Sk18 Shop Manuall

APPLICABLE No.
SK18 PFB1
Book code No. S5PFB101E01

(MMB38ENMA00100)
2016.04
{S5PFB101E01} {0711CsCshWbYs}
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.
(7) Use the jig for press-fitting the bearings, bushes and oil seals. When Sealing tape
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
*11
ø4
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 SV18

Main specifications of machine
Dimensions
Overall length
Standard 3660
(Transportation position)
Transportation position 2280
Overall height
Cabin Traveling position 2280
Full machine width 1320
Overall width mm
<retracted undercarriage> <980>
Transportation position 2205
Overall height
Canopy Traveling position 2205
Full machine width 1320
Overall width
<retracted undercarriage> <980>
Tumbler center distance (rubber track) 1200
Track gauge (Maximum / Minimum) 1090 / 750
Minimum ground clearance 160
Traveling performance
Travel speed Low speed km/hr 2,2

Rubber track
High speed km/hr 4,1
Permissible water depth limit mm 360
Work performance
Width (Standard) mm 300
Bucket [Standard. JIS heaped capacity] m3 0,03
Number of teeth / Installation method pcs. 3 / Bolt
Work range
Maximum With blade raised for cabin <canopy> mm 2580 <2580>
digging depth With blade on the ground for cabin <canopy> mm 2420 <2420>
Maximum depth of vertically digging for cabin <canopy> mm 2140 <2140>
Maximum dumping height for cabin <canopy> mm 2740 <2740>
Minimum front swing radius Cabin mm 1540
(with boom in front center) Canopy mm 1540
Minimum front swing radius Cabin mm 1340
(with boom in full swing) Canopy mm 1340
2-1-1
2. TECHNICAL DATA
Item Unit SV18

Main specifications of machine
Work performance
Rear end swing radius mm 980
Left degrees 40
Cabin
Right degrees 80
Boom swing angle
Left degrees 40
Canopy
Right degrees 80
Bucket kN 15,2
Maximum digging force
Arm kN 7,4
Low speed kN 17
Maximum tractive force
High speed kN 8,8
Maximum swing inclination angle (with standard bucket) degrees 20 or more
Swing speed rpm 10
Fuel consumption in practical Maximum idling speed L/h 2,4
operation Eco mode L/h -
Blade
Width × Height mm 980-1320 x 230
Capacity Side open / close cm3 0.066 / 0.049
Standard
Lift above ground level mm 240
Digging depth mm 300
Mean contact pressure
Cabin kPa 0,33
JIS Rubber track
Canopy kPa 0,3
Mass
Cabin kg 1900
Machine mass Rubber track
Canopy kg 1760
Cabin kg 1975
Operating mass Rubber track
Canopy kg 1835
2-1-2
2. TECHNICAL DATA
Item Unit SV18

Hydraulic equipment
Hydraulic pump
Engine → CF Coupling
Drive method -
→ Pump (Direct drive)
Type of main pump - Variable pump
Number of pumps pcs. 1
cm3/rev 23
Theoretical discharge volume
Maximum P.T.O. flow L/min 42,7
Control valve
Number of connected valves pcs. 5
System relief set pressure P1 MPa 10,2
Boom (at rod end) MPa 23
Boom (at bottom end) MPa -
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 23
Boom swing (at rod end) MPa -
Boom swing (at bottom end) MPa -
Blade (at rod end) MPa 10
Blade (at bottom end) MPa -
Extand (at rod end) MPa 10
Extand (at bottom end) MPa -
2-1-3
2. TECHNICAL DATA
Item Unit SV18

Hydraulic equipment
Cylinder
Stroke mm 415
Inside diameter mm 60
Boom Piston rod diameter mm 35
Up (Ground - Max. height) sec. 2,5
Speed
Down (Max. height - Ground) sec. 1,7
Stroke mm 450
Arm Piston rod diameter mm 35
Full stroke for digging sec. 2,1
Speed
Full stroke for dumping sec. 3,3
Stroke mm 317
Bucket Piston rod diameter mm 30
Full stroke for digging sec. 1,9
Speed
Full stroke for dumping sec. 2,4
Stroke mm 125
Blade Piston rod diameter mm 35
Up (Ground - Max. height) sec. 1,0
Speed
Down (Max. height - Ground) sec. 0,8
Stroke mm 295
Boom swing Piston rod diameter mm 35
Full stroke to the right rpm 9,7
Speed
Full stroke to the left rpm 9,7
Swivel joint
G 1/4 × 15
Swivel joint port diameter × Number inch × pcs.
+ G 3/8 × 8
2-1-4
2. TECHNICAL DATA
Item Unit SV18

Hydraulic equipment
Motor
Type - Orbit motor
Displacement cm3/rev 233

Swing motor
Type - Relief valve (F072-4)
Brake valve
Relief set pressure MPa 10 to 11,5
Variable displacement
Type -
piston motor
Displacement (Low/High) cm3/rev 16,8
Type - Counterbalance valve

Travel motor Brake valve
System pressure MPa 20
Shockless valve - -
Parking brake - -
Planetary gear
Type of reduction gear -
(reduction gear assy)
Hydraulic oil tank
Hydraulic oil amount (Tank capacity / Others) L 20 / 8,5
Type - Strainer
Suction filter Filtration area cm² 550
Filtration accuracy µ 125

Type - Bypass
Filtration area cm² 2200

Return filter
Filtration accuracy µ 15
By-pass valve opening pressure MPa 0,15
Locking device
Lever lock - Oil pressure controlled
Boom swing lock - Oil pressure controlled
Swing lock - Mechanical brake
Cut off valve
Number of valves pcs. 1
Relief set pressure (P4) psi (MPa) 3,5
Swing device
Planetary gear
Swing bearing -
(with reduction mechanism)
Swing motor shaft gear →
Power transmission -
Swing gear
Type of brake - Mechanical controlled
Brake mounting position - Swing motor
2-1-5
2. TECHNICAL DATA
Item Unit SV18

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 SV18

Engine
Main specifications
Engine model - 3TNV70-VBVA2
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 9,9 / 2100
Maximum torque / engine speed (N•m/rpm) 47,1 ~ 51,4
Specific fuel consumption g/kW•h 276
Maximum idling speed rpm 2135 to 2185

Minimum idling speed rpm 1225 to 1275
Forced lubrication
Lubricating method -
with trochoid pump
Compression pressure (at 250 rpm) MPa 3,24
Cylinder head
Open b TDC degrees 7 to 17
Intake valve timing
Close a BDC degrees 35 to 45
Open b BDC degrees 35 to 45
Exhaust valve 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
Ring shape - Keystone
First compression ring
Ring quantity pcs. 3
Ring shape - Tapered face
Second compression ring
Bevel cutter
Ring shape -
Oil-ring (with coil expander)
2-1-7
2. TECHNICAL DATA
Item Unit SV18

Engine
Governor
Name - -
Type - Centrifugal-all speed governor
Fuel feed system
Filter paper with automatic air
Fuel filter -
release device
Fuel filter filtration area cm² 432
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 71
Thermostat full-open temperature ºC 85
Radiator cap pressure MPa 88,3
Radiator fan pcs.×Ømm 5 × 290
Operating temperature of water temperature alarm switch ºC 107 to 113
Air cleaner
Type - Cyclone type
Filtration area cm² 4400
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 14 to 16
Firing order - 1-3-2
Nozzle
Type NP-DN0PDN 161
Nozzle hole diameter × Number of holes mm × pcs. 1.0 × 1
Spray angle degrees 5 to 10
Fuel injection pressure MPa 12.3 to 13.28
2-1-8
2. TECHNICAL DATA
Item Unit SV18

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 12-36
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 12 - 6
Horn V-W 12 - 18
Blade fuse A × pcs. 40 x 2, 30 x 1, 25 x 1, 20 x 1,
Fuse 15 × 2, 10 × 1, 5 × 2
Slow blow fuse A × pcs. 60 × 4, 50 x 1
Boom light V-W 12 - 27
Room lamp (for cabin) V-W -
Wiper motor (for cabin) V-W -
Cabin heater (for cabin) V-W 12 - 110
Cigarette lighter (for cabin) V-W 12 - 120
2-1-9
2. TECHNICAL DATA
2-2 Outline Drawing and Working Area
Unit : mm
A 355 P 3660
B 400 Q 3950
C 635 R 4040
D 165 S 2580
E 245 T 770
F 980–13201 U 2140
G R980 V 2420
H <swing> 1540 <1340> Y 2740
I 240 Z 3760
K Cabine / 2250 190

Canopy AA
L 300 AB 230
M 1095 AC 750–10901
N 1560 AD 980–13201
1. Lower frame extended
2-2-1
2. TECHNICAL DATA
2-3 Weight List of Main Parts

[Unit: kg]
SV18
Equipment No. Part Canopy Cabin
Front implement
1 Bucket Ass’y 32
3 5
2 Bucket arm & link Ass’y 7,8
3 Bucket cylinder Ass’y 10,3
2 4 4 Arm Ass’y 37,7
5 Arm cylinder Ass’y 16
7 6 6 Boom Ass’y 55,3

1 7 Boom cylinder Ass’y 15,8
8 8 Boom bracket Ass’y 24,2
017463-00X01
Undercarriage 1 Idler Ass’y 16,5 x 2

2 Track adjuster Ass’y 3,5 x 2
3 Track roller Ass’y 4x6
6 11 5 12 8 9 4 Sprocket Ass’y 6x2
5 Track guide Ass’y 0,6 x 2
6 Track frame Ass’y 204,4
7 Rubber track Ass’y 51,5 x 2
8 Blade cylinder Ass’y 7,5
9 Blade Ass’y 80
10 Travel motor Ass’y 25 x 2
10 4 7 3 2013866-00X
1 11 Swing bearing Ass’y 18,1
12 Swivel joint, hose & fitting Ass’y 16
Upperstructure 1 Engine hood Ass’y 5,4
2 Canopy/Cabin Ass’y 81,5 / 230
3 Hydraulic oil tank with filter Ass’y 9,8
4 Operator's seat & mount Ass’y 71,4
5 Engine Ass’y 110
6 Turning frame Ass’y 247,2
7 Control valve, fitting & hoses Ass’y 30
8 Controls Ass’y 5
9 Battery Ass’y 12
10 Covers, steps and panels Ass’y 25,5
11 Pump, mount & hoses Ass’y 7,5
12 Swing motor Ass’y 16
13 Counter weight Ass’y 103,4
- Fuel tank & piping 23
- Boom swing cylinder Ass’y 14,4
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
= Maximal load lifted by the machine
= Housing overload alarm value setting
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
= Maximal load lifted by the machine
= Housing overload alarm value setting
2-4-2
2. TECHNICAL DATA
2-5 Specifications for Attachment

Q Unit: in. (mm)
Item/Model SV18
Dimensions
A 109
R P
B 105
C 190
D 190
E1 External width of arm end boss 105
S E 1' Internal width of bucket pin boss 106
E2 External width of bucket link boss 105
J K E 2' Internal width of bucket pin boss 106
O E 3 External width of bucket arm pivot pin boss 105
O’
F1 External width of bucket arm 149
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 65
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 902
E3 K Cylinder length when it is fully extended 952
G3
M 5
G3’
b O 1055
O' 1160
C
I1 P 215
G3’ b
Q 128
R 558,5
H1
c S 153
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
○: Verification and adjustment ●: Replacement □: Cleaning ■: Greasing
Every Every
Every Every 1000h / 2000h /
Parts & Operations Daily Every 50h
250h 500h Every Every
year two years
Missing or broken parts ○

Tightening of nuts and bolts ○
General.
Motor state ○
Machine □
Transmissions Oil for travel gears ● 1st time ○ ●
Hydraulic oil ○ ●
Aspiration filter □
Hydraulic
circuit Hydraulic oil return filter ● 1st time ●
Operation of the accumulator ○
Greasing points ■
Greasing
Rotation pin and crown ■
Bearing rollers and bearings, ■
idler wheels
○
Chassis
Track tension ○
Headlights, horn, travel alarm ○
Electrical
equipment Dashboard and indicators ○
System state ○
Water separator ○
GO filter ● ●
Air filter (dusty atmosphere
every 250 h)
●
Engine oil ○ ● 1st time ●*
Oil filter ● 1st time ●*
Engine
Cooling fluid ○ ●
Belt ○ ●
Radiator vents ○ □
Fuel hose, coolant hose ●
Intake and exhaust valves ○
Injectors and injection pressure ○
Heating ○
*. Every 500h / Every year

2-6-1
2. TECHNICAL DATA
Periodic servicing points of the machine (greasing, filtres...)
= Hydraulic oil
= Engine oil
= Hydraulic oil return filter
= Side movement reducers
= Greasing points
= Air filter
= Fuel filter
2-6-2
2. TECHNICAL DATA
2-7 Fuel, Lube Oil and Grease Recommended
Temperatures °C
Components Fluid Quantity prescribed (L)
- -20 -10 0 10 20 30 +
SAE 10W CD
Thermal engine Engine oil SAE 10W-30CD 2,8 –
SAE 15W-40CD
Side movement SAE 90 (GL-4) 0,5 by reducer
Box oil
reducers
20,0 in the tank
Hydraulic circuit Hydraulic oil ISO VG46
8,5 the rest
N° 2-D
Fuel tank Diesel N° 3-D 24,5 –
N° 3-D (S)
3,2 radiator
Cooling system Diluted long lasting cooling fluid YANMAR POWER
COOLANT B–36 0,4 expansion flask
2-7-1
SWING MOTOR DRIVE MOTOR L DRIVE MOTOR R
233cm 3/rev 16.8/8.7cm3 /rev. PS PS 16.8/8.7cm3 /rev.
T T BOOM SWING CYL ARM CYL

T BLADE CYL 65x 35x295 BOOM CYL 55x 35x450 BUCKET CYL
60x 35x125 60x 35x415 55x 30x317
P2 P2 1
1
10 6 4 9 1 10
MPa 36.8 P1 5 3 7 2 8 P1 36.8
EXTAND CYL C F G A
D B Dr E
H
A DR B 60x 35x340 SWIVEL
(CW) (CCW)
JOINT
SELECTOR VALVE
C1
P1 C2
C4
OIL P2 C3
COOLER
2-8 Hydraulic Circuit Schematic
PTO
(BOOM END)
BOOM TRAVEL TRAVEL

M Pil Pb1 B1 A1 ARM Pb2 B2 A2 SWING Pb3 B3 A3 BUCKET Pb4 B4 A4 BOOM B5 A5 BLADE Pb6 B6 A6 OPTION Pb7 B7 A7 SWING B8 A8 LEFT B9 A9 RIGHT
P
b b b
2-8-1
LS
TAP
a a a
196 bar
T
T B A T T B
A T T B T B A T
230 bar 230 bar 230 bar 100 bar

P CUT-OFF VALVE
Pa1 Pa2 Pa3 Pa4 Pa6 Pa7
3.5 MPa
2. TECHNICAL DATA
A PILOT VALVE,R
PILOT VALVE,L T
2 SPEED SAFETY P P T
ACCUMULATOR
p0:15Bar SELECTOR
v0:0.32L 4 2 1 3 3 1 2 4 VALVE
T R2 R1
C4 P2
C1 P1
C3
C2
A B
L
PROPORTIONAL VALVE
M
ENGINE
PUMP 3TNV70VBVA2
23cm3/rev 9,5kW HYD.TANK
2100 rpm
SUCTION FILTER RETURN FILTER

125µ 15µ
2. TECHNICAL DATA
2-9 Wiring Diagram
2-9-1
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
3-3-2 Steel Track Specifications.......................................................... 3-3-2
3-3-3 Common Specifications of Steel & Rubber Crawlers................. 3-3-4
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........................................................................................ 3-7-5
3-7-3 Tightening Torque for General Bolts and Nuts .......................... 3-7-6
3-7-4 Hydraulic Fitting ......................................................................... 3-7-7
3-8 Pressure Adjustment .......................................................................... 3-8-1
3-8-1 Relief Valves .............................................................................. 3-8-1
3-8-2 Swing Brake Valve..................................................................... 3-8-4
3-8-3 Cut-Off Valve ............................................................................. 3-8-5
3. SERVICE STANDARDS
3. Service Standards
3-1 Machine Performance
Applicable model SV18

Item Measuring condition Unit Standard Allowable
Machine performance
Working speed
Boom speed Machine position
Max. cylinder extension Up 2,4 2,6

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

• Hydraulic oil temp.: 50 to 60°C Down 1,7 1,8
Bucket teeth grounded
• Excluding cushion
• Site: Firm, flat ground
Arm speed Machine position
Max. cylinder retraction Extend 2,1 2,5
No load
sec.
013869-00E
• Engine: Rated speed Retract 3,3 3,5

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

• Hydraulic oil temp.: 50 to 60°C
Boom swing speed Machine position
Right
2,8 3,6
Max. cylinder retraction swing
013871-00X sec
Left
• Hydraulic oil temp.: 50 to 60°C 2,7 3,3
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 1,0 1,1
sec.
013872-00E
• Engine: Rated speed Down 0,8 0,9

Blade grounded
• Hydraulic oil temp.: 50 to 60°C
Machine position
High
32,2 -
speed
Travel speed sec.

013959-00E
• Engine: Rated speed Low

17,5 -
• Hydraulic oil temp.: 50 to 60°C speed
• Traveling time for 20 m after an
approach run of 5 m or more.
Machine position
High
90° to 105° 8,1 -
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
15,6 -
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
013959-00E

• Hydraulic oil temp.: 50 to 60 °C mm / <300 600
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.
20 m
X
10 m
013961-00E
Machine position
Traveling drift 15° mm <120 180

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
14 25
(Cylinder rod retraction)
Same
Arm drift No load
height
11 20
(Cylinder rod extension) 013963-00E
mm
• Engine: stopped
Bucket drift • Hydraulic oil temp.: 50 to 60 °C 5 9
(Cylinder rod extension) • Site: Firm, flat ground
• Make the boom and bucket pins the same height.
• Measure the retraction or extension of each
cylinder rod after leaving the machine at the
Blade drift above position for 10 min.
5 9
(Cylinder rod extension) • Lift the blade to the highest position, and
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 <5
013964-00E 8
(Cylinder rod extension)
• Engine: stopped
• 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 degrees <30 45

• 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 sec./
No load 5 turns 30 34.0
height
Swing time 013965-00E
[rpm] [9,7] [9,9]

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

Machine performance
Machine position
No Same
load height Engine stop: 0
15°
013964-00E
Swing drift mm
• Engine: stopped
• Park the machine on a slope with an inclination of 15
degrees and turn the upperstructure 90 degrees to the Engine running: <40
crawler. (< 10°)
• 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-VBVA2

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
Valve stem outside diameter mm 5,96 to 5,975 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 5,945 to 5,960 5,9
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
Intermediate Camshaft outside diameter mm 39,910 to 39,935 39,875
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 to 0,6 -
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 “4-2-8. 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
[Unit: mm]

Measuring
Part Standard Wear limit
position
Rubber track specifications
(1) Rubber track
A 17 8
A
048504-00X00
(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
013971-00X
(2) Track roller & shaft

A Ø25 −
D
B Ø52 −
C Ø67 -
B C E
D 58 -
A
048593-00X00
E Ø130 -
(5) Slide plate
A 42,5 37,5
3-3-4
3-4 Controls

Item Measuring conditions Unit Standard Allowable limit
Controls
Operating force
Right control lever • Engine : stopped up: 1
(Boom & Bucket) • Hydraulic oil temp. : 122 to 140 °F (50 to 60 °C) down: 1,2
• Lever operating force : Measure the force by left: 1,1
hanging the spring scale on the lever grip. right: 1
• Pedal operating force : Measure the force by
Left control lever applying load as shown below. up: 1
(Arm & Swing) down: 1,3
Spring scale Press
kg left: 1,2
right: 1,1
high < low engine speed>7,5
Accelerator lever
low < high engine speed> 8,5
Blade lever up: 3,5 / down: 2,5

Travel levers 1,5
Play of control lever & pedal
Right control lever • Engine : stopped up: 100
(Front & rear / left & right) • Hydraulic oil temp. : 122 to 140 °F (50 to 60 °C) down: 80
• Play of each control lever and pedal : left: 70 10 or less
Left control lever
Measure the total play (front, rear, left and right) right: 70
(Front & rear / left & right)
at the lever grip end or the pedal end.
up: 22
Blade lever Play Play 20
mm down: 30
forward: 80
Right travel lever 8
backward: 80
forward: 70
Left travel lever 8
016253-00E backward: 65
high>down:175 10
Accelerator lever
down>high: 175
Control valve
Spool stroke
Boom
AB
Stroke
Bucket
Arm
Swing
Parallel-flow divider
Inlet
013982-00E
mm 6 6
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)

