remove

the bolts 8 then remove the filter 9.
7-1-5
Procedure
(45) Remove the clamps and suction hose 1 from the

hydraulic pump.
(46) Remove the hoses 2, 3, 4 and 5 from the hydraulic

pump.

(47) Remove the bolts 1 to remove the rear engine stopper 2.
(48) Remove the bolts 3 to remove the engine ground cable 4.
(49) Remove the bolts 5 to remove the front engine stopper 6.
(50) Remove the bolts 7 from absorber shock to remove

the engine 8.
Note: Take care to use lifting accessories suitable for
the load to be lifted and which are in good condition.
2) Reinstallation
Reinstall the engine in the reverse order of the removal procedure.
Note :
• Secure the harness with a band.
• For bolts Tightening torque value, refer to Section “List of Tightening Torque” on page 3-7-1
• For fittings Tightening torque value, refer to Section “Hydraulic Fitting” on page 3-7-6
7-1-6
7-1-2 Removal and Reinstallation of Starter Motor
1) Removal
Procedure
(1) Lower the bucket to the ground and stop the engine.
(2) Open the cover under the seat to access to the battery
cable, then disconnect the battery cables.
Note :
machine.
(3) Remove the bolt 1 to remove the battery clamp 2.

Then remove the battery 3.
(4) Disconnect the wire harness 1 from the starter motor 3.
(5) Remove the mounting bolts 2 to remove the starter

motor 3.
2) Reinstallation
Reinstall the starter motor in the reverse order of the removal procedure.
Note :
7-1-7
7-1-3 Removal and Reinstallation Generator
1) Removal
Procedure
Note :
machine.
(3) Remove the bolt, collar and nut 1 then remove the belt 2.
(4) Remove the bolt and nut 3, then remove the generator 4.
(5) Adjustment of tension belt:

a) Check that the pulleys, the V-groove, the fan belt are
not damaged.
b) Check that the fan belt is not touching the lower part
of the V-groove.
c) Adjust the belt tension by unscrewing the bolt 1,
pulling on the aternator and tightening the bolt 1.
d) Check the belt tenstion so that the setting matches
the value in the illustration opposite. Repeat the
adjustment if necessary.
2) Reinstallation
Reinstall the generator in the reverse order of the removal procedure.
Note :
7-1-8
7-1-4 Removal and Reinstallation of Fuel Injection Pump
1) Removal
Procedure
Note :
machine.
(3) Open the engine bonnet.
(4) Remove the clamp 1, then remove the bolts 2

to remove the air filter 3.
(5) Loosen the sleeve nuts 1 at the fuel injectors after

removing the retainers 2 from the fuel injection
pipes 3 and then loosen the sleeve nuts 4 at
the fuel injection pump 5.
7-1-9
Procedure
(6) Disconnect the fuel hoses 1 (filter-fuel injection pump)

and 2 (fuel injection pump-filter).
(7) Remove the engine oil pipe 3 (cylinder block-fuel

injection pump).
(8) Remove the end nut 4 after removing the HOP cover
5 from the gear case 6.
Note :
• Put a mark 7 on the engaging point of the FIP gear 8 and
the idle gear.
• Do not remove the FIP gear 8 from the gear case 6.
(9) Remove three nuts 9 to remove the fuel injection pump 6

from the gear case 6.
Note :
• Remove the fuel injection pump 10 after putting a mark on
it and the gear case 6.
• Do not turn the crankshaft after removing the fuel injection
pump10. When a mark 7 on the engaging point of the FIP
gear 8 and the idle gear does not align, match the marks
of the idle gear with the crankshaft gear 11, cam gear 12
and FIP gear 8.
• Never loosen the FIP coupling 14 and FIP gear 8 holding
screws 13.
2) Reinstallation
Reinstall all parts in the reverse order of disassembly.
Note :
• Do not use the FIP coupling 14 assembled on a new fuel injection pump assembly.
• The injection timing should be verified by the FID method.
7-1-10
7-1-5 Removal and Reinstallation of Fuel Tank
1) Removal
Procedure
(1) Swing the upperstructure so that the under cover of the
fuel tank is positioned halfway between the right and left
the engine.
(2) Disconnect the battery cables.

Note :
machine.
(3) Turn the locks by 1/4 turn 1, then remove the floor 2
and 3.
(4) Remove the cover 1 on the right side of the machine.

(5) Remove the fuel tank cap 2, then take the end of
fuel drain hose out from the frame and pull out the
plug 3 to drain fuel.
Fuel quantity 24.5 L
Warning : Put a container under fuel drain hose.
7-1-11
Procedure
(7) Remove the hose clip 1 of the fuel hose 2 and the hose
clip 3 of the fuel hose 4.
(8) Disconnect the wire harness 5 from the fuel level gauge
unit.
(9) Remove the bolts 6 and the plate 7, then remove

the fuel tank 8.
2) Reinstallation
Reinstall the fuel tank in the reverse order of the removal procedure.
Note :
• Before reinstalling the fuel tank, clean up the inside of it. In particular, remove the deposits on the bottom of the
fuel tank completely.
7-1-12
7-1-6 Removal and Reinstallation of Radiator
1) Removal
Procedure
(1) Swing the upperstructure so that the cooling fluid drain
plug 1 is positioned halfway between the right and left
the engine.

Note :
machine.