037112-00E02
Unit: mm
Cylinder Track gauge
Boom Arm Bucket Boom swing Blade
No. change
1 675 902 554 550 360 551
2 415 450 317 295 125 340
3 72 265 64 81 82 49
4 Ø 60 Ø 55 Ø 55 Ø 65 Ø 60 Ø 60
5 Ø 35 Ø 35 Ø 30 Ø 35 Ø 35 Ø 35
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 3/8 G 1/4 G 1/4 G 1/4 G 1/4
Standard Ø 35 Ø 30 Ø 30 Ø 40 Ø 30 Ø 35
7-1
Allowable limit Ø 35.5 Ø 30,5 Ø 30,5 Ø 40,5 Ø 30,5 Ø 35,5
Standard Ø 35 Ø 30 Ø 30 Ø 40 Ø 30 Ø 35
7-2
Allowable limit Ø 35,5 Ø 30,5 Ø 30,5 Ø 40,5 Ø 30,5 Ø 35,5
Thread size M24 x 3 M24 x 3 M20 x1,5 M24 x 3 M22 x 2 M22 x 2
Tightening torque (N•m) 490 to 588 490 to 588 294 to 343 490 to 588 220 to 250 220 to 250
Screw locking agent Loctite 242 / Three Bond 1324
Until serial Number ( →│~ ) PFB1-601520

8
Thread size M22 x 1,5 M24 x 1,5 M22 x 1,5 M24 x 1,5 M24 x 1,5 M24 x 1,5
Tightening torque (N•m) 380 to 420 380 to 420 380 to 420 380 to 420 380 to 420 380 to 420
Screw locking agent Loctite 262 / Three Bond 1324
From serial Number ( ~│→ ) PFB1-604587
Symbol Name
G (PF) Straight pipe thread
R (PT) Taper pipe thread (male)
Rc (PT) Taper pipe thread (female)
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
SV18 Pin Bore of bush or hole
1 Boom swing fulcrum Ø50
2 Boom fulcrum Ø35
3 Boom swing cylinder, rod Ø40
4 Boom swing cylinder, bottom Ø40
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
2 3
013512-00X
Unit: mm
Applicable model Wear limit

No. Measuring point
SV18 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 10 46 to 54
2 Engine × Engine mount (Front Left) M10×25 67 to 79 ThreeBond 1324
3 Engine × Engine mount (Front Right) M10×25 67 to 79 ThreeBond 1324
4 Engine × Engine mount (Rear Left) M10×25 67 to 79 ThreeBond 1324
5 Engine × Engine mount (Rear Right) M10×25 67 to 79 ThreeBond 1324
6 Engine mount × Stopper (Left) M10×20 46 to 54 ThreeBond 1324
7 Engine mount × Stopper (Front Right) M10×20 46 to 54 ThreeBond 1324
8 Air cleaner M8×16 23 to 27
9 Air cleaner intake hose Hose clip 60 2,5 to 3,5
10 Radiator hose Hose clip 25 2,5 to 3,5
11 Radiator hose Hose clip 35 2,5 to 3,5

M5×16
12 Fuel level gauge unit 1,9 to 2,0
(Pan head screw)
13 Fuel oil tank hoses Hose clip 16 2,5 to 3,5
14 Fuel oil tank drain plug Hose clip 16 2,5 to 3,5
2,45 to 2,94)
Nut 10 <For tension>
15 Fuel oil tank holding band
46 to 54
Nut 10 <For Lock nut>
2,45 to 2,94)
Nut 8
<For tension>
16 Battery holding rod
Nut 8 23 to 27
<For Lock nut>
17 LCD monitor × Panel cover M6×20 1,0 to 1,5
18 Panel cover (lower) × Panel cover (upper) M5×16 2,55 to 3,3
19 Safety switch (Travel speed) Locknut (Fine thread) 20 19.6 to 24.5
20 Safety switch (Cut-off lever) Locknut (Fine thread) 20 19.6 to 24.5
21 Accelerator dial (holding nut) M6 5.5 to 6.5
3-7-1

Travel device
1 Idler screw plug R1/8 6,9 to 8,8 Loctite 572
2 Nipple valve M16 49 to 54,2
3 Sprocket M10x30 67 to 79 ThreeBond 1324
4 Idler seal cover × Track tension spring M10×35 46 to 54 ThreeBond 1324
5 Track roller M10x25 10.9T 67 to 79 Loctite 262 or K-965
Controls
M4 × 8
1 Grip × Travel lever (L, R), blade lever 1,77 to 2,55 ThreeBond 1324
(Binding head screw)
2 Lever (L, R) × Remote control valve Locknut 14 55 to 61 ThreeBond 1324
3 L-ball/Link ball (Link arm holding) Nut 8 23 to 27
4 L-ball/Link ball (Link rod locking) Nut 8 23 to 27
5 Control valve plate × Turning frame M10×20 46 to 54 ThreeBond 1324
Frame
1 Swing bearing × Track frame M12×50 116 to 138 Loctite 262 or K-965
2 Swing bearing × Turning frame M12×45 116 to 138 Loctite 262 or K-965
3-7-2

Rigging
1 4-pole canopy × Turning frame M16x40 (10.9T) 291 to 339 ThreeBond 1324
2 Cabin × Turning frame M16x90 (10.9T) 291 to 339 ThreeBond 1324
3 Under cover × Track frame M10x25 46 to 54 ThreeBond 1324
4 Key lock plate × Key cylinder U nut 10 7,9 to 11,8
5 Bonnet B × Key cylinder U nut 10 7,9 to 11,8
6 Bonnet B × Hinge CMP M6×12 9,5 to 11,5
Hydraulic equipment
CHC M10 × 20
1 CF coupling 49 to 58.8 ThreeBond 1324
(Allen head screw)
2 Swivel joint × Track frame M10×30 46 to 54 ThreeBond 1324
3 Travel motor × Track frame M10×35 46 to 54 ThreeBond 1324
4 Swing motor × Turning frame CHC M12×40 116 to 138 ThreeBond 1324
5 Hydraulic oil tank × Turning frame M12x25 79 to 93 ThreeBond 1324

Hydraulic oil level gauge ×
6 M12 8 to 10
Hydraulic oil tank
7 Drain plug × Hydraulic oil tank M16 7

Water temp sensor (w/seal washer) M12 × 1.5
8 20 to 24
× Hydraulic oil tank (Fine Thread)
9 Hydraulic hose Hose clip 60 2,5 to 3,5
3-7-3

Implement
1 Boom fulcrum pin lock plate M10×20 67 to 79 ThreeBond 1324
2 Arm fulcrum pin lock plate M10×20 67 to 79 ThreeBond 1324
3 Boom cylinder bottom end pin lock plate M10x16 46 to 54 ThreeBond 1324
4 Boom cylinder rod end pin lock plate M10x20 67 to 79 ThreeBond 1324
Boom swing cylinder bottom end pin lock

5 M10×20 46 to 54 ThreeBond 1324
plate
6 Boom swing cylinder rod end pin lock plate M12×25 79 to 93 ThreeBond 1324
7 Arm cylinder bottom end pin lock plate M10x20 67 to 79 ThreeBond 1324
8 Arm cylinder rod end pin lock plate M10x16 46 to 54 ThreeBond 1324
9 Bucket cylinder bottom end pin lock plate M10x16 46 to 54 ThreeBond 1324
10 Blade fulcrum pin lock plate M10×25 46 to 54 ThreeBond 1324
13 Blade cylinder pin lock plate M10x25 46 to 54 ThreeBond 1324
14 PTO tube clamp × Boom M8x40 37 to 40 ThreeBond 1324
3-7-4
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
3-7-5
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
3-7-6
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 (female)
37°
(male 37° sheet)
Unit : N•m
screw thread
Example
7/16-20UNF 17,7 to 21,6 Unified screw thread (female) Unified
(male 37° sheet)
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
3-7-7
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: 49.0 MPa
2) Relief Valve Specification
[Unit: MPa at max rpm]

Set pressure
Control valve
SV18
Primary relief valve P 19,6
Boom (rod end) B4 23
Boom (bottom end) -
Arm (rod end) -
Arm (bottom end) A1 23
Bucket (rod end) -
Secondary relief valves
Bucket (bottom end) B3 23
Boom swing (rod end) -
Boom swing (bottom end) -
Blade (rod end) A5 10
Blade (bottom end) -
3-8-1
3) Measuring points on the primary relief valve
(1) Open rear bonnet 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

(P) in the control valve, retract the bucket cylinder to
its stroke end, hold the lever and read the gauge.
4) Adjustment Procedure on the primary relief valve
The pressure of the hydraulic circuit sets through the primary relief valve of the control valve.
WARNING
The pressure is factory setting, all necessary adjustment must be done by YANMAR dealer.
(1) Remove floor mat 1 and step 2.
(2) Open the rear bonnet 3.
(3) Remove the left cover of the machine 4.
(4) To adjust the pressure of the hydraulic circuit, it is

necessary to break the plastic cap 5 on the control
valve.
(5) Adjust the pressure if necessary by turning the

adjusting screw a on the hydraulic control valve until
you reach the correct pressure.
a
Clockwise
(for increase in pressure)
Counterclockwise
(for reduction in pressure)
3-8-2
(5) Measuring points on the secondary relief valves
(1) Open rear bonnet 1.
(2) Remove the plug from the pressure port 2 and

install the oil pressure gauge.
(3) To check the pressure of a secondary relief valve it

is neccessary to increase the pressure of the primary
relief valve to 24MPa.
Operate the PTO function and adjust the primary relief
valve pressure, following (4) Adjustment Procedure
on the primary relief valve, page 3-8-2 .
(4) Operate the corresponding hydraulic function to

check the pressure of the required secondary relief
valve.
Important:
If the checked pressure is not correct it is necessary to replace the secondary relief valve assembly.
See 6-2-6 Distribution Element Repair Procedure, page 6-2-8.
Note
the secondary relief valve can not be adjusted but replace only.
(5) When the operation of measurement on the secondary relief valve is complete, adjust the primary relief valve
to its operating pressure. See (4) Adjustment Procedure on the primary relief valve, page 3-8-2
3-8-3
3-8-3 Cut-Off Valve
1) Conditions
(1) Engine: rated speed
(2) Hydraulic oil temperature: 50 to 60°C
(3) Set pressure: 3.5 MPa
2) Measuring Procedure
(1) Remove floor mat 1 and step 2.

(2) Open the rear bonnet 3.
(3) Remove the left cover of the machine 4.
(4) Remove the fitting 5 and install a Tee fitting

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

position, and read the gauge.
3) Pressure Adjustment Procedure
WARNING
The pressure is factory setting, all necessary adjustment must be done by YANMAR dealer.
1 (1) To adjust the pressure of the hydraulic circuit, it is

necessary to break the plastic cap 1 on the cut-off valve.
(2) Loosen the lock nut 2.
(3) Turn the adjust screw 3 to adjust the pressure to

the specified value.
(4) After adjustment, hold the adjust screw 3 and tighten

the locknut 2.
Clockwise
(for increase in pressure)
2 Counterclockwise
(for reduction in pressure)
3-8-5
CHAPTER 4
ENGINE
This chapter explains the engine proper and is a faithful of YANMAR DIESEL ENGINE'S service manuals.
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
injury.
A
with most safety statements. It
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.
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
0000191
guides (Figure 4-2-10, (1)) out of the cylinder
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

A
Adjust the fuel injection timing after installation. 5
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)
(6)
0002238
(5)
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
A
A
5
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
-G
(3)
(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
into a suitable container to catch the fuel spray . .5 MPa; 5 kgf/cm2 higher than one
(Figure 4-3-31). that has been operated 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
3.43 ± 0.1 MPa; 35 ± 1 kgf/cm² 2.75 ± 0.1 MPa; 28 ± 1 kgf/cm² 0.2 to 0.3 MPa; 2 to 3 kgf/cm²
Engine Speed and Compression Pressure (Use for Reference)
Engine speed (min-1)
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
4. ENGINE
This Page Intentionally Left Blank
4-9-5
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
4-9-6
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
4-9-7
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
4-9-8
4. ENGINE
4. ENGINE
4-9-9
CHAPTER 5
ELECTRIC SYSTEM
5-1 Electric Equipment of Machine ........................................................... 5-1-1

5-1-1 Electric Equipment of Machine .................................................... 5-1-1
5-1-2 LCD Monitor and Alarm Systems............................................... 5-1-5
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............................................................................ 5-2-3
5-3 Error Code List .................................................................................... 5-3-1
5. ELECTRIC SYSTEM
5. Electric System
5-1 Electric Equipment of Machine
1) Harness A
5-1-1
5. ELECTRIC SYSTEM
2) Harness B and C
5-1-2
5. ELECTRIC SYSTEM
3 &DELQ
5-1-3
5. ELECTRIC SYSTEM
Ref. No. Part Ref. No. Part

1 Battery 32 Thermo-switch
2 Cut-circuit 33 Temperature sensor

3 Starter motor 34 Oil pressure switch
4 Slow-blow fuses 35 Engine-stop solenoid
5 Fuel gauge sensor 36 Glow plug
6 Fuel feed pump 37 Hydraulic oil temperature sensor
7 Generator 38 Boom swing / P.T.O.1 selector valve
8 Fusebox 39 P.T.O.1 valve
9 Buzzer 40 Travel alarm (option)
10 Timer (1s) 41 12V power outlet
11 Relay 42 Wiper motor
12 Safety relay 43 Washer pump
13 Relay timer, stop solenoid 44 Radio (option)
14 Glow relay 45 Speaker harness
15 Glow timer (15s) 46 Cabin lamp (front)
16 LCD monitor assembly 46-a Rear cabin lamp (option)
17 Starter switch 46-b Beacon (option)
18 Harness C 47 Room lamp
19 Joystick, right 48 Earth
20 Cut-off switch 49 Safety valve pressure switch (option)
21 Rear light (option) 50 Track extension selector valve
22 To Cabin harness 51 Relay heater
23 Second speed switch 52 Relay PTO/Swing
24 Boom light switch 53 Relay add power
25 Wiper and washer pump switch A To harness A
26 Heater switch B To harness B
27 Boom swing / P.T.O.1 switch
28 Track extension switch
29 Cut-off valve
30 Horn
31 Boom lamp
5-1-4
5. ELECTRIC SYSTEM
/&'0RQLWRUDQG$ODUP6\VWHPV
For safer machine operation, the operator needs to have a clear understanding of the machine's condition. However,
it is difficult for the operator to keep an eye on every aspect of the machine he/she is operating.
Therefore, gauges and alarms are installed to warn the operator of any trouble of the machine at the early stage.
Note:
The monitors do not give a full assurance of the machine's condition. The indications shown on them should be used
as a guide for daily check and periodic maintenance according to the operation and maintenance manual.
3DUW1DPH
LED lamps
Caution lamp
Warning lamp Information lamp

Direction indicator lamp
Direction indicator lamp (right)
(left)
Battery charge lamp
Hydraulic oil temp. lamp
High speed travel lamp Engine oil pressure lamp
Low speed travel lamp
Clock AM 10:00 LCD screen
Hour meter h
1234.5
Fuel meter
Engine water temp. meter
Menu switch
Function switches
menu F1 F2 F3 F4
F4 switch
F1 switch
F3 switch
F2 switch 047257-02EN01
5-1-5
5. ELECTRIC SYSTEM
$ODUP6HQVRU)XQFWLRQ
• When the starter switch is turned to the ON position, relevant LED lamps should come on and the buzzer should
sound for a few seconds, then the lamps should go out and the buzzer should stop.
• The battery charge and engine oil pressure lamps should stay on until the engine is started.
• All the LED lamps should remain off while the engine is running.
,QWKHHYHQWRI0DFKLQH)DLOXUH
In the event of machine failure, icon(s) and error code(s)
corresponding to the failure(s) are displayed on the LCD
screen and the warning and/or caution lamps flash, where
applicable.
For details of error codes, refer to Section 5-5.
00 000110.00
AM
10:00
h STOP
1234.5
PHQX ) ) ) )
046905-00X00
6HQVRU2SHUDWLRQ
(1) Oil pressure switch (for detecting low engine oil pressure)
When the engine oil pressure falls, the lamp comes on and
the buzzer sounds.
Starter switch Engine start

ON
Lamp
Lamp OFF
Engine oil ON Lamp
Buzzer sounds
pressure ON
Normal
Pressure drop
< 0.04 to 0.06 MPa
041589-01EN00
When this switch detects low engine oil pressure, it causes

the engine oil pressure warning lamp on the LCD monitor to
come on and the buzzer to sound.
• Working pressure: 0.04 to 0.06 MPa PT1/8
• Installation position: Engine block
Terminal 24 mm
5-1-6
5. ELECTRIC SYSTEM
If the buzzer sounds, the following items must be checked.

• Engine oil degradation
• Oil filter element clogging
• Oil pressure switch malfunction
For details of the inspection procedure, refer to Section 4-4-4 of Chapter 4 “Engine.”
• Pressure regulator malfunction
• Lube oil pump wear or breakage
(2) Water temperature sensor

This sensor displays the temperature of the engine cooling water.
If the temperature of the engine cooling water rises abnormally during operation of the machine, the water tempera-
ture meter and the warning lamp flash and the error code and icon that indicate an abnormal cooling water tempera-
ture are displayed and at the same time the buzzer sounds.
Starter switch
ON
Lamp goes out two seconds later.
Lamp
Engine start Buzzer sounds
ON
Lamp Lamp
Engine oil ON OFF
pressure Water temperature rise
> 107 to 113 °C
Normal
044688-01EN00
Turned on: Cooling water temp.: 107 to 113°C M16×1.5(fine)

21 mm
Turned off: Cooling water temp.: 100°C or less Installation
position: Cooling water pump on engine
If the buzzer sounds, checks must be carried out in accordance

with Section 4-3-5 of Chapter 4 “Engine” and Chapter 8 “Trou-
bleshooting.”
(3) Battery charge

When a potential difference occurs between the output voltage of the alternator and the voltage of the battery, the
battery charge lamp comes on and the buzzer sounds, and at the same time, the caution lamp flashes.
Starter switch Engine start Lamp

ON Lamp Buzzer sounds.
ON
OFF
Lamp
Alternator’s Battery
ON
terminal voltage voltage
Normal Potential difference

(Voltage drop) 041593-01EN00
If the buzzer sounds, the following items must be checked.

• Battery degradation or malfunction
• Refer to Section 3-2 “Circuit Description of Engine Start, Stop and Battery Charging.”
5-1-7
5. ELECTRIC SYSTEM
(4) Fuel meter

When the starter switch is turned to the ON position, the fuel
meter is activated and indicates the fuel level in the fuel tank.
When the fuel level in the tank becomes low, the fuel meter
and the caution lamp flash. 050809-00X00
The remaining fuel level indication can change depending

on the inclination of the machine body, which does not con-
stitute a malfunction.
)XHOJDXJHXQLW
Full : 24,5L Half: 15L 1/6: 6L
Reserve: 6L Full
Float position 5HVLVWDQFHȍ

91.3
Full 9.5~11.0
1/2 29.0~35.0
Empty 78.0~92.0
69.6
Empty
(5) Hour meter

When the starter switch is turned to the ON position, the
hour meter is activated.
h
(6) Hydraulic oil temperature sensor

1234.5
046874-00X00
This sensor measures the hydraulic oil temperature in the

hydraulic oil tank.
M12×1.5(fine)
Hydraulic oil tank
19 mm
5-1-8
5. ELECTRIC SYSTEM
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
Turn the starter switch to "ON" posi- The starter switch B is always supplied with power from the battery.
tion. (Battery → Slow blow fuse <Main> → Starter switch B)
The timer (1s) is supplied with power. Starter switch B → Starter switch BR1 →Lead wire B → Fuse 15A →
Lead wire R/Y → Timer (1s) R
The relay is supplied with power from Timer (1s) R → Lead wire R/W & Y → Relay 31, Relay 32 → Timer (1s) A
the timer (1s) and the relay solenoid is
excited.
The relay works to connect its termi- The Relay timer 1C is always supplied with power from the battery through the
nals 1C and 6. slow blow fuse (Start).
The stop solenoid G (Pull) is supplied The stop solenoid H (Hold) is supplied with power when the starter switch is in ON
with power from the relay 6 to press position.
the engine control lever.
In about one second after the starter switch is turned to ON position, the timer works
Power supply to the stop solenoid P to cut off power to the stop solenoid P. However, the stop solenoid H is still supplied
(Pull) stops. with power as long as the starter switch is in ON position, so that the engine control
lever stays pressed.
The starter motor B is always supplied with power from the battery. Also, the safety
Turn the starter switch to
relay B (2P coupler) is supplied with power from the battery through the slow blow
"START" position.
fuse (Starter) and lead wire R/L.
Starter switch BR1 → Fuse 10A → Safety relay ACC (4P coupler)
The safety relay works. Starter switch C2 → Relay 17, 39 → Safety relay C (4P coupler)
The safety relay S (2P coupler) and The magnet switch of the starter motor works to allow the pinion gear to jump out
the starter motor S in order are and engage the ring gear on flywheel. At the same time, the crankshaft of the
charged to run the starter motor. engine rotates and the engine starts to run.
The alternator 12A (P terminal) and safety relay P (4P coupler) are connected via
the diode. When the engine speed reaches the rated one, the signal from the alter-
The primary function of the safety
nator flows to the safety relay and cuts off the connection between the safety relay
relay works.
S (2P coupler) and the starter motor S, which causes the pinion gear to be pulled
back and the engine to be prevented from overrunning.
2. Engine Stop
Turn starter switch to "OFF" position.
The stop solenoid H (Hold) is stopped The engine control lever blocks fuel oil flow to stop the engine.
being supplied with power and the
engine control lever is pulled back.
5-2-1
5. ELECTRIC SYSTEM
5-2-2
5. ELECTRIC SYSTEM
%DWWHU\FKDUJH
The electric current generated by The electric current flows from the generator to the battery through the slow
the generator flows to the blow fuse (Charge) to charge the battery.
battery + terminal to be charged.
When the voltage generated by the alternator decreases, the logical circuit in the
The battery charge alarm calls alternator is turned on so that the terminal of the battery charge alarm in the LCD
for poor battery charging. monitor and that of the alternator are connected to raise alarm over poor charging.
(Generator → Lead wire W/G → LCD monitor 31)
5-2-3
Error code Classification Error description Detection condition Causes Corrective measures
00 000091.00 Caution Accelerator sensor malfunction: Sensor voltage is 4.6 V or Check the connectors, harnesses and engine
above normal operating range (SAEJ1843) more, or 0.2 V or less. • Connection failure of connectors
control dial.
• Defective accelerator sensor Turn the starter switch to the “OFF” position
00 000091.01 Caution Accelerator sensor failure: Sensor voltage is 4.6 V or and then to the “ON” position to check if the
below normal operating range (SAEJ1843) more, or 0.2 V or less. error code is displayed again.
00 000091.02 Caution Accelerator sensor malfunction: Sensor voltage is 4.6 V or • Connection failure of connectors
intermittent failure more, or 0.2 V or less.
• Harness wiring failure (nearly broken wiring of sensor signal line,
sensor 5 V line or sensor GND line)
3 (UURU&RGH/LVW
• Defective accelerator sensor
00 000091.03 Caution Accelerator sensor malfunction: short Sensor voltage is 4.6 V or • Connection failure of connectors Check the connectors, harnesses and accelerator
circuit to high voltage side more, or 0.2 V or less. sensor.
• Harness wiring failure (sensor GND line disconnected or sensor
signal line short circuited to power supply) Turn the starter switch to the “OFF” position and
then to the “ON” position to check if the error
• Defective accelerator sensor code is displayed again.
00 000091.04 Caution Accelerator sensor malfunction: short Sensor voltage is 4.6 V or • Connection failure of connectors
circuit to low voltage side more, or 0.2 V or less. • Harness wiring failure (sensor signal line disconnected or short circuited
to GND, or sensor 5V line disconnected or short circuited to GND)
• Defective accelerator sensor
00 000100.01 Warning Abnormal engine oil pressure Engine oil pressure • Low engine oil pressure Inspect the engine oil system. Check the
switch is on after • Defective engine oil system harnesses and engine oil pressure switch.
engine has started.
• Harness wiring failure (engine oil pressure switch wiring short circuited Turn the starter switch to the "OFF" position
and then to the "ON" position to check if the
to GND)
error code is displayed again.
• Defective engine oil pressure switch
5-3-1
00 000100.04 Warning Engine oil pressure switch failure Engine oil pressure switch is • Connection failure of connectors Check the connectors, harnesses and engine oil
off while engine is stopped pressure switch. Turn the starter switch to the
with starter switch in the "ON" • Harness wiring failure (engine oil pressure switch wiring
"OFF" position and then to the "ON" position to
position. disconnected or short circuited to power supply)
check if the error code is displayed again.
00 000110.00 Warning Engine coolant temperature sensor Sensor voltage is 4.8 V or • Engine overheating Inspect the engine cooling system. Check the
malfunction: too high more.
• Insufficient amount of engine coolant connectors, harnesses and coolant temperature
sensor. Turn the starter switch to the “OFF”
• Defective engine cooling system
position and then to the “ON” position to check
5. ELECTRIC SYSTEM
• Defective coolant temperature sensor system if the error code is displayed again.
00 000110.02 Warning Engine coolant temperature sensor Error undefined is • Connection failure of connectors Check the connectors, harnesses and coolant
malfunction: intermittent failure detected 10 times. temperature sensor. Turn the starter switch to
the “OFF” position and then to the “ON”
sensor 5 V line or sensor GND line)
position to check if the error code is displayed
• Defective coolant temperature sensor again.
00 000110.03 Warning Engine coolant temperature sensor malfunction: Sensor voltage is 4.8 V or • Connection failure of connectors
short circuit to high voltage side more.
• Harness wiring failure (sensor signal line disconnected or short circuited
topower supply, or sensor GND line disconnected)
• Defective coolant temperature sensor
00 000110.04 Warning Engine coolant temperature sensor Sensor voltage is 0.2 V or • Connection failure of connectors Check the connectors, harnesses and coolant
malfunction: short circuit to low less. temperature sensor.
voltage side • Harness wiring failure (sensor signal line short circuited to
Turn the starter switch to the “OFF” position and
GND or sensor GND line short circuited to power supply)
• Defective coolant temperature sensor code is displayed again.
00 000167.01 Caution Insufficient battery charge Battery charge switch is on • Low battery charge Inspect the battery charging system of the engine.
after engine has started • Defective alternator Check the harnesses and battery charge switch.
• Harness wiring failure (battery charge switch wiring short Turn the starter switch to the "OFF" position and
circuited to GND) then to the "ON" position to check if the error code
• Defective battery charge switch is displayed again.
00 000167.04 Caution Battery charge switch failure Battery charge switch is • Connection failure of connectors Check the connectors, harnesses and battery
off while engine is charge switch.
• battery charge switch wiring disconnected or short-circuited to
stopped with starter Turn the starter switch to the “OFF” position
switch in the "ON" position power supply)
and then to the “ON” position to check if the
• Defective battery charge switch error code is displayed again.
00 000190.00 Warning Abnormal engine speed: overspeed Engine speed increases over • Harness wiring failure (rack actuator line short circuited to GND) Inspect the engine and the harnesses on the
600 RPM more than the • Improper generation of rotation sensor signal pulse (incorrect machine body side.
maximum idling speed. wirring of rotation sensor) Check the rack actuator system.
• Overspeed due to rotations accompanying load from
implement side
code is displayed again.
• FOP control failure (rack actuator line short circuited to GND)
00 000100.01 Engine oil pressure switch • Low engine oil pressure Inspect the engine oil system. Check the
Warning Abnormal engine oil pressure
is on after engine has harnesses and engine oil pressure switch.
• Defective engine oil system
5-3-2
started. Turn the starter switch to the "OFF" position
• Harness wiring failure (engine oil pressure switch wiring short and then to the "ON" position to check if the
circuited to GND) error code is displayed again.
00 000638.02 Warning Engine: failure • Engine stalls during • Harness wiring failure (rack actuator line short circuited to Inspect the engine and the harnesses on the
machine operation with power supply or GND) machine body side.
malfunction of rack position Check the rack actuator system.
• Engine speed increase due to rotations accompanying load
sensor. Turn the starter switch to the “OFF” position and
from machine side
5. ELECTRIC SYSTEM
• Unexpected increase in then to the “ON” position to check if the error

engine speed is detected. • FOP control failure
00 000638.03 Warning Rack actuator malfunction: short Detected rack actuator current • Connection failure of connectors Check the connectors, harnesses and rack
circuit to high voltage side is above the upper limit. actuator.
• Harness wiring failure (rack actuator line short circuited to Turn the starter switch to the “OFF” position and
power supply) then to the “ON” position to check if the error
• Defective rack actuator code is displayed again.
00 000638.04 Warning Rack actuator malfunction: short Detected rack actuator current • Connection failure of connectors Check the connectors, harnesses and rack
circuit to low voltage side is below the lower limit. actuator.
• Harness wiring failure (rack actuator line disconnected or
short cir-cuited to GND) then to the “ON” position to check if the error
• Defective rack actuator code is displayed again.
00 000638.07 Warning Rack actuator malfunction: Specified operation is not Sticking of rack Check the connectors, harnesses and rack
mechanical failure performed in rack operation actuator.
check at start up. Turn the starter switch to the “OFF” position
and then to the “ON” position to check if the
00 001078.04 Warning Engine fuel injection pump • Engine speed cannot be • Connection failure of connectors Check the connectors, harnesses and rotation
rotation sensor detected although engine start sensor.
malfunction: short circuit • Insufficient engine speed (battery voltage reduction, defective starter
recognition (E8) is on. Turn the starter switch to the “OFF” position and
to low voltage side system, frozen fuel or increase of load from implement side accompanied
• Amount of instantaneous then to the “ON” position to check if the error code
by engine rotations)
decrease in engine speed is is displayed again.
• Harness wiring failure (sensor signal line disconnected or short circuited
over the rated value. to GND, or starter signal line short circuited to power supply)
00 001079.02 Caution Sensor 5 V malfunction: Detected monitoring voltage • Harness wiring failure (sensor 5 V line short circuited to GND) Check the harnesses.
intermittent failure is approx. 0 V. Turn the starter switch to the “OFF” position and
then to the “ON” position to check if the error code
is displayed again.
00 001079.03 Caution Sensor 5 V malfunction: Detected monitoring • Harness wiring failure (sensor 5 V line short circuited to power sup-ply Check the harnesses.
short circuit to high voltage is 5.5 V or more. or sensor GND line disconnected) Turn the starter switch to the “OFF” position and
voltage side then to the “ON” position to check if the error
00 001079.04 Caution Sensor 5 V malfunction: Detected monitoring • Harness wiring failure (sensor 5 V line short circuited to GND) Check the harnesses.
short circuit to low voltage voltage is 4.5 V or less. Turn the starter switch to the “OFF” position and
side then to the “ON” position to check if the error
00 000638.03 Warning Rack actuator malfunction: Detected rack actuator current • Connection failure of connectors Check the connectors, harnesses and rack
short circuit to high voltage is above the upper limit. • Harness wiring failure (rack actuator line short circuited to power actuator.
side supply) Turn the starter switch to the “OFF” position and
• Defective rack actuator
5-3-3
00 000638.04 Warning Rack actuator malfunction: Detected rack actuator current • Connection failure of connectors
short circuit to low voltage is below the lower limit. • Harness wiring failure (rack actuator line disconnected or short circuited
side
to GND)
00 000638.07 Warning Rack actuator malfunction: Specified operation is not Sticking of rack
mechanical failure performed in rack operation
check at start up.
5. ELECTRIC SYSTEM
00 001078.04 Warning Engine fuel injection pump Detected rack actuator current • Connection failure of connectors
rotation sensor is below the lower limit. • Harness wiring failure (rack actuator line disconnected or short cir-
malfunction: short circuit
to low voltage side cuited to GND)
00 001079.02 Caution
Sensor 5 V malfunction: Detected monitoring voltage is • Harness wiring failure (sensor 5 V line short circuited to GND) Check the harnesses.
intermittent failure approx. 0 V. Turn the starter switch to the “OFF” position and
Caution code is displayed again.
00 001079.03 Sensor 5 V malfunction: Detected monitoring voltage is • Harness wiring failure (sensor 5 V line short circuited to power supply or
short circuit to high 5.5 V or more. sensor GND line disconnected)
voltage side
00 001079.04 Caution Sensor 5 V malfunction: Detected monitoring voltage • Harness wiring failure (sensor 5 V line short circuited to GND)
short circuit to low voltage is 4.5V or less
side
00 001210.03 Warning Rack position sensor malfunction: short • Rack position sensor voltage • Connection failure of connectors Check the connectors, harnesses and rack
circuit tohigh voltage side is above the rated maximum actuator.
• Harness wiring failure (sensor GND line disconnected,
value in rack self-diagnosis. sensor signal line short circuited to power supply, or rack Turn the starter switch to the “OFF” position and
• Rack position related to rack actuator line short circuited to GND) then to the “ON” position to check if the error code
actuator output is above the • Defective rack position sensor is displayed again.
rated maximum value.
00 001210.04 Rack position sensor malfunction: short Rack position related to rack • Connection failure of connectors Check the connectors, harnesses and rack
Caution
circuit to low voltage side actuator output is below the actuator.
• Harness wiring failure (sensor signal line or sensor Turn the starter switch to the “OFF” position and
rated minimum value. 12 V line disconnected or short circuited to GND) then to the “ON” position to check if the error
• Defective rack position sensor code is displayed again.
00 522241.02 Caution Rack actuator relay malfunction: Unconfirmed error is detected • Connection failure of connectors Check the connectors, harnesses and rack
intermittent failure 10 times. • Harness wiring failure (nearly broken rack actuator actuator relay.
relay line) Turn the starter switch to the “OFF” position and
00 522241.03 Warning Rack actuator relay malfunction: OFF signal is detected • Connection failure of connectors Check the connectors, harnesses and rack
circuit fault B although rack actuator relay actuator relay.
• Harness wiring failure (rack actuator relay line
ON command has been sent. short circuited to power supply) Turn the starter switch to the “OFF” position and
then to the “ON” position to check if the error code
• Defective rack actuator relay
is displayed again.
00 522241.04 Warning Rack actuator relay malfunction: ON signal is detected • Connection failure of connectors
circuit fault A although rack actuator relay • Harness wiring failure (rack actuator relay line
OFF command has been sent. disconnected or short circuited to GND)
• Defective rack actuator relay
5-3-4
00 522243.02 Caution Intermittent failure of air heater relay Unconfirmed error is detected Check the connectors, harnesses and starting
• Harness wiring failure (nearly broken starting aid relay line)
(Intermittent failure of starting aid relay) 10 times. aid relay.
00 522243.03 Caution Air heater relay circuit fault B (Starting OFF signal is detected • Connection failure of connectors Turn the starter switch to the “OFF” position and
aid relay malfunction) then to the “ON” position to check if the error
although air heater relay ON • Harness wiring failure(starting aid relay line short
command has been sent. circuited to GND)
• Defective starting aid relay

• Engine ECU internal circuit failure
5. ELECTRIC SYSTEM
00 522243.04 Caution Air heater relay circuit fault A (Starting ON signal is detected although • Harness wiring failure (starting aid relay line
aid relay malfunction) air heater relay OFF command disconnected or short circuited to power supply)
has been sent.
• Defective starting aid relay
00 522314.00 Caution Abnormal coolant temperature Coolant temperature switch is • Engine overheating Inspect the engine cooling system.
on after engine has started. • Insufficient amount of engine coolant Check the harnesses and coolant temperature
switch.
• Defective engine cooling system
Turn the starter switch to the "OFF" position and
• Harness wiring failure (coolant temperature switch then to the "ON" position to check if the error code
wiring short circuited to GND) is displayed again.
• Defective coolant temperature switch
28 000096.02 Caution Short circuit of fuel sensor Sensor resistance is 1 Ω or less • Connection failure of connectors Check the connectors, harnesses and fuel
• Harness wiring failure (sensor signal line short circuited to sensor.
GND or sensor GND line short circuited to power supply) Turn the starter switch to the “OFF” position and
then the “ON” posi-tion. Then check that the
• Defective fuel sensor
28 000096.04 Caution Disconnection of fuel sensor Sensor resistance is • Connection failure of connectors Check the connectors, harnesses and fuel sensor.
100 Ω or more. • Harness wiring failure (nearly broken wiring of sensor signal line, Turn the starter switch to the “OFF” position and
sensor 5 V line or sensor GND line) then the “ON” posi-tion. Then check that the error
• Defective fuel sensor
28 000100.00 Abnormal engine oil pressure Engine oil pressure • Insufficient amount of engine oil Check the engine oil filter element, engine oil
Warning
decrease during engine pressure switch and lube oil pump.
• Clogging of engine oil filter
operation
• Defective engine oil pressure switch or engine oil pressure decrease
28 000110.00 Warning Abnormal engine coolant Water temperature • Engine overheating Inspect the engine cooling system.
temperature: too high alarm switch is on. Check the connectors, harnesses and coolant
• Insufficient amount of engine coolant
• Defective engine cooling system temperature sensor. Turn the starter switch to the
“OFF” position and then to the “ON” position to
• Defective coolant temperature sensor system check if the error code is displayed again.
28 000110.02 Caution Short circuit of engine coolant Sensor resistance is 80 • Connection failure of connectors Check the connectors, harnesses and coolant
temperature sensor Ω or less. • Harness wiring failure (sensor signal line short circuited to GND or temperature sensor. Turn the starter switch to the
sensor GND line short circuited to power supply) “OFF” position and then to the “ON” position to
check if the error code is displayed again.
• Defective coolant temperature sensor
28 000110.04 Caution Disconnection of engine Sensor resistance is 30 • Connection failure of connectors Check the connectors, harnesses and coolant
coolant temperature KΩ or more. • Harness wiring failure (nearly broken wiring of sensor signal line, temperature sensor. Turn the starter switch to
sensor sensor 5 V line or sensor GND line) the “OFF” position and then to the “ON” position
5-3-5
• Defective coolant temperature sensor to check if the error code is displayed again.
28 000167.00 Caution Low battery charge Low battery charge signal • Connection failure of connectors Check the battery, alternator and harnesses.
detected during engine • Disconnection or short circuit of harness
operation
28 520777.02 Caution Short circuit of hydraulic oil Sensor resistance • Connection failure of connectors Check the connectors, harnesses and hydraulic
temperature sensor is 80 Ω or less. • Harness wiring failure (sensor signal line short circuited to GND or oil temperature sensor.
sensor GND line short circuited to power supply) Turn the starter switch to the “OFF” position and
then the “ON” posi-tion. Then check that the error
• Defective hydraulic oil temperature sensor code is displayed again.
5. ELECTRIC SYSTEM
28 520777.04 Caution Disconnection of hydraulic oil Sensor resistance • Connection failure of connectors Check the connectors, harnesses and hydraulic
temperature sensor is 30 KΩ or more. oil temperature sensor.
sensor 5 V line or sensor GND line) then the “ON” position. Then check that the error
• Defective hydraulic oil temperature sensor code is displayed again.
28 520780.00 Caution Air cleaner clogging Air cleaner • Air cleaner clogged Clean the air cleaner.
clogging signal is • Short circuit of air cleaner switch connector If the error code is still displayed, check if the
detected. connectors, terminals and harnesses of the dust
indicator are correctly connected. Also, check the
installation condition.
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 Section Drawing ..............................................6-6-1
6-2-1 Boom.................................................................. 6-2-1 6-6-2 Disassembly ....................................................6-6-2
6-2-2 Arm ....................................................................6-2-3 6-6-3 Cleaning ..........................................................6-6-2
6-2-3 Bucket................................................................ 6-2-5 6-6-4 Inspection & Replacement .............................. 6-6-2
6-2-4 Swing .................................................................6-2-7 6-6-5 Lubrication ...................................................... 6-6-2
6-2-5 Boom Swing....................................................... 6-2-9 6-6-6 Reassembly .................................................... 6-6-3
6-2-6 PTO ................................................................... 6-2-11 6-7 Travel Motor............................................................. 6-7-1
6-2-7 Blade ................................................................. 6-2-13
6-7-1 External Drawing ............................................ 6-7-1
6-2-8 Extand cylinder ................................................. 6-2-15
6-7-2 Section Drawing and Spare Part List............... 6-7-2
6-2-9 Travel ................................................................ 6-2-17
6-7-3 Disassembly ................................................... 6-7-3
6-3 Hydraulic Pump ..........................................................6-3-1
6-7-4 Reassembly .................................................... 6-7-10
6-3-1 Exploded View and Component Parts ...............6-3-1
6-7-5 Installation Procedure Duo-Cone Seals .......... 6-7-17
6-3-2 Disassembly ...................................................... 6-3-3
6-7-6 Geared Motor Assembly Tool ........................ 6-7-21
6-3-3 Installation tools .................................................6-3-7
6-7-7 Torque Wrench Setting ................................... 6-7-22
6-3-4 Reassembly .......................................................6-3-9
6-7-8 Technical Information ..................................... 6-7-23
6-4 Control Valve ..............................................................6-4-1
6-4-1 Introduction ........................................................6-4-1
6-4-2 Troubleshooting .................................................6-4-2
6-4-3 Fundamental Rules ........................................... 6-4-3
6-4-4 Removal / Installation of the SX 10
Control Block ...................................................... 6-4-3
6-4-5 Inlet Elements Repair Procedure ...................... 6-4-5
6-4-6 Distribution Element Repair Procedure ............. 6-4-8
6-4-7 Maintenance Instruction of Inlet and Distribution
element equipped with Translation Stand-by .......6-4-19
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, variable displacement plunger pump, a control valve, a selector valve,
a boom cylinder, an arm cylinder, a bucket cylinder, a boom swing cylinder, a variable frame cylinder,
a blade cylinder, a swing motor, a swivel joint, two travel motors and a hydraulic oil tank.
The oil discharged from the variable displacement plunger pump flow to the actuators through the control valve. The
hydraulic pilot control system comprises a cut-off valve, an accumulator, two pilot valves, a proportional valve and
a selector valve.
The oil discharged from the variable displacement plunger pump flows into the pilot ports of the control valve
through the cut-off valve, the pilot valves and the proportional valve with the control valve to control the valve spool
movement in proportion to the pressure at the port.
1= Arm cylinder
2= Bucket cylinder
3= Boom cylinder
4= Boom swing cylinder
5= Blade cylinder
6= Pilot valve R
7= Pilot valve L
8= Swing motor
9= Swivel joint
10= Hydraulic oil tank
11= Hydraulic pump
12= Control valve
13= Travel motor
14= Accumulator
15= Cut-off valve
16= PTO valve
17= Hydraulic manifold
18= Valve PTO / Boom swing
19= Valve extensible frame
20= Variable frame cylinder
6-1-1
6. HYDRAULIC SYSTEM
1) Hydraulic Pump
The variable displacement 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 SV18
1 Variable pump P 23
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 port P of the cut off valve and to the port P of the control valve.
The flow from the port P of the inlet section feeds the arm cylinder, the swing motor, the boom, bucket,
blade cylinders, the PTO (option), the boom swing, the left and right travel motor through the appropriate
sections of the control valve.
Due to the closed center of the sections of the control valve, the oil pressure increases until the
differential valve setting pressure (15 bar), 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 T of the cut-off valve. The oil flows through the cut off valve relief valve back
to the hydraulic oil tank.
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 Pa4 of the boom section to operate its spool.
(2) Oil flow from hydraulic pump
The oil discharged from the pump flows to the boom section through the port P of the inlet section.The oil flows
through the port A4 to the bottom port of the boom cylinder to extend its cylinder rod, raising the boom.
The return oil from the rod port of the boom cylinder flows back to the hydraulic oil tank through the port B4 and T
of the control valve. Some return oil from the port T flows directly to the tank while the remaining 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 pulled forward to raise 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 Pb4 of the boom section its spool.