(6) Remove the bolt 1, then remove the plate 2.
(7) Remove the hose clip 3 of the oil hose 4 and

the hose clip 5 of the oil hose 6.

7-1-13
Procedure
clip 3 of the coolant hose 4 and the hose clip 5 of the
coolant hose 6.
2) Reinstallation
Reinstall the radiator in the reverse order of the removal procedure.
Note :
• For Tightening torque value, refer to Section “List of Tightening Torque” on page 3-7-1
• For Refilling the radiator, refer to Section “Fuel, Lube Oil and Grease Recommended” on page 2-7-1
7-1-14
7-2 Undercarriage
7-2-1 Outline
The undercarriage consists of travel motors, frame, track rollers, front idlers, rubber crawlers, variable frame
cylinder and other parts. Hydraulic oil fed through the control valve and the swivel joint from the hydraulic pump
causes the travel motors to rotate, so that the power is transmitted to the crawlers via the sprockets.
The forward and reverse travel of the machine is switched using the travel levers.
Viewed from the top

Slide plate
Idler Stopper bolt Variable frame Travel motor

cylinder
Track roller
Swivel joint
A Section A-A
A
Grease adjuster Track roller Sprocket
7-2-1
7-2-2 Points of Reassembly
Bolt 103 0,
Apply Three Bond 1324 or its equivalent.
Tightening torque:
46 to 54 Nm
Install rubber crawler

so that lug is set in di-
rection as shown in
top view below.
Bolt 1225
Tightening torque:
116 to 138 Nm
Bolt 103 5
Tightening torque: Check that track roller
67 to 79 Nm moves smoothy after
Section A-A installing it into frame.
Idler should smoothly

move back and forth. A
A
Apply heavy-duty Check that track roller moves
grease to moving smoothly after installing it into
area of idler. frame.
Variable frame cylinder
Nut M16
Stopper bolt
Tightening torque :
198 to 230 Nm
Bolt 1645
Tightening torque :
Full extension length 198 to 230 Nm
156 ±3 mm
Shoe slide plate
7-2-2
7-2-3 Removal and Reinstallation of Crawler
! When raising the machine, support it with safety blocks of sufficient strength.
When loosening or removing the nipple valve 1, the high internal pressure could cause grease to eject or the nipple valve
! to blow. Do not bring your face close to the nipple valve 1.
1) Removal of Rubber Crawler

Handle the rubber crawlers with great care, as they are heavy.
!
Rubber crawler : 46 kg each
Procedure
(1) Lower the bucket to the ground, and remove the nipple
valve 1 to loosen the rubber crawler tension.
Note :
Move the machine back and forth if the grease is not dis-
charged smoothly.
(2) Swing the upperstructure to position the implement in the

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

1 Idler 1 7 Internal snap ring C62 1
2 Internal snap ring C62 1 8 Idler fork R 1
3 Idler fork L 1 9 External snap ring C25 1
4 Seal QLN306213.2Y 1 10 Seal QLN306213.2Y 1
5 Shaft 1 11 Bearing 6206 1
6 Bearing 6206 1
2) Disassembly
Procedure
(1) Remove the idler assembly from the crawler frame.
Crawler frame
Idler assembly
7-2-4
Procedure
(2) Remove the mounting bolts to remove the crawler adjust-
ing spring. Mounting bolt
(3) Remove the snap ring C 9 and then remove the idler fork
R 8, the seal 10 and the snap ring C 7. Crawler adjusting
spring
(4) Drain the lube oil inside the idler. Then, pull out the shaft 5
(with the bearing 11) using a press.
Oil quantity 25 cc
98
Warning : Take care to put the lube oil in a container.
10
7
(5) Remove the seal 4, and then remove the snap ring C 2 11
and the bearing 6.
1
Note : 5
The shaft 5 is press-fitted into the idler fork L 3.
6
24
3
3) Reassembly
Reassemble the idler in the reverse order of the disassembly procedure.
Notes :
[1] Clean all the parts and check them for damage or
defects.
[2] Replace the seals with new ones.
[3] Apply multipurpose grease to the lips of seals 4 and 10.
4, 10
[4] When installing the seal 10, to release air from the
inside of the idler, remove the sleeve from the seal
and install the seal, then install the sleeve.
Crawler adjusting spring mounting bolt (M10)
Adhesive : Three Bond 1324 or its equivalent.
Note :
• For Tightening torque value, refer to Section
“List of Tightening Torque” on page 3-7-1
[5] Oil to be used for idler:
Sleeve
Type Engine oil SAE 30
Quantity 25 cc
7-2-5
7-2-5 Disassembly and Reassembly of Track Roller
1) Structure and Component Parts
1 2 3 4 5 6 7
For rubber crawlers