The oil discharged from the pump flows through the port P 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 Pa1 of the arm section to operate its spool.
The oil discharged from the pump flows to the arm section through the port P of the inlet section. The oil flows
through the port A1 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 B1 and
T of the control valve. Some return oil from the port T flows directly to the tank while the remaining 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 Pb1 of the arm section to operate its spool.

The oil discharged from the pump flows through the port P 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 Pb3 of the bucket section to operate its spool.
The oil discharged from the pump flows to the bucket section through the port P of the inlet section. The oil flows
through the port B3 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 A3 and T
of the control valve. Some return oil from the port T flows directly to the tank while and the remaining flows back to
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 Pa3 of the arm section to operate its spool.

The oil discharged from the pump flows through the port P 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 Pb2 of the swing section to move its spool.
The oil discharged from the pump flows to the swing section through the port P of the inlet section. The oil flows
through the port B2 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 A2 and T of
the control valve. Some return oil from the port T flows directly to the tank while the remaining flows back to
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 Pa2 of the swing section to move its spool.

The oil discharged from the pump flows through the port P 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 P.T.O/Boom swing switch controls the proportional solenoid valve through the output current
of the solenoid driver in the remote control lever.
1) Right Boom Swing

(1) Pilot oil flow
When the boom swing switch is moved to the right, the pilot oil from the pump flows through the cut-off valve
to the port P of the proportional valve. Pilot oil flows through the port B of the proportionnal valve to the port P2
of the selector valve and then from the port C4 to the port Pb7 of the boom swing section to move its spool.
(2) Oil Flow from Hydraulic Pump
The oil discharged from the pump flows to the boom Swing section through the port P of the inlet section.
The oil flows through the port B7 to the rod port 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 A7 and T of the control valve. Some return oil from the port T flows directly to the tank while
the remaining flows back to the tank through the oil cooler and the return filter.
2) Left Boom Swing
(1) Pilot oil flow
When the boom swing switch is moved to the left, the pilot oil from the pump flows through the cut-off valve
to the port P of the proportional valve. Pilot oil flows through the port A of the proportionnal valve to the port P1
of the selector valve and then from the port C1 to the port Pa7 of the boom swing section to move its spool.
The oil discharged from the pump flows through the port P 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.
P.T.O/Boom swing switch controls the P.T.O. proportional solenoid valve through the output current
of the solenoid driver in the remote control lever.
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) Pilot oil flow
When the P.T.O. switch is moved to the left, the pilot oil from the pump flows through the cut-off valve
to the port P of the proportional valve. Pilot oil flows through the port A of the proportionnal valve to the port P1
of the selector valve and then from the port C2 to the port Pa6 of the Option section section to move its spool.
The oil discharged from the pump flows to the Option section through the port P of the inlet section.
The oil flows through the port A6 to the A port of the PTO line to operate the accessory.
The return oil from the B port of the PTO line flows back to the hydraulic oil tank through three lines, through
the opened stop valve, through the port T of the control valve while the remaining oil through the oil cooler and
the return filter.
3) Double Acting P.T.O.

(P.T.O. stop valve is closed)
1) Pilot oil flow
When the P.T.O. switch is moved to the left, the oil flow is same as the flow in "Single acting P.T.O.".
When the P.T.O. switch is moved to the right, the pilot oil from the pump flows through the cut-off valve
to the port P of the proportional valve. Pilot oil flows through the port B of the proportionnal valve to the port P2
of the selector valve and then from the port C3 to the port Pb6 of the Option section section to move its spool.
When the P.T.O. switch is moved to the left, the oil flows to P.T.O. circuit in the same direction to the oil flow
in the "Single acting P.T.O."
When the P.T.O. switch is moved to the right, the oil flows in opposite direction to the oil flow when the P.T.O. slide
switch is moved to the left.
6-2-11
6. HYDRAULIC SYSTEM
6-2-12
6. HYDRAULIC SYSTEM
6-2-7 Blade
Blade/extand cylinder switch controls the selector solenoid valve through the output current of the cut-off switch
in the lever stand.
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 pulled.
Oil Flow from Hydraulic Pump
The oil discharged from the pump flows to the blade section through the port P of the inlet section and B5 of
the blade section. Pilot oil flows to the port P1 of the selector valve and then from the port C1 of the selector valve
it flows through the ports C and 3 of the swivel joint to the bottom of the blade cylinder.
The return oil from the rod port of the blade cylinder flows back through the ports 4 and D of the swivel joint
to the port C4 of the selector valve. Then it flows from the port P2 of the selector valve back to the hydraulic oil
tank through the ports A5 and T of the control valve. Some return oil from the port T flows directly to the tank while
the remaining 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 pressed.
The oil discharged from the pump flows through the port P 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 Extand cylinder

Blade/extand cylinder switch controls the selector solenoid valve through the output current of the cut-off switch
in the lever stand.
The blade lever is linked to the spool of the control valve through a blade cable.
1) Extanded undercarriage
When the blade lever is pushed forward to extand the undercarriage, the spool is pulled.
The oil discharged from the pump flows to the blade section through the port P of the inlet section and B5 of
the blade section. Pilot oil flows to the port P1 of the selector valve and then from the port C2 of the selector valve
it flows through the ports 5 of the swivel joint to the bottom of the extand cylinder.
The return oil from the rod port of the extand cylinder flows back through the ports 6 of the swivel joint to
the port C3 of the selector valve. Then it flows from the port P2 of the selector valve back to the hydraulic oil tank
through the ports A5 and T of the control valve. Some return oil from the port T flows directly to the tank while the
remaining flows back to the tank through the oil cooler and the return filter.
2) Narrowed undercarriage
When the blade lever is pulled back to narrow the undercarriage, the spool is pressed.
The oil discharged from the pump flows through the port P of the inlet section to the blade section.
The oil flows in the opposite direction to the oil flow in the "Extanded undercarriage" operation with regard
to the extand 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 flows through the port P of the inlet section, the port B9 of the right travel section and
the ports E and 8 of the swivel joint to the port P2 of the right travel motor to rotate it.
The return oil from the port P1 of the right travel motor flows back to the hydraulic oil tank through the ports 10
and A of the swivel joint, the port A9 of the right travel section and the port T of the control valve. Some return oil
from the port T flows directly to the tank while the remaining 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 flows through the port P of the inlet section, the port B8 of the left travel section and
the ports F and 7 of the swivel joint to the port P1 of the left travel motor to rotate it.
The return oil from the port P2 of the leftt travel motor flows back to the hydraulic oil tank through the ports 9
and B of the swivel joint, the port B8 of the left travel section and the port T of the control valve. Some return oil
from the port T flows directly to the tank while the remaining 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 R2 of the solenoid valve to the port G and H of the swivel joint
and is divided into two flows to the port 1 there to flow to the ports PS 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
6-3-1 Exploded View and Component Parts
6-3-1
6. HYDRAULIC SYSTEM
No. Part Q'ty

1 Piston DVP (Assy) 10
2 Steel plug TCEI G1/2 with OR 18, 72x2, 62 1
3 Bleeder plug TE 3/8 gas with OR 15, 08x2, 62 1
4 Cover SVP Right L-*GD/GD HP 1
5 Ball bearing 6205 1
6 Bearing HK 2020 (26x20x20) 1
7 Screw TCEI M 10x50 UNI 5931-12.9 4
8 Nut M UNI 5589-A-SG 1
9 Plug M12x40 - 5923 - 12.9 1
10 Shoulder washer cylinder block LVP28 1
11 Washer KSA GM2000 M 12 (9,8x19x1,5) 3
12 O-ring seal OR 3575 70DEG 8H.A (145,72x2,62) 2
13 O-ring seal OR-028 90GRA 8H.A (34,65x1,78) 1
14 Shaft seal BAUM3SLX7 25x52x7 1
15 Ring 32 UNI 7437-DIN 472 (AB) 1
16 Ring 52 UNI 7437-DIN 472 2
17 Ring 25 UNI 7435-DIN 471 1
18 Splined ring LVP 30 1
19 Cylinders block SVP 4
20 Spring guide DVP 1
21 Pistons spring LVP 28 1
22 Secondary pilot spring DVP type B HP 1
23 Main pilot spring DVP 15-CC 1
24 Pistons guide plate DVP 3
25 Swash plate DX DVP 15-CC 1
26 Valve plate SVP DX(1) 1
27 Limiter pin max displacement SVP 23CC 5
28 Shaft DVP version 04 FS-R 5
29 Roller DVP ceramic coated 1
30 Pump body SVP 85-LMD HP (0,2mm) 18L 1
31 Pilot piston DVP type L 1
32 Dowel pin elastic MM.4,5x18 UNI 6873 1
33 Dowel pin casehardened MM.3x25.8 DIN 5402/ISO3096 1
34 Dowel pin MM.5x10 UNI1707 H8 1
35 Dowel MM.10x24 UNI-EN 28734-B 1
36 Dowel pin casehardened MM.6x18 UNI 1707 M6 1
37 Plug GSA 22 4
6-3-2
6. HYDRAULIC SYSTEM
6-3-2 Disassembly
Procedure
1. Measure the limiter screw length
Important
It’s important to measure the length of the power limiter
screw from the nut to the end of the power limiter screw.
The dimension X is important during the reassembly to reset

the maximum absorbed power.
2. Put the pump on the working bench.

1 2 3
3. Loosen and unscrew the nut (1), remove the washer (2)
and unscrew the power limiter screw (3)
4. Put the pump in the vice with the shaft in down position.
Grab the pump by the centring.
Note
Use some aluminium protection on the vice to not
damage the machined surfaces.
Vice Vice
6-3-3
6. HYDRAULIC SYSTEM
Procedure
5. Loosen the screws.
Important 1
Remove the screws following the sequence shown in
the picture. 3
2
4
6. Remove the rear cover from the SVP pump body.
Note
Pay attention to the valve plate doesn’t fall down.
Keep the pump in the disassembly position.
Note
If the cover is stuck, put a screwdriver into the slot to
leverage on the cover as in the picture.
6-3-4
6. HYDRAULIC SYSTEM
Procedure
7. Put the cover on the working bench. Screw the grub
screw until the DVP pushing spring is outside the cover.
Note
Remove the grub screw from the cover before reassembling
the DVP pushing spring.
8. Remove the O-Ring seal from the cover.
9. Remove the O-Ring seal from the DVP pushing spring.
10. Protect the shaft spline with the proper CASAPPA tool pn
06100050 or with adhesive tape to avoid damaging the
shaft seal.
6-3-5
6. HYDRAULIC SYSTEM
Procedure
11. Remove the snap ring (1).
12. Remove the shaft seal (2).

Note
It’s necessary to damage the shaft seal to remove it.
13. Remove the plug:

a. Using a screwdriver, make a hole in the center of the
plug (hammering on the screwdriver until the tool is
into the plug).
b. Make lever and exctrat the plug keeping attention not
damage the plug housing.
Note
It’s necessary to damage the plug to remove it.
6-3-6
6. HYDRAULIC SYSTEM
6-3-3 ,QVWDOODWLRQWRROV
&DVDSSDWRROSQ

&$6$33$WRROSQ

&$6$33$WRROSQ

7
6. HYDRAULIC SYSTEM
0
&DVDSSDWRROSQ50
1x45°
8
V
27
0.8
2
66
39
34
V
0.8
2
6.2
6-3-8
6. HYDRAULIC SYSTEM
6-3-4 5HDVVHPEO\
3URFHGXUH
1&KHFNWKHSOXJKRXVLQJDQGFKDQJHWKHSOXJ5HDVVHPEOH
WKHSOXJLQWRWKHKRXVLQJXVLQJWKHSURSHU&$6$33$WRROSQ
+DPPHUWKHEXIIHUZLWKDPDOOHWXSWRFRQWDFW
ZLWKWKHSXPSERG\
2 5HPRYHWKH&$6$33$WRROSQDQGDVVHPEOH
WKHVKDIWVHDOXVLQJWKHSURSHU&$6$33$WRROSQ
+DPPHUWKHWRROZLWKDPDOOHWXQWLOWKHVHDOLVLQ
SODFH
3 3XWEDFNWKHVQDSULQJDQGFKHFNLILWLVFRUUHFWO\SRVLWLRQHG
LQWKHJURRYH
4. Place on the cover the new static seal.

Use clean grease to keep the seals in place.
9
6. HYDRAULIC SYSTEM
3URFHGXUH
5 3XWVRPHJUHDVHEHKLQGWKHYDOYHSODWHLQRUGHUWRNHHSLW
LQLWVFRUUHFWSRVLWLRQZKLOHUHDVVHPEOLQJWKHUHDUFRYHU
1RWH
3D\DWWHQWLRQWRWKHSLQ´
6. Place on the DVP pushing spring the new O-Ring seal.

Use clean grease on the seal.
7 8VLQJDPDOOHWSXWWKH'93SXVKLQJVSULQJEDFNLQWRWKH
FRYHUZLWKWKHSURSHU&DVDSSDWRROSQ
8 %HIRUHUHDVVHPEOLQJWKHUHDUFRYHUFKHFNWKHVSULQJVHDW
LVFRUUHFWO\SRVLWLRQHGLQLWVVSKHULFDOVHDWLQWKHVZDVK
10
6. HYDRAULIC SYSTEM
Procedure
9 7RNHHSWKHUHDUFRYHUDQGWKHVSULQJLQWKHFRUUHFW
SRVLWLRQILUVWVFUHZWKHWZRVFUHZVRQWKHVSULQJVLGHRI
WKHFRYHU
10. Tighten the scews with a torque wrench. The cover must
be kept horizontal during this operations.
Note
Insert the screws following the sequence shown in
the picture.
Tightening torque: 70 Nm
11. Put the pump on the working bench.

3 2 1
12. Screw the washer (1) on the power limiter screw (2) to the
plane of the cover.
13. Lock the nut (3).

Tightening torque: 50 Nm.
6-3-11
6. HYDRAULIC SYSTEM
Procedure
14. To reset the exact maximum absorbed power,

it’ s necessary to screw the power limiter screw (torque
X
limiter) as much as measured (X) at the first step of
the disassembly.
15. With a clamp verify that the shaft of the pump can rotate
after the operation in both directions. The shaft must
easily rotate.
If the shaft is locked this means that some of the seals

have come out of their seats during assembly.
If this happens the whole operation must be done again

and the damaged seals replaced
6-3-12
6. HYDRAULIC EQUIPMENT
6-4 Control Valve
Directional control block with flow distribution inde-pendent of the pressure and available flow
Type SX 10, series 1X

TRAVEL R
TRAVEL L
BOOM SWING
Forward OPTION
BLADE
BOOM
BUCKET
SWING
ARM
P
Left side
6-4-1 Introduction
1) Foreword
This manual deals with the instructions relative to servicing and maintenance operations for the SX 10 control block.
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
prod-uct information available at the time of publication. In its attempts to maintain a high-quality product, BOSCH
REXROTH 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
opera-tions.
CAUTION :
Warning against possible equipment damage.
Note :
Useful information.
6-4-1
6-4-2 Troubleshooting
CAUTION :
Before starting any procedures of trouble shooting or removing the control block, inspect the global machine's
hydraulic system to eliminate all possible malfunctions not related to the SX 10 control block.
Abnormal operation of the actuators connected to the control block

Malfunction Probable cause Additional checks Remedy
Lack of strength at all actua- (1) LS pressure relief valve Take a pressure Replace LS pressure relief
tors defective measure-ment valve
(2) LS pressure relief valve Make necessary adjustments
out of adjustment
Lack of force on one actuator Secondary pressure relief Replace secondary pressure
only valve defective or unsuitable relief valve
Lack of speed in the perfor- (1) Spool stroke incorrect Manual control: measure If stroke is incorrect: replace
mance of a movement or all spool stroke housing + spool assembly
movements
(2) Hydraulic operator Make necessary adjustments
adjustable stopnut out of
adjustment
(3) Individual compensator Replace housing + pressure
pressure blocked compensator assembly
Lack of load hold (1) Load hold check valve Replace check valve
failure
(2) Excessive clearance Replace housing + spool
between the housing and assembly
the spool
Simultaneous (1) Blockage of the individual Remove and clean individual
movement malfunction compensator orifice compensator
(2) Individual pressure com- Replace the housing + pres-
pensator blocked sure compensator assembly
(3) LS line leakage Replace flow regulator
Abnormal machine operation

Malfunction Probable Cause Additional Checks Remedy
Engine remains under load (1) Flow regulator blocked Replace flow regulator
after spools are returned to
(2) Flow regulator filter Replace the filter
neutral
clogged
Abnormal machine operation

Increase of force on controls (1) Control block assembly Check tightening torque Loosen and tighten to torque
or spool return defective tie rods too tight 15 ± 10% N.m.
CAUTION :
Remove control block from
its fixation points
(2) Spool seals obsolete Replace spool seals
6-4-2
Visual defects
Spool leaking oil (1) Spool seals defective Replace spool seals
(2) Tongue seal or spool Replace tongue seal or spool
adapter seal defective extremity seal
Oil leakage at secondary Seals defective Remove pressure relief
valves valve, anti-cavitation
check valve or plug and
replace seal
Oil leakage between ele- Seals plates defective Remove working sections
ments and replace seals plates
Oil leaking from hydraulic (1) Seal between housing Replace seal
operator housing and body defective
(2) Tightness of adjustable Check nut tightening torque Tighten to torque
stop nut defective 30 ± 10% N.m.
or replace nut and screw
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 Removal / Installation of the SX 10 Control Block
1) General Recommendations
CAUTION :
Before removing the sx 10 control block from the machine, the block and its surroundings must be thoroughly
cleaned (do not direct the jet of a pressure washing unit directly at the unit).
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.
Use the lifting eyes and suitable handling equipment.
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.
6-4-3
2) Removal of the SX 10 Control Block

Install a vacuum pump on the tank to limit oil leakage when connections are removed.
After disconnecting the lines from the block, immediately fit the sealing plugs. Make sure to collect any possible oil
leakage in a suitable receptacle.
Unscrew the mounting screws and remove the control block.
3) Installation of the SX 10 Control Block

Contact faces must be perfectly clean.
Check the evenness of support area on the machine (Tolerance: 0.5 mm).
Check the condition of line connector seals.
Clean the block if it has been in storage for a long period of time.
Correctly place and secure the control block onto the machine with the mounting screws.
Connect the lines to the block as per the connecting diagram and tighten to the torque specification (refer to the
table in the Data sheet).
Ensure that hoses are not twisted or rub.
Once correctly installed, the unit can be placed into operation.
4) Starting, Maximal Pressure Set Up