8
No. Part Q’ty No. Part Q’ty

1 Seal TW 25 52 18 1 5 Shaft 1
2 Roller 1 6 Bearing 6205 1
3 Internal snap ring C52 1 7 Internal snap ring C52 1
4 Bearing 6205 1 8 Seal TW 25 52 18 1
2) Disassembly
Procedure
(1) Remove the mounting bolts and remove the track roller Mounting bolt
from the crawler frame.
Crawler frame
Track frame
7-2-6
Procedure
(2) Remove the seal 1 from the track roller 2 and drain the
lube oil.
1
Oil quantity 40 cc 3
4
Warning : Take care to put the lube oil in a container.
5
(3) Remove the snap ring C 3 and pull out the shaft 5 (with 2
the bearing 4) using a press.
(4) Remove the seal 8, and then remove the snap ring C 7 6
and the bearing 6.
7
8
3) Reassembly
Reassemble the track roller in the reverse order of the
disassembly procedure.
1, 8
Notes :
[1] Clean all the parts and check them for damage or
defects.
[2] Replace the seals with new ones.
[3] Apply multipurpose grease to the lips of seals 1 and 8.
[4] When installing the seal 1, to release air from the
inside of the track roller, remove the sleeve from the
seal and install the seal, then install the sleeve.
Track roller mounting bolt (M10)
Adhesive: Three Bond 1324 or its equivalent.
Note :
• For Tightening torque value, refer to Section
“List of Tightening Torque” on page 3-7-1 Sleeve
[5] Oil to be used for track rollers :
Type Engine oil SAE 30
Quantity 40 cc
7-2-7
7-3 Controls
7-3-1 Adjustment of Lock Lever Switch
1) Operation of Lock Lever

(1) The operating force for moving the lock lever from N to P should be 53 N +/- 5 N.
(2) The lock lever switch 1 should not allow the implements to operate when the lock lever is in N position.
N
1
062787-00X00
Tightening torque:
19.6 to 24.5 N•m
27 mm
(ON) *Note: Overtorque may
cause the switch to be damaged.
35 mm
(OFF)
Detail of cut-off switch
Lock lever switch operation

Lever Switch Switch Cut-off Implement
position condition circuit valve operation
operation
Pushed
P ON Operate Operate
Normal
Can not
N OFF Stop
operate
7-3-1
7-3-2 Adjustment of Accelerator Lever
Procedure
Adjustment of Maximum Idling Speed
(1) Loosen the stopper bolt 1, and then move

the accelerator lever 2 back until the regulator
handle 3 on the engine side touches the adjusting
bolt 4 for the maximum idling speed in the governor
case.
(2) Check that the maximum idling speed is within a

specified range (2755 to 2805 rpm).
(3) After the adjustment of the maximum idling speed,

screw in the stopper bolt 1 until the bolt end touches
the accelerator arm 2 and fix it with the nut 6.
Adjustment of Minimum Idling Speed
(1) Loosen the stopper bolt 7, and then move the

accelerator lever 2 forward.
(2) When the regulator handle 3 on the engine side

touches the stopper bolt 5 for the minimum idling
speed, check whether the minimum idling speed
is within a specified range (1525 to 1575 rpm).
(3) If the minimum idling speed is not within the range,

make adjustments to the speed by tightening or
loosening the stopper bolt 5.
(4) After the adjustment of the minimum idling speed,

the accelerator arm 2 and fix it with the nut 8.
7-3-2
7-3-3 Adjustment of Travel Levers
Procedure
Adjustment of travel cables on lever side

(1) Loosen the nut 1 at the maximum position.
(2) Screw the cable 2 all most is possible, then unscrew

the cable 2 between 1 to 2 turns.
(3) Screw the nut 3 and fix it with the nut 1.
Adjustment of travel cables on MCV side

(1) Loosen the screw 4.
(2) Lossen the screws 5, then remove the cover 6.
(3) Check the pin 7, if necessary change it.
(4) Put the cover 6 in place, then tighten the screws 5

to 6.37 Nm +/-0.5.
(5) Check the cable sheath moves freely in the cover 6 by

moving the travel lever forward and backward.
(6) Put the lever in neutral position then tighten the screw 4
to 5 Nm.
Adjustment of travel lever stopper

(1) Loosen the stopper bolts 8 and 9.
(2) Move the travel lever forward, unscrew the stopper

bolt 8 until the bolt touches the lever bracket then it
screw 1/2 turn and fix with the nut.
(3) Move the travel lever backward, unscrew the stopper

bolt 9 until the bolt touches the lever bracket then it
screw 1/2 turn and fix with the nut.
Repeat all the steps for the other travel lever.
7-3-3
7-3-4 Adjustment of Blade Lever
Procedure
Adjustment of blade lift movement

the blade lever 2 back until the balde lift.
(2) After the adjustment of the blabe lift movement,

the blade lever 2 and fix it with the nut 3.
Adjustment of blade down movement

the blade lever 2 back until the balde down.
(2) After the adjustment of the blabe down movement,

the blade lever 2 and fix it with the nut 5.
7-3-4
7-4 Swing Bearing 1 3

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

25 kgf
Inner race
Steel ball diameter Ø17.4625 mm ⎯
Tuning frame¯outer race M12¯60 Apply Loctite 262

Tightening torque (10.9 T) See note
Track frame¯inner race M12¯45 or its equivalent.
(Bolt 10.9)
Note :
• Put multipurpose grease into the swing bearing.
• For Tightening torque value, refer to Section “List of Tightening Torque” on page 3-7-1
4) Parts of Swing Bearing

5 7 1, 4 2 6
No. Part Q'ty
1 Steel ball 66
2 Seal A 1
3 Seal B 1
8
4 Support 66
5 Outer race 1
6 Inner race 1
7 Taper pin 1
8 Plug 1
3
5) Inspection
(1) Check the gear teeth surfaces for nicks, flaws, cracks, wear and breakage. Replace the swing bearing if the
damage is excessive.
(2) Check for abnormal sound. Clean, grease or replace the swing bearing if necessary.
(3) Check the inner and outer races for play and irregular rotation. Refer to the service standards for repair or
replacement.
(4) Check for grease leak from the swing bearing seal. Replace the swing bearing if the leakage is excessive.
7-4-2
7-5 Hydraulic Equipment
7-5-1 Removal and Reinstallation of Hydraulic Pump

1) Removal
Procedure
(1) Swing the upperstructure so that the drain plug 1 of the
hydraulic oil tank is positioned halfway between the right
and left crawlers. Then, lower the bucket to the ground
and stop the engine.