• Decalibrate the LS pressure relief valve (19 mm open end spanner on counternut) before starting the machine,
• Maintain one of the control block spool valve in action before the linked hydraulic receiver is at the end of stroke.
CAUTION :
On the spool valve, the value of the secondary valve pressure must be greater than that of the ls pressure relief valve to adjust.
• Adjust the maximum pressure measured in M using the LS pressure relief valve (6 mm socket wrench).
• Tighten the counternut of the adjusting screw to the torque : 20 ± 10% N.m.
6-4-4
6-4-5 Inlet Elements Repair Procedure

1) LS Pressure Relief Valve Replacement
Procedure
Note :
The control block does not need to be removed from the
machine to perform this operation.
Machine off :
- place all of the machine's actuators connected
to the control block in neutral position,
- release stored pressure by operating all the
spools.
Note :
Install a vacuum pump on the tank to limit oil leakage during
this operation.
Collect possible leaks with a suitable receptacle.
On the inlet element, unscrew the LS pressure relief valve (24

mm open end spanner).
Reassembly :
- install the LS pressure relief valve on the inlet element,
torque : 45 ± 10% N.m.
- set the LS pressure relief valve to the specified value.
- fit a new appropriate locking cover.
6-4-5
2) Flow Regulator Replacement

Procedure
Note :
Machine off :
- release stored pressure by operating all the
spools.
Note :
this operation.
On the inlet element, unscrew the flow regulator (22 mm open

end spanner).
Reassembly :
- install the flow regulator on the inlet element,
torque : 20 ± 10% N.m.
Flow regulator filter replacement

Using pliers, extract the filter from the end of the flow
regula-tor.
Be careful not to damage the seal and the end of the flow reg-
ulator.
Filter
6-4-6
3) Removal of the Flushing Valve

Procedure
Note :
Machine off :
- release stored pressure by manipulating all the
spools.
Note :
this operation.
On the inlet element, unscrew the flushing valve plug (27 mm

open end spanner).
Reassembly : torque : 70 ± 10% N.m.
Remove: - plug,
- shim, - Plug
spring, -
piston. Shim
Replace parts assembly. Spring
Reassemble parts in reverse order.
Piston
6-4-7
6-4-6 Distribution Element Repair Procedure

1) Secondary Valves Replacement
Procedure
Note :
Machine off :
spools.
Note :
this operation.
Pressure relief valve replacement

On the distribution element in question, unscrew the pressure
relief valve plug (10 mm socket wrench).
Remove: - plug,
- conical spring,
- pressure relief valve.
Replace seal of pressure relief valve plug.
6-4-8
Procedure
Anti-cavitation check valve replacement
On the distribution element in question, unscrew the anticavi-
tation
Remove: - plug,
- anti-cavitation check valve.
Replace seal of pressure relief valve plug.
Plug replacement
On the distribution element in question, unscrew the plug (8
mm socket wrench).
Replace plug seal or plug.
6-4-9
2) Spool Stroke Measurement

Procedure
Move the control lever of the element in question in all possi-
ble positions, and measure the corresponding spool stroke
values at the tongue.
6
Position 1 and 2
6
6-4-10
3) Removal of Spool with Spring Return

Procedure
Note :
Machine off :
spools.
Note :
this operation.
Tongue side
Remove mounting screws and plate (3 mm socket wrench).
Remove wiper ring and O-ring.
Reassembly :
- grease and install the new seals.
CAUTION :
Position the wiper ring lip on the outside.
Cover side
Remove mounting screws and cover (3 mm socket wrench).
Remove the spool from the working section.
6-4-11
Procedure
Return system removal for seals replacement
Note :
Use the spool clamp (DSI.-No: 08102858) and a vice to
secure the spool.
CAUTION : Tongue
Mounting screw
In order to avoid breaking the clamp, place it approximately
Tongue O-ring
15 mm from the end of the spool (never in the centre).
Wiper ring
Beforehand, heat the spool to 200°C in an oven or, failing Clamp DSI.-No: 08102858
that, with a heat gun. Loctite 242
Plate
Wear thick protective gloves when handling the O-ring O-ring
hot spool. Plate
Note :
Spring
Keep the load hold check valve located inside each spool side Loctite 242
clean. Wiper ring
Remove: - 2 spring retainers,
- spring,
- plate, Spring retainers
Slotted head screw
- wiper ring and O-ring.
Reassembly :
CAUTION :
Position the wiper ring lip on the outside.
- priory to spool system reassembly, the new O-ring and wiper

ring must be fitted onto the end of the spool so that they are
not damaged on the spool grooves.
- grease the spring,
- apply a droplet of Loctite 262 on the end of the spool adapter
internal thread,
- reassemble the return system parts in reverse order after.
- slotted head screw torque: 5 ± 10% N.m.
CAUTION :
Wait for 8 hours before using the machine to let the Loctite
262 dry completely.
6-4-12
Procedure
Tongue replacement (if necessary)
Beforehand, heat the spool to 200°C in an oven or, failing
that, with a heat gun.
Wear thick protective gloves when handling the

hot spool.
CAUTION :
Do not use a welding torch to heat the tongue as spool defor-
mation may result.
Note :
Keep the load hold check valve located inside each spool side
clean.
Loosen the tongue using an open end wrench (6 mm open

end spanner).
Note :
Keep the load hold check valve located inside each spool side
clean.
Reassembly :
- replace tongue seal
- apply a droplet of Loctite 262 on the end of the tongue
thread,
- torque: 5 ± 10% N.m.
CAUTION :
262 dry completely.
6-4-13
4) Hydraulic Operation Removal

Procedure
Note :
Machine off :
spools.
Note :
this operation.
Tongue replacement (if necessary)

Note :
Using a vernier, measure before
replacement the dimension y
between the stopnut screw and the
nut tip (see diagram below).
This value y is to be thoroughly
respected when reassembling to y
ensure an identical flow adjustment. 013743-00X
Remove: - nut (13 mm open end spanner)

- screw (4 mm socket wrench)
Hydraulic control housing removal

Remove the 2 mounting screws (screwdriver Torx Tx20 for
Torx screws, or 3 mm socket wrench for CHc screws).
Remove: - housing
- spring
- spring retainer
Replace the O-ring.
6-4-14
5) Individual Pressure Compensator Removal

Procedure
Preliminary operations
Remove the control block from the machine.
Disassemble the control block.
Note :
Secure the distribution element taking care not to damage the
element faces in contact with the seals plate.
On the distribution element in question, unscrew the compen-

sator plug (6 mm socket wrench).
Remove: - plug
- compensator piston using a magnet to extract it
from its bore.
Reassembly :
- replace the assembly,
torque : 30 ± 10% N.m
Clean the piston’s nozzle with compressed air to remove all

traces of pollution.
Check the condition of the bore in the distribution element

body.
6-4-15
6) Load Hold Check Valve Removal

Procedure
Note :
Machine off :
spools.
Note :
this operation.
On the distribution element in question, remove the mechani-

cal operation or hydraulic operation.
Note :
Use the spool clamp (DSI.-No: 08102858) and a vice to
secure the spool.
On the spool, unscrew the spool end:

- hydraulic operation : 6 mm open end spanner.
- mechanical operation : 4 mm socket wrench.
Reassembly :
- replace the spool adapter seal
- apply a droplet of Loctite 262 on the end of the spool adapter
thread,
- torque : 5 ± 10% N.m.
CAUTION :
262 dry completely.
Remove: - spring
- check valve
Visually check the condition of parts and replace the assembly

check valve and spring if necessary.
6-4-16
7) Control Block Disassembly / Assembly

Procedure
Preliminary operations:
Remove the 3 nuts (13 mm ring wrench).

Remove the outlet element.
Separate the working sections from the inlet element.
Reassembly :
- replace seals plates located between the working sections,
the inlet element and the outlet element.
- check the cleanliness of the element faces.
- place the control block horizontally on an even support area
to tight the nuts.
CAUTION :
When reassembling, make sure the seals plates are correctly
positionned so that the seals location fit with the canals to
tighten.
If the inlet element is to be replaced, remove the tie rods.
Reassembly :
- make sure that the tie rods are tightened to the specified
torque (30 ± 10% N.m)
6-4-17
MA = 70 Nm
5
22
2
6
MA = 20 Nm
MA = 45 Nm
I
m P
n
MA = 20 Nm
8 MA = 20 Nm
25 103
qp
o LS 103
7
MA = 20 Nm
Pil T M
MA = 30 Nm
230
9
6-4-18
6-4-7 Maintenance Instruction of Inlet and Distribution element equipped with Translation Stand-by
1) Introduction
• This dedicated manual deals with the instructions relative to servicing and maintenance operations for SX10
Translation Inlet and distribution element (See maintenance instruction manual RE 64132-S for further informa-
tion) .
• 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 the manual RE64132-S together with this instruction thoroughly
• All information, illustrations, instructions and characteristics contained in these documents are based on the latest
product information available at the time of publication. In its attempts to maintain a high-quality product, BOSCH
REXROTH reserves the right to make design or technical modifications at any time and without prior notification.
• Before removing the parts, the unit and its surroundings must be thoroughly cleaned (Do not direct the jet of a
pressure washing unit directly at the unit).
• No impurities must enter the hydraulic system.
• Make sure to collect any possible oil leakage in a suitable receptacle.
• 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 or
open.
• With the machine off, release the pressure remaining in the system by manipulating all of the distribution spools.
6-4-19
3) Removal of Flushing Valve on Translation Inlet

Procedure
Note :
Machine off :
spools.
Note :
this operation.
On the inlet element, unscrew and remove the flushing valve

plug (27 mm open end spanner).
Remove: - 2 shims
- spring Plug
- piston
Reassembly : replace the complete assembly. Shim
Spring
Piston
6-4-20
4) Removal of Translation Stand-by Kit on Translation Inlet

Procedure
Note :
Machine off :
spools.
Note :
this operation.
On the inlet element, unscrew and remove the translation

stand-by plug (6 mm socket wrench).
Remove: - spring
- piston
Reassembly : replace the complete assembly. Plug
Spring
Note :
Check that the piston is correctly
Piston
oriented.
6-4-21
5) Individual Pressure Compensator Removal on Translation Pair Element

Procedure
Disassemble the control block.
Note :
Secure the distribution element taking care not to damage the
element faces in contact with the seals plate.
On the distribution element in question, unscrew and remove

Plug
the compensator plug (6 mm socket wrench).
Spring
Piston
Remove: - Spring
- Compensator piston using a magnet to extract it
from its bore. Seals plate
Reassembly : replace the complete assembly.

Throttle
Clean the piston’s nozzle with compressed air to remove all

traces of pollution.
Check the condition of the bore in the distribution element

body.
6-4-22
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
prod-uct 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 Leak between guide Lift the boot to perform Replace guides + plungers
originating from under the and push buttons a visual inspection
boot
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

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
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 :
4 plunger guidesa
4 plain plungersb4
spring rings c
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 :
4 plunger guides a
4 plain plungers b
4 spring rings c
6-5-9
6-6 Swing Motor

6-6-1 Section Drawing
6-6-1
6-6-2 Disassembly
The listed item numbers refer to the sectional drawing and the spare parts list on page 6-6-1.
Fix the motor in a holding tool, with the motor shaft pointing downwards.
Item Part to remove Comments

9 Screw (2 off)
116 Valve block
8 & 10 O-ring
44 Screw (4 off)
16 Valve housing
19 Disc valve
22 Spacer
18 Balance plate Half fill balance plate center hole with hydraulic oil. Rapidly press
mandrel (Ø14.5) into hole. The balance plate will now be pressed out
by the oil and can be removed.
46 ,47 & 48 O-ring
24 Spring washer
20 Channel plate
21 Valve drive
42 Gear wheel set Carefully lift out the gear wheel set. Hold one hand underneath to
prevent gear wheel rollers from sliding out.
48 O-ring
43 Cardan shaft
61 Intermediate plate
50 Seal ring
56 Nut Bearing nut is locked.
49 O-ring
54 Shaft Fix the bearing housing in a press and push shaft out of bearing
housing.
57 & 55 Roller bearing and spacer Press roller bearing and spacer out of bearing housing.
39 & 45 Shaft seal and back-up ring Take the shaft seal and back-up ring out of bearing housing.
6-6-3 Cleaning
Clean all parts carefully in low aromatic kerosene.
6-6-4 Inspection & Replacement

Check all parts carefully and make any replacement necessary.
6-6-5 Lubrication
Before assembly, lubricate all parts with hydraulic oil and grease rubber parts with vaseline.
6-6-2
6-6-6 Reassembly
Replace all O-rings and seals with new O-rings and seals.
Item Part to mount Comments

39 & 45 Shaft seal & back-up ring Assemble shaft seal and back-up ring into the bearing housing.
54 Shaft Grease seal and carefully mount shaft in bearing housing. Don't dam-
age seal. Support shaft by tool A.
57 Roller bearing (front) Press front inner-ring onto the shaft and thereafter the outer-ring into
the bearing housing.
55 Spacer Place spacerring.
57 Roller bearing (rear)) Press rear outer-ring into the bearing housing and thereafter the
inner-ring onto the shaft. Control that there is no backlash in the
bearing package.
56 Nut Tighten bearing nut to 120+/-10 Nm, and secure by blowing with
mandrel and hammer in the appropriate grove.
50 Seal ring Mount vaseline greased seal ring in intermediate plate.
49 O-ring
61 Intermediate plate
43 Cardan shaft
48 O-ring
42 Gear wheel set Carefully place gear wheel set on intermediate plate with O-ring
groove pointing upwards. Hold one hand underneath to prevent rotor
and rollers from sliding out during assembly. Place hole in gear wheel
rim (Ø6 mm) in line with corresponding hole in intermediate plate.
With a pen, mark rotor of gear wheel set at the point where the root of
a tooth in splines is opposite the root of a tooth in outside toothing of
rotor.
6-6-3

48 O-ring
21 Valve drive Mark a spline tooth tip on valve drive.
Fit valve drive into gear wheel set so that markings on rotor and valve
drive correspond to one another.
20 Channel plate Mount channel plate so that hole (Ø6 mm) lines up with hole in gear
wheel set.
48 O-ring
19 Disc valve Place disc valve on channel plate so that hole (A) in outer rim lines
up with marking on valve drive. Turn disc valve counter-clockwise till
splines engage with splines on valve drive.
The drawing shows the correct fitting of the disc valve in relation to
valve drive and rotor.
6-6-4

24 Spring washer Fit spring washer into valve housing.
46 & 47 O-ring Mount two vaseline greased O-rings in balance plate grooves.
18 Balance plate Place balance plate in valve housing and carefully press into position
using a brass block and a hammer.
22 Spacer Grease spacer with vaseline and guide into center hole of balance
plate.
16 Valve housing Mount valve housing so that hole (Øloch 6 mm) lines up with hole in
channel plate.
44 Screw (4 off) Tightening torque 7.5 +0.5/0 daNm
AF 16 mm
8 & 10 O-ring
9 Screw (2 off) Tightening torque 4.5 0.5 daNm
AF 8 mm
6-6-5
6-7 Travel Motor
6-7-1 External Drawing
6-7-1
6-7-2 Section Drawing and Spare Part List
013521-00X
N° Code Description Q’ty

1 1725.008.025 Output housing 1
2 1725.110.001 End cover 1
3 1725.333.097 Motor mor 15,76 1
4 1725.517.042 Sun gear 1
5 1725.806.099 Lappeda bearing + Front seal 1
6 4725.007.200 Planetary gear set 1
7 4725.010.200 Planetary gear set 1
8 1725.825.042 Pad 1
9 9010.603.000 External retaining ring 1
10 9010.646.000 Internal retaining ring 1
11 9010.661.000 Internal retaining ring 1
12 9030.234.951 O-ring 2,62¯139,37 1
13 9030.235.001 O-ring 2,62¯145,72 1
14 9110.624.000 Ball bearing 16019 1
15 9479.008.014 Shims kit 12,2¯19,8 1
16 9510.018.059 1/8" gas plug with o-ring 2
17 20M16.027 Valve plug 2
18 24OR2-119 O-RING 2,62¯23,47 2
19 20M16.028 Valve spring 2
20 20M16.029 Valve washer 2
21 6.701880003 Counterbalance valve spool 1
5725.KIT.0026 : Basic seal kit

5725.KIT.0027 : Major rebuilt kit (5725.KIT.0026 + item 5)
6-7-2
6-7-3 Disassembly
Procedure
After having drained the lubricant, unscrew the two drain
plugs, remove the internal snap ring securing the reduction
gear cover.
Remove the reduction gear cover.
To remove the reduction gear cover, insert two screwdriver

into the upper groove and lift the cover from the housing.
An alternative solution for removal of the cover.
May be ottained by unscrew the two drain plugs and install

two threaded pins (1/8" GAS) wich will be used to lift the cover
from the housing.
6-7-3
Procedure
Remove the O-ring from the cover.
The first stage planetary carrier can now be removed from the
unit by hands.
To disassemble the first stage planetary carrier assembly,

remove the retaining rings, the antirotation washer, planetary
gears, needle bearings and the thrust washer.
Remove the retaining ring from the second reduction sun gear
and push it down to slide it out from the planetary carrier.
6-7-4
Procedure
The second stage planetary carrier can now be removed from
the unit by hands.
To disassemble the stage planetary carrier assembly, remove

the retaining rings, the antirotation washer, planetary gears,
needle bearings and the thrust washer.
Remove the retaining ring from the hub to free the two bear-
ings, ring gear and motor.
To separated the hub from the ring gear, use three M10
screws as indicated in the illustration.
6-7-5
Procedure
Remove the O-ring from the ring gear, and the retaining ring
securing the bearing.
Now remove the ball bearing by pushing from underneath.
Remove the lapped bearing/front seal will require the use of a

commercial bearing extractor and supporting cap as shown.
Caution :
Be careful not to damage the bottom polished/lapped surface
of the bearing.
The front seal ring may now be removed by hands.
6-7-6
Procedure
The following valve parts may now be removed by
hands: plugs with O-Rings, springs, valve piston and the
other plug.
Remove the six head socket cap screw and relatives washers
securing the motor cover.
Remove the cover and the two dowel pins.
Note :
Remove the dowel pins is optional.
Remove from the motor cover the O-Ring, the O-rings, the pin
and the roller bearing with a bearing puller.
Note :
Remove the dowel pins is optional.
6-7-7
Procedure
Remove the bronze motor valve plate and the dowel pin.
Note :
Remove the dowel pin is optional.
After inverting the motor hub the rotating block will now slide
out.
The angle faced plate can be removed by hands.

Remove the pin and the oil seal can now be removed.
Note :
Remove the dowel pin is optional; remove the oil seal in case
if it is damaged.
Remove the internal retaining ring retaining the bearing/drive

shaft, push from beneath as shown in the illustration.
Note :
It is understood that the seal ring will be damaged and must
require replacement.
6-7-8
Procedure
Remove the first external retaining ring, the ball bearing can
now be removed.
The second external retaining ring can now be removed.
The unit can now be re-assembled by reversing the above

procedure.
Please keep in mind the following requirements:
1) If one of the gears of the planetary units has been dam-
aged it is advisable to replace the damaged planetary
stage assembly complete with the sun gear.
The reason is obvious, in that damage from one gear can
cause microscopic fatigue cracks in mating gear teeth,
leading to premature failure after servicing.
2) Use standard mechanical procedures, such lubricating O-
rings, seals, etc..., upon reassembly.
6-7-9
6-7-4 Reassembly
Procedure
Fit the first external retaining ring 1 on the drive shaft in the 3
first retaining ring seat A.
2
Mount on the shaft the ball bearing 2 and insert the second
external retaining ring 3 in the second retaining ring seat B. 1
B
A
Fit the oil seal in its seat in the hub.
Install the drive shaft in the hub centering the oil seal and lock
with internal retaining ring.
6-7-10
Procedure
Insert the two sphere in their seats on the hub. Insert the
washers, the springs, the pistons and the angled face
plate onto the hub.
Install the rotating block into the motor hub, bringing it into
contact with the angled face plate.
Install the valve plate and relative centering pin on the motor
cover.
Install the roller bearing onto the motor cover, proceeding so

that it extends from the face of the cover by 2,5 to 2,8 mm
(0.098 to 0.110 inches).
Mount the O-ring onto the motor cover.
6-7-11
Procedure
Install the motor cover onto the hub with the six head cap
screw with relatives washers and tighten to a torque.
M8 - 42/50Nm
Clean the two M5 restrictors with air.

In case they are damaged or very dirty removing the restric-
tors with a key, clean the calibrated holes and reinstalling in
their threaded holes.
Restrictor
Air
Install the change displacement valve in the following

sequence:
left plug, piston valve, spring and the other plug with
relatives O-Ring.
Install the valve in the following sequence: valve,

washers, springs, plugs and relatives O-Rings.
After assembly of the hydraulic motor, check that the

drive shaft turns freely with no binding.
Using the tool (Code M725.000.16.01) shown on page 6-5-21

as a support, install the first ball bearing.
6-7-12
Procedure
Secure the ball bearing by means of an internal retaining ring,
install the O-ring.
Note :
Be sure to use grease on the O-ring.
Using the same tool (Code M725.000.16.01) mentioned for

the first ball bearing, install the second ball bearing keeping
Lapped face
the lapped part up and using extreme caution not to damage
the lapped surface of the bearing.
Install the front seal.