Note :
machine.
(3) Remove the cover 1 under the upper carriage.

(4) Remove the drain plug 2 from the hydraulic oil tank and
drain the hydraulic oil.
Warning : Put a container under the hydraulic oil drain plug.
7-5-1
Procedure
(8) Remove the clamps and suction hose 1 from the

hydraulic pump.
(9) Remove the hoses 2, 3, 4 and 5 from the hydraulic

pump.
(10) Remove the bolts 1 then remove the pump 2.
(11) Disasemble the fitting 3 and 4.
2) Reinstallation
Reinstall the hydraulic pump in the reverse order of the removal procedure.
Notes :
• Apply heavy-duty grease to the spline shaft of the hydraulic pump.
• Hydraulic oil to be used :
YANMAR SUPER HYDRO OIL

Type
(VG 46 class) or its equivalen
Quantity (total) 34 L
• After the installation of the hydraulic pump, make a test run and operate the relief valves to check for oil leak or
other abnormality.
7-5-2
7-5-2 Removal and Reinstallation of Control Valve
1) Removal
Procedure
hydraulic oil tank is accessible from the back of
the machine between the right and left crawlers and
the control valve 2 is accessible from the side above
the left crawler. Then, lower the bucket to the ground

Note :
machine.

(5) Turn the locks by 1/4 turn 1 to remove the floor mat 2 and
3.
7-5-3
Procedure
(6) Remove the hydraulic hoses and the pilot hoses from the
control valve 1.
Notes :
• Remove the hydraulic hoses and the pilot hoses from the
control valve in right-to-left order.
• Mark the removed hoses to identify their respective fitting
positions.
(7) Loosen the screw 1, loosen the screws 2, move back

the cover 6, then remove the pin 4 to disconnect the
Travel L section.
(8) Repeat the same steps to disconnect the PTO section.
(9) Repeat the same steps to disconnect the Travel R

section.
(10) Repeat the same steps to disconnect the Boom Swing

section.
(11) Remove the mounting bolts 1, and then remove the con-
trol valve 3 from the valve plate 2.
2) Reinstallation
Reinstall the control valve in the reverse order of the removal procedure.
Notes :
[1] Install the hoses so that each of them is not in contact with any other hoses or parts.
[2] Hydraulic oil to be used :

Type (VG 46 class) or its equivalent
Quantity (total) 34L
[3] After the installation of the control valve, raise the hydraulic oil temperature to 50 to 60 °C and operate the relief
valves, to check for oil leak.
7-5-4
7-5-3 Removal and Reinstallation of Swing Motor
1) Removal
Procedure

Note :
machine.

(5) Remove the cover 1 on the right side of the machine.
(6) Remove fuel tank cap 2, then take the end of fuel drain
hose out from the frame and pull out the plug 3 to drain
fuel.
Fuel quantity 24.5 L
Warning : Put a container under the fuel drain hose.
(7) Remove the bolt 1 and 2, then remove the plate 3.
7-5-5
Procedure
(8) Remove the hose clip 1 of the fuel hose 2 and the hose
clip 3 of the fuel hose 4.
(9) Disconnect the wire harness 5 from the fuel level gauge
unit.
(10) Remove the bolts 6 and the plate 7, then remove

the fuel tank 8.
(12) Remove the cabin bolts 1, 2 and 3, disconnect the cabin

harness 4 to remove the cabin 5.
(13) Turn the locks 1/4 turn 1 to remove the floor mat 2 and 3.
(14) Remove the bolts 1 to remove the seat 2 with the bracket.
Note: If the machine is equiped of seat bealt sensor,
take care to disconnect the seat harness before to
remove the seat.
7-5-6
Procedure
(15) Remove the hydraulic hoses from the swing motor 1.

• Hose 2 (control valve to swing motor)
• Hose 3 (control valve to swing motor)
• Pilot hose 4 (cut off valve R2 to swing motor)
• Drain hose 5 (swing motor to oil cooler)
(16) Remove the mounting bolts 1 and lift a little

the seat mount Assy 2 in order to be able to remove
the swing motor.
Notes :
• Make sure that the harnesses are free enough so that
they are not stretched during the lifting of the seat mount.
• Lift the seat support only as little as necessary so to not
damage the components not removed from the machine.
(17) Remove the mounting bolts 1 and remove the swing

motor 2.
2) Reinstallation
Reinstall the swing motor in the reverse order of the removal procedure.
Notes :
• Swing motor mounting bolt : Apply three bond 1324 or its equivalent.
[1] Install the hoses so that each of them is not in contact with any other hoses or parts.

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

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


Note :
machine.