See the installation procedure at page 6-5-17.
Using a press, insert the reduction unit and motor assembly

into the seat of the ball bearing.
6-7-13
Procedure
Install the external retaining ring so as to secure the bearing
and motor reduction unit.
Assemble the secondary planetary stage in the following

sequence: bottom thrust washer, planetary gears and rela-
tives needle bearing, antirotation thrust washer and external
retaining rings.
Note :
Always turn the opening of the retaining ring towards the out-
side.
Install the secondary planetary stage into the ring gear/hous-

ing.
Install the secondary planetary sun gear into the primary plan-
etary carrier assembly and lock with the retaining ring.
6-7-14
Procedure
Assemble the primary planetary carrier assembly in the fol-
lowing sequence: bottom thrust washer, planetary gears and
relatives needle bearing, antirotation thrust washer and exter-
nal retaining rings.
Note :
Always turn the opening of the retaining ring towards the out-
side.
Install the primary planetary stage into the ring gear/housing.

Note :
Apply grease on contact surface.
Install the primary planetary sun gear, the shims

(theoretical shimming 0,5mm) and lock with the retaining
ring.
Note :
Apply grease on contact surface.
Check the following measurement:

Measurement A - The distance between the cover support
face and the sun gear height.
Measurement B - The distance between the cover face and Shims position
the pad.
The clearance given by the difference between the two mea-
sures shall be between 0,4mm and 0,6mm; in case such
clearance was higher, remove the thrust pad and increase the A Sun gear face
thickness by adding more shims underneath.
B Pad face
Note :
In case after the assembly there is no clearance or a slight
interference, please check if the assembly was made correctly.
6-7-15
Procedure
Install the O-ring on the cover.
Install the reduction cover in the rotating housing.
Install the reataining ring and lock the cover.

Install the lubrication oil as described, close the two holes with
the drain plugs.
FINAL FUNCTIONAL TESTINGS

After the assembly the following operations and tests shall be
carried out to assure the good function of the unit.
1) Leakage test, by pressurizzing the unit at 0,4bar through
the hole of the breather plug previously removed. The unit
connected with an air hose shall be immersed in water to
find out if there is any leakages identified by bubbles.
2) Connect the hydraulic hoses to the value and carry out a
rotation test of the unit in both directions for about 30 sec.
3) Fill the unit with oil according to the procedure described in
the service manual introduction pages.
6-7-16
6-7-5 Installation Procedure Duo-Cone Seals

Seal rings, torics, and housings must be clean and free of
any oil film, dust, or other foreign matter. Use a solvent
that evaporates quickly, leaves no residue, and is compat-
ible with the rubber toric rings. The recommended solvent
is 1-1-1 Trichloroethane. (Note: Follow all safety guide-
lines for use on the solvent’s Material Safety Data Sheet).
Ring and housings should be wiped with a solvent-soaked
1.Seal Ring 4.Housing Ramp
lint free cloth or paper towel. 2.Rubber Toric Ring 5.Seal Ring Housing
3.Housing Retaining Lip
After all components have been wiped clean, the torics should be installed on the metal seal rings so that they rest in
the radius on the tail of the metal ring. Insure that the torics are not twisted by inspecting the mold flash line on the
outside diameter of the toric for for true circumferential tracking around the seal. Twisted torics will cause nonuniform
face load that can result in leakage of lubricant and pumping of debris past the toric. If a twist is apparent, it can be
eliminated by gently pulling a section of a toric radially away from the metal seal ring and letting it "snap" back.
Repeating this in several places around the ring will eliminate any twist in the toric ring.
Put the toring ring 2 on seal The toric ring 2 can twist if it is not wet all around Eliminate toric twist by gently pulling a section
ring 1, at the bottom of the during installation or if there are burrs or fins on the of the toric 2 rapidly away from the seal ring 1
seal ring ramp 7 and retaining lip 3 of the housing 5. and letting it "sanp" back.
against the retaining lip 8.
After the torics are installed on the seal rings, teh seal
assembly is ready to be installed into the retainer housing.
It is recommended to use installation tools available
through Comer Industries (tool A05) to insure accurate
assembly.
These durable installation tools are designed to locate on
the toric ring and slide it past the housing retaining lip. A
sedond locator is designed into larger seal installation A05
tools to insure the proper seal stand out height. Improper
seal assembly installation into the reatainer housing can
result in poor seal performance due to nonuniform loding.
Duo-Cone Seal installation tools help insure precise
installation. Seal ring locator
Toric ring locator
6-7-17
Place the installation tool around the seal ring and dip the
seal ring into a pan of 1-1-1 Trichloroethane solvent to
lubricate the toric ring.
It is essential to lubricate the toric with Ttichlor so that the
toric will slip past the housing retaining lip and seal uni-
formly in the housing nose radius.
Insufficient lubrication can cause poor seal performance
due to nonuniform loading (twisted torics or cocked Put the installation tool 9 onto the seal ring 1 with toric
ring 2. Lower the rings into a container with
seals). Use solvents other than 1-1-1 Trichloroethane can Trichloroethane until all surfaces of the toric 2 are wet.
leave a residue on the toric or ramps and allow the toric to
slide rather than roll in the seat. This can also result in
poor seal performance due to nonuniform loading.
After dipping the seal assembly in the solvent, shake the excess solvent from the seal assembly and immediately
"pop" the seal into the housing with a firm push of the installation tool. Remove the installation tool and check the
seal standout height at several places around the circumference of the ring to verify an accurate installation. If the
seal does not meet the height specification, inspect the toric for twists or obvious bulges.
013629-00X
With all surfaces of the toric ring 2 wet with 1-1-1 Trichloroethane,
use the installation tool 9 to position seal ring 1 and the toric ring 2
squarely against the housing 5 as shown. Use sudden and even
pressure to pop (push) the toric ring 2 under the retaining lip 3 of
the housing 5.
(1.00 mm)
013630-00X
Check the assembled height A in at least four

places, 90q apart. Refer to the chart for standout
height specification.
6-7-18
The seal can be adjusted by gently pushing the toric into position by hand or by using a fabricated adjustment hook.
If the seal can not be adjusted to meet the standout height specification, remove the seal and repeat the procedure.
013631-00X
If small adjustments are necessary, do not push directly on the seal

ring 1 ; use the installation tool 9 to push down or the adjustment
tool 11 to pull up.
A thin film of light oil should be applied to the seal faces

prior to assembly. Use an applicator, a disposable tissue
or a clean finger to distribute the oil evenly. Be careful not
to get any oil on the rubber toric rings.
Be sure there is no visible debris on either of the seal

faces-even a small piece of lint can hold the seal faces
apart and cause leakage.
After successful installation, wait one minute for the Trichlor to dry before assembling the two seal halves in the final
loaded position. This delay is to allow any excess solvent to dry so thet the torics roll, rather than slide, in the hous-
ingas the faceload is increased. If the toric slide, this can produce a nonuniform load that can result in poor seal
per-formance.
6-7-19
Results of Incorrect Assembly:

Point "A" and point "B" remain stationary.
Point "X" and point "Y" rotate 180°.
This causes high pressure at "A"/"Y" and possible galling. When rotated, points "B"/"X" has low pressure and
possi-ble leakage.
013634-00X
Original "As Assembled" Position Rotated 180qFrom "Original Position"
After the unit to be sealed is assembled, a post-assembly leakage test can be performed to insure the seal is prop-
erly installed. A vacuum check is recommended rather than a pressure check as vacuum checks are more
sensitive. Many users find this is an easy check to combine with a vacuum fill technique for the lubricant. It is
recommended yhe compartment be filled to the correct level with lubricant and then rotated slowly several
revolutions to seat the seals. Avacuum test will catch gross seal damage such as broken seal rings or cut torics that
may be caused in the last phases of assembly. The Duo-Cone-Seals is not designed to seal air, so come leakage
can be expected using such a procedure.
Follow these guidelines and recommendations should insure optimum performance from your The Duo-Cone-Seals.
6-7-20
6-7-6 Geared Motor Assembly Tool

(Code M725.000.16.01)
Mat.C40 Bon. UNI7620 / 1042 Hardened ASTM
6-7-21
6-7-7 Torque Wrench Setting (N x m)

Screw on steel or cast iron
ISO METRIC THREAD - coarse pitch

Nom. size pitch quality 4.8 quality 6.8 quality 8.8 quality 10.9 quality 12.9
(mm) (mm) min max min max min max min max min max
4 0,7 1,5 1,9 2,3 2,8 3,1 3,8 4,4 5,3 5,2 6,3
5 0,8 3,0 3,7 4,5 5,5 6,0 7,3 8,5 10,3 10,2 12,4
6 1 5,2 6,3 7,8 9,5 10,4 12,7 14,7 17,8 17,6 21,4
8 1,25 12,5 15,2 18,7 22,7 25,0 30,3 35,1 42,6 42,1 51,1
10 1,5 25,0 30,3 37,4 45,5 49,9 60,6 70,2 85,2 84,2 102,3
12 1,75 42,5 51,6 63,7 77,4 85,0 103,2 119,5 145,1 143,4 174,2
14 2 67,6 82,1 101,5 123,2 135,3 164,3 190,2 231,0 228,3 277,2
16 2 102,4 124,3 153,6 186,5 204,8 248,6 287,9 349,6 345,5 419,6
18 2,5 142,7 173,3 214,1 259,9 285,4 346,6 401,4 487,4 481,7 584,9
20 2,5 200 243 300 364 400 486 562 683 675 819
22 2,5 268 326 402 489 537 652 755 916 906 1.100
24 3 346 420 518 629 691 839 972 1.180 1.166 1.416
27 3 504 612 756 918 1.008 1.224 1.418 1.721 1.701 2.066
30 3,5 688 835 1.032 1.253 1.375 1.670 1.934 2.349 2.321 2.818
ISO METRIC THREAD - fine pitch

Nom. size pitch quality 4.8 quality 6.8 quality 8.8 quality 10.9 quality 12.9
(mm) (mm) min max min max min max min max min max
8 1 13,1 15,9 19,7 23,9 26,2 31,8 36,9 44,8 44,2 53,7
10 1,25 26,0 31,5 38,9 47,3 51,9 63,0 73,0 88,6 87,6 106,4
12 1,25 45,3 55,0 67,9 82,4 90,5 109,9 127,3 154,6 152,8 185,5
12 1,5 43,9 53,3 65,8 79,9 87,8 106,6 123,4 149,9 148,1 179,8
14 1,5 71,4 86,7 107,1 130,0 142,8 173,4 200,8 243,8 241,0 292,6
16 1,5 107,2 130,1 160,8 195,2 214,3 260,3 301,4 366,0 361,7 439,2
18 1,5 154,9 188,0 232,3 282,1 309,7 376,1 435,6 528,9 522,7 634,7
20 1,5 215 261 322 391 430 522 604 734 725 881
22 1,5 286 347 429 521 572 695 805 977 966 1.173
24 2 367 446 551 669 734 891 1.032 1.254 1.239 1.504
27 2 531 645 797 968 1.063 1.291 1.495 1.815 1.793 2.178
30 2 739 897 1.108 1.345 1.477 1.794 2.077 2.522 2.493 3.027
Above mentioned torque tables correspond to an axial preload, which is between 70% and 85% of the screw
mate-rial yield stress.
Coefficient of Friction: 0,14
With lubricated thread use 70% of above mentioned tables.

When quality 12,9 fasteners are used in tapped holes in grey cast iron, the fasteners should be torqued to quality
10.9 specifications.
6-7-22
6-7-8 Technical Information

Liquid bonding agents (Loctite) must always be used in the following cases:
(1) Screws assembled inside reduction gears.
(2) Screws tightened on aluminum boxes.
(3) Bearing adjustment ring nuts including ring nuts but not ring nuts with safety washers and ring nuts of axle wheel
hubs which do not require
adhesives.(4) Cranks and extensions.
(5) Data Sheet requirements.
When assembling with adhesives, the following must be degreased and free of washing residues:
(1) Ring nuts, screws, stud bolts, nuts, cranks, and extensions if their surfaces are not protected by galvanizing
or Dacromet 320.
(2) Threads on shafts and
boxes.
When liquid bonding agents are required, use:
Description Size Loctite

Screws tightened on cast iron or steel up to and including M8 243
over M8 270
Screws tightened on aluminum all diameters 243
Stud bolt root (box) up to and including M12 243
over M12 270
Stud (nut) up to and including M12 no
over M12 243
Bearing adjustment ring nuts all diameters 270
Cranks and extensions for caps all diameters 243
When there are no washers, O-rings, or other types of seals, use Loctite 518 as a sealer.
All of these instructions are valid unless otherwise specified in the "Technical Manual".
6-7-23
CHAPTER 7
ADJUSTMENT AND REPAIR
7-1 Engine and Electric Equipment ................................. 7-1-1 7-5-7 Removal and Reinstallation of
7-1-1 Removal and Reinstallation of Engine ............. 7-1-1 Hydraulic Oil Tank.......................................... 7-5-20
7-1-2 Removal and Reinstallation of 7-5-8 Piping Layout.................................................. 7-5-23
Starter Motor .................................................... 7-1-7 7-6 Implements ............................................................. 7-6-1
7-1-3 Removal and Reinstallation of 7-6-1 Removal and Reinstallation of
Fuel Injection Pump ......................................... 7-1-8 Implements .................................................... 7-6-1
7-1-4 Removal and Reinstallation of Fuel Tank .......... 7-1-10
7-1-5 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 Crawler Tension Adjustment Procedure ............ 7-2-3
7-2-4 Removal and Reinstallation of Crawler............. 7-2-4
7-2-5 Disassembly and Reassembly of Idler ............. 7-2-5
7-2-6 Disassembly and Reassembly of Track Roller .. 7-2-9
7-2-7 Removal and Reinstallation of
Track Gauge Change Cylinder ......................... 7-2-9
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
7-4 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 ... 7-5-4
7-5-3 Removal and Reinstallation of Swing Motor..... 7-5-7
7-5-4 Removal and Reinstallation of Swivel Joint...... 7-5-10
7-5-5 Disassembly and Reassembly of
Swivel Joint ...................................................... 7-5-13
7-5-6 Disassembly and Reassembly of
Hydraulic Cylinder............................................ 7-5-16
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 1
the engine.
2
(2) In the cabine, turn the main switch 1 to the OFF position
to disconnect the battery RI WKH PDFKLQH

1RWH
3ODFHD0$,17(1$1&(,1352*5(66ODEHORQWKH
PDFKLQH
(3) Remove the drain plug 1 from the hydraulic oil tank and
drain the hydraulic oil.
Type YANMAR SUPER

HYDRO OIL (VG 46 class)
Quantity or its equivalent 20 L
2
1
Warning : Put a container under hydraulic oil drain plug.
(4) Remove the drain plug 2 from the two-way cock

for cooling fluid and drain the cooling fluid.
Cooling fluid quantity 3,2 L
Warning : Put a container under coolant drain plug.
(5) Remove the step B 1, the arm rests 2, the panel L 3

and the panel R 4.
(6) Remove the switches 5, and then disconnect the harness

connectors.
(7) Remove LCD carter 6 and disconnect the LCD harness.
7-1-1
Procedure
(8) Disconnect the battery cable (negative) 1 and the battery
cable (positive) 2 and remove the battery clamp 3.
Then remove the battery 4.
3
2
1
(9) Remove the cover R 1, the cover L 2, the bonnet 3 and

the lim 4.
(10) Remove twelve pilot control hoses from both the remote
Viewed from upper 1
control valves L and R 1. 1 1
T P T P
4 2 4 2
3 3
Right side Left side P T
Front
1
P
T
7-1-2
Procedure
(11) Remove the operator's seat plate 1 (with the
operator's seat).
(12) Remove the cover (accelerator, remove the snap pin 2

and disconnect the accelerator cable 3 from the acceler-
ator lever 4.
(13) Remove the accelerator cable 3 from the seat mount.
(12) Remove the retaining bolts 1 from the end holder and
remove the plug plate 2. 6
(13) Remove the nuts 3 from the L-ball of the cable con-
nected to the blade lever and the cable 4 and disconnect
the cable from the lever.
5
(14) Remove the lever bracket 5 with the blade lever 6. 3
(15) Remove the blade cable from the seat mount.
2
4
1
(16) Disconnect the harness A from the fuel gauge unit 5

respectively.
(17) Disconnect the connectors of the harnesses A and

B from each other.
(18) Disconnect the harness A from the connectors of

the horn 30, the boom swing/PTO1 selector valve 38,
the PTO1 valve 39, the travel alarm 40 and the boom
lamp 31.
(19) Disconnect the harness B connectors from the cabin

harness 22.
(20) Disconnect the connectors of the starter motor 3,

the fuel feed pump 6, the generator 7, the thermo-
switch 32, the temperature sensor 33, the oil pressure
switch 34, engine-stop solenoid 35 and glow plug 36
from the engine.
(21) Disconnect the wire harness of the track extension

selector valve 50, cut-off switch 20, cut-off valve and
two-speed valve 29.
(22) Disconnect the slow-blow fuse and the fuse plate

before to remove it from the operator's seat mount.
7-1-3
Procedure
(23) Remove the canopy or cabin 45.
(24) Remove the radiator support 46 and the filler 47.

45
(25) Loosen the hose clip 49 on the intake manifold side and
remove the air cleaner hose B 48 from the intake mani-
fold.
(26) Disconnect the fuel hoses (fuel tank - water separator)

from the separator.
(27) Disconnect two fuel hoses (fuel filter - engine) from

the filter.
(28) Disconnect the fuel return hose (fuel filter - tank) from
the filter.
(29) Disassemble and rope the operator's seat mount 50

and lift it up, to remove it.
Note :
Take care that the harnesses and clamps do not catch on any
other parts when lifting up the operator's seat mount.
51
48
49
46
47
50
013591-00X
7-1-4
Procedure
(30) Remove the hoses connected to the hydraulic oil tank 1.
a. Suction hose
b. Return hose (drain block to hydraulic oil tank)
c. Return hose (radiator to hydraulic oil tank)
Note :
Remove the return hose from the joint.
d. Hydraulic oil drain hose
(31) Remove the hydraulic hoses from the hydraulic pump.

a. Hose (Measurement)
b. Hose (control valve)
c. Hose (cut-off valve)
d. Hose (suction hose) a
b
c
(32) Remove the cooling fluid drain hose 1.
(33) Remove the hydraulic hoses 2, 3, 4, 5, 6 from the 4

oil cooler.
7-1-5
Procedure
(34) Remove the PTO valve and selector valve from the bat-
tery mount to dismantle it.
(35) Remove the engine ground cable 1, battery ground cable

and wire harness ground from the base mount.
(36) Remove the base mount from the frame.
(37) Rope the engine using its lifting lugs and lift it up,
to remove it.
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.

1RWH
PDFKLQH
(3) Disconnect the battery cable (negative) 1 and the battery

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

motor 1. 3
1
2) Reinstallation
Reinstall the starter motor in the reverse order of the removal procedure.
Note :
Secure the harness with a band.
Starter motor mounting bolt (M10)

Tightening torque 46 to 54 Nm
7-1-7
7-1-3 Removal and Reinstallation of Fuel Injection Pump
1) Removal
Procedure
(1) Loosen the hose clip 2 of the air cleaner hose B 1 to dis-
connect with the air intake manifold of engine, and A
remove the air cleaner assembly with the hose B 1. 4
3
(2) Loosen the sleeve nuts 5 at the fuel injectors after remov-
ing the retainers 4 from the fuel injection pipes 3 and
then loosen the sleeve nuts 7 at the fuel injection pump 6.
(3) Disconnect the fuel hoses 8 (filter-fuel injection pump) and 5 A

9 (fuel injection pump-filter).
(4) Remove the engine oil pipe 10 (cylinder block-fuel injec- 2 1 4

INT
tion pump). 7
(5) Remove the end nut 13 after removing the HO-P cover 12 8
from the gear case 11.
6
Note :
• Put a mark 15 on the engaging point of the FIP gear 14 and
the idle gear. 10
• Do not remove the FIP gear 14 from the gear case 11.
(6) Remove three nuts 16 to remove the fuel injection pump 6

from the gear case 11.
9
Note :
• Remove the fuel injection pump 6 after putting a mark on it Marking 11
and the gear case 11.
• Do not turn the crankshaft after removing the fuel injection 16
pump 6. When a mark 15 on the engaging point of the FIP
gear 14 and the idle gear does not align, match the marks
of the idle gear with the crankshaft gear 17, cam gear 18
and FIP gear 14.
• Never loosen the FIP coupling 19 and FIP gear 14 holding
screws 20. 12
14
20
6
13
19
From the gear case side
Fuel injection pump drive gear
Cam gear
15
B
B C C
A
Idol gear 18
A
17
Lubricating oil
Crank gear
pump gear 013600-00E
7-1-8
2) Reinstallation
Reinstall all parts in the reverse order of disassembly.
Note :
• Do not use the FIP coupling 19 assembled on a new fuel injection pump assembly.
• The injection timing should be verified by the FID method.
End nut
Apply engine oil
Tightening torque 58.8 to 68.8 Nm
7-1-9
7-1-4 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
crawlers. Then, lower the bucket to the ground and stop
the engine.