(7) Loosen the bolts 1 to remove the frame cover 2.
7-5-8
Procedure
(8) Turn the locks by 1/4 turn 1 to remove the floor mat 2
and 3.
(9) Remove the hydraulic hoses and the pilot hoses from
the control valve in order to get more space to acces to
hydraulic hoses of the swivel joint.
Notes :
• Remove the hydraulic hoses and the pilot hoses from the
control valve in right-to-left order.
positions.
(10) Remove the hydraulic hoses from the turning frame

side of the swivel joint:
-(J): hose 1 for blade or variable track cylinder (bottom)
-(E): hose 2 for blade cylinder (rod)
-(A): hose 3 for travel motor left (forward)
-(G): hose 4 for second speed (two speed valve)
-(D): hose 5 for travel motor right (forward)
-(H): hose 6 for travel motor left & rigth (drain)
-(B): hose 7 for travel motor right (backward)
-(C): hose 8 for travel motor left (backward)
-(F): hose 9 for variable track cylinder (rod)
-(I): plug 10.
Note :
Mark the removed hoses to identify their respective fitting
positions.
(11) Remove the hydraulic hoses from the lower frame

side of the swivel joint:
-(J): hose 2 for blade cylinder (bottom)
-(J): hose 3 for variable track cylinder (bottom)
-(E): hose 4 for blade cylinder (rod)
-(C): hose 5 for travel motor left (backward)
-(H): hose 6 for travel motor right (drain)
-(H): hose 7 for travel motor left (drain)
-(A): hose 8 for travel motor left (forward)
-(F): hose 10 for variable track cylinder (rod)
-(D): hose 11 for travel motor right (forward)
-(B): hose 12 for travel motor right (backward)
-(I): plug 13.
Notes :
• Remove the hydraulic hoses from the turning frame side in
bottom-to-top order.
positions.
7-5-9
Procedure
(12) Loosen the bolts 1 to remove the swivel joint 2.
2) Reinstallation
Reinstall the swivel joint in the reverse order of the removal procedure.
Notes :
• Swing motor mounting bolt : Apply three bond 1324 or its equivalent.
[1] Install each connector at a specified mounting angle.


7-5-10
7-5-5 Disassembly and Reassembly of Swivel Joint
1) Structure
The swivel joint is used to prevent the hydraulic piping from twisting when the upperstructure swings.
The swivel joint consists of the shaft, a hub and seal kit. The shaft and hub have holes and grooves, and the oil
supplied from the port of the shaft, passing through the hub groove, is fed to the actuators of the undercarriage.
No. Part Quantity No. Part Quantity
1 Swivel joint assembly 1 9 Back-up ring 1

2 Swivel shaft 1 10 Dust seal 1
3 Swivel flange 1 11 O-ring 1
4 Swivel hub 1 12 Snap ring 1
5 Thrust ring 1 13 Spring washer 4
6 Seal kit 1 14 Bolt H M8x25 4
7 O-ring 1 15 Plug PT 1/4 1
8 Slipper seal 9 16 O-ring 1
7-5-11
2) Disassembly and Reassembly of Swivel Joint
• Disassembly
(1) Remove the bolts 14.
(2) Remove the swivel flange 3 and the O-ring 11.
(3) Remove the external snap ring 12 and the thrust ring 5 from the swivel shaft 2.
(4) Pull the swivel shaft 2 out of the swivel hub 4 and remove the dust seal 10.
(5) Remove the slipper seals 8, O-ring 7 and back-up ring 9 from the swivel hub 4.
• Reassembly
(1) Install slipper seals 8, O-ring 7 and back-up ring 9 into swivel hub 4.
(2) Apply multi-purpose grease to the inner surface of swivel hub 4.
(3) Install the O-ring 10 on the swivel shaft 2 and insert the shaft into the swivel
hub 4 slowly.
• Use a jig E-004
• Apply multi-purpose grease to the outer surface of the shaft.
(4) Install the thrust ring 5 and the external snap ring 12 to the swivel shaft 2.
(5) Install the swivel flange 3 with O-ring 11, on the swivel hub 4 in this order
and tighten bolts 14.
3) Cautions for Handling and Storing Seals

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

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

(1) Disassemble and reassemble at a place free from dust.
(2) Completely remove the contamination, foreign matter
(sludge), etc. from the disassembled parts. Fig. 3 Fig. 4
(3) Check for flaws or nicks on the seal surface of the shaft.
Repair or replace the part when necessary.
(4) Replace the shaft if it is worn.
(5) Replace all seals in reassembly.
7-5-12
7-5-6 Disassembly and Reassembly of Hydraulic Cylinders
1) Sectional View and Component Parts
1 6 5 4 3 2
No. Part
1 Seal kit, scrapper Bearing bush

2 Nut
3 Piston
4 Cylinder
5 Rod Assembly
6 Guiding bush

(1) Parts are high precision-made. Be careful not to damage any parts by dropping them or knocking them together
when handling them.
(2) If there are any burrs on the surface of seal installation parts or O-ring grooves, remove them.
(3) Never use the lock washer removed once.
(4) Replace once removed seals and O-rings with new ones.
(5) Clean all the parts and dry them by air blow.
7-5-13
3) Disassembly
Procedure
(1) Drain the oil from the hydraulic cylinder.
Warning : Take care to put the oil in a container.
(2) Hold the cylinder at the bottom end or using the pin hole
at the bottom end, and put the rod side of the cylinder on
a block.
(3) Raise the pawl of the lock washer 1 on the head 2 and
loosen the head 2.
Note :
Use a hook wrench or a jig to loosen the head 2.
(4) Pull out the rod assembly 1 from the cylinder tube and
then hold the cylinder rod assembly at the rod end or
using the pin hole at the rod end.
(5) Disassembly of boom cylinder