1RWH
PDFKLQH
(3) Remove the under cover.
(4) Take the end of fuel drain hose 1 out from the frame
and pull out the plug 2 to drain fuel.
Fuel quantity 24.5 L
Warning : Put a container under fuel drain hose.
7-1-10
Procedure
(5) Remove the cover R 1 and the step B 2.
(6) Remove the hose clips 2 of the fuel hoses 3, 5 and

the drain hose 4..
(7) Disconnect the wire harness from the fuel level gauge
unit.
(8) Remove the fuel tank clamp 6 and the support 7, and then
remove the fuel tank 1.
7-1-11
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
7-1-5 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
crawlers. Then, lower the bucket to the ground and stop
the engine.
1

1RWH
PDFKLQH
(3) Remove the drain plug 1 from the two-way cock 2 for cool-
ing fluid and drain the cooling fluid.
2
Cooling fluid quantity 3.2 L
Warning : Put a container under coolant drain plug.

1
(4) Remove the cover R 3, the lim 4 and the radiator

support 5.
(5) Remove the filler 6.
7-1-13
Procedure
(6) Remove the hoses 4 and 5 from the engine.
4
(7) Remove the return hose 6 and cooling fluid drain hose 1.
(8) Remove two hoses 2, 3 from the oil cooler.

7
(9) Remove the radiator 7 (with the shroud) from 5
the engine bracket 8. 6
2) Reinstallation
Reinstall the radiator in the reverse order of the removal procedure.
Hose clip 60
Tightening torque 2.5 to 3.5 Nm
7-1-14
7-2 Undercarriage
7-2-1 Outline
The undercarriage consists of travel motors, frame, track rollers, front idlers, rubber crawlers 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 track frame can be widened and narrowed by the track gauge change cylinder (track gauge change type).
Viewed from the top

Slide plate
Idler Stopper bolt Track gauge Travel motor

change 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 5,
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.
Track gauge change cylinder

Stopper bolt
Nut M16
Tightening torque :
198 to 230 Nm
Bolt 1645
Tightening torque :
Standard length 198 to 230 Nm
219.5 mm
Shoe slide plate
7-2-2
7-2-3 Crawler Tension Adjustment Procedure
(1) Raise one crawler using the boom. Track roller

(2) Position the mark on the inside surface of the rub-
ber crawler on the slide plate.
(3) Measure the clearance H shown in the figures
below, and adjust the crawler tension so that the
clearance H will be within the specified range.
Crawler
Clearance to be measured for
tension adjustment
H=60 to 65 mm
7-2-3
7-2-4 Removal and Reinstallation of Crawler
! When rasing 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 : 52 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
7-2-4
7-2-5 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
7-2-5
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 disas-
sembly 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.
[5] Oil to be used for idler:
Type Engine oil SAE 30

Sleeve
Quantity 25 cc
7-2-6
7-2-6 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
7-2-7
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 (M12)
[5] Oil to be used for track rollers :
Type Engine oil SAE 30 Sleeve

Quantity 40 cc
7-2-8
7-2-7 Removal and Reinstallation of Track Gauge Change Cylinder
1) Removal of Track Gauge Change Cylinder

Procedure
(1) Widen the track frame fully by operating the track gauge
change cylinder, and then remove the right rubber
crawler 1.
Note :
Refer to Section "7-2-4 Removal and Reinstallation of
Crawler".
1
Rotating direction
Steel pipes
(2) Raise the machine using the implement and the blade,
and then place blocks under the lower center frame 2.
Note : 2
Place blocks which have sufficient height to allow work under
the lower center frame 2.
Blocks
(3) Swing the upperstructure so that the drain plug 3 of the

hydraulic oil tank is positioned halfway between the right
and left crawlers, and then stop the engine.
(4) Remove the drain plug 3 from the hydraulic oil tank and 3
Hydraulic oil quantity 20.0 L
Warning : Put a container under the hydraulic oil plug.
7-2-9
Procedure
(5) Remove the motor cover 5, and then remove
the hydraulic hoses 7 from the left travel motor 6. 7 T
5 P1
P2
Note :
Mark the hydraulic hoses 7 to identify their respective fitting
positions. 6
(6) Remove the under cover (SJ) 8.
8
(7) Remove the mounting bolts 12 for the pin 10 at the rod
end and the pin 11 at the bottom end of the track gauge
change cylinder 9, and pull out the pins.
(8) Remove the left stopper bolt 13, and then pull out
the crawler frame (L) 14 from the lower center frame 2. 13
(9) Remove the hydraulic hose of the cylinder from
the lower part of the lower center frame 2. 11
12
Warning : Take care to put the oil in a container.
2
(10) Remove the track gauge change cylinder 9 from 9
the lower center frame 2. 12
A
10
13
A
14
7-2-10
2) Reinstallation of Track Gauge Change Cylinder

Reinstall the track gauge change cylinder in the reverse order of the removal procedure.
Notes :
[1] Clean the square pipes of the crawler frames and the square pipe holes of the lower center frame.
[2] Apply heavy-duty grease to the four sides of each square pipe hole of the lower center frame over 200 mm from
the entrance.
[3] Stopper bolt setting procedure:
After fully screwing the stopper nut onto the stopper bolt, loosen the nut one turn. Then tighten the bolt.
219.5 mm
013846-00X
Stopper bolt and stopper nut (M16)

[4] Hydraulic oil to be used :

YANMAR SUPER HYDRO OIL
Type
(VG 46 class) or its equivalent
Quantity 20 L
7-2-11
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 less than 39,8 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
1. Adjustment of Maximum Idling Speed

(1) Loosen the stopper bolt 1, and then move the acceler-
ator lever 4 back until the regulator handle 7 on the
engine side touches the adjusting bolt 8 for the maxi-
mum idling speed in the governor case.
(2) Check that the maximum idling speed is within a spec-
ified range (2250 to 2300 rpm).
(3) Make adjustments with the accelerator cable 6 in the
part A shown in the figure so that the stopper 9 for the
maximum idling speed for the accelerator lever 4 will
touch the accelerator arm 3.
2. Adjustment of Minimum Idling Speed

(1) Move the accelerator lever 4 forward.
(2) When the regulator handle 7 on the engine side
touches the stopper bolt 6 for the minimum idling
speed, check whether the minimum idling speed is
within a specified range (2250 to 2300 rpm).
(3) If the minimum idling speed is not within the range,
make adjustments to the speed by tightening or loos-
ening the stopper bolt 6.
(4) After the adjustment of the minimum idling speed,
screw in the stopper bolt 1 for the accelerator lever 4
until the bolt end touches the accelerator arm 3 and fix
it with the nut 2.
7-3-2
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 engine.
of Engine".
(3) Remove the swing motor.
of Swing Motor".
(4) Remove the hydraulic hoses from the swivel joint.
of Swivel Joint".
(5) Rope the turning frame 1 at three points and sus-
pend it temporarily.
(6) Remove the seventeen 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 ⎯

M12¯45
Tuning frame¯outer race M12¯50 Apply Loctite 262
Tightening torque (10.9 T) 116 to 138 Nm
Track frame¯inner race M12¯55 or its equivalent.
(Bolt 10.9)
Note :
Put multipurpose grease into the swing bearing.
4) Parts of Swing Bearing

5 7 1, 4 2 6
No. Part Q'ty
1 Steel ball 60
2 Seal A 1
3 Seal B 1
8
4 Support 60
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
and left crawlers. Then, lower the bucket to the ground
and stop the engine. 1

1RWH
PDFKLQH
(3) Remove the under cover 2.
Hydraulic oil quantity 20 L

1
2
7-5-1
Procedure
(5) Open the bonnet center 1 and remove the cover L 2.

1
(6) Remove the hydraulic hoses from the hydraulic pump 12.
a. Hose (Measurement)
b. Hose (control valve)
c. Hose (cut-off valve)
d. Hose (suction hose) 12
a
(7) Remove the mounting bolts 13 and remove the hydraulic
pump 12. b
c
d
13
7-5-2
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 pump installation bolt M12
• Hydraulic oil to be used :

Type
(VG 46 class) or its equivalen
Quantity 20 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.
7-5-3
7-5-2 Removal and Reinstallation of Control Valve
1) Removal
Procedure
hydraulic oil tank and the under cover (CV) 2 are posi-
tioned halfway between the right and left crawlers. Then, 1
lower the bucket to the ground and stop the engine.

1RWH
PDFKLQH
(3) Remove the under cover (CV) 2.
(5) Remove the step 3 and the cover L 4.
7-5-4
Procedure
(6) Remove the hydraulic hoses and the pilot hoses from the
control valve 6. TRAVEL.R
Right side
TRAVEL.L
Notes :
BOOM SWING
• Remove the hydraulic hoses and the pilot hoses from the Forward OPTION
control valve in right-to-left order.
BLADE
• Mark the removed hoses to identify their respective fitting
BOOM
positions.
BUCKET
SWING
ARM
P
6 Left side
(7) Remove the nuts 12 from the L-balls 11 connected to the

travel (L) section 8 and the travel (R) section 9.
Remove the pins 16 to disconnect those sections from
the links 13.
(8) Remove the pins 16 to disconnect the cable 14 connected

to the blade lever, the cable 14 connected to the P.T.O.
and the cable 14 connected to the swing from the spools
of the control valve 6.
(9) Remove the mounting bolts 17, and then remove the con-
trol valve 6 from the valve plate 18.
7-5-5
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.

Type (VG 46 class) or its equivalent
Quantity 20 L
[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.
Forward
7-5-6
7-5-3 Removal and Reinstallation of Swing Motor
1) Removal
Procedure
and left crawlers. Then, lower the bucket to the ground 1
and stop the engine.
(2) &XW WKH PDLQ VZLWFK RI WKH PDFKLQH
1RWH
PDFKLQH
(4) Remove the step 2.
7-5-7
Procedure
(5) Remove the hydraulic hoses from the swing motor 8.
• Hose 9 (control valve to swing motor) 13 G
• Hose 10 (control valve to swing motor)
• Drain hose 11 (swing motor to drain block) 12
• Drain hose 12 (control valve T to swing motor)
• Drain hose 13 (swing motor to oil cooler)
Dr B
T
H
11
8
9
10
(6) Remove the mounting bolts 14 and remove the swing

motor 8.
14
7-5-8
2) Reinstallation
Reinstall the swing motor in the reverse order of the removal procedure.
Notes :
Swing motor mounting bolt (M12)
Adhesive 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.

Quantity 20 L
[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.
7-5-9
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

1RWH
3ODFHD0$,17(1$1&(,1352*5(66ODEHORQWKH 1
PDFKLQH
(5) Remove the under cover (SJ) 2.
1
(7) Remove the step 3.
7-5-10
Procedure
(8) Remove the hydraulic hoses from the turning
frame side of the swivel joint:
-(A): hose E for travel motor left (forward)
-(B): hose D for travel motor right (reverse)
-(C): hose A for travel motor left (reverse)
-(D): hose C for travel motor right (forward)
-(E): hose G for blade cylinder (rod)
-(F): hose J for blade cylinder (bottom)
-(G): hose K for second speed (two speed valve)
-(I): hose H for track gauge cylinder (rod)
-(J): hose I for track gauge cylinder (bottom)
Notes :
• Remove the hydraulic hoses from the turning frame side in
bottom-to-top order.
• Mark the removed hoses to identify their respective fitting
positions.
(9) Remove the hydraulic hoses from the lower frame

side of the swivel joint:
-(A): hose C for travel motor left (forward)
-(B): hose F for travel motor right (reverse)
-(C): hose D for travel motor left (reverse)
-(D): hose C for travel motor right (forward)
-(E): hose G for blade cylinder (rod)
-(F): hose J for blade cylinder (bottom)
-(G): hoses E and A for drain (travel motors)
-(H): hose H (travel motor R) and B (travel motor L) for
second speed
-(I): hose H for track gauge cylinder (rod)
-(J): hose I for track gauge cylinder (bottom)
Note :
Mark the removed hoses to identify their respective fitting
positions.
(10) Remove the mounting bolts for the swivel joint.
(11) Remove the swivel joint from the upper frame.
7-5-11
2) Reinstallation
Reinstall the swivel joint in the reverse order of the removal procedure.
Notes :
[1] Install each connector at a specified mounting angle.
Swivel joint mounting bolt (M10)
Adhesive Apply Three Bond 1324 or its equivalent.

Quantity 20 L
7-5-12
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, 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 8 Slipper seal (O-ring) 9

2 Swivel shaft 1 9 Thrust ring 1
Swivel flange 10 Snap ring 1
3 1
(with spring washer 10¯30) 11 O-ring 1
4 Swivel hub 1 12 Plug R1/8 1
5 Seal dust 1 13 Bolt M 8x25 (10.9T) 4
6 Back-up ring 1 14 Bolt M 10x25 (10.9) 4
7 O-ring 1
7-5-13
2) Disassembly and Reassembly of Swivel Joint
• Disassembly
(1) Remove the bolts 13.
(2) Remove the swivel flange 3 and the O-ring 11.
(3) Remove the external snap ring 10 and the thrust
ring 9 from the swivel shaft 2.
(4) Pull the swivel shaft 2 out of the swivel hub 4 and
remove dust seal 5.
(5) Remove the swivel seals 8, O-ring 7 and back-up
ring 6 from the swivel hub 4.
• Reassembly
(1) Install swivel seals 8, O-ring 7 and back-up ring 6
into swivel hub 4.
(2) Apply multi-purpose grease to the inner surface of
swivel hub 4.
(3) Install the dust seal 5 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 9 and the external snap
ring 10 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 13.
7-5-14
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.
7-5-15
7-5-6 Disassembly and Reassembly of Hydraulic Cylinders
1) Sectional View and Component Parts
No. Part
1 Seal kit, scrapper Bearing bush

2 Nut
3 Piston
4 Cylinder
5 Rod Assembly
6 Guiding bush
7 O-ring
8 Metal plug
7-5-16
2) Precautions for Disassembly and Reassembly

(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.
3) Disassembly
Procedure
(1) Drain the oil from the hydraulic cylinder. Pipe
Cylinder
Warning : Take care to put the oil in a container. Jig
Hook wrench
(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 2 on the head 4 and
loosen the head 4.
4 2
Bolt
Note :
Use a hook wrench or a jig to loosen the head 4. Adjuster
(4) Pull out the rod assembly 16 from the cylinder tube 9, and
then hold the cylinder rod assembly at the rod end or
using the pin hole at the rod end.
16
Hold cylinder rod assembly
(5) Disassembly of boom cylinder

Remove the U-nut 15, and then the piston 14, the cushion
plunger 11, the cushion collar 10, and the head 4 in that 14
order. 11
10
4
9
16 15
7-5-17
Procedure
(6) Disassembly of bucket, arm, boom swing, blade and track
gauge change cylinders
Remove the U-nut 15, and then the piston 14 and the 15
head 4 in that order. 14
4
16
9
(7) Remove the O-rings 3, 5 and 8, the dust seal 1, the ISI
packing 6, the RGU packing 12 and the PWL bearing 13. 7
5
Note : 3
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- 4 6
ula to remove it.
8
1
12, 13
14
7-5-18
4) Reassembly
Reassemble the hydraulic cylinder in the reverse order of the disassembly procedure.
Notes :
• Take care not to install the cushion plunger 11 of the boom cylinder in the wrong direction.
• Replace the O-rings, packings and seals with new ones.
11
Head side
U-nut Size end Tightening Torque
Until serial Number ( →│~ ) From serial Number ( ~│→ )

PFB1-601520 PFB1-602848
No. Cylinder U-nut size Tightening torque U-nut size Tightening torque Adhesive
1 Boom M24 490 to 588 Nm M22 380 to 420 Nm
2 Arm M24 490 to 588 Nm M24 380 to 420 Nm
3 Bucket M20 294 to 343 Nm M22 380 to 420 Nm Three Bond 1324
or its equivalent
4 Boom swing M24 490 to 588 Nm M24 380 to 420 Nm
5 Blade M22 220 to 250 Nm M24 380 to 420 Nm
6 Track gauge change M22 220 to 250 Nm M24 380 to 420 Nm
7-5-19
7-5-7 Removal and Reinstallation of Hydraulic Oil Tank

1) Removal
Procedure
1RWH
PDFKLQH
(4) Remove the cabin (or canopy) and seat mount (refer to
Disassembly/Reassembly of engine). 1
(5) Remove the hoses connected to the hydraulic oil tank 1.

a. Suction hose
b. Return hose (drain block to hydraulic oil tank)
c.Return hose (radiator to hydraulic oil tank)
Note :
Remove the return hose from the joint.
d. Hydraulic oil drain hose
(6) Remove the mounting bolts 2 and remove the hydraulic

oil tank with its bracket.
7-5-20
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 20 L
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.
7-5-21
7-5-8 Piping layout
1) Upperstructure
(Hydraulic oil tank → Hydraulic pump → Control valve)
7-5-23
2) Swing motor
(Control valve → Swing motor)
7-5-24
3) Swivel joint
(Two speed valve or Selector valve→ Control valve → Swivel joint)
7-5-25
(Swivel joint→ Travel motors, Track gauge cylinder, Blade cylinder)
7-5-26
4) PTO/Boom swing
(PTO/Boom swing selector valve→Hydraulic manifold→PTO valve→control valve→PTO line)
(PTO/Boom swing selector→Control valve→Boom swing cylinder)
7-5-27
5) Kinematics
(Control valve→ Bucket cylinder, Arm cylinder, Boom cylinder)
7-5-28
6) Control levers
(Joysticks→ Control valve→ drain block)
(Joysticks→ Cut-off valve→ Control valve)
(Joysticks→ Control valve)
7-5-29
6) Return lines
(Control valve, Swivel joint, Swing motor → Hydraulic oil tank)
7-5-30
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
(1) Lower the bucket 1 to the ground with its back face down.
(2) Remove the lock pins 2 and remove the pins 3. 3

(3) Remove the bucket 1.
1
2
013677-00X
7-6-1
2) Removal of Arm
Procedure
(1) Remove the bucket.
5
(2) Remove the nuts 1 (M10) and pull out the pins 2. Then 4
remove the bucket link 3 and the bucket arms 4.
1
(3) Lightly place the top end of the arm 5 on the ground per- 2
pendicularly to the ground. 5
3
About 90 degrees
(4) Remove the hydraulic hoses from the bucket cylinder 6,

and remove the bolt 7 (M10) to pull out the pin 8. Then
remove the bucket cylinder 6.
Rope
Note :
Rope the bucket cylinder and remove it using a lifting device.
8
7
(5) Remove the hydraulic hoses from the hydraulic hose.
(6) Remove the bolt 13 (M8) and remove the plate.
13
(7) After roping the arm 5, remove the bolt 10 (M10) and 11
remove the pin 12 from the arm cylinder 11 (on the rod Block
side). 10
Note : 12
Place a block under the arm cylinder.
(8) Remove the bolt 13 (M10) and pull out the arm pin 14.
Then remove the arm 5 using a lifting device. 14
13

5
7-6-2
3) Removal of Boom
Procedure
(1) After raising the boom 12 fully, remove the slide cover 2
from the boom cylinder 1.
1
(2) Place the top end of the boom 12 on the ground.
12
Note :
Install an expansion plug to the connector from which the
hydraulic hose has been removed and start the engine.
2
(3) After roping the arm cylinder 3, remove the hydraulic

hoses from the arm cylinder. 5
Rope
(4) Remove the bolt 4 (M10) and pull out the pin 5. Then
remove the arm cylinder 3.
3
Note : 4
Remove the arm cylinder using a lifting device.
(5) After roping to the boom cylinder 1, remove the hydraulic

hoses from the boom cylinder. 7
7
(6) Remove the bolts 6 (M10) and pull out the pins 7. Then
remove the boom cylinder 1. 6
Note : Rope
6
Remove the boom cylinder using a lifting device.
(7) Disconnect the connectors 8 of the boom light wiring har-

ness.
(8) Remove the boom light 9 and cover 10 (light cover). 9

10
8
7-6-3
Procedure
(9) Disconnect the hydraulic hoses from the P.T.O. tubes and
remove tube clamp bolts (M10) to remove the P.T.O.
tubes.
(10) After roping the boom 12, remove the bolt 13 (M10) and
pull out the pin 14. Then remove the boom 12. Rope
Notes :
12
• Remove the boom using a lifting device.
• Take care that the hoses do not catch on any other parts.
14
13
7-6-4
4) Removal of Blade
Procedure
(1) Turn the implement to the blade side, lower the bucket
and the blade 1 to the ground and stop the engine. 4
(2) Remove the protector 2 and remove the hydraulic hoses. 3 7
6
(3) Remove the bolts 3 (M10) and pull out the pins 4. Then
remove the blade cylinder 5.
(4) After roping the blade 1, remove the bolts 6 (M10) and pull 6 7
out the pins 7. Then remove the blade.
Note : 2
Remove the blade using a lifting device. 5
3
4
7-6-5
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. 3

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

Refer to Section "7-6-1 3) Removal of Boom".
1
(4) Remove the bolt 4 (M12) and pull out the pin 5 (for the
boom swing cylinder).
(5) Remove the bolt 6 (M12) and the snap ring C 7, and pull
out the pin 8. Then remove the boom bracket 9.
Note :
Rope the boom bracket and remove it using a lifting device. 7
5
9
4 6
7-6-6
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.
(2) Remove the frame cover R 2 and supports 9 to move the

fuel tank outside from its original position. Then remove
the hydraulic hoses 4 from the boom swing cylinder 3.
(3) Remove the bolt 5 (M12) and pull out the pin 6 at the rod
end of the boom swing cylinder 3.
(4) Remove the plate 7 and pull out the pin 1 at the bottom
end of the boom swing cylinder 3.
(5) Remove the boom swing cylinder 3 from the turning

frame 8.
7-6-7
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 Time Lag on Travel Speed Switching.......................................... 8-1-4
8-1-6 Fluctuation in Oil Level of Hydraulic Oil Tank Due to
Temperature Change ................................................................ 8-1-7
8-2 Troubleshooting .................................................................................. 8-2-1
8-2-1 Machine and Engine.................................................................... 8-2-1
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.
Swing motor
10 MPa
A DR B
(Right) (Left)
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 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.
008457-00E
(Travel straight in spite of turning operation.)
Reason
Spool
Motor
Brake valve
Swivel joint
Motor
008458-00E
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 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 high-speed
switch released).
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.
Travel motor PS
Swash plate angel switch piston A

T
1 P2
36.8 P1 High-speed switch
High-speed switch valve

Travel motor swash plate
8-1-4
8. TROUBLESHOOTING
8-1-6 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)
0,1925 L
Expansion by temp. rise
20°C 70°C
Hydraulic oil
50 L 50 L
Expansion by temp. rise

0,088 L
Hydraulic oil tank 20°C 70°C

(Steel) 50 L 50 L
8-1-5
8. TROUBLESHOOTING
8-2 Troubleshooting
8-2-1 Machine and Engine
(How to use the charts)
Trouble
A Aa Ab
B Ba Bb Bc
C Ca Cb Cc Ce
Factors related to the trouble are enumerated

in the columns and instructions for corrective
procedures are given below. It is recommended
that the troubles be inspected and corrected
one by one according to the chart.
Inspection item
Remedy for failure
8-2-1
8. TROUBLESHOOTING
Low output
Does the work Hydraulic Set relief pressure

implement work power
normally? source of control valve
Excessive in- Clogging of Clogging of

take resistance air cleaner intake pipe
Clean Clean
Excessive Clogging of Clogging of Clogging of

exhaust exhaust port of
resistance muffler exhaust pipe cylinder head
Clean or replace Clean Clean
Defective fuel Air in fuel Clogging of Clogging of

system system fuel filter fuel pipe
Release the air Clean or replace Clean
Clogging of air release port in

fuel tank
Insufficient fuel
discharge from
feed pump
Improper ad- Fuel injection Clogging of fuel Sticking of fuel

Governor injection nozzle
justment pressure hole injection valve
Adjust Adjust Clean or replace Replace
Defective lever Improper Malfunction of Defective delivery Wear of

injection plunger
link timing fuel pump rack valve barrel
Repair or replace Adjust Repair or replace Repair or replace Replace
Low compres- Improper clear- Defective seat Seizing of intake Deterioration or

ance of intake of intake or or exhaust valve breakage of
sion pressure or exhaust valve exhaust valve stem valve spring
Adjust Smooth or Replace Replace
replace seat
Compression leak from
head gasket
Replace
Sticking, damage, or Scuffing or Scuffing or

wear of
wear of piston ring piston wear of liners
Replace Replace Replace
Overheating Refer to Overheating
8-2-2
8. TROUBLESHOOTING
Overheating

implement work
normally? power source of control valve
Cooling water Low cooling Damage or Clogging of Excessive

Loose fan belt wear of fan exhaust
system water level belt radiator resistance
Supply Adjust Replace Clean Clean
Clogging or Defective Clogging of Malfunction Malfunction

defect of of cooling
radiator cap thermostat radiator hose water pump of radiator
Clean or replace Replace Clean Replace Replace
Excessive intake Clogging of Clogging of

resistance air cleaner intake pipe
Clean or replace Clean
Excessive exhaust Clogging of Clogging of Clogging of

cylinder head
resistance muffler exhaust pipe exhaust port
Clean Clean Clean
Gas leak from Crack of

Cylinder head
head gasket cylinder head
Replace Replace
Improper Defective fuel

Fuel system
injection timing injection valve
Correct Repair or replace
Intake or exhaust Improper clear- Improper valve

valve opening/ ance of intake or opening/closing
closing timing exhaust valve timing
Adjust Adjust
Piston Seizing
Replace
8-2-3
8. TROUBLESHOOTING
Black smoke
emission

implement work
normally? power source of control valve
Low output See Low output
Fuel Improper fuel
Replace
Fuel injection Advanced Excessive Uneven injec-

pump injection timing injection volume tion volume
Adjust Adjust Adjust or replace
Improper Defective lever or

Governor
adjustment link
Adjust Repair or replace
White smoke
emission
Mixing with low

Fuel Water in fuel quality fuel or
impurities
Replace Replace
Lubricating oil Improper grade
Replace
Excessive intake Clogging of air Clogging of
resistance cleaner intake pipe
Clean or replace Clean or replace
Fuel injection Delayed injection

pump timing
Adjust
Defective valve Damage or Damage or

Oil down wear of valve wear of valve
stem seal stem guide
Sticking, damage Scuffing or Scuffing or
Oil up or wear of piston
ring wear of piston wear of liners
Gas leak from
head gasket
Excessive Replace
Malfunction of thermostat
cooling
Replace
8-2-4
8. TROUBLESHOOTING
Starter motor does not turn Except seizure of engine and

or output is low. trouble of any work implement
Disconnection Disconnection Connection

or connection Battery terminal Ground terminal failure of
failure of wire coupler
Repair Repair Repair Repair
Battery Specific gravity Voltage Damaged battery
Recharge Supply electrolyte Replace

or recharge
Damage or rust of Internal contact Damaged

Starter switch
terminal failure of switch switch
Replace or repair Replace Replace
Damage or rust Malfunction of

Safety relay
of terminal relay
Replace or repair Replace
Malfunction or
Damage or rust Defective Burnout of Layer
Starter motor poor contact of
of terminal magnetic switch brushes coil short-circuit
Replace or repair Replace Replace starter Replace starter

motor motor
Clutch slipping
Replace
Inspection procedures
When the starter motor cannot be started by turning the starter switch on, check it as follows.
(Battery, starter switch and wiring assumed to be normal.)
(1) Safety relay & starter motor magnetic switch
Connect the S-and B-terminals of the starter motor directly.
[1] When the starter motor turns : The safety relay is faulty.
[2] When the starter motor does not turn : Either the starter motor magnetic switch or the starter motor is faulty.
(2) Starter motor

Connect the B-and M-terminals of the starter motor directly. S
[1] When the starter motor turns : Magnetic switch is faulty. M
B
[2] When the starter motor does not turn : Starter motor is faulty.
8-2-5
8. TROUBLESHOOTING
Battery dies or battery

cannot be charged (during operation)
Charging failure Discharges
Disconnection Battery Ground Discon- Connection Starter

or connection nection of failure of ON
failure terminal terminal wire coupler switch
Repair Repair Repair Repair Turn off
Damaged
Battery Wiring Short-circuit
battery
Replace Replace
Starter Damage Internal contact

or rust of Electrical
switch failure of switch Alternator
terminal equipment
Repair or Replace
replace
Electrical Damaged
Alternator Regulator
equipment diode
Replace
Short-circuit or Short-circuit
Loose fan belt
breakage of lead wire of coil
Adjust Replace Replace
alternator
Damaged diode Defective IC regulator

Replace Replace alternator
Defective
brushes
Repalace or replace
Burnout
of coil
Replace alternator
Layer short-circuit
Replace alternator
8-2-6
8. TROUBLESHOOTING
Work implement does not move

at all or its operation is slow.
Hydraulic oil
ψ Insufficient ψ Deterioration ψ Viscosity
quantity
Supply Replace Specified
hydraulic oil
Piping ψ Faulty joint (Aeration or cavitation)
Repair
Hydraulic Insufficient dis- Wear of spline of Breakage Inner part

ψ Oil leak ψ ψ ψ ψ
pump charge volume joint of shaft failure
Repair or replace Replace Replace Replace Replace
Cut-off valve
Malfunction of
ψ solenoid valve spool ( Inspect pilot valve by replacing
hoses with those of another
normal pilot circuit.
)
Replace
Filter ψ Clogging
Clean or replace
8-2-7
8. TROUBLESHOOTING
Work Implements
Weak digging force 㨇Boom, arm and bucket cylinders㨉
Do other
Cut-off valve ψ implements work
normally?
Pump P4 ψ Relief valve

pressure
Check the pressure
and adjust it. Refer
to section 5-4 ̍Pres-
sure Adjustment̍
Inspect pilot valve by switching

Internal leakage or malfunction
Pilot valve ψ Lever stroke ψ hose with hose of other normal
of valve spool
circuit
Replace Replace
System relief Dust in Malfunction of Improper Defective pilot

Control valve ψ valve pressure ψ control valve ψ system relief ψ circuit relief ψ
valve valve pressure poppet seat
Check the pressure Clean Replace Adjust Replace system
and adjust it. Refer relief valve
sure Adjustment̍
Movement of
valve spool ψ
Internal leakage
Replace Repair of parts

Movement of main valve
Hydraulic Internal spool in inlet section
cylinder ψ Oil leak ψ leakage
Replace
Repair or replace Replace seal or
whole assembly
Unintended descent of hydraulic cylinder =Boom and arm cylinders]
Anti-drift Dust in
valve
ψ control valve
Clean
Circuit relief Dust in Defective seat of
Control valve ψ valve pressure ψ control valve ψ circuit relief
valve
Check the pressure Clean Replace circuit
and adjust it. Refer relief valve
sure Adjustment̍
Hydraulic Internal
cylinder ψ Oil leak ψ leakage
Repair or Replace seal or
replace whole assembly
Inspection procedure
Switch the hose with the hose of the other circuit using the control valve.
[1] No descent : Control valve is faulty.
[2] Descent : Cylinder is faulty.
8-2-8
8. TROUBLESHOOTING
Slow implement working speed 㨇Boom, arm and bucket cylinders㨉
Relief valve
Cut-off valve ψ pressure
Check the pressure
sure Adjustment̍
Internal leakage or malfunction Inspect by switching hose

Pilot valve ψ Lever stroke ψ of valve spool with hose of other normal
circuit
Replace Replace
System relief Movement of Internal Movement of valve

Control valve ψ ψ ψ ψ spool in parallel-
valve pressure valve spool leakage flow divider
Check the pressure Repair or replace Repair or Replace
and adjust it. Refer replace
sure Adjustment̍
Movement of main valve

Hydraulic spool in inlet section
cylinder ψ Oil leak ψ Internal leakage
Replace
whole assembly
Hydraulic Insufficient oil discharge

ψ volume from pump
pump
Replace
Control lever cannot be held at

neutral position 㨇Travel, blade and boom swing cylinders㨉
Wear of
Control valve ψ Cap ψ Spring ψ
spring seat
8-2-9
8. TROUBLESHOOTING
Drifting of boom swing
Extent of Measure telescopic motion amount of

drifting cylinder rod on 15-degrees slope
Steering Boom swing Sticking of swing

equipment pedal pedal link
Adjust neutral Repair pedal link or apply grease
position Replace bush
Control Circuit relief Dust in circuit Wear of circuit relief

valve valve pressure relief valve valve seat surface
Check the pressure
and adjust it. Refer Clean or replace Replace circuit
to section 5-4 Pres- relief valve
sure Adjustment
Dust in control Wear of anti-void valve

valve seat surface
Clean or replace Replace
Defective spool
fitting
Replace spool section
Hydraulic Internal
Oil leak
cylinder leakage

whole assembly
Inspection procedure
Switch the hose with the hose of the other circuit using the control valve.
[1] No boom swing drifting : Control valve is faulty.
[2] Boom swing drifting : Hydraulic cylinder is faulty.
8-2-10
8. TROUBLESHOOTING
Boom swing cannot be made or is slow
Hydraulic Do other work implements

source work normally?
Boom swing Sticking of swing Slackness or Breakage

Controls
pedal pedal link of push-pull cable
Adjust neutral Repair pedal link or apply grease Install or replace
position Replace bush
Circuit relief Dust in circuit relief Permanent set of circuit relief

Control valve
valve pressure valve valve seat surface
Check the pressure Clean or replace Replace circuit relief valve
to section 5-4 "Pres-
sure Adjustment"
Malfunction Fall or wear of

of spool spool link pin
Adjust lever stroke. Install or replace
Internal
Hydraulic cylinder Oil leak
leakage
whole assembly
8-2-11
8. TROUBLESHOOTING
Upperstructure cannot swing or

swing speed is slow
No outside Remove the

resistance? ψ resistance source
Hydraulic Do other implements

power source ψ work normally?
Operation of Relief valve

Cut-off valve ψ solenoid
ψ pressure
Replace Check pressure. Refer
to section 5-4 Pres-
sure Adjustment
Movement of [Inspect by switching hose with

Pilot valve ψ
valve spool hose of other normal circuit.]
Repair or replace
Relief valve Movement of Dust in

Control valve ψ pressure
ψ valve spool ψ control valve
Check pressure. Refer Repair or replace Clean
sure Adjustment
Hydraulic motor ψ Oil leak ψ Internal leakage ψ Internal breakage

Replace seal or Replace Replace
whole assembly
Breakage of swing Wear or rust of
Swing braring ψ bearing gear
ψ swing bearing ball
Replace Replace
8-2-12
8. TROUBLESHOOTING
Swing only to one side
Relief valve
Cut-off valve ψ pressure
Check pressure. Refer
sure Adjustment
Movement of [Inspect pilot by switching hose with

Pilot valve ψ valve spool hose of other normal circuit]
Repalr or replace
Movement of
Control valve ψ valve spool
Repalr or replace
Drifting of swing [Brake does not work]
Extent of drifting ψ Measure drifting
Compare with service

standard valve
Is valve spool
Pilot valve ψ returned to neutral?
Repair or replace
Hydraulic motor ψ Oil leak ψ Internal leakage
Replace seal or Replace

whole assembly
8-2-13
8. TROUBLESHOOTING
Drifting of swing [Unintended drifting on slopes]
Measure motion amount of swing bearing

Extent of drifting ψ outer race on 15 degrees slope.
Refer to 3-1 "Machine Performance"
Is valve spool
Pilot valve ψ returned to neutral?
Repair of replace
Defective spool
Control valve ψ fitting
Hydraulic motor ψ Oil leak ψ Internal leakage

whole assembly
8-2-14
8. TROUBLESHOOTING
Travel Equipment
No travelling
Crawler tension Before making checks, remove dirt from

and clogging undercarriage and adjust crawler tension

lock lever
power source work normally?
Release
R and L relief Dust in

Control valve
valves pressure control valve
Check the pressure and Clean
adjust it. Refer to sec-
tion 5-4 Pressure Ad-
justment
Spool link pin

comes off
Install
Swivel joint Internal leakage
Replace seal
Driving Lift machine body and check undercar-

mechanism riage turns under external force
Brake valve (or Loosen ports P1 and P2 Dust in plunger Plunger plug
Sticki of plunger
counterbalance valve) joints and check oil flow orifice loosened
Clean Retighten Repair or replace
Hydraulic motor
Oil leak Internal leakage Internal breakage
and reduction gear
Replace seal or Replace Replace motor
whole assembly
8-2-15
8. TROUBLESHOOTING
Cannot travel straight
Crawler tension, Before making checks, remove dirt from

clogging undercarriage, and adjust crawler tension.
Hydraulic Do other implements work Lift machine body and Check hydraulic
power source normally? check R and L revolutions pump
Replace hydraulic
pump
Improper adjustment of
lever stopper bolt
Readjust
Controls Link operation Wear of link joint
Repair or replace Replace
R and L relief valves Dust in Wear of relief

Control valve
pressure control valve valve seat surface
Check the pressure and Clean Replace
adjust it. Refer to section
5-4 Pressure Adjustment"
Internal
Swivel joint Oil leak
leakage
Replace seal Replace seal
Brake valve Sticking of Dust in Wear of check

(or counter balance valve) plunger check valve valve seat surface
Repair or replace Clean Repair or replace
Hydraulic Internal Malfunction of

Oil leak
motor leakage 2-speed spool
Replace seal or Replace motor Replace
whole assembly 2-spool valve
8-2-16
8. TROUBLESHOOTING
1. When the hydraulic tester is not used :
(1) Reverse the hoses between the control valve and the swivel joint.
Phenomenon : Reversed ...........................................Overhaul or replace the control valve.
(2) Reverse the hoses between the swivel joint and the brake valve (or counter balance valve).
Phenomenon : Reversed ...................Overhaul or replace the swivel joint.
(3) Reverse the left and right hydraulic motors.
Phenomenon : Reversed ...........................................Replace the counter balance valve (or counter balance
valve) or the motor.
2. When the hydraulic tester is used :

(1) Flow volume at no load (Check the difference between the right and left motors.)
(2) Flow volume when loaded (Check the difference between the right and left motors.)
Conditions :
(1) Discharge volume at no load
Make judgment by reading the difference
between the right and left motors.
(2) Discharge volume when loaded
(3) Engine at rated speed.
(4) Hydraulic oil temp. at 50 to 60°C
8-2-17
8. TROUBLESHOOTING
Cannot make spin

turning
Site condition Dry ground Wet ground Sndy
Crawler tension Before making checks, remove dirt from

and clogging under carriage and adjust crawler tension.

power source work normally?
R and L relief Wear of relief valve

Control valve Dust in control valve
valves pressure seat surface
Lift machine body Clean Replace
Check the pressure and
R and L relief Wear of relief valve

Brake valve Dust in brake valve
valves pressure spring and seat surface
Lift machine body Clean Replace
Check the pressure and
Hydraulic motor Oil leak Internal leakage

whole assembly
8-2-18
8. TROUBLESHOOTING
Drift of machine
body on slopes
Check the drift with machine

Extent of drift
placedon a 15 degrees slope.
Hydraulic Internal
Oil leak
motor leakage
whole assembly
Brake valve (or counter Leakage from Dust in check Wear of check Breakage of
balance valve plunger valve valve seat surface spring
Replace valve Clean Repair or replace Replace
Check the drift with the machine placed on a slope with an inclination angle below 15 degrees.
[1] Continuous drift : Brake valve (or counter balance valve) is faulty.
[2] Discontinuous drift : Hydraulic motor is faulty.
8-2-19
8. TROUBLESHOOTING
No switching to high-speed
One side? Both side?
High-speed Switch
switch operation
Replace
Solenoid Relief valve

Cut-off valve
operation pressure
Replace Check the pressure
Oil leak
Pipings
from joint
Repair or replace
Internal
Swivel joint Oil leak
leakage
Repair or replace Replace seal
Hydraulic Operation of Internal

Oil leak
motor high-speed spool failure of motor
Repair or replace Overhaul or replace
assembly
Breakage
Orifice clogged Dust in spool
of spring
Clean Clean Replace
8-2-20
8. TROUBLESHOOTING
Travelling speed is switched to high-speed naturally

or high-speed cannot be cancelled
One side? Both side?
High-speed Switch
switch operation
Replace
Solenoid Spool
Cut-off valve
operation operation
Replace Repair or replace
Hydraulic Operation of Internal

motor high-speed spool failure of motor
Faulty spool
Dust in spool
movement
Clean or replace Repair or replace
8-2-21

Sk18 Shop Manuall

Uploaded by

Copyright:

Available Formats

Sk18 Shop Manuall

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Sk18 Shop Manuall

Uploaded by

Copyright:

Available Formats

What are the main sections covered in the document?

What are the main sections covered in the document?

What are some of the safety precautions mentioned?

What are some of the safety precautions mentioned?

APPLICABLE No.

Book code No. S5PFB101E01

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.

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.

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 SV18

Travel speed Low speed km/hr 2,2

Item Unit SV18

Item Unit SV18

Type of main pump - Variable pump

Number of pumps pcs. 1

Item Unit SV18

Item Unit SV18

Displacement cm3/rev 233

Displacement (Low/High) cm3/rev 16,8

Type - Counterbalance valve

Suction filter Filtration area cm² 550