Remove the U-nut 1, and then the piston 2, the cushion
plunger 3, the cushion collar 4, and the head 5 from the
rod 6 in that order.
(6) Disassembly of bucket, arm, boom swing, blade and

variable track cylinders.
Remove the U-nut 1, and then the piston 2 and the head
3 from the rod 4 in that order.
7-5-14
Procedure
(7) Remove the O-rings 1, 2 and 3, the dust seal 4 from

the head cylinder 5.
(8) Remove the RGU packing 6 and the PWL bearing 7

from the piston 8.
Note :
Use a sharp tool to raise each of the O-rings, the ISI packing,
the RGU packing or the PWL bearing, and then insert a spat-
ula to remove it.
4) Reassembly
Reassemble the hydraulic cylinder in the reverse order of the disassembly procedure.
Notes :
• Take care not to install the cushion plunger 1 of
the boom cylinder in the wrong direction.
• Replace the O-rings, packings and seals with
new ones.
U-nut Size end Tightening Torque

No. Cylinder U-nut size U-nut tightening torque Adhesive
1 Boom M24x2 410 to 430 N•m
2 Arm M24x2 470 to 490 N•m
3 Bucket M22x1,5 300 to 320 N•m
Loctite 262
4 Boom swing M22x1,5 300 to 320 N•m
5 Blade M24x1,5 380 to 420 N•m
5 Extension M22x1,5 300 to 320 N•m
7-5-15
7-5-7 Removal and Reinstallation of Hydraulic Oil Tank

1) Removal
Procedure

Note :
machine.


(7) Remove the bolt 1 and 2, then remove the plate 3.
7-5-16
Procedure
(8) Remove the bolt 1, then remove the plate 2.
(9) Remove the hose clip 3 of the oil hose 4 and the hose
clip 5 of the oil hose 6.

clip 3 of the coolant hose 4 and the hose clip 5 of
the coolant hose 6.
(12) Remove the bolt 1.

(13) Remove the hose clip of the suction hose 2.

the oil temp gauge.
(15) Remove the hose 4, then remove the hydrulic tank 5.

7-5-17
2) Reinstallation
Reinstall the hydraulic oil tank in the reverse order of the removal procedure.
Notes :
[1] Completely drain the oil from the hydraulic oil tank and wipe off the deposits from the bottom of the tank.
[2] Replace the return filter 1 with a new one.
[3] Clean the suction filter 2. Replace it if the wire gauze is damaged.
[4] Replace the oil when it reaches the replacement time or it has been deteriorated. If reusing the oil,
maintain the oil quality so that it has no impurities.
[5] Check the O-rings for oil leak.
If any oil leak is found, replace the O-ring.

Type
(VG 46 class) or its equivalent
Quantity 34 L (in tank and circuit)
3) Oil Level Check

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

(1) Retract the bucket and arm cylinder rods fully to lower
the bucket to the ground.
(2) Lower the blade to the ground.
7-5-18
7-5-8 Piping layout
1) Upperstructure
(Hydraulic oil tank → Hydraulic pump → Control valve)
7-5-19
2) Swing motor
(Control valve → Swing motor)
7-5-20
3) Swivel joint
(Selector valve → Control valve → Swivel joint)
7-5-21
4) Return lines
(Joystick, Swivel joint, PTO valve, Control valve, Swing motor, Cut off valve → Hydraulic oil tank)
7-5-22
5) Lower structure
(Swivel joint→ Travel motors, Track gauge cylinder, Blade cylinder)
7-5-23
6) PTO/Boom swing
(Boom swing cylinder, PTO circuit, PTO valve → Control valve)
7-5-24
7) Kinematics
(Control valve→ Bucket cylinder, Arm cylinder, Boom cylinder)
7-5-25
8) Control levers
(Joysticks→ Control valve, Cut off → Swing motor)
7-5-26
7-6 Implement
7-6-1 Removal and Reinstallation of Implement
Notes :
• When removing a pin, check the number of shims installed and their positions.
• When removing a hose, put a plug into the hose connection port to keep the oil from flowing out.
1) Removal of Bucket
Procedure
Note : Lower the bucket with its back face down.

Note :
machine.
(3) Remove the lock nut 1 and remove the pins 2.
(4) Remove the bucket 3.
7-6-1
2) Removal of Arm
Procedure
(1) Remove the bolt 1 and remove the pin 2.
(2) Remove the bucket link 3.
(3) Remove the bolt 4 and remove the pin 5.
(4) Remove the links bucket 6 and 7.
(5) Remove the hose 1 and the hose 2 from the

bottom side of the bucket cylinder.
(6) Remove the hose 3 and the hose 4 from the rod
side of the bucket cylinder.
Note :
Remove the 3rd circuit hydraulic hoses if the machine
is equipped with this option.
(7) Remove the bolts 1 (M8) to remove the brackets 2

on both side.
(8) Remove the bolt 1 (M10) to pull out the pin 2.

Then remove the bucket cylinder 3.
Note :
Rope the bucket cylinder and remove it using a lifting device.
(9) After roping the arm 1, remove the bolt 2 (M10) and
pull the pin 3 from the arm cylinder on the rod side.
Note :
Place a block under the arm cylinder.
(10) Remove the bolt 4 (M10) and pull out the arm pin 5.
Then remove the arm 1 using a lifting device.
7-6-2
3) Removal of Boom
Procedure
(1) After raising the boom fully, roping the arm cylinder 1
remove the hydraulic hoses 2 from the arm cylinder 1 1.
(2) Remove the bolt 3 (M10) and pull out the pin 4.
Then remove the arm cylinder 1.
Note :
Remove the arm cylinder using a lifting device.
(3) Remove the bolt 1 (M8) disconnect the connectors of

the harness, then remove the work lamp 2.
(4) Remove the bolts 3 (M8) to remove the bracket 4.
(5) Remove the harness 5.
(6) Remove the hoses 1 on both side.
(7) Remove the hose 2 from rod side of boom cylinder.
(8) Remove the hose 3 from bottom side of boom cylinder.
(9) After roping the boom cylinder 1, remove the bolt 2 (M10)
and pull out the pin 3.
(10) Remove the bolt 4 (M10) and pull out the pin 5.
Then remove the boom cylinder 1.
Note :
Remove the boom cylinder using a lifting device.
(11) After roping the boom 1, remove the bolt 2 (M10),

pull out the pin 3 and remove the collar 4.
Note :
• Remove the boom using a lifting device.
• Take care that the hoses do not catch on any other parts.
7-6-3
4) Removal of Blade
Procedure
Note : Turn the implement to the blade side, lower the
bucket and the blade to the ground.

Note :
machine.
(3) Remove the bolts 1 to remove the blade cover 2.
(4) Remove the hose 3 from the rod side of the blade
cylinder and remove the hose 4 from the bottom side
of the blade cylinder.
(5) Remove the bolt 1 (M10) and pull out the pin 2,
remove the bolt 3 to pull the pin 4, then remove the
blade cylinder 5.
(6) Rope the blade, remove the bolt 1 (M10) and pull out
the pin 2 on both sides, then remove the blade 3.
Note :
Remove the blade using a lifting device.
7-6-4
5) Removal of Boom Bracket

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

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

Refer to Section "7-6-1 3) Removal of Boom"
Note :
Rope the boom bracket and remove it using a lifting device.
(4) Remove the bolt 1 (M10) and the nuts 2 at the top and
bottom, pull out the pin 3 at the top and bottom , then
remove the boom bracket 4.
7-6-5
6) Removal of Boom Swing Cylinder

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

Note :
machine.
(3) Remove the bolts 1 to remove the cover R 2.
(4) Remove the hose 1 from the rod end of the boom swing
cylinder, then remove the hose 2 from the bottom side of
the boom swing cylinder.
(5) Remove the bolts 1 (M10) and pull out the pin 2 from
the rod end of the boom swing cylinder 3.
(6) Remove the bolts 4 (M10) to remove the plate 5 and

pull out the pin 6 from the bottom side of the boom
swing cylinder 3.
(7) Remove the boom swing cylinder 3 from the turning

frame.
7-6-6
CHAPTER 8
TROUBLESHOOTING
8-1 Non-Breakdowns ................................................................................ 8-1-1

8-1-1 Natural Release of Bucket ......................................................... 8-1-1
8-1-2 Discontinuous Arm Movement ................................................... 8-1-1
8-1-3 Drifting of Upperstructure on Quick Travel Operation................ 8-1-2
8-1-4 Thermal Shock of Travel Motor.................................................. 8-1-3
8-1-5 Elongation of Boom Swing Cylinder on 65 degrees Swing........ 8-1-4
8-1-6 Time Lag on Travel Speed Switching ........................................ 8-1-5
8-1-7 Fluctuation in Oil Level of Hydraulic Oil Tank Due to
Temperature Change ................................................................ 8-1-6
8. TROUBLESHOOTING
8. Troubleshooting
8-1 Non-Breakdowns
8-1-1 Natural Release of Bucket
Phenomenon
When the arm is extended while scooping with the
bucket, the scooping side of the bucket is restricted by
the arm and causes back pressure because oil cannot
be supplied to the bucket cylinder in time.
When the boom is raised immediately in this condition,
the bucket is released naturally because of the back
pressure in the piston side of the cylinder
Operation
This problem can be solved by using a sequence of
three actions of bucket scooping, arm extension and
boom raising.
(For the models that cannot make the triple sequence
actions, extend the arm after raising the boom.)
8-1-2 Discontinuous Arm Movement
When scooping with the arm, the arm tends to move

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

speed is in the low to medium speed range. Discontinuous phenomenon appears in this renge.
Advise your users fully that this will happen in hydraulic
equipment and that this is not a breakdown.
8-1-1
8. TROUBLESHOOTING
8-1-3 Drifting of Upperstructure on Quick Travel Operation
Phenomenon
The upperstructure drifts on quick travel operation (especially, on spin-or pivot-turning).
Drift
Reason
Inertial force is given to the upperstructure through the quick operation of the undercarriage, and high pressure is
applied to the swing motor. The relief valve is activated to turn the swing motor.
Inertial force
Mechanical brake
release port
Relief valve
P1
8-1-2
8. TROUBLESHOOTING
8-1-4 Thermal Shock of Travel Motor
Phenomenon
When the traveling operation is made for pivot turning in cold temperatures after raising the hydraulic oil to more
than 140°F (60°C) higher than the ambient temp. through relief valve operation, etc., without traveling after starting
the engine, the machine may travel straight instead of making a pivot turn.
(Travel straight in spite of turning operation.)
Reason
Spool
Motor
Brake valve
Swivel joint
Motor
When the hot hydraulic oil is suddenly fed to the cold brake valve and motor, the spool in the brake valve sticks
momentarily due to thermal expansion, canceling the braking force.
Evaluation
Since the phenomenon disappears in 20 to 30 seconds and this situation is generally rare, this phenomenon pres-
ents no problem.
8-1-3
8. TROUBLESHOOTING
8-1-5 Elongation of Boom Swing Cylinder on 65 degrees Swing
Phenomenon
The boom swing cylinder elongates in digging operation at a 65 degrees swing.
External force
Reason
When an outside sideways force is applied to the bucket, the force extends (retracts) the boom swing cylinder. At the
65 degrees swing position, however, the cylinder’s internal pressure is higher than in other positions due to the link
ratio. Remaining air in boom swing hydraulic circuit may elongate the boom swing cylinder.
If necessary operate several time the boom swing fully to bleed the air off the circuit.
Left 43° Bottom end
Rod end
External force
Boom swing cylinder elongation
Front
Right 65°
Pressure caused inside the cylinder
when identical external force is applied.
044653-00EN01
8-1-4
8. TROUBLESHOOTING
8-1-6 Time Lag on Travel Speed Switching
Phenomenon
At cold temperatures, there is a time lag in switching from the high-speed to low-speed (with the 2nd gear switch
on the blade lever).
Reason
The shock caused during switching from the high-speed to low-speed is lightened by the throttles of A. At cold tem-
peratures, however, the passage resistance of the throttles becomes larger and it takes more time for the swash
plate of the travel motor to return to the low-speed.
8-1-5
8. TROUBLESHOOTING
8-1-7 Fluctuation in Oil Level of Hydraulic Oil Tank Due to Temperature Change
Phenomenon
The oil level of the hydraulic oil tank varies between before operation (the machine is cool) and after operation (the
machine is warm).
After operation (machine warm)
Before operation (machine cool)
Reason
The oil level changes because the thermal expansion factor of oil is far larger (about 20 times) than that of steel.
1. Liner thermal expansion factor of steel : 11.710 -6

2. Cubical thermal expansion factor of steel : 3.5110 -5
3. Cubical thermal expansion factor of hydraulic oil : 7.710 -4
(Example)
0.51 Gals. (0.1925 L)

Expansion by temp. rise
68°F (20°C) 158°F (70°C)

Hydraulic oil
13.2 Gals. (50 L) 13.2 Gals. (50 L)
Expansion by temp. rise

0.023 Gals. (0.088 L)
Hydraulic oil tank 68°F (20°C) 158°F (70°C)

(Steel) 13.2 Gals. (50 L) 13.2 Gals. (50 L)
8-1-6
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SERVICE

GENERAL CAUTIONS FOR MAINTENANCE WORK

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

1. General Cautions for Maintenance Work

1-1 Correct Work

1-2 Safety Precautions

1-4 Cautions for Disassembly and Reassembly

(1) Clean the machine before disassembly.

1-5 Cautions for Removal and Installation of Hydraulic Equipment

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

1-6 Cautions for Removal and Installation of Hydraulic Piping

(1) Installation of hydraulic hose

1-7 Cautions for Handling Seals

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

1-8 Correct Installation of Hydraulic Hose

Not good Good

Not good Good

Not good good

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

Not good good

Not good good

Not good good

Not good good

Hose mark Hose mark

1-9 Specifications of Hydraulic Hose

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

4 Nominal dia. (inch)

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

Fitting type Code Fitting type Code

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

45° 45 degrees bent type.

Straight pipe thread with

30° 30 degrees bent type.

1-10 Air Release of Hydraulic Equipment

1. Air Release of Variable Displacement Piston Pumps

2. Air Release of Each Hydraulic Component

3. Air Release of Hydraulic Cylinders

1.97 to 3.9 in. 1.97 to 3.9 in.

4. Air Release of Hydraulic Oil tank

HEX41 can be used R1

" " dimensions

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

Item Unit SV15VT

Item Unit SV15VT

Maximum tractive force Rubber track kN 13,3

Item Unit SV15VT

Number of pumps pcs. 2

Item Unit SV15VT

Item Unit SV15VT

Displacement cm3/rev 195

Displacement (Low/High) cm3/rev 245 (Low)/ 490 (High)

Type - Counterbalance valve

Type of reduction gear - -

Hydraulic oil tank

Suction filter Filtration area cm² 440

Filtration area cm² 925

Swing bearing - Planetary gear

Item Unit SV15VT

Item Unit SV15VT

Number of cylinders - Bore × Stroke pcs - mm × 3 - 70 × 74

Total displacement cm3 854

Rated output / engine speed (GROSS) kW/rpm 12,1 / 2600

Maximum torque / engine speed (N•m/rpm) 48,1 to 52,4 / 1800

Specific fuel consumption 279 at rated